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LaserHybrid Ultracompact Twin
Operating Instructions
EN
LaserHybrid
42,0426,0255,EN 003-16082017
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Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
EN
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Contents
Safety rules ................................................................................................................................................ 9
Explanation of safety symbols .............................................................................................................. 9
General ................................................................................................................................................. 9
Proper use ............................................................................................................................................ 10
Environmental conditions...................................................................................................................... 10
Obligations of the operator.................................................................................................................... 10
Obligations of personnel ....................................................................................................................... 11
Personal protective equipment ............................................................................................................. 11
Danger from toxic gases and vapours .................................................................................................. 11
Danger from escaping shielding gas..................................................................................................... 12
Danger from flying sparks ..................................................................................................................... 12
Hazards from welding current ............................................................................................................... 12
Vagrant welding currents ...................................................................................................................... 13
EMC measures ..................................................................................................................................... 13
Specific hazards.................................................................................................................................... 14
Informal safety measures...................................................................................................................... 15
Safety measures at the installation location.......................................................................................... 15
Safety measures in normal operation ................................................................................................... 16
Safety inspection................................................................................................................................... 16
Alterations ............................................................................................................................................. 16
Replacement and wearing parts ........................................................................................................... 17
Calibration of power sources ................................................................................................................ 17
CE marking ........................................................................................................................................... 17
Copyright............................................................................................................................................... 17
EN
General information 19
General ...................................................................................................................................................... 21
General ................................................................................................................................................. 21
Proper use/intended purpose................................................................................................................ 21
Advantages ........................................................................................................................................... 21
Application areas .................................................................................................................................. 22
System overview................................................................................................................................... 22
Laser welding head scope of supply..................................................................................................... 23
Optional components ............................................................................................................................ 23
Requirements............................................................................................................................................. 24
System requirements and minimum equipment required for the laser-twin welding process ............... 24
Power source synchronisation .............................................................................................................. 24
Software activation................................................................................................................................ 24
Mechanical requirements...................................................................................................................... 25
Dimensioning of the robot ..................................................................................................................... 25
Functional principle .................................................................................................................................... 26
Functional principle ............................................................................................................................... 26
Lead power source and trail power source ........................................................................................... 26
Welding technology aspects ...................................................................................................................... 27
Welding technology aspects ................................................................................................................. 27
Earth connection ................................................................................................................................... 27
Welding circuit inductivity L, welding circuit resistance r....................................................................... 27
Tilt angle of the welding torch ............................................................................................................... 28
Possible arc combinations .................................................................................................................... 28
Pulse/Pulse ........................................................................................................................................... 28
Connecting to the robot control.................................................................................................................. 30
Robot interfaces for the laser-twin welding process ............................................................................. 30
Standard robot interfaces...................................................................................................................... 31
Twin fieldbus systems .......................................................................................................................... 32
Standard fieldbus systems.................................................................................................................... 33
Control elements and connections 35
Description of the device............................................................................................................................ 37
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Description of the device....................................................................................................................... 37
Connection specifications .......................................................................................................................... 39
Connection specifications ..................................................................................................................... 39
Compressed air diagram....................................................................................................................... 40
Start-up 41
General ...................................................................................................................................................... 43
Safety.................................................................................................................................................... 43
Setup regulations .................................................................................................................................. 43
Mains connection .................................................................................................................................. 43
Assembling a laser-twin system............................................................................................................ 43
Commissioning (overview).................................................................................................................... 45
Fitting the laser welding head to the robot ................................................................................................. 46
Requirements for the robot ................................................................................................................... 46
Fitting the laser welding head to the robot ............................................................................................ 46
Connecting the LaserHybrid Ultracompact Twin hosepack to the laser welding head .............................. 47
Preparatory work................................................................................................................................... 47
Connecting the LaserHybrid Ultracompact Twin hosepack to the laser welding head ......................... 48
Connect/replace the external wirefeeding hoses on the laser welding head ........................................ 52
And finally... .......................................................................................................................................... 53
