Contact welding repair. Organization of maintenance of contact machines. Photo instruction on how to make a spot welding machine

The maintenance of contact welding machines includes adjustment to a given technological mode or selection of a mode for welding a batch of these parts, current adjustment in order to maintain the stability of the mode and the required quality of welded joints, and repairs - current, medium and overhaul.

At enterprises, sites or workshops that have 3-5 serial contact machines, adjustment work can be performed by an electrician and a mechanical fitter, servicing other machines; selection of the mode and adjustment of the welding process of new parts is carried out under the guidance of a technologist or master. Medium and major repairs of machines are carried out by the mechanics and power engineering services of the enterprise. However, an electrician and mechanic servicing contact machines must know the features of their design and operation.

If there are more than five contact machines in production or for servicing complex units, it is necessary to allocate a special adjuster who would be responsible for the operation of the machines. If a large number of machines, numbering in dozens, is concentrated in production, then a section or adjustment group is organized, subordinate to the head of the shop. Each adjuster of such a group is attached to a specific area; in this case, the adjuster (or a team of adjusters) reports to the head of the site or the production foreman and works according to his instructions. A repair or repair and adjustment workshop is also subordinate to the head of the section; this workshop is part of the setup section; in any case, line adjusters and repair fitters should have a single leadership.

The functions of a linear adjuster are to select a mode or adjust the machine to a given technological mode, maintain a stable mode during welding of the entire batch of parts, inspect and check machines before starting work and during work. The adjuster starts and stops the machines, monitors the operation of all components and devices, promptly informing the mechanics and power engineering department about malfunctions and malfunctions. The duties of the line adjuster also include cleaning electrodes, electrode holders, contact surfaces and contact plates, changing electrodes, current-carrying cables, welding tongs, guns, etc. If welding is performed on devices that are structurally related to the welding circuit of the machine (for example, stops, mounted in sponge electrodes of butt machines, clamps for relief welding, etc.), then the service technician must also monitor them.

In the repair shop of the section or adjustment group, all work is carried out to ensure the normal and uninterrupted operation of the contact machines under its jurisdiction. These works include:

A) preparation (check, adjustment, fine-tuning) of electrodes, electrode holders and other parts of the welding circuit of the machine;
b) restoration and repair of equipment;
c) measurement of the electrical resistance of the welding circuit, primary and secondary currents, voltage, cooling water temperature;
d) measurements of the parameters of the technological regime (performed together with the line adjuster);
e) providing line adjusters with specialized tools (special keys for changing electrodes, manual and mechanized tools for stripping electrodes, etc.);
f) planning the manufacture of tooling for contact machines produced by tool shops.

The repair shop is completed with the necessary equipment and devices; if a lot of portable contact machines (welding tongs, pistols, etc.) are installed in the workshop or on the site, then the workshop should have a control unit (stand or shield) for checking current-carrying flexible cables, tongs, pistols, etc.
The adjustment section decides which machines and in what terms should be handed over for medium or overhaul. The current minor repairs are carried out either by the repair shop, or by the mechanic and power engineering services of the shop at its request.

The line adjuster must be well aware of the features of the machines that he serves, freely navigate the operation of all mechanical and electrical components, imagine their interdependence, the possibility of adjustment, the permissible degree of wear of parts. The fitter must be able to perform welding operations on the machines he serves, for example, flash and resistance welding on butt machines, correct installation of parts in fixtures in spot welding, control of moving fixtures in seam welding, freely manipulate welding guns, etc.

To perform adjustment to the required technological mode, current adjustment and elimination of minor damage in contact machines, the adjuster must always have a serviceable universal tool: a metalwork hammer, a mallet, a chisel, flat files, screwdrivers, pliers, wire cutters, a knife, an adjustable wrench, sets of wrenches and sockets. keys.

When filling, cleaning and changing electrodes, it is advisable to use a specialized tool, which allows you to speed up the setup and significantly improve its quality. To clean the electrodes of point machines, a special cutter inserted into the holder is used. The cutter is clamped between the electrodes and rotated in one direction or the other. Mill - replaceable; this makes it possible to use the tool for stripping electrodes of different types. A greater effect when stripping is given by the use of a pneumatic tool, which is an angle wrench equipped with a one-sided cutter. In addition, for stripping the electrodes, you can use a simple device - a mandrel in which two or four files are fixed. In the first case, one electrode is cleaned, in the second, both electrodes are cleaned simultaneously.

