VIRTUAL WELDING Future Developments and Experience in Practice Josef Kreindl Fronius International GmbH Division Welding Technology Froniusplatz 1 4600

VIRTUAL WELDINGFuture Developments and Experience in Practice

Josef Kreindl

Fronius International GmbH

Division Welding Technology

Froniusplatz 1

4600 Wels

2 Fronius International GmbH / Josef Kreindl / Virtual Welding 2012

CONTENTS

/ Simulation, Virtual welding is here…

/ IIW Guideline IAB 252 -11

/ System versions

/ Functional principle

/ Didactic learning with Virtual Welding

/ Area of application / configuration

/ References

/ Further developments

/ Summary


SIMULATION

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RAILWAY TRAIN DRIVER

NEDUNFEG SULSCHAB

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Fronius International GmbH / Josef Kreindl / Virtual Welding 20124

VIRTUAL WELDING IS HERE...

Video Virtual Welding



IIW Guideline IAB 252 -11

I.3.1 For the IWE; IWT, and IWS

This part does not aim at providing practical skills to the welding engineer/technologist/specialist but on gaining knowledge on the control of the different welding processes. The students shall become as familiar as possible with the problems and typical defects associated with incorrect use of the different welding methods.

During their exercises the students are guided by skilled welding teachers.

Practical trainings hours:•MIG/MAG /Fluxcored wire arc welding arc 16 hours

It is possible to use the advantages of Virtual Weld Training systems but maximum to 50% of the practical training hours!


SYSTEM VERSIONS

Stand-up terminal

/ Portable/ Network-enabled/ Different welding positions/ Workpiece versions/ Storage area for torch,

welding helmet and accessories

/ 22" touchscreen


SYSTEM VERSIONS

Portable case

/ For external training/ Network-enabled/ Real welding torch/ Haptic workpieces


Software package

Sensors22" touchscreen

Haptic workpieces Magnetic field sensor

FUNCTIONAL PRINCIPLE


Training session Simulation session

DIDACTIC LEARNING WITH VIRTUAL WELDING

/ Training sessionSupports the user with "ghosts"

/ Simulation sessionProduces a weld seam based on the actual torch movement

/ Permits changes to welding parameters



Training session

/ Speed/ Stick out/ Torch position/ Objective evaluation of performance/ Provides a controlled learning

sequence



Simulation session

/ Representation of weld seam according to actual torch movement

/ Visual assessment of the bead/ Performance also evaluated using

points system



Simulation session

/ The session allows practice on the virtual weld seam using user-defined welding parameters

/ This instructs trainees in the welding parameters used for short circuit and spray arcs

/ The video analysis provides immediate feedback about the exercise that has just been carried out

/ Trainees can independently analyse and correct their mistakes



Additional interactive functions

/ Enhancing basic knowledge of welding technology

/ Explanation of components/ Function overviews/ Help functions/ Choice of up to 16 languages / Login


Variable ghost

/ Individual adjustment of the preferred torch movement for each trainer

/ No deviation from the real welding torch position and movement

/ High acceptance by the trainers and coaches

/ Oscillating movements easy to adapt and optimize

AREA OF APPLICATION / CONFIGURATION


Variable ghost – recording

/ Create personally torch movement depending on application and work piece

/ Optimize, Correct/ Change of already existing Ghost / Support from Playback



Login / Creation of a personal profile/ Overview of the ranking lists for the

relevant courses/ Welding results give an indication of

how the trainee is progressing/ Promoting competition / Detailed results of the welding that

has been carried out/ Playback function enables trainees to

analyse errors themselves



REFERENCES

Facts/ RIO TINTO Oyu Tolgoi mining Industry

/ 7 units

Arguments/ Language Mongolia

/ Easy use

/ Reliability

REFERENCE Mongolia


Facts/ Trainingsinstiute ITI

/ 60 units one province

Arguments/ Language Guaratj

/ Touchscreen

/ Haptic workpiece

REFERENCE India



Professor Dr. Reisgen

Image and reality play an important role in computer-based simulation and modern teaching methods, which is why Virtual Welding is so popular with the students in Aachen.

In terms of time, almost all the lesson is spent practising welding.

Explanations, instructions and safety supervision are not necessary because the virtual system is self-explanatory and intuitive.

REFERENCE ISF Aachen Germany

REFERENCE WIFI / Austria

Application of the equipment: / For MAG training as a supplementary "teaching tool" to train the skills.

/ As an attraction for WIFI clients to draw the attention to the welding technology. .


Coach acceptance:Various responses:No age-related trend in the acceptance can be noted.1/3 is satisfied because the participants are quickly improved the manual skills.1/3 are feeling neutral towards the system.1/3 are feeling critical towards the system.

REFERENCE WIFI / Austria


/ Start 2 unit actual, 4 system

/Trainees which are starting a MAG education begin their training on the simulator. / Depending of the content of the training sessions the simulator plays an interaction between the real training and the simulation./ No exact time limit - just a recommendation

REFERENCE SZF Schulungszentrum Fohnsdorf / Austria


/ The trainer feedback is mostly very positive. Of course there are fears to use the system. The coach must have a profound knowledge and has to be able to operate welding simulator before we can let the trainees work with the system./ It will never replace the coach and the real training, but it is a very valuable tool, which supports the coach and is a tool for quality Education. Fronius International GmbH / Josef Kreindl / Virtual Welding 201227

REFERENCE SZF Schulungszentrum Fohnsdorf / Austria


FURTHER DEVELOPMENTS

MMA Process/ Ignition / Re-ignition

/ Welding Position (PA, PB, PD PE )/ New workpiece / Filler Material (Stick electrode basic typ)

/ Export of all cource-details via USB Stick

/ Result of each participent

/ Progress, Analysis Archiving


FURTHER DEVELOPMENTS

Summary


/ Simulation with Virtual Welding will be an integral part of the welding training

/ Software and weld seam display are constantly improved

/ Virtual Welding Systems are reliable and easy to use

/ Welding Simulation are supported by the IIW Guidelines

/ Virtual Welding Trainings Systemes improve Image and Interest in Welding technology


VIRTUAL WELDING

Thank you for your attentionen

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VIRTUAL WELDING Future Developments and Experience in Practice Josef Kreindl Fronius International GmbH Division Welding Technology Froniusplatz 1 4600