Goldschmidt-Thermit-Group

SmartWeld ControlFor measuring the Thermit® Welding Process

ThermitWelding (GB)

SmartWeld ControlFor measuring the Thermit® Welding Process

The SMARTWELD CONTROL is a retro-fit tool designed to be used with all alumino-thermic welding processes and replaces the current analogue pressure gauges.

Its purpose is to assist the welder with controlling the welding process and monitor performance during preheating.

Benefits:

• Preprogrammed with ALL Thermit® Welding

process parameters

• Reliable and Accurate measurement and recording

of the welding process

• Robust and compact with no moving parts

• Calibration

• Data can be downloaded to produce weld records

and customer specific reports.

Provided with standard hose fittings and all associated safety devices, the control unit can be inserted into any gas supply to measure rail cutting and preheating parameters and record all other key process variables, including weld location, date and time of welding, rail type, portion and mould information, rail and ambient temperature.

Once the welder has selected the process and type of rail to be welded, the required welding variables are displayed, and recorded throughout the welding process. If any of the measured conditions run out of tolerance the device emits a visual and audible alarm. The controls are all back lit for night use.

The Significance of the Preheating Process A preheating process forms the critical part of ALL Alumino-thermic welding methods. Its purpose is to:

• Preheat the rail ends to a sufficient degree for full fusion

• Control solidification to produce a symmetrical weld profile

• Prevent oxidation of the rail ends prior to casting of the steel

• Avoid melting of the rail ends which may result in weld defects

• Minimize the size of the heat affected zone in the rail.

• Remove moisture from the system

Features While the prime role of SMARTWELD CONTROL is to aid accurate control of the welding process and monitor the system during the welding process, additional functionality has been built in to provide all the key information – to the track engineer, welding manager or quality inspector – that currently has to be provided manually. This includes:

Site – date, time, GPS + detail site location, ambient & rail temperature,

Welder and welder, company welding skillsContractor –

Rail and Welding rail profile, manufacture, wear, age, welding portionmaterials – and mould

Welding process Preheating time, gas pressures, gas temperature,monitoring – Tapping time

Input Information:

USB: Welding Process Parameters,

GPS: Co-ordinates, time, date (Advance location co-ordinates linked to Sat. Nav)

Barcode Reader: welding consumables (Rail information) welder information (option)

Magnetic tag: Welder information – skills, permits, employer

Touch screen Rail Details, Site / weld location,menus: Stressing information:

Process Control and Monitoring

The drop down menus and simple push button controls guide the operator through the setting up procedure and display all the operating parameters. The preheating conditions are monitored continuously and recorded throughout the welding process. If any of the measured conditions run out of tolerance the device emits a visual and audible alarm. The controls are all back lit for night use.

Records & Reporting – SMARTWELD DATA

SMARTWELD CONTROL can store records for up to 2000 welds, before its memory is full. The battery condition is displayed and the unit should operate for over 8 hours before recharging.

The i-button access is used to allow authorized users to download the weld data or upload new process parameters via a USB link to a PC. The latest version has a built in GPS transmitter to send all data to a secure server with text messaging for emergency reporting.

The windows based SMARTWELD DATA software provided with the unit is used to input process parameters, programme the I-buttons, and download the weld data to produce weld installation reports, or export into XL ERP or third party secure servers.

Digital Display: Selected weld records including date, time, preheat

USB – Download to PC

GSM Sim – text messaging and upload to secure server

In addition to automatic download into the central server, Data can be sent as text files or a more detailed report the encrypted date can be converted to produce “standard” weld records of the type used by Network Rail or a bespoke record designed to customer.

Goldschmidt-Thermit-Group

ThermitWelding (GB)

Technical data

Pressure measurement Range accuracy >100B - +/- 0.05B

Units Bar, p.s.i, Kpa,

Temperature measurement Range accuracy >80 deg C +/- 0.5 deg C

Units Deg C, deg F

Operating voltage 12v DC

Max data storage 2,000 welds

Weight 7.8 kg (excl hoses)

Dimensions 350 x 300 x 150mm

For more information please call: 0044 1708 522626

Email: info@thermitwelding.co.uk

www.thermit-welding.com

Thermit Welding (GB) Ltd.

87 Ferry Lane, RainhamEssexRM13 9YHEngland

Telephone: +44 (0)1708 522626Fax: +44 (0)1708 553806info@thermitwelding.co.uk

www.thermit-welding.com

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Components – Supplied with the Smart Control

Item Part No. No. each

SMARTWELD CONTROL – version 1.5 160105Fittings included: (Also available separately)

Hose – 2 m – oxygen – incl. fittings 161000 1

Hose – 2 m – fuel gas – incl. fittings 161100 1

Dallas buttons – red – welders 161200 4

Dallas buttons – yellow – supervisor 161210 1

Dallas buttons – green – manager 161220 1

Dallas button programming unit 161500 1

Dallas button programming unit – connector 161600 1

Charger with mains lead 161700 1

In car charger 161800 1

Bar code reader 161900 1

CD containing manual plus software 160800 1

USB cable 162000 1

Accessories and spares (not supplied with standard pack)

Rail Stand 160200 1