Measurement Algorithms for HF Pre-Weld Inspection System

Xiris Automation announced a new release of its HF Pre-Weld Inspection (HFPW) system, introducing advanced measurement algorithms and a high-performance HMI that provide tube and pipe manufacturers with more precise, visibility and control over High-Frequency welding processes.

High-Frequency tube welding requires precise control of strip edge geometry and welding temperatures to maintain weld quality and production efficiency. However, traditional monitoring tools often provide limited or incomplete process visibility, forcing manufacturers to rely heavily on operator intuition and post weld manual inspection.

The latest HF Pre-Weld Inspection system release was developed in collaboration with customers to deliver more robust measurement capabilities and improved production monitoring tools. The result is greater process insight, helping manufacturers maintain quality, improve productivity and reduce operational risk.

Next-generation HMI performance

The release also introduces support for the new Xiris Gen4 HMI, delivering increased processing power, improved connectivity and enhanced visualization tools.

This enables operators and plant personnel to:

• Monitor welding performance with improved clarity
• Manage and analyze production data more efficiently
• Simplify workflow management and system configuration

Improved operator safety

The system provides an exceptionally clear, real-time remote view of the welding process, allowing operators to monitor production without direct interaction with hazardous mill environments or interrupting production for manual inspection.

100 % inspection capability

By combining precise thermal and geometric measurements, the system enables continuous monitoring of the welding process. Custom alarm and warning limits allow operators to receive real-time alerts and take immediate corrective action to prevent defects.

Industry 5.0 ready integration

The enhanced HFPW system integrates seamlessly with mill PLCs and supports data sharing through OPC-UA and ModBus/TCP interfaces. Measurement data can be recorded within the system or shared in real time to support automation, traceability, and digital manufacturing initiatives.

How it works

The HF Pre-Weld Inspection system uses the XIR-1800 thermal camera in a rugged industrial housing paired with advanced software and an intuitive HMI interface to monitor welding parameters more than 30 times per second. The system analyzes combined thermal and geometric data to help manufacturers detect process variations, stabilize welding performance and improve production consistency.

(Source: Xiris Automation Inc.)