ESAB EWH 50 FSW User manual

Brand: ESAB

Model: EWH 50 FSW

Type: User manual

Instruction manual

Original instructions

0463 624 001 GB 20191211

Valid for: serial no. 840-, 904-xxx-xxxx

EWH50FSW

Friction stir welding head

TABLE OF CONTENTS

0463 624 001 © ESAB AB 2019

SAFETY

.......................................................................................................

1.1 Meaning of symbols

...............................................................................

1.2 Safety precautions

.................................................................................

INTRODUCTION

..........................................................................................

2.1 Equipment

...............................................................................................

2.2 Main components of the welding head

................................................

TECHNICAL DATA

......................................................................................

INSTALLATION

............................................................................................

4.1 Handling of the welding head

................................................................

4.2 Installation of the cooling water hoses and electrical cables to the

welding head

...........................................................................................

4.3 Installation of the welding head

............................................................

OPERATION

................................................................................................

5.1 Leak alarm holes

....................................................................................

5.2 Operation at low load

.............................................................................

5.3 Noises during operation

........................................................................

5.4 Changing the welding tool

.....................................................................

MAINTENANCE

...........................................................................................

6.1 Validation of the load cell

......................................................................

6.2 Replacing the front and rear bearings

..................................................

TROUBLESHOOTING

.................................................................................

ORDERING SPARE PARTS

........................................................................

DIAGRAM

............................................................................................................

ORDERING NUMBERS

.......................................................................................

ACCESSORIES

...................................................................................................

Rights reserved to alter specifications without notice.

1 SAFETY

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1 SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER!

Means immediate hazards which, if not avoided, will result in immediate,

serious personal injury or loss of life.

WARNING!

Means potential hazards which could result in personal injury or loss of life.

CAUTION!

Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual

and follow all labels, employer´s safety practices and

Safety Data Sheets (SDSs).

1.2 Safety precautions

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who

works on or near the equipment observes all the relevant safety precautions. Safety

precautions must meet the requirements that apply to this type of equipment. The following

recommendations should be observed in addition to the standard regulations that apply to

the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the

equipment. Incorrect operation of the equipment may lead to hazardous situations which can

result in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

○ its operation

○ location of emergency stops

○ its function

○ relevant safety precautions

○ the friction stir welding application

2. The operator must ensure that:

○ no unauthorised person is stationed within the working area of the equipment

when it is started up

○ no-one is unprotected when work is started with the equipment

3. The workplace must:

○ be suitable for the purpose

1 SAFETY

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4. Personal safety equipment:

○ Always wear recommended personal safety equipment, such as safety glasses

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which

could become trapped or cause burns

5. General precautions:

○ Work on high voltage equipment may only be carried out by a qualified

electrician

○ Appropriate fire extinguishing equipment must be clearly marked and close at

hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

WARNING!

Friction stir welding can be injurious to yourself and others.

Work on the friction stir welding equipment may only be carried out by qualified

personnel trained for this purpose.

Never attempt to perform any type of service or maintenance work on the friction stir

welding equipment when welding is in progress.

WARNING!

Rotating parts can cause injury, take great care.

CAUTION!

Class A equipment is not intended for use in residential

locations where the electrical power is provided by the

public low-voltage supply system. There may be

potential difficulties in ensuring electromagnetic

compatibility of class A equipment in those locations,

due to conducted as well as radiated disturbances.

1 SAFETY

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NOTE!

Dispose of electronic equipment at the recycling

facility!

In observance of European Directive 2012/19/EC on

Waste Electrical and Electronic Equipment and its

implementation in accordance with national law,

electrical and/or electronic equipment that has reached

the end of its life must be disposed of at a recycling

facility.

As the person responsible for the equipment, it is your

responsibility to obtain information on approved

collection stations.

For further information contact the nearest ESAB dealer.

ESAB has an assortment of welding accessories and personal protection equipment

for purchase. For ordering information contact your local ESAB dealer or visit us on

our website.

2 INTRODUCTION

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2 INTRODUCTION

EWH50 FSW is an electromechanical friction stir welding head intended for use on a

welding robot or other welding carrier. It is designed for welding plates up to 10mm in Al6000

alloys. EWH50FSW is equipped with an integrated liquid cooling system of the motor

spindle and the FSW tool to secure high volume production and a long lifetime.

ESAB accessories for the product can be found in the "ACCESSORIES" chapter of

this manual.

2.1 Equipment

EWH50 FSW is supplied with:

• Instruction manual

2 INTRODUCTION

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2.2 Main components of the welding head

Serial no. 840-xxx-xxxx:

From serial no. 904-xxx-xxxx:

1. Welding head 6. Inlet tool cooling

2. Load cell 15 kN 7. Outlet tool cooling

3. Tool holder 8. Leak alarm holes

4. Inlet motor cooling 9. Power cable

5. Outlet motor cooling 10. Signal and temperature cable

For further information about the components included in the welding head, see the spare

parts list.

