Metro Rail News team Interviewed Mr V.V. Kamath during IREE 2023. He is the Managing Director of Fronius India Private Limited. This interview explores the latest innovations and technologies ushered by Fronius India Private Limited in the Indian mobility sector, emphasising Railways. This interview also unravels the company’s commitment towards sustainability and an environmentally friendly approach to business.
Mr. V.V. Kamath is the Managing Director of Fronius India Private Limited. With over 30 years in the welding industry and a background in mechanical engineering, he has led Fronius India since 2013. Beyond welding, his purview extends to solar energy and battery charging across SAR countries. Here are the edited excerpts:
Question: 01 Fronius’s motto is ‘changing the world for the better.’ How would you define this mission, and what major efforts is the company undertaking to fulfil it? Additionally, what does sustainability mean for Fronius?
Fronius firmly believes that sustainability is an action rather than a word. Our commitment to sustainability stems from our desire to leave a better Earth for future generations, including the unborn child. Our founder, Mr Gunter Pronius, believed that every product we make must endure its full life cycle and be easily repairable. At Fronius, we adhere to the three R principles: repair, reuse, and recycle. This is the foundation of our business model. We take great care to ensure that our products have the lowest possible CO2 emissions from the purchasing phase to the end of their life cycle. Our first battery charger was created using scrap materials, and the discarded battery charger was later transformed into a functional device.
Our welding machines, used since 1950 in Austria, are utilised globally. Some machines are still operational after 40 years of usage and remain recyclable. We take great care to safeguard the health of our planet by using the lowest amount of resources possible and returning them. Our welding business is centred on joining metal, while our solar energy business is focused on returning energy to the grid. We acquire energy from the grid in the former, but in the latter, we return energy to the grid. For us, this is the essence of sustainability.
Question: 02 How does Fronius ensure an efficient energy supply for various industries? Are there tailored solutions to optimise operating costs, especially for organisations in the railroad industry?
When considering passenger or freight transport, it is imperative to remember that the vehicle’s longevity is of utmost importance. Minimal repairs are necessary to ensure its longevity. This can only be achieved if the manufacturing process is handled carefully. Proper welding joints are key to ensuring durability and reducing the need for repairs. This is where Fronius comes in. With over 73 years of experience in the welding business, Fronius is committed to providing perfect welding joints through their welding machines. Fronius has 36 subsidiaries worldwide, offering experience in welding across various atmospheres and continents. They focus on transferring welding skills from the welder’s hand to the machine, ensuring a sound output. Furthermore, Fronius machines have been designed to consume the lowest power in the world, resulting in less grid energy consumption and a sound welding joint. With decades of proven success and satisfied customers, Fronius is a leading manufacturer in the industry.
Question: 03 Give us an overview of Fronius’ customised welding solutions. What are the major developments in robotic and automation systems in welding, and could you elaborate on TPS/i WireSense?
The history of robotic welding dates back several decades, during which the robot was considered the primary system, while the welding power source was relegated to a secondary position. However, this dynamic has shifted with technological advancements, and today, both the robot and welding power source are considered equally important. The welding power source has significantly developed, improving welding equipment technology. Robots would not be able to accomplish much without a welding power source. Modern welding machines are designed to achieve sound joints, with the robot as an arm to hold the equipment.
Regarding the TPSI wire sense program, this is a unique feature developed exclusively by Pronus for robotic welding. This program ensures that the welding path is maintained, even if there is a deviation from the sightline welding program. Our company offers customised welding solutions for various applications, including railroad, oil and gas, thermal power plants, etc. We have developed a specialised welding solution for bogey frames involving a complex welding path and restricted joint areas. Our solution ensures that the entire bogey frame is welded to meet the required quality standards. At our IREE stall, we showcase our welding solution for the specialised steel Indian railway, which is looking to modernise its rolling stock by incorporating aluminium racks.
Our company has already begun executing plans to expand our market reach by creating aluminium coaches, specifically the Pune Metro, which has been operating for the past eight months. The fabrication for these coaches was done by Titagarh Wagon using only our welding system, and the results have been world-class. Our next step is to move forward with the Vande Bharat passenger coaches, and we are currently in discussions with the contractors who have won the bid. We are dedicated to bringing customised, world-class welding solutions to our country to produce more Vande Bharat coaches in less time. As someone who has recently visited various facilities globally, our team is committed to action and producing results.
Question: 04 How is welding data management revolutionising the production environment? What software solutions does Fronius offer for data management?
Data management is integral to every aspect of our lives today, from communication to manufacturing. To this end, we present to you our solution, WeldCube, which offers various levels of data management systems depending on the needs of our customers. We offer WeldCube Basic and WeldCube Premium, and our data management solution can also be rented out to customers. This allows them to understand the required data, and if they are satisfied, they can continue with the solution. If not, they can short-close the contract.
We capture the essence of the arc, including voltage current, wire feed speed, gas consumption, energy consumption, and barcode scanning. If a product fails in the field, you can retrieve data on who welded it, what day it was welded, and what current and amperage were used. If corrective action is needed, it can be taken. Our complete end-to-end data management solution ensures you have all the tools to manage your data easily.
Question: 05 With over 25 years of experience in the rolling stock manufacturing industry, how is Fronius supporting the rail and metro industry with its welding systems and technologies?
It is important to note that we are in a business partnership where both parties benefit. The strength of our business is comparable to our strong welding joints. At Fronius India, we support Indian Railways in underframe manufacturing, bogey frame manufacturing, and coach manufacturing. We provided a welding solution during the manufacturing of Train 18, now named Vande Bharat, which faced numerous welding challenges. In the manufacturing of the Metro, passenger safety is of utmost importance, and we ensure that we provide quality welding joints that can last longer.
In addition to our welding mission, we have a team of 150 people in India and 14 offices spread across the country. We have over eleven robotic welding stations exclusively dedicated to our customers for their welding trials and over 40 manual welding stations for our customers’ training and conducting trials. We also aim to develop underprivileged families’ society kids to become employable welders and secure a place in the industry. Our program has successfully placed 70 kids in the industry in and around Pune, and we plan to take this program across the country to ensure that we have quality welders who can guarantee good-quality rolling stock in the future.
Question: 06 Fronius India has been recognised as a ‘Great Place to Work.’ What makes it stand out as an award-winning workplace?
In response to your query, Fronius India is an exceptional workplace. The team at Fronius India comprises individuals who are passionate about their work and are committed to the progress of our nation. The workplace environment is conducive to growth and development, and this sense of satisfaction makes Fronius India an ideal workplace. Although we do not boast luxurious offices or extravagant perks, the people at Fronius India make it a great place to work. We want to collaborate more with individuals like yourself to ensure our people’s and their projects’ success. With the support of reliable vendors, we aim to enhance the lifespan of rolling stock and provide the best services to our clients.
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