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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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[customer] => 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
[alias] => finsterle-gmbh
[customer] => 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
[alias] => vogelsang-gmbh-co-kg
[customer] => 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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[catid] => 57
[name] => MST Parts Group
[alias] => mst-parts-group
[customer] => MST Parts Group
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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
[customer_logo] => images/referenzen/logos_lebens/igefa-logo.png
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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
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[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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[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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[customer] => Geschwister-Scholl-Schule 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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[name] => Gebrüder Stahl GmbH 2020
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[customer] => Gebrüder Stahl GmbH
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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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[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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[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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[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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[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] => Gains in productivity and guaranteed quality
[benefit_subtext] => Increased throughput times, better productivity, minimal post-weld work, reliable quality – ISW GmbH Steel Components switched their entire welding production to EWM. With components with a 300-millimetre thickness, 20-metre length and weighing up to 100 tonnes
[teaser] => Increased throughput times, better productivity, minimal post-weld work, reliable quality – ISW GmbH Steel Components switched their entire welding production to EWM. With components with a 300-millimetre thickness, 20-metre length and weighing up to 100 tonnes, ISW demands a lot from their entire welding setup. From welding machines and processes, through quality assurance from ewm Xnet 2.0 to welding torches and contact tips, ISW Steel Components relies on EWM technology for their whole welding production, saving both time and material.
[casestudy_status] => ISW GmbH Steel Components, a company based in Ennsdorf in lower Austria, specialises in the manufacture of large, heavy and complex basic frames for machines and systems. This involves welding black steel with a thickness of 300 millimetres and over, lengths of up to 20 metres and a total weight of up to 100 tonnes. This is completed primarily using a MAG welding procedure and multi-pass welding. ISW welders tried out machines from three notable manufacturers during a test period.
[casestudy_solution] => After the test period, the ISW welders opted for the EWM machines. The M9 contact tips from EWM have a 15% longer contacting surface in comparison to M8 contact tips and a 30% larger threaded cross section. Contact with the welding wire is better and heat is dissipated more effectively. Thanks to the integrated control and graphic display on the RD3X function torch, all the relevant parameters can be set directly on the welding torch. The LED lighting illuminates dark working areas. The innovative forceArc puls welding process from EWM stands out due to its great penetration even with significantly reduced heat input. The ewm Xnet 2.0 quality management software for welding records welding data in real time and can analyse and manage all welding processes within a network-supported system.
[casestudy_effectiv] => The result? Increased throughput time and reduced downtimes thanks to a longer service life of the contact tips. The welding torches can last for up to eight hours, as long as it takes on average to fully weld a component in an automated system. Before, the contact tip could only last a maximum of one hour. The integrated control and graphic display on the RD3X professional welding torch saves walking to and fro, as all the relevant parameters can be set directly on the welding torch. The innovative forceArc puls welding process from EWM is the only welding process used in ISW’s production. Less heat input via this process means less distortion and less tension in the component and thus less arduous straightening work. Thanks to ewm Xnet 2.0, quality can be completely and thoroughly proven.
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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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[benefit_headline] => Game, set and match in all aspects of welding technology
[benefit_subtext] => Ebner wanted to update all of their welding technology. Four welding machine manufacturers stepped up to the challenge set by the industrial furnace manufacturer. In the end, Ebner welders, maintenance staff and welding coordinators opted for
[teaser] => The Leonding-based company Ebner (near Linz in Austria), specialists in heat treatment technology and industrial furnace construction, wanted to update all of their welding technology. Four welding machine manufacturers stepped up to the challenge – the winner would be their new supplier. In the end, Ebner welders, maintenance staff and welding coordinators opted unanimously for EWM. EWM’s expert and extensive range of welding technology, including both machines and process technology, really impressed the Austrian company. Ebner’s entire welding production process is now equipped with 45 EWM welding machines that encompass both TIG and MIG/MAG welding.
