Without proper temperature regulation, a lot of manufacturing processes that are heat sensitive will either deteriorate or result in an altered finished product. Various types of industrial chillers are available for widespread use in metallurgy and industrial welding. Industrial welding chillers for resistance welding like spot welding, MIG welding, and TIG welding can help improve product quality and process efficiency.
Cold Shot Welding Chillers Help Minimize Process Costs
For industrial operators performing resistance welding, the heat generated by the process can be significant and needs to be dissipated. As the heat of a welding reaction directly correlates to the amount of current applied at each weld, maintaining a steady temperature will help stabilize current flow and improve the overall efficiency of welding.
Achieving a steady temperature for resistance welding requires the use of a cooling source. City water sources have been used historically, but more modern and effective cooling can be achieved with the use of specialized welder chillers. Among the major advantages, a closed-loop chiller for welding reduces long-term operational costs and facilitates more accurate thermoregulation.
Spot Welding Cooling Systems
As earlier stated, temperature regulation during spot welding is critical to the success of the process. Several methods can be used to adjust thermal conditions.
Cooling Via City Water Systems
While this method incurs very few costs at setup, continuous use will generate other costs from:
- proper wastewater treatment
- water usage
- sewer usage
Even more worrisome is the fact that city water is usually at a temperature below dew point which will cause precipitation on electronic process components. Resulting electrical shorts and corrosion may lead to system failure that requires costly maintenance.
Recirculating Welding Water Coolers
This option provides a solution to the high costs of treatment and sewage disposal but cannot be used for larger welding projects due to limited heat dissipation.
Industrial Process Chillers
Industrial chillers used for spot welding operate like recirculating coolers as they use the same closed-loop setups. However, process chillers can be modified to handle industrial cooling on a larger scale. Industrial chillers also have condensers, evaporators, and automated temperature controls that make them more efficient.
Sizing Your Welding Chillers
Conventionally, the rule when sizing industrial process chillers is for manufacturers to have at least 1-ton of chilling capacity for 100KVA of welder capacity. This method of calculation in the field can help operators get a general idea of the size of process chiller that will be suitable for their operation.
A more accurate way of determining appropriate chiller size is by computing BTU using a standard formula that also accounts for the duty cycle.
To calculate for resistance welding:
BTU/hr = (welder KVA) x (duty cycle) x (0.85) x (0.6) x 3415 BTU/hr
To calculate for resistance welding:
BTU/hr = (welder KVA) x (duty cycle) x (Eff power supply) x (Eff heat collection) x 3415
Eff. power supply = the percentage of output to input power
Eff. heat collection = the percentage of heat absorbed by chilling water (varies by approximately 50-70%)
Duty cycle = weld time on/ time elapsed
Get a Quote on Industrial Welding Chillers from Cold Shot
As a leading industrial chiller manufacturer, Cold Shot Chillers is dedicated to supplying high-quality process chillers for a wide range of industries. Our knowledgeable staff will help you find the industrial chiller best suited to your unique process application.
Contact us online today for a quote on our industrial welding chillers or to ask about other cooling solutions we offer.