HOTSPOT HOTSPOT I User Manual

HOTSPOT I 产品使用说明书

产品使用说明书

HOTSPOT I

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HOTSPOT I 产品使用说明书

WAWRNING

Operator safety is of primary importance! The HOT SPOT
can generate potentially dangerous voltages, particularly if
the internal 80 V limiter fails. Care should be taken to avoid
coming into direct contact with the welder5 s electrodes.
This caution should be exercised for both AC and battery
powered operation. Those familiar with welding will not
have to be reminded of the danger from sparks and sprays of
molten metal. Avoid flammable clothing, inflammable or
explosive material in the area, and wear eye protection
devices. Use in a well ventilated location. Breathing of the
compounds generated by the high temperature welding arc
from the various components of the wire, insulation, and
base materials should be minimized. The internal sealed lead
acid battery may develop explosive hydrogen gas while
charging. This battery contains a corrosive sulfuric acid gel
and should be handled with caution.

警告

操作安全第一！Hotspot 可能产

生危险的电压，特别是内置 80
伏电压限制器失灵时。使用时应
该小心，身体防止与焊接机的电
极直接接触，在交流电源和电池
电源操作时都应该注意该警告。
焊接时注意熔融金属喷溅的火
花，易燃材料和易爆材料不要靠
近焊接区域。焊接时要佩戴护目
设备。在通风条件良好的环境下
使用，以减少操作人员对高温电
弧（来自金属丝、绝缘材料和基
材等成分产生的）产生的混合气
体的吸入。机壳内安装的铅酸电
池在充电时可能产生易爆炸的
氢气，并且该电池里面还含有腐
蚀性的硫酸液体，都应该小心处
理！

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HOTSPOT I 产品使用说明书

GENERAL DESCRIPTION AND OPERATION

The Hot Spot Capacitive Discharge Welder is designed to help solve
your thermocouple fabrication and attachment problems. The welder
generates an electric arc for fusing standard couple elements and
welding them to any thickness base metal. This capability is handled
by the interaction of the various circuit functions shown in the block
diagram below.

The system is powered directly from the AC line through a step-down
transformer, or from a gel type storage battery. The storage battery is
automatically recharged whenever the unit is connected to AC power.
When the Hot Spot is turned on, the capacitor charging circuit charges
the large energy storage capacitor to the level set by the level control.

To perform a weld, the wire to be welded is held in the attachment
pliers, and the magnet electrode is connected to the base material.
With the wire pressed into contact with the base material the operator
depresses the firing switch. This triggers the SCR, discharging the
stored energy through the thermocouple wire and causing an arc
discharge at the contact point with the base material. This arc relea ses
a burst of heat to locally melt both the wire and base, producing a
fusion weld. More will be said about the steps to be taken to produce
good junctions in the other sections of this manual.

Using welded thermocouples solves the couple generation and
attachment problem in one operation. Merging these steps with the
HOT SPOT, generates obvious advantages in the areas of cost,
flexibility, accuracy, and the time required for installation.

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概述与操作

Hotspot 电容放电焊接机是帮您解决

热电偶制造和焊接的设备。焊接机产生电

弧熔化标准热电偶元件并且把它焊接在

任何厚度的基体金属上。该性能是通过下

图显示的各种电路的相互作用来实现的。

该系统直接由降压变压器提供交流

电，或充电电池提供直流电。当该装置与

交流电源连接时就会自动充电。当打开焊

接机开关时，电容器充电电路会通过大容
量电容器的电位计达到被设定的级别。

为了执行焊接，被焊接的电线放在焊

接钳上，磁体电极和基体材料连在一起。

当电线被熔化与基体材料接触后，操作员

按下点火开关。该操作可以触发半导体整

流器，通过热电偶电线释放储存的能量并

在基体材料触点产生电弧。该电弧释放热

量来熔化导线和基体材料，从而产生熔化

焊接。在该手册的其它部分将会告诉你采
取何种步骤能产生好的接合。

只需一个操作，热电偶焊接就可以解

决热电偶结球和焊接问题。按照热电偶焊

接机操作手册规定的步骤操作，就会发现

它在成本、灵活性、精确性和效率上有明
显的优势。

WHA T YOU WANT , WHEN YOU WANT, WHERE YOU W ANT

您需要什么，什么时候需要，什么地方需要

Maybe you won't get all you want, but the Hot Spot is such a flexible
tool that you're going to find many new ways of making and
employing thermocouples. There's no lack of possible configurations
and attachment schemes. The photographs to the right show some
popular examples.

