Technology - Welding Technology

PERFECTION IN WELDING

Fronius is the global technology leader and European market leader in welding technology. Since 1950, we have been developing new welding technologies and bringing them successfully to market. Time and again we introduce innovations that revolutionise the world of welding technology. We have mastered the arc like no other and therefore give our customers the competitive edge: maximum productivity and availability of their welding systems, maximum welding speed, excellent weld-seam quality and the efficient use of all resources.

Intelligent and powerful power sources, highly dynamic wirefeeding technology and the most advanced welding torches on the market form the basis of our premium product range. By combining these products, we create tailored welding systems with a specially customised range of services. We have also got all of the welding processes covered, including MIG/MAG, TIG, arc welding, MMA welding, resistance spot welding and plasma welding, as part of the high-quality package. Sophisticated automation solutions to tackle complex welding tasks complete our portfolio.

HARALD LANGEDER, HEAD OF R&D, FRONIUS PERFECT WELDING

“We are constantly striving to be ahead of our time, to address future requirements and even predict what they might be. This is how we keep shifting the limits and investigating solutions that may sound obscure today, but could become the norm in future. This is what makes our products stand out, and these are the expectations that we place on ourselves as the technology leader.”

THE INTELLIGENT REVOLUTION IN WELDING TECHNOLOGY

The TPS/i MIG/MAG power source platform, which was first unveiled in 2013, has led the industry into a new era. The individually customisable and upgradeable appliances stand out due to their high intelligence and extensive communication capabilities. This makes them easier to operate, suitable for any application and able to deliver virtually limitless performance.

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Intelligent Revolution – TPS/i

ACCUBOOST TECHNOLOGY

AccuBoost Technology was developed by Fronius engineers to exploit the outstanding properties of the AccuPocket high-powered battery in order to achieve noticeable improvements in MMA welding. Compared to conventional inverter technology, the special electronic control system delivers tangible improvements in the ignition properties, the arc stability and the arc-force dynamic. Firstly, the electronics exploit the high currents from the battery to minimise electrode-sticking very effectively. Secondly, AccuBoost uses the electronically enhanced output voltage of the battery to prevent arc breaks.

ACTIVE WAVE

LOW-NOISE TIG WELDING WITH DIGITAL ARC CONTROL

The digital TIG systems from Fronius use a digital signal processor, and offer all the familiar benefits of other digital welding systems; namely reproducibility, precision and speed. Along with complete digitisation, we have added something extra special: peace and quiet. Noise has always been an issue for TIG AC welding. Fronius calls the underlying principle Active Wave, because the digital signal processor always calculates the current curve that offers the highest possible arc stability and lowest possible noise emissions precisely and in real time. High-frequency superimposition has also become a thing of the past with alternating current.

DIGITAL RESONANT INTELLIGENCE

A CONSISTENTLY PERFECT ARC FOR OPTIMUM WELD PROPERTIES

The tried-and-tested digital resonance system for electrode inverters has been further developed and improved for the new TransPocket 150 and TransPocket 180 generation of devices. Even more precise and faster control of the welding current and the constant power reserves enable them to react immediately to peculiarities and changes in the arc, which results in a practically ideal starting characteristic. A consistently perfect arc with minimum spattering leads to the optimum weld properties.

LSC ADVANCED

MINIMAL SPATTERING EVEN WITH LONG HOSEPACKS

The TPS 400i LSC Advanced power source platform was developed to open up the advantages of the LSC process for longer hosepacks as well. The built-in LSC module in the power source guarantees that the inductivity generated in the hosepack is dissipated. This ensures more constant droplet detachment in the dip transfer and intermediate arcs, resulting in perfect weld properties with minimal spattering, even with longer hosepacks.

THE NEW GENERATION OF WELDING TORCHES: PERFECT COOLING & SIMPLIFIED HANDLING

Higher productivity thanks to innovative features – in the new generation of Fronius welding torches, the wearing parts and torch components have been perfectly tailored to the welding power. In making these adjustments, we have also optimised the cooling, as well as handling and comfort for the user. Maximum precision and service lives are the result. To the products

A new generation of welding torches

CONTEC

CURRENT CONTACTING WITH A LONG-LASTING EFFECT

The Contec MD contacting system allows the user to prolong the service life of their welding torch several times over during automated welding compared to conventional nozzles. Two moveable split tips keep the contacting surfaces and contact forces between the contacting system and the welding wire exactly in the defined target range. This results in 100% consistent contacting, considerably longer service lives and increased process stability. Find out more

COOLING SYSTEM

UNIQUELY COOL

The new Fronius welding torches represent new milestones in cooling technology. By extending the cooling ducts in the direction of the contact tip and using screwed rather than push-on gas nozzles, it has been possible to considerably increase the cooling capacity. Narrower contact tips absorb less arc radiant heat, keeping the welding torch cooler. This optimised cooling concept allows longer welding times and dramatically increases the service life of the wearing parts. It is even possible for welders to change the gas nozzle with their bare hands only around 90 seconds after welding at 500 A!

MAGNETIC CRASHBOX

EVEN MORE COST-EFFECTIVE

The refined CrashBox for robot systems dramatically reduces the load on the torch body in the event of a collision. This minimises the force impact of the load immediately following the collision, preventing damage to the torch body and drive unit. The extremely high reset accuracy (+/- 0.05 mm) allows production to be quickly resumed, thus saving the user time and money.

PULLMIG

SMALL, LIGHT AND ROBUST

Weighing a mere 1,600 grams, the new PullMig welding torch from Fronius is incredibly light for a push-pull welding torch. Thanks to a sophisticated design concept, the torch combines precision and performance in the smallest space. The extremely robust design also brings advantages in all areas of application, which have been proven in a drop withstand test from a height of three meters – the welding torch surviving the fall completely unscathed. The revolutionary cooling technology and improved thermal dissipation enable users to weld for longer and extend the service lives of the wearing parts considerably. It is even possible for welders to change the gas nozzle with their bare hands only around 60 seconds after welding at 320 A! To the product

ROBACTA DRIVE

THE WORLD’S MOST COMPACT PUSH-PULL ROBOT WELDING TORCH

Fronius has launched the world’s most compact push-pull robot welding torch: the Robacta Drive TPS/i. Thanks to its compact design and refined engineering, the component accessibility and TCP precision of the welding torch has been improved even further. What’s more, the dynamic of the drive unit has been increased to 33 m/s² – ten-times that of its predecessor generation. A consistent, modular structure not only eases the workload for servicing engineers, but simplifies the storage of spare and replacement parts as well. With all these benefits the Robacta Drive TPS/i allows even more welding tasks to be cost-effectively performed with robots.

Virtual Welding

In the welding technology sector, after-sales and on-site services are increasingly becoming a success factor. This is why our training and development – delivered by experienced trainers – is based on practical, real-life situations as far as possible. Virtual Welding is the innovation Fronius has developed for this purpose. Using a customisable welding simulator, not only do qualified professionals have the opportunity to improve and expand their know-how under realistic conditions, but also beginners can complete virtual training modules. This allows them to learn how to weld effectively and safely while conserving resources.

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WELDING PROCESSES

UNSURPASSED QUALITY, MAXIMUM RELIABILITY, HIGHEST EFFICIENCY

At Fronius, we have been working tirelessly for decades to decode the “DNA of the arc”, so that you can achieve optimum welding results. As the global innovation leader and welding technology leader, we have mastered welding processes – from arc welding to resistance spot welding – to a tee. Find out more