Circumferential welding systems

We have the right welding system for every application. Our solutions are the ultimate in precision and efficiency, meeting the full scope of requirements for quality and reliability in tank, vessel, and pipeline construction in particular.

We also offer custom solutions that stand up to any challenge. Working with our mechanized circumferential welding systems, you can weld components of very different sizes and weight classes—thanks to systems ranging from compact welding cells for smaller components through to robust systems for heavy workpieces.

Cutting-edge technology and premium materials deliver top results, making our welding systems incredibly versatile, simple to use, and easy to maintain. Even welds, high process stability, and less rework are just a few of the advantages—and you can benefit too.

Applications

Cylindrical vessels and components are used in many different industries, e.g., for storing liquids or processing bulk materials.

The modular design of our circumferential welding systems makes them an ideal solution for components with a diameter of 50 mm to 6 m and length of up to 25 m.

Base materials:

Steel, stainless steel, aluminum, duplex, nickel-based alloys

Industries:

- Pipeline and vessel construction

- Mechanical and equipment engineering

- Food, chemical, and pharmaceutical industries, etc.

Select the right system for your application

Specification of maximum component sizes.

FCW Smart

L = 1,200 mm/860 mm (with tailstock) Ø = 450 mm payload = 300 kg

FCW Compact

L = 6,000 mm (with tailstock) Ø = 800 mm payload = 300 kg

FMW

L = 12,000 mm Ø = ~ 1,300 mm payload = 2,000 kg

FCW Heavy

L = ~ 24,000 mm Ø = ~ 4,000 mm payload = ~ 15,000 kg

FCW Smart—a cobot isn’t always a must

The perfect way to get started with mechanized welding of pipe-pipe and pipe-flange connections, as well as valve and bearing seats. Easy to operate and program, the FCW welding cell is also an intelligent response to the acute shortage of skilled welding specialists and stands out thanks to its versatility when using various welding processes.

The advantages for you:

/ Low investment costs

/ Simple, user-friendly operation and programming

/ Motorized welding torch axes (AVC/OSC)

/ CE-compliant safety housing with automatic glare protection

/ Multiprocess

FCW Smart Lean variant

The advantages for you:

/ Cost-optimized solution

/ Little space needed

/ Simple, user-friendly operation and programming

/ Motorized welding torch axes (AVC/OSC)

/ Multiprocess

System overview

Rotary unit

- Motorized rotary unit
- Can be pivoted via hand crank
- Face plate 450 mm
- Hollow shaft 120 mm
- Forming gas unit (option)

Tailstock (option) - Mounted on the linear unit
- Electro-pneumatic infeed
- Distance between centers 860 mm

Protective cabin

- CE-tested
- Glare shield raises/lowers automatically
- Manual sliding doors on both sides
- Can be fitted with fume extraction system

Motorized linear axes - Horizontal axis for oscillating function
- Vertical axis for automatic distance control (AVC)

Controls - 5" touchscreen for operation and programming

Welding table - 1,500 x 1,000 mm
- D28 bores with 100 x 100 mm grid

Rotary unit

- Motorized rotary unit
- Can be pivoted via hand crank
- Face plate 450 mm
- Hollow shaft 120 mm
- Forming gas unit (option)

Tailstock (option)

- Mounted on the linear unit
- Electro-pneumatic infeed
- Distance between centers 860 mm

Protective cabin

- CE-tested
- Glare shield raises/lowers automatically
- Manual sliding doors on both sides
- Can be fitted with fume extraction system

Motorized linear axes

- Horizontal axis for oscillating function
- Vertical axis for automatic distance control (AVC)

Controls

- 5" touchscreen for operation and programming

Welding table

- 1,500 x 1,000 mm
- D28 bores with 100 x 100 mm grid

Controls - 5" touchscreen for operation and programming

Rotary unit - Motorized rotary unit
- Can be pivoted 90° (hand crank)
- Face plate 450 mm
- Hollow shaft 120 mm
- Forming gas unit (option)

Motorized linear axes - Welding torch positioning
- Horizontal axis for oscillating function
- Vertical axis for automatic distance control (AVC)

