Results in Physics 54 (2023) 107056

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Results in Physics
journal homepage: www.elsevier.com/locate/rinp

Design and simulation analysis of physical heat dissipation structure for

welding robot controller
Yongqiang Chen a, *, Zhaoguo Ye b, Zhuanzhe Zhao c
a
College of Intelligent Manufacturing, Wuhu Institute of Technology, Wuhu, Anhui 241006, China
b
Anhui Ruixiang Industry, Wuhu, Anhui 241000, China
c
College of Artificial Intelligence, Anhui Polytechnic University, Wuhu, Anhui 241000, China

A R T I C L E I N F O A B S T R A C T

Keywords: In order to understand the physical heat dissipation structure of welding robot controllers, the author proposes a
Welding robot research based on the design and simulation analysis of the physical heat dissipation structure of welding robot
Heat dissipation test controllers. The author first analyzed that the design of welding heating system is the key to the research of
Structural design
welding robot heating technology, which is divided into the design of induction heating system temperature
control circuit and temperature control program. The induction heating system is closely related to power
electronics technology, with inverter design and soft switching technology being the focus and difficulty of this
chapter. Secondly, using modular design methods, an induction heating system with a frequency of 450KHz and
a power of 100 W is designed. This part is connected through an optocoupler and an induction heating system for
power regulation and temperature control. Starting from designing the minimum system of a microcontroller,
through keyboard input, temperature signal processing, analog-to-digital conversion, and finally to digital tube
display output, the design of each module of the temperature control circuit was completed. Finally, in order to
verify the effectiveness of the design, actual heat dissipation testing is required. By establishing an appropriate
testing environment in the laboratory, the temperature changes and heat dissipation efficiency of the controller
under different working conditions can be measured. Based on the actual test results, further adjustments and
improvements can be made to the design to meet the heat dissipation needs of the welding robot.

Introduction
There are many types of welding robots, but they are generally
specialized robots developed by combining part processes. For example,
in the construction of long oil and gas pipelines, a pipeline all position
welding robot is designed and developed. For the welding process of
large workpieces (such as gas storage tanks), complex long weld welding
robots are designed and developed; A box steel structure circumferential
welding robot has been designed and developed to address the need for
circumferential welding of box steel structures; We have designed and
developed a clamp type plug-in pipe welding robot for the intersecting
line welding generated by the orthogonal and oblique connection be­
tween pipes [1]. The heat transfer efficiency of the heat pipe in the heat
pipe radiator is high, and its thermal conductivity is 2100 times that of
the same silver thermal conductivity and 6200 times that of the purple
pipe; The steam in the inner chamber of the heat pipe is in a saturated
state, and the pressure drop and temperature drop generated by the
saturated steam flowing from the evaporation section to the condensa­
tion section are very small. Therefore, the heat pipe has excellent
isothermal properties, which can reduce the maintenance cost of the
equipment; The design structure of the heat pipe radiator is compact,
with low flow resistance, flexible heat transfer methods, and small
volume and light weight; Because there is no liquid absorbing core in the
heat pipe, compared with ordinary heat pipes, it not only has simple
structural design, convenient manufacturing, low manufacturing cost,
but also good thermal conductivity and safe and reliable operation.
However, the welding process in the processing of heat pipe radiators is
still in the manual welding stage. Based on this situation, the author
proposes to use induction welding heat pipe radiators [2]. In order to
cooperate with induction welding equipment, it is necessary to develop
corresponding motion control devices to complete the welding task of
heat pipe radiators. Advantages of using welding robots in the welding
industry:

* Corresponding author.
E-mail addresses: YongqiangChen5@126.com (Y. Chen), ZhaoguoYe8@163.com (Z. Ye), ZhuanzheZhao9@126.com (Z. Zhao).

