gifa press conf 2007 | abb industrial robotics

PRESSCONFERENCE 14-06-2007

© A

BB

Robotics –

C.B

ER

G

ABB - Leader in power and automation technologies

ProcessAutomation

Power Systems

RoboticsPower Products

AutomationProducts

� Orders received 2006: USD 28,4 billion

� Integrated solutions for grid reliability, productivity and energy efficiency

� Extensive global network of value-added channel partners

� About 109 000 employee in 100 countries

Process Automation at Metec Hall5/Booth E19

Excellence in Metallurgical Technology

� From primary metals and rolling mills to processing lines

Products

� Automation systems for control, monitoring & optimization

� Force measurement products

� Electromagnetic solutions for continuous casting: � Electromagnetic solutions for continuous casting: Stirrers, Brakes

� Motors & Drives-Solutions

Our benefits

� Maximum quality

� Higher throughput

� Decreased down times

� Optimization, Simulation, Modeling of metallurgy processes

Innovations at Metec 2007

� Roll@xA� Automation System 800xA

� Production Planning

� Drive Systems

� Measuring systems and instrumentation

� Collaborative Production Management

� Execution Manager

Production Information Management� Production Information Management

� ECS/EPR Integration

� Surface Imaging System HDI800

� Reliable measurement 24/7

� Accurate results

� Smart tracking to origin

ABB Robotics

ABB Robotics

� More than 150,000 ABB Robots installed worldwide

� 4600 employees worldwide� 4600 employees worldwide

� Comprehensive portfolio of industrial robots and software

� Standard manufacturing cells for welding, cutting, painting,

machine tending and assembling

� Life cycle service for robots and robots systems

ABB Robotics World-Wide

� Represented in 35 countries of the world

� R&D and manufacturing in Sweden, Norway, China and Japan

� Production capacity 17 000 robots per year

ABB Robotics Foundry

ABB Robotics – Foundry

� Automation is the key

� Experience Makes a Difference

� We Believe in Partnership� We know your products and the demands of your industry

Application AreasApplication Areas� Sand Casting� Die Casting

� Forging

� Lost Foam� Gravity Casting

� Precision Casting

� Cast Cleaning & Machining

� Surface Treatment� Quality & Control

ClientPSA Peugeot Citroën (France) and BMW

ApplicationForging of cylinder crankcases, crankshafts and

track rods. System installed by Müller Weingarten,

Germany.

Case Study: Forging

Key Drivers & Benefits� 15 percent increase in production

� Total cylinder head production 25 percenthigher than highest previous rate

� Investment itself 30 percent less than

replaced process� Ground area 15 percent less

“Crankcases are made

with a new patented

solution and the track

rods are forged in duplicate, giving a 10% gain on the price per piece”.Mr. Singer, PSA

ClientLjunghäll AB, Södra Vi, Sweden

ApplicationCasting, machining, finishing and cleaning of die-cast aluminum automotive, telecom and other

parts. Some 44 ABB robots in all models except the

IRB 7600, for which they have no need.

Case Study: Die casting

Key Drivers & Benefits� No. of manufacturing stages reduced

� Production increased� Flow of material linked with finished products that

can be delivered directly to customer’s

manufacturing lines

“These robot cells have

led to an extensive

rationionalization of our

manufacturing.”

Nicklas JaldefeldtLjunghäll AB

ClientVolkswagen, Poznan, Poland

ApplicationLubrication of light alloy pressure die-cast engine

components. IRC5 robot controller. System

installed by Acheson.

Key Drivers & Benefits

Case Study: Die Casting - Spraying

Key Drivers & Benefits�Lubrication and robot software integrated so that

appears to be one program for customer

�User-friendly software

�Lubrication is water-free and environmentally friendly, with lubricating film capable of forming

independent of temperature

“…our customer can

take advantage of all of

the process control

features.”

Dieter ThummAcheson

ClientHWS, Bad Laasphe, Germany

ApplicationVenting of castings of high-compression molds. IRB 4400 robot.

