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YASKAWA MOTOMAN
HAS A WELDING
SOLUTION FOR ALL
INDUSTRIES AND A
COMPREHENSIVE
SUPPORT NETWORK
THAT EXTENDS
WORLDWIDE
ARCWORLD
FABWORLDROBOTIC WELDING
SOLUTIONS
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WORLD SOLUTION = PRE-ENGINEERED, STANDARDIZED WORKCELLReduced Cost and Risk n Improved Quality and Documentation n Reduced Delivery Time n Single-Source Support and Warranty for Workcell
Wide range of ArcWorld® and FabWorld® solutions pro
ArcWorld and ArcWorld CMid-range workcells
Low- to medium-volume fabrication
Automotive applications
n Roll-up doors allow for reduced oorspace
n Cells accommodate one or two robots
AW1000 AW6000
AWC-52 AWC-500
Since their introduction in 1990, our ArcWorld solutions have been continuously improved and expanded to not only a myriad of arc welding
solutions, but also to most other robotic processes. The robot(s), welding equipment, part positioner and workcell safeguarding are all
fully integrated and designed to work together. Yaskawa Motoman now offers the widest product line of standard arc welding workcell
congurations in the robot industry, providing the best t for your specic needs.
AWII-52 AWII-100
AWII-500 AWII-6000
ArcWorld IIEconomical workcells
Low-volume; high-mix
Job shop applications
n Most cells accommodate a single robot
n Fence and positioners lagged to the oor
n Equipment bases optional
Big 5 Auto 1st Tier 2nd Tier Agricultural Equipment L
Body
FrameChassis
Exhaust
Interior
Suspension
ImplementsBackhoes
Skid Ste
ArcWorld III ArcWorld IV ArcWorld VArcWorld C QR4C/TR3C/DR2C
Trunnion Positioners
FabWorld
ArcWorld ArcWorld III FabWorld FabWorld II
ComArc MH-Series Positioners DR2C
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vanced fabrication capabilities at an attractive ROI
AWV-1200 AWV-6300
ArcWorld VReduced footprint workcells
High-volume fabrication
Automotive Tier 1 applications
n Overhead robot mounting reduces oorspace (up to 40%);simplies automatic unloading of parts
n Cells accommodate one to four robots
FWII
FW-DRC FW, MA3100
FabWorld and FabWorld IILarger workcells
Low- to medium-volume; high-mix
Large, heavy weldments
n Two large load/unload stations
n Open oor and overhead access for part loadingby forklift or crane
n Heavy-duty positioners with payloads up to 6,000 kg
AWIII-1200
AWIV-6200SL
AWIV-4200
AWIV-6300XHD
ArcWorld III and ArcWorld IVHigher-performance workcells
Higher-volume fabrication
Automotive and construction applications
n High-end positioner performance/payload
n Multi-axis positioners (AWIV-series)
n Cells can accommodate one to four robots
vy Construction Heavy Transportation General Fabrication Job Shop
ifts
Bulldozers
Rail
Truck Trailers
ATV
StoreFixtures Food
Equipment
ElectricalEnclosures Manufacturing
Products
op Center Positioners Multi-layerotoSweep ComArc
ArcWorld ArcWorld II ArcWorld III
FabWorld II ComArc
Turntable Positioners
ArcWorld ArcWorld II FabWorld II
MH-Series Positioners MotoRail MotoSweep ComArc
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Flat Table WorkcellsFor simple parts that can be welded from one side or
manually ipped into subassembly xture(s).
n Single- or dual-load stationsn Manual or powered door guard operation
n Fixture plates/tables available as options to provide toolchange capability
Turntable WorkcellsFor parts that do not require positioning to orient the
part for welding.
