FABTECH 2011: Welding (Part One)

FABTECH 2011 exhibited the latest advancements in arc, gas, resistance and laser welding for diverse material joining applications, including sheet metal, pipes and tubes, jewelry, plastics and other exotic materials. Now our Show-in-Site brings some of those welding systems and related equipment to you!

Over 35,450 attendees returned to North America’s largest metal forming, fabricating, finishing and welding event in McCormick Place on November 14-17, with over 1,200 exhibitors covering more than 450,000 net sq ft of floor space.

FIBER LASER SYSTEMS CUT THICK AND THIN MATERIALS
Hypertherm, Inc. (Hanover, NH) is expanding its HyIntensity Fiber Laser product line with the introduction of two new systems – a 2 kW system for thicker metal cutting and increased productivity and a 1 kW system for thinner applications – to join a 1.5 kW system unveiled at last year’s show.

The HyIntensity Fiber Laser systems, developed and manufactured in the U.S., are the only fiber laser systems specifically designed to work together as one complete cutting solution. The fiber laser supply, cutting head, automatic gas console, operator interface consoles, motion controls and software are all combined into one integrated package.

Hypertherm will sponsor a number of educational programs during this year’s show that cover a range of topics for both beginner and advanced users of metal cutting systems. The educational sessions will include presentations on hand cutting, mechanized plasma, fiber laser, consumable optimization, and more.

Hypertherm experts will present at two show-sponsored events as well. Jim Colt and Dan McLenithan will discuss advancements in mechanized plasma cutting. The presentation, on the afternoon of Monday, November 14, will include a comparison of plasma to other cutting technologies, such as laser and waterjet. Two days later, on the morning of November 16, Bob Boyes and Derek Weston will show attendees how to produce twice as many parts per hour. Attendees will learn how to minimize non-cutting time through the use of rapid ignition and motion optimization techniques that require no operator intervention. www.hypertherm.com

AUTOMATION AND ALUMINUM WELDING
Miller Electric Mfg. Co. (Appleton, WI) will introduce brand new welding equipment, safety products, and showcase recent technology advances in comprehensive welding systems and market-specific solutions designed for manufacturing, fabrication, shipbuilding, construction and commercial welding applications. Key points-of-interest in the Miller booth include:

• Live welding demonstrations highlighting new welding technologies and processes.
• Aluminum welding demonstrations featuring Miller’s AlumaFeed™ Synergic Aluminum Welding System and premium MAXAL aluminum wire.
• Contests and giveaways from Miller’s Arc Armor™ brand of welding personal protective equipment (PPE).

New, industry-leading technologies featured in the booth will include:

• Miller’s Axcess® E with Insight™, an advanced MIG welding system that includes fully integrated data monitoring capabilities within the power source.
• The new XMT® 450 MPa multiprocess welding power source: features the reliability and arc performance of the XMT 350 MPa but with more amperage, exceptional power efficiency and additional programs for Pulsed MIG welding with up to .052 in and 1/16 in wires. Rated at 450 amps at 100 percent duty cycle.
• Miller Welding Automation’s PerformArc™ pre-engineered welding cells.
• Miller’s premium Powered Air Purifying Respirator (PAPR) with Titanium 9400i industrial welding helmet for extreme welding protection in heavy applications.
• Point-of-use controls, such as Miller’s wireless remote controls for TIG, MIG/Flux Cored and Stick welding applications, and the Weld Cable Control (WCC) system popular in shipbuilding and construction applications.
• Miller’s exclusive PipeWorx™ multiprocess pipe welding system for advanced process flexibility and fast changeover times.

Miller will also announce promotions straight from the show floor and keep those who can’t attend updated regularly through its dedicated FABTECH page located at MillerWelds/FABTECH. MillerWelds.com

AUTO-DARKENING HELMETS, WIRE FOR SHIPBUILDING
The new VIKING™ 3350 Series auto-darkening welding helmets from The Lincoln Electric Company (Cleveland, OH) feature top-quality LCD optics for a clear, natural view in varied ambient light settings. The solar-powered helmets, augmented with a user-replaceable lithium battery, have a substantial 3.34 in height viewing area in a U.S. standard 5.25 in x 4.5 in sized cartridge shell.

