Robotics

FlexArc® – Robotic Arc-Welding CellsModular solutions to meet your requirements

Contact us

ABB, s.r.o.Stetkova 1638/18 140 00 Praha 4 E-mail: FlexArc@cz.abb.com

www.abb.com

Standard configurationPlatform, Fencing with the torch service window, service door, robots, pedestals, positioner, controller, power distribution panelWelding power sourceWelding torchOperator panelSafety equipment PNOZ Multi including Vertical Light Curtains

SoftwareFlexPendant - Graphical User Interface for operatorsWelding error handlerProduction monitoringProduction managerNavigator

Optional configurationRobot IRB 1600, 1600 ID, 2600, 2600 ID, 4600 Welding power sourcesAccording to end-user requirements

Welding torchesAccording to end-user requirements

OthersPLC, OP PanelsManual JogFull Air and Gas distribution panelFull floor coverage Programming platform

Safety Horizontal light curtainsRoll-down door, Two-Hand control

Tool serviceService center for torches Torch cleanerBullsEye®: TCP calibration Wire cutterSeam FindingSmarTac, WeldGuide III

Fume extraction hoodsCoverage of welding station onlyCoverage of welding station and load/unload station

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A new dimension in Robotic Arc Welding

Optimal productivity requires equipment that combines effective operation with maximum cost-efficiency. Modular, standardized robot cells are an established way of provid-ing this type of solution.

FlexArc® - A New Generation of Welding CellsFlexArc® is a new generation of standardized welding cells, which are designed to deliver cost-effective, state of-the-art robotic welding operations. All cells deliver maximum perfor-mance whilst making optimum use of available space. The basic options feature either a single robot, or two robots with Multi-Move, a choice of ABB positioners from our extensive range and welding equipment to suit your needs. All equipment is installed on the common platform which provides for easy relocation within the production facilities. The cells are equipped with centralized power distribution - all components such as robots, positioners, welding equipment, lighting and other peripheral devices are supplied from one source; this means that only one power supply cable for the whole cell is necessary.

FlexArc® Advantages� Low investment cost� Intuitive graphical user interface for operators � Reduced downtime thanks to improved error handling� Higher quality through automatic production and process monitoring� Improved cost-efficiency thanks to global standardization� Short delivery times

� Proven two-station principle (loading and welding)� Off-line programming for fast and easy implementation� Improved workspace safety

Boosting your workflowFlexArc® features the FlexPendant graphical user interface, which not only provides operators with an overview of the status of the cell, but also important quality and production data. The interface allows the operator to communicate effectively with all of the functions within a cell and access all information regar-ding cell performance, including the status of the robot and cont-roller along with other functions such as roll-down door control. With minimum training, the user can organize the welding opera-tion into a series of work steps. The operator has all the informa-tion necessary to keep track of the number of parts produced, cycle times, the number of welds produced and the individual weld length. Easy implementation makes the FlexArc® standard approach the natural choice for “plug-and-produce” operations.

FlexArc® is the Most Effective Solution in your industry� General industry: - Door modules, grids, switch boards, printing units, steel furniture, shopping carts, racks, compressors, lawnmowers, two wheelers and construction and agricultural equipment components� Automotive industry: - Cross members, engine cradles, door modules, exhaust systems, brake components, car seats, wheels, axles, dash boards and more

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A virtual replica of each FlexArc cell is available for free at www.abb.com/robotics

Virtual FlexArc® Advantages� Train operators on the virtual cell without losing valuable production time on the real cell� Generate programs off-line before your new system arrives� Generate programs for new parts while the real cell continues to produce uninterrupted � Design the weld fixture around an optimized robot welding program� Verify that tooling provides proper weld torch access to the weld seam prior to building the weld fixture

Tools for Quality and Increased Uptime

BullsEye® - Tool Calibration and Automated CheckThe patented BullsEye® allows accurate definition and automatic updating of the Tool Center Point (TCP) and the torch angle. The BullsEye® operates in two modes – “Set up mode” (to define a new tool in the system) and “quick check” (a periodic check of the tool – the frequency of checking is specified within the pro-gram and automatically updated when a deviation 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 = Tool Center Point - a reference point where the welding wire should touch the workpiece. The programmed path is the path of the TCP

Production MonitoringThe robot system automatically monitors weld lengths and number of welds made on a component and reports with a screen message and a warning light if a part was not produced according to the original specification. This enables the operator to take immediate action to repair or reject the faulty component.

