resistance welding. em34.so.320 /h technical ... · resistance welding. technical specifications...

© RENAULT 2010 Origine : PEGI - Renault Page : 1 /28

Resistance welding. Technical specifications for robotized welding guns with electric motors

EM34.SO.320 /H ________________________________________

Standard ________________________________________

Status Applicable

Important Note: This document has been translated from the French. In the event of any dispute, only the French version is referred to as the reference text and is binding on the parties.

Objet Specifying the technical characteristics of robotized welding guns with electric motors for

welding equipment Scope Renault Group Issued by 65304 - Standard Process Engineering Confidentiality Not confidential Approved by Function Signature Application date

B. CONZELMANN Chef du service 65304 04/2010

EM34.SO.320 /H


Change record

Version Updated Summary of the principal modifications Written by A 12/1997 Replaces MC 34-320 Index A S. RAMOND sce 65304 H 04/2010 Update for X10 project. The changes are marked by a vertical

line in the margin S. HARDILLIER sce 65304 (1)

Replaces EM34.SO.320 /G of 05/2009 Availability Renault in-house on the intranet: http://gdxpegi.ava.tcr.renault.fr

Renault external on the internet: www.cnomo.com E.mail : [email protected]

Reference documents

Regulations

International : CEI 60270, CEI/TS 60034-17, CEI/TS 60034-25, ISO 10656, ISO 5826.

European : French : CNOMO : Renault : EB15.70.200, EM34.FL.000, EM34.FL.005, EM34.PN.375,

EM34.SO.000, EM34.SO.006, EM34.SO.122, EM34.SO.140, EM34.SO.170, EM34.SO.173, EM34.SO.176, EM34.SO.730, EP34.SO.650, GE34.SO.302, GE34.SP.100.

Other internal docs. : Other external docs. : Codification ICS : 25.160.30 Class E34 Key words soudage par résistance, pince à souder, machine à souder multipoint, resistance welding,

welding gun, multispot welding machine Language English Site Dept. Name Site Dept. Name TCR 65304 GRARE TCR 65304 GORITO TCR 65304 BREQUIGNY TCR 65304 CHARRON TCR 65304 BOURREAU

EM34.SO.320 /H

© RENAULT 2010 Source : PEGI - Renault Page : 3 / 28

Contents

1 General technical points ..........................................................................................................4 1.1 Definition and functional dimensions of X-type guns ................................................................................. 4 1.2 Definition and functional dimensions of J-type (or C-type) guns ............................................................... 5 1.3 Principles .................................................................................................................................................... 5 1.4 Choice of resistance welding guns for the project ..................................................................................... 6 1.5 Mechanical elements.................................................................................................................................. 6 1.6 Motorization................................................................................................................................................ 6 1.7 Indexing ...................................................................................................................................................... 7 1.8 Cooling ....................................................................................................................................................... 7 1.9 Protections.................................................................................................................................................. 8 1.10 Loom/gun electrical links............................................................................................................................ 9 1.10 Mechanical robot/gun links....................................................................................................................... 10 1.11 Compatibility couple gun / Robot ............................................................................................................. 11 1.12 Nominal conditions of use for standard and specific guns....................................................................... 11 1.13 Operating range of the welding transformer ............................................................................................ 11 1.14 Identification and description.................................................................................................................... 12 1.15 Secondary connections of arms............................................................................................................... 13 2 Functional capacities of a robotized welding gun with electric motor..............................13 2.1 Functional capacities of the motors and regulators ................................................................................. 13 2.2 Functional mechanical capacities ............................................................................................................ 14 2.3 Electrical gun capabilities ......................................................................................................................... 14 3 Gun validation.........................................................................................................................16 3.1 Type approval of a gun or gun supplier.................................................................................................... 16 3.1 Validation method for project use............................................................................................................. 16 4 Gun types, variants and families...........................................................................................16

5 Servo parameters ...................................................................................................................17 5.1 Principle.................................................................................................................................................... 17 5.2 Diversity of parameters (gun families)...................................................................................................... 17 5.3 Determining the parameters..................................................................................................................... 17 6 Documentation........................................................................................................................17 6.1 Start of project .......................................................................................................................................... 17 6.2 Guns delivery ........................................................................................................................................... 18 7 Reliability.................................................................................................................................18

8 Maintainability.........................................................................................................................18

9 Guarantees..............................................................................................................................19 9.1 First-fit guns.............................................................................................................................................. 19 9.2 Exchange guns......................................................................................................................................... 19 10 Delivery....................................................................................................................................19

11 List of reference documents..................................................................................................19

Appendix 1: Example working space .................................................................................................20

Appendix 2: Capability monitoring .....................................................................................................21

Appendix 3: Working dimensions.......................................................................................................22

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1 General technical points The welding guns must meet the requirements described in guide GE34.SO.302.