VIKING helmets are ideal for stick, TIG, pulsed TIG, MIG, pulsed MIG and flux-cored welding, as well as gouging and grinding. An internal switch allows users to toggle shade control between 6-9 or 10-13 for handling plasma cutting up through heavy plate welding. Internally mounted controls also can be used to pre-test helmet/battery condition before welding.

Continuously variable delay allows users to vary how quickly the helmet returns from a darkened view back to a light state, while continuously variable sensitivity makes the helmet adaptable to different welding environments and lighting conditions. The helmets have four independent arc sensors that help users avoid blind spots, which otherwise could prevent auto-darkening.

Weighing in at 21 oz (602 g), the VIKING 3350 helmets are lighter in weight than many auto-darkening helmets. Additionally, the helmet’s “grind mode” control allows it to be used as a grinding shield for weld prep or post-weld clean-up activities. These helmets come in standard black and four additional graphic styles – Patriot™, Tribal™, Motorhead™ and Chip Foose-designed Terracuda™. The black helmets include a decal sheet, allowing the user to customize their helmet with flags, logos or letter characters.

All VIKING helmets include additional inside and outside cover lenses, a bandana and a Sport-Pak helmet bag. The helmets also are magnifying “cheater” lens and hard hat-adapter capable. All VIKING helmets meet ANSI Z87.1, CAN/CSA Z94.3 and CE Certifications.

New UltraCore^® HD-C is a mild-steel gas-shielded flux-cored wire produced by Lincoln Electric that is an ideal choice for out-of-position welding requirements with 100 percent CO2 in the shipbuilding industry and other fabrication applications. Designed to provide high deposition rates and a flat bead appearance in all positions, UltraCore HD-C delivers premium arc performance and fast-freezing slag with a low fume-generation rate. The wire has a wide operating range and is able to reach deposition rates of up to 10 lbs/hour, even in out-of-position applications.

UltraCore HD-C wire exhibits low spatter levels and is specially formulated to weld over light rust, mill scale and primer. It conforms to American Welding Society (AWS) 5.20/A5.20M: 2005 E71T-1C-H8 and E71T-9C-H8 and American Bureau of Shipping (ABS) 3YSA H10. This new wire initially is available in 0.045, 0.052 and 1/16 in. (1.1, 1.3 and 1.6 mm) wire diameters wound on 15 lb (7 kg) plastic spools, 33 lb (15 kg) fiber spools and 50 lb (23 kg) coils. www.lincolnelectric.com

GRIND AND FINISH STEEL, STAINLESS, ALUMINUM
The MULTI-MAX multi-purpose benchtop grinder from CS Unitec, Inc. (Norwalk, CT) is ideal for all workshop grinding, blending and finishing jobs. Two opposing shaft mountings – one for flap discs and one for longitudinal abrasive wheels – provide multiple methods for grinding, sanding and finishing steel, stainless steel, aluminum and more. Optional flexible shaft allows for grinding and finishing awkward workpieces that cannot be brought to the machine.

The MULTI-MAX has a powerful 3-phase, 750 watt, 220V or 440V motor. The load  speed of 2800 rpm is ideal for finishing. The transparent, hinged grinding guard on the roller side protects the user and support guides position work for accurate results. The flap disc side features an adjustable support rail with a safety hood for discs up to 7 in diameter with a 5/8-11 thread or 7/8 in arbor. www.csunitec.com

AUTOMATION FOR UNATTENDED OPERATIONS
The powerful, high-speed MH80 robot Motoman/Yaskawa America, Inc. (Miamisburg, OH) has an extremely flexible design, allowing it to be used for a variety of material handling applications. The long reach of the MH80 model makes it ideal for handling large parts. Fast axial speeds and acceleration reduce cycle times and increase production output.  Internally routed cables and hoses maximize system reliability, minimize interference and facilitate programming.

The MH80 features an 80 kg (176.4 lb) payload, 2,061 mm (81.1 in) horizontal reach, 3,578 mm (140.9 in) vertical reach and ±0.07 mm (0.003 in) repeatability. Its wide work envelope and small interference zones allow the MH80 to be placed in close proximity to workpieces and equipment, reducing floorspace requirements. The robots have brakes on all axes and can be floor-, wall- or ceiling-mounted for layout flexibility.

