Resistance spot weld head with integrated accelerometer

A welding system comprising:

• a computing device that comprises:
• one or more processing circuits including one or more microprocessors;
• and
• a display,
• a resistance spot weld (RSW) head that defines a PGW configuration and an opposed welding configuration, the RSW head comprising:
• a first arm that is configured to receive a first electrode;
• a second arm that is configured to receive a second electrode, wherein the first electrode and the second electrode are in contact with a first set of components on one side;
• and
• an accelerometer securely attached to the first electrode at a location adjacent to the first electrode;
• a first base with a first securing platform configured to secure first set of components;
• and
• a second base with a second securing platform configured to secure a second set of components and including a third electrode for opposed RSW (opposed weld),
• wherein the first electrode and the second electrode are configured to execute a parallel gap RSW (PGW) on the first set of components as secured to the first base when the RSW head is in the PGW configuration,
• wherein the first electrode and the third electrode are configured to execute an opposed weld on the second set of components as secured to the second base when the RSW head is in the opposed welding configuration,
• wherein the one or more processing circuits are configured to cause the accelerometer to gather a PGW set of acceleration data of the first electrode during the PGW and gather an opposed weld set of acceleration data of the first electrode during the opposed weld,
• wherein the one or more processing circuits are configured to execute instructions of identifying weld defects stored in a memory so as the one or more processing circuits are configured to indicate a first weld defect of the first set of components on the display based on determining that a first portion of the PGW set of acceleration data indicates the first weld defect by including at least one acceleration value outside of a threshold acceleration range, wherein the first portion includes relatively less volatility of acceleration data than a subsequent second portion of the PGW set of acceleration data, and
• wherein the one or more processing circuits are configured to indicate a second weld defect of the second set of components on the display based on determining that a first portion of the opposed weld set of acceleration data indicates the second weld defect by including at least one acceleration value outside of the threshold acceleration range, wherein the first portion of the opposed weld set of acceleration data includes relatively less volatility of acceleration data than a subsequent second portion of the opposed weld set of acceleration data.

A method of welding comprising:

• executing a parallel gap resistance spot weld (RSW) to a first set of components secured to a first base with a welding system that includes one or more processing circuits including one or more microprocessors configured to execute instructions for identifying weld defects stored in a memory and a weld head and a first and second electrode secured to the weld head by providing current to the first electrode and enabling the current to exit through the second electrode when the first and second electrodes are contacting the first set of components, wherein the first electrode and the second electrode are in contact with the first set of components on one side;
• gathering, by an accelerometer secured to the weld head, a PGW set of acceleration data of the first electrode during the period of time during which the first electrode provided current to the first set of components;
• determining, by the one or more processing circuits according to the instructions, that the PGW set of acceleration data indicates a first weld defect by identifying that the PGW set of acceleration data includes at least one acceleration value outside of a first threshold acceleration range;
• executing, with the welding system, an opposed RSW (opposed weld) to a second set of components secured to a second base that includes a third electrode, the opposed weld executed by providing current to the first electrode and enabling the current to exit through the third electrode when the first electrode and the third electrode are contacting the second set of components;
• gathering, by the accelerometer, an opposed weld set of acceleration data of the first electrode during the period of time during which the first electrode provided current to the second set of components;
• and
• determining, by the one or more processing circuits according to the instructions, that the opposed weld set of acceleration data indicates a second weld defect by identifying that the opposed weld set of acceleration data includes at least one acceleration value outside of a second threshold acceleration range.