GM Confidential

General Motors International Operations

GMIO ME BODY (TCI)

Training :Weld parameter Basics / checking Gauges / pendants(Day 1)

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Karthikeyan D / Welding Engineer

Date:- 11th – August 2015

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CONTENTS

1. Weld parameters basics .

2. Force Gauge Analog Checker

3. Current Gauge Checker

4. Weld Display pendant

5. Teaching Display pendant

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1.GWS 1 A – Global Weld Standards Observation Points :

1. Weld Parameter selection is based on four important values.

• FSC ( Faying Surface Condition ) Example : BB,BG,GG { B:Bare (Non coated) ,G – Galvanized }

• DT ( Determining Thickness ) Example : 0.8 , 1.2 – 0.8 mm & 0.8 , 1.2 , 1.0 – 1.0 mm

• Weld controller Spec . Example : HFDC , AC 60 HZ , AC 50 HZ {High Freq Direct Current}

• Panel sheet type . Example : Conventional Steels / AHSS {Advance High Strength Steel} .

2. Based on Schedule Tables from GWS 1A : 2-1 to 2-18 , Weld Parameters are entered in WCS .

3.Welding Performed in Real condition , based on the Quality of Weld and Spatter condition -

Weld parameters are changed / Updated in WCS to achieve Weld Quality .

Examples : Current , Weld time values change for Spatter , Cold Weld , Spot Indentation .

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1.GWS 1 A – Global Weld Standards – Snap shot : 4

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51.GWS 1 A – Global Weld Standards – DT

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1.GWS 1 A – Global Weld Standards – Tables selection method

Second thin

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1.GWS 1 A – Global Weld Standards – List of tables

panel type FSC ( Bare / Coating ) Weld Controller Spec

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2.Force Calibration Methods – ANALOG FORCE GAUGE CHECKER

Air Regulator should be adjusted Until standardpressure display in Force Gauge checker

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Current Gauge Tool Current Calibration

• Initial Transformer Ratio set up 17 (Example Value) in Pendant to TC .

• Current Gauge cable is placed in the area between Weld Electrodes

• Weld operation is performed by Electrodes.

• Weld Current Value displayed in visible screen like 10,410 A( Example)

• TR change to 19 , Current gauge Reading 10,012 A which is spec Value .[Trans Ratio is changed in pendant ( TR increase , Current Decrease)]

• Repeat Checking process and to check for 10,000 A reading in Gauge

• Proceed for Next Gun to calibrate Weld Current .

Weld Electrode – Current calibration done to Weld Elec Specification Current of 10 KA (10000 A)

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93.Current Calibration Methods – CURRENT GAUGE CHECKER

Note : Authorized person to be trained for changing TR values .

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104.Weld Display pendantWeld display pendant is used as a handy device in which therunning parameters can be displayed

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5.Weld Teaching pendant 11

Weld teaching pendant is used as a handy device in which theWeld parameters can be checked and also teach to timer .

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Thank you

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