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[benefit_headline] => Efficient and automated welding with EWM React
[benefit_subtext] => Quality, efficiency and process optimisation. The demands in the manufacturing industry are constantly increasing and require the use of innovative welding technologies. For this reason, alwitra GmbH, a leading provider of system solutions for flat roofs, relies on EWM React. Almost all of the products used for the more than 175 million square metres of sealed roof surfaces per year have to be welded. It is often not only the functionality of the weld seams that counts, but also their appearance. With EWM React, alwitra secures a decisive competitive advantage.
[teaser] => Quality, efficiency and process optimisation. The demands in the manufacturing industry are constantly increasing and require the use of innovative welding technologies. For this reason, alwitra GmbH, a leading provider of system solutions for flat roofs, relies on EWM React. Almost all of the products used for the more than 175 million square metres of sealed roof surfaces per year have to be welded. It is often not only the functionality of the weld seams that counts, but also their appearance. With EWM React, alwitra secures a decisive competitive advantage.
[casestudy_status] => In the past, alwitra used a standard pulse MIG process to manufacture components. The level of automation in the company was rather low at around 30%, as special products made up the majority of production. However, there is great potential for optimisation, particularly in the production of standard components, as increasing automation can further improve quality and reduce costs. alwitra is constantly adapting its product range to current market requirements and is therefore all the more dependent on the use of innovative welding technology.
[casestudy_solution] => Process stability plays an important role for alwitra when using welding robots. This is where EWM React comes into play as an automation solution, as the welding process is the ideal combination of short arc and digital welding process control. Combined with a highly dynamic torch drive, the result is a precise and reliable automation process that delivers perfect welds. EWM React gives the user full control over the droplet transfer and, with the process variants Speed, Positionweld and superPulse, offers tailor-made solutions for even the most demanding welding tasks.
[casestudy_effectiv] => The objective of the cooperation between alwitra and EWM was clearly defined: Automated welding was to take productivity to a new level. This is exactly what has been achieved with EWM React, as the high deposition rates of the spray arc range have been combined with all the advantages of the short arc. Hardly any spatter, minimal distortion, enormous process stability and a reduction in heat input of up to 35% - these advantages speak for themselves. With alwitra, the result is a time saving of more than one minute per workpiece - both during welding and in post-processing.
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[name] => Nordic Steel AS
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[customer] => Nordic Steel AS
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[benefit_headline] => EWM enhances environmental commitment at Nordic Steel
[benefit_subtext] => Nordic Steel AS is a leading company in the steel industry and a comprehensive provider of mechanical production solutions. The company has firmly positioned itself as a driving force not only in Norway, but also on a global level. The extensive reference list includes major players from a wide range of industries, such as renewable energy, oil and gas, aquaculture, maritime, HVAC, transport, infrastructure, construction, piping, defence, aerospace, and various other sectors. Nordic Steel has strong and long-lasting partnerships in all these sectors, making it a full-service provider.
[teaser] => Nordic Steel AS is a leading company in the steel industry and a comprehensive provider of mechanical production solutions. The company has firmly positioned itself as a driving force not only in Norway, but also on a global level. The extensive reference list includes major players from a wide range of industries, such as renewable energy, oil and gas, aquaculture, maritime, HVAC, transport, infrastructure, construction, piping, defence, aerospace, and various other sectors. Nordic Steel has strong and long-lasting partnerships in all these sectors, making it a full-service provider.
[casestudy_status] => Nordic Steel AS has been using welding machines from EWM for many years. However, before the strategic partnership between them began, the Norwegian company had problems with various other welding machines. These occurred particularly when welding aluminium, which led to rapid downtimes throughout the welding operation. After analysing the situation in detail, Nordic Steel AS decided to work with EWM in 2010. Since then, the efficiency and quality of the entire welding operation has increased significantly.
[casestudy_solution] => Every welding task is different for the Norwegian full-service provider from the steel industry and with the welding machines from EWM, Nordic Steel is ideally prepared for a wide range of conditions. There are now 26 welding machines at the Bryne site, which are very well suited for aluminium welding thanks to the built-in position welding function and effectively reduce downtimes. In addition, the experience of the company's welders confirms that the machines are user-friendly, produce perfect weld seams and have a robust design.
[casestudy_effectiv] => A central component of Nordic Steel's corporate philosophy is its outstanding commitment to the environment. High standards for top performance and sustainability apply throughout the entire welding operation and are maintained using EWM welding equipment. This is ensured, among other things, by the resource-saving inverter technology and the energy-efficient welding processes. Nordic Steel has been recognised as the most environmentally friendly steelworks in Norway, and its status as an industry pioneer with a strong environmental focus was recognised in 2021 with the "Miljøfyrtårn" (Environmental Lighthouse) award.
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[name] => Bilfinger SE
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[customer] => Bilfinger SE
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[benefit_headline] => Documentation down to seam level
[benefit_subtext] => Traceability and documentation are typical buzzwords, especially when it comes to certified components. Who welded which seam with which parameters and when? All this data is necessary to comply with the obligatory documentation requirements – an obligation that is often perceived as too time-consuming. ewm Xnet provides a remedy and supports welding coordinators and welders in their daily work – as well as doing so much more.
[teaser] => As a nuclear and magnet technology specialist, Bilfinger Noell is certified in accordance with DIN EN 10190 in the highest execution class EXC 4 – with special obligatory documentation.
[casestudy_status] => This documentation often involves huge sheets of paper with extensive tables that are shuffled back and forth between the welding coordination personnel's office and production at the welding site. Welders transfer the welding parameters and the coordinator countersigns them. But it’s so easy to make a writing error when transferring the welding parameters to the paper table. And is it really stored in such a way that it can be retrieved at any time? After all, the worst-case scenario for any welding coordination personnel is when something happens but the relevant documents are not available.
[casestudy_solution] => ewm Xnet brings together everything you need for the documentation. It starts with the relevant WPS. In addition to the parameters, the welding sequence can also be defined. When it comes to welding, the welder logs on via Xnet. This also fulfils the documentation requirements. The barcode assigned to each weld seam is used to set the correct parameters on the machine straight away. This ensures quality that can be proven. All data can be found at any time and can also be analysed afterwards – completely tamper-free.
[casestudy_effectiv] => The introduction of ewm Xnet changes everything in the daily work of a welding coordinator – but at the same time doesn’t really change anything at all. After all, ewm Xnet does not change the work itself. It simply makes work simpler, safer and more efficient. Secure and fast access to all data and the associated documents is a great help, especially during audits and in the event of a warranty claim. The additional recording of consumption data also gives users an idea of actual capacity and costs of the respective projects. The bottom line: weak points can be uncovered quickly and potential utilised.
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[name] => SBS Kft Hungary
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[customer] => SBS Kft
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[benefit_headline] => A brief look at contract manufacturer SBS Kft Hungary.
[benefit_subtext] => Higher welding quality with a significant reduction in the time required for both welding itself
and finishing work – this sums up contract manufacturer SBS Kft., based in Erdőtelek, Hungary
around 130 km east of Budapest. Thanks to a
greater arc penetration depth, the new forceArc
welding process results in significant time savings alongside an increase in welding quality.
Another benefit is that EWM welding machines
require far fewer spare and wear parts despite a
higher duty cycle. All these effects lead to an increase in productivity.
[teaser] => Higher welding quality with a significant reduction in the time required for both welding itself
and finishing work – this sums up contract manufacturer SBS Kft., based in Erdőtelek, Hungary
around 130 km east of Budapest. Thanks to a
greater arc penetration depth, the new forceArc
welding process results in significant time savings alongside an increase in welding quality.
Another benefit is that EWM welding machines
require far fewer spare and wear parts despite a
higher duty cycle. All these effects lead to an increase in productivity.
[casestudy_status] => Increasing quality requirements and greater cost
pressure are the challenges faced by most contract
manufacturing companies. In the case of welding,
this is synonymous with high welding quality produced in less time. Only through this combination
can a true productivity advantage be achieved.
The spectrum begins with selection of the welding
procedure and can also include design measures.
This was precisely the challenge faced by SBS Kft.
[casestudy_solution] => If a weld seam can be welded from just one side
instead of both, it saves a lot of time – both in
terms of handling and the welding process itself.
This substantial change to the workflow is possible thanks to the innovative forceArc welding
process from EWM. ForceArc is a heat-minimised
pulsed arc with both great penetration depth and
outstanding gap bridging. This makes it possible
to weld the carbon steels being used in a reliable
way with nearly no spatter, yet with the same outstanding welding quality and considerably less finishing work
[casestudy_effectiv] => SBS Kft. were so impressed by the quality and long
duty cycle of the Taurus welding machines from
EWM that they procured 20 welding machines in
a single order and equipped their welding shop
with them. In addition to improving quality, the
company are able to reduce costs thanks to both
a significant reduction in finishing work and a considerable decrease in the number of consumables
used – all the parts used last much longer than
they used to (wear parts in particular).
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[name] => Dražice
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[customer] => Dražice
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[benefit_headline] => Hot water storage tanks and water heaters (boilers)
[benefit_subtext] => Dražice started with the idea of manufacturing the most economical and least failure-prone water heater ever – in short: the best boiler. This became the company’s philosophy. Despite achieving its targets every year, the company continues to optimise its products. This continuous improvement of the quality of their water heaters (boilers), buffer tanks and heating elements has been recognised with various awards, such as the AOVT 2021 Award and the Czech Business Superbrands 2022.
[teaser] => Dražice is the Czech Republic’s leading manufacturer of hot water storage tanks and water heaters.
[casestudy_status] => The Dražice portfolio includes over 380 types or modifications of hot water storage tanks and water heaters as well as various types of buffer tank. The basic structure of the tanks is always similar: A sheet is shaped into a pipe and the seam is welded. A base and lid are then added and also radially welded. It is important to have high-quality seams which will withstand the pressure in the heat accumulators later on.
[casestudy_solution] => The base material for the heat accumulator is structural steel with a yield strength of 230 MPa; the diameters of the pipes range between 500 and 850 mm; the material thickness is between 2 and 3 mm. Each component requires individualised weld seams. With the wide range of welding machines and innovative welding processes, EWM machines always deliver optimal results. What’s more, the control of the welding machines can be easily integrated into Dražice’s plant controls, allowing automated or semi-automated production of the base bodies.