Connecting the laser optics system, Crossjet and additional extractor...................................................... 54
Connecting the laser optics system ...................................................................................................... 54
Connecting the Crossjet and additional extractor ................................................................................. 56
Laying the hosepack on the robot.............................................................................................................. 57
Laying the hosepack on the robot......................................................................................................... 57
Threading the wire electrode ..................................................................................................................... 58
Preparatory work................................................................................................................................... 58
Removing the welding torch wearing parts ........................................................................................... 58
Threading the wire electrode ................................................................................................................ 59
Fitting the welding torch wearing parts ................................................................................................. 62
Setting the radial air flow............................................................................................................................ 64
Requirements........................................................................................................................................ 64
Setting the radial air flow....................................................................................................................... 64
Adjusting the laser welding head ............................................................................................................... 67
Stick out ................................................................................................................................................ 67
Adjustable axes..................................................................................................................................... 67
Adjusting device on the laser welding head.......................................................................................... 68
Adjusting the x-axis............................................................................................................................... 68
Adjusting the y-axis............................................................................................................................... 69
Creating a reference program.................................................................................................................... 70
Safety.................................................................................................................................................... 70
General ................................................................................................................................................. 70
Creating a reference program............................................................................................................... 70
Signal sequence for LaserHybrid welding.................................................................................................. 72
Safety.................................................................................................................................................... 72
Signal sequence for LaserHybrid welding............................................................................................. 72
Measures to be taken before the start of welding ...................................................................................... 74
Measures to be taken before the start of welding ................................................................................. 74
Parameter settings on the power source .............................................................................................. 74
Recommendations for operating a laser-twin welding system................................................................... 75
Recommendations for operating a laser-twin welding system.............................................................. 75
Maintenance 77
Changing the wire electrode ...................................................................................................................... 79
Preparatory work................................................................................................................................... 79
Unthreading the wire electrode ............................................................................................................. 80
Changing the wire electrode ................................................................................................................. 82
Replacing wearing parts ............................................................................................................................ 83
Preparatory work................................................................................................................................... 83
Removing the feed rollers ..................................................................................................................... 83
Replacing the inlet nozzles ................................................................................................................... 86
Replacing and installing the feed rollers ............................................................................................... 86
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Replacing the welding torch and welding torch inner liners ....................................................................... 88
Safety.................................................................................................................................................... 88
Preparatory work................................................................................................................................... 88
Replace the welding torch..................................................................................................................... 89
Replacing the welding torch inner liners ............................................................................................... 90
Replacing welding torch wearing parts ...................................................................................................... 91
Safety.................................................................................................................................................... 91
Welding torch spare parts ..................................................................................................................... 91
Removing the welding torch wearing parts ........................................................................................... 91
Fitting the welding torch wearing parts ................................................................................................. 93
Replacing the spatter guard sheet ............................................................................................................. 95
Removing the spatter guard plate......................................................................................................... 95
Fitting the spatter guard plate ............................................................................................................... 95
Replacing the laser optics system ............................................................................................................. 97
Safety.................................................................................................................................................... 97
Preparatory work................................................................................................................................... 97
Removing the laser optics system ........................................................................................................ 98
Mounting positions for installing the laser optics system ...................................................................... 101
Installing the laser optics system .......................................................................................................... 102
Fitting the spatter guard plate ............................................................................................................... 105
And finally... .......................................................................................................................................... 105
Creating a reference program and setting the position of the wire electrode in relation to the focus point
of the laser .................................................................................................................................................
Safety.................................................................................................................................................... 106
General ................................................................................................................................................. 106
Checking the position of the wire electrode in relation to the focal spot of the laser ............................ 106
Example: Using the reference program after changing the welding torch ............................................ 107
Measures to reduce optics contamination ................................................................................................. 108
Measures to reduce optics contamination ............................................................................................ 108
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EN
Appendix 111
Technical data............................................................................................................................................ 113
LaserHybrid Ultracompact Twin(laser welding head) ........................................................................... 113
LaserHybrid Ultracompact Twin hosepack ........................................................................................... 113
Spare parts list: LaserHybrid Ultracompact Twin....................................................................................... 114
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Safety rules
EN
Explanation of
safety symbols
General
DANGER! Indicates immediate and real danger. If it is not avoided, death or se-
rious injury will result.
WARNING! Indicates a potentially dangerous situation. Death or serious injury
may result if appropriate precautions are not taken.
