Quality monitoring of resistance spot welding based on digital twin

As an important means to realize intelligent manufacturing, digital twin is a digital expression of physical entities, which realizes virtual-real interaction and iterative optimization of product design and manufacturing by constructing a bridge of information mapping between the physical world and the virtual world. Resistance spot welding technology is widely used in automotive manufacturing, aerospace and other fields as a spot linking process for the manufacture of thin sheet structures. Resistance spot welding is a highly nonlinear coupled process, and physical models make it difficult to accurately monitor its quality. This paper takes 2219/5A06 aluminum plates with different thicknesses as the object, and applies digital twin technology to the welding process monitoring of aluminum plates to effectively improve the quality and efficiency of aluminum plate welding. In order to break through the key technologies such as information interaction in the digital twin system, a data acquisition system for resistance spot welding process is established and a real-time data processing technology based on wavelet threshold analysis is proposed. Based on the real-time data, the processed process parameters are tested in Digital-twin space to verify the feasibility of the solution. Feedback process parameters to physical entities to enable online quality monitoring of resistance spot welding and promote product quality stability during production.