VIRTUAL WELDING
Fronius International GmbH
Welding Technology division
Froniusplatz 1
4600 Wels, Austria
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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Fronius International GmbH / Virtual Welding / 09.06.2011
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 computergenerated 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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Fronius International GmbH / Virtual Welding / 09.06.2011
VIRTUAL WELDING IS HERE...
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Fronius International GmbH / Virtual Welding / 09.06.2011
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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Fronius International GmbH / Virtual Welding / 09.06.2011
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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Fronius International GmbH / Virtual Welding / 09.06.2011
SYSTEM VERSIONS
Portable case
/ For external training
/ Network-enabled
/ Real welding torch
/ Haptic workpieces
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Fronius International GmbH / Virtual Welding / 09.06.2011
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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Fronius International GmbH / Virtual Welding / 09.06.2011
FUNCTIONAL PRINCIPLE
22" touchscreen
Sensors
Software package
Haptic workpieces
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Magnetic field sensor
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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
Training session
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Simulation session
Fronius International GmbH / Virtual Welding / 09.06.2011
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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Fronius International GmbH / Virtual Welding / 09.06.2011
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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Fronius International GmbH / Virtual Welding / 09.06.2011
DIDACTIC LEARNING WITH VIRTUAL WELDING
Simulation session
/ The session allows practice on the
virtual weld seam using userdefined 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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Fronius International GmbH / Virtual Welding / 09.06.2011
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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Fronius International GmbH / Virtual Welding / 09.06.2011
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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Fronius International GmbH / Virtual Welding / 09.06.2011
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
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RANKING LISTS / RESULTS
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
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Fronius International GmbH / Virtual Welding / 09.06.2011
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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Fronius International GmbH / Virtual Welding / 09.06.2011
BENEFITS / EFFICIENCY
Costs
/Average material costs for a basic
MIG/MAG course with 60 training
units (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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Fronius International GmbH / Virtual Welding / 09.06.2011
REFERENCES
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
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Fronius International GmbH / Virtual Welding / 09.06.2011
REFERENCES Germany /Austria
/ SZF Fohnsdorf Training Centre
/ ISF Aachen
/ Rhine-Ruhr Training Centre
/ BFW Siegen
/ SL Magdeburg
/ Schäfer GmbH Dillingen
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Fronius International GmbH / Virtual Welding / 09.06.2011
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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Fronius International GmbH / Virtual Welding / 09.06.2011
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
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Fronius International GmbH / Virtual Welding / 09.06.2011