Engineered for manufacturers seeking to quickly deploy an automated solution for medium- and high-volume applications, the ROBBI 360 cobot provides flexibility and user-friendly programming for quick setup and easy adjustments.

The ROBBI 360 manual load/unload turntable features a maximum payload of 150kg per side enabling users to boost productivity by up to 60% compared to cobots with a single loading station. A cobot with a turntable can easily enable an arc-on of 50 to 80%, or a 4X to 8X improvement compared to manual welding.

ROBBI 360 is delivered as a complete “plug and play” package that has been weld-tested before shipping. With the addition of power, shop air, filler metal and shielding gas, it is ready to weld. ROBBI 360 includes a Universal Robots’ UR10e cobot, a 3469 x 2228 x 2628mm cell enclosure for protection, turntable with a 1200 x 800mm work envelope, an ESAB Aristo 500ix or Aristo Edge 500R power source and matching feeder, an integrated fume extraction hood and all electrical and gas connections. The entire assembly is mounted on a skid with fork truck pockets for easy positioning and redeployment. The fully-enclosed workstation has rigid aluminium cell walls and a rugged steel base that ensures no vibration and a stable TCP (tool centre point) that prevents having to make adjustments after moving.

“With its simplicity of ordering, deployment and operation – plus our safety and health features – ROBBI 360 overcomes traditional barriers to welding automation,” says Tom van Dooren, Global Product Manager, Integrated Robotic Systems and Mechanised Solutions, ESAB.

“The ESAB Teach Tool uses a ‘no code’ or plain language program so users can effortlessly incorporate a multitude of functions that enhance performance and productivity. There is no need for a robot programmer on staff, which is often the case with small- to medium-sized operations. I like to say, ‘If you can count to three, you can program me.’ Users can easily program each side of the turntable to weld different parts!”

Safe and sturdy

ROBBI 360 provides a controlled welding environment with UV and infrared protection, integrated fume extraction hoods, noise reduction and dust and debris trays. Walls contain dark green inactinic polycarbonate DIN 5 see-through glass to protect against light from the welding arc. Pressure sensors are located throughout the Cobot arm for crash protection. Safety interlocks ensure the Cobot will not operate if the table is not correctly locked or if the doors are open. As an option, users can add ESAB’s WeldQAS automatic weld monitoring system.

Power source options

The Aristo Edge 500R power source and RoboFeed Edge robotic wire feeder offer next-generation process control and wire feeding capabilities. Aristo Edge 500R ensures precise arc starts and enhanced stability across four advanced WeldModes – THIN, ROOT, ROOT Pipe and SPEED – as well as an Advanced Pulse WeldMode. All WeldModes enhance arc stability, offer more control at faster travel speeds and reduce spatter for less post-weld clean-up. The Aristo Edge platform also empowers independent development of synergic lines and process updates.

The Aristo 500ix, paired with the RobustFeed wire feeder, delivers proven reliability in the toughest industrial conditions and features pre-programmed synergic lines for MIG and pulsed MIG applications using most welding alloys.

“The ROBBI 360 cobot and Tracfinder mechanised tractors overcome traditional barriers to welding automation, especially among small- to medium-sized enterprises,” says Tom van Dooren, Global Product Manager, Integrated Robotic Systems and Mechanised Solutions, ESAB.

“They deploy quickly and easily, feature operator-friendly controls, do not require robotic programing knowledge and are suitable for high-mix/low-volume and medium- to high-volume production runs. ESAB automation solutions enable fabricators and manufacturers to leverage the talents of existing staff to increase output per employee while also improving the operator’s working environment.”

ROBBI 360 Cobot

ROBBI 360 is delivered as a complete “plug and play” cobot package that has been weld-tested before shipping. Connect power, shop air, filler metal and shielding gas, and it is ready to weld. 360 includes a Universal Robots’ UR10e cobot, a 3469 x 2228 x 2628mm cell enclosure for protection, turntable with a 1200 x 800mm work envelope, an ESAB Aristo 500ix or Aristo Edge 500R power source and matching feeder, an integrated fume extraction hood and all electrical and gas connections.

The entire assembly is mounted on a skid with fork truck pockets for easy positioning and redeployment. The fully-enclosed workstation has rigid aluminium cell walls and a rugged steel base that ensures no vibration and a stable TCP (tool centre point) that prevents having to make adjustments after moving.

