A method for multi-specification output and monitoring of a manual resistance welding controller

Abstract

The application relates to the field of welding equipment control, and discloses a manual resistance welding controller multi-specification output and monitoring method, which comprises the following steps: selecting a welding specification through a welding tongs handle dial switch, and outputting a welding specification signal in an 8421 coding mode; the signal is received by a 16-way switch quantity detection module and transmitted to a communication adapter board through an RS485 communication mode, and then transmitted to a controller main control board to set the welding specification. After receiving a welding starting signal, the controller main control board executes a welding operation, and simultaneously transmits welding specification information to a digital tube display module through the communication adapter board to display a welding state in real time. The application supports up to 16 welding specification outputs, realizes real-time monitoring of a welding process, adapts to diversified welding demands, has the advantages of simple operation, stable signal and high welding quality, and effectively reduces the trial production cost of new vehicle models.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of welding equipment control, in particular to a method for multi-specification output and monitoring of a manual resistance welding controller. BACKGROUND

[0002] Manual resistance welding controllers have been widely used in the field of automobile manufacturing, especially in the welding process of the body-in-white, due to their flexibility and efficiency, they have become indispensable equipment. However, with the continuous introduction of new vehicle models, the trial workshop of the automobile factory has put forward higher requirements for the function of the welding controller. The traditional manual resistance welding controller currently in use can usually only support a limited number of welding specifications, and usually only two welding specifications can be configured for one device. This limitation leads to the need to frequently replace the equipment when dealing with different welding requirements, increasing the complexity and time cost of operation, and making it difficult to adapt to the diversified welding specifications required by the trial workshop.

[0003] In addition, the existing welding controller usually lacks real-time monitoring function, and the parameter changes during welding cannot be fed back to the operator in a timely manner. This lack of monitoring design makes it difficult for the operator to intuitively understand the current welding state, and the stability of the welding quality is also difficult to guarantee. Once there is a parameter anomaly or an operation error, it is difficult to take timely measures to correct it, which may result in substandard welding quality, increase the scrap rate, and affect the overall progress and cost control of the trial. Therefore, the existing manual resistance welding controller has deficiencies in the diversity of specification output and real-time monitoring capability, and it is difficult to effectively meet the high standard requirements of the welding equipment in the trial stage of new vehicle models. SUMMARY

[0004] In view of the deficiencies of the prior art, the present application provides a method for multi-specification output and monitoring of a manual resistance welding controller, which solves the problem that the existing manual resistance welding controller is difficult to support multiple welding specification outputs and lacks real-time monitoring function.

[0005] To achieve the above purpose, the present application is implemented by the following technical scheme: a method for multi-specification output and monitoring of a manual resistance welding controller, comprising the following steps:

[0006] Selecting a welding specification by a plurality of welding tongs handle dial switches, the dial switches output a welding specification signal through the 8421 encoding method;

[0007] The welding specification signal of the dial switch is received by a 16-way switch quantity detection module, and the signal is transmitted to a communication adapter board through an RS485 communication method;

[0008] The communication adapter board transmits the welding specification signal to the controller main control board, and the controller main control board sets the corresponding welding specification according to the welding specification signal;

[0009] The controller mainboard receives a welding start switch signal on the welding tongs handle and performs a welding operation based on a welding specification and the welding start signal;

[0010] The controller mainboard transmits current welding specification information to the nixie tube display module through the communication adapter, and the nixie tube display module displays the current welding specification state, realizing real-time monitoring of the welding process.

[0011] Preferably, the dial switches include a 1# tongs 1# handle dial switch, a 1# tongs 2# handle dial switch, a 2# tongs 1# handle dial switch and a 2# tongs 2# handle dial switch, each of which is connected to a different input port of the 16-way switch quantity detection module for identifying different welding specifications.

[0012] Preferably, the output end of the 16-way switch quantity detection module is connected to the input end of the communication adapter, data transmission is realized through an RS485 communication mode, and the communication adapter receives the welding specification signal and transmits the signal to the controller mainboard.

[0013] Preferably, the 16-way switch quantity detection module receives 8421 code signals of each dial switch and identifies up to 16 welding specifications based on the code signals.

[0014] Preferably, the welding start switches on the tongs handle include a 1# tongs 1# handle welding start switch, a 1# tongs 2# handle welding start switch, a 2# tongs 1# handle welding start switch and a 2# tongs 2# handle welding start switch, and the signal of the welding start switch is input to the corresponding port of the controller mainboard for starting the welding operation.

