Transformation of Resistance Welding Technology - Digitization

With the continuous advancement of technology and the increasing sophistication of industrial production, resistance welding technology has become a significant welding method and is extensively utilized in various fields. However, traditional resistance welding technology encounters issues such as low control accuracy, high energy consumption, and unstable welding quality. To address these problems, digital technology has been incorporated into resistance welding technology, resulting in significant enhancements in automation and welding quality. 

Digital resistance welding

Digital resistance welding is a welding technique that utilizes digital technology to accurately control and optimize the resistance welding process. It digitizes welding parameters, process data and equipment status information to enable real-time monitoring and automatic adjustment of the welding process. Digital resistance welding possesses the following characteristics:

1. High control accuracy: It can precisely control welding current, voltage, time and other parameters to ensure the stability and consistency of welding quality.

2. High degree of automation: The welding process is automated, reducing manual intervention and improving production efficiency.

3. Energy saving and environmental friendly: By optimizing welding parameters and processes, it can reduce energy consumption and minimize the emission of pollutants such as exhaust gas and waste residue.

4. Strong traceability: It can record various data during the welding process, providing excellent support for product quality traceability. 

Importance of Digital Resistance Welding

1. Improving welding quality: Accurate control of welding parameters and processes ensures the stability and consistency of welding quality.

2. Improving production efficiency: Automated control and optimization of the welding process reduce manual intervention.

3. Reducing production costs: By optimizing welding parameters and processes, can reduce energy and material consumption.

4. Enhancing enterprise competitiveness: It improves the technical and management levels of enterprises, enhancing their market competitiveness and sustainable development capabilities.

Application of Digital Resistance Welding

1. Welding parameter control

In the resistance welding process, controlling welding parameters has a significant impact on welding quality. Digitization technology enables real-time monitoring and adjustment of welding current, voltage, time and other parameters to ensure the stability and consistency of the welding process.

2. Welding process optimization

Digitization technology can automatically adjust welding process parameters based on factors such as welding materials, workpiece shape and thickness, to optimize the welding process. Through simulation and data analysis, digital resistance welding can predict changes in the temperature field, stress field, and provide a scientific basis for welding process optimization. Additionally, digitization technology enables remote monitoring and fault diagnosis of the welding process, improving equipment reliability and service life.

3. Welding quality inspection

Digitization technology enables real-time monitoring and analysis of welding quality. By collecting parameters such as voltage, current, and temperature during welding, digital resistance welding can determine whether the welding quality meets user requirements. Simultaneously, digitization technology can also perform non-destructive testing on welded joints to detect defects and potential hazards during welding.

4. Intelligent management

Digital resistance welding enables intelligent management of the welding process. By integrating technologies such as the Internet, big data, and cloud computing, digital resistance welding can achieve real-time monitoring of equipment status, fault diagnosis, and warning maintenance. Additionally, digital technology enables visual display and data analysis of the welding process, providing excellent support for production.

As a leading provider of metal connection solutions, Heron is continuously exploring the development path of digital resistance welding. In 2022, we developed and manufactured the HRC650 resistance welding quality real-time monitoring system. The HRC650 resistance welding quality real-time monitoring system is a precision device that can be used for high-speed real-time detection of current, secondary voltage, joint resistance, electrode displacement, electrode pressure data and curves that affect weld quality. It can also independently set the limit range for each data. If the data exceeds the set value, it will trigger alarm and display an envelope curve. 

The application of digital resistance welding technology has become an inevitable trend in the industry's development. With the continuous development and improvement of digital technology, resistance welding technology will become more efficient, precise and intelligent welding process. In the future, Heron will continue to explore the path of digital resistance welding and provide excellent support for the transformation and upgrading of industrial production.