Resistance spot welding control based on fuzzy logic

Resistance spot welding is one of the most important welding procedures. Therefore, a lot of research is done in order to increase its cost effectiveness. One of the problems is short electrode life, especially when coated materials are welded. This paper presents a fuzzy logic-based controller which is capable of detecting expulsion and stopping the welding process when it occurs. Consequently, electrodes are spared of unnecessary high stresses which occur when the energy is being poured into the weld region after expulsion. Their life is therefore substantially increased.