AUTOMATIC RESISTANCE SPOT WELDING FOR WELDING OPERATION

A PROJECT REPORT

Submitted by

AJAY.P (17TB0803)

HARIHARASIVAN.S (17TB0819)

RAMKUMAR.U (17TB0855)

JALALUDEEN.M (17TB0823)

Under the guidance Of

Mr.KRISHNABRARATHY K, M.E.
Assistant Professor
Department of Mechanical Engineering

In partial fulfilment of the requirement for the award of the degree

Of

BACHELOR OF TECHNOLOGY

IN

MECHANICAL ENGINEERING

CHRIST
COLLEGE OF ENGINEERING AND TECHNOLOGY Pitchaveeranpet,
Moolakulam, Puducherry –605 010

MARCH 2021

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 CHRIST

COLLEGE OF ENGINEERING & TECHNOLOGY

(Approved by AICTE, New Delhi & Affiliated to Pondicherry University)

PITCHAVEERANPET, MOOLAKULAM, PUDUCHERRY -605 010

Phone: 0413 –2293491, 2293493, Website: www.christcet.org

BONAFIDE CERTIFICATE
This is to certify that the project report entitled “AUTOMATIC RESISTANCE SOPT
WELDING FOR WELDING OPERATION” submitted by “P.AJAY (17TB0803),
S.HARIHARASIVAN (17TB0819),U.RAMKUMAR (17TB0855), M.JALALUDEEN
(17TB0823).”in partial fulfillment of the requirements for the award of the Degree of
Bachelor of Technology in “MECHANICAL ENGINEERING” is a bonafide record
ofthe work carried out under my guidance and supervision at CHRIST COLLEGE OF
ENGINEERING AND TECHNOLOGY.PROJECT GUIDE HEAD OF THE
DEPARTMENT Mr.K.KRISHNABHARATHY Dr. C. SUBRAMANIAN Assistant
professor Professor & Head Dept. of Mechanical Engineering Dept. of Mechanical
Engineering

This project report was evaluated by us on .........

INTERNAL EXAMINER EXTERNAL EXAMINER

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 ACKNOWLEDGEMENT
My deep sense of gratitude goes to our beloved Chairman & Managing Director Dr.
S.R.S. PAUL, M.E., Ph.D., B.L., Sam Paul Educational Trust who provided all facilities
and necessary encouragement during the course study.

We extended our gratitude and sincere thanks to our Principal Prof. Dr. A.
SIVAKUMAR, M.E., Ph.D., M.I.S.T.E., for his valuable support in carrying out project
work.

It is our privilege to honor Dr. C. SUBRAMANIAN, M.Tech., Ph.D., Professor &

Head of the Department, Mechanical Engineering, for his suggestion, support and
encouragement for completion of this project.

We would like to express our unbounded gratefulness to our project guide

Mr.K.KRISHNABHARATHY,M.E, Assistant Professor Department of Mechanical
Engineering for his valuable guidance and encouragement throughout this work. He has
been a constant source of inspiration and has provided consistent succor and precious
suggestions throughout this project.

We also express our gratitude to all the faculty members, supporting staffs, parents and
my fellow mates who have helped us to carry out this work. Last but not the least , we
thank my almighty god for his blessing showed on me during this period.

AJAY

HARIHARASIVAN

JALALUDEEN.U

RAMKUMAR.M

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 INDEX

Title Page no

CHAPTER 1

INTRODUCTION
1.1 Overview 1

1.2 List of Welding Process Prevailing in the Company 1

1.2.1 Arc Welding 2

1.2.2 Mental Inert Gas Welding 2

1.2.3 Inert Welding 2

1.2.4 Stud Welding 3

1.2.5 Spot Welding 4

1.3 Application 4

1.4 Processing 5

1.5 A Brief Overview of the Components 5

1.5.1 Dc gear Motor 5

1.5.2 Servo Motor 6

1.5.3 Step Down Transformer 7

1.5.4 Welding Electrodes 8

1.6 Lead Screw 9

1.7 Spot Welding Sequence 10

1.7.1 Welding Cycle 10

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1.7.2 Squeeze Time 11

1.7.3 Weld Time 11

1.7.4 Hold Time 11

1.7.5 Off Time 11

1.8 Spot Welding Variables 11

1.9 Welding Current 12

1.10 Pressure Control 12

1.11 Avr Control 12

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 CHAPTER 2

LITRATURE SURVEY 14

CHAPTER 3

EXPERIMENTAL DETAILS
3.1 Experimental Setup 18

3.2 Factor of Project Selection 19

3.2.1 Limitation of Various Existing Spot Welding Machine 19

3.2.2 Expected Outcome of Project 20

3.3 Installation of Spot Welding Machine 20

3.4 Preparation for Installation 20

3.5 Setting The Machine 21

3.6 Safety Requirements 21

3.7 Electrical Installation 21

3.8 Spot Welding Parameters 22

3.9 Dc gear Motor Specification 23

3.10 Servo Motor 24

3.11 Step Down Transformer 25

3.12 Material Selection 26

3.12.1 Bulk Modulus 26

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 3.12.2 Elastic Modulus 27

3.12.3 Density 27

3.12.4 Hardness 27

3.12.5 Elongation At Break 27

3.12.6 Fracture Toughness 28

3.12.7 Fatigue Strength 28

3.13 Electrode Characteristics 28

3.13.1 Copper Chromium 28

3.14 Design of Welding Machine 30

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 CHAPTER 4
Future Scope 32

References 33

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 LIST OF TABLES

Table Page
3.1 Step Down Transformer 25

3.2 Material Comparison 26

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 LIST OF FIGURES

Figures Page
1.1 Construction of Induction Motor 5

1.2 Construction of Break Motor 7

1.3 Schematic Diagram of Step- down Transformer 8

1.4 Step Down Transformer 9

1.5 Welding Electrode 10

1.6 Lead Screw 11

1.7 Avr Micro controller 13

3.1 Dc gear Motor 23

3.1 Servo Motor 24

3.2 Design of Machine 29

3.3 Front View 29

3.4 Side View 30

3.6 Top View 30

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 ABSTRACT
A Virtual Machine has led to a fully automatic spot welding system. All necessary
parameters are created by measuring systems and algorithms running in the Virtual
Machine.

A hybrid operating circuit allows the Virtual Machine to read the exact process voltage
between the tips of the electrodes every 50 us. Actual welding voltage and current allow
for the first time reading process impedance, electric power and total energy being
transferred to the spot weld. Necessary energy input is calculated by a calorimetric model
after measuring the total thickness of the materials to be welded as soon as the welding
tipis positioned at the Work piece.

A precision potentiometer implemented in the tip delivers the total material thickness
within the 0.1 mm range during the pre-pressure phases. The internal databank of the
Virtual Machine controls all essential parameters to guide the total welding process.

Special generator characteristics of the welding power unit are created by the Virtual
Machine just during the upslope and the welding phases. So the process will be initialized
in differentiating the kind of material, mild steel or high strengthen steel. This will affect
the kind of energy input and current decrease during the upslope and downslope phases.

Keywords: Automatic spot welding machine, Hybrid operating, Electric power, Welding
tip, Material thickness, Virtual machine, Mil steel.

