MeltView^TM Weld Monitoring Cameras

At its core, MeltView™ technology delivers a clear, rich welding image in high-resolution and in real-time. This visualization technology allows operators and welders to observe every aspect of their work, from arc initiation to puddle solidification, as it occurs.

Our MeltView™ HD SDI cameras provide the highest resolution on the market (1920x1080) at 30 frames per second, for an image that captures subtle details and is perfect for real-time weld process monitoring.

Our MeltView™ monitoring cameras utilize HD SDI video, which is one of the lowest latency video signals, ~100ms, while our MeltView™ AI-ready cameras utilize GigE video that is slightly longer, ~150 ms. We do not do any image processing that would increase the latency.

MeltView™ cameras are designed to withstand the harsh conditions found in many welding environments. These camera systems perform reliably under the most demanding conditions, from high temperatures to intense radiation to extreme vapor and spatter. Moreover, no two welding projects are exactly the same (unless you are trying very hard to make them so!), and neither are the requirements for monitoring those projects.

Built to last, MeltView™ cameras are packed with features that protect the optics and electronics and allow for simple maintenance to keep the camera running for decades. Some of these include integrated cooling, integrated gas/air knife, replaceable gaskets, sealant glass and spatter shields and proper grounding.

We design and machine all of our cameras, so we can customize any camera body and optics, and often do so when a particular piece of welding equipment requires a camera of a certain profile to be mounted at a particular angle and working distance with a specific cable routing. We are driven to make our cameras smaller and nimbler every time we CAD.

Camera sensors and optics can be combined in sophisticated ways to provide the image that is most useful for a given purpose, whether that be a thermal image to measure the temperature profile of a solidifying weld and the substrate temperature in three-dimensional printing or a high dynamic range image to aid an operator in monitoring wire position and alignment.

We offer several monochrome and color imaging options for different welding processes as well as laser protective optics and matching customized lighting. Selecting the appropriate wavelengths of light and supplemental light makes all the difference in obtaining a clear image that is suitable for human viewing or AI analysis.

We work in three principal types of imaging modes. We pioneered high dynamic range (HDR) imaging in 2010, and this is style of imaging utilized in our MeltView™ weld monitoring cameras. As we developed AI for welding, we realized the value of a thermal image provided by SWIR sensors and we offer this as one of our AI-ready cameras. Finally, pulsed illumination has proven to be a valuable for obtaining an almost arcless image, and our newest cameras offer this imaging mode.

• Improved Weld Quality: Real-time feedback enables immediate welding adjustments.
• Defect Detection: MeltView™ cameras allow early detection of defects such as porosity, inclusions, and improper fusion, allowing instant corrections and minimizing rework.
• Increased Productivity: Reduced time spent on post-weld inspections and rework.
• Real-Time Adjustments: On-the-fly issue correction without interrupting the workflow, maintaining a smooth and efficient production process.
• Remote Monitoring: With the option to add wireless transmission systems, supervisors and quality control personnel can monitor welding operations from a distance.

Investing in MeltView™ cameras is an investment in the future of your welding operations. With advanced monitoring capabilities, Artificial Intelligence (AI) integration, improved productivity, and enhanced safety, MeltTools provides the tools you need to achieve the highest standards of quality and efficiency.

Learn more about how MeltView™ cameras can transform your operations by contacting us today to schedule a consultation or request a demo.