Modification of Energy Saving for Safe Welding Process: Case Study in Manufacturing of SME

Abstract

Welding is a popular method for connecting metal in manufacturing. However, welding fumes are hazardous and pose a severe health risk to workers. To provide a safe environment, many manufacturing companies install fume extractors. Even though the air quality is improved in the welding area, fume extractors are always on in non-production hours, which wastes power. Thus, we modified a fume extractor by establishing an automated interconnection system integrated with the Metal Inert Gas (MIG) welding equipment for energy savings. The automated interconnection system was examined for its impact and energy-saving degree. The system includes a relay and timer to connect a fume extractor with MIG welding equipment. The fume extractor is on standby or active modes based on the welding gun operation. The active mode is on when the welding gun is operated, signaling the fume extractor to turn on and vice versa with a 30-second lag to turn off. A case study was conducted in Indonesia's Small and Medium Enterprises (SME) firm. The company's power usage significantly was reduced by more than 25% and operational expenses and CO2 emissions were also decreased. The system is practical and affordable for SMEs, especially those that rely on MIG welding and fume extractors for their operations.