Air-gapped operation
The loop closes with no internet connection. Cloud sync is opt-in per site and data class.
Features
Every capability,itemised — andattached to a number.
In brief
A feature that cannot be tied to first-pass yield, rework hours, defect escapes or takt does not belong on a fabricator's shop floor. Here is the full list, with the metric each one moves.
Next step
Welding
Weld and parameter control
The arc, held inside the envelope your welding engineer qualified.
- Process coverage
- GMAW, FCAW, GTAW, SAW, laser and resistance welding, single and multi-pass.
- Seam tracking
- Laser and through-arc tracking with sub-millimetre correction during the pass.
- Heat-input control
- Live control of current, voltage, travel speed and wire feed to a target kJ/mm.
- Weave and oscillation
- Adaptive weave width and dwell for gap variation and vertical positions.
- Multi-pass planning
- Pass count, placement and interpass temperature planned on the twin.
- Envelope enforcement
- Every write bounded by the qualified WPS range and logged.
Upstream
Cutting, forming and fit-up
The geometry decisions that determine whether the weld can succeed at all.
- Nesting and cutting
- Yield-optimised nesting with kerf compensation and remnant reuse.
- Bevel and edge prep
- Bevel angle and root-face control handed forward to the weld agent.
- Forming and springback
- Bend compensation from measured material behaviour, not nominal tables.
- Fit-up measurement
- Root gap, alignment, mismatch and bevel measured before tacking.
- Weldability gate
- Go/no-go against the WPS envelope, with the reason recorded.
- Tack strategy
- Tack placement and size chosen on the distortion model.
Distortion
Distortion and residual stress
Heat moves metal. The only question is whether you planned for it.
- Sequence planning
- Weld order and direction optimised for balance and restraint.
- Distortion prediction
- Predicted out-of-plane distortion per sequence revision, before welding.
- Residual stress
- Hot-spot prediction for stress concentration and post-weld treatment planning.
- Pre-camber
- Recommended pre-set and restraint to land the assembly in tolerance.
- Measured feedback
- Post-weld measurement fed back to correct the model for your parts.
- Straightening avoidance
- Attribution of straightening-bay hours to the sequences that caused them.
Inspection
Defect detection and NDT
Machine-read, engineer-approved.
- Radiographic interpretation
- Digital RT read for porosity, cracks, lack of fusion, undercut and slag.
- Ultrasonic
- Phased-array UT interpretation with indication sizing and location.
- Vision
- Bead geometry, undercut, spatter and surface condition from shop cameras.
- Predictive indications
- Defect probability inferred from arc signature and fit-up during the pass.
- Confidence and escalation
- Every call carries a confidence; low confidence escalates to your inspector.
- Acceptance workflow
- Accept, reject or re-inspect recorded against the weld with the inspector's identity.
Operations
Yield, takt and robots
The features an operations director reads before anyone else's.
- First-pass-yield attribution
- FPY broken down by station, joint type, welder, procedure and shift.
- Rework accounting
- Rework hours attributed to the upstream cause, not the station that repaired it.
- Takt balancing
- Station cycle times against line takt, with scenario modelling.
- Robot motion
- Collision-free approach and reach planning around fixtures and large weldments.
- Positioner coordination
- Coordinated motion for headstock, tailstock and gantry positioners.
- Part handling
- Loading, re-orientation and unloading integrated with the weld schedule.
Conformance
Quality, genealogy and code
Traceability as a by-product of control, not a clipboard exercise.
- Weld genealogy
- WPS, consumable lot, fit-up, heat input, passes, NDT and distortion per weld.
- Code regimes
- AWS D1.1, ASME BPVC, ISO 3834 and EN 1090 requirement modelling.
- Qualification tracking
- Welder and procedure qualification currency, with expiry alerts.
- Non-conformance
- NCR raising, disposition and closure linked to the underlying weld record.
- Audit export
- Client and notified-body export packages generated from the live record.
- Deviation log
- Every parameter deviation, override and stop, timestamped and attributable.
In practice
What a controlled pass looks like
One weld, one record: the sensed seam, the parameters held, the beads laid and the envelope respected.
Platform
Features underneath the features
The unglamorous capabilities that make the rest deployable in a real shop.
Version pinning
Model and runtime versions are pinned per cell, with staged rollout and one-click rollback.
Confidence policy
Per-cell thresholds decide when the platform acts, advises, or stops. You set them.
Shadow mode
Run the platform alongside your welders for weeks, comparing decisions before granting write authority.
Offline buffering
Genealogy and telemetry buffer locally through network loss and reconcile on reconnect.
Role-based access
Operator, welding engineer, inspector and administrator roles with distinct authorities.
Impact
The four numbers features are judged on
FPY
first-pass yield on the pilot cell or line
Rework
hours of rework and straightening recovered
Escapes
defect escapes reaching NDT re-inspection or the field
Takt
station cycle time against line takt
Figures on this page describe the pilot scorecard Weldeon underwrites with design partners. They are target outcomes, not audited customer results; customer names and traction are not yet public.
“If a feature does not move first-pass yield, rework, escapes or takt, it is decoration.”
Questions
Feature questions
-
Yes, and most shops should. Weldeon runs alongside your welders with read-only access, making the same decisions without writing them, until the comparison is convincing.
-
Partially. Perception, inspection, genealogy and yield attribution work on manual stations. Parameter and motion control require a robotic or digitally controlled power source.
-
On Enterprise, yes. Custom material, joint and code models are part of the scope, and your existing labelled NDT data materially improves the starting point.
Begin
Bring autonomy to thearc, the fit-up andthe inspection bay.
Book a pilot on one cell or line. We agree the scorecard before we start — first-pass yield, rework hours, defect escapes, takt — and we report against it in the open.