The Xiris Blog

Detecting Bead Ripple During Tube Manufacturing

Posted by Cameron Serles on Friday, October 05, 2018 @ 11:45 AM

Lighter wall mild steel pipe production requires bead height monitoring for bead ripple. Bead ripple is a condition sometimes associated with a weld process that is too hot and may result in longitudinal weld cracks.  Bead ripples appear along the length of the weld bead as undulations with measurable differences in height by as much as 1/8” (3 mm).  Often the height of the bead ripple on a welded pipe is a function of the heat that has gone into the weld process:  the higher the heat, the greater the height of the bead ripple. In most applications, a weld bead should have a smooth, consistent height as an indicator of a stable weld process.

Bead Ripple1An image of a weld bead with bead ripple

In some applications, a weld bead ripple can be desired, such as in certain coated steel products. This ensures that all contaminants from the area of the weld have been squeezed out, preventing potential inclusions from occurring in the weld bead, which would result in compromised weld quality.

By measuring the bead height on a weld bead over a period of time using a laser based triangulation system , an indication of the smoothness of the weld bead can be made.  By calculating ongoing historical statistics of the head height (e.g. min/max, average, standard deviation), an indication of smoothness of the weld bead or bead ripple can be made.  Tolerances of the amount of smoothness or ripple can be set to match the process and when exceeded, an alarm can be set.

Bead Ripple Detection1 Measuring the weld bead height over successive images can detect bead ripple over time

Topics: tube mill, tubedefects, productivity tools, tube, bead height, Tube and Pipe welding, quality control

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

Seam Monitoring for Coil Joining

Posted by Cornelius Sawatzky on Tuesday, September 04, 2018 @ 10:00 AM

Monitoring the welding process during coil joining at the front end of a tube mill is crucial to the integrity of the weld as it moves through the tube mill.  Coil joint failure can be costly in terms of both time and efficiency of production on the mill. Operator safety must also be maintained by removing them from the direct welding area as much as possible while enabling them to monitor the coil joining process.

Continuous welding processes used in coil joining require real time operator monitoring to ensure that the process continues smoothly and efficiently. The Xiris XVC-1100e50 camera provides a way to do just that.

A recent Xiris customer manufactures thick walled steel pipe in a continuous high frequency welding process at 70 feet (20 m) per minute.  The customer had implemented a semi-automatic coil end joining system on the infeed buffer of the pipe mill, giving the operator about 10 minutes to end sheer, mate and weld a new coil. This is sometimes referred to as end joining.

The welding process used a MIG welding torch mounted onto a linear track with dual axis torch position adjustment via a remote control pendant. With the Xiris XVC-1100e50 camera mounted to the traveling torch assembly, the operator was able to close the curtain, providing greater weld arc shielding while maintaining a clear view of the weld torch-to-seam alignment on a display screen.

The camera provided the operator with a clear, close up view of the weld process, which allowed the operator be remote from the direct welding area.  By providing a clearer image of the weld process, the operator was able to make more consistent welds, reducing the potential for a joint failure as the strip is driven through the pipe making process.

For a video of the coil joining process taken by the XVC-1100e50 camera, please view the video below. 

coil joining

This is just one example of how Xiris products can enhance your manufacturing process. Contact Xiris sales to see how our products can enhance your unique process.

 

Topics: tubedefects, Tube and Pipe welding, coil joining, tube mill, mill

Tracking Tube Production Using the WI2000 and WI3000 systems

Posted by Cornelius Sawatzky on Thursday, June 21, 2018 @ 09:00 AM

Xiris' WeldInspection System Helps Identify the Root Cause of Variations in Tube Production

Many applications require tube producers to identify and document their tubes by batch, date and sometimes even time stamp for trace-ability. If a tube segment fails at a sub process or worse at the end user, a detailed analysis and root cause investigation follows.

 

audit logs 3

Audit Log Files from Xiris' WeldInspection System

When the original tube production date and time information is available, a helpful tool to identify anomalies is to review the audit log files generated on Xiris’ WeldInspection system.The audit log files are date and time stamped and easily accessible to look for any weld related geometries that may have deviated for a time period during the production run.

Variations may be a change in bead shape/size that can be an indicator of squeeze pressure or weld heat change. With the WeldInspection system monitoring multiple geometrical conditions such as mismatch, bead height, width and potential freeze line, much information can be gained by reviewing the log files and identifying a potential root cause. Additionally if a particular condition has been identified as the potential cause, the audit logs can be utilized to determine for how long that condition existed therefore helping reduce the volume of product that might be quarantined for further evaluation.

 

If you are interested in learning more about how our WeldInspection system can benefit you and your company, please contact us here.

 

Topics: Tube and Pipe welding, WI-2000p, tube, defects, pipe, tubedefects

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

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: Tube and Pipe welding, weld inspection

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