Customization: Dual Open Arc and Inspection Camera Systems

The customer wanted a dual camera system combining a MeltView® DART2 for monitoring the gas metal arc welding (GMAW) process and a cost-effective inspection camera for post-weld inspection of the weld bead surface.

MeltTools Customization

After listening to our customer and understanding their specifications, we reconfigured our standard PXCC1 electronics to provide power and control for both the DART2 and the additional inspection camera, known as the PROWatch camera. We employed an off-the-shelf M12 cable to transmit all signals to a custom-made junction box. We also customized PCBs in the junction box to distribute the necessary control signals, camera power, and LED power, while simultaneously transmitting the video feeds to a dual monitor setup.

Feedback and Design Changes

Following the receipt of the first article, the customer requested several changes. We redesigned the inspection camera interconnect on the junction box so it could be disconnected and extended the cable length. It's important to note that there are some limitations to cable lengths in this configuration, but we've utilized readily available off-the-shelf cables.

Product name Qty
MeltView® DART2 camera        1
X-coded cable        1
PROWatch camera        1
X-coded compact camera controller        1
Junction box        1
Power/control cable        1
Video cable        2
Dual monitor        1

Benefits to customer

  • Low cost customerized system
  • Simple direct-to-monitor welding and inspection cameras
  • High image quality
  • (Mostly) off the shelf cables

Want to learn more about our products or our customization capabilities? Fill out our Contact Us Form or Schedule a Meeting with our MeltTools team.

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