Your Welding Machines deserve a Digital Upgrade – without any new investment
Your welding machines are running — but do you really know how efficiently?
Whether from Fronius, Lorch, EWM, Kemppi, ESAB, Rehm, Cloos, KUKA, Panasonic, SKS Welding Systems, Miller, Lincoln Electric or others — many manufacturing companies in Germany still rely on reliable but non-transparent welding machines from a wide range of manufacturers and machine ages.
The welding machines do good work — but nobody knows exactly where time is being lost, how productive the welding process really is, or how high the actual energy consumption is.
Especially with older MIG/MAG, TIG, or spot welding systems, the data foundation required for informed decisions is often missing. Different control systems, welding processes, or machine generations make it appear almost impossible to map the entire machine park in one system — but this is exactly where Novo AI comes in.
With the AI sensor system and the WatchMen platform, we make your welding machines transparent — in real time, across manufacturers, and without interfering with the control technology.
Our solution captures machine states, cycles, runtimes, idle times, and downtime directly at the machine — from the automated robotic welding cell from KUKA to the classic MIG/MAG system from EWM and the mobile TIG welding machine from Fronius.
No Matter the Machine Age or Manufacturer — We Retrofit Your Welding Machines
Whether you operate welding machines from Fronius, Lorch, EWM, ESAB, Kemppi, Cloos, Rehm, SKS Welding Systems, KUKA, Panasonic, Miller, Lincoln Electric, Migatronic, OTC Daihen, TELWIN, Dalex, CEA, Technolit, Helvi, Orbitalum, Oerlikon, Heron, TBi, Dinse, Carl Cloos, Saf-Fro, Cebora, Ideal-Werk, Fessmann, Hürner, Weco, Kjellberg, KEMPER, Böhler Welding, Soyer, Merkle, Elektra Beckum, Mennekes, Bavaria Schweißtechnik or Thyssen Schweißtechnik, Novo AI can help you digitize and monitor them with ease.
Perhaps your production environment includes a mix of machine generations, welding processes (MIG, MAG, TIG, spot welding, plasma welding), and automation levels — from portable TIG welding units and traditional welding power sources to fully automated robotic welding cells.
No problem. With Novo AI, you can retrofit all of these welding systems quickly, safely, and without costly modifications or direct integration into the machine control system.
Our AI sensors are mounted externally on the welding machine, regardless of age, condition, or machine type. They capture high-precision vibration signals, acoustic data, and energy consumption directly at the machine and transmit this information in real time to the central WatchMen platform — or, if preferred, directly into your existing ERP or MES system.
Whether it's an automated robotic welding cell from KUKA, a mobile TIG welding unit from Fronius, a pulse welding machine from Lorch, or a refurbished production machine from EWM, we make every welding machine visible and comparable — regardless of manufacturer, retroactively, and without requiring IT expertise on your side.
Your machine fleet becomes a unified digital welding system — standardized, energy-efficient, and future-proof.
Welding machines, welding unit, spot welding system, laser welding machines, MIG/MAG welder, TIG welding machines — equipment from manufacturers such as Fronius, TRUMPF, KUKA, EWM, or CLOOS can be retrofitted with Novo AI sensors to make welding cycles, energy consumption, machine runtimes, and production performance digitally visible in real time.
Fast & Simple Retrofit — Even Without an IT Team
Many companies operating welding machines face the same challenge:
"We don't have an IT department, and our employees aren't digitalization experts – how is this supposed to work?"
The answer: With Novo AI, it's not a problem.
Our AI sensor can be installed on a welding machine in less than 15 minutes — without interfering with the machine control system, without specialized knowledge, and without any risk to existing warranties.
All you need is:
✅ A power connection
✅ A Wi-Fi connection or LAN port
The sensor is simply mounted externally on the welding machine — no opening of the machine, no connection to the control system, and no impact on machine functionality.
After installation, everything runs automatically.
The sensor transmits captured operating and energy data to our central WatchMen platform in real time. There, you can instantly see:
👉 What your welding machine is doing right now — live and easy to understand.
Typical machine states captured include:
- Productive (active welding process)
- Setup (e.g. torch change, workpiece positioning)
- Idle (ready for operation but not welding)
- Unplanned downtime (e.g. wire feed fault, shielding gas depletion)
- Planned stop (e.g. breaks, shift changes)
- Maintenance and servicing
- Run-down time / cooling phase
- Setup mode / test welding
- Standby mode / energy-saving operation
Whether you operate a mobile TIG welding unit from Fronius, an automated welding cell from KUKA, or a traditional MIG/MAG welding power source from Lorch, the retrofit process is always simple and straightforward.
