The Xiris Blog

Xiris Automation: Let Our Customers Do the Talking!

Posted by Margaret Montgomery on Thursday, September 13, 2018 @ 10:00 AM

Our weld camera and tube & pipe inspection systems are only part of the solution we provide to our customers. 

Xiris Automation also had an exceptional service team which supports the integration of our products into several different processes and applications around the world. 

Not only is our service team available to answer questions about product functionality, system operation and integration, but they have also proven to be crucial when helping in situations when cameras or equipment are damaged during the manufacturing process and require a quick repair. One customer recently recounted an incident "when a series of events on-and off-shift led to improper re-assembly of a damaged camera cable", and:

"Xiris' service team proved to be as exceptional in their response as their equipment has been in its welding process role."

                   - Brian Dobben, Flowserve Corporation

You can read Brian's blog on valuable new technologies in arc vision for welding here.

As Brian says, Xiris' technical support team travels worldwide to help customers onsite with installation and training issues after they have purchased a product from Xiris directly, in order to help make the application of our products smooth and painless. Our technical support team often deals with cases that are unique to the customers' particular welding environment, answering any inquiries often the same day of the inquiry, when received during regular working hours. When a service request comes in, Xiris employees simulate the customer's issue on in-house equipment, answering questions about how to set up the equipment to get the best view of the welding process. 

tech support

A Xiris tech support employee working on an industrial computer.

In short, Xiris Automation not only provides innovative products for the fabricating and steel production industries, it also backs up those products with a team of experienced service professionals who are determined to make every customer satisfied with their user experience!

 

Topics: Tube and Pipe welding, productivity, color weld camera, weld camera system

DED Additive Manufacturing: 5 Things You Can Monitor With A Weld Camera

Posted by Cameron Serles on Thursday, July 05, 2018 @ 12:00 PM

Of greatest interest to most users of Additive Manufacturing using Direct Energy Depostion (DED) processes is the ability to constantly monitor the deposition process and to stop the process if the deposition goes awry. DED power sources generate a lot of light which is difficult to properly image using a traditional camera.  By using a Xiris Weld Camera placed around the DED head to monitor the DED process, an operator can stop the deposition process and repair the defective region then resume the deposition without adding additional material on top of the defective area. 

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 A detailed image of the Additive Manufacturing process, captured by a Xiris Weld Camera.

With a Xiris Weld Camera, the bright light arc from the DED power source can be clearly seen as well as the detail of its immediate surrounding environment.  Here are 5 areas where the operator is able to see more details of the additive process with such a camera:

  1. Amount of shielding gas being used (Plasma or TIG)

With a clear view of the arc used to melt the fed powder or wire, operators can monitor how much shielding gas is being used and whether adjustments are needed

  1. Alignment of weld torch to previous layer

With a clear view of the previous pass of material, the operator can make sure that the DED head is tracking the layer properly.

  1. Keyhole spot size, location and shape (Laser)

All features of the molten material being deposited can be better monitored with a clearer view of the weld environment.

  1. The powder or wire being deposited,

With a clear view of the arc used to melt the fed powder or wire, operators can monitor how much shielding gas is being used and whether adjustments are needed

  1. The quality of the resulting melt pool and formed final bead.

Looking for dross, good quality melting and proper wetting in the melt pool and proper final bead shape one the bead has cooled is possible with a weld camera as the operator can see enough detail for these features to be visible.

 

Summary

By adding a Xiris weld camera to a DED process, operators can ensure that their parts quality is optimized during production and expensive rework is avoided.

 

Topics: color weld camera, additive manufacturing, 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

Why Weld Cameras are Essential when Welding Large Pipe

Posted by Cameron Serles on Monday, April 03, 2017 @ 12:56 PM

 

 

Apr 3 image 1.png

Large Pipe Fabrication

Welding large pipes using either Submerged Arc or Open Arc welding processes may pose a number of problems, such as:

  • poor alignment of torch to seam
  • improper levels or placement of shielding gas or flux
  • improper joint preparation
  • jammed wire feeders
  • wrong welding power levels

to name just a few.

 In order to avoid these problems and ensure the highest possible quality, welding processes must be monitored closely.  When automated welding processes were first introduced, fabricators stationed an operator in a chair atop a welding machine, such as a column and boom welder, to visually monitor the welding process directly.  Surprisingly, this is still a widely used approach to weld monitoring!

