Pole position in welding technology: welding chassis components for motorcycles

WP Performance Systems GmbH, headquartered in Munderfing, Austria, is one of Europe’s largest motorcycle chassis component manufacturers. WP develops and produces performance-defining components for the suspension, frame, cooling systems and exhaust systems. It counts many well-known manufacturers in the motorcycle and powersports industry among its customers, including KTM, BMW and Ducati.

WELDING CHALLENGE

A great deal of dexterity is required in motorcycle frame and exhaust system welding. Manual welding is unavoidable in areas with tube intersections on the frame that the robot just cannot get to. It is important to achieve reliable, constant penetration and with no spatter. On the exhaust system, one millimetre thick stainless steel, structural steel or titanium sheets must be accurately welded. Even the most advanced MIG/MAG power sources cannot stand up to these requirements.  


“The TPS/i from Fronius enables us to maintain and extend our leading position in welding technology.” Josef Baier, Performance Systems GmbH

SOLUTION

The perfect weld properties of the TPS/i from Fronius come into their own at WP. The penetration stabilizer regulates the arc quickly and precisely to ensure that penetration remains constant. The extremely high arc stability allows spatter-free welding, ruling out the need for mechanical reworking. In addition, due to a special current profile, the TPS/i ensures an excellent gap-bridging ability for thin sheets, guaranteeing high quality in the production of exhaust systems. At the same time, the TPS/i increases the welding speed by almost 20 percent. Productivity has therefore increased dramatically in the manufacture of exhaust pipes at WP.