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Improve your competitiveness: Automate your welding processes

2023-02-28 | 

Optimizing production processes is a top priority in the age of digitalization and Industry 4.0. Companies have to deliver more and more output in perfect quality while at the same time, working in an tautological manner. Automated welding systems with digital control technology and networked components not only ensure a consistently high level of quality, they also lead to a significant reduction in production times.

Gradual automation of your welding application is key in times of cost pressure being combined with the highest technical requirements for welded structures.

Böhler Welding is the best partner for the next level of welding productivity with its innovative, future-oriented automation solutions. We have developed a full range of automated Full Welding Solutions, from welding carriages to collaborative robots to highly efficient industrial robotic solutions.

Benefit from coordinated packages:

 

CO-BRO®

CO-BRO® / URANOS NX range / diamondspark MC range

Our customers benefit from a solution, which is quickly ready to use, especially when changing the part to weld. The result is maximum flexibility.

We offer a plug-and-play system that can be fine-tuned with our Böhler Arc welding programs and RapiDeep special process. Suitable fro small to medium size, it offers higher productivity and better quality than semi-automatic welding.

Advantages:

  • Easy to program and use
  • Easy to integrate
  • High penetration rate
  • High deposit rate
  • Low risk of undercut

For welding brackets, supports and machinery; leverages and other un-alloyed and low alloyed steel small to medium components as single unit or small series.

CO-BRO® / URANOS NX range / ECOspark range

Our CO-BRO® collaborative welding system, the URANOS NX welding machine and our ECOspark solid wire, offer an ecological method of production.

It can be also be fine-tuned with the Böhler Arc welding programs and the special process QuickPulse and offers clean technologies including our unique greenWave technology, which minimizes the reactive power consumption and the installed power required.

Customers benefit from a fast set-up, high flexibility and productivity.

Advantages:

  • Easy to program and use
  • Easy to integrate
  • High penetration rate
  • High disposit rate 
  • Low risk of undercut

For welding brackets, supports and machinery; leverages and other un-alloyed and low alloyed steel small to medium components as single unit or small series.

CO-BRO® / URANOS NX range / Stainless steel solid wires range

This plug and play solution offers the highest level of quality combined with perfect aesthetics. Coordinated with Böhler Arc, maximum flexibility and productivity are achieved. 

Customers benefit from fast set-up, fast operational readiness, high flexibility and efficiency as no post-cleaning is required.

Advantages:

  • Easy to program and use
  • Easy to integrate
  • No spattering, perfect aesthetics of the bead
  • Less heat input
  • Less deformation

For welding of small tanks and stainless steel components as single unit or small series.

pipeRunner®

pipeRunner® / TERRA 400 PRM / diamondspark X RC-pipe

This package gives customers a fully mechanized and programmed solution. Precise movements, a wide weldability window and a high material recovery rate are the result of this precision in movement thanks to the digital controls and the high performance of the diamondspark flux cored wires.

If you are looking for a solution that saves time and is easy to use, this is the one for you. Digital controls and full parameters programming also ensure WPS are always maintained, resulting in high quality and repeatability.

It is also characterized by less and easy cleaning after the weld and a minimum to zero repair rate.

Advantages:

  • High repeatability
  • No risk of lack of fusion
  • Possible to weld with a single parameter setting
  • High deposition rate

For welding orbital girth welds of un- and low-alloyed pipeline and piping applications.

With our FOXcore stainless and nickel alloy flux cored wires, this solution is also suitable for use in high alloys and clad pipe and piping applications.

For the use in orbital girth welds of all alloy 625/825 clad pipes we specifically recommend the combination with the FOXcore 625-T1.

Industrial robots

Industrial robots / URANOS NX PSR series / diamondspark MC range

We offer a wide range of setups within this solution. These setups are characterized by high material recovery, low hydrogen and no moisture pickup.

Welding behavior can be optimized with our Böhler Arc welding programs and rapiDeep special process. The result is perfect welds for each specific application, high productivity and improved quality over semi-automatic welding.

Advantages:

  • Equipment matches perfect with the manufacturing needs
  • High penetration
  • High deposition rate
  • Low risk of undercut
  • Perfect weld bead aspect

For welding transportation frames, industry, yellow and green goods as well as heavy fabrication applications and accessories in large series.

Industrial robots / URANOS NX PSR series / ECOspark range

Our customers benefit from an automated solution offering a wide range of set ups, including environmental benefits with our unique greenWave technology and low fume emissions. With a number of features such as maximum wire speed and a low silicate rate, it results in a perfect weld seam for each specific application. This ensures both higher productivity and higher quality. In combination with Böhler Arc and the special process QuickPulse multiple benefits can be seen.

Advantages:

  • Equipment matches perfect with the manufacturing needs
  • High penetration
  • High deposition rate
  • Low risk of undercut
  • Perfect weld bead aspect

For welding transportation frames, industry, yellow and green goods as well as heavy fabrication applications and accessories in large series.

Industrial robots / URANOS NX PSR / high-strength solid wires range

The combination of high quality, welded joints mechanical properties and productivity is crucial to meet the customer demand in high strength structural steels industrial sectors. Our robotic equipment in combination with high performance solid wires, Böhler Arc welding programs and QuickPulse special process deliver the following advantages.

Advantages:

  • Low travel speed
  • Lowest heat input, resulting in low deformation and mechanical properties also met for thin high strength plates
  • High deposition rate
  • Low risk of undercut
  • Perfect weld bead aspect

For welding high strength structures in the crane and lifting industry, heavy fabrication applications and civil engineering structures

Industrial robots / URANOS NX PSR series / high-alloyed solid wires range

When used in combination with high-alloy solid wires, our solution offers advantages such as no spattering, perfect aesthetics of the bead, less heat input and less deformation. It also has the advantage of low dilution and layer savings during cladding.

No post-cleaning and the highest level of weld bead quality contribute to higher productivity as well. Böhler Arc welding programs together with pulsed arc PulseDrive for joining or CladPulse for cladding, make the difference in increasing weld joint quality to the highest level while saving welding time and material.

Advantages:

  • Equipment matches perfect with the manufacturing needs
  • Low spattering
  • Perfect beat aesthetics
  • Less heat input
  • Less deformation

For welding food and beverage tanks, CPI tanks, pipework, machinery components, large series of white good parts, and cladding of valves and vessels.