American University of Science and Technology

Faculty of Engineering
Department of Mechatronics Engineering

MTE 497: Mechatronics Engineering Senior Design

Proposal

Seam Welding Machine

By
Dani Sleiman
Jihad Awar
Rana Al Hajj
Project Advisor: Dr. Adel Chit

A Proposal Submitted to the Department of Mechatronics Engineering,

American University of Science & Technology,
in Partial Fulfillment of the Requirements for the Degree of
Bachelor of Science

Beirut, Lebanon

February 7 , 2017
 Summary Description of the Project

Investigators:
Dani Sleiman, Rana Al Hajj, and Jihad Awar.

Project Director:
Dr. Adel Chit

Title of the Project:

Seam Welding Machine

Keywords:
Seam, Thyristors, Snubber, Wheel Electrodes, Pneumatic Cylinders, Pulse
Device

Brief Statement of Project Objectives:

The new resistive welding machine was build to replace the old traditional
welding techniques. Based on the use of lead and flux. This traditional
welding process was prohibited by the United Nations since it is causing
cancer and heart issues. For this reason the modern welding processes are
based on electric resistive welding and avoid the application of lead. This
technology was introduced by the Swiss company SODETEG and it is based
on the concept of low voltage and high current to perform the welding
procedure. The system of the machine includes the use of an extra wire to
get a good welding joint. This extra wire is very hard to implement and
expensive to perform. For this reason the elimination of the wire system can
create a simple but effective solution. Our project is based on the design and
implementation of a simple welding machine without the use of the
complicated wire system.
 List of Figures
Figure 1: Resistance seam welding front view.........................................................................6
Figure 2: Single phase seam welder circuit................................................................7
Figure 3: flow of current inside the seam welder machine.........................................7
Figure 4: Seam welding design...................................................................................8
Figure 5: Electrical Power Transformer................................................................................11
Figure 6: Wheel Electrodes............................................................................................... 11
Figure 7: Copper Sheets................................................................................................... 12
Figure 8: Pneumatic Cylinder.................................................................................... 12
Figure 9: Servo Motor............................................................................................... 13
Figure 10: Arduino Uno............................................................................................. 13
Figure 11: Power Supply........................................................................................... 14
Figure 12: Air Control..................................................................................................... 14
 List of Tables
Table 1. Timetable...................................................................................................... 3
Table 2. Cost Description................................................................................................. 15

I. RATIONALE

I.A Statement of The Problem

The old traditional welding was based on using lead and flux
that were causing cancer and heart issues. For this reason the
United Nations prohibited the use of any lead and flux in the
welding process. This paved the way for the appearance new
technology which is electric resistive welding. Resistive
welding machines are based on the concept of low voltage
high current to perform the welding procedure. The major
problem of this new system is using an extra wire which is
very complicated to build and very expensive to perform.

I.B Hypothesis

Electric resistive welding is a welding procedure in which parts

to be welded are initially heated to the melting temperature by
the resistance of work piece to the stream of electric current and
then pressed by the mechanical weight to finish the weld. No
lead is used in this process.

In this way, SODETEG electric resistance welding alludes to a

gathering of welding procedures, for example, spot and seam
welding to create combination of the faying surfaces where heat
to shape the weld is produced by the electrical resistance of the
material joined with the time and compel used to hold the
materials together amid the weld.

The use of this technology instead the old welding process has
replaced the disadvantage of using lead in the welding procedure
and thus gave welding more powerful specification by causing
less pollution to the environment and saving the life of the
 welder from dangerous heart problems and cancer. In addition,
the old technology also used lead in the welding procedure
and this was also a major cause of cancer.

