Battery Welding with Matuschek © 2022 1
Matuschek headquarter in Alsdorf
Alsdorf
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Partners
www.matuschek.com
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History
1985 Now
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Production at Matuschek
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SilverSPATZ & AutoSPATZ – The old generation
• constant current, constant voltage, constant power control
• 0.5 ms control cycle
• signal inputs for current, voltage, force and displacement
• sensor fault detection
• parameter limit checking for
- weld current - electrode voltage
- final resistance - total energy
- current time - displacement
- electrode force - trigger angle
• displacement controlled current switch off
AutoSPATZM600L • recorder for the last 10,000 weld data
• tolerance band supervision for current, voltage, resistance
SilverSPATZM600LL/LW • 63 weld schedules with 16 pulses in each schedule
• slope up / down and force schedules
• stepper function with 63 independent steppercounters
• 13 digital input, 8 digital output (24 V DC)
• output for proportional valve (0-10 V or 4-20 mA analog)
• Profibus DP interface for robot or PLC communication
• Ethernet interface for weld timer network and line PC
• RS232 interface for PC programming
• RS485 interface for hand held programming device SPATZBG-02
• internal 24 V DC / 4 A power supply (only AutoSPATZ)
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SPATZ+ Power supplies for micro and battery welding
M300 M400-900
H9000 H300
P500 M300AC M400-900AC
H12 H300X
H300AC
Polarity:
Transformer:
Output: 100A-12000A 10A-500A 100A-12000A (300A) (400/600/900)A
Closed Loop Control: Constant Current , -Voltage and -Power Control
Monitoring: Limits, Tolerance Band, Voltage Peak, Penetration, Part & Force check
Fieldbus: Handshake with PLC, Status & Error, QA-Data, Read/Write-Interface for PLC
Handling: SPATZStudio, SPATZStudioNET(E), M2M - Interface
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SPATZ+M400W – M900W
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SPATZ+M400W – M900W
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SPATZ+MxxxW – Mounting Plate SLKOC001
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1000 Hz / 20 kHz DC Inverter Power Unit
U U U U
t t
t t
L1
L2
L3
High Speed DC Power Sources for Resistance Welding
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Welding tasks
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Resistance Welding with Matuschek SPATZ+ Systems
Microwelding BIW Welding
Weld Lab at Matuschek
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Resistance Welding in- and outside Car Body's
~ 6000 joints > 70% Spots
~ 500 Sheet Thickness Combination
~ 600 different weld guns
Furthermore weld spots for
• E-Mobility & batteries
• Sensors and Actors
• Generator and motors
• Contacts for switches, relays …
• Lamps
In total another 5000 spots
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Modern Weld Timers for Battery Welding
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Lead Batterie Welding
contact detection via
voltage measurement
welding tips
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Welding of lead in starter batteries
• Welding electrodes with
projection embossing tool
• Contact supervision via voltage
supervision
• Hydraulic electrode force
Weld position before the embossing
with the electrodes
and after the embossing of the projection
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SPATZKAM Contact Detection Modul
• available for SPATZ+ weld systems
• easy to install plug in module
• repeatable delay between first contact and welding
The result:
Weld Current Ignition with optimised contact area
Contact area too small - SPLASH! Contact area too big - COLD weld points
(surface resistance too small for the initial melting point)
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Weld sequence with contact supervision (KAM) for welding
of lead starter batteries
1 2 3 4 5
contact = start pause time in weld program
Electrode force
Impulses 1 2 3 4 5
Weld current
Contact- 1 t
detection 0
CDT closing Pause Weld time Hold time Opening
projection time
forming to reach needed
contact area !
Prog Nr. 1 t
and Start 0
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Error 172 of KAM module
1
Error 172 = KAM Isolation
No contact = No start Pause time in weld Program – and Error 172
Electrode force
Impulses 1
No contact within max delay = 5000 ms
Contact- 1 t
Error 172 = KAM Isolation
detection 0
CDT closing
projection
forming
max delay = 5000 ms
Prog Nr. 1 t
and Start 0
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Error 171 of KAM module
1
Error 171 = KAM short circuit
Contact before Start signal = No start weldprogam – and Error 171
Electrode force
Impulses 1
Contact- 1 t
detection 0
CDT closing
Contact detection MUST be 0 before Start
projection
or Error 171 short circuit
forming
Prog Nr. 1 t
and Start 0
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SPATZ+ I/O connection
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Comparison between SPATZ+ and Old SPATZ with KAM connection
SPATZ KAM
SPATZ+KAM
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SPATZ KAM-Module
Input 12 has to be activated to use the KAM-module.
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SPATZ+ KAM-Module
The module can be deactivated if necessary.
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SPATZ+ weld program with KAM-module
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SPATZ+ weld program without KAM-module
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SPATZ+ Weld Program
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Tasks in Resistance Welding Applications
Parameter Determination
Maintenance Parameter Setting
Equipment Process Control
Database Connection Process Supervision
Documentation Process Analysis
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Smart Factory
Supervision Manufacturing Execution System Production
LAN / Ethernet
Line-PC Welding Controller PLC
Fieldbus
Service Operator Operating / HMI
USB
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Example: StudioNET with history windows
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Network Communication
Group 1
Line-PC
Ethernet / Wire
Office
Remote Access (Desktop)
Wifi / Air to Air
Group 2
Ethernet / Wire
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Function of the extended Bus-Communication
Handshake with PLC for Welding
Status of Error and Limits
Writing and Reading of Programparameter
Writing and Reading of Limits
Writing Part-ID
Reading an actual process datum
Receive of an QS-data-telegram
Register for extra values – e.g. Position
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Communication between PLC and SPATZ+System
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More Information with Bus about Errors and Status
Wrong part
Good weld Limit Wrong
error force
No cooling
Missing Hardware-
Voltage Error
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What is the Trigger Angle of DC Inverter?
The term trigger angle was taken from the well known 50Hz system and describes the
proportion of 'on' time to the regular interval or 'period' of time
Inverter-technique: trigger angle = duty cycle
S = t_on / T * 100 duty cycle
Um = U * S / 100 av voltage
I = Um / Resistance current
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Weld control mode for miniatur part resistance welding:
Resistance
Resistance
Resistance
Electrode voltage
Electrode voltage Electrode voltage
Power
= constant
Current = constant Power = constant Power
Current
Current
KLR
KSR KUR
Constant-Power-Control
Constant-Current-Control Constant-Voltage-Control
• Current Sensor
• Current Sensor Voltage Sensor
• Voltage Sensor
Impuls Impuls
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
electrode force electrode force
welding current
welding current
t t
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Current, Voltage, Resistance and Manipulated Value
of a Constant Current Weld
programmed value
calculated final value
calculated mean value
8
Iset 200
Rend
Resistance
Irms
Current 4 100 calculated
measured current curve resistance curve
0 0
0 10 20 30 40 50 0 10 20 30 40 50
Current time Current time
2 setted final value
calculated mean value Send
80
Trigger Angle
Voltage
Urms
1
Manipulated Variable
40
measured voltage curve
0 0
0 10 20 30 40 50 0 10 20 30 40 50
Current time Current time
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Measuring Device SPATZ Multi 04
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Our Little Specialists.
Thanks for your attention!
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