Control of resistance plug welding using quantitative feedback theory

Technical Report · Sat Nov 30 23:00:00 EST 1996

DOI:https://doi.org/10.2172/431135· OSTI ID:431135

Bentley, A E ^[1]; Horowitz, I ^[2]; Chait, Y; Rodrigues, J ^[3]

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1. Sandia National Lab., Albuquerque, NM (United States)
2. Univ. of California, Davis, CA (United States)
3. Univ. of Massachusetts, Amherst, MA (United States)

Resistance welding is used extensively throughout the manufacturing industry. Variations in weld quality often result in costly post-weld inspections. Applications of feed-back control to such processes have been limited by the lack of accurate models describing the nonlinear dynamics of this process. A new system based on electrode displacement feedback is developed that greatly improves quality control of the resistance plug welding process. The system is capable of producing repeatable welds of consistent displacement (and thus consistent quality), with wide variations in weld parameters. This paper describes the feedback design of a robust controller using Quantitative Feedback Theory for this highly complex process, and the experimental results of the applied system.

• Research Organization: Sandia National Labs., Albuquerque, NM (United States)
• Sponsoring Organization: USDOE Office of Financial Management and Controller, Washington, DC (United States)
• DOE Contract Number: AC04-94AL85000
• OSTI ID: 431135
• Report Number(s): SAND--94-0795; ON: DE97002486
• Country of Publication: United States
• Language: English

Related Subjects

42 ENGINEERING
CONTROL SYSTEMS
DESIGN
FEEDBACK
RESISTANCE WELDING