Development Of 50H_z Resistance Welding Controller

Modem industry's requirement to the resistance spot-welding joint's quality is becoming more and more stricter, so more account, control method is required for the process and quality of the spot-welding so as to promote the reliability of spot-welding joint. In this paper, aiming at the low control precision of the traditional spot-welding controller, we design a new model of control technology and applied in the resistance spot-welding. As the same time, the method of I~2C,CANBUS, proportioning valve, Rogowski coil and so on, have been taken use of spot-welding controller design.In this paper, the concept of the electric resistance welding, three factors about welding quality, and some parameters we need are firstly presented, a typical complete process of welding cycle is introduced; the research objective is presented by analyzing the lack of the application; the master functions and techniques are listed in detail.Secondly, the central plan of the project is presented ,which includes: the conceptions and relations about the factors in electric resistance welding system such as control angle, conductor angle and power angle; some methods how to gain the correct power angle, the current virtual value and the correct control angle in constant current mode.Thirdly, the hardware design based in Philips IC 80C552 is presented, which included: the rules and methods how to choose the correct instruments, especially about the principle of Rogowski coil; the design principle of the master control board, including the hardware design of programming machine.Fourthly, the software design based in Philips IC 80C552 is presented, which included: the flow process lists of the programs, the principle descriptions about I2C,CANBUS and RS485,the software design of programming machine.Fifthly, some anti-jamming measures are presented. By analyzing the jamming source, some measures are taken in the hardware and software of the welding system.At last, the tests of the welding control machine are presented, which includes: functional test, constant current test, fluctuant power test, and network test. In particular, the constant current test and fluctuant power test are taken in the different transformer loads. It points the error factors by analyzing the test data.