Frontline benefits from ABB’s robotic technology

Producing perfect aluminium welds and eliminating harmful dust during polishing operations has been achieved by the acquisition of a series of CSF (Complete Surface Finishing) robotic solutions at Frontline Australasia at its plant in outer south-east Melbourne.

The systems, designed, manufactured and installed by CSF Australia using ABB robots, have produced a series of important benefits for Frontline, by greatly improving the quality of the welded aluminium products while abolishing the dirty manual labour that was previously a by-product of the manufacturing process.

Turning to the relationship with ABB and CSF, Hooper described it as first class, with good technical backup and technical support, training, availability of spare parts and prompt service when the need arises, ensuring seamless operation of 20 hours a day, six days a week for the six ABB robots. The initial robot was purchased four years ago, with five additional units added over the last nine months.

Among these are a twin polishing robotic cell with two IRB 6640 robots, an aluminium robotic welding cell with one IRB 2400 robot and Fronius welding source, and a water jet robotic cutting cell with one IRB 4400 robot Foundry protected.

Apart from the welding processes, Frontline, supported by a $1.5 million grant from the federal government, has also developed a globally patented process for manufacturing titanium pipes to be price competitive with stainless steel pipes. This process can produce titanium pipes at a cost of about 25% of product currently available from existing technology.

The close cooperation between CSF and ABB was a very important element in providing the specialised technology that has provided the equipment to Frontline.

Frederick Kolak, director of CSF, described the development of the latest robotic applications as initially originating with the supply of robotic polishing cells. “Polishing represents a major production cost, and an area where robots can produce significant savings. This cooperation later evolved into the development of welding robots to handle the first mass-produced bull bar line.

“One of the challenges was to design the software that would successfully weld two separate aluminium alloys, requiring different temperature settings, and allowing round-the-clock production,” Kolak said.

Turning to robotics in general, Kolak said that designing and innovating new product applications is vital to keep work in Australia, as well as promoting export opportunities.

Kolak said there are opportunities for exporting to the Asian market, as our geographic location can provide short time lines of service, giving Australian-based companies a distinct advantage over European suppliers in this region. CSF is currently working on a range of innovative projects, adapting robots to surface finishing, with R&D and software development a vital component for optimum benefit to industry.

CSF provides extensive and ongoing post installation support and training as part of the service they provide. “We have been working with ABB for over three years now, and can only describe their quality and total support as a major factor that enables us to provide total solutions to our clients’ needs,” Kolak said.