Fronius offers smart welding assistance systems with robots

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Precise seam tracking during welding

The Fronius assistance system, Seamtracking, particularly shows its advantages in the manufacturing of rail or construction vehicles. When welding thick sheets or long seams, the heat input can lead to component distortion. To ensure the robot welds at the correct location despite this, a system is needed that can reliably detect the welding position during the process—such as at a fillet weld or a prepared butt weld. For this purpose, the robot oscillates back and forth between the two sheets while welding. The actual values detected during this process are converted by the welding controller into signals for the robot control, as explained. Based on these signals, the robot identifies the intended welding position or possible deviations. It can then automatically correct the welding path accordingly, ensuring that the welding is reliably carried out at the correct position.

Thus, the welding robot follows the command faster

The key to high quality in robot welding also involves teaching the correct welding path. In this regard, Fronius highlights the Teachmode function, which aids in setting the welding seam positions on the robot, reportedly speeding up the programming process by about 30%. This function uses the reversing wire motion to prevent the wire from bending when it comes into contact with the component. This saves users from having to cut off the deformed wire and re-measure the so-called stickout.

Gallery

No matter what comes, with the assistance systems Wiresense, Touchsense, Seamtracking, and Teachmode from Fronius, one can always hit the right parameters for ideal robotic welding seams, as they say.(Image: Fronius)

Here we see the Robacta Drive CMT drive unit from Fronius, which is emphasized as being highly dynamic and precise. During wire movement, it successfully scans components with the welding wire, bringing us back to the topic of "the welding wire as a sensor."(Image: Fronius)

React correctly every time with "intelligent" support! Wiresense from Fronius can also detect gaps in overlap seams. The robot then automatically performs the appropriate welding jobs, provided these have been predefined.(Image: Fronius)

Teaching is about 30 percent faster with the Fronius Teachmode feature because the reversing wire movement prevents the wire from bending when touching the component. This saves the user from having to cut off the bent wire and from having to remeasure the stickout.(Image: Fronius)

This can be said about welding assistance systems in general:

Using the existing wire electrode as a sensor not only saves costs and maintenance expenses for additional sensor hardware but also creates more space for welding, as the accessibility of the component is not restricted in any way. At the same time, Fronius assistance systems reduce scrap and costly rework because welding is always performed at the correct position. The need for subsequent reprogramming of the robot paths is also minimized because the robot can autonomously correct the seam trajectory. Overall, this enhances the efficiency of the production process in welding and simultaneously minimizes both time and material expenditure.

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Date: 08.12.2025

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