An electric welder works by creating a high-temperature arc between the positive and negative poles during an instantaneous short circuit. This arc melts both the solder and the material being welded, allowing them to fuse together. The basic design is quite simple—it’s essentially a high-power transformer. Welding machines can be categorized into two types based on their power output: AC (alternating current) and DC (direct current). They operate using the principle of inductance. When the inductor is turned on and off, a large voltage fluctuation occurs, which creates the high-voltage arc needed for welding. This arc is crucial for melting the electrode and achieving a strong bond. Proper maintenance of the welding machine is essential to ensure safe and efficient operation.
Daily maintenance tips for welding machines:
1. Ensure the welder’s output wiring is correctly specified, securely connected, and oriented vertically with an angle greater than 70° from the horizontal.
2. Inspect the screw fastenings at the cable connections. Use hex bolts M10×30, and make sure the flat and spring washers are complete, free from rust and oxidation.
3. Verify that the exposed length of the wire is less than 10mm.
4. Confirm that the welder’s casing is properly grounded.
5. Check the power supply connection and ensure the base metal is well grounded and meets the required specifications.
6. Make sure the cable connections are insulated properly and taped if necessary.
7. Examine the shielding on the power cable, welding cable, and internal wiring for any damage or wear.
8. Test the cooling fan to ensure it rotates smoothly and operates normally.
9. Inspect the power switch, indicator lights, and adjustment knob. Ensure the ammeter and voltmeter pointers move freely and are accurate. Check that the panel is intact and free from cracks, and that the switch functions properly.
10. Check for COâ‚‚ gas leaks in the system.
11. Inspect the welder’s overall condition for any serious deformation or damage.
12. Ensure the hexagonal socket head screws at the connection between the COâ‚‚ welding gun and the wire feeder are tight, and check that the welding torch is not loose.
13. Confirm that the cables and air hoses on the COâ‚‚ wire feeder are properly wrapped and secured.
14. Check the correction wheel and wire feed wheel on the COâ‚‚ wire feeder for wear and replace them when necessary.
15. Ensure the motor is firmly fixed and the insulation coil is in good condition.
16. Check the remote control box on the COâ‚‚ wire feeder for any looseness or damage.
17. When installing the COâ‚‚ welding torch, secure the switch plug and insert it into the guide groove. After installation, tighten the fastening screw to ensure stability.
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