Weld Monitoring System (Bajaj)
Bajaj’s robotic welding was sampled at only 10 data points/sec, too slow to catch process issues in 2–5 second weld cycles. A custom high-speed logger now captures 3,000+ points/sec per seam for predictive maintenance.
Problem Statement
Bajaj Auto deployed 33 welding robots at SM Auto (Chakan), with 20 robots dedicated to KTM bike chassis welding. The short weld runs (2-5 seconds across 32 seam points per chassis) were being monitored at a low rate of only 10 data points per second for current and voltage. This low sampling rate made it extremely difficult to track real-time process dynamics, analyze welding behavior, or run accurate predictive maintenance models. Bajaj needed a system capable of capturing high-frequency data at 2,000-3,000 data points per second per seam and logging it locally or on a server PC.
Solution
We engineered a high-speed, two-phase Voltage and Current Welding Monitoring System (V-WMS) designed to capture DC power parameters (Peak Current: 400A, Min Current: 35A, Voltage: 24V) at an accuracy of ±5%:
Phase 1: High-Precision Data Capture Unit: Built a custom sensing unit utilizing a combination of high-capacity current transformers (0A to 1000A) and voltage sensors (0V to 100V DC power supply) linked with shielded cables for maximum noise immunity.
Phase 2: Data Logging & Storage Engine: Developed an in-house hardware logging unit powered by a 32-bit processor and a high-resolution 12-bit ADC. The unit maps specific seam numbers to current/voltage readings, streaming readable CSV files directly to local storage (onboard up to 128 GB via SD card/external SSD) and server PCs at over 3,000 data points per second.
Functionalities
High-Frequency Data Acquisition
Achieves high sampling speeds (>3,000 to 4,000 data points/sec).
Seam-Level Tracking
Automatically maps voltage and current metrics directly to individual weld seam numbers (32 seam points).
Real-Time Local & Server Storage
Streams data in structured CSV formats directly to local storage media or server PCs.
Customized Monitoring & Reporting
Offers a bespoke interface with one-click report generation for quality audits.
Shielded Signal Integrity
Uses industrial-grade, protected shielded cabling to eliminate high-frequency EMI noise in the welding shop floor environment.
Tech Stack
Layer
Technology Stack
Hardware Architecture
32-Bit Microprocessor, High-Speed 12-Bit ADC.
Sensing Equipment
0-1000A Current Sensors / Current Transformers, 0-100V DC Voltage Sensors
Storage & Connectivity
Onboard 128 GB Storage, Memory Card/External SSD, Shielded Industrial Cabling.
Impact on Client
Enhanced Process Stabilization
High-density data points enabled granular insight into short 2–5 second weld cycles, significantly reducing process variation and material loss.
Predictive Maintenance Enabler
Allowed plant engineers to detect micro-anomalies in voltage/current signatures before hardware failure occurred.
Six Sigma Integration
Provided the continuous data resolution required to maintain strict Six Sigma manufacturing quality control.
Cost Efficiency
Delivered a complete end-to-end hardware and software monitoring system within a project budget of ₹400,000.
Testimonials
"I’ve worked with the Velodynamics team for several months and know them inside out. They consistently deliver innovative solutions, prompt support, and excellent project management. If an issue ever comes up, they move fast to fix it. Their product development team is top-notch!"
Sudeep Naik
R&D Head
ZP
December 2021
