FACE TO FACE
The Handling-to-Welding robotic welding cell .
Above : Protective equipment from Fronius .
Synchronised welding with two individually controllable arcs can now be done with new TPS / i TWIN systems and PMC TWIN / CMT TWIN welding processes . The TPS / i TWIN Push-Pull solution is designed for use in vehicle and railway vehicle construction and used to weld aluminium profiles or pressure containers using the PMC ( Pulse Multi Control ) process . The new TPS / i CMT TWIN system also uses the CMT ( Cold Metal Transfer ) process for welding aluminium , nickel-base alloys and high-strength steels . The controlled heat input provided by the Cold Metal Transfer process is particularly well suited for thin-sheet applications .
Strategic focus and objectives
Scherleitner confirmed that emphasis has been placed very firmly on quality , sustainability and health / safety issues .
“ These important issues drive our initiatives , research and our product development . The human very much comes into focus here . For us , quality awareness is not just an empty promise , but a corporate value that is lived and practised . We put our products through up to 13 different endurance tests during the development phase . This is the only way to guarantee a long working life . To ensure responsible use of resources , we emphasise durability , repairability and recycling right from the development stage . High quality always goes hand in hand with reliability , health protection and ease of use in all our products and services ,” he confirmed .
Fronius ’ customer-oriented strategy has also driven its focus on health and safety issues in welding . It has developed a range of equipment , such as helmets and clothing , that protect welders from hazardous fumes , spatter and flashes . It also intends to launch more health and safety equipment at the end of this year .
Scherleitner is keen , however , to point out that quality and accuracy are the cornerstones that underpin all Fronius products .
“ Although we increasingly think about Industry 4.0 digitisation in this industry , you must still fulfil the basic requirements and that means , first and foremost , quality in welding . You still need to join two different materials accurately , before looking at further data analysis . Everything springs from this . Service then becomes key i . e . commissioning new systems , optimising product lines , supporting equipment life , training etc . It really is important to get the basics right ,” he confirmed .
The company has adopted the motto ‘ Let ’ s Get Connected ’ to continue its ongoing discussions and feedback from customers and help it to develop further new technologies , software and services .
In the Fronius 900 square-metre prototyping centre , at its facility in Wels ( Austria ),
CMT welding cell in the Fronius prototyping centre . specialists develop customised solutions to tackle every welding challenge .
“ We support our customers in the manufacturing of prototypes and feasibility studies because these are costly , labour-intensive and time-consuming . This is in response to the challenges we are seeing . We don ’ t just offer technical support ; we have expanded our range of services to include various hightech analyses and simulations . We always try to find the perfect welding solution for the customer ,” added Scherleitner .
“ At the moment , we are focusing on e-mobility issues as OEMs and car producers are facing new material challenges ( for instance , how to weld battery cell trays ). The centres recommend the optimum welding processes to meet these requirements . They also examine prototype wire arc additive manufacturing processes . This is a great technology for remote operations ,” he added .
Whether it is battery trays for e-mobility ; axles ; frame sections or various applications for other industrial sectors , parts of up to 1,500kg and 3 x 2 metres can all be joined in the new prototyping centre . It offers a range of services including 3D equipment fabrication , 3D measurement and an offline programming option complete with welding process simulation . Heat and distortion simulation ; welding seam inspection ; a laser seamtracking camera ; hot active plasma technology for surface cleaning and a laboratory for metallographic examination all come as standard . WeldCube software , for documenting and analysing welding data , makes it possible to trace the entire component history in detail .
Fronius will be exhibiting at FABTECH in Atlanta , USA , this November , as well as at Metalex in Thailand . n