In spite of advanced robot technology and almost seamlessly interconnected systems, inaccuracies and deviations repeatedly occur in industrial production. In some cases, minimal material differences or imprecise clamping devices can have a negative influence on the welding result and potentially cause time-consuming rework, costly component rejects, or huge cycle time losses. This is where a robot welding system plays a crucial role. Integrators often resort to using optical measuring systems to avoid having to make time-intensive manual readjustments. However, laser and camera systems are expensive to buy and maintain, plus require space, which restricts access to the component. Fronius offers the solution through high-tech systems such as the Fronius robotic welding solutions, which deliver superior performance without the need for additional cameras or manual readjustments.
Also read: Trinity Engineering Graduate Launches Autonomous Marine Drone Startup
The Power of the TouchSense Assistance System
The robot welding system by Fronius uses the TouchSense assistance system that has been specially developed for fillet welds. Before each weld, the robot automatically touches the sheets being joined at the start and end of the weld. It does not matter whether it is the wire electrode or gas nozzle that makes contact: the signal is always clearly assigned and correctly transferred. The low sensor voltage creates a short circuit when the torch touches the workpiece, which enables the robot to precisely determine the weld position and adjust the welding parameters dynamically.
Another helpful feature is the immediate warning issued if a spatter bridge forms between the contact tip and gas nozzle. This allows it to be cleaned promptly, increasing precision and quality in production.
WireSense Technology for Precise Welding
What’s so clever about WireSense is its simplicity. “Adding special controller software to our highly sensitive and dynamic CMT drive turns the welding wire into a sensor that can identify contours or air gap deviations on the component,” reports Philipp Schlor, Strategic Product Manager at Fronius International. To ensure precise control of the welding wire, the **Fronius robotic welding** system simply needs to be equipped with a CMT-ready system. The **automatic welding system** can then use this technology for accurate adjustments.
CMT-ready systems consist of a wire feeder on a wire drum or spool, a wire buffer, and a CMT Robacta Drive, which means a second wire feeder on the torch itself. A reversing wire movement at around 100 Hz causes the electric motor in the drive unit to scan the metal surface with the wire. This scanning provides the necessary levels of precision, even on uneven surfaces, such as sheets lying at an angle.
Revolutionary Scanning for Perfect Results
“Our revolutionary WireSense technology uses the scanning function of the reversing CMT wire movement to determine the exact position of the component and edge, as well as air gap heights,” emphasises Schlor. Steel, stainless steel, and aluminum sheets from 0.5 to 20 millimeters thick can be scanned quickly and precisely.
Each raising and lowering operation on the component is recorded accurately relative to a reference point specified at the start of the scanning process. In just seconds, the robot compares the taught positions with those measured, checking the stored values against the actual position data. If it detects any differences, the seam course is adjusted accordingly, ensuring the weld is produced in the right place.
Applications of Robot Welding Systems in Industry
WireSense opens up a multitude of possibilities for robot integrators to identify high-quality solutions for challenging welding tasks,” reveals Schlor. The edge being welded doesn’t necessarily have to be detected, as any fixed reference edge on the component, such as the component edge or a notch, can serve as the starting point. This flexibility enables even difficult-to-detect parts, like a rounded sheet, to be welded at the desired position.
The robot welding system is particularly advantageous in industries where thick sheets or long seams need to be welded. In these cases, heat input can lead to component distortion, but Fronius technology ensures the robot continues to weld in the correct location. The robot moves back and forth between the two sheets during welding, and the controller converts the actual values into signals for the robot controller, ensuring reliable welding in the right location.
Improved Programming with TeachMode
The key to high quality lies in teaching the correct welding path. The tried-and-tested TeachMode assistance system helps the welder set the weld seam positions on the robot, making the programming process extremely easy. The reversing wire movement prevents the wire from bending in the event of contact with the component, saving the user from having to remove deformed wire or re-measure the stickout.
Efficient, Cost-Effective Welding Systems
Using the existing wire electrode as a sensor not only reduces expenditure and maintenance costs for additional sensor hardware but also frees up space, as access to the component is not restricted. At the same time, the Fronius assistance systems cut rejects and time-consuming rework because welding is performed reliably at the correct location. Subsequent re-programming of robot paths is also minimized as the robot can correct the weld seam path by itself.
All these factors increase efficiency in production while reducing the amount of time spent and material used. With robot welding systems from Fronius, industries can achieve optimal results and improved cost efficiency in welding tasks.
Conclusion
In conclusion, robot welding systems from Fronius offer an intelligent solution to the challenges faced in industrial welding. These systems significantly reduce defects, prevent time-consuming rework, and increase overall production efficiency. The integration of advanced technologies like TouchSense and WireSense ensures precise, reliable, and cost-effective welding, making Fronius robotic welding a game-changer for industries worldwide.
