© Fronius Virtual Welding A modern innovative simulation system for training both beginners and advanced welders Kreindl Josef Fronius International Sparte

© Fronius

Virtual Welding

A modern innovative simulation system for training both beginners and advanced welders

Kreindl Josef

Fronius International

Sparte Dienstleistungsmanagement

Buxbaumstrasse 2

4600 Wels

[email protected]

mailto:[email protected]

Fronius Virtual Welding

Software package

Sensors22” Touch screen interface

Main work station and example Magnetic field input sensor

Functionality of the Virtual Welder


Virtual Welding

Work piece variations:Fillet weld, V butt weld

Possible welding positions: PA, PB, PF

Training analyses availability

Pre-set parameter availability

Operator specific

parameter availability


A structured learning process

The concept behind the virtual welding is to combine a training simulation aid with a showroom presentation capability .


Structured learning The virtual trainer (ghost) allows the operator the

possibility to optimise welding torch control.

Stick out control Angle of approach And welding speed


Training-Mode

The training mode is made up a number of short predetermined courses, each course is sub-divided into different pre-defined exercises .


Training-Mode

It is also possible in this mode to create more personalised exercises, were by the operator can increase the difficulty levels, allowing the virtual welder to be individually programmed.


Training-Mode Also available is a video

analyses which presents the operator with a visual representation of the exercises being carried out, enabling the operator to self analyse and improve techniques.

Using a point system displayed in a table format, the trainer can determine the performance and objective of each operator.


Simulation-Mode

At the end of each pre-determined programmed exercise a simulated welded seem can be observed as a direct result of the actual welding torch movement.


Simulation-Mode

In addition to professionally training the manual dexterity of the operator, it is also possible to train operators in the correct use of parameter setting/corrections by way of the toggle switches on the welding torch body.

Toggle switches


Simulation-Mode

Also through the use of the toggle switches on the welding torch body the can practice optimising the correct working point in relation to Volts and Amps required

Target working area


Showroom-Mode

The showroom mode is for example ideal for, audiences, trade fares, training schools and also for any other interested parties who wish to develop a quick understanding of virtual welding.

The well defined and easy to read screens enable any operator the possibility to use the VW even in the absence of a qualified person .


Network possibilities

•Online (internet)

•Internal (intranet)

•Offline



A simple ranking system allows the trainer to quickly and with ease compare the results between all course participants.

Quick and reliable Online service is available. The operator can also carry out necessary online updates

quickly and with ease.



In addition and also available online are:

Additional processes Additional languages New training programs Ordering parts on line


Network possibilities Online support around the clock for all systems Data security Archiving of results Updating new training exercises Configuration of personalised training processes Direct feedback all faults Exchange of information and experiences (Community

forums) Compare results Rank listing overview Encouragement of healthy competitiveness Additional work cells easily added


Terminal variations


Equipment Facilities

Height adjustable work surface Over head welding position possible Equipment closet integrated 22” Touch screen display VR Glasses integrated (optional)

15

cm


Potable cased version

Weight approx 30kg Modular build design Fully portable Integrated trolley system


Cost saving possibilities The average material cost saving for a normal

MIG/MAG basic course with 60 training unit’s e.g. (Gas, Welding wire, Training materials and consumables) is approx:

130 – 150 € Per participant

Other financially affected aspects;

Workshop availability increases (often a point of contention) Theoretical are normally available Increased attention due to a less distracted environment Increased educational image for institutes

Source of information WIFI Linz


Economical effect Student apprenticeship two (2) years

without any previous knowledge The exercise was a fillet weld 5mm in

the PB position The saving achieved was approx 20%

of raw material and consumables


Adaption der Ausbildungsrichtlinien

Objective: To convert a certain percentage of the welding apprenticeship into a digital format

Amortisation example:

Welder training MIG/MAG Number of training units 120 Total cost of course WIFI: € 1.400,00

*Assuming: 20 % of training carried out using the VW

without Virtual Welding With Virtual Welding*Raw material costs € 250,00 € 200,00Cost of trainer € 390,00 € 312,00Total € 640,00 € 512,00

Potential saving per course € 128,00 Training amortised for 146 positions (€ 18.640,00 : € 128,00 = 146) After 500 apprenticeships at WIFI Austria over one year using 5 virtual welding systems,

the cost for acquiring the units had been recuperated after just 18 months !


Target areas Young people in there early stages of

choosing a career

Trade and professional schools

Apprenticeship workshops

Institutes e.g. TWI, WIFI etc

Universities (technical)

Welding Organisations

Companies with in house training requirements


Main uses

Reducing raw material cost for training

Standardisation of training

A portable method of training

Reduced possibility for injury

Clean quiet training environment increasing awareness


Future developments Integrated mathematical calculations for calculating the affects of heat

influences A greater verity of welding processes Costumer specified welding requirements e.g. samples Direct interfaces to welding systems allowing possible data transfer Simulate customer specific complex components before the end

welding stage Simulation interface for observing the weld pool reaction (Fluent ®

simulation)

PERFECT WELDING

Documents

© Fronius Virtual Welding A modern innovative simulation system for training both beginners and advanced welders Kreindl Josef Fronius International Sparte