1 3HAC M98 Product On-line Manual IRB 1400 Please Click the Picture to continue ABB Flexible Automation2 The information...
Product On-line Manual IRB 1400 3HAC 2914-1 M98
Please Click the Picture to continue
ABB Flexible Automation
The information in this document is subject to change without notice and should not be construed as a commitment by ABB Robotics Products AB. ABB Robotics Products AB assumes no responsibility for any errors that may appear in this document. In no event shall ABB Robotics Products AB be liable for incidental or consequential damages arising from use of this document or of the software and hardware described in this document. This document and parts thereof must not be reproduced or copied without ABB Robotics Products AB´s written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted. Additional copies of this document may be obtained from ABB Robotics Products AB at its then current charge.
© ABB Robotics Products AB Article number: 3HAC 2914-1 Issue: M98 ABB Robotics Products AB S-721 68 Västerås Sweden
ABB Flexible Automation AB Product Manual IRB 1400 M97A, On-line Manual
MAIN MENU Introduction
Installation and Commissioning
Product Specification IRB 2400
Maintenance
Product Specification RobotWare
Troubleshooting Tools
Safety
Fault tracing guide
CE-declaration
Circuit Diagram
Configuration List
Repairs
System Description
Spare parts
Description
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Product Specification IRB 1400 M97A/BaseWare OS 3.0
Introduction CONTENTS Page 1 How to use this Manual........................................................................................... 3 2 What you must know before you use the Robot ................................................... 3 3 Identification ............................................................................................................ 4
Product Manual
1
Introduction
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Product Manual
Introduction
Introduction 1 How to use this Manual This manual provides information on installation, preventive maintenance, troubleshooting and how to carry out repairs on the manipulator and controller. Its intended audience is trained maintenance personnel with expertise in both mechanical and electrical systems. The manual does not in any way assume to take the place of the maintenance course offered by ABB Flexible Automation. Anyone reading this manual should also have access to the User’s Guide. The chapter entitled System Description provides general information on the robot structure, such as its computer system, input and output signals, etc. How to assemble the robot and install all signals, etc., is described in the chapter on Installation and Commissioning. If an error should occur in the robot system, you can find out why it has happened in the chapter on Troubleshooting. If you receive an error message, you can also consult the chapter on System and Error Messages in the User’s Guide. It is very helpful to have a copy of the circuit diagram at hand when trying to locate cabling faults. Servicing and maintenance routines are described in the chapter on Maintenance.
2 What you must know before you use the Robot • Normal maintenance and repair work usually only require standard tools. Some repairs, however, require specific tools. These repairs, and the type of tool required, are described in more detail in the chapter Repairs. • The power supply must always be switched off whenever work is carried out in the controller cabinet. Note that even though the power is switched off, the orangecoloured cables may be live. The reason for this is that these cables are connected to external equipment and are consequently not affected by the mains switch on the controller. • Circuit boards - printed boards and components - must never be handled without Electro-Static-Discharge (ESD) protection in order not to damage them. Use the carry band located on the inside of the controller door. All personnel working with the robot system must be very familiar with the safety regulations outlined in the chapter on Safety. Incorrect operation can damage the robot or injure someone.
Product Manual
3
Introduction
3 Identification Identification plates indicating the type of robot and serial number, etc., are located on the manipulator (see Figure 1) and on the front of the controller (see Figure 2). The BaseWare O.S diskettes are also marked with serial number (see Figure 3). Note! The identification plates and label shown in the figures below, only serves as examples. For exact identification see plates on your robot in question.
ABB Robotics Products AB S-721 68 Västerås Sweden Made in Sweden IRB 6400 M98
Type:
IRB 6400/2.4-150
Robot version:
XXXXXX
Man. order: Nom. load
See instructions
Serial. No:
6400-XXXX
Date of manufacturing: Net weight 2,4.120 : 1870 kg 2,4-150 : 2010 kg 2,8-120 : 2010 kg
IRB 140(0)
IRB 640
Identification plate showing the IRB 6400
1997-XX-XX 3.0-75 : 2010 kg S/2,9-120 : 2240 kg PE/2,25-75 : 1590 kg
IRB 2400
IRB 6400
IRB 4400
IRB 840/A
Figure 1 Example of identification plate and it’s location on different manipulator types.
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Product Manual
Introduction . ABB Robotics Products AB S-721 68 Västerås Sweden Made in Sweden Type: Robot version: Voltage: 3 x 400 V Power: Man. order: Re.No: Serial. No: Date of manufacturing: Net weight:
IRB 6400 M98 IRB 6400/2.4-150 Frequency: 50-60 Hz 7.2 kVA XXXXXX RXXXXXXXXXX 64-XXXXX 1998-XX-XX 240 kg
Figure 2 Identification plate on the controller.
64-00000 System Key S4C 3.1 Program No 3 HAB2390-1/03 B o o t d i s k 1 (1) Property of ABB Västerås/Sweden. All rights reserved. Reproduction, modification, use or disclosure to third parties without express authority is strictly forbidden. Copyright 1993. Restricted to be used in the controller(s) with the serial no as marked on disk.
