Micro Resistance Welding Control for Consistent Weld Quality
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Solution Overview
Problem
Current micro resistance welding technologies face challenges in achieving long-term stable weld performance and consistency due to small changes in component size, positioning, surface finish, electrode wear, and mechanical tolerance, leading to batch manufacturing defects and production downtime, especially in safety-critical sectors like medical, aerospace, and automotive.
Innovation Solution
A micro welding apparatus with a controller that supplies a controlled welding current defined by a sequence of segments, operating in different modes such as current, voltage, or power control, using real-time feedback to adjust parameters and optimize electrode life, enabling digital closed-loop control of power supplies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If real-time feedback control with multiple segments and modes is implemented, then weld quality consistency and process control are improved, but device complexity increases
Solution Approach 1:
The welding current profile is divided into multiple segments (e.g., rise, hold, fall segments) where each segment can operate in different control modes. This segmentation allows precise control of specific welding phases while keeping the overall system manageable through modular control logic.
Solution Approach 2:
The controller dynamically switches between different control modes (current control, voltage control, power control) based on the welding segment and real-time feedback conditions. This dynamic adaptation enables the system to respond to changing welding conditions without requiring complete redesign of the control architecture.
2Duration of action of stationary object
If real-time feedback control is implemented, then electrode wear is reduced and electrode life is optimized, but device complexity increases
Solution Approach 1:
The system continuously monitors welding parameters (voltage, current, power) and uses this feedback to adjust control signals in real-time. This feedback mechanism prevents excessive electrode wear by adapting the welding parameters to actual conditions, extending electrode life without requiring complete system redesign.
Solution Approach 2:
The controller dynamically adjusts welding parameters (current magnitude, duration, waveform shape) based on real-time feedback and segment-specific requirements. By changing parameters adaptively rather than using fixed high-current pulses, the system reduces electrode erosion while maintaining weld quality.
3Productivity
If post-product analysis and batch sample testing are used, then manufacturing cost is reduced, but production defects are not detected in real-time leading to downtime
Solution Approach 1:
The system performs real-time monitoring and adjustment during the welding process itself, detecting and correcting potential defects before they result in failed products. This preliminary detection prevents production downtime by identifying issues during manufacturing rather than after completion.
Solution Approach 2:
Real-time feedback from sensors monitors welding parameters and product quality indicators during manufacturing. This continuous monitoring enables immediate detection of deviations from quality standards, allowing corrective action before batch defects occur, thereby maintaining production continuity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances process control and production yields by allowing real-time analysis and correction of welding parameters, reducing electrode wear, and ensuring consistent weld quality, thereby improving manufacturing efficiency and reducing defects.
Implementation Method 1
passing high current and low voltage through a work piece to heat up the joint interfaces to form a weld
Implementation Method 2
the controller is configured to supply said controlled welding current in dependence upon electrical feedback from the weld head circuit
Data Source
AI summary
The present invention relates micro resistance welding apparatus and to a method of welding. In particular, the present invention relates to small scale or micro welding apparatus and to a method of micro resistance welding using a controlled sequence of current, voltage and/or power signal profile for an electric arc. The invention provides a welding apparatus comprising: a controller supplying a controlled drive current to a weld head circuit in which the controller supplies said controlled drive current in dependence upon electrical feedback from the weld head circuit and in which the controlled drive current is defined by a sequence of segments and for each segment the welding apparatus operates in a mode defined by setting one of a predetermined current target, a predetermined voltage target or a predetermined power target; and at least two of the segments are operated in a different mode from one another. The invention also provide a method of operating such an apparatus.