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DC fuse electric resistance spot welding process condition optimization using design of experiment method for electric vehicle and energy storage system

  • Journal of the Korean Crystal Growth and Crystal Technology
  • Abbr : J. Korean Cryst. Growth Cryst. Technol.
  • 2026, 36(1), pp.25~35
  • DOI : 10.6111/JKCGCT.2026.36.1.025
  • Publisher : The Korea Association Of Crystal Growth, Inc.
  • Research Area : Engineering > Materials Science and Engineering
  • Received : March 16, 2026
  • Accepted : March 24, 2026
  • Published : March 31, 2026

Hwang, Joon 1,  Seung-Woo Ra 1

1한국교통대학교

Accredited

ABSTRACT

In this study, we developed an automated process technology for the electric resistance spot welding process of direct current fuses (DC fuses), the demand of which is rapidly increasing due to the growing global demand for carbon neutrality and the expansion of the development and utilization of electric vehicles (EVs) and energy storage systems (ESS). To improve the productivity and quality of DC fuse manufacturing, we defined key process variables for the spot resistance welding process, such as welding current, pressure, and welding time. We analyzed the effects of each variable on the heat generation characteristics and melting zone shape during welding. Based on this, we established weld quality evaluation criteria, and through data-driven design of experiments (DOE) and experimental analysis, we derived optimal process conditions and identified defect types and causes. In this experiment, we measured the tensile strength, weld nugget size, and melting degree (no melting, normal melting, and over-melting) at eight points on the upper and lower slopes of the DC fuse (a total of 32 points) using the three-factor, four-level orthogonal array (L16(4 )) method. Through analysis of3each main effect and interaction effect, the optimal operating conditions satisfying the tensile strength (1.53 kgf) and weldnugget size (1.47 mm) specifications were identified: a welding current of 6.5 kA, an applied pressure of 1.75 kgf/cm2, and a welding time of 1.5 seconds. Furthermore, the strong interaction between current and time confirmed that heat input balance is a key factor in weld quality, with applied pressure playing a supplementary role in stabilizing this balance. Based on this, an automated point resistance welding system was designed and an integrated architecture of mechanical, electrical, instrumentation, and data/MES was established to enable current-time-based heat input control and applied pressure stabilization. A real-time production process monitoring system was established, and a prototype capable of process sequence control was manufactured and successfully tested in the field. This study is expected to contribute to increased corporate sales by enabling high-reliability quality control and enhanced productivity through precision welding of plate- shaped DC fuse elements. Furthermore, the results of this study are expected to contribute to improving the technological level required for the development of electric vehicles and energy storage systems (ESS).

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