SmartWeld Solution

where welding meets IIoT 4.0

INTRODUCTION
SmartWeld Solution from eBIW enables welding intelligence through industry 4.0 IIOT that facilities customers in
achieving:
a. Increased Welding Productivity
b. Improved Welding Quality
c. Reduced Operational Cost
d. Reduced Welding Machine Downtime
FEATURES
Visibility & Monitoring
SmartWeld Solution provides visibility of all the key operational parameters vs target parameters for providing actionable
intelligence to take necessary counter measures to improve operational efficiency:

1. Machine Operational Time

2. Machine Welding Time (Arc-on time: Actual Vs Target)
3. Machine Productivity (Weld deposition: Actual Vs Target)
4. Quality Parameter Variations (Current, Voltage, Gas-flow*: Actual Vs Target)
5. Welding Cost (Actual vs Target Level)
6. Link each welders’ performance in terms of productivity and quality
7. 24x7 real-time monitoring and requisite indications and alarms of:
i. Welding Productivity,
ii. Welding Cost,
iii. Welding Quality,
iv. Welding Availability,
v. Welders’ Efficacy
vi. Machine Conditions
vii. Wear parts Conditions

Automated Alerts
Automated Specific & Customized Alerts related to parametric variations on Welding Abnormalities ensuring the free flow of
information needed by operations managers, service technicians, and welding engineers.
Root Cause Analysis
SmartWeld Solution provides deep insights on the root causes of welding abnormalities related to productivity, quality, cost,
and machine health.

Archiving
Archive the customer-specific necessary data for future actions and analyses.

Decision / Accountability
Data Trends captured from the related to different process parameters will help in decision making for the management
related to:
i. Effectiveness of the welders, training needs, and many more.
ii. Effectiveness of the machine, its reliability of performance related to quality and productivity will help in evaluating
machine efficacy, and this will help in databased shortlisting of the machine suppliers for future requirements.
iii. Effectiveness of the parameters on the productivity and quality will help in refining the parameter over a period of time to
get the best performance from the man and the machine
iv. Effectiveness of materials will help in selecting right consumables to achieve the optimum performance in terms of quality
and productivity (Brands & Types).
v. Implementation of this will help the user to convince and assure its customers regarding existence of seamless digital QAP,
which will ensure supply of consistent product without any deviation. This becomes a strong marketing tool for any
fabricator to convince its internal/external customers.
Traceability
The SmartWeld Solution will help to document all welding procedures and ensures detections of any welding deviations or
faults providing fault minimization and providing 100% traceability to the welding inspectors. This also acts as a Sales Tool for
the user to showcase their robustness to their customers.

Real-time welding reports

The dashboard has a real-time chart showing welding parameters for each welding machine which aid in the monitoring
process, especially for the supervisors:
1. Welding Voltage
2. Welding Current
3. Welding Gas-flow (optional)
4. And other welding parameters as required by the welding supervisors.
SPECIAL FEATURES
User-Friendliness
Straightforward graphical visualization of all recorded data for quick and easy analysis. This makes it possible to quickly detect
errors that develop on components over the course of several welding processes

Customization
Different Subscription models based on different customer needs with CEO/CFO/COO/etc. and Plant Manager Level KPIs

Central Server(optional)
1. Reports accessible to multiple users on their machines
2. Higher scalability and performance than desktop machines
3. Ability to store historical data
4. Historical data can enable machine learning and other analytics

Smart Connectivity
SmartWeld device is battle-tested in production use in numerous different environments with all sorts of arc welding. This
device is not limited to any specific brand, and can work with any standard welding machine brands.

Distinguishability
SmartWeld device knows when the welding arc is ignited and stopped, and can thus distinguish individual welding runs and
tally arc time be it a small tack weld of under few seconds or long mechanized weld where the arc is it lit for many minutes.
Smart Data Retention
SmartWeld device does not need to store welding parameter data on an SD card, it can store up to 1 month of data in case of
any sudden issues, and send data in near real-time to prevent any loss of data.

