Adjustment of Electrode Pressure in Mid-Frequency Spot Welding Machine

When operating a mid-frequency spot welding machine, adjusting the electrode pressure is one of the crucial parameters for spot welding. It’s essential to adjust the parameters and pressure according to the nature of the workpiece. Both excessive and insufficient electrode pressure can lead to reduced load-bearing capacity and increased dispersion of the weld, especially affecting its resistance to tensile loads.

Insufficient electrode pressure results in increased contact resistance, excessive current density, and rapid heating, leading to splashing. On the other hand, excessive electrode pressure increases the contact area in the welding zone, reducing contact resistance. However, this reduces resistance heating, leading to defects such as lack of fusion and detachment. Appropriate pressure during solidification of the weld nugget prevents defects such as shrinkage holes and cracks. Therefore, dynamic monitoring of electrode pressure is essential for ensuring spot welding quality.

Increasing electrode pressure while appropriately adjusting welding current or welding time helps maintain consistent heating in the welding zone. Additionally, increased pressure eliminates adverse effects on weld strength caused by pressure fluctuations due to factors such as assembly clearances and uneven rigidity of workpieces. This not only maintains weld strength but also significantly improves stability.

The force applied by the electrode on the workpiece can be divided into two parts: one overcomes the elastic deformation of the parts to ensure contact, while the other part is used to press the contact surfaces of the welded parts together. The force to overcome workpiece deformation and the pressure applied by the electrode to the workpiece are related to the thickness of the workpiece. As the thickness of the workpiece increases, so does the pressure.

If other parameters remain unchanged, increasing electrode pressure gradually decreases weld strength. This is because increased electrode pressure reduces current density while increasing heat loss, making heating of the welding zone more difficult, inevitably reducing weld nugget size and decreasing welding quality.

By increasing electrode pressure while simultaneously increasing welding current or appropriately extending welding time to maintain consistent weld strength, weld strength becomes more stable with increasing electrode pressure.

Suzhou Agera Automation Equipment Co., Ltd. specializes in the development of automated assembly, welding, testing equipment, and production lines, primarily serving industries such as household appliances, automotive manufacturing, sheet metal, and 3C electronics. We offer customized welding machines, automated welding equipment, and assembly welding production lines according to customer needs, providing suitable overall automation solutions to assist companies in quickly transitioning from traditional production methods to high-end production methods. If you are interested in our automation equipment and production lines, please contact us: leo@agerawelder.com