ABB Robotics Operational,

Programming, and Maintenance

Training
Presented by Giovanni Sutanto and Whidi Kusuma
PT Unilever Indonesia, Skin Care Factory, Cikarang, 2 – 5 July 2012
Trainning Contents [1]
1. Company & Organizational Overview
2. System Overview
2.1 IRC5 Controller
2.2 Manipulator
2.3 Safety
3. Basic Operation
3.1 Starting the System
3.2 Operator Panel Operation
3.3 GTPU Operation
3.3.1 W indow menu
3.3.2 Quickset Menu

ABB Robotics
Trainning Contents [2]
3.3.3 Main Menu
- Jogging - Event Log
- Program Editor - Backup &
Restore
- Program Data - Calibration
- Inputs/Outputs - Control Panel
- Production W indow - Restart &
Shutdown
4. Robot Coordinate System
4.1 W hat is a Coordinate System ?
4.2 Base Coordinate System
4.3 World Coordinate System
4.4 Tool – TCP Coordinate System
4.5 User Coordinate Systems
4.6 Work Object Coordinate Systems

ABB Robotics
Trainning Contents [3]
5. Programming
5.1 Modules
5.1.1 Program Module
5.1.2 System Module
5.2 Routines
5.2.1 Procedure
5.2.2 Function
5.2.3 Trap
5.3 Instructions
5.3.1 MoveL
5.3.2 MoveJ
5.3.3 MoveC
5.3.4 MoveAbsJ
5.3.5 ProcCall

ABB Robotics
Trainning Contents [4]
6. RobotStudio Introduction
6.1 3D Simulation
6.2 Offline Design and Programming
6.3 Online with IRC5 Controller
7. Maintenance & Troubleshooting
7.1 IRC5 Controller Inspection Activity
7.2 Manipulator Inspection Activity
7.3 Troubleshooting
8. Remote Service

ABB Robotics
 July 2012

Introducing ABB
ABB Group

© ABB Group
August 10, 2018 | Slide 6
Power and productivity for a better world
ABB’s vision

As one of the world’s leading engineering companies, we

help our customers to use electrical power efficiently, to
increase industrial productivity and to lower environmental
impact in a sustainable way.

© ABB Group
August 10, 2018 | Slide 7
Shaping the world we know today through innovation
Pioneering technology since 1883

Founding fathers Steam turbine Turbochargers Gas

turbine
1900 1920 1930 1940

Industrial robot Gas-insulated switchgear Gearless motor drives HVDC

1950

1970 1960
1980

Variable-speed motor Electric propulsion Extended control

drives systems Ultrahigh voltage
systems

1990 2000

© ABB Group
August 10, 2018 | Slide 8
 Jakarta

ABB in Indonesia

© ABB
10 August 2018 | Slide 9
 ABB Presence
in Indonesia

Branch Office & Sales Rep. Branch Office Branch Office & Sales Rep. Branch Office & Workshop
MEDAN PEKANBARU BATAM BALIKPAPAN

Head Office
JAKARTA
Service & Workshop
Turbocharging
Sunter, JAKARTA

LV Products Factory Service & Workshop Branch Office, Service, Workshop

CIBITUNG Electrical equipments Workshop MAKASSAR
TANGERANG SURABAYA
Indonesia
Sales and Engineering Office Facilities

LV Products
Demo Room Training Room
Showroom

§ Configuration for the § Display in this § Training room

controller, control network showroom represents accommodates in-house
and the fieldbuses ABB’s cutting edge training for Industrial IT
Automation Products System 800xA, Bailey
§ Pressure and Temperature
like Electrical Wiring systems, Advant system,
Transmitters
Accessories (EWA), drives and other ABB
§ PH Analyzer connected to Home Switches, Line technology for our
FF-HSE, Electromagnetic Protection devices customers
Flowmeter connected via (Breaker and Switches,
Profibus MCB and other DIN
§ TZIDC positioner connected rails), Instrumentation,
via HART Protocol Control Products (PLC)
and many more
§ All equipments are integ-
rated with AC800M System
© ABB Group
August 10, 2018 | Slide 13
 Robotics Division

ABB Robotic Programing and Maintenance

Trainning
For PT. Unilever Indonesia
Skin Care Factory, Cikarang
© ABB Group
August 10, 2018 | Slide 14
 Trainning Contents
Ø Safety Operation
§ Safety Knowledge

ØIRB 4600 Basic Knowledge (Manipulator)

• Manipulator Sytstem

ØIRC5 Basic Knowledge (Controller)

• Controller System
 Ø Safety Operation
§ Safety Knowledge

© ABB Group
August 10, 2018 | Slide 16
© ABB Group
August 10, 2018 | Slide 17
 Lifting The Robot

© ABB Group
August 10, 2018 | Slide 18
 Lifting The Controller

© ABB Group
August 10, 2018 | Slide 19
SAFETY
Emergency Stop

§ Built-in emergency stop pushbutton

are found both on the FlexPendant
and the Controller as default.
§ Extra emergency stops can be
connected to the robot system
safety chain.

ABB Robotics
 ØSafety Operation

In Maintenance Activity you must be Careful with any Status or Condition

of Your Robot
ü Make sure the Key Mode in Manual Mode
ü Understand and pay attention with Safety Symbols on Robot
ü Make sure for your Tools and stuff is Right with your type Of Job
ü Always Use Wrist Strap when you do some job inside the Controller

© ABB Group
August 10, 2018 | Slide 21
 IRB 2400 Manipulator

© ABB Group
August 10, 2018 | Slide 22
 IRB 2400 VARIANTS

© ABB Group
August 10, 2018 | Slide 23
 IRB 2400 VARIANTS

© ABB Group
August 10, 2018 | Slide 24
 IRB 2400 Manipulator Dimension

Type:
IRB 2400/L

© ABB Group
August 10, 2018 | Slide 25
 IRB 2400 Manipulator Dimension

Type:
IRB 2400/10
IRB 2400/16

© ABB Group
August 10, 2018 | Slide 26
 IRB 2400 Ambients temperature

© ABB Group
August 10, 2018 | Slide 27
 IRB 2400 Load Diagrams
IRB 2400/L

IRB 2400/10

© ABB Group
August 10, 2018 | Slide 28
 IRB 2400 Load Diagrams
IRB 2400/16 without
Extra Load on Wirst

IRB 2400/16 with Extra Load on wirst

© ABB Group
August 10, 2018 | Slide 29
 IRB 2400 Working Area /Axis
IRB 2400/L

IRB 2400/10 and IRB 2400/16

© ABB Group
August 10, 2018 | Slide 30
Manipulator cables

Measurement cable Motor cable

© ABB Group
August 10, 2018 | Slide 31
 IRC5 Controller Overview

© ABB Group
August 10, 2018 | Slide 32
 IRC5 Controller Overview

© ABB Group
August 10, 2018 | Slide 33
 IRC5 Controller Overview

Single Cabinet Controller

ABB Robotics
 IRC5 Controller Overview

Single Cabinet
(Other View)

ABB Robotics
 IRC5 Controller Weight & Dimension

© ABB Group
August 10, 2018 | Slide 36
 IRB 2400 Controller

© ABB Group
August 10, 2018 | Slide 37
 IRC5 Controller Key Mode

© ABB Group
August 10, 2018 | Slide 38
 IRC5 Controller System Overview

© ABB Group
August 10, 2018 | Slide 39
 IRC5 Controller Supply Power

© ABB Group
August 10, 2018 | Slide 40
 IRC5 Controller Flexpendant

ABB Robotics
 IRC5 Controller Flexpendant

ABB Robotics
 IRC5 Controller Flexpendant

ABB Robotics
SAFETY
Enabling Device (Dead Mans Grip)

§ Enabling device is a press switch with three positions.

