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teachWELD User Manual

1. teachWELD Welding Simulation User Guide s n teachWELD Table of Contents Table of Contents Page 2 teachWELD Introduction 3 Inspection 30 Inspection Mode 30 teachWELD Simulation Components 3 Retry 31 teachWELD Hardware 3 Adjust 31 teachWELD Software 4 Quit 31 teachWELD Instructor Server 4 Main Menu 32 Main Menu Details 32 35 teachWELD Instructor Site 5 Passes and Welding Finishing 36 Adding Student Accounts to Retrying or Discarding a Weld 37 System 6 7 Spatial Adjustment of Assembly 38 39 Access to Student Diagnostic Reports 8 9 teachWELD Replay 40 View the Welding Parameters User Selection Window Replay Sheets WPS for Welding Types 10 Mode Admin Only 4 Student View 42 teachWELD Software Menu 11 Replay Selection Window 43 Workstation Setup 12 13 Replay Mode 44 Calibrating Coupons 14 15 Calibrating Workstation 16 17 teachWELD Exercise 45 Student Log in 18 19 Exercise Mode 46 Exercise Grading 47 teachWELD Software Modes 20 Multiple Attempts at Mode Selection Menu 21 hel erdes 48 Welding Options Menu 22 23 Replay an Exercise 48 Howto Weld 24 Glossary 49 teachWELD Practice 25 Mode Overview Troubleshooting Guide 50 55 Welding Toolbar Li 29 teachWELD Subscription and License Return 21 Agreement 56 57 Start Li End 21 Realityworks Limited Warranty 58 Diagnostic 28 Diagnostic Report 28 29 Procedure 29 Procedure Datasheet 30 pe Realityworks 123 EXPERIENTIAL LEARNI
2. www realityworks com 800 262 3806 29 Manual Dexterity Motion Straightness This value measures performance against the ideal positioning of the arc along the welding joint Travel Angle This criterion is the angle in which to lean the nozzle in the same direction as the path of the weld On a horizontal plate this corresponds to a left right motion of the wrist The simulator detects whether you push or pull the seam and adjusts its diagnostics accordingly Work Angle This is the angle of the nozzle perpendicular to the path of the joint On a horizontal plate this corresponds to an up down motion of the wrist Nozzle plate Distance This value determines what should be the ideal distance between the nozzle and the assembly A nozzle too close or too far may lose points in this category Welding Speed To produce an adequate seam there is an ideal travel speed calculated from welding parameters Amperage Voltage Depending on the datasheet these two parameters can be interchangeable or only one of the two can be used Both are measures of the electric arc although not always equivalent depending on the datasheet Heat Input It is a calculation of the number of joules of thermal energy transferred to the plate in one second This heat is responsible for the fusion of metal and the size of the seam among other things Weld Size Too much or not enough heat can adversely affect the weld Also known as the height of t
3. Applet O Do you want to quit gt the current weld Applet started teach 9 Realltyworks WELD re EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it i welding simulation oor www realityworks com 800 262 3806 38 Spatial Adjustment of Assembly Red Line Moves coupon left and right side to side along the red line Red Line rotates the coupon forward and backward around the red line Green Line Moves coupon up and down along the green line Green Line rotates the coupon around left and right the green line Blue Line Moves coupon forward and backward along the blue line Blue Line rotates the coupon around vertically the blue A N te TRF i line It is possible to modify the position of the welding assemblies in the Practice mode If and only if no weld beam has been made either just after having chosen a recipe or after a restart you can access these controls by simply pressing the Adjust button An Adjustment can correct for a coupon calibration offset within the program without having to close out and recalibrate If a Student uses this feature it will only affect their use of their simulator NOTE This feature should not be used by the Instructor as any saved changes will affect any student users regardless of which workstation they are using There are two columns of controls and one central button to save In each column
4. How many workstations can I have on a single computer Only one workstation works on a computer at a time however you can use any workstation on any computer as long as you go through the add new workstation process What problems could occur if someone were to enter the wrong WS SN when adding the WS and the number is recognized Each workstation is calibrated and then the calibration can be saved for that workstation So if you use a workstation with the incorrect or wrong SN you will be getting the calibration for that other workstation This could cause some issues when using the unit I need to order more student accounts who do I contact You can contact our sales department at 800 262 3806 If I do not use all student accounts in a year will they carry over to the next No they are reserved for one year license after the year is over they become null and void What are the system requirements for installation http www realityworks com images teachWELDspecs pdf Where does the diagnostic info save to The diagnostic info saves to the Cloud What this is an online server system held by Realityworks that allows students and instructors to be able to see all previous results Why do some of the welds say position is horizontal and one say flat when they are all horizontal welds Not all are horizontal the tjoint and lap joint are horizontal and the v groove is flat Will this work on Mac Not currentl
5. Step 3 Place the tip of the welding gun in the center hole on the top right side of the workstation You may have to remove a plastic cap Front of Workstation ook for Assembled in the USA sticker on the front of your workstation Step 4 Hold the tip of the gun perfectly vertical as possible vertical The tip should remain as throughout this process 45 Degrees Step 5 Rotate the welding gun so the handle is pointing 45 degrees from the back of the workstation as shown in the picture This is the starting position for calibration Step 6 Press and release the trigger to begin calibration Step 7 Slowly rotate the gun assembly back and forth in a short arc approximately 5 to 10 degrees as shown by the dashed lines in the above picture As you rotate the gun assembly the line of will grow from left to right If you do not see this increasing move the gun further Note This process should take less than 1 minute i em C Windows system32 cmd exe USBManagerWing2 check_devices device connected Cid B size 535 Hold the gun in position and pull the trigger Rotate the gun aroune tha_ pivot point Collecting sample Step 8 When the calibration matrix seen in the picture below appears verify that the RMS error circled in red is less than 1 00 NOTE If it is not below 1 00 your workstation will need to be recalibrated until you are below 1 00 Review the cali
6. workstation click Add a new workstation pe Figu re A The first time you connect a workstation to a computer you will need to click the Add a New ____ Add Workstation Workstation button enter the serial number off the workstation and click on Add Workstation Figure A This retrieves the Factory Default Back Exit Calibration file for the workstation from the Re alityw teachWELD Version 1161035 Realityworks server Live it J Loor ee A 123 XPER LEARNING Oo Any subsequent time that you connect a workstation to a computer click on the number that corresponds to the workstation you are using during this session to move to the next step Figure B Add a New Workstation Workstation codes can be found on the back of each individual workstation next to the USB cord Check For Updates Exit l Realityworks www realityworks com 800 262 3806 Figure B Realityworks EXPERIENTIAL LERRNING TECHNOLOGY MG WOr www realityworks com 800 262 3806 12 Step 3 This screen Figure C shows up after you have selected the workstation You will need to perform a coupon calibration This will also be required when you select a different workstation than the one used in the previous session Press Calibrate to continue E teachWELD Versigusl 16 1035 0 an EXPERIENTIAL LERRNING TECHNOLOGY SN 0038 Student Log in Figure C Calibrate Please
7. Calibrate to enable Login ENGINEERING teachWELD123 com Real ity works www realityworks com 800 262 3806 Live it Learn it Step 4 Your screen will ask you to Press Calibration Coupons to collect hardware and software data points Click on the button that reads Calibrate Coupons e Coupon calibration is the main user calibration required for successful use of the simulator e More Calibration Options for troubleshooting precision issues this allows you to reset your workstation calibration to factory default or recalibrate with Product Support help ee ee es Wo EXPERIENTIAL LEARNING TECHNOLOGY Calibration points Calibrate Coupons Required More Calibration Options Press Calibrate Coupons to collect hardware and software data Back Exit Reali works www realityworks com 800 262 3806 Live it Learn it Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 13 Calibrating Coupons Step 1 Click on the Calibrate Coupons button teachWELD Version 1 16 1035 0 i e eah w WELD A welding simulation feat Calibration Press Calibrate Coupons to collect hardware and software data points Calibrate Coupons Required Back Exit He al ity works www realityworks com 800 262 3806 Live it Learn it Step 2 After clicking on the Calibrate Coupons button a new data screen wil
