Working in nuclear manufacturing poses significant risks due to handling radioactive materials and potential exposure to ionizing radiation.
Our customer is a France-based provider of welding-for-hire services, that specializes in delivering critical welding solutions to the global nuclear industry. Orbital welding and Narrow Gap TIG welding are the two frequently used techniques in manufacturing critical components for nuclear reactors and infrastructure. Given the nature of their work, worker safety and maintaining weld quality are paramount, and they sought an advanced solution.
Recognizing the potential of Xiris' technology, they turn to our weld monitoring cameras. These cameras offer a unique opportunity for remote monitoring and control, helping to protect their employees from radiation. This case study explores how the XVC-310 Lipstick cameras addressed their needs effectively.
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XVC-310 Lipstick Weld Camera Installed on Narrow Gap Tig (NGT) Equipment |
The Story of Our Customer
The European provider specializes in providing critical welding solutions and is equipped with a range of advanced equipment, including the POLYSOUDE POLYCAR 80-2 orbital welders. These automated machines are capable of handling 4”, 6”, and 8” tubes, which are integral to their operations highly regulated sectors. Despite their sophisticated equipment, significant challenges arose when they were awarded a contract with a nuclear facility.
All because direct supervision in such environments is impractical, and the lack of monitoring hinders their ability to manage weld quality. Given the stringent safety and quality requirements, it was clear that a remote monitoring solution was necessary.
To overcome these challenges, the European provider turned to Xiris’ XVC-310 Lipstick camera. The tiny camera offered advanced solutions tailored for processes in confined spaces like Narrow Gap and Orbital applications.
Integrating the XVC-310 cameras with their POLYSOUDE POLYCAR 80-2 welders significantly enhanced their ability to perform high-quality, remote welding operations safely and efficiently.
The Challenge Before XVC-310 Lipstick Weld Camera
Working in nuclear manufacturing poses significant risks due to handling radioactive materials and potential exposure to ionizing radiation. To mitigate these risks and keep engineers and technicians out of radiation areas, the welding services provider ruled out direct supervision and adopted the solution of remote monitoring with the help of welding cameras.
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Why the Elite Weld-Service Providers Chose XVC-310 Lipstick Weld Camera
To monitor the POLYSOUDE POLYCAR 80-2 orbital welders remotely in high-radiation environments, key factors are considered including the compactness, clarity, and precision of the welding cameras used. Out of the many options available, the XVC-310 Lipstick weld camera stood out due to its high-resolution imaging, easy retrofitting capabilities, multiple camera integration with one software package, and versatile lens options. The XVC-310 Lipstick Weld Camera accessories include the integrated LED Cooling Block, which provides cooling to the camera head in harsh environments.
How is XVC-310 Lipstick weld camera used in this Scenario?
Our customers are now using the dual XVC-310 lipstick weld cameras, each equipped with integrated LED Cooling Blocks, in the best possible way. Their setup (Leading and Trailing view) is designed to effectively meet their specific monitoring needs.
- Leading torch view enables their personnel to:
- See the torch position (torch height and horizontal position)
- See the Tungsten electrode quality and wear during the welding operation.
- Monitor correct wire speed and placement during the operation.
- Trailing camera enables their personnel to:
- Check for correct torch oscillation with good wetting to the side of the groove.
- Synchronize images and record weld parameters for quality purposes.
- Monitor the Melt Pool size and shape
- Monitor the quality of the cooling melt bead.
“Integrating our automated welders with Xiris’ XVC-310 cameras was a game-changer. The high-resolution images and the ease of operation and installation allowed us to monitor and control our welding processes with unmatched clarity and precision.”
The Results
Using XVC-310 had a profound impact on the operations of this weld service provider:
- Recognizing the capabilities of XVC-310 lipstick weld cameras, our company immediately received an order for the first two camera systems to incorporate into their equipment. More orders are pending as they equip their entire fleet of machines.
- The cameras allowed the end customer to minimize time spent in high-radiation areas by enabling welders to operate the welding equipment remotely and monitor the torch and wire feeder position before, during, and after welding.
- The cameras also allowed the customer to constantly monitor the best welding power source settings to achieve superior welding results with immediate visual feedback.
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