§ The switch must be in the middle in order to activate the motors.
§ All robot movement will immediately stop if the switch is released or pressed
to the bottom.

ABB Robotics
 ØIRC5 Basic Knowledge
• Controller System

Single cabinet – Rear side with hood removed

Harting holes
& Multimove
connections

Holes for heat

exchanger
(computer)

Drive system
fan unit

Cooling
channels for
drive heat
sinks &
bleeder
resistor

Mains IRB 66/7600

transformer inductors

© ABB Group
August 10, 2018 | Slide 45
IRC5 hardware overview
Diagnostics

Control module Drive module

Power &
Power
UPS(Optional) Safety IRB xxx
Drive
panel Safety
USB
LAN Main Axes SMB
Service computer computer
Brake
release

I/O, Sensors and Drives Motor

Process equipment

Cooling
system
© ABB Group
August 10, 2018 | Slide 46
Block diagram of drive system (MDU)

Bleeder resistor Servo motors

(4-6)
Capacitor unit Motor cable
(3-phase * 4-6) M
Main servo
drive unit
Rectifier

IGBT power
DC Bus modules (4-6) DC Bus

Supervision
Current control
AC Mains DSP
&
SPI
(3-phase) measurement

SPI (to axis

computer)
AC voltage
DC bus voltage Gate
DC current driver

Temperature Single axis

drive unit(s) IGBT power
Bleeder supervision
modules
Motor cable
M
(3-phase)

© ABB Group
August 10, 2018 | Slide 47
© ABB Group
August 10, 2018 | Slide 48
ABB Robotics
Starting the System [1]

Main Switch

OFF ON

n Before switch ON the system, make sure that there

is no one inside the safeguarded space around the
robot.
n Switch ON the mains switch. The robot is then will
automatically booting.

ABB Robotics
Starting the System [2]

Main Switch

n Switch ON the Main Switch at the

controller to power ON the system.

ABB Robotics
Starting the System (Welcome Screen) [3]

Welcome Screen
n After the system has finished booting, the Welcome
Screen will appear on the display.
ABB Robotics
Operator Panel Operation [1]

Main Power
ON/OFF

Emergency Stop

Motors ON

Mode Switch

Operator Panel

ABB Robotics
Operator Panel Operation [2]

Main Power ON/OFF

n To Power ON the controller/system.

n ON/OFF Switch for system shut down.

Emergency STOP

n To STOP all operation immediately, especially

the robot itself.
n Need to perform Emergency STOP recovery /
Reset Emergency STOP state.

ABB Robotics
Operator Panel Operation [3]

Reset the Emergency STOP

n Release all pushed Emergency STOP buttons (both on Controller
and GTPU/FlexPendant).
n Press Motor ON button on the Controller to deactivate the
Emergency STOP status.

ABB Robotics
Operator Panel Operation [4]

Motors ON

n Push Button for turning ON the Motors in

AUTO mode. Motors ON Motors OFF
State State
n Indicator Lamp indicates Motors ON Status.

Mode Switch

n There are two types of mode switch :

1) two-positions mode switch
2) three-positions mode switch
n To select Operation Mode (Manual or Auto).

ABB Robotics
Operator Panel Operation [5]
Two-Positions Operation Mode Switch

a) Automatic Mode
b) Manual Reduced-Speed Mode (<250 mm/s)

Manual
Automatic Reduced-Speed
Mode Mode

ABB Robotics
Operator Panel Operation [6]
Three-Positions Operation Mode Switch

a) Automatic Mode
b) Manual Reduced-Speed Mode (<250 mm/s)
c) Manual Full-Speed Mode (100%)

Manual Reduced-Speed
Mode
Automatic Manual Full-Speed
Mode Mode

ABB Robotics
Operator Panel Operation [7]

Automatic Mode

n Used to run for Production.

n Cannot move the robot manually (using the joystick).
n Also known as Production Mode.

Robot in Automatic Mode

ABB Robotics
Operator Panel Operation [8]
Manual Reduced-Speed Mode

n Used to do programming, move to robot

manually, and parameter setting.
n Need to press the enabling device to
activate the robot’s motors.
n Also known as Programming Mode. Programming Mode

Manual Full-Speed Mode

n Used to test run the robot program at full

programmed speed.
n Need to press the enabling device to activate
the robot’s motors.
Testing Mode
n Also known as Testing Mode.

ABB Robotics
GTPU Operation (Window Menu) [1]

Touch Screen Elements

ABB Robotics
GTPU Operation (Window Menu) [2]

ABB Menu Operator Window

n Contains programs, n Displays messages

configurations, and from the program.
applications.

ABB Robotics
GTPU Operation (Window Menu) [3]

Status Bar

n Displays information about the system and messages such

as operation mode, system, and active mechanical unit.

ABB Robotics
GTPU Operation (Window Menu) [4]

Close Button

n Tapping the close button closes the presently open view or

application.

Task Bar

n Displays all open views and applications.

Quickset Menu

n Contains shortcuts
to jogging and
settings

ABB Robotics
GTPU Operation (Window Menu) [5]

Mechanical Unit

Increment

Run Mode

Step Mode

Speed

Quick Menu Elements

ABB Robotics
GTPU Operation (Quickset Menu) [1]

Mechanical Unit
Elements

ABB Robotics
GTPU Operation (Quickset Menu) [2]

Increment
Elements

ABB Robotics
GTPU Operation (Quickset Menu) [3]

Run Mode

ABB Robotics
GTPU Operation (Quickset Menu) [4]

Step Mode

ABB Robotics
GTPU Operation (Quickset Menu) [5]

Speed

ABB Robotics
GTPU Operation (Main Menu)

ABB Menu / Main Menu

ABB Robotics
GTPU Operation (Jogging) [1]

Jogging Window

n Jogging functions are found in the Jogging window.

n Common used jogging functions are also available under the
Quickset menu.
n Can jog in Manual mode only.
ABB Robotics
GTPU Operation (Jogging) [2]

Jogging Property Function

Mechanical unit Select active mechanical unit
Absolute accuracy Off is default. If the robot has the
Absolute accuracy option, then On
is displayed
Motion mode Select motion mode
Coordinate system Select coordinate system
Tool Select tool
Work object Select work object
Payload Select payload
Joystick lock Select locking joystick directions
Increment Select movement increments

ABB Robotics
GTPU Operation (Jogging) [3]
Selecting Motion Mode

ABB Robotics
GTPU Operation (Jogging) [4]
Joystick Direction (Axis by Axis)

Axis 1 - 3 Axis 4 - 6

ABB Robotics
GTPU Operation (Jogging) [5]
Joystick Direction (Axis by Axis)

Axis by Axis Direction on

Manipulator
Joystick Direction for
Axis by Axis
ABB Robotics
GTPU Operation (Jogging) [6]
Joystick Direction (Linear and Reorient)

Linear Reorient

Reorient Direction
Linear Direction on on Tool
Manipulator

ABB Robotics
GTPU Operation (Jogging) [7]
Joystick Direction (Linear and Reorient)

Joystick Direction for

Linear and Reorient

ABB Robotics
GTPU Operation (Jogging) [8]
Joystick Lock

n Joystick can be locked in specific directions to prevent

movement for one or more axes.
n Very useful on fine tuning positions during teaching / jogging.

