How to enhance your profitability and growth through the effective use
ABB Robotics, Singapore, April 2013 How to enhance your profitability and growth through the effective use of technology Introduction © ABB Group - Robotics April 12, 2013 Mr. Ang Boon Hua Local Business Unit Manager Robotics ABB This session will share how technology can be use to enhance your profitability and growth in various application. © ABB Group April 12, 2013 | Slide 3 Technology used in Arc Welding Application Packaging Application Batch Production Application © ABB Group - Robotics April 12, 2013 Arc welding process for robotics © ABB Group - Robotics April 12, 2013 Arc Welding Processes Pressure Welding Fusion Welding Arc Welding Gas Welding Aluminothermic Welding Electron Beam Electro-Slag Welding Light Radiation Welding Laser Metal Arc Welding Resistance Welding Blacksmith Welding Carbon Arc Welding Manual Metal Arc Submerged arc Welding Forge Welding Pressure Welding Hammer Welding Resistance Welding Stitch Welding TIG Roll Welding Butt Flash Welding Multiple Spot Welding Series Spot Welding Arc Spot Welding MIG Welding Ultra Sonic Welding HF Pressure Welding Spot Welding Seam Welding Roller Spot Welding Cold Welding Projection Welding Atomic Hydrogen Welding MAG Welding © ABB Group April 12, 2013 | Slide 6 Plasma Arc Welding Electro-gas Welding Diffusion Welding MIAB Welding Friction Welding Explosive Welding Percussion Welding Butt Seam Welding Foil Butt Seam Welding + More many more variants Arc Image HF Resistance Welding Arc Welding Processes for Robotics © ABB Group April 12, 2013 | Slide 7 Arc Welding Processes MIG/MAG Welding MIG/MAG Welding © ABB Group April 12, 2013 | Slide 8 MIG/MAG Welding Terminology Welding!! Welding as we know it, first started in the early 1800s during the Industrial revolution CO2 Welding (MAG) however, was not invented until the 1920’s and did not see regular use until the 1950’s Today MIG/MAG Welding accounts for most of the worlds Arc Welding with Robots © ABB Group April 12, 2013 | Slide 9 MIG/MAG Welding Terminology CO2 Welding - Is welding with Carbon Dioxide as the shielding gas MIG Welding - Is Metal Inert Gas welding MAG Welding - Is Metal Active Gas welding MIG/MAG Welding - The collective term for welding with all gas types GMAW - The term for MIG/MAG welding by USA standards © ABB Group April 12, 2013 | Slide 10 MIG/MAG Welding The 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 © ABB Group April 12, 2013 | Slide 11 MIG/MAG Welding Common Issues Conventional MAG-Process The finishing is rough Cleaning of nozzle and cutting of wire (TSC) Wire feeding control Require fixture General pre-machining process CMT-Process © ABB Group April 12, 2013 | Slide 12 Spatter MIG/MAG Welding CMT (Fronius) – Cold Metal Transfer Special equipment Controlled droplet detachment based on Short Arc Very Low heat input Very low Spatter production Excellent for most materials © ABB Group April 12, 2013 | Slide 13 Arc Welding Processes TIG Welding © ABB Group April 12, 2013 | Slide 14 TIG Welding Terminology 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 © ABB Group April 12, 2013 | Slide 15 TIG Welding High 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 © ABB Group April 12, 2013 | Slide 16 Arc Welding Processes Plasma Welding © ABB Group April 12, 2013 | Slide 17 Plasma Welding High Quality Welding Excellent Manual Process – Ideal for Robotic applications DC welding - for most materials AC welding for Aluminium Optional wire feed © ABB Group April 12, 2013 | Slide 18 Arc Welding Processes Laser Welding © ABB Group April 12, 2013 | Slide 19 Laser Welding High 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 © ABB Group April 12, 2013 | Slide 20 Robotics Arc welding Everything you need High performing, easy-to-use robots Controllers for superior motion control Application software for fast and accurate programming and operation Track motions and workpiece positioners for synchronized motion of workpiece and torch Pre-engineered systems and building blocks for custom solutions Process tools to facilitate the arc welding process Application specific equipment © ABB Group April 12, 2013 | Slide 21 Robotics Arc Welding productivity tool Product to maximize your productivities RobotWare Arc © ABB Group April 12, 2013 | Slide 22 RobotStudio AW PowerPac RPC S-400 A314EB PSF315 Torch Service Center with BullsEye Weldguide III Robotics Arc Welding productivity tool Positioning products. © ABB Group April 12, 2013 | Slide 23 1F/1G every time Robotics Arc Welding productivity tool Simulation software Build new solutions quickly: Evaluate alternatives Initial feasibility studies Initial cycle-time calculations Visualize solutions: Address problem areas