Versatility and Flexibility During Automated Welding

Versatility and flexibility during automated welding

Excellent weld appearance, targeted heat input, reproducible ignition – these are just a few of the characteristics the Fronius iWave features when used in robot applications or as the core element in automation systems. The all-rounder is now available in power categories 300i, 400i, and 500i, each as a DC or AC/DC variant, and with water or gas cooling as required. With dynamic wire control, this system is a 2-in-1 solution for future high-end TIG and MIG/MAG welding.

Whether in rolling stock construction, production of automotive parts or container and pipeline construction, the iWave increases productivity in TIG welding in industrial manufacturing and delivers weld quality for every material. Innovative technologies ensure targeted heat input, significantly improved ignition and maximum control over the arc. The CycleTIG process variant, for example, is an appropriate solution whenever an excellent weld appearance with fewer temper colors is crucial. Control over the weld pool and precise heat input are particularly beneficial when working with very thin sheets or when delicate corner and butt welds are on the agenda, as well as for repairs involving edge applications. The extremely stable ignition behavior due to the high-frequency (HF) ignition during TIG welding is another mentionable feature. The RPI auto setting ensures fast and reproducible ignition regardless of the material properties and the tacking function causes the weld pool to oscillate, which can reduce the time needed for tacking by up to 50 %.

Air gap bridging of up to 30 % thanks to automatically controlled wire speed

“Equipped with the patented Fronius TIG DynamicWire Welding Package, the iWave is taking cold wire TIG welding to a whole new level,” emphasizes Paul Hofer, technical product manager at Fronius International GmbH. “The innovative advantage over conventional continuous wire feeding is the dynamic wire control, which always supplies the exact amount of wire needed at the time. This means the iWave actively adjusts the wire speed to the conditions and can easily compensate for air gaps of up to 30 % in relation to the material thickness.” With TIG DynamicWire only one parameter needs to be defined, such as the welding current, and all other values are automatically determined based on the material's specific characteristics. All existing iWave cold wire systems can be expanded to include TIG DynamicWire at any time by simply upgrading the software.

Multiprocess PRO

“You never know what your welding work will involve in one, two, or five years,” Hofer points out. “The iWave Multiprocess PRO is flexible and adaptable. No matter what welding requirements you come across in the future, it will always be easy to individually expand your iWave’s range of applications.” In addition to all the high-tech TIG functions, it provides you with access to the full scope of process variants from the MIG/MAG range and even enables AC/DC welding for the first time. The range of modular welding packages is huge and includes Standard, Pulse, PMC (Pulse Multi Control), LSC (Low Spatter Control), CMT (Cold Metal Transfer), PMC AC, and CMT AC—the iWave even has the perfect characteristic for additive manufacturing. 

Switching TIG and MIG/MAG in a single step

Equipped with suitable peripheral components, such as a welding torch and wirefeeder, a single high-tech welding machine becomes a universal all-rounder while taking up minimal space. Users can switch between processes manually or this can be automated with the appropriate equipment. The user interface also changes automatically and clearly displays the main parameters required in each case. Another highlight is the new hosepack with its own torch coupling, which allows the corresponding torch body to be replaced quickly without having to change the entire hosepack.

Full connectivity, security and transparency

The iWave is equipped with the most important communication standards, e. g., WiFi, Bluetooth and Ethernet, and meets the highest requirements when it comes to cybersecurity. Peripheral devices or remote controls can be connected wirelessly and thanks to WeldCube Premium’s central data documentation, transparency and control are gaining traction in welding production. Potential savings can be determined based on the welding data obtained, for example, in relation to material, energy and gas consumption, to make production more resource-efficient.

(Souce: Fronius International GmbH Press Release)