weld monitoring
weld monitoring
Digital Process Sentry
• Measure voltage, current, force
and displacement
• Dual channel capability
• Configurable user interface with
four display quadrants
• Full on-screen SPC capability
• 99 available schedules with
password protection
• Serial output via RS-232
• Weld interrupt function
With increased emphasis on accountability,
the MG3 Digital Process Sentry offers the
tools required for process development,
production monitoring, data collection, and
analysis to support your ISO, GMP and TQM
The MG3 represents the very latest
technology in resistance weld monitoring;
it provides precision real-time dynamic
measurement of all the welding variables
and is an invaluable tool for:
Process Development
Welding Evaluation and Research, DoE
Studies, Process Optimization, Process
Process Monitoring
Data Logging, Setting Process Limits, Electrode Maintenance,Troubleshooting, Set-up
Verification, Statistical Process Control
Quality Control
Traceability, Process Certification and
Analysis, Calibration Confirmation, Statistical
Process Control
With three models to choose from, the
MG3 can monitor up to two simultaneous
channels of current and voltage from up to
two AC, DC or CD power supplies for spot
or seam welding. In addition to the basic
model, the W1 and W2 models have single
and dual channel displacement capability,
respectively, and also offer inputs for force
and pressure sensors.
Upper and lower limits can be set to trigger
alarms for all measurements; for more
advanced users, these limits can be set as
envelopes that follow the contour of the
waveform. Judgment of good/bad welds
can be determined by status LED’s on the
front panel and outputs from the MG3’s I/O.
All welding parameters are stored in internal
memory, available from the built-in RS-232
port, and data may be transferred to a
Compact Flash (CF) card and directly
exported into Excel® for user-defined
analysis. The MG3 also has a convenient
“SNAPSHOT” feature to save screenshots
for reports. Comprehensive SPC functions
include run chart logging and histograms.
Designed for Flexible Use – (Configurable Run Screen)
The high resolution color display and user configurable
run screen enables users to configure the display to
show information relevant to their particular job
function or chosen welding environment.Two-channel
capability allows simultaneous measurement and
comparison of two welding systems.
The MG3 is easy to program via a single rotary
encoder knob. Up to 100 monitoring programs can
be stored for multiple parameters.
Examples of full view display. View is configurable to show graphic or numeric parameters in each quadrant. An individual quadrant can be selected as the main view.
Measurement Capability
The MG3 can measure AC, CD and DC welding systems and monitor the following parameters when fully configured with sensors:
• Current (RMS, Peak, Amp-Sec.) • Time (ms/cycles)
• Voltage (RMS, Peak, Volt-sec.)
• Displacement (mm, In.)*
• Power
• Force (lbs., N)*
• Energy
• Pressure (psi, bar)*
• Resistance
High Frequency
Linear DC
Inverter (HF)
*Available on MG3 W1 and W2 only
Discharge (CD)
Energy (A.C.)
Welding Oscilloscope Functionality (Process Development)
The MG3 can be used like an oscilloscope to analyze waveforms and compare parameters on a single screen using different pen colors for
up to 4 measurement traces.
Multiple graphic trace with moveable cursors and zoom functions are perfect for weld analysis.
“Snap Shot” to Compact Flash Memory Card – (Quality Assurance)
Pressing the control button for three seconds saves the current screen as a .bmp file on the Compact
Flash (CF) memory card. Waveforms can also be saved in .csv format for importing to an Excel file.
32MB CF card supplied. Accepts up to 1GB
CF card. Alternatively, data can be collected
via RS-232 for storage and analysis.
Snapshot of screen is saved to CF card as a .bmp file.
Limits and Envelope Functionality (Process Monitoring)
Maximum and warning values can be set for
parameters, which will trigger both front
panel LED’s and alarm outputs.
Reference waveforms can be automatically averaged from numerous welds and results
may be used to specify envelope limits applied to the average or typical weld. Two
envelopes may be applied to any parameter or two separate parameters, or to a specific
section of the weld to ensure weld consistency.
