Improved stepper display and adjustment
Presently, the user cannot tell which step to adjust for a cold weld. A graphic display of stepper progress along a boost line would help, and alerting when the wrong step is being adjusted, would help a lot. Those controls that boost in 1% increments cause slight expulsion on critical cosmetic welding, as 1% is usually 250 amps! It is difficult to pinpoint this as the cause of expulsion. SEE MORE ON THIS on the Stepper page
Stepper boosts heat time, along with current
A chart of acceptable combinations of current and time reveals that as the tips mushroom, more time is needed to make the larger weld. Presently the stepper can only be set to boost current; the weld time is therefore not optimum at all times.
Unsolicited, programmable announcements to the master workstation
This would allow immediate attention called to faults, schedule changes, etc., as they occur on the plant floor. Commonly, a "polling routine" is used to generate "exception reports" early in the morning, before production starts, but probably well after the schedule or set-up changes were performed.