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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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[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] => Productiviteitsstijging en kwaliteitsgarantie
[benefit_subtext] => Hogere doorlooptijden, stijging van de productiviteit, minimale nabewerkingstijd, gegarandeerde kwaliteit – ISW GmbH Steel Components heeft zijn volledige lasproductie omgezet naar EWM. Bij bouwdelen met een dikte van 300 millimeter, een lengte van 20 meter en een gewicht tot 100 ton stelt ISW hoge eisen aan de volledige lasuitrusting.
[teaser] => Hogere doorlooptijden, stijging van de productiviteit, minimale nabewerkingstijd, gegarandeerde kwaliteit – ISW GmbH Steel Components heeft zijn volledige lasproductie omgezet naar EWM. Bij bouwdelen met een dikte van 300 millimeter, een lengte van 20 meter en een gewicht tot 100 ton stelt ISW hoge eisen aan de volledige lasuitrusting. ISW Steel Components stapt over op EWM-techniek, van lasapparaten, lasprocessen, kwaliteitsgarantie met ewm Xnet 2.0 en lastoortsen tot contacttips, en bespaart daarmee tijd en materiaal.
[casestudy_status] => ISW GmbH Steel Components uit het Oostenrijkse Ennsdorf heeft zich gespecialiseerd in de productie van grote, zware en complexe basisframes voor machines en installatie. Daarbij wordt zwart staal gelast met een minimale dikte van 300 millimeter, lengte tot 20 meter en totaalgewicht tot 100 ton. Dit wordt hoofdzakelijk met het MAG-lasproces en meerlagenlassen uitgevoerd. De lassers van ISW hebben tijdens een testfase de apparaten van drie bekende fabrikanten getest.
[casestudy_solution] => Na de testfase kozen de lassers van ISW voor de apparaten van EWM. De M9-contacttips van EWM hebben een 15 procent langer contactoppervlak in vergelijking met de M8-contacttips en een 30 procent grotere schroefdraaddiameter. Het contact van de lasdraad is beter en de warmte wordt efficiënt afgevoerd. Op de functiebesturing RD3X met display en geïntegreerde besturing kunnen alle lasparameters rechtstreeks op de lastoorts worden ingesteld. De LED-verlichting verlicht donkere werkomgevingen. Het innovatieve EWM-lasproces forceArc puls wordt gekenmerkt door een goede inbranding bij aanzienlijk gereduceerde warmte-inbreng. ewm Xnet 2.0, de kwaliteitsmanagementsoftware voor lassen, registreert in real-time de lasgegevens en kan alle lasprocessen netwerkbeveiligd analyseren en beheren.
[casestudy_effectiv] => Hoge doorlooptijden en gereduceerde stilstandtijden door de langere levensduur van contacttips zijn het resultaat. Ze zitten gedurende acht lasuren in de lastoorts en zo lang duurt het gemiddeld om een bouwdeel met de geautomatiseerde installatie te lassen. Vroeger hield de contacttip het maximum een uur uit. De geïntegreerde besturing van de professionele lastoorts RD3X met display beperkt loopafstanden aangezien alle relevante parameters op de lastoorts kunnen worden ingesteld. Het innovatieve EWM-lasproces forceArc puls wordt als enig lasproces in de productie van ISW gebruikt. De lage warmte-inbreng door dit proces betekent minder vervorming en minder spanningen in het bouwdeel, en daarmee minder moeizaam richtwerk. Dankzij ewm Xnet 2.0 kan de kwaliteit perfect en uitgebreid worden aangetoond.
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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] => Punt, set en match in alle categorieën van de lastechniek
[benefit_subtext] => Het bedrijf Ebner wilde de volledige lastechniek vernieuwen. Daarvoor organiseert de industriële ovenbouwer een challenge tussen vier fabrikanten van lasapparaten. De uiteindelijke keuze werd gemaakt door lassers, onderhoudstechnici en lastoezichthouders
[teaser] => Het bedrijf Ebner, specialist in warmtebehandelingstechnologieën en industriële ovenbouw uit Leonding bij Linz in Oostenrijk, wilde de volledige lastechniek vernieuwen. De selectie werd gemaakt aan de hand van een challenge tussen vier fabrikanten van lasapparaten. Na de challenge kozen de lassers, onderhoudstechnici en lastoezichthouders unaniem voor EWM. Het aanbod in lastechniek van de experts uit Westerwald overtuigde over de hele lijn, zowel in apparaat- als in procestechniek. Ondertussen is de volledige lasproductie van Ebner van 45 lasapparaten uitgerust met EWM-lasapparaten voor TIG- en MIG/MAG-lassen.
[casestudy_status] => Bij Ebner wordt een hoge flexibiliteit van de lassers gevraagd: Het materiaalspectrum dat het bedrijf gebruikt is even breed als er verschillende bouwdelen zijn. De industriële ovens kunnen al gauw de grootte van een eengezinswoning hebben en zijn vaste constructies. Er bestaan geen standaard werkomgevingen waar altijd dezelfde werkzaamheden worden uitgevoerd. Lassers gaan steeds nieuwe uitdagingen aan, werken direct met het apparaat aan het bouwdeel en moeten daarbij vaak van plaats en positie veranderen. Deze flexibiliteit, deze speciale randvoorwaarden op de werkplaats en eenvoudig bedienbare lasapparaten waren de uitdagingen die aan de aanbieders werden gesteld.
[casestudy_solution] => In drie wezenlijke punten stak EWM AG uit boven de concurrentie en daarmee was de keuze gemaakt: de systeemgedachte en het complete aanbod bij de lasapparaten, de flexibiliteit van de lasprocessen en de overtuigende service. De lassers moesten vaak wisselen tussen verschillende lasprocessen. In dat geval is het handig om een apparaat te gebruiken dat het volledige opdrachtenpallet bevat, zowel voor MIG/MAG- als voor TIG-lassen. De machine is via twee draadaanvoerapparaten uitgerust met twee draadrollen, twee lastoortsen en twee gasflessen. De lasser kan eenvoudig van lastoorts wisselen. De rest kan met een druk op de knop op de machine worden uitgevoerd.
