The weld is not correctly made due to the use of an incorrect cable or shunt.
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.
- 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 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
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.
- Correct conductor not immediately available.
- Increase in jobs per hour, weld current, or weld time requirements.