3 TECHNICAL DATA

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3 TECHNICAL DATA

EWH50 FSW, from serial no. 840-xxx-xxxx

Rated power supply voltage 400VAC

Rated supply input frequency AC with 50to 400Hz ±5% orDC

Rated input current:

Continuous 40.4A

Peak 93.5A

Maximum spindle rotation 4000 rpm

Spindle power 20 kW

Number of poles 10

Torque 50Nmat0–3200rpm,

15Nmat4000rpm

Tool holder Weldon 25

Axial force 15 kN

Radial force 4.5 kN

Connection motor cooling 2hosesockets, 9.5mm

(for hosewith 8mminnerdiameter)

Connection tool cooling 2hosesockets, 9.5mm

(for hosewith 8mminnerdiameter)

Force sensor for axial force (capacity load cell type) Resolution20kN/1000,

Accuracy0.1%

Operating temperature +5 to +50°C

Certification mark Declaration of Incorporation

Dimensions Length=297mm, Diameter=232mm

Weight 60kg

4 INSTALLATION

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4 INSTALLATION

The installation must be carried out by a professional.

CAUTION!

This product is intended for industrial use. In a domestic environment this product

may cause radio interference. It is the user's responsibility to take adequate

precautions.

WARNING!

Rotating parts can cause injury, take great care.

4.1 Handling of the welding head

When the welding head is not mounted on a carrier, use a sling strap to lift the welding head.

NOTE!

Differences may occur in the image compared to the item, depending on the serial

number of the item.

4.2 Installation of the cooling water hoses and electrical cables to

the welding head

1. Connect the water hose from the cooling unit to the motor cooling inlet.

2. Connect the motor cooling outlet to the tool cooling inlet.

3. Connect the tool cooling outlet to the return connector on the cooling unit.

4. Connect the load cell to the applicable input terminal (see diagram).

5. Connect the signal and temperature cable from the welding head to the applicable

terminal (see diagram).

6. Connect the supply power cable to the rated input supply voltage according to the

"TECHNICAL DATA" chapter.

4 INSTALLATION

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NOTE!

There is also the possibility to use two closed cooling systems, one dedicated for

cooling of the motor and one dedicated for cooling of the tool. In that case there is

no need for a connection in series according to items 1–3 above.

Serial no. 840-xxx-xxxx:

4 INSTALLATION

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From serial no. 904-xxx-xxxx:

NOTE!

Do not use pure water. Always use ESABs ready mixed coolant, containing

anti-freeze and corrosion protection.

4.3 Installation of the welding head

If the welding head should be installed to a welding robot, an adapter plate designed for the

specific robot is used for the installation. The graphic below shows the screw holes for

attachment of the adapter plate to the welding head and an example of adapter plate.

4 INSTALLATION

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Serial no. 840-xxx-xxxx:

From serial no. 904-xxx-xxxx:

5 OPERATION

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5 OPERATION

General safety regulations for handling the equipment can be found in the "SAFETY"

chapter of this manual. Read it through before you start using the equipment!

For instructions regarding control of the welding head, see the instruction manual for the

applicable control system.

5.1 Leak alarm holes

CAUTION!

There are three leak alarm holes in the friction stir welding head. If water is dripping or

running from any of these holes, there is a dangerous internal leakage in the welding

head and welding must be stopped immediately! Never start welding again before the

welding head has been checked and repaired by an authorised service technician!

Serial no. 840-xxx-xxxx: From serial no. 904-xxx-xxxx:

5.2 Operation at low load

CAUTION!

At very low or no load, the front and rear bearings in the welding head will be

overheated, which will result in a very short lifetime! Therefore never run the welding

head at noload for more than a maximum of 5 minutes!

5.3 Noises during operation

NOTE!

Pay attention to any noises from the welding head during operation! Noises can be

symptom of a worn bearing that needs to be replaced. Instructions for replacment of

the front and rear bearings are to be found in the service manual.

5 OPERATION

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5.4 Changing the welding tool

WARNING!

Several parts of the welding head, for instance the welding tool and the spindle, and

also the workpiece, become very hot during welding!

Use personal protection equipment when touching the welding head after welding.

Do as follows to change the welding tool:

1. Turn off the cooling system.

2. Put a container of approximately 1liter beneath the welding tool to collect residual

cooling liquid. If the welding head is mounted on a robot, the head could be positioned

horizontally to prevent leakage of cooling liquid.

3. Loosen the Allen screw on the tool holder, without removing the screw.

CAUTION!

Hold the welding tool while loosening the screw so that the tool does not fall

down and cause damage to personell or equipment!