[casestudy_effectiv] => De lassers kozen voor de eenvoudige bediening van het apparaat en de lastoorts, de goede toegankelijkheid, de procesveiligheid van de apparaten en de storingsvrije draadtoevoer. De handelaren zagen duidelijke besparingen tot 50 procent door de reductie van uitrustingskosten dankzij de langere gebruiksduur van stroom- en gaskoppen. Zo kwam EWM over de hele lijn als winnaar uit de challenge. Ondertussen is EWM de enige fabrikant van lastechniek wiens apparaten, ook die van de nieuwste generatie, bij Ebern worden gebruikt.
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[metadesc] => Die Firma Ebner wollte ihre gesamte Schweißtechnik erneuern. Dafür veranstaltete der Industrieofenbauer einer Challenge unter vier Schweißgeräteherstellern. Schließlich entschieden sich sowohl Schweißer als auch Instandhalter und Schweißaufsichtspersonen
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[name] => Terranets bw GmbH
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[benefit_headline] => Demagnetiseren van pijpleidingen
[benefit_subtext] => Terranets bw GmbH onderzoekt zijn 2000 km lange leidingsnetwerk voor aardgas regelmatig met "pijpleidingschrapers", die de buizen magnetiseren. Reparaties waarbij moet worden gelast zijn hierdoor een moeilijke aangelegenheid. Als oplossing werd het demagnetiseringsapparaat Degauss 600 van EWM aangeschaft.
[teaser] => Terranets bw GmbH onderzoekt zijn 2000 km lange leidingsnetwerk voor aardgas regelmatig met "pijpleidingschrapers", die de buizen magnetiseren. Reparaties waarbij moet worden gelast zijn hierdoor een moeilijke aangelegenheid. Als oplossing werd het demagnetiseringsapparaat Degauss 600 van EWM aangeschaft, dat direct op de bouwplaats kon worden ingezet.
[casestudy_status] => Het bedrijf terranets bw GmbH in Stuttgart verbindt Baden-Württemberg en aangrenzende gebieden met de Europese energie-infrastructuur. De gasleidingen en installaties worden via een hoogwaardig glasvezelnetwerk aangestuurd en bewaakt, zodat een efficiënte voorziening 24 uur per dag kan worden gegarandeerd. Aangezien de hogedrukgasleidingen aan de hoogste veiligheidsnormen moeten voldoen, controleert terranets bw GmbH als leverancier regelmatig de wanddikte met "pijpleidingschrapers". Deze testsystemen zorgen echter voor een probleem: ze magnetiseren de leidingen. Als reparatie nodig is, wordt de vlamboog tijdens het lassen afgebogen en worden er poriën en bindingsfouten ingesloten.
[casestudy_solution] => Om dit probleem op te lossen heeft EWM het demagnetiseringsapparaat Degauss 600 ontwikkeld. Dit handig en compact apparaat is niet alleen gebruiksvriendelijk, maar ook geschikt voor bouwplaatsen. Om de leiding te demagnetiseren, wordt een stroomkabel zo strak mogelijk om de leiding gewikkeld. Door de stroom in de kabel wordt een tegenmagnetisch veld van gelijke sterkte gegenereerd waardoor het restmagnetisme wordt geëlimineerd. Hoe meer wikkelingen er worden aangebracht, des te groter is de maximale veldsterkte die met een constante stroom kan worden opgewekt. De Degauss 600 biedt twee mogelijkheden voor demagnetiseren. Met de Degauss-functie wordt de stroomtoevoer stapsgewijs verminderd, te beginnen met een hoge stroomwaarde met wisselende polariteit. Zo wordt het bouwdeel gedemagnetiseerd. Deze methode werkt zeer goed bij korte componenten. Daarentegen is de activgauss-methode geschikt voor lange componenten zoals pijpleidingen. Bij deze methode loopt er continu stroom door de wikkelingen, waardoor een permanent magnetisch veld ontstaat.
[casestudy_effectiv] => De Degauss 600 is door zijn laag gewicht en kleine afmetingen geschikt voor bouwplaatsen en bovendien eenvoudig te bedienen. De stroombron kan dankzij de afstandsbediening ook buiten de bouwput worden geplaatst. Met dit apparaat kan het probleem van magnetisme tijdens reparatielassen in de pijpleidingbouw worden opgelost, zelfs bij sterke magnetische velden. Het gebruik van het demagnetiseringsapparaat op de bouwplaatsen van terranets bw GmbH heeft niet alleen het leveranciersbedrijf zelf overtuigd, maar ook het uitvoerende bouwbedrijf Leonhard & Weiss GmbH en de verantwoordelijke onafhankelijke controle-ingenieur van 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] => Lastechniek beheren met een systeem
[benefit_subtext] => Een moderne lastechniek moet vanzelfsprekend een hogere productiviteit en kwaliteit bij gelijktijdige kostenreductie leveren. Vandaag worden echter lasmanagementsystemen ...
[teaser] => Een moderne lastechniek moet vanzelfsprekend een hogere productiviteit en kwaliteit bij gelijktijdige kostenreductie leveren. Vandaag worden echter lasmanagementsystemen die relevante gegevens beheren en documenteren, en tegemoetkomen aan alle vereisten van kwaliteitscontrole steeds belangrijker. Juist deze systeemgedachte en het complete aanbod van EWM hebben POLLRICH overtuigd. In 2018 heeft de fabrikant van industriële ventilatoren zijn volledige productie omgezet naar EWM en hij haalt sindsdien ook alle slijtageonderdelen en het lastoevoegmateriaal bij EWM.
