On-line estimation of electrode face diameter based on servo gun driven by robot in resistance spot welding

Abstract

Enlargement of electrode face diameter in resistance spot welding was the main factor that led to undersize nugget diameter. A mathematics model was established to estimate electrode face diameter by applying the characteristic that servo gun can detect axial wear online but not equip additional measurement apparatuses. Firstly the precision of servo gun was compensated to assure it can meet the requirement of axial wear measurement online. Then the model was established to estimate electrode face diameter online by a minimum amount of experiment data to determine the numerical constant in the model. To verify the model, electrode life tests for welding different galvanized steels were carried out. It was shown that estimation results of the model agreed well with the experiment results and spot welding the steels with higher electrode wear rate would result in a shorter electrode life. © 2007 Springer-Verlag Berlin Heidelberg.