In this paper, a new control strategy is proposed to improve the quality of the welding products. The conventional nonlinear power control system of spot welders is linearized using nonlinear feedback linearization technique based on differential geometry theory. An evolution strategy(ES) geometry is used to find optimal gain of PI controllers. It tries to find out the optimal control parameters by imitating the natural evolution. Some Simulation and experimental results show that the proposed variable power control system using ES algorithm has better dynamic performances than the conventional one.