1.1 Definition and functional dimensions of X-type guns X-type guns are composed of two articulated arms, one of which is fixed or location-indexed, and another (mobile) arm that moves around an articulation axis. The welding plane passes through the articulation axis Diagram:

• D1 : Distance between articulation and motorization axis • D2 : Distance between articulation and active sides of tips

• LU 0+3 Working length • HU1 0+3 Working height 1

• HU2 0+3 Working height 2

• OU 0+3 Gun opening

• Id. 0+2 Indexing X

• Position of tool point / attachment plane Y ± 0,5 Z

X

Y

Z

+ 3 0

+ 3 0

+ 3 0

+ 3 0

+ 2 0

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1.2 Definition and functional dimensions of J-type (or C-type) guns J-type guns are composed of two arms, one of which is fixed or location-indexed and the other (mobile) arm whose displacement is controlled by tool guides.

Diagram: • LU 0+3 Working length



• OU 0+3 Gun opening

• Id. 0+2 Indexing

X • Position of tool point / attachment plane Y ± 0,5

Z

1.3 Principles The design of the guns must be such that it is possible to accept or reject optional balancing. • General

The gun must be designed so that it is possible to restore it to its original configuration, particularly in terms of the clearance, the offsetting of tips and the tool point dimensions. The adjustment possibilities (authorized by the manufacturer and at ATMP (Production Start-up Technical Approval) must remain close to the median position.

The welding transformer is built into the gun, unless otherwise authorized, and must be interchangeable without having to dismantle the gun from the robot, (Component-replacement time < 20min).

The electrical characteristics of the welding transformer are compliant with Standard ISO 10656 and its supplement EM34.SO.173. However, the mechanical characteristics, mounting principle and primary or secondary connection principle are left to the initiative of the manufacturer. In all cases, whether the transformer is 100 % ISO compliant or not, the transformer validation tests are compliant with the standard ISO 5826.

The transformer I2P must be 6,200A Choose the transformers according to standard EM34.SO.170. The gun must withstand acceleration of the robot selected by the project The gun must be designed so that the opening is greater than 45mm and the electrode wear can

be at least 7.5 + 7.5 mm.

X

Y

Z

+ 3 0

+ 3 0

+ 3 0

+ 3 0

+ 2 0

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• Balanced gun specifications:

The guns are suspended around the theoretical position (± 13mm to ± 15mm) with a balancing system and designed so that they do not cause deformation of the panels to be assembled.

The balancing can be adjusted according to the position of the gun in space. It is set by the integrator.

The guns must operate on the same robot in a minimum angular range of 90°, with efficient balancing, regardless of the position of the gun in space. The J-type guns must be equipped with a system known as “double-balancing”.

Each time the gun is opened, the indexing mechanism positions the ‘fixed’ arm so that it rests against the gun attached to the support. This mechanism is released at each weld spot.

1.4 Choice of resistance welding guns for the project Complies with standard EM34.SO.006. Working dimensions of guns A basic variety of guns is available per project. This gun variety is defined on the basis of the working dimensions. These are characterized by the geometric forms of the arms, and it must be possible for all manufacturers to produce them in their entirety (see appendix 4 and the EM34.SO.006 standard).

1.5 Mechanical elements

1.5.1 Gun stiffness The stiffness of the guns must not exceed 200daN/mm. Any case to the contrary requires special dispensation.

1.5.2 Lengtheners and tips These comply with the EM34.SO.122 standard for standard lengtheners and tips. Any request for a specific tip must be accompanied by a request to study the specific material, validated by the specialist of Department 65304. Recommendation for tip assembly:

two centered tips one centered tip and one off-center tip

Note: Sloping electrodes, along with two off-center or sloping tips, are not recommended and require special dispensation.

1.5.3 Attaching lengtheners to arms These are attached using keys, in compliance with the EM34.SO.122 standard. The guns are designed in such a way that it is possible to change and dress the tips in accordance with the space requirement dimensions defined in the EM34.SO.140 and EM34.SO.730 standards.

