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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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[benefit_headline] => Incremento della produttività e garanzia della qualità
[benefit_subtext] => Tempi di esecuzione più elevati, maggiore produttività, ripassatura minimale, qualità garantita – ISW GmbH Steel Components è passata a EWM per la sua intera produzione di saldatura. Per componenti di 300 millimetri di spessore, di 20 metri di lunghezza e fino a 100 tonnellate di peso, ISW richiede requisiti elevati per l'intera attrezzatura di saldatura.
[teaser] => Tempi di esecuzione più elevati, maggiore produttività, ripassatura minimale, qualità garantita – ISW GmbH Steel Components è passata a EWM per la sua intera produzione di saldatura. Per componenti di 300 millimetri di spessore, di 20 metri di lunghezza e fino a 100 tonnellate di peso, ISW richiede requisiti elevati per l'intera attrezzatura di saldatura. Dai generatori di saldatura ai procedimenti di saldatura e alla garanzia di qualità con ewm Xnet 2.0 fino alle torce e agli ugelli porta corrente, ISW Steel Components punta sulla tecnica EWM e così risparmia tempo e materiale.
[casestudy_status] => ISW GmbH Steel Components con sede nella città di Ennsdorf, in Bassa Austria, si è specializzata nella produzione di telai di base grandi, pesanti e complessi per macchine e impianti. Per realizzare questa produzione viene saldato dell’acciaio nero con uno spessore di 300 millimetri e oltre, lunghezze fino a 20 metri e con un peso complessivo fino a 100 tonnellate. Ciò viene eseguito principalmente nel processo di saldatura MAG e come saldatura a più strati. I saldatori di ISW hanno testato gli apparecchi di tre rinomati produttori.
[casestudy_solution] => Dopo la fase di prova, i saldatori di ISW hanno scelto gli apparecchi EWM. Gli ugelli porta corrente M9 di EWM hanno superficie di contatto più lunga del 15% rispetto agli ugelli porta corrente M8 e una sezione di filettatura più grossa del 30%. Il contatto del filo di saldatura è migliore e il calore viene deviato in maniera effettiva. Sulla torcia per saldatura funzionale RD3X si possono impostare direttamente tutti i parametri sulla torcia con il display grafico e il dispositivo di comando integrato. L’illuminazione LED illumina aree di lavoro buie. L’innovativo procedimento di saldatura EWM forceArc plus si distingue per una buona penetrazione con una contemporanea riduzione evidente dell’apporto di calore. ewm Xnet 2.0, il software di gestione qualità per la saldatura, registra i dati di saldatura in tempo reale e può analizzare e gestire tutti i processi di saldatura in rete.
[casestudy_effectiv] => Grazie alla maggiore durata degli ugelli porta corrente si ottengono tempi di esecuzione più lunghi e periodi di inattività ridotti. Essi rimangono nella torcia fino a otto ore di tempo di saldatura, che è il tempo mediamente impiegato per saldare un componente nell’impianto automatizzato. Prima l’ugello porta corrente durava al massimo un’ora. Il dispositivo di comando integrato della torcia professionale RD3X con visualizzatore grafico elimina le distanze di cammino, in quanto tutti i parametri rilevanti si possono impostare direttamente sulla torcia. L’innovativo procedimento di saldatura EWM forceArc plus viene impiegato da ISW come unico procedimento di saldatura nella produzione. Un inferiore apporto termico grazie a questi processi significa minore distorsione e minori tensioni nel componente e così un raddrizzamento meno faticoso. Grazie a ewm Xnet 2.0 la qualità può essere attestata in modo continuo ed esaustivo.
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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] => Punto, set e partita in tutte le categorie della tecnica di saldatura
[benefit_subtext] => L’azienda Ebner ha voluto rinnovare completamente la sua tecnica di saldatura. A tal fine il produttore di forni industriali ha organizzato una sfida tra quattro produttori di generatori di saldatura. Infine, sia i saldatori sia il personale di manutenzione e il personale incaricato del controllo delle operazioni di saldatura hanno deciso
[teaser] => L’azienda Ebner, specialisti di tecnologie per il trattamento del calore e per la costruzione di forni industriali con sede nella città austriaca di Leonding vicino Linz, ha voluto rinnovare completamente la sua tecnica di saldatura. La selezione ha avuto luogo sotto forma di una sfida tra quattro produttori di generatori di saldatura. Infine, saldatori, personale di manutenzione e personale incaricato del controllo delle operazioni di saldatura hanno deciso all'unanimità a favore di EWM. La proposta degli esperti di tecnica di saldatura del Westerwald ha convinto su tutta la linea – sia per gli apparecchi che per la tecnica di processo. Ora l’intera produzione a mezzo saldatura di Ebner è dotata di 45 generatori di saldatura EWM – per la saldatura TIG e MIG/MAG.
