Incorrect Cylinder

Definition

The weld cylinder will not provide the proper range of electrode force or motion.

Description

The weld cylinder serves two primary functions: 

1. The cylinder stroke separates the electrodes to allow part access 
2. The cylinder closes the electrodes on the workpiece to provide the required welding force 

The following is a basic list of cylinder characteristics which must be considered for proper equipment function: bore, stroke, single or dual action, type (air, hydraulic, or hybrid), seal type, shaft length, overall length, mounting details, cushions, etc.

Detection

Detectable evidence may include: 

• Cracks and Holes
• Excessive Indentation
• Expulsion/Burn Through
• Inconsistent Weld Quality
• Nonround Weld
• Poor Class A Appearance
• Sticking/Stuck Tips
• Stuck Weld
• Undersized Weld
• Gun will not completely close
• Incorrect force
• Off-location welds
• Part access difficulties
• Short cylinder life
• Short electrode life
• Visual inspection

Significance

Quality, Workplace Issues, Cost, Downtime, Maintenance, Throughput (cycle time; PPH), are all potentially affected by this condition.

Subordinate Causes

• Correct cylinder unavailable 
• Improper maintenance 
• Incorrect nameplate 
• Incorrect rework 

Notes

Similar considerations may be applied to servo motor systems.