The WireSense system turns the wire electrode into a sensor that checks the component position before each weld says Fronius
The company claims that manufacturing inaccuracies can be compensated for and by reliably detecting actual sheet edge heights and positions, welding efficiencies improved. The welding torch scans the component with a reversing wire movement and the welding system sends the height information and the edge position to the robot, which adjusts the weld seam process based on an application-specific program. Fronius says that by evaluating the height information, the robot can determine both the course of the edge and the actual edge height.
During commissioning, welding parameters for different air gap sizes can be defined and saved. This enables the robot to determine the actual component conditions in order to call up the suitable welding parameters, claims the company. WireSense can be used with any TPS/i welding system from Fronius that is configured for the use of the CMT welding process and can be retrofitted to existing welding systems.