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VIRTUAL WELDING
/ The welder training of the future

VIRTUAL WELDUCATION BASIC APP

BASIC

Get it now for free and discover great

3D animations and videos in this folder!
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BECOME A WELDING EXPERT

WITH VIRTUAL TRAINING.
Many professions are already exploiting the advantages of virtual
training in order to prepare for the real world. That’s how pilots
train, practising countless take-offs and landings in a simulator
before they fly a real plane. The bigger, more expensive and more
dangerous the equipment used, the more often training is carried
out in the virtual world. So why not facilitate welder training with
virtual tools as well?

Virtual training is the ideal instrument to Fronius Virtual Welding is available with
realistically simulate complex processes and four function packages allowing three pro-
difficult situations in a risk-free and cost-ef- cess variants to be practised:
fective way and to practise them again and
again. This is why it is also ideally suited to / MANUAL METAL ARC WELDING 111
welder training. / MAG WELDING 135
/ MAG WELDING 135 MECHANISED
The safety risk for beginners, which is signif- / TIG WELDING 141
icantly higher for welding than other profes-
sions due to the hot arc, disappears entirely Mechanised MAG welding enables users to
when welding virtually. With Virtual Weld- take part in risk-free and cost-effective weld-
ing, trainees can learn and practise basic ing robot training without the need for sig-
welding skills step-by-step on typical work- nificant structural alterations. No extraction,
pieces. Furthermore, virtual training allows eye protection or fireproof floor is needed –
expensive consumables such as metal, wire just a standard seminar room with a func-
and shielding gas to be saved. tional robot.

Look for the icons

throughout this folder
and use your Virtual
Welducation Basic
App for getting more
interesting content.
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LET THE “GHOST” GUIDE

YOU TO THE
PERFECT WELD SEAM
The first step is always the training sequence where the
trainee welds under the guidance of the “Ghost”. Next the
real welding situation is simulated.
In the training sequence, the
virtual trainer or “Ghost” shows
trainees the optimum welding
speed, the distance to the work-
piece, the tilt angle for the weld-
ing torch or the electrode holder,
and the filler metal. Traffic-light
colour signals on the screen and MANUAL METAL ARC WELDING MAG WELDING
real-life welding noises give the In manual metal arc welding, the train- Welding beginners learn the skills in-
trainees real-time feedback, ing focuses first on igniting the elec- volved in MAG welding in separate
showing them where and how trode. The user then practises the other training steps. A real MIG/MAG welding
they are on-target or deviating motion sequences. Two types of elec- torch is provided for this.
from target. This allows them to trode can be used; a long one for prac-
make corrections in real time. tising ignition and a short one for weld- The focus is on the various set values
ing, whereby the electrode virtually for MAG welding – more precisely with
The variable “Ghost” lets train- melts off. the dip transfer and pulsed arc – and
ers store their own know-how the effects they have on the welding
and manual skills in a few steps The trainee can also practise with dif- results. In the first step, the arc is sim-
and provide them to their train- ferent electrode diameters. After weld- ulated and in the second trainees can
ees to use as a training guide- ing, the slag can even be removed vir- (must) set the parameters themselves.
line. This allows the trainer to tually.
pass on their welding style one-
to-one.
MECHANISED MAG WELDING TIG WELDING
In the simulation sequence, the Trainees practise programming the op- In addition to the special TIG welding
trainee practises in a real weld- timal welding torch position with a ro- torch guidance, a separate sensor helps
ing situation – with no help bot welding torch. The “Ghost” provides teach the user to apply the optimum
from the “Ghost”. The result is a feedback about the welding speed and amount of filler metal. The addition of
virtual weld seam, displayed in the distance and tilt angle to the work- the filler metal is individually adjusta-
a true-to-life three-dimensional piece. ble, depending on the task.
way. After the simulation, this
can be replayed and analysed The simulation enables the trainee to With further practice, the steady hand
with the help of the “Ghost”. experience a virtual representation of guiding the torch and the addition of
the programmed welding results. The the filler metal are consolidated. All im-
filling volumes and position of the weld perfections in the weld seam are shown
seam on the sample workpiece are realistically.
shown realistically.
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Three process variants, Efficient use of time

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four function packages and higher training

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Variable “Ghost” for

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BENEFITS
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welding novices / / know-how
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Positive group dynamic

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and comparability of

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Manual metal arc welding training sequence Manual metal arc welding simulation sequence
results

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MAG training sequence MAG simulation sequence

Mechanised MAG simulation sequence Mechanised MAG training sequence

TIG training sequence TIG simulation sequence

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VIRTUAL WELDING EXTREMELY

INTUITIVE
THE PERFECT OPERATION
TRAINING SYSTEM Ultra-simple menu navigation and
touchscreen option-selection com-
bine to make Virtual Welding very
easy to use.

