Projects
Embedded Controller for Spot Welding Machine
The digital controller for a spot welding machine involves precise control of timing, current, and pressure to ensure accurate, repeatable clean and consistent welds.
Core Functions
- Control welding time (milliseconds precision)
- Pulse/Double-pulse weld modes
- Control welding current using an SCR or TRIAC
- Display settings on an LCD/OLED
- Provides safety mechanisms (overheat, current surge protection)
Safety Features
- Overcurrent Protection: Using a current sensor
- Thermal Cutoff: Monitor transformer or MOSFET temperature
- Emergency Stop: Physical button to halt operations
- Continuously check for overcurrent.
- Stop welding if abnormal conditions are detected.
Advanced Features
- Phase Sequencer / Phase Sequence Detector is used to detect and ensure the correct order of the three-phase power supply, preventing damage to charging capacitor and other connected equipment.
- Identifies the correct sequence of the three-phase supply. Indicates if the phase sequence is correct or reversed.
- Multi-pulse modes for improved welding strength
- Foot pedal control for hands-free operation
Power Switching Components
- Solid-State Relay (SSR): For isolating high-current welding lines.
- SCR (Silicon Controlled Rectifier): For high current pulse welding.
- MOSFET: Ideal for DC spot welding control.
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