The Design And Realization Of The Intelligent Spot Welder Controller

Resistant Welding is wildly used in the industries. In modern society, it is common in the fields of machine, aviation, spaceflight and automobile. So, there is a huge market demand for the resistant welder.In this paper, based on the market demand, we designed an intelligent spot welder controller for the commercial purpose after researching a lot of related references. The software and hardware of the spot welder controller are both adopted module design method. It can do the single spot welding or continuous spot welding. The controller has the function of saving data automatically after power down and can store upto 30 criteria for the users. It's man-machine interface is friendly and easy to use.On the hardware part, there is a single chip controller in both front panel and main board, which is called "double MCU core structure" by us. The I/O interfaces of the two single chip controllers are used sufficiently, so they could complete the functions we demand quite well. The liquid crystal screen, which uses MGLS19264 module, could display 4 rows and 12 lines Chinese characters. The SCR pulse trigger circuit adopts a dual retriggerable resettable monostable multivibrator that could supply a stable width trigger pulse. The pulse width is set by the hardware circuit. So the circuit can insure to trigger the SCR, and meanwhile it saves the single chip controller system resources. The welding current, which is fed back by the current sensor, will enter AD7574 and be finally processed by the single chip controller. And the single chip controller will get the real-time welding current and the next trigger angle demanded by the next cycle.On the software part, we used the "from bottom to top" method. Above all, we designed the every single part of the function modules, and then assembled them together. We used the assembly language to write the program, and debugged them in the IDE WAVE6000.