Xiris Automation

Resources

Xiris White Papers

Cover image of Xiris Audio Monitoring White Paper


How Audio Monitoring Can Improve Welding Quality

Weld Cameras with audio capture deliver essential benefits for any manufacturer.

Cover image of The Xiris Glossary of Weld Imaging Terminology White Paper


The Xiris Glossary of Weld Imaging Terminology

Weld Camera terminology is unique. Use this glossary of  terms to avoid confusion.

Cover image of Xiris 8 Ways to Improve Productivity White Paper


8 Ways to Improve Welding Productivity Using a Weld Camera

Learn eight ways to improve welding productivity using a weld camera.

Cover image of Xiris Weld Camera Compatibility Checklist White Paper


Weld Camera Capabilities and Selection Checklist

Use this checklist to ensure you get best Weld Camera solution for your business.

Cover image of Xiris Why an Operator Can Still Outperform an Automated Laser Seam Tracker White Paper


How an Operator can Outperform Automated Laser Seam Tracker

Automated seam trackers have some significant problems when put to use in the field.

Cover image of Xiris A Short History of Using Cameras for Weld Monitoring White Paper


A Short History of Using Cameras for Weld Monitoring

A history of using High Dynamic Range (HDR) imaging with a video camera for monitoring welding.

Cover image of Xiris Using a Weld Camera to Teach Welding Students White Paper


Using a HDR Weld Camera to Teach Welding Students

Use a Weld Camera in the classroom. Demo a weld once & record to playback for students.

Cover image of Xiris Welding Like You've Never Seen it Before White Paper


Welding Like You’ve Never Seen Before

Xiris HDR cameras capture detail in the arc and background with more precision than even the human eye can deliver.

Cover image of Xiris Improving Productivity with a Weld Camera White Paper


Improving Productivity with an HDR Weld Camera

Weld cameras can improve productivity by reducing set-up time and costs due to bad welds.

Cover image of Xiris Non Destructive Inspection of Tube and Pipe Welds White Paper


Non-Destructive Inspection of Tube and Pipe Welds

Better understand how laser-based inspection can improve weld quality and efficiency on tube or pipe mills.

Cover image of Xiris Non-Destructive Inspection of Tube and Pipe Welds Chinese White Paper


Non-Destructive Inspection of Tube and Pipe Welds-Chinese

Better understand how laser-based inspection can improve weld quality and efficiency on tube or pipe mills.

Cover image of Xiris Weld Cameras Mean Better Weld Quality for Tube and Pipe Production White Paper


Weld Cameras Mean Better Quality for Tube & Pipe Production

Tube and Pipe fabricators can benefit from real time weld monitoring using HDR cameras.

Cover image of Xiris Glossary of Machine Vision Terminology White Paper


The Xiris Glossary of Machine Vision Terminology

Machine Vision terminology is not common and well known. Use this glossary to get the full picture.

Cover image of Xiris Ensuring a Perfect Image White Paper


Ensuring a Perfect Image – Building Better Print Inspection

Careful inspection ensures the quality and smooth operation of the printing process.

Cover image of Xiris Ensuring Quality in Metal Additove Manufacturing White Paper


Ensuring Quality in Metal Additive Manufacturing

Learn how investing in technology to improve your Metal AM quality is a worthwhile step.

Image of a Xiris White Paper Cover


Improving Metal Additive Manufacturing Using Cameras

Improve quality and process control by generating high-contrast images and videos using HDR cameras.

Cover image of Xiris Metal Additive Manufacturing White Paper


Metal Additive Manufacturing Like You’ve Never Seen It Before

See how HDR Weld Cameras can show operators materials in real-time during the additive process.

Cover image of Xiris Justifying the Cost of Automatic Weld Inspection on a Tube Mill White Paper


Justifying the Cost of Automatic Weld Inspection on a Tube Mill

This paper features Return on Investment (ROI) calculations to justify productivity investments.

FAQ’s

XVC-1000/1100

  • The XVC-1000 produces a monochrome image, while the XVC-1100 produces a color image.

  • The serial number sticker found on the back of the camera will note either 1000 or 1100 in the date field. (i.e.: 1000/071519).

  • The standard combination is: ND Filter (ND060-27) followed by UV+NIR Cut Filter (SP705-27) and Clear UV Filter for spatter protection (No Markings)

    * If a camera is purchased with a Xiris optics kit.
    * These are defaults that will work for most applications, you can modify as needed.

