Fronius Robotic Welding

/ 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 technologies 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 superlative 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 TransSteel

/ MIG/MAG CMT

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 suitable 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.

/ Plasma welding with MagicWave

/ TIG cold-wire welding with MagicWave

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.

COMPARISON OF ARC TECHNOLOGIES Uw [V] N ATI R OT TIM PUL

S

GA

RC

E

Y ARC SPRA ED PCS

ARC ARC

ARC RC AR SE A BUL ARC PUL GLO SFER MT C N . A . .. -TR ..... DIP ..... RC ..... EA ..... C . ULS . . . DP R ... E . A . C . T . .. CM ADVAN ARC ..... ED T ..... CM VANC ..... D ..... . . . TA . ... CM

Iw [A]

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. Low power range up to 250 A

PLASMA

High power range from 250 A

DTA

Welding speed Gap-bridging ability

CMT

CMT ADVANCED

TIG

LASER PLASMA TWIN HYBRID

CMT TWIN

T.I.M.E. SPRAY PULSED CMT ARC PULSE

TIG

Metal thicknesses / 5

METAL THICKNESSES

STEEL 0.5 – 2.0 MM STANDARD CMT

2.0 – 5.0 MM

> 5.0 MM

DTA

Spray arc T.I.M.E.

CMT CMT Advanced

CMT Pulse

PULSED

Pulsed PCS arc

T.I.M.E.

TWIN

Time Twin CMT Twin Plasma

PLASMA

Laser Hybrid

LASER HYBRID

METAL THICKNESSES

ALUMINIUM 0.5 – 2.0 MM

2.0 – 5.0 MM

> 5.0 MM Spray arc

STANDARD CMT

CMT CMT Advanced

CMT Pulse

Pulsed

PULSED

Time Twin

TWIN TIG

TIG

Laser Hybrid

LASER HYBRID

METAL THICKNESSES

CrNi 0.5 – 2.0 MM

2.0 – 5.0 MM DTA

STANDARD CMT

Spray arc

CMT CMT Advanced

CMT Pulse Pulsed PCS arc

PULSED CMT Twin

TWIN

TIG

TIG PLASMA

> 5.0 MM

Microplasma

Plasma keyhole Soft-plasma

LASER HYBRID

/ Abbreviations: DTA: dip-transfer arc; CMT: Cold Metal Transfer

Laser Hybrid

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 functions 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 / Fronius is a byword for high-quality system components for robot welding. And thus for dependable, long-life welding systems.

MAXIMUM SYSTEM AVAILABILITY / 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.

FULL-LINE SYSTEM SUPPLIER / 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 / 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.

WORLDWIDE DIRECT SALES ORGANISATION / Fronius has a closely meshed distribution network of subsidiaries and partner firms, spread across all five continents.

OVER 30 YEARS’ EXPERIENCE / 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.

SERVICE THAT’S CLOSE AT HAND / Our customers enjoy swift and capable ‘on-the-spot’ service which is of the same high quality throughout the world.

8 / The application modules

APPLICATIONS AND WELDING RESULTS AT A GLANCE. 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

/ SyncroPuls: Saves time, perfect seam appearance

/ Steel Root

5 mm/0.20 in

/ Root fusion guaranteed

/ Steel Root

6 mm/0.24 in

/ Excellent gapbridging ability

CMT (COLD METAL TRANSFER) / Spatter-free MIG/MAG welding / Minimised thermal input / Outstanding process characteristics / Steel/aluminium hybrid join / Crash-test safe

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

/ Excellent seam appearance

/ Perfect root fusion

/ TIG AC – 1: 125 A, U: 17.2 V, Vwire: 1.2 m/min, Vweld: 40 cm/min. Material: aluminium 1 mm

THE ROBOT WELDING SYSTEM – THE HIGHLIGHTS. /

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WIREFEEDER / Compact wirefeed unit means greatly reduced obstacle contours.

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INTERFACE / Our robot interfaces function with all common field-bus and analogue signals.

