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1
Prepared By - Jay Modi
Contents

• Basics of Robots
• Detailing of Robots
• Process Parameters
• Programming
• Interlocks
• Data Movement
• Maintenance
• Troubleshoot

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Basics of ABB Robots

• We have ABB interior robots of IRB 5500 Series for interior painting of car body.
• They come in forms of Base Mount, Rail Mount or Track Mount and Wall Mount.
• There are total 6 axes in the wall mount robots.

• Atomizer comes in RB1000 Series.

• Atomizer is of two types SAD and SSD.
• SAD – 1k System , Clear type paint.
• SSD – 2k System, Clear and Hardener type paint .

• Controller – IRC 5P (Modern / Latest Version)

• Industrial robot controller.

• TPU- Teach Pendant Unit.

• Color Non- Touch Screen.

• Cap Cleaner :- Atomizer and bell cup cleaning

• 2 Air and 2 thinner spray holes , which cleans the atomizer and bell cup .

• Operational Panel:- PC, CPU and UPS.

3
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 Base Coat Zone – 1
• 12 Robots
• Single power distribution panel for common supply to all the robots.
• PLC panel common for all the robots.
• Air panels – 6 in quantity.

• Now I Have to know how the controller , PLC , Operational Panel , TPU work together to do a specific task . Or can say
implementation part of robot.

• Put some pictures of ABB robots of booth BC and CC interior robots and also with axes details.

Prepared By - Jay Modi c Copyright, Confidential, Tata Motors Limited 4

Mechanical part in a Robot
• 6 axes are having 6 servo motors along with 6 encoders to give them feedback .

• Color Changing Valve (CCV)

• Atomizer consists of following things:-

• Air Motor
• Needle
• Shaping Air Nozzle
• Valves
• Dump
• Solvent bell C
• Air Bell C
• HV cascade

• Pressure Control Valve

• Gear Pump
• Pressure Sensor
• ACU Unit

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• HVC card for High Voltage Control
• Purging Unit
• VCB – Provides Pilot air to operate the valve.
• Gear Pump Motor – Maintain the flow of paint.

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Conveyor Tracking
Date:- 17 Jan 2024
• The conveyor tracking function enables the robot to follow the parts
as they move along a conveyor line..

• It consists of three main components:-

1. The conveyor encoder which detects the motion of the conveyor.

2. The sync switch which detects the position of the objects on the
conveyor.
3. The tracking software which control the process.

How it Works?

 With Conveyor tracking, the path of the robot ( tool center point)
will follow the work object on the conveyor .
 The result is that the work object on the conveyor can move at
Figure Tracking design overview
different speeds, stop completely and even move backwards without
affecting the finishing result as long as it is within the reach of the
robot.

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Conveyor Tracking
 The position of the work object can also be shifted during
programming , as the control system also will keep track of the
location of the work object in programming mode.

The Encoder

 The signals from the encoder inform the robot controller about the
motion of the conveyor.
 A two-phase type encoder is necessary to detect the direction of the
motion.

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Brush Table Fixings
How to fix the problem of Sag , Thin Paint and Uncovered area?

 The Sag, Thin Paint and Uncovered area can be seen by just
observation after painting the car body .
 We can also check this after taking car to offline , when it passes
through the Top coat oven . We use DFT tool to check it .
 To mitigate this problem we change the brush table parameters.
Mainly the flow , pattern of the brush and HV.
 We set the different brushes for different area and set the flow
accordingly to the sag /Thin Paint / Uncovered area.

 Let’s say 15 no. brush represent the FD full stroke to hinge. And it
has some flow of 350 cc , and we have an issue of thin paint . Then
we can adjust the flow by 380/400 cc to fix this problem.

 In interior car body painting we don’t change the HV ( High

Voltage ) , because a small change in it can make a big difference .
And there can be a chance of error. So, we don’t do that .

Prepared By - Jay Modi c Copyright, Confidential, Tata Motors Limited 9

Jogging and Programming
Date:- 18 Jan 2024
Jogging of Robot

• The illustration shows the keypad layout. The keys are grouped
according to type of operation.

• Green group: Navigation

• There are two green key groups present here, which are used to
navigate through menu.
• The green colour indicates that there is no dangerous operation
associated with this group of keys.

• Orange group: Run - Step – Stop

• Below the navigation keys are the orange-colored Run-group
keys.
• The orange color indicates that using these keys can result in
robot motion directly.
• The Runkeys are Halt, Run, Step forwards and Step backwards.

