A Proportional-Integral Controller for Resistance Spot Welding Using Nugget Expansion

[+] Author and Article Information
H. S. Chang

Department of Mechanical Engineering, Myong Ji University, Yong-In, Kyung-Gi, Korea

Y. J. Cho

Daewoo Shipbuilding & Heavy Machinery LTD., Ok-Po, Kyung-Nam, Korea

S. G. Choi

Hyundai Electronics Industries Co. LTD., Seoul, Korea

H. S. Cho

Department of Production Engineering, Korea Advanced Institute of Science & Technology, Seoul, Korea

J. Dyn. Sys., Meas., Control 111(2), 332-336 (Jun 01, 1989) (5 pages) doi:10.1115/1.3153055 History: Received January 01, 1987; Online July 21, 2009


An electrode wear has been found to cause considerable quality variation in the process of resistance spot welding. This paper presents a study on the electrode wear growth and develops a microprocessor-based feedback controller that can compensate weld quality variation due to electrode deterioration. The controller developed in this study utilizes a PI control algorithm, incorporating the electrode movement as a feedback signal. A series of experiments was performed to clarify the wear growth phenomenon and to evaluate the performance of the controller. The experimental results show that the electrode wear can significantly cause quality deterioration, but this can be effectively compensated via application of this proposed control technique.

Copyright © 1989 by ASME
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