[casestudy_status] => POLLRICH produceert industriële ventilatoren. Ze zorgen voor de luchtventilatie in tunnels, winkelcentra en luchthavengebouwen. In de(petro-)chemische, hout- en betonindustrie transporteren ze ook abrasieve en agressieve media. Voor dergelijke veiligheidsbouwdelen moeten alle vereisten op het gebied van documentatie worden bijgehouden om aan de vereisten van kwaliteitscontrole en traceerbaarheid tegemoet te komen.
[casestudy_solution] => EWM Xnet is het lasmanagementsysteem van EWM. Het ondersteunt, bewaakt en documenteert het volledige productieproces van het bouwdeel, van de werkvoorbereiding tot de naberekening. Alle lasgegevens en verbruikswaarden worden in real-time geregistreerd en alle lasresultaten kunnen worden geanalyseerd, gecontroleerd en beheerd. Bovendien ondersteunt Xnet het beheer van bouwdelen, het opstellen van lasvolgordeplannen en het toewijzen van lasvoorschriften. Deze kunnen ook worden beheerd en indien gewenst worden opgesteld. Bovendien behoren de individuele bewaking van keuringscertificaten van de lasser en de toewijzing van individuele toegangsrechten tot de portfolio van Xnet.
[casestudy_effectiv] => "Met Xnet is het volledige beheer van de lastechniek met een enkel systeem mogelijk", zegt Thorsten Wirtz, lastoezichthouder en manager van de kwaliteitscontrole bij POLLRICH. Aangezien de lasapparaten, draadtoevoersystemen en lastoortsen ook afkomstig zijn van EWM, is de gegevensuitwisseling binnen het systeem en tussen desbetreffende componenten optimaal afgestemd en verloopt het werken met Xnet eenvoudig, snel en veilig.
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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] => Tot 10 % meer aanhangers per werkplek en jaar
[benefit_subtext] => Aanvankelijk was de wens om het aantal overuren tot nul terug te brengen. Het resultaat was de omzetting van de volledige productie op EWM-producten...
[teaser] => Aanvankelijk was de wens om het aantal overuren tot nul terug te brengen. Het resultaat was de omzetting van de volledige productie op EWM-producten: Hüffermann Transportsysteme GmbH in Neustadt (Dosse) kon na innovatie- en technologieadvies ewm maXsolution de werktijd op een enkele werkplek verlagen met 15 procent en de productie tegelijk met 10 procent verhogen. De investering kon binnen een jaar worden afgeschreven – reden te meer om in de toekomst alleen nog maar met EWM te werken.
[casestudy_status] => “Aanvankelijk was het onze bedoeling om alleen maar de noodzakelijke overuren te verminderen. Alleen met overuren konden wij onze leveringstermijnen nakomen," zegt Torsten Völker, productieleider "getrokken eenheden" bij Hüffermann. Toralf Pekrul, manager van de EWM-vestigingen Wittstock en Rathenow, en de EWM-buitendienstmedewerker Jeffrey Kube hadden de opdracht om de productie op een werkplek zodanig te optimaliseren dat er geen overuren meer nodig waren.
[casestudy_solution] => In het kader van het holistische advies ewm maXsolution hebben vakmannen van EWM het volledige proces en elk detail van de productie geanalyseerd: van de gas- en draadtoevoer en het lasproces tot de contacttip. De EWM-specialisten hebben op een werkplek elk detail geoptimaliseerd en alle stappen van de productieketen op elkaar afgestemd.
[casestudy_effectiv] => … een aanzienlijke tijdbesparing en de afschrijving van de investering binnen een jaar: Door de implementatie van de vele door EWM voorgestelde maatregelen heeft het bedrijf een oplossing gevonden die zowel tegemoet kwam aan de medewerkers als aan de groeiende vraag van de markt. De verlaging van tot 15 procent van het aantal werkuren, de gelijktijdige productieverhoging tot 10 procent en de verlaging van het gasverbruik met eenderde bij gelijkblijvende kwaliteit, op basis van cijfers van het eigen bedrijf, waren voor de marktleider in systemen voor transport- en recyclingsvoertuigen overtuigende argumenten om de complete lasproductie van 68 werkplaatsen om te zetten naar EWM. Met de tijdsbesparing van het volledige concept kon de productie niet alleen worden gehandhaafd, maar zelfs worden verhoogd. Door Völker is dat het doorslaggevende aspect, want "men kan alles kopen, behalve tijd!"
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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] => Nog maar een vierde van de lastijd
[benefit_subtext] => Ondanks de strikte industriële normen voor de grote chemische industrie kon AST Apparatebau GmbH uit het Duitse Siegerland de lastijd met tigSpeed tot 75 procent verlagen…
[teaser] => Ondanks de strikte industriële normen voor de grote chemische industrie kon AST Apparatebau GmbH uit het Duitse Siegerland de lastijd met tigSpeed tot 75 procent verlagen. tigSpeed is een draadtoevoersysteem voor TIG-lassen. De draad wordt niet alleen continu toegevoerd, zoals bij MIG/MAG-lassen, maar wordt automatisch uit het lasbad getrokken. Zo imiteert de draadtoevoer het handmatige lasproces bij TIG-lassen.
[casestudy_status] => De voor roerwerken vereiste koelslangen worden over het algemeen als halfbuizen extern op het reservoir gelast. Bij grote roerwerkreservoirs kunnen de naadlengtes snel meerdere honderden meters bedragen. In overeenstemming met de industriële normen moeten de grondlasnaden met het TIG-proces worden gelast. De deklaag wordt vervolgens met het MAG-proces gemaakt. De productietijd van een TIG-lasnaad van één meter is met ongeveer 25 minuten aanzienlijk boven de lassnelheid van MAG-lassen.
