/ Perfect Welding / Solar Energy / Perfect Charging
TPS/i TWIN Push
THE ULTIMATE IN TANDEM WELDING
/2
SINGLE-V BUTT WELD 15 mm
SINGLE PASS WELDING
WITH DEPOSITION RATE OF 20 KG
PER HOUR.
The TPS/i TWIN Push system enables tandem welding with the very best results:
Two TPS/i high performance power sources form the basis for perfectly synchronized arcs
that generate a common weld pool – ensuring the process is extremely stable.
A high deposition rate, high quality weld seams and high welding speeds are the result.
The commercial benefits of the tandem welding process are particularly apparent when
welding longer seams on thick sheets.
What’s your
welding challenge?
Let’s get connected.
/3
TANDEM WELDING
THE BENEFITS
STABLE WELDING Special TWIN characteristics mean the two arcs are
PROCESS perfectly synchronized:
// Reliable ignition
// High process stability
// Easier to set parameters
HIGH DEPOSITION Deposition rate can be seen either in the seam strength
RATE kg/h or a higher welding speed:
// Up to 30 kg/h
// Shorter welding times
Result of deposition rate with simultaneously higher
HIGH WELDING process stability:
SPEED // Shorter welding times
cm/min
// Reduced heat input
// Less rework due to reduced distortion
GOOD GAP- Bigger weld pool allows for the compensation of
BRIDGING ABILITY component tolerances:
// Less time and effort spent on processing
// Good welding results despite tolerances
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SYSTEM DESIGN
TPS/i TWIN PUSH
The entire TPS/i TWIN Push system is characterized by perfectly matched components.
Two power sources and one welding torch – with two electrically isolated contact tips (’lead’ and ’trail’) – form the basis
for the PMC TWIN tandem welding process. The torch service station and the exchange station perfectly complements
the system: Service life of wear parts increases and torch body exchange proceed in no time at all – in turn saving time
and money.
TWIN WF 30i Wirefeeder
// Two wirefeeders in one housing allow a central media
conduit and improve accessibility
2x TPS/i
// Up to 2x 500 A with 100% duty cycle
// Provides a reliable, seam tracking
signal independent of the process to
reduce the robot teaching effort and
potential rework
TWIN Controller
// Synchronizes the welding process
// One central robot interface – available
for all common welding robots
/5
TWIN Welding Torch
OPTIMIZED COOLING DUE TO WATER-COOLED GAS NOZZLE AND
WATER-COOLED NOZZLE FITTING
// Increases service life of wear parts
// Less cleaning required due to reduced spatter adhesion
// Less downtime
COMPACT DESIGN
// The compact size and fewer pinch points allow improved accessibility
to parts
FASTER REPLACEMENT OF Wear PARTS
// Clamping lever attachment enables gas nozzle to be swapped quickly
// Few tools needed
ADJUSTABLE CONTACT TIP ANGLE
// It is easy to convert the nozzle fitting holder so that the contact tip
angle can be adjusted to suit the application
TX/i Torch Body Exchange Station
AUTOMATIC TORCH BODY exCHANGE
// There is an increased need to switch from Twin to
Single when accessibility is an issue
// Automatic torch body swap (with newly fitted
wear parts)
TSS/i Torch Service Station
EFFECTIVE TORCH BODY CLEANING
// Varied cleaning options for constant weld seam
quality
// High pressure cleaning (16 bar) with parting agent
for inside of gas nozzle
// Regular cleaning also increases the service life of
wear parts
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WELDING PROCESS
PMC TWIN
PMC TWIN is the new process for
the TPS/i TWIN Push system.
New functions, in combination
with the arc length and penetration
stabilizer, significantly improve
process stability.
Optimum synchronization of the
lead and trail give the PMC TWIN
process even greater stability.
CHARACTERISTICS
The PMC TWIN welding process features greater penetration, higher welding speed and low heat input. This allows the user to
choose between three different characteristics in the area of the modified pulse and spray arc. Use of the universal characteristics
is recommended for pulsed arcs.
PMC TWIN UNIVERSAL PMC TWIN PCS PMC TWIN MULTI ARC
PULSED ARC SPRAY ARC PULSED ARC
/ Shorter focused arc / The lead produces penetration / Optimized characteristics for
/ Enables synchronized droplet / The trail fills the seam with material welding with multiple welding
detachment on lead and trail / Enables deep penetration systems in one welding cell
electrode / Ideal for narrow gap applications / All properties of PMC TWIN
/ Enables high welding speeds Universal also available
Advantages /7
SYNERGIC TWIN
// Automatic control of the TWIN parameters
without additional settings 35
78
// Larger process window 22
65
// Easy commissioning and operation
// Saves time and costs
INDEPENDENT WIRE feed SPEEDs LEAD TRAIL
The pulse ratio between the lead and trail electrode is automatically
adapted to the selected arc power. This allows for a greater difference
in the wire feed speeds of lead and trail, even for synchronized
tandem processes.
/ Pulse ratio Lead Trail - 1:1
// Deep penetration
// High welding speeds
// Stabilized welding process
/ Pulse ratio Lead Trail - 2:1
VARIABLE DROPLET DETACHMENT
The TWIN characteristics also determine the optimum points of
droplet detachment between the lead and trail electrode.
If necessary, this pulse shift can also be modified manually.
// Lower interference between the arcs / Pulse shift 50%
// Reduced arc blow
// High welding speeds
// Improved quality and appearance of the weld seam
// Stable welding process
/ Pulse shift 25%
SYNCHRONIZED IGNITION
Ignition of the trail arc is synchronized and happens with a slight
delay to the lead arc: This prevents the two arcs deflecting one another,
ensuring optimum welding start.
// Reduces the number of failed ignitions
// Improves the seam appearance
// Reproducible ignition
/ Ignition
TPS/i TWIN Push
PmC Twin
Penetration
+34%
PMC twin 2,97
PulsE twin 2,21
0 1 2 3 4 mm
Comparison – welding a PMC Twin PulsE Twin
fillet weld
The advantages of the new PMC TWIN 3,95 mm
4,68 mm
All information is without guarantee in spite of careful editing - liability excluded. Copyright © 2011 Fronius™. All rights reserved.
process based on TPS/i compared to
a conventional PULSE TWIN process 2,97 mm 2,21 mm
based on TPS. 1,27 mm
4 mm 2,24 mm 4 mm
Text and images correspond to the current state of technology at the time of printing. Subject to modifications.
Position: PB
Shielding gas: Ar +18% CO₂
Filler metal: ER70S-6 Ø 1.2 mm Welding speed
+23%
PMC twin 160
cm/min PulsE twin 130
0 30 60 90 120 150 180 210 240 cm/min
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