PRESSCONFERENCE 14-06-2007
© A
BB
Robotics –
C.B
ER
G
ABB
ABB - Leader in power and automation technologies
ProcessAutomation
Power Systems
RoboticsPower Products
AutomationProducts
� Orders received 2006: USD 28,4 billion
� Integrated solutions for grid reliability, productivity and energy efficiency
� Extensive global network of value-added channel partners
� About 109 000 employee in 100 countries
Process Automation at Metec Hall5/Booth E19
Excellence in Metallurgical Technology
� From primary metals and rolling mills to processing lines
Products
� Automation systems for control, monitoring & optimization
� Force measurement products
� Electromagnetic solutions for continuous casting: � Electromagnetic solutions for continuous casting: Stirrers, Brakes
� Motors & Drives-Solutions
Our benefits
� Maximum quality
� Higher throughput
� Decreased down times
� Optimization, Simulation, Modeling of metallurgy processes
Innovations at Metec 2007
� Roll@xA� Automation System 800xA
� Production Planning
� Drive Systems
� Measuring systems and instrumentation
� Collaborative Production Management
� Execution Manager
Production Information Management� Production Information Management
� ECS/EPR Integration
� Surface Imaging System HDI800
� Reliable measurement 24/7
� Accurate results
� Smart tracking to origin
ABB Robotics
ABB Robotics
� More than 150,000 ABB Robots installed worldwide
� 4600 employees worldwide� 4600 employees worldwide
� Comprehensive portfolio of industrial robots and software
� Standard manufacturing cells for welding, cutting, painting,
machine tending and assembling
� Life cycle service for robots and robots systems
ABB Robotics World-Wide
� Represented in 35 countries of the world
� R&D and manufacturing in Sweden, Norway, China and Japan
� Production capacity 17 000 robots per year
ABB Robotics Foundry
ABB Robotics – Foundry
� Automation is the key
� Experience Makes a Difference
� We Believe in Partnership� We know your products and the demands of your industry
Application AreasApplication Areas� Sand Casting� Die Casting
� Forging
� Lost Foam� Gravity Casting
� Precision Casting
� Cast Cleaning & Machining
� Surface Treatment� Quality & Control
ClientPSA Peugeot Citroën (France) and BMW
ApplicationForging of cylinder crankcases, crankshafts and
track rods. System installed by Müller Weingarten,
Germany.
Case Study: Forging
Key Drivers & Benefits� 15 percent increase in production
� Total cylinder head production 25 percenthigher than highest previous rate
� Investment itself 30 percent less than
replaced process� Ground area 15 percent less
“Crankcases are made
with a new patented
solution and the track
rods are forged in duplicate, giving a 10% gain on the price per piece”.Mr. Singer, PSA
ClientLjunghäll AB, Södra Vi, Sweden
ApplicationCasting, machining, finishing and cleaning of die-cast aluminum automotive, telecom and other
parts. Some 44 ABB robots in all models except the
IRB 7600, for which they have no need.
Case Study: Die casting
Key Drivers & Benefits� No. of manufacturing stages reduced
� Production increased� Flow of material linked with finished products that
can be delivered directly to customer’s
manufacturing lines
“These robot cells have
led to an extensive
rationionalization of our
manufacturing.”
Nicklas JaldefeldtLjunghäll AB
ClientVolkswagen, Poznan, Poland
ApplicationLubrication of light alloy pressure die-cast engine
components. IRC5 robot controller. System
installed by Acheson.
Key Drivers & Benefits
Case Study: Die Casting - Spraying
Key Drivers & Benefits�Lubrication and robot software integrated so that
appears to be one program for customer
�User-friendly software
�Lubrication is water-free and environmentally friendly, with lubricating film capable of forming
independent of temperature
“…our customer can
take advantage of all of
the process control
features.”
Dieter ThummAcheson
ClientHWS, Bad Laasphe, Germany
ApplicationVenting of castings of high-compression molds. IRB 4400 robot.
Case Study: Sand Casting
Key Drivers & Benefits�Savings by using one robot for insertion and
milling�Increased efficiency, no interruptions
�Reduced system complexity�Time saved due to simple programming
“Innovative solution of
mold venting with ABB
robots.”
