Effect of Initial (Reference) Welding Current for Adaptive Control and It's Optimization to Secure Proper Weld Properties in Resistance Spot Welding

Md., Ashadudzzaman; Choi, Il-Dong; Kim, Jae-Won; Nam, Dae-Geun; Park, Yeong-Do

doi:2015.33.6.13

J Weld Join > Volume 33(6); 2015 > Article

Special Issue

Journal of Welding and Joining 2015;33(6):13-20.
DOI: https://doi.org/10.5781/JWJ.2015.33.6.13 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^*

Correspondence: Yeong-Do Park,
Email: ypark@deu.ac.kr

Abstract

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.

Key Words: Resistance spot welding, Adaptive control, Optimal welding current, Process disturbances