RESISTANCE SPOT WELDING - LASKA Technika · PDF file 1 As one of the leading suppliers of copper components for resistance spot welding, our product range includes such items as: –

RESISTANCE SPOT WELDING

VEHICLE ASSEMBLY

DOMESTIC APPLIANCES

CONSTRUCTION

MACHINE-BUILDING

POWER INDUSTRY

Contents

The company 1

Copper alloys for resistance welding 4

Electrodes 7

Male tips 7

Welding caps 8

Special welding electrodes 10

Self-adjusting electrodes 12

Standard electrode holders 13

Welding gun arms 14

Angled electrode holders 15

Nut welding 16

Locating pins 17

Nut projection welding 18

Screw projection welding 21

Production tooling 22

Weld cap dressing systems 27

Tip dress quality-checking 33

Ceramic face automotive sensors 34

Welding cables 35

Shunts 35

Low-reactance cable, bipolar 36

Jumper cables 37

Unipolar cables 38

MIG/MAG consumables 41

Insulation and protection 42

Insulating bandages & covers for electrical cables Pyro-Jacket® 42

Welding gun splash-protection covers 43

TIGON Balancers 44

1www.laska.com.pl

As one of the leading suppliers of copper components

for resistance spot welding, our product range includes

such items as:

Copper alloys, –

Welding caps, –

Special welding tips, –

Welding gun arms, electrode holders (shanks), –

Welding tooling – holders , clamping systems, –

Special tooling made of copper alloys, –

Ceramic and steel pins, –

Kickless cables, jumper cables, shunts (water and –

air cooled),Tip dressers – for manual and automatic weld –

guns,Anti-spark covers for welding gun bodies, –

Balancers. –

This is what has fired our company from the very first!

Our staff are our greatest asset. These qualities are

what drives them in their day-to-day business. This

combination enables them to develop innovative solu-

tions and products with conviction, and leads to their

long-term loyalty.

We entered the Polish market in 1992. Our headquar-

ters is in Tychy, Upper Silesia, the hub of Polish vehicle

manufacture - which is why we focused our attention

on the automotive sector right from the start. We col-

laborate closely with automotive companies’ design

and manufacturing departments. We have taken the

lead in introducing new technology into the manufac-

turing process.

Creativity! Enthusiasm! Professionalism!

We have transferred our experience from the automo-

tive sector directly to other industrial sectors where we

have customers, such as machine-building and the

power industry.

Laska Technika is one of the leading suppliers of cop-

per consumable parts to meet most production, main-

tenance and servicing needs. Our innovative problem-

solving, professionalism and the engagement of our

team are what has established us in a strong market

position.

Our main advantages

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Our main advantages

Design and Technology

The experience of our Design and Technology Depart-

ment is at your disposal. Our design solutions for new

and refurbished systems have received strong com-

mendation. The design process uses the 3D CAD sys-

tem, which makes the whole process much faster and

guarantees that the technical documentation will be on

time.

The Design and Technology Department is the link be-

tween you, the customer, and our production process.

We are able to undertake the whole project, starting

from the design phase, through the technology docu-

mentation and manufacturing, right up to the final prod-

uct. This enables us to make modifications at each step

of the process and reduce the lead time.

We take an active part in the integration and launch

phases of our products. If our equipment is part of

a complete production line, we are able to optimize the

robot’s path and establish process parameters.

Production

Our modern toolshop and optimal manufacturing tech-

nology, combined with our experience, professionalism

and people-involvement, guarantee the completion of

your order on time.

Experience

During our years of existence, we have, in conjunction

with our customers and partners, solved a broad range

of problems. We use all of our combined know-how to

achieve completion of your projects in such a way as to

guarantee you a service with high manufacturing stan-

dards and a short lead time.

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Quality

Quality is our top priority. The basis of this is high qual-

ity copper alloys from our partner, Le Bronze Industriel.

Laska Technika’s quality assurance procedures enable

us to fulfil the high quality requirements of our automo-

tive customers.

Warehousing

We keep a minimum stock level of the most popular

copper alloys in the full range of profiles, and sufficient

welding cap reserves to cover our customers’ immedi-

ate needs.

Our main advantages

As standard, we provide measurement protocols and

materials certificates for each production batch at

the customer’s request. Our measurement room is

equipped with the most up-to-date specialist measur-

ing instruments. We are able to provide 100% product-

quality inspection at our customers’ request.

Our collaboration with the biggest shipping compa-

nies and having our own transport facilities together

minimize delivery times. We can deliver parts from our

store within 2 working days.

Continuous improvement and development

We are continually monitoring our processes and pro-

cedures. The weakest points are thus identified and

form the basis for improvements and further develop-

ment.

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Name Material Class DIN ASTM NF EN 12163 Cr % Zr % Co % Ni % Be % Al % W % Mo % Cu % Hardness

HB

UTS Tensile strength

Yield stress-point >MPa

ES, 65 √S Plasticity

limit >%

Specific gravity g/cm3

Electrical conductivity

% IACS


MS/m

Thermal conductivity 20°–200°C

Melting point °C Applications

CRM16X CuCr1Zr 2 2.1293 C18100 CW 106C >0.4 0.03–0.15 — — — — — — Residual 140–160 480 420 18 8.9 >78 >46 320 500

Use for resistance welding: gun arms, electrode holders, welding caps, plates. Optimal for carbon and zinc coated steel spot welding. Very good electrical conductivity with hardness of 160 HB and high melting point. Suitable for clod forming (bending).

ZR16X CuZr 2 2.1580 C15000 CW120C — 0.15 — — — — — — Residual 125–150 430 420 >12 8.9 >82 >48 340 500 High melting point and very good electrical conductivity. Use for steel, aluminium and brass spot welding.

BICOP CuAl2O3 2 C15735 — — — — — — — 0.6 — — Residual 140–150 430 410 12 8.9 >85 >49 340 650 Innovative copper alloy with aluminium addition in vacuum environment. High electrical and thermal conductivity. Suitable mechanical properties.

