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Precise, quick and reliable: The use of laser beams in the welding and cutting technology offers many advantages. CLOOS presents the QIROX Laser Cell, a new product line of compact cells for automated laser cutting and welding.
The demands on productivity, repeatability and quality are continuously increasing in industrial production. This has to be met by the welding and cutting technology, too. Modern welding technologies allow increasing the quality, productivity and efficiency of the complete production process. The importance of laser welding and cutting in particular will grow in future. The main reasons for this are the high efficiency and accuracy of the laser beam. Laser welding and cutting often allows a much higher process speed with at the same time a better quality than with conventional processes. The exact work with a precise heat input minimises the heat affection and thus the thermal distortion. This reduces any time-consuming rework to a minimum.
With the QIROX Laser Cell CLOOS developed an extensive range of laser cells for maximum efficiency and quality. Each laser cell system is a tailor-made unit with components which match each other perfectly. They do not require much space and can be easily integrated into any production. The turnkey systems consist of a laser welding head, safety equipment, operating terminal, positioner, QIROX robot, flat screen with HD camera for visualisation and a pre-assembled media room.
The laser cells are equipped with a high-tech diode laser offering a maximum electrical efficiency. Other features of this laser type are the high availability, low maintenance expenditure, easy operation and an excellent process stability.
The 2-station systems are available with different types of positioners for different workpieces and can be loaded from outside. At one end employees can remove the welded workpieces, check the quality of the welding and reload the system while the welding process takes place at the other end. This results in an enormous saving on time for the whole process.
CLOOS develops, manufactures and delivers innovative solutions to more than 40 countries worldwide. With our QINEO®, the new generation of welding machines for manual and automated applications, and QIROX®, the system for automated welding and cutting, our product range covers the entire spectrum of arc welding technology. Our product portfolio includes intelligent software, sensor and safety technology solutions – all of which are customised to meet your specific needs and requirements! Leadership and competence equals process automation and welding at its best. Whatever your needs are, we “Weld your way.”
Modern harvesting machines are very complex units which allow to carry out many steps of the harvesting process in a confined space. To ensure highest reliability the individual components must be perfectly constructed regarding functionality, robustness and weight. A welding robot mounted overhead on a C-frame welds different medium-sized thin plate components. The robot system is equipped with a double-station positioner which changes the station with a horizontal rotary axis. Each of the two stations is equipped with a turn/tilt positioner with counter bearing. Due to the arrangement of the turn/tilt axes even complex workpieces can be perfectly positioned for welding. Thus positions which are difficult to access can be reached and an optimum weld quality is achieved. The stations have quick clamping systems so that the working stations can be retrofitted to another workpiece within a few minutes. Thus retrofit times are reduced to a minimum and the efficiency of the robot system is guaranteed also in the case of frequent retrofits.
CLOOS robots used for welding aluminium tanks for HGVs. The two-station robot machine – fitted with the most modern welding technology – guarantees optimum welding results and maximum efficiency. The QIROX QRC 350 robot welder is mounted overhead on a C-shaped frame. This position allows the robot better access to the workpiece. The C-frame is mounted on a floormounted linear track so that the robot can be moved horizontally and flexibly between the two stations. The CST Flex D laser online sensor carries out corrections immediately thus ensuring optimum welding results.
In the Saxon AMS Apparate-Maschinen-Systeme Technology GmbH production the time-consuming manual work of cutting the stainless steel material is done by a robot. Instead of the previous two days manual work, the robot only needs less than four hours. The robot is equipped with a tactile sensor for an exact workpiece measurement. Thus manual marking-out works are not required. And only a minimum of rework is necessary. The two-station system ensures highest system efficiency because the operator works parallel to the robot. Due to the RoboPlan software the workpieces can be programmed offline on a PC during cutting. This considerably reduces the set-up and downtimes. In addition, there is a high level of conformity from the drawing to the product. In this way AMS can produce reproducible components which will make the subsequent exchange of containers simply possible.
Borsig Process Heat Exchanger GmbH manufactures cooling units for gases with high temperatures and pressures in the chemical and petrochemical industry. To weld the thick units, the Berlin company invested in a CLOOS robot system. The robot of the new system welds sleeve nozzles at the heat exchanger casing with diameters from 250 to 500 mm using the MSG nar row gap process. This process offers a particular economic efficiency for welding thick-walled components. Due to the use of the narrow gap technology new system Borsig could considerably reduce the production times costs and - at the same time - increase the quality.
