ARCAgent™ Applications PDF Print E-mail

These applications represent real companies that have used ARCAgent™ weld monitoring systems to understand, improve, and control their welding processes.

Manual | Fixed Torch | Robotic | Continuous

 

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Manual Welding Applications

Customer Type: OEM
Weldment: Motorcycle & ATV Frames
Problem Area: Missing Welds
 

Application Challenge:
Motorcycle and ATV frames were regularly being found with missing welds after final paint and assembly had already been completed. Repair costs were climbing and frustration was the norm. Using IMPACT's Patented Part Tracking™, they are controlling the process by dynamically counting welds and ensuring the right number of welds are being performed. Customer recently stated that "the only missing welds they struggle with are on stations that don't yet have your equipment."

 
Equipment: ARCAgent™ Weld Counter
Current Sensor
PC Hosting ARClient® HMI w/ Part Picture(s)
PLC Interface: Digital I/O
PC Interface: Ethernet
Fault Handling: Lock Fixture and Authorized Key Reset Required
 

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Fixed Torch Welding Application

Customer Type: Tier I Supplier
Weldment: Axle Manufacturer
Problem Area: Short/Incomplete Welds and Process Parameter Control

 

Description of Problem(s):
Who hasn't shipped short or incomplete welds to a customer? When human inspection is involved, even 200% or 300% visual inspection can miss this weld defect. This customer was forced to hire independent visual inspectors to sort through loads of parts. They have since integrated ARCAgent™ weld monitoring systems to reduce the risk by requiring a specified amount of ARC ON time for every weld. At the same time, they began monitoring each weld's set-point parameter averages and now know when their process becomes unstable.

 
Equipment:

ARCAgent™ 2000
Current & Voltage Sensors
Wire Sensor
Gas Flow Sensor

PLC Interface: Digital I/O
PC Interface: Ethernet to PC Located in Welding Area
Fault Handling: Lock Fixture and Authorized Key Reset Required
 
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Robotic Welding Applications

Customer Type: Tier II Supplier
Weldment: Miscellaneous Components
Problem Area: General Weld Defects Due to Equipment Fatigue

 

Description of Problem(s):
This customer exemplifies the majority of our customer base. They have weld defects, not from poor design or improper setup, but from the vast number of arc welding robots they maintain. They have deployed over 50 ARCAgent™ 2000 systems because, in their words, "when the system detects faults, there is something wrong and it needs to be addressed." "We [the customer] have identified 7 or more defective welding power supplies in the last few years." They enjoy enhanced process quality because they use ARCAgent™ technology to analyze each weld to detect instabilities before they become serious defects. This customer's management team has decided that real-time, 24/7, arc weld monitoring is one of the key ways they can ensure the highest quality welds for their customers.

 
Equipment: ARCAgent™ 2000 w/ Voltage Sensor
Current & Voltage Sensors
PC Hosting ARClient® HMI w/ Part Picture(s)
PLC Interface: Digital I/O
PC Interface: Ethernet
Fault Handling: Lock Fixture and Operator Resets
After [x] faults, operator notifies maintenance to resolve.
 
continuous-header.png Continuous Welding Applications
Customer Type: OEM
Weldment: Tube and Pipe
Problem Area: General Weld Defects

 

Description of Problem(s):
When using through-the-arc weld monitoring technology, a weld defect is a weld defect. The tube industry presents a unique challenge in that they can weld for hours, if not days, at a time without even one arc extinguishment. IMPACT designed and implemented a unique monitoring technique specific for continuous weld monitoring applications. The implementation was so successful that the customer began to automatically cut our sections of welded tube solely on analysis and feedback from the ARCAgent™ weld monitor.

 
Equipment:

ARCAgent™ 3000
Current & Voltage Sensors
PC Hosting ARClient® HMI and Continuous Part Tracking™ View

PLC Interface: Digital I/O
PC Interface: Ethernet
Fault Handling: Delayed output drives automated shop saw to cut out suspect portions.
 
 


ARClient® Software

arclient_small.pngARClient® software provides powerful PC based tools to make each arc weld monitoring system work efficiently and effectively for our customers.

ARCAgent™ 3000

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Our best arc welding data monitor system for advanced weld defect detection or advanced algorithm development and deployment.

ARCAgent™ 3000P

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Advanced, portable arc  welding data acquisition and arc welding data monitor system with proven benefits for engineering, techs, and maintenance personnel.

ARCharter™ Software

archarter_small.pngARCharter™ is our SQL database solution for advanced data analysis, reporting and charting. Off-the-shelf and custom reports available.

ARCAgent™ 2000

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Most widely deployed arc weld data monitoring system for robotic and automated welding applications. Offers 3 layers of weld monitoring defense.

ARCAgent™ Totalizer

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Automatically records, communicates and charts real-time arc weld production data and information that facilitates informed decision making.

ARCAgent™ 1000

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Entry level arc weld data monitoring system for robotic and automated welding applications. Offers 2 layers of weld monitoring defense.

IMPACT pcOi

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17" Touch Operator Interface. Combine the power of Windows® XP Embedded with durability of a panel view.

IMPACT pcOi Lite

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12" Windows® XP Embedded Touch Operator Interface. Perfect for complex applications that require operator interaction.

AA™ Weld Counter

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Designed specifically for manual weld process control and monitoring. 100's have been deployed to detect missing welds alone.