Thin Line Weld Heads Technical Datasheet

Thin Line Weld Heads Technical Datasheet
™
Weld Heads
Amada Miyachi's Thin-Line Heads
for spot welding applications
comprise three families of fullfeatured products for resistance
spot welding: 80 Series (20 lbs
(89N) - 40 lbs (178N)), and 180
Series (100 lb (445 N)). All are
precision, low inertia, force-fired
designs, with narrow vertical
profiles. Inline and parallel gap spot
welding configurations available.
Ideal for both production line and
benchtop applications, Thin-line
weld heads can operate at speeds
greater than 3600 welds per hour.
TYPICAL APPLICATIONS
KEY FEATURES
• Low inertia, fast follow-up designs improve weld consistency, reduce
metal expulsion, and improve weld appearance
• Adjustable force firing ensures weld force is independent of electrode
stroke length resulting in higher quality welds
Magnet wire to terminal
• Patented EZ-AIR technology ensures force consistency and simplifies
set-up
• Rugged industrial design improves productivity, minimizes repair costs
and ensures long life
• Pneumatic or manual actuation
Coin cell battery tab
Honeycomb tacking
1/8
RESISTANCE WELDING
Thin-line
RESISTANCE WELDING
PRECISION PERFORMANCE THROUGH INTELLIGENT DESIGN
The Thin-Line Ranges
Amada Miyachi's Thin-Line Weld Heads
consist of two families of full-featured
products for precision metals joining:
80 Series – 0.25 to 20 lbs. (1.1 to 89 N)
4 to 40 lbs. (18 to 178 N)
180 Series – 5 to 100 lbs. (22 to 445 N)
Durable High Quality Design
Rugged construction, linear ball bearing
bushings and an over-sized, anti-rotation
bearing system provide perfect linear travel
of the upper electrode arm. This system
minimizes the potential for electrode
wiping action during the weld, even at
maximum force settings. Based on actual
test data, bearing life exceeds 25 million
operations when used according to the
specifications.
High Speed Capability
EZ-Air ensures repeatable, reliable, highspeed operation in automated applications.
Threaded holes on the back of the heads
make them easy to mount, without their
post or base, in automated work stations.
EZ-Air provides unsurpassed repeatability
and ease of set-up.
Precision Control
Thin-Line Weld Heads add consistency and
control to complex welding applications.
Their low inertia designs ensure the fast
dynamic response required for the
electrodes to follow the minute expansion
and contraction of the weld joint as it heats
and cools. A differential motion force-firing
system initiates the welding control at the
precise moment when the pre-set
electrode force is applied to the
workpieces.
Electrodes and
Accessories
A complete line of accessories and
electrodes are available. Optics are
available for all heads. All heads are
supplied with firing switch cables,
mounting hardware, and one set of
electrodes.
ELECTRODE CONFIGURATIONS MATCH SPECIFIC APPLICATION NEEDS
Step Configuration
Opposed
Configuration
Top and bottom electrodes
are used to hold the parts
and provide the current path.
An opposed weld is preferred
over other configurations
because it is easier to set-up
and control the current path.
It should be used whenever
possible.
Thin-Line weld heads
designed for series welding
can also be set up in a step
configuration. Two top
electrodes are used, but one
electrode contacts the top
part and the other electrode
contacts the bottom part. A
single weld is produced at
the part to part interface.
Step weld
Independent force control
allows the electrode force on the bottom part to be set much higher
than the force on the top part.
Opposed weld
Series Configuration
Parallel Gap
Configuration
Using two top electrodes, a
series weld can be used
when there is no access to
the bottom part. Both
electrodes contact the top
part and current is passed
through the top part to the
bottom part. Two weld spots
are produced, one under
each electrode. Independent
Series weld
force control allows for
separate adjustment of each electrode force and is used to balance
the heat between the two weld spots.
Parallel gap welding results
in a single weld spot under
the gap between the
electrodes. It is used to weld
very small parts. Two styles
of parallel gap electrodes
are available: Unitips®
Parallel gap weld
which are permanently
bonded together with an insulating spacer and fixed gap; and
Unibond Electrodes® which allow for adjustment of the gap.
2/8
RESISTANCE WELDING
HIGH QUALITY, FULL FEATURED
All Amada Miyachi weld heads are subjected to environmental life testing designed to
guarantee specifications and performance.
Air actuated weld heads are supplied with an EZ-Air force control module. The air
actuation system includes a linear spring which ensures proper operation at low forces.
