Intelligent Sensor Software for Robust and Energy-Sustainable Decision-Making in Welding of Steel Reinforcement for Concrete

Abstract

In today’s industrial landscape, optimizing energy consumption, reducing production times, and maintaining quality standards are critical challenges, particularly in energy-intensive processes like resistance spot welding (RSW). This study introduces an intelligent decision support system designed to optimize the RSW process for steel reinforcement bars. By creating robust machine learning models trained on limited datasets, the system generates interactive heat maps that provide real-time guidance to production engineers or intelligent systems, enabling dynamic adaptation to changing conditions and external factors such as fluctuating energy costs. These heat maps serve as a flexible and intuitive tool for identifying robust operational points that balance quality, energy efficiency, and productivity. The proposed methodology advances decision-making in welding processes by combining robust predictive modeling with innovative visualization techniques, offering a versatile solution for multiobjective optimization in real-world industrial applications.