Wiresensor

2 — Welds detect themselves

No wiring to the robot is needed: the wire only moves while welding, so welds are detected directly from the wire signal. Weld 1, weld 2, … weld n — each one is checked against its own reference, 20 and more welds per part are no problem. Wire inching and burn-back retract are filtered out. Optionally, a start signal from the PLC (24 V digital input) or an MQTT message makes the assignment fully deterministic.

3 — Monitor every part in production

The dashboard shows the live signal on top of the taught envelope: green inside the band, red outside. Next to it, the status of every weld of the current part.

• Envelope comparison — if the speed leaves the tolerance band for longer than an adjustable time, the weld is NOK and an alarm fires with exact part, weld, time and maximum deviation.

• Alarm output — a 24 V output in fail-safe logic (energised = OK) stops the line or switches a signal lamp; a second output signals “monitoring active”. Acknowledge in the browser, via MQTT or at the machine.

• Sensor check — if the wire stands still during a weld, a separate “check sensor/wire” fault is raised, clearly distinguished from slip.

4 — Early warning instead of rejects

Slip rarely starts with a bang. Worn rolls first show up as a rising scatter of the wire speed within a weld. The MWS-2 tracks mean, standard deviation and wire length of every weld across parts and warns as soon as the scatter rises significantly above the taught level — while the parts are still good. This makes it a wear indicator for drive rolls and liners at the same time: plan the maintenance instead of stopping the line.

5 — Full traceability

Every event — weld OK/NOK, part result, alarm, trend warning, acknowledgement, program change — is logged with part number, weld, deviation and timestamp, together with the weld statistics of every part. The archive is stored on a microSD card in the box, day by day. In the dashboard you filter it by date and time and download it as a CSV file for your quality records — ready for Excel. Timestamps come from a battery-backed real-time clock, synchronised via NTP.

You don't have to use the monitoring intelligence at all. The MWS-2 is just as much at home as a simple, precise wire speed gauge: mount the sensor, connect the box, subscribe to the MQTT topic — done. Every message contains a timestamp, the true wire speed in m/min and the fed wire length, at a rate of up to 10 messages per second.

In the browser, the live view shows speed, total wire length and the signal of the last 60 seconds — no teach-in, no configuration. The wire counter is battery-backed and survives a power failure.

Ideal for process development, welding labs, machine builders and data acquisition projects: for everyone who needs trustworthy wire feed data in their MES, database or test setup without building a measuring chain themselves. Start with the measurement today — the full reference monitoring is already on board whenever you want to switch it on.

Know what is left on the spool or drum

Enter wire diameter, material and net weight of the package — the MWS-2 calculates the remaining quantity from the measured wire length, in kilograms, percent and metres. Below an adjustable threshold it warns in the dashboard, logs the event, publishes it via MQTT and switches a 24 V output — so the next drum is ready before the robot runs dry. One click on “New package” starts the count again, also for partly used packages. The consumption is stored battery-backed and survives a power failure.

Stopwatch: weld time, arc time and wire per part

For welding procedure specifications, cost calculation and documentation: press START, weld the part, press STOP. The MWS-2 measures the total time, the arc time (wire running), the wire length and wire weight and the resulting duty cycle — measured in the box in 20 ms steps, independent of the browser. On STOP, the values are written to the archive; one click copies them for your report.

Built-in simulator for demonstrations and training

The complete workflow can be shown without a welding cell: the simulator generates welding cycles with a selectable number of welds. Teach them in, activate the reference, start the monitoring — and then switch on “with faults and trend”: one weld becomes increasingly unsteady until the trend warning appears, and every fifth part slips and triggers an alarm. A clear “SIMULATOR” label ensures that nobody confuses the demo with real data.

Built for the shop floor

• Firmware update in the browser — select the file, done. The new firmware is checked line by line and verified completely before it is activated; an interrupted upload changes nothing.

• Self-monitoring — a hardware watchdog restarts the box if anything hangs; afterwards it continues monitoring with the last active program automatically.

• Settings in the browser — network (fixed IP or DHCP), MQTT broker, time synchronisation, calibration and admin password. Viewing is open to everyone, changes require the admin login.