Heinrich Wagner,Sinto Maschinenfabrik
ClientEvolut, Brescia, Italy
ApplicationDeburring of cast-iron castings. Special anti-
vibration solution avoids excess strain.
Case Study: Cast Cleaning
Key Drivers & Benefits�Software allows for feasibility study prior to
application.�Robots can continue working while simulation is
being done, thus preventing extra downtime and
saving money.
“Plant installation times
can be reduced, saving
time and money.”
Giordano LancelottiEvolut
ClientSIR, Modena, Italy
ApplicationDeburring, milling and grinding of cast iron foundry
parts. IRB 6600 robot.
Key Drivers & Benefits�Cycle times can vary from 90 seconds to four
Case Study: Machining
�Cycle times can vary from 90 seconds to four minutes
�Precision to within a few tenths of a millimeter
�Compact but easily accessible cells of no more than 35 square meters
�ABB Robot Studio gives a virtual tour of the
proposed plant
“Inside the cab is a
genuine miniature
workshop…”
Davide PassoniSIR
ClientBMW, in Munich, Steyr and Hams Hall
ApplicationInjection flood washing, deburring and drying of
cylinder heads, crank cases and other automotive engine parts. Foundry Prime ABB IRB 6600 robot.
System installed by Dürr Ecoclean, Germany
Case Study: Surface Treatment
Key Drivers & Benefits� Operates in extremely tough environment
without need of protective casing� High flexibility with changes to nozzles made
by control panel instead of manually
The new cleaning
modules have become
the standard for the
BMW group.
ClientAlteams-Stilexo, Skillingaryd, Sweden
ApplicationPicking, placing, loading and deburring of aluminium automotive components. Mix of IRB
4400 and IRB 140 robots.
System installed by SVIA, Sweden
Case Study: Quality & Control
Key Drivers & Benefits� Shortened cycle times of 5 seconds
� Tough robots can handle high heat
� 30,000 pairs of castings weekly
� Vision inspection of 100 percent means
little follow-up inspection necessary
“It would not be
possible to match
industry production
requirements without this technology.”
Per JanssonAlteams Stilexo
ABB Robotics at GIFA 2007
Exhibits
� Remote Service
� Foundry Prime
� Robot Ware DieCast
� IRB 6660-High Performance Machining Robot
� IRB 6620- Payload 150kg
� True View� True View
� Function Package Force Control Machining
� Flex Finishing Cell
�
ABB activities at GIFA
� Innovative technology for the machining treatment of cast parts using robots”ABB’s theme at the WFO Technical Forum At 12:45, 14.06.07/Hall10-GIFA meeting point
� ABB Partner Game “Win an Apple IPod with ABB and their partner’s at GIFA”
Remote Service
ProductAdvanced robot diagnostic via Internet using a
robot-mounted logging device connected to the
console and service port of the controller. Potential robot failures and wear can be detected and
resolved even before they occur.
ApplicationAll kind of robot application
Key Drivers & Benefits“Remote Service is part
of our customer care
Program”
ABB Robotics,
Rene Nispeling
Key Drivers & Benefits
�Apply smart Maintenance Methods
�Faster Trouble Shooting
�Maintain only what needs to maintained and when
�Improved productivity or higher efficiency
�High uptime for robot system
�Low maintenance cost
�Immediate action for unplanned stoppages
True ViewProductTrueViewTM is the ABB brand name for a proven Vision
Guided Robotics System fully integrated into the ABB
robot. TrueViewTM combines the industry-leading
robotics expertise of ABB with the revolutionary eVF
software 2D, 2.5D and 3D. All with one hardware and
using a single camera.
ApplicationAll kind of robot application
Key Drivers & Benefits
“True ViewTM –
Proven Vision
Guided Robotics System”,
David Baucus,
ABB Robtics, US
Key Drivers & Benefits�True 3D Single camera vision system including software
and hardware components.
�A complete ABB robot integrated product. Easy to integrate
and start up.
