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