Abstract: In the automobile industry, Resistance Spot Welding (RSW) is widely used for its low cost, high speed, simple mechanism and applicability for automation. RSW has become the predominant means of auto body assembly, resulting in two to six thousands spot welds performed on each manufactured car. In the North American automobile industry there are approximately 100 billion spot welds, which are done every year. RSW is the joining of two or more metal parts together in a localized area by resistive heating and pressure. Small Scale RSW (SSRSW) is commonly used for medical devices and electronic components, because the welded parts are thinner and smaller compared to common RSW applications, such as automotive applications. This project study will focus on studying and improving weld power supplies, weld schedules and control modes. One of the goals for this project is to improve the consistency of weld nugget size and strength by using different control parameters, which will be weighted geometric averages of voltage and current. These control parameters are fed back to a Proportional Integral Derivative (PID) controller that is designed to control the Direct Current (DC) power supply for the RSW to come up with the best control parameters that will improve the consistency of the RSW spot welds.

Keywords: Resistance Spot Welding (RSW), Small Scale RSW, Large Scale RSW, DC power Supply, Timer IC and Buck Converter.