1.6 Motorization

1.6.1 Electric The motor must be cooled by air or by water. For all proposed technologies, the supplier must provide the limitations of their motors according to the duty cycle and cycle times (see § 2.3.3)

An identification label must be visible on the motor and the 400V or 600V voltage painted in red on the casing:

Height of digits: 30mm. Thickness of lines: 5mm.

The identification must be visible once the gun is installed.

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1.6.2 Pneumatic Pneumatic cylinder jacks may be used if dispensation has been granted. They are mechanically interchangeable with the electric motors

1.6.3 Motorisation avec Frein Guns with a working length LU > 450 mm as well as those equipped with a tool changer must be equipped with a motor with a brake. The brake motor must be controlled with the same connectors as used by a motor without a brake.

1.6.4 Lifespan of the motor Motors must be designed to have a lifespan of 60 million cycles. This can be achieved with the implementation of preventive maintenance within Renault plant maintenance workshops. The maintenance plan and frequency are to provided by the gun supplier. The frequency must not be lower than 3 million cycles.

1.7 Indexing Where the gun has been built with a balancing system, the indexing must:

Fulfill its function (minimum 50 daN to be withstood by tips) whatever the acceleration of the carrier robot.

If the system is pneumatic, it must operate under a pressure of ≤ 5 bars. A monostable, manual control enables de-indexing. At rest, the gun is indexed. The monostable solenoid valve is controlled for de-indexing. This is as small as possible and placed as close as possible to the cylinder to enable the shortest possible response time.

1.8 Cooling

1.8.1 Diagram See the diagram in the EM34.FL.005 standard.

1.8.2 Flow rate The flow rate for the gun is 5l/min. per arm with a ∆p of 1.5 bar for φ16 tips, with 12mm cones

and φ 4 x 6.3 flexible injector tubes (PTFE). The flow rate for the gun is 5l/min. per arm with a ∆p of 1.5 bar for φ20 tips, with 15mm cones

and φ 6 x 8.3 flexible injector tubes (PTFE). In all cases, the flow rates and pressures are measured with the pipes and connections mounted on the gun (gun assembly). The flow difference between the arms shall not exceed 20% of the nominal rate. The cross-section of the injectors must look like this (see EP34.SO.650):

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1.8.3 Flow rate control The gun must be able to integrate two fixed (or detachable, upon dispensation) flow measurement tubes with quick connects (see EM34.FL.005 standard).

1.8.4 Water supply and return apertures The integrator makes the connection to the water supply and return network using a Y-connect attached to the gun. This Y-connect is supplied with the gun. The apertures are identified respectively by the wording “In” and “Out” stamped on the metal.

1.8.5 Connections and pipes The connections are corrugated hoses or quick connects and are supplied with the gun. They can be detached without removing the elements of which the gun is constituted. The connections are made using 4-hole banjo couplings. The hoses must be resistant to weld spatter and friction..

Robotic Loom for ABB IRC5 The pipes are DN12, with rotating tips NORMYDRO M20 x 1,5 .EAT 14-13 The colors are green for the arrival and black for the return

1.8.6 Water quality The water quality and its treatment, that need to be taken into account for cooling the welding equipment, are detailed in the EM34.FL.000 standard.

1.9 Protections

1.9.1 Objectives Increasing the reliability of the robotized welding guns Reducing the costs of plant maintenance

1.9.2 General technical points • Main functions:

Protecting the welding gun from weld spatter Protecting the welding gun from glue and water projections Facilitating the easy assembly and removal of the protection (partial or complete)

• Technical functions: Resisting weld spatter Accompanying gun movements Marrying the form of the gun Not interfering with the gun operation (water, heating pipes, etc.) Not interfering with the surrounding associated functions (honing machines, hinged

support, loom changer, robot, etc.) Enabling access to the gun settings Resisting sheet metal and tool friction Being repairable on the gun Not being conductive Enabling the off-flow of water leaks Protecting the hinge joints and shunts

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1.9.3 Equipment selected by Renault

1.9.3.1 Authorized overall solutions

• A “made-to-measure” protective cover, • An “adjustable” protective cover, • Rigid protective housing (case) The gun manufacturer is responsible for the correct functioning of the gun with its protection in place. The cover or housing is an integral part of supplying the gun and must be assembled before the Production Start-up Test (TMP) under the responsibility of the integrator, in compliance with the gun manufacturer’s installation guidelines.