CAUTION! Indicates a situation where damage or injury could occur. If it is not
avoided, minor injury and/or damage to property may result.
NOTE! Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT! Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
If you see any of the symbols depicted in the "Safety rules" chapter, special care is required.
The LaserHybrid head is manufactured using state-of-the-art technology and
according to recognised safety standards. If used incorrectly or misused, however, it can cause:
- injury or death to the operator or a third party,
- damage to the LaserHybrid head and other material assets belonging to
the operator,
- inefficient operation of the LaserHybrid head.
All persons involved in commissioning, operating, maintaining and servicing
the LaserHybrid head must:
- be suitably qualified,
- have sufficient knowledge of welding and
- carefully observe these operating instructions as well as the operating instructions for the following system components:
the laser
the laser optics system
the power source and its wirefeeder
the robot and its control system
The operating instructions must always be at hand wherever the LaserHybrid
head is being used. In addition to the operating instructions, attention must
also be paid to any generally applicable and local regulations regarding accident prevention and environmental protection.
All safety and danger notices on the LaserHybrid head
- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.
For the location of the safety and danger notices on the LaserHybrid head, refer to the "General" section in the operating instructions for your LaserHybrid
head.
Before switching on the device, rectify any faults that could compromise safety.
This is for your personal safety!
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Proper use
The LaserHybrid head is to be used exclusively for its intended purpose.
The LaserHybrid head is intended solely for use in LaserHybrid welding of aluminium, CrNi and steel materials.
Any use above and beyond this purpose is deemed improper.
The manufacturer shall not be held liable for any damage arising from such
usage.
Proper use also includes:
- carefully reading and following all the instructions given in the operating
instructions
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and servicing work.
Never attempt to use the LaserHybrid head or the power source being used
for thawing frozen pipes.
The LaserHybrid head is designed for use in industry and the workshop. The
manufacturer accepts no responsibility for any damage caused through use in
a domestic setting.
The manufacturer likewise accepts no liability for inadequate or incorrect work
results.
Environmental
conditions
Obligations of the
operator
Operation or storage of the LaserHybrid head outside the stipulated area will
be deemed as not in accordance with the intended purpose. The manufacturer
shall not be held liable for any damage arising from such usage.
Ambient air temperature range:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -25 °C to + 55 °C (-13 °F to 131 °F)
Relative humidity:
- up to 50% at 40 °C (104 °F)
- up to 90% at 20 °C (68 °F)
The ambient air must be free from dust, acids, corrosive gases or substances,
etc.
Can be used at altitudes up to 2000 m (6561 ft. 8.16 in.)
The operator must only allow persons to work with the LaserHybrid head who:
- are familiar with the fundamental instructions regarding safety at work and
accident prevention and have been instructed in how to use the LaserHybrid head
- have read and understood these operating instructions, especially the
"Safety rules" section, and have confirmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are
working in a safety-conscious manner.
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Obligations of
personnel
Before starting work, all persons using the LaserHybrid head undertake:
- to observe the basic instructions regarding safety at work and accident
prevention
- to read these operating instructions, especially the "Safety rules" section
and sign to confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to
any harm in your absence.
EN
Personal protective equipment
For your personal safety, take the following precautions:
Persons in the closed cell for the LaserHybrid process must:
wear solid footwear that provides insulation even in wet conditions
protect their hands by wearing suitable gloves (electrically insulated and heatproof)
protect their eyes from laser beams by wearing regulation-compliant laser
safety goggles. In addition, they must protect their faces and eyes from UV
rays using a protective visor and regulation filter element for laser protection
class 4 worn in front of the laser safety goggles and the face. Even when using
this regulation filter element for laser protection class 4, they should not look
into the laser beam.
only wear suitable (i.e. flame-retardant) clothing
Danger from toxic
gases and vapours
use ear protectors to protect them from the cross-jet noise (120 dbA)
If other persons are in the closed cell for the LaserHybrid process, you must:
- make them aware of all the dangers that may occur during operation (e.g.
risk of a build-up of gases that are detrimental to health, possible risk of
suffocation due to lack of oxygen in the air, danger from laser light, etc.)
- provide them with protective equipment
- erect safety screens or curtains
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that may, under certain circumstances,
cause birth defects or cancer.
Keep your face away from welding fumes and gases.
