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Game-like technology Kemppi’s Pro Trainer is based on CS WAVE, which was developed by French company Diginext and is already in use in more than 150 educational institutions, around the world. The product was ‘The technology created through a Europeanprovides a new tool Union-funded project in for communication 2002–2004. between the student ‘An instructor at and the teacher.’ AFPA, a vocational training organisation in France, noticed that playing with game consoles such as the Nintendo Wii effectively developed young people’s co-ordination. He realised that it was possible to use similar technology to refine the motion paths used in welding,’ says CS WAVE Product Manager Laurent Da Dalto. Thirty months and around a million euros later, the first CS WAVE system was unveiled in March 2004 in Paris. The product and the technology it is based on have been further developed since then. However, Da Dalto stresses that virtual learning is not intended to replace traditional methods of teaching welding, even in the future. He explains: ‘The technology provides a new tool for communication between the student and the teacher. It allows making significantly more observations than had previously been possible in a real-world welding situation. For example, in a real welding situation, the teacher is not able to observe the student’s hand movements perfectly.’ ‘In addition, virtual practice accelerates learning and helps the student to understand the significance of motion paths,’ he says. The virtual learning environment is already being used in a number of fields. ‘Our latest applications are used to practise painting, spot welding, and NDT (non-destructive testing),’ Da Dalto explains. ”The ProTrainer gives its user constant feedback and instructions.” ‘Additionally, the first few times, the arc burn, runny weld pool, rattling noise, and spatter are sure to take the attention away from hand positions,’ he attests. A personal trainer that never ceases to spur one on The ProTrainer can be used for MMA and MIG/MAG welding practice in flat, horizontal, and vertical positions alike. The device enables one-on-one teaching, as individual exercises can be tailored for each student. The teacher does not need to be present: students can work independently. Nykänen says: ‘The teacher can use a computer to define personal, passwordprotected tasks for each student. The results are saved in the device memory and can be reviewed together afterwards.’ The tasks may focus on the steadiness of the motion, speed, or work angles of the welding torch or on its distance from the target piece. The hardest part for the student generally is to manage all of these elements simultaneously, remaining within the prescribed tolerance levels. The ProTrainer gives its user constant feedback and instructions. ‘The teacher can also test how well the training has been taken in, by turning off the instructions that guide the user,’ says Nykänen. The ProTrainer has been developed primarily for basic welding training at educational institutions, but it has also attracted interest from companies. ‘Companies can have welders carry out various kinds of tasks to help them stay in touch with their trade,’ Nykänen says. The Kemppi ProTrainer was unveiled in Finland in early November 2010, and it has attracted great interest ever since. The device is now also available in Norway, Sweden, and Denmark. Texts: Pirjo Kemppinen 20 Kemppi ProNews 2011
Could I become a welder I have always been fascinated by welding. The burning welding arc, scattering sparks, crackling sound and misty smoke create a capturing atmosphere that is controlled by the person behind the mask. For the same reasons, the sight is also awesome. I pulled my courage up and decided to try welding when I was offered the chance to practice with a Kemppi ProTrainer. Laurent Da Dalto lists the pluses and minuses of learning welding in a virtual environment: Benefits: + Reduces material and equipment costs. + Accelerates learning. + Improves communication between the teacher and student. + Reveals information that cannot be seen with traditional methods. + Enhances the image of welding by linking it with new technology and a game-like environment. + Boosts and supports self-study. Challenges: – In some cases there may be critical attitudes towards the integration of IT and high technology in a traditional training process. Welding manager Juha Nykänen adjusts the ProTrainer display panel at a suitable height. When he clicks the options on the panel menus to choose the parameters for my practice session, the welding torch looks quite real and works like a joystick in a console game. My first task is probably the easiest possible. I’ll concentrate in keeping the welding torch at the correct distance from a fillet joint for about 30 cm in length. Vertical down welding offers the possibility to stand solidly on my own feet. Because I’m using a virtual training device I don’t need any protective safety equipment. In practice the welding joint is indicated by green lines in the display panel, and the spot representing the weld pool runs between them. The blue lines indicating the distance of the torch must remain above the green lines. If the tip of the torch wanders too far or too close to the joint, the blue lines become yellow to warn the user or red to give an alarm. I place the tip of the torch on top of the weld pool and pull the trigger. My eyes are fixed on the spot moving down, hand is sweating when I squeeze the handle an I feel my left index finger shaking while supporting the tip of the torch. My performance is registered by an indicator that reminds me of an electrocardiogram. Two thirds of the way the arc progresses surprisingly steadily, but then it suddenly jumps. That is where I breathed for the first time. My practice becomes more difficult each time. Eventually the various indicators on the panel show the distance of the welding torch, torch angle, and speed and steadiness of the motion, and give out alarms of these features. When the trigger is pulled, the weld pool rattles inevitably downwards. I try to keep it at the correct distance compared to the speed, but then the torch angle goes all wrong. The display panel is filled with messages which I cannot even observe at the same time, to say nothing of adjusting my performance according to them. And how to keep my hand steady until the end of the welding joint Should I courtsey or bow to reach the bottom of the joint For a first timer, the experience is like an educational game. I get more and more enthusiastic each time, and I’m already wondering who to challenge to a duel. The positive experiences in the virtual world relieve my tension when I move on to try a real welding situation under guidance of welding instructor Hannu Saarivirta. The preparations take a lot more time and effort. My teacher adjusts the welding machine, tapes the weld pieces together, and leaves them to wait until I have put the protective coat, gloves and the welding mask on. At that time the sweat sticks my hair on my forehead. The view through the visor is dim and the feel through thick gloves is clumsy. My objective is to weld a similar joint as in the virtual world. I bravely pull the trigger, but at that very instant let it go. The igniting arc, a couple of sparks and The first weld of my life. 1.5 mm thick steel sheets have been joined by a fillet joint created by vertical welding. The MinarcMig 170 Adaptive was an excellent choice for a beginner, as all you need to adjust is the voltage and sheet thickness. Although, I was not able to do even that myself. a rattling noise make me instinctly back up. At the second try I keep the trigger pulled and weld all the way to the bottom of the joint. There are no colours, lines or tick marks to guide my movements. If the system should draw a curve of this, it would certainly be far from even. It is however comforting to hear that the joint I managed to create, although it was welded too slowly and burned almost through, is strong. The experience was lots of fun, and made me appreciate welders even more. They make their work seem so easy and effortless. Now I know why: they are true professionals. − Pirjo Kemppinen Kemppi ProNews 2011 21
Page 1 and 2: PRO News Kemppi customer magazine 2
Page 3 and 4: editorial One of the best ways to f
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Page 15 and 16: Is what you see, what you get Today
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Page 19: Innovation: Kemppi ProTrainer ProTr
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Page 27 and 28: Case: Peikko Oy, Lahti, Finland Del
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