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ARCWORLD

FABWORLD

ROBOTIC WELDING
SOLUTIONS
YASKAWA MOTOMAN
HAS A WELDING

SOLUTION FOR ALL


INDUSTRIES AND A
COMPREHENSIVE
SUPPORT NETWORK
THAT EXTENDS
WORLDWIDE

WORLD SOLUTION = PRE-ENGINEERED, STANDARDIZED WORKCELL

Reduced Cost and Risk n Improved Quality and Documentation n Reduced Delivery Time n Single-Source Support and Warranty for Workcell
n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n

Since their introduction in 1990, our ArcWorld solutions have been continuously improved and expanded to not only a myriad of arc welding
solutions, but also to most other robotic processes. The robot(s), welding equipment, part positioner and workcell safeguarding are all
fully integrated and designed to work together. Yaskawa Motoman now offers the widest product line of standard arc welding workcell
configurations in the robot industry, providing the best fit for your specific needs.

ArcWorld and ArcWorld C


Mid-range workcells
Low- to medium-volume fabrication
Automotive applications

AW1000

AW6000

AWC-52

AWC-500

n Roll-up doors allow for reduced floorspace


n Cells accommodate one or two robots

ArcWorld II
AWII-52

Economical workcells
Low-volume; high-mix
Job shop applications

AWII-100

n Most cells accommodate a single robot


n Fence and positioners lagged to the floor
n Equipment bases optional

AWII-500

AWII-6000

Wide range of ArcWorld and FabWorld solutions provides


Frame
Chassis
Body

Big 5 Auto

Interior
Exhaust

1st Tier
ArcWorld III ArcWorld IV ArcWorld V
ArcWorld C QR4C/TR3C/DR2C
Trunnion Positioners

Suspension

2nd Tier

Implements

Skid Steers
Backhoes

Agricultural Equipment
ArcWorld ArcWorld III FabWorld FabWorld II
ComArc MH-Series Positioners DR2C

Light and
FabWorld MA3100
MotoRail

n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n

ArcWorld III and ArcWorld IV


Higher-performance workcells
Higher-volume fabrication
Automotive and construction applications

AWIII-1200

AWIV-4200

AWIV-6200SL

AWIV-6300XHD

n High-end positioner performance/payload


n Multi-axis positioners (AWIV-series)
n Cells can accommodate one to four robots

ArcWorld V

Reduced footprint workcells


High-volume fabrication
Automotive Tier 1 applications
n Overhead robot mounting reduces floorspace (up to 40%);

AWV-1200

simplifies automatic unloading of parts


n Cells accommodate one to four robots

AWV-6300

FabWorld and FabWorld II


Larger workcells
Low- to medium-volume; high-mix
Large, heavy weldments

FW, MA3100

FW-DRC

n Two large load/unload stations


n Open floor and overhead access for part loading

by forklift or crane

n Heavy-duty positioners with payloads up to 6,000 kg

FWII

advanced fabrication capabilities at an attractive ROI


Truck
Trailers

Bulldozers
Manlifts

Heavy Construction
Drop Center Positioners Multi-layer
MotoSweep ComArc

Rail

Store
Fixtures
ATV

Heavy Transportation

Food
Equipment

General Fabrication

ArcWorld ArcWorld II FabWorld II


MH-Series Positioners MotoRail MotoSweep ComArc

Electrical
Enclosures

Manufacturing
Products

Job Shop
ArcWorld ArcWorld II ArcWorld III
FabWorld II ComArc
Turntable Positioners

WIDEST RANGE OF WORKCELL POSITIONERS IN THE INDUSTRY

Guarded Tables n Turntables n Headstock/Tailstocks n Trunnions n Multi-Axis Positioners n Rotating and Linear Robot Transporters
n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n

Flat Table Workcells


For simple parts that can be welded from one side or
manually flipped into subassembly fixture(s).
n Single- or dual-load stations
n Manual or powered door guard operation
n Fixture plates/tables available as options to provide tool
change capability

