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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] => Ökad produktivitet och kvalitetssäkring
[benefit_subtext] => Längre omloppstider, ökad produktivitet, minimalt efterarbete, säkrad kvalitet – ISW GmbH Steel Components har ställt om hela svetsproduktionen till EWM. Med komponenter som är 300 mm tjocka, 20 meter långa och som väger upp till 100 ton ställer ISW höga krav på hela svetsutrustningen.
[teaser] => Längre omloppstider, ökad produktivitet, minimalt efterarbete, säkrad kvalitet – ISW GmbH Steel Components har ställt om hela svetsproduktionen till EWM. Med komponenter som är 300 mm tjocka, 20 meter långa och som väger upp till 100 ton ställer ISW höga krav på hela svetsutrustningen. Från svetsmaskinerna via svetsprocesserna och kvalitetssäkringen med ewm Xnet 2.0 och vidare till svetsbrännarna och kontaktrören använder ISW Steel Components EWM:s teknik och sparar därmed tid och material.
[casestudy_status] => ISW GmbH Steel Components från Ennsdorf i den österrikiska delstaten Niederösterreich har specialiserat sig på att tillverka stora, tunga och komplexa stativ och chassin för maskiner och anläggningar. Man svetsar svartstål som är tjockare än 300 mm i längder upp till 20 meter och med en totalvikt på upp till 100 ton. Detta sker huvudsakligen med MAG-svetsproceduren och utförs som svetsning av flera strängar. Under en testperiod testade svetsare från ISW maskiner från tre namnkunniga tillverkare.
[casestudy_solution] => Efter testperioden beslutade sig svetsarna hos ISW för maskinerna från EWM. M9-kontaktrören från EWM har en kontaktyta som är 15 procent längre jämfört med M8-kontaktrör och 30 procent större gängsektion. Kontakteringen av svetstråden är bättre och värmen leds effektivt bort. På funktionsbrännare RD3X med grafisk display och integrerad styrning kan man ställa in samtliga parametrar direkt på svetsbrännaren. LED-belysningen lyser upp mörka arbetsområden. Den innovativa EWM-svetsprocessen forceArc puls utmärker sig genom en god inträngning med en samtidigt avsevärt reducerad värmeinträngning. ewm Xnet 2.0, kvalitetsstyrningsprogramvaran för svetsning, registrerar svetsdata i realtid och kan analysera och administrera alla svetsprocesser med nätverksstöd.
[casestudy_effectiv] => Högre omloppstider och reducerade stilleståndstider blir resultatet av att kontaktrören har längre livslängd. De befinner sig i svetsbrännaren i upp till åtta timmars svetstid, så lång tid tar det i genomsnitt tills en komponent har svetsats färdigt i den automatiserade anläggningen. Tidigare höll kontaktröret max. en timme. Den integrerade styrningen av proffs-svetsbrännaren RD3X med grafisk display minskar springet eftersom samtliga relevanta parametrar kan ställas in direkt på svetsbrännaren. Den innovativa EWM-svetsprocessen forceArc puls används som den enda svetsprocessen vid tillverkningen hos ISW. Lägre värmeinträngning med den här processen innebär mindre deformering och mindre spänningar i komponenten och därmed mindre besvärligt riktningsarbete Tack vare ewm Xnet2.0 kan kvaliteten upprätthållas utan avbrott.
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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] => Game, set och match inom svetsteknikens alla kategorier
[benefit_subtext] => Företaget Ebner ville byta ut all sin svetsutrustning. Därför organiserade industriugnstillverkaren en tävling mellan fyra svetsmaskinstillverkare. Slutligen bestämde sig såväl svetsare som reparatörer och svetsförmännen
[teaser] => Företaget Ebner, specialister inom värmebehandlingsteknik och tillverkning av industriugnar från Leonding i närheten av Linz i Österrike, ville byta ut all sin svetsutrustning. Valet gjordes i form av en tävling mellan fyra svetsmaskinstillverkare. Därefter beslutade sig svetsare, reparatörer, svetsförmän enhälligt för EWM. Erbjudandet från experterna inom svetsteknik övertygade i alla avseenden – såväl när det gäller maskintekniken som processtekniken. Sedan dess är hela svetstillverkningen hos Ebner utrustad med 45 svetsmaskiner med EWM – för TIG- och för MIG/MAG-svetsning.
[casestudy_status] => Svetsarna hos Ebner måste vara mycket flexibla: Företaget bearbetar ett lika stort spektrum av komponenter som material. Industriugnar kan snabbt bli lika stora som ett enfamiljshus – och är därmed orörliga. Följaktligen finns det inga standardiserade arbetsområden där man om och om igen arbetar med samma uppspänningar. Varje gång ställs svetsaren inför nya utmaningar, arbetar direkt vid komponenten med sin maskin och byter därför ofta plats och position. Denna flexibilitet, de speciella restriktionerna i arbetsomgivningen och samtidigt lätthanterliga svetsmaskiner var kraven som anbudsgivarna ställdes inför.
