Novarc Technologies computer vision system to produce X-ray quality welds with zero operator intervention
In the pipe welding industry, advancements in automation continue to provide solutions to the labour gap caused by an acute shortage of skilled welders. Novarc Technologies Inc., a full-stack robotics company specialising in designing and manufacturing cobots and computer vision AI for automated welding applications, has been a pioneer in welding automation since 2013, providing a solution to the welding labour shortage.
Weld Australia predicts a shortage of nearly 70,000 skilled welding operators in Australia by 2030. With an aging welder workforce and a need for uptake of the welder trade, there are no simple solutions to the welder demographic.
According to Geoff Crittenden (CEO, Weld Australia), a member survey conducted in 2023 found that “labour shortages, and the rising cost of materials, energy and labour remain high on the agenda for the welding industry. Without funding and support from governments at all levels, these challenges will make it nearly impossible for industry to deliver the necessary manufacturing capability required for the Federal Government’s ambitious renewable energy revolution.”
Novarc Technologies Inc.’s flagship product is the Spool Welding Robot (SWR™), the world’s first collaborative welding robot that automates the pipe welding process. The SWR works alongside a human welder to increase productivity, weld quality, and consistency, potentially recovering capital investment within six to 18 months.
Novarc recently launched a new computer vision and image processing system that fully automates the pipe welding process, called NovEye™ Autonomy (Gen 2).
With NovEye Autonomy (Gen 2), the SWR is armed with game-changing software developed using years of Novarc’s data collection and deep learning. The software is embedded in the SWR’s control system and controls the weld in exactly the same way a human welder would, allowing the boring, repetitive welds to be delegated to the robot.
NovEye Autonomy (Gen 2) delivers X-ray quality welds with zero operator intervention, maximising productivity and minimising errors. The autonomous welding process continuously improves through a terabyte-scale library of welding videos, ensuring unmatched precision and reliability.
NovEye Autonomy (Gen 2) uses live-stream video from the camera mounted on the SWR’s torch to analyse the scene and detect welding states. The AI then adjusts welding and motion parameters in real-time based on these detected states.
“This marks the beginning of a new era as we have developed the intelligence to automate the welding process fully,” said Soroush Karimzadeh, CEO of Novarc. “This accomplishment has resulted from years of data collected through machine learning, and we are extremely excited to be able to offer this solution to the industry.”
Novarc has been developing NovEye Autonomy (Gen 2) for several years, performing extensive internal and external tests to ensure all features perform properly and the weld quality meets ASME standards. The technology delivers a perfect root pass by controlling the weld and motion parameters against gaps, hi-lo, tacks, and out-of-round pipe changes.
This development will have a positive impact on fabricators and contract manufacturers in Australia and New Zealand. They are held to strict standards to provide sophisticated welds for industries such as mining, energy, utilities, and manufacturing. All of these industries stand to benefit from the consistent, X-ray-quality welds that result from the engineering features and advanced AI provided by NovEye Autonomy (Gen 2).
NovEye Autonomy (Gen 2) can easily integrate into customers’ existing manufacturing processes across a range of industries. The Spool Welding Robot with NovEye Autonomy (Gen 2) is designed with a very small footprint but a very long reach, enabling it to fit in almost all fabrication shops and ease the adoption of automation.
NovEye Autonomy (Gen 2) also dramatically reduces human exposure to all welding hazards, as it positions the operator several metres away from the welding arc and fumes. Operators can program the weld and observe the weld away from the arc, reducing the risk of exposure to dangerous fumes and radiant heat. Muscle fatigue is also reduced as the welding process is fully automated: ultimately, a win-win for the health/safety and job satisfaction of the welder and the productivity of the fabrication shop.
“NovEye Autonomy is truly hands-free welding. It can change welding parameters and torch manipulation in real-time, all based on the current joint geometry,” said Karimzadeh.
This is helping to solve the labour issue in the welding industry, as the prospect of working with a cobot attracts more young people into the profession and does not require the high level of skill that is currently mandatory.
“NovEye Autonomy (Gen 2) does not require the operator to be a highly skilled welder. After some basic training on how to operate the SWR, an operator can oversee equipment that can make X-ray quality welds in a fraction of the time, at a fraction of the cost to the fabrication shop,” said Karimzadeh.
Novarc’s technology solves the labour gap, which is particularly ominous in the welding industry. It allows less skilled welders to do more sophisticated welds, making welding more attractive to young people considering the profession. “The welder just has to get the pipe fitted and on positioner, hit weld, and NovEye handles the rest,” added Karimzadeh.
Novarc’s SWR is sold in Australia, New Zealand, North America, Europe, and the Middle East.