[casestudy_status] => Da Ebner viene richiesta ai saldatori un’elevata flessibilità: i componenti che l'azienda lavora sono grandi quanto la gamma dei materiali. I forni industriali possono velocemente raggiungere le grandezze di una casa unifamiliare – e sono quindi immobili. Dunque, non c’è un’area di lavoro standardizzata in cui si lavora continuamente con gli stessi apparecchi. Il saldatore deve invece affrontare ogni volta nuove sfide, lavorare direttamente sul componente con la sua attrezzatura e in più cambiare spesso posto e mansione. Questa flessibilità, queste speciali condizioni limite nell’ambiente di lavoro e contemporaneamente una buona maneggevolezza del generatore di saldatura rappresentavano le esigenze esposte dai fornitori.
[casestudy_solution] => EWM AG si distingue in tre punti importanti rispetto alla concorrenza e quindi alla fine la scelta va da sé: la concezione dei sistemi e l’offerta completa di sistemi di saldatura, la flessibilità nei procedimenti di saldatura e il servizio clienti convincente. I saldatori devono spesso cambiare tra diversi procedimenti di saldatura. Quindi è più vantaggioso se un apparecchio copre tutte le mansioni – sia per saldature MIG/MAG che per saldature TIG. Oltre a due dispositivi trainafilo, la macchina è fornita di due rulli del filo, due torce e due bombole a gas. Se la richiesta cambia, il saldatore sostituisce soltanto la torcia. Premendo un pulsante, la macchina provvede al resto.
[casestudy_effectiv] => I saldatori sono stati convinti dalla facile maneggevolezza dell’apparecchio e della torcia, dalla buona accessibilità, dalla sicurezza del processo dell’apparecchio e dall’alimentazione filo priva di interferenze. I commercianti hanno potuto risparmiare nettamente grazie alla riduzione delle spese di equipaggiamento del 50% ca., grazie a una durata nettamente più elevata degli ugelli di corrente e dell’ugello guidagas. Così EWM ha vinto la sfida a tutti i livelli. Ora EWM è l’unico produttore di tecniche di saldatura, i cui apparecchi sono stati impiegati da Ebern – anche nell’ultima generazione.
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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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[benefit_headline] => Smagnetizzazione di tubazioni
[benefit_subtext] => terranets bw GmbH controlla regolarmente la sua rete di condotti per gas naturale lunga 2000 km con il “pigging”, che magnetizza i tubi. Le riparazioni per cui è richiesta la saldatura risultano molto difficili. L’apparecchio di smagnetizzazione Degauss 600 di EWM garantisce il rimedio.
[teaser] => terranets bw GmbH controlla regolarmente la sua rete di condotti per gas naturale lunga 2000 km con il “pigging”, che magnetizza i tubi. Le riparazioni per cui è richiesta la saldatura risultano molto difficili. L’apparecchio di smagnetizzazione Degauss 600 di EWM garantisce una soluzione che può essere impiegata direttamente sul cantiere.
[casestudy_status] => terranets bw GmbH collega l’azienda di Stoccarda Baden-Württemberg e i paesi esteri limitrofi con l’infrastruttura energetica europea. I gasdotti e gli impianti di trasporto del gas vengono controllati e sorvegliati con una rete in fibra ottica d’alta qualità, garantendo un’erogazione efficiente 24 ore su 24. Poiché le tubazioni di gas ad alta pressione devono soddisfare i più elevati standard di sicurezza, terranets bw GmbH controlla regolarmente, in qualità di gestore, lo spessore delle pareti con il “pigging”. I sistemi di controllo comportano però un problema: magnetizzano le tubazioni. Se le riparazioni diventano necessarie, durante la saldatura si verifica una deviazione dell’arco e di conseguenza si creano pori ed errori di fusione.
[casestudy_solution] => Per risolvere questo problema, EWM AG ha sviluppato l’apparecchio di smagnetizzazione Degauss 600. L’apparecchio, compatto e maneggevole, non è solo facile da usare, ma anche adatto ai cantieri. Per smagnetizzare un tubo, viene fasciato un cavo corrente nel modo più stretto possibile intorno al tubo. Tramite un flusso di corrente nel cavo può essere creato un controcampo magnetico della stessa forza ed eliminato il magnetismo residuo. Più avvolgimenti vengono applicati, più grande è l’intensità di campo massima che può essere creata con una corrente costante. Il Degauss 600 offre due possibilità di smagnetizzazione. Con la funzione Degauss il flusso di corrente viene abbassato gradualmente con un valore di corrente inizialmente alto e con polarità alternante. Così il componente viene smagnetizzato. Questo metodo funziona molto bene in caso di elementi corti. Al contrario il metodo activgauss è adatto ai componenti lunghi come le tubazioni. Con questo metodo la corrente scorre continuamente attraverso gli avvolgimenti con conseguente creazione di un campo magnetico permanente.