I.C Proposed Solution

Seam Resistive Welding is a procedure that delivers a weld at

the faying surfaces of two comparable metals. The seam can be
a butt joint or a cover joint and it is typically a robotized
procedure. Seam welding depends on two electrodes, normally
produced using copper, to apply pressure and current. [1]. The
electrodes are disk molded and turn as the material goes
between them. This permits the anode to remain in steady
contact with the material to make long consistent welds. The
terminals may likewise move or help the development of the
material.
This electric resistance welding process uses low voltage and
high current supplied by a transformer, and it does not cause the
welder any electric shocks due to the low voltage. Introducing
this new technology will solve the problem of traditional welding
techniques that are based on the usage of flux and lead to
perform the welding. Therefore, seam electric welding will make
the welding process cleaner to the environment and will save the
welders life from hazardous health issues.
Seam Resistive welding is a new technology used by SODETEG
that is using an extra wire to pass the welding current across the
metallic parts to be joined. Our work consists of eliminating this
extra wire and making the current pass across the copper
electrode directly.
This solution has many advantages such as: less weight, less
adjustment work to install the wire, and less in price and volume.

I.D Specific Objectives and Proposed Timetables

1. Tasks and Deliverables

The project tasks can be described in six phases:
a. Design and manufacturing of the machine
body.
 b. Design and implementation of the mechanical
part of the welder (motor and pneumatic
cylinder control).
c. Design of the wheel electrode using red copper.
d. Design of the pneumatic system.
e. Adding servo motor for the rotating copper
disk.
f. Design of a dimmer system to control the
voltage and current of the welding machine.

2. Project Management:
Each block represents a week of work. The 24 th of
December was set to begin developing and preparing
the parts of projects. The software includes the
position control of the servo motor and the timing
control of the welding process depending on the
material being welded. The hardware is the
mechanical part of the welding machine. In
implementation, the hardware and software will be
combined in every step in order to make sure that
each step is functioning alone before combining all
tasks together to create a whole prototype.

Table 1. Timetable

Senior Project Proposal Report Fall 2016-2017

Hardware Week one and two of Spring 2016-2017
Computer Software Week two and three of Spring 2016-2017
Implementation Week three, four, and five of Spring
2016-2017
Debugging and testing Week six, seven, and eight of Spring
2016-2017
Senior Project report and presentation Last week of Spring 2016-2017

I.E Significance of this work

 This system is able to save the use of the extra wire used by
SODETEG and transmit the welding current directly to the wheel
electrodes. In addition, this system is a unique system that is
able to do a new form of success in the welding history. This
design is capable of translating the welding process from its old
traditional aspect to a new aspect based on using electric
resistive welding.
This new technology is more efficient and cause less pollution to
the environment since its based on using electricity which is a
clean source of energy. Moreover, this system has a wide range
of applications which are: manufacturing of round or rectangular
steel tubing, manufacturing of steel can beverages,
manufacturing of steel fuel tanks for motor vehicles, and manufacturing of
steel drums and domestic radiators.

II. LITERATURE REVIEW

Welding is the most economical and efficient way to join metals

permanently. It is the only and the best way of joining two or more pieces of
metal and combines them to act as a single piece. So welding is a fabrication
that joins materials, usually metals, by causing fusion, which is a lower
temperature metal joining technique such as soldering. In addition a filler
material is typically added to the joint to form a pool of molten material
which cools to form a joint that is usually stronger than the base material.
Pressure may be also used to produce a welding joint. Also, it is often said
that over 50% of the gross national product of the U.S.A. is related to welding
in one way or another. Welding involves high ranking among industrial
processes and involves more sciences and variables than any other industrial
process.

There are many ways for performing the weld and many different kinds of
welds. Some processes cause sparks and others do not even require extra
heat. Welding can be done anywhere outdoors and indoors, underwater and
in outer space.

Nearly everything we use in our daily life is achieved by welding or made by

equipment that is welded. The welders help to build space vehicles and
millions of other products ranging from oil drilling rigs to automobiles. In
construction, welders are virtually rebuilding the world, extending subways,
building bridges, and helping to improve the environment by building
pollution control devices [2]. The use of welding is practically unlimited.
There is no lack of variety of the type of work that is done.

There are different types of welding such as:

Shielded metal arc welding: this method is based on using

an electrode that has flux around it to protect the weld puddle. The
electrode holder holds the electrode as it slowly melts
away. Slag protects the weld puddle from atmospheric contamination.

