African Fusion March 2017

from virtual to real welding

Above: The VRTEX® 360 is Lincoln Electric’s most advanced simulation trainer. Right: Lincoln’s REALWELD® Advanced Trainer engages students in real welding, but it includes all of the coaching features associated with VRTEX simulation. Left: Used with advanced welding equipment such as the Power Wave® C300, REALWELD exposes students to the advanced manufacturing technologies used in today’s industry.

As well as the GMAW (MIG) process, SMAW (stick) and FCAW processes can be accommodated. The system has a multi-pass monitoring capability for fil- let, flat and vertical positions and pipe and pipe to flange welding can also be accommodated. “REALWELD uses motion sensors, not cameras. This means that ideal ma- nipulation and weld path parameters are constantly being analysed, which is far more useful than simply recording video footage of the welding. “With the REALWELD system, feed- back is immediate and accurate, which will obviously speed up the skills devel- opment process,” Uys argues. “This revolutionary training ap- proach allows each student in the mod- ern training centre to have their own personal live coach in a training cubical with fume extraction, a real welding machine and real welding conditions and positions,” Uys tells African Fusion , adding that the trainer’s role is changed to recording, analysing the results and identifying next steps in the programme. As part of its commitment to im- prove welding training standards in South Africa, Lincoln Electric will be hosting a training seminar at its Weld Technology Centre in Midrand during May this year. “Training standards in South Africa can be improved. The combination of VRTEX and REALWELD offers an alterna- tive approach that is already proving highly effective in the US,” concludes Lamotte.

and consumables, they give welding students live and continuous feedback aboutwhere they gowrong, whichaccel- erates skills development and success rates significantly,” he explains. REALWELD: The next step By adding a REALWELD® Advanced Trainer to a welding programme, train- ing speed and results canbe accelerated even further. “This system involves real arcs and real welding, but it includes all of the coaching features associatedwith VRTEX simulation. It takes the student out of the classroom, but maintains continuity with the skills development approach completed in the virtual world,” Uys explains. Used with advanced welding equip- ment such as the Power Wave® C300, REALWELD exposes students to the advanced manufacturing technologies used in today’s industry. This is accom- panied by audio coaching, instructor reviews and objective scores based on five welding parameters: weld speed, torch angles, aim, contact tip to work- piece distance/arc length and the posi- tion in the weld seam. Audio cues can also be turned off at any time, allowing the student or prospective employee to demonstrate learned behaviours. “REALWELD is ideal for the student starting to learn how to weld and we see its main function as a training tool. But it can also be used it to validate the skills of experienced welders based on specific welding procedures or approv- als,” Uys adds.

sumables. The system includes introductory welding lessons, including safety, machine and process selection, welding procedure set up, welding theory and more. A version one up from Engage is VRTEX Mobile™, designed to provide mobility in an easy to use and engaging weld- ing training tool. The VRTEX Mobile is ideal for initial, basic welding training, as a recruitment tool for education and industry, for employment and screening for human resources, or as anevaluation tool for instructors and educators to get a baseline on student skills. The VRTEX 360 is Lincoln Electric’s most advanced welding simulation trainer. With an innovative full-scale welding table, student can practice in all positions. Coupons are available for a great number of welding joints, includ- ing pipe and pipe on plate. Inaddition, through theExtensions TM Upgrade Program, the VRTEX 360 can grow with the training programme. The systemhas abend test capability, carbon steel, stainless steel andaluminiumweld simulation routines, DemoMode toshow optimal welding technique and Replay Mode to play back the trainees’ weld performance from any angle. “People think the systems are ex- pensive,” continues Lamotte, “ but training itself is expensive and these machines are very cost-effective when used to complement a high quality training programme. While saving time

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March 2017

AFRICAN FUSION