MOTOWELD-RL350. Digital Inverter Controlled Welding Power Source for MOTOMAN -MA1900, -MH6, -HP20D. Application: Arc Welding

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1 Digital Inverter Controlled Welding Power Source for MOTOMAN Application: Arc Welding Manipulator: MOTOMAN-VA1400, -MA1400, -MA1900, -MH6, -HP20D

2 V 2 h Droplet Vector Control V 2 h Variable Pulse Control Function 1 Function 2 Droplet vector control greatly improves previously unstable CO2 welding! Spatter is reduced, so a beautiful flat finish is achieved. For pulsed arc welding, a variable pulse control that optimizes waveform according to the welding conditions has been developed. Droplet transfer is stable even at low voltage. Significant reduction in spatter generation! Advanced arc-welding technologies V 2 h Function 3 Heat and Waveform Control Improved Reliability and Maintainability The new Heat and Waveform Control (HAWC) corrects the instructed current and voltage values in real time! HAWC prevents welding defects that arise as a result of variations in workpiece accuracy and teaching accuracy, and improves productivity. This welding power source has improved reliability and maintainability in all kinds of environments by improving the internal structure of the unit and adopting digital communications. establishes a new era for arc welding. Applicable Manipulator Lineup Models optimized for arc welding General-purpose models Manipulators MOTOMAN- VA1400 MA1400 MA1900 MH6 HP20D 2

3 Droplet Vector Control d- ector Conventional method of CO2 welding Compared to MAG welding, the conventional method of CO2 welding tended to be unstable and a lot of spatter was generated. This is because, compared to MAG, CO2 is characterized by a greater tendency for the reaction force of the arc to become concentrated, which lifts the droplet up and causes it to waver. The figure below shows the cause of welding instability. The reaction force of the arc causes the droplet to waver. The reaction force of the arc concentrates and the droplet is lifted. The droplet is thrown upward, generating spatter. The arc regenerates. What is droplet vector control? Droplet vector control adjusts the current and voltage to generate an originally-developed waveform that makes it possible to achieve stable CO2 welding. It reduces spatter when compared with conventional technology and enables welding with a beautiful flat finish. POINT 1 The directivity of the arc has been improved by gradually raising the welding current. Stable welding becomes possible, and spatter is reduced. Conventional waveform POINT 2 Test Details A waveform that maintains a short arc length by smoothly changing the current has been developed. Spatter is reduced because building of the droplet is suppressed, making it less susceptible to the reactive force of the arc. Current: 150 A, Voltage: 16.3 V, Robot speed: 80 cm/min Shielding gas: 100% CO2 used POINT 1 POINT 2 Conventional welding method New welding method (with droplet vector control) New waveform Welding Results With the conventional welding method, the bead sometimes falls into disorder because the arc is unstable. With the new welding method including droplet vector control, stable welding is possible so the bead doesn t fall into disorder and a beautiful fl at fi nish can be achieved. Comparison of Spatter Generation Conventional model 5 Current 150 A 180 A 200 A 4 Conventional model Spatter generation g g g Spatter generation (g) % 65% 80% (with droplet vector control) 1 Spatter generation g g g A 180 A 200 A Welding current 3

4 Variable Pulse Control -Pulse What is variable pulse control? Conventionally, decreasing the voltage during welding to avoid burn-through and undercutting has resulted in unstable welding accompanied by the generation of large amounts of spatter. Variable pulse control changes the waveform according to the welding status from high to low voltages, achieving stable welding with little spatter. Test Details The appearance of the welding bead was checked by actually welding underbody parts. Shielding gas: MAG Welding conditions: 170 A, 23 V, Robot speed 90 cm/min Workpiece / Weld line Welding Results Conventional method New method (with variable pulse control) In the conventional method, there was some distortion in the appearance of the bead after welding, as shown in the photograph at the top to the right. In addition, a lot of spatter was generated during welding, as shown in the photograph at the right. In the new method (with variable pulse control), the bead has a beautiful flat finish after welding, as shown in the photograph at the top to the right. We can also see from the photograph at the right that there is a substantial reduction in spatter when compared with the conventional method. Enlarged view Enlarged view Comparison of Spatter Generation Robot speed 80 cm/min 80 cm/min 80 cm/min 80 cm/min 80 cm/min Current 175 A 175 A 175 A 175 A 175 A Voltage 22 V 23 V 24 V 25 V 26 V Conventional model 65% Conventional model Spatter generation 0.40 g 0.11 g 0.06 g 0.04 g 0.02 g MOTOWELD- RL350 (with variable pulse control) Spatter generation 0.14 g 0.06 g 0.04 g 0.03 g 0.02 g Spatter generation (g) V 45% 23 V 24 V 25 V Instructed voltage 26 V 4

