The Xiris Blog

Using Weld Cameras to Reduce Health Risks

Posted by Robin Montgomery on Thursday, October 03, 2019 @ 11:30 AM

High Dynamic Range (HDR) weld cameras provide clear images of a welding process including detail of the weld arc as well as the darker surrounding background environment, making it easy to monitor and control precise welding processes. Not only do weld cameras enable operators to see more detail of the welding process, by allowing them to see it remotely, they can improve the health and safety of operators on the job and reduce workplace costs associated with safety.

 

Common on-the-job risks that can be eliminated by removing the operator from the immediate welding environment include:

·         electrical shock 

·         "welding eye" (direct exposure of the weld arc to the human eye)

·         contact with weld spatter

·         injuries from moving or falling objects 

·         welding fume inhalation

 

Many of these risks can cause serious damage to a weld operator. It is proven that workers exposed to welding fumes are more likely to develop lung cancer than those who are not1. Adding a weld camera eliminates the need to be close to the welding process, significantly reducing operators’ risk. Using a high dynamic range weld camera can also reduce fatigue and stress, making the job safer, more enjoyable, and more appealing to existing and prospective operators.
Introducing a weld camera will also reduce costs that are associated with health and safety, such as:

·        workers' compensation insurance rates

·        employee health insurance rates

·        costs due to lost productivity

·      possible litigation

There are many other benefits to using a weld camera, but health and safety is such an important factor that cannot be overlooked. When operators are able to view the welding process in a safe, remote location, there are a multitude of positive results.

For more information visit our website or contact us!

 

Better Images. Better Decisions. Better Process Control.

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Sources:

1https://www.channelnewsasia.com/news/world/more-evidence-welding-fumes-raise-lung-cancer-risk-11553186

Topics: quality control, weld environment, High Dynamic Range, safety, health, HDR, weld camera system, consistent

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.

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

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.

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

Xiris Launches New Support Center

Posted by Robin Montgomery on Wednesday, June 19, 2019 @ 12:00 PM

Our team at Xiris has always been dedicated towards providing an excellent customer experience, from the products we design and build, to how we support our customers before and after a sale is made. Creating the Support Center for our customers was our next step in improving the overall customer experience.


View of Support Center for Xiris Customers

 

Whether you are an end user customer, OEM or distributor, there is content that has been customized for you. The new Support Center includes specific product related documents, manuals and installation guides such as trade articles, white papers, how-to articles, video tutorials, case studies, dictionaries or glossaries, and soon it will have a frequently-asked questions (FAQ) section. Essentially, the Support Center will contain anything that helps our customers and partners use and grow their understanding of our products or services such as our Weld Cameras or our Tube and Pipe Weld Inspection Systems.

 

Customers can create an account and have access to the latest product information and user manuals 24 hours per day, 7 days per week. Forrester, a researching company, found that 70% of customers prefer to use a company’s website to get answers to their questions rather than calling or emailing customer service1. We are embracing this and providing a platform that customers can use to answer their own questions.

 

Xiris always tries to be proactive in all areas of our business, including creating happy and successful customers. Our new Support Center is allowing customers to answer all of their own questions about our Weld Cameras and Tube and Pipe Weld Inspection Systems on a user friendly platform. This results in happy customers with a great overall experience using Xiris products and services.

 

Better Images. Better Decisions. Better Process Control.

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Sources: 

1https://go.forrester.com/

Topics: weld camera, weld inspection, Tube and Pipe welding, weld camera system, inspection system, online support, customer service

10 Reasons Why You Should Add a Weld Camera to Your Classroom

Posted by Cameron Serles on Thursday, May 30, 2019 @ 01:00 PM

Adding cameras to view and recording welding is a constant desire of progressive welding schools. However, for many years, there was a lack of the appropriate camera technology with High Dynamic Range imaging capability to properly image welding and display it on a standard 8-bit monitor. The Xiris Weld Camera has overcome this with a combination of advanced electronics and software that map the output to a computer monitor for best viewing results, presenting 10 compelling reasons why Instructors should add a weld camera to their program:

