Parker Products WCS-SIF-01 User Manual
WCS-SIF-01
Pneumatic Division
Richland, Michigan 49083
Training & Maintenance Manual
ISSUED: November, 2006
Supersedes: June, 2006
Pneumatic Spotwelding
Control Systems
Training & Maintenance Manual
WCS-SIF-01
Pneumati
c
Front View
Back View
Weld Stroke
Valve
Retract
(Pre-Stroke)
Valve
Feedback
Sensor
Flow
Control
Weld Stroke
Valve
Quick
Exhaust
(Air
Operated)
Retract
(Pre-Stroke)
Valve
WR-
ANSI (3 Ported Cylinder Option)
Inductive Sensor / Connection: Turck
Connection Diagram Inductive Sensor
1 Brown +24 VDC Power Supply
3 Blue 0 V Power Supply
4 Black Switch Wire
W+R+
Pw
Pr
Retract (Pre-Stroke)
Valve
Weld Stroke
Valve
14 4 2 12
14 4 2 12
1
pnp
+3-
4
Description & Operation
General Description of Spotwelding Units
The spotwelding system is an integrated pneumatic
controlled circuit that is specifically designed to increase
production throughput, while improving weld quality and
reducing decibel noise level.
Each unit consists of 2 independent, 2 position, directional
control valves for retract (pre-stroke) and weld stroke. Each
valve is dual pressure, with single solenoid / spring assist
return or double solenoid available. Also included with each
unit is a proportional / quick dump valve, a feedback sensor
for initiating the welding process, and a flow control for
metering the impact speed of the weld tips.
Training & Maintenance Manual
General Operation of
Spotwelding Units – 3 ported guns
Spotwelding systems control both retract (pre-stroke) and
weld stroke motions. When a 3 ported cylinder is used, the
control block functions as follows:
1. The pre-stroke (retract) valve is energized, allowing
the weld cylinder to extend under full line pressure by
actuating the quick exhaust valve and moving to its
predetermined position prior to welding.
2. The quick exhaust valve time is adjusted by the knob
on top of the unit. To start, the white line on the dial
is set at top dead center. Turn knob clockwise to set
quick exhaust valve open time. Continuing to turn knob
clockwise will lengthen time until it reaches a full 360°
rotation, which covers the complete timing range.
3. The weld stroke valve is then energized using a selected
weld schedule pressure. The closure speed of the weld
tips is controlled by the use of an adjustable flow control,
thus creating “low impact”.
4. Immediately following weld tip contact with the sheet
metal, two actions take place.
a. The proportional / quick dump valve that senses
pressure allows the front end of the cylinder to exhaust
(by-passing the flow control), providing weld schedule
pressure instantly.
b. The proportional / quick dump valve also actuates a
feedback sensor to start the weld cycle.
5.
Once the weld cycle is complete, the weld stroke valve
is de-energized, allowing the weld tips to open under
full pressure.
6. The retract (pre-stroke) valve is then de-energized,
allowing the weld cylinder to open completely under
full line pressure.
Note: Dual pressure is provided to the control block. Line
(high) pressure is used for both retract stroke and weld
stroke open. Weld schedule pressure is used for weld stroke
close. Dual pressure provides for weld tips to be closed for
tip dressing using any pressures available, from as low as
5 PSIG to maximum line pressure.
2
Parker Hannifin Corporation
Pneumatic Division
Richland, Michigan
www.parker.com/pneumatics
WCS-SIF-01
Pneumati
c
W-
Pw
Pr
ANSI (2 Ported Cylinder Option)
Inductive Sensor / Connection: Turck
Connection Diagram Inductive Sensor
1 Brown +24 VDC Power Supply
3 Blue 0 V Power Supply
4 Black Switch Wire
W+
1
pnp
+3-
4
W-
ANSI (4 Ported Cylinder Option)
Inductive Sensor / Connection: Turck
Connection Diagram Inductive Sensor
1 Brown +24 VDC Power Supply
3 Blue 0 V Power Supply
4 Black Switch Wire
W+R-
R+
Pw
Pr
1
pnp
+3-
4
Front View
Back View
Weld Stroke
Valve
Retract
(Pre-Stroke)
Valve
(4 Ported
Gun Only)
Feedback
Sensor
Flow
Control
Weld Stroke
Valve
Retract
(Pre-Stroke)
Valve
(4 Ported
Gun Only)
Description & Operation
General Operation of
Spotwelding Units – 2 and 4 ported guns
Spotwelding systems control both retract (pre-stroke) and
weld stroke motions. When a 4 ported cylinder is used, the
control block functions as follows:
1. The retract (pre-stroke) valve is energized, allowing
the weld cylinder to extend under full line pressure and
moving to its predetermined position prior to welding.
