ABB Robotics, Singapore, April 2013 How to enhance … to enhance your profitability and growth through the effective use of technology ABB Robotics, Singapore, April 2013

How to enhance your profitability and growth through the effective use of technology

ABB Robotics, Singapore, April 2013

Introduction

This session will share how technology can be use to enhance your profitability and growth in various application.

Mr. Ang Boon HuaLocal Business Unit Manager

RoboticsABB

Technology used in

Arc Welding Application

Packaging Application

Batch Production Application

Arc welding process for robotics

Arc Welding Processes

Pressure Welding Fusion Welding

Arc Gas Aluminothermic Electron Electro-Slag LightWelding Beam Welding Radiation Welding

Laser Arc Image

Metal Arc Carbon Arc TIG Arc Spot Atomic Plasma ArcWelding Welding Welding Hydrogen Welding

Welding

Manual Submerged arc MIG MAG Electro-gasMetal Arc Welding Welding Welding Welding

Resistance Forge Pressure Ultra Sonic Diffusion MIABWelding Welding Welding Welding Welding Welding

Blacksmith Hammer Roll HF Pressure Cold Friction ExplosiveWelding Welding Welding Welding

Resistance Butt Flash Spot Seam Projection Percussion HFWelding Welding Welding Welding Resistance

Welding

Stitch Multiple Series Roller Butt SeamWelding Spot Spot Spot Welding

Foil Butt SeamWelding

+ More many more variants

Welding Welding

Welding Welding Welding

Arc Welding Processes for Robotics

Arc Welding ProcessesMIG/MAG Welding

MIG/MAG Welding

MIG/MAG WeldingTerminology

Welding!!

CO2 Welding (MAG) however, was not invented until the 1920’s and did not see regular use until the 1950’s

Welding as we know it, first started in the early 1800s during the Industrial revolution

Today MIG/MAG Welding accounts for most of the worlds Arc Welding with Robots

MIG/MAG WeldingTerminology

GMAW - The term for MIG/MAG welding by USA standards

MIG/MAG Welding - The collective term for welding with all gas types

MAG Welding - Is Metal Active Gas welding

MIG Welding - Is Metal Inert Gas welding

CO2 Welding - Is welding with Carbon Dioxide as the shielding gas

MIG/MAG WeldingThe most common robotics Welding process

Excellent Manual Process for beginner – Easy to control for Robotic applications

Less sensitive to gaps.

General pre-machining process

Good for most materials

Commonly used and low cost

MIG/MAG WeldingCommon Issues

The finishing is rough

Cleaning of nozzle and cutting of wire (TSC)

Wire feeding control

Require fixture

General pre-machining process

Spatter

Conventional MAG-Process

CMT-Process

MIG/MAG WeldingCMT (Fronius) – Cold Metal Transfer

Special equipment

Controlled droplet detachment based on Short ArcVery Low heat input

Very low Spatter production

Excellent for most materials

TIG Welding

TIG WeldingTerminology

ArgonArc Welding – Old term

TIG Welding - Tungsten Inert Gas welding

TAGS Welding - Tungsten Arc Gas Shielded Welding

HeliArc or Heliweld – Old term from USA

GTAW – TIG/TAGS welding by USA standards

TIG WeldingHigh Quality Welding

Excellent Manual Process – Difficult to control for Robotic applications

DC welding - for most materials

AC welding for Aluminium

Nice clean weld finishing

No spark, splatter or fumes

Weld in all positions

Require good pre-machining process

Require good fixturing design

Optional wire feed

Plasma Welding

Plasma WeldingHigh Quality Welding

Excellent Manual Process –Ideal for Robotic applications

DC welding - for most materials

AC welding for Aluminium

Optional wire feed

Laser Welding

Laser WeldingHigh Quality Welding

Weld are fast and nice finishing

Weld are small, very precise and a neat process

Very low distortion due to low heat input

Deep penetration without high heat input

Minimal dilution when welding dissimilar metal

Better control on aluminium welding

Robotics Arc weldingEverything you need

High performing, easy-to-use robotsControllers for superior motion controlApplication software for fast and accurate programming and operationTrack motions and workpiece positioners for synchronized motion of workpiece and torchPre-engineered systems and building blocks for custom solutionsProcess tools to facilitate the arc welding processApplication specific equipment

Robotics Arc Welding productivity toolProduct to maximize your productivities

RobotWareArc

RobotStudioAW PowerPac

PSF315 Weldguide IIITorch Service Centerwith BullsEye

RPC S-400

A314EB

Robotics Arc Welding productivity toolPositioning products. 1F/1G every time

Robotics Arc Welding productivity toolSimulation software

Build new solutions quickly:

Evaluate alternativesInitial feasibility studiesInitial cycle-time calculations

Visualize solutions:

Address problem areas at an early stage

Verify new designs quickly:

Check reachabilityAvoid collisionsDetect singularity issues

Robotics Arc Welding productivity toolVirtualArc® Software for weld parameter setting

What you see on the prediction, you get in reality

Robotics Arc Welding productivity toolTorches Service Center for consistently better weld

Torch Service Centre Makes your robot welding more effective and accurate

Decreased the cycle time and increased the uptime

In order to weld with good quality and accuracy. Welding torches require regular cleaning ,measuring and TCP-definition

It is impossible to avoid spatter during welding operations. Hot particles from the arc easily adhere into the gas nozzle.