[casestudy_status] => Welders at Ebner require a high level of flexibility: The range of materials is just as extensive as the range of components processed by the company. Industrial furnaces can quickly reach the size of a house, making them immobile. As a result, there are no standardised working areas in which the same setup can be used each time. Instead, welders are faced with new challenges for each task, working directly on the component with their machines and constantly changing location and position. This flexibility, the ability to deal with unique constraints in the working area and good welding machine manageability were all on the list of customer requirements.
[casestudy_solution] => EWM AG stood out from the competition in three crucial aspects: the system concept and the complete range of welding machines, the flexibility in its welding processes and the impressive service. These ultimately resulted in EWM being chosen to take on the job. Welders must often switch between different welding processes. This makes it all the more important for a machine to be able to cover the whole range of tasks – for MIG/MAG as well as TIG welding. As well as two wire feeders, the machine is equipped with two wire rollers, two welding torches and two shielding gas cylinders. If the task changes, the welder only has to change the welding torch. The machine takes care of the rest at the push of a button.
[casestudy_effectiv] => The welders made their decision based on the easy handling of the machine and welding torch, the good accessibility, the process safety of the machines and the interference-free wire feed. Dealers were able to make significant savings through the reduction of setup costs by up to 50%, thanks to the much longer service lives of power and gas nozzles. EWM decided to take on the challenge at all levels. EWM is now the only manufacturer of welding technology whose machines are used at Ebern – even in the latest generation.
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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] => Degaussing of pipelines
[benefit_subtext] => terranets bw GmbH regularly inspects their 2000 km long supply network for natural gas using pipeline inspection gauges, or “pigs”, which magnetise the pipe. Repairs that require welding can thus be difficult. The solution: the mobile degaussing machine
[teaser] => terranets bw GmbH regularly inspects their 2000 km long supply network for natural gas using pipeline inspection gauges, or “pigs”, which magnetise the pipe. Repairs that require welding can thus be difficult. The solution: a mobile degaussing machine from EWM that can be deployed directly on the construction site – the Degauss 600.
[casestudy_status] => The Stuttgart-based company, terranets bw GmbH, connects Baden-Württemberg and the surrounding countries to European energy infrastructure. The gas transport lines and systems are controlled and monitored using a high-quality fibreglass network to ensure an efficient, round-the-clock supply. As high-pressure gas lines must comply with the strictest safety standards, terranets bw GmbH, as the operating company, regularly inspects pipe wall thicknesses using so-called “pigs”. However, this inspection system can be problematic as it magnetises the pipelines. If repairs are needed, this magnetisation causes arc deflection during welding, resulting in trapped pores in the weld and a lack of fusion.
[casestudy_solution] => To solve this problem, EWM AG developed the Degauss 600 degaussing machine. The handy, compact machine is both user-friendly and suitable for use on the construction site. To degauss the pipe, a power cable is coiled around it as tightly as possible. A current flow through the cable then creates an opposing magnetic field of equal strength to eliminate the residual magnetism. The more coils are wrapped around the pipe, the greater the maximum field strength that can be generated with a constant current. The Degauss 600 is able to degauss in two ways: Using the degauss function, the current flow starts off high and is subsequently reduced in steps and alternating polarity. This has the effect of degaussing the component. This method is great for short components. In contrast, the activgauss method is suitable for long components such as pipelines. Using the activgauss method, the current flows continuously through the coils to create a permanent magnetic field.
[casestudy_effectiv] => The Degauss 600 is easy to operate thanks to its light weight and compact size, perfect for use on the construction site. As it comes with a remote control, the power source can even be placed outside the excavation. The problem of magnetism when repair welding in pipe construction is not a problem anymore with the Degauss 600, even when there are strong magnetic fields. Seeing the degaussing machine in action on terranets bw GmbH’s construction sites didn’t only convince the operating company itself of how great this machine is, but construction contractors Leonhard & Weiss GmbH and the responsible, independent inspecting engineer from TÜV Süd were also blown away by it.
