Intelligent parameters measurement of electrical structure of medium frequency DC resistance spot welding system

Three phase medium frequency direct current (DC) resistance spot welding (RSW) machine has a complex electrical structure. Because the structure included various electrical components, it is hard to establish an accurate and integrated numerical model to simulate the energy delivery and control process. This study employed a particle swarm optimization (PSO) algorithm to conduct an intelligent parameters measurement. The measurement process included three procedures, based on electrical and physical characteristics of the objective electrical system. To verify the accuracy and reliability of the measurement, another numerical model established by MATLAB Simulink was employed. The comparative results showed that the maximum error of all measured parameters was 1%, which meant that the proposed intelligent parameter measurement method was effective, and convinced measurement results can be obtained. This study can benefit to establish a full process numerical calculation or evaluation model of the medium frequency DC RSW system.