Cell

Door Guard

AWII-50
AWII-52
AWC-50
AWC-52
AWII-200
AWC-200

Manual
Manual
Roll-up
Roll-up
Electric Door
Roll-up

Common
Base
Optional
Optional
Standard
Standard
Optional
Standard

Number of
Robots
1
1
1
1
1
1

Number of
Stations
1
2
1
2
2
2

Part Length
(mm)
1,425
700
1,650
760
1,180
1,180

Part Width
(mm)
700
700
700
700
625
1,100

Turntable Workcells
For parts that do not require positioning to orient the
part for welding.
Higher productivity; allows operator to
load/unload from a single point while robot
welds on the opposite side.
n Wide range of payload capacities and indexing times
n Low-inertia H-style tabletop for higher performance and
easy fixture mounting
n Standard 60-inch tabletop; most workcells accept optional 1,829 mm (72-in) diameter table top
n Optional fixture plates for tooling changeover; 500 mm L x 350 mm W, 1,000 mm L x 650 mm W
with notched corners
Cell
AWII-100
AW1000/1200
AWIII-1000/1200
AWV-1000/1200
AWV-1200HS

Index Time
(sec.)
4
4
2
4
2

Common
Base
Optional
Standard
Standard
Standard
Standard

Number of
Robots
1
1, 2
1, 2
1, 2
1, 2

Thru-hole
(mm)
None
120
100
120
100

*1,000 kg payload positioner with 4-second index time available as an option

HyperProductivity with Multiple Robot Control


n Improve productivity by adding more robots/arcs in same workcell (up to four robots)
n Reduce floorspace with modules; half-size cabinets to house extra amplifiers

n Reduce costs savings by using modules (with less components) is passed on to customers
n Ease programming standard software allows robot multi-tasking and coordination

with servo positioners

Payload
(kg)
200
300
500*
300
500*

Headstock/Tailstock Workcells

that
to norient
n n n n n n n n n n n n n n n n n n n n n n n n n n For
n nparts
n n n
n require
n n n npositioning
n n n n n
n n the
n npart
n nfor
n welding.
n n n n n n n n n n n n n n n n n n n n n
n Servo-controlled headstocks can be programmed in any orientation
n Single- or dual-load stations
n Coordinated motion software (standard) that enables robot(s) to weld while positioner is rotating parts
n Manual or powered door guard operation
n Compact headstock module with MotoMount tailstock for longer part spans
n Single- or two-axis part positioning
Cell

Door Guard

AWII-50S
AWII-52S
AWC-50S
AWC-52S
AWII-500
AWC-500
AWC-500TR

Manual
Manual
Roll-up
Roll-up
Electric Door
Roll-up
Roll-up

Common
Base
Optional
Optional
Standard
Standard
Optional
Standard
Standard

Number of
Robots
1
1
1
1
1
1
1

Trunnion Workcells

Number of
Stations
1
2
1
2
2
2
2

Part Length
(mm)
1,300
550
1,300
550
1,000
1,300
234/370

Part Dia.
(mm)
700
700
700
700
800
1,100
800/400

Payload
(kg)
180
180
180
180
550
1,075
500

OPULAR
MOST P URATION
CONFIG

For longer parts that require positioning.


n Two versions:

Economical, patented single-motor design


High-performance version with independent servo drives
on all three axes

n Coordinated motion software (standard) enables robot to

weld while positioner is rotating parts


n HyperProductivity achieved by adding a second,
third or even fourth robot (motion controlled with
single programming pendant)
n Optional slip ring kits deliver air, power, signal and hydraulics without cable flexing to fixturing
n Requires less floorspace than rotating turntables
n Most positioners can be extended to 5-meter span
Cell
AWII-6000*
AWII-6000HD*
AW6000
AWIV-6000SL
AWIV-6000SLHD
AWIV-6000XHD
AWV-6000

