Perfect Welding

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Perfect Welding

Smart Robotic Welding Welding Robots

Robotic welding is a worthwhile investment. And not just in series production!

Flexible, user-friendly and cost effective

The industry is undergoing increasing transformation, and so too is welding. Until recently, what would have been welded manually is now welded automatically. There are many reasons for this transition. More and more companies are demanding both consistent, high welding quality that can be reproduced at any time, and full documentation of all welding parameters. Ever-tightening safety standards and a chronic shortage of skilled workers are also having an effect. Robotic welding solutions are now becoming increasingly smart, more collaborative and completely cost effective, even for small and medium-sized businesses. This is all thanks to offline programming, system autonomy and extremely fast setup times from a batch size of just one.

 

Robotic welding offers optimal solutions for unleashing your welding potential.

Advantages of robotic welding for you



Solution Provider

When designing the robotic welding cells, we always keep all procedures in mind. These range from ideal component handling to an efficient welding process. We also integrate the latest arc technology and sensors into our systems, providing a competitive edge for our customers.
Solution Provider


Seamless documentation of welding data

WeldCube Premium, our full-featured welding data management software, documents all the relevant welding parameters from the welding process. Each individual weld can be traced down to the last detail and can be reproduced at any time.


Simulation ensures reliability

Fronius Pathfinder® enables the simulation of welding sequences on the digital twin of the welding system. The software identifies axis limits, calculates start points, end points and journeys, and sets teaching points independently. Obstacles can be visualized and welding torch positions corrected on time, before the first weld is made.


Extremely fast setup times

Customers who opt for our offline Pathfinder® programming software avoid lengthy setup times and downtimes. The software significantly reduces the time-consuming process of teaching the robots. Programming takes place offline away from the welding cells. This means that welding work can continue without interruption.

Solution provider for welding robots

The platform is at the heart of our engineering process. We define it as an intelligent matrix comprised of technical development, project management, technology, partnerships, and service. During the process we always keep an eye on our customers’ needs, the common denominators of which are perfection during welding, ease of use, future viability and cost effectiveness.
Welding technology
  • Welding tests in the technology and prototype center
  • Smart integration of the Fronius arc technology
  • Modern sensors for guiding and checking welds
Individual conception
  • Engineering and feasibility studies
  • Modular system with standardized modules
  • Simulation of all welding processes
  • Component-specific storage and clamping systems
Intelligent Software
  • Visual Components engineering software
  • Fronius Pathfinder® simulation software
  • HMI-T21 RS system controls
  • Robot controller
Project management
  • Methodical procedure (planning and organization)
  • Transparent communication
  • Reliable contact person
Service at Fronius
  • Commissioning with user training
  • Remote maintenance, on-site maintenance, and regular calibration
  • International service network
Technology partnership
  • Strong partnerships for software, robotics, control, and jig manufacturing
  • Professional supplier management

Our modular system Our customers’ requirements are component-specific and varied. No two robotic welding systems are alike in every detail. However, if we were to constantly reinvent the wheel, then system reliability and cost effectiveness would suffer. With this in mind, we use a modular system of reliable components from reputable technology partners when engineering and assembling our systems.
Component Lock Gates / Incoming and outgoing transport of components, including during primary processing time
1
Welding Torch Systems and Service Station

/ Tailored to the welding process

/ TCP measurement

/ Torch cleaning

/ Torch replacement

/ Contact tip replacement

2
Gripper Deposit System

/ For different components (geometry, size and weight)

/ For different welding processes (MIG/MAG, TIG, TWIN, etc.)

/ For various manipulation processes (preheating, cleaning, etc.)

3
Handling Robot

/ Range and model depending on application

/ Load capacities of 27–1,543 lbs

/ Extreme repeatability

4
Positioner

/ Different configurations and sizes

/ Rotating/tilting positioner

/ Turnover positioner

Heavy-duty positioner

5
Robot Track

Track with robot base

/ Various C-frames

/ Platform for welding equipment

/ Track length can be extended

6
Welding Robots

/ Six-axis articulated robot with hollow shaft

/ High stability and repeatability

/ Load capacity and range depending on the application

/ Extreme repeatability

7
1
Component Lock Gates
/ Incoming and outgoing transport of components, including during primary processing time
2
Welding Torch Systems and Service Station

/ Tailored to the welding process

/ TCP measurement

/ Torch cleaning

/ Torch replacement

/ Contact tip replacement

3
Gripper Deposit System

/ For different components (geometry, size and weight)

/ For different welding processes (MIG/MAG, TIG, TWIN, etc.)

/ For various manipulation processes (preheating, cleaning, etc.)

4
Handling Robot

/ Range and model depending on application

/ Load capacities of 27–1,543 lbs

/ Extreme repeatability

5
Positioner

/ Different configurations and sizes

/ Rotating/tilting positioner

/ Turnover positioner

Heavy-duty positioner

6
Robot Track

Track with robot base

/ Various C-frames

/ Platform for welding equipment

/ Track length can be extended

7
Welding Robots

/ Six-axis articulated robot with hollow shaft

/ High stability and repeatability

/ Load capacity and range depending on the application

/ Extreme repeatability

Other examples of implementation from our modular system

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 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.

HMI-T21 RS System Controls

When in use, all our robotic welding systems monitor and coordinate all components such as robots, the welding system, positioners, changeover, and shelving systems, as well as torch cleaning. They also visualize all processes in real time.

The proverbial highlights include the program editor for defining all program processes and the three-dimensional real-time visualization.

Fronius Pathfinder®

The software provides a range of functions for creating and simulating welding sequences.

Highlights include: Autoseam—the automatic generation and management of welds along a track, multirun welding, or weld tracking with gas nozzle.

Quality control and WPS (Welding Procedure Specification) are also integrated.

Faster, more accurate welding



Visual Arc Monitoring

Our ArcView 2 high-resolution camera system provides a live view of the arc and therefore direct monitoring of the weld pool. If weld errors occur, welders can respond immediately.


Sensors for Increased Efficiency

SeamTracking automatically offsets weld deviations and TouchSense enables the robot to determine positions for offsetting component tolerances. WireSense measures these tolerances and sends them directly to the robot. Our sensors reduce welding errors, rework and wastage, and directly increase the cost effectiveness of our robotic welding systems.


Automatic Replacement of Contact Tips

Manual replacement of contact tips is time consuming and disrupts production. The Robacta CTC automates this work step. Replacement takes no more than 40 seconds, which is up to ten times faster than manual replacement.


Automatic Wire Change

Our WireSwitch system can be used to weld two different wires alternately on one welding system. If a component is welded with two different filler metals, automatic wire change is possible within just a few seconds. The WireSwitch technology significantly reduces downtimes.

Ideal for beginners



Cobot welding cell

Thanks to the enormous flexibility when welding different components, the CWC-S offers the best conditions for cost effective welding.
Precise weld torch movements produce high-quality, reproducible welds at any time; from batch sizes of 1 up to small-scale production. Operation can be learned in just a few hours as

no programming skills are required. Trainees can operate the CWC-S in no time at all and significantly reduce the workload of your welding specialists. Protective cabin and welding fume extraction ensure safety. Rotary unit and high-tech welding packages are available as options.

More information about the cobot welding cell

Customer solutions that are impressively cost effective

 

Our customers need systems that produce perfect welds throughout the entire product life cycle. They need to be efficient and as profitable as possible. During the engineering phase we therefore place great importance on feasibility studies, simulations and welding tests.

To our customer solutions

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