Alan Stapelberg, BIW Product Manager, 29/09/2012
GateFramer Flexible Framing System Š ABB Group May 8, 2013 | Slide 1
Framing
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”
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ABB’s “Framing” History
1996: ABB Preciflex more than 30 in production
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2000: ABB FlexFramer more than 40 in production
GateFramer A multiple car model framing machine
Š ABB Group May 8, 2013 | Slide 4
GateFramer Terminology
Framing Robots Gate Gate Sorter Storage unit for one gate Š ABB Group May 8, 2013 | Slide 5
Gate Setter
Flexibility in your production
Accommodates up to 6 car models Reuse of capital investment Allows easy introduction of new models
Fully random production Model change over does not affect on cycle time Allows production to be adjusted to suit market demand
Š ABB Group May 8, 2013 | Slide 6
Modular Design
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
Š ABB Group May 8, 2013 | Slide 7
Simple, faster and safer Programming 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. Š ABB Group May 8, 2013 | Slide 8
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
Š ABB Group May 8, 2013 | Slide 9
Alan Stapelberg, BIW Product Manager, 29/09/2012
GateFramer Technical Features Š ABB Group May 8, 2013 | Slide 10
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 (1)
Š ABB Group May 8, 2013 | Slide 11
Excluding tooling clamping and unclamping
Performance & Accuracy
Specifications
ABB GateFramer
Mechanical protection Electrical 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
Š ABB Group May 8, 2013 | Slide 12
Main Dimensions Example of 6 models 18000 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.
18270 mm
Š ABB Group May 8, 2013 | Slide 13
Main Dimensions Example of 4 models 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.
4330
Š ABB Group May 8, 2013 | Slide 14
1600
2100
3100
The framer does not require a pit. This results in a direct saving in time and money during the design and construction phased.
Robots in Framer Platform 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
4.2 m
Total = 14 robots
Š ABB Group May 8, 2013 | Slide 15
10 m
Š ABB Group May 8, 2013 | Slide 15
Robots in Framer Platform This allows for 77 spot welding points to be completed assuming 18 seconds of welding
5.5 m
(50% reach 6 spots, and 50% reach 5 spots).
13 m
Š ABB Group May 8, 2013 | Slide 16
Key Benefits Summary
Modular Design Flexibility Simply to use Easy maintenance Standardized Product IRC5 Controlled
Š ABB Group May 8, 2013 | Slide 17
Summary of Highlights
Performance: Geometrical accuracy and Stiffness Lightweight and Flexibility Commercial: Cost effective solutions with short delivery time: Single point of supply for Framing Station & Robots Delivery & support all over the world Cost of ownership Little or no maintenance. Small number of spare parts Lifetime of 1 million cycles + Qualified support & services close by Integration with ABB Products Portfolio Compatible with IRC5 robot controllers, reduced training of operators Robots on same track as Gate carriers: better accessibility thru the gate, no need for additional track motions Š ABB Group May 8, 2013 | Slide 18
Example
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Example
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Example
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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 Models 1 Model – No robots
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Multiple Models 1 Model – With Robots
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Multiple Models 1 Model – With Robots & Maintence Storage
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Multiple Models 2 Model – With Robots
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Multiple Models 3 Model – With Robots & No Sorter
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Multiple Models 3 Model – With Robots
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Multiple Models 4 Model – With Robots
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Multiple Models 5 Model – With Robots
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Multiple Models 6 Model – With Robots
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Multiple Models
Š ABB Group May 8, 2013 | Slide 33