  1. A more-enjoyable, “high-tech” learning experience. By introducing cameras into your training curriculum, students will appreciate the modern approach to training an old skill. The result - enhanced prestige for your weld training facility.
  2. Use of recorded welding videos in the classroom. The ability to repeatedly view, and learn from, recorded demonstrations of good and bad welds can improve the overall effectiveness of your learning program.  Imagine having an ongoing source of video material for multiple classroom discussions, or to recreate lessons of key concepts.
  3. A clear view of all the features of the weld process. Never again worry during welding instruction that all students can see what is being taught.  A camera output to a large display makes all the features of a weld visible to everyone in your class.
  4. Better use of classroom layout. No more worry about classroom space, how many students can fit around a particular weld demonstration and how close they can be to the demonstration.
  5. Better capability to demonstrate new or subtle welding techniques. By building up a library of various techniques, students could review the videos of the best or newest welding technique possible.
  6. Reduced material consumption. Use less welding consumables by being able to minimize the amount repetitive arc on-time by students and instructors of the same welding process.
  7. Better curriculum development. Using cameras provides a whole new dimension in developing a better curriculum for welding courses by allowing instructors to employ digital video content in their classroom.
  8. Differentiation from schools without Weld Cameras in classrooms. Let’s face it – attracting students is a tough job and your school is competing with other schools across town and around the world.  The more appealing you can make your program will raise its appeal to prospective students.
  9. More students moving through existing facilities, faster. By providing students live and recorded content on a large display, more students can be learning via video.  The learning via video can happen while other students learn by doing, reinforcing the learning experience and doubling student throughput.
  10. Testing and verifying of new processes and techniques. When new equipment, process or technique is presented to your school, instructors could make a new video to test out the equipment or process, setting a standard for students to attempt to emulate.

With so many powerful reasons to introduce a weld camera into your curriculum, why wait? 

Contact Xiris today for a consultation.

Better Images. Better Decisions. Better Process Control.

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

Color or Not? Five Questions to Consider When Choosing a Weld Camera

Posted by Cameron Serles on Thursday, May 02, 2019 @ 11:00 AM

Welding is not a very colorful operation. The metal, torch and other materials are usually varying shades of grey. The arc is bright white. The background is almost black. To accurately monitor and inspect welds, being able to see a massive tonal range, from the brightest to the darkest, is essential.

Color image of TIG WeldMonochrome Image of TIG welding process

 Color and Monochrome images of a TIG Welding Proces

Standard cameras, and even the human eye, are incapable of distinguishing all features when faced with such a range of brightness. However, Xiris’ high dynamic range weld cameras can, either in color (the 1100 and 1100e) or black and white (the 1000 and 1000e).
As humans, we often think that color is better. But in weld cameras, that is not always the case. Determining whether a color or monochrome weld camera will work best depends on a company’s operations. Here are five questions to consider when choosing between color and monochrome weld camera:


1. What kind of welding process are you using?
TIG (GTAW) or Plasma welding benefit most from being viewed in color, simply because there is more color present in those welding processes. Evaluating the color of the torch tip, shielding gas, melt pool and even the Heat Affected Zone can help operators to assess the quality of the weld.

2. What do you want to monitor during welding?
For example, do you want to see certain features, such as the boundary between the end of the torch and the shielding gas and arc? That might help you closely monitor the integrity of the torch tip and avoid contamination.

Or, are you concerned about the amount or type of shielding gas in the process? The shielding gas can sometimes take on a unique color as it is consumed by the welding arc. Changes in the color can signify a change in the gas chemistry and alert operators to the possibility of impurities.

Or is the Heat Affected Zone (HAZ) of interest? The leading edge of the HAZ may become visible as the parent material colorizes at elevated temperatures. This can indicate the amount of heat penetration and energy transfer made during the welding process. Discoloration of the metal can signify the presence of excess heat.

3. Is color more important than resolution?
To generate a color image, the image sensor in the weld camera is “painted” with color filters. Each pixel becomes filtered with red, green or blue light in a standard pattern known as a Bayer pattern. The imaging software then mathematically recombines the pixels into a color image. One drawback of this process is that the resolution of a color image is decreased by approximately half compared to that of a monochrome image.

With higher resolution, monochrome cameras generate images with sharper detail than color cameras. In monochrome images, edges appear crisper and subtle details are more visible—important for assessing the texture of the melt pool, for example. However, the hues in a color image give the human eye the ability to better evaluate boundaries between various weld components, like the melt pool, torch tip and shielding gas.

4. Is camera speed important for your operation?
Despite being lower resolution, color image files are larger than monochrome because each pixel is described by 3 bytes of data, whereas in monochrome images, only 1 byte of data is required. As a result, a color camera often will transmit data slightly slower than a monochrome camera to its output device.

5. Does color provide additional information that can help your welding process?
Everyone’s welding operation is unique. You may have additional features such as guiding markers on your parent material, or wire being fed into the welding process that might be best suited to monochrome or color cameras. Our team can help you to assess your needs and advise whether color or monochrome will work best for your application.

Whatever the operational needs, Xiris’ weld cameras, in either monochrome or color, provide high contrast, clear images of the welding process, allowing manufacturers to quickly and easily monitor their welds for better process control.

Better Images. Better Decisions. Better Process Control.

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

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Topics: weld inspection, manufacturing, defects, weld monitoring, XVC Weld Camera, HDR, color weld camera, color imaging, weld camera system, welding education, consistent

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