Leak & Water Sensor for Robotic Welding System

A robotic welding water saver plays an important role because it helps to cool down the welding equipment when it heats up. The WeldSaver™ welding water saver from Proteus is the best because it works as a coolant and a leak detector. Using it will help you prolong automated welding parts such as electrodes & caps and also water-cooled motors. The WeldSaver technology from Proteus has been around for 20 years, and many OEMs have used it in robotic welding. With cutting-edge tools, this type of water weld saver can check cap loss and detect leaks. 

The weld saver also has essential cooling circuits and can connect with valve shut off and via a web-based monitor. The ODVA data formats for inputs and outputs make it easy to sync the WeldSaver, welder, PLC, and robot. To understand better how a WeldSaver works, let’s first break down what a coolant control is. 

What is a Coolant Control System? 

A coolant control system helps welders to manage coolant flow rate and also control engine heat. Load and speed, which are the engine driving state, are what the coolant depends on. A leak detection system, on the other hand, has various designs. The designs are made particularly to suit or cater to different flow and pipeline demands. LDS are grouped based on how they detect or sense leaks. Leak detectors are available in three major types: software-based, hardware-based, and bio-based leak detectors. 

The WeldSaver™ device, in robotic welding, is used for flow control and water safety. It is also used for leak detection. You can use it to monitor weld guns, coolant flow, or a weld cell’s cooling circuit. If there is flow loss due to cap loss, hose burst, or any other event that causes flow loss, the WelderSaver device will not miss it. 

Welders are also protected by the WelderSaver device, which monitors the outgoing and incoming water for the robotic welding in a coolant. When the flow rate or temperature goes beyond the pre-set parameters, the welding water saver will signal the equipment used to the flow. This can be the robot, weld controller, or PLC. Again, it relies on set-point values to send a warning or report fault values. Once it is turned off, the WeldSaver will work as a water saver. Again, an electric solenoid is used for this.

The interface is where all the information gathered from the welding water saver is displayed. The best thing about it is that it intuitively relays these reports. 

Features of a WeldSaver 

Intelligent Leak Detection 

This water saver device easily captures flow changes. Motion effects, temperature, and pressure changes are used to sense real leaks. Within 0.3 seconds, the operator will know that there is a leak somewhere in the pipeline. A shutoff valve can also be closed with the WeldSaver. 

Flow Monitoring and Measuring 

Flow sensors such as vortex or rugged have coolant supplies from the WeldSaver and return channels. Each time a fluid flows around a bluff object, swirls are formed. These swirls are taken by flowing liquid downstream—low and high-pressure zones alternate the vortex streams. Every time a vortex passes through the sensor, a piezoelectric crystal senses it. The amount of swirls formed is directly proportional to the liquid’s linear flow. The liquid flow rate is provided by a micro PC, which is also used in a supply chain to measure the vortex flow.

Coolant Shutoff Valve 

The WeldSaver™ can also stop the flow of coolant water using an optional shutoff valve. If the WeldSaver stops, an override feature allows the water to flow into the system. When this happens, leaks are tested without using the 24 VDC power. 

Web Browser User Interface 

The welding water saver also gives real-time reports on the device’s status from the user interface. The reports are easy to read due to their clear indicators. Through a particular network, the user can use any JavaScript™-enabled web browsers to access the interface. All the user has to do is type the working IP address of the WelderSaver. 


If you intend to install a robotic welding system in your plant, welding water savers are essential devices. However, welding machines generate a lot of heat, and if you don’t have a proper cooling system, you may damage these costly machines. What makes the WeldSaver device from Proteus Industries great is that it serves as a water saver and a leak detection system. They have designed and built the WeldSaver robotic welding machine to properly monitor liquid flow rate and protect expensive equipment from overheating.