energy - Fronius

WELDING TECHNOLOGY MAGAZINE
N° 26 – April 2011
ENERGY:
Everything flows
RESPECTFUL: That’s the Fronius approach to that vital raw material, energy
PROBLEM-SOLVER: CMT Advanced welds most difficult seam ever
LOOK-AHEAD: Klaus Fronius’ ‘energetic’ vision of the future
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A few words on our cover picture:
The quintessential emblem of ‘energy’: a
red-hot flow of lava welling up from deep
inside the earth. Unimaginably hot and
inexhaustible. Maybe geothermal energy –
that is, generating power from terrestrial
heat – will be one of the future replacements
for our declining reserves of fossil fuels.
3-6
Cover story
All the way from the Big Bang to free energy
7-11
Totally R&D
At full power – in energy-saving mode
Robacta TX changes torch bodies all on its own
Wirefeed hose on rollers
12-13
Brief and to the point
News from Fronius
14-19
Case studies
CMT Advanced rises to the challenge of aluminium
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2
Editorial
10 times the service life thanks to Contec
Steel for ski-jumpers
20-21
The company
22-23
Travel Tip
Energy turning-point in sight
Mexico’s ‘city of angels’
Everything
flows
ENERGY IS WHAT DRIVES
ALL LIFE, AND ALL GROWTH,
ON OUR WHOLE PLANET.
Everything flows. This
classical quotation attributed
to the Greek philosopher
Heraclitus originally described
his doctrine of the “unity of
opposites”, but can also be
applied to the all-embracing
subject of energy. Energy is
life. When everything is in
motion and in flux, there also
has to be energy all the time
and everywhere. For motion
is energy. The question
that springs to mind here is
this: Is energy visible and
measurable in every case?
What about ‘life-energy’; what
about the inner drive that
often impels us to achieve
the extraordinary; what about
free energy? Read on and get
a fresh ‘take’ on the subject
of energy, from the Big Bang
to the underrated electrical
pioneer Nikola Tesla, and from
Tesla to spectacular visions.
Fronius 2011
Cover story
3
‘Energy’ is older than human history –
came into being from an unimaginably
from an energy source, we today are still
obviously, as without it, our universe
dense and hot state in the Big Bang.
connected to all things, meaning that
wouldn’t exist in the first place. There is
Whatever happened in the first few
we all have access to one and the same
also a direct link between ‘energy’ and
seconds after this ‘explosion’, it must
‘field’ – with all the many very different
the development of mankind and human
have expanded at infinitely high speed
consequences that can be drawn from
civilisation. At the beginning of man’s
across infinitely huge space. This
this. The question that springs to mind
harnessing of energy, there was fire. In
infinitely hot universe consisted of
here is how energy of this type affects
Heraclitus’ time, man was already using
nothing but ‘primordial force’ – of pure
us, and whether it is really there at all if
the energy of the strung bow, baking
energy, then. That, at any rate, is the
we can’t even see it.
bread and firing pottery. People knew
modern-day astrophysical creation myth.
about energy from water, the sun and
And there’s plenty of this primordial
other celestial bodies, the Chinese were
force still around. Both out in the cosmos
already using natural gas, and magnetism
and down here on Earth. Even though
was no longer unknown. The further
the Earth’s crust has cooled, deep down
Let’s take an example from nature,
you move along the time-axis towards
inside there is still hot, pure energy. This
the waterfall. In a waterfall, the water
the present day, the faster you see
gigantic force also makes itself felt in
releases kinetic energy. This is a well-
developments in this field taking place.
the sun, in volcanoes, and in tectonic
known phenomenon that can be both
What is this force that drives us all?
shifts. Not surprisingly, this elemental
measured and put to good use. In
energy has given rise to many and varied
waterfalls there are other forces at work
speculations. Not only in the realm
as well, forces which are nowhere near
of physics, then, but also in various
as well-known, even if some of them
As the most widely-held theories have it,
spiritual doctrines, we find indications
have already been studied. Whatever
some 15 billion years ago our universe
that because everything came into being
factors may play a role here, the fact is
Big Bang
4
Cover story
The waterfall as
an energy source
© www.shaolin-moenche.de
that waterfalls give off a finely atomised
calorific units, or whether other ‘energy
instinct – an important Darwinian
mist which not only cleans and heals the
sources’ such as calm, meditation,
selection principle. This touches not only
respiratory tract but also strengthens
nature etc. are also needed.
upon psychology, but also upon biology,
as for example in stress situations
the psyche. This is another side of the
all-embracing topic of ‘energy’ that is
Bundling energy
the body secretes measurably higher
quantities of hormones which enable us
not easy for everyone to understand.
Colloquially, people talk about “boosting
A fine example of a holistic approach to
to rise to unusual challenges. What this
their energy”, “vital energy”, “devoting
using energy is given us by the Shaolin
means is that nature (in this case the
energy” to something, “energy fields”,
monks. Their Shaolin Kung Fu is not
human body) makes sure that for certain
“tapping energy” and so on. Does this
so much a martial art as a lifestyle
tasks and at certain times, we have more
intangible, inexplicable energy not also
philosophy. Watch a Shaolin monk
energy to draw on. This state of affairs
touch upon the same energy source from
fighting, and you’ll probably conclude
cannot continue for long, of course,
which we all originate, the elemental
that he must possess superhuman
otherwise man would have been turned
energy of the Big Bang? All sorts of
abilities. The secret lies in his thinking
into a ‘perpetuum mobile’ – a provocative
scientific attempts have since been
and his consciousness, which enable
term often heard in connection with
made to establish this, but it would go
him to control and direct energy in the
notions like ‘free energy’ or ‘space
beyond the scope of this article to look
right way. We experience something
energy’. Concepts which do not exist in a
into these any further. The fact is that
similar ourselves, albeit not to this
scientific sense, but have long existed in
mankind constantly consumes energy
degree of perfection, when we set
some people’s heads. Nikola Tesla’s, for
and must keep on feeding energy into
ourselves an important goal and mobilise
example.
