BIOS-CT-01 – welding machine monitoring with no changes to the welder
In many plants, a key challenge is reliable information about the real working time of welding machines. BIOS-CT-01 is a specialised measuring module that detects when welding equipment is working, in a completely non-invasive way. Welding machine monitoring in Scout is based on this module.
The BIOS-CT-01 module is housed in a 5-pin three-phase connector rated up to 63 A and fitted between the power supply and the welder. By analysing current draw, the module automatically recognises when the welder starts and stops working – with no need to modify its control or electronics.
Example set-up below:
Welder work detected from real current draw
The principle is simple and safe for the equipment:
- Plug-in adapter: BIOS-CT-01 plugs in as an adapter between the power socket and the welder’s plug.
- Load detection: the module detects current draw. Exceeding a set threshold means actual work (an electric arc), not just the machine being on standby.
- Data transfer: the signal goes to a BIOS-IO-01 module, which sends the data to Scout MES over the LAN. One BIOS-IO-01 handles up to 4 BIOS-CT-01 modules.
This approach removes the errors that come from declared statuses or manual reporting. The system records the real working time, based solely on actual current draw.
Minimum intervention, maximum information
BIOS-CT-01 was designed for industrial environments:
- no changes to the welder’s control,
- no changes to the machine’s software,
- quick to fit and start up.
This kind of welding machine monitoring works wherever other ways of integrating with a welder are impossible, expensive or not worth it.
More about the module: BIOS-CT-01 – welding machine arc-on time sensor on bios-iot.com.