  • The standard combination is: Red Bandpass (BP635-27) followed by UV+NIR Cut Filter and Clear UV Filter for spatter protection (No Markings)

    * If a camera is purchased with a Xiris optics kit.
    * These are defaults that will work for most applications, you can modify as needed.

  • To choose the right lens (based on your desired working distance and field of view), please refer to Lens Configuration Chart PDF located under Resources in the Support Center.

  • A good starting point is f/4.0. You can adjust the aperture to let more or less light in depending on your environment or application.

    1. Ensure all the cables are correctly connected. The camera has 2 green LEDs located below the RJ45 connector, which when lit, indicate connectivity.
    2. If the ethernet LEDs are active and there is still no camera image, check your network adapter settings to ensure that the IP address is set to automatic.
    3. If you are using WeldStudio™, try restarting the software. The camera will start a few moments after the software appears.

XVC-1000e/1100e

  • The XVC-1000e produces a monochrome image and has a red filter in front of the lens, while the XVC-1100e produces a color image and has a clear filter in front of the lens. Additionally the serial number sticker found on the top of the camera will note either 1000e or 1100e in the date field. (i.e.: 1000e/083019)

  • The spatter shield can be easily removed and replaced by sliding it in and out of its mount. No tools are required.

  • Are there different types of spatter shields available?
    Yes. Xiris offers both a borosilicate glass for high temperature and a Makrolon self-cleaning plastic shield for spatter protection.

  • Without cooling, the XVC-1000e/1100e cameras can handle ambient air temperatures up to 35°C/95°F. With air or water cooling, ambient air temperatures up to 75°C/167°F are acceptable. With a Xiris high temperature kit, the XVC-1000e/1100e can handle ambient air temperatures up to 260C/500F.

  • Yes. Shop air can be used as long as it is clean air from a regulator at a pressure of no more than 60 PSI. This will ensure no damage to the camera internals occurs. Using a Xiris vortex for cooling is recommended.

  • Yes, clean water can be used to cool the camera (Max pressure – 40 PSI).

1000e System Software

  • Yes. The camera requires a PC running XVC-1000e System Software to view the camera.

  • The latest version of XVC-1000e System Software can be downloaded from the Support Center located under the XVC-1000e System Software tab.

  • Click on Support Centre in the footer of this page. To register a new account, a product serial number is required. Alternatively, you can contact us at 905-331-6660 ext. 248 if you would like Xiris to create your account or if you are experiencing difficulties accessing your account.

  • Click the User icon, located above the Xiris logo. You must enter the correct password associated with each user level account. There are 3 user levels: Operator, Technician, Administrator.

  • Yes, once logged in as an administrative user, click the User icon above the Xiris logo and click Setup. From here you can disable specific features for different user levels.

  • Focus is controlled within the software and can be adjusted using the focus slider located under the Camera tool/icon on the Settings menu (wrench icon).

  • Check your IP address settings for the camera. The IP address for Camera 1 should be set to 172.16.3.x with subnet mask of 255.255.255.0. The IP address for Camera 2 should be set to 172.16.4.x with subnet mask of 255.255.255.0. Automatic IP addresses cannot be used. Refer to manual and/or quick start guide for detailed instructions of how to set/reset IP address.

XVC-700/710

  • The XVC-700 produces a monochrome image, while the XVC-710 produces a color image. Additionally the serial number sticker found on the top of the camera will note either 700 or 710 in the date field. (i.e.: 700/093019)

  • 0°, 15° and 75° formats are available today with other angles available on demand.

  • Yes. The slimline profile is suitable for cladding applications with small diameter pipes.

  • The XVC-700 is best when:

    • Space is tight and a smaller, more versatile camera is needed or an angled optical assembly is useful to see hard to reach features.
    • Weight is a factor. At just 100g and a single M12 ethernet connection, it is well suited applications where weight is a consideration.

    The XVC-1000 is best when space is not restricted and a photodiode, C-Mount optics, trigger and digital I/O are needed to interface to an external process.

    The XVC-1000e is best when integration ease and speed are important. The XVC-1000e includes a protective window and integrated lighting, air / water cooling, optics with a fine focus under software control, and simplified cabling.