[casestudy_effectiv] => Grazie al suo peso ridotto e alle piccole dimensioni, Degauss 600 è adatto ai cantieri e facile da usare. La fonte di corrente può essere posizionata anche al di fuori dello scavo attraverso il dispositivo di regolazione remota. Con questo attrezzo si può risolvere il problema del magnetismo durante la saldatura di riparazione nella costruzione di tubazioni anche in caso di forti campi magnetici. L’impiego dell’apparecchio di smagnetizzazione sui cantieri di terranets bw GmbH ha convinto non solo l’azienda responsabile stessa, ma anche l’impresa di costruzioni sviluppatrice Leonhard & Weiss GmbH, così come l’addetto ingegnere di controllo indipendente di 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] => La gestione delle tecniche di saldatura con un solo sistema.
[benefit_subtext] => Una tecnica di saldatura moderna dovrebbe ovviamente comportare produttività e qualità più elevate insieme a una riduzione dei costi. Al giorno d’oggi i sistemi di gestione di saldatura diventano sempre più importanti...
[teaser] => Una tecnica di saldatura moderna dovrebbe ovviamente comportare produttività e qualità più elevate insieme a una riduzione dei costi. Al giorno d’oggi diventano sempre più importanti i sistemi di gestione di saldatura che gestiscono e documentano i dati rilevanti e soddisfano tutti i requisiti di controllo qualità. Le soluzioni EWM hanno convinto POLLRICH proprio grazie a questa concezione di sistema e all’offerta completa. Nel 2018 il produttore di ventilatori industriali è passato a EWM per tutti i suoi prodotti e da allora si rifornisce dallo stesso fornitore anche per i ricambi di consumo e per il materiale d'apporto.
[casestudy_status] => POLLRICH produce ventilatori industriali. Arieggiano gallerie, grandi magazzini o interi aeroporti. Nell’industria (petrol)chimica, del legno o del calcestruzzo trasportano anche materiali abrasivi e aggressivi. Per tali componenti di sicurezza devono essere soddisfatte tutte le richieste in termini di documentazione per soddisfare i requisiti del controllo qualità e della tracciabilità.
[casestudy_solution] => EWM Xnet è il sistema di gestione di saldatura prodotto da EWM. Esso supporta, monitora e documenta l’intero processo di produzione del componente dalla preparazione del lavoro fino al calcolo consuntivo. Tutti i dati di saldatura e i valori di consumo vengono registrati in tempo reale e i risultati di saldatura possono essere analizzati, controllati e gestiti. Inoltre, Xnet supporta la gestione dei componenti, la creazione di schemi di sequenza di saldatura e l’assegnazione di istruzioni di saldatura. Queste ultime possono essere anche gestite e, se necessario, perfino create autonomamente. E infine, ma non per importanza, Xnet offre anche il controllo individuale dei certificati di prova dei saldatori, nonché l’attribuzione di diritti di accesso individuali.
[casestudy_effectiv] => “Con Xnet è possibile gestire completamente la tecnica di saldatura con un singolo sistema”, spiega Thorsten Wirtz, responsabile della sorveglianza alla saldatura e responsabile del controllo qualità per POLLRICH. Poiché anche i generatori di saldatura, i sistemi di alimentazione del filo e la torcia sono prodotti da EWM, lo scambio di dati all’interno del sistema e tra i suoi componenti è sincronizzato in maniera ottimale e, di conseguenza, il lavoro con Xnet risulta facile, veloce e sicuro.
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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] => Fino al 10% in più di rimorchi per posto di lavoro e per anno.
[benefit_subtext] => All’inizio c’era il desiderio di ridurre le ore di straordinario a zero. Il risultato è stata la conversione dell'intera produzione a prodotti EWM...
[teaser] => All’inizio c’era il desiderio di ridurre le ore di straordinario a zero. Il risultato è stata la conversione dell'intera produzione a prodotti EWM: Hüffermann Transportsysteme GmbH di Neustadt (Dosse) è riuscita, grazie alla consulenza su innovazione e tecnologia ewm maXsolution, a ridurre l’orario di lavoro del 15% in un solo posto di lavoro e, allo stesso tempo, ad aumentare il rendimento del 10%. L'investimento è stato ammortizzato in un anno ‒ ragione sufficiente per lavorare anche in futuro solo con EWM.