Index Time
(sec.)
4
7
4
6.5
2.25
2.95
2.95

Number
of Robots
1, 2
1, 2
1, 2
1, 2, 3, 4
1, 2, 3, 4
1, 2, 3, 4
1, 2, 3, 4

Payload
(kg)
250
500
250
250
750
1,200
1,200

Number
of Motors
1
1
1
3
3
3
3

Fixture
Mounting
Faceplate
Faceplate
Faceplate
MotoMount
MotoMount
MotoMount
MotoMount

Part Length
(mm)
2,600
3,000
2,600
2,920
2,920
2,920
2,920

Part Dia.
(mm)
1,170
1,350
1,170
1,300**
1,300**
1,300**
1,300**

* Workcell is designed for equipment to be lagged to the floor


** Positioner has limited depth indexing to one side

Multi-Axis Rotating Turntable Workcells

For shorter parts (<2-m L) that require positioning.


n Headstocks/tailstocks are indexed between operator and robot
n Servo-driven axes allow fixtures to rotate while station indexes
n MotoMount fixture mounts reduce cost and speed tooling changeover
n Coordinated motion software (standard) enables robot to weld while positioner is rotating parts
n Pedestal-mounted operator station with joystick to jog the load/unload station
n Workcell can be configured to accept 3-meter part spans
Cell
AWIV-4000
AWIV-4000HD

Index Time
(sec.)
4
7

Number of
Robots
1, 2
1, 2

Payload (kg)
500
750

Number of
Motors
3
3

Part Length
(mm)
1,977
1,977

Part Dia.
(mm)
1,300
1,300

FABWORLD SOLUTIONS

n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n

FabWorld solutions are designed to weld very large, heavy parts that require positioning
and low- to medium-part volumes with high product mix. FabWorlds generally require
extended-reach robots and can include tracks, rails or robot transporters to provide better
part access.
FabWorld solutions provide:
n Extended-reach robotic welding with MA1900 or MA3100 robots
n Flexible layout configurations with one or two robots and medium- to

heavy-payload positioners
n Coordinated motion software (standard) that enables robot to weld while
positioner is rotating parts
n MotoMount fixture mounts speed tooling changeover and ease installation
n Easy installation

FabWorld II includes common base for positioner and robot for easy setup
FabWorld features a flexible floor-mounted configuration with wireways for cable management
Precision alignment of headstock and tailstock not required due to MotoMount

Cell
FWII, Single
FWII, Dual
FW, MA1900
FW, Dual
FW, MA3100

Common
Base
Standard
Standard
None
None
None

Number of
Robots
1-MA1900
2-MA1900
1-MA1900
2-MA1900
1-MA3100

Maximum Payload (kg)


MHT-500
MHT-1600
MHT-3100
1,075
3,000
N/A
1,075
3,000
N/A
1,075
3,000
6,300
1,075
3,000
6,300
1,075
3,000
6,300

Part Length
(mm)
2,920
2,920
2,920*
3,920*
3,920*

Part Dia.
(mm)
1,350
1,350
2,000**
2,000**
2,000**

*Designed spans, positioners are lagged to the floor and can be moved closer or farther apart at installation
**Maximum part diameter for MHT-500 is 1,630

STANDARD DUAL-ROBOT FABWORLD

FABWORLD WITH SOLID PANELS PER SPEC

DUAL-ROBOT FABWORLD WITH DROP-CENTER


POSITIONER AND CUSTOMER PAINT SPEC

DUAL-ROBOT FABWORLD WITH EXTENDED-REACH


HANDLING ROBOT

FABWORLD EXTENDED WITH DUAL MH50-20 ROBOTS

DUAL-ROBOT FABWORLD WITH SKYHOOK POSITIONERS


AND FOLDING DOOR SAFEGUARDS

ELIMINATE COSTLY PLC AND OPERATOR PANELS

n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n

Concurrent I/O Ladder Logic


The DX100 controller has built-in PLC and
pendant-based operator panel capability for fixture
and workcell control.
n Over 1,000 lines of logic available for programming

fixture control or communicating status to host PLC


n Color touch screen on pendant can be used to
program ladder logic or aid in troubleshooting by
monitoring signals
n Use of robot concurrent I/O provides access to hundreds
of status registers within controller
n Interface panel function allows buttons, status indicators or
register values to be programmed
n Screens can be programmed to increase flexibility and
conveniently present information to personnel
n All major control networks supported by DX100 controller

