Abstract
Resistance spot welding is a process commonly used for joining a stack of two or three metal sheets at desired spots. Such welds are accomplished by holding the metallic workpieces together by applying pressure through the tips of a pair of electrodes and then passing a strong electric current for a short duration. This kind of welding process often suffers from two common drawbacks, namely, inconsistent weld quality and inadequate nugget size. In order to address these problems, a new theoretical approach of controlling resistance spot welding processes is proposed in this paper. The proposed controller is based on a simplified dynamical model of the resistance spot welding process and employs the principle of adaptive one-step-ahead control. It is essentially an adaptive tracking controller that estimates the unknown process parameters and adjusts the welding voltage continuously to make sure that the nugget resistance tracks a desired reference resistance profile. The modeling and controller design methodologies are discussed in detail. Also, the results of a simulation study to evaluate the performance of the proposed controller are presented. The proposed control scheme is expected to reduce energy consumption and produce consistent welds.
Subject
Applied Mathematics,Computational Mathematics,General Engineering
Reference27 articles.
1. Resistance Welding Fundamentals and Applications;Zhang,2012
2. A Nonlinear Current Control Method for Resistance Spot Welding
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