Tps/I Additional Robotic Features

Fronius International GmbH
Technical Product Management IWS TPS/i ADDITIONAL ROBOTIC

Froniusplatz 1, 4600 Wels
Austria
FEATURES
ROBOTIC WELDING CHALLENGES
Stickout
Multiple Welding geometry
Heat input Acute Angles

Spatter
Welding Parameters
Welding Speed
Uniform Penetration
Collision & TCP Correction
Teaching without wire bending

What are all the
challenges…
CHALLENGES
Acute angles
Reach Angle
Part Consistency
5 One Job… too many Geometries…

CHALLENGES
Penetration
Robot Teaching
Collision & TCP Correction
Speed & Arc Stability
Spatter
Expecting the
Welding Machine to be…
Intelligent !!!
INTELLIGENT SYSTEM
/ stability directly
/ interface to the
at the arc
outside world
intelligent / perfect iginition
/ WeldCube
SPEED NET
/ Remote Service
(FEEL)
intelligence
up to the
torch body
/ completely
intelligent base
/ higher welding
/ ready for new intelligent speed
innovations control / Ethernet as a
/ unknown possibilities
standard
10
Fronius India PL 2015 / TPS/i Robotics
SeamTracking
11
Fronius International GmbH / first name last name / Titel of presentation / xx.xx.20xx - v03
SEAMTRACKING WITH TPS/I
/ Why SeamTracking
12
Fronius International GmbH / Seamtracking with TPSi
General Limits of SeamTracking TPS:

/ Process CMT
/ System TWIN
/ Travel speed/Robot speed;
/ Poor weldparameter (i.e. short arc);
/ Weaving amplitude;
/ Materiel thickness;
/ Weaving pattern
13
General Limits of SeamTracking TPS/i:

/ Process CMT
/ System TWIN
/ Travel speed/Robot speed;
/ Poor weldparameter (i.e. short arc);
/ Weaving amplitude;
/ Materiel thickness;
/ Weaving pattern
14
/ Why new SeamTracking Signal for TPS/i:
/ No special welding characteristics are needed anymore (like TPS P0554/P0555);
/ Due to the fact that all new smart parameters for TPS/I like “Arc lenght stabilizer” or “Penetration stabilizer”
influence the current we cannot use them anymore;
/ Also with the new Signal is possible to do seam tracking with CMT;
Behavior at TPS Behavior if „Penetration stabilizer“ is activatet Behavior at CMT

 current/voltage feedback  NO current feedback  NO current/voltage feedback
15
/ Principle of SeamTracking – Horizontal tracking
16
/ Principle of SeamTracking – Vertical tracking
17
/ Function „New SeamTrack Signal“ (V2.1.0)
/ Advantage is, that the value is independent from „perfect“ Stickout
/ At „perfect“ Stickout the seamtrack value should be approx. 5000 (Reference: Steel 1,2mm Ø)
/ Advantage is No reference weld should be neccesary
18

/ The Value is independent from Wirematerial (Steel, CrNi)
/ The Value is independent from Wirediameter (0,8mm / 1,0mm / 1,2mm,….)
/ The Value is independent from Weldingprocess (Std, Puls, PMC, CTM,…)
Stickout Seamtracking Value for Welding characteristic A  5000
[mm] 36
33 Seamtracking Value for Welding characteristic B  5000
30
Seamtracking Value for Welding characteristic C  5000
27
24
21
18
15
12
50 100 150 200 250 300 350 400 450 500 550 600 650 700 750
Weldingcurrent [A]
19
20
New SeamTracking Signal (V2.1.0) available for:
Fe 1,0mm Ø & 1,2mm Ø

