sales@weld-monitor.com

© 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

Controlled Linear, HFDC & Hybrid DC Resistance Welding Power Supplies

Controlled power supplies regulate their output in accordance with real-time feedback measurements.  Typical operational modes will include Constant (Regulated) Current, Constant Voltage & Constant Power.

In all resistance welding applications, the heat energy at the weld is entirely proportional to the welding current and the dynamic resistance of the weld.  Thus all modes of operation can and will suffer from process variability caused by changes in operators, materials, electrodes, weld head setups etc…  

As with capacitor discharge applications, Quality Weld Monitoring will verify the welding process repeatability and detect changes in the delivered heat energy.

Controlled power supplies are more complex and generally more expensive than Capacitor Discharge units.  The additional sophistication allows output currents and hence heating profiles to be programmed in terms of amplitude and time.  

This capability provides greater flexibility when dealing with a wide range of material applications. The ability to control the rate at which current is applied to the weld can be beneficial in optimising electrode life and compensating for some material variations.

HFDC & Hybrid supplies tend to have switching noise and ripple associated with their outputs which can to some extent obscure the real time process visibility.  

The Weld Monitoring Unit includes carefully chosen filtering components that minimise the effect of output noise on measurements.