is called a used when theree 3c is can only be placed on one Electrodes formation. the high- the melting process. When fused, the Weld Pressure

Transcription

1 Cap pacitivv Disschargg, Fin n Sp t Rssistancc W lr E N G I N E E R I N G Insttructi n Pam mphlt CD150DP / CD300D C DP / CD4 450DP / CD750D C DP Funamntals f Cap pacitiv charg R sistanc Wling g Disc Capa acitiv isccharg rsistanc w ling usss capa acitrs t st r nrgy fr quick rl as. Figur 1 shws a typica al capacitr ischarg cu urv. acitiv rssistanc wlrs, w a als call Capa capa acitiv isch harg r CD D wlrs, hav manyy ava antags vr thr wlr typs: Quick nrgy rla as fr wling highlyy uch as cpp r cnuctivv mtals su Small h at ffct wl w zns Rpatab bl nrgy rlas in pnnt ff lin vlta ag fluctuati ns Capabl f xtrrmly fin n nrgyy nt. ajustm W l nuggt f rmatin tak ks plac uring th firstt fw milli-scn s f th w ling prc ss. A CD D wl r allws xtrmly fa ast nrgy rlas with h larg pak curr nts. Mr f th nrrgy gs int wl frmatin an lss in nt hating surruning g mat rial. Th hat aff ct zn, whr th prp prtis f th mtal hav bn chang by rapi hatting an c ling, is lccaliz t a small ara a aru un th wl spt. Th quick isch harg rat f CD wlrs alss allws lctrically an n thrmallyy uctiv mat rials, such as cppr r aluminum m, cn t b wl. Capacitiv C w lrs liv r rpatabl wl s vn uring lin vlta ag fluctuati ns bcaus wl nrgy is str s bfr us. Wl Frmatin Sp t wling r lis n mta al rsistivity (rsistanc ) t hat an fus mtal. A larg currnt is pass thrugh th wrrk pic mttal. Enrgy is issipat sistanc in th frm ff hat which h u t mtal r m Th hr ar tw mltts an fusss th wl matrials. Cpyright 2007 Sunstn Enginring 1

2 phass t th mlting prcss. Th wlr must vrcm bth th matrial cntact rsistanc an Surfac 1 Cntactt pint Surfac 2 Figur 2: On th micr scal, surfac rughnss limits surfaclwr t surfac cntact. Mr cntact pints rsult in a cntact rsistanc. Elctr Cnfiguratins Figur 1: Sampl capacitr ischarg curv. th bulk rsistanc f th matrial. Figur 2 shwss an xampl f a micr-scal surfac prfil. On th micr-scal, matrial surfacs ar rugh an nly cntact in a limit numbr f lcatins. In th first fw milli-scns f wl frmatin th high- rsistanc mtal brigs mlt allwing thr brigs t cm int cntactt t cntinu th mlting prcss. Whn all f th brigs hav fus, th cntact rsistanc is zr. Th bulk rsistanc f th mtal thn plays th final rl in th wl frmatin. Figur 3 shws svral lctr cnfiguratins us in rsistanc wling. Figur 3a is call a irct wl. Currnt is pass frm n lctr thrugh bth wrk pics an ut an ppsing lctr. Figur 3b shws a stp lctr cnfiguratin. This cnfiguratin is us whn thr is accss t nly n si f th wrk pic an an lctr can b plac n bth matrials. Figur 3c is a sris cnfiguratin. Elctrs can nly b plac n n mtal surfac frm n si. Currnt is ivi btwn th tw parts. This wl cnfiguratin rquirs mr wl nrgy. Wl Prssur Svral thr factrs play a part in th cntactt rsistanc. Th largr th cntact rsistanc th httr th rsultant wl. On th micr-scal, cntact rsistanc is ruc whn mr mtal brigs r cntact pints ar frm (s Figur 2). Using mr lctr prssur crats mr mtal brigs. This rsults in a lwr cntact rsistanc an a clr wl. Cnvrsly, light lctr prssur rsults in lss mtal cntact, highr rsistanc, an a httr wl. An apprpriat amunt f prssur shul b us t insur g wl strngth. a. b. c. Figur 3: Exampls f rsistanc wling lctr cnfiguratins: a. irct, b. stp, c. sris. Dtrmining Wl Enrgy A capacitiv ischarg wlr cntrls th vltag f th wling capacitrs. Hwvr, th nrgy str in th capacitr is a functin f th vltag squar (E = ½*C*V 2 ). This rlatin stats that a small iffrnc in vltag maks a larg iffrnc in wl nrgy. Sunstn CD150DP CD750DP Cpyright 2007 Sunstn Enginring 2

