Ends in bad weld ????

[W.olly]

We ahe this auto welder/positioner. It's use a lot. Recently the welds have gone bad.

From this

To this at the last part of the run.

All i can think is it's the welder itself ???
The Volts stay stable. Vary between 23.2 and 23.7. Set at 23.5. Amps are 263 vary 4 up an down.

Any ideas please folks.

 

[Robotstar5]

Is it the start/finish point?

 

[knighty]

try welding bit by hand with the same welder and see how it goes?


how does the earth connection work? I'd look at that, some sort of slip ring I'd guess?

you could clamp an earth onto the work piece and let it twist the cable a bit to test?

 

[barracuda816]

I agree with the slip ring being worth a check as it looks like the failure is in the same spot for both.

 

[W.olly]

Is it the start/finish point?

Its at the end now, as in the pics, before this though it has been intermitent all around. not as bad as in the pics though. more the weld moved up and down from base to leg.

try welding bit by hand with the same welder and see how it goes?


how does the earth connection work? I'd look at that, some sort of slip ring I'd guess?

you could clamp an earth onto the work piece and let it twist the cable a bit to test?

its was tried by hand and still not as good as it should, but better than in these pics. Its very intermotent when it does ity. can do 6 or 12 welds good then this. The earth is a ring termional bolted to the earth fitting on the positioner.

When i ran the set up i was doing around 25000 legs a year and was fine, yes a few alterations in amps/V etc and torch adjustment but never as bad as this. I built this housing and still good for last 6 months, last few months though its been getting worse. Now very intermitent.

 

[hotponyshoes]

Is that the normal position for the welder?
Looks like the kink in the torch is a bit sharp if it is..
I'd check feed first, lift the roller up and try pulling wire from the tip end by hand and see if everything is feeding smoothly?

 

[W.olly]

Is that the normal position for the welder?
Looks like the kink in the torch is a bit sharp if it is..
I'd check feed first, lift the roller up and try pulling wire from the tip end by hand and see if everything is feeding smoothly?

Yes that has been the same troch position for last 5 years. Wire feed has been set aswell. Wire feeds prefic.

 

[addjunkie]

Yes that has been the same troch position for last 5 years. Wire feed has been set aswell. Wire feeds prefic.

5 years….worn liner right through? Roller worn? Simple first…

 

[W.olly]

5 years….worn liner right through? Roller worn? Simple first…

Its had new torch recently and, rollers checked a while ago. New feed/giuide tube.
This is what has puzzled me and a few others.

Its had done, new or replaced in last few weeks

tip everyday
shroud when needed
new torch
roller adjusted ( checked)
Volts / speed adjusted to see if that helped ( nothing much changed )
earth checked not loose and good contact, many times
serviced the rig and poisitioner ( i still think its to do with that though myseff for some reason )
torch does move move in the holder
positioner is free from any movement. ( last year the bearing had failed so i serviced it and all good then )

 

[tom2207]

do a factory reset on the welder , and try a fresh regulator ,,, interesting its in the same place every time ,

 

[Hood]

As a test can you programme/set to go past the end point? If you can and say go another 90 degrees does the issue now appear at the new end point or does it appear at the current location?
If the former then it would suggest something on the welder side of things, if the latter then it would suggest it is positioner side of things.

 

[8ob]

Bad earth contact in that position on the rotator ?

Bob

 

[Erie Fred]

The earth is a ring termional bolted to the earth fitting on the positioner.

It has to more than just that.
Internal to the positioner should be a brush set-up.

It needs removed, opened up and looked at.

Try rotating with just an Ohm meter attached.

 

[8ob]

It has to more than just that.
Internal to the positioner should be a brush set-up.

It needs removed, opened up and looked at.

Try rotating with just an Ohm meter attached.

I have a Mickey Mouse rotator, all that has is a carbon brush on a spring rubbing on the back of the chuck.

Bob

 

[Blobber]

Try rotating with just an Ohm meter attached.

That would be a really good idea, certainly rule out one cause

 

[Erie Fred]

I have a Mickey Mouse rotator, all that has is a carbon brush on a spring rubbing on the back of the chuck.

Bob

Yes, but when it fails ?
can you simply look at it and determine if it's o.k. ?

 

[W.olly]

well the supplier was called out, glad as it makes my life easier. I found that the complete set up has not been calibrated in over 6 years. Serviced yes. christ i can do that. Its about £50 for a calibration, i have been asking for it to be done time after time. I was told it was done 6 month ago, that was a bloody service. not a calibration.. whast thsio space and ill bget abck to you

thanks all for the advice. but working with pigeons you will never be an eagle i guess.

 

[colnerov]

well the supplier was called out, glad as it makes my life easier. I found that the complete set up has not been calibrated in over 6 years. Serviced yes. christ i can do that. Its about £50 for a calibration, i have been asking for it to be done time after time. I was told it was done 6 month ago, that was a bloody service. not a calibration.. whast thsio space and ill bget abck to you

thanks all for the advice. but working with pigeons you will never be an eagle i guess.

It looks like your keyboard may have a similar problem.