XPro Series Weld Process Controllers

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General

The XPro Series of Weld Controls expands upon the same basic architecture as our proven XM Controller with precision control modules integrating the welding power supply and welding axes for a complete turnkey solution. However, the XPro Series, including the Pro, Pro-Mobile, and Pro-Portable, has an increased capacity for tackling even the most demanding welding needs. It utilizes the same Digital Signal Processor (DSP) technology found in the XM, but adds an enhanced HMI (human machine interface) with a touch screen to make weld program creation and menu navigation even easier. The advanced hardware combined with the user-friendly interface results in a capable yet easy to program welding solution. Once created, weld programs can be initiated directly from the touch screen interface or the handheld remote pendant.

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Define your manufacture needs.


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Capacities

  • Units of Measurement: Capable of operating using Imperial or Metric Units.
  • Storage: 100s of weld programs can be created and stored on the XPro console. Additional storage is available by using a USB flash drive and downloading or uploading files to and from the XPro. An ethernet port is also available for integrating with an external storage device.
  • Modules: Up to 16 modules can be integrated into an XPro controlled welding system.
  • Weld Processes:

    • GTAW (Gas Tungsten Arc Welding) or TIG
    • GMAW (Gas Metal Arc Welding) or MIG
    • SAW (Submerged Arc Welding)
    • FCAW (Flux Cored Arc Welding)
    • PAW (Plasma Arc Welding)
    • VPPAW (Variable Polarity Plasma Arc Welding)
    • VPGTAW (Variable Polarity Gas Tungsten Arc Welding)

Advantages

  • Single Controller: A single controller integrates with the motion axes, wire feeders, and the welding power supply providing a central control point for all welding and motion parameters.
  • Touch Screen Interface: The human machine interface features a large touch screen display for easy navigation and weld program creation, and a hand pendant with tactile feedback for operations control.
  • Advanced Programming: The XPro Series offers advanced programming functionality allowing even the most challenging of applications to be completed with ease.
  • Expandable: The XPro Series features modules that allow increased system capabilities by simply plugging in a new module. When a new module is introduced, it is automatically recognized and integrated.
  • Long-term Support: The XPro Series utilizes an Embedded Linux operating system ensuring that AMET will be able to provide long-term support and stability. AMET writes the XPro software and manufactures the hardware, including the control boards, ensuring no risk of obsolescence due to third-party changes.
  • Retrofit Capable: The XPro Series can be integrated with existing fixtures such as lathes, seam welders, and manipulators to extend equipment service life. Retrofits can even be performed on equipment that was not produced by AMET, which helps reduce costs by reusing large positioning equipment.

Controls

The XPro Weld Controllers are capable of integrating with and controlling the following equipment:

  • Welding Power Supply: Controls all weld parameters of several brands and models of welding power supplies.
  • Arc Voltage Control: The AVC provides constant arc standoff and also allows for touch starts and touch retract
  • Cold Wire Feed Control: Wire feed speeds and wire retract are programmable
  • Hotwire Feed Control: Wire feed speeds and voltage to the wire before it enters the weld puddle are programmable.
  • Linear Travel Control (horizontal or vertical): Motion is programmable by distance, speed, or time.
  • Oscillation Control:
    • Mechanical Oscillation: Dwell time and oscillation distance are programmable.
    • Magnetic Oscillation: Programmable control of slew time, dwell time, amplitude, and arc position. The are can be deleted and maintained in a set position to aid in certain types of welding such as fillet welding.

  • Rotation Control: Motion can be programmed by RPM, degrees of rotation, or time, Continuous or manual (jogging) rotation are also available on the remote pendant.
  • Gas Flow: Enable/disable located on hand pendant. Also capable of mass flow controller integration.

Technical Data

Call AMET: (208) 356-7274
Standard Features
Optional Features
End Use Applications

Standard Features on XPro Series Weld Process Controllers


1

The human machine interface includes an LCD touchscreen. The Weld, Edit, and Setup Modes, and their program screens are intuitively presented on the touchscreen for program creation and execution. Simply tap the corresponding area to open the menu, and then use the keyboard for data input.

2

The digital meters display the programmed, actual, and override values of a weld parameter to allow real- time monitoring of the welding process. Up to six (6) meters are displayable simultaneously on the touchscreen monitor with one (1) displayable at a time on the remote pendant. The operator can easily adjust which meters are displayed and can toggle through several parameters for each meter.

3

The screen graphically displays the current weld segment of the program, including the upslope and downslope. The current segment as well as the total number of segments in the weld program are displayed. This information helps the operator monitor the exact status of the current weld program.

4

Video integration is built into the monitor. A popup window can be opened to display the real-time video feed without the need for an additional monitor. The window can be increased to about twice the size of the window displayed in the picture to the left. Arc Viewing Cameras are available as an option.

5

The Emergency Stop (E-Stop) button immediately aborts the weld program and ceases all motion.

6

The remote handheld pendant includes two joysticks and four sets of soft keys for eight axes of jogging motion control. These are used for positioning the parts and weld head prior to the weld and can be used to make adjustments during the weld. The pendant is also used for monitoring the weld and override capabilities.

7

A keyboard with a built-in touch pad is included to quickly and easily input or change parameters while creating or editing weld programs. A fold down tray is included to house the keyboard and keep it within reach while using the touchscreen.

