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.

本项目为热塑性复合材料电阻焊接领域的集成化开源平台，具备自动化压力调控、实时仪器监测与自动化数据记录功能。该系统旨在作为高成本工业焊接工作站的低成本独立式替代方案。
系统硬件采用模块化铝制框架与隔热木质焊接基座，可防止电气与热泄漏。压力调控通过由Arduino控制的线性执行器与称重传感器构成的自主反馈环路实现。
系统通过专用的基于Python的图形用户界面（GUI）进行操作，可实现高精度的过程控制与监测：
• 实时可视化：软件可显示焊接周期内电压（V）随时间变化的实时曲线图。
• 高级数据采集：通过K型热电偶（Type-K thermocouple）监测温度，并采集电压与功率输出数据，实时计算加热元件的功率密度与电阻值。
• 自动化报告生成：每次焊接流程结束后，软件将自动生成两类文件：
1. PDF报告：包含工艺参数、试样尺寸以及最终电压-时间曲线图的综合总结文档。
2. 原始数据日志：以文本文件（.txt）格式存储每秒采样的同步数据，包括电压（V）、电流（A）、功率（W）、压力（MPa）与温度（℃）。
系统供电采用华为（Huawei）R4850G2整流器与JUNTEK DPM8624转换器，并完全集成于Python控制逻辑中，可确保精准的生产数据与稳定可复现的焊接质量。