The weld quality is critical since it affects the life cycle of product or user safety, which leads industrialists to use consistent and profitable methods to achieve control weld quality in real time. Repetition of manufacturing and inspection cycle is observed if products are found defective in offline weld quality inspection. Internet of Things (IoT)-based online monitoring systems equipped with multi-sensory systems in the welding can favor correction in process and reduce weld defect. It helps to reduce production time, cost and enhance the reliability of the welded components. Development of an online monitoring system equipped with a smart sensor system is attempted in proposed work employing low-cost smart Hall effect sensor and microcontroller for wire feed and weld speed measurement for submerged arc welding (SAW). Data collected from welding region is transferred to user-friendly mobile and computer dashboard using open source MQTT protocol and HIVEMQ platform. Use of low-cost smart sensor and open source platforms lead to low-cost automation with reliability and accuracy of assurance of welding process data with cyber physical system. Experimental investigations are carried out to validate the developed IoT enabled smart process monitoring system for wire feed and weld speed of SAW. Digital screen is placed at SAW machine to compare smart sensor data with old traditional analog meters. Also, data received from smart sensors are transferred to remote location of supervisor/owner mobile/computer device via MQTT protocol, leading to close control over weld process behavior. Two-way communication using http protocol is used, which helped to control welding process behavior in case of any abnormal welding condition occurring. Two-way communication over http protocol through mobile/computer devices ensured online welding quality control. Comparison of analog signal monitoring from traditional meter with digital signals has shown instrumental error of analog signal and potential scope of implementation of Industry 4.0 in SAW. IoT enabled real-time smart welding system is important as it helps supervisors to track the welding works from remote location. Intelligent monitoring system helps to enhance the overall performance of welding process in modern manufacturing scenarios.

焊接质量至关重要，因为它影响产品的生命周期或用户安全，这导致工业家使用一致且有利可图的方法来实时控制焊接质量。如果在离线焊接质量检查中发现产品有缺陷，则观察制造和检查周期的重复。基于物联网 (IoT) 的在线监测系统配备了焊接中的多传感器系统，可以有利于过程中的校正并减少焊接缺陷。它有助于减少生产时间、成本并提高焊接部件的可靠性。在提议的工作中，尝试开发配备智能传感器系统的在线监控系统，采用低成本智能霍尔效应传感器和微控制器进行埋弧焊 (SAW) 的送丝和焊接速度测量。使用开源 MQTT 协议和 HIVEMQ 平台从焊接区域收集的数据传输到用户友好的移动和计算机仪表板。使用低成本智能传感器和开源平台可实现低成本自动化，并通过网络物理系统确保焊接过程数据的可靠性和准确性。进行了实验研究，以验证开发的物联网智能过程监控系统，用于 SAW 的送丝和焊接速度。数字屏幕放置在 SAW 机器上，用于将智能传感器数据与旧的传统模拟仪表进行比较。此外，从智能传感器接收的数据通过 MQTT 协议传输到主管/所有者移动/计算机设备的远程位置，从而对焊接过程行为进行密切控制。使用使用http协议的双向通信，这有助于在发生任何异常焊接情况时控制焊接过程行为。通过移动/计算机设备通过http协议进行双向通信，确保在线焊接质量控制。将传统仪表的模拟信号监测与数字信号进行比较，可以看出模拟信号的仪器误差以及 SAW 中工业 4.0 的潜在实施范围。支持物联网的实时智能焊接系统非常重要，因为它可以帮助主管从远程位置跟踪焊接工作。智能监控系统有助于提升现代制造场景中焊接工艺的整体性能。将传统仪表的模拟信号监测与数字信号进行比较，可以看出模拟信号的仪器误差以及 SAW 中工业 4.0 的潜在实施范围。支持物联网的实时智能焊接系统非常重要，因为它可以帮助主管从远程位置跟踪焊接工作。智能监控系统有助于提升现代制造场景中焊接工艺的整体性能。将传统仪表的模拟信号监测与数字信号进行比较，可以看出模拟信号的仪器误差以及 SAW 中工业 4.0 的潜在实施范围。支持物联网的实时智能焊接系统非常重要，因为它可以帮助主管从远程位置跟踪焊接工作。智能监控系统有助于提升现代制造场景中焊接工艺的整体性能。