8. NOTE if you do not exit from this window the main program will appear to hang Return to this window and press any key to resolve this potential problem Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 15 Software Coupon Adjustment Once you have logged into the teach WELD simulation software you are ready to weld If the physical coupon has some discrepancy with accuracy to what is being shown on the software or virtual coupon you can adjust the coupon on your computer screen to align with the physical welding coupon Moves coupon from Tilts coupon forward side to side left to right or vice versa or backward on the red axis line Moves coupon up Tilts coupon around toward ceiling and on the green axis line down toward table Tilts coupon Moves coupon sideways on the blue forward closer and ideway u backwards farther Ee w axis NOTE Due to the nature of virtual welding after coupon calibration you have the option to always remove the physical coupon from the teach WELD workstation and weld solely in the virtual world looking at your computer screen teach 9 Realltyworks WELD re EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it i welding simulation oor www realityworks com 800 262 3806 16 Calibrate Workstation NOTE the Factory Default work
9. changes one unit at a time There is no way to show these values in another measurement system IMPORTANT NOTE The middle button saves changes in the user s data on the server thus making them permanent If adjustment data is not saved leaving the adjust mode by starting a weld or by clicking again on the Adjust button will reset all values to the last saved state There is no easy way to reset all values except by sending them back to zero and then saving Zero in all values is the default It is important to remember that all adjustments are unique to each recipe They are not shared between multiple recipes even very similar ones Also replays save the adjustments so there are not adverse effects changing the adjustments once a diagnostic and replay are saved using a prior adjustment Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 40 teachWELD REPLAY Realityworks EXPERIENTIAL LEARNING TECHNOLOGY it amp Learn it www realityworks com 800 262 3806 41 User Selection Window Replay Mode Administrator Only Practice Replays User choice a a o Srani Hima i Sudani asion A Applet started This window only appears if an authenticated user is a supervisor administrator It allows the supervisor to select the user for whom he would like to replay welds that the user made All students and supervisors of the same profi
10. there are three identical groups of three buttons each These groups are color coded and associated with a specific value for easy identification A single button at the bottom is used to show or hide the ins controls Hiding a column lowers the visual clutter for easier viewing When hidden the button icon changes to represent the different state as shown b gt Each group of three buttons has the same purpose These are assigned to a single value which has the same color as the group s background The first button which looks like arrows pointing left resets the value to zero The second button which l teach amp WELD R welding simulation e voni www realityworks com 800 262 3806 39 i Healifyworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it Weed q looks like a plus sign is used to increase the value by a set amount The third and last button symbolized by a minus sign decreases the value by the same amount The set amount varies according to the column The left column modifies the position and the right column modifies the rotation For position adjustments the axis is invisible This is because they are fixed no matter what the actual position or rotation values There are three axis while looking straight at the poster on the back wall the first axis is left right the second axis is down up and the third is away towards yourself Values are expressed in millimeters and
11. warranted for either 1 year or the remainder of the original warranty period whichever is longer All replaced items become Realityworks Inc s property What this Warranty Does Not Cover This warranty does not cover a damage from misuse use other than normal or customary manner accident or neglect b damage from improper operation maintenance adjustment alternation or modification c damage from spills of food ink or liquid d all vinyl plastic surfaces that are scratched stained or damaged due to normal use e damage to our products caused by the use of equipment not supplied by Realityworks Inc f products which have the serial numbers removed or made illegible and g repairs that have been made or attempted by others Any unauthorized repair or modification of the product shall void this warranty How to Get Warranty Service Please call 715 830 2040 or 800 830 1416 or fax 715 830 2050 for a Return Authorization number and information on returning your product to Realityworks Inc For any return of product to Realityworks Inc you must prepay shipping costs and include your name address phone number Return Authorization number and an explanation of the problem Please use the original container and packing materials if possible in shipping a product to Product Support Department Realityworks Inc 2709 Mondovi Road Eau Claire Wisconsin USA 54701 Realityworks Inc will pay any shipping costs for returning a prod
12. which will be updated along with the position of the gun in real time PARAMETERS This submenu shows some additional information about the currently loaded welding recipe It is purely informative ce Realityworks Live it Learn it os 123 EXPERIENTIAL LEARNING TECHNOLOGY Zoi ore www realityworks com 800 262 3806 33 WELDER PROFILE Welder s profile D Welder s profile D Dexterity guides This submenu contains some easily modifiable options for configuring the simulator Making modifications here gives faster access to some of these configurations but the changes will not be permanent Here you can change the options from wire speed to amps change the ease of implementation from left to right handedness and vice versa change the difficulty of the current practice exercise and mask darkness You can also set the unit system from metric to imperial The bloom options modify the lighting effects of the weld pool during welding This is purely for eraphic effect and does not affect weld diagnostics in any way It may be used to better see the weld pool dimensions but is cosmetic in nature DEXTERITY GUIDES efoto D Calibration Dexterity guides Dexterity guides Trajectory _ Travel angle This submenu contains the guides available to the user Each can be turned on or off simply by checking or unchecking the box next to each guide Examples of Travel angle work angle and Arc S
13. you Arc speed would be measuring Straightness Arc Speed Distance Work Angle and Travel Angle all at the same time Pass grade 80 Nurwer of tries u Evaluation criteria Distance Work angle Travel angle Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it www realityworks com 800 262 3806 48 Multiple attempts at the exercises Each exercise can be attempted an unlimited number of times whether successful or not The simulator saves in its memory several statistics concerning each exercise First the description indicates whether an exercise was attempted successful or failed for each level of difficulty An appropriate color lights the button representing the exercise as well as to represent the status Secondly it retains the highest score achieved according to the level of difficulty which is displayed in the description of the exercise Thirdly the number of attempts failed or successful is also displayed Fourthly the criteria evaluated for each exercise are also displayed Note that the number of attempts and the best score are updated even after the exercise has been successful In the case of an exercise with multiple points to check the highest score is always the average of the attempt that has the highest average for its manual dexterity diagnostics Replay an exercise There is no higher score than the one that is kept in the memory there is also the replay of the highe
