Insufficient Cooling

Definition

The coolant flow rate is below, or temperature is above, the nameplate rating for the resistance welding component.

Description

The cooling requirements of a resistance welding component are defined by rate, temperature, and sometimes direction.

• The minimum rate of the coolant flow is given on the nameplate of the component in either gpm (gallons per minute) or lpm (liters per minute).
• The maximum temperature for the coolant is given on the nameplate of the component.
• Certain components (e.g., tips) may require a specific coolant flow direction.

Detection

Detection evidence may include:

• Cracks and Holes
• Inconsistent Weld Quality
• Sticking/Stuck Tips
• Stuck Weld
• Undersized Weld
• Excessively high component temperatures (indicated by accelerated discoloration)
• Excessive tip wear

Significance

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

Maintenance: The life of components requiring coolant can be significantly reduced by the lack of cooling. Operating the component with insufficient cooling can damage or destroy it.

Subordinate Causes

• Plugged filters in cooling system
• Failed in cooling system flow valves
• Inadequate flow rates or pressure in series/parallel components within the cooling system
• Buildup of deposits within the cooling path