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JWJ > Volume 33(6); 2015 > Article
Journal of Welding and Joining 2015 December;33(6) :13-20.
Published online December 31, 2015.
Effect of Initial (Reference) Welding Current for Adaptive Control and It's Optimization to Secure Proper Weld Properties in Resistance Spot Welding
Ashadudzzaman Md.*, Il-Dong Choi**, Jae-Won Kim***, Dae-Geun Nam****, Yeong-Do Park*
*Dept. of Advanced Materials Engineering, Dong-Eui University, Busan 614-714, Korea
**Dept. of Materials Engineering, Korea Maritime and ocean university, Busan 606-791, Korea
***School of Materials Science and Engineering, Pusan National University, Busan 609-735, Korea
****Dongnam Regional Division, Korea Institute of Industrial Technology, Busan 619-203, Korea
Correspondence: Yeong-Do Park  Email:
  Published online December 31, 2015
Many automotive companies are endeavoring to improve the quality of resistance spot welding by updatingbody-in-white (BIW) production line with adaptive control spot welding system to compensate the process disturbances such as gap, electrode wear, oxidized surfaces, poor fit up and adhesive etc. Most of the commercial adaptive weld controllers require proper “Initial Welding Schedule” or “Reference weld” to achieve compensation in welding parameters during real time welding. In this study, the compensation of a commercial adaptive weld controller had been observed and analyzed thoroughly for various process disturbances to find optimal initial welding schedule. It was observed that 90 percent of the expulsion current in constant current control as reference welding schedule conferred the maximum button diameter in adaptive control welding. Finally, effects of each disturbance in combined field disturbances system with adaptive control had also been confirmed with the design of experiment (DOE) by minitab?16 for combined disturbances situation and suitability of optimum initial weld current had also established with real body part validation test.
Keywords: Resistance spot welding | Adaptive control | Optimal welding current | Process disturbances
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