Resistance welding controller

Details Resistance welding controller Resistance welding controller

1999-09-04

2001-04-10

Shaw, Clifford C. (Department: 1725)

Electric heating

Metal heating

For bonding with pressure

Reexamination Certificate

active

06215086

ABSTRACT:

BACKGROUND OF THE INVENTION
The present invention relates to a resistance welding controller which supplies a given level of alternating (“AC”) current to a resistance welder.
A resistance welder welds a workpiece sandwiched between two electrodes as current flows. The current flow heats the workpiece and forms a molten metal weld “nugget.” After the welding current stops flowing, the weld nugget solidifies to form the weld.
There are two types of resistance welders: AC and direct (“DC”) current. A DC resistance welder and an associated resistance welding controller provide the advantage that the current supplied to resistance welder (and, in turn, to the electrodes) can be controlled within stringent limits. However, there are two major disadvantages: the equipment required is expensive and the electrodes wear out quickly because current flows in one direction only during welding. In contrast, an AC resistance welder and an associated resistance welding controller provide the advantages that the equipment required is inexpensive and the electrodes wear out very slowly. However, a disadvantage is that current supplied to the AC resistance welder
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(and, in turn, to the electrodes) can be controlled only within fairly loose limits.
One way to control both types of resistance welders is to install a separate resistance welding controller for each. However, having two separate controllers is costly.
In view of the foregoing, it would be desirable to provide a resistance welding controller which can control both AC and DC resistance welders while using electricity efficiently and improving welding performance.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a resistance welding controller which can control both AC and DC resistance welders while using electricity efficiently and improving welding performance.
The disadvantages and limitations of previous resistance welder controllers are overcome by the present invention which provides a resistance welding controller for supplying a substantially constant level of AC current to a resistance welder.
In one embodiment, the resistance welding controller automatically switches modes to provide compatibility with both AC and DC resistance welders. Operators are not required to visually check the type of the resistance welder and switch the mode, making the welder easier to use.


REFERENCES:
patent: 4503316 (1985-03-01), Murase et al.
patent: 4763237 (1988-08-01), Wieczorek
patent: 5171960 (1992-12-01), Takano et al.
patent: 5196668 (1993-03-01), Kobayashi et al.
patent: 5406045 (1995-04-01), Kiriishi et al.
patent: 5560842 (1996-10-01), Kitaguchi et al.
patent: 5589088 (1996-12-01), Boilard
patent: 5945011 (1999-08-01), Takano et al.

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