VirtualArc General Presentation 040209

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VirtualArc 1.0

Software Product

Presentation


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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 ImprovedQuality and Productivity

VirtualArc =


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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


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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


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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


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VirtualArc Technology - VirtualArc Software Tool


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Predicted Weld Profile


Real Weld Profile


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VirtualArc Economy - VirtualArc Software Tool


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VirtualArc Software Pay-back

Before using VirtualArc:

Process mode: Shortarc

Welding Speed: 13 mm/sec

After using VirtualArc:

Process mode: Rapidarc

Welding Speed: 30 mm/sec



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Cost reduction: 1.57 EUR/m 0.97 EUR/m = EUR 0.6/m


In the same robot station Rapidarc Shortarc



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Productivity improvement: 54.0 m/h 32.8 m/h = 21,2 m/h

= 160,650 m/year


Calculation example, at 85 %

Utilisation in one AW Robot cell:

3500 h/year x 0.85 x 54.0 m/h =

Rapidarc / Shortarc



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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 !!


Also giving: 3500 h/year x 0.85 x 21.2 m/h =

= 63,070 m/year extra production !!



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VirtualArc Documentation - VirtualArc Software Tool


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Documentation: Welding Process Specification

VirtualArc Documentation - VirtualArc Software Tool


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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


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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

themost a lications it can be used directl .

Kim Hurup IWE, Invacare EC-Hng, Denmark


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Documents

VirtualArc General Presentation 040209