Technology Made Simple
High-Tech Welding Machines Made Simple. Do you have a welding machine on your plant floor that seems so complicated that only a few are allowed to run the product? After visiting many of my customers I found that this is a common situation. Many companies have welding needs for higher level welding capabilities and have purchased equipment that meets those needs. However, the front panel of the machine looks similar to the cockpit of the space shuttle. The welding operators have no idea how to run the machine, and managers are afraid that without proper training the machine can be easily programmed incorrectly and not run effectively. So it is put in the corner, or left on a boom out of reach. Unfortunately, most companies are experiencing a severe shortage of trained welding operators and fewer and fewer “welding experts” on staff to figure out this high-tech equipment. And, with welding technology evolving and capabilities continually increasing, there is a need, more than ever, for simple machines. Examples of complexity are machines that use programmed weld sequences for weld procedures. It is true that these machines meet a variety of complex weld procedures however, traditionally these sequences did not relate to each other and you had to program them each separately. This type of set-up is involved and confusing, and when not programmed accurately, you end up with a welding machine that is virtually ineffective. Today, we are working toward combining the sophistication required for complex industrial applications, with an entry-level, simple machine traditionally used in fabrication and manufacturing applications. This includes removing the numerous knobs, dials, and switches that seem to be a mainstay on all high-technology welding machines. Instead of having all these opportunities for mishap, we’ve found ways to include the “newer” technologies within the one or two controls located on the front panel of entry-level welding power sources. By re-designing the weld sequence system, so that the start sequence is based on the weld sequence and only the wire feed speed needs input, and then the rest of the sequence automatically adjusts – as well as including the same weld sequence system on the separate wire feeder so that everything is working in conjunction – are just a few areas where we are evolving. What if you could put an untrained welding operator on your production line and with little guidance have that operator welding with your “high-tech” machines? How much time, money, and frustration could that save you? The next time you are researching a welding purchase, don’t stop with the welder that “just” has the capabilities to meet your welding procedures. Look for the one that can meet your needs, has a simple front panel, and is quick and easy to set-up and operate. Consider ease-of-use as an essential component for equipment purchases. Let me know what you think…Post your comments and questions.
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April 28th, 2006 at 4:23 pm
You are absolutley right that the workplace is lacking trained welders but by making welders more user friendly doesn’t solve a thing. Most welders i work with don’t even understand the reason for using the cover gas or the electode required for the job at hand. More education in the science of welding is needed in the training of a welder so that he/she can understand the reasons for pre/post heat, electrode selection, gas required, restraint requirements etc. of the job at hand. With a strong knowledge of welding and the reasons why things are, and need to be done, the more efficient a company can be. Don’t get me wrong. not all welding requires an Einstien to get the job done nor can we be all knowing in all fields but if you weld sanitary/food grade stainless you ought to know not just how to weld it but why you weld it the way you do. In case you wonder, yes i’m a welder, 16 years and still learning!
May 22nd, 2006 at 8:37 am
Jeff Thank you for your real world perspective regarding welding machine simplicity. The simplicity of the machine may make a difference, but it’s not a silver bullet. It may be better to think of machine simplicity as only one slice of the pie. As a manufacturer of welding equipment, one has to ask what can we do, or offer, to improve welder knowledge in our country. Can we do anything? Can our machines help teach? or should our manuals do more in this regard? Would your fellow workers realistically think of looking to a welding manufacturer for an answer of Why, vrs How to?
June 15th, 2006 at 7:10 am
Hi from downunder. I agree with Jeff, I think that there is a “dumbing down” of the industry as a whole and this appears to be happening worldwide. We certainly have similar problems here in Australia with very poor training of tradespeople either by government or private enterprise. This certainly wasn’t the case when I served my apprenticeship nearly 30 years ago.
Even now 3 decades on I enjoy Tig welding immensely and I’m not afraid to learn new tricks. The current crop of inverter Tigs are so way ahead of the old transformer machines in performance it beggars belief.
If I have one gripe about the current inverters it’s the manufacturers insistence on using a “menu” based system and essentially one LED through which all the parameters are viewed.
I have used quite a variety of inverter tigs including Miller, Lincoln, Esab, Kemppi etc and they all use basically the same “menu” type system.
By contrast my usual machine at work is an OTC AVP 300 inverter, this machine has all the bells and whistles like the others but the controls on the machine are all analogue (good old fashioned dials & switches)
For the novice coming in it looks very complicated but it’s set out logically and for an experienced welder it works brilliantly. At a glance, I can see where all the parameters are set at any time without having to enter a menu to find a certain value. If AC balance needs to be changed, move the dial, the same with all the parameters.
As the manufacturer, I think you’re probably right in the current (and probably future) climate of semi skilled rather than skilled workers to almost make the machines child proof but it won’t help in improving the mind set of better training requirements. After all, if the workers were better trained they wouldn’t be afraid of trying these new machines no matter how many dials they have.