Gas tungsten arc welding: this method is based on using a non-consumable

tungsten electrode to produce the weld. The welded area is protected from atmospheric
contamination by an inert shielding gas such as argon or helium.

Submerged arc welding: this method is based on using an automatically fed consumable
electrode and a blanket of granular fusible flux. The molten weld and the arc zone are
protected from atmospheric contamination by being "submerged" under the flux blanket.

Electro slag welding: a highly productive, single pass welding process for thicker
materials between 1 inch (25 mm) and 12 inches (300 mm) in a vertical or close to
vertical position.

Electric resistance welding: a welding process that produces coalescence of laying

surfaces where heat to form the weld is generated by the electrical resistance of the
material. In general, an efficient method, but limited to relatively thin material.

Many different energy sources can be used for welding, including a

gas flame, an electric arc, a laser, an electron beam, friction,
and ultrasound. Welding requires some precautions to
avoid burns, electric shock, and vision damage, inhalation of poisonous
gases and fumes, and exposure to intense ultraviolet radiation because it
is a hazardous undertaking. Until the end of the 19 th century, the only
welding process was forge welding, which had been used for centuries to
join iron and steel by heating and hammering. Arc welding and ox-fuel
welding were among the first processes to develop late in the century,
and electric resistance welding followed soon after.

Welding technology advanced quickly during the early 20 th century as the

world wars drove the demand for reliable and inexpensive joining
 methods. Following the wars, several modern welding techniques were
developed, including manual methods like SMAW, now one of the most
popular welding methods, as well as semi-automatic and automatic
processes such as GMAW, SAW, FCAW and ESW. Developments continued
with the invention of laser beam welding, electron beam
welding, magnetic pulse welding (MPW), and friction stir welding in the
latter half of the century. Today, the science continues to advance. Robot
welding is commonplace in industrial settings and researchers continue to
develop new welding methods and gain greater understanding of weld
quality [3].

The use of some traditionally welding techniques such as welding using solid wires like
soldering has increased the rate of pollution and has caused the welder a lot of health issues
such as heart problems and cancer. This has motivated engineers specially the ones involved
in the industrial process to search for new welding processes that are more efficient and cause
less pollution to the environment and the user. This has paved the new to the appearance of
new technologies such as electric resistance welding that uses electricity to perform the
welding procedure. The most commonly used type of resistance welding is seam resistance
welding that is mainly used in the welding of fuel tanks and many other applications [4].

The resistance seam welder is based on the following welding methods.

First, two metal plates are placed to overlap each other at their end
portions. Moreover, the overlapping portions are pressed by a pair of
electrode wheels and continuously welded together by applying a welding
current. At the same time, the joint portion softened by being heated to
high temperature is rolled by the electrode wheels to reduce the thickness
of the joint portion. However, this welding method cannot roll the joint
portion to a level corresponding to the base material thickness. There is a
problem in that the thickness of the joint portion is increased to
approximately 120% to 160% of the thickness of the base material (the
metal plate), which forms a step between the joint portion and the base
material [5].

III. WORK PROPOSED

III.A DESIGN SPECIFICATIONS

The design of the resistance seam welding machine consists of
an upper drive wheel with a lower idling wheel. The lower wheel
uses a yolk and bushing design, with replaceable inserts to allow
repairs to damaged or poorly maintained surfaces.
The welding electrodes of this machine are motor driven wheels
and this result in a rolling resistance weld or seam weld.
The electrical pass is based on a dimmer to adapt the welding
current to the thickness of the metal by changing the primary
voltage of the transformer. Where the old system consist of
installing power coils in the primary of the transformer to vary
the secondary voltage.

