Skip to Main Content

Remote Monitoring for Friction Stir Welding Systems

Proactive Insight into Hydraulic Power Unit Health

Hydraulic Power Units (HPUs) are critical to friction stir welding performance. Small changes in temperature, pressure, filtration, or flow can quickly impact weld quality, system availability, and long-term reliability.

PAR’s remote system monitoring service provides continuous visibility into HPU health, helping customers identify issues early, reduce unplanned downtime, and keep systems operating in their optimal window.

I-STIR friction stir welding equipment.

Proactive Asset Reporting

Assured uptime. Better performance. Greater confidence.

Our remote monitoring solution combines real-time system data, configurable alerts, and PAR’s deep application expertise to support smarter maintenance and faster response when conditions begin to drift.

With PAR Monitoring, customers gain:

  • Continuous insight into HPU operating conditions
  • Early warning of developing issues before they become failures
  • Actionable data to support maintenance planning and troubleshooting
  • The option for PAR experts to proactively review system health and communicate findings

System Health Visibility: Your Way

Monitoring is delivered through customizable dashboards and interactive trend charts designed to surface meaningful insights, not just raw data.

Key platform capabilities include:

  • Real-time dashboards showing current system status and health indicators
  • Historical trending and charts with configurable time spans
Robot performing friction plug welding operation to fill hole in aluminum alloy
  • Visual low/high thresholds to quickly identify operating variances
  • Event logs capturing alarms, faults, and system changes
  • Email alerts to notify users of potential concerns

Mobile-friendly access for monitoring from desktop, tablet, or phone

HPU Monitoring Packages

The base HPU connectivity package* Includes key status information available on the HPU interface, providing foundational visibility into system operation:

  • Core operating data
  • Pump status
  • Motor status
  • Alarms
  • Faults

*depending on hardware configuration

Alerts That Drive Action

Alerts are configurable based on thresholds, trends, and fault conditions, ensuring notifications are meaningful and timely.

  • Email notifications delivered directly to designated users
  • Visual indicators tied to chart thresholds and dashboards
  • Event logs provide context for troubleshooting and root cause analysis

Optional HPU Monitoring Packages

Temperature Monitoring

Additional thermal insight for systems where temperature control is critical:

  • Heat exchanger water temperature (in & out)
  • Heat exchanger oil inlet temperature
  • HPU oil outlet temperature

Filtration & Accumulator Monitoring

Early indicators of filtration degradation and pressure stability:

  • Return filter pressure
  • High-pressure filter pressure
  • Accumulator gas pressure

Heat Exchanger Performance

Monitoring flow and moisture conditions affecting heat transfer efficiency:

  • Water saturation in oil
  • Water flow
  • Return oil flow

Advanced Condition Monitoring Options

Fluid Contamination

Detect early signs of oil degradation and component wear:

  • Particle count > 4 µm
  • Particle count > 6 µm
  • Particle count > 14 µm

Power Monitoring

Understand electrical load and energy usage:

  • 3-phase voltage
  • 3-phase current
  • Power (kW)
  • Energy consumption (kWh)

Leak Detection

Rapid identification of hydraulic leaks:

  • Optical liquid leak detectors (up to 4 zones)

Proactive Monitoring by PAR Systems

Monitoring is more than data collection- it’s what you do with the data that matters.

Customers can choose to have PAR engineers:

  • Review system health and performance trends
  • Identify early signs of abnormal operation
  • Proactively communicate observations and recommendations
  • Support faster diagnosis and informed maintenance decisions

This service brings PAR’s friction stir welding and hydraulic system expertise directly into day-to-day operations.

remote monitoring dashboard

Designed for Friction Stir Welding Environments

This monitoring capability is purpose-built to support:

  • High-value production systems
  • Mission-critical weld processes
  • Long-term system reliability and serviceability

Whether supporting a single system or multiple assets, remote monitoring provides scalable insight aligned with real-world operational needs.