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FlexArc®&

The Cycle of Automation

Andy MorwoodArc Welding Specialist

ABB Inc. - Robotics

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Introduction

Andy Morwood, ABB Robotics

Over 15 years in the robotics and welding industry

Responsible for project applications for chassis assembly for Ford, General Motors and Chrysler.

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Outline

Who is ABB

Define Robotic Arc Welding

FlexArc® Solution

Cycle of Automation for Weld Applications

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Facts about ABB

Headquarters: Zurich, Switzerland

More than 110,000 employees in about 100 countries

Orders in 2007: $34.3 billion

Revenues in 2007: $29.2 billion

Listed on Stockholm, Swiss & New York exchanges; traded on virt-x

A leading power and automation technology company with strong market positions in core businesses

We help our customers:

to use electrical power efficiently

to increase industrial productivity

to lower environmental impact in a sustainable way

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What we offer: divisional structure and portfolio

ProcessAutomation

Power Systems RoboticsPower

ProductsAutomation

Products

2007 revenues (US$) and employees per division

$9.8 billion32,000 employees

$5.8 billion14,000 employees

$8.6 billion33,000 employees

$6.4 billion26,000 employees

$1.4 billion5,000 employees

Transformers, high-and medium-voltage switchgear, breakers,automation relays

Substations, FACTS, HVDC, HVDC Light, power plant & network automation

Low-voltage products, drives, motors, power electronics, and instrumentation

Control systems and application-specific automation solutions for process industries

Robots, peripheral devices and modular manufacturing solutions for industry

Market-leading positions in most key product areasIntegrated solutions for grid reliability, productivity and energy efficiencyRobust global value chain to serve established and emerging marketsExtensive global network of value-added channel partners

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Robotics divisionKey deliverablesProducts, systems and services for industrial robotics

Robots, related equipment and software

Standardized manufacturing cells for material handling, machine tending, welding, cutting, painting, finishing, etc.

Engineering for turnkey solutions in press automation, body-in-white, paint process automation, power train assembly

Product, system and asset management services

Markets servedAutomotive and Tier 1 suppliersGeneral industries such as foundry, metal fabrication, plastics, electronics, consumer industries

Over 160,000 ABB robots installed worldwide

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Small robotsSmall robots

Large robotsLarge robots

Paint robotsPaint robots

Gantry robotsGantry robots

ABB Robot Range©

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ABB market offer: Industry specific applications

Spot Welding Arc Welding Painting/Coating Cutting

Press Tending Finishing Material Handling Machine Tending

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A reprogrammable, multifunctional manipulator designed to move material, parts, tools, or specialized devices through various programmed motions for the performance of a variety of tasks.

— Robot Institute of America, 1979

What is a Robot?©

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Simplified ABB Definition for Robot

Computer controlled manipulator with multiple axes.

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What is Robotic Arc Welding?

GMAW – Gas Metal Arc Welding – A typical manual setup

Continually fed wire is melted to the base metal of the part by electricity

One of the most common robotic welding process

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Examples of Robotic GMAW Arc Welding Robots

Feeder Assembly

Hose Pack Assembly

Torch

Wire Spool and Conduit

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ArcWeld Robot Family

IRB 140, 0.81m

IRB 1600, 1.20m

IRB 1600, 1.45m

IRB 1410, 1.44m

IRB 2400-16, 1.5m

IRB 2400L, 1.8m

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ArcWeld Robot Family

IRB 1600ID

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Advantages of Robotic Arc Welding

Part repeatability and consistency Accuracy and speed Programmability Reduction in scrap and bad parts Reduction in overall cost Tireless, continuous operation (No Break Time)Higher Quality of finished parts

Accurate and automatic monitoring of welding parameters Capability of welding complex shapes at higher speeds than manual welding Real Return On Investment (ROI) Reduction in cost through volume productionRemoves workers from hazardous work environments

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Considerations for Robotic Arc Welding

Higher initial capital vs. manual operations

Longer startup

Difficulty handling part inconsistencies

Manual programming

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A standard cost effective production solution wherever you are in the world.

Consisting of integrated components onto one common platform.

Designed to use minimum amount of floor space.

Easy to install and relocate.

Low investment cost – High value

Short lead time

Virtual FlexArc (available for free at www.abb.com/robotics)

High Customer Value

FlexArc® Solutions©

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FlexArc® Solutions – Single RobotFlexArc L Compact FlexArc 500C FlexArc 250R

FlexArc 250KFlexArc 500/750RFlexArc 500/750K

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FlexArc 500/750R-MultiMove

FlexArc® Solutions – Dual RobotsFlexArc 500C-MultiMove

FlexArc 250K-MultiMove FlexArc 500/750K-MultiMove

FlexArc 250R-MultiMove©

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Torch Service Center

FlexArc Cell ComponentsAW-Robot

IRBP Positioner

Software: AW & Cell control

Virtual FlexArc

Fume Extraction Hood

Safety

Welding Torch

Process Equipment

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Global FlexArc® 250R©

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Global FlexArc® 250K

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Typical parts welded in FlexArc Cells©

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Additional Advantages from ABBCollision Detection

Integrated Error Handling

BullsEye

• Shorter stop time

• Less risk of damaging the torch

• Robot backs away from collision

• Detection in all directions

• Quicker re-start after collision

• Reliability: no mechanical parts

• Sensitivity: changed on the fly

• The “heart” of robotic arc welding

• Automatic definition of TCP

• Automatic check/update of TCP

• TCP repeatability of +/- 0.1mm

• Consistent part quality

• Higher system up-time

• ABB patented technology

• Fast recovery after weld stop

• Cell can stay in automatic mode

• Gun maintenance from outside cell

• No risk for collision

• No need to know programming

• Higher system up-time

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FlexArc Benefits…..

When taking a robotic welding cell into production the following must be considered.

Welding fixture(s) must be designed and built.

Robot welding programs must be created.

Welding parameters must be defined.

Robot cycle time must meet the required part production rates.

Feedback from the system regarding its performance and part quality.

ABB has standard solutions for all of the above….

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WebWare

The Cycle of Automation

Robot Studio FlexArc

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Cycle of Automation

3- Commissioning

RobotStudioonline

ArcWeld PowerPac

2- Programming1- Planning

RobotStudio

5- Production Monitoring

Program Manager

4 - Operation

FlexPendant

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ArcWeld PowerPac – Virtual FlexArc

Virtual FlexArc Library - exact replicas of real FlexArc stations

Down-load your FlexArc cell for free from ABB Website

Pre-installed and ready for programming

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Robot Studio Online

Included with every robotConnects your computer to the robotSystem Builder – Software Installation ToolAll Arc-Related softwareis included and selectable in BasewareConfigure I/O and other system parameters directly through PCDownload your Programs from Robot StudioEdit your programs w/o using the Flexpendant

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Graphical Teach Pendant - The FlexPendant©

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Operator concept - RobotWare Arc

Main menu

Tuning

Blocking

Manual

Settings

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FlexArc Integrated Controls – Dual Robot©

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Integrated Power SourceSingle point access for all robot and weld programming and parameters.

Complete access to all weld synergic functions and controls, right from the pendant

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Production Monitoring

Automatic collection of process data

Completed Welds

Individual & Total Weld Length

Number of Errors or Stops

Provides silent or process stopping alarms

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Summary: Cycle of Automation Success

Only ABB Can Offer This Level of Automation

Save Time and Money Through Efficiency

Eliminate Costly Mistakes

Standardize Your Robot Production

Increase Your Competitiveness

The Power Of Software Functionality

Secure Your Automation Future With ABB

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Cycle of Automation Success

Questions?

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Thank You!