Welding robot

Smart robotic welding

Smart robotic welding

Welding automation as a solution to the skilled labor shortage: why you should invest in robotic welding now

Flexible, user-friendly, and cost effective

Industrial manufacturing is undergoing a transformation—and welding is no exception. Many components that would have been welded manually in the past are now increasingly being welded automatically.

There are many reasons for this transition. More and more companies are demanding consistent, high-quality welds that can be reproduced at any time as well as full documentation of all welding parameters. Stricter safety standards and a chronic shortage of skilled workers are putting even more pressure on businesses.

Modern robotic welding solutions are the answer to these challenges, especially as they are becoming increasingly smart, collaborative, and highly cost effective, even for small and medium-sized enterprises. This is all thanks to offline programming and system autonomy, which reduce setup times even for batch sizes of just one.

Advantages of robotic welding for you
Holistic approach
When designing robotic welding cells, we consider every aspect, from optimal component handling to an efficient welding process. We also integrate the latest arc technology and sensors into our systems so that we can give our customers a competitive edge.
Seamless documentation of welding data
The HMI Cockpit makes machine data easy to understand and lays the foundation for quick, informed decisions. WeldCube Premium documents all relevant parameters, ensuring that every weld seam is traceable and reproducible.
Go to WeldCube Premium
Simulation ensures reliability
Fronius Pathfinder enables welding sequences to be simulated on a digital twin of the welding system. The software automatically detects axis limits and singularities, calculates start and end points as well as approach paths, and independently sets teach points. Obstacles can be visualized and welding torch positions corrected before the first weld is made.
Go to Pathfinder
Optimized setup times
Our Pathfinder® offline programming software helps you reduce costly setup times and downtime to a minimum. The time-consuming task of teaching the robots is largely eliminated, since all programming work takes place away from the welding cells. This means that welding work can continue without interruption.
Holistic approach
When designing robotic welding cells, we consider every aspect, from optimal component handling to an efficient welding process. We also integrate the latest arc technology and sensors into our systems so that we can give our customers a competitive edge.
Seamless documentation of welding data
The HMI Cockpit makes machine data easy to understand and lays the foundation for quick, informed decisions. WeldCube Premium documents all relevant parameters, ensuring that every weld seam is traceable and reproducible.
Go to WeldCube Premium
Simulation ensures reliability
Fronius Pathfinder enables welding sequences to be simulated on a digital twin of the welding system. The software automatically detects axis limits and singularities, calculates start and end points as well as approach paths, and independently sets teach points. Obstacles can be visualized and welding torch positions corrected before the first weld is made.
Go to Pathfinder
Optimized setup times
Our Pathfinder® offline programming software helps you reduce costly setup times and downtime to a minimum. The time-consuming task of teaching the robots is largely eliminated, since all programming work takes place away from the welding cells. This means that welding work can continue without interruption.

Solution provider for welding robots

Our work is centered on a holistic approach. We view robotic welding as a combination of technical development, project management, technology, partnerships, and service.

We always keep the needs of our customers in mind as we seek to combine weld quality, ease of use, future viability, and cost effectiveness in the most effective way.

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    Intelligentes Roboterschweißen von Fronius

    Welding technology

    • Welding tests in the technology and prototyping center
    • Smart integration of Fronius arc technology
    • Modern sensor systems for guiding and checking weld seams
    Konzeption Intelligentes Roboterschweißen

    Individual concept

    • Engineering and feasibility studies
    • Modular system with standardized modules
    • Simulation of all welding processes
    • Component-specific deposit and clamping systems
    Polaris Mobile Panel

    Intelligent software

    • Fronius Pathfinder®: offline programming software
    • Modular system with standardized modules
    • Simulation of all welding processes
    • Component-specific deposit and clamping systems
    Trainingssituation bei Fronius

    Project management

    • Structured planning and organization
    • Transparent communication
    • Reliable contact person
    Umfassender Service von Fronius

    Comprehensive service

    • Commissioning with user training
    • Remote maintenance, on-site maintenance, and regular calibration
    • International service network
    Technologiepartnerschaft mit Fronius

    Technology partnerships

    • Strong partnerships in the fields of software, robotics, sensor technology, control systems, and fixture construction
    • Professional supplier management
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    Modular robotic welding systems: quality with Fronius technology

    Our customers’ requirements are as diverse as their components, which means no two robotic welding systems are the same. To ensure that system reliability and cost effectiveness are still maintained, we rely on a sophisticated modular system consisting of proven components from Fronius and reputable technology partners when developing and assembling our systems.
    Modular system for robotic welding systems

    Custom robot welding systems: real-world examples of specialized systems 

    When the standard is no longer enough

    When standard welding cells reach their limits, we develop custom robotic welding systems for your specific needs.