CB4 CuCoBe 3 2.1285 C17500 CW104C — — 2.2 — 0.5 — — — Residual 240–260 700 650 8–15 8.9 >43 >25 200 470Suitable mechanical properties and hardness but smaller electrical conductivity than CuCrZr alloys. Use mainly for projection and butt welding. Recommended for resistance spot welding and seam welding of stainless steel.

CNB spec. CuNi2Be 3 2.0850 C17510 CW110C — — — 1.7 0.3 — — — — 210–250 670 650–700 10–14 8.8 69 40 290 480 Recommended for welding of stainless and heat-resisting steel.

CBE2 CuBe2 4 2.1247 C17200 CW101C — — >0.2 — 2.0 — — — Residual 320–360 1150 1000 2–4 8.3 >30 >17 110 300Alloy with the best mechanical properties. Use for gun arms, electrode holders worked with extremely high weld forces. Recommended for injection mould tool and insert, as well.

WCu70 WCu 10 5182 — — — — — — — — 70 — 30 160–180 390 380–430 3–5 14 >49 >29 150 930Sintered tungsten-copper used for projection and butt welding application. Multiple use electrode for EDM (Electrical Discharge Machining) process and inserts for resistance upset and riveting processes.

WCu80 WCu 11 5182 — — — — — — — — 80 — 20 200–230 490 480–520 3–5 15.3 >30 >15 130 1000Sintered tungsten-copper used for projection and butt welding application. Multiple use electrode for EDM (Electrical Discharge Machining) process and inserts for resistance upset and riveting processes.

Wolfram W 99.99% — — — — — — — — — — 99.95 — — 320–370 1100 — 0–1 19.3 >31 >18 125 1000 Used for copper and brass welding. Owing to cost mainly as an insert for electrodes

made of CRM16.

Molibden Mo 99.99% — — — — — — — — — — — 99.99 — 190–210 630 580 15–20 10.2 >35 >20 130 870 Used for copper and brass welding. Owing to cost mainly as an insert for electrodes

made of CRM16.

Electral® – high-quality copper alloy.

All materials are held in stock, in Tychy. Cutting is free of charge.

Copper alloys for resistance welding

All materials specifications are approximate. For detailed information, please check the materials certification sheet.

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Name Material Class DIN ASTM NF EN 12163 Cr % Zr % Co % Ni % Be % Al % W % Mo % Cu % Hardness

HB

UTS Tensile strength

Yield stress-point >MPa

ES, 65 √S Plasticity

limit >%

Specific gravity g/cm3


% IACS


MS/m

Thermal conductivity 20°–200°C

Melting point °C Applications

CRM16X CuCr1Zr 2 2.1293 C18100 CW 106C >0.4 0.03–0.15 — — — — — — Residual 140–160 480 420 18 8.9 >78 >46 320 500

Use for resistance welding: gun arms, electrode holders, welding caps, plates. Optimal for carbon and zinc coated steel spot welding. Very good electrical conductivity with hardness of 160 HB and high melting point. Suitable for clod forming (bending).

ZR16X CuZr 2 2.1580 C15000 CW120C — 0.15 — — — — — — Residual 125–150 430 420 >12 8.9 >82 >48 340 500 High melting point and very good electrical conductivity. Use for steel, aluminium and brass spot welding.

BICOP CuAl2O3 2 C15735 — — — — — — — 0.6 — — Residual 140–150 430 410 12 8.9 >85 >49 340 650 Innovative copper alloy with aluminium addition in vacuum environment. High electrical and thermal conductivity. Suitable mechanical properties.

CB4 CuCoBe 3 2.1285 C17500 CW104C — — 2.2 — 0.5 — — — Residual 240–260 700 650 8–15 8.9 >43 >25 200 470Suitable mechanical properties and hardness but smaller electrical conductivity than CuCrZr alloys. Use mainly for projection and butt welding. Recommended for resistance spot welding and seam welding of stainless steel.

CNB spec. CuNi2Be 3 2.0850 C17510 CW110C — — — 1.7 0.3 — — — — 210–250 670 650–700 10–14 8.8 69 40 290 480 Recommended for welding of stainless and heat-resisting steel.

CBE2 CuBe2 4 2.1247 C17200 CW101C — — >0.2 — 2.0 — — — Residual 320–360 1150 1000 2–4 8.3 >30 >17 110 300Alloy with the best mechanical properties. Use for gun arms, electrode holders worked with extremely high weld forces. Recommended for injection mould tool and insert, as well.

WCu70 WCu 10 5182 — — — — — — — — 70 — 30 160–180 390 380–430 3–5 14 >49 >29 150 930Sintered tungsten-copper used for projection and butt welding application. Multiple use electrode for EDM (Electrical Discharge Machining) process and inserts for resistance upset and riveting processes.

WCu80 WCu 11 5182 — — — — — — — — 80 — 20 200–230 490 480–520 3–5 15.3 >30 >15 130 1000Sintered tungsten-copper used for projection and butt welding application. Multiple use electrode for EDM (Electrical Discharge Machining) process and inserts for resistance upset and riveting processes.

Wolfram W 99.99% — — — — — — — — — — 99.95 — — 320–370 1100 — 0–1 19.3 >31 >18 125 1000 Used for copper and brass welding. Owing to cost mainly as an insert for electrodes

made of CRM16.

Molibden Mo 99.99% — — — — — — — — — — — 99.99 — 190–210 630 580 15–20 10.2 >35 >20 130 870 Used for copper and brass welding. Owing to cost mainly as an insert for electrodes

made of CRM16.

Copper alloys for resistance welding

All materials specifications are approximate. For detailed information, please check the materials certification sheet.