3 wl rs hav a vltag v aju ustmnt ial. Th pwrr str in th wlr can b fun f by rffrring t th qua atin abv r by visiting g Tabl 1. Using Sunsttn Dua al Puls Wlrs W Wl Enrgy In nicatin Figur 4 shwss th Sunstn Engin ring Dual Puls CD wlr frnt panl. Wl vltag iss iniccat with a blu bac cklit LCD isplay. T cnvvrt this valu t watts s*scns (juls) ( us Eqn.. 1 r s Ta abl 1 fr a simplifi s list. Puls s Cntrl Sunstn Dual Puls wl rs hav tw puls with h p can b ajust nrrgy cntrlss. Each puls spa aratly r tu urn ff if sir. Bth h pulss can n b turn ff withut ajusting puls valus t ha lctr facilitat wl stup r ntnanc. Puls 1 is ajustabl btwn b 1% % main an apprximattly 50% f th ttal st r nrgyy. Pulss 2 is ajusstabl btw n 1% an 100% f th str nrgy (s Tabl 2). Plass nt tha at wh n us in ual puls m m th Puls 2 nrgyy lv l rprsntss th prc nt f rmaining pwrr. Fr xampl if Puls P 1 wass st t 25% % th Puls 2 sttiing wul acctually b ta akn frm th h rmaining g 75% % f th st-p pint nrgyy. Eqn. 1. Figur 5: Wlr bacck panl: Extrnaal triggr prt, 6A 6 fus, 110VAC C vltagg input. En rgy Ajustm mnt Figur 4: Wlr fr nt panl faturs: Blu LCD v ltag inicatin n isplaay, asy t us puls p with an vltag cntrll intrfac, ach h puls can b turn ff iniviually an bth can b b turn ff att th saam tim fr wl ha stup, larg wl ha hk up p cablss fr 1/4 an 5//16 stus, r backlit n/ff sw witch. Each Sunstn wlr is infinitlyy ajustabl wn its min nimum an maximum nrgy. Th btw CD1 150DP - CD7 750DP wl rs hav w l rptitin n rats f up t wls/min (th harw war fin limitt). S Tabl 5 fr aitinal ta ails n wl rp titin rats.. Th wl vltag v knb is us t st th ttal w lr nrgyy strag (ss Tabl 1 an Eqn. 1) an is als us t st th pak wl abl 2). Th puls wi ths ar thn n currrnt (s Ta aju ust t pr vi th apprpriat wl w nrgyy rla as uring ach wl. Cpyright 2007 Sunstn Enginring 3

4 fus. A 750W wall circuit shul b us t run th wlr. Wl Actuatin Th wlrs ar actuat by mans f an xtrnal triggr prt lcat n th back f th wlr (s Figur 5). Th triggr uss a DIN 3 cnnctr an rquirs shil wir. Figur 6 shwss th prprr pin placmnt fr custm xtrnal triggr cabls (shwn fr wlr back panl cnnctr). Th stanar xtrnal triggr cabl cnnctr is an SD- 30LP ma by CUI Inc. Figur 6: Extrnal triggr wiring iagram fr th wlr back panl cnnctr. N.O. stans fr Nrmally Opn. Figur 7: Capacitr ischarg using th ual puls stting. Wl Attachmnts Sunstn Enginring prucs a varity f wling han pics an wl has t accmmat a ivrs rang f wling applicatins. Han pic wling attachmnts allw as f us an vrsatility, whil fix wl has prvi cntrl an prcisin. Cabling btwn wlr an wl ha is imprtant in trmining pak wl currnt an ajusting wl puls timing. Tabl 2 inicats th Puls 1 an 2 sttings t b us with iffrnt cabling. Tabl 3 inicats pak currnts that can b xpct with 3 t 4 ft sctins f ths cabls. Typically, han pics will us 4 r 8 AWG gaug wir whil wl has will b hk up with 0 r 4 AWG gaug wir. Vltag an Pwr Rquirmnts Th CD150DP CD750DP wlrs us 110VAC wall pwr. If using th wlr in a cuntry whr 220VAC tc. wall pwr is us, a vltag transfrmr can b purchas frm Sunstn Enginring. Th wlr uss a 6mm x 30mm 6A Using th Dual Puls Wl Functin Using multipl currnt pulss incrass wl quality. In ual puls m Sunstn wlrs will fir twic frm a singl actuatin. Th first puls is us t rmv surfac incnsistncis an cntaminants. This initial burst f nrgy isplacss ils an braks thrugh xi layrs. Th puls als sats th wling lctrs. Th scn puls is n at a much highr nrgy lvl (watt*scns) an prfrms th actual wl. Figur 7 shwss what th wlr ischarg curv wul lk lik using th ual puls stting as utlin abv. Stting Puls 1 an 2 Th Puls 1 nrgy stting shul b chsn such that th parts ahr wakly. T trmin Puls 1, turn ff Puls 2 an a sris f tst wls starting at a lw puls nrgy stting. Incras th puls nrgy 3-5% vry tst until th parts just stick tgthr. Puls 1 nrgy shul thn b cras by 3-5%. Puls 2 shul thn b st at a lvl 4 5 tims that f Puls 1. A tst wl shul b prfrm an pull apart t trmin Cpyright 2007 Sunstn Enginring 4