[casestudy_status] => “Inizialmente volevamo solamente ridurre il numero delle ore di straordinario. Solo con le ore di straordinario potevamo rispettare i nostri tempi di consegna", ha spiegato Torsten Völker, responsabile di produzione “Veicoli trainati” presso Hüffermann. Il compito di Toralf Pekrul, responsabile delle sedi EWM di Wittstock e Rathenow, e del collaboratore addetto al servizio esterno EWM Jeffrey Kube è stato prima di tutto quello di ottimizzare la produzione in un'unica postazione di lavoro in modo che non fossero più necessarie le ore di straordinario.
[casestudy_solution] => Gli specialisti di EWM, nell’ambito della consulenza a tutto tondo ewm maXsolution, hanno osservato tutta la catena produttiva verificando con la massima attenzione possibile ogni dettaglio del processo, dall’alimentazione di gas e filo al procedimento di saldatura fino all’ugello porta corrente. Hanno ottimizzato ogni vite di regolazione e su un luogo di lavoro hanno sincronizzato tutte le fasi della catena di produzione nel sistema.
[casestudy_effectiv] => ...gli effetti sono stati un risparmio notevole di tempo e un ammortamento dell’investimento in un anno. L’implementazione di molte delle singole misure proposte da EWM ha consentito all’azienda di trovare una soluzione che soddisfa sia le esigenze del lavoratore che le crescenti richieste del mercato. I convincenti argomenti che hanno portato il leader del mercato di sistemi da trasporto e riciclaggio a passare a EWM per tutta la sua produzione a mezzo saldatura con 68 posti di lavoro sono stati la riduzione delle ore di lavoro fino al 15% con contemporaneo aumento del rendimento fino al 10% e diminuzione di un terzo del consumo di gas, mantenendo la stessa qualità e con la prova dei numeri interni all’azienda. La produttività, grazie al risparmio dei tempi derivante dal progetto complessivo, non è stata solamente mantenuta, ma persino aumentata. Per Völker ciò rappresenta l’aspetto decisivo, poiché “si può comprare tutto, ma non il tempo!”
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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] => Solo un quarto ancora del lavoro di saldatura
[benefit_subtext] => Nonostante la direttiva di rigide norme industriali per le grandi aziende chimiche, AST Apparatebau GmbH con sede nel Siegerland ha potuto ridurre il tempo di saldatura fino al 75% grazie all’impiego di tigSpeed...
[teaser] => Nonostante le specifiche di rigide norme industriali per le grandi aziende chimiche, AST Apparatebau GmbH della regione di Siegerland ha potuto ridurre il tempo di saldatura fino al 75% grazie all’impiego di tigSpeed. tigSpeed è un sistema di avanzamento del filo per la saldatura TIG. Il filo non viene solo alimentato in modo continuo come già noto dalla saldatura MIG/MAG, ma viene anche automaticamente tirato fuori dal bagno di fusione in modo automatico. In questo modo il dispositivo trainafilo imita il procedimento di saldatura manuale per la saldatura TIG.
[casestudy_status] => Le serpentine refrigeranti necessarie per gli agitatori vengono abitualmente saldate come semitubi dall’esterno verso il coperchio del contenitore. Con grossi recipienti per miscelatori le lunghezze dei cordoni di saldatura possono velocemente arrivare a diverse centinaia di metri. Per essere conformi alle norme industriali, le passate alla radice devono essere saldate tramite processo TIG La passata finale viene in seguito realizzata con il procedimento MAG. I tempi di lavorazione per un metro di saldatura TIG sono di circa 25 minuti nettamente superiori alla velocità di saldatura della saldatura MAG.
[casestudy_solution] => Grazie al sistema di avanzamento del filo tigSpeed per la saldatura TIG è possibile una saldatura TIG continua con alimentazione illimitata del materiale d'apporto, senza punti di inizio causati dalla sostituzione delle bocchette di apporto. Non finisce qui: con l’impiego di un filo caldo è possibile fondere più materiale e quindi saldare più velocemente.
[casestudy_effectiv] => I saldatori della costruzione di apparecchi AST hanno bisogno attualmente solo di cinque minuti per un metro di cordone di saldatura TIG con tigSpeed e filo caldo. Ciò comporta un risparmio di tempo di circa il 75% rispetto al procedimento di saldatura manuale. Per l’amministratore delegato Joachim Jung questo procedimento presenta ancora un altro vantaggio: “Particolarmente interessante per la saldatura TIG con tigSpeed è la possibilità di automatizzare ulteriormente il lavoro di saldatura.” Ma anche se l'azienda non ha ancora preso questa strada, l’aumento significativo di produttività del nuovo processo è stato così convincente che ora anche i serbatoi devono essere saldati con tigSpeed e filo caldo – e sui recipienti per miscelatori ci sono parecchi serbatoi.
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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] => Ridurre i tempi di inattività fino al 50%
[benefit_subtext] => Saldare i collegamenti tubo-flangia con TIG era inizialmente solo un’idea del collaboratore addetto al servizio esterno EWM. Alla fine, si sono ottenuti risparmi fino al 50%...
