XM Weld Process Controller

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General

The XM Weld Process Controller minimizes or eliminates the need to learn and use multiple control interfaces to run an automated weld system. XM-integrated automation can be programmed, controlled, and monitored from this intuitive pendant. Weld data with graphical representation of parameters are displayed on the 6.4 in (162.6 mm) screen. Input is entered via the soft buttons, function buttons, sequence buttons, joysticks, and programming knobs.

AMET's advanced control systems put weld automation in a compact and intuitive package. XM controls allow the user to program multiple parameters of the weld process including (but not limited to) motion and power supply function, and automate up to ten pre-weld and ten post-weld tasks, such as part loading, gas flow enable/disable, and touch retract torch positioning.

Capacities

The XM Controller is a very versatile weld process controller capable of meeting the needs of almost any weld process. The XM has the following built-in capacities to effectively perform a large range of functions and welds:


  • Units of Measurement: Capable of operating using Imperial or Metric units.

  • Programs: Capable of storing 200+ weld programs. Weld programs can be saved and loaded directly from the Weld or Edit mode screens. Weld programs can be given specific names or numbers when saved such as part numbers or product names. Additional storage is available by inserting a USB flash drive and downloading files from one of the two USB ports located on the XM Controller.

  • Additional Languages: The XM is capable of displaying menus in English, Spanish, French, Russian, Korean, and Chinese (partial)

  • Modules: Up to 16 modules can be integrated into each XM controller. Each module is equipped with an internal processor to share the computing load and prevent overworking the XM.

  • Equipment Capabilities: The combination of the XM and the modules allows control over motion axes and power supplies.

  • 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

The XM Controller is a very powerful and capable weld controller. It offers the following advantages over the competition's controllers and non-automated welding systems:


  • The XM Controller utilizes Linux, which ensures that AMET will be able to provide long-term support and stability. AMET writes the XM software, so there is no risk of the XM becoming obsolete due to third-party software changes.

  • Expandable for future needs. The XM features "Plug and Weld" modules that allow increased system capabilities by simply plugging in a new module. When a new module is introduced into the system, the XM automatically recognizes it and integrates it into the system.

  • Easy-to-use interface. Weld programs can be created, edited and run by a combination of the buttons and programming knobs. The intuitive layout makes it easy to program each segment in an organized and sequential manner.

  • Overrides for all axes and parameters are possible during welds. The operator can make adjustments to account for variations in the materials and weld joints.

  • A supervisor or welding engineer can create the welding programs and then set override limits to prevent the operator changing parameters too much. These limits can be protected to ensure that only those with certain access can make changes.

  • A sensor box can be integrated into the system to monitor water flow for water-cooled torches or other components. If water flow is not detected the XM displays an alert to help prevent damage to the water-cooled components. Gas flow is also monitored and reported in a similar manner to help ensure cover gases are in the weld zone to maintain welding integrity.

Controls

The XM Controller is a very powerful weld controller. It is capable of integrating with and controlling the following equipment:


  • Welding Power Supply: The XM is capable of controlling all weld parameters of several brands and types of welding power supplies.

  • Arc Voltage Control (AVC): 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 and 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 arc can be deflected 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 and manual (jogging) rotation are also available on the XM Controller.

  • Gas Flow: Soft button to Enable/Disable located on XM.

Technical Data

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

Standard Features on XM Weld Process Controller


1

The Emergency Stop (E-Stop) button immediately aborts the weld program, stops weld current output from the power supply, and ceases all servo-controlled motion. The shield gas will remain flowing until the end of the Post Weld segment to prevent oxidization of the weld piece. The system remains inactive until an operator pulls out the Emergency Stop button and pushes the Clear E-Stop soft button.

2

Each soft button has a corresponding label or grey area (indicating an inactive button) on the LCD screen. Based on the selected Mode (Weld, Edit, or Set Up) and the screen within that mode, the function of the soft buttons will change. Details are explained in each corresponding section.

3

The Mode buttons (Weld, Edit, and Set Up) put the controller into its corresponding mode of operation. Controller and module preferences and settings are addressed in the Set Up Mode while weld programs (or schedules) are built in the Edit Mode, then executed in Weld Mode.

4

The Sequence buttons (Start, Stop, and Advance) are used with the weld program. The Start button activates the current weld program. The Stop button terminates any running process or operation. If depressed during a weld program, the Stop button will advance the current weld segment to the down slope segment. If the program is already in the down slope, pressing the Stop button will terminate the program. The Next (or Advance) button’s function depends on the weld program settings and can be depressed to progress to the next programmed event. The Advance button illuminates when it can be used to advance a sequence in the program.

5

The Joystick Controls command movement of their assigned axes. The joystick control has a proportional feature, meaning, the farther the physical joystick is moved along its throw, the faster the axis it commands will travel. Each Joystick is divided into two axes of motion: a vertical axis and a horizontal axis with corresponding labels. Each axis has programmable parameters (Command, High Speed, and Low Speed) and can be assigned to any axis.

6

The Function buttons are quick access buttons to move positioners or axes, enable or disable process-specific functions, and control gasses. These buttons are divided into four sections: Disable, Gas, Motion, and Jog.

7

Two USB ports are included to facilitate file transfers to and from external sources. Files can be added to or deleted from a USB memory device directly from the XM Controller. The USB connections are located under covers behind the front panel.

8

The Soft Programming Knobs (or simply soft knobs) override weld program parameters in Weld mode. In Edit and Set Up Mode, the knobs navigate through the screen and adjust the settings. By rotating a knob clockwise or counter-clockwise, the operator can scroll through the display to reach a desired item and then increase or decrease a value. Each knob also acts as a push button by pressing down on the knob, which allows the operator to select different parameters depending on the current mode.

9

The LCD Display presents the graphical interface screens on the 6.4” TFT screen. The Weld, Edit, and Set Up Modes and their program screens are presented on the display for data entry or manipulation.

Controller new labeled

Optional Features on XM Weld Process Controller


Automation software
Automation

A critical part of the allure of XM Controls is the ability to automate functions in the welding process. The system may be set up to enable laser tracking, start part rotation when the weld commences, and even load and unload a part. Up to10 pre-weld and 10 post-weld operations can be programmed into each weld program.

Data acquistion
Data Acquisition and Tolerance Checking Software

Data is collected and analyzed in real-time to ensure all modules are within the set tolerances. The data points can be displayed graphically on the display and can also be exported as a .csv file and viewed on a program such as Microsoft Excel. These files can be exported through one of the USB or Ethernet ports on the XM or XPro Controller.

Weldscreenchinese
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.

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.

End Uses For XM Weld Process Controller