Fumes and hazardous gases
- must not be breathed in
- must be extracted from the working area using appropriate methods.
Ensure an adequate supply of fresh air.
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Otherwise, a protective mask with an air supply must be worn.
Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
If there is any doubt about whether the extraction capacity is sufficient, the
measured toxic emission values should be compared with the permissible limit
values.
The following components are responsible, amongst other things, for the degree of toxicity of welding fumes:
- Metals used for the workpiece
- Electrodes
- Coatings
- Cleaners, degreasers, etc.
The relevant material safety data sheets and manufacturer's specifications for
the listed components should therefore be studied carefully.
Flammable vapours (e.g. solvent fumes) should be kept away from the radiation area of the laser and the arc.
Danger from escaping shielding
gas
Danger from flying sparks
Risk of suffocation from the uncontrolled escape of shielding gas
Shielding gas is colourless and odourless and, in the event of a leak, can displace the oxygen in the ambient air.
- Ensure an adequate supply of fresh air with a ventilation rate of at least
20 m³/hour.
- Observe safety and maintenance instructions on the shielding gas cylinder or the main gas supply.
- Close the shielding gas cylinder valve or main gas supply if no welding is
taking place.
- Check the shielding gas cylinder or main gas supply for uncontrolled gas
leakage before every start-up.
Flying sparks may cause fires or explosions.
Never weld close to flammable materials.
Flammable materials must be at least 11 m (35 ft.) away from the LaserHybrid
welding process, or alternatively covered with an approved cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small
gaps or openings. Take appropriate precautions to prevent any danger of injury or fire.
Welding must not be performed in areas that are subject to fire or explosion or
near sealed tanks, vessels or pipes unless these have been prepared in accordance with the relevant national and international standards.
Do not carry out welding on containers that are being or have been used to
store gases, propellants, mineral oils or similar products. Residues pose an
explosive hazard.
Hazards from
welding current
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An electric shock can be fatal. Every electric shock is hazardous to life.
All welding cables must be firmly attached, undamaged and properly insulated. Replace any loose connections and scorched cables immediately.
Vagrant welding
currents
If the following instructions are ignored, vagrant welding currents may occur.
These can destroy earthed conductor terminals, the power source being
used, the LaserHybrid welding head and other electrical equipment.
Ensure the workpiece clamp is connected tightly to the workpiece.
On electrically conductive floors, the power source must be set up in such a
way as to be insulated from the floor, wherever possible.
EN
EMC measures
Warning, electromagnetic field. Electromagnetic fields may cause as yet
unknown damage to health.
It is the operator's responsibility to ensure that no electromagnetic interference
occurs in electrical and electronic devices.
If electromagnetic interference is found to be occurring, the owner/operator is
obliged to take all necessary measures to prevent this interference.
Check for possible problems, and check and evaluate neighbouring devices'
resistance to interference according to national and international requirements:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
- The health of persons in the vicinity, e.g. users of pacemakers and hearing aids
Individuals with pacemakers must seek advice from their doctor before approaching the welding work area.
Supporting measures for avoidance of EMC problems:
a) Mains supply
- If electromagnetic interference arises despite the correct mains con-
nection, additional measures are necessary (e.g. use of a suitable
line filter)
b) Welding power-leads
- must be kept as short as possible
- must be laid close together (also to avoid EMC problems)
- must be laid apart from other leads
c) Equipotential bonding
d) Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
e) Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation
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Specific hazards
Risk of injury to the eyes from the laser beam. In addition to the protective visor
with regulation UV filter element, ensure that all persons wear regulation laser
safety goggles to protect their eyes from laser beams. You should still ensure
that nobody can accidentally look into the laser beam.
With highly shiny, reflective workpiece surfaces, there is a further danger
caused by reflected and scattered laser radiation. Suitable precautions must
be taken to ensure that all persons in the area are sufficiently protected from
scattered laser radiation.
Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive components.
Covers and side panels may only be opened or removed for as long as maintenance or repair work is being carried out.
During operation:
- Ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
The welding wire emerging from the welding torch poses a high risk of injury
(piercing of the hand, injuries to the face and eyes, etc.).
Therefore always keep the welding torch away from the body (devices with
wire-feed unit) and wear suitable protective goggles.
