Abstract: A novel high effective welding method named DE-GMAW (double-electrode gas metal arc welding) was presented. A rapid prototyping control system for DE-GMAW real-time target based on xPC was established. A hardware experimental real-time system was built up,and software platform was designed by using Matlab/Simulink tools. Then experimental research on the characteristics and technology of welding under fuzzy control and nine-optimal control was carried out. The results show that the rapid prototyping control system has good effects,such as fast response,stable welding process,good weld forming and lower spatter.