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FSC – FRONIUS SYSTEM CONNECTOR / Central connection-point for all media / Firmly locks the hosepack with no need for any tools

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EASE OF HANDLING / The movable wirefeeder holder makes for much easier handling when changing the inner liner.

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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

The application modules / 11

APPLICATIONS AND WELDING RESULTS AT A GLANCE. 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

/ Excellent appearance

/ Pore-free welding seams

/ Plasma – 1: 210 A, U: 21.5 V, Vweld: 50 cm/min Material: CrNi 3 mm

/ Steel 10 mm

/ 6 passes / Position PF, narrow-gap

/ After wear

7.9 mm/ 0.31 in

6.5 mm/ 0.26 in

5 mm/ 0.20 in

/ High welding speeds – Vweld 150 cm/min

/ Custom application

/ Steel 12 mm

/ Steel 4 – 8 mm

12 mm/0.47 in

/ Shorter fabrication times / Welding speeds of up to 9 m/min / Deeper penetration and narrow seams, yet less thermal input

/ Contact tip at beginning

/ Steel 70 mm

10 mm/0.39 in

/ Simultaneously with Time Twin (PA) and CMT (PE) / Without seam preparation / Minimal distortion

LASERHYBRID / The laser beam and the arc act jointly in one welding zone, influencing and supporting one another

CONTEC MD / Novel contacting technology

/ Steel 3.5 mm

70 mm/2.76 in

/ Aluminium 60 mm

60 mm/2.36 in

TIME TWIN / Ultra-high deposition rates of up to 30 kg/h achieved by using two synchronised pulsed arcs that weld alternately.

/ Through-welded on one side, without seam preparation

/ Fillet weld, throughwelded on one side, w/o seam preparation

/ Contec at beginning

/ After wear

7.9 mm/ 0.31 in

5 mm/ 0.20 in

/ Penetration on the workpiece decreases as the contact tip becomes increasingly worn.

6 mm/ 0.24 in

7.9 mm/ 0.31 in

5 mm/ 0.20 in

5 mm/ 0.20 in

/ The flexible half-shells keep the contact tip unvaryingly constant. The penetration remains constant and unchanged.

/ What Günter Fronius started in 1945 in Pettenbach, Austria, has now become a modern 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 of what‘s possible. While others progress step by step, we innovate in leaps and bounds. WELDING TECHNOLOGY / We develop welding technologies, such as entire systems for arc and resistance spot welding, and have set ourselves the task of making impossible weld joints possible. Our aim is to decode the »arc welding‘s DNA«. We are the technology leader worldwide and the market leader in Europe.

SOLAR ELECTRONICS / The greatest challenge of our time is to make the leap to a regenerative energy supply. Our vision is to use renewable energy to achieve energy independence. With our mainsconnected inverters and products for monitoring photovoltaics systems, we are now one of the leading suppliers in solar electronics. v03 2011 EN

BATTERY CHARGING SYSTEMS / We started a technological revolution with Active Inverter Technology and are now one of the leading suppliers in Europe. We are driven by the aim of providing intelligent energy management systems that ensure mobility stays as economically viable as possible in the twenty-first century.

Text and images correspond to the current state of technology at the time of printing. Subject to modifications. All information is without guarantee in spite of careful editing - liability excluded. Copyright © 2011 Fronius™. All rights reserved.

WE HAVE THREE DIVISIONS AND ONE PASSION: SHIFTING THE LIMITS.

Fronius Canada Ltd. 2875 Argentia Road, Units 4,5 & 6 Mississauga, ON L5N 8G6 Canada Telephone +1 905 288-2100 Fax +1 905 288-2101 [email protected] www.fronius.ca

Fronius USA LLC 10421 Citation Drive, Suite 1100 Brighton, Michigan 48116 USA Telephone +1 810 220 4414 Fax +1 810 220 4424 [email protected] www.fronius-usa.com

Fronius UK Limited Maidstone 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 International GmbH Froniusplatz 1 4600 Wels Austria Telephone +43 7242 241-0 Fax +43 7242 241-953940 [email protected] www.fronius.com

M,06,0046,EN v01 2012 aw14

Further information about all Fronius products and our global sales partners and representatives can be found at www.fronius.com