Capstan Wire Feeder and Control - semirca, ca

WF-100Wire Feed SystemAdd-On Capstan Wire Feed SystemThe Thermal Arc WF-100 Cold Wire Capstan Feeder is a compact, lightweight, precisionwire feeder for robotic or automation fixture applications. The Capstan's small size andlightweight (less than 6lbs.) allows the wire feeder to be placed directly on the automatedfixture or robot wrist. The Capstan also provides an increase in wire drive contact area bywrapping the wire around the wire drive wheel.This wire drive method has three major benefits:- Plastic deforms the filler wire, virtually eliminating wire cast.- Increased drive force eliminates wire slip, flattening and damage to wire surface.- Integral wire straightener on the discharge side of the feeder allows the WIre Driveto precisely locate the filler wire independent of wire cast.MARKETS- Aerospace/Aircraft- Automotive- Robotics- Automated Welding Systems IntegratorsThe WF-100 Capstan Feeder is designed for the WC-1 Weld Process Controller

Ordering InformationDescriptionPLASMA WELDING SYSTEM CONFIGURATION......................................................................................1WF-100 CAPSTAN WIRE FEEDER ............................................................................................................3SYSTEM DESCRIPTION ......................................................................................................................3DRIVE TYPES .......................................................................................................................................4PRODUCT MANUALS...........................................................................................................................4FILLER WIRE SPECIFICATIONS .........................................................................................................40.030” to 0.052” STEEL ALLOY WIRE CONFIGURATIONS................................................................5CAPSTAN DRIVE TORCH BRACKET ASSEMBLY ...................................................................................7ADJUSTABLE ROBOTIC MOUNT ASSEMBLY .........................................................................................8PIVOT LINK ARM .........................................................................................................................................9LINER/CASING RETAINER .........................................................................................................................9WIRE SPOOL ASSEMBLY.........................................................................................................................10WIRE SPOOL LINER ASSEMBLIES .........................................................................................................11ARTICULATOR LINER AND CASING.......................................................................................................12COLD WIRE PLASMA TORCH ARTICULATOR ASSEMBLY..................................................................13CONTACT TIPS..........................................................................................................................................15Page

Capstan Wire Feeder and ControlParts ListPLASMA WELDING SYSTEM CONFIGURATIONThese illustrations indicate the standard equipment required for a Plasma welding configuration.Wire Spool Liner Assembly(See Page 17)Wire Spool AssemblyP/N: S2A5001(See Page 10)Capstan WireFeeder Mounting(See Next Page)1-3/8” AdjustableArticulator AssemblyP/N: E2A5194(See Page 13)Contact Tips(See Page 15)Articulator Liner and Casing(See Page 12)Plasma Welding Wire Feed System ConfigurationEffective 06-01-02Page 1

Capstan Wire Feeder and ControlParts ListCapstan Wire Feeder(See Page 3)Adjustable RoboticMount Assembly(See Page 8)Torch Bracket AssemblyP/N: E2A5190(See Page 7)Liner/Casing RetainerP/N: S2A5002(See Page 9)Pivot Link ArmP/N: E2M5816(See Page 9)Capstan Wire Feeder MountingEffective 06-01-02Page 2

Capstan Wire Feeder and ControlParts ListWF-100 CAPSTAN WIRE FEEDERSYSTEM DESCRIPTIONThe Capstan Wire Feeder is a compact, lightweightprecision wire feeder for robotic or automated fixtureapplications. This product was introduced in 1989.Industry analysts project dramatic growth in the use ofrobots for arc welding in future years. In a random surveyby an independent consultant 21 out of 55 people interviewedhad robotic or fully auotmated welding operations and 12people out of 21 who did have robotoc or auotmated weldingoperations experienced problems with feeding welding wire.Major problems cited were wire cast, helix, and wire feedspeed control.The Capstan's small size and light weight (less than 6 lbs.)allows the wire feeder to be placed directly on the automated fixture or robot wrist, The Capstanalso provides an increase in wire drive contact area by wrapping the wire around the wire drive wheel.This wire drive method has three major benefits:Plastic deforms the filler wire, virtually eliminating existing wire cast.Increased drive force eliminates wire slip, flattening and damage to wire surface.Integral wire straightener on the discharge side of the feeder allows the Wire Drive to preciselylocate the filler wire independent of wire cast.The WF-100 Capstan wire feed drive can be used with the WC-1 Thermal Arc Process ControllerMARKETSAerospace/AircraftAutomotiveAutomotive Satellite IndustriesOEM's - Arc Welding RobotsAutomated Welding Systems IntegratorsADVANTAGES OVER COMPETITIONWire feed speed accuracyBroad dynamic rangeBetter/more versatile controlBetter control over wire position in the weld jointAbility to mount on robot armCompetitive priceProcess versatility (GTAW, PAW)Effective 06-01-02Page 3

