Resistance spot welding control system and method thereof

A system for regulating welding parameters of a spot welding machine joining a plurality of panels, the system comprising:

• an ultrasonic sensor installed inside an electrode of a welding gun, applying a ultrasonic wave to a welding part of the panel, and detecting a reflected ultrasonic signal;
• an ultrasonic analyzer that creates ultrasonic analysis information by analyzing in real time the ultrasonic signal;
• and
• a welding controller receiving the ultrasonic analysis information from the ultrasonic analyzer, performing adaptive welding control with the welding parameters set based on information of the plurality of panels, and compensating in real time one or more welding parameters according to the received ultrasonic analysis information, wherein the welding controller comprises:
• a communication module for communicating with a manufacturing execution system server, which centrally manages the ultrasonic analyzer and welding operation through a multi-channel communication interface;
• an information collection module analyzing a message type and a receiving time of the ultrasonic analysis information received by the ultrasonic analyzer;
• a timer module for performing time division-based counting in milliseconds (ms) during the welding operation;
• a current conversion module of converting the current for the spot welding according to a signal applied;
• a storage module storing at least one program and setting data for welding control and storing information generated according to the welding operation;
• and
• a control module obtaining the information of the loaded panel, transmitting the information of the loaded panel to the ultrasonic analyzer, setting the welding parameters according to the information of the panel, and then starting the welding operation.