The Miller LiveArc Welding Performance Management System is a comprehensive training system designed for MIG (GMAW), Gas Shielded Flux Core (FCAW-G), and Stick (SMAW) welding with optional equipment. It provides a realistic welding experience for students and allows instructors to manage assignments, track progress, and review test history.
Function Description:
The LiveArc system is an interactive welding training tool that simulates real-world welding scenarios. It uses a SmartGun or SmartStinger with integrated cameras and sensors to track gun/stinger position, work angle, travel angle, travel speed, and contact tip to work distance (CTWD). The system provides real-time visual and haptic feedback to guide users in maintaining proper technique. It supports both simulated (SIM) and live welding modes, allowing users to practice without consuming materials or to perform actual welds while still receiving performance feedback. Instructors can create and manage assignments, view detailed performance metrics, and track user progress. The system also includes features for equipment setup, calibration, and maintenance.
Important Technical Specifications:
- Dimensions (Unit with Positioning Arm): 45.5 x 31.5 in. (116 x 79 cm)
- Dimensions (Unit with Optional Stick Upgrade Module): 45.5 x 32.75 x 81.5 in. (116 x 83 x 207 cm)
- Weight (Unit Base): 480 lb (218 kg)
- Weight (Unit with Optional Stick Upgrade Module): 506 lb (230 kg)
- Input Power: 120 Volts AC, 15 Amps, 60 Hz
- Operating Conditions (Maximum Relative Humidity): 80% for temperatures up to 88°F (31°C) and decreasing linearly to 50% at 104°F (40°C)
- Training System Operating Modes: GMAW/FCAW: Simulated (SIM) and Live Arc (WELD); SMAW: SETUP and Live Arc (WELD)
- Welding Power Source: GMAW/FCAW: Constant Voltage (CV); SMAW: Constant Current (CC) with Dinse 35 Connector
- Recommended Wire Feeder: Any Constant Voltage (CV) or Voltage Sensing Feeder with Power-Pin Connection and Four-Pin Trigger Receptacle
- Software Version: Displayed On Software Updates Screen (See Section 8-3)
- IP Rating: IP21 (designed for indoor use and not intended to be used or stored outside)
- Operating Temperature Range: 32 to 104°F (0 to 40°C)
- Storage/Transportation Temperature Range: -25 to 160°F (-31 to 82°C)
Usage Features:
- User Login and Registration: Users log in with a username and password. New users can be registered by instructors, specifying their name, ID, handedness (left/right), and role (student/instructor).
- Assignment Management: Instructors can create new assignments, copy existing ones as templates, edit parameters (joint design, base metals, filler metals, shielding, position, electrical characteristics, technique, preheat, postweld heat treatment, welding procedure, and completion criteria), and manage user access to assignments.
- Calibration: The system requires calibration of the weld table, joint calibration tool, and SmartGun/SmartStinger for accurate performance. This involves placing calibration plates or tools in specific positions and confirming settings on the touchscreen.
- Welding Modes:
- SIM (Simulation) Mode: Allows users to practice welding without consuming materials. Provides real-time feedback on technique parameters like work angle, travel angle, CTWD, and travel speed.
- WELD (Live Arc) Mode: Enables actual welding with real materials while still providing performance feedback and scoring.
- Real-time Feedback: Visual guides on the touchscreen monitor and haptic feedback from the SmartGun/SmartStinger help users maintain proper gun/stinger positioning and technique. The SmartGun/SmartStinger LEDs track movement and provide status indications.
- Performance Tracking: The system captures various parameters during weld tests, including gun technique (work angle, travel angle, CTWD, travel speed) and arc parameters (volts, amps). It provides a total score and detailed graphs for each parameter, allowing users to review their performance history.
- User Management: Instructors can view current users, add new users, edit user information, delete users, and review individual user history for each assignment.
- Dashboard: Provides an overview of system usage, including the total number and duration of tests in both Weld and Sim modes, and contactor life.
- Language Selection: The system supports multiple languages, configurable on the user login screen.
Maintenance Features:
- Daily Maintenance:
- Touchscreen and Camera Lens Cover: Clean with a clean, damp cloth. Avoid chemicals, solvents, or abrasive cleaning solutions.
- Work Table Surface and Markers: Remove debris. Clean with a clean, damp cloth. Avoid chemicals, solvents, or abrasive cleaning solutions for table markers. If the table surface is uneven due to grinding, it can be flipped or replaced.
- Positioning Arms: Check for free movement.
- Joint Calibration Tool: Clean with a clean, damp cloth. Avoid chemicals, solvents, or abrasive cleaning solutions.
- Every 3 Months Maintenance:
- Labels: Inspect for damage or unreadability and replace if necessary.
- Weld Cable: Inspect for cracks and repair or replace if necessary.
- Gun Cable/Stinger Cable: Inspect for damage.
- Outer Surfaces: Clean.
- Inside Unit: Inspect.
- After Each Spool of Wire:
- Gun Liner: Inspect and replace as needed. Instructions for removal and replacement are provided in Section 13-5.
- Nozzle and Contact Tip: Inspect and replace as needed. Instructions for removal and replacement are provided in Section 13-4.
- Overload Protection: The system is protected by F1 and F2 fuses. If a fuse opens, it indicates an internal problem and requires replacement by a Factory Authorized Service Agent.
- Software Updates: Software updates can be downloaded from MillerWelds.com/LiveArcSoftware and installed via a USB flash drive.
- Data Backup and Restoration: User data, assignments, and test histories can be backed up to or restored from a USB device or a selected network location.
- System Defaults: The system can be restored to factory default settings, which will delete all custom assignments, user profiles, and test history. This option should be used with caution.
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