Perfect Welding

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Perfect Welding

Assistance Systems for more Efficiency in Robot Welding

Support through assistance systems for welding robots

One particularly important factor in robotic welding is increasing the efficiency and quality of welding tasks.
Fronius offers technologies for this that help save time and money.


Identifying and adapting component and clamping tolerances.
Without opticalmeasuring devices.

Component deviations such as varying air gaps or clamping tolerances can impair the perfect weld seam in automated manufacturing. In some cases, minimal material differences or imprecise clamping devices can have a negative influence on the welding result and cause costly and time-consuming rework. With WireSense, these problems area thing of the past.

WireSense uses the wire electrode as a sensor.

And delivers a corresponding signal to the robot byprecisely scanning the component in advance ofperforming the weld, so that the robot can adapt itsprogram to the current component position.

The advantages at a glance

Edge detection

  • Detection of the edge position for optimal positioning of the welding start point and end point
  • Component and clamping tolerances can thus be compensated for

Height measurement

  • Detection of an unwanted air gap
  • Detection of sheet thicknesses between 0.5 and 20 mm, both for steel and stainless steel as well as aluminum
  • High-precision measurement

Wire = sensor

  • No additional optical measuring devices required
  • Excellent component accessibility
  • No wear
  • No maintenance or cleaning costs
  • No calibration between sensor and TCP required


Highly efficiant robot programming.
No more wire deforming.

TeachMode helps the welder program weld seam positions on the robot, making the programming process more efficient. The reversing wire movement prevents the wire from bending in the event of unwanted contact with the component. The set stick out always remains the same.

This function is included at no extra cost in all TPS/i configurations.

The advantages at a glance

Save time

If the stick out goes below the defined value, the wire is automatically retracted to prevent deformation. This enables highly efficient component programming.

Constant stick out

If the stick out falls below the defined value, the wire will then be automatically corrected to the defined stick out.

Suitable for use with all filler metals

TeachMode is compatible with all filler metals (steel, CrNi, aluminum).

TouchSense and SeamTracking

Identifying and adapting component
and clamping tolerances.

Before and during welding.

With TouchSense and SeamTracking, the teaching requirement is reduced enormously, so that even smaller batch sizes of heavy-duty steel constructions can be produced efficiently. The assistance systems also minimize reworking, as clamping tolerances or small deviations in the component position are compensated for intelligently. This leads to the potential for considerable savings in series production.

The result is a perfect weld seam without the need for rework.


TouchSense determines the precise component position before fillet welds and butt welds are welded. The start and end positions are detected by scanning the workpiece with a wire or gas nozzle. After transmitting the signals to the robot, TouchSense calculates the precise seam path. 


SeamTracking intervenes during the welding process. The robot automatically corrects the course of the seam by changing parameters in response to oscillating movements. This ensures precise tracking of the seam path at all times, in this way avoiding welding errors due to clamping and component tolerances.

The advantages at a glance

Save costs and time

  • Reduced teaching requirement ideal for smaller batch sizes in heavy-duty steel construction
  • Short changeover times for different component variants
  • Reduction in welding errors and rework

Compensation for component and clamping tolerances

  • Detection of the component position before starting the welding process (TouchSense)
  • Robot path is adapted to the actual seam position by determining the welding start and end point (TouchSense)
  • Automatic correction of the robot path during the welding process in case of component deviations (SeamTracking)


  • SeamTracking signal works with all processes: suitable for welding with dip transfer, spray and pulsed arc as well as in combination with CMT or TWIN
  • The TouchSensing process can be used both with a gas nozzle and wire electrode

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