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TRANSCRIPT
DeltaSpotResistance Welding
GENERAL REMARKS
And with DeltaSpot, that’s just what we’ve done
“Shifting the limits” is our credo. And we’ve definitely
lived up to this challenging motto again with DeltaSpot.
The absolutely innovative thing about this resistance-
welding process is its spooling process tape, and it is
this which gives the process its improbable-sounding
advantages: Every weld-spot is 100 % reproducible;
every spot is, so to speak, welded with an unused
electrode; high, indeed unrivaled process reliability;
zero surface spatter; any type of join is possible, even
aluminum to aluminum or steel to aluminum. As so often
with great innovations, the principle is simplicity itself.
So you can look forward to getting results that will
“knock spots off” the competition.
PROCESS
Process reliability that’s “got it taped”
The relatively simple yet so radically new principle
behind this process is the spooling process tape. This
runs between the electrode and the workpiece. After
every spot, the process tape spools on to its next
position. This means that the contact surface always
stays clean. Spot for spot, identically high-quality
conditions for starting the process. Spot for spot, a
“new” electrode. This is what makes the quality so 100 %
predictable. The surface of the electrode itself stays
clean no matter how long it is in use. Depending on the
application, you can expect to get up to 21,000 spot-
welds per tape.
Boundaries are there to bestretched: For us, at any rate
The process tape infl uences the heat balance, with the result that a lower welding current is needed. This means that power sources with a
comparatively low power rating can be used for DeltaSpot. Also, the process tape actively infl uences the position of the weld nugget: despite
differing material resistances, all the sheets are welded.
The process tape protects the
electrode from alloying effects
and provides constant, high-
quality starting conditions. Spot
for spot, a “new electrode”.
WELDING PROPERTIES
“Top Gun” with the C-pincer
The C-pincer gun is a powerful addition to the pincer
gun range, complete with all the familiar advantages of
DeltaSpot. Among the merits of the C-pincer gun are
its high contact pressure and the good accessibility
it allows for special component geometry. It welds
challenging 3-sheet joints with complete process-
reliability, and the high electrode force of 8 kN ensures
good spot-welded joins even in the case of super-high-
strength steel bimetal joins.
Keeping disturbance variables to a minimum
There are certain disturbance variables that are very
common in resistance spot welding. Electrode wear, a
shunt, and batch-related differences in the materials
and coatings are all typical disruptive factors. Here
too, DeltaSpot is different from other resistance spot-
welding systems. The unique process tape is able to
greatly minimize the effects of these disruptive factors.
The vertical electrode manipulation performed by the C-pincer gun is ideal for visually exposed spot-welds using the Expo
electrode. Use of the Q-Master quality assurance system is also possible, of course.
UTILIZATION
All-rounders
DeltaSpot opens up hitherto undreamed-of
perspectives in many different sectors. It can weld
any material: Steel and coated steel, both high and
super-high-strength; aluminum, chrome-nickel,
titanium, magnesium, bimetal joins, steel/aluminum-
joins. As well as joining materials of differing
thicknesses and types, DeltaSpot also welds multi-
sheet joins, with complete process-reliability.
Through thick and thin
DeltaSpot works with all metallic materials. 3-sheet
joins between different materials, thick or thin, can
be welded with just the same high process-reliability
as aluminum to aluminum. And resistance-welding
joins of aluminum have always been a high art
in themselves. In multi-sheet joins, the different
materials and sheet thicknesses encountered here
cause different material resistances to occur. The
choice of process tape can be “fine tuned” to take
account of these dissimilarities.
“Spot-on”, every time
3-sheet join between different steel alloys (1.8 mm / 1.75 mm / 1.0 mm = 0.071” / 0.069” / 0.039”)
Material: H400 1.8 mm (0.071”) / DX 53 D + Z 140 MB;
1.75 mm (0.069”) / DX 56 D + Z 140 MB 1.0 mm (0.039”)
Electrode: R+70
Process tape: plus PT1200, minus PT3000
Parameters: 8kA 500ms 4kN
Aluminum 3-sheet join(3.0 mm / 2.0 mm / 1.0 mm = 0.118” / 0.079” / 0.039”)
Material: AlMg3 3 mm (0.118”) / AlMg3 2 mm (0.079”) /
AlMg3 1mm (0.039”)
Electrode: R+70
Process tape: PT1407
Parameters: 17kA 700ms 4kN
Super-high-strength steel 2-sheet join(1.35 mm / 1.35 mm = 0.053” / 0.053”)
Material: 22MnB5 1.35 mm (0.053”) / 1.35 mm (0.053”)
Electrode: R+70
Process tape: PT1200
Parameters: 7.0 kA 590ms 3.6 kN
Suitable for any utilization
By developing several different pincer guns, Fronius
has opened up a much wider variety of utilizations.