Figure 1: Resistance seam welding front view

The electrical power system of the single phase seam welder

machine can be thought of simply a dimmer circuit that consists
of two antiparallel thyristers to control the voltage and a
transformer according to the thickness of the welding joint. The
thyrister shown in this figure is used simply to initiate and
terminate the welding current.
The available frequency for the seam welding machine is 50 Hz.
There is direct relation between the thickness of the material and
power of the transformer hence, the thicker the material is more
power is needed by the transformer to perform the welding
process [6].
 Figure 2: Single phase seam welder circuit

The current flow from the secondary terminal of the transformer

to the primary terminal. In order to transfer the flow of current
from the transformer to the wheel electrodes where the welded
material is placed, copper sheets are used to conduct the
electricity and to pass the flow of current to the electrodes to
complete the welding procedure [7].

Figure 3: flow of current inside the seam welder machine

The seam welding machine uses the concept of low voltage high current and
this is the technology used behind most resistance welding
machines.
 The main frame is high quality welded steel construction styled for trim
appearance and functional design. The slim design requires a minimum of
floor space. The upper arm extension is built integrally with the frame. The
upper knee is steel, and supports the transformer; this allows the
transformer to move up and down with the upper knee. A removable rear
cover permits ready access to the frame interior for inspection and
maintenance. The movement of the upper knee supplies the needed
pressure during the welding process while the lower knee remains fixed. In
addition, a hydraulic system is used to control the movement of the upper
knee using a plc controller. This machine below was built by SEAMRITE a
welding company.
Figure 4: Seam welding design

III.B DESIGN CONSTRAINTS

Resistance seam welding depends on three factors which are:

Welding current
Welding time
Electrode force

1. Welding Current

Welding current is the most significant parameter that

controls the heating at the joint of sheet to sheet interface and
hence the weld nugget development and formation takes
place. AC currents possess different characteristics in total
heating and heat input rate and their effect on weld quality
and weld formation. Increase in the current increases the
diameter of the weld, root penetration. It also increases
strength of the weld. Excess current value gives rise to
excessive indentation and burning of the weld nugget area.

2. Welding Time

Weld time includes squeeze time, welds time, holds time and
off time. Prolonged weld time increases the size of the weld.
Due to the heat transfer from the weld zone to the base metals
and to the electrodes, as well as the heat loss from the free
surfaces to the surroundings, a minimum welding current as
well as a minimum welding time will be needed to make a
weld. If sufficient welding current is not used, by increasing the
welding time alone will not produce a weld. When the welding
current is high enough, the size of the weld nugget increases
with increasing welding time until it reaches a size similar to
the electrode tip contact area. If welding time is more,
expulsion of the workpiece will occur or in the worst cases the
electrode may stick to the workpiece.

3. Electrode Force
Electrode force is the force exerted by the electrodes on to
the workpiece during welding cycle. The pressure exerted by
the electrode tips on the workpiece has great effect on the
amount of current that flows through the welding joint [8].
Electrode conveys the force and welding current to desired
location. If the electrode force is high, the contact area will be
large resulting in low current density and low contact
resistance that will reduce heat generation and the size of weld
nugget. Large indentation lowers the strength of the weld. If
the welding force is too low, expulsion may occur immediately
after starting the welding current because of the contact
resistance is too high, resulting in rapid heat generation.

Other constraints of the design are:

Bulk Resistivity: The higher the bulk resistivity of the

material, the higher the heating (H=I2Rt) and thus the
higher the travel speed possible.

Current Density: As travel speed increases, more

material is presented to the rolls per half cycle of current
thus reaching a limit to the current density in the part.

Conductive Coating Materials: When conductive

coatings are present at the faying surface, they offer an
increased shut path for current and thus also reduce
current density. Welding takes place when these
coatings are melted and extruded out of the weld zone.

Expulsion: With increased travel speed, complete

nugget formation is delayed until the weld forms outside
the pressure influence of the rolls and expulsion is
easier.

