The Xiris Blog

Weld Safety: Before and After

Posted by Margaret Montgomery on Friday, May 18, 2018 @ 01:37 PM

According to the Bureau of Labor Statistics, welders and cutters "have one of the highest rates of injuries of all occupations." [1] 

safety before+ after larger

                              BEFORE                                                                       AFTER                                   Before installing a weld camera, welders are often perched at unsafe heights, giving them a poor view of their welding activities. 

Welders Work in Precarious Positions

Many welding activities are done at unsafe heights, while the welder attempts to monitor and control the welding process. The moving machinery around them forces them to work in small, constrained working areas- which is often dangerous and uncomfortable for the operator. In these conditions- behind a helmet and perched above the welding process- welders miss important details in the welding arc, which can lead to mistakes and inaccuracies that are costly and timely to fix. Not only are these conditions a safety risk, but they make it harder for welders to ensure that they execute a high quality weld.

Weld Cameras Give Welders an Eye Into Detail

Xiris Automation weld cameras enable workers to perform a weld without leaving the ground. Our solutions give welders a consistent image quality regardless of the angle of the weld. They can view multiple images of the weld from leading, trailing or side views of the weld process. 

 

Don't pay for accidents, prevent them using machine vision technology. 

 

If you are interested in learning more about our company and products, please contact us here.

 

[1]“Welders, Cutters, Solderers, and Brazers.” U.S. Bureau of Labor Statistics, U.S. Bureau of Labor Statistics, 13 Apr. 2018, www.bls.gov/ooh/production/welders-cutters-solderers-and-brazers.htm#tab-3.

Topics: weld camera, weld safety, arc welding, mig welding, weld camera system

April 2018: Looking Back

Posted by Margaret Montgomery on Friday, May 04, 2018 @ 04:24 PM

April was an extremely successful month for Xiris Automation! Read below for a recap of the month's events. 

Tube Dusseldorf 2018

Xiris exhibited at Tube Dusseldorf 2018 in Dusseldorf, Germany, from April 16-20. This was an important opportunity for those in the tube and tube processing industry to witness new technology and innovation in the field. We were thrilled to be an exhibitor at such a pre-eminent event! 

IMG-20180414-WA0007

Our team demonstrated how our innovative quality control solutions add value to tube and pipe welding activities, especially for detecting problems sooner in the tube manufacturing process using our WI2000 inspection system.Overall, it was an extremely successful event for Xiris and an excellent opportunity to engage with leaders in the tube processing and fabrication industries.

 

 

Rapid + TCT

Xiris exhibited at the Rapid + TCT conference in Forth Worth, Texas, USA from April 24-26. Rapid is a significant event for innovation in the additive manufacturing industry, and attracted leaders in 3D Manufacturing from around the world. 

rapid booth

Through demonstrations and interactions with these companies, the Xiris team showed how our HDR weld cameras can decrease building times, reduce operating and engineering costs, and lower materials costs in research and development for Metal Additive Manufacturing. When our High Dynamic Range (HDR) weld cameras are added into an Additive Manufacturing machine, operators can monitor every step of the welding process in real time to ensure quality outputs, detecting any material placement issues such as warping without having to stop the machine.

Japan International Welding Show

Xiris attended the 2018 Japan International Welding Show in Tokyo from April 25- 28, displaying our cameras in the Matsumoto Group booth. This was Japan's largest exhibition of welding technology, and was thus an extremely significant opportunity for Xiris. 

Our extremely durable, industrialized weld camera was on display at the show, as seen below. 

Japan Welding show

 

If you are interested in learning about or displaying one of our cameras, please contact us here.

 

 

Topics: Tube and Pipe welding, weld, Tube Dusseldorf, conference, weld monitoring, XVC Weld Camera, color weld camera

Rugged Cameras for Tough Weld Environments

Posted by Dean Zhao on Tuesday, April 24, 2018 @ 11:16 AM

Tandem MIG Welding - Environmental Concerns?  Not everyone was as confident as we were that our XVC-1000e weld cameras would last in this welding environment.

But they did. 

In fact, installed over three years ago, two Xiris XVC-1000e weld cameras were installed in a tandem MIG welding operation.  Over the past two years, they have been operating 24 hours per day, 7 days per week in some of the harshest MIG welding conditions amidst extensive smoke, fumes and weld spatter.

We are happy to say that the cameras are still going strong!

2018_4_24 _ Rugged Weld Cameras for Tough Weld Environments.jpg

The cameras as they were when they were first installed

 

2018_4_24 _ Rugged Weld Cameras for Tough Weld Environments_One Month.jpg

The cameras after one month

 

2018_4_24 _ Rugged Weld Cameras for Tough Weld Environments_3 Years..jpg

The cameras 2 years later – still running, still going strong!

 

The Xiris XVC-1000e cameras are equipped with a rugged industrial housing that allows the camera to be protected from ambient dirt, smoke and fumes.  Equipped with optics with motorized focus, integrated LED lighting, replaceable spatter window and cooling chamber, the Xiris cameras can withstand some of the most rugged welding environments!

Topics: weld camera

SPC Measurements on a Tube Mill

Posted by Cameron Serles on Tuesday, April 10, 2018 @ 02:58 PM

Statistical Process Control (SPC) is the use of inspection data to determine the characteristics of a process, using techniques to find and remove abnormal variations in completed tubes.  Variable data is quantitative and is generated from actual measurements, such as the Mismatch, Bead Height, Deflection or similar measurements obtained from the Xiris WI2000 Weld Inspection system when it is placed right after the weld box on a tube mill. 

