DS / January 2004 VirtualArc 1.0 Software Product Presentation

DS/ January 2004 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 Improved Quality and Productivity VirtualArc ® =

DS/ January 2004 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

DS/ January 2004 Power source R Anode Wire Work Piece Arc L System Parameters Cable Resistance Inductance Power Source Full Control of the complete system Robotic Arc Welding Process

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 Predicted Weld Profile VirtualArc Technology - VirtualArc® Software Tool Real Weld Profile

DS/ January 2004 VirtualArc Economy - VirtualArc® Software Tool

DS/ January 2004 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 VirtualArc Economy - VirtualArc® Software Tool

DS/ January 2004 Cost reduction:1.57 EUR/m – 0.97 EUR/m = EUR 0.6/m VirtualArc Economy - VirtualArc® Software Tool In the same robot stationRapidarc Shortarc VirtualArc Software Pay-back

DS/ January 2004 Productivity improvement:54.0 m/h – 32.8 m/h = 21,2 m/h = 160,650 m/year VirtualArc Economy - VirtualArc® Software Tool Calculation example, at 85 % Utilisation in one AW Robot cell: 3500 h/year x 0.85 x 54.0 m/h = Rapidarc / Shortarc VirtualArc Software Pay-back

DS/ January ,650 m/year EUR 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 !! VirtualArc Economy - VirtualArc® Software Tool Also giving: 3500 h/year x 0.85 x 21.2 m/h = = 63,070 m/year extra production !! VirtualArc Software Pay-back

DS/ January 2004 VirtualArc Documentation - VirtualArc® Software Tool

DS/ January 2004 Documentation: Welding Process Specification VirtualArc Documentation - VirtualArc® Software Tool

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