Design, Simulation, Implementation and Control Of Spot Welding Process

Abstract

The resistance spot welding can be defined as autogenously fusion welding process, in which the heat necessary to produce a joint is generated by the joule effect based on the electrical resistance at the contact surfaces between the welded parts. The resistance spot welding process 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 vary in function of the characteristics of the materials to be welded. The application of the electrical current is by means of two copper electrodes brought in contact with the welded parts while the required pressure is applied by means of pneumatic or hydraulic systems. This major project presents the simulation, design, implementation and control of resistance welding system which is used for performing a welding process. The project is divided into four sections. First, a brief introduction about welding, methods of welding control and electronic control used in resistance welding. Secondly, the critical factors in the design of a welding process are dealt along with the principle of the welding process. Following this, the introduction to the design of the control scheme employed with the basic block diagram of the welding system and the functioning is presented. Thirdly, the design and development of the control algorithm is dealt with. Simulation is carried out in two different software MATLAB 2006 and PROTEUS. Finally, the conclusions is drawn along with its working and future improvements.