SECTION 6
6.1.1.
Weld
guns shall be obtained from an AZ Automotive approved weld gun source.
6.1.2.
The
supplier is responsible for the design of
weld guns. Weld gun assembly. drawings and related details shall be completed
by an AZ Automotive approved weld gun design supplier. All original drawings and/or CAD
files shall become the property of AZ Automotive.
6.1.3.
The
supplier shall work to the current AZ Automotive Process Standard to determine weld force
requirements. AZ Automotive Standard Weld forces for sheet metal are available in chart form, see sidebar index to the left, or
click here for the Spot Weld Lobe form.
click here for the Spot Weld instuctions.
click here click here for the Projection Weld Lobe form.
click here click here for the Projection Weld instuctions.
Note that these forces apply to all applications; Mild steel , HSLA, DP, TRIP and AHSS, coated and bare, and are to be achieved at 80 psi.
GMT or Governing Metal Thickness is the thinner of the two in a 2-layer stackup, or the second thinnest in a 3-layer stackup.
The supplier must insure that a
weld lobe study has been performed for each weld type performed by the weld tooling.
One weld lobe study will suffice for each unique stackup, no matter how many times this same stackup is welded in the tooling.
Please contact AZ Automotive to see if a weld study for this stackup has been performed, and, if so, a copy of this
study will be sufficient.
See the separate section "AZ Weld Lobe Study" for an example weld lobe chart, from the index bar on the left.
Contact your AZ Weld & Assembly Manager, David Bacon at 586 880 2050 for the interactive eXcel spreadsheet, and the materials to perform this study.
6.1.4.
Representative
weld gun designs are available in CATIA to the supplier.
6.1.5.
The
O.E.M. shall select and/or develop the specific gun for each application. The
weld gun selection shall be determined by the geometry of the parts to be
welded and the weld schedules required. An existing weld gun design should be
utilized for any new application. However, if an improvement in the operation
can be accomplished with a new design, then the design may be new or modified.
6.1.6.
All
weld gun designs (new and existing) shall be considered prior to the
design of the tooling.
6.1.7.
Design
approval for weld guns shall follow the following guidelines:
A.
The
supplier shall submit to the AZ Automotive Process Engineer a complete design proposal
package for approval. This package shall include a layout drawing of the weld
gun in which the mounting bracket, welding transformer location, composite part
sections, and the relative position of the robots’ gear train is shown.
B.
Upon
approval of this proposal the supplier shall submit to the AZ Automotive Weld Gun
Standards Group a preliminary drawing (2 copies) which includes all known
detail part numbers. If new detail components are required, they are indicated
as "new design" on the drawing. Every effort shall be made to use
existing details to keep the number of new designs to a minimum. Components
shall be dimensioned to coincide with established AZ Automotive standards.
C.
This preliminary
drawing shall be returned to the supplier with AZ Automotive standard numbers added along
with any requests for modifications. Only AZ Automotive Weld personnel shall assign new
weld gun numbers and detail part numbers. The supplier shall update and verify the final weld gun drawing. The AZ Automotive
Weld Engineer must approve any additional changes made to the weld gun.
D.
The final
documentation of the weld gun assembly and all new details shall be delivered
to AZ Automotive no later than 60 days following the official vehicle launch date. In
addition to the CATIA requirements this documentation shall include two (2)
Xerox copies of the following:
Portable: Robotic and Manual
|
|
Size
|
Weld Gun Assemblies
|
11x17
|
Movable Yokes
|
11x17
|
Stationary Gun Bodies
|
11x17
|
Hangers
|
11x17
|
Holders
|
8.5x11
|
Cap Adaptors
|
8.5x11
|
Cylinders
|
8.5x11
|
Miscellaneous
|
8.5x11
|
Fixture mounted, and Pedestal Weld
Guns:
|
|
Size
|
Weld Gun Assemblies
|
11x17
|
Yokes: Cylinder and Rod Side
|
11x17
|
Cradles
|
11x17
|
Holders
|
8.5x11
|
Cap Adaptors
|
8.5x11
|
Cylinders
|
8.5x11
|
Miscellaneous
|
8.5x11
|
E. Full sized print of the weld gun assembly
shall be shipped to the user plant with the weld gun. New prints shall be furnished
to the user plant as changes occur during launch.