And if you ever need assistance?
We're here to help. Our team supports you during implementation — remotely or on-site.
No IT expertise is required. The solution works even if you've managed your production processes with paper and Excel until now.
✅ No programming
✅ No IT configuration
✅ No risk
👉 Simply get started — and immediately see what your welding machines are really capable of.
Direct ERP Integration — For Seamless Production Workflows
Do you already use an ERP system such as SAP, proALPHA, ABAS, Microsoft Dynamics, PSIpenta, Infor, Oxaion, or an industry-specific solution? Perfect – because that is exactly where your machine data should arrive.
With Novo AI, connecting to your ERP system is simple and efficient. Our WatchMen platform was designed from the beginning to be open and compatible:
✅ Integration via API or standardized ERP connectors
✅ Automatic transfer of your production, machine state, and energy data
✅ Compatible with existing infrastructures – without complicated adjustments
✅ Optional: Direct collaboration with your ERP provider or IT system integrator
As soon as our AI sensor is installed on your welding machines, it transfers relevant information to WatchMen in real time – from cycle time and machine state to downtime and cycle analysis. If desired, this data can be made available directly in your ERP system, for example for:
- Order and production feedback
- Productivity analysis
- Post-calculation and controlling
- Energy or CO₂ reports
- Live dashboards for management or planning
You decide which data flows where, at what level of detail, and at what frequency. We advise you individually and implement the ERP integration together with your team or external partners – practical and aligned with your existing IT landscape.
Building Trust — Welding Machines in Focus, People at the Center
Digital transparency is the foundation of modern manufacturing — but it also raises important questions:
"What exactly is being captured? Who can see the data? And is this about monitoring people?"
At Novo AI, the focus is not on surveillance, but on continuously improving your welding processes.
Our AI sensor provides objective data on machine runtimes, cycle times, energy consumption, cycle deviations, and more — without interfering with the machine control system or requiring major modifications to existing equipment.
Many production employees rely on experience, routine, and intuition. That works well — until a welding machine unexpectedly stops, cycle times become inconsistent, or a weld seam fails quality inspection.
What is often missing in these situations is a single critical piece of information needed to make the right decision immediately.
This is exactly where WatchMen helps.
Our platform shows what is happening in your welding operations in real time — transparently, intuitively, and in a way that is easy to understand.
Employees on the shopfloor can:
- Identify problems more quickly
- Understand why a welding machine is idle
- See which parts are currently being welded and how efficiently
- Proactively improve their workflows instead of simply reacting to issues
Managers gain a powerful tool that enables them to:
- Analyze processes objectively
- Make fact-based decisions
- Support teams more effectively
- Identify and implement improvements together with employees
👉 The data reveals root causes — not just symptoms
👉 Hidden relationships become visible
👉 The goal is problem-solving, not assigning blame
And that is exactly what builds trust. When everyone on the team understands how their work contributes to overall performance, a stronger culture of collaboration emerges — based on facts rather than assumptions.
The WatchMen platform reduces pressure instead of creating it. It helps prevent downtime, increase productivity, and above all, make everyday work around welding operations simpler, clearer, and fairer.
Get Started Now — Without Risk and With Full Cost Transparency
Getting started with digital transparency for your welding machines does not need to become a large-scale project.
Quite the opposite: With Novo AI, you start small, efficiently, and without risk — and see immediate results without major investment pressure.
Our solution is modular and scalable. That means:
You can start with just one welding machine — whether from Fronius, Lorch, EWM, or Cloos — and experience the effects live in your production environment.
Even a single AI sensor provides valuable insights into operating times, idle phases, cycle deviations, and energy consumption.
Your advantages when getting started:
✅ Low entry costs through pilot projects
We offer smart starter packages specifically designed for testing individual machines — without long-term commitments and without risk.
✅ Funding programs & support available
Together, we evaluate whether you may qualify for regional or national digitalization funding programs — and actively support you throughout the application process and project planning.
✅ Grow at your own pace
As soon as you experience the benefits, you can flexibly expand the retrofit to additional welding stations — with a transparent cost structure and a coordinated rollout.
Most of our customers report concrete “aha moments” after just a few days:
👉 Where energy is being lost unnoticed
👉 Where welding cycles start to slow down
👉 Where small adjustments create significant impact
The fact that Novo AI has also been presented with exactly this approach at events such as the Produktionsleiter-Forum underlines the industry’s trust in our solution.
Getting started with data-driven welding production has never been this simple — or this secure.
