NDT.net May 2006, Vol. 11 No.5

Ultrasonic System Ensures the Quality of the Spot Welds
Rexroth’s PSQ 6000 — Ultrasonic and Current/Voltage Adaptive Control Quality Monitoring System Provides Maximum Reliability for Spot Welds

Rexroth demonstrates its ingenuity in the interests of safe and cost-effective resistance spot welding in developing adaptive current/voltage and ultrasonic measuring techniques for quality control. The PSQ 6000 monitoring system from Rexroth provides non-destructive testing for medium-frequency applications in automotive welding and assembly lines. The system guarantees absolute process reliability and consistency of weld quality — even with the most demanding material combinations.

For maximum quality in spot welding, Rexroth offers the PSQ 6000 system designed for current/voltage and/or ultrasonic control. The PSQ 6000 quality assurance system controls, monitors and logs the entire welding process.

Adaptive Current/Voltage Control for Maximum Spot Weld Quality
The adaptive current/voltage control mode gives you added flexibility for future requirements in the welding process. By measuring current and voltage, the course of resistance and energy can also be recorded, controlled and accurately evaluated during welding. The adaptive control algorithm ensures constant weld quality and reduced expulsion. Expensive rework is therefore eliminated.

Ultrasonic Control for Constant Spot Weld Diameter
The ultrasonic measuring and monitoring system ensures the quality of the spot welds during the actual welding process. Being based on an independent measurement, the advantage of the ultrasonic transmission curve is its reliability in displaying and documenting the spot weld diameter. The destructive testing of spot welds with hammer and chisel can be omitted. The ultrasonic system consists of the XQR control board, UDM signal processor and ultrasonic sensors.

Combined User Interface
Rexroth BOS 6000 is the Windows-based user interface for weld control and quality monitoring. The BOS 6000 system provides users with full-featured programming, monitoring and logging of the entire welding process.

The Bosch Group is a leading global manufacturer of automotive and industrial technology, consumer goods, and building technology. In fiscal year 2004, some 242,000 associates generated sales of 40 billion euros. The Bosch Group today comprises a manufacturing, sales, and after-sales service network of some 260 subsidiaries and more than 10,000 service centers in over 130 countries.

In North America, the Bosch Group manufactures and markets automotive original equipment and aftermarket products, industrial automation and mobile products, power tools and accessories, security technology, thermo technology, packaging equipment and household appliances. Bosch employs nearly 23,000 associates in more than 80 primary and 20 associated facilities throughout the region with reported sales of $7.8 billion in 2004.

Under the industrial automation and mobile products segment, Bosch Rexroth Corporation is a wholly owned subsidiary of Robert Bosch GmbH. In the year 2004, Bosch Rexroth achieved sales of approximately $5.3 billion (4.1 billion Euros) with 26,400 employees worldwide.

Under the brand name of Rexroth, the company offers all relevant drive, control and motion technologies: from mechanics, hydraulics and pneumatics to electronics and associated services. Rexroth has 500,000 customers in over 80 countries and is an extensive supplier of components and systems for industrial and factory automation and mobile applications. For more information, visit www.boschrexroth-us.com.

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