All for Joomla All for Webmasters

Displaying items by tag: fronius

Friday, 31 July 2020 08:50

Fronius welds prototypes for suppliers

In late autumn 2020, the new prototyping centre from Fronius International will be put into operation. At the site in Wels, Upper Austria, the welding technology manufacturer will not only be working on individual solutions for customers in the field of joining technology, but also welding small series components for the prototype phase.
 
Trends such as e-mobility are resulting in new components and thus new challenges in production, for example when it comes to specific knowledge in joining technology. The special systems that are required, particularly for prototype manufacturing, can pose an investment risk. “When working with suppliers over the past few years, we have discovered that the construction of prototypes is an important topic that comes with a degree of uncertainty for our customers. For this reason, we have decided to support them in this regard,” explains Harald Scherleitner, head of sales in the Fronius Business Unit Perfect Welding.
 
As an important strategic step towards becoming a solutions provider, in the future Fronius Perfect Welding will be welding components for prototypes according to customer requirements. This means the customer does not need to invest in their own prototyping centres and also has the welding knowledge of Fronius at their disposal. Wolfgang Scherleitner, head of the prototyping centre, continues: “We offer our customers technical support and develop the ideal welding solution for the specific component in house. If this eventually goes into series production, as a general contractor we can also supply the necessary welding systems.” The Fronius prototyping centre will be put into operation at the start of November this year.

The new prototyping centre in Wels covering a total area of 900 square metres consists of two welding cells with MIG-CMT and LaserHybrid technology, as well as an optical measuring system. Components with dimensions up to 3x2 metres can be processed here.The new prototyping centre in Wels covering a total area of 900 square metres consists of two welding cells with MIG-CMT and LaserHybrid technology, as well as an optical measuring system. Components with dimensions up to 3x2 metres can be processed here.

Business Unit Perfect Welding
Fronius Perfect Welding is the innovation leader for arc welding and is the global market leader for robot assisted welding. As system providers, Fronius Welding Automation also turns customer-specific automated complete welding solutions into reality in a number of areas, from container construction right up to cladding for the offshore sector. Power sources for manual applications, welding accessories and a wide range of services add to our portfolio. With more than 1,000 sales partners worldwide, Fronius Perfect Welding is never far away from our customers.

Fronius International GmbH

Fronius International is an Austrian company with headquarters in Pettenbach and other sites in Wels, Thalheim, Steinhaus and Sattledt. Founded by Günter Fronius in 1945, this long-standing company with a rich tradition will be celebrating its 75th anniversary in 2020. What began as a local one-man venture has grown into a global player with more than 5440 employees worldwide working in the areas of welding technology, photovoltaics and battery charging systems. Its export ratio of around 93 percent is achieved with 34 international Fronius subsidiaries and sales partners/representatives in more than 60 countries. Moreover, its innovative products and services and its portfolio of 1264 registered patents make it an innovation leader on the world market.

Published in Production
Tagged under
Tuesday, 28 July 2020 08:34

All From A Single Source

Fronius International visits the long-established Innsbruck construction company Huter und Söhne. The Metalworking division in particular enjoys an outstanding reputation here: The company’s own metalworking shop alone employs 60 people, who have 10 permanent welding stations and additional mobile welding systems at their disposal. Across all processes, Huter relies exclusively on welding technology from Fronius.

Innsbruck, at the heart of the Tirol: Huter und Söhne has been active in the construction industry here for more than 150 years – the city center is shaped by numerous buildings that owe their existence to Huter. To date, Huter und Söhne has gradually succeeded in establishing itself in a variety of different branches of the construction industry.

Universal Construction Concepts
From conventional construction, carpentry, and laminated timber construction to joinery services and metalworking – Huter und Söhne is a general contractor offering complete solutions. From foundation to roof truss, from solid wood front door to corrosion-resistant railings – they make more than 70% of the construction components themselves. This results in turnkey construction approaches being made available to the citizens of Innsbruck, of course.
 
“With around 250 employees, we can cover a variety of different architectural styles: from housing estates, office buildings and business premises, to industrial building and hall extensions – and we also have the expertise to build a sturdy home”, says Thomas Gattringer, master metalworker, welding practitioner and instructor for Huter und Söhne. “It goes without saying that we take up all the challenges posed by innovations in structural engineering. Energy-saving construction is also part of our service portfolio, for example.”

: The individual components are welded together to make finished steel door frames: The individual components are welded together to make finished steel door frames

The Huter und Söhne Metalworking Shop
It becomes clear during a subsequent tour of the Metalworking division’s facilities that the metalworking shop is basically separated into materials.
 
