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WELDEYE
3.1.1 How welding data is recorded
Smart Reader collects welding parameter data automatically. Every weld is recorded, and the data
is stored.
Smart Reader communicates with the welding machine via a data link, reading information such
as current, voltage, and wire feed speed. This is possible natively with some Kemppi-branded
welding machines. For other arc welding machines, an additional adapter device is needed.
The adapter has a sensor that measures the current and voltage from the poles of the welding
machine's power source.
Smart Reader knows when the welding arc is ignited and stopped, and can thus distinguish
individual welding runs and tally arc time.
Smart Reader stores welding parameter data on an SD card. After every weld run, the data is
sent to the WeldEye cloud service for analysis and reporting. In a normal situation, the welding
data is visible in WeldEye within a few seconds after welding has ended. It is not possible to see
ongoing welding in the WeldEye cloud service; the information is transmitted only after welding
has ended.
If Smart Reader is not connected to WiFi or cannot connect to the Internet, the data is kept in
the buffer/queue until network becomes available again. The SD card has enough space to store
several months' welding data (in three shifts around the clock). When network connectivity is
restored, the data is sent to WeldEye.
Smart Reader is battle-tested in production use in numerous different environments, with all sorts
of arc welding: manual, mechanized and fully automated robotic welding, including MMA, MIG,
TIG and SAW processes. Smart Reader can handle welds of all lengths, be it a small tack weld of
under a second or long mechanized weld where the arc is it lit for many hours.
Smart Reader collects the welding parameters with a resolution of 1/10th of a second (10 samples
per second). Some averaging is performed in the WeldEye cloud service to reduce the natural
jitter in weld data. It is possible to filter away starts and stops of the weld, as hot start and crater
fill mechanisms of welding machines are not compliant with WPSes.
3.1.2 Identifier database
Smart Reader can provide 100 % traceability to every weld. To do this, various identifiers are
entered to the system before welding in order to give meaning to the welding data; for example,
the person welding, the WPS, and the weld number.
The identifying data is created and managed in the WeldEye cloud service. Smart Reader receives
this information from the cloud service and matches it with the identifiers that the welder enters
manually or with barcodes.
The identifier database is synchronized from WeldEye to the Smart Reader every 15 minutes when
the device is online. In Smart Reader, the database is stored in the SD card, so Smart Reader can
be used reliably in times when network connectivity is poor. If a new barcode (for example, a new
filler batch number) is entered to the system, it becomes available in the cloud service and for all
the Smart Readers connected to the service.
The 15 minute delay in updating the identifier database means that it will take up to 15 minutes
for Smart Reader to recognize any new identifiers that are added to the WeldEye database.
3.1.3 Measurement of parameters
OPERATING MANUAL | EN
12
3.1 Smart Reader operating principle
©
KEMPPI | 2017-12-22
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