The Xiris Blog

Xiris Launches Audio Monitoring for Weld Cameras!

Posted by Cameron Serles on Tuesday, July 23, 2019 @ 11:25 AM

Xiris is proud to announce a revolutionary addition to our industry-leading cameras: SOUND!

At Xiris, we strive to be a world leader in developing sensors and inspection systems for welding processes. Our team of multidisciplinary experts have extended our weld camera product line with the addition of audio capture and monitoring capability. We are committed to continuously improving our products to meet the needs of our customers, and audio monitoring is something our clients have been asking for.

Adding audio capture and playback to Xiris’ weld cameras introduces a new dimension to welding quality control. Now fabricators can use two sensory inputs – sight AND sound – to help them determine if the welding process is functioning correctly or needs fine tuning to provide the best weld process possible. This enhancement gives operators another tool to assess, monitor and improve the consistency and effectiveness of their welding processes.

Xiris Launches Audio monitoring for welding camerasAn Audio Waveform Picture from the Xiris Audio Recorder

A study in the January 2017 edition of the Journal of Intelligent Manufacturing found that multisensory evaluation of seam welds was 97% more accurate recognizing defects. Various academic and anecdotal studies confirm that sound is key to real-time monitoring of welding quality and process control for intelligent manufacturing.

Welders draw on years of experience to recognize what quality welds sound like. Each type of welding can generate a unique sound signature when it is “in tune” and when it is “out of tune”. In upcoming blogs, we will be talking about the different types of welding and what to listen for. We will also share more details about the Xiris audio recording and playback option and how you can add it to your operations.

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Topics: quality control, weld camera, weld monitoring, audio

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!

 

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

Ground-Breaking Technology + Dedicated Customer Service = Great Value

Posted by Cameron Serles on Thursday, June 13, 2019 @ 01:00 PM


Welding Process Image Once we’ve demonstrated to potential customers how a Xiris weld camera can help their business, the technology practically sells itself.

Brian Dobben, a welding engineer for Flowserve’s Flow Control Division, could see the value as soon as he saw our camera in action.

It’s worth its weight in gold. It’s just way too valuable not to have,” he recently told us.

Dobben credits Xiris’s cameras with significant cost and time savings, a higher level of safety, and more-effective operator training.

He also appreciates that we travelled from Ontario, Canada to North Carolina, U.S.A. to demonstrate the weld cameras and show personnel how to use the technology (it’s so intuitive, it doesn’t take a tremendous amount of training). Brian was also impressed with our quick turnaround on a necessary repair after a mistake by one of their operators.

We believe our high dynamic range (HDR) weld cameras can increase the efficiency and profitability of any welding operation, and we are committed to making our cameras a game-changing solution. But we don’t just sell cameras, we will do everything possible after a sale to help our customers reap maximum benefit out of them as possible—and that’s a lot of benefit.

To read Brian’s full account of his experience with Xiris—and to get a feel for what we could do for you—we invite you to download this testimonial.

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Topics: quality control, weld inspection, weld safety, High Dynamic Range, operator, XVC Weld Camera, HDR, #testimonial, consistent, inspection system

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.

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

How Weld Inspection Helps Tube Producers Meet Weight Reduction for Automotive Sector

Posted by Emily Blackborow on Tuesday, May 14, 2019 @ 01:00 PM

The Automotive Sector is constantly trying to reduce the weight of cars. Part of that effort is to approach their suppliers to see what they can do to reduce the weight of their components. Fabricators of tubes for the automotive sector are constantly being asked to meet more difficult weight limitations of their tubes.   

In order to achieve the desired weight reduction of a tube, tube fabricators need to use:

  • Lighter materials;
  • Thinner Wall Thicknesses; and
  • Higher Yield strength materials.

These are only possible if tighter manufacturing specifications and process tolerances are established.

Tubes fabricated from higher yield strength material are more susceptible to mismatch during fabrication. Traditionally; fabricators used a common practice of allowing mismatch on a longitudinal welded tubes of up to 5% of the wall thickness. 5% becomes a very small number very quickly when wall thickness is reduced. 

Experience has shown that for higher yield strength materials a mismatch of 5% will result in a higher weld split failure. In these applications tube producers need to maintain a mismatch tolerance in the 2% to 3% range, well below common practice on milder materials. These tight tolerances make it difficult for mill operators to see or detect using traditional means of looking at the scarf material, the finger nail scratch without stopping the mill interrupting production.

High resolution geometrical measurements are required in the weld zone making this an ideal application for laser based technologies such as Xiris’ Weld Inspection Solutions. The WI2000 or WI3000 makes continuous measurements providing the operator with a clear visual of the weld zone form process while also being able to set tolerance limits to alarm when an unexpected variation occurs.

WI2000 System for tube & pipe inspectionWI2000

WI3000 System  for tube & pipe inspection

 WI3000

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Topics: quality control, weld inspection, High Dynamic Range, pipe, tube, HDR, weld seam, tubedefects, consistent, WI-2000, inspection system, WI-3000

Using the Photodiode with an XVC-1000 Weld Camera

Posted by Emily Blackborow on Tuesday, April 16, 2019 @ 01:00 PM

A photodiode is an electronic which, when exposed to light, generates a change in its electrical resistance. When incorporated into an electronics circuit, it can generate a signal when exposed to the right amount of light. The Xiris Weld Cameras are equipped with photodiodes to detect the presence of a weld arc. 

Using Xiris  WeldStudio software, the photodiode circuit can be used to toggle the operating mode of a weld camera from “NO WELD” mode to “WELD” mode or vice versa, based on the amount of light present in the weld environment.  As a result, two sets of parameters can be defined, each associated with one of the two camera modes. Of the many parameters that can be defined, there is the shutter mode, which can be set typically for Rolling shutter in the NO WELD mode and Global shutter in the WELD mode. Toggling between the two modes can happen automatically by enabling the Auto Weld Mode option in the WeldStudio software.

The photodiode sensitivity threshold can be adjusted from within the WeldStudio software to ensure that the NO WELD/WELD triggers on the right amount of light coming from the weld process. When light is emitted from the welding process, the photodiode will activate, toggling the software from NO WELD to WELD mode. When the welding process ceases, the lack of light will have the opposite effect.

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Topics: quality control, weld inspection, High Dynamic Range, XVC Weld Camera, weld camera system, consistent, trigger, photodiode

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