In today’s manufacturing world, greater focus is being placed on maximizing the efficiency of all processes and operations on the plant floor. When it comes to welding, shielding gas consumption is a central issue facing welding engineers and plant managers as they seek efficient and cost-effective manufacturing processes. As gases are not visibly consumed during the welding process and often their usage is not tracked and gauged as vigorously, it is a more difficult “part” to keep track of in it’s usage. Failing to track this, however, leads to increased and unnecessary costs being spent on gas, shorter lifetimes on the tanks that store them, and increased handling costs for having to shuffle out tanks with more regularity.
Solutions exist that save gas consumption with outstanding results. Electronic Welding Regulators, pioneered by Regula and carried by ABICOR BINZEL, are one of the most cost-effective and easy to implement solutions to save on shielding gas consumption.
How It Works:
The EWR is a device that controls the flow of shielding gas for arc welding. When the welding process begins, the gas that is between the outlet of the EWR and inlet of the gas solenoid is set at a predetermined pressure in a non-flow state. The EWR monitors this set pressure level and maintains it during the non-flow condition. The gas is stored in the section of hose between the EWR outlet and the gas solenoid inlet, and the length of that hose determines the required gas pressure.
After the solenoid is opened the pressurized gas is then released into the welding torch, purging the torch of moisture that may have developed in the gas line during the non-welding condition. During the actual welding cycle, the EWR monitors the welding current and meters shielding gas based on the amount of current in the welding arc. The gas current is applied via a standardized curve within the unit and flow can be added or reduced by changing the start point of the curve.
Benefits of the EWR:
Using an Electronic Welding Regulator offers multiple advantages that will improve your welding operation. From up to a 60% saving on shielding gas, to increased process stability, improved welding arc due to gas flow consistency, and longer tank lifetimes, the EWR will make your welding process more economical and efficient. Using the EWR will also allow for a stronger and more stable gas flow as opposed to the standard gas flow without it. It can also be used on bulk systems as well as bottles if the gas pressure is controlled between 45 and 65 PSI. With the EWR Pro Display Unit the gas usage and pressure can be viewed with additional information displaying data that would suggest leakage and pressure issues as well. In the video below, we demonstrate the difference of welding with the EWR and without it.
We also have an ROI Calculator that you can use to compared your current gas usage with an EWR and the potential cost benefit.