Nospark Engineering

Airoli, Navi Mumbai, Maharashtra

Robust construction with maximum resistance to deflection. Welding Transformer enclosed in the frame. Pneumatic accessories mounted on the side of the frame.

Welding Transformer :

Water cooled, class F insulation with thermo switch protection from over heating.

Current Control :

Welding current adjustable from 50% to 100% by tap switch.

Cooling System:

Thyristor, Transformer, secondary connection and electrode wheel are water cooled.

Electrode Force:

Upper ram is actuated by pneumatic cylinder controlled by solenoid valve.Compressed air at 2 ksc to 5.6 ksc provide the electrode force.

Electrode Drive :

Machines are provided with different drive system depending on the application. Customer has to specify the system.

1) Direct Drive : Direct gear drive is given to any one of the wheels.2) Knurl Drive: One of the weld wheel or both the weld wheel driven by a serrated hardened wheel depending on type of weld. Constant dressing of weld wheel maintain uniform profile. Constant linear welding speed irrespective of weld wheel diameter.

Motor Drive :

Machine will be supplied with geared motor and AC speed drive.

Electronic Control :

1) A squeeze time control adjustable from 2-25 cycles to select delay between initiation of the foot switch and the start of the weld.2) Synchronous timing of 1-9 cycles ON and 0-9 cycle OFF both in step of one cycle each for weld time.3) Phase shift heat control for firing the thyristors and to adjust the welding current between 50 and 100% over and above the transformer.4) High power switching device consisting of two thyristor connected in inverse parallel and mounted on a water cooled heat sinks. Protective devices for high voltage surges and thermo switches are standard feature.5) Hold time having a range of 2-25 cycles to provide a delay between stoppage of weld and separation of weld wheel.

a) For Transformer: 415V single phase 50 cycles (suitable for connection to 2 lines of 3 phase supply). Main supply cable for transformer connection. Disconnect switch with fuses of recommended rating.

b) For motor: 415V, 3 phase 50 cycle for A.C. motor drive. Supply cable 1.5 sq. mm. & 3 core, Switch fuse unit 500V, 15 amps, A.C. Motor Drive system.

Compressed Air:

Supply of air at recommended flow volume at 5.6 ksc.

Cooling Water:

Water at 2.6 ksc pressure and below 30 degree C. at recommended flow rate.

Robust construction with maximum resistance to deflection. Welding Transformer enclosed in the frame. Pneumatic accessories mounted on the side of the frame.

Welding Transformer :

Water cooled, class F insulation with thermo switch protection from over heating.

Current Control :

Welding current adjustable from 50% to 100% by tap switch.

Cooling System:

Thyristor, Transformer, secondary connection and electrode wheel are water cooled.

Electrode Force:

Upper ram is actuated by pneumatic cylinder controlled by solenoid valve.Compressed air at 2 ksc to 5.6 ksc provide the electrode force.

Electrode Drive :

Machines are provided with different drive system depending on the application. Customer has to specify the system.

1) Direct Drive : Direct gear drive is given to any one of the wheels.2) Knurl Drive: One of the weld wheel or both the weld wheel driven by a serrated hardened wheel depending on type of weld. Constant dressing of weld wheel maintain uniform profile. Constant linear welding speed irrespective of weld wheel diameter.

Motor Drive :

Machine will be supplied with geared motor and AC speed drive.

Electronic Control :

1) A squeeze time control adjustable from 2-25 cycles to select delay between initiation of the foot switch and the start of the weld.2) Synchronous timing of 1-9 cycles ON and 0-9 cycle OFF both in step of one cycle each for weld time.3) Phase shift heat control for firing the thyristors and to adjust the welding current between 50 and 100% over and above the transformer.4) High power switching device consisting of two thyristor connected in inverse parallel and mounted on a water cooled heat sinks. Protective devices for high voltage surges and thermo switches are standard feature.5) Hold time having a range of 2-25 cycles to provide a delay between stoppage of weld and separation of weld wheel.

SERVICE FACILITIES (To be provided by customer)

Power Supply:

a) For Transformer: 415V single phase 50 cycles (suitable for connection to 2 lines of 3 phase supply). Main supply cable for transformer connection. Disconnect switch with fuses of recommended rating.

b) For motor: 415V, 3 phase 50 cycle for A.C. motor drive. Supply cable 1.5 sq. mm. & 3 core, Switch fuse unit 500V, 15 amps, A.C. Motor Drive system.

Compressed Air:

Supply of air at recommended flow volume at 5.6 ksc.

Cooling Water:

Water at 2.6 ksc pressure and below 30 degree C. at recommended flow rate.

This machine is for welding tin sheet, black sheet with thickness of 0.2 to 0.5mm and body diameter from 52 to 300 mm. and max.height upto 450 mm depending on arm size.

Nospark Engineering Container Side Seam Welding Machine model SSW-01 is a trustworthy and economic way of producing consistent, faultless weld at highest working speeds.

