The current invention is a system and application that provides key insight into the technological processes that encompass a welding calculator apparatus consisting of a calculator casing, an optical rotary encoder in the calculator casing for providing weld length data, a time counter in the calculator casing for providing weld time data and a microcontroller device in the calculator casing for processing weld length data and weld time data, weld travel speed data and heat input data

To provide a spot welding system of high reliability which, when an abnormality such as a spot missing in spot welding occurs, is capable of more precisely and accurately detecting this immediately. Provided are a robot-side system having a robot and a robot-side control unit which controls driving of the robot; and a welder-side system having a welding gun mounted to the robot, and a welder-side control unit, in which the robot-side system includes: a storage unit which stores in advance a required welding time needed in a spot welding operation of one location or a plurality of spot welding operations; a welding time measurement unit which measures an actual time from when a welding start command is outputted until receiving a welding completion command; and a comparative determination unit which determines quality by comparing the required welding time stored in the storage unit and the actual welding time measured by the welding time measurement unit.

To improve quality control of welding, there is included in resistance welding: a magnetic field measuring unit (205) disposed around a welded part and configured to measure a local current at the welded part; a high-speed camera (202) configured to capture an image for measuring local temperature at the welded part from variation of luminance of emission by capturing light emission state of the welded part; a comparison determination unit (106) configured to determine whether or not at least one of current information and temperature information has an abnormal value by comparing the current information calculated based on magnetic field information acquired from the magnetic field measuring unit with past current information and comparing the temperature information measured from an image of the high-speed camera (202) with past temperature information.

To improve quality control of welding, there is included in resistance welding: a magnetic field measuring unit (205) disposed around a welded part and configured to measure a local current at the welded part; a high-speed camera (202) configured to capture an image for measuring local temperature at the welded part from variation of luminance of emission by capturing light emission state of the welded part; a comparison determination unit (106) configured to determine whether or not at least one of current information and temperature information has an abnormal value by comparing the current information calculated based on magnetic field information acquired from the magnetic field measuring unit with past current information and comparing the temperature information measured from an image of the high-speed camera (202) with past temperature information.

Provided is an evaluation system including: an analog-to-digital converting section comprised of a programmable circuit and configured to convert an analog signal, the analog signal being acquired by a physical quantity acquiring section and indicative of a time-series change of at least one of (i) welding current, welding voltage, or load applied to pieces to be welded and (ii) a displacement, during welding, of a welding head; and an evaluating section configured to determine, based on a digital signal, whether or not the time-series change satisfies a predetermined condition, wherein configuration data for configuring the programmable circuit is arranged to be changeable by a user.

A method for adaptive control of the traveling electrode of a spot welding gun includes causing the traveling electrode of the welding gun to move at a first speed when performing a welding (working) cycle and to switch to a second speed at a point, the coordinate of which is calculated based on the point of contact of the coordinate of the electrode obtained at the configuration cycle performed before the working cycle. The method allows for a reduction in welding cycle time.

A spot welding monitoring method is configured to monitor a state of spot welding that holds a work including metal plates stacked on each other, between electrodes in a pair, and supplies electricity between electrodes. The spot welding monitoring method includes: by a converter disposed in a vicinity of a weld zone of the work, detecting a change in magnetic flux density of a magnetic field generated around the weld zone by the supplying of the electricity between electrodes, and converting the change in the magnetic flux density into a current; and calculating three-dimensional data on a melting zone of the work, based on a temporal change in a value of the current.

A spot welding monitoring method is configured to monitor a state of spot welding that holds a work including metal plates stacked on each other, between electrodes in a pair, and supplies electricity between electrodes. The spot welding monitoring method includes: by a converter disposed in a vicinity of a weld zone of the work, detecting a change in magnetic flux density of a magnetic field generated around the weld zone by the supplying of the electricity between electrodes, and converting the change in the magnetic flux density into a current; and calculating three-dimensional data on a melting zone of the work, based on a temporal change in a value of the current.

Aspects of this disclosure relate to a welding system that is configured to execute opposed, step, and parallel gap resistance spot welds (RSW) and associated methods. The system may be configured to switch bases to switch between an opposed weld configuration, a step weld configuration, and a parallel gap configuration. The system may include an accelerometer that is secured to the weld head adjacent one of the electrodes. The system may use the accelerometer to determine whether or not an RSW was defective. Acceleration data may indicate a defective weld when it includes acceleration data that is outside of a threshold range of acceptable acceleration data.

Aspects of this disclosure relate to a welding system that is configured to execute opposed, step, and parallel gap resistance spot welds (RSW) and associated methods. The system may be configured to switch bases to switch between an opposed weld configuration, a step weld configuration, and a parallel gap configuration. The system may include an accelerometer that is secured to the weld head adjacent one of the electrodes. The system may use the accelerometer to determine whether or not an RSW was defective. Acceleration data may indicate a defective weld when it includes acceleration data that is outside of a threshold range of acceptable acceleration data.