Since last year, the Caldera Heating Group (Bursa, Turkey) has been operating two robot systems from CLOOS. The automated machines weld many different varieties of boilers. Both machines each have two stations and are fitted with a six-axis QRH 360 robot. By introducing automated welding, Caldera was able to increase the productivity and the quality of manufacturing considerably.
Faun as the most successful manufacturer of waste disposal vehicles in Europe offers customised solutions for the most different waste types. The company uses the Speed Weld Process to weld the interior housing of the Variopress container. The main advantage of this process is a very directionally stable and powerful arc. Thus relatively high welding speeds can be reached with the Speed Weld process. Furthermore, a deeper penetration at a high welding speed is achieved. The transversal track with a length of 5 m moves the robot into the container interior for welding the guiding rails.
In the two-station robot system a QRC350 welds different steel supports for systematised building construction. These supports are used for offices, car parking and production halls as well as for municipal buildings such as hospitals, schools and sports halls. The MAG pulsed arc ensures optimum weld seam quality at high weld speed. The welding robot is mounted on an approx. 20 m floor-mounted linear track and has a rotating positioner with counter bearing which is used to always position the supports perfectly for welding.
On an enclosed surface of 5600 x 4400 mm a double station workpiece positioner for a horizontal rotation is placed in the middle. Whilst the root welds in one station, the operator removes the readily welded workpiece from station 2 and inserts a new one. Both stations have a swivelling and turning axis to perfectly place the pump components external housing, impellers and suction connections for the QIROX robot 350E.
As one of the biggest manufacturers of forklift trucks and warehouse handling equipment Linde Material Handling GmbH at its production site Aschaffenburg trusts in manual and automated welding technologies by CLOOS. The flexible robot welding system for mast production was individually adapted to the special conditions at site. As the production hall has low ceilings, the system is positioned relatively widely. The two welding robots are in the middle of the system whilst a track flexibly moves the positioners between the two stations. Due to the large number of variants, Linde Material Handling uses the RoboPlan offline programming software by CLOOS for automated welding. While the robot system is in production, a new program can be simultaneously produced in RoboPlan. The welding, search and travel paths and tools can be determined using 3D models, and the welding parameters and other functions required for running the program can then be defined.
The Manitowoc Group is one of the world's leading crane manufacturers. The US Group produces its GROVE brand auto-cranes at the Wilhelmshaven site. To increase competitiveness, the company is currently investing in state-of-the-art production technology and optimised material flow in the traditional manufacturing shops. Its heart is a 60 m-long CLOOS laser welding/cutting system around which the production of the telescopic booms flows.
As a competent system supplier for chassis and frame construction, laser cutting, sheet machining and stainless steel processing, MBH Maschinenbau & Blechtechnik GmbH relies on the latest production technologies, quality and productivity from CLOOS. A highlight is the new robot syste m which allows to weld complex components with different sizes and variants. The system controls two independent, programmable welding robots, which can weld simultaneously on a single component in single station mode, but in two station mode can also process different, smaller component s completely independently. The turn/tilt positioner always positions th e complex workpiece perfectly for welding. Thus positions which are difficult to access can be reached and an optimum weld quality is achieved. The torch changing system facilitates the use of single wire and tandem processes with a single robot. The entire welding process is designed in such a way that welding times and ancillary activities are of the same duration. This is how MBH achieves an optimum degree of utilisation of the system and efficient use of personnel which makes production quick and attractively priced.
F.X. Meiller GmbH & Co. KG is specialised to manufacture tipper bodies and trailers. For decades, the company has trusted in the technology of the welding specialists from Haiger. The fully automated system at the Czech site of Slaný consists of three working stations. Due to the 33 m long gantry the two robots can reach all stations. This ensures the maximum flexibility and efficiency of the system.
For many years, Siemens has belonged to the group of leading manufacturers in the world with innovative gas turbines for power stations. In order to be able to manage the greatly increasing demand and at the same tim e improve the working environment for employees, Siemens is using narrow gap welding by means of robots for handling huge turbine housings weighing up to 80 tons. Up to 300 mm thick plates can be welded without an extensive weld preparation. Compared to the previous manual welding the production time reduces by more than 80 %. There is an enormous potential saving with regard to the filler material, shielding gas and power consumption. And the relatively low heat input reduces the material distortion during welding. The use of the narrow gap technology considerably increases the efficiency of the robot system and leads to an improved welding result.
