Number 1
1964 - 67
© ABB Group July 3, 2012 | Slide 4
1985
3D off-line
TRACS system
1985
1989
IPS
Electrical - C5
1988
2000
2008
Next level…
Process arm
Small painter
300 200
100 0
thickness (µm) -100 -200 -300 -400 -500 0 2 4 6 8 10 12 14 16 x(mm)
500 400
300 200
100 0
thickness (µm) -100 -200 -300 -400 -500 0 2 4 6 8 10 12 14 16 x(mm)
Confidential © ABB Group Group Function Corporate Communications January 2009 | Slide 5
Original Concept
▪StayOn
▪High acceleration robot
▪Acceleration compliant Atomizer
▪Paint Flow Rate Range
▪① Current/Normal ▪② Current max. ▪③ HF Range
Original Concept
▪StayOn
▪High acceleration robot
▪Acceleration compliant Atomizer
▪NoPatch
KangQiao Facility Inaugurated May 12th, 2009 100,000 Sqaure Meters Over 1,100 Employees Robotics China
Engineering – PTA/PAS/BIW/RA/PPA Customer Service Robot Production
Reduction of number of Atomizer / Robot
▪1
▪2
▪3
▪6
▪5 ▪4
of At▪o3mizer ▪2
▪ Num▪1ber ▪0
▪Number of robots ▪Theoretical limit
▪ 300 ▪ 400 ▪ 500 ▪ 600 ▪ 700 ▪ 800 ▪ 900 ▪ 1000▪ 1100▪ 1200 ▪Flow rate per Atomizer (cc/min)
100 140 180 220 260 300 340 380 420 460 500
Po i nt ( m m )
▪Ex small
▪Small
▪Large
Performance Data – Variable Pattern
▪Pattern control coating method
▪Bell cup ： φ40mm ▪ SA ring ： PC SA ring
▪NoPatch
▪Very large work envelope robot
▪6 ▪5 ▪4 ▪3 ▪2 ▪1 ▪0
▪ 30▪ 040▪ 050▪060▪ 070▪ 080▪ 090▪010▪ 0101▪ 010200
▪High flow
▪High paint flow rate ▪Fast color change
500 400
300 200
100 0
thickness (µm) -100 -200 -300 -400 -500 0 2 4 6 8 10 12 14 16 x(mm)
500 400
300 200
100 0
thickness (µm) -100 -200 -300 -400 -500 0 2 4 6 8 10 12 14 16 x(mm)
StayOn
▪ Reduce Cycle Time ▪ Reduce Over Spray ▪ Reduce Paint Consumption
StayOn is a robot programming method that keeps the atomizer on the area to be painted, thus reducing the overspray and
▪Pattern Control Bell
Customer Benefits Highlight
▪1. Higher Paint flow capability
▪Reduce number of Atomizer ▪/ Robot
▪Lower investment & operational cost
500 450 400 350 300 250 patt2e0rn0 width sb50 (mm) 150 100
0
100 200 300 400 500 600 700 800
shaping air outside (Nl/min)
▪CONDITIONS ▪Paint Flow Rate
▪Rotation Speed ▪SA inside ▪TCP Speed ▪Motion ▪Number of Path ▪Bell cup ▪Paint
▪Φ70mm Pattern control coating method
▪Ex small
Pattern size：220mm ▪ E-40ö70Al(35)
80 60
40
20 Film thickness(ìm)
0
60 20 20 60
500 460 420 380 340 300 260 220 180 140 100
Product Development
▪Large work envelope ▪High acceleration ▪IRB 5500 Robot ▪RB1000 Atomizer ▪High Flow Rate
IRIRBB55505000Robot – RB 1000 CBS Atomizer
800ml/min
50,000rpm 500Nl/min 900mm/sec Left-Right, Right-Left 1 70 mm Titanium WB Primer (36%wt)
PVerafroiarmblaenPceatDteartna – Variable Pattern
Performance Data – Variable Pattern
IRB 5500 Versus IRB 5400
Velocity Acceleration
IRB 5400 150 deg/sec 14 m/s²
NoPatch requires robots with large work envelope
NoPatch & StayOn Painting Method
NoPatch & StayOn Painting Method
Atomizer Quantity Versus Paint Flow Rate
RB1000 Atomizer
▪ Variable spray pattern ▪ Solvent & Water borne ▪ Cartridge or feed line
Performance Data – Pattern Size
Spray Pattern Control
500 400
P o i n t ( m 10m0 ) 140 180 220 260 300 340 380 420 460 500
▪Pattern size：520mm L-37 ö70Al (35)
80
60 40
Film20thick
500 460 420 380 340 300 260 220 180 140 100
Process integration
2010
S4
1997
New exterior concept
2006
The Challenge of Today’s Paint Line Design
Reduce footprint Reduce paint consumption Reduce energy consumption Reduce impact on environment
Maxwell Zhou, Jun, 2012
Flexible Application Concepts with ABB Robots ABB机器人带来的柔性化解决方案
© ABB Group July 3, 2012 | Slide 1
ABB ShangHai KangQiao Facility Snapshot
▪Ex small
▪Pattern size：60mm ▪Small
▪Pattern size：150mm ▪Large
▪Pattern size： 300mm
▪Ex small ▪Large
▪Small
Performance Data – Variable Pattern
▪Current RoboBel
NoPatch
• NoPatch is a robot programming method that eliminates the “patchwork” required when panels are painted with multiple robots.
NoPatch - Painting Method
▪Very large work envelope robot