Assistance systems for robot welding

Support for welding robots through assistance systems

Increasing the efficiency and quality of welding tasks are important factors in robotic welding.

Our technologies help you to save time and money while doing so.

WireSense

No optical measuring systems required: detect and compensate for component and clamping tolerances

Even minimal material differences or imprecise clamping devices can have a negative influence on the welding result and cause costly and time-consuming rework. With WireSense, these problems become a thing of the past.

WireSense uses the wire electrode as a sensor.

WireSense delivers a corresponding signal to the robot by precisely scanning the component in advance of performing the weld, so that the robot can adapt its program to the current component position.

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The advantages at a glance

Edge detection

Detection of the edge position for optimal positioning of the welding start point and end point
Component and clamping tolerances are compensated for

Height measurement

Detection of an unwanted air gap
Detection of sheet thicknesses between 0.5 and 20 mm, both for steel and stainless steel as well as aluminum
High-precision and high-speed measurement

Wire = sensor

No additional optical measuring devices required
Excellent component accessibility
No wear
No maintenance or cleaning costs
No calibration between sensor and TCP required

TeachMode

No bent wires thanks to efficient robot programming

TeachMode helps the welding specialist to program welding positions on the robot. The reversing wire movement prevents the wire bending upon unwanted contact with the component, ensuring the set stickout remains unchanged.

This function is included free of charge with all TPS/i configurations.

The advantages at a glance

Save time

If the stickout drops below the defined value, the wire is automatically retracted to prevent deformation. This results in highly efficient component programming.

Constant stickout

If the stickout drops below the defined value, the wire will be automatically corrected to the desired length.

Suitable for use with all filler metals

TeachMode is compatible with all filler metals (steel, CrNi, aluminum).

TouchSense and SeamTracking

Detect and compensate for component and clamping tolerances before and during welding.

With TouchSense and SeamTracking, the teaching effort is reduced enormously, so that even smaller batch sizes can be produced efficiently for heavy-duty steel structures. The assistance systems also minimize rework, as clamping tolerances or small deviations in the component position are compensated for intelligently. This represents a considerable potential for savings in series production.

The result is a perfect weld seam without the need for rework.

TouchSense

TouchSense determines the precise component position before welding fillet welds and prepared butt welds, whereby the start and end positions are determined by scanning the workpiece with a wire or gas nozzle. After transmitting the signals to the robot, TouchSense calculates the exact seam path.

SeamTracking

Avoid welding defects with SeamTracking, which intervenes as necessary during the welding process. The robot automatically corrects the course of the seam by changing parameters in response to oscillating movements. This ensures precise tracking of the seam path and prevents welding errors due to clamping or component tolerances.

The advantages at a glance

Save time and money

Less time required for teaching is ideal for smaller batch sizes in heavy-duty steel construction
Short changeover times for different component variants
Fewer welding errors and less rework

Compensation for component and clamping tolerances

Detection of the component position before starting the welding process (TouchSense)
Robot path is adapted to the actual seam position by determining the welding start and end point (TouchSense)
Automatic correction of the robot path during the welding process in case of component deviations (SeamTracking)

Flexibility

Process-independent: SeamTracking can be used for welding with a dip transfer, spray, and pulsed arc as well as in combination with CMT or TWIN
TouchSense process: can be carried out both with the gas nozzle and with the wire electrode

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Perfect Welding

Assistance systems for more efficiency in robot welding

Support for welding robots through assistance systems

WireSense