The DeltaSpot pincer gun’s many different welding-
throat depths make for superior weld accessibility in
widely varying areas of utilization. In the automotive
and supplier industries, for instance, where it ensures
welding with complete process-reliability. Or for
highly demanding spot-welded joins in the mechanical
engineering, plant construction or railed-vehicle
construction fields.
MaximumDesignation Throat depth electrode force Weight
BASIC DESIGN OFPINCER GUN
X350 350 mm 7 kN 102 kg
(13.8”) (225 lb)
X500 500 mm 5 kN 106 kg
(19.7”) (234 lb)
X750 750 mm 3 kN 116 kg
(29.5”) (256 lb)
C300 300 mm 8 kN 120 kg
(11.8”) (265 lb)
Every spot is documented
immediately after welding, and
inspected for quality, diameter,
size, spot-position and spatter,
providing a seamless, traceable
data record.
QUALITY ASSURANCE
Controlling with Fronius Xplorer
This software was specially developed as an easy-
visualization tool for administering networked and
automated production areas, and for operating,
monitoring, documenting and diagnosing them on
a centralized basis. Any number of systems can be
controlled from a master control station. When it comes
to user-friendliness, Fronius Xplorer is hard to beat.
For ease and speed of handling, Fronius Xplorer is also
touchscreen-capable, of course.
Inspecting with DeltaSpot Q-Master
DeltaSpot Q-Master is a brand-new quality assurance
system developed specifically for DeltaSpot. Automated
and cost-effective. Q-Master can completely replace
the usual destructive testing methods. 100 % inspection
is possible at only minimal extra expense.
DeltaSpot Q-Master photographs and measures
each individual spot, by which we mean every single
“fingerprint” on the tape. The camera that does this sits
directly on the pincer-gun arm.
Fronius Xplorer is very easy indeed to operate: For example, the program
lets you create ideal curves for certain characteristics not only by keying in
exact figures, but also completely intuitively, by drawing the curve yourself.
SYSTEM
Versatile configurability
One of the big advantages of DeltaSpot is that it is
a perfectly matched, interoperable welding system
comprising various different components. These
include the pincer welding gun and the gun control. Any
standard medium-frequency inverter can be used as the
welding power source. The mechanical and electrical
interfaces enable the DeltaSpot system to be flexibly
connected to all common types of robot and field-bus
systems.
Example of a DeltaSpot system
1. DeltaSpot pincer gun
C- or X-pincer gun using medium-frequency
technology (1000 Hz).
2. Pincer-gun control
With its graphic user interface, the pincer-gun control
makes it easy to create the welding parameters.
3. Medium-frequency inverter
All common MF inverters with analog addressing
can be used here.
4. Water heat exchanger
Cooling unit for cooling the pincer-gun arm and
the MF transformer.
FACTS
Process characteristics
- process tapes protect the electrodes and
the materials to be joined
- 100 % reproducible weld-spots
- spatter-free spot-welding, with complete
process-reliability, even of 3-sheet joins
between different types of materials and
thicknesses of sheets
Recommended base metals
- steel, coated steel, high and
super-high-strength steels
- aluminum materials
- CrNi steel, titanium, magnesium
- bimetal joins, e.g. steel-to-aluminum
Customer segments
- automotive and supplier industries
- mechanical engineering and plant
construction
- construction of rail vehicles & rolling stock
ECONOMY
Surface spatter:None, zero, null, ninguna, nessuno
DeltaSpot leaves no surface spatter on the material. Both
the weldment itself and the working environment stay
clean, and there is no need for laborious cleaning of the
workplace. Nor, in most cases, is any post-weld machining
of the workpieces needed.
Welding on narrow flanges
An electrode specifically developed for use on flanges
provides superior weld accessibility, making it possible to
reduce the flange width by as much as 40 %. This means
that less base metal is needed and that the entire weldment
can be lighter. The process tape lessens wear-and-tear on
the electrode, ensuring long electrode service life.
Invisible with the Expo electrode
For visually demanding applications, the Expo electrode
has been developed. This is arched towards the inside
rather than the outside. Thanks to this special shape, the
base metal has sufficient space in which to expand before
regaining its original shape after the end of the joining-
process. The result is that the electrode indentation on the
workpiece disappears to almost nothing – and in turn, so
does the post-weld machining: there is no longer any need
to regrind the join. The Expo electrode is suitable for all
metallic materials such as aluminum, CrNi, steel or special
metals.
The special shape of the Expo electrode makes for minimal
electrode indentation.
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FRONIUS USA LLC10421 Citation Drive, Suite 1100Brighton, Michigan 48116, USA
Tel: +1 810 220 4414Fax: +1 810 220 4424
E-Mail: [email protected]
FRONIUS INTERNATIONAL GMBHBuxbaumstrasse 2, P.O.Box 264
A 4602 Wels, AustriaTel: +43 7242 241-0, Fax: +43 7242 241-3940
E-Mail: [email protected]
www.fronius.com
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