the system in order to sustain it. The
all our strength (that is, all our energy)
question is whether this energy input
in order to achieve it. This motivational
can only be in the form of measurable,
energy represents our natural survival
Fronius 2011
Cover story
5
Nikola Tesla, energy genius
of his revolutionary ideas. One such idea
age there are countless projects – many
was that of looking for ways to harness
of them spectacular and visionary –
Born in 1856 in what is now Croatia,
this energy. In a lecture given to the
for generating energy from alternative
Tesla is often referred to as a forgotten
American Institute of Electrical Engineers
sources. Two final examples will show
genius. He was a notable inventor in the
in 1891, Tesla is alleged to have said:
what the future might have in store for
field of electricity. It is to his colossal
“Throughout space there is energy (...).
us: A German physicist is pursuing
creative powers that we owe many
If kinetic – and this we know it is, for
a fantastical plan and underpinning
crucial inventions, among them the
certain – then it is a mere question of
it with hard data. A 125 km 2 patch of
discovery of alternating current, which
time when men will succeed in attaching
Algerian desert could generate enough
was far superior to the direct current
their machinery to the very wheelwork
photovoltaic electricity for the whole
that was usual at the time, because this
of nature.” Which brings us back to
of Europe. The second example also
latter was not pulsed and so could not
the cosmic energy which supposedly
comes from Germany. The idea is
be transmitted across large distances.
surrounds us all. It remains to be seen
to ‘kill two birds with one stone’, by
Other discoveries included the principle
what changes the next few years may
producing biomass from micro-algae.
of radar, radio remote-control, X-ray
bring in the state of scientific knowledge
The raw-material needed: industrial CO 2
radiation, the Tesla turbine, lightning
on this topic ... At any rate, there is still
emissions. It’s plain to see that a lot is
protection, the thermomagnetic motor
a long way to go before the many open
going to happen here in the next few
and over 700 internationally filed patents.
questions here can be answered – if
years, not only in scientifically ‘safe’
Apart from all this, Tesla is also known
ever.
terrain but definitely also in fields that
as the forefather of robot technology.
Tesla’s dream was “free energy for
all”, which is why there is so much
many today still consider rather dubious.
Energy from algae, ecoelectricity from the Sahara
speculation surrounding his person,
most of it boiling down to the assertion
Returning to ‘classic’ power generation,
that Tesla was simply boycotted because
in our resource-constrained day and
6
Cover story
Watch this space!
Full power ahead –
in energy-saving mode
GOING EASY ON BOTH HUMAN AND MECHANICAL ENERGY
When you’re developing a product, there are many
different aspects you can focus on. A lot of attention
is often paid to its energy consumption, because this
is a clear-cut performance metric that can easily be
compared. Fronius takes a rather different approach
here. And always has done. An approach which is
always focused on making careful, respectful overall
use of energy as a raw material.
Fronius 2011
Totally R&D
7
Saving energy is a highly topical issue,
Embodying attributes such as ‘resource-
which technology is best for the lowest
but at Fronius it’s also an age-old one.
saving’, ‘economical’, ‘innovative’ and
possible power consumption is really
The firm’s very first appliances testified to
‘quality-driven’, the Fronius Values
only a small cog in a much larger
the care it has always taken with the use
provide a ‘compass’ here, coupled with
machine. The developers need to
of energy. ‘Energy’ being much more than
a claim to technological leadership.
know how every single process-step
just what comes out of the power socket.
The only way to hold onto this position
is interwoven with all the others, and
Fronius takes a very individual approach
is if the organisational procedures
what knock-on effects it has. From
here, seeing ‘energy’ as something that
are sufficiently well thought-out to
one step to the next, this meshwork of
begins with the human effort needed to
make innovations possible, and if the
effects and counter-effects becomes
operate a machine and achieve certain
corporate values are right. Transposed
ever-more exhaustive, until finally
results, and that ends with the materials
to the subject of energy, at Fronius a
everything is crystal-clear and you know
used and consumed both for the machine
development project only has a chance
precisely which ‘cog’ you can still turn
itself and for the process.
if it treats the ‘raw material’ of energy in
to improve the overall energy efficiency.
an eco-friendly, cost-efficient, innovative
Some examples? Why not try tracing a
and ultra-quality-conscious way. These
developer’s train of thought and consider
parameters flow into one another, of
how the individual features affect the
course, blurring the boundaries between
system as a whole?
Clear parameters influencing
the development strategy
In its development work, Fronius follows
them – in the same way as a single factor
a line that is lived-out by all its people.
can be extremely multifacetted on its
The ‘Fronius Way’ is made up of values
own, as the following example of ‘cost
that are lived-out and interiorised by
efficiency’ shows very nicely.
every single Fronius employee. These
influencing parameters shape the
development process and lead to an
From zero spatter to
automatic cap-shaping
Fronius welding systems come with
Cost-efficient thinking at all
process levels
outcome that is the product of this
many features that lessen the amount
of human and mechanical effort needed
to operate them. All in all, they are the
values-based strategy. Any development
If you claim to be cost-effective in
result of product developments which
project, then, will involve an approach to
a comprehensive sort of way, you
are underlain by the company’s core
energy that is informed by these values.
need to be capable of some very
values: ingenious process management
So what are these influencing factors?
complex thinking. The question of
means zero spatter and thus no post-
8
Totally R&D
weld machining; automatic cap-shaping
effectiveness, that makes careful and
reduces the effective work-time still
sparing use of energy. And the result?
further; top-quality components add
Quiet, continuous, full-power operation
many years to the service life and
– in energy-saving mode. This is energy
mean that there are fewer wearing
efficiency that goes far beyond mere
parts; special ‘colder’ weld processes
power consumption.
obviate the need for work-steps like
post-weld machining; superior welding
properties mean that no weld-seam
preparation or finishing is needed; a
radically new contacting system ensures
precision contacting and long service
life. Some more examples: loss-free
gas supply; automatic cooling-unit
cut-out; low open-circuit power; high
power efficiency; modular, versatile
system principle; easy servicing; higher
welding speeds. And any number of
protective features: protection from
soiling, protection of the control panel,
protection of the current socket,
protection against overheating, a digital
gas regulator, and – again and again –
precision in the arc.
