ABB Robotics in Rail Application

© ABB Group September 21, 2010 | Slide 1

ABB robot applications in RailImproving productivity, quality & workplace safety

InnoTrans 2010

Railway industries Overview

Industries served

� Rolling stock manufacturing

� Rolling stock maintenance and inspection

� Fixed Infrastructure parts manufacturing

Customer needs

� Shortage of skilled workers / rising cost of labor

� Need for consistent high quality

Flexibility in responding to production demands


� Flexibility in responding to production demands

� Improvements in uptime and productivity

� Health & safety improvements

� Utilization of high cost machinery

ABB’s Offer

� Robots & selected application equipment

� Easy to use operator interfaces

� Vision guidance systems

� Modular manufacturing cells and engineered systems

� Simulation & offline programming software

� Service agreements & productivity improvements

Over 100 ABB robots installed in Railway Industries

� Arc Welding

� Press Tending

� Materials Handling

� Painting


� Painting

� Cleaning and Washing

� Inspection and Maintenance

Railway Industries - Arc Welding Applications

� Wagon and Chassis

� Side Plates

� Boggies

� Trackside Enclosures


� Trackside Enclosures

� Seats

Welding extremly large structures


Arc welding of Boggies


8 systems supplied. Each with:

� Robot and process equipment

� 10,000 kg workpiece positioner

� Complete welding package

Large, flexible arc welding system for Rail Car applications


� Complete welding package

� Seam tracking with adaptive volume

� Tool changer

� Robotic holding fixtures

� Fume filtration and extraction

Robot welding systems for Railway IndustriesCustomized solutions tailored to your needs


Multi robot systems Laser hybrid welding

Main beam welding

Example: Wagon Chassis Welding

Country: Australia

Customer: United Group

Partner: Mars

Main Benefits

1: Reduced labour cost


1: Reduced labour cost

2: Increased production output

3: Improved access and safety

Critical Success Factors

1: Seam tracking & searching

2: High weld deposition rates

3: Offline programming & simulation

Example: Arc Welding of Side Plates

Country: UK

Customer: Confidential

Process: Twin wire arc welding

Main Benefits

1: Reduced labour in manual process


1: Reduced labour in manual process

2: Increased flexibility

3: Improved & consistent quality

Critical Success Factors

1: Offline programming & simulation

2: Twin wire welding

3: Seam tracking and searching

Railway Industries – Paint applications

� Consistent high painting quality

� Minimum tolerances in film thickness

� Minimum overspray and waste


� Minimum repair work

� Increased productivity

� Improved working conditions

SNCF, FranceExample: Carriage painting for SNCF France


Example: Carriage painting for Alstom in Spain


Example: Carriage painting in Wuhan, China


Wuhan Maintenance Base

Cleaning applicationsExtending the working life of Rolling Stock


Press Tending applications


ABB Robotics in Rail Application

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