The Control Weld process covers the whole range of controlled MIG/MAG welding and is suitable for different applications. The classic MIG/MAG process offers a stable metal transfer from short arc to spray arc. At low power a short arc forms which is particularly advantageous when joining thin components and out-of-position welds. With regard to spray arc, this process has more energy and there is more heat input in the base material. There are only few spatters due to the small, short-circuit proof metal transfer which also results in less rework.
Speed Weld is used in all sectors of metal machining. The voltage-controlled MIG/MAG pulsed arc process allows a very high arc pressure even under demanding conditions. With Speed Weld you achieve high welding speeds because of the highly powerful arc. You benefit from the excellent weld quality due to the deep penetration. You avoid extensive reworks as spatters and undercuts are reduced to a minimum.
Vari Weld is a MIG/MAG pulsed arc for a very wide range of applications. The current-controlled MIG/MAG pulsed arc process allows controlling the penetration profile at a multitude of materials and applications. The material characteristics remain nearly unchanged, particularly in the case of heat-sensitive materials. You avoid extensive reworks as spatters are reduced to a minimum. So you achieve optimum welding results even under demanding conditions.
Rapid Weld is a focused high-capacity MIG/MAG spray arc and provides advantages wherever high penetration depths and a safe root fusion are required. The special control generates a very focused stable arc with a very high arc pressure. The one-knob-operation allows you to specifically model the penetration profile from small to wide. Due to the very small opening angle you reduce filler material and shielded gas. You obtain complete fusions due to the deep penetration. You reduce the welding time as considerably less welding layers are necessary.
Due to the optimum heat input, Cold Weld is perfectly suitable for demanding materials. Cold Weld combines a pulsed arc arc with AC technology. Due to the adjustable AC part you can individually control the heat input into the component. With Cold Weld you can get higher welding speed as you increase the deposition rate at a lower heat input. The optimum heat input has a positive effect on the component and material characteristics. You keep the original material properties because of the minimised heat input. You reduce the component distortion and avoid extensive reworks. You compensate material tolerances due to the good gap bridging ability.
Tandem Weld can be universally applied either for thin or for thick plate welding. In the Tandem Weld process, two arcs burn in a common molten pool. The process is based on two electrically separated processes which match each other perfectly. This possibility opens up a multitude of combinations. The front wire ensures a safe penetration, the back wire quickly fills big joints with filler material. The high deposition rate can result in both weld speed and volume filling. Therefore, Tandem weld is suitable for thin and for thick plates. With Tandem Weld you reduce your welding times due to the high deposition rate. You reduce the component distortion and avoid extensive reworks thanks to the low heat input. You compensate material tolerances due to the good gap bridging ability. You benefit from the wide range of applications as Tandem Weld can be used for many materials and thicknesses.
MoTion Vari Weld is particularly suitable for fine plate applications and applications in the lowest capacity ranges. The welding process provides advantages everywhere where special demands to weld surface and appearance are made. MoTion Vari Weld is a combination of the proven CLOOS Vari Weld process and reversing wire. In the process, the wire is drawn back and forward at a frequency of up to 180 Hz which results in an extremely high process stability to the lowest capacity range. You avoid extensive reworks due to the minimised formation of spatters and powder residues. Due to these characteristics MoTion Weld is particularly suitable for applications in the additive production.
Laser Hybrid Weld is perfectly suitable for long, straight weld seams. Laser Hybrid Weld combines a laser beam with a MIG/MAG welding process in one common process zone. You benefit from the advantages of both welding processes. A restricted light beam with focus on the weld is created which is characterised by a very high energy density. The laser beam penetrates the material deeply and forms a keyhole. The MIG/MAG arc following the laser stabilises the process, supports a perfect joining of the edges and improves the gap bridging ability. The main advantages of Laser Hybrid Weld are a deep penetration, low heat input and perfect side wall joints. With Laser Hybrid Weld you increase your productivity due to highest welding speeds. You need less filler material because of the reduced number of welding layers. You reduce the component distortion and avoid extensive reworks thanks to the low heat input. You accelerate your whole production process by means of the reduced weld preparation.
The Laser Cut process strongly restricts the arc and generates a small focussed spot with a very high energy density. This energy melts the material and due to the kinetic energy of an additional cutting gas the molten metal is removed out of the groove. Laser cutting is characterised by an excellent cutting quality, an extremely high cutting speed and a very good automation capability. Depending on the requirement different laser types with different characteristics can be used.