[casestudy_effectiv] => Depending on the application, the Titan XQ 400 puls DW or the Picomig 355 puls is used for automated welding, as they provide the right welding parameters for any material, even aluminium. In manual welding, the Phoenix 405 Progress puls stands out with its wide range of applications, from MIG/MAG to electrode all the way to TIG welding. The drive 4X wire feeder feeds the filler metal safely to the weld spot. This results in almost spatter-free seams, high weld seam quality and minimal post weld work, because for Dražice, reliable weld seams mean high productivity and thus strong performance.
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[name] => BRS Motorsport
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[benefit_headline] => Formula Student: students build racing car
[benefit_subtext] => Formula Student is an international engineering competition for students. To take part in the competition, each team designs, constructs and manufactures a small formula racing car and also participates in international competitions with it. This gives students a chance to build on their theoretical knowledge from their studies with practical experience in construction and production as well as learn about the economical aspects of the industry.
[teaser] => Every year, BRS Motorsport e. V. develops and manufactures a spectacular electric racing car ...
[casestudy_status] => BRS Motorsport e. V. is a coalition of students that take part in the international Formula Student competition every year. From design and construction all the way to production – the team completed yet another spectacular electric racing car this year. Students are supported by a wide range of industry partners from across all different sectors in their quest to produce innovative vehicles.
[casestudy_solution] => The chassis is a full carbon monocoque constructed using no steel or aluminium welded constructions. To protect the driver’s body and legs in the event the car rolls over or is involved in an accident, the car has a “large” roll bar (main hoop) and a “small” roll bar (front hoop). These are welded constructions made from steel pipes and aluminium square pipes. The aluminium in particular poses a challenge when it comes to the welding procedure and can only be welded safely using high-quality welding machines and suitable welding processes.
[casestudy_effectiv] => Following a training session by EWM application engineers, the students used both the Picomig 305 and Tetrix 230 AC/DC welding machines to weld the individual components on their own. This also included the battery container, a welded construction made from aluminium sheet. Various victories in the electric vehicle class are testament to the club’s high-quality and innovative work.
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[name] => Finsterle GmbH
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[benefit_headline] => Overcoming the challenges of automated welding with fine-grained steels
[benefit_subtext] => Welding without crack formation. Welders need to be able to weld without cracks forming when joining (weight-bearing) steel components made from fine-grained steels. Preheating the corresponding component reduces thermal stress. Finsterle GmbH’s task for EWM was to automate this step. Developers at our Sales and Technology Centre in Neu-Ulm quickly came up with the basic framework: the system is designed using two separate robot welding cells, each with a positioner, and an integrated preheating unit.
[teaser] => Welding without crack formation. Welders need to be able to weld without cracks forming when joining (weight-bearing) steel components made from fine-grained steels. Preheating the corresponding component reduces thermal stress. Finsterle GmbH’s task for EWM was to automate this step. Developers at our Sales and Technology Centre in Neu-Ulm quickly came up with the basic framework: the system is designed using two separate robot welding cells, each with a positioner, and an integrated preheating unit.
[casestudy_status] => As a toll manufacturer, flexibility is absolutely crucial for Finsterle GmbH. Ultimately, nobody can predict what orders customers will approach the metal construction company with – neither in terms of the application nor in terms of the components. A robot system with two welding cells, each with a positioner, is the perfect base concept. Clamped components are accessible from both sides and the robot can easily reach them. However, previous systems have been purely robot welding solutions without any consideration for a preheating unit.
[casestudy_solution] => The robot arm is equipped with a pneumatically operated tool changer and can be used to hold all kinds of tools. The oxyacetylene torch and the welding torch are located on different sides of the welding booth to avoid any hoses getting in the way during operation. First, the gripper takes hold of the oxyacetylene torch. This is ignited at an external ignition station. Once the base temperature of the component has been sufficiently increased, the oxyacetylene torch is placed in the parking position. The gripper then grabs the welding torch to start welding the steel components.
[casestudy_effectiv] => The automated system for Finsterle GmbH is the first solution of its kind. An automated welding process has previously never been designed for this material due to the required preheating for fine-grained steels. This development is particularly interesting for components with large batch sizes. But Finsterle’s automated solution isn’t just a win from a production standpoint. In times of skilled worker shortages, the new robotic welding system also means the company is now better equipped to face the future challenges of the labour market.
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[name] => Vogelsang GmbH & Co. KG
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[benefit_headline] => The user-friendly way to process all kinds of material thicknesses
[benefit_subtext] => The user-friendly way to process all kinds of material thicknesses
With ten new MIG/MAG XQ welding machines, the company was able to quickly establish welding sites in line with the state of the art.
The result: significantly reduced rework and even more efficient welding processes in the company.
[teaser] => The user-friendly way to process all kinds of material thicknesses
With ten new MIG/MAG XQ welding machines, the company was able to quickly establish welding sites in line with the state of the art.
The result: significantly reduced rework and even more efficient welding processes in the company.
[casestudy_status] => With its machines, the Essen-Oldenburg-based company focuses on the waste management, abattoir, fishing and agricultural sectors. Almost all of its products involve welding work on a wide range of materials, including unalloyed and low-alloy construction steels or chrome-nickel steels with various material thicknesses. This diverse spectrum of work is bolstered by Vogelsang’s high degree of vertical integration. With such a wide range of materials and material thicknesses, the company has high demands for ist welding machines.
[casestudy_solution] => In 2021, the company quickly settled on EWM’s new XQ series. Vogelsang was immediately blown away by what was possible with the new power sources, noting in particular how user-friendly the machines were. The saved JOBs for different materials and material thicknesses were a particular highlight for the company, offering potential to significantly simplify work sequences. These allow the welder to load optimised, pre-programmed machine settings for every task.
[casestudy_effectiv] => The new XQ machines and their processes allow the company to work with extremely low spatter. They also significantly reduce the amount of post-weld work required. In just a few weeks, the positive effects of the XQ welding machines on energy and material consumption will also be clear to see. The machine users were also impressed: they wanted to replace all welding machines with the MIG/MAG XQ series as soon as the first machines were commissioned.
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[benefit_headline] => MST/Hi-Spec Manufacturing manufactures the largest dredger buckets...
[benefit_subtext] => The dredger buckets of earthmoving and mining machines have one job: to pick up and move large quantities of heavy rock and stone. It almost goes without saying that the materials used on these machines need to be incredibly wear-resistant and repairs are just part and parcel of the work involved. That’s where the UK-based MST Parts Group comes in as one of the international market leaders in the manufacturing of the world’s largest dredger buckets and their related repairs.
[teaser] => The dredger buckets of earthmoving and mining machines have one job: to pick up and move large quantities of heavy rock and stone. It almost goes without saying that the materials used on these machines need to be incredibly wear-resistant and repairs are just part and parcel of the work involved. That’s where the UK-based MST Parts Group comes in as one of the international market leaders in the manufacturing of the world’s largest dredger buckets and their related repairs.
[casestudy_status] => One cubic metre of natural rock weighs around two tonnes – an MST bucket can carry up to five cubic metres without even breaking a sweat. Of course, this can be particularly demanding on the dredger and its power, as well as the bucket itself. The use of wear-resistant steels as a material choice and for the welding consumables is common...
[casestudy_solution] => From welding machines and a wide variety of welding consumables to bespoke welding torches – EWM’s extensive range makes it the perfect partner for MST Parts Group. To ensure successful repairs, material quality is fundamental when it comes to processing wear-resistant steels such as S355, Weldox and all Hardox materials...
[casestudy_effectiv] => It’s not just MST’s customers who are thrilled with the welding results. The EWM products’ reliability was quickly noticed by MST, too. Thanks to their robust design, EWM products mean no more repair invoices for welding machines...
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[name] => IGEFA WEINBRENNER Energy Solutions GmbH
[alias] => igefa-weinbrenner-energy-solutions-gmbh
[customer] => IGEFA WEINBRENNER Energy Solutions GmbH
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[benefit_headline] => Skilled worker shortages, full order books and high quality standards
[benefit_subtext] => Heat exchangers made by Hof-based company, IGEFA WEINBRENNER Energy Solutions GmbH in the Westerwald region of Germany, are used across many different sectors, from the food, brewing and beverage industry and energy/chemical sector, all the way to the pulp and paper industry. And, just like the production and industrial systems used in these sectors, the heat exchangers used also have to be tailored to the needs of the industry. When it comes to constructing and designing these systems, the use of special materials is just as important as continuous data collection for the purposes of quality assurance.
[teaser] => Heat exchangers made by Hof-based company, IGEFA WEINBRENNER Energy Solutions GmbH in the Westerwald region of Germany, are used across many different sectors, from the food, brewing and beverage industry and energy/chemical sector, all the way to the pulp and paper industry. And, just like the production and industrial systems used in these sectors, the heat exchangers used also have to be tailored to the needs of the industry. When it comes to constructing and designing these systems, the use of special materials is just as important as continuous data collection for the purposes of quality assurance.
[casestudy_status] => Many sectors and companies are currently faced with a challenging combination of skilled worker shortages, full order books and high quality standards to maintain, making efficient and safe processes that ensure optimum use of the given resources all the more important...
[casestudy_solution] => IGEFA WEINBRENNER Energy Solutions GmbH successfully implemented a line of EWM welding machines in the area of TIG welding. As part of the planned switchover within welding production, it also made sense to take a closer look at EWM machines for MAG welding, too...
[casestudy_effectiv] => Choosing the right welding procedure can significantly decrease the amount of post weld work needed and subsequently increase productivity. The increased weld seam quality in the root pass and the reduction in overall welding times both play a part here. That means a more efficient component production...
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[name] => Hüffermann Transportsysteme GmbH
[alias] => hueffermann-transportsysteme-gmbh
[customer] => Hüffermann Transportsysteme GmbH
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[benefit_headline] => 300 weld seams in 90 minutes
[benefit_subtext] => It was primarily a shortage of skilled workers that motivated Hüffermann Transportsysteme GmbH to break new ground in chassis production. The lorry trailer manufacturer based in Neustadt (Dosse) in the Brandenburg region of Germany now manufactures 16 skeletal and container trailers using the EWM-Euen system every week, almost doubling its production while reducing manpower.
