Catalogue wire-transport

Index Wire transport ............................................................................................................................................................. 4-11 Proper design of wire transport systems ..................................................................................................................... 4 Friction coefficient of MIGAL.CO conduits ................................................................................................................... 5 Extraction force from MIGAL.CO drums ...................................................................................................................... 5 Calculation of transport forces for the proper design of wire transport systems ......................................................... 5 Wire transport for un- and low-alloy steel wires ........................................................................................................ 6-7 Wire transport for high-alloy steel wires and non-ferrous alloys ............................................................................... 8-9 Wire transport for aluminium alloys with MIGAL.CO Eco or Jumbo-Drums ......................................................... 10-11 Transport devices ..................................................................................................................................................... 12-14 Universal drum transport trolley UFTW1 and UFTW2 .......................................................................................... 12-14 RoboDock ............................................................................................................................................................. 12-13 Drum hoods .............................................................................................................................................................. 15-16 Decoiling aids ............................................................................................................................................................17-22 Decoiling aid ASH 81 for Eco-drums .................................................................................................................... 17-18 Installation of Eco-drums ........................................................................................................................................... 19 Decoiling aid TOU400/580 for Jumbo-drums ............................................................................................................. 20 Installation of Jumbo-drums ....................................................................................................................................... 21 Decoiling aid ASH-XL2 for wire diameters up to 4 mm ............................................................................................. 22 Decoiling aid Jumbo DC 380/580 ............................................................................................................................. 22 Drum connector ............................................................................................................................................................. 23 Pulley .............................................................................................................................................................................. 24 Wire straightener RoboStraight ................................................................................................................................ 25-26 Wire end control ............................................................................................................................................................ 26 Conduits .................................................................................................................................................................... 27-42 Toughliner - for un-, low- and high-alloy steel wires ................................................................................................. 27 Toughliner EXTRA - for extreme demands ............................................................................................................... 28 Toughliner FLEX - extremely flexible ........................................................................................................................ 28 Softliner - for non-ferrous metals and high alloyed steels ................................................................................... 29-30 DUROliner - for non-ferrous metals and high-alloy steels with extreme kink resistance ..................................... 29-30 Wall brackets for Toughliner and Softliner and DUROliner ........................................................................................ 30 Strain relief for Toughliner and Softliner and DUROliner ........................................................................................... 31 Rolliner NG - the second generation ................................................................................................................... 32-34 Perfect cutting of Softliner, DUROliner and Rolliner NG ............................................................................................ 34 Rolliner 3G - up to 1.6 mm wire diameter and no tools needed for assembly ..................................................... 35-37 Hose holder and accessories .................................................................................................................................... 38 Rolliner XL2 - up to 4 mm wire diameter and no tools needed for assembly ...................................................... 39-42 Wall bracket ............................................................................................................................................................... 42 Couplings & Connectors ......................................................................................................................................... 43-46 Screw- and quick couplings for Rolliner NG, Rolliner 3G and Rolliner XL2 ............................................................... 43 Coupling CRNG40 for Toughliner, Softliner, DUROliner, Rolliner 3G und Rolliner XL2 ........................................ 43-45 Connectors to wire feeders ................................................................................................................................... 45-46 Wire feed and wire management ............................................................................................................................. 47-54 Pneumatic feed assist DLDA1 for extreme wire feeding distances .................................................................... 47-48 RoboFeed - pushing the limits of wire transport .................................................................................................. 49-51 RoboFeed-WireManager - pushing the limits of wire transport and wire management ...................................... 52-54 Adapter for basket spool B 300 ...................................................................................................................................... 55 Anti spatter - Ceramic surface protection KRA-1000 for fixtures and welding torches .................................................. 56 3

Wire transport Proper design of wire transport systems α1=90° α2=90° n α=∑α i i=1 Fin Fout = Fin * eα*μ Fout α4=90° α3=180° Schematic presentation of a robotic welding system with bulk wire supply With the application of bulk wire systems (drums, large spools) instead of standard coils (7 kg in aluminum, 15 kg in steel) the use of conduits is necessary. At the same time the constancy of the wire feed speed is a crucial parameter in arc- or beamwelding. The movement of the electrode wire in the wire guide hose is inhibited by friction and it can very easily lead to situations in which the wire speed required can no longer be maintained. Thus, the correct design of the entire wire guide system is crucial. Own research and practical experience from MIGAL. CO has shown that the formula from Euler-Eytelwein is sufficiently accurate to design wire transport systems for a stable long-term operation. The following informations are necessary: • Required force in Newton to pull the wire out of the bulk pack • Pulling force of the wire feeder in Newton which can be safely maintained uring continuous operation • Friction coefficient of conduit • Sum of the radii of the conduit in degrees Fout 90 N 80 N 70 N 60 N 50 N 40 N 30 N 20 N 10 N conventional conduit Rolliner α ° 0 0 0 2 ° 0 0 5 ° 0 0 0 1 ° 0 0 5 1 The products of MIGAL.CO are uniquely matched to each other, thereby guaranteeing optimum wire transport and reliable welding processes in large scale production. For latest details regarding the content of this page see www.migal.co 0 Exponential curves of two different conduits 4

Wire transport Friction coefficient of MIGAL.CO conduits Conduit Rolliner 3G Rolliner XL2 Toughliner Softliner Type of friction Rolling friction Rolling friction Sliding friction Sliding friction * for steel wires only. Toughliner cannot transport aluminum wires! Extraction force from MIGAL.CO drums Type of drum Eco-drum aluminum with decoiling aid ASH 81 Jumbo-drum with decoiling aid TOU400/580 Eco-drum CrNi with decoiling ring Extraction force [N] 1.5 N (ML4043 1.6 mm) 1.0 N (ML5087 1.2 mm) 0.6 N (ML 18.8 Mn 1.2 mm) Friction coefficient 0.08 0.08 0.20 * 0.20 Calculation of transport forces for the proper design of wire transport systems With the following calculation form the application of the Euler-Eytelwein formula for designing a wire transport system is possible. The following entries are to be made: • Drag force in Newton - how much is for example the force required to pull the wire out of the drum (see table) • Angle α in degrees - Sum of the bending angles with which the conduit is installed • Friction coefficient µ (see table) It calculates the force with which the wire feed motor has to pull. You can enter a maximum value (e. g. 30 N). The values are also displayed graphically in the diagram. Drag force G [N] Sum of angles α [°] Friction coefficient μ Maximum force Fmax [N] Force F [N] 3 500 0.08 30 6.03 Calculate An interactive form for the calculation of transport forces is available at www.migal.co 5