6.1.8.
All
new weld gun drawings shall be delivered to AZ Automotive Weld Engineer in CATIA
format. The drawings shall meet the following requirements:
A.
All new
Assembly and Detail drawings to be supplied in CATIA by the OEM.
B.
One (1)
complete drawing shall reside in one (1) model and shall adhere to the
following Model Naming Convention:
1.
supplier. name (DCT, Lamb, PICO, Utica, Valiant)
2.
supplierTracking Number
3.
Weld gun supplier (Center Line, Grossel, Milco, Savair,
PICO)
4.
Weld gun manufacturer number.
5.
Phone number of gun manufacturer contact.
6.
DRAW or SOLID, indicating whether the model is a drawing or
a solid model.
7.
Revision level
o
Example: Valiant - VLT95678 - Milco - XX-XXX-XXX - (810)
123-4567 DRAW rel.
C. Models may consist of "draw" or
"space" vector elements. No scanned data.
D. Models may be translated from other CAD
systems, provided no data is lost due to the translation process.
E. Store model with a draw window, displaying
complete drawing.
F. All models shall be shipped via electronic
data transfer. Contact AZ Automotive CAD Department at (810) 759-2200 regarding
questions concerning the CATIA drawing deliverable.
6.1.9.
Any
new weld gun designs, which are solid modeled in CATIA per platform requirement,
shall be delivered to AZ Automotive no later than 60 days following the official
vehicle launch date. The solid model shall be drawn to the latest revision
level of the assembly drawing with the following requirements :
A.
Solid
model to be supplied by the OEM.
B.
Geometry
to be in layer 158.
C.
Model to
show the entire outline of the weld gun as shown on the assembly drawing,
including water fittings. Internal components are not required.
D.
Show
mounting holes on the hanger / cradle.
E.
The weld
point of the weld gun to be located on the origin (axis1) of the CATIA model.
Relate the weld gun to the axis as follows:
"X" - positive direction towards the fulcrum
"Y" - resultant
"Z" - "normal" to weld spot, with the
positive direction toward the movable gun body.
F.
For robot
applications, show axis 2 where the robot mounts to the adaptor plate.
G.
Show open
and retract position of weld tips, gun bodies, and cylinder in phantom.
H.
Store
model with default isometric window displayed with the weld gun being in the
weld position.
I.
Use the model naming convention shown in 6.1.8 for the
model name.
J.
All models shall be shipped via electronic data transfer.
Contact AZ Automotive CAD Department at (810) 759-2200 regarding questions concerning
the CATIA solid model deliverable.
6.1.10.
All
existing weld gun designs shall be re-evaluated by the AZ Automotive Weld Engineer before re-ordering or being ordered
for new tooling.
6.1.10.1
Solid models that are retrieved from the MDM database must
be checked for accuracy prior to re-use. Use the assembly drawing to verify
accuracy.
6.1.11.
Firing
of open weld guns shall not be permitted without written approval from an AZ Automotive
Weld Engineer.
6.1.12.
Weld
guns shall be positioned with serviceability in mind. (See Illustration 6-2.0
and 6-2.1)
6.1.13.
No air
over oil weld gun cylinders shall be allowed without prior approval from an
AZ Automotive Weld Engineer.
6.1.14.
When
increasing the piston area of the welding cylinder on a weld gun, the strength
of the weld gun components must be verified using an approved stress analysis
program.
6.1.15.
Cylinder
area, bore and stroke, and weld force information shall be noted on the
assembly drawing, located on the weld cylinder.