ABB Robotics
GTPU Operation (Jogging) [9]

Joystick Unlock

n Joystick can be unlocked for one or more axes in a

same time.

Unlock All

Unlock Individual

ABB Robotics
GTPU Operation (Jogging) [10]
Incremental Movement

n Used to adjust the position of the robot exactly.

n To jog the robot in small steps, which enables very precise
positioning.

ABB Robotics
GTPU Operation (Jogging) [11]
Incremental Movement Size

n Consists of Small, Medium, Large and User Increment.

Normal (continuous) User defined increments

movement
ABB Robotics
GTPU Operation (Program Editor) [1]

Program Editor Window

ABB Robotics
GTPU Operation (Program Editor) [2]
Zoom Out

Scroll Up

Page Up

Page Down

Scroll Down

Zoom In
PROGRAM Program Editor Window Elements
ABB Robotics
GTPU Operation (Program Editor) [3]

Add Instruction Menu

ABB Robotics
GTPU Operation (Program Editor) [4]

Edit Menu

ABB Robotics
GTPU Operation (Program Editor) [5]

Debug Menu

ABB Robotics
GTPU Operation (Program Editor) [6]

Modify Position
(To record a robot position)

ABB Robotics
GTPU Operation (Program Editor) [7]

Hide Declarations and

Show Declarations

ABB Robotics
GTPU Operation (Program Data) [1]

Program Data Window

ABB Robotics
GTPU Operation (Program Data) [2]

To show
each
internal
data types

To view
Used Data
Type or All
Data Type

PROGRAM
DATA Program Data Window Elements
ABB Robotics
GTPU Operation (Program Data) [3]
Creating a new data

ABB Robotics
GTPU Operation (Program Data) [4]
Viewing Data

ABB Robotics
GTPU Operation (Program Data) [5]
Editing Data Values

Deleting Data

ABB Robotics
GTPU Operation (Inputs and Outputs) [1]

Inputs and Outputs Window

ABB Robotics
GTPU Operation (Inputs and Outputs) [2]
Simulating and changing signal values

ABB Robotics
GTPU Operation (Production Window) [1]

Production Window

ABB Robotics
GTPU Operation (Production Window) [2]

Program
Data
Window
Elements

Program to
be run

To start the
To load other program from
program beginning
ABB Robotics
GTPU Operation (Event Log) [1]

Event Log Window

ABB Robotics
GTPU Operation (Event Log) [2]

Event Log

n Open the event log to:

1) view all present entries.
2) study specific entries in detail.
3) handle the log entries, such as saving it.
n Use to monitor and record any robot or system events.

ABB Robotics
GTPU Operation (Event Log) [3]

EVENT LOG

Type of Event

Save all the Event Log Window

event logs Elements
ABB Robotics
GTPU Operation (Event Log) [4]

Open and Close the Event Log

ABB Robotics
GTPU Operation (Event Log) [5]

Saving log entries

n Save log entries when:

1) You want to send log entries to ABB Robotics
technical support to solve a problem.
2) You want to keep log entries for future reference.

ABB Robotics
GTPU Operation (Event Log) [6]

Save all log entries

ABB Robotics
GTPU Operation (Backup and Restore) [1]

Backup and Restore Window

ABB Robotics
GTPU Operation (Backup and Restore) [2]

What does a backup contain?

n All of the files/folders stored under Home directory in your

system.
n The system parameters (e.g. naming of I/O signals).
n A backup contains the info that allows your system to go
back to behave as it did when the backup was taken.
n Saves all system parameters, system modules and
program modules.

ABB Robotics
GTPU Operation (Backup and Restore) [3]

ABB recommends performing a backup :

n Before installing new RobotWare.

n Before making any major changes to instructions and/or
parameters to make it possible to return to the previous
setting.
n After making any major changes to instructions and/or
parameters and testing the new settings to retain the new
successful setting.

ABB Robotics
GTPU Operation (Backup and Restore) [4]

Backup the system

ABB Robotics
GTPU Operation (Backup and Restore) [5]

ABB recommends performing a restore :

n If, for any reason you suspect the program file corrupt.
n If any changes made to the instructions and/or
parameters’ settings did not prove successful, and the
previous settings is desired.

NOTE :
During the restore, all system parameters are replaced and
all modules from the backup directory are loaded.

ABB Robotics
GTPU Operation (Backup and Restore) [6]

Restore the system

ABB Robotics
GTPU Operation (Calibration) [1]

Calibration Window

ABB Robotics
GTPU Operation (Calibration) [2]
Check robot calibration status

What kind of calibration is needed?

ABB Robotics
GTPU Operation (Calibration) [3]
Update Revolution Counters

n Jog all of the 6 axis to the sync marks.

n Update Revolution Counters.
n Check if Revolution Counters where correctly updated.
n Also possible to update the axis one by one.

ABB Robotics
GTPU Operation (Calibration) [4]
Storing the revolution counter setting

ABB Robotics
GTPU Operation (Calibration) [5]
Checking Revolution Counters using MoveAbsJ

n Takes the manipulator to sync position.

n Insert MoveAbsJ instruction.
n Choose star position, Edit / View Value, put all 6 axis to
zero.

ABB Robotics
GTPU Operation (Calibration) [6]
Edit Motor Calibration Offset

n Type in the fine calibration values manually.

n Use moc.cfg values from Backup or silver label in back of
manipulator with 6 values.

ABB Robotics
GTPU Operation (Calibration) [7]
Fine Calibration

n Is tuned in by ABB or on site with special equipment,

value stored in Serial Measurement Board (SMB).
n Only needs to be retuned if a motor / gearbox is replaced.

ABB Robotics
GTPU Operation (Calibration) [8]
Serial Measurement Board (SMB) memory

n SMB data update :

1) If SMB is replaced or manipulator is fine calibrated in the field,
eg. motor breaks down or gearbox is replaced (Pic 1).
2) If cabinet is moved to another manipulator, eg. X-start and then
activating another system. (Pic 2).

