VIRTUAL WELDING Fronius International GmbH Welding Technology division Froniusplatz 1

2. VIRTUAL WELDING • Fronius International GmbH • Welding Technology division • Froniusplatz 1 • 4600 Wels, Austria

3. 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

4. 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 computer-generated simulations (coordination following natural disasters, rescue operations, kidnappings, etc.) • Novice welders would train and perfect their basic skills on the Virtual Welder

5. VIRTUAL WELDING IS HERE...

6. 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.

7. SYSTEM VERSIONS • Stand-up terminal • Portable • Network-enabled • Different welding positions • Workpiece versions • Storage area for torch, welding helmet and accessories • 22" touchscreen

8. SYSTEM VERSIONS • Portable case • For external training • Network-enabled • Real welding torch • Haptic workpieces

9. SYSTEM VERSIONS • VR glasses • Realistic welding environment with helmet • Different viewing angles • Dual visualisation(VR glasses + screen) • Can be adjusted to individual requirements

10. FUNCTIONAL PRINCIPLE • Sensors • 22"touchscreen • Software package • Haptic workpieces • Magnetic field sensor

11. DIDACTIC LEARNING WITH VIRTUAL WELDING • Training sessionSupports the user with "ghosts" • Simulation sessionProduces a weld seam based on the actual torch movement • Permits changes to welding parameters Training session Simulation session

12. DIDACTIC LEARNING WITH VIRTUAL WELDING • Training session • Speed • Stick out • Torch position • Objective evaluation of performance • Provides a controlled learning sequence

13. 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

14. DIDACTIC LEARNING WITH VIRTUAL WELDING • Simulation session • The session allows practice on the virtual weld seam using user-defined 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

15. 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

16. 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

17. AREA OF APPLICATION / CONFIGURATION • Showroom mode Ready to use in foyers, reception areas, entrance areas, trade fairs • Course modeThe trainee practises welding according to a didactic concept • Open modeIdeal for product presentation and work outside a didactic environment

18. 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

19. 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

20. BENEFITS / EFFICIENCY • Costs • Average material costs for a basicMIG/MAG course with 60 trainingunits (gas, wire, sheets, spare parts) € 130-150 per participant Source: WIFI LinzOther aspects: • Less pressure on workshops (often oversubscribed) • PR boost for the training institute

21. 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

22. REFERENCES Germany /Austria • SZF Fohnsdorf Training Centre • ISF Aachen • Rhine-Ruhr Training Centre • BFW Siegen • SL Magdeburg • Schäfer GmbH Dillingen

23. REFERENCES worldwide • IDAN Iceland • TVERSKOY Russia • INDUSTRIJSKO Obrtnicka skola Croatia • URALMASH Russia • ÉCOLE CENTRALE DE NANTES France • CFAI Languedoc RoussillionFrance • BAEST Czech Republic • VIPS Žilina Slovakia • PanGas Dagmersellen Switzerland

24. SZF FOHNSDORF TRAINING CENTRE

25. VIRTUAL WELDING – WHAT NEXT?

26. 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