Never touch the workpiece during or after welding - risk of burns.
Slag can jump off cooling workpieces. The specified protective equipment
must therefore also be worn when reworking workpieces, and steps must be
taken to ensure that other people are also adequately protected.
Welding torches and other parts with a high operating temperature must be allowed to cool down before handling.
Special provisions apply in areas at risk of fire or explosion
- observe relevant national and international regulations.
Power sources for work in areas with increased electric risk (e.g. near boilers)
must carry the "Safety" sign. However, the power source must not be located
in such areas.
Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting coolant flow or return lines.
Observe the information on the coolant safety data sheet when handling coolant. The coolant safety data sheet may be obtained from your service centre
or downloaded from the manufacturer's website.
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Use only suitable load-carrying equipment supplied by the manufacturer when
transporting devices by crane.
- Hook chains or ropes onto all suspension points provided on the load-carrying equipment.
- Chains and ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).
If the wirefeeder is attached to a crane holder during welding, always use a
suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).
If the device has a carrying strap or handle, this is intended solely for carrying
by hand. The carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or other mechanical hoist.
All lifting accessories (straps, handles, chains, etc.) used in connection with
the device or its components must be tested regularly (e.g. for mechanical
damage, corrosion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national
standards and directives as a minimum.
Odourless and colourless shielding gas may escape unnoticed if an adapter
is used for the shielding gas connection. Prior to assembly, seal the deviceside thread of the adapter for the shielding gas connection using suitable Teflon tape.
EN
Informal safety
measures
Safety measures
at the installation
location
The operating instructions must always be at hand wherever the LaserHybrid
head is being used.
In addition to the operating instructions, any generally applicable and local
regulations regarding accident prevention and environmental protection must
be provided and followed.
All safety and danger notices on the LaserHybrid head must be kept in a legible condition.
The cell for the LaserHybrid welding process must meet the following requirements:
- be sealed off from adjoining rooms to make it lightproof
- be screened with min. 1 mm thick steel plate and/or approved laser protective glass to prevent any UV or laser radiation escaping
- both the laser welding process and the arc welding process must stop automatically as soon as the cell is opened
A device that topples over can easily kill someone. Place the device on a solid,
level surface.
- The maximum permissible tilt angle is 10°.
Special regulations apply in rooms at risk of fire or explosion
- Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment
is always clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protection shown on the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1
ft. 7.69 in.) to ensure that cooling air can flow in and out freely.
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When transporting the device, observe the relevant national and local guidelines and accident prevention regulations. This applies especially to guidelines
regarding the risks arising during transport.
Before transporting the device, allow coolant to drain completely and detach
the following components:
- Wire feed speed
- Wirespool
- Shielding gas cylinder
After transporting the device, the device must be visually inspected for damage before commissioning. Any damage must be repaired by trained service
technicians before commissioning the device.
Safety measures
in normal operation
Safety inspection
Only operate the LaserHybrid head if all protection and safety devices are fully
functional. If the safety devices are not fully functional, there is a risk of
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operator,
- inefficient operation of the device.
Any safety devices that are not functioning properly must be repaired before
switching on the device.
Never bypass or disable safety devices.
Before starting up the LaserHybrid head, ensure that no one is likely to be endangered.
Check the LaserHybrid head at least once a week for obvious damage and
proper functioning of the safety devices.
The operator is obliged to have the LaserHybrid head checked by a qualified
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2
1
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electrician to ensure it is safe for use after any modifications, alterations, re-
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pairs, care and maintenance, and in any case at least every twelve months.
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Regulation Title
IEC (EN) 60 974-1 Arc welding equipment - Part 1: Power sources
BGV A2, §5 Electrical plant and equipment
BGV D1, §33 / §49 Welding, cutting and associated processes
VDE 0701-1 Repair, modification and inspection of electrical ap-
pliances;
general requirements
VDE 0702-1 Repeat tests on electrical equipment
Alterations
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Do not carry out any modifications, alterations, etc. to the LaserHybrid head
without the manufacturer's consent.
Components that are not in perfect condition must be replaced immediately.
Replacement and
wearing parts
Use only original spare and wearing parts (also applies to standard parts).
