Catch Surface Defects and Arc Instability in One System
DuoSense™ AI fuses vision and acoustic analytics so you see overlap, undercut, and arc instability at the same time—before parts leave the cell.
Visual-only systems miss arc issues. Acoustic-only systems miss surface defects.
Relying on one sensor means half the story. Visual cameras catch surface flaws but not arc stability; acoustic sensors hear instability but can’t prove appearance.
Signs you feel this gap
- Spatter, undercut, or overlap discovered after grinding
- Arc instability causes inconsistency but isn’t visible
- Customer returns demand both appearance and stability proof
Business impact
- Rework and inspection hold up throughput
- Auditors ask for objective evidence you can’t provide
- Process engineers struggle to diagnose root causes quickly
Dual-modality monitoring that sees and hears defects in real time
High-resolution visual inspection plus acoustic analytics deliver complete context for every weld. Quality, maintenance, and process teams get the same truth instantly.
4K visual inspection
Detect overlap, undercut, crater issues, and surface roughness down to 0.1 mm.
- Meets ISO 5817 / AWS D1.1 criteria
- High-speed capture up to 120 FPS
- Rugged housing for robotic or manual cells
Arc stability acoustics
Acoustic signatures reveal arc blow, gas issues, or wire feed problems before they show up visually.
- Frequency analysis highlights drift
- Alerts operators when parameters fall out of spec
- Correlates with visual data for faster diagnostics
AI-driven decisions
Fuses sensors with deep learning for accurate pass/fail calls and root-cause hints.
- Reduces false positives compared to single-sensor systems
- Explains why the weld failed (appearance vs. stability)
- Feeds reports to QMS Copilot™ instantly
Next steps
Compare monitoring stacks and see how evidence connects to CAPA/PPAP workflows.
Want deeper context? Read AI weld defect detection methods.
Frequently asked questions
Quick answers for engineers and quality teams evaluating DuoSense AI: Dual Thermal & Visual Weld Monitoring | Therness.
What’s the difference between DuoSense and HeatCore?
HeatCore focuses on thermal monitoring to catch subsurface risks. DuoSense adds visual inspection (surface geometry) plus stability analytics so you can cover both appearance defects and process instability in one system.
Which defects can DuoSense help detect?
DuoSense can flag surface issues like undercut, overlap, spatter, and crater irregularities, and it can highlight instability patterns that correlate with defect formation. Coverage depends on your joint types and configured acceptance criteria.
Can DuoSense export evidence for audits and customers?
Yes. It produces traceable records and can generate audit-ready evidence packs aligned to ISO 17635 workflows. Outputs can also feed QMS processes (CAPA/PPAP) when connected to QMS Copilot.
Does DuoSense work on robotic and manual cells?
Yes. Deployments depend on line access and field of view, but the system is designed for both robotic and manual environments with ruggedized hardware.