[casestudy_solution] => EWM AG utmärkte sig gentemot sina konkurrenter på tre viktiga punkter och detta ledde till det slutliga avgörandet: systemtanken och det kompletta utbudet av svetsmaskiner, flexibiliteten under svetsprocesserna och den övertygande servicen. Svetsarna måste ofta växla mellan olika svetsprocesser. Då är det en stor fördel när en maskin klarar alla uppgifter – såväl MIG/MAG- som TIG-svetsningar. Via två trådmatarenheter är maskinen utrustad med två trådrullar, två svetsbrännare och två skyddsgasflaskor. Om kraven ändras byter svetsaren bara svetsbrännare. Resten klarar maskinen med en knapptryckning.
[casestudy_effectiv] => Avgörande för svetsarna var att maskinerna och svetsbrännarna är enkla att hantera, den goda tillgängligheten, maskinernas processäkerhet och den störningsfria trådmatningen. Inköpspersonalen kunde göra avsevärda besparingar genom minskade riggningskostnader på grund av märkbart längre brukstid för ström- och gasmunstyckena med upp till 50 procent. Därmed avgjorde EWM tävlingen till sin fördel på alla nivåer. Idag är EWM den enda tillverkaren av svetsteknik vars maskiner används hos Ebern – även av den yngre generationen.
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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] => Avmagnetisering av rörledningar
[benefit_subtext] => terranets bw GmbH undersöker regelbundet sitt 2 000 km långa ledningsnät för naturgas med ”rörskrapor” som magnetiserar rören. Det är svårt att utföra reparationer som kräver svetsning. Detta kan avhjälpas med det mobila avmagnetiseringsaggregatet Degauss 600 från EWM.
[teaser] => terranets bw GmbH undersöker regelbundet sitt 2 000 km långa ledningsnät för naturgas med ”rörskrapor” som magnetiserar rören. Det är svårt att utföra reparationer som kräver svetsning. Detta kan avhjälpas med det mobila avmagnetiseringsaggregatet Degauss 600 från EWM, som kan användas direkt på byggarbetsplatsen.
[casestudy_status] => terranets bw GmbH i Stuttgart kopplar ihop den tyska delstaten Baden-Württemberg och det angränsande utlandet med den europeiska energiinfrastrukturen. Gastransportledningarna och -anläggningarna styrs och övervakas via ett förstklassigt fibernät så att effektiv försörjning är möjlig dygnet runt. Eftersom gashögtrycksledningar måste uppfylla de högsta säkerhetsstandarderna kontrollerar terranets bw GmbH som driftsföretag regelbundet väggarnas tjocklek med rörskrapor. Detta kontrollsystem orsakar dock ett problem: Det magnetiserar ledningarna. Om det blir nödvändigt att utföra reparationer leder det till att ljusbågen böjs av vid svetsningen och därmed till inneslutning av porer och bindfel.
[casestudy_solution] => För att lösa detta problem har EWM AG utvecklat avmagnetiseringsaggregatet Degauss 600. Det lätthanterliga och kompakta aggregatet är inte bara lätt att använda utan även lämpligt för byggarbetsplatser. För att avmagnetisera röret lindas en strömkabel så tätt runt röret som möjligt. Genom strömflödet i kabeln kan man skapa ett motriktat magnetfält med samma styrka och därmed eliminera restmagnetismen. Ju fler lindningar, desto större är den maximala fältstyrkan som kan alstras med konstant ström. Degauss 600 erbjuder två olika metoder för avmagnetisering. Med Degauss-funktionen börjar man med ett högt strömvärde och minskar därefter strömflödet stegvis med alternerande polaritet. Därmed blir komponenten avmagnetiserad. Denna metod fungerar mycket bra på korta komponenter. I motsats till detta är activgauss-metoden lämplig för långa komponenter som rörledningar. Vid denna metod flödar en kontinuerlig ström genom lindningarna varvid ett permanent magnetfält alstras.
[casestudy_effectiv] => Degauss 600 med sin låga vikt och kompakta storlek är lämplig att använda på byggarbetsplatser och dessutom lätt att manövrera. Tack vare fjärrstyrningen kan strömkällan placeras utanför byggropen. Med den kan man lösa problemet med magnetism vid reparationssvetsningar i rörledningskonstruktioner även vid kraftiga magnetfält. Användningen av avmagnetiseringsaggregatet på terranets bw GmbH:s byggarbetsplatser har inte bara övertygat själva driftsföretaget, utan även entreprenören Leonhard & Weiss GmbH samt den ansvarige, oberoende övervakningsingenjören från 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] => Administrera svetsutrustningen med ett enda system
[benefit_subtext] => Modern svetsutrustning ska naturligtvis leverera högre produktivitet och kvalitet och samtidigt bidra till att sänka kostnader. Svetshanteringssystem blir mer och mer relevanta ...
[teaser] => Modern svetsutrustning ska naturligtvis leverera högre produktivitet och kvalitet och samtidigt bidra till att sänka kostnader. Något som blir mer och mer relevant är dock svetshanteringssystem, som administrerar och dokumenterar relevanta data och uppfyller samtliga krav på kvalitetssäkring. Det var just med detta system och det fullständiga erbjudandet som EWM kunde övertyga POLLRICH. 2018 ställde tillverkaren av industrifläktar om hela produktionen till EWM och sedan dess köper de även in alla slitagedelar och tillsatsmaterial därifrån.
