Search results for: process control systems

Authors: Christopher C. Ihueze, Constance C. Obiuto, Christian E. Okafor, Charles C. Okpala

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This paper presents a methodical approach for designing and optimizing process parameters in oil blending industries. Twenty seven replicated experiments were conducted for production of A-Z crown super oil (SAE20W/50) employing L9 orthogonal array to establish process response parameters. Power law model was fitted to experimental data and the obtained model was optimized applying the central composite design (CCD) of response surface methodology (RSM). Quadratic model was found to be significant for production of A-Z crown supper oil. The study recognized and specified four new lubricant formulations that conform to ISO oil standard in the course of analyzing the batch productions of A-Z crown supper oil as: L1: KV = 21.8293Cst, BS200 = 9430.00Litres, Ad102=11024.00Litres, PVI = 2520 Litres, L2: KV = 22.513Cst, BS200 = 12430.00 Litres, Ad102 = 11024.00 Litres, PVI = 2520 Litres, L3: KV = 22.1671Cst, BS200 = 9430.00 Litres, Ad102 = 10481.00 Litres, PVI= 2520 Litres, L4: KV = 22.8605Cst, BS200 = 12430.00 Litres, Ad102 = 10481.00 Litres, PVI = 2520 Litres. The analysis of variance showed that quadratic model is significant for kinematic viscosity production while the R-sq value statistic of 0.99936 showed that the variation of kinematic viscosity is due to its relationship with the control factors. This study therefore resulted to appropriate blending proportions of lubricants base oil and additives and recommends the optimal kinematic viscosity of A-Z crown super oil (SAE20W/50) to be 22.86Cst.

Keywords: Additives, control factors, kinematic viscosity, lubricant, orthogonal array, process parameter.

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Authors: Andrey V. Timofeev

Abstract:

This paper introduces an original method for guaranteed estimation of the accuracy for an ensemble of Lipschitz classifiers. The solution was obtained as a finite closed set of alternative hypotheses, which contains an object of classification with probability of not less than the specified value. Thus, the classification is represented by a set of hypothetical classes. In this case, the smaller the cardinality of the discrete set of hypothetical classes is, the higher is the classification accuracy. Experiments have shown that if cardinality of the classifiers ensemble is increased then the cardinality of this set of hypothetical classes is reduced. The problem of the guaranteed estimation of the accuracy for an ensemble of Lipschitz classifiers is relevant in multichannel classification of target events in C-OTDR monitoring systems. Results of suggested approach practical usage to accuracy control in C-OTDR monitoring systems are present.

Keywords: Lipschitz classifiers, confidence set, C-OTDR monitoring, classifiers accuracy, classifiers ensemble.

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Authors: Hadi Adibi-Asl, Alireza Doosthosseini, Amir Taghavipour

Abstract:

This paper studies the design of an adaptive control strategy to tune an active steering system for better drivability and maneuverability. In the first step, adaptive control strategy is applied to estimate the uncertain parameters on-line (e.g. cornering stiffness), then the estimated parameters are fed into the pole placement controller to generate corrective feedback gain to improve the steering system dynamic’s characteristics. The simulations are evaluated for three types of road conditions (dry, wet, and icy), and the performance of the adaptive pole placement control (APPC) are compared with pole placement control (PPC) and a passive system. The results show that the APPC strategy significantly improves the yaw rate and side slip angle of a bicycle plant model.

Keywords: Adaptive control, active steering, pole placement, vehicle dynamics.

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Authors: P. Abhishesh, B. S. Ryuh, Y. S. Oh, H. J. Moon, R. Akanksha

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This paper discusses about the conceptual design and development of the control system software using Programmable logic controller (PLC) for autonomous driving and agricultural operations of Multipurpose Agricultural Robot Platform (MARP). Based on given initial conditions by field analysis and desired agricultural operations, the structural design development of MARP is done using modelling and analysis tool. PLC, being robust and easy to use, has been used to design the autonomous control system of robot platform for desired parameters. The robot is capable of performing autonomous driving and three automatic agricultural operations, viz. hilling, mulching, and sowing of seeds in the respective order. The input received from various sensors on the field is later transmitted to the controller via ZigBee network to make the changes in the control program to get desired field output. The research is conducted to provide assistance to farmers by reducing labor hours for agricultural activities by implementing automation. This study will provide an alternative to the existing systems with machineries attached behind tractors and rigorous manual operations on agricultural field at effective cost.