Available sections:

– Round

– Square

– Hexagonal– Flat – Plates

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Round bars

DiameterCRM16 CB4

kg/m6 0.25 8 0.45 10 0.70 12 1.01 12.5 1.10 12.7 1.13 13 1.20 14 1.40 15 1.60 16 1.80 18 2.30 19 2.54 20 2.81 21 3.10 22 3.40 23 3.72 24 4.05 25 4.40 26 4.75 27 5.12 28 5.51 30 6.33 32 7.20 33 7.65 35 8.61 38 10.15 40 11.25 42 12.40 45 14.23 48 16.20 50 17.57 52 19.01 55 21.16 60 25.31 63 27.90 65 29.70 70 34.44 75 39.54 80 44.99 82 47.27 91 58.21 100 70.29 101 71.71 111 86.61 120 101.22 121 102.92 122 104.62 126 111.60 132 122.48 141 139.75 150 158.16 170 202.90 180 227.40 190 253.20 200 280.50

Flat bars

DimensionsCRM16 CB4

kg/m10x10 0.9010x20 1.8010x30 2.7010x40 3.6010x50 4.5010x100 8.9015x15 2.0115x20 2.7015x25 3.3615x35 4.7015x30 4.0315x40 5.3715x50 6.7020x20 3.6020x25 4.5020x30 5.3720x35 6.2720x40 7.1620x45 8.0620x50 8.9520x60 10.7420x80 14.3220x100 17.8025x25 5.6025x30 6.7125x50 11.1925x60 13.4330x30 8.0630x40 10.7430x50 13.4330x60 16.1130x70 18.8030x80 21.4830x 100 26.8540x40 14.3240x50 17.9040x60 21.4840x80 28.6440x100 35.8040x120 42.9645x45 18.1250x50 22.3850x60 26.8550x70 31.3350x80 35.6050x100 44.7560x60 32.2260x80 42.9660x120 64.4470x70 43.8680x80 57.2880x160 114.5690x90 72.50100x100 89.50120x120 128.88

Plates

DimensionsCRM16 CB4

kg/szt.4x500x2000 35.805x500x2000 44.756x500x2000 53.707x500x1000 31.338x500x1000 35.8010x500x1000 44.7512x500x1000 107.4013x500x1000 116.3516x305x1000 43.6816x500x1000 71.6020x305x1000 54.6020x500x1000 89.5022x500x1000 98.4525x305x1000 68.2425x500x1000 111.8830x300x1000 80.5530x500x1000 134.2532x305x1000 87.3535x305x1000 95.5435x500x1000 156.6338x305x1000 103.7340x300x1000 107.4040x500x1000 179.0045x305x500 61.4245x500x1000 201.3850x300x1000 134.2550x305x500 68.2450x500x1000 223.7560x300x1000 161.1060x500x1000 268.5065x500x1000 290.8870x500x1000 313.2580x305x1000 218.3880x500x1000 358.00

Hexagonal bars

DimensionsCRM16 CB4

kg/mSW 12 1.17SW 14 1.52SW 17 2.22SW 19 2.78SW 22 3.73SW 24 4.47SW 26 5.24SW 27 5.83SW 30 6.94SW 36 10.05

Delivery range

All other dimensions available upon request.

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Welding caps

Male tips

Hardness: >160HB. Materials: CRM16X, CuZr, BICOP*. In accordance with DIN, ISO and NFA norms.* * See pages 4-5.

We offer the full range of welding caps from Le Bronze Industriel.

Their extremely high quality has been confirmed by testimonials from the

largest car makers. Mass production by the cold forming method provides

additional induration.

Standard welding caps, which accord to the DIN/ISO norm and car makers’

internal standards, are available from our stock in Tychy.

Taper gauge checkers

Electrodes

Type 311619/B Type 73.590

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Ordering code: form +d1, e.g., F16.Materials: CRM16 (CuZrCr), CuZr, BICOP.Hardness: >160HB.Tolerance: in accordance with DIN ISO 2768-m.

d1 h11

d2 d3 L1 L2+0,5 e R1 R2

Max. welding forceFmax / [kN]

13 5 10 18 8 3 32 5 — 2.5

16 6 12 20 10.5 4 40 6 15° 4

20 8 15 22 11.5 5 50 8 22.5° 6.3

Welding caps – DIN/ISO 5821

Form G

Form A

Form D

Form B

Form E

Form C

Form F

Electrodes

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Materials: CuCrZr, CuZr, CuAl2O3.Hardness: >160HB.Tolerance: in accordance with DIN ISO 2768-m.

Tip wrenchesWe have available special tip wrenches for easy and safe cap-changing.Diameter range: 12–25 mm.Material: Vanadium-Extra.

Welding caps – to car makers’ standards

Type 1978/1

Type 3.9.1 Type 3.9.2

Type 3.9.5

Type 3210PType 1978/2

Electrodes

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We offer a full technical service, together with the man-

ufacturing documentation derived from a given master

product model. We provide a quality inspection report

and material certificates for each product at the cus-

tomer’s request.

Special welding electrodes

Produced at our Tychy plant with Le Bronze

Industriel copper alloys. Our main customers are pro-

duction plants from the automotive, domestic appli-

ance, industrial heating and fencing and grating sec-

tors. About 80% of our production is exported. Shape

and design according to customer’s needs and speci-

fications.

Special welding tips and electrodes.

Circular electrodes for seam welding, in accordance

with customer documentation.

Diameter range: Ø90–Ø300 mm.

Materials: CRM16X, CB4.

Electrodes

Seam welding electrodes

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Electrodes and special toolingSpecial electrodes, –

Electrodes for pipe welding, –

Heating teeth for hardening processes, –

Inductors, –

Pistons for cold-chamber casting process, –

Copper modules. –

Electrodes

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Self-adjusting electrodes

Used for the resistance spot welding process on

visible surfaces, where a high degree of smoothness is

required. The working surface of the electrode adjusts

itself to the welded surface. The optimal solution for

manual portable welding guns. Our innovative cooling

system for the electrode cap guarantees long electrode

life.

NEW:

Electrode type EWAL has direct connector for Argon,

for making “invisible” spots on stainless steel (without

visible surface overheating).