Transport devices Universal drum transport trolley UFTW1 and UFTW2 There are round, octagonal, square, small, large, light and heavy wire bulk packs. And now there is a single trolley that can deal with all these barrels without unnecessarily taking up space at the same time. UFTW 1 is adjustable by 40 mm steps in five levels, has four lockable plastic wheels and a sturdy handle. The UFTW 1 is constructed so that the drums have the largest possible contact surface precisely where it is needed - in the outer diameter range. The trolley is made from 5 mm steel and powder coated. UFTW is available in 4 versions: UFTW1 for a drum diameter of 500 - 700 mm and UFTW2 for a drum diameter of 620 - 780 mm, each one with or without RoboDock. Technical Data Maximum load L x B x H over all Product weight Roll diameter An empty UFTW 1 can be pushed easily by the handle. UFTW2 suitable for drum diameter UFTW1 suitable for drum diameter 1.000 kg 850 x 740 x 915 mm 18.4 kg 125 mm 500 - 700 mm 620 - 780 mm Universal drum transport trolley UFTW1 RoboDock and UFTW2 RoboDock Increasingly, welding wire drums are being used for automated production lines. These are characterised by long operation without interruptions for changing a wire spool. However, it is unpleasant when the wire runs out at some point during operation. The connection of a proximity sensor at the outlet of the drum offers a possibility here, but only alarms at the immediate end and thus often too late. RoboDock from MIGAL.CO is a pre-warning solution in combination with a drum transport trolley. RoboDock positions the trolley at a predetermined point and contains a height-adjustable proximity sensor. This is pressed against the drum wall under spring pressure. As soon as the wire level in the drum drops below the sensor position, the corresponding signal is sent to a system controller. This informs the system operator that a standstill is to be expected in the near future The design sheet for the UFTW1 as well as the video explaining the RoboDock is available on www.migal.co 12

Transport devices and that a new drum must be brought to the system as soon as possible. A combination with a sensor at the drum outlet can be very useful. The sensor can detect all materials such as steel, stainless steel, copper alloys and aluminium. The guide corresponds to the RoboDock without sensor. This means that the barrel is always positioned in the same place. RoboDock with MIGAL.CO Jumbo-drum RoboDock front view RoboDock side view Proximity sensor detects the wire level in the drum RoboDock rear view UFTW 1 with RoboDock side view Overview table Item number 10,10,1,0001 10,10,1,0005 10,10,1,0007 10,10,1,0008 10,10,1,0003 Designation Universal drum transport trolley UFTW 1 Universal drum transport trolley UFTW 1 RoboDock Universal drum transport trolley UFTW 2 Universal drum transport trolley UFTW 2 RoboDock RoboDock with wire end control for UFTW 1 and 2 10,10,1,0006 For latest details regarding the content of this page see www.migal.co RoboDock guide for UFTW 1 und 2 Weight 18,4 kg 18,4 kg 18,4 kg 18,4 kg 7 kg 7 kg 13

Drum hoods Drum hoods for round, octagonal and square drums Drum hoods serve to attach the conduit and protect the drum contents from contamination. The hoods of MIGAL.CO are made of LDPE and fully recyclable. The two opposite slits are covered with a PVC window. RND-520S Round drum hood with lip for drums without clamping ring diameter 500 - 520 mm. RND-520 Round hood for drums with clamping ring diameter 520 mm. QUA-600 Square cap for drums with 600 mm edge length. OCT-520 bzw. OCT-590 Octagonal hood for drums with 520 mm (590 mm) incircle diameter. RND-750 Round hood for JumboXL-drum For latest details regarding the content of this page see www.migal.co 15

Drum hoods Overview table Item number 10,10,2,0001 10,10,2,0002 10,10,2,0003 10,10,2,0004 10,10,2,0006 10,10,2,0008 Reference table Designation Round drum hood for drums with clamping ring RND-520 Dimensions 520 mm outside diameter Round drum hood with lip RND-520S for drums with 500 - 520 mm outside diameter Square drum hood QUA-600 Octagonal drum hood OCT-520 Octagonal drum hood OCT-590 for drums with 600 mm edge length 520 mm incircle diameter 590 mm incircle diameter Round drum hood RND-750 for JumboXL-drum 750 mm incircle diameter Weight 1.7 kg 1.7 kg 2.7 kg 2.4 kg 2.5 kg 3.6 kg Manufacturer Type Round drum hood 520 Round drum hood with lip Square drum hood Round drum hood 750 MIGAL.CO MIGAL.CO MIGAL.CO MIGAL.CO Eco-drum aluminum- and copper alloys x Eco-drum CrNi Jumbo-drum JumboXL-drum x x x A reference table for drums of other manufacturers is available at www.migal.co For latest details regarding the content of this page see www.migal.co 16