ROBBI comes with two welding options. The Aristo Edge 500R power source and RoboFeed Edge robotic wire feeder ensure precise arc starts and enhanced stability across four advanced WeldModes – THIN, ROOT, ROOT Pipe and SPEED – as well as an Advanced Pulse WeldMode. All WeldModes enhance arc stability, offer more control at faster travel speeds and reduce spatter for less post-weld clean-up. The Aristo Edge platform also empowers independent development of synergic lines and process updates. The Aristo 500ix, paired with the RobustFeed wire feeder, delivers proven reliability in the toughest industrial conditions and features pre-programmed synergic lines for MIG and pulsed MIG applications using most welding alloys.

A combination of macroeconomic and operational factors makes robotic retrofitting an increasingly attractive option. The global shortage of skilled welders continues to constrain production, as manufacturers struggle to maintain output with a shrinking labour force. According to the American Welding Society, an additional 320,500 welding professionals will be needed by 2029, while more than 157,000 current welders are nearing retirement.

At the same time, customer expectations for consistency, traceability and defect-free performance are rising – particularly in highly-regulated sectors such as automotive, aerospace and defence. Meeting these expectations using manual processes alone is becoming less feasible.

Retrofitting enhances existing workstations by integrating automation, allowing manufacturers to preserve their current layout and infrastructure while significantly boosting performance. This strategy enables cost-efficient gains in weld consistency, capacity and throughput – all without expanding physical space or personnel.

Rather than replacing entire production lines, robotic retrofitting modernises manual stations with advanced capabilities. For manufacturers managing a hybrid landscape of legacy equipment and next-generation production goals, retrofitting represents a logical step toward Industry 4.0 integration.

Identifying automation readiness

Knowing when to retrofit is crucial. Many signs are already present on the shop floor: inconsistencies in weld quality linked to operator fatigue or shift changes, rising rework and scrap rates, or frequent downtime in high-mix environments. These inefficiencies often signal readiness for automation.

Increasing product complexity can also push manual methods to their limits, particularly when precision geometries or tighter delivery windows are involved. In these cases, the inability to scale consistently and predictably becomes a strategic liability, directly impacting margins and competitiveness.

A robotic retrofit typically integrates a programmable robotic arm into an existing manual welding cell, accompanied by peripheral technologies such as rotary or tilt positioners, seam-tracking vision systems and programmable logic controllers (PLCs) to manage weld paths. Many setups now incorporate real-time sensors and closed-loop feedback systems that adjust weld parameters – such as current, voltage or torch speed – on the fly to maintain weld quality even on variable joint profiles.

One of the key advantages of modular systems such as Tezmaksan’s CubeBOX Welding Pro is their ability to adapt to diverse part geometries and cell configurations. This flexibility is critical in facilities with frequent changeovers or low-to-medium volume production.

Addressing common misconceptions

Despite increasing adoption, robotic welding retrofitting is still slowed by persistent misconceptions. One outdated belief is that automation is only viable for high-volume, repetitive work. In reality, modern platforms support rapid reprogramming, dynamic tooling and multi-part workflows – making them cost-effective even for job shops and contract manufacturers.

Another concern is workforce displacement. In practice, automation reshapes roles rather than eliminating them. Skilled welders transition into programming, process optimisation and quality assurance – functions that rely heavily on their technical knowledge and ensure the long-term success of automated systems.

Cost is also often perceived as a barrier. However, retrofitting is significantly more accessible than greenfield automation, as it leverages existing infrastructure. Furthermore, regional government grants and tax incentives aimed at boosting industrial automation can offset some of the upfront investment.

Quantifiable outcomes

Robotic retrofitting delivers both immediate and long-term performance improvements. Once deployed, these systems achieve highly repeatable results with minimal deviation, often within sub-millimetre tolerances. This consistency dramatically lowers rework rates and improves first-pass yield.

With higher arc-on times than human operators and no fatigue, robotic welders sustain output across shifts and even enable lights-out manufacturing. Integrated data capture allows manufacturers to track weld metrics in real time, contributing to traceability, predictive maintenance and audit compliance – and this is particularly valuable for facilities seeking ISO certification.

Precision heat input, enabled by stable travel speeds and dwell times, reduces distortion in thin or complex components. Over time, improvements in scrap rates, labour efficiency and production uptime yield a strong return on investment.

