Abstract: A clinching station for securing a first workpiece to a second workpiece includes control logic receiving a punch position sensor output and processing the punch position sensor output and an established position signature to generate a clinching operation status signal. The clinching station includes a punch and die assembly including a punch and a die mounted opposite each other for movement relative to each other along a working axis. A position sensor is configured to monitor the position of the punch relative to the die, and has an output indicative of the position of the punch relative to the die. The established position signature corresponds to an acceptable clinching operation, and allows the control logic to generate the clinching operation status signal.

Abstract: A welding system for real-time weld quality detection during resistance welding of a workpiece has a sensor assembly including a winding and a core mounted generally coaxially within the cylinder of the welding gun. A piston and piston rod assembly are mounted for coaxial movement within the cylinder. The piston rod has an end protruding from the cylinder for affixing an electrode thereto. Axial movement of the piston rod relative to the cylinder causes axial movement of the core relative to the winding to vary a length of core and winding overlap. The sensor assembly produces an output signal based on the length of core and winding overlap to indicate piston rod position relative to the cylinder. Weld control logic receiving the sensor assembly output controls welding of the workpiece in real-time.