ETR - Endless Torch Rotating System

Mechanised overlay welding

WELDING PROCESSES: TIG HOT WIRE / SPEEDCLAD TWIN

More often than not, heavy and highly complex components pose a huge challenge. This is exactly where the advantages of the Fronius ETR system come into play: thanks to the intelligent FPA 9000 system control, components with multiple boreholes and different borehole angles can be welded as standard. The time-consuming centring of large components is a thing of the past – the Automatic Centering function does this automatically and drastically reduces the time taken up by centring. This also has another advantage: the exact positioning noticeably improves the quality of welding.

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Fronius SpeedClad TWIN cladding process

Fronius Welding Automation - system solutions

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PRODUCT DETAILS

Characteristics

Fronius, Endless Torch Rotating System, ETR, illustration — 3D illustration: ETR-S cladding system

ETR SYSTEM – EVERYTHING FROM A SINGLE SOURCE.

The entire system consists exclusively of Fronius components, which work in perfect harmony and deliver unsurpassed welding results. Fronius offers the best cladding technologies and has established itself as the global technology and market leader.

FEATURES.

Increased productivity

High degree of reproducibility

Leading welding technology

Designed for maximum performance and easy servicing

Display of welding parameters in real time

SYSTEM CONTROLLERS AND REMOTE CONTROL

FPA 9000.

The system is controlled via a user-friendly touchscreen. Equipped with an industrial PC with a Windows Embedded operating system, the FPA can be connected to the network and also allows communication between several FPA system controllers. Remote support can be provided thanks to the internet connection.

12.1" touch display
3D process visualisation
Laser printer for data documentation
Limit function – actual value display
Network-enabled – remote support
Software functions: bore-to-bore/race-track/automatic centering/rectangle (optional)
Datalogger – recording of actual value welding data (optional)
Dataviewer – data analysis from Datalogger on external PC (optional)
Cabinet air conditioning (optional)

HMI-RC REMOTE CONTROL.

Lightweight, robust unit housing
3.4" colour display
Emergency Stop button and 3-stage enabling button
23 function keys with LED lighting
Interchangeable insert strips depending on the application
10 m connection cable that can be unplugged from the device
Plug & play

Components

Fronius ETR Endless Torch Rotating System - Column and Boom — FCB column and boom with ETR-S welding head

FCB COLUMN & BOOM.

Available in a variety of sizes and with different travel paths.

CABLE MANAGEMENT.

Cabling protected using energy chains.

Fronius power sources set for Compact Cladding Cells — Fronius TransTig power sources

DIGITAL POWER SOURCE SET.

The power team: TransTig 5000 Job with 4000R high-performance cooling unit and TransTig 2200 Job – completely digital for optimum welding results with the TIG HW welding process.

Fronius, ETR, Endless Torch Rotating System, carriage — 3D illustration: base unit with carriage

BASE UNIT WITH CARRIAGE (OPTIONAL).

The column and boom can be equipped with a carriage as an option.

Fronius, ETR, Endless Torch Rotating System, welding head with FCS Cross Slide System — 3D illustration: ETR-S welding head

ETR WELDING HEAD / FCS CROSS SLIDE SYSTEM.

The key component of the ETR-S is the endlessly rotating welding head. The FCS is available with various travel paths.

Fronius, ETR, Endless Torch Rotating System, turntable — 3D illustration: rotary table

FRT ROTARY TABLE (OPTIONAL).

For certain component geometries, an optional rotary table can increase productivity.

ETR ENDLESS ROTATING WELDING HEAD

Fronius, ETR, Endless Torch Rotating System, welding head — 3D illustration: ETR-S welding head

THE CENTREPIECE – THE ENDLESSLY ROTATING WELDING HEAD.

The endlessly rotating welding head is at the heart of the ETR system. The welding torch and wirefeeder rotate about the bore axis. The welding current, gas, torch cooling and electrical control signals are conveyed without interruption via the transfer module. An “Extension” or a “Swivel Adapter” can be added to the ETR depending on the application.