Variation is the difference between things that should be alike because they were produced under the same conditions.  Variation can be measured and groups of these measurements can be plotted as a frequency distribution, or histogram.  Since quality is a measure of conformance to specifications, poor quality results when variation falls outside the upper and lower specification limits.

2018_4_3 - SPC Data Logging Utility Display, Xiris WI2000.jpg

The SPC Data Logging Utility Display from a Xiris WI2000 system

 

SPC data can now be recorded and reviewed off line using the WI2000 measuring a number of parameters, including: 

  • Mean - the average of a group of values of a particular measurement.
  • Median -  the middle value of a group of ordered measurements.
  • Mode - the measurement occurring with the highest frequency.  This is the peak of the histogram.  In a true normal distribution, the mean, median and mode are all equal.
  • Range - the highest minus the lowest value in a set of measurement data.  This is a simple measure of the dispersion, or spread, in a set of data.
  • Standard Deviation - a measure of dispersion computed from the square root of the sum of the deviations from the mean, divided by the total frequency. 

Statistical process control uses the concept of subgroup sampling.  This is a method of data collection that considers a series of consecutive measurements together as a single group.  A typical subgroup size is five (5) measurements.  In order to smooth out the variability associated with an individual measurement, five consecutive measurements would be considered together as a representative sample. 

Xiris has implemented an SPC measurement logging capability to provide a way for fabricators to monitor their tube mills and identify abnormal variations in their completed tubes.

 

Topics: weld inspection, Tube and Pipe welding

Monitoring High Amperage Welding on Aluminum

Posted by Justin Grahn on Tuesday, March 27, 2018 @ 02:32 PM

Aluminum welding needs to be performed typically "hot and fast." When using automated welding equipment, it is very challenging to get the process parameters correct. To aid in automated aluminum welding processes, a weld camera can be used to monitor for process variations that could cause a poor weld, including:

  • Burnthrough: Higher thermal conductivity and lower melting point of aluminum alloys can easily lead to burnthrough. Even on thicker material, welders have to carefully monitor that welding current high enough to penetrate the weld joint adequately does not cause burnthrough.
  • Cracking: Aluminum TIG welds often have a tendency to crack if there is not enough filler metal to change the weld chemistry to make it less crack-sensitive.
  • Weld Shape: A good aluminum weld will be flat to slightly convex in shape. If welds are ropey or convex, it is usually an indication that not enough energy was provided to the weld and cold procedures or undersized equipment was used.
  • Heat Affected Zone: by monitoring the size and shape of the HAZ, operators can reduce how much the base metal melt, reducing the opportunity for stress cracking;
  • Shielding gas: In thick aluminum welding, monitoring shielding gas size, shape and color can indicate its chemistry. Altering the chemistry can vary the heat input, changing the weld root width penetration, and reduce porosity.
  • Weld discoloration: may indicate metal oxides are cooling outside of the shielding gas range on the base metal, increasing the possibility of contaminants.
  • Oxide layer: if oxide layer has not been adequately removed in the weld arc, contaminants could migrate into the weld, causing porosity or cracking.
All these phenomena can be seen by a trained operator when remotely monitoring the aluminum welding process with a welding camera. To achieve best quality of image, a monochrome weld camera can be used at low exposure rates to produce the best image because the aluminum weld arc is so bright, offering better contrast and dynamic range than a color camera.

 2018_3_27 - Monitoring High Amperage Welding on Aluminum with a Weld Camera

Image of Aluminum welding with a Monochrome camera,

at extremely low exposure

 

Topics: weld camera, Aluminum, High Amperage Welding

Watching a Rotating Cladding Process

Posted by Justin Grahn on Tuesday, March 13, 2018 @ 10:46 AM

Cladding material on to the inside surface of a pipe requires movement of the torch head relative to the pipe surface. This is done by either rotating the pipe, keeping the welding torch stationary, or by rotating the welding torch and keeping the pipe stationary. For longer sections of pipe, or for pipe that has already had a number of sections welded together, moving the pipe itself is not always practical. Instead, the weld torch must be rotated to perform the cladding operation.

To remotely monitor the cladding process, a weld camera can be mounted next to the weld torch, allowing operators to detect defects in the cladding process while they are happening and respond immediately with positional adjustments or even by tweaking the material inputs to the optimize the clad. While it is not too difficult when the torch remains stationary, it is more of a challenge when the torch has to rotate through many rotations to complete the cladding operation.

To solve this problem, the Xiris XVC-1000 and XVC-1000e weld cameras were integrated and successfully tested on a slip ring to transmit the power and electrical signals from the camera inside the pipe to an external computer. A slip ring is an electromechanical device that allows the transmission of power and electrical signals from a stationary device such as the external computer to a rotating device – the weld camera inside the pipe.

With the successful testing of the video transmission by slip ring, it is now possible to equip cladding machines that have rotating torches or carriages with a weld camera. This provides much better process monitoring in ways that were not possible previously as operators were forced to watch the cladding through a welding shield or helmet, trying to follow the arc around in circles as best as they could.

 

2018_3_13 - Watching a Rotating Cladding Process

The View from a Weld Camera as Transmitted over a Slip-Ring



Topics: Pipe Cladding, weld monitoring, Slip Ring

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