ABB Wall Assembly Cell – Robotization of Construction Processes

1. Introduction

ABB's history - from a pioneer of electrification to a leader in automation.

ABB is a global technology company. It was established in 1988 from the merger of two European giants - the Swedish ASEA and the Swiss BBC (Brown, Boveri & Cie). Its roots date back to the late 19th century. From the very beginning, ABB focused on the development of innovations in the fields of energy, industrial automation and robotics.

In the following decades, the company developed dynamically, investing in digitalization, intelligent control systems and Industry 4.0 technologies. Thanks to its global presence and extensive experience, ABB became a leader in production automation. Today, it introduces its solutions - including ABB technology - to modular construction and prefabrication, revolutionizing the way building elements are produced.

What is modular construction?
Modular construction is a modern way of building. It involves the prefabrication of entire building segments in a factory.

They are then transported and assembled on site. Unlike traditional methods, where most of the work is done on the construction site, here the process is moved to a controlled production environment, where, among other things, an assembly line operates, supported by a control module and industrial coils.

2. Benefits of Using the ABB Cell

The ABB Cell introduces precision and repeatability – key features in modern modular construction. Here are the most important advantages of its use:

Reduced investment implementation time

Thanks to the automation of tasks such as connecting walls, applying adhesives, drilling or welding walls, the time needed to prepare a single module is significantly reduced. The ABB Cell can work in continuous mode, which increases the efficiency of the assembly line and speeds up the implementation of the entire investment.

Increased precision and quality of workmanship

Vision systems, positioning sensors and precise robotic arms ensure maximum accuracy of assembly of structural elements. This reduces the number of manufacturing errors, improves the quality of wall welds and reduces the amount of material waste.

Automation and work safety

The ABB Cell takes over many repetitive, difficult and potentially dangerous tasks, thus improving health and safety conditions in the prefabrication plant. Employees can focus on controlling the operation of systems such as the control module, which increases efficiency and safety.

Reduced costs and material waste

By precisely controlling raw material consumption, including advanced industrial coils and dosing systems, the ABB cell reduces material waste. This translates into lower costs and more sustainable production.

3. Technical Specification

Below we present the detailed technical specification of the ABB cell that we have in our offer.

Technical Specification:

• Model: Complete ABB welding cell for wall assembly
• Year of production: 2021
• Manufacturer: ABB

Welding robots:

• Type: ABB IRB 4600-20/2.50
• Quantity: 4 pieces
• Load capacity: 20 kg
• Working range: 2.50 m
• Positioning accuracy: ± 0.05 mm

Movement and transport system:

Track: IRBT Robot Travel Track

Feed system: Column feeder

Welding package:

Model: Fronius TPS/I 400

Application: Robotic welding

Gripper system:

Type: Gripper for handling column components

Function: Precise handling of structural elements

Application: Automation of the welding process of wall structures

4. Application of the ABB cell for wall assembly

How does the ABB cell work?

The ABB cell is an automated workstation equipped with industrial robots that perform specific stages of wall assembly in the prefabrication process. Depending on the configuration, it can perform operations such as:

• feeding and positioning of structural elements (e.g. posts, beams, plates),
• application of glue, foam or other binding material,
• drilling holes and mechanical assembly (e.g. screwing, stitching),
• quality control of the connections made,
• marking elements or preparation for further processing.

The ABB cell control systems are fully programmable, which allows its operation to be adapted to various types of walls - load-bearing, partition, with an insulating layer or with a ready finish.

Stages of wall assembly using the cell

The process of wall production using the ABB cell takes place in several automated steps:

• Feeding components - a robot or transport system delivers wall frame elements (e.g. posts, beams, OSB boards).
• Positioning and connecting – the robot arm precisely arranges and connects components in accordance with the CAD/BIM design.
• Mechanical assembly – the robot drills and fastens screws or staples, in accordance with the established parameters.
• Material application – the system automatically applies adhesives, foams, vapor barrier foils, etc.
• Quality inspection – built-in sensors or cameras check the correctness of the execution and completeness of the wall.

Thanks to integration with design systems (e.g. BIM), the cell can receive data directly from technical documentation, which minimizes the risk of errors and speeds up configuration.

Examples of applications in projects

The ABB cell is used in prefabricated building factories that produce ready-made walls for, among others:

• single-family and terraced houses in frame technology,
• multi-family buildings from prefabricated modules,
• schools, kindergartens and public utility buildings,
• residential and technical containers,
• modular hotels and recreational houses.

5. Summary

ABB, a global leader in industrial automation, provides advanced solutions for prefabrication and assembly of walls. The use of ABB cells automates processes such as wall welding, wall joining, or adhesive application. In combination with elements such as a control module, industrial coil or vision systems, it allows for increased precision, quality and efficiency. Thanks to ABB technology and full integration with digital design, each prefabricated wall is created faster, cheaper and with a smaller impact on the environment.