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This project concentrates on improving the mechanical properties of Aluminium 2024(Al
2024) by adding Green Silicon Carbide and Adenanthera Pavonina seed powder as
reinforcement to it. Aluminium MMC is prepared by varying the weight composition of
green SiC and Adenanthera Pavonina seed powder by stir casting method. The fabricated
work pieces undergo various tests like tensile test, yield strength test, hardness test to
study the change in its properties

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INTRODUCTION

CHAPTER 1

INTRODUCTION
1.1 OVERVIEW

Resistance spot welding (RSW) is a process in which contacting metal surfaces

are joined by the heat obtained from resistance to electric current. Work-pieces are held
together under pressure exerted by electrodes. Typically the sheets are in the 0.5 to 3 mm
(0.020 to 0.118 in) thickness range. The process uses two shaped copper alloy electrodes
to concentrate welding current into a small "spot" and to simultaneously clamp the sheets
together. Forcing a large current through the spot will melt the metal and form the weld.
The attractive feature of spot welding is that a lot of energy can be delivered to the spot in
a very short time (approximately 10 -100 milliseconds).That permits the welding to occur
without excessive heating of the remainder of the sheet. The amount of heat (energy)
delivered to the spot is determined by the resistance between the electrodes and the
magnitude and duration of the current. The amount of energy is chosen to match the
sheet's material properties, its thickness, and type of electrodes. Applying too little energy
will not melt the metal or will make a poor weld. Applying too much energy will melt too
much metal, eject molten material, and make a hole rather than a weld.

1.2List of welding processes prevailing in the company

Are welding

Inert Gas (CO:) welding

Spot welding

Stud Welding

TIG Welding

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INTRODUCTION

1.2.1 ARC WELDING

Arc welding is a type of welding that uses a welding power supply to create an
electric arc between an electrode and the base material to melt the metals at the welding
point. They can use either direct (DC) or alternating (AC) current, and consumable or
non-consumable electrodes. The welding region is usually protected by some type of
shielding gas, vapor, or slag.

Arc welding processes may be manual, semi-automatic, or fully automated. First

developed in the early part of the 20th century, are welding became commercially
important in s hip building during the Second Word War. Today it remains an important
process for the fabrication of steel structures and vehicles.

1.2.2 METAL INERT GAS WELDING:

Metal inert gas (MIG) welding or metal active gas (MAG) welding, is a welding in which
between electric arc forms process an consumable wire electrode and the work piece
metals), which heats the work piece metals), causing them to melt, and join. Along with
the wire electrode, a shielding gas feeds through the welding gun, which shields the
process from contaminants in the air. The process can be semi-automatic or automatic. A
constant voltage, direct current power source s most commonly used with GMAW, but
constant current systems, as well as alternating current, can be used.

There are four primary methods of metal transfer in GMAW, called globular,
short-circuiting, spray, and pulsed-spray, each of which has distinct properties and
corresponding advantages and limitations.

TIG WELDING
Tungsten inert gas (TIG) welding is an arc welding process that uses a non consumable
tungsten electrode to produce the weld. The weld area is protected from atmospheric

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contamination by an inert shielding gas (argon or helium), and a filler metal is normally
used, though some welds, known as auto genous welds, do not require it.

INTRODUCTION
A constant-current welding power supply produces energy which is conducted
across the arc through a column of highly ionized gas and metal vapors known plasma.

STUD WELDING
Stud welding is a form of spot welding when a bolt or specially formed nut is
welded onto another metal part. The bolts may be automatically fed into the spot welder.
Weld nuts generally have a flange with small nubs that melt to form the weld. Studs have
a necked down, un-threaded area for the same purpose. Weld studs are used in stud
welding systems.

Capacitor discharge weld studs range from 14 gauge to 3/8 diameter. They can
come in many different lengths ranging from 1/4" to 5" and larger. The tip on the wed
end of the stud serves a two fold purpose.

1.2.5 SPOT WELDING:

Spot welding is a process in which contacting metal surfaces plane joined by the
heat obtaned from esistance to current. Work-pieces are held together under pressure
exerted by electrodes. Typically the sheets are in the 0.5 to 3 mm (0.020 to 0.12 in)
thickness range. The process uses two shaped copper alloy electrodes to concentrate
welding current into a small "spot" and to simultaneously clamp the sheets together.

Foring a large current through the spot will melt the metal and fom the weld. The
attractive feature of spot welding is a lot of energy can be delivered to the spot in a very
short time.

The amount of heat (energy) delivered to the spot is determined by the resistance
between the electrodes and the amperage and duration of the current. The amount of
energy is chosen to match the sheet's material properties, its thickness, and type of

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electrodes. Applying too little energy won't melt the metal or will make a poor weld.
Applying too much energy will melt too much metal, eject molten material, and make a
hole rather than a weld. Another attractive feature of spot welding is the energy delivered
to the spot can be controlled to produce reliable welds.

INTROCTION

The advantages of the method include efficient energy use, limited wok peace
deformation n, high production rates, easy automation, and no required filer materials.
While the shear strength of each weld is high, the fact that the weld spots do not form a
continuous seam means that the overall strengthis often significantly lower than with
other welding methods, limiting the usefulness of the process. It is used extensively in the
automotive industry cars can have several thousand spot welds.

1.3APPLICATIONS
Spot welding is typically used when welding particular types of sheet metal,
welded wire mesh or wire mesh. Thicker stock is more difficult to spot weld because the
heat flows into the surrounding metal more easily. Spot welding can be easily identified
onmany sheet metal goods, such as metal buckets.

Aluminium alloys can be spot welded, but their much higher thermal conductivity
and electrical conductivity requires higher welding currents. This requires larger, more
powerful, and more expensive welding transformers. Spot welding of BMW 3 series car
bodies with KUKA Industrial Robots Perhaps the most common application of spot
welding is in the automobile manufacturing industry, where it is used almost universally
to weld the sheet metal to form a car.

Spot welders can also be completely automated, and many of the industrial robots
found on assembly lines are spot welders (the other major use for robots being painting).
In the North American automobile industry there are approximately 100 billion spot
welds, which are done every year. Spot welding is also used in the orthodontist's clinic,
where small scale spot welding equipment is used when resizing metal "molar bands"
used in orthodontics.

Another application is spot welding straps to nickel-cadmium or nickel-metal-

hydride cells to make batteries. The cells are joined by spot welding thin nickel straps to

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the battery terminals. Spot welding can keep the battery from getting too hot, as might
happen if conventional soldering were done.

INTRODUCTION

PROCESSING
Spot welding involves three stages; the first of which involves the electrodes
being brought to the surface of the metal and applying a slight amount of pressure. The
current from the electrodes is then applied briefly after which the current is removed but
the electrodes remain in place for the material to cool. Weld times range from 0.01 sec to
0.63 sec depending on the thickness of the metal, the electrode force and the diameter of
the electrodes themselves.

1.5A Brief Overview of the Components:

1.5.1DC GEAR MOTOR:

Dc gear motors, as the name implies, use direct uni-directional current. Dc motors are
used in special applications where high torque starting smooth acceleration over a broad
speed range is required.

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 Fig 1.1 DC GEAR MOTOR

INTRODUCTION
A gear motor is an all-in-one combination of a motor and gearbox.
The addition of a gear head to a motor reduces the speed while increasing the torque
output. The most important parameters in regards to gear motors are speed (rpm), torque
(lb-in) and efficiency (%). In order to select the most suitable gear motor for your
application you must first compute the load, speed and torque requirements for your
application.

