/ Battery Charging Systems / Welding Technology / Solar Electronics

ROBOT WELDING.
/ Long-life system solutions for all welding requirements.
2 / About us

/ Ever since 1950, we’ve been developing innovative comprehensive solutions for arc
welding and resistance spot-welding. Like our Cold Metal Transfer technology CMT. This
revolutionary welding process has swept away one old prejudice: that you can’t weld
aluminium and steel to one another. Day-in, day-out, we’re working on our vision: to
‘decode the DNA of the arc’. No wonder that we’re the welding-sector’s technological
leader worldwide, as well as being the European market leader.

LONG-LIFE SOLUTIONS FROM THE WORLD MARKET
LEADER AND INNOVATION PACESETTER.
/ Fronius is the strong partner that provides every robot brand,
every system and every application with outstanding tech-
nologies and excellent service. We have a decades-long track
record as a system supplier to all relevant sectors. In this, we
insist on always delivering the same high quality, everywhere,
every time. As a single-source supplier, we achieve this not
least through our worldwide subsidiaries, our huge store of
experience and our excellent service – no matter where.
SYSTEM SUPPLIER WITH OVER 30 YEARS’ EXPERIENCE.
/ At Fronius, tradition and experience are close companions.
For more than 30 years now, we have been delivering super-
lative product quality in the field of robot welding. The close
working relationships that we have with our customers and
with all robot manufacturers mean that we are completely
familiar with their industry and their requirements.

/ MIG/MAG TransSteel

/ MIG/MAG CMT
 About us / 3

WORLD MARKET LEADER AND INNOVATION
PACESETTER.
/ Our innovations have made a home for themselves just
about everywhere. All round the world, Fronius is involved
in the main technological innovations – in the automobile
industry, for instance.
PERFECT SYSTEM SOLUTIONS FOR EVERY
REQUIREMENT.
/ We are the full-line system manufacturer and single-source
supplier of robot welding systems. Our technologies are suit-
able for all types of robot and all robot manufacturers. This
means that no matter whether it’s standardised or customised,
Fronius has the right solution for every application.

/ Plasma welding
with MagicWave

/ TIG cold-wire welding

with MagicWave
4 / Single-source supplier

LONG-LIFE SOLUTIONS WITH SUPERIOR WELDING

PROPERTIES – FOR ALL APPLICATIONS.
/ As a global market leader in the robot-welding field, we have all the latest technologies
for arc welding and resistance spot-welding. Our customers can be sure that all the
components of the innovative Fronius welding systems will work together in perfect
harmony for years and years to come. As a single-source supplier, we deliver ultra-high
product quality, absolute efficiency, and unrivalled service.

COMPARISON OF ARC TECHNOLOGIES

Uw [V]
RC
N GA
ATI
R OT
E
TIM
Y ARC
ARC SPRA
S ED
PUL
ARC
PCS

ARC RC
AR SE A
BUL ARC PUL
GLO SFER C MT
A N .. . .
-TR .....
DIP ..... RC
..... EA
. . ..... C ULS
. . . ... . .
A R C E DP
T
.....
.. . CM ADVAN ARC
..... T
CM VANC
ED
.....
. . . . ..... TA
D
... CM

Iw [A]

EVALUATION CRITERIA FOR MAKING THE RIGHT SELECTION

/ Fronius offers the right weld processes and arcs for every application. For most materials, welding speed and gap-bridging
ability can be used as the evaluation parameters.

Low power range High power range

up to 250 A from 250 A

PLASMA DTA CMT CMT TIG LASER PLASMA TWIN CMT T.I.M.E. SPRAY PULSED CMT TIG
ADVANCED HYBRID TWIN ARC PULSE

Welding speed
Gap-bridging ability
 Metal thicknesses / 5

STEEL METAL THICKNESSES

0.5 – 2.0 MM 2.0 – 5.0 MM > 5.0 MM

DTA Spray arc
STANDARD
T.I.M.E.
CMT CMT Pulse
CMT
CMT Advanced
Pulsed T.I.M.E.
PULSED
PCS arc
Time Twin
TWIN
CMT Twin

