Bosch Rexroth Launches Next-Generation Adaptive Resistance Welding Controller

  • January 14, 2022
  • Bosch Rexroth
Bosch Rexroth Launches Next-Generation Adaptive Resistance Welding Controller
Bosch Rexroth Launches Next-Generation Adaptive Resistance Welding Controller

The PRC7000 provides faster commissioning, advanced adaptability and energy efficiency to automotive manufacturers and others using high-throughput automated welding systems, with both the highest-quality weld control and 90% faster, more user-friendly commissioning. 

Bosch Rexroth is an industry leader in the development of automated resistance welding controllers, introducing several generations of more sophisticated adaptive resistance control systems that incorporate advancements in software and processor performance. 

The PRC7000 provides the highest-quality weld control, with reliable high weld spot quality and ultraprecise adjustment of the welding current to eliminate spatter and expensive reworking. Innovative software tools and a modular design enable up to 90% faster commissioning, making it much easier for manufacturers to implement and use the system. 

The PRC7000 can store up to 10,000 welding programs that can be easily selected and built via a drag-and-drop graphical interface to program more sophisticated welding sequences that can have 100 or more separate heat blocks. Through user-friendly programming tools, each heat block can be configured to handle specific weld criteria.

The system also features a new, Industry 4.0-ready dual-processor architecture for both process control and communications with higher-level automation systems. This design enables high data transfer rates without affecting the process control; combined with an integrated web server, this supports wireless operator control and diagnostics via mobile devices. 

The new system has a more compact design, with features created to improve energy efficiency. The PRC7000 reduces energy consumption by 30% in operating mode, compared to previous systems, and up to 80% in idle mode. New performance electronics reduce power loss and enable the use of smaller, more compact cooling systems to help keep the system’s footprint to a minimum.

Patented technology addresses changes in automotive manufacturing

The PRC7000 system incorporates major advances in controller hardware and software to help address key developments in automotive manufacturing, such as an increased use of high-strength steel, aluminum and next-generation materials in vehicle bodies and parts. 

The core of adaptive resistance welding control is having the capability to adjust the quality of the weld within a millisecond time frame. With the PRC7000, Rexroth is introducing a patented capability for the controller’s force feedback system that reads the expansion of the aluminum due to heat and can regulate the weld through adaptive control of the weld tip pressure and the current being applied.

This new capability makes it easier for manufacturers to incorporate new materials in their vehicle and equipment designs without risking complications and added costs or quality control problems in their assembly operations.

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