It is impossible to guarantee that parts sourced from third parties are designed
and manufactured to meet the demands made of them, or that they satisfy
safety requirements.
When ordering, please give the exact designation and part number as shown
in the spare parts list, as well as the serial number of your device.
EN
Calibration of
power sources
CE marking
Copyright
In view of international standards, regular calibration of power sources is necessary. Fronius recommends a 12-month calibration interval. For more information, please contact your service centre.
The LaserHybrid head fulfils the fundamental requirements of the Low Voltage
Directive and the Electromagnetic Compatibility Directive and is thus CEmarked.
Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We
reserve the right to make changes. The contents of the operating instructions
shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any
mistakes that you have found in the instructions, we will be most grateful for
your comments.
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General information
General
EN
General
Proper use/intended purpose
The LaserHybrid Ultracompact Twin is a
further development of the LaserHybrid Ultracompact head.
The LaserHybrid Ultracompact Twin head
is used specifically for components requiring high welding speeds.
Throughout the rest of these Operating Instructions, the LaserHybrid Ultracompact
Twin head is referred to as the laser welding head.
Alongside the laser welding head, the lasertwin welding process is also described in
these Operating Instructions.
The LaserHybrid ultracompact Twin is intended exclusively for MAG tandem (Twin) welding.
Utilisation for any other purpose, or in any other manner, shall be deemed to be not in accordance with the intended purpose.
The manufacturer shall not be held liable for any damages arising from such usage.
Proper use also includes
- Complying with all the instructions from the respective Operating Instructions for the
individual components
- Performing all stipulated inspection and maintenance work
Advantages Advantages of the laser welding head:
- High welding speed and therefore highly cost-effective
- High process stability combined with low reject numbers and little need for rework
- High weld seam quality
- Low heat input, low distortion
- High availability of welding system, long service life for wearing parts
- Flexibility
- Good gap tolerance
- Can be adapted for fibre, disc and diode lasers
- No slip in the hosepack, resulting in a stable arc
- Few wearing parts - low maintenance costs
- Simple layout
Advantages of the laser-twin welding process:
- Arc can be controlled selectively
- Minimal arc blow during pulsed arc
- Small weld pool due to short arc, which results in a high welding speed
- Same menu navigation as the TPS 4000/5000
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Application areas The LaserHybrid Ultracompact Twin laser welding head is primarily used in laser-MAG ap-
plications:
- For axle and bodywork production with sheet thicknesses of 1 - 4 mm in the motor vehicle industry
- For tank and boiler manufacturing
Other application areas:
- In rolling stock manufacturing for longitudinal seams and profiles
- In shipbuilding for fillet welds and profiles
- In vehicle manufacturing for lap joints and welding of wheel rims
- In container construction for lap joints and circumferential welds
- For edge welds on lifting gear
System overview
(4)
(2)
(1)
(1) Welding wire drum
(2) Unreeling wirefeeders:
WF 25i REEL R /SA/2R/G/W
+ OPT/i WF wire straightening
section (4,100,880,CK)
(3) Lead power source
+ Twin DeviceNet Interface
+ LHSB connection option
+ LHSB connection cable
+ Software activation
+ Software update from the
Fronius database
+ Drive Easy Twin control box
+ FK 9000 R cooling unit / part 1
+ RCU 5000i remote control
+ Upright console (secured)
(4) Wirefeeding hoses
(1)
(3)
(5)
(6)
(7)
(12)
(11)
(8)
(9)
(10)
(5) LHSB cable connection between
the power sources
(6) Trail power source
+ LHSB connection option
+ Software activation
+ Software update from the
Fronius database
+ FK 9000 R cooling unit / part 2
+ RCU 5000i remote control
+ Upright console (secured)
(7) LaserHybrid Ultracompact Twin
hosepack
(8) Fieldbus
(9) Robot control
(10) Robot
(11) CrashBox
(12) LaserHybrid Ultracompact Twin
laser welding head
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Laser welding
head scope of
supply
- 1 LaserHybrid Ultracompact Twin laser welding head (complete)
- 1 LaserHybrid Ultracompact Twin hosepack
- 1 metal gauge for adjusting the focal spot
- 1 flat spanner (8/10 mm)
- 1 slotted screwdriver, 2.5 mm
