Title: Carriage Control Settings
Course: WLDT 260 Welding Automation

Carriage Control Settings
Learning Objectives
Objective SCO 2759
Instructions
NOTE  -- DO NOT BEGIN THIS ASSIGNMENT UNTIL YOU HAVE COMPLETED ASSIGNMENT #2

First read all of the steps shown below, then follow the steps shown in the order given.
1. Retrieve your lab notebook.
2. Review, take complete notes and memorize on the information contained on the following pages.
3. Contact your instructor when you are ready to be tested on the above.

Safety RequirementsPersonal Protective Equipment (PPE) Requirements

The following personal protective equipment is required when operating the SWIC Longitudinal Seamer.
1. OSHA Approved Safety Glasses with Sideshields
2. Leather Work Boots
3. Weld shop appropriate full length work pants
4. Weld shop appropriate long sleeve work shirt
5. Welding helmet with a #10 shade lens or a full face shield appropriate for seamer welding with a #10 shade lens
6. Ear plugs (when sound levels are 85 decibels or above)
7. Work gloves (preferably thin gloves made for gas tungsten arc welding) Note: do not wear gloves when using pedestal grinder or around any moving parts where gloves may get caught and pull hands and fingers into pinch points

Pinch Points

The following is a list of potential pinch point areas of the SWIC Lontitudinal seamer. Keep yourself and others safe while operating the seamer by staying clear of these areas.
1. Between the carriage and the sidebeam
2. Between both the front and rear banks of fingers and the mandrel
3. Between the slide block and the slide base
4. Between the end latch and the mandrel
5. Between the torch and the mandrel or the weld piece
6. Between the torch and either end of the upper frame

Additional Safety Requirements
1. Follow all weld lab safety rules as posted upon entry into the weld lab
2. Follow all additional safety precautions as given by your instructor
3. If you feel unsafe at any time, or have any other safety concerns, safely stop what you are doing and tell your instructor
4. Always maintain an awareness of your surroundings and activities going on around you with safety in mind
5. Notify your instructor immediately if you or someone else is injured

Turning on the Seamer Carriage ControlWatch the following video.  It shows how to turn on seamer carriage control.

Programming the Seamer Carriage Control
Although many of the same types of carriage control settings are needed for operating seamers of different models and from different manufacturers, there are many different carriage controls found in industry.  Some are very simple with basic buttons, switches and potentiometers while others are very complex computerized systems.  The control on the external seamer used in this course is somewhere in between.  All of the typical requirements for an automated sequence are programmed into a small programmable logic control (PLC).  A full understanding of how to set the control for making automated sequence welds in this course should provide a good knowledge base for transferring to other seamer controls found in industry.

Once the seamer carriage control has been turned on, the PLC screen will come on.  This is where the settings for the automated sequence will be programmed.  The PLC used on the SWIC seamer has a touchscreen.  The following video shows how to scroll through the different items that can be set.  The following pages describe the different settings.

Weld Distance
This setting allows the weld distance to be programmed.  The setting can be either set to ON or OFF.  When set to ON the weld distance in inches can be programmed.  The programmed distance is how far the carriage will move from the time the weld starts until it goes into the travel stop delay setting.

Weld Time
As an alternative to setting the weld distance, the time of the weld can be set.  Thus, when the weld time is set it replaces the weld distance with a period of time that the carriage will move with the weld output on prior to any programmed travel stop delay.

Weld Direction
Weld direction sets the direction of the automatic sequence.  In the case of the seamer used in this course, Forward is from left to right, Reverse is from right to left.

Weld Pass CountThe control used on the seamer in this course is also compatable with sidebeam and carriages that are used in systems with equipment that rotates such as turning rolls, headstocks and positioners.  When used with this type of equipment for multipass welds the Weld Pass Count setting can be used to continue the weld for a certain number of passes.  It is typically set to the OFF positon for use with a seamer.

Travel Start / Stop DelayTravel Start Delay is typically used to delay the start of the travel so that the arc can be properly established prior to movement.

Travel Stop Delay is typically used to delay the stop of the travel.  This may be used so that the weld can go through downslope while the carriage is still moving or to pick up unused flux when using the submerged arc welding process.

Home Sequence

Home Sequence set to the ON position will tell the carriage to return to the home position which is set with the limit switch trip magnet.  NOTE:  When set to ON, the carriage will continue until the return home limit switch is tripped.  It is unsafe to set the home sequence to ON without having properly set the limit switch trip magnet.

Home Sequence set to the OFF position will tell the carriage control to sit at the end of the weld without returning home.

The Home Delay Time setting allows a time to be set that delays the carriage from returning home after the weld.

Torch Lift
Torch Lift allows the selection of either ON or OFF as well as Down Time, UP Delay and UP Time.

When the selection is ON the torch will raise at the end of the weld cycle at the end of the programmed UP Delay Time.

When the torch lift selection is OFF, the torch will remain in the lowered position until the torch up button is pressed.

The Down Time is a setting that allows a period of time to be set at the beginning of the weld cycle for the torch to reach the down position.

Up Delay is a period of time that the torch stays in the lowered position at the end of the weld cycle prior to raising.  This time may be set to allow the post gas flow to cover the weld until it cools enough that it will not be contaminated.

Up Time is a time setting following the Up Delay time.  It provides time for the torch to raise prior to the carriage returning home.  Note: If the torch up time is not set long enough, the carriage will begin to return home while the torch is still down or still raising.  This may not be desireable depending on the application and other programmed settings.

Unclamp
The Unclamp Auto setting allows the selection of either ON or OFF as well as Unclamp Delay and Unclamp Time

When the selection is ON the fingers will raise for the period of time set in the Unclamp Time setting following the period of time set under the Unclamp Delay time setting.

When the selection is OFF, the fingers will remain clamped until the unclamp footswitches are activated.

Jog SpeedThe Jog Speed screen allows the Jog Speed and the Rapid Speed to be set.

The Jog Speed setting is set as a percentage of the maximum available travel speed of the carriage.  It is the speed that the carriage will move when either the left or right arrow pushbuttons on the carriage control are held down with a single push.  When the pushbutton is released the travel will cease.

The Rapid Speed setting is set as a percentage of the maximum available travel speed of the carriage.  It is the speed that the carriage will move when either the left or right arrow pushbuttons on the carriage control are pushed twice in rapid succession.  When this occurs, even though the pushbutton is released, the carriage will continue to move at the set rapid speed until either the stop or E-Stop pushbuttons are pressed, an end of travel or home limit switch is activated, power to the control is lost or some mechanical crash occurs.  Note:  If a mechanical crash occurs, until power is removed, power will still be going to the carriage drive motor and trying to drive the carriage.