Thank you again for all of your help last week during our consult. I think everyone ended the week feeling like we got a lot of value out of your time, and learned a lot about ways to improve our processes. I have sent the first parts we ran on the machine over to our quality department to do push testing on samples for weld strength. They came back with very consistent numbers! The standard deviation of the push strength amongst those welds is probably close to the standard deviation of our test apparatus, that’s how consistent they were. … Since swapping out our existing control with the WeldComputer adaptive control we have been able to increase our production speed by 25% while producing 30% stronger welds with 1/5^th the standard deviation.

Conclusion: Our capability of the tested material far exceeds the required 99.5% level and using S.P.C. to control it through the Weld Computer will assure consistent high quality welds. This method of Taguchi augmented S.P.C. perfected the process where control limits can be developed for each weld schedule. Approvals would mean that the concepts is approved where details of control limits of all alloys will be developed per the weld schedule. Read the summary report here.

As a tier one supplier of automotive components, quality is the key to our continuing success. WeldComputer Corporation’s Multi-Channel WeldView Monitor has helped us optimize our weld schedules and maintain control over the consistency of our resistance welding processes. We have been able to reduce our reliance on destructive testing while improving our level of confidence in the reliability of our products.

We have been able to identify the key characteristics in our material to make it weld consistently. The WeldView Monitor has been invaluable in sorting out the failure modes and understanding how to adjust the weld schedule.”

“WeldComputer is this company’s best way to success.”

I evaluated several commercially available controls in production environments. I chose the WeldComputer system after evaluation at the McDonnell Douglas facility, where it was used in the fabrication of fighter planes. The WeldComputer is available as a complete control system or a process monitor only. For Lee Rowan I chose the process monitor to preserve the company’s investment in standard welding controls. To get the most information with the minimum investment in sensors, we chose to monitor current and displacement.

The purpose of this report is to establish that the resistance welding process as controlled and monitored by WeldComputer’s equipment, is sufficiently reliable to allow the substitution of nondestructive evaluation for the currently required destructive testing…  Because each individual weld’s expansion value is monitored by the controller, there would be greater confidence in spot weld quality than with the periodic destructive monitoring required by Mil-W-6858. Read the Report

“the presented results clearly shows that WeldComputer is roughly 45% more efficient to obtain the same results. If energy consumption/efficiency and overall reticulation balance are driving factors in a design, the WeldComputer is really the controller to use.”