Automation International Inc.

Randolph P Formanek

William M Derby, Jr

Larry E Moss

Johnny B Hogg, Deceased

The present invention is an improved butt welding technique that provides adaptive control of force that is applied to a part during a welding process to enable a maintained joint resistance across joint. The force may be adjusted to account for the changing conditions of the part. The present invention may be implemented within any electrical welder having at least one movable platen for carrying a part to be welded, at least one hydraulic cylinder coupled to the movable platen, the hydraulic cylinder having a first chamber and a second chamber, and a servo valve coupled to the hydraulic cylinder. The present invention includes means for making voltage drop measurements across the joint to be welded. The voltage measurements provide feedback as to whether the force should be adjusted. A force control module may be implemented to provide controlled force to the part.

Techniques for adaptive control of force in resistance welding applications

Techniques for assuring the accuracy of the welding of a part including a part calibration cycle, a tap check cycle and a gap detection cycle. The part calibration cycle determines the electrical load presented by the part to the welder transformer. The tap check cycle verifies that the operator has set the correct tap on the primary of the welder transformer, The gap detection cycle finds the actual spacing between the platen when the ends of the part are substantially touching so that the ends of the part can be accurately spaced at the beginning of the weld cycle.

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Danville, IL, United States of America

Randolph P Formanek