DIGITAL WELD INTERFACES

n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n

As the global leader in arc welding, Yaskawa Motoman


has high level digital interfaces for the most brands
of power supplies. These interfaces share common
Motoman features such as:
n One key navigation between robot program and

weld settings in Arc Start File


n Graphic representation of weld sequence for
start and end, including sloping parameters
n Standard weld functions such as arc retry
or arc restart
These digital interfaces also support:

n Access to process libraries stored on the welder


n Display of live weld parameters on the pendant
n Password protection to effect process changes
n Control of power source arc monitoring

(when equipped)

WORLD SOLUTION ADVANTAGES

Yaskawa Motoman has more welding experience than any other robot company, and more robot experience than any other welding company!

n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n

STANDARD FEATURES
Robots/Controller

n Industry-leading application-specific Master Arc

welding robots

MA1400: High-speed welding robot with 1,400 mm reach


MA1900: Extended-reach welding robot with 1,900 mm reach
VA1400: 7-axis flexibility for dual-station workcells
MA3100: Extra-long 3,100 mm reach for FabWorlds
n Patented integrated upper-arm torch cable reduces

interference and makes programming easier


n Multiple robot control allows up to FOUR robots to be
controlled by a single controller and programmed by a
single programming pendant
n Menu-driven arc welding software and coordinated motion with servo positioners is standard

Arc Welding Packages

n Air-cooled torch with X,Y,Z-compliant torch shock sensor

(water-cooled option)
n Collision detection software to minimize torch impact
absorbed by shock sensor
n Two-year warranty on torch cable
n Arm-mounted 4-roll wire feeder
n Fronius, Miller, Lincoln or SKS power source models
with full feature digital interfaces
n HyperStart function to reduce cycle times
n Weld-in-Teach function for improved safety
n Optimized robot dress to manage weld cabling for long life

Positioners/Transporters

n Designed and built in the United States


n Continuously life-tested to ensure reliable performance
n Yaskawa Motoman provides complete service and spare parts
n Engineered for welding with integrated weld grounds

and safety switches

Total Safety Environment


XRC
Dual-Robot
Controller

Compliant with current U.S. robot safety standard requirements ANSI/RIA15.06-1999 and ISO 10214-1;
and Canadian (CSA) safety requirements.
n Arc flash curtains and wire fencing with interlocked gate(s) and light curtains

Power Source

n Safety-rated components with dual-channel E-stop circuit provide control reliability


n Latching cycle start (interlocked with safeguards) and operator E-stop buttons
n Safeguarded in accordance with the Prescribed Method outlined in the safety standard

OPTIONS

n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n

Workcell Options

n Common base for AWII-series workcells (standard on other ArcWorld series)


n DRC, TRC, QRC

Dual, triple or quadruple robots with a single controller for reduced cost and floorspace
(standard for multiple robot workcells)
n DR2C, TR3C, QR4C multiple robots with separate controllers for potential redeployment
n Powered roll-up door reduces floorspace of workcell
n Light beacons for workcell status
n Tooling plates (flat table and turntable cells)
n Tip change window mounted in fence permits safe, convenient access to the torch for tip changes
n Wiring routed through tailstock via rotating slip ring
n The Functional Safety Unit (FSU) provides safe operating zones for the robot and can limit its
motion range; Category 3 safety-rated

Operator Station Options


n Pedestal- or fence-mounted

n Thumbwheel switch for program selection (0-99)


n Manual jog (joystick) for moving station axis

(standard in many workcells)


n Opto-touch actuators for cycle start
n Color monitors (PanelView 600/1000)
n PC-based PC-HMI operator station