Decoiling aids MIGAL.CO - decoiling aids - decades of experience for wire without knots The wire extraction from drums and coils is fundamentally different. While coils rotate through the extraction and the wire is drawn tangentially, drums stand still and the wire is usually taken vertically upward in the axial direction. This leads to a twist of the wire (torsion). Depending on the mechanical properties of the wire, it may cause a sudden entanglement preventing further withdrawal of the wire electrode. Such tangles are also often referred to as knots. Especially aluminum wires of alloys of the 5000 group are particularly vulnerable, but basically, this can also occur in other steel and non-ferrous alloys. Decoiling aid ASH 81 for Eco-drums Our ECO-drums are mainly used for aluminum alloys of the 4000 series, as well as for copper alloys. Here, our decoling finger built-into the drum hood has been proven in conjunction with 70 wooden balls (40 mm diameter) thousands of times. Using this decoiling finger no further connector for the conduit is necessary. The decoiling aid provides a 1/4“ internal thread and a 1/2“ external thread. Decoiling aid ASH 81 Rotating decoiling finger for integration into drum hood. ASH 80 built into drum hood RND-520 For latest details regarding the content of this page see www.migal.co 17

Decoiling aids Decoiling aid TOU400/580 for Jumbo-drums Our jumbo drums are mainly used for aluminum alloys of the 5000 series, but also for copper alloys. Specifically the 5000 alloys are particularly prone to knot formation. The newly developed decoiling aid of MIGAL.CO reliably prevents the formation of wire knotting. Due to the plastic ring directly sitting on the wire, the individual turns can not escape unintentionally. A rotating decoiling finger guides the wire as much as possible and avoids free loops of wire which otherwise could form knots. The decoiling finger is equipped with the Rolliner NG and therefore shows extremely low friction and wear. During wire removal, the decoiling aid falls to the bottom of the wire drum, is withdrawn and used in the next drum. Thus, costly downtime and system failures can be avoided. The decoiling aid is protected by the utility model DE 20 2011 108 769.0. TOU400/580 Decoiling aid for Jumbo packs with rotating decoiling finger. TOU400/580 Set Necessary items for decoiling of Jumbo packs (Aluminum- and copper alloys). Overview table Item number 10,10,4,0001 Designation Decoiling aid TOU400/580 Weight 1.0 kg A video of the decoiling aid in action is available at www.migal.co 20

Decoiling aids Decoiling aid ASH-XL2 for wire diameters up to 4 mm The decoiling aid ASH-XL2 can be used for wire diameters from 2.0 to 4.0 mm. Using this decoiling finger no further connector for the conduit is necessary. The decoiling aid provides a 1/4“ internal thread and a 1/2“ external thread. Decoiling aid Jumbo DC 380/580 Decoiling aid ASH-XL2 Decoiling aid Jumbo DC 380/580 This decoiling aid is used with the Jumbo-drum and 4043 wire in 1,2 mm diameter. For application just remove the card board ring and put it on the wire. Make sure to remove everything inside the drum (bottom) so the decoiling aid can settle down straight when the drum becomes empty. Decoiling aid Jumbo DC 380/580 ready for operation in the Jumbo drum Overview table Item number 10,10,3,0006 10,10,4,0005 Designation Decoiling aid ASH-XL2 Decoiling aid Jumbo DC 380/580 Weight 0.9 kg 3.42 kg For latest details regarding the content of this page see www.migal.co 22

Drum connector Connector for drum hoods A connector is required to attach the conduit to the drum hood. This provides a 1/4“ internal thread and a 1/2“ external thread. All conduits from our product range can be connected. A variant with a ceramic insert is available for steel wires. AER201-K Inlet AER201 Inlet for Aluminum- and copper alloys (right), and for steel with ceramic insert (left) Individual parts of drum connector AER 201 Inlet for drum hood complete Sideview of the AER 201 built into drum hood Overview table Item number 10,10,5,0005 Designation Connector drum hood AER201 10,10,5,0006 Connector drum hood AER201-K Weight 0.05 kg 0.05 kg Additional information Plastic inlet for aluminum and copper alloys Ceramic inlet for steel wires For latest details regarding the content of this page see www.migal.co 23

Pulley Pulley for straight welds Wire from drums with alloys of the 5000 series is preformed sinusoidal. In mechanized welding this may lead to inaccurate positioning of the wire and specifically when small weld cross sections are welded with large wire diameters (e.g. a4 fillet weld with 1.6 mm wire diameter). In this case, the pulley is used. This plastically deforms the wire electrode and thus the wire is pre-bent always in the same direction.The pulleys ULR-2 and ULR-3 are delivered with a quick coupling, which provides a 1/4“ male thread for connection to the conduit. Attachment to the drum hood as well as a borehole for connecting the wire end control SMA-2 (10,10,7,0001) is included. The pulley ULR-3 has additionally a transparent cover to protect against dust and the wire exit leads vertically upwards. The pull-out forces are substantial, and as follows: • ML 5087, ML 5183, ML 5356 1.2 mm: 9 N • ML 5087, ML 5183, ML 5356 1.6 mm: 25 N Pulley ULR-2 Pulley ULR-3 with connected Rolliner 3G Overview table Item number 10,10,6,0001 10,10,6,0002 Designation Pulley ULR-2 Pulley ULR-3 Weight 0.85 kg 1.05 kg For latest details regarding the content of this page see www.migal.co 24

Wire straightener Straightening device RoboStraight Welding wires that are taken from wire drums are usually characterised by relatively large bounce, i.e. they are fairly straight. Nevertheless, it can be seen that the wires often come out of the drum slightly wavy, or even in a spiral shape. This can lead to considerable process disturbances in sensitive applications such as laser processes or gas- shielded welding of small sheet thicknesses, as the wire tip then changes position from the wire outlet nozzle in a circular, or sometimes erratic, manner. Circling wire tip when wire is not straight The use of a wire straightener directly at the barrel outlet is able to straighten even considerably deformed wires reliably. The use of a total of 14 adjustable straightening rollers in conjunction with a quick opener enables stable operation. Adjusting the wire straightener is amazingly easy and takes only a few minutes. For aluminium, a separate set of rollers (U-shaped) is required for each wire diameter; for steel, a single set of rollers (V-shaped) covers the entire diameter range from 0.8 to 2.0 mm. A higher conveying force must be taken into account, which can be overcome, for example, by an auxiliary drive (RoboFeed). It has been shown that by using the wire straightener, the formation of knots in the wire barrels and the bouncing of the wire within the guide tube can also be avoided. A mounting plate is supplied to attach the straightener to the decoiling hood. For this purpose, 4 holes with a diameter of 8.5 mm must be drilled in the decoiling hood. The wire can then be fed out either via a quick coupling CRNG-20 and then further e.g. with a Rolliner. Alternatively, a wire feeder, e.g. RoboFeed, can be mounted directly above it. Wire straightener with RoboFeed mounted above it For latest details regarding the content of this page see www.migal.co RoboStraight mounted on drum hood by means of a mounting plate 25

