Steps To Successful Adaptive Operation

For General Motors

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1. Install Workstation Computer and / or View-R
2. Review weld matrix – understand stack-ups, metal types
3. *Complete Pre-requisites
4. Operate in Constant Current / with steppers. Create
Reference Welds using only one part. (Some expulsions
OK)
5. Review data of one tip dress cycle for consistency using
the Quality tab.
6. *Create SoftQ PI Envelope limits using EASY BUTTON #1
7. *Create SoftQ Monitoring limits using EASY BUTTON #2
8. Create data files and backup information.
9. *Take action and maintenance steps required as required
as notified by SoftQ alerts / faults.
* See addition information in following pages

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1. Common welding practices
 Gun alignment
 Check spot locations for edge, fit-up, electrode
skidding and shunting
 Verify tip force and current
 Check water tubes / water flow
2. Adaptive practices
 Add tip wires (per specification requirements)
 One schedule per spot
 Perform R measure

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 SoftQ - PI Envelope (msec data)
Timer
RAFT EASY
Button
#1

Reference Weld

AdaptQ SoftQ

EASY BUTTON #1 - PI Envelope

Graph Data Summary Data
ms * 4 variables 64 fields with each weld
Should be created with a minimum of
upper (+10%) and lower (-10%)
windows for each millisecond of
resistance. Easy button uses data in
the Workstation or View-R collected
PI Envelope SoftQ Monitoring
over one tip dress.
64 fields with each weld
Resistance Curve
The shape of the weld resistance curve is directly
related to the processes position in the weld lobe.
PI (0 to 100%) Welds that stay in this position are in control and
produce good welds. Welds outside the limits
Percent of ms points in limits
may or may not produce good welds.

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 SoftQ – Monitor (weld summary data)
Timer
RAFT

SoftQ Variables by Schedule

1. Resistance
- Tip Dress
- Tip Check

Reference Weld 2.

3.
NI
TI
4. Cfactor
5. Energy
6. PI Envelope

AdaptQ SoftQ 7.

8.
Heat
Current
9. Secondary Voltage
Weld time
EASY
10.

Button
#2 EASY BUTTON #2 –
Graph Data Summary Data Monitor (Welds)

ms * 4 variables 64 fields with each weld Automatically creates

upper (+3 std) and
lower (-3 std) windows
of Fault and Trend
limits for all SoftQ
PI Envelope SoftQ Monitoring monitoring variables.
These limits are based
64 fields with each weld
Resistance Curve on data collected over
a selected period of
time within in the
workstation or View-R
PI (0 to 100%) database.
Percent of ms points in limits
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# Name Range How Calculated How used Maintenance
Most commonly used
action
1 Resistance 0—1000 Micro- Secondary tip wires Tip Dress Repair tip dresser.
ohm Tip Check Dress weld caps.
2 NI 0-150% Total energy, R-drop, Confidence factor of Check entire weld
R-peak, R-curve, Total Heat, an acceptable process.
current and weld time of the nugget.
subject weld as compared to
the reference weld.
3 TI 0-150% C-Factor measured in latter Measures the health Maintain tooling:
section of weld but also of the tooling (more Check wear on shunts
compared to the reference accurate than C- Remove weld flash on
weld. Factor). gun.
4 C-Factor 0-1000 ON time, nominal line voltage, Measures the health Maintain tooling:
DC bus voltage, turns ratio, of the tooling. Check wear on shunts
primary current. Remove weld flash on
gun.
5 Energy 0-65535 Sum of voltage * current only Indicate delivery Check for electrical
Joules over the weld portion. Energy Shorts.
6 PI 0—100% From PI Envelope section Quality indicator Check for process
Envelope changes:
Different work piece,
thickness, material
type, force, etc.
7 Heat 0-65535 watt Volt * Current Check proper Replace inverter or coil
constant current pickup.
action.
8 Sec. 0-40000 Tip wires Indicates need for Broken or worn tip
Voltage mill-volt immediate attention. wires.
9 Current 0-100,000 Primary Coil Check proper Change weld schedule.
constant current 6
Low current Flat Caps

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