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WTC Advancing to Industry 4.0

Force Integrity
Nugget Integrity
Porosity Protection
Expulsion Detection and Reduction
Process Integrity
Fast Rise Time and Current Control
DYI Welding Schedule Customization

Learn about the resistance welding process that is widely used for assembling metalic pieces togther with superior strength and superb quality. If done correctly, resistance welds will be stronger than the parent materials.

Resistance welding involves the controlling of electrical currents ranging from as low as 1000 amperes to has high as 250,000 amperes. The voltage that is required across the workpiece to deliver this level of current is only around one volt.

The power transfer is accomplished with the use of a welding transformer.

Once you have determined what kind of power transformer will be used for providing welding current to the welding tools, you then select an appropriate welding control type. There five types of welding controls as described in the post.

The list of problems with their solutions listed in this section are part of the legacy derived from the introduction of micro-processors to resistance welding controls since the mid 1970s. Today, WTC continues to develop intelligent algorithms as new materials are emerging.

The welding control provides tools that assist welding engineers to improve and maintain welding quality. All components of the resistance welding process are important. The mechanical tools must be well designed, the power transfer must be efficient and in good shape. The control algorithm must be capable of dealing with anomalies. As controls are becoming faster in processing and capable of achieving thoughtful algorithms, it becomes wise to implement some of these tools into the production environment. Some of the most common problems are listed in the posts with solutions that follow.