[0015] Preferably, the controller mainboard controls welding current and voltage welding parameters based on the welding start switch signal and the welding specification signal to adapt to the needs of different welding specifications.

[0016] Preferably, the controller mainboard sends a current welding specification state signal to the nixie tube display module through the communication adapter, and the nixie tube display module is used to display the current welding specification state in real time for the convenience of the operator to monitor.

[0017] The application also provides a manual resistance welding controller, which comprises:

[0018] A plurality of tongs handle dial switches are used to select a welding specification.

[0019] A 16-way switch quantity detection module is used to receive a welding specification signal of the tongs handle dial switch.

[0020] A communication adapter is connected to the 16-way switch quantity detection module and is used to receive a welding specification signal and transmit the signal to the controller mainboard through an RS485 communication mode.

[0021] The controller main board is used for setting the welding specification according to the welding specification signal and controlling the welding operation according to the welding start switch signal;

[0022] The digital tube display module is connected with the communication adapter board and is used for displaying the current welding specification state in real time.

[0023] Preferably, the plurality of welding tongs handle dial switches comprises:

[0024] 1# welding tongs 1# handle dial switch -1S1, 1# welding tongs 2# handle dial switch -1S2, 2# welding tongs 1# handle dial switch -2S1, and 2# welding tongs 2# handle dial switch -2S2;

[0025] The wiring points 1, 2, 4 and 8 of -1S1 are respectively connected to the wiring points IN1, IN2, IN3 and IN4 of the 16-way switch quantity detection module -ZY, the wiring points 1, 2, 4 and 8 of -1S2 are respectively connected to the wiring points IN5, IN6, IN7 and IN8 of -ZY, the wiring points 1, 2, 4 and 8 of -2S1 are respectively connected to the wiring points IN9, IN10, IN11 and IN12 of -ZY, and the wiring points 1, 2, 4 and 8 of -2S2 are respectively connected to the wiring points IN13, IN14, IN15 and IN16 of -ZY.

[0026] The C point of the dial switch is short-circuited and connected to the positive pole of the 24V power supply.

[0027] Preferably, the controller main board further comprises:

[0028] The power supply V+ end of the 16-way switch quantity detection module -ZY is connected to the positive pole of the P4 terminal of the communication adapter board -ZP, and the GND end is connected to the negative pole of the P4 terminal;

[0029] The A / D+ end of the RS485 interface of -ZY is connected to the P4 interface A of -ZP, and the B / D- end of the RS485 interface is connected to the P4 interface B of -ZP;

[0030] The positive pole and the negative pole of the power supply interface of -ZP are respectively connected to the positive pole and the 0V negative pole of the 24V power supply, the positive pole of the P5 interface is connected to the power supply positive pole of the digital tube display module -ZS, the negative pole is connected to the power supply negative pole of -ZS, the A end of the P5 interface is connected to the A / TX interface of -ZS, and the B end is connected to the B / RX interface of -ZS;

[0031] The welding start switches -1H1, -1H2, -2H1, and -2H2 on the welding clamp handle are connected to ports IO1, IO2, IO3, and IO4 on the main control board -C1 of the controller, respectively. Port 13 of the welding start switch is shorted and connected to the COM port of -C1.

[0032] This invention provides a method for multi-specification output and monitoring of a manual resistance welding controller. It has the following beneficial effects:

[0033] 1. This invention supports up to 16 welding specifications through a DIP switch with 8421 encoding. This design allows the controller to adapt to diverse welding specifications for different vehicle models, materials, and welding requirements, effectively improving the flexibility of the equipment and meeting the needs of various welding processes in the trial production of new vehicle models.

[0034] 2. This invention uses a digital tube display module to show the current welding specification status in real time, allowing operators to intuitively view the specification selection and welding status during the welding process. This real-time monitoring function not only improves operational accuracy but also effectively prevents incorrect specification selection, thereby enhancing the stability of welding quality.

[0035] 3. This invention employs RS485 communication, which has strong anti-interference capabilities and is particularly suitable for signal transmission requirements in industrial environments. This ensures that welding specification signals can be transmitted stably and accurately in complex production environments, thereby reducing the impact of signal interference on welding quality and guaranteeing the stability of the welding process.

[0036] 4. With this invention, the operator only needs to select the specification by toggling the DIP switch and press the welding start switch to complete the operation, eliminating the need for cumbersome setup procedures. This simple operation method significantly reduces the difficulty of operation and improves work efficiency, especially in situations where frequent switching of welding specifications is required.

