Welding Monitoring Systems

RoboCenter is a browser-based real-time monitoring platform for industrial welding systems. It receives MQTT telemetry data from multiple welding power sources — including MIGAL.CO Sensorboxes and Fronius TPS/i machines — and displays live process parameters such as current, voltage, gas flow, and wire feed speed in an interactive web dashboard. All measurements are persisted in an InfluxDB time-series database for historical analysis with configurable aggregation and zoom-to-reload charting. The platform features automatic device discovery, online/offline detection, welding state recognition, and source-specific detail panels. Deployed as a set of Docker containers with automated CI/CD builds, RoboCenter provides a manufacturer-agnostic monitoring solution that can be extended to additional welding equipment through its modular MQTT bridge architecture.

The Wiresensor MWS-2 is a reference-based wire feed monitor for robotic GMAW that catches wire-feed slip before it turns into a weld defect. Welding power sources can't see slip: they infer feed speed from the drive motor's rotation, so a slipping wire and a perfectly fed one look identical to the machine. The MWS-2 instead measures the true wire movement directly — with a slip-free two-roller encoder — and compares every part against the recorded signal of a verified good part: the "golden part" principle. No bus integration, no manufacturer lock-in. One retrofittable sensor and a compact edge box run segmentation, envelope comparison, statistics, and a browser dashboard entirely on board. It monitors 100 % of production, raises alarms with exact part-and-weld reference, flags creeping roll wear early, and streams timestamped speed and wire-length data via MQTT — or works fully standalone.

The Wiresensor MWS-3 combines the slip-free wire speed measurement of the MWS-2 with a 7-inch touch display at the welding cell. Operators see live wire feed speed, motor current, wire consumption and the remaining quantity in the drum or spool without any network or PC. The device logs every weld, keeps totals and history, raises six configurable alarms and drives four programmable 24 V outputs. Modbus RTU over RS-485 connects it to the PLC. The golden-part monitoring of the MWS-2 – teach-in, envelope comparison, trend warning, programs, stopwatch and simulator – is on board. Ethernet/PoE with web dashboard and MQTT is available as an option.

The Sensorbox is a compact, microcontroller-based measurement platform for capturing welding process data in industrial environments. Built around an STM32H7 dual-core architecture, it synchronously acquires welding current, voltage, shielding gas flow, and wire feed speed at high sampling rates. The device transmits data via MQTT/JSON for cloud-based monitoring and time-series storage, while a parallel UDP stream enables real-time oscilloscope-grade visualization. Additional interfaces include OPC UA for industrial system integration and a built-in web dashboard for configuration. Designed for process transparency and traceability, the Sensorbox serves as the data acquisition layer for RoboCenter and RoboScope, supporting applications from automated WPS documentation to AI-based quality analysis.