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• Blue group: Information, alt. use
• To the lower left is an Info-key that is intended to display context-
sensitive information about the current operation.
• To the lower right is a Shift-key that enables an alternative mode
for the soft-keys and in certain contexts the functions of the arrow
keys.
Info-key Shift-key/
• Soft-keys Context sensitive help Programmable
• Below the display is a row of soft-keys that can be used for any keys
task indicated in the associated display field.
• Any menu utilizing these keys will clearly indicate what they will
do in that particular menu.

• Joysticks
• Just like on a game controller, the pendant has two symmetrically
arranged, thumb-operated joysticks.
• Each joystick has two degrees of freedom.

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• Display layout

• The display consists of 3 sections: The status line on top, the main
section where you find all the icons leading to the different sub-
menus, and the soft-key windows on the bottom line.

• Selecting language

• To get access to different languages, use the ’Service’ menu and

then ’Language’.

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• The Status Line Date:- 19 Jan 2024

• Showing system info:- The status line shows the following

information:

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• Examples
• Some examples of the appearance of these icons are shown.

• Robot icon (3), paint supply icon (4) and applicator icon (5)
show if any errors are present on these units, and if they are
enabled.
• If everything is OK, the icon is shown unobscured, but if an
error occurs, an error icon is overlaid:

• The Operating mode icon (7) shows the position of the

operating mode selector.

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• The run chain / motor status icon

• The Run chain / Motor status icon (8) shows the status of
the run-chain and the Emergency-stop circuits if engaged.

• If these are OK, the run status is shown (Running, halted

etc.)
• If a particular status is preventing the robot from starting,
the icon will show this, see examples :

Prepared By - Jay Modi c Copyright, Confidential, Tata Motors Limited 15

 4D Report
TPEML-Paint shop Sanand
4D Work Order # Paint Shop Date Issued : 20-January-24 Lead : Pushpal Kumar
Units Lost: NA Down Time: 1 hr 30 min Team :
Vivek , Pushpal and ABB Team
Location Description: Spray Booth Paint robots LINE 2
Asset Location Code: Clear Coat Asset/Equipment Code:
Classification : Equipment Reported By : Pushpal Kumar
Issue Title : Pump in Pressure low of Clear Coat interior Robot R12.
Describe Problem : During Ghost mode trial Paint in Pressure of R12 interior robot was showing low.

(A) Emergency Response Action:-

1. Solvent Line Valve closed .
2. All CC Robots Moved to Home position.
3. We checked the Pump Pressure coming from PMR.
4. R12 robot taken in Maintenance Position to inspect the Pump in Pressure.
(B) Interim Containment Actions:-
Removed
5. We Checked the Pump Flow by opening the Arm 2. Pump in
6. Checked for if any delay in Pump Pressure .
7. Taken the flow and adjusted the PCV( Pressure Control Valve ) Pressure . Still error was coming. Sensor
8. Replaced the Pump in Pressure Sensor in Arm 2.
Interim Containment
Actions (ICA) :

Replaced
Pump in
Sensor

Root Cause : Pump in Pressure Sensor was showing error and level was low as per standard.
Permanent Corrective Replaced the Pump in Pressure Senor .
Actions (PCA) :
Operator Panel Overview
• In First row we have following Push on Buttons / Lock Key

 Auto Mode
 Conveyor Run
 LC Entrance Bypass OFF/ON
 Robot Motor On
 Robot Cycle Start
 Mode Selection T1/T2 /Auto
 Lamp Test

• In Second row we have following Push on Buttons / Lock Key

 Manual Station
 Conveyor Bypass OFF / ON
 LC Exit Bypass OFF/ ON
 Robot Motor OFF
 Robot Cycle Stop
 HV On
 HV Operate
 Fault Reset
 Emergency Stop and Mode Selection are in Left and Right Side of Operating Panel respectively.

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Operator Panel Overview
 Auto Mode:- We push this button when we have to take the station in Date:- 09 Feb 2024

Automatic operation mode . The lamp will glow in green and will be constant
.
 Conveyor Run:- We push this button when we have to start the conveyor
and stop the conveyor. It will glow in green when Conveyor is running and
will be off while Conveyor stop.

 LC Entrance Bypass OFF/ON :- We use this key operating lock to take the
Light Curtain in Bypass mode and vice-versa .
 Robot motor On :- We use this button to turn on the motors of all robots .

