Design and implementation of a medium frequency direct current resistance spot welding system integrated with welding control interface
AIN SHAMS ENGINEERING JOURNAL, vol.16, no.5, 2025 (SCI-Expanded, Scopus)
- Publication Type: Article / Article
- Volume: 16 Issue: 5
- Publication Date: 2025
- Doi Number: 10.1016/j.asej.2025.103357
- Journal Name: AIN SHAMS ENGINEERING JOURNAL
- Journal Indexes: Science Citation Index Expanded (SCI-EXPANDED), Scopus, Compendex, INSPEC, Directory of Open Access Journals
- Open Archive Collection: AVESIS Open Access Collection
- Bursa Uludag University Affiliated: Yes
Abstract
The increasing demand for high-precision welding requires advanced systems with real-time feedback control. Traditional resistance spot welding (RSW) technologies struggle with managing complex welding profiles and ensuring consistent weld quality. This study presents a medium-frequency direct current (MFDC)-RSW system integrated with a Python-based welding control interface (WCI) to enhance precision and adaptability. The system enables real-time parameter optimization and closed-loop current regulation using a LaunchXL-F28069M microcontroller. Experimental validation demonstrated high accuracy, achieving 97-98 % tracking accuracy in welding current and reducing RMSE from 0.178 kA to 0.109 kA. Closed-loop control outperformed open-loop configurations, enhancing process stability. The WCI facilitated efficient parameter adjustments and robust operation under varying conditions. By improving weld precision, process consistency, and adaptability, the proposed system overcomes limitations of traditional RSW, contributing to the advancement of adaptive welding technologies. Future research may explore enhanced feedback mechanisms and broader industrial applications.