Automatic Spot Welding Machine

Aim:

            The main stay of the project is to design, mechanize and fabrication of an automatic spot welding machine powered by electric motor.

Proposed System:

          Here we are going to create an automatic spot welding machine which is powered by an electric motor. It has a welding equipment attached to a slider which moves up and down, when two pieces of sheet metal is placed when the slider is up and when slider comes down it will spot weld both the sheet metal. 

Advantages:

1. In this type of welding the base metal does not undergo to large heat affected area.
2. This type of welding is a easy process.
3. Spot welding has a high production rate.
4. Spot welding can be applied to different metals to join.
5. Spot welding is a low-cost process.

Abstract:

           A Virtual Machine has led to a fully automatic spot welding system. All necessary parameters are created by measuring systems and algorithms running in the Virtual Machine. A hybrid operating circuit allows the Virtual Machine to read the exact process voltage between the tips of the electrodes every 50 μs. Actual welding voltage and current allow for the first time reading process impedance, electric power and total energy being transferred to the spot weld. Necessary energy input is calculated by a calorimetric model after measuring the total thickness of the materials to be welded as soon as the welding gun is positioned at the workpiece.

            A precision potentiometer implemented in the gun delivers the total material thickness within the 0.1 mm range during the pre-pressure phases. The internal databank of the Virtual Machine controls all essential parameters to guide the total welding process. Special generator characteristics of the welding power unit are created by the Virtual Machine just during the upslope and the welding phases. So the process will be initialized in differentiating the kind of material, mild steel or high strengthen steel. This will affect the kind of energy input and current decrease during the upslope and downslope phases.