Abstract: A continuity sensor determines continuity between welding electrodes by detecting a change in a voltage of a sensed tracer signal across the electrodes from a time when a weld cycle is initiated to a time when the electrodes contact material to be welded. As the electrodes are brought together with low force, the continuity sensor detects changes in the sensed voltage level exceeding a threshold thereby representing continuity and enables the welder to apply the higher welding force. However, if the continuity sensor does not detect a change in the voltage signal, then the welder will not apply the full welding force, thereby preventing pinch-point injury to the operator. The digital continuity sensor reestablishes a baseline for detecting the change in voltage with every new weld cycle such that the digital continuity sensor is not subject to changing voltages or changes in the welder configuration.

Abstract: A continuity sensor determines continuity between welding electrodes by detecting a change in a voltage of a sensed tracer signal across the electrodes from a time when a weld cycle is initiated to a time when the electrodes contact material to be welded. As the electrodes are brought together with low force, the continuity sensor detects changes in the sensed voltage level exceeding a threshold thereby representing continuity and enables the welder to apply the higher welding force. However, if the continuity sensor does not detect a change in the voltage signal, then the welder will not apply the full welding force, thereby preventing pinch-point injury to the operator. The digital continuity sensor reestablishes a baseline for detecting the change in voltage with every new weld cycle such that the digital continuity sensor is not subject to changing voltages or changes in the welder configuration.