Welding Power source technology transformation to Industry IoT 4.0- KEMPPI

Photo of Rashmi Ranjan Mohapatra
Mr. Rashmi Ranjan Mohapatra, Managing Director, Kemppi India Pvt. Ltd.

In the early 1900s, it was discovered that transformers could be used in the arc welding process, which was in its beginning at that time. It took several years to work through various electrical designs to be able to control the arc, which also brought about the need to create covered (or coated) arc welding electrodes, a process that is commonly referred to as shielded metal arc welding (SMAW) or stick welding. The inverter based welding power source is one of the welding industry’s most important technology advances of the last two decades. This new era of technology that centered on electronics, coinciding with the growing popularity of personal computers. As the electronics and software industry grew, engineers soon realized that software-controlled inverters could be used to weld, opening up a new world of possibilities.

As you all know that, Industry IoT 4.0 is a name for the current trend of automation and data exchange in manufacturing technologies. It includes cyber-physical systems, the Internet of things, cloud computing and cognitive computing. Industry 4.0 creates what has been called a “smart factory”. Within the modular structured smart factories, cyber-physical systems monitor physical processes, create a virtual copy of the physical world and make decentralized decisions. Over the Internet of Things, cyber-physical systems communicate and cooperate with each other and with humans in real time, and via the Internet of Services, both internal and cross-organizational services.

MIG / MAG Welding by KEMPPI INDIAKemppi is a pioneering welding company in the world. Kemppi Introduced the new Innovative X8 MIG Welder, first time in the world Which supports Industry IoT 4.0 revolution technology. Covers it all, from synergic and pulsed MIG/MAG and stick (MMA) welding to MIG brazing, cladding, and gouging. The intelligent equipment provides you with extremely precise control of the arc, high-duty welding performance up to 600 A, and connectivity with WeldEye welding management software. Unsurpassed usability based on actual user needs are designed and manufactured in every aspect of the power source, wire feeder, welding guns, user interface, and other components. It has best arc characteristics for high speed and aluminum (WiseFusion), narrow gap (RGT), root pass (WiseRoot+), thin sheet (WiseThin+) and the new special application software WiseSteel. It challenges related to the globular transfer are now tackled. This is achieved by alternating short arc transfer with spray transfer, which reduces spatter, increases travel speed, and produces high-quality welds characterized by regular fish-scale pattern. In short-circuit transfer, Wise Steel adaptively improves the arc stability, thus providing better out-of-position welding capabilities. The X8 MIG Welder redefines ergonomics in welding guns: the hand grip, mobility, and stability have been optimized to meet the requirements of the most demanding welding tasks.

Welding Power source technology transformation to IndustryMany standards such as ASME, AWS, and ISO 3834 require the use of WPSs. The industry tradition has been to use printed WPSs, which doesn’t necessarily match today’s quality and performance requirements. The X8 MIG Welder’s ability to use WPSs digitally redefines this process. Connecting the X8 MIG Welder to the WeldEye cloud service allows for the use of digital WPS (dWPS) and makes printed WPS documents unnecessary. It allows welders to search, view and activate WPSs on the Control Pad’s display and automatically use the right parameters during welding. The WPSs are transferred from the WeldEye software over the Internet to the X8 MIG Welders on the shop floor. This revolutionizes WPS management in welding production from both the welder’s and welding coordinator’s viewpoint.

In addition, the Control Pad serves as a reader device. It can be used to collect fabrication information for verifying that welding is carried out according to WPSs, and analysing welding productivity based on arc time tracking.

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