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ESAB EWH 50 FSW User manual

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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
1
SAFETY
.......................................................................................................
4
1.1 Meaning of symbols
...............................................................................
4
1.2 Safety precautions
.................................................................................
4
2
INTRODUCTION
..........................................................................................
7
2.1 Equipment
...............................................................................................
7
2.2 Main components of the welding head
................................................
8
3
TECHNICAL DATA
......................................................................................
9
4
INSTALLATION
............................................................................................
10
4.1 Handling of the welding head
................................................................
10
4.2 Installation of the cooling water hoses and electrical cables to the
welding head
...........................................................................................
10
4.3 Installation of the welding head
............................................................
12
5
OPERATION
................................................................................................
14
5.1 Leak alarm holes
....................................................................................
14
5.2 Operation at low load
.............................................................................
14
5.3 Noises during operation
........................................................................
14
5.4 Changing the welding tool
.....................................................................
15
6
MAINTENANCE
...........................................................................................
17
6.1 Validation of the load cell
......................................................................
17
6.2 Replacing the front and rear bearings
..................................................
17
7
TROUBLESHOOTING
.................................................................................
18
8
ORDERING SPARE PARTS
........................................................................
19
DIAGRAM
............................................................................................................
20
ORDERING NUMBERS
.......................................................................................
21
ACCESSORIES
...................................................................................................
22
Rights reserved to alter specifications without notice.
1 SAFETY
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© ESAB AB 2019
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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© ESAB AB 2019
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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© ESAB AB 2019
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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© ESAB AB 2019
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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© ESAB AB 2019
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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© ESAB AB 2019
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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© ESAB AB 2019
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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© ESAB AB 2019
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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© ESAB AB 2019
Serial no. 840-xxx-xxxx:
From serial no. 904-xxx-xxxx:
5 OPERATION
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© ESAB AB 2019
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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© ESAB AB 2019
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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© ESAB AB 2019
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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© ESAB AB 2019
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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© ESAB AB 2019
DIAGRAM
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