[teaser] => It was primarily a shortage of skilled workers that motivated Hüffermann Transportsysteme GmbH to break new ground in chassis production. The lorry trailer manufacturer based in Neustadt (Dosse) in the Brandenburg region of Germany now manufactures 16 skeletal and container trailers using the EWM-Euen system every week, almost doubling its production while reducing manpower.
[casestudy_status] => The clamping for manual welding of the 7-metre-long components was rather basic. Precise alignment of the longitudinal beams and other components is, however, fundamental for high-quality lorry trailers. That’s why the clamping was planned in such a way as to ensure that the components remained aligned and in position. The integrated longitudinal axis of rotation also improves accessibility, allowing almost all seams to be welded in the flat position. However, a question was raised during the planning of the clamping device: “Why not automate the welding process too?”
[casestudy_solution] => The automation system had to be planned with consideration of circumstances such as the hall structure, clamping device and space conditions. The gantry system with a welding robot on the gantry consists of two separate working areas. The shared sliding door closes one section at a time and the robot can weld while the open side is being loaded. The welding machine, a Phoenix puls, is situated near the partition. The drive 4X wire feeder is situated directly above the drums with the welding consumable and conveys the wire via the cable drag chain (which also carries electricity and gas) to the robot. forceArc puls is the only welding process used. The arc is powerful and deeply penetrates the material. At the same time, the heat input is reduced by the pulsing.
[casestudy_effectiv] => The plant produces 16 skeletal trailers every week with four welders. The welders are mainly charged with loading and tack welding the individual components and assemblies. The actual welding is done by the robots. This has resulted not only in faster welding but also increased quality. Continuous monitoring of the welding parameters in automated welding ensures high-quality weld seams at all times. As the process also produces very little spatter, the post weld work is reduced by 30 per cent and productivity is increased.
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[name] => Schroeder Valves GmbH & Co. KG
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[benefit_headline] => Welding 50 different components fully automatically? That was the challenge for Schroeder Valves, the pump protection fittings manufacturer.
[benefit_subtext] => Welding 50 different components fully automatically? That was the challenge for Schroeder Valves, the pump protection fittings manufacturer. All of the components did have one thing in common, though: they were all rotationally symmetrical...
[teaser] => Welding 50 different components fully automatically? That was the challenge for Schroeder Valves, the pump protection fittings manufacturer. All of the leading specialist’s components did have one thing in common, though: they were all rotationally symmetrical. This was the starting point for welding machine manufacturer EWM in their mission to develop a custom automation solution tailored to this multifaceted challenge – for parts ranging from just a few hundred grams to up to two and a half tonnes.
[casestudy_status] => Schroeder Valves’ pump protection valves are used particularly for transporting critical media: in refineries, in the chemical industry, in processing and in (nuclear) powerplants. Components used in these areas have to be extremely reliable and last for years. Sealing surfaces of components made from cheap construction steel are therefore reinforced with high-quality stainless steel. Due to both the shortage of good welders and growing quality assurance requirements, however, automation of this step was crucial.
[casestudy_solution] => The solution to this challenge soon became clear to EWM automation experts: a robot system was needed. Having to deal with so many different component sizes was a cause for concern. Small parts require higher dynamics than large components. This quickly gave rise to the idea of three processing stations: one large L-positioner with tilting function for the large valve bodies, one small turning/tilting positioner on a system bench for the small valve bodies, and a third station with a system bench without positioners for any other components.
[casestudy_effectiv] => As the parts were rotationally symmetrical, it was easy to teach the components; teaching is always based on the same programs. Users simply have to set the radius, number of passes and the geometric dimensions of the soft armouring and the robot control will take care of the rest. Some components have an interior diameter of just 32 mm, making them extremely difficult to access. This required a special welding torch construction with a particularly small torch head and large torch neck. The fact that EWM produces its own welding torches in-house was a major plus here.
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[name] => Heinrich Döpke GmbH
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[customer] => Heinrich Döpke GmbH
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[benefit_headline] => Every single EWM welding machine saves nearly two tonnes of CO2 compared to the old welding machines...
[benefit_subtext] => Every single EWM welding machine saves nearly two tonnes of CO2 compared to the old welding machines – every year. But for Heinrich Döpke GmbH, replacing their old welding machines was especially attractive because of the government subsidy of 18,000 euros.
[teaser] => Every single EWM welding machine saves nearly two tonnes of CO2 compared to the old welding machines – every year. But for Heinrich Döpke GmbH, replacing their old welding machines was especially attractive because of the government subsidy of 18,000 euros. Under the new EU Ecodesign Directive, the German government subsidises every tonne of CO2 saved with up to 900 euros. According to this directive, all step switch controlled welding machines are to be taken off the market by 2023 because of their high power consumption and be replaced by more energy-efficient inverter welding machines.
[casestudy_status] => The components that are welded by hand every day at Heinrich Döpke GmbH are more than 20 metres long and several metres wide. Plate thicknesses between 5 and 80 mm require a lot of weld seams. Their step switch controlled welding machines were in use constantly. The company was very sceptical about inverter welding machines, as they’d had a lot of bad experiences with them. And because of that, EWM’s field representative received a rather restrained reception when visiting the new potential customer.
[casestudy_solution] => Nevertheless, the Döpke representatives were already impressed with the EWM welding machines’ inverter technology whilst the products were being demonstrated to them on their own components and in their own production hall. In addition to the machines’ technical performance, they were impressed with the warranty period of up to five years without any limit on operating hours. Then, when a large project was pending and several welding machines failed at the same time, they had to make a decision: repair or invest. Ultimately, the BAFA (Federal Office for Economic Affairs and Export Control) subsidy suggested by the EWM field representative, and its approval after only three weeks, were the crucial arguments for converting the entire production to EWM machines.
[casestudy_effectiv] => The German government rewards every tonne of CO2 saved with up to 900 euros. For savings of nearly two tonnes of CO2 per welding machine per year and a total of 13 new Titan XQ 350 puls and Phoenix welding machines, Heinrich Döpke GmbH was awarded a subsidy in the amount of 18,000 euros. Now, the company not only owns energy-saving inverter welding machines, but it can save lots of other costs as well; gas consumption, wear on gas nozzles and working time are also significantly reduced. So, the investment pays off in every regard: for the company and for the environment.
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[benefit_headline] => Chassis axles designed to carry huge axle loads represent a major challenge in the quality assurance process. This is why SAF-Holland relies on…
[benefit_subtext] => Chassis axles with axle loads of up to 26 tonnes represent a major challenge in the quality assurance process. This is why SAF-Holland relies on ewm Xnet for quality monitoring and control of the manually welded pendulum axes. This welding management system not only continuously monitors and documents every welding parameter, but also ensures the consistent quality of the weld seams.
[teaser] => Chassis axles with axle loads of up to 26 tonnes represent a major challenge in the quality assurance process. This is why SAF-Holland relies on ewm Xnet for quality monitoring and control of the manually welded pendulum axes. This welding management system not only continuously monitors and documents every welding parameter, but also ensures the consistent quality of the weld seams.
[casestudy_status] => SAF-Holland has fully adopted the zero-defect strategy. When it comes to welding processes, this strategy ensures that every weld seam is created using exactly the right welding parameters – every single time. This is easy to verify when using automated and robotic processes, as these parameters are subject to continuous automatic monitoring. It’s more difficult with manual welding. This is where the welding management system ewm Xnet comes in.
[casestudy_solution] => ewm Xnet works continuously to record and store every welding parameter during the manual welding process, allowing them to be accessed and checked whenever necessary. If the welding parameters are within certain predefined tolerances, then the welding result is of the required quality.
In order to achieve a clear allocation between the welding parameters and the component, every single component at SAF-Holland receives a unique dot-peened serial number as well as a QR code. This ensures that the component is clearly defined and allows all parameters to be assigned to it.
[casestudy_effectiv] => This makes the welder’s job a lot easier, and choosing incorrect welding parameters is impossible. Before welding, the welder scans the component’s serial number. They then hold the Xbutton in front of the welding machine. The Xbutton is an RFID chip in which the welding coordination personnel preset the relevant parameters and tolerances. Wrong choices of settings are avoided thanks to the welding parameters being allocated to components on the Xbutton. This is because the welder only has access to the preset parameters. An essential component of the zero-defect strategy.
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[name] => Geschwister Scholl school Leutkirch
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[benefit_headline] => Geschwister Scholl school uses EWM complete solution.
Vocational students are being trained with ewm Xnet
[benefit_subtext] => The Geschwister Scholl school, a competence centre for business, care, social services and technology in Leutkirch, is preparing its students for a future in Industry 4.0. To that end, Anton Netzer, technology instructor in the metal construction department, uses the Welding 4.0 solution by EWM AG in Mündersbach.
[teaser] => Industry 4.0 is when people, machines and industrial processes connect intelligently. This is how the German Federal Ministry for Economic Affairs and Energy defines the fourth industrial revolution that is currently taking place in companies. The Geschwister Scholl school, a competence centre for business, care, social services and technology in Leutkirch, is preparing its students for this aspect of the future. To that end, Anton Netzer, technology instructor in the metal construction department, uses the Welding 4.0 solution by EWM AG in Mündersbach.
[casestudy_status] => Industry 4.0 is currently a hot topic for all businesses within the world of metal construction. Many companies are already working with networked processes and using state-of-the-art welding machines and digital management solutions. The Geschwister Scholl school was faced with the challenge of preparing its students for this new reality and training them accordingly. “We want our students to learn the technologies that are offered in companies,” says Netzer. However, until 2020, the school only had access to step switch-controlled machines.
[casestudy_solution] => The school’s technical arsenal of nine welding booths was upgraded with Welding 4.0, the EWM complete system for welding. It includes state-of-the-art welding machines and the digital quality management system for welding, ewm Xnet. The future construction mechanics and construction technicians training here now work with the EWM inverter welding machine Tetrix 230 for TIG and the Titan XQ puls for MIG/MAG and MMA. In addition, the multi-process welding machine provides the trainees directly with all the innovative XQ welding processes by EWM.
[casestudy_effectiv] => The modern EWM complete solution has completely changed training at the vocational school. Students now learn on the same machines that they use at their training companies. What’s more, the system with ewm Xnet also detects parameter changes immediately and signals these to the user. Anton Netzer takes advantage of these features for his training: “We can weld and then immediately look at the data together, analyse it and complete it. Where are the mistakes? Where is room for improvement?” explains Netzer.
