WeldTrace — Voltage, Current, Wire Feed and Gas at 25 kHz
WeldTrace is a data acquisition unit that records voltage, current, and wire feed speed simultaneously at 25 kHz, plus shielding gas flow at 10 Hz, on every weld pass — capturing what the welding equipment actually delivered, not what it was set to deliver.
Built as a modular component of the HeatCore platform, WeldTrace connects over a single Ethernet cable that carries both power and data. Its recordings synchronize with PoolDrop frames and HeatCore thermal records, and feed the Weld Parameters module so the Golden Curve quality baseline covers current, voltage, wire feed and gas — not only temperature.
Thermal tells you how the weld behaved. It doesn't tell you what the machine actually delivered.
A thermal deviation without electrical and feed data has no assignable cause — you can see that something went wrong, not why.
What thermal alone can't show
- Whether voltage or current drifted from setpoint
- Wire feed slipping or running irregular
- Shielding gas flow dropping mid-pass
What you lose without it
- A thermal deviation with no assignable cause
- WPS/PQR qualification records missing electrical evidence
- QC alarms limited to temperature alone
Four channels, sampled simultaneously at 25 kHz
WeldTrace records voltage, current, and wire feed speed together at 25 kHz, with shielding gas flow sampled at 10 Hz — every channel time-aligned to the same weld pass.
Voltage
- Range: ±100 V
- Resolution/accuracy: 0.01 V
- 25 kHz simultaneous acquisition
Current
- Range: ±500 A continuous, ±700 A short-duration peak
- Resolution: 0.1 A
- 25 kHz simultaneous acquisition
Wire feed speed (WFS)
- Range: ±25 m/min
- Resolution: 0.021 m/min
- 25 kHz simultaneous acquisition
Gas flow
- Range: 0.1–25 L/min or 0.2–50 L/min, depending on configuration
- Sampled at 10 Hz
- Optional closed-loop gas-saving module
One cable, a browser tab, per-channel control
A single Ethernet cable carries both power and data. WeldTrace is operated through a browser-based HMI, with no client software to install.
Single-cable connection
A single Ethernet cable carries both power and data — one run to the unit, nothing else to route.
Browser-based HMI
No client software to install. Data has internal storage with online playback and export.
Per-channel control
- Per-channel calibration
- Adjustable per-channel acquisition rate
Compact housing
210 × 140 × 100 mm — sized to fit in a cell without becoming an installation project.
Synchronized across the HeatCore platform
WeldTrace doesn’t run in isolation: its recordings synchronize with PoolDrop frames and HeatCore thermal records, feed the Weld Parameters module, and provide input to the Therness AI models.
PoolDrop & HeatCore sync
WeldTrace recordings synchronize with PoolDrop frame timestamps and feed HeatCore thermal dashboards, so electrical, visual, and thermal evidence line up on the same weld pass.
Weld Parameters module & Golden Curve
The Weld Parameters add-on module displays and records current, voltage, wire feed speed, and gas synchronized with the thermal recordings, feeding the Golden Curve so the baseline covers electrical and process parameters, not only thermal. Weld Parameters needs WeldTrace or, alternatively, the separate PLC Integration module as its data source.
Feeds the Therness AI models
Parameter data recorded by WeldTrace provides input to the Therness AI models.
Documented applications
Where WeldTrace parameter data is used today.
Quality & compliance
- WPS/PQR qualification records
- Production QC alarming on out-of-spec voltage/current
- Wire-slip and feed-irregularity detection
Process & data
- Shielding-gas consumption reduction
- WAAM traceability
- AI training-data collection
- R&D waveform analysis
Key specifications
Simultaneous, per-channel data acquisition for weld electrical and feed parameters.
WeldTrace hard specifications
| Specification | WeldTrace |
|---|---|
| Simultaneous acquisition | 25 kHz (voltage, current, wire feed speed) |
| Voltage | ±100 V, 0.01 V resolution |
| Current | ±500 A continuous, ±700 A short-duration peak, 0.1 A resolution |
| Wire feed speed (WFS) | ±25 m/min, 0.021 m/min resolution |
| Gas flow | 0.1–25 L/min or 0.2–50 L/min, sampled at 10 Hz |
| Connection | Single Ethernet cable carries both power and data |
| Interface | Browser-based HMI, no client software required |
| Calibration | Per-channel calibration |
| Acquisition rate | Adjustable per channel |
| Data | Internal storage with online playback and export |
| Optional module | Closed-loop gas-saving module |
| Dimensions | 210 × 140 × 100 mm |
Related products, systems & guides
Where WeldTrace fits in the Therness weld-monitoring stack.
WeldTrace pairs with PoolDrop for synchronized visual evidence and with HeatCore AI for thermal monitoring on the same platform. For wire arc additive manufacturing, see how parameter data supports WAAM traceability. For the wider category, see welding parameter monitoring. If your project needs an engineered, application-specific setup, see custom thermal imaging solutions.
Frequently asked questions
What is WeldTrace?
WeldTrace is a data acquisition unit that records voltage, current, and wire feed speed simultaneously at 25 kHz, plus shielding gas flow sampled at 10 Hz, on every weld pass — so you have a record of what the equipment actually delivered, which is not always what it was set to deliver.
What are the measurement ranges and accuracy for each channel?
Voltage: ±100 V, 0.01 V resolution. Current: ±500 A continuous, ±700 A short-duration peak, 0.1 A resolution. Wire feed speed: ±25 m/min, 0.021 m/min resolution. Gas flow: 0.1–25 L/min or 0.2–50 L/min depending on configuration, sampled at 10 Hz.
How does WeldTrace store and play back data?
WeldTrace has internal storage with online playback and export. An optional closed-loop gas-saving module is also available.
How does WeldTrace install and how do I operate it?
A single Ethernet cable carries both power and data. WeldTrace is operated through a browser-based HMI, so there is no client software to install. Each channel has its own calibration, and the acquisition rate is adjustable per channel. The unit measures 210 × 140 × 100 mm.
How does WeldTrace relate to the Weld Parameters module and the Golden Curve?
The Weld Parameters add-on module is a perpetual-licence item that displays and records current, voltage, wire feed speed, and gas synchronized with the thermal recordings, and feeds that data into the Golden Curve so the quality baseline covers electrical and process parameters, not only thermal. Weld Parameters needs a data source — either WeldTrace or, alternatively, the separate PLC Integration module.
How does WeldTrace fit with PoolDrop and HeatCore?
WeldTrace recordings synchronize with PoolDrop frame timestamps and feed HeatCore dashboards, and the parameter data also provides input to the Therness AI models.
What is WeldTrace used for?
WPS/PQR qualification records, production QC alarming on out-of-spec voltage/current, wire-slip and feed-irregularity detection, shielding-gas consumption reduction, WAAM traceability, AI training-data collection, and R&D waveform analysis.
Does WeldTrace go by another name in earlier quotations?
Yes — SignalMonitor is the designation used in earlier quotations for the same unit now sold as WeldTrace, so offers already sent under that name reconcile with this product.
