This news article was originally written in Spanish. It has been automatically translated for your convenience. Reasonable efforts have been made to provide an accurate translation, however, no automated translation is perfect nor is it intended to replace a human translator. The original article in Spanish can be viewed at Cómo aumentar la eficacia energética durante la soldadura

An innovative technique of welding allows to save energy, material and human resources

How to increase the energy efficiency during welding

Source: fronius international gmbh 17/07/2009

July 17, 2009

Energy efficiency has become the main theme of industrial progress. In the field of welding, efficiency requires a few procedures that offer less splashing, a welding speed clearly superior, as well as a puenteado slot considerably improved with a controlled heat absorption. With CMT, LaserHybrid and the procedure of welding DeltaSpot, Fronius offers three Smart practical solutions that provide greater energy efficiency and a rapid ROI (Return on Investment).

In terms of energy saving, for welding are not only relevant electrical characteristic data of the procedure, but also holistic contemplation of the production process. This includes above all the effects of the previous and subsequent steps.

Splashes and blockages in the nozzles of welding cause unstable welding processes, poor performance of welding and frequent interruptions during robot welding, so that the effectiveness is reduced.

Three typical applications

Profitable robot welding requires a work without interruption. However, the robots equipped with systems of welding MAG (metal active gas) conventional have to interrupt the process very often to clean the nozzles of welding splashes. You can here get some significant savings in time, energy and material, as evidenced by Ph. D. Yong joon Cho of Hyundai Motor Company. The change to the CMT procedure not only provides a number of welding splashes considerably minor, but above all a transition from more stable metal and a clearly inferior tendency of the electrode be attached. This only reduces the time of failure of the cells of welding robotic in more than 60% and at the same time, also increases the efficiency of the electrical energy used.

High welding speed, reduced deformation, the formation of splashes clearly reduced, as well as higher quality and security of production, LaserHybrid is also more efficient from the energy point of view.

A bridged slot highest possible reduces work and costs for the previous production steps, as well as the setting of the pieces to be welded. According to Heiko Steinmetz, responsible for the planning of production, area of technology and concepts, technique of processing, Assembly and Assembly of Mercedes Benz, welding LaserHybrid offers considerable advantages for use in large series. From conventional procedures MIG or laser with cold wire feed, you get a three times higher welding speed and a power consumption clearly lower, due to the reduced energy of stretching, and at the same timea more reduced thermal deformation.

High-tech from the idea to the finished product: in the development of new processes, simulations also help to increase energy efficiency.

Conventional welding points, especially in the case of aluminium parts, is characterized by its high consumption of electricity and high wear of electrodes. The consequences are frequent interruptions in the process to change the electrodes and higher costs for the electrodes. DeltaSpot is a system of welding with a Ribbon from process perimeter between the electrodes and the sheets to assemble that protects the electrodes, makes available the new material at the points of contact and reduces energy consumption. The process is flexible and controllable universally, so allows welding continued with a constant quality of pieces of aluminum, different qualities of steel, galvanized metal sheets and an organic coating. Demonstrable quality of the product and higher productivity of the installation, the clearly lower defective products, as well as the savings of energy and material has been made, give rise to a safer and more effective production.