Precision in motion: Fruehauf leads the way in bulk trailer manufacturing with advanced Fronius welding technology.
Fruehauf's rich heritage is a true testament to its inventive spirit and steadfast dedication to the bulk trailer manufacturing sector. With a history that spans over a century, the company has consistently pushed the boundaries of trailer design and production. This continuous evolution mirrors the unwavering commitment to quality and service upheld by Fronius.
At their Grantham facility, Fruehauf utilises an impressive array of 31 TPS 400i high-performance MIG/MAG welding systems from Fronius, alongside a Fronius iWave 300i AC/DC, and has recently integrated a FlexTrack 45 Pro for automated sidewall welding into their operations.
As an industry pioneer, producing in excess of 500 trailers annually, Fruehauf manages the entire manufacturing process for their tipping and bulk trailers at their Grantham plant. Each trailer is crafted to meet exacting specifications, tailored to the unique needs of their customers, and delivered on schedule. Fruehauf precisely engineers both chassis and body components, completing the transformation from raw materials to finished product in under two weeks.
“For the past two years, we've relied on Fronius welding systems because their offerings align perfectly with our core values of commitment to quality and reliability.” Artūras Mitunevičius, Production Director at Fruehauf shared. “As a valued partner, Fronius consistently provides insightful advice and introduces cutting-edge products that enhance our operations. The continuous technical advancements, such as those found in the TPS 400i and its exceptional welding capabilities, have significantly improved our performance by increasing the speed and flexibility of our manufacturing processes. These systems enable us to confidently deliver the dependable products our reputation is built upon, ensuring that their strength and reliability remain unmatched– qualities that result in almost zero warranty issues.”
Fruehauf's trailers retain their worth over the years, and the company provides extensive service and repair solutions, including replacement or courtesy trailers when needed. This ensures customers experience consistent support, even during the rare instances of warranty repairs.
Welds in all components
The trailers incorporate a multitude of welded components that must withstand high mechanical stresses such as shock, vibrations and torsion. “We take great pride in our weld quality. Defective welds can lead to significant issues and so we have very strict standards regarding the quality of our welds. We focus particularly on ensuring flawless welds in the load-bearing parts such as the load support structure or subframe, where we use high tensile S700MC steel. Additionally, we ensure that all welds are aesthetically pleasing as they are visible on the exterior of the trailers.” Continues Artūras.
Optimising lightweight design for a competitive edge
The aluminium bodies are structurally capable of bearing up to 30 tonnes, yet they offer a significant weight advantage over standard trailers, saving up to 250kg. This reduced weight allows customers to carry a higher payload, providing a competitive edge.
Welding these aluminium bodies presents numerous challenges, including distortion and porosity. Aluminium’s high thermal conductivity and expansion rate make it susceptible to warping. Moreover, welding dissimilar material thicknesses introduces its own set of difficulties, such as when welding the 5/6 mm thick top rail to the aluminium panels of only 2.2 mm wall thickness. This necessitates precise heat control to avoid burn-through and lack of fusion.
Fronius TPS 400i: precision-tuned welding for maximum efficiency
All of these challenges and requirements are expertly managed when employing the Fronius TPS 400i, which is designed to address complex welding challenges, especially those encountered in aluminium fabrication like at Fruehauf.
The TPS 400i is equipped with intelligent control systems that allow precise adjustment of welding parameters. Penetration and Arc Length Stabilisers ensure consistent weld quality by maintaining the desired penetration and arc length, which aids in controlling the heat input more effectively. The TPS/i can be customised with various software packages to meet specific welding requirements. The Pulse feature is typically used at Fruehauf to ensure the thicker top rail receives sufficient heat for fusion, while the thinner panel is protected from overheating. Pulse technology enables the arc to alternate between high peak current and a low background current. This reduces heat input, minimising distortion and burn-through, which is especially critical when welding thin to thick materials. The controlled droplet transfer in pulse mode also reduces spatter and enhances weld bead appearance.
