System and method for monitoring electrodes of a welder

A system for monitoring compression pressure of first and second electrodes of a welder, the system comprising:

• an apparatus comprising:
• connectedly spaced apart top and bottom plates,
• an aperture disposed in the top plate for receiving the first electrode therein,
• an aperture disposed in the bottom plate for receiving the second electrode therein, and
• a load cell attached to the bottom plate and in axial alignment with the apertures disposed in the top and bottom plates, the load cell being contacted by the first and second electrodes for sensing compression pressure between the first and second electrodes;
• and
• a data processing unit in electrical communication with the load cell for monitoring and determining whether the compression pressure of the first and second electrodes exceeds a threshold value.

A system for monitoring alignment of first and second electrodes of a welder, the system comprising:

• an apparatus comprising:
• connectedly spaced apart top and bottom plates,
• an aperture disposed in the top plate for receiving the first electrode therein,
• an aperture disposed in the bottom plate for receiving the second electrode therein, and
• a limit switch mounted on the bottom plate, the limit switch being activated when either of the first and second electrodes contacts the top and bottom plates, respectively, thereby denoting misalignment;
• and
• a data processing unit in electrical communication with the limit switch for monitoring and determining whether alignment of the first and second electrodes exceeds a threshold value.

A method for monitoring temperature, compression pressure, and alignment of first and second electrodes of a welder, the method comprising the steps of:

• determining whether the first and second electrodes are in alignment and, if not, indicating misalignment;
• compressing a load cell between the first and second electrodes to produce a load cell signal;
• comparing the load cell signal to criteria and determining whether the compression pressure of the first and second electrodes is within a set range;
• indicating an anomaly of the compression pressure between the first and second electrodes if the compression pressure is not within the set range;
• determining temperature of the first and second electrodes;
• and
• indicating insufficient cooling of the first and second electrodes if temperature of the first and second electrodes is greater than a threshold temperature.