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Virtual Welding

/ MIG/MAG<br>/ MMA <br>/ Robotic welding<br>/ TIG-Welding Language: Thanks to the ingenious structure of the software, Virtual Welding is available in many different language versions, so trainees do not need to overcome a language barrier in order to work with it. Software updates are easy to carry out using an external DVD drive. Ranking lists, detailed welding results, curricula and courses and the Variable Ghost can all easily be transferred to a USB stick and stored for documentation/archiving purposes. For practising ignition, there are 2 different types of electrode: a long version for trainees to perfect their ignition technique, and a short version for the actual welding operation where the electrode virtually “melts off”.|theme/default/img/sghanqian.jpg For GMA work, there is a real MIG/MAG torch, complete with the JobMaster function. Depending on the practice assignment they have been given, trainees can set either a dip-transfer or spray-arc range on the JobMaster.|theme/default/img/hanqian.jpg Microsensor in torch<br /> and filler rod<br /> Up/Down function <br />Flexible hose pack <br />Realistic torch weight|theme/default/img/tghangqiang.jpg Helmet with integral VR goggles: To allow the helmet and VR goggles to work together better, the helmet has an enlarged viewing panel which makes it easier to adjust the VR goggles.|theme/default/img/toukui.jpg / Virtual Welding thus provides training in the following welding positions: PA, PB, PC, PD, PE, PF and PG. / The following types of seam have been implemented: V-seams (single and multi-pass), fillet seams (single and multi- pass) and melt-run (single-pass) / In addition to the existing workpieces such as V-seam (1- and 2-/3- pass) and fillet seam, Virtual Welding has been extended by the addition of a workpiece featuring two different weld-seams – a pipe- to-pipe weld and a pipe-to-sheet weld.|theme/default/img/gongjiang.jpg / Self-explanatory software, ultra-simple menu navigation and touchscreen option-selection all combine to make this training tool very easy to use.

OUTLOOK

Virtual Welding is fit for the future – easy to set up, and easy to keep updated with the latest versions of the software. In short: Virtual Welding is the future of welder training!

Input data
Virtual Welding Terminal
Virtual Welding Mobile Case
Dimensions W x H x L
62.8 x 190 x 60.8 cm / 24.72 x 74.8 x 23.9 in
66.6 x 67.9 x 56.8 cm / 26.2 x 26.7 x 22.4 in
Weight
92.17 kg / 203.2 lb
52.77 kg / 116.34 lb
Power consumption
1.2 A
1.2 A
Mains voltage
110 V – 230 V 50/60 Hz
110 V – 230 V 50/60 Hz

Training Phase

Phase 1

In this sequence, the “Ghost” (i.e. the virtual instructor) provides the best assistance one could imagine, by showing trainees the optimum welding speed, the tip-to-work distance and the tilt angle that they should maintain for the torch or electrode holder. Traffic-light colour signals and real-life welding noises give the trainees real-time feedback, showing them where and how they are on-target or deviating from target. This makes direct, instant correction possible, from right inside the process. A new feature is the Variable Ghost: this lets trainers store their own know-how and special manual skills in a virtual format, and to present this to their trainees as the target to train towards. This means that there is no difference between how the trainer manipulates his torch or electrode in practice and the desired torch manipulation shown on the simulator. This can easily be adjusted via the menu, in a few simple steps.

GMA

This, the most commonly used weld process, is practised here in several separate training steps.

Three Steps:

MMA

In manual-electrode (MMA) welding, the training focuses first on ignition. Igniting the electrode is an important motion sequence that has to be practised again and again before trainees can melt off a rod electrode successfully. Once they have mastered this, they practice the other motion sequences needed in MMA welding.

Three Steps:

Phase 2

After trainees finish the training sequence, they move on to Simulation Mode. In this sequence, trainees start practising in a real welding situation – with no help from the Ghost. The result is a virtual weld-seam, displayed in a true-to-life three-dimensional way.

GMA

In the simulation sequence that follows, trainees set the necessary parameters themselves. This phase of the training aims to make trainees aware of the different settings in GMA – particularly with dip-transfer and spray arcs – and of how these affect the welding process.

MMA

The Virtual Welding system also gives trainees a realistic practice environment in its MMA simulation sequence. This offers a choice of several different electrode diameters. To get even closer to real-life welding, users can even “remove” the slag from the seam after finishing the weld.

Additional features

/ Curricula and courses: By drawing up curricula and courses himself, in line with his own requirements, the trainer can tailor the assignments given to trainees so that they exactly match these requirements. This means that the training can be flexibly and individually adapted to each target group, and focused on specific manual skills.

/ Lexicon function: A click on the “Details” button gives the trainee basic welding information on the selected topic, such as workpiece, welding position etc. This is a helpful reference tool for the novice welder.

TIG Mode

As of now, the existing training functions for MIG/MAG, robot and manual metal arc processes have been joined by a Virtual Welding solution for TIG welding processes.The new package contains a special TIG welding torch and a separate sensor, which helps teach the user to apply the optimum amount of filler metal. A total of ten training and simulation tasks are available, which can be performed on a variety of different workpieces. Here too Fronius has expanded the range of possibilities: joining the existing models for the execution of fillet welds, single-V butt welds, pipe-pipe and pipe-plate joints and melt runs comes the ability to perform three-millimetre thick square butt welds.

Robot Mode

Virtual Welding Robotics by Fronius is now available to instructors to assist the training of robot programmers. Thanks to this simulation platform, trainees from the field of robotic welding can now get even closer to the action without the limitations imposed by safety devices or missing welding equipment. The system shows the user whether they have programmed the robot correctly or if the welding torch was handled in the right way. A virtual instructor provides specific instructions as to which corrective movements should be made if the system identifies deviations from the ideal torch guidance. In a subsequent simulated step, the weld seam can be illustrated to visually assess the welding result. The data gathered in the training session can be saved to document progress and stored for further analyses. As such, robot programmers can quickly develop a greater sense of the effects of their programming actions and understand how robotic movements affect the welding result.

Advantage

Main benefits


Reducing raw material cost for training

Standardization of training

Portable training method

Reduced risk of injury and health risks

Clean and quiet training reducing distraction