For Lee Rowan I chose the process monitor to preserve the company's investment in standard welding controls. To get the most information with the minimum investment in sensors, we chose to monitor current and displacement. Displacement is measured with an optical sensor mounted on the electrodes, allowing work piece thickness and thermal expansion to be measured. Measuring thickness alerts the operator to improper parts. Thermal expansion is extremely sensitive to variation in any of the process parameters.
Current monitoring is used to help diagnose machine problems.
The WeldView monitor establishes upper and lower control limits on each parameter using a setup sequence. Lee Rowan uses the non-destructive test device to quickly assess weld quality during this procedure. If the parameter falls between these limits during welding, then the weld is good. A process parameter that goes below the lower control limit signifies a problem with the weld. When a problem in the welding process occurs, the monitoring system not only alerts the operator to the problem, but also identifies what parameter in the process is out of bounds.