Steel
Right at the start is the steel workshop: railings, stairs, ramps, canopies, car ports etc., are made here from conventional construction steel. The employees handling the solid steel girders that bar the way as you enter are not exactly holding back: “Brute force is needed here”, explains Gattringer. “Mounting brackets for balcony boxes, for example. The metal plates are 20-30 millimeters thick. We use 1.2 mm wire and then weld the whole thing in three layers. So you need an enormous amount of power, which is why we mostly use the robust TransSteel 3500c.”
 
Gattringer also explains that due to regulation EN 1090, welding tasks like this at Huter must only be carried out by the TransSteel 3500c. Of course, the TransSteel 2200 also comes under the prescribed certificate of conformity package, but not only does the TransSteel 3500c have the necessary high power, it also and most importantly has water cooling, which is vital for overcoming welding challenges like this. “If the tasks are minor, we also make use of the older VarioStar systems, which are simply indestructible.”
 
Frame construction – a subdivision of structural steelwork in the next workshop hall – demonstrates really clearly how little Huter actually has to buy: the door frames leaning against the wall are made from scratch in-house. First the fitters cut suitable strips from the 1.5 mm galvanized steel plate and trim them to make complex profiles. The individual components are then welded together to make finished door frames.
 
Aluminum
The aluminum workshop is next in line. This is where all aluminum system construction takes place, producing profiles for windows, doors and facades, and complete roof structures.
 
Stainless Steel
The stainless steel workshop is just a few meters away: The workers there wear T-shirts and white gloves – it is all about fine dexterity. The employees in this department are real TIG specialists and you can clearly see the almost artistic requirement of their work. At present, they are mainly working on handrails, stainless steel door frames, and railings. The spotless visible seams were all made by the Fronius MagicWave 230i, or the TransTig 230i.
 
At the end of the workshop visit, Gattringer explains: “We have high quality standards, so of course we need the right tools. When it comes to thermal joining, we only work with welding technology from Fronius.”
 
Mobile Use and the TransSteel 2200
“We also rely on Fronius systems for mobile finishing work”, continues the welding practitioner. Smaller tack welding jobs on stair railings are quickly and easily resolved with TransPocket. But when it comes to joining prefabricated handrails with high-quality visible seams, the fitters are happy to have the TransSteel 2200 to hand: “Because the seam appearance is important with this type of work, TIG welding is essential.”
 
Fitters seem to be totally convinced, particularly by the TransSteel 2200’s touchdown ignition in TIG mode: “System operation is so smooth that we find it easy to work and remain highly professional at the same time. It is true to say that you only need the minimum of practice and after just a few attempts, welding tasks can be performed at a level we would otherwise only manage in the workshop with the high frequency TIG systems TransTig and MagicWave.”
 
Easy Handling
Gattringer also explains that the weight and handling of the TransSteel 2200 are most impressive: “The Multiprocess capability is a real plus, of course – especially the quick switch between processes. It takes no time at all to convert the system for the different process variants, as adjustments can be made intuitively and immediately, without requiring much previous knowledge. So we are ready to go extremely quickly.”
 
In fact, the simplicity of the Fronius devices wins favor with the welding practitioner in other aspects too: “The mere fact that we do not need high-voltage current! Since this is often unavailable on construction sites, we occasionally found ourselves having to organize generators in the past – a significant amount of extra work that is now no longer required.”
 
Universal Application with Multiprocess
Construction sites where there is no clear definition of the tasks to be completed are also part of everyday life for fitters: “In this situation, we are sure to pack the little TransSteel in the car just in case, because then we are ideally equipped for all tasks.”
 
Huter fitters really do have to draw on all the process variants in mobile use: “We can apply all the processes professionally and weld at more or less the same high level.”
 
Huter and the Jeweler
Only recently, there was a typical assignment for TransSteel at one of Innsbruck’s famous jewelers. Part of the renovation work required solid steel girders to be put in to support the ceiling construction.
 
But with so many upright structures (temporary supporting elements to support the ceiling) taking up space, we were severely restricted: “There was not enough room anywhere; we had to weld in all positions and it was always out-of-position welding. The lack of space meant we would have been at our wits end with the larger MAG systems, and if we had been forced to use smaller electrode welding systems, we would probably still not be finished. TransSteel flexibility definitely came to the rescue here!”
 
Quality and Service
Gattringer and his colleagues love the quality of Fronius products: “High-quality materials that last forever! But if there should be a problem, someone comes out at once and repairs the whole thing. If that doesn’t work, the equipment is replaced immediately – a service that is almost indispensable, with our deadline pressure.”
 