(short arc + spray arc)
Fe & CrNi all Ø (only spray arc)
Fe & CrNi all Ø

CMT-Mix
Fe & CrNi all Ø
PMC TWIN
Fe & CrNi all Ø Fe & CrNi all Ø
21
Starting parameter for SeamTracking
PMC - FILLET WELD - PB
Weldparameter:
Process: PMC
Characteristic Nr.: 3189
Wirefeedspeed vd: 12 m/min
: ON
SeamTracking:
Robotspeed: 55 cm/min
Dwell time left/right: 0 sec.
Weaving pattern: Triangle
: 4mm
: 2mm
: 2mm
: 3mm
23
PMC - FILLET WELD - PB
Weldparameter:
Process: PMC
Characteristic Nr.: 3264 / 3189
Wirefeedspeed vd: 7 / 6,5 m/min
: ON
SeamTracking:
Weaving pattern: Zig-Zag
: 8mm
: 4mm
: 4mm
Basematerial thickness 3 & 6mm
24
CMT – FILLET WELD - PB
Weldparameter:
Process: CMT
Wirefeedspeed vd: 8,6 m/min
SeamTracking:
Dwell time left/right: 0
: 4mm
: 2mm
: 2mm
: 3mm
Basematerial thickness 4mm
25
CMT – OVERLAPP SEAM - PB
Weldparameter:
Process: CMT
Wirefeedspeed vd: 6,4 m/min
SeamTracking:
Robotspeed: 80cm/min
Dwell time left/right: 0
: 3mm
: 1,5mm
: 1,5mm
: 2,2mm
Basematerial thickness 2mm
26
TWIN PMC - FILLET WELD - PB
Weldparameter:
Process: TWIN PMC
Wirefeedspeed vd: 2 * 9 m/min
: ON
SeamTracking:
: 4 mm
: 2 mm
: 2 mm
: 3 mm
27
SHORT ARC - VERTICAL UP - PF
Weldparameter:
Process: Standart shortarc
Wirefeedspeed vd: 3,6m/min
: OFF
SeamTracking:
Robot speed: 16 cm/min
Dwell time left/right: 0,4 sec.
: 14mm
: 7mm
: 7mm
: 2,5mm
28
CMT - VERTICAL UP - PF
Weldparameter:
Process: CMT
Wirefeedspeed vd: 3,6m/min
SeamTracking:
Robot speed: 20 cm/min
Dwell time left/right: 0,4 sec.
: 14mm
: 7mm
: 7mm
: 2,5mm
29
30
Little helpers for
Robotic Welding
31
WIRE STICK TO WORK PIECE @ WELD END
/ An open wire end stuck in the weld puddle

causes the robot not to be able to move to the next
position – crash box or robot motor current
detection will cause a fault in the robot cell
 Result: Down-Time
/ A Burn Back Correction usually prevents that the

wire get’s stuck in the weld puddle. This causes a
bigger droplet at the open wire end
which can lead to ignition problems
for the next seam or more spatters
32
TPS/i WELD END SEQUENCE
/ How does it work…

/ The current is limited when the wire is immersed in the molten bath, and reduced just
before the short circuit breaks
/ The reverse distance can be set with the parameter „ wire retract“ (per Job)
33
TPS/i WELD END SEQUENCE
/ The result…
/ Prevents that the wire is stuck in the weld puddle
/ Optimized wire shape for ignition
/ Prevention of burn-backs to the contact tip
34
WIRE STICK TO WORK PIECE („WIRE NOODLING“)
/ „Noodling“ is caused if the arc has to less voltage – the wire only „glows or
noodles“.
/ The problem in robotic welding: since there is still current running within the
welding circuit the robot gets the information  Arc stable
/ The result: missing welds
35
WIRE STICK TO WORK PIECE (WIRE NOODLING)
/ The Wire stick work piece function detects if

the arc is not established and the wire is only
„noodling“
/ Error 9702 is thrown if this is set to „error“
36
WIRE STICK TO CONTACT TIP
/ A Burn back to the contact tip is mostly caused

