JB/T 9533-1999 Technical requirements for wire feeding devices of welding machines
Some standard content:
—1999
IB/T9533
This standard is a revision of ZBJ64021-1989 "Technical Specifications for Wire Feeders of Welding Machines".
According to the requirements of GB/T1.1--1993 and GB/T1.3-1997, only editorial changes have been made to ZBJ64021-1989. This standard will replace ZBJ64021-1989 from the date of implementation. This standard is proposed and managed by the National Technical Committee for Standardization of Electric Welding Machines. The drafting unit of this standard: Chengdu Electric Welding Machine Research Institute. The main drafter of this standard: Zhou Youmin.
1 Scope
Machinery Industry Standards of the People's Republic of China
Wire Feeders of Welding Machines
Technical Specifications
The specifications for wire feeders This standard specifies the main performance and general technical requirements of solid steel welding wire feeders. JB/T9533-—1999
Replaces ZBJ64021-1989
This standard applies to wire feeding devices (hereinafter referred to as devices) for continuous feeding of solid steel welding wire in MIG/MAG, TIG welding machines and submerged arc welding machines.
For devices with special requirements, they can be specified in the standards or technical conditions of the device. For devices that feed welding wires of other materials, this standard can be implemented as a reference. 2 Cited standards
The provisions contained in the following standards constitute the provisions of this standard through reference in this standard. When this standard is published, the versions shown are valid. All standards will be revised, and parties using this standard should explore the possibility of using the latest versions of the following standards. GB/T2900.22--1985 Electrical terminology Electric welding machine GB/T8118-1995 General technical requirements for arc welding machines GB15579--1995 Safety requirements for arc welding equipment Part 1: Welding power source (idtIEC60974/1:1989) GB15579.12--1995
Safety requirements for arc welding equipment Part 12: Welding cable coupling device (idt IEC 60974/12:1992)
Steel welding wire for fusion welding
GB/T 14957.--19942
GB/T14958--1994 Steel wire for gas shielded welding 3 Definitions
This standard adopts the following definitions.
3.1 Wire feeding speed
The length of the welding wire fed per unit time, in m/min. 3.2 Wire feeding mechanism
A mechanism that feeds welding wire and has the ability to move along its axial direction. It is generally composed of a drive motor, a reducer, a wire feeding roller, a clamping mechanism, etc. 3.3 Wire feeding device
A device that feeds welding wire and can adjust and control parameters such as wire feeding speed. It is generally composed of a wire feeding mechanism, a wire reel support, an electrical control system, etc. The electrical control system of some devices can also be set separately. Other term definitions should comply with the provisions of GB/T2900.22. 4 Types and basic parameters
The device can be manufactured into two types of constant speed wire feeding and variable speed wire feeding according to this standard. 4.1
4.2 Basic parameters
Approved by the State Machinery Industry Bureau on August 6, 1999 and implemented on January 1, 2000
4.2.1 Wire feeding working mode: continuous.
JB/T9533—1999
See Table 1 for the diameter range and rated traction force of the welding wire conveyor. Table 1 Diameter range and rated traction force of welding wire conveyor Wire diameter, mm
Traction force, N
Note: The traction force of welding wire with a diameter less than 0.8mm and greater than 6mm shall be specified by the enterprise standard. 4.2.3 Rated welding current, duty cycle 1.6~3.0
For devices with welding circuits passing through, the welding current level shall comply with the provisions of GB/T8118. Duty cycle and working cycle shall comply with the relevant welding machine standard push regulations. 5 Normal use conditions
5.1 Altitude shall not exceed 1000m.
5.2 Relative humidity
The average maximum relative humidity of the wettest month is 90%, and the average minimum temperature of the month is 25℃. 5.3 The ambient air temperature shall not exceed the following limits: a) Maximum temperature
b) Minimum temperature
+40℃
Devices with water cooling system
Devices without water cooling system
10℃
5.4 The place where the device is used shall be free of gases, steam, chemical deposits, dust and other explosive and corrosive media that seriously affect the use of the device, and shall not be subject to severe vibration and bumps.
6 Technical requirements
6.1 The device shall comply with the provisions of this standard and be manufactured in accordance with the drawings and technical documents approved by the prescribed procedures. 6.2 Wire feeding traction
According to the maximum diameter of the welding wire to be transported, the device shall be able to achieve the rated traction specified in Article 4.2.2, and the wire feeding shall be even and reliable without slipping.