[0037] 5. Upon receiving the welding specification signal, the main control board of this invention automatically sets the optimal welding current, voltage, and other parameters to adapt to different material and process requirements. Precise parameter control ensures high-quality consistency in every welding operation, reduces the incidence of welding defects, and improves product reliability and service life.

[0038] 6. This invention enables a single device to support multiple welding specifications, avoiding the cost of configuring multiple devices for different welding needs. It is particularly suitable for the diverse needs of new vehicle model trial production, significantly reducing trial production and production costs and improving resource utilization. Attached Figure Description

[0039] Figure 1 This is a flowchart of the method of the present invention;

[0040] Figure 2 This is a schematic diagram of the system configuration of the present invention;

[0041] Figure 3 This is a schematic diagram of the electrical principle of the present invention. Detailed Implementation

[0042] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0043] Please see the appendix Figure 1 - Appendix Figure 3 This invention provides a method for multi-specification output and monitoring of a manual resistance welding controller, aiming to meet the diverse needs of manual resistance welding in new model prototyping workshops in the automotive manufacturing industry. Through multi-specification output and real-time monitoring, the flexibility and reliability of the welding process are improved, and the prototyping cost of new models is reduced. The specific embodiments of this invention are described in detail below.

[0044] like Figure 2 and Figure 2 As shown, this method relies on the system structure of a manual resistance welding controller, including multiple welding clamp handle DIP switches, a 16-channel switch quantity detection module, a communication adapter board, a controller main control board, a digital tube display module, and a welding start switch. The functions and connection methods of each module are as follows:

[0045] Welding clamp handle DIP switches: used to select welding specifications, specifically including DIP switch for handle #1 of welding clamp (-1S1), DIP switch for handle #2 of welding clamp (-1S2), DIP switch for handle #2 of welding clamp (-2S1), and DIP switch for handle #2 of welding clamp (-2S2).

[0046] 16-channel switch quantity detection module (-ZY): Used to receive welding specification signals from multiple welding clamp handle DIP switches and convert the signals into digital signals for transmission.

[0047] Communication adapter board (-ZP): Used to receive welding specification signals from 16-channel switch quantity detection modules and communicate with the main control board of the controller via RS485 communication. It is also responsible for transmitting signals from the main control board of the controller to the digital tube display module.

[0048] Controller main control board (-C1): As the core module of the controller, the main control board receives welding specification signals and welding start signals, and executes corresponding welding operations according to the set welding specifications.

[0049] Digital tube display module (-ZS): Displays the current welding specification status in real time, facilitating operator monitoring of the welding process.

[0050] Welding start switches: including welding start switch for welding clamp 1# handle 1# (-1H1), welding start switch for welding clamp 2# handle 1# (-1H2), welding start switch for welding clamp 1# handle 2# (-2H1), welding start switch for welding clamp 2# handle 2# (-2H2), used to start welding operations.

[0051] The connections and signal flow between the various modules of the system are as follows:

[0052] 1. Connection between the welding clamp handle DIP switch and the 16-channel switch quantity detection module

[0053] The welding clamp handle DIP switch outputs welding specification signals via 8421 encoding. Specifically:

[0054] The connection points 1, 2, 4, and 8 of -1S1 are connected to the connection points IN1, IN2, IN3, and IN4 of the 16-channel switch quantity detection module (-ZY), respectively.

[0055] The terminals 1, 2, 4, and 8 of -1S2 are connected to the terminals IN5, IN6, IN7, and IN8 of -ZY, respectively.

[0056] The terminals 1, 2, 4, and 8 of -2S1 are connected to the terminals IN9, IN10, IN11, and IN12 of -ZY, respectively.

[0057] The connection points 1, 2, 4, and 8 of -2S2 are connected to the connection points IN13, IN14, IN15, and IN16 of -ZY, respectively.

[0058] The above connections ensure that the 8421 encoded signal of each DIP switch can be identified and processed by the -ZY module. Simultaneously, the C-point of all DIP switches is shorted and connected to a 24V positive power supply to ensure stable transmission of the encoded signal.

[0059] 2.16-channel switch quantity detection module and communication adapter board connection

[0060] After receiving the welding specification signals from the DIP switches, the 16-channel switch quantity detection module (-ZY) converts these signals into digital signals and transmits them to the communication adapter board (-ZP) via RS485 communication.