[teaser] => Saldare i collegamenti tubo-flangia con TIG era inizialmente solo un’idea del collaboratore addetto al servizio esterno EWM. Alla fine, si sono ottenuti risparmi fino al 50% semplicemente riducendo i tempi di inattività. La saldatura TIG aveva sempre giocato solo un ruolo secondario presso Hering AG (Gunzenhausen). EWM ha fornito in prestito all'azienda che produce scambiatori di calore un dispositivo trainafilo tigSpeed per la saldatura TIG. Dopo appena mezz’ora i saldatori hanno ottenuto risultati migliori del dimostratore. E quando l’apparecchio doveva essere ritirato dopo il periodo di prova di una settimana, i saldatori già discutevano riguardo chi dovesse lavorare con tigSpeed.
[casestudy_status] => Sono innumerevoli i tubi che vengono impiegati da Hering: molti tubi sono raggruppati in fasci di tubi e poi inseriti in un altro tubo. Presso Hering AG i processi di saldatura a scelta per la produzione di questo scambiatore di calore erano la saldatura a elettrodo rivestito e la saldatura MIG/MAG. La saldatura TIG gioca soltanto un ruolo secondario. Di conseguenza la saldatura TIG è predestinata ai collegamenti tubo-flangia. Il processo fornisce cordoni di alta qualità con contemporanea riduzione dell’apporto termico e una minima formazione di spruzzi. Ciò ridurrebbe nettamente la ripassatura. Certamente i collaboratori sono abituati a lavorare solo con una sola mano per la saldatura con elettrodo rivestito e all’alimentazione del filo continua per la saldatura MIG/MAG.
[casestudy_solution] => Il collaboratore addetto al servizio esterno ha proposto di unire i collegamenti tubo-flangia con TIG e tigSpeed, essendo qui particolarmente necessarie giunzioni di saldatura di alta qualità. Per vincere l’iniziale scetticismo, ha fornito in prestito un dispositivo corrispondente. tigSpeed è un dispositivo trainafilo TIG. Esso imita la saldatura TIG manuale, sovrapponendo all'alimentazione del filo continua un ulteriore movimento in avanti e indietro. Il materiale d'apporto, in questo modo, viene estratto in continuazione dal bagno di fusione passando a gocce. Il materiale d'apporto, durante la saldatura a filo caldo, viene già pre-riscaldato. Ciò aumenta ulteriormente la velocità di fusione, il materiale fluisce molto meglio ed il risultato è un cordone dall’aspetto molto uniforme.
[casestudy_effectiv] => I vantaggi si riconoscono immediatamente: grazie all’alimentazione automatizzata del filo il saldatore può concentrarsi completamente sul procedimento di saldatura. “Una flangia può essere saldata al tubo in un’unica fase di lavoro, senza punti di inizio causati dalla sostituzione delle bocchette di apporto”, dice Valmir Xhaferi, saldatore presso Hering AG, riassumendo il processo. Inoltre, la seconda mano rimane libera grazie all’alimentazione automatica e può sostenere la mano guida. “Questo rappresenta un’agevolazione in caso di cordoni lunghi”, afferma Xhaferi. Christian Rasch, CEO/membro dell’organo direttivo presso Hering AG, è convinto che i risparmi per le aziende con meno tempo di preparazione sarebbero ancora più elevati.
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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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[name] => MESA
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[benefit_headline] => Elevata qualità di saldatura e costi ridotti grazie a maXsolution ewm
[benefit_subtext] => Quando durante la produzione di un grande ordine il calcolo è sfuggito di mano, MESA ha consultato il responsabile della filiale EWM di Rathenow. In soli tre mesi ...
[teaser] => Quando durante la produzione di un grande ordine il calcolo è sfuggito di mano, MESA ha consultato il responsabile della filiale EWM di Rathenow. In soli tre mesi l'azienda ha convertito l'intera produzione dopo un'analisi da parte della consulenza su innovazione e tecnologia ewm maXsolution. Oggi, con la nuova attrezzatura di saldatura di EWM, l’azienda può non solo produrre nella più alta classe di qualità CL1, ma ha potuto anche abbassare enormemente i costi.
[casestudy_status] => Come la maggior parte delle medie imprese nel settore delle costruzioni in metallo e acciaio, anche MESA deve produrre nel modo meno costoso possibile e allo stesso tempo con un elevato livello di qualità e occupare, possibilmente, nicchie di mercato redditizie. MESA ha fatto esperienza di questo nella costruzione di mezzi su rotaie che esige requisiti di qualità particolarmente elevati. Tuttavia, la produzione con tecniche di saldatura convenzionali e con apparecchi di altri produttori si è rivelata così costosa che rendeva difficoltoso rispettare i calcoli. L’azienda ha dovuto così cercare alternative di produzione.
