PECO Welding Systems GmbH
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 Real-time monitoring of welding
processes
PECO Welding's core business is manufacturing of intelligent
measurement systems for real-time monitoring of welding processes. This
is a multi-processor system with graphic display, which measures and
analyzes weld seams with sampling rates of a few μs in the μm range. On
behalf of PECO Welding, SYS TEC developed a hardware component for this
system for receiving and processing measurement signals. A Freescale
PowerPC was sued as the computer core. Particular value was placed on
the design of 56 digital and 16 analog I/Os. In consideration of the
rough operating environment of welding equipment a solution was created
that measured up to an elevated interference effect with unlimited
functionality. Communication with other processors and PLDs in the
overall system is done via the address / databus. This is prepared
using its own PLD, in order to realize the required bus timing. A can
and a RS-232 interface round off the functionality. The high
requirement of speed, accuracy, computing and flexibility could be
realized only with a 32-bit processor. In this project, SYS TEC could
make use of its experience in using Freescale PowerPC and PLD
programming. Our experience in EMV-relevant design of circuit boards in
industrial controls was a decisive fundamental in being able to satisfy
the high EMV requirements in welding machines. Serial production of the
boards is done at SYS TEC. For this product, too, there are special
quality requirements in production testing for compliance with the
technical parameters. The close contact of the development engineers
with production ensures consistent quality and fast response times.
Changes can also be implemented into serial production without
complication.
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