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Protecting automated welding machines in your workshop is paramount. Robotic welders cost a fortune, and if they are not protected from overheating or leaks, they may break down and even cause injuries to the operators when they malfunction. 

To avoid such problems when operating welders, you need an effective cooling and leak detection system. The WeldSaver system from Proteus is the best welding water saver system to use in your automated welders because it prevents welders from overheating. This equipment is also ideal when you want to save on expensive welding caps, electrodes, water-cooled motors, and other weld parts. 

In this post, you will take an extensive look at the WeldSaver system and how it works in automated welding. Read on for more insights. 

What is a WeldSaver? 

Being state-of-the-art equipment, the WeldSaver machine has been around in the welding industry for over 20 years. Top OEMs trust this coolant technology to deliver high-quality metal products and guard their pricey welding equipment against breakage and damage from overheating. It is used to check leaks, critical cooling circuits, and cap loss. With it, you can connect a web-based monitor with a valve shutoff and teach pendants. 

The WeldSaver technology allows users to sync it with the welder, PLC, and robot seamlessly. What makes this possible are the inputs and output data formats provided by ODVA. 

In robotic welding, the WeldSaver device is used for sensing and monitoring leaks and flow control water safety. The welding water saver device can also be used to check weld guns, coolant flow, or a weld cell’s entire cooling circuit. The automated welding device is very sensitive and can detect the loss of flow due to cap loss, hose burst, and any other event.

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Benefits of the WelderSaver 

  • By checking the heat conditions and coolant flow, electrodes are cooled
  • Once cap loss or flow loss is noticed, it only takes less than 1 second to shut off the flow
  • An alarm is sent to the weld control in less than 0.4 seconds
  • The device has a patented leak-sensing algorithm
  • Flow rate and coolant checking is done constantly using the WeldSaver device 
  • The user can scale up process parameters and alarm settings if it’s necessary 
  • To effectively manage gun changers and the weld cap, the user needs to control the system and the valve remotely
  • The WeldSaver coolant and leak detection technology has an optional local display and user interface that are browser-based 

WeldSaver as a Coolant Control System 

The WeldSaver offers more control when you want to manage the coolant flow rate and engine heat. When controlling heat, the system relies on the engine’s load and speed. A study was done to test the effectiveness of the WeldSaver cooling system. A model was validated with heat, and the outcome revealed that during the cold engine starts, the valve and a water pump on active coolant control reduced the coolant warm-up time. 

Leak Detection in the WeldSaver System

When dealing with fluids and gases stored in tanks or flow through pipes, leak detection systems are very important. LDS have increased in types for the last few years, with each type tailored to fit a certain industry needs in flow systems. They are all designed uniquely by how they monitor and identify leaks. The three major types of leak sensors include hardware-based, bio-based, and software-based LDS. 

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When using the WeldSaver device, a signal is transmitted to the PLC, robot, and weld controller, devices used to control flow. This happens when the temperature exceeds the preset limit. Depending on the preset values, it can send a warning or fault signal. The WeldSaver device is unique in operating as a welding water saver once the welder is shut off. The electric solenoid is what makes this possible. All the information gathered by the coolant device is displayed on the web interface. The user will easily understand the reports because they are conveyed in an intuitive format. 

Intelligent Leak Detection 

The WeldSaver device is a great automated weld saver system because the leak detection part of it is intelligent and can detect even the subtle flow changes that occur within the flow system. This makes it easier to establish between real leaks due to temperature, motion, or pressure change. A leak is detected in less than 0.3 seconds. In case of any cap loss or other types of leaks, the WeldSaver device will alert the weld control panel to stop the welding process or close an attached shutoff valve.


It is constantly good to protect your investment. Robotic welding equipment doesn’t come cheap, and failure to properly operate them may lead to unnecessary breakage and expenses. Acquiring the WeldSaver device will allow you to prevent your welders from heating up and monitoring leaks when they occur in the cooling system. You will not only protect your expensive welding system but also generate sufficient ROI.