PlasmaTIG Weld Package

Transcription

1 PlasmaTIG Weld Package Torch system with TIG dressing Contact-free ignition without high frequency Solutions for: ABB // FANUC // KUKA // MOTOMAN Solutions PlasmaTIG for: Weld Package: DCT power source + Water cooler //Weld process controller // Robot interface // Wire feeder // Wire Guidance // PlasmaTIG Module // Cable bundle // Ground cable // Control cable // Torch system // Cold Wire Feeding // Consumables // Goosenecks // Document no.: DOC-0116EN Revision: sks1109.en.2.g.ms

2 SKS Weld Package: System Design 4 6 2a SKS Weld Package: Overview 1 DCT power source + Water cooler 2 Weld process controller + Software 3 Robot interface 4 Wire feeder 5 Wire Guidance 6 PlasmaTIG module 7 Cable bundle 8 Ground cable 9 Control cable Torch system: Torch system PlasmaTIG Cold wire feeding Consumables 13 TCP drawings Checking fixtures 14 Exploded drawing

3 SKS PlasmaTIG Weld Package Contact-free ignition without high frequency SKS Weld Package. Torch system with TIG dressing Torch system PlasmaTIG with integrated cold wire feeding (TIG dressing) This brochure contains information about the SKS Weld Package, the torch system PlasmaTIG, as well as consumables and spare parts. There are various features of the welding machine components and torch systems available depending on the robot system and the welding task. The PlasmaTIG Weld Package can be used with common industrial robots. Please look for color coding to specify the robot types ABB, FANUC, KUKA and MOTOMAN ( ). The PlasmaTIG Weld Package is designed for the following welding processes, materials and power range: Processes: TIG (Plasma) Materials: Fe, CrNi, CuSi Wire diameter: mm Max. power: 350 A - 60 % duty cycle/40 C, water-cooled

4 1 Power source and water cooler Direct Control Technology DCT The LSQ5 ensures the optimum arc energy. It uniquely adjusts to different weld processes. Unlike conventional power sources with inverter technology, the LSQ5 with Direct Control Technology controls its switching transistors without any fixed clock frequency according to the needs of the weld process. Without any delay, the energy needed for the process is provided instantly. The flexible fine tuning is done by a central processor. The CPU continuously analyzes the weld process and current/voltage values on the basis of data obtained and optimally drives the switching transistors of the power section. This results in an extremely high efficiency and a low temperature development. The power source can be configured with only two buttons and four LED indicators. For world-wide usage, voltages can be configured without opening the power source. Power source LSQ5-PT Stromquelle LSQ5 The main benefits are: DCT provides a speed regulation up to ten times higher compared to conventional inverter technology. This leads to excellent control behavior and shorter response times. The weld properties are substantially improved. Software replaces hardware: Fewer components also increase the reliability in continuous operation. Option Specifications: LSQ5-PT Performance 420 A - 60 % duty cycle/40 C Processes PlasmaTIG Weight 49 kg Primary voltage 3 x 400 (480)V Wall mounting Yes (optional) Conformities CE, CSA, UL Dimensions L/W/H 450 x 400 x 540 mm Wall mount for LSQ5 Space-saving design that makes for easy cleaning/maintenance. LSQ5 option Wall mount Water cooler WK5 The SKS water cooler WK5 perfectly integrates into SKS systems. With a cooling range for TIG/MIG: 0-600W (dt=20 C) it provides perfect cooling of the PlasmaTIG torch system. The cooler can be filled with max. 20 l, is equipped with a water level indicator, water flow monitoring and can be filled/emptied with a button. The cooling unit is air-cooled. WK5 is supplied with power over the SPW-bus no additional power supply needed. Water cooler WK Water cooler WK5

5 2 Weld process controller Innovative Control Concept with Touch Screen. New. With the new Q84 up to four weld machines can be controlled centrally. Weld Process Controller Q84 The new Q84 is equipped with a 10 inch touch screen, an innovative usability concept and an advanced visualization technology for much easier operating. The user interface has the look and feel of the Q8Tool4 software. The real weld controllers are in card slots in the Q84. This new weld controller concept can host up to four Q81 weld process controller cards. Every single Q81 card can independently control a weld machine.

