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Weld Monitors.
Merlin Control Systems Ltd design and manufacture a range of accurate, reliable and cost-effective monitors for most types
of resistance welding machines, including spot and projection welders, seam welders, wire butt welders, and high-speed
contact welders.
These units are microprocessor based, and designed for ease of use by unskilled staff. All units have eight internally
stored sets of weld parameter limits, one of which is selected for use by bcd coded inputs, either from a manual switch,
or from a PLC. The operator is guided through a simple set-up proceedure to input his required weld limits for all eight
programs.
The monitor will measure either RMS weld current, or the integral of current over time. This is effectively the area under
a graph of current against time, and equates to the total power put into the weld.
The unit has a simple voltage-free relay contact, which changes over in the event of a weld being outside of the preset
limits. A synchronisation input is also provided for an external signal, so that a good weld must be measured between one
edge of the synchronisation input and the next, making the unit particularly suited for automatic or high speed applications.