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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] => Welding technology management in just one system
[benefit_subtext] => It goes without saying that modern welding technology should deliver higher productivity and quality whilst reducing costs. Much more relevant today, however, are welding management systems...
[teaser] => It goes without saying that modern welding technology should deliver higher productivity and quality whilst reducing costs. Much more relevant today, however, are welding management systems that administrate and document the relevant data and meet all the requirements of quality assurance. It was precisely this system concept and our full range of products that convinced POLLRICH to choose EWM. In 2018, the industrial fan manufacturer switched its entire production to EWM, relying on us since then for all their wear parts and welding consumables.
[casestudy_status] => POLLRICH manufactures industrial fans. These fans ventilate tunnel systems, department stores or entire airport terminals with air. In the (petro) chemical, wood or concrete industries, they also transport abrasive and aggressive substances. For such safety components, all documentation requirements must be complied with in order to satisfy all quality assurance and traceability requirements.
[casestudy_solution] => ewm Xnet is EWM’s welding management system. It supports, monitors, and documents a component’s entire production process – from work preparation to product costing analysis. All welding data and consumption values are recorded in real time and the welding results can be analysed, controlled and managed. Xnet also provides support in component management, the creation of subsequent welding plans and the allocation of welding procedure specifications. These can also be managed and, if necessary, even individually created. And last but not least, individual monitoring of the welders’ test certificates as well as the allocation of individual access permissions are also features of ewm Xnet.
[casestudy_effectiv] => “Xnet makes it possible to manage all of our welding technology in just one system,” enthuses Thorsten Wirtz, welding coordination personnel and Head of Quality Assurance at POLLRICH. As the welding machine, wire feed system and welding torch are all from EWM, data exchange within the system and between components is perfectly coordinated, making work with Xnet easy, fast and secure.
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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] => Up to 10% more trailers annually per workstation
[benefit_subtext] => It all started with the goal to reduce overtime hours to zero. To make this happen, EWM products were to be used for the whole production process...
[teaser] => It all started with the goal to reduce overtime hours to zero. To make this happen, EWM products were to be used for the whole production process: After their ewm maXsolution innovation and technology consultation, Neustadt-based (Dosse) Hüffermann Transportsysteme GmbH was able to reduce the work time at just one workstation by 15% whilst increasing output by 10%. The investment had already paid for itself within one year – another reason to stick solely with EWM in the future.
[casestudy_status] => “Originally, we just wanted to reduce overtime. Again and again, we found overtime necessary in order to meet our delivery deadlines,” explained Torsten Völker, Manager for Trailer Production at Hüffermann. Toralf Pekrul, Head of the EWM Wittstock and Rathenow locations, and EWM field sales employee, Jeffrey Kube, were responsible for optimising production initially at just one workstation to reduce overtime to zero.
[casestudy_solution] => As part of the ewm maXsolution holistic consultation solution, specialists at EWM looked at the entire process chain and closely examined every detail of production – from gas and wire feeding, through the welding process to the contact tip. EWM specialists optimised every single factor and streamlined all the steps of the system production chain at one workstation.
[casestudy_effectiv] => It saved an unbelievable amount of time, paying for itself within one year: By implementing the large number of individual measures recommended by EWM, the company was able to find a solution which satisfied both the worker and the growing demands of the market. Reducing work time by up to 15% while simultaneously boosting output by up to 10% and cutting gas consumption by a third, all with the same quality as before and backed up by company figures – these were the arguments that convinced the market leader in transport and recycling vehicles systems to switch its entire welding production – including 68 workstations – to EWM. Thanks to the time savings from putting the overall concept into practice, it was possible not only to maintain performance, but to increase it. The way Völker saw it, this was the decisive factor, because “you can buy everything except time!”
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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] => Just a quarter of the welding time
[benefit_subtext] => Despite the provisions of strict industrial standards for major chemical companies, Siegerland-based AST Apparatebau GmbH was able to reduce welding time by up to 75% by using tigSpeed...
