Alan Stapelberg, BIW Product Manager, 29/09/2012 ...€¦ · Framing the stage in the BIW assembly...
Transcript of Alan Stapelberg, BIW Product Manager, 29/09/2012 ...€¦ · Framing the stage in the BIW assembly...
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GateFramerFlexible Framing System
Alan Stapelberg, BIW Product Manager, 29/09/2012
© ABB Group May 8, 2013 | Slide 1
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Framing the stage in the BIW assembly process where the geometry of the shell of the car body is welded together.
It is the critical stage in the production, as the integrity of the complete car body assembly is secured during this stage.
This is normally performed in a “framing machine”
Framing
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ABB’s “Framing” History
© ABB Group May 8, 2013 | Slide 3
1996: ABB Preciflexmore than 30 in production
2000: ABB FlexFramermore than 40 in production
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GateFramerA multiple car model framing machine
© ABB Group May 8, 2013 | Slide 4
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GateFramerTerminology
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Gate Sorter
Storage unit for one gate Gate Setter
Framing Robots
Gate
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Accommodates up to 6 car modelsReuse of capital investment Allows easy introduction of new models
Fully random productionModel change over does not affect on cycle timeAllows production to be adjusted to suit market demand
Flexibility in your production
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New models can be added at any time without modification to the existing installation
With / without welding robots
Allows progressive investment as future models are launched
Modular Design
© ABB Group May 8, 2013 | Slide 7
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Simple, faster and saferProgramming and Control
Controlled by the proven IRC5 controller
Fast startup : No additional trail-out of motion normally required with custom designed machines
Programmed like a robot : No additional training required
Coordinated motion from robot controller removes complexity in the programming of interlocks between moving parts
Complete machine acts as a “state machine” making it easier to diagnose errors, debug, add models and recover from unplanned stoppages.
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Standardized and easy to maintain
No or few maintenance
Small number of spare parts
Lifetime of 1 Million cycles +
Qualified nearby support & services: mechanic, electric, welding
Complete documentation for installation, maintenance and operation
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© ABB Group May 8, 2013 | Slide 10
GateFramerTechnical Features
Alan Stapelberg, BIW Product Manager, 29/09/2012
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Performance & Accuracy
Specifications ABB GateFramer
Strokes (mm) 3000 maxi
Repeatability (mm) +/- 0.1
Max Tooling weight (Gate) (kg) 3000 kg
Max Speed (mm/s) 1.1 m/s for setters – 2.1 m/s for storages
Cycle time (sec) 18 seconds total gate change (in fully random mode) (1)
Stiffness (daN/mm) / Flexibility (mm/daN) S =1 00 daN/mm / F = 0.01 mm/daN
Max Static Force (daN) in Y 300 daN for each side
Lifetime 1 million + cycles
Flexibility (car models) Up to 6
Dimensions (LxWxH) (mm) 18000 x 18270
Number of robots in the Framer 14
© ABB Group May 8, 2013 | Slide 11
(1) Excluding tooling clamping and unclamping
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Performance & Accuracy
Specifications ABB GateFramer
Mechanical protectionElectrical protection
IP54 IP65
Sensors Motor resolvers + Cam sensors + Gate position error sensors + RFID (gate identification)
Linear Ball bearing Free-lub Rollers
Electrical equipment ABB IRC5 robot controller
© ABB Group May 8, 2013 | Slide 12
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18000 mm
18270 mm
The framer takes only 80% of the floor space of similar solutions.
The stations before and after the framer can still be used for re-spot stations.
Main DimensionsExample of 6 models
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The working height for the car body is low to the ground at only 1m. The result is the whole transfer line can be lower, saving cost in risers to raise up the robots on the re-spot stations.
The framer does not require a pit. This results in a direct saving in time and money during the design and construction phased.
Main DimensionsExample of 4 models
© ABB Group May 8, 2013 | Slide 14
2100
3100
4330 1600
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Robots in FramerPlatform
Integrated 4 robots inside the GateFramer
Possible to have 4 more robots mounted on tracks on the floor
Additional 6 shelf mounted robots on overhead platform
Total = 14 robots
© ABB Group May 8, 2013 | Slide 15
© ABB Group May 8, 2013 | Slide 15
10 m
4.2
m
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Robots in FramerPlatform
© ABB Group May 8, 2013 | Slide 16
13 m
5.5 m
This allows for 77 spot welding points to be completed assuming 18 seconds of welding
(50% reach 6 spots, and 50% reach 5 spots).
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Key Benefits Summary
Modular DesignFlexibilitySimply to useEasy maintenanceStandardized ProductIRC5 Controlled
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Summary of Highlights
Performance:Geometrical accuracy and StiffnessLightweight and Flexibility
Commercial: Cost effective solutions with short delivery time:Single point of supply for Framing Station & RobotsDelivery & support all over the world
Cost of ownershipLittle or no maintenance. Small number of spare partsLifetime of 1 million cycles +Qualified support & services close by
Integration with ABB Products PortfolioCompatible with IRC5 robot controllers, reduced training of operatorsRobots on same track as Gate carriers: better accessibility thru the gate, no need for additional track motions
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Example
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Example
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Example
© ABB Group May 8, 2013 | Slide 21
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Reference List
Ford CFMA - China – 4 Models
BAIC - China– 4 Models
FORD OTOSAN - Turkey – 2 Models
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Multiple Models1 Model – No robots
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Multiple Models1 Model – With Robots
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Multiple Models1 Model – With Robots & Maintence Storage
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Multiple Models2 Model – With Robots
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Multiple Models3 Model – With Robots & No Sorter
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Multiple Models3 Model – With Robots
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Multiple Models4 Model – With Robots
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Multiple Models5 Model – With Robots
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Multiple Models6 Model – With Robots
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Multiple Models
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