DC Inverter Power Supplies for Resistance Welding Applications
DC Inverter Power Supplies for Resistance Welding Applications
The DC Tech Series has been discontinued and is no longer available, please contact a service representative to discuss best options.
We are proud however to suggest some of our other items (Adobe Acrobat Format 444K) as a replacement. Please feel free to give our expert staff a call at any time. Putting our expertise to work for you, finding the right solution is just a phone call away.
For Spot Welding:
IS-120A
IS-444B
IS-471B
ISA-500A
For Seam Welding:
IS-443B
IS-470B
Typical Applications and Uses
For Spot Welding:
Stainless and galvanized doors and furniture
Automotive sheet metal and components
Aluminum structural components
Copper wire solidification
High Speed copper to galvanized cross wire welding
Motor Armature fusing
For Seam Welding:
Water filtration components
Vehicle fuel tanks
Aluminum and titanium aircraft components
Heavy gauge wire shelving
High speed bi-metal electrical contacts
Features
High Speed Adaptive Feedback
Process Control
Closed Loop Feedback
Technically advanced Inverter Technology
Shorter Weld Times
Benefits
Provides consistent, reliable welds with optimal nugget formation, superior joint strength, and excellent surface appearance.
Provides millisecond control over the resistance welding process
A feedback rate of every 500 microseconds actively maintains the programmed weld current or power
Improves spot and seam welding of traditionally “hard to weld” materials including coated steels, aluminum, brass, and copper.
Compared to conventional AC welders, DC Inverter technology produces heat more efficiently, thus decreasing weld times as much as 1/3rd and reducing the heat affected zone (HAZ).
With quality and production demands increasing, DC inverter resistance welding offers benefits that traditional AC welding cannot address. In the broadest sense, inverter welding offers more flexibility than conventional AC welding. Virtually any application that can be done with an AC weld control can be done with inverter technology.
Inverter Performance Benefits
Many resistance weld failures can be traced to inconsistent secondary welding current. Adaptive feedback systems used in inverter technology utilize pulse width modulation to continuously monitor and adjust the weld current throughout the weld, compensating for non-uniform workpiece resistance, worn electrodes, and power source fluctuations, resulting in extremely consistent weld current delivery throughout every weld. The benefits derived include shorter weld times, lower currents and forces, faster speed and throughput, longer electrode life, less weld splash, and less surface deformation of the part.
Efficient Weld Current Delivery Improves Quality
In resistance welding, a weld joint (or nugget) is formed as weld current flows through the workpieces, encountering different electrical resistanaces and generating heat. AC controls, by definition, cycle weld current on and off twice per cycle. The AC “cycling” can cause embrittlement and irregular nugget formation, hurting weld quality and strength. By contrast, inverter systems deliver current without cycling, thus continuously heating the weldments. Weld times can be adjusted in one millisecond increments. This precise control allows inverter welders to utilize shorter weld times and control how current can be introduced into the parts by “shaping” the current weldform. Lower weld current and less force (compared to AC weld controls) and be utilized to achieve the desired molten state of the weldments for optimal nugget formation.
Hard to Weld Materials
Inverters are capable of successfully welding a broad range of materials. Softer metals, particularly those with high electrical and thermal conductivity are good candidates for inverter resistance welding. Higher electrical conductivity means that higher weld currents must be used. High thermal conductivity requires that the weld current must be delivered quickly to minimize the heat affected zone. Zinc coated galvanized steels also fall into this category.
High Current Output – Small Transformer Package
Compact inverter equipment features small, lightweight welding transformers for use in manual, automated, and robotic (transgun) configurations. In AC resistance welding, higher current outputs generally require extremely large transformers. The physical size and weight of the AC welding transformer is especially critical in transgun configurations, often limiting the current output available. Inverter transformers are often as much as 50% smaller, lighter, and deliver higher current outputs than conventional AC transguns.
Inverter Realities
Inverter performance benefits can result in higher production rates with less time lost to electrode maintenance and changes. According to many manufacturers, weld failures, part rejects, and costly re-works have been dramatically reduced. Shorter weld times, lower weld currents, and balanced line loads, lessen the primary current demand – reducing electrical usage and expense. Adaptive feedback control modes and millisecond programming make precise control over the resistance welding process a reality. DC inverter welding allows for a broader process window to overcome workpiece variances and production changes. This larger process window is one of the primary reasons that inverter welding meets today’s demand for higher quality and delivers such an attractive return on investment.
DC inverter power supplies offer large benefits in some resistance welding applications. Offered in capacities of up to 325 kVA, dc inverter technology is able to deliver superior weld quality by using lower weld currents, shorter weld times, and lower weld forces than conventional AC controls. Through the use of a high speed control monitoring multiple weld functions using adaptive feedback, the user is able to regulate the welding process.
Superior control over current and heat generation results in a reduction in energy use and increase in electrode life, as well as improved weld quality, increased production efficiency, and reduced cost.
Closed Loop Feedback Control
A closed loop feedback system means that the control receives input as to how this particular weld is progressing and adjusts to maintain the weld at the entered specification. The control is able to maintain either weld current or power (user selected) by measuring and adjusting the secondary current and voltage. The control gets new feedback every 500 microseconds, consistent weld current (or power) at the electrodes is maintained, overcoming power fluctuations and workpiece material variances that hurt weld quality.
For more information, or help selecting or pricing a DC Inverter system, feel free to contact T. J. Snow. We will be glad to help in any way we can.
MA-627A
Remote Program Unit
Used to store weld schedules and program multiple units.
MA-628A Monitor Unit
Adds process security by displaying Current, Power, time and error data while inhibiting access to programming functions.
To put together a complete system you need the following separate components:
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