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DS
/ Ja
nuar
y 20
04
VirtualArc 1.0Software Product
Presentation
DS
/ Jan
uary
200
4
What is VirtualArc® ?
Process Know-How Based SW Tool
to Help ABB Customers to Easily
Set-Up & Install Robotic Arc Welding
in Production with Highly Improved
Quality and Productivity
VirtualArc® =
DS
/ Jan
uary
200
4
Short description of VirtualArc®
Virtual Arc is a tool that combines:
Arc physics
2D wire-arc-work piece simulation tool
Experimental measurement and practical experience
Bayesian neural network (self learning program)
ARC MODELING
WELD PROFILE MODELING
DS
/ Jan
uary
200
4
Power source
RAnode Wire
Work Piece
Arc
L
System Parameters Cable Resistance Inductance Power Source
Full Control of the complete system
Robotic Arc Welding Process
DS
/ Jan
uary
200
4
What can you do with VirtualArc® ?
Off-line tuning of MIG/MAG welding parameters
Off-line prediction of weld shape & penetration
Off-line prediction of geometric weld quality
Off-line prediction of geometric welding defects
DS
/ Jan
uary
200
4
VirtualArc Technology - VirtualArc® Software Tool
DS
/ Jan
uary
200
4
VirtualArc Technology - VirtualArc® Software Tool
DS
/ Jan
uary
200
4
VirtualArc Technology - VirtualArc® Software Tool
DS
/ Jan
uary
200
4
VirtualArc Technology - VirtualArc® Software Tool
DS
/ Jan
uary
200
4
VirtualArc Technology - VirtualArc® Software Tool
DS
/ Jan
uary
200
4
VirtualArc Technology - VirtualArc® Software Tool
DS
/ Jan
uary
200
4
VirtualArc Technology - VirtualArc® Software Tool
DS
/ Jan
uary
200
4
VirtualArc Technology - VirtualArc® Software Tool
DS
/ Jan
uary
200
4
VirtualArc Technology - VirtualArc® Software Tool
DS
/ Jan
uary
200
4
VirtualArc Technology - VirtualArc® Software Tool
DS
/ Jan
uary
200
4
Predicted Weld Profile
VirtualArc Technology - VirtualArc® Software Tool
Real Weld Profile
DS
/ Jan
uary
200
4
VirtualArc Economy - VirtualArc® Software Tool
DS
/ Jan
uary
200
4
VirtualArc Software Pay-back
Before using VirtualArc:Process mode: ShortarcWelding Speed: 13 mm/sec
After using VirtualArc:Process mode: RapidarcWelding Speed: 30 mm/sec
VirtualArc Economy - VirtualArc® Software Tool
DS
/ Jan
uary
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4
Cost reduction: 1.57 EUR/m – 0.97 EUR/m = EUR 0.6/m
VirtualArc Economy - VirtualArc® Software Tool
In the same robot station Rapidarc Shortarc
VirtualArc Software Pay-back
DS
/ Jan
uary
200
4
Productivity improvement: 54.0 m/h – 32.8 m/h = 21,2 m/h
= 160,650 m/year
VirtualArc Economy - VirtualArc® Software Tool
Calculation example, at 85 %Utilisation in one AW Robot cell:
3500 h/year x 0.85 x 54.0 m/h =
Rapidarc / Shortarc
VirtualArc Software Pay-back
DS
/ Jan
uary
200
4
160,650 m/yearEUR 0.6 /m
Savings: Possible production:
Return On Investment:
EUR 0.6 /m x 160,650 m/year =
= 96,390 EUR / Year per robot station !!
VirtualArc Economy - VirtualArc® Software Tool
Also giving: 3500 h/year x 0.85 x 21.2 m/h =
= 63,070 m/year extra production !!
VirtualArc Software Pay-back
DS
/ Jan
uary
200
4
VirtualArc Documentation - VirtualArc® Software Tool
DS
/ Jan
uary
200
4
Documentation: Welding Process Specification
VirtualArc Documentation - VirtualArc® Software Tool
DS
/ Jan
uary
200
4
Benefits with VirtualArc® giving you cost savings
Daily process support in your factory
Shorter process implementation time
Optimised welding productivity
Optimised welding quality
Improved welding procedure documentation
DS
/ Jan
uary
200
4
From VirtualArc® Customer evaluation
“The major strength of this program is the easiness of performing and fine-tuning welding tests off-line. This means that testing time in the production is reduced to a very low level.”
“The first year of investment the program has paid itself back.” “Another noteworthy aspect is the easy use. Very quickly, you get familiar with the program.” “The result from the virtual test is very precise and for the most applications it can be used directly.”
Kim Hurup IWE, Invacare EC-Høng, Denmark