Technology That Makes Industrial Robots Available To Everyone

About ABAGY

ABAGY operates in industrial robotics field and has created a software product that for the first time made use of robots economically attractive in high mix production such as individual and small series manufacturing.

TECHNOLOGY.

MARKET. INDUSTRIAL ROBOTS

0
per 10,000 workers
0%
market growth in 2019 (IFR)
0%
market growth annually 2020-2022 (IFR)

CORE TECHNOLOGY. PROBLEM WE SOLVE

LARGE SCALE PRODUCTION

Low product mix/High Volume
Example: Automotive

SMALL AND MEDIUM SCALE PRODUCTION

High product mix/Low Volume
Example: Steel bridge construction

Robots are NOT used in small/medium scale production because they:

  • Require zero tolerance to any deviations in the workpiece or its position
  • Must be re-programmed for each new item resulting in prohibitively high costs

ROBOTICS DEVELOPMENT.

TODAY TOMORROW
Not adaptable to deviations in production process Adaptable to deviations, no “zero point” required
High switch cost: programming and calibrating by user for new items No programming required
Complicated engineering integration Plug and play integration

Mass production:

HIGH VOLUME & LOW MIX

Small series and custom manufacturing:

HIGH MIX & LOW VOLUME

MARKET

MASS PRODUCTION
EFFECTIVE FOR HIGH VOLUME & LOW MIX

SMALL AND MEDIUM SCALE PRODUCTION

BATCH SIZE= 1 ITEM

EFFECTIVE CUSTOMIZED PRODUCTION

PRODUCT.

ABAGY IS A SOFTWARE SOLUTION THAT AUTOMATICALLY MANAGES ROBOTIC CELLS IN REAL TIME AND DO NOT REQUIRE SPECIAL USER`S COMPETENCE IN ROBOTICS

  • 1st solution that makes small series production with robots cost effective
  • 2-4 times cheaper than manual work

  • Unit economics work even with one Customer

STEEL STRUCTURE 12х2х0,7 m

Total welds 46,5 m

3,5 tons hard to fix in robotic cell

Assembled by worker = not ideal

Different products –high mix (small batches)

8000 pieces annually

ROBOTIC WELDING. PROGRAMMING REQUIRED

Online programming

  • 8 h programming
  • 3 h welding

Offline programming

  • 4 h programming
  • 3 h welding

ABAGY software

  • 1 х 10 min –tech chart for 3D model
  • 1 min programming
  • 3 hours welding

ABAGY TECHNOLOGY.

ABAGY OPERATING SYSTEM — cloud based software that automatically process 3D CAD models and production operation parameters into real-time and adoptive execution of production process by robotic
HOW TECHNOLOGY WORKS (ex. WELDING):
  • analysis of user 3D model and detection of joints
  • definition by the user parameters of welding process
  • simulation of theoretical production, based on exact robotic cell configuration
  • identification of a working piece in a working zone, conformity with initial 3D model
  • simulation of all production cycle based on exact piece, its orientation, exact robotic cell

USING ABAGY. STEP BY STEP

ANALYSIS OF USER 3D MODEL AND DETECTION OF JOINTS

DEFINITION BY THE USER PARAMETERS OF WELDING PROCESS

SIMULATION OF THEORETICAL PRODUCTION, BASED ON EXACT ROBOTIC CELL

IDENTIFICATION OF A WORKING PIECE IN A WORKING ZONE, CONFORMITY WITH INITIAL 3D MODEL

SIMULATION OF COMPLETE PRODUCTION CYCLE BASED ON EXACT PIECE, ITS ORIENTATION, EXACT ROBOTIC CELL

ABAGY OS HIGHLIGHTS.

  • Core of the system (ABAGY)
  • Different application features (YASKAWA)
  • Dynamic programming
  • Adaptability to any deviations

ABAGY TECHNOLOGY BENEFITS.

INTUITIVE USER INTERFACE
  • No manual programming (neither ONLINE or OFFLINE)
  • Only CAD model is required to start production
FAST AND CHEAP ROBOT ADOPTABILITY
  • Beneficial for high mix production
  • Flexible and adaptable (accepts deviation in working piece and its position), with real time correction
  • Works with major equipment brands
  • User defined cell configuration (including multiple robots, external axis etc.)

FINISH WELDING OF BIG METAL STRUCTURES.

Project Commissioning: September 2019

ROBOTIC CELL CONSIST OF:
Industrial robots – 2 units
Welding equipment – 2 units
Linear axes of movement
Machine vision(3D and 2D laser scanners)
ABAGY Software for robots management
  • Processing power ~200,000 linear meters of weld seam per year
  • Dimensions of welded structures: up to 18m x 3m x 1m
  • Products: beams, supports, connectors, girders and other large metalwork
  • Assembly is done manually, parts are assembled by tack welding. The robots perform finish welding
  • Parts which deviate from the template are allowed
  • Deviation tolerance is set by the enterprise production engineer
  • It is not necessary to fix the pieces in the work zone to specified zero-points. Pieces can be placed free-handedly
  • Operation is achieved with the help of ABAGY software

PAINTING OF FURNITURE ITEMS.

