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 MWS-1 Wire Sensor is a high-precision measurement system for continuous monitoring of wire feed speed in arc and beam welding processes. Utilizing a dual-roller encoder with 600 impulses per revolution, the sensor achieves an accuracy of 0.7% at 10 m/min and supports wire diameters from 0.8 to 1.6 mm. An integrated Ethernet interface with MQTT-based data output enables direct integration into SCADA systems and IoT platforms, with TLS 1.3 encryption for secure communication. With its compact aluminum housing and a built-in web interface for configuration and live monitoring, the MWS-1 is designed for robotic welding cells, process quality documentation, and retrofit digitalization of existing welding equipment.

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.