Evolution of arc welding Design in welding MicroTack - Kemppi
Evolution of arc welding Design in welding MicroTack - Kemppi
Evolution of arc welding Design in welding MicroTack - Kemppi
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8<br />
INNOVATION<br />
<strong>Kemppi</strong> ProNews 1 • 2008<br />
<strong>Kemppi</strong> delivers a<br />
new productivity<br />
solution for <strong>weld<strong>in</strong>g</strong><br />
The new <strong>weld<strong>in</strong>g</strong> data collection and<br />
analysis solution <strong>Kemppi</strong> Arc System<br />
has been developed by <strong>Kemppi</strong> to erase<br />
misconceptions related to <strong>weld<strong>in</strong>g</strong><br />
productivity and to make room for<br />
unbiased facts.<br />
What level do you th<strong>in</strong>k <strong>weld<strong>in</strong>g</strong> work productivity is at <strong>in</strong><br />
your company? This question can usually be answered only<br />
on the basis <strong>of</strong> assumptions and feel<strong>in</strong>gs, as it is diffi cult to<br />
obta<strong>in</strong> accurate <strong>in</strong>formation on the matter.<br />
However, it is important to monitor productivity, particularly<br />
<strong>in</strong> companies that use <strong>weld<strong>in</strong>g</strong>, s<strong>in</strong>ce the majority <strong>of</strong> the<br />
<strong>weld<strong>in</strong>g</strong> expenses are <strong>in</strong>curred by labour. Filler materials<br />
and shield<strong>in</strong>g gases, expenses from <strong>weld<strong>in</strong>g</strong> mach<strong>in</strong>es, and<br />
the consumption <strong>of</strong> electricity only cause a fourth <strong>of</strong> the<br />
expenses. The rest is labour.<br />
The problem <strong>in</strong> monitor<strong>in</strong>g <strong>weld<strong>in</strong>g</strong><br />
productivity has traditionally been<br />
that assessment is based on s<strong>in</strong>gle<br />
observations, which are <strong>of</strong>ten uncerta<strong>in</strong><br />
and ambiguous. Systematic <strong>in</strong>formation<br />
collection can elim<strong>in</strong>ate these<br />
uncerta<strong>in</strong>ties and allow estimation <strong>of</strong><br />
productivity developments <strong>in</strong> a reliable<br />
way. With facts <strong>in</strong>stead <strong>of</strong> guesses as the foundation for the<br />
decisions, th<strong>in</strong>gs may look surpris<strong>in</strong>gly different.<br />
Service us<strong>in</strong>g state-<strong>of</strong>-the-art technology<br />
The <strong>Kemppi</strong> Arc System solution represents the absolute<br />
state <strong>of</strong> the art <strong>in</strong> systematic <strong>weld<strong>in</strong>g</strong> data collection.<br />
With this system, <strong>weld<strong>in</strong>g</strong> data can be collected digitally<br />
from <strong>weld<strong>in</strong>g</strong> mach<strong>in</strong>es and sent via base stations to a<br />
<strong>Kemppi</strong> Arc System server, which has tools for <strong>in</strong>spect<strong>in</strong>g,<br />
analys<strong>in</strong>g, and report<strong>in</strong>g on data.<br />
The new <strong>Kemppi</strong> <strong>weld<strong>in</strong>g</strong> mach<strong>in</strong>es are controlled digitally,<br />
and therefore separate sensors are not needed for collection<br />
<strong>of</strong> <strong>weld<strong>in</strong>g</strong> data. The <strong>in</strong>ternal signals <strong>in</strong> the <strong>weld<strong>in</strong>g</strong> mach<strong>in</strong>e<br />
can be monitored with a dedicated data collection device.<br />
The <strong>weld<strong>in</strong>g</strong> data are cont<strong>in</strong>uously stored <strong>in</strong> the memory <strong>of</strong><br />
the device whenever the mach<strong>in</strong>e is used for <strong>weld<strong>in</strong>g</strong>. This<br />
way, detailed <strong>in</strong>formation on <strong>weld<strong>in</strong>g</strong> current, voltage, wire<br />
feed speed, the mach<strong>in</strong>e’s ma<strong>in</strong>tenance requirements, and<br />
<strong>in</strong> the com<strong>in</strong>g years many other issues is recorded.<br />
The data collected by the collector are transferred wirelessly<br />
to base stations and further to the server computer. Often<br />
<strong>weld<strong>in</strong>g</strong> mach<strong>in</strong>es need to be moved <strong>in</strong> factories and<br />
workshops, and therefore wireless data transfer is an<br />
important feature <strong>of</strong> the system. Information security is<br />
ma<strong>in</strong>ta<strong>in</strong>ed <strong>in</strong> every step <strong>of</strong> data transfer. The data on the<br />
server can be accessed only by the customer.<br />
Reports facilitate the monitor<strong>in</strong>g <strong>of</strong><br />
productivity developments<br />
The coverage <strong>of</strong> a wireless base connection is approximately<br />
100 metres per base station, but several base stations can<br />
be connected to expand the coverage area to any size<br />
required.<br />
In large companies, the production facilities may also<br />
be spread across several geographic locations. Even<br />
this will not be a problem, as<br />
report<strong>in</strong>g is centralised <strong>in</strong> the<br />
<strong>Kemppi</strong> Arc System solution.<br />
Information collected at different<br />
sites is accessible <strong>in</strong> all reports to<br />
allow for consolidated production<br />
enhancement plann<strong>in</strong>g.<br />
<strong>Kemppi</strong> Arc System features a<br />
report<strong>in</strong>g tool accessible via a Web browser. It can be<br />
used for all <strong>weld<strong>in</strong>g</strong> work areas, from the <strong>weld<strong>in</strong>g</strong> level<br />
to the management level. Weld<strong>in</strong>g <strong>in</strong>formation, both raw<br />
and processed, can be accessible to welders, production<br />
managers, and the management. Each <strong>of</strong> these parties has<br />
a separate set <strong>of</strong> views <strong>of</strong> the <strong>in</strong>formation collected, and<br />
all levels <strong>of</strong> the organisation can use the <strong>in</strong>formation <strong>in</strong><br />
develop<strong>in</strong>g their work or enhanc<strong>in</strong>g productivity.<br />
The report<strong>in</strong>g service refers to automatic refi nement <strong>of</strong> the<br />
collected <strong>weld<strong>in</strong>g</strong> data <strong>in</strong>to reports accord<strong>in</strong>g to rules that<br />
have been agreed upon with the customer. The fi nished<br />
reports are then delivered to the customer by e-mail<br />
accord<strong>in</strong>g to the desired schedule, which facilitates easy<br />
monitor<strong>in</strong>g <strong>of</strong> productivity.<br />
With facts <strong>in</strong>stead <strong>of</strong><br />
guesses as the foundation<br />
for the decisions, th<strong>in</strong>gs<br />
may look surpris<strong>in</strong>gly<br />
diff erent.