ABB Robotics
GTPU Operation (Control Panel) [1]

Control Panel Window

ABB Robotics
GTPU Operation (Control Panel) [2]

Control Panel Window Elements (1)

ABB Robotics
GTPU Operation (Control Panel) [3]

Control Panel Window Elements (2)

ABB Robotics
GTPU Operation (Restart / Shutdown) [1]

Restart / Shutdown Window

ABB Robotics
GTPU Operation (Restart / Shutdown) [2]

Press Warm Start to restart

the system
ABB Robotics
GTPU Operation (Restart / Shutdown) [3]

Shutdown the system

ABB Robotics
GTPU Operation (Restart / Shutdown) [4]

Shutting Down

ABB Robotics
© ABB Group
August 10, 2018 | Slide 126
ABB Robotics
WHAT IS COORDINATE SYSTEM?
Overview

A coordinate system defines a plane or space by axes from the fix point
called the origin. Robot targets and position are located by measurements
along the axes coordinate systems. A robot uses several coordinate
systems, each suitable for specific types of jogging or programming :
§ Base coordinate system
§ World coordinate system
§ Tool coordinate system
§ User coordinate system
§ Work Object coordinate system

ABB Robotics
BASE COORDINATE SYSTEM
§ The base coordinate system has it
zero point in the base of the robot,
which makes movement predictable
for fixed mounted robots.

ABB Robotics
WORLD COORDINATE SYSTEM
§ The world coordinate
system has its zero point on
a fixed position in the cell or
station. This make it useful
for handling several robots or
robots moved by external
axes. For a system with only
one robot, by default the
world coordinate system
coincidences with the base
coordinate system of the
robot.

ABB Robotics
TOOL - TCP COORDINATE SYSTEM
§ The tool coordinate system has its zero position at the center of the tool.
It thereby defines the position and the orientation of the tool. The tool
coordinate system abbreviated to TCP (Tool Centre Point) or TCPF (Tool
Centre Point Frame).

ABB Robotics
TOOL - TCP COORDINATE SYSTEM
Creating a tool

§ The tool center point of the default tool (tool0) is in the center of the robot’s
mounting flange and with the mounting flange’s orientation.
§ By creating a tool, you can define another tool center point.

ABB Robotics
TOOL - TCP COORDINATE SYSTEM
Creating a tool

ABB Robotics
TOOL - TCP COORDINATE SYSTEM
Tool Declaration Setting

ABB Robotics
TOOL - TCP COORDINATE SYSTEM
Defining Tool Frame

§ To define the tool frame, you first need a reference point in the world
coordinate system.
§ If you need to set the TCP orientation, you also need to define axis elongators
of the tool.

ABB Robotics
TOOL - TCP COORDINATE SYSTEM
Defining Tool Frame

ABB Robotics
TOOL - TCP COORDINATE SYSTEM
Defining Tool Frame

§ This procedure describes how to define the TCP in Cartesian Coordinate.

ABB Robotics
TOOL - TCP COORDINATE SYSTEM
Defining Tool Frame

ABB Robotics
TOOL - TCP COORDINATE SYSTEM
Defining Tool Frame

§ This procedure describes how to define the elongator points.

ABB Robotics
USER COORDINATE SYSTEM
§ The user coordinate
system can be used for
representing equipment
like fixture or workbench.
This gives an extra level
in the chain of related
coordinate systems, which
might be useful for
handling equipment that
hold work object or other
coordinate systems.

ABB Robotics
USER COORDINATE SYSTEM
Defining user frame
§ Below procedures describes how to define a user frame.

ABB Robotics
USER COORDINATE SYSTEM
Defining user frame

ABB Robotics
WORK OBJECT COORDINATE SYSTEM
§ The work object coordinate system corresponds to the work piece:
It defines the placement of the work piece in relation to the world
coordinate system (or any other coordinate system).

ABB Robotics
WORK OBJECT COORDINATE SYSTEM
Creating a work object

§ Below procedure shows how to create a work object.

ABB Robotics
WORK OBJECT COORDINATE SYSTEM
Work Object Declaration Setting

ABB Robotics
WORK OBJECT COORDINATE SYSTEM
Work Object Declaration Setting
§ Below procedures describe how to select a method.

ABB Robotics
WORK OBJECT COORDINATE SYSTEM
Defining the work object frame
§ Below procedures describes how to define work object frame.

ABB Robotics
ABB Robotics
Before you start programming
2 things that must be remembered:
a) Define tools, payloads and work objects
b) Define coordinate systems

TIP!
n Need to know more about the RAPID language and structure? See the manuals
RAPID reference manual - RAPID overview, RAPID reference manual -
Instructions, and RAPID reference manual - Functions and data types.

ABB Robotics
What is a Program Module?

nA program module can consist of different

data and routines.

nOne of the modules contains the entry

procedure, a global procedure called main.

nThe program can include many modules, but

only one of these will have a main procedure.

nProgram Modules are normally stored/loaded

with the program.

nProgram Modules can be stored/loaded

separately.

ABB Robotics
What is a System Module?

ØSystem modules are used to define common,

system-specific data and routines, such as tools.

ØA System Module is not included when a

program is saved, meaning that any update
made to a system module will affect all existing
programs currently in, or loaded at a later stage
into the program memory.

ABB Robotics
What is a Routines? [1]

There are three types of routines (subprograms):

Procedures, Functions and Trap:

- Procedures do not return a value and are used

in the context of instructions.

- Functions return a value of a specific type and

are used in the context of expressions.

- Trap routines provide a means of dealing with

interrupts.

ABB Robotics
What is a Routines? [2]

§ A routine can contain routine declarations (including parameters), data,

a body, a backward handler (only procedures) and an error handler.
§ Routine declarations cannot be nested, i.e. it is not possible to declare
a routine within a routine.

ABB Robotics
ABB Robotics
Handling of programs

How to:
§ create a new program
§ load an existing program
§ save a program
§ rename a program
§ delete a program
Each task must contain one program, no more, no less.

ABB Robotics
Handling of programs [1]
Creating a new program

ABB Robotics
Handling of programs [2]
Loading an existing program

ABB Robotics
Handling of programs [3]
Saving a program

Renaming a loaded program

ABB Robotics
ABB Robotics
Handling of modules

How to handle program modules, i.e.:

§ create a new module
§ load an existing module
§ save a module
§ rename a module
§ delete a module

ABB Robotics
Handling of modules [1]
Creating a new module
Step Action
1 On the ABB menu, tap Program Editor.
2 Tap Modules.
3 Tap File, then tap New Module.
4 Tap ABC... and use the soft keyboard to enter the new module’s name. Then tap
OK to close the soft keyboard.
5 Select which type of module to be created:
• Program
• System
Then tap OK.
The differences between module types are described in section The structure of
a RAPID application on page 134.

ABB Robotics
Handling of modules [2]
Load an existing module

Step Action
1 On the ABB menu, tap Program Editor.
2 Tap Modules.
3 Tap File, then Load Module .
4 Tap OK to load the selected module.
The module is loaded.