�Easy to make calibration and accuracy test before starting
up the production, this will save time and money.
�Customer shall use less fixtures, precision dunages, and
accurate pallets for part positioning. Cost and time
saving.
�Standard hardware components, commercially available
off the shelf.
�Proven solution. Over 130 installations.
Foundry Prime
ProductRobot protection for harsh environments, available
for selective robot variants.Features
Pressurized robot , Corrosion protection, Special
paint, Sealing compound, etc.
ApplicationWater Jet Cleaning and other applications with
similar requirements
Key Drivers & Benefits
�Reduced maintenance cost
�Improved flexibility
�Improved uptime
�Improved end product quality
�Improved cycle time
�More compact cleaning cells
“Protection against
all odds”
Andreas Eriksson,ABB Robotics, Sweden
RobotWare Die Cast
“Easy programming as
ProductTool for intuitive configuration, programming and
operation of an ABB Robot
FeaturesGraphical User Interface
Standardized application with modifiable libraries secure reliability and flexibility
Application“Easy programming as
surfing the Internet”
ABB Robotics,
ApplicationMachine tending of Die Casting Machines
Key Drivers & Benefits
�Easy to install
�Delivered and tested with ABB robot
�Easy to program
�Programming wizard
�Standardised program with modifiable
libraries
�Easy to operate
�Safe Home Run and easy re-programming
IRB 6660-205/1.9
ProductA robot for high-performance machining
applications. The new robot design will support high
productivity, uptime and accuracy
ApplicationThe robot is designed for machining applications where robot stability is a key factor for success
Milling, grinding, cutting, sawingMilling, grinding, cutting, sawing
Key Drivers & Benefits
�High productivity�Improve material removal rate
�High accuracy�Stiff, compact and robust design
�Shorter cycle timeHigh Performance
Machining Robot
IRB 6620- Four robots in one
ProductCompact and agile robot for flexible installation
load capacity = 150 kg
Reach, 2.2 meter
Application
Machine tendingMaterial handlingMaterial handling
Key Drivers & Benefits
�Hanging installation; Saves floor space�Semi shelf; Facilitates compact cell design
�Compact and agile; Large working range in
relation to size
New compact and agilepower robot
IRC5 – Filter options
ProductCooling air filter guarantee reliable protection of the
IRC5 robot controller in harsh foundry
environments. 1. A metal mesh filter for moist particles
2. A polymeric filer for moist dust
Application All Foundry application & Machine shops
“Secure cooling capacity
with ABB’s innovative
air filter’s.”
Peter Fixell,ABB Robotics, Sweden
Key Drivers & Benefits
�Secure the cooling capacity; Filters will prevent
air ducts and fans from being clogged by moist
particles or dust
�Secure availability; Reducing unplanned stops and replacing filters while the robot is running
�Reduced maintenance costs
Function Package Force Control Machining
ProductThe offer includes the necessary equipment to run
a robot force controlled. Function Packages as a
starting kit for those customers that would like to integrate the machining application / process
themselves.
ApplicationGrinding, Deburring, Polishing, Buffing, Milling,
“Take the robot by
the hand and reducethe programming
time up to 80%.”
Kurt Mühlgrabner,
ABB Robotics, Austria
Sawing, Deflashing, Sanding, etc..
Key Drivers & Benefits
�Easy to use, robot programming by hand
�Secures controlled contact force (not positions)
�Less cycle times – higher tool life time
Flex Finishing Cell
ProductThe FlexFinishing cell as basic solution for flexible
production consists of a 5kg-robot, the function
package force control, a manual turntable table, a variety of tools incl. tool-changing system and the
necessary safety equipment. Additionally a human-machine-interface helps the operator to run the cell in an efficient way.
ApplicationApplication
A standardized solution for robotized machining
applications. Ready to use for different grinding operations on small-size parts.
Key Drivers & Benefits
�Easy to use and ready to produce
�Less space in production and removable design
�Fast return on investment
“Complete package for
Mechanical finishing.”
Kurt Mühlgrabner, ABB Robotics, Austria
Summing up
Summary� “Join our live demonstration”� Please take your Information Package