Resistance spot welding (RSW) faces critical monitoring challenges in industrial applications due to nonlinear coupling characteristics and production line disturbances. This study developed a Zigbee-enabled real-time monitoring system to address the precision limitations of conventional methods in tracking RSW parameters. Using DP780/DP590 dual-phase steel specimens with thickness variations, we implemented a dedicated data acquisition system capturing welding current, voltage, and barometric pressure dynamics. The experimental results demonstrated measurement accuracies within ±0.49% for current, ±0.25% for voltage, and 3.72% average relative error for barometric pressure with stable operational deviations (0.017–0.024 MPa).