[casestudy_solution] => Met het draadtoevoersysteem tigSpeed voor het TIG-lassen is een continue TIG-las met eindeloze toevoer van het lastoevoegmateriaal mogelijk, zonder aanzetpunten door de vervanging van lasstaven. En: Door het gebruik van hete-draad kan meer materiaal worden gesmolten en zodoende op hogere snelheid worden gelast.
[casestudy_effectiv] => De lasser van AST Apparatebau heeft vandaag voor een continue TIG-lasnaad van één meter met tigSpeed en hete-draad zelfs vijf minuten nodig. Dit is een tijdsbesparing van ongeveer 75 procent ten opzichte van het handmatige lasproces. Dit proces heeft voor de technische bedrijfsvoerder Joachim Jung nog een ander voordeel: “Uniek bij het TIG-lassen met tigSpeed is de mogelijkheid om de lasopdracht verder te automatiseren.” Maar ongeacht of het bedrijf deze weg wil inslaan, de hoge productiviteitsstijging van het nieuwe proces heeft zodanig overtuigd dat nu ook de aansluitingen met tigSpeed en hete-draad worden gelast, en roerwerkreservoirs hebben een hele hoop aansluitingen.
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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] => Beperking van de bewerkingstijden tot 50 procent
[benefit_subtext] => Bij aanvang was het slechts een idee van EWM-buitendienstmedewerkers om buis/flensverbindingen met TIG te lassen. Uiteindelijk werd hierdoor tot 50 procent bespaard ...
[teaser] => Bij aanvang was het slechts een idee van EWM-buitendienstmedewerkers om buis/flensverbindingen met TIG te lassen. Uiteindelijk werd hierdoor tot 50 procent bespaard, alleen al door de reductie van bewerkingstijden. Daarbij had het TIG-lassen bij Hering AG (Gunzenhausen) altijd een ondergeschikte rol gespeeld. EWM leende aan het bedrijf dat warmtewisselaars produceert een draadaanvoerapparaat tigSpeed voor TIG-lassen. Al in het eerste halfuur behaalden de lassers daarmee betere resultaten. Tegen het einde van de testperiode van een week wilde elke lasser met de tigSpeed werken.
[casestudy_status] => Bij Hering worden talloze verschillende buizen gebruikt: Veel buizen worden in buisbundels gegroepeerd en vervolgens in een andere buis geplaatst. Voor de productie van warmtewisselaars gaf Hering AG de voorkeur aan de lasprocessen elektrode lassen en MIG/MAG-lassen. TIG speelde slechts een ondergeschikte rol. Bovendien is TIG-lassen speciaal ontwikkeld voor buis/flensverbindingen. Het proces levert hoogwaardige lasnaden bij gereduceerde warmte-inbreng en minimale spatvorming. Dat zou een aanzienlijke reductie van nabewerkingstijden betekenen. De medewerkers waren al gewend aan werken met slechts een hand bij elektrode lassen en aan de constante draadtoevoer bij MIG/MAG-lassen.
[casestudy_solution] => De buitendienstmedewerker stelde voor om de buis/flensverbindingen met TIG en tigSpeed te lassen aangezien in dit geval hoogwaardige lasverbindingen nodig zijn. Om het aanvankelijke scepticisme te breken leende hij het desbetreffende apparaat aan het bedrijf. tigSpeed is een TIG-draadaanvoerapparaat. Het gebruik lijkt sterk op handmatig TIG-lassen dankzij de continue draadtoevoer met overlappende voor-/achteruitbeweging. Zo wordt het lastoevoegmateriaal steeds weer uit het lasbad gehaald en druppelsgewijs doorgevoerd. Bij hete-draadlassen wordt het lastoevoegmateriaal al voorverwarmd. Dat verhoogt de neersmelt, het lastoevoegmateriaal vloeit beter en het resultaat zijn uniforme lasnaden.
[casestudy_effectiv] => De voordelen liggen voor de hand Dankzij de automatische draadtoevoer kan de lasser zich volledig concentreren op het lasproces. “Een flens kan in enkele werkstappen aan de buis worden gelast – zonder aanzetpunten door vervanging van lasstaven”, zegt Valmir Xhaferi, lasser bij Hering AG, over het lasproces. Bovendien blijft de andere hand door de automatische toevoer vrij en kan hij de geleidende hand ondersteunen. “Dat is vooral handig bij lange lasnaden”, zegt Xhaferi. Christian Rasch, CEO/bestuurslid van Hering AG is ervan overtuigd dat de besparingen binnen het bedrijf door minder uitrustingstijd nog veel hoger kunnen uitvallen.
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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] => Hogere laskwaliteit en lagere kosten door ewm maXsolution
[benefit_subtext] => Wanneer de berekening bij het produceren van een grotere opdracht uit de hand liep, nam MESA contact op met de manager van de EWM-vestiging in Rathenow. In slechts drie maanden ...
[teaser] => Wanneer de berekening bij het produceren van een grotere opdracht uit de hand liep, nam MESA contact op met de manager van de EWM-vestiging in Rathenow. In slechts drie maanden na analyse door innovatie- en technologieadvies zette het bedrijf zijn volledige productie om. Met de nieuwe lasuitrusting van EWM kan het bedrijf vandaag niet alleen op hoogste kwaliteitsklasse CL1 produceren, maar ook de kosten drastisch verlagen.
[casestudy_status] => Zoals de meeste middelgrote bedrijven in de metaal- en staalbouwindustrie moest ook MESA voordeliger en tegelijk hoogwaardig produceren om een positie in een lucratieve marktniche in te nemen. Een dergelijke mogelijkheid zag MESA in de spoorvoertuigenbouw met zeer hoge kwaliteitseisen. De productie met conventionele lastechniek en met apparaten van andere fabrikanten bleek echter de kosten op te drijven en de rentabiliteit te verlagen. Het bedrijf moest op zoek naar andere productiealternatieven.