Wire end control Overview table Item number 10,10,6,0006 10,10,6,0007 10,10,6,0008 10,10,6,0009 Designation Straightening device RoboStraight 14-rolls 1.6 mm Straightening device RoboStraight 14-rolls 1.2 mm Straightening device RoboStraight 14-rolls 1.0 mm Straightening device RoboStraight 14-rolls 0.7 - 2.2 mm steel Weight 5.82 kg 5.82 kg 5.82 kg 5.82 kg End of wire clearly detected For the detection of the wire end a non-contact sensor is available. The proximity switch is closed when welding wire is available. The operating voltage is 24 Volts. Included is the power cable (10 m), the sensor block and the proximity switch. The terminal block on the inlet side has a 1/4“ male thread (connection to drum connector AER-201 or decoiling aid ASH-81) and the outlet side a 1/4“ internal thread and a 1/2“ external thread (connection to the conduit). Individual parts of wire end control Wire end control connected to drum connector AER-201 and conduit Overview table Item number 10,10,7,0001 10,10,7,0002 Designation Sensor with power cable SMA-2 Wire end sensor block DES-2 Weight 0.05 kg 0.03 kg A data sheet of the sensor is available at www.migal.co 26

Conduits Toughliner - for un-, low- and high-alloy steel wires Toughliner is the conduit with extremely high wear resistance and low coefficient of friction at the same time. The spiral is made of flat steel wire with rounded edges and a tensile strength of more than 1,500 N/mm2. The tube is encased in two layers with PE inside and outside with PA12. This gives an excellent durability, achieved even under extreme conditions. The hose is so stiff on one hand, that it always sets the largest possible bending radius (as shown on photograph page 20) and yet so flexible that even strong robot movements over a long time can be tolerated. With the coupling CRNG40 the Tough liner is connected without interfering transitions. Toughliner detail with quick coupling CRNG40 Toughliner with plug CRNG40 The Toughliner is completely passed through the coupling, and the wire doesn‘t touch the coupling at any point. The Toughliner is directly connected by the coupling and there are no pro- blems during wire inching. Toughliner with quick coupling CRNG40 The Toughliner is completely passed through the coupling, and the wire doesn‘t touch the coupling at any point. The Toughliner is directly connected by the coupling and there are no pro- blems during wire inching. Technical data Toughliner, Extra, Flex Weight of product Coefficient of friction Outside-/Inside diameter Diameter of welding wire 0.25 kg/m 0.20 11.7 mm / 5.7 mm up to 2.4 mm For latest details regarding the content of this page see www.migal.co Section Toughliner The Toughliner is made of flat rolled round wire. Thus, the edges are rounded and sharp edges are avoided. 27

Conduits Toughliner EXTRA - for extreme demands Toughliner Extra is built of a flat steel wire with rounded edges and an additional fortification with longitudinal wires. This allows Toughliner Extra to withstand extreme tensile stress. The couplings CRNG40 may be used the same way as with Toughliner. Structure of Toughliner EXTRA Cross section of Toughliner EXTRA Toughliner FLEX - extremely flexible Toughliner Flex consists of a round wire spiral with a soft sheathing and is thus extremely flexible. Toughliner Flex can be used in areas with extreme flexibility requirements.The couplings CRNG40 may be used the same way as with Toughliner. Structure of Toughliner FLEX extremely flexible Overview table Item number 10,40,1,0002 10,10,7,0006 10,10,7,0007 Designation Conduit Toughliner Conduit Toughliner EXTRA Conduit Toughliner FLEX Weight 0.25 kg/m 0.25 kg/m 0.25 kg/m For latest details regarding the content of this page see www.migal.co 28

Conduits Softliner - for non-ferrous metals and high alloyed steels Softliner is a high density PE hose with a low coefficient of sliding friction and yet good resistance. Softliner is used for filler metals made of aluminium and copper alloys, as well as for high-alloy steels. This hose is recommended for more static applications. For use with robots and strong movements, the DUROLINER should be used. With the CRNG40 coupling, the softliner is connected without any interfering transitions. Softliner detail with quick coupling CRNG40 Softliner with plug CRNG40 The Softliner is completely passed through the coupling, and the wire doesn‘t touch the coupling at any point. The Softliner is directly connected by the coupling and there are no pro- blems during wire inching. Softliner with quick coupling CRNG40 The Softliner is completely passed through the coupling, and the wire doesn‘t touch the coupling at any point. The Softliner is directly connected by the coupling and there are no pro- blems during wire inching. DUROliner - for non-ferrous metals and high-alloy steels with extreme kink resistance DUROLINER is a significantly improved PE hose with high hardness and low coefficient of sliding friction. DUROLINER is used where breaks occur with Softliner due to strong axial movements, especially in the area of the connections. In addition, DUROLINER is identical to Softliner. With the CRNG40 coupling, the DUROLINER is connected without disturbing transitions. For cutting Softliner and DUROliner we recommend our Cutty tool. Technical data (Softliner and DUROliner) Weight Coefficient of friction Outside-/Inside diameter Diameter of welding wire 0.05 kg/m 0.20 11.7 mm / 7.7 mm up to 2.4 mm DUROliner For latest details regarding the content of this page see www.migal.co 29

