AUTOMATIC PORTABLE SPOT WELDING

MACHINE

KARTHIK J 1PE15ME062 Mr. Ravishankar M K

JEEVANKUMAR 1PE15ME066 Assistant Professor
Department of Mechanical Engineering
KEERTHANA D 1PE15ME074
MAHESH BALAGARI 1PE16ME415
 INTRODUCTION
• Resistance Spot welding(RSW) is a process in which contacting metal surface
points are joined by the heat obtained from resistance to electrical current.

• Copper alloy electrode are used to apply pressure and convey the electrical
current through the workpiece.

• This method is extensively used in joining low carbon steel component,

stainless steel, aluminium, titanium and copper alloys. It is extensively used in
battery manufacturing(bus bar assembly).

• The presently used conventional spot welding machine consumes a lot of

space thus making it rigid and very heavy.
• Therefore, to achieve portability one needs to scale down the
machine to a large extent.
• Automation is obtained by integrating the timing of both the
workpiece as well as the electrode movement which are coupled to
the microcontroller.
• From the suitability study of materials that is depending on three
factors namely:
1. Surface condition
2. Chemical composition
3. Metallurgical condition
From which mild steel sheet of 0.5mm thickness is selected as
specimen for testing.
 LITERATURE REVIEW
Sl.no Title Author Year Highlights

Application of Taguchi A.G. Thakur, T.E. Rao, M.S. Mukhedkar, The highly effective parameters are
method for Resistance V.M.Nandedkar Nov current and time, whereas force and
1.
Spot Welding of (ARPN Journal of Engineering and Applied 2010 diameter are less effective
Galvanized steel Sciences) parameters.
Study of Spot-Welding Shamsul Baharin Jamaludin, Mohammad Increasing welding current increases
of Austenitic Stainless Hisyam January the nugget size. The nugget size
2.
Steel type 304 (Journal of Applied Sciences) 2007 does not influence the hardness
distribution.
Fabrication of portable Rishabh Sharma, Deepak Kumar Singh, Study of various factors like the
Spot welding machine Vikas Kumar Jha, Ram Bhajan Kumar thermo-effect of nugget growing in
(International Journal for Innovative Oct Single phase AC RSW. Fcators
3.
Research in Science & Technology) 2016 affecting electrode such as chemical
composition, pressure force, time of
welding current.
Sl.no Title Author Year Highlights

Depending on the welding

parameters, the effects of zinc
coating on the weld nugget
Resistance Spot geometry was studied, and the
Nov
4. Weldability of Hayriye Ertek Emre and Ramazan Kaçar results were compared. The coating
2016
Galvanize Coated and (MDPI- METALS) on the surface of the TRIP steel
Uncoated TRIP Steels caused a decrease in the weld
nugget size and tensile shear
strength of the weldment.
Microstructure and Here, the nugget size increased with
Tensile-Shear Qiang Jia , Lei Liu , Wei Guo , Yun Peng , the increase of heat input, but when
Properties of Guisheng Zou , Zhiling Tian and Y. Norman January the welding current exceeded the
5.
Resistance Spot- Zhou 2018 critical value, the tensile-shear load
Welded Medium Mn (MDPI- METALS) increased slowly and became
Steel unstable due to metal expulsion.

The analysis was based on a SORPAS

Heating of electrodes Z. Mikno , Z. Bartnik program. FEM calculations were
Oct
6. during spot resistance (Archives of Civil and Mechanical verified experimentally through
2016
welding in FEM Engineering ) measurements of electrode
calculations temperature during welding cycles.
NEED FOR PRESENT WORK
• To obtain accurate weld by automating the arc welding process
• Possibility of automatic movement of the sheet metal using Arduino
and hence less human effort.
• Unlike traditional spot welding machine, this machine is potable
because of light weight.

OBJECTIVE
To design and fabricate automated portable spot welding machine to arc
weld the sheet metals at a programmed distance.
COST ESTIMATION
Sl.no COMPONENT COST(unit) QUANTITY COST
1. Copper electrode 750 2 1500
2. Transformer 450 1 450
3. Electromagnet 1500 1 1500
4. Arduino UNO 445 2 445
5. Switch Mode Power Supply (10 amps) 350 2 700
6. Leadscrew 450 2 900
7. Relay switch 85 2 170
8. Driver board 135 4 540
9. Sheet metal (mild steel) 50 - 50
10. L angle frame (mild steel) 1250 - 1250
11. Jumping wires 250 1 250
12. Mild steel Guide rods 100 3 300
12. Miscellaneous 7500
TOTAL 15,555
DESIGN CALCULATIONS
CONSTRAINTS ASSUMPTION
1) Yield strength of mild steel= 250MPa Thickness of mild steel = 0.6 mm
2) Density of mild steel= 7700 kg/m3 Width of mild steel = 152.4 mm
Length of mild steel = 609.6 mm

