ABB- Robotics, Bangalore

Basic Robot Training:

Trainer : YATHIRAJU.GN
ABB Robotics, Bangalore,
© ABB Group
December 15, 2011 | Slide 1
© ABB Group
December 15, 2011 | Slide 1
 Day1 Agenda
• Introduction to ABB robot
• Safety
• Definition of Industrial Robot
• Description of Manipulator
• Description of Controller
• Description of Flexpendent
• Pictorial description of Robot Connection
• Jogging
– Motion Mode
– Coordinate System
• Practice

© ABB Group
December 15, 2011 | Slide 2
 ROBOT SPECIFICATION

• ABB robots are specified using a designation IRB say for example, IRB140, IRB1400, IRB2400,
IRB1600, IRB6600, IRB340 etc.
• IRB stands for Industrial Robot Body
Some important specifications to look for in a
Robot are:
1.Payload
2.Reach
3.Supplementary load.
4.Speed

© ABB Group
December 15, 2011 | Slide 3
 Robots Overview
6 axis robots Paint robots Dedicated 4 axis robots

Picking
Packing
Palltizing

• Comprehensive range from 1kg to 650kg payload capacity

• Robust, rigid, reliable, easy to use
• Customization through modular design concept
• Protection with IP67, Clean Room, Foundry Plus, Foundry Prime,
Wash Down

© ABB Group
December 15, 2011 | Slide 4
 Small robot family
Pay load 5kg to 60kg
6kg 0.81m 5kg 1.44m 6-8kg 1.2/1.45m

IRB 140 IRB 1410 IRB 1600

4kg 1.5m 5-20kg 1.5/1.8m 60kg 1.95m

Integrated Dressing
IRB 1600ID IRB 2400 IRB 4400

© ABB Group
December 15, 2011 | Slide 5
 Robots
New family of mid range robots – IRB 4600
45 or 60kg 2.05m 40kg 2.55m 20kg 2.5m

• 4 robots in one
• Fast, accurate, robust, compact, large working range
• Flexible mounting – floor, tilted 15 degrees , inverted, shelf
• Protection with IP67, Clean Room, Foundry Plus, Foundry Prime,
Wash Down
• Fieldbus on upper arm. Electronic Position Switches (EPS)

© ABB Group
December 15, 2011 | Slide 6
 Large robot family
Pay load 90kg to 650kg*
150kg 2.2m 205kg 1.9m 130kg 3.1m

IRB 6620 IRB 6660 Pre Machining IRB 6660 Press Tending

90-200kg 3.0/3.9m 130-235kg 2.55/3.2m 150-500kg 2.55/3.5m

* 650kg capacity
IRB 6650S IRB 6640 IRB 7600 with wrist down

© ABB Group
December 15, 2011 | Slide 7
New 150kg capacity rail mounted robot
IRB 6620LX – Linear Axis

Cost effective solution - can serve several

machines
Small floor space needed – can work above
machines
Very flexibility – Hanging or side mounted robot
versions. Can be tailor-made for different lengths
(max 40 m) and heights (max 4 m)
High reliability – Built on standard pre-proven
products
Made also for harsh environments – Foundry
Plus protection as an option

Side mounted version

© ABB Group
December 15, 2011 | Slide 8
 Paint robot family
With dedicated controller
All ABB paint Compact Flexwrist & CP prog. Hollow Wrist
robots, paint
controllers and
paint
programming
units are
Explosion
Protected.
See data sheets
for more
information.

IRB 52 IRB 540 IRB 580/58

Process or Slim Arm Car Body Painter Paint Controller

IRB 5400 IRB 5500 IRC5P for paint

© ABB Group
December 15, 2011 | Slide 9
 Dedicated 4 axis robot family
Overview - picking, packing, palletizing
High speed picker Top loading packer Palletizer
1-3kg 1.13m or 1.6m 30kg 1.5m 180-250kg 3.15m

IRB 360 FlexPicker IRB 260 IRB 660

Serving fully
integrated
packing lines

© ABB Group
December 15, 2011 | Slide 10
 The FlexPicker family
Now extended with new “long arm” version
Existing pickers New picker variant

IRB 360/1-800 1kg capacity IRB 360/1kg capacity

Compact footprint IRB 360/3kg capacity
800mm x 800mm with reduced cycle IRB 360/1-1600 kg capacity
Working range 800mm dia. Working range 1130mm dia. Working range 1600mm dia.