[casestudy_status] => POLLRICH tillverkar industrifläktar. De ventilerar tunnelanläggningar, varuhus och hela flygplatsbyggnader med luft. Inom (petro-)kemi-, trä- och betongindustrin transporterar de även frätande och aggressiva medier. För sådana säkerhetskomponenter måste samtliga krav på dokumentationen följas för att uppfylla alla krav på kvalitetssäkring och spårbarhet.
[casestudy_solution] => EWM Xnet är svetshanteringssystemet från EWM. Det stöder, övervakar och dokumenterar hela tillverkningsprocessen för en komponent, från förberedelserna av arbetet till efterberäkningarna. Samtliga svetsdata och förbrukningsvärden registreras i realtid och svetsresultaten kan analyseras, kontrolleras och administreras. Dessutom stöder Xnet komponentadministrationen, skapandet av svetsföljdsplaner och tilldelningen av svetsanvisningar. Vid behov kan man även administrera och skapa dessa själv. Och inte minst ingår den individuella övervakningen av svetsarnas provningscertifikat samt tilldelningen av individuella tillträdesbehörigheter i portföljen från Xnet.
[casestudy_effectiv] => ”Med Xnet är det möjligt att administrera hela svetstekniken med ett enda system”, säger Thorsten Wirtz, svetsförman och chef för kvalitetssäkringen hos POLLRICH, med ett leende. Eftersom svetsmaskinerna, trådmatarsystemen och svetsbrännarna också kommer från EWM är datautväxlingen inom systemet och mellan dess komponenter optimalt anpassad och arbetet med Xnet blir enkelt, snabbt och säkert.
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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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[customer] => Hüffermann Transportsysteme GmbH
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[benefit_headline] => Upp till 10 % fler släpvagnar per arbetsplats och år.
[benefit_subtext] => I början var önskemålet att minska övertiden till noll. Resultatet blev en omställning av hela produktionen till EWM-produkter ...
[teaser] => I början var önskemålet att minska övertiden till noll. Resultatet blev en omställning av hela produktionen till EWM-produkter: Hüffermann Transportsysteme GmbH i Neustadt (Dosse) kunde efter innovations- och teknologirådgivningen från ewm maXsolution minska arbetstiden med 15 procent bara på en arbetsplats och dessutom öka produktionen med 10 procent. Investeringen betalade sig själv på mindre än ett år – tillräcklig anledning att fortsätta arbeta med EWM i framtiden.
[casestudy_status] => ”Från början ville vi bara minska vår ständiga övertid. Då kunde vi bara klara våra leveranstider med övertid”, förklarade Torsten Völker, produktionschef för ”dragna enheter” hos Hüffermann Uppgiften som Toralf Pekrul, chef för EWM-filialerna Wittstock och Rathenow, och EWM-utesäljare Jeffrey Kube fick var att först optimera produktionen på en arbetsplats så att övertid inte skulle behövas mer.
[casestudy_solution] => Under rådgivningen från ewm maXsolution betraktade specialisterna från EWM hela processkedjan och synade denna i detalj under tillverkningsförloppet, från gas- och trådmatningen via svetsprocessen och fram till kontaktröret. EWM-specialisterna optimerade inställningarna på varje justerskruv och anpassade alla steg i produktionskedjan till varandra.
[casestudy_effectiv] => ... blev en fantastisk tidsbesparing och investeringen betalade sig på mindre än ett år: Genom att tillämpa många av de åtgärder som EWM föreslog kunde företaget hitta en lösning som passade både de anställda och marknadens allt högre krav. Arbetstiden reducerades med upp till 15 procent, samtidigt som produktionen ökade med 10 procent och gasförbrukningen minskade med en tredjedel, med samma kvalitet. Detta bevisades även av företagets egna siffror och övertygade marknadsledaren för system för transport- och återvinningsfordon att ställa om hela svetstillverkningen med 68 arbetsplatser till EWM. Med tidsbesparingen som kom med helhetskonceptet kunde omsättningen inte bara bibehållas utan till och med ökas. För Völker var det en avgörande aspekt eftersom tiden är begränsad och inte till salu.
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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] => Bara en fjärdedel av svetstiden
[benefit_subtext] => Trots riktlinjerna med strängare industristandarder för högvolymkemikalier kunde AST Apparatebau GmbH i Siegerland minska svetstiden med upp till 75 procent genom att använda tigSpeed...
[teaser] => Trots riktlinjerna med strängare industristandarder för högvolymkemikalier kunde AST Apparatebau GmbH i Siegerland minska svetstiden med upp till 75 procent genom att använda tigSpeed. tigSpeed är ett trådmatarsystem för TIG-svetsning. Tråden matas inte bara kontinuerligt som vid MIG/MAG-svetsning utan den dras hela tiden automatiskt ut ur smältbadet. Trådmatningen imiterar därmed den manuella svetsprocessen vid TIG-svetsning.
[casestudy_status] => Kylslangarna som är nödvändiga för rörverk svetsas vanligtvis på som halvrör på utsidan av behållarens hölje. På stora rörverksbehållare kan foglängderna snabbt komma upp i flera hundra meter. För att uppfylla industristandarderna måste rotsträngarna svetsas med TIG-metoden. Toppsträngen svetsas därefter med MAG-metoden. Tillverkningstiden för en meter TIG-fog ligger med ungefär 25 minuter märkbart över svetshastigheten för MAG-svetsning.
