robot welding. - fronius.com · robot welding. / long-life system ... ‘decode the dna of the...
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/ Battery Charging Systems / Welding Technology / Solar Electronics
ROBOT WELDING./ Long-life system solutions for all welding requirements.
2 / About us
/ Ever since 1950, we’ve been developing innovative comprehensive solutions for arc welding and resistance spot-welding. Like our Cold Metal Transfer technology CMT. This revolutionary welding process has swept away one old prejudice: that you can’t weld aluminium and steel to one another. Day-in, day-out, we’re working on our vision: to ‘decode the DNA of the arc’. No wonder that we’re the welding-sector’s technological leader worldwide, as well as being the European market leader.
LONG-LIFE SOLUTIONS FROM THE WORLD MARKET LEADER AND INNOVATION PACESETTER./ Fronius is the strong partner that provides every robot brand, every system and every application with outstanding tech-nologies and excellent service. We have a decades-long track record as a system supplier to all relevant sectors. In this, we insist on always delivering the same high quality, everywhere, every time. As a single-source supplier, we achieve this not least through our worldwide subsidiaries, our huge store of experience and our excellent service – no matter where.
SYSTEM SUPPLIER WITH OVER 30 YEARS’ EXPERIENCE./ At Fronius, tradition and experience are close companions. For more than 30 years now, we have been delivering super-lative product quality in the field of robot welding. The close working relationships that we have with our customers and with all robot manufacturers mean that we are completely familiar with their industry and their requirements.
/ MIG/MAG CMT
/ MIG/MAG TransSteel
About us / 3
WORLD MARKET LEADER AND INNOVATION PACESETTER./ Our innovations have made a home for themselves just about everywhere. All round the world, Fronius is involved in the main technological innovations – in the automobile industry, for instance.
PERFECT SYSTEM SOLUTIONS FOR EVERY REQUIREMENT./ We are the full-line system manufacturer and single-source supplier of robot welding systems. Our technologies are suit-able for all types of robot and all robot manufacturers. This means that no matter whether it’s standardised or customised, Fronius has the right solution for every application.
/ TIG cold-wire welding with MagicWave
/ Plasma welding with MagicWave
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4 / Single-source supplier
LONG-LIFE SOLUTIONS WITH SUPERIOR WELDING PROPERTIES – FOR ALL APPLICATIONS.
/ As a global market leader in the robot-welding field, we have all the latest technologies for arc welding and resistance spot-welding. Our customers can be sure that all the components of the innovative Fronius welding systems will work together in perfect harmony for years and years to come. As a single-source supplier, we deliver ultra-high product quality, absolute efficiency, and unrivalled service.
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ROTATING ARC
TIME
PULSED ARCSPRAY ARC
PCS ARC
DIP-TRANSFER ARC
CMT PULSE ARC
CMT ARC
CMT ADVANCED ARC
CMT ADVANCED PULSE ARC
GLOBULAR ARC
Uw [V]
COMPARISON OF ARC TECHNOLOGIES
EVALUATION CRITERIA FOR MAKING THE RIGHT SELECTION/ Fronius offers the right weld processes and arcs for every application. For most materials, welding speed and gap-bridging ability can be used as the evaluation parameters.
PLASMA DTA CMT CMT ADVANCED
TIG
Low power range up to 250 A
LASER HYBRID
PLASMA TWIN CMT TWIN
T.I.M.E. SPRAY ARC
PULSED CMT PULSE
TIG
High power range from 250 A
Welding speed
Gap-bridging ability
ALUMINIUM METAL THICKNESSES
0.5 – 2.0 MM 2.0 – 5.0 MM > 5.0 MM
STANDARD
CMT
PULSED
TWIN
TIG
LASER HYBRID
CRNI METAL THICKNESSES
0.5 – 2.0 MM 2.0 – 5.0 MM > 5.0 MM
STANDARD
CMT
PULSED
TWIN
TIG
PLASMA
LASER HYBRID
STEEL METAL THICKNESSES
0.5 – 2.0 MM 2.0 – 5.0 MM > 5.0 MM
STANDARD
CMT
PULSED
TWIN
PLASMA
LASER HYBRID
Metal thicknesses / 5
/ Abbreviations: DTA: dip-transfer arc; CMT: Cold Metal Transfer
T.I.M.E.Spray arc
T.I.M.E.