    These may include complex component geometries, integrated handling-to-welding, special materials, or challenging cycle times.

    The mechanics, control unit, welding process, and system components are coordinated to perfection and implemented as an end-to-end solution, giving you a system that is precisely tailored to your components, processes, and production goals.

    Robot cell with a linear track
    Advanced robot cell with multi-station operation
    Simple two-station cell with L-positioner
    Mobile, compact two-station cell
    Complex handling-to-welding robot cell
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    Figure 1: Robot cell with a linear track
    Figure 2: Advanced robot cell with multi-station operation
    Figure 3: Simple two-station cell with L-positioner
    Figure 4: Mobile, compact two-station cell
    Figure 5: Complex handling-to-welding robot cell

    Welding robot technology

    Welding processes
    We choose the right welding process depending on the component, material, and quality requirements. MIG/MAG, TIG hot wire and cold wire, ArcTig (keyhole welding), plasma, and LaserHybrid are all available. Our high-tech processes such as CMT (Cold Metal Transfer), PMC (Pulse Multi Control), and LSC (Low Spatter Control) optimize welding quality and cost effectiveness.
    Welding methods and processes
    Polaris system controls
    The Fronius Pathfinder® monitors and coordinates components such as robots, welding machines, and positioners (as well as tool changing, racking, and torch cleaning systems) across all of our welding systems in operation. It also displays process data in real time.
    Mann steuert ein Fronius Roboterschweißsystem
    Fronius Pathfinder®
    Software for creating and simulating welding sequences. Highlights include multirun welding and weld seam detection using a gas nozzle. Also included: quality control and WPS.
    Learn more about the Fronius Pathfinder
    Fronius Pathfinder
    Faster, more accurate welding
    Visual arc monitoring
    Our ArcView 3 high-resolution camera system provides a live view of the arc and therefore direct monitoring of the weld pool. If any errors occur, the welder can respond immediately.
    Integrated sensors to improve efficiency
    SeamTracking automatically offsets weld deviations while TouchSense enables the robot to determine accurate positions to compensate for component tolerances. WireSense measures these tolerances and sends them directly to the robot. Our sensors reduce welding errors, rework, and waste, which directly increases the cost effectiveness of our robotic welding systems.
    More about WireSense
    Automatic contact tip replacement
    With the Robacta CTC, replacing the contact tip takes only 40 seconds—ten times quicker than replacing it manually. This will save you valuable time and help you avoid production downtimes.
    Learn more about Robacta CTC
    Automatic TIG electrode replacement
    The used tungsten electrode is quickly replaced automatically, with virtually no downtime and no manual intervention required.
    Automatic wire change
    With our WireSwitch, you can weld while switching between two different wires, but with just one welding system. The automated wire change takes just a few seconds and significantly reduces downtime.
    Visual arc monitoring
    Our ArcView 3 high-resolution camera system provides a live view of the arc and therefore direct monitoring of the weld pool. If any errors occur, the welder can respond immediately.
    Integrated sensors to improve efficiency
    SeamTracking automatically offsets weld deviations while TouchSense enables the robot to determine accurate positions to compensate for component tolerances. WireSense measures these tolerances and sends them directly to the robot. Our sensors reduce welding errors, rework, and waste, which directly increases the cost effectiveness of our robotic welding systems.
    More about WireSense
    Automatic contact tip replacement
    With the Robacta CTC, replacing the contact tip takes only 40 seconds—ten times quicker than replacing it manually. This will save you valuable time and help you avoid production downtimes.
    Learn more about Robacta CTC
    Automatic TIG electrode replacement
    The used tungsten electrode is quickly replaced automatically, with virtually no downtime and no manual intervention required.
    Automatic wire change
    With our WireSwitch, you can weld while switching between two different wires, but with just one welding system. The automated wire change takes just a few seconds and significantly reduces downtime.
    Fronius Cobot - CWC-S

    Ideal for beginners: cobot welding cell

    Thanks to the excellent flexibility when welding different components, the CWC-S offers the perfect conditions for cost effective welding.

    Precise torch movements ensure consistent, high-quality welds at all times—from single-piece production to small-batch runs. Learning to use it takes just a few hours

    and no programming knowledge required. Trainees can operate the CWC-S in no time at all, significantly reducing the workload of your experienced welders. A protective cabin and welding fume extraction system ensure safety while a rotary unit and high-tech welding packages are available as options.  

    More information about the cobot welding cell
    Customer solutions that boost your bottom line
    Efficiency and profitability are non-negotiables for commercial success, so our customers need systems that produce perfect welds throughout their entire life cycle. That’s why we employ feasibility studies, simulations, and welding tests as early as the engineering phase to ensure that every solution is technically sound and economically viable.
    Fronius Kundenlösung

    Send your non-binding request directly to Fronius