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Study and implementation of a force stepper and a part fit-up solver algorithm for a servo controlled MFDC spot welder

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3 Author(s)
Venugopal, D. ; Dept. of Electr. & Comput. Eng., Oakland Univ., Rochester, MI, USA ; Das, M. ; Fernandez, V.

The goal of this research is to study the effect of a time-varying electrode force on the weld nugget size for mid frequency direct current (MFDC) resistance spot welding (RSW) systems. Using SORPASTM, a software for simulation and optimization of resistance welding process, simulations were performed for MFDC RSW with changing force profiles and weld times. Additionally, an algorithm was developed to automatically detect a bad stack fit-up and correct it by applying an additional compensating force. This was implemented on a resistance spot welding gun fitted with a 4.5 KW servo motor along with a built-in resolver, a UnidriveTM motor controller and a real time embedded program. The simulation and experimental results are presented and compared with results obtained using a constant current (CC) welding process with constant force profile.

Published in:

Electro/Information Technology, 2009. eit '09. IEEE International Conference on

Date of Conference:

7-9 June 2009

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