© ABB Group
December 15, 2011 | Slide 11
 Robot control family
Overview
Modular version Panel mount version Paint version

FlexPendant
graphical user
interface

Multi-robot control, up to 36 axis, with MultiMove

Programmable user interface with joystick motion control with FlexPendant
World leading motion control with TrueMove & QuickMove
“Next generation safety” with SafeMove
Powerful connectivity through network interfaces
Now available with Remote Service option

© ABB Group
December 15, 2011 | Slide 12
 DEFINITION OF AN INDUSTRIAL ROBOT

• An industrial robot is a programmable multi-functional, multi

DOF manipulator powered by electricity.

© ABB Group
December 15, 2011 | Slide 13
 ABB Safety Solutions – an Overview
• Emergency stop
• Operating mode
– Auto
– Manual < 250 mm/s
– Manual 100%
• Enabling device
(Dead mans grip)
• Hold-to-run
• Safeguard stop
(Auto and Manual)
• Limiting the workspace

© ABB Group
December 15, 2011 | Slide 14
 Accident Risks

• Fault tracing
• Repair
• Change of
program
• Test run

Always avoid PINCH POINTS

© ABB Group
December 15, 2011 | Slide 15
 Emergency Stop

• Built in emergency stop

pushbuttons are found both on
the FlexPendant and Control
module standard.
• Extra emergency stops can be
connected to the robot systems
safety chain.

Recover by resetting pushbutton and

pressing the Motors On button.

© ABB Group
December 15, 2011 | Slide 16
 Hold-to-Run

• Option (this function can be activated in the parameters

for manual reduced speed mode)
• The enabling device and one of the hold-to-run buttons
must be pressed simultaneously to start the motors

Enabling device

Hold-to-run buttons
(for left or right hand)
© ABB Group
December 15, 2011 | Slide 17
 Safeguard Stop
• The connection of safeguard stop enables inter-locking of external safety equipment, such
as: doors, photo-electric trip device, photo cells or sensible mats
• There are two categories of Safeguard stop:
– Manual – the safeguard stop is active regardless of operating modes (Emergency Stop,
General Stop, Superior Stop)
– Auto – the safeguard is active when automatic mode is selected (Auto Stop)
• It is possible to activate Delayed Safeguard Stop.
A delayed stop gives a smooth stop. The robot stops in the same way as at a normal program
stop with no deviation from the programmed path. After approx. 1 second the power
supplied to the motors shuts off.

© ABB Group
December 15, 2011 | Slide 18
 Limiting the Workspace

• To avoid the risk of getting caught

between the robot and the
perimeter safety equipment, e.g. a
fence, the robot’s workspace can be
limited:
– All axis can be software limited
– On some robots Axis 1–3 can be
limited by adjustable mechanical
stops and controlled by limit
switches

© ABB Group
December 15, 2011 | Slide 19
 Safety Regarding Grip Device

• All grip devices should be designed so the work piece will be held even on power failure and
other disturbances in the robot system
• There should be possibilities to release the work piece manually

© ABB Group
December 15, 2011 | Slide 20
 Electrical Safety

• Hazardous power in both the cabinet and the robot

• Control Module
– Power supply – 230 VAC
– Customer equipment – …
• Drive Module
– Power Source – 480 VAC
– Power supply – 230 VAC
– Power supply to robot motors – 370VDC up to 700 VDC

© ABB Group
December 15, 2011 | Slide 21
 Safety Regarding Releasing the Breaks

• The brakes on the robot motors can be manually released.

• Before the brakes are released, be sure the weight of the robot arm
is supported to avoid robot arm falling and doing damage to
equipment or people.

© ABB Group
December 15, 2011 | Slide 22
MANIPULATOR

© ABB Group
December 15, 2011 | Slide 23
 DESCRIPTION OF A MANIPULATOR

• A manipulator is an assemblage of rigid links connected by joints.