Keywords: Agricultural operations, autonomous driving, MARP, PLC.

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Authors: Mykola S. Shestavin

Abstract:

A strategy for the creation of a Virtual Interactive Platform (or Networking Platform) to combine the four web-baseness of expert systems on the transfer and diffusion of low-carbon technologies. It used the concept of “Open Innovation” and “Triple Helix” with regard to theories of “Green Growth” and “Carbon Footprint”. Interpreters expert systems operate on the basis of models of the “Predator-Prey” for the process of transfer and diffusion of technologies, taking into account the features caused by the need to mitigate the effects of climate change.

Keywords: Climate Change, Expert Systems, Low-Carbon Technology, Open Innovation, Virtual Interactive Platform.

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Authors: Debabrata Pradhan, Dong J. Kim, Jong G. Ahn, Seoung W. Lee

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Spent petroleum catalyst from Korean petrochemical industry contains trace amount of metals such as Ni, V and Mo. Therefore an attempt was made to recover those trace metal using bioleaching process. Different leaching parameters such as Fe(II) concentration, pulp density, pH, temperature and particle size of spent catalyst particle were studied to evaluate their effects on the leaching efficiency. All the three metal ions like Ni, V and Mo followed dual kinetics, i.e., initial faster followed by slower rate. The percentage of leaching efficiency of Ni and V were higher than Mo. The leaching process followed a diffusion controlled model and the product layer was observed to be impervious due to formation of ammonium jarosite (NH4)Fe3(SO4)2(OH)6. In addition, the lower leaching efficiency of Mo was observed due to a hydrophobic coating of elemental sulfur over Mo matrix in the spent catalyst.

Keywords: Bioleaching, diffusion control, shrinking core, spentpetroleum catalyst.

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Authors: T Rusu, P I Moraru, I Bogdan, A I Pop, M L Sopterean

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The paper presents the influence of the conventional ploughing tillage technology in comparison with the minimum tillage, upon the soil properties, weed control and yield in the case of maize (Zea mays L.), soya-bean (Glycine hispida L.) and winter wheat (Triticum aestivum L.) in a three years crop rotation. A research has been conducted at the University of Agricultural Sciences and Veterinary Medicine Cluj-Napoca, Romania. The use of minimum soil tillage systems within a three years rotation: maize, soya-bean, wheat favorites the rise of the aggregates hydro stability with 5.6-7.5% on a 0-20 cm depth and 5-11% on 20-30 cm depth. The minimum soil tillage systems – paraplow, chisel or rotary grape – are polyvalent alternatives for basic preparation, germination bed preparation and sowing, for fields and crops with moderate loose requirements being optimized technologies for: soil natural fertility activation and rationalization, reduction of erosion, increasing the accumulation capacity for water and realization of sowing in the optimal period. The soil tillage system influences the productivity elements of cultivated species and finally the productions thus obtained. Thus, related to conventional working system, the productions registered in minimum tillage working represented 89- 97% in maize, 103-112% in soya-bean, 93-99% in winter-wheat. The results of investigations showed that the yield is a conclusion soil tillage systems influence on soil properties, plant density assurance and on weed control. Under minimum tillage systems in the case of winter weat as an option for replacing classic ploughing, the best results in terms of quality indices were obtained from version worked with paraplow, followed by rotary harrow and chisel. At variants worked with paraplow were obtained quality indices close to those of the variant worked with plow, and protein and gluten content was even higher. At Ariesan variety, highest protein content, 12.50% and gluten, 28.6% was obtained for the variant paraplow.

Keywords: Minimum tillage, soil properties, yields quality.

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Authors: Ali Akbar Sadat Asl

Abstract:

Diagnosis and deciding about diseases in medical fields is facing innate uncertainty which can affect the whole process of treatment. This decision is made based on expert knowledge and the way in which an expert interprets the patient's condition, and the interpretation of the various experts from the patient's condition may be different. Fuzzy logic can provide mathematical modeling for many concepts, variables, and systems that are unclear and ambiguous and also it can provide a framework for reasoning, inference, control, and decision making in conditions of uncertainty. In systems with high uncertainty and high complexity, fuzzy logic is a suitable method for modeling. In this paper, we use type-2 fuzzy logic for uncertainty modeling that is in diagnosis of leukemia. The proposed system uses an indirect-direct approach and consists of two stages: In the first stage, the inference of blood test state is determined. In this step, we use an indirect approach where the rules are extracted automatically by implementing a clustering approach. In the second stage, signs of leukemia, duration of disease until its progress and the output of the first stage are combined and the final diagnosis of the system is obtained. In this stage, the system uses a direct approach and final diagnosis is determined by the expert. The obtained results show that the type-2 fuzzy expert system can diagnose leukemia with the average accuracy about 97%.