Example for portable guns :
3" Bore X 3" stroke (7.07 sq. in. area) - 565
lbs. @ 80 p.s.i. (Air)
Examples for machine type guns:
3" Bore X 3" stroke (7.07 sq. in. area) - 425
lbs. @ 60 p.s.i (Air)
1 3/8" Bore X 3" Stroke (1.5 sq. in area) -
600lbs. @ 400 p.s.i. (Hydraulic)
6.1.16.
Use 1
1/4" diameter shoulder bolts at the main pivot, where possible, for any
new weld gun designs and show a section through the pivot area on all weld gun
assembly drawings.
6.1.17.
Do not
tolerance reamed or bored holes. Use the terms "slip fit" (S.F.)
or" press fit" (P.F.).
6.1.18.
Do not
use limit-type dimensioning (ex. .626/.625 ). Use basic dimension with
tolerance
+.001)
(ex. .625 -.000).
6.1.19.
All
machined electrical contact surfaces shall have a maximum roughness of 32
micro-inches (R.M.S.).
6.1.20.
Drum
locks with screws smaller than 5/16"-18 are not permitted.
6.1.21.
Heli-coil
type inserts shall be used when mounting details to non-ferrous and/or cast
components.
6.1.22.
Deflector tubes:
For 5/8" diameter cap adapters do not use a deflector tube larger than .210 O.D.
Tube material other than brass or copper requires approval of the AZ Welding Engineer.
System must allow at least one-half GPM water flow per electrode with no more than 10 PSI differential pressure at the manifold.
6.1.23.
All
contact surfaces of details carrying secondary weld current shall be portable
electroplated using Royal Silver Plating Solution #11971 or equivalent.
6.1.24.
Grade
8 bolts, screws, nuts and zinc-plated washers shall be used for coppers, jack
screws, cables, shunts and all non-magnetic details in secondary fields. On
weld guns, all secondary connections shall use supertanium bolts,
nuts and washers to attach the cables to the weld guns and to the transformers
(Torque to 90 ft/lbs).
6.1.25.
Design
shall provide a minimum of 1/2" over travel on weld guns.
6.1.26.
AZ Automotive
standard male electrode caps shall be used wherever possible, titanium-coated
tips preferred.
For tip life considerations, the largest standard cap size feasable is the preferred size.
The use of the 1/2" diameter cap is allowed only where both the weld schedule is less than 10 cycles of heat, and the duty cycle is less than 5%.
Generally this is for bare steel of 1mm or less. The AZ Welding Engineer must approve of any application exceeding this.
6.1.27.
A
spare cutter assembly shall be provided by the OEM for each tip dresser used
for robotic application.
6.1.28.
Series
welding shall not be permitted, except with prior approval from AZ Automotive Weld
Engineer.
6.1.29.
Steel
piston rods, hardened, and chrome plated are to be used in all cylinders.
6.1.30.
Provide
a protector on the inner & outer most leaf of all leaf style shunts.
6.1.31.
Weld gun
assembly drawings shall show all fittings (air, water, oil).
6.1.32.
Provide
a flash shield to protect the pivot assembly (fulcrum area) on all weld gun
assemblies.
6.1.33.
Adhere
to the following weld gun design preferences:
1.Pinch type
2.Scissors type
3.C-type
6.1.34.
Weld
gun suppliers, weld line integrators, Commodity Distributors and AZ Automotive User
Plants shall notify the AZ Automotive Weld Engineer of all revisions made to any AZ Automotive
standard weld gun assembly or weld gun component. The AZ Automotive Weld Gun Group
shall be furnished with the documentation in CATIA format as soon as the
changes are implemented.
6.1.35.
The
maximum stress level on any wrought component shall not exceed 35k.s.i.. The
maximum stress on any cast component shall not exceed 16 k.s.i.. The weld gun
designer must verify that stress calculations have been performed to the
satisfaction of the AZ Automotive Weld Engineer .
6.1.36.
All
weld guns shall have pre-lubed cylinders.
6.1.37.
All
weld guns shall be checked by a the AZ Automotive Plant Manufacturing Engineer before the gun
is shipped to the Weld line integrator.