Every single feature has been thoroughly
thought out with regard to its manifold
impacts on the system as a whole. Over
all these years the aim has always been
to develop equipment with maximum
In its development work, Fronius follows a line that is lived-out by all its
people: Energy is a ‘raw-material’ that should be used in an eco-friendly,
economical, innovative and highly quality-conscious way.
Fronius 2011
Totally R&D
9
Wear-part exchange
on demand
ROBACTA TX DELIVERS ENHANCED FLEXIBILITY AND OPTIMISED DUTY-CYCLES
With Robacta TX, the welding cell becomes increasingly autonomous. The change of torch-body takes place within 30 seconds, without human
intervention and independently of work-shifts. Robacta TX is available for water- and gas-cooled welding systems with pay-off packs.
In robot applications and with large production runs, the need to exchange wearing parts
on the welding torch is a factor that reduces system availability. After all, it means that the
robot welding cell has to stop work while the contact tip or the gas nozzle is changed.
And every standstill costs money. This is where Robacta TX comes in, exchanging the
torch bodies entirely on its own. It can also exchange torch-bodies of various different
geometries, which greatly increases flexibility when working with a robot system.
What used to be a maintenance
cycle time or number of operating hours.
that is needed is an extra base stand
procedure taking several minutes is now
The servicing work on the torch bodies
with an integral torch-body rack, and
dealt with by Robacta TX in less than
can then be carried out conveniently and
an interchangeable coupling between
just 30 seconds. The job of changing
at any location.
the torch body and hosepack. A
compressed-air mechanism operating
the torch bodies is done completely
automatically, without any manual
With only minor alterations to existing
via the existing blow-out line actuates
intervention. The time at which this
Fronius welding systems, to the robot
the interchangeable-coupling valve,
service operation is performed no longer
and the compressed-air supply,
which holds or releases the torch body.
depends on work-shifts, but can be
autonomous torch-body changing is
scheduled to take place after a certain
possible in any robot welding cell. All
10
Totally R&D
Long, longer,
PowerLiner
A NEW WIREFEED HOSE WITH
HUGE POTENTIAL
Less sliding friction during wirefeed – thanks to PowerLiner. The hosepacks can be much longer,
and the wire bulk-pack no longer needs to be located inside the welding shelter.
A wirefeed hose with integral
plastic rollers is the defining
feature of PowerLiner. The
welding wire is guided and
advanced by small rollers,
with many advantages as
a result: Longer hosepack
lengths, less abrasion,
and fewer downtimes for
exchanging wearing parts.
PowerLiner combined
with the robot welding
torch RobactaDrive equals
PowerDrive – a system
whose components all work
together perfectly.
Fronius 2011
Small rollers, big role. Much less
With the handy QuickConnect system,
sliding friction is generated when the
PowerLiner is quick and easy to plug
PowerLiner wirefeed hose is used, and
onto and unplug from bulk pay-off
this permits hosepack lengths of up to
systems, wirefeeders and welding
20 metres. The wire bulk-pack no longer
torches. PowerLiner is suitable for all
needs to be located inside the welding
types of wire and for wire diameters of
cell, meaning that preparations for
up to 1.6 mm.
changing the pack can be made outside
the cell at any time.
PowerDrive – perfect interplay
with RobactaDrive
There are even more advantages when
it comes to the handling: the fact that
Combine PowerLiner with the push/pull-
PowerLiner no longer needs any inner
welding torch RobactaDrive, and the
liner, for instance. This cuts maintenance
result is PowerDrive. The RobactaDrive
costs, as preparations for changing
takes over the job of feeding the wire
the inner liner, and the downtimes this
here. Hosepack lengths of up to 10
entailed, are now a thing of the past.
metres are possible.
Totally R&D
11
News
New solar subsidiary
in Australia
Virtual Welding on tour
Austria’s biggest solar power
plant runs on Fronius inverters
Fronius is now represented by its own
The welding education of the future has
Austria’s biggest solar power plant went
solar electronics sales subsidiary in
a name: Fronius Virtual Welding. The
on-grid in 2010. On an area equivalent
Melbourne. An internationally diverse
simulator has already made a name for
to one and a half football fields, 4700
team of eleven staff from China,
itself at events and institutions all round
solar panels and 18 Fronius CL central
Germany, Austria, New Zealand and
the world: The SZF training centre in
inverters generate an annual output of
Australia started work ‘Down Under’
Fohnsdorf, Austria, recently introduced
950 MWh. The 18 Fronius CL central
in October 2010. Managing Director
Virtual Welding, giving a significant
inverters excel for their unique, world-
David Hart is very upbeat: “Our new
boost to the quality of its training. The
first modular system concept, known
sales branch will help us to keep on
ISF institute of welding and materials-
as the Fronius MIX TM concept. Inside a
boosting our position on the Australian
joining technology at the RWTH technical
Fronius CL there are up to 15 identical
market and to give our customers the
college in Aachen, Germany, has also
power racks at work. As required by the
top-class Fronius Service they deserve.”
turned to Virtual Welding. Its director,
degree of insolation, some or all of these
With around 1700 m² of space, the
Prof. Dr. Uwe Reisgen, is impressed
are switched on or off, also depending
new subsidiary’s premises comprise
by the system’s quality and ease of
on each rack’s op-hours total.
sales offices, a service centre and
handling. In the central Russian town
warehousing.
of Kaluga, too, a new training centre
Special componentry monitors the
has started using Virtual Welding. And
system’s output in detail, enabling
Fronius was one of the first
the journey goes on: At the WELDEX
an immediate response in the event
manufacturers of solar inverters to
international welding expo in Moscow,
of a malfunction. Data for further
discover the Australian market. Thanks
Russia, Virtual Welding won first prize as
processing are logged by networkable
to this head-start, Fronius is now one
the best equipment in the “Welding and
Fronius Dataloggers, while the
of the biggest suppliers on this market.
