Implementation and Control of Integral Cycle Controller for Resistance Spot Welding

The Resistance Spot Welding (RSW) process requires simultaneous application of high electrical current and appropriate pressure over short periods in order to keep the molten material inside the weld zone. Values of these parameters vary in function of the characteristics of the materials to be welded. The application of the electrical current is by means of two copper electrodes brought in contact with the welded parts while the required pressure is applied by means of pneumatic or hydraulic systems. This paper presents the simulation, design, and control of resistance welding system which is used for performing a welding process. The paper is discussed about two aspects. First, simulation of the concept of ICC used for the specific application of RSW. Secondly, the critical factor and method employed for the implementation of the controller. This paper also discuss about the implementation methodology of the RSW. The simulation for the RSW is carried out in PROTEUS software. Index Word: Constant Current Feedback, Integral Cycle Control (ICC), Resistance Spot Welding, Sequential Timer. --------------------------------------------------------------------***---------------------------------------------------------------------