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[metadesc] => Die Geschwister-Scholl-Schule, Kompetenzzentrum für Gewerbe, Pflege, Soziales und Technik in Leutkirch, bereitet ihre Schülerinnen und Schüler auf eine Zukunft in Industrie 4.0 vor. Im Bereich Metallbau nutzt Anton Netzer, Technischer Lehrer, dafür die Welding-4.0-Lösung der EWM AG aus Mündersbach.
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[name] => Gebrüder Stahl GmbH 2020
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[benefit_headline] => Gebrüder Stahl is working with EWM.
TIG welding is faster than MAG welding
[benefit_subtext] => Gebrüder Stahl GmbH in the Sauerland has, for the most part, replaced its MAG welding with TIG welding. With tigSpeed, the wire feeder for TIG welding, the Wenden-based company has increased its welding speed and quality when welding heat exchangers and cooler bundles.
[teaser] => Gebrüder Stahl GmbH in the Sauerland has, for the most part, replaced its MAG welding with TIG welding. With tigSpeed, the wire feeder for TIG welding, the Wenden-based company has increased its welding speed and quality when welding heat exchangers and cooler bundles.
[casestudy_status] => With a diameter of up to 3 metres and a length of up to 30 metres, heat exchangers have an individual weight of up to 35 tonnes. High-alloy special materials are used here that require appropriate welding fillers when welding nickel-based alloys. The weld seams must be x-ray proof. However, these materials also have a tendency to form hot cracks.
[casestudy_solution] => The use of tigSpeed reduces the heat input during TIG welding. This prevents hot cracks and increases the weld seam quality. The low welding speed is also increased through the use of tigSpeed by EWM. As with MIG/MAG welding, for the wire feeder for TIG welding, the filler material comes from the spool. Here, an additional movement can be superimposed on the continuous wire feeding, which feeds and retracts the wire.
[casestudy_effectiv] => Higher, even seem quality at higher speed, saving materials, energy and work time – Operations Manager Carsten Schröter is very pleased: “The EWM machines are the perfect match for our company. The greatest benefits are the flexibility, the short set-up times and the position-independent welding result.”
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[metadesc] => Bei der Gebrüder Stahl GmbH im Sauerland hat das WIG-Schweißen das MAG-Schweißen in großen Teilen abgelöst. Mit tigSpeed, dem Drahtvorschubgerät fürs WIG-Schweißen, hat das Wendener Unternehmen beim Schweißen von Wärmetauschern und Kühlerbündeln die Schweißgeschwindigkeit und -qualität sogar gesteigert.
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[name] => Bell Equipment Deutschland 2020
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[benefit_headline] => Bell establishes own welding production line with EWM
[benefit_subtext] => When looking to establish its own welding production line at its German site near Eisenach, South African construction machinery manufacturer, Bell Equipment, sought the help of Ralf Rauh, site manager at EWM in Nossen, to plan and implement the new line. As part of ewm maXsolution, Bell Equipment opted for an EWM complete solution with modern inverter technology. After just a few months, its new production line had proven to be an economical and sustainable success.
[teaser] => When looking to establish its own welding production line at its German site near Eisenach, South African construction machinery manufacturer, Bell Equipment, sought the help of Ralf Rauh, site manager at EWM in Nossen, to plan and implement the new line. As part of ewm maXsolution, Bell Equipment opted for an EWM complete solution with modern inverter technology. After just a few months, its new production line had proven to be an economical and sustainable success.
[casestudy_status] => Bell Equipment Deutschland supplies 22 European countries and North America with articulated dump trucks and spare parts. Until 2018, the bins for these trucks produced in Germany came from South Africa. However, the environmental ideas rooted in the companies’ principles, as well as other reasons, led to the company establishing its own production line in Germany. This line was intended to take over the South African welding production processes with its step switch-controlled machines.
[casestudy_solution] => Bin production for Bell Equipment Deutschland has now been going strong since 2019. Taking the advice of Ralf Rauh, the company opted for the EWM complete solution with a total of 22 Taurus 505 Basic welding machines. The power source is similar to a step switch-controlled machine in its operation, yet, thanks to digital technology and the EWM quality, it saves a lot of energy.
[casestudy_effectiv] => Bell Equipment Deutschland can now respond to enquiries and orders more quickly and with more flexibility. It also means production is more economical and sustainable. Working with EWM, in no time Bell Equipment were able to save up to 30% on consumables and wear materials, depending on the use and workspace. In close coordination with South Africa, the company now aims to further streamline production in the coming years together with EWM.
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[metadesc] => Als der südafrikanische Baumaschinenhersteller Bell Equipment an seinem deutschen Standort nahe Eisenach eine eigene Schweißproduktion aufbaute, war Ralf Rauh, Leiter des EWM-Standorts in Nossen, in Planung und Umsetzung einbezogen. Er stellte dafür im Rahmen von ewm maXsolution eine EWM-Komplettlösung mit moderner Invertertechnologie zusammen. Nach nur wenigen Monaten hatte sich die eigene Fertigung wirtschaftlich und nachhaltig bereits bewährt.
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[name] => Chamber of Commerce Aurich 2020
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[customer] => HWK Aurich
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[benefit_headline] => HWK Aurich places trust in EWM. Aurich Chamber of Commerce 2020
[benefit_subtext] => Budding metalworkers, apprentices in metal construction and attendees of retraining courses offered by the Aurich Chamber of Commerce (HWK) are well-equipped for the future of all things welding: Working together with EWM Ibbenbüren site manager, Johann Martin, Matthias Siefken’s (head of welding technology at Aurich IHK) entire department switched to EWM machines.
[teaser] => Budding metalworkers, apprentices in metal construction and attendees of retraining courses offered by the Aurich Chamber of Commerce (HWK) are well-equipped for the future of all things welding: Matthias Siefken’s (head of welding technology at Aurich IHK) entire department was provided with modern welding machines such as the Titan XQ 400 AC puls or the compact and decompact Titan XQ puls.
[casestudy_status] => The Aurich Chamber of Commerce trains metalworkers, apprentices in metal construction and attendees of retraining courses. Matthias Siefken, head of the welding technology department, aimed to switch the welding machines used in training to one manufacturer. For the HWK, it was important to use this opportunity to invest in state-of-the-art welding solutions.
[casestudy_solution] => Together with sales partner Azetylenwerk Ernst Schulz GmbH, the EWM site in Ibbenbüren provided the HWK Aurich with 32 new EWM welding machines and the corresponding welding torches. As well as the Titan XQ 400 AC puls and the compact and decompact Titan XQ puls, apprentices will now get to work with welding machines such as Tetrix, Wega and Pico puls. In addition, all of the welding machines – including the step switch-controlled Wega – were connected to one another using gateways with the welding quality management software, ewm Xnet.
[casestudy_effectiv] => From now on, budding metalworkers, apprentices in metal construction and attendees of retraining courses held by Matthias Siefken will weld exclusively using EWM welding machines. In doing so, they will learn about various welding procedures and how to work with different materials and state-of-the-art welding processes. With ewm Xnet, the used parameters can be recorded and read in real time, allowing welders to identify welding errors easily and clearly. Another plus is that the welding machines already comply with the new Ecodesign Directive that will come into effect in January 2021.
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[name] => Ebner Industrieofenbau GmbH
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[benefit_headline] => Every function accessible on the welding torch – Ebner Industrieofenbau GmbH 2019
[benefit_subtext] => At Ebner, the specialist for heat treatment technology and industrial furnaces, based in the Austrian city of Leonding near Linz, welders are able to weld large sections with components sometimes reaching the dimensions of a standard detached house. The PM welding torch RD3 X from EWM doesn’t just save welders all the toing and froing.
[teaser] => At Ebner, the specialist for heat treatment technology and industrial furnaces, based in the Austrian city of Leonding near Linz, welders are able to weld large sections with components sometimes reaching the dimensions of a standard detached house. With the PM welding torch RD3 X from EWM, all parameter settings can be made directly via the integrated display. This means it is no longer necessary to walk to and from the welding machine, making welding much more productive.
[casestudy_status] => For the components welded at Ebner, the weld seams are often situated up to five meters above the ground. The welders are always provided with ample safety equipment, but once they’re up there, they want to weld, not climb.
[casestudy_solution] => With the PM welding torch RD3 X by EWM, the welder can make changes to the machine control from their welding position The action radius between the welding machine and the welding torch can reach up to 50 metres. What’s more, the welding torches also come with improved ergonomics and are lightweight with a balanced design and integrated signal light to light up dark working areas.
[casestudy_effectiv] => “Being able to change parameters on the torch itself, without restriction” is one of the main advantages of a PM welding torch, according to Christian Gruber, Ebner’s welding supervisor. The welding torch also features long-lasting consumables with the contact tip, significantly reducing consumption and replacement times, as well as saving on their related costs.
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[metadesc] => Bei der Firma Ebner, Spezialist für Wärmebehandlungstechnologien und Industrieofenbau aus dem österreichischen Leonding bei Linz, legen die Schweißer große Strecken zurück, denn die Bauteile können schon mal die Dimensionen eines Einfamilienhauses erreichen. Mit dem PM-Brenner RD3 X von EWM sparen Schweißer nicht nur lange Wege.
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[name] => Schoeller Werk GmbH & Co. KG
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[customer] => Schoeller Werk GmbH & Co. KG
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[benefit_headline] => Top quality in continuous use at Schoeller Werk GmbH & Co. KG
[benefit_subtext] => The family-run Schoeller Werk GmbH & Co. KG is one of the world’s leading manufacturers of longitudinally welded stainless-steel tubes. Schoeller’s customers have the most demanding requirements for their products. To meet these requirements, Schoeller has been relying on EWM AG welding machines for around 25 years – and successfully so.
[teaser] => The family-run Schoeller Werk GmbH & Co. KG is one of the world’s leading manufacturers of longitudinally welded stainless-steel tubes. Schoeller’s customers have the most demanding requirements for their products. To meet these requirements, Schoeller has been relying on EWM AG welding machines for around 25 years – and successfully so.
[casestudy_status] => Schoeller has had special demands of EWM welding machines for many years. The welding machines run around the clock in three-shift operation, sometimes even four-shift operation. In addition, the walls of the tubes are becoming thicker, which in turn increases the current load of each individual machine. Driven by innovation, the Hellenthal-based company in the Eifel hills is always working on the development of its product portfolio in line with the demands of its customers and the market. And Schoeller customers from car manufacturing and industry hold its products to the highest standards.