5 Heat and Waveform Control AWC What is the HAWC (Heat And Waveform Control) function? The wire extension (distance between the contact tip and the workpiece) might change according to the workpiece accuracy and the teaching accuracy. With conventional equipment the execution current fluctuated due to the changing length of the wire extension, and this caused burn-through and poor penetration. When the HAWC function is used, the actually applied current and voltage values are fed back to the instructed current and voltage in real time to keep the heat input constant, preventing poor welds. Change in wire extension due to defective teaching Change in wire extension due to deformation of the workpiece Tip position Without HAWC (conventional method) Actual current Actual current changes Actual current changes With HAWC Actual current Arc start position The instruction value is adjusted when the actual current starts changing to control the actual current (heat input) at a constant value. Arc end position Test Details The difference in the welding results with and without the HAWC function was checked while changing the wire extension from 15 mm to 10 mm and back to 15 mm during welding. Workpiece thickness: 4.5 mm Joint type: Butt joint Welding conditions: 270 A, 26 V, Robot speed 90 cm/min Welding Results Without HAWC (conventional method) Burn-through has occurred in the section with a wire extension of 10 mm. With HAWC The infl uence by the change in the wire extension is not seen. Wire extension: 15 mm Wire extension: 10 mm Wire extension: 15 mm Test Details Seam welding (at a butt joint) of the pipe of 5 mm in thickness was carried out while changing the wire extension. (15 mm to 10 mm to 15 mm) Shielding gas: MAG Welding conditions: 200 A, 19.7 V, Robot speed 60 cm/min Welding Results Start Bead appearance without HAWC End Macro picture without HAWC Wire extension: 15 mm Wire extension: 10 mm Wire extension: 15 mm Penetration is unstable. Wire extension: 15 mm Wire extension: 10 mm Wire extension: 15 mm Wire extension: 15 mm Bead appearance with HAWC Wire extension: 10 mm Wire extension: 15 mm Macro picture with HAWC Penetration is constant. 5

6 Improved Reliability and Maintainability Conventional Ease of use and method smooth of CO2 setting welding with the digital communication function! Settings and operations of the welding power source and data management are handled by the robot controller through the digital interface using the WELDCOM function. This enables centralized control of welding data, which has cut the operation man-hours while also greatly improving reliability and maintainability. Digital communication (bidirectional) DX100 robot controller Detailed welding power source settings are possible. The welding power source settings can be backed up in an external memory device. Settings saved for other equipment can be transferred to and set in other welding power supplies. When replacing the welding power source, the previous settings can be transferred to the new power source. welding power source Easy internal maintenance, inspection and repairs! Modularized inverter circuits The welding power source can be maintained and inspected where it is installed, without moving it. Changing power source units on e.g. the deck floor of a facility, which has been a difficult job until now, can be accomplished using much fewer man-hours. Internal maintenance (control section, right side, left side) Simple monitor with high visibility Exterior panels can be removed more easily than on previous units. The number of fixing screws has been reduced by more than 50%, reducing the working time taken up by inspection and maintenance. 6

