The Drive & Control Company Rexroth Bosch Group Product Catalog Resistance Welding

Product Catalog Restistance Welding | Introduction

Introduction | Product Catalog Resistance Welding 3 Weld Controls PRC15 Overview 16 Ordering information, Handbooks 25 Options, Accessories, Spare Parts 24 System Components for Communication, Gun Control and 27 Fieldbus Couplers and I/O-Modules 28 Fieldbus Couplers and I/O-Modules S20 29 Fieldbus Couplers and I/O-Modules S67 30 Safety Zone Module HZS01 35 Gun Data Modules GDM and MGDM 37 Technical Data, Ordering information, Handbooks 46 Primary Terminal Boxes 68 Counterplugs for Power and Signals 69

Product Catalog Restistance Welding | Introduction

Introduction | Product Catalog Restistance Welding 5 Introduction 5 Resistance Welding Why Welding with Medium Frequency? Controls for Resistance Welding

Product Catalog Restistance Welding | Introduction Resistance Welding – Efficient and in the Highest Quality Welding processes in the automotive industry have to meet control and monitoring concept: users benefit from quicker the strictest requirements regarding process safety and commissioning, maximum availability and energy efficiency, quality. Weld controls PRC 7000 and welding transformers simple handling and maximum flexibility. PSG 6000 from Rexroth – that is much more than a proven Weld controls PRC provide: ▶▶ Up to 90 percent faster commissioning, in comparison to conventional technology...

Introduction | Product Catalog Restistance Welding 7 Further system components from the Rexroth product portfolio extend the functional possibilities of the weld control: ▶▶ Fieldbus couplers and I/O-Modules allow connection of operating and display elements and further digital and analog signals ▶▶ Servo drives control servoelectric motors for gun stroke and/or tip dresser ▶▶ The Safety zone module monitors the safety devices and ensures a safe movement of the weld gun, if required ▶▶ Gun data modules store data and possibly transmit weld gun signals from/to the weld control Welding transformers...

Product Catalog Restistance Welding | Introduction Why Welding with Medium Frequency? Resistance welding requires current strength in the Medium frequency welding combines the advantages of kiloampere range. For this purpose, a small voltage higher working frequency and direct current. A power (e.g. 9 V) with a large current is generated from the mains inverter generates a controlled square-wave voltage in the voltage (e.g. 400 V), with a welding transformer. kilohertz range from the mains voltage. This voltage is For classic AC welding with mains frequency (50 or 60 Hz), transformed down by...

Introduction | Product Catalog Resistance Welding 9 Welding Inverter Welding Transformer current current signal voltage signal Process Control The welding inverter is connected to three phases of the mains, which is always loaded symmetrically - a further advantage compared to the thyristor with AC welding. At 1000 Hz operating frequency, the process control can react to disturbances within a millisecond and adjust the current or the weld time in 1 msec steps. This is the prerequisite for the use of an adaptive process regulation (see below). Short weld times and steep current rise are possible....

10 Product Catalog Resistance Welding | Introduction The weld control PRC is a process control and at the The system configuration for two typical applications is same time a power inverter. It also controls various shown below. technological processes: from opening and closing the weld gun to the dressing of the electrode tips. PRI: Workstation with software PRI 7000 NFD: Mai ns filter for servo drives HZS: IndraDrive safety zone module HCS: IndraDrive servo module Weld interface controller bus Communication bus Measuring gun data module Welding transformer PSG 6000 Analog feedback signals:...

Introduction | Product Catalog Resistance Welding 11 The control components are installed in a compact control cabinet (“welding box”) or mounted on the weld gun. The welding transformer PSG 6000 generates the required high amperages and rectifies the welding current on the secondary side. The weld control PRC 7000 supplies the transformer with a regulated 1000-Hz AC voltage, which is fed from the 3-phase mains. The inverter controls the resulting power in the secondary circuit over the pulse width. The process control is integrated in the welding inverter. It plays a central role in the execution,...

12 Product Catalog Resistance Welding | Introduction WIC: Weld interface controller bus S20-DO: Digital output module S20-DI: Digital i nput module HIP: Hall installation plate for air and water MGDM: Measuring gun data module I(t), U(t): Analog feedback signals: current, voltage DO, DI, T: Digital control and monitoring signals AO, AI: Analog control and monitoring signals

Introduction | Product Catalog Restistance Welding 13 Fieldbus couplers Sxx-S3 and I/O modules Sxx-DI, Sxx-DO For other applications, such as: and Sxx-AIAO, expand the signal input/output field of the –– robot cell with several servo-electric weld guns, weld control by additional digital and analog inputs/ –– the robot controls the gun as “seventh axis” outputs, e.g. for the connection of operating and display –– stationary welding machines, elements as well as for enable, command and feedback the system configuration can also be optimally designed. signals. The programmable logic function of...

14 Product Catalog Resistance Welding | Introduction Which Current Source for Which Welding Task? We are offering weld controls in two power classes and for two mains voltage ranges, each with air and water cooling. The integrated process control is equipped with bus interfaces for the respective application and provides different special functions. You will find technical basic data and engineering notes on weld controls on page 15 et sqq. Welding transformers are available in nine power classes and two secondary voltage classes, in some cases for different primary voltages and with different...