[0061] The specific link is as follows:

[0062] The power supply V+ terminal of -ZY is connected to the positive terminal of P4 of -ZP, and the GND terminal is connected to the negative terminal of P4 to ensure power supply stability.

[0063] In the RS485 interface of the -ZY, the A / D+ port is connected to the P4 interface A of the -ZP, and the B / D- port is connected to the P4 interface B of the -ZP, forming an RS485 communication connection. This connection method ensures the anti-interference capability of signal transmission and is suitable for use in industrial environments.

[0064] 3. Connection between the communication adapter board and the digital tube display module and the main control board of the controller.

[0065] In addition to receiving welding specification signals, the communication adapter board (-ZP) also connects to the digital tube display module and the main control board of the controller, as detailed below:

[0066] - The ZP's power connector is connected to a 24V positive power supply and a 0V negative power supply, respectively, to ensure power supply.

[0067] The positive and negative terminals of the P5 interface of the -ZP are connected to the positive and negative terminals of the power supply of the digital tube display module (-ZS), respectively. The A end of the P5 interface is connected to the A / TX interface of the -ZS, and the B end is connected to the B / RX interface of the -ZS to ensure that the welding specification information can be displayed on the digital tube in real time.

[0068] The P1 interface of the -ZP is connected to the X8 interface of the controller main board (-C1) via RS485 communication to ensure that the welding specification signal can be successfully transmitted to the controller main board.

[0069] 4. Welding the start switch to the controller main control board

[0070] Each welding clamp handle is equipped with a welding start switch (-1H1, -1H2, -2H1, -2H2) to initiate the welding operation. The specific connections are as follows:

[0071] Port 14 of -1H1 is connected to IO1 port of the controller main board, port 14 of -1H2 is connected to IO2, port 14 of -2H1 is connected to IO3, and port 14 of -2H2 is connected to IO4.

[0072] The No. 13 port of each welding start switch is shorted and connected to the COM port of the controller main control board to form a common ground for the start switches.

[0073] like Figure 1 As shown, this invention provides a method for multi-specification output and monitoring of a manual resistance welding controller. This method aims to achieve the selection, execution, and real-time monitoring of multiple welding specifications through a single controller, thereby meeting the needs of different welding conditions, improving welding quality, and is particularly suitable for the manual welding process of the body-in-white in automobile manufacturing.

[0074] This invention utilizes multiple welding clamp handle DIP switches to select the welding specification. The welding specification signal is transmitted to the controller's main board via a 16-channel switch detection module, and then combined with a welding start signal to control the welding operation. Simultaneously, the controller's main board transmits the welding specification information to a digital display module via a communication adapter board, enabling real-time display of the welding specification. This method allows a single welding controller to support multiple welding specifications and monitor the current welding status in real time, ensuring the accuracy and stability of the welding process.

[0075] The specific implementation steps of the method of the present invention are as follows:

[0076] Step 1: Selection of Welding Specifications

[0077] The operator selects the welding specification using the DIP switches on the welding clamp handle. Each DIP switch outputs the welding specification signal using the 8421 encoding method. For example, different combinations of DIP switches (such as DIP switch 1S1 for welding clamp #1, DIP switch 1S2 for welding clamp #2, etc.) can represent different welding specifications.

[0078] 8421 Encoding Method: Each DIP switch outputs an 8421 encoded signal through a combination of connection points (e.g., connection points 1, 2, 4, and 8). 8421 encoding is a binary weighted encoding that can combine to form 16 different signals, thus supporting up to 16 welding specifications. Different combinations of encoded signals can represent different welding current, voltage, and other process parameter settings.

[0079] Operating Procedure: The operator selects the welding specification by toggling the DIP switch. For example, when a specific welding specification is selected, the 8421 encoded signal from the DIP switch will be output from each connection point and transmitted to the 16-channel switch quantity detection module.

[0080] Step 2: Detection and transmission of welding specification signals

[0081] The welding specification signal is transmitted to the 16-channel switch quantity detection module through the wiring points of each DIP switch. The input terminals (IN1 to IN16) of this module are connected to different DIP switch signal input points.

[0082] Signal detection: The 16-channel switch quantity detection module receives the 8421 encoded signal and converts it into the corresponding welding specification data. The function of this module is to convert physical switch quantity signals (i.e., encoded signals) into digital signals for subsequent data processing and communication.

[0083] Signal Transmission: The 16-channel switch detection module transmits the digitized welding specification signals to the communication adapter board via RS485 communication. RS485 is a commonly used industrial communication standard with good anti-interference capabilities, suitable for signal transmission in industrial environments, ensuring stable transmission of welding specification signals.