6.3 Wire feeding speed and its rate of change
6.3.1 The wire feeding speed shall be indicated by an instrument or scale, and its indication accuracy shall not exceed ±10% of the measured value. If relative scale indication is used, its indication accuracy shall be specified by the standards of each device. 6.3.2 The wire feeding speed shall be continuously adjustable, and its speed adjustment range shall be specified in the device specification. 6.3.3 Deviation of wire feeding speed range
The minimum wire feeding speed shall not be greater than +10% of the value indicated on the nameplate; the maximum wire feeding speed shall not be less than -5% of the value indicated on the nameplate. 6.3.4 Within the specified wire feeding speed range, when the grid voltage fluctuates within ±10% of the rated value, the rate of change of the wire feeding speed shall not exceed ±5%. 6.3.5 When the device works from cold state to hot state, the rate of change of the wire feeding speed shall not exceed ±5%. 6.3.6 Within the specified wire feeding speed range, when the wire feeding traction force changes from 50% to 100% of the rated value, the rate of change of the wire feeding speed shall not exceed ±5%.
6.3.7 The control system of the device shall meet the following requirements: 6.3.7.1 Before welding begins, it shall be able to control and adjust the welding wire being transported. 6.3.7.2 When welding begins, it shall be able to automatically connect the welding power supply and transport the welding wire. 6.3.7.3 When welding stops, it shall be able to reliably stop transporting the welding wire and cut off the welding power supply. 6.4 Sealing performance
JB/T9533—1999
6.4.1 For devices with gas protection function, its gas circuit system shall work normally under an inlet pressure of 0.1MPa and shall not have any leakage. 6.4.2 For devices with a water cooling system, its water cooling system shall work normally under an inlet pressure of 0.2MPa and shall not have any water leakage or seepage. 6.5 Temperature rise and temperature limit value
6.5.1 When the device is in rated working state, the temperature rise of the drive motor shall not exceed the temperature rise specified in its product standard. 6.5.2 The surface temperature of the bearing cover shall not exceed 90℃. 6.5.3 The welding circuit in the device shall be able to pass the rated welding current, and the temperature rise of its cables and joints shall comply with the provisions of GB15579.12. 6.6 Welding wire, wire reel and its bracketbzxZ.net
6.6.1 The welding wire used in the device shall comply with the provisions of GB/T14957 and GB/T14958. 6.6.2 The wire reel used in the device shall be replaceable without using tools. 6.6.3 The support shaft of the reel-type wire reel shall have a damping function to prevent the wire from unwinding. 6.7 The gearbox of the device shall not leak oil during operation. 6.8 The noise limit of the device under normal working conditions shall not exceed 75dB of the A-weighted sound power level. 6.9 The surface protective layer of the unpainted ferrous metal parts in the device, except for the friction fitting part, shall comply with the relevant standards. 6.10 The paint layer of the device should be smooth and flat, with uniform thickness, without cracks, bubbles, wrinkles or peeling. 6.11 The device should be supplied as a complete set. Wire feed rollers and wire guide nozzles of different specifications should be equipped with accessories. There should be spare parts for its wearing parts, and their specifications and quantities are specified by the standards of each device.
6.12 Parts such as wire feed and clamping rollers manufactured according to the same drawings should be interchangeable. 6.13 When the wire feed roller is running, its axial and radial runout shall not exceed 0.1mm. 6.14 The working hardness of the wire feed and clamping rollers shall not be less than HRC52. 6.15 Reliability
a) Average service life of the device: 5a;
b) Average service life of wire feed rollers and clamping rollers: 500h; c) Average trouble-free working time: 1000h. Notes
1 Damage to wearing parts is not included.
2 This item is a recommended indicator.
7 Safety requirements
7.1 The minimum protection level of the control box shell of the device is IP20. 7.2 The edges of all holes at the inlet and outlet of the welding cable should be smooth and flat. 7.3 The voltage of the control circuit that is often moved and easily in contact with the human body is stipulated as follows: AC power frequency: not more than 42V (effective value):; DC: not more than 48V (average value).
7.4 For devices with input voltage higher than that specified in Article 7.3, safety protection measures and reliable grounding should be provided. The terminal of the grounding wire shall not be used for other purposes, and the diameter of the grounding screw shall not be less than 8mm. 7.5 Except for necessary anti-interference devices or protection devices, the welding circuit shall not be connected to the grounding electrode or the frame, and the effective value of the leakage current through the above devices shall not exceed 1mA.