1.9.3.2 Selected comprehensive protection suppliers

• Made-to-measure covers: SOLANA PROTECTION, J77-type, Valladolid. (ref. 803). • Adjustable covers: ASP. (ref. ASPPMODJ50505000) • Casing: Gun manufacturer properties.

1.9.3.3 Obligatory protective equipment on the gun:

• A comprehensive protective system (according to § 1.9.3.1 and § 1.9.3.2) specified by the gun manufacturer.

• The arms of the gun are protected by boron nitride or an equivalent treatment, • A front end panel shield, interchangeable and resistant to weld spatter. • Screw heads with hexagonal sockets located outside of the comprehensive protective system are

protected by plugs.

1.10 Loom/gun electrical links

1.10.1 Gun/loom Welding Power Links The power link of guns must be achieved through direct connections (studs / lugs) via a housing Glands Access to the distribution box for dismantling must be possible:

From the upper surface of the distribution box From one of the side surfaces.

In all cases, the gun/loom welding power link dismantling time must be less than or equal to 15 minutes. For guns (mounted or ground-based) with a separate transformer, all the transformer connections are handled by the integrator.

1.10.2 Motor/loom links and gun information The electrical links of guns are ensured by a “separate” connector. Separation of the motor power, resolver control and gun information.

• Carrier robot made by ABB The motor power connections must be Intercontec 8 points connectors directly connected

to the loom. The motor power connections must be Intercontec 12 points connectors directly

connected to the loom. The gun command electrical link must be via a distribution box with an M23 Intercontec

19 pin input socket.

All the plugs and sockets face the same direction.

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Characteristics required of the distribution box:

Mechanical interfaces and electrical characteristics identical for all gun manufacturers Attached to the gun and can be removed Is an integral part of the gun Is as small as possible Is accessible with the gun mounted on its support. It must be possible to take measurements. IP65 waterproof Is equipped with screw holes to attach and orientate the plug connectors

NOTE : The connections must be secure and withstand robot accelerations.

1.10.3 Protection during operation The gun supplier must specify the gun connector protection level (shielding) in order to guard

against potential problems caused by its product in the welding phase. The gun supplier provides a single solution in terms of protection. The list of relevant suppliers will

be provided by technical experts from department 65304 Standard Assembly Facilities UET. The gun supplier is responsible for the validation of the selected protection system and must

provide proof of correct functioning during operation of command signals. The gun supplier will identify the maximum permitted level, in terms of disturbance of its product in

LF and HF mode. In all cases, the gun must be designed so that the field resulting from the operation of the gun at maximum current does not exceed 1mT in a radius range of 100mm in relation to the motor shell.

1.10 Mechanical robot/gun links The mounted guns are attached by a standard support to the nose of the robot. Attachment via the transformer is prohibited and requires special dispensation. In the event of gun disassembly, the support remains on the robot. A mechanism for aiding reassembly should be used to guide the operation. Handling guns: Screw holes for attaching slings are provided to enable the assembly / disassembly of the gun on the robot. A sling attachment diagram is supplied with the gun, with identification on the gun.

A radius of 100mm around the engine

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1.11 Compatibility couple gun / Robot The electrical compatibility (EMC : Electro Magnetical Compatibility, PDIV : Partial Discharge Inception Voltage) of couple gun / robtot must be guaranteed by CEI/TS 60034-17, CEI/TS 60034-25 (Guide for the design and performance of cage induction motors specifically designed for converter supply), CEI 60270 (Test techniques for high voltage, partial discharge measurements), All engines on offer for Renault must be held at PDIV of 2000 V min (under a rising edge of 0,2 µs). In the case where compatibility withstand PDIV less than the requested value, a protection device (filter) is expected. Its technical definition and its complete supply shall be borne by the gun’s manufacturer.

1.12 Nominal conditions of use for standard and specific guns Two force ranges are to be taken into consideration:

Range 1: Force on electrodes: 450daN Clamping time: 45 periods of 50Hz or 900ms Welding current: 16200A Rate: 30 spot welds per minute Duty cycle: 40 %.

Range 2: Force on electrodes: 630daN Clamping time: 90 periods of 50Hz or 1800ms Welding current: 18900A Rate: 20 spot welds per minute Duty cycle: 54%.