6 2 Weld process controller Controlling up to four weld machines at the same time Weld process controller Q84 Please note: The Q84 can be equipped with up to four Q81 weld process controller cards. The universal weld process controller Q84 calculates the optimal parameters for each welding process. Only basic data such as material, wire type, wire feed speed and type of gas must be entered. Processes/features: TIG-DC, TIG Pulse, Plasma, MIG/MAG (GMAW), I-Pulse, U-Pulse, KF-Pulse, RWDE, NWDE Programs: 992 (x4) General functions: Display and saving of readings, alarms Monitoring functions: Weld current monitoring, auto compensation, arc and ignition monitoring, motor current, gas and water monitoring Easy to network via Ethernet: Traceability Ports: RJ45-Ethernet, SPW-Bus, micro SD Remtote Control/Administration: Q8Tool, VNC client Overview weld process controller Q84 with 1 Q81 weld process controller card Q84 with 2 Q81 weld process controller cards Q84 with 3 Q81 weld process controller cards Q84 with 4 Q81 weld process controller cards Overview Q84 Mounting kits Mounting on Power Source LSQ5 Wall mounting

7 2a Weld process controller Alternative Weld process controller Q8pt and Q8pw Weld process controller Q8pt The Q8pt is the alternative to the Q84. It has the same functionality/features as a single weld card of the Q84. The illuminated LCD display shows clearly all parameters and values needed for the weld task or program selection. Processes/features: TIG-DC, TIG Pulse, Plasma, MIG/MAG (GMAW), I-Pulse, U-Pulse, KF-Pulse, RWDE, NWDE Programs: 992 General functions: Display and saving of readings, alarms Monitoring functions: Weld current monitoring, auto compensation, arc and ignition monitoring, motor current, gas and water monitoring Easy to network via Ethernet:up to traceability Ports: RS232, USB, RJ45-Ethernet, SPW-Bus Weld process controller Q8pw Same functionality as Q8pt but in a wall mount version (-w) Overview weld process controller Q8pt Q8pw b Software/IT Q8Tool software The Q8Tool software provides accurate and comprehensive process monitoring. The user can store weld parameters for documentation on a PC and/or administrate them. It offers basic functions such as reading, modifying and documenting of weld parameters. Additionally, new weld parameters can be created and transferred to the universal weld control Q8pt/w. The Q8pt/w weld data is portable and the installation of further control units on new equipment is easy. Also, the software allows reading and exporting of measurements and alarms. Graphical and numerical recording of measures helps defining and optimizing parameters for new parts. Users have a powerful tool for analyzing and documenting their weld results. Network The weld controller units can easily be networked via Ethernet ports: Time savings through centralized administration of all controllers within the corporate network. There is a central backup of all welding parameters, management of user rights and access, process monitoring up to traceability. The Q8Tool software is provided free of charge with the Q8 series weld controller. No additional hardware or software is required.

8 3 Robot interface Perfect integration. Interfacing all industrial robot types. A B or Interface UNI 5 With the universal interface solution from SKS, weld controllers can be connected with all industrial robot types. Users basically have two options for connecting robots with weld controllers: The connection can be realized with the SKS interface UNI 5 or by integrating into a given field bus environment with a field bus solution. Standard application Field bus application Robot controllers or overall system controllers (e.g. PLC) use digital or analog signals to communicate with the SKS weld controller. The interface UNI 5 translates these signals for the SKS welding machine. With just one interface, a variety of digital encodings and analog levels can be processed. The interface UNI 5 comes with a preconfigured connection kit for easy installation. Field bus systems exchange signals via serial communication. The field bus master, usually the robot controller or overall system controller, bundles and processes the signals of the connected field bus, including the welding machine. Standard field bus systems are e.g., Interbus-S, Profibus DP or Device- Net. The SKS field bus interface FB5 translates the field bus signals for the SKS welding machine using a standardized protocol. It makes no difference which type of field bus system is used. The signals are always at the same place on the field bus. This makes the preparation of the robot or system controller much easier.