 Robot Cycle Start :- We use this button to turn on the cycle and ensure that
robots are in automatic mode.
 Mode Selection Key:- We use this lock key to select the modes . We have 3
modes Auto , T1 and T2.
 Lamp Test :- It is used to ensure all lamps are ok or not and also used with
fault reset to clear the queue.
 Manual Station :- We use this push button to take the station in manual
mode.

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Operator Panel Overview
 Conveyor Bypass OFF/ON:- We use this lock key to bypass the line
and vice versa.
 LC Exit Bypass OFF/ON:- We use this button to Bypass the Light
Curtain and vice-versa.
 Robot Motor OFF:- To turn off the Robot Motors.
 Robot Cycle Stop:- To stop the robot cycle and clear the queues.

 HV ON:- We use this push button to turn on the HV.

 HV Operate :- We use this lock key to ensure that HV is on or not.

 Fault Reset:- We use this push button to acknowledge the fault as well
as reset the faults .
 Emergency Stop :- We use this Push button to Stop the operation in
case of any emergency to ensure no any damage to robots and car body
.
 Mode Selection:- We use this channel knob to select different Modes
of operation. We have Clean Mode , Maintenance Mode and Work
Mode.

Prepared By - Jay Modi c Copyright, Confidential, Tata Motors Limited 1919

Troubleshoot

Troubleshoot of Today Issues Date:- 09 Feb 2024

1. CC2, Interior Paint Flow

Issue:- Flow of the paint was not proper . So, some of
the car body got no paint application.

Steps Taken to Resolve :-

 First we checked the flow by just observing the
robots.
 Then, We saw that flow was coming low . So, we
checked the STN Consumption in Reporting Section
of Scada Screen.
 We found that the consumption was very low .
 We opened the , Rob View Software User
Screens Brush Factors .
 We entered the value of Flow, Atom , Shape, Shape 2
and HV to 100 to fix the Proper flow.

Prepared By - Jay Modi c Copyright, Confidential, Tata Motors Limited 2020

Learning Status

Sr . No. Topics Proficiecncy

1 Operational Panel Overview 10 Profi ciecncy
2 Scada Screen Overview 9 Atomizer Overview and it's Flushing Cycle 7
3 Different Modes- T1/T2/Auto 9
Process Parameters Overview 8
4 Teach Pendant Unit 7
Bell Cup and Shaping Air Removal 7
5 Rob View Software Overview 7
Booster Pump Overview 5
6 Robot Studio Software Overview 6
Different Modes of Robot Operations- Ghost Mode, Home Position, Clean Mode,
7 Faults Troubleshooting 5 Maintenance Mode etc. 8

Faults Troubleshooting 5
Different Modes of Robot Operations- Robot Studio Software Overview 6
8 Ghost Mode, Home Position, Clean 8
Mode, Maintenance Mode etc. Rob View Software Overview 7

Teach Pendant Unit 7

9 Booster Pump Overview 5
Different Modes- T1/T2/Auto 9
10 Bell Cup and Shaping Air Removal 7
Scada Screen Overview 9
11 Process Parameters Overview 8
Operational Panel Overview 10
12 Atomizer Overview and it's Flushing 7
Cycle 0 2 4 6 8 10 12

 Note:- Proficiency on the scale of 1 to 10.

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Faults Table

Date:- 13 Feb 2024

Sr. No Type of Fault Description Solution Solved By

1. Joint Out Of Range When the Painting Robots Move Move Robot to next position with ABB Team and Me.
from it’s position to retract the the help of TPU . Go to Editor and
conveyor , this fault arise run the next programme by Set PP
and move it to next position.
2. Close to Singularity

3. Arm Check Point

4. Gripper Error

5. DMC Error

6. Air Supply Value low

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Robot Overview
Axis 1

• Axis 1 rotates the base unit.

• The drive motor is located on the lower rear side inside the manipulator base
unit and controls the rotation of the complete arm assembly via a gearbox.
• Mechanical stops are installed for the axis 1.
• The rotation may be limited by altering the position of mechanical clamps on the
base unit.

Axis 2
Axes 1-6 overview, example for IRB 5500 wall mounted robot
• Axis 2 rotates the axis 2 arm.
• The drive motor is located on the upper rear side inside the manipulator base
unit and controls the upward/downward motion of the axis 2 arm via a gearbox.
• Mechanical stops are installed for the axis 2.

