Due to its high production efficiency, low cost, and material savings, precision spot welding machines are widely used in industries such as handicrafts, electronic components, instruments and meters, electrical switches, cable manufacturing, mufflers, metal packaging, and chemical containers. The working principle of precision spot welding machines is to use the high-temperature arc generated by the instantaneous short circuit of the positive and negative poles to melt the solder and the material to be welded on the welding electrode, in order to achieve their bonding. The process parameters that affect the welding quality of precision spot welding machines include welding current, electrode pressure, energization time, and electrode working surface dimensions.
Precision spot welding machines may encounter some common faults during use, and the corresponding solutions are analyzed as follows:
1、 Presenting splashes:
a. Check if the electrode tip is severely oxidized.
b. Check whether the welded workpiece is severely corroded and has poor contact.
c. Check if the adjustment switch is set too high.
d. Check if the electrode pressure is too low and if the welding procedure is correct.
2、 Lack of workpiece strength:
a. Check if the electrode pressure is too low and if the electrode rod is securely fastened.
b. Check if the welding energy is too low and if the welded workpiece is severely corroded, resulting in poor contact of the welding points.
c. Check if there is too much oxide between the electrode head and electrode rod, and between the electrode rod and electrode arm.
d. Check if the cross-sectional area of the electrode tip has increased due to wear, resulting in a decrease in welding energy.
e. Check if the electrode and copper soft junction and bonding surface are severely oxidized.
3、 Overheating phenomenon:
a. Check if the insulation resistance between the electrode holder and the body is poor, resulting in a partial short circuit.
b. Check if the inlet pressure, water flow rate, and water supply temperature are suitable, and if there are any blockages in the water system caused by dirt, resulting in overheating of the electrode arm, electrode rod, and electrode head due to poor cooling.
c. Check if the contact surface between the copper flexible joint and electrode arm, electrode rod, and electrode tip is severely oxidized, resulting in increased contact resistance and severe heat generation.
d. Check if the cross-section of the electrode tip has been excessively worn, causing the welding machine to overload and generate heat.
e. Check if the welding thickness and load duration exceed the standard, causing the welding machine to overheat due to overload.
Severe indentation and extruded material:
a. Check if the current is too high.
b. Check if there are any unevenness in the welded workpiece.
c. Check if the electrode pressure is too high, and if the shape and cross-section of the electrode tip are suitable.
When operating precision spot welding machines, it is important to wear gloves, aprons, and protective goggles to avoid burns caused by sparks flying out. The sliding part should be well lubricated, and metal splashes should be removed after use. As the electrode tip deforms and wears, the contact area increases and the strength of the solder joint decreases. The oxides, dirt, oil, and other impurities on the surface of the workpiece increase the contact resistance, and an excessively thick oxide layer can even prevent current from passing through.
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