Case Study: Sand Casting

Key Drivers & Benefits�Savings by using one robot for insertion and

milling�Increased efficiency, no interruptions

�Reduced system complexity�Time saved due to simple programming

“Innovative solution of

mold venting with ABB

robots.”

Heinrich Wagner,Sinto Maschinenfabrik

ClientEvolut, Brescia, Italy

ApplicationDeburring of cast-iron castings. Special anti-

vibration solution avoids excess strain.

Case Study: Cast Cleaning

Key Drivers & Benefits�Software allows for feasibility study prior to

application.�Robots can continue working while simulation is

being done, thus preventing extra downtime and

saving money.

“Plant installation times

can be reduced, saving

time and money.”

Giordano LancelottiEvolut

ClientSIR, Modena, Italy

ApplicationDeburring, milling and grinding of cast iron foundry

parts. IRB 6600 robot.

Key Drivers & Benefits�Cycle times can vary from 90 seconds to four

Case Study: Machining

�Cycle times can vary from 90 seconds to four minutes

�Precision to within a few tenths of a millimeter

�Compact but easily accessible cells of no more than 35 square meters

�ABB Robot Studio gives a virtual tour of the

proposed plant

“Inside the cab is a

genuine miniature

workshop…”

Davide PassoniSIR

ClientBMW, in Munich, Steyr and Hams Hall

ApplicationInjection flood washing, deburring and drying of

cylinder heads, crank cases and other automotive engine parts. Foundry Prime ABB IRB 6600 robot.

System installed by Dürr Ecoclean, Germany

Case Study: Surface Treatment

Key Drivers & Benefits� Operates in extremely tough environment

without need of protective casing� High flexibility with changes to nozzles made

by control panel instead of manually

The new cleaning

modules have become

the standard for the

BMW group.

ClientAlteams-Stilexo, Skillingaryd, Sweden

ApplicationPicking, placing, loading and deburring of aluminium automotive components. Mix of IRB

4400 and IRB 140 robots.

System installed by SVIA, Sweden

Case Study: Quality & Control

Key Drivers & Benefits� Shortened cycle times of 5 seconds

� Tough robots can handle high heat

� 30,000 pairs of castings weekly

� Vision inspection of 100 percent means

little follow-up inspection necessary

“It would not be

possible to match

industry production

requirements without this technology.”

Per JanssonAlteams Stilexo

ABB Robotics at GIFA 2007

Exhibits

� Remote Service

� Foundry Prime

� Robot Ware DieCast

� IRB 6660-High Performance Machining Robot

� IRB 6620- Payload 150kg

� True View� True View

� Function Package Force Control Machining

� Flex Finishing Cell

�

ABB activities at GIFA

� Innovative technology for the machining treatment of cast parts using robots”ABB’s theme at the WFO Technical Forum At 12:45, 14.06.07/Hall10-GIFA meeting point

� ABB Partner Game “Win an Apple IPod with ABB and their partner’s at GIFA”

Remote Service

ProductAdvanced robot diagnostic via Internet using a

robot-mounted logging device connected to the

console and service port of the controller. Potential robot failures and wear can be detected and

resolved even before they occur.

ApplicationAll kind of robot application

Key Drivers & Benefits“Remote Service is part

of our customer care

Program”

ABB Robotics,

Rene Nispeling


�Apply smart Maintenance Methods

�Faster Trouble Shooting

�Maintain only what needs to maintained and when

�Improved productivity or higher efficiency

�High uptime for robot system

�Low maintenance cost

�Immediate action for unplanned stoppages

True ViewProductTrueViewTM is the ABB brand name for a proven Vision

Guided Robotics System fully integrated into the ABB

robot. TrueViewTM combines the industry-leading

robotics expertise of ABB with the revolutionary eVF

software 2D, 2.5D and 3D. All with one hardware and

using a single camera.

ApplicationAll kind of robot application


“True ViewTM –

Proven Vision

Guided Robotics System”,

David Baucus,

ABB Robtics, US

Key Drivers & Benefits�True 3D Single camera vision system including software

and hardware components.

