Welding Automation – the Best Entertainment with High-Tech Welding!
It was Thursday morning: 40 people had arrived at the WA building. How are industrial skillets welded? At the start of the event, an introductory video gave the visitors an insight into the sector and provided them with a fascinating first impression of the exciting world of Welding Automation. The welding robots from the Steinhaus production facility did a superb job – the whole audience caught the WA bug!
A short while later, the group split up into smaller groups to enable them to observe fascinating demonstrations at the following five stations:
Station 1
WAAM process – Wire Arc Additive Manufacturing
The wire arc additive manufacturing (WAAM) process was demonstrated by a robot from Fanuc, which welded an object while the visitors watched the process unfold live via a monitor. The unusual thing about this process is that it doesn’t involve joining two existing plates, instead an entire component is created just by adding welding wire. The process is comparable to 3D printing…
Station 2
FCW Compact – Fronius Circular Welding System Compact
FCWcompact – the name says it all. The compact circular seam welding system (FCW) can weld components up to 1000 millimeters wide and with a diameter between min. 50 mm and max. 500 mm. The maximum component weight is 300 kg. This welding process was demonstrated at the event on a chrome-nickel pipe with a diameter of 115 mm and a wall thickness of 6 mm. The demonstration highlighted three key features of the system:
- Easy handling
- Powerful welding packages are available (ArcTig, CMT or TIG hotwire)
- The system has high-end system controls (HMI T-10)
Station 3
FSRC (Fronius Standard Robotic Cell)
The FSRC uses the FLEXARC Robotic System from ABB. More specifically, the FlexArc B robot welding cell that has been fitted with Fronius welding components. The process equipment and welding torch were made by Fronius. In the future, the system will be sold under the Fronius brand (FSRC). Unfortunately, it was not possible for us to carry out welding trials with the FSRC during the week of the ISSM and Product News 2019, as the designated welding system had already been sold to the end customer. However, the motion sequences for a fictitious welding application were demonstrated: A component was clamped onto the H-frame positioner and rotated through 180°…
Station 4
Fanuc COBOT Robot
The Fanuc COBOT is a collaborative welding robot. On Product News Day, the COBOT traveled along a specified path – the length of a workpiece clamped onto a welding table, allowing all of the possible welding processes to be simulated. A number of plausible benefits that could be implemented into Fronius systems in the future became clear during the demonstrations – for example, during a safety demonstration, the COBOT stopped as soon as a person approached the process.
An in-depth discussion also considered the potential demand for COBOTs.
Station 5
E-Mobility – Battery Tray Welding
The last station focused on the use of Fronius welding technology in the e-mobility segment. The video in the ETR seminar room made it clear that:
Fronius is supporting clients in the automotive industry in the industrial development phase through the Fronius robot welding cell based on the LaserHybrid welding process. Systems for constructing prototype battery trays for e-mobility were welded. As these systems demand large unit numbers, even at the pre-series stage, Fronius is playing a pioneering role and acting as a solution provider here. As the technology leader, Fronius also sees significant market potential in this area.