AI automated welding robotics firm Novarc Technologies has introduced NovAI, a new AI-powered system that brings vision and real-time adaptation to articulated robotic and mechanised welding.

NovAI is designed to produce less defects as real-time AI adjustments help ensure consistent high-quality welds. Overwelding is virtually eliminated, reducing scrap and fixturing costs. As there is no need to set up manually or pre-scan the welds, and less reliance on skilled talent, production is quickened.

NovAI works with leading robot systems and can scale according to the evolution of production needs. Novarc has introduced three modules alongside its NovAI launch: NovAI Capture, NovAI Control and NovSync. NovAI Capture brings machine vision into the robotic welding process, giving welders real-time visibility into the weld pool, and automatically recording every weld with full parameter data. NovAI Control combines human expertise with robotic welding to handle complex welds more easily, and more accurately, reducing the need for precise fit-up and heavy fixturing. Operators can adjust weld paths and process parameters in real-time as they watch the weld pool through machine vision, dramatically minimising the risk of costly defects due to fit-up variations.

Available later this year, NovAI Autonomy will allow robots to see and adapt like expert welders. This will eliminate the need for pre-scanning, manual adjustments, and rework and therefore speeding up manufacturing time, and increasing the quality of the welds. The AI-powered system automatically adapts welds in real-time to fit-up variations, tacks and seam distortions, so no operator input is required.

All of these technologies are powered by the NovSync Dashboard. This collects and connects all weld video and parameter data in one platform. Users can upload, store and access all weld data and videos (for example through NovAI Capture) in a single location, enabling efficient tracking and tracing throughout the manufacturing process. This allows remote monitoring and insights; allowing users to gain real-time visibility into welding activities from any location, proactive decision-making and process optimisation.

“The introduction of NovAI is extremely exciting for us; its development is based on two decades of research and practical industrial grade deployments of our award winning Spool Welding Robot (SWR). Our solution promises to transform welding automation by bringing the precision of human expertise through AI to articulated robots, cobots and mechanised welders, which will help manufacturers to automate difficult welding jobs that could not be automated before and reduce manufacturing waste such as overwelding and post weld grinding  while improving the finished weld quality. This is critical as the US embraces a demand for manufacturing combined with pressure due to reshoring initiatives,” said Soroush Karimzadeh, CEO of Novarc Technologies.