Alternatif Akım Direnç Nokta Kaynak Sistemleri için Toroidal Rogowski Bobini Tabanlı Bir Akım Algılama Devresinin Tasarımı ve Gerçeklenmesi

Abstract

Bu çalışmada, AC direnç nokta kaynağı (AC-DNK) sistemlerinde hassas akım algılama için toroidal Rogowski bobini ile entegre edilmiş aktif bir entegratör devresinin tasarımı, uygulaması ve deneysel doğrulaması sunulmaktadır. Önerilen sistem, kısa süreli kaynak çevrimleri sırasında tipik olarak üretilen yüksek genlikli geçici akımların doğru ve kararlı bir şekilde izlenmesini sağlamayı amaçlamaktadır. Performans değerlendirmeleri hem laboratuvar koşullarında hem de gerçek bir endüstriyel AC-DNK ortamında gerçekleştirilmiştir. Laboratuvar kurulumunda, entegratör devresi 100 mV ila 1000 mV arasında değişen sinüzoidal giriş sinyalleri ile test edilmiştir. Sonuçlar, R² = 0,9965, MAE = 3,65 mV, RMSE = 4,69 mV ve MAPE = %2,88 regresyon metrikleri ile oldukça doğrusal bir çıkış tepkisi göstermiştir. İkinci aşamada, sistem 5 ila 20 kA arasında gerçek kaynak akımlarına maruz bırakılmıştır. Entegratörün çıkış voltajı tepe noktaları referans akım ölçümleriyle karşılaştırılmış ve R² = 0,9981, MAE = 0,55 mV, RMSE = 0,63 mV ve MAPE = %1,29 elde edilerek endüstriyel koşullarda uygulanabilirliği teyit edilmiştir. Bulgular, önerilen sistemin AC-RSW uygulamalarında geleneksel akım ölçüm yöntemlerine uygun maliyetli, ölçeklenebilir ve elektromanyetik olarak sağlam bir alternatif sunduğunu göstermektedir. Doğrusal tepkisi, yüksek ölçüm doğruluğu ve zorlu çalışma koşullarına uyarlanabilirliği ile geliştirilen sistem, gerçek zamanlı endüstriyel akım izleme görevleri için güçlü bir potansiyele sahiptir.

Keywords

• Rogowski bobini
• aktif integratör devresi
• alternatif akım direnç nokta kaynağı
• yüksek akım algılama

Design and Implementation of a Toroidal Rogowski Coil-Based Current Sensing Circuit for AC Resistance Spot Welding Systems

Abstract

This study presents the design, implementation, and experimental validation of an active integrator circuit integrated with a toroidal Rogowski coil for precise current sensing in AC resistance spot welding (AC-RSW) systems. The proposed system aims to enable accurate and stable monitoring of high-amplitude transient currents typically generated during short-duration welding cycles. Performance evaluations were conducted under laboratory conditions and a real industrial AC-RSW environment. In the laboratory setup, the integrator circuit was tested with sinusoidal input signals ranging from 100 mV to 1000 mV. The results demonstrated a highly linear output response, with regression metrics of R² = 0.9965, MAE = 3.65 mV, RMSE = 4.69 mV, and MAPE = 2.88%. The system was subjected to actual welding currents between 5 and 20 kA in the second phase. The integrator’s output voltage peaks were compared with reference current measurements, yielding R² = 0.9981, MAE = 0.55 mV, RMSE = 0.63 mV, and MAPE = 1.29%, confirming its applicability in industrial conditions. The findings suggest that the proposed system offers a cost-effective, scalable, and electromagnetically robust alternative to conventional current measurement methods in AC-RSW applications. With its linear response, high measurement accuracy, and adaptability to harsh operating conditions, the developed system holds strong potential for real-time industrial current monitoring tasks.

Keywords

• Rogowski coil
• active integrator circuit
• AC resistance spot welding
• high-current sensing

Supporting Institution

This study was supported by The Scientific and Technological Research Council of Türkiye (TÜBİTAK) under the 2209-A University Students Research Projects Support Program (Project Number: 1919B012333117). The authors gratefully acknowledge TÜBİTAK for its valuable support.

Ethical Statement

There is no conflict of interest with any person/institution in the prepared article.

Thanks

The authors would also like to thank Siff Elektromekanik San. Tic. Ltd. Şti. and the Department of Electrical and Electronics Engineering for their support in the experimental studies.

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