Wiresensor MWS-1
Precise Wire Speed Measurement for Arc and Beam Welding Applications for Industry 4.0 and IoT
The MIGAL.CO Wiresensor MWS-1 is a high-precision measuring system designed for the continuous monitoring of wire feed speed in arc and beam welding processes. This compact and robust device is specifically developed for industrial use in automated welding environments.
Mechanical Design and Sensing Technology
At the core of the MWS-1 is a high-resolution incremental encoder with 600 pulses per revolution, integrated into a reliable two-roller mechanism. This mechanism ensures accurate, slip-free measurement of the wire movement and supports wire diameters ranging from 0.8 mm to 1.6 mm. The mechanical design allows for seamless integration into existing wire feeding systems without interfering with the welding process.
Communication and Configuration
Equipped with an Ethernet interface, the MWS-1 can be easily integrated into industrial networks. An intuitive web interface is built in, enabling users to configure network settings (such as IP address and DHCP options) and monitor the current wire speed in real-time using any modern web browser.
MQTT-Based Data Output
Measurement data is transmitted using the MQTT protocol, ensuring platform-independent and reliable data exchange with SCADA systems, data loggers, or cloud platforms. This makes the MWS-1 ideal for both local monitoring and distributed IoT applications.
Application Areas
The MWS-1 is perfectly suited for:
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Robotic and automated welding systems
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Process quality monitoring and documentation
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Research and development in welding technology
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Retrofit projects for digitalizing existing welding equipment
The sensor box with the microcontroller is well suited for industrial environments. It features a robust aluminum housing with connectors for network, power supply, and encoder.
Technical data
| Wire Diameter Range | 0.8 mm – 1.6 mm (larger on request) |
| Encoder Resolution | 0.114 mm, 600 pulses per revolution |
| Accuracy | 0.7 % at 10 m/min and 0.1 s sample rate |
| Interface | Ethernet (10/100 Mbit/s) |
| Data Output Protocol | MQTT (3.1.1 and 5) |
| Web Interface | For configuration and real-time display |
| Supply voltage | 9 - 12 Volts DC |
| Network | DHCP, fixed IP |
| Message frequency | 0.1 - 5 per second |
| Encryption | TLS 1.3 |
| Wire feed speed | 0 - 50 m/min |
| Dimensions of sensor box | 160 x 100 x 60 mm (LxWxH) |
| Weight of sensor box | 0.55 kg |
| Weight of encoder | |
| Protection | IP 20 |
Webinterface
MQTT-Message
JSON object with the following fields:
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timestamp: String (ISO 8601 format, UTC) – The time at which the measurement was recorded.
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m/min: Float – The wire feed speed in meters per minute at the given timestamp.
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mm: Float – The wire length in millimeters fed since the previous message.
Examples:
timestamp: "2025-05-17T10:12:00Z"
m/min: 4.54
mm: 37.83
timestamp: "2025-05-17T10:12:01Z"
m/min: 7.34
mm: 61.14
timestamp: "2025-05-17T10:12:01Z"
m/min: 6.79
mm: 56.59
timestamp: "2025-05-17T10:12:02Z"
m/min: 6.02
mm: 50.13
Scope of Delivery
Sensor box with microcontroller and connectors for Ethernet, power supply (9–12 V DC), and encoder, 12 V plug-in power supply, and PoE adapter.
Additional informations
Manual_wiresensor.pdf496 KB