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DMG MORI, Mazak, Okuma, Haas Automation, Makino, JTEKT, GF Machining Solutions, Trumpf, Hurco, EMAG, CHIRON, MAG / MAG IAS, Hardinge, Amada, TSINFA, Sodick, Methods Machine Tools, Jyoti CNC Automation, Fanuc, Siemens, TRUMPF
Learn more: Capture Data from CNC Machines
TRUMPF, AMADA, Bystronic, Durma, Baykal, SafanDarley, Gasparini, Jorns, Hämmerle, EHT, LVD, Danobat, BLM Group, FACCIN, DAVI, WAFIOS, NUMALLIANCE, Herber, YLM, CML, REMS, Bernardo, KNUTH, HEZINGER, Stierli-Bieger, Altendorf, RAS, Pedax, AMB PICOT, Holzmann, Epple, LECHNER, HSM, TRACTO-TECHNIK, KRENN, BJZ, RASI, Vingriai, Reinhard Klein
Learn more: Capture Data from Bending Machines
TRUMPF, AMADA, Bystronic, Durma, SafanDarley, LVD, Baykal, Gasparini, Hämmerle, EHT, Jorns, CoastOne, Prima Power, Yawei, Ermaksan, Cincinnati, HACO, Deratech, Schröder, Ermaksan, JFY, Yangli, VLB Group, Dener, Vimercati, Dimeco, IMAC, G.A.D.E., Bernardo, KNUTH, Stierli-Bieger, HEZINGER, BLEMA, Epple, Holzmann, BPR, STR, Danobat, Eisele, Colly, Schechtl, HACO-Kingsland, RICO, Beyeler (heute Bystronic), Pullmax, Pivatic, Darley, UZMA, RASI, Reinhard Klein, Vingriai, LVD-EHT, Hämmerle, Metallkraft, Biegetechnik Müller, MUBEA
Learn more: Capture Data from Press Brakes
Union, TOS Varnsdorf, Scharmann, Dörries Scharmann, Wotan, Pama, JUARISTI, SORALUCE, FPT, Lazzati, Skoda, Ingersoll, Giddings & Lewis, Lucas, HBM Machines, Toshiba, Asquith, Berthiez, Lymco, You Ji, Kira, Nomura, Dainichi, Alesa Monti, Sacem, Sacem-Greda, FERMAT, Kuraki, Zayer, Huller Hille, SIP, Stanko, Binns & Berry, Devlieg, Kearns-Richards, Henri Line, Niles-Simmons, Colgar, Comev, Giana, Jobs, San Rocco, Heckert, Cincinnati Gilbert, Rambaudi, Csepel, Tos Hostivar, Mecof, Sachman, Hüller Hille, Mandelli, MTE, Boehringer, Rambaudi, Froriep, Naxos Union
Learn more: Capture Data from Drilling Machines
DMG MORI, Gildemeister, Mazak, EMAG, Okuma, Haas, Weiler, INDEX, Doosan, Spinner, Hyundai WIA, Takisawa, Colchester, Tornos, Hwacheon, Hardinge, Biglia, Monforts, Schaublin, Mischungen aus modernen CNC-Zentren und älteren manuellen Maschinen
Learn more: Capture Data from Turning Machines (Lathes)
Fräsmaschinen von DMG MORI, Mazak, Hermle, HAAS, Okuma, Chiron, Makino, Hurco, Deckel Maho, Heller, Bridgeport, Kearney & Trecker, Schaublin, Gildemeister, Matsuura, Doosan, Cincinnati, Aciera, Emco, Hwacheon, Spinner, Colchester, Mikron, Fehlmann, Lagun, Hartford, Fexac, Weiler, Maho, Kondia, Sigma, Kitamura, Leadwell, ZPS, Toshiba, TOS, MTE, Deckel, Rambaudi, Giddings & Lewis
Learn more: Capture Data from Milling Machines
TRUMPF, Bystronic, AMADA, Mazak, LVD, Prima Power, Mitsubishi Electric, Eagle, HSG Laser, Bodor, Han’s Laser, Trotec, Coherent (Rofin), IPG Photonics, Raycus, Ermaksan, Cincinnati, MicroStep, HGTech, Golden Laser, Salvagnini, Dener, Yawei, Durma, Baykal, Dreis & Krump, Tanaka, Farley Laserlab, ACL, Koike, Penta Laser, Senfeng, Bylaser, ESAB Lasertec, Laserlab, Haco-Laser, HF Laser, Optonics, Mischung aus CO₂-Anlagen, modernen Faserlasern, fliegender Optik, Portalmaschine, Kombianlagen mit automatischer Be- und Entladung
Learn more: Capture Data from Laser Cutting Machines