4. Pull out the welding tool.

5. When the welding tool has been removed from the tool holder, make sure the O-ring is

still located at the back-end of the tool. If the O-ring is not at the back-end of the

welding tool, it has got stuck in the tool holder and has to be manually removed!

6. Check that the new tool to be fitted is not damaged and that it has got the correct size

for the object to be welded.

7. The old welding tool still holds some cooling liquid. Pour that cooling liquid into the tool

to be fitted.

8. Check that the O-ring is not damaged. Use a new O-ring if needed! Fit the O-ring to

the tool to be fitted.

9. Insert the new tool into the tool holder and fasten it loosely by means of the Allen

screw.

NOTE!

Only fasten the screw enough to prevent it from falling out of its place, not

more!

10. To compress the O-ring, first move the welding head so that the tool is located above

the pressure point. Then run the tool down towards the pressure point. When the tool

meets the pressure point, keep going until a force of 4–5kN is reached.

11. Fasten the new tool using the Allen screw.

12. Open the cooling liquid system and check for water leaks.

5 OPERATION

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6 MAINTENANCE

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6 MAINTENANCE

NOTE!

Regular maintenance is important for safe and reliable operation.

CAUTION!

All warranty undertakings from the supplier cease to apply if the customer attempts

any work to rectify any faults in the product during the warranty period.

6.1 Validation of the load cell

The accuracy of the load cell is recommended to be validated every 12 months. To validate

the load cell you need an additional load cell, that has been calibrated externally. Place the

externally calibrated load cell perpendicular to the friction stir welding head and press the

welding head against the load cell. Compare the value from the externally calibrated load cell

with the value received from the friction stir welding head and check if the received value is

within the accepted tolerance.

If the accuracy is found to be out of tolerance, calibrate the load cell according to instructions

in the control system instruction manual.

6.2 Replacing the front and rear bearings

Expected life of the front and rear bearings in the welding head at different loads are

according to below. Replace the front and rear bearings in a good time before the expected

life is out depending on the actual use case!

Load (in Zdirection) Expected bearing life

15kN (maximum permitted load) At least 5000h

10kN (robot applications) 10000–30000h

NOTE!

At very low or no load, the front and rear bearings in the welding head will be

overheated, which will result in a very short life! Therefore never run the welding head

at no load for more than a maximum of 5 minutes!

Instructions for replacment of the front and rear bearings are to be found in the service

manual.

7 TROUBLESHOOTING

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7 TROUBLESHOOTING

Fault symptom Actions

Motor

The motor does not turn. Check the electrical connections.

Check any error code on the control system.

Incorrect motor speed Check the settings on the control system.

Temperature alarm Stop the motor and check that the cooling unit is turned on

and that there is enough flow in the cooling system.

Stop the motor and check the cooling water temperature.

Cooling

Leakage from the hoses Check that the hose clamps are properly tightened and that

the hoses are not damaged.

Leakage at the weld tool Check that an O-ring is correctly located at the back end of

the tool and that the O-ring is not damaged.

Leakage at leak alarm holes

(see the "OPERATION"

chapter)

Stop welding immediately and send for an authorised

service technician! There is a dangerous internal leakage in

the welding head. Do not start welding again before the

welding head has been repaired by an authorised service

technician!

Load cell

The load cell does not respond. Check the connections for the load cell.

Contact your nearest ESAB service support office.

The load cell presents an

incorrect value, i.e. the load cell

accuracy is out of tolerance.

Check that the load cell or its cable has not been damaged.

Calibrate the load cell to bring the accuracy back into

tolerance according to instructions for the specific control

system.

Bearings

Noise from the bearings Stop welding and send for an authorised service

technician. One or both bearings need to be replaced.

Vibrations from the bearings Stop welding and send for an authorised service

technician. One or both bearings need to be replaced.

Axial play in bearing more than

0.03mm

Send for an authorised service technician. The bearing

needs to be replaced.

CAUTION!

Never run the welding head at very low or no load for more than a maximum of 5

minutes! At no load the bearings will be overheated and might be damaged.

8 ORDERING SPARE PARTS

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8 ORDERING SPARE PARTS

CAUTION!

Repair and electrical work should be performed by an authorised ESAB service

technician. Use only ESAB original spare and wear parts.

EWH50FSW is designed and tested in accordance with the international and European

standard EN60034-1. It is the obligation of the service unit which has carried out the service

or repair work to make sure that the product still conforms to the mentioned standards.

Spare parts and wear parts can be ordered through your nearest ESAB dealer, see

esab.com. When ordering, please state product type, serial number, designation and spare

part number in accordance with the spare parts list. This facilitates dispatch and ensures

correct delivery.

DIAGRAM

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DIAGRAM

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ESAB EWH 50 FSW User manual

ESAB EWH 50 FSW User manual

ESAB EWH 50 FSW User manual

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