While retrofitting offers compelling advantages, it demands careful technical planning. Spatial constraints may dictate robot arm size, reach and safety enclosure placement. Electrical infrastructure must be assessed to ensure capacity for high-duty welding operations. Operator training is equally important – modern interfaces are user-friendly, but onboarding remains critical to ensure safety and performance.

Software integration is another key consideration. When connected to MES or ERP platforms, robotic systems enable synchronised scheduling, real-time analytics and closed-loop quality control – all essential features for modern manufacturing.

Robotic retrofitting is not about replacing everything – it’s about evolving intelligently. By modernising existing assets with modular, adaptive automation, manufacturers can incrementally transition toward smart, connected production systems without wholesale disruption.

For companies looking to enhance quality, boost efficiency and future-proof their operations, robotic retrofitting is no longer a speculative investment, it’s a technically validated and economically sound solution.

Having been used to great success in the automotive industry for several years already, WireSense can now be used in the construction and agricultural machinery sector, commercial transportation and the metalworking industry or the first time. More versatile than ever before, WireSense delivers impressively accurate results with all common seam geometries, including in steel and container construction or on chrome-nickel components.

Despite the great care taken in industrial production with robot welding systems, inaccuracies still occur due to clamping tolerances or upstream processes. A challenge for companies and robot integrators alike, Fronius has created a pioneering solution with the WireSense robot assistance system.

WireSense turns the welding wire into a sensor to precisely determine the position of the component, making it possible to react precisely to positional deviations and correct weld paths accordingly. Rework and component rejects are thereby reduced to an absolute minimum.

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 centre 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.

WireSense is a prime example of the transition to intelligent manufacturing. It offers a number of advantages that benefit system integrators in particular:

• Precise position measurement even with difficult component accessibility
• Reliable weld quality, process security, and repeat accuracy
• Detection of sheet thicknesses from 0.5 mm
• Evaluation of gap sizes for automatic selection of stored welding parameters
• Reduction of rework and rejects by up to 100%
• No additional sensors: no cameras, calibration, or maintenance required

The assistance system requires a CMT-Ready setup consisting of the Robacta Drive CMT drive unit and the corresponding CMT wire buffer as well as the WireSense software package (the CMT software itself is not required). It is integrated via the Fronius welding machine, which transmits the sensor signal to the robot controller at lightning speed. Fronius works closely with robot manufacturers so that all the most common robots can process WireSense signals without issue.

A free software update will be all it takes to enjoy all the new features from mid- 2026. Tip: An update may also be needed for the robots too – please contact the robot manufacturer for more information.

“Many of our customers are already using the hardware, i.e., the Robacta Drive CMT drive unit, but not yet WireSense. Now is the perfect time to exploit the full potential of this powerful solution,” emphasises Schlor. “WireSense is a software-only feature, which in this case can be activated without additional components to extract the maximum benefit from an existing investment.”

Visitors to the world’s leading trade fair for joining, cutting and surfacing will be able to see how the Panasonic TAWERS G4 Welding Robot System – two-years on from launch – continues to break new barriers in automated welding control and quality across a variety of different processes and industry requirements.

The Panasonic TAWERS G4 Welding Robotic System is the latest evolution in integrated welding solutions, combining advanced robot control and power source technology in one seamless system. Designed for maximum precision, speed and reliability, it delivers outstanding weld quality with reduced spatter and cycle times. The intuitive interface, real-time data feedback and enhanced adaptability make it ideal for high-mix, high-volume production environments. Additionally, the simplified programming of the TAWERS G4 helps manufacturers boost productivity, improve consistency and reduce operating costs.

New automated welding processes using the TAWERS G4 on show at the Panasonic booth include live demonstrations of its Argon-Rich Low-Slag welding process for mild steel. This delivers exceptionally clean, high-quality welds – saving time, reducing costs and boosting productivity. By using a stable, argon-rich shielding gas mix and precisely controlled automation, the TAWERS G4 ensures consistent, low-spatter results without the need for a special wire. It’s ideal for high-throughput manufacturing environments and is a powerful solution for customers looking to improve weld quality and efficiency across their production lines.