The standard gun library (working range dimensions given in appendix 4) must be available in Range 1 and Range 2. Specific guns must be built to meet the requirements of Range 2. Definition of the duty cycle:

1.13 Operating range of the welding transformer For each force range, the transformer is selected so as to be as close as possible to the optimum conditions of use (adjustment range of welding equipment according to standard EM34.SO.000).

Maximum effort of the 450daN gun: maximum available current of 18000A with no panel, for an operating range of 8100 A (45%) to 16200 A (90%)

Maximum effort of the 630daN gun: maximum available current of 21000A with no panel, for an operating range of 9900 A (45%) to 18900 A (90%)

All guns outside of these ranges are considered as specific and are subject to special dispensation. Each gun type is equipped as basic with the largest transformer that can be supported. Changing the size of the transformer (for a smaller version) should cause no changes in the fastenings and overall dimensions of this same type of gun.

Clamping time

Cycle time X 100 Duty cycle =

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1.14 Identification and description The identification of guns must comply with the standard EM34.SO.006. The description of a gun must be in accordance with the following diagram: Key to sections:

Section 1: Supplier gun code. This section can only have a maximum of 3 characters and must identify the type and gun body. This code is provided by the supplier.

Section 2: Gun library code. This code is submitted by Renault and corresponds to the library (therefore the project) in which the gun is stored.

Section 3: Gun working range dimension code. This section identifies the dimensions of the gun's working range (LU). It is made up of 3 numbers. Example: 050 for an LU 500mm gun.

100 for an LU 1000mm gun etc. Section 4: Transformer code. This code is made up of a single letter corresponding to the

transformer type of the gun. When this has not yet been finalized (in the design phase or for archiving in the library) the code is ‘’X’’. As soon as the choice of transformer has been finalized, this X is replaced by the transformer code in accordance with the following system: 6.1V transformer represented by the letter ‘’G’’ 7.1V transformer represented by the letter ‘’K’’ 8V transformer represented by the letter ‘’P’’ 10V transformer represented by the letter ‘’T’’ 13.5V transformer represented by the letter ‘’U’’

Section 5: Gun variant code in the working range. Distinguishes guns with the same LU, but with different arm shapes.. This code is made up of 2 numbers, starting from 01, and continues empirically: 01 up to 99

Section 6: Terminal components variant code in the same gun. This code distinguishes terminal component variants for the same gun. It is made up of a maximum of 1 to 3 characters and is provided by the gun manufacturer.

Example of description: Gun type X body No.1 (PX1) created in library 62 (62) with an LU of 400mm (040) with a 10V transformer (T), variant no.1 (01) with type 1 terminal components (ET1).

X X X X X 0 X X X X X X X X

Section 1

Section 2

Section 3

Section 4 Section 6

Section 5

PX1 62 040 T 01 ET1

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1.15 Secondary connections of arms The secondary connection of the 2 gun arms is provided by:

Either a shunt with blades moving along a linear or angular axis EM34.SO.176 Or one or more braids moving along a linear or angular axis and cooled by water. In both cases, the secondary connections system is connected to surfaces cooled by water.

In the case of an attachment using a single screw, the connection surfaces of the shunt with blades or the braid feature an anti-rotation lug (on one of the three shunt faces).

The mounting elements are specified in the technical standard EM34.SO.176. The secondary connections must be designed to have a minimum lifespan of 6 million cycles under a maximum current of 21,000A and an I2P of 6,200A.

2 Functional capacities of a robotized welding gun with electric motor The functional capacity of an electric welding gun derives directly from the elements of which it is composed, i.e.:

the electric motor and its regulator the hinge joint and guides the arms the terminal elements (electrode carrier + lengtheners + tips) the transformer (with bipolar cable if not built-in)

The gun may be called into action in its operating cycle as long as the functional capacity of each of the elements has not been exceeded. The following limits are distinguished:

the electrical limits imposed by the motor and its regulator the mechanical limits deriving from the gun’s construction the weight and inertia of the gun and its support the short-circuit current (Icc in A) deliverable by the gun and limited by the gun’s dimensions

(impedance) the permanent current (I2p), limited by the number of spot welds, the number of welding periods

and the number of cycles

2.1 Functional capacities of the motors and regulators The motor must be adapted to the system regulator used to control the gun.