Capstan Wire Feeder and ControlParts ListDRIVE TYPESThe WF-100 Capstan Wire Drive can be purchased in various configurations as follows:PART NO.E2A5099DESCRIPTIONWF-100 PWM Drive with 9 CM MotorWire Feed Range: 10 - 625 IPM (4-265 mm/s)Motor Full Load Pull Capacity: 20 LBS (9 kg)Operation / Installation ManualNote: WF-100 Drives are not equipped with any specific wire component parts. Specific wire kits must beordered separately for each wire diameter and filler wire material.Interface Control Circuit for WC-1 Process ControllerPART NO.C3A5005DESCRIPTIONInterface Control Circuit (Includes Wire Feed Printed Circuit Board)Note: Must be ordered when using WC-1 Process ControllerFILLER WIRE SPECIFICATIONSThe WF-100 requires different component parts for each diameter of filler wire used. Refer to nextsections to select the correct drive wheel and inlet wire guide for the wire diameter and filler wire materialrequired. There are four primary configurations for the WF-100.1. 0.030” to 0.052” Steel Alloy Wire Configuration2. 0.030” to 0.062” Aluminum Wire Pick-up Block Configuration3. 0.030” to 0.052” Aluminum Wire Straightener Configuration4. 0.062” Aluminum Wire Straightener ConfigurationEffective 06-01-02Page 4

Capstan Wire Feeder and ControlParts List0.030” to 0.052” STEEL ALLOY WIRE CONFIGURATIONSWhen using a 0.030” to 0.052” steel alloy filler wire with the capstan, a Steel Alloy Wire Kit specificallymade for each size wire must be installed on the capstan. All parts that are wire size specific in these kitsare marked with color codes to prevent mixing incompatible parts. Figure 1 shows all the parts that areincluded in these kits. The capstan drive is not part of these kits.CONFIGURATION KITSWIRE SIZE COLOR CODES PART NO.0.030” (0.8mm) White E2A51640.035” (0.9mm) Red E2A51650.040” (1.0mm) Gold E2A51660.045” (1.1mm) Yellow E2A51670.047” (1.2mm) Yellow E2A51670.052” (1.3mm) Blue E2A5168COMPONENT PARTSThe drawing below shows the location of the common and wire specific parts that are included in the Steel AlloyWire Kits.Wire Feed Cover (not included in kits)6-32 x 1/4 Lg. Socket Head Cap Screw4 PlacesCapstan Wheel (see next page)10-32 x 3/4 Lg. Button Hd Screw6-32 x 3/4 Lg. Button Hd Screw2 PlacesStripper Cover P/N: E2M5592Bearing P/N: X2B0373Stripper Bearing SpacerP/N: E2M5590Stripper P/N: E2M5593Cam Follower P/N: X2B5028#10 Internal Lock Washer8-32 x 3/16 Lg. Sckt. Set ScrewO-Ring P/N: X4S5010Wire Out Guide P/N: E2M5594Hex Fitting P/N: X6F5061Torch Liner (see next page)Liner - 1' Long P/N: X7C5033Inlet Wire Guide (see next page)Spring P/N: X2N5003Standard Hand Capstan Drive(not included in kits)Figure 1: Steel Alloy Wire Component PartsEffective 06-01-02Page 5

Capstan Wire Feeder and Control0.030” to 0.052” STEEL ALLOY WIRE CONFIGURATIONSPART NO.E2M5583E2M5157E2M5633E2M5156E2M5584E2M5616E2M5617E2M5634E2M5619E2M5620E7C5001E7C5002E2M5590E2M5592E2M5593E2M5594X2B0373X2B5028X2N5003X4S5010X6F5061X7C5033DESCRIPTIONCapstan Wheel for 0.030" (0.8mm) WireCapstan Wheel for 0.035" (0.9 mm) WireCapstan Wheel for 0.040" (1.0 mm) WireCapstan Wheel for 0.045" (1.1 mm) and 0.047" (1.2 mm) WireCapstan Wheel for 0.052" (1.3 mm) WireInlet Wire Guide for 0.030" (0.8 mm) WireInlet Wire Guide for 0.035" (0.9 mm) WireInlet Wire Guide for 0.040" (1.0 mm) WireInlet Wire Guide for 0.045" (1.1 mm) and 0.047" (1.2 mm) WireInlet Wire Guide for 0.052" (1.3 mm) WireTorch Liner for 0.030" (0.8 mm) Wire to 0.047" (1.2 mm) WireTorch Liner for 0.052" (1.3 mm) WireStripper Bearing SpacerStripper CoverStripperWire Out GuideBearingCam FollowerPressure Roller Shoe SpringO-RingHex FittingLiner, 1 foot longEffective 06-01-02Page 6