- 1 Allen key, 2.5 mm
- 1 ball-ended hex screwdriver, 3 mm
- 1 ball-ended hex screwdriver, 4 mm
- 1 driving-gear spanner
- 1 stick out gauge
- 1 PushIn coupling connection
- 1 hose 4x750 mm
- 1 flow rate meter (up to 25 l/min)
- 1 set of Operating Instructions
- Wirefeeder accessories and feed rollers, depending on the configuration
EN
Optional components
The following components are available as options for the "LaserHybrid Ultracompact
Twin" laser welding head:
- Focus monitoring
- Various laser beam sources
- Temperature sensor
- CrashBox
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Requirements
System requirements and minimum equipment
required for the
laser-twin welding process
(1) LaserHybrid Ultracompact Twin welding head
(2) LaserHybrid Ultracompact Twin hosepack
(3) Two unreeling wirefeeders
WF 25i REEL R /SA/2R/G/W (stand-alone)
+ OPT/i WF wire straightening section option (4,100,880,CK)
(4) Two power sources
TPS 5000 (+ variants)
+ Official UST V3.10.33 firmware and higher
+ LHSB connection option
+ "TimeTwin Digital" software activation
+ Software update from the Fronius database
+ Standard I/O robot interface or fieldbus
The options are required on both power sources.
(5) Drive Easy Twin control box
(6) Cooling unit
FK 9000 R (2-part)
Power source
synchronisation
Software activation
The power sources are synchronised with one another during the laser-twin welding process via:
- The LHSB connection option on the power sources
- The LHSB connection cable
The P-C (Power-Control) parameter is available following successful installation of the
LHSB connection. The P-C parameter is displayed on the power source under Setup menu
- Level 2.
Possible settings:
On / oFF
NOTE! For the laser-twin welding process, the P-C parameter must be set to "On"
on both power sources.
Activation of the "TimeTwin Digital" software (item number 4,061,110) is required on both
power sources for the laser-twin welding process.
The t-C (Twin-Control) parameter is available following successful activation and establishment of an active LHSB connection. The t-C parameter defines the lead power source.
This power source specifies the frequency for the trail power source.
IMPORTANT! Software activation on the power sources is monitored via the LHSB connection. If the software is not activated on a power source and the t-C parameter is therefore not available, the t-C parameter is also not displayed on the other power source.
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Possible settings:
On / oFF
Display/setting:
- No robot interface available... the t-C parameter is displayed and configured on the
power source under Setup menu - Level 2.
- Robot interface available ... the t-C parameter is controlled by the robot control in such
a way that either the first or second power source functions as the lead power source,
depending on the welding direction.
The t-C parameter must be set to "On" on the lead power source via the robot control.
This can be checked on the t-C parameter display on the power source under Setup
Menu - Level 2.
EN
Mechanical requirements
Dimensioning of
the robot
For a stable and reproducible laser-twin process, the following mechanical requirements
must be met:
- Precise torch guidance for robots or single-purpose machines (e.g. straight-line carriage)
- Exact joint preparation
- Low component tolerances
- Seam guidance systems with low deviation
Please note the following when dimensioning the robot:
- The torch holder on the robot must be stable. A LaserHybrid Ultracompact Twin welding head weighs roughly 10.4 kg.
- The CrashBox must be designed for the weight of the laser welding head.
- The LaserHybrid Ultracompact Twin hosepack must be considered when dimensioning the robot. The robot hosepacks and wirefeeding hoses must be routed via a balancer in the robot cell.
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Functional principle
Functional principle
(5)
(4)
(7)
(3)
(2) (2)
(8)
(6)
(1) (1)
(9)
- Two wire electrodes (5) and (11) are welded by a laser beam (6) in a weld pool under
a gas shroud.
- The welding process is performed using two independent power sources (4) and (10).
- The power sources (4) and (10) are synchronised (7).
- The wire is fed via two unreeling wirefeeders (2) and a shared frontpull drive (8).
- The frontpull drive (8) is controlled by a control unit (3).
- Both wire electrodes are brought together in the welding torch in such a way that two
independent welding potentials (9) are available.
(11)
(10)
Lead power
source and trail
power source
IMPORTANT! The laser-twin welding process only works when used with filler metal from
welding wire drums (1).
