Industrial joining technology is being confronted by continually growing material diversification. Modified materials and coatings require, to achieve excellent seam quality, the precisely co-ordinated arc. Environmental influences, specific to the customer, with a physical effect on the arc must be neutralised. High tech applications with the focus on high fusion performance, are pushing for their theoretical potential to be realised.
The link-up to the world of industrial robots and special purpose machines must be made possible with a simple installation. The results should be process-safe and reproducible. As well as the applications accumulated at the upper end of the demand scale, it is appropriate to offer to the market solutions appropriate for the requirements of the so-called standard applications in arc joining technology.
With globalisation new markets are opening up for the manufacturers of technical welding equipment, as well as for their users, on the other hand both sides can however see that they are being subjected to growing pricing pressure. This means for the manufacturer of technical welding equipment, that they should convert the total of all demands into:
- hard and software solutions specific to the customer (best ignition and welding properties, appropriate range of capacity co-ordinated
to the automation environment and suitable for the relevant operation environment);
- >>On board<< technical process intelligence (safe, rapid adjustment to changing welding jobs, guaranteeing process safety and
reproducibility of the welding results);
- high dependability (high total availability);
- simple, intuitive operation (low demands on the theoretical expert knowledge of the welder, reduces the >>size of human error<<,
requires low training costs);
- good value (most economical solution) as well as
- short delivery times.
Platform strategy enables lots of variations
With the new welding machine generation QINEO® from Cloos (www.cloos.de) the most modern freely configurable power source technology is /will be available. Primary cycled (Inverter) and secondary cycled power sources (chopper), step-switch power sources and machines with infinitely adjustable power preselection, normal and pulse process as well as fully digitalised welding process regulation form the basis for an optimum equipment configuration specific to the customer. A specifically converted platform strategy (modular construction) enables sensible variations and the realisation of application orientated equipment levels. Hence the integration of the operating panel in the wire drive, in the power source or in a portable remote control housing can be achieved. For all pulse equipment three control types are available, which offer the alternative of the scope of control, adapted to the task in hand. Power sources with integrated wire drive or with wire drive in its own housing, no water cooling (gas cooled torch), integrated or external water cooling, stacking feet as well as normal or large wheels are further configurable features.
The first range is the robust QINEO® STEP
With QINEO® STEP the first range in the QINEO® series is available on the market. The step-switch MIG/MAG welding machines are distinguished by simple, intuitive operation and special robustness. The types STEP 180, STEP 250 and STEP 300 are designed as gas-cooled compact systems for the workshop and repair welding operation and are therefore particularly suitable for short-arc welding on sheet thicknesses of 0.5 to 4 mm (180, 250 and 300 A weld current at 40% duty cycle, 10 min and 40°C). The types STEP 350 Eco or Master, STEP 450 Eco/Master and STEP 600 Eco/Master can be freely configured with regard to their construction, equipment and cooling (350, 450 and 600 A weld current at 60% duty cycle, 10 min and 40°C).
The machines are designed for manual welding in the industrial sector. Short and spray arc welding can be undertaken. In synergy operation the welder selects the desired step switch position. The characteristic curves automatically adapt to the required parameters, depending upon the pre-selected wire thickness and the material-gas combination. For the wire feed speed a fine adjustment can be undertaken by means of the rotating potentiometer. Since in practice certain tolerances to the reference conditions when constructing the characteristic curves may occur, a relative change in the additional parameter values becomes possible in the programming mode by means of a rotating actuator.
Parameters can also be individually set
The selection of non-present synergy characteristic curves or the pre-selection of a voltage outside the pre-selected characteristic curves is also shown in the operating display as a range of possible fault sources (for example wire drive not connected or incorrectly connected). Naturally the synergy operation can be switched off and an individual parameter setting can be undertaken. To achieve the optimum weld results, varying throttle stages can be accessed, in addition to the normal settings for this machine class of the voltage level and the wire speed. For welding with mixed gas or CO2 separate earth connecting sockets are available.
The ignition reaction of the power source is decidedly improved by a defined increase in the weld current >>Soft Ignition<< in the ignition phase. The ignition parameters deposited in the synergy characteristic curve can be adjusted to deviating marginal conditions in the programming mode. The equipment can be operated in the 2-cycle operation, in the 4-cycle operation, in the spot welding mode or in the interval mode and can be supplied with various network voltages specific to the country.