[casestudy_solution] => Med trådmatarsystemet tigSpeed för TIG-svetsning är en kontinuerlig TIG-svetsning med ändlös tillförsel av tillsatsmaterial möjlig utan skarvställen på grund av byte av svetsstavar. Och: Genom att använda hettråd kan mer material smältas på och följaktligen kan man svetsa med högre hastighet.
[casestudy_effectiv] => I dag behöver svetsarna på AST Apparatebau bara fem minuter för en meter kontinuerlig TIG-svetsfog med tigSpeed och hettråd. Det innebär en tidsbesparing på ungefär 75 procent jämfört med den manuella svetsprocessen. Denna metod visar ytterligare en fördel för den tekniska verkställande direktören Joachim Jung: ”Särskilt attraktiv vid TIG-svetsning med tigSpeed är möjligheten att ytterligare automatisera svetsuppgiften.” Även om företaget inte har testat denna metod har den stora produktivitetsökningen med de nya metoderna övertygat så att man nu även ska svetsa stutsarna med tigSpeed och hettråd – och stutsar finns det en hel del av på rörverksbehållarna.
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[metakey] =>
[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] => Minska outnyttjad tid med upp till 50 procent
[benefit_subtext] => Från början var det bara en idé från EWM:s utesäljare att svetsa rör-fläns-förbindelser med TIG. Resultatet blev besparingar på upp till 50 procent ...
[teaser] => Från början var det bara en idé från EWM:s utesäljare att svetsa rör-fläns-förbindelser med TIG. Det slutade med besparingar på upp till 50 procent bara genom att minska den outnyttjade tiden. Tidigare hade TIG-svetsningen hos Hering AG (Gunzenhausen) bara en underordnad betydelse. EWM lånade ut en trådmatarenhet tigSpeed för TIG-svetsningen till företaget som tillverkar värmeväxlare. Efter bara en halv timme uppnådde svetsaren bättre resultat än demonstratören. Och när maskinen skulle hämtas efter en veckas provtid kivades svetsarna om vem som skulle få lov att arbeta med tigSpeed.
[casestudy_status] => Hos Hering används ofantligt många rör: Många rör sammanfattas i rörbuntar och sätts sedan in i ytterligare rör. Hos Hering ABG hade man valt att använda sig av manuell elektrodsvetsning och MIG/MAG-svetsning för tillverkningen av de här värmeväxlarna. TIG hade bara en underordnad betydelse. Men TIG-svetsningen är som gjord för rör-fläns-förbindelser. Metoden levererar kvalitativt förstklassiga skarvar samtidigt som värmeinträngningen minskar och vid minimal sprutbildning. Det innebär mycket mindre efterarbete. Visserligen utförde svetsarna arbetet med bara en hand vid manuell elektrodsvetsning och var vana vid den kontinuerliga trådmatningen vid MIG/MAG-svetsning.
[casestudy_solution] => Utesäljaren föreslog att rör-fläns-förbindelserna skulle sammanfogas med TIG och tigSpeed, eftersom detta kräver svetsförbindelser av extra hög kvalitet. För att bemöta den första skepsisen lånade han ut en lämplig maskin. tigSpeed är en TIG-trådmatarenhet. Den härmar den manuella TIG-svetsningen genom att den kontinuerliga trådmatningen överlagras av ytterligare fram- och bakåtrörelser. Tillsatsmaterialet dras hela tiden ut ur smältbadet och övergår droppvis. Vid hettrådsvetsning förvärms tillsatsmaterialet. Det ökar smälteffekten ytterligare, materialet flyter mycket bättre och resultatet är en mycket jämn fogbild.
[casestudy_effectiv] => Fördelarna är uppenbara: Tack vare den automatiserade trådmatningen kan svetsaren helt och full koncentrera sig på svetsprocessen. ”En fläns kan svetsas fast på röret i ett enda arbetssteg – utan skarvar till följd av svetsstavsbyte”, sammanfattar Valmir Xhaferi, svetsare hos Hering AG metoden. Dessutom förblir den andra handen ledig tack vare den automatiska matningen och kan hjälpa styrhanden. ”Det underlättar mycket just vid långa fogar”, menar Xhaferi. Christian Rasch, CEO/direktör för Hering AG, är övertygad om att besparingarna i företaget kommer att bli ännu större med kortare riggningstider.
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[metakey] =>
[metadesc] => Ursprünglich war es nur eine Idee des Außendienstmitarbeiters von EWM, Rohr-Flansch-Verbindungen mit WIG zu schweißen. Am Ende standen Einsparungen von bis zu 50 Prozent
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[benefit_headline] => Högre svetskvalitet och minskade kostnader tack vare ewm maXsolution
[benefit_subtext] => När beräkningen spårade ur vid tillverkningen av en större order rådfrågade MESA chefen för EWM-filialen i Rathenow. Redan inom tre månader ...
[teaser] => När beräkningen spårade ur vid tillverkningen av en större order rådfrågade MESA chefen för EWM-filialen i Rathenow. Inom tre månader ställde företaget om hela sin tillverkning efter att innovations- och teknologirådgivningen ewm maXsolution hade gjort en analys. Med den nya svetsutrustningen från EWM kan företaget idag inte bara tillverka den högsta kvalitetsklassen CL1 utan kan även sänka kostnaderna påtagligt.
