Real-time monitoring systems provide greater understanding of the joining process, as well as heightened quality control, traceability, feedback control, and reduction in waste. EWI offers development of real-time quality monitoring systems and an on-site monitoring service.

In developing real-time monitoring systems, we use data fusion, or the combining of multiple sensory technologies into a single system. Fusing the data together during processing takes advantage of each sensors core competency yet helps to negate the drawbacks on any single sensor. For example, laser-based profiling is combined with arc welding data to help detect welding defects as they are happening, allowing for remedial action before the weld becomes unacceptable. Ultrasonic inspection can be combined with laser-based inspection to generate a complete picture of the surface and subsurface of a weld.

We perform on-site monitoring with data acquisition (DAQ) or laser-based inspection equipment. Data acquired from various types of sensors (i.e. voltage, current, wire feed speed, travel speed, distance (LVDT), and temperature) are analyzed. The analysis helps uncover problems, provide detailed information about a process, and archive data for future use.

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