FOCUS ON JOINING
Fronius has been introduced , in combination with a TPS 400i power source , for the series production of identical parts . The iWave Pro series , the new generation of Fronius multiprocess welding machines , is also being used for specific applications . Viñolas Metall has been certified to ISO 3834-2 by the Fronius Welding Academy .
Welder wearing the Vizor-Air / 3X-Connect helmet system as protection against welding fume .
Meeting new challenges
Welding currently accounts for 70-80 % of the company ’ s production times . Carbon steel , stainless steel ( 304 , 316 , duplex and super duplex ), aluminium and COR-TEN ® are the most common materials processed .
For the most part , it is smaller components that are joined as well as large and heavy components . Sheet thicknesses range from 2-40mm . Welding is carried out in PA ( flat position ), PB ( horizontal vertical position ) and PC ( horizontal position ). Out-of-position welding on vertical beams and pipes is performed in PF ( vertical up ) and PG ( vertical down ) positions .
The most frequently used processes are TIG and MIG / MAG for manual tasks , as well as the ArcTig keyhole welding process for automated applications . Orbital welding systems are also employed , where the welding torch rotates around the component during joining .
As it specialises in technically demanding , complex metal structures , Viñolas Metall faced two new challenges . The first was finding a solution for creating high-quality , reproducible welds for series production where industry specifications and welding standards had to be respected . The components produced are exposed to high loads and used in highly corrosive environments such as plant construction .
The second requirement focused on welding autonomy and system optimisation . The required system needed the capability to switch between two welding processes ( TIG and MIG / MAG ) independently and without sacrificing weld quality during the course of a quick process change .
Matheus Borborema , mechatronics engineer at Viñolas Metall .
Robotic welding cell with TPS 400i CMT power source .
Robotic welding cell with TPS 400i CMT
As a result of the previous positive experiences that Viñolas Metall had enjoyed with Fronius welding machines and processes , it turned to Fronius once more for a solution .
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