Resistance welding control system

• US 4,963,707 A
• Filed: 07/05/1989
• Issued: 10/16/1990
• Est. Priority Date: 07/06/1988
• Status: Expired due to Term

• Current Assignee: Nippondenso Co., Ltd. (DENSO Corporation)
• Original Assignee: Nippondenso Co., Ltd. (DENSO Corporation)
• Inventors: Sugiyama, Tsuyoshi, Zyokou, Keizou, Ito, Shinzo
• Primary Examiner(s): Shaw, Clifford C.
• Application Number:
  US07/375,778
• Time in Patent Office: 468 Days
• Field of Search: 219/110, 219/114
• US Class Current: 219/110
• CPC Class Codes: B23K 11/256 the measured parameter being the inter-electrode electrical resistance

Abstract

A resistance welding control system is disclosed which comprises a resistance detection unit for detecting an interelectrode resistance by measuring welding current and voltage applied between electrodes; a compensation section for comparing a resistance value as detected with a predetermined model resistance value and determining an amount of compensation of the welding current in accordance with the difference therebetween; and a current control section for controlling the welding current on the basis of the amount of compensation of the compensation section.

Claims

1. A resistance welding control system comprising:

resistance detection means for detecting an interelectrode resistance by measuring a welding current and a voltage applied between electrodes;

compensation means for comparing a detected resistance value detected by said resistance detection means with a predetermined model resistance value and determining an amount of compensation of the welding current in accordance with a difference between the detected resistance value and the model resistance value; and

current control means for controlling an amount of said welding current on the basis of said amount of compensation determined by the compensation means, wherein said compensation means operates such that a first rate at which the welding current is reduced when the detection resistance value is higher than the model resistance value is higher than a second rate at which the welding current is increased when the detection resistance value is lower than the model resistance value.

2. A resistance welding control system according to claim 1, further comprising:

peak hold means for detecting a substantial peak value Rep of the detection resistance value; and

energization control means for stopping a supply of the welding current when the detected resistance value decreases by a predetermined amount Δ

R below the peak value Rep.

3. A resistance welding control system according to claim 2, wherein said energization control means includes Rm1/Rmp memory means for storing a ratio Rm1/Rmp where Rmp is a peak value and Rm1 is a value that is a predetermined amount lower than the peak value Rmp, based on a waveform of the interelectrode resistance R involving a sound joint condition, the welding current being stopped when a ratio between a resistance value Rel and Rep reaches Rm1/Rmp, where Rel is a detection resistance value lower than Rep, and Rep is the peak value.

4. A control system of a resistance welding apparatus for welding base metals held between electrodes, comprising:

resistance detection means for detecting an interelectrode resistance at each energization cycle by measuring a welding current and a voltage applied between the electrodes;

compensation means for comparing a detection resistance value detected by the resistance detection means with a predetermined model resistance value and determining an amount of compensation of the welding current for the next cycle in accordance with the difference between the detection resistance value and the model resistance value;

current control means for controlling the welding current on the basis of the amount of compensation of the compensation means; and

preheat means for supplying a predetermined current between the electrodes thereby to heat the base metals and stabilize the interelectrode resistance before detecting the interelectrode resistance.

5. A system according to claim 4, further comprising means for cooling the base metals for a given period after supplying the predetermined current from the preheat means.

6. A control system of a resistance welding apparatus for welding base metals held between electrodes, comprising:

resistance detection means for detecting an interelectrode resistance at each energization cycle by measuring a welding current and a voltage applied between the electrodes;

compensation means for comparing a detection resistance value detected by the resistance detection means with a predetermined model resistance value and determining an amount of compensation of the welding current for the next cycle in accordance with the difference between the detection resistance value and the model resistance value wherein said amount of compensation is detected while using the resistance value detected at the first cycle by said resistance detection means as a resistance value at a given cycle when the model resistance value is approximate to said detected resistance value;

means for changing the model resistance value of the compensation means in response to the magnitude of an interelectrode resistance detected in first cycle by the resistance detection means; and

current control means for controlling the welding current on the basis of the amount of compensation of the compensation means.

