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Weld Monitors in Automation

Full and Semi Automatic manufacturing methods in micro joining applications generally improve output consistency. Nevertheless, process changes inevitably occur through electrode wear, machine wear and material variations.

Monitoring an automatic process allows the system design to incorporate process adaptation features, such as automatic electrode cleaning, automatic reject systems etc…

The standard Weld Monitoring Unit is fitted with a 15W D type connector that provides 4 optically isolated digital outputs specifically designed to interface with industrial PLCs.

1. Weld Signal - This signal provides the timing to indicate the start and end of a welding sequence.

2. Weld OK - This signal indicates a “no fault status” and can be used solely to determine the state of the process.

3. Weld Energy High Limit - This signal is latched for 250mS after the weld sequence if a High Energy Limit Fault is detected

4. Weld Energy Low Limit - This signal is latched for 250mS after the weld sequence if a Low Energy Limit Fault is detected

These timing signals can also be used in conjunction with the optional Isolated Analogue Channel Outputs in order to provide triggering and capture signals for data acquisition purposes.  Once configured, such systems can then be programmed to operate automatically over a wide range of welding schedules, effectively ignoring the manual settings on the unit.  Click here for a detailed guide