[0084] Step 3: Signal processing and transmission on the communication adapter board

[0085] After receiving the welding specification signal from the 16-channel switch quantity detection module, the communication adapter board acts as a signal relay station and transmits the welding specification signal to the controller main control board via RS485 communication.

[0086] Signal relay: After receiving the welding specification signal, the communication adapter board converts the signal into a standard data format that the main control board can receive through the internal communication protocol, and then sends it to the controller main control board.

[0087] Synchronous signal transmission: In addition to transmitting to the main control board of the controller, the communication adapter board is also responsible for sending welding specification information to the digital tube display module so as to display the welding specification status in real time, so that the operator can intuitively understand the current welding status.

[0088] Step 4: Set the soldering specifications on the controller main board and wait for the start signal.

[0089] After receiving the welding specification signal transmitted by the communication adapter board, the controller main control board parses the welding specification and prepares the corresponding welding output conditions (such as welding current and voltage) according to the set parameters. This step allows the controller main control board to load the welding specification settings in advance, preparing for welding to start.

[0090] Parameter settings: Based on the welding specification signals, the main control board loads the corresponding process parameters such as welding current, voltage, and pulse time. For example, for welding high-strength steel, the main control board can set a higher welding current; while for welding thin plates or aluminum alloys, a relatively low welding current will be set to avoid weld burn-through or poor quality.

[0091] Ready state: After receiving the welding specification signal, the controller main control board enters the ready state and waits for the welding start signal input.

[0092] Step 5: Receive the welding start signal and execute the welding operation.

[0093] When the operator presses the welding start switch (such as -1H1, -1H2, etc.) on the welding clamp handle, the start signal is transmitted to the designated port (such as IO1 to IO4) of the controller main board through a dedicated signal line.

[0094] Start signal recognition: After receiving the welding start signal, the controller main board confirms that the operator has selected a specific welding clamp and welding specifications. Before starting welding, the system will reconfirm that the welding specifications signal is correct.

[0095] Welding Execution: After confirming the welding start signal and welding specification signal are correct, the controller main board begins the welding operation. Based on the loaded parameter settings, the main board controls the output of the welding current and executes the welding according to the preset welding current, voltage, and time parameters, ensuring the stability of the welding process quality.

[0096] Step 6: Real-time display of welding specification status

[0097] During the welding operation, the main control board of the controller will transmit the current welding specification information to the digital tube display module through the communication adapter board, and display the current welding specification status in real time.

[0098] Standard Display: The digital tube display module can intuitively display information such as welding specification number and welding status (in progress, completed, or abnormal). This display function ensures that the operator can understand the specification status during the welding process at any time, facilitating real-time monitoring of the welding process.

[0099] Abnormal alert: If an abnormality occurs during the welding process, such as excessive or insufficient current, the main control board will transmit an alarm message to the digital tube display module through the communication adapter board, reminding the operator to take immediate action.

[0100] In summary, this invention selects the welding specification via a DIP switch on the welding clamp handle, transmits the signal using 8421 encoding, and then transmits the welding specification signal to the main control board for setting via a 16-channel switch detection module and a communication adapter board. Upon receiving the welding start signal, the main control board executes the welding operation. Simultaneously, the main control board transmits the welding specification information to the digital display module in real time via the communication adapter board, enabling real-time monitoring of the specification. This method supports up to 16 welding specification outputs, adapting to different welding needs and improving the flexibility and stability of the welding process. It is particularly suitable for new model prototyping in the automotive manufacturing industry.

[0101] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for multi-specification output and monitoring of a manual resistance welding controller, characterized in that, Includes the following steps: Welding specifications are selected via multiple welding clamp handle DIP switches, and the DIP switches output welding specification signals via 8421 encoding. The welding specification signal of the DIP switch is received by the 16-channel switch quantity detection module and transmitted to the communication adapter board via RS485 communication. The communication adapter board transmits the welding specification signal to the main control board of the controller, and the main control board of the controller sets the corresponding welding specification according to the welding specification signal. The controller's main control board receives the welding start switch signal from the welding clamp handle and executes the welding operation based on the welding specifications and the welding start signal; The main control board of the controller transmits the current welding specification information to the digital tube display module through the communication adapter board. The digital tube display module displays the current welding specification status, realizing real-time monitoring of the welding process. The DIP switches include a 1# welding clamp 1# handle DIP switch, a 1# welding clamp 2# handle DIP switch, a 2# welding clamp 1# handle DIP switch, and a 2# welding clamp 2# handle DIP switch. Each welding clamp is connected to different input ports of a 16-channel switch quantity detection module to identify different welding specifications. The output of the 16-channel switch quantity detection module is connected to the input of the communication adapter board, and data transmission is achieved through RS485 communication. The communication adapter board receives the welding specification signal and transmits the signal to the main control board of the controller.

