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Welding Robot Package    A new level of perfection

The complete welding systems

for automated processes




A new level of perfection:

  • Expands the working area of the spatterless welding
  • From thin sheets
    up to thick materials
  • Higher welding speed
  • Increased deposition efficiency
  • Simultaneously dramatically reduced heat input
  • Extended parameter tolerance

Synchronisation process:

  • High-speed control of the arc via the OTC Welbee processor (Peak-Dip-Transfer)
  • High-precisely synchronisation of welding
    current and wire feeding system

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SynchroFeed: welding splatters were things of yesterday 




Fig.: Spatter-free welding process with SynchroFeed


OTC DAIHEN EUROPE GmbH, has developed a special pioneering role in automated MIG / MAG welding, thanks to new SynchroFeed technology. Through the new procedure, the company meets up with the increased demands from industries, to weld medium and, in particular, thin sheets without deformation, to take into account of the gap tolerance and, above all, to drastically reduce welding spatter. The entire process is now also to be effected at correspondingly high speed and in a particularly economical manner.


Schweißspritzer SynchroFeed 

Fig.: Common automated welding process with weld spatter


As the name suggests, SynchroFeed has important synchronization principles that focuses on the precision of the wire guide. In order to take get a closer look at this principle, a side view of the classical process is necessary: During automated pulse welding, droplet dissolution usually occurs above the weld seam. The drop is literally pinched, tapered, and then blown off by the wire. With a corresponding distance, it passes into the melt. The distance and the impact of the drop will inevitably result in welding spatter.


Repeater SynchroFeed

Fig .: For the largely spatter-free welding, a melting of the droplet at the time of the current peaks at a particularly predefined location, is of the utmost importance.


SynchroFeed basically works according to the same principle of drop formation and constriction. However, the wire is controlled in such a way that the droplet is dipped directly into the melt. Thus, a separation does not take place above the melt, but only in it. The wire feed plays the decisive role. The wire withdrawal from the melt takes place so fast that no adhesion occurs.

The fact that this process of the wire feed or retraction must be perfectly synchronized is obvious: In the fast run, the working steps are 'wire feed', 'drop formation', 'dipping', 'detach' and 'wire retraction'… Such a process is not feasible with commercially available push-pull systems, which is readily comprehensible for the required speed of 100 Hz for this process.



Classic push-pull systems are not enough

In the area of the high-performance exchangeable neck torch, as well as in the rear area - on the wire barrel - suitable servo drives for the synchroFeed system are installed. Both engines are sufficient to perform the synchronized process of the wire feed and pull-out at a reasonably high speed and precision.


Roboter frei SynchroFeed



Fig .: In the area of the high-performance exchangeable neck torch, as well as in the rear area - on the wire barrel – suitable servo drives for the SynchroFeed system.


Normally, the motor in the front area of the torch alone would be enough to pull the wire. However, depending on the frequency, this would be associated with a very high slip, which in turn would result in excessive wear on the wire. For this reason, the second motor at the wire barrel is important, which synchronizes the wire movement in combination with the front motor. In order to assist, the front motor receives the necessary thrust through the rear motor. Within the hose pack, compression or bruising of the wire is thereby avoided.

In the case of uniform wire consumption, this device usually does not have any complications, if everything runs smoothly. However, there are difficulties when temporarily higher or lower wire demands are required - for example with deviating arc length. The following happens mechanically:
The front motor pulls on the wire, but the reaction speed of the rear motor is minimized. As a result, the wire in the hose pack stretches or compresses in an unpredictable manner; a process that spontaneously generates too much friction.


Teamwork of wire buffer and control unit (buffer position control)

An "S" shaped wire buffer is provided on the third robot axis, which ensures that the wire can expand mechanically in this region, without encountering resistance or generating undesired friction in the hose pack. A rotary encoder in this area is also used to measure the exact wire position in this area. The position of the wire in the middle of the "S" shaped wire buffer is measured accordingly. If there is an overhang or lack of wire there, this can be read off at the respective orientation via the sensor.


This then registers every minimal synchronization deviation and automatically gives the motor the necessary impulse on the rear barrel, to provide the wire material faster or slower.


Synchronization of welding current and wire feed

Without the precision of the wire feed, spatter-free welding would not be possible. The current flow is of decisive importance for the exact melting of the droplet. It is only at the exact time of the current peak that the wire dips into the intended location of the melt. If the whole thing takes place too early or too late, the plan fails. The Welbee P500L welding machine, which produces this specially tuned current waveform for high-quality welding, is decisive. It is also responsible for the 100% synchronization with the wire movement. OTC is referred to here as Peak Dip Transfer - the controlled drop transition in the short-circuit phase.




Fig .: SynchroFeed in comparison with identical wire feed speed, has the lowest welding voltage









The low-spattered automated welding by the precise introduction of the droplets into the melt depends solely on the involved SynchroFeed components. The challenge is to pull the wire back

quickly enough so that it does not stick. At the same time, direct dripping into the melt ensures that the amount of spatter is greatly decreased or even nullified.

The principle of replacing the drop inside the melt and not over it is a unique feature, which can only be realized via the OTC SynchroFeed system.

Comparable methods always solve the drop above the melt and, in addition to welding spatter, also cause problems during the synchronization of the wire feed - triggered by simple pulling systems, which cause an increased wire abrasion.



Parameter tolerance for gap dimensions


Via SynchroFeed, it is possible to introduce more wire into the respective gap with reduced heat input, through the highly dynamic control process, since spatter-free feature works, and the drop can be more modulated. This is not due to the least precise wire control.
A different width of the welding gap does not have any negative effect on the weld results with SynchroFeed. SynchroFeed's process tolerance against flexible gaps is far greater than that of conventional welding processes. There are often unbridgeable problems or ugly welds with changing gap dimensions. In such cases, an increased wear of the contact tube in the torch is also to be expected.



Fig.: A high parameter tolerance for deviating splitting dimensions can be obtained by the SynchroFeed method.


With the same energy balance, SynchroFeed can introduce higher amounts of wire and thus closing larger gaps. In the case of narrower columns, the welding process with SynchroFeed is significantly faster.


By reducing welding spatter, reworking of the work-pieces can be kept to a minimum.

The use of SynchroFeed requires a complete welding robot system, consisting of OTC robots (FD-B4), welding power source (OTC Welbee P500L), push feeder unit, wire buffer, high-performance exchangeable neck torch and robot control. All components later communicate with each other at the required speed.


Komplettes System SynchroFeed 


Fig .: SynchroFeed welding robot system with OTC robot (FD-B4), welding power source (OTC Welbee P500L), push feeder unit, wire buffer, high-performance exchangeable neck torch and robot control.



From thinnest sheets to thickest materials

terms of materials, there are practically no restrictions whatsoever: with SynchroFeed, you can process steels, stainless steels and aluminum. However, the OTC AC / MIG process is even more suitable for aluminum.

For electroplated (galvanized) steels, the effect of the reduced heat input with SynchroFeed can be directly recognized by the lower zinc burnout. The combustion zone is significantly smaller. Even welding with CO2 leads to surprisingly positive results.


Schweißnaht SynchroFeed SynchroFeed Überlappnaht


Fig .: SynchroFeed weld seam for thin sheets

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