The Fronius sales team is also extremely well informed about workshop processes. The wearing and spare parts warehouse is checked regularly by Fronius employees, who are responsible for keeping it stocked: “The high-quality service from Fronius saves us a great deal of time and energy. All in all, this is an extremely valuable partnership for us.”

Business Unit Perfect Welding
Fronius Perfect Welding is an innovation leader for arc welding and a global market leader for robot-assisted welding. As a systems provider, the Fronius Welding Automation division also implements customized automated complete welding solutions, for the construction of containers or offshore cladding for example. The range is rounded off by power sources for manual applications, welding accessories, and a broad spectrum of services. With more than 1000 sales partners worldwide, Fronius Perfect Welding has great customer proximity.

Fronius International GmbH
Fronius International GmbH is an Austrian company with headquarters in Pettenbach and other sites in Wels, Thalheim, Steinhaus and Sattledt. With 4,760 employees worldwide, the company is active in the fields of welding technology, photovoltaics and battery charging technology. 92% of its products are exported through 30 international Fronius subsidiaries and sales partners/representatives in over 60 countries. With its innovative products and services and 1,253 granted patents, Fronius is the global innovation leader.
 
Contact details for publishing:
Fronius UK Ltd
+44 1908 512300
This email address is being protected from spambots. You need JavaScript enabled to view it.
www.fronius.co.uk

Published in Production
Tagged under
Thursday, 04 June 2020 09:27

Vizor Connect welding helmet from Fronius

Intelligent occupational safety for maximum comfort

The Vizor Connect is the world’s first welding helmet that communicates with a power source via Bluetooth. This means that it darkens prior to ignition rather than waiting until the arc is lit. The helmet also eliminates the problem of interference from external light and reliably darkens even in demanding welding situations. It therefore ensures a higher degree of both safety and comfort.
 
Using Fronius PreTrigger technology, the power source sends a signal to the welding helmet via Bluetooth as soon as the user presses the On button on the welding torch. The helmet therefore darkens before the arc is ignited. This protects users against the abrupt flash of light that would previously appear before the helmet darkened. This completely protects the welder’s eyes from welding light and reduces tiredness. 

Using Fronius PreTrigger technology, the power source sends a signal to the welding helmet via Bluetooth as soon as the user presses the On button on the welding torch.Using Fronius PreTrigger technology, the power source sends a signal to the welding helmet via Bluetooth as soon as the user presses the On button on the welding torch.

The auto-darkening filter cartridge remains in place even at the lowest currents and if the arc is concealed and in constrained positions, as long as the arc is burning. This is because the helmet reliably responds to the signal sent by the connected power source. This improves occupational safety for the welder. The level of protection applicable to the welding process is automatically adjusted between DIN 5 and DIN 12. The darkness level is therefore perfectly adapted to the intensity of the arc at all times. The welder also has the option of switching to manual mode and infinitely adjusting the darkness as required.                                                                                                                  
A clear view at all times
A further advantage is that the Vizor Connect eliminates the problem of interference from external light. Conventional welding helmets sometimes darken at inappropriate times as a result of light reflections, warning lights, or external welding light. Not the Vizor Connect. The helmet provides ideal protection during activities before and after welding, including grinding. When the welder disconnects the Bluetooth connection between the helmet and the power source, the Vizor Connect acts like a conventional protective helmet and darkens in the presence of light sources as of a certain intensity.
When the helmet is not darkened, it provides a clear view with a brightness level of 2.5 as well as real colour perception thanks to a specially developed UV and infrared filter. The auto-darkening filter cartridge with nose cut-out gives the welder an unobstructed line of sight and makes the helmet extremely comfortable to wear. The special shape increases the field of view up to six times and reduces the weight of the helmet.

Business Unit Perfect Welding
Fronius Perfect Welding is an innovation leader for arc welding and a global market leader for robot-assisted welding. As a systems provider, the Fronius Welding Automation division also implements customized automated complete welding solutions, for the construction of containers or offshore cladding for example. The range is rounded off by power sources for manual applications, welding accessories, and a broad spectrum of services. With more than 1000 sales partners worldwide, Fronius Perfect Welding has great customer proximity.

Fronius International GmbH
Fronius International GmbH is an Austrian company with headquarters in Pettenbach and other sites in Wels, Thalheim, Steinhaus and Sattledt. With 4,760 employees worldwide, the company is active in the fields of welding technology, photovoltaics and battery charging technology. 92% of its products are exported through 30 international Fronius subsidiaries and sales partners/representatives in over 60 countries. With its innovative products and services and 1,253 granted patents, Fronius is the global innovation leader.

