High Heat: Welding operations generate high temperatures, particularly when the substrate is preheated or the process heat is contained.

Weld Slag and Spatter: Molten metal spatter and weld slag can burn through the outer jacket of ordinary cables. This slag can accumulate on sensors and cables, potentially causing them to fuse together at connection points. Removing solidified slag from sensors and cable bundles can be time-consuming and can be avoided by judicious use of cable sleeves.

Physical Stress and Movement: Automated welding often involves constant motion. If the camera is moving, so is the cable. In such scenarios, the cables should be highly flexible and resistant to fatigue from bending and flexing.

Cable Routing: It is critical to ensure that the cable is not kinked and that the minimum bend radius is not exceeded. Space constraints and complicated routes can be challenging to work with and around, particularly when the only place for the signal cable is next to the welding power cable. MeltTools offers short interconnect cables for both X and F-style systems, preventing costly downtime running new cables along tracks.

Electromagnetic (EMI) and Radio Frequency Interference (RFI): Welding equipment is a significant source of strong electromagnetic interference that can negatively impact signal integrity in nearby cables. MeltTools offers additional methods to solve these problems; please contact us.

Long Distances: The distance from the weld to a safe monitoring location may exceed the distance that a particular cable technology can deliver.

Harsh Environment: Other factors worth considering in a welding environment include potential cuts, abrasions, moisture, oils, chemicals, ozone and sunlight, all of which can lead to cable damage and failure.

X-coded cables are a standardized solution for transmitting signals and power in industrial environments. X-coded cables are ideal for MeltView® direct-display camera solutions at distances up to 30m (98ft) in 5m increments.

The X-coded cables offered by MeltTools are kept on-the-shelf in our standard grades and lengths. They are also quick to obtain from electronic and industrial distributors, particularly in shorter lengths. X-coded cables are offered with drag chain properties, different jacket materials and occasionally with right angle connectors. However with right angle cables, different manufacturers may orient the cable direction in a variety of manners. Use of this type of cable is limited by an operating temperature at 20°C (68°F).

Short interconnect cables between the camera and the longer cable are available to minimize downtime associated with rerouting the cables due to cable failure.

Because these cables are readily available, the X-coded cables are perfect for off-the-shelf simple systems and can be used with a range of MeltView® cameras and our advanced and X-coded compact camera controller. X-coded cables cannot be used with F-style advanced and compact camera controllers.

F-style cables are custom built at MeltTools to provide our customers with the exact solution needed. They are highly customizable in length, up to a distance of 30m (98ft), making them ideal for situations where standard lengths are not convenient.

We offer two cable materials, primarily designed for high flex and high temperatures. We have tested our high temperature cables in a furnace at 400°C (752°F). The high-temperature cable also has a relatively small bend radius.

Right angle connectors at the camera end may be oriented as desired. Additional shielding and/or an integrated ferrite may further protect the system electronics in high noise environments.

Short interconnect cables between the camera and the longer cable are available to minimize downtime due to cable failure.

The F-style flex cables made by MeltTools are kept on the shelf in standard lengths of 10, 20 and 30m. Other lengths and high-temperature F-style cables have a typical lead time of 2-3 weeks. These cables can be used with our DART2 and PIXI MeltView® cameras as well as with our compact controllers for F-style cables and our advanced camera controller. F-style cables are ideal for users requiring custom solutions when compared to X-coded cable options. F-style cables cannot be used with the X-coded camera controller.

Fiber optic cables are ideal for transmitting video signal very long distances (up to 2 km (1.2 miles)) with very low latency. Transmission is also immune to electromagnetic interference. Customers typically use these at 60-100m (196-328ft) lengths.

General fiber transmission is considered vulnerable due to material properties of the optical medium. MeltTools offers fiber transmission systems with a crush-proof shell. However, because these cables are less common and more expensive, the lead time of a camera system using this type of transmission system may take 6 weeks longer than systems utilizing other cable options.

When using our weld monitoring cameras with fiber optic cables, a MeltTools advanced camera controller is required. A camera system with this type of cable is expensive, but when looking for an option for long distance transmission with little to no chance of EMI, fiber optic transmission may be the best choice.

Coax cable systems may be employed along with separate power cables as part of a lower cost camera system that does not require control, or they may be used when video must be transmitted at lengths greater than 30m. With the right grade, the video may be transmitted up to 90m (295ft). Cable length and grade are customizable and have a moderate lead time of up to 3 weeks.

Coax cables can be used with the MeltTools advanced camera controller or our junction box. These cables are in the middle ground when it comes to both distance and price as compared to the X-coded and F-style cables versus fiber optic cables.

In applications where cable transmission is impractical, MeltTools offers a simple wireless transmission system using a 5" wireless transmitter and receiver kit. This monitor kit can be used with any of our MeltView® cameras and controllers. The monitors have an operating distance of up to 150m (450ft), and multiple systems can be used in the same facility without interference. Note that the camera is still connected to the camera controller and wireless transmitter by means of a cable, but monitoring the weld is not limited by the cable length or routing challenges.

The challenges and solutions of video signal transmission in a welding environment are summarized in the table below. For further assistance, please contact us.