Influence of Mechanical Failures of the Welding Gun on the Magnetic Field Generated in the Measurement of Misalignment

The present work presents an advance in the method for the detection of electrode misalignment. In previous research, a new method for detecting misalignment of the electrodes was shown, in which, it was stated that by means of the analysis of the magnetic field generated by the short-circuited electrodes, it was possible to determine if the electrodes were well aligned [1]. This paper seeks to continue with the optimization of the method, delving into the behavior of the magnetic field in the welding electrodes. Throughout this paper simulations of the different typical cases of welding guns that could influence the measurement of the magnetic field are carried out. In short, this work analyzes the theoretical robustness of the method. Welding guns often present other mechanical problems apart from misalignment of the electrodes, therefore, it is essential to study if these problems would cause false positives in detection and to what extent these mechanical problems could or could not be detected using the same method. This paper serves to validate the method definitively and give a positive response to what has been carried out in previous publications.