Frequently Asked Questions – XVC-O Weld Camera System

 

Q. What does the system do?

A. The XVC-O Weld Camera system is intended for monitoring all open arc welding processes such as GMAW, GTAW, Plasma, laser or stick welding while they are in operation.

Q. What does XVC-O stand for?

A. XVC-O stands for Xiris View Camera – Open Arc. While it is mainly intended for Open Arc Applications, it can also be used in Sub Arc Applications.

Q. Which welding applications are intended to use the camera?

A. The XVC-O system is designed to monitor all welding applications including:

  • Pipe Cladding
  • Pressure Vessel Welding/Overlay
  • Orbital Welding
  • Tailor Blank Welding
  • Robotic Welding
  • Tube and Pipe Mills
  • General Fabrication
  • Education/Training

 

Q. What are the benefits of using the XVC-O Weld Camera?

A.Monitor and Control of the Welding Process:

  • Quality control and quality assurance purposes
  • Ensure a sound weld with full fusion has been created
  • Increased accuracy of welding
  • Mechanized (buggy/track) system welding
  • Seam tracking applications
  • Orbital welding of pipe
  • Assist pipe cladding where bead placement is detrimental
  • Hard-facing applications for increased accuracy in bead placement
  • Welding applications with more than one welding head/torch
  • Autogenously welding of thin materials
  • ll welding/manufacturing industries: automotive, aerospace, military, nuclear, pressure piping, etc.

 

B. Removal of Operators from Extremely Dangerous or Inaccessible Areas:

  • Dangerous welding environments such as pressure vessels in high radiation environments
  • Inaccessible welding environments such as cladding the ID of small diameter pipe
  • Welding of narrow groove, thick wall pipe applications where precision and accuracy are necessary

 

C. Ability to monitor Fully Automated Welding:

  • Improve Productivity through increased monitoring of almost any automatic welding process
  • Monitor shielding gas, weld pool, keyhole, other parameters
  • Ensure weld placement is correct and accurate relative to the seam

 

D. Research and Development:

  • Gain further understanding of welding and the science behind it
  • R&D projects to help improve welding technology
  • Observe the characteristics of the weld zone and develop welding parameters accordingly
  • Observe how manipulation of welding variables will affect the outcome of the finished weld
  • Observe welding discontinuities as they occur and develop methods and technologies to avoid them

 

E. Educational and Demonstration:

  • Universities and Colleges to teach and demonstrate welding processes
  • Demonstrate correct welding technique
  • Teach and demonstrate the visual differences between welding processes

 

Q. How does the XVC-O system work?

A. The XVC-O system incorporates a novel camera technology which can handle extremely high dynamic range light conditions of more than 140 dB, meaning that scenes can be imaged with brightness variations as much as 10,000,000:1. As a result, details of the weld arc as well as the weld pool, keyhole, weld seam, weld bead, and many other details of the welding environment can be clearly observed using the XVC-O camera.

Q. What are the main system components?

A. The system consists of the camera module, HMI Console, and interconnecting main cable. The camera module has an extremely high dynamic range sensor combined with sophisticated electronics. The HMI Console includes a computer that acquires images from the camera module and processes them to get images suitable for the operator. The HMI Console includes a touch-screen monitor to provide control and communications to the camera module and display the processed images from the camera. (Insert Open Arc View Pic)

Q. What are the field of view and the corresponding working distance of the system?

A.XVC-O Optical Specification Chart

  XVC-48s XVC-32s XVC-34e XVC-21e XVC-16e XVC-8e
39x39 mm 28x28 mm 26x26 mm 18x18 mm 11x11 mm 6x6 mm
A 48x48 mm 32x32 mm 34x34 mm 21x21 mm 16x16 mm 8x8 mm
A' 63x63 mm 37x37 mm 44x44 mm 23x23 mm 26x26 mm 14x14 mm
150 mm 150 mm 380 mm 450 mm 360 mm 360 mm
B 200 mm 200 mm 480 mm 480 mm 480 mm 480 mm
B' 250 mm 270 mm 590 mm 510 mm 750 mm 730 mm
L 132 mm 132 mm 205 mm 205 mm 205 mm 205 mm
D.O.F 2 mm 2 mm 12 mm 6 mm 6 mm 6 mm
Notes:
A – Field of view
B – Camera Working Distance
L – Camera Body Length
D.O.F. – Depth of Field
A°, A', B°, B' are factory set by customer requirements

Q. What are the environmental and temperature ratings of the XVC-O system?

A.

