Thursday, December 18, 2014

5 FAQs Welding Cables For Resistance Welders, Robotic Welders

The most frequently asked questions at Cal Manufacturing, Inc "Calcables" provide solutions at your fingertips, technical resources and content.

1.       Can you produce a cable even if someone else manufactured it before?  The simple answer is yes.   Cables utilized in spot welding, resistance welding, robotic welding originate from the OEM; however, it is not necessary to track back the manufacturer of the original equipment.  In fact, you may find that the product we manufacture is actually more efficient and effective incorporating the newest technology as well as aftermarket follow up to ensure correct placement, bend radius recommendations, etc.

2.      How do I figure out the correct cable I need?  First off, look at your welding equipment.  If there is a lot of pulse, kick or vibration during the weld process, consider extra-flexible copper braided rope as it reduces breakage, fraying and pulling apart.   Second, to determine the MCM (circular mill size) you need to know the duty cycle, current and length of the cable (always measured bolt hole center to bolt hole center).

Find the closest duty cycle on the left and use the multiplier on the right - this will give you the continuous duty current of the cable.

In Diagram 1, locate the length and follow up to the continuous duty current, angle over and you will find the correct MCM (circular mill size).

1.       How do you measure a shunt?  This is always a good question and a valid one, at that.  Copper laminated shunts come in literally thousands of designs from very small to extremely large depending on their application.   The measurements of a shunt include the overall length (factoring in bend radii if applicable), width and thickness (less clips).

My production line is down due to cable failure.  Calcables has the ability to expedite same day shipping for down production lines or other urgent needs.  
NEW, this year is a 
*  Two-day expedited shipping program as well for anticipated urgent needs.  Life happens at any time of the day and we make your emergency our emergency.

2.      What MCM are our cables rated to?  150 MCM is typically the smallest circular mill size, 250, 300, 325, 350, 400, 450, 500, 600, 650, 750, 800, 1000, 1200, 1500, 2000 are all available.  Specialty cables are available in sizes not listed; however, these are the most commonly ordered circular mill sizes.  Larger MCM cables are often utilized in induction heating purposes and these are also available upon request.

Frequently asked questions related to resistance welding, spot welding, robotic welding power leads/jumpers are not exclusive to the above; however, these are definitely the top five.  Technical support related to recommended cable placement, bend radius minimums, high temperature are all questions the engineers at CAL can answer for your individual equipment, welding cell, robotic welding. Find the closest duty cycle on the left and use the multiplier on the right - this will give you the continuous duty current of the cable.

                                            Special (SPL) cables - available upon request

All cables are tested for water pressure, polarity extensively before shipping

Friday, October 17, 2014

3 Important Ways CALcables Is A Part Of Your Everyday Life

How could a little Tier II supplier in manufacturing possibly affect the daily lives of the general population?   We simply don't make the products you use everyday.   From the moment you wake up in the morning to the time you end your day, many of the products you use over and over again required a spot weld and that's where we come in.  Take a look below and see if you can identify some of the everyday items you use and think of CAL - the little Tier II supplier who makes your day a little better and a little easier.

The soccer mom minivan Chrysler has a full line of spot welders (MIG) welders utilizing a copper laminated shunt that welds the frame of your minivan.

Hauling materials, snowmobiles, and ATV's in your trailer today?   The metal frames of trailers require an appropriate spot weld to hold the joints in place - as you drive down the highway, the last thing you want to worry about is whether or not your trailer is going to fall apart.

Food Service - restaurants, bakeries, cafeterias need aluminum racks to shelve trays, cool pans of fresh baked goods, and stock shelves at the grocery store.

Whether you are driving a minivan full of kids to a soccer game, hauling equipment in a trailer or utilizing aluminum racks in a restaurant, baker or grocery store, you probably don't think for a second that any of these items would fail to work.   CALcables doesn't worry either, as we supply quality welding power leads to manufacturers, automakers, and other Tier I and Tier II suppliers enabling them to appropriately power up and weld a variety of metals that meets industry standards.  Oh yeah...also providing the products you use just about every day.   

Thursday, October 16, 2014

People On The Move

People On The Move

CALCABLES is on the move with MLIVE and People On The Move.  In the business section, CAL features Plant Manager, Russell Hayward and Board Trustee, Cheryl Benson.

Click the link to read the press release and others in the Kalamazoo area who are moving into new positions.

MLIVE Business Editor, Al Jones, with the story.

