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 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.