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. T o 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 tech nique  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  unaweza 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 , redu cing manual intervention and improv ing production efficiency.

3  Energy saving and environmental friendly : By optimiz ing  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, provid ing   excellent  support for product quality traceability.  

Importance of Digital Resistance Welding

1  Improv ing  welding quality : A ccurate control ya welding parameters and processes ensur es  the stability and consistency of welding quality.

2  Improv ing  production efficiency : A utomat ed  control and optimization of the welding process   reduc e manual intervention.

3  Reduc ing  production costs : By optimiz ing welding parameters and processes,  can reduce energy and material consumption

4  Enhanc ing  enterprise competitiveness : It improve s the technical and management levels of enterprises, enhanc ing their market competitiveness and sustainable development capabilities.

Application of Digital Resistance Welding

1  Welding parameter control

In the resistance welding  process , control ling  welding parameters has a significant  impact on welding quality. Digit ization  technology enables real-time monitor ing  and adjust ment of  welding current, voltage, time and other parameters to ensure the stability and consistency of the welding process.

2  Welding process optimization

Digit ization  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, na provid e  a scientific basis for welding process optimization.  Additionally , digit ization  technology enables  remote monitoring and fault diagnosis of the welding process, improv ing   equipment  reliability and service life.

3  Welding quality inspection

Digit ization  technology enables real-time  monitor ing  na analysis of welding quality. By collect ing  parameters such as voltage, current, and temperature during welding, digital resistance welding can determine whether the welding quality meets user  requirements. Simultaneously , digit ization 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 f uture, He ron  will continue to explore the path  of digital resistance welding and provide excellent  support for the transformation and upgrading of industrial production.