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Micro controller Based Spot Welding Controllers


Welding Controller

Features
  • Compact User-Friendly micro controller based circuitry.
    • 3W-OL/15 : Three consecutive programmable weld timings - preheat (W1), weld (W2), anneal (W3) with intermediate cool timings in one weld schedule to achieve high quality splash free welding.

    • WCU/15 : Programmable WELD Time and Cool Time in a schedule.

  • Non-Volatile Memory (EEPROM) to store up to 15 weld schedules.
  • Easy to program with UP/DOWN and ENTER keys. Values programmed are indicated by a two-digit LED display. Individual operations within a weld schedule indicated by LEDs.
  • Key lock switch provided for SET and RUN mode.
  • Timings settable in terms of HALF / FULL cycles of mains supply frequency to achieve better resolution. Half cycle =10msec / cycle for 50Hz supply. OR Full cycle = 20msec / cycle for 50Hz supply.
  • Precise time and energy control ensures consistent weld quality.
  • ONE CYCLE and REPEAT CYCLE mode selectable by toggle switch. WELD / NO WELD switch provided on the front panel.
  • Two weld schedules Externally Selectable by Two Foot Switches. This features is suitable for spot welding Guns and multispot welding machines.
  • Dual Gun operation option available.

  • Specifications
  • Input Supply : 230V / 415V AC, 50Hz/60Hz

  • Output : Gate- Cathode Drive signal to drive a pair of back to Back thyristors of any capacity.
    • Built in back to back thyristors for up to 95A primary current.
    • Normally Open Relay contacts for Solenoid valves.

    • 2 Footswitch, 2 Valve operation suitable for Spot Welding Guns.

  • Compensation : Supply voltage fluctuation compensation. (Output Voltage remains within ±3 % as against ± 15% variation in mains voltage.)

  • Trigger : External Normally Open contacts of Footswitch. There are two options available:
    • Single / Double Initiation Footswitch

    • Two different schedules selectable by independent footswitches.

    • Option available for drive signal for two pairs of thyristors and two solenoid valves.

    Note: 'Forge Delay' and 'Multi-Spot' options available on request.


    Adjustment of various parameters possible as per table :

    Squeeze Time 0-99 half cycles Weld Energy (W2) 0-99% programmable
    Preheat Time (W1) 0-99 half cycles Cool (2) Time 0-99 half cycles
    Energy Level (W1) 0-99% programmable Anneal Time (W3) 0-99 half cycles
    Cool (1) Time 0-99 half cycles Energy Level (W3) 0-99% programmable
    Slope of W2 0-9 half cycles Hold Time 0-99 half cycles
    Weld Time (W2) 0-99 half cycles Off Time (in repeat mode) 0-99 half cycles
    Applications :

  • Precision Control of Resistance Spot Welding Machines of any capacity 0.1kVA to 300kVA.

  • Precision Control of Resistance Spot Welding Guns / Dual Guns etc.

  • Multi-Spot welding machines.

  • Retrofitting controls for any make / any capacity spot welders.