Perfect Symbiosis of Welding Technology and Kinematics

9/28/2023

Welding engineers all over the world associate the name Fronius with innovative welding technology. Above all, the innovators are known for providing high-performance, high-tech welding systems. The name Fronius is also associated with revolutionary welding processes such as Cold Metal Transfer (CMT), intelligent seam detection sensors such as WireSense, and the brand-new DynamicWire wirefeeder. However, there is little awareness across all industries that Fronius Welding Automation supplies automated welding systems from a single source. Only in the oil and gas offshore sector does the company have a strong profile among potential customers as a renowned manufacturer of cladding systems.

There is a long tradition of plant construction at Fronius. Take, for example, the longitudinal seam welding system from 1979 for welding sheet metal sections made of steel. The company has been developing sustainably designed welding systems that have future potential since 1975. That’s why most of their solutions can be upgraded and expanded by adding extra features such as welding processes, sensor technology, and software updates. Today, more than 3,500 installed systems are in use across 45 different countries with over 2,000 active customers. Covering an area of more than 11,000 square meters, around 150 employees (a number that is increasing) take on the welding technology challenges presented by their customers.

Technological Advantage

Since the invention of the "cold" MAG welding process, Cold Metal Transfer (CMT), if not earlier, Fronius has continuously achieved technological leadership in many welding-related areas, resulting in state-of-the-art mechanized and automated welding systems. Advanced power source technology stabilizes the arc and ensures perfect welding results. Modern monitoring sensors optimize guidance of the welding torch and compensate for component tolerances. Last but not least, smart data documentation systems assist in perfecting the welding process.

Cost-Effective from Batch Sizes of One

Collaborative systems, intelligent sensor technology, software solutions for data management, and offline programming including welding simulation open up profitable welding opportunities for metal processing companies starting with a single batch. That is why Fronius robotic welding cells prove profitable not only for large companies, but also for small- and medium-sized enterprises.

Modular System and Project Management

The specific requirements for the welding technology are analyzed together with the customer. This is followed by the creation of an individual solution. To do this, Fronius has an extensive construction kit of standardized components at its disposal. Starting with the feasibility study and continuing with planning, engineering, manufacturing, and start-up, the sale of welding systems is handled as a project. During this time, customers have one main point of contact: the project manager. He or she takes care of the entire project process and acts as the interface between the customer and all the Fronius sections involved. In doing so, the project manager ensures that processes run smoothly, cooperation is effective, and projects are successfully completed.

“The platform concept is at the heart of our engineering process. We define this as an intelligent matrix of management, technology, modular system, partnerships, and service”, says Anton Leithenmair, Head of Fronius Welding Automation.

Automation from a Single Source

Almost every project starts with a feasibility study, which determines the entire engineering process. It forms the basis for a solution that is tailored both in terms of technical and commercial viability. The integration of welding technology into the kinematic elements depends on the following factors: component conditions, process accuracy, and profitability. Welding Automation sources specialized components such as robots, sensors, clamping systems, and shelving systems from qualified cooperation partners.

Offline Programming and Welding Data Management

Fronius provides and relies on software solutions that enable a high degree of control and optimal interaction between all system components. Pathfinder provides all customers with an offline programming and simulation solution that significantly increases the profitability of welding systems. WeldCube is programmed for the evaluation of welding data. The innovative software seamlessly records welding data, makes welds reproducible without any limitations, and supports users in identifying optimization potential and maintenance intervals.

All-inclusive Service

Right from the start and throughout the entire service life of a welding system, Fronius Welding Automation is there to help its customers wherever they are in the world: providing support with everything from planning to feasibility studies, welding tests, commissioning, user training, remote maintenance, calibration, predictive maintenance, and on-site maintenance work.

One Range for All Industries

Mechanized Welding Systems: All welding torch movements are controlled automatically without the use of robots. Examples include boiler welding systems, seam welders, orbital welding systems, and magnetic or rail-guided welding carriages.

Robotic Welding Cells: Robots are used to control the movement axes. They are ideal for automating complex welding tasks on a variety of components. In combination with intelligent offline programming and simulation software for batch sizes as small as one.

Overlay Welding Systems (Cladding Systems): Overlay welding is used primarily in the cladding of metals to protect against abrasion and corrosion. Typical fields of application include rising pipes as well as valves for the oil and gas industry or membrane walls for power plants and waste incinerators.

Click here for more information on Fronius Welding Automation.

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