2. The method for multi-specification output and monitoring of a manual resistance welding controller according to claim 1, characterized in that, The 16-channel switch quantity detection module receives the 8421 encoded signal from each DIP switch and identifies up to 16 welding specifications based on the encoded signal.

3. The method for multi-specification output and monitoring of a manual resistance welding controller according to claim 1, characterized in that, The welding start switches on the welding clamp handle include welding start switches for welding clamp 1# handle, welding clamp 2# handle, welding clamp 1# handle, welding clamp 2# handle, and welding clamp 2# handle. The signal input of the welding start switches is sent to the corresponding port of the controller main control board to start the welding operation.

4. The method for multi-specification output and monitoring of a manual resistance welding controller according to claim 1, characterized in that, The controller's main control board controls the welding current, voltage, and welding parameters based on the welding start switch signal and welding specification signal to adapt to the needs of different welding specifications.

5. The method for multi-specification output and monitoring of a manual resistance welding controller according to claim 1, characterized in that, The controller main control board sends the current welding specification status signal to the digital tube display module through the communication adapter board. The digital tube display module is used to display the current welding specification status in real time so that the operator can monitor it.

6. A manual resistance welding controller, applied to the method as described in any one of claims 1-5, characterized in that, include: Multiple welding clamp handle DIP switches are used to select welding parameters; A 16-channel switch quantity detection module is used to receive welding specification signals from the DIP switches on the welding clamp handle; The communication adapter board connects to the 16-channel switch quantity detection module and is used to receive welding specification signals and transmit them to the controller main control board via RS485 communication. The main control board of the controller is used to set the welding specifications according to the welding specification signal and to control the welding operation according to the welding start switch signal; The digital tube display module connects to the communication adapter board and is used to display the current welding specification status in real time.

7. A manual resistance welding controller according to claim 6, characterized in that, The plurality of welding clamp handle DIP switches include: 1# Welding clamp 1# handle DIP switch-1S1, 1# Welding clamp 2# handle DIP switch-1S2, 2# Welding clamp 1# handle DIP switch-2S1, and 2# Welding clamp 2# handle DIP switch-2S2; Specifically, connection points 1, 2, 4, and 8 of -1S1 are connected to connection points IN1, IN2, IN3, and IN4 of the 16-channel switch quantity detection module -ZY, respectively; connection points 1, 2, 4, and 8 of -1S2 are connected to connection points IN5, IN6, IN7, and IN8 of -ZY, respectively; connection points 1, 2, 4, and 8 of -2S1 are connected to connection points IN9, IN10, IN11, and IN12 of -ZY, respectively; and connection points 1, 2, 4, and 8 of -2S2 are connected to connection points IN13, IN14, IN15, and IN16 of -ZY, respectively. The C point of the DIP switch is shorted and connected to the positive terminal of the 24V power supply.

8. A manual resistance welding controller according to claim 6, characterized in that, Also includes: The power supply V+ terminal of the 16-channel switch quantity detection module-ZY is connected to the positive terminal of the P4 terminal of the communication adapter board-ZP, and the GND terminal is connected to the negative terminal of the P4 terminal. The A / D+ terminal of the RS485 interface of -ZY is connected to the P4 interface A of -ZP, and the B / D- terminal of the RS485 interface is connected to the P4 interface B of -ZP. The positive and negative terminals of the power interface of -ZP are connected to the positive terminal of 24V power supply and the negative terminal of 0V power supply, respectively. The positive terminal of the P5 interface is connected to the positive terminal of the power supply of the digital tube display module -ZS, and the negative terminal is connected to the negative terminal of the power supply of -ZS. The A terminal of the P5 interface is connected to the A / TX interface of -ZS, and the B terminal is connected to the B / RX interface of -ZS. The welding start switches -1H1, -1H2, -2H1, and -2H2 on the welding clamp handle are connected to ports IO1, IO2, IO3, and IO4 on the main control board -C1 of the controller, respectively. Port 13 of the welding start switch is shorted and connected to the COM port of -C1.

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