EZ-Air provides high repeatability and eliminates overforce. The air systems can be
moved to other locations when the heads are incorporated in work stations or
automated systems. The heads can be supplied with an optional Hall Effect Limit Switch
Kit, which will detect when the head is in the up or down position. This feature can
prevent damage when automated machine tooling is indexed.
80 SERIES DESIGN FEATURES
Upspeed Adjustment
Adjustable Downstop can be
Used to Protect Tooling
Air Cylinder
Optional Hall Effect "Head Up” Sensor
Adjustable Upstop Reduces
Stroke and Travel Time
Teflon Impregnated Sleeve Bearings
Increase Life and Reduce Friction
Weld Force Can be Set to Trigger Power
Source at Forces from .25 lbs to 40 Ibs
Depending Upon Model
Downspeed Adjustment
Two Tapped Mounting Holes on Spine
Simplify Installation on Automated Machines
Over-sized Cam Adjusts
Force Triggering Sensitivity
Smooth, Low Friction,
Play-free Motion is
Insured by Linear Ball
Bearings, with Bearing
Clearance Adjustments,
Which Guide a Hardened
Low Inertia Steel Shaft
Pull Rod and Return
Spring Used on Foot
Actuated Models
Over-sized AntiRotation Bearing
System Resolves
Side Loads and
Minimizes Wiping Action
Flexibility is Provided
by Opposed, Series, and
Parallel Gap Holders
Adjustable Tare Spring on
20 Lb Models can Compensate
for Weight of Electrode Arm Assembly
A Variety Of 1/8 or
1/4 Inch Diameter
Electrodes, Unibond,
or Unitip Electrodes
Can be Used
Flexure Design Provides
Long Life and Reduces
Drag Which Improves
Weld Quality
1, 1.25, or 1.5 Inch
Stroke Depending
on Model
Select From Three
Mounting Stands:
Post Mount,
L-bracket, or
I-column
Offset, In-line, or Table
Electrode Arrangements
Can be Used
3/8
RESISTANCE WELDING
80 SERIES THIN-LINE WELD HEADS –
Force Range 0.25 to 20 Lbs.(1.1 to 89 N)
TECHNICAL SPECIFICATIONS
Model
Unit of Measure
80F1
80A/EZ
86F2*
86A/EZ*
87F1
87A/EZ
88F
88A/EZ
Maximum lb (N)
Minimum lb (N)
KVA (Watt-secs)
Manual
20 (89)
.25 (1.1)
2 (250)
Air
20 (89)
.5 (2.2)
2 (250)
Manual
20 (89)
.25 (1.1)
1 (125)
Air
20 (89)
.5 (2.2)
1 (125)
Manual
20 (89)
.25 (1.1)
2 (125)
Air
20 (89)
.5 (2.2)
2 (125)
Manual
20 (89)
.5 (2.2)
5 (250)
Air
20 (89)
.5 (2.2)
5 (250)
Actuation
Weld force
Maximum rating
Maximum electrode stroke
Electrode diameter
in (mm)
in (mm)
1 (25)
1 (25)
.125 (3.2) .125 (3.2)
1 (25)
1 (25)
1 (25)
1 (25)
1 (25)
Unibond
Unibond Thermodes Thermodes 0.245 (6.2)
Unitips
Unitips
Unitips
Unitips
Opposed Parallel gap Parallel gap Parallel gap
N/A
Series
1 (25)
0.245 (6.2)
Electrode configuration
Opposed
Electrode holder type
Maximum throat size (H x D)
Offset
Offset
Offset
Offset
Offset
Offset
Offset
Offset
1.94 x 6.0 1.94 x 6.0 3.38 x 5.19 3.38 x 5.19 2.55 x 5.25 2.55 x 5.25 6.2 x 6.25 6.2 x 6.25
(49 x 152) (49 x 152) (86 x 132) (86 x 132) (65 x 133) (65 x 133) (157 x 159) (157 x 159)
–
–
0.040
0.040
0.040
0.040
1.75
1.75
–
–
(1.0)
(1.0)
(1.0)
(1.0)
(44.5)
(44.5)
ES-0400 ES-0400 EU or UT
EU
174 or UT
174
ES-0800E ES-0800E
in
(mm)
Iin
(mm)
Maximum gap
between electrodes
Electrode series