Input/Output Options

n Expanded input/output capacity


n Variety of fieldbus configurations
n Programmable controller (PLC) in controller or in

top-mounted cabinet on controller

n Interface Panel Function allows HMI to be constructed on

DX100 pendant

Peripherals and Software Options


n Torches from leading manufacturers

(Tregaskiss, Binzel and Dinse)


n Water-cooled torches
n Specialty processes: Tandem MIG, push-pull torch,
cold metal transfer (CMT), GTAW, PAW, PAC and RW
n Reamers/nozzle cleaners/sprayers
n ToolSight torch alignment gage
n Torch alignment jigs
n Automatic wire cutters
n Weld sensors
Touch-sensing (seam-finding)
AccuFast (seam-finding)
ComArc (seam-tracking)
Laser or vision sensors

n Wire spool mount


n MotoSim off-line simulation
n MyMotoman remote robot monitoring

CUSTOMIZED SOLUTIONS

n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n

Customized
Yaskawa Motoman often receives requests for an ArcWorld or FabWorld solution with minor (or sometimes major) tweaks to the
design. This might be a longer span positioner, different arc curtains or barriers, robot transporters or even a second positioner in the
cell. These custom configuration requests are processed as modifications to the standard systems we build every day.

Integrated
Several options are available to integrate an ArcWorld or FabWorld to make your parts.
n Tooling can be added by do-it-yourself users to an ArcWorld or FabWorld solution.
n Our network of Motoman Strategic Partners (MSPs) can add tooling and provide support services on a local basis.
n Yaskawa Motomans Automation Group can quote complete projects, including tooling, part programming and
start-up commissioning.
Your Yaskawa Motoman Regional Sales Manager will help evaluate your application and support needs, then recommend
the best solution source.

DOUBLE-ENDED SKYHOOK WORKCELL

DUAL-ROBOT FABWORLD WITH MOTOSWEEP


GANTRIES AND DROP CENTER POSITIONER

CUSTOMER SPEC ARCWORLD WITH ARC AND


SPOT WELDING ROBOTS

FABWORLD WITH OPPOSING SKYHOOKS AND


CENTER LOAD STATION

JIGLESS WORKCELL WITH HANDLING AND


WELDING ROBOT

AWIV-6200XHD WITH TWO TRUNNION


POSITIONERS

LASERWORLD 6000 WITH PATENTED LIGHT TIGHT


TRUNNION POSITIONER

JIGLESS WORKCELL WITH WELDING (2) AND


HEAVY-PAYLOAD HANDLING (1) ROBOTS

DUAL-ROBOT FABWORLD WITH PART HANDLING


ROBOT TO PLASMA CUT AND ETCH TUBES

AWC-50S MODIFIED WITH FULL-LENGTH DOOR


AND CUT-OUT IN BASE

FIVE-AXIS TURNTABLE WITH CUSTOMER


PAINT SPEC

TILT/ROTATE POSITIONERS IN TWO-STATION CELL WITH


RECESSED DOOR TO ALLOW OVERHEAD ACCESS

SPOTWORLD 6200 WITH ES165 ROBOTS

SINGLE-STATION WORKCELL WITH D500


TILT/ROTATE

DUAL-ROBOT FABWORLD WITH SERVO TRACKS


FOR EXTRA LENGTH

AWII-500 MODIFIED WITH POWER ROLL-UP


DOORS INSTEAD OF SOLID DOOR PANELS

AWIV-4300 WITH TWO POSITIONERS AND


3-METER SPAN

AWV-6400 WITH EXPERT ARC ROBOTS

AW1200 WITH FOUR MH180 HEADSTOCKS FOR


WELDING MANIFOLDS

ARCWORLD CAN BE EQUIPPED WITH TANDEM MIG,


PAW, GTAW, PAC, RSW AND VISION SENSORS

FABWORLD WITH MOTOSWEEP AND DUAL


DROP-CENTER POSITIONERS

Yaskawa
America

Yaskawa
Europe

Yaskawa Electric
Corporation

SPARK YOUR PRODUCTIVITY!