Education” category. Big-name Russian
integrated sensors deliver valuable
Australia is an excellent location for
firms such as TVZ and Uralmasch
extra information and are the ideal
a Fronius solar subsidiary, for several
already have the simulator in day-to-
complement to the monitoring system.
reasons: Households in this sun-blessed
day use for welding instruction. Once a
continent benefit from an attractive
year, the town of Wels becomes Austria’s
programme of government grants and
‘career-guidance Mecca’, at the “Jugend
good feed-in tariffs.
& Beruf” youth career fair, where Fronius
and Virtual Welding were a big crowdpuller.
12
Brief and to the point
Honda presents world’s
first series fuel-cell car
Focusing on long
service lifespan
New subsidiary:
Fronius Istanbul
Honda recently presented the world’s
When you run a fleet of nearly 100 electric
Fronius was first represented on the
first series-production fuel-cell car at
industrial trucks with over 100 traction
Bosphorus by a representative office,
Fronius’ Sattledt facility. The invited
batteries, it pays to think about how you
starting in 2008. In 2010, a full subsidiary
journalists who test-drove the Honda
can prolong battery life. At packaging
was established in Istanbul, Turkey,
FCX Clarity were given an exclusive
specialists Constantia Teich GmbH, the
for the Solar Electronics and Welding
foretaste of the future of motoring.
answer was Selectiva series battery
Technology Divisions. The chosen
charging systems with Active Inverter
location was in the industrial district of
Some 40 journalists came to the Fronius
Technology from Fronius. It was mainly the
Tuzla, near the port. It currently has a
facility in Sattledt for the presentation
expensive traction batteries’ short lifetimes
staff of eleven. Nusret Bilen, who has
and test-drives of the Honda FCX
of only three to four years that prompted
been with Fronius for four years, has
Clarity, and were thrilled by Honda’s
Constantia Teich GmbH to take a long hard
been made Executive Manager: “I’m
revolutionary technology. The vehicle
look at the whole issue of battery- and
really excited about my new challenge,
produces no exhaust apart from steam,
charging technology. Various studies
and take a very positive view of the
reaches top speeds of up to 160 km/h
proved that the temperature-rise in the
future. The feedback from the Turkish
and has 100 kW (that’s approx. 134 BHP)
battery during the charging process has a
market has confirmed the rightness of
of power. The FCX Clarity’s fuel supply of
major influence on battery lifespan. Other
our decision to set up the subsidiary.
4.2 kg of compressed hydrogen (at 350
factors pointing to Fronius were its
With our six dealerships and two sales
bar) gives it a range of around 460 km.
chargers’ compact and space-saving
and service-partner teams in Istanbul
constructional design, and the easy way
and Bursa, we are very well placed
It was a great honour for Fronius to host
that the optimum charging characteristic
to offer our customers top-quality
this exclusive presentation. Just like
can be programmed in via the integral
innovative welding technology and
Fronius, Honda has also set itself the
display.
expert service. I’m absolutely certain that
goal of conserving the earth’s resources
For Constantia Teich, going into this issue
together with our dealers and Fronius
and developing technologies that will
in such depth has definitely paid off: in the
International, we’re going to achieve a
make this possible. The Honda FCX
rough-and-tumble of everyday use, their
lot”.
Clarity is a momentous step along the
traction batteries’ lifespan has been
way to a zero-emission automotive
lengthened to between six and seven
future.
years.
Fronius 2011
Brief and to the point
13
Futuristic construction for
Olympic ski-jump ramp
DYNAMIC ARCHITECTURE SHAPED IN STEEL
Ski-jumpers, spectators
and tourists on GarmischPartenkirchen’s Gudiberg
mountain can now admire a
structure that embodies both
discerning architecture and
engineering achievement.
The new Olympic ski-jump
fulfils some very varied
specifications: today’s
more advanced ski-jumping
techniques; shapes inspired
by the topography; futuristic
cantilevering design, and
integrating many very varied
functions. Ski-jumpers will
launch from it in the Four
Hills Tournament, spectators
will experience not just this
sporting attraction but also
the play of light and shadow
from its translucent facade,
and tourists visiting outside
the skiing season will enjoy
panoramic views of the Alpine
scenery from the viewing
platform.
The steel construction of the new ski-jump ramp in Garmisch-Partenkirchen, Germany, was joined using 25 TransPuls Synergic 5000 welding systems.
14
Case studies
The load-bearing and shape-imparting
quality standards and to the Welding
in Fronius, with its dependable, high-
steel structure was erected in 2007 by
Producer Specification EN ISO 3834. The
performing welding systems. I know
Bitschnau GmbH of Nenzing, Austria.
main grade of steel used was S355J2+N.
from my staff that system attributes
One of the most notable structural-steel
The relatively thick steel plates were
like ease of operation, quick-access
fabrication projects in Central Europe,
pre-heated on the rear of the parts to
welding-jobs, from-the-torch parameter
this structure was singled out by the
be joined, preventing crack-formation
control, flexibility in terms of hosepack
German structural steelwork association
as the parts slowly cooled after welding.
length and thus high mobility all help us
DSTV on 8th October 2010 for an award
Higher-strength S460N or S690QL1
to achieve high efficiency and quality”,
under the “German Structural Steel
steels were used for parts subjected to
says Bitschnau’s MD Michael Schmid,
Prize 2010” (commendation statement:
more severe mechanical stressing.
summing up his company’s experience of
working with Fronius equipment.
see grey box). The total weight of all
the steel plates and sections, 90 % of
Experience and precision
which were joined together to make
weld-fabricated beams, was 780 tonnes.
