A Novel Method for the Real-time Force Losses Detection in Servo Welding Guns.

Nowadays, real-time detection methods are increasingly necessary for predictive maintenance in production processes. Specifically, in the metal joining production processes that use the resistance welding process, the optimization of maintenance programs is sought to improve both the quality of the body and its manufacturing cost. In this novel paper a new method is presented for the sensorless detection of pressure losses in welding lines. The proposed system bases its operation on the measurement of the existing variables in the resistance welding process carried out using servo guns. This paper also shows the proposed system for the data acquisition, data sending and visualization in real-time of the health of the welding gun. This results in a system with a low installation cost but with great performance in reducing problems associated with force losses in welding guns.