14. 0 100 100 Expert 9 EXPERIENTIAL LEARNING TECHNOLOGY Realityworks Live it Learn it www realityworks com 800 262 3806 View the Welding Parameters Sheets WPS for all welding types Step 1 Login to the online system Step 2 Click on the teachWELD link in the top left corner Step 3 Click on the WPS link at one of the two locations shown Version 1 1 9 643 Randy Lee admin Logout Administration teachWELD Diagnostics EXPERIENTIAL LEARNING TECHNOLOGY teachWELD Step 4 The Welding Parameters Sheet WPS will show up with Identifiers click on the linked numbers to see the specific Welding Parameter Sheet of interest WPS Profile RW ka Code Identifier Base metal Process Assembly Position GO 1_T _1 954 293 1123 Mild Steel GMAW T joint fillet weld Horizontal GO 1_L 17 954 794 1124 Mild Steel GMAW T joint fillet weld Horizontal G 2 _ B11 _127_ 954 295 1125 Mild Steel GMAW Square groove butt joint Plate RW x1 1176 Aluminium GMAW T joint fillet weld Horizontal RW X2 1127 Stainless Steel GMAW T joint fillet weld Horizontal WELDING DATA SHEET aie ess RW X3 1128 Aluminium GMAW T joint fillet weld Horizontal PETIT n RW X4 1129 Stainless Steel GMAW T joint fillet weld Horizontal TS Ms RW 5 1130 Stainless Steel GMAW Square groove butt joint Plate c RW X6 1131 Aluminium GMAW Square groove butt joint Plate MATERIAL pongwngny STS FILLER METAL R
15. 06 36 Passes and Weld Finishing After a welding pass has been carried out several things can happen Most of them are automatic but it is important to specify them here To get the reports you will need to click on the End icon to save your welding work Intermediate pass e A diagnostic report becomes available It is possible for the user to view the exact result of previous passes as well as the overall score until now e The datasheet becomes available Final pass e All events of an intermediate pass occur e It becomes impossible to initiate another arc The welding cannot be changed e The welding is saved and therefore can be viewed in the replay mode K Applet Viewer arc RwApplet CE Applet Viewer arc RwApplet Applet Applet atr Applet started Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 37 Retrying or Discarding a Weld When a welding has already begun and the welder wants to either retry or change the welding parameters you can retry a weld by clicking on the Retry icon A message appears on the screen asking if you want to continue the action to cancel the welding already begun or if he wants to cancel the action and return to the welding The same screen appears when you want to go to the Mode Selection Menu while a welding is underway Applet Viewer arc RwApplet soda R
16. 495 6 Gas 5 Ar 5e COZ Gat 25 30 l min 50 64 CTH 020CESS E POLARITY bc Blece TEAM RAL LENGTE 315 075 POSIT ICN Hori pontal PRISLA JOINT TYPE T joint fillet weld Realltyworks Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 10 teachWELD Software Menu Realityworks www realityworks com 800 262 3806 EXPERIENTIAL LEARNING TECHNOLOGY 11 Workstation Setup To access the teachWELD welding simulation software you must first install the software Please look at the teach WELD System A 123 EXPERIENTIA EARNING S eon Requirements and Installation CD for more information Step 1 Launch the teachWELD software using the desktop shortcut le or by browsing through the Windows Start menu to All Programs Realityworks teachWELD Add a New Workstation Workstation codes can be found on the back of each individual workstation next to the USB cord NOTE you can click the Check for Updates link on this A rg eee screen to launch a browser window that will let you know if Check For Updates Exit any updates are available for your software i oe y Healtfyworks www realityworks com 800 262 3806 Step 2 Select the workstation you are using Each workstation has a unique serial number printed on a label next to the USB cable on the back of the Enter the serial number below and
17. D welding simulation to manage users and view student results This site can be accessed from the web without the need for specially installed software EXPERIENTIAL LEARNING TECHNOLOGY Welcome to teachWELD login Username _ Password Connect Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 4 teachWELD Instructor Site Realityworks www realityworks com 800 262 3806 EXPERIENTIAL LEARNING TECHNOLOGY 5 Adding Student Accounts to teachWELD System Actual images are subject to change Step 1 Login to the system at the website contained within the information emailed to you by the Realityworks Product Support Team If you do not have this information please contact them at productsupport realityworks com EXPERIENTIAL LEARNING TECHNOLOGY Welcome to teachWELD login ee rr Step 2 Use the administration menu and click on the user management link Version 1 1 9 689 New Instructor Logout Administration teachWELD User Management EXPERIENTIAL LEARNING TECHNOLOGY Administration User Management gi Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it Learn it www realityworks com 800 262 3806 Step 3 Click the add new user button in the user management screen EXPERIENTIAL LEARNING TECHNOLOGY User Management Name Role aame Em Delete _
18. NG TECHNOLOGY Live it J Learn it A Torn www realityworks com 800 262 3806 2 teachWELD Introduction This manual contains information that is necessary for the proper setup and usage of the teach WELD simulator Before setting up and usage of the simulator please read through this manual This manual is the main resource for all the installation usage and explanations of the various features of the teachWELD simulation It is our intent to for you the user to be able to gain basic understanding of the teach WELD simulator and how to operate it accordingly Not all welding terms are explained because this manual assumes that the user has some basic knowledge of the welding field teachWELD Simulation Components teachWELD Hardware The teachWELD welding simulation comes with one main hardware component and several accessories e The main welding component is the teach WELD workstation o The workstation is I comprised of a GMAW 2 welding gun and a g workstation welding box Figure 1 e The accessories are as follows o Welding Coupons a t joint lap joint amp v groove Figure 2 4 4 ss o Welding Helmet with clear u EURA Sy and colored lenses Figure 3 o Welding Gloves Figure 4 The coupons can be easily removed and replaced with the corresponding coupon guide that you are virtually welding on the software Note gloves and helmet are strongly su
19. Step 4 Enter the student s information and click Save new user to create the student account Name Username Password and Role are required You can return here to edit a student account to change name password or difficulty However the Username cannot be changed after it is created New Account Confirm password Role High School student High School student Sf Save new user Clear FINISHED The new user is saved and has access to the teach WELD system The new student will now appear on the user list Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 7 Access to Student Diagnostic Reports Step 1 Login to the online system Step 2 Click on the teachWELD link in the top left corner Version 1 1 9 643 Randy Lee admin Logout Administration 4 teachVWWELD User Management EXPERIENTIAL LEARNING TECHNOLOGY Administration User Management Realityworks www realityworks com 800 262 3806 Step 3 Click on the Diagnostics link at one of the two locations shown Version 1 1 9 645 Randy Lee admin Logout WPS Diagnostics PERIENTIAL LEARNING TECHNOLOGY teachWELD i Diaanostic i 2 Zs www realityworks com 300 267 3306 Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 8 Step 4 The Diag
20. alibration saved to C Users jmcintosh REALITYWORKS arc calib hase Press any key to continue teache v WELD lt welding simulation eon Step 3 Place the T joint coupon on the workstation Make sure the coupon it is fully seated on the workstation Step 4 Place the tip of the gun on the weld line on the far LEFT edge of the coupon This is point 1 Hold the gun at a 45 work angle and a 0 to 15 travel angle Pull the trigger Step 5 Place the tip of the gun on the weld line on the far RIGHT edge of the coupon This is point 2 Hold the gun at a 45 work angle and a 0 to 15 travel angle Pull the trigger Step 6 Place the tip of the gun on the front far right corner of the coupon This is point 3 Hold the gun at a 45 work angle and a 0 to 15 travel angle Pull the trigger Point 1 Point 2 Point 3 USBManagerWin32 check_devices device connected Cid O size 53 gt a Reading gun calibration matrix from C Users Administrator imG PC arc calib gu ae Position the gun at calibration point 1 and pull the trigger Position the gun at calibration 2 and pull the trigger Position the gun at calibration 3 and pull the trigger 0 64451 0 08846 8 2 25683 0 15453 0 98786 0 106 52179 0 74882 0 12773 8 228 44287 4 66668 6 66668 O 1 66666 Calibration matrix written to C Users Administrator imG PC arc calib hbase Press any key to continue
