FACE TO FACE
Left : The iWave DynamicWire welding package .
Below : Industry 4.0 is a core design element for Fronius products .
Digitalisation and automation
“ Digitisation is an ongoing trend — going forward , we assume that everything that can be digitised will be digitised . This is also true for automation . However , creativity and innovative strength will always lie with people , and we want to unleash their full welding potential ….,” Harald Scherleitner told ISMR .
Digitalisation influences joining technology in many ways . Fronius has developed software solutions , such as WeldCube , to improve the performance of welding systems in terms of ease of operation , weld quality and speed . The documentation software logs all welding conditions . Software-based analyses are designed to enable economical use of materials – filler wire and inert gas , for example . Cloud applications help to evaluate data and identify and immediately resolve weak spots . Remote access enables condition analysis and service in real-time to provide a basis for smart maintenance planning .
As a solution to the worldwide shortage of skilled workers , it has also developed the CWC-S Cobot welding cell for small to large batchwork where welders need no programming knowledge . Welding specialists can be released from routine activities and are available for more complex tasks .
“ We are digitising welding expertise so that customers are not dependent upon skilled welders . Digitising this expertise is a real challenge . The cobot cells are a great solution – they are simple to program and make jobs more attractive for workers . The cobot handles all the hard work and the worker ’ s experience is poured into the application with the cobot . This process also unlocks new applications and opportunities ,” confirmed Scherleitner .
Precise torch movements , with a repeatability of +/ - 0.04mm , are designed to guarantee weld reproducibility in the Cobot welding cell , even in batches if necessary . Intelligent Fronius welding technology controls the welding process and records all welding data as required . The WeldCube data
management software , optionally available with the welding cell , stores and evaluates these data .
The welding cell ’ s standard equipment includes a Fanuc Cobot CX10 iA with a reach of 1,249mm and a payload of 10kg , and a welding table with a working area of 1,500 x 1,000 x 700mm . Operator safety measures include a pneumatic glare shield , sliding side doors with viewing windows and an extraction hood .
The Handling-to-Welding robotic welding cell from Fronius Welding Automation , or HTW for short , joins parts of different geometries and materials . Two robots complete the job – the handling robot positions the workpieces , and the second robot performs the welding . Various configuration options and software solutions mean that the system can be seamlessly integrated into production processes .
Processes and technologies
Fronius is also addressing industry requirements with a range of modular , flexible and user-friendly high-end devices e . g . the iWave Multiprocess PRO , which was launched in January 2022 . It is a multiprocess machine for different welding processes . It can also be retrofitted ( for example with welding packages ) as required .
“ We developed the iWave to enable the very best TIG weld quality and flawless results to be produced on different metals . The Option CycleTIG provides for maximum control over the arc and targeted heat input . Further highlights include improved ignition control and greater ease of use with intuitive operation . The series is available in power categories from 190A to 500A . Multi-process capability is important if you are switching between different welding tasks on a day-to-day basis . The Multiprocess PRO option gives the user unlimited access to all MIG / MAG processes in power categories from 300A . It is ideally suited for manual metal arc welding , even with cellulose electrodes ,” explained Harald Scherleitner .
“ TIG cold wire components are now also available for the Fronius iWave . This new innovation lies in their intelligent control . With the patented new Welding Package , TIG DynamicWire , even amateurs can create perfect TIG weld seams . Because the dynamic wire control always selects the right feed speed , welders can concentrate fully on the arc and the welding system regulates the optimum wire feed speed at all times . The process adapts to the welder , not the other way around . This system will be available in October 2022 ,” he added
Fronius has also added to its range of smart , high-end TPS / i TWIN tandem welding systems .
The CWC-S cobot welding cell .