5 wl strngth. A nickl strip t nickl plat stl wl, typically sn in battry pack manufacturing, shul pull apart laving hls in th thin nickl mtal an laving th wl nuggts n th battry trminal. Thickr matrials shul b pull with a spcific pull frc rquirmnt in min. Tabls Quick-rfrnc Tabls 1 7 prvi usful infrmatinn fr using Sunstn Dual Puls wlrs. SAFETY Plas fllw ths pints t hlp cmfrt an safty. insur yur 1. Always war safty glasss whn wrking with spt wlrs an wl has. 2. Rmv han jwlry bfr wling. 3. Avi tuching wl spts immiatly aftr th wl has bn prfrm as thy will b ht. 4. B carful nt t pinch fingrs in mving wl ha parts r btwn wling lctrs. 5. All wls ar prfrm at lw vltag fr incras safty f pratin. Aitinal Infrmatin Fr aitinal infrmatin an instructinal vis plas visit ur wb pags. cm Cpyright 2007 Sunstn Enginring 5

6 Tabl 1: Enrgy strag with wl vltag. Ml CD150DP 14 CD300DP 27 CD450DP 41 CD750DP 43 Vltag (Vlts) N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A Tabl 2: Enrgy rlas by hk up cabl gaug numbr (AWG) an Puls ial stting. Fur an ight AWG cabling is typically sn whn using han hl attachmnts. Dial Markr 1 2 Puls 1 0 gaug 4 gaug 8 gaug 2% 1% 0% 6% 5% 1% Puls 2 0 gaug 4 gaug 8 gaug 7% 5% 1% 25% 20% 4% 3 14% 10% 2% 4 19% 15% 3% 5 46% 37% 9% 6 66% 55% 15% 7 67% 57% 15% 52% 42% 10% 69% 58% 16% 91% 83% 30% 100% 99% 63% 100% 100% 70% Tabl 3: Pak wl currnt shwn by ml numbr an xtrnal cabling gaug numbr (AWG). Fur an ight AWG cabling is typically sn whn using han hl attachmnts. Ml 0 AWG 4 AWG 8 AWG Cpyright 2007 Sunstn Enginring 6

7 Tabl 4: Sunstn Dual Puls gnral tchnical spcificatins. Fatur Dual Puls Puls 1 Enrgy Ajustmnt (% f st-pint nrgy) Puls 2 Enrgy Ajustmnt (% f st-pint nrgy) Pak Currnt CD150DP / CD300DP / CD450DP / CD750DP Ys 1% - 50% 1%-100% Amps Tabl 5: Wl sp in wls pr minut by Dual Puls ml numbr at maximum nrgy st pint. Puls with (max nrgy stpint) Rp Rat CD150DP wls/min (puls nrgy) Rp Rat CD300DP wls/min (puls nrgy) Rp Rat CD450DP wls/ /min (puls nrgy) Rp Rat CD750DP wls/min (puls nrgy) 5% 166 (7.5ws) 166 (15ws) 1666 (23ws) 166 (38ws) 25% 166 (38ws) 166 (75ws) 1666 (113ws) 166 (188ws) 50% 166 (75ws) 166 (150ws) 150 (225ws) 120 (375ws) 100% 166 (150ws) 89 (300ws) 59 (450ws) 36 (750ws) Tabl 6: Wl puls charactristics. Ml Min an Max Output Capacitr Bank Puls With Ris Tim (t max vltag) Min Puls Hight CD150DP 0.2 ws ws 800,000 μf Min 0.1 ms Max 10 ms CD300DP 0.4 ws ws 1,600,000 μf Min 0.1 ms Max 20 ms CD450DP 0.6 ws ws 2,400,000 μf Min 0.1 ms Max 30 ms CD750DP 0.6 ws ws 2,400,000 μf Min 0.1 ms 0.6 ms Max 30 ms 0.6 ms Cpyright 2007 Sunstn Enginring 7

8 Tabl 7: Sunstn Dual Puls wlr physical charactristics. CD150DP CD300DP CD450DP CD750DP Inchs cm Inchs cm Inchs cm Inchs cm Hight With Dpth Wight 35 lbs (16 kg) 38 lbs (17 kg) 40 lbs (18 kg) 45 lbs (21 kg) Sunstn Enginring Rsarch an Dvlpmnt Crpratin Cpyright Canyn Cv Dr. Paysn, Ut Phn: Fax: Cpyright 2007 Sunstn Enginring 8