https://doi.org/10.1016/j.rinp.2023.107056
Received 6 September 2023; Received in revised form 23 September 2023; Accepted 3 October 2023
Available online 5 October 2023
2211-3797/© 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-
nc-nd/4.0/).
Y. Chen et al.
(1) The welding quality is very stable. It will not be affected by
human factors, and welding can be achieved by setting welding
process parameters. The welding process parameters include
welding current, arc voltage, welding speed, welding wire
extension length, gas flow rate, pipe diameter size, and pipe
mouth position. During the welding process, the welding process
parameters are stable, and the welding quality of each weld seam
is consistent. In order to prevent the local temperature of the
workpiece from being too high, interval welding can be set
without affecting the welding speed and quality, effectively
reducing the local temperature and ensuring the impact perfor­
mance of the weld.
(2) Significantly reduce personnel labor intensity. The welded parts
are lifted to the designated position, placed flat, and the robot
parameters are set to basically complete the work. The welding
spatter is small, and the weld seam shape is beautiful, reducing
the workload of polishing work [3].
(3) Safety and environmental protection. Operators do not need to
observe the welding process up close, thus keeping away from the
radiation of the welding arc; The robot is equipped with smoke
and dust removal equipment, and the harmful gases generated by
welding are collected, filtered, and discharged. This not only
provides protection for operators, but also ensures that the air in
the entire manufacturing workshop is not polluted.
(4) Improve production efficiency. Robots are all continuous opera­
tions, and each pipe corner weld welding robot can automatically
identify and track the weld seam, accurately locate the starting
and ending points of the weld seam, as well as the reference point
of the arc length [4]. The arc sensor is used to control the voltage
for adaptive control, in order to achieve adaptive control of the
welding gun tracking the position of the weld seam.
(5) This greatly shortens the cycle of product transformation and
replacement, and correspondingly reduces equipment invest­
ment. Welding robots can achieve automation of small batch
products and adapt to different working conditions by modifying
programs, which has obvious advantages over traditional
welding.
Literature review
Industrial robots are widely used in production, processing, and as­
sembly in the industrial field. Different types of industrial robots have
different functions, among which robots that can achieve welding
functions are called welding robots. Through research on the develop­
ment of welding robot technology both domestically and internation­
ally, the vast majority of welding robots are articulated robots. And
welding robots generally have six degrees of freedom. The first three
degrees of freedom can achieve positioning of different spatial positions,
and the last three degrees of freedom can achieve positioning of different
spatial postures of the end effector. Compared to domestic welding
technology, foreign welding technology is more advanced, with better
welding quality and high work stability, and has occupied a majority of
the market share. The research on welding robots in China is relatively
late, and both welding quality and stability are not ideal. At present, the
vast majority of high-end welding robots in China rely on imports. As a
major industrial country, the development of welding robot technology
in China directly affects the overall level of the country’s industrial
manufacturing industry [5]. Therefore, based on the study of the supe­
rior performance of foreign six degree of freedom welding robots, in
order to meet the actual welding production needs in China, and to
consider the high risk of manual welding operations, low welding effi­
ciency, and high labor costs, research and design welding robots with
good economic and reliable production and processing capabilities, in
order to strengthen the production and welding competitiveness of en­
terprises and achieve the goal of fully automatic welding technology for
enterprises, meeting the actual needs of domestic welding enterprises is
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Results in Physics 54 (2023) 107056
of crucial significance.
With the continuous development of welding technology, the weld­
ing robot controller, as an important component of the welding process,
its performance and stability play a crucial role in welding quality and
efficiency. However, during long-term operation, the welding robot
controller generates a large amount of heat. If it cannot dissipate heat in
a timely manner, it not only affects the efficiency and lifespan of the