Smart Storage Flexibility

We have both on-premise and cloud storage flexibility.

USB & Ethernet Connectivity

We have both USB and ethernet connectivity on the device for wired transmission of the welding parameters.

Savings
Save up to 50% in production lead time by reducing idle time on weld events.

Smart Card
Smart Card for welders.

Contactless
No-contact digital support.
USER APPLICATION
WELD INPUTS
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Users

Location

Shift
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Machines

Job Config

Specification

Machine Component Tracking

Machine Report
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Shielding Gas

Filler Material

Joint Design

Welding Sequence

Welding Material
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User Filter
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User Filter

New User
Name Email

Role (Superadmin, PlantManager, StorePerson, Operator, Admin, Supervisor, MaintenancePerson)

Hierarchy Group (Location, site, block) Certificate No

Phone Number ID

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uppercase letter and one number

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Location Filter

Location Name Latitude Longitude Time zone

Delhi 28.70 77.10 India

+ Site

Site
Site Name
Site 1

+ Hierarchy Group

Hierarchy Group Name

B Block
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Shift Filter
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Shift Filter

Shift
Shift Name

Start Time

End Time

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Machine Filter
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Machine Filter

Machine Setup
IMEI No Name

Status (Active, Idle, Breakdown Pending, Breakdown in repair)

Type (Small, Medium, Large) Hierarchy Group

Configuration (Job1, Job2, Job3, etc.) Component Specification (S1, S2, etc.)

Description

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Job Config Filter

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Job Config Job Config Filter

Job Name Reference Standards

Welding Threshold

High Weld Voltage (Volt) Low Weld Voltage (Volt) High Weld Current (Amp) Low Weld Current (Amp)

High Weld Gas (Litre/Min) Low Weld Gas (Litre/Min)

Motor Threshold

High Motor Threshold (Volt) Low Motor Threshold (Volt) High Motor Current (Amp) Low Motor Current (Amp)

Heat / Temperature Threshold

Weld Heat Input Max (KJ/mm) Weld Heat Input Min (KJ/mm) Heat Sink Threshold (Celsius) Ambient Threshold (Celsius)

Temp Threshold Old (Celsius)

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Job Config Job Config Filter

Wire Speed Threshold

Wire Speed High (metre/min) Wire Speed Low (metre/min)

Travel Speed Threshold

Travel Speed Max (mm/min) Travel Speed Min (mm/min)

Miscellaneous

Event Threshold Duration (min) Part Threshold (min) Target Arc Time (Hr/shift) Target Weld Deposit (Kg/Hr)

Target Weld Cost (₹/Kg) Current Polarity (AC / DC)

Shielding Gas

Shielding Gas (SG1, SG2, etc.)

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Job Config Job Config Filter

Filler Material

Filler Material (FM1, FM2, etc.)

Welding Material

Welding Material (TIG, MIG, ASME)

Joint Design

Joint Design (JD!, JD2, etc.)

Welding Sequence

Welding Sequence (WS1, WS2, etc.)

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Specifications Filter
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Specifications Machine Component Specification Filter

Specification Name Roller Diameter (mm) Energy Cost Performance

Wire

Wire Diameter (mm) Wire Density (Kg/m3) Wire Weight Per Length (Kg/m) Wire Cost (₹/Kg)

Gas

CO2 Gas Cost (₹/litre) Argon + CO2 Cost (₹/litre)

Nozzle

Nozzle Cost (₹) Nozzle Life (Hr)

Contact

Contact Tip Cost (₹) Contact Tip Life (Hr)

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Specifications Machine Component Specification Filter

Orifice

Orifice Cost (₹) Orifice Life (₹)

Gas

CO2 Gas Cost (₹/litre) Argon + CO2 Cost (₹/litre)

Nozzle

Nozzle Cost (₹) Nozzle Life (Hr)

