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R&D at ABBMarkus BayeganChief Technology Officer ABB

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R&D pipeline produces outstanding results

Recent technology success storiesIndustrial IT Automation System 800xAImprovements for industrial processes (e.g. steel, paper)New features for motors, drives and soft-startersUpgrades in flexible AC transmission systems (FACTS)Wide area grid management to stabilize power transmissionAugmented reality to improve robot programming

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Technology a major asset for ABB

Cutting-edge technology gives our core power and automation business

a distinct advantageover our competition

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R&D driving forces at ABB Reliable and robust products and systemsFunctional integration, fewer partsSafe and environ-mentally friendlyEasy to engineer, install, operate, maintainRemote monitoring, diagnosis, supportOptimum asset utilization Towards

optimizedmanufacturingand customer processes

Towards optimized power infrastructure and reliable grids

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Mission of industrial R&DLink between customer needsand technology offerings

Dynamic and vital source for technology based innovation

Spearhead for technological breakthroughs in relevant areas

Connected to scientific community

Monitoring most recent developments in science and technology world

Attractive recruiting agent for high calibretechnical personnel

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R&D priorities

Create more value through technology

Be responsive to external world

Build partnerships with customers and universities

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Key technologies

Electrical insulation

Power electronics

Communication

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Sensors and actuators

Control and optimization

Software development

Key technologies (2)

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Current research programs

Power device technologyPower transmission and distribution applicationsPower electronicsMechatronics and robotics applicationControl and optimizationAutomation networks and devicesSoftware architecture and processesAdvanced materialManufacturing technologies

Securing and developing ABB´s core competence

Cutting-edgetechnologies

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Power device technologies

Electrical insulationImproved polymer with embedded field controlImproved electric field configuration for compact products

245 kV plug to gas insulated switchgear

Dry insulation, maintenance free

ArrestersPolymeric housing for high mechanical stress

PASS M00Most compact MV SF6 breaker

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Power device technologies (2)

Current interruptionBroad implementation of self-blast technology

One technology platform for various breaker applications

Motor drives platform for contact movement

HECS generator breaker

10 percent more power20 percent lower volume12 percent lower weight

LTB 170 kVNew motor drive with less moving parts

ELK-0 145 kVVery compact with new breaker

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Power device technologies (3)

Improving material propertiesThin metallized polypropylene films with self-healing insulation after breakthrough in capacitors

Fast curing epoxy resins to cut down production time

Housing material for transformers: first combined flame retardant and shock resistant

Oil-filled

Dry

Distribution transformer withcycle time reduced by 80 percent

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Power electronicsConverter technologies

Topologies and controlSemiconductor utilization

Hardware integrationSemiconductor packagingCooling technologiesElectrical interference

Simulation methodologyElectrical machinesPower converters

ABB Drives product family

IGBT platform (chip design, packaging, process development)

HVDC Light (series connection of IGBTs, control algorithms)

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Monitoring transmission flows in large gridsOptimizing electrical transmission

Maximizing use of installed gridsEnsuring secure operation at maximum load

Minimizing transmission lossesConnecting grids with different operational parametersCoupling various power generation sources to gridProviding environmentally friendly transmission and distribution

Power transmission and distribution applications

Advanced technologies for better controlof transmission flows and voltages

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Ensuring reliable power supply

Wide Area Monitoring and Control

FACTS (Flexible AC transmission systems) for network control

HVDC and HVDC Light

Innovations enhance network flexibility for better stability and reliability

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GPSSignal

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FACTSFACTS

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FACTS: helping to prevent blackouts

Maximum available power supplyMaximum power qualityMinimum transmission lossesMinimum investment costMinimum environmental impact

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Mechatronics and robot applications

New concepts for mechanical structuresEasier robot programmingKnowledge-based application programs

New mechanical arm for heavy-duty pre-machining operations

TeachSaver: offline programming of robot foundry cleaning

VirtualArc for tuning of process parameters

ArtVis: augmented reality for robot programming

IRB 940 Tricept

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Augmented reality: making the complex simple

Operator sees program input overlaid on object that is being worked on

Huge potential for engineering applications

Makes programming easier

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Control and optimization800xA platform for system integrationOptimization in industry lines

Oil and Gas: enhanced oil production well monitoringMetals: advanced process control for hot/cold rolling millsPower generation: boiler controlPulp and paper: online mill performanceCement: production more economic

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Networks

Automation networks and devices

Intelligent devicesAdvanced signal processingDiagnosticsPlug and operate

Enabling “digital field”Industrial ethernetSafety, security and reliability

Wireless communicationSensors and actuatorsMobile asset managementWireless robots

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Software quality Efficient technology migrationSecurity and integrity assurance

Software architecture and processes

Reduction of system installation time by 75 percent

Plug and operate of field devices reduces commissioning time by 50 percent

Software development processCapability maturity model-based improvement (CMMI)Automated testing

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Monitoring material technology (nano)

Nano-composites for electrical insulationThin films for electrical contactsNano-tubes for electrical conductionCoatings and surface treatmentsConductive composites for indicators

No voltage 2 kV voltage 3 kV voltage

Transparent conductive nano-layer inside liquid crystal display

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Boosting productivity in our own factories

Sweden Time from order to delivery reduced from 60 to 15 days

Poland Manufacturing lead time reduced from 110 to 14 days

Czech Rep. Offer and order handling reduced from days to minutes

Switzerland Reduction of inventories by 30 percent

Finland Time to market reduced by 30 percent

U.S. Cycle time reduction by 50 percent

Others Reduction of set-up time by 75 percent and lead time by 25 percent

Improved processes to serve customers better

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Successful R&D needs reliable transformation process

Monitoring and analyzingScientific progressCompetitor approachesCustomer needs

ForecastingTechnology developmentMarket needs

Strategic planningPlatform developmentProduct and system development

ExecutionResourcesTarget oriented approach

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Successful R&D needs global network

Universities are incubators of future technologiesIndustrial research to transform science into technology platformsProduct development to generate products and systems on platformsMeeting customer needs

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Universities: partnership for technical excellence

Massachusetts Institute of Technology U.S.Carnegie Mellon University U.S.Stanford University U.S.Cambridge University U.K.Imperial College U.K.Federal Institute of Technology CHChalmers University SERoyal Institute of Technology SERWTH Aachen DETechnical University Berlin DEKarlsruhe University DETsing Hua University CN

and more than 50 other partners

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Research close to customers and universities

Raleigh U.S.Wickliffe U.S.

Västerås SEBaden CHLadenburg DEKrakow PLOslo NOVaasa FI

Beijing CNShanghai CNBangalore IN

Global labs for power and automation technologies

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Worldwide recognition for innovative power

Charlotte Skourup MIT: 100 Young Innovators 2004 (augmented reality)Christian Rehtanz MIT: 100 Young Innovators 2003 (transmission systems)Alexander Fay MIT: 100 Young Innovators 2002 (Industrial IT)Uno Gäfert IEEE Dakin award 2004 (electrical insulation)Ekkehard Schade Dyke award 2004 (high current vacuum arcs)Peter Isberg Thureus award Royal Swedish Society 2004

(nanotechnology)Wall Street Journal Gold Award 2002 (wireless proximity sensor)

and many more

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Generating value with R&DSupporting sales: depending on individual business 30-80 percent of present sales based on product innovation from last 5 years

Creating intellectual property: average number of annual patent applications exceeds 1,400, total patent portfolio more than16,000

Sharing knowledge: more than 150 scientific publications annually

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