Fast performance part in the PULSE design
The new QINEO® PULSE welding machines are robust, infinitely adjustable, secondarily cycled MIG/MAG pulse welding power sources for manual and automated industrial welding operation. The machines are available as compact systems and systems with separate wire drive for 350, 450 and 600 A weld current (each at 60% duty cycle, 10 min. and 40°C). With regard to the type of cooling, the variations in control and the scope of the equipment, all the machines can be freely configured. Pulse welding machines are available from June 2008.
The power sources of the PULSE series are equipped using the most modern transistors with a very fast switching power unit. The digital weld current control uses up a considerably more extensive number of parameters relevant to results in such a way that an optimum welding result and highest possible reproducibility are achieved. Specified regulating algorithms thus favour the weld result. For all normal gas-material combinations and wire diameters the optimised parameters in the form of synergy characteristic curves are stored in a data bank of the power source.
This guarantees uncomplicated handling for the user. The conditions occurring in practice often deviate from the reference conditions which were available when generating the characteristic curves. To correct such deviations the welder has available significantly increased possibilities which in addition represent uniqueness in the pulse equipment market. With the >>Arc Length<< function a fine adjustment of the arc length and with the >>Arc Dynamic<< function a fine adjustment of the arc dynamics can be achieved.
999 storage spaces are available for jobs
In the programming mode, dependent upon the selected type of operation, the relevant additional parameters of the momentary value can be changed up or down by dimensionless correction values. So that the ideal results ascertained on the part of the user from the fine adjustment carried out or the adjusted parameters with switched off synergy operation can be used again at any time, the welder will have 999 storage spaces for jobs available. A job consists of the user-defined parameters for a welding task.
The QINEO® PULSE equipment has at its disposal the operation modes
>>2-cycle<<, >>4-cycle<<, >>super-4-cycle<<, >>spot/interval<< and >>external<<. The external operation is designed for the automation (PLC) or robot operation. The selection of the individual signals takes place via the automation interface of the power source. Communication between the power source and the controller of the automation components can take place with an >>Open Machine Interface<< or via a standardised bus system such as >>Profibus DP<<, >>Profinet<< or >>Interbus S<<. As an option a weld data acquisition with evaluation is obtainable. As well as the recording of the welding process measures can be introduced or warnings given if fixed limit values are exceeded or fallen below. The QINEO® PULSE welding machines dispose of a fault diagnosis and display system as well as a block function, which prevents unintended input or change of parameters.
With the PULSE machine series the procedures described below may be used:
- ELECTRODE: With this type of process all standard electrodes can be welded (DC).
- CONTROL WELD: this process guarantees low specific heat input and good gap bridging ability. As a result it is suitable for welding thin
sheets using mixed gas or CO2.
- SPEED WELD: A focussed pulse arc is available with medium to great fusion output. At high weld speeds good penetration depths and a
perfect side wall fusion can be achieved. The application for this process is mainly in the automated sector and is suitable for middle to
high sheet thicknesses.
- VARI WELD: The easy to control pulsed arc is distinguishable by an excellently controllable weld bath and absolutely low spatter drop
transfer. >>Vari Weld<< also enables, in varying outer conditions very stable arc conditions. The process is suitable for welding C-steel,
aluminium and chrome-nickel steels, as well as for MIG soldering.
- RAPID WELD: The highly constricted high capacity spray arc achieves high deposition rates at high wire feed speeds with deep
penetration. The process is suitable in particular for high capacity welding of thick wall steels.
- DUO PULSE: A second, low frequency pulse overlays the standard pulse process, which causes a clear change in the energy entry at a
defined point of a time slot. This achieves improved gap bridging ability and specific heat transmission. In addition a >>Designer
Surface<< of the weld seam is achieved (for example desired aluminium weld ripples). The process is suitable for all materials.
- CLEAN START: For the start the special igniting routine >>Clean Start<< is available for all processes, as well as the usual ignition mode.
It guarantees reliable and low spatter ignition.
Further machine types are to be announced
The next machine type in the QINEO® range will be an inverter machine QINEO® Tronic with infinitely adjustable power preselection. Synergy characteristic curves, job memory and automation interface are included in the scope of the equipment of the Tronic machines, which will be available at the end of 2008. The further machine types will be specially adjusted to the requirements of the automotive branch of industry, the follow-on model to the current top technological power source QUINTO II as well as inverter machines for TIG and Plasma welding.
