Development of an Instrumented Equipment for Intelligent Resistance Spot Welding

The present study introduces an instrumented and remotely controlled resistance spot welding machine that enables the intelligent control of the main process parameters. The machine was developed by modifying an existing resistance spot welding machine through interfacing with 'proportional relays,"controlled through an I.O. device and a LabVIEW program. Preliminary welding tests were performed to assess the main machine's capabilities in terms of repeatability, the capacity of control as well as the response time of the equipment. Preliminary tests were conducted to weld low-carbon steel sheets 1.2 mm thick. The tests were conducted by varying the main process conditions, namely the current and the welding time. Other process parameters that contribute to determining the welds' final quality were kept constant during the experiments. Quality assessment of the welds was performed through destructive single-lap shear tests. A dimensional analysis of the welds was also performed.