Panasonic’s second live demonstration will debut its new TAWERS AC TIG welding process for aluminium. This process combines precise waveform control with high welding speeds, made possible by the pre-heating of the filler wire. The result is visually flawless, spatter-free welds with minimal distortion – ideal for applications like bicycle and motorcycle frames, furniture manufacturing, tank construction and the offshore industry. Customers benefit from precise heat input, excellent corrosion resistance and consistently high weld quality.

Panasonic’s third live demo showcases its latest development in aluminium welding: the Pulse Mix Process with Twin Harmonized Software, using two TAWERS WG4 AWP robots. This new solution introduces synchronised dual-robot welding, where one robot leads and the other follows – cutting production time by up to half. With just one teach pendant, operators can program both robots simultaneously, making the system highly user-friendly and efficient. The combination of Pulse Mix welding and push-pull torch technology ensures beautiful bead appearance, minimal spatter, no burn-through and precise heat input control – all at high speed. This system is ideal for aluminium and steel welding in industries where tact time and throughput are critical, such as automotive and industrial manufacturing.

Visitors will also see a brand-new solution for thick aluminium plate welding, featuring a TAWERS WGH4 robot with a DK-positioner in a fully automated cell. For the first time at a live show, Panasonic will demonstrate welding 16-22mm thick aluminium plates using a 500A power source and a pull torch with high penetration – without using Helium. This is a major step forward in aluminium welding capabilities: in addition to cost savings, a reduced environmental impact provides significant benefits. This system enables the automated, cost-effective welding of heavy materials with consistent high quality and reduced labour costs. Ideal for demanding sectors like offshore and shipbuilding, it expands the welding range for manufacturers looking to tackle large, structural components.

Panasonic’s fifth welding innovation on show will be a new Zi-Tech process, focusing on Automotive underbody parts. This new Zi-Pulse process offers a breakthrough in tackling the well-known challenges of welding zinc-galvanized plates. Through precise process optimization, Panasonic has significantly reduced porosity, burn-through and weld defects – delivering cleaner, stronger welds with minimal rework. The result: higher production quality, greater efficiency and lower labour and material costs. Ideal for the automotive industry, especially for underbody parts, this solution ensures production meets even the most demanding quality standards.

And the final showcase at the event is the debut of Welding Navigation Plus, an enhanced software feature designed to make robotic welding simpler, smarter and more accessible. Building on the original Weld Navi tool, which automatically sets optimal welding parameters based on material thickness, A-dimension and speed, Weld Navi Plus goes further – allowing users to easily adjust penetration depth and weld geometry for even better results. The system is ideal for industries facing skilled welder shortages, as it enables high-quality, consistent welds without the need for prior welding or programming experience. Everything is handled through the TAWERS Teach Pendant, eliminating the need for external devices like PCs or third-party software. With just one short training course, users can operate the robot, manage welding parameters and control the full system – all through a single, cost-effective and user-friendly interface. This is Panasonic’s “just weld it” approach: all-in-one, intuitive automation that puts welding excellence within anyone’s reach

Sergio Maeda, Department Head for Robot and Welding at Panasonic Factory Solutions Europe, said: “Visitors will see first-hand the next wave of welding innovation with these new processes and software enhancements – all designed to deliver cleaner, faster and more consistent welds across a wider range of materials and applications. It’s more reasons why so many manufacturers are now upgrading to the TAWERS G4 platform or switching to Panasonic for the first time: unmatched weld quality, fully integrated systems, user-friendly operation and the power to future-proof their production.”

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The highly intuitive and streamlined design of MyCo cobots allows seamless integration into dynamic environments, making them ideal for warehousing, intralogistics, packaging, arc welding and light assembly – key sectors identified as part of Comau’s ongoing diversification strategy.

The robust yet lightweight construction supports easy relocation and redeployment, while the IP66 protection ensures reliable performance even in demanding conditions. The new cobots are also fitted with advanced safety features, six degrees of freedom and best-in-class precision with intuitive programming capabilities. The six distinct models feature payloads from 3-15 kg and a reach between 590mm to 1300mm.

In addition to expanding its vast robotics portfolio, the new MyCo robot family embodies Comau’s ongoing commitment to delivering highly accessible and easy to use automation for a wide spectrum of industries. By leveraging its extensive industrial robotics expertise and cutting-edge technology, Comau is bringing its powerful automation solutions to a broader array of industries and in doing so, is helping companies of all sizes reduce integration complexity and improve productivity.