ABB Robotics Products AB Figure 3 Example of a label on a BaseWare O.S diskette.
Product Manual
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Introduction
6
Product Manual
Product Specification IRB 1400 CONTENTS Page 1 Introduction ..................................................................................................................... 3 2 Description ....................................................................................................................... 5 2.1 Structure.................................................................................................................. 5 2.2 Safety/Standards ..................................................................................................... 6 2.3 Operation ................................................................................................................ 7 2.4 Installation .............................................................................................................. 9 2.5 Programming .......................................................................................................... 9 2.6 Automatic Operation .............................................................................................. 12 2.7 Maintenance and Troubleshooting ......................................................................... 12 2.8 Robot Motion.......................................................................................................... 14 2.9 External Axes ......................................................................................................... 17 2.10 Inputs and Outputs................................................................................................ 17 2.11 Serial Communication .......................................................................................... 18 3 Technical specification .................................................................................................... 19 3.1 Structure.................................................................................................................. 19 3.2 Safety/Standards ..................................................................................................... 22 3.3 Operation ................................................................................................................ 23 3.4 Installation .............................................................................................................. 24 3.5 Programming .......................................................................................................... 28 3.6 Automatic Operation .............................................................................................. 32 3.7 Maintenance and Troubleshooting ......................................................................... 32 3.8 Robot Motion.......................................................................................................... 33 3.9 External Axes ......................................................................................................... 36 3.10 Inputs and Outputs................................................................................................ 37 3.11 Communication..................................................................................................... 41 4 Specification of Variants and Options........................................................................... 43 5 Accessories ....................................................................................................................... 55 6 Index ................................................................................................................................. 57
Product Specification IRB 1400 M98/BaseWare OS 3.1
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Product Specification IRB 1400
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Product Specification IRB 1400 M98/BaseWare OS 3.1
Introduction
1 Introduction Thank you for your interest in the IRB 1400. This manual will give you an overview of the characteristics and performance of the robot. IRB 1400 is a 6-axis industrial robot, designed specifically for manufacturing industries that use flexible robot-based automation. The robot has an open structure that is specially adapted for flexible use, and can communicate extensively with external systems. The robot is equipped with an operating system called BaseWare OS. BaseWare OS controls every aspect of the robot, like motion control, development and execution of application programs communication etc. The functions in this document are all included in BaseWare OS, if not otherwise specified. For additional functionality, the robot can be equipped with optional software for application support - for example gluing and arc welding, communication features - network communication - and advanced functions such as multitasking, sensor control etc. For a complete description on optional software, see the Product Specification RobotWare. All the features are not described in this document. For a more complete and detailed description, please see the User’s Guide, RAPID Reference Manual and Product Manual, or contact your nearest ABB Flexible Automation Centre. Different robot versions The IRB 1400, as mentioned above, is available in two different versions: - IRB 1400, for floor mounting - IRB 1400H, for inverted mounting. How to use this manual The characteristics of the robot are described in Chapter 2: Description. The most important technical data is listed in Chapter 3: Technical specification. Note that the sections in chapter 2 and 3 are related to each other. For example, in section 2.2 you can find an overview of safety and standards, in section 3.2 you can find more detailed information. To make sure that you have ordered a robot with the correct functionality, see Chapter 4: Specification of Variants and Options. In Chapter 5 you will find accessories for the robot. Chapter 6 contains an Index, to make things easier to find.
Product Specification IRB 1400 M98/BaseWare OS 3.1
3
Introduction Other manuals The User’s Guide is a reference manual with step by step instructions on how to perform various tasks. The programming language is described in the RAPID Reference Manual. The Product Manual describes how to install the robot, as well as maintenance procedures and troubleshooting. The Product Specification RobotWare describes the software options.
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Product Specification IRB 1400 M98/BaseWare OS 3.1
Description
2 Description 2.1 Structure The robot is made up of two main parts: a manipulator and a controller. Axis 3 Axis 4 Axis 5 Axis 6
Axis 2
Axis 1
Figure 1 The IRB 1400 manipulator has 6 axes.
Teach pendant
Mains switch
Operator´s panel Disk drive
Figure 2 The controller is specifically designed to control robots, which means that optimal performance and functionality is achieved.
The controller contains the electronics required to control the manipulator, external axes and peripheral equipment.