Conduits Overview table Item number 10,40,1,0001 10,10,7,0008 Designation Conduit Softliner Conduit DUROliner Weight 0.05 kg/m 0.05 kg/m Wall brackets for Toughliner, Softliner and DUROliner For the attachment of Toughliner, Toughliner Extra, Toughliner Flex, Softliner and DUROliner to a wall a suitable bracket is available. The internal thread is M6. Wall bracket for Toughliner, Softliner and DUROliner, side view and topview The Toughliner is stiff enough for a uniform bend radius. Cutting tool Cutty Softliner and DUROliner can easily and preci- sely be cut by our cutting tool Cutty. Overview table Item number 10,40,1,0005 Designation Wall bracket Toughliner, Softliner, DUROliner Weight 0.01 kg For latest details regarding the content of this page see www.migal.co 30

Conduits Rolliner NG - the second generation ROLLINER NG is the second generation of a completely new approach to wire feeding. Away from friction in liners, away from abrasion, from fluctuating feeding and from unnecessary maintenance. With ROLLINER feeding occurs through rolls only, shifted by 90° - without any sliding friction. ROLLINER NG has a diameter of 20 mm and may be shortened or lengthened easily – without any tools. The maximum bending radius is 120 mm and the weight was substantially reduced – ideal for highly dynamic movements. ROLLINER NG is the ultimate solution for any wire feeding! Application • Connecting bulk-wire systems to the wire-feeder • Connecting wire-feeders to welding guns Advantages Schematics Rolliner NG elements • No abrasion due to extremely small forces on the wire • Reduced cost due to the reduction to one wire drive only, and no maintenance necessary • Stable arc due to precise wire feeding • Simplified setup of welding systems due to more freedom in situating the bulk-wire system Technical data Outside diameter Weight / meter Min. bending radius for wire inching Min. bending radius Maximum torsion Max. inner diameter Recommended wire diameter Length per packaging unit Coefficient of friction 20 mm 150 grams 150 mm 120 mm 180° / meter 2 mm (wire 1.6) 0.6 - 1.2 mm 25 m 0.08 Warranty For Rolliner we provide a warranty of 1 year! For latest details regarding the content of this page see www.migal.co 32

Conduits Rolliner NG - the second generation Delivery form ROLLINER NG is supplied by the meter. The required connectors can be easily fitted by the user. The connector ENG20S represents a 1/4“ female thread. For the connection to the drum hood connector AER-200 either a screw connector RNG20 or a quick connector CRNG20 is required. Alternatively, the wire end control (page 17) can be used. For the connection to the wire feeder by the universal connector ASR-PR no additional coupling is required. Note: The connector ENG20S with strain relief RES20 replaces the earlier product ENG20! Rolliner NG with connector ENG20S, strain relief RES20, quick coupling CRNG20, connector drum hood AER201. Rolliner NG in standard configuration with connector ENG20S and strain relief RES20. For latest details regarding the content of this page see www.migal.co 33

Conduits Rolliner 3G - up to 1.6 mm wire diameter and no tools needed for assembly Rolliner 3G is the continuation of the roll-guided wire feed hose, which has been successful for 10 years, with significant improvements. The individual elements contain a pair of rollers and are connected to one another via joints. Each element is turned by 90 ° to the adjacent element, whereby the welding wire is guided entirely by rollers. As a result, the friction is significantly reduced in comparison to conventional wire guide hoses. Between the individual pairs of rollers there is a conical guide, which during threading leads the wire to the next pair of rollers, thus ensuring trouble-free threading over narrow radii. Effortless threading by means of a patented, conical guide of the wire from roller pair to roller pair! Advantages • Due to its low friction, Rolliner 3G allows significantly longer wire runs between the pay-off pack and the wire feeder. In many cases it is possible to avoid additional drives. • Rolliner 3G is not a wearing part and is maintenance-free for many years. The welding process becomes more stable as less slippage occurs due to the low forces in the wire transport system. • Rolliner 3G can be shortened or extended without tools. For shorting the use of a separation tool is recommended. Technical Data Lengths Outside diameter Bending radius Maximum wire diameter Conveyable alloys Maximum wire feed speed Weight per meter Wire temperature Coefficient of friction any - maximum length of protective hose 25 m, can be extended with hose connector 28.5 mm minimum 70 mm at wire threading and during operation 1.6 mm all material types can be transported by Rolliner 3G (round wires), i. e. steel, stainless steel, aluminum, copper, etc. 30 meters per minute 200 grams max. 40° Celsius 0.08 For latest details regarding the content of this page see www.migal.co 35

Conduits Rolliner 3G - up to 1.6 mm wire diameter and no tools needed for assembly Overview table Item number 10,30,3,0001 10,30,3,0002 10,30,3,0003 10,30,3,0100 10,20,2,0004 10,40,2,0001 10,30,1,0003 10,10,8,0001 10,10,8,0002 Rolliner 3G without protective hose, view of single element Designation Connector wire inlet Rolliner 3G with retaining clip Connector wire outlet Rolliner 3G with retaining clip Retaining clip Rolliner 3G Rolliner 3G with protective hosePA12 Connector protective hose PA12 Rolliner 3G Separation tool Rolliner 3G Quick coupling CRNG20 complete (plug and coupling) Plug CRNG40 Coupling CRNG40 Easy assembly • • • Connect the wire inlet and outlet Insert elements into protective hose Insert the holding clips at the inlet and outlet Weight 0.05 kg 0.05 kg 0.004 kg 0.2 kg/m 0.03 kg 0.05 kg 0.08 kg 0.07 kg 0.16 kg Arrows on each element of the Rolliner 3G show the wire feed direction as well as the insertion direction Rolliner 3G elements without protective hose For latest details regarding the content of this page see www.migal.co 36

