OmniVance™ FlexArc® – robotic arc welding cells

Exceptional product quality, process reliability and manufacturing flexibility

Getting the highest possible welding efficiency requires equipment that offers highly productive operations at a reasonable cost. ABB’s modular, robotic arc welding cells offer the best combination of price and performance for custom-built welding.

ABB FlexArc® robotic welding cells are complete robot systems, available in several flexible, modular packages. Proven in applications worldwide, they offer an outstanding, versatile, flexible, cost-effective and easy to program system that offers the technology you need at the right price.

Achieving optimum productivity demands equipment that is both effective and cost-efficient. Modular, pre-engineered robot cells are the best way to meet these needs.

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Our portfolio

OmniVance™ FlexArc® Compact

ABB cells for laser welding and cutting

Arc welding solutions

Welding applications

Service

FlexArc RobotStudio Files

FlexArc Digitalization

Description	Rev.	Type	PDF 2D	RobotStudio Station	RobotStudio Library	RobotStudio Station 5.11
FlexArc 250K Single with IRB2400L	1	Station		sim
FlexArc 250R Single	1	Station		sim
FlexArc 250R Single	2	Station		sim
FlexArc 250R MultiMove	1	Station		sim
FlexArc 500C Single	1	Station		sim
FlexArc 500C MultiMove	1	Station		sim
FlexArc 500-750R Single	1	Station		sim
FlexArc 500-750R MultiMove	1	Station		sim
MigRob 500	0	Power Source			sim
Fronius TPS 4000	0	Power Source			sim
Fronius MTG 4000	0	Welding Torch			sim
Tregaskis ToughGun 500A 22	0	Welding Torch			sim
PKI 500 22	0	Welding Torch			sim
Fronius VR 1500	0	Wire Feeder			sim
Operator Panel	0	Cell Component			sim
RobotStudio 5.11 stations	0	Station	compl
Virtual FlexArc 250K D1000 L2500 Single Horizontal Curtain	0	Station				sim
Virtual FlexArc 250R D1000 L1600 Single	0	Station				sim
Virtual FlexArc 500C Single_5_11		Station				sim
Virtual FlexArc 500K D1200 L2500 Single IRB 2400L Horizontal Curtain	0	Station				sim
Virtual FlexArc 500K D1200 L3150 Single IRB 2400L Horizontal Curtain	0	Station				sim
Virtual FlexArc 500-750K D1000 L2500 MultiMove IRB1600	0	Station				sim
Virtual FlexArc 250R D1000 L1600 Single ac	0	Station				sim
Virtual FlexArc 500R D1200 L2000 MutliMove IRB1600 ac	0	Station				sim
Virtual FlexArc 500R D1200 L2000 MultiMove IRB1600	0	Station				sim
Virtual FlexArc 500R D1000 L2000 MultiMove IRB1600ID Rolldoor	0	Station				sim
Virtual FlexArc 500K D1000 L3150 Single IRB2400L	0	Station				sim
Virtual FlexArc 500-750R D1000 L2000 Single IRB 1600 ID	0	Station				sim
Virtual FlexArc 500K D1200 L2500 MultiMove IRB 2400L Horizontal Curtain ws	0	Station				sim

We decided to utilize many years of experience and knowledge of robotic workplaces and create a digital layer that can be integrated into any FlexArc robotic cell to allow maximum use of modern technology. If you want to have a detailed overview and control of your process, do not hesitate to contact our sales team.

We transform data into added value for our customers
Digital FlexArc aims to provide our customers with maximum optimization of the OEE (Overall Equipment Efficiency) parameter. In order to achieve this, we collect on-line data from all components of the FlexArc cell, so that we can interconnect the individual data and analyze them simultaneously within user-friendly applications and reports (dashboards). Individual applications focus on availability, performance and quality. Full traceability is an integral part of the whole solution providing the customer with a "black box" / birth certificate of each manufactured piece. These pieces of information also enable us to transform the whole quality process into a predictive one using advanced mathematical algorithms.

Manage your data
The entire solution is designed to be able to operate only within the customer's corporate network. This ensures the safety and speed of the entire solution. Depending on the needs and wishes of the customer the entire solution can be integrated into the customer's ecosystem in a very intuitive way and data sent to superior systems using standard communication protocols.

Arc welding components

FlexArc design overview

Workpiece Positioners

Robots

Controllers

SafeMove

Arc welding software

Design

The stations’ design helps to both shorten the process time for welding and reduce acquisition costs. FlexArc® welding cells are installed within a few hours. Emphasis was placed on minimal space requirements. Each option is equipped with one or two or three robots with the ABB MultiMove function, ABB positioners and welding equipment that is chosen by the customer. Everything is located on a common pallet, which makes for easy relocation within the production premises.

The cells are further equipped with a central power distribution, so that all components, such as the robots, positioners, the welding power source, lighting and other peripherals, are powered from one place, which results in only one power supply cable for the entire cell.

The entire cell undergoes tests during production, including a welding test. Thus, the customer receives a fully functional workplace that does not need to be reactivated during commissioning at the installation site.

Loading zone

The area for loading and unloading welded parts must meet strict requirements for the safety of operating personnel.

The choice between light curtain or rolldoor version of the loading zone affects the footprint of the workplace or the value of the cycle time.

Ligh curtain or rolldoor

A security element that ensures the presence of the operator in the loading zone. Vertical Light Curtains (VLC) can be combined with either Pre-reset button or Horizontal Light Curtain (HLC) or scanner. In a welding station equipped with rolldoors, either an HLC or a scanner is used to secure the loading zone.

Positioners

Positioners from the ABB range offer a simple and clear means of programming. They use the same drive systems and software as ABB robots and are optimized for handling workpieces during arc welding and other applications. All axes can be fully coordinated with the robot during programming and operation.

Offered positioners have a robust construction that ensures excellent stability and they are well protected for operation even in demanding operating conditions.

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Robots

Robots from the IRB 1600 and IRB 2600 series are used in FlexArc welding cells, including their ID variants. For applications requiring greater robot reach and work in a demanding environments, the welding station can be equipped with IRB 4600 robots with standard IP 67 protection or the Foundry Plus 2 option.

These models are ideal for applications requiring fast, repeatable and highly accurate movements between points or along a path.

More information

IRC5 Controller

The IRC5 gives our robots the ability to perform their tasks in a highly efficient manner. Based on advanced dynamic modelling, the IRC5 automatically optimizes the performance of the robot by reducing cycle times (QuickMove®) and providing precise path accuracy (TrueMove®).

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FlexArc in action

Katcon maximizes its operational efficiency & flexibility with FlexArc Robots

FlexArc welding cell

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