Fronius WireSense is perfect for robotic welding. PHOTO: Fronius International GmbHClick image to enlargeWireSense is the assistance system from Fronius which turns the wire electrode into a sensor that checks the component position before each weld.

This reliably detects actual sheet edge heights and positions. Rework and component rejects are largely eliminated, while additional optical measuring devices become unnecessary.

Many manufacturers use optical sensors for robotic welding. They are expensive, restrict component accessibility, require cleaning and additional calibration between the Tool Center Point (TCP) and the sensor.

With WireSense, the welding torch scans the component with a reversing wire movement and the welding system sends the height information and the edge position to the robot. The robot adjusts the weld seam based on an application-specific program.

By evaluating the height information, the robot determines the course of the edge and the actual edge height, as well as the exact air gap between the sheets. Edges are detected from a height of 0.5 millimeters. WireSense can be used with steel, stainless steel, aluminum, and other alloys. It is with aluminum that WireSense truly comes into its own, as reflective surfaces are frequently a major obstacle for optical measuring devices.

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