-Two leaders additions were announced recently at Cal Manufacturing Inc., of Vicksburg, a manufacturer of resistance welding cables, resistance welders, arc welders and related industry equipment. Russ Hayward has been appointed plant manager. Hayward brings many years of experience in the welding industry, including managing industrial plant functions, supervising staff and managing inventory. He joined Cal in 2011 as a welder. Cheryl Benson has been named operations manager. In that post, she will oversee plant production, human resources, sales and strategic purchasing.Benson joined the woman-owned, woman-run business in 2011 as member of its board of trustees.

Of course, at CAL we love social media and the opportunity to bring a face to a name for our many customers, suppliers and colleagues in the industry.   A part of our customer service is making sure continually evaluate our processes internally and externally and alter our course of navigation when needed to hit the goals we have set.  

In the Kalamazoo area?   Stop in and visit with the team at CALcables, your partner in the resistance welding consumables industry.

5 Important Things About Calcables You May Not Know

Resistance welding cables - a product you may not use in your everyday life; however, it is an integral part of a spot welder that assembles almost everything you utilize in the course of your day from your vehicle to your spice rack.

Every day, millions of Americans get in their car and travel to and from work, school, shopping and the first thing you do (or should do) is buckle your seatbelt!  Calcables manufactures a specific air cooled cable that has application on a robotic spot welder that assembles parts for seatbelts.

Flying the friendly skies?  The aerospace industry utilizes welding cells in automation with state-of-the-art robotic MIG welders that utilize a dual conductor kickless cables.

Have we all seen Apollo 13 starring Tom Hanks?   NASA's institutions utilize a special 8-foot dual conductor kickless cable to weld equipment in their research institutes.

Spice racks, tool cabinets, and decorative shelving in stores like GAP are all built by a manufacturer utilizing welding equipment powered by Calcables.

Calcables is most likely the last thing you might think about when it comes to these everyday applications; however, our specialized resistance welding cables are utilized in the assembly of just about everything we touch in our daily lives.

Wednesday, September 10, 2014

Resistance Welding Cables & Consumables - CAL Manufacturing, Inc "CALCABLES": You Might Be A Welder If....You Find This Humorous...

Resistance Welding Cables & Consumables - CAL Manufacturing, Inc "CALCABLES": You Might Be A Welder If....You Find This Humorous...: Welding is serious business and there's not a lot of "humor" practically speaking about a welder heading off to work and hand...

You Might Be A Welder If....You Find This Humorous

Welding is serious business and there's not a lot of "humor" practically speaking about a welder heading off to work and handling some potentially hazardous material in the course of the day...but humor me for a moment...

How many welders does it take to change a lightbulb?
None.. Welder's aren't afraid of the dark!

And...there is welding fashion...

Pretty cool that you get to dress like "Darth Vader" for work

When your friends say.."It's Miller Time" you grab your gloves and shield and think of this:
Saving the best for last...what kind of music do welder's listen to?

Enjoying a little welding humor today and celebrating the challenges of being a welder.
Resistance Welding Cables & Consumables

Tuesday, September 9, 2014

Go Big Or Go Home - With the Swivel King

Swivel's a trademark name that sounds like an 80's dance maneuver; however, it's actually a component of a welding cable specifically designed for the robotic welding industry.  

The automotive industry utilizes the Swivel King on a welding cable as it allows the weld head to twist 180 degrees in either direction.  Technicians working on placement of the robotic welders received the greatest benefit from the Swivel King due to the fact that with as little as 15 lbs of pressure the cable will twist 180 degrees relieving stress on the shoulders, arms and wrists.

This is good news when it comes to workman's compensation injuries that occur due to repetitive movements such as carpal tunnel syndrome, neck pain and ligamentus type injuries to the shoulders and arms.

From the Design Phase

To the Implementation Phase...complete with aftermarket care and followup.

Regardless of your industry, the Swivel King is a solid investment saving valuable dollars over time in replacement cables, undue wear on the welding equipment and to prevent repetitive strain type injuries in manual jobs, choose the Swivel King welding cable for robotic welding equipment in automation


Which Welding Cable Are You?