21. bration instructions for proper calibration requirements Otherwise click any key to exit and continue oe Realityworks m S 3123 EXPERIENTIAL LEARNING TECHNOLOGY Live it J Learn it Spy nit Cerne www realityworks com 800 262 3806 18 NOTE if you do not exit from this window the main program will appear to hang Return to this window and press any key to resolve this potential problem US BManagerWin32 icheck_devices device connected tid B size 53 gt Hold the gun in position and pull the trigger Rotate the gun around the pivot point Collecting samples Tip position ie Joe iz 68 78216 66 872 72 gt RMS error H 43499 8 23257 Beep ree2bh 8 82495 36 32212 8 75541 H 19673 8 62582 68H 786218 J 8 61259 4 12652 H 78H21 60 07272 1 4 HHH H nnani H HHQH8 1 6600 J Calibration matrix written to C Users Administrator imG PC arc calib gun Press any key to continue Step 1 Once you have performed the Coupon Calibration click on the Back button to return to the Main E teachWELD Version 1 16 1035 0 Wee Page Calibration Press Calibrate Coupons to collect hardware and software data points Calibrate Coupons More Calibration Options CD Exit d Real ity works www realityworks com 800 262 3806 Live it Learn it Step 2 The Student Log in button should now be visible Click it to continue If this button is not v
22. cases where there are plates of different thickness the plate thickness refers to the main plate of the assembly These vary based on metal type stainless steel mild steel or aluminum aE K J an ORT CA X Retry Adust On a A 4 Select the welding position SELECT THE WELDING POSITION The position of the plate really it is the assembly s represents your desired welding position Depending on Horizontal the type of coupon it will be could be horizontal or flat siti Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 24 How to Weld Once you are ready to weld bring the tip of the welding gun close to the plate and pull the trigger to start an electrical arc Once metal is added a deposit will be made and a seam will be formed The screen will become very dark during this step simulating the tinted lens of a welding helmet By moving the arc the molten pool will move by creating the seam behind it When you cut the arc the light comes back almost instantly and the seam freezes When the seam is frozen it becomes solid and it is possible to weld on top of it This is required in certain procedures when multiple superimposed seams are required This feature is called multi pass The methods used to create a seam vary depending on the process and on the type of base metal used The GMAW processes use a gun that automatically a
23. e movement of the internal hardware Always move and use the teachWELD workstation with care and if the rattle affects the usage of the system please call product support Coupon becomes broken If your coupon is broken please call Realityworks Product Support We do have replacement pieces available for sale Can I delete a workstation from my list No once you have added a workstation it is there for future usage The next time you plug in the workstation that has already been setup What is the difference between the WS and WS Local WS and WS Local give two different pieces of information For WS it shows a workstation that has not been calibrated but rather is the factory default calibration For WS Local it shows that the local workstation once plugged in will go to the calibration settings of the last user of that workstation So if you are a new user of that workstation you will want to use the WS and recalibrate to your specifications If you are returning to the workstation and were the last to calibrate you can use the WS Local as it is already set to your calibration specifications Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 03 How do I find the workstation number if the serial number is missing from the workstation If the serial number is missing you will want to contact Product Support They will have your serial number on file
24. e previous window Simply click on a date to select and view the information displayed on the right side of the screen If you want to play a selected replay simply click the OK button to go to the main screen of the replay mode In the event that you wish to go back and choose another date interval click on the tab of the previous window identified by a calendar If you want to return to the Mode Selection Menu click the Return button If no replay is available either due to incorrect date selection or simply because no replay exists in the selected date interval the left part of the screen will be blank with an explanatory message An additional back button will display there At that time you can either go back to the mode selection menu or select a new date interval by clicking on the calendar Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 44 Replay Mode Applet Welcome to the Arc simulator HP j Inspection tet Applet started The Start button plays the All other buttons work exactly The In loop button allows replay and will be replaced by the same as in Practice Mode automatic restart of the a pause button when activated see Practice Mode for details replay once it is finished The replay mode allows you to view previous welds made by users on the simulation A weld is saved automatically when a user completes their pass and saves the w
25. eld The replay will cut off unnecessary movements of the gun and weld when no welding is taking place This can eliminate idle time and reduce the size of the replay Once the replay is chose a screen very similar to the one on the welding mode will be displayed It will be impossible to weld Here you can only view the replay from the beginning You are unable to access the Main Menu at this time teach 9 Realltyworks my 12 EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it WELD welding simulation oor www realityworks com 800 262 3806 45 teachWELD EXERCISE Realityworks www realityworks com 800 262 3806 EXPERIENTIAL LEARNING TECHNOLOGY 46 Exercise Mode Applet Exercise choice Exercise details Name Straightness Status Untried Beginner Untried Intermediary Untried Applet started This mode allows you to practice certain particular aspects of the simulator concerning manual dexterity Some datasheets are activated to serve as a model for the exercises and each is divided into 17 separate tests The supervisor can choose which operation sheets of the practice mode are available for the exercises To help the user each exercised is based on one or more elements that are assisted by a particular guide In the more advanced exercises more than one guide will be activated at one time The selection of exercises is similar to the practice mode except that only the datas
26. en it is in contact with the virtual metal The entered password is always incorrect Contact Realityworks product support at 1 800 830 1416 or productsupport realityworks com The Save button does not work For the save button to work you have to have welded over 80 of the joint on the coupon when in the Practice or Exercise modes The Diagnostics button does not work Have you pressed the Save button For the Diagnostics to work you must first save the weld to be able to have a diagnostic report You must also have a working internet connection as the report comes from the matrix that is found on the internet If you do not have an internet connection you will not be able to retrieve a report The Simulation screen turns red when welding rather than dark grey or light black Due to the high volume of graphics that the teachWELD welding simulation uses it needs to have newer technology and drivers on the computer The red color during welding will not disrupt the weld in any way with the change in color If you need more information see the teachWELD System Requirement Sheet or contact Realityworks product support at 1 800 830 1416 or productsupport realityworks com Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 51 The virtual gun is not showing up at all Make sure the hardware gun is close enough to the coupon so that the senso
27. ermined to be invalid or unenforceable under any applicable law it shall be deemed omitted and the remaining provisions shall continue in full force and effect This Agreement may be modified only in writing authorized by Realityworks Realityworks waiver of any right shall not constitute a waiver of that or any other right in the future This Agreement shall be governed by and construed in accordance with the laws and in the state and federal courts of the State of Wisconsin This Agreement constitutes the entire understanding between the parties with respect to the subject matter hereof and all prior agreements representations statements and undertakings oral or written are hereby expressly superseded and canceled Should you have any questions regarding this Agreement you may contact Realityworks by telephone at 715 830 2040 or email at ProductSupport realityworks com Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 5 REALITYWORKS INC LIMITED WARRANTY l APPLICABLE TO THE FOLLOWING PRODUCTS RealCareer teachWELD Simulator What this Warranty Covers Realityworks Inc warrants its products against defects in material and workmanship under normal use for year from the original ship date Realityworks Inc at its option will repair the product with new or reconditioned parts or replace it with new or reconditioned product Repaired replacement products or parts are