controller, but also may lead to a decrease in welding quality. Godart, P.
et al. designed an effective heat dissipation structure as the key to
improving the performance of welding robot controllers. Firstly, the
design of the heat dissipation structure needs to consider the selection of
materials [6]. Materials with good thermal conductivity should be
selected to quickly transfer heat to the heat dissipation structure.
Common heat dissipation materials include metal materials such as
copper and aluminum, whose good thermal conductivity can improve
heat dissipation efficiency. Secondly, the shape and layout of the heat
dissipation structure also need to be reasonably designed. Structures
such as heat dissipation fins and fins can be used to increase surface area
to improve heat dissipation efficiency. In addition, the layout of the heat
dissipation structure should be closely integrated with the welding robot
controller to ensure close contact between the heat dissipation structure
and the controller, in order to effectively conduct heat. In order to
optimize the design of the heat dissipation structure, thermal conduction
analysis and thermal radiation convection heat dissipation analysis can
be carried out. Through thermal simulation software, the heat dissipa­
tion effects of different heat dissipation structures can be simulated to
evaluate their heat dissipation performance. Analyze the temperature
distribution and heat flux distribution under different structures, iden­
tify the structure with better heat dissipation performance, and optimize
the design [7–9]. Through simulation analysis, the heat dissipation ef­
fect of different heat dissipation structures can be evaluated. You can
compare the temperature changes of controllers under different struc­
tures to find the optimal heat dissipation structure design. By optimizing
the heat dissipation structure, the temperature of the welding robot
controller can be effectively reduced, and its work efficiency and life­
span can be improved.
Methods
Design of welding heating system
In ordinary welding, a temperature of about 260 ℃ can meet the
welding requirements, while in lead-free welding, the welding temper­
ature is often as high as 350 ℃, and faster heat compensation speed is
required. Compared to ordinary resistance heating, induction heating
has obvious advantages in lead-free welding. From an economic and
applicable perspective, we take the heating system power as 100 W. Due
to the frequency variation of 320KH, it will interfere with long wave
band communication, and frequencies higher than 520KHz will have an
impact on radio broadcasting communication. Considering the fluctua­
tion of frequency in actual work, the inverter frequency is chosen as
450KHz. Considering that the welding temperature requirement is
above 220 ℃, the service life of the high-frequency soldering iron
handle is greatly shortened when working at a high temperature of 500
℃ for a long time. We have set the welding temperature range to 210 ℃
~490 ℃. The design of the welding heating system consists of three
parts, namely the induction heating system, temperature control circuit,
and software program.
Induction heating system
In an induction heating system, two basic power supplies need to be
designed. Among them, the 52 IV DC power supply will be used for
inverter, and the 13 V DC power supply will be used to supply power to
related components. Due to the fact that the power grid provides 55 Hz
AC power and the required AC frequency for induction heating is
450KHz, it is necessary to first convert the AC power of the power grid
Y. Chen et al.
into DC, and then invert the DC power into 450KHz AC. As shown in
Fig. 1. In circuits with inductive and capacitive components, the voltage
and current at both ends of the inductive and capacitive components are
different phases, resulting in reactive power loss. In order to match the
impedance of the output stage, it is necessary to adjust the parameters of
each component so that the load is in the resonant circuit. In summary,
the design of an induction heating system roughly includes three parts,
namely the design of a basic power supply, a high-frequency inverter
circuit, and a soft switching resonant circuit.
Design of basic power supply
For the power supply of the inverter circuit, the 36 V AC voltage
output by the transformer is rectified by a single-phase bridge rectifier
circuit and filtered by a large capacitor. The reason why switching
power supply is not used is because it has extremely high static voltage
and may leak, which can damage the integrated circuit during circuit
board welding. Finally, a 150 W isolated transformer was selected,
which is relatively safe due to the isolation of the output end from the
power grid.
The rectified DC voltage value is equation (1)
√̅̅̅
UO = 2 × 36V = 5V (1)
According to the design requirement of output power Po = 100 W,
