But what exactly is
synergic welding?
At its simplest, synergic welding uses high-speed
electronics and computer software to control the welding arc precisely through
electrical feedback. Practically, the welding power supply changes the internal
arc settings to ensure that the arc is more stable, accurate and uses only the
energy needed to perform the job. It
almost sounds like the welding professional is no longer needed, but nothing
could be further from the truth. In
actuality, the welding power supply watches the arc through electronic sensors.
It only makes changes when the sensors detect a need to do so. The experience and capability of the person
holding the welding torch (or dialing in a robotic weld) will reduce the
changes so that the only thing the power supply worries about are environmental
factors that are often beyond the welder’s control. Like a high-end race car, the final
performance is as dependent on the driver as on the equipment being used. If
your goal is to achieve the highest quality, most profit-making welds, then you
want to ensure you have top welders using top equipment.
One of the most common questions concerning the
quality of the synergic power supply: is one better than another? The simple
answer: absolutely. Three things can help determine this: Component Quality,
Processor/Bus Speed, and Software.
Unfortunately, rating these components often requires a high
level of technical skill or deep access to the architecture. Lucky for us, there is an easier way, weld
with it and see how it performs for yourself.
A machine that excels in all three of these traits will be
easy to set up and almost immediately demonstrate a smooth arc and high-quality
finish. A couple of good examples are the Fronius TPS/i or the Fronius
TransSteel. But the real test comes when the arc is tried under less than
ideal conditions. In this case, you will
see the arc trying to maintain stability and establish a quality bead to the
limits of physics.
Now, suppose you’re using a machine with cheap electronics,
a slow processor, or poor software. In that case, you will immediately see the
difference. Too often, poor welding is
blamed on the welders performing the job when the actual culprit is the
equipment that’s being used.
Intelligent welding?
Synergic welding has opened yet another door in recent
years, the idea of Intelligent Welding.
The Fronius TPSi’s Pulse Multi Control (PMC) and Low Spatter Control (LSC) are two excellent examples of this sort of technology.
Standard pulse and CV waveforms are concerned with the
stability and quality of the arc. PMC
and LSC take this computer control to the next level and interpret the
electronic feedback to go beyond just the stability of the arc. Stabilizers are
introduced to the process. They look at
the electrical pattern of the weld and actively modify the arc to ensure
characteristics such as penetration and arc length are as consistent as
possible through the length of the entire weld.
Ease of use is another advantage that synergic welding
brings to welding. Many of us have lived
and died based on a painted mark on the dial of the welding machine. That mark represented the ‘ideal’ settings
that have worked for the job we need to get done. But when the job changes or
the material isn’t quite right, we struggle to get the arc just right.
Synergic welding has computerized these paint marks giving
you a starting point by simply selecting the material, gas, wire, and dialing
in the thickness of your plate. From
here, you have a starting point that allows you to dial in a stable arc and are
producing a good bead in seconds. When
the job changes, you dial in the new starting point and are back to work
delivering both quality and quantity.
Such simple use speaks to a confident set-up by both
experienced and inexperienced welders, because let's face it, if the technology presented to you requires an advanced degree to use, why would you
want to use it?
Synergic welding is finally becoming a standard part of the
welding language.
More and more welder
supply companies are starting to present their version of this solution.
At Fronius, we jumped into the technology well over 20 years
ago. We’ve used that time to master it
and deliver a series of products that make this not only powerful to the
industry but approachable and easy to use for anyone that chooses to pick up
the torch. All of our welding platforms,
TPSi, TransSteel, TransPocket, AccuPocket, and MagicWave, have this synergic
technology at the core. We set the
standard that others strive to achieve.
But don’t just believe it, give us a call and try for yourself.