Development of a Hybrid Ultrasonic-Resistance Spot Welding System for Aluminum Sheet

2018 ◽  
Author(s):  
L. Lindamood ◽  
J. Gould ◽  
D. Workman
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Aluminum Sheet ◽  
Resistance Spot ◽  
Welding System

Detecting saturation level in the iron core of a welding transformer in a resistance spot-welding system

2008 ◽  
Vol 320 (20) ◽  
pp. e878-e883 ◽  
Author(s):  
Klemen Deželak ◽  
Beno Klopčič ◽  
Gorazd Štumberger ◽  
Drago Dolinar
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Saturation Level ◽  
Iron Core ◽  
Resistance Spot ◽  
Welding System

scholarly journals Minimization of Welding Time for an AC Resistance Spot Welding System With 60Hz Transformer

2010 ◽  
Vol 15 (3) ◽  
pp. 218-225
Author(s):  
Jin-Kyu Seok ◽  
Sung-Kwan Kang ◽  
Woong-Hyub Song ◽  
Eui-Cheol Nho ◽  
In-Dong Kim ◽  
...  
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Time ◽  
Resistance Spot ◽  
Welding System

scholarly journals Capacitor Discharge Spot Welding of Aluminum, Part 2: Electrode Life Assessments

2021 ◽  
Vol 100 (11) ◽  
pp. 349-358
Author(s):  
JERRY E. GOULD ◽  
◽  
LINDSEY LINDAMOOD ◽  
JULIO MALPICA ◽  
PATRICK LESTER ◽  
...  
Keyword(s):  
Power Systems ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Cooling Water ◽  
High Volume ◽  
Aluminum Sheet ◽  
Capacitor Discharge ◽  
Wear Rates ◽  
Resistance Spot ◽  
Polarity Switching

A major challenge for high-volume resistance spot welding of aluminum sheet is durability of the electrodes themselves. In production today, electrodes have total anticipated lives (including dressing) on the order of 1000 welds. This is largely related to the use of medium-frequency direct current (MFDC) power. The single-polarity orientation of MFDC welding results in excessive heating of one electrode (anode) and accelerated wear rates. Recently, technology employing capacitor discharge (CD) welding in conjunction with polarity switching has been developed. This work is the first effort in examining the response of resistance spot welding on aluminum sheet using this power source. Part 1 of this research (Ref. 1) described basic process robustness in spot welding with CD power systems. Part 2 addresses electrode life response. Duplicate electrode life tests were completed for 2000 welds without failure. These results were related to the polarity switching and short time that produced balanced and minimized wear. Additional testing was done without the use of electrode-cooling water. A limited test (500 welds) largely paralleled the ones done with cooling, suggesting that long-term spot welding with polarity-switching CD power and no water was possible.

scholarly journals Modified Recurrence Plot for Robust Condition Monitoring of Electrode Tips in a Resistance Spot Welding System

2020 ◽  
Vol 10 (17) ◽  
pp. 5860
Author(s):  
Wonho Jung ◽  
Hyunseok Oh ◽  
Dong Ho Yun ◽  
Young Gon Kim ◽  
Jong Pil Youn ◽  
...  
Keyword(s):  
Condition Monitoring ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Welding Process ◽  
Recurrence Plot ◽  
External Noise ◽  
Dynamic Resistance ◽  
Resistance Spot ◽  
Welding Electrode ◽  
Welding System

Degraded electrodes in a resistance spot welding system should be replaced to ensure that weld quality is maintained. Welding electrodes are subjected to different environmental and operational loading conditions during use. When they are replaced with a fixed interval, replacement may occur too early (raising maintenance costs) or too late (leading to quality issues). This motivates condition monitoring strategies for resistance spot welding electrode tips. Thus, this paper proposes a modified recurrence plot (RP) for robust condition monitoring of welding electrode tips in resistance spot welding systems. The overall procedure for the proposed condition monitoring approach consists of three steps: (1) transformation of a one-dimensional signal to a two-dimensional image, (2) unsupervised feature extraction with LeNet architecture-based convolutional neural networks, and (3) health indicator calculation. RP methods convert dynamic resistance waveforms to RPs. The original RP method provides an image with binary-colored pixels (i.e., black or white) that makes this method insensitive to the change of the waveform signal. The proposed RP method is devised to be sensitive to the change of the waveform signal, while enhancing robustness to external noise. The performance of the proposed RP method is evaluated by examining simulated aperiodic waveform signals with and without external noise. A case study is presented to examine the proposed method’s ability to monitor the condition of resistance spot welding electrodes. The results show that the proposed method outperforms handcrafted, feature-based condition monitoring methods. This study can be used to accurately determine the lifetime of welding electrodes in real time during the spot welding process.

A prototype fuzzy resistance spot welding system

1995 ◽  
Vol 33 (7) ◽  
pp. 2023-2036 ◽  
Author(s):  
L. P. KHOO ◽  
H. Y. YOUNG
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Resistance Spot ◽  
Welding System
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