[teaser] => Despite the provisions of strict industrial standards for major chemical companies, Siegerland-based AST Apparatebau GmbH was able to reduce welding time by up to 75% by using tigSpeed. tigSpeed is a wire feed system for TIG welding. The wire is continuously fed, as with MIG/MAG welding, and is automatically and repeatedly extracted from the weld pool. In this way, the wire feeder imitates the manual welding process of TIG welding.
[casestudy_status] => Cooling coils required for agitators are often welded onto the vessel casing as half-pipes from the outside. For large agitator vessels, seam lengths can quickly become up to several hundred metres long. To satisfy industrial standards, root passes must be welded using a TIG process. The cover pass is then created using a MAG process. Production times for a one-metre-long TIG seam are approximately 25 minutes longer than the MAG welding speed.
[casestudy_solution] => With the tigSpeed wire feed system, however, uninterrupted TIG welding with continuous consumable feeding is possible – all without contact points which are created by switching welding rods. What’s more: By using hot wire, more material can be melted and then welded at a much higher speed as a result.
[casestudy_effectiv] => AST Apparatebau welders now need just five minutes to weld a one-metre continuous TIG seam using tigSpeed and hot wire. That’s a time saving of approximately 75% in comparison to the manual welding process. This process also has another advantage for Technical Managing Director, Joachim Jung: “What’s really attractive about TIG welding with tigSpeed is the chance to further automate welding tasks.” However, even if the company does not go down this route, the increase in productivity thanks to the new process is so impressive that now even connecting pieces are to be welded using tigSpeed and hot wire – and there are a lot of connecting pieces on agitator vessels.
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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] => Reduce non-productive times by up to 50%
[benefit_subtext] => Originally, it was the idea of an EWM field sales employee to weld pipe-flange connections using a TIG process. In the end savings totalled up to 50%...
[teaser] => Originally, it was the idea of an EWM field sales employee to weld pipe-flange connections using a TIG process. In the end, savings totalled up to 50% through reduction of non-productive times alone. TIG welding always took a backseat at Hering AG in Gunzenhausen, Germany. EWM provided the heat exchanger manufacturer with a tigSpeed wire feeder for TIG welding on loan. After just half an hour, the welders had achieved better results than the demonstrator. At the end of the one-week trial period when the machine was meant to be collected, the welders were already fighting over who was going to work with the tigSpeed.
[casestudy_status] => Countless pipes are used at Hering: Many pipes are joined together to make pipe bundles and then used in another pipe. The welding procedures of choice for manufacturing heat exchangers at Hering AG were MMA and MIG/MAG welding. TIG welding takes a backseat, predestined for pipe-flange connections. This procedure delivers high-quality seams with reduced heat input and minimal spatter formation, significantly reducing post-weld work. However, employees are used to working with just one hand for MMA welding and with MIG/MAG welding, there is continuous wire feeding.
[casestudy_solution] => The field sales employees suggested joining the pipe-flange connections using TIG and tigSpeed, as this type of join requires a particularly high-quality weld connection. To quash the initial doubt, the employee loaned the company the corresponding machine. tigSpeed is a TIG wire feeder. It imitates manual TIG welding by superimposing an additional forward and backward movement on the continuous wire feed. As a result, the welding consumable is repeatedly drawn out of the weld pool and passes over drop by drop. In the case of hot wire welding, the welding consumable is preheated. This further increases the deposition rate, which allows the consumable to flow better, thereby producing a very uniform weld seam.
[casestudy_effectiv] => The advantages are obvious: Thanks to automatic wire feeding, the welder can concentrate totally on the welding process. “A flange can be welded onto the pipe in just one working step and because I don't need to change welding rods, there are no contact points,” explains Valmir Xhaferi, one of the welders at Hering AG. In addition, the automatic feed keeps your second hand free to support the guide hand. “It's a great help, particularly with long seams,” says Xhaferi. And Christian Rasch, CEO/Executive Board member at Hering AG, is convinced that these savings could be even bigger in companies with less setup time.