Ekato, Netzsch, Ystral, Lödige, Drais, IKA, Hosokawa Micron, BHS-Sonthofen, Zeppelin Systems, Mixaco, VMI, Lindor, Winkworth, Silverson, Hockmeyer, Gericke, B&P Littleford, Amixon, Charles Ross & Son, Morton, PerMix, Henschel, Bühler, Lodige Process Technology, Hüttlin, Volkmann, Maschinenfabrik Gustav Eirich, Fielder, Diosna, Vortex, Lodige, Hüttlin, Hecht, Bepex, Matcon, Forberg, Romaco, Bohle, Teagle, Kemutec, Processall, Omga-Mix, Scott Turbon, Jaygo, Nauta, Lodige Werke, Eppensteiner, Mischtechnik Schwab, Allgaier, Alpine, MÜLLER Mischtechnik, Schugi, Littleford Day, Collette, Kestner, WAB Willy A. Bachofen
Learn more: Capture Data from Mixing and Stirring Machines
Behringer, KASTO, MEBA, Amada, Kaltenbach, Bomar, Beka-Mak, Ficep, Everising, Trennjaeger, Danobat, Pedrazzoli, Eisele, Hyd-Mech, Imet, Soitaab, Berg & Schmid, Pressta-Eisele, Rusch, Julia, Emmegi, Cosen, ExactCut, MACC, Tecnomac, Nishijimax, HUVEMA, Rusch, MEP, BSM, BTM, KMT, Voortman, Bianco, DoAll, Friggi, Thomas, SABI, Karmetal, Peddinghaus, Forte, Pegic, Kaltmeier, Säge-Union, Schanbacher, RASOMA, PNK-Maschinenbau
Learn more: Capture Data from Sawing Machines (Saws)
Schuler, Aida, Andritz Kaiser, Bruderer, Erfurt, SEYI, Komatsu, Mecfond, Chin Fong, AP&T, Beutler Nova, Fagor Arrasate, Bliss, Minster, Sangiacomo, SIMPAC, Sutherland, Manzoni, Stamtec, Heilbronn, Erichsen, Ebu, Smeral, Lasco, LVD, Wemhöner, Kraus, Fischer, Dreis & Krump, Balconi, Schmedt, Rossmann, Yadon, IMS, Weingarten, Voest-Alpine, Kaiser Pressen, Dunker, Peddinghaus, Sachs, Rossi, Neff, Kieserling
Learn more: Capture Data from Punch Presses
ELB, Blohm, Jung, Okamoto, Studer, Kellenberger, Reform, KEHREN, ABA, Geibel & Hotz, Tschudin, LIZZINI, Campbell Grinder, Lodi, WEMA, Voumard, Mägerle, Lodi Grinding, TOS Hostivař, Micron, Danobat, Palmary, Supertec, KUGEL, Tschudin, Koyo, Cylindrix, Tacchella, DELTA, Cincinnati Milacron, Jones & Shipman, KMT, Erwin Junker, Lodi, Fortschritt, REKORD, Stankoimport, Praga, Karstens, Reinhard Klein
Learn more: Capture Data from Grinding Machines
Arburg, Engel, KraussMaffei, Sumitomo (SHI) Demag, Wittmann Battenfeld, BOY, Haitian, Negri Bossi, Ferromatik Milacron, Fanuc, Toshiba, JSW, Dr. Boy, Italpresse, MAPLAN, Sandretto, Stork, Chen Hsong, LK Machinery, Tederic, Windsor, Hemscheidt, Battenfeld, Netstal, Hüller Hille, Welltec, Niigata, Toyo, Demag Ergotech, Ankerwerk, SIG Maschinenbau, Mir, Klockner Ferromatic, Satra, Battenfeld Austria, Anker, Hemscheidt Maschinenbau, Heinz Weiler
Learn more: Capture Data from Injection Molding Machines
Fronius, Lorch, EWM, ESAB, Kemppi, Cloos, Rehm, SKS Welding Systems, KUKA, Panasonic, Miller, Lincoln Electric, Migatronic, OTC Daihen, TELWIN, Dalex, CEA, Technolit, Helvi, Orbitalum, Oerlikon, Heron, TBi, Dinse, Carl Cloos, Saf-Fro, Cebora, Ideal-Werk, Fessmann, Hürner, Weco, Kjellberg, KEMPER, Böhler Welding, Soyer, Merkle, Elektra Beckum, Mennekes, Bavaria Schweißtechnik, Elektrodenwerk Bad Liebenwerda, Stürmer, Weltronic, ESM Schweißtechnik, Thyssen Schweißtechnik
Learn more: Capture Data from Welding Machines