Contact

Contact Tip Cost (₹) Contact Tip Life (Hr)

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Filter

EDIT EDIT
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REFILL

REFILL

REFILL

Refill cleaning gel

Refill wire

Refill gas

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REFILL

REFILL

REFILL

Refill cleaning gel

Refill wire

Refill gas

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Report Filter
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Report Filter

Report Issue
Machine Name (MIG or SMAW)

Machine Status (Active, Idle, Breakdown Pending, Breakdown in repair)

Event Time

Description

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Shielding Gas Filter

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Shielding Gas Filter

Shielding Gas
Ref. Name Shielding Gas Name

Shielding Gas Group Purging Gas Name

Purging Gas Group

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Filler Material Filter

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Filler Material Filter

Filler Material
Ref. Name Trade Name

Filler Material Group Classification

Wire Diameter Wire Density

Wire Weight Per Length Cancel Save

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Joint Design Filter

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Joint Design Filter

Joint Design
Ref. Name Joint Type

Product Type Backing

Sides Throat Thickness

Torch Angle Stick Out Length

Layers Welding Position

Technique
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Welding Sequence Filter

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Welding Sequence Filter

Welding Sequence
Ref. Name Back Gouging

Welding Procedure Backing

Metal Transfer Mode Flux Designation

Joint Preparation and Cleaning Tungsten Electrode

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Welding Material Filter

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Welding Material Filter

Welding Material
Reference Specification Material Name

Grade Thickness (mm)

Diameter (mm) Material Group

Standard Delivery Condition

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USER DASHBOARD
WELD REPORTS
SUMMARY SHEET (CEO)
AVAILABILITY
PRODUCTIVITY – WELD DEPOSIT
PRODUCTIVITY – WELD ARC-ON
QUALITY – WELD DEVIATIONS
QUALITY – MACHINEWISE MONITORING
COST
PREDICTIVE INDICATIONS
WELD DEVIATION DETAILS
REALTIME REPORT (IN POWER BI)
REALTIME REPORT (IN WEB APP)
SOFTWARE ARCHITECTURE
 Rest-APIs

PostgreSQL UI Components
(Angular, NodeJS)

Storing sensor data in

PostgreSQL DB

Fetching JSON payload

from sensors over MQTT Smartweld UI Interface

Smartweld Device Sensors

Report Consumption
(Desktops, Tablets, Smartphones, etc.)

Fetching JSON payload Sending sensor data in Power BI

from sensors over MQTT Streaming Dataset

Power BI Streaming Dataset

(Temporary)
REALTIME ARCHITECTURE
IN POWER BI
Smartweld Device Sensors
Fetching JSON payload
from sensors over MQTT

Sending sensor data in Power BI

Streaming Dataset

Power BI Streaming Dataset

(Temporary)
Report Consumption
(Desktops, Tablets, Smartphones, etc.)
DEVICE FEATURES
 Weld Current Sensor

Gas Flow Sensor Weld Voltage Sensor

USB & Ethernet Wire Feed-Rate Sensor

Connectivity

Weld Speed RFID Personnel Management

2G / GPRS (optional) GPS (optional)

Wi-Fi (optional)
HARDWARE SET-UP
 Weld Machine

220V AC

400A
Wire feeder cable connector ( + )
Welding Gun
Control cable connection

Earth return cable connector ( – )

3 PIN 12 PIN 9 PIN
13-39V

Current Sensor Welding Bench

Positive Pole Welding Cable Earth return cable ( – )

Control Cable

0-24V RPM Sensor

Gas Flow Sensor

.

