Design and Implementation of a Toroidal Rogowski Coil-Based Current Sensing Circuit for AC Resistance Spot Welding Systems

Uyar M., İşeri M.

Turkish Journal of Science and Technology, cilt.20, sa.2, ss.431-443, 2025 (TRDizin)

Özet

This study presents the design, implementation, and experimental validation of an active integrator circuit integrated with a toroidal Rogowski coil for precise current sensing in AC resistance spot welding (AC-RSW) systems. The proposed system aims to enable accurate and stable monitoring of high-amplitude transient currents typically generated during short-duration welding cycles. Performance evaluations were conducted under laboratory conditions and a real industrial AC-RSW environment. In the laboratory setup, the integrator circuit was tested with sinusoidal input signals ranging from 100 mV to 1000 mV. The results demonstrated a highly linear output response, with regression metrics of R² = 0.9965, MAE = 3.65 mV, RMSE = 4.69 mV, and MAPE = 2.88%. The system was subjected to actual welding currents between 5 and 20 kA in the second phase. The integrator’s output voltage peaks were compared with reference current measurements, yielding R² = 0.9981, MAE = 0.55 mV, RMSE = 0.63 mV, and MAPE = 1.29%, confirming its applicability in industrial conditions. The findings suggest that the proposed system offers a cost-effective, scalable, and electromagnetically robust alternative to conventional current measurement methods in AC-RSW applications. With its linear response, high measurement accuracy, and adaptability to harsh operating conditions, the developed system holds strong potential for real-time industrial current monitoring tasks.