Echipament sudura MIG/MAG FRONIUS Transpuls Synergic 4000

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TransSynergic 4000 / 5000 / 7200 / 9000 TransPuls Synergic 3200 / 4000 / 5000 / 7200 / 9000 MIG/MAG, TIG DC & rod electrode (MMA) welding Now some wholly new standards apply GENERAL REMARKS The digital system That’s the way it goes: Revolutions are either a failure, The digital welding systems come with the right soon forgotten, or they succeed and take their place in peripherals for every application, each optimally history. Successful revolutions turn the status quo upside harmonised with all the others. From MMA all the way down. Which is what the digital welding systems from through to fully automated welding, the entire spectrum is Fronius have done. In the entire industry, they were a covered, taking in anything from torches, hosepacks and genuine sensation. And still are. Except that today, they cooling units to welding-data documentation and even have moved on from being youthful upstarts to being communications interfaces and the facility for using high- est

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ablished players on the welding scene – indeed, the performance processes. digital welding systems have laid down wholly new standards: In terms of perfection, reproducibility of welding results, operator convenience and the variety The thoroughly digitised, microprocessor-controlled and digitally regulated power sources are available from 320 A to 900 A. With or without pulsed arc. of available peripherals. Chromium-nickel is a tricky material to work with – which is why we’ve developed the CrNi series of machines specially for it. They all come with pre-programmed characteristics for working easily yet precisely with solid and flux-cored wires and for chrome-nickel brazing. The “Human” hosepack boom prolongs the service life of the hosepack and makes for much easier handling. UTILISATION Rising to any challenge From the avant-garde to the mainstream The TS and TPS machines are out-and-out professionals. Fronius’ digital machines are among its most sought- With

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a correspondingly extensive field of application. In after products. One reason why these “trailblazers” both the craft/workshop and industrial sectors, they meet have developed so fast and so well is certainly their the most exacting demands. Thanks to their modular multiprocess capability. MIG/MAG, robot welding, TIG design concept, they are ideal for use in the automobile welding with touchdown ignition, MMA – thanks to their manufacturing and component supplier industries, in the integrated expert knowledge, they master every process fields of apparatus construction and chemical plant with 100 % perfection. engineering, in the construction of machinery and rolling stock, and in shipyards. In terms of materials, each of the machines is basically suitable for welding any metal. Nevertheless, the TS machines tend to be used more for steel, while the pulsed-arc facility on the TPS machines also makes them especially suitable for aluminium, chrome-nickel, galvanised s

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heets and for brazing. The TPS 9000 puts out up to 900 A of power and is designed with automated and robot welding applications in mind. Welding two different materials is easy - using twin wirefeeders. Perfection is the measure of all things WELDING PROPERTIES Ideally programmed ignition sequence What prompted the development of the digital machines was a desire to achieve absolute perfection in the welding process, and 100 % reproducibility of any welding result once this has been optimised. This may be seen first and foremost in the ignition. Both the TS and the TPS machines feature an ignition sequence that has been optimised and programmed right down to the very last detail, and that is available over and over again, in the same high quality. Depending on the application in question, there are Conventional power source: End of welding without burnback impulse. various different ignition variants. One of these is Digital power source: End of welding with burn-back impulse.

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conventional welding start-up. Here, the ignition parameters are precisely matched to the diameter and quality of the wire. Quiet, jerk-free ignition is the result. At the end of welding, a controlled current pulse sheds the last molten droplet, preventing a solid globule from forming at the tip of the electrode. And in conjunction with the Robacta Drive torch, SFI ignition makes spatter-free welding start-ups a reality. Spatter free ignition: Wirefeed forwards Wirefeed stop: short-circuit recognition Wirefeed backwards: pilot arc is ignited Wirefeed backwards: arc-length is set Wirefeed forwards: ignition is complete – pulsed arc starts up Metal transfer Multifunctional, in terms of both arc and process With digital machines, all sorts of things become In addition, the SyncroPuls function was developed for possible. They adapt to any and every task. Particularly the TPS machines. This function superimposes a low- in the case of the arc, very different requirements may