2.1.1 System built into the carriers The supplier commits to providing a motor that is compatible with the carrier control specifications (regulators) and available from the robot suppliers. The control cabinets or bays on the Renault panel are:

ABB type IRC5

2.1.1 System independent of the carrier (autonomous) The gun supplier commits to providing a motor that is compatible with the independent system control specifications (regulators) and available from the supplier. The independent control cabinets on the Renault panel are:

ARO: Ibox type SERRA: Serratron type

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Fe

2.2 Functional mechanical capacities The mechanical limits of the gun depend only on its construction. They are independent of the operating rate and are provided by the gun manufacturer.

2.2.1 Limits of the hinge joints Each hinge joint has a mechanical limit which is the responsibility of the resistance welding material supplier, corresponding to the maximum torque that it can transmit in Nm. The maximum force at the tips (Fe max.) depends on the D1 and D2 moment arms for the X-type guns.

)(2tan).()max(.

mDceDismNqueMaximumtorNFe =

2.2.2 Limits of arms and terminal parts The required objective is 450 or 630 daN at the electrodes. Any elements that restrict these ranges (electrodes, lengtheners) require special dispensation.

2.2.3 Mechanical limits of the gun The mechanical limit taken into consideration is that of the weakest element. This force or torque must not be exceeded at the risk of premature wear and tear on the gun or even breakage (annotation to be included on the gun label). Note: Motorization over-capacity. On certain guns, the force applied by the motor to the gun may enable the maximum force or torque that can be supported mechanically to be exceeded. This is why it is important to limit the maximum current of the motor when setting the parameters in the robot controller. This limit is provided by the gun supplier on the servo parameters sheet.

2.2.4 Transformer limits and calculations The calculation of the transformer size depends on:

the welding range the gun impedance

The gun supplier is responsible for the impedance of his gun with respect to a given welding range. The integrator is responsible for the welding range and for installing the robot on site. Consequently, the integrator is responsible for the gun and transformer capabilities and must have them checked with the gun supplier.

2.3 Electrical gun capabilities The characteristics of the gun duty cycle must always fall within the electrical and mechanical limits of the working space. Any change to any of the elements of the gun may require a change of space, which must be compatible with the required cycle. In accordance with the EM34.SO.006 standard, the integrator is responsible for computing the capability of each gun.

M

D2 D1

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2.3.1 Software The software for computing the capabilities must be supplied by the gun suppliers. The software allows the capability sheet of each gun to be printed on A4 format paper. The gun suppliers distribute their software to each project team, with an explanatory note for the following parties:

all integrators the gun and welding specialists of Dept. 65304 the plants

Furthermore, they undertake to update and re-distribute their software throughout the course of the project and during operation if there have been any technical modifications liable to modify the capabilities computation, and to take responsibility for all technical and financial consequences.

2.3.2 Definition of the working space The "working space” of a gun is delimited in a graphic that characterizes its electrical and mechanical capacities by positioning the corresponding calculated limits. The x-axis represents the operating rate graduated in resistance spot welds / min. The y-axis represents the permissible force at the electrodes graduated in daN (see attached diagram, for example, in appendix 1).

2.3.3 Motorization limits Cycle limit (motor limit): In the working space, there is a curve defining the limits of the forces available at the electrodes due to the motorization limits. According to article 2.1, these limits depend on the work rate, which can be assimilated with a duty cycle. Each point of operation on this curve corresponds to operation at the motor's limits.

2.3.4 Regulator limits Electric limit of the regulator This is a limit imposed by the regulator controlling the gun. This limit corresponds to the force on the electrodes that the gun is able to develop up to the limits of the regulator’s possibilities (rating). This limit does not depend on the work rate. However, it is a limit that is only theoretically accessible during the transitional phases of acceleration and deceleration (dynamic phases < 1 second). Under no circumstances may it be exceeded. Thermal limit of the regulator The gun manufacturer must ensure that the regulator is suitable.

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3 Gun validation

3.1 Type approval of a gun or gun supplier All gun type approvals for Renault must be in accordance with the guide GE34.SP.100. All guns proposed for type approval must be in accordance with the Guide GE34.SO.302 in terms of performance. The list of suppliers of type-approved guns is available from the Technical Leader of department 65304 Resistance welding and manufacturing plan UET.

