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SEAM WELDING

Resistance Seam Welding

Our WeldComputer Controls and Monitors help you tackle problems with seam welding operations.

Monitoring can detect several sources of weld variation, and keep poor-quality and inconsistent welds from leaving the factory. However, manufacturers can still end up with a very high, very expensive reject rate.

Learn more about WeldComputer Adaptive Controls for seam welding applications in this Welding Journal featured article;

Operating with an adaptive seam schedule is the easiest way to prevent bad welds from occurring due to these types of problems.

The adaptive weld schedule can automatically detect and correct each of these problems to produce consistent welds, and prevent a bad weld from occurring in the first place. And when the variations are too severe to be corrected, the system can notify the operator instantly about the problem.

Seam welding operations are traditionally faced with such problems as:

  • inconsistent heat from weld to weld,
  • inconsistent spot spacing,
  • inconsistent wheel velocity,
  • inconsistent force over the length of the seam,
  • edge variation,
  • inconsistent wheel acceleration at the start and end of the seam,
  • inconsistent face contact area of the seam wheel rolling on the part, and
  • wheel-to-brush contact resistance variations.

Why WeldComputer for your seam welding operation

Many manufacturers are unknowingly operating their resistance seam welding processes at speeds far slower than what is feasible. By boosting the speed of these machines, companies can dramatically improve productivity without adding machines to meet production demands. Despite attempts to bolster production and weld quality, conventional inverter MFDC control has sadly failed many operations. In fact, many times these controls have the opposite impact and limit the ability to produce consistent quality seam welds. With the WeldComputer, your seam welding operation is able to increase speed and production throughput without sacrificing quality. Our Adaptive Control allows your operation to compensate for variations so you can unlock higher output levels while maintaining high-quality welds every time!

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Four Common Seam Welding Problems

Seam welding systems with conventional controls result in:

  • inconsistently sized welds that can have variable spacing on the seam
  • the first few welds being hotter than the rest of the welds in the seam
  • similar problems with the welds at the end of the seam

In edge-to-edge seam welding operations, where the seam wheels have to roll up on the front of the part, roll across the part, and off the back edge of the part, these problems are further compounded by:

  • wheel bouncing
  • vibration and dynamic geometry changes that occur on the front and back edges

Monitoring can detect all of these sources of weld variation, and keep poor-quality and inconsistent welds from leaving the factory. An adaptive control can prevent a bad weld from occurring in the first place.

monitoring-seam-welding

Learn more about how to increase speed while maintaining quality by downloading the full presentation.

Learn more about WeldComputer Adaptive Control for seam welding applications in this Welding Journal featured article.

Many clients rely on WeldComputer to solve their resistance welding needs. Contact us for more information and a free consultation to see if WeldComputer is right for your resistance welding application.

Email us or call us at 800-553-9353

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WeldComputer technology is protected by the following U.S. Patents: 4,714,913 4,742,473 4,803,331. Other Patents Pending.