Abstract
The current study investigated the main welding process of the box. We first performed a simple simulation of the welding process for the four long weld lines on CTB (Coil Terminal Box) outbox by using the finite element analysis mode of SYSWELD. Then a 2m length mock up box was welded for R&D to optimize the welding parameters and deformation distribution. Base on the R&D experiences, we designed a special tooling of the prototype box which can be used to control the deformation during the welding process. A 8m length CTB outbox prototype was successfully welded by using double torch automatic MIG (Metal Inert-Gas) welding. The dimension inspection results confirmed that the welding deformation of the box can be controlled within 3mm on each side. Based on the ultrasonic inspection, all the welding seams met quality level B by standard EN 5817.
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