In addition to material handling, the MH80 robot is ideal for dispensing and material cutting applications. It uses Motoman Robotics’ dynamic, next-generation DX100 controller that includes patented multiple robot control technology to easily handle multiple tasks and control up to eight robots (72 axes), I/O devices and communication protocols. Featuring a robust PC architecture with unmatched memory capacity, the DX100 uses a Windows® CE programming pendant with color touch screen. The energy-saving DX100 controller features faster processing speeds for smoother interpolation, advanced robot arm motion, built-in collision avoidance, quicker I/O response and accelerated Ethernet communication.

Its extensive I/O suite includes integral PLC and HMI pendant displays, 2,048 I/O and a graphical ladder editor that can provide system level control.  The DX100 controller supports all major fieldbus networks. It is compliant to ANSI/RIA R15.06-1999 and other relevant ISO and CSA safety standards.

The industrial-grade Adaptive Gripper offers unique capabilities and reduces tooling cost. Ideal for a wide range of applications including machine tending, fixture load/unload, high-mix part handling and kitting, the Adaptive Gripper (Robotiq S-Model) has three articulated fingers that can adapt automatically to a wide range of parts of varying size and shape.

The Adaptive Gripper is ideal for applications requiring a single robot to handle a high mix of part types, eliminating the need for a tool changer and multiple tools. Compared to custom tooling, the Adaptive Gripper reduces setup costs and cycle time due to its short stroke and elimination of tool change delays. The Adaptive Gripper features four operation modes, including basic, wide, scissor and pinch. Its sensorless grip detection distributes pressure on up to 10 contact points, minimizing potential for part slippage. Delicate or dangerous objects can be easily handled.

MyMotoman Remote Monitoring Service is a new era in equipment monitoring, brought on by customers’ desire to have information at their fingertips at any time, on any device that has access to the Internet. MyMotoman provides the ability to maintain a pulse on robot equipment by sending crucial alerts, current production information and preventive trends in a proactive, “always-on” fashion. Knowing current status and performance trends allows subscribers to better keep plants running smoothly and efficiently.

Because there is no need to purchase servers or software, MyMotoman eliminates the need to invest in expensive IT manpower and equipment. All that is needed to access valuable robot information is a unique login and a secure password. Just log in and start using it; it is that simple. Customization is also easy. With the click of a mouse, the user can configure views and add fields. Upgrades are automatic, and customization stays intact. Data is protected with physical security, data encryption, user authentication and more.

Robots never sleep, and neither does MyMotoman technology, which leverages proven cloud computing and wireless technologies to provide information at a fraction of the cost of historical methods. MyMotoman sends alerts and predictive maintenance trend data on concerning situations, enabling service to be more efficient and responsive. Subscribers to the expanded service program will receive valuable equipment status information on a mobile phone, laptop, desktop or any device that has access to the web. With MyMotoman, “lights-out” manufacturing is now a reality, providing savings in operating costs, improving throughput and ensuring six-sigma quality. www.motoman.com

RIGHT ANGLE GRINDING SOLUTIONS
Saint-Gobain Abrasives, Inc./Norton (Worcester, MA), the world’s largest abrasives manufacturer, will be exhibiting new abrasives products that feature the latest in right angle grinding solutions for welding and metal fabrication applications.

The Norton Abrasives booth will have four main displays, three of which will be product towers featuring right angle grinding solutions from different categories, and one which will feature live demonstrations of a variety of the products being displayed at the show. Each product category will feature BEST, BETTER and GOOD solutions. The BEST category is for users looking for highest productivity and lowest total cost; BETTER solutions are an excellent blend of performance and price; and GOOD products provide consistent performance and low initial cost.

One information tower will feature Flap Discs including SG Blaze® R980P, NorZon® BlueFire™ and Merit® Metal discs. New this year is the Quick Trim backing on SG Blaze® and TwinStar™ flap discs, providing a new flexible, easily-trimmed plastic back plate, allowing full use of the flaps to reduce material and labor costs.  SG Blaze is the industry’s best product and offers the lowest total cost solution on stainless and alloys.