ABB Robotics
Handling of modules [3]
Save module
Step Action
1 On the ABB menu, tap Program Editor.
2 Tap Modules and tap to select the module you want to load.
3 Tap File, then Save Module As...
4 Tap on the suggested file name and use the soft keyboard to enter the module’s
name. Then tap OK.
5 Use the file searching tool to locate where you want to save the module.
The default location is on the controller disk.
The tap OK.
The module is saved.

ABB Robotics
Handling of modules [4]
Rename a module

Step Action
1 On the ABB menu, tap Program Editor.
2 Tap Modules.
3 Tap File, then Rename Module...
The soft keyboard is displayed.
4 Use the soft keyboard to enter the module’s name. Then tap OK.

ABB Robotics
Handling of modules [5]
Delete a module

Step Action
1 On the ABB menu, tap Program Editor.
2 Tap Modules and tap to select the module you want to delete.
3 Tap File, then Delete Module...
A dialog box is displayed.
4 Tap OK to delete the module without saving it.
If you want to save the module first, tap Cancel and save the module first.

ABB Robotics
ABB Robotics
Handling of routine [1]
Creating a new routine

ABB Robotics
Handling of routine [2]
Deleting a routine

ABB Robotics
ABB Robotics
Handling of Instructions [1]
Adding Instructions

Instructions
List

ABB Robotics
Handling of Instructions [2]
Editing Instructions Argument (1)

ABB Robotics
Handling of Instructions [3]
Editing Instructions Argument (2)

ABB Robotics
Handling of Instructions [4]
Editing Instructions Argument (3)

ABB Robotics
Handling of Instructions [5]
Editing Instructions Argument (4)

ABB Robotics
Handling of Instructions [6]
Copying and pasting instructions or arguments

Cutting an instruction

ABB Robotics
Handling of Instructions [7]

Changing motion mode for a move instruction

Running a specific routine

ABB Robotics
Handling of Instructions [8]
Restart a program from the beginning

Stopping program

ABB Robotics
MoveL - Moves the robot linearly

§ MoveL is used to move the tool centre point (TCP) linearly

to a given destination.

§ When the TCP is to remain stationary, this instruction can

also be used to reorientate the tool.

ABB Robotics
MoveL - Moves the robot linearly

Type of path Speed specified in speed data

v100=100mm/s
- L = Linear
Tool (TCP)

MoveL *, v100, z10, tool1

Destination position Zone size specified in zone data

- * = stored in instruction z10 = 10mm
- P10 = stored in position data p10 (in Program Data)

ABB Robotics
 Speed Data

§ Speed data is used to specify the velocity at which both the robot
and the external axes move.
§ It defines the velocity:
§ At which the tool centre point moves.
§ Of the reorientation of the tool.
§ At which linear or rotating external move.
§ Example :
§ V100 = 100 mm/s

ABB Robotics
 Zone Data

§ Zone data is used to specify how a position is to be terminated, i.e.

How close to the programmed position the axes must be before
moving towards the next position. In other words, Zone data
describes how close to the destination position the TCP must be
before the next instruction can be executed.
§ A position can be terminated either in the form of a stop point or a
fly-by-point.

ABB Robotics
MoveJ - Moves the robot by joint movement

§ MoveJ is used to move the robot quickly from one point to

another when that movement does not have to be in a
straight line.

ABB Robotics
MoveJ - Moves the robot by joint movement

Type of path Speed specified in speed data

v100=100mm/s
- J = Joint
Tool (TCP)

MoveJ p10, v100, z10, tool1

Destination position Zone size specified in zone data

- * = stored in instruction z10 = 10mm
- P10 = stored in position data p10

ABB Robotics
MoveL versus MoveJ

MoveJ

MoveL

ABB Robotics
MoveC - Moves the robot circularly

§ MoveC is used to move the tool centre point (TCP)

circularly to a given destination.

§ During the movement, the orientation normally remains

unchanged relative to the circle.

ABB Robotics
MoveC - Moves the robot circularly
Circle position
- * = stored in instruction
Type of path
- P20 = stored in position data p20
C = circular

MoveC p20, p30, v100, z10, tool1

Destination position
- * = stored in instruction
- P30 = stored in position data p30

ABB Robotics
MoveC - Example

ABB Robotics
MoveAbsJ - Moves the robot to an absolute joint position

§ MoveAbsJ (Move Absolute Joint) is used to move

the robot to an absolute position, defined in axes
positions.
§ The final position of the robot, during a movement
with MoveAbsJ, is neither affected by the given tool
and work object, nor by active program displacement.
§ However, the robot uses these data to calculating the
load, TCP velocity, and the corner path.
§ The robot and external axes move to the destination
position along a non-linear path.
§ All axes reach the destination position at the same
time.
ABB Robotics
MoveAbsJ - Moves the robot to an absolute joint position

Type of path Speed specified in speed data

v1000=1000mm/s
- J = Joint
Tool (TCP)

MoveAbsJ p10, v1000, z10, tool1

Destination position Zone size specified in zone data

- * = stored in instruction z10 = 10mm
- P10 = stored in position data p10

ABB Robotics
ProcCall - Calls a new procedure [1]

§ A procedure call is used to transfer program

execution to another procedure.
§ When the procedure has been fully executed,
program execution continues with the instruction
following the procedure call.

ABB Robotics
ProcCall - Calls a new procedure [2]

Procedure main
procedure fetch_part
...
fetch_part MoveJ *,vmax,z50,tool1;
leave_in_machine MoveL *, v1000,z30,tool1;
process_part MoveL *,v200,fine,tool1;
fetch_fr_machine grip;
leave_part MoveL *,v200,z30,tool1;
...

grip

Set gripper;
WaitTime 0.3;

release
Reset gripper;
WaitTime 0.3;

ABB Robotics
 Comments in Program

• Comments are used to make the program easier to understand.

• Comments have no influence on the program execution, i.e. the
line is not executed.

! This is a comment.
! This line is not executed.

ABB Robotics
© ABB Group
August 10, 2018 | Slide 193
ABB Robotics
RobotStudio Introduction

Main Functions of RobotStudio

a) 3D Simulation for the Robot Cell

Especially to check whether the robot specification selected is correct or
not (in reachability to target work object, maneuverability in the cell, etc.).
b) Offline Design and Programming
• Much more convenient programming environment (as compared to
programming on GTPU/FlexPendant).
• Enable creation of virtual systems for simulation.
c) Online with IRC5 Controller
Enables online programming and parameter settings to IRC5 Controller.

ABB Robotics
RobotStudio Introduction

3D Simulation for a Robot Cell

ABB Robotics
RobotStudio Introduction

RobotStudio Offline

ABB Robotics
RobotStudio Introduction

RobotStudio Online

- Install/create a new robot system (with System Builder) :

- Create a new or modify an existing robot system.
- Download an existing virtual robot system into a controller.
- Configure/maintain existing robot systems :
- Backup and restore.
- Modify/configure system parameters (system unique setting).
- Read event, status fault logs.

ABB Robotics
RobotStudio Introduction

Connect RobotStudio Online to the Controller

§ Use the twisted Ethernet cable that was shipped with the controller.
§ Connect one end to your PC, and the other to service port on the controller.

