VR Welding Simulator
It can perform Electric arc welding (SMAW), Gas arc welding (GMAW-GTAW), Flux-cored wire arc welding (FCAW) in Virtual reality and Augmented reality based welding simulator.
Insufficient penetration, slag inclusion, combustion groove, porosity, poor drop placement, excessive concavity, wrong weld size, excessive spatter and melting / blowing welding errors can be analyzed.
It consists of a welding machine, welding table, gas and Tig torches of original weight and structure, specially designed welding pliers, position plates and a Virtual reality / Augmented reality supported welding mask.
Parameters such as feed rate, feed angle, working angle, arc length distance, position, and distance between the contact nozzle and the workpiece can be analyzed.
For virtual welding environments, Military maintenance area, Construction site, Welding workshop, Shipyard areas where ships are built can be selected.
Meta (Oculus) Quest 2 virtual reality system produced by Meta (Facebook), the most preferred company all over the world, is used. It can be quickly integrated into new virtual reality systems. Image clarity, realism, fluency and torch tracking are at the highest level.
It has a user-friendly interface. Installations and Source data can be entered into the system very easily.
While welding in a virtual environment, data such as feed rate, feed angle, working angle, position, arc length distance can be reported instantly.
Using welding simulator technology instead of traditional methods in welding applications prevents material waste, eliminates occupational safety problems, and can quickly change joining methods, welding positions, materials, material thicknesses and welding type.
Analysis Screen:
– Welding parameters and welding errors can be analyzed instantly.
– All data can be viewed graphically on the data screen.
– Live weld seam can be examined.
– Welding defects and their locations on the material are shown.
– The source can be analyzed and scored.
– Welded parts and passes can be analyzed separately.
– Welding report and welding video can be recorded.
– Splattering slags and melting of the electrode can be simulated.
– The weld shell can be removed and the weld seam can be cleaned.
Part Selection Screen:
– The positions of the parts to be welded (ceiling, vertical, horizontal, cornice) can be adjusted.
– The parts to be welded and the joining positions can be selected.
– The thickness of the parts to be welded can be selected between 3mm and 10mm.
– The material of the parts can be selected from carbon steel, stainless steel and aluminum.
Help (Visual Hint) Screen:
Visual hints can be opened before or during the welding process to help the user to weld more accurately.
– By opening the guide line help, the place where welding needs to be done can be shown.
– By turning on speed assistance, the forward speed can be kept at optimum values.
– By turning on the angle aid, the feed and working angle can be kept at optimum values.
– By turning on the distance aid, the arc length can be kept at optimum values.
Environment Selection Screen
You can experience welding in different areas by changing the environment to be welded. It is possible to move in any direction within the selected virtual environment.
– Construction area (open environment) can be selected.
– Welding workshop environment (closed environment) can be selected.
– Care center environment (open environment) can be selected.
Welding Parameters Entry Screen
– Current, volts, wire feed speed values can be adjusted.
– AC, DC+, DC- polarization can be selected.
– Gas mixture and gas flow rate can be adjusted.
– Electrode material and diameter can be selected.
– Welding seam direction and sewing technique can be selected.
User Evaluation Screen
– All data of the resource made by users can be accessed.
– Users can watch the video image recorded during welding.
– Multiple choice exams can be created to evaluate users.
– Exam result data can be examined.
It has original gas and tig torches and specially designed electrode arc welding pliers (SMAW- Electric arc welding).
Welds and straight seams can be made according to 6 welding positions (V-Butt 6” (150 mm) Pipe, V-Front Plates, T-Inner corner, T-Inner Corner 6” (150 mm) butt pipe and plate and plate overlap).
Accuracy measurements of working angle, feed speed and angle, feed coordinates, weld seam guide lines and arc length distance can be made and the data (Numbers and Graphs) can be displayed instantly.
The thickness of the workpiece can be selected from a wide range of 3 to 10 mm or more and can be made in material selection (Carbon Steel, Stainless Steel and Aluminum).
According to the welding types, welding tongs, gas metal and tig torches are of the original weight and structure (with their real equivalents), and different wire thicknesses can be chosen by choosing the electrode.
There are at least CO2, ARGON-CO2 mixture and ARGON options as protective gas.
It provides real-time feedback on the applied welding technique using visual cues.
Supervision and control of resource applications and ethernet or wireless access to all data are available via the teacher's computer.
Amperage can be adjusted according to welding types and positions.
When choosing arm height, it says cm.
It is possible to store the exercises performed by the users and the analysis results of these exercises, as well as the video of the exercise on the simulator device.
After the simulation is finished, the video can be played.
Scoring can be done by taking into account how well the student welds in accordance with the welding technique determined by the teacher.
Student works or possible source errors can be analyzed by the system, reported and transferred to the teacher's computer via the simulator screen.
The welding technique applied by the student is shown with a graph containing lines of different colors, and this graph consists of lines belonging to different parameters.
There is a scoring system to evaluate the user, with the help of this system users can be tested, and with the teacher software, users can be given a multiple choice exam.
Position of the welded joint, distance between the contact nozzle and the workpiece, working angle, feed angle, feed speed, reaching the target, weld porosity, electrode; It simulates situations where it melts and can be replaced with a new one and slag splashes while using it. The advancement angle is 5 degrees in basic and 45 degrees in rutile and cellulosic. The feed rate is 25 for basic and 35 for rutile and cellulosic.
In the welding simulator, overlap welding from normal and single pass to 4 passes can be done.
The simulator allows manual and automatic trigger options when simulating gas metal, flux-cored wire and TIG welding.
Straight, zig zag, triangular crescent and circular welding seam options are available.
With the right-to-left and left-to-right welding feature, the welding equipment and software are also suitable for right-handed and left-handed users.
There is cleaning with a brush.
There is an adjustable work stand in different positions to place the welding parts.
The welding mask is adjustable with full head protection and has sufficient internal depth (5 cm) between the screen inside the mask and the forehead so that students with glasses can use it. The devices have VR or AR technology.
There is a crust cleaning feature for observation before and after removing the weld crust in electrode and flux-cored wire welding.
If the electrode is selected by pushing at the source, it gives a warning. It gives a warning when you make the wrong hand choice. (Right to left is selected with the left hand, left to right is selected with the right hand)
The welding simulator has a licensed teacher software. Software can be updated in accordance with technological requirements.
Since the system is a computerized simulation, the system has a minimum of 21” touch monitor and other equipment, internal USB, Ethernet and HDMI cable to view the images.
To simulate a real welding process, 1 pair of welder gloves conforming to EN388:C3 EN407:04 EN 12477 + A1/05 norms is delivered with the set.
The optimum parameter values required for scoring the weld and analyzing weld defects are created by the system. The instructor can make changes to these evaluation parameters.
Pre-welding adjustments and selections can be made via the touch screen on the simulator and through the teacher software.
Virtual or augmented reality headsets with 6 degrees of freedom are used to track precise position and angle of head and hand movements.
An Android application with a perpetual license, an iOS application with a perpetual license, and a Windows 10 application with a perpetual license are provided for the teacher software system.
Turkish language support, training documents and training videos are provided in Turkish in the device and teacher software.
Training is provided by setting up the simulator on site.