[casestudy_solution] => Nell’ambito della consulenza su innovazione e tecnologia maXsolution ewm, gli esperti di EWM hanno analizzato minuziosamente ogni singolo passaggio nella catena di produzione lungo l’intera catena di processo. "La consulenza offertami non solo è stata competente e proattiva, ma ha compreso anche soluzioni per problemi di cui prima non eravamo neanche consapevoli", riassume Pierre Mack, amministratore delegato di MESA Metall-Stahlbau GmbH. Con l’impiego dei generatori di saldatura e delle torce di EWM, così come dell’innovativo processo di saldatura sono stati ottenuti risparmi in tutti i settori possibili: sul tempo di saldatura, sul materiale, sul gas di protezione, sul materiale d'apporto, sul consumo di corrente, sui ricambi di consumo e in particolare sulla ripassatura.
[casestudy_effectiv] => "Per quanto riguarda i tempi di produzione di saldatura e levigatura, siamo riusciti ad ottenere una riduzione persino del 57%", riferisce Mack. Ciò si deve soprattutto al nuovo procedimento di saldatura forceArc puls. Questo innovativo arco è caratterizzato da un ridotto apporto di calore, è quasi privo di spruzzi e consente una velocità di saldatura maggiore. Oltre alla saldatura manuale, che ha richiesto solo periodi di addestramento molto brevi, MESA è riuscita anche a meccanizzare alcuni processi di saldatura. La meccanizzazione ha anche aumentato la qualità del procedimento di saldatura grazie a una costanza stabilmente elevata. L’investimento è stato già ammortizzato dopo pochissimo tempo. Soprattutto, però, ha aumentato in modo significativo la gamma di produzione di MESA: "Se non sapessimo saldare in questo modo, non riceveremmo neanche molti dei nostri attuali ordini", dichiara Mack. "In molti casi, con gli impianti tradizionali non avremmo potuto neanche offrire questo servizio."
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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] => Saldatura a riporto con velocità di fusione fino a 13,8 kg
[benefit_subtext] => ITAG Valves & Oilfield Products GmbH
[teaser] => Le valvole a sfera e i rubinetti di chiusura della ITAG Valves & Oilfield Products GmbH vengono utilizzati negli oleodotti di gran parte del mondo – dagli aridi deserti di sabbia ai ghiacci perenni. Lì devono resistere per oltre 25 anni senza che le sostanze aggressive possano danneggiarli. Con una combinazione della saldatura MAG e dell'alimentazione supplementare del filo caldo, la tecnologia EWM raddoppia immediatamente la velocità di fusione. Allo stesso tempo è fondamentale un’elevata costanza di tutti i parametri, in quanto il processo è estremamente delicato nonostante la sua efficienza.
[casestudy_status] => NBA 625 è una lega a base di nichel con un'ottima resistenza alla corrosione – ma solo finché la sua composizione tecnologica rimane intatta. Specialmente il contenuto in ferro può alterare la proprietà del materiale. È dunque un’impresa ardua applicare uno strato di NBA 625, mediante processo termico, su un acciaio al carbonio senza ottenere una grande miscela dei diversi materiali e mantenendo la purezza dello strato di rivestimento. Questi strati sono stati in gran parte saldati meccanicamente, o attraverso il processo MAG a una velocità di fusione di 5 chilogrammi all'ora o con TIG a una velocità di fusione di 2,5 chilogrammi all'ora.
[casestudy_solution] => Lo scopo è quello di raggiungere la più alta velocità di fusione possibile contemporaneamente ad una miscela esigua. Anche se all’inizio sembrava strano anche agli stessi tecnici di EWM, la saldatura MAG alla ITAG è stata combinata con un'alimentazione del filo supplementare mediante l'alimentatore a filo caldo tigSpeed. L'idea alla base era quella di portare più energia dell’arco nel materiale d'apporto. Dunque, è stato fuso meno materiale di base, il che comporta un vantaggio per la purezza dello strato di rivestimento. In questo modo, è stato possibile raddoppiare la portata e la velocità di fusione in un solo colpo.
[casestudy_effectiv] => Le velocità di fusione fino a 13,8 kg all’ora sono più del doppio rispetto alla saldatura MAG e quattro volte superiori rispetto alla saldatura a filo caldo TIG. Inoltre, i cordoni di saldatura, molto vicini tra loro, presentano solo un'ondulazione molto ridotta (al di sotto di 0,5 millimetri) grazie alla costanza estremamente elevata nell’alimentazione del filo e nei parametri di saldatura. Le saldature dello strato di rivestimento devono essere dunque realizzate solo circa 1 millimetro al di sopra della successiva misura prevista ottenuta con il taglio. In questo modo ITAG può risparmiare non solo tempo, ma anche una grande quantità di materiale costoso.
