The Xiris Blog

How to Implement Audio Monitoring for your Welding Operation

Posted by Cameron Serles on Tuesday, September 03, 2019 @ 11:32 AM

Our team at Xiris has released an audio monitoring package for our weld cameras. Today, we’re sharing how you can set up audio monitoring capability with weld cameras for your operations.

Audio monitoring with weld cameras involves both hardware—the microphone and other equipment—and software—Xiris’ WeldStudio™ software.           

Audio Monitoring Hardware

Audio monitoring starts with the microphone. The welding environment is not very friendly for electronics and sensitive equipment, so Xiris has developed a rugged microphone capable of capturing the full spectrum of audio using a specialized sensor. This sensor captures sound frequency from 40hz up to 20khz. This means that you not only get the low rumbles at the bottom of the range, but you also get the sizzle and pop at the high end.

The microphone has been “ruggedized” so that it is suitable for the welding environment. A protective covering provides thermal, environmental and dust protection for the sensitive microphone elements. The microphone is also directional, meaning once it is pointed at the welding process, it will ignore some of the surrounding noises.

The microphone has been designed to be located near the welding camera, although it can be positioned elsewhere if needed.

Cables and wires connect the microphone and transmit the audio signals to the Xiris HMI computer, which contains Xiris’ specially developed audio processing card. It is here that the signal is processed and conditioned for integration with the video images.

Audio Monitoring Software

The audio feature is part of Xiris’ WeldStudio™ software utility, where operators are able to play back, record and adjust the audio that they’re hearing. The audio signal is synchronized with the video stream from the weld camera, so operators can see and hear what’s happening with their welding at the same time.

Audio 2 image

User Interface of WeldStudio™ with audio feature.

Using equalization controls, operators are able to reduce or eliminate certain frequencies, such as those caused by other mechanical noises or environmental noises unrelated to the welding. The software allows operators to completely control the equalization curve to meet their specific needs, suppressing or enhancing certain frequency ranges depending on what they want to listen to. Audio is a module in the WeldStudio™ software, so the touch and feel of the interface and the tools within the program will feel familiar to experienced users.

Summary

Video monitoring using weld cameras has brought many benefits to fabricators and their operations. However, there was something missing. Sound.

Experienced welders understand how sound can help to tune and monitor their welding processes. With this new audio monitoring package, Xiris is providing this capability as an option with the Xiris weld camera system.

 

Better Images. Better Decisions. Better Process Control.

Follow Xiris on social media for regular updates and welding videos!

Instagram LinkedIn FacebookTwitter

Topics: quality control, weld camera, weld monitoring, audio, hardware, software

Weld Cameras: The New Tool to Teach Welding

Posted by Robin Montgomery on Tuesday, August 20, 2019 @ 12:45 PM

Using weld cameras in a classroom has many benefits for students, instructors, and administrators by providing high dynamic range images with a clear view of the weld arc, torch tip as well as the darker surrounding features such as the weld pool and seam. Weld cameras will enhance your classroom training, making them indispensable tools for teaching welding techniques.

 

Rather than always having to crowd around the instructors, with weld cameras, students are able to clearly see all features of the weld process, providing a better weld instruction experience, without the instructor having to restart or repeat the welding process should the student have missed some portion of the instruction.

 

“By displaying the captured welding video on a remote screen, the instructors can vastly improve the learning experience of their students, with improved learning success, which is always the instructors’ goal”. – Chris Manning, Chair of Welding Programs at Northern Alberta Institute of Technology (NAIT)

 

Not only do welding instructors achieve their goal of improving the learning success, they also don’t have to worry about classroom space and students’ proximity to weld demos.

 

Having each lesson recorded also gives students the ability to repeatedly view and learn from those demos, and enables instructors to keep an on-going source of recorded material to avoid constantly recreating lessons.

 

Administrators experience benefits from the use of weld cameras in classrooms as well. This technology eliminates space constraints in weld training booths and allows instructors to teach more students, faster. Weld cameras can also enhance the program’s reputation, which attracts even more students to the school.

