In any industry, welding is performed in different environments. It may take place in the open air, underwater, or even in outer space. Other energy sources are used in weldings such as a gas flame, a laser, an electric arc, an electron beam, ultrasound, and friction.

Welding is an essential part of the industry. It places a lot of emphasis on the accountability and traceability of resistance welding processes, weld temperature, exposure to fumes, health hazards data monitoring, etc. Thus, there is an increasing need for monitoring of the process and enhancement of process control.

Weld monitors provide precision and real-time dynamic measurement of all the variables of the welding and prove to be an imperative component for the following –

• Development of process: evaluation and research of welding, DoE (design of experiment) studies in resistance welding, process optimization and validation
• Monitoring of process: data logging, setting the limits for operation, maintenance of electrodes, setting up verification, troubleshooting, and statistical process control
• Control of quality: traceability, certification, and analysis of strategy, confirmation of calibration, statistical process control

Thus, the weld monitors and weld counter’s specific function is to measure the voltage and the current during the resistance welding process. The primary tasks of weld data monitoring are to provide data that can be statistically used to determine and monitor the ongoing operations while alerting the user to any unacceptable variations in any voltage or a current-based parameter.