[casestudy_status] => Precis som de flesta medelstora företag i metall- och stålbranschen måste även MESA tillverka så billigt som möjligt, men samtidigt ha en mycket hög kvalitet, och om det går, hitta lukrativa nischer på marknaden. En sådan nisch hittade MESA inom tillverkningen av rälsbundna fordon som har mycket höga kvalitetskrav. Tillverkningen med konventionell svetsutrustning och maskiner från andra tillverkare hade dock visat sig vara så kostsam att det var svårt att få det att gå ihop ekonomiskt. Företaget måste se sig om efter alternativ tillverkning.
[casestudy_solution] => Inom ramen för innovations- och teknologirådgivningen ewm maXsolution granskade och analyserade EWM:s experter varje steg i tillverkningsförloppet över hela processkedjan. ”Rådgivningen var inte bara kompetent och proaktiv, utan den omfattade även nya lösningar på problem som vi ännu inte hade insett”, sammanfattar Pierre Mack, verkställande direktör för MESA Metall-Stahlbau GmbH. Genom användningen av svetsmaskiner och svetsbrännare från EWM samt de innovativa svetsprocedurerna uppnåddes besparingar inom alla tänkbara områden: när det gällde svetstiden, materialet, skyddsgasen, tillsatsmaterialet, strömförbrukningen, slitagedelarna och speciellt vid efterarbetet.
[casestudy_effectiv] => ”Vi lyckades med att minska produktionstiden för svetsning och slipning med så mycket som 57 procent”, rapporterar Mack. Anledningen var framförallt den nya svetsprocessen forceArc puls. Denna innovativa ljusbåge utmärker sig med en låg värmeinträngning, är i princip sprutfri och ger en högre svetshastighet. Utöver den manuella svetsningen, som behöver mycket korta inarbetningstider, kunde MESA även mekanisera vissa svetsprocesser. Mekaniseringen gav en stabil och konstant svetsprocess med märkbart ökad kvalitet. Investeringen har redan betalat sig efter mycket kort tid. Framför allt har MESA:s tillverkningsspektrum ökat avsevärt: ”Många av uppdragen hade vi absolut inte fått om vi inte kunde svetsa så här”, kungör Mack. ”Med vanliga maskiner behövde vi inte i vissa fall inte ens försöka.”
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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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[sectorId] => COM_EWMREFERENCE_ROHRLEITUNGSBAU
[materialId] => ["COM_EWMREFERENCE_NICKEL_BASIS"]
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[benefit_headline] => Fyllnadssvetsning med upp till 13,8 kg smälteffekt
[benefit_subtext] => ITAG Valves & Oilfield Products GmbH
[teaser] => Kulkranarna och avstängningskranarna från ITAG Valves & Oilfield Products GmbH används i pipelines över hela världen – såväl i torra sandöknar som i evig is. Där måste de hålla i mer än 25 år utan att de frätande medierna kan komma åt dem. Med en kombination av MAG-svetsning och extra tillförsel av värmetråd fördubblar EWM-tekniken smälteffekten vid första försöket. Samtidigt är det viktigt att samtliga parametrar är stabila eftersom processen är extremt känslig trots sin styrka.
[casestudy_status] => NBA 625 är en nickelbaserad legering med mycket god korrosionsbeständighet – dock bara så länge den tekniska sammansättningen bibehålls. Speciellt kan järnhalten påverka materialegenskaperna. Det är alltså mycket svårt att med termiska metoder föra på ett NBA 625-lager på kolhaltigt stål utan att blanda de olika materialen för mycket och bibehålla renheten i det påförda lagret. Dessa lager svetsas till stor del mekaniskt, antingen med MAG-metod och en smälteffekt på 5 kg per timme eller med TIG och en smälteffekt på 2,5 kg per timme.
[casestudy_solution] => Målet är att uppnå en så hög smälteffekt som möjligt samtidigt som uppblandningen hålls så låg som möjligt. Även om till och med tillämpningsteknikerna hos EWM till en början var tveksamma, så valde man att kombinera MAG-svetsningen hos ITAG med en extra trådmatning med hjälp av varmtrådsmataren tigSpeed. Anledningen var att man ville föra in mer ljusbågsenergi i tillsatsmaterialet. Det leder till att en mindre andel av grundmaterialet smälter, vilket främjar renheten hos det påförda lagret. På så sätt kan transportkapaciteten och därmed smälteffekten fördubblas på en och samma gång.
[casestudy_effectiv] => Smälteffekter på upp till 13,8 kg per timme är mer än dubbelt så mycket som vid MAG-svetsning och fyra gånger så mycket som vid TIG-hettrådssvetsning. Dessutom visar de tätt liggande svetssträngarna på mycket låg vågighet (mindre än 0,5 millimeter) tack vare trådmatningens och svetsparametrarnas extremt höga stabilitet. Det innebär att svetsningarna på det påförda lagret bara behöver göras ungefär 1 mm högre än det senare börvärdet som uppnås vid spånskärning. På så sätt kan ITAG utöver tidsbesparingen även spara in på en stor mängd dyra material.
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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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[benefit_headline] => Med EWM kan man bevisa kvalitet
[benefit_subtext] => Desto mer kritisk en komponent är, desto högre är kraven på kvalitetscertifikat och spårbarhet Med kvalitetsstyrningsprogramvaran ewm Xnet finns dessa data alltid tillgängliga – och kan prestera ännu mer ...