Regards Andrew.
ps: I love the specs on your new Dynasty 700, it looks like a worthy replacement for the legendary Aerowave.
August 4th, 2006 at 4:31 pm
Yes Jeff. 1000% correct. alot of companies are transforming the weld shop to high tech. and not enough skill to pull them through. I mean its all taking place in the voc.trade. A lot of welders are leavind school with what is deemed as basic skills. and when they hit the real world…Its a different story.The bosss says ”make this box”. actually it only takes a hour tops. the employee takes35to40 mins extra. And on top of that its still not right.how do you think a welder that barely has the basics anyway to be able to deal the bells and wisthles of these new tech machines?Well the companies have taken that into consideration.and thats why we are seeing less welder knowledge and know how when it comes to operating these machines.I work with linclons.(WHY. I DONT KNOW)roses r red violets r blue so my miller machine too. but any how these things are one touch operational. it has PRE SETS FOR CRYING OUT LOUD. to the extent of the size of wire involved to the type of wire. including stick, fcaw ,tig alum and s.s.All of this inside the panel for you to read and set to with the turn of a knob and the press ot a button. TRUST ME in no WAY am i advocating this. but it just goes to show how much of a sad shape our welding world is in.to the point where old school is just that.at this rate welding will require no skill.accept reading,squeezing a trigger or striking a arc.take away all the gizmos and ask them to weld.see what happens.where did the understanding go on knowing what kind of heat you had based on how youre weld puddle looked,and electrode/wire sounds?.
Im all for technology. but i still belive that as a welder you should be able to preform even if it wasnt here.They have to learn that youre only good as the last weld you made. and that controled enviorment(school) is gone.AND most importantly…a high tech welding machine does NOT make you a better welder.YOU can not compromise true welding skills. thanks 4 letting me get that off my chest.YES. welding for 13+yrs…and still learning and loving.
August 27th, 2006 at 7:52 am
I agree with most if not all the comments made. But being close to 25 years out of school and being self tought in the more advanced welding process’s I have to look at the problem from the personal stand point first then the big picture. I had and still have the drive to learn more every chance I get, there are few things in life that I could do so much of and never really get tired of it (theres one other that comes to mind but thats way off subject). Many production welders are just that, they are no different then the guy assembling door handles or what ever on the assembly line, and they view welding as just a job. The pay for these jobs is not going to make them rich, so their drive to learn more is not there and you may as well make the machines better and more simple to learn.
Kids these days are probably not as drivin as most of us “older” generation, and if they are they are going to choose a field that pays them for their effort. Its the computer age man- who wants to be the $10.00 an hour guy staring at an arc all day when he can be the $30+ and hour guy designing the machine or components that make that arc ?
Schools are pulling their machine, weld shops, & class’s right out of the high schools and even tech schools to use the space for more needed studies, it kills me to think about it. I lived for all those class’s and owning a job shop where is my next helper going to come from ? A 18 year old today doesnt know what a lathe, mill or welder really is (other then orange county choppers) much less how to use them, and it isnt going to get any better.
Like the true tool and die guys of yesterday, great welders may some day be a thing of the past.
From the view of the companys making the machines. Technology is making leaps and bounds still today, the machines are getting better and the number of skilled operators are becomming fewer. What else is there to do from their stand point but try to make the machines as “friendly” as possible for every one to use ?
I wish there were more seminars available for those of us that dont have a lot of time but still have the desire to learn more.
hope that all makes sense. I dont have time to put more thought in to this, I have sparks to make !
September 19th, 2006 at 7:40 pm
the machines are getting better thanks to miller and thenumber of skilled welders are fewer. this nation must learn how to be a adult before you canbe a skilled tradesman
October 5th, 2006 at 8:03 pm
A SKILLED weldor can make good money in this day and age. Call the local pipe fitters, construction or ironworkers union! The guys can’t find enough SKILLED people due to lack of enrollment in the local trade schools, many of which have closed in recent years due to poor attendance!!! The problem with todays generation is that welding requires HARD WORK! This country faced the same problem in the past and the solution usually is resolved with the hiring of immigrants (think railroads). I’ve meet more “weldors” that got certified in 1-g by taking night classes one nite a week for 6-7 weeks and walk on the job thinking they’re the greatest thing since low-hydrogen! The welding jobs are plentiful and well paid if the individual is willing to work. Thats the problem, WORK! The need for educated weldors is dire because of the public saftey that is dependent on them (bridges, buildings, cranes/ hoists,aerospace, constuction,shipbuilding, etc.) As far as “this nation being a adult”(?????), our skilled tradesPEOPLE have done more for industry than most nations combined!( i don’t know of many engineers that left America to pursue an education because our schools lacked the knowledge).
April 25th, 2007 at 9:33 am
Best starting points for my balance and PPS for new Syncro 200
I am a very good Mig wleder and I welded both aluminum and steel, but never changed the setting because it looked pretty good. I am simply looking for a base line.
Thanks Scott Peterson.
Aluminum:
Balance?
PPS?
Steel:
Balance?
PPS?