Xiris Weld Camera Kit for Educators

Xiris offers a Weld Camera Kit specifically designed for Educators that comes with everything you need for easy applications of weld cameras in your welding program.

 

So, are you ready for weld cameras in your classroom?

 

Visit our website, download our Education Whitepaper or contact our Education Account Manager for more information.

 

Better Images. Better Decisions. Better Process Control.

Follow Xiris on social media for regular updates and welding videos!

Instagram LinkedIn FacebookTwitter

Topics: quality control, weld inspection, weld environment, High Dynamic Range, HDR, weld camera system, consistent, inspection system, educator, weld school, visual arc system

Video Learning Guides for WeldStudio™

Posted by Brian Wirth on Wednesday, August 07, 2019 @ 11:47 AM

Even the best users sometimes find it difficult to read through an operating manual for a software product. Recognizing this, Xiris Automation has created a series of easy-to-use training videos to help users set up and use the WeldStudio™ software utility provided by Xiris. There are currently 15 short videos available, with more being constantly created as new features are added to the WeldStudio™ software. The current video guides include the following topics:

  • WeldStudioTM Features Overview
  • WeldStudioTM Installation
  • Camera Tools (multiple videos)
  • Image Tools (multiple videos)
  • Media Tool
  • Virtual Camera & Raw Video Playback
  • Backing Up & Restoring Settings

This video series offers the user a very detailed explanation of how to install the WeldStudioTM utility, providing an in-depth look at all of the features in the program used to control the Xiris weld cameras. Special detail is provided on how to use the impressive video processing options WeldStudio™ has to offer, as well as details on how to properly record and playback video and raw images.

Xiris customers have exclusive access to the video guides through our Support Center website. The Xiris Support Center is a great resource for customers providing access to product manuals, the latest software updates and more. If you’re an existing customer and would like to access the WeldStudio™ Video Guides, contact support@xiris.com to get connected with Support Center today!

Video Learning Guides Available

Better Images. Better Decisions. Better Process Control.

Follow Xiris on social media for regular updates and welding videos!

Instagram LinkedIn FacebookTwitter

Topics: weld camera, WeldStudio, video guides, training

Xiris Launches Audio Monitoring for Weld Cameras!

Posted by Cameron Serles on Tuesday, July 23, 2019 @ 11:25 AM

Xiris is proud to announce a revolutionary addition to our industry-leading cameras: SOUND!

At Xiris, we strive to be a world leader in developing sensors and inspection systems for welding processes. Our team of multidisciplinary experts have extended our weld camera product line with the addition of audio capture and monitoring capability. We are committed to continuously improving our products to meet the needs of our customers, and audio monitoring is something our clients have been asking for.

Adding audio capture and playback to Xiris’ weld cameras introduces a new dimension to welding quality control. Now fabricators can use two sensory inputs – sight AND sound – to help them determine if the welding process is functioning correctly or needs fine tuning to provide the best weld process possible. This enhancement gives operators another tool to assess, monitor and improve the consistency and effectiveness of their welding processes.

Xiris Launches Audio monitoring for welding camerasAn Audio Waveform Picture from the Xiris Audio Recorder

A study in the January 2017 edition of the Journal of Intelligent Manufacturing found that multisensory evaluation of seam welds was 97% more accurate recognizing defects. Various academic and anecdotal studies confirm that sound is key to real-time monitoring of welding quality and process control for intelligent manufacturing.

Welders draw on years of experience to recognize what quality welds sound like. Each type of welding can generate a unique sound signature when it is “in tune” and when it is “out of tune”. In upcoming blogs, we will be talking about the different types of welding and what to listen for. We will also share more details about the Xiris audio recording and playback option and how you can add it to your operations.

Subscribe to our blog so you don’t miss out!

 

Better Images. Better Decisions. Better Process Control.

Follow Xiris on social media for regular updates and welding videos!

