RESISTANCE WELDING CONTROLLER
Smart Resistance Welding Control for Consistent and Efficient Production
The Resistance Welding Controller is a high-precision control unit designed to manage and optimize the welding parameters of resistance welding machines such as spot, projection, or seam welders. It enables operators to monitor, program, and adjust critical welding parameters in real-time, ensuring consistent weld quality, repeatability, and energy efficiency.
Modern controllers use digital microprocessor or PLC technology, providing millisecond-level control over welding current, electrode force, and weld duration. These controllers are essential for applications where high-volume production, tight tolerances, and material-specific welding profiles are required.
By integrating a Resistance Welding Controller, manufacturers can reduce scrap, prevent equipment overloading, and improve overall welding performance, making it indispensable in automotive, electrical, appliance, and general fabrication industries.
Key Features
- Suitable for single phase AC spot/projection welder and seam welder.
- CPU carries out the Feedback control during welding. It ensures the stable welding current even the fluctuation of power supply there. Guaranteed the welding quality.
- Count the welding spots. Detect the actual voltage of the power supply. Detect the actual welding current (CC mode).
- Two type of current feedback: Welding transformer primary side and secondary side.
- Automatic self-diagnosis, display Error number for any abnormal condition.
- Power limit interface for convenient limiting the power capacity.
SPECIFICATION
| Model Items | KCT01 |
|---|---|
| Control factor / times | 4/15 parameters / 3 times pulse control |
| Pressure valve drive | 2 pressure valves, DC 24V |
| Feedback mode | Welding transformer primary side / secondary side |
| Rated input voltage (V) | 415V / 1 phase, ±10% |
| Frequency (Hz) | 50/60 |
| Control parameter range – Pressure | Pressure valve 1 |
| Parameter | 1 – 15 |
| Initial pressure delay (cycle) | 0 – 199 |
| Initial pressure time (cycle) | 1 – 199 |
| Current upslope time (cycle) | 1 – 199 |
| Pre-heat time (cycle) | 0 – 199 |
| Pre-heat current (×100A) | 20 – 199 |
| First cooling time (cycle) | 0 – 199 |
| Welding time (cycle) | 0 – 199 |
| Welding current (×100A) | 20 – 199 |
| Second cooling time (cycle) | 0 – 199 |
| Temper time (cycle) | 0 – 199 |
| Temper current (×100A) | 20 – 199 |
| Current downslope time (cycle) | 0 – 199 |
| Hold time (cycle) | 1 – 199 |
| Off time (cycle) | 0 – 99 |
| Transformer turn ratio (M) | 1 – 99 |
| Number of welding circuits | 1 – 4 |
| Over current limit | 5 – 99% |
| Under current limit | 5 – 99% |
| Adding weld control under current limit | 1 / 1 time adding weld allowed, 0 / No adding weld |
| Suitable welding power source | Thyristor |
| Start mode | Pulse, Normal |
| Welding mode | Spot / Projection, Seam |
| Keep ending signal | Built-in |
| Power signal | Built-in |
| Power control signal | Built-in |
| Monitor function | Weld spot count, welding current, current ratio, etc. |
| Count function | Count welding spots |
| Switch running mode | Welding/Adjustment, Discontinuous/Continuous |
Frequently Asked Questions
What you should know
What is a resistance welding controller?
A resistance welding controller is an electronic device used to regulate and control the welding process in resistance welding machines. It precisely manages parameters like current, voltage, time, and pressure to ensure consistent and high-quality welds.
How does a resistance welding controller work?
It works by controlling the electrical energy supplied to the welding electrodes. The controller adjusts welding current and timing based on programmed settings, ensuring the metal reaches the correct fusion temperature for a strong and reliable weld.
What are the key features of a resistance welding controller?
Key features include programmable welding schedules, constant current control, real-time monitoring, fault detection, multi-mode welding support (spot, seam, projection), and user-friendly digital interfaces for easy operation.
What are the applications of resistance welding controllers?
Resistance welding controllers are widely used in automotive manufacturing, sheet metal fabrication, electrical component production, battery welding, aerospace industries, and appliance manufacturing.
What are the benefits of using a resistance welding controller?
It improves weld accuracy, ensures repeatability, reduces material wastage, enhances production efficiency, and provides better control over welding quality compared to manual systems.
Can resistance welding controllers be used with existing machines?
Yes, most modern resistance welding controllers are designed for easy integration and can be retrofitted into existing spot welding, seam welding, or projection welding machines without major modifications.