Automatic Spot Welding Equipment Overview
Automatic Spot Welding equipment can be a great benefit to any industry, as it allows for less down time when employing workforce in welding operations. This is particularly important for industries where the workload is very large, and there is generally a lot of downtime during the year. The following information will provide an overview of what welders use to achieve welds with ease. It should be noted that there are many different types of equipment available, which can vary between types of industries and types of sites.
Most modern automatic spot welding equipment uses tumblers for work pieces. A tumbler is simply one that has a metal surface on it, this surface can be smooth metallic one or can be rough like stone, tile or concrete depending upon the type of tumbler and the requirements of the work piece. Tumblers work by compressing a gas (usually a combination of argon and oxygen), into the work piece, and then sealing this gas away before welding begins. As you might guess, this acts as an oven by heating up the metal in question, giving it the correct internal temperatures for the required fusion. An automatic welder uses tumblers to create welds and this is the most common method, although some do use belt-driven tumblers, which are quicker and more often used in single plasma arc welding (SMAW).
Other forms of automatic welding equipment incorporate three electrodes. These electrodes are placed around the work piece, and a current is run through them, creating the weld. These are the most widely used in a variety of industries, and they tend to be the most expensive type of welding process available. However, because they offer so many benefits, especially when compared to tumblers, they are now becoming more popular among welders. In fact, they are rapidly outdoing traditional welders in most industries, and their popularity shows no signs of waning.
These days there are essentially three types of electrodes in an automatic spot welding equipment setup. These are generally known as beryllium copper electrodes (BCE’s), stainless steel electrodes and aluminium electrodes. The different types have different advantages. For example, stainless steel electrodes require more direct heat from the welding equipment itself to create clean welds, which means less wasted heat and energy. They also last longer than the other two and have a much smoother arc. They can only be used in a few different varieties of metal (it is possible to use only one, but these are generally not used) because of the resistance that these electrodes experience.
There are also three different types of electrodes. This is because the tumbler is the tool that creates the weld, which is controlled via a machine (or ‘robot’) which is in the same robot as the welders. The three different types of electrodes include thermal, direct-vent and consumable-metal electrodes. The difference between the different types is that the thermal electrode requires no heat to generate a weld – which means that it is cheaper to produce automatic spot welders and that it can be used on lower grade metals.
Finally there are the welders themselves. These generally sit on the work piece and are either fully automatic or semi-automatic (with the T-feed). A fully automatic weld is one in which the tumbler moves up and down on a fixed pivot point and locks onto the work piece once it is halfway open. Semi-automatic welds allow the tumbler to remain in place until the weld is complete, and the last type of weld is the consumable-metal weld, which is the cheapest and most convenient type of weld. All three types of welding electrodes, tumbler, work pieces and robot control can then all be run using one controller (usually a separate controller for each type of welding electrodes, depending on the size of the weld chamber).