TRANSFER MODULE

Transmission unit for the rotational movement. Boasts maintenance-free electronics thanks to the high-quality gold contacts.

WIREFEEDER

Four-roller wirefeeder for constant, smooth wirefeeding. TWIN setup optional.

WIRESPOOLS

Rotating wirespool. A second wirespool is fitted with the TWIN option.

SAFETY DOORS

Equipped with shatter-proof glass and safety switch.

TORCH SYSTEMS

Fronius, TTHW torches, 3D-illustration — Illustration: TTHW welding torch

TTHW WELDING TORCH.

TTHW welding torch for components with internal diameters of 25 - 320 mm. Minimum component Ø for TTHW 6000M SpeedClad: 150 mm.

SMALL EXTENSION.

TTW welding torch with Small Extension for components with an external diameter of up to 711 mm.

SWIVEL ADAPTER.

Swivel adapter with TTHW welding torch for components with an internal diameter of up to 1400 mm.

LARGE EXTENSION.

TTW welding torch with Large Extension for components with an external diameter of up to 500 mm.

APPLICATION EXAMPLES - COMPONENT GEOMETRIES

cylindrical drilling — Illustration - cylindrical bore

CYLINDRICAL BORE.

cylindrical drilling with ground — Illustration - cyl. bore with base

CYLINDRICAL BORE WITH BASE.

cylindrical drilling with several diameters — Illustration - cyl. bore with multiple diameters

CYLINDRICAL BORE – MULTIPLE DIAMETERS.

BORE-TO-BORE.

HMI-T10 / FPA 9000CC

ADVANCED BORE-TO-BORE.

FPA 9000CC only

cylindrical conical drilling — Illustration: cylindrical and conical bore

CYLINDRICAL AND CONICAL BORE.

RING-GROOVE.

RACE-TRACK.

Rectangle drilling, Fronius — Illustration: Rectangle bore

RECTANGLE (OPTIONAL).

CONFIGURATIONS

STANDARD CONFIGURATION (VARIANTS POSSIBLE):

FCB 3000-3000/ML700/ETR 50/60Hz
FCS 2000-1000/ML375
FRT 5000 H/C/FPA
TTHW5000M ø125 ETR F++/1.8m ABL welding torch
ETR-S 25-320/TIG HW
FPA 9000/ETR TIG HW system controller
TransTig 5000 Job G/F power source with FK 4000 Rob cooling unit
TransTig 2200 Job G/F power source

Fronius ETR Endless Torch Rotating System with SpeedClad Twin torch — 3D illustration: ETR-S SpeedClad TWIN System

SPEEDCLAD TWIN CONFIGURATION (VARIANTS POSSIBLE).

The SpeedClad Twin torch system is the centrepiece of the SpeedClad TWIN process. It is controlled by a fully digitised, SpeedClad TWIN-optimised communication system to which two additional TransTig 5000 Job and TransTig 2200 Job power sources are added.

FCB 3000-3000/ML700/ETR 50/60Hz

FCS 2000-1000/ML375

FRT 5000 H/C/FPA

TTHW6000M SpeedClad ø150 F++/1.8m ABL welding torch

ETR-S 25-320/TIG HW

FPA 9000 - ETR TIG HW SpeedClad TWIN-optimised system controller

2 x TransTig 5000 Job G/F power source with FK 4000 Rob cooling unit

2 x TransTig 2200 Job G/F power source

KEY COMPETITIVE ADVANTAGES.

SpeedClad TWIN drastically increases the cost effectiveness of the TIG hot wire process with no detrimental impact on quality whatsoever. Using two tungsten electrodes and two welding wires for one weld pool, all of which can be controlled separately, makes it possible to obtain much higher welding speeds and deposition rates. This guarantees maximum productivity, especially for larger components.

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