DTA
CMT PulseCMT Advanced
PulsedPCS arc
CMT TwinTime Twin
Plasma
Laser Hybrid
CMT
Spray arc
CMT PulseCMT Advanced
Pulsed
Time Twin
TIG
Laser Hybrid
CMT
DTA Spray arc
CMT PulseCMT Advanced
PulsedPCS arc
CMT Twin
TIG
Microplasma Plasma keyholeSoft-plasma
Laser Hybrid
CMT
6 / Robot welding – the highlights
WE OFFER THE ULTIMATE IN ROBOT-WELDING SYSTEMS AND SERVICE, WORLDWIDE./ If you’re serious about exploiting the scope of excellent welding properties and func-tions to the full, you have to think in terms of systems. Which is what we do, everywhere. Just like we think about our customers, with capable teams of applications and service technicians delivering fast, expert ‘on-the-spot’ advice and support.
SUPERLATIVE PRODUCT QUALITY
MAXIMUM SYSTEM AVAILABILITY
FULL-LINE SYSTEM SUPPLIER
/ Fronius is a byword for high-quality system components for robot welding. And thus for dependable, long-life welding systems.
/ Because they are designed for interoperability, the system components keep operational downtimes exceptionally low: for example, Contec ensures constant welding properties, while Robacta TX allows the the torch body to be changed without human intervention, independently of work-shifts.
/ We supply modular system components to ensure the very greatest flexibility with all applications and welding processes. Perfect interplay between all the components of the welding system is a matter of fact here.
Robot welding – the highlights / 7
PERFECT WELDING PROPERTIES
OVER 30 YEARS’ EXPERIENCE
SERVICE THAT’S CLOSE AT HAND
/ Our mastery of the arc is unrivalled. The precision of our control systems means that we achieve for example the best gap-bridging ability, the highest welding speeds, and spatter-free applications.
/ Our long-standing working relationships with robot manufacturers and integrators mean that we have had a hand in all the trend-setting innovations and technical milestones.
/ Our customers enjoy swift and capable ‘on-the-spot’ service which is of the same high quality throughout the world.
WORLDWIDE DIRECT SALES ORGANISATION/ Fronius has a closely meshed distribution network of sub-sidiaries and partner firms, spread across all five continents.
TRANSPULS SYNERGIC/ Digitally controlled welding system, 100 % reproducible welding results
/ Spatter-free ignition (SFI)/ Multiprocess-capable/ Start-up program for aluminium/ SyncroPuls
TRANSSTEEL/ Perfect steel welding/ Extremely stable arc/ Easy system handling
CMT (COLD METAL TRANSFER)/ Spatter-free MIG/MAG welding/ Minimised thermal input/ Outstanding process characteristics
MAGICWAVE/TRANSTIG/ All-digitally controlled TIG welding systems with integral cold-wire-feeder unit
/ Superior weld-seam quality/ Completely harmonised, interoperable welding system/ Perfect root fusion with TIG pulse welding
8 / The application modules
APPLICATIONS AND WELDING RESULTS AT A GLANCE.
/ SyncroPuls: Saves time, perfect seam appearance
/ Excellent gap-bridging ability
/ Steel Root
/ Perfect root fusion/ Excellent seam appearance
/ TIG AC – 1: 125 A, U: 17.2 V, Vwire: 1.2 m/min, Vweld: 40 cm/min. Material: aluminium 1 mm
/ Root fusion guaranteed
/ Steel Root
/ Steel/aluminium hybrid join/ Crash-test safe
5 mm/0.20 in 6 mm/0.24 in
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THE ROBOT WELDING SYSTEM – THE HIGHLIGHTS.
WIREFEEDER/ Compact wirefeed unit means greatly reduced obstacle contours.
INTERFACE/ Our robot interfaces function with all common field-bus and analogue signals.
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MAGNETIC CRASHBOX/ Compact design = smaller obstacle contours in the 6th robot axis/ Minimised obstacle contours/ Trigger forces can be adjusted by modular magnetic rings
FSC – FRONIUS SYSTEM CONNECTOR/ Central connection-point for all media/ Firmly locks the hosepack with no need for any tools
EASE OF HANDLING/ The movable wirefeeder holder makes for much easier handling when changing the inner liner.