Axis 3

• Axis 3 rotates the axis 3 arm.

• The drive motor is located on the rear side inside the manipulator axis 2 arm and
controls the upward/downward motion of the axis 3 arm via a gearbox.
• Mechanical stops are installed for the axis 3.

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Robot Overview
Axis 4-6
• Axes 4-6 rotate the three sections of the hollow wrist unit.
• The drive motors for axes 4-6 are located in the rear end of the axis 3 arm and control the
motion of the wrist via 3 drive shafts and gearwheels.

Axes motion

• The illustration shows the layout of the drive system for the 3 main axes of an inverted
vertical configuration (180°) manipulator.

Axis 1 system
• The axis 1 motor controls the base unit. The gearbox is integrated in the base unit. The
foot unit is directly mounted on the gearbox.

Axis 2 system
• The axis 2 motor controls the axis 2 arm. The gearbox is integrated in the base unit. The
axis 2 arm is directly mounted on the gearbox.

Axis 2 system
Axes 1, 2, 3 configuration, manipulator (180°) side view
• The axis 3 motor controls the axis 3 arm. The axis 3 arm is directly mounted
on the slewing ring.

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Parameter Change
 H11 Hood opener velocity has been changed for closing
points . Earlier the velocity was 800 mm/s and now it is 500
mm/s.

From Point p170 we have reduced the velocity till p200 point. These are closing points of Hood Opener H11, in BC1 Interior.

Prepared By - Jay Modi c Copyright, Confidential, Tata Motors Limited 25

Conveyor Jerk Fault
Probable Causes of Conveyor Jerk :-

 Speed of Conveyor
 Motor Starting
 Drive used for Motor
 PLC Logic
 Gearbox
 Encoder
 Conveyor Chain
1. Clean or Dirty
2. Material Stuck
3. Loose or Tight
 Loading on Conveyor

 My Observation:- At drive end, I found that when the

conveyor starts it jerks after one second in horizontal and
vertical direction.

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 4D Report
TPEML-Paint shop Sanand
4D Work Order # Paint Shop Date Issued : 06-March-24 Lead : Pushpal Kumar, Noor Mohammed
Units Lost: NA Down Time: 5 min Team :
Vivek , Pushpal and ABB Team
Location Description: Spray Booth Paint robots LINE 2
Asset Location Code: Clear Coat Asset/Equipment Code:
Classification : Equipment Reported By : Pushpal Kumar
Issue Title : R22 Applicator Error fault.
Describe Problem : R22 Applicator Error fault due to low Pump out pressure Value.

(A) Emergency Response Action:-

1. Checked the Scada Screen for fault status.
2. In Robot Studio Found Pump Out Pressure Value low .
3. We checked the Pump Pressure coming from PMR.
4. We checked the bearing Pump value and found ok . It was 6.58 bar. Bearing
(B) Interim Containment Actions:-
pressure

5. In Teach Pendant Unit (TPU) , Entered in Restart Menu .

6. Clicked on Advanced . In radio buttons selected Shutdown main computer .
7. Purging started in TPU shown on Screen .
8. Restarted the Operational panel PC.
Interim Containment
Actions (ICA) :

Purging
Started

Root Cause :
Permanent Corrective Replaced the Pump in Pressure Senor .
Actions (PCA) :
 4D Report
TPEML-Paint shop Sanand
4D Work Order # Paint Shop Date Issued : 11-March-24 Lead : Pushpal Kumar, Noor Mohammed , Pradeesh
Units Lost: NA Down Time: 15 min Team :
Pushpal and ABB Team
Location Description: Spray Booth Paint robots LINE 2
Asset Location Code: Base Coat Asset/Equipment Code:
Classification : Equipment Reported By : Pushpal Kumar
Issue Title : PLC Communication Fault.
Describe Problem : PLC Communication was not coming in BC2 Interior and station was not in auto mode.

(A) Emergency Response Action:-

1. Checked the Scada Screen for fault status.
2. In .
3. RESET the PLC Panel of BC2 Interior .
(B) Interim Containment Actions:-
4. .
5. .
6. Downloaded the back up of SCADA .
7. PLC Communication restored.

Interim Containment
Actions (ICA) :

Root Cause :
Permanent Corrective .
Actions (PCA) :
Applicator Error
CC2 Interior,

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 Thank You

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