Geared DC motors can be defined as an extension of DC motor which already had its

Insight details demystified. A geared DC Motor has a gear assembly attached to the

motor. The speed of motor is counted in terms of rotations of the shaft per minute and is

termed as RPM .The gear assembly helps in increasing the torque and reducing the speed.

Using the correct combination of gears in a gear motor, its speed can be reduced to any

desirable figure. This concept where gears reduce the speed of the vehicle
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but increase its torque is known as gear reduction.  This Insight will explore all the

minor and major details that make the gear head and hence the working of geared DC

motor.

External Structure

At the first sight, the external structure of a DC geared motor looks as a straight

expansion over the simple DC ones.

The lateral view of the motor shows the outer protrudes of the gear head. A nut is placed

near the shaft which helps in mounting the motor to the other parts of the assembly

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OUTER BODY OF GEAR HEAD & REAR VIEW

The outer body of the gear head is made of high density plastic but it is quite easy to open

as only screws are used to attach the outer and the inner structure. The major reason

behind this could be to lubricate gear head from time to time.

The plastic body has a threading through which nut can be easily mounted and vice versa

from the gear head.

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Rear View

The rear view of the geared motor is similar to the DC motor and it has two wires

soldered to it.

Specifications

 DC supply: 4 to 12V
 RPM: 300 at 12V

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  Total length: 46mm
 Motor diameter: 36mm
 Motor length: 25mm
 Brush type: Precious metal
 Gear head diameter: 37mm
 Gear head length: 21mm
 Output shaft: Centred
 Shaft diameter: 6mm
 Shaft length: 22mm
 Gear assembly: Spur
 Motor weight: 90gms

Working

Working of the DC Geared Motor

The DC motor works over a fair range of voltage. The higher the input voltage more is

the RPM (rotations per minute) of the motor. For example, if the motor works in the

range of 6-12V, it will have the least RPM at 6V and maximum at 12 V.

In terms of voltage, we can put the equation as:

RPM= K1 * V, where,

 K1= induced voltage constant

V=voltage applied

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Functional Mechanism of Gear Assembly

The working of the gears is very interesting to know. It can be explained by the principle

of conservation of angular momentum. The gear having smaller radius will cover more

RPM than the one with larger radius. However, the larger gear will give more torque to

the smaller gear than vice versa. The comparison of angular velocity between input gear

(the one that transfers energy) to output gear gives the gear ratio. When multiple gears are

connected together, conservation of energy is also followed.  The direction in which the

other gear rotates is always the opposite of the gear adjacent to it.

In any DC motor, RPM and torque are inversely proportional. Hence the gear having

more torque will provide a lesser RPM and converse. In a geared DC motor, the concept

of pulse width modulation is applied.  The equations detailing the working and torque

transfer of gears are shown below:

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Fig. 15: Gear Assembly Placed in Gear Head

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In a geared DC motor, the gear connecting the motor and the gear head is quite small,

hence it transfers more speed to the larger teeth part of the gear head and makes it rotate.

The larger part of the gear further turns the smaller duplex part. The small duplex part

receives the torque but not the speed from its predecessor which it transfers to larger part

of other gear and so on. The third gear’s duplex part has more teeth than others and hence

it transfers more torque to the gear that is connected to the shaft.  

1.5.2SERVOMOTOR:

The servo motor is most commonly used for high technology

devices in the industrial applications like automation technology. It is a self contained
electrical device, that rotates parts of machine with high efficiency and great precision.
Moreover the output shaft of this motor can be moved to a particular angle.

Servo motors are mainly used in homeelectronics, toys, cars,

airplanes and many more devices.Thus this blog discusses the definition, types,
mechanism, principle, working, controlling, and lastly the applications of a servo
machine

Types of Servo Motor

Servo motors are classified into different types based on their application, such as
AC servo motor, DC servo motor, brushless DC servo motor, positional rotation,
continuous rotation and linear servo motor etc. Typical servo motors comprise of three
wires namely, power control and ground. The shape and size of these motors depend on
their applications. RC servo motor is the most common type of servo motor used in
hobby applications, robotics due to their simplicity, affordability and reliability of control
by microprocessors.

DC Servo Motor

The motor which is used as a DC servo motor generally have a separate DC

source in the field of winding & armature winding. The control can be archived either by
controlling the armature current or field current. Field control includes some particular
advantages over armature control. In the same way armature control includes some
advantages over field control. Based on the applications the control should be applied to
the DC servo motor. DC servo motor provides very accurate and also fast respond to start

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or stop command signals due to the low armature inductive reactance. DC servo motors
are used in similar equipments and computerized numerically controlled machines.

DC Servo Motor

2) AC Servo Motor

AC servo motor is an AC motor that includes encoder is used with controllers for
giving closed loop control and feedback. This motor can be placed to high accuracy and
also controlled precisely as compulsory for the applications. Frequently these motors
have higher designs of tolerance or better bearings and some simple designs also use
higher voltages in order to accomplish greater torque. Applications of an AC motor
mainly involve in automation, robotics, CNC machinery, and other applications a high
level of precision and needful versatility.

AC Servo Motor

3) Positional Rotation Servo Motor

Positional rotation servo motor is a most common type of servo motor. The
shaft’s o/p rotates in about 180o. It includes physical stops located in the gear mechanism

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to stop turning outside these limits to guard the rotation sensor. These common servos
involve in radio controlled water, radio controlled cars, aircraft, robots, toys and many
other applications.

4) Continuous Rotation Servo Motor

Continuous rotation servo motor is quite related to the common positional rotation
servo motor, but it can go in any direction indefinitely. The control signal, rather than set
the static position of the servo, is understood as the speed and direction of rotation. The
range of potential commands sources the servo to rotate clockwise or anticlockwise as
preferred, at changing speed, depending on the command signal. This type of motor is
used in a radar dish if you are riding one on a robot or you can use one as a drive motor
on a mobile robot.

Continuous Rotation Servo Motor

5) Linear Servo Motor

Linear servo motor is also similar the positional rotation servo motor is discussed
above, but with an extra gears to alter the o/p from circular to back-and-forth. These
servo motors are not simple to find, but sometimes you can find them at hobby stores
where they are used as actuators in higher model airplanes.

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Linear Servo Motor

Servo Motor Working Principle

A unique design for servo motors are proposed in controlling the robotics and for
control applications. They are basically used to adjust the speed control at high torques
and accurate positioning. Parts required are motor position sensor and a highly developed
controller. These motors can be categorized according the servo motor controlled by
servomechanism. If DC motor is controlled using this mechanism, then it is named as a
DC servo motor. Servo motors are available in power ratings from fraction of a watt to
100 watts. The rotor of a servo motor is designed longer in length and smaller in diameter
so that it has low inertia.

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Uses &Applications of Servo Motor

The servo motor is small and efficient, but serious to use in some applications like
precise position control.This motor is controlled by a pulse width modulator signal. The
applications of servo motors mainly involve in computers, robotics, toys, CD/DVD
players, etc. These motors are extensively used in those applications where a particular
task is to be done frequently in an exact manner.

