OPTIMIZE WELDING PERFORMANCE & OEE

Weld Central® is a Process Optimization System that monitors and tracks key MIG welding process variables, including current, voltage, wire feed speed, arc stabilization period (ASP), gas flow and feed motor current. With the collected data and real-time monitoring, the system provides a revolutionary way to make process improvements to maximize uptime and Overall Equipment Effectiveness (OEE). Combined with the Wizard View® software, Weld Central® is the ultimate weld cell performance monitoring system!

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  • Monitor robotic or semi-automatic weld cells through a PC or mobile device using the Wizard View® software, where collected data can be viewed, charted and exported in a user friendly web browser interface
  • Each controller can monitor up to four torches with inputs for up to four sets of sensors
  • Equipment agnostic — utilizes sensors compatible with all brands of wire feeders and power sources
  • Capacitive touchscreen displays arc status, wire speed, gas flow and wire/gas remaining
  • More than just a data acquisition system — PLC integration through Modbus or Profinet protocol can be utilized to activate an alarm or stop the welding process if welds fall outside of user defined parameters, preventing costly weld quality issues
  • Internal memory on controller can store up to 180 days of weld summary data (varies based on duty cycle)
  • Monitor a single torch or an entire facility (with Wizard View® Advanced Software)
  • Gas flow sensor is pre-calibrated for a variety of gas mixtures to cover nearly all GMAW welding applications


WIZARD VIEW® MONITORING & DATA ACQUISITION SOFTWARE
MONITORING & DAQ WITH AN INTUITIVE USER INTERFACE

Wizard View® provides an easy to use interface for the Weld Central® system that graphs and logs data, alerts, wire and gas usage and other key welding performance information. The software collects data from any torch with the Weld Central® hardware installed. Simply browse to the desired torch to see a visual representation of the welding data along with the wire and gas usage information.

  • Monitor, graph and export welding data to a CSV file
  • Basic and Advanced versions of Wizard View® are available. Choose Wizard View® Basic for monitoring performance on individual torches or weld cells. Wizard View® Advanced features the ability to monitor performance and productivity for an entire facility or assembly line.
  • Track and compare welding performance data to test and verify process improvements
  • Intuitive dashboard displays all welding data in an interactive chart and shows overview of the total number of welds, wire usage, gas usage, power usage and arc on time for a selected time frame
  • Integrated ROI Calculator provides a quick and easy way of calculating cost savings after making process improvements
  • Logs and displays user defined alerts so problems can quickly be detected and resolved
  • Provides much of the data necessary to determine weld cell OEE (overall equipment effectiveness)
  • Viewable on computer, tablet or mobile device


WELD CENTRAL® SYSTEM OVERVIEW VIDEO
Check out our overview video of the Weld Central® Optimization System! Contact your Wire Wizard® Technical Sales Representative to schedule a live software demonstration.


Click here to watch this video on the Wire Wizard® Youtube Channel

SOUTHEAST US TECHNICAL SALES REPRESENTATIVE, RANDY LOVE

Wire Wizard® Welding Products is pleased to announce the hiring of Randy Love as Technical Sales Representative for the Southeastern US region, including Georgia, North Carolina, South Carolina, Eastern Tennessee and Northern Florida. Randy brings with him over 35 years of experience in technical sales in the welding supply industry with both distributors and manufacturers. He has held long term positions with companies in the industry such as ESAB®, National Standard®, Linde Gas® and others. If you're in the southeast US region, contact Randy today to solve your toughest welding challenges!


Randy Love

Connect with Randy on LinkedIn | Email: rlove@wire-wizard.com

DON'T GET BURNED BY BURNBACKS!
Burnbacks are one of the most common problems that occur in an industrial welding environment. All welders will encounter them at some point, and they are one of the leading causes of downtime in both semi-automatic and automated arc welding applications. Burnbacks occur when a weld forms in the contact tip, resulting in a ruined tip and extra time to install a new one. Here are a few common causes of burnbacks and some steps you can take to prevent them in the future...
  1. Poor Wire Feed
    One of the leading causes of burnbacks are problems in the wire delivery system. The Wire Wizard website has a helpful guide to help you design the perfect wire delivery setup from the drum to the wire feeder. On the other side of the feeder, a worn or badly performing torch liner can cause burnbacks as well. Wire Wizard® E-Power Torch Liners feature a patented design using elliptical wire for superior feedability with low wire skid friction, resulting in extended liner service life and a more consistent wire feed. They’re also available as direct replacements for most major MIG torch manufacturers.

  2. Poor Conductivity
    Poor conductivity caused by bad consumables, damaged cable or a bad ground results in inconsistent voltage and can lead to frequent burnbacks. The PowerBall® consumable design features an all-copper current path to maximize conductivity. Combined with PowerBall® Welding Cables with consolidated copper lugs and Wire Wizard® Magnetic Ground Clamps with a copper grounding point, the current transfer in the secondary loop of your MIG welding system can be optimized for consistent performance without the burnbacks!

  3. Improper Wire Feed Speed or Other Welding Parameters
    Adjusting the wire speed and/or voltage is one of the easiest adjustments a welder can make to prevent burnbacks. If the wire feed itself is smooth through the wire delivery system, the feed speed may need to be adjusted. Typically, burnbacks due to feed speed are caused by the wire feed being too slow. For automated applications, the Weld Central® system features an alert setting for both improper feed speed and voltage, triggering an alert that can help prevent burnbacks before they happen.

  4. Holding the MIG Gun Too Close to the Workpiece
    This happens most often in semi-automatic welding applications where there is room for more human error. The skill level of the welder certainly is a big factor here, but there are steps that can be taken to help prevent this. Switching from a flush or protruding tip at the nozzle to one that is recessed and less likely to make contact with the base metal is one easy change a welder can make to reduce burnbacks. Overall performance and ergonomics of the MIG gun design is another factor, and sometimes just changing MIG welding guns can make a big difference!



WIRE WIZARD® PRODUCT CATALOGS

To request printed catalogs, please call customer service at 517-782-8040 ext. 236 or email us at sales@wire-wizard.com


WIZARD TECH ONLINE TRAINING & WEBINARS
Expand your industry knowledge by learning about new products, tools and techniques to solve the toughest welding challenges. Our comprehensive online training system includes a series of training modules that cover everything from wire dispensing basics to optimizing equipment for maximum arc welding performance and productivity.

Click here for more information on the Wizard Tech Online Training Program





ELCo Enterprises, Inc. • 5750 Marathon Drive • Jackson, MI 49201
Phone: 517-782-8040 • Fax: 517-782-8039 • www.wire-wizard.com
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