• Each joint is driven by an actuator (AC Servo motors in ABB robots).
• Actuators are coupled to joints via geared transmission.
• An industrial manipulator has 4 OR 6 degrees of freedom.
• Brakes are installed in every joint motor to hold the manipulator in position against gravity in
motors off state.

© ABB Group
December 15, 2011 | Slide 24
 Block Diagram of Robot

Manipulator Power cable

CONTROLLER
ROBOT MANIPULATOR
SMB Cable
Ext Ax Power

Resolver Cable

EXTERNAL AXIS

R
Y
B 3 Phase 415VAC

© ABB Group
December 15, 2011 | Slide 25
Six Axis Robot Movement

© ABB Group
December 15, 2011 | Slide 26
 DEGRES OF FREEDOM

The number of independent movements a robot can make is known as the degree of
freedom of the robot manipulator. In other words the number of rotary axes a
manipulator has is known as its degree
of freedom.

© ABB Group
December 15, 2011 | Slide 27
 THE MAJOR AND MINOR AXES OF A ROBOT

• The first 3 axes (axis 1/2/3/) of a robot are known as the major axes because they help in
positioning the wrist at a required point on the workpiece.
• The last 3 axes (4/5/6) of a robot are called as the minor axes because they allow the wrist to
reorient in any required direction without changing its position.

© ABB Group
December 15, 2011 | Slide 28
CONTROLLERS

© ABB Group
December 15, 2011 | Slide 29
 Controllers
S1 1974 - 1982 S2 1983 - 1991 S3 1987 - 1996 S4 1994 - 1999

S4C 1996 - 2000

IRC5 2004 -
S4Cplus 2000 - 2007

© ABB Group
December 15, 2011 | Slide 30
IRC5 – the 5th generation Robot Controller

© ABB Group
December 15, 2011 | Slide 31
 Single Cabinet Controller
Drive and control functions combined in one cabinet
Clean AluZinc cabinet
(only front painted)
resistant to environmental
influence
self healing if scratched
Dimensions 970 x 725 x 710 (H x D x W)
Full option range, including MultiMove
Max 2 internal I/O units

900
© ABB Group
December 15, 2011 | Slide 32
 Pictorial description of Controller (Outside)
Main Disconnect

E-Stop

Motors On

Mode Selector

Run Chain Status

USB Port
Ethernet Service

Hour Meter

© ABB Group
December 15, 2011 | Slide 33
 OPERATING MODES OF A ROBOT

A robot can be operated in three different modes:

• Manual mode.
• Manual 100% mode.
• Automatic mode.
 Inside IRC5 Single Cabinet Controller
Power supply units Computer unit
Computer UltraCap Panel unit (safety interface)
(right inside wall)

Power ON/OFF
Manipulator signal
interface

Operator´s panel

Service ports
USB (option)
Drive unit Customer (I/O) space
Ethernet
section
FlexPendant
connection
Axis computer
Options: (right inside wall)
Duty Time Counter
230/120 V service
outlet Power intake
Motors On contactors Manipulator connections
and interface board
(left inside wall) Customer connections
(behind optional cover)

© ABB Group
December 15, 2011 | Slide 35
Single Cabinet Controller

© ABB Group
December 15, 2011 | Slide 36
Drive Module for MultiMove Requirements

Contains drive system, axis

computer, transformer, mains
connection & filter
Controls up to 8 or 9 internal axes
(depending on robot size)
Building block for MultiMove (up to
4 drive cabinets connected to a
single control cabinet)
Height 625 mm,
footprint 700 * 700 mm

© ABB Group
December 15, 2011 | Slide 37
 Process Module

• Extension for more customer equipment space

• Common look and feel
• Fits on top of any other module (Single Cabinet Controller, Drive Module)

© ABB Group
December 15, 2011 | Slide 38
 Module Family Concept

Flush sides for reduced floor space

Front access
All modules fit on top of each other
No air filter
MTTR < 10 min

© ABB Group
December 15, 2011 | Slide 39
 MultiMove Stand-Alone

• One controller for up to 4 drive units

• Totally 32-36 axes (depending on drive size)
• Arbitrary mix of drive module types
• Up to four machines with kinematics
• Up to six independent motion tasks
• Possibility to mix IRB’s and external machines
• Possibility for geometrically co-ordinated operation of multiple machines

