ABB Welding Cell Overview
Standardized robotic welding cells provide a cost-effective alternative to customized ones. Pre-engineered cells simplify the welding automation process and allow for improved efficiency and productivity. This is why top robot manufacturers offer standardized welding work cells, including ABB with their FlexArc systems. ABB’s FlexArc systems feature numerous flexible and versatile modular work cells designed for arc welding applications. These welding cells pair nicely with robots from ABB’s arc welding line, such as the ABB IRB 2600-12.Base packages for the FlexArc models allow for configurations with one to two ABB robots, choice of ABB positioner, welding equipment, and safety package. Standardized FlexArc systems give customers the option of choosing welding equipment from Miller, such as the Miller Auto-Axcess 450, Fronius, SKS, ESAB, or Kempi. While customers have their choice of welding torch from Fronius, Dinse, Binzel, or SKS. Safety equipment included with these welding work cells include safety fencing, light curtains, laser scanner, roll doors, safety locks, and safety PLC. While this may sound like a lot of equipment and setup required, ABB eliminates the need for any on-site engineering. All equipment is routed and connected at the factory, so work cells arrive at facilities ready for operation. The common platform for the equipment also allows for easy relocation. FlexArc cells also feature a more simple power supply design, as only one power supply cable is needed with their centralized power distribution setup.
One of the biggest advantages of FlexArc systems is their software that requires minimum training. Operators can be up and running in no time, organizing welding applications into steps with these weld cells. FlexArc systems also provide valuable feedback to operators with their advanced monitoring to track productivity, cycle times, welds produced, and weld length. All FlexArc models come with virtual FlexArc software that creates a virtual replica of the weld cell. This allows for offline training and programming, which helps to keep operations moving since the cell can still operate a previous program while users create a different one for a new workpiece. Virtual FlexArc software also allows for tooling verification to ensure high quality welds are always achieved.
ABB’s FlexArc line offers a wide variety of models to choose from, with model selection varying based upon the positioner type. These systems are designed based upon a two station principle which allows for the loading and welding of workpieces simultaneously. FlexArc weld cells have a handling capacity range from 300 kg to 1000 kg. Some popular models include the FlexArc 250B, which allows for a single robot configuration. The FlexArc 500C allows for a one to two robot configuration. While the FlexArc 1000K allows for one or multiple robots and is one of the more robust models allowing for heavy part welding of up to 1000 kg. ABB offers pre-engineered work cells that can be used for a variety of welding applications including: laser welding, plasma welding, GMAW, and GTAW.
FlexArc weld cells can be found in a variety of industries as they are well suited for general fabrication. They are especially popular amongst the automotive industry in which they are used to weld wheels, axles, door modules, and engine cradles among many other vehicle components.