To remove the electrodes, the adjuster must have special keys, the use of which speeds up the operation of changing the electrodes, preserves the inner conical surface of the electrode holder and facilitates the work of the adjuster.

To strip the roller electrodes of the seam machine, a carriage with freely rotating cutters should be used. The cutters, sandwiched between the rotating electrodes, remove the formed mushroom shape with their notch. The entire process of filling the rollers lasts no more than 5 minutes.
In addition to the tool, the adjuster must always have annealed steel wire with a diameter of 0.8-1.0 mm, clamps for fastening rubber and durite hoses, lead and rubber gaskets, copper foil 0.2-0.5 mm thick, low and high pressure hoses and insulating tape.

The main activity of PO SVARTEKH LLC is the production, repair, deep modernization and adjustment of spot and seam resistance welding machines, as well as welding cycle and welding current control equipment (resistance spot welding regulators, seam welding, thyristor contactors). Over the years, our company has significantly increased the supply of spare parts and components for contact welding machines. The presence of a huge base of drawings allows us to produce spare parts for machines only by the name of the brand and year of manufacture of the machine, which greatly simplifies the task of finding spare parts for the Customer. The main consumables, along with resistance welding electrodes, are electrode holders And trunk welding machine, and flexible copper bars.

Equipment for resistance spot welding of fittings and masonry mesh.

Resistance spot and butt welding of reinforcing cages is by far the most common method of welding reinforcing cages and mesh. Therefore, this type of welding is widely used in house-building enterprises for the production of reinforced concrete products and masonry mesh. Resistance welding machines have a number of advantages compared to manual arc welding: high productivity, low cost, etc. There is no need to attract highly skilled workers to work on welding machines.

Resistance welding of rebars is used to obtain a reliable cross-shaped one-piece connection by melting the rebars. To obtain such joints, if it is necessary to weld flat frames, it is possible to use stationary contact welding machines, and if it is necessary to weld volumetric frames or frames of large dimensions, it is possible to use suspended contact welding machines with various types of welding tongs.

For welding hard-to-reach places and bulky reinforcing cages, we offer welding tongs at competitive prices KTP 8-6 , KTP 8-7 , KTP8-1 to suspended resistance welding machines of the type MTP-1110, MTP-1111. These pliers can additionally be equipped with current-carrying cables.

Through the use of innovative technologies, using a modern element base of trusted suppliers and manufacturers, our company managed to minimize the cost of products, increase their quality and service life. Our design engineers are constantly working to improve and modernize the manufactured welding equipment. Thus, the experience of operating thyristor optocouplers TO-125 installed in the control boards of thyristor contactors KT-07M and KT-11M showed the unreliability of their operation and frequent failure. It was decided to replace the TO-125 with a pulse transformer, the reliability of which is not in doubt. Constant monitoring and analysis of the causes of breakdowns in welding equipment enables our company to produce equipment with a very low percentage of failures.

We guarantee: high-quality assembly, timely delivery, full technical support during commissioning and operation, warranty and post-warranty service.

In Russia and neighboring countries, there are a huge number of spot welding machines with obsolete electrical (welding cycle controllers, thyristor contactors) and pneumatic parts (pneumatic actuator, pneumatic valve, air preparation units) in need of repair or modernization. Our specialists have many years of experience in the modernization and repair of machines of this class.

Repair

Modern industry actively uses various types of welding equipment in its production, from simple foot-operated machines to robotic welding complexes. Different welding principles (alternating current, rectified current, low frequency current), different dimensions (from small machines to huge automatic lines for welding reinforcing meshes), different welding methods are not able to ensure the operation of equipment without maintenance and repair.

Welding equipment belongs to the category of a high degree of wear of the constituent parts of the machine. Exposure to high temperatures in the welding zone, electromagnetic fields, temperature fluctuations during operation, instability of the supply voltage, poor air quality of the pneumatic system and many other factors lead to the fact that even durable and reliable components and materials may become unsuitable for further operation of the machine. To eliminate the possible consequences of a negative impact on the equipment, it is necessary to carry out scheduled maintenance and, if necessary, repair of resistance welding machines.

Over time, under the influence of high currents and temperatures, the current-carrying parts are burned, and the current-carrying parts of the machine can also be oxidized, which leads to a decrease in the welding current in the parts and an unnecessary load on the transformer and the supply network. Further operation of the machine can lead to the combustion of the welding transformer and, accordingly, to subsequent costly repairs.