© ABB Group
December 15, 2011 | Slide 40
Flexpendant

© ABB Group
December 15, 2011 | Slide 41
 IRC5 – FlexPendant
Status bar
ABB Menu
Main menu

Windows style
“switch between Quickset or
open windows/views” © ABB Group “COG” Menu
December 15, 2011 | Slide 42
Graphical color touch screen
IRC5 – FlexPendant 4 Hard keys for fast access
Programmable

3-way joy stick

4 Hard keys for running programs

Start
© ABB Group Execute Backward/Forward
December 15, 2011 | Slide 43
Stop program
Quickset or COG button

© ABB Group
December 15, 2011 | Slide 44
 MODES OF JOGGING

Jogging can be done in three modes:

• Axes mode (joint by joint )
• Linear mode (along X / Y / Z)
• Reorient mode (changing orientation of tool)

© ABB Group
December 15, 2011 | Slide 45
 Jogging the robot

Remember that the joystick assumes you are facing the front of the robot.
© ABB Group
December 15, 2011 | Slide 46
 Jogging the robot
+3 +4
-5
+6

-2
-3
-4 +5 -6
+2
+5
+2
-1 +1
-4 +4
-1 +1
+6 -6
+3 -3
-5
-2

+Z Z
Y
+Y
-X
-X
X
-Y +Y
-Y +Y
+Z -Z
+Z -Z +X
+X
+X

© ABB Group
December 15, 2011 | Slide 47
INCREMENTAL MODE

© ABB Group
December 15, 2011 | Slide 48
 Coordinate Systems
TCPZ
Y
X
Tool coordinates

Z
Y
X
Base coordinates
Z Z
Y
Y

X WorkObject
World coordinates
X

© ABB Group
December 15, 2011 | Slide 49
 Right Hand Rule
+Z

+X

+Y

© ABB Group
December 15, 2011 | Slide 50
 Day-2 Agenda

• Defining a tool
• Defining a workobject
• Motion instruction
• Basic Programming Structure
• Practice

© ABB Group
December 15, 2011 | Slide 51
TOOL

© ABB Group
December 15, 2011 | Slide 52
 Tool Definition
“Keeps Tool Frame
Directions same as
TCP Default Orient Tool0
Tool Definition

TCP & Z

TCP & Z,X

© ABB Group
December 15, 2011 | Slide 53
 Tool Coordinate System

• Tool coordinate system

Tool coordinates
Y
Tool0

X Z
Benefits using Tool:
Jogging
Re-orientation
Easy to change
Z
Y

Base coordinates

X © ABB Group
December 15, 2011 | Slide 54
 Coordinate System

• Different examples of tools and TCPs.

TCP
TCP

TCP

TOOL0
TCP

Tool0 is always the

ref.point for the other tools

© ABB Group
December 15, 2011 | Slide 55
 Define a Tool, 4-point Method

• tPen

Fixed point

© ABB Group
December 15, 2011 | Slide 56
 Defining a Tool

• Create a Tooldata on FlexPendant

– Tap ABB : Program Data : Tooldata : Show Data : New

Give tool a name.

Tap Initial Value.
Page down to Mass and enter the weight
of the tool in Kg.
Cursor down to COG X and enter a value
in mm.
Tap OK : OK : OK
© ABB Group
December 15, 2011 | Slide 57
 Type of TCP Definition/Quaternions
q1 q2 q3 q4

