Tips to Monitor and Control Your Welding Systems


20th July 2022 author_smartweld Shalini Ghose

The necessity for welding monitoring and control systems has increased steadily over time. The requirement for faster, more effective, and higher-quality welding resulted in the creation and refining of welding control and monitoring techniques and systems. When changes in the parameters and established methods are recognized, a robotized welding system may require a controller to adapt the process parameters in real-time. To apply these settings, the system must be outfitted with sensors and control and monitoring systems that connect, as well as welding equipment and the robot, to offer a real-time response.
A welding automation system consists of a set of components with the capability of capturing process parameters and comparing them to average values by default, as well as modifying these characteristics in real-time as necessary. Certain welding monitoring and control system parameters must be maintained during the operation to ensure that they remain within permissible ranges. To do so, controllers incorporated into the automated system control and alter the parameters using sensors that read the parameters referrals, depending on the type of sensor, the type of parameter to measure, and the type of sensor.

Why do you need a Weld Monitor System?

A welding data monitoring system can give you the information you need to make improvements and achieve your goals. You'll be able to get more done, make higher-quality welds, and keep expenses under control, which could be limiting your company's growth.

When do you need a Weld Monitor System?

Manual data collection is time-consuming and adds to potential response times. It's also prone to mistakes. Before choices can be taken, manually gathered weld data must be combined, processed, and analyzed. Investing in a data monitoring system can solve these problems by providing a faster and more accurate way to collect data and turn it into useful information.
The decision to purchase a data monitoring system, like any other technological investment, should be carefully considered. It's critical to think about the operation's goals and the key performance indicators you want to track first.

How to Choose a Weld Monitor System?

Some businesses only need basic productivity statistics, while others require extensive process control. Other businesses can benefit from a specific combination of Insight Core and Insight Centerpoint.
When selecting a solution, consider the installation requirements, the key performance indicators you want to track, and the level of control and feedback you require. In many ways, this comparison chart is useful in comparing Insight Core versus Insight Centerpoint.
Understand some crucial do's and don'ts for establishing these systems to get the best results. Because data monitoring isn't a silver bullet for every problem in your welding shop, it's critical to keep your expectations in check.

Insight Core Suggestions:

Before making any changes to your business, make sure you have a decent baseline of data with your final goal in mind. Because there are upstream and downstream dependencies that affect your welding efficiency, don't assume that the weld station is always responsible for arc-on time. A counter intuitive strategy can sometimes produce greater outcomes. Separating tacking and welding, for example, can increase throughput since the expert welder can spend more time welding and less time fitting the parts together.

Tips from the Insight CenterPoint:

Don't dive immediately onto the component with the highest weld count. That way, you can get a taste of how the software will work best for you in a bite-sized chunk. Select a technical champion who will be responsible for part configuration and solution comprehension if you decide to apply the solution plant-wide following a successful trial. This person does not need to have a background in engineering or a designation as an engineer. Don't start with Insight Centerpoint's full control capabilities. Instead, start with easy directions or guidance and work your way up as needed. To expand on your triumphs, take a step-by-step strategy.
The primary type of sensors to monitor the welding operations of industrial awareness is a systematized way of existing information concerning welding technology monitoring and control systems.

Sensors of various types

Because each sensor is associated with a certain sort of information, the precise selection of a sensor for a given parameter is crucial for good welding process management and good results. Based on their applications, the various types of sensors available on the market and utilized in welding can be divided into three groups.
  • sensors for monitoring of Board
  • sensors for control of the arc length
  • sensors to control the welding penetration

Optical image acquisition systems

It consists of cameras, lenses, lighting sources, a personal computer, image capture plates, software, databases, I/O (input/output) plates, a PLC, a robot driver, and the robot itself. This system can be linked to a server for coordinating the welding process with other industrial operations at various phases of the production process. It is true that all objects, to some degree or another, reflect light that strikes them. The color of the item is determined by the intensity of the light, which is focused on CCD sensors (for example) by a lens system. Visible light is converted into electrical signals by these sensors. Depending on the resolution required for each application, CCD sensors can be of varying sizes. The size is smaller.

Automatic control techniques

Automatic control approaches allow the welding process to be controlled automatically, allowing the system to respond to changes in the process. Monitoring of the Board, control of the arc length, control of welding penetration, metal transfer mode control, control of the quantity of heat introduced, and final quality check (after the cord has solidified) are all examples of automatic control procedures.
Welding penetration control is one of the most critical and difficult control factors to master. To this end, certain ultrasonic-based technologies have been created, among other things. In the MIG/MAG procedure, it has been discovered that the transmission of metal can be regulated by analyzing light emissions during the separation of drops of supply threads.


The research conducted within the scope of this paper leads us to conclude that it is critical to continue research in the field of welding factor control and monitoring, sensors, and automatic control systems. New correlations between the parameters have been uncovered, and the final quality will be investigated for industrial uses. It is possible to control processes in real-time with the appropriate quality using modern electronic circuits and existing specialized technology.


Subscribe to our newsletter and be among the first to know the latest from Smartweld