Full control with every weld

With the new Fronius WeldCube Navigator software, there is now a digital welding sequence plan available for TPS/i. This guides the welder precisely and safely through the tasks required for a component.

WeldCube Navigator combines two main functions in one piece of software: The sequencer uses pictures to guide the user step-by-step through the work instruction, shows what needs to be done and how, and automatically selects predefined welding parameters on the welding system. It is easy to digitise the required work instruction in the editor.

With a well-thought-out welding sequence plan, companies can optimize their welding processes in manual series production. In each case, the best sequence is set as the standard, and the structured, uniform approach means that employees complete all steps correctly within the defined tolerances. This not only ensures high weld quality, but also saves time and costs during production.

WeldCube Navigator also enables new welders to quickly get up and running in production, and existing skilled workers to easily switch between different workstations, eliminating the time-consuming task of reading the instructions, even when the components are very rarely needed.

Eliminating errors

High-quality welds are essential for many components. Faulty or missed welded joints lead to high manufacturing costs. The earlier these errors are detected in the production process, the quicker the response can be. This is where WeldCube Navigator’s guidance and job preset function comes into play: If the employee deviates from the welding sequence plan, the function immediately alerts them.

If it detects a deviation (limit violation) on seams that have been defined as safety-relevant, WeldCube Navigator can automatically block any further welding until released by a welding supervisor. This means that errors are not repeated or duplicated, but corrected immediately. High quality is maintained despite the large number of pieces produced, and the amount of repair work or rejects can be significantly reduced.

The welding system paired with WeldCube Navigator software provide a perfect all-in-one solution. Fronius paid particular attention to ensuring that the device is easy to operate. Simply upload images in the editor and enter the necessary information. This predefines all the important welding parameters and sets the system’s responses in the event of a plan deviation. Needless to say, it is also possible to integrate general work steps such as preparatory work or intermediate steps that do not involve welding.

The sequencer then guides the welder safely to the intended result using the digital welding sequence plan in the editor. The welder is able to easily navigate through the sequence right at the welding torch: select, confirm, proceed. The screen at the workstation clearly shows each step and it does not proceed until everything has been completed to satisfaction.

As a result, physical paper instructions, often in different languages, become a thing of the past. Furthermore, the system’s error messages are sent directly to the operator resulting in time and material savings by reducing production errors and the need for rework. This makes weld sequencing attractive from an economic and ecological point of view and also helps when welding specialists are absent or frequently change.

Effective solution for quality assurance

New and less experienced welders can use the digital welding sequence plan to complete their tasks quicker and more efficiently because they can easily follow the visualized step-by-step instructions. This helps to ensure that all welds are performed according to requirements and standards. Nothing can be overlooked and the welding parameters are already preset.

Using a digital welding sequence plan, companies can pool their expertise and welding skills and transfer them to all employees. This ensures continuous production and reduces dependence on skilled workers.

WeldCube Navigator represents another important component in the Fronius software portfolio. Combined with WeldCube Premium’s central data documentation and analysis function or its central user management function, companies can further increase the range of functions and the resulting benefits for their business and in so doing unleash their full welding potential.