Digital Inverter Controlled Welding

Power Source for MOTOMAN

MOTOWELD-RL350
Application: Arc Welding
Manipulator: MOTOMAN-VA1400, -MA1400,
-MA1900, -MH6, -HP20D
 V2h
Droplet Vector Control V2h
Variable Pulse Control
Function 1 Function 2

Droplet vector control greatly improves For pulsed arc welding, a variable pulse
previously unstable CO2 welding ! control that optimizes waveform according to
Spatter is reduced, so a beautiful flat finish the welding conditions has been developed.
is achieved. Droplet transfer is stable even at low voltage.

Significant reduction
in spatter generation!
Advanced arc-welding technologies

V2h
Heat and Waveform Control Improved Reliability and
Maintainability
Function 3

The new Heat and Waveform Control (HAWC)
corrects the instructed current and voltage
values in real time !
HAWC prevents welding defects that arise as
a result of variations in workpiece accuracy
and teaching accuracy, and improves
productivity.
This welding power source has improved
reliability and maintainability in all kinds
of environments by improving the internal
structure of the unit and adopting digital
communications.

MOTOWELD-RL350
establishes a new era for arc welding.
Applicable Manipulator Lineup

Models optimized for arc welding General-purpose models

Manipulators

MOTOMAN- VA1400 MA1400 MA1900 MH6 HP20D

2
Droplet Vector Control
d- ector
Conventional method of CO2 welding
Compared to MAG welding, the conventional method of CO2 welding tended to be unstable and a lot of spatter was generated.
This is because, compared to MAG, CO2 is characterized by a greater tendency for the reaction force of the arc to become
concentrated, which lifts the droplet up and causes it to waver. The figure below shows the cause of welding instability.

The reaction force of the arc causes the droplet

to waver.
The reaction force of the arc concentrates and
the droplet is lifted.
The droplet is thrown upward, generating spatter.
The arc regenerates.

What is droplet vector control ?

Droplet vector control adjusts the current and voltage to generate an originally-developed waveform that makes it
possible to achieve stable CO2 welding.
It reduces spatter when compared with conventional technology and enables welding with a beautiful flat finish.

POINT The directivity of the arc has been improved by gradually raising the welding current.
1 Stable welding becomes possible, and spatter is reduced.

A waveform that maintains a short arc length by smoothly changing the current
POINT has been developed.
2 Spatter is reduced because building of the droplet is suppressed,
making it less susceptible to the reactive force of the arc.
Conventional waveform
Test Current: 150 A, Voltage: 16.3 V, Robot speed: 80 cm/min
Details Shielding gas: 100% CO2 used

POINT
POINT 2
1
【 Conventional welding method 】 【 New welding method (with droplet vector control) 】

With the conventional welding method, the bead sometimes falls into disorder because the arc
Welding is unstable.
New waveform Results With the new welding method including droplet vector control, stable welding is possible so the
bead doesn t fall into disorder and a beautiful flat finish can be achieved.

Comparison of Spatter Generation Conventional model MOTOWELD-RL350

Current 150 A 180 A 200 A

4
Spatter generation (g)

Reduc
ed by
Conventional model 3 65%
Reduc
ed by
57% Reduc
ed by
Spatter generation 0.565 g 1.224 g 4.301 g 2 80%

MOTOWELD-RL350 1
(with droplet vector
control)
0
150 A 180 A 200 A
Spatter generation 0.242 g 0.431 g 0.873 g Welding current

3
 Variable Pulse Control
-P
Pulse
What is variable pulse control ?
Conventionally, decreasing the voltage during welding to avoid burn-through and undercutting has resulted in
unstable welding accompanied by the generation of large amounts of spatter.
Variable pulse control changes the waveform according to the welding status from high to low voltages, achieving
stable welding with little spatter.

Test The appearance of the welding bead was checked by actually welding underbody parts.
Details Shielding gas: MAG Welding conditions: 170 A, 23 V, Robot speed 90 cm/min

Workpiece / Weld line

Welding New method

Conventional method
Results (with variable pulse control)

In the conventional method, In the new method ( with variable

there was some distortion in pulse control ) , the bead has a
the appearance of the bead beautiful flat finish after welding,
after welding, as shown in the as shown in the photograph at the
photograph at the top to the top to the right. We can also see
right. from the photograph at the right
In addition, a lot of spatter was that there is a substantial reduction
generated during welding, as in spatter when compared with the
shown in the photograph conventional method.
at the right.