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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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[customer] => MESA Metall-Stahlbau GmbH
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[benefit_headline] => Better welding quality and reduced costs with ewm maXsolution
[benefit_subtext] => When calculations for the production of a large order were getting out of control, MESA consulted the head of the EWM branch in Rathenow. Within just three months...
[teaser] => When calculations for the production of a large order were getting out of control, MESA consulted the head of the EWM branch in Rathenow. Within just three months, the company had switched its entire production to EWM after an ewm maXsolution innovation and technology consultation. With the new EWM welding equipment, today the company can manufacture CL1 of the highest quality, all whilst significantly reducing costs.
[casestudy_status] => As is the case for most medium-sized companies in the metal and steel industry, MESA must manufacture high-quality products as cheaply as possible whilst fulfilling as lucrative a market niche as possible. With its particularly high quality requirements, MESA saw such a niche in rail vehicle construction. However, production using conventional welding technology and other manufacturers’ machines proved to be rather costly, so much so that it almost became unfeasible. The company had to look for other production alternatives.
[casestudy_solution] => As part of the ewm maXsolution innovation and technology consultation, experts from EWM carefully examined and analysed every step in the production process across the entire process chain. “Not only was the consultation very competent and proactive, it also gave us new solutions to problems that we hadn’t previously recognised ourselves,” says Pierre Mack, Managing Director at MESA Metall-Stahlbau GmbH. Using EWM’s welding machines, welding torches and innovative welding processes means savings in all areas imaginable: welding time, materials, shielding gas, welding consumables, power consumption, wear parts and, most importantly, post-weld work.
[casestudy_effectiv] => “We have managed to cut down production times for welding and grinding by an incredible 57 percent,” reports Mack. The reason: the new forceArc puls welding process. Virtually spatter-free, the innovative arc excels thanks to a low heat input and also allows greater welding speeds. As well as manual welding that takes only little time to become familiar with, MESA was also able to mechanise certain welding processes. This mechanisation significantly increased the quality of the welding process once more, due to the constant, high level of consistency. The investment paid for itself in no time. Above all else, however, mechanisation has massively widened MESA’s production portfolio: “We would miss out on a lot of contracts if we weren’t able to weld in the required way,” testifies Mack. “With conventional machines we wouldn’t be able to compete at all.”
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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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[customer] => ITAG Valves & Oilfield Products GmbH
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[benefit_headline] => Cladding with a deposition rate up to 13.8 kg
[benefit_subtext] => ITAG Valves & Oilfield Products GmbH
[teaser] => Ball valves and gate valves from ITAG Valves & Oilfield Products GmbH are used in pipelines all over the world, from dry sandy deserts to permanent icy conditions. Here the valves must stay in place for over 25 years, withstanding the effects of such aggressive conditions. Using a combination of MAG welding and additional hot wire feeding, EWM technology doubles the deposition rate right from the start. A high level of consistency for all the parameters is also essential, as the process is still extremely sensitive, despite its high performance level.
[casestudy_status] => NBA 625 is a nickel-based alloy with an incredible resistance to corrosion – as long as its technological composition is preserved. The iron content especially may have a negative effect on the material properties. It is therefore a difficult endeavour to apply an NBA 625 layer to a carbonic steel using a thermal process without mixing the various materials and maintaining the purity of the surface finish. The layers are mechanically welded in large parts, either using a MAG process and a deposition rate of 5 kilograms per hour, or using a TIG process with a deposition rate of 2.5 kilograms per hour.
[casestudy_solution] => The aim is to achieve the highest possible deposition rate with the lowest level of dilution. Although this seemed strange to EWM application engineers to begin with, the MAG welding process at ITAG is combined with additional wire feeding using the tigSpeed hot wire feeder. The idea behind this was to transfer more arc energy to the welding consumable. This meant that less base material was melted which is, in turn, helpful for maintaining the purity of the surface finish. As a result, both the feed and deposition rate could be doubled in one go.
