Impact of the Switching Frequency on the Welding Current of a Spot-Welding System

Brezovnik, Robert; Černelič, Jernej; Petrun, Martin; Dolinar, Drago; Ritonja, Jožef

doi:10.1109/tie.2017.2711549

Cited by 20 publications

(10 citation statements)

References 16 publications

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“…In order to optimize spot welding parameters of automobile steels, researchers have studied the influence of spot welding parameters, especially current, electrode force, and welding time, on the microstructure and mechanical properties of spot welding joints [5][6][7]. In recent years, alternating current (AC) spot welding machines with variable frequency have been developed and more widely used in resistance spot welding in the automobile industry [8][9][10]. In this case, except for the above mentioned three traditional parameters, some other parameters like frequency and pulse duration would influence the spot welding process, and thereby the mechanical properties of the joints.…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Properties of Spot Welded Joints of Hot-Stamped Ultra-High Strength Steel Used for Automotive Body Structures

Qiao

Lian-jin

et al. 2019

Metals

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Hot-stamped ultra-high strength steels have been widely used in automobile structural parts. Considering the high splash tendency in resistance spot welding due to their extremely high hardness, in this work, microstructural characteristics and mechanical performance of the resistance spot welded ultra-high strength steels are investigated. The results indicate that the interface between the nugget and heat-affected zone (HAZ) is the weakest zone where fractures initiate. In tensile shearing tests, a qualified spot welding joint failed with a button-shaped fracture. Welding defects would significantly decrease the load-carrying capacity and lead to interfacial fracture, except for a button-shaped fracture. In spot welding, it was found that a specific mid-frequency alternating current (AC) input mode, in which a 6 ms cooling cycle was inserted between every two neighboring current pulses, can avoid the splash in the spot welding of hot-stamped hardened steels.

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Section: Introductionmentioning

confidence: 99%

Microstructure and Properties of Spot Welded Joints of Hot-Stamped Ultra-High Strength Steel Used for Automotive Body Structures

Qiao

Lian-jin

et al. 2019

Metals

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“…In this way, comparable results for the presented analysis were obtained. The drawback of the additional bus system was, however, that the total resistances on the secondary side of the transformer were increased in comparison to a compact industrial RSW transformer [5]. The measured total resistances for both winding arrangements are shown in Table 1.…”

Section: Laboratory Experimental Systemmentioning

confidence: 99%

“…Nowadays the DC RSW systems are generally replacing the older AC RSW systems due to several advantages [3,4]. A typical contemporary high power RSW system consists of a AC-DC converter that operates at a frequency around 1 kHz, which is generally classified as a medium frequency RSW system [4][5][6][7]. A medium frequency RSW system with a DC welding current is shown in Figure 1.…”

Section: Introductionmentioning

confidence: 99%

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Impact of the Winding Arrangement on Efficiency of the Resistance Spot Welding Transformer

Habjan

Petrun

2019

Energies

Self Cite

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In this paper, the impact of the winding arrangement on the efficiency of the resistance spot welding (RSW) transformer is presented. First, the design and operation of the transformer inside a high power RSW system are analyzed. Based on the presented analysis, the generation of imbalanced excitation of the magnetic core is presented, which leads to unfavorable leakage magnetic fluxes inside the transformer. Such fluxes are linked to the dynamic power loss components that significantly decrease the efficiency of the transformer. Based on the presented analysis, design guidelines to reduce the unwanted leakage fluxes are pointed out. The presented theoretical analysis is confirmed by measurements using a laboratory experimental system. The presented experimental results confirm that the proposed improved winding arrangement increased the efficiency of the transformer in average for 6.27%.

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“…The converters at the second stage provide high-frequency transformer (HFT) isolation and enable a refurbishing action on the control of the dc voltage The conventional welding power source illustrated in Figure 1 involves diode rectifier followed by high frequency inverter transformer and high-frequency rectifier to complete a three stage conversion of the input ac power to dc (Klumpner and Corbridge, 2008). The operating frequency of inverter decides the maximum welding current (Brezovnik et al, 2017). In addition, researchers have also proposed dc-dc converterbased welding power source.…”

Section: Introductionmentioning

confidence: 99%

Variable speed PMSG design and implementation for wind driven welding power source

S¹,

Balaji²

2020

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Purpose The purpose of this paper is the attempt to model a variable speed permanent magnet synchronous generator (PMSG) for extracting a standalone power source to assuage the needs of a welding application. The emphasis orients to evolve a framework for the effective exploration of renewable energy resource and prevent the injection of grid harmonics. Design/methodology/approach The system involves the use of self-commutated dc-dc converter interfaces to extradite the current and voltage requirements of the welding attributes. The philosophy incites a pulse width formulation for reducing the voltage ripples in the dc output and improving the time response characteristics. Findings The proper selection of closed loop Fuzzy tuned PI control ensures the restriction on the magnitude of the current drawn from the source, enhances the dynamic response and betters steady state response. Originality/value PMSG-based welding power source with parallel-connected cascaded buck fed cuk converters. MATLAB-based simulation of the methodology offer interesting results in the sense it orchestrates the range of converter operation and the ability to provide a high-quality weld without polluting the ac mains. The experimental prototype further proliferates to validate the simulated performance and claims a space for its use in the real-world utilities.

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Impact of the Switching Frequency on the Welding Current of a Spot-Welding System

Cited by 20 publications

References 16 publications

Microstructure and Properties of Spot Welded Joints of Hot-Stamped Ultra-High Strength Steel Used for Automotive Body Structures

Microstructure and Properties of Spot Welded Joints of Hot-Stamped Ultra-High Strength Steel Used for Automotive Body Structures

Impact of the Winding Arrangement on Efficiency of the Resistance Spot Welding Transformer

Variable speed PMSG design and implementation for wind driven welding power source

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