Instagram LinkedIn FacebookTwitter

Topics: quality control, weld camera, weld monitoring, audio

Xiris Seam Tracking for Laser Welding on Tube Mills

Posted by Greg Cooke on Tuesday, July 09, 2019 @ 01:00 PM

Laser welding offers several advantages over conventional TIG or Plasma welding processes especially for difficult to weld materials where lightweight, high strength and corrosion resistance is needed.

Advantages include:

  • High welding speed (up to 60 m / min), especially for thin walled material
  • Produces a small Heat Affected Zone (HAZ) with less joint distortion
  • Favourable fine grain structure of the weld bead with excellent material properties
  • Very clean welding process with minimal spatter, small weld beads and high precision
  • Well suited for welding exotic alloys of stainless steel, titanium and aluminum

Since laser welding is fast and generates a small melt pool, it requires precise positioning (typically within a few tenths of a mm) relative to the weld seam. Even small misalignments in the fit-up can lead to weld defects in the tube such as lack of sidewall fusion or porosity.  

The Xiris SeamMonitor™ for laser welding has been specifically developed for seam tracking of laser welded seams. The SeamMonitor™ software in combination with a Xiris High Dynamic Range (HDR) weld camera enables real-time monitoring of the melt pool size and shape, and the relative location of the weld seam to the laser keyhole spot using machine vision technology.   

Demo-A

Video of the User Interface of the SeamMonitorTM for a Laser Welding Process

The SeamMonitor™ system includes a Xiris open arc weld camera, industrial HMI controller, SeamMonitor™ software, optics and interfaces to integrate with other automation devices. It can be added to any laser welding process, either mounted off-axis to the laser beam, or on-axis through a suitable laser beam delivery camera port. Regardless as to how the camera is mounted, the SeamMonitor™ can help align the laser before welding, and monitor the laser welding process and track the seam during the welding process. All parameters and images can be recorded for process monitoring and quality assurance based on the set-up parameters and defined warning limits.

The SeamMonitor™ provides a powerful way to manually monitor the laser welding process while automatically measuring the laser keyhole-to-seam alignment and perform spot size. 

Contact Xiris sales to see how our products can enhance your unique process.

Topics: Laser welding, Tube and Pipe welding, tubedefects, tube mill, mill

Why You Should Use a CellView Camera

Posted by Greg Cooke on Thursday, June 27, 2019 @ 12:45 PM

Welding automation is becoming increasingly more common and necessary to ensure high-quality welds and productivity. Using weld cameras, such as the Xiris CellView camera, helps operators see the welding process more clearly and helps them make any in-process adjustments. 

CellView cameras enable operators to view a weld cell from a broader perspective, they see the bigger picture of the welding process. This allows the operator to ensure the related equipment and area are clear and working properly. Since the operator can view the weld cell from a monitor with a CellView camera, the operator can work in safer conditions further away from any dangerous welding process. With the additional visibility from utilizing the CellView camera system along with other weld cameras, operators and supervisors can increase the “arc-on time” (time spent welding) by reducing the amount of time needed for set-up, or to make adjustments to the welding process while in operation.

 

Diagram of how a CellView camera would be set-up with another weld camera. 

CellView Camera System

CellView Camera BenefitsThe Xiris CellView camera is a robust adjustable color camera with a wide-angle view with motorized zoom. It is typically installed with the XVC-1000e weld camera for maximum results. As the CellView camera is integrated with the Xiris camera system, it can be managed and monitored from the same HMI. Coarse adjustments can also be made utilizing the larger view and the Xiris weld camera for the final setup. Xiris cameras can be located up to 100 meters away without loss of image quality making the monitoring of very large automation cells or multiple cells from a control room possible, and the addition of more cameras and views easy.

 

For more information contact us or request a free, one-on-one, no obligation consultation!

 

Better Images. Better Decisions. Better Process Control.

Follow Xiris on social media for regular updates and welding videos!

Instagram LinkedIn FacebookTwitter

 

Topics: quality control, weld environment, safety, health, weld camera system, wide-angle, CellView camera, welding cell

Latest Posts

Follow Me