Research on online intelligent welding system based on resistance spot welding of aluminum galvanized steel

The article follows a resistance spot welding system, which integrates a six-axis industrial robot, power supply, pneumatic actuator, welder, cooler, trimmer, software control system, welding analyzer, force feedback sensor and welding fixture to realize monitoring of welding quality and real-time adjustment of welding parameters. Taking the resistance spot welding of 6 series aluminum alloy and DC06 galvanized steel as a study, four groups of electrode combinations, 16-6/16-6, 16-10/16-10, 16-7/16-10, and 16-5/16-16 (steel side/aluminum side), are selected for simulation and analysis, and the electrodes are optimized with the simulation results. By selecting the optimal electrode combination to carry out experiments and analyzing the influence of welding current and welding time on the joint performance, the average pulling shear force of the aluminum alloy steel resistance spot weld head is finally realized to exceed the average pulling shear force of the aluminum alloy aluminum resistance spot weld head, and the fracture is all started from the parent material of the alloy side to achieve the failure of the button, and ultimately a good welding effect is achieved.