The entire cleaning operation is automatic in one sequence, including mechanically cleaning, pneumatic cleaning and finally oil injection into the gas nozzle.

ABB TSC

Wire cutter

BullsEye

Nozzel cleaner

Robotics Arc Welding productivity toolWeld process guiding tool

WeldGuide is a combined process control and “Through the Arc” adaptive seam tracking system integrated into the robot controller

It is using two sensor inputs - the welding current and the arc voltage, which means that we both "look and listen".

It is designed to track welding joint variations due to fixturing or part fit up and will, in an automatic mode, monitor and track the weld seam during the weld process.

The measurements are synchronized with the weave pattern of the robot along the weld seam and provides both vertical and horizontal correction signals to the robot controller, to ensure consistent location of the welding arc along the seam. In heavy welding applications this is of utmost importance.

Weldguide III can perform thru-the-arc tracking in several different welding modes such as spray-arc, short-arc and pulsed-arc.

Adaptive fill mode

Single side tracking mode

Multi-pass

Torch to work mode

Centerline mode

Packaging application with intelligent software and application know-how

Outline

Picking and Packing applications

PickMaster 3 - Application Software

Multi robot Lines

News - Racerpack

Packaging application includePicking Packing and Palletizing

Picking

Packing

Palletizing

Serving Packaging Machines – before and after

InputThe machines need consistent ordered product flows

OutputThe wrapped products need to be packed

Thermo forming

Flow wrapping

Tray Sealing

Picking and Packing Applications

Preparing blisters

Mixing of assortment parts

Replacing hard automation

Feeding of material from vendor

Vibratory feeders

Dispensers

Picking to patterns then packing

Picking with IRB360Single picking, max 2-3 parts

Sort and prepare

Case Packing with IRB360/140/260/4600

Multi-grippers

Multiple layers into deep cases

Ordered patterns into cases

Products not stable one by one

Bag or Pouches Packing

Picking/packing bags directly into carton boxes

Boxes on separate lanes

Outline

PickMaster 3 / 5 - Application Software

Multi robot Lines

News - Racerpack

Palletizing

PickMaster- The ABB Packaging software

Packing

Picking

Application Software

PickMaster Excellence

PC application for design and central process control

Powerful Vision and Inspection

Instant target communication

Superior Conveyor tracking and Robot work flow collaboration concept

Lean Operator’s Control

High Adaptability

Application Software: PickMaster 3

Essential parts in Robotics Picking

Fast and Accurate Robots

Application Software with vision

Grippers

Lighting

Material flow

Application Software: PickMaster 3

Outline

PickMaster 3 - Application Software

Multi robot Lines

News - Racerpack

Pre-scheduling of work

Load Balancing (LB)Optimizes robot load

Cost efficient camera distribution

Less CPU load

Dynamic redistribution

Cam/Sensor

Load BalancingMulti Robot Lines

Never miss a product or pocket

Adaptive Task Completion (ATC)Progressive and filling of patterns

Dynamically allocated positions per robot

Full packages guaranteed

Dynamic redistribution of all positions

Load Balancing

Multi Robot Lines

Robot for in batch production environmentApplication in Pharmaceutical industry

Pharma Industry Secondary Production

The Pharma industry primary versus secondary packing.

Highly dedicated machines and solutions for primary packing are available on the market eg. blister machines filling machines etc.

The availability of dedicated secondarypacking solutions are limited. Most of the available machines on the market are dedicated for F&B industry.

Main differentiator comparing with F&B

Lower capacity.

Shorter batches.

Higher regulatory demands eg. GMP FDA.

Cost of the product to packed are higher.

Primary Pack

Solution for batch production

Secondary Packaging

Robot combined with conventional packaging methodsgives

Flexibility

80-100% automatic change over

New packaging -Adjust system

New product -add program

Availability

Less moving parts

High reliability

Good overviev of production

Easy to clean

The top 10 reasons for robot investment

Increase production output rates

Reduce operating costs

Improve process quality

Improve workplace health & safety

Increase product manufacturing flexibility

Reduce material waste and increase yield

Reduce labour turnover and difficulty of recruiting workers

Save space in high value manufacturing areas

Reduce capital costs (inventory, work in progress)

Improve quality of work for employees

Based on research carried out by the International Federation of Robotics (IFR)

ABB Robotics, Singapore, April 2013 How to enhance … to enhance your profitability and growth through the effective use of technology ABB Robotics, Singapore, April 2013

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