0
TECHNICAL BRIEFS

Monitoring Resistance Spot Nugget Size by Electrode Displacement

[+] Author and Article Information
D. F. Farson, J. Z. Chen, K. Ely, T. Frech

Industrial, Welding and System Engineering Department, The Ohio State University, Columbus, OH 43221

J. Manuf. Sci. Eng 126(2), 391-394 (Jul 08, 2004) (4 pages) doi:10.1115/1.1644550 History: Received September 01, 2003; Online July 08, 2004
Copyright © 2004 by ASME
Your Session has timed out. Please sign back in to continue.

References

Ely,  K. J., and Zhou,  Y., 2001, “Microresistance Spot Welding of Kovar, Steel, and Nickel,” Sci. Technol. Weld. Joining, 6(2), pp. 63–72.
Williams, N. T., 1997, “Use of Voltage Integration for Monitoring and Feedback,” Resistance Welding Control and Monitoring, TWI, pp. 13–18.
Dickinson,  D. W., Franklin,  J. E., and Stanya,  A., 1980, “Characterization of Spot Welding Behavior by Dynamic Electrical Parameter Monitoring,” Weld. J. (Miami, FL, U. S.), 59(6), pp. 170s–176s.
Patange,  S. R., Anjaneyulu,  T., and Reddy,  G. P., 1985, “Microprocessor-based Resistance Welding Monitor,” Weld. J. (Miami, FL, U. S.), 64(12), pp. 33–38.
Livshits,  A. G., 1997, “Universal Quality Assurance Method for Resistance Spot Welding Based on Dynamic Resistance,” Weld. J. (Miami, FL, U. S.), 76(9), pp. 383s–390s.
Gedeon,  S. A., Sorensen,  C. D., Ulrich,  K. T., and Eagar,  T. W., 1987, “Measurement of Dynamic Electrical and Mechanical Properties of Resistance Spot Welds,” Weld. J. (Miami, FL, U. S.), 66(12), pp. 378s–385s.
Li,  W., Hu,  S. J., and Ni,  J., 2000, “A Method for On-Line Quality Prediction of Resistance Spot Welding,” ASME J. Manuf. Sci. Eng., 122(3), pp. 511–512.
Waller,  D. N., and Knowlson,  P. M., 1965, “Electrode Separation Applied to Quality Control in Resistance Welding,” Weld. J. (Miami, FL, U. S.), 44(4), pp. 168s–174s.
Wood,  R. T., Bauer,  L. W., Bedard,  J. F., Bernstein,  B. M., Czechowski,  J., D’ndrea,  M. M., and Hogle,  R. A., 1985, “A Closed-loop Control System for Three-phase Resistance Spot Welding,” Weld. J. (Miami, FL, U. S.), 64(12), pp. 26–30.
Taylor,  J. L., and Xie,  P., 1987, “A New Approach to the Displacement Monitor in Resistance Spot Welding of Mild Steel Sheet,” Metal Construction, 19(2), pp. 72–75.
Chien, C. S., and Kannatey-Asibu, E., Jr., 1998, “Displacement Measurement Using a Fiber Optic Sensor in Resistance Spot Welding,” Trends in Welding Research, Proc. of the 5th Inter. Conf., Pine Mountain, Georgia, pp. 622–627.
Beemer,  R. D., and Talbot,  T. W., 1970, “Analyzer for Nondestructive Process Control of Resistance Welding,” Weld. J. (Miami, FL, U. S.), 49(1), pp. 9s–13s.
Mironov,  L. G., Afanasev,  L. K., and Zaitsev,  V. A., 1979, “Control of the Quality of Welds Directly during Resistance Spot Welding,” Welding Production, 26(2), pp. 40–43.
Heb,  J., Kern,  T., Kriegl,  W., and Schweizer,  M., 1998, “Visualization of the Resistance Spot Welding Process in the Production Line,” Weld. J. (Miami, FL, U. S.), 77(12), pp. 495s–502s.
Hirsch,  R. B., 1993, “Tip Force Control Equals Spot Weld Quality,” Weld. J. (Miami, FL, U. S.), 72(3), pp. 57–60.
Tang,  H., Hou,  W., Hu,  S. J., and Zhang,  H., 2000, “Force Characteristics in Resistance Spot Welding,” Weld. J. (Miami, FL, U. S.), 79(7), pp. 175s–183s.
Mansour,  T. M., 1988, “Ultrasonic Inspection of Spot Welds in Thin-gage Steel,” Mater. Eval., 46(4), pp. 650–658.
Beatson, E. V., 1977, “An Introduction to Quality Control Systems in Resistance Welding,” Resistance Welding Control and Monitoring, TWI, pp. 2–7.
Satonaka,  S., and Matsuyama,  K., 2000, “Review on Inspection Techniques for Spot Welds,” Welding on the World, 44(3), pp. 4–10.
Messler,  R. W., and Jou,  M., 1996 “A Review of Control Systems for Resistance Spot Welding,” Sci. Technol. Weld. Joining, 1(1), pp. 1–9.
Shriver, J., Peng, H., and Hu, S. J., 1999, “Control of Resistance Spot Welding,” Proceedings of the American Control Conference, San Diego, California, June, pp. 187–191.
Brown,  J. D., Rodd,  M. G., and Williams,  N. T., 1998, “Application of Artificial Intelligence Techniques to Resistance Spot Welding,” Ironmaking Steelmaking, 25(3), pp. 199–204.
Jou,  M., Li,  C. J., and Messler,  R. W., 1998, “Controlling Resistance Spot Welding Using Neural Network and Fuzzy Logic,” Sci. Technol. Weld. Joining, 3(1), pp. 42–50.
Chang,  H. S., Cho,  Y. J., Choi,  S. G., and Cho,  H. S., 1989, “A Proportional-integral Controller for Resistance Spot Welding Using Nugget Expansion,” ASME J. Dyn. Syst., Meas., Control, 111(2), pp. 332–336.
Haefner,  K., Carey,  B., Bernstein,  B., Overton,  K., and D’Andrea,  M., 1991, “Real-time Adaptive Spot Welding Control,” ASME J. Dyn. Syst., Meas., Control, 113(1), pp. 104–112.
Irving,  B., 1996, “The Search Goes on for the Perfect Resistance Welding Control,” Weld. J. (Miami, FL, U. S.), 75(1), pp. 63–68.
Chang,  B. H., Li,  M. V., and Zhou,  Y., 2001, “Comparative Study of Small Scale and ‘Large Scale’ Resistance Spot Welding,” Sci. Technol. Weld. Joining, 6(5), pp. 273–280.
Farson,  D., Chen,  J., Ely,  K., and Frech,  T., 2003, “Monitoring of Expulsion in Small Scale Resistance Spot Welding,” Sci. Technol. Weld. Joining, 8(6), pp. 431–436.
Overfelt,  R. A., Taylor,  R. E., and Bakhtiyarov,  S. I., 2000, “Thermophysical Properties of A356 Aluminum, Class 40 Gray Iron, and CF8M Stainless Steel,” AFS Trans., 108, pp. 369–376.

Figures

Grahic Jump Location
Obtaining electrode displacement from motion analyzer images (a) original images captured by the analyzer (b) images after threshold processing
Grahic Jump Location
Displacement of electrodes in welding and the abrupt change of electrode velocity in cooling
Grahic Jump Location
Relationship of electrode displacement in first stage in cooling to nugget thickness
Grahic Jump Location
Nugget thickness versus maximum electrode displacement
Grahic Jump Location
Nugget diameter versus displacement in first stage in cooling

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In