9 3 Robot interface A Robot interface UNI 5 The interface connects the welding equipment with all industrial robot types. With its high degree of standardization, the UNI 5 is the perfect choice for connecting the weld controller (e.g. Q8pt/w) with an industrial robot. The UNI 5 comes preprogrammed and configured for different robot types. Configuration to a particular robot type is handled easily by programming the interface with two buttons for the given robot type. Overview of robot interfaces For robot type-abb UNI 5A for IRC For robot type-fanuc UNI 5A for RJ3iC For robot type-kuka UNI 5A for KR C For robot type-motoman UNI 5C for NX 100 / DX Alternative B Field bus connection Various field bus types are supported (e.g. Profibus DP, DeviceNet). The field bus interface has drilled bore holes for flexible mounting within the weld cell. Two additional mounting kits provide easy installation at the power source or into the cabinet. Additionally, external power can be connected to the interface. More details on SKS solutions for the specific field bus types are available on request. Overview FB 5 interfaces Interbus-S (copper line) Profibus DP DeviceNet Cabinet mounting Mounting kit for cabinet Control cable with bracket Power source mounting Mounting kit for power source Optional power supply (24V) Connection cable 2.0m (with open ends)

10 4 Wire feeder for cold wire feeding Wire feeder PF5-KD Smaller and less weight accompanied by improved efficiency over conventional wire feeders the PF5 follows the steady development of arc welding robots. Modern motor, gear and control technology provide a strong performance and highest precision possible. The robust plastic housing is electrically insulated. As a "lightweight" the PF5 is the perfect choice for the new generation of robots with outer or inner cable dress. Overview of PF5 PF5-KD Technical data Weight Motor Wire feeding speed Roll diameter 3.8 kg 70W m/min mm 4a Wire Feeder accessoiries Connection cable for PlasmaTIG Module PT-M5 to PF5-KD for cold wire feeding With the connection cable wire stick monitoring is installed. Connection cable PT-M5 to PF5-KD Connection cable PT-M5 to PF5-KD Center guides for PF5 Available in two versions: For steel or aluminium wires Overview of center guides Wire-ø < 2 mm for steel wire Wire-ø < mm for steel wire

11 4a Wire Feeder accessoiries Drive roll for wire feeder For wire diameters of mm and different groove-types (V-groove for steel and U-groove for aluminum wires) Overview of drive rolls Wire-ø 0.8 mm, V-groove Wire-ø 1.0 mm, V-groove Wire-ø 1.0 mm, U-groove Pressure roll Pressure roll for wire feeder Pressure roll Pressure roll

12 5 Wire Guidance Wire inlet body with quick coupling at wire feeder Connector for polymer conduit Polymer conduit Drum connector With the new SKS polymer guidance, the high efficiency of the whole system extends up to the drum. Advantages of polymer wire guidance Extraordinary good glide properties reduces motor load Minimized abrasive wear and reduced dirt in wire feeder and torch system Lightweight design and a high inherent stability for easy installation Length can be freely chosen by the customer Cost optimized exchange: only the polymer conduit must be changed, connectors are reuseable. Optimized materials for longer life and reduced downtimes Alternative Wire inlet bodies for additional systems Beside the wire inlet body for the SKS wire guidance, inlet bodies for additional systems are available. Overview of wire inlet bodies for additional systems M10 with internal thread for ESAB UNF 3/8x24 with external thread with 9.6 mm bore hole with 13 mm bore hole for cold wire feeding with PG9 thread