[casestudy_effectiv] => Deposition rates from up to 13.8 kg per hour are more than double those of MAG welding and quadruple those of TIG hot wire welding. What’s more, the tightly-packed weld beads displayed only very little rippling (< 0.5 millimetres) thanks to extremely high consistency in the wire feeding and welding parameters. As a result, welds on the surface layer only needed to be carried out approximately 1 millimetre higher than the specified height which would then be reached through machining. This allowed ITAG to save both time and a large amount of expensive materials.
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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] => Get certifiable quality with EWM
[benefit_subtext] => The more critical the component, the higher the need for quality certification and traceability. With the ewm Xnet quality management software, this data is available anytime, anywhere – and can do so much more...
[teaser] => The more critical the component, the higher the need for quality certification and traceability. With the ewm Xnet quality management software, this data is available anytime, anywhere – and can do so much more. At the Dutch company Machinefabriek & Apparatenbouw Geha b.v., a welding data analysis revealed the peak and non-productive times. Where non-productive times were too high, the reasons were analysed and, if necessary, measures were taken such as increasing support for handling tasks or a subsequent delivery of consumables to the workstation. Reducing non-productive time means increasing productivity, as more non-productive time means greater additional costs.
[casestudy_status] => The heat exchangers complete with steel constructions manufactured by Geha are used worldwide, even under very climatically challenging conditions. Geha already had EWM welding machines with the oldest one dating back to 2002. The aim was to network all the machines and continuously record all the welding parameters to be able to reliably prove the weld seam quality at any time. According to Franc van Wilgen, Managing Director of Geha B.V., continuous welding data recording is becoming more and more important. Quality can really only be proven through continuously recorded data. These requirements now apply for compliance with DIN EN 1090.
[casestudy_solution] => After pre-installation of LAN cables – there is too much steel in Geha’s production to establish a WiFi connection as steel disrupts radio communications necessary for a WiFi network – all five welding machines were integrated into the network within one day. Since then, Geha has used ewm Xnet to log all the data for the five welding machines completely automatically online. This allows the data to be analysed and evaluated by welding coordination personnel, both in real-time and also at a later point. Data are recorded offline on external construction sites and stored temporarily on a storage medium. The data are then transferred to the server.
[casestudy_effectiv] => ewm Xnet guarantees welding quality, makes it possible to prove quality and helps the welder to work proactively. The welding data allow welders to determine the optimum time to change wear parts so as to leave them on for as long as possible. This has two advantages in terms of savings: It means that working, functional parts are not exchanged, thus postponing downtimes as much as possible and increasing welding productivity. Using ewm Xnet means that Geha can always be sure that they have manufactured their products to the required quality – and can prove it.
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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] => Up to 60% savings thanks to narrower preparation angles
[benefit_subtext] => Fewer weld beads means a shorter welding time. This requires a lower heat input, which in turn limits welding distortion and the need for subsequent straightening work. In total, this can lead to savings of up to 60% on wages and material and energy costs –
[teaser] => Fewer weld beads means a shorter welding time. This requires a lower heat input, which in turn limits welding distortion and the need for subsequent straightening work. In total, this can lead to savings of up to 60% on wages and material and energy costs – just like at Siemens. Siemens achieved this by using the innovative forceArc welding process by EWM. Switching to the EWM welding process has another advantage, though: It also significantly cuts welding fume emissions, preserving the welder’s health.
[casestudy_status] => Higher quality with simultaneously lower costs is one of the most common customer requirements. That’s why welding engineers at Siemens are always on the look-out for opportunities to save in the area of welding technology. This is where EWM came in. As part of a DVS Congress, explanations by EWM welding experts on new arc types and future-orientated approaches to production impressed Siemens. A demonstration date was then agreed at the Congress.