As if the demands made of the welders
The constantly varying sections of
were not complex enough already, their
these beams are at once typical and
skill was further put to the test by the
technically demanding. The construction
high fitting accuracy and tolerances
as a whole is made up of individually
required here. The boundaries they had
pre-fabricated components weighing up
to comply with were laid down by the
to 16 t and of up to 22 m in length. These
tolerance specified in EN ISO 13920. In
were bolted or welded together flat on
practice, this means taking account of
the ground. After being largely fitted out
weldment shrinkage due to the thermal
and encased in its external cladding, the
input during welding. “When it came
in-run tower was then tilted up by 35°
to planning the weld sequence and
into its final position.
calculating the heat-induced shrinkage,
Commendation
statement for “German
Structural Steel Prize
2010”
our welding-know-how was simply
Turning plates into girders
indispensable. Our employees’ high
skill is reflected in the precision of
“Joining individual plates to make weld-
their on-site assembly work and in the
fabricated beams, then joining these into
exact results that were obtained in all
components and ultimately into the final
subsequent inspections”, notes Michael
construction – this was where the key
Schmid, in a tribute to the over 35 highly
technology came in on this exceptional
qualified welders from his firm who
project” says Bitschnau’s MD Michael
were involved in this project, all of them
Schmid, underlining the importance of
certified to EN 287-1 and given further
the value-adding work. To put this in
training by Fronius.
more concrete terms, the firm’s expert
structural steel fabricators welded some
Bitschnau’s success on this prestigious
45 km of seams with GMA (gas metal
‘structure of the century’ is underlined
arc) welding systems. As the plates to be
by the record construction time of only
joined varied in thickness between 1 and
11 months from start to finish, including
120 mm, this also applied to the build-up
the constructional design/engineering/
of the welded joints (mostly longitudinal
operations-scheduling work, site-
fillet welds). As well as single-pass
assembly and erection, and finally the
seams, many of these consisted of up to
installation of the cellular polycarbonate
35 passes. Most of these were welded
facade. “We were able to meet our
using as many as 25 TransPuls Synergic
deadline, quality and cost goals, thanks
5000 machines, to the very highest
also to the capable partner that we have
Fronius 2011
With the new Olympic ski-jump
in Garmisch-Partenkirchen, the
architects and engineers have
succeeded in developing a new
form of architectural expression
derived from the changed
requirements of modern-day skijumping, in terms of both in-run and
launch technique.
It takes in the topography of the
surrounding landscape and, with
its dynamic form, symbolises
the ideal of flying. Constantly
alternating between transparent
and translucent, the envelope
turns the meticulously crafted steel
construction into a visual feature of
the structure. At the same time, the
huge cantilever of this ‘sculpture’,
transferring all the loads via two
points only, provides an impressive
demonstration of just what the
material is capable of.
Case studies
15
Cold – colder –
CMT Advanced
MANUAL OR AUTOMATED WELDING
WITH A ‘COLD’ PROCESS
Magna Steyr produces a wide spectrum of components, systems and entire
passenger vehicles for noted automobile industry OEMs at its automotive
facility in Graz, Austria. The aluminium bodywork for premium limousines
and sports cars presents a particular challenge here. On the Mercedes
SLS, the firm’s jointing specialists rely on CMT Advanced Pulse. For Magna,
this process has been engineered so that its heat input results in sufficiently intensive penetration, yet while keeping distortion down within the prescribed tolerances.
With the autobody for the SLS, Magna is
creating the basis for a series-produced
‘dream car’ made of aluminium. Due
to the small production numbers, this
limited series is largely designed to be
welded by hand. Set against this is the
fact that each autobody includes around
70 m of arc-welded seams. In theory, the
only way to meet high technical, aesthetic
and haptic requirements like these would
be with TIG welding. However, this would
be so time-consuming that it would be
out of the question for series production,
given the high number and total length of
the seams involved.
CMT manual instead of TIG
This is why Werner Karner – the man
in charge of welding in the prototyping
field – looked for an alternative: “Plasma
welding was not an option because it
inputs too much heat and would cause
distortion. MIG welding creates seams
that are too coarsely rippled, and too
Manual CMT Pulse welding is doing sterling service on the aluminium bodywork of the Mercedes
SLS, with its 70 m of weld-seams.
16
Case studies
Welded with CMT Advanced, this joining- and filler weld fulfils both the production conditions and the exacting requirements regarding ‘look and feel’.
For this most difficult seam, Magna Steyr welding expert Werner Karner introduced the CMT Advanced process.
much spatter. Then Fronius presented
thick sheet of the B-pillar to the equally
CMT to us. The seam-geometry, the
thick one of the roof. Both of them
rippling and the absence of spatter were
consist of the AlMgSi alloy 6014, and are
all just right. However, the penetration
fillet-welded in a lap joint. This fillet-
was not intensive enough and we would
weld compensates for the cumulative
have had to robot-weld”.
production-related errors in the design
dimension resulting from the difference
Karner and his welding partners solved
in height between the B-pillar and the
both these challenges in mutual dialogue,
roof. In practice, the groove width to be
and through welding-trials. After only
filled can amount to several millimetres,
a few months, the production-ready
meaning that bridging these gaps while
solution was ready for action: CMT
avoiding weld-metal drop-through is an
manual in pulsed mode. For this, the
extremely difficult requirement to meet.
CMT robot torch was modified for manual
operation by adapting the integral ‘back-
With help from Fronius experts, a
and-forward’ wirefeeder in such a way
workable solution was soon found.
that the welders were also able to guide
However, because of the combination of
it by hand at the joins. The narrow power
a high deposition rate and low thermal
window of the ‘pure-play’ CMT process
input, the welding speed has to be at
has been widened by combining it with
least 40 cm/min – a high speed that only
the pulsed-arc process. CMT Pulse has
a robot can manage consistently for any
been engineered for Magna so that its
length of time. “Because our production
heat input results in sufficiently intensive
people were very dissatisfied with this
penetration, yet while keeping distortion
join, we showed them the specimen part
within the prescribed tolerances.
we had welded with CMT Advanced.
