WeldTrainer is an innovative virtual reality-based welding simulator designed specifically for schools and institutions providing welding training. Using real-time motion detection and state-of-the-art technology, WeldTrainer allows users to practice welding techniques in a virtual welding workshop environment. This method is not only more effective but also safer than traditional hands-on training.
WeldTrainer works with 100% virtual reality simulation, so users can learn welding processes without risk. The simulator is not only useful for welding training, but is also an excellent tool for educating technologists and engineers, as it allows them to learn about welding processes and effects in depth. In this way, WeldTrainer provides a significant advantage in the education of the welding profession.

 

 

With more than 13 years of experience and continuous innovation, the 2024 edition of the Apolo Weldtrainer standard represents the next generation of the Weldtrainer welding simulator family. The latest version, which provides users with professional welding training, not only enables the development of practical skills, but also results in significant cost savings and productivity gains. Weldtrainer provides unique brain-muscle connection training while creating a safe and engaging working environment. The Weldtrainer provides all the tools to make welding training more efficient and cost-effective, all at a competitive price.

Features:

- The world's best tracking technology tightly integrated into hardware and software to provide the most accurate, reliable and trustworthy welding simulation.
- Sub-millimeter accuracy in weld gun spatial detection without latency and without technical limitations that compromise the efficiency, reliability and credibility of training.
- The simulation is completely driven by the user's actions, 100% free from pre-made behaviours, made-up results, dubious credibility or compromised user feedback.
- A highly sophisticated, unique workbench that offers unparalleled functionality, ease of use, high productivity, robustness and accessibility.
- It provides a variety of training tools that are impossible to replicate in real welding.
- Its design ensures the healthiest sharing between different users.
 

Custom developed VR headset

The Apolo Studios Weldtrainer welding simulators are equipped with a custom-designed virtual reality display integrated into the welding helmet, providing a detailed, crystal-clear, high-resolution display. No interpupillary distance adjustment is required. Thanks to the special design, the VR headset can be worn with minimal facial contact, even with glasses. And the ergonomic headband and large forehead pad ensure maximum comfort when wearing them. As with currently available VR headset, there are integrated speakers in the helmet. Thanks to the unique development, all parts are replaceable.

 

- A custom-designed VR display integrated into a welding shield that adapts superbly to the user's varied facial features.
- Crystal-clear display that saves distortion and protects the user from eye fatigue even after prolonged use.
- Integrated audio system.
- Floating design with only two easy-to-clean foam straps.
- A design that promotes healthy and hygienic use, ensuring that the user's breath is always outside.
- Light weight, elegant cable management and strong protection of components.
- Unique development by Apolo Studios ensures long life.

 

Realistic welding tools with quick coupling

Using a tool that is the right weight, size and shape of the real thing is the best way to carry out the exercises. The quick coupling, interchangeable USB 3 devices vibrate to indicate when the welding tools are not held correctly. A joystick integrated into the tools allows quick and easy navigation through the menu and access to all settings. Welding parameters can also be set very easily, and fusion and porosity control can be accessed from the welding tools with a single movement. All the buttons needed to operate the simulator are located on the tools.

 

Theory test module:

Students can also complete a test using the simulation. Users can test their knowledge of welding procedures and safety through various test questions. Custom test questions can be imported using the instructor software installed on the laptop that comes with the simulator. Test results and statistics will also be available in the instructor position software.

 

 

Simulation module:

The training is carried out efficiently, without the hazards of welding, in a clean environment, without harmful emissions, in an energy-efficient way. Using VR headset and a real-time leap motion system, the user can try welding in a complex virtual space, similar to the real world.

 

 

Thanks to real-time motion tracking, you can see what you are doing in real life without delay, as you move your arms and head. When the user wears the vr headset, the virtual space adapts to the movement without delay.

 

The user is immersed in a 3D view of a real welding shop, where their head movement controls the live viewpoint and their right or left hand controls the welding gun or electrode holder.