NavigatorThe Navigator functionality includes cell calibration for off-line gene-rated programs, tooling calibration (including integrated co-ordinated measurement functionality) and cell self-diagnostics.

Integrated Error ResolutionThere 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 e.g. changing the contact tip etc. This saves valuable production time and gives an increase in productivity.

FlexArcR-300R-600R-1000

VersionSingle/MultiSingle/MultiSingle/Multi

Robot1,21,21,2

PositionerIRBP R-300IRBP R-600IRBP R-1000

Payload300 kg600 kg1000 kg

Distance in mm (between head and talistock)160020002000

Max. turning diameter in mm100012001200

Station footprint (L x W x H) with a light curtain6300 x 2800 x 22006800 x 3500 x 22006800 x 3500 x 2200

Station footprint (L x W x H) with a roll-down door 5300 x 2800 x 22005600 x 3500 x 22005600 x 3500 x 2200

Cells based on R-type positioners

FlexArcB-250B-500B-750

VersionSingleSingleSingle/Multi

Robot111,2

PositionerRBP B-250IRBP B-500IRBP B-750

Payload250 kg500 kg750 kg

Distance in mm (between head and talistock)90010001000

Max. turning diameter in mm100014501450

Station footprint (L x W x H) with a light curtain6700 x 2320 x 22007700 x 4400 x 22007700 x 4400 x 2200

Station footprint (L x W x H) with a roll-down door On request6900 x 4400 x 22006900 x 4400 x 2200

Cells based on B-type positioners

FlexArcD-300D-600

VersionSingleSingle

Robot11

PositionerIRBP D-300IRBP D-600

Payload300 kg600 kg

Distance in mm (between head and talistock)16002000

Max. turning diameter in mm10001200

Station footprint (L x W x H) with a light curtain6850 x 4300 x 22007400 x 4600 x 2200

Station footprint (L x W x H) with a roll-down door On requestOn request

Cells based on D-type positioners

Cells based on K-type positioners

FlexArcK-300K-600K-1000K-1000

VersionSingle/MultiSingle/MultiSingle/MultiTriple

Robot1,21,21,23

PositionerIRBP K-300IRBP K-600IRBP K-1000IRBP K-1000

Payload300 kg600 kg1000 kg1000 kg

Distance in mm (between head and talistock)4000400040004000

Max. turning diameter in mm1200140014001400

Station footprint (L x W x H) with a light curtain5600 x 4200-5700 x 22006200-6500 x 4300-5300 x 2200-32006200-6500 x 4300-5300 x 2200-32006200-6500 x 4300-5300 x 2200-3200

Station footprint (L x W x H) with a roll-down door 4900 x 4200-5700 x 22004800-5300 x 4300-5300 x 2200-32004800-5300 x 4300-5300 x 2200-32004800-5300 x 4300-5300 x 2200-3200

Cells based on C-type positioners

FlexArcC-500C-1000

VersionSingle/MultiSingle/Multi

Robot1,21,2

PositionerIRBP C-500IRBP C-1000

Payload500 kg1000 kg

Distance in mm (between head and talistock)500 1000

Max. turning diameter in mm- -

Station footprint (L x W x H) with a light curtain6300 x 2800 x 22006800 x 3200 x 2200

Station footprint (L x W x H) with a roll-down door 5300 x 2800 x 22005800 x 3200 x 2200

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