Rashidi Asari

Perusahaan Otomobil Nasional Sdn Bhd (Tanjung Malim) · Welding Shop

The presentation slide presents the basic equation of spot welding, welding block diagram for simulation & weldability lobe (process window) according to ISO 14327:2004(E)

The slides present an overview of smart manufacturing system including IR 4.0 assessment & adoption, modern automation protocol & system architecture, and robot application in automotive welding shop.

A review of automotive joining technology trend towards cyber physical system. The slides also discuss about case study of welding simulation and adaptive welding control system that currently been implemented in automotive welding shop

The process window simulation that applied to spot welding, MIG welding and drawn arc stud welding processes in automotive welding shop. The main purpose is to optimized welding parameters setting before real implementation at production line

This paper evaluate the readiness of automotive welding shop for IR 4.0 adoption. It includes self evaluation, gap analysis and comparison between 3 welding plant. Based on analysis, system or equipment upgrading proposal is established.

In modern manufacturing practice, energy consumption is getting more and more concern by automotive car manufacturers due to the constantly increasing energy cost and to the ecological burden related to the energy production and use. The great use of electrical energy for industrial operations is responsible for significant CO2 emissions and thus,...

Spot welding process window simulator is developed using Microsoft Excel, generated using simple mathematical modelling formulated from from various experiments conducted at line side. This simulator is intended for engineers / welding technicians to simulate the impact on output (nugget diameter) when varying several process inputs. Also can be us...

This video shows how process window simulator for drawn arc stud welding works, by entering or varying several inputs to estimate the final output (destructive torque value)

Experimental study of drawn arc stud welding process parameters impact on strength against various steel sheet panel thickness and stud's coating

In automotive manufacturing processes especially at Body Shop, industrial robots are widely used to increase productivity while maintaining desired quality standard and design specification in production line. The application are mainly on welding (spot / arc welding), sealant / adhesive application and material handling. Therefore, the selection o...

A simple mathematical modelling to develop resistance spot welding - process parameter (weldability lobe) simulation using 'steady state' dynamic resistance approximation. This graphical weldability lobe is used to ease engineers and technicians to select the optimized welding parameters that suit with sheet metal and equipment to be used at produc...

The development of mathematical modelling and graphical tool for welding engineers & technicians to select the optimized welding parameters that suit with sheet metal and equipment to be used at production line side

In automotive manufacturing processes especially at Body Shop, industrial robots are widely used to increase productivity while maintaining desired quality standard and design specification in production line. Aligned with industry 4.0 revolution, production line is also equipped with cyber physical system in order to achieve smart and adaptive fac...

This article shows the impact of welding transformer and electrode tip on weld nugget formation in resistance spot welding (RSW). The impact is shown in weldability lobe, a graphic that represent the acceptable welding parameters set that may results in acceptable weld quality. Understanding of welding equipment and its system is the key for weldin...

A financial approach in evaluating & selecting industrial robot brand to be used in automotive body assembly processes

Process equipment upgrade study and proposal towards adaptive & smart manufacturing system in automotive body assembly shop

This article shows the relationship and impact of spot welding process parameters - weld force, weld current & weld time in weld nugget formation in automotive body manufacturing.

This article shows the relationship between spot welding parameters namely weld force, weld current and weld time & how they are inter related in weld nugget formation. Graphical lobe curve is used as presentation for better understanding. Lobe curve is very useful especially in spot welding process parameters optimization.

In spot welding process, process parameters optimization means improve spot welding quality while reduce operational cost especially power consumption and welding consumables. Lobe curve generators may assist welding engineers and technicians to select the best welding parameters according to their requirements.

The article shows the comparison of energy efficiency - types of welding machine versus electrode tip material composition since the energy efficiency may greatly impact to the welding process window / weldability Lobe, resulting to lower operational cost (utilities & consumables) & enhance welding quality

Spot welding process window simulation is graphically represent the range of acceptable welding parameters set (welding current, force & weld time) that may result in acceptable weld quality (nugget diameter)

Automated guided vehicle (AGV) is widely used in industries as parts / material handling at warehouse, or from warehouse to production assembly line. In this project, the AGV is designed to potentially replace traditional factory's conveyor, whether floor or overhead conveyor. The main advantages of AGV as conveyor are path flexibility - easy to pr...

A comparison of 3 different welding processes in term of equipment & operational cost

A comparison using simulation (mathematical modelling) to study the impact of weldability lobe in spot welding process

In low production volume body assembly line (low automation level), manual quality confirmation is done through various methods such as quality gate / check point (QC final check) or self check (workers confirm their own product quality after process complete). However, the disadvantages of quality gate are too many check points & defective parts /...

Current stepper method is a technique to compensate electrode tip worn out during spot welding process. This method may reduce spatter produced during welding process while prolong electrode tip life span (cost reduction)