Product Specification IRB 1400 M98/BaseWare OS 3.1
5
Description
2.2 Safety/Standards The robot complies fully with the health and safety standards specified in the EEC’s Machinery Directives as well as ANSI/RIA 15.06-1992. The robot is designed with absolute safety in mind. It has a dedicated safety system based on a two-channel circuit which is monitored continuously. If any component fails, the electrical power supplied to the motors shuts off and the brakes engage. Safety category 3 Malfunction of a single component, such as a sticking relay, will be detected at the next MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty section is indicated. This complies with category 3 of EN 954-1, Safety of machinery safety related parts of control systems - Part 1. Selecting the operating mode The robot can be operated either manually or automatically. In manual mode, the robot can only be operated via the teach pendant, i.e. not by any external equipment. Reduced speed In manual mode, the speed is limited to a maximum of 250 mm/s (600 inches/min.). A speed limitation applies not only to the TCP (Tool Centre Point), but to all parts of the robot. It is also possible to monitor the speed of equipment mounted on the robot. Three position enabling device The enabling device on the teach pendant must be used to move the robot when in manual mode. The enabling device consists of a switch with three positions, meaning that all robot movements stop when either the enabling device is pushed fully in, or when it is released completely. This makes the robot safer to operate. Safe manual movement The robot is moved using a joystick instead of the operator having to look at the teach pendant to find the right key. Over-speed protection The speed of the robot is monitored by two independent computers. Emergency stop There is one emergency stop push button on the controller and another on the teach pendant. Additional emergency stop buttons can be connected to the robot’s safety chain circuit. Safeguarded space stop The robot has a number of electrical inputs which can be used to connect external safety equipment, such as safety gates and light curtains. This allows the robot’s safety functions to be activated both by peripheral equipment and by the robot itself. Delayed safeguarded space stop A delayed stop gives a smooth stop. The robot stops in the same way as at normal program stop with no deviation from the programmed path. After approx. one second the power supplied to the motors shuts off.
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Product Specification IRB 1400 M98/BaseWare OS 3.1
Description Restricting the working space The movement of each of the axes can be restricted using software limits. Axes 1 and 2 can also be restricted by means of an adjustable mechanical stop. Axis 3 can be restricted using an electrical limit switch. Hold-to-run control “Hold-to-run” means that you must depress the start button in order to move the robot. When the key is released the robot will stop. The hold-to-run function makes program testing safer. Fire safety Both the manipulator and control system comply with UL’s (Underwriters Laboratory) tough requirements for fire safety. Safety lamp As an option, the robot can be equipped with a safety lamp mounted on the manipulator. This is activated when the motors are in the MOTORS ON state.
2.3 Operation All operations and programming can be carried out using the portable teach pendant (see Figure 3) and the operator’s panel (see Figure 5).
Display
1 2
P1
7
8
9
4
5
6
1
2
3
Joystick
P2 P3
Emergency stop button
Figure 3 The teach pendant is equipped with a large display, which displays prompts, information, error messages and other information in plain English.
Information is presented on a display using windows, pull-down menus, dialogs and function keys. No previous programming or computer experience is required to learn how to operate the robot. All operation can be carried out from the teach pendant, which means that a specific keyboard is not required. All information, including the complete programming language, is written in English or, if preferred, some other major language.
Product Specification IRB 1400 M98/BaseWare OS 3.1
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Description
Menu keys File
Edit View 1 Goto ... Inputs/Outputs 2 Goto Top 3 Goto Bottom Value Name 1 0 1 0 1 1 13
di1 di2 grip1 grip2 clamp3B feeder progno
I/O list
1
Menu 4(6)
Line indicator
Cursor
Function keys Figure 4 Window for manual operation of input and output signals.
Using the joystick, the robot can be manually jogged (moved). The user determines the speed of this movement; large deflections of the joystick will move the robot quickly, smaller deflections will move it more slowly. The robot supports different user levels, with dedicated windows for: - Production - Programming - System setup - Service and installation Operator’s panel
Motors On button
Operating mode selector
and indicating lamp
Emergency stop
Duty time counter
Figure 5 The operating mode is selected using the operator’s panel on the controller.
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Product Specification IRB 1400 M98/BaseWare OS 3.1
Description Using a key switch, the robot can be locked in two or three different operating modes depending on chosen mode selector:
100%
• Automatic mode:
Running production
• Manual mode at reduced speed:
Programming and setup Max. speed: 250 mm/s (600 inches/min.)
• Manual mode at full speed (option): Equipped with this mode, the robot is not approved according to ANSI/UL
Testing at full program speed
Both the operator’s panel and the teach pendant can be mounted externally, i.e. outside the cabinet. The robot can then be controlled from there. The robot can be remotely controlled from a computer, PLC or from a customer’s panel, using serial communication or digital system signals. For more information on how to operate the robot, see the User’s Guide.
2.4 Installation The robot has a standard configuration and can be operated immediately after installation. Its configuration is displayed in plain language and can easily be changed using the teach pendant. The configuration can be stored on a diskette and/or transferred to other robots that have the same characteristics. There are two versions of IRB 1400, one for floor mounting and one for inverted mounting. An end effector, weighing a maximum of 5 kg, including payload, can be mounted on the robot’s mounting flange (axis 6). Other equipment, weighing a maximum of 10 kg, can be mounted on the rear of the upper arm.
