Fronius Polaris: Cutting-edge operating concept combining cybersecurity, user-friendly controls, and digitalization

Software is the key factor putting companies ahead in the world of manufacturing today. While it's true that hardware forms the essential basis, it's the data and smart features that truly set the experience apart. By introducing Polaris, Fronius is setting new standards in welding automation and creating a control system that brings together cybersecurity, user-friendly operation, welding expertise, and the foundation for future AI applications in a single platform. This gives manufacturers a competitive edge through more efficient processes, enhanced security, and a solid foundation for future automation projects.

Software is the key factor putting companies ahead in the world of manufacturing today. While it's true that hardware forms the essential basis, it's the data and smart features that truly set the experience apart. By introducing Polaris, Fronius is setting new standards in welding automation and creating a control system that brings together cybersecurity, user-friendly operation, welding expertise, and the foundation for future AI applications in a single platform. This gives manufacturers a competitive edge through more efficient processes, enhanced security, and a solid foundation for future automation projects.

Automated industrial welding is seeing a fundamental shift in requirements. In recent years, productivity, the skills shortage, and process quality have been the main drivers of development. Now, another factor is taking center stage: Cybersecurity. With the EU's Cyber Resilience Act (CRA) and Machinery Regulation set to take effect in 2027, cybersecurity is becoming an essential element in manufacturing. In terms of legal requirements, the CE label will continue to serve as proof of compliance. However, the requirements to meet CE conformity are set to be expanded to include a wide range of cybersecurity aspects in the future. A modern machine must be designed in accordance with the IEC 62443 series of international standards, operate safely, and be protected against cyber risks throughout its total life cycle.

This will also significantly increase the security requirements placed on industrial automation and control systems. "At one time, automated welding was primarily about the machine design and hardware. But software and control technology are now playing an increasingly important role in determining how efficient, future-proof, and cost-effective a system is," sums up David Kreuzeder, Product Manager for Robotics and Digital Tools at Fronius International. In addition to the new Polaris system controls, Fronius has engineered the HMI Cockpit, a standalone analysis tool that provides comprehensive insights into system and process data. By pairing Polaris and the HMI Cockpit, manufacturers gain a wealth of valuable production data. These insights create greater transparency across the entire manufacturing process, forming the basis for digital services, data-driven decision-making, and future AI applications.

A control system for automated welding systems

Polaris integrates software, system controls, and welding technology into a common architecture and offers a unified operating concept for a variety of automation solutions-from mechanized welding systems to highly automated robotic welding systems. In the case of robotic welding systems, Polaris takes welding process control to the next level by also coordinating complex production workflows involving component handling as well as racking, loading, and unloading systems. At the same time, the platform is a great fit for fixed automation systems, where it handles central control of axes, rotating units, and welding equipment. Thanks to the common system architecture, robotic systems and mechanized welding systems can be seamlessly integrated with one another, resulting in a consistent user experience across all systems. "Along with security, a big aspect for us when designing Polaris was making sure the system was intuitive to use without an operating manual," notes Andreas Fischer, Fronius Solution Expert at Fronius International.

Programming-free automation

Digitalization opens up a world of possibilities, but companies need to be able to access these benefits in day-to-day production without draining valuable time and staff resources. Polaris also rises to this challenge with process flows that can be set up without any specialist programming skills. Once the default settings or add-ons for custom solutions have been configured, users have access to a drag-and-drop interface where they can select ready-made modules from a library. These modules can then be combined and saved as reusable templates, resulting in guided program sequences that allow manufacturers to integrate welding parameters alongside work steps and safety instructions. In addition to reducing sources of error and increasing process reliability, this also makes it easier to train new employees. "Polaris lets manufacturers capture automation and welding process expertise that they have accumulated over the years and make it permanently available to their team-so knowledge becomes a scalable aspect of manufacturing," Fischer notes.

Direct access to the welding process

Polaris is also tightly integrated with Fronius welding technology. The control system can access the welding machine in real time, allowing welding parameters to be adjusted directly through the user interface. Operators can now adjust settings on the spot rather than at the welding machine itself. This lets them respond flexibly to component tolerances, changes in material properties, or temperature fluctuations. At the same time, real-time synchronization ensures that the correct parameters are used at all times. "To ensure transparency and traceability, Polaris is equipped with a comprehensive user management system that establishes clear guidelines for permissions and individual user rights," says Kreuzeder. Plus, Polaris offers integrated welding data logging for detailed analyses, which serve as the basis for further optimizations.

Fronius Polaris creates a comprehensive digital foundation for all current and future automation solutions. By using the platform to their advantage, modern manufacturing companies can set themselves apart from the competition and make their production more efficient, secure, and cost-effective.

Learn more about Polaris and Fronius automation solutions: https://www.fronius.com/en/welding/products/automated-welding-systems

Fact box

What is Polaris?	Polaris is the new Fronius control system for automated welding systems that combines system control, welding processes, and welding technology into a single, central platform.
What problem does Polaris solve?	Polaris supports manufacturing companies in addressing key challenges such as cybersecurity, increasing system complexity, and growing demands around efficiency, quality, and digitalization.
What are the biggest benefits that Polaris offers users?	A unified, user-friendly operating concept, real-time access to welding parameters, and simple drag-and-drop programming make the platform easy and efficient to use. Polaris combines fixed automation solutions and robotics on a common system architecture, allowing for seamless combination of both types of systems.
Is Polaris future-proof?	Yes. The platform was developed in compliance with the OT security standards specified in IEC 62443. It incorporates modern security standards while laying the groundwork for future AI applications. As such, Polaris offers a scalable architecture to meet future requirements in welding production processes.

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