28. ggested to be worn while using the simulation to replicate the correct feel of welding and to promote proper safety of welding for when they preform an actual weld Attention teach WELD hardware should not be in direct contact with any metal surface as metal can have an adverse effect on the welding simulator technology Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it A on www realityworks com 800 262 3806 teachWELD Software The teachWELD welding simulation comes with two CDs e Installation CD System Requirement a ieee K 3 Installation CD n e i s o Please review the teachWELD System Requirements on the CD to ensure your computer meets the minimum requirements to avoid unexpected behavior when using the simulator o To install the teach WELD software insert the Installation CD and run the Realityworks MSI installer Directions are included in the installer o This CD includes teachWELD User Guide teachWELD Quick Start Guide and teachWELD System Requirements ye Curriculum CD o The Curriculum is comprised of 13 lessons on Welding Safety Welding Defects Welding Basics and the teachWELD Welding Simulation o Each lesson may consist of Presentation Slides Notes Fact Sheets Realityworks Worksheets Quizzes Projects and much more teachWELD Instructor Site The teachWELD Instructor Site allows instructors and administrators of the teach WEL
29. gineered or included in other software LIMITED WARRANTY REALITYWORKS MAKES NO WARRANTY OR REPRESENTATION EXPRESSED OR IMPLIED WITH RESPECT TO THE LICENSED MATERIALS WHICH ARE LICENSED AS IS ALL WARRANTIES ARE EXPRESSLY EXCLUDED AND DISCLAIMED INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ANY WARRANTIES ARISING BY STATUTE OR OTHERWISE IN LAW OR FROM COURSE OF DEALING COURSE OF PERFORMANCE OR USE OF TRADE ANY STATEMENTS OR REPRESENTATIONS MADE BY ANY OTHER PERSON OR ENTITY ARE VOID YOU ASSUME ALL RISK AS TO THE QUALITY FUNCTION PERFORMANCE AND ACCURACY OF THE LICENSED MATERIALS Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 96 LIMITATION OF LIABILITY IN NO EVENT WILL REALITYWORKS OR ANY OTHER PARTY WHO HAS BEEN INVOLVED IN THE CREATION PRODUCTION PROMOTION OR MARKETING OF THE LICENSED MATERIALS BE LIABLE TO YOU OR ANY OTHER PARTY FOR ANY SPECIAL INDIRECT INCIDENTAL RELIANCE EXEMPLARY OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF DATA OR PROFITS OR FOR INABILITY TO USE THE LICENSED MATERIALS EVEN IF REALITYWORKS OR SUCH OTHER PARTY HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES IN NO EVENT SHALL REALITYWORKS OR SUCH OTHER PARTY S LIABILITY FOR ANY DAMAGES OR LOSS TO YOU OR ANY OTHER PARTY EXCEED THE LICENSE FEE PAID FOR THE LICENSED MATERIALS GENERAL If any provision of this Agreement is det
30. he seam it is the height of the seam from its center usually located on the weld joint By this height the welder can infer many things about the metallurgy of the welding Root Penetration Depending on the angle of the gun in connection with the gap of the two metals this will show how deep you would be able to penetrate into the gap and fill the seam PROCEDURE seu The Procedure button will display the operational welding mode or datasheets in a a browser Like the diagnostics button it will appear after at least one pass is complete Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 30 PROCEDURE DATASHEET A welding datasheet is a precise specification of an operation mode to achieve a weld Generally it includes the disposition of the assembly the metal type the welding process the desired metallurgical result all according to a well established welding standard Each datasheet in the teachWELD simulation has been developed by a certification body or a qualified welding engineer Some examples of these organizations are the American Welding Society AWS The Canadian Welding Board and the American Society of Mechanical Engineers ASME Realityworks INSPECTION INSPECTION MODE The simulator allows a view of the scene This makes a number of things possible such as watching
31. heets associated with exercises will be displayed The displays will correspond with the beginner intermediate and advanced aT m states of the exercises 49 0 mn Arc speed 177 8 381 0 mm min Distance Se 28 6 mm Work angle 25 0 65 0 Travel angle 5 0 35 0 Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 47 Exercise Grading When a weld is finished in this mode a diagnostic and a replay are saved as in the practice mode However an exercise is not considered successful unless the parameter that exemplifies the manual dexterity has been as least 80 success which makes some tests very difficult to succeed at particularly the last one because it affects all of the criteria for manual dexterity simultaneously The overall score for the exercise is the average of all the related scores but even if the average is higher than 80 the exercise can be considered successful only if each point has earned at least 80 individually Exercise choice Difficulty Beginner Exercise details Name Final exercise FEN Status Untried Beginner Untried Intermediary Untried XS Expert Untried There are 17 different exercises that must be completed at the Beginner intermediary and Expert levels The hardest level would be looking fora passing grade of 80 at the Expert level Straightness In this case as the picture shows
32. icon to start or resume exercises In this mode you are guided through each datasheet in a gradual sequence and must demonstrate 80 performance to complete each Exercise 22 Wie gl Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live if 8 Learn it www realityworks com 800 262 3806 22 Welding Options Menu This will show up in the Practice and the Exercise section of the teachWELD simulation software Select a base metal SELECT A BASE METAL The first window shows the choices of base metal The base metal refers to the metal plate in the assembly not the filler metal Select a welding process SELECT A WELDING PROCESS Depending on the selected metal the GMAW process appears The welding process shows which are the required markers and can affect certain functionality mo ey KE 1 Select a gun type SELECT A GUN TYPE The welding simulation allows for three types of gun types to pick from Default should be the Bernard d i teachZ 7 x Realifyworks WELD 1lZ EXPERIENTIAL LERRNING TECHNOLOGY Live it Learn it welding simulation toy www realityworks com 800 262 3806 23 teach amp WELD S welding simulation oaa Select a assembly type SELECT AN ASSEMBLY TYPE The type of assembly refers to the configuration ee Ne T joint fillet weld a the plates that form the assembly Select a plate thickness SELECT A PLATE THICKNESS In
33. ill impact his her view every time that student uses the simulator If an Instructor saves an Adjust adjustment it will impact all of the Students as well as any Instructors on their account NOTE this feature should only be changed by an administrator or for special situations Use sparingly QUIT The Quit button returns to the Mode Selection Menu MAIN MENU The Main Menu button at the lower right will reveal an additional menu at the bottom of the screen called main menu because it contains most of the commands of the teachWELD welding simulation Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 32 Main Menu The main menu is where most of the less used commands of the simulation or those that could not be accessed on the main screen It is divided into several submenus to better categorize the options Each submenu will be described in detail INFORMATION This submenu is the first visible menu of the main menu It displays most of the current parameters of the gun and the weld itself such as the wire speed or amperage the voltage the arc deployment speed the stick out and both the travel angle of the gun and its work angle Only the wire speed or amperage and the voltage can be modified The other information is for reference purposes only The non modifiable information includes the stick out work angle and travel angle
34. isible you must click Calibrate and perform the Coupon Calibration to enable the button SN 0016 LOCAL Student Log in Back EXPERIENTIAL LEARNIN Realityworks Live it Learn it www realityworks com 800 262 3806 Step 3 The Student Login page will load in a new window Enter your Username and Password and press Connect to log in You can also log in with your instructor username and password from this screen W i X 123 EXPERIENTIAL LEARNING TECHNOLOGY Fen ait rep Student Login Username i Password v1 16 943 2012 08 16 15 31 44 Exit Realityworks www realityworks com 800 262 3806 Learn it Live it Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it www realityworks com 800 262 3806 20 teachWELD Software Modes Realityworks www realityworks com 800 262 3806 EXPERIENTIAL LEARNING TECHNOLOGY 21 Mode Selection Menu Disconnect PE EN a You have 4 options from this main page e Click Disconnect in the upper right corner to log out and return to the Student Log In Page e Click on the Practice icon to practice your welding skills In this mode you can select any welding situation adjust difficulty and use dexterity guides e Click the Replay icon to view previous welds In this mode you can browse your weld history by date and see video like replays as well as review diagnostic reports e Click on the Exercises