SERVICE
Fronius offers high-quality and profes-
sional services for Virtual Welding.
From customer-specific planning and
advice, to tailored support and selected
service packages, we create the perfect
solutions for our customers and ensure
everything runs smoothly.

EASY TO UPDATE
Virtual Welding can easily be updat-
ed with the latest version of the soft-
ware and new processes using an
external DVD drive.

DATA SECURITY
Ranking lists, welding results, curricula
and courses, and the variable “Ghost” can
be transferred and saved to a USB flash
drive. The results can also be used for
certificates.

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ANALYSIS TOOL
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Every welding process is recorded

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and can be replayed at any time,

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meaning it can be closely analysed

FLEXIBLE against the optimal target.
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Thanks to the Mobile Case, the system

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can be used flexibly, for example in

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external training rooms.

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 7

REALISTIC PERSPECTIVE
The headband and sensor determine the position NO LANGUAGE
BARRIERS
of the welder’s head. Wearing a real welding
helmet with an enlarged viewing window and
integrated 3D glasses (optional), the trainee is Available in many languages, so lan-
virtually in the welding environment. guage barriers are non-existent during
training.

EXTENSIVE
TRAINING OPTIONS
/ Variety of workpieces for different welding requirements;
single-V butt weld (multi-pass), fillet welds (multi-pass),
square butt weld, pipe-pipe joints and pipe-plate joints
/ Different welding positions: PA (1G), PB (2F), PC (2G), PD
(4F), PE (4G), PF (3G, 3F) and PH (5G), PJ (5G)
/ Different weld seam types: single V-butt welds (single and
multi-pass), fillet welds (single and multi-pass), melt runs
and square butt welds (single-pass)

POSITIVE
MAKING LEARNING FUN WITH GROUP
QUIZZES DYNAMIC
One question, three possible answers – welding beginners
A pedagogically sophisticated
can have fun testing and expanding their welding knowledge,
points system means that compa-
alone or in a group. The questions can be individually con-
rable training results can be
figured and updated. The integrated glossary acts as a refer-
achieved again and again; this al-
ence aid for the welding novice.
lows the trainees to be assessed
objectively and transparently. By
spurring one another on and inter-
acting in this way, as well as being
INDIVIDUAL CURRICULA assessed professionally, trainees

AND COURSES learn swiftly and effectively.

The trainer can personally create curricula and courses, allow-

ing the training to be individually tailored to target groups REALISTIC
and specific skills. WELDING TORCHES
The right, ergonomically designed
welding torch (or electrode holder),
faithfully modelled on the original,
for every process.
 GERHARD ZUBER
Head of the Welding Technology department, Fohnsdorf Training Centre

“Fohnsdorf Training Centre uses ‘Virtual plement what you’ ve learned in prac-
Welding’ for MMA and MAG welding tice. The playback function provides a
qualifications. It is an exceptional tool constant analysis of errors from the sys-
that enables the user to improve their tem, allowing the user to continually im-
skills. The simulators are fully integrat- prove their skills. The training modules
ed into the training content. First, the are designed to create an interplay be-
individual welding positions are prac- tween virtual and real applications.”
tised on the simulator and then you im-

All information is without guarantee in spite of careful editing - liability excluded. Copyright © 2011 Fronius™. All rights reserved.
Text and images correspond to the current state of technology at the time of printing. Subject to modifications.
INPUT DATA VIRTUAL WELDING TERMINAL VIRTUAL WELDING MOBILE CASE
Dimensions W x H x L 62.8 x 190 x 60.8 cm 66.6 x 67.9 x 56.8 cm
Weight 92.17 kg 52.77 kg
Current consumption 1.2 A 1.2 A
Mains voltage 110 V - 230 V 50/60 Hz 110 V - 230 V 50/60 Hz

/ Perfect Welding / Solar Energy / Perfect Charging

THREE BUSINESS UNITS, ONE GOAL: TO SET THE STANDARD THROUGH TECHNOLOGICAL ADVANCEMENT.
What began in 1945 as a one-man operation now sets technological standards in the fields of welding technology, photovoltaics and battery charging. Today, the
company has around 3,800 employees worldwide and 1,242 patents for product development show the innovative spirit within the company. Sustainable
development means for us to implement environmentally relevant and social aspects equally with economic factors. Our goal has remained constant throughout:
to be the innovation leader.

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