considering various losses and taking efficiencyη = 90 %, the output
power of the rectifier is required to be equation (2)
Pd = P0/ ≈ 133W (2)
η
Therefore, the output current of the rectifier is equation (3)
IO = Pd/ ≈ 2.6A (3)
UO
The current passing through a single diode is equation (4)
ID = IO/2 ≈ 1.3A (4)
O
The maximum reverse voltage that the rectifier diode can withstand is
equation (5)
√̅̅̅
UDRM = 2 × 36V ≈ 51V (5)
Temperature control circuit
The design of the welding heating system is divided into two parts. In
addition to the induction heating system in the previous section, the
other part is the temperature control circuit. In specific circuits, the two
parts are often designed separately on two circuit boards [10–11]. This is
mainly due to the following four reasons: Firstly, the voltage, current,
and power properties of the two parts of the circuit differ greatly. In
induction heating systems, the resonant voltage of the capacitive com­
ponents can reach several hundred volts and the power is over a hundred
watts. In contrast, the highest voltage of the temperature control circuit
is only 10 V and the power is less than 12 W. The two parts of the circuit
belong to different fields, Separation makes it easier to design; Secondly,
the circuit connection is very simple. By using an optocoupler switch,
Fig. 1. Structure diagram of induction heating system.
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Results in Physics 54 (2023) 107056
the two parts can be easily connected, thus achieving the control of the
induction heating system by the microcontroller circuit; Thirdly, the
electromagnetic noise of the induction heating system is relatively high,
which can cause electromagnetic interference to the temperature con­
trol circuit; The fourth is to make troubleshooting easier and debugging
more convenient when problems occur, while also benefiting personal
safety [12]. As shown in Fig. 2. The design of temperature control circuit
is divided into four parts, namely temperature signal processing circuit,
analog-to-digital conversion circuit, microcontroller and its auxiliary
circuit, and input and output circuit.
The primary factor in temperature control is the processing of tem­
perature signals. In modern industry, commonly used temperature
measurement components include traditional thermocouples, thermis­
tors, advanced integrated temperature sensors, digital temperature
sensors, and optical temperature sensors for measuring ultra-high tem­
peratures [13–14]. In high-frequency soldering iron handles, a common
K-type thermocouple is used, and its voltage corresponds to a temper­
ature signal of 40.8uV/℃. Process temperature signals through the
AD585 chip. AD585 is a specialized conditioning chip designed for K-
type thermocouples, which integrates signal amplification, cold junction
compensation, freezing point reference, and fault alarm circuits. Its
output voltage corresponds to a temperature signal of 10 mV/℃.
For analog-to-digital conversion, a 16 bit resolution chip AD7705 is
selected. SCLK is the serial clock input bit, which is set to high level
between adjacent data transfers to ensure reliable data input and output.
DRDY is a status bit that indicates whether the current data update is
complete and whether it can be read. DIN and DOUT are data input and
data output bits, which interact with the microcontroller in a serial
manner [15]. As shown in Fig. 3.
Software Program Design
Program structure and process
In terms of structure, the temperature control software program
mainly consists of two parts: the main program and the subroutine. The
specific content is divided into four parts: the temperature setting pro­
gram, the temperature display program, the current temperature solving
program, and the temperature control judgment program. In addition,
there are delay subroutine auxiliary programs. Among them, the tem­
perature setting program can be further divided into keyboard scanning
program and temperature setting reading program, while the current
temperature program can be further divided into sampling program,
analog-to-digital conversion program, and temperature value calcula­
tion program [16]. As shown in Fig. 4:
Selection of program algorithms
As shown in Fig. 5, there are three issues that need to be addressed in
the design of software algorithms. The first problem is that when
calculating the current temperature, due to electromagnetic interfer­
ence, A/D chip errors, and other reasons, the digital voltage signal will
experience uncertain fluctuations, which will cause deviations in the
calculated temperature value. The second problem is that we need to
choose a simple and applicable temperature control algorithm from PID
control, fuzzy control, neural network control, etc. The third issue is the
Y. Chen et al. Results in Physics 54 (2023) 107056

