Wrong Cables/Shunts

Definition 


The weld is not correctly made due to the use of an incorrect cable or shunt.

Description 


Cross Sectional Area: 

• Too small: Current flow is restricted due to the increase in impedance. 
• Too large: Conductor stiffness can cause problems in properly locating equipment; premature wear to the machine components; or achieving weld force. 

Conductor Length: 

• Too long: Current flow is restricted due to the increase in impedance; proper weld placement can be hindered by cable drag and entanglement; short circuits may result from the above conditions. 
• Too short: Inadequate length can cause problems in properly locating equipment; premature wear to machine components; or achieving required weld force.

Detection 


Detection evidence may include: 

• Inconsistent Weld Quality
• Mislocated/Edge Weld
• Missing Weld
• Nonround Weld
• Poor Class A Appearance
• Sheet Metal Distortion
• Sticking/Stuck Tips
• Stuck Weld
• Undersized Weld
• Burns and sparks on equipment suggesting short circuits
• Excessive manual effort to position equipment

Significance 


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

Quality: Cables that are improperly sized can cause variations in welds from operator to operator in manual operations. 

Subordinate Causes

• Correct conductor not immediately available. 
• Increase in jobs per hour, weld current, or weld time requirements.