Software provides offline control of welding

VirtualArc is a powerful software tool that gives robot welding engineers full "offline" control of the MIG/MAG process.

VirtualArc is a powerful software tool that gives robot welding engineers full "offline" control of the MIG/MAG process.

Featuring an easy-to-use software interface, VirtualArc can be operated from a single PC or laptop and provides users with efficient offline welding process tuning to predict a wide range of results including: weld shape and penetration; weld quality; and possible welding defects.

Predicting such results brings substantial benefits including shorter implementation time, better optimised welding productivity and quality, as well as better documented welding procedures.

In turn these considerations contribute to lower product costs.

As well as saving time and money through better production, VirtualArc is also an efficient training tool for robot operators, programmers and production/welding engineers, and an excellent platform for retrieving and storing arc welding process information for future developments.

VirtualArc is also useful for comparing different weld procedures in cost per metre welded.

The technology behind the VirtualArc software is based on the combination of arc physics, welding simulation, arc welding practical experience and experimental measurements.

Weld profile and quality predictions are obtained using Bayesian neural network tools.

Predictions from arc simulations, and heat and mass transfer to the workpiece, are used as input to the neural network to predict weld quality, weld profile and weld defects.

The accuracy of predictions and robustness of VirtualArc software has been verified by applying the methodology to a large number of welds.

It was found that the system consistently reproduced arc dependent properties as well as final weld penetration profile and quality.

Mark Oxlade of ABB, comments: "ABB strongly believes that the need for production enhancing tools like VirtualArc will become more and more important as the number of skilled welding engineers and welders are decreasing on the market.

ABB's development of VirtualArc software and technology is an important step forward in helping arc welding customers to automate their production in an efficient manner".

The Mild Steel Edition of VirtualArc will be officially launched at ABB's arc welding customer days on 20th May 2003.

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