Robotic Welding Systems

Universal Robots and Fronius collaborative welding solution is designed for your welding production needs.

Small Footprint

Easy To Program

World Class Welding Capability

This system merges the collaborative robot capabilities of Universal Robots UR10e with industry-leading weld process control of Fronius TPS/i welding solutions. Systems can ship in weeks, not months, and production welding can start in as little as a day, once powered up. A team with decades of experience in industrial robotic welding created the user interface to be easy to teach, employing powerful functionality, all with an intuitive interface.

All systems are capable of welding: Aluminum, Carbon Steel, and Stainless Steel materials.

Fronius offers the widest lists of welding processes such as: Synergic Pulse, Synergic Pulse with Syncro-Pulse, CMT (cold metal transfer), CMT Mix Drive, CMT Cycle Steps, PMC (Pulse Multi Control), PMC Mix Drive, PMC Ripple Drive, LSC (Low Spatter Control), and LSC Root.

fronius welding equipment
Universal robots UR10e collaborative robot
CMT Rev 5 Dual Table w_SideCar 1
THG Automation URW-2PA collaborative welding system with Fronius CMT

We are continually adding options to our already versatile COBOT welding solution, like our Dual Table kit for added welding area. The left side table option adds an extra 4 feet by 3 feet to the left for a total of 3 feet by 8 feet of the welding area. The dual table kit works with all existing systems.

FEATURES

  • Weaving - Set the weave pitch, length, angle, dwell left, and dwell right.
  • Seam Tracking - Follow part deviation with ease.
  • Part Check - Quickly check to see if a part or feature is present with touch sensing to protect your tooling and configure your welding process.
  • Touch Sensing - Find part variations to adjust weld points in multiple dimensions.
  • 1000 weld jobs - Large welding job storage and access to those jobs at any point in the welding process.
  • Job Editor - Access all your welding job parameters to copy, move, edit, backup, and restore to speed up welding development.
  • Fronius Teach Mode - Protect the welding wire from getting bent while teaching and simulating program points.
  • Welding Simulation - Quickly turn welding simulation on and off while the welding program is running with a dedicated hand-held wand.
  • Copy and Pattern welding programs - Use Universal Robots Features to move, copy, or pattern welding programs.
  • Stitch weld, quickly set two points, weld length, and the number of welds to automatically create a series of strip welds.
  • Wire Feeding - Feed wire from a barrel or from the optional spool holder.
  • Starter kit of welding consumables including welding tips liners
  • Pendant Armor teach pendant protector
  • Screen Protector
  • Robot arm spatter guard system
  • Fronius specific tool kit
  • Free software upgrades for a year, including future options
  • Free phone support
  • And more coming soon...

Add-on Options

  • Fronius Wire Sense software option for wire sense searching in weld nodes and Edge Detect node (CMT wire feed only)
  • Path recording and multi-pass welding (in beta)
  • Additive manufacturing WAAM/DED support - import G-Code to perform additive manufacturing (works with all systems)
  • SideCar - flip a switch and use the same power source to perform manual welding with added manual wire feeder.
  • Duel table add-on kit for a total 3' X 8' welding surface
  • Weld divider to operate as a two-station system
universal robots teach pendant
THG Automation user interface universal robots fronius
THG Automation user interface universal robots fronius
THG Automation user interface universal robots fronius

Proprietary URCaps installation for easy, but powerful, programming

Visuals to guide you through the programming process

 

Wizard-like interface for quick concise programming of weld points

Convenient Free Drive button for quick placement of weld points

UR10e fronius URF-1 collaborative robot solution reach top
UR10e fronius URF-1 collaborative robot solution reach front
UR10e fronius URF-1 collaborative robot solution reach right
CMT REV 5 Single Table 1JPG-Enhanced-Edit (1)

System 1

Base Push System

The base push system is an air-cooled system that is great for welding carbon steel, stainless steel and can push aluminum. We suggest moving to System 3 if you want to run a lot of aluminum or aluminum wire sizes under .062” or 1.6 mm 

The base push system includes these Fronius options:

  • TPS 400i Power Source with 1000 jobs, Teach Mode, Job Editor, and more
  • Wire Feeder
  • Spool Holder or wire barrel kit (optional)
  • Push Torch

Each system includes the Universal Robots UR10e 12.5 kg payload robot with the THG Automation interface software, which includes all the features listed above.

Included MIG welding processes:

  • Synergic Standard
  • Synergic Pulse
  • Synergic Syncro-Pulse
  • PMC
  • PMC mix

And additional options upon request:

  • LSC
  • LSC Root

System 2

Water-Cooled Push System

Just like the air-cooled push system, the water-cooled push system is great for welding carbon steel, stainless steel and can push aluminum. We upgraded the power source to the TPS 500i 500 amp unit for high duty cycles. The water-cooled torch cools faster improving tip life. We suggest moving to System 3 if you want to run a lot of aluminum or aluminum wire sizes under .062” or 1.6 mm.

CMT REV 5 Single Table Side

Included MIG welding processes:

  • Synergic Standard
  • Synergic Pulse
  • Synergic Syncro-Pulse
  • PMC

Add additional options upon request:

  • LSC
  • LSC Root

System 3

Base Push-Pull System

The base Push-Pull system is great for welding carbon steel and stainless steel, but especially aluminum. This system includes the Base Push system options plus PMC Ripple Drive for TIG like appearances with aluminum, which is only available with the additional wire buffer unit and Pull torch. This system is also water-cooled for higher duty cycles with aluminum. 

This system includes the following additional Fronius options:

  • Wire Buffer
  • Push-Pull Torch
  • PMC software options plus PMC Ripple Drive

Each system includes the Universal Robots UR10e 10 kg payload robot with the THG Automation interface software, which includes all the features listed above.

Supported MIG welding processes:

  • Synergic Standard
  • Synergic Pulse
  • Synergic Syncro-Pulse
  • PMC
  • PMC Mix Drive
  • PMC Ripple Drive

And additional options upon request:

  • LSC
  • LSC Root

System 4

Advanced Push-Pull System

This system is excellent for welding carbon steel, stainless steel, and aluminum, which includes all the options in the Base Push system, the Base Push-Pull system, and these additional Fronius options:
-Fronius CMT ready Push-Pull MIG gun
-CMT software for advanced welding of thin materials and TIG like appearance

Each system includes the Universal Robots UR10e 10 kg payload robot with the THG Automation interface software which includes all the features listed above.

Supported MIG welding processes:

  • Synergic Standard
  • Synergic Pulse
  • Synergic Syncro-Pulse
  • PMC
  • PMC Mix Drive
  • PMC Ripple Drive
  • CMT
  • CMT Mix

And additional options upon request:

  • LSC
  • LSC Root
  • CMT Cycle Steps
CMT REV 5 Single Table (1)
SideCar Front_01 2

The SideCar

Add-on Hand Welding System

With the SideCar, the users can now simply flip a switch, and their system can become a manual welding tool using the same power source as the automated process. Want to go back to automated welding? Flip the switch back, and voila - the robot will take over again. This will make it easier to tack your parts together and finish all the rest of the welding with your robot. 

Fronius Process and Material Availability Matrix By Model

Fronius option matrix