Comau’s vision for collaborative robotics gives an industrial perspective to human-robot collaboration, emphasising the critical role of incorporating application and process know-how within the design parameters. More importantly, Comau’s comprehensive robot portfolio grants customers access to the best choice between industrial, collaborative or a combination of the two robots, for their particular needs. All this is further complemented by Comau’s vision systems and IoT expertise, as well as its strategic partnerships with leading end-effector brands.

“With the launch of our new MyCo robot family, Comau is taking yet another concrete step in accelerating our powerful diversification strategy,” said Stefania Ferrero, Chief Marketing Officer at Comau. “We estimate that the global collaborative robotics market should see a CAGR of 15% (2024 to 2028). This is fuelled by a growing demand in non-traditional sectors such as food & beverage, pharmaceuticals, renewable energy and logistics, in addition to the increased adoption by small and medium-sized enterprises. MyCo is a cost-effective and versatile response to these trends, as each of the six models allows us to deliver a highly flexible, user-friendly, and transportable solution that supports safe and efficient operations in dynamic environments.”

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This will enable manufacturing sub-contractor, Grovinvest, to vastly increase flexibility and automation in the production of specialist medical equipment for customers across Europe.

First deploying previous iterations of Panasonic’s robot cells in 2009, with a subsequent upgrade delivered in 2014, the upgraded production line at Grovinvest’s northern Romania facility enables it to seamlessly manufacture four variations of Haelvoet’s medical bedframes. With all required components automatically detected prior to production starting, Panasonic’s TAWERS G4 Welding Robot System delivers the required welding precision and speed, whilst minimising ramp-up time.

Panasonic’sintegrated TAWERS G4 Welding Robot System optimises welding process management into a single controller for high-speed, high-quality arc welding. It features increased controller processing speeds, and optimised communication between the controller and the robot. When compared to previous models, the G4 is more reliable and smaller, saving space and costs without compromising reliability.

Furthermore, the G4′s teach pendant touchscreen simplifies programming on the production line, whilst consumables – such as contact tips – last longer than previous models. This reduces the need to keep excessive spares, and minimises maintenance downtime.

The G4 also features offline programming software, enabling remote digital access to real-time production and system operating data. This enables Grovinvest’s engineers to re-programme all or some of the parts of the welding process while the robot is still running.

Bogdan Pienaru, Managing Engineer of Haelvoet contractor, Grovinvest, comments: “Regardless of the size of components used, Panasonic’s G4 instantly starts the required manufacturing program instantly – saving valuable time when switching between manufacturing programs. The welding quality provided by the G4 is superb; Panasonic continues to set the standard in welding precision, speed, and accuracy. Overall, our upgraded production line, and the service provided by Panasonic and SYN-TIG, has been excellent.”

The system features a rail-traversing wagon mounted by two FANUC robots which detect internal and external defects. The robots then perform fully automatic repairs using welding, milling and grinding processes. Robel Rail Automation is already seeing high demand for the system, particularly in the case of time-consuming and complicated repair work of points, as rail companies are finding it increasingly challenging to secure skilled workers such as welders.

In addition to carrying out continuous maintenance work safely and efficiently, the use of FANUC robots in the Robel Rail Automation System ensures consistent quality and a high level of traceability, thanks to wagon-mounted ultrasound equipment, eddy current measuring systems and a camera system. This covers damage that is not visible to the naked eye and ensures measurement and process data is digitally available to the end-user.

Both FANUC and Robel Rail Automation are optimistic about the future use of robots for infrastructure maintenance, as there is a need for modernisation across both the rail and road networks. Robots can help to speed up the completion of lengthy maintenance projects by taking over repetitive work and least partially compensating for the growing labour shortage.

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The rotation of the J3 axis is 395° and is supported by a payload of 500kg, a reach of 2,830mm and an ultra-strong 3-axis wrist with high torque and high inertia. The high strength and versatility of the FANUC M-950iA/500 makes it particularly suited to the automotive industry, for applications such as handling large castings (for example engine blocks, EV batteries or car body panels), as well as friction stir welding, drilling and riveting.

Process flexibility comes courtesy of the robot’s J3 arm, which can stand above and rotate backwards of the robot itself. The J3 axis rotation of 395° is 75% greater than the 224° offered by the comparable M-900iB/360 parallel-link robot. A larger operating area therefore means the new robot can be operated in various layout configurations in line with specific customer requirements.

