The FLACS RWS system is a large-scale remote system that
uses a mirror driven by two axes to very quickly position a
high-performance laser beam on a component. This allows metal components to be welded very precisely and quickly.
The RWS remote welding box is based on a completely new functional
structure with highly dynamic linear motors and direct drives for
diverting the mirror axis. The system is controlled via IRC 5, a world-
renowned ABB robotic control system.
This allows for very simple and functional programming. In addition, it
can be programmed right at the component manufacturer’s work-
place using RobotStudio, an offline programming system. This avoids
system downtimes, in turn providing enormous savings potential.
The bending mirror is designed in such a way that no warping
occurs during assembly, which means there is no disad-
vantage for the focus point. The mirror is controlled via two
direct drives, with a water-cooled design. This makes
them highly dynamic. Each axis is equipped with a brake.
The compact structure of the rotary drive for the mirrors allowed
us to make the exit window significantly smaller. This provides
better dust protection for the entire system. The beam exit window,
moving in sync with the mirror carriage, can be freely posi-
tioned anywhere within the work area. The remaining path is pro-
tected by metal slats against sparks and reflections from below.
The carrier structure was completely adjusted for the dynamics of the module. It
uses modular steel carriers filled with concrete polymer to ensure rigidity and
a high level of vibrational stability. One enormous advantage is that the structure
is completely detached from the rest of the cab.
The system is operated via an overriding PC control unit that is
already used for cutting components in our standard FLACS
system. This control unit is well-known by our customers world-
wide and has been proven in practice. The system can be
completely operated through this control unit, and it also allows
you to monitor the process.
ABB’s RobotStudio offline programming system allows the entire system to
be programmed offline. Section analyses, cycle time calculations and pro-
cess optimizations can be carried out this way. Naturally, the programs can
be transferred to the original system in order to complete the program-
ming quickly and easily. CAD data, such as STEP, IGES and CATIA data, can
be entered and processed directly.