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34

CrashBox

General

CrashBox /i installed on the robot arm with clamp sys

-

tem

The CrashBox /i is a protection device for 

the torch body and the torch body coupling. 

In the event of a collision, the CrashBox 

emits a signal to the robot controls, which 

causes the robot controls to stop the robot 

immediately. Thanks to the welding torch 

holder of the CrashBox, the welding torch 

and the installed system components are 

protected from damage in the event of a 

collision.

The magnetic coupling of the CrashBox all

-

ows for a low-force deflection with large de

-

flection path in the event of a crash.

The clamp system is used to hold the TWIN welding torch. If a 45° torch body is used, the 

clamp system positions the welding torch so that the TCP is in the 6th axis depending on 

the torque angle gauge.

A robot-specific, insulating robot flange is required for the installation of the CrashBox /i.

Also required for 

the installation

Depending on the respective robot:

-

1 x robot flange with screws

Robot flange as per price list

Observe torques:

Max. tightening torque for screws with 

strength class 8.8

M4

3.3 Nm

M5

5.0 Nm

M6

6.0 Nm

M8

27.3 Nm

M10

54 Nm

M12

93 Nm

Содержание TPS/i Robotics TWIN Push

Страница 1: ...free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy 42 0426 0277 EA 006 30012020 Welding System TPS i Robotics TWIN Push Operating Instructions...

Страница 2: ...2...

Страница 3: ...ty Measures in Normal Operation 15 Maintenance and repair 16 Safety Inspection 16 Disposal 16 Safety Symbols 17 Backup 17 Copyright 17 General Information 19 General 21 Application areas 21 System ove...

Страница 4: ...refeeder Rear 58 Interconnecting hosepack 60 Interconnecting Hosepack Connections 60 Installation and Startup 61 Safety Installation and Commissioning 63 Safety 63 Insulated Guiding of the Wire Electr...

Страница 5: ...welding 86 Troubleshooting Maintenance and Disposal 87 Troubleshooting 89 Safety 89 Troubleshooting 89 Displayed Error Codes 91 Service maintenance and disposal 93 General 93 Safety 93 During Each St...

Страница 6: ...6...

Страница 7: ...ng to the operating company Inefficient operation of the equipment All persons involved in the commissioning operation maintenance and servicing of the device must Be suitably qualified Have knowledge...

Страница 8: ...10 C to 40 C 14 F to 104 F During transport and storage 20 C to 55 C 4 F to 131 F Relative humidity Up to 50 at 40 C 104 F Up to 90 at 20 C 68 F Ambient air free of dust acids corrosive gases or subs...

Страница 9: ...ge Safety helmet Cuffless pants Protective clothing involves the following Protecting the face and eyes from UV radiation heat and flying sparks with a face guard featuring a regulation compliant filt...

Страница 10: ...is taking place close the valve of the shielding gas cylinder or the main gas supply Danger from Fly ing Sparks Flying sparks can cause fires and explosions Never undertake welding near flammable mate...

Страница 11: ...ocket with a ground con ductor contact Operating the device on a grid without a ground conductor and on a socket without a ground conductor contact is considered gross negligence The manufacturer acce...

Страница 12: ...on area for which it was designed e g when there is sen sitive equipment at the same location or if the site where the device is installed is close to either radio or television receivers If this is t...

Страница 13: ...rom the body devices with wirefeeder and use suitable protective goggles Do not touch the workpiece during or after welding burning hazard Slag may fly off cooling workpieces Therefore also wear regul...

Страница 14: ...mg m Use filters if necessary Danger from Shielding Gas Cylinders Shielding gas cylinders contain compressed gas and may explode if damaged Shielding gas cylinders are an integral part of the welding...

Страница 15: ...o ensure that the applicable national and regional guidelines and accident pre vention regulations are observed when transporting the device especially guidelines con cerning hazards during transport...

Страница 16: ...out any modifications alterations etc to the device without the manufac turer s consent Components that are not in perfect condition must be replaced immediately When ordering please give the exact d...

