Epro Combi Machine Manuale utente

Version 1.0

April 2021

Combi Machine

User Manual

Contents

Product description:............................................................................................................ 4

Intended use:............................................................................................................... 4

General structure:........................................................................................................ 5

Functional principle: .................................................................................................... 6

General safety instructions:................................................................................................ 7

General instructions for device configuration:................................................................... 7

Electrode management system with compliance balancer: ....................................... 8

Selection of the milling tool:........................................................................................ 8

Installation instructions: ..................................................................................................... 9

Process flow welding-milling exchanging: ........................................................................ 10

General process flow:................................................................................................ 10

Milling sub-process:................................................................................................... 12

Exchange or replacement sub-process:..................................................................... 13

Programming: ................................................................................................................... 14

Alignment: ................................................................................................................. 14

Milling programming:................................................................................................ 15

Programming electrode extractor:............................................................................ 16

Orientation and grease access: ................................................................................. 17

Programming electrode replacement: ...................................................................... 18

Exchange and changing of the electrode cartridges: ................................................ 19

Testing electrodes and adapters: .............................................................................. 19

Optimization of milling process: ....................................................................................... 20

Operating parameters: .............................................................................................. 20

Milling format:........................................................................................................... 21

Chip formation and service life of the electrode: ..................................................... 22

Gun pressures that can impact performance:........................................................... 23

Troubleshooting:............................................................................................................... 23

Maintenance:.................................................................................................................... 32

Inspection of magazine cartridges (2-3 days):........................................................... 32

Inspection of changing canisters (monthly): ............................................................. 32

Care of the milling tools: ........................................................................................... 32

Overview of maintenance intervals: ......................................................................... 33

Contact.............................................................................................................................. 34

Product description:

Intended use:

The Combi machine is designed for spot welding devices and robotic applications. It is an

automated process compliant with ISO 5821 (CuCrZr) where electrode caps on a resistance

spot welding gun are reshaped by a milling tool or removed and replaced through an

automatic electrode exchange process.

Important Safety Notes:

Objects in the milling tool of the machine must not be handled manually. Electrode

caps milling devices for hand-welding guns must be used according to the service

instructions.

No work pieces or materials other than spot welding electrodes according to ISO 5821

(CuCrZr, CuZr, CuCr) may be used.

Personal protective equipment to be used as required.

For correct use of the machine, please review the entire operating manual and follow the

safety instructions.

We do not take responsibility for any injury or damage which had been

caused by improper use, inadequate installation or maintenance.

General structure:

The Combi machine (figure 1) has a modular design that is individually configured for a wide

variety of reshaping and replacement electrode applications. The machine can be oriented

vertically or horizontally, consist of a Cap Dresser assembly, Gearbox, Lenze smart motor

m300, Magazine, evacuation system that consists of a tube and a cap collecting canister, Stand

(supporting system), adapting plate allowing to switch between the vertical and horizontal

configuration.

The Combi machine is made up of several subcomponents as indicated by Figure 1 . Cleaning

of the milling tools from excess electrode material takes place during and after milling.

Removed electrodes are collected in separate integrated collection container.

Optional: Used electrodes and milling debris can be collected in separate waste container

depending on container configuration while electrical box configurations and stand

configurations can vary depending on need and requirement.

Figure 1 Combi Machine

Cap

Dresser

Assembl

Lenze Smart

Motor m300

Gearbox

Evacuation

Tube

Cap Collecting

Canister

Stand

Magazine

Adapting

plate

Functional principle:

In spot welding, the heat required to fuse the weldments is determined by the current, the

current flow time and the pressure of the closing force that form the weld nugget. Figure 2

shows the process and the formation of the weld nugget. Due to the constant interaction of

heat and pressure, the working surface geometry of the electrode cap changes and the work

surface increases in addition to the formation of a burr at the periphery. As the working area

increases in size the current per mm2 of work surface decreases, resulting in the deterioration

of the weld quality.

Welding quality degradation can also be associated with the properties of copper and zinc.

For example, in the automotive industry for reasons of corrosion protection, galvanized steel

sheets is being used more often. Through the welding process there is a formation of

contaminant material (buildup of zinc layers) on the electrode work surfaces resulting in an

increase of resistance to the work area, resulting in a loss of energy at the electrode working

surface, which is needed for heating the weld metal. This result in a lack of repetitiveness of

the expected welding result.

In order to achieve a reproducible welding result, the specific current intensity can be adjusted

proportionally to the work area magnification and the loss resistance via a stepper function.

Electrode management systems are used to repair and replace worn tips of welding electrodes

(ISO 5821). The welding robot brings the electrode caps or tips to the closed position in the

rotating cutter tool where both electrodes are brought to an acceptable shape at the same

time, free of impurities and deformed material.

Figure 2 Spot welding time cycle

General safety instructions:

Care on part of the owner / operator:

The machine may only be operated by persons who are trained, instructed and authorized to

do so. These persons must be familiar with the operating manual and act accordingly when

accessing the machinery.

Basic safety measures to be addressed include:

The welding machine should not operate on its own.

