Universal Spot Welding Machine
Spot welding is a process to join two metal sheets by applying heavy amount of current. Spot welding depend upon electrode force, time cycles of current flow and the amount of current flow. If amount of force that is applied by the electrode is greater than the bearing capacity of metal sheets then
2025-06-28 16:36:30 - Adil Khan
Universal Spot Welding Machine
Project Area of Specialization Electrical/Electronic EngineeringProject SummarySpot welding is a process to join two metal sheets by applying heavy amount of current. Spot welding depend upon electrode force, time cycles of current flow and the amount of current flow. If amount of force that is applied by the electrode is greater than the bearing capacity of metal sheets then hole is made instead of gripping the sheet. If the electrode force is less than the specific amount of force then the electrode grip is weak and it is dangerous for us. Amount of current flow and time cycles for current flow are also an important factors in spot welding. If the amount of current flow is greater than specific amount of current than sheets melt instead of welding. If the amount of current flow is less than the specific amount of current then proper nugget is not formed. Welding of dissimilar materials is a difficult task that is mostly used in automobile industries. Welding of dissimilar materials is a challenge. A small time interval is the best option for proper nugget formation. In this project we shall control the electrode force, time cycles of current and amount of current by microcontroller. Controlling parameters are vary by material to material and also depend on the thickness of the material. User only select the material type and thickness of the material. Other parameters is adjust by the controller and it send control signal to piston that is connected to the electrodes and adjust the electrode force. A control signal also send to the welding contactors that control the amount of current flow and time cycles for current flow. By the automation of spot welding, the welding of similar and dissimilar material is an easy task in industries. By varying parameters dissimilar materials are welded. No filler material is required for spot welding. Dangerous flame is not make in spot welding. It is a high welding rate.
Project Objectives- To increase the strength of spot welding by controlling the parameters.
- To control the parameters (electrode force, weld time and time of current flow) of spot welding by microcontroller
Input switches are used for selecting of the spot wtype of material use for spot welding and thickness of sheets which we want to spot welding.
Control Circuit:It contain the microcontroller that control the whole process of the spot welding machine.
Firing Circuit:It is use to convert the input from one level to another level.
Solenoid Valve:It is use to control the piston pressure.
Welding Contactors:These are connected to the primary of transformer and used for switching i.e SCR.
Welding Transformer:It is step down transformer and used for spot welding.
Today is the world of automation.Every customer wants the products in best form of production.Due to our project parameters of spot welding exactly controlled, effectiveness and strength of spot welding will be increased.Also our project will help for spot welding of different material of different thickness.There are some application of our project are
- Automobile Industries
- Electronics
- Battery Manufacturing
- Orthodontics/Biomedical Industries
- Nuts and Bolts Manufacturing
- Fabrication and Repair Shops ( metal doors, windows and other damaged metallic items )
TThis spot welding machine will be work on single phase 2220V AC.First of all we will select the material then thickness of material. And in this way controller automatically select the exact weld time, amount of current flow, Electrode force and weld cycle.
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 70000 | |||
| microcontroller | Equipment | 1 | 18000 | 18000 |
| copper electrode | Equipment | 2 | 10000 | 20000 |
| transformer | Equipment | 1 | 25000 | 25000 |
| keypad and LCD | Equipment | 1 | 6000 | 6000 |
| power wire | Equipment | 1 | 1000 | 1000 |