Conduits Hose holder and accessories For Rolliner NG, Rolliner 3G, as well as the protective hose PA12 suitable brackets and wear rings are offered. Overview table Item number 10,30,1,0008 10,30,1,0010 10,30,1,0009 10,30,1,0014 Designation Wall bracket for Rolliner NG SNG20 Wall bracket for protective hose PA12 Wear ring for protective hose PA12 Hose holder for Rolliner NG, 3G and protective hose PA12 Weight 0.02 kg 0.05 kg 0.02 kg 0.1 kg Wall bracket for protective hose PA12 Wear ring for protective hose PA12 Wall bracket for Rolliner NG SNG20 For latest details regarding the content of this page see www.migal.co Hose holder for Rolliner NG and protective hose PA12 38

Conduits Rolliner XL2 - up to 4 mm wire diameter and no tools needed for assembly Rolliner XL2 is the continuation of the roll-guided wire feed hose, which has been successful for 10 years, with significant improvements. The individual elements contain a pair of rollers and are connected to one another via joints. Each element is turned by 90 ° to the adjacent element, whereby the welding wire is guided entirely by rollers. As a result, the friction is significantly reduced in comparison to conventional wire guide hoses. Between the individual pairs of rollers there is a conical guide, which during threading leads the wire to the next pair of rollers, thus ensuring trouble-free threading over narrow radii. Effortless threading by means of a patented, conical guide of the wire from roller pair to roller pair! Advantages • Due to its low friction, Rolliner XL2 allows significantly longer wire runs between the pay-off pack and the wire feeder. In many cases it is possible to avoid additional drives. • Rolliner XL2 is not a wearing part and is maintenance-free for many years. The welding process becomes more stable as less slippage occurs due to the low forces in the wire transport system. • Rolliner XL2 can be shortened or extended without tools. Technical Data Lengths Outside diameter Bending radius Maximum wire diameter Conveyable alloys Maximum wire feed speed Weight per meter Wire temperature Coefficient of friction any - maximum length of protective hose 25 m, can be extended with hose connector 42.5 mm (55 mm at the connectors) minimum 150 mm at wire threading and during operation 4 mm all material types can be transported by Rolliner XL2 (round wires), i. e. steel, stainless steel, aluminum, copper, etc. 30 meters per minute 500 grams maximum 40° Celsius 0.08 Connectors The inlets and outlets of the Rolliner XL2 have a 1/4“ internal thread and a 1/2“ external thread. As a result, the CRNG20 or CRNG40 quick couplings can be used. For an overview of all couplings with fotos and item numbers see page 40. For latest details regarding the content of this page see www.migal.co 39

Conduits Rolliner XL2 - up to 4 mm wire diameter and no tools needed for assembly Overview table Item number 10,20,2,0001 10,20,2,0002 10,20,2,0003 10,20,2,0100 10,30,3,0004 10,30,1,0003 10,10,8,0001 10,10,8,0002 Designation Connector wire inlet Rolliner XL2 with retaining clip Connector wire outlet Rolliner XL2 with retaining clip Retaining clip Rolliner XL2 Rolliner XL2 with protective hose PA12 Connector protective hose PA12 Rolliner XL2 Quick coupling CRNG20 complete (plug and coupling) Plug CRNG40 Coupling CRNG40 Weight 0.1 kg 0.1 kg 0.004 kg 0.5 kg/m 0.03 kg 0.08 kg 0.07 kg 0.16 kg Easy assembly • • • Connect the wire inlet and outlet Insert elements into protective hose Insert the holding clips at the inlet and outlet Rolliner XL2 Elements For latest details regarding the content of this page see www.migal.co Arrows on each element of the Rolliner XL2 show the wire feed direction as well as the insertion direction 40

Couplings & Connectors Screw- and quick couplings for Rolliner NG, Rolliner 3G and Rolliner XL2 These couplings are used to connect the Rolliner NG with the drum hood connector AER-201 or the wire end control. A plastic insert protects the wire against damage. It must be inserted in the direction of the wire transport. The outer thread is 1/4“. Screw coupling RNG20 Quick coupling CRNG20 Overview table Item number 10,30,1,0004 10,30,1,0003 Quick coupling CRNG20 divided Designation Screw coupling RNG20 Quick coupling CRNG20 Weight 0.025 kg 0.08 kg Coupling CRNG40 for Toughliner, Softliner, DUROliner, Rolliner 3G and Rolliner XL2 The coupling CRNG40 is used to connect the conduits Toughliner, Softliner, DUROliner, Rolliner 3G or Rolliner XL2. The special feature of this coupling is that the wire can never touch the metal parts of the coupling. This is achieved by the fact that the conduits are directly routed through the coupling and face each other nearly without a gap. The coupling provides a 1/2“ internal thread. Toughliner, Softliner or DUROliner are fixed by a compression fitting. For latest details regarding the content of this page see www.migal.co 43

Couplings & Connectors Coupling CRNG40 for Toughliner, Softliner, DUROliner, Rolliner 3G and Rolliner XL2 Quick coupling CRNG40 with Softliner on drum hood. Plug CRNG40 on drum hood. Connectors to wire feeders To connect the Rolliner, as well as Softliner and Toughliner various fittings to wire feeders are available. Universal connector for wire feeders ASRPR brass Suitable for Fronius, EWM, Lorch, Rehm, Kemppi (9,5/11,5/12/13 mm). For steel wires only. Connector for wire feeders ASRPR with plastic insert Fits for Fronius, EWM, Lorch, Rehm, Kemppi (9,5/11,5/12/13 mm). Suitable for aluminum- and copper alloys. For latest details regarding the content of this page see www.migal.co 45