Maximum and Pre-Warning
Acceptable – Weld Envelope
Reject – Weld Envelope
Statistical Process Control (SPC) and Quality Assurance
The MG3 performs a vital role in any production process
and provides both data logging and on-screen SPC including
run charts, histograms and analysis. Welds can be collected
in the on-screen histogram, and pre-determined standard
variation (2, 3, 4, 5, 6 sigma) values can be processed and
set as production limits. The unit is able to transfer all weld
data to a host PC and can save it to a log file on the CF card
for further analysis in programs such as Excel.
Winweld ® data collection and analysis software provides an
easy method for process and variable comparison and storage.
Good/Bad Analysis Ratios
Run Chart with Limits
Histogram with Limits
SPC Data Logger. All welds, rejects or last can be saved to the memory card.
Model Numbers
Measurement Capability
MG3 Digital Basic
2 channel current
2 channel voltage
MG3 Digital W1
MG3 Digital W2
2 channel current
2 channel current
2 channel voltage
2 channel voltage
1 channel displacement
2 channel displacement
Includes 1 sensor
Includes 2 sensors
Analog inputs for force or pressure
Analog inputs for force or pressure
2, 5 ,20, 100, 500 kA
0.2, 0.5, 2, 10, 50 kA
0.5, 2.5, 10, 50 V
ms or cycles, 50/60 Hz. Peak I / Average I / Cond. angle
Rectified, Inverter, DC
Capacitor Discharge, ms
Inverter, AC
Power P = VRMS x IRMS
Energy E = VRMS x IRMS x t
Charge Q = IRMS x t
Resistance R = P/IRMS2
±1.5% of full scale
DC 1–2,000 ms, AC 1–5,000 ms (.5 cycles – 300 cycles)
(V, I) = 100 kHz per channel, simultaneous sampling V, I of each channel
measure time <= 50msec: resolution 40 points per msec
measure time > 50msec: resolution 5 points per msec
Pressure 10 points/ms
Force 10 points/ms
Digital distance 5 points/ms
0.0 Bar – 10 Bar
External sensor with output DC 0-10V
Power supply 24V DC
2 channels parallel measurement
External sensor with output DC 0-10V
Power supply 24V DC
Force depends on sensor
2 channels parallel measurement
1µm – 99999µm (incremental, glass scale, noise free, 1 micron resolution)
2 channels parallel measurement
90 - 260V, 50 / 60 Hz
2500 welds internal, 1 GB Compact Flash (32 Mb card supplied)
RS-232 data collection, CF card, Win Weld Data Collection Software
QVGA Display, 6 LED's dedicated fault and good indications
11 dedicated inputs plus 8 binary for schedule selection
13 dedicated outputs plus 8 binary for schedule selection
7 inputs and 15 outputs for displacement functions
5.3 (135) x 11.0 (279) x 13.0 (330)
11.0 (5.0)
Current Measurement Range (X1 Coil)
Current Measurement Range (X10 Coil)
Voltage Measurement Range
Profile: AC
Derived Parameters
Accuracy (Current/Voltage)
Sampling Rate
Graphic Resolution
Note: unit will measure force
or pressure, not both.
Displacement (Digital Distance)
Models W1 and W2
Input Power
Front Panel
Binary Inputs
Binary Outputs
Additional Displacement I/O
Size Inches H x W x D (mm)
Weight Lbs. (kg)
MG3 Digital Basic
MG3 Digital W1
MG3 Digital W2
1 ea. current coil (internal dia.) 2.5”
1 ea. voltage measurement leads
1 ea. 32MB CF card
1 ea. current coil (internal dia.) 2.5”
1 ea. voltage measurement leads
1 ea. 32MB CF card
1 ea. displacement sensor (1µm)
2 ea. current coils (internal dia.) 2.5”
2 ea. voltage measurement leads
1 ea. 32MB CF card
2 ea. displacement sensors (1µm)
Your Local Representative
1338 N. Knollwood Circle
Anaheim, CA 92801
t: 714-252-5330
f: 714-252-5335
Specifications subject to change without notice.
Copyright© 2006 Miyachi Unitek Corporation. The material contained herein cannot
be reproduced or used in any other way without the express written permission of
Miyachi Unitek Corporation. All rights reserved.
991-515 01/06
w w w. s e e d o r f f we l d e r s. co m
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