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