Fronius’ WeldCube is suite of data management solutions that enable customers to prepare, train, record, analyse and evaluate welding data across multiple power sources. It is an all-inclusive package that incorporates hardware, software and services and is designed to link directly with Fronius TPS/i, TPS, TS and iWave welding systems.
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Documenting, visualising, collecting and analysing welding data for quality management and traceability purposes are increasingly important in many production operations. Consisting of different hardware and software components as well as corresponding services, Fronius’ WeldCube solutions can help fabricators to produce the high-quality welds that are essential for any critical plant equipment and most welded products, and to generate the documentation needed as evidence.
In addition, welding flaws lead to high rejection rates, which raise manufacturing costs. The earlier these flaws – and the circumstances that cause them to arise – can be identified in the manufacturing process, the quicker the response can be to eliminate them from the components being welded.
WeldCube Navigator
At the starting point of Fronius’ suite of WeldCube options is WeldCube Navigator, a training and familiarisation tool for helping welders to develop and understand the welding requirements of a new welding task or procedure. WeldCube Navigator delivers step-by-step support for the manufacturing process. It provides visualisation of each task in the sequence and defines the pre-set welding parameters that need to be used, which can automatically be downloaded to the welding machines being used. This comprehensive upfront visual support is designed to help minimise the risks of errors and flaws being introduced during welding. Across all the welders in a production site, it also helps to standardise manufacturing processes, increasing consistency and the quality of production.
The Sequencer in WeldCube Navigator takes the welder or welding specialist through a pre-defined step-by-step guide of welding sequences and associated tasks for each given job. These steps – digitally created in the editor by a welding supervisor or engineer – can be displayed on any suitable screen, and the correct welding parameters associated with each weld in the sequence are sent to the power source by the welder via buttons on his Fronius welding torch.
WeldCube monitoring and data analysis
Once welding starts, WeldCube goes into data collection, monitoring and data analysis mode. For safety-critical or multirun welds, the system is constantly monitoring the welding parameters against the requirements of the welding procedure specifications. The system can immediately take corrective action should to these parameters fall outside the specifications. This avoids a part being rejected and minimises – or completely avoids – time-consuming repair work.
WeldCube is also able to halt further welding if there is an indication that a weld seam will be defective if, for example, the gas shielding has failed. This will then require a welding supervisor to inspect the workpiece before the system can be reset and welding resumed.
For seamless integration into manufacturing processes. additional digital solutions in the Fronius WeldCube portfolio add further functionality for the WeldCube and provide optimal support in unleashing welding potential.
Through Central User Management. individual authorisations can be assigned to each user via the authorisation system integrated into every Fronius welding machine. When someone logs in with a key card or fob, the system immediately knows what they are, and are not, allowed to do. A standalone solution in the WeldCube portfolio, Central User Management enables user rights to be defined with just a few clicks, and this can be done centrally so it applies to an individual machine or several systems. The relevant information is automatically sent to all connected systems.
In terms of data management, WeldCube Air is a cloud-based data and documentation solution for centrally recording welding data. Access to this data is available via any device with an internet connection.
At a level above, WeldCube Premium is a central server-based solution that collects the welding data from all connected welding systems in the manufacturing operation. It also offers intelligent management, analysis and statistical functions, as well as graphical visualisation of results and analyses. This means, for example, that an entire component in the process of being fabricated can be visualised live, with its progress being monitored in real time.
Through its Rework Station, WeldCube Premium can also indicate the need for rework action, with the option of setting the status of a seam/component to ‘OK’ following a successful repair.
As an innovation leader for arc welding and the global market leader for robot-assisted welding, Fronius creates advances inspired by its sustainability mindset. “We enjoy long-standing relationships with our customers. Fronius’ strength lies in combining the knowledge of customers with our own expertise to unleash their full welding potential,” says Edric van der Walt of Fronius South Africa.
www.fronius.com/en-za/south-africa
