Open-source Modular Resistance Welding Equipment for Thermoplastic Composites

This project is an integrated open-source platform for the resistance welding of thermoplastic composites, featuring automated pressure control, real-time instrumentation, and automated data logging. The system is designed as a low-cost, self-contained alternative to expensive industrial welding stations.
The hardware consists of a modular aluminum frame and an insulated wooden welding base to prevent electrical and thermal leakage. Pressure is managed via an autonomous feedback loop using an Arduino-controlled linear actuator and a load cell.

The system is operated through a dedicated Python-based GUI that provides high-fidelity process control and monitoring:
• Real-time Visualization: The software displays a live graph of Voltage (V) vs. Time during the welding cycle.
• Advanced Data Acquisition: It monitors temperature via a Type-K thermocouple and captures voltage and power output, calculating power density and electrical resistance of the heating element in real-time.
• Automated Reporting: At the end of each process, the software automatically generates two types of files:
1. PDF Report: A comprehensive summary including process parameters, specimen dimensions, and the final voltage/time graph.
2. Raw Data Log: A text file (.txt) containing synchronized readings of Voltage (V), Current (A), Power (W), Pressure (MPa), and Temperature (ºC) sampled every second.
Power is supplied by a Huawei R4850G2 rectifier and a JUNTEK DPM8624 converter, fully integrated into the Python control logic to ensure precise manufacturing data and repeatable weld quality.