African Fusion March 2017

March 2017

AFRICAN FUSION

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.

FlexArc:

a new generation welding cell

ABB’s new-generation FlexArc® robotic welding cells

are complete robot systems available in several

flexible and versatile standard modular packages.

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

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.

Virtual FlexArc: the ultimate

productivity tool

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.

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

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.

ABB’s FlexArc robot cell