virtual welding

yardbellAI and Robotics

Nov 14, 2013 (3 years and 5 months ago)

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VIRTUAL WELDING





Fronius International GmbH

Welding Technology division

Froniusplatz 1

4600 Wels, Austria

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Fronius International GmbH / Virtual Welding / 09.06.2011


CONTENTS

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Virtual welding is here…


/
System versions


/
Didactic learning with Virtual Welding

/
Functional principle


/
Area of application / configuration

/
Ranking lists / results

/
Benefits / efficiency

/
References

/
Further developments

/
Preview

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Fronius International GmbH / Virtual Welding / 09.06.2011


WHO WOULD HAVE BELIEVED 15 YEARS AGO, THAT...


/
Pilots would be trained on flight simulators

/
We would navigate without road maps

/
Surgeons would perfect their operating
skills in a virtual environment

/
Emergency services would prepare for
worst
-
case scenarios in computer
-
generated simulations (coordination
following natural disasters, rescue
operations, kidnappings, etc.)

/
Novice welders would train and perfect
their basic skills on the Virtual Welder

Fronius International GmbH / Virtual Welding / 09.06.2011


5

VIRTUAL WELDING IS HERE...

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Fronius International GmbH / Virtual Welding / 09.06.2011


Professor Dr. Reisgen

Image and reality play an important role in computer
-
based
simulation and modern teaching methods, which is why Virtual
Welding is so popular with the students in Aachen.


Given that welding trainer places and staffing capacity are very
limited, Virtual Welding has numerous additional benefits.


In terms of time, almost all the lesson is spent practising welding.


Explanations, instructions and safety supervision are not
necessary because the virtual system is self
-
explanatory and
intuitive.

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Fronius International GmbH / Virtual Welding / 09.06.2011


SYSTEM VERSIONS

Stand
-
up terminal

/
Portable

/
Network
-
enabled

/
Different welding positions

/
Workpiece versions

/
Storage area for torch,
welding helmet and
accessories

/
22" touchscreen

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Fronius International GmbH / Virtual Welding / 09.06.2011


SYSTEM VERSIONS

Portable case

/
For external training

/
Network
-
enabled

/
Real welding torch

/
Haptic workpieces

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Fronius International GmbH / Virtual Welding / 09.06.2011


SYSTEM VERSIONS

VR glasses

/
Realistic welding environment

with helmet

/

Different viewing angles

/
Dual visualisation

(VR glasses + screen)

/
Can be adjusted to individual
requirements

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Fronius International GmbH / Virtual Welding / 09.06.2011


Software package

Sensors

22"

touchscreen

Haptic workpieces

Magnetic field sensor

FUNCTIONAL PRINCIPLE

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Fronius International GmbH / Virtual Welding / 09.06.2011


Training session

Simulation session

DIDACTIC LEARNING WITH VIRTUAL WELDING

/
Training session

Supports the user with "ghosts"


/
Simulation session

Produces a weld seam based on the
actual torch movement


/
Permits changes to welding
parameters





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Fronius International GmbH / Virtual Welding / 09.06.2011


DIDACTIC LEARNING WITH VIRTUAL WELDING

Training session

/
Speed

/

Stick out

/
Torch position

/
Objective evaluation of performance

/
Provides a controlled learning
sequence






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Fronius International GmbH / Virtual Welding / 09.06.2011


DIDACTIC LEARNING WITH VIRTUAL WELDING

Simulation session

/
Representation of weld seam
according to actual torch movement

/
Visual assessment of the bead

/
Performance also evaluated using
points system






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Fronius International GmbH / Virtual Welding / 09.06.2011


DIDACTIC LEARNING WITH VIRTUAL WELDING

Simulation session

/
The session allows practice on the
virtual weld seam using
user
-
defined welding parameters


/
This instructs trainees in the welding
parameters used for short circuit and
spray arcs

/
The video analysis provides
immediate feedback about the
exercise that has just been carried
out

