Robotic welding
Welding technology for consistently high weld quality
Robotic welding: precise, efficient, and future-proof from the very first batch
As a result of industrial quality specifications, documentation requirements, increasingly stringent safety standards, and a chronic shortage of skilled labor, robotic welding is increasingly becoming a key technology in modern manufacturing. Whether in series production or for small batch sizes, automated welding with robots enables the highest quality, repeat accuracy, and process reliability.
What is robotic welding?
In robotic welding, a welding robot guides the welding torch precisely along the weld seam. Among the many benefits are:
- Consistent weld quality
- High process speed
- Minimization of rejects and rework
- Full documentation of welding data
What makes up a welding system and what are the most important components?
The fact that robotic welding works smoothly is not just down to the welding robot alone. Every component in the welding system has to work together seamlessly:
The welding machine is the heart of a robotic welding system. A good welding machine must:
- Be quickly adjustable (e.g., via high-speed bus systems)
- Work reliably, even with high-tech arc processes such as CMT (Cold Metal Transfer), PMC (Pulse Multi Control), or LSC (Low Spatter Control)
- Be network compatible for integration into production lines or smart factories
Our welding machines, such as the TPS/i Robotics, offer all these qualities and more—including intelligent assistance systems such as WireSense, TeachMode, TouchSense, or SeamTracking.
A precisely controlled wirefeeder is crucial for ideal welding results. This is a highly sophisticated mechanism that controls the entire welding process and feeds the wire according to exact parameters. Fronius wirefeeders include:
- Process-synchronized wirefeeders for precise forward and backward movements in the millisecond range
- Push systems: The welding wire is moved from the wirefeeder to the torch (short hosepacks)
- Push-pull systems: The wire is pushed by the wirefeeder (push) and pulled by the torch motor (pull)—ideal for long hosepacks
- Integrated sensor systems for edge detection and seam tracking
The hosepack is the connection between the welding machine and the torch. It must:
- Be mechanically resilient yet also flexible
- Guarantee reliable wirefeeding and stable current transmission
- Cool down efficiently while retaining thermal stability
High-quality robot welding torches guarantee precision and process reliability. Our welding torches are characterized by:
- TCP (Tool Center Point) precision
- Modularity and flexibility in lengths and angles
- Efficient gas or water cooling
- Effective collision protection
Robotic welding with Fronius
If you want to enjoy the benefits of robotic welding, you need more than just a welding robot. It is the combination of an intelligent welding machine, precise system components, and smart software that truly makes the difference. As a solution provider and general supplier, we offer customized complete solutions such as robot and cobot welding cells in addition to our welding technology products—all of which are modular, scalable, and future-proof.
Robotic welding machines—digital intelligence for every application
As a system provider, we supply our customers with the right welding machine for their system configuration—regardless of whether a single-wire, multi-wire, LaserHybrid, TIG, or plasma solution is required.
Robot peripherals—optimizing the welding process with smart components
In addition to the robot welding machine, modern robotic welding systems are supported by peripheral system components and software-controlled solutions that optimize the welding process. Assistance, camera, and cleaning systems are all available as well as changing stations for contact tips and torch bodies.
What our customers say
Lightweight construction cuts carbon emissions
Progress in aluminum: three simple words that describe a pioneering approach. The Salzburger Aluminium Group (SAG Group) brings innovative lightweight construction methods to vehicle construction, thereby helping to cut carbon emissions. Welding is performed using patented CMT and WireSense technology from Fronius.