 The servo motor is used in robotics to activate movements, giving the arm to its
precise angle.
 The Servo motor is used to start, move and stop conveyor belts carrying the
product along with many stages. For instance, product labeling, bottling and
packaging
 The servo motor is built into the camera to correct a lens of the camera to improve
out of focus images.
 The servo motor is used in robotic vehicle to control the robot wheels, producing
plenty torque to move, start and stop the vehicle and control its speed.
 The servo motor is used in solar tracking system to correct the angle of the panel
so that each solar panel stays to face the sun
The Servo motor is used in metal forming and cutting machines to provide
specific motion control for milling machines
 The Servo motor is used in Textiles to control spinning and weaving machines,
knitting machines and looms
 The Servo motor is used in automatic door openers to control the door in public
places like supermarkets, hospitals and theatres

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30
Step-down Transformer

Working Principle of transformer:

An important property of electricity is that a

magnetic field is produced around a wire when electric current is flowing. The more
current flowing, stronger the magnetic field. An uniformly stronger magnetic field can be
produced by winding the magnetic field into a coil. Now the magnetic field of adjacent
wires add together to form one strong magnetic field.The electric current flowing in a
transformer is alternating current.

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 As a result, current first flows in one direction,
stops then, reverses and flow in the other direction. So, the magnetic field around the
winding is constantly in motion. When a magnetic field moves around a wire, a voltage is
induced into the wire.If a second coil of wire is placed in a moving magnetic field, then
the voltagecan be induced in the second coil. Electric energy is converted into a magnetic
field and then converted backinto a electric energy in the second winding. The trick is to
do this with little or no loss of energy

The magnetic field loses strength quickly in air, therefore, a special steel core is used.
The core is composed of thin sheet of a silicon-steel alloy. The magnetic field is
concentrated in the core and the energy loss is reduced to a minimum.

Working Principle

The step-down transformer working principle of a step-down transformer is Faraday’s

law of electromagnetic induction. In a transformer, mutual induction is necessary
between two windings for transmission. In Faraday’s law, once the magnetic flux
connecting a circuit changes, then an electromotive force can be induced within the
circuit that is proportional to the flux linkage’s rate of change.

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The induced electromotive force can be determined through the number of windings
present in the transformer. So this is called turns ratio. The transformers voltage
reduction ability mainly depends on this turns ratio. When the no. of windings present in
the secondary coil is low as evaluated with the primary coil, then the linkage of flux to
the secondary coil is also less as compared with the primary coil.

So, the electromotive force induced is low in the secondary coil, due to this reason the
voltage is reduced at the secondary winding as contrasted to the primary winding.

Formula

The step-down transformer formula is

Ns/Np = Vs/Vp

Where the ‘Ns’ is no. of windings in secondary

‘Np’ is no. of windings in the primary

‘Vs’ is the voltage in secondary

‘Vp’ is the voltage in the primary

In this transformer, the no. of windings in secondary is always less as compared with the
windings in the primary

Ns < Np

Types of Step Down Transformer

Step-down transformers are classified into three types like single phase, center phase and
multi tapped.

 Single-phase is used to step down the ratings of current as well as the input
voltage to give less voltage & output current like 12V AC.
 Center Tapped includes one primary & a center split within the secondary so it
gives the output voltage with a center split like 12v to 0 to 12v.
 Multi Tapped has numerous tapping within secondary winding and these are used
to obtain the preferred output through secondary coils like 0 to12v, 0 to18v.

Construction of Step Down Transformer

The construction of a step-down transformer can be done using two or more coils wound
on the transformer’s iron core. The efficient transformers mainly include the
ferromagnetic core as this material turns into magnetized using the primary coil &

33
transmits the energy to the secondary coil. A simple method to get a ferromagnetic coil is
to discover 2-3 inches of big steel washer or a wrecking yard.

Step Down Transformer

Construction

To make the coils in the transformer, any type of conducting wire can be used but the
best one is a magnetic wire with 28 gauges. This is a thin copper wire with insulation
coated. To make the primary coil, cover the wire strongly in the region of the washer. If
required, wind it in the form of layers. Count the number of windings and note the
number.

Once winding is done, maintain the two ends open to connect the power source & cover
with masking tape in the region of the wires to maintain them in place. While designing
this transformer, the windings in the secondary coil should be less. The actual amount
mainly depends on the required voltage which can be calculated through the formula of
the transformer.

Advantages

The advantages of a step-down transformer include the following.

 Durability is high
 Reliability is high
 Less cost
 Efficiency is high
 Used to step down the voltage so that transmission power making is cheaper as
well as simple
 Provides different voltage supplies

Disadvantages

The disadvantages of the step-down transformer include the following.

 It needs more maintenance

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  The rectification of fault takes more time
 Instability within feedstock costs

Applications

The applications of a step-down transformer include the following.

 Electrical Isolation
 Voltage Stabilizers
 Inverters
 Power Distribution Network
 TVs
 In welding machines
 Home Appliances
 Transmission lines to step down
 Adapters
 CD players
 Doorbells
 Chargers

1.5.4 Welding Electrodes:

To achieve the desired current density within a small region, electrodes are used. It is
important to have a proper electrode shape for which three main types of electrodes are
used; these are pointed, domed, and flat electrodes.

Pointed Tips:

Pointed tips are most widely used particulars for ferrous materials; with continued wear
they mushroom uniformly. The pointed electrodes are basically truncated cone electrodes
with an angle of 120 degree to 140 degree.

Domed Electrodes:

Domed electrodes are characterized by their ability to withstand heavier pressure and
serve heating without mushrooming which makes them particularly useful for welding
non-ferrous metals.Off-set Electrodes:

Offset electrodes can be used to make spot welds in places that are inaccessible to weld
by conventional type electrodes e.g. for making corner welds, and for welding parts with
overhanging flanges.

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LEAD SCREW :

A lead screw (or lead screw), also known as a power screw! or translation screw,4 is
ascrew used as a linkage in a machine, to translate turning motion into linear motion.

Because of the large area of sliding contact between their male and female members,
screw threads have larger frictional energy losses compared to other linkages. They are
not typically used to carry high power, but more for intermittent use in low power
actuator and positioning mechanics.

36
Types

Power screws are classified by the geometry of their thread. V-threads are less suitable
for leadscrews than others such as Acme because they have more friction between the
threads. Their threads are designed to induce this friction to keep the fastener from
loosening. Leadscrews, on the other hand, are designed to minimize friction. Therefore,
in most commercial and industrial use, V-threads are avoided for leadscrew use.
Nevertheless, V-threads are sometimes successfully used as leadscrews, for example on
microlathes and micromills.

Square thread
Main article: Square thread form

Square threads are named after their square geometry. They are the most efficient, having
the least friction, so they are often used for screws that carry high power. But they are
also the most difficult to machine, and are thus the most expensive.

Acme thread / Trapezoidal thread

An Acme screw

37
Acme threads have a 29° thread angle, which is easier to machine than square threads.
They are not as efficient as square threads, due to the increased friction induced by the
thread angle.Acme threads are generally also stronger than square threads due to their
trapezoidal thread profile, which provides greater load-bearing capabilities.

Buttress thread

Buttress threads are of a triangular shape. These are used where the load force on the
screw is only applied in one direction.They are as efficient as square threads in these
applications, but are easier to manufacture.

Advantages & disadvantages:

Leadscrews are used to raise and lower the front door of the Boeing 747-8F Freighter
aircraft.

The advantages of a leadscrew are:

 Large load carrying capability

 Compact
 Simple to design
 Easy to manufacture; no specialized machinery is required
 Large mechanical advantage
 Precise and accurate linear motion
 Smooth, quiet, and low maintenance
 Minimal number of parts
 Most are self-locking (cannot be back-driven)

The disadvantages are that most are not very efficient. Due to the low efficiency they
cannot be used in continuous power transmission applications. They also have a high
degree of friction on the threads, which can wear the threads out quickly. For square
threads, the nut must be replaced; for trapezoidal threads, a split nut may be used to
compensate for the wear.

