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Robotic Plasma Welding
The iRS company is engaged in the development, manufacturing, and supply of robotic plasma welding technological complexes. Plasma welding (PAW) is a welding process in which the energy source is a plasma stream. Plasma welding is essentially an evolution of the TIG process. In this welding method, plasma torches (plasmatrons) are used. In the plasmatron, gas is fed into the arc zone where it is heated by the arc and ionized. Due to the thermal expansion of the gas, which increases its volume by 50–100 times, it rapidly flows out of the plasmatron nozzle. The kinetic energy of the ionized gas particles and the thermal energy serve as the main sources of welding energy.
Plasma Welding Process
The plasma welding process is very similar to the TIG process, but it has several advantages. The main reasons for using a plasma welding system are reliable, high-quality results and higher welding speeds. This applies to all chrome-nickel materials, coated and uncoated steels, titanium, and all nickel-based materials. Areas of application include the automotive industry, pipeline and container construction, mechanical engineering and metal structure manufacturing, railway and shipbuilding industries. Advantages of plasma welding:
- Increase in welding speed up to 20%;
- Up to 30% reduction in required filler wire amount;
- Spatter-free welding with no pores;
- Deep penetration and reduced deformation of welded products.
At iRS, every welding process is initially considered as a complete system. This is the only way to guarantee that all components (each of which is, of course, of the highest quality) are compatible and operate in perfect harmony. A plasma welding system consists of four main components: a digital TIG power source with a cooling unit, a PlasmaModule 10, and a plasma torch. The exact system configuration can be adapted to individual requirements.
General Layout of the Robotic Plasma Welding Complex
- Power Source
- Plasma Module 10
- Robacta PTW 1500 Plasma Torch
- Cooler
| Power Source | |
 |
Fully digital MagicWave and TransTig TIG power sources from 0.5 to 500 A are ideal for plasma welding. Using these TIG welding systems, you can adjust your plasma system at any time. |
| PlasmaModule 10 | |
 |
This upgradeable attachment supports plasma gas flow from 0.2 L/min to 10.0 L/min, ensuring that any welding result can be reproduced with the highest quality. Additionally, PlasmaModule 10 provides digital control of the auxiliary arc in the range of 3–30 A. |
| Robacta PTW 1500 Plasma Torch | |
 |
Torch models are available for both manual and robotic control. The flexible robotic welding torch can be mounted directly on the robot in four positions. The tool center point (TCP) is rigidly fixed and is identical to that of robotic TIG welding torches of the same design. |
| Cooler | |
 |
A robust and reliable cooling unit adapted to the modular welding system concept. It ensures optimal water cooling of the welding torch. |
The robotic complex can be equipped with an automatic tool change system. It is designed for automatic replacement of welding heads installed on the flange of the robot manipulator's 6th axis. This makes it possible to perform different production tasks using several welding processes — for example, TIG, MIG/MAG, PAW, etc. — on a single complex.
iRS offers the base solution iRS Plasma Weld Basic.
| No. | Item |
| 1. | Industrial Robot — Fanuc Arc Mate 100iD |
| 2. | Robotic Welding Power Source TransTig 2200 |
| 3. | Plasma Module PlasmaModule 10 |
| 4. | Welding and Programming Training Course for 3 Persons |
| Price: 99 000 EUR including VAT | |