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be frequency pulse over the normal pulse, resulting in seam made, depending on the application. The digital inverter quality that is comparable with that of a TIG weld, and power sources permit tailor-made solutions here. When it ensuring immaculate weld-seam appearance. comes to pulsed arcs, for example, there is a special All digital power sources are multiprocess-capable, pulse-form to go with every material. The machines meaning that they are just as suitable for MIG/MAG function so precisely that only one single droplet of filler welding as they are for TIG and MMA. The machines metal is detached for each current pulse. This results in come with a particularly interesting TIG-welding function: virtually spatter-free welding, and means that for the first TIG Comfort Stop. This cures the arc of its annoying habit time, precision working is possible at the lower end of of breaking at the end of welding. A defined movement of the power range: a 0.6 mm (0.02 in.) alum

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inium sheet can the welding torch causes the welding current to drop be welded under a pulsed arc using a 1.2 mm (0.05 in.) automatically, uninterrupted gas shielding is ensured, and wire electrode with no difficulty at all. the end crater is filled to perfection. The digital arc-length control opens up wholly new perspectives as well. It works with such speed and precision that the arc length remains constant at all times; even when the stick-out changes, there is hardly any spatter. 1 2 3 4 I t Constant arc length despite varying stick-out - thanks to digital weld process control. Metal transfer with a pulsed arc: One droplet per pulse. Start-up program for aluminium There is an extra ignition variant for aluminium: In order to prevent fusion defects, the base metal has to start being melted right away, in the start-up phase. For this reason, ignition is effected at considerably higher power. After this, the welding power is lowered again. However, in order to avoid an

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y risk of drop-through, it is also possible to immediately lower the welding power down to the crater-fill current. Without start-up program fusion defects at beginning of seam With start-up program no fusion defects Base metal: AlMg 3 Sheet thickness: 0,6 mm (0.02 in.) Filler metal: AlMg 5, diam. 1,2 mm (0.05 in.) Shielding gas: Argon Easy working HANDLING ECONOMY Plug & Weld: Make your choice, and off you go A system with efficiency built in Right from the product-development phase, the overriding Investing in a digital power source is worthwhile in every principle at Fronius is to make the machines as easy as way. Thanks to their multi-process capability, you can possible to handle. The result is power sources which are weld using any welding process, be it MIG/MAG, TIG or pleasant for everyone to work with. Even the complex MMA, all with one and the same machine, and always digital machines, then, are operated using the practical with superlative quality. Also, yo

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u save gas every time “synergic-mode”: One dial is all you need, to control you weld. Firstly, because of the loss-free gas supply to everything. Select the material and the sheet thickness – the torch, and secondly, due to the intelligent gas-flow that’s all. Then off you go! The digital power sources now control. On top of this, there are the savings from the automatically access their integrated expert knowledge great reductions in welding spatter, the automatic and control the entire welding process. For instance, cooling-unit cut-out, low open-circuit power, high when you specify the sheet thickness, the correct efficiency, modular (and thus highly flexible) system matching parameters are all called up immediately. principle, ease of access for servicing, updates via laptop …. As we said, a system with efficiency built into it. The control panel makes it easy for everyone The control panel is clearly and systematically laid out, so that everybody will “s

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ee what’s what” straight away. This makes for straightforward, convenient working, because everything is so easy to adjust, as well as being practically self-explanatory. By the way, you’ll find an extremely practical function called Job Mode on the control panel. This series function lets you save optimised machine settings so that you can then re-use them whenever you need them. Even directly from the torch. For improved visibility, the control panel is positioned at a slant, and in such a way as to protect it from mechanical impact. Setting dial Display zone Memory button Material selection Operating mode Weld process JobMaster welding torch with integral remote control and weld-data display. The success package SYSTEM Perfect interplay Smooth wirefeed If you want to exploit all these possibilities, outstanding With the wirefeed, the most important thing is that the welding properties and useful functions to the very full, wire is fed reliably, precisely and as s

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moothly as possible. then you must start thinking in terms of systems. In All the way from the wire drive to the contact tip. Firstly, conjunction with all the peripherals, the digital power so that the wire does not get damaged, and secondly, so sources are perfectly co-ordinated, highly innovative that the welding operation runs perfectly. Fronius offer and intelligent welding systems. Depending on your various different wirefeeder units, each of them just right requirements, we can put together a custom welding for the application in question. For example for shipyards, system for you that is precisely tailored to your individual for robot welding, for aluminium applications etc. All of needs. them with high-grade wire drives: 2-roller or 4-roller drive, or the planetary “PT-Drive”. The latter was developed specially for soft aluminium wires; its larger contact area transports the wire even more exactly. As the motor speed on every wirefeeder is digitally controlle