35. ividual is employed by a student or parent of a student at or otherwise affiliated with the Institution LICENSE Realityworks Inc in consideration of payment of the applicable subscription fee and acceptance of this Agreement grants you a non exclusive transferable license and right to use and access the purchased teachWELD Welding Simulation subscription the Licensed Materials for the purchased term and number of student users affiliated with the Institution USER ACCOUNT INFORMATION You are responsible for maintaining the confidentiality of your account access codes You agree to notify Realityworks Inc immediately of any unauthorized account use OWNERSHIP The Licensed Materials including without limitation all copyrights and other intellectual property rights therein are the sole and exclusive property of Realityworks or its parents subsidiaries affiliates or designers or its suppliers By indicating that you accept these terms you do not become the owner of the Licensed Materials but are entitled to use them according to the terms of this Agreement PROHIBITED USES Except as expressly permitted in this Agreement any copying distribution or modification of the Licensed Materials is strictly prohibited No part of the Licensed Materials may be copied for resale or other commercial use or posted on public bulletin boards web sites Internet domains or online chat rooms No part of the Licensed Materials may be reverse en
36. l pop up The next steps are performed with the welding gun a Q Se fos CAWindows system32 cmd exe Reading gun calibration matrix from C Users jmc intosh REALITYWORKS arc calib gun Position the gun at calibration point 1 and pull the trigger 5 g C Windows system32 cmd exe F igure D USBManagerWin32 check_devices device connected Cid O size 53 Reading gun calibration matrix from C Users jmcintosh REALITYWORKS arc calib gun Position the gun at point 1 and click the trigger Position the gun at point 2 and click the trigger a m ma C Windows system32 cmd exe HUS BManagerWin32 check_devices device connected Cid B size 53 Reading gun calibration matrix from C Users jmcintosh REALITYWORKS arc calib E gun Position the gun at point 1 and click the trigger Position the gun at point 2 and click the trigger Position the gun at point 3 and click the trigger CAWindows system32 cmd exe USBManagerWin32 check_devices device connected Cid t size 53 Reading gun calibration matrix from C Users jmcintos REALITYWORKS arc calib gun Position the gun at point 1 and click the trigger Position the gun at point 2 and click the trigger Position the gun at point 3 and click the trigger 6 53687 6 14316 0 83143 130 82423 6 61183 6 74462 4 26685 165 66006 4 58689 6 65196 6 48735 22 89948 J 4 66606 4 66608 4 66608 1 66666 1 Base c
37. le will appear on the list Once the user is selected the time span selection window will appear and the rest of the procedure is then identical to that of a normal student Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 42 Student View Time Span Selection Window In this l window Time span choice User Student 1 you must select two April 2012 April 2012 dates Both dates will be the time Tue Wed Tue Wed Thu limits for searching the replays You must pick a start date on the first calendar and an end date on the second calendar You can change the month with the transverse arrows but the time cannot be before the year of 2008 teach amp WELD welding simulation eent www realityworks com 800 262 3806 43 ein Realityworks EXPERIENTIAL LERRNING TECHNOLOGY Live it 8 Learn it Replay Selection Window Replay choice User Student 1 OTRAS Hrgeass SMA DPF OS Taare mpgs ey ZUG AS 8 EA Prsssssc Cully AR Pace ee SA GE ROCESS MAV RS Te AB ias Pidesss KEMENY oaa e Midesss GMA PZI AGESANG Pideass SNA IPEE ERAN mrsesss GMA Replay details AON AG TT 2G G20 7 OTA GTZ Sia 08 Trj 1 r it a5 20120116 7720020 Process GMAW Once the dates are selected this window appears and displays all the replays that have been made between the dates specified in th
38. nostics listing will show the most recent 10 diagnostic reports for each student An and David in the example shown below Each row shows a brief summary for each individual Diagnostic with the Dexterity and Metallurgy scores found at right J e Click See complete list to see a student s entire Diagnostic history Diagnostics An Id Date Process Assembly Base metal Plate thickness Dexterity Metallurgy 24390 2012 08 03 12 16 59 GMAW T joint fillet weld Mild steel 6 4 81 33 24389 2012 08 03 11 02 54 GMAW T joint fillet weld Mild steel 6 4 94 58 24381 2012 07 27 13 36 37 GMAW T joint fillet weld Mild steel 6 4 79 8 23954 2012 07 26 16 34 54 GMAW T joint fillet weld Mild steel 6 4 90 45 23946 2012 07 26 16 31 04 GMAW T joint fillet weld Mild steel 6 4 80 32 23719 2012 07 26 13 47 21 GMAW T joint fillet weld Stainless steel 6 0 78 65 23575 2012 07 26 11 17 50 GMAW T joint fillet weld Aluminum 10 0 63 37 23559 2012 07 26 11 08 54 GMAW T joint fillet weld Mild steel 6 4 80 33 23386 2012 07 26 09 07 09 GMAW T joint fillet weld Mild steel 6 4 99 71 23091 2012 07 25 14 47 14 GMAW T joint fillet weld Mild steel 6 4 96 73 See complete list View Progress David Id Date Process Assembly Base metal Plate thickness Dexterity Metallurgy 23157 2012 07 25 15 20 37 GMAW T joint fillet weld Stainless steel 6 0 55 31 23152 2012 07 25 15 17 12 GMAW T join
39. ny use of your Realityworks Inc product constitutes your agreement that the laws of the Unite States of America shall apply to any and all actions under this extended warranty and such shall be under the jurisdiction of and venued in t Circuit Court Eau Claire County State of Wisconsin with the Court applying Wisconsin law Realityworks EXPERIENTIAL LERRNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 08
40. of the screen is used to display the Main menu If you activate it the main menu will appear and take a portion of the screen teach 9 Realltyworks WELD PA EXPERIENTIAL LERRNING TECHNOLOGY Live it Learn it welding simulation on n 2 Welding Toolbar The Menu button calls again for the welding parameters selection wizard It is used to quickly change the settings for the next welding 41S SS Sa z E lt PLA M p e Procedura vets A O A a gt i The Return button allows you to go back to the main screen of the teach WELD a simulation You will return to the Mode Selection Menu Retr START The Start button is used from the Mode Selection Mode When you have picked all your welding information you can click on the start button to begin practice welding END The End button allows you to save your weld When you save your weld it will then save to the Replay mode of the teachWELD simulation You will also be able to see the diagnostic report The Diagnostic button will not be clickable until a weld has been done DIAGNOSTIC The Diagnostic button is available after the first pass has been completed When activated it will display the current welding score in a web browser iil Realityworks 123 EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it toy www realityworks com 800 262 3806 28 DIAGNOSTIC REPORT The diagnostics is a
41. order to decide if the user misses points on this quality of movement In the profile of a welder there is a variance in the level of difficulty This variance affects the margin between the minimal maximal and perfect values The higher the level of difficulty the more the margin of error shrinks When possible the guides try to reproduce visually this margin of error and or to indicate the necessary corrections INSPECTION Camera position fined view Inspection B D information D Parameters paeran bo oute This menu is used to change the camera view 1 Predefined views a The predefined views are a basic position for the camera depending on the position of the assembly The front view is somewhat set at a low angle and the other three views are perpendicular to the center of the plate Each view can then be modified to see something in more detail 2 Camera position a The red button acts like a joystick that can interact with the touch screen by clicking and dragging When activated it can either move or turn the camera with an equivalent force to the distance to the original point of the joystick The two buttons on the left of the joystick are mutually exclusive One indicates that it is in the rotation mode the other indicates the movement mode You can also press the eight arrows around the joystick but they can be more difficult to operate Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn i