SMS group, Schuler, Lasco, Beche, Müller Weingarten, Weingarten, Danieli, Siempelkamp, Wepuko PAHNKE, Fagor Arrasate, Banning, Hydralic Press Company, Schlebach, Ajax, Raufoss, Hasenclever, Mönninghoff, GFM, Niles-Simmons, Sack & Kiesselbach, Eumuco, Ernst Thielenhaus, Ernst Schubert, Dürr, Loewy, Sundwig, MPM, Maschinenfabrik Erfurt, Mavag, Rautomead, Waldrich Siegen, UnionChemnitz, Fagor Ederlan, SKET, Cincinatti, Farrel, HITACHI Zosen, Kobe Steel, Komatsu, Inoue, Omav, HMP, Eumuco, Makino, UBE Industries, Boehringer, Carl Wezel, Rautenbach, Naxos Union, Mannesmann Demag, Davy McKee, Aichelin
Learn more: Capture Data from Forming Machines
Krones, Bosch Packaging Technology (heute Syntegon), MULTIVAC, IMA, Rovema, Optima, Gerhard Schubert, Theegarten-Pactec, LoeschPack, ULMA, Marchesini, Uhlmann, GEA, Ilapak, Cavanna, Ishida, KHS, SIG, Bradman Lake, Pacmac, Fuji Packaging, Norden, Romaco, Coesia, HASSIA, HMC, Trepko, MGS, Volpak, ACMA, Cama Group, Tisma, OK International, Smipack, Econocorp, Viking Masek, Adco, Sepha, Wrapade, Aesus, Oystar, Waldner Dosomat, Klöckner Medipak, Kalix, Dividella, Oka, Bosch Cartoning, Hayssen, Mateer-Burt, Laudenberg, IWKA, SIG Pack, Mohrbach, BWI Manesty, Manurhin, Kisters, Klockner Bartelt, GRONINGER, Möllers
Learn more: Capture Data from Packaging Machines
Rosendahl Nextrom, Maillefer, Troester, Davis Standard, SAMP, MFL Group, EXTRUDEX, Sikora, Reelex, Queins
Learn more: Capture Data from Extrusion Machines
Niehoff, Maillefer, Rosendahl Nextrom, SAMP, MFL Group, Koch, Mario Frigerio, Henrich, Kieselstein, WAFIOS, Maschinenfabrik Niehoff
Learn more: Capture Data from Wire Drawing Machines
Sikora, Zumbach Electronic, Hipotronics, HighVolt, HFSAB, NDC Technologies, HV Technologies, Megger, BAUR, Phenix Technologies
Learn more: Capture Data from Cable Testing Systems
Schleuniger, Komax, Metzner, Kabatec, Artos, Metzner Maschinenbau, Eraser, Kingsing, Carpenter Manufacturing, Kodera
Learn more: Capture Data from Cable Shielding Machines
Niehoff, Maillefer, Rosendahl Nextrom, Setic, Pourtier, SAMP, Troester, MFL Group, SKET, Caballé, Queins, Watson
Learn more: Capture Data from Stranding Machines
Rosendahl Nextrom, Maillefer, SAMP, Niehoff, Windak, MFL Group, Sikora, Setic, Pourtier, MAG, Bühler, Voith, Aumann, Marsilli, Jota
Learn more: Capture Data from Winding Machines
Sikora, Zumbach Electronic, Rosendahl Nextrom, Maillefer, Beta LaserMike, NDC Technologies, Taihan, HFSAB, Hipotronics
Learn more: Capture Data from Spark Testers
Maillefer, Rosendahl Nextrom, Troester, Davis Standard, SAMP, MFL Group, EXTRUDEX, Queins, Reelex, Windak
Learn more: Capture Data from Jacket Extruders
WiCa, Niehoff, Maillefer, Rosendahl Nextrom, Setic, Pourtier, SAMP, MFL Group, SKET, Caballé, Bartell Machinery, Queins
Learn more: Capture Data from Bow Stranders
Windak, Rosendahl Nextrom, Maillefer, Niehoff, SAMP, MFL Group, Voith, Goebel IMS, Kampf, Atlas Converting, Kampf Schneid- und Wickeltechnik
Learn more: Capture Data from Drum Twisters
Niehoff, Herzog, Wardwell, Spirka Schnellflechter, OMEC, Steeger, Karg, Mayer & Cie, OMAC, KOKUBUN
Learn more: Capture Data from Braiding Machines
Maillefer, Rosendahl Nextrom, SAMP, MFL Group, Niehoff, SKET, Pourtier, Setic, Queins, WiCa
Learn more: Capture Data from Armoring Machines
Questions or interested in learning more? We’re happy to help.