Design and implementation of a medium frequency direct current resistance spot welding system integrated with welding control interface

Abstract

The increasing demand for high-precision welding requires advanced systems with real-time feedback control. Traditional resistance spot welding (RSW) technologies struggle with managing complex welding profiles and ensuring consistent weld quality. This study presents a medium-frequency direct current (MFDC)-RSW system integrated with a Python-based welding control interface (WCI) to enhance precision and adaptability. The system enables real-time parameter optimization and closed-loop current regulation using a LaunchXL-F28069M microcontroller. Experimental validation demonstrated high accuracy, achieving 97-98 % tracking accuracy in welding current and reducing RMSE from 0.178 kA to 0.109 kA. Closed-loop control outperformed open-loop configurations, enhancing process stability. The WCI facilitated efficient parameter adjustments and robust operation under varying conditions. By improving weld precision, process consistency, and adaptability, the proposed system overcomes limitations of traditional RSW, contributing to the advancement of adaptive welding technologies. Future research may explore enhanced feedback mechanisms and broader industrial applications.