Foot pedal model
Footswitch model
CP
VAC
–
–
FS1L,
FS2L
24
–
–
FS1L,
FS2L
24
–
–
FS1L,
FS2L
24
–
–
FS1L,
FS2L
24
Air pressure for max. force
psig (bar)
–
65 (4.5)
–
65 (4.5)
–
65 (4.5)
–
65 (4.5)
Air cylinder inside diameter
Cycle rate: @min. force
@> 20% of rated force
in (mm)
Full strokes/sec
Full strokes/sec
–
–
–
.75 (19)
1
2.5
–
–
–
.75 (19)
1
2.5
–
–
–
.75 (19)
1
2.5
–
–
–
.75 (19)
1
2.5
16 (406)
6.6 (168)
2.2 (56)
16.5 (419)
13.8 (350)
3.5 (89)
16 (406)
7.0 (178)
2.2 (56)
16.5 (419)
13.8 (350)
3.5 (89
16.7 (424)
13.5 (343)
4 (102)
19.3 (490)
15.6 (396)
5.6 (142)
5.5 (2.5)
7 (3.2)
5.5 (2.5)
7 (3.2)
14 (6.4)
17 (7.7)
Air solenoid voltage
–
–
CP
–
CP
–
MSP
Series
–
WEIGHT & DIMENSIONS
Maximum dimensions
(including stand & air kit)
Weight (before packing)
Height – in (mm) 13.7 (348) 15.9 (404)
Depth – in (mm) 6.93 (176) 13.8 (350)
Width –in (mm) 1.8 (46) 3.5 (89)
lb (kg)
5 (2.3)
7 (3.2)
*A UTA to mount Unitips is needed on the 86 weld heads
(1) Model 80FLF and 87FLF have a force range of 0.25 - 10 lbs (1.1 - 44.5N).
(2) Model 86FRE and 86ARE use 1/8 inch (3.2mm) diameter Series E0-0400 35° Offset Electrode Holders and Electrodes.
(3) See page 7 for EZ-AIR specifications.
(4) 17BM, 17F, 17M, 17P or 17SR
80A/EZ
88A/EZ
86F
Offset/opposed
Offset/parallel gap
(See EZ-AIR)
Offset /series
(See EZ-AIR)
4/8
Force Range 4 to 40 Lbs. (18 to 178 N)
TECHNICAL SPECIFICATIONS
Model
Actuation
Weld force
Maximum rating
Unit of Measure
82A1
84F
84A/EZ
89F
89A/EZ
Maximum lbs (N)
Minimum lbs (N)
KVA (Watt-secs)
Air
40 (178)
6 (27)
5 (250)
Manual
40 (178)
4 (18)
5 (250)
Air
40 (178)
6 (27)
5 (250)
Manual
40 (178)
4 (18)
5 (250)
Air
40 (178)
6 (27)
5 (250)
Maximum electrode stroke
in (mm)
1 (25)
1 (25)
1 (25)
1 (25)
1 (25)
Electrode diameter
in (mm)
.25 (6.4)/.125 (3.2)
.25 (6.4)
.25 (6.4)
0.245 (6.2)
0.245 (6.2)
Opposed
Opposed
Opposed
Series
Series
In-Line
N/A
–
–
ES-0800/ES-0400
Offset
3.3 x 6.1
(84 x 155)
–
–
ES-0800
Offset
3.3 x 7.8
(84 x 198)
–
–
ES-0800
Offset
8.7 x5.6
(221 x 142)
1.75
(44.5)
ES-0800E
Offset
8.7 x 8.2
(221 x 208)
1.75
(44.5)
ES-0800E
–
MSP
–
MSP
–
–
FS1L, FS2L
–
FS1L, FS2L
–
FS1L, FS2L
VAC
24
–
24
–
24
Electrode configuration
Electrode holder type
Maximum throat size (H x D)
Maximum gap between
electrodes
Electrode series
in
(mm)
in
(mm)
Foot pedal model
Footswitch model
Air solenoid voltage
Air pressure for max. force
psig (bar)
55 (3.8)
–
55 (3.8)
–
55 (3.8)
Air cylinder inside diameter
Cycle Rate: @ min. force
@> 20% of rated force
in (mm)
Full strokes/sec
Full strokes/sec
1.0625 (27)
1
2.5
–
–
–
1.0625 (27)
1
2.5
–
–
–
1.0625 (27)
1
2.5
Maximum Dimensions
(including stand & air kit)
Height – in (mm)
Depth – in (mm)
Width – in (mm)
16.2 (411)
17.7 (450)
4.6 (117)
16.7 (424)
10.0 (254)
2.6 (66)
19.3 (490)
11.9 (302)
4.6 (117)
21.9 (556)
14.6 (371)
4.9 (124)
24.5 (622)
16.0 (406)
10.5 (267)
Weight (before packing)
lb (kg)
5 (2.3)
8 (3.6)
10 (4.5)
20 (9.1)
23 (10.4)
WEIGHT & DIMENSIONS
(1) Model 82A does not come with the mounting stand, lower electrode or the lower electrode holder.
