Design of Control Kit for Arc Welding Process with Atomised Digital Controlled Welding System

This Research paper studies about the designing and simulation aspects of automatic arc welding system using digital control with the help of Proteus Simulation software. The welding sequence considered for the study consists of five intervals they are Standby, Squeeze, Weld, Hold, and Release intervals. A separate stepping interval circuit with a decoder to step the intervals from one to another is designed and analysis is done using a decoding technique. The designed stepping circuit ensures the correct order of the five intervals of the welding system, also a separate stepping of heat-cool sub intervals of weld interval is also designed with a user defined preset time counter circuit so that welding interval can be timed based on the user defined priority and can also be stepped between the two heat and cool sub intervals based on the total time assigned by the user. The digital automatic control system is developed to accurately control the arc welding system for welding of two given metal pieces. This report concerns automatic welding system with digital control and is directed to the improvement of certain drive and guide means for a relatively freely carried welding of wheel rim and wheel spider for continuous welding of a part resting on a freely rotatable table. The drive and guide means are carried on the welding head and impart drive to the part while maintaining the welding head properly positioned relative to the part. The system presented is a slightly simplified version of a real automobile wheel-welding system. Although system operation is explained in terms of wheel welding, the design of the system has much in common with other welding operations utilizing the basic industrial automatic welding sequence of Squeeze, Weld, Hold, Release, and Standby with digital control. (C) 2015 Published by Elsevier Ltd.