ABB wins massive order for multi-robot, multi-axis, arc welding systems and controllers

Citation

(2005), "ABB wins massive order for multi-robot, multi-axis, arc welding systems and controllers", Industrial Robot, Vol. 32 No. 6. https://doi.org/10.1108/ir.2005.04932fab.001

ABB wins massive order for multi-robot, multi-axis, arc welding systems and controllers

ABB wins massive order for multi-robot, multi-axis, arc welding systems and controllers

Keywords: Robotics, Arc welding

ABB, the global power and automation technologies group, has been awarded the first of two orders from a global, tier one automotive supplier, for 400 welding robots and state-of-the-art IRC5 control systems, destined for production plants in Europe and the USA.

The ABB technology is being installed at the plants in Germany, Spain, the Czech Republic, France, Italy and the USA, where the robots will manufacture automotive parts and components for DaimlerChrysler, General Motors, Fiat, Peugeot and Renault.

Two hundred and seventy eight of the robots will operate in a “MultiArc” arrangement, an advanced new system whereby multiple welding robots can be integrated with a part positioner, due to the technological breakthroughs that underpin the new ABB robot controller, the IRC5 (Plate 1).

Plate 1 Many of the robots will operate in a “MultiArc” arrangement

The IRC5 with its new MultiMove function embedded into the IRC5 software, allows up to four robots, including part positioners and other devices, to work in fully co-ordinated operation. Such advanced functionality is made possible by the exceptional processing power of the IRC5 control module computer, capable of calculating MultiMove path calculations for up to 36 servo axes, while directing up to four drive modules.

Robots can be programmed to carry out complex, co-ordinated activities – a typical configuration being three robots working together. One robot holds an object, while the other two work on it, thus eliminating the need for a positioner. Though the IRC5 can integrate as many as four robots at the same time, the optimum solution in the majority of industrial arc welding applications is based on a combination of two team-working robots and one positioner.

MultiArc has significant advantages over single robot arc welding systems and/or conventional controllers. By using the IRC5 to co-ordinate two welding processes, synchronisation time between robots is eliminated, and when combined with its superior path accuracy and excellent repetition, cycle times are further reduced.

As well as the advantages of cycle time reductions, conducting two welding processes at the same time improves heat distribution, thereby minimising the risk of deformations or cracks, and safeguarding quality.

Using MultiArc also reduces floor space, thereby increasing flexibility and reducing fixed production costs, while integrating two welding processes is also 70 per cent more efficient than a single robot solution, thus output is also increased.

Depending upon customer applications, the MultiArc standard configurations include two IRB 140, IRB 1400, or IRB 2400 robots paired with one positioner. These standard configurations cover the majority of industrial arc welding applications, though this does not preclude the possibility of non-standard configurations being devised for a specific application. Two robots of different types can be integrated, or even three or four robots, of which one might be occupied with material handling operations.

A particular feature of the IRC5 that attracted the customer is the FlexPendant robot interface unit – a robust, easy-to-use, handheld console with touch-sensitive colour screen that enables the operator to program or edit the movements of each robot so that they work in coordination, or independently, of one another.

The ABB technology allows changes in programming and product switchover to be implemented rapidly – factors that all automotive manufacturers strive for.

MultiArc enhances an already diverse and impressive portfolio of robotic products. This portfolio includes a comprehensive range of robots for all sectors of industry, as well as robot controllers, software, application equipment and robot peripherals.

For more information please contact: David Marshall, ABB Manufacturing Automation, Auriga House, Precedent Drive, Rooksley, Milton Keynes MK13 8PQ. Tel: +44 (0) 1908 350300; Fax: +44 (0) 1908 350301; E-mail: david.marshall@gb.abb.com