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tions. Waveform Control Technology® is
Lincoln’s proprietary welding software
platform that controls and shapes the
welding output waveform. Since the
waveform is shaped digitally using
software with an inverter-based Power
Wave® welder, optimized results are
delivered accounting for a specific
material type and thickness, electrode
wire type and diameter, shielding gas
mix and other variables.
In the case of Valley Industries, the
material is typically mild steel ranging
in thickness from 16
gauge to 1-inch. The
Power Wave welding
power source delivers
conventional MIG
welding procedures
as well as Pulsed MIG
welding procedures
for more difficult joint
configurations when
controlling heat input
to minimize distortion
is especially critical.
“The Power Waves
produce a very
consistent, stable arc
and deliver improved
deposition rates. With
automation, faster travel
speeds can be more
easily accomplished
than with manual or semiautomatic
welding,” said Ownbey. “We are able to
manipulate arc characteristics, resulting
in a weld bead that is more uniform in
appearance. We also experience far less
spatter. Because these power sources
create high quality welds, we are able
to go directly to the paint stage of our
processing, without having to do any
grinding or finish work on the welds.”
Valley Industries also uses the real-time
Production Monitoring™ capabilities of
the Lincoln Power Wave power sources
to monitor arc current, voltage and wire
feed speed. Technicians and operators
review the information to assist in
refining weld programs and to identify
and correct problems. As an added
bonus, Ownbey reports the Power
Wave 455M units are very durable in
an inherently dirty environment for
electronics.
Hitch and Towing Components
Valley Industries’ trailer hitches require
an average of 16 welds per unit. Most of
the components are plate and round or
square tubing requiring single pass fillet
joint welds that range from 1/2-inch to
12-inches in length. On average, nine
component parts are loaded into the
work cell fixturing to complete a typical
hitch.
Demand and volume dictate which parts
are welded robotically versus those
completed by manual or semiautomatic
welding. The robots at Valley Industries
are currently running 24 hours a day, 6
days a week to keep up with the
demand. Automation allows the 250-
employee company to produce smaller
batches of parts with greater speed.
All new products are tested using the
transportation industry standard SAE J-
684 test (more commonly known as the
V-5 test) which simulates thousands of
miles of towing under extreme
conditions. “We take much care in the
design stage to ensure the safety of our
products, especially since most of them
will be used to tow recreational and
commercial trailers at highway speeds.
The consistent performance and weld
quality of automated welding are
naturally an enhancement in this area.”
said Ownbey.
According to Ownbey, because the
robotic weld sequence and weld joint
locations are
programmed, the same
exact process is re-
peated time after time.
This makes control of
distortion within the
welded assembly very
manageable compared
to hand welding.
Engineering tolerances
become less of a
challenge, manu-
facturing costs are
reduced, and more
options are realized
in product design.
In tandem with the
Lincoln Automation
system, Valley Industries
is utilizing .045-inch
diameter Lincoln
SuperArc® L-50 MIG wire with a 92%
Argon / 8% CO
2
shielding gas blend.
The wire is supplied in 1,000-pound
Accu-Trak® drums, which according
to Ownbey, are delivering consistent
performance and are quick to set up.
“The L-50 is the highest quality welding
wire I have used in my 27 years in
manufacturing. Lincoln wire has a
distinct advantage in automation
applications, because it is clean and
very stiff. The copper coating doesn’t
flake, and it comes out of the container
straight. Arc starts are more consistent
and overall feeding problems are
minimal.”
Lincoln Service
“Our experience with Lincoln service has
been excellent. Technicians in Cleveland,
Ohio, are available by phone and often
Valley Industries
Automation
“The Power Waves produce
a very consistent, stable arc
and deliver improved
deposition rates.”
Pulsed GMAW
WAVEFORM CONTROL TECHNOLOGY
®