Electrode EWL Electrode EWAL

Electrodes

Taper ØD L Ordering code

Ø12 1:10 22 42 EWL-12-22

Ø12 1:10 30 45 EWL-12-30

Ø15.5 1:10 30 52 EWL-15.5-30

Ø18 1:10 30 52 EWL-18-30

MK1 22 34 EWL-MK1-22

MK2 30 45 EWL-MK2-30

Taper ØD L Ordering code

Ø12 1:10 22 42 EWAL-12-22

Ø12 1:10 30 45 EWAL-12-30

Ø15.5 1:10 30 52 EWAL-15.5-30

Ø18 1:10 30 52 EWAL-18-30

MK1 22 42 EWAL-MK1-22

MK2 30 56 EWAL-MK2-30

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ØD1 ØD2 Ød L Ordering code

16 15.5 10 60 OWL-15.5-10-60

16 15.5 12 60 OWL-15.5-12-60

16 15.5 12 80 OWL-15.5-12-80

16 15.5 12 100 OWL-15.5-12-100

16 15.5 12 120 OWL-15.5-12-120

20 19 15 100 OWL-19-15-100

20 19 15 120 OWL-19-15-120

ØD1 ØD2 Ød L E Ordering code

16 15.5 10 80 10 OGL-15.5-10-80-10

16 15.5 12 80 10 OGL-15.5-12-80-10

16 15.5 12 80 15 OGL-15.5-12-80-15

16 15.5 12 80 20 OGL-15.5-12-80-20

20 19 15 100 10 OGL-19-15-100-10

E Ordering code

25 OGDL-85-25

30 OGDL-85-30

40 OGDL-85-40

50 OGDL-85-50

ØD1 ØD2 Ød L Ordering code

16 15.5 10 60 OZL-15.5-10-60

16 15.5 12 60 OZL-15.5-12-60

16 15.5 12 80 OZL-15.5-12-80

16 15.5 12 100 OZL-15.5-12-100

16 15.5 12 120 OZL-15.5-12-120

20 19 15 100 OZL-19-15-100

20 19 15 120 OZL-19-15-120

Standard electrode holders

Electrodes

Electrode holder OZL

Electrode holder OGL Electrode holder OGDL

Electrode holder OWL

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Welding gun arms

Arms are produced according to the manufacturing

documentation supplied, from copper alloys such as

CuZrCr, CuCoBe, CuNi2Be, brass and aluminium.

Manufactured using cold forming methods, such as

bending, stamping, extrusion, upset or squeeze.

Welding gun arms

Our Design Office will willingly help you solve problems

with the durability of welding gun arms and welding gun

bodies. We are able to provide the manufacturing doc-

umentation for a given product model at the customer’s

request.

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Angled electrode holders

Produced at our manufacturing facility in Tychy. Our

main customers are companies from the automotive

industry (GM, VW, FIAT and PSA) and the manufactur-

ers of domestic appliances, heaters, and gratings and

fences.

About 60% of our production is exported to Western

Europe. The design and technical specification is in ac-

cordance with the customer’s requirements and stan-

dards. We offer a full technical service, together with

the manufacturing documentation derived from a given

master product model.

We provide a quality inspection report No. 2.2 and ma-

terial certificates for each product at the customer’s re-

quest.

Electrode holders

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Nut welding

On the basis of our experience and close collaboration with our customers from the automotive sector, we have

developed a standardized welding electrode method for nuts and screws in the M4–M12 range. Pins and isolating

bushings are made of KCF material or ceramics. Standardization has reduced costs and enabled the whole range of

products to be available from our stock.

For your convenience, all products are available with a wide variety of mounting systems, so that you do not need to

re-arm your welder (see pages 18–21).

CERAMIC PINS:

Ideal insulator, –

Maintenance-free up to 1400° C, –

No whiskers or shunting effect, –

High hardness and impact strength, –

Perfect positioning, –

Cost-reduction by means of longer life, –

Better productivity, –

Standardized product group. –

KCF* PINS:

20–30 µm deep insulating layer, –

Insulation stability at high temperatures, –

No whiskers or shunting effect, –

Hardness of 50 HRC, –

Perfect positioning, –

Low operational cost, –

No isolation bushing in electrode design, –

Standardized product group. –

*KCF alloy – Ferritic stainless steel with additional chrome and aluminium. This alloy forms an oxide film on the surface when carrying out special coating using high temperature. The principal component of this coating is chemically stable aluminium. Properties: chemical stability, heat-resistance, high hardness and insulation coating of 20–30 µm.

Ceramic pins

Allows of the optimization of the projection welding

process. The adaptation of insulated pins has revolu-

tionized projection welding. Standardized pins made of

stainless steel with thermo-setting resin insulation have

now almost been replaced by pins made of ceramics

and KCF*. Insulators guarantee process stability, which

makes your production cheaper.

Nut welding

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For individual use, we produce ceramic pins and

bushing according to customer specification.

If you lack the documentation, you can put the

dimensions on our default drawing and send it to

us with a request for a quotation.

We are able to produce special tooling for both single machines and

complete production lines according to your specification.

Materials:

Quality steel, –

Powder steel, –

Non-ferrous metals and alloys, –

Thermo-setting resins. –

Ceramic pins

Non-standard pins

Special steel tooling

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Nut welding

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Nut welding

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Nut welding

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Bottom electrode EDSL 1:10

Bottom electrode EDSL M18

KCF bushing TL

Screw size ØD Ød L L1 L2 Ordering code

M4 22 6.1 50 20 20 EDSL-4-M18M5 22 7.1 50 20 20 EDSL-5-M18M6 22 8.1 60 25 25 EDSL-6- M18M8 22 10.1 70 30 30 EDSL-8- M18M10 22 12.1 80 40 30 EDSL-10- M18M12 25 14.1 80 40 30 EDSL-12- M18

Screw size ØD Ød L Ordering code

M4 6.1 4.2 20 TL-4M5 7.1 5.2 20 TL-5M6 8.1 6.2 25 TL-6M8 10.1 8.2 30 TL-8

M10 12.1 10.2 40 TL-10M12 14.1 12.2 40 TL-12

Screw welding

Screw size ØD Ød L L1 L2 Ordering code

M4 16 6.1 50 20 20 EDSL-4-1:10M5 16 7.1 50 20 20 EDSL-5-1:10M6 18 8.1 60 25 25 EDSL-6-1:10M8 18 10.1 70 30 30 EDSL-8-1:10

M10 22 12.1 80 40 30 EDSL-10-1:10M12 25 14.1 80 40 30 EDSL-12-1:10

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Tooling

Our brand is inseparably associated with high quality

consumable parts for the resistance spot welding pro-

cess. Our standard range includes: electrodes, shanks,

welding arms, mains current cables, jumper cables and

a whole range of peripheral equipment as used by the

automotive sector.

