Abstract: A system and method for monitoring compression pressure, temperature, and alignment of first and second electrodes of a robotic welder. An apparatus is provided with hingedly connected, spaced apart top and bottom plates. An aperture is disposed in the top plate for receiving the first electrode therein and an aperture is disposed in the bottom plate for receiving the second electrode therein. Temperature sensors are mounted adjacent to the top and bottom plates for sensing temperature of the electrodes. A load cell is included in the apparatus for sensing pressure between the electrodes as well as a limit switch for indirectly sensing misalignment between the electrodes. A data processing unit is in electrical communication with the temperature sensors, load cell, and limit switch for performing software analysis.

Abstract: A system and method for monitoring the operating condition of an electrode dresser for an automated spot welder includes a sensor for sensing an operating characteristic of the dresser. The output produced by the sensor is analyzed by a data acquisition system to determine the operating condition of the dresser. Various types of sensors may be employed including a current sensor which senses current flowing through the dresser motor, a flux sensor which senses leakage flux produced by the dresser motor, and a vibration sensor which senses vibration produced during operation of the dresser. Operating characteristics determined by the data acquisition system include whether the electrode dresser is operational, whether the dresser has been engaged by the electrodes of the welder, the amount of time that the welder electrodes were in dress, and the quality of the dress.