2. The weld stroke valve is then energized using a selected
weld schedule pressure. The closure speed of the weld
tips is controlled by the use of an adjustable flow control,
thus creating “low impact”.
3. Immediately following weld tip contact with the sheet
metal, two actions take place.
a. The proportional / quick dump valve that senses
pressure allows the front end of the cylinder to exhaust
(by-passing the flow control), providing weld schedule
pressure instantly.
b. The proportional / quick dump valve also actuates a
feedback sensor to start the weld cycle.
4.
Once the weld cycle is complete, the weld stroke valve is deenergized, allowing the weld tips to open under full pressure.
5.
The retract (pre-stroke) valve is then de-energized, allowing
the weld cylinder to open completely under full line pressure.
Training & Maintenance Manual
Note: Dual pressure is provided to the control block. Line
(high) pressure is used for both retract stroke and weld stroke
open. Weld schedule pressure is used for weld stroke close.
Dual pressure provides for weld tips to be closed for tip
dressing using any pressures available, from as low as
5 PSIG to maximum line pressure. 2 ported guns perform
the same steps as above, except that the retract (pre-stroke)
portion of the cylinder does not exist. Steps 2–4 only apply.
3
Parker Hannifin Corporation
Pneumatic Division
Richland, Michigan
www.parker.com/pneumatics
WCS-SIF-01
Pneumati
c
3 Ported Installation 4 Ported Installation
Weld Stroke
Connector(s)
Exhaust
High
Pressure
Inlet
Retract
Extend
Weld
Extend
Weld
Pressure
Inlet
Weld
Return
High
Pressure
Inlet
Weld
Pressure
Inlet
Weld Stroke
Connector(s)
Retract
(Pre-Stroke)
Connector(s)
Retract
(Pre-Stroke)
Connector(s)
Retract
Extend
Weld
Extend
Weld
Return
Retract
Return
Installation & Setup Instructions
Installation – Air and Electrical
A. Installing Weld Block with Existing Equipment
1. Shut off air supply to weld gun and turn power off to cell.
2. Disconnect air hoses from existing weld block ports. This
will vary depending on weld gun type, and whether the
existing weld block is single or dual pressure.
Note: If the current weld block is mounted directly to the
cylinder, then only the inlet port hoses will be disconnected.
3. Disconnect solenoid connectors from valves. Be sure
to note which connectors are being used for pre-stroke
(retract) valves and weld stroke valves.
4. Remove current weld block from gun.
B. Installing Weld Block on New Equipment
5.
Mount weld block spotwelding system to robot using (4) M8
screws and torque to 130 to 145 in. lbs (14.7 to 16.4 Nm).
6. Connect all air hoses to weld block (see schematic on
pages 2 or 3).
Note: An additional air hose may be necessary for the
inlet, since this unit is dual pressure. If so, connect the
already existing hose to the Pw port (pressure weld).
This hose should be supplying scheduled pressures from
a proportional regulator. Connect the additional hose
before the proportional regulator using a T-fitting so that
full line pressure is being used. This hose should be
connected to the Pr port (pressure retract).
7. Connect the solenoid cables to the proper valves.
Connect an M12 sensor cable to the feedback sensor on
the unit. The other end of this cable should be wired to
the PLC controller.
