AZ Automotive Weld Tooling & Assembly Equipment Standards Revision 1.2 15Dec2003
PRINTED COPIES ARE UNCONTROLLED
Deviations that improve safety, quality, or cost ARE ALWAYS WELCOME.
SECTION 12
The induction curing system shall inductively heat, at production rates, a hemmed flange containing a one-part temperature sensitive epoxy adhesive. The Adhesive shall be advanced to the gelled state providing adequate shear strength to withstand the mechanical stresses incurred by the subsequent production and/or shipping operations prior to full adhesive curing during the paint process.
The Supplier shall provide adequate training relating to the maintenance and operation of power supplies, controls, and diagnostic systems, for the unit plant personnel.
The Supplier shall provide an induction curing system, which shall include the following main components:
The programmable controller will be the existing line controller. The manipulation of the induction heat cycle and coordination of the mechanical movements shall be the Supplier 's responsibility.
The operating mechanism must be capable of accepting the part from the existing transfer rail, aligning part to nest, holding part during the heating cycle, and unclamping the part enabling the overhead shuttle to remove the assembly from the fixture.
All tooling must be adequately designed for the automotive production environment.
A balcony sufficient for the mounting of the closed loop water system, inverter (power supply), heat station and all electrical controls will be provided by the machine line builder.
The system installation shall comply with all applicable federal audio noise and safety standards.
Suppliers shall assist in both the installation and start-up of the equipment.
All systems and components shall be warranted for a period of one (1) year from the date of shipment.
A. Provide the following control requirements:
B. A constant voltage transformer (SOLA) for all electronic systems.
C. A permanently attached tag with all of the heat settings required for each part shall be supplied with each unit.
D. All control wiring which must be disconnected for shipping of the fixture must use AZ Automotive approved plugs and receptacles.
E. Provide a Master J-Box for control wiring.
F. The Induction Curing station builder will provide the receptacle to plug the fixture into the line. The fixture construction source will provide the cable and plug.
G. The control system for the fixture functions such as raise and lower lifters, clamps, etc. will be operated from the line programmable controller. All signals to and required from the line for heat station functions will be via dry contacts. All relays will be part of the heat station. All control of the heat cycle will be part of the Induction Cure station.
H. Provide a fused disconnect switch, which is capable of disconnecting all power to the Induction Cure station.
I. Push buttons and indicating lights for all functions required at the cure station which shall include but are not limited to the following:
PUSH BUTTON STATION
|
Indicating Lights Required |
Push Buttons Required |
|
POWER ON |
AUTO |
|
MANUAL |
E-STOP |
|
PUMP ON |
CYCLE STOP |
|
INVERTER READY |
PUMP START |
|
HEAT ON |
PUMP STOP |
|
PART OUT OF POSITION |
MANUAL HEAT |
|
CLAMPS EXTENDED |
EXTEND CLAMPS |
|
CLAMPS RETURNED |
RETURN CLAMPS |
|
WATER LEVEL LOW |
|
|
WATER FAULT |
|
|
CURE FAULT* |
*Must indicate all faults other than water faults.
Note: Indicating lights and push buttons for "ALL" fixture motions shall be required.
Coil and Nest requirements shall include but are not limited to the following:
A. Provide a non-conductive shield around the power connections on the nest.
B. The single-turn coil and part nest must be designed for overhead loading.
C. Provide appropriate draft on the nest to assist in part alignment.
D. Provide an evenly epoxy coated water-cooled work coil contoured to the work piece with spare(s).
E. The fully contoured part nest must be capable of withstanding both the thermal and mechanical stresses of the application.
F. Provisions to adjust and positively lock the coil in the nest are required.
G. The nest must be mounted on an aluminum tooling plate with provisions for positive alignment during tool change.
H. Quick disconnect fittings on the water lines.
The requirements for the Solid State Inverter, Heat Station, and Power Supply shall include, but are not limited to, the following:
A. A variable ratio transformer for load matching.
B. Be capable of employment in power transfer application.
C. Defeatable door interlock switches.
D. A heavy gauge N.E.M.A. 12 enclosure.
E. Two (2) heat level devices 100KW (min.). Supplier shall recommend the suitable frequency for the application.
a. One (1) to obtain the desired heat level.
b. One (1) to maintain the desired heat level.
F. A fused disconnect with flange-mounted operator.
G. A three-phase 460 Volt isolation contactor that is interlocked with the doors, safety gates, and Emergency Stop circuit.
H. A self-checking solid-state fault detection system for S.C.R. and ground fault protection.
I. Supply a 1" N.P.T. fitting in the floor of the inverter enclosure for a drain line.
J. An isolation transformer on the inverter output. Identify the isolation transformer with an engraved tag as follows:
--------------------------
| ISOLATION |
| TRANSFORMER |
-------------------------
K. Thermal sensors.
L. The power on the voltage output must be regulated to within 1% for either a 10% line or load fluctuation.
M. Capable of operating with power transfer switch option.
N. Multiple power settings.
O. Kilowatt - Second energy monitor.
P. An output voltage meter.
Q. A frequency meter.
R. An output power meter.
S. Push buttons and indicating lights for all functions required at the Inverter, which shall include but are not limited to the following:
|
Indicating Lights |
Push Buttons |
|
POWER ON |
POWER ON |
|
DOOR OPEN |
E. STOP |
|
TRANSFORMER OVER TEMPERATURE |
PUMP START |
|
WATER FLOW |
|
|
WATER PRESSURE |
WATER TEMPERATURE |
|
CAPACITOR WATER PRESSURE * |
*If Required
A. A re-circulating distilled water system capable of cooling the power supply and all of the heat stations and coils employed in the installation.
B. A stainless steel reservoir (12 gallon minimum).
C. A water-to-water heat exchanger.
D. A non-ferrous pump, heat exchanger, and piping.
E. An indicating water temperature controller.
F. A water quality monitor.
G. A water level monitor, which will signal when the reservoir level is below 70%.
H. A reservoir sight gage.
I. The fill tube must not exceed 48" in height from the base of the inverter enclosure.
J. A pressure switch shall be installed at the discharge side of the pump.
K. K.Flow switches (universal type) shall be installed on all of the return lines from the inverter and coil nest.
L. A T.E.F.C. 3600 R.P.M. pump motor.