Bosch Rexroth Introduces PXC7100 Precision Welding Control System for Low Voltage Resistance Welding

Bosch Rexroth’s PXC7100 control system expands its resistance welding portfolio to better serve precision welding operations in the welding, forming, metal joining and assembly industries. The PXC7100 is cost-effective, simplifies commissioning and improves precision from enhanced process monitoring.

The PXC7100 control system is suitable for applications with particularly low voltage, like splice compacting micro strands, contacting sensors or welding batteries. Unlike ultrasonic welding, resistance welding enables manufacturers to reliably extend or compress coated strands, making it well-suited for electronic applications that require corrosion-resistant conductors.

Intuitive connection and control

As part of the PRI-web user interface, a setup wizard enables quick commissioning of the PXC7100. When using the optional Measuring Gun Data (MGD) module, only one bus cable is required for all signal cables for the welding control unit, which significantly reduces the amount of cabling required. The MGD module digitizes all analog sensors such as force signal, position signal, current signal, transformer data and process data directly at the welding head. 

The pre-processed data is transferred directly to the welding control in real time with a 1 kHz cycle rate via the Weld Interface Controller (WIC) Bus, where it’s processed further. The scaling data, counters and mechanical data are also stored in the MGD module. When using the integrated servo function, no additional PLC or machine-side motion logic is required to control the electrode. Thanks to the web-based PRI-web user interface, users can operate the PXC7100 simply and intuitively, on the computer or via mobile devices.

Process data can be transferred via the IoT Connector, which supports the MQTT and OPC UA protocols, so that it can then be further processed as required and used as part of quality assurance or predictive maintenance tasks. 

The PXC7100 builds on Bosch Rexroth's comprehensive resistance welding and joining solutions portfolio, which combines intelligent controls, software and automation technologies to deliver precise, repeatable welding processes across automotive, battery, electronics and industrial manufacturing applications. 

For more information about Bosch Rexroth's resistance welding and joining solutions, visit www.boschrexroth.com/en/in/industrial-automation/joining-technology/.