Higher productivity; allows operator to
load/unload from a single point while robot
welds on the opposite side.n Wide range of payload capacities and indexing times
n Low-inertia “H-style” tabletop for higher performance andeasy xture mounting
n Standard 60-inch tabletop; most workcells accept optional 1,829 mm (72-in) diameter table top
n Optional xture plates for tooling changeover; 500 mm L x 350 mm W, 1,000 mm L x 650 mm Wwith notched corners
*1,000 kg payload positioner with 4-second index time available as an option
Cell Door GuardCommon
BaseNumber of
RobotsNumber ofStations
Part Length(mm)
Part Width(mm)
AWII-50 Manual Optional 1 1 1,425 700
AWII-52 Manual Optional 1 2 700 700
AWC-50 Roll-up Standard 1 1 1,650 700
AWC-52 Roll-up Standard 1 2 760 700
AWII-200 Electric Door Optional 1 2 1,180 625
AWC-200 Roll-up Standard 1 2 1,180 1,100
CellIndex Time
(sec.)Common
BaseNumber of
RobotsThru-hole
(mm)Payload
(kg)
AWII-100 4 Optional 1 None 200
AW1000/1200 4 Standard 1, 2 120 300
AWIII-1000/1200 2 Standard 1, 2 100 500*
AWV-1000/1200 4 Standard 1, 2 120 300
AWV-1200HS 2 Standard 1, 2 100 500*
WIDEST RANGE OF WORKCELL POSITIONERS IN THE INDUSTRYGuarded Tables n Turntables n Headstock/Tailstocks n Trunnions n Multi-Axis Positioners n Rotating and Linear Robot Transporters
HyperProductivity® with Multiple Robot Control
n Improve productivity by adding more robots/arcs in same workcell (up to four robots)
n Reduce oorspace with “modules”; half-size cabinets to house extra ampliers
n Reduce costs – savings by using modules (with less components) is passed on to customers
n Ease programming – standard software allows robot multi-tasking and coordinationwith servo positioners
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Trunnion WorkcellsFor longer parts that require positioning.
n Two versions: – Economical, patented single-motor design – High-performance version with independent servo drives
on all three axes
n Coordinated motion software (standard) enables robot toweld while positioner is rotating parts
n HyperProductivity achieved by adding a second,third or even fourth robot (motion controlled withsingle programming pendant)
n Optional slip ring kits deliver air, power, signal and hydraulics without cable exing to xturing
n Requires less oorspace than rotating turntables
n Most positioners can be extended to 5-meter span
Multi-Axis Rotating Turntable WorkcellsFor shorter parts (
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FabWorld solutions are designed to weld very large, heavy parts that require positioning
and low- to medium-part volumes with high product mix. FabWorlds generally require
extended-reach robots and can include tracks, rails or robot transporters to provide better
part access.
FabWorld solutions provide:
n Extended-reach robotic welding with MA1900 or MA3100 robots
n Flexible layout congurations with one or two robots and medium- toheavy-payload positioners
n Coordinated motion software (standard) that enables robot to weld whilepositioner is rotating parts
n MotoMount xture mounts speed tooling changeover and ease installation
n Easy installation – FabWorld II includes common base for positioner and robot for easy setup – FabWorld features a exible oor-mounted conguration with wireways for cable management – Precision alignment of headstock and tailstock not required due to MotoMount
CellCommon
BaseNumber of
RobotsMaximum Payload (kg)
MHT-500 MHT-1600 MHT-3100Part Length
(mm)Part Dia.
(mm)
FWII, Single Standard 1-MA1900 1,075 3,000 N/A 2,920 1,350FWII, Dual Standard 2-MA1900 1,075 3,000 N/A 2,920 1,350
FW, MA1900 None 1-MA1900 1,075 3,000 6,300 2,920* 2,000**
FW, Dual None 2-MA1900 1,075 3,000 6,300 3,920* 2,000**
FW, MA3100 None 1-MA3100 1,075 3,000 6,300 3,920* 2,000**
TANDARD DUAL-ROBOT FABWORLD FABWORLD WITH SOLID PANELS PER SPEC DUAL-ROBOT FABWORLD WITH DROP-CENTER
POSITIONER AND CUSTOMER PAINT SPEC
UAL-ROBOT FABWORLD WITH EXTENDED-REACH
ANDLING ROBOT
FABWORLD EXTENDED WITH DUAL MH50-20 ROBOTS DUAL-ROBOT FABWORLD WITH SKYHOOK POSITIONERS
AND FOLDING DOOR SAFEGUARDS
*Designed spans, positioners are lagged to the oor and can be moved closer or farther apart at installation
**Maximum part diameter for MHT-500 is 1,630
FABWORLD SOLUTIONS
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Concurrent I/O Ladder LogicThe DX100 controller has built-in PLC and
pendant-based operator panel capability for xture
and workcell control.