Magna Steyr
This Austrian company belongs
to the global Magna International
group, which posted 2009 revenues
of around 17.5 bn US dollars. The
most diversified automotive supplier in the world, Magna develops
and manufactures vehicle parts and
highly differentiated products at its
80 engineering and R&D centres
and 245 manufacturing operations.
The spectrum offered by Magna
Steyr at its Graz facility includes
not only complete contract-manufactured cars but also fuel-tank
components and systems, development services, and the entire
panoply of roof systems. Among
its next-generation technologies
are alternative vehicle drivetrain
and energy storage systems. As a
brand-independent manufacturing
partner of international automobile
manufacturers, Magna Steyr is the
worldwide market leader in the field
of roof systems.
After final machining of the weld-seam,
CMT Advanced for the
toughest seam ever
they were really impressed. We then
tested the CMT Advanced solution under
production conditions. The result was
“This is the most difficult seam I’ve come
that we put the test equipment to work in
up against in all the 30 years I’ve spent
our series production operations straight
in the profession”, explains welding
away”, reports Magna’s very satisfied
expert Werner Karner. It joins the 1.1 mm
testing expert, Werner Karner.
Fronius 2011
Case studies
17
From innovation
to production
CONTEC CONTACTING TECHNOLOGY PASSES
SERIES-PRODUCTION TEST WITH FLYING COLOURS
With an equipment
line-up comprising
the automated CMT
process and Contec
contacting technology,
SAG Alutech GmbH
of Salzburg, Austria,
has put itself at
the cutting edge of
aluminium welding.
Particularly in the
welding of reservoirs
for air spring systems,
quality is paramount.
One such quality goal
is to durably obtain
a 10-times longer
service life than with
conventional contact
tips, by using Contec.
The joins welded on these compressed-air reservoirs, which have bursting pressures
of up to 100 bar, are critically important and must fulfil a wide range of requirements.
“The contacting system makes a vital
tips was very high, necessitating frequent
suffers too. “It’s a bit like with the
contribution towards process reliability
changes (approx. 2 per shift) on the
welding wire. We used to feed it from a
and thus towards staying competitive.
automated welding systems used in
spool, then from a bulk pay-off pack and
This is why we tested Contec and
production, Alutech switched over to the
nowadays we take it from a bulk wire
worked with Fronius to optimise it for our
new contacting technology Contec back
container. In this way we minimise soiling,
applications”, says Dr. Gregor Wasle,
in 2009.
changes in the wirefeed and – most
Managing Director of Alutech. The
Changing the contact tip has serious
importantly of all – interruptions. Smooth,
welding experts at Alutech and Fronius
side-effects: every time it is changed, the
troublefree operation is the desired
have long worked together closely and
workflow suffers, process parameters
result”, notes welding engineer Alexander
well. Because consumption of contact
may change, and process reliability
Ottino, describing the progress that has
18
Case studies
been achieved in practice.
life of the reservoirs exceeds that of the
SAG Alutech uses a well equipped
vehicles they are fitted to, and they are
in-house engineering centre for the
100 % recyclable. Materials commonly
tests needed in the run-up to series
used at Alutech include AlMg3 and
production, where alternative or new
AlMg4.5Mn. The wall thicknesses are
hardware and technologies are tested
between 2.0 and 3.3 mm. Other boundary
in robot welding cells. Contec first had
conditions applying to welding are the
to prove its suitability for actual practice
identical weld filler metals (diam. 1.2 mm
here, especially for the critical seams on
wires) and the use of argon shielding gas.
the compressed-air storage systems.
During the tests in the engineering
“The big advantage with us is that our
centre, the welding experts from Alutech
processes run flawlessly. This enabled
and Fronius optimised technical details
us to concentrate on the differences
relating to the design and build of the
between conventional contact tips and
contacting system. Dr. Wasle notes
Contec. We were looking to increase the
that “We are now confident of getting
service life by a factor of at least five”,
a ten-fold increase in contact-tip
recalls Wasle, who was Head of R&D at
lifespan with Contec.” Among the other
the time.
equally positive improvements, in both
quantitative and qualitative terms, are a
Compressed-air reservoirs
for premium vehicles
reduction in rejects, a more stable arc,
less porosity and thus greater gas-
Contec – a novel
contacting technology
The Contec contacting technology
is the first-ever system to transfer
the welding energy onto the welding
wire constantly and reproducibly –
and to do so throughout the entire
service life of the contact tip. This
exceptionally high process stability
results in superlative welding
properties, fewer welding defects
and – by minimising spatter – less
post-weld machining. At the same
time, Contec hugely prolongs the
service life of the contact tip.
tightness.
SAG and its subsidiary Alutech produce
compressed-air reservoirs for the
For SAG Alutech as an automotive
braking systems of premium limousines
supplier, another important factor is that
and sports cars, as well as for trucks
the changeover to Contec does not entail
and railed vehicles. These reservoirs
any organisational changes. There is thus
are suitable for operating pressures of
every prospect that all Alutech’s welding
between 10 and 25 bar and for bursting
cells with two CMT systems will soon be
pressures of up to 100 bar. The service
upgraded to Contec.
SAG Motion and SAG
Alutech GmbH
Salzburg Aluminium Group (SAG)
AG is a leading international
supplier of (aluminium)
components to the automotive,
aerospace and railway-vehicle
manufacturing industries. A
further area of expertise is highperformance materials and
mouldings for various industrial
sectors. Energy storage and
management systems are a
speciality of its subsidiary SAG
Alutech GmbH.
