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Elio Electro Tech CC

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Choose Topics

  • Introduction
  • Hot Spot Welding (HSW) Mini
  • Hot Spot Welding Power Module
  • Arc Welding (AWS) Mini

Introduction

Easy to integrate into automated processes, these inverter power supplies can control the energy for the welding process with almost any kind of required pulse shape. The main voltage is first rectified and then passed through a controlled rectifier inverter and a transformer to provide direct voltage. Feedback results of the primary and secondary voltage and current are provided, thus permitting perfect process control.

In addition to output current, cycle rate is also an important process-determining parameter when selecting an inverter. The higher the cycle rate, the more effectively the device delivers pulses with high edge steepness and optimum control performance.

As output increases, these requirements become less important, allowing lower frequencies to be used.

They also feature high-performance and easy-to-use software to carry out complex control functions.

Our software has been developed with real processes in mind and offers a range of powerful tools:
> Current control
> Voltage control
> Power control
> Limitation of control values
> Creation of controlled advanced pulses
> Part conditioning
> Weld to electrode displacement
> Data recording for process analysis

Hot Spot Welding (HSW) Mini

The Hot Spot Welding mini is a complete system enclosed in one unit (430 x 420 x 150 mm) for resistor welding applications. It is composed of:

> Primary inverter
> High frequency transformer
> Power diodes
> Shunt
> Control Processing Unit with RS232 serial line
> Operator control panel with 1 line by 16 characters display
> Main switch

Controlled via RS232 serial line by a PC/PLC or CRS remote control unit (Part Number: REM305 or REM306).

HSW Mini Specifications Unit of Measurement CW-AH01
Air – 2500A
7.5V / 7%
em>CW-WH01
Water – 2500A
7.5V / 10%
Max welding output voltage (Max load) Volt 7.5 7.5
Max output current (Peak value) Ampere 2500 2500
Instant power W 18750 18750
Continuous duty cycle % 7 10
Short term (10 cycles) duty cycle % 15 15
Peak primary current required A/ac 54 54
Minimum primary current requirement A/ac 25 16
Adjustment precision (In line conforming with EN50160) % 2 2
Number of welding profile phases each 3 3
Max time for each phase Ms 2000 2000
Number of transformers incorporated in ferrite E70 each 2 1
Working frequency on the primary stage kHz 15 15
Working temperature °C 30 40
Interface RS232   Present Present
Short circuit protection   Present Present
Overheating protection   Autolimit Autolimit
Phase loss detection   Present Present
Graphic memorization A + V real time   Present Present
Mains voltage Vac 400 400
Mains frequency Hz 50 – 60 50 – 60
Cos §   1 1

Hot Spot Welding Power Module

The power module for Hot Spot Welding (HSW) applications is a device operating with a PWM technique at 50kHz equipped with a parallel type interface hardware (20 pole bus with flat cable). This interface facilitates the parallel interconnection of more than one power module.

Power modules can be integrated in automated welding systems.

Required in addition to the power module:

> Control Processing Unit (Part Number: CPU063)
CPU card that interconnects with the power modules via 20 pole bus. It is equipped with RS232 serial communication line to connect either a PC/PLC or a CRS remote control unit (REM).

> Auxiliary transformer card (Part Number: MIN001)
Power supply of the CPU card.

> Remote Control Unit (Part Number: REM305 or REM306))
Remote control unit with operator control panel.

> Flat cable – from CPU to MOD (Part Number: CBF105 or CBF106)
Standard 20 pole flat cable to connect power module to CPU card.

> Flat cable – from MOD right to MOD left (Part Number: CBF103)
Standard 20 pole flat cable to connect both sides of the power module. Not needed in case of using only half power module.

> RS232 cable – CPU to REM
Standard cable for RS232 serial communication line to connect CPU card to REM

Optional:
> Operator panel kit (Part Number: OPP001)
Front display card used for configuration set-up and check. If installed, debug jumper of the CPU card must be turned ON.

> Flat cable – from CPU to OPP (Part Number: CBF201)
Standard 34 pole flat cable to connect CPU card to operator panel.

HSW Power Module Specifications Unit of Measurement Air
2500A
7.5V / 7%
Water
2500A
7.5V / 10%
CWM-W01 Water
5000A
7.5V / 5%
Max welding output voltage (Max load) Volt 7.5 7.5 7.5
Max output current  (Peak value) Ampere 2500 2500 5000
Instant power W 18750 18750 37500
Continuous duty cycle % 7 10 5
Short term (10 cycles) duty cycle % 15 15 10
Peak primary current required A/ac 54 65 130
Minimum primary current requirement A/ac 25 16 110
Adjustment precision (In line conforming with EN50160) % 2 2 2
Number of welding profile Phases   each 3 3 3
Max time for each phase Ms 2000 2000 2000
Number of transformers incorporated in ferrite E70 each >2 1 2
Working frequency on the primary stage kHz 15 15 15
Working temperature °C 30 NA NA
Interface RS232   Present Present Present
Short circuit protection   Autolimit Autolimit Autolimit
Overheating protection   Present Present Present
Phase loss detection   Present Present Present
Graphic memorization A + V real time   Present Present Present
Mains voltage
Vac
400 400 400
Mains frequency
Hz
50 – 60 50 – 60 50 – 60
Cos §  \ 1 1 1

Arc Welding (AWS) Mini

The Arc Welding System mini is a 100V/50A continuous current mode switching power generator with an embedded header driver. Included with the machine is one ignition coil to be placed near the target. The machine can drive up to two ignition coils.

The most important and unique characteristic of this machine is that it allows the welding to take place without any added material (tin or brazing alloys); instead, the welding takes place due to the fusion of the parts.

This method is an improvement versus the conventional tin immersion method in that it works without mechanically touching the parts being welded and thus avoiding any mechanical stress or disturbance. More over, since the welding process takes less than 50ms the thermal stress is reduced to an area of 1mm2.

AWS mini is enclosed in a case and is controlled by a microprocessor to permit the connectivity with robotized systems to obtain perfect synchronization for highly automated welding systems.

AWS mini also monitors every single welding (shot) by storing in the local memory the waveform profile of current and voltage and is communicated via the serial port to the host system to be analyzed.

The most popular applications for this technology are:
> Relay terminals
> Solenoid terminals
> Lamps terminal
> Thermocouple

Controlled via RS232 serial line by a PC/PLC or CRS remote control unit (Part Number: REM305 or REM306)

AWS Mini Specifications Unit of Measurement CWA-A01 Air 50A
100V / 50%
Max welding output voltage (Max load) Volt 100
Max output current  (Peak value) Ampere 50
Continuous duty cycle % 50
Short term (10 cycles) duty cycle % 100
Minimum primary current requirement A/ac 16
Adjustment precision (In line conforming with EN50160) % 2
Max number of heads each 2
Number of welding profile Phases each 3
Max time for each phase Ms 999
Working frequency on the primary stage KHz 25
Working temperature °C 40
Interface RS232 Present
Short circuit protection Autolimit
Overheating protection Present
Graphic memorization A + V real time Present
Mains voltage Vac 400
Mains frequency Hz 50 – 60
Cos § 1

The welding process is as follows:

> One cathode tungsten (negative polarity) is placed at 0.6mm from the target.
> The target to be welded is connected to the anode (ground).
> The machine through the control of the embedded header driver brings up the voltage to 15000V and ionizes the gas (air or inert gas) between anode and cathode.
> When the spark is started the power supply generator drives the current to generate and maintain the plasma arc according with the time and current parameters set in the memory.

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