[teaser] => Desto mer kritisk en komponent är, desto högre är kraven på kvalitetscertifikat och spårbarhet Med kvalitetsstyrningsprogramvaran ewm Xnet finns dessa data alltid tillgängliga – och kan prestera ännu mer. På Machinefabriek & Apparatenbouw Geha b.v. i Nederländerna uppenbarade en analys av svetsdata huvudtid och outnyttjad tid. Om den outnyttjade tiden var för hög analyserade de ansvariga orsakerna och vidtog åtgärder som stöd vid hanteringsuppgifter eller efterleverans av förbrukningsmaterial till arbetsplatsen. Att reducera outnyttjad tid innebär ökad produktivitet, medan mycket outnyttjad tid innebär höga extrakostnader.
[casestudy_status] => Värmeväxlarna, inklusive stålkonstruktionerna, som tillverkas av Geha används världen över under klimatmässigt hårda förhållanden. Geha hade redan svetsmaskiner från EWM; den äldsta var från 2002. Målet var att koppla samman samtliga maskiner i ett nätverk och att kontinuerligt registrera samtliga svetsparametrar för att alltid säkert kunna intyga svetsfogskvaliteten. Enligt Franc van Wilgens, verkställande direktör för företaget Geha B.V., blir kontinuerlig svetsdataregistrering allt viktigare. Det är bara med kontinuerligt registrerade data som man rent faktiskt kan bevisa kvaliteten. Dessa krav gäller redan idag för att uppfylla SS-EN 1090.
[casestudy_solution] => När nätverkskablarna hade förinstallerats – det finns för mycket stål i tillverkningen hos Geha som skulle störa en Wi-Fi-anslutning – tog det bara en dag att ansluta alla fem svetsmaskinerna till nätverket. Sedan dess registrerar ewm Xnet helt automatiskt alla data från de fem svetsmaskinerna online. Svetsförmannen kan analysera och utvärdera data såväl i realtid som i efterhand. På externa byggarbetsplatser registreras data offline och sparas på ett lagringsmedia. Därefter överförs data till servern.
[casestudy_effectiv] => ewm Xnet säkrar svetskvaliteten, gör det möjligt att bevisa den och hjälper svetsarna att arbeta förutseende. Med hjälp av svetsdata kan man fastställa optimala tidpunkter för byte av slitagedelar, för att byta dessa så sent som möjligt. Det ger dubbla besparingar: Fortfarande fungerande delar byts inte ut och arbetstidsbortfallet flyttas så långt fram som möjligt. Det ökar tiden för produktiv svetsning. Genom att använda ewm Xnet är man på Geha alltid säker på att man har tillverkat den beställda kvaliteten – och kan bevisa det.
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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] => Upp till 60 % besparing genom mindre fogöppningsvinkel
[benefit_subtext] => Färre svetssträngar innebär kortare svetstid. Det ger lägre värmeinträngning, vilket reducerar svetsdeformationen och därmed riktningsarbetena. Sammantaget kan det leda till besparingar på lön-, material- och energikostnader på upp till 60 % –
[teaser] => Färre svetssträngar innebär kortare svetstid. Det ger lägre värmeinträngning, vilket reducerar svetsdeformationen och därmed riktningsarbetena. Sammantaget kan det leda till besparingar på lön-, material- och energikostnader på upp till 60 % – som för Siemens. Dessa resultat har Siemens uppnått genom att använda den innovativa svetsprocessen forceArc från EWM. Omställningen till EWM-svetsprocessen medförde ytterligare en fördel: Även svetsrökutsläppen reducerades kraftigt vilket skonar svetsarnas hälsa.
[casestudy_status] => Högre kvalitet samtidigt som kostnaderna minskar är en av de vanliga kraven från kunderna. Därför är svetsspecialisterna på Siemens inom området svetsteknik alltid på jakt efter besparingsmöjligheter. Då kom presentationerna av EWM:s svetsexperter på DSV-kongressen om nya typer av ljusbågar och framtidsinriktade tillverkningsmetoder till sin rätt. Redan på kongressen avtalades en demonstrationstid.
[casestudy_solution] => Den innovativa EWM-svetsprocessen forceArc utmärker sig genom sin värmeminimerade, riktningsstabila och tryckstarka ljusbåge. Den uppnår ett stort inträngningsdjup med samtidigt färre inträngningsspår. Därmed kan man minska öppningsvinkeln märkbart. Minskningar från ursprungliga 60° till 30° är vanligt. Det reducerar även förarbetet. Även antalet svetssträngar minskas kraftigt, vilket minskar svetstiden och materialförbrukningen i motsvarande grad. Viktigare är dock den lägre värmeinträngningen: Den ger en avsevärd minskning av svetsdeformeringen och sparar i sin tur in många riktningsarbeten.
[casestudy_effectiv] => Den stora besparingen i arbetstid på grund av färre svetssträngar, eftersom fogöppningsvinkeln har reducerats vilket leder till minskade kostnader för gaser och ström till svetsmaskinen, dessutom lägre värmeinträngning som leder till mindre deformering och därmed till mindre efterarbete: Det är effekterna av att den innovativa svetsprocessen forceArc används hos Siemens. Svetsprocessen är dessutom i stort sett fri från sprutbildning och svetsrökutsläppen avsevärt mindre. Därmed skonas svetsarnas hälsa och efterarbetena minimeras. Totalt ledde omställningen till den innovativa svetsprocessen forceArc på Siemens till totala besparingar om 60 % på lön-, material- och energikostnader – en ekonomiskt kännbar framgång.
