Design of Resistance Spot Welding System using Integral Switching Cycle Control Technique

Abstract

The process of combining metal of similar composition by heating at suitable temperature with or without pressure and application of filler material is known as Welding. Resistance Spot Welding (RSW) is defined as a process which requires simultaneous application of high electrical current and appropriate pressure over short periods in order to keep the molten material inside the weld zone. Values of these parameters are varied in function of the characteristics of the materials to be welded. The application of the electrical current carrying two copper electrodes brought in contact with the welded parts while the required pressure is applied by means of pneumatic or hydraulic systems. This paper presents a novel design of resistance welding system using Integral Switching Cycle Control Technique used for performing a welding process. The paper is discussed about two aspects. First, a brief introduction about welding, methods of welding control and electronic control used in resistance welding. Secondly, the critical factors in design of a welding process are dealt along with the principle of the welding process. Following this, the introduction to the design of control scheme employed with the basic block diagram of welding system and its functioning is presented.