[casestudy_solution] => Schoeller has been relying on EWM’s inverter technology since 1995. The high-quality manufacturing of their products is made possible by modern machinery. If there is a change in what is required of the machines, EWM reacts immediately. “EWM also invests a great deal in its own research and development, which allows us to drive innovation together,” Stefan Fink explains. Schoeller has a testing facility where it tries out new EWM technologies. As a result, Schoeller now uses TIG plasma technology, whereas before it only used TIG welding.
[casestudy_effectiv] => EWM has worked with Schoeller to customise the welding machines according to their own specific requirements. The company’s decision to start manufacturing fuel rails in 2008 was eventually put into practice in collaboration with EWM, and now Schoeller is Europe’s leading producer of these tubes.
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[metadesc] => Das Familienunternehmen Schoeller Werk GmbH & Co. KG ist einer der weltweit führenden Hersteller von längsnahtgeschweißten Edelstahlrohren. Die Kunden von Schoeller stellen höchste Anforderungen an die Produkte. Um diesen Ansprüchen gerecht zu werden, setzt Schoeller seit rund 25 Jahren auf Schweißgeräte der EWM AG
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[name] => ISW GmbH Steel Components
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[benefit_headline] => Productivité accrue et qualité assurée
[benefit_subtext] => Temps de cycle prolongés, productivité accrue, retouches minimales, qualité assurée – ISW GmbH Steel Components a adopté EWM pour l’ensemble de sa production par soudage. Avec des composants de 300 millimètres d’épaisseur, 20 mètres de long et d’un poids allant jusqu’à 100 tonnes, ISW impose des exigences élevées à l’ensemble de l’équipement de soudage.
[teaser] => Temps de cycle prolongés, productivité accrue, retouches minimales, qualité assurée – ISW GmbH Steel Components a adopté EWM pour l’ensemble de sa production par soudage. Avec des composants de 300 millimètres d’épaisseur, 20 mètres de long et d’un poids allant jusqu’à 100 tonnes, ISW impose des exigences élevées à l’ensemble de l’équipement de soudage. Depuis les générateurs de soudage jusqu’aux torches de soudage et aux tubes contact en passant par les procédés de soudage et l’assurance qualité avec ewm Xnet 2.0, ISW Steel Components mise sur la technique EWM pour économiser du temps et des matériaux.
[casestudy_status] => L’entreprise ISW GmbH Steel Components, établie dans la ville d’Ennsdorf en Basse-Autriche, s’est spécialisée dans la fabrication de châssis de grandes dimensions lourds et complexes pour les machines et installations. Elle soude des pièces en acier noir avec des épaisseurs de 300 millimètres et plus, des longueurs allant jusqu’à 20 mètres et un poids total pouvant aller jusqu’à 100 tonnes. Ces opérations sont réalisées principalement par le mode opératoire de soudage MAG et par un soudage à plusieurs passes. Dans une phase d’essai, les soudeurs d’ISW ont testé les générateurs de trois fabricants renommés.
[casestudy_solution] => À l’issue de cette phase d’essai, les soudeurs d’ISW ont choisi les générateurs EWM. Les tubes contact M9 d’EWM offrent une surface de contact supérieure de 15 pour cent par rapport aux tubes contact M8 et une section de filetage supérieure de 30 pour cent. La mise en contact du fil à souder est meilleure et la chaleur est efficacement dissipée. La torche fonctionnelle RD3X avec affichage graphique et commande intégrée permet de régler tous les paramètres directement sur la torche de soudage. L’éclairage LED illumine les zones de travail sombres. Le procédé de soudage EWM innovant forceArc puls se distingue par une bonne pénétration avec un apport de chaleur réduit. ewm Xnet 2.0, le logiciel de gestion de la qualité pour le soudage, enregistre les données de soudage en temps réel et peut analyser et gérer l’ensemble des procédés de soudage dans le cadre d’une mise en réseau.
[casestudy_effectiv] => Le résultat : des temps de cycle prolongés et des temps d’interruption réduits grâce à la durée de vie accrue des tubes contact. Ils peuvent rester dans la torche de soudage pour un temps de soudage allant jusqu’à huit heures, ce qui correspond à la durée moyenne du soudage complet d’un composant dans l’installation automatique. Auparavant, le tube contact résistait au maximum une heure. La commande intégrée de la torche de soudage professionnelle RD3X avec affichage graphique réduit les déplacements, car elle permet de régler tous les paramètres importants directement sur la torche de soudage. Le procédé de soudage innovant EWM forceArc puls est le seul procédé de soudage utilisé dans la fabrication d’ISW. L’apport de chaleur réduit de ce procédé entraîne une moindre déformation et une réduction des tensions dans le composant, ce qui signifie un travail de redressage moins laborieux. Grâce à ewm Xnet 2.0, la qualité peut être démontrée entièrement et sans lacune.
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[metadesc] => Höhere Durchlaufzeiten, gesteigerte Produktivität, minimale Nacharbeit, gesicherte Qualität – ISW GmbH Steel Components hat die gesamte Schweißproduktion auf EWM umgestellt. Bei Bauteilen mit 300 Millimetern Dicke, 20 Metern Länge und bis zu 100 Tonnen Ge
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[name] => Ebner Industrieofenbau GmbH 2019
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[benefit_headline] => Jeu, set et match dans toutes les catégories de la technique de soudage
[benefit_subtext] => L’entreprise Ebner souhaitait renouveler totalement sa technique de soudage À cette fin, le constructeur de fours industriels a organisé une compétition entre quatre fabricants de générateurs de soudage. La décision finale a été prise par les soudeurs, le personnel d’entretien et les coordonnateurs en soudage.
[teaser] => L’entreprise Ebner, un spécialiste des technologies de traitement thermique et de la construction de fours industriels établi dans la ville autrichienne de Leonding, près de Linz, a souhaité renouveler l’ensemble de sa technique de soudage. Pour faire son choix, l’entreprise a organisé une compétition entre quatre fabricants de générateurs de soudage. Les soudeurs, le personnel d’entretien ainsi que les coordonnateurs en soudage ont unanimement accordé leur voix à EWM. L’offre des spécialistes en technique de soudage du Westerwald a convaincu l’entreprise sur toute la ligne – en matière de générateurs comme de technique de procédé. La fabrication par soudage d’Ebner emploie aujourd’hui 45 générateurs de soudage EWM – pour le soudage TIG et MIG/MAG.
[casestudy_status] => Chez Ebner, les soudeurs doivent faire preuve d’une grande flexibilité : le spectre des matériaux employés est très large, tout comme la gamme des composants traités par l’entreprise. Les fours industriels peuvent rapidement atteindre la taille d’une maison unifamiliale – ce qui les rend immobiles. Il n’existe donc pas de zones de travail standardisées dans lesquelles les soudeurs travailleraient toujours avec des fixations standard. Bien au contraire, les soudeurs doivent se confronter à chaque fois à de nouveaux défis, travailler avec leur générateur directement sur la pièce et changer fréquemment d’emplacement et de position. Cette flexibilité, ces conditions spéciales de l’environnement de travail ainsi qu’une bonne maniabilité des générateurs de soudage : telles étaient les exigences imposées aux fournisseurs.
[casestudy_solution] => Pour remporter la victoire, EWM AG s’est distingué de la concurrence sur trois aspects essentiels : l’approche systématique et l’offre complète en matière de générateurs de soudage, la flexibilité dans les procédés de soudage et la qualité du service. Les soudeurs doivent fréquemment basculer entre différents procédés de soudage. Un générateur capable de couvrir la gamme complète des tâches – en MIG/MAG comme en TIG – est donc avantageux. Grâce à deux dévidoirs, la machine est équipée de deux rouleaux de fil, de deux torches de soudage et de deux bouteilles de gaz. Si la tâche change, le soudeur change simplement de torche de soudage. La machine fait le reste sur simple pression d’un bouton.
[casestudy_effectiv] => Les soudeurs ont fait le choix d’une manipulation simple du générateur et de la torche de soudage, d’une bonne accessibilité, d’une sécurité des procédés des générateurs et d’un dévidage sans accroc. Les agents commerciaux ont pu réaliser des économies substantielles grâce à une réduction des frais d’équipement, avec des durées de vie des tubes contact et des buses de gaz jusqu’à 50 pour cent plus longues. EWM a ainsi remporté la victoire sur tous les niveaux. Aujourd’hui, EWM est le fournisseur unique des générateurs de soudage d’Ebner – même pour la dernière génération.
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[metadesc] => Die Firma Ebner wollte ihre gesamte Schweißtechnik erneuern. Dafür veranstaltete der Industrieofenbauer einer Challenge unter vier Schweißgeräteherstellern. Schließlich entschieden sich sowohl Schweißer als auch Instandhalter und Schweißaufsichtspersonen
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[name] => Terranets bw GmbH
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[benefit_headline] => Démagnétisation des conduites
[benefit_subtext] => terranets bw GmbH examine régulièrement les 2000 km de son réseau de conduites de gaz naturel à l’aide de « racleurs de conduites » qui magnétisent les conduites. Ceci rend difficile les réparations nécessitant un soudage. L’entreprise fait appel au démagnétiseur mobile Degauss 600 d’EWM.
[teaser] => terranets bw GmbH examine régulièrement les 2000 km de son réseau de conduites de gaz naturel à l’aide de « racleurs de conduites » qui magnétisent les conduites. Ceci rend difficile les réparations nécessitant un soudage. Pour parer à ce problème, l’entreprise fait appel au démagnétiseur mobile Degauss 600 d’EWM, qui peut être utilisé directement sur le chantier.
[casestudy_status] => La société terranets bw GmbH relie la région de Stuttgart et le Bade-Wurtemberg aux pays voisins et à l’infrastructure énergétique européenne. Les conduites et installations de transport de gaz sont commandées et surveillées via un réseau de fibres de verre de haute qualité afin d’assurer en permanence un approvisionnement efficace. Les conduites de gaz sous haute pression doivent répondre à des normes de sécurité très strictes, et l’entreprise exploitante, terranets bw GmbH, contrôle donc régulièrement l’épaisseur des parois à l’aide de « racleurs de conduites ». Toutefois, ces systèmes de contrôle génèrent eux-mêmes un problème : ils magnétisent les conduites. Si des réparations sont nécessaires, on observe une déviation de l’arc lors du soudage, entraînant ainsi une inclusion des pores et des défauts de fusion.