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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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[benefit_headline] => Kvaliteten blir bättre – konkurrensförmågan ökar
[benefit_subtext] => Den tryckstarka riktningsstabila forceArc-ljusbågen från EWM har rentav inlett en teknisk förändring av produktionen av tunga stålstommar – även för komponenter med stora volymer, som de som Plauen Stahl Technologie GmbH bearbetar ...
[teaser] => Den tryckstarka riktningsstabila forceArc-ljusbågen har rentav inlett en teknisk förändring av produktionen av tunga stålstommar – även för komponenter med stora volymer, som de som Plauen Stahl Technologie GmbH bearbetar. Med forceArc bildas stödsträngen nästan av sig själv, inklusive det nödvändiga a-måttet. Dessutom uppfylls samtliga kvalitetskrav. Därmed underlättas svetsarbetet. Det leder också till att man slipper två arbetssteg.
[casestudy_status] => Stora volymer av komponenter vars lättaste delar väger 50 ton tillhör det dagliga arbetet hos Plauen Stahl Technologie GmbH (PST). Komponenterna är brosegment som till bron vid Millau i Frankrike, stativ för kraftverksanläggningar eller slussportar med imponerande spännvidder. Det är just vid sådana konstruktioner med högsta tekniska krav och arkitektoniskt extravaganta projekt som säkerhet och kvalitet har högsta prioritet.
[casestudy_solution] => Den innovativa svetsprocessen forceArc från EWM har övertygat de ansvariga med svetsresultaten: god bindning vid djup inträngning och enastående rotbildning och flankbearbetning. Och forceArc innebär fördelar även för den ekonomiska sidan: Minskat för- och efterarbete och besparingar när det gäller lön-, material-, gas- och energikostnader minskar kostnaderna för hela fogprocessen – med högre produktivitet. Svetsarna arbetar också gärna med forceArc-svetsprocessen.
[casestudy_effectiv] => Om man hos PST tidigare svetsade samman sträckor på mer än 500 mm med underpulversvetsning fogar man i dag samman sträckor på upp till 800 mm och materialtjocklekar på upp till 80 mm med forceArc-processen – vilket märkbart minskar riggningstiden. De outnyttjade tiderna vid svetsning av HV-fogar kunde reduceras kraftigt genom att använda forceArc, eftersom puts- och fogningsarbetena bara är minimala. Rotinsjunkningen uppnås med säkerhet och utseendet kan styras definierat. Därmed ger rotinsjunkningen en kälfog med fastställd hålkäl, motsvarande överhäng och nödvändigt a-mått.
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[metadesc] => Der druckvolle richtungsstabile forceArc-Lichtbogen von EWM hat förmlich einen Technologiewandel in der Produktion des schweren Stahlhochbaus eingeläutet – auch bei großvolumigen Bauteilen, wie sie die . Plauen Stahl Technologie GmbH bearbeitet
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[name] => Leadec Holding BV & Co. KG
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[benefit_headline] => Kundnytta upphöjt till fyra
[benefit_subtext] => Även om den manuella elektrodsvetsningen hade föreskrivits som svetsprocedur övertygade pipeSolution från EWM även TÜV Hessen och certifierades på kort tid för användning på Großkraftwerk Mannheim (GKM) ...
[teaser] => Även om den manuella elektrodsvetsningen hade föreskrivits som svetsprocedur övertygade pipeSolution från EWM även TÜV Hessen och certifierades på kort tid för användning på Großkraftwerk Mannheim (GKM). Därmed kunde Voith Industrial Services minska antalet arbetsmoment och fyrdubbla tillverkningshastigheten jämfört med manuell elektrodsvetsning. Efter bara 14 dagars utbildning av svetsarna på svetsmaskinen alpha Q och pipeSolution-processen godkändes de för arbete i block 9 på GKM efter att de hade avlagt ett prov på den svetstekniska utbildningsanstalten (SLV) i Mannheim.
[casestudy_status] => Diameter på upp till 3 400 mm och väggtjocklekar på upp till 30 mm är vanliga dimensioner för kylvatten- och fjärrvärmeledningarna i GKM. För rör i sådana dimensioner finns det inga förtillverkade böjar. Allting måste tillverkas segment för segment och exakt svetsas ihop på byggarbetsplatsen. Kanterna förses med en fasvinkel på 60°. Efter svetsning av fogsträngen med den gamla manuella elektrodsvetsningen måste hela strängen fogas i och en stödsträng svetsas.
[casestudy_solution] => Den innovativa EWM-svetsprocessen är speciellt konstruerad för svetsning av rörledningar. Utan badsäkringen kan rotsträngen läggas med pipeSolution och massiv tråd i ett enda arbetsförlopp. Därefter svetsas fyllnadssträngarna och toppsträngarna direkt på rotsträngen med rörtråd. Fogningen kan man hoppa över helt. Eftersom svetsmaskinerna är utrustade med två trådmatarenheter för två olika tillsatstrådar från rullen – massiv tråd och rörtråd – byter svetsaren bara svetsbrännare efter att rotsträngen har slutförts och aktiverar den andra trådmatarenheten. Därmed svetsar han fyllnads- och toppsträngarna.
