Friction Stir Link Inc. is a small system integrator developing a new welding method – to differentiate its offer to manufacturers in the American automobile industry. With deep roots in the robot world, the Wisconsin ‘job-shop’ sees ABB’s off-line pro- gramming software as vital to bringing their investment to fruition. they already have a 3D representation of their product, so we can import it in to RobotStudio. Then we can do a reach study, cycle analysis, and see the product clamping or how the product is going to work. Showing we can control the process brings the technology back down to earth.” Christopher B. Smith, “Practitioner” Responsible for simulations and solutions at Friction Stir Link, Chris is a smart young, engineer. Chris has been using RobotStudio for nine months now, both as a marketing tool and as an engineering-analysis tool. He explains that the friction stir welding process is based on the combination of a revolving tool and significant pressure – in this case provided by an IRB 7600. Friction Stir Link are trying to commercialize a new process called friction stir welding. Apart from being clean, it’s ideal for aluminium and alloys that can’t otherwise be welded. The process was invented in Cambridge, UK, (1991) and as the name implies, it uses friction to create a weld – without melting the material. The application possibilities are numerous, not least in the automobile industry where aluminium is becoming increasingly popular. Today, the company is unique in offering friction stir welding in the U.S. Golden pioneer The company’s CEO, John Hinrichs, remembers working with the first five-axis robots in 1978 and was on the team that won the Golden Robot Award in Japan, in 1989. John explains how difficult it is to break through with new technology in the current economic climate: “We’re like farmers who’ve sown new seed. There are plenty of blossoming plants, some are beginning to bear fruit. We have many samples of friction stir welding, we even carry some on our key-rings. What customers want to see next, is if it’s possible to apply the process to their products. That’s where RobotStudio plays a vital role. It’s useful if Launching new technology with RobotStudio. New technology – friction stir welding. RobotStudio TM Case Study: Friction Stir Link– subcontractor automotive industry Q1/2003 New practitioner – Chris Smith Case Study Friction 2003-01-30 10.57 Sida 1
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Friction Stir Link Inc. is a small system integrator developing a new welding method – to differentiate its offer to manufacturersin the American automobile industry. With deep roots in the robot world, the Wisconsin ‘job-shop’ sees ABB’s off-line pro-gramming software as vital to bringing their investment to fruition.
they already have a 3D representation of theirproduct, so we can import it in to RobotStudio.Then we can do a reach study, cycle analysis, and see the product clamping or how the productis going to work. Showing we can control theprocess brings the technology back down toearth.”
Christopher B. Smith, “Practitioner”Responsible for simulations and solutions atFriction Stir Link, Chris is a smart young, engineer.Chris has been using RobotStudio for nine monthsnow, both as a marketing tool and as anengineering-analysis tool. He explains that thefriction stir welding process is based on thecombination of a revolving tool and significantpressure – in this case provided by an IRB 7600.
Friction Stir Link are trying to commercialize anew process called friction stir welding. Apartfrom being clean, it’s ideal for aluminium andalloys that can’t otherwise be welded. Theprocess was invented in Cambridge, UK, (1991)and as the name implies, it uses friction to createa weld – without melting the material. Theapplication possibilities are numerous, not least in the automobile industry where aluminium isbecoming increasingly popular. Today, thecompany is unique in offering friction stirwelding in the U.S.
Golden pioneerThe company’s CEO, John Hinrichs, remembersworking with the first five-axis robots in 1978 andwas on the team that won the Golden RobotAward in Japan, in 1989. John explains howdifficult it is to break through with new technologyin the current economic climate: “We’re likefarmers who’ve sown new seed. There are plentyof blossoming plants, some are beginning to bearfruit. We have many samples of friction stirwelding, we even carry some on our key-rings.What customers want to see next, is if it’s possibleto apply the process to their products. That’swhere RobotStudio plays a vital role. It’s useful if
Launching new technology with RobotStudio.
New technology – friction stir welding.
RobotStudioTM
Case Study: Friction Stir Link– subcontractor automotive industry
Q1/2
003
New practitioner – Chris Smith
Case Study Friction 2003-01-30 10.57 Sida 1
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Do it once and do it right.Saving money is important at all stages of a newsystem installation, not least because the frictionstir welding processes requires heavy-dutyequipment. Chris explains: “Error proofing is aprimary area for RobotStudio. When we’reworking up-front to show the customer howthings are going to look, we find out whatresources are necessary. Once we’re given theproject, we do a much more detailed analysiswhere RobotStudio helps us plan things exactly,while uncovering more possibilities.” Knowingwhich size of robot will be needed, or even howmany robots, can make a big difference to theeconomy of a new production system. Chris sums up: “RobotStudio helps to save money. If you know your ABB robot, then you can useRobotStudio very effectively.”
Chris tells us: ‘‘When it comes to developingfixtures for friction stir welding, the high loads of the process provide different challenges to gas metal arc welding. It’s almost impossible to visualize how a robot is going to be oriented,because there are so many possibilities. So,unless you have a tremendous amount ofexperience actually jogging and driving the robot, there’s no way of knowing where the robot is going to be and what it’s going to hit – without RobotStudio.’’
Selling the pig in the poke. Chris explains that when pitching an unknownprocess like theirs, risk-reduction is a majorhurdle: “RobotStudio is most important in thebeginning of a relationship. It makes the customerfeel better about it because they can visualizewhat they’re buying. 2D line drawings are difficultto understand for a lot of people, but theRobotStudio simulation is very clear.” That bringsFriction Stir Link to the next step, presenting thequote. According to John Hinrichs, that’s a loteasier thanks to the simulation. “When thecustomer sees how we’re solving the problems,the quote becomes less of an issue. RobotStudiois a great tool to get people on both sidesworking together instead of finger pointing.”
RobotStudioTM
Case Study: Friction Stir Link– subcontractor automotive industry
www.abb.com/robotics
John Hinrichs, Friktion’s CEO and Golden Robot veteran.
Test and touch-up with the teach pendant.
IRB 7600-400
S4C plus controller
Version 2.0
1
Type of robot:
Controller versions:
RobotStudio:
Number of RS units:
FACTS AND FIGURES ABOUT FRICTION STIRLINK’S STIR WELDING SET-UP:
Case Study Friction 2003-01-30 10.57 Sida 2
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