7. A system as in claim 6, wherein the model resistance value determining means including means for detecting a cycle in which a model resistance value was changed approximate to the resistance value detected in the first cycle by the resistance detection means and for changing the resistance value detected in the first cycle to be substantially consistent with the model resistance value in the detected cycle.

8. A control system of a resistance welding apparatus for welding base metals held between electrodes, comprising:

resistance detection means for detecting an interelectrode resistance at each energization cycle by measuring a welding current and a voltage applied between the electrodes;

compensation means for comparing a detection resistance value detected by the resistance detection means with a predetermined model resistance value and determining an amount of compensation of the welding current for the next cycle in accordance with the difference between the detection resistance value and the model resistance value;

current control means for controlling the welding current on the basis of the amount of compensation of the compensation means, and

Rmc/Rma memory means for storing a first proper value corresponding to a ratio Rmc/Rma, where Rma is an amount from an initial value to a peak value and Rmc a predetermined value a predetermined amount lower than the peak value based on a waveform of the interelectrode resistance R associated with a satisfactory join condition,

peak detection means for detecting an initial value of the detection resistance value and a difference Rea between said detection resistance value and a detection resistance value Res in a first cycle, to a substantial peak value thereof,

Rec/Rea calculation means for calculating a value corresponding to a ratio Rec/Rea where Rec is the difference between the peak value and the resistance value detected for each cycle, and

energization control means for stopping energization when the calculated ratio Rec/Rea reaches the first proper value Rmc/Rma.

9. A resistance welding control system according to claim 8, further comprising energization control means for reducing the welding current by a predetermined amount when the detection resistance value decreases by a first predetermined amount from the substantial peak value of the detection resistance value and stopping the supply of the welding current when the detection resistance value decreases by a second predetermined amount greater than said first predetermined amount.

10. A control system of a resistance welding apparatus for welding base metals held between electrodes, comprising:

resistance detection means for detecting an interelectrode resistance at each energization cycle by measuring a welding current and a voltage applied between the electrodes;

compensation means for comparing a detection resistance value detected by the resistance detection means with a predetermined model resistance value and determining an amount of compensation of the welding current for the next cycle in accordance with the difference between the detection resistance value and the model resistance value; and

current control means for controlling the welding current on the basis of the amount of compensation of the compensation means,

energization control means for reducing the welding current by a predetermined amount when the detection resistance value decreases by a first predetermined amount from the substantial peak value of the detection resistance value and stopping the supply of the welding current when the detection resistance value decreases by a second predetermined amount greater than said first predetermined amount, and

number-of-cycles detection means for detecting a number of cycles before the detection resistance value reaches a peak value, the welding current being reduced in an amount progressively greater with the decrease in the number of cycles.

11. A resistance welding control system according to claim 10, further comprising means for issuing an alarm when a number of cycles from the first cycle to a cycle associated with an energization stop is larger than a predetermined value.

12. A control system of a resistance welding apparatus for welding base metals held between electrodes, comprising:

resistance detection means for detection an interelectrode resistance at each energization cycle by measuring a welding current and a voltage applied between the electrode;

compensation means for comparing a detection resistance value detected by the resistance detection means with a predetermined model resistance value and determining an amount of compensation of the welding current for the next cycle in accordance with the difference between the detection resistance value and the model resistance value; and

current control means for controlling the welding current on the basis of the amount of compensation of the compensation means,

wherein said model resistance value includes a model upper limit and a model lower limit with a predetermined margin from a proper model resistance value therebetween, said compensation means being such that a rate at which the welding current is reduced when the detection resistance value is higher than said model upper value is higher than a rate at which the welding current is increased when said detection resistance value is lower than said model lower limit value, said rates being progressively greater with the increase in the difference between the detection resistance value and selected one of the model lower limit value and the model upper limit value.