Capstan Wire Feeder and ControlParts ListCAPSTAN DRIVE TORCH BRACKET ASSEMBLYBracket Assembly is required to install our Articulator Liner and Casing onto the Capstan Drive.It includes a quick disconnect fitting for easy installation of welding wire liner.ASSEMBLIESPART NO.E2A5190DESCRIPTIONCapstan Drive Torch Bracket AssemblyE2M5810X6F5090E2M5813COMPONENT PARTSPART NO.E2M5813E2M5810X6F5090Capstan Drive Torch BracketInsulating BlockQuick Disconnect FittingDESCRIPTIONEffective 06-01-02Page 7

Capstan Wire Feeder and ControlParts ListADJUSTABLE ROBOTIC MOUNT ASSEMBLYRobotic Mount can be installed onto Capstan with or without the Torch Bracket installed. Also, it can beinstalled on either side of Capstan.ASSEMBLIESPART NO.E2M5646E2A5120DESCRIPTIONAdjustable Robotic Mount Assembly for Right Side MountingAdjustable Robotic Mount Assembly for Left Side MountingE2M5710E2M5711Right Side MountingLeft Side MountingCOMPONENT PARTSPART NO.E2M5710E2M5711Bracket BaseBracket ArmDESCRIPTIONNote: Both right and left side mountings use the same component parts.Effective 06-01-02Page 8

PIVOT LINK ARMCapstan Wire Feeder and ControlParts ListPivot Link Arm operates with the Robotic Mount to make pivot adjusts for the Capstan Wire Feeder. TheArm has five mounting holes for installation onto your fixture.ASSEMBLIESPART NO.E2M5816Pivot Link ArmDESCRIPTIONLINER/CASING RETAINERThis retainer is an inexpensive way to capture welding wire liner and casing.ASSEMBLIESPART NO.S2A5002Casing/Liner RetainerDESCRIPTIONEffective 06-01-02Page 9

WIRE SPOOL ASSEMBLYCapstan Wire Feeder and ControlParts ListThis assembly will accommodate a 12” diameter welding wire spool. It issupplied with a quick disconnect fitting for easy installation of welding wireliner and casing.ASSEMBLIESPART NO.S2A5001Wire Spool AssemblyDESCRIPTIONCOMPONENT PARTSPART NO.S2M5027S2M5028S2M5029S2M5177X6Z5053X6F5090X6F5105DESCRIPTIONWire Spool StandWire Spool ArmWire Spool CoverWire Spool Shaft BracketSpool Holder AssemblyFemale Quick Disconnect Fitting¼” NPT Female x ½” NPT Male PVC Schedule 80 BushingEffective 06-01-02Page 10

Capstan Wire Feeder and ControlParts ListWIRE SPOOL LINER ASSEMBLIESOur Wire Spool Liner Assemblies are supplied in 10’ and 15’ lengths for both steel alloy and aluminumwire. They are supplied with quick disconnect fittings for ease of installation to Wire Spool Assembly andCapstan Wire Feeder.ASSEMBLIESPART NO.E7A5001E7A5002E7A5003E7A5004E7A5005E7A5006E7A5007E7A5008E7A5009E7A5010DESCRIPTION10’ Long Assembly for 0.030” – 0.047” Steel Alloy Wire15’ Long Assembly for 0.030” – 0.047” Steel Alloy Wire10’ Long Assembly for 0.052” – 0.062” Steel Alloy Wire15’ Long Assembly for 0.052” – 0.062” Steel Alloy Wire10’ Long Assembly for 0.030” – 0.035” Aluminum Wire15’ Long Assembly for 0.030” – 0.035” Aluminum Wire10’ Long Assembly for 0.040” – 0.052” Aluminum Wire15’ Long Assembly for 0.040” – 0.052” Aluminum Wire10’ Long Assembly for 0.062” Aluminum Wire15’ Long Assembly for 0.062” Aluminum Wire10’ or 15’QD FittingP/N: X6F5102Tube FittingP/N: X6F5104LinerCasingTube FittingP/N: X6F5104Modified QD FittingP/N: E2M5824LinerCOMPONENT PARTSPART NO.E7C5007E7C5008E7C5009E7C5010E7C5011E7C5012E7C5013E7C5014E7C5015E7C5016E7C5017E7C5018X6F5104E2M5824X6F5102DESCRIPTION10’ Long Liner for 0.030” – 0.047” Steel Alloy Wire15’ Long Liner for 0.030” – 0.047” Steel Alloy Wire10’ Long Liner for 0.052” Steel Alloy Wire15’ Long Liner for 0.052” Steel Alloy Wire10’ Long Liner for 0.030” – 0.035” Aluminum Wire15’ Long Liner for 0.030” – 0.035” Aluminum Wire10’ Long Liner for 0.040” – 0.052” Aluminum Wire15’ Long Liner for 0.040” – 0.052” Aluminum Wire10’ Long Liner for 0.062” Aluminum Wire15’ Long Liner for 0.062” Aluminum Wire10’ Long Liner Casing15’ Long Liner CasingTube FittingModified Quick Disconnect FittingMale Quick Disconnect FittingEffective 06-01-02Page 11

