Welding Data Monitoring & Analysis Made
Simple

Each company wants to be able to make the most of the resources available to
them. Often when out of turn orders are expected or a sudden surge in volume
is likely to hit after a lean patch, the first reaction is to increase capacity,
increase productivity at any cost. Usually, this hits the pockets a bit hard and
affects the usually bottom line. There isn’t enough time to think about and
know for sure if we are using the resources we have to the hilt. More often the
case is lack of enough data on the utility of resources. How much are the
machines used, how many hours did the welder actually weld on the job.
Sometimes you are doing a critical job and the customer wants to know exactly
what parameters, welding consumables have been used to do the job. How far
has the job progressed? How are you ensuring that the WPS is being followed?
What if all this data and more importantly its analysis is available on your
finger tips all the time?
First step for any of this to happen is to have the DATA in place real time or
stored for each machine, each operator. This is now easily possible to have a
DMS (Data Monitoring System) that works like a black box and sits on your
existing machines collecting data. Each time the machine is switched on it
starts accumulating the data.
In case of welding equipments, critical data such as welding parameters of
Welding Current, Welding Voltage, Wire Speed (In case of MIG / SAW) can be
easily logged against a timestamp. Additional sensors can help add Gas flow,
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Wire Speed and Welding Speed (in case of automation). This can be also
accompanied with the welder and machine data, so when the welder is about
to start the day he can login to the ‘DMS’ and enter his Name or Welder ID and
choose the welding consumable he is welding with (wire size and wire type in
case of MIG/ SAW). The DMS records at regular intervals (once / twice a
minute) the welding parameters, the welding consumable used in the weld
joint, the welder name who did the welding and if required also the job number
(part he is welding)