It is the responsibility of the weld line integrator to assure that this procedure is followed.
6.1.38.
All
weld gun electrodes must be aligned within .020".
6.1.39.
All
weld guns shall be perpendicular to the surface of the material being welded
(+/- 3 degrees off normal allowed only with the approval of AZ Automotive).
6.1.40.
All
projection weld applications shall allow the part to float free during the projection weld. Any clamps that hold the part must be released to accomplish this. Welding of multiple projection welds is discouraged also, they must not interfere with each other by one gun holding the part during the weld on the other gun.
6.1.41.
All
spot weld applications shall be run with standard tips. In no case shall the tip be cut to size for production welding operations, as any deviations in the surface profile cause deviations in the current density, and will produce expulsion or cold welds. An exception to this is made for tip dressers, but each application of tip dressers must be approved.
6.2.1.
Portable and Robot weld guns
shall be sized at 80 p.s.i. All related components shall be able to withstand
the force incurred at 100 p.s.i. during production operations. Do not design
weld guns to operate under 40 p.s.i. on multiple weld schedules.
6.2.2.
The
mounting of the welding gun to the robot shall provide for the minimum robot
cycle time and the smoothest robot operational path.
6.2.3.
All
weld guns including spares shall be supplied as a complete assembly with all
the necessary hangers, kickless welding cables, air and water hoses, fittings,
etc.
6.2.4.
Spare
robot and portable Welding Guns, per design, shall be supplied based upon the
following:
QUANTITY
|
QUANTITY
|
Active
Guns
|
Spare
Guns
|
1 to 4
|
1
|
5 to 8
|
2
|
9 &
up
|
3
|
Note:
Spare quantities are based on the number of active guns of the same design.
Each separate design would require additional spares accordingly.
6.2.5.
The
supplier shall furnish (12) spare sets of all electrodes, caps, adaptors, and (2)
spare holder/adaptor combination per welding gun and ship them with each robot
and/or portable weld gun.
6.2.6.
Robot mounted
weld guns shall include the complete installation package to be used between
the weld gun and the robot face plate including socket head cap screws (class
12.9), metal back-up washers, lock washers, insulation washers, bushings, and
insulation pad (pre-drilled). One (1) complete set of installation parts to be
used as spares shipped with each weld gun.
6.2.7.
The
supplier shall pay strict attention to the routing of the secondary welding
cable, air and water hoses so as to eliminate any rubbing and/or pinching as
the robot performs its assigned program.
6.2.8.
The
supplier shall determine the size and length of the secondary cable.
6.2.9.
All
manual weld guns without a retraction feature shall have a minimum point
opening of 3/4".
6.2.10.
All
robotic & manual welding applications shall utilize grounding reactors on
the secondaries of welding transformers.
6.2.11.
All
robot guns shall be installed to the robot with an adaptor plate, utilizing two (2) dowels from adapter plate to robot face.
6.2.12.
Self-equalizing
cylinder must be called out separately on the weld gun assembly drawing.
6.2.13.
All
robot weld guns shall have a minimum weld stroke tip opening of 1 1/4" and
a maximum of 1 3/4"(not including retract stroke). The stationary jaw
shall have a minimum of 3/4" equalizing movement to enhance auto tip
dress.
6.2.14.
Aluminum
weld gun castings are not to be used unless no other alternative is possible.
6.2.15.
All
electrodes requiring restrictive side motion are to be keyed in position. Key slots must be long enough to
allow for adjustment.
6.2.16.
Hardened
wear plates and bumpers are to be used on all hanger brackets where self-equalizing
cylinders are employed.
6.2.17.
Double
bend cap adaptors on "C" type weld guns should be 7/8" minimum
diameter.
6.2.18.
Electrode
holders or electrode holder/adaptor combinations shall not exceed 6"
stickout from the casting, without approval.
6.2.19.
All components
requiring maintenance (cylinders, shunts, etc.) must be readily accessible.
