ABB has joined forces with a market leader in welding,
ESAB, and a specialist in welding torches,
Abicor-Binzel, to offer customers a comprehensive robotics, arc-welding package direct from ABB factories in Västerås, Sweden and Shanghai, China. Ideal for the welding of carbon steel, stainless steel and aluminium, the package combines each partner’s expertise in welding and automation.
The new package is available with ABB’s reliable IRB1600, IRB1600ID (Integrated Dressing) and IRB2400L robots.
Central to the package is ESAB’s welding technology, including the Aristo™ Mig power source, the latest generation of integrated inverter power sources with up to 500A/39V at 60% duty cycle, designed specifically for robotic MIG/MAG welding in metal fabrication industries. The Aristo™ Mig supports a variety of arc-welding capabilities, including robotic short arc, spray arc, pulsed arc, high speed welding (rapid arc) and the unique SuperPulse™ technology. The power sources are compact and sturdy, based on inverter Insulated Gate Bipolar Transistor (IGBT) technology and an advanced process regulator that combined, offers reliable equipment with outstanding welding characteristics providing excellent control with a minimum of spatter, even at high welding speeds.
The ESAB Aristo™ SuperPulse™ is a further development of the pulse/pulse concept, expanding the scope of the pulse MIG/MAG-process to thinner sheet and thicker plates in stainless or aluminium. By combining the pulse arc mode with the short arc mode on the low-heat input side, and with the spray arc mode on the high heat-input side, two completely new MIG/MAG arc types are created each with specific advantages. The pulse/short arc mode enables spatter free welding of aluminium sheet, from 0.6 mm thickness, and very thin stainless steel, as well as the MIG/MAG-brazing of very thin material. It’s use includes productivity on welding of root passes, replacing the much slower TIG process while preserving the TIG weld appearance.
Hundreds of ready-to-use synergic welding lines, providing complete combinations of welding method, material, wire diameters and shielding gases, allow for easy setup and operation. All the operator has to do is select the desired wire-feeding speed, and the AristoMig will automatically select the appropriate voltage.
Single point of programming
Both the power source and the robot controller are set up via the robot FlexPendant, ABB’s portable interface unit, using intuitive icons instead of cryptic codes. Only one set of data needs to be entered, speeding up programming while reducing the risk of human error. Welding data, such as voltage and current data as well as error messages from the power source, is displayed on the robot FlexPendant – putting the operator in control of the welding process at all times.
Complete offer
The new robotics arc-welding package contains connections to the media necessary for arc welding, like electrical power, large welding drums and bobbins for wire, shielding gas and pressurised air. There is a choice of air cooled or water cooled torches to fit the customer needs as well of different kind of cable management.
Another option is the torch service center (TSC) which offers a nozzle cleaner, a wire cutter and the unique Bulls Eye calibration tool that ensures the torch always to be shaped and tuned for most reliable and accurate welding.
Of course the robotics arc-welding package can be delivered with a complete range of the popular ABB IRBP positioners to fit the specific needs of the customer for work pieces from 250 to 5000 kg. The complete motion system with the robot and the positioner is controlled for shortest possible cycle time and accurate coordinated motion with the robot based on advanced software dynamic modelling technique.
Off-line programming
Using ABB’s RobotStudio, users can configure and test their automated system offline – the best way to maximise return on investment for robot systems. ABB’s simulation and offline programming software allows robot programming to be done on a PC in the office without shutting down production. It also enables robot programs to be prepared in advance, increasing overall productivity.
Arc Welding PowerPack
Included in the optional ABB RobotStudio Arc Welding PowerPack, for further easy of programming of the geometry especially for arc welding, is ABB’s unique VirtualArc. Featuring an easy-to-use software interface, VirtualArc can provide users with efficient off-line welding process tuning to predict a wide range of results including weld shape and penetration; weld quality; and possible welding defects.
Commenting on the introduction of the new arc-welding package, Thord Porsander, Product Manager for ABB’s arc welding products says: “ESAB and Abicor-Binzel are well-established in delivering solutions for welding globally. By creating this seamlessly integrated package for delivery directly from ABB factories, we can ensure all our customers to get a well proven and tested package for trouble free start up and welding for years to come.”
Abicor-Binzel has developed a special high flexible and torsion resistant Bikox cable especially for the new IRB 1600ID robot and offers solutions with air- and water-cooled torches for ID robots and standard robots too.
“This however does not restrict ABB for actively supporting other welding manufacturers to offer ready-to-use packages for ABB robots on a local delivery from ABB or Partners, it is of course the customer that makes the choice to fit his needs.” adds Thord Porsander.