(2) See page 7 for EZ-AIR specifications.
EZ-AIR can be set for 24VDC operation.
84A/EZ
89A/EZ
Offset/opposed
Offset/series
5/8
RESISTANCE WELDING
80 SERIES THIN-LINE WELD HEADS –
RESISTANCE WELDING
180 SERIES MID-FORCE WELD HEADS
Force Range 5 to 100 Lbs. (22 to 445 N)
TECHNICAL SPECIFICATIONS
Model
Unit of Measure
180F
180A/EZ
182A
188A/EZ
Maximum lbs (N)
Minimum lbs (N)
KVA (Watt-secs)
Manual
100 (445)
5 (22)
20 (875)
Air
100 (445)
5 (22)
20 (875)
Air
100 (445)
5 (22)
20 (875)
Air
100 (445)
5 (22)
20 (875)
Maximum electrode stroke
in (mm)
1.25 (32)
1.25 (32)
1.25 (32)
1.25 (32)
Electrode diameter
in (mm)
Actuation
Weld Force
Maximum rating
.25 (6.4)
.25 (6.4)
.25 (6.4)
.245 (6.22)
Opposed
Opposed
Opposed
Series
Offset
6.1 x 8.5
(154.9 x 215.9)
–
–
ES-0800
Offset
6.1 x 11.1
(154.9 x 281.9)
–
–
ES-0800
In-Line
2.8 x 6.3
(71.1 x 160.0)
–
–
ES-0800
Offset
6.0 x 11.5
(152.4 x 292.1)
3.0
(76.2)
ES-0800E
Electrode configuration
Electrode holder type
Maximum throat size (H x D)
in
(mm)
in
(mm)
Maximum gap between
electrodes
Electrode series
Foot pedal model
MSP
–
–
–
Footswitch model
–
FS1L, FS2L
FS1L, FS2L
FS1L, FS2L
Air solenoid voltage
VAC
24
24
24
60 (4.4)
60 (4.4)
60 (4.4)
1.5 (38.1)
–
1.5 (38.1)
1
2
1.5 (38.1)
1
2
1.5 (38.1)
1
25
Height – in (mm)
Depth – in (mm)
Width – in (mm)
24 (610)
14.9 (378)
3.5 (89)
24.75 (629)
20.15 (512)
4.2 (107)
25 (635)
13.4 (340)
6.4 (163)
24.9 (632)
19.79 (503)
6.6 (168)
lb (kg)
18.5 (8.4)
21.5 (9.8)
21.5 (9.8)
36.5 (16.6)
Air pressure for max. force
psig (bar)
Air cylinder inside diameter
Cycle Rate: @ min. force
@> 20% of rated force
in (mm)
Full strokes/sec
Full strokes/sec
–
WEIGHT & DIMENSIONS
Maximum dimensions
(including stand & air Kit)
Weight (before packing)
(1) See page 7 for EZ-AIR specifications.
EZ-AIR can be set for 24VDC operation.
180A/EZ
Offset/opposed
6/8
RESISTANCE WELDING
EZ-AIR TECHNOLOGY
The EZ-AIR weld force control system simplifies
the set-up process to a single adjustment and
helps prevent weld over-force by closing off the
input air when the actual weld force reaches the
programmed weld force level, delivering
accurate force control which is repeatable
across multiple weld heads without complex
setup or operator training.
• Firing force is important because it controls
contact resistances and, therefore, heat
generation at the electrode-to-part and partto-part interface.
• Superior force control = process stability and
higher production yield with reduced
maintenance time.
Final Force
Firing Force
Firing Force = Final Force
Figure 1, above, shows an incorrect balance of firing force to air pressure
set by an operator after cleaning the electrodes, on a traditional weld
head, resulting in poor set-up and force control.
EZ-AIR insures correct set-up and good force control as seen in Figure
2, above. EZ-AIR requires no balancing of air pressure as the air pressure
is constant once the firing force is reached.
The following series of simplified diagrams explain how the EZ-AIR weld force control system works through independent control
of upper and lower air chambers.
Electrode up position – air pressure in the lower chamber
keeps the piston in the up position. Waste air exhausts from
the upper chamber.
Electrode moves down – air pressure in the upper
chamber forces the piston down. Waste air exhausts from
the lower chamber.
EZ/DAK dual air kit
EZ/SAK single air kit
7/8
Electrode reaches weld force – both solenoid valves close
within 4ms and air pressure is trapped in both the upper and
lower chambers. Weld force remains constant since the air
cylinder piston cannot move. Compression spring provides
instantaneous follow-up.
