1. Welder Training Technology: Accelerated Practice to Production Paul Boulware, Application Engineer, EWI By Bill Forquer, CEO, RealWeld Systems Presented at GSI SLV Welding Trainer Conference Duisburg Germany – Sept 2012

2. © RealWeld Systems, Inc. 2012 Slide 2 About EWI Shortage of Skilled Welders RealWeld Trainer™ Overview RealWeld Trainer™ Accuracy Test & Results RealWeld Trainer™ Efficacy Test Plan Our Talk Today

3. Who is EWI?  Manufacturing technologies company  Founded in 1984 in Columbus, Ohio  Leader in materials joining and allied technologies  Innovate, mature, and commercialize to advance manufacturing competitiveness

4. Our Resources  132,000 square-foot facility with full-size test labs  Over $20 million in capital equipment  Highly educated staff of 130+ engineers, technicians, industry experts, and member advocates  Partnerships with leading universities, institutes, and organizations  Our many customers with whom we collaborate

5. Leading-Edge Manufacturing Technologies Innovate, mature, commercialize technology for industry ─Nondestructive evaluation ─Numerical modeling and simulation ─Plastic and composite fabrication ─Resistance welding ─Ultrasonic additive manufacturing ─Ultrasonic joining ─Weldability and mechanical testing; metallurgical analysis ─Advanced arc welding ─AcousTech™ Machining ─Automation, sensors, controls ─Brazing and soldering ─Dissimilar materials joining ─Friction processing ─Laser processing ─Material forming

6. © RealWeld Systems, Inc. 2012 Slide 6 EWI Industry Survey (800 respondents; not all sectors or responses shown) “What technical advancements would have the greatest impact on your business?”

7. © RealWeld Systems, Inc. 2012 Slide 7 Current Situation New welders not being trained fast/well enough to keep up with demand Current training techniques are inefficient, time-consuming, and costly Measurement of welding skills is highly subjective and therefore inconsistent Companies often forced to retrain welders to meet their specific skill needs (Photo courtesy of flickr user Spakalakazifeuln)

8. © RealWeld Systems, Inc. 2012 Slide 8 Introducing RealWeld Trainer™ With the arc on With the arc off Analyze Your Technique

9. © RealWeld Systems, Inc. 2012 Slide 9 System Components Welding training stand

10. © RealWeld Systems, Inc. 2012 Slide 10 Camera Sees This Fixed position weld root Target mounted on torch X Y Z space Splatter is ignored

11. © RealWeld Systems, Inc. 2012 Slide 11 WPS Library Welding Trainee Assessment Welding Learning Activities Business Objectives Curriculum Library Welding Trainee Library Welding Motion Scores Welding Instructors Welding Trainees Configurable Reporting Software Components

12. © RealWeld Systems, Inc. 2012 Slide 12 Results from a Trial The low score and high variability in each parameter is indicative of a novice trainee.

13. © RealWeld Systems, Inc. 2012 Slide 13 Tracking Progress Training curriculum is comprised of a series of WPSs

14. © RealWeld Systems, Inc. 2012 Slide 14 Sweet Spots The WPS identifies the “sweet spot”.

15. © RealWeld Systems, Inc. 2012 Slide 15 Tracking Improvement This screen compares a trainee’s technique Today versus all their prior trials for this WPS. Today’s scores indicate the trainee’s technique is improving. This report can also be shown as a daily plot.

16. © RealWeld Systems, Inc. 2012 Slide 16 Accuracy Testing Panasonic TA-1600 robotic welder 100% compliance with all WPS parameters

17. © RealWeld Systems, Inc. 2012 Slide 17 Efficacy Test Design Experimental Group Control Group Novice, Beginner, Intermediate, Advanced Trainee sees RealWeld Trainer™ scores after each trial. RealWeld Trainer™ scores are blind to both trainee and instructor.

18. © RealWeld Systems, Inc. 2012 Slide 18 Partners

19. © RealWeld Systems, Inc. 2012 Slide 19 Today and Tomorrow Today 1. Processes Stick (SMAW) Mig (GMAW) Flux-Cored (FCAW) 2. Positions Flat (1G, 1F) Horizontal (2G, 2F) Vertical (3G, 3F) 3. Applications Accelerate Training Screen newhires 4. English Tomorrow 1. Processes Tig (GTAW) 2. Positions Overhead (4F, 4G) Pipe (5G, 5F) 3. Applications Portable Credentials Quality Monitoring 4. More languages

20. © RealWeld Systems, Inc. 2012 Slide 20 Come See for Yourself Real and Sim In the Welding Workshop Downstairs

21. © RealWeld Systems, Inc. 2012 Slide 21 Thank You bill.forquer@realweldsystems.com pboulware@ewi.org Follow Us: @realweld, @EWI_innovation