 Electrode diameter  Mass of workpiece  Torque equation

Diameter = 5 X (t) .5
= 5 X (0.5).5
= 3.53 mm
Standard diameter– 6-8 mm
Mass= Density X Volume Torque =
(𝑙𝑜𝑎𝑑 (𝑘𝑔) 𝑋 𝑙𝑒𝑎𝑑 (𝑚))
(2 X π X efficiency)
=7700 X 0.6 X 152.4 X 609.6 X 10-9
Efficiency = 35%
= 0.4292 kg
Torque = 1.068X10-3 kg-m
= 10.4735 X 10-3 N-m
  Speed of Lead Screw
 Speed of work bench
Pitch of Lead Screw = 1 mm
Speed of work bench = motor speed X lead
Motor speed = 100 rpm
= 0.1 X 1
Speed of work table = Pitch X Motor speed
= 0.1 m/s
= 1 X 100 mm/min
• Diameter of screw, (Mild steel screw) 100
= = 1.66 ≈ 2 mm
60
dc = 𝜋
2𝐹
𝜎
 Transformer Current calculations
X( )
2 𝐹𝑂𝑆
VP = 230 V
Considering F = 200 N
IP = 5A
Factor of Safety (FOS) =10
VP 𝐼𝑆
=
dc = 𝑉𝑆 𝐼𝑃
200X4

𝜋X448X 106 𝑉𝑃 𝑋 𝐼𝑃 230 𝑋 5

= 2.38 mm IS = =
𝑉𝑆 6

Standard diameter – 10mm IS = 191.38 A

• Heat generated

H = I2 x R x t

= 191.32 x 1 x 10-9 x 3 = 1.098 J

MODELLING LOGIC
 for(int i=0;i<rot2;i++){
PROGRAMMING myStepper.step(stepsPerRevolution);}
digitalWrite(relay,HIGH);
#include <Stepper.h> delay(d);
int rot1=10; digitalWrite(relay,LOW);
int rot2=10;
int rot3=10; for(int i=0;i<rot3;i++){
int rot4=10; myStepper.step(stepsPerRevolution);}
int relay=8; digitalWrite(relay,HIGH);
int d=1000*1; delay(d);
const int stepsPerRevolution = 200; digitalWrite(relay,LOW);
Stepper myStepper(stepsPerRevolution, 2, 3, 4, 5);
void setup() { for(int i=0;i<rot4;i++){
myStepper.setSpeed(180); myStepper.step(stepsPerRevolution);}
Serial.begin(9600);
pinMode(relay,OUTPUT); digitalWrite(relay,HIGH);
} delay(d);
void loop() { digitalWrite(relay,LOW);
Serial.println("clockwise");
for(int i=0;i<rot1;i++){ Serial.println("counterclockwise");
myStepper.step(stepsPerRevolution);} for(int i=0;i<rot4+rot3+rot2+rot1;i++){
digitalWrite(relay,HIGH); myStepper.step(-stepsPerRevolution);
delay(d); }
digitalWrite(relay,LOW); while(1);}
MATERIAL USED FOR FABRICATION

COPPER ELECTRODE ELECTROMAGNET TRANSFORMER SWITCH MODE POWER SUPPLY

RELAY SWITCH ARDUINO UNO JUMPING WIRES DRIVER CIRCUIT BOARD

FABRICATION
RESULTS AND DISSCUSSIONS
• Two tests were conducted to find the strength and nature of weld
obtained which are:
1. Shear Strength
2. Chisel test
• Three types of specimen were prepare based on:
1. Keeping the Weld distance constant varying the Weld time.
2. Keeping the Weld time constant varying the Weld distance.
3. Keeping the Weld time constant and incremental increase in weld
distance.
• Shear strength for constant weld distance
From the above graph, it is found that the load bearing capacity increases with decreasing the distance
between the weld. Therefore, to get higher weld strength the weld distance should be kept at as minimum as
possible. Further it is to be noted that when the weld distance was lowered too much, due to the heat
affected zone the weld quality detorated. Therefore choosing a optimal spacing for welds plays a significant
role in quality weld.
Shear strength for constant weld time
From the above graph, it is found that the load bearing capacity increases with increasing the weld time.
Therefore, to get higher weld strength the weld time should be kept as higher as possible.Further it is to be
noted that when the weld time was too high, it formed an dent in workpiece as the sheet metal melted
instead of forming a joint. Therefore choosing a optimal weld time also plays a vital role in weld quality.
Chisel Test
• From ISO 10447 2006, which states that after the weld is broken with
the chisel the nugget diameter should be equal to the diameter
obtained from equation d = 5×t1/2. Where, d is the nugget diameter, t
is the thickness of the sheet metal. So, from the equation the suitable
nugget diameter should be 3.535mm.Therefore, the nugget obtained
for a weld time of 4 seconds is close to that of the diameter predicted
by the equation. Hence, optimal weld time for a specimen of 0.5 mm
thickness can be taken as 4 seconds.
CONCLUSION
• Spot welding of mild steel sheet of thickness 0.6mm has been achieved

• The auto feed mechanism is done by using arduino UNO which helps in
nugget formation exactly at 1cm distance between them.

• The drawback of the machine is, the weld is of low strength.

Future Work
• The portability of spot-welding machine is achieved however there are certain
points that can be considered for the future work which includes:
• Flexibility in electrode assembly, so that changing the electrodes for different
sheet metal materials and thickness suitably.
• Flexibility of changing the input power, here the input power is kept constant
however when the thickness of sheet metal changes the same constant power
cannot be used so a suitable design of flexible transformer wherein the user can
tune into the desired power.
• Use of adjustable electromagnet so that even the electrode force can be adjusted
by the user.
• Here, the weld distance or weld time if needed to be changed, the program
needs to be changed each time. So, there is possibility of taking the input from
the user himself for weld time, weld distance, squeeze force and the other
required parameters. To achieve a fully automated, customer desired machine
THANK YOU