Training & Maintenance Manual
8. Turn air supply and power on.
9. Check for air leaks. The weld cylinder should be in the
home position (completely open). If not, check that all
air hoses are connected to the correct ports. Verify that
all solenoids are de-energized, and valve overrides are
unactuated. Once this is done, verify the function of the
weld block, by actuating the weld block valves using the
manual overrides. Press and hold the retract (pre-stroke)
valve manual override. The weld cylinder should move to
the weld stroke position. Press and hold the weld stroke
valve manual override [still holding the retract (pre-stroke)
override]. The weld cylinder should now close. Release
the weld stroke override and the retract (pre-stroke)
override. The weld cylinder will return to home position.
Note: The weld stroke portion of the cylinder will move
slower than the pre-stroke. This is due to the regulated
pressure being used, as well as the flow control.
Adjusting the speed of the cylinder will be covered in the
Setup Instructions. Repeat this process, now energizing
the solenoids. The cylinder should perform the same. If
not, verify that the solenoid connectors are located on the
proper valves. Once the unit has been properly installed,
the following setup procedure can be used to ensure that
the Parker weld system is used to its fullest potential.
Wiring
Refer to valve Instruction Sheet for proper wiring connections.
Available at: www.parker.com/pneumatic (see B6 and ISO
size 2 valves Installation and Service Instructions).
4
Parker Hannifin Corporation
Pneumatic Division
Richland, Michigan
www.parker.com/pneumatics
WCS-SIF-01
Pneumati
c
Open
Flow Control
Close
Flow Control
5mm
Allen Wrench
Required For
Flow Control
Adjustment
Electrical Changes (Sample):
GUN PR
ESS
TEACHI
NG
M005
00061
CUT CA RE-WEL
BLE CH D(PB)
ECKING
M052 M03C P1-M00F
K2 STR
OKE CH
ANGE
P1-M00F
TEACHI
NG
P1-M00F
GUN PR
ESS
M005
CUT CA RE-WEL
BLE CH D(PB)
ECKING
M052
RE-WEL
D(PB)
WELD R
EADY S
ENSOR
X024 1022 WELD START
M00B M03C
CHECK
MODE/P
ROGRAM
P1-L04B
STROKE
CHANG
E TIME
T015
AUTO R
E-WELD
M05B
RE-WEL
D
M00B
MANUAL
WELD
P1-L058
Insert contact on the
WELD START rung of
the Robot PLC program.
Installation & Setup Instructions
Setup
Below are the step by step setup procedures for properly
setting the flow control and feedback sensor.
How to Set the Flow Control Properly
Begin by turning the flow control clockwise until it stops. If
this is done properly, then the weld stroke should move
extremely slow or not at all.
Note: As stated in the Installation procedure, the pre-stroke
valve must be actuated prior to the weld stroke valve in order
for the weld cylinder to move correctly.
Slowly (1/4 to 1/2 turn at a time) begin to open the flow
control by turning counterclockwise. The weld tips should
now close upon actuation of the valves. At this point, you
should begin to hear a second exhaust coming from the
weld unit once the weld tips have made contact. This
second exhaust is the air from the front side of the cylinder
bypassing the flow control. As you continue to speed up the
weld stroke by turning the flow control, the delay between
the tips closing and the second exhaust will get shorter.
Also, check the feedback sensor while this is occurring. The
indicator light from the sensor should illuminate when you
hear the second exhaust. This is the key to determining the
proper setting of the flow control. The optimum setting for
each weld block will be different for each gun, based on the
bore size and weld stroke used. Continue to open the flow
control, allowing the weld tips to close faster until:
Training & Maintenance Manual
1. You have reached an impact speed you are happy with.
2. You have reached an acceptable decibel noise level.
3. You see that the second exhaust and feedback sensor
illumination occur “just” as the weld tips contact.
Note:
This is a judgement call. If the flow control is set
too far open, then the weld block could result in welding
misfire causing the gun to fire before the weld tips close
fully. The reason this would occur is because the flow
control has been opened so much that all the air on the
front side of the cylinder has exhausted before the tips fully
close, thus negating the “low impact” benefit of the system.
To guarantee proper performance, find the setting where
the exhaust / illumination occurs “just” as the tips close,
and then adjust the flow control 1/2 turn clockwise.
How to Set the Feedback Sensor Properly
The purpose of the feedback sensor is to provide an input
signal at the exact moment that full weld pressure has been
obtained at the weld tips. Traditionally this is achieved using
squeeze time. An experienced weld / electrical engineer
is needed to place the feedback sensor input into the PLC
program. The location of this input will vary depending on
the PLC manufacturer. Consult the robot manufacturer for
the proper input location.
