Energy Saving Solution for Welding Process: A SME Case Study of Fume Extractor

In the manufacturing industry, welding is commonly used for the metal joining process. However, welding yields fume, which is toxic and dangerous for workers regarding health issues. Many companies install fume extractors to reduce these risks to eliminate fume from the working environment. As it effectively removes fume, fume extractors are used all the time during office hours. It is wasteful of electricity, especially during non-operational time. This is inefficient, too, and is called vampire power due to wasted electrical energy. To save energy, researchers proposed an energy-saving solution to modify the fume extractor by implementing an automation system that is integrated with the MIG welding machine and analyzing its impact on energy savings. In this study, the fume extractor was analyzed for its effects. The conceptual design was created for a fume extractor integrated with a MIG welding machine using a relay and a timer. The mechanism of the fume extractor was based on the chain reaction between the welding gun at standby and active modes. When the welding gun was used, the welding machine turned on the fume extractor. To turn it off, there was a 30-s delay. The fume extractor was tested in a company in Indonesia. The result demonstrated a significant reduction in electricity consumption, resulting in lower operational costs and decreased CO2 emissions. The proposed solution was feasible and cost-effective for small and medium companies that use MIG welding and fume extractors.