The Weldtrainer simulation is driven by a mathematical model that is "complex" enough to simulate in real time the consequences of all the user's movements. The ordering and appearance of the puddle depends 100% on the user's movements and settings. There are no pre-built, pre-written movements.

The Apolo WeldTrainer is currently capable of simulating BKI(111), MIG-MAG(135), FCAW-S, FCAW-G Powder arc welding with shielded arc and self-shielded wire (136) and AWI (141) processes. For MMA welding, electrodes with diameters of 2.5mm, 3.25mm, 4mm, 5mm can be selected. The simulator includes a number of exercises related to all welding processes.

 

Exercises for all welding positions:

• Exercises featuring a square plate to perform flat welding in straight lines with different
directions and also curved lines with different radius.
• Exercises featuring fillet joint in all positions (1F, 2F, 3F, 4F) / (PA, PB, PF, PD).
• Exercises featuring lap joint in all positions (1F, 2F, 3F, 4F) / (PA, PB, PF, PD).
• Exercise featuring butt joint without edge preparation.
• Exercises featuring butt joint with edge preparation in all positions (1G, 2G, 3G, 4G) / (PA, PC, PF, PE).
• Exercise featuring pipe to pipe butt joint in all positions (2G, 5G, 6G) / (PC, PH, PG, H-L045) with two different pipe diameters.
• Exercises featuring pipe to plate fillet joint in all positions (1F, 2F, 4F, 5F) / (PA, PB, PH, PG) with two different pipe diameters.

Extended specific content:
The new modules and exercises are exclusive to Apolo Studios WeldTrainer, made unique by the ability to integrate complex workpieces with unique shapes and designs. The weldtrainer simulator has a unique feature that allows to import to the system, or any workpiece any shape where we can make to let the user weld on it according to the customer requests.

 

Real time feedback

During the execution of welding exercises, all relevant parameters are displayed on the screens to assist the user in the correct execution. On-screen visual cues provide detailed explanations on the correct use of the welding gun and the application of various welding techniques. The software provides real-time feedback on every step of the welding process, arc length, speed and accuracy of weld angles. The user-friendly interface provides easy-to-understand instructions to help the user perform welding tasks efficiently and safely.

 

 

The simulator performs real-time error checking during simulations, monitoring distance, travel and working angles and speed, and displaying these to the user during task execution. Each task is recorded, allowing interactive 3D review and analysis of completed tasks.

At the end of each exercise, the simulator generates a telemetry report showing the percentage accuracy and precision of each parameter checked. These reports are directly accessible from the simulation menu, allowing a more comprehensive evaluation of task performance. During the simulation, the user can freely adjust the welding parameters at any time using the joystick located on the welding tools. This feature simplifies the explanation of the effects of changes in amperage, wire feed speed, voltage, shielding gas, electrode diameter, wire diameter and polarity on different procedures.

 

The 3D graphics displayed in the simulation are the proprietary development of Apolo Studios. Thanks to the advanced lighting system and complex programming, the technology and visual quality used by Weldtrainer surpasses all other welding simulators currently available on the market. A unique feature is the analysis of fusion and porosity, which, in addition to verifying the correct setting of welding parameters, makes it possible to study the welding defects that can occur as a result of incorrect welding speed and tool handling.

 

The WeldTrainer simulator offers many advantages:

• Students complete a greater number of training because each session taught on the simulator consists almost entirely of welding (no need to change parts, wait for them to cool, remove slag, etc.).
• Training costs are reduced. The simulator shortens the initial training period and significantly reduces material consumption.
• Any potential accidents or hazardous situations can be avoided during the training by using the simulator.
• The learner's initial learning curve is steeper. Students learn the motor controls (e.g. distance, angle, speed) faster and more thoroughly.
• All manual arc welding procedures in one unit.
• Environmentally friendly welding practice.

Warranty:

Apolo Studios provides full customer support to every customer who owns any product sold under the Apolo Studios brand name and offers a lifetime warranty on the software.