In addition, FANUC’s iRVision fully-integrated visual detection system and various intelligent features make it easy to diversify between different product lines.

The three main axes (J1-J3) of the M-950iA/500 move at up to 100° per second thanks to FANUC’s AC servomotor drive system, making it a fast and strong option for heavy part lifting, heavy palletising/packaging and demanding material handling operations. Positioning accuracy is ±0.08 mm and a FANUC Accuracy and Stiffness Enhancement Option is also available for applications that require even higher precision or where external forces are likely to impact the robot.

In addition to the user-friendly FANUC iPendant as a teaching device, the M-950iA/500 connects to the company’s R-30iB Plus controller with FANUC iHMI set-up guides for programming and large memory capacity.

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Welding remains a vital joining process in the metalworking industry and it requires in-depth specialist knowledge and skill. Despite the attractive salary, the number of young people taking up this profession continues to decline, as it is often regarded as unappealing, harmful to health, and dirty. This is where cobots come in.

Today there are several types of cobot (collaborative robot): mobile individual workstations or fully enclosed one or two-station solutions. A diverse range of technical equipment is available, including robot tracks, turn/tilt positioners, automatic extraction systems, and safety doors. High-tech welding machines, processes, and software solutions for offline programming frequently form part of the standard equipment now.

Times have changed and welding is increasingly becoming a high-tech profession. As well as increasing productivity in commercial and industrial enterprises, welding automation will counteract the growing shortage of skilled workers and make the profession cleaner, safer, and more appealing. The career ladder for welders is now high and ranges from a welding specialist to an International Welding Engineer (IWE).

The major advantages of cobot welding systems

Even the best welding professionals can’t produce welds around the clock with a consistent level of quality. Cobots, on the other hand, master this task with ease, and guarantee 100% reproducible, identical welds.

Equipped with modern welding machines from Fronius, such as the TPS 400i CMT or the Multiprocess version iWave 400i AC/DC CMT, a wide range of metals can be welded, including steel, stainless steel, aluminium, copper, and titanium. Innovative Welding Packages, such as Low Spatter Control (LSC), Pulse Multi Control (PMC), or the world-famous Cold Metal Transfer (CMT) can also be used.

The LSC function produces a modified, low-spatter dip transfer arc with an increased deposition rate. PMC offers an optimised pulsed arc, with stabilisers for penetration and arc length ensuring the best welding quality and high welding speeds. CMT combines a new type of droplet detachment with a reversing wire motion, whereby the heat input is lower than with a conventional dip transfer arc. This makes the process particularly suitable for thin sheet welding.

“One of the major advantages of cobot welding systems, especially the Fronius systems, is how easy and intuitive it is to program the welding processes. This makes it much easier to get started with automated welding,” emphasises Christian Neuhofer IWS, Product Manager at Fronius International.

Three steps to the welding program

To program an industrial robot, you need both welding experience and sound programming skills. It’s a completely different story with cobots. With Fronius systems, you simply grab the welding torch, guide it to the starting point, select the right welding torch position, and press the save button on the control handle. Then you set the contour points along the welding sequence to the end point. These points are saved at the touch of a button and form the welding path. Once this has been created, the welding process is programmed – intuitively via drag and drop – using the graphical user interface of the teach pendant.

“Compared to programming industrial robots, cobot teaching requires hardly any training for the majority of applications. Welding specialists in particular, who are used to working with touchscreens and have some computer skills are able to weld their first components after just a few hours,” explains Neuhofer.

Valid welding parameters from your smartphone

Thanks to the practical WeldConnect app, welding specialists have a personal parameter manager at hand at all times. The innovative online welding assistant offers professional support in selecting suitable welding parameters. These can be saved as a job and transferred to the cobot system’s welding machine via NFC signal so welders can get started with welding straight away.

The WeldConnect app can store numerous jobs, which can be accessed at any time. Young welding specialists in particular, who are used to using smartphones, appreciate the app, as it provides reliable welding parameters for a wide range of tasks. Together with the WeldConnect app, cobots are helping to alleviate the shortage of skilled workers and make welding an appealing career choice again.