USES:

38
Leadscrews are commonly used in linear actuators, machine slides (such as in machine
tools), vises, presses, and jacks. Leadscrews are a common component in electric linear
actuators. Leadscrews are manufactured in the same way as other thread forms (they may
be rolled, cut, or ground).

1.11 AVR CONTROLLER

AVRwas one of the first microcontroller families to use on-chip flash memory for
program storage, as opposed to one-time programmable ROM, EPROM, or EEPROM
used by other microcontrollers at the time.AVR microcontrollers find many applications
as embedded systems. They are especially common in hobbyist and educational
embedded applications, popularized by their inclusion in many of the Arduino line of
open hardware development boards.

39
Development

One book credits TI engineers Gary Boone and Michael Cochran with the successful
creation of the first microcontroller in 1971. The result of their work was the TMS 1000,
which became commercially available in 1974. It combined read-only memory,
read/write memory, processor and clock on one chip and was targeted at embedded
systems.

During the early-to-mid-1970s, Japanese electronics manufacturers began producing

microcontrollers for automobiles, including 4-bit MCUs for in-car entertainment,
automatic wipers, electronic locks, and dashboard, and 8-bit MCUs for engine control.

Partly in response to the existence of the single-chip TMS 1000,Intel developed a

computer system on a chip optimized for control applications, the Intel 8048, with
commercial parts first shipping in 1977. It combined RAM and ROM on the same chip
with a microprocessor. Among numerous applications, this chip would eventually find its
way into over one billion PC keyboards. At that time Intel's President, Luke J. Valenter,
stated that the microcontroller was one of the most successful products in the company's
history, and he expanded the microcontroller division's budget by over 25%.

Most microcontrollers at this time had concurrent variants. One had EPROM program
memory, with a transparent quartz window in the lid of the package to allow it to be
erased by exposure to ultraviolet light. These erasable chips were often used for
prototyping. The other variant was either a mask programmed ROM or a PROM variant
which was only programmable once. For the latter, sometimes the designation OTP was
used, standing for "one-time programmable". In an OTP microcontroller, the PROM was
usually of identical type as the EPROM, but the chip package had no quartz window;

40
because there was no way to expose the EPROM to ultraviolet light, it could not be
erased. Because the erasable versions required ceramic packages with quartz windows,
they were significantly more expensive than the OTP versions, which could be made in
lower-cost opaque plastic packages. For the erasable variants, quartz was required,
instead of less expensive glass, for its transparency to ultraviolet light—to which glass is
largely opaque—but the main cost differentiator was the ceramic package itself.

In 1993, the introduction of EEPROM memory allowed microcontrollers (beginning with

the Microchip PIC16C84) to be electrically erased quickly without an expensive package
as required for EPROM, allowing both rapid prototyping, and in-system programming.
(EEPROM technology had been available prior to this time, but the earlier EEPROM was
more expensive and less durable, making it unsuitable for low-cost mass-produced
microcontrollers.) The same year, Atmel introduced the first microcontroller using Flash
memory, a special type of EEPROM.Other companies rapidly followed suit, with both
memory types.

Nowadays microcontrollers are cheap and readily available for hobbyists, with large
online communities around certain processors

Embedded design

A microcontroller can be considered a self-contained system with a processor, memory

and peripherals and can be used as an embedded system.The majority of microcontrollers
in use today are embedded in other machinery, such as automobiles, telephones,
appliances, and peripherals for computer systems.

While some embedded systems are very sophisticated, many have minimal requirements
for memory and program length, with no operating system, and low software complexity.
Typical input and output devices include switches, relays, solenoids, LED's, small or
custom liquid-crystal displays, radio frequency devices, and sensors for data such as
temperature, humidity, light level etc. Embedded systems usually have no keyboard,
screen, disks, printers, or other recognizable I/O devices of a personal computer, and may
lack human interaction devices of any kind.

microcontroller features

Microcontrollers usually contain from several to dozens of general purpose input/output

pins (GPIO). GPIO pins are software configurable to either an input or an output state.
When GPIO pins are configured to an input state, they are often used to read sensors or
external signals. Configured to the output state, GPIO pins can drive external devices
such as LEDs or motors, often indirectly, through external power electronics.

Many embedded systems need to read sensors that produce analog signals. This is the
purpose of the analog-to-digital converter (ADC). Since processors are built to interpret

41
and process digital data, i.e. 1s and 0s, they are not able to do anything with the analog
signals that may be sent to it by a device. So the analog to digital converter is used to
convert the incoming data into a form that the processor can recognize. A less common
feature on some microcontrollers is a digital-to-analog converter (DAC) that allows the
processor to output analog signals or voltage levels.

In addition to the converters, many embedded microprocessors include a variety of timers

as well. One of the most common types of timers is the programmable interval timer
(PIT). A PIT may either count down from some value to zero, or up to the capacity of the
count register, overflowing to zero. Once it reaches zero, it sends an interrupt to the
processor indicating that it has finished counting. This is useful for devices such as
thermostats, which periodically test the temperature around them to see if they need to
turn the air conditioner on, the heater on, etc.

A dedicated pulse-width modulation (PWM) block makes it possible for the CPU to
control power converters, resistive loads, motors, etc., without using many CPU
resources in tight timer loops.

A universal asynchronous receiver/transmitter (UART) block makes it possible to receive

and transmit data over a serial line with very little load on the CPU. Dedicated on-chip
hardware also often includes capabilities to communicate with other devices (chips) in
digital formats such as Inter-Integrated Circuit (I²C), Serial Peripheral Interface (SPI),
Universal Serial Bus (USB), and Ethernet.

Types

As of 2008, there are several dozen microcontroller architectures and vendors including:

 ARM core processors (many vendors)

o ARM Cortex-M cores are specifically targeted toward microcontroller
applications
 Microchip Technology Atmel AVR (8-bit), AVR32 (32-bit), and AT91SAM (32-
bit)
 Cypress Semiconductor's M8C core used in their PSoC (Programmable System-
on-Chip)
 Freescale ColdFire (32-bit) and S08 (8-bit)
 Freescale 68HC11 (8-bit), and others based on the Motorola 6800 family
 Intel 8051, also manufactured by NXP Semiconductors, Infineon and many others
 Infineon: 8-bit XC800, 16-bit XE166, 32-bit XMC4000 (ARM based Cortex
M4F), 32-bit TriCore and, 32-bit Aurix Tricore Bit microcontrollers[34]
 Maxim Integrated MAX32600, MAX32620, MAX32625, MAX32630,
MAX32650, MAX32640
 MIPS
 Microchip Technology PIC, (8-bit PIC16, PIC18, 16-bit dsPIC33 / PIC24), (32-
bit PIC32)

42
  NXP Semiconductors LPC1000, LPC2000, LPC3000, LPC4000 (32-bit),
LPC900, LPC700 (8-bit)
 Parallax Propeller
 PowerPC ISE
 Rabbit 2000 (8-bit)
 Renesas Electronics: RL78 16-bit MCU; RX 32-bit MCU; SuperH; V850 32-bit
MCU; H8; R8C 16-bit MCU
 Silicon Laboratories Pipelined 8-bit 8051 microcontrollers and mixed-signal
ARM-based 32-bit microcontrollers
 STMicroelectronics STM8 (8-bit), ST10 (16-bit), STM32 (32-bit), SPC5
(automotive 32-bit)
 Texas Instruments TI MSP430 (16-bit), MSP432 (32-bit), C2000 (32-bit)
 Toshiba TLCS-870 (8-bit/16-bit)

Microcontroller Applications:

Microcontrollers  are  intended  for  embedded  devices,  in  comparison  to  the  micro-
processors  which are  used  in  PCs  or  other  all-
purpose  devices.  Microcontrollers  are  employed  in automatically managed 
inventions  and  appliances  like- power  tools,  implantable  medical  devices, 
automobile engine  control  systems, office  machines,  remote  controls  appliances, 
toys  and  many  more
embedded systems. By dipping the size and expenditure in comparison to a design that
make use of a  different  micro-processor,  I/O  devices  and  memory,  micro-controllers 
formulate  it  inexpensive  to digitally control more & more appliances and operations.
Mixed signal micro-
controllers are general; putting together analog constituents required controlling non-
digital electronic structures.

