The Challenge
ABB Smart Power needed a new production line to produce its next-generation switchgear range. It also needed a flexible, future-proof solution that is durable enough to protect ABB’s investment for the anticipated 25-year life of the new production line.
The Solution
System integrator JOT Automation has delivered the first 16 of a total of 19 cells for an automated assembly line. Featuring a mix of 20 ABB industrial robots, small and medium SCARA robots, and software, the cells can be readily adapted by either JOT Automation or the end user to meet changing needs. A further three-cells will be operational within months.
The Application
The first section of the line began full production in early 2024 to support low volume, high diversity production requirements and makes eight different models of switchgear in the same production line without changing tools.
ABB Smart Power’s factory in Vaasa, Finland needed an assembly line tailored for its updated range of energy-efficient switchgear products, as well as for enabling new, automated ways of working. The life cycle of the new line is estimated at 25 years, so long-term reliability and the availability of ongoing expert support and service from ABB Robotics were a top priority.
The manufacturer had previously used system integrator JOT Automation to provide another line at the Vaasa site and was keen to work with them again. JOT Automation is a system integration partner for ABB Robotics, so its automation solutions often rely heavily on ABB’s fast, compact six-axis industrial robots to enhance the efficiency and flexibility for automation solutions.
The assembly line was delivered in two parts. The first section produces larger frame sizes. JOT Automation carried out the mechanical and electrical design work offsite, before beginning work at the Vaasa factory.
The large-size assembly line produces eight different types of switches. "The challenge was how to design a solution that could efficiently assemble different products without changing any tools," said Juntunen.
The production cells feature a mix of ABB industrial robots including 10 IRB 1200 robots for scanning and assembly, an IRB 1600 and IRB 2600 for loading and unloading and an IRB 910SC SCARA robot, also used for handling assembly tasks. The robots come complete with control software that enables them to handle all the product variants by adjusting their programming, rather than swapping out the tooling.
"Stability is crucial to electronics manufacturing, so it was essential that every part of the assembly line could work together smoothly, especially given the number of cells and the complexity of the project,” said Juntunen. “The quality and reliability of ABB’s robots and software technology plus the choice of different sized industrial and SCARA robots helps to meet this need by ensuring a steady and consistent automation solution for the production of the switches.”
The initial installation took place in late 2023, with JOT’s engineers on site to fine tune operations in preparation for full production to begin in spring 2024. To ensure the automated cells would work properly once installed, virtual models were first built in ABB’s RobotStudio® offline programming tool, enabling engineers to carry out full testing without disrupting the physical production line.
Once the first section was complete, JOT Automation moved onto the second, faster section of the line, which produces the smaller frame sizes in the ABB Smart Power range. At the time of writing, this section was expected to begin production by the end of the year.
"The milestones are good because we now have a lot of important lessons learned for the next phase to improve upon," says Tomi Kyllönen, Global Account Manager at JOT Automation.
"JOT Automation's great technical expertise made for an outstanding solution," confirms Jani Keränen, Production Manager at ABB Smart Power. "When the smaller frame size line is completed, we will have a full product variation and portfolio for sales and manufacturing."
Both parties are pleased with the results of the collaboration. "We have grown together with the project," says JOT Automation's Kyllönen. "The customer relationship and cooperation with ABB Smart Power has been outstanding because we are driven by a common goal."
About JOT Automation
JOT Automation provides world-leading production automation and testing solutions for automotive, telecom, renewable energy, consumer and power electronics industries. JOT Automation’s high-performance products and custom automation solutions help customers increase productivity and improve cost efficiency. For more information about JOT Automation, please visit JOT Automation website.
