VIRTUAL WELDING Future Developments and Experience in Practice Josef Kreindl Fronius International GmbH Division Welding Technology Froniusplatz Wels

2Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 CONTENTS / Simulation, Virtual welding is here… / IIW Guideline IAB / System versions / Functional principle / Didactic learning with Virtual Welding / Area of application / configuration / References / Further developments / Summary

3Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 SIMULATION pilot training Safety through training RAILWAY TRAIN DRIVER NEDUNFEG SULSCHAB Lorem ipsum dolor sit amet, consec tetuer adipiscing elit. Aenean Medical Research creates securtity

Fronius International GmbH / Josef Kreindl / Virtual Welding VIRTUAL WELDING IS HERE...

Video Virtual Welding Fronius International GmbH / Josef Kreindl / Virtual Welding 20125

6 IIW Guideline IAB I.3.1 For the IWE; IWT, and IWS This part does not aim at providing practical skills to the welding engineer/technologist/specialist but on gaining knowledge on the control of the different welding processes. The students shall become as familiar as possible with the problems and typical defects associated with incorrect use of the different welding methods. During their exercises the students are guided by skilled welding teachers. Practical trainings hours: MIG/MAG /Fluxcored wire arc welding arc 16 hours It is possible to use the advantages of Virtual Weld Training systems but maximum to 50% of the practical training hours!

7Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 SYSTEM VERSIONS Stand-up terminal / Portable / Network-enabled / Different welding positions / Workpiece versions / Storage area for torch, welding helmet and accessories / 22" touchscreen

8Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 SYSTEM VERSIONS Portable case / For external training / Network-enabled / Real welding torch / Haptic workpieces

9Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 Software package Sensors 22" touchscreen Haptic workpieces Magnetic field sensor FUNCTIONAL PRINCIPLE

10Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 Training sessionSimulation 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

11Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 DIDACTIC LEARNING WITH VIRTUAL WELDING Training session / Speed / Stick out / Torch position / Objective evaluation of performance / Provides a controlled learning sequence

12Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 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

13Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 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

14Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 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 16 languages / Login

15Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 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

16Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 Variable ghost / Individual adjustment of the preferred torch movement for each trainer / No deviation from the real welding torch position and movement / High acceptance by the trainers and coaches / Oscillating movements easy to adapt and optimize AREA OF APPLICATION / CONFIGURATION

17Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 Variable ghost – recording / Create personally torch movement depending on application and work piece / Optimize, Correct / Change of already existing Ghost / Support from Playback AREA OF APPLICATION / CONFIGURATION

18Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 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 AREA OF APPLICATION / CONFIGURATION

19Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 REFERENCES

Facts / RIO TINTO Oyu Tolgoi mining Industry / 7 units Arguments / Language Mongolia / Easy use / Reliability REFERENCE Mongolia 20Fronius International GmbH / Josef Kreindl / Virtual Welding 2012

Facts / Trainingsinstiute ITI / 60 units one province Arguments / Language Guaratj / Touchscreen / Haptic workpiece REFERENCE India 21Fronius International GmbH / Josef Kreindl / Virtual Welding 2012

22Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 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. 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. REFERENCE ISF Aachen Germany

REFERENCE WIFI / Austria Application of the equipment: / For MAG training as a supplementary "teaching tool" to train the skills. / As an attraction for WIFI clients to draw the attention to the welding technology.. Fronius International GmbH / Josef Kreindl / Virtual Welding

Coach acceptance: Various responses: No age-related trend in the acceptance can be noted. 1/3 is satisfied because the participants are quickly improved the manual skills. 1/3 are feeling neutral towards the system. 1/3 are feeling critical towards the system. REFERENCE WIFI / Austria Fronius International GmbH / Josef Kreindl / Virtual Welding

General / Terminals in workshop-course freely accessible / As soon as someone starts the Virtual Welding quickly draws the attention and an audience is quickly formed / Young people are very excited. The competition motivates to use Virtual Welding. REFERENCE WIFI / Austria Fronius International GmbH / Josef Kreindl / Virtual Welding

/ Start 2 unit actual, 4 system /Trainees which are starting a MAG education begin their training on the simulator. / Depending of the content of the training sessions the simulator plays an interaction between the real training and the simulation. / No exact time limit - just a recommendation REFERENCE SZF Schulungszentrum Fohnsdorf / Austria Fronius International GmbH / Josef Kreindl / Virtual Welding

/ The trainer feedback is mostly very positive. Of course there are fears to use the system. The coach must have a profound knowledge and has to be able to operate welding simulator before we can let the trainees work with the system. / It will never replace the coach and the real training, but it is a very valuable tool, which supports the coach and is a tool for quality Education. Fronius International GmbH / Josef Kreindl / Virtual Welding REFERENCE SZF Schulungszentrum Fohnsdorf / Austria

28Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 REFERENCE SZF Schulungszentrum Fohnsdorf / Austria / 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

29Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 FURTHER DEVELOPMENTS MMA Process / Ignition / Re-ignition / Welding Position (PA, PB, PD PE ) / New workpiece / Filler Material (Stick electrode basic typ)

/ Export of all cource-details via USB Stick / Result of each participent / Progress, Analysis Archiving Fronius International GmbH / Josef Kreindl / Virtual Welding FURTHER DEVELOPMENTS

31Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 Selection / Welding Process (MMA, GMAW) / Weld Shape (Fillet weld, V- Joint / Welding Position (PA, PB, PD, PF, PE) / Number of Layer 1; 2; 3) / Ghost (individual configuration) / Welding Torch (GMAW MMA) / Filler Material (solid wire, Stick electrode) FURTHER DEVELOPMENTS

Summary 32Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 / Simulation with Virtual Welding will be an integral part of the welding training / Software and weld seam display are constantly improved / Virtual Welding Systems are reliable and easy to use / Welding Simulation are supported by the IIW Guidelines / Virtual Welding Trainings Systemes improve Image and Interest in Welding technology

33Fronius International GmbH / Josef Kreindl / Virtual Welding 2012 VIRTUAL WELDING Thank you for your attentionen

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