WORLD-LEADING
CUSTOMER SATISFACTION!
YOUR PARTNERS IN PERFORMANCE
24-HOUR HOTLINE: 937.847.3200
Mission Statement

Yaskawa Motoman is dedicated to delivering high quality,


innovative automation solutions which help our customers
to be world competitive and to providing the highest level of
customer satisfaction in the automation industry.
n Technical Education Center


IACET accredited programs


Training classes on-site or at any of our eight centers
in North America
Hands-on training; maximum two students per robot
One call support; 24/7 coverage
Web-based Customer Care Center
(anywhere, anytime access to self-serve capabilities)
Regional and COE-based technicians
Application-specific trained resources
Included in installation and start-ups

n Support program offerings include:





Robot Life Cycle Management (service and maintenance plans)


RobotPro software (maintenance, troubleshooting
and documentation) Local PC or web-based
Condition-based maintenance (diagnostics monitoring)
Rebuilds, repairs and retrofits

CUSTOMER SATISFACTION
IS OUR #1 GOAL!

Yaskawa America, Inc.


Motoman Robotics Division
100 Automation Way
Miamisburg, Ohio 45342
Tel: 937.847.6200
Fax: 937.847.6277

MANUFACTURING FACILITY
1050 South Dorset Road
Troy, Ohio 45373
Tel: 937.440.2600

Yaskawa Canada Inc.


3530 Laird Road, Unit 3
Mississauga, Ontario L5L 5Z7
Canada
Tel: 905.569.6686
Fax: 905.569.2240

n Field Services


HEADQUARTERS

INTERNATIONAL FACILITIES

n Customer Care Center



GLOBAL SUPPORT NETWORK

Yaskawa Canada Inc.


Montreal Technical Center
298 Labrosse
Pointe Claire, Quebec H9R 5L8
Canada
Tel: 519.693.6770
Fax: 519.693.9212
Motoman Robotica do Brasil
Av. Dona Ida Cerati Magrini, 936 Vila Oriental
09951-260 - Diadema - So Paulo
CEP 09951-260
Tel: 55 11.4352.3002
Fax: 55 11.4352.3338

U.S. REGIONAL FACILITIES


Detroit Regional Center
2050 Austin Avenue
Rochester Hills, MI 48309-3665
Tel: 248.668.8800
Fax: 248.668.8811
Los Angeles Regional Center
1701 Kaiser Avenue
Irvine, California 92614
Tel: 949.263.2640
Fax: 949.263.2644

Yaskawa Motoman Mexico S.A. de C.V.


Circuito Aguascalientes Oriente 134-C
Parque Industrial del Valle
de Aguascalientes
Aguascalientes, AGS. Mexico 20140
Tel: 52.449.973.1170
Fax: 52.449.973.1171
Yaskawa Motoman Mexico S.A. de C.V.
Monterrey Mexico Regional Office
Av. Regioparque #128
Fracc. Industrial Regioparque
Apodaca, N. L. C. P. 66633 Mexico
Tel: 52.81.8386.8113
Fax: 52.81.8386.8112

www.motoman.com
ALL DIMENSIONS ARE METRIC (MM) AND FOR REFERENCE ONLY
REQUEST DETAIL DRAWINGS FOR ALL DESIGN/ENGINEERING REQUIREMENTS
TECHNICAL SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
DS-349-D 2013 YASKAWA AMERICA, INC. FEBRUARY 2013

YASKAWA AMERICA, INC. MOTOMAN ROBOTICS DIVISION


100 AUTOMATION WAY, MIAMISBURG, OHIO 45342
TEL: 937.847.6200 FAX: 937.847.6277

MOTOMAN IS A REGISTERED TRADEMARK


MILLER IS A REGISTERED TRADEMARK OF MILLER ELECTRIC CORP.
ALL OTHER MARKS ARE THE TRADEMARKS AND
REGISTERED TRADEMARKS OF YASKAWA AMERICA, INC.