2.5 Programming Programming the robot involves choosing instructions and arguments from lists of appropriate alternatives. Users do not need to remember the format of instructions, since they are prompted in plain English. “See and pick” is used instead of “remember and type”. The programming environment can be easily customised using the teach pendant. - Shop floor language can be used to name programs, signals, counters, etc. - New instructions can be easily written. - The most common instructions can be collected in easy-to-use pick lists. - Positions, registers, tool data, or other data, can be created. Programs, parts of programs and any modifications can be tested immediately without having to translate the program. The program is stored as a normal PC text file, which means that it can be edited using a standard PC. Product Specification IRB 1400 M98/BaseWare OS 3.1
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Description Movements A sequence of movements is programmed as a number of partial movements between the positions to which you want the robot to move. The end position of a movement is selected either by manually jogging the robot to the desired position with the joystick, or by referring to a previously defined position. The exact position can be defined (see Figure 6) as: - a stop point, i.e. the robot reaches the programmed position or - a fly-by point, i.e. the robot passes close to the programmed position. The size of the deviation is defined independently for the TCP, the tool orientation and the external axes. Stop point
Fly-by point User-definable distance (in mm)
Figure 6 The fly-by point reduces the cycle time since the robot does not have to stop at the programmed point.The path is speed independent.
The velocity may be specified in the following units: - mm/s - seconds (time it takes to reach the next programmed position) - degrees/s (for reorientation of the tool or for a rotation of an external axis) Program management For convenience, the programs can be named and stored in different directories. Areas of the robot’s program memory can also be used for program storage. This gives a very fast memory where you can store programs. These can then be automatically downloaded using an instruction in the program. The complete program or parts of programs can be transferred to/from a diskette. Programs can be printed on a printer connected to the robot, or transferred to a PC where they can be edited or printed.
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Product Specification IRB 1400 M98/BaseWare OS 3.1
Description Editing programs Programs can be edited using standard editing commands, i.e. “cut-and-paste”, copy, delete, find and change, undo etc. Individual arguments in an instruction can also be edited using these commands. No reprogramming is necessary when processing left-hand and right-hand parts, since the program can be mirrored in any plane. A robot position can easily be changed either by: - jogging the robot with the joystick to a new position and then pressing the “ModPos” key (this registers the new position) or by - entering or modifying numeric values. To prevent unauthorised personnel making program changes, passwords can be used. Testing programs Several helpful functions can be used when testing programs. For example, it is possible to: - start from any instruction - execute an incomplete program - run one cycle - execute forward/backward step-by-step - simulate wait conditions - temporarily reduce the speed - change a position - tune (displace) a position during program execution. For more information, see the User´s Guide and RAPID Reference Manual.
Product Specification IRB 1400 M98/BaseWare OS 3.1
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Description
2.6 Automatic Operation A dedicated production window with commands and information required by the operator is automatically displayed during automatic operation. The operation procedure can be customised to suit the robot installation by means of user-defined operating dialogs.
Select program to run:
Front A Front B Front C
Other
SERVICE
Figure 7 The operator dialogs can be easily customised.
A special input can be set to order the robot to go to a service position. After service, the robot is ordered to return to the programmed path and continue program execution. You can also create special routines that will be automatically executed when the power is switched on, at program start and on other occasions. This allows you to customise each installation and to make sure that the robot is started up in a controlled way. The robot is equipped with absolute measurement, making it possible to operate the robot directly from when the power is switched on. For your convenience, the robot saves the used path, program data and configuration parameters so that the program can easily be restarted from where you left off. Digital outputs are also set automatically to the value before the power failure.
2.7 Maintenance and Troubleshooting The robot requires only a minimum of maintenance during operation. It has been designed to make it as easy to service as possible: - The controller is enclosed, which means that the electronic circuitry is protected when operating in a normal workshop environment. - Maintenance-free AC motors are used. - Oil is used for the main gear boxes. - The cabling is routed for longevity, and in the unlikely event of a failure, its modular design makes it easy to change. - It has a program memory “battery low” alarm.
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Product Specification IRB 1400 M98/BaseWare OS 3.1
Description The robot has several functions to provide efficient diagnostics and error reports: - It performs a self test when power on is set. - Errors are indicated by a message displayed in plain language. The message includes the reason for the fault and suggests recovery action. - A board error is indicated by an LED on the faulty unit. - Faults and major events are logged and time-stamped. This makes it possible to detect error chains and provides the background for any downtime. The log can be read on the display of the teach pendant, stored in a file and also printed on a printer. - There are commands and service programs in RAPID to test units and functions. Most errors detected by the user program can also be reported to and handled by the standard error system. Error messages and recovery procedures are displayed in plain language.
Product Specification IRB 1400 M98/BaseWare OS 3.1
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Description
2.8 Robot Motion
1793 1456
1195
50 150
716
511
1008
1444
1282
733 254
1051 150
150
770 1127
1221
1645
Axis 1 +145o -135o Axis 1 ± 170o
Figure 8 Working space of IRB 1400 (dimensions in mm).