 Apr 3 image 2.png

An empty chair waiting for the operator….

Even today, there are fabricators who are unfamiliar with automated inspection process and are forced to place an operator on a chair high above the welded pipe to monitor the welding process.  This is a health and safety problem waiting to happen!  Not only does the operator face fume inhalation, they risk injury from moving equipment, inadequate protection and dangerous heights.

Apr 3 image 3.png

Can you see the Operator monitoring the process?

In addition to the safety concerns, work breaks are a major drain on productivity.  Just think of the production time lost while moving the gantry robot or hoisting equipment down so that the operator can safely exit the equipment at ground level, not to mention the idle time until the operator returns to their position.

Apr 3 image 4.png

Or Here?

A Better Solution

The better solution is to use a remote monitoring weld camera installed at the weld head that can be viewed from as far as 100 m away.  Operators are on the production floor, removed from the welding process but still able to see all the details of a welding process.   Watch the video below, created by LJ Welding in Edmonton, Alberta, Canada, for an excellent demonstration of how weld cameras are being used in the field:

 Apr 3 image 5-1.png

 

You can visit our

WELD VIDEO LIBRARY

for dozens of examples of the camera in action. 

For more information on how Xiris Weld Cameras can enhance your weld processes visit Xiris.com or REQUEST A DEMONSTRATON 

Don't miss any of our amazing videos! Sign up to receive the Weld Video of the Month 

Topics: quality control, Xiris, welding, weld safety, Tube and Pipe welding, color weld camera, productivity tools

Using Weld Cameras For Torch Alignment

Posted by Catherine Cline on Tuesday, August 16, 2016 @ 11:09 AM

When Xiris demonstrates its weld camera systems, one of the unexpected benefits an operator notices right away is the ability to quickly align the torch and seam.   Xiris weld cameras have integrated LED’s that provide a nice bright image of the seam and torch prior to starting the weld process.  Before we begin our demonstration, we ask the operator to align the torch and the seam which is usually done manually with a visual check.  Once we are told the system is aligned, we ask the operator to look at the computer screen and, 90% of the time, the torch and seam are misaligned.  The operator then begins to use the weld camera system right away to achieve perfect alignment on a consistent basis.

Here are three videos that demonstrate the alignment process.  In these examples the manufacturer has installed a positioning sensor on the robotic arm which is meant to ensure perfect torch alignment during each weld and the operator simply verifies the alignment prior to welding.

Operator Alignment:

The positioning sensor and the operator have misaligned the torch, resulting in a bad weld.

 

 

Weld Camera Assisted Alignment:

The operator has used the weld camera system to verify the alignment and you will see the adjustments that were made after the robot had been aligned.  Not only do the cameras ensure accuracy, the operator can perform the alignment quickly, right from the console rather than bending, stretching or climbing up on to the equipment to achieve proper alignment.

 

 

 

 

 

 

 

 

 

 

 

For more information on how Xiris Weld Cameras can ensure accurate alignment of your torch and weld seam, visit Xiris.com

Topics: quality control, weld camera, welding, High Dynamic Range, productivity, color weld camera, weld seam, weld seam alignment

Weld Revolution Uses the Xiris Color Weld Camera

Posted by Catherine Cline on Tuesday, July 05, 2016 @ 02:00 AM

 

 

Last week Xiris Automation was given the opportunity to work with the team at Weld Revolution and record some footage with the new XVC-1100 color camera.   

Weld Revolution’s SpinArc® welding torches utilize a high speed rotating weld arc to enable the welding of all metals in any position using either metal-cored or solid wires in spray transfer or pulse modes.  

The unique stirring action delivers clean robust welds and is extremely effective for narrow groove welding.  The above video, captured with the XVC-1100 color weld camera, shows how smooth and consistent the SpinArc® process welds as it travels down a 3” deep groove and as a result, the weld bead typically requires little or no beveling.

Even with the incredible brightness of the arc and the outer walls of the narrow groove, the XVC-1100 colour camera was able to automatically adjust and deliver an excellent picture with detail of the melt pool, side wall tie-in, alignment, heat effected zone, and even wire spin.

   
For more information on how Xiris Weld Cameras can help with your Orbital Welding applications, visit Xiris.com

Sign up to receive our Weld Video of the Month

Topics: quality control, weld camera, welding, High Dynamic Range, weld pool, productivity, color weld camera

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