TCP Default Orient

1 0 0 0

TCP & Z x x 0 0

TCP Z & X x x x x

(q1)2+(q2) 2+(q3) 2+(q4) 2=1

-1 X 1
© ABB Group
December 15, 2011 | Slide 58
workobject

© ABB Group
December 15, 2011 | Slide 59
 Origin & Frame Orientation
Y1
Y axis

X axis

X2
90°

Origin

X1
© ABB Group
December 15, 2011 | Slide 60
 Work Object Coordinate System

• User Coordinate System

– Object Coordinate System
Z
Y

TCP Z WorkObject
Y
X X
Tool coordinates

Z
Y
X
Base coordinates

© ABB Group
December 15, 2011 | Slide 61
 Work Object Coordinate System

• Define coordinate systems

Object
User User

© ABB Group
December 15, 2011 | Slide 62
Create a Work Object

Figure drawn in a work object

© ABB Group
December 15, 2011 | Slide 63
 Create a Work Object

• Activate the measuring tool

(tPen)
• Create the work object
• Define the coordinates

Origin y1

x1 Work object axis Y

x2
wobjA4

Work object axis X

© ABB Group
December 15, 2011 | Slide 64
WORK OBJECT DEFINITION

© ABB Group
December 15, 2011 | Slide 65
Activating a Work Object

© ABB Group
December 15, 2011 | Slide 66
 Programs/Routines/Modules Structure

X Task PROGRAMS
Y Task
Created By Default

Mainmodule M N
Mainmodu P Q
le

R1( )
R1( )
R2 ( ) Main()
Main()

R6( ) R7( )

R2( )
R3( ) R5( )
ROUTINES
R6( )
R3( ) R7( )
R4( )
R4( )

R5( )
© ABB Group
December 15, 2011 | Slide 67
 Create a program
• To Create a new program:
(If no program exists)
– Tap ABB
– Tap Program Editor
– Select Robot Task
– Tap New.
– Give your program a name
– Tap OK

© ABB Group
December 15, 2011 | Slide 68
 Saving and Loading a program
To create a new program or load an existing program or Save a program:

•Tap ABB
•Tap Program Editor
•Select Robot Task
•Tap Tasks and Programs
•Select a Task if multiple
robots
•Tap File

•Tap New Program:

•To create a new program

•Tap Load Program:

•To load an existing program

•Tap Save Program as:

•To save a program

© ABB Group
December 15, 2011 | Slide 69
 Saving a program

• A folder with the program name is created

• Module: MainModule (all programs have)
• File extension: pgf
• Is an XML file that points to MainModule and other program modules.

The same
name

© ABB Group
December 15, 2011 | Slide 70
 Changing a Program

Select item to
change by double
Tapping.

Then choose new

value and press
OK.

© ABB Group
December 15, 2011 | Slide 71
MOTION INSTRUCTION

© ABB Group
December 15, 2011 | Slide 72
 MoveJ or MoveL?
MoveJ

Joint interpolation is often the fastest way to move between two points
as the robot axes follow the closest path between the start point and the
destination point (from the perspective of the axis angles). Use when in
open spaces such as moving from one fixture to another.

MoveL

LINEAR interpolation is the most accurate motion between two points.

The robot will maintain a straight line of the TCP from the starting point to
the end point. If this is not possible an event will be generated. Use
when robot is moving close to other objects such as fixtures or
parts. © ABB Group
December 15, 2011 | Slide 73
 Circular Movement
• MoveC
pCircle20

pCircle30

pCircle40

© ABB Group
December 15, 2011 | Slide 74
 Circular Movement
• Circle with MoveC’s

pCircle20

This robtaget can be copied and pasted

pCircle30
pCircle50

pCircle40
Press Modify pos

© ABB Group
December 15, 2011 | Slide 75
 Velocity and Zones
z
MoveL p40, v1000, z40, tool0;

MoveL p30, v300, z30, tool0;

© ABB Group
December 15, 2011 | Slide 76
 Inserting Move Instructions
• To add instructions to your program:
– Tap Add Instruction
– Jog robot into position
– Tap MoveJ or MoveL
– Jog robot to next position
– Repeat

© ABB Group
December 15, 2011 | Slide 77
 Modifying a Position

Step to the move

to be modified.

Jog the robot to

the new position.

Tap
Modify Position

© ABB Group
December 15, 2011 | Slide 78
 Day-3 Agenda

• Error handling
• Offset function
• Program Flow instruction
• Communication Instruction
• Backup
• Calibration
• Practice

© ABB Group
December 15, 2011 | Slide 79
ERROR HANDLING

© ABB Group
December 15, 2011 | Slide 80
Introduction

Event Messages are divided into.

I
– Information
– E.g: Hold to run must be pressed.
Information of how to proceed

– Warning
– E.g: Manual movement full speed is selected.
The operator is informed about a potential risk.