8

Tapping the Mode icons (Weld, Edit, and Setup) puts the controller into its corresponding mode of operation. Controller and module preferences and settings are addressed in the Setup Mode while weld programs (or schedules) are built in the Edit Mode, then executed in Weld Mode.

9

The Sequence icons (Start, Stop, and Advance) are used during weld program operation. The Start icon activates the currently loaded weld program. The Stop icon terminates any running process or operation and advances to the downslope segment. The Advance icon initiates the next programmed event. Start and Stop buttons are also located on the handheld pendant for remote operation of the weld program.

Xpro standard features

Optional Features on XPro Series Weld Process Controllers


Borecladintersecting sized
Intersecting Bore Cladding Capability

Intersecting bore location and size can be programmed through the XM or XPro Controller. During cladding, the arc will automatically be extinguished when the torch reaches the edge of the intersecting bore and then reignite once it reaches the other side. This will be repeated until the system has clad around the entire intersecting bore and then continuous cladding will resume. Bores must intersect the main part at an angle perpendicular to the center.

Offline programming
Offline Programming Software

Weld programs can be created, modified, or stored on a PC. These programs can be moved back and forth between the controller and the PC using a USB storage device or through an Ethernet connection. This software can increase productivity by allowing programs to be created/edited while the weld controller is executing another weld program.

Sequencer remote pendant wireless small
Wireless Remote Pendant

The remote pendant can be wireless to eliminate the cord and increase portability. The pendant communicates with the XPro Controller via bluetooth and includes a rechargeable battery. There is a cradle on the XPro Controller for the hand pendant when not in use. The cradle also charges the pendant when connected.

Amet camera light attached smaller
Arc Viewing Camera

Arc Viewing Cameras can be added to a GTAW/PAW system giving the operator a view of the weld arc from a remote location. This keeps the operator in a safe location and reduces operator stress and fatigue. Additionally the image that is shown on the monitor is magnified and shows greater detail than what could be observed without the camera. Multiple cameras may be integrated for projects where a view of the lead and trail side of the weld zone is required. Please see the Arc Viewing Camera page for additional information.

Laser tracking unit
Laser Seam Tracking

The XM or XPro integrate with a laser sensor to scan and track the weld joint during welding. The laser continuously scans the joint profile and makes the necessary adjustments to ensure the torch maintains the programmed location. The scanned profile is also displayed in real-time on the operator console monitor. Seam tracking can be configured for single or multi-pass welds.

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Localization Software

The XM and XPro screens can be displayed with languages other than English. Spanish, Korean, Russian, French and Chinese (Partial) are available. Other languages may require fees for translation costs.

Avc module
AVC for GTAW/PAW System

An AVC (Arc Voltage Control) Module is added to provide the weld head with automatic arc standoff. The module provides automatic height adjustments to maintain a consistent arc voltage throughout the entire weld, including automatic adjustments on multi-pass welds.

Tig   plasma head
Multiple Process Weld Head

Our advanced controls allow us to integrate multiple weld processes into one weld head. Each process can be operated independently or simultaneously. For example, a TIG & Plasma weld head would feature two AVC axes (one for each torch) and either torch could operate or they can both operate simultaneously for Keyhole Plasma with a TIG trail. We offer TIG & Plasma, TIG & MIG, TIG MIG & Plasma, and SAW & MIG. Any of these combinations are available and would be completely programmable from ONE central controller. Other combinations are also available. Please contact us with any requests.

Coordinated motion opt
Coordinated Motion Module

Up to four motion axes can be integrated together. This allows each axis to function and coordinate together, much like the axes of a CNC milling machine, to perform welds on unique part geometries.

Virtual alignment
Virtual Alignment (Teaching Mode)

The operator can “teach” a weld path by manually moving the weld torch along the seam and selecting points. Up to 20 points can be selected to create a circumferential, longitudinal, or combination weld path. After all of the desired points are selected, the system will retrace each one to create a custom weld path. This can be helpful if parts or materials vary or have unique joint configurations. The path can be repeated for multiple pass welds, or offsets can be applied to repeat the motions of the original path in a new location.

Programmable Gas Control

Adds programmable gas flow control for GTAW and PAW applications.

Monitoring Sensors

AMET offers several sensors to monitor several functions and aspects of the weld. Each one of these sensors can automatically terminate the weld program if levels exceed the set parameters. The following sensors are available:
• Humidity Sensors – measures humidity levels at the weld puddle
• Oxygen Sensors – measures oxygen levels at the weld puddle
• Water Sensors – monitors water flow for components such as torches
• Gas Sensors – monitors gas flow for shielding/backing/purging gas

Wireless symbol
Wireless Communication

Includes hardware and software that allows weld programs or data to be transferred between a PC or sever and the XM Controller wirelessly.

Barcode scanner
Bar Code Program Selection

Weld programs can be automatically selected by scanning a bar code associated with a specific part. This can help eliminate the incorrect program being loaded and run. Beneficial if many different parts are to be welded and operator needs to frequently switch between weld programs. Includes the bar code scanner and the necessary software to integrate with the XM or XPro Controller.

End Uses For XPro Series Weld Process Controllers