Your Success in Metal Fabrication

Robotics Solutions for the Metal Industries

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More than 30 years ago, ABB started developing and building robots. Today, we are still in the foreof innovation and a global leader in robot-based automation. Customers and system partners inmetal fabrication benefit from ABB’s unique combination of pioneering know-how and inventivedrive on a global scale.

■ The market sets new rules

The continuous globalization in metal fabrication

opens up new markets and opportunities – but it also

increases the competition and challenges the overall

efficiency of production processes. The ability to

adapt to the global market’s new rules and faster pace

is the most crucial factor to any company’s success

within this business.

With the experience of an installed base of more than

120,000 robots and a profound knowledge of the

metal industry, its markets and changing demands,

ABB can provide the right solutions, keeping our

customers and partners always one step ahead of

their competitors.

■ Safeguard your future

Flexibility is the key to cope with shorter product

cycles, the need for higher productivity and the ability

to quickly react to the changing requirements of

markets and customers. ABB’s robot-based solutions

are adaptable to future demands and ensure sound

investments in automation technology. With fresh

ideas and innovative solutions like the new modular

IRC5 robot controller, ABB continues to expand the

possibilities of robot technology even further.

■ Choose a global leader

Sometimes good is just not good enough. ABB pro-

vides its customers and system partners with a highly

competitive robot range and the service, support and

expertise only a global leader can offer. Wherever

your business may take you and whatever you choose

to do – ABB will always be at your side. ABB’s sup-

port is something you can count on. Anywhere and

anytime.

P u t Yo u r Tr u s t i n t o a C o m p e t e n t P a r t n e r

■ Use the complete offer

As a global leader in automation technology, ABB

offers far more than state-of-the-art robots for all

applications, ranging from cutting and joining up to

surface treatment and material handling. Together

with highly specialized partners, ABB can offer turn-

key solutions for almost any task in metal fabrication.

■ Benefit from our process know-how

Every process and each application has its own

requirements. Finding the right, customized solution

based on standardized products to guarantee a

maximum of availability and productivity requires

a profound know-how of all processes involved.

Based on 30 years of experience and backed-up by a

complete service offer, ABB can provide the metal

industry with tailor-made concepts and installations

for applications along the entire value-added chain.

■ Always at your service

ABB’s robots and solutions are backed-up by a

complete range of value-adding services. They are

available through our global network of sales and

service centers providing support and technical

assistance to ABB customers on all continents. Global

service agreements ranging from the supply of spare

parts, training and maintenance to full service pack-

ages are readily available. ABB can help you with

dedicated Value Based Productivity Solutions to

increase productivity while still saving money. By

providing technical and logistical support through

help desks and the Internet, we are always close at

hand.

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M e t a l F a b

The applications involved in metal fabrication are highly complex and sophisticated. ABB has the system-competence to offer turn-key solutions. Our strong partners andtechnology leaders provide specialized process and application know-how in areas asdiverse as laser cutting, arc welding, sealing and many more. In this way, ABB can offerthe right solutions to control processes and thereby enhance quality, productivity andflexibility in your production.

G e t t i n g t h e P r o d u c t i o n U n d e r C o n t r o l

IRB 2400 cutting metal components.

■ Cutting· oxy cutting

· plasma cutting

· laser cutting

· mechanical cutting

■ Joining· arc welding

· laser welding

· plasma welding

· poke welding

· spot welding

· stud welding

· brazing

· clinching

· hemming

· gluing

Arc welding with two IRB 1400 on positioner IRBP 250R.

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Six IRB 5400 are painting drivingcabs in fully automatic mode.

■ Forming· press tending

· press brake

tending

· tube bending

■ Surface treatment/surface finishing· deburring/grinding/cleaning

· plasma coating

· polishing/finishing

· enameling

· painting

· sealing

■ Inspection/measuring

- final parts inspection

- inline measuring

■ Material handling· holding and manipulating workpieces

while processing

· material handling between operations

- loading/unloading of fixtures and workpieces

- transfer of work pieces between stations and

machines

· stacking/de-stacking

· picking

· palletizing/de-palletizing

· CNC machine tending

IRB 6400R handling roller bearings while processing.

Two IRB 140 robots equipped withmeasuring systems contribute toprocess safety while producing crossbars.r i c a t i o n

Six IRB 6400R in a press line provide for a cost-effective production of sheet metalcomponents for the automotive industry.

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Only flexible and efficient production processes can guarantee the profitability in today’scompetitive environment. ABB provides its customers with the best products to handle and the right tools to analyse and fine-tune any robot-based process in metalfabrication to obtain the best possible results.

■ Robots: Fit for any Challenge or Environment

Floor mounted, wall mounted or suspended from the

roof, ABB robots can handle payloads of up to 500 kg

with ease and precision. Whatever the application and

no matter how hostile the environment: ABB has the

robots to cover the whole spectrum of processes

within metal fabrication. In more than 120,000 installa-

tions all over the world, they are continuously proving

their skills and are setting the standards for perfor-

mance, reliability and speed.

■ IRC5: Modularly to Success

IRC5 is ABB’s fifth generation robot controller. It

sets the new standard with its modular concept, a

completely new ergonomically designed portable

programming-unit called FlexPendant and fully

synchronous multiple control of up to four robots

through its MultiMove function. The modularity of

the IRC5 is a major step forward in robot control

turning every system into a cost-efficient investment,

designed to match the exact needs of the user while

being easily expandable to meet future demands.

■ Software: Intelligent Support

A wide range of controller-based and PC-based soft-

ware products support all ABB-robot applications.

Powerful tools like RobotStudio, a software for true

offline-programming and simulation, improve the

overall system efficiency. ABB is the world leader

in robotics software and the only supplier with a

virtual controller for identical motion control offline

as online. Based on our process know-how, we

are continuously developing process-software for

specific applications, displaying entire processes

and providing easy access to improved production

and performance.

A B B ’s P r o d u c t s H a v e G o t W h a t I t T a k e s

MultiMove function

FlexPendant Positioner

Virtual Arc softwareRobotStudio simulation

www.abb.com/robotics

Over the last three decades, ABBhas remained committed to build-ing and strengthening relationshipswith customers, integrators andpartners throughout the world.Underpinning this commitment isour belief that at the heart of inno-vative robotics lie mutual trust andconfidence.This belief has helped us to achieveclear leadership in a demandingfield.Today, in the automotive, metalfabrication, foundry and plasticsindustries, our solutions help to pave the way for optimisedproduction. Across the world, our global network of salesand service centres, and our carefully selected partners,make ABB products, systems and services available wher-ever they are needed.

Welcome to ABB –

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