The WeldMS Universal continuous real-time monitoring system is ideal for manufacturers who require digital records and management of their welds. The system performs a basic weld analysis based on the type of resistance welder. The block diagram below depicts a generalized view of the Universal monitoring system for various kinds of resistance welders.
For each resistance welding process, the monitoring system requires the applicable set of sensing devices to provide a basic welding analysis to ensure each weld remains within established parameters. The parameters define the allowable limits for each input variable in the welding process. If any measurement falls outside its parameters, the system flags the weld for review.
The following table summarizes the typical welding sequence and the minimum required sensing devices for each welding process.
The process involved in retrofitting the WeldMS Universal is described in the two-phase implementation below.
Phase 1 – Welder Retrofitting & Data Collection
Based on the welder’s welding process, we select the sensing devices. We provide any missing sensing devices that are not found on the welder. We carefully review the welding process to ensure we are able to pull signals from the welding sequence. From our findings, we configure the monitoring system ready for retrofit. On completion of the retrofit, we prepare for phase two of the installation by collecting welding data for each weld schedule through our monitoring system.
Phase 2 – Software & Engine Analysis Tuning
In this phase, we configure the software and the basic analysis engine based on our study of data collected from phase one. It is also in this phase where we can further modify the software for those requiring additional features or customized reports. The final version is then electronically sent for installation or we can install it remotely.