The link-up to the world of industrial robots and special purpose machines must be made possible with a simple installation. The results should be process-safe and reproducible. As well as the applications accumulated at the upper end of the demand scale, it is appropriate to offer to the market solutions appropriate for the requirements of the so-called standard applications in arc joining technology.
With globalisation new markets are opening up for the manufacturers of technical welding equipment, as well as for their users, on the other hand both sides can however see that they are being subjected to growing pricing pressure. This means for the manufacturer of technical welding equipment, that they should convert the total of all demands into:
- hard and software solutions specific to the customer (best ignition and welding properties, appropriate range of capacity co-ordinated
to the automation environment and suitable for the relevant operation environment);
- >>On board<< technical process intelligence (safe, rapid adjustment to changing welding jobs, guaranteeing process safety and
reproducibility of the welding results);
- high dependability (high total availability);
- simple, intuitive operation (low demands on the theoretical expert knowledge of the welder, reduces the >>size of human error<<,
requires low training costs);
- good value (most economical solution) as well as
- short delivery times.
Platform strategy enables lots of variations
With the new welding machine generation QINEO® from Cloos (www.cloos.de) the most modern freely configurable power source technology is /will be available. Primary cycled (Inverter) and secondary cycled power sources (chopper), step-switch power sources and machines with infinitely adjustable power preselection, normal and pulse process as well as fully digitalised welding process regulation form the basis for an optimum equipment configuration specific to the customer. A specifically converted platform strategy (modular construction) enables sensible variations and the realisation of application orientated equipment levels. Hence the integration of the operating panel in the wire drive, in the power source or in a portable remote control housing can be achieved. For all pulse equipment three control types are available, which offer the alternative of the scope of control, adapted to the task in hand. Power sources with integrated wire drive or with wire drive in its own housing, no water cooling (gas cooled torch), integrated or external water cooling, stacking feet as well as normal or large wheels are further configurable features.
The first range is the robust QINEO® STEP
With QINEO® STEP the first range in the QINEO® series is available on the market. The step-switch MIG/MAG welding machines are distinguished by simple, intuitive operation and special robustness. The types STEP 180, STEP 250 and STEP 300 are designed as gas-cooled compact systems for the workshop and repair welding operation and are therefore particularly suitable for short-arc welding on sheet thicknesses of 0.5 to 4 mm (180, 250 and 300 A weld current at 40% duty cycle, 10 min and 40°C). The types STEP 350 Eco or Master, STEP 450 Eco/Master and STEP 600 Eco/Master can be freely configured with regard to their construction, equipment and cooling (350, 450 and 600 A weld current at 60% duty cycle, 10 min and 40°C).
The machines are designed for manual welding in the industrial sector. Short and spray arc welding can be undertaken. In synergy operation the welder selects the desired step switch position. The characteristic curves automatically adapt to the required parameters, depending upon the pre-selected wire thickness and the material-gas combination. For the wire feed speed a fine adjustment can be undertaken by means of the rotating potentiometer. Since in practice certain tolerances to the reference conditions when constructing the characteristic curves may occur, a relative change in the additional parameter values becomes possible in the programming mode by means of a rotating actuator.
Parameters can also be individually set
The selection of non-present synergy characteristic curves or the pre-selection of a voltage outside the pre-selected characteristic curves is also shown in the operating display as a range of possible fault sources (for example wire drive not connected or incorrectly connected). Naturally the synergy operation can be switched off and an individual parameter setting can be undertaken. To achieve the optimum weld results, varying throttle stages can be accessed, in addition to the normal settings for this machine class of the voltage level and the wire speed. For welding with mixed gas or CO2 separate earth connecting sockets are available.
The ignition reaction of the power source is decidedly improved by a defined increase in the weld current >>Soft Ignition<< in the ignition phase. The ignition parameters deposited in the synergy characteristic curve can be adjusted to deviating marginal conditions in the programming mode. The equipment can be operated in the 2-cycle operation, in the 4-cycle operation, in the spot welding mode or in the interval mode and can be supplied with various network voltages specific to the country.