7.6 Insulation resistance
a) The insulation resistance between the power supply circuit (including the control circuit connected to it) and the frame and other circuits shall not be less than 2.5M2; b) The insulation resistance between the welding circuit (secondary circuit) and the frame and other circuits shall not be less than 2.5Ma. 7.7 Dielectric strength
7.7.1 Between the welding circuit and the frame: 1500V. 7.7.2 Control circuit
JB/T9533—1999
a) Between the control circuit electrically connected to the primary circuit of the welding power source and the frame: 2500V; b) Between the control circuit with a supply voltage of more than 50V and less than 127V and the frame: 1000V; c) Between the control circuit with a supply voltage of less than 50V and the frame: 800V; d) Between the control circuit and the welding circuit: 1000V; e) Between the control circuit and the primary circuit: 2500V. Note: The above voltage values are all effective values of the actual sine waveform of 50Hz. 7.8 Clearance and creepage distance
The live circuit in the device shall have the clearance and creepage distance required for sufficient dielectric strength, and its value shall not be less than the value listed in Table 2:
Table 2 Clearance and creepage distance
Rated voltage, V
Clearance, mm
Cable distance, mm
8 Inspection method
8.1 General
8.1.1 The device to be inspected should be new and dry, and inspected under the normal use environment specified in this standard. 8.1.2 The accuracy level requirements for the instrument for inspecting electrical parameters are as follows: a) Type inspection: 0.5 level;
b) Factory inspection: 1.0 level.
8.1.3 Speed detector accuracy: ±2%.
8.1.4 Thermometer accuracy: soil 0.5℃.
8.1.5 Instrument type
The instrument type should be selected correctly according to the current or voltage waveform. For AC or rectified current with a ripple factor greater than 10%, the effective value should be measured; for DC or rectified current with a ripple factor less than 10%, the average value should be measured. 8.2 Wire feeding speed adjustment range and deviation measurement 8.2.1 The wire feeding speed is measured using a speedometer, stopwatch, or ruler. Measure the minimum and maximum wire feeding speed values, and be able to adjust continuously within this range.
8.2.2 The deviation value of the wire feeding speed range is calculated according to the formula (1): △=[(v—0/v]×100%
Wherein: --deviation value;
actual value of wire feeding speed;
--nameplate value of wire feeding speed.
8.3 Determination of wire feeding speed indication accuracy
Measurements are carried out at the minimum wire feeding speed and 50% and 100% of the maximum wire feeding speed. The indication accuracy is calculated according to the formula:
Wire feeding speed indication accuracy-[(indication value-actual value)/indication value]×100%8.4 Determination of the cold and hot change rate of wire feeding speed8.4.1 Determination of wire feeding speed in cold state
a) First, let the device stand still in the room for a period of time, and use a thermometer to measure the outer surface temperature of the drive motor and reducer bearing cover of the wire feeding mechanism. If the difference between this temperature and the ambient temperature does not exceed ±3℃, the device is in cold state at this time; b) Press the wire feeding roller and put it in normal wire feeding state, then start the wire feeding device to run at the maximum wire feeding speed, and immediately measure the wire feeding speed value in cold state.
8.4.2 Determination of wire feeding speed in hot state
JB/T9533-1999
a) After the wire feeding speed is measured in cold state, the welding wire is pulled out. Apply a rated counter torque to the wire feeding roller and continue to run at the given maximum wire feeding speed;
Note: The rated counter torque is equal to the product of the rated traction force and the radius of the wire feeding roller. b) During the test, record the wire feeding speed (or roller speed), counter torque, armature voltage and current value of the drive motor, and the temperature of the motor and bearing housing every 30 minutes;
c) When the temperature rise rate of the tested component does not exceed 2°C per hour, release the counter torque immediately, then press the wire feeding roller to feed the welding wire and measure the wire feeding speed value Wh at this time.
8.4.3 The cold and hot change rate of wire feeding speed is calculated according to formula (2): Aveh - [(ve --v)/h]X100%.
Where: Auth---
Cold and hot wire feeding speed change rate:
Wire feeding speed in cold state;
Wire feeding speed in hot state.
8.5 Determination of wire feeding speed change rate when the grid voltage fluctuates (2)
The device is disconnected from the welding gun hose. The test is conducted at three points where the grid voltage is 90%, 100% and 110% of the rated voltage, and the measurements are conducted in the following two states:
a) Maximum wire feeding speed and minimum wire diameter; h) Minimum wire feeding speed and maximum wire diameter. The rate of change of wire feeding speed when the grid voltage fluctuates is calculated according to formula (3): Auu=[(vu-Veu)/ve.J× 100%
Rate of wire feeding speed change;
Where; AU,---
.Wire feeding speed at rated voltage;
--Wire feeding speed at 90% or 110% of rated voltage. 8.6 Traction force measurement
8.6.1 Device state
The device is disconnected from the welding gun hose, and the measurement is conducted at the minimum wire feeding speed using the welding wire with the largest diameter. 8.6.2 Test method
(3)
The method is to use the device to lift the static load by hooking the wire feed wheel. During the measurement, an ammeter is connected to the armature circuit of the drive motor. When the static load applied makes the armature current reach its rated value, and the wire feed speed is uniform, and the welding wire does not slip or deform significantly, the load mass at this time is the traction force of the device.
