Robotics - 1 01-10-24

Andrea Albanesi

RobotStudio Global
solution for Arc Welding
Robot Systems

Key Facts: ABB Robotics

About 4600 employees worldwide

2007 revenues $1.7 billion

Key Deliverables:

Industrial robots and software

Standardized manufacturing cells for material

handling, welding, cutting, painting, etc.

Turnkey solutions in press automation, body-inwhite, paint processes, power train assembly

Product, system and asset services

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Customers Served:

Automotive and Tier 1 suppliers

General industries such as foundry, metal

fabrication, plastics, electronics, consumer

Over 160,000 ABB

robots installed
worldwide

ABB market offer: Robot products

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Robots

Accessories and
Application Equipment

Software

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Applications examples in Automotive Industry

Global resources to serve global customers

Lead Centers

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Local Operations
Factories

Committed to both established and emerging markets

Large installed base drives service opportunities
Revenues by region: EU 50% - NA 35% - Asia 15%

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Top Robot Customers in Automotive Industry

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Facts About ABB Robotics Romania

Headquarter in Bucharest

ABB actively promoting Robot Sales

and Service from August 2006

6 people dedicated exclusively to

Robotics

RobotStudio 3D Offline programming

Reduces the risk in the planning phase

Speeds up the installation
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Improves system uptime

Improve comprehension of quotations

Short description of VirtualArc

Virtual Arc is a tool that combines:

ARC MODELING

Arc physics
2D wire-arc-work piece simulation tool

Experimental measurement and practical experience

Bayesian neural network (self learning program)

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WELD PROFILE MODELING

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VirtualArc Technology - VirtualArc Software Tool

What can you do with VirtualArc ?

Off-line

tuning of MIG/MAG welding parameters

Off-line prediction of weld shape & penetration

Off-line prediction of geometric weld quality

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Off-line prediction of geometric welding defects

FLEXARC Standard Arc Welding Robot Cell

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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)

Global FlexArc Solutions

FlexArc L Compact

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FlexArc 500/750R

FlexArc 500C

FlexArc 250R

FlexArc 250K

Off-line Programming & Tooling Design

Normal sequence of operation
The welding fixture is generally designed and build with
assumptions of robot torch access.

The robot program is generated after the welding fixture is

mounted in the robot station.

Robot/Torch Accessibility issues are often not discovered until this

time.

Tooling rework will be required:

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Expensive
Time consuming
Compromises are often required to keep cost to a minimum.

Parts to be Produced

Control Arms

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Front Cross
Member

Trailing Arm

Suspension
Member

Trailing Axle

Cross Member

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Trailing Axle

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Weld Simulation with VirtualArc

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Weld no.1: RapidArc-welding Throat size 2.5 mm

Welding speed: 25 mm/sec

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Trailing Axle Orientation in Positioner

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Trailing Axle AW Program to Tooling Builder

Simulation and Fine - Tuning

Communication with the fixture designer by e-mail

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Collision:
Remove material!

Simulation and Fine - Tuning

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Collision:
Remove 50 mm

50 mm

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Trailing Axle Tooling

Design a fixture around the program and welding gun.

The outcome will be a fixture where the welding process
controls the design of the fixture.

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Trailing Axle Welding Program with Tooling

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FlexArc 500K Run-Off Prior To Shipment

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Trailing Axle Tooling: Fine Tuning of AW Program

Off-line Programming & Tooling Design

Recommended sequence of operation

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Choose the standard Virtual FlexArc cell from the Robot Studio library
Import the 3-D part into the cell
Define process parameters with VirtualArc software
Generate the robot welding program with optimized torch angles
Present the robot welding program to the tooling supplier
Design the weld fixture around the existing robot program
Verify that the robot has good access to all welds
Build the tooling
Calibrate the real cell with the virtual & download the off-line generated program
Fine tune robot program

Summary: Off-line Programming & Tool Design

Elimination of costly tooling mistakes/re-work

Optimized robot path program = shortest possible cycle time
Optimized weld position and torch angles = weld quality
Robot programs can be generated concurrent to system build
Reduced overall cost: Capital investment, production startup
New tooling and robot programs can be generated while system
stays in production

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Short changeover time

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THANK YOU