Using welding cameras to visually monitor welding processes in real-time is becoming a more prominent and common process monitoring method.
Welding process evaluation has typically been done through post-weld inspections such as destroying a selection of completed welds to test for quality, NDT test measurements, topography sensors or visually by an experienced weld inspector.
Image Credit: Cavitar Ltd.
However, these methods mean that by the time of detection, the possible welding defects have already occurred and can necessitate costly and time consuming, if not, impossible repairs.
A welding camera for acquiring high-quality images of welding processes has been developed by Cavitar. The Cavitar Welding Camera is robust and small, and it is built to withstand harsh industrial environments.
It was designed and developed to provide a detailed view of the welding process and at the same time improve welders’ safety, thereby addressing the needs in industry and in welders’ education.
This article will explore some different areas where Cavitar Welding Cameras can benefit operations.
Better Process Monitoring and Understanding Through Clear Images
It is possible to detect defects and problems early on by using a welding camera for monitoring and visual inspection during the welding process. One typical use for the camera is to ensure the welding torch is properly aligned to the gap.
The camera can also assist the process operator in more accurately placing the filler materials to the weld. It is also possible to observe defects, such as inclusion, by making the melt pool characteristics visible.
The process can be immediately and remotely realigned once a problem is detected. A flaw getting noticed early in the process leads to higher yield and less scrap. This minimizes lost production time or downtime caused by repairs.
Furthermore, the same high-quality process can be repeatedly produced by studying and recording the welds and welding parameters, which creates high consistency from batch to batch.
Clear View to T-Joint MIG Welding taken with Cavitar Welding Camera
Video 1: MIG welding of a T-joint. Video Credit: Cavitar Ltd.
Non-destructive post-weld analysis that allows for quality checking is enabled by recording the welding process with the welding camera. Recordings can be provided as evidence ensuring that the welding has been of high quality in the event of customer claims.
Studying how different parameters, such as welding angles and speed, as well as materials like protection gases and filler materials, affect the welding process of different welded materials is enabled through having a clear view of the process.
This has been used mostly by research and development to find best practices and to improve the process. However, it can also allow on-site process engineers to better understand their processes.
It is beneficial to confirm that the torch stays at the programmed path before the weld starts for automated welding applications. This makes it possible to adjust the program before the actual weld starts and enables quick startup of the real process; it also reduces defects due to inaccuracies in the program.
Cavitar Welding Cameras are able to see through blinding welding process light and heat, meaning they can provide the same image quality regardless of whether the welding process is on or off, allowing for optimal understanding of the process.
Improving Working Conditions for Welders
Quick and easy remote alignment of weld torch and gap is enabled by welding cameras. Traditionally, this task has been done manually by eye through a welding helmet and is often performed in places that are difficult to access and close to the welding process, meaning the welders are exposed to heat and toxic fumes.
Welding cameras can monitor the welding process, but they also improve ergonomics and enhance work safety. Compact welding cameras can be used to obtain a clear view of the process in real-time while allowing the monitoring and adjusting of the process to occur remotely from a safe distance when integrated into the welding process.
Ergonomics improves when using a welding camera as the operator can view and manage the welding process without being forced into uncomfortable positions. This enables a longer working life for welders and leads to happier and healthier employees.
Seeing through the bright light of the welding process is also advantageous for welding education. Cavitar Welding Cameras provide a clear view of all the details of the process, from the melt pool to the weld seam, weld arc and the torch tip.
Cavitar's Welding Camera Solution Used by Serimax
Video 2: Cavitar Welding Camera for orbital GMAW welding at Serimax. Video Credit: Cavitar Ltd.
The camera allows weld instructors to show all features of the welding process easily and clearly to students. It also makes enables welding defects like porosity, cracks and inclusions visible, as well as the conditions that lead to them.
Cameras also enable students to watch the welding from a screen or monitor instead of needing to crowd around the instructor. Demonstrations can also be recorded, allowing students to repeatedly view and learn from the lessons.
Recording lessons allows instructors to maintain a permanent record of lesson material, thereby avoiding the need to recreate lessons constantly. Students can also record their practice welds which allows them to track their personal learning progress.
Root and Face View of a MIG Welding with Cavitar Welding Camera
Video 3: Top and bottom view of the same GMAW welding process. Video Credit: Cavitar Ltd.
Image Credit: Cavitar Ltd.
This information has been sourced, reviewed and adapted from materials provided by Cavitar.
For more information on this source, please visit Cavitar.