Many useful types can be formed Butt welds may be made using side
by side, end to end, and crossed or intersecting wires. Third party
junctions, employing another material in addition to the thermocouple
wires, can either incorporate the surface of the end item being sensed
or use a freestanding pad Such junctions will sense temperature at a
single point if a common weld spot is used or will sense an "average"
surface temperature if the welds of the two sensing wires are separated
by a length of intervening base material. However, situations should
generally be avoided where the separation spans material of
non-uniform temperature.

The Hot Spot can also perform simple fastening tasks using steel,
copper, stainless wire or thin plate. When using flat materials in place
of the normal wire, a corner or sharp edge of the flat strip should be
used as the weld point A spot welding mode is also possible. For this a
large round copper rod is held in the pliers’ jaws, and the material to be
welded pressed between the flat end of the rod and the base material.
Sufficient pressure is applied to eliminate arcing and so a "spot weld"
is produced when the circuit is fired. This approach is sometimes
used for attaching thermocouple wires of 30 gauge or finer to a flat
base. With non-standard materials and procedures, the results are
unpredictable and must be determined empirically.

HOTSPOT I 产品使用说明书

也许你不会得到所有你需要的，但是

Hotspot 是灵活的工具，你可以发现很多

新的制作热电偶和使用热电偶的方式。还

有很多可能的外形和配套方案。右边的图
解给你展示了一些通用的焊接例子。

很多型号的热电偶丝都可以通过并

排、首尾相连、交叉或相交来完成接焊接。

第三方接合，除了使用热电偶线外还需要

额外的材料，既可以与被测温部件尾部接

合，也可以使用垫圈连接。常见的结球会

感应到某个点上的温度，如果两根感应线

的焊接被一段距离的基体材料隔断时会
感应到“平均的”表面温度。

使用钢、铜和不锈钢线或薄板，

Hotspot 也能执行简单的固定操作。当用

扁平材料代替焊接线时，拐角或尖缘应作

为熔结点，同时进行点焊方式操作。对于

这个大圆形铜棒，焊接材料应压放在棒的

扁平面。操作时需要充分的压力来减少电

弧，通过线的燃烧来产生焊接点。该方法
有时用来把规格为#30（0.25mm）或更细

的热电偶线焊接在平面上。用非标的材料

和焊接程序，结果是难以预料的，应该根
据经验进行操作。

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HOW TO

Variations in thermocouple and base materials, the site environment, as
well as the particular style employ ed by the operator, keep capacitive
discharge welding of thermocouple wire an art rather than a science.
The " flash" welding of thermocouples is a fusion or arc welding
process, where enough electrical energy is released at the weld site to
melt the materials being joined The numerous base and thermocouple
materials differ in compatibility with the process and with each other.
Where appearance and mechanical strength are important
considerations, more care will have to be taken in material selection
and operator training

The combination of operator ingenuity and Hot Spot flexibility allows
a wide variety of welded junctions to be produced. The photographs in
this manual illustrate some Hot Spot fabrication techniques and
results. They are provided as a suggestion of the range of possibilities
available to the TC fabricator. The thermocouple weld is produced by
fusing the wires in an arc generating electrical discharge formed
between the ends of the wire pair to be joined and a conductive base
material. Stripped wire pairs should be positioned in the plier electrode
so that each wire is contacted Asymmetrical contact can produce a
distorted bead. Other factors, including wire material, contribute to
bead distortions. If the first firing does not produce the expected result,
multiple discharges using the same junction may help in producing the
desired shape. The pliers holding electrode must grasp the
thermocouple wire firmly and near to the end which is to be welded
( 1/4" to 1/2"). Poor contact with the pliers will allow arcing at the
jaws, which will damage the pliers and the wire, and rob energy from
the intended weld.

HOTSPOT I 产品使用说明书

怎样操作

因热电偶基体材料、操作环境以及操

作员采用热电偶型号的不同，电容放电焊

接热电偶线，结果会有所不同。“闪光”

