Submerged Arc Welding (SAW) is a welding process known for high deposition rates and safer weld operations due to the layer of flux. However, it presents unique operational challenges as it is commonly conducted at height or in inaccessible locations, such as inside of pipes or tanks.
Because the arc and molten pool are entirely submerged beneath granular flux, operators cannot directly observe the wire alignment or joint trajectory in real time. A slight off-track drift can lead to missed joints, lack of fusion or other defects that are only discovered after the slag has been removed.
MeltTools leverages the MeltView® PIXI camera to eliminate guesswork and safeguard weld integrity for SAW operations. This compact camera delivers a high resolution of 1920x1080 and features built-in cooling capability. Because the PIXI camera is highly customizable, operators can choose the tools they want in their SAW monitoring system to guarantee precise alignment and successful completion of their tasks. In the following article, we break down our two sub-arc welding camera monitoring systems, highlighting the unique advantages of each and comparing their key differences.
Compact vs. Advanced Sub-Arc Systems: Which Fits Your Setup?
MeltTools offers two tailored PIXI packages for SAW so that fabricators can choose based on cost effectiveness, the machine being used and the monitoring goals.
Compact Sub-Arc System
- Cost-Effective & Straightforward: Designed for operations seeking clear, real-time video feedback of the torch position and flux delivery zone without needing laser target projection.
- Streamlined Setup: Keeps equipment footprint minimal on the boom or column while providing reliable HD imagery to keep operators out of dangerous or awkward positions.
Advanced Sub-Arc System
- Laser-Guided Precision: Integrates water-cooled laser diodes with protective spatter guards that shine bright alignment points or crosshairs directly onto the weld seam. Additional digital PIXI camera crosshairs can be used alongside the laser diodes to ensure the machine remains within operator-set guidelines for continuous alignment.
- Integrated Advanced Controller: Supplies dedicated power for the laser diodes directly through the control box.
In a previous article, we explored the applications of our advanced sub-arc system in detail, such as the various laser alignment configuration options, the utilization of laser diodes in tandem with digital crosshairs and key advantages that this system delivers.
Breakdown Between Compact and Advanced Sub-Arc Systems
| Feature | Compact Sub-Arc System | Advanced Sub-Arc System |
| Primary Focus | Cost-effective visual monitoring | High-precision seam alignment & guidance |
| Camera | MeltView® PIXI welding camera | MeltView® PIXI welding camera |
| Cable Type and Length | X-coded cable up to 30m in length | Flex style cable up to 30m in length with customized length capabilities |
| Laser Diodes | None | Optional laser diode(s). Comes with water cooling capability and replaceable spatter guards |
| Camera Controller | Compact PXCC8 camera controller | Advanced camera controller with power for laser diode(s) |
| Mounting | Free arm camera mount for PIXI camera | Dual fixed arm camera mount for PIXI camera and laser diode(s) |
| Display Monitor | 15.6" HD-SDI monitor for 1920x1080 resolution display, other monitor displays available. | 15.6" HD-SDI monitor for 1920x1080 resolution display, other monitor displays available. |
| Best For | Standard SAW setups where seam tracking is already automated or guided mechanically | Complex joints, long seam runs and setups needing precise visual laser alignment |
Summary: Upgrade Your SAW Quality Control
Whether you need a simple visual monitor to keep operators safe and informed, or a laser-guided targeting system to ensure minimal seam deviation, MeltTools provides flexible camera systems built for industrial welding environments.
Want to learn more about Sub-Arc system configurations for your specifications? Leave us a message or schedule a meeting to talk to an engineer.