Today’s advanced, intuitive and versatile programmability can deliver greatly increased efficiency with your orbital welding costs, training, cycle times, safety, and welding results.
One of the distinct advantages of a modern mechanized welding system is the introduction of process control by built-in microprocessors and CPUs, the same chips that are the “brains” in your laptop or desktop PCs. Similar to the files that reside on a regular computer, a programmable welding controller uses special files that define weld parameters, steps, positioning, and timing (among many other functions).
Centralized weld program development
Depending on the organization, control files can be developed in advance of a production role or specific project. Files can be developed by welding supervisors, then easily stored or transferred to one or any number of orbital welding systems, at the same location – or across an enterprise via email, CD-DVDs, or USB drives.
Archival library of preloaded and customized programs
By utilizing this method of control file development, companies can build an ever-increasing reference archive of standard and special automated welding procedures. When tasked to perform a weld, an operator can first refer to successful welds that have been previously performed, while still having the opportunity to quickly make any changes as required by the work at hand.
In many industries, this concept is referred to as a “Best Practice Guideline.” In the field of welding, as with countless other industries and professions, the adoption and implementation of pre-established best practices can result in a dramatic, immediate effect in reduced labor costs and consistent weld quality.
A benefit to welders with less skills or education
An archive of weld control files is instrumental in the reduction of duplicated effort in determining optimal settings. Along with increased efficiency, archived orbital welding files are extremely valuable to address the workplace that may employ welders with a wide range of experience and skills. This is important when considering the widely recognized worldwide shortage of experienced welders.
Working with exotic materials
Welding with rarely specified, non-typical alloys can be a time consuming, costly proposition. Having reference control files that have been previously used with a unique or difficult-to-weld parent metal can be a major time-saver that provides significant ongoing cost and labor savings, and reduced operational overhead.
Safer Weld Operation
Pre-programming weld control files can also lead to safer welding operations in terms of reduced hazardous (hexavalent chrome) fumes. By developing and storing weld settings that correlate to dedicated circuitry designed specifically to reduce spatter and smoke, the company can deploy control files that are proven to result in a much safer workplace, and with safer, increased visibility.
As you can see, Getting with the Program by creating, storing, and distributing dynamic weld control files results in many additional advantages beyond the high quality welds that are produced by today’s mechanized welding systems.