BlueFire discs feature new zirconia alumina plus abrasives for an increased cut rate, offering an exceptional blend of performance and price with up to 30 percent longer life over conventional zirconia products on carbon steel and weld. Merit Metal abrasives utilize an engineered blend of two high-performance zirconia products to provide the best starting specification, when price is a primary consideration.

Norton’s new Non-Woven Right Angle Discs, including SG Blaze® Rapid Strip™ and Vortex® Rapid Blend™ will be featured in a second tower. SG Blaze discs, which have Norton SG ceramic alumina grain for faster cutting and longer life, are a better choice for stripping rough rust and scale off of metal parts while still being flexible enough to avoid gouging the base material. New Vortex discs feature an innovative, high-performance engineered grain and improved resin bond system, providing aggressive, fast stock removal and a fine finish in deburring and blending operations.

Depressed Center Wheels will be featured in a third tower and will include an exciting new product line introduction in this category – new BlueFire™ advanced zirconia wheels will be debuted. This upgrade from the Charger™ line to the all new BlueFire wheels features the latest generation of the patented Norton SG and Norton Norzon grain combination. Depressed center wheels ranging from 4 in to 9 in with thickness from 1/8 in to ¼ in will be featured. Depressed center wheels are designed to handle the most severe right angle grinding applications from heavy stock removal and rough blending to notching/cut-off.

Norton Abrasives’ booth will also have a Live Demonstration Area where many abrasives, including the new product solutions, will be put through their paces. www.nortonindustrial.com

ROBOTIC WELDING FOR SMALL TO MEDIUM OPERATIONS
ABB Robotics North America (Auburn Hills, MI), a leading supplier of industrial robots, has developed the LeanArc™ 1410, a fully configured, quick start robotic welding package with an array of options to suit the needs of many small to medium welding operations. The base package is priced in the range of $35,000 and includes an IRB 1410 robot; the new IRC5 Compact controller; a Fronius TransSteel 3500 power supply and wire feeder; and a Tregaskiss 500 amp air cooled welding torch. End-users also have the option of Miller, Lincoln or ESAB power supply.

“The LeanArc 1410 responds to the demand from our distribution network and small to medium size metal fab and welding shops for an economical, easy-to-use robotic welding package that will deliver high quality welds all day long,” said Joe Campbell, the vice president of the ABB Robot Products Group in the U.S. “The base package includes all a shop needs to set up a high quality robotic welding operation.”

The centerpiece of the package is the 6-axis ABB IRB 1410 robot, especially designed for arc welding, featuring a 5 kg handling capacity with a supplementary 18 kg load capacity on the upper arm for application equipment. Known for its compact design, long reach and robust construction, the IRB 1410 also operates at low noise levels with long intervals between routine maintenance. With superior positional repeatability (±0.025 mm) the IRB 1410 delivers high quality welds even in tight, restricted locations.

Providing easy programming and superior control is the desktop sized IRC5 Compact controller, offering the same functionality as ABB’s industry leading IRC5 controller in a small, easy to place model. With powerful RAPID programming language and an array of arc welding software programs the compact controller allows less experienced end-users to easily program and operate the LeanArc1410. The IRC5 Compact controller also enables easy commissioning through its single-phase power input, external connectors for all signals and a built-in, expandable 16 in, 16 out I/O system.  And with the LeanArc 1410 package the compact controller will come with a special enclosure to protect it from welding debris.

Highlights of additional standard package components include the Fronius TransSteel Robotics welding system, comprising the power source with DeviceNet robotic interface, an interconnecting hosepack, and a wire feeder. The wire feeder is equipped with an innovative motor plate and the Fronius System Connector, making it considerably smaller and delivering a much smaller obstacle contour (www.fronius.com).