3.1 Validation method for project use A gun can only be used in a project if it has been type-approved. The integrator is responsible for his weld range but must have its capability checked with the gun supplier. The two parties sign the Technical Schedule for Trouble-Free Integration (BTBI) before passing it on to Dept. 65304. THE VALIDATION OF AN ELECTRICAL GUN IS ONLY VALID FOR A GIVEN WELDING RANGE (see appendix 2)

4 Gun types, variants and families The notion of gun types may be understood according to the following criteria:

the gun body or hinge joint the working dimensions deriving from the forms of the arms

The gun variants may be understood according to the following criteria: the transformers the lengtheners and electrodes

The notion of gun family depends on the following characteristics: mechanical electrical servo parameters

Definition of “family”: set of guns which, on account of their mechanical similarity (motorization and arms), work with a set of servo parameters that is unique (for all guns in the family) and exclusive (no gun outside the family has the same set of parameters).

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5 Servo parameters

5.1 Principle The electrical guns are servo-controlled for position and force. Consequently, there exist two types of parameter:

“Position” parameters “Force” parameters

They allow the robot controller to control the gun.

5.2 Diversity of parameters (gun families) Two guns from the same family must have the same set of parameters.

5.3 Determining the parameters They are determined for each family by the gun supplier in consultation with the robot manufacturer. One gun from each family is validated by the robot manufacturer under the auspices of the gun manufacturer. If the robot manufacturer does not deem the gun acceptable, special dispensation must be requested from Renault. The parameters are formalized per family in a single document designated "Servo parameters directory" that is submitted when the guns are delivered:

to the integrator to the specialist of Dept. 65304 to the plant

This document indicates clearly the procedure for setting up the parameters in the controller. Each gun is delivered with a CD, its parameters sheet and its qualification report (according to GE34.SO.302). The integrator is responsible for the correct integration on site (according to GE34.SO.302).

6 Documentation 6.1 Start of project

Once nominated, the guns supplier supplies: the paper catalog of the standard guns chosen for the project by Dept. 65304 to the integrators,

to the specialist of Dept. 65304 and to the project team the ROBCAD digitizations to the IT specialist aided by the guns specialist of Dept. 65304

according to their recommendations in line with the standard EM34.PN.375 The digitization of a gun must take account of the overall dimensions of the largest permissible welding transformer for the gun.

his capability software to the integrator, the guns specialist of Dept. 65304 and the plant.

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6.2 Guns delivery The guns supplier provides the integrators, the Dept. 65304 specialist, the project teams and the plant with the following documents on paper and in IT format (Internet authorized) according to the milestones in the EM34.SO.006 standard:

Robcad digitization of guns Technical Schedule for Trouble-Free Integration (BTBI) Labels BDN or TDI Servo parameters Inspection report Parts lists Capabilities Assembly plans and sub-assembly plans Detailed plans of non-Renault standard wear parts and spare parts (*)Reminder: The guns supplier has to provide assembly plans, dimensioned sub-assembly plans and

plans of definition check for manufacturing (Plan with Renault title block in compliance with the norme EB15.70.200 standard ) from the attachement of the arm up to the electrode (Electrodes, Lengthener, PE (specific lengthener), arm, key).

The gun supplier provides the integrator with the following, per gun: 2 additional lengtheners per arm at TMP if the gun is equipped with movable lengtheners as

standard 1 additional mass electrode holder (PE) per arm if the gun is equipped with a mass electrode

holder as standard 1 set of 10 Removable caps (tips) for each arms

These are passed on at the plant by the integrator to the plant client

7 Reliability Number of breakdowns for 1 million spot welds: 0.1.

8 Maintainability The instructions for maintenance and use must detail the maintainability conditions and, in particular, the following items that the gun supplier may break down by gun type if necessary.

Cleaning time for 1 million spot welds (in minutes per gun) 30 minutes Exchange time for protection mechanism against weld spatter (in minutes per gun)

10 minutes

Number of spot welds between two exchanges of the protection mechanism against weld spatter (for one gun)

8,000,000 spot welds

Preventive maintenance time (excluding cleaning time) for 5 million spot welds (in minutes for one gun)

60 minutes

Exchange time for the gun (in minutes for one gun) 40 minutes Life span with annual preventive maintenance 60,000,000 spot welds

Allonge / PE (Allonge spécifique)

Key

Electrodes

Lengthener / electrode holder (PE) (Specific lengthener)

EM34.SO.320 /H


9 Guarantees

9.1 First-fit guns 18 months as from the Production Run Technical Approval (ATMP) under normal working conditions.

9.2 Exchange guns 8 million spot welds under normal working conditions.

10 Delivery The guns are delivered pre-set and packaged, ready for immediate use. Any damage during transportation is the responsibility of the gun supplier when delivered to the plant or to the integrator, if the transportation service has been bought from him.