Страница 17: ...e http www fronius com Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA Backup The user is responsible for backing up any changes made to...

Страница 18: ...18...

Страница 19: ...General Information...

Страница 20: ......

Страница 21: ...for fillet welds and profiles in vehicle manufacturing for lap joints and wheel rim welding in automotive engineering in container construction for butt welds longitudinal seams lap joints and circumf...

Страница 22: ...screwed in place 8 SpeedNet cable from RI FB Pro i TWIN Controller to power source 1 9 SpeedNet cable from RI FB Pro i TWIN Controller to power source 2 10 HP 95i CON G 10 m intercon necting hosepack...

Страница 23: ...and above 9 Cooling unit CU 2000i Pro MC 2 part 10 TWIN Controller RI FB Pro i TWIN Controller firmware official_robpro 1 4 1 xx svn6108_official 11 2 x grounding cable Mechanical re quirements The f...

Страница 24: ...st be laid using balancers in the robot cell Measures to in crease system availability The use of the following welding torch cleaning devices is recommended in order to in crease the system availabil...

Страница 25: ...rounding cables Shared grounding cable grounding bridge Grounding cable with bifilar winding Grounding cable coiled Further information on connecting the grounding cable can be found from page 81 Note...

Страница 26: ...er source In the TWIN welding process the two power sources are referred to as the lead power source and trail power source The lead power source is defined by the welding direction During pulsed arc...

Страница 27: ...vice is intended exclusively for wirefeeding in automated MIG MAG welding in com bination with Fronius system components Any other use does not constitute proper use The manufacturer accepts no liabil...

Страница 28: ...perating Instructions All system component Operating Instructions especially the safety rules Welding is dangerous To ensure that this device can be used correctly and safely the fol lowing basic requ...

Страница 29: ...s such as Do not reach into rotating gears of the wire drive or into rotating drive parts Covers and side parts must only be opened removed during maintenance and repair work Gears Feed rollers Wiresp...

Страница 30: ...operation Keep hands and metal objects away 1 Electric shock can kill 1 1 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves 1 2 Protect yourself from e...

Страница 31: ...not weld on drums or any closed containers 4 Arc rays can burn eyes and injure skin 4 1 Wear hat and safety glasses Use ear protection and button shirt collar Use weld ing helmet with correct shade of...

Страница 32: ...gas cooled interconnecting hosepack W water cooled interconnecting hosepack The interconnecting hosepacks connect the power sources to the TWIN wirefeeder In TWIN welding systems one water cooled and...

Страница 33: ...torch hosepack is designed for water cooled TWIN robot applications It connects the TWIN wirefeeder with the TWIN welding torch Scope of supply Hosepack MHP 2x500i R W FSC Not included in the scope o...

Страница 34: ...tic coupling of the CrashBox all ows for a low force deflection with large de flection path in the event of a crash The clamp system is used to hold the TWIN welding torch If a 45 torch body is used t...

Страница 35: ...Bellows 5 Cylinder head screws M4 x 16 mm 6 Magnetic ring Mounted on bellows 4 on delivery NOTE Do not assemble the CrashBox i holder 1 and magnetic ring 6 before installing on the robot It is difficu...

Страница 36: ...lding torch transfers the arc power to the workpiece The TWIN welding torches are designed for use with the CrashBox i XXL and are available in two versions PA with contact tips arranged one over the...

Страница 37: ...quired for each angle 4 OPT i MTB TWIN 4 0 sym 4 101 105 CK 8 OPT i MTB TWIN 8 0 sym 4 101 108 CK 11 5 OPT i MTB TWIN 11 5 sym 4 101 102 CK NOTE The tilt angle dependent dimensions of the welding torc...

Страница 38: ...38...

Страница 39: ...Welding Technology Aspects...

Страница 40: ......

Страница 41: ...solenoid valve for the power source selected by the robot controls Gas pre flow gas post flow with TWIN welding torch the same value should generally be set on both power sources if the values are di...