Above is a sample PLC program where the feedback sensor
was placed during a typical install. The location of the input
should be right before the weld start command. Once the input
has been placed into the program, disconnect the sensor cable
from the feedback sensor. This will allow you to determine
whether or not the input was placed in the correct spot.
Perform a trial run. If on the first weld, the weld tips close
and the robot stops, then the sensor input has been located
correctly in the program. If the robot continues to run, despite
the cable being disconnected, then the sensor input is not
correct. Review the location and then try the trial run again.
Note: The weld block should perform the same whether the
robot is in manual or automatic mode.
5
Parker Hannifin Corporation
Pneumatic Division
Richland, Michigan
www.parker.com/pneumatics
WCS-SIF-01
Pneumati
c
Specifications
Training & Maintenance Manual
Pneumatic System
with Low Impact and
Rapid Approach Control
Description
Pneumatic valve block for use with pneumatic weld
gun cylinders. The block has an integrated low impact
system and is provided with two solenoid operated
“Namur” or ISO size 2 valves. One valve for the retract
(pre-stroke) and one for the weld stroke. The valves
can be of the single solenoid type or the double
solenoid type. The block is available for different
constructions of cylinders:
DH / WH = 3 Ported Cylinders
DP / WP = 2 and 4 Ported Cylinders
Ordering Code: See pages 7 – 13.
Dimensions: See pages 15 – 18.
Applications
The Spotwelding System can be used with any
Pneumatic Spot Weld Cylinder.
Mounting
The weld block can either be mounted on the side of
the robot or directly to the cylinder. See pages 10 – 12
for bolt hole patterns for robot mount. Consult Parker
for cylinder mount application.
Technical Data
Medium .......................... Compressed air, filtered to
40µ and dried to a dewpoint
of 37°F (3°C), lubricated
or non-lubricated. Once
lubricated air is applied, this
must be maintained.
Working Pressure ..........37 to 145 PSIG (2.5 to 10 bar)
WH Series Air Operated
Quick Exhaust ..........40 to 115 PSIG (2.7 to 7.9 bar)
Ambient Temperature ...... 41°F to 120°F (5°C to 49°C)
Weight –
DP ................................................. 12.0 lbs (5.4 kgs)
DH ................................................... 7.0 lbs (3.2 kgs)
WP (with Baseplate) ...................... 14.0 lbs (6.4 kgs)
WH (with Baseplate) ...................... 18.0 lbs (8.2 kgs)
Pneumatic Valve
24 VDC
Operating Voltage Solenoids
Power Consumption .....................................4.8W
Class of Protection ....................... IP65 (with plug
mounted)
Connector ............................ M12, 22mm, 30mm,
Auto (ISO 2 only)
120 VAC
Operating Voltage Solenoids
Frequency ............................................50 / 60 Hz
Power Consumption ..................... 7.8 VA / 6.3 VA
Class of Protection ....................... IP65 (with plug
mounted)
Connector ............................ M12, 22mm, 30mm,
Auto (WP / WH only)
Proximity Sensor
24 VDC
Supply Voltage ................................10 to 30 VDC
Rated Operational Current ........................200mA
Degree of Protection .....................................IP67
Ambient Temperature Range ....... -13°F to 158°F
(-25°C to 70°C)
Switching Indication ................... By LED (Yellow)
Output ..............................................PNP or NPN
120 VDC (Consult factory for availability)
Supply Voltage .............................. 20 to 140 VAC
Frequency ......................................... 50 or 60 Hz
Supply Voltage Indication ........... By LED (Green)
Rated Operational Current .......................400 mA
Degree of Protection .....................................IP67
Ambient Temperature Range ...... -13°F to 158°F
(-25°C - +70°C)
Switching Indication ................. By LED (Orange)
....24 VDC +10/-15%
...120 VAC +10/-15%
Service Kits: See page 9.
6
Parker Hannifin Corporation
Pneumatic Division
Richland, Michigan
www.parker.com/pneumatics
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