Welding Gun Cable

Gas Feeder Cable

Weld Gas Cylinder Weld Wire Feeder

Gas-flow Sensor

RFID Dashboard

Voltage Sensor

2G MQTT
Microcontroller Server

RPM Sensor

GPS (optional)

Ampere Sensor Application

SMART WELD DEVICE SMART WELD APP

DATA TRANSMISSION PROCESS FLOW
WELDING MACHINE 1 WELDING MACHINE 2 WELDING MACHINE 3 WPS INPUTS TO SMARTWELD APP VISUALIZATION WITH CUSTOM REPORTS

SMARTWELD DEVICE 1 SMARTWELD DEVICE 2 SMARTWELD DEVICE 3

BROKER GATEWAY AZURE IoT PLATFORM POWER BI

HARDWARE SCHEMATICS
ON-CLOUD
 WIRE FEEDER

WIRE FEEDER
MIG WELDING MIG WELDING
1 2
Welding machine SMARTWELD Current sensor Welding machine SMARTWELD Current sensor MIG WELDING x
temperature DEVICE 1 Voltage sensor temperature DEVICE 2 Voltage sensor
sensor Gas-flow sensor sensor Gas-flow sensor
Wire speed sensor Wire speed sensor
Built-in ambient RFID Automated Built-in ambient RFID Automated
temperature sensor Welder Scanner timestamp / feed temperature sensor Welder Scanner timestamp / feed

GPRS TRANSMISSION GPRS TRANSMISSION GPRS TRANSMISSION x

IoT CLOUD SERVER

Wi-Fi Router WPS INPUTS ON SMARTWELD APP Wi-Fi Router SMARTWELD REPORTS

WHERE x = TOTAL MACHINES*

HARDWARE SCHEMATICS
ON-PREMISE
 Rotary transducer (For measuring rotational speed)
Rotary transducer (For measuring rotational speed)

STB 1 STB 2

SmartWeld Trigger Button (For Joint number ) SmartWeld Trigger Button (For Joint number )

WIRE FEEDER

WIRE FEEDER
MIG WELDING MIG WELDING
1 2 MIG WELDING x
SMARTWELD Current sensor SMARTWELD Current sensor
Automated DAQ 1 DAQ 2
Automated
timestamp / feed Voltage sensor timestamp / feed Voltage sensor

Gas-flow sensor Gas-flow sensor

Built-in ambient Built-in ambient
temperature sensor Wire speed sensor temperature sensor Wire speed sensor
SET-UP 1 SET-UP 2 SET-UP x

COMPANY DBMS (OPTIONAL)

LAN HUB SMARTWELD PC ON INTRANET
WHERE x = TOTAL MACHINES*
DEVICE IMAGE
Temperature Sensor
Current Adapter Smartweld Device AC Connector
Cable

Current Adapter Device to Current Adapter

Anode Connector Sensor Connector
Connector Connector
FUTURE MILESTONES
1. Next level move from M2P to M2M for auto correction of deviations.

2. Use ML more extensively to find the root causes of outliers related to Man, Machine,
Methods, Materials with more granularity.

3. Integrate with HR/IR package to identify training needs and skill mapping.

4. Integrate Jobs with sensors like RFID et all for auto settings of WPS.

5. Integrate with ERP for JIT material & consumable planning.

COMPANY INFO
eBIW is a consortium of industry experts across many industries who share a passion for
solving business problems using data and analytics. Our leaders are practitioners with over
twenty-five years’ experience in product development, consulting and business in many of the
world’s largest firms. Our focus is to deliver leading, proven approaches for reporting,
statistical analysis, forecasting solutions and predictive analytics.

SmartWeld Solutions

Site: https://smartweld.ebiw.com/

Company: EBIW Info Analytics Pvt Ltd

Office Address: CD-271, CD Park, Salt Lake, Sector I, Kolkata – 700064 (WB), INDIA

Company site: ebiw.com

Contact number: +91-9831 410 498

 Thank You
“Everything you can imagine is real”
 eBIW
Info Analytics Pvt Ltd

CD-271, CD Park,
+91-9831410498 Salt Lake, Sector I,
ebiw.com support@ebiw.com
+91-8961474130 Kolkata – 700064
(WB), INDIA