Published in Production
Tagged under

Limited space and high quality requirements demand clever solutions so that welders can work efficiently, ergonomically, and safely. To find such a solution, you need look no further than Fronius. They advised Bilfinger Industrial Services to invest in a push-pull welding torch with a long hosepack, while a TPS/i power source ensures the perfect weld seam is achieved.

The purchase was prompted by an order for steel components for the nearby Traunleiten hydroelectric power plant, which is undergoing significant reconstruction works. The contract covered the engineering, production, delivery, and assembly of 23 different steel components weighing around 350 tons in total. These components included intake gates, turbine intake bulkhead gates, coarse screens to protect the turbines, and two weir gates, known as fish belly flap gates.

Forty-Four-Meter-Long Fish Belly Flap Gate
Fronius Logo
In run-of-river plants, fish belly flap gates control the level of the water. They owe their name to their arched shape, which is reminiscent of a fish belly and makes them particularly torsion-resistant. For the Traunleiten project, two rotary gates, each measuring 44 meters in length, were ordered, and which are connected to the side wall of the barrage at one end by means of a hydraulic positioning drive. The approximately 2.5-meter-high gates are connected to the threshold of the barrage via a rotation axis. This allows the fish belly flap gate to be raised and lowered and thus the water level to be regulated quickly.

“Due to the transport restrictions, the gate bodies were divided into three segments of up to 16 meters each,” says Bernhard Brindl, Project Manager in the Hydro Division of Bilfinger in Wels. “The parts were joined on the construction site using flange plates with high-strength bolted connections, which requires regular checking of the tightening torque.” A resealable manhole with a diameter of 650 millimeters had to be provided for each segment.

Indispensable Multiple Manholes? Not Any More!
For an access point to be sufficient for maintenance, Bilfinger needed at least two manholes in order to weld together the 16-meter-long segments with the welding equipment previously available. Welders would have needed to take the power source, including the wirefeeder, into the inside of the gate segments in order to achieve all the necessary welding positions. “We would have had to subsequently weld the additional access points shut again and check their tightness. Aside from the additional costs, each additional manhole represents a weak point where water could penetrate,” Brindl explains.

600 Meters of Weld Seams
Fronius recommended that the Bilfinger experts use a long hosepack in conjunction with a push-pull welding torch and a power source from the latest generation of TPS/i devices. Bilfinger has long relied on Fronius. “We have several hundred Fronius devices, used by more than 300 welders – both in workshops and on construction sites,” adds Brindl. The industrial service provider therefore followed the recommendation and ordered an eight-meter-long PullMig welding torch as well as a TPS 500i for the construction of the torsion gates.

The experts mainly welded S355 steel plates with fillet welds and some V butt welds with a total length of roughly 600 meters. They started with the construction of a steel tray that forms one side of the gate, onto which struts and then the “lid” were welded. The welders had to adhere to tight tolerances in the millimeter range and observe minimum welding distortion so that the parts could subsequently be bolted together precisely and mounted on the rotation axis. In order to largely avoid out-of-position welding, the welders repositioned the gate several times with a roller crane.

More Freedom of Movement
“The result impressed us all,” says Brindl. “The extended operating radius due to the long hosepack allowed us to dispense with the second manhole for each segment, saving us the additional work this involved.” In addition, the workers were able to place the power source together with the wirefeeder outside the gate body and still attain all the required positions. “This not only gives us better freedom of movement in the already space with a cross-section of just 1,500 by 800 millimeters, but also facilitates – and this is crucial for us – access and recovery for emergency rescue workers.”

The equipment offers a number of other advantages, which also have a direct impact on efficiency, ergonomics, and quality in pipeline, container, and ship construction. All the important welding parameters can be set via the JobMaster remote control, which can be called up directly on the torch body. This allows the welder to perform different welding tasks straightaway without additional work and long interruptions. “Our welders rated the steady wire speed particularly highly,” reports Brindl. In addition, an LED light integrated in the welding torch makes it easier to work in poorly lit areas. Yet the welding torch is extremely compact and weighs only 1.6 kilograms, despite the integrated two-roller drive, making it one of the lightest in its class. Together with the rapid control of the arc and the stabilizing PMC pulse process that are typical for the TPS/i devices, the highest quality requirements can be met efficiently, safely, and conveniently.

Lasting Success
“The welders would prefer to only work with this device,” summarizes the Project Manager. “We immediately reserved the TPS 500i with the long PullMig welding torch for our department. The container construction department followed suit and also ordered a long hosepack. This allows the welders to devote themselves entirely to the task at hand and benefit from the increased operating radius, even with larger containers.”

Published in Production
Tagged under

By clicking “Accept All Cookies”, you agree to the storing of cookies on your device to enhance site navigation, analyze site usage. Site Terms and conditions