Electrical Impact of Return Clamp Placement for on Onboard Electronic Equipment during Railway Carbody Welding

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This research aims to quantify the electrical impact of return clamp placement near welding points on railway carbody electronic equipment.
A numerical analysis using a Poisson equation-based potential field model and finite difference method (FDM) was established.
The study involved an idealized thin homogeneous plate model of the railway vehicle carbody to simulate electrical effects.
Proximity of the return clamp was analyzed at different distances (0.3 m and 1.0 m) to evaluate branch current and potential spread.
Moving the return clamp from 1.0 m to 0.3 m reduced equipment branch current from 0.26-0.40% to 0.07-0.10% of the welding current.
The reduction rate of branch current per equipment ranged between 65-71%, with an overall average reduction of 75.6%.
Branch current was confirmed to be less than 1% compared to welding current, validating the assumption of one-way coupling.

Evaluates the effect of return clamp placement on branch current in railway carbody welding, indicating potential improvements.

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Lee et al. (2026) studied this question.

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