The Xiris Blog

An Eye Into the Future: Weld Cameras in the Classroom

Posted by Margaret Montgomery on Thursday, July 19, 2018 @ 10:00 AM

Xiris's XVC-1100 kit and XVC-1000e HDR weld cameras are transforming the way aspiring weld operators are taught. 

Xiris Cameras an Asset in the Classroom

The XVC-1100 weld camera kit, which is being used at the Southern Alberta Institute of Technology (SAIT), enables students and instructors alike to capture and save videos of their welds. During instruction, the XVC-1100 allows students to see what the instructor is doing on a large, projected screen- rather than having to crowd around the instructor performing the weld. During practical work, students are able to perform a weld and save the recorded video so that they can review their weld and technique after they are finished.

 20180601_113704 enhanced

The Xiris XVC-1100 camera installation at SAIT Polytechnic enables students to film and review their welds.

The XVC-1000e weld camera is being used at Santa Anna College. The camera is mounted directly on a weld robot, similar to how welding occurs in many manufacturing environments today-thereby providing students with correct training in the welding techniques they'll use in the workplace once they graduate.  

The XVC-1100 and XVC-1000e cameras both feature adjustable optics. With a tightly focused view, students can see the interaction taking place between the wire fed metal and the parent material as well as a clear view of the weld arc and the resulting melt pool. When the camera is configured with a larger view of the welding process and its coupon, the student can see all the motion during the weld process so they can learn the hand and torch positioning techniques from the instructor. 

Both types of cameras allow welding instructors to demonstrate to their students good and bad welds- and what determines the difference between a good and bad weld.

As weld cameras increasingly become a standard tool in welding processes of all types, their use in welding education is becoming an important step in the training of the next generation of welders. Not only do the cameras help students learn the basics of welding, bringing cameras into the classroom provides another way for students to learn welding adopt new technologies in their future professions. 

This is why the use of the Xiris Weld Cameras in instructional settings will continue to grow.

Our XVC Evaluation Kit for educators includes everything instructors need to record and playback their welding processes, including cables, an assortment of lenses, and more. 

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

Topics: weld camera, weld camera system, welding course, welding education

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 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

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

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 1,000,000 Watt Plasma Arc!

Posted by Justin Grahn on Tuesday, February 27, 2018 @ 01:17 PM

Usually Xiris Weld cameras are used to monitor open weld arcs of many kinds of processes, including plasma welding processes, where the power settings are usually in the range of a few hundred Watts of power.

So imagine when presented with the challenge of monitoring a one million Watt plasma arc! This is exactly what Xiris was asked to do – mount a camera to see such a powerful arc as part of an industrial process. We were not sure how well the camera would respond to the plasma arc as it was so hot and generated such intense bright light that even the dynamic range of the XVC-1000 weld camera may not be sufficient to properly image it.

When setting up the camera, we had to mount the camera far away from the plasma arc, at about 6 ft. (2 m) away, while monitor the entire process in a completely different room. The plasma arc was so powerful that our camera would shake when the arc was activated. Even from a protected room, the noise that the plasma arc generated seemed like standing next to a jet engine.

We were happy to discover that, even with such a powerful light source, the Xiris XVC-1000 weld camera was able to capture clear images of the high-powered plasma arc. The images were good enough to see sufficient detail in the arc for research staff to analyze the behavior of the return arc remotely, without having to be close enough to the plasma source to create hazardous work conditions.

2018_2_27 - Watching a 1,000,000 Watt Plasma Arc

An Actual Image of a 1,000,000 Watt Plasma Arc!

 

Topics: weld camera, weld monitoring, Plasma

Xiris is Growing!

Posted by Catherine Cline on Tuesday, February 13, 2018 @ 11:33 AM

In 2017 Xiris saw business growth of more than 40% over the previous year. This growth was due in part to the large increase in automation throughout the manufacturing industry, an increase in metal additive manufacturing in the aerospace industry and a new focus on employee training, health and safety for welding processes.

North American Industry saw the highest number of robots delivered in 2017, with twenty-seven thousand delivered in the first nine months, according to Machine Design magazine. The largest installations of robots came from the automotive components and metals manufacturing markets with food and consumer goods close behind. The machine vision market also saw a growth rate of 14% in 2017 with 14% of those being vision systems.

The Xiris XVC family of weld cameras have become critical tools in advancing weld automation processes across the board, particularly in the growing markets mentioned above. The Xiris weld cameras become the eyes of the robot and enable operators to safely see the weld process from start to finish.

In order to keep up with this growth, Xiris is also expanding. We have added a number of new employees in all areas of the company. We now have a Sales Manager in Dusseldorf to address increased demand in Europe. We have also increased staff at our head office in Burlington in all areas of the business including software/hardware design and development, production and product support. With these added resources we feel well positioned to meet growing demands and look forward to continued growth and success in 2018 and the coming years.

Thank you to all our great customers and partners for a great 2017!

Xiris personnel.jpg

 

Topics: weld camera, welding automation, Machine Vision, Robotic Welding

Latest Posts

Follow Me