by wire feeding problems from the barrel / spool
/ The Problem: the arc is still active between the
tip and the work piece – the robot doesn't detect
the fault
/ Worst case: the burn back melts the contact tip
and destroys the torch body
37
WIRE STICK TO CONTACT TIP
/ The Wire stick contact tip functions is able to

detect a burn back.
/ How does it work: a short circuit based welding
process is necessary (short arc, PMC with active
arc length stabilizer, CMT). Within the set filter
time a short circuit has to be detected . If not an
error is thrown and welding is stopped.
38
Using the Magnetic Crash Box
SYSTEM PROMISES Shorter downtime in production after collision
/ After a collision the fixing torque is at 0% (at TPC
transfer more than 2,5mm)
/ The magnetic crash box can be moved out of the
collision spot immediately, because it is fully released.
STABILITY AND (Time until robot is ready for welding again is approx.
RELIABILITY
5 minutes)
Reduction of downtimes
to a minimum / At a spring system the fixing torque is at 200% after the
collision
(Time until robot is ready for welding again is approx.
30 minutes)
/ Costs robot per minute: approx. € 20,-  Saving per
collision: approx. € 500,-
39
POSITION REPEATABILITY & MAX. EXCURSION
/ Position repeatability:
/ Position repeatability of the TCP at

300mm distance from robot flange (36°
standard torch body with PAP system):
±0,05mm
L=300mm ±0,05mm / Crashbox releases at 2,5mm TCP transfer (=0,5°)

/ Max. excursion: approx. 100mm (=20°)
/ Max. excursion:
Clamp
Lengthening
Wrist
Collision
TCP positions with clamp lengthening
*
* *
*
with 44,0350,3729 Clamp-lengthening/i 80mm or
alternatively with 44,0350,3730 Clamp-lengthening/i 120mm
with 44,0350,3994 Clamp-lengthening/i 80mm / 90°
* * 45° Index disc is included as standard

* * Index disc adapted to torch body angle (order separately)
with 44,0350,3993 Clamp-lengthening/i 80mm / 45° or alternatively

with 44,0350,3995 Clamp-lengthening/i 120mm / 45°
41
Productivity ....
Higher speeds
with TPS/i
42
Fronius International GmbH / Product Launch Perfect Welding 2016
STEEL BUMPER IGNITION SIMULATION
/ Steel Bumper Simulation
/ Material: Steel 2mm
/ Wire material: Steel 1.2
/ Gas: 82/18 12l/min
/ TPS 5000 vs. TPS/i 500
/ 39 Ignitions on the part
43
STEEL BUMPER IGNITION SIMULATION
TPS Time TPS/i Time

Standard 94sec. Standard 84sec.
Pulse 95sec. Pulse 85sec.
LSC 84sec.
PMC 85sec.
/ 10sec. difference on part  time saving ~ 250ms per Ignition

/ Arguments:
/ Feeder-creep-speed at TPS/i is adjusted per Ignition
/ Burn back setting with TPS vs. Wire retract setting with TPS/i (faster signal release)
/ Difference of the internal signal speed TPS vs. TPS/i
/ Interface communication speed
COSMA EUROPE
/ Customer – Magna Cartech
/ TPS/i in production line since Nov. 2014
/ 3 shift operation
45
PMC IN PRODUCTION @ MAGNA CARTECH
Welding Speed Pulse: 1 m / min

Comparision conventional Pulse process with new PMC process
welding Speed PMC: 1,2 m / min
Cycle time welding time robot movement & Production time Parts shift Parts / shifts Production days / parts /
Robots
[s] [s] Torch cleaning [s] / Shift [s] /robot shift / day Volume / day week week
PULSE 65 43 22 28800 443 1 443 3 1329 5 6.646
PMC 58 35,83 22 28800 498 1 498 3 1494 5 7.470
• Estimated component costs 1€

• Increased output per production week 824 parts
 PMC amortises during one production week

