ROBOTS ARE TAKING OVER THE WORLD!!!

Ok, not the whole world – just the job parts…

ABB’s VirtualArc robot welding simulation software teaches robots without waste

19 August 2009

ABB says its VirtualArc robot welding simulation software allows welding robots to achieve precise, clean, mass-produced welds.

Human welders draw on experience, intuition and trial-and-error to establish the right parameters for a welding job. Transferring this skill to robots can be complex.

While robots speed productivity, and provide accurate repeatability of tasks, they can only get the welding right if they have been programmed correctly.

“Teaching” a robot to perform a arc-weld, means providing it with the knowledge that comes from many years of human experience and the intuition that enables it to choose the appropriate process for a new task.

Traditionally, experienced welder set up the welding parameters on robots by performing a series of test welds and adjusting parameters to hone the result. This approach uses up materials, manpower and energy.

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So, what do you think?  Yay or nay to robots on the job?

Sponsors of the upcoming Fabtech International & AWS Welding Show (including Metalform) in Chicago were polled about their plans for future business growth in light of the recession.  The results were surprising — in a very good way.

Poll: Manufacturers detail recession survival strategies, report better conditions

Opportunities for manufacturers abound as economy improves suggests a poll by sponsors of the Fabtech International & AWS Welding Show, including Metalform, in Chicago. Sponsors are American Welding Society (AWS), Fabricators & Manufacturers Association Int’l (FMA), Society of Manufacturing Engineers (SME), and Precision Metalforming Association (PMA).

– Manufacturing Business Technology, 9/8/2009 8:02:43 PM MDT

To survive what many view as the worst economic downturn since the Great Depression, 69 percent of manufacturers indicated they reduced their workforce, followed by delaying capital expenditures (66 percent), negotiating with suppliers for better deals (48 percent) and cutting promotional activities (37 percent.) The survey asked 1,046 past or prospective registrants of Fabtech International & AWS Welding Show, including Metalform. The poll was conducted in late July.

However, with signs that the economy is currently improving, those surveyed plan to reverse downsizing — nearly one-third of those surveyed said they expect to add to their workforce in the next 12 months. Manufacturers reported an increase in demand in product as the leading factor that would prompt an increase to the workforce (78 percent) followed by the opportunity to upgrade workforce (7 percent) and the need for new skill sets (6 percent).

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Look what I found as I was browsing through the wonderful world of the Miller discussion boards!  If you haven’t read these already, you’re in for a treat, and if they’re not already up in your shop, well then… I don’t know what to tell you.

So, without further ado,

The 10 Welding Commandments

1. Thou shalt not weld on an unpurged tank, for the noise will be very loud when the tank explodes and thy friends will console thy widow in ways generally unacceptable to thee.

2. Thou shalt secure thy tanks, lest one fall on thy foot and transform thee into less than a graceful dancer when called upon by thy wife or other female friend.

3. Thou shalt clean thy work carefully, lest thy gaze upon thy work falling apart as it passeth out of thy sight.

4. Thou shalt place thy work in jigs, or other holding fixtures, for the eye is a poor instrument for the measurement of angles and great will be the wrath of thy leader as thou art doing thy task a second time.

5. Thou shalt not weld near batteries, compressed gasses, or flammable materials lest a spark from thy labors would cause thee to continue thy chosen profession in an open field or other such drafty place.

6. Thou shalt take great care of thy tools and equipment, lest thy friend who is in charge of such things smites thee about thy head and shoulders for being a wastrel and a knave.

7. Thou shalt not perform thy art without proper ventilation, for the smell of toxic gasses produced by the heating of primers, and plated or painted sufaces is worse than a bad cigar and will remain with thee until the end of thy days.

8. Thou shalt not weld without goggles, nor shalt thou allow others to gaze upon thy labors, lest thy employment, or the employment of others be changed to sitting on cold and rainy streets while selling pencils.

9. Thou shalt wear sturdy gloves, for burns upon thy hands are a source of great pain when thou art attempting to raise thy bowling average.

10. Thou shalt ground thy work, when thou weldeth with a machine of arcs, for thou art a poor conductor of electricity and the shock which thou shalt receive shall ruin thy plans for thy weekend.

Toby Gewertz wants to make metalwork that will stand the test of time and so makes sure that he and his company, Metalformz, only use the best of materials.

Napa sculptor makes works meant to last

By MAUREEN MCCABE Register Correspondent
Posted: Wednesday, January 20, 2010 12:00 am

In this plastic, throw-away culture, where obsolescence is built into almost every mass-produced item, Toby Gewertz who sticks with material that will last.

Using stainless steel, bronze, copper, aluminum and titanium, Gewertz designs and constructs signs, sculptures, railings and doors, among other items, for commercial and residential clients.

Local restaurants call on his company, Metalformz, for signage and decorative pieces.

Gewertz crafted the carrot fence at First Squeeze, as well as the medieval Gothic art at the former Belle Arti on the creek in Napa, now the Little Gourmet.

Although the restaurant has been through several owners, all have kept Gewertz’s candleholders and partitions for the breezeway and counter top.

He’s also done Celadon’s signs, the door handles and liquor display racks at Fumé, the sign and interior metalwork at the old Piatti restaurant in Yountville, and the old Brix restaurant’s sign plus indoor railings and coffee tables.

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The importance of a good weld goes far deeper than just good looks; on Navy vessels, a good weld can throughly impact a ship’s overall lifespan.

Some ships built on Coast flawed, Navy says
THE ASSOCIATED PRESS • JANUARY 25, 2010

NEW ORLEANS — The Navy says numerous welds may be bad on warships built in the past two years by Northrop Grumman Shipbuilding at Gulf Coast shipyards.