Coil Width and Shape: When the coil is narrow

compared with the wall thickness, the heated zone will
have a shape that resembles a half-cylinder. The heat
flow bends in tangential direction close to the inner
surface. A narrow coil, therefore, requires longer heating
time (zone length) than a wider coil, where the heat flow
 has a more radial direction in the required zone width at
the inner surface. Normally, one type of coil must cover a
range of wall thicknesses. Coils with sufficient width to
heat the largest wall thickness at minimized heating zone
length create a wider zone and require more power than
is necessary for the smaller wall thickness range. A wider
heated zone gives better temperature homogeneity,
which may also lower the maximum temperature for
smaller wall thicknesses. The zone width also influences
the cooling rate [9].

III.C MATERIALS

i. Transformer
An electrical power transformer is a static device that
transforms electricity between electric circuits without any
direct electrical connection and with the help of mutual
induction between two windings. It transformers power
from one circuit to another without changing its frequency
but it may affect the voltage level [10].

Figure 5: Electrical Power Transformer

ii. Wheel Electrodes

Wheel electrodes are used for continuous welding, these electrodes are
usually made from pure copper. For perfect welding the wheel electrodes
must be also perfect so they can conduct the electricity supplied by the
transformer in the best way [11].
 Figure 6: Wheel Electrodes

iii. Copper sheets

Copper sheets are good conductors of electricity and they are used to
transfer the high current from the transformer to the wheel electrodes to
induce the welding process.

Figure 7: Copper Sheets

iv. Pneumatic Cylinder

Pneumatic cylinder is a mechanical device that uses the power of
compressed gas to produce a force in reciprocating linear motion. In the
seam welding machine the pneumatic cylinder is very important in
applying pressure to the wheel electrodes during the welding process [12].
 Figure 8: Pneumatic Cylinder

v. Servo Motor
Servo motor is a rotary actuator that is used for precise control of angular
position, velocity, and acceleration. It consists of a motor combined with a
sensor for position feedback. In the seam welding machine servo motors
are used to control the rotary of the wheel electrodes depending on the
type of applications being used [13].

Figure 9: Servo Motor

vi. Arduino Uno

Arduino Uno is a micro controller used to control the seam welding
machine it is used to control the servo motor and the movement of the
pneumatic cylinder [14].
 Figure 10: Arduino Uno

III.D METHODS

Supply voltage and Frequency

The Seam welding machine can be supplied for any
one standard voltage supply of 220, 380, 440, or 550
volts, 50 cycles, single phase.

Figure 11: Power Supply

Heat Control
Precisely controlled heating is required to achieve
consistent, reliable welds. The medium frequency
inverter achieves this level of control by precisely
 managing and monitoring weld parameters. The
higher frequency permits much faster (1000 times
per second) process control, which again results in
better weld quality

Air Accessories
Standard Equipment included air pressure regulator,
gauge, lubricator, speed control valve, and solenoid
valve for control of the cylinder [15].

Figure 12: Air Control

III.E TESTING AND VALIDATION

Validation and testing will have to be done for the

hardware and software in parallel. These are the main
testing and validation points:

1. Hardware:
Testing the servo motor to achieve the exact
position of the wheel electrodes.
Obtaining a continuous seam weld.
Checking the functionality of the pneumatic
cylinder if its supplying the correct pressure.
2. Software:
Building the machine controller using plc
controllers
Testing the validity of the data given by the
Arduino
Controlling the timing of the welding process
and detecting
the point of perfect welding

III.F COST ANALYSIS

 The prototype requires a lot of mechanical work, therefore
increasing its budget. The total estimated budget is around
1000$. The project will be funded by the team members.

Table 2. Cost Description

Item Description Value/ Quantit Unit Total

No. Specs y Price Cost
1 Transformer 7KVA 1 250$ 250$
2 Wheel 15cm 2 75 $ 150 $
Electrodes
3 Copper Sheets 2 kg 2 75$ 150$
4 Copper Bars - 2 20$ 40 $
5 Pneumatic - 1 50 $ 50 $
Cylinder
6 Servo motor STM32F 1 70 $ 70 $
7 Arduino Uno ATmega 328 1 30 $ 30 $
8 Mechanical - 1 300$ 300 $
body
Total 1040 $

IV. SOCIAL ISSUES

IV.A Ethical

The functionality of the seam welding machine is to save the welder

using the machine from getting an electric shock or electrocuted since
this machine is using the technology of low voltage- high current. This
technology is very efficient since its saving the life of the welder and
causing less pollution to the environment.

