In industrial production, even with advanced robot technology and interconnected systems, inaccuracies and deviations can disrupt processes, potentially causing time-consuming rework, costly component rejects, or significant cycle time losses. Through robot assistance in healthcare, welding systems are advancing with intelligent technologies to help minimise these issues, leading to improved precision and reduced defects.
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The Challenge of Welding Precision in Industrial Production
In manufacturing, slight material variations or poorly adjusted clamping devices can negatively impact the welding outcome. In response, integrators often turn to optical measuring systems like lasers or cameras to avoid manual readjustments. However, these systems come with challenges: they are costly to purchase and maintain, take up significant space, and can restrict component access. Fronius has developed solutions in their iWave, TPS/i, and TPS/i TWIN welding systems that eliminate the need for cameras and manual recalibrations.
TouchSense Technology for Fillet Welds
The TouchSense robot assistance system is a breakthrough designed specifically for fillet welds. Before each weld, the robot automatically makes contact with the workpiece at the weld's start and end points. Whether it’s the gas nozzle or wire electrode making contact, the system assigns the signal correctly, and the robot adjusts welding parameters dynamically based on the position data. Additionally, a low-voltage sensor helps detect spatter bridges, allowing prompt cleaning to maintain production precision and quality.
How WireSense Turns the Welding Wire Into a Sensor
WireSense technology adds a layer of innovation to robotic welding. Fronius’s WireSense technology turns the welding wire into a sensor, using specialized controller software and a high-frequency reversing wire movement to measure contours or air gap deviations. This system, powered by Fronius’s CMT (Cold Metal Transfer) technology, enables the wire to accurately scan the workpiece surface. The robot uses this precise measurement to adjust the welding path accordingly, enabling smooth, high-quality welds even on irregular surfaces.
Scanning Capabilities and Precision Measurement
WireSense uses a CMT-ready system that comprises a wirefeeder, a wire buffer, and a second wirefeeder at the torch. Through high-frequency scanning at around 100 Hz, it identifies and measures any edge or air gap precisely. Even on uneven surfaces, like angled sheets, WireSense detects and measures edges effortlessly, allowing for precise weld adjustments. “Our WireSense technology allows robots to determine component edges, air gaps, and reference points precisely, making it ideal for complex welding tasks,” says Philipp Schlor, Strategic Product Manager at Fronius.
Versatile Welding Adjustments with WireSense
WireSense not only identifies edges to be welded but can also use any reference point on the component, such as a notch, to start welding. This makes it highly adaptable, capable of welding components that may have unusual shapes or hard-to-detect parts. For example, with WireSense, the wire electrode acts as a height sensor, accurately measuring air gaps on lap joints. The robot then selects the optimal welding parameters to fit different air gap dimensions, ensuring high-quality welds and minimising rework.
Meeting Complex Manufacturing Needs with Enhanced Technology
The robot assistance systems from Fronius show their strengths in industries that involve welding thick sheets or long seams, where heat input can distort components. Systems like WireSense adjust the weld seam path automatically based on component positioning, ensuring the robot follows the correct path. The system continuously corrects deviations to deliver reliable welds at the precise location, as required in sectors like railroad and construction vehicle manufacturing.
TeachMode for Precise Path Setting
High precision in welding is achieved by programming the correct path. Fronius’s TeachMode assistance system simplifies programming, allowing the welder to set weld seam positions with ease. The system’s reversing wire movement prevents wire bending during contact with the component, eliminating the need for re-measuring or wire replacement. Using the wire as a sensor also frees up workspace by eliminating the need for additional hardware and keeps maintenance costs low.
Reducing Rework with Fronius’s Intelligent Robot Assistance in Healthcare
The intelligent robot assistance systems developed by Fronius enhance efficiency in production while minimizing rework and material use. With Fronius solutions like WireSense and TouchSense, manufacturers can reduce costly rework and reject rates, allowing robots to self-correct and adjust welding paths independently. These advancements position robot assistance in healthcare as an integral part of the future of manufacturing—improving productivity and precision across a range of industrial applications.