  • The camera is cooled by air. The rear of the camera contains an air inlet for filtered and regulated shop air to be inserted into the camera. Between 45 to 60 PSI is recommended. A vortex is recommended to control the temperature of the air going into the camera.

  • Yes. Shop air can be used as long as it is clean air from a regulator at a pressure of no more than 60 PSI. This will ensure no damage to the camera internals occurs. Using a Xiris vortex for cooling is recommended.

  • Yes. The OEM version contains a VGA output for connecting a monitor directly into the OEM box.

  • Yes. The XVC-S+ version comes with an HMI with built in computer. This will allow you to record and store videos.

  • There are 3 types of XVC-S controllers available: XVC-S OEM, XVC-S HMI and XVC-S+.

  • a. The OEM version is a small control pad with input from the camera and output to your own monitor using VGA. 1 camera is supported by each OEM box.

    b. HMI is a robust housing with built in monitor and control pad with camera input. This version is used only to view the camera. No recording is available on this model. 1 camera is supported on this system.

    c. XVC-S+ is a robust housing with built in monitor and full PC. This version allows you to store and record videos. This model will also allow up to 2 cameras to be connected to the system for leading and trailing cameras.

  • The XVC-S camera is enclosed in robust housing meant for harsher environments. It is also air cooled to ensure proper operating temperatures for long periods and ensure the longevity of the camera.

  • All 3 controller types have the same interface. Crosshairs are available and can be used to line up objects on screen.

  • No, this camera was designed specifically to monitor sub arc welding only. For open arc viewing please view the XVC-1000e/1100e, XVC-1000/1100, or XVC-700/710 line of cameras.

  • Xiris can provide a Camera Articulated Arm with Super Clamp Mount that can be used in mounting the camera.

  • Yes, you can use your own mounting from the top or bottom via 2 X M3 screws.

  • Yes, but you will need to use the XVC-S+ HMI to do so.

  • Typically, no. Occasional replacement of the front lens (due to dirt from years of use) is needed and can be purchased from Xiris.

  • The camera can be set anywhere from 150 – 400 mm (5.9” – 15.7”) away from the subject.

  • [87 x 63] mm to [211 x 154] mm / [3.4” x 2.5”] to [8.3” x 6”]

  • Yes, brightness levels can also be adjusted through the controller along with turning them on and off.

  • 40m (131ft)

  • The ambient air conditions of the camera are 0 to 45°C (32 to 113°F).

  • All XVC-S models are colour cameras.

  • Only sub arc cameras can be used on a sub arc system and only open arc cameras can be used on an open arc system at this time.

  • Power and data from the camera are transferred from one cable into the camera itself. The power will come from the controller it is connected to which is usually an 120V outlet.

WeldStudio™

  • Yes. The camera requires a PC running WeldStudio™ to view the camera.

  • The latest version of WeldStudio™ may be downloaded from the Support Center under the WeldStudio™ tab.

  • Click on Support Centre in the footer of this page. To register a new account, a product serial number is required. Alternatively, you can contact us at 905-331-6660 ext. 248 if you would like Xiris to create your account or if you are experiencing difficulties accessing your account.

  • To change modes, click on the welding torch icon in the bottom right corner of the camera screen. This will switch from global shutter (welding mode) to rolling shutter (setup mode). Modes may also be switched by enabling Auto Weld mode (located in Preferences) along with the camera’s photodiode to detect when welding has started.

  • Yes. Clicking the red record button on the Video tab of the Media tool, will start video recording.

  • Video files are limited to 2 hours and broken up every 4GB. To record more, simply start a new recording each time the limit is reached.

  • All videos are recorded in AVI format.

  • Snapshots are taken in PNG format and can be opened in any standard image viewing software in Windows 10. Simply navigate to the folder where your Snapshots are saved and double-click a file to view it.

  • RAW images are opened using a Virtual Camera from the Tool menu (click “Create Virtual Camera”). Once opened, select the folder icon at the bottom right to locate the folder that contains your RAW images. Click play to view the RAW images.

WI2000/3000

  • The WI2000 is suitable tube diameters ranging from 5mm up to about 250-300 mm diameter and it can see weld beads no larger than about 6-8 mm. The lower position of the Sensor and higher vertical resolution makes it ideal for detecting smaller defects.