13 5 Wire Guidance 1 Wire inlet body with quick coupling Wire inlet body for PF5 with quick coupling Wire inlet body with quick coupling Wire inlet body with quick coupling Connector for polymer conduit Connection nipple for polymer conduit Connector for polymer conduit Connector for polymer conduit Please note: Two connectors necessary. 3 Polymer wire conduit Polymer wire conduit (sold by meter) Polymer wire conduit Polymer wire conduit, blue Connector for wire drum Quick connector with ceramic-inlet Connector for wire drum Connector for wire drum

14 6 PlasmaTIG PlasmaTIG Module 5 The PlasmaTIG Module is mounted on the wire feeder bracket, in front of the wire feeder for a good accessibility. The control electronics for the HF-free ignition is in the module. Additionally, a flowmeter for gas and gas monitoring is integrated. For a perfect mounting of the torch cable, torch connectors for the PT350 PlasmaTIG torch system is integrated into the module. PlasmaTIG Module 5 PlasmaTIG Module Technical Data Weight Features 2.7 kg HF-free ignition/gas flow control and monitoring Wire feeder bracket Wire feeder bracket for PF5: with bore holes and screws, ready to install Overview Wire Feeder Brackets for PT-M5 For robot type-abb Model IRB1600 IRB on request For robot type-fanuc Model M10iA M20iA on request on request For robot type-kuka Model KR5 arc / KR For robot type-motoman Model SSF2000 / HP

15 7 Cable bundles Cable bundles: Power source to wire feeder PF5 Coaxial power cable 72 mm 2 with internal gas flow, control cable L-700, disconnect cable, corrugated tube and cable holder. Water-cooled version. Overview of cable bundles 3 m 5 m 7 m 10 m 12 m 15 m a Clamping set Mounting cable bundle: Clamping set Provides perfect installation of the cable bundle for all different robot types. Undefined cable movements are prevented. This results in higher lifetime. Overview of cable bundle clamping sets For robot type-abb Model IRB1600 IRB2600 on request on request For robot type-fanuc Model M10iA M20iA on request on request For robot type-kuka Model KR5 arc KR16 on request on request For robot type-motoman Model SSF2000 HP

16 8 Ground cable Ground cable with 70 mm 2 connector and cable plug Cables with larger diameters are available on request. Overview of ground cables Length 3 m 5 m 6 m 10 m 15 m 20 m 25 m Control cable Control cable: L-700/SPW-bus Standard control cable to connect the components: Weld controller, power source, robot interface, wire feeder. Overview of control cables Length 0.5 m 1 m 2 m 3 m 5 m 7 m 10 m 12 m 15 m

17 10 Torch system PlasmaTIG : TIG dressing Contact-free ignition without high frequency. TIG dressing for applications with open arc. PlasmaTIG torch system with integrated cold wire feeding (TIG dressing) The PlasmaTIG torch system comes with contact-free arc-ignition without high frequency. Known risks of electromagnetic noise from HF-waves to humans and machines are avoided and EMC- compatibility is guaranteed. Depending on the torch front end the user can vary between plasma- and classic TIG-welding. The PlasmaTIG torch system consists of the Power Clutch safety clutch, the torch body for TIG and Plasma, a mounting flange for different robot types, the torch cable and the corresponding consumables. TIG dressing is especially for applications with open arc. The PlasmaTIG Weld Package is designed for the following welding processes, materials and power range: Processes: TIG (Plasma) Materials: Fe, CrNi, CuSi Wire diameter: mm Max. power: 350 A - 60 % duty cycle/40 C, water-cooled

18 10a Torch system: Collision protection Collision protection Power Clutch for welding robots with outer cable dress The SKS collision protection is based on the Power Joint concept, continuing the modular structure of the SKS components. This ensures the same high precision TCP accuracy in the Dual Wire Select as found in SKS PlasmaTIG systems. Power Clutch Collision Protection 71-5 Technical Data Collision protection deflection 10 Reset accuracy ± 0.2 mm with TCP 400 mm Weight 1.5 kg 10b Torch system: Torch body PlasmaTIG Torch body PlasmaTIG The TIG torch body has an integrated lifting unit to provide HF-free ignition. A cold wire feeding unit can be attached to torch body, to increase the flexibility of the whole system. Additionally, the torch body supports different electrode diameters. Overview torch bodies, short, with quick-change connectors, consumables included ø 2.4 mm ø 3.2 mm ø 4.0 mm c Torch system: Torch mounting arm PlasmaTIG : Torch mounting arm Precise torch mounting arm with adjustable skew correction PlasmaTIG PlasmaTIG torch mounting arm