Application of Microcontroller in Day to Day Life Devices:

 Light sensing & controlling devices

 Temperature sensing and controlling devices
 Fire detection & safety devices
 Industrial instrumentation devices
 Process control devices

43
Application of microcontroller in Industrial Control Devices:

 Industrial instrumentation devices

 Process control devices

Application  of  microcontroller  in  Metering  &  Measurement Devices:

 Volt Meter
 Measuring revolving objects
 Current meter
 Hand-held metering systems

Arduino is a prototype platform (open-source) based on an easy-to-use hardware and

software. It consists of a circuit board, which can be programed (referred to as a
microcontroller) and a ready-made software called Arduino IDE (Integrated
Development Environment), which is used to write and upload the computer code to the
physical board.

The key features are −

 Arduino boards are able to read analog or digital input signals from different
sensors and turn it into an output such as activating a motor, turning LED on/off,
connect to the cloud and many other actions.

 You can control your board functions by sending a set of instructions to the
microcontroller on the board via Arduino IDE (referred to as uploading software).

 Unlike most previous programmable circuit boards, Arduino does not need an
extra piece of hardware (called a programmer) in order to load a new code onto
the board. You can simply use a USB cable.

 Additionally, the Arduino IDE uses a simplified version of C++, making it easier
to learn to program.

 Finally, Arduino provides a standard form factor that breaks the functions of the
micro-controller into a more accessible package.

Arduino – Board
introduction

Arduino is a prototype platform (open-source) based on an easy-to-use hardware and

software. It consists of a circuit board, which can be programed (referred to as a
microcontroller) and a ready-made software called Arduino IDE (Integrated

44
Development Environment), which is used to write and upload the computer code to the
physical board.

The key features are −

 Arduino boards are able to read analog or digital input signals from different
sensors and turn it into an output such as activating a motor, turning LED on/off,
connect to the cloud and many other actions.

 You can control your board functions by sending a set of instructions to the
microcontroller on the board via Arduino IDE (referred to as uploading software).

 Unlike most previous programmable circuit boards, Arduino does not need an
extra piece of hardware (called a programmer) in order to load a new code onto
the board. You can simply use a USB cable.

 Additionally, the Arduino IDE uses a simplified version of C++, making it easier
to learn to program.

 Finally, Arduino provides a standard form factor that breaks the functions of the
micro-controller into a more accessible package.

Board Types

45
Various kinds of Arduino boards are available depending on different microcontrollers
used. However, all Arduino boards have one thing in common: they are programed
through the Arduino IDE.

The differences are based on the number of inputs and outputs (the number of sensors,
LEDs, and buttons you can use on a single board), speed, operating voltage, form factor
etc. Some boards are designed to be embedded and have no programming interface
(hardware), which you would need to buy separately. Some can run directly from a 3.7V
battery, others need at least 5V.

Here is a list of different Arduino boards available.

Arduino boards based on ATMEGA328 microcontroller

Operating Clock Digital Analog Programming

Board Name PWM UART
Volt Speed i/o Inputs Interface
Arduino Uno USB via
5V 16MHz 14 6 6 1
R3 ATMega16U2
Arduino Uno USB via
5V 16MHz 14 6 6 1
R3 SMD ATMega16U2
Red Board 5V 16MHz 14 6 6 1 USB via FTDI
FTDI-
Arduino Pro
3.3V 8MHz 14 6 6 1 Compatible
3.3v/8 MHz
Header
FTDI-
Arduino Pro
5V 16MHz 14 6 6 1 Compatible
5V/16MHz
Header
FTDI-
Arduino mini 05 5V 16MHz 14 8 6 1 Compatible
Header
FTDI-
Arduino Pro
3.3V 8MHz 14 8 6 1 Compatible
mini 3.3v/8mhz
Header
FTDI-
Arduino Pro
5V 16MHz 14 8 6 1 Compatible
mini 5v/16mhz
Header
FTDI-
Arduino
5V 16MHz 14 6 6 1 Compatible
Ethernet
Header
Arduino Fio 3.3V 8MHz 14 8 6 1 FTDI-
Compatible

46
 Header
LilyPad FTDI-
Arduino 328 3.3V 8MHz 14 6 6 1 Compatible
main board Header
LilyPad FTDI-
Arduino simple 3.3V 8MHz 9 4 5 0 Compatible
board Header

A DC motor (Direct Current motor) is the most common type of motor. DC motors
normally have just two leads, one positive and one negative. If you connect these two
leads directly to a battery, the motor will rotate. If you switch the leads, the motor will
rotate in the opposite direction.

Warning − Do not drive the motor directly from Arduino board pins. This may damage
the board. Use a driver Circuit or an IC.

We will divide this chapter into three parts −

 Just make your motor spin

 Control motor speed
 Control the direction of the spin of DC motor

Components Required

You will need the following components −

 1x Arduino UNO board

 1x PN2222 Transistor

47
  1x Small 6V DC Motor
 1x 1N4001 diode
 1x 270 Ω Resistor

Procedure

Follow the circuit diagram and make the connections as shown in the image given below.

48
Precautions

Take the following precautions while making the connections.

 First, make sure that the transistor is connected in the right way. The flat side of
the transistor should face the Arduino board as shown in the arrangement.

 Second, the striped end of the diode should be towards the +5V power line
according to the arrangement shown in the image.

LITREATURE SURVEY
MR. NIRANJAN KUMAR SINGH ETAL, 2012 Optimization method
used for the austenitic stainless steel AISI 301L in RSW () [1]. A two-dimensional model
is utilized to predict temperature and stress fields during and after resistance spot welding
process, Increasing the applied welding voltage leadsto an increase in the weld nugget
size. Welding time has the same role, however, increasing the welding time causes to
enhance heat transfer to surroundings and therefore less heat is consumed in formation of
weld nugget

Mr.Ranjbar Nodeh etal, 2008 To study of mechanical strength for three

testgeometry lap-shear, cross-tension and coach-peel, For lapshear strength, a strong
relationship with weld nugget diameter was observed; whilst discrete strength levels were
found for coach-peel test geometry. For cross-tension strength; there is arelationship with
nugget diameter; but data are sensitive to nugget periphery defects.