/
Trainees can independently analyse
and correct their mistakes



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Fronius International GmbH / Virtual Welding / 09.06.2011


DIDACTIC LEARNING WITH VIRTUAL WELDING

Additional interactive functions

/
Enhancing basic knowledge of
welding technology

/
Explanation of components

/
Function overviews

/
Help functions

/
Choice of up to 15 languages

/
Login




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Fronius International GmbH / Virtual Welding / 09.06.2011


AREA OF APPLICATION / CONFIGURATION

Course management

/
These courses and the study

programmes on which they are
based are easy to access


/
Courses can be tailored to individual
requirements or adapted to suit the
target group



/
Different levels of difficulty allow
specific training requirements to be
met



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Fronius International GmbH / Virtual Welding / 09.06.2011


AREA OF APPLICATION / CONFIGURATION


/
Showroom mode

Ready to use in foyers, reception
areas, entrance areas, trade fairs

/
Course mode

The trainee practises welding
according to a didactic concept

/
Open mode

Ideal for product presentation and
work outside a didactic environment

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Fronius International GmbH / Virtual Welding / 09.06.2011



Login


/
Creation of a personal profile

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Overview of the ranking lists for the
relevant courses

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Welding results give an indication of
how the trainee is progressing

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Promoting competition

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Detailed results of the welding that
has been carried out

/
Playback function enables trainees to
analyse errors themselves



RANKING LISTS / RESULTS

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Fronius International GmbH / Virtual Welding / 09.06.2011


BENEFITS / EFFICIENCY

Virtual / reality


/
Manual skills developed using Virtual
Welding are put into practice straight
away

/
Variable training structure

/
Course participants take
responsibility for their own work

/
Digital documentation of tasks and
results

/
Less pressure on the trainers

/
More time for the participants



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Fronius International GmbH / Virtual Welding / 09.06.2011


BENEFITS / EFFICIENCY

Costs

/
Average material costs for a basic

MIG/MAG course with 60 training

units (gas, wire, sheets, spare parts)



130
-
150 per participant


Source: WIFI Linz


Other aspects:

/
Less pressure on workshops

(often oversubscribed)

/
PR boost for the training institute


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Fronius International GmbH / Virtual Welding / 09.06.2011


Who can use Virtual Welding?

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Training institutes (WIFI, BFI, etc.)

/
Welding associations (IIW, DVS, SLV,
etc.)

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Training workshops

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Welding companies

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State schools, technical colleges

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Agricultural colleges

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Technical colleges

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Specialist colleges

/
Universities

REFERENCES

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Fronius International GmbH / Virtual Welding / 09.06.2011


REFERENCES Germany /Austria

/
SZF Fohnsdorf Training Centre


/
ISF Aachen


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Rhine
-
Ruhr Training Centre


/
BFW Siegen


/
SL Magdeburg


/
Schäfer GmbH Dillingen



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Fronius International GmbH / Virtual Welding / 09.06.2011


REFERENCES worldwide

/
IDAN
Iceland

/
TVERSKOY
Russia

/
INDUSTRIJSKO Obrtnicka skola
Croatia

/
URALMASH
Russia

/
ÉCOLE CENTRALE DE NANTES
France

/
CFAI Languedoc Roussillion

France

/
BAEST
Czech Republic

/
VIPS Žilina
Slovakia

/
PanGas Dagmersellen

Switzerland




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Fronius International GmbH / Virtual Welding / 09.06.2011


SZF FOHNSDORF TRAINING CENTRE

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VIRTUAL WELDING


WHAT NEXT?

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Fronius International GmbH / Virtual Welding / 09.06.2011


FURTHER DEVELOPMENTS


Preview

/
Experts simulate different
applications and save data

/
Saved data is implemented in a real
power source via networks

/
Welding parameters applied to an
actual workpiece

/
Robot welds perfect weld seam on
workpiece