8.7 Change rate of wire feed speed caused by traction force change 8.7.1 Test at the minimum and maximum wire feed speeds. At a given wire feed speed, the corresponding static loads are applied when 50% and 100% of the rated traction force are applied respectively, and the wire feed speed or roller speed is measured at different static loads.
8.7.2 The rate of change of wire feeding speed when the traction force changes shall be calculated according to (4): u, =[(u, - wet)/et]×100%
Wherein: u
The rate of change of wire feeding speed when the traction force changes; -100% of the rated traction force; Ve.
The wire feeding speed when the rated traction force is 50%.
8.8 The test methods for other items specified in this standard shall be carried out in accordance with the relevant provisions of GB15579 and GB/T8118. 9 Inspection rules
(4)
9.1 The device must be inspected and qualified by the inspection department before it can be shipped out of the factory. The device sold separately shall be accompanied by documents proving the quality of the device. 215
JB/T9533-—1999
Each device shall be subject to factory inspection. The inspection items and requirements are shown in Table 3.9.2
Table 3 Factory inspection items and requirements
Appearance inspection
Insulation resistance inspection
Dielectric strength
Operation test
Sealing test
Inspection items
Requirements
Compliance In line with 6.9;6.10;7.4;7.8;10.1;10.2In line with 7.6
In line with 7.7
In line with 6.3.7;6.7
In line with 6.4
Wire feeding speed adjustment range and indication accuracy
Complete set inspection
In line with 6.3.1,6.3.2,6.3.3
In line with 6.11;10.3.6
9.3 In any of the following cases, in addition to the inspection items listed in Table 3, the type inspection listed in Table 4 shall also be carried out. a) New products to be trial-produced; b) When there are major changes in the design, process or materials used; d) The factory inspection results of the device are not allowed to deviate from the previous type inspection results; e) Regular sampling inspection of mass-produced devices, no less than once every two years; f) When the national quality supervision agency proposes a type inspection requirement. Table 4 Type test items and requirements
Traction
Test items
Wire feeding speed stability test
a) Power grid fluctuation
b) Thermal stability
c) Traction force variation
Leakage current
Interchangeability
Enclosure protection
Type test, each test shall be conducted on no less than two devices Comply with 6.2
Comply with 6.3.4
Comply with 6.3.5
Comply with 6.3.6
Comply with 7.5
Requirements
Comply with 6.6;6.12;6.13
Comply with 6.8
Comply with 7.1
Each item of the type test shall comply with the requirements of this standard. If one or more indicators are unqualified, double the number of devices shall be sampled for retest. If there are still unqualified indicators, the device shall be considered unqualified. 10. Labels, signs, packaging, transportation and storage 10.1 Labels 10.1.1 The device shall be equipped with labels in obvious positions and fixed reliably. 10.1.2 The materials and writings of the labels shall not be easily erased during the entire service life of the device and shall comply with the provisions of relevant standards. 10.1.3 The items that should be marked on the sign are as follows: a) Name and trademark of the manufacturer (if there is a trademark); b) Name and model of the device,
c) Standard code;
d) Date of publication and number:
e) Wire feed speed range;
f) Wire diameter;
g) Input voltage and current;
JB/T9533—1999
h) Rated welding current (when welding current passes). 10.2 Marking
10.2.1 Parts that are linked to the device and power supply, control box, protective gas, etc. should be marked or described in words. 10.2.2 Each knob, switch, etc. should have words or symbols to indicate its operating function. 10.2.3 For parts that are only suitable for running in one direction of rotation, the direction of rotation should be indicated. 10.2.4 A grounding mark should be provided near the grounding device. 10.3 Packaging
10.3.1 The device can be packed with supporting equipment such as welding machines and power supplies, or it can be packed separately. 10.3.2 The device should be packed in a cover box and can be adapted to outdoor storage and transportation. 10.3.3 When packing the device and its accessories, spare parts, etc., anti-vibration measures should be taken and they should be firmly fixed to prevent damage or loss during transportation. 10.3.4 The outer wall of the device box should be marked with: a) the name and address of the manufacturer;
b) the name and address of the consignee;
c) the name, model, and factory number of the device; d) the net weight, gross weight, the outer dimensions of the wing box, and the words or signs such as "handle with care", "do not invert", and "moisture-proof". 10.3.5 The words on the packaging box should be guaranteed not to be blurred by sunlight or rain. 10.3.6 Technical data supplied with the device: a) Packing list; b) Device factory certificate; c) Device operating instructions. 10.4 Transportation and storage 10.4.1 All fasteners in the packaging box should be prevented from loosening or accidents during transportation. 10.4.2 The packaging box should be protected from rain and snow during transportation and storage. During long-term storage, the device should be stored in a warehouse with a relative humidity of no more than 85% and good air circulation. The storage environment temperature is -25℃ to 55℃. 217
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