[casestudy_solution] => Pour résoudre ce problème, EWM AG a conçu le démagnétiseur Degauss 600. Cet appareil compact et pratique est facile à utiliser et peut être employé sur les chantiers. Pour démagnétiser le tube, un câble de courant est enroulé aussi serré que possible autour du tube. Le flux de courant dans le câble peut générer un champ magnétique opposé de même intensité et ainsi éliminer le magnétisme résiduel. Plus le nombre de spires est élevé, plus l’intensité maximale du champ qui peut être générée avec un courant constant est élevée. Le Degauss 600 offre deux possibilités de démagnétisation. Avec la fonction Degauss, le flux de courant est réduit pas à pas à partir d’une valeur de courant élevée et d’une polarité alternée. Ceci démagnétise le composant. Cette méthode fonctionne très bien avec des composants courts. La méthode activgauss convient quant à elle pour les composants longs comme les conduites. Avec cette méthode, le courant circule continuellement à travers les bobines, créant un champ magnétique permanent.
[casestudy_effectiv] => Avec son poids réduit et ses dimensions compactes, le Degauss 600 peut être utilisé sur les chantiers et est facile à manipuler. La source de courant peut également être placée à l’extérieur de la fosse d’excavation grâce à la commande à distance. Le Degauss 600 permet de résoudre le problème du magnétisme pendant le soudage de réparation dans le tuyautage même avec des champs magnétiques forts. L’utilisation du démagnétiseur sur les chantiers de terranets bw GmbH a convaincu l’entreprise exploitante elle-même mais aussi l’entreprise de construction exécutante Leonhard & Weiss GmbH ainsi que l’ingénieur superviseur indépendant de l’organisme de contrôle TÜV Süd.
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[metadesc] => Die terranets bw GmbH untersucht ihr 2000 km langes Leitungsnetz für Erdgas regelmäßig mit „Rohrleitungsmolchen“, die die Rohre magnetisieren. Reparaturen, bei denen geschweißt werden muss, fallen so schwer. Abhilfe schafft das mobile Entmagnetisierungsgerät Degauss 600 von EWM
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[benefit_headline] => Gestion de la technique de soudage avec un système unique
[benefit_subtext] => Une technique de soudage moderne doit naturellement accroître la productivité et la qualité tout en réduisant les coûts. Mais aujourd’hui, les systèmes de gestion du soudage prennent une importance croissante ...
[teaser] => Une technique de soudage moderne doit naturellement accroître la productivité et la qualité tout en réduisant les coûts. Mais un autre aspect prend aujourd’hui la priorité : des systèmes de gestion du soudage qui administrent et documentent les données pertinentes et répondent à toutes les exigences de l’assurance qualité. C’est cette approche systématique et l’offre complète d’EWM qui ont convaincu l’entreprise POLLRICH. En 2018, ce fabricant de ventilateurs industriels a converti toute sa production à EWM. Depuis, il achète également à EWM l’ensemble de ses pièces d’usure et métaux d’apport.
[casestudy_status] => POLLRICH fabrique des ventilateurs industriels. Ils sont utilisés pour l’aération des tunnels, des centres commerciaux ou même de terminaux aéroportuaires entiers. Dans la (pétro)chimie et dans les industries du bois et du béton, ils transportent également des fluides abrasifs et agressifs. Pour ces composants de sécurité, toutes les exigences en matière de documentation doivent être respectées afin de garantir une assurance qualité et une traçabilité adéquates.
[casestudy_solution] => EWM Xnet est le système de gestion du soudage d’EWM. Il prend en charge, surveille et documente l’ensemble du processus de fabrication du composant, de la préparation du travail au calcul rétrospectif. Toutes les données de soudage et valeurs de consommation sont enregistrées en temps réel et les résultats de soudage peuvent être analysés, contrôlés et gérés. Xnet prend également en charge la gestion des composants, la création des séquences de soudage et l’affectation des descriptifs de modes opératoires de soudage. Ceux-ci peuvent également être gérés et même créés si nécessaire. Dernier point, mais non des moindres, le contrôle individuel des certificats de vérifications des soudeurs et l’attribution d’autorisations d’accès individuelles font partie du portefeuille d’Xnet.
[casestudy_effectiv] => « Xnet permet de gérer l’ensemble de la technique de soudage au sein d’un système unique, » se réjouit Thorsten Wirtz, coordinateur du soudage et Directeur de l’assurance qualité chez POLLRICH. Étant donné que les générateurs de soudage, les systèmes de dévidage et les torches de soudage proviennent tous d’EWM, l’échange de données au sein du système et entre ses composants est optimal et le travail avec Xnet est simple, rapide et sûr.
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[metadesc] => Eine moderne Schweißtechnik soll selbstverständlich eine höhere Produktivität und Qualität bei gleichzeitiger Kostenreduktion liefern. Doch viel relevanter werden heutzutage Schweißmanagementsysteme
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[benefit_headline] => Jusqu’à 10 % de remorques en plus par poste de travail et par an
[benefit_subtext] => Au départ, l’intention était de réduire à zéro les heures supplémentaires. Le résultat a été l’adoption de produits EWM pour toute la production ...
[teaser] => Au départ, l’intention était de réduire à zéro les heures supplémentaires. Le résultat a été l’adoption de produits EWM pour toute la production : Grâce à la consultation en innovation et en technologie ewm maXsolution, la société Hüffermann Transportsysteme GmbH, basée à Neustadt (Dosse) est parvenue, sur un poste de travail unique, à réduire le temps de travail de 15 pour cent tout en augmentant le rendement de 10 pour cent. L’investissement a été amorti en six mois – une raison suffisante pour travailler exclusivement avec EWM à l’avenir.
[casestudy_status] => « Au départ, nous voulions simplement réduire les heures supplémentaires récurrentes. Car sans heures supplémentaires, il nous était impossible de tenir nos délais de livraison, » explique Torsten Völker, Directeur de la production « Unités embouties » chez Hüffermann. La mission initiale de Toralf Pekrul, Directeur des sites EWM de Wittstock et Rathenow, et de Jeffrey Kube, agent commercial extérieur d’EWM, était d’optimiser la production sur un poste de travail de manière à mettre fin aux heures supplémentaires.
[casestudy_solution] => Dans le cadre de la consultation complète ewm maXsolution, les experts EWM ont examiné la chaîne complète des processus et ont étudié chaque détail au sein du processus de production, de l’approvisionnement en gaz jusqu’au tube contact, en passant par le dévidage et le procédé de soudage. Les experts d’EWM ont optimisé la moindre vis de réglage et harmonisé toutes les étapes de la chaîne de production sur un poste de travail.
[casestudy_effectiv] => ... fut un gain de temps extraordinaire et un investissement amorti en un an : En mettant en œuvre les nombreuses mesures individuelles proposées par EWM, l’entreprise a été en mesure de trouver une solution qui répond autant aux besoins des ouvriers, qu’aux exigences croissantes du marché. Temps de travail réduit de 15 pour cent, avec un rendement accru de 10 pour cent et une consommation de gaz réduite d’un tiers, à qualité égale et le tout démontré par les propres chiffres de l’entreprise – ces arguments ont convaincu le leader du marché des véhicules de transport et de recyclage d’adopter les produits EWM pour les 68 postes de travail de sa production par soudage. Avec le gain de temps découlant du concept global, le rendement a pu non seulement être maintenu, mais même augmenté. Pour M. Völker, c’est le point crucial, car « on peut tout acheter, sauf le temps ! »
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[metadesc] => Am Anfang stand der Wunsch, die Überstunden auf Null zu reduzieren. Das Ergebnis war die Umstellung der gesamten Produktion auf EWM-Produkte
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[benefit_headline] => À peine un quart du temps de soudage
[benefit_subtext] => Malgré les normes industrielles strictes en vigueur dans la chimie industrielle, la société du Siegerland AST Apparatebau GmbH a diminué ses temps de soudage jusqu’à 75 pour cent grâce à l’emploi de tigSpeed...
[teaser] => Malgré les normes industrielles strictes en vigueur dans la chimie industrielle, la société du Siegerland AST Apparatebau GmbH a diminué ses temps de soudage jusqu’à 75 pour cent grâce à l’emploi de tigSpeed. tigSpeed est un système de dévidage pour le soudage TIG. Le fil n’est pas seulement avancé en continu comme dans le soudage MIG/MAG, mais retiré puis replongé automatiquement dans le bain de fusion à intervalles réguliers. Le dévidage imite ainsi le procédé de soudage TIG manuel.
[casestudy_status] => Les serpentins de refroidissement utilisés pour les mélangeurs sont en général constitués de demi-tubes soudés sur la coque des réservoirs. Sur les réservoirs de mélange de grandes dimensions, les longueurs de soudure cumulées peuvent rapidement atteindre plusieurs centaines de mètres. Pour respecter les normes du secteur, les passes de racine doivent être soudées par procédé TIG. La passe de finition est ensuite réalisée par procédé MAG. Avec environ 25 minutes par mètre, les temps de fabrication des cordons TIG sont sensiblement supérieurs aux vitesses de soudage du soudage MAG.
[casestudy_solution] => Le système de dévidage tigSpeed pour le soudage TIG permet une soudure TIG en continu avec une alimentation sans fin en métal d’apport, sans points de raccord dus au changement de métal d’apport. Et : L’utilisation de fil chaud permet de fondre une plus grande quantité de métal et d’atteindre ainsi de plus grandes vitesses de soudage.
[casestudy_effectiv] => Il ne faut aujourd’hui que cinq minutes aux soudeurs d’AST Apparatebau pour réaliser un cordon de soudure TIG continu d’un mètre avec tigSpeed et fil chaud. Soit un gain de temps de 75 pour cent par rapport au procédé de soudage manuel. Pour Joachim Jung, Directeur de l’entreprise, ce procédé présente encore un autre avantage : « Le soudage TIG avec tigSpeed est particulièrement intéressant car il permet d’automatiser davantage la tâche de soudage. » Mais même si l’entreprise ne s’est pas encore engagée sur cette voie, le gain de productivité important du nouveau procédé s’est révélé si convaincant que les manchons eux aussi sont désormais soudés avec tigSpeed et fil chaud – et les réservoirs mélangeurs comptent de nombreux manchons.
