上海交通大学学报（英文版） ›› 2013, Vol. 18 ›› Issue (1): 101-104.doi: 10.1007/s12204-013-1371-8

• 论文 • 上一篇    下一篇

Modeling, Identification and Simulation of DC Resistance Spot Welding Process for Aluminum Alloy 5182

GONG Liang1* (贡亮), XI Yan2 (席艳), Ma Zhe-ren1 (马喆人), LIU Cheng-liang1 (刘成良)   

  1. (1. Institute of Mechatronics, Shanghai Jiaotong University, Shanghai 200240, China; 2. Department of Electrical Engineering, Yantai Vocational College, Yantai 264000, Shandong, China)
  • 出版日期:2013-02-28 发布日期:2013-03-19
  • 通讯作者: GONG Liang1* (贡亮) E-mail:gongliang mi@sjtu.edu.cn

Modeling, Identification and Simulation of DC Resistance Spot Welding Process for Aluminum Alloy 5182

GONG Liang1* (贡亮), XI Yan2 (席艳), Ma Zhe-ren1 (马喆人), LIU Cheng-liang1 (刘成良)   

  1. (1. Institute of Mechatronics, Shanghai Jiaotong University, Shanghai 200240, China; 2. Department of Electrical Engineering, Yantai Vocational College, Yantai 264000, Shandong, China)
  • Online:2013-02-28 Published:2013-03-19
  • Contact: GONG Liang1* (贡亮) E-mail:gongliang mi@sjtu.edu.cn

摘要： Currently the aluminum alloy resistance spot welding (AA-RSW) has been extensively used for light weight automotive body-in-white manufacturing. However the aluminum alloys such as AA5182 have inferior weldability for forming the joint due to their high reflectiveness to heat and light. Therefore it is necessary to further develop the high performance control strategy and the set-up of a new welding schedule. The welding process identification is the essential issue where the difficulty arises from the fact that the AA-RSWis a nonlinear time-varying uncertain process which couples the thermal, electrical, mechanical and metallurgical dynamics. To understand this complicated physical phenomenon a novel dual-phase M-series pseudo-random electrical pattern is adopted to excite the AA-RSW electrical-thermal process and the thermal response is recorded according to the welding power outputs. Based on the experimental information, the transfer function of an AA-RSW electricalthermal mechanism is identified, and the optimum model order and parameters are determined. Subsequently a control-oriented DC AA-RSWmodel is established to explore the welding power control algorithm. The simulated results of the control model show agreement with the experimental data, which validates its feasibility for the corresponding welding control.

关键词: resistance spot welding (RSW), aluminum alloy, system identification, modeling and simulation

Abstract: Currently the aluminum alloy resistance spot welding (AA-RSW) has been extensively used for light weight automotive body-in-white manufacturing. However the aluminum alloys such as AA5182 have inferior weldability for forming the joint due to their high reflectiveness to heat and light. Therefore it is necessary to further develop the high performance control strategy and the set-up of a new welding schedule. The welding process identification is the essential issue where the difficulty arises from the fact that the AA-RSWis a nonlinear time-varying uncertain process which couples the thermal, electrical, mechanical and metallurgical dynamics. To understand this complicated physical phenomenon a novel dual-phase M-series pseudo-random electrical pattern is adopted to excite the AA-RSW electrical-thermal process and the thermal response is recorded according to the welding power outputs. Based on the experimental information, the transfer function of an AA-RSW electricalthermal mechanism is identified, and the optimum model order and parameters are determined. Subsequently a control-oriented DC AA-RSWmodel is established to explore the welding power control algorithm. The simulated results of the control model show agreement with the experimental data, which validates its feasibility for the corresponding welding control.

Key words: resistance spot welding (RSW), aluminum alloy, system identification, modeling and simulation

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