Fig. 2. Structure diagram of temperature control circuit.

For the pulsation problem of analog-to-digital conversion results, in

Fig. 3. Temperature Signal Processing Circuit.
selection of induction heating power regulation methods, such as phase
shift pulse width regulation, DC voltage regulation, frequency modula­
tion power regulation, and so on.
order to improve the reliability of the system and the accuracy of the
signal, it is necessary to smooth the sampled signal through software
programs [17]. Its methods include finite amplitude filtering, median
filtering, and arithmetic mean filtering. Due to the simplicity and con­
venience of the arithmetic mean filtering method, which accurately
reflects the true situation of the measured temperature and can meet the
requirements for temperature display stability, the arithmetic mean
filtering method is adopted in this program.
In terms of selecting temperature control algorithms, the classic PID
control method is selected. PID algorithm is one of the most widely used
algorithms in industry, and it is undoubtedly a universal algorithm. It is
also the simplest and most reflective control algorithm of feedback
ideas. It controls the controlled quantity through error signals, and the
controller itself is the sum of the three links of proportion, integration,
and differentiation. Assuming we specify that at time t, the input
quantity is rin (t), the output quantity is rout (t), and the deviation
quantity is err (t) = rin (t) - out (t), then the control law of PID is
equation (6)

Fig. 4. Software Program Structure Diagram.

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Y. Chen et al.
Fig. 5. Software Program Structure Diagram.
1 the experimental results were compared with simulation results to verify
u(x) = kp(err(t) ) + (6)
T the correctness of the entire design theory, laying the foundation for
Due to the fixed values of AC frequency, voltage, etc. designed during
induction heating, these characteristics cannot be changed. Therefore,
when controlling the temperature of the welding head, pulse density
power modulation PDM will be used. The PDM control method adopts
uncontrolled rectification, which has the advantages of simplified
equipment and simple control method. It can ensure that the induction
heating circuit operates under constant frequency and voltage condi­
tions, and can easily achieve soft switching technology at high fre­
quencies, and is also easy to achieve digital control. The basic idea of
PDM control is to assume that there are N power adjustment units within
a working cycle, where M power adjustment units output power to the
load by the inverter, while the remaining (N-M) units do not output
power. The load energy gradually decays in the form of natural oscil­
lation, and the power output pulse density is M/N. By changing the pulse
density, the average output power is changed, thereby achieving tem­
perature control.
Experiments
Debugging and experiments
The induction heating system and temperature control circuit in the
welding heating system belong to different fields, so they are designed
separately. Similarly, in order to reduce the difficulty of troubleshooting
problems during the experimental process, the method of first debug­
ging two circuit boards separately and then assembling them together
for comprehensive experiments is also adopted. The induction heating
system and temperature control circuit are soldered onto two different
circuit boards, which reduces the volume space required after assembly
and facilitates the subsequent production of additional shells. On the
other hand, the mass of components such as magnetic rings in induction
heating systems is relatively large, and if made into a circuit board, it
will cause significant mechanical vibration. Due to the significant elec­
tromagnetic radiation generated by the induction heating system during
operation, which affects the operation of control circuit components, it
is not easy to handle the electromagnetic shielding problem by
combining the two circuits on the same circuit board. The debugging of
the induction heating system is the focus and difficulty of the entire
experiment [18]. On the one hand, this is because there is a resonance
peak voltage of several hundred volts on the soft switching resonant
component, which makes debugging more dangerous; On the other
hand, high voltage and high current also make electronic components
easy to burn out, thereby affecting the operation of the entire circuit
board. In the temperature control circuit, the method of modular pro­
gramming and debugging is adopted to reduce the complexity of pro­
gram debugging. Finally, comprehensive debugging was conducted and
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Results in Physics 54 (2023) 107056
further improvement and optimization of the welding heating system.
Debugging of induction heating system
In order to ensure safety during the debugging process and avoid
extensive damage to components in the event of faults, a nominal 1A
fused complete machine fuse has been installed in the primary circuit of
the transformer. Before debugging the induction heating system board,
it is necessary to explain the two related parts of the iron powder core
magnetic ring and the simple temperature control board. In order to
prevent magnetic core saturation during large DC bias, both inductors
L1 and L2 need to use low permeability magnetic cores. We have chosen
American style iron powder core magnetic ring T130-2. Powder core
magnetic cores compress independent ferromagnetic particles into
various shapes and volumes under high pressure, mixing magnetic and
non magnetic materials. The effective air gap is evenly distributed
within the material body, resulting in higher saturation magnetic flux
density, lower magnetic permeability, and greater energy storage ca­
pacity. Therefore, for iron powder core materials, smaller magnetic
cores can be used to effectively reduce core loss. Due to the high satu­
ration magnetic flux density of the material, the required number of
winding turns for the same inductance is reduced, which minimizes the
eddy current loss and allows it to operate at a high frequency of 450KHz.
And it will not lead to the loss of inductance due to magnetic saturation,
causing severe heating of the magnetic core and even burning of the
power tube. At the same time, the electromagnetic radiation of the cir­
cular structure is relatively low, and the iron powder magnetic core also
has excellent noise suppression and absorption ability. The inductance
value of Ll is 26uI, and a 2 mm diameter enameled wire is uniformly
wound for 45 turns. The inductance value of L2 is 22uH, and 42 turns of
enameled wire with a diameter of 1 mm are uniformly wound.
The circuit can be divided into three parts. The first part is a signal
processing circuit for ordinary thermocouples, which is equivalent to a
K-type thermocouple thermometer, performing cold junction compen­
sation, zero adjustment, voltage amplification, and linearization work
[19]. The emission junction of the IN3904 transistor is a cold junction
compensation circuit, and the negative input end of the sensor is con­
nected to a bridge correction network, adjust the impact of operational
amplifier offset voltage and resistance matching through a 500Q vari­
able resistor, i.e. perform 0 ℃ adjustment. Using LM324 operational
amplifier to make a 255-fold signal amplification circuit, the corre­
sponding relationship between the measured temperature and the
output voltage is 12 mV/℃. The second part is the temperature setting
resistor network, it sets the welding temperature by providing a speci­
fied voltage, compares the set voltage with the actual temperature
voltage processed in the comparator, and outputs an optocoupler control
signal to control high-frequency heating. The third part is a digital
Y. Chen et al. Results in Physics 54 (2023) 107056

