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The Welding Wire to the Sensor for Seam Tracking

Even when all system components work together almost perfectly, deviations in layered welding can occur without seam tracking sensors, as the experts note. This can lead to defects such as burn-through or insufficient leg dimensions. Fronius Wiresense, therefore, uses the wire electrode as a sensor for seam tracking, eliminating the need for optical measuring aids that could impair the torch's accessibility to the workpiece. By pinpoint scanning with high-frequency reversing wire movements, the various workpiece geometries are detected, and the position of the individual sheets relative to each other is precisely determined. Wiresense also operates without additional torch attachments and requires neither calibration nor maintenance. Thanks to this special sensor technology, Trumpf benefits from flawless weld seams and reduced production costs.

No Machine Today Operates Without Suitable Control Systems

And the user-friendly control system HMI-T21 RS is, as stated, the centerpiece of Trumpf's welding system. It monitors and coordinates all peripheral components (robots, welding power source, tilt positioners, and torch cleaning). Thanks to available 3D real-time views, welding specialists can track all robot movements live on the monitor. They have the option to choose between pre-configured or self-created views and save these to always enjoy optimal visualization. According to Fronius, a key element of the control system is its program editor. Operators use it to define individual program sequences, assign them to a processing station, and save them as a sequence chain. In the status bar, fault, warning, or important messages are displayed in plain text. If no messages are present, all system states and the program sequence are visualized, with the logged-in user shown in the right column. The status overview displays the condition of all available sensors. In case of a fault message, all signals can be checked using the HMI.