PRODUCT

The Thermo Profile Scanner System

Inline Weld Seam Monitoring with Passive Thermography

The ThermoProfileScanner (TPS) is a patented inline monitoring system for volumetric, non-destructive testing of weld seams in tube and profile welding lines. It is based on a high-resolution infrared line camera that captures the real thermal field directly behind the welding point and derives reliable real-time conclusions about weld quality.

What Does the System Do?

100% Seam Monitoring – Directly in the Process TPS inspects every single weld seam during ongoing production. Testing is performed inline – without additional time or labor effort.

Real-Time Thermal Field Acquisition

Temperature

Seam width

Temperature distribution

Symmetry

Based on this data, the system automatically evaluates the weld seam quality.

Automatic Evaluation and Response

Position-accurate signal output

Symmetry

Automatic sorting

Integration into PLC / fieldbus / company network

Defective tubes or profiles are reliably detected before delivery.

Which Defects Does the Thermo Profile Scanner Detect?

Incomplete or asymmetric penetration
Deviations in penetration depth
Cold welds
Pores and holes
Lack of fusion
Plasma disturbances
Power drops
Edge misalignment
Strip edge damage
Focus or laser position deviations

In ERW/HFI welding processes, the system detects critical cold welds where conventional eddy current testing often reaches its limits. The method is recognized as a testing procedure according to ÖNORM M 10893-13:2018-11-01.

How Does the (TPS) Work?

The TPS uses passive thermography with a patented infrared line camera to monitor the weld seam volumetrically and non-destructively – inline, in real time, during production.

Measurement

Measurement of the thermal field directly behind the welding point.

Analysis

Analysis of temperature distribution across the entire seam.

Calculation

Calculation of characteristic weld parameters.

Evaluation

Automatic real-time evaluation

Signal output

Signal output for marking, separation, or process correction

Operational Benefits in Daily Production

The ThermoProfileScanner makes weld quality measurable. It combines inline thermography, automated evaluation, and direct process feedback into an integrated monitoring system that ensures quality, reduces costs, and creates transparency in the welding process.

Reduction of scrap through real-time monitoring
Immediate detection of process deviations
Shorter setup times
Optimization of welding parameters
Traceability of every individual tube/profile
Significantly reduced need for destructive testing
Prevention of defective product delivery

In a nutshell

The ThermoProfileScanner makes weld quality measurable. It combines inline thermography, automated evaluation, and direct process feedback into an integrated monitoring system that ensures quality, reduces costs, and creates transparency in the welding process.

An Overview in 120 Second

TPS System – Applications - Key Facts

Continents: Europe, North and South America, Asia, Africa 

Applications: 300+ 

Countries: 30+

Welding processes: TIG, Plasma, HFI, ERW, HFW, resistance butt welding, Laser, MAG, MIG

Material thickness: 0.05 to 20 mm

Materials: steel, stainless steel, copper, brass, bronze, titanium, nickel (all metals and alloys with a melting temperature above 900°C)

Pipe diameter: 1.5 to 1000 mm

Welding speed: up to 200 meters per minute

Seam width: up to 25 mm

Why Leading Tube Manufacturers Choose the Thermo Profile Scanner System – Again and Again!

The decision for a quality monitoring system is more than a technical investment. It is a strategic commitment to stability, sustainable competitiveness, and reputation.

Strategic Added Value

Sustainable reduction of scrap and complaint costs
Higher production capacity through increased line availability
Protection against liability and quality risks
Strengthening the image as a technologically leading quality supplier
Securing long-term competitiveness

Sales Argument with Market Impact

Communicate “100% monitored quality”
Clear differentiation from competitors
Support premium pricing strategies
Measurably strengthen customer trust
Demonstrate technological leadership

Maximum Process Stability in Production

Real-time monitoring of every single seam
Immediate detection of process deviations
More stable parameter control
Significantly reduced rework
Minimised downtime through early fault localisation

Operator Support Instead of Additional Burden

Clear visual representation of quality status
Intuitive user interface
Reliable alarm structure
Relief in quality decision-making
Objective data basis instead of subjective assessment
Remote support via internet if required

Comprehensive Quality Assurance & Audit Capability

Complete documentation of every produced weld seam
Audit-proof data storage
Support for ISO, API, and customer audits
Transparent traceability down to individual batches
Data basis for continuous process improvement

Reputation and Trust Enhancement

Strengthened market perception of competence
Increased credibility with OEMs and end customers
Greater investment security
Enhanced personal decision confidence for responsible managers

Technical Integration without Complexity

Customized, series-manufactured complete solution
Seamless integration into existing production lines and IT structures
Support for analog, digital, and serial interfaces including fieldbuses and networks
Standard output to markers, saws, signal lights or horns
Configurable production documentation on company servers
Industrial-grade hardware designed for 24/7/365 operation under welding EMC conditions
Commissioning within a few hours

Conclusion

100% quality monitoring
Higher process stability
Reduced defect and scrap rates
Comprehensive documentation
Stronger market position
Sustainable profitability

Contact us – we are happy to answer all your questions.

The ThermoProfileScanner makes weld quality measurable. It combines inline thermography, automated evaluation, and direct process feedback into an integrated monitoring system that ensures quality, reduces costs, and creates transparency in the welding process.

100% quality monitoring
Higher process stability
Reduced defect and scrap rates
Comprehensive documentation
Stronger market position
Sustainable profitability

Need Any Help

Instantly available help tips for the most common customer inquiries – the fastest way to the right solution.