Perfect Welding

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Perfect Welding

FlexTrack 45 Pro

Rail guided welding carriage for mechanised orbital welding

WELDING PROCESSES: MIG-MAG / CMT
 
The compact welding tractor can be used in a wide range of applications. Depending on the requirements, one of three different rail types can be selected. FlexTrack 45 Pro welding tractors are perfect for all-round use in industries where surface geometries vary, for example in shipbuilding or container construction.

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FlexTrack 45 Pro orbital welding
Welding tractor FlexTrack 45 Pro, oribital welding

FlexTrack 45 Pro stands for:

  • Flexibility for orbital and longitudinal seam applications
  • Fast production processes
  • Improvements in output quality
  • Reduced costsIncreased competitiveness

System highlights.

  • Flexibility: Modular rail concept for different welding applications on different component geometries
  • Comfort: Quick and easy set-up of rails and carriage
  • Precision: Precise movements and constant welding speed
  • Quality: Perfect reproducibility of welding results, particularly in conjunction with TPS/i power sources
  • Robustness: Compact cast aluminium housing, ideal for use under harsh conditions

More flexibility + more quality = more cost effectiveness = FlexTrack

Remote control FRC 45 basic
FRC-45 Basic remote control

FRC-45 Basic.

  • Robust housing
  • Easy to operate
  • Compatible with "old" FlexTrack

Equipment and functions.

  • Numerical display (metric/imperial)
  • Welding mode (with/without arc)
  • Communication with TPS/i power sources
  • Direction of travel
  • Speed of travel
  • Offset
  • Oscillation mode, oscillation speed, oscillation path, dwell time
  • End-crater filling
  • Arc length monitoring (ACC - Arc Current Control)
  • Segment welding of orbital and longitudinal seams
Remote Control FRC 45 Pro
FRC-45 PRO Remote Control

FRC -45 Pro.

  • Robust housing
  • Easy to operate
  • Compatible with "old" FlexTrack

Equipment and functions.

  • Numerical touch display and function wheel
  • 5 languages (DE, EN, ES, FR, PL) and further languages on request
  • Welding mode (with/without arc)
  • Communication with TPS/i power sources
  • Adjustable power source parameters
  • Direction of travel
  • Speed of travel
  • Offset
  • Oscillation mode, oscillation speed, oscillation path, dwell time
  • End crater filling
  • Arc length control (ACC - Arc Current Control)
  • Segment welding of orbital and longitudinal seams
Fronius power source TPS/i
Fronius Welding unit TPS/i, the intelligent revolution

Automatic component detection for greater convenience (plug& weld)

  • Tool-less plug-in
  • TPS/i detects all available components
  • Warns of any incompatibility

Better control and analysis of the welding process (SpeedNet)

  • High-speed bus for 200-times faster communication between system components

Peerless Low Spatter Control (LSC) reduces costs

  • Extremely low-spatter dip transfer arc process
  • Including with long hosepacks
  • Less rework, lower costs

Massively improved droplet detachment Pulse Multi Control (PMC) for increased quality

  • Excellent stability and consistent penetration
  • Even at high welding speeds
  • Greater welding quality
  • More competitiveness

Simple device update

  • Easy upgrades with USB flash drive or via Internet
  • For new welding process, characteristics, applications, firmware updates, etc.

Future-proof

  • Upgrade functions and high-quality hardware
  • State-of-the-art welding processes for years to come

Customer freindly with cost-saving remote maintenance

  • Remote maintenance and system Analysis via Internet
Linear oscillation
FlexTrack 45 Pro, linear oscillation

Linear oscillation modes.

  • No oscillation, rectangular, trapezoid, triangular
Radial oscillation
FlexTrack 45 Pro, radial oscillation

Radial oscillation modes.

  • No oscillation, rectangular, trapezoid, triangular
  • The radial oscillation is used specifically for fillet welds

Arc Current Control
FlexTrack 45 Pro, ACC module

Greater arc constancy – perfect weld seam.

  • Automatic adjustment of the distance between the welding torch and the workpiece
  • Optimum welding results– including on off-centre rails or uneven surfaces

Ease of use and safety.

  • Compact design
  • Quick and easy installation
  • Spatter guard
Ring of flexible rails, mechanized welding
Flexible rail ring, FlexTrack 45 Pro

Flexible guide rails.

Can also be mounted as a ring for internal and external pipe welding. Different segment lengths (1130/1695/1884 mm) cover a wide diameter range.

Ring of rigid rails, mechanized welding
Rigid rail ring, FlexTrack 45 Pro

Rigid guide rails.

Ring with rigid aluminium profiles. The rails are connected using a hinge and catch for quick and easy set-up.

magnetic bridge, FlexTrack 45 PRO
Magnetic bridge for FlexTrack 45 Pro

Magnetic bridge.

  • For magnetic components. Heat-resistant to 180 °C.
  • The magnetic force is controlled by a lever.
vacuum bridge
Vacuum bridge for FlexTrack 45 Pro

Vacuum bridges.

  • For non-magnetic components with smooth surfaces, such as aluminium or stainless steel.
  • Operating temperature of 0 to 120 °C (optional from -30 to 250 °C).
bridge with screwfeet
Bridge with adjustable foot for FlexTrack 45 Pro

Bridges with adjustable foot.

  • Recommended for rigid rings up to 840 mm in diameter.
Vacuum pump, Fronius
Vacuum pump for FlexTrack 45 Pro

Vacuum pump.

  • In the case of non-magnetic materials, vacuum bridges are used to attach the guide rail. These require a suitable vacuum pump.
  • Pump is integrated into robust steel tubing frame, suction power for maximum 13 vacuum bridges, suction power can be regulated with stop valves.

Standard equipment.

  • Dry-running, oil-free, rotary vane vacuum pump
  • Portable base frame
  • Direct-on-line starter
  • Suction filter
  • Pressure manometer
  • Mains cable with plug, 5 m

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