Impact of the Switching Frequency on the Welding Current of a Spot-Welding System

This paper deals with an analysis of a middle-frequency resistance spot-welding (RSW) system with a dc welding current controlled by a pulsewidth modulated inverter, which supplies a welding transformer with a full-wave rectifier mounted at the secondary. Welding transformers in the automotive industry are usually mounted on the arm of a moving robot, so the weight is important. To achieve the same welding power with a large welding current, the transformer's weight can be reduced with a higher PWM switching frequency. This higher frequency allows a reduction in the transformer's iron-core cross section with shorter primary and secondary windings. Unfortunately, the leakage inductances prevent the RSW system from achieving the same nominal welding current at higher frequencies. The frequency-dependent maximum welding current is a characteristic behavior of the RSW system, which can be determined by sophisticated and time-consuming simulations or with the expensive measurements. The third option presented in this paper is determination of an analytical solution, which allows calculation of the maximum welding current as function of frequency or any parameter of the RSW system circuit model. The analytically calculated frequency-dependent function of the maximum welding current was completely confirmed by measurements on an industrial RSW system and by numerical simulations.