42. ot have one Pass Adding a welding seam on a joint Practice Option to choose your own welding parameters to use Replay Option to view a previously made saving Trigger Located on the welding gun the trigger allows the beginning of the electric arc Zoom Operation to move the camera in the virtual scene Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 90 Troubleshooting The virtual gun does not follow the actual movements of the gun The detection is imperfect To make the detection of the gun and other items perfect make sure that the environment surrounding the simulator is adequate Metal objects even pop cans or coffee mugs can cause interference with the workstation technology The calibration of the coupons could also be off This can happen if you have started the workstation cold and after about 20 minutes it has warmed up causing a recalibration of the coupon on the technology In this case it is best to recalibrate the coupon first to correct the problem A last resort is to recalibrate the workstation but this should only be done after you have tried to recalibrate the coupons The arc does not initiate when you press the trigger First check whether or not the gun is virtually hitting the coupon Depending on your angle of view it may look like you are hitting the coupon and actually just shy of the coupon The trigger should only work wh
43. peed are shown below 3 SA RE es Po gt 3 a Pa v s a B a p gt EDR S ed p 7 _ a a ait gt d eJ 5 bA aa Guid es zo tra Y e and work angle are shown above When you are in incorrect position the red itself with a green line for you to follow If you are too arrows will show and start to turn green and fade far behind or ahead the green line will start to turn away as you move to the correct position red showing you to either speed up or slow down Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it Learn it www realityworks com 800 262 3806 34 The guides activated in practice mode manually are indicators of the ideal movement that the user should follow First of all let us define the ideal movement Every possibility of a plate in the simulator is linked to an operational mode datasheet It is this association that makes the welding parameters as true as possible because they are based on a method used in real life by certified welders Included with this operational datasheet in the simulation is a set of criteria for the movements the perfect work angle the perfect speed and others With these ideal parameters comes a margin of error For example if the angle of welding should be 45 degrees the user can tolerate between 55 and 35 degrees to the upper and lower limits It is on the values that the diagnostics rely in
44. pplies the filler metal through the nozzle In this method simple press the trigger and the creation of the arc and the molten pool are almost instantaneous It is important to keep the trigger pressed so that the intake or metal can be continuous and the arc can be maintained The arc will be cut in three ways 1 The user ceases to press the trigger The user tries to weld outside the plate 3 The distance between the plate and the nozzle is too great oe Realityworks m S 3123 EXPERIENTIAL LEARNING TECHNOLOGY Live it J Learn it Spy nit Cerne www realityworks com 800 262 3806 29 teachWELD PRACTICE Realityworks www realityworks com 800 262 3806 EXPERIENTIAL LEARNING TECHNOLOGY 26 eee Practice Mode Overview ee s J ae a works com o r gt Ea N a Procedure Inspection Retry Adjust gt x a i This is the main mode of the simulator It is possible to weld without any constraint in Practice mode The toolbar at the bottom is always present and contains the main welding commands In this screen you will see most of the graphic items that make up the simulator namely welding plates the virtual gun and after welding the seams and the welding effects The background workshop as well as the work plate is only presented to enhance the vision these are only graphics and have no impact on the welding to be done The button at the bottom right
45. rs of the welding gun can show up on the software If you have the gun close to the hardware coupon and it still is not showing up make sure that the USB cord of the workstation is connected to the computer You may need to check and make sure that you have added the workstation to the teachWELD workstation setup see page 13 Check the serial number on the workstation on the back bottom next to where the USB cord exits the workstation to make sure it has been loaded into the teachWELD system It takes a long time to save a virtual weld The software must be connected to the internet to be able to pull down a diagnostic report Due to the high volume of data being sent over the internet it is always best to have a direct internet connection If you are using wireless or a hotspot these times may increase for the weld to save as this may have weaker internet access available Why is the welding gun out in space The welding gun has a ghosting look when the gun is not in the correct position As you move the gun to the correct work angle travel angle and stick out distance the ghost gun starts to disappear This is an added feature that helps the user understand proper welding technique Gun on the screen does not move When you are in practice mode make sure that the Inspection icon is not engaged When looking at the Main Menu make sure that the Main Menu is closed before trying a weld Welding gun jumps all over the
46. screen when I get it close to the coupon If you see the gun jumping on the screen there are two main issues that may be causing the problem The first issue is calibration Recalibrate the workstation and also the coupons The second main issue may be interference Check to make sure that you don t have metal objects that are close to the workstation Due to the technology of the workstation it needs to have a distance of about 3 feet from any heavy metal objects I log into my account and images are missing If you see images that are missing the first option would be to logout and try logging in again The second option would be to call product support to see if there is a server error or new software download that you have not uploaded Realityworks EXPERIENTIAL LERRNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 52 What are the system requirements for the welding simulator http www realityworks com images teachWELDspecs pdf Is distance and stick out terms used interchangeably Distance and stick out are the same in this case what is being asked is distance from the coupon which is directly related There is a rattling noise in the workstation The workstation is comprised of technology components that work directly with the computer and software These electronic components when in use may make small amounts of noise However rattling noises in the workstation may indicat
47. st score that is saved So if at least one attempt has been made on an exercise a replay is saved and is available for viewing To do this select an exercise that has at least one test and click above it the button should be green At this time instead of launching the exercise you can press the button labeled as View better replay The Replay Mode interface will appear and you can view the attempt at the exercise The features are the same as in the replay mode The replay is chosen based on the scores and level of difficulty In case of similar or even lower score if the exercise is successful the simulator will choose a higher level of difficulty Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 49 GLOSSARY Camera Position of the view in the virtual space Datasheet Sheet describing a formal method and the welding parameters to use In this document it is our own model for welding recipes Diagnostic Evaluation document of a virtual welding Disconnect Action to return to the user selection menu Electric arc Small flash occurring during welding Exercise Welding where only certain criteria are evaluated with or without the help of the guides Joint Section of an assembly where a welding Marker Reflecting ball used by the motion capture system Nozzle Front part of a welding gun through which the filler metal passes Some welding guns do n