Keywords: Expert system, leukemia, medical diagnosis, type-2 fuzzy logic.

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Authors: Sanda Win, Tin Shein, Khin Maung Latt

Abstract:

This document describes an electronic speed control designed to drive two DC motors from a 6 V battery pack to be controlled by a commercial universal infrared remote control hand set. Conceived for a tank-like vehicle, one motor drives the left side wheels or tracks and the other motor drives the right side. As it is shown here, there is a left-right steering input and a forward– backward throttles input, like would be used on a model car. It is designed using a microcontroller PIC16F873A.

Keywords: Assembly Language, Direction Control, SpeedControl, PIC 16F 873A

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Authors: Nooshin Salari, Viliam Makis

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In this paper, we propose a condition-based maintenance policy for multi-unit systems considering the existence of economic dependency among units. We consider a system composed of N identical units, where each unit deteriorates independently. Deterioration process of each unit is modeled as a three-state continuous time homogeneous Markov chain with two working states and a failure state. The average production rate of units varies in different working states and demand rate of the system is constant. Units are inspected at equidistant time epochs, and decision regarding performing maintenance is determined by the number of units in the failure state. If the total number of units in the failure state exceeds a critical level, maintenance is initiated, where units in failed state are replaced correctively and deteriorated state units are maintained preventively. Our objective is to determine the optimal number of failed units to initiate maintenance minimizing the long run expected average cost per unit time. The problem is formulated and solved in the semi-Markov decision process (SMDP) framework. A numerical example is developed to demonstrate the proposed policy and the comparison with the corrective maintenance policy is presented.

Keywords: Reliability, production, maintenance optimization, Semi-Markov Decision Process.

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Authors: Daniel Siahaan, Aditya Prapanca

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The emerging Semantic Web has been attracted many researchers and developers. New applications have been developed on top of Semantic Web and many supporting tools introduced to improve its software development process. Metadata modeling is one of development process where supporting tools exists. The existing tools are lack of readability and easiness for a domain knowledge expert to graphically models a problem in semantic model. In this paper, a metadata modeling tool called RDFGraph is proposed. This tool is meant to solve those problems. RDFGraph is also designed to work with modern database management systems that support RDF and to improve the performance of the query execution process. The testing result shows that the rules used in RDFGraph follows the W3C standard and the graphical model produced in this tool is properly translated and correct.

Keywords: CASE tool, data modeling, semantic web

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Authors: K. Liagkouras, K. Metaxiotis

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Customer relationship management (CRM) systems in business are a reality of the contemporary business world for the last decade or so. Still, there are grey areas regarding the successful implementation and operation of CRM systems in business. This paper, through the systematic study of the CRM implementation paradigm, attempts to identify the most important challenges and opportunities that the CRM systems face in a rapidly changing business world.

Keywords: Customer Relationship Management, CRM, Business, Information Systems.

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Authors: Fayssal Amrane, Azeddine Chaiba

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In this paper, type-2 fuzzy logic control (T2FLC) and neuro-fuzzy control (NFC) for a doubly fed induction generator (DFIG) based on direct power control (DPC) with a fixed switching frequency is proposed for wind generation application. First, a mathematical model of the doubly-fed induction generator implemented in d-q reference frame is achieved. Then, a DPC algorithm approach for controlling active and reactive power of DFIG via fixed switching frequency is incorporated using PID. The performance of T2FLC and NFC, which is based on the DPC algorithm, are investigated and compared to those obtained from the PID controller. Finally, simulation results demonstrate that the NFC is more robust, superior dynamic performance for wind power generation system applications.

Keywords: Doubly fed induction generetor, direct power control, space vector modulation, type-2 fuzzy logic control, neuro-fuzzy control, maximum power point tracking.