Mobile and flexible use: the CWC-mobile from Fronius

The mobile cobot system offers an intelligent combination of mobility, advanced welding technology, and outstanding value. It makes it easier for smaller workshops, in particular, to introduce automated welding technology. Thanks to retractable transport rollers, the system is also suitable for welding larger components. “Those who need to weld larger items such as excavator buckets can push the CWC-mobile to the ready-to-weld component with ease,” says Neuhofer, highlighting the versatility of the system.

In addition to its flexibility when welding, the CE-certified cobot system offers no-compromise safety: the power and torque limiter for the articulated arm, mobile welding fume extraction, movable glare shield, and standard-compliant personal protective equipment (PPE) – consisting of puncture-proof gloves, welding helmet and protective clothing – protect against illness and injuries. This means the CWC-mobile fully meets the requirements of the European Machinery Directive; the precondition for CE certification.

Single and dual systems

With the CWC-S and the CWC-D, Fronius offers two fully enclosed cobot welding cells for one- and two-station operation. Just like the CWC-mobile, both systems feature the latest welding technology.

The CWC-D two-station solution is ideal for welding components with a length of up to 3 metres. If you remove the central partition wall that is screwed to the welding table, this creates an extended work surface of 3,000 x 1,000 x 600 mm for one-station operation.

“With two-station operation, the system enables welding to be carried out in parallel to setup and is ideal for small-series production of components with a maximum side length of 1.5 meters. While welding is being carried out on one side, the other side can be equipped to increase productivity. Both stations can weld components weighing up to 2 tons,” explains Neuhofer.

The smaller, compact CWC-S has been specially developed for components that are no wider than 1.5 meters. Turn and turn/tilt positioners are available for both the CWC-S single system and the CWC-D dual system for circumferential welding of cylindrical components. The turn positioner is optionally available with a tailstock on the longitudinal axis. The Coordinated Motion software option, which is available for all positioners, enables the welding torch and positioner to move in sync. The Robacta Reamer V torch cleaning station is available in the range as an accessory.

Bringing together cobots and welding robots

The fully enclosed Fronius cobot welding systems CWC-S and CWC-D enable seamless changeover from cobot to robot mode. In this mode, the power/torque monitoring and the speed limiter of 250 mm/s are deactivated, allowing speeds of up to 2 m/s to be reached. If programming is performed with the iPendant robot controller, in addition to high articulated arm speeds, more complex movement sequences can also be carried out and devices can be controlled in robot mode. This allows the full potential of the systems to be unleashed, giving a significant boost to productivity.

Cobots are an ideal way to get started in the world of automation. They enable the robot’s workings to be understood through manual teaching and the kinematics to be learned without a high risk of injury. Welding specialists benefit from better understanding of the kinematic processes, which is an advantage, especially when starting to work with robotic welding later on.

Increase productivity with offline programming

With the Fronius Pathfinder offline programming software, welding processes can be programmed independently of the cobot welding system, without any interruption to ongoing production. Unlike manual teaching, the software enables welds to be copied and mirrored, scanning processes to be created, and complex movement sequences to be simulated.

This minimises downtime and increases productivity by up to 80%, especially for complex component geometries. As soon as a program has been created, it is transferred to the welding cell and manually adjusted if necessary. Another advantage of Fronius is that the software and welding system come from a single source and work perfectly together.

High level of safety with Fronius cobots

Fronius worked with an external safety inspector to carry out a series of intensive safety tests, which delivered impressive results. These tests included attempts to pierce a glove with wire – unsuccessfully. The impact force of the gas nozzle and the edges of the torch holder were also measured and lie safely within the defined limits. Of particular note is the fact that the water-cooled welding torches are lukewarm within seconds, effectively minimizing the risk of burns. All these results confirm that Fronius products meet the highest safety standards and ensure maximum safety.

The path to automation with Fronius

Fronius is there for its customers right from the start and offers customised automation solutions, ranging from simple systems to complex applications.

“As a general contractor, we help our customers select the ideal solutions for them, whether that be cobots, welding robots or mechanised systems such as welding carriages, circumferential and longitudinal seam welding systems, seam welders, or orbital systems,” concludes Neuhofer.

“Our advice doesn’t stop once you’ve made a purchase. We also support our customers during commissioning and have a global service network to provide rapid, reliable help with any problems. This ensures our customers benefit from a high level of efficiency and safety with their welding processes.”