  Environmental Rating Temperature Rating
Camera Module IP54/NEMA13 60°C (with standard cooling) 300°C (with high temperature cooling option)
HMI Console IP54/NEMA13 35°C
Main Cable IP67/NEMA6 80°C

Q. Does the system require cooling?

A. Yes, the XVC-O camera requires cooling to be applied while it is in operation. The camera can be cooled either by air or liquid. The HMI Console is cooled by fan out to the ambient air, or optionally by Vortex cooling.

Q. How much air is required for the camera and HMI cooling?

A. 4 bar / 60 psi shop air is recommended for ambient temperature that is below 45°C (110°F). The regular cooling system uses 225 l/min (8 CFM).

Q. What is the difference between regular camera air cooling and the high temperature cooling kit?

A. The regular air cooling is sufficient enough to maintain the internal temperature of the camera housing below 45°C (110°F) with a maximum ambient temperature of 80°C (175°F) as the main cable is rated up to 80°C. The regular air cooling package includes an air regulator and Vortex Cooler with tubing to run the air to the camera.

The high temperature cooling kit contains an Air regulator, Vortex Cooler (675 l/min or 25 CFM rated), 10m air cooling line, and custom fitted high temperature heat reflective wrap to isolate the camera, regulator, vortex cooler, air cooling line, and main cable from the ambient heat up to 300°C (570°F).

Q. What is the difference between the XVC-O and XVC-S Weld Cameras?

A. The XVC-O is for Open Arc Welding, the XVC-S is for Submerged Arc Welding. The XVC-S uses a high fidelity color camera with a standard image sensor with an automatic gain control that allows for imaging in regular, room-like lighting. The XVC-O is a much more advanced camera that is specifically designed for High Dynamic Range imaging where the operator wants to view both the detail in a bright open arc as well as the dark work environment around it. As well, the standard XVC-O has a number of additional system features not present in the XVC-S (see datasheets for more detail).

Q. Does the XVC-O system record and playback welding videos?

A. Yes. The basic XVC-O and XVC-S+ systems can both record videos up to 55 hours. The videos can be played back via the HMI console, or exported to an external device using a USB key.

Q. What Service and Support is available?

A. Xiris’ Standard Warranty on the XVC-O weld camera system is 1 year, during which time Xiris will replace, free of charge, any defective components that failed for reasons other than environmental or operational misuse. The light sources and optical components are not included in the warranty. Support beyond the warranty period could be arranged by either subscribing to the XVC-O Maintenance Programs, or by contacting Xiris Customer Service department.

Q. What are the consumables required?

A. The XVC-O system consumables are: Protective Windows, HMI Console Fan Filter, and Camera Cooling Air regulator Filter. Please refer to the Operator Manual for the recommended maintenance procedures and intervals, and for ordering the right part numbers.

Q. How do you protect the camera against weld splatter?

A. A piece of protective window is equipped on the camera to protect from weld splatter. The protective window is affordable and easy to change and it is secured by two clamp springs.

Q. How robust is the system?

A. The XVC-O system is designed to work in a harsh industrial welding environment. Our production technicians conduct systematic procedures to test and ensure each system will sustain real welding environment before shipping the product to our customers. As long as appropriate cooling is applied onto the camera, the system will maintain its functionality.

Customer Testimonial - ATI

 
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“The operators like using the system for its ease of use and instantaneous response.”
Ed LassalineAssociated Tube Industries

Customer Testimonial - Babcock and Wilcox

 
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“I would highly recommend Xiris vision systems to anyone that wants a robustly built weld monitoring system that can be custom tailored to your specific needs.”
Andrew SpreitzerBabcock and Wilcox

Customer Testimonial - EMI

 
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“The false accept rate (the rate of passing a bad disc) is zero – we have never seen the system pass a bad disc.”
Dan MiddletonEMI Music

Customer Testimonial - Panasonic

 
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“Xiris initial training to our lead technicians has been excellent and will help us in our own training program.”
Joe PerezPanasonic

Customer Testimonial - Tenneco

 
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“The instantaneous feedback to mill setup changes saves operators time and makes them more efficient.”
Joe HeppnerTenneco

Customer Testimonial - LJ Welding

 
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“The Xiris camera system has helped us win welding automation business that we might not have otherwise won.”
Ryan HoltLJ Welding