[casestudy_solution] => In het kader van innovatie- en technologieadvies ewm maXsolution hebben de experts van EWM alle stappen van de productieketen onder de loep genomen en geanalyseerd. "Het advies was niet alleen vakkundig en proactief, maar omvatte ook nieuwe mogelijke oplossingen voor door ons niet eerder voorziene problemen", benadrukt Pierre Mack, bedrijfsvoerder van Mesa Metall-Stahlbau GmbH. Door het gebruik van lasapparaten en lastoortsen van EWM en het innovatieve lasproces werden op alle denkbare gebieden besparingen gerealiseerd: bij de lastijd, het materiaal, beschermgas, lastoevoegmateriaal, stroomverbruik, slijtageonderdelen en vooral bij nabewerkingstijden.
[casestudy_effectiv] => "Wij hebben de productietijd voor lassen en slijpen met ongeveer 57 procent verlaagd", zegt Mack. De reden hiervoor is het nieuwe lasproces forceArc puls. Deze innovatieve vlamboog wordt gekenmerkt door een lagere warmte-inbreng, is nagenoeg spatvrij en maakt een hogere lassnelheid mogelijk. Naast het handmatig lassen, waarvoor slechts een zeer korte inwerkingstijd nodig was, kon MESA enkele lasprocessen ook mechaniseren. De mechanisering heeft de kwaliteit van het lasproces verhoogd en de consistentie aanzienlijk verbeterd. De investering kon in korte tijd worden afgeschreven. Vooral het productiespectrum van MESA is aanzienlijk uitgebreid: "Veel opdrachten zouden we helemaal niet krijgen als we niet zo konden lassen", verklaart Mack. "Met gangbare apparaten hoeven we helemaal niet aan te komen."
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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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[name] => ITAG
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[customer] => ITAG Valves & Oilfield Products GmbH
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[benefit_headline] => Oplassingen tot 13,8 kg neersmelt
[benefit_subtext] => ITAG Valves & Oilfield Products GmbH
[teaser] => De kogelarmaturen en afsluitkranen van ITAG Valves & Oilfield Products GmbH worden wereldwijd in pipelines gebruikt, zowel in droge warme als in ijskoude gebieden. Daar moeten ze 25 jaar lang meegaan zonder aantasting door agressieve media. Met de combinatie van MAG-lassen en extra hete-draadtoevoer heeft de EWM-technologie de neersmelt verdubbeld. Tegelijkertijd is een hoge stabiliteit van alle parameters van fundamenteel belang aangezien het krachtige proces extreem gevoelig is.
[casestudy_status] => NBA 625 is een nikkelbasislegering met een zeer goede corrosiebestendigheid, zij het alleen wanneer de technologische samenstelling wordt behouden. Vooral het ijzergehalte kan de materiaaleigenschappen sterk beïnvloeden. Het is dan ook een moeilijke opgave om met behulp van het thermische proces een NBA 625-laag op koolstofhoudend staal aan te brengen zonder verregaande vermenging van verschillende werkstoffen met behoud van de zuiverheid van de oplassing. Deze lagen werden in grote delen mechanisch gelast, hetzij via het MAG-proces met een neersmelt van 5 kilogram per uur of via TIG met een neersmelt van 2,5 kilogram per uur.
[casestudy_solution] => Het doel is om een zo hoog mogelijke neersmelt bij gelijktijdige lage opmenging te behalen. Hoewel het voor de EWM-toepassingstechnici vreemd leek, werd het MAG-lassen bij iTAG een extra draadtoevoer gecombineerd met het hete-draadaanvoerapparaat tigSpeed. De redenering hierachter was om meer vlamboogenergie in het lastoevoegmateriaal te brengen. Zo werd er minder basismateriaal gesmolten, wat een voorwaarde is voor de zuiverheid van de oplassing. Op deze manier kon het toevoervermogen en daarmee de neersmelt in een keer worden verdubbeld.
[casestudy_effectiv] => Neersmelt van tot 13,8 kg per uur is dubbel zoveel als bij MAG-lassen en vier keer zoveel als bij TIG-hete-draadlassen. Bovendien zorgen de dicht aanliggende lasrupsen door de extreem hoge stabiliteit van de draadtoevoer en lasparameters voor een zeer lage rimpeling (lager dan 0,5 millimeter). Zo moet het lassen van oplassingen slechts ca. 1 millimeter hoger worden uitgevoerd dan de latere effectieve maat die door verspaning wordt bereikt. Zo kan ITAG naast tijd ook veel dure materialen uitsparen.
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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] => Met EWM is kwaliteit aantoonbaar
[benefit_subtext] => Hoe belangrijker het bouwdoel, hoe hoger de vereisten aan kwaliteitsbewijzen en traceerbaarheid. Met de kwaliteitsmanagementsoftware ewm Xnet zijn deze gegevens altijd en overal beschikbaar, en kan er met de gegevens nog veel meer worden gedaan ...
[teaser] => Hoe belangrijker het bouwdoel, hoe hoger de vereisten aan kwaliteitsbewijzen en traceerbaarheid. Met de kwaliteitsmanagementsoftware ewm Xnet zijn deze gegevens altijd en overal beschikbaar, en kan er met de gegevens nog veel meer worden gedaan. Bij het Nederlandse bedrijf Machinefabriek & Apparatenbouw Geha bv bracht een analyse van de lastijden de hoofd- en bewerkingstijden aan het licht. Als de bewerkingstijden te lang waren, werden de redenen daarvoor door het management geanalyseerd en werden er maatregelen getroffen, zoals ondersteuning bij handlingopdrachten of nalevering van verbruiksmateriaal op de werkplaats. Het verkorten van de bewerkingstijden komt neer op een productiviteitsverhoging, want lange bewerkingstijden brengen hoge bewerkingskosten mee.