ABB Robotics
© ABB Group
August 10, 2018 | Slide 200
 Robotics Division

ABB Robotic Programing and

Maintenance Training

© ABB Group
August 10, 2018 | Slide 201
 IRB 2400 Cleaning Activities

© ABB Group
August 10, 2018 | Slide 202
 IRB 2400 Preventive maintenance

© ABB Group
August 10, 2018 | Slide 203
 IRB 2400 Oil Specification & Requirements

© ABB Group
August 10, 2018 | Slide 204
 IRB 2400 Changing Oil on Wrist Unit

© ABB Group
August 10, 2018 | Slide 205
 IRB 2400 SMB Board & Battery

© ABB Group
August 10, 2018 | Slide 206
 IRB 2400 Replacement harness cable 1st-3rd Axis

© ABB Group
August 10, 2018 | Slide 207
 IRB 2400 Replacement harness cable 4th-6th Axis

© ABB Group
August 10, 2018 | Slide 208
 IRB 2400/10 & 2400/16 Calibration Point

© ABB Group
August 10, 2018 | Slide 209
 IRB 2400L Calibration Point

© ABB Group
August 10, 2018 | Slide 210
 IRB 2400 Calibration Mode on Flexpendant

© ABB Group
August 10, 2018 | Slide 211
 IRB 2400 Brake Release Operation

Brake Release
§ Use ONLY for restoring the mechanical
unit of the robot after crash!!!
§ Be aware that the corresponding axis
may fall down, because the brake is
released when the motor is not
active!!!
§ Make sure that the corresponding axis
is held properly before pushing the
Brake Release button.
§ Be extremely careful with Brake
Release of axis 2 and 3, since these
two hold a massive load (the mass of
the arm itself and the robot’s
payload)!!!

ABB Robotics
 IRC5 Maintenance Activity

© ABB Group
August 10, 2018 | Slide 213
 IRC5 Maintenance Activity

© ABB Group
August 10, 2018 | Slide 214
 IRC5 Maintenance Activity

© ABB Group
August 10, 2018 | Slide 215
 IRC5 Part List

© ABB Group
August 10, 2018 | Slide 216
 IRC5 Part List

© ABB Group
August 10, 2018 | Slide 217
 IRC5 Flexpendant Maintenance Activity

Cleaning the Flex Pendant Unit

© ABB Group
August 10, 2018 | Slide 218
 IRC5 Flexpendant Maintenance Activity

How to Lock the Screen

© ABB Group
August 10, 2018 | Slide 219
© ABB Group
August 10, 2018 | Slide 220
 René Nispeling, GPG Robotics Service, March 2011

Service Agreements with remote

service technology
A new dimension in customer care
© ABB Group
August 10, 2018 | Slide 221
Our vision on service

ABB Robotics Service wants to be the reason

why customers continue to buy from ABB,
providing world-class services locally,
wherever there is an installed base of ABB robots.

© ABB
© ABB Group
Group
August 10,
August 10, 2018
2018 || Slide
Slide 222
222
Market expectations

In the past
§ Traditional service
§ Spare Parts

§ Break-fix field service

§ Basic preventive maintenance

Today
§ Value-adding service solutions
§ Fast Response and Resolution

§ Reducing Total cost of ownership

§ Increase utilization ratio

© ABB Group
August 10, 2018 | Slide 223
 ABB Robotics Service Agreements
with Remote Service
§ Maintenance Package
Maximize the MTBF

§ Response Package
Minimize the MTTR
§ Warranty Package
Control over the TCO

§ Partner Support Package

Faster ramp-up during
commissioning

© ABB
© ABB Group
Group
August 10,
August 10, 2018
2018 || Slide
Slide 224
224
A Life-Cycle Approach

Customer
Value

Major
Minor
Failure
Failure
Traditional
Life-Cycle

Commissioning Warranty Life of Installation

Time
© ABB Group
August 10, 2018 | Slide 225
A Life-Cycle Approach

Customer
Value

Service
Agreements
and Training
Major
Minor
Failure
Failure
Traditional
Life-Cycle

Commissioning Warranty Life of Installation

Time
© ABB Group
August 10, 2018 | Slide 226
A Life – Cycle Approach

Customer
Value

Productivity
Improvement
Projects

Service
Agreements
and Training
Major
Minor
Failure
Failure
Traditional
Life-Cycle

Commissioning Warranty Life of Installation

Time
© ABB Group
August 10, 2018 | Slide 227
A Life – Cycle Approach

Customer
Value
Performance
Services

Productivity
Improvement
Projects

Service
Agreements
and Training
Major
Minor
Failure
Failure
Traditional
Life-Cycle

Commissioning Warranty Life of Installation

Time
© ABB Group
August 10, 2018 | Slide 228
Background
Unplanned stop at your customer

What are the options?

§ Try to communicate over the phone and
ask for more information?
§ Make best guess and send a variety of
spare parts?
§ Take a technician off a customer project
and put him on the first plane?

Typical figures
§ 2 hours to get relevant data per case
§ 8 hours lost production per failure
§ 2 - 5 visits during commissioning and
tuning period

© ABB Group
© ABB
Slide
August229
10, 2018 | Slide 229
ABB has the solution
Service Agreement with Remote Service

…You can
§ receive a notification with error message
§ view the alarm history and alarm status
§ request a program back-up
§ retrieve the last program back-up
§ view the robot condition report
§ get an ABB expert to analyze the
problem over the phone using overall
diagnostics
robot data.

All remotely!

© ABB Group
© ABB
Slide
August230
10, 2018 | Slide 230
Technology shift
Efficient infrastructure to monitor robot systems

Remote Access since 90s § High investment/maintenance cost’s

§ High maintenance cost for equipment
§ Firewall restrictions
§ Limited diagnostic information
§ No history of failures
§ Dedicated full time staff needed

ABB Remote Service § Low investment/maintenance cost

§ Direct access - without accessing customer
factory network
§ Automatic monitoring
§ Advanced diagnostics
§ Whole history available at any time
§ Information on demand

© ABB
© ABB Group
Slide 231
August 10, 2018 | Slide 231
Remote Service support network
Authorized staff can access robots from anywhere

1150 service employees operating in

over 50 countries and in 100 locations
§ Technical Support engineers
§ Remote Service engineers
§ Field Service engineers
© ABB
© ABB Group
Group
August 10,
August 10, 2018
2018 || Slide
Slide 232
232
Fast & Professional Support
24/7 to reduce MTTR

§ Immediate notification of critical failure

§ All relevant information available
§ Robot Configuration
§ Complete Event Logs
§ Device information
§ Last Backup
§ Failure history
§ Key measurements of robots status

© ABB Group
August 10, 2018 | Slide 233
Increased Uptime
Keep your robots producing

§ Robot program back-up

§ Condition based maintenance
§ Predictive measurements
§ Trend key controller parameters
§ Manipulator diagnostics

© ABB Group
August 10, 2018 | Slide 234
 Preventive Maintenance
Robot Condition Report
Features
§ Overview of actual condition
§ Overview of alarms
§ Maintenance update
Benefits
§ Discover problem areas
§ Reduce unplanned production stops
§ Reduced cost & increase MTBF