MICROPLASMA, SOFT-PLASMA, PLASMA KEYHOLE/ Plasma welding systems can be retrofitted to existing TIG installations
/ Complete freedom from porosity/ Flawless seam appearance/ Spatter-free applications
TIME TWIN/ Ultra-high deposition rates of up to 30 kg/h achieved by using two synchronised pulsed arcs that weld alternately.
LASERHYBRID/ The laser beam and the arc act jointly in one welding zone, influencing and supporting one another
/ Shorter fabrication times/ Welding speeds of up to 9 m/min/ Deeper penetration and narrow seams, yet less thermal input
CONTEC MD/ Novel contacting technology
The application modules / 11
APPLICATIONS AND WELDING RESULTS AT A GLANCE.
/ Pore-free welding seams/ Excellent appearance
/ Plasma – 1: 210 A, U: 21.5 V, Vweld: 50 cm/min Material: CrNi 3 mm
/ Custom application
/ Fillet weld, through-welded on one side, w/o seam preparation
/ Steel 70 mm
/ Steel 4 – 8 mm
/ After wear/ After wear
/ The flexible half-shells keep the contact tip unvaryingly constant. The penetration remains constant and unchanged.
/ Penetration on the workpiece decreases as the contact tip becomes increasingly worn.
/ High welding speeds – Vweld 150 cm/min
/ Through-welded on one side, without seam preparation
/ Simultaneously with Time Twin (PA) and CMT (PE)/ Without seam preparation/ Minimal distortion
/ 6 passes/ Position PF, narrow-gap
/ Steel 3.5 mm
/ Steel 12 mm
/ Contec at beginning/ Contact tip at beginning
/ Steel 10 mm/ Aluminium 60 mm
70 m
m/2
.76
in
60 m
m/2
.36
in
10 m
m/0
.39
in
6 mm/0.24 in
7.9 mm/0.31 in
6.5 mm/0.26 in
7.9 mm/0.31 in
7.9 mm/0.31 in
12 m
m/0
.47
in
5 mm/0.20 in
5 mm/0.20 in
5 mm/0.20 in
5 mm/0.20 in
SOLAR ELECTRONICS/ The greatest challenge of our timeis to make the leap to a regenerativeenergy supply. Our vision is to userenewable energy to achieve energyindependence. With our mains-connected inverters and products for monitoring photovoltaics systems,weare now one of the leading suppliers in solar electronics.
WELDING TECHNOLOGY/ We develop welding technologies,such as entire systems for arc andresistance spot welding, and have set ourselves the task ofmaking impos-sible weld joints possible. Our aim is to decode the »arc welding‘s DNA«. We are the technology leader world-wide and themarket leader in Europe.
BATTERY CHARGING SYSTEMS/ We started a technological revolutionwith Active Inverter Technology andare now one of the leading suppliers inEurope. We are driven by the aim ofproviding intelligent energy manage-ment systems that ensure mobilitystays as economically viable as possible in the twenty-first century.
Further information about all Fronius products and our global sales partners and representatives can be found at www.fronius.com
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WE HAVE THREE DIVISIONS AND ONE PASSION:SHIFTING THE LIMITS.
/ What Günter Fronius started in 1945 in Pettenbach, Austria, has now become amodern day success story. Today, the company has more than 3,000 employees worldwide and owns 737 active patents. Since the very beginning, our goal has not changed: to be the technology and quality leader. We shift the limits ofwhat‘s possible. While others progress step by step,we innovate in leaps and bounds.
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Fronius International GmbHFroniusplatz 14600 WelsAustriaTelephone +43 7242 241-0Fax +43 7242 [email protected]
Fronius UK LimitedMaidstone Road, Kingston Milton Keynes, MK10 0BD United Kingdom Telephone +44 1908 512 300 Fax +44 1908 512 329 [email protected] www.fronius.co.uk
Fronius USA LLC10421 Citation Drive, Suite 1100Brighton, Michigan 48116USATelephone +1 810 220 4414Fax +1 810 220 [email protected]
Fronius Canada Ltd.2875 Argentia Road, Units 4,5 & 6 Mississauga, ON L5N 8G6Canada Telephone +1 905 288-2100 Fax +1 905 288-2101 [email protected]