Have you ever seen the noxious quizzes, particularly on social media sites such as Facebook, that allure you to tap the link to see "Which State Are You?"  or even better "Which Disney Character Will You Marry?"   Guilty as charged..I have sat glued to my LCD screen taking social media quizzes and then posted the result to Facebook like some kind of victory badge.  As I recharge the lost brain cells in this process we switch to the quiz, "Which Welding Cable Are You?"   This may not be a quiz, but it is certainly a question we have attempted to answer on a daily basis.  Identifying welding cables in the field can be challenging particularly if you are dealing with a customer via email or on the phone and cannot personally inspect the welding equipment.  There are, however, a few things that you can do to correctly identify your customer's cable sight unseen.

Measuring the cable.  This is probably the simplest way to identify a welding cable in the field.  Utilizing a tape measure, having the customer measure the length of the cable hole center to hole center will provide the overall length.  Identifying the circular mill size or width of the cable can be determined by measuring the circumference of the cable even with the nonconductive black hose covering.

Visual identification.  All welding cables should be clearly stamped with the circular mill size and length.  A visual identification will tell you if the nonconductive black hose covering is clamped on or sits loose.  If the covering is clamped on with bands, the cable is water cooled.  If the covering is sitting loose on the cable it is an air cooled cable.

Terminal ends are a little bit more tricky to identify; however, once it is established whether the cable is air cooled or water cooled, the terminal ends are a little easier to identify.

Copper terminals are always utilized on welding cables; however, they may be silver plated.  The terminals are all engraved with the circular mill size on one end.  Over time and with use, this may become a little more difficult to see, but it should still be visible.  Measuring the flat surface of the cable is important as well as identification of the holes (for attachments onto the machine and with water ports).

Charts for weld ampacity.  When the information above is unavailable, it is possible to configure the weld ampacities and identify an appropriate cable utilizing a formula:

To determine the required MCM rating, it is first necessary to know: (1) the duty cycle, (2) current to be used and (3) length of the cable to be used, measured bolt hole center to bolt hole center.
Once this has been determined, proceed as follows:
1. Find the closest duty cycle shown on the multiplier chart to the left. Take your current level and multiply it times the multiplier shown. This will give you the continuous duty current of the cable.

2. Refer to the chart below. Looking up from the length of your required cable, find the angular line closest to the continuous current level you just established. Then follow the angular line to the right for the MCM rating.

Identifying a welding cable for a customer can be frustrating when you are behind a computer or on the phone; however, asking a few simple questions, much like the noxious quizzes in social media, you can identify the correct welding cable. With technology and "Smart" phones, mobile photographs can also be extremely helpful to identify a part.  Technical support from the team at CAL is always available when you need a behind the scenes "expert" to sort out the correct cable information - let us make you the heroine in your customer's "Welding Cable Quiz".

Monday, February 17, 2014

Copper Bar Stock

Calcables uses a variety of different types of copper products for resistance welding cables, consumables.  Understanding the difference between them is an important factor not only in the product we produce, but the process of the product we produce.

Tellerium - Interesting Facts:

 PHOTO:  Shows a NEW cable utilizing Tellurium - the machining process is cleaner, we use less in the way of saw blades to cut bar stock and have far less in the way of rejected parts.

This is 110 copper bar stock, shown on a USED cable.  I wanted to show a cable that has had some use so you can see that 110 cooper bar stock is not a bad choice and does, in fact, hold up very well in the welding environment.

The word Tellerium comes from the Latin word tellus which means earth.  Tellerium was discovered in 1782 by Muller von Reichenstein.  It was named by a German chemist, Martin Heinrich Klaproth in 1798.

Tellurium is a silvery-white metalloid, its pure version has a metallic luster.  Crystalline tellurium is easily pulverised.  In its molten state, tellurium is corrosive to copper, iron and stainless stell.

Tellerium Used In Resistance Welding versus 110 Copper Bar Stock:

That scientific information is all fine and good, but when it comes to resistance welding cables, why does this matter?

Tellurium copper is readily available in the world wide market in rod, hex and rectangle (C14500). Tellurium is added to copper for machine-ability. The tellurium serves the same purpose as lead in free machining brass (C36000). Both lead and tellurium enter the grain boundaries to act as a chip release. Without tellurium in pure copper, machining is very gummy and chips will string. When detailed machining is needed, tellurium copper (C14500) is needed for high volume and detailed machining applications.You pay about $1.00/lbs. more for the C14500 but you will save yourself machining time and headaches.

Ask the experts at Calcables, which cable is right for you and have the peace of mind knowing our products are only the best, while still maintaining excellent price and delivery.

Want to know more about copper products we use?  Contact Calcables