at an early stage Verify new designs quickly: Check reachability Avoid collisions Detect singularity issues Robotics Arc Welding productivity tool VirtualArc® Software for weld parameter setting What you see on the prediction, you get in reality © ABB Group April 12, 2013 | Slide 25 Robotics Arc Welding productivity tool Torches Service Center for consistently better weld Torch Service Centre Makes your robot welding more effective and accurate BullsEye Decreased the cycle time and increased the uptime Wire cutter In order to weld with good quality and accuracy. Welding torches require regular cleaning ,measuring and TCPdefinition Nozzel cleaner It is impossible to avoid spatter during welding operations. Hot particles from the arc easily adhere into the gas nozzle. ABB TSC The entire cleaning operation is automatic in one sequence, including mechanically cleaning, pneumatic cleaning and finally oil injection into the gas nozzle. Robotics Arc Welding productivity tool Weld process guiding tool WeldGuide is a combined process control and “Through the Arc” adaptive seam tracking system integrated into the robot controller Multipass Torch to work mode Centerline mode 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. Single side tracking mode © ABB Group April 12, 2013 | Slide 27 Adaptive fill mode Weldguide III can perform thru-the-arc tracking in several different welding modes such as sprayarc, short-arc and pulsed-arc. Packaging application with intelligent software and application know-how © ABB Group April 12, 2013 | Slide 28 Outline Picking and Packing applications PickMaster 3 - Application Software Multi robot Lines News - Racerpack © ABB Group April 12, 2013 | Slide 29 Packaging application include Picking Packing and Palletizing Packing Picking Palletizing © ABB Group April 12, 2013 | Slide 30 Serving Packaging Machines – before and after Flow wrapping Input The machines need consistent ordered product flows Output The wrapped products need to be packed Thermo forming Tray Sealing Picking and Packing Applications © ABB Group April 12, 2013 | Slide 31 Preparing blisters Mixing of assortment parts Picking and Packing Applications © ABB Group April 12, 2013 | Slide 32 Replacing hard automation Feeding of material from vendor Vibratory feeders Dispensers Picking and Packing Applications © ABB Group April 12, 2013 | Slide 33 Picking to patterns then packing Picking with IRB360 Single 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 © ABB Group April 12, 2013 | Slide 34 Bag or Pouches Packing Picking/packing bags directly into carton boxes Boxes on separate lanes Picking and Packing Applications © ABB Group April 12, 2013 | Slide 35 Outline Picking and Packing applications PickMaster 3 / 5 - Application Software Multi robot Lines News - Racerpack © ABB Group April 12, 2013 | Slide 36 PickMaster- The ABB Packaging software Packing Palletizing Picking Application Software © ABB Group April 12, 2013 | Slide 37 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 © ABB Group April 12, 2013 | Slide 38 Essential parts in Robotics Picking Fast and Accurate Robots Application Software with vision Grippers Lighting Material flow Application Software: PickMaster 3 © ABB Group April 12, 2013 | Slide 39 Outline Picking and Packing applications PickMaster 3 - Application Software Multi robot Lines News - Racerpack © ABB Group April 12, 2013 | Slide 40 Pre-scheduling of work Load Balancing (LB) Optimizes robot load Cost efficient camera distribution Less CPU load Dynamic redistribution Cam/Sensor Multi Robot Lines © ABB Group April 12, 2013 | Slide 41 Load Balancing 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 In Out Multi Robot Lines © ABB Group April 12, 2013 | Slide 42 ATC Robot for in batch production environment Application in Pharmaceutical industry © ABB Group April 12, 2013 | Slide 43 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 secondary packing solutions are limited. Most of the available machines on the market are dedicated for F&B industry. Primary Pack Main differentiator comparing with F&B Lower capacity. Shorter batches. Higher regulatory demands eg. GMP FDA. Cost of the product to packed are higher. Secondary Pack © ABB Group April 12, 2013 | Slide 44 Solution for batch production © ABB Group April 12, 2013 | Slide 45 Secondary Packaging Robot combined with conventional packaging methods gives 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 Flexibility + Availability = Value added Productivity !!! © ABB Group April 12, 2013 | Slide 46 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 Group April 12, 2013 | Slide 47 Get the Youtube version !!! © ABB Group - Robotics April 12, 2013
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