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Product Specification IRB 1400 M98/BaseWare OS 3.1
Description Motion performance The QuickMoveTM concept means that a self-optimizing motion control is used. The robot automatically optimizes the servo parameters to achieve the best possible performance throughout the cycle - based on load properties, location in working area, velocity and direction of movement. - No parameters have to be adjusted to achieve correct path, orientation and velocity. - Maximum acceleration is always obtained (acceleration can be reduced, e.g. when handling fragile parts). - The number of adjustments that have to be made to achieve the shortest possible cycle time are minimized. The TrueMoveTM concept means that the programmed path is followed – regardless of the speed or operating mode – even after an emergency stop, a safeguarded stop, a process stop, a program stop or a power failure. The robot can, in a controlled way, pass through singular points, i.e. points where two axes coincide. Coordinate systems Y Tool coordinates Z Z
X
Tool Centre Point (TCP)
Y Z
Base coordinates Z Z X
User coordinates Y
Object coordinates Y X
Y World coordinates
X
X Figure 9 The coordinate systems, used to make jogging and off-line programming easier.
The world coordinate system defines a reference to the floor, which is the starting point for the other coordinate systems. Using this coordinate system, it is possible to relate the robot position to a fixed point in the workshop. The world coordinate system is also very useful when two robots work together or when using a robot carrier. The base coordinate system is attached to the base mounting surface of the robot. The tool coordinate system specifies the tool’s centre point and orientation.
Product Specification IRB 1400 M98/BaseWare OS 3.1
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Description The user coordinate system specifies the position of a fixture or workpiece manipulator. The object coordinate system specifies how a workpiece is positioned in a fixture or workpiece manipulator. The coordinate systems can be programmed by specifying numeric values or jogging the robot through a number of positions (the tool does not have to be removed). Each position is specified in object coordinates with respect to the tool’s position and orientation. This means that even if a tool is changed because it is damaged, the old program can still be used, unchanged, by making a new definition of the tool. If a fixture or workpiece is moved, only the user or object coordinate system has to be redefined. Stationary TCP When the robot is holding a work object and working on a stationary tool, it is possible to define a TCP for that tool. When that tool is active, the programmed path and speed are related to the work object. Program execution The robot can move in any of the following ways: - Joint motion (all axes move individually and reach the programmed position at the same time) - Linear motion (the TCP moves in a linear path) - Circle motion (the TCP moves in a circular path) Soft servo - allowing external forces to cause deviation from programmed position can be used as an alternative to mechanical compliance in grippers, where imperfection in processed objects can occur. If the location of a workpiece varies from time to time, the robot can find its position by means of a digital sensor. The robot program can then be modified in order to adjust the motion to the location of the part. Jogging The robot can be manually operated in any one of the following ways: - Axis-by-axis, i.e. one axis at a time - Linearly, i.e. the TCP moves in a linear path (relative to one of the coordinate systems mentioned above) - Reoriented around the TCP It is possible to select the step size for incremental jogging. Incremental jogging can be used to position the robot with high precision, since the robot moves a short distance each time the joystick is moved. During manual operation, the current position of the robot and the external axes can be displayed on the teach pendant.
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Product Specification IRB 1400 M98/BaseWare OS 3.1
Description
2.9 External Axes The robot can control up to six external axes. These axes are programmed and moved using the teach pendant in the same way as the robot’s axes. The external axes can be grouped into mechanical units to facilitate, for example, the handling of robot carriers, workpiece manipulators, etc. The robot motion can be simultaneously coordinated with a one-axis linear robot carrier and a rotational external axis. A mechanical unit can be activated or deactivated to make it safe when, for example, manually changing a workpiece located on the unit. In order to reduce investment costs, any axes that do not have to be active at the same time can use the same drive unit. Programs can be reused in other mechanical units of the same type.
2.10 Inputs and Outputs A distributed I/O system is used, which makes it possible to mount the I/O units either inside the cabinet or outside the cabinet with a cable connecting the I/O unit to the cabinet. A number of different input and output units can be installed: - Digital inputs and outputs - Analog inputs and outputs - Remote I/O for Allen-Bradley PLC - InterBus-S Slave - Profibus DP Slave The inputs and outputs can be configured to suit your installation: - Each signal and board can be given a name, e.g. gripper, feeder - I/O mapping (i.e. a physical connection for each signal) - Polarity (active high or low) - Cross connections - Up to 16 digital signals can be grouped together and used as if they were a single signal when, for example, entering a bar code Signals can be assigned to special system functions, such as program start, so as to be able to control the robot from an external panel or PLC. The robot can work as a PLC by monitoring and controlling I/O signals: - I/O instructions can be executed concurrent to the robot motion. - Inputs can be connected to trap routines. (When such an input is set, the trap routine starts executing. Following this, normal program execution resumes. In most cases, this will not have any visible effect on the robot motion, i.e. if a limited number of instructions are executed in the trap routine.) Product Specification IRB 1400 M98/BaseWare OS 3.1
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Description - Background programs (for monitoring signals, for example) can be run in parallel with the actual robot program. Requires option Multitasking, see Product Specification RobotWare. Manual functions are available to: - List all the signal values - Create your own list of your most important signals - Manually change the status of an output signal - Print signal information on a printer Signal connections consist of either connectors or screw terminals, which are located in the controller. I/O signals can also be routed to connectors on the upper arm of the robot.
2.11 Serial Communication The robot can communicate with computers or other equipment via RS232/RS422 serial channels or via Ethernet. However this requires optional software, see the Product Specification RobotWare.
