Visual real-time monitoring of welding processes utilizing welding cameras is becoming a more common and prominent process monitoring method. Typically the evaluation of the welding process has been done through post-weld inspections e.g. visually by an experienced weld inspector, topography sensors, NDT test measurements or even by destroying a selection of completed welds to test for quality. However, by the time of detection, the possible welding defects have already happened and will lead to time consuming and costly, if not impossible, repairs.
Cavitar has developed a welding camera for acquiring high-quality images of welding processes. The Cavitar Welding Camera is small and robust and it is built to withstand harsh industrial environments. It was developed and designed to address the needs in industry and in welders’ education in order to provide a detailed view to the welding process and at the same time improving welders’ safety. Below you can find different areas where Cavitar Welding Cameras can benefit your operations.
Better Process Monitoring and Understanding Through Clear Images
Using a welding camera for the visual inspection and monitoring during the welding allows the detection of problems and defects early on. A typical use for the camera is to see if the welding torch is properly aligned to the gap. The camera also helps the process operator in placing the filler materials more accurately to the weld. In addition, it is possible to observe the melt pool characteristics, which can indicate defects like inclusions. Once a problem is detected, the process can be immediately and remotely realigned. This leads to less scrap and higher yield because a flaw was noticed early one in the process. Therefore downtime or lost production time due to repairs is minimized. Furthermore, by studying and recording the welds and welding parameters, the same high-quality process can be produced repeatedly, thus giving high consistency from batch to batch.
Video 1: MIG welding of a T-joint.
Recording the welding process with the welding camera enables non-destructive post-weld analysis that allows for quality checking. In case of customer claims, recordings can be provided as proof that the welding has been of high quality.
A clear view to the process also allows the studying of how different parameters, such as welding speed and angles, as well as materials like filler materials and protection gases, effect the welding process of different welded materials. This has been typically used by research and development to improve the process and to find best practices. However, it can also help process engineers on site to understand their processes better.
In automated welding applications, it is beneficial to confirm that the torch stays at the programmed path before the weld starts. This allows for adjustment of the program before the actual weld and enables quick startup of the real process as well as reduces defects due to inaccuracies in the program. Due to the ability to see through heat and the blinding welding process light, Cavitar Welding Cameras provide the same image quality regardless if the welding process is on or off, thus allowing for optimal understanding of the process.
Improving Working Conditions for Welders
Welding cameras enable easy and quick remote alignment of weld torch and gap. A task that has traditionally been done manually by eye through a welding helmet and performed often in difficult to access places close to the welding process and therefore with exposure to heat and toxic fumes.
Welding cameras enhance work safety and improve ergonomics in addition to their ability to monitor the process. Compact welding cameras can be integrated to the welding process to obtain a clear view to the process in real-time while the monitoring and adjustment of the process can be done remotely from a safe distance. The use of a welding camera improves ergonomics greatly as the operator can manage and view the welding process without being forced into uncomfortable positions. This does not only lead to happier and healthier employees, but also enables longer working life for welders. Here you can read how SERIMAX has been using our welding cameras in their challenging orbital welding application. https://www.cavitar.com/library/cavilux-welmon-welding-camera-used-serimax-orbital-welding-offshore-pipes/
Video 2: Cavitar Welding Camera for orbital GMAW welding at Serimax.
Teaching the Future Welders with the Help of Welding Cameras
Video 3: Top and bottom view of the same GMAW welding process.
The ability to see through the bright light of the welding process brings advantages also in welding education. Cavitar Welding Cameras provide a clear view to the details of the process – to the melt pool, weld seam, weld arc and the torch tip. The weld instructor can show all features of the welding process to the students clearly and easily. Also the welding defects, such as inclusions, cracks and porosity are visible as are the conditions that lead to them. The students can watch the welding from a screen/monitor rather than crowding around the instructor. The demonstrations can be recorded, which allows students to repeatedly view and learn from the lessons. By recording lessons the instructors can maintain a permanent record of material, avoiding the need to constantly recreate lessons. Also the students’ practice welds can be recorded which makes it possible for the students to track their personal learning progress.
The example applications show that welding cameras are a powerful tool for companies in the welding industry. With Cavitar Welding Camera solutions manufacturers and educators get a high-quality view and understanding of their critical processes. Feel free to get in contact with us under www.cavitar.com/contact.
See the product: Cavitar Welding Camera