The service center of PO SVARTEKH LLC repairs welding equipment, spot and seam resistance welding machines, control equipment for resistance spot welding machines (resistance welding controllers, thyristor contactors), inverter welding machines, semi-automatic welding machines, etc. Our company has excellent repair equipment and highly qualified performers, which allows us to repair welding equipment in the shortest possible time with any complexity of breakdown. The presence of a mobile team of adjusters makes it possible to carry out repairs outside of St. Petersburg.

Service

Maintenance of contact welding machines is carried out in order to maintain the working condition of welding equipment and additional equipment during operation through periodic technical inspection and additional work. The purpose of maintenance is to prevent possible damage to the equipment. It is clear that it is much more economically profitable to avoid a possible failure of the equipment than its further repair. The failure of welding equipment can stop the further process of assembling products, and the cost of equipment downtime can be ten times higher than the cost of timely maintenance of welding equipment.

Maintenance includes the performance of work on external inspection and performance testing of all units of spot welding machines and welding machines, preventive maintenance (replacement of consumables), identification of worn parts and parts that need to be replaced soon.

The work carried out during the maintenance of welding equipment is aimed at timely prevention of possible breakdown, and, consequently, the loss of welding equipment from the production process. As a rule, many malfunctions can be diagnosed at an early stage of their occurrence, which significantly saves the cost of repairing welding equipment.

When servicing spot welding machines, the operability of the contact welding controller, thyristor contactor and pneumatic equipment is checked. The machine is checked for tightness of the pneumatic system and cooling system. If necessary, the necessary repairs are made, recommendations are given for the further operation of contact welding.

Modernization

Over the years, our specialists have accumulated a wealth of experience in the modernization of old spot welding machines. After modernization, the customer receives a machine equipped with modern pneumatic drive and welding cycle control equipment.

During the modernization of spot welding machines, as a rule, the resistance welding controller, thyristor contactor are replaced and the pneumatic actuator is upgraded (replacement of pneumatic valves, compressed air preparation unit, pneumatic tubes, fittings, etc.).
When modernizing a spot welding machine, an analysis of the technical condition of the machine is carried out, based on the results of which a modernization project is drawn up that takes into account the real tasks of the welding machine and the wishes of the customer.

As a result, the upgraded machine will have a set of functionality in strict accordance with the wishes and tasks of the customer.

Our company has been engaged in the repair of welding equipment in Moscow and the region for 10 years. Quality, service, responsibility is our mission. We repair welding equipment of all manufacturers quickly and inexpensively.

Our specialists work with all types of welding equipment, we repair welding inverters, semi-automatic devices, transformers, rectifiers, starting-charging devices, power tools.

Our specialists have been trained by leading manufacturers and have certificates. Spare parts and a full package of documentation are in stock.

If you have a need to repair the equipment, call us. We will get your equipment back in service.

Repair shop contacts

Our service center provides repair of welding equipment and power tools of the following brands:

	DUGA series rectifiers		Welding equipment BARS		Welding equipment FIMER
	Welding equipment NEON		Welding semiautomatic devices and transformers PLASMA		Welding equipment SVAROG
	GYSMI Welding Equipment		Welding semiautomatic devices RIKON		Welding equipment LINKOR SEMALI
	Welding equipment CORUND		TELWIN Welding Equipment		FUBAG welding equipment
	Welding equipment POWER MAN		Contact welding pliers ADAM		FEB welding equipment
	Foxweld Welding Equipment		Welding equipment ETA		Aurora Welding Equipment
	Welding equipment SELMA		Merkle welding equipment		Kuhtreiber Welding Equipment
	Welding equipment CONTACT		Welding equipment RusElCom		Migatronic welding equipment
	Welding equipment Thermite

Price-list
for repair work for semiautomatic devices, inverters and
power tools
(imported and domestic equipment)

