ISSM
ISSM

Industrial Welding Systems

A captivating 12 minute presentation informed viewers all about the latest IWS product innovations. At this year’s Product News day, IWS focused mainly on high performance welding and the newTPS/i Steel Edition. The presentation concluded with a fascinating discussion on the various software solutions.

There was time at the end for visitors to delve deeper into the subject matter. A variety of live demonstrations aimed to make this sometimes highly-complex business segment more accessible.

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Station 1

High Performance Welding

Two particular aspects of high performance welding were the main focus of Product News day 2019:

1. THE NEW TPS/i TWIN Push System

The new TPS/i TWIN Push System is now available with all TPS/i power sources. The whole TPS/i TWIN Push system, including a welding torch change station and a welding torch service station, will be available for purchase from May 2019.

Sales training will form part of the market launch. The training program is being offered as the sales department, as well as the technicians, need to be fully up to speed with the new system: The TWIN process features innovative process control that gives it exceptional stability and an extended process window. The newly developed TWIN welding torch has been specifically developed to give the very best performance thanks to its unique cooling system. The advantage of the TWIN wirefeeder is its compact design.

Huge harvester wheel rims were welded as part of a live demonstration. Two synchronous arcs (synchronized tandem process), an incredible deposition rate and a high welding speed – the raw energy released in the process is staggering!

2. High Performance Power Source – TPS 600i

The repositioning of the “TPS 600i” high performance power source was also communicated during the ISSM and Product News day. The main goal is to differentiate it from the rest of the TPS/i range. The strategic pricing, paired with new communication media, will help the Sales department to highlight the advantages of the TPS 600i in the future.

Station 2

TPS/i Steel Edition

The aim is to make clear that steel applications are the main focus – and that the TPS/i Steel Edition is the perfect power source for these applications.

Core message: From now on there will be a configurable power source. Instead of universal welding packages, the customer can now purchase the TPS/i with a characteristics package that has been specifically optimized for steel applications, which will ultimately bring down the street price. This should make the TPS/i even more attractive for the price-conscious steel market.

The advantages of the Pulsed Controlled Spray Arc characteristic (PCS) – such as a deep penetration profile – will be highlighted at the same time. These have been clearly demonstrated in various different trials, during which manual welding was carried out in two different settings. A fume extraction torch and a water-cooled welding torch were used. 

As a further sales argument, it will be stressed that the WPS steel package is supplied with every purchase of the Steel Edition. This is absolutely essential to ensure compliance with EN1090! From now the new WPS Steel Package is available for TransSteel, TPS and TPS/i Products.

    Station 3

    IWS and the Power of Data - A Software Portfolio

    Fronius is leading the way in the software sector, where BIG data and SMART data are the watchwords. Innovations in this sector include:

    • WeldCube Connect
    • Central user management
    • Traceability (with Weld Connect)
    • WeldCube Premium Release 2.3

    1. WeldCube Connect

    WeldCube Connect is an umbrella term for data interfaces. More specifically, it is a range of interface solutions that enable data to be exchanged with third-party systems.

    Fronius APIs (Application Programming Interfaces)

    WELDCUBE turns BIG DATA into SMART DATA. The new APIs developed by Fronius aim to make this step partially reversible. If the customer wants to design their own customized data analysis system, they need the microdata – BIG DATA. The Fronius APIs make reading this microdata possible. A distinction is usually drawn between two interfaces:

    • WeldCube Premium interface: This API displays data that have already been evaluated and interpreted. 
    • Power source interface (TPS/i): Displays the current status of the welding system and live data from the system that does not access previously saved historical data.
    What Does This Enable?

    Independent evaluations, analyses, summaries and visualizations. For example, programming a display so that during a specific welding process, key data – power consumption, wire speed, welding speed, etc. – can all be tracked on a display screen. 

    2. Central User Management

    Central User Management was also introduced – this is a central, server-based system for authorization management.

    This system is used to securely manage the authorizations of individual users: the user who is logged into the welding system should only be able to carry out the processes and tasks that they are qualified for and that they have been assigned to do. Not only does this ensure process reliability and support quality assurance, it also helps to avoid errors. A new solution is expected to be launched in June 2019: this solution focuses on centralizing management in a single location, instead of administration having to be carried out on each system (via the display or SmartManager).

    Tangible Improvement?   

    Configuring a single power source requires up to 100 clicks on the display – until now, this process had to be repeated by hand on each device. The advantages of networking are clear:

    • Significant time savings
    • Safety is maximized (employees are only permitted to work on systems that have been assigned to them)  

    3. Traceability

    Traceability is an important aspect of the seamless documentation of relevant welding data.

    Traceability is ensured at component level – this means that: in combination with user management data, it is now possible to compile information about the welder, the component processed by the welder and the weld seams applied to the workpiece.

    Traceability data can ultimately be seen as ID data for a component and its weld seams. These data provide an extra level of assurance when it comes to accurately documenting work to produce safety components.

    4.WeldCube Premium Release 2.3

    In May 2019, the next software update for WeldCube Premium will be released and will cover two areas:

    1. WeldOptimizer 

    • Lists faulty components
    • Automatic diagram visualization
    • The customer can define what a faulty component costs  

    Conclusion: WeldOptimiser displays the potential for savings and optimization. 

    2. Error Statistics

    This is a new function that can be used to generate error statistics. It gives information about the following: Which error occurred on what machine? Number? When, on what day and for how long (duration)?  

    Overall Software Solutions Conclusion: It is clear that, in the future, the individual welding software solutions will become an established part of every area of welding. 

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