Linear DC Weld Controls Add High-Speed Process Monitoring

Precision resistance welding in electronics, automotive components and medical devices depends on tightly controlled energy delivery and traceable process data. Linear DC weld controls are used where consistent current profiles and minimal thermal variation are required. In this context, AMADA WELD TECH has released the next generation of its UB Series Linear DC Resistance Weld Controls, adding higher-speed feedback, expanded data handling and secure network integration.

Faster Closed-Loop Control at 40 kHz
The updated UB Series operates with 40 kHz closed-loop feedback for current or voltage regulation. Higher sampling frequency allows the controller to respond more quickly to changes in contact resistance during the weld cycle, helping stabilize current flow and waveform shape. This level of control supports more consistent weld nugget formation, reduced variation between parts and lower risk of overheating or distortion in thin or heat-sensitive materials.

A new “Weld to Displacement” control mode ends the weld cycle automatically when a programmed electrode displacement target is reached. Because displacement correlates with material softening and nugget formation, this method provides an additional process variable beyond time, current or voltage. It is suited to applications involving delicate components or materials with variable surface conditions.

Designed for Automated Production Cells
The controls are intended for both standalone benchtop systems and integration into automated manufacturing lines. A built-in 10-inch high-resolution touchscreen provides local operation, while an optional remote display supports installation within enclosed or space-constrained production cells.

Industrial communication interfaces include REST API and MQTT for IoT-style data exchange, along with RS-232 and direct I/O. EtherNet/IP is available as an option. These interfaces allow weld parameters, status information and results data to be linked with supervisory control systems, manufacturing execution systems and broader Industry 4.0 infrastructures.

High-Resolution Waveform Capture
Process monitoring is supported by full waveform capture of current, voltage, power and dynamic resistance at a 40 kHz sampling rate. Data is stored with 16-bit resolution, enabling detailed analysis of each weld cycle. Such high-resolution datasets can be used for statistical process control, traceability and early detection of electrode wear or material inconsistencies.

Remote network access allows engineers to carry out diagnostics, apply software updates and perform maintenance tasks without local intervention, reducing downtime in automated environments.

Network Security in Connected Manufacturing
As welding controls become network-connected devices, protection of process data and system access is increasingly important. The UB Series incorporates certificate-based authentication and TLS encryption implemented through OpenSSL. These mechanisms help ensure that only authorized systems and users can access the equipment and that transmitted data remains protected within connected production networks.

By combining high-speed feedback control, displacement-based process termination, detailed waveform recording and secure connectivity, the updated UB Series is positioned for resistance welding applications that require both precise energy control and integration into data-driven manufacturing environments.

www.amadaweldtech.com