Process analysis&Model Selection of Insulation Pin Stud Welding

Process analysis&Model Selection of Insulation Pin Stud Welding

 
Usual kinds of insulation pin as following:
Ⅰ. Suction type insulation pin


The insulation pin of photo A:
1. Feature: the diameter is 1.8mm usually with different length(30mm is the most): Distinguish from the latter two pins, it is assembled with a insulating rubber boot near the suction(the length is 20mm usually)
2. Applicable model: RSR-630B insulation pin stud welder; applicable welding gun: SRQ4 Suction type insulation pin welding gun
3. Analysis: This insulation pin has small diameter, its zinc coating is thin compare to photo B and its diameter is small compare to photo C, so it needs less energy, meanwhile, the energy consumption is not existed because it is totally electroinsulating between the pin and aluminum firm of insulation wool when welding thanks to the protection of insulating rubber root. So model: RSR-630B can be qualified.
 
The insulation pin of photo B:
1. Feature: the diameter is 1.8mm usually with different length(30mm is the most); it is not assembled with a insulating rubber root compare to photo A and its diameter is smaller compare to photo C
2. Applicable model: RSR-1250B insulation pin stud welder; applicable welding gun: SRQ4 Suction type insulation pin welding gun
3. Analysis: this insulation pin have small diameter, but its zinc coating is thicker compare to photo A and without insulating rubber root, so the energy consumption maybe generated because of the strike arc between the pin and aluminum foil of insulation wool; so we recommend the model: RSR-1250B. Special reminder:  this insulation pin is cheap and easy manufacturing, so the practical application is wide.
 
The insulation pin of photo C:
 
1. Feature: the diameter is bigger as 3mm usually with different length(65mm is the most); it is not assembled with a insulating rubber root and is bigger diameter compare to photo A and its diameter is bigger compare to photo B
2. Applicable model: RSR-1600B insulation pin stud welder; applicable welding gun: SRQ4 Suction type insulation pin welding gun
3. Analysis: This pin needs more energy to ensure the welding FPY because its diameter is big and without the protection of insulating rubber root. We recommend the model: RSR-1600B
 

 

Ⅱ.Copper coating  Insulation Pin


The insulation pin of photo A:
1. Feature: this pin’s diameter is 5mm or 6mm usually with different length(50mm is the most). The end face of welding flange is level with a embossed point(it is called arc strike point); it is applicable for ship building. The application method: welding the pin--paving the insulation wool--fixing the wool by baffle which with Threaded.
2. Applicable model: RSR-1600 CD stud welder; applicable welding gun: SRQ3
3. Analysis: this pin is Energy-storing pin(though its character is insulation pin in ship building field); the stud flange is molten instantaneously by point discharge and inserted to weld pool fast, then the welding is finished after solidification.
 
The insulation pin of photo B:
1. Feature: The insulation pin of photo B: this pin’s diameter is 3mm usually with different length. The end face of welding flange is not level with bigger radian; it is applicable for ship building: welding the pin on mother board-paving the insulation wool-- let the pin pass through the circle plastic flat--buckling the appeared pin to fix the insulation wool.
2.  Applicable model: RSR-1250E CD stud welder special for ship building; applicable welding gun: SRQ3 welding gun or welding tongs
3. Analysis: because of the big taper of end face, the welding of generic insulation pin will generate bulk splash which will cause the welding pool is not full and welding strength is not qualified. So it need special welder to weld this pin to extend welding time and deduct the splash. We recommend the model: RSR-1250E.
 
The insulation pin of photo C:
1. Feature: this pin’s diameter is 3mm usually with different length; the point is similar with five-pointed star and the end face is level; it is applicable for ship building; the welding process is same as photo B.
2. Applicable model: RSR-1250E CD stud welder special for ship building; applicable welding gun: SRQ3 welding gun or welding tongs
3. Analysis: because of the complicated end face, the welding of generic insulation pin will generate bulk splash, so we recommend the model: RSR-1250E as well.
 

Special reminder:
For the welding of photo B and photo C, because some clients have high expectations with the welding strength, so they would like to choose Arc stud welder: RSN7-800 or RSN-1200 for welding.
 
The difference of Arc stud welding machine and CD stud welding machine:
CD stud welding machine is called Energy storage stud welding machine. Firstly the energy is preset and charged into capacitor, then the power will be discharged totally one time when welding, the welding time is 1~3ms.The welding capacity is limited because the power is not supplied inexhaustibly, it is applied to the diameter 2~10mm studs commonly.
 
Arc stud welding also named drawn arc stud welding. It does not have the process of charging into the capacitor which is different from Energy Storage stud welding. It discharges directly after lowering voltage through the transformer or rectifier.According to the power capacity of device, the adjustable diameter of studs is 3~36mm thanks to the continuous power discharge and controllable welding time because of no need of precharge.