PLASMA Plasma

LASER HYBRID Laser Hybrid

ALUMINIUM METAL THICKNESSES

0.5 – 2.0 MM 2.0 – 5.0 MM > 5.0 MM

STANDARD Spray arc

CMT CMT Pulse

CMT
CMT Advanced

PULSED Pulsed

TWIN Time Twin

TIG TIG

LASER HYBRID Laser Hybrid

CRNI METAL THICKNESSES

0.5 – 2.0 MM 2.0 – 5.0 MM > 5.0 MM

STANDARD DTA Spray arc

CMT CMT Pulse

CMT
CMT Advanced
Pulsed
PULSED
PCS arc

TWIN CMT Twin

TIG TIG

Microplasma Plasma keyhole

PLASMA
Soft-plasma

LASER HYBRID Laser Hybrid

/ Abbreviations: DTA: dip-transfer arc; CMT: Cold Metal Transfer

6 / Robot welding – the highlights

WE OFFER THE ULTIMATE IN

ROBOT-WELDING SYSTEMS AND
SERVICE, WORLDWIDE.
/ If you’re serious about exploiting the scope of excellent welding properties and func-
tions to the full, you have to think in terms of systems. Which is what we do, everywhere.
Just like we think about our customers, with capable teams of applications and service
technicians delivering fast, expert ‘on-the-spot’ advice and support.

SUPERLATIVE
PRODUCT QUALITY
/ Fronius is a byword for high-quality system components for robot
welding. And thus for dependable, long-life welding systems.

MAXIMUM SYSTEM AVAILABILITY

/ Because they are designed for interoperability, the system components keep
operational downtimes exceptionally low: for example, Contec ensures
constant welding properties, while Robacta TX allows the the torch body to
be changed without human intervention, independently of work-shifts.

FULL-LINE SYSTEM SUPPLIER

/ We supply modular system components to ensure the very greatest flexibility with all
applications and welding processes. Perfect interplay between all the components of the
welding system is a matter of fact here.
 Robot welding – the highlights / 7

PERFECT WELDING
PROPERTIES
/ Our mastery of the arc is unrivalled. The precision of our control systems means
that we achieve for example the best gap-bridging ability, the highest welding speeds,
and spatter-free applications.

WORLDWIDE DIRECT
SALES ORGANISATION
/ Fronius has a closely meshed distribution network of sub-
sidiaries and partner firms, spread across all five continents.

OVER 30 YEARS’
EXPERIENCE
/ Our long-standing working relationships with robot manufacturers and integrators mean that
we have had a hand in all the trend-setting innovations and technical milestones.

SERVICE THAT’S
CLOSE AT HAND
/ Our customers enjoy swift and capable ‘on-the-spot’ service which is
of the same high quality throughout the world.
8 / The application modules

APPLICATIONS AND WELDING RESULTS

AT A GLANCE.

TRANSPULS SYNERGIC
/ Digitally controlled welding system,
100 % reproducible welding results

/ Spatter-free ignition (SFI)

/ Multiprocess-capable
/ SyncroPuls: Saves
/ Start-up program for aluminium time, perfect seam
/ SyncroPuls appearance

/ Steel Root / Steel Root

TRANSSTEEL
/ Perfect steel welding
/ Extremely stable arc
/ Easy system handling

5 mm/0.20 in 6 mm/0.24 in

/ Root fusion / Excellent gap-

guaranteed bridging ability

CMT (COLD METAL TRANSFER)

/ Spatter-free MIG/MAG welding
/ Minimised thermal input
/ Outstanding process characteristics

/ Steel/aluminium hybrid join

/ Crash-test safe

MAGICWAVE/TRANSTIG
/ All-digitally controlled TIG welding systems with
integral cold-wire-feeder unit

/ Superior weld-seam quality

/ Completely harmonised, interoperable welding system
/ Excellent seam / Perfect root fusion
/ Perfect root fusion with TIG pulse welding appearance

/ TIG AC – 1: 125 A, U: 17.2 V, Vwire: 1.2 m/min,

Vweld: 40 cm/min. Material: aluminium 1 mm
THE ROBOT WELDING SYSTEM –
THE HIGHLIGHTS.
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WIREFEEDER
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INTERFACE
/ Our robot interfaces function
with all common field-bus and
analogue signals.
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FSC – FRONIUS SYSTEM CONNECTOR

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EASE OF HANDLING
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MAGNETIC CRASHBOX
/ Compact design = smaller obstacle
contours in the 6th robot axis
/ Minimised obstacle contours
/ Trigger forces can be adjusted by
modular magnetic rings
 The application modules / 11

APPLICATIONS AND WELDING RESULTS

AT A GLANCE.

