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Super-MIG™
Products
The Super-MIG™ Interface
- Compatible with
most popular robot controllers
- Includes
an integrated Unitronics
PLC
- Capable of
storing multiple welding
programs
- Gas flow monitor
allows gas mixture adjustment
- Plasma
power source
- Pump and reservoir
for the torch cooling system
- Patented “Softstart™” plasma
pilot arc ignition system
allows customer to switch between
welding processes (i.e. Plasma
Tack, Std. Mig, or Plasma/Mig
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The Super-MIG™ Torch
The Super-MIG™ Torch is
designed as a compact, in-line
unit utilizing industry standard
consumable MIG™ and
plasma tips. It is capable of 250amps
for plasma and 350amps for MIG,
and can accommodate wire diameters
up to 1.2mm. It’s compact
head is electrically isolated,
water-cooled, and pre-aligned ensuring
repeatable performance and easy
maintenance. 
Features of the Super-MIG™ Torch
include:
- Compact Head
- Capable of 250A
for plasma and 350A for MIG
- Pre-aligned
to ensure repeatable performance
and easy maintenance
- Water Cooled
- Electrically Isolated
- Can use
.035” or .045” wire
diameters
- Quick change Tungsten
Electrode
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 Super-MIG Consumables Lifetime
Plasma Components
- Electrode – 8-10
Hours Rotate or Replace (once
per shift)
- Nozzle – 8-10
Hours (once per shift)
MIG Components
- MIG Tip – 8-10
Hours (once per shift)
- Gas Shielding
Nozzle
- 80 – 100 Hours Duty
Cycle
- Dependant upon Application
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The Super-MIG™ Torch Cleaning
Device
The Super-MIG™ Torch Cleaning
Device is yet another innovation
by PLT that is designed to work
automatically within a robotic
welding cell. This device removes
the gas-shielding nozzle from the
torch, simultaneously cleans the
nozzle and welding tips, and places
the nozzle back on the torch ready
for the next weld cycle. The entire
four step cleaning process takes
approximately 8 seconds.
 Step 1
Gas Shield Nozzle is removed and
cleaned with spinning wire brush
Step 2
Torch moves to forward position
where spinning blades clean MIG
and Plasma tips
 Step 3
Torch moves back to first position
where Gas Shielding Nozzle is
reattached
Step 4
Torch Nozzle is sprayed with a
small amount of anti-spatter
liquid
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The Super-MIG™ Weld Process
Monitor
 The
Super-MIG™ Weld Process Monitor
has the capability to monitor and
store data for the following signals:
MIG voltage and current, plasma
voltage and current, and wire speed.
The unit is expandable to monitor
and store data for up to two hundred,
fifty-six parameters (i.e. gas flow
rates, or seam tracking signals)
with established control limits
allowing for real-time weld quality
monitoring. Communication is accomplished
via Ethernet connection allowing
data to be accessed locally or by
remote factory information systems.
The weld process monitor can be
used with other MIG or Plasma welding
systems and is not exclusively for
the Super-MIG™ process.
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Welding Solutions Services
WS, Inc. represents over 40 years of
experience in welding application
and equipment. We are able to provide
customers specific welding applications
to suit their individual needs using
the knowledge base of our staff
including PhD’s in mechanical
engineering and plasma physics.
We also provide entire integrated
solutions using the Super-MIG™
technology.
Welding Solutions, Inc. Services
include:
- Development of production applications:
Provide cost effective welding
applications to improve efficiency
and deliver quality product
to meet specific production
requirements.
- Weld failure and defect analysis:
Experienced personnel can review
your process and parameters
to provide the root cause source
and suggested corrective actions
- Prototype Welding:
Develop and demonstrate to
our customers a superior welding
technology based on the Super-MIG™
welding process for their current
and potential production applications.
- Weld Tool Verification - identifies
and resolves design or construction
problems and develops baseline
weld parameters.
- Technical support - includes
on-site support in robot programming
start-up and debugging, for mechanical
integration and process controls
related to Super-MIG™ applications.
- Laboratory Services - capable
in providing comprehensive mechanical
properties and metallurgical integrity
investigations.
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