Andrea Albanesi RobotStudio Global

solution for Arc Welding

Robot Systems
Robotics - 1 -
01-10-24
 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-in-
white, paint processes, power train assembly
Product, system and asset services
Over 160,000 ABB
Customers Served: robots installed
Automotive and Tier 1 suppliers worldwide

General industries such as foundry, metal

Robotics - 2

fabrication, plastics, electronics, consumer

 ABB market offer: Robot products

Robots Accessories and

Application Equipment
Robotics - 3

Software
 Applications examples in Automotive Industry
Robotics - 4
 Global resources to serve global customers

Lead Centers
Local Operations
Factories

Committed to both established and emerging markets

Robotics - 5

Large installed base drives service opportunities

Revenues by region: EU 50% - NA 35% - Asia 15%
 Top Robot Customers in Automotive Industry
Robotics - 6
 Facts About ABB Robotics Romania

Headquarter in Bucharest
ABB actively promoting Robot Sales
and Service from August 2006
6 people dedicated exclusively to
Robotics
Robotics - 7
 RobotStudio 3D Offline programming

Reduces the risk in the planning phase

Speeds up the installation
Improves system uptime
Robotics - 8

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)

WELD PROFILE MODELING

Robotics - 9
 VirtualArc Technology - VirtualArc Software Tool
Robotics - 10
 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

Off-line prediction of geometric welding defects

Robotics - 11
 FLEXARC Standard Arc Welding Robot Cell
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)
Robotics - 12
 Global FlexArc Solutions
FlexArc L Compact FlexArc 500C FlexArc 250R

FlexArc 500/750R FlexArc 250K

Robotics - 13
 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:
Expensive
Time consuming
Compromises are often required to keep cost to a minimum.
Robotics - 14
 Parts to be Produced

Control Arms Trailing Arm Trailing Axle

Front Cross Suspension

Member Cross Member
Member
Robotics - 15
 Robotics - 16

Trailing Axle
 Weld Simulation with VirtualArc
Robotics - 17
 Weld no.1: RapidArc-welding Throat size 2.5 mm

Welding speed: 25 mm/sec

Robotics - 18
 Trailing Axle Orientation in Positioner
Robotics - 19
 Trailing Axle AW Program to Tooling Builder
Robotics - 20
 Simulation and Fine - Tuning
Communication with the fixture designer by e-mail

Collision:
Remove material!
Robotics - 21
 Simulation and Fine - Tuning

Collision:
Remove 50 mm
50 mm
Robotics - 22
 Trailing Axle Tooling

Design a fixture around the program and welding gun.

Robotics - 23

The outcome will be a fixture where the welding process

controls the design of the fixture.
 Trailing Axle Welding Program with Tooling
Robotics - 24
 FlexArc 500K Run-Off Prior To Shipment
Robotics - 25
 Trailing Axle Tooling: Fine Tuning of AW Program
Robotics - 26
 Off-line Programming & Tooling Design
Recommended sequence of operation
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
Robotics - 27
 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
Short changeover time
Robotics - 28
 Robotics - 29

THANK YOU