Enlarged view Enlarged view

Comparison of Spatter Generation Conventional model

MOTOWELD-RL350

Robot speed 80 cm/min 80 cm/min 80 cm/min 80 cm/min 80 cm/min 0.5

Reduc
Current 175 A 175 A 175 A 175 A 175 A ed by

Voltage 22 V 23 V 24 V 25 V 26 V
65%
0.4
Spatter generation (g)

Conventional
0.3
model

Reduc
Spatter generation 0.40 g 0.11 g 0.06 g 0.04 g 0.02 g 0.2 ed by
45%
MOTOWELD-
RL350 0.1
(with variable
pulse control)
0.0
22 V 23 V 24 V 25 V 26 V
Spatter generation 0.14 g 0.06 g 0.04 g 0.03 g 0.02 g
Instructed voltage

4
Heat and Waveform Control
AWC
What is the HAWC (Heat And Waveform Control) function ?
The wire extension (distance between the contact tip and the workpiece) might change according to the workpiece
accuracy and the teaching accuracy. With conventional equipment the execution current fluctuated due to the
changing length of the wire extension, and this caused burn-through and poor penetration.
When the HAWC function is used, the actually applied current and voltage values are fed back to the instructed
current and voltage in real time to keep the heat input constant, preventing poor welds.

Change in wire Change in wire extension

extension due to due to deformation
defective teaching of the workpiece

Tip position

Without HAWC
Actual
(conventional method) current
Actual current changes Actual current changes

Actual
With HAWC current

Arc start position The instruction value is adjusted when the actual current starts Arc end position
changing to control the actual current (heat input) at a constant value.

The difference in the welding results with and without the HAWC function was checked while changing the wire extension
Test
from 15 mm to 10 mm and back to 15 mm during welding.
Details
Workpiece thickness: 4.5 mm Joint type: Butt joint Welding conditions: 270 A, 26 V, Robot speed 90 cm/min

Welding
Results Without HAWC Burn - through has occurred in the
(conventional method) section with a wire extension of 10 mm.

The influence by the change in the wire

With HAWC extension is not seen.

Wire extension: 15 mm Wire extension: 10 mm Wire extension: 15 mm

Seam welding (at a butt joint) of the pipe of 5 mm in thickness was carried out while changing the wire extension.
Test
(15 mm to 10 mm to 15 mm)
Details
Shielding gas: MAG Welding conditions: 200 A, 19.7 V, Robot speed 60 cm/min

Welding Wire extension: 15 mm Wire extension: 10 mm Wire extension: 15 mm

Results
Macro picture
without HAWC
Start Bead appearance without HAWC End

Penetration is unstable.
Wire extension: 15 mm Wire extension: 10 mm Wire extension: 15 mm

Bead appearance with HAWC Macro picture

with HAWC
Wire extension: Wire extension: Wire extension:
15 mm 10 mm 15 mm
Penetration is constant.

5
 Improved Reliability and Maintainability

Ease of use and

Conventional smooth
method setting
of CO with the digital communication function !
2 welding

Settings and operations of the welding power source and data management are handled by the robot controller
through the digital interface using the WELDCOM function.
This enables centralized control of welding data, which has cut the operation man-hours while also greatly
improving reliability and maintainability.

Digital communication
(bidirectional)

・Detailed welding power source settings are

possible.
・The welding power source settings can be
backed up in an external memory device.
・Settings saved for other equipment can be
transferred to and set in other welding power
supplies.
・When replacing the welding power source, the
previous settings can be transferred to the new MOTOWELD-RL350
DX100 robot controller
power source. welding power source

Easy internal maintenance, inspection and repairs !

Modularized
inverter circuits

The welding power source can

be maintained and inspected
where it is installed, without
moving it.
Changing power source units on
e.g. the deck floor of a facility,
which has been a difficult job
until now, can be accomplished
Internal maintenance
using much fewer man-hours.
(control section, right side,
left side)

Exterior panels can be removed

more easily than on previous units.
Simple monitor
The number of fixing screws
with high visibility
has been reduced by more than
50%, reducing the working time
taken up by inspection and
maintenance.

6
 Reinforcement of the Cooling / Dustproofing Systems
The interior of the unit has been divided up into sections to prevent dust getting into the control and power circuits,
improving reliability in adverse environments with conditions like high temperatures or dust.
This is combined with a new construction that features channels providing a cooling airflow in the center of the unit
and concentrates the heat-generating parts on the cooled faces, so cooling efficiency is maximized while ensuring
dustproofing. The number of exhaust routes has been increased too, giving 20% better suppression of temperature
rise than previous units.
Temperature of
Internal Structure of the MOTOWELD-RL350 heat-generating parts
(Compared to previous units)
Control section