7 ON OFF m/min Type ) Interface For Robot(Analog) For Push Motor CON 3 CON 6 Output Terminal Voltage Sensing SW1 Base Metal A CON 8 V TM1 ) Interface For Robot (Digital) AC200V/220V Reinforcement of the Cooling / Dustproofing Systems The interior of the unit has been divided up into sections to prevent dust getting into the control and power circuits, improving reliability in adverse environments with conditions like high temperatures or dust. This is combined with a new construction that features channels providing a cooling airflow in the center of the unit and concentrates the heat-generating parts on the cooled faces, so cooling efficiency is maximized while ensuring dustproofing. The number of exhaust routes has been increased too, giving 20% better suppression of temperature rise than previous units. Temperature of Internal Structure of the heat-generating parts (Compared to previous units) Control section Cooling airflow 20% DOWN! Cooling airflow Back Front Secondary side Primary side Dimensions Units: mm Top V A P % C L _ + _ R MOTOWELD AA Back Left side Front Right side 7

8 Ratings and Specifications Welding Power Source Model Rated Input Voltage, Number of Phases Rated Frequency Rated Input Rated Output Current Rated Output Voltage Rated Operation Rate Welding Method Welding Material Dimensions Approx. Mass YWE-RL350-AJ VAC ±10% / VAC ±10%, three phases (Changing the input voltage requires changes to the internal wiring.) Setting on shipment: VAC 50 / 60 Hz 18 kva, 15 kw A (Depending on wire diameter) V (Depending on wire diameter) 60% (for 10 minutes) CO2/MAG/MIG/pulsed arc welding Iron, stainless steel 371 (W) 636 (D) 602 (H) mm (not including projecting parts such as eyebolts or screws) 60 kg Sales Department HEAD OFFICE 2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyushu, Fukuoka , Japan Phone: Fax: YASKAWA America, Inc. (Motoman Robotics Division) 100 Automation Way, Miamisburg, OH 45342, U.S.A. Phone: Fax: YASKAWA Europe GmbH (Robotics Division) Yaskawastrasse 1, 85391, Allershausen, Germany Phone: Fax: YASKAWA Nordic AB Bredbandet 1vån. 3 varvsholmen Kalmar, Sweden Phone: Fax: YASKAWA Electric (China) Co., Ltd. 12F, Carlton Bldg., No.21 HuangHe Road, HuangPu District, Shanghai , China Phone: Fax: YASKAWA SHOUGANG ROBOT CO., LTD. No.7 Yongchang North Road, Beijing E&T Development Area China Phone: Fax: YASKAWA India Private Ltd. (Robotics Division) #426, Udyog Vihar Phase-IV, Gurgaon, Haryana, India Phone: Fax: YASKAWA Electric Korea Co., Ltd 9F, Kyobo Securities Bldg., 26-4, Yeouido-dong, Yeongdeungpo-gu, Seoul , Korea Phone: Fax: YASKAWA Electric Taiwan Corporation 9F, 16, Nanking E. Rd., Sec. 3, Taipei, 104 Taiwan Phone: Fax: YASKAWA Electric (Singapore) PTE Ltd 151 Lorong Chuan, #04-02A New Tech Park, Singapore Phone: Fax: YASKAWA Electric (Thailand) Co., Ltd. 252/ th Floor, Tower B Muang Thai-Phatra Complex Building, Rachadaphisek Road, Huaykwang, Bangkok 10320, Thailand Phone: Fax: PT. YASKAWA Electric Indonesia Menara Anugrah Lantai 1, Kantor Taman E.3.3, Jl. Mega Kuningan Lot , Kawasan Mega Kuningan, Jakarta, Indonesia Phone: Fax: YASKAWA ELECTRIC CORPORATION In the event that the end user of this product is to be the military and said product is to be employed in any weapons systems or the manufacture thereof, the export will fall under the relevant regulations as stipulated in the Foreign Exchange and Foreign Trade Regulations. Therefore, be sure to follow all procedures and submit all relevant documentation according to any and all rules, regulations and laws that may apply. Specifications are subject to change without notice for ongoing product modifications and improvements YASKAWA ELECTRIC CORPORATION. All rights reserved. LITERATURE NO. KAEP C A Published in Japan January