The Xiris Blog

LASIMM project goes live with Xiris Automation

Posted by Emily Blackborow on Wednesday, February 27, 2019 @ 01:00 PM

Lasimm Machine

 

The Large Additive Subtractive Integrated Modular Machine (LASIMM) project is now live and ready to build large 3D printed metal structures for construction. The machine is the first of its kind and is predicted to keep Europe's manufacturing industry as a leading competitor in the global market. The project highlights a milling robot – the first for additive manufacturing of aluminum and steel - to integrate seamlessly additive, subtractive, metrology and cold work applications into a single machine. 

LASIMM will enable the creation of mixed-material structures by using similar and incompatible substances along with  software to generate tool paths and machine sequences. The machine will ensure the component's structural integrity by allowing in-process, non-destructive testing and restoration of defects. 

Xiris partnered with Cranfield University, a defining member of the project, and delivered the XVC-1000 HDR Weld Camera as an inspection solution for LASIMM. We are honoured to contribute to this project and are excited to see the results of the project and the impact LASIMM will have on Europe's additive manufacturing industry. 

Topics: weld camera, Education, High Dynamic Range, manufacturing, applications, XVC Weld Camera, HDR, weld camera system, consistent, inspection

How to Improve Your Sub Arc Business

Posted by Cameron Serles on Tuesday, October 14, 2014 @ 12:59 PM


The submerged arc welding process is used in a variety of industries all that work with thick, heavy and expensive materials. Many of these industries also perform cladding, where weldment material is added to the base material to improve its wear resistance. In many cases, having a cladding process located near the sub arc welding process can increase the health and safety risk for operators who must monitor the welding process close by. Instead, a welding camera could be added to the submerged arc welding process (SAW) to assist the operator in monitoring the process remotely, providing a number of benefits:


1. Cost Savings

One of the first and most substantial benefits a welding camera provides to the SAW process is to eliminate an abundance of rework and set up time. By adding a camera to remotely monitor the welding process, operators can ensure that all welds are lined up correctly and make immediate adjustments if necessary while welding. This reduces scrapped material as well as any machine down time in order to reset the process.

2. Safety Benefits

Remote monitoring of the sub arc welding process provides health and safety benefits to the welding operators by:

o   Removing them from a high heat environment without having to compromise their monitoring of the welding process. By working remotely to monitor the weld process, the operator has a quieter, cleaner, healthier work environment while still being able to control the weld alignment and surrounding environment.

o   Removing them from dangerous monitoring positions. Some sub arc welding tasks require operators to monitor the weld process from immense heights, or tight spaces in order to ensure weld quality and process efficiency. A welding camera with a remote display screen allows the operators to view the weld in a less hazardous environment, improving employee safety without sacrificing quality.

Xiris View Camera for Submerged Arc Welding

The Xiris View Camera for Submerged Arc Welding (XVC-S)

3. Eliminates Failure Rates

As already mentioned, SAW involves a lot of costly, heavy materials, many that are used in industries such as shipbuilding. In this high demand, high quality industry, there is no room for failure or risk of low quality welds. It is absolutely crucial that every weld involved is durable, reliable, and of the best standard of quality. The addition of a weld camera would allow an operator to eliminate a possible failure, by monitoring the process as it occurs.

4. Automation Benefits

As the demand in industries such as shipbuilding, bridge-building, spiral pipe applications and green energy technology increases, the demand and expectations of the quality of SAW processes continue to rise. By using automation to improve the consistency and repeatability of SAW processes, fabricators can better meet the quality requirements of their customers. As more advanced technology allows for the manipulation of material, spinning and moving the weld as it occurs, this can make monitoring more difficult. The addition of a welding camera would allow the weld head to be easily installed to most automation equipment, moving with the material or weld torch as it moves.

Secondly, in terms of changing materials, sizes or processes in general, the addition of a welding camera would allow automation lines to changeover much more quickly through faster set ups. As the automation equipment is prepared to run again, the operator can speed the set up process quicklyprocess quickly, making adjustments on the fly so that there is minimal scrap or lost time when changeover begins


There are numerous benefits to adding a welding camera to a SAW process. With the ability to remotely monitor the position, alignment and operation of the weld tip, operators can reduce down time, increase productivity and improve weld quality.

The Xiris product line includes cameras that can be used in both submerged and open arc welding processes, and can be found on our website.
See the benefits yourself by adding a weld camera today!


 

Topics: quality control, Sub Arc welding, camera, applications, productivity

Improve Safety for Submerged Arc Welding Applications!

Posted by Cameron Serles on Tuesday, August 27, 2013 @ 05:16 PM

Submerged arc welding processes are typically run as automatic or semi-automatic processes with automatic flux feed delivery systems. The automation of a sub arc welding process provides the fabricator with a number of distinctive advantages, such as higher quality, higher capacity, and of course much higher productivity in the fabrication process. 

Weld Cameras can improve monitoring of sub arc welding processes.

Automatic sub arc welding can be accomplished by moving the work piece underneath the weld head or moving the weld head over a stationary work piece. However, no matter how much of the process is automated, it is still important for the operator to have visibility of the welding process and see the parameters of the weld (such as wire feed speed, arc current and voltage, travel speed, and wire stick-out) to ensure that the weld process is running efficiently enough. 

If any parameter does go out of control, it is important for the operator to be able to see the process so as to make adjustments before the weld quality deteriorates.

Traditionally, the welding operator has had to be stationed near the weld head to be able to adequately see and manipulate the weld head. However, this close proximity to the weld head often puts the operator at risk and/or in extreme discomfort. This is due to commonly occurring conditions such as:

  • The operator has to sit high over ground to monitor a welded pressure vessel or assembly.
  • The operator has to work with restricted freedom of movement, which may include kneeling or sitting in a cramped space, such as inside a small diameter pressure vessel.
  • Conductive elements are present with which the welder may make accidental contact during the welding process, causing potential electrical shock.
  • The operator has to monitor the weld in wet, damp, or humid conditions, which reduce the skin resistance of the body and the insulating properties of accessories, causing additional potential of shock.

In all of these situations, health risks to the operator can be avoided by removing the operator from the immediate area of the weld environment. This can be accomplished using a Xiris XVC-S Sub Arc Camera. With the use of such a camera, the operator can monitor the progress of the sub arc weld from up to 40 meters away. 

The benefits of using the XVC-S? For the fabricator, easier compliance with an ever-increasing set of regulatory guidelines that limit how and when operators can access the weld area. For the operator, higher productivity by avoiding the distractions caused by the hazards of the immediate vicinity of the sub arc weld area.

Conclusion

Automatic or semi-automatic submerged arc welding requires in-process operator monitoring of the weld, which can best be achieved with a Weld Camera—freeing the operator from the health risks of direct proximity to the weld.

 

Image courtesy of ESAB.

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Topics: weld camera, weld safety, Sub Arc welding, safety, weld, applications, visibility

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