To better meet our customers’ needs, we brought a fur-

ther team of experienced engineers into our Construc-

tion Office, in 2003.

Experienced designers, combined with the use of 3D

CAD software (Autodesk Inventor), guarantee a quick

development method for the optimal final solution.

Locating the manufacturing process in our own toolshop

cuts delivery times and allows us to make changes at

any stage during production.

Technology tooling

The diversity of our company’s projects is driven by

customers’ needs. Special tools and checkers are our

core products. We are able to redesign, refurbish or

develop backup solutions for your tooling, together with

new documentation.

At the customer’s request, we can develop process pa-

rameters, program the PLC or optimize a robot’s path.

Main elements:

Jig stations for resistance and projection welding, –

Tooling for welding stations, –

Jig stations for Nelson and Tucker stud welding, –

Checking fixtures and checkers, –

Assembly stations. –

We collaborate with the best components suppliers

(of clamps and electrical parts). On the basis of our long

experience, we are always able to recommend proper

equipment for your solution, taking into consideration

the working conditions and process specification.

Laska Technika provides full project management,

starting from the initial outline, right up to the start of

regular production.

After a thorough investigation of the project require-

ments, by way of the technical specification, quality

Production tooling

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requirements and production volume, we are ready to

produce an outline, which forms the basis of our discus-

sions with the customer. Once provisional acceptance

of the concept has been given, we issue a quotation for

the price and timing.

Production tooling

Project phases.

Continuous designer supervision and support at all

project stages guarantees the highest manufacturing

quality.

When all the mechanical parts have been made, we

move to the next phase, assembly. After this, we install

electrical sensors and run the first tests.

Once the quotation has been accepted, we start devel-

oping 3D models using the Autodesk Inventor program.

All potential collisions are eliminated and process-sim-

ulation is carried out to avoid problems later, during the

integration phase. 3D models are sent to the customer

for final acceptance: all suggestions regarding the de-

sign are taken into consideration and implemented dur-

ing the next design loop.

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Tool for 2 bushes welded on car seats in automatic cycle: SICK vision part present sensor.

Welding fixtures for inserts, laser part present checking system.

Production tooling

On the following pages, we present projects we have already carried out for different manufacturing processes:

Station for projection welding (nuts, screws, bushes) assembled from: copper parts made of CRM (CuCrZr) –

or CB4 (CuCoBe) alloys, ceramic or isolated stainless steel pins, manual or pneumatic clamping system, wide range of part detection sensors,Measuring and checking tooling for production and quality departments used for semi-finished products, ready –

products, check-ins for geo stations,Stud welding stations – repeatable positioning for difficult application places, –

Assembly stations – standardization for assembly process on automatic lines. –

25www.laska.com.pl

Automatic welding cell. Welding fixture for safety belt mounting bracket. Neodymium magnet for part-positioning.

Modification of robot welding cell. Geo checking fixture..

Fixture for Nelson and Tucker stud weld. Universal tool for “left hand” and “right hand” parts. Fixture with pneumatic clamping system for Nelson and Tucker stud welds.

Production tooling

26 www.laska.com.pl

Geometry-checking fixture. Seat mounting pallet: Bosch Rextroth transfer system.

Checking fixture for seat frame geometry.

Fixture for Nelson and Tucker stud weld. Universal tool for “left hand” and “right hand” parts. Fixture with pneumatic

clamping system for Nelson and Tucker stud welds.

Inductor for rear axle welding.

Production tooling

27www.laska.com.pl

Welding cap dressing systems

Advantages of LS head:

low operating cost, –

long-life cutting and guiding blades, –

precise and stable face diameter, –

high surface finish (smoothness), –

quick and simple blade-exchange, –

very good chips exhaust system. –

In the resistance spot welding process, the weld tips

work at high temperature and under dynamic mechani-

cal loads. In addition to the process environment, there

is another problem: alloying with a coated steel sur-

face. This alloying of zinc and copper creates a brass

alloy coating and reduces electrical conductivity.

To maintain welding process quality regarding weld

nugget size, strength and shape, it is necessary to

maintain the tip working surface in good condition in

terms of both the diameter and being clean of brass

alloy and other dirt. Our tip dressers are the best way

to meet these requirements. Type SFE–LRS and RFP-

600 for manual welding guns or SFE-LA 400 and SFE-

LA 400 Twin for automatic stations.

For pedestal welding guns, we have the swivel unit

PSP-100. We have available a whole range of cutting

heads for different welding tip workface shapes..

Welding cap dressing systems

Precision cutting headOur cutting head type LS dress welding tips are in ac-

cordance with DIN, VW, Fiat, Ford, Mabec and other

automotive standards.

The cutting head type LS is assembled from a stan-

dardized body, which is common to all types and de-

signs of cutting blade. The head is available with differ-

ent types of locking system: bayonet, “Quick-Lock” and

“Torx” (all others available to special requirement).

The cutting head is equipped with:

cutting blade type K, 1pcs., –

guiding blades type S. 3pcs. –

Process optimization

Cutting head LS gives you the opportunity to improve tip

dress operation. Force and time optimization extends

welding tip life and shortens tip dress operation time to

the minimum necessary.

Finally, fewer production stops for cap-changing.

All the above-mentioned designs are patented.