© ABB Group
August 10, 2018 | Slide 235
Preventive Maintenance
Robot Assessment Report

Features
§ Optimize robot work cycle
§ Estimate wear of parts for preventive
change
§ Create maintenance plan according to
usage
Benefits
§ Longer equipment life time
§ Reduce unplanned production stops
§ Reduced cost & increase MTBF

© ABB Group
August 10, 2018 | Slide 236
MyRobot on abb.com
24/7 access to robot status from anywhere

At any time you can:

§ View list of connected robots

§ Alarm list and alarm status
§ Follow ongoing support cases
§ View key ABB contacts
§ Retrieve latest program back-up
§ Request new back-up
§ Access Condition Reports

© ABB Group
© ABB
Slide
August237
10, 2018 | Slide 237
Example of a real case, ….
9/14/2010 9:30AM
Mr.Prakash
Subject: to INABB
Intermittent Motion Engineer
SupervisionMr.Nikhilesh
Errors in Robots.
Hello9/14/2010
Mr.Prakash,
12:30PM
I have been
Subject Re:studying some of the
Intermittent data being
Motion relayed by our
Supervision Remote
Errors in Service
Robots. box for the above robot,
We found there were intermittent motion supervision Errors occurring in your robot as follows.
Mr.Nikhilesh,
Robot Sr.No: 76-51719, New 9/14/2010 4:42:32 AM 50204 Motion supervision
New
We9/13/2010
have 4:25:13
checkedAM 50204
robotMotion
as per supervision
suggestions given by you. Yes, this problem has arise
New 9/12/2010 6:08:16 PM 50204 Motion supervision
post we did changes in our existing part extraction cycle. As suggested by you to do fine
tuning of robot programmed path at stacking position, this problem has eradicated.
Robot Sr.No: 66-58233 New 9/10/2010 9:37:34 AM 50204 Motion supervision
New 9/10/2010 2:56:25 AM 50204 Motion supervision
ABB RS technology has helped to identify
New 9/9/2010 2:22:19 PM 50204 Motion supervision
the problem remotely and providing right
solution to avoid breakdown in robot.
Please can you ensure & check following things,
Thanks for your support.
1) Check If the mechanical unit is exposed to forces from the external processes.
2) Check for collision with foreign articles near by Robot.
Br/ Prakash N
3) Are there any changes made in your existing process & robot positions. If yes please correct
robot positions for correct stacking of parts without any force on robot axes

Br/ Nikhilesh Kale,

Engineer After sales & Services.

© ABB Group
August 10, 2018 | Slide 238
Example of a real case, ….
02.23.2010 05:20 PM
Mr.Siddharth
Subject: Memorytoover
INABB
usageEngineer
in RAW 50Mr.
FlexNikhil/Vikas
Arc cell
02/27/2010
Hello 10:59 AM
Mr. Amit/Siddharth,
Please find above the first controller component information that Remote Service has relayed. The hard disc
Subjectand
is overused Re:hasMemory over available
too less space usage inforRAW
further 50
dataFlex
to beArc cell
saved.
We will investigate the importance of the data present on the CF card as of now. Please action proper plan to
Mr.more
make Nikhil/Vikas,
disc space available.
This is ref to the remote service unit which has been started in suspension shop.
The system has started functioning .This is a good system provided we receive errors
which are important
Thanks for your support.
Regard,
S.Siddharth

Br/Vikas Bhat.

© ABB Group
August 10, 2018 | Slide 239
Example of a real case, ….

Motor Temperature High Alarm was reported 51 times immediately after installation of RS kit. Prior
to this no information was cascaded by customer to ABB. Upon Investigation and diagnosis on the robot by
ABB technician it was observed that the robot 66-59941 was over loaded and was running with higher payload.
This was thus informed to customer to take action and reduce the tool load with the help of their system
integrator.

The Robot was under warranty and thus helped us to reduce unprecedented cost towards warranty
&ABBpremature
© Group failure of the Robot.
August 10, 2018 | Slide 240
Example of a real case, ….
2/25/2011 8:30AM
2/25/2011
Subject: Communication error IRB-1600 robot
Subject: Communication error IRB-1600 robot
Mr Gonçalves of a large construction company with 24 ABB robots called ABB and reported a
Customer
problem value:
with an arc-welding robot that is critical to their production.
ABB could remotely establish that there was a communication problem in the IRC5 controller
Immediate
and response
determined that aand
the accurate
flash-diskfault-finding
could be the avoiding shipping
root-cause of thea failure.
variety of spare-parts
potentially
An engineer wasseveral visits,with
dispatched causing
a newa down-time
flash-disk. of serveral
After a shortdays.
investigation the engineer
found indeed that the computer-unit flash card had crashed.
In a normal case the customer would without back-up been forced to reprogram all
Afterprograms,
installing atypically
new flashdozens of programs
card the customerand wasfine-trimming the robot
asked for a recent positions.
back-up of the system.
TheThe production
customer loss would
answered with be as big
a pale faceasthat
several
theredays
weretonomore than aavailable!
back-ups week.

The
Due to Remote Service
the remote SLA
service had a pay-back
solution after just
with automatic one failure!!!
back-up ABB was able to recover all
programs and parameters of this robot system and upload to the robot memory.
This customer will likely have remote on all S4C+ and IRC-5 robots
(and
ABB make
could back-ups)
upload both program and parameter back-ups and the robot was up and
running again 2/25/2011at 11.00 AM

Tijn van Pelt

Senior Field Service engineer & Remote Service Specialist
ABB Robotics Benelux
© ABB Group
August 10, 2018 | Slide 241
Example of a real case, ….

Subject: Multiple Motion Supervision errors

Customer Value:

This Robot was under warranty and thus helped ABB to reduce potential cost
towards warranty & premature failure of the Robot.

It helped the Customer to avoid unplanned stops and production losses.

Motor Temperature High Alarm was reported 51 times immediately after installation of RS kit. Prior to this no
information was cascaded by customer to ABB. Upon Investigation and diagnosis of the robot by ABB
technician it was observed that the robot 66-59941 was over-loaded and running with higher payload. This
was conveyed to customer to take action and reduce the tool load with the help of their system integrator.

© ABB Group
August 10, 2018 | Slide 242
ABB Service Agreement with Remote Service
Case Study: Swedwood, Hultsfred in Sweden

Client
§ Swedwood in Sweden (subsupplier to Ikea)

Application
§ Material handling

Products:
§ The famous PAX wardrobe exclusively for IKEA

Key Drivers & Benefits

§ Ensures highest possible availability
§ ABB can anticipate problems
§ Program backups on the robots
§ Support from ABB 24/7
§ To focus on their core business

“Remote Service is like an insurance policy. We

insure ourselves for availability so we can focus on
our core business which is manufacturing furniture”.
AndreasTeodorsson, maintenance manager at
Swedwood.