n Over 1,000 lines of logic available for programmingxture control or communicating status to host PLC
n Color touch screen on pendant can be used toprogram ladder logic or aid in troubleshooting bymonitoring signals
n Use of robot concurrent I/O provides access to hundredsof status registers within controller
n Interface panel function allows buttons, status indicators orregister values to be programmed
n Screens can be programmed to increase exibility andconveniently present information to personnel
n All major control networks supported by DX100 controller
As the global leader in arc welding, Yaskawa Motoman
has high level digital interfaces for the most brands
of power supplies. These interfaces share common
Motoman® features such as:
n One key navigation between robot program andweld settings in Arc Start File
n Graphic representation of weld sequence forstart and end, including sloping parameters
n Standard weld functions such as arc retryor arc restart
These digital interfaces also support:n Access to process libraries stored on the welder
n Display of live weld parameters on the pendant
n Password protection to effect process changes
n Control of power source arc monitoring(when equipped)
DIGITAL WELD INTERFACES
ELIMINATE COSTLY PLC AND OPERATOR PANELS
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Robots/Controller n Industry-leading application-specic “Master Arc”
welding robots – MA1400: High-speed welding robot with 1,400 mm reach – MA1900: Extended-reach welding robot with 1,900 mm reach – VA1400: 7-axis exibility for dual-station workcells – MA3100: Extra-long 3,100 mm reach for FabWorlds
n Patented integrated upper-arm torch cable reducesinterference and makes programming easier
n Multiple robot control allows up to FOUR robots to becontrolled by a single controller and programmed by asingle programming pendant
n Menu-driven arc welding software and coordinated motion with servo positioners is standard
Power Source
XRC
Dual-Robot
Controller
Total Safety EnvironmentCompliant with current U.S. robot safety standard requirements ANSI/RIA15.06-1999 and ISO 10214-1;
and Canadian (CSA) safety requirements.
n Arc ash curtains and wire fencing with interlocked gate(s) and light curtains
n Safety-rated components with dual-channel E-stop circuit provide control reliability
n Latching cycle start (interlocked with safeguards) and operator E-stop buttons
n Safeguarded in accordance with the “Prescribed Method” outlined in the safety standard
Positioners/Transportersn Designed and built in the United States
n Continuously life-tested to ensure reliable performance
n Yaskawa Motoman provides complete service and spare parts
n Engineered for welding with integrated weld grounds
and safety switches
STANDARD FEATURES
Arc Welding Packagesn Air-cooled torch with X,Y,Z-compliant torch shock sensor
(water-cooled option)
n Collision detection software to minimize torch impactabsorbed by shock sensor
n Two-year warranty on torch cable
n Arm-mounted 4-roll wire feeder
n Fronius, Miller, Lincoln or SKS power source modelswith full feature digital interfaces
n HyperStart® function to reduce cycle times
n
Weld-in-Teach function for improved safetyn Optimized robot dress to manage weld cabling for long life
WORLD SOLUTION ADVANTAGESYaskawa Motoman has more welding experience than any other robot company, and more robot experience than any other welding company!