Mr.Han, M. Thornton, D. Boomer, M. Shergold, 2011 Tests of thin-walled

beams joined by spot weldingMr.Yanjun Xiao etal, 2011To establish thermoelectric
coupling finite element model, this model can predict the temperature distribution and
spot welding joints melt nuclear forming process. By providing the necessary conditions
to conclude that: The workpiece and the contact position of workpiece formed melted,
first, with initial molten nuclear heating process, melting with nuclear size increases;
Along with the increase of contact resistance welding are also on the increase nuclear
size; The decrease of the electrode pressure can reduce molten nuclearsize,which because
of increased contact surface area, smaller contactresistance,heat generation also
subsequently reduced; If the increase of the diameter workpiece, form qualified nuclear
needed current fusion and electrode pressure should also increase

49
 Mr. Erta and FazılO.Sonmez, 2011 Experimental and modeling
investigation of the failure resistance of Advanced High Strength Steels spot welds.

Mr. S. Dancette etal, 2011 Contact conditions on nugget development

during resistance spot welding of Zn coated steel sheets using rounded tip electrodes
andcompared to the flatted tip electrode, analysis has to be carryout.

Mr.R. Raoelison, A. Fuentes, 2012 Weld growth mechanism of resistance spot

welds in zinc coated steel and compared to the uncoated steel andmicrographs showing
the location of initial heat development in both steel plate.

Mr. Harlin, T.B. Jones , J.D. Parker, 2003 NDT test has been carryout through
C-scan in resistance spot welding.

Mr.M. Thornton et al, 2012I nsmall-scale resistance welding to analyze the

effect of electrode force and compared to the large scale resistance welding.

Mr.B.H. Chang, Y. Zhou, 2003 and also to monitoring the weld quality of small-
scale resistance welding for titanium alloy

Mr.Dawei Zhao and Yuanxun Wang, 2013 To discuss the dynamic joint
strength evaluation procedures and the measured dynamic strength data for 13 joint
populations of self-piercing rivets (SPR) and resistance spot welds (RSWs) joining
similar and dissimilar metals.

Mr.Xin Sun, Mohammad A. Khaleel, 2007 A study investigating the effect of

sheet surface condition on resistance spot welding (RSW) of aluminium has been carried
out

Mr.A. K. PANDEY et al, 2013 usingthe Taguchi method to optimize the

resistance spot welding and The concentration of current density at the edge of contact
area which forms sharp corners was reproduced by the proposed FEM simulation method

Mr.Ninshu Ma and Hidekazu Murakawa, 2010 use of the nearest neighbours

method to identify similar weldingprocesses with the similarity measure, it could be
decided whether a similar enough process is already stored in the database or whether a
more extensive data set is needed in RSW application..

Mr.R. Lee and Y.J. Choo, 2001 studied the quality assurance technique using a
Neuro-Fuzzy Algorithm for RSW..

Mr.AMBROZIAK et al, 2010 use the spot welding for joining aluminium
elements in automotive industry.

50
 Mr.Zhenzhen Lei et al, 2011use the Three Sheets assemblies for Transient
Thermal Characteristics through FEA in resistance spot welding.

Mr.H. Song and H.Huh, 2011proposes an accurate failure criterion toinvestigate

of spot welds under combined axial and shear loading condition.

Mr.X. Tran and J. Pan, 2009 investigated Fatigue behavior of dissimilar friction
stir spot welds or spot friction welds In lap-shear and cross-tension specimens

Mr.Lin and D.-A. Wang, 2010 investigated stress intensity factor by the finite
element analysis for U shape element.

Ding Min et al, 2013researched on the effects of parameters on microstructures

and mechanical properties of spot welding ferrite steel .

J. Pan et al, 2003investigated the circumferential failure mode of spot weldsunder

combined loading conditions

G.R. Payen et al,2012 developed a novel test for the in situ failure analysis of
spot-welded joints , Facing the need of a better understanding of spot-weld strength and
failure mechanisms of advanced high strength steels.

EXPERIMENTAL DETAILS

3.1 EXPERIMENTAL SETUP

Manual operating spot welding is used mostly. To get desired mechanical strength it is
necessary to get repeatability in weld size i.e constant pressure, constant weld time,
constant strength ,nugget diameter hardness etc which is almost impossible in this case .
in manual spot welding to have constant time makes it difficult to avoid expulsion and
interfacial failure. another alternative is automatic spot welding machine involving
disadvantages likewelding operation has less time, less skilled workers need, minimum
error spotted , less man power. So use of motor which offer features like accuracy,
repeatability, in position for end of the strokes, high efficiency, time adjustment and
energy consumption only during operation, can serve the purpose. Use of mild steel in
applications like barrels, drums etc involves multiple welds, so it is important to know
minimum distance between two spot welds to get desired shear strength. Test method like
shear testing on universal testing machine enable us to know the spacing between welds
so as to avoid failures. Also it is important to know weld strength when combination
involving different thickness of sheet is used

51
Factors for Project Selection:

3.2.1 Limitations of various Existing spot Welding Machine:

Force applied is not constant which doesn't give a proper weld

.Inability of the welder to know the proper force required for spot weld

.There isa lot of exhaustion for the welder as work has to be done against stifferspring.
Due to spring failure if any take place, the whole machine will not work

.In case of pneumatic welding machine, it is difficult to maintain the repeatability, tip
contact the part at high speed generating high impact on part. A spare part inventory has
to be maintained due to different mounting requirements

.Due to the following limitations of the existing spot welding machine, we have
designed a motor operated RSW machine keeping in view the above mentioned
problems. We have overcome these problems. The advantage of our designed machine is
as under:

Due to the incorporation of de motor the exhaustion factor of welder is completely

eliminated which is the main advantage.

 Proper force is maintained required for desired spot weld

. Constant weld force application and constant time consumption

 Due to spring elimination, the motor has the ability to bring back the electrodes at
desired position, thus eliminating the spring failure.

 Minimum environmental impact such as noise, contamination, energy/power efficiency.

Reduced or no spare parts inventory required

Motor requires energy supply when only in action

52
Taking in consideration the load carryingcapacity with F.O.S of mild steelin various
members, minimum material is used. Thus, weight is reduced.

The cost factor is taken into study by using mild steel which is cheap and has good
mechanical properties compared to aluminum and stainless steel.

Expected Outcome of Project:

Anew idea has been generated which will result in less time consumption, less
laboreffort and cheaper way of spot welding equipment or machine is designed.

 Proper investigations of welds is done on mild steel on varying thicknesses which

increases the utilization of spot welding in various applications.

Welding distance plays an important role which can be proved by shear testing.

Taking in consider at ion the ability of designed machine having controlled parameters
like weld force, weld current, accuracyand repeatability. the strength is better than
existing machines.

3.3 INSTALLATION OF SPOT WELDING MACHINE

The original installation of a piece of a equipment has a large bearing on its subsequent
operation and trouble free performance. This then deserves first preference in the overall
subject of service. 'This is especially true for resistance welding machine because of the
numerous utility services required electric power, often two one for motor power and the
other for the welding power. In addition the welding machine may also require cooling
water, air, hydraulic and sometimes even gas services.

3.4 PREPARATION FOR INSTALLATIONU

pon receipt the equipment should be checked thoroughly, with all packing lists,
instructions, special tools, etc., properly accounted for. Also at the time of receipt, the
machine, motor and control name should be checked for proper service requirements.