[casestudy_status] => De door Geha geproduceerde warmtewisselaars, inclusief stalen constructies, worden wereldwijd in de moeilijkste weersomstandigheden ingezet. Geha had al lasapparaten van EWM; het oudste apparaat dateert van 2002. Het doel was om alle apparaten in een netwerk te verbinden en de continue registratie van alle lasparameters om op elk moment de lasnaadkwaliteit te kunnen bewijzen. Volgens Franc van Wilgen, bedrijfsleider van Geha bv, wordt de continue registratie van lasgegevens steeds belangrijker. Alleen met continu geregistreerde gegevens kan de kwaliteit daadwerkelijk worden gecontroleerd. Deze vereisten gelden vandaag al in het kader van de norm NEN-EN-1090.
[casestudy_solution] => Na de voorinstallatie van LAN-kabels (voor een WiFi-verbinding is er in de productie van Geha te veel staal aanwezig dat een storende werking op de draadloze verbinding van het WiFi-netwerk zou hebben), werden alle vijf lasapparaten binnen een dag in het netwerk geïntegreerd. Sindsdien registreert ewm Xnet automatisch online alle gegevens van de vijf lasapparaten. De gegevens kunnen door de lastoezichthouder zowel live als achteraf worden geanalyseerd en geëvalueerd. Op de externe bouwplaatsen worden de gegevens offline geregistreerd en tijdelijk op een opslagmedium opgeslagen. De gegevens worden vervolgens opgeslagen op de server.
[casestudy_effectiv] => ewm Xnet garandeert de laskwaliteit, legt ze vast en ondersteunt de lasser om vooruitkijkend te werken. Zo kunnen met behulp van de lasgegevens de optimale tijdstippen voor de vervanging van slijtageonderdelen worden vastgesteld om ze op het juiste moment te vervangen. Dat levert op twee fronten besparingen op: Nog geschikte onderdelen worden niet vroegtijdig vervangen en werkuitvaltijden worden beperkt. Dit verhoogt de productieve lastijd. Door ewm Xnet te gebruiken weet Geha zeker dat er wordt geproduceerd tegen de vereiste kwaliteit en dit kan ook aantoonbaar worden gemaakt.
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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] => Een besparing tot 60 % door kleine naadopeningshoek
[benefit_subtext] => Minder lasrupsen betekent een kortere lastijd. Dat betekent een lagere warmte-inbreng, wat de lasvervorming en het richtwerk reduceert. In totaal kan een kostenbesparing tot 60 % op loon-, materiaal- en energiekosten worden gerealiseerd –
[teaser] => Minder lasrupsen betekent een kortere lastijd. Dat betekent een lagere warmte-inbreng, wat de lasvervorming en het richtwerk reduceert. In totaal kan net zoals bij Siemens een kostenbesparing tot 60 % op loon-, materiaal- en energiekosten worden gerealiseerd. Deze resultaten heeft Siemens door het gebruik van het innovatieve lasproces forceArc van EWM behaald. Maar de overstap naar het EWM-lasproces had nog een ander voordeel: ook de lasrookuitstoot is aanzienlijk gereduceerd waardoor de gezondheid van de lassers wordt ontzien.
[casestudy_status] => Hoge kwaliteit bij lagere kosten is een gangbaar vereiste van klanten. Daarom zijn de lasingenieurs van Siemens op het gebied van lastechniek altijd op zoek naar besparingsmogelijkheden. De presentaties over nieuwe vlambogen en toekomstgerichte processen door EWM-lasexperts op het DVS-congres vielen daarom in goede aarde bij de lasingenieurs. Nog op het congres werd een presentatiedag afgesproken.
[casestudy_solution] => Het innovatieve EWM-lasproces forceArc wordt gekenmerkt door een warmtereducerende, richtingsstabiele en krachtige vlamboog. Het proces biedt een grote inbranddiepte bij weinig randinkartelingen. Hierdoor kan de openingshoek aanzienlijk worden gereduceerd. Typerend zijn reducties van een aanvankelijke hoek van 60° tot 30°. Daarmee wordt de voorbewerkingstijd al gereduceerd. Ook het aantal lasrupsen wordt aanzienlijk verlaagd, wat de lastijd en het materiaalverbruik vermindert. Maar nog belangrijker is de lage warmte-inbreng: hij zorgt voor een aanzienlijke vermindering van de lasvervorming en reductie van het richtwerk.
[casestudy_effectiv] => De grote besparing op werktijd door minder lasrupsen dankzij gereduceerde naadopeningshoek en daarmee verbonden lagere gas- en stroomkosten van het lasapparaat, en de lagere warmte-inbreng met minder vervorming en minder nabewerkingen waren doorslaggevend. Deze effecten waren overtuigend voor het gebruik van het innovatieve lasproces forceArc bij Siemens. Daarnaast is het lasproces grotendeels spatvrij en wordt de lasrookuitstoot aanzienlijk gereduceerd. Zo wordt de gezondheid van de lasser ontzien en worden nabewerkingen geminimaliseerd. In totaal leidde de overstap naar het innovatieve lasproces forceArc bij Siemens tot besparingen van 60 % in loon-, materiaal- en energiekosten – een zichtbaar economisch succes.
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[metakey] =>
[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] => Kwaliteit verbeterd – concurrentievaardigheid verhoogd
[benefit_subtext] => De krachtige richtingsstabiele forceArc-vlamboog van EWM heeft formeel een technologische sprong ingeluid in de productie van zware staalskeletbouw, ook bij grote componenten zoals ze door Plauen Stahl Technologie GmbH worden bewerkt ...
