African Fusion March 2017

ABB’s FlexArc robot cell

FlexArc: a new generation welding cell

Optimal productivity requires welding equipment that combines effective operation with maximum cost-effi- ciency. Modular and modern standardised robot cells such as ABB’s FlexArc® are an established way of raising quality and productivity standards. With minimal training, the user

F lexArc® welding cells are de- signed to deliver cost-effective, state of-the-art robotic welding operations. All cells deliver maximum performance whilst making optimum use of available space. The basic cell options feature a single or two robots with Multi-Move, a choice of ABB po- sitioners from an extensive range and welding equipment to suit the needs of the application. All equipment is installed on a com- mon movable platform, which provides for easy relocationwithin theproduction facilities. The cells are also equipped with centralised power distribution – all of the connected equipment such as robots, positioners, welding machines, lighting andother peripheral devices are supplied from a single power connec- tion, which means that only one supply cable for the whole cell is necessary. Advantages of adopting ABB’s Flex- Arc welding cells include: • Low investment costs. • An intuitive graphical user interface for operators. • Reduced downtime thanks to im- proved error handling. • Higher quality through automatic production and processmonitoring. • Improved cost-efficiency thanks to global standardisation. • Short delivery times. • Proven two-station principle – load- ing and welding. • Off-line programming for fast and easy implementation. • Improved workspace safety. • Boosts workflow. FlexArc features the FlexPendant graphi- cal user interface, which not only pro- vides operators with an overview of the status of the cell, it also records and dis- plays important quality and production data. The interface allows the operator tocommunicateeffectivelywithall of the functions within a cell and to access all information regarding cell performance, including the status of the robot and controller along with other functions such as controlling the roll-down doors.

can organise welding operations into a series of process steps. The opera- tor has all the information necessary to keep track of the number of parts produced, cycle times, the number of welds completed and the lengths of individual welds. Easy implementation makes the FlexArc’s standard approach the natural choice for plug-and-produce operations. In general industry the system is ideal for fabricating door modules, grids, switchboards, printing units, steel furniture, shopping carts, racks, compressors, lawnmowers, two wheel- ers and construction and agricultural equipment components. In the automotive industry; cross members, engine cradles, door mod- ules, exhaust systems, brake compo- nents, car seats, wheels, axles and dash boards can all be successfully manufac- tured using a FlexArc cell. A virtual replica of each FlexArc cell is available free from the ABB robotics website. This enables operators to be trained in the virtual world, in advance, obviating the need to lose valuable production time due to training on the real system. The virtual cell can be used to gen- erate specific part welding programs off-line before the new system arrives, enabling production to hit the ground running as soon as installation is com- plete. It also enables weld fixture to be designed and optimised without need- ingdirect access to thewelding cell itself. This allows tool and weld torch access along a weld seam to be verified in ad- vance, prior tomanufacturing clamping and fixture tools. Virtual FlexArc: the ultimate productivity tool

ABB’s new-generation FlexArc® robotic welding cells are complete robot systems available in several flexible and versatile standard modular packages. torch angle. BullsEye operates in two modes: Set up mode, to define a new tool in the system; and Quick check, a periodic tool checking routine. The frequency of checking is specifiedwithin the programand automatically updated whenadeviation is found. These checks/ updates result in an improvement in the quality of welded parts and a significant increase in productivity of the cell. TCP continuously establishes ref- erence points for the welding wire so that it always contacts the workpiece accurately along all points of the pro- grammed weld path. The robot system incorporates pro- duction monitoring to automatically monitor weld lengths and the number of welds made on a component. Reports, screenmessages andwarning lights are displayed if a part is not being produced according to the original specification. This enables the operator to take im- mediate action to repair or reject a faulty component. ABB’sNavigator technology includes cell calibration for off-line generated programs, tooling calibration– including integrated coordinated measurement functionality – and cell self-diagnostics. In addition, thanks to Integrated Er- ror Resolution, there is no need to enter the cell when a weld error occurs. At the push of a button the robot will go to the service pocket in the guard, where the operator can service the welding gun, change the contact tip, etc. This saves valuable production time and results in increased productivity.

Tools to raise quality and increased uptime

ABB’s patented BullsEye® allows accu- rate definition and automatic updating of the tool centre point (TCP) and the

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March 2017

AFRICAN FUSION