[casestudy_effectiv] => Upp till fyra gånger snabbare kunde svetsarna från Voith svetsa fogarna med hjälp av de nya svetsprocesserna och den nya maskinutrustningen. Dessutom tillkommer en minskning av fasvinkeln från 60° till 50°. Därmed reduceras fogens tvärsnittsarea som ska fyllas med mer än 13 procent, vilket leder till enorma besparingar av tillsatsmaterial på mer än hundra kilo. pipeSolution övertygade alla deltagare som den snabbaste och säkraste processen för rotsvetsning med hög kvalitet på plåtar och rör i alla positioner.
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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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[benefit_headline] => Utrustningsskifte hos Hische med de båda nya svetsprocesserna coldArc och forceArc
[benefit_subtext] => Hische AG etablerade två innovativa svetsprocesser från EWM i sin stålkonstruktion: coldArc och forceArc. Resultatet blev hög svetshastighet och en möjlighet för företaget att ge sig in på en helt ny marknad.
[teaser] => Hische AG etablerade två innovativa svetsprocesser från EWM i sin stålkonstruktion: coldArc och forceArc. Resultatet blev hög svetshastighet och en möjlighet för företaget att ge sig in på en helt ny marknad. coldArc, en modifierad kortljusbåge, ersätter TIG-svetsningen – med MAG-hastighet. forceArc-processernas tryckstarka ljusbåge ökar också svetshastigheten. Med den kan man minska fogöppningsvinkeln. Därmed minskar antalet svetssträngar, vilket sparar tid och material, och värmeinträngningen minimeras. Dessutom genomsvetsas kälfogar redan med en sträng – utan stödsträng.
[casestudy_status] => Det fanns två stora områden hos Hische där svetstekniken spelade en betydande roll. Det ena var runda fogar på rörkomponenter för gasturbinkraftverk. De runda fogarnas rotsträngar på rörkomponenterna svetsades med TIG. Det andra området var svetsningen av långa fyrkantrörsprofiler. För att uppnå säkrare svetsresultat för de tre meter långa komponenterna med MIG/MAG-svetsmaskiner måste man först lägga under en skena vid varje hörn. Det var enda sättet att förhindra sättning av fogen och därmed otillräcklig kvalitet.
[casestudy_solution] => coldArc, en modifierad kortljusbåge för MIG/MAG-metoden, levererar önskade resultat för rotsvetsningen hos Hische, som tidigare utfördes med TIG. Svetshastigheten är avsevärt högre för MIG/MAG- än för TIG-svetsning. forceArc-ljusbågen är målinriktad och koncentrerad och utmärker sig genom djup inträngning, god flankbearbetning och sprutfri svetsning. Vid svetsning av fyrkantrörsprofilerna kan HV-fogarna på den ena sidan genomsvetsas och stödsträngen bildas automatiskt på baksidan.
[casestudy_effectiv] => Genom att svetsa rotsträngarna med MIG/MAG och coldArc i stället för TIG ökade svetshastigheten med 40 procent – med i stort sett likvärdig kvalitet. Genom att använda forceArc vid svetsningen av kantprofilerna kan Hische hoppa över förtillverkningen och häftningen av skenorna – något som ger stora besparingar såväl på material som tid. Med forceArc spänns de olika delarna fast och genomsvetsas sedan. Det innebär en besparing på två timmar för varje kranbom, utöver besparingarna på gas och tillsatsmaterial. Med forceArc kunde även öppningsvinkeln för svetsfogen reduceras, vilket minskar svetstiden, värmeinträngningen och därmed även deformeringen. Tack vare den höga svetsfogskvaliteten kunde Hische erövra en ny marknad med de nya svetsprocesserna: marinteknik, där kraven på produktkvalitet och -säkerhet är extra höga.
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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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Gebrüder Stahl is working with EWM.
TIG welding is faster than MAG welding
Bell Equipment Deutschland 2020
Fordonstillverkning
Bell establishes own welding production line with EWM
Chamber of Commerce Aurich 2020
Övrigt
HWK Aurich places trust in EWM. Aurich Chamber of Commerce 2020
Ebner Industrieofenbau GmbH
Stålkonstruktion
Every function accessible on the welding torch – Ebner Industrieofenbau GmbH 2019
Schoeller Werk GmbH & Co. KG
Stålkonstruktion
Top quality in continuous use at Schoeller Werk GmbH & Co. KG
Ebner Industrieofenbau GmbH 2019
Stålkonstruktion
Game, set och match inom svetsteknikens alla kategorier
MESA
Stålkonstruktion
Högre svetskvalitet och minskade kostnader tack vare ewm maXsolution
Siemens
Tillverkning av rälsbundna fordon
Upp till 60 % besparing genom mindre fogöppningsvinkel
Plauen Stahl Technologie GmbH (PST)
Stålkonstruktion
Kvaliteten blir bättre – konkurrensförmågan ökar
Hische AG Stahlbau und Industrieanlagen
Entreprenad
Utrustningsskifte hos Hische med de båda nya svetsprocesserna coldArc och forceArc