EZ-Air force control technology is
available with Amada Miyachi
Thin-Line weld heads as original
equipment and as a retrofit for
previously purchased Thin-Line air
actuated weld heads. See the
Ordering Guide for more
information.
RESISTANCE WELDING
THIN-LINE WELD HEAD ORDERING GUIDE
Model
Description
Weld heads
80 Series, 180 Series
Foot
actuators
Model
FS1L
FS2L
CP
MSP
Head
Model
options &
HS20
accessories
Weld head, manual or air actuation, or EZ-AIR model, please refer to Weld Head Table, pages 4, 5 and
6, for model numbers and specifications. For air actuation, add /24 for 24 VAC or /115 for 115 VAC
solenoid. Example:80A/24, Model 80A with 24 VAC solenoid. For EZ-AIR model, add /EZ. Example:
80A/EZ, Model 80A with EZ-AIR.
Head Type
Air
EZ-AIR
Manual
Manual
Description
Footswitch, single level (for all pneumatic weld heads).
Footswitch, two level (for all pneumatic weld heads).
Cable pedal, rated: 25 lbs, 1 in stroke, with 6 ft cable (for models 80F, 86F, or 87F).
Foot pedal, medium force swing type, rated: 100 lbs, 5:1 mechanical advantage (for models 84F, 88F,
89F, or 180F).
Description
Hall effect sensor kit for 20 lb cylinders. Includes: cylinder, clamp, and sensor. Use on 80A, 86A, 87A,
88A. 88A requires two kits.
Hall effect sensor kit for 40 lb cylinders. Includes: cylinder, clamp, and sensor. Use on 82A, 84A, 89A.
89A requires two kits.
Firing switch junction box. Connects two firing switch cables in parallel to one power supply.
Series firing switch junction box. Connects two firing switch cables in series (included in models 88, 89,
and 188).
Base plate, anodized. Supports optic mounting assembly.
Type
Option
HS40
Option
DFS
DFS/88
Accessory
Accessory
BPTL
Accessory
Viewing accessories
OMA
Optic mounting assembly. Use with Nikon, and BPTL.
NIKON
Optic, stereo zoom, Nikon, 10X eyepiece, 0.5X auxiliary
objective lens.
BLFOI
Fiber optic illuminator system, 115V-50/60 Hz. Self-supporting
gooseneck, bifurcated light pipes, focusing lenses and
mounting adapter for optic mounting assembly.
BLFOI/230
Fiber optic illuminator system, 230V-50/60 Hz. Self-supporting
gooseneck, bifurcated light pipes, focusing lenses formounting
adapter for optic mounting assembly.
Process set-up tools
FG20
Electrode force gage, 20 lb, scale 20 lb x 0.2 lb
FG100
Electrode force gage, 100 lb, scale 100 lb x 1 lb
FG200
Electrode force gage, 200 lb, scale 200 lb x 2 lb
FG10KG
Electrode force gage, 10 kg, scale 10 kg x 0.1 kg
FG100KG
Electrode force gage, 100 kg, scale 100 kg x 1 kg
All available with or without serial number.
Miscellaneous accessories
UTA
Unitip adapter, allows use of Unitip electrodes in model 86.
WP
Work Positioner, 3 in diameter. Height adjustable from
1-7/16 in to 2 in (models 86, 87, 88, 89).
EZ-AIR TECHNICAL SPECIFICATIONS
DESCRIPTION
SPECIFICATION
Force adjustment range models: 80A/EZ, 86A/EZ, 88A/EZ
1 to 20 lbs (4.4 to 89 N)
Force adjustment range models: 84A/EZ, 89A/EZ
4 to 40 lbs (17.8 to 178 N)
Force adjustment range models: 180A/EZ
5 to 100 lbs (22 to 445 N)
Valve driver input
24 VAC
Input air pressure
85 to 130 psi (482 kPa to 896 kPa), unlubricated air
1820 S. Myrtle Ave. • Monrovia, CA 91016 US
T: (626) 303-5676 • F: (626) 358-8048
info@amadamiyachi.com • www.amadamiyachi.com
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Specifications subject to change without notice. Copyright© 2015 Amada Miyachi America, Inc. The material contained herein cannot
be reproduced or used in any other way without the express written permission of Amada Miyachi America, Inc. All rights reserved.
8/8
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info@miyachiindia.com
991-100 09/15
AMERICAS
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America Midwest
Wixom, MI 48393
T: (248) 313-3078
midwestsales@amadamiyachi.com
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