An Electrothermal Model Based Adaptive Control of Resistance Spot Welding Process

• 作者: Manohar Das Ziyad Kas
• 来源期刊: 智能控制与自动化(英文)
• 学科: 医学
• 关键词: RESISTANCE SPOT Welding Adaptive Control NUGGET Formation Energy SAVING
• 年，卷（期）: 2015,（2）
• 页码范围: 134-146
• 页数: 13页
• 分类号: R73

摘要

Resistance Spot Welding (RSW) is a process commonly used for joining a stack of two or three metal sheets at desired spots. The weld is 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. Inconsistent weld and insufficient nugget size are some of the common problems associated with RSW. To overcome these problems, a new adaptive control scheme is proposed in this paper. It is based on an electrothermal dynamical model of the RSW process, and utilizes the principle of adaptive one-step-ahead control. It is basically a tracking controller that adjusts the weld current continuously to make sure that the temperature of the workpieces or the weld nugget tracks a desired reference temperature profile. The proposed control scheme is expected to reduce energy consumption by 5% or more per weld, which can result in significant energy savings for any application requiring a high volume of spot welds. The design steps are discussed in details. Also, results of some simulation studies are presented.