The Xiris Blog

Detecting Skip Welds During Fabrication

Posted by David Giannotti on Wednesday, January 22, 2020 @ 10:00 AM

Skip welding, otherwise known as Tack Welding, is a commonly used welding technique used by fabricators to help limit excess heat penetration in, and therefore minimize distortion of the parent material during welding. However, sometimes weld skips can occur unexpectedly and disrupt the process of a good weld. Weld skips can be difficult to predict because they are random events that leave weld operators scratching their heads for a cause.

Fig. 1 Weld Skip on a Section of Welded Tube

An Interesting find!

Recently, at a customer’s site, a robot was performing a longitudinal weld on a large component used in the agricultural industry when a random weld defect was identified by an employee monitoring the weld process.  Unknowingly, it turned out that approximately one in every twenty welds were made with this defect.   Not knowing how to correct the defect, the customer invested in a Xiris weld camera.  After setting up the weld camera to get a better look at the welding live, the weld camera revealed that the weld torch would suddenly skip over a segment of the weld seam that was supposed to be welded, something that is commonly referred to in the welding industry as a “weld skip”. But the question still remained: what was causing the weld to skip?

After carefully examining the recorded video from the weld process, it became clear to the welding engineers what was triggering the defect: an interference in the weld had caused the weld torch to momentarily become stuck in position before the pulling force would build up to enough to cause it to come loose.  Once the torch would come loose, it would jump over a segment of the seam before resuming the weld, resulting in a weld skip.

 

How Xiris Weld Cameras Can Help

Weld skips can be disastrous to a production process, causing product defects which can be costly to rework.  Having an employee continuously monitor a weld process can be unsafe and an unproductive use of their time, resulting in lost time, money and production. As a result, for some fabricators, their weld processes need to be constantly monitored for their weld skip. This is where Xiris’ weld cameras can help by providing real-time, close up views of the weld process while it is happening, capturing live images of potential welding defects for the operator who can make process parameter changes before the defects turns in to a major production problem. The Xiris weld cameras have the ability to archive the weld videos to allow operators to review the videos offline and analyze what caused a weld defect to occur.  In addition, using a Weld camera can provide employees with a safe means of remotely viewing the welding process, avoiding the need to monitor the welding process in hazardous or confined work spaces, increasing employee focus on other operations.

Topics: welding, weld camera system, inspection

5 Welding Applications Where Angled Optics Optimize Monitoring

Posted by David Giannotti on Thursday, December 05, 2019 @ 03:01 PM

xvc-700-side-by-side-header-2

The XVC-700, the new weld camera from Xiris, features a unique flex design allowing for a “periscope” configuration of the housing. This means this camera can be mounted anywhere from 0-135° relative to the main body axis of the housing.

The range of applications where angled optics enable better placement of the camera are only limited by your imagination, but here are 5 we are sure you will find interesting:

1. Monitoring of ID Cladding in Small Diameter Pipe

By combining a shallow angle (less than 30°) with angled optics and the weld camera mounted under the welding torch and parallel to the axis of the pipe, the user can see the tip of the torch. Alternatively using an angle that looks past 90 degrees, the weld camera can be mounted beyond the torch tip and look back to get a clear, unrestricted view.

2. Orbital Welding (stud or Tube to Tube sheet)

A Weld Camera with angled optics can be easily placed to rotate with the orbital head, whether ID or OD, minimizing the radial space needed.

3. Continuous welding (Tube and Pipe Mills, Seamers, Orbital Welding, etc.)

Using near 90 degree angles, a weld camera with angled optics can be mounted vertically, allowing users to see the weld process while minimizing the footprint of the camera in the area around the weld head.

4. Seamers & Tube Mills      

In processes and equipment where optical length is critical, for example in the horizontal space of a tube mill set-up, an angled weld camera’s tilted optics allow for optimum positioning.

5. LSAM (WAAM) Robots

In additive manufacturing environments, weld cameras with angled optics can be compactly positioned to best monitor bead height.

Do you have a welding process where an XVC-700 with angled optics would improve your quality assurance practices? Contact us and get a complimentary consult from one of weld camera experts.

 

Topics: XVC Weld Camera, inspection

LASIMM project goes live with Xiris Automation

Posted by Emily Blackborow on Wednesday, February 27, 2019 @ 01:00 PM

Lasimm Machine

 

The Large Additive Subtractive Integrated Modular Machine (LASIMM) project is now live and ready to build large 3D printed metal structures for construction. The machine is the first of its kind and is predicted to keep Europe's manufacturing industry as a leading competitor in the global market. The project highlights a milling robot – the first for additive manufacturing of aluminum and steel - to integrate seamlessly additive, subtractive, metrology and cold work applications into a single machine. 

LASIMM will enable the creation of mixed-material structures by using similar and incompatible substances along with  software to generate tool paths and machine sequences. The machine will ensure the component's structural integrity by allowing in-process, non-destructive testing and restoration of defects. 

Xiris partnered with Cranfield University, a defining member of the project, and delivered the XVC-1000 HDR Weld Camera as an inspection solution for LASIMM. We are honoured to contribute to this project and are excited to see the results of the project and the impact LASIMM will have on Europe's additive manufacturing industry. 

Topics: weld camera, Education, High Dynamic Range, manufacturing, applications, XVC Weld Camera, HDR, weld camera system, consistent, inspection

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