19 10d Torch system: Installation PlasmaTIG robot flange With the robot flange the PlasmaTIG torch system is mounted simply and safely on the sixth robot axis. Übersicht Anschlussflansch For robot type-abb Model IRB IRB For robot type-kuka Model KR5 arc KR For robot type-fanuc Model M10iA / M20iA For robot type-motoman Model SSF2000 / HP e Torch system: Torch cable/accessories Torch cable for PlasmaTIG torch system Highly flexible coaxial cable 72 mm 2 with Power Pin and Power Clutch connector including switch-off cable for the robot Overview of torch cables Length 1.0 m 1.2 m 1.8 m f Torch system: Accessories PlasmaTIG Adjustment tool for tungsten electrodes With this special tool the lifting unit can be fixated; thus the exchange of the clamping sleeve is much easier. PlasmaTIG Adjustment tool for tungsten electrodes Adjustment tool for tungsten electrodes PlasmaTIG Spanner With two fixed points in the tool, for welding or programming, the stickout of the electrode can be correctly adjusted. PlasmaTIG Spanner Spanner

20 11 Cold wire feeding Cold wire feeding The wire feeding can be adjusted exactly with a knurled-head screw. All necessary components for mounting included. Cold wire feeding Cold wire feeding Cold wire elbow pipe For wire feeding Cold wire elbow pipe Cold wire elbow pipe, long, 45 /65 mm Cold wire tip With the exact calibrated bore hole, the way of the wire material is precisely defined. Overview cold wire tips 0.8 mm 1.0 mm a Cold wire feeding: Accessoiries Wire guidance conduit Polymer materials for less abrasive wear and extraordinary good glide properties Wire guidance conduit 4.19 x 8.9 / 2 m Liner From wire feeder to cold wire feeding Restricted Guidance (Spiral) 1.45 x 3.15 / 2 m

21 12 Torch system: Consumables PlasmaTIG Welding inset For distribution of the center gas Overview Welding inset ø 4.0 mm for 2.4 mm electrode ø 4.8 mm for 3.2 mm electrode ø 5.6 mm for 4.0 mm electrode Tungsten electrodes Free from torium to avoide unwanted side effects Overview tungsten electrodes 2.4 x 75 mm / x 75 mm / x 75 mm / Nut for clamping sleeve To fixate the electrode and to clamp the clamping sleeve Overview nut for clamping sleeve 2.4 mm / 3.2 mm / 4.0 mm Clamping sleeve To secure guidance of the tungsten electrode Overview clamping sleeves 2.4 mm 3.2 mm 4.0 mm Ceramic center tube For alignment (center) and isolation of the clamping sleeve Overview Ceramic center tubes 8 mm 33 mm Copper Gas Nozzle Copper-chrome-zirconium alloy for high lifetime Copper Gas Nozzle Copper gas nozzle 18 mm

22 13 Torch sytem: TCP drawings PlasmaTIG a Torches: Checking fixtures To check TCP of goosenecks and the complete torch system. Checking fixtures are available for all listed goosenecks with PlasmaTIG torch system. Please contact us for detailed information.

23 14 Torch system: Exploded drawing Protective gas Protective gas Weld current Power source LSQ A S Workpiece The center gas flows in to support the ignition. In the head of the torch the ignition takes place. The arc takes the shortest way after the ignition: up to the part.

24 SKS Welding Systems GmbH Austrasse 2a Landstuhl Germany Phone +49(0)6371/ Fax +49(0)6371/ Subject to change.