48. station calibration should work in most circumstances This calibration should only be attempted if you are experiencing interference from metal electronics or magnetism in your use environment Only calibrate the workstation when you are troubleshooting precision issues with the teachWELD software Step 1 Click on More Calibration Option on the Calibration page Figure E then click on the Calibration Workstation button Figure F E wooo verso sin E ae 123 rA S Tenn amp teachWELD Version 1 16 10 LO V teno Calibration Workstation Calibration should only be done when you are troubleshooting precision issues with the teachWELD software You may wish to contact Product Support for additional help Figure F Calibrate Workstation Reset to Factory Defaults Figure D Press Calibrate Coupons to collect hardware and software data points Calibrate Coupons Required More Calibration Options Back Exit Realityworks www realityworks com 800 262 3806 Learn it Back Exit Realityworks www realityworks com 800 262 3806 Live it Learn it Step 2 After clicking on the Calibrate Workstation button a new data screen will pop up C Windows system32 cmd exe oB xT Hold the gun in position and pull the trigger Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 17
49. t www realityworks com 800 262 3806 35 A rotation is a movement around a fixed point as if one moved around a sphere The point in question is always directly in front of the camera at the center of the screen point of sight In a movement the camera and the point of sight move on a two dimensional plane Rotating the camera is similar to turning the head with the help of the neck while standing still For movement you are moving your position while keeping your point of sight at the same place WORK ANGLE CALIBRATION Work angle Calibration Calibrate v Se e l Minimum 47 8 Capture D Dexterity guides Maximum 83 8 Capture This menu is used to fine tune the work angle calibration Step 1 To enable this calibration check the Calibration box on the left side of the screen This is the default setting Step 2 While holding the gun with the tip on the weld joint at the center of the T joint coupon and the handle touching the front edge of the workstation click the Capture button beside the Minimum number Step 3 While holding the gun with the tip vertical and touching the vertical plate of the T joint coupon click the Capture button beside the Maximum number This calibration should only be done if the reported Work Angle is different from the actual observed Work Angle Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it conn www realityworks com 800 262 38
50. t fillet weld Stainless stee 6 0 80 95 21854 2012 07 20 06 46 15 GMAW Lap Joint Mild steel 6 4 88 52 21851 2012 07 20 06 45 06 GMAW Lap Joint Aluminum 10 0 95 66 21849 2012 07 20 06 44 18 GMAW Lap Joint Aluminum 10 0 95 64 21846 2012 07 20 06 43 19 GMAW Lap Joint Aluminum 10 0 86 65 21843 2012 07 20 06 41 45 GMAW Lap Joint Aluminum 10 0 76 55 21841 2012 07 20 06 41 00 GMAW Lap Joint Aluminum 10 0 75 65 21803 2012 07 20 06 15 46 GMAW Lap Joint Aluminum 10 0 71 57 21801 2012 07 20 06 14 57 GMAW Lap Joint Aluminum 10 0 78 8 See complete list View Progress To view the entire diagnostic report click on the Id link and it will open in a new tab or window Step 5 Click View Progress on the Diagnostic page to see a student s Exercise history broken down by assembly type metal and difficulty Click on a link to see detailed information Progress Through Exercises Back to user list David Mild steel Aluminum Stainless steel Beg Int Exp Beg Int Exp Beg Int Exp T joint fillet weld 0 17 0 17 0 17 0 17 17 17 0 17 1 17 7 17 0 17 Lap Joint O 17 0 17 0 17 0 17 17 17 0 17 Of 17 0 17 0 17 V groove with backing plate 1 17 O 17 Of 17 0 17 17 17 0 17 Of17 0 17 0 17 Exerose 1 Exerose 2 Exerase 3 Exerose 4 Exerase 5 Exerase 6 High Scores For Exercises Back to progress summary Beginner David T joint fillet weld Aluminum High score 0 Intermediary 100 87 100 10
51. the seam very closely having a stable camera and having a field of vision that gives you the best view of your weld There are two control groups for the inspection mode but you cannot go into inspection mode wherever you wish Generally you can access the inspection mode with the Inspection button of the main option bar at the time when you are not welding However once a welding arc is created it automatically switches off the inspection mode As soon as you enter the inspection mode a few additional buttons will appear to the right of the screen The top one indicates the camera the middle one indicates zoom in and the bottom one indicates zoom out The camera button repositions the camera to a neutral position set back and viewing the plate toward the bottom The zoom in button moves the camera a little forward The zoom out button does exactly opposite Please note that it is possible to move forward and backward endlessly in this way Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 31 RETRY The Retry button removes all passes made and returns to the original welding status If the welding has not been saved a window will appear to confirm this selection The Adjust button shows additional controls to further modify the spatial position of the welding assembly Once saved these changes are fixed If a Student saves an adjustment it w
52. uct to you It is highly encouraged that returned items be insured for replacement value Do not return any loose parts or any accessories that are not defective wit your product to avoid damage and loss in transit General Provisions This warranty sets forth our responsibilities regarding this product Repair or replacement at Realityworks Inc s option is your exclusive remedy THIS WARRANTY IS GIVEN IN LIEU OF ALL OTHER EXPRESS WARRANTIES IMPLIED WARRANTIES INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FO A PARTICULAR PURPOSE AND SUCH IMPLIED WARRANTIES ARE LIMITED TO THE DURATION OF THIS EXTENDED WARRANTY IN NO EVENT SHALL REALITYWORKS INC BE LIABLE FOR DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE PRODUCT FOR ANY LOSS OF USE INCONVENIENCE OR OTHER INCIDENTAL SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE SUCH PRODUCT TO THE FULL EXTENT SUCH MAY BE DISCLAIMED BY LAW This disclaimer applies both during and after the term of the warranty The terms of this warranty are exclusive and there is no other dispute resolution mechanism State Law Rights SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LIMITATIONS ON HOW LONG AN EXTENDED WARRANTY LASTS SO THE ABOVE LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU This warranty gives you specific legal rights and you may also have other rights which vary from state to state A
53. webpage containing the results of a weld made in the simulation There are two main categories for evaluation the first relating to the gestures of the user during the welding and the second relating to the metallurgical quality of the weld To evaluate a weld several criteria are taken into account in each category and an average of these scores make up the final score in the category METALLURGY DIAGVOSTIC 2 es 407 EXPERIENTIAL LEARNING TECHNOLOGY Live it Diagnostic Scores Most of the scores are derived from the operational mode datasheets from the gesture data and mathematical formulas aiming to approximate the best possible welding phenomenon of welding for the metallurgical qualities While both are calculated separately they are in fact interdependent the welding is the result of the accuracy of the gesture and the gesture is calculated by taking into account the parameters required to create a proper weld For the criteria for gesture also known as manual dexterity the guides mentioned in the welding mode section are indicators of each evaluation criterion Each criterion has an ideal value and an acceptable variation which may be different if you are over or below the value Also there is an option in the main menu and the welder profile where you can increase or decrease the margin of error by changing the difficulty level from beginner intermediate and expert Realityworks Learn it
54. y Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 54 Will instructors have the ability to change their own username and password If they do and if they forget is it a matter of us logging into their account profile and changing it ourselves Yes on both accounts All other questions can be directed to Realityworks product support at 1 800 830 1416 or ProductSupport realityworks com Realityworks EXPERIENTIAL LEARNING TECHNOLOGY Live it 8 Learn it www realityworks com 800 262 3806 99 REALITYWORKS INC Subscription and License Agreement READ THE FOLLOWING USE CONDITIONS AND DISCLAIMERS IN THIS AGREEMENT CAREFULLY BEFORE INDICATING YOUR ACCEPTANCE By selecting the Accept button and returning the accompanying registration form you agree to become bound by the terms of this Subscription and License Agreement Agreement If you do not agree to these terms select the Decline button and return to the vendor In this Agreement the term you refers to i an individual purchasing a subscription as an agent for a corporation organization or other entity ii a corporation organization school institution or other entity purchasing a subscription or iii an individual consenting to this Agreement as a condition of using the teachWELD Welding Simulation through a subscription purchased by a school or other institution Institution where the ind

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