VIRTUAL WELDING Fronius International GmbH Welding Technology division Froniusplatz 1

VIRTUAL WELDING

Fronius International GmbH

Welding Technology division

Froniusplatz 1

4600 Wels, Austria

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CONTENTS

/ 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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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

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VIRTUAL WELDING IS HERE...

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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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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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SYSTEM VERSIONS

Portable case

/ For external training/ Network-enabled/ Real welding torch/ Haptic workpieces

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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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Software package

Sensors22" touchscreen

Haptic workpieces Magnetic field sensor

FUNCTIONAL PRINCIPLE

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Training session Simulation session

DIDACTIC LEARNING WITH VIRTUAL WELDING

/ Training sessionSupports the user with "ghosts"

/ Simulation sessionProduces a weld seam based on the actual torch movement

/ Permits changes to welding parameters

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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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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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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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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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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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AREA OF APPLICATION / CONFIGURATION

/ Showroom mode Ready to use in foyers, reception areas, entrance areas, trade fairs

/ Course modeThe trainee practises welding according to a didactic concept

/ Open modeIdeal for product presentation and work outside a didactic environment

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Login / Creation of a personal profile/ Overview of the ranking lists for the

relevant courses/ Welding results give an indication of

how the trainee is progressing/ Promoting competition / 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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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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BENEFITS / EFFICIENCY

Costs

/Average material costs for a basicMIG/MAG course with 60 trainingunits (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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Who can use Virtual Welding?

/ Training institutes (WIFI, BFI, etc.)/ Welding associations (IIW, DVS,

SLV, etc.)/ Training workshops/ Welding companies / State schools, technical colleges/ Agricultural colleges/ Technical colleges/ Specialist colleges / Universities

REFERENCES

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REFERENCES Germany /Austria

/ SZF Fohnsdorf Training Centre

/ ISF Aachen

/ Rhine-Ruhr Training Centre

/ BFW Siegen

/ SL Magdeburg

/ Schäfer GmbH Dillingen

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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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SZF FOHNSDORF TRAINING CENTRE

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VIRTUAL WELDING – WHAT NEXT?

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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