• In case of 50 production weeks:
 Estimated 41.200€ profit / unit (welding cell)
46
TPS/I FIRMWARE 2.3.0
What's new in SW 2.3.0
 Wire force monitoring (former motor current monitoring)
47
TPS/I FIRMWARE 2.3.0 FOR TESTING
What's new in SW 2.3.0
 Limit monitoring for welding duration and energy per seam – focus manual welding
(OPT/i limit monitoring required)
48
TPS/i locking function
/ … with 4,044,031 TPS/i Key Fob
/ … with 4,044,032 TPS/i Key Card
49
Key card / Key Fob
/ Card and Fob standard with TPS/i from SN: 2708xxxx
/ All current TPS/i power sources on the market are

equipped with the required NFC-Modul. This Module
will be activated automatically with the software 1.6.4.
(only in CE area)
/ Functionality is available for all other regions beyond

CE area from SN: 26254554 (MCU V1.3)
/ User management will follow

50
Fronius International GmbH / Segment Management Meeting Robotics / 28.04.2016
Product Management Mig/Mag IWS WireSense
14.11.2019
Available January 2020
WireSense
TPS/i delivers measurements …
robot programm needs to use them
… to create a solution
52
Fronius International GmbH / Wire Sense
WireSense – The wire as high-resolution distance sensor
/ This technology uses the wire electrode to scan the workpiece in order to detect workpiece
edges even on thin materials in robotic welding without additional optical measurement
systems.
/ WireSense enables the detection of workpiece edges and surfaces. The measurement of
edge heights allows to detect component irregularities like gaps which are compensated by
adjusted welding parameters in the background – a big step towards adaptive robotic
welding.
53
Fronius International GmbH / OUTLOOK: WireSense / 2019
WIRESENSE
WireSense
Edge detection Distance

information in mm
Function of the power source Information signal to the robot
54
55
CHALLENGES IN ROBOTIC WELDING
/ Non consistent parts, due to tolerances

 lead to welding defects and rework
Programmed path Programmed path

Point A Point B Point A Point B
Welding seam Welding seam
56
OUR SOLUTION: WireSense
/ Function: Edge detection

/ Sense the real start position prior welding even on thin material (>0.5 mm)
/ Robot automatically shifts the welding start and end position or change welding parameter
Programmed path Edge Detection Shifted path
Point A Point B Sequence 1 Sequence 2 Mod. Point 1 Mod. Point 2
Welding seam
Welding seam
57
SYSTEM REQUIREMENTS
System must be CMT ready:

/ WF60i RobactaDrive CMT
/ Wire buffer CMT or SB 60i
/ WF25i REEL or WF30i REEL
&
/ 4,067,020 - OPT/i Wire Sense
(Gross price 2.140,- €)
* If the welding process CMT is needed the WP CMT must be

added to the configuration
58
WireSense
/ The welding wire as a distance sensor

/ Scanning up to max. 100 Hz possible
/ No adjustment between torch (TCP) and sensor necessary - the torch is the sensor!
/ Possible substitution of optical measurement systems
/ No additional interference (Sensor contour)
/ The customer is able to detect and offset part tolerances in robotic welding.
/ WireSense detects edges starting from 0.5 mm thickness on steel, aluminium and all other alloys.
59
WireSense
Technical details
WireSense
Edge detection Contour sensing Seam verification
Edge position detection and Sensing of part contours Determination of “a”-dimension

height measurement before welding after welding
61 Fronius International GmbH / OUTLOOK: WireSense / 2019

WireSense
Edge Detection
EDGE DETECTION – SIGNAL SEQUENCE
/ Edge detection is active when

“WireSense edge detection” is
between 0,5 and 20mm
/ The “WireSense position” signal
shows only the height of the edge
/ The “touch signal” is active and Signal from the robot to determine the minimal
edge height that triggers the edge detection
represents the position of the
detected edge
Signal from robot to start / stop the wire
/ Detection of gaps is also possible sense function
Signal from power source for the detected

edge position
Signal from power source for the edge height

measurement
63
EDGE DETECTION – SIGNAL FLOW CHART
Edge detection V Robot
Wire sense edge detection 3mm (“ON”)