SETTING THE MACHINE

Any machine that has mechanical motions, whether air hydraulic or electrical actuation
should be anchored to a rigid stationary surface to prevent creeping or walking. The
extent of this attachment to the for or other surface will depend upon the size weight or

53
operation of the equipment also on the type of building or floor. Pits are especially
desirable for large spotwelding machines to act as a receptacle for the flash metal from
the weld. In any case the machine should be leveed at its weight equally distributed on all
legs or hold down member. Careless setting of the machine may cause undue strain on its
members or bonding of ways slides etc

3.6 SAFETY REQUIREMENTSS

afety for the operating personnel and the elimination of fire hazards are of paramount
importance. Welding equipment manufacturers provide their machine with majority
safety features. Adequate guarding of gearing and other moving parts safe and approved
electrical wiring as well as various types and kinds of safety controls such as simple pam
buttons to prevent operating the machine without both hand on the buttons interlocks etc.
Never attempt to override or evade these safety measures. In addition users may install
additional safety precautions: area exhaust systems, flash shield, etc. Rigorous
maintenance of good housekeeping procedures should be exercised at all the times.

3.7 ELECTRICAL INSTALLATIONW

ith the machine set properly in position, electrical service is run through the weld controls
to the welding transformers and to the motors when required. The electrical service to the
motors will be the same as any normal electrical motor service which is adequately
covered by city or national electric codes.The voltage rating of the cables used for
welding trans former supply is important.Welding cable which is not marked or stamped
600v is not acceptable for resistance welding primary lines. The cableis amust a rating of
600v ac or above

When machine are installed in a temporary manner a proper electrical earth found must
be provided to prevent electrically hazardous condition.

SPOT WELDING PARAMETERS

Spot welding parameters include:

Electrode force

Diameter of the electrode contact surface

Squeeze time

Weld time

.Hold time

54
weld current

Off time

The determination of appropriate welding parameters fors pot welding is a very complex
due. A small change of one parameter will affect all the other parameters. This, and the
fact that the contact Surface of the electrode is gradually increasing, makes it difficult to
design a welding parameter table, which shows the optimum welding parameters for
different circumstances.

Dc Gear Motor Specifications

Part no = PG28M395

Motor type =Dc

Gear ratio= 4:6:1

Power Rating= 12.75

Voltage= 12VDC

RPM=1081rpm

Current (mA) = 1.065A

Rated torque= 5.5N-m

Rated base motor rpm =6000

Operating temperature =40 to 100

Gear material= powder metallurgy, steel, POM

Housing material =Metal

55
SERVO MOTOR

Product category =Dc

servo motor Output Power = 0.06HP

Torque constant =4.6 amp

Voltage = 12 V

Frequency = 60 Hz

Current = 7.1ATorque = 1.9 In lbs

Rated Speed =4000rpm

56
STEP DOWN TRANSFORMERPower Rating = 10K V A

Cool Style = Air Cooled

Phase = Single

Electrode Material = Copper Electrode

Face Diameter = 4mmMaximum

Sheet Thickness = 1mm+1mm

Material Selection = Mild Steel Galvanized Iron

57
Bulk Modulus:A measure of a materials resistance to reduction in volume due to
compression from all sides.Mild Steel and Stain less steel has good compression
resistance which acts on column beam after completion of weld cycle.

3.12.2 Elastic Modulus

A measure of a materials stiffness, expressed as the stress required to produce a unit of

elastic strain in the same direction. So it is resistance to tension. Aluminumhas poor
elasticity.

58
3.12.3 Density:

More the density, more will be increase in weight.Clearly, stainless steel will have more
weight compared to mild steel. So, dc motor selection have to be done on the bas is on
weight to be lifted.

3.12.4 Hardness:

A test-specific measure of a material's resistance to mechanical

penetrationCondensationof its surface. All hardness values are reported as belonging to
some hardness scale. Some of the most popular scales are Brinell, Knoop,
Rockwell,Shore, and Vickers.Cast iron is very hard so chances of cracks are always
which can propagate further with time. Aluminumis highly ductilein nature. Mild steel is
within range.

3.12.5 Elongation at break:

Elongation between zero stress and final rupture, as a percent of original specimen
length. For example, a I meter specimen that stretches to 1.I meters before breaking in
two has 10% elongation at break.A material must have lower elongation as higher the
elongation more will be skidding problem during weld. Mild Steel provides good value.

6 Fracture toughness:

A measure of a materials resistance to the propagation of an existing crack. Useful for

evaluating the material's ability to resist the effects of fabrication defects and operational
damage on mechanical service.Stainless steel on bending loses its properties to great
extent so lower will be its fracture toughness. Alternative is Mild Steel.

3.12.7 Fatigue Strength:

The maximum amount of tensile stress that can be applied to a material over somewhere
near 10'cycles without causing failure. The fatigue strength for a Test with just one cycle
is equal to the ultimate tensile strength (UTS). As the number of cycles increases, the
value decreases. Some metals (most steels, some brasses, and a few others) will
eventually floor out, so that, past a certain number of cycles, the maximum allowed stress

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per cycle will no longer decrease. This is called the endurance limit.Fatigue Strength of
mild steel and stainless steel is good.

3.13 ELECTRODE CHARACTERISTICSS

3.13.1 COPPER CHROMIUM

Many applications demands Copper to have higher mechanical properties and to be

capable of use at elevated operating temperatures while still retaining the good
conductivity for which it is selected in the first place.The high-copper alloy family
includes Beryllium Coppers, 2% Beryllium CopperChromium Coppers, Zirconium
Copper, Copper chromium and NickelSilicon Chromium Copper. The Copper chromium
is essential Copper alloys which has a small addition of Zirconium. The addition of
inhibits chemical reaction of Copper at elevated temperatures. It also helps to retain the
physical properties at elevated temperatures. Also it marginally increases annealing
temperature. Coppers chromium are used widely

in areas where high electrical and thermal conductivity are required combined with good
mechanical properties. Uses include Resistance Welding Machine Electrodes, Seam
Welding Wheels, SpotWelding Tips, Flash Butt Welding Electrodes, Anvil Contact Bars,
ElectricalSwitch Gear Contacts & Terminals, Electrode Holds, Cable Connectors,
CurrentCarrying Arms and Shafts, Circuit Breaker Parts, Heat Sinks, Short Circuit
Rings,MIG welding contact tubes and many other applications.where Copper would
normally be the ideal choice for High Conductivity but is just not Strong enough. Copper

chromiumis used extensively for cap style resistance welding electrodes. Evidence
suggests that it can provide less sticking and resist defamation longer than its chromium
copper counterpart in some specific situations.

CONCLUSION:
By this, we conclude that the we fabricated a
portable spot welding machine at a very low cost. By this machine, we can fulfill all our
domestic spot welding purpose and also we can fulfill some workshop purposes also. We
manufactured this machine with the very low cost so even a small workshop also can
accommodate. Due to financial constraints,

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 we have used a half kV transformer if we use the
more capacity transformer we get the more efficient welding if we increase the power the
time of weld will be decreased . For our machine, there is no need of separate cooling the
air cooling is enough . if we want to increase the capacity of our machine then better
provide a sufficient cooling by using an exhaust fan.

DESIGN OF WELDING MACHINE

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62
63
Fig 3.5 Left Side view

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FUTURE SCOPE

In phase 2 automatic spot welding machineis made by assembling the motors, gears,
moving rods, parts together into a single machine. Assembly is done with the help of
design which is made in the solid work software. After assemble the all parts the welding
machine was working properly.

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