Unlock Energy Efficiency for Your Resistance Welding Operations
Proven Solutions for Power Problems
WeldComputer Controls are carefully crafted systems that keep power steady, boosting welding performance and saving energy at the same time. These controls are trusted by a wide range of resistance welding manufacturers who rely on them for their proven track record of delivering dependable, efficient, and cost-saving solutions.
Solve power problems in your resistance welding operations today. Sign up for a test evaluation and see the difference WeldComputer Controls can make.
Speak to the Experts
“I didn’t believe the magic at first. I thought they were selling snake oil, and I had to see it to believe it… But after we plugged the [evaluation] unit in, we went from welding at a RMS amperage of 260 down to just 65 amps and maintained a Power Factor efficiency level of 85-90% without any drops. The WeldComputer control is something that’s going to help us every day and is expected to substantially reduce our electric bill… We’ve since placed an order for more units.”
—Ronnie Harris, Manager at McCorvey Sheet Metal
Real-World Success Stories
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IMPROVE PERFORMANCE, REDUCE SURGES
Results:
Power surges reduced by 93% after replacing SCR control
“I couldn’t believe it was the same machine!”
– Mike Smith,
JANDA Company, Inc.
High Performance with Less Power
Results:
Achieved the same flash welding performance using only 15% of the power
“We went from welding at 400 amps to 60 amps making the same weld.”
– Casey Cloud,
H&H Resistance Welders
Substantial Energy Savings
Results:
45% energy savings and eliminated the need for a $250,000 capacitor bank to correct their power factor
“The WeldComputer Adaptive Control is roughly 45% more efficient to obtain the same results.”
– Clifford Machines & Technology independent study
Enhance Power
Efficiency
Results:
Improved power factor by 80%, reduced current draw by 75%
“Our amperage draw was undetectable. I had to double-check to make sure we were welding.”
– Ronnie Harris,
McCorvey Sheet Metal
Let’s Help You Eliminate Demand Charges
Did you know that reducing your peak demand can save thousands of dollars annually? Many locations in the USA have a “Demand Charge” from the utilities companies. Customers are charged an extra fee that’s linked to the maximum peak power drawn during your billing cycle.
This becomes a major challenge for operations who suffer from power surges when they perform resistance welds. While the overall energy usage when running resistance welders may be less than some other welding processes, the demand during the moment each weld is made may be off the charts and cause your operation to incur a “Demand Charge”.
By swapping out your existing control with a WeldComputer Control, you can dramatically lower your highest peak power usage, thus avoiding hefty demand charges from your power company and reaching payback with the control significantly faster. For example, if the power company issues demand charges of 12.5 USD/kW, simply reducing peak demand by 100 kW can save you $15,000 per year!
“I’ve installed and serviced just about every resistance welding control on the market. No other control delivers higher performance than the WeldComputer… We were getting better performance and flashing consistency. The WeldComputer Adaptive Control is clearly the best control choice for any flash welding operation.”
—Mike Smith, Manager of Resistance Welding Technical Support, JANDA Company
Flickering Lights? It’s Worse Than You Think
Often we hear manufacturers who tell us their lights flicker every time a weld is made. Unfortunately, that flicker can lead to more than just an annoyance. When the light dims due to welding, it’s actually a result of a momentary voltage drop, which, unfortunately, can cause havoc on your operation’s equipment.
Sudden drops in voltage are often responsible for burning out motors and compressors if the drop occurs when these devices are starting up. The line transients created are also responsible for causing premature failure of every type of electronic equipment in the building, from the CNC controllers to copy machines. These actual costs are often not linked to resistance welders because most operations lack the necessary instrumentation to document when equipment failures coincide with surges from resistance welding machines.
Because WeldComputer Controls help improve energy efficiency and reduce the power draw on the grid, your operation won’t suffer from damaging surges and light flickering every time a weld is made.
Test a Proof of Concept in Your Factory
Not convinced the WeldComputer Control will work for you? Test it out in your facility on your machine and see for yourself!
With our evaluation offer, the WeldComputer team will work with you to temporarily hook up a fully functioning welding control to your weld machine so you can see the results for yourself, without having to make a capital equipment investment to see proof. Let us help you solve your power, welding quality, and/or control reliability problems, and prove it to you on your own equipment.
