Zydeceltico
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- Dec 5, 2017
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I know nothing of your business, nor welding. So you are going to have to explain to me what real world process those tables are capturing. The simpler the terms the better. I know no welding jargon and you shouldn't use database jargon in explaining the real world process.
Point straight up with the index finger of your left hand. At the same time point down with the index finger of your right hand. Touch the tip of your left with your right - straight up and down. Lift and lower the right hand repeatedly - slowly and touch fingertips every few 10 seconds or so. Your fingers together comprise one welding gun. The time spent with fingertips touching is a weld cycle.
To explain the AC welder which is slightly more complex than the DC welders, touch your fingertips as above. While they are touching, press the tips together for 100 millseconds, relieve the pressure but don't separate the tips, apply pressure again, relieve, apply pressure and hold for 2 seconds.
That is a full weld cycle on an AC welder.
ALL welders - AC and DC have at least four guns (pairs of fingertips). All four guns are not required for all products - on either welder. Depending on the requirements of the product being made, only one gun may be used or two or three or all four - and in a very rare case on a single welder that we own - five.
When you are intentionally pressing the tips together we measure 1) the amount of pressure and 2) the length of time you are holding that pressure. This process can repeated multiple times.
Also, for every time you press your fingertips together an electrical current can be passed from the upper fingertip to the other. The amount of that current can be programmed differently for every time you press the tips together.
The pressing together can happen 1 time or more than once - usually twice but sometimes three.
So you have a "weld time" which is the length of time tips are touching; "weld pressure" (the amount of force between tips) and weld amperage (the amount of current passing through tips) - and again - on an AC welder this can all happen multiple times WITHIN ONE WELD CYCLE (see my 1st paragraph above).
The various programmable settings on the welder control this process. This amount of programmability only happens on an AC welder and the controls are named very differently than on a DC welder.
If the AC welder is the Maserati of welders, the DC welders are the Ford F-150s (or Dodge Ram or whatever). They are not "mindless" but they are not nearly as complex as the AC welders. Their controls are similar as you can see from looking at the two tables but only similar - they are not the same.
For one thing, on a DC welder, the fingertips only touch once and that is it. The "pumping" action of the fingertips only happens on the AC welders.
With that said, I would try to combine tblDCWelderMeasure and tblACWelderMeasures. They already share a lot of the same fields, and with a little finessing they could share more.
So - because I have to eventually create forms that collect this data in this most efficient - on the shop floor manner - I am struggling to see how I can normalize these two tables anymore. I am also not completely sure that I have them realting to the correct table in the mockup I sent earlier.
THe more I think about it though - I just realized that every weld nugget record from tblWeldNuggets is defined and recorded as the product of a specific weld gun on a specific welder.
Weld nuggets: To do a weld test we take a piece of material (2"x4") that is from the same original stock as the real parts we are welding together. We clamp these two pieces together. This is called a weld coupon. Each of the two pieces in the weld coupon is marked with 1) the job number; 2) the Coil number that it came from (original material); and 3) the weld gun number - SO - AHA - each weld nugget (A and B) is related to a specific weld gun on a specific welder (AC or DC).
The only bugger I just realized is that with AC welder - the entire process I described above - the programming - happens for EACH OF THE FOUR GUNS on an AC welder whereas, on the DC welders, the settings are global to the welder itself and one set of settings effects all four guns.