[casestudy_solution] => EWM’s innovative forceArc welding process stands out thanks to its reduced-heat, directionally-stable and powerful arc, which can achieve large penetration depths and reduced undercut at the same time. This also allows the welder to considerably narrow the preparation angle, with reductions typically from 60° down to 30°. This in turn means there is less pre-weld work. This arc angle also significantly reduces the number of weld beads, saving both welding time and materials. More important, however, is the lower heat input. Lower heat input means far less welding distortion and subsequent straightening work that would be required.
[casestudy_effectiv] => Working time is slashed thanks to the narrowed preparation angle creating fewer weld beads. What’s more, less gas and power is needed for the welding machine as well as lower heat input, leading to less distortion and subsequent post-weld work required. All this was experienced by Siemens through the use of the innovative forceArc welding process. In addition, the welding process is largely spatter-free and significantly cuts welding fume emissions, preserving the welder’s health and minimising post-weld work. Altogether, the switch to the innovative forceArc welding process at Siemens saved them a total of 60% on wages and material and energy costs – a true economic success.
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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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[name] => Plauen Stahl Technologie GmbH (PST)
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[benefit_headline] => Improved quality – increased competitiveness
[benefit_subtext] => The powerful, directionally-stable forceArc arc has marked a technological transformation in the production process of heavy structural steelwork as well as large-volume components that Plauen Stahl Technologie GmbH work with...
[teaser] => The powerful, directionally-stable forceArc arc has marked a technological transformation in the production process of heavy structural steelwork as well as large-volume components that Plauen Stahl Technologie GmbH work with. With forceArc, the backing run practically welds itself, including the required throat thickness, fulfilling all quality requirements and making welding work easier by cutting out two work steps.
[casestudy_status] => Plauen Stahl Technologie GmbH (PST) located in Vogtland in Germany works with large-volume components with individual parts weighing from 50 tonnes upwards on a daily basis. The components they handle include bridge segments such as those used for the Millau Viaduct in France, boiler support structures for power plants or floodgates with an enormous span. These kinds of constructions have the highest technical demands and safety and quality are extremely important. This is also true for extravagant architectural projects.
[casestudy_solution] => The innovative forceArc welding process from EWM impressed PST senior employees with its welding results, boasting great binding properties with a deep penetration and excellent root and sidewall fusion. In addition, the forceArc also has some economic advantages: The reduced pre- and post-weld work and savings in wages, materials, gas and energy costs mean lower costs for the whole joining process, and all with increased productivity. PST welders also enjoyed working with the forceArc welding process.
[casestudy_effectiv] => In the past, PST welded sections over 500 millimetres using submerged arc welding. Today, sections up to 800 millimetres and material thicknesses up to 80 millimetres are joined using the forceArc process, significantly reducing setup time. Non-productive times when welding single-bevel groove seams could be considerably lowered by using forceArc, as this would require only minimal cleaning and gouging work. Excess weld metal on the root can be reached safely and its appearance controlled with definition. In this process, the excess weld metal on the root creates a fillet weld with a specified concave fillet, corresponding overlap and the required throat thickness.
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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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[name] => Leadec Holding BV & Co. KG
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[benefit_headline] => Four times more customer benefits
[benefit_subtext] => Even though MMA welding was the stipulated welding procedure, EWM’s pipeSolution impressed TÜV Hessen and was soon certified for use in the Großkraftwerk Mannheim (GKM) [Mannheim Large Power Plant]...
[teaser] => Even though MMA welding was the stipulated welding procedure, EWM’s pipeSolution impressed TÜV Hessen and was soon certified for use in the Großkraftwerk Mannheim (GKM) [Mannheim Large Power Plant]. The process allowed Voith Industrial Services to reduce the number of work operations and quadruple welding speed in comparison to MMA welding. After just 14 days’ training on the alpha Q welding machine and the pipeSolution process and following a manual production trial at the Mannheim Schweißtechnischen Lehr- und Versuchsanstalt (SLV) [Mannheim Welding Technology Academy and Research Institute], welders received approval to work in block 9 of the GKM.