The Tregaskiss 500 amp air-cooled robotic torch is engineered to provide the durability and performance required to take on the demands of a high-volume welding operation. Features include an aluminum armored gooseneck, aircraft grade aluminum housing, and spring guard strain reliefs (www.tregaskiss.com). The LeanArc 1410 is delivered as a kit that can be assembled and set-up in three to four hours. The option exists for the unit to be delivered in pre-assembled form for even quicker installation. www.abb.com/robotics

DIY PORTABLE WELDING SYSTEMS
Completing the DC welder series that includes the 95 S, 161 S and 161 STL, the Thermal Arc® 201 TS portable welder from Thermadyne® (St. Louis, MO) is now available. The 201 TS is designed to provide increased power and control for tradesman or welders with more demanding requirements. Powerful yet compact and portable, this Stick/Lift & High Frequency TIG unit delivers 100 amps on standard 115 volt circuits for Stick welding and 150 amps for TIG. When used on 208-230 volt circuits, maximum output is 200 amps for either welding process.

Like the other portable welders in the series, the 201 TS offers:
• Superior value
• Increased electrical efficiencies
• Reduced amperage draw compared to traditional style power supplies
• Wider range of welding output on smaller input power circuitry (115V)

Attractive to both the DIY market and light industrial use, the 201 TS is particularly appealing to companies who want to save costs by bringing the welder right to the job site. The price, power and portability make these welders extremely favorable for a variety of industries and applications, including:
• Maintenance, repair and light industrial
• Farm and ranch
• Stainless steel & sanitary pipe fabrication
• Shipboard installation and repair
• Petro/chemical fabrication
• Various on-site and portable welding applications

“The 201 TS opens a new level of portability to the professional who needs the flexibility to work onsite, in the field or in the shop,” says Tom Wermert, the senior product manager for the Thermal Arc brand. “We originally envisioned this series of welders to be embraced by home hobbyists, but professional users are finding the power and punch of these units to be extremely beneficial as well.”

Thermal Arc is also launching the first in a series of 3-in-1 multi-process, fully integrated portable welding systems designed to take on many MIG, Stick and TIG applications. Never before has there been anything like the 3-in-1 in this market segment. The introductory Thermal Arc Fabricator® 181i system is a portable powerhouse that delivers up to 180 amps of welding output power. Weighing less than 33 lb in a small compact system enables superior portability, and the ability to go from job to job as easily as you can go from MIG to Stick to TIG welding.

By far the best value of any product in the market in this category today, the Fabricator® 181i is essentially a free Stick/TIG welder for the price of a MIG unit. The system is ideally suited for farm and ranch use, as well as many other applications such as automotive, light fabrication, technical hobbyists, do-it-yourselfers, maintenance repair and educational training. This portable powerhouse delivers process flexibility and performance to match for an unlimited range of applications.

This system comes with a comprehensive list of standard features including three welding process capabilities (MIG, Stick & TIG); detailed weld set up guide for optimum welding performance over a wide range of materials and shielding gases; digital meters with preview; infinitely variable voltage control; metal feed plate with quick change drive rolls and a receptacle for connecting remote control devices/spool gun. The system is made complete with high quality Tweco® and Victor® accessories.

The Thermal Arc® Fabricator ®181i, with its leading technology, sets a new standard for portable welding equipment delivering 3 in 1 MIG, Stick and TIG capability from one integrated portable system. www.thermadyne.com

MIG GUNS, ACCESSORIES REDUCE OPERATING COSTS
Bernard Welding Equipment (Beecher, IL) will display its MIG guns and consumables in the booth that it shares with Hobart Brothers, Smith Equipment, Tregaskiss and Weldcraft. All products to be showcased have been selected for their ability to address quality and productivity challenges in the fabricating and manufacturing industries. Bernard will also have experts in the booth to address welding and product inquiries from visitors. www.bernardwelds.com

DIAMOND WHEELS, FLAP DISCS FOR TOUGH APPLICATIONS
CGW-Camel Grinding Wheels (Niles, IL) has a line of diamond wheels engineered for demanding metal applications. Utilizing a high concentration of diamond grit, a solid steel body and an advanced brazing process, CGW’s diamond wheels are made to last at least 50 times longer than traditional, bonded abrasives. Longer-lasting life spans allow for increased production times and lower grinding and cutting cost ratios.