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d, the wirefeed speed, too, can be set accurately and reproducibly. 4-roller drive for precision, abrasion-free wirefeed. “PT-Drive” push-pull welding torch. The drive force is applied across a large area, ensuring superb wirefeed - even with very soft aluminium wires. Robot welding torches for reliable current transfer In the front line with Robacta Drive The Robacta robot welding torch comes with a brilliantly Robacta Drive is a torch with an integral wire drive for ingenious feature: Forced contacting. This ensures a robot welding. It is mounted directly on the front axis of defined, reliable current transfer, as the welding wire is the welding robot. In this way, the master drive is where guided through the contact tip at an exactly defined the action is, ensuring absolutely uniform wire travel and angle. Random, punctual current transfers are now a thing thus the very highest precision in the welding process. of the past. The result: consistently high welding q

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uality. Even with long hosepacks. And another very special innovation is the external wire guidance system. The inner liner can be changed very quickly, with no tools needed, and this keeps downtimes to a minimum. Forced contacting for exactly defined current transfer. The welding process achieves greater precision, and there is less wear-and-tear. Robacta Drive with external wire guidance system: Inner liner can be changed very quickly, downtime is minimised. Everything is thinkable, everything is doable Maximised intelligence: RCU 5000i Weld-data management: Welcome to WeldOffice The RCU 5000i is an extremely easy-to-use, comfort- With Fronius WeldOffice, you can aggregate the data feature-laden remote-control unit with a full-text display. from all your power sources at one central point. And by A real innovation. You can place it right next to the “data”, we don’t just mean the welding data, but also all weldment, so that you can create and manage all jobs the

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telemetry data – i.e. all the data relating to the status and characteristics “on the spot”, as well as monitoring of the machines. These data can then be visualised and all the welding data. It really couldn’t be easier. The RCU archived on a computer. All the power sources can be 5000i gives you concrete assistance every step of the given their own TCP/IP addresses and networked, way – as you need it. The other thing is that the guidance creating the best possible basis for efficient weld-data menu is structured in the same way as PC software, with management. a main menu, sub-menus etc. All very clearly laid out and user-friendly. The user-guidance menu is orientated to the needs of different user groups. Each user is given his own noncontacting transponder key with which he can activate the functions that have been enabled for him. Also included: the SmartMedia card, a storage medium to which all the data can be saved for back-up, and from which it can be uploa

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ded to the next power source or computer. The RCU 5000i also comes with an integrated quality assurance system and a Windows-compatible USB interface for updates. RCU 5000i WeldOffice lets you collect, visualise, evaluate and archive the welding data from all your power sources at one central point. Everything at a glance: Fronius Xplorer The user-friendly Fronius Xplorer software is the easy way to visualize and administer networked welding systems used in automated manufacturing. The special thing about this virtual control station is its graphical user interface and self-explanatory symbols. As well as this, the location and status of each system can be seen at a glance. For quicker handling, the software System example: Robot welding Important: - perfect co-ordination of all system components, from the power source to the wirefeed and the welding torches, and including weld-data monitoring and documentation - remote control with user privileges - flexible interfacing with the

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robot interface can also be operated via a touchscreen. 3 RCU 5000i 5 2 1 ROB 5000 4 I/O 6 Robot Control 7 Elements for Plug & Weld: 1. TPS 4000 power source 2. RCU 5000i remote-control unit 3. VR 1500 wirefeeder 4. Rob 5000 robot interface 5. Robacta welding torch 6. Robot control 7. Wire supply This is just one example, for robot welding. In the same way, many different variants could also be drawn up for various materials and applications. As well, of course, as countless configurations for all other requirements. Controlling and monitoring your welding systems, quality management on the basis of the target and actual processdata, analyzing results and errors, all the way up to complete documentation of the required target and actual data – with the Fronius Xplorer, all this can be just an everyday routine The whole is more than the sum of the parts. VR 1500 VR 2000 PRODUCTS Welding power sources Wirefeed systems - TS 4000 / 5000, TPS 3200 / 4000 / 5000 - VR 150