The two power sources are referred to as the lead power source and the trail power source
in the laser-twin welding process.
- The lead power source is determined by the welding direction.
- The t-C (Twin-Control) parameter must be set to "On" on the lead power source.
(See also "System requirements" chapter, "Software activation" section).
- The lead power source specifies the frequency for the trail power source.
- The wire electrode of the lead power source is the front wire electrode, in terms of the
welding direction.
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Welding technology aspects
EN
Welding technology aspects
Shielding gas
ArO2 ... for unalloyed and low-alloy steels
Gas flow
total gas flow rate approx. 15 - 20 l/min
TPS 5000 welding characteristics (database 02-0043)
Material Gas 1.2 (L) 1.0 (T)
G3Si1-Twin M22 - 96% Ar, rest O
G3Si1-Twin M22 - 96% Ar, rest O
G3Si1-Twin M21 - 90% Ar, rest O
* ... Recommended by Fronius for the laser-twin welding process
L ... Lead wire electrode
T ... Trail wire electrode
2
2
2
02-1922 02-1919 *
02-1921 02-1918 *
02-1920 02-1917
Earth connection Use a separate grounding (earthing) cable for each power source:
Welding circuit
inductivity L,
welding circuit resistance r
Separate grounding (earthing) cable Shared grounding (earthing) cable, earth socket
Grounding (earthing) cable laid in a loop Grounding (earthing) cable coiled
IMPORTANT! The welding circuit inductivity L and the welding circuit resistance r must be
calibrated separately for each power source and for each twin welding process.
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Tilt angle of the
welding torch
Select the welding torch tilt angle so that
the lead wire electrode (= the electrode of
the lead power source) is positioned neutrally or slightly forward.
90 - 100°
Welding torch tilt angle neutral to slightly forward
Possible arc combinations
Pulse/Pulse
The LHSB connection on the power sources means that various arc types can be combined in the laser-twin welding process.
The welding direction is defined by the wire pairing (Ø 1.2 mm lead power source / Ø 1.0
trail power source) and the design of the welding torch.
Lead wire electrode
(=lead power source)
Trail wire electrode
(= trail power source)
Pulse Pulse
I (A)
I
L
I
T
t (s)
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IL > I
T
Welding current/time curve and schematic representation of the material transfer
Trail wire electrode
Lead wire electrode
Active pulsed arc with droplet transfer
Inactive pulsed arc (no droplet transfer)
EN
I
L
I
T
Welding current of lead power source
Welding current of trail power source
Welding direction
A "Master selection signal" is output by the robot control. This signal defines the lead power
source.
Synchronisation of both power sources:
The welding current pulses of the trail power source are placed precisely between the two
welding current pulses of the lead power source (180° phase shift).
This results in:
- Optimal material transfer (one droplet of material per welding current pulse)
- Minimal arc blow during pulsed arc
- Stable arc across the entire power range
- Reproducible process
- Excellent heat input and high welding speed
The lead wire electrode usually has a wire diameter of 1.2 mm, while the trail wire electrode
has a wire diameter of 1.0 mm.
This ensures:
- Targeted heat input
- Good melting of the cold base material
- Precise root pass formation
- Trail wire electrode fills the weld pool
- Longer degassing time (reduced proneness to porosity)
- High welding speed
NOTE! The Pulse/Pulse arc combination should be used for all general welding
applications.
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Connecting to the robot control
Robot interfaces
for the laser-twin
welding process
There are two special robot interfaces available for the laser-twin welding process, for connecting to the robot control:
- Twin Standard I/O Job (0-24 V digital)
- Twin Standard I/O Synergic / Job (0-24 V digital, 0-10 V analogue)
Each of these "Twin interfaces" features an integral programmable logic controller (PLC).
The signals are connected logically by the PLC. Both power sources are therefore triggered simultaneously by a signal from the robot control. Only one "Twin interface" is required for two power sources. The "Twin interface" in installed in the switch cabinet.
Application example:
No. Part/device No. Part/device
(1) LocalNet connection (5) Twin interface
(2) LocalNet connection (6) Connection to robot control
(3) Power source (7) Robot control
(4) Power source
(1)
(2)
(3)
(4)
(5)
(6)
(7)
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