– Error
– E.g: Motor On when Emergency Stop is active.
The system cannot operate before a measure is
carried out.

© ABB Group
December 15, 2011 | Slide 81
Error Message
• When the computer detects a problem or possible problem, it
generates an error message with description and action.
– Unacknowledged message is displayed in red on the status bar

Unacknowledged
message displayed

© ABB Group
December 15, 2011 | Slide 82
 Event Log
Symbol Code Title Time stamp
© ABB University -99

© ABB Group
December 15, 2011 | Slide 83
Event Log

Scroll the list with the yellow arrows

Tap on a specific message to get more information
The time stamp is not reliable on hundredth of seconds

© ABB Group
December 15, 2011 | Slide 84
 Event Log
• Logs are stored under different topics
• Tap view and select the topic of interest
– Topic common consist of a mixture of the last created loggs

© ABB Group
December 15, 2011 | Slide 85
 Programmable Keys
• Setup a programmable key.
– Tap ABB : Control Panel : ProgKeys
– Select Key to setup.
– Select Type (usually Output)
– Select Output.
– Select Key Pressed
– Tap OK.

© ABB Group
December 15, 2011 | Slide 86
offset function

© ABB Group
December 15, 2011 | Slide 87
 Function Offset
Function Offset
In the Move command position definition, choosing
function will enable move with offset (Offs). A
displacement of the robot position.
Example
Used to displace a position
Move type Speed
from original position
C, J, L Accuracy

Move_ Offs(pStart,-100,0,0), v500, fine, toolx;

Z Offset
Position data to
Y Offset
be displaced
X Offset

© ABB Group
December 15, 2011 | Slide 88
 Making a Perfect Circle
To Make a Perfect Circle
MoveL pStart, v500, fine, toolx;
MoveC Offs(pStart,-100,-100,0),Offs(pStart,-200,0,0),v500,z1,toolx;
MoveC Offs(pStart,-100,100,0), pStart,v500,z1,toolx;

Which direction will

the circle be drawn?

CW or CCW

© ABB Group
December 15, 2011 | Slide 89
 Offset Example
Example

© ABB Group
December 15, 2011 | Slide 90
 Square with Offsets
MM X
Example 100
Which quadrant will
the square be drawn?
75
1 2
50 1 2 3 4
25
100 75 50 25 -25 -50 -75 -100
Y MM

-25 pSTART
-50
3 4
-75
-100

From the previous example program:

pSTART
_____________is the FIRST point of drawing a square
and also the ____________point
LAST of the square.

© ABB Group
December 15, 2011 | Slide 91
 Debug

Program
Pointer (PP)

© ABB Group
December 15, 2011 | Slide 92
 PROGRAM FLOW INSTRUCTIONS

• IF ELSE
• GOTO
• FOR
• COMPACT IF
• TEST CASE

© ABB Group
December 15, 2011 | Slide 93
 COMPACT IF

IF reg1=1 MoveJ *,v500,z20,tool0;

• It executes a single instruction if a given condition is found to be true.

© ABB Group
December 15, 2011 | Slide 94
 IF ELSE

IF reg2=10 THEN
MoveJ *,v500,z80,tool0;
MoveL *,v1000,z50,tool0;
ELSE
MoveL *,v500,z20,tool0;
MoveC *,*,v500,z20,tool0;
ENDFOR

If a given condition is true it executes a set of instructions and if it is false then it executes
another set of instructions.

© ABB Group
December 15, 2011 | Slide 95
 GOTO

GOTO start;
………….
………….
………….
start:
On seeing the instruction the program pointer goes to the line containing the
label start.

© ABB Group
December 15, 2011 | Slide 96
 FOR

FOR x FROM 1 TO 10 STEP1 DO

…………
…………
………….
………….
ENDFOR

It is used to repeat a given set of instructions a fixed number of times.

© ABB Group
December 15, 2011 | Slide 97
 TEST

TEST reg1
Case 1: …………
…………
Case 2: ………….
…………
Case 3: …………
…………
ENDTEST

Executes set of instructions based on the integer values of a variable eg. reg1.