MoTion Control Weld is particularly suitable for fine plate applications and applications in the lowest capacity ranges. The welding process provides advantages everywhere where special demands to weld surface and appearance are made. MoTion Control Weld is a combination of the proven CLOOS Control Weld process and reversing wire. In the process, the wire is drawn back and forward at a frequency of up to 180 Hz which results in an extremely high process stability to the lowest capacity range. You avoid extensive reworks due to the minimised formation of spatters and powder residues. Due to these characteristics MoTion Weld is particularly suitable for applications in the additive production.
MoTion Vari Weld is particularly suitable for fine plate applications and applications in the lowest capacity ranges. The welding process provides advantages everywhere where special demands to weld surface and appearance are made. MoTion Vari Weld is a combination of the proven CLOOS Vari Weld process and reversing wire. In the process, the wire is drawn back and forward at a frequency of up to 180 Hz which results in an extremely high process stability to the lowest capacity range. You avoid extensive reworks due to the minimised formation of spatters and powder residues. Due to these characteristics MoTion Weld is particularly suitable for applications in the additive production.
Fine Weld is an energy-reduced, current-controlled MSG short arc process for mixed gas and CO2 welding. Due to the minimised spatter formation, Fine Weld is suitable particularly for thin, coated plates and fine visible weld seams. The stable arc is characterised by an optimum gap-bridging ability and can be mastered excellently in all welding positions. With Fine Weld, the lowest possible current flows in an arc phase before a drop short circuit occurs. When the liquid wire end comes into contact with the molten pool, a molten bridge should form as free as possible. For this purpose, the current is reduced even further for a short time. The short-circuit current which is then significantly increased to generate the pinch effect is very quickly reduced to low values again shortly before the short circuit is resolved, i.e. before the molten bridge is separated. As a result, the power in the newly ignited arc is kept low and the molten pool remains quieter due to the lower arc pressure. A short, uncritical current pulse afterwards ensures optimum drop formation at the end of the wire. With Fine Weld, you reduce the workpiece distortion through the controllable heat input. You avoid extensive reworks due to the minimised spatter formation.
Rapid Pulse Weld is a focused high-capacity MIG/MAG pulsed arc, and provides advantages wherever high penetration depths and a safe root fusion are required. Especially for manual applications, the pulse control ensures a high arc pressure even in the case of stickout changes. The one-knob-operation allows you to specifically model the penetration profile from small to wide. Due to the very small opening angle you reduce filler material and shielded gas. You obtain complete fusions due to the deep penetration. You reduce the welding time as considerably less welding layers are necessary.
Root Weld is an energy-reduced, controlled MIG/MAG short arc which is suited for the special requirements of root welding or thin plate welding. where out-of-position welds and varying gap widths often arise. Compared to the standard short arc, Root Weld is considerably quieter and produces less spatters.. Due to the improved process control, Root Weld is more stable and can thus be perfectly controlled even in the lower capacity range.. With Root Weld you reduce the workpiece distortion because of the lower heat input. You avoid extensive reworks due to the minimised spatter formation. You always achieve optimum welding results as the arc is resistant to external influences.
Vari Weld is a MIG/MAG pulsed arc for a very wide range of applications. The current-controlled MIG/MAG pulsed arc process allows controlling the penetration profile at a multitude of materials and applications. The material characteristics remain nearly unchanged, particularly in the case of heat-sensitive materials. You avoid extensive reworks as spatters are reduced to a minimum. So you achieve optimum welding results even under demanding conditions.
In addition to welding technology, grinding and polishing are among the key machining operations in numerous industries and sectors. The applications are extremely diverse. Use also our solutions for automated grinding and polishing. The robots offer consistently high quality even in 24/7 operation. You also benefit from shorter cycle times, minimised costs and increased productivity.
Choose from the wide range of customised grinding solutions that achieve an optimum surface quality with reliable force control and the necessary sensitivity. The constant contact force reduces abrasive consumption and noticeably reduces the cleaning effort thanks to the integrated extraction system. The innovative grinding systems are suitable for surface processing of almost all materials.
QINEO, are the high-quality welding power sources by CLOOS which have been developed specifically for Commercial and industrial welding purposes. They meet every demand of manual and automated welding. Moreover, the modular QINEO system allows individual solutions which can be adapted to your specific production requirements and objectives. From capacity class to special equipment, each QINEO is customised and supplemented by a comprehensive accessories program and matching services.