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[metadesc] => Trotz der Vorgabe strenger Industrienormen für die Großchemie konnte die AST Apparatebau GmbH aus dem Siegerland die Schweißzeit durch den Einsatz von tigSpeed um bis zu 75 Prozent senken
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[benefit_headline] => Réduction des temps morts jusqu’à 50 pour cent
[benefit_subtext] => À l’origine, c’est l’agent commercial d’EWM qui avait eu l’idée de souder les assemblages tube-bride par procédé TIG. Pour finir, les économies ont atteint 50 pour cent ...
[teaser] => À l’origine, c’est l’agent commercial d’EWM qui avait eu l’idée de souder les assemblages tube-bride par procédé TIG. Pour finir, la simple réduction des temps morts a engendré des économies allant jusqu’à 50 pour cent. Chez Hering AG (Gunzenhausen), le soudage TIG n’avait jamais joué qu’un rôle secondaire. À titre de prêt, EWM a mis à disposition de cette entreprise productrice d’échangeurs thermiques un dévidoir tigSpeed pour le soudage TIG. Après une demi-heure seulement, les soudeurs obtenaient avec cet appareil de meilleurs résultats qu’avec son prédécesseur. Et comme il devait être repris après une période d’essai d’une semaine, les soudeurs se sont disputé le droit de travailler avec tigSpeed.
[casestudy_status] => Chez Hering, d’innombrables tubes sont employés : de nombreux tubes sont rassemblés en faisceaux puis insérés dans un autre tube. Pour la production de ces échangeurs thermiques, Hering AG privilégiait le mode opératoire de soudage à l’électrode enrobée et le soudage MIG/MAG. TIG ne jouait qu’un rôle secondaire. Pourtant, le soudage TIG est prédestiné aux assemblages tube-bride. Ce procédé génère des cordons de haute qualité avec un apport de chaleur réduit et des projections minimales. Il réduirait donc sensiblement les retouches. Toutefois, les employés sont habitués au travail à une main lors du soudage à l’électrode enrobée et au dévidage continu lors du soudage MIG/MAG.
[casestudy_solution] => L’agent commercial a donc proposé de réaliser les assemblages tube-bride avec TIG et tigSpeed, car ces assemblages nécessitaient une qualité de soudage particulièrement élevée. Pour répondre au scepticisme initial, il a fourni en prêt l’appareil correspondant. tigSpeed est un dévidoir TIG. Il imite le soudage TIG manuel en superposant au dévidage continu un mouvement supplémentaire vers l’avant et vers l’arrière. Ainsi, le métal d’apport est régulièrement retiré du bain de fusion et déposé par gouttes. Lors du soudage à fil chaud, le métal d’apport est déjà préchauffé. Ceci accroît encore la vitesse de dépôt ; le métal d’apport coule bien mieux et le résultat est un cordon d’aspect très homogène.
[casestudy_effectiv] => Les avantages sont évidents : Le dévidage automatique du fil permet au soudeur de se concentrer entièrement sur le procédé de soudage. Valmir Xhaferi, soudeur chez Hering AG, résume le procédé : « Une bride peut être soudée au tube en une seule étape de travail – sans point de raccord dû au changement de métal d’apport ». De plus, grâce au dévidage automatique, la deuxième main reste libre et peut soutenir la main directrice. « C’est un soulagement, particulièrement pour les longs cordons », explique Valmir Xhaferi. Et Christian Rasch, PDG de Hering AG, est convaincu qu’avec une réduction des temps d’équipement, les économies pour l’entreprise se révéleraient encore plus élevées.
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[metadesc] => Ursprünglich war es nur eine Idee des Außendienstmitarbeiters von EWM, Rohr-Flansch-Verbindungen mit WIG zu schweißen. Am Ende standen Einsparungen von bis zu 50 Prozent
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[benefit_headline] => Une qualité de soudage supérieure et des coûts réduits avec ewm maXsolution
[benefit_subtext] => Lorsque leurs calculs de coûts pour la fabrication d’une grande commande ont commencé à dérailler, l’entreprise MESA a consulté le Directeur de la succursale EWM de Rathenow. En trois mois à peine ...
[teaser] => Lorsque leurs calculs de coûts pour la fabrication d’une grande commande ont commencé à dérailler, l’entreprise MESA a consulté le Directeur de la succursale EWM de Rathenow. En seulement trois mois, l’entreprise transformait l’ensemble de sa production après une analyse d’ewm maXsolution, le service de consultation en innovation et technologie d’EWM. Avec le nouvel équipement de soudage d’EWM, l’entreprise est aujourd’hui en mesure de fabriquer en CL1, la classe de qualité la plus élevée, et elle est parvenue à réduire ses coûts de manière spectaculaire.
[casestudy_status] => Comme la plupart des entreprises de taille moyenne dans le secteur de la construction métal et acier, MESA doit assurer une haute qualité de production de la manière la plus économique possible et s’efforcer d’occuper des niches de marché lucratives. MESA a identifié une telle niche dans la construction de véhicules ferroviaires, un secteur aux exigences de qualité particulièrement élevées. Toutefois, la fabrication avec une technique de soudage conventionnelle et des générateurs d’autres fabricants s’était révélée si coûteuse que les calculs de marge étaient devenus serrés. L’entreprise a dû rechercher des méthodes de fabrication alternatives.
[casestudy_solution] => Dans le cadre de la consultation en innovation et technologie ewm maXsolution, les experts d’EWM ont examiné à la loupe et analysé chaque étape individuelle du processus de fabrication, tout au long de la chaîne de procédé. « Nous avons bénéficié non seulement d’un conseil compétent et proactif, mais aussi de pistes de solutions pour des problèmes dont nous n’avions même pas conscience » résume Pierre Mack, Directeur de MESA Metall-Stahlbau GmbH. Le recours aux générateurs et torches de soudage d’EWM et à des modes opératoires de soudage innovants a permis de réaliser des économies dans tous les domaines imaginables : temps de soudage, matériaux, gaz protecteur, métaux d’apport, consommation de courant, pièces d’usure et surtout retouches.
[casestudy_effectiv] => « Au total, nous avons pu réduire notre temps de production de 57 pour cent pour le soudage et le meulage » rapporte M. Mack. Ceci est dû avant tout au nouveau procédé de soudage forceArc puls. Cet arc innovant se distingue par son apport d’énergie réduit, il est presque exempt de projections et offre une vitesse de soudage élevée. En plus du soudage manuel, qui n’a nécessité qu’un temps d’adaptation très bref, MESA a également procédé à la mécanisation de certaines opérations de soudage. La mécanisation a amélioré la qualité du procédé de soudage grâce à une constance supérieure. Cet investissement a été amorti en très peu de temps. Mais il a surtout élargi sensiblement le spectre de fabrication de MESA : « Si nous n’étions pas en mesure de proposer ce type de soudage, il y a de nombreuses commandes que nous n’aurions même pas reçues » témoigne M. Mack. « Avec des appareils traditionnels, nous n’aurions même pas pris la peine de nous proposer pour certains projets ».
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[metadesc] => Als die Kalkulation beim Fertigen eines größeren Auftrags aus dem Ruder lief, konsultierte MESA den Leiter der EWM-Niederlassung in Rathenow. Innerhalb von nur drei Monaten
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[benefit_headline] => Rechargement par soudage avec une vitesse de dépôt jusqu’à 13,8 kg
[benefit_subtext] => ITAG Valves & Oilfield Products GmbH
[teaser] => Les vannes à boisseau et robinets d’arrêt de l’entreprise ITAG Valves & Oilfield Products GmbH sont utilisés dans des pipelines partout dans le monde – dans les déserts arides comme dans les glaces éternelles. Ils doivent y résister plus de 25 ans sans être endommagés par les fluides agressifs. Grâce à une combinaison de soudage MAG et d’alimentation en fil chaud supplémentaire, la technologie EWM double immédiatement le taux de dépôt. Dans le même temps, il est essentiel d’assurer la constance élevée de l’ensemble des paramètres, car le processus est très sensible en dépit de sa puissance.
[casestudy_status] => Le NBA 625 est un alliage à base de nickel qui présente une très bonne résistance à la corrosion – mais à condition que sa composition technologique soit préservée. La teneur en fer peut notamment nuire aux propriétés du matériau. Il est donc très délicat de déposer une couche de NBA 625 par procédé thermique sur un acier au carbone sans provoquer un mélange important des différents matériaux et affecter ainsi la pureté de la couche de rechargement. Ces couches étaient en grande partie soudées mécaniquement, soit par procédé MAG avec un taux de dépôt de 5 kilogrammes par heure, soit par TIG avec un taux de dépôt de 2,5 kilogrammes par heure.
[casestudy_solution] => L’objectif est d’obtenir des taux de dépôt maximaux tout en maintenant une dilution réduite. Les techniciens d’application d’EWM eux-mêmes ont tout d’abord trouvé cela étrange, mais chez ITAG, le soudage MAG a été combiné avec un dévidage supplémentaire à l’aide du dévidoir à fil chaud tigSpeed. L’idée était d’accroître l’énergie de l’arc dans le métal d’apport. Ceci réduit la fusion du matériau de base, ce qui améliore la pureté de la couche de rechargement. De cette manière, l’entreprise a doublé en une fois le taux de dévidage et donc le taux de dépôt.
[casestudy_effectiv] => Des taux de dépôt allant jusqu’à 13,8 kg par heure représentent plus du double qu’avec le soudage MAG, et quatre fois plus qu’avec le soudage TIG au fil chaud. De plus, grâce à la constance très élevée du dévidage et des paramètres de soudage, les passes de soudure serrées les unes contre les autres présentent une ondulation très réduite (moins de 0,5 millimètres). Ainsi, il suffit d’exécuter les soudures de la couche de rechargement environ 1 millimètre au-dessus de la cote nominale prévue qui sera obtenue par enlèvement de copeaux. Ceci permet à ITAG de gagner du temps, mais aussi de réaliser des économies importantes de matériau onéreux.