IV.B Social

Some social aspects may include accidents that can result from using
this seam welding machine. To avoid such accidents we are offering a
step by step explanation to guide the welder about the procedure of
using this machine. This will decrease the possibility of any injury that
might occur when using such machine.
 Taking into consideration that this welding machine can be used by any
user willing to learn about it by just reading the user manual and he
can start using the machine right out of the box.

IV.C Economic

Welding is the most efficient and economical way to join metals

permanently. It is the only way of joining two or more pieces of metal
to make them act as a single piece. This shows the economical aspect
of the welding process since it is reusing the old materials or any
unwanted part to join it into a new part that can be used in a lot of
applications. Everything surrounding us is made using welding and this
is inducing the economical process by offering a lot of job opportunities
and selling various welded materials.

IV.D Health and Safety

The seam welding machine includes a user manual to allow the user to
use the machine in a safe way. The priority of the seam welding
machine was to safe the health of the user by using the concept of
resistance welding that protects the user from any smells getting out
from the combustion of solid wires used in the older machines and this
will protect the welder from various health problems like heart issues
and cancer. In addition the user is protected from any electric shocks
due to the low voltage used in the machine and this reflects the safety
manners used in our design.

IV.E Manufacturability
This welding machine is feasible and can be implemented following
some well-organized procedures. Moreover, the needed materials and
parts are available locally at very economical prices.
The mechanical part of the machine can be done using the inventor
professional (CAD software) to be easily implemented in real-life. Since
by using this software we can study all the forces and stress-strain
analysis of the design. Hence, testing the validity of the design.

IV.F Sustainability
The welding process caused a revolution in the field of industry since
everything we use in our daily life is welded or made by equipment
that is welded.
 Therefore, this welding machine can continue to be viable and useful
for a reasonable amount of time since the welding process will never
stop and it will always be used in manufacturing automobiles and
buildings.

IV.G Environmental Impact

This welding machine is based on electricity; this means there is no
use of any combustible materials like fuel and oil. This reduce the
environmental impact by causing less pollution due to the fact that
clean energy is used to supply the welding machine.
However, some natural resources are used in the manufacturing of this
machine like copper sheets and copper bars but the main property of
this machine is that there is no pollution and effects on the
environment.

IV.H Usability
This seam welding machine is not considered a straightforward
machine. Since this machine is based on a complicated process, the
user should have some mechanical and control systems knowledge in
order to use it.
However, we are offering a user manual that describes for the user the
steps for using the machine and how to troubleshoot the machine in
case of any error occurring in the system.

IV.I Lifelong Learning

This project will provide us with many new information concerning the
welding techniques used in the project. We may also need to study
new material in order to accomplish the best outcome. The seam
welding machine can be used in future development where we can
implement it in reality. The concept of the machine may be involved in
many industrial applications.

V. DISCUSSION AND CONCLUSION

The exact purpose of the project is to build a welding machine capable

to be used for wide range of applications based on the concept of
electric resistance welding. This machine is using low voltage high
current to perform the welding process and this new technology will
pave the way for a clean welding operation that will not affect the
 environment and will save the welder from the consequences of using
the soldering wires in welding.
The aim of the project is to reduce pollution that was caused by old
traditional welding techniques and save the life of the user that was
threatened with some dangerous health problems such as cancer.
The aim of this project is to build a simple welding machine affordable
in price and easy to use. Our project has a wide range of applications
such as steel can beverages, and automobile fuel tanks.
The project will cost around 1000$ and will take 3 to 4 months of hard
work.

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[8] John Inge Asperheim, Leif Markegrd: Optimization of seam

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[12] S. Campbell and N. Inc, "Guidelines for selecting pneumatic

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[13] electrical 4 u, "What is servo motor?," 2011. [Online]. Available:

http://www.electrical4u.com/what-is-servo-motor/.

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