This white paper, by Thomas Hold of voestalpine Bohler Welding, discusses the importance of welding machine usability – for efficiency, quality welds and, ultimately, welder satisfaction – and the various factors that contribute to it.
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Welding machines are essential tools in a wide range of industrial applications, from construction and manufacturing to shipbuilding and repair. The usability of these machines can have a significant impact on the efficiency and quality of the welding process, and thus on the overall performance of the industry.
A good welding machine is characterised by several factors, including:
- POWER OUTPUT: Measured in amperes (A), the output is an important factor to consider when selecting a machine. It determines the size of filler metal and thickness of the material that can be welded and the type of weld that can be performed.
- DUTY CYCLE: The amount of time a welding machine can be used continuously before it needs to cool down. A higher duty cycle means a more efficient and reliable machine.
- PORTABILITY: An important consideration for those who need to move their welding machine from jobsite to jobsite.
- VERSATILITY: A versatile welding machine can perform a variety of welding processes, such as GMAW, GTAW (with high frequency arc ignition) and SMAW.
- QUALITY OF THE WELD: A good welding machine should produce consistent, high-quality welds, with minimal splatter and no porosity, undercut, pores or any other common defects.
- PRICE-PERFORMANCE-RATIO: The price of welding machines can vary widely, so it is important to consider the budget and what features are most important before making a purchase.
- BRAND REPUTATION: Consider purchasing a welding machine from a reputable brand with a history of producing high-quality products and providing good customer support.
- SAFETY FEATURES: Welding can be dangerous, so be sure to look for machines with built-in safety features, such as over-voltage protection and thermal overload protection.
- WARRANTY: Consider the warranty offered by the manufacturer, as this can give you peace of mind and protection against potential defects or problems with your welding machine.
- Ease of Use: A good welding machine should be easy to set up and use, with clear controls and intuitive settings.
The usability in welding machines
Usability, defined as the ease of use and learning of a product, system, or service, is an important factor in determining the success and widespread adoption of a technology. For welding machines, usability refers to the ease with which operators can use the machine to perform welding tasks and the speed with which they can learn to use it effectively. This applies to actions such as finding the right welding parameters or switching between different operating modes.
Several factors contribute to the usability of welding equipment, including ergonomics, user interfaces, customisability, connectivity, and the availability of documentation and training.
Ergonomics: Ergonomics is a critical aspect of welding machine usability, as it directly affects the comfort and productivity of the operator. Welding machines can be heavy and cumbersome, and they often require operators to work in awkward positions. A well-designed welding machine should have ergonomic features that reduce the physical strain on the operator, such as adjustable height, easily accessible controls, and well-placed handles.
User interfaces: The user interface is the primary means by which the operator interacts with the welding machine. A user-friendly interface should be intuitive and easy to understand, with clear, concise labelling and well-organised controls. The interface should also provide feedback to the operator, such as status updates and error messages, to help them understand the machine’s current state and take appropriate action.
Customisability: The level of customisability of welding machines can be an important factor for a variety of users, depending on their specific needs and requirements. Here are a few reasons why customisation may be important:
- Improved efficiency: Customisation allows welding machines to be optimised for specific applications, resulting in improved efficiency and productivity. Böhler Welding enables you to choose from a wide range of power sources, wire feeders and software packages to meet your current needs. But even if your needs change over time, you can still upgrade the performance and versatility of your welding equipment.
- Increased safety: Customisation can add safety features to the machine, such as emergency stops or safety barriers, which can help to prevent accidents and injuries. Uranos and Terra welders work with standardised bus systems that allow you to connect the machine to a variety of welding automation devices, including safety systems.
- Better weld quality: Customisation can help to ensure that the welding machine is set up correctly for the specific application, which can result in improved weld quality and consistency. The fact that Böhler Welding offers a huge portfolio of filler metals and has specially designed Synergic programs associated to our filler metals available for our equipment, makes a perfect weld easily achievable. The symbiosis of machine, process and consumables makes it possible.
- Enhanced user experience: Customising a welding machine to the specific needs and preferences of the user can make the machine easier and more enjoyable to use, improving the overall user experience. When you customise your welding program or the design of the welding display that can store different jobs on the machine, you are ready to weld as quickly as you are ready to select your favourite channel on your television.
Connectivity: Welding machines can be connected to various automation devices to enhance their capabilities and improve the overall efficiency of the welding process. Some common welding automation devices and the methods used to connect them to welding machines are:
- Welding positioners: Welding positioners are devices that precisely rotate and/or position workpieces. They are typically connected to welding machines through a control panel that allows the welder to control among others, the speed and direction of the positioner.
- Welding robots: Welding robots are multi axis automated systems that perform welding tasks using pre-programmed instructions. They are connected to welding machines through a control system that can be operated through a computer interface.
- Welding columns and booms: Welding columns and booms are multi axis devices that provide a flexible, adjustable platform for positioning welding heads over workpieces. They are connected to welding machines through a control panel that allows the welder to control welding parameters in addition to the movement and positioning of the device over a workpiece.
- Welding carriages: A welding carriage is a device that is connected to a welding machine and is used typically for linear welding applications. Use of welding carriages makes it possible for the welder to comfortably carry out long weld seams with consistent positioning of the carriage-mounted weld head over the weld joint and to adjust the weld parameters as required during welding.
Documentation and training: Adequate documentation and training can also greatly affect the usability of welding equipment. Each machine should be accompanied by a comprehensive manual that provides step-by-step instructions for setting up and using the machine, as well as troubleshooting information. Training should be available for operators, either in person or online, to help them understand how to use the machine and get the most out of it.
Conclusion
Usability is an important factor in the design and acceptance of welding equipment. By considering ergonomics, user interfaces, customisability, connectivity, and the availability of documentation and training, manufacturers can create welding machines that are easy to use, learn and maintain.
This ultimately leads to increased efficiency, quality welds and better long-term welder satisfaction.
