Force  This patented breakthrough technology provides accurate measurement of weld electrode force right at the point of weld.  The sensor produces a high speed analog signal up to 50K amps.  Integrated with the WeldMeter, the WeldThru sensor provides a force trigger to your PLC or weld controller to fire current only after your preset force is met.  This ensures the right pressure has been achieved and minimizes the squeeze time.

Current  An internal current sensor provides an accurate secondary current signal that is insensitive to position, orientation, and current frequency all within the same rugged package.  This current sensor eliminates the need for external coils and associated electronics.

Temperature  A temperature sensor provides an indicator of coolant flow through the sensor and the electrode.  Integrated with our WeldMeter, a relay output can be used as safety interlock to indicate loss of coolant

The WeldProbe is designed for long life in the harsh welding environment by using Sensotec's standard fully-welded load cell construction and NEMA 4 electronic packaging.  The easy-to use design includes a simple push-button format and a large LCD display that provides both continuous and peak (MAX) force values in keypad-selectable engineering units.

High-speed digital electronics sample force readings during the squeeze-weld-hold sequence and capture the peak force for display.  A simple, one-button CLEAR prepares the instrument for the next reading.  Two standard 9-volt alkaline batteries provide 80 hours of continuous use.  Battery life is maximized with programmable power-off feature.

The WEL measures force right at the pint of contact.  Its unique design allows it to be inserted directly into existing tooling-right in the weld current path-or used with optional adapters that mate the RWMA standard tapers.  In all applications, the load washer is installed under compressive preload allowing it to measure forces in both tension and compression.  Compressive loads measure the force applied to the weld-critical to providing the proper nugget growth and controlling expulsion.  Tensile loads can detect sticking weld tips.

Coupled with charge amplifier and Sensotec WeldMeter, the Dynamic Load Washer can ensure that proper weld force is achieved and maintained throughout the squeeze, weld, and hold cycle.  The WeldMeter monitors weld tip force and triggers current firing based on preset force limits and monitors peak force to ensure that preselected forces are not exceeded.

The WEL AND WeldMeter are used to improve your weld quality, reduce scrap and rework, reduce cycle time, and guard against ship bad welds.  These systems can be applied to existing machines or included on new machine orders.

Weld Force Pancake Load Cell (Model WPK) The weld quality of resistance spot welding depends largely on controlling your weld force.  To reduce flash and ensure the proper nugget formation, it is critical that minimum force (or pressure) is reached before current is fired and maximum force is not exceeded during the weld.  To minimize the weld cycle time, weld as soon as the current force is reached and eliminated wasted squeeze cycles.

Retrofit your existing press welders or custom weld machines with a system that allows you to calibrate an accurate initial force level and monitor weld-tip force during every weld or design it into your new machines.  The model WPK Pancake Load Cell is easily mounted between the air cylinder and the mounting block and interfaced with WM9000 WeldMeter.

Use the system to set the pressure regulator to provide an acceptable weld force.  Then, preset a force limit to a value approximately 5% lower than this force and connect the relay output of the WeldMeter to your PLC or weld controller.   The system will now monitor every weld and fire current precisely when the correct force is reached.

During the weld, it is important that the pressure does not continue to increase resulting in a cold weld or small nugget.  Use the second programmable limit to detect high forces and signal the operator when the tip force exceeds your acceptable limit.

WM9100 WeldMeter is a single-channel instrument that integrates with any sensor and provides four programmable limits and relays.