New Method to Monitor and Regulate Resistance Welding

摘要

The present invention actively mines servo-gun data during resistance welding in order to: 1. Identify and/or compensate for metal fit-up gaps 2. Measure or estimate the gun force required to close a stiff fit-up gap 3. Measure and/or record thinning of metal due to weld indentation of electrode tips 4. Measure and/or record the extent of projection collapse during resistance projection welding Using even existing conventional servo-gun hardware, the method closes the gun in a stepwise manner at progressively higher force leading up to the weld force. At each step the force-displacement data are measured and analyzed. 1. A tight-fitting metal stackup is sensed as a rigid object, and the force-displacement ratio matches the flexing and compliance history of the weld gun by itself.