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International Journal of Frontiers in Engineering Technology, 2024, 6(1); doi: 10.25236/IJFET.2024.060116.

Design and Implementation of Integrated Control System for Fixed Spot Welder in Human-machine Fusion Mode


Qiu Luwei1, Jiang Xiaohui1, Peng Shenyue1, Hu Yunge1, Dong Yuanfa2

Corresponding Author:
Qiu Luwei

1Department of Mechanical and Electrical, College of Science and Technology of China Three Gorges University, Yichang, 443002, China

2College of Mechanical & Power Engineering, China Three Gorges University, Yichang, 443002, China


To address the inefficiencies, high labor intensity, and low precision inherent in traditional fixed manual welding, a dedicated spot welding control system was designed using Siemens S7-1200 series PLC and a touch screen interface. This system operates by controlling three stepper motors which in turn maneuver the welding machine along a cylindrical coordinate system, thus facilitating complex three-dimensional spot welding tasks. The parameters of the spot welding process can be dynamically adjusted through a human-machine interface interacting with the PLC, allowing for real-time modifications based on practical needs during the welding process. This innovative system marks a significant improvement over traditional welding methods. Its use of advanced PLC technology ensures higher control precision and a greater degree of automation. These enhancements not only optimize the welding process but also significantly reduce the physical strain traditionally associated with manual welding tasks. Moreover, the system’s adaptability and practical applicability are noteworthy, making it a versatile solution for various industrial welding needs. Overall, the implementation of this PLC-based control system in spot welding machines represents a substantial advancement in welding technology. By automating the process and allowing for real-time adjustments, it addresses the core challenges of manual welding, bringing about a new era of efficiency and precision in industrial welding applications.


spot welding; stepper motor; process parameters; cylindrical coordinate system; programmable logical controllers (PLC); human-machine integration

Cite This Paper

Qiu Luwei, Jiang Xiaohui, Peng Shenyue, Hu Yunge, Dong Yuanfa. Design and Implementation of Integrated Control System for Fixed Spot Welder in Human-machine Fusion Mode. International Journal of Frontiers in Engineering Technology (2024), Vol. 6, Issue 1: 101-106. https://doi.org/10.25236/IJFET.2024.060116.


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