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Progressive current limit control for a resistance welder

  • US 5,386,096 A
  • Filed: 12/23/1993
  • Issued: 01/31/1995
  • Est. Priority Date: 12/23/1993
  • Status: Expired due to Fees
First Claim
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1. A weld controller system for controlling the operation of a welder including a weld transformer and at least one pair of contact tips that apply current to create weld heat between at least two workpieces, said weld controller having a plurality of welding cycles, said weld controller system comprising:

  • A. a microprocessor;

    B. welder power means controlled by a program operating in said microprocessor and operatively connected to said weld transformer for supplying weld current to said contact tips to create said weld heat in said workpieces, said program for increasing said weld heat in increments following a predetermined stepper program having a plurality of weld cycles to provide compensation for deterioration of said contact tips wear;

    C. a current sensor for sensing current supplied by said welder power means to said weld transformer, said current sensor for providing weld current data for use by said program;

    D. a current limit control having an upper current threshold and a lower current threshold, said current limit for comparing said sensed weld current data with a current profile at each of said plurality of weld cycles, said current limit control for indicating an event condition if said sensed weld current data exceeds said upper current threshold or is below said lower current threshold; and

    E wherein said upper current threshold and said lower current threshold track said current profile by a predetermined current offset at each of said plurality of weld cycles.

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