Optimization of resistance welding by using electric servo actuator

Abstract

The paper is focused on the control of resistance projection welding process applied in joining of thin-walled metal elements. The motion of electrode is generated by electric servo actuator that controls the force exerted on electrode or alternatively, just travel itself of electrode. The projection welding has been discussed for welding of 1.5 mm thick DX53 steel sheets where one sheet contains an embossed projection. Apart of electric servo actuator, another source of force has been described, i.e. pneumatic actuator (classical one), for the reason of comparison. The solution where the electric servo operates together with appropriate algorithm makes the new solution that is alternative for classical, pneumatic one. Optimized motion of electrode due to new proposed source of electrode force or/and travel, based on relevant algorithm yields improved quality of joints.