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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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[customer] => Machinefabriek & Apparatenbouw Geha b.v.
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[benefit_headline] => Con EWM la qualità è dimostrabile
[benefit_subtext] => Più il componente è critico, più elevati sono i requisiti per la verifica della qualità e la tracciabilità. Con il software di gestione qualità ewm Xnet questi dati sono disponibili in qualsiasi momento e in qualsiasi luogo – e possono dare molto di più.
[teaser] => Più il componente è critico, più elevati sono i requisiti per la verifica della qualità e la tracciabilità. Con il software di gestione qualità ewm Xnet questi dati sono disponibili in qualsiasi momento e in qualsiasi luogo – e possono fare molto di più. Presso l’azienda olandese Machinefabriek & Apparatenbouw Geha B.V., un'analisi dei dati di saldatura ha mostrato i tempi principali e i tempi di inattività. Se i tempi di inattività sono stati troppo elevati, gli addetti analizzano i motivi e adottano eventualmente misure come il supporto nelle attività di utilizzo o la successiva consegna del materiale di consumo sul posto di lavoro. Ridurre i tempi di inattività significa aumentare la produttività, quindi tempi di inattività maggiori significano maggiori costi aggiuntivi.
[casestudy_status] => Gli scambiatori di calore prodotti da Geha, comprese le costruzioni in acciaio, vengono impiegati in tutto il mondo, anche nelle condizioni climatiche più difficili. Geha aveva già generatori di saldatura EWM; il più vecchio risale al 2002. L'obiettivo era la messa in rete di tutti gli apparecchi e il rilevamento continuo di tutti i parametri di saldatura per poter attestare in qualsiasi momento la qualità del cordone di saldatura in maniera sicura. Secondo Franc van Wilgen, amministratore delegato di Geha B.V., il rilevamento continuo di dati di saldatura diventa sempre più importante. Solo con dati continuamente aggiornati la qualità può essere davvero provata. Questi requisiti valgono già oggi per il rispetto della norma DIN EN 1090.
[casestudy_solution] => Dopo la preinstallazione dei cavi LAN – per un collegamento WLAN c'è troppo acciaio nella produzione di Geha, cosa che interferirebbe con il collegamento radio della rete WLAN – tutti e cinque i generatori di saldatura sono stati integrati nella rete in un solo giorno. Da allora ewm Xnet registra online, in modo completamente automatico, tutti i dati dei cinque generatori di saldatura. I dati possono essere analizzati e valutati dal responsabile della sorveglianza alla saldatura sia in tempo reale che in seguito. Sui cantieri esterni i dati vengono registrati offline e salvati temporaneamente su un’unità di memoria. In seguito, i dati vengono trasmessi al server.
[casestudy_effectiv] => ewm Xnet assicura la qualità della saldatura, la rende verificabile e aiuta i saldatori a lavorare in maniera previdente. Grazie ai dati di saldatura è così possibile stabilire i tempi ottimali per il cambio dei ricambi di consumo al fine di sostituirli il più tardi possibile. Ciò consente di risparmiare su due aspetti: non vengono sostituti pezzi ancora in grado di funzionare e le sospensioni di attività sono rimandate il più tardi possibile. Questo aumenta il tempo della saldatura produttiva. Grazie all’impiego di ewm Xnet, Geha è sempre sicura di aver prodotto la qualità richiesta – e per di più può attestarlo.
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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] => Fino al 60% di risparmio grazie a un angolo di apertura della saldatura più piccolo.
[benefit_subtext] => Meno cordoni di saldatura comportano un tempo di saldatura minore. Ciò causa un inferiore apporto termico, cosa che riduce la distorsione di saldatura e quindi il raddrizzamento. Complessivamente è possibile risparmiare fino al 60% di costi di lavoro, materiale ed energia –
[teaser] => Meno cordoni di saldatura comportano un tempo di saldatura minore. Ciò causa un inferiore apporto termico, cosa che riduce la distorsione di saldatura e quindi il raddrizzamento. Complessivamente è possibile risparmiare fino al 60% di costi di lavoro, materiale ed energia – come da Siemens. Siemens ha raggiunto questo risultato grazie all’impiego dell’innovativo procedimento di saldatura forceArc di EWM. Ma il passaggio ai procedimenti di saldatura EWM ha avuto un ulteriore vantaggio: anche le emissioni di fumi di saldatura sono nettamente ridotte, cosa che riguarda la salute del saldatore.
[casestudy_status] => maggiore qualità a costi minori è una delle comuni richieste dei clienti. Per questo gli ingegneri di Siemens specializzati nel campo della tecnica di saldatura sono sempre alla ricerca di possibilità di risparmio. Nell’ambito di un congresso DVS, gli esperti di saldatura di EWM hanno esposto agli ingegneri i nuovi tipi di arco e le innovative impostazioni di produzione. Sempre al congresso è stato concordato un incontro di presentazione.