    The WI3000 is suitable for all tube diameters 11mm and upwards, and weld beads that are 3-28mm in width. The higher position of the Sensor allows for a much lower risk of contamination in harsh environments, at the expense of a small amount of vertical resolution.

  • The system measures the geometry of the weld bead and adjacent area on a tube or pipe, looking for weld quality and process related defects.

  • The system projects a laser line across the tube/pipe while a camera images the laser line reflection from a direction different than the projection. This allows for accurate weld profile measurement independent of the base material surface conditions and the weld seam image displayed as a profile line in real time. Specialized software processes the image from the camera, applying values to the laser line reflection. All calculated weld seam parameters are displayed graphically on the HMI screen, and are also logged to files on the Computer hard drive for off line reference.

  • The system consists of the Sensor Head, Head Mount, Light Tower, Cables, PLIM and HMI Console. The Sensor Head – contains the high-speed camera and laser lighting optics and the HMI Console (includes PC) processes images from the Sensor Head; evaluates parametric values; communicates the results to external devices (e.g. PLCs) via the PLIM (Production Line Interface Module) or the OPC Service. The HMI Console also includes a touch-screen monitor to provide data input and display of the GUI and measurements.

  • The WI2000 system can inspect tubes/pipes from 5-200 mm in diameter with weld bead widths from 0.25-8 mm.
    The WI3000 system can inspect tubes/pipes from 11-3000 mm in diameter with weld bead widths from 5-28 mm.

  • No. The WI2000/3000 system uses a high-resolution sensor that only looks at the weld bead and its immediate vicinity of the tube or pipe.

  • No. The WI2000/3000 software is designed to inspect profiles where the zone around the weld is flat (such as square profiles, butt welds, or welded blanks), circular (such as round, or elliptical/oval tubes) or V shaped (such as special tube or profile shapes).

  • No. The WI2000/3000 system is designed to inspect only the outer surface of the tube/pipe. A custom versions of the WI2000/3000 is available to look at the weld bead profile from the inner diameter.

  • The standard WI2000 system is designed to work on Laser, TIG, Plasma and HF/ERW welding lines where the environmental conditions around the Sensor Head are not too hostile. The WI3000 system is designed to work on Laser, TIG, Plasma and HF/ERW welding. Its rugged housing and closed-loop liquid cooling make it ideal for harsh HF/ERW environments.

  • The standard WI2000/3000 system is designed to work on most materials, including Carbon or Stainless steels, aluminum, copper and exotic metals. Some non-metallic materials that are opaque such as certain plastics could also be used – check factory for details.

  • No. The WI2000/3000 system is designed as an optical measuring device that uses reflections from the top surface. The laser light does not penetrate through the metal material and cannot look inside the wall.

  • The WI2000/3000 offers a complete, absolute inspection of the contour of the weld that does not rely on comparison of one measurement with a previous measurement. UT and/or ECT systems detect only when there is a sudden difference, missing defects that occur from a gradual move out of tolerance.
    The WI2000/3000 can detect weld quality anywhere in its field of view, even if the weld seam location moves (i.e. Weld Roll) as the material is fed into the mill.
    The WI2000/3000 can detect certain defects, like Mismatch, that cannot be reliably detected by other methods.
    The WI2000/3000 can differentiate and provide distinct measurements for various Sunken Welds, such as Undercut, which are often lumped together into one classification when using traditional UT or ECT tools.

  • The Standard Resolution WI2000 (SR5, SR12) sensor can tolerate up to 2mm vertical movement and 3 mm horizontal movement. The High Resolution version (HR9. HR22) is limited to 0.6 x 1 mm accordingly. WI3000 Sensors come in a large variety of sizes. The HR15 and HR21 can tolerate up to 4-6mm of vertical movement. The HR35, HR50 and H75 models can tolerate much more, from 8 – 19mm of vertical movement.

  • The WI2000/3000 is best installed immediately after the weld head where the most information about the weld bead and tube profile can be measured before the bead is scarfed/ground away. Alternatively the system can also be located after the scarfing/grinding station where measurements can be made to detect the quality of the scarfing process as well as some welding and forming related issues that are still visible outside the scarf/grinding area.