[teaser] => De krachtige richtingsstabiele forceArc-vlamboog heeft formeel een technologische sprong ingeluid in de productie van zware staalskeletbouw, ook bij grote componenten zoals ze door Plauen Stahl Technologie GmbH worden bewerkt. Met forceArc ontstaat de tegenlaag praktisch vanzelf, inclusief de vereiste a-maat. Bovendien is aan alle kwaliteitseisen voldaan. Daarmee wordt het laswerk vereenvoudigd. Bovendien bespaart het twee werkstappen.
[casestudy_status] => Grote bouwdelen met individuele componenten waarvan het stukgewicht bij 50 ton begint, vormen de dagelijkse activiteit van het bedrijf Plauen Stahl Technologie GmbH (PST) in het Duitse Vogtland. Deze bouwdelen zijn brugsegmenten zoals voor de brug in Millau Frankrijk, ketelconstructies voor krachtcentrale of sluisdeuren met indrukwekkende spanwijdte. Juist bij dergelijke constructies met strikte technische eisen en bij architectonisch extravagante projecten komen veiligheid en kwaliteit op de eerste plaats.
[casestudy_solution] => Het innovatieve EWM-lasproces forceArc heeft de manager met lasresultaten overtuigd: goede binding bij diepe inbranding en uitstekende grond- en flankbevochtiging. Bovendien scoort forceArc op economisch gebied: De gereduceerde voor- en nabewerkingen en bespaarde loon-, materiaal-, gas- en energiekosten verlagen de kosten van het gehele verbindingsproces en garanderen hogere productiviteit. De lassers werken bovendien graag met het forceArc-lasproces.
[casestudy_effectiv] => In het verleden werd bij PST-trajecten vanaf 500 millimeter onderpoeder gelast. Vandaag worden trajecten tot 800 millimeter en met materiaaldiktes tot 80 millimeter met het forceArc-proces gelast, waardoor de instellingstijd aanzienlijk wordt verlaagd. De nabewerkingstijden van het lassen van HV-lasnaden konden door het gebruik van forceArc aanzienlijk worden verlaagd aangezien de poets- en dichtwerkzaamheden nu slechts minimaal zijn. De grondnaaddoorhang wordt veilig behaald en het uiterlijk kan gedefinieerd worden aangestuurd. Daarmee genereert de grondnaaddoorhang al een hoeklas met gedefinieerde holle groef, de desbetreffende overhang en vereiste a-maat.
[documents] => {"doc_name":["PraxisReport Plauen Stahl DE","CustomerStory Plauen Stahl EN"],"doc_link":["ewm0106_13_plauen_DE_low.pdf","ewm0409_13_plauen_GB_low.pdf"],"description":["PraxisReport Plauen Stahl DE","CustomerStory Plauen Stahl EN"]}
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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
[alias] => leadec-holding-bv-co-kg
[customer] => Leadec Holding BV & Co. KG
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[sectorId] => COM_EWMREFERENCE_ROHRLEITUNGSBAU
[materialId] => ["COM_EWMREFERENCE_EDEL_ALU"]
[processId] => ["COM_EWMREFERENCE_PIPE_SOLUTION"]
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[benefit_headline] => Benuttingsfactor 4 voor klanten
[benefit_subtext] => Ofschoon elektrode lassen als voorgeschreven lasproces gold, kon pipeSolution van EWM zelf TÜV Hessen overtuigen en werd in korte tijd het gebruik gecertificeerd voor de krachtcentrale Mannheim (GKM). …
[teaser] => Ofschoon elektrode lassen als voorgeschreven lasproces gold, kon pipeSolution van EWM zelf TÜV Hessen overtuigen en werd in korte tijd het gebruik gecertificeerd voor de krachtcentrale Mannheim (GKM). Daarmee kon Voith Industrial Services het aantal werkprocessen reduceren en de productiesnelheid verviervoudigen in vergelijking met elektrode lassen. Na een opleiding met het lasapparaat alpha Q en het pipeSolution-proces van 14 dagen werden de lassers na succesvolle afronding van het handvaardigheidsexamen bij Schweißtechnischen Lehr- und Versuchsanstalt (SLV) in Mannheim gecertificeerd voor werkzaamheden in blok 9 van de GKM.
[casestudy_status] => Diameters tot 3400 mm en wanddiktes tot 30 mm zijn gangbare afmetingen van GKM-pijpleidingen voor koelwater en externe warmte. Voor pijpleidingen van deze afmetingen bestaan geen gefabriceerde bochten. Alles moet segment voor segment worden geproduceerd en op de bouwplaats nauwkeurig worden gelast. De randen zijn voorzien van een afgeschuinde hoek van 60°. Na het lassen van de grondlasnaad met elektrode lassen moet de complete grondlasnaad worden afgewerkt en tegengelast.
[casestudy_solution] => Het innovatieve EWM-lasproces pipeSolution is speciaal ontwikkeld voor het lassen van pijpleidingen. Zonder badondersteuning kan de grondlasnaad met pipeSolution en massieve draad in een werkgang worden uitgevoerd. De vullagen en de deklaag worden vervolgens direct met gevulde draad op de grondlaag gelast. Het opvullen van voegen komt helemaal te vervallen. Aangezien de lasapparaten met twee draadaanvoerapparaten voor twee verschillende toevoegdraadrollen zijn uitgerust, massieve en vuldraad, hoeft de lasser na het lassen van de grondlasnaad alleen van lastoorts te veranderen en het tweede draadaanvoerapparaat te activeren. Daarmee kan hij vul- en deklagen lassen.
