Welding Pressure Control Apparatus and Method

A welding pressure control assembly comprising:

• a welding wheel electrode;
• a welding support assembly and a mounting structure which are independently moveable;
• a load cell;
• a processor;
• and
• a linear actuator adapted to move the welding support assembly in relation to the mounting structure,
• wherein:
• the welding wheel electrode is fixedly attached to the welding support assembly;
• the load cell is disposed intermediate the welding support assembly and the mounting structure;
• the load cell is adapted to measure force transmitted to the welding wheel electrode through the welding support assembly;
• the load cell is in informational communication with the processor;
• the processor is in informational communication with the linear actuator;
• the processor is adapted to utilize force information communicated by the load cell to control operation of the linear actuator;
• and
• controlled operation of the linear actuator allows controlled movement of the welding support assembly in relation to the mounting structure, which thereby provides control of the pressure applied by the welding wheel electrode.

A method for providing controlled welding pressure in a wire wrap screen manufacturing process comprising:

• a rib support step comprising providing a support for a plurality of ribs, the support comprising a rotating spindle, wherein a proximate end of each rib is connected to a tailstock;
• a wire feed step comprising providing a wire to an intersecting surface of one of the ribs;
• a welding device placement step comprising providing a welding device in contact with the wire at the intersecting surface, wherein the welding device is supported on a support assembly;
• an initial force determination step comprising determining a pressure exerted on the wire by the welding device;
• a pressure adjustment step comprising adjusting the pressure exerted by the welding device on the wire to a predetermined level;
• a welding step comprising welding the wire to the rib at the intersecting surface;
• a rotating step comprising rotating the spindle;
• a linear drive step comprising driving the tailstock away from the support assembly;
• a feedback step comprising obtaining measurement information of the pressure exerted on the wire by the welding device;
• and
• a control step comprising receiving the measurement information, processing the measurement information, and outputting control commands to adjust the pressure exerted by the welding device on the wire according to predetermined parameters.