Capstan Wire Feeder and ControlParts ListARTICULATOR LINER AND CASINGThese Articulator Liners and Casings are 3 foot long but can be supplied in longer lengths as required forboth steel alloy and aluminum wire.ASSEMBLIESPART NO.E7A5011E7A5012E7A5013E7A5014E7A5015DESCRIPTION3’ Long Assembly for 0.030” – 0.047” Steel Alloy Wire3’ Long Assembly for 0.052” – 0.062” Steel Alloy Wire3’ Long Assembly for 0.030” – 0.035” Aluminum Wire3’ Long Assembly for 0.040” – 0.052” Aluminum Wire3’ Long Assembly for 0.062” Aluminum Wire3’LinerLiner CasingCOMPONENT PARTSPART NO.E7C5019E7C5020E7C5021E7C5022E7C5023E7C5024DESCRIPTIONLiner for 0.030” – 0.047” Steel Alloy WireLiner for 0.052” Steel Alloy WireLiner for 0.030” – 0.035” Aluminum WireLiner for 0.040” – 0.052” Aluminum WireLiner for 0.062” Aluminum WireLiner CasingEffective 06-01-02Page 12

Capstan Wire Feeder and ControlParts ListCOLD WIRE PLASMA TORCH ARTICULATOR ASSEMBLYThe Articulator Assembly provides a convenient means for adjusting the position of the cold wire withrespect to the PAW welding torch. The articulator provides X –Y– Z-axis motion and a pivot axis for wireimpingement angle. The cold wire feed guide assembly is isolated from the torch mount and uses areplaceable contact tip. The articulator may be used as a hot wire torch by connecting a power cable tothe wire guide assembly.COMPLETE ASSEMBLIESPART NO.E2A5194DESCRIPTION1-3/8” Adjustable Articulator AssemblyNote: Contact tips are not supplied with assemblies. See Component Parts below for a list of contact tips.Effective 06-01-02Page 13

Capstan Wire Feeder and ControlParts List116Plasma Torch(Reference Only)14 57931484 13151021512Contact Tip (For Reference Only)COMPONENT PARTSITEM PART NO. DESCRIPTION1 E2M5762 Articulator “Y” Adjust Clamp2 E2M5763 Articulator Tip Retainer3 E2M5838 1-3/8” Articulator Front Torch Barrel Clamp4 E2M5839 1-3/8” Articulator Rear Torch Barrel Clamp5 E2M5840 Articulator “XY” Adjust Clamp6 E2M5841 Articulator “X” Adjust Shaft7 E2M5842 Articulator “Y” Adjust Shaft8 E2M5843 Hex Adaptor9 X6F5085 5/16” Tube Fitting10 #8-32 x 1-1/2” Long Socket Cap Head Screw11 #8-32 x 1/2” Long Socket Cap Head Screw12 #8-32 x 7/8” Long Socket Cap Head Screw13 #8-32 Hex Nut14 #10-32 x 1/4” Long Socket Set Screw15 #5/16-18 Hex NutEffective 06-01-02Page 14

Capstan Wire Feeder and ControlParts ListCONTACT TIPSListed below are the contact tips for the Articulator Assembly.COMPONENT PARTSPART NO.X7T5005X7T5003X7T5004X7T5033X7T5034X7T5026X7T5002X7T5035X7T5027DESCRIPTION0.030" Solid or Flux Core Wire0.035" Solid or Flux Core Wire0.045"/0.047” Solid or Flux Core Wire0.052” Solid or Flux Core Wire0.030" Aluminum or Stainless Steel Wire0.035" Aluminum or Stainless Steel Wire0.045"/0.047” Aluminum or Stainless Steel Wire0.052” Aluminum or Stainless Steel Wire0.062" Aluminum or Stainless Steel WireNOTE: Consult factory for additional required components and pricing.Form No. 84-2230 (8/02)