6.3.1.
Air operated
machine type weld guns shall be sized at 80 p.s.i. All related components shall
be able to withstand the force incurred at 100 p.s.i. during production
operations
6.3.2.
Hydraulically
operated machine type weld guns shall be sized at 400 p.s.i. All related weld
gun components shall be able to withstand the force incurred at 525 p.s.i.
during production operations.
6.3.3.
A weld
gun search shall be conducted utilizing existing weld gun databases before
designing any new weld guns.
6.3.4.
Spare
machine Welding Guns, per design, shall be supplied based upon the following:
QUANTITY
|
QUANTITY
|
Active
Guns
|
Spare
Guns
|
1 to 6
|
1
|
7 to12
|
2
|
13 &
up
|
3
|
Note:
Spare quantities are based on the number of active guns of the same design.
Each separate design would require additional spares accordingly.
6.3.5.
The
supplier shall furnish (12) spare sets of all electrodes, caps, adaptors, and (2)
spare holder/adaptor combination per welding gun and ship them with each
machine type weld gun.
6.3.6.
Interchangeability
shall be considered for all weld gun standard components.
6.3.7.
All weld
guns shall be perpendicular to the surface of the material being welded (+/- 3
degrees off normal allowed only with the approval of the AZ Automotive Design
Coordinator and the Process Engineer).
6.3.8.
Weld
gun assemblies shall be designed with the cylinder side grounded and the rod
side insulated (double insulated weld guns are not acceptable).
6.3.9.
On
long-stroke dump units that position the weld guns, the welding transformers
shall move with the weld guns.
6.3.10.
Rear
hairpin mount is the preferred mounting for weld cylinders using straight gun
applications. Stud mount to be used only with the approval of AZ Automotive.
6.3.11.
All
weld guns shall have cable crosshole connectors wherever possible. This allows choices when attaching jumpers.
6.3.12.
Removed
6.3.13.
Removed
6.3.14.
Removed
6.3.15.
Removed
6.3.16.
Removed
6.3.17.
Use
at least two mounting holes per cylinder trunnion mounting plate.
6.3.18.
Spotface
adjusting screw mounting surface.
6.3.19.
Removed
6.3.20.
All
machine type equalizing weld guns shall have (3)- way adjustment (See
Illustration 6-1.0, 6-1.1 and 6-1.2).
6.3.21.
Weld
cable conditions/design considerations. (See Illustration 6-3.0, 6-3.1 and
6-3.2)
6.3.22.
Weld
cable conditions and transformer service/design considerations (See
Illustration 6-4.0)
6.3.23.
Weld
transformer and cable access/design considerations. (See Illustration 6-5.0,
6-5.1 & 6-5.2)
6.3.24.
Provide
adequate clearance for welding cables when designing lugs. (See Illustration
6-1.3)
6.3.25.
Weld
guns with tip opening of 3" or greater must incorporate a retract cylinder.
Robot controlled weld guns with retract shall incorporate a device that would electrically indicate, to the robot, that the weld gun is in the fully retracted position. Cylindicators can be used only with AZ Automotive approval.
6.3.26.
All
weld gun cylinders for machine type guns to have rod scrapers.
6.4.1.
Pedestal type weld
guns shall be sized at 80 p.s.i. All related weld gun components shall be able
to withstand the force incurred at 100 p.s.i. during production operations.
6.4.2.
In
Pedestal welding applications the weld guns used shall include, but not be
limited to, the following:
A.
Retract feature with a four (4) port welding air cylinder.
B.
Cylinder actuated equalizing, when needed.
C. 0.5
gallon per minute cooling water flow per tip/gun arm.
6.5.1.
Air
over Oil weld guns to be used only with approval.
6.5.2.
Air
over oil type weld guns shall follow the recommended sizing and installation procedures
from the weld gun manufacturer.
6.6.1.
Machines
or fixtures that use opposing weld guns shall have the guns mounted in line in
the machine or fixture such that the metal part being welded shall be centered
between the weld gun points, being equidistant and symmetrical from either
point.
