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© Mark Aherne 2023 :  The Tudors, The Street, Brantham, Essex  CO11 1PH :   Email : Sales@bespoke-electronics.co.uk   UK Company Registration Number : 12556716 : Dissolved 19 October 2021

Weld Monitor Applications

Capacitor Discharge DC Resistance Welders - a new era for monitoring

Capacitor Discharge Welding Power Supplies are common place the world over and with their simple design and operation, they provide highly effective micro joining / spot welding solutions, especially where conductive materials necessitate higher welding currents.  

Ironically, the relatively low purchase cost of such power supplies is often less than the cost of a conventional weld monitoring system and hence many Cap Discharge applications exist without external Quality weld monitoring !

• The Weld Monitoring Unit offers a simple, low cost monitoring solution for Capacitor Discharge users.

Since the capacitor discharge process is electrically uncontrolled, overall product quality relies heavily upon well trained operators and well configured weld heads and consistent materials to maintain a stable process.

The Weld Monitor measures the heat energy delivered to the weld by measuring the discharge current.

If the power supply output changes, or the electrodes wear, or the materials change, or the operator varies what they do, then the electrical resistance characteristics of the joint will be dynamically affected and hence the discharge current will be modified and detected as an erroneous change to the normal process.

All the process engineer need do, is determine settings that are indicative of a good welding process and then set upper and lower limits accordingly.