[casestudy_effectiv] => Dankzij het nieuwe lasproces en apparaatuitrusting kunnen de lassers van Voith tot vier keer sneller lassen. Bovendien wordt de afgeschuinde hoek gereduceerd van 60° tot 50°. Hierdoor wordt de op te vullen dwarsdoorsnede van de lasnaad met meer dan 13 procent gereduceerd, wat een enorme besparing aan lastoevoegmateriaal van meerdere honderden kilo's oplevert. pipeSolution overtuigde alle geïnteresseerden als proces voor snel en veilig grondlassen met hoge kwaliteit van platen en buizen in alle posities.
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[metadesc] => Obwohl E-Hand-Schweißen als Schweißverfahren vorgeschrieben war, überzeugte pipeSolution von EWM sogar den TÜV Hessen und war in kurzer Zeit für den Einsatz im Großkraftwerk Mannheim (GKM) zertifiziert.
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[name] => Hische AG Stahlbau und Industrieanlagen
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[customer] => Hische AG Stahlbau und Industrieanlagen
[customer_logo] => images/referenzen/logos_sonst/hische GmbH_Logo.JPG
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[sectorId] => COM_EWMREFERENCE_ANLAGEBAU
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[benefit_headline] => Technologische omwenteling bij Hische dankzij de beide nieuwe lasprocessen coldArc en forceArc.
[benefit_subtext] => Hische AG heeft in zijn staalbouw meteen twee innovatieve lasprocessen van EWM geïmplementeerd: coldArc en forceArc. Het resultaat waren hoge lassnelheden en de instap in een compleet nieuwe markt.
[teaser] => Hische AG heeft in zijn staalbouw meteen twee innovatieve lasprocessen van EWM geïmplementeerd: coldArc en forceArc. Het resultaat waren hoge lassnelheden en de instap in een compleet nieuwe markt... coldArc, een gemodificeerde korte vlamboog met MAG-snelheid als vervanger van TIG-lassen. De krachtige vlamboog van het forceArc-proces verhoogt eveneens de lassnelheid. Met deze vlamboog kan de naadopeningshoek worden gereduceerd. Zo wordt het aantal vereiste laslagen verlaagd, wat tijd en materiaal bespaart, en wordt de warmte-inbreng beperkt. Bovendien wordt bij hoeklassen de volledige aansluiting al bereikt met een laag zonder tegenlaag.
[casestudy_status] => Er zijn twee grote activiteiten bij Hische waar lastechniek een wezenlijke rol speelt. De rondlasnaden op buiscomponenten voor krachtcentrales met gasturbines. Het grondlassen van rondlasnaden aan buiscomponenten werd met TIG gelast. Daarnaast speelt het lassen van lange kastprofielen een belangrijke rol. Om bij drie meter lange bouwdelen met MIG/MAG-lasapparaten veilige lasresultaten te behalen, moest elke hoekzijde van een rail worden voorzien. Alleen zo kon het doorzakken van de lasnaad en daarmee ontoereikende kwaliteit worden voorkomen.
[casestudy_solution] => coldArc, een gemodificeerde korte vlamboog van het MIG/MAG-proces, levert bij Hische de gewenste resultaten bij grondlassen die voorheen met TIG werden behaald. De lassnelheid tussen TiG en MIG/MAG is bij MIG/MAG echter aanzienlijk hoger. De forceArc-vlamboog is doelgericht, geconcentreerd en gekenmerkt door een diepe inbranding, goede flankbevochtiging en spatvrij lassen. Bij het lassen van de kastprofielen kunnen de HV-lasnaden van een kant als volledige aansluiting worden gelast, de tegenlaag ontstaat automatisch aan de achterkant.
[casestudy_effectiv] => Door de grondlagen met MIG/MAG en coldArc in plaats van met TIG te lassen, wordt de lassnelheid met 40 procent verhoogd en blijft de kwaliteit behouden. Door het lassen van de randprofielen kan Hische dankzij het gebruik van forceArc afzien van de productie van de vier rails, een grote besparing in materiaal en tijd. Met forceArc worden de individuele onderdelen alleen nog gespannen en vervolgens doorgelast. Dit betekent een besparing van twee uur per giek, afgezien van de besparingen in gas en lastoevoegmateriaal. Met forceArc kan immers ook de openingshoek van de lasnaad worden gereduceerd, waardoor de lastijd, warmte-inbreng en vervorming gereduceerd worden. Dankzij de hoge lasnaadkwaliteit kon Hische met de nieuwe lasprocessen ook een nieuwe markt veroveren: de scheepstechniek, waar productkwaliteit- en productveiligheidseisen erg hoog zijn.
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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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SAF-Holland
Voertuigconstructie
Chassis axles designed to carry huge axle loads represent a major challenge in the quality assurance process. This is why SAF-Holland relies on…
Geschwister Scholl school Leutkirch
Overige
Geschwister Scholl school uses EWM complete solution. Vocational students are being trained with ewm Xnet
Gebrüder Stahl GmbH 2020
Overige
Gebrüder Stahl is working with EWM.
TIG welding is faster than MAG welding
Bell Equipment Deutschland 2020
Voertuigconstructie
Bell establishes own welding production line with EWM
Chamber of Commerce Aurich 2020
Overige
HWK Aurich places trust in EWM. Aurich Chamber of Commerce 2020
Ebner Industrieofenbau GmbH
Staalbouw
Every function accessible on the welding torch – Ebner Industrieofenbau GmbH 2019
Schoeller Werk GmbH & Co. KG
Staalbouw
Top quality in continuous use at Schoeller Werk GmbH & Co. KG
Ebner Industrieofenbau GmbH 2019
Staalbouw
Punt, set en match in alle categorieën van de lastechniek
Plauen Stahl Technologie GmbH (PST)
Staalbouw
Kwaliteit verbeterd – concurrentievaardigheid verhoogd
Hische AG Stahlbau und Industrieanlagen
Installatiebouw
Technologische omwenteling bij Hische dankzij de beide nieuwe lasprocessen coldArc en forceArc.
