To maximize the flexibility of ABB’s robotic welding cells, 27 FlexArc robots were quickly installed at the automotive parts manufacturing plant to respond faster to end customer needs while maintaining cost efficiency.
The customer installed 27 ABB FlexArcs to serve the company’s production activities
Manufacturing of catalytic converters for automobiles
The customer wants to quickly increase the productivity of their factory and is looking for an automated welding solution that can be easily programmed to enhance production flexibility at the factory.
After preliminary calculations and detailed planning, 27 Robot FlexArc units were installed at the automotive parts manufacturing plant. ABB’s standard solution meets the customer’s needs, providing the necessary flexibility and allowing the plant to quickly scale production up or down to maximize operational efficiency.
From a single product manufacturer to a global supplier of automotive exhaust products. In just 27 years, the catalytic converter manufacturer has expanded its portfolio, expanded into new geographic regions, and is now a leading supplier to some of the world’s largest automotive companies.
As the business booms globally, this world’s largest automotive parts supplier faces a rapidly growing need for its production capacity. After some research, the company decided it needed an automated welding solution that could be easily programmed to enhance production flexibility at the plant by allowing the company to quickly scale production up or down to maximize operational efficiency. Available in a range of standardized packages, the FlexArc robotic welding cell incorporates everything needed for welding applications, including a welding robot with superior motion control software, positioners, and related welding equipment, all built on a common platform.
The ABB Robotics Application Center has designed a welding cell that can be easily replicated to increase capacity. Unlike other welding solutions that need to be built from scratch, operators can seamlessly load programs from previous work cells onto the new ABB FlexArc, using the same fixture design. Replicable across any factory globally, the robot helps reduce the time and cost associated with modifying production lines to meet changing customer demands.
Flexibility is at the core of FlexArc design. An important variable in the operation of the automotive industry is that there is no demand for guaranteed quantities from the end customer and a solution is needed to mitigate this uncertain demand.
FlexArc ABB is an ideal solution because a soldering cell can be easily adapted to other products. Depending on the purpose of the end customer, the factory can set up a welding process and use more or less FlexArc depending on the needs. The flexibility of the welding cell allows the company to use the same jig to fabricate products for different customers with minimal design changes.
FlexArc cells are helping to improve both productivity and worker safety. On one side of the positioner, the operator loads the parts that need to be welded on a fixture. The robot IRB2600 located on the other side then welds the parts together. When the welding process is complete, the machine will hand over the finished parts to the operator, who will unload them and replace them with new parts. The robot’s welding accuracy and speed are enhanced by ABB’s TrueMove and QuickMove motion platforms that optimize weld seams, reduce rework and reduce production cycle times.
FlexArc’s integrated design provides a higher level of safety during welding. The metal sheets cover the electrical equipment and the conductors are enclosed in special steel frames. This also protects the cell from the sparks generated during the soldering process. All ABB FlexArcs are supplied with a fume hood that can be connected to the fume extraction system needed to protect people and keep the work chamber free of debris.
Every FlexArc built by ABB can be simulated on RobotStudio, ABB’s offline robot programming software. Using ABB’s dedicated PowerPac welding software add-on, the factory can create complex robotic paths for its FlexArcs in a short period of time. Using RobotStudio, the company can test every aspect of the welding process virtually before the actual setup is done without affecting the actual production process. Possible problems such as collisions between welding torches and jigs will be highlighted in the work simulation, allowing them to be fixed if necessary.
‘RobotStudio gives the auto parts factory another avenue to maximize the investment in FlexArc welding umbrellas. By simulating a new project, the factory can estimate production costs, cycle times, and calculate the operating manpower or the number of robots for the project. By connecting to RobotStudio with engineering programs such as AutoCAD, ABB can also import jig designs and test the entire welding process set up before starting production.’ Robert Mrozik – Expert from ABB said.
Every new design of the jig and any new parts produced can be uploaded to Robot Studio for customers to check if any problems still exist. We can test accessibility for welding, torch positioners, and jig constructions. We can easily check the collision between the welding torch and any part of the jig. Overall, this solution reduces the cost of producing welding jigs, which means savings for the factory’s customers.
An important advantage with the standard FlexArc cell design is that the company’s employees do not have to undergo intensive training before starting machine operation. Furthermore, the intuitive FlexPendant graphical user interface makes it easy for operators to get an overview of the entire status of the cell and allows them to communicate effectively with all the functions in the cell and access information related to the cell’s performance.