  • The WI2000/3000 system is designed to comply with CE Design Standards for CE Marking (Machinery (98/37/EEC), EMC (89/336/EEC) and Low Voltage (73/23/EEC) Directive for Electrical Safety. In addition, due to the fact that the Sensor Head is using a Class 3B laser for illumination, the system is designed to follow the regulations of IEC 60825-1:2007 standard, and in compliance with 21 CFR 1040.10 and 1040.11 except for deviations pursuant to Laser Notice No. 50, dated June 24, 2007. Users and maintainers must always obey the Warning and Caution indications displayed on the Safety Labels attached to the unit, and depicted in the Operations and Service Manuals.

  • A Class 3B laser classification implies that the laser output power is greater than 5 mW and less than 500 mW. Lasers in this category are normally hazardous when intrabeam ocular exposure occurs (i.e. within the Nominal Optical Hazard Distance) including accidental short time exposure. Class 3B lasers may also cause skin damage with prolonged exposure, however the laser beam on the WI2000/3000 is diffused significantly by the time it comes out of the camera head to form a laser line. It is further diffused when reflecting off the tube and viewing diffuse reflections is normally safe as is short term skin exposure.

  • Under normal operating conditions, laser life expectancy is rated at 2500 hours of operation, longer if it is kept below 30 °C. We recommend all systems undergo an annual re-certification by Xiris to qualify each sensor head for laser power level, optical alignment, focus and overall system cleanliness.

  • The WI2000/3000 system Storage Temperature is 0 to 50 °C, and the HMI Console Operating Temperature is 10 to 40 °C. The ideal Sensor Head Operating Temperature (internal) must be maintained below 25 °C (using the Air Cooling assembly) for optimum operating life.

  • The WI2000 is air cooled. The WI3000 is liquid cooled.

  • The WI2000 Sensor Head uses 10 CFM (280 l/min) @ 60-80 psi (4-6 bar) of plant air.

  • Yes. The WI2000/3000 system has 4 configurable digital outputs that can be connected to external marking or alarm systems via the PLIM (Production Line Interface Module) unit that is supplied with the system. The PLIM facilitates connection of the WI system to standard encoders and other equipment used on tube or pipe mills. The optional OPC Service can provide communication with the PLC via KepServerEX. The Xiris Weld Inspection software self-generates its own predetermined tags that can be added to a PLC program.

  • Horizontal and Vertical accuracy varies between 7 µm for the High resolution Sensor models, to 20 µm for the Standard resolution Sensor models of the WI2000. The WI3000 is slightly less accurate due to its larger field of view.

  • Individual tolerance limits can be set for the various inspection measurements. Outputs from the system can then be configured to raise an alarm if any of the tolerance limits are exceeded by measurement results.

  • No. The system has an open-loop design so that results of inspection are reported to the external control system and/or to the operator for the purpose of quality control. There are no back-loop signals except the inspection Start/Stop.

  • The WI2000 Sensor Head dimensions are 128 x 59 x 244 mm (Length x Width x Height).
    The WI3000 Sensor Head dimensions are 180 x 100 x 265 mm (Length x Width x Height).

  • Yes. The WI2000/3000 system logs measurement results, and optionally, images and profiles, onto the Computer hard drive for off-line Audit or Failure Analysis purposes. In addition, interval data recorded can be made to record average values over an interval for Statistical Process Control.

  • Xiris Standard Warranty on the WI2000/3000 Weld Inspection 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. Support beyond the warranty period could be arranged by either subscribing to the WI2000/3000 Maintenance Programs, or by contacting Xiris Customer Service department.

  • Yes. The WI2000/3000 system allows the use of pre-recorded images as input instead of the live camera. The system player allows review of logged information in order to replicate inspection results together with metric limits set at the time of logging.

  • One day is all that is required for a typical installation including basic system training.

  • The WI system will work on flat welded blanks and can inspect the characteristics that exist on a weld between two pieces of similar or dissimilar thickness. The system must be fixed so material can move under the camera head. For spirally welded pipes, if operated in a pipe mill, the weld head must be mounted in a fixed position straddling the weld bead as the two sides of the parent material are fed underneath.

  • Protective Windows, Filter Media – HMI Monitor Fan, Filter Media – Computer Fan, Filter Element – Sensor Cooling, and Laser Safety Warning labels (Complete Replacement Set). Please refer to the Service Manual for the recommended maintenance procedures and intervals, and for ordering the right part numbers.

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