28 www.laska.com.pl

SFE-LA 400

TECHNICAL DATA

Voltage (V) 3 400

Frequency (Hz) 50

Current (A) 2.8

Power (kW) 1.1 kW-3S-25%

cos 0.86

Motor rotation (RPM) 1380

Head rotation (RPM) 280

Control voltage (V) 24

Compressed air for chips blow-up (bars) 3–6

Weld cap dressing systems

29www.laska.com.pl

SFE-LA 400 Twin

TECHNICAL DATA

Voltage (V) 3 400

Frequency (Hz) 50

Current (A) 3.7


cos 0.86


Head rotation (RPM) 2 x 280


Compressed air for chips blow-up (bars) 3–6


30 www.laska.com.pl

SFE-LRS

TECHNICAL DATA

Voltage (V) 3 400

Frequency (Hz) 50

Current (A) 2.8


Cutting head torque (Nm) 40


Head rotation (RPM)) 280


Max tip dressing force (kN) 4.5


31www.laska.com.pl

RFP-600

TECHNICAL DATA

Head rotation (RPM) 700

Cutting head torque (Nm) 45

Air consumption (m3/min) 0.66

Max inlet pressure (MPa) 0.63

Air connection G 1/4’’

Noise level (dB) 84

Vibration level (m/s2) < 2.5

Weight (kg) 1.9


32 www.laska.com.pl

Swivel arm for pedestal welding gun

PSP-100

TECHNICAL DATA

Torque at 6 bars air pressure min. 19.6 kN

Horizontal rotation angle 1°–150°

Vertical rotation angle 1°–150°

Max. working pressure max. 8 bar

Weight (kg) 35


33www.laska.com.pl

BLO8E

BLO8E PANELTECHNICAL DATA

Supply voltage 10–30 V DC

Load current < 130 mA

Work temperature 5–40°C

Ambient temperature –20–70°C

DISPLAY

Tip dress condition top 0.1 or 1+ (poor, good, very good)

Tip dress condition bottom 0.1 or 1+ (poor, good, very good)

Weld force 200–5000 N

Tip dress quality-checking automotive sensors

Q110 – devices for weld force calibration check and tip dress quality - type Q3263L1Q110053.

APPLICATION: automated resistance spot welding line.FUNCTION: weld force calibration checking and monitoring.

TECHNICAL DATA

Supply voltage 18–30 V DC

Load current < 200 mA

Delay < 150 ms

Ambient temperature 5–50°C

Resistance 500 Ohm

Voltage drop < 2 V

OPTICAL TIP DRESSING QUALITY CONFIRMATION

Infrared 0–2 mm

Programmable Teach-in

WELD FORCE MEASUREMENTS

Accuracy ±1.5%

Range 0.2–8 kN

PROTECTION

IP 67 Short-circuit protection

IP 67 Overload protection

IP 67 Polarization-change protection

MECHANICAL

Enclosure Nickel steel

Optic sensor PMMA scratch-protected

ACCESSORIES

BLOE 8 Panel Programmer with display (optional)

CONNECTION DIAGRAM

Weld force checker 1 +2 Free3 –4 Analogue output5 Earth

+

-

1

5

423

+

-

1

5

423

1

3

2 4

5

1

3

2 4

5Optical tip dressing quality confirmation 1 +2 TOP electrode output3 –4 BOTTOM electrode output5 Earth

+

-

1

5

423

+

-

1

5

423

1

3

2 4

5

1

3

2 4

5

Weld force/time 200–5000 N / < 2.5 ms

Output/weld force 0.5 V, PNP

Output/tip dressing PNP NO

34 www.laska.com.pl

1

3

2 4

Ceramic face automotive sensors

Sensors “Automotive Line – ceramic”. Proximity sensors designed for use on MIG/MAG and resistance welding lines, and progressive die and transfer presses in the automotive sector. Ceramic front-face insert protects sensor from weld splashes sticking. Their higher impact-strength and friction-resistance makes these sensors best suited for press shop applications (progressive tooling, grippers for transfer presses).

Induction sensors – 2-signal type NO, NC

TECHNICAL DATA

Thread M12 M18 M30

Order number A 120212M120311K A 120212M180711K A 120212M301011K

Supply voltage 10–30 V DC 10–30 V DC 10–55 V DC

Max load current 1.5–100 mA 1.5–100 mA 1.5–100 mA

Voltage drop < 5 V < 5 V < 5 V

Current consumption – open state < 600 mA < 600 mA < 600 mA

Ambient temperature –25–70°C -25–70°C -25–70°C

Hysteresis 3–15% 3–15% 3–15%

PROTECTION

IP 67 Short-circuit protection Short-circuit protection Short-circuit protection

IP 67 Short-circuit protection Short-circuit protection Short-circuit protection

IP 67 Overload protection Overload protection Overload protection

IP 67 IP 67 IP 67

MATERIALS

Enclosure black Teflon coated brass black Teflon coated brass black Teflon coated brass

Sensor Front/Face Ceramics Ceramics Ceramics

Input signal control Yellow LED Yellow LED Yellow LED

CONNECTION

Connector M12 M12 M12

Wire-protection PUR* PUR* PUR** High temperature resistance wire-protection cover.

Electrical diagrams +

-1

4

+

-1

4

+

-1

4

Work range 3 mm 7 mm 10 mm

Output function NO NO NO

Frequency response 150 Hz 100 Hz 150 Hz

Cable length 2 m 2 m 2 m

Pin connection diagram

Please refer to our website for the full range.

35www.laska.com.pl

The cables are made by the Italian manufacturer

GB Cavi, and are distinguishable by their high flexibility

and very good electrical features. Water- or air-cooled.

Optimal flexibility and long working life. Cable protec-

tive cover made of non-silicone rubber with good me-

We manufacture all the different types of shunt for

welding guns. Our products are characterized by high

flexibility, guaranteeing an extended working life. We

expanded our range of products in 2004, by adding

shunts with silvered leaves having very good electrical

conductivity.

If you have no documented specification, please use our default drawing on page 40.

chanical features. All the connecting terminal types for

automotive manufacturers’ specifications are available.

Special terminal versions are manufactured according

to customer specification.