Welding equipment

- TIG: iWave 400i
MIG/MAG: TPS 320i
CMT: TPS 400i
- Choice of different welding packages

Tailstock (option) - Mounted on the linear unit
- Electro-pneumatic infeed
- Distance between centers 860 mm

Controls

- 5" touchscreen for operation and programming

Rotary unit

- Motorized rotary unit
- Can be pivoted 90° (hand crank)
- Face plate 450 mm
- Hollow shaft 120 mm
- Forming gas unit (option)

Motorized linear axes

- Welding torch positioning
- Horizontal axis for oscillating function
- Vertical axis for automatic distance control (AVC)

Welding equipment

- TIG: iWave 400i
MIG/MAG: TPS 320i
CMT: TPS 400i
- Choice of different welding packages

Tailstock (option)

- Mounted on the linear unit
- Electro-pneumatic infeed
- Distance between centers 860 mm

FCW Compact

Efficient welding for a wide range of applications

Versatile functions paired with a compact design: our FCW Compact circumferential welding system is the perfect solution for vessel and pipeline construction. The system takes up very little space, making it a precise and efficient choice for welding different components such as pipes, flanges, and vessels.

The advantages for you

/ Versatility: The FCW Compact is designed as a modular welding system that can take on a wide range of jobs. From MIG/MAG, CMT, and TIG through to ArcTig and plasma, this system supports many different welding processes.

/ Compact design: Despite offering a wealth of functions, the FCW Compact takes up very little space. It can be configured for component lengths up to 6 m and component diameters up to 800 mm.

/ Second welding head unit as an optional extra: The FCW Compact system can be equipped with a second, independently controlled welding head unit to make work even more flexible.

/ Tailstock with electropneumatic clamping system: The tailstock fixes components securely in place during the welding process.

Modular concept

HMI system controls

HMI T5

- 3 axes can be controlled
- 2 welding machines

HMI T10
- 11 axes can be controlled
- 4 welding machines
- Remote control

Welding equipment

MIG/MAG (CMT): TPSi

TIG DC: TransTig

TIG AC: MagicWave

Plasma: TransTig/PM10

ArcTig: TransTig 5000/9000

Rotary units Different rotary units (fixed, manual, or motorized tiltable) are available for components up to 300 kg and a diameter of up to 800 mm.

Rotary units Manual or motorized stand available for adjusting the horizontal and vertical axes.

Component support Choose between a tailstock and various support units.

Welding torches

MIG/MAG/CMT: PushPull welding torch

TIG/plasma: ArcTig welding torch

TIG/plasma: Wirefeeders

HMI system controls

HMI T5

- 3 axes can be controlled
- 2 welding machines

HMI T10
- 11 axes can be controlled
- 4 welding machines
- Remote control

Welding equipment

MIG/MAG (CMT): TPSi

TIG DC: TransTig

TIG AC: MagicWave

Plasma: TransTig/PM10

ArcTig: TransTig 5000/9000

Rotary units

Different rotary units (fixed, manual, or motorized tiltable) are available for components up to 300 kg and a diameter of up to 800 mm.

Rotary units

Manual or motorized stand available for adjusting the horizontal and vertical axes.

Component support

Choose between a tailstock and various support units.

Welding torches

MIG/MAG/CMT: PushPull welding torch

TIG/plasma: ArcTig welding torch

TIG/plasma: Wirefeeders

FMW – Multi welding system

Our Multi welding system makes it possible to combine universal welding applications in a single system. Different welding processes are also available on an individual basis and new processes can be added as required. Our Multi welding system is the number one choice in sectors where different types of components (pipes, flanges, reducers, fittings, valves, etc.) and different metal alloys play a significant role, such as the food, plant construction, and energy technology industries.

In addition to the intuitive HMI, the Multi welding system lets you switch between welding processes in next to no time. Equipped with quick-release fasteners, welding torches can also be changed in seconds. Developing customer-specific sequence controls and programming the welding process has never been so easy, both saving time and opening up completely new possibilities.

The advantages for you

/ Modular design: Fronius put a great deal of thought into the concept behind the Multi, with its highly modular design allowing the welding system to be adapted perfectly to suit customers’ needs. Components with a diameter of up to 1,200 mm and length of up to 12 m can be welded without any difficulty.