MICROPLASMA, SOFT-PLASMA, PLASMA KEYHOLE

/ Plasma welding systems can be retrofitted to existing TIG installations

/ Complete freedom from porosity

/ Flawless seam appearance
/ Spatter-free applications
/ Excellent appearance / Pore-free welding seams
/ Plasma – 1: 210 A, U: 21.5 V, Vweld: 50 cm/min
Material: CrNi 3 mm

/ Aluminium 60 mm / Steel 10 mm / Steel 3.5 mm / Steel 70 mm

TIME TWIN
/ Ultra-high deposition rates of up
60 mm/2.36 in

10 mm/0.39 in

70 mm/2.76 in
to 30 kg/h achieved by using two
synchronised pulsed arcs that weld
alternately.

/ 6 passes / Simultaneously with Time / High welding speeds / Custom application

/ Position PF, Twin (PA) and CMT (PE) – Vweld 150 cm/min
narrow-gap / Without seam
preparation
/ Minimal distortion

/ Steel 12 mm / Steel 4 – 8 mm
LASERHYBRID
/ The laser beam and the arc act jointly in one welding zone,
12 mm/0.47 in

influencing and supporting one another 6 mm/

0.24 in

/ Shorter fabrication times

/ Welding speeds of up to 9 m/min
/ Deeper penetration and narrow seams, yet less thermal input
/ Through-welded on
one side, without seam
preparation
/ Fillet weld, through-
welded on one side,
w/o seam preparation

/ Contact tip at / After wear / Contec at beginning / After wear

CONTEC MD beginning
/ Novel contacting technology

7.9 mm/ 6.5 mm/ 7.9 mm/ 7.9 mm/

0.31 in 0.26 in 0.31 in 0.31 in

5 mm/ 5 mm/ 5 mm/ 5 mm/

0.20 in 0.20 in 0.20 in 0.20 in

/ Penetration on the workpiece decreases as the / The flexible half-shells keep the contact tip
contact tip becomes increasingly worn. unvaryingly constant. The penetration remains
constant and unchanged.
 WE HAVE THREE DIVISIONS AND ONE PASSION:
SHIFTING THE LIMITS.
/ What Günter Fronius started in 1945 in Pettenbach, Austria, has now become a
modern day success story. Today, the company has more than 3,000 employees
worldwide and owns 737 active patents. Since the very beginning, our goal has not

All information is without guarantee in spite of careful editing - liability excluded. Copyright © 2011 Fronius™. All rights reserved.
changed: to be the technology and quality leader. We shift the limits of what‘s possible.
While others progress step by step, we innovate in leaps and bounds.

BATTERY CHARGING SYSTEMS
/ We started a technological revolution
with Active Inverter Technology and
are now one of the leading suppliers in
Europe. We are driven by the aim of
providing intelligent energy manage-
ment systems that ensure mobility
stays as economically viable as
possible in the twenty-first century.
WELDING TECHNOLOGY
/ We develop welding technologies,
such as entire systems for arc and
resistance spot welding, and have set
ourselves the task of making impos-
sible weld joints possible. Our aim is
to decode the »arc welding‘s DNA«.
We are the technology leader world-
wide and the market leader in Europe.
Text and images correspond to the current state of technology at the time of printing. Subject to modifications.
SOLAR ELECTRONICS
/ The greatest challenge of our time
is to make the leap to a regenerative
energy supply. Our vision is to use
renewable energy to achieve energy
independence. With our mains-
connected inverters and products for
monitoring photovoltaics systems, we
are now one of the leading suppliers
in solar electronics.

v03 2011 EN
Further information about all Fronius products and our global sales partners and representatives can be found at www.fronius.com

Fronius Canada Ltd. Fronius USA LLC Fronius UK Limited Fronius International GmbH
M,06,0046,EN v01 2012 aw14

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