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Product Specification IRB 1400 M98/BaseWare OS 3.1
Technical specification
3 Technical specification 3.1 Structure Weight:
Manipulator Controller
225 kg 240 kg
Volume:
Controller
950 x 800 x 540 mm
Airborne noise level: The sound pressure level outside the working space
< 70 dB (A) Leq (acc. to Machinery directive 89/392 EEC)
50
800
540
Cabinet extension Option 115
800 Extended cover Option 114
500
250
200 950 980 *
Lifting points for forklift
* Castor wheels
500
Figure 10 View of the controller from the front and from above (dimensions in mm).
Product Specification IRB 1400 M98/BaseWare OS 3.1
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Technical specification 1100
170
170
720
85
120
600 1310
475
398
150 667
R=350
120
685
Figure 11 View of the manipulator (floor mounted version) from the side and above (dimensions in mm).
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Product Specification IRB 1400 M98/BaseWare OS 3.1
Technical specification
667 150
398
475
1160 450
120
170 170
720
85
1100
R= 400
348 120 450
690 342
Figure 12 View of the manipulator (inverted mounted version) from the side and above (dimensions in mm).
Product Specification IRB 1400 M98/BaseWare OS 3.1
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Technical specification
3.2 Safety/Standards The robot conforms to the following standards: EN 292-1 Safety of machinery, terminology EN 292-2 Safety of machinery, technical specifications EN 954-1 Safety of machinery, safety related parts of control systems EN 60204 Electrical equipment of industrial machines IEC 204-1 Electrical equipment of industrial machines ISO 10218, EN 775 Manipulating industrial robots, safety ANSI/RIA 15.06/1992 Industrial robots, safety requirements ISO 9787 Manipulating industrial robots, coordinate systems and motions IEC 529 Degrees of protection provided by enclosures EN 50081-2 EMC, Generic emission EN 50082-2 EMC, Generic immunity ANSI/UL 1740-1996 (option) Safety Standard for Industrial Robots and Robotic Equipment CAN/CSA Z 424-94 (option) Industrial Robots and Robot Systems - General Safety Requirements Safeguarded space stops via inputs External safety equipment can be connected to the robot’s two-channel emergency stop system in several different ways (see Figure 13). Operating mode selector Auto mode safeguarded space stop
General mode safeguarded space stop External emergency stop Emergency stop
1 Mohm 0.61 mV (14 bits) +0.2% of input signal
min. min.
+10 V 2 kohm 2.44 mV (12 bits) 4-20 mA 800 ohm 4.88 µA (12 bits) +0.2% of output signal
Analog outputs (option 23x) Output voltage (galvanically isolated): Load impedance: min. Resolution: Accuracy: Potential difference: Time intervals: hardware software:
0 to +10 V 2 kohm 2.44 mV (12 bits) ±25 mV ±0.5% of output voltage max. 500 V ≤ 2.0 ms ≤ 4 ms
Signal connections on robot arm Signals
12
60 V, 500 mA
Product Specification IRB 1400 M98/BaseWare OS 3.1
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Technical specification System signals Signals can be assigned to special system functions. Several signals can be given the same functionality. Digital outputs
Motors on/off Executes program Error Automatic mode Emergency stop Restart not possible Run chain closed
Digital inputs
Motors on/off Starts program from where it is Motors on and program start Starts program from the beginning Stops program Stops program when the program cycle is ready Stops program after current instruction Executes “trap routine” without affecting status of stopped regular program1 Loads and starts program from the beginning1 Resets error Resets emergency stop System reset Synchronizes external axes
Analog output
TCP speed signal
1. Program can be decided when configuring the robot.
For more information on system signals, see User’s Guide - System Parameters.
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Product Specification IRB 1400 M98/BaseWare OS 3.1
Technical specification
3.11 Communication The robot has two serial channels - one RS232 and one RS422 Full duplex - which can be used to communicate point to point with printers, terminals, computers and other equipment (see Figure 22).
Figure 22 Serial point-to-point communication.
The serial channels can be used at speeds of 300 to 19200 bit/s (max. 1 channel with speed 19200 bit/s). For high speed and/or network communication, the robot can be equipped with Ethernet interface (see Figure 23). Transmission rate is 10 Mbit/s.
Figure 23 Serial network communication.
Character-based or binary information can be transferred using RAPID instructions. This requires the option Advanced functions, see Product Specification RobotWare. In addition to the physical channels, a Robot Application Protocol (RAP) can be used. This requires either of the options FactoryWare Interface or RAP Communication, see Product Specification RobotWare.
Product Specification IRB 1400 M98/BaseWare OS 3.1
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Technical specification
42
Product Specification IRB 1400 M98/BaseWare OS 3.1
Specification of Variants and Options
4 Specification of Variants and Options The different versions of and options for the IRB 1400 are described below. The same numbers are used here as in the Specification form. For software options, see Product Specification RobotWare. Note! Options marked with * are inconsistent with UL/UR approval.