temperature display, essentially a digital voltmeter that displays the

actual temperature and voltage signal after processing, with a voltage of
1 V corresponding to a temperature of 100 ℃. The temperature regu­
lating resistor network uses a 4.7 K wire wound potentiometer, which
ensures that the set temperature varies linearly. When heating, as the
comparator outputs a high potential power voltage, a current limiting
resistor needs to be connected in series between it and the optocoupler.
In addition, a positive feedback large resistor is installed on the
comparator to accelerate the temperature control reaction speed and
also avoid the vibration type temperature control of the entire machine.
Frequent switching of the switch tube may cause significant power
loss and generate heat, so a heat sink is installed on it. In addition, due to
the connection between the back of IRFP460 and the drain electrode, it
is necessary to use thermal and non-conductive phase change plastic to
electrically isolate it from the heat sink. In order to reduce electro­
magnetic interference, the connecting wires on the induction heating
system board should be kept as short as possible. The debugging of the
induction heating system is essentially the debugging of the resonant
circuit of the power output stage. Due to manufacturing errors inherent
in each component, it will have an impact on the resonant frequency,
resulting in impedance mismatch. This not only reduces the output Fig. 6. Temperature Rise Curve of Welding Head.
power, but also generates a large amount of reactive power, causing
severe heating or even burnout of the MOS transistor. We adjust the analysis, a constant 100 W power is used as the heat source for heat
value of L2 to achieve impedance matching in the output stage. Starting transfer, and there is fluctuation in the heating power under actual
from the initial 41 turns, we add or decrease the number of coil turns in conditions, with 100 W being the peak heating power. At the same time,
the order of 2 turns, and adjust the number of coil turns in combination it is also impossible to achieve complete and accurate simulation of
with the heating current value. In the experiment, the debugging effect materials, environmental characteristics, etc. Overall, the experimental
is best when L2 takes 45 turns corresponding to an inductance value of results are consistent with the simulation within the allowable error
23uH. range, thus verifying the correctness of the relevant design theories.
After the welding head is heated to the set temperature of 350 ℃, in
Comprehensive Experiment of Welding Heating System order to verify the temperature control effect of the microcontroller
system and the heat compensation speed of induction heating during the
After debugging the induction heating system board and tempera­ welding process, ϕ 4 mm, ϕ 4 mm, 8 × Welding with three different sizes
ture control circuit board separately, the two circuit boards are assem­ of 6Mn solder joints, each type of solder joint is welded with 12, with a
bled together to form a complete welding heating system. Based on this welding interval of 3 s. The solder wire is made of lead-free Sn/Ag/Cu
experimental platform, the final comprehensive debugging is carried composition. According to the experimental data, the temperature is
out. In terms of power supply, the high-power induction heating system almost constant when welding smaller ϕ 4 mm and ϕ 6 mm solder joints,
board uses the selected 160 W transformer. In order to avoid mutual and the temperature control effect of the microcontroller is good. When
interference between two circuit boards as much as possible, for tem­ welding larger 8 × When the 6 mm solder joint is welded, the temper­
perature control circuit boards, a separate power supply is provided ature of the solder joint fluctuates within the temperature range of 339