11 List of reference documents NOTE : For any documents that are not dated, the latest version applies. CEI/TS 60034-17 : Rotating electrical machines - Part 17: Cage induction motors when fed from

converters - Application guide CEI/TS 60034-25 : Rotating electrical machines - Part 25: Guidance for the design and performance of

a.c. motors specifically designed for converter supply CEI 60270 : High-voltage test techniques - Partial discharge measurements ISO 5826 : Resistance welding equipment – Transformers –General specifications applicable to

all transformers ISO 10656 : Electric resistance welding. Integrated transformers for welding guns EB15.70.200 : Industrial machines, installations and tool. Plans in mechanical dossier. - General

recommendations (for the BED) - Media (for the BED and APF) EM34.FL.000 : Design and/or construction rules concerning specific utilities for the body shop. EM34.FL.005 : Resistance welding. Flow rate control of cooling water in welding guns EM34.PN.375 : Digitization principle for Robcad library components EM34.SO.000 : Resistance welding techniques and facilities EM34.SO.006 : Choosing resistance welding guns and compiling dossiers EM34.SO.122 : Detachable pin end pieces and lengtheners for robotized guns EM34.SO.140 : Automatic changers for detachable pin end pieces for mounted welding guns EM34.SO.170 : Equipment recommended by Renault. Branch: Resistance welding. 50Hz resistance

welding transformers (all types) EM34.SO.173 : Electric resistance welding. Integrated transformers (TI) for robot weld guns.

Supplementary information for standard ISO 10656 EM34.SO.176 : Electric resistance welding. Leaf shunts connected to water-cooled surfaces EM34.SO.730 : Automatic tip dressing system for detachable pin end pieces for mounted welding

guns EP34.SO.650 : Process functional specifications. for hand-held guns with built-in transformer GE34.SO.302 : Acceptance testing guide for robotized electric welding guns and control systems GE34.SP.100 : Equipment Innovation Quality Assurance (AQIM) for the bodywork assembly facilities.

EM34.SO.320 /H Appendix 1 Normative


Appendix 1: Example working space

Example range: Real range:

Sequence No. Clamping force (daN) Clamping time (periods) Number of spots 1 200 20 8 2 350 31 1 3 270 29 1 Equivalent MOTOR range for cycle time P1 (4, 248):

Cycle time Rate Feq teq 70 hundredths of a min. 14 spot welds / min 248daN 20 periods

Equivalent REGULATOR range for welding time P2 (19, 248):

Cycle time Rate Feq teq 53 hundredths of a min. 19 spot welds / min 248daN 20 periods

Equivalent REGULATOR range for the four most penalizing resistance spot welds P3 (53, 306):

Cycle time Rate Feq teq 8 hundredths of a min. 53 spot welds / min 306 spot welds / min 20 periods

Rate (Spot welds / min )

F electrodes (daN)

P1 P2 P3

200

400

600

800

1 000

1 200

1 400

10 20 30 40 50 60 70 80

Regulator limit curve

Motorization limit curve

Mechanical limit of hinge joint

Max. force of range Mechanical limit of arms

P = f (rate, frequency)



Appendix 2: Capability monitoring

Who does what?

Modification of welding range,

transformer, gun body

Modification of welding range

Modification of welding range

Modification of welding range,

transformer, gun body

Plant

Integrator

Gun supplier

ATFE

TMP

Section stacking

Weld range

Gun pre-selection

Gun / regulator / transformer selection

BTBI

Capabilities

BTBI

Capabilities

Capabilities

OK Y

Y

Y

N

N

N



Appendix 3: Working dimensions

X-type guns

N ° 1 N ° 1

N ° 5

N ° 4

N ° 1

N ° 3

N ° 5

N ° X1

N ° X3

N ° 6

N ° X2

N ° X4

N ° 6 N ° X5 N ° X6



N ° X7 N ° X8

N ° X9 N ° X10

N ° X11 N ° X12



N ° X13 N ° X14

N ° X15 N ° X16

N ° X17 N ° X18



N ° X19 N ° X20

N ° X21 N ° X22



N ° X23 N ° X24

N ° X25 N ° X26

N ° X27

N ° X28



J-type guns

N° J1 N° J2

N° J3 N° J4

N° J5 N° J6



N ° J7

N ° J8

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