IN: BIT 256-271 (0,5 - 20mm)
Wire sense start “ON” The edge detection function detects

IN: BIT 29 the position and the height of the edge
Wire sense position 0mm

OUT: BIT 256-271 (max. +/- 24mm)
Touch signal “ON”

OUT: BIT 7
Wire sense position -5mm

OUT: BIT 256-271 (max. +/- 24mm)
Wire sense start “OFF”

IN: BIT 29
64
EDGE DETECTION & HEIGHT MEASUREMENT DEMO
65
WireSense – EDGE DETECTION SCREEN OVERVIEW
Edge detection: OFF
Edge detection: 0,9mm
Edge detection: 20mm
66
WireSense – EDGE DETECTION SCREEN OVERVIEW
Edge detection: Hight measurement: 2,4mm
67
WireSense
Contour Sensing
CONTOUR SENSING – SIGNAL SEQUENCE
/ Contour sensing is active when

“WireSense edge detection” is OFF
(<0,5mm)
/ When contour sensing is active the signal
“WireSense position” is always the real
For contour sensing the wire sense edge detection
wire position (live value). signal from robot has to be OFF (< 0,5mm)
INPUT: wire sens e ed ge detection t
/ The “touch signal” is not active
/ Additional signal: Signal from the robot to start / stop the
contour sense function
The “WireSense break” signal stops the INPUT: wire sens e start t
movement of the wire but does not reset

When contour sensing is active, there is no
the actual wire sense position signal (useful touch signal output from the power source
to get over gaps and then continue the OUTPUT: touch s ignal t
actual sense process) When contour sensing is active the wire sense position
signal is always the real wire position (live value)
OUTPUT: wire po sition t
69
CONTOUR SENSING – SIGNAL FLOW CHART
Contour sensing
Wire sense edge detection 0mm (“OFF”) V Robot

IN: BIT 256-271 (0,5 - 20mm)
Wire sense start “ON”

IN: BIT 29
Wire sense position 0mm

OUT: BIT 256-271 (max. +/- 24mm)
5mm When the contour
Wire sense break “ON”
sensing is active the
IN: BIT 30
signal “WireSense
Wire sense break “OFF”
position” is always
IN: BIT 30 the real wire position
(live value). The
Wire sense position 0mm Touch Signal is not
OUT: BIT 256-271 (max. +/- 24mm) active.
Wire sense position -5mm 7mm

OUT: BIT 256-271 (max. +/- 24mm)
Wire sense position -7mm

OUT: BIT 256-271 (max. +/- 24mm)
Wire sense start “OFF”

IN: BIT 29
70
CONTOUR SENSING DEMO
71
WireSense – CONTOUR SENSING SCREEN OVERVIEW
Wire Sense ON
Wire sense active  Live Value
72
WireSense – CONTOUR SENSING SCREEN OVERVIEW
73
WireSense
Properties
OUTLOOK: INTERFACE SIGNALS
Robot Signals Input to Power Source Output to Robot Data Type Factor Value
Wire Sense – Contour Sensing Function
Wire sense start (BIT 29) X BIT

Wire sense break (BIT 30) X BIT
Wire position (BIT 256-271) X WORD (SINT) in mm 100 -327,68 / +327,67 (max. Distance +/- 25,00mm)
+/-
Wire Sense – Edge Detection Function
Wire sense start (BIT 29) X BIT
Touch signal (BIT 7) X BIT (300ms)
Wire sense edge detection (BIT 256 - 271) X WORD (UINT) in mm 10 OFF / 0.5 – 20.0 mm
Wire position (BIT 256 - 271) X WORD (SINT) in mm 100 -327,68 / +327,67 (max. Distance +/- 25,00mm)
Teach Mode
Teach Mode (BIT 25) X BIT
Wire position (BIT 256 - 271) X WORD (SINT) in mm
Touch signal (BIT 7) X BIT (300ms)
75
Fronius International GmbH / OUTLOOK: Wire Sense / 2019
OUTLOOK: WireSense FUNCTION PROPERTIES
Contour Sensing Edge Detection Teach Mode

