1. FLEXTRACK 45 WELDING CARRIAGE Mark Zablocki
Welding Application Technician
Perfect Welding Division
Fronius Canada

2. Table of Contents General Overview Configurations and Options
Features and Functions
Applications
Live Demo
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3. General Overview

4. FLEXTRACK 45 WELDING CARRIAGE
/ INDUSTRY: power generation, shipyard, welding on site / WELDING PROCESS: MIG-MAG, CMT / AREA OF USE: longitudinal-, circular welding

5. Overview
The Flextrack is a mobile and economical Automated welding solution
Fronius Welding equipment used to increase productivity, and quality of welds using Fronius Welding Technology
Fast and Easy Set-up of Rails and Carriage
Modular and Flexible Design
Designed for rough area applications
Made from the highest quality components and Robust aluminum housing
Type of welding: Straight line and Circular welds
Compatible with Manual or Robotic torches
Can be used with MIG/MAG, CMT and TIG systems
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6. Compatible Systems MIG/MAG, CMT, TIG
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7. Technical Data Welding Carage sutible for all welding positions
Carriage Weight without tool holder Kg ( 27.6 lbs)
Welding Speeds
Horizontal travel speed cm/min ( in/min)
Vertical travel speed cm/min ( in/min)
Max Load Capacity
Horizontally Kg (99.2 lbs)
Vertically Kg (66.1 lbs)
Oscillation (option)
Oscillation speed cm/min ( in/min)
Amplitude mm ( in)
Off set mm (0 - 2 in)
Dwell time seconds
Main Voltage 50 – 60 Hz /230V
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8. Configurations and Options

9. Main System Components
Welding Carriage
Torch Oscillator or Height Adjustment
FRC-45 Remote Control Unit
Power Supply and Control Box
Remote Cables and Harness
Main Options
Torch Holder Brackets
Flextrack Rails Straight and Circular
Bridge Mounting Solutions
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10. Configuration of Flextrack Carriage
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11. Flextrack 45 8,045,565 Control Box Flextrack 45 Carriage Harness
Hosepack Relief bracket
Remote Start Signal (9 pin)
Tools
FRC-45 Remote Control
8,045,565
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12. Torch Oscillation and Adjusmets
Oscillation Unit
Adjusts welding Position and Welding Pattern (Weaving)
8,045,579
Manual Torch Ajustment
Horizontal and Vertical Movement
8,045,578
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13. Torch Oscillation and Adjusmets
Radial Oscillation Unit
Provides a weaving pattern for 45 Deg Joints. Ideal for Fillets welds
Software upgrades to the Flextrack system are required.
New item!
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14. Torch Mounting Brackets
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15. Torch Mounting Brackets
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16. RING (inside / outside)
RAIL TYPES
Mountable on flat or curved surfaces
Min. inside radius: 1500 mm (59.1 in)
Min. outside radius: 1100 mm (43.3 in)
FLEXIBLE RAILS
For vertical and horizontal applications
Straight rail with aluminium profile
RIGID RAILS
STRAIGHT / CURVED
RING (inside / outside)
For inside & outside welding of tubes
Different segment length for a wide diameter range
1560 mm – 3360 mm (61.4 in – in)
STRAIGHT
RING (outside)
For outside welding of tubes
Rigid rail with aluminium profiles
200 mm – 1560 mm (7.9 in – 61.4 in)
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17. RAIL Dimensions Joining elements:
Rail flexible 1130mm (44,49inch)
Rail flexible 1695mm (66,73inch)
Rail flexible 1884mm (74,17inch)
RAILS
STRAIGHT / CURVED
STRAIGHT RIGID
Rigid Rails 1884mm
(74.17inch)
Joining elements:
Two joining elements to extend the rails are included with every rail.
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18. Actuating Cam
An Actuating Cam or block is used to limited the travel distance on a track. Or is used as a stopper to ensure the Flextrack Carriage does not fall of the rails and get damaged.
2 Actuating Cam are required as safety requirements
8,100,224
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19. Rigid Ring Rails
Rigid Ring Rails are formed rings with reinforced aluminum ribs
Designed for external pipe welding
Quick and Easy Set-up
Snap Lock Mechanism
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20. Rigid Ring Rails
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21. Rigid Ring Rails Dimensions
Rigid ring rail (workpiece-Ø mm / 7,87-33,07inch)
48,0005, Rigid ring rail mm (7,87-11,81inch)
48,0005, Rigid ring rail mm (11,81-18,89inch)
48,0005, Rigid ring rail mm (18,89-25,98inch)
48,0005, Rigid ring rail mm (25,98-33,07inch)
Rigid ring rail (workpiece-Ø mm / 33,07-61,41inch)
48,0005, Rigid ring rail mm (33,07-40,15inch)
48,0005, Rigid ring rail mm (40,15-47,24inch)
48,0005, Rigid ring rail mm (47,24-54,33inch)
48,0005, Rigid ring rail mm (54,33-61,41inch)
Adjustable mounting bridge
feet not included!
Please see reference Chart
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22. Flexible Ring Rails Flexible Rails
48,0005, Rail flexible 1130mm (44,49inch)
48,0005, Rail flexible 1695mm (66,73inch)
48,0005, Rail flexible 1884mm (74,17inch)
Please Use Reference Chart to determine the recommended number of rail sections and mounting solutions
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23. Reference Chart Reference Pricelist 2014 Euro V3 Page 344.
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24. Reference Chart
Reference Operation Instructions 42,0426,0205,EN V
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25. Mounting Solutions Can Hold up to 750 N of Force
Temperature rating 180°C
48,0005,1759
Number of Recommended Magnetic Supports per Rail 1884 mm
Rigid Straight
Flexible Straight
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26. Mounting Solutions Adjustable Screw Feet
Used mostly with Rigid Ring Rails up to 840mm (33.07in)
48,0005,1764
Magnetic Bridge with Distance Block
Mostly used with Rigid Ring Rails 840 mm – 1560 mm
48,0005,1769
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27. Mounting Solutions
Magnetic Bridge with Distance Block and Metric Adjustment
Mostly used with Flexible Ring Rails from 1560mm and up.
48,0005,1770
Vaccum Bridge
Mostly used on non-magnetic surfaces Al / CrNi
Special Request**
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28. Wire Feeder Options In order for the TransSteel or TPSi Platform to be used with the Flextrack system, an External Trigger Start Signal I-kit is required to be installed in the Wirefeeder. This I-kit will install a 9 Pin rectangular receptacle, in the back of the feeder. Option: 4,100,779,IK OPT/i WF ext. start signal
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29. Features and Functions

30. FEATURES ONE CARRIAGE FOR VARIOUS RAIL TYPES FLEXIBLE STRAIGHT RING
OSCILLATION (OPTION)
MACHINE TORCHES: MULTILOCK, ROBACTA , ROBACTA DRIVE, CMT DRIVE, MANUAL TORCHES
REMOTE CONTROL
with magnetic holder
MAGNETIC
VACUUM
SCREW FEET

31. ROBUST ALUMINIUM HOUSING
REMOTE CONTROL FRC-45
FUNCTIONS FRC-45:
Start-stop welding
Travel speed
Travel direction
OSC: Mode, Amplitude, Dwell time, Speed, Offset
End crater filling
Stop welding or change direction when limit switch is activated
NUMERIC DISPLAY
PROTECTION HANDLES
ROBUST ALUMINIUM HOUSING
MAGNETIC HOLDER

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33. Applications

34. APPLICATIONS

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