The diamond wheels also produce fewer sparks, no odor and less material debris since they do not wear down like traditional abrasives. Because the CGW diamond wheels are made from solid steel and will not fracture during use like resin bonded wheels, they are safer to use.

CGW’s diamond wheel line consists of type 29 depressed center grinding wheels, type 1 notching/grinding wheels and 16 in to 20 in combination cutting wheels for chop saws, stationary saws, gas saws and rail cutting machines. The new depressed center grinding wheels are made to last 50 times longer than conventional abrasives and are ideal for weld removal, pipe beveling and stock removal on all ferrous and nonferrous metals.

The notching/grinding wheels are engineered to last 50 times longer than conventional abrasives and are designed for foundry gate/riser removal, sectional tubing and hard face metal alloys. The new 16 in to 20 in combination cutting wheels will last 70 times longer than conventional abrasives and are used for rail track, ductile iron and carbon/mild steel applications.

CGW expanded its trimmable flap disc line with trimmable C3 ceramic flap discs. The flap discs have a disc backing designed to trim down to expose ceramic flaps for extended working life, allowing for fewer disc changes and longer production times. The U.S.-made trimmable C3 flap discs have a hybrid compact flap design that compresses and compact flaps at a 4 deg angle for additional edge strength and 20 percent more material than regular C3 flap discs.

Manufactured from self-sharpening ceramic grain and a strong polyester flap backing, the new discs are recommended for aggressive cutting action on hard-to-grind materials such as stainless steel. C3 flap discs also provide contaminate-free results and will not rust stainless steel. The flap discs are available in 4½ in and 5 in diameters, with 7/8 in arbor holes or 5/8-11 hub and grit sizes of 40, 60 or 80. www.cgwcamel.com

COMPACT CONVEYOR DELIVERS HIGH SPEED PRECISION
DE-STA-CO (Auburn Hills, MI), a worldwide leader in robotic tooling, workholding and flexible industrial automation solutions, offers the CAMCO® Rite-Link conveyor. Rite-Link’s slim, compact design features narrow links (30.4 mm wide) with 75 mm, 115 mm, or 150 mm pitches. There are five standard center distances available or a custom one can be provided, assembled, and tested for the customer’s particular industrial or medical application, and can be used in either an over/under or carousel configuration.

The energy efficient Rite-Link requires no lubrication, so it is virtually maintenance free. Built with lightweight components, it runs quietly, even at higher operating speeds. “Rite-Link is the perfect fit for manufacturers that have been looking for a cost-effective conveying solution that is more accurate and stable than roller chain,” said Lou Wozniak, the product manager for DE-STA-CO. “It’s easy to install and integrate into any shop environment, and lends itself to flexible indexing with CAMCO^®’s precision 115RSD rotary servo drive, or a customer’s standard servo and planetary drive.” www.destaco.com

SEMI-AUTOMATIC AND ROBOTIC MIG GUNS
Tregaskiss Products (Windsor, ON) will showcase its semi-automatic and robotic MIG guns, along with its consumables and welding peripherals. New and showcased products of special interest to the fabricating and manufacturing industries include:

AutoLength Liner System: This new spring-loaded module, housed inside the power pin, ensures that the liner remains seated properly while offering up to one inch forgiveness if the liner has been cut too short or too long. The AutoLength Liner System was created to minimize wire feeding and quality issues, as well as downtime, commonly associated with the liner being trimmed to the incorrect length. This system is designed specifically for use with QUICK LOAD™ Liner System. The innovative front-loading QUICK LOAD Liner System has recently become standard on TOUGH GUN™ and TGX™ Semi-Automatic MIG Guns, and has been standard on TOUGH GUN Robotic and Automatic MIG Guns since 2010.

TOUGH GUN™ ThruArm™ G2 Series Robotic MIG Guns: These new robotic MIG guns are compatible with all robotic systems, including those by FANUC, ABB, Motoman and KUKA. The new series has the same reliable features as previous ThruArm Robotic MIG Guns, including the exclusive Tregaskiss LSR (Low-Stress Robotic) Unicable Technology that minimizes stress caused by robotic wrist rotation. Plus, the guns now have a new solid mount and custom arm.