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Authors: A. Boualouch, A. Essadki, T. Nasser, A. Boukhriss, A. Frigui

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This paper presents a power control for a Doubly Fed Induction Generator (DFIG) using in Wind Energy Conversion System (WECS) connected to the grid. The proposed control strategy employs two nonlinear controllers, Backstipping (BSC) and slidingmode controller (SMC) scheme to directly calculate the required rotor control voltage so as to eliminate the instantaneous errors of active and reactive powers. In this paper the advantages of BSC and SMC are presented, the performance and robustness of this two controller’s strategy are compared between them. First, we present a model of wind turbine and DFIG machine, then a synthesis of the controllers and their application in the DFIG power control. Simulation results on a 1.5MW grid-connected DFIG system are provided by MATLAB/Simulink.

Keywords: Backstipping, DFIG, power control, sliding-mode, WESC.

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Authors: Sky Chou, Joseph C. Chen

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This paper focuses on using six sigma methodologies to reach the desired shrinkage of a manufactured high-density polyurethane (HDPE) part produced by the injection molding machine. It presents a case study where the correct shrinkage is required to reduce or eliminate defects and to improve the process capability index Cp and Cpk for an injection molding process. To improve this process and keep the product within specifications, the six sigma methodology, design, measure, analyze, improve, and control (DMAIC) approach, was implemented in this study. The six sigma approach was paired with the Taguchi methodology to identify the optimized processing parameters that keep the shrinkage rate within the specifications by our customer. An L9 orthogonal array was applied in the Taguchi experimental design, with four controllable factors and one non-controllable/noise factor. The four controllable factors identified consist of the cooling time, melt temperature, holding time, and metering stroke. The noise factor is the difference between material brand 1 and material brand 2. After the confirmation run was completed, measurements verify that the new parameter settings are optimal. With the new settings, the process capability index has improved dramatically. The purpose of this study is to show that the six sigma and Taguchi methodology can be efficiently used to determine important factors that will improve the process capability index of the injection molding process.

Keywords: Injection molding, shrinkage, six sigma, Taguchi parameter design.

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Authors: S. Carpintero, R. Barcham

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Light rail systems have proliferated in Spain in the last decade, following a tendency that is common not only in other European countries but also in other parts of the world. This paper reviews the benefits of light rail systems, both related to environmental issues and mobility issues. It analyses the evolution of light rail projects in Spain and shows that light rail systems in this country have evolved towards an extensive use of public-private partnerships. The analysis of the Spanish projects, however, does not contribute any conclusive evidence about whether public-private partnerships have been more efficient than publicly owned enterprises in building and operating light rail systems.

Keywords: Light rail systems, public-private partnerships, BOT.

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Authors: F. Habib, A. Shokoohi

Abstract:

Urban problems are problems of organized complexity. Thus, many models and scientific methods to resolve urban problems are failed. This study is concerned with proposing of a fuzzy system driven approach for classification and solving urban problems. The proposed study investigated mainly the selection of the inputs and outputs of urban systems for classification of urban problems. In this research, five categories of urban problems, respect to fuzzy system approach had been recognized: control, polytely, optimizing, open and decision making problems. Grounded Theory techniques were then applied to analyze the data and develop new solving method for each category. The findings indicate that the fuzzy system methods are powerful processes and analytic tools for helping planners to resolve urban complex problems. These tools can be successful where as others have failed because both incorporate or address uncertainty and risk; complexity and systems interacting with other systems.

Keywords: Classification, complexity, Fuzzy theory, urban problems.

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Authors: S. H. Teh, S. Malawaraarachci, W. P. Chan, A. Nassirharand

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The purpose of this paper is to present the design and instrumentation of a new benchmark multivariable nonlinear control laboratory. The mathematical model of this system may be used to test the applicability and performance of various nonlinear control procedures. The system is a two degree-of-freedom robotic arm with soft and hard (discontinuous) nonlinear terms. Two novel mechanisms are designed to allow the implementation of adjustable Coulomb friction and backlash.

Keywords: Nonlinear control, describing functions, AdjustableCoulomb friction, Adjustable backlash.

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Authors: Anselm L. Schüle, Thomas Rollmann, Reiner Anderl

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Within the collaborative research center 666 a new product development approach and the innovative manufacturing method of linear flow splitting are being developed. So far the design process is supported by 3D-CAD models utilizing User Defined Features in standard CAD-Systems. This paper now presents new functions for generating 3D-models of integral sheet metal products with bifurcations using Siemens PLM NX 6. The emphasis is placed on design and semi-automated insertion of User Defined Features. Therefore User Defined Features for both, linear flow splitting and its derivative linear bend splitting, were developed. In order to facilitate the modeling process, an application was developed that guides through the insertion process. Its usability and dialog layout adapt known standard features. The work presented here has significant implications on the quality, accurateness and efficiency of the product generation process of sheet metal products with higher order bifurcations.