20%
Co

DOWN !
oli
n

a ir
g

flo
w
Co
o li
ng
a ir
flow

Back Front

Secondary side Primary side

Dimensions Units: mm

Top
576.4

22.0 518.2

371.0 44.1
38.0

)
)
Interface For Robot(Analog) For Push Motor Interface For Robot (Digital)
CON 8
Voltage Sensing
V A m/min Type
SW1

TM1
P % Output
Terminal
Base
Metal

C + CON 3
CON CON 6
A V
L R
_

MOTOWELD
547.2
635.3

ON

OFF

AC200V/220V

1203809120001

AA
7.0

64.2
55.0

40.0 28.0
264.0
10.0 400.0 112.2
355.0
43.7 Back
488.0

Left side Front Right side

7
MOTOWELD-RL350

Ratings and Specifications

Welding Power Source Model YWE-RL350-AJ0
200−220 VAC ±10% / 380−400 VAC ±10%, three phases
Rated Input Voltage, Number of Phases (Changing the input voltage requires changes to the internal wiring.)
Setting on shipment: 380−400 VAC
Rated Frequency 50 / 60 Hz
Rated Input 18 kVA, 15 kW
Rated Output Current 30−350 A (Depending on wire diameter)
Rated Output Voltage 12−36 V (Depending on wire diameter)
Rated Operation Rate 60% (for 10 minutes)
Welding Method CO2/MAG/MIG/pulsed arc welding
Welding Material Iron, stainless steel
371 (W)×636 (D)×602 (H) mm
Dimensions
(not including projecting parts such as eyebolts or screws)
Approx. Mass 60 kg

Sales Department YASKAWA India Private Ltd. (Robotics Division)

#426, Udyog Vihar Phase-IV, Gurgaon, Haryana, India
HEAD OFFICE Phone: +91-124-475-8500 Fax: +91-124-475-8542
2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyushu, Fukuoka 806-0004, Japan
Phone: +81-93-645-7745 Fax: +81-93-645-7746 YASKAWA Electric Korea Co., Ltd
9F, Kyobo Securities Bldg., 26-4, Yeouido-dong, Yeongdeungpo-gu, Seoul 150-737, Korea
YASKAWA America, Inc. (Motoman Robotics Division) Phone: +82-2-784-7844 Fax: +82-2-784-8495
100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone: +1-937-847-6200 Fax: +1-937-847-6277 YASKAWA Electric Taiwan Corporation
9F, 16, Nanking E. Rd., Sec. 3, Taipei, 104 Taiwan
YASKAWA Europe GmbH (Robotics Division) Phone: +886-2-2502-5003 Fax: +886-2-2505-1280
Yaskawastrasse 1, 85391, Allershausen, Germany
Phone: +49-8166-90-100 Fax: +49-8166-90-103 YASKAWA Electric (Singapore) PTE Ltd
151 Lorong Chuan, #04-02A New Tech Park, Singapore 556741
YASKAWA Nordic AB Phone: +65-6282-3003 Fax: +65-6289-3003
Bredbandet 1vån. 3 varvsholmen 392 30 Kalmar, Sweden
Phone: +46-480-417-800 Fax: +46-480-417-999 YASKAWA Electric (Thailand) Co., Ltd.
252/125-126 27th Floor, Tower B Muang Thai-Phatra Complex Building,
YASKAWA Electric (China) Co., Ltd. Rachadaphisek Road, Huaykwang, Bangkok 10320, Thailand
12F, Carlton Bldg., No.21 HuangHe Road, HuangPu District, Shanghai 200003, China Phone: +66-2693-2200 Fax: +66-2693-4200
Phone: +86-21-5385-2200 Fax: +86-21-5385-3299
PT. YASKAWA Electric Indonesia
YASKAWA SHOUGANG ROBOT CO., LTD. Menara Anugrah Lantai 1 , Kantor Taman E.3.3, Jl. Mega Kuningan Lot 8.6-8.7, Kawasan
No.7 Yongchang North Road, Beijing E&T Development Area China 100176 Mega Kuningan, Jakarta, Indonesia
Phone: +86-10-6788-2858 Fax: +86-10-6788-2878 Phone: +62-21-57941845 Fax: +62-21-57941843

YASKAWA ELECTRIC CORPORATION

In the event that the end user of this product is to be the military and said product is to be
employed in any weapons systems or the manufacture thereof, the export will fall under the
relevant regulations as stipulated in the Foreign Exchange and Foreign Trade Regulations.
Therefore, be sure to follow all procedures and submit all relevant documentation according
to any and all rules, regulations and laws that may apply.
Specifications are subject to change without notice
LITERATURE NO. KAEP C940550 00A
for ongoing product modifications and improvements. Published in Japan January 2013 13-1
© 2013 YASKAWA ELECTRIC CORPORATION. All rights reserved. 13-1-33