Left: The Contec contacting system gives Alutech up to 10 times longer contact-tip service life,
and process reliability. Right: Dr. Gregor Wasle and welding engineer Alexander Ottino decided
to deploy Contec after their very positive experience with this new contacting system.
Fronius 2011
Case studies
19
Energy
without
limits
Energy crisis, peak oil,
climate change. The problem
presents itself with evergreater immediacy, on a
global scale. But what forms
of energy will replace fossil
fuels, and what will the future
bring? All questions that Klaus
Fronius wants to answer by
developing next-generation
technologies.
The hidden crisis
crisis is creeping up on us, yet still we
see only tentative signs of a change in
“We need an ‘energy turningpoint’ – right now!”
All over the world, one problem unites
attitudes. We still take it too much for
us: the increasing global scarcity of raw
granted that electricity simply comes
Klaus Fronius is convinced that
materials, coupled with skyrocketing
out of the plug socket; the sheer size of
alongside political decision-makers,
demand for energy. The International
the whole problem is more than we can
companies must share the responsibility
Energy Agency expects the world’s
grasp. “We’re squeezing our planet dry
for making this transformative
energy requirements to have risen
and don’t really know what technologies
process happen. Indeed, it is also this
another 36 percent by 2035. The share
we’re going to replace all these fossil
dramatically increasing scarcity of raw
of renewables in the world’s energy-mix
fuels with”, says Klaus Fronius. “If we
materials which drives Fronius to develop
is still negligible, with over 86 percent
don’t change course, 30 years from now
new technologies that can help find a
of global energy-needs still being met
it’ll be too late.”
long-term solution to the world’s energy
by fossil fuels. A worldwide energy
20
The company
problems: “Supplying the world’s needs
with alternative energies, and making
management at all levels, both for single,
Fronius. After all, “We need to think
more careful use of the energy that we
small and large households as well as for
about energy globally, as only then will
already have, is something that ought to
businesses. The Fronius Energy Cell is a
it be available without limits and without
concern every single one of us.”
big step in this direction.”
borders”.
The Fronius energy vision
Mankind must change course radically
Welios, the energy theme park in Wels,
if it is to ward off the impending energy
looks into this topic in all its many facets.
In half an hour, as much energy reaches
crisis. This will remain a challenge for
(See info box).
the earth’s surface in the form of sunlight
many generations to come. “It would be
as the world’s population needs in a
wonderful if we could reach a shared
whole year. “And the sun can’t be bought
understanding across the continents
up by anybody, and no country can grab
regarding energy, for this is something
it for itself – thank goodness!” grins
that affects all of us”, wishes Klaus
Klaus Fronius. Fronius has been working
with photovoltaics since 1992, building
solar inverters based on the inverter
technology with which it was already
familiar from the welding field.
However, maintaining a power supply
from solar energy is difficult at night
or in very cloudy weather. This is why
Fronius has developed a technology
for storing this energy efficiently: The
Fronius Energy Cell, which converts
solar electricity into hydrogen and stores
this in readiness for periods of little or
no sunshine. Fronius has already won
several different awards for developing
this trailblazing technology. Only: “Back
then, our ideas sounded almost a bit
utopian. When my schoolfriend Josef
Rauscher and I started this project
Solar energy to experience, feel and discover
with a ‘back-of-the-envelope’ sketch
in 2001, hardly anyone questioned the
long-term viability of oil or gas supplies”,
remembers Klaus Fronius.
The end of the petroleum age
The days when wars were fought over
oil or gas deposits will hopefully soon
be a thing of the past, as the earth’s
resources are nearly exhausted. Klaus
Where does energy come from, and
where’s it going to come from in future?
What forms and sources of alternative
energy are there – and how can these
be explained and made easier to
understand? In April 2011, Austria’s
biggest Science Centre will be opening
its doors to a 3000 m² “World of Energy”
with 150 hands-on exhibits which make
solar energy, hydropower, wind power,
geothermal energy and biomass ‘come
alive’ for the visitor.
visitors can literally ‘feel at home’ and
try everything out: You can listen to
thrilling stories in the bathtub of the
‘bathroom’, play around with kitchen
appliances in the ‘kitchen’, and find out
all there is to know about biomass out in
the ‘forest’ and the ‘meadow’. Above the
roofs of the ‘house’, visitors can unlock
the scientific phenomena of solar energy
by twiddling dials, pressing buttons and
cranking handles.
Taking the form of a residential dwelling,
the exhibition area is designed so that
www
www.welios.at
Fronius knows which way the wind is
blowing: “There are two big trends. One
of them is electromobility, as a transition
technology to FCEVs (fuel-cell electric
vehicles). The other is efficient energy
Fronius 2011
The company
21
Mysticism and modernism
in the “City of the Angels”
THE WORLD HERITAGE SITE OF PUEBLA, MEXICO: A FASCINATING BLEND
OF MANY EPOCHS
Puebla is a city that buzzes with a dynamism that is all its
own. Backdropped by a gigantic silhouette of volcanoes, this
Mexican metropolis is brimming with energy both old and new.
In Puebla you’ll find both the largest-known earth-covered
pyramid (the ‘Gran Pirámide de Cholula’, one of the oldest
archaeological sites in the Americas), nearly 5000 colonial era
buildings, and over 60 churches. And in between, big markets
for traditional crafts, stunning natural beauty spots and an
array of different industries.
Mexico City
Puebla
Puebla was founded in 1531 by King
angels not only told him the place where
around 60 churches. The Capilla Real,
Charles V., making it one of the oldest
the city was to be built, but had already
for example, one of the oldest churches
Spanish cities in Mexico. As the legend
traced it out with twine. Again and again,
in Puebla. Built next-door to the San
has it, the bishop of Tlaxcala gave the
you can sense a certain mystical force
Gabriel monastery in 1540, this church
city its original name Ciudad de Los
at work in this beautiful city. For a start,
remained unroofed until the end of the
Angeles (“city of the angels”) after angels
you can hardly go anywhere in Puebla
16th century, so that churchgoers at first
had appeared to him in a dream. These
without stumbling across one of its
had to gather in an open atrium.