Couplings & Connectors Connectors to wire feeders Connector CLOOS Connector SKS-Q591D Connector SKS-PF5 Adapter 1/2“ to M20 Reference and overview table Item number 10,20,1,0012 10,20,1,0013 Designation Universal connector for wire feeders ASRPR with plastic insert Universal connector for wire feeders ASRPR with brass insert 10,20,1,0014 Adapter 1/2“ to M20 10,20,1,0009 Connector CLOOS 10,20,1,0011 Connector SKS PF5 10,20,1,0010 Connector SKS Q591D Fits for Fronius, EWM, Lorch, Rehm Fronius, EWM, Lorch, Rehm Fronius CLOOS SKS PF5 SKS Q591D Weight 0.07 kg Additional information for non ferrous metals 0.07 kg for steels 0.007 kg 0.005 kg 0.05 kg 0.05 kg all alloys all alloys all alloys For latest details regarding the content of this page see www.migal.co 46

Wire feeder Pneumatic feed assist DLDA1 for extreme wire feeding distances The friction of the wire in the conduit is caused by the fact that the wire rests against the inside of the tube. This grows exponentially with the bending angle and, depending on the coefficient of friction rapidly to a complete blocking of the wire electrode. The pneumatic feed assist DLDA1 exerts a permanent and continuously adjustable pressure to the wire electrode. The latter is pressed against the outer wall of the conduit, where it causes about the same friction as otherwise against the inner wall. Ideally, the air pressure is adjusted so that the wire at the outlet of the conduit may be pulled or blocked with just two fingers (few Newtons). The wire feeder can then supply any quantity of wire with the least amount of force. The Euler-Eytelwein formula fails here. However, approximately the double angle can be achieved by using the DLDA1. The DLDA1 can either be placed on the drum hood with the connector AER200 or decoiling aid ASH-80, or just snapped in between the conduit (Toughliner, Softliner, Rolliner). The coupling CRNG40 is provided for standard use with the DLDA1. Pneumatic feed assist DLDA-1 on drum hood Using the inlet guide 1/4“ the pneumatic feed assist connects to the drum connector AER-201 or the decoiling finger ASH-81. Technical data Wire feed speed Feeding force Dimensions L x B x H Weight Wire diameter Air consumption 0 - 30 m/min 0-60 N (adjustable by air pressure 0-6 Bar) 100 x 140 x 160 mm 5.1 kg 0.8 - 1.6 mm approx. 20 - 30 cbm/h For latest details regarding the content of this page see www.migal.co 47

Wire feeder Pneumatic feed assist DLDA1 for extreme wire feeding distances Overview table Item number 10,50,1,0001 10,50,1,0002 10,50,2,0001 10,50,2,0002 10,50,3,0008 10,50,3,0010 10,50,3,0012 10,50,3,0016 10,50,4,0008 10,50,4,0010 10,50,4,0012 10,50,4,0016 Designation Pneumatic feed assist DLDA-1 Maintenance unit for DLDA-1 Inlet/outlet guide 1/4“ für DLDA-1 Inlet/outletguide 1/2" für DLDA-1 Set feed rolls 0,8 mm Fe Set feed rolls 1,0 mm Fe Set feed rolls 1,2 mm Fe Set feed rolls 1,6 mm Fe Set feed rolls 0,8 mm Al Set feed rolls 1,0 mm Al Set feed rolls 1,2 mm Al Set feed rolls 1,6 mm Al Weight 5.1 kg 0.9 kg 0.02 kg 0.04 kg 0.11 kg 0.11 kg 0.11 kg 0.11 kg 0.11 kg 0.11 kg 0.11 kg 0.11 kg Pneumatic feed assist DLDA-1 with conduit in in- and outlet Inlet/outlet guide 1/2“ for DLDA-1 The quick connector CRNG-40 connects to the DLDA-1 with the inlet guide 1/2“. Inlet/outlet guide 1/4“ for DLDA-1 Connects to the drum connector AER-201, the decoiling finger ASH-81 or to the Rolliner. For latest details regarding the content of this page see www.migal.co 48

Wire feeder RoboFeed - pushing the limits of wire transport The friction of the wire in the conduit is caused by the fact that the wire rests against the inside of the tube. This grows exponentially with the bending angle and, depending on the coefficient of friction rapidly to a complete blocking of the wire electrode. The electrically driven feed assist RoboFeed exerts a permanent and continuously adjustable pressure to the wire electrode. The latter is pressed against the outer wall of the conduit, where it causes about the same friction as otherwise against the inner wall. Ideally, the feed force is adjusted so that the wire at the outlet of the conduit may be pulled or blocked with just two fingers (few Newtons). The wire feeder can then supply any quantity of wire with the least amount of force. An electrical connection between RoboFeed and the main drive is not necessary. RoboFeed comes to a standstill by itself when the main drive stops and delivers the right amount of wire by itself when the main drive is running, up to wire speeds of 50 m/min. Even in welding processes with rapidly changing wire speeds, RoboFeed reliably delivers the required wire speed. If an electrical connection is still required to relieve the drive during long breaks, RoboFeed also provides this in any case. Technical data Wire feed speed Feeding force Dimensions L x B x H Weight Wire diameter Power supply 0 - 50 m/min 0 - 165 N (maximum force can be limited with cfg-file) 440 x 255 x 190 mm 9.4 kg (RoboFeed Wire Manager 9.9 kg) 0.8 - 1.6 mm (larger diameter on request) 115 - 230 volts / 50 - 60 Hz For latest details regarding the content of this page see www.migal.co 49