Materials:

Copper strips: 99.9% Cu, thickness 0.1 or 0.2 mm –

Copper rope stranding, flat. –

Welding cables

Resistance welding cables and secondary connectors

Shunts

36 www.laska.com.pl

Low-reactance cable, bipolar

Bipolar, water-cooled, low-reactance cables with flex-

ible protective rubber cover. Used in manual portable

welding gun systems in the same way as in automated

systems.

Single copper wire, thickness: 0.25 mm.

Cooling water required: 9 l/min.

Type ERD32 Type EDR40 Type EDR50

Section 2 x 160 mm2 Section 2 x 200 mm2 Section 2 x 250 mm2

D = 48 mm D = 52 mm D = 57 mm

Type Length Type Length Type Length

EDR32 150 1520EDR32 180 1830 EDR40 180 1830 EDR50 180 1830EDR32 200 2130 EDR40 200 2130 EDR50 200 2130EDR32 250 2440 EDR40 250 2440 EDR50 250 2440EDR32 300 3050 EDR40 300 3050 EDR50 300 3050

Ω x 10-6

Section Length Resistance Impedance Reactance Power ratio

2 x 160

1520 345 378 52.5

0.991830 428 446 652130 502 522 77.52440 570 598 89.5

2 x 200

1520 287 296 61.2

0.981830 345 356 78.32130 398 414 85.52440 465 474 97.6

2 x 250

1520 234 243 59.7

0.971830 286 292 71.42130 328 339 83.52440 377 387 95.6

2 x 320

1520 192 210 48.1

0.961830 231 246 59.82130 269 282 71.52440 312 322 83.2

Welding cables

37www.laska.com.pl

Jumper cables

Unipolar jumper cables, type DSC, used for each bi-

polar cable, transformer polarity or welding gun arm

connection. High flexibility combined with long working

life. Protective cover made of rubber with very good

mechanical features.

Connecting terminals mounted with M30 x 1.5 and

water inlet/outlet port type DCS/1/.

Single copper wire, thickness: 0.25 mm

Cooling water required: 9 l/min.

Typ DSC16 Typ DSC20 Typ DSC30

Section 1 x 160 mm2 Section 1 x 200 mm2 Section 1 x 300 mm2

D = 40 mm D = 40 mm D = 48 mm

Type Length Type Length Type Length

DSC16 60 600 DSC20 60 600 DSC30 60 600DSC16 70 700 DSC20 70 700 DSC30 70 700DSC16 80 800 DSC20 80 800 DSC30 80 800DSC16 90 900 DSC20 90 900 DSC30 90 900DSC16 100 1000 DSC20 100 1000 DSC30 100 1000

Welding cables

38 www.laska.com.pl

Unipolar cables

Type CNR2 Type CNR3 Type CNR4 Type CNR5

Section 200 mm2 Section 300 mm2 Section 400 mm2 Section 500 mm2

S = 18 mmD = 38 mm

F = 13 mmP = 30 mm

S = 18 mmD = 45 mm

F = 13 mmP = 35 mm

S = 18 mmD = 45 mm

F = 13 mmP = 32 mm

S = 24 mmD = 52 mm

F = 13 mmP = 32 mm

Type L T Type L T Typ L T Type L TCNR2 40 400 432 CNR3 40 400 432 CNR4 40 400 432 CNR5 40 400 432CNR2 45 450 482 CNR3 45 450 482 CNR4 45 450 482 CNR5 45 450 482CNR2 50 500 532 CNR3 50 500 532 CNR4 50 500 532 CNR5 50 500 532CNR2 55 550 582 CNR3 55 550 582 CNR4 55 550 582 CNR5 55 550 582CNR2 60 600 632 CNR3 60 600 632 CNR4 60 600 632 CNR5 60 600 632CNR2 65 650 682 CNR3 65 650 682 CNR4 65 650 682 CNR5 65 650 682CNR2 70 700 732 CNR3 70 700 732 CNR4 70 700 732 CNR5 70 700 732CNR2 75 750 782 CNR3 75 750 782 CNR4 75 750 782 CNR5 75 750 782CNR2 80 800 832 CNR3 80 800 832 CNR4 80 800 832 CNR5 80 800 832CNR2 85 850 882 CNR3 85 850 882 CNR4 85 850 882 CNR5 85 850 882CNR2 90 900 932 CNR3 90 900 932 CNR4 90 900 932 CNR5 90 900 932

Welding cables

39www.laska.com.pl

Type CNA3 Type CNA4 Type CNA5

Section 300 mm2 Section 400 mm2 Section 500 mm2

S = 17 mmD = 34 mm

F = 13 mmP = 32 mm

S = 20 mmD = 39 mm

F = 13 mmP = 32 mm

S = 24.5D = 44 mm

F = 13 mmP = 32 mm

Type L T Type L T Type L TCNA3 40 400 432 CNA4 40 400 432 CNA5 40 400 432CNA3 45 450 482 CNA4 45 450 482 CNA5 45 450 482CNA3 50 500 532 CNA4 50 500 532 CNA5 50 500 532CNA3 55 550 582 CNA4 55 550 582 CNA5 55 550 582CNA3 60 600 632 CNA4 60 600 632 CNA5 60 600 632CNA3 65 650 682 CNA4 65 650 682 CNA5 65 650 682CNA3 70 700 732 CNA4 70 700 732 CNA5 70 700 732CNA3 75 750 782 CNA4 75 750 782 CNA5 75 750 782CNA3 80 800 832 CNA4 80 800 832 CNA5 80 800 832CNA3 85 850 882 CNA4 85 850 882 CNA5 85 850 882CNA3 90 900 932 CNA4 90 900 932 CNA5 90 900 932

Welding cables

40 www.laska.com.pl

Leaf shunts – defeult order sheet

Welding cables

41www.laska.com.pl

MIG/MAG consumables

Parts for welding torchesWe have available components for welding torches

manufactured by:

Fronius, –

Dinse, –

Esab, –

Binzel, –

SKS. –

For difficult working conditions, the best solution is

nozzles made of combined material, where the core

is dispersion hardened Cu covered in electrolytic coo-

per. Nozzles made of this material are characterized by

high friction resistance and high softening temperature.