22
Travel Tip
1JDUVSFPOMFGUQBHF5IF1PQPDBUÏQFUMWPMDBOPGPSNTBTUVOOJOHCBDLESPQUPUIF*HMFTJBEFMPT3FNFEJPTDIVSDI
1JDUVSFTPOSJHIUQBHF5IPVTBOETPG
DPMPVSGVMUJMFTBEPSOUIFDIVSDIPG4BO'SBODJTDP"DBUFQFD5IFPMERVBSUFSPG1VFCMBJTB6OFTDP8PSME)FSJUBHF4JUF
Inside is the Chapel Royal, with
Exactly. Industry. For Puebla is a major
Like Arab-inspired tiles or one-of-a-kind
49 domes and 7 naves. Another
manufacturing location for international
pieces made from semi-precious stones
ecclesiastical highlight, considered to
companies. The automobile and textile
and marble, or handcrafted costumes
be a masterpiece of Mexican Baroque, is
industries are particularly important.
in indigenous designs. In the Barrio del
the church of San Francisco Acatepec,
Volkswagen de Mexico is the city’s
Artista district, you can acquire all sorts
whose facade is covered in colourful
biggest employer; the VW Beetle is now
of artefacts directly from their makers.
Talavera tiles, each hand-made by
produced only in Puebla, for example.
Another street not to miss is the Calle
Puebla’s potters. Not forgetting the
By the way, Fronius also has a direct
de Santa Clara, named after a former
Iglesia de los Remedios, of course,
connection to Mexico and to Puebla:
monastery of Clarissan nuns known for
built atop the pyramid of Cholula. This
A subsidiary has been in operation in
their superb sweetmeats. In the Calle de
is also well worth a visit because of the
Monterrey since 2005, and in 2011 two
Santa Clara, you will thus find countless
spectacular panoramic view it affords of
new VSP teams started up – one in
popular sweets on sale, as well of course
the whole of Puebla.
Puebla and the other in Valle de Mexico.
as centuries-old handicrafts that give a
Cultural sites old and new
Universities aplenty
fascinating demonstration of Puebla’s
multicultural heritage. Incidentally, the
blend of pre-Columbian, Moorish, French
Around Puebla lie several extremely
Another sort of ‘cultural site’, and one
and Spanish influences is also very much
interesting archaeological sites that
which this time has rather more to do
apparent in the local cuisine. Be sure
bring ancient cultures vividly to life. One
with the original meaning of the term, is
to try “mole poblano” (Pueblan spiced
such place is Cantona: Covering 12 km²,
education. Puebla boasts an unusually
sauce), a sauce containing chocolate
this is one of the biggest pre-Columbian
large number of universities; in fact, this
and various chili peppers that is served
sites in Central America, encompassing
city of 1.5 million inhabitants is home to
with poultry. Definitely a dish to give you
a three-part temple complex, the
over 20 institutions of higher learning. An
a taste of the energy and diversity that is
Acrópolis, over 3000 courtyards and
impressive tally!
Puebla ...
24 ‘pelota’ ballgame courts. Among
the region’s old cultural sites are many
monasteries, several of which can still be
Traditional handicraft still
highly prized
visited today. The oldest convent dating
from before the city was founded is the
Alongside its modern-day industrial
Franciscan monastery in Huejotzingo,
enterprises, Puebla is still an important
with a perfectly preserved altarpiece and
centre for traditional handicraft,
some extraordinary stonework.
especially glassware, ceramics and tiles.
And what about all the new ‘cultural
In the downtown districts there are ample
sites’? Admittedly, it may be stretching
opportunities to admire these classic
this term somewhat, but then what do
hand-made items, many of them still
most people associate with Puebla?
crafted using time-honoured techniques.
Fronius 2011
Travel Tip
23
printed climate-neutrally
$1*,4/S
Austria
Brazil
Canada
Czech Republic
France
Germany
FRONIUS DO BRASIL COMÉRCIO INDÚSTRIA E SERVIÇOS LTDA t"W%S6MZTTFT(VJNBSÍFTt
7JMB/PHVFJSB%JBEFNB41t$&1t5FMt'BYt
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FRONIUS ČESKÁ REPUBLIKA S.R.O. t%PMOPNĪDIPMVQTLÈt$;1SBIBt
5FMt'BYt&.BJMQSBIB!GSPOJVTDPN
FRONIUS FRANCE SARLtBWFOVF'ÏMJY-PVBU#1t'4FOMJT$FEFYt
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Mexico
FRONIUS MEXICO S.A DE C.V.t$USB.POUFSSFZ4BMUJMMP&4$PMPOJBt
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Norway
FRONIUS NORGE ASt'JOOFWFJFOt/)PLLTVOEt
5FMt'BYt&.BJMTBMFTOPSXBZ!GSPOJVTDPN
Slovakia
Switzerland
Ukraine
&/DPQJFT
FRONIUS INTERNATIONAL GMBHt'SPOJVTQMBU[t"8FMTt
5FMt'BYt&.BJMTBMFT!GSPOJVTDPN
7&353*&#½45&33&*$)t5FMt'BYt&.BJMTBMFTBVTUSJB!GSPOJVTDPN
FRONIUS SLOVENSKO S.R.O.t/JUSJBOTLBt4,5SOBWBt
5FMt'BYt&.BJMTBMFTUSOBWB!GSPOJVTDPN
FRONIUS SCHWEIZ AGt0CFSHMBUUFSTUSBTTFt$)3àNMBOHt
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FRONIUS UKRAINE GMBHt8VM4MBXZt4,OKBTIJUTDIJt6",JFXTLBZB0CMt
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Türkey
FRONIUS İSTANBUL Elektronik Ticaret ve Servis Ltd. Ști.t#04#"ZE‘OM‘.BIBMMFTJt
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