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[metadesc] => Die Kugelarmaturen und Absperrhähne der ITAG Valves & Oilfield Products GmbH werden in Pipelines überall auf der Welt eingesetzt – in trockenen Sandwüsten ebenso wie im ewigen Eis. Mit einer Kombination aus MAG-Schweißen und zusätzlicher Heißdrahtzufuhr verdoppelt EWM-Technologie auf Anhieb die Abschmelzleistung.
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[name] => Geha b.v.
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[customer] => Machinefabriek & Apparatenbouw Geha b.v.
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[benefit_headline] => Avec EWM, la qualité est démontrable
[benefit_subtext] => Plus le composant est critique, plus les exigences de démonstration de la qualité et de traçabilité sont élevées. Avec le logiciel de gestion de la qualité ewm Xnet, ces données sont disponibles partout et à tout moment – et peuvent être exploitées pour un bénéfice encore plus important ...
[teaser] => Plus le composant est critique, plus les exigences de démonstration de la qualité et de traçabilité sont élevées. Avec le logiciel de gestion de la qualité ewm Xnet, ces données sont disponibles partout et à tout moment – et peuvent être exploitées pour un bénéfice encore plus important. Chez l’entreprise néerlandaise Machinefabriek & Apparatenbouw Geha b.v., une analyse des données de soudage a mis en lumière les temps de travail et les temps morts. Là où les temps morts étaient excessifs, les responsables ont analysé les causes et pris les mesures nécessaires, par exemple une aide aux tâches de manipulation ou la livraison des consommables sur le poste de travail. Réduire les temps morts signifie accroître la productivité, car des temps morts élevés entraînent des frais annexes élevés.
[casestudy_status] => Geha fabrique des échangeurs thermiques avec bâti en acier qui sont employés dans le monde entier dans les conditions climatiques les plus rigoureuses. Geha possédait déjà des générateurs de soudage EWM, dont le plus ancien avait été acquis en 2002. L’objectif était de mettre en réseau l’ensemble des appareils et d’enregistrer en continu tous les paramètres de soudage afin d’être en mesure de démontrer à tout moment la qualité des soudures. De l’avis de Franc van Wilgen, Directeur de l’entreprise Geha B.V., l’enregistrement des données de soudage en continu prend une importance toujours croissante. Seules des données enregistrées en continu permettent une démonstration effective de la qualité. Ces exigences sont déjà applicables aujourd’hui pour le respect de la norme EN 1090.
[casestudy_solution] => Après l’installation préalable de câbles LAN – la quantité d’acier dans les installations de fabrication de Geha perturberait la connexion radio d’un réseau Wi-Fi – les cinq générateurs de soudage ont été intégrés au réseau en une journée. Depuis lors, ewm Xnet enregistre automatiquement en ligne toutes les données des cinq générateurs de soudage. Les données peuvent être analysées et évaluées par le coordinateur de soudage en direct ou a posteriori. Sur les chantiers externes, les données sont enregistrées hors ligne et transférées via un support de stockage. Elles sont ensuite transmises au serveur.
[casestudy_effectiv] => ewm Xnet garantit la qualité du soudage, permet de la démontrer et aide les soudeurs à anticiper leur travail. Les données de soudage permettent ainsi de définir les moments optimaux pour remplacer les pièces d’usure, afin de retarder au maximum leur échange. Ceci assure une double économie : aucune pièce encore fonctionnelle n’est échangée et la perte de temps de travail est reportée aussi loin que possible dans le temps. On augmente ainsi le temps de soudage productif. En utilisant ewm Xnet, l’entreprise Geha est toujours sûre de fabriquer avec la qualité requise – et peut même le démontrer.
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[metadesc] => Je kritischer das Bauteil, desto höher die Anforderungen an Qualitätsnachweise und Rückverfolgbarkeit. Mit der Qualitätsmanagement-Software ewm Xnet stehen diese Daten immer und überall zur Verfügung – und können noch viel mehr leisten
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[benefit_headline] => Jusqu’à 60 % d’économie grâce à un angle d’ouverture plus étroit
[benefit_subtext] => Moins de passes de soudure signifie un temps de soudage réduit. Ceci implique un apport de chaleur moins important, ce qui réduit la déformation au soudage et ainsi le travail de redressage. Au total, cela peut représenter jusqu’à 60 % d’économie sur les coûts de main-d’œuvre, de matériaux et d’énergie –
[teaser] => Moins de passes de soudure signifie un temps de soudage réduit. Ceci implique un apport de chaleur moins important, ce qui réduit la déformation au soudage et ainsi le travail de redressage. Au total, cela peut représenter jusqu’à 60 % d’économie sur les coûts de main-d’œuvre, de matériaux et d’énergie – comme c’est le cas pour Siemens. Siemens a obtenu ces résultats en utilisant le procédé de soudage innovant forceArc d’EWM. L’adoption du procédé de soudage d’EWM présentait un autre avantage : une diminution significative des émissions de fumées de soudage, ce qui préserve la santé des soudeurs.
[casestudy_status] => Une qualité supérieure pour des coûts réduits constitue l’une des exigences les plus courantes des clients. C’est pourquoi les ingénieurs en technique de soudage de Siemens sont toujours à la recherche de potentiels d’économie. Dans le cadre d’un congrès du DVS, ils ont été très intéressés par les explications des spécialistes en soudage d’EWM quant aux nouveaux types d’arcs et aux stratégies de fabrication innovantes. Dès le congrès, un rendez-vous était pris pour une démonstration.
[casestudy_solution] => Le procédé de soudage innovant forceArc d’EWM se distingue par son arc à température réduite stable et puissant. Il permet d’obtenir une grande profondeur de pénétration avec moins de caniveaux. L’angle d’ouverture peut ainsi être sensiblement réduit. Un angle initial de 60° diminue en général jusqu’à 30°. Le travail de préparation est réduit d’autant. Le nombre de passes de soudure diminue lui aussi sensiblement, ce qui réduit le temps de soudage et la consommation de matériaux. Mais plus important encore est l’apport de chaleur réduit : il diminue sensiblement la déformation au soudage et permet d’éliminer de nombreux travaux de redressage ultérieurs.
[casestudy_effectiv] => D’importantes économies de temps de travail grâce au nombre réduit de passes de soudure généré par l’angle d’ouverture plus étroit, des dépenses moindres en gaz et en courant pour le générateur de soudage, mais également un apport de chaleur réduit qui entraîne une déformation moindre et donc moins de retouches : avec le nouveau procédé de soudage innovant forceArc, Siemens bénéficie de tous ces avantages. Par ailleurs, le procédé de soudage est largement exempt de projections et produit nettement moins d’émissions de fumées de soudage. Ceci préserve la santé des soudeurs et minimise les retouches. Au total, l’adoption par Siemens du procédé de soudage innovant forceArc a conduit à des économies de 60 % sur les coûts de main-d’œuvre, de matériaux et d’énergie – une réussite économique incontestée.
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[metadesc] => Weniger Schweißraupen bedeuten eine kürzere Schweißzeit. Das bedingt einen geringeren Wärmeeintrag, was den Schweißverzug und damit die Richtarbeiten reduziert. In Summe kann das zu bis zu 60 % Einsparungen von Lohn-, Material- und Energiekosten führen
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[benefit_headline] => Qualité améliorée – Compétitivité accrue
[benefit_subtext] => L’arc forceArc stable et puissant d’EWM a constitué une véritable révolution technologique dans la production de pièces pour la construction métallique lourde – y compris les composants de grand volume comme ceux fabriqués par l’entreprise Plauen Stahl Technologie GmbH ...
[teaser] => L’arc forceArc stable et puissant a constitué une véritable révolution technologique dans la production de pièces pour la construction métallique lourde – y compris les composants de grand volume comme ceux fabriqués par l’entreprise Plauen Stahl Technologie GmbH. Avec forceArc, la passe sur l’envers est générée presque automatiquement, y compris la profondeur de gorge requise. De plus, toutes les exigences de qualité sont satisfaites. Ceci simplifie le travail de soudage. Par ailleurs, deux étapes de travail sont ainsi éliminées.
[casestudy_status] => Les composants de grand volume avec des pièces individuelles pesant chacune un minimum de 50 tonnes forment le quotidien de l’entreprise du Vogtland Plauen Stahl Technologie GmbH (PST). Ces composants peuvent être des segments de pont comme ceux qui forment le viaduc de Millau en France, des châssis de chaudière pour les centrales électriques ou des portes d’écluses aux largeurs impressionnantes. Pour ces constructions très ambitieuses sur le plan technique, destinées à des projets architecturaux extravagants, la sécurité et la qualité ont une importance cruciale.
[casestudy_solution] => Le procédé de soudage innovant EWM forceArc a convaincu les responsables par ses résultats de soudage : une bonne liaison avec une pénétration profonde et une saisie exceptionnelle des racines et des flancs. forceArc marque également des points au niveau économique : réduction des travaux préalables et des retouches, baisse des coûts de main-d’œuvre, de matériaux, de gaz et d’énergie entraînent une diminution des coûts pour l’ensemble du processus d’assemblage – avec une productivité accrue. Les soudeurs apprécient eux aussi le procédé de soudage forceArc.
[casestudy_effectiv] => Chez PST, les segments de plus de 500 millimètres étaient auparavant soudés sous flux en poudre. Aujourd’hui, les segments jusqu’à 800 millimètres et les épaisseurs de matériau jusqu’à 80 millimètres sont soudés avec le procédé forceArc, ce qui réduit sensiblement le temps d’installation. forceArc assure donc une diminution importante des temps morts lors du soudage de cordons HV, car les travaux de nettoyage et de jointage sont réduits au minimum. La pénétration de la racine est obtenue de manière sûre et son aspect peut être défini et contrôlé. Ainsi, la pénétration de la racine génère directement une soudure en angle avec rainure creuse définie, portée correspondante et profondeur de gorge requise.
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[metadesc] => Der druckvolle richtungsstabile forceArc-Lichtbogen von EWM hat förmlich einen Technologiewandel in der Produktion des schweren Stahlhochbaus eingeläutet – auch bei großvolumigen Bauteilen, wie sie die . Plauen Stahl Technologie GmbH bearbeitet
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Chassis axles designed to carry huge axle loads represent a major challenge in the quality assurance process. This is why SAF-Holland relies on…
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Geschwister Scholl school uses EWM complete solution. Vocational students are being trained with ewm Xnet
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Jusqu’à 10 % de remorques en plus par poste de travail et par an
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Qualité améliorée – Compétitivité accrue
