abb robotics, singapore, april 2013 how to enhance … to enhance your profitability and growth...
TRANSCRIPT
How to enhance your profitability and growth through the effective use of technology
ABB Robotics, Singapore, April 2013
© ABB Group - RoboticsApril 12, 2013
Introduction
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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
© ABB Group - RoboticsApril 12, 2013
Arc Welding Application
Packaging Application
Batch Production Application
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Arc welding process for robotics
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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 Welding Welding
Welding Welding Welding
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Arc Welding Processes for Robotics
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Arc Welding ProcessesMIG/MAG Welding
MIG/MAG Welding
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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
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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
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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
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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
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Special equipment
Controlled droplet detachment based on Short ArcVery Low heat input
Very low Spatter production
Excellent for most materials
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Arc Welding Processes
TIG Welding
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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
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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
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Arc Welding Processes
Plasma Welding
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Plasma WeldingHigh Quality Welding
Excellent Manual Process –Ideal for Robotic applications
DC welding - for most materials
AC welding for Aluminium
Optional wire feed
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Arc Welding Processes
Laser Welding
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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
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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
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Robotics Arc Welding productivity toolProduct to maximize your productivities
RobotWareArc
RobotStudioAW PowerPac
PSF315 Weldguide IIITorch Service Centerwith BullsEye
RPC S-400
A314EB
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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
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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.
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Adaptive fill mode
Single side tracking mode
Multi-pass
Torch to work mode
Centerline mode
Packaging application with intelligent software and application know-how
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Outline
Picking and Packing applications
PickMaster 3 - Application Software
Multi robot Lines
News - Racerpack
Packaging application includePicking Packing and Palletizing
Picking
Packing
Palletizing
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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
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Preparing blisters
Mixing of assortment parts
Picking and Packing Applications
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Replacing hard automation
Feeding of material from vendor
Vibratory feeders
Dispensers
Picking and Packing Applications
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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
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Bag or Pouches Packing
Picking/packing bags directly into carton boxes
Boxes on separate lanes
Picking and Packing Applications
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Outline
Picking and Packing applications
PickMaster 3 / 5 - Application Software
Multi robot Lines
News - Racerpack
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Palletizing
PickMaster- The ABB Packaging software
Packing
Picking
Application Software
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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
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Essential parts in Robotics Picking
Fast and Accurate Robots
Application Software with vision
Grippers
Lighting
Material flow
Application Software: PickMaster 3
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Outline
Picking and Packing applications
PickMaster 3 - Application Software
Multi robot Lines
News - Racerpack
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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
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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
In
Out
ATC
Load Balancing
Multi Robot Lines
Robot for in batch production environmentApplication in Pharmaceutical industry
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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
Secondary Pack© ABB Group April 12, 2013 | Slide 44
Solution for batch production
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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
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)
Get the Youtube version !!!© ABB Group April 12, 2013 | Slide 47
© ABB Group - RoboticsApril 12, 2013