Electromagnetic modelling of resistance spot welding system

In this study the modeling of a resistance spot welding (RSW) system is described. The numerical field solution based on the 3D finite formulation allows the calculation of the equivalent circuit parameters, with particular attention to the resistance of each part, and allow the estimation of external magnetic fields. Determining the equivalent circuit is crucial for the efficiency of the RSW, and assessing environmental field pollution is essential for protecting humans and equipment. Two different resistance spot welding operating conditions, AC and DC, are examined. To validate the proposed method, some experimental analyses are conducted on some parts of the RSW system and numerical and experimental results are compared.