Project Commissioning: October 2018

ROBOTIC CELL CONSIST OF:
Industrial robot –1 unit
Painting equipment – 1 unit
Single axis positioner – 1 unit
Machine vision(3D and 2D laser scanners)
ABAGY Software for robots management
  • Total capacity ~220 000 m2 of surface per year
  • Products:any structure with dimensions up to 3m x 3m x 3m
  • Pieces can be placed free-handedly, there is no need to restrain them
  • Save up to 40% of paint usage compared to hand painting
  • Operation is achieved with the help of ABAGY software

DEMO-CENTERS.

ESAB

Gothenburg, Sweden

Blumenbecker

Prague, Czech republic

ABAGY

Moscow, Russia

MARKET.

MARKET STRUCTURE. ENTIRE ROBOTIC MARKET

COST OF ADOPTABILITY IMPLEMENTATION PER ITEM

MARKET. ROBOT PENETRATION IN INDUSTRY

NOW WITH ABAGY TECHNOLOGY
99 robots per 10,000 employees 1000 robots per 10,000 employees
Big companies with 500+ employees:
Mass production
Any size companies

Now robots require too much costly preparation before production itself so only mass producers can use them cost-effectively

VALUE. ~$40 billion

ABAGY reduces preparation tasks to zero making robots cost effective for almost every manufacturer

VALUE. ~$ 500 billion

CUSTOMERS.

CUSTOMER PROFILE

HIGH MIX, LOW VOLUME MANUFACTURER: HIGH VARIABILITY OF PRODUCTS

REQUIRED MINIMUM PRODUCTION VOLUME IS CURRENTLY MADE BY 5-10 WORKERS OR MORE

Customer benefits:

  • vast reduction in cost per item
  • Increased quality
  • extra production capacities at almost 0 costs

Ship Building

General Industry

Metal products

Yellow goods

And other industries…

END USER PRICE CALCULATION.

Manual welding
PRICE PER METER 7,8 EURO

Robotic welding with ABAGY (1-3 shifts)
PRICE PER METER 5,1 –2,2 EURO
ANNUAL SAVINGS 110 000 –690 000 EURO

COST EFFICIENCY FOR END CUSTOMER. WELDING EXAMPLE

INDICATORS MANUAL WORK ROBOTIC CELL ROBOTIC CELL
OPERATING TIME
Overall shift, hours 8 8 8
Total shifts 1 1 3
Working days per month 22 30 30
Seek Leave, holidays, etc 25 20 20
Overall working days, year 239 340 340
Overall working hours, year 1,912 2,720 8,160
ACTUAL OPERATING TIME
Arc time 15% 70% 70%
Actual welding time, hours/year 287 1,958 5,875
PRODUCTIVITY
Speed of welding, m/h 21 21 21
Total production, m/year 6,023 41,126 123,379
COSTS
Labourcosts, Euro per year 84,000 30,000 90,000
Equipment cost (with End User license price), Euro per year 5,000 179,260 179,260
Total costs involved, Euro 89,000 209,260 269,260
Cost of weld per m, Euro 7,8 5,1 2,2
Factor Robotic vs Manual (End User license) 1,5 3,6

KEY USER’S CHALLENGES.

WHILE AUTOMATING OF HIGH MIX/LOW VOLUME MANUFACTORY

  • Changing the mentality (use robots where they were not applicable before)
  • Pairing manual process with robotic in customer’ s workflow
  • Extracting technical knowledge from the people’s heads to formalize technological parameters
  • Lack of ability to calculate cost per operation (cost of ft of welding seam/sq ft of a painted surface)
  • Lack of robotic experience (same as computer usage experience in the old days) raises lots of questions on how to use/maintain new robotic set up which is production critical

WORKFLOW WITH THE CUSTOMER.

CRITERIA FOR INITIAL SEARCH

Industry segments: steel structure fabricators, machinery

Type of application: arc welding, painting or coating

Number of welders/painters: 30+

Type of production: high mix production
– either limited number of SKUs (items produced), but all preassembled by worker, therefore high adaptability required
– or high number of SKUs -50+

Robot experience: does not matter, we can take both and check their feedback on license if they already have robots and need adaptability

Decision making process: preferably the companies where the decisions can be made fast/we can talk with the decision maker as well (mid size companies)

CUSTOMER PROFILE

Yellow goods
Steel structures
Shipbuilding
General industry

INFORMATION FOR THE START

In order to provide a customer with a commercial proposal and economic efficiency calculations we need following information:

  • Description of production operation required (e.g. welding, cutting, coating, etc.), video preferably
  • Minimum and maximum dimensions of product, so that we could configure the robotic cell
  • 3D CAD models in .stp/.step format of several typical products (could be saved in this forma from any CAD program)
  • Technical drawings with production parameters data

  • Required production volume monthly / annually
  • Current costs and production time per chosen item / operation

1

Description of production operation required (e.g. welding, cutting, coating, etc.), video preferably

2

Minimum and maximum dimensions of most products

3D CAD models in .stp/.step format of several typical products

Required production volume monthly / annually

Based on provided information we define the configuration of robotic cell

3

Customer identifies 1-2 products for quotation and provides:

Technical drawings with production parameters data+ 3D CAD model

Production time per chosen item / operation required

Required costs of production if applicable

Based on 1-2 products we do the quotation:

Production time per item and annual capacity of the robotic cell

Cost of production with robot and estimation of manual work

Estimated savings with robotics