Wire feeder RoboFeed - pushing the limits of wire transport RoboFeed has a powerful wire feed motor with 100 Watts of power at its drive shaft. It assists the main wire feed motor by supplying always sufficient welding wire even at large distances from the wire-pack to the welding robot. Optionally, RoboFeed can also be used as a stand-alone wire feeder with constant, adjustable wire speed from 0 - 50 /min. It allows a liner length of more than 50 m and therefore makes the welding cell design more flexible. The forces in the wire feed system are significantly reduced which cares for less wire feeding problems and a more stable welding process. It can operate fully independent and saves the time consuming wire insert by hand during wire pack change. • Quad roll drive • RoboFeed applies a constant feed force, no electrical connection to the welding power source or welding robot required, but possible • Parameters like maximum feed force, wire feed direction, maximum wire feed speed, maximum speed and force during keying operation (wire forward/backward) can be set in a configuration file via a USB-connector. • Liner length between wire pack and robot of more than 50 m • Prepared for wall mount (brackets are included) • Floor mount with optional stand • Can be used with Rolliner NG, 3G, XL2 and with all standard liners • The panel can be rotated for vertical or horizontal wire feed direction • Electrical interface (24 Volts) for Start/Stop and wire forward/backward • Operating mode with constant, adjustable wire speed as option RoboFeed side view RoboFeed front view View from left side Overview table Item number 10,1020,00,10 Designation RoboFeed - Feed assist Weight 9.4 kg For latest details regarding the content of this page see www.migal.co 50

Wire feed and wire management RoboFeed-WireManager - pushing the limits of wire transport and wire management RoboFeed-WireManager has a powerful wire feed motor with 100 Watts of power at its drive shaft. It assists the main wire feed motor by supplying always sufficient welding wire even at large distances from the wire-pack to the welding robot. Additionally it records the wire consumption, warns when the remaining wire quantity is low, inserts the wire at a specific length, shows statistical data, provides a stopwatch and talks to other devices via MQTT or OPC UA. It allows a liner length of more than 50 m and therefore makes the welding cell design more flexible. The forces in the wire feed system are significantly reduced which cares for less wire feeding problems and a more stable welding process. It can operate fully independent and saves the time consuming wire insert by hand during wire pack change. For latest details regarding the content of this page see www.migal.co 52

Wire feed and wire management RoboFeed-WireManager - pushing the limits of wire transport and wire management • Quad roll drive • RoboFeed - WireManager applies a constant feed force, no electrical connection to the welding power source or welding robot required, but possible • Optional barcode reader to recognize quantity, item number, batch number and manufacturing date of the wire (VDA- label) • Rejects wire pack change if wire item number is not correct • Statistics function • Shows remaining wire content with pre-warning and warning thresholds • Signal output, email and SMS as end-of-wire warning • MQTT protocol for IoT (batch, drum content, wire speed) • OPC UA server for IoT (batch, drum content, wire speed) • CANopen (currently internal) • Liner length between wire pack and robot of more than 50 m • Prepared for wall mount (brackets are included) • Floor mount with optional stand • Can be used with Rolliner NG, 3G, XL2 and with all standard liners • The panel can be rotated for vertical or horizontal wire feed direction • Electrical interface (24 Volts) for Start/Stop and wire forward/backward • Setup function for commissioning • Jogging with wireless remote control (battery-free EnOcean), 2 speeds • Automatic threading (setting of feed force and length) • Wire retraction during threading if wire gets stuck • Stopwatch function for wire length, weight, duty cycle • Settings with PIN code RoboFeed Wire Manager view from left side RoboFeed Wire Manager side view Powerful quad wire drive Panel rotated for horizontal wire direction Backside with brackets for wall mount For latest details regarding the content of this page see www.migal.co 53

Wire feed and wire management RoboFeed-WireManager - pushing the limits of wire transport and wire management Normal operation display Screen for Setup to determine feeding force Stopwatch function for wire consumption and threading length and duty cycle Screen for keying (jogging) - wire Statistics display for wire speed Screen for threading function - feeds forward/backward and feeding force the wire into the liner with a preset length Datamatrix code code on VDA label for batch number, weight, production date and item number QR code on wire label for batch number, weight, production date and item number Overview table Item number 10,1020,00,20 Designation RoboFeed-WireManager Weight 9.9 kg For latest details regarding the content of this page see www.migal.co 54

Basket spool adapters Adapters - for basket spools Adapters are required for some applications and some spool. Additionally to the shown variants we also have the option for custom designs. Please contact us. Adapter for basket spool B 300 The wire basket B-300 is very environmentally friendly as it can easily be disposed as scrap steel. With this adapter, the wire basket can be attached to the common 52 mm mandrel of all standard wire feeders. The adapter is easy to put together using zip closure. All basket spools B 300 according to EN ISO 544:2011 can be used. Overview table Item number 10,70,1,0001 Designation Adapter for basket spool B 300 Weight 0,8 kg For latest details regarding the content of this page see www.migal.co 55

Anti spatter Ceramic surface protection KRA-1000 for fixtures and welding torches The ceramic surface protection spray KRA-1000 protects surfaces exposed to temperatures up to 1000° C. The lifetime of MSG gas nozzles and contact tubes, electrodes of resistance welding machines and outlet nozzles of cold wire feeders for laser and plasma welding will be prolonged significantly. Surfaces of welding fixtures and clamping elements are optimally protected from weld spatter or other sparks. Benefits • Spatter will either stick not to the surface or will be much easier to remove from nozzles or fixtures • Less downtime and maintenance costs due to less frequent cleaning • Up to ten times lifetime of nozzles and devices • Stable welding processes, and thus less scrap Application Shake the can for at least 30 seconds before each use. Spray a thin film from a distance of approx. 30 cm. Avoid repeated overspray and consequent thick layers. Allow sprayed film to dry before use for 30 seconds! Samples of gas nozzles and contact tips with ceramic coating Warning Irritating to eyes and mucous membranes Inhalation of vapors may cause drowsiness and dizziness • Extremely flammable. Keep away from open flames or other sources! • • Pressurized container • Skin contact may cause skin dryness or cracking • • Do not expose aerosol to direct sunlight or temperatures above 50° C • Do not pierce or burn, even after use • Do not spray on an open flame or any hot surfaces • Keep away from sources of ignition - No smoking! • Keep out of the reach of children • Use only in well-ventilated areas • Avoid contact with skin and eyes Overview table Item number 10,60,1,0001 Designation Ceramic spray KRA-1000 400 ml For latest details regarding the content of this page see www.migal.co 56 Welding fixture with ceramic coating Weight 0,38 kg