Highly upgraded Automotive facility uses Robot spot welding technics to meet stringent quality and to ensure the reliability of welding as well as optimizing cooling process. So Robot welding operator must be detect the leakage accurately in the cooling system and electrode caps as well as other defects.
Burkert provides the cooling system consist of TYPE 8611 PID controllers , TYPE 8081 ultrasonic flow transmitter , TYPE 2031 pneumatic diaphragm valve with customized piping. Robot welding units produce high end welding with short life cycle which consume more current this results heat. In order to cooling this system water circulation happens every minute with six liters of water to electrode caps. Due to the heating electrode caps should be often cooled with the help of cooling system. If not it wouldn’t occur cost instead loss of productivity due to the increased life cycle and maintenance shutdowns.
Cooling System with pneumatic process valve ( Diaphragm valve ) :
The integrated cooling water monitoring block consists of a pilot valve, a feed and return valve and a flow rate sensor . The main advantages of the block solution are its compact size and the option to provide additional connections for secondary cooling processes such as for example a thyristor cooling system.
To prevent this, the modular cooling system can be equipped with a relief cylinder in the form of a MasterJet unit from Burkert . This cylinder is pneumatically preloaded during operation ( diaphragm valve TYPE 2031 ) and relieved in the event of a leak or during cap replacement. The pressure inside the electrode clamps of maximum 2 bar is thus relieved through the cylinder.
This ensures that no water can escape the system while the caps are being replaced,
irrespective of the actual pressure in the electrode clamps. The Master- Jet offers another significant advantage: when the cooling system is restarted, water is fed back from the cylinder into the pipeline, effectively preventing air bubbles in the lines. There is thus no need for additional bleeding measures and the system can be restarted without faulty sensor signals. Restarting therefore takes only two to three seconds. Without the MasterJet, the restart time would be around 15 to 20 seconds.
Cooling System with electrical control valves ( Solenoid Control Valve ) :
Instead of using pneumatic control valve Burkert introduce electrical control valve with the same cooling system for robot welding units along with additional port of cooling of Thyristor. These electrical operated control valve systems are recommend for the automotive industry / robot welding manufacture where electric servo motor exist on their facility. This would prevent incurring cost of compressed air for this users.
This cooling system consist of Sensor technology for electrode clamp cooling Paddle wheel sensor ( TYPE 8012 ) for systems with 4-20 mA/frequency and switching output Ultrasonic sensor ( TYPE 8081 ) with 4-20 mA or frequency output Dual paddle wheel sensor for separate flow monitoring at each electrode cap by using e-Control - Universal Controller ( PID controller TYPE 8611 ) along with Solenoid control valve (motor driven control valve TYPE 3280 )
We would like to hear from you regards leak detection in your robot welding units.