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is used for automatic quality monitoring and documentation in industrial production for welding methods such as:
- Gas-shielded metal arc welding
- Resistance welding
- Stud welding
- Laser welding
- High-frequency welding (conduction and induction welding)
Automated welding processes require automated quality checks.
The WeldQAS system is an automatic welding process monitor and controls 100% of the production.
Since parameters are directly monitored during the welding process, an immediate reaction is possible in case of an error thus averting consequential damage.
WeldQAS can be used to acquire latest knowledge about welding production, to optimise it and use it cost-effectively in the production processes.
1. Evaluation through a quality rating
In a stable and quality-compliant welding production, the measurable parameters (welding current, welding voltage) vary in stable patterns. Deviating changes indicate problems.
The evaluation model of WeldQAS analyses these deviations with a rating between 1 and 7 that is proportional to the magnitude and the time duration of the deviation. In case of a good rating, all variables are within the permissible tolerances.
2. Monitoring using envelope curves
Unlike the monitoring using fixed limits (for processes that can be defined chronologically – masking of start and end times), monitoring using envelope curves allows up to 40% better detection of welding faults due to:
- Monitoring of all sections of the welding process
(including ignition and crater fillings)
- Precise adaptation of monitoring as per the “natural” progression of welding process parameters
- Especially suitable for fully automated welding processes
The WeldQAS system supports the tolerance specifications with fixed limits (e.g. for extremely long welding seams or in the UP area) as well as monitoring using envelope curves.
3. Automatic statistical learning process
The WeldQAS system is an unique system that offers an automatic learning function from the recorded data parallel to the ongoing production.
The signal behaviour is statistically analysed and abnormal sequences are automatically ruled out.
Figure: Monitoring limits (errors) have been automatically learnt from the progression of several welding processes shown here.
4. Pioneering Fault Detection (PFD)
Patented fault detection by evaluating the electric arc dynamics
The PFD process is based on determining a process index and
detects minor dynamic changes in the welding current and welding voltage in case of welding irregularities such as
- Pores, holes, contaminations
- Seam offset, incomplete fusion, weld penetration faults
- due to the effect of gas and wire
The WeldQAS exists in 2 Hardware – versions, µQAS and QASV5, both devices have:
- integrated network function
- USB keyboard in addition
- practical operation by means of a turning knob or optional via touch
- operating system WIN XP embedded
- integrated error outputs and program inputs
- bus connection (optional)
- the highest failure safety by modern flash memory and passive cooling
- compact size (255 x 165 x 155mm)
- TFT - display 6,5 inch
- µQAS 1K - for monitoring of one or two welding torches