The trend of using technology in the industrial sector is increasing. The revolution of Industry 4.0 is becoming the most crucial part of the welding industry too.
Data collection in the welding industry using digital mediums refers to technologies used for data processing. The following blog offers an overview of the applications and the benefits of data collection in welding technology.
The role of data monitoring and collection in the welding industry
The welding industry process involves two significant concepts. Process data collection includes the data collection or analysis of welding arc for burn through or lack of gas. The second and the foremost important step is production data collection, which includes data as arc time and how many welds are being made in the time frame.
Since the inception of the manufacturing era and automation, welding process management entities are continuously working to collect more data points to understand the overall production efficiency. The modern weld monitoring products create a weld record for every single weld made on every machine throughout the machine shop. That weld data informs the weld fabricators of the comparison with the time of day. It also collects voltage, current, arc duration, wire feed rates, and weld energy, as well as high and low values for all of those parameters.
Time wasted with less productivity can not be tolerated in the welding industry. Welding Contractors, manufacturers, and engineering firms constantly find out the technology to improve the quality process and cost expenditure.
However, the proper solutions also require a willingness to adapt to certain advancements such as weld data monitoring sensors and equipment. Making this implementation can deliver benefits — and savings — to help a company reach its annual productivity goals.
How can the New Data Monitoring Technology Help?
New welding power sources and weld counter-like integrations can quickly calculate the correct information— improving the ability to control the welding jobs every day. By understanding this information, directing the arc energy becomes easy and effective. A stable, more consistent arc is also achieved, resulting in improved weld quality and less time-consuming and costly rework.
Advancements in data measuring technology and welding arc control also offer numerous benefits, particularly in Jobsite applications. With automated weld counter and data monitoring solutions on the market, operators have complete control of welding parameters at the weld joint. This results in delivering more weld jobs in less time and achieve higher efficiency and productivity.
Other welding equipment technology advancements, such as data communications and HMIs, natural human touch interfaces, have made the welding process more intuitive and easier to use, impacting productivity by reducing the time spent on machine setup and changeover.
Advantages of weld monitoring and why it is crucial for businesses?
Automated data monitoring for the manufacturing industry isn’t a new concept. But implementing these becomes a new normal for the businesses to achieve the highest quality work and stay competitive.
Integrating the complete welding process and operation using a data-centered approach can help companies optimize production, produce higher-quality parts, and control production costs. Tracking and analyzing weld data plays a crucial role in this process.
Here are some advantages of Weld Data Monitoring:
Many more prominent manufacturers know the value of an integrated, holistic approach, and they often have the right technology to implement a full-scale welding process. But usage of weld monitoring devices and sensors can also deliver benefits to small- and medium-sized businesses that have the personnel to implement it.
The data monitoring in the welding process gives an advantage of:
- Complete planning of weld process from scratch
- Get accurate weld data with real-time information change.
- Reduced cost per weld job with the accurate welding process
- Get the correct information for future job predictions and time-efficient parameters. This helps ensure fewer errors and rework, which saves time and money.
- Having past data also makes it easier to determine the root cause of the welding problem and where the improvements can be made.
What’s the Bottom Line?
Welding technology advancement and data monitoring features have evolved to provide real-time data with control on productivity and efficiency.
The new era of a modern understanding of the weld process data ensures the potential productivity gains offered by advanced welding processes. It also helps an organization ensure that jobs are completed on time — and budget.