焊接热电偶是一个熔融或电弧焊接过程，

在焊接点会释放出足够的电能，从而熔化

需要焊接的材料。各种基材和热电偶的适

应各有不同，外形和机械强度是最重要

的，因此在基材选择和操作员培训上应该
特别注意。

操作人员的精明与 HotSpot 的灵活结

合使得多种焊接成为可能。操作手册上的
图解说明了一些 Hotspot 焊接机的制造技

术和效果。它们给热电偶焊接机的各种可

能操作提供了建议和指导。热电偶焊接机

是通过热电偶线末端和导电基体材料之

间产生的放电电弧来熔化热电偶线的。金

属丝热电偶线应该充分与电极接触而达

到完全焊接。非对称的接触会产生弯曲的

焊道。其他的因素，如导线材料也能引起

焊道变形。如果第一次焊接没有达到预期

的效果，那么在同一个接合处的多次放电

将有助于产生预期的形状。钳子的夹持端

必须紧紧夹住热电偶线并且靠近焊接末
端约 1/4 英寸～1/2 英寸（6.35mm～

12.7mm） 。与钳子接触不好会在钳子口

处产生电弧，这样会损坏钳子和热电偶
线，同时还会损耗焊接机的存储电能。

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Free-standing junctions are produced by holding the paired wires in
the electrode pliers and touching them to the carbon block electrode,
while pushing the Hot Spot firing switch.
dial energy settings may be used as an initial guide for heat level.
However, they should be modified to suit the individual operator,
wire type, and desired result, #30 wire pairs, 20 Watt seconds; #26,
30 Watt seconds; #24,40 Watt seconds; and #20 wire pairs or.#16
single strands, full power. Wires may be welded by pressing the
firing button before or after the wire is in contact with the base.
Pre-firing allows somewhat larger wire to be welded, prepositioning
provides better placement precision. Pre-firing is also frequently
used when forming free-standing junctions with a carbon block (hold
in until contact is made).

The Hot Spot is very useful for welding thermocouples directly to
metal items which will be monitored or to brackets, nuts, bolts,
clamps, etc., which are assembled to such items. Best control and
attachment is obtained if free-standing junctions are first made, and
then "smacked" down to the metal surface (attached to the other
welder wire) while the firing button is depressed Where positioning
is critical, the junction can be held with light pressure (rather than
smacked) against the metal base, and then the firing button pushed
Neither approach is useful when the wires are finer than #26 or #28,
since they will not support the pressure needed to keep them in
contact with the base material during the welding period。

Release of the welding energy instantaneously raises the contact
point between the thermocouple wire and the base metal to the
melting temperature and a fusion weld is formed. Cutting the wires
evenly and to points helps to create the arc and to generate a more
symmetrical junction. A peak current of several thousand amperes
flows during the welding cycle. The circuit between the magnet and
pliers electrodes should be only a few inches in length and the
intervening materials a good conductor (under .01 ohm resistance) so
that excessive energy is not dissipated along this path.

The following calibrated

HOTSPOT I 产品使用说明书

通过把热电偶线夹在带电极的钳子上

并且使它们与碳块电极接触，与此同时按

下热电偶焊接机的点火开关就能产生自动

结球。能量调节旋钮刻度可作为焊接级别

的初始向导。尽管如此，操作员还应根据

电偶线类别、期望效果、焊接线需要的能
量（如#30（20w·s）、#26(30w·s)、#24(40

w·s)、#20 的热电偶线或.#16 的单根丝）

等进行适当的调节，从而便于操作。在热

电偶线与碳块接触之前或之后按点火按钮

就可以进行焊接热电偶线操作了。预焊接

是为了焊接某些大尺寸的电偶线，预先放

置或定位，产生更好的焊接角度。预焊接

也常用在通过碳块结热电偶球过程上（夹
住热电偶线直到球形成）。

Hot Spot 在把热电偶直接焊接到被监

控的金属部件或可以与这些金属部件组装

在一起的支架、螺母、螺钉、夹具上也是

很有用的。如果结球一开始就已经制成，

直接将其与金属表面（或与其他焊接线接

在一块的）碰触，按下点火按钮就可以产

生最好的监控装置。在那些关键的地方可

以使用钳子夹住接合处（而不是碰触）并
且紧靠金属基体, 然后按下点火按钮。当热
电偶线的尺寸比#26 （ 0.4mm ）或
#28(0.315mm)还细时，以上的任何一种方法

都不可以使用，因为它们在焊接时没有支
持使它们与基体材料接触所需求的电压。

焊接能量的释放会把热电偶线和基部

材料的接触点的温度升高至熔化温度，然

后产生熔化焊接。把热电偶线对齐剪切好

有助于产生电弧和更对称的焊接。在焊接

周期会产生几千安培的峰值电流。钳子、

磁铁与机器的连接线必需是几英寸长，并
且传导材料的导电性必需很好（0.01 欧姆

以下的电阻），这样的话，额外的能量不会
在线路上被消耗。

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