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Mechanised welding, cutting and Industry 4.0

29 October 2018

ESAB Welding & Cutting Products showcased solutions for manual and automated welding and cutting products at this year's EuroBLECH, which took place in Hannover from 23rd to 26th October.

Marcel Stemvers, regional sales & marketing director Germanic region, ESAB, says: “Our Industry 4.0 experts provided demonstrations of ESAB’s Digital Solutions, which include the ESAB WeldCloud and ESAB CutCloud platforms. Coupled with our broad filler metal portfolio, which now includes the welding wire operations of Sandvik Materials Technology, ESAB offers a complete system solution for welding and cutting challenges.” 

Various systems and product made their European and worldwide debut, including some for mechanised welding and cutting, MIG/MAG welding, PPE, carbon-arc gouging and more. 

ESAB’s Digital Solutions platform provides several capabilities (ESAB WeldCloud, ESAB CutCloud and more to come) that connect digital ecosystems for welding and mechanised cutting, respectively. At EuroBlech, ESAB showcased new architecture — powered by Microsoft Azure IoT and utilising the ThingWorx Industrial Innovation Platform from PTC — that allow for on-premise, hybrid and cloud based architectures.

“ESAB Digital Solutions help fabricators improve asset management, streamline documentation/traceability, increase quality and boost overall operation efficiency,” says Mike Pantaleano, VP Data Driven Advantage, ESAB. “No matter where you are in your digital journey, ESAB is ready. We can connect your first machine or deliver at scale for an entire fleet. Once you harness the power of data, you can further increase uptime and lower operational costs by leveraging the process knowledge of our welding and cutting experts.”

Plasma cutting and software

ESAB demonstrated mechanised plasma cutting and beveling featuring its iSeries plasma cutters, Combirex cutting table and DMX Automated Plasma Beveller, a next-generation bevelling system delivering performance improvement through a simple, compact design. 

For mechanised cutting, ESAB introduced its Columbus III version 1.6 CAD/CAM software. The latest version simplifies programming various cutting processes, as well as marking and labeling processes. Intelligent wizards contribute to intuitive operation so users can perform simple and highly complex cuts, labeling and nesting jobs quickly and easily. The 1.6 version now includes ability to calculate offers and orders for customers.

Mechanised welding

ESAB launched its new modularised system for SAW, GMAW and Gouging featuring the Versotrac EWT 1000 tractor, Versoarc EWH 1000 welding head and EAC 10 controller. This tractor system recognises the portability needs of ship, barge, offshore, wind tower and structural steel applications with a no-tools disassembly/assembly design for easy transportation into confined area and remote spaces.

The new Railtrac B42V is a universal rail-mounted tractor for welding and cutting that operates in the flat, horizontal or vertical positions. Powered by 42V from the welding system or an optional 18V battery, the Railtrac B42V features the new W8000 remote weaving unit for making weave welds up to 60mm wide and for weld path tracking. Stepper motors for both the drive and weave functions ensure smooth operation and high precision. Operators can program weave patterns, travel speeds and control voltage and wire feed speed for five standard programs.

ESAB also featured its new Miggytrac B5001, a battery-operated compact, programmable tractor for MIG/MAG welding using a standard torch. A colour TFT LCD with an intuitive, modern interface separates the B5001 from the competition. It can be used with any wire feed system, but connecting it to an ESAB wire feeder enables adjustment of weld parameters and arc start and stop. Operators can adjust multiple functions to improve weld quality, program weld patterns and weaves and even program a faster intermittent travel speed between stitch welds (to 170 cm/min). 

Upgraded torches

ESAB will introduce two enhanced torches for manual MIG/MAG welding. The PSF series of premium torches now feature a more ergonomic handle with soft-grip areas and stronger water-cooled performance for high-heat applications. Knuckle joints and spring supports add improved flexibility to reduce wrist strain. ESAB boosted the duty cycle of its MXL industrial series and now offers a full range of gas- and water-cooled torches designed for industry-duty applications. A new handle offers better ergonomics, while the refreshed front-end design accepts the same standard ESAB consumables. 


For heavy duty protection from welding fume and particulates when welding, gouging and grinding, an ESAB welding helmet can be combined with the company's new PAPR (Powered Air Purifying Respirator) system. This features the latest control technology, allowing the operator to adjust air flow between 170 and 220 L/min to suit the environment and application. As an extra measure of safety, ESAB added visual and audible alarms to alert the operator in the event of a blocked filter or low battery. Other features include a P3 filter and pre-filter, and Li-Ion battery pack with up to 8h duration @ 220L/min and LED airflow indictor. 

Gouging torch

Arcair, an ESAB brand, has introduced the AirPro X4000 torch and cable for manual carbon arc gouging. Where previous torch models required 27lbs of grip pressure to open the torch, the AirPro X4000 uses the compressed air already flowing through the torch. When the operator pushes a rocker switch, the AirPro X4000 torch pneumatically opens the torch jaws so operators can insert, adjust and remove carbons without effort. The rocker switch also controls the compressed air on/off function so that no air can flow through the torch or cable without the operator initiating flow through the rocker switch. A latch mechanism locks air flow on when in use to reduce hand fatigue.