Fruehauf faces the same shortage of skilled welders that has affected many manufacturing industries in recent times. Using the Fronius TPS/i ensures that repeatable welds can be achieved with the consistent quality required. This is because the parameters for each job can be set and stored on the system, allowing any operator to quickly and easily pick up any given job in the production process. These welding machines have been paired with the Push-Pull torch with 10-metre hose pack.
Enhancing welding efficiency with the Jobmaster Push-Pull torch.
Artūras explains, “Before we introduced the Fronius TPS/i machines, we frequently encountered wirefeed issues and consequently had to change the liner regularly. We have been using the 10m Fronius Push Pull torch, which includes a motorised pull system that synchronises with the wire feeder, ensuring uninterrupted wire feed. Since adopting these we have significantly increased efficiency. We opted for the Job Master model so the welder can select parameters, including pre-saved jobs, directly on the torch without having to return to the machine. This is very convenient when you are welding body lengths of 9-12 metres. The user-interface on the screen is also relatively simple to use.”
The “EasyJob” setting on the Jobmaster torch allows users to store up to five welding tasks directly on the welding torch and quickly switch between them. This feature enables them to access essential welding tasks for their daily work right on the torch, eliminating the need for frequent trips between the welding system and the workpiece. Consequently, their daily operations become more convenient and notably more efficient. The ergonomic design and multi-lock torch neck also makes it ideal for positional welding, thereby improving weld quality and speed.
Fruehauf adopts automation to enhance production quality
The construction of sidewall panels involves three main components: the front post, planks and top rail. These elements are created from extruded aluminium profiles, which are supplied to the bulk trailer manufacturer from production plants in Padron, Spain and Doncaster, United Kingdom. Before the welding process begins, the profiles are cut to the necessary length and shaped using both band and circular saws. In recent developments, the manufacturer has started assembling the side panels of the trailer using a specially created assembly jig, after which the panels are immediately welded. This welding process utilises the Fronius FlexTrack 45 Pro rail guided welding carriage for longitudinal seam welding and employs a TPSi 400i.
The company conducted an evaluation of this semi-automated process and determined that, when compared to a fully robotic system, the Fronius FlexTrack welding carriage was more cost-efficient.
Artūras explains that after several months of testing and modifications to tailor the welding process for side panels in Fruehauf’s Research and Development department, the versatile FlexTrack 45 Pro has been used in production since June 2024. It is utilised daily for a minimum of eight hours, with significant advantages including the consistent quality of the weld, thanks to precise movements, steady welding speeds, and improved comfort for the operator. Additionally, he notes that the company has managed to save roughly one hour per sidewall in welding time, translating to approximately 800 to 1,000 welding hours annually. With current labour rates, these time savings amount to financial savings of £20,000 to £25,000 per year, with the return on investment being achieved in under two years.
“Today, it is difficult to envision our aluminium body production without the FlexTrack welding equipment. It ensures perfect reproducibility of welding results, especially when used with the TPS/i welding source,” Artūras states. “We have also found the FlexTrack to be very reliable. We have been operating this application for 18 months without experiencing a single breakdown.”
The company continues to refine small details within this process to enhance operator comfort and fine-tune welding parameters for optimal welding quality. Artūras remains optimistic about the advantages of automation, “It holds the promise of not only enhancing production quality but also improving safety, reducing waste, and creating a more resilient and adaptable business environment.”
This dedication to automation marks an exciting chapter for Fruehauf, as the company integrates its long-established engineering expertise with cutting-edge advancements, setting the stage for future growth and innovation.
A century of excellence in trailer manufacturing
Fruehauf’s century-long legacy in trailer manufacturing is defined by its relentless pursuit of innovation, precision, and quality. By integrating advanced Fronius welding technologies like the TPS 400i and FlexTrack 45 Pro, Fruehauf has significantly enhanced its production capabilities, ensuring superior weld quality, efficiency, and structural integrity. These systems not only address the challenges of welding high-strength steel and lightweight aluminium but also help mitigate the skilled labour shortage through automation and intuitive controls. With a strong focus on durability, aesthetics, and customer satisfaction, Fruehauf continues to set industry benchmarks, delivering trailers that are as reliable as they are refined.
