ABB Robotics, Singapore, April 2013 How to enhance your profitability and growth through the effective use of technology

ABB Robotics, Singapore, April 2013 How to enhance your profitability and growth through the effective use of technology

Introduction - 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. April 12, 2013 Slide 3

Technology used in Arc Welding Application Packaging Application Batch Production Application - Robotics April 12, 2013

Arc welding process for robotics - Robotics April 12, 2013

Arc Welding Processes Pressure Welding Fusion Welding Arc Gas Aluminothermic Electron Electro-Slag Light Welding Welding Welding Beam Welding Radiation Welding Laser Arc Image Metal Arc Carbon Arc TIG Arc Spot Atomic Plasma Arc Welding Welding Welding Hydrogen Welding Welding Manual Submerged arc MIG MAG Electro-gas Metal Arc Welding Welding Welding Welding Resistance Forge Pressure Ultra Sonic Diffusion MIAB Welding Welding Welding Welding Welding Welding Blacksmith Hammer Roll HF Pressure Cold Friction Explosive Welding Welding Welding Welding Welding Welding Welding Resistance Butt Flash Spot Seam Projection Percussion HF Welding Welding Welding Welding Welding Welding Resistance Welding Stitch Multiple Series Roller Butt Seam Welding Spot Spot Spot Welding Welding Welding Welding Foil Butt Seam Welding + More many more variants April 12, 2013 Slide 6

Arc Welding Processes for Robotics April 12, 2013 Slide 7

Arc Welding Processes MIG/MAG Welding MIG/MAG Welding 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 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 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 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 CMT-Process General pre-machining process Spatter April 12, 2013 Slide 12

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 April 12, 2013 Slide 13

Arc Welding Processes TIG Welding 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 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 April 12, 2013 Slide 16

Arc Welding Processes Plasma Welding 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 April 12, 2013 Slide 18

Arc Welding Processes Laser Welding 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 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 April 12, 2013 Slide 21

Robotics Arc Welding productivity tool Product to maximize your productivities RobotWare Arc RobotStudio AW PowerPac RPC S-400 A314EB PSF315 Torch Service Center with BullsEye Weldguide III April 12, 2013 Slide 22

Robotics Arc Welding productivity tool Positioning products. 1F/1G every time April 12, 2013 Slide 23

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 April 12, 2013 Slide 25

Robotics Arc Welding productivity tool Torches Service Center for consistently better weld BullsEye Wire cutter Nozzel cleaner Torch Service Centre ABB TSC 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 TCPdefinition 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.

Robotics Arc Welding productivity tool Weld process guiding tool Multipass Torch to work mode Centerline mode 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. Single side tracking mode Adaptive fill mode Weldguide III can perform thru-the-arc tracking in several different welding modes such as sprayarc, short-arc and pulsed-arc. April 12, 2013 Slide 27

Packaging application with intelligent software and application know-how April 12, 2013 Slide 28

Outline Picking and Packing applications PickMaster 3 - Application Software Multi robot Lines News - Racerpack April 12, 2013 Slide 29

Packaging application include Picking Packing and Palletizing Packing Picking Palletizing April 12, 2013 Slide 30

Serving Packaging Machines before and after Input Flow wrapping The machines need consistent ordered product flows Output The wrapped products need to be packed Thermo forming Tray Sealing Picking and Packing Applications April 12, 2013 Slide 31

Preparing blisters Mixing of assortment parts April 12, 2013 Slide 32 Picking and Packing Applications

Replacing hard automation Feeding of material from vendor Vibratory feeders Dispensers April 12, 2013 Slide 33 Picking and Packing Applications

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 April 12, 2013 Slide 34

Bag or Pouches Packing Picking/packing bags directly into carton boxes Boxes on separate lanes April 12, 2013 Slide 35 Picking and Packing Applications

Outline Picking and Packing applications PickMaster 3 / 5 - Application Software Multi robot Lines News - Racerpack April 12, 2013 Slide 36

PickMaster- The ABB Packaging software Packing Picking Palletizing April 12, 2013 Slide 37 Application Software

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 April 12, 2013 Slide 38 Application Software: PickMaster 3

Essential parts in Robotics Picking Fast and Accurate Robots Application Software with vision Grippers Lighting Material flow April 12, 2013 Slide 39 Application Software: PickMaster 3

Outline Picking and Packing applications PickMaster 3 - Application Software Multi robot Lines News - Racerpack 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 Load Balancing April 12, 2013 Slide 41

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 ATC April 12, 2013 Slide 42

Robot for in batch production environment Application in Pharmaceutical industry 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 April 12, 2013 Slide 44

Solution for batch production 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!!! 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) April 12, 2013 Slide 47 Get the Youtube version!!!

- Robotics April 12, 2013