Weldability :

The machine is capable of welding a wide range of materials, Tin sheets, Black and TFS sheets (after proper edge cleaning) with thickness ranging from 0.2 to 0.4 mm and body diameters ranging from 52 to 300 mm and body height up to 450 mm.

Intermediate Electrode :

Use of electrolytic copper wire as an intermediate electrode between weld wheel and tin sheet, avoids deposition of molten tin on weld wheels and ensures consistent, quality weld without frequent cleaning of weld wheels.

Welding Upper Arm :

Upper arm made out of high tensile brass is common for complete range of can diameters and is operated by a hydro-pneumatic damping cylinder to avoid initial impact on weld wheels and to maintain constant welding force.

Welding Lower Arm :

Lower arm made out of high tensile brass is complete with carriage guide rail, Z-bar, weld wheel etc. Three standard sizes of lower arms are available. Any one size of arm will be provided with machine, other sizes will be available at extra cost.

Weld wheels & Z-bars :

Antifriction, mercury contact weld wheels made out of special copper alloy & Z-bars made out of wear resistant material are available in three standard sizes i.e. 52, 65 and 100 size suitable for respective arms. These wears out parts are available as spares. Standard overlap provided on Z-bar is 4 mm.

Carriage :

Carriage assembly with built-in pneumatic clamping and limit switches for low/high current initiation and auto cut off is mounted on antifriction bearings and can be adjusted for different can lengths easily. Different sizes of carriages are available to match each size of arm. Movement of carriage is actuated by automatic fly-start system to maintain normal welding speed from the start.

Electronic Control :

High precision fully solid state welder control incorporating thyristors permits uniform weld quality. Two-stage heat control unit controls the intensity of weld current at the beginning of weld cycle at desired low levels. Current control is through transformer taps and potentiometers.

Operation and work cycle :

Once the welding parameters like current, pressure, speed, carriage positioning, high /low heat and cut-off limit switch setting is over, operator must feed a pre-rolled sheet into the carriage and Z-bar.

On operating foot switches all further operations take place automatically.

• Rolled body is clamped at the rear with pneumatic clamps.
• Upper weld wheel comes down making contact with lower weld wheel and welding pressure is developed between wheels by hydro-pneumatic damping cylinder and spring.
• Once the correct welding force is generated, the switch fitted on cylinder actuates wire feed system.
• The carriage is pushed forward at the start of operation by means of fly-start mechanism.
• Initially reduced current is applied for a pre-determined length and thereafter-full welding current is provided. The weld initiation with reduced current and change over to full current is done automatically by weld controller.
• At the end of weld, the current is cut-off, wire, feed system stops and upper weld wheel goes up automatically.
• The work piece can be taken out after de-clamped and carriage is pulled back by spring balancer making machine ready for next work piece.

This machine is for welding tin sheet, SS304, black sheet with thickness of 0.6 mm and body diameter from 250 to 300 mm. and max.height upto 480 mm.

Nospark Engineering has developed Spot/Projection Welding machine :

1. Ear lugs welding machine, model: SPW-01-01
2. Wire handle (chapdi) welding machine on can top lid (upto 5 kg.), model:SPW-01-02
3. Handle welding machine on 5 ltr. rectangular can top lid (one side at a time), model:SPW-01-03
4. Wire handle (chapdi) welding machine on 15 kg. Container top lid, model:SPW-01-04

SPECIFICATION

Type :

Pneumatic operated stationary press type Spot/Projection welders with pneumatic cylinder mounted on upper arm.

Construction :

Robust construction frame with transformer enclosed in and pneumatic accessories mounted on the side of the frame and upper & lower arms mounted on front of the frame. Operating control station mounted on the machine to clearly visible and within easy reach to the operator.

Welding Transformer :

Water cooled transformer with class 'F' insulation with thermo switch protection for overloading.

Cooling System :

Transformer, Electrode holders, welding electrodes and thyristors are water cooled.

Electrode Force System :

The upper electrode actuated by a heavy duty 2-way cushioned pneumatic cylinder controlled by an electrically operated solenoid valve. Compressed air at 1.5 Ksc - 5.6 ksc (20 to 80 psi) acting on the pneumatic cylinder provides electrode force. Electrode force can be adjust by air pressure regulating valve provided on the machine.

Machine provided with air filter, air lubricator, air pressure regulating valve, air pressure gauge.

Weld Initiation :

By means of foot-switch connected to low voltage safe initiating circuit.

Control :

Control model NE-101, CMOS integrated circuits based. Fully synchronous weld parameter is incorporated with the machine. The timers, slope control, heat control and control station are housed in a chassis with plug-in cards mounted on the side of the machine.

Timers :

Squeeze, weld, hold and off time of 1-99 cycles +/- zero cycle in steps of 1 cycle to provide accurate timings.