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Research on an Online Intelligent Monitoring System for Resistance Spot Welding Based on Wireless Communication
Shuwan Cui1, Xuan Zhou1, Baoyan Zhang2
1School of Mechanical and Automotive Engineering, Guangxi University of Science and Technology, Liuzhou 545006, China.
Abstract:
Resistance spot welding (RSW) faces critical monitoring challenges in industrial applications due to nonlinear coupling characteristics and production line disturbances. This study developed a Zigbee-enabled real-time monitoring system to address the precision limitations of conventional methods in tracking RSW parameters. Using DP780/DP590 dual-phase steel specimens with thickness variations, we implemented a dedicated data acquisition system capturing welding current, voltage, and barometric pressure dynamics. The experimental results demonstrated measurement accuracies within ±0.49% for current, ±0.25% for voltage, and 3.72% average relative error for barometric pressure with stable operational deviations (0.017-0.024 MPa).
