In automotive robotic welding, achieving faster cycle times, reducing scrap, and maximizing uptime are crucial to maintaining productivity and profitability. As welding operations push for higher efficiency, weld-gun cooling and coolant management have become increasingly important. Even a single coolant leak or weld-gun cap-off event can bring an entire weld cell to a costly halt.
The WeldSaver™ 6 Passport with eVac™ Coolant Retraction Module delivers an indispensable solution for robotic welding coolant monitoring, helping welding engineers detect issues early and respond instantly. By preventing unnecessary downtime, equipment damage, and scrap, the system often pays for itself after just one incident is avoided.
As an authorized automation distributor, RAM Solutions provides advanced weld-cell reliability solutions designed to meet the demands of OEM and Tier automotive environments.
Capabilities Welding Engineers Rely On
Continuous Monitoring of Critical Weld-Gun Cooling Metrics
The WeldSaver 6 Passport continuously monitors:
• Coolant supply and return flow rates
• Coolant temperature
These parameters are measured against preset warning and fault thresholds. When a fault is detected, the system immediately sends a state change signal to the weld controller, allowing for fast, automated response and preventing further damage.
This level of real-time coolant monitoring is essential for maintaining consistent weld quality and protecting robotic welding equipment.
Fast, Accurate Cap-Off and Leak Detection
Using proprietary flow accelerometer technology, the WeldSaver 6 Passport accurately distinguishes true coolant leaks from normal flow variations.
Key performance advantages include:
• Leak or cap-off detection in under 0.3 seconds—the fastest response time in the industry
• Automatic coolant shutoff in under 1 second
These rapid response times are crucial in automotive spot welding, where even small disruptions can negatively impact cycle time, throughput, and overall weld-cell performance.
The eVac Advantage — Protecting Cap Changers and Equipment
As the use of high-cost automatic cap changers continues to grow, protecting them from coolant expulsion damage is more important than ever. The Proteus eVac Coolant Retraction Module is specifically designed to address this challenge.
When a leak or cap-off event occurs, the eVac module:
• Actively retracts coolant from the weld-gun circuit, overcoming the limitations of volume-restricted drawback cylinders
• Keeps cap changers dry and cleaner, improving reliability and extending equipment life
• Reduces weld-cell cleanup and recovery time
• Helps prevent unplanned downtime that disrupts cycle timing and downstream manufacturing processes
Built for Automotive Automation Integration
The WeldSaver 6 Passport with eVac features fully integrated hardware and firmware, eliminating the need to assemble and integrate multiple valves, flow meters, or auxiliary components.
The system connects directly to:
• EtherNet/IP™
• PROFINET®
This enables seamless integration with major robotic weld controllers used in OEM and Tier supplier environments. No additional I/O hardware is required, reducing installation time and overall system cost.
Simple Setup and Ongoing Maintenance
Each system arrives pre-configured for your specific welding application and can be easily fine-tuned using:
• A local keypad and LED display
• A browser-based GUI, including compatibility with teach pendants
This simplifies commissioning, troubleshooting, and long-term maintenance for welding and controls teams.
Learn More from RAM Solutions
For additional insights on weld-cell reliability, robotic welding automation, and coolant management best practices, call RAM Solutions.
If you’d like help determining the best WeldSaver configuration for your weld cell, you can contact RAM Solutions. Our automation experts are happy to walk through your options and support your application.