Keywords: Linear Flow Splitting, CRC 666, User Defined Features.

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Authors: Sandeep Khimta, Parvinder S. Sandhu, Amanpreet Singh Brar

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The traditional software product and process metrics are neither suitable nor sufficient in measuring the complexity of software components, which ultimately is necessary for quality and productivity improvement within organizations adopting CBSE. Researchers have proposed a wide range of complexity metrics for software systems. However, these metrics are not sufficient for components and component-based system and are restricted to the module-oriented systems and object-oriented systems. In this proposed study it is proposed to find the complexity of the JavaBean Software Components as a reflection of its quality and the component can be adopted accordingly to make it more reusable. The proposed metric involves only the design issues of the component and does not consider the packaging and the deployment complexity. In this way, the software components could be kept in certain limit which in turn help in enhancing the quality and productivity.

Keywords: JavaBean Components, Complexity, Metrics, Validation.

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Authors: Debal Saha, NirmalBaranHui

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The present paper discusses the basic concepts and the underlying principles of Multi-Agent Systems (MAS) along with an interdisciplinary exploitation of these principles. It has been found that they have been utilized for lots of research and studies on various systems spanning across diverse engineering and scientific realms showing the need of development of a proper generalized framework. Such framework has been developed for the Multi-Agent Systems and it has been generalized keeping in mind the diverse areas where they find application. All the related aspects have been categorized and a general definition has been given where ever possible.

Keywords: Generalized framework, multiagent systems.

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Authors: Didier Casner, Jean Renaud, Remy Houssin, Dominique Knittel

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In this paper, a novel approach for the multidisciplinary design optimization (MDO) of complex mechatronic systems. This approach, which is a part of a global project aiming to include the MDO aspect inside an innovative design process. As a first step, the paper considers the MDO as a redesign approach which is limited to the parametric optimization. After defining and introducing the different keywords, the proposed method which is based on the V-Model which is commonly used in mechatronics.

Keywords: mechatronics, Multidisciplinary Design Optimization (MDO), multiobjective optimization, engineering design.

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Authors: C. Patrascioiu

Abstract:

The paper describes the modeling and simulation of the heat pumps domain processes. The main objective of the study is the use of the heat pump in propene–propane distillation processes. The modeling and simulation instrument is the Unisim^® Design simulator. The paper is structured in three parts: An overview of the compressing gases, the modeling and simulation of the freezing systems, and the modeling and simulation of the heat pumps. For each of these systems, there are presented the Unisim^® Design simulation diagrams, the input–output system structure and the numerical results. Future studies will consider modeling and simulation of the propene–propane distillation process with heat pump.

Keywords: Distillation, heat pump, simulation, Unisim Design.

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Authors: Ibrahim F. Jasim

Abstract:

This paper presents a new stable robust adaptive controller and observer design for a class of nonlinear systems that contain i. Coupling of unmeasured states and unknown parameters ii. Unknown dead zone at the system actuator. The system is firstly cast into a modified form in which the observer and parameter estimation become feasible. Then a stable robust adaptive controller, state observer, parameter update laws are derived that would provide global adaptive system stability and desirable performance. To validate the approach, simulation was performed to a single-link mechanical system with a dynamic friction model and unknown dead zone exists at the system actuation. Then a comparison is presented with the results when there is no dead zone at the system actuation.

Keywords: Dead Zone, Nonlinear Systems, Observer, Robust Adaptive Control.

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Authors: Lili Sun, Hua Wang

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As privacy becomes a major concern for consumers and enterprises, many research have been focused on the privacy protecting technology in recent years. In this paper, we present a comprehensive approach for usage access control based on the notion purpose. In our model, purpose information associated with a given data element specifies the intended use of the subjects and objects in the usage access control model. A key feature of our model is that it allows when an access is required, the access purpose is checked against the intended purposes for the data item. We propose an approach to represent purpose information to support access control based on purpose information. Our proposed solution relies on usage access control (UAC) models as well as the components which based on the notions of the purpose information used in subjects and objects. Finally, comparisons with related works are analyzed.