They are recommended for applications where high

temperature and welding current are used.

We have available special current nozzles with chrome

or silver coating. This coating prevents weld sparks

sticking to the current nozzle.

Spare parts

We manufacture other parts for welding torches

such as:

Gas nozzles, –

Gas diffusers, –

Isolators, –

Setting rings, etc. –

Current nozzle

Current nozzles, especially as used on automated

lines, are normally made of CuCrZr copper alloy.

Comparison of current nuzzles’ durability.

We should point out that Laska Technika Przemysłowa Sp. z o.o. is not associated with the OEM producers mentioned above. The components on offer are not original parts made by OEM, but are manufactured by Laska Technika Przemysłowa Sp. z o.o., based on our own design documentation. OEM’s product names and identification numbers are used for ease of identification and customers’ convenience.

We can also refurbish torches and hose packages

at the Customer’s request.

42 www.laska.com.pl

Insulating bandages

Type Width [cm] Length [m]802002 5 3.6802003 7.6 3.6802004 10.1 3.6802004 12.7 3.6

Type Inner diameter (ins) Inner diameter (mm)

PJ5 5/16” 8

PJ6 3/8” 10

PJ7 7/16” 11

PJ8 1/2” 13

PJ10 5/8” 16

PJ12 3/4” 19

PJ14 7/8” 22

PJ16 1” 25

PJ18 1.1/8” 29

PJ20 1.1/4” 32

PJ22 1.3/8” 35

PJ24 1.1/2” 38

PJ26 1.5/8” 41

PJ28 1.3/4” 44

PJ32 2” 51

PJ36 2.1/4” 57

PJ40 2.1/2” 64

PJ44 2.3/4” 70

PJ48 3” 76

PJ52 3.1/4” 83

PJ56 3.1/2” 89

PJ60 3.3/4” 95

PJ64 4” 102

PJ72 4.1/2” 114

PJ80 5” 127

Temperature resistance:> 260°C – continuous exposure,> 1090°C – max. 15 min.,> 1640°C – max. 20 sec.

Covering sheaths made of high-bulk fibreglass, coated with high temperature-resistant rubber. Ideal protection for elec-

trical cables and hoses against welding sparks and weld spatters. Fireproof – can resist open flame exposure (e.g., gas

torch). Also used as effective protection against burns from hot hoses. Excellent flexibility and mechanical strength.

Application: as protective cover for electrical cables and anti-burn cover for hoses.

Insulating bandages

Bandage-style covers protect welding gun arms

from mechanical damage and electrical shunt-

ing. High mechanical strength against friction and

hits. Good alternative to plastic insulating tape.

The following sizes are available:

Covers for electrical cables - Pyro-Jacket®

43www.laska.com.pl

Welding gun splash-protection covers

We are a designated dealer for JUTEC GmbH, the

manufacturer of heat protective dress packs for weld-

ing guns, electrical cables and robots. Highly flexible,

heat-resistant material, which fulfils all the safety re-

quirements.

The gun drawing is required for the design and manu-

facture of a welding gun cover design.

Additional options are available, according to customer

requirement: inspection opening, pockets, rubber gun

pivot-point cover.

Advantages:

Optimal security for the welding gun against weld –

splashes, Heat and electrical protection, –

Maintenance cost-reduction, –

Fewer breakdowns. –

Available material types:

600 g/m – 2 – use for automatic welding gun cover,280 g/m – 2 – thinner material: use for cable package and dress pack covers.

Protective covers

44 www.laska.com.pl

TIGON Balancers

Balancers - series TW

Model Load [kg] Rope length [m] Weight [kg]TW 00 0.5–1.5 0.5 0.2TW 0 0.5–1.5 1.0 0.5TW 3 1.0–3.0 1.3 1.4TW 5 2.5–5.0 1.3 1.5TW 9 4.5–9.0 1.3 3.4TW 15 9.0–15.0 1.3 3.8TW 22 15.0–22.0 1.5 7.2TW 30 22.0–30.0 1.5 7.6TW 40 30.0–40.0 1.5 9.8TW 50 40.0–50.0 1.5 10.4TW 60 50.0–60.0 1.5 11.6TW 70 60.0–70.0 1.5 11.8TW 90 70–90 15.80TW 105 85–105 19.20TW 120 100–120 21.50

Improves work safety & efficiency:

conical cable drum assembly, –

coated rope – extends life of rope and drum, –

360° pivot hook, –

safety: –

main hook – increased strength,• additional upper safety chain (optional) – as protection for main hook,• safety lock – stops drum rotation when main spring is broken,• additional bottom safety chain (optional) – as protection for load hook,• manual lock – balancer locking.•

Balancers

It is possible to order the products which are specified in this catalogue in different sizes and different materials from

those listed. Such an order would, however, be subject to a minimum production volume.

This catalogue describes our products. Please note that the information given here might not apply to your particular

application. All the parameters and calculations are only approximate values and might change according to the

specific working environment. We strongly recommend that you conduct trials before use.

No part of this publication may be copied, reproduced or published without the prior permission

of Laska Technika Przemysłowa Sp. z o.o.

All company names mentioned herein are used for information purposes only and are the trademarks of their respec-

tive owners.

© Laska Technika Przemyslowa Sp. z o.o. All rights reserved.

Wydanie 2/2009/PL

HEAD OFFICE:

43-100 Tychy, ul. Towarowa 35Poland tel.: +48 32 326 24 50fax: +48 32 326 24 51e-mail: [email protected]

GERMANY:

44-793 BochumCarolinenglückstr. 35Tel.-Nr. +49 234 952 30 30Fax-Nr. +49 234 952 30 27E-Mail: [email protected]

1/2009/EN

Documents

RESISTANCE SPOT WELDING - LASKA Technika · PDF file 1 As one of the leading suppliers of copper components for resistance spot welding, our product range includes such items as: –