Synergic WPQR & WPS

[eski1]

Hi
I am wondering if anyone has an example of a Synergic WPQR & WPS that they don't mind sharing?

A problem has arisen where we have submitted Mig/Mag WPQR & WPS for a job and the client has now seen that they were done by a synergic welding machine and because they don't like automated processes they have asked us what parameters do the Synergic part control. In our case we are using Kempi welding machines and the fusion programme i believe, the issue is Kempi won't tell us what their Fusion system controls i.e Amps , Volts , Wire speed etc due to it being their IP and this is what our Client needs to know to be able to sign off the WPQR & WPS so we are stuck unless we issue new WPQR & WPS and only use the welding machine in a non- synergic function.

so we are thinking if we could see an WPQR & WPS that has been done with a synergic Mig/ Mag welder then this might help us understand what's on it.

Any help greatly received

 

[kingnero]

Whether or not the synergic function is used should not matter. it is something I tick off in a box om a pWPS and WPQR, but that's it. Main parameters are still wire feed (+ amps), volts and travel speed.
Special waveforms and pulse programs are another matter. At one point all "special waveforms" were to be qualified separately under ISO standards, but that rule is gone now. I expect the confusion has something to do with this, as synergic really doesn't mean anything apart that wire feed and volts are set to a predefined value, depending on (mostly) plate thickness. But you can set the amps and adjust (or trim) the voltage freely, so you're back at standard MIG/MAG welding basically.

 

[eski1]

Hi Kingnero

Thanks for the reply
I'm not really sure what the Synergic part does on a Welder , but i thought it has the capability to adjust Parameters like Arc length as you weld to assist you rather than it presets them but i may be wrong.
I think my client just wants to know exactly what the Synergic part is affecting to be able to sign it off.

 

[kingnero]

Synergic is basically nothing more than a predefined voltage value for each wire feed speed (that you still can change).
It depends on a few predefined parameters (steel, stainless, alu), wire diameter, shielding gas, ... but all of those should be mentioned on the WPS/WPQR anyway.

 

[weldstan]

Synergic systems are not considered automatic unless the torch position is controlled electro-mechanically. They are semi-automatic when torch position is manually controlled.

 

the issue is Kempi won't tell us what their Fusion system controls i.e Amps , Volts , Wire speed etc due to it being their IP

Then it may be time to change welding system providers. Not only should you be told this information (or be provided with better tech support), but your shop techs/welders should be trained in how to set up programs and then tweak them as necessary.

Like robotics maintenance, this is no longer an exotic technology that needs to be kept secret. Every machine maker's program for a given set of wire size, classification and gas are not very different from each other.

"Everyone is entitled to their own opinions, but they are not entitled to their own facts."

 

[kingnero]

Or hook it up to a weld scanner and have a complete graph like an oscilloscope visualization, that shows amps and volts over the time.
If the system also has a wire feed speed meter, you'll also have that info. But in practice an average speed give you more than enough info.