Fast performance part in the PULSE design
The new QINEO® PULSE welding machines are robust, infinitely adjustable, secondarily cycled MIG/MAG pulse welding power sources for manual and automated industrial welding operation. The machines are available as compact systems and systems with separate wire drive for 350, 450 and 600 A weld current (each at 60% duty cycle, 10 min. and 40°C). With regard to the type of cooling, the variations in control and the scope of the equipment, all the machines can be freely configured. Pulse welding machines are available from June 2008.
The power sources of the PULSE series are equipped using the most modern transistors with a very fast switching power unit. The digital weld current control uses up a considerably more extensive number of parameters relevant to results in such a way that an optimum welding result and highest possible reproducibility are achieved. Specified regulating algorithms thus favour the weld result. For all normal gas-material combinations and wire diameters the optimised parameters in the form of synergy characteristic curves are stored in a data bank of the power source.
This guarantees uncomplicated handling for the user. The conditions occurring in practice often deviate from the reference conditions which were available when generating the characteristic curves. To correct such deviations the welder has available significantly increased possibilities which in addition represent uniqueness in the pulse equipment market. With the >>Arc Length<< function a fine adjustment of the arc length and with the >>Arc Dynamic<< function a fine adjustment of the arc dynamics can be achieved.
999 storage spaces are available for jobs
In the programming mode, dependent upon the selected type of operation, the relevant additional parameters of the momentary value can be changed up or down by dimensionless correction values. So that the ideal results ascertained on the part of the user from the fine adjustment carried out or the adjusted parameters with switched off synergy operation can be used again at any time, the welder will have 999 storage spaces for jobs available. A job consists of the user-defined parameters for a welding task.
The QINEO® PULSE equipment has at its disposal the operation modes
>>2-cycle<<, >>4-cycle<<, >>super-4-cycle<<, >>spot/interval<< and >>external<<. The external operation is designed for the automation (PLC) or robot operation. The selection of the individual signals takes place via the automation interface of the power source. Communication between the power source and the controller of the automation components can take place with an >>Open Machine Interface<< or via a standardised bus system such as >>Profibus DP<<, >>Profinet<< or >>Interbus S<<. As an option a weld data acquisition with evaluation is obtainable. As well as the recording of the welding process measures can be introduced or warnings given if fixed limit values are exceeded or fallen below. The QINEO® PULSE welding machines dispose of a fault diagnosis and display system as well as a block function, which prevents unintended input or change of parameters.
With the PULSE machine series the procedures described below may be used:
- ELECTRODE: With this type of process all standard electrodes can be welded (DC).
- CONTROL WELD: this process guarantees low specific heat input and good gap bridging ability. As a result it is suitable for welding thin
sheets using mixed gas or CO2.
- SPEED WELD: A focussed pulse arc is available with medium to great fusion output. At high weld speeds good penetration depths and a
perfect side wall fusion can be achieved. The application for this process is mainly in the automated sector and is suitable for middle to
high sheet thicknesses.
- VARI WELD: The easy to control pulsed arc is distinguishable by an excellently controllable weld bath and absolutely low spatter drop
transfer. >>Vari Weld<< also enables, in varying outer conditions very stable arc conditions. The process is suitable for welding C-steel,
aluminium and chrome-nickel steels, as well as for MIG soldering.
- RAPID WELD: The highly constricted high capacity spray arc achieves high deposition rates at high wire feed speeds with deep
penetration. The process is suitable in particular for high capacity welding of thick wall steels.
- DUO PULSE: A second, low frequency pulse overlays the standard pulse process, which causes a clear change in the energy entry at a
defined point of a time slot. This achieves improved gap bridging ability and specific heat transmission. In addition a >>Designer
Surface<< of the weld seam is achieved (for example desired aluminium weld ripples). The process is suitable for all materials.
- CLEAN START: For the start the special igniting routine >>Clean Start<< is available for all processes, as well as the usual ignition mode.
It guarantees reliable and low spatter ignition.
Further machine types are to be announced
The next machine type in the QINEO® range will be an inverter machine QINEO® Tronic with infinitely adjustable power preselection. Synergy characteristic curves, job memory and automation interface are included in the scope of the equipment of the Tronic machines, which will be available at the end of 2008. The further machine types will be specially adjusted to the requirements of the automotive branch of industry, the follow-on model to the current top technological power source QUINTO II as well as inverter machines for TIG and Plasma welding.