6.6.2.
Removed
6.7.1.
Pedestal
(stationary) seam welders shall NOT use needle bearings in the head assembly
where weld current is involved but shall have a wiper bar or plate arrangement
in the current carrying area. Utilize caster oil lubrication.
6.7.2.
Knurled
cutters, wheel dressers, or knurled wheel drives used on seam welders shall
utilize needle bearings.
6.7.3.
Both
upper and lower heads on a seam welder shall be driven mechanically; either
direct coupled, gear driven, chain driven, or with an extension shaft directly
coupled to a remote transmission.
6.8.1.
All
transformers must be sized on second highest tap, at 65% - 70% heat. Any that fall outside
this specification must have a signed deviation by the appropriate AZ Automotive
representatives.
At AZ, it is customary to use 100KVA as a minimum standard for MFDC transformers, to allow for future applications. Any sized below this must be approved by the Plant Manufacturing Engineer.
6.8.2.
Suppliers
shall provide the calculations used for selecting and sizing transformers on
all resistance spot welding applications.
6.8.3.
AZ Automotive shall
approve cable and transformer sizing for remote transformer applications.
6.8.4.
Balancing
of secondary welding current shall be held within 5 %.
6.8.5.
All
secondary-welding cables used on 70 KVA and 100 KVA transformers shall be
minimum 1200 MCM and 16" maximum in length.
6.8.6.
Extensions
or 90-degree adapters shall not be used in the transformer secondary loops on
machine type weld guns unless approved by a AZ Automotive.
6.8.7.
Grounding
of welding transformer secondaries shall use the same ground potential
(negative) throughout the system or tool, with applicable sized ground cable.
6.8.8.
All MFDC welding transformers shall have a built-in transformer overtemp switch, to be wired into the logic similar to the water flow switch.
6.9.1.
Kickless
(low reactance) portable gun cables shall be 400 MCM minimum.
A.
Maximum
length on robot and manual guns is:
400 MCM 10 Feet.
B.
Maximum length
on machine remote transformers is:
400 MCM 3-5 Feet
500 MCM 5-8 Feet
800 MCM 8-12 Feet
6.9.2.
All
welding cables shall be held together with straps. Any deviation shall be
approved by a AZ Automotive.
6.9.3.
When
using a welding gun (robot or manual type) the kickless cable bolt assembly
shall be torqued down securely.
6.9.4.
Robot
kickless cable applications that are at, or exceed, 180 degrees gun rotation
must utilize high flex Water Edge or Flex-Cable only cables.
General
6.10.1.
Documentation
and pictorials for welding sequence, operation number, weld length, and
parameters will be provided by supplier at 50% design review. Changes will be
documented as needed. Final documentation will be provided to AZ Automotive at buy off.
Tooling
6.10.2.
Removed
6.10.3.
By request in the purchase order, a
manufacturing date stamp will be provided on each part for tracking and
identification.
6.10.4.
Avoid
multiple geometry fixtures. If multiple geometry fixtures are necessary, the
AZ Automotive program manager must approve the application.
6.10.5.
Spatter
free areas and weld nuts will be protected from debris and weld spatter
throughout the entire process.
6.10.6.
Tooling
and equipment in spatter prone areas will be protected.
Maintenance
6.10.7.
Weld
line must have adequate zoning for maintenance during incidental down time.
6.10.8.
Maintenance
personnel must have protected access to each zone. This access must not
interfere with the cycle of adjacent zones.
Adequate
accessibility for programming, preventative maintenance, etc. will be provided
for each zone.
6.10.9.
Ability
to change contact tips from the outside of the system will be provided where
possible.
Welding
6.10.10.
Keep weld
joint positions in proper orientations for welding. Flat welds with minimum
torch movement offer the best chance for quality welds.
6.10.11.
Torch
studies must be performed by supplier, and approved by an AZ Automotive weld engineer
at 50% design review.
6.10.12.
