Turning Welding Wire into Sensor

The welding wire as a sensor 

WireSense uses the wire electrode not only for welding, but also for measuring component geometries. Thanks to the high-frequency, reversing wire movement, the system detects precise component and seam geometries, edges, height differences and air gaps – and all without any additional sensor hardware. The benefits of WireSense are particularly pronounced on reflective surfaces such as aluminium, where optical systems such as cameras often fail.

“The measurement is contact-based and works on the basis of a weld-free short circuit being established. What’s more, WireSense is compatible with all standard filler metals,” explains Philipp Schlor, Strategic Product Manager at Fronius International. “The Fronius welding machine – an iWave or TPS/i – detects edges or impacts and transmits this information to the robot controller. This then compares the data with the programmed path and automatically corrects the tool center point (TCP), ensuring that the seam is always welded at exactly the desired location.”

New version, new application possibilities

The new WireSense version now supports all seam geometries: fillet welds, square butt joints, flange welds and complex, rounded shapes. It can also be used flexibly and reliably with materials such as steel, stainless steel, aluminium, and CrNi alloys, making it attractive for significantly more applications – especially for companies that work with varying sheet thicknesses and complex geometries. Even thicker materials of 4 mm and more can now be reliably detected and processed.