Keywords: Purpose, privacy, access control, authorization

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Authors: Abdelaziz Guerrouat, Harald Richter

Abstract:

In this paper test generation methods and appropriate fault models for testing and analysis of embedded systems described as (extended) finite state machines ((E)FSMs) are presented. Compared to simple FSMs, EFSMs specify not only the control flow but also the data flow. Thus, we define a two-level fault model to cover both aspects. The goal of this paper is to reuse well-known FSM-based test generation methods for automation of embedded system testing. These methods have been widely used in testing and validation of protocols and communicating systems. In particular, (E)FSMs-based specification and testing is more advantageous because (E)FSMs support the formal semantic of already standardised formal description techniques (FDTs) despite of their popularity in the design of hardware and software systems.

Keywords: Formal methods, testing and validation, finite state machines, formal description techniques.

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Authors: Tomas Duranik, Juraj Ruzbarsky, Markus Stopper

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CONWIP (constant work-in-process) as a pull production system have been widely studied by researchers to date. The CONWIP pull production system is an alternative to pure push and pure pull production systems. It lowers and controls inventory levels which make the throughput better, reduces production lead time, delivery reliability and utilization of work. In this article a CONWIP pull production system was simulated. It was simulated push and pull planning system. To compare these systems via a production planning system (PPS) game were adjusted parameters of each production planning system. The main target was to reduce the total WIP and achieve throughput and delivery reliability to minimum values. Data was recorded and evaluated. A future state was made for real production of plastic components and the setup of the two indicators with CONWIP pull production system which can greatly help the company to be more competitive on the market.

Keywords: CONWIP, constant work in process, delivery reliability, hybrid production planning, PPS.

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Authors: Elke Mackensen

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Systems Engineering plays a key role during industrial product development of complex technical systems. The need for systems engineers in industry is growing. But there is a gap between the industrial need and the academic education. Normally the academic education is focused on the domain specific design, implementation and testing of technical systems. Necessary systems engineering expertise like knowledge about requirements analysis, product cost estimation, management or social skills are poorly taught. Thus there is the need of new academic concepts for teaching systems engineering skills. This paper presents a project-orientated training concept to prepare students from different technical degree programs for systems engineering activities. The training concept has been initially implemented and applied in the industrial engineering master program of the University of Applied Sciences Offenburg.

Keywords: Educational systems engineering training, requirements analysis, system modelling, SysML.

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Authors: Dalyah Y. Al-Jamal, Maryam H. Eshtaiwi, Liyakathunisa Syed

Abstract:

Connecting health services with technology has a huge demand as people health situations are becoming worse day by day. In fact, engaging new technologies such as Internet of Things (IOT) into the medical services can enhance the patient care services. Specifically, patients suffering from chronic diseases such as cardiac patients need a special care and monitoring. In reality, some efforts were previously taken to automate and improve the patient monitoring systems. However, the previous efforts have some limitations and lack the real-time feature needed for chronic kind of diseases. In this paper, an improved process model for patient monitoring system specialized for cardiac patients is presented. A survey was distributed and interviews were conducted to gather the needed requirements to improve the cardiac patient monitoring system. Business Process Model and Notation (BPMN) language was used to model the proposed process. In fact, the proposed system uses the IOT Technology to assist doctors to remotely monitor and follow-up with their heart patients in real-time. In order to validate the effectiveness of the proposed solution, simulation analysis was performed using Bizagi Modeler tool. Analysis results show performance improvements in the heart monitoring process. For the future, authors suggest enhancing the proposed system to cover all the chronic diseases.

Keywords: Business process model and notation, cardiac patient, cardiac monitoring, heart monitoring, healthcare, internet of things, remote patient monitoring system, process model, telemedicine, wearable sensors.

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Authors: Jawad Saleem, Abdul Majid, Kent Bertilsson, Torbjörn Carlberg, Nazar Ul Islam

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Resistance spot welding process comprises of electric, thermal and mechanical phenomenon, which makes this process complex and highly non-linear and thus, it becomes difficult to model it. In order to obtain good weld nugget during spot welding, hit and trial welds are usually done which is very costly. Therefore the numerical simulation research has been conducted to understand the whole process. In this paper three different cases were analyzed by varying the tip contact area and it was observed that, with the variation of tip contact area the nugget formation at the faying surface is affected. The tip contact area of the welding electrode becomes large with long welding cycles. Therefore in order to maintain consistency of nugget formation during the welding process, the current compensation in control feedback is required. If the contact area of the welding electrode tip is reduced, a large amount of current flows through the faying surface, as a result of which sputtering occurs.

Keywords: Resistance spot welding, Finite element modeling, Nugget formation, Welding electrode, Numerical method simulation,

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