In view of the technical difficulties encountered by precision spot welding machines when welding chip inductor hollow coils, enameled wires and copper wires, the editor of Huandian has specially summarized and shared a series of valuable experiences for your reference.
In welding practice, have you ever encountered frequent explosions, no molten cores or direct burnouts when welding enameled wires? The following reveals the main reasons behind it:
Accurate control of current and time: If the current is too large or the welding time is too long, it is very easy to cause explosions or spattering. Although power supply stability is the key, its impact in such problems is almost negligible (unless an alarm occurs).
The importance of welding pressure: During the welding process, the pressure applied by the electrode is often ignored by many manufacturers. Too low or unstable pressure can also cause spattering or explosions. It is worth noting that welding pressure does not refer to the maximum pressure that the cylinder can provide, but to the actual pressure of the electrode at the moment of welding. In order to achieve precise control, it is recommended to use a pressure sensor device, which sends a discharge signal to the power supply when the preset pressure is reached. Compared with delay control, this method is more stable and reliable, avoiding unstable factors caused by differences in the skills of the machine adjusters or differences in the mechanical structure springs.
Enameled wire stripping quality: When precision spot welding, if the enameled wire is not stripped completely or only one side is stripped, the welding effect will be seriously affected. Recently, some customers have adopted laser stripping, but because the laser can only irradiate one side of the wire, the stripping is not complete. For such situations, traditional old power supplies are difficult to deal with due to the lack of pre-welding inspection function. Our latest inverter welding power supply is equipped with a pre-welding function (i.e. pre-welding inspection). Before the formal discharge, pre-weld with a small current and measure the resistance value. For products with incomplete stripping, the system will automatically alarm and choose not to weld, thereby effectively avoiding the phenomenon of explosion during welding, while reducing electrode damage and reducing the frequency of grinding.
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