Welding system
Welding monitoring uses connected sensors on a welding system to record temperature, voltage, current and power at connectors and cables. Maintenance teams find faults faster, even in hard-to-reach places, and operators see how welding equipment is actually used.
Welding system at a glance
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Verified projects featuring Welding system
Scalable HSE (Health Safety Environment) – through central IoT monitoring instead of additional personnel
Networked connectors for efficient troubleshooting
Welding monitoring: find faults and make usage transparent
IMS Connector Systems’ SmartMod connectors look like 4-pin M12 circular connectors but contain sensors for temperature, voltage, current and power. An integrated chip transmits the readings via Bluetooth Low Energy to a smartphone or tablet, or to gateways that integrate them into the existing control system via ProfiNet, Modbus or Ethernet. The data is also sent to the IMS cloud via cellular network. The connectors can be retrofitted and require no new wiring. For predictive maintenance, AI-Omatic’s digital maintenance assistant uses machine learning to learn normal operation and detect deviations.
The examples come from mechanical engineering and oil and gas plant construction. A typical coil welding line stretches over 120 metres, with many enclosures full of electrical components. There, the connected connectors show whether a fault lies in the connector itself or in the cable harness. An industrial technology company from the Middle East introduced 44 health and safety applications on the Cumulocity platform during the construction of offshore oil and gas facilities. One of the use cases it developed uses sensors to record the actual usage of welding equipment and assign it to specific teams.
Welding monitoring: frequently asked questions
What data does monitoring a welding system provide?
In the solution examples, monitoring a welding system provides condition data on the electrical system and usage data on the equipment. IMS Connector Systems’ SmartMod connectors measure temperature, voltage, current and power directly at the connection and detect kinked cables, damage or a missing power supply. During the construction of offshore oil and gas facilities, sensors also record the actual usage of welding equipment and assign it to teams.
How can faults be found faster on a long welding line?
Connected connectors show whether a fault lies in the connector itself or in the cable harness between two end points. A typical coil welding line stretches over 120 metres, with many enclosures full of electrical components, so manual troubleshooting is very time-consuming. The SmartMod connectors can be retrofitted and need no new wiring. Broken cables or torn-off connectors are detected immediately, and maintenance technicians complete their diagnosis faster.
How can a coil welding line be protected against unplanned downtime?
A coil welding line can be protected with predictive maintenance that detects faults before they lead to downtime. IMS Connector Systems combines its smart connectors with AI-Omatic’s digital maintenance assistant, which monitors machines automatically and unattended. Using machine learning, the system captures normal operation and recognises from minimal deviations when a fault is developing. According to the provider, only a brief data alignment is needed beforehand.
How does fleet management for welding equipment work?
Fleet management for welding equipment uses sensors to record when and by whom each device is actually used. An industrial technology company from the Middle East has developed such a use case on the Cumulocity platform: the data is assigned to specific teams, and customers get an overview of usage patterns. The company expects this to improve how machines are distributed and allocated and to reduce waste.
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