As an alternative to the standard operator
panel that displays the main welding operating conditions
and any alarms in the form of simple text strings, the system
can also be equipped with a very high quality industrial
computer and state-of-the-art supervision and diagnostic
software developed by EMMEDI in order to provide its customers
not only with complete functional control but also with
a set of interactive type utilities with the production
operator.
The structural logic of the program promotes extremely easy,
guided navigation through the various options of the main
menu. All generator operating functions are controlled in
real-time.
It is also possible to consult and if
necessary print the log of events that may have stopped
the production cycle, or to browse through the so-called
“recipes”
in which the operator can insert and save the characteristic
data of each single production run and automatically obtain
a set of practical proposals able to optimize plant efficiency
from the system. This information, if stored, can be re-used
during a subsequent similar production run.
The classical electrical parameters
of the H.F. generator and any optional process variables,
such as speed, temperature and frequency, are shown on the
screen using bar-type virtual tools with also digital indication
of a size that is clearly visible also from a certain distance.
These variable working parameters can also be converted
into both dynamic and historical “trends”
in order to trace evolution of these in relation to a particular
settable period of time. This function is particularly useful
when monitoring the production process in time.
Any alarms present at system power-on
or which occur during operation of the H.F. generator are
managed by the supervision system in a completely innovative
manner. The text of each alarm can be further selected and,
using a handy “HELP”
key, the system displays a list of the most probable causes
of the alarm, also suggesting how to eliminate these.
A set of digitized photographs indicates the location of
the sensor that has detected the alarm in order to permit
extremely fast, precise tracing of this.
From today, EMMEDI makes a new equipment
available on request: a fully automated welding system that
starts the high-frequency generator and automatically adjusts
its output power, by directly using the parameters previously
stored in the selected “recipe”, with no manual
setting by the operator.
Thus, after selecting the specially-made “recipe”
for the type of production to be started, all you have to
do is press the START button: the control logic will perform
the remaining tasks.
Moreover, in order to better use the supervision system,
the number of the “recipes” that can be stored
has been increased to 999, and a further note field has
been provided for each recipe, which can be edited and recalled
on-line.
On request, the supervision system
can be equipped with a special software that enables the
system to be fully remote-controlled. This means that a
technician standing in our company’s test room can
set a connection, through an access provided by the customer
on the Internet, directly to the plant, whatever its location,
as well as interact with the system simultaneously to the
operator attending the machine.This makes it possible to
perform on-line all the checks and changes necessary to
solve possible malfunctions, or investigate the cause of
a failure as if the technician were personally present at
the plant. Cost are greatly reduced and cut down, in the
best case, to the cost of a simple local telephone call
made by the customer.
At present, the system works
only through a SDN digital line modem connection; however,
research is being carried out into other types of connection,
among which the one by means of a mobile phone, which will
be available as soon as technological advances allow these
data to be transmitted at a higher speed.
2. MANUAL OR MOTORIZED ADJUSTABLE SUPPORT (cm. 600 x 600) FOR WELDING HEAD
The adjustable support has been
designed mainly as a device to be combined to the high-
and mid-frequency generators for induction welding, in order
to hold the welding head next to the forming machine. The
support is equipped with three manual movement controls
along axes X, Y and Z, and allows the operator to accurately
position the inductor relatively to the tube, thus making
operations easier between the maintenance and production
changes.
The standard provision allows
for total displacement of 100 mm along axes X and Y, and
of 150 mm along axis Z. The overall dimensions, 600 x 600
x 655 (±75 mm), make it possible to position the
adjustable support and the welding head in small spaces
next to the forming machine’s affected area. The bearing
plane has a surface of 600 x 600 mm.
The equipment can be used for
many applications other than the mentioned ones; on request,
customised models can be supplied, which provide different
travel extension along the three axes, motor versions and
bearing surface size.