using a switching power supply. During the experiment, the welding ℃ and 340 ℃, and when welding is stopped, the temperature returns to
temperature was first set to 350 ℃ using a matrix keyboard, and then the constant. Meet the temperature control accuracy requirements [20]. As
power board automatically entered the high-frequency induction heat­ shown in Fig. 7.
ing stage of the welding head. Record the displayed temperature on the
digital tube every second for a duration of 30 s. From the experimental
data, it can be seen that the initial temperature of the welding head is the
ambient temperature of 26 ℃. During the initial heating time of about 8
s, the temperature of the welding head rises slowly, and then the tem­
perature value rapidly increases at an approximate uniform rate until it
reaches the set temperature of 350 ℃. The temperature rise curve of the
welding head is shown in Fig. 6.
In the initial stage, the temperature rise is relatively slow, mainly due
to the inability of the induction heating power to reach its peak in an
instant, which is consistent with the overall current starting at 1.8A and
gradually reaching a peak of 2.6A when the induction heating system is
debugged separately. Reaching the set temperature of 350 ℃ in about
26 s, and then maintaining a constant temperature under the action of
the microcontroller power control system. Fit the temperature change
data of the intermediate peak power heating stage, and since the tem­
perature changes approximately linearly with time at this time, the
fitting function adopts a quadratic function. At a confidence level of 96
%, the function model is f (t) = 13.38 t-16.04. The temperature rise of
the welding head under peak heating power conditions is approximately
13.5 ℃/S. In electromagnetic thermal simulation analysis, the temper­
ature measurement point reaches 350 ℃ at 22 s, with an average tem­
perature rise of 18.8 ℃/S. This is mainly because in the simulation Fig. 7. Welding 8 × Temperature variation curve at 6 mm solder joint.

6
Y. Chen et al.
Conclusion
Through experimental testing, it can be concluded that the induction
heating system board only outputs at full power of 100 W during initial
heating and welding of larger components. When welding ordinary
circuit boards, the output power is around 52 W, and the power loss
during standby constant temperature is about 10 W. When conducting
physical welding, the high power output makes the heat compensation
speed of the welding head very fast, thus meeting the requirements of
lead-free welding. At the same time, the switch tube is in a soft switching
state, generating less heat. In the temperature control circuit, tempera­
ture setting and real-time temperature display functions are achieved
through step-by-step programming and debugging of modules such as
digital tube output display, temperature signal digital processing, matrix
keyboard temperature setting, and integrated temperature control sys­
tem. In the comprehensive experiment of the welding heating system,
the welding head heats up to the set temperature at a nearly linear speed
of 13.5 ℃/S, and then maintains a constant temperature under the ac­
tion of the microcontroller temperature control system. The temperature
rise experimental results are consistent with the electromagnetic ther­
mal simulation analysis results, thus verifying the correctness of the
relevant design theory and laying the foundation for subsequent
research on welding robot heating technology.
CRediT authorship contribution statement
Yongqiang Chen: Writing – original draft. Zhaoguo Ye: Writing –
original draft. Zhuanzhe Zhao: Writing – original draft.
Declaration of Competing Interest
The authors declare that they have no known competing financial
interests or personal relationships that could have appeared to influence
the work reported in this paper.
Data availability
No data was used for the research described in the article.
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