/ Freely configurable: Choose between six different sizes to suit the dimensions of the components. A selection of rotating units and manipulators makes every system an individual customer solution.

/ Wide range of welding processes: Depending on the application, you can also choose from a range of suitable welding processes (TIG cold wire, TIG hot wire, ArcTig, plasma, MIG/MAG, CMT, etc.).

System overview

HMI T10 System controls with lots of intelligent features for simple operation and programming

Rotary units Various types of positioners are available depending on the application. Speeds of rotation from 0.06 to 6.0 rpm are possible.

Welding head unit All horizontal and vertical welding head axes can be moved by motor for precision positioning of the welding torch—even after the end of welding.

Carriage platform All welding components are on the same platform, guaranteeing maximum process reliability with the shortest possible cable lengths.

Track Any track length can be selected for component dimensions from 2 m to 12 m.

HMI T10

System controls with lots of intelligent features for simple operation and programming

Rotary units

Various types of positioners are available depending on the application. Speeds of rotation from 0.06 to 6.0 rpm are possible.

Welding head unit

All horizontal and vertical welding head axes can be moved by motor for precision positioning of the welding torch—even after the end of welding.

Carriage platform

All welding components are on the same platform, guaranteeing maximum process reliability with the shortest possible cable lengths.

Track

Any track length can be selected for component dimensions from 2 m to 12 m.

FCW Heavy

FCW Heavy is the perfect solution for components with a diameter of up to six meters. Whether you’re working with pressure vessels in the aerospace industry or food storage tanks, every application has its own specific requirements. From component manipulation to the optimum welding process, a well-designed modular system sets the stage for perfect solutions that are nonetheless fully standardized.

Modular system concept

Machine carrier - Various dimensions
- Stationary or with a motorized carriage

Camera system / seam tracking - ArcView camera system
- Tactile or laser sensor system

Positioner - Horizontal or turn/tilt positioner

Roller blocks - Permanently mounted
- Motor movable on rails

Welding equipment

- MIG/MAG/CMT
- TIG/ArcTig
- Plasma

Controls - HMI T10 system controls with remote control

FCW Heavy controls

Machine carrier

- Various dimensions
- Stationary or with a motorized carriage

Camera system / seam tracking

- ArcView camera system
- Tactile or laser sensor system

Positioner

- Horizontal or turn/tilt positioner

Roller blocks

- Permanently mounted
- Motor movable on rails

Welding equipment

- MIG/MAG/CMT
- TIG/ArcTig
- Plasma

Controls

- HMI T10 system controls with remote control

FCW Heavy controls

Precisely tailored to your application:

A wide range of standardized components enables versatile solutions. Read on for a few practical examples:

FCW Heavy Stationary

Application

Welding components in the PC position (e.g., CrNi vessels in the food industry)

Configuration

/ Permanently mounted machine carrier

/ Horizontal rotary table

/ Motorized carriage for welding torch positioning

FCW Heavy Motion

Application

Welding vessels and fixtures in the PA/PB position

Configuration

/ Column and boom with motorized base on rails

/ Movable roller blocks on rails

/ Welding head with motorized horizontal/vertical carriage

/ Tactile seam tracking system

FCW Heavy Extended

Application

Dual-station operation for final assembly of vessels and fixtures (pipe-flange connections)

Configuration

/ Column and boom with motorized base on rails

/ Movable roller blocks on rails

/ Turn/tilt positioner

/ Welding head with motorized horizontal/vertical carriage and torch change system

Send your request directly to Fronius

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Perfect Welding

Circumferential welding systems

Applications

Select the right system for your application

FCW Smart

FCW Compact

FMW

FCW Heavy

FCW Smart—a cobot isn’t always a must

The advantages for you:

FCW Smart Lean variant

FCW Compact

Efficient welding for a wide range of applications

The advantages for you

FMW – Multi welding system

The advantages for you

FCW Heavy

Precisely tailored to your application:

FCW Heavy Stationary

FCW Heavy Motion

FCW Heavy Extended

Send your request directly to Fronius

Let´s get connected.

Thank you for your message. We will process your request as soon as possible.