Tregaskiss experts will also be available at the booth to answer questions about these and other Tregaskiss products. www.tregaskiss.com

DUST COLLECTOR REDUCES MAINTENANCE AND DOWNTIME
Donaldson Company, Inc. (Minneapolis, MN), a leading, worldwide manufacturer of filtration systems offers a family of Torit® brand PowerCore® dust collectors – the VH Series – designed to meet the specific requirements of applications with abrasive dust in the metalworking and mining markets.

Like the PowerCore CP Series collectors for the baghouse market, the PowerCore VH Series collectors are designed to be smaller and smarter. “Smaller” means that the VH Series will take up less valuable floor space –up to 70 percent less than some baghouses and cartridge collectors – that can be used for other important needs within the operation. “Smarter” means the VH collector is designed to reduce labor costs and downtime with easy, time-saving filter change-outs with no confined spaces to deal with.

The Torit PowerCore VH Series collectors will handle airflows of 5000 cfm to 50,000 cfm. Like the CP and TG Series, the VH Series utilizes PowerCore filter packs. One PowerCore VH filter pack replaces up to twenty 8 ft baghouse bags and up to three standard, round cartridges. When comparing the VH series to a 13,600 cfm, 162-bag baghouse, the VH Series – with 8 filter packs – has a 70 percent smaller footprint, is 50 percent shorter and has 95 percent fewer filters. That’s 154 fewer filters to change. When compared to a cartridge collector, the VH Series is approximately 40 percent smaller and uses 16 fewer filters. Fewer filters mean reduced maintenance and downtime for the operation.

To better handle the harsh environment created by abrasive dusts, the PowerCore VH Series features heavy gauge steel and all-welded construction. Its single hopper option and single air inlets/outlets reduce ducting, installation and material handling costs. And, unlike other collectors, the VH Series includes a zero-turn pulse cleaning system, which forces dust directly down into the hopper, which decreases the chance of re-entrainment on adjacent filters. www.donaldson.com

NEW WIRE-FEED SYSTEM FOR ALL WIRE TYPES
The new PowerLiner from Fronius USA, LLC (Brighton, MI) is a wire-feed system for all standard wire types. No matter what type of wire – steel, silicon bronze, aluminum or stainless – PowerLiner handles them all. Wire diameter is not an issue either; all the usual wire diameters, from 0.030 in to 1/16 in, can be used without any problems. The minimum feeding radius is 6 in.

Another plus is that the PowerLiner no longer requires inner liners. The wire electrode is guided by rollers set at an angle of 90 deg. Seventy-six rollers are used for each meter of wire-feed hose. As a result, rolling friction rather than slip friction occurs while the wire is being transported. This gives a virtually zero-resistance and wear-free wire feed, a feature that is particularly important in industrial applications.

The PowerLiner can easily be built to the length required. The minimum bending radius of 5 in and the small diameter of 0.8 in (without corrugated protective hose) enable it to be used in even the most awkward routing situations. With conventional welding systems, PowerLiner lengths of 65 ft are no problem. For Robacta Drive applications, lengths of up to 32 ft can be used. Troublefree wire transport is always ensured.

The PowerLiner can be connected to large spool systems, wire drums, welding torches or wire-feed units very quickly and easily using the QuickConnect quick-locking system, another advantage when operating in an industrial environment. Advantages of the PowerLiner include:

• No abrasion thanks to the extremely low forces exerted on the wire electrode
• No special wire liners necessary
• Simpler plant layout as greater flexibility in positioning of wire spools
• Also extremely suitable for awkward routing situations or large distances
• PowerLiner can be prepared to almost any length
• QuickConnect system facilitates rapid connection/disconnection of feed system

www.fronius-usa.com

FILLER METALS IMPROVE PRODUCTIVITY, LOWER COSTS
Hobart Brothers Company (Troy, OH) will showcase its filler metals, including tubular wires (flux-cored and metal-cored) designed specifically to improve productivity and lower costs on fabricating and manufacturing applications, as well as aluminum GMAW and GTAW filler metals from MAXAL. Hobart Brothers experts will also be available to discuss filler metal solutions and to answer questions from visitors. Hobartbrothers.com