/ The welding wire used as high-resolution / Edge position detection and height / No bending of welding wire during robot
distance sensor measurement teaching process
/ Faster alternative to standard touch
sensing function
/ Sampling rate approx.. 100 Hz / Sampling rate approx.. 100 Hz / Sampling rate approx.. 4 Hz
/ Measurement accuracy at Steel 0.3mm / Height measurement accuracy
/ Recommended max. sense time 30sec. at Steel 0.3mm
/ Max. measurement range +/- 24mm / Min. sheet thickness: 0,5mm

/ Max. sheet thickness: 20mm
/ Robot speed 50cm/min up to 3m/min
Recommended 1,5m/min
76
All information is without guarantee in spite of careful editing - liability excluded.
Intellectual property and copyright: all rights reserved. Copyright law and other laws protecting intellectual property apply to the content of this presentation and the documentation enclosed (including texts, pictures, graphics, animations
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Fronius International GmbH

Technical Product Management IWS TPS/i ADDITIONAL ROBOTIC

Heat input Acute Angles

Collision & TCP Correction

Teaching without wire bending

5 One Job… too many Geometries…

Collision & TCP Correction

Speed & Arc Stability

General Limits of SeamTracking TPS:

General Limits of SeamTracking TPS/i:

Behavior at TPS Behavior if „Penetration stabilizer“ is activatet Behavior at CMT

/ Function „New SeamTrack Signal“ (V2.1.0)

Fe 1,0mm Ø & 1,2mm Ø

Fe & CrNi all Ø (only spray arc)

Fe & CrNi all Ø

Basematerial thickness 3 & 6mm

Basematerial thickness 4mm

Basematerial thickness 2mm

/ An open wire end stuck in the weld puddle

/ A Burn Back Correction usually prevents that the

/ How does it work…

/ The Wire stick work piece function detects if

/ A Burn back to the contact tip is mostly caused

/ The Wire stick contact tip functions is able to

/ Position repeatability of the TCP at

L=300mm ±0,05mm / Crashbox releases at 2,5mm TCP transfer (=0,5°)

* * 45° Index disc is included as standard

with 44,0350,3993 Clamp-lengthening/i 80mm / 45° or alternatively

TPS Time TPS/i Time

/ 10sec. difference on part  time saving ~ 250ms per Ignition

Welding Speed Pulse: 1 m / min

• Estimated component costs 1€

 PMC amortises during one production week

 Estimated 41.200€ profit / unit (welding cell)

What's new in SW 2.3.0

 Wire force monitoring (former motor current monitoring)

What's new in SW 2.3.0

/ … with 4,044,031 TPS/i Key Fob

/ … with 4,044,032 TPS/i Key Card

/ Card and Fob standard with TPS/i from SN: 2708xxxx

/ All current TPS/i power sources on the market are

/ Functionality is available for all other regions beyond

/ User management will follow

robot programm needs to use them

Edge detection Distance

Function of the power source Information signal to the robot

/ Non consistent parts, due to tolerances

Programmed path Programmed path

Welding seam Welding seam

/ Function: Edge detection

System must be CMT ready:

* If the welding process CMT is needed the WP CMT must be

/ The welding wire as a distance sensor

Edge detection Contour sensing Seam verification

Edge position detection and Sensing of part contours Determination of “a”-dimension

61 Fronius International GmbH / OUTLOOK: WireSense / 2019

/ Edge detection is active when

Signal from power source for the detected

Signal from power source for the edge height

Edge detection V Robot

Wire sense edge detection 3mm (“ON”)

Wire sense start “ON” The edge detection function detects

Wire sense position 0mm