Simplification was the top requirement of ABB. Festo utilised its MS series of flexible service units to offer a single module for all robot types, providing a complete, ready-to-install solution that offered perfect paint finishes and safe working in potentially hazardous conditions.
Previously, the ABB paint spraying robots had been characterised by wide ranging pneumatic customisation. ABB had to configure the compressed air preparation systems on a customer-specific basis from numerous individual components sourced from different manufacturers, assemble the service units on mounting plates and connect the tubing components. This was costly in terms of time and administration work.
Festo has supplied a flexible, simple, compressed air supply solution to ABB, for paint spraying robots on the production line
The manufacturer resolved to set new standards with the start of production of a new generation of robots with optimised compressed-air supplies.
"The objective of the changeover was for us to buy this as a complete ready-to-use solution suitable for use with all our robot models, with few exceptions, and thus simplify our engineering, installation and maintenance processes," says Kenneth Mikalsen, process engineer, ABB Research and Development department.
ABB found support for its objectives with Festo Norway which was commissioned to develop an optimum solution for the compressed air preparation modules of the robots.
The Festo project engineers were provided with an initial sketch and a list of the most important technical data, such as the maximum possible weight and the desired size of the service unit. Working with ABB, Festo created a ready-to-install module which could be fitted directly to the vertical robot arm. At the heart of this service unit are five block-mountable pressure regulators from the MS4 series.
One compressed air module supplied as a complete ready-to-install solution is suitable for all robot types
The deciding factors in the selection of the MS series by ABB included flexibility and compact design of the MS modules. Despite their low weight, the modules offer an impressive performance density ratio and do not impair the freedom of movement of the robot arm. The pressure gauges integrated into the pressure regulators are practical and space-saving.
Together with the modules from the MS series, the ready-to-install system unites the functions of the previous 40 or so components in a single housing. Assembly is carried out by Festo, which supplies the robot manufacturer with a fully-assembled and tested solution. ABB then need only mount the compressed air supply unit to the vertical arm of its painting robots, and the system is ready to go. If malfunctions occur at a later date, the module and its integrated supply manifold can be replaced quickly and easily, leaving the tubing connections in place. By changing over to this ready-to-install solution, ABB has managed to reduce the required production time for its paint spraying robots and their subsequent maintenance costs considerably.
ABB is also able to save time and money in other areas along the value-creation chain.
"Our purchasing department only needs to manage one part number to order a complete air supply for the robots. This makes stock control easier. For our sales people, the laborious business of writing specifications for endless customer-specific solutions is a thing of the past. Quality control is now required only on a random sample basis, the number of spare parts we need to keep in stock is smaller, and our documentation has become simpler thanks to the ready-to-install system," concludes Mikalsen.
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