[casestudy_solution] => L’innovativo procedimento di saldatura EWM forceArc si distingue per il suo arco di saldatura ad apporto di calore ridotto, dalla direzione stabile e ad alta pressione. Esso raggiunge una grande profondità della penetrazione con una minore formazione di solchi. Così l’angolo di apertura della saldatura può essere nettamente ridotto. Sono tipiche le riduzioni dagli originari 60° a 30°. Così il lavoro di preparazione viene già abbreviato. Anche il numero dei cordoni di saldatura viene nettamente ridotto, garantendo una riduzione del tempo di saldatura e del consumo di materiali. Ancora più importante è il ridotto apporto di calore: riduce in modo significativo la distorsione di saldatura e consente di risparmiare successivamente molti lavori di raddrizzamento.
[casestudy_effectiv] => Il grande risparmio di tempo di lavoro grazie a meno cordoni di saldatura, dal momento che l’angolo di apertura della saldatura è ridotto e legato anche a un minore impiego di gas e corrente per il generatore di saldatura, un minore apporto termico che comporta una minore distorsione e quindi una minore ripassatura: questi sono i risultati ottenuti presso Siemens grazie all’impiego dell’innovativo procedimento di saldatura forceArc. Inoltre, il procedimento di saldatura è ampiamente privo di spruzzi e riduce nettamente le emissioni di fumi di saldatura. Così viene tutelata la salute del saldatore e minimizzata la ripassatura. Complessivamente, il passaggio agli innovativi procedimenti di saldatura forceArc per Siemens ha portato in totale a dei risparmi del 60% dei costi di lavoro, di materiale e di energia – un significativo successo economico.
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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] => Qualità migliorata – competitività aumentata
[benefit_subtext] => L'arco forceArc di EWM, potente e dalla direzione stabile, ha ufficialmente dato il via ad un cambiamento della tecnologia nella produzione dell’edilizia in acciaio pesante – anche per i componenti di grandi dimensioni, come quelli lavorati da Plauen Stahl Technologie GmbH...
[teaser] => L'arco forceArc, potente e dalla direzione stabile, ha ufficialmente dato il via a un cambiamento della tecnologia nella produzione dell’edilizia in acciaio pesante – anche per i componenti di grandi dimensioni, come quelli lavorati da Plauen Stahl Technologie GmbH. Con forceArc la saldatura di rinforzo si crea quasi da sola, compresa la misura a richiesta. Inoltre, sono soddisfatte tutte le esigenze qualitative. In questo modo il lavoro di saldatura si semplifica. È possibile risparmiare due operazioni.
[casestudy_status] => Pezzi di grandi dimensioni con componenti singoli, il cui peso per pezzo inizia parte da 50 tonnellate, rappresentano l’attività quotidiana dell’azienda del Vogtland Plauen Stahl Technologie GmbH (PST). Per quanto riguarda i componenti, si tratta di segmenti di ponti come per il ponte Millau in Francia, impalcature per la costruzione di centrali elettriche o cancelli di chiusura con campate impressionanti. Sicurezza e qualità hanno la massima priorità in tali costruzioni con requisiti tecnici molto elevati e in progetti architettonici stravaganti.
[casestudy_solution] => L’innovativo procedimento di saldatura EWM forceArc ha convinto i responsabili grazie ai risultati di saldatura: una buona unione di penetrazione profonda e perfetta inclusione dei fianchi e della radice della saldatura. Inoltre, forceArc può avere successo da un punto di vista economico: il lavoro preparatorio e la ripassatura ridotti, i costi di lavoro, materiale, gas ed energia risparmiati, abbassano i costi dell’intero processo di giunzione – con una maggiore produttività. Anche i saldatori lavorano volentieri con il procedimento di saldatura forceArc.
[casestudy_effectiv] => In passato presso PST venivano saldate sezioni da 500 millimetri con saldatura ad arco sommerso, oggi vengono unite sezioni fino a 800 millimetri e spessori di materiale fino a 80 millimetri sono uniti con il processo forceArc – cosa che riduce notevolmente il tempo di installazione. I tempi di inattività durante la saldatura di cordoni HV potrebbero essere considerevolmente ridotti con l’impiego di forceArc, in quanto l’intonacatura e la giunzione sono solo minimali. La penetrazione della radice di saldatura viene ottenuta in modo sicuro e il suo aspetto può essere controllato in maniera definita. Così la penetrazione della radice di saldatura produce già una saldatura d'angolo con un raccordo concavo fisso, uno sbalzo corrispondente e una misura a richiesta.
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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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