Fronius

Smart Welding Solutions for the Automotive Industry

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Fronius Perfect Welding is a manufacturer and single source supplier of standardised and customised welding systems. The global technology leader based in Austria is a trusted partner of well-known companies from all industry sectors – from machine building and robotics to offshore technology – and especially automotive. Together with their customers, Fronius engineers powerful and efficient solutions that specifically meet the user’s requirements. Products range from hand-held welding torches to fully automated robot welding systems.

Fronius Perfect Welding is a manufacturer and single source supplier of standardised and customised welding systems. The global technology leader based in Austria is a trusted partner of well-known companies from all industry sectors – from machine building and robotics to offshore technology – and especially automotive. Together with their customers, Fronius engineers powerful and efficient solutions that specifically meet the user’s requirements. Products range from hand-held welding torches to fully automated robot welding systems.

Fronius plays a leading role in the welding of aluminium joints.

 

With DeltaSpot, the company has developed an innovative resistance spot welding process for aluminium, steel and other materials. The key feature is the tape that runs between the electrodes and the sheets being joined. This continuous movement leads to an uninterrupted welding process producing consistently high quality. The process tape transfers the welding current while protecting the contact surfaces of the electrodes from contamination. This results in a significantly increased service life.

What’s more, every welding spot is 100% reproducible. The indirect sheet contact produces a largely spatter-free welding result.

The new DeltaCon spot welding guns from Fronius enable users in sectors such as the automotive and component supply industry to perform spot welding processes easily, cost-effectively and flexibly. The advantages include minimal downtimes, optimal accessibility to components and high productivity when joining aluminium. Users can connect the DeltaCon guns to all different types of robots. As a full system supplier, Fronius offers entire solutions for resistance spot welding from a single source. Not only can customers choose their preferred parts and components, they also have a choice of a wide range of services, giving them the best possible welding processes whatever their requirements.

Reduced heat input for optimum welding results

 

The thermal joining of different materials such as steel and aluminium is of crucial importance in automotive lightweight construction. However, this process is particularly challenging due to the different physical and chemical properties of the materials. It is difficult to achieve highquality, stable results and the options for further working of the semi-finished parts are significantly restricted. The solution to these challenges is a welding process with reduced heat input – the Cold Metal Transfer (CMT) process developed by Fronius. The low level of spattering coupled with the constant and extremely stable arc deliver optimum welding results. The steel base material is only wetted by these braze-welded joints and does not melt. This means it perfectly meets the requirements for use in the automotive industry.

Steel welding with a push system

 

Not every welding application is high-tech and high-end. In many cases, steel is the perfect material – straightforward, robust and cost-effective. The same characteristics apply when welding this material with the push system. This configuration option for the TPS/i helps ensure high levels of system availability and optimises system costs in procurement and operation. The system has a motor in the wirefeeder. The welding torch does not require a motor of its own, keeping it lightweight. Therefore less powerful robots are required, reducing the overall system costs even further. The push system ensures consistently high quality of welding results. The Low Spatter Control and Pulse Multi Control welding packages include assistance systems to help welders achieve high-quality seams even when conditions are tough.

High-speed welding in superlative quality

For particularly high welding speeds, Fronius has developed the LaserHybrid welding process. It combines the advantages of industrial-scale MIG and laser-beam welding with excellent gap-bridging ability and easy weld-seam preparation of MIG welding, as well as the low heat input, deep penetration and speed of laser welding. This enables the automated joining of various aluminium and steel components at a speed of up to 8 metres per minute, in superlative quality. Fronius solutions are for example used in the production of battery trays for electrically powered vehicles.

Data management with WeldCube

 

WeldCube documents the actual values of every weld seam. The browser-based software allows users to exploit information like current, voltage and welding speed to improve welding processes and optimize consumption. A customizable dashboard provides a simple overview. The results are not only available on the computer, but also on mobile devices. Around 50 power sources can be networked with WeldCube.

This helps to document data across sites and devices at component level, promoting transparency and traceability of each component produced.

 

 

Fronius International GmbH

Froniusplatz 1

A-4600 Wels

Tel: +43 (7242) 241 3000

contact@fronius.com

www.fronius.com