广汽新能源项目铝点焊03 - roman变压器

10/9/2024CompanyConfidentiality10/9/2024CompanyConfidentiality2RoManRDC-7641ReversingMFDCunit10/9/2024CompanyConfidentiality3ChallengesofAluminuminHighProductionRWApplicationsHighersecondarycurrentsareneededtoweldaluminumHighercurrentsmeanlowerelectrodelifeHighersecondarycurrentsonrobotgunsmeansusingMFDCtechnologytokeeptransformersaslightaspossible.ExistingMFDCtechnologyonlypassescurrentinonedirectionWhenusingMFDCtoweldaluminum,variablessuchas:dissimilaraluminumalloys,useofaluminumextrusions,andcastingsinautobody,presentseriousweldingchallengesduetovariableresistancesandthePeltiereffect10/9/2024CompanyConfidentiality4RDC-7641Specs10/9/2024CompanyConfidentiality5RDC-7641WiringDiagram6DCReversingWaveformSecondaryCurrent(kiloAmperes)Time(milliseconds)10/9/2024CompanyConfidentiality7ReversingMFDCunits10/9/2024CompanyConfidentiality8Howdoesitwork?10/9/2024CompanyConfidentiality9ToestablishtheWeldRangeIMin-IMaxthefollowingmethodwillbeutilized.Begintheweldcouponsat70%oftheabovementionedweldcurrents.Eachamperagewillbeweldedfor3weldsandthenincrease500ampsuntilminimumprescribednuggetdiameterismeasuredonthe3welds(Imin).ToestablishImaxcontinuetheweldincreaseof500ampsuntiloneofthefollowingoccurs:Excessiveindentation,expulsionorsticking(IMax).FortheLifetestsitwasdeterminedbytheformulaof5.3Sqrt(T)thatthe1.0mm6022willbeweldedat29.5Ka.TestProcedure(ElectrodeLifeTest)10/9/2024CompanyConfidentiality10Byswitchingpolarityaftereachwelditshowsa2ximprovementoncaplifecomparedtothesinglepolarityweldinglifetest.SinglePolarity“A”ReversingPolarity“A/B”10/9/2024CompanyConfidentiality11-100%abovemin.nuggetdiameter4Sqrt(T)-79.15%abovesetupsize5sqrt(T)-88.54%abovemin.nuggetdiameter4Sqrt(T)-61.67%abovesetupsize5sqrt(T)RobustnessofWeldingCont.10/9/2024CompanyConfidentiality12Thestudywilltestthefollowingthree(3)scenarios:5000-6000materials,equalthicknessesmaterials,thintothickgaugeandthenathin-thick-thick3Tstack-up.Samepeelcouponlayoutbeutilized,andtheweld#3

willbecutandetchedtoproperlyshownuggetgrowthcharacteristics.Theywillbeweldedinthesameorientationwith(A)polarityandthen(B)polarityto

showthegrowthtendenciesasitrelatedtopolarity.NuggetMigrationTesting10/9/2024CompanyConfidentiality1310/9/2024CompanyConfidentiality1410/9/2024CompanyConfidentiality1510/9/2024CompanyConfidentiality1610/9/2024CompanyConfidentiality17UnderstandingMFDCPowerSupplyRatings10/9/2024CompanyConfidentiality18PrimaryVoltage:480V/60HzWeldCurrent:13,000AWeldTime:49CyclesWelds/minute:18weldsspacedatleast2.0secondsapartUtilizinganMFDCpowersupplywith13VInformationNeededforSizingofMFDC10/9/2024CompanyConfidentiality19WeldTimeIntegratingPeriodWeldsPerMinuteDutyCycle*Note:Integratingperiodfortransformeris60secondsandtherectifierisbasedoffofthetimebetweenwelds.10/9/2024CompanyConfidentiality20DutycycleTX=WeldTimexWelds/minutex100%60seconds/minutexFrequency=49cy.x18welds/mx(100)=24.5%60s/mx60hzDutycycleRECT.=49cy.x(100)=28.9%

49cy.on+120cy.off

Note:WeldSchedulesshownabovearegivenandassumedasbeing60hz.DUTYCYCLECALCULATIONS10/9/2024CompanyConfidentiality21SecondaryVoltageSecondaryCurrentDutyCycleKVA10/9/2024CompanyConfidentiality22KVA

50%DutyCycle:ISTHENAMEPLATEKVARATINGORTHERMOCAPACITYOFTHETRANSFORMER.THERATINGISBASEDON50%DUTYCYCLEAND1MINUTEINTEGRATINGPERIOD.Note:Mustchecknameplateratingswhencomparingtransformers.100KVAat50%DutyCycle=148KVAat20%DutyCycle.ManyEuropeanandAsiancompetitorsuse10-20%ratingstoconfusecustomers.KVAInstantaneousDEMAND:ISTHEACTUALLOADIMPOSEDONTHETRANSFORMERDURINGWELDING.Secondaryvoltagemultipliedbythesecondarycurrent.Example:13voltsX12,500Amps=162,500VA162,500/1000=162.5KVAKVA

50%DC=

KVA

DEMANDX

169.0KVAX169X.7=118KVA@50%rating24.5%7.07DUTYCYCLE%7.07KVACALCULATION10/9/2024CompanyConfidentiality2310/9/2024CompanyConfidentiality24RoManhasInterchangeableFamilyofMFDCPowerSupplies

135-185KVASize3/3.5

85-150KVASize2

225KVASize6.

170-225KVASize4FitsUL,RA,andFlexGunsFitsUL,RA,andFlexGunsFitsFlexGunsHeavyDutyApplications.Aluminum/projectionweldingAbovemodelsallhavesameframeandsecondaryconnectionswhichmeansCLcantak