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Workcell Optionsn Common base for AWII-series workcells (standard on other ArcWorld series)
n DRC, TRC, QRCDual, triple or quadruple robots with a single controller for reduced cost and oorspace(standard for multiple robot workcells)
n DR2C, TR3C, QR4C – multiple robots with separate controllers for potential redeployment
n Powered roll-up door – reduces oorspace of workcell
n Light beacons for workcell status
n Tooling plates (at table and turntable cells)
n Tip change window mounted in fence – permits safe, convenient access to the torch for tip changes
n Wiring routed through tailstock via rotating slip ring
n The Functional Safety Unit (FSU) provides safe operating zones for the robot and can limit itsmotion range; Category 3 safety-rated
Operator Station Optionsn Pedestal- or fence-mounted
n Thumbwheel switch for program selection (0-99)n Manual jog (joystick) for moving station axis
(standard in many workcells)
n Opto-touch actuators for cycle start
n Color monitors (PanelView 600/1000)
n PC-based PC-HMI™ operator station
Input/Output Optionsn Expanded input/output capacity
n Variety of eldbus congurations
n
Programmable controller (PLC) in controller or intop-mounted cabinet on controller
n Interface Panel Function – allows HMI to be constructed onDX100 pendant
Peripherals and Software Optionsn Torches from leading manufacturers
(Tregaskiss, Binzel and Dinse)
n Water-cooled torches
n Specialty processes: Tandem MIG, push-pull torch,cold metal transfer (CMT), GTAW, PAW, PAC and RW
n Reamers/nozzle cleaners/sprayersn ToolSight® torch alignment gage
n Torch alignment jigs
n Automatic wire cutters
n Weld sensors – Touch-sensing (seam-nding) – AccuFast (seam-nding) – ComArc (seam-tracking) – Laser or vision sensors
n Wire spool mount
n MotoSim® – off-line simulation
n MyMotoman – remote robot monitoring
OPTIONS
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CUSTOMER SPEC ARCWORLD WITH ARC AND
SPOT WELDING ROBOTS
DUAL-ROBOT FABWORLD WITH MOTOSWEEP™GANTRIES AND DROP CENTER POSITIONER
AWIV-6200XHD WITH TWO TRUNNIONPOSITIONERS
CustomizedYaskawa Motoman often receives requests for an ArcWorld or FabWorld solution with minor (or sometimes major) “tweaks” to the
design. This might be a longer span positioner, different arc curtains or barriers, robot transporters or even a second positioner in the
cell. These custom conguration requests are processed as modications to the standard systems we build every day.
Integrated
Several options are available to integrate an ArcWorld or FabWorld to make your parts.n Tooling can be added by do-it-yourself users to an ArcWorld or FabWorld solution.
n Our network of Motoman Strategic Partners (MSPs) can add tooling and provide support services on a local basis.
n Yaskawa Motoman’s Automation Group can quote complete projects, including tooling, part programming andstart-up commissioning.
Your Yaskawa Motoman Regional Sales Manager will help evaluate your application and support needs, then recommendthe best solution source.
DUAL-ROBOT FABWORLD WITH PART HANDLROBOT TO PLASMA CUT AND ETCH TUBES“JIGLESS” WORKCELL WITH WELDING (2) ANDHEAVY-PAYLOAD HANDLING (1) ROBOTSLASERWORLD®
6000 WITH PATENTED LIGHT TIGHTTRUNNION POSITIONER
FABWORLD WITH OPPOSING SKYHOOKS ANDCENTER LOAD STATION
“JIGLESS” WORKCELL WITH HANDLING ANDWELDING ROBOT
DOUBLE-ENDED SKYHOOK WORKCELL
CUSTOMIZED SOLUTIONS
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AWV-6400 WITH “EXPERT ARC” ROBOTS AWIV-4300 WITH TWO POSITIONERS AND
3-METER SPAN
AWII-500 MODIFIED WITH POWER ROLL-UPDOORS INSTEAD OF SOLID DOOR PANELS
SINGLE-STATION WORKCELL WITH D500
TILT/ROTATE
SPOTWORLD® 6200 WITH ES165 ROBOTS
AWC-50S MODIFIED WITH FULL-LENGTH DOOR AND CUT-OUT IN BASE
TILT/ROTATE POSITIONERS IN TWO-STATION CELL
RECESSED DOOR TO ALLOW OVERHEAD ACCESS
FIVE-AXIS TURNTABLE WITH CUSTOMER
PAINT SPEC
ARCWORLD CAN BE EQUIPPED WITH TANDEM MIG,PAW, GTAW, PAC, RSW AND VISION SENSORS AW1200 WITH FOUR MH180 HEADSTOCKS FORWELDING MANIFOLDS
DUAL-ROBOT FABWORLD WITH SERVO TRAFOR EXTRA LENGTH
FABWORLD WITH MOTOSWEEP AND DUALDROP-CENTER POSITIONERS
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YASKAWA AMERICA, INC. • MOTOMAN ROBOTICS DIVISION
100 AUTOMATION WAY MIAMISBURG OHIO 45342
L DIMENSIONS ARE METRIC (MM) AND FOR REFERENCE ONLY
EQUEST DETAIL DRAWINGS FOR ALL DESIGN/ENGINEERING REQUIREMENTSC C S C C O S S C O C G O O C
MOTOMAN IS A REGISTERED TRADEM
MILLER IS A REGISTERED TRADEMARK OF MILLER ELECTRIC CO S S
www.motoman.com
HEADQUARTERS Yaskawa America, Inc.