© ABB Group
August 10, 2018 | Slide 243
Swedwood Video
 Global Market References

Indian Market References

© ABB Group
August 10, 2018 | Slide 245
 Remote Service
A feature of ABB Robotics Service Agreements

Already 1000 units in 2008

Konnichi wa!
HOLA! I’m fine, thanks for
My next service is due… asking…
HELP!
I don’t feel so
good…

© ABB
© ABB Group
Group
August 10,
August 10, 2018
2018 || Slide
Slide 246
246
Benefits to Remember

Higher Uptime (longer MTBF)

Fast response (lower MTTR)
Lower TCO (e.g. maintenance)
Peace of Mind:
Robot program back-up
Condition and Status reports
© ABB Group
August 10, 2018 | Slide 248
Exercise 1

§ Start up the robot system under consideration of the safety

procedures
§ Choose the JOG window on the teach pendant
§ Choose the following settings
§ Coordsys : Base
§ Tool : tool0
§ Workobj : Workobj0
§ Move each joint of the robot in joint mode
§ Move one axis all the way to the limit of the working limit.
Confirm the error message and move in the opposite direction
§ Move the robot in linear motion mode
§ Change the speed of the movement by selecting incremental…
§ Move the robot by selecting reorientation mode

ABB Robotics
Exercise 2

1. Select the Program window and choose File.

2. Select New and prss Enter button
3. Write the name of the program on the numerical
keyboard, EX2 and press OK
4. Press the manu key IPL1
5. Select Common (1)
6. Choose Move instruction according to the program
example next page
7. The positions p10 - p50 shall be programmed so that
when executing the program, the pencil moves linearly on
the table except from p50 to p10.
8. Select Test and set the speed adjustment (-%) to 10%.
Run the program in Manual mode (<250 mm/s), first step-
by-step forwards (FWD) and then continuously (Start)
ABB Robotics
PROC main()
MoveJ p10, v500, fine, tool0
MoveL p20, v500, fine, tool0
MoveL p30, v500, fine, tool0
MoveL p40, v500, fine, tool0
MoveL p50, v500, fine, tool0 p40 p10
p50
ENDPROC

p30 p20
Exercise 3 [1]

1. Continue from the EX2

2. Create and define a tool (choose View: Data Types: Tooldata) called tool2
(using 4 point definition)
3. Exchange all tool0 arguments in the program to tool2 and run the program
What happened and why?
……………………………………………………………………………………
…………………………………………………………………………………...
4. Reprogram all the positions to the “right” place by using the key ModPos and
test run the program again
5. Increase the speed (+%) by steps to 50% while running the program in
continuous mode. To reach a higher speed the Operation Mode Selector has
to changed to 100%
Observe the robot behavior (the speed) at the positions programmed
…………………………………………………………………………………….
…………………………………………………………………………………….
ABB Robotics
Exercise 3 [2]

6. Change the zone argument from fine to z30 for positions p20, p30 ans p40.
Set the speed correction (-%) to 10% and run the program, first step-by-step
(FWD) and then in continuous mode (Start)
Observe the difference in movement at the z30 positions
…………………………………………………………………………………..
7. Change the speed for position p30 to v300 and for p40 to v1000
Run the program with different speed correction settings and check the path
performance at the fly-by positions.
Is there a difference?
………………………………………………………………………………….
8. Insert a time of waiting for 5 seconds (IPL1: Various : WaitTime) after the
instruction for p40.
Run the program and notice the robot position when the waiting is executed

ABB Robotics
Exercise 3 [3]

9. Remove the instructions for the waiting and p50 from the
program.
Run the program again and notice the new behavior.
10. Change the instructions for p20 and p30 from MoveL to
MoveJ
Observe the movement change when executing the
program
……………………………………………………………………
…………….
11. Insert the position p50 again and put an obstacle
between p30 and p40, which the robot has to pass in a
proper way, by programming four new instructions (MoveL)
with suitable speed and zone size. (p60, p70, p80, p90)
Run the program and notice the robot position when the
activation of the output starts.
ABB Robotics
Exercise 3 [4]

13. Change the zone argument for p30 to fine

Run the program again and watch the difference compared
to item 12
……………………………………………………………………
…………….
14. Perform a backward execution of the program (BWD),
watching the movements and what is happening at the
logical instruction.
……………………………………………………………………
……………..
15. Save the program with the new name of EX3

ABB Robotics
Exercise 4 [1]

1. Which group of coordinate systems are available in the

robot system?
A) ………………………………………
B) ………………………………………
C) ………………………………………
D) ………………………………………
E) ……………………………………...
2. Re-open program EX2
3. Create and define a workobject called wobj2 (in PERS
datatype)
(User coordsys = Base coordsys)
4. Modify the program so that it is uses the workobject wobj2
in the Move instruction (re-teach the point)
5. Create another workobject wobj3 (with location show in
ABB Robotics next page)
Exercise 4 [2]

wobj3 wobj2
+x +x

+y +y

ABB Robotics
Exercise 4 [3]

6. Change the Workobject in Move instruction from wobj2 to

wobj3
Observe the movement change when executing the
program
………………………………………………………………………
………….
7. Save the program with the new name of EX4

ABB Robotics
Exercise 5 [1]

1. Create a routine according to the flowchart below and call EX5

2. Add an instruction to the routine.
3. Complete the program by putting in another routine.
4. Add a position (phome) at the beginning of the program.

Triangle Square Circle

Routine Routine Routine

ABB Robotics
Exercise 5 [2]

PROC Square() PROC Cricle()

MoveJ pHome, v500, z20, tool0; MoveJ pHome, v500,z20,tool0;
MoveL sq1, v150, fine, tool0; MoveL c1, v500, z20, tool0;
MoveL sq2, v150, fine, tool0; MoveL c2,c3, v200, fine, tool0;
MoveL sq3, v150, fine, tool0;
MoveL c4,c1,v200,fine,tool0;
MoveL sq4, v150, fine, tool0;
MoveJ pHome, v500,z20,tool0;
MoveL sq1, v150, fine, tool0;
ENDPROC
MoveJ pHome, v500, z20, tool0;
ENDPROC

PROC Triangle()
MoveJ pHome, v500,z20,tool0;
MoveJ tri1, v500, z20, tool0;
MoveL tri2, v200, fine, tool0;
MoveL tri3,v200,fine,tool0;
MoveL tri1, v200, z20, tool0;
MoveJ pHome, v500,z20,tool0;
ENDPROC

ABB Robotics
Exercise 6 [1]

1. Continue the EX5.

2. Using the procall method to link all the routine.

Main
procedure

Triangle Square Circle

procedure procedure procedure

ABB Robotics
Exercise 6 [2]

PROC main()
Circle;
Square;
Triangle;
ENDPROC

ABB Robotics
 Q&A

ABB Robotics
References
1. ABB Limited – Robotics, IRC5 Programming and
Operation, 2007.
2. ABB Malaysia, Basic Robot Programming Training
IRC5.
3. ABB Robotics, Robot Documentation M2004, Rev. F,
RW 5.14.02.
4. ABB Group – Robotics, ABB Robotics Overview, 2012.

ABB Robotics