• Journal of Power Electronics
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• v.15 no.4
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• pp.1139-1147
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• 2015

In this paper, an algorithm based on a model analysis of the online calculation of the root-mean-square (RMS) value of welding current for single-phase AC resistance spot welding (RSW) was developed. The current is highly nonlinear and typically non-sinusoidal, which makes the measuring and controlling actions difficult. Though some previous methods focused on this issue, they were so complex that they could not be effectively used in general cases. The electrical model of a single-phase AC RSW was analyzed, and then an algorithm for online calculation of the RMS value of the welding current was presented. The description includes two parts, a model-dependent part and a model-independent part. Using a previous work about online measurement of the power factor angle, the first part can be solved. For the second part, although the solution of the governing equation can be directly obtained, a lot of CPU time must be consumed due to the fact that it involves a lot of complex calculations. Therefore, a neural network was employed to simplify the calculations. Finally, experimental results and a corresponding analysis showed that the proposed algorithm can obtain the RMS values with a high precision while consuming less time when compared to directly solving the equations.

• Proceedings of the KWS Conference
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• 2001.10a
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• pp.184-186
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• 2001

Quality estimation of the weld has been one of the important issues in RSW which is a main process of the sheet metal fabrication in auto-body industry. It was well known that among the various welding process variables, dynamic resistance has a close relation with nugget formation. In this study, a new quality estimation algorithm is developed with the primary dynamic resistance measured at welding machine timer. For this, Back propagation algorithm of neural network is used.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.2
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• pp.93-100
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• 2021

Copper sheets has been used widely in electric and electron industry fields because they have good electric and heat conduction property of the material. And, in order to bond copper material, a kind of soldering process is generally used. But, because it is difficult to bond by soldering between overlapped thin copper sheets, so, another kind of brazing bonding process can be used in that case. But, because the brazing process needs wide bonding area, it needs heat treatment process in electric furnace. Generally, for spot welding of sheets, a conventional electric Resistance Spot Welding process(RSW) has been used, it has welding characteristics using contact resistance heating induced by electric current flow between sheets. But, because copper sheets has the low electric resistance, it is difficult to weld by electric resistance spot welding. So, in this study, an electric Resistance heated Surface Friction Spot Welding process(RSFSW) is suggested and is testified for the spot welding ability of thin copper sheets. It is known from the experimental results and simulation that the suggested spot welding process will be able to improve the spot welding ability of copper sheets by the combined three kinds of heating generated by surface friction by rotating pin, and conducted from heated steel electrode, and generated by contact resistance of electricity.

• 제어로봇시스템학회:학술대회논문집
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• 2001.10a
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• pp.46.6-46
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• 2001

A servo gun welding system having a AC servo motor and a PC control system is presented for the improvement of quality control in the spot welding. The spot welding process is composed of the press stage, the weld stage, and the hold stage. The changes of gun press forces according to three stages in the spot welding process are controlled and measured through the load cell in order to know the influence on the welding quality. The relation between the measured force changes according to three stages and welding qualities is also implemented on the multilayer perceptrons, one of supervised learning method of neural network, which are powerful for realization of complex mapping characteristics. The estimated results and ...

• Journal of Welding and Joining
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• v.21 no.5
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• pp.513-517
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• 2003

Resistance welding processes are widely used in automotive applications. In particular, Mash-Seam resistance welding is typically used in Tailored Blank process. If spot welds are changed to a continuous weld, it's easy to reduce noise and to be more stable in cars. A arc welding, laser welding, seam welding using wheel electrode are available to make continuous welds on a car body, but they demand operator with advanced skills and expensive cost to develop. Therefore, flat electrode continuous mash-seam resistance welding process has been used to improve the weak points in currently available system in lap seam welding. This developed process has much more strength and air tightability, and also has much better plastic workability than laser welding. Moreover, commercial RSW machine can be readily used in this welding process.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2009.06a
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• pp.123-124
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• 2009

• Transactions of the Korean Society of Automotive Engineers
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• v.23 no.6
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• pp.642-649
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• 2015

Resistance Spot Welding (RSW) is the method for joining two overlapped base materials when high pressure and current is applied from electrodes. Due to the safety problem such high pressure and voltage, automation should be early adopted. In this paper, the spot welding is developed as a computational model of wheel house from GM Korea and the welding condition such as weld sequence is considered. The computational analysis is preceded as a static and elasto-plastic procedure and used thermal expansion coefficient represents a dependency of spot volume between two panels. In case of welding sequence, the efficiency which depends on the distance between current spot point and the other is calculated in several cases.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.19 no.3
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• pp.52-60
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• 2018

In the automobile industry, in order to increase the fuel efficiency and conform to the safety regulations, it is necessary to make the vehicles as light as possible. Therefore, it is crucial to manufacture dual phase steels, complex phases steels, MS steels, TRIP steels, and TWIP from high strength steels with a tensile strength of 700Mpa or more. In order to apply ultra-high tensile strength steel to the body, the welding process is essential. Resistance spot welding, which is advantageous in terms of its cost, is used in more than 80% of cases in body welding. It is generally accepted that ultra-high tensile strength steel has poor weldability, because its alloy element content is increased to improve its strength. In the case of the resistance spot welding of ultra-high tensile steel, it has been reported that the proper welding condition area is reduced and interfacial fracture and partial interfacial fracture occur in the weld zone. Therefore, research into the welding quality judgment that can predict the defect and quality in real time is being actively conducted. In this study, the dynamic resistance of the weld was monitored using the secondary circuit process variables detected during resistance spot welding, and the factors necessary for the determination of the welding quality were extracted from the dynamic resistance pattern. The correlations between the extracted factors and the weld quality were analyzed and a regression analysis was carried out using highly correlated pendulums. Based on this research, a regression model that can be applied to the field was proposed.

• Proceedings of the KWS Conference
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• 2003.11a
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• pp.172-174
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• 2003

In this paper, a 2D axisymmetric model of thermoelectric Finite Element Method (FEM) is developed to analyze the transient thermal behavior of Resistance Spot Welding (RSW) process using commercial software, called ANSYS. The determination of the contact resistance at the faying surface is moderately simplified to reduce the calculating time, while the temperature dependent material properties, phase change and convectional boundary conditions are taken account fur the improvement of the calculated accuracy. The thermal history of the whole process (including cooling) and temperature distributions for any position in the weldment is obtained through the analysis.

• International Journal of Advanced Culture Technology
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• v.3 no.1
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• pp.153-160
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• 2015

This article is aimed to study the effects of resistance spot welding (RSW) on the lap joint properties between AA1100 aluminum alloy and SGACD zinc coated steel and its properties. The summarized experimental results are as follows. The summarized experimental results are as follows. The optimum welding parameters that produced maximum tensile shear strength of 2200 N was a welding current of 95 kA, a holding time of 10 cycles, and a welding pressure of 0.10 MPa. Increasing of welding current, increased the tensile shear strength of the joint and also increased the amount of aluminum dispersion at the joint interface. The lap joint of steel over the aluminum (Type I) showed the higher joint tensile shear strength than a lap joint of aluminum over the steel (Type II). The indentation depth and the ratio of the indentation depth to the plate thickness decreased when the welding current was increased in the type I lap joint and also decreased when the welding current was decreased in the type II lap joint. The interface structure showed the formation of the brittle $FeAl_3$ intermetallic compound that deteriorated the joint strength.