Страница 42: ...the diameter D of the wire electrode 1 Wire electrode 1 2 Contact tip 1 3 Gas nozzle 4 Contact tip 2 5 Wire electrode 2 The distance of the wire electrodes depending on the tilt angle of the contact...

Страница 43: ...CO2 TWIN universal 3833 Steel 1 2 mm M21 Ar 15 20 CO2 TWIN PCS 3834 Steel 1 2 mm M20 Ar 8 10 CO2 TWIN PCS 3837 Steel 1 2 mm M21 Ar 15 20 CO2 TWIN multi arc 3838 Steel 1 2 mm M20 Ar 8 10 CO2 TWIN multi...

Страница 44: ...iptions of the welding process combination op tions below Lead wire electrode lead power source Trail wire electrode trail power source Welding direction PMC TWIN PMC TWIN PCS TWIN PCS TWIN Single wir...

Страница 45: ...outputs at lead and trail wire electrode The TPS i TWIN welding system enables significantly different outputs or wire speeds to be used even during synchronized PMC tandem processes A significantly...

Страница 46: ...ire electrode and a pulsed arc at the trail wire electrode Advantages high penetration by the standard arc of the lead wire electrode large seam cross sections possible large difference in the wire fe...

Страница 47: ...position or restricted position of the weld seam the single wire welding can be carried out by the lead or trail power source The second power source pauses NOTE In order to ensure a full gas shield...

Страница 48: ...d in a TWIN welding system when welding very tight radii when welding in difficult positions and restricted positions to fill up end craters if there has been a switch to a single welding torch on the...

Страница 49: ...y that it differs between lead and trail by an integral multiple Only every second or every third pulse is then executed for the trail arc The characteristic for automatic auto mode contains an optimu...

Страница 50: ...tain the optimum location of the two main current phases in relation to one another and this can change along the characteris tic When set manually the phase shift can be set between the two pulses as...

Страница 51: ...the lead arc The trail arc starts without contact and considerably more smoothly This prevents or re duces the number of failed ignitions Automatic auto mode implements an optimum ignition delay When...

Страница 52: ...52...

Страница 53: ...Operating controls connections and mechanical components...

Страница 54: ......

Страница 55: ...h 2 Current socket with fine thread 1 For connecting the power cable from the interconnecting hosepack 3 SpeedNet connection 1 For connecting the SpeedNet cable from the interconnecting hosepack 4 Shi...

Страница 56: ...de without gas or current 4 Wire threading button 1 for threading the wire electrode into the torch hosepack without gas or current 5 4 roller drive 1 6 Clamping lever 1 for adjusting the contact pres...

Страница 57: ...pause the wirefeeder continues retracting the wire electrode if the wire return button is kept pressed down then the speed increases with each further second by 10 m min 393 70 ipm until the preset wi...

Страница 58: ...steps Always press touch the wire threading button for less than 1 second If the wire electrode meets a ground earth connection then the wirefeeding is stopped and the wire electrode is retracted aga...

Страница 59: ...59 EN US 4 Dummy cover 5 Dummy cover...

Страница 60: ...Interconnecting Hosepack Con nections W water cooled interconnecting hosepack G gas cooled interconnecting hosepack 1 SpeedNet cable 2 Coolant hoses 3 Protective gas shield hose 4 Power cable 1 2 3 4...

Страница 61: ...Installation and Startup...

Страница 62: ......

Страница 63: ...lly the safety rules WARNING An electric shock can be fatal Before starting the described work Switch the power switch on the power source to O Disconnect the power source from the grid Ensure that th...

Страница 64: ...d wire electrode that comes into contact with an electrically conductive object during the welding process a lack of insulation between the wire electrode and the grounded housing limit of a ro bot ce...

Страница 65: ...the cooling units on the upright brackets and cor rectly positioned and fastened in the welding cell The TWIN Controller is available and fastened close to the power sources e g using a corresponding...

Страница 66: ...wirefeeding hoses to the TWIN wirefeeder Insert the feed rollers Close all covers Defining weld nuggets 1 and 2 on the power sources Switch on power source 2 leave power source 1 switched off Place s...