Motoman Robotics Division
100 Automation Way
Miamisburg, Ohio 45342
Tel: 937.847.6200
Fax: 937.847.6277
MANUFACTURING FACILITY1050 South Dorset Road
Troy, Ohio 45373
Tel: 937.440.2600
U.S. REGIONAL FACILITIESDetroit Regional Center
2050 Austin Avenue
Rochester Hills, MI 48309-3665
Tel: 248.668.8800
Fax: 248.668.8811
Los Angeles Regional Center
1701 Kaiser Avenue
Irvine, California 92614
Tel: 949.263.2640
Fax: 949.263.2644
GLOBAL SUPPORT NETWORK
INTERNATIONAL FACILITIES Yaskawa Canada Inc.
3530 Laird Road, Unit 3
Mississauga, Ontario L5L 5Z7Canada
Tel: 905.569.6686
Fax: 905.569.2240
Yaskawa Canada Inc.
Montreal Technical Center
298 Labrosse
Pointe Claire, Quebec H9R 5L8
Canada
Tel: 519.693.6770
Fax: 519.693.9212
Motoman Robotica do Brasil
Av. Dona Ida Cerati Magrini, 936 -
Vila Oriental
09951-260 - Diadema - São PauloCEP 09951-260
Tel: 55 11.4352.3002
Fax: 55 11.4352.3338
Yaskawa Motoman Mexico S.A. de C.V.
Circuito Aguascalientes Oriente 134-C
Parque Industrial del Vallede Aguascalientes
Aguascalientes, AGS. Mexico 20140
Tel: 52.449.973.1170
Fax: 52.449.973.1171
Yaskawa Motoman Mexico S.A. de C.V.
Monterrey Mexico Regional Ofce
Av. Regioparque #128
Fracc. Industrial Regioparque
Apodaca, N. L. C. P. 66633 Mexico
Tel: 52.81.8386.8113
Fax: 52.81.8386.8112
Mission StatementYaskawa Motoman is dedicated to delivering high quality,innovative automation solutions which help our customersto be world competitive and to providing the highest level ofcustomer satisfaction in the automation industry.
n Technical Education Center – IACET accredited programs
– Training classes on-site or at any of our eight centersin North America
– Hands-on training; maximum two students per robot
n Customer Care Center – One call support; 24/7 coverage
– Web-based Customer Care Center(anywhere, anytime access to self-serve capabilities)
n Field Services – Regional and COE-based technicians
– Application-specic trained resources
– Included in installation and start-ups
n Support program offerings include: – Robot Life Cycle Management (service and maintenance plans)
– RobotPro® software (maintenance, troubleshootingand documentation) Local PC or web-based
– Condition-based maintenance (diagnostics monitoring)
– Rebuilds, repairs and retrots
CUSTOMER SATISFACTIONIS OUR #1 GOAL!
WORLD-LEADING
CUSTOMER SATISFACTION! YOUR PARTNERS IN PERFORMANCE24-HOUR HOTLINE: 937.847.3200
YaskawaAmerica
YaskawaEurope
Yaskawa ElectricCorporation