[casestudy_status] => Diameters up to 3,400 mm and wall thicknesses of up to 30 mm are typical dimensions for GKM pipelines for coolant water and district heating. There are no pre-manufactured elbows for pipes of these dimensions. Everything needs to be built segment by segment and then welded together precisely on the building site. Edges have a bevel angle of 60°. After welding the root using the traditional MMA process, the entire root had to be gouged and welded on the reverse side.
[casestudy_solution] => EWM’s innovative pipeSolution welding process is specially designed for welding pipelines. Using pipeSolution and solid wire, the root can be created in one work operation without the need for backing. The filler passes and final pass are then welded directly onto the root pass with flux cored wire. There is no need for gouging. As the welding machines are equipped with two wire feeders for two different filler wires (solid and flux cored wire rolls), after completing the root pass, the welder only needs to change the welding torch and activate the second wire feeder. This can be used to weld both filler and final passes.
[casestudy_effectiv] => Welders at Voith can weld seams up to four times faster using the new welding process and equipment. In addition to all this, the bevel angle can be narrowed from 60° to 50°. The weld cross section being filled is thus reduced by more than 13%, which represents incredible savings in welding consumables of several hundred kilograms. pipeSolution truly convinced all those taking part that it is the best process when it comes to fast, safe and high-quality root welding on metal sheets and pipes in all positions.
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[benefit_headline] => Technological transformation at Hische with both new coldArc and forceArc welding processes
[benefit_subtext] => Hische AG also implemented two innovative EWM welding processes in their steel construction: coldArc and forceArc. The results were high welding speeds and access to a completely new market.
[teaser] => Hische AG also implemented two innovative EWM welding processes in their steel construction: coldArc and forceArc. The results were high welding speeds and access to a completely new market. coldArc, a modified short arc, replaces TIG welding but with the speed of MAG welding. The powerful arc of the forceArc process also increases welding speed. It allows the welder to narrow the preparation angle, reducing the number of welding layers needed. This saves time and material and minimises heat input. In addition, full penetration can be achieved with just one layer for fillet welds, without backing run.
[casestudy_status] => There were two main sections at Hische which made significant use of welding technology: The welding primarily involved circumferential seams on pipe components for gas turbine power plants. The weld roots of the circumferential seams on the pipe components were welded using a TIG process. The company also welds long box profiles. To achieve reliable results when welding three-metre-long components with the MIG/MAG welding machines, a rail first had to be placed underneath every side of the box profile. This was the only way to prevent sagging of the seam and subsequent poor quality.
[casestudy_solution] => coldArc, a modified short arc for MIG/MAG processes, was used by Hische to get the desired results from root welding that were previously only possible with TIG welding. Between TIG and MIG/MAG, however, MIG/MAG welding offers significantly higher welding speeds. The forceArc arc is targeted and concentrated. It is further characterised by deep penetration, good sidewall fusion and spatter-free welding. When welding box profiles, single-bevel groove seams can be welded with full penetration from one side and the backing run is automatically created on the rear side.
[casestudy_effectiv] => Welding the root pass with MIG/MAG and coldArc instead of TIG boosts the welding speed by 40% and with almost identical quality. When welding box profiles, Hische can use forceArc to avoid pre-assembly and having to tack weld the four rails. This saves a significant amount of material and time. With forceArc, the individual parts are tensioned and then welded with full penetration, saving two hours per crane boom, not to mention reductions in the amount of gas and welding consumable used. This is because the forceArc allows the welder to narrow the preparation angle of the weld seam, thereby cutting welding times, heat input and distortion. Thanks to the high weld seam quality of Hische’s newly-acquired welding processes, the company was able to access the new market of marine technology, an industry with extremely high requirements on product quality and safety.
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[metadesc] => Gleich zwei innovative Schweißprozesse von EWM hat die Hische AG in ihrem Stahlbau etabliert: coldArc und forceArc. Das Ergebnis waren hohe Schweißgeschwindigkeiten und der Einstieg in einen völlig neuen Markt
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