Страница 67: ...r holder depends on the ro bot Follow the Installation Instructions for the wirefee der holder 2 7 Allen screws 6 mm tightening torque 20 Nm 3 6 Allen screws 6 mm NL wedge locking washers tightening t...

Страница 68: ...the hose clamps until they audibly engage Install side hold ers for the inter connecting hosepacks on the robot 1 Installation of the side holder depends on the robot Follow the Installation Instruct...

Страница 69: ...two interconnecting hosepacks Lay interconnecting hosepacks to the wirefeeder IMPORTANT When connecting the interconnecting hosepacks observe marks 1 and 2 on the interconnecting hosepacks and on the...

Страница 70: ...necting hosepack 2 gas cooled interconnecting hosepack NOTE If the interconnecting hosepack is laid incorrectly it can have a significant influence on the welding results a stable welding process is n...

Страница 71: ...ck 1 Connecting power source to the TWIN Con troller via SpeedNet cable TPSi 1 power source 1 TPSi 2 power source 2 HP CON 1 interconnecting hosepack 1 HP CON 2 interconnecting hosepack 2 Connecting T...

Страница 72: ...Weld ing Torch Mounting the CrashBox i on the robot Observe the torques when fitting the robot flange Max tightening torque for screws with strength class 8 8 M4 3 3 Nm M5 5 0 Nm M6 6 0 Nm M8 27 3 Nm...

Страница 73: ...3 EN US 5 6 7 Installing the in ner liner in the torch hosepack NOTE So that the inner liner can be correctly installed lay the hosepack out straight when installing the inner liner 1 2 2x 5 6 7 1 1 2...

Страница 74: ...e front in the hosepack IMPORTANT The screws for securing the inner liners must not be loosened 5 2x 6 2x Screw the clamping nipple onto the inner liner up to the stop The inner liner needs to be visi...

Страница 75: ...g the torch hosepack pay attention to marks 1 and 2 on the torch hosepack and on the wirefeeder 3 4 5 Connect coolant hoses from the welding torch according to the color markings on the coolant supply...

Страница 76: ...76 Prepare torch body with steel inner liner 1 2 3 4 5 6 1 2 3 4 5 6...

Страница 77: ...77 EN US 7 8 9 10 11 12 7 8 9 10 11 12...

Страница 78: ...ng torch 1 Install the torch body coupling NOTE The coupling areas between the torch body coupling and torch body must always be free of oil grease and dust and be dry 1 2 1 6 2 2 4 9 8 3 5 7 1 1 2 3...

Страница 79: ...opens and closes correctly check the manual locking of a torch body in the torch body coupling Flawless operation of the interchangeable coupling can only be guaranteed with a vertical alignment faci...

Страница 80: ...80 5 6 1 2 4 1 5...

Страница 81: ...pply Connect the grounding cable NOTE If the grounding cables are laid incorrectly it can have a significant influence on the welding results a stable welding process is not guaranteed As far as possi...

Страница 82: ...ers which match the wire electrode An overview of the available feed rollers and their possible uses can be found in the Spare Parts Lists Inserting Chang ing Feed Rollers CAUTION Danger due to feed r...

Страница 83: ...en the welding sys tem and workpiece CAUTION Risk of damage to the welding torch due to sharp edged end of the wire electrodes Thoroughly deburr the end of the wire electrodes before inserting CAUTION...

Страница 84: ...t the tip of the welding torch points away from the face and body use suitable protective goggles do not point the welding torch at people ensure that the wire electrodes do not touch any electrically...

Страница 85: ...ure 1 NOTE Set the contact pressure so that the wire electrode is not deformed but correct wire transport is guaranteed Use the specified standard values on the sticker on the protective cover to adju...

Страница 86: ...wirefeeder Feed rollers inserted into wirefeeder Wire electrode threaded in Contact pressure of the feed rollers set Motor calibration carried out All covers closed all side pieces installed and all s...

Страница 87: ...Troubleshooting Maintenance and Disposal...

Страница 88: ......

