VirtualArc 1.

0 Software Product Presentation

DS / January 2004

What is VirtualArc ?

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
DS/ January 2004

Short description of VirtualArc

Virtual Arc is a tool that combines:

ARC MODELING

Arc physics 2D wire-arc-work piece simulation tool

Experimental measurement and practical experience Bayesian neural network (self learning program)

WELD PROFILE MODELING

DS/ January 2004

Robotic Arc Welding Process

Anode Wire R Arc Power source Work Piece

System Parameters Cable Resistance Inductance Power Source Full Control of the complete system

DS/ January 2004

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/ January 2004

VirtualArc Technology - VirtualArc Software Tool

DS/ January 2004

VirtualArc Technology - VirtualArc Software Tool

DS/ January 2004

VirtualArc Technology - VirtualArc Software Tool

DS/ January 2004

VirtualArc Technology - VirtualArc Software Tool

DS/ January 2004

VirtualArc Technology - VirtualArc Software Tool

DS/ January 2004

VirtualArc Technology - VirtualArc Software Tool

DS/ January 2004

VirtualArc Technology - VirtualArc Software Tool

DS/ January 2004

VirtualArc Technology - VirtualArc Software Tool

DS/ January 2004

VirtualArc Technology - VirtualArc Software Tool

DS/ January 2004

VirtualArc Technology - VirtualArc Software Tool

DS/ January 2004

VirtualArc Technology - VirtualArc Software Tool

Predicted Weld Profile
Real Weld Profile

DS/ January 2004

VirtualArc Economy - VirtualArc Software Tool

DS/ January 2004

VirtualArc Economy - VirtualArc Software Tool

VirtualArc Software Pay-back

DS/ January 2004

Before using VirtualArc: Process mode: Shortarc Welding Speed: 13 mm/sec

After using VirtualArc: Process mode: Rapidarc Welding Speed: 30 mm/sec

VirtualArc Economy - VirtualArc Software Tool

VirtualArc Software Pay-back

In the same robot station

Rapidarc

Shortarc

Cost reduction:
DS/ January 2004

1.57 EUR/m 0.97 EUR/m = EUR 0.6/m

VirtualArc Economy - VirtualArc Software Tool

VirtualArc Software Pay-back

Productivity improvement:
Rapidarc / Shortarc

54.0 m/h 32.8 m/h = 21,2 m/h

Calculation example, at 85 % Utilisation in one AW Robot cell: 3500 h/year x 0.85 x 54.0 m/h =

= 160,650 m/year
DS/ January 2004

VirtualArc Economy - VirtualArc Software Tool

VirtualArc Software Pay-back

Savings:

Possible production:
160,650 m/year

EUR 0.6 /m

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 =
DS/ January 2004

= 63,070 m/year extra production !!

VirtualArc Documentation - VirtualArc Software Tool

DS/ January 2004

VirtualArc Documentation - VirtualArc Software Tool

Documentation: Welding Process Specification

DS/ January 2004

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/ January 2004

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.
DS/ January 2004

The result the virtual test is very precise and for Kim Hurup IWE,from Invacare EC-Hng, Denmark the most applications it can be used directly.