FOCUS ON WELDING
Jaan Zabolotski operating the FlexTrack 45 Pro welding carriage on the specifically engineered assembly jig. The power source being used here is the Fronius TPS 400i.
The power source used here to weld the trailer body is the Fronius TPS 400i. equipped with intelligent control systems to adjust the welding parameters.
“ Penetration and Arc Length Stabilisers ensure consistent weld quality by maintaining the desired penetration and arc length, which aids in controlling heat input more effectively. The TPS / i can be customised with various software packages to meet specific welding requirements. The Pulse feature is typically used at Fruehauf to ensure the thicker top rail receives sufficient heat for fusion, while the thinner panel is protected from overheating. Pulse technology enables the arc to alternate between high peak current and a low background current. This reduces heat input, minimising distortion and burn-through, which is especially critical when welding thin to thick materials. The controlled droplet transfer in pulse mode also reduces spatter and enhances weld bead appearance,” explained Fronius.“ Using the Fronius TPS / i ensures that repeatable welds can be achieved with the consistent quality required. The parameters for each job can be set and stored on the system, allowing any operator to quickly and easily pick up any given job in the production process. These welding machines have been paired with the Push-Pull torch with 10-metre hose pack,” it added.
Enhancing welding efficiency
“ Before we introduced the Fronius TPS / i machines, we frequently encountered wirefeed issues and consequently had to change the liner regularly. We have been using the 10m Fronius Push Pull torch, which includes a motorised pull system that synchronises with the wire feeder, ensuring uninterrupted wire feed. Since adopting these we have significantly increased efficiency,” Artūras Mitunevičius explained.
“ We opted for the Job Master model so the welder can select parameters, including pre-saved jobs, directly on the torch without having to return to the machine. This is very convenient when you are welding body lengths
of 9-12 metres. The user-interface on the screen is also relatively simple to use,” he continued.
The“ EasyJob” setting on the Jobmaster torch allows users to store up to five welding tasks directly on the welding torch and quickly switch between them. This feature enables them to access essential welding tasks for their daily work right on the torch, eliminating the need for frequent trips between the welding system and the workpiece.
“ As a result, their daily operations become more convenient and notably more efficient. The ergonomic design and multi-lock torch neck also makes it ideal for positional welding, thereby improving weld quality and speed,” added Fronius.
Above: Pulse technology enables the arc to alternate between high peak current and a low background current.
Automation to enhance production quality
The construction of sidewall panels for trailers involves three main components: the front post, planks and top rail. These elements are created from extruded aluminium profiles, which are supplied to the bulk trailer manufacturer from production plants in Padron( Spain) and Doncaster( UK).
Before the welding process begins, the profiles are cut to the necessary length and shaped using band and circular saws. In recent developments, the manufacturer has started assembling the side panels of the trailer using a specially created assembly jig, after which the panels are immediately welded.
This welding process utilises the Fronius FlexTrack 45 Pro rail guided welding carriage for longitudinal seam welding and employs a TPSi 400i.
The company conducted an evaluation of this semi-automated process and determined that, when compared to a fully robotic system, the Fronius FlexTrack welding carriage was more cost-efficient. The FlexTrack 45 Pro has now been used in production since June 2024.
“ It is utilised daily for a minimum of eight hours. Significant benefits include the consistent quality of the weld thanks to precise movements, steady welding speeds and improved comfort for the operator,” outlined Fronius.
Mitunevičius noted that the company has managed to save roughly one hour per sidewall in welding time( approximately 800 to 1,000 welding hours annually). With current labour rates, these time savings mean savings of £ 20,000- £ 25,000 per year, with return on investment achieved in under two years.“ Today, it is difficult to envision our aluminium body production without the FlexTrack welding equipment. It ensures perfect reproducibility of welding results, especially when used with the TPS / i welding source,” he added.“ We have also found the FlexTrack to be very reliable. We have been operating this application for 18 months without experiencing a single breakdown.”
The company continues to refine small details within this process to enhance operator comfort and fine-tune welding parameters for welding quality.
Artūras remains optimistic about the advantages of automation:“ It holds the promise of not only enhancing production quality but also improving safety, reducing waste and creating a more resilient and adaptable business environment,” he said. n
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ISMR February 2026 | ismr. net | 19