Страница 89: ...ally charged components e g capacitors are discharged CAUTION Danger due to hot system components Serious personal injury and damage to property may result Before starting work allow all hot system co...

Страница 90: ...ange gas cylinder Cause Gas pressure regulator faulty Remedy Replace gas pressure reducer Cause Gas hose not attached or damaged Remedy Attach or replace gas hose Cause Welding torch faulty Remedy Cha...

Страница 91: ...ct tip Cause Incorrect wire alloy or incorrect wire diameter Remedy Check wire electrode in use Cause Incorrect wire alloy or incorrect wire diameter Remedy Check weldability of the base material Caus...

Страница 92: ...markings 1 and 2 18229 Welding process does not start Cause The second power source is not ready Remedy Check whether the second power source is switched on check whether the second power source is co...

Страница 93: ...urce from the grid Ensure that the power source remains disconnected from the grid until all work is com plete After opening the device use a suitable measuring tool to ensure that electrically charge...

Страница 94: ...close to electronic parts Open covers dismantle device side panels and blow the inside of the device clean with dry reduced compressed air After cleaning restore the device to its original con dition...

Страница 95: ...Technical Data...

Страница 96: ......

Страница 97: ...f shielding gas 7 bar 101 53 psi Coolant Original Fronius Maximum pressure of coolant 5 bar 72 53 psi Wire speed 1 30 m min 39 37 1181 10 ipm Wire drive 4 roller drive Recommended wire diameter 1 2 1...

Страница 98: ...eight Angle of curvature L Length 11 5 30 PB PA 45 PB PA SO mm L1 mm s mm x mm L mm H mm L mm H mm 15 60 56 10 44 7 43 327 14 82 00 336 92 136 75 16 61 55 10 44 7 23 328 00 82 50 337 78 137 25 17 62 5...

Страница 99: ...0 139 92 22 67 89 13 65 10 58 333 49 85 67 342 27 140 42 23 68 89 13 65 10 44 334 35 86 17 344 13 140 92 4 0 30 PB PA 45 PB PA SO mm L1 mm s mm x mm L mm H mm L mm H mm 15 61 24 17 32 16 27 327 73 82...

Страница 100: ...0 C C1 EN 439 100 D C 250 100 D C 330 100 D C 400 mm in 0 8 1 2 0 032 0 047 0 8 1 6 0 032 0 063 0 8 1 6 0 032 0 063 D C duty cycle MTB 500i W R TX TXM MTB 700i W R TX TXM X Imax 10 min 40 C M21 EN 439...

Страница 101: ...60974 2 depending on the hosepack length I ampere 10 min 40 C M21 EN 439 100 D C 1000 2 x 500 I ampere 10 min 40 C C1 EN 439 100 D C 1000 2 x 500 1 2 1 6 0 05 0 06 1 3 2 3 3 3 4 3 18 7 6 55 10 9 92 1...

Страница 102: ...P 120i D C duty cycle Welding current at 10 min 40 C 104 F 40 D C 400 A 60 D C 365 A 100 D C 320 A Welding current at 10 min 40 C 104 F 60 D C 600 A 100 D C 500 A Welding current at 10 min 40 C 104 F...

Страница 103: ...weight distance diagram a A distance of 300 mm away from the robot flange Item number 44 0350 3380 Degree of repeatability 1 0 05 mm a Triggering torques in x y direction See table on the next page Ma...

Страница 104: ...ance max 1 5275 max mm 8 min 0 664 min mm 3 5 Weight distance mm kg 400 15 78 300 21 03 200 31 55 100 63 1 50 126 2 Triggering torque 10 63 1 Nm CrashBox i XXL 0 25 50 75 100 20 30 80 130 180 230 280...

Страница 105: ...105 EN US...

Страница 106: ...106...

Страница 107: ...107 EN US...

Страница 108: ...TERNATIONAL GMBH Froniusstra e 1 A 4643 Pettenbach Austria E Mail sales fronius com www fronius com Under www fronius com contact you will find the addresses of all Fronius Sales Service Partners and...

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