Weld controller system for coupling to a common database system on a communication network

A weld controller system for controlling the operation of a welder including a weld transformer and at least one pair of contact tips that apply current to create heat between at least two workpieces, the weld controller system comprising:

• A. a microprocessor;
• B. welder power means controlled by a weld program operating by the microprocessor and operatively connected to the weld transformer for supplying weld current to the contact tips to create said heat in said workpiece, said weld program for increasing the weld heat in increments following a predetermined weld schedule having a plurality of weld cycles to provide compensation for deterioration and wear of said contact tips;
• C. a current sensor for sensing current supplied by said welder power means to said weld transformer, said current sensor for providing weld current data for use by said weld program;
• D. a voltage sensor for sensing input voltage supplied to said weld power means, said voltage sensor for providing weld voltage data for use by said weld program;
• E. a memory for storing said program, weld current data, and voltage data;
• F. a first communication port for coupling said weld controller system to a communications network, said network including at least one operator interface unit, said operator interface unit including a system database for storing said weld current data and voltage for use in monitoring, controlling, and editing said weld controller system;
• G. a data interface coupled to said first communication port, said data interface for detecting addressed data packets containing commands from said interface unit, said commands including an upload command for requesting data from said memory and a download command for entering data to said memory;
• said data interface unit for extracting said requested data from said memory and sending said data back to said interface unit in a data packet, and said data interface unit for extracting said received data from said data packet and storing said data in said memory;
• and
• H. wherein said weld controller sends and receives data packets to said system database in said operator interface unit regardless of said system database's data structure.