WELDING SIMULATOR

The welding simulator provides students with a realistic welding experience in a virtual environment, offering a safe and controlled workspace. With precise control, analyses and instant feedback, it enables students to develop their skills and prepare for real work conditions.

Learning Technologies
ARCPro+ Welding Simulator

The welding simulator not only provides experience in the welding process but also offers the opportunity to practice safely and in a controlled manner in a virtual environment. Electronic equipments integrated into the welding mask and torches worn by the user allows for precise control through real-time motion tracking. This equipment enhances the accuracy and quality of the welding process, helping students improve their welding skills.

The precision data is designed to be fully compatible with the actual welding process. This way, students are better prepared for real welding environments while practicing in the virtual welding workshop. The simulator allows users to easily change all necessary settings during the welding process via their virtual mask. Thus, users can continue working and maintain their focus without needing to remove the mask. By utilizing virtual reality (VR) and augmented reality (AR) technologies, the welding simulator makes welding training more immersive and interactive. VR and AR enable users to closely examine welding solutions.

Additionally, the simulator's educational content includes various welding scenarios and tasks. This allows users to diversify and reinforce their skills by experimenting with different welding techniques and material combinations.

Simulator Highlights

The welding simulator offers various training modules covering different materials and techniques related to welding. These modules enable students to diversify and deepen their skills in different welding scenarios.

It provides an immersive experience with a high-resolution virtual reality (VR) headset.

The simulator is user-friendly. It allows the entire system to be operated using joysticks and a trigger on the torches, without the need for a keyboard/mouse or removing the VR headset.

It tracks critical parameters for the welds (such as travel speed and orientation angle) and graphically displays analyses like porosity analysis, penetration analysis and spatter analysis.

With its instructor interface, different reports can be recorded for each student, instructor, class, or group and training results can be obtained digitally or printed out.

The simulator analyzes errors occurring during the welding process and provides instant feedback to the student. This allows the student to immediately understand and correct their mistakes.

At the end of each weld pass, the welding simulator generates a statistical report showing the accuracy percentages for each controlled parameter in the practice. These reports are recorded on the instructor's computer.

All training sessions can be recorded and later reviewed with an instructor. During playback, camera angles can be changed to view the practice from different perspectives. The recording feature is one of ArcPro+'s most unique attributes in the industry.

ArcPro+ detects real-time errors during the simulation. Distance, orientation angles, and speed are monitored. Correct grip and angles are indicated to the user with arrow directions. Each exercise is recorded in a way that allows for 3D interactive review later.

The user can freely change welding parameters (such as voltage, wire speed, wire angle, etc.) at any time using the joystick on the welding torch.

Software Features

The simulation software enables the welding process to be carried out in a completely virtual world.

The software of the welding simulator allows for the import of any part or shape into the virtual world and enables welding on it.

In the welding simulator software, the welding process is modeled with a high level of fidelity, allowing for realistic welding training.

It can provide training for MIG/MAG gas metal arc welding, electrode (SMAW) welding, TIG welding, FCAW-S, and FCAW-G flux-cored arc welding.

The simulator supports welding positions including PA, PC, PF/PG, PE, PH/PJ, H-L045/J-L045, PB, PD, 1F, 2F, 3F, 4F, 1G, 2G, 3G, 4G, 5G, and 6G.

With the welding simulator, at least 14 different welding parts can be welded in different positions.

Errors made during the simulation are monitored in real-time and the user is provided with necessary information.

It supports both American and European welding standards.

During the welding process, the student's interaction with the simulation software can be controlled via application interfaces on the welding gun's button without removing the mask.

The orientation of the electrode can be selected.

To ensure that the theory of the welding process is well understood, theoretical information related to the lesson should be provided at the beginning of the relevant lesson. The provided theoretical information enables teaching through the theoretical test section. This feature also allows the instructor to add questions with images to the theoretical test section.

The software can be fully controlled with a VR headset and torch types. After starting the software, the student can select and start the desired training from the menus.

The software can perform penetration, porosity and spatter analyses.

An interactive playback system is available. The user can replay, pause and move forward or backward through a previously recorded lesson.

The software interface can be used in Turkish, English and other preferred languages.

Equipment Requirements

• 1 simulation computer
• 1 monitor/TV
• 1 virtual welding mask
• 1 motion tracking system
• 1 welding cabin
• 1 welding table and welding parts
• 1 uninterruptible power supply (used to ensure data and system security against power outages.)

Welding Process

Trainings with the content described below can be carried out with the welding simulator.
Weld deposition on plates in PA position jamb welding
Joining plates by welding
Pipe welding
Overhead welding
Vertical source

Welding Mask

It enables the welding process to be carried out in a virtual environment. With the virtual glasses inside, it gives the student the feeling of working in a welding workshop. The welding mask also includes the necessary adapters and cables to connect the virtual glasses to the computer system.

Welding Table and Welding Parts

The welding mask and torch tracking systems are located above the welding table. The welding table is designed to accommodate welding on at least 10 different parts in various positions. The height of the welding table is adjustable, allowing for welding on different parts in different positions. There are designated places on the welding table for placing the torches.

Welding Torches

In the welding simulator, the welding torches are electronically tracked with a tracking accuracy of at least 0.2mm. The simulator includes torches for MIG/MAG gas metal arc welding, electrode (SMAW) welding, TIG welding, FCAW-S and FCAW-G flux-cored arc welding. The characteristics and weight of all welding-related equipment are similar to real equipment. The transition between different types of welding is facilitated by the easy interchangeability of accessories, allowing for smooth and effortless changes.

Welding Machine Controls

With the welding simulator, operations such as course selection and real-time changing of the required welding parameters during the welding process can be performed by the user with the help of appropriate control interfaces on the welding gun, without removing the welding mask.

Motion Tracking System

The precise tracking of the head movements of the user wearing the welding mask allows for real-time interaction with the virtual world. The accurate tracking of the welding gun's position is crucial for correctly monitoring the quality of the welding process and for subsequent analyses. Therefore, electromagnetic measurement systems are used for tracking the position of the welding torches.

Quantification and Consideration

The welding simulator includes a reporting module that can generate outputs in HTML or PDF formats containing the following information at the end of the scenario. The reporting system eliminates record-keeping confusion and makes training more efficient.