020 ROBOT VERSIONS 021 IRB 1400 For floor mounting. 022 IRB 1400H For inverted mounting.
040 APPLICATION INTERFACE Air supply and signals for extra equipment to upper arm 04y Hose for compressed air is integrated into the manipulator. There is an inlet at the base and an outlet on the upper arm housing. Connections: R1/4” in the upper arm housing and at the base. Max. 8 bar. Inner hose diameter: 6.5 mm. For connection of extra equipment on the manipulator, there are cables integrated into the manipulator’s cabling. Number of signals: 16 signals 49 V, 500 mA. Connector on upper arm: Burndy 12-pin UTG 014-12S Connector on robot base: Burndy 12-pin UTG 014-12P One of the alternatives below, 045 or 67x, must be selected. 04z Control cabling to arc welding wire-feeder is integrated into the manipulator’s cabling. Control signals: 16 signals, 49 V, 500 mA Connector on upper arm housing: Burndy 23-pin UTG 618-23PN Connector on robot base: Burndy 23-pin socket UT001823SHT Power signals: 12 signals, 300 V, 4 A Connector on upper arm housing: Burndy 12-pin socket UTG 614-12SN Connector on robot base: Burndy 12-pin UT001412PHT This option is not available for IRB 1400H and not together with option 67x. 045 The signals are connected directly to the robot base. The cable from the manipulator to the controller is not supplied.
Product Specification IRB 1400 M98/BaseWare OS 3.1
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Specification of Variants and Options 67x The signals are connected to 12-pole screw terminals, Phoenix MSTB 2.5/12-ST-5.08, to the controller (see Figure 29). Only available with option 04y.
If 04y or 04z
070 POSITION SWITCH
If 67x
Switches indicating the position of axis 1. A design with two stationary switches is available. The switches are manufactured by Telemecanique and of type forced disconnect. The two switches divide the working area of axis 1 into two fixed working zones, approx. 175o each. Together with external safety arrangement, this option allows access to one working zone at the same time as the robot is working in the other one. 07x The signals are connected to 12-pole screw terminals, Phoenix MSTB 2.5/12-ST-5.08, in the controller (see Figure 24).
Controller
Figure 24 Connections of the switches.
081 Two switches, axis 1 stationary.
691 SAFETY LAMP A safety lamp with orange fixed light can be mounted on the manipulator. The lamp is active in MOTORS ON mode.
110 CABINET SIZE 111 Standard cabinet (with upper cover). 112 Standard cabinet without upper cover. To be used when cabinet extension is mounted on top of the cabinet after delivery. 114 With extended cover 250 mm. The height of the cover is 250 mm, which increases the available space for external equipment that can be mounted inside the cabinet. 115 With cabinet extension, 800 mm. A cabinet extension is mounted on top of the standard cabinet. There is a mounting plate inside. (See Figure 25). The cabinet extension is opened via a front door and it has no floor. The upper part of the standard cabinet is therefore accessible. This option cannot be combined with option 142.
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Product Specification IRB 1400 M98/BaseWare OS 3.1
Specification of Variants and Options
Shaded area 40x40 (four corners) not available for mounting
705
730 Figure 25 Mounting plate for mounting of equipment (dimensions in mm).
120 CABINET TYPE 121 Standard, i.e. without Castor wheels. 122 Cabinet on Castor wheels.
130 CONNECTION OF MAINS The power is connected either inside the cabinet or to a connector on the cabinet’s lefthand side. The cable is not supplied. If option 133-136 is chosen, the female connector (cable part) is included. 131 Cable gland for inside connection. Diameter of cable: 11-12 mm. 133* 32 A, 380-415 V, 3p + PE (see Figure 26).
Figure 26 CEE male connector.
134 Connection via an industrial Harting 6HSB connector in accordance with DIN 41640. 35 A, 600 V, 6p + PE (see Figure 27). 136* 32 A, 380-415 V, 3p + N + PE (see Figure 26).
Figure 27 DIN male connector.
Product Specification IRB 1400 M98/BaseWare OS 3.1
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Specification of Variants and Options 140 MAINS SWITCH 141* Rotary switch in accordance with the standard in section 3.2 and IEC 337-1, VDE 0113. 142 Rotary switch according to 141 with door interlock. 143 Flange disconnect in accordance with the standard in section 3.2. Includes door interlock. Additions to the mains switch: 147/149 Circuit breaker for rotary switch. A 16 A (transformer 2 and 3) or 25 A (transformer 1) circuit breaker for short circuit protection of main cables in the cabinet. Circuit breaker approved in accordance with IEC 898, VDE 0660.