�A complete ABB robot integrated product. Easy to integrate

and start up.

�Easy to make calibration and accuracy test before starting

up the production, this will save time and money.

�Customer shall use less fixtures, precision dunages, and

accurate pallets for part positioning. Cost and time

saving.

�Standard hardware components, commercially available

off the shelf.

�Proven solution. Over 130 installations.

Foundry Prime

ProductRobot protection for harsh environments, available

for selective robot variants.Features

Pressurized robot , Corrosion protection, Special

paint, Sealing compound, etc.

ApplicationWater Jet Cleaning and other applications with

similar requirements


�Reduced maintenance cost

�Improved flexibility

�Improved uptime

�Improved end product quality

�Improved cycle time

�More compact cleaning cells

“Protection against

all odds”

Andreas Eriksson,ABB Robotics, Sweden

RobotWare Die Cast

“Easy programming as

ProductTool for intuitive configuration, programming and

operation of an ABB Robot

FeaturesGraphical User Interface

Standardized application with modifiable libraries secure reliability and flexibility

Application“Easy programming as

surfing the Internet”

ABB Robotics,

ApplicationMachine tending of Die Casting Machines


�Easy to install

�Delivered and tested with ABB robot

�Easy to program

�Programming wizard

�Standardised program with modifiable

libraries

�Easy to operate

�Safe Home Run and easy re-programming

IRB 6660-205/1.9

ProductA robot for high-performance machining

applications. The new robot design will support high

productivity, uptime and accuracy

ApplicationThe robot is designed for machining applications where robot stability is a key factor for success

Milling, grinding, cutting, sawingMilling, grinding, cutting, sawing


�High productivity�Improve material removal rate

�High accuracy�Stiff, compact and robust design

�Shorter cycle timeHigh Performance

Machining Robot

IRB 6620- Four robots in one

ProductCompact and agile robot for flexible installation

load capacity = 150 kg

Reach, 2.2 meter

Application

Machine tendingMaterial handlingMaterial handling


�Hanging installation; Saves floor space�Semi shelf; Facilitates compact cell design

�Compact and agile; Large working range in

relation to size

New compact and agilepower robot

IRC5 – Filter options

ProductCooling air filter guarantee reliable protection of the

IRC5 robot controller in harsh foundry

environments. 1. A metal mesh filter for moist particles

2. A polymeric filer for moist dust

Application All Foundry application & Machine shops

“Secure cooling capacity

with ABB’s innovative

air filter’s.”

Peter Fixell,ABB Robotics, Sweden


�Secure the cooling capacity; Filters will prevent

air ducts and fans from being clogged by moist

particles or dust

�Secure availability; Reducing unplanned stops and replacing filters while the robot is running

�Reduced maintenance costs

Function Package Force Control Machining

ProductThe offer includes the necessary equipment to run

a robot force controlled. Function Packages as a

starting kit for those customers that would like to integrate the machining application / process

themselves.

ApplicationGrinding, Deburring, Polishing, Buffing, Milling,

“Take the robot by

the hand and reducethe programming

time up to 80%.”

Kurt Mühlgrabner,

ABB Robotics, Austria

Sawing, Deflashing, Sanding, etc..


�Easy to use, robot programming by hand

�Secures controlled contact force (not positions)

�Less cycle times – higher tool life time

Flex Finishing Cell

ProductThe FlexFinishing cell as basic solution for flexible

production consists of a 5kg-robot, the function

package force control, a manual turntable table, a variety of tools incl. tool-changing system and the

necessary safety equipment. Additionally a human-machine-interface helps the operator to run the cell in an efficient way.

ApplicationApplication

A standardized solution for robotized machining

applications. Ready to use for different grinding operations on small-size parts.


�Easy to use and ready to produce

�Less space in production and removable design

�Fast return on investment

“Complete package for

Mechanical finishing.”

Kurt Mühlgrabner, ABB Robotics, Austria

Summing up

Summary� “Join our live demonstration”� Please take your Information Package