Weld Quality Assurance Method using Statistical Analysis of Primary Dynamic Resistance During Resistance Spot Welding

1차 동저항 패턴의 통계적 분석에 의한 저항 점 용접의 용접 품질 예측에 관한 연구

  • Published : 2000.10.01


In previous studies, the dynamic resistance, which was calculated by the process variables measured at the electrode of the welding machine, and the electrode displacement were used for quality exa mination. However, in-process usage of such systems is not effective in systems that include a welding gun attached to a robot. In order to overcome such problems, we obtained and used the process variables from the welding machine timer. This would allow us to estimate real time in -process weld quality. For quality estimation, the features were extracted as factors from the primary dynamic resistance patterns, which were measured in t he welding machine timer. The relationship between the indexes and nugget size of the welds was observed through the regression analysis. Using the analyzed factors, a regression model that could estimate nugget diameter was developed. Two regression equations of the model were suggested depending on the factors, and it was showed that the model developed by stepwise method was effective one for weld quality estimation. The developed estimation model was in good linearity with the nugget diameter obtained through the experimentation.


Resistance Spot Welding;Primary Dynamic Resistance;Regression Analysis;Correlation;Quality Estimation


  1. 조용준, 이세헌, 엄기원, 1998, '퍼지 알고리즘을 이용한 저항 점 용접의 실시간 품질 평가 기술 개발에 관한 연구,' 대한용접학회지, Vol. 16, No. 5, pp. 76-85
  2. 김주석, 이재익, 이상룡, 1998, '퍼지 추론을 이용한 저항 점 용접 부위의 품질 평가 알고리듬,' 대한기계학회논문집 A권, Vol. 22, No. 3, pp. 644-653
  3. Livshits, A. G., 1997, 'Universal Quality Assurance Method for Resistance Spot Welding Based on Dynamic Resistance,' Welding Journal, Vol. 76, No. 9, pp. 383s-390s
  4. 최용범, 장희석, 조형석, 1993, '저항 점 용접에서 인공신경회로망을 이용한 용융부 추정에 관한 연구,'대한기계학회논문집, Vol. 17, No. 2, pp. 393-406
  5. Tsai, C. L., Dai, W. L., Dickison, D. W., and Papritan, J. C., 1991, 'Analysis and Development of a Real-Time control Methodology in Resistance Spot Welding,' Welding Journal, vol. 70, No. 12, pp. 339s-351s
  6. Hao, M., Osman, K. A., Boomer, D. R., and Newton, C. J., 1996, 'Development in Characterization of Resistance Spot Welding of Aluminuim,' Welding Journal, Vol. 75, No. 1, pp. 1s-8s
  7. Gedeon, S. A., Soresen, C. D., Ulrich, K. T. and Eagar, T. W., 'Measurement of Dynamic Electrical and Mechanical Properties of Resistance Spot Welds,' Welding Journal, Vol. 66, No. 12, (1987), pp. 378s-385s
  8. Dickinson, D. W., Franklin, J. E. Franklin, and Stanya, A. Stanya, 1980, 'Characterization of Spot Welding Behavior by Dynamic Electrical Parameter Monitoring,' Welding Journal, Vol. 59, No. 6, pp. 170s-176s
  9. Johnson, k. I. and Needham, J. C., 1972, 'New Design of Resistance Spot Welding Machine for Quality Control,' Welding Journal, Vol. 51, No. 3, pp. 1s-8s
  10. Savage, W. F., Nippes, E. F. Nippes, and Wassell, F. A. Wasswll, 1978, 'Dynamic Contact Resistance of Series Spot Welds,' Welding Journal, Vol. 57, No. 2, pp. 43s-50s
  11. Roberts. W. L., 1951, 'Resistance Variations During Spot Welding,' Welding Journal, Vol. 30, No. 11, pp. 1004-1019