© ABB Group
December 15, 2011 | Slide 98
 COMMUNICATION INSTRUCTIONS

• TPWrite “TIME FOR THE CYCLE IS”,reg1;

• TPErase;
• TPReadNum reg2;
• TPReadFK

© ABB Group
December 15, 2011 | Slide 99
 TPWrite& TP Erase
• TPWrite instruction is used to write messages to the screen. Certain data values can also be
written.
• TPErase instruction is used to clear the screen.

© ABB Group
December 15, 2011 | Slide 100
 Eg:-

The decision is made by the operator/inspector.

© ABB Group
December 15, 2011 | Slide 101
TP Read Num
TPReadNum nfigures, “How many figures do you want?

© ABB Group
December 15, 2011 | Slide 102
 TPReadFK

TPReadFK nFigure, “Is this a GOOD or BAD part?”, stEmpty, “GOOD”, stEmpty, “BAD”, stEmpty;

(1) 2 (3) 4 (5)

© ABB Group
December 15, 2011 | Slide 103
CALIBRATION

© ABB Group
December 15, 2011 | Slide 104
 CALIBRATION

• An uncalibrated system.

© ABB Group
December 15, 2011 | Slide 105
REVOLUTION COUNTER

© ABB Group
December 15, 2011 | Slide 106
 Updating Rev. Counters

1. Use the Joy stick and

Move the Robot to
the Calibration
Position and align
the witness marks.

© ABB Group
December 15, 2011 | Slide 107
 Updating Rev. Counter Procedure
1. Jog the robot to the witness marks / Calibration position.
2. Tap ABB : Calibration
3. Select the robot to be calibrated.
4. Tap Update Revolution Counter
5. Tap YES to confirm this is what you want to do.
6. If needed select the axes to be updated.
7. Tap Update and Update again.

© ABB Group
December 15, 2011 | Slide 108
 Checking Robot Calibration
• MoveAbsJ
– Create a new routine (GotoCalib)
– Insert MoveAbsJ instruction
– Choose star position, Edit / View Value, put all 6 axis to zero

© ABB Group
December 15, 2011 | Slide 109
 Fine Calibration
• Fine Calibration
– Tells the current angle of engine shaft when robot is in sync position
– Is tuned in by ABB or on site with special equipment
– Only needs to be retuned if a motor / gearbox is replaced

Requires special tools!

Cannot be made correctly
by eye Measurement.

© ABB Group
December 15, 2011 | Slide 110
 Edit Motor Calibration Offsets
• Type in the fine calibration values manually
• Use moc.cfg values from Backup, Silver label in back of manipulator with 6 values, or original
Motor Calibration values on floppy shipped with system.

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December 15, 2011 | Slide 111
BACK UP

© ABB Group
December 15, 2011 | Slide 112
 BACKUP

© ABB Group
December 15, 2011 | Slide 113
BACKUP

© ABB Group
December 15, 2011 | Slide 114
 Day4 Agenda
• I/O Configuration
• I/O Instruction
• Practice

© ABB Group
December 15, 2011 | Slide 115
IRC5 I/O - System
I/O System includes
Field buses
IO-Definitions
I/O Configuration in RSO (Unit, Unit Type and Signals).
Unit Mapping
The Internals of an I/O Unit
Configuration Of Analog Signals
Access Level
Simple and Logical Cross Connection
I/O UNITS SUPPORTING DEVICENET COMMUNICATION
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December 15, 2011 | Slide 118
 Parts

Item Description
A Status LEDS
X1 Digital Output
X2 Digital Output
X3 Digital Input
X4 Digital Input
X5 Device Net Connector

Technical data

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December 15, 2011 | Slide 119
 Connector X1
Connection to X1

© ABB Group
December 15, 2011 | Slide 120
 Connector X2
Connection to X2

© ABB Group
December 15, 2011 | Slide 121
 Connector X3
Connection to X3

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December 15, 2011 | Slide 122
 Connector X4
Connection to X4

© ABB Group
December 15, 2011 | Slide 123
Connector X5

© ABB Group
December 15, 2011 | Slide 124
 CONFIGURING THE I/O S

• Select CONTROL PANEL.

• Select CONFIGURATION OF SYSTEM PARAMETERS
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December 15, 2011 | Slide 126