Diagnostics
power tools
semi-automatic
inverters
MERKLE(pro)
Replacement of components
Our customer service round the clock accepts orders for the repair of failed spot welding machines in Moscow and the Moscow region. An application can be made on the website or by calling the hotline to our dispatch service. We can send you a specialist for on-site repair or you can bring your equipment to one of our service centers yourself. You can also take advantage of the free transportation of equipment to the service and back. Free diagnostics, high-quality repair of spotters and a company warranty provided for all work and installed spare parts will be the key to the smooth operation of the equipment in the future. We offer professional spotter repairs with a lifetime warranty on all work. We are the largest service company in the Moscow region. Only we have a large warehouse of spare parts, modern equipment, a network of service centers located in every district of Moscow. Separately, I would like to mention our team of specialists. A complex system of selection and training of service engineers allows us to guarantee our customers the impeccable quality of the work performed and the long-term uninterrupted operation of the equipment in the future. Nevertheless, we try to keep our prices slightly lower than those of competitors, which, together with high quality, gives the most favorable repair conditions in Moscow. Repair room of the service department Service department Spare parts for machine tools Diagnostics and repair of machine electronics MOSSKlad ​​offers a wide range of spare parts for equipment from RAS, PRINZING, SENTE MAKINA, BENDMAK, ALZMETALL, SCHECHTL, SAHINLER, RECORD POWER and many others. We carry out prompt delivery and replacement of worn parts, spare parts, consumables, gears, brackets, electrical panel containers and other parts for machine tools. All spare parts are supplied directly from our manufacturing partners, so we guarantee you the quality of the offered spare parts. We have the most popular spare parts for popular machines in stock, so we are ready to provide you with a hot replacement for a failed unit or unit. If any parts are not in stock, we will order them for you as soon as possible. Urgent order of spare parts Make an urgent order of spare parts by e-mail or by calling the service department: +7 495 739 51 01 Service maintenance Any complex equipment requires preventive maintenance, repair and scheduled replacement of parts of the mechanism. MOSSklad offers after-sales service for your machine park. When you sign up for service, you get: Inspection and detailed diagnostics of your equipment; Identification of components and parts requiring replacement; Scheduled/unscheduled replacement of consumables; Checking the performance of the equipment in accordance with the recommendations of the manufacturer; Conclusion on the current state of the equipment; Instructing personnel on the rules of maintenance and operation of equipment. Installation supervision and commissioning This is one of the most important works when starting production of any complexity and scale. Properly carried out installation and commissioning work will allow the equipment to be put into operation as quickly and without errors as possible, and will also make it possible to carry out continuous and trouble-free operation with the required performance. This will eliminate failures and defects, both at the beginning of work and in further operation, and will reduce financial and material and technical costs, reducing the payback period of the equipment. Any machine needs initial adjustment and adjustment, and only trained specialists know exactly how to provide it. Our engineers have been trained in service centers at the factories of suppliers for the repair and maintenance of machine tools, and are ready to perform high-quality warranty and post-warranty repairs of machines, equipment and tools from the following manufacturers: TRUMPF power tools, HYPERTHERM, CEBORA, TECNA, SPIRO, JOUANEL, STALEX, RAS, TAPCO, PRINZING, HORNUNG, TECHNOMARK, ACL, DURMA, SAHINLER, ISITAN, SCHECHTL, SCHLEBACH, STD, SENTE MAKINA, SCHNELLDORFER and others. During commissioning, the following set of works will be performed: Inspection and assessment of the suitability of the installation site; Installation and assembly of dismantled units at the production site; Health check; Adjustment of technological accuracy in accordance with the tasks of production; Instruction and training of the operating personnel responsible for the operation of the equipment; Transfer of equipment to the customer. Diagnostics and repair Correction of malfunctions in the operation of equipment is achieved through timely diagnosis and subsequent repair. Trained personnel are able to carry out an initial diagnosis of a malfunction before it becomes critical and call the appropriate specialist. The stages of equipment diagnostics include: Primary certification; Assessment of the technical condition (satisfactory / minor defects / unsatisfactory); Elimination of defects during testing; In case of serious breakdowns, repair and restoration work; Checking the performance after repair work; Conclusion for admission to operation. Timely diagnostics and preventive maintenance of equipment allows you to avoid serious breakdowns and expenses for repair and subsequent commissioning of failed equipment, often at a cost comparable to buying a new machine. MOSSklad carries out repairs of equipment purchased from our company, and in the event of a breakdown, supplies all the necessary spare parts directly from manufacturing plants, bypassing resellers. Our prices for original spare parts from machine tool manufacturers are among the lowest on the market. Application forms for repairs Departure to the object on average 2 working days after receipt of the application. Application form for repair of Technomark markers in MS Word format: Download Application form for the repair of all machines in MS Word format: Download Something interested? Send us an inquiry We will process your request and send you a response. Did not find an answer to your question? Look at here What sound-absorbing and sound-proofing materials to choose Voltage indicators Electric circuit of the voltage indicator Ivan Organization of maintenance of contact machines