PRODUCT REVIEWS
Faster automated TIG welding
A firm grip
“ Metalworkers are faced with several challenges : high variance of workpieces with small batch sizes , cost pressures and a lack of personnel due to strenuous and monotonous activities in sheet-metal processing . With our ivOS Sheet Metal Solution Kit , companies can automate machine loading simply , flexibly and economically ,” Schmalz told ISMR .
The vacuum specialists from Germany ’ s Black Forest automate the handling of sheet metal parts . Its Solution Kit consists of the latest 3D camera technology , the ivOS vision operating system and the flexible FMG matrix gripper . This gripper features seven modules , each with twelve suction cups which are linked to form a flexible area gripper . The 84 individually controllable suction points adapt automatically to changing workpiece geometries . This offers users flexibility when handling different sheets and gripper changes can be reduced to a minimum .
“ Sheet-metal processors and contract manufacturers want to produce efficiently to be profitable and ensure their competitiveness . The challenge : high part variance with fluctuating batch sizes . Labour shortages and rising wage costs exacerbate the situation ,” highlighted Schmalz , outlining the versatility of its solution kits .
Schmalz products are used in logistics applications as well as in the automotive industry , the electronics sector and furniture production . Schmalz is represented with its own locations and trading partners in around 70 countries . The family-owned company employs around 1,800 people at its German headquarters ( Glatten , Black Forest ) and in 29 other companies worldwide . In September , the Schmalz Group established its 30th location in Slovenia . The sales company , Schmalz d . o . o ., is based in Vrhnika and focuses on south-eastern Europe .
Arc welding specialist , EWM GmbH , has highlighted new added value ( increased speed and straightforward handling ) for its forceTig ® welding process which is used for automated TIG welding .
“ The forceTig ® process effectively constricts the arc in comparison to conventional TIG welding . The arc energy is focused on a smaller surface . This concentration of energy increases the arc force , meaning greater energy density . This allows users to weld thin CrNi , nickelbased or titanium sheet metal at high speed . It also allows welders to weld thick metal of up to ten millimetres thick in a single pass without weld seam preparation . PA and PC positions can be used for both welding scenarios ,” explained EWM .
“ The modular forceTig ® system includes the power source with re-cooling unit , the forceTig ® welding torch system , a cold or hot wire feeder and all the required interfaces for automatic operation . Each individual component is tailored to one another and compatible with all market-standard mechanisation and automation components ,” it continued .
The forceTig ® welding torches are optimised for automatic welding and are designed to be easy to handle . For the FT1000 , welders can change electrodes in four steps : unscrew the gas nozzle , remove the worn electrode , screw in the new electrode and reattach the gas nozzle . The electrode and gas nozzle are the only consumables in the welding torch system .
“ As the electrode is calibrated , even inexperienced users can replace the electrodes safely and consistently . There is no separate setting gauge . The distance between the tungsten electrode tip and the component does not change once the electrode is replaced , meaning the welding results stay the same . The FT1002 offers users the advantages of a conventional TIG welding torch with its adjustable tungsten electrode , making it perfect for roots and extra-thick metal plates .
The forceTig ® process effectively constricts the arc in comparison to conventional TIG welding . The arc force is stronger and the energy penetrates deeper into the material .
The water-cooled gas nozzle ensures a long service life in heavy operation . All welding torches are incredibly crash-resistant , thanks to their sturdy design ,” added EWM .
The benefits of the forceTig ® process also come to the fore when working with technically challenging high-alloy materials . Hydrogen is liquid and stored under extremely low temperatures , meaning weld seams need to be 100 % tight , even with high loads .
“ The optimised forceTig ® process also means there is no need for weld seam preparation , resulting in significant time savings , increased efficiency and improved productivity ,” concluded the manufacturer . n
www
. ewm-group . com / en /
Above : Micrographs allow users to identify how deep the energy from the forceTig ® arc penetrates into the material to create a weld seam that , says EWM , is 100 % tight .
Left : The arc force in relation to welding current . A high arc force helps energy penetrate deep into the material . www . schmalz . com
ISMR November 2023 | ismr . net | 91