This page describes how to integrate and set up communication between Fronius TPS/i series power sources and SmoothTool X.
Hardware Configuration
SmoothTool X is compatible with Fronius TPS/i series power sources. To set up communication between the software and a power source, the following items are required:
- Fronius products (contact your local Fronius dealer for more information):
- The RI FB Inside/i interface, configured for the Ethernet/IP protocol.
- One of the following Ethernet/IP modules:
- RI MOD/i CC-M40 Ethernet/IP-2P
- RI MOD/i CC Ethernet/IP-2P
- Ethernet RJ45 cable from the power source to the robot.
Note
SmoothTool X communicates with the Fronius TPS/i over the standard Ethernet/IP protocol. Set this protocol on the Fronius interface itself, following the interface’s instruction manual — it is not configured in SmoothTool X.
RI FB Inside/i Interface — IP Address
Before installing the RI FB Inside/i interface, select a valid IP address for the interface. The IP address must be on the same subnet as the robot.
- If the selected IP address falls under 192.168.0.X, specify the last octet using the 8 physical dip-switches on the interface. Each dip-switch represents one bit of the missing byte.
- If the selected IP address does not fall under 192.168.0.X, set all dip-switches to 0 and configure the IP address via the web interface of the power source.
More information about setting the IP address can be found in the interface instruction manual. Visit the Fronius download page to acquire it.
Installing the Interface and Module
After setting the physical dip-switches, install the RI FB Inside/i interface by following its instruction manual. Then insert the Ethernet/IP module into the suitable slot, fasten it with two screws, and connect the module to the robot using the Ethernet cable.
Software Configuration
Once the hardware is configured, add and connect the Fronius TPS/i in SmoothTool X.
Add the Fronius TPS/i
Tap SmoothTool X Settings from the Application view. In the sidebar, under Components, tap Power Sources, then tap Add new power source.
In the Add power source dialog, select the Fronius tile and choose the Fronius TPS/i model, then tap Add power source.
Configure the Fronius TPS/i
Fill in the configuration fields:
| Field | Description |
|---|---|
| Custom name | A name to identify this power source. |
| Power source IP address | The IP address you set for the interface. The robot uses this address to communicate with the power source. Ensure it is set correctly; otherwise the robot cannot connect. |
| Configure parameters in the software | Controls whether program nodes override the power source parameters at runtime — see Configure parameters in the software below. |
When done, tap Done to save the power source.
Configure parameters in the software
The Configure parameters in the software toggle controls how welding parameters are applied:
- Disabled (default) — the power source keeps the parameters set on the machine; program nodes do not override them.
- Enabled — program nodes override the power source parameters at runtime, letting you set welding parameters per node from the weld node’s Power source tab.
Connect to the Fronius TPS/i
Back on the Power Sources page, expand the new entry, tap Selected to make it the active power source, then tap Connect. When the connection is established, a connection status tag is shown on the entry.
Programming with SmoothTool X and Fronius TPS/i
When Configure parameters in the software is enabled, you can adjust the welding parameters per node from the program tree.
Select a weld node (e.g. Weld Seam) in the program tree and open its Power source tab. The parameters apply when the program reaches that node.
The power source offers two methods for setting the weld parameters: Job number mode and Synergic mode.
Job number mode
Select Job number mode to run a predefined weld data number stored on the power source.
| Identifier | Description |
|---|---|
| Job number | The job containing predefined parameters stored on the Fronius power source. |
| Transfer parameters | Sends the current parameters to the power source. Available once connected. |
Note
In Job number mode the power source uses the parameters stored under the selected job; wire feed speed, arc length, dynamic, and synchro pulse cannot be overridden. Use Synergic mode if you need to override those.
Synergic mode
Select Synergic mode to find the right synergic line through a guided wizard. Tap Guided setup and follow the steps to select the Material, Wire diameter, Gas, Process, and Property. You can also enter a known Synergic line number directly. Once a line is selected, the button collapses to an edit icon you can tap to change the selection.
Once a synergic line is selected, the parameters below become available:
| Identifier | Description |
|---|---|
| Arc length correction | Desired arc length correction. |
| Dynamic correction | Desired dynamic correction. |
| Wire feed speed | Desired wire feed speed. |
| Synchro pulse | Enable or disable synchro pulse. |
| Transfer parameters | Sends the current parameters to the power source. Available once connected. |
Manual power source controls
The manual controls live in the Power source popover, opened from the button in the operator screen toolbar.
When connected to the Fronius TPS/i, the following manual controls are available:
| Control | Description |
|---|---|
| Forward | Feeds the welding wire forward. |
| Backward | Retracts the welding wire. |
| Error reset | Sends a reset-error signal to the power source. |
| Gas | Opens the gas valve for the duration of the press. |
Warning
Connected to a power source that provides the option to control the wire. Do not use these functions without ensuring no harm can come to people or material. Make sure the area around the welding torch is clear before use.
Simulation
The Simulation toggle at the top of the popover runs the program as a dry run: the robot executes the full program and motion path, but the power source does not weld (no arc, wire feed, or gas). Use it to test a program safely, then turn it off to weld for real.