Torch
angles must be able to move +/- 10 degrees off of optimum with clearance for
robot arm and cables.
6.10.13.
Torch
contact tip must be able to extend one inch from proper work distance with
clearance for robot arm and cables.
6.10.14.
Mechanical
lugs required for ground cables.
6.10.15.
Proper
ground path required. (P.L.P. blocks, back-ups, etc. are not acceptable.)
6.10.16.
Ground
cables will be adequately sized and routed so as not to create a trip hazard.
6.10.17.
Torch
cables must be free from strain and interference.
6.10.18.
Wire feed
conduits must be free from obstruction.
6.10.19.
Adequate
guarding will be provided to protect operators from weld flash.
6.10.20.
The
supplier will provide a program and necessary equipment for Tool Center Point
check for each weld robot.
Equipment
6.10.21.
Welding
power source will be sized for adequate duty cycle.
6.10.22.
Torch
will be properly sized for required workload.
6.10.23.
The
use of a water or air cooled torch will be by the direction of the AZ Automotive weld
engineer.
Perishables
and Consumables
6.10.24.
The
build vender will supply all welding consumables for tryout and buy off.
6.10.25.
Welding
equipment and perishables must be industry standard (off the shelf items).
6.11.1.
The
cable used for the primary wiring of weld control panels shall be a minimum of 4/0 cable.
6.11.2.
(2)
conductor type W cable sized properly shall be used to connect primary side of
weld transformers to 4/0 leads from weld controllers. Provide cord grips with
basket weave for flexing applications.
6.11.3.
For
welding transformer primary connections use AZ Automotive approved distribution panels
in all installations readily accessible from floor level. Locations are to be
approved by AZ Automotive. T-taps are not approved for welding transformer primary
connections in lay in duct or in areas readily accessible from floor level.
Where flexible cable is used for platen movement the cable shall be supported
vertically at both ends. Flexible conduit shall NOT be allowed.
6.11.4.
Supplier
shall take and record the tip forces, transformer tap settings, gun supply
pressures, line voltages, and secondary current readings for machine weld
certification. Two copies shall be supplied to a AZ Automotive Launch Technician.
6.11.5.
On
PUSH-PULL welding applications the Supplier shall install AWG #4 wire to insure
proper grounding of secondary welding circuits. (See Illustration 6-6.0)
6.11.6.
Dual
weld guns shall use two (2) separate transformers except with prior approval.
6.11.7.
Primary
electrical cable size for trans-guns shall be three (3) conductor #2 Type W
cable for single weld gun and four (4) conductor Type W cable #2 for dual weld
gun.
6.11.8.
Welding
power conductors passing through metal openings shall pass through in pairs
with no magnetic material between the conductors.
6.11.9.
Each
weld gun control firing circuit shall control a unique weld gun circuit to ensure
weld guns are retracted immediately after firing. Each timer and phase of a
three-phase weld control shall be considered a unique circuit.
6.12.1.
Supplier
shall stencil identification in a contrasting color on the Welding Transformers
- The call out A1-A2-A3-A4, B1-B2-B3-B4, etc., with 2" high letters on
transformer visible from the floor on the service side of the line where
possible. All welding transformers shall also be numbered on the mechanical
layout sequencing schematics.
6.12.2.
For Weld
cylinder identification procedures see "Section 3", Mechanical, item
3.2.1
6.12.3.
All
weld guns shall have a weld gun identification tag mounted on the weld gun in
an area where it is accessible after the weld gun has been mounted. A duplicate
tag shall be provided and wired loosely to the gun so that it may be affixed to
the fixture by the OEM at the direction of a weld gun group representative.
This tag shall be white with 3/16" high letters. (See Illustration 6-7.0)
6.12.4.
Weld
gun supplier shall stencil or stamp AZ Automotive Standard Number on the body of all
weld gun cylinders.
6.12.5.
Pre-lubed
cylinders shall be identified as such with a 3/4 inch wide gold band on its
periphery.