Access to the Cap Dresser and/or the protected area should remain clear but also

secure.

Robots and other plant components should be suitably secured.

Be aware of all safety protocols related to robots and electrical codes.

When changing tools and working on a machine, the power has to be switched off.

Work on the terminal box must be carried out by qualified personnel (electricians).

Operating without a protective cover removed is not recommended and protective

eyewear is recommended.

Gloves are recommended when working with chips or debris from the machinery.

Be aware of pinch points on the unit.

Stay away from electric drive when in operation or under power.

General instructions for device configuration:

Devices are modular so they can be quickly and easily adapted to the various installation

configurations.

Before commissioning the device, it should be checked by a simulation or locally in the welding

system to identify that it has been configured correctly. The geometry of the welding guns

must permit for a collision-free entry and retraction of the electrode caps into the milling

cutter for satisfactory milling result.

Also, the use of tools that are not suitable for the existing electrode pairing, can lead to serious

damage of the milling tool or electrode caps.

Electrode management system with compliance balancer:

The optimum use of the electrode management system is a vertical mounting configuration

although options are available for mounting in different configurations.

The task of the compliance balancer (Figure 3) is to compensate

for slight differences in the shortening of the welding caps. In a

new electrode configuration with two new welding caps, the

compliance balancer should remain in the normal position.

Selection of the milling tool:

Selecting the correct milling tool is based on the geometry of the upper and lower electrode

caps. The milling tool consist of a holder and cutter or blade that is held in place with a set

screw (Figure 4). Some tools come with Blue rings that must be snapped in place to ensure a

proper fit. Other holders come without a ring and equally provide enough protection so that

debris does not enter the housing.

Before the first use of the electrode milling tool, the selection of the tool must be checked on

the basis of basic characteristics which include total electrode diameter (D), effective surface

diameter (d), radius of active surface (r), as well as electrodes flanks (R) or flank angle ()

(Figure 5). Provide these specifications so that the correct product can be ordered to your

customized needs.

Figure 4 Cutters and holders Figure Figure 5 Features of the milling tool

Figure 3 Balancer

Installation instructions:

Precise installation is required for the stand or pivot arm so that a robot can mill or

change an electrode cap with precision.

The milling tool can be reached directly from the welding robot. Long distances can

unnecessarily extend the cycle time of the entire system. Review gun dimensions to

ensure accessibility of the electrode caps to the Milling tool.

Position the tool as indicated in Figure 9 so that the lugs or wings from the blade holder

fit into the machine gear and turn 90 degrees. Test that the tool is in place by pushing

on the backside of the holder. The holder should be secured and should not be

dislodged if the lugs are in place.

If the holder of the milling tool is equipped with the blue ring, ensure the ring is

snapped in place to the holder. Alternate holders are available without the blue ring

(Figure 10).

Ensure there are no collisions with welding parts, robots or other moving elements in

the welding area. As a check, the entire workflow should be simulated.

All machine connections including cables, hoses and pipelines, should be laid so that

they do not cause a tripping hazard. Laying cables and hoses with prescribed bending

radiuses are to be observed to avoid leaks and electrical contact.

Ensure all fasteners are secured.

Ensure accessibility for maintenance and repair work is to be observed.

Additional supply and electrical connections:

Filtered compressed air for the chip removal at 6-8 bar.

Supply for the three-phase drive depending on the device (380-575 VAC / 50-60 Hz).

Current protection 8 amps.

Lines with 24 VDC for motor switches, valves, as well as rotation speed and limit

position switches.

Optional: Remote bus system e.g. Interbus-S.

Check the function of each supply line independently via the manual overrides or the system

PLC. Ensure FIGURE 9 HOLDER AND BLADE INSTALLATION FIGURE 10 STANDARD HOLDER AND

BLADE THAT MAKE UP THE MILLING TOOL8

An air steam is present within the milling unit on both sides, diagonally above the

milling tool as well as at the end of the exhaust pipe.

The electric drive has the correct direction of rotation (clockwise from the top of the

gearbox).

The machine is not designed for continuous operation and as a result it is

recommended that subroutine be developed in the PLC run-time limiting run time to

a maximum 30 seconds.

In the system PLC, the rotation signal exists while in operation. One version presents a LED

with a fast pulsing signal. An optional version with integrated speed evaluation (3 LED), has a

continuous signal delivered with the correct milling speed.

Process flow welding-milling exchanging:

General process flow:

The process Flow consists of several steps, each of which is set up and optimized for the

number of spot welds before each milling process which depends wear caused by the welding

task. In general, electrodes are to be reshaped after 50-200 weld spots based on optimum

running conditions. Reshaping of electrode pairs may be repeated approximately 20-50 times

before electrodes are replaced.

The general process flow is shown in Figure 6 For a better indication of cutter or blade life it is

recommended that milling be performed before replacing electrodes to in order to measure

the difference in weld face size can electrode quality. The process chain should be followed

for program routine of the PLC device and the robot controller.

Make sure there is no welding current flow during the

milling and electrode replacement cycles. It may damage

the device or components!

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