(File photo/The Associated Press)

Since last summer, engineers have been inspecting Northrop Grumman-built warships after engineers found that between 10 percent and 15 percent of pipe welds inside vessels built at the shipyards in Pascagoula and Avondale, La., were not thick enough and could shorten a vessel’s life-span, the Navy said.

“We’re talking about thousands and thousands of welds to inspect, and we’re probably talking about hundreds of welds that need to be fixed on each ship,” said Jay Stefany, the Navy’s program manager for the LPD 17 amphibious assault ships.

The Navy said faulty pipe welds were found on destroyers, LPD assault ships and on one LHD big-deck amphibious assault ship. All were built at Northrop Grumman’s Avondale and Pascagoula shipyards.

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Looking to go back to school for welding? Where better to learn the tricks of the trade than from good ol’ Lincoln Electric?

The Lincoln Electric Welding School Announces Its 2010 Schedule

Cleveland – The Lincoln Electric Welding School, which has instructed more than 120,000 students since its inception in 1917, announces its 2010 schedule.

The Lincoln Electric Welding School is the oldest and one of the most respected arc welding schools in the United States. Classes are taught by the school’s seven full-time instructors who have more than 100 years of combined industry experience. Courses are designed to teach the arc welding skills that employers need. Lincoln-trained students are in high demand by welding fabricators at pay levels that tend to exceed the industry average.

Classes range from a six-week basic course to an advanced 15-week comprehensive course, as well as one-week classes on specific welding processes, certification and customized programs. Students spend 80 percent of their time in the booth learning to weld. Additionally, Lincoln limits class sizes to 15 students per class in order to maximize learning and guarantee one-on-one instruction time.

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Isn’t it time you started getting involved? That’s what these students thought!

I met them recently at one of our local AWS (American Welding Society) section meetings.  Daren Hitchman and Fred Paregoy (3rd from left in top and bottom rows) are the member recruiter and publicity chairman of their AWS student chapter, respectively.

I spent some time talking with them and I couldn’t help but take a picture of their workbooks. Unfortunatly, I did not capture the notes and diagrams on the inside; they were very detailed and technical — I was impressed with the level of training that these new students go throught to get certified.

Though they both are currently going to welding school at ECC in San Diego, they make the time to get involved in the local welding community by coming to events like this one.

Through attending meetings and events sponsored by local welding supply companies, professional organizations etc., these students are getting a better idea of the jobs that are available to them once they leave school.

Who knows? They might even meet a future boss, or learn about an opportunity to open their own shop just by hanging around and learning about the latest welding equipment!

Find a chapter of AWS near you and get involved!

But by and large, the spirit of DIY is actually dwindling amongst Americans nowadays. We don’t often build, we don’t do repairs, and I think, really, we just don’t want to work at it much anymore.

Do you still tinker?

If you build it, you’re unusual; survey finds more in U.S. avoid hands-on projects or repairs

By Rick Barrett
December 17, 2009
Milwaukee Journal Sentinel

MILWAUKEE — The United States has become a nation of “non-tinkerers,” a new survey shows, and it has harmed the way we live and work.

In a poll of 1,000 U.S. adults, nearly six in 10 said they had never made or built a toy.

Twenty-seven percent had not made or built even one item from a list of eight common projects, including furniture and a flower box.

Sixty percent avoided doing major household repairs themselves, noted the survey from The Foundation of the Fabricators and Manufacturers Association, based in Rockford, Ill.

It’s worrisome because the “hands off” policy around the house has kept people from learning valuable skills — including ones associated with productive careers, according to the association, which has more than 2,300 members in the metal fabrication industry.

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Interested in learning about restoring classic cars? Well, you’ve come to the right place!

The folks over at Second Chance Garage have given us a step-by-step guide to choosing the right welder for the job:

Selecting the Right Welder for Classic Car Restoration Projects

What Welder To Use?

The most common welders used in auto restoration, therefore, are MIG (metal arc welders, gas or flux-cored), TIG (tungsten arc welders using shielding gas) and Arc Welders (the traditional “stick” electrode).

To choose the most appropriate one for your needs, you have to consider the following parameters:

* What is the maximum and minimum thickness of metal to be welded? Fortunately, automobiles use metals that fall into a relatively narrow range.

* What is the metal type? Again, automobiles generally are made of steel and, rarely, aluminum.

* What is the normal position the welding “head” will be put in? Do you need to do a lot of welding overhead? The answer is usually no here.

* How much current is available in your shop and do you have 220 volts? Check your circuits.

Let’s be frank. Our overwhelming favorite type of welder is the MIG. We’ll explain why shortly, but first we’ll give an overview of the other contenders. Here we go!

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Once you’ve chosen a welder, come on over to Arc-Zone.com where you’ll find MIG guns, TIG Torches, Oxy-Fuel Torches, Plasma Arc Cutting Torches…  not to mention some really trick accessories like Trailing Shields, and everything you need to Weld Like a Pro!

Want some free Miller welding equipment???

This month, Miller Electric is giving away over $2,000 worth of welding supplies to one lucky grand prize winner!

To enter for a chance to win, just sign up for one of Miller’s eNewsletters to keep in touch with industry news and the latest how-to advice!

Complete Grand Prize Package:

• Choice of Millermatic® 211 Auto-Set™ MIG welder, Diversion™ 165 TIG welder, OR Spectrum® 375 X-TREME plasma cutter
• ArcStation™ welding workbench
• Performance Series™ auto-darkening welding helmet
• Arc Armor combo welding jacket
• Pair of MIG, TIG, and Metalworker gloves
• iPod touch