ADAPTIVE STEPPER

An adaptive stepper for adjusting welding heat boost to compensate for deterioration (flattening) of the electrode tips of a welder. Heat boost is provided to the welder as a function of expulsion rather than by a series of linear step profiles specified by a weld engineer. An operator sets up an adaptive schedule based upon an expected resistance difference between consecutive half-cycles considered to be "normal." If differences equal to or less than the normal level are detected during a group of welds, the heat boost will be incremented by 1% after a preprogrammed number of welds have been made. If differences greater than normal are detected, indicating expulsion, the boost will be decremented immediately by 1% between increases, if decrements are allowed at the time.