Implementation of different weld schedules using programmable logic controller in resistance spot welding machine.

Resistance spot welding is a commonly used method in the automotive and aerospace industries for joining two sheet metals. The quality of the weld nugget is determined by factors such as weld schedule, weld current, and electrode pressure. However, achieving different spot-welding schedules manually can be challenging and result in poor quality welds. To address this issue, a Programmable Logic Controller (PLC) controlled Resistance Spot Welding machine was developed in this study to implement various weld schedules and improve the quality of spot welds. Finite element analysis was conducted on the lower and upper electrode arms for different working squeeze forces to ensure that the operating stress levels were within the yield strength of the material. A high-power Solid-State Relay (SSR) was utilized to switch the input power supply of the two-phase transformer. The effectiveness of the PLC-based controller for the RSW machine was tested using different weld schedules. [ABSTRACT FROM AUTHOR]