150 MAINS VOLTAGE The robot can be connected to a rated voltage of between 200 V and 600 V, 3-phase and protective earthing. A voltage fluctuation of +10% to -15% is permissible in each connection. 151-174
Voltage 200 V 220 V 400 V 440 V
Voltage
400 V 440 V 475 V 500 V
Voltage
475 V 500 V 525 V 600 V
175 MAINS FILTER The mains filter reduces the emission of radio frequency on the incoming power, to levels below requirements in the Machinery Directive 89/392/EEC. For installations in countries not affected by this directive, the filter can be excluded. 177-179
46
Mains filter
Product Specification IRB 1400 M98/BaseWare OS 3.1
Specification of Variants and Options 180 OPERATOR’S PANEL The operator’s panel and teach pendant holder can be installed either 181 Standard, i.e. on the front of the cabinet, or 182 External, i.e. in a separate operator’s unit. All necessary cabling, including flange, connectors, sealing strips, screws, etc., is supplied. External enclosure is not supplied. M4 (x4) M8 (x4) 45o
196
Required depth 200 mm 193
180 224 240
223
70
62 140
96 Holes for flange
184
External panel enclosure (not supplied)
Holes for teach pendant holder
Teach pendant connection
Connection to the controller
200 Holes for operator’s panel
90
5 (x2)
155
Figure 28 Required preparation of external panel enclosure (all dimensions in mm).
Product Specification IRB 1400 M98/BaseWare OS 3.1
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Specification of Variants and Options 183 External, mounted in a box, (see figure on the right).
M5 (x4) for fastening of box
Cable length 185 186 187
15 m 22 m 30 m
337
Connection flange 370
190 OPERATING MODE SELECTOR 193 Standard, 2 modes: manual and automatic 191* Standard, 3 modes: manual, manual full speed and automatic. This option is inconsistent with UL/UR approval.
200 I/O MODULES MOUNTED IN CABINET The standard cabinet can be equipped with up to four I/O units. For more details, see Technical Specification 3.10.
X1 (SIO1)
Backplane
X2 (SIO2) I/O units (x4)
X10 (CAN3) X16 (CAN2)
XT5, customer signals XT6, customer power XT8, position switch
XT31 (24V supply) and service outlet
Figure 29 I/O unit and screw terminal locations.
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Product Specification IRB 1400 M98/BaseWare OS 3.1
Specification of Variants and Options 20x Digital 24 VDC I/O: 16 inputs/16 outputs. 22x Analog I/O: 4 inputs/4 outputs. 23x AD Combi I/O: 16 digital inputs/16 digital outputs and 2 analog outputs (0-10V). 25x Digital 120 VAC I/O 16 inputs/16 outputs. 26x Digital I/O with relay outputs: 16 inputs/16 outputs. Relay outputs to be used when more current or voltage is required from the digital outputs. The inputs are not separated by relays. Connection of I/O The signals are connected directly to the I/O modules in the upper part of the cabinet (see Figure 29). Connectors Phoenix MSTB 2.5/xx-ST-5.08 (MC 1.5/xx-ST-3.81 for option 22x) or equivalent are included: Option 20x: 4 pieces of 10 pole connectors Option 25x, 26x: 4 pieces of 16 pole connectors Option 23x: 4 pieces of 10 pole + 1 piece of 6 pole connector
280 FIELD BUSES For more details, see Technical Specification 3.10. 281 Allen-Bradley Remote I/O Up to 128 digital inputs and outputs, in groups of 32, can be transferred serially to a PLC equipped with an Allen Bradley 1771 RIO node adapter. The unit reduces the number of I/O units that can be mounted in cabinet by one. The field bus cables are connected directly to the A-B RIO unit in the upper part of the cabinet (see Figure 29). Connectors Phoenix MSTB 2.5/xx-ST-5.08 or equivalent are included. 284 Interbus-S Slave Up to 64 digital inputs and 64 digital outputs can be transferred serially to a PLC equipped with an InterBus-S interface. The unit reduces the number of I/O units that can be mounted in the cabinet by one. The signals are connected directly to the InterBus-S slave unit (two 9-pole D-sub) in the upper part of the cabinet. 286 Profibus DP Slave Up to 128 digital inputs and 128 digital outputs can be transferred serially to a PLC equipped with a Profibus DP interface. The unit reduces the number of I/O units that can be mounted in cabinet by one. The signals are connected directly to the Profibus DP slave unit (one 9-pole D-sub) in the upper part of the cabinet. 288 Encoder interface unit for conveyor tracking Conveyor Tracking, or Line Tracking, is the function whereby the robot follows a work object which is mounted on a moving conveyor. The encoder and synchronization switch cables are connected directly to the encoder unit in the upper part of the cabinet (see Figure 29). Screw connector is included. For more information see Product Specification RobotWare.
Product Specification IRB 1400 M98/BaseWare OS 3.1
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Specification of Variants and Options 290 COMMUNICATION As standard, the robot is equipped with one RS232 (SIO 1) and one RS422 (SIO 2) connector inside the cabinet. The connectors to be used (Phoenix MSTB 2.5/12-ST-5.08) are not included. See Figure 22 and Figure 29. 292 Ethernet (see Figure 23). Connectors: RJ45 and AUI on the board front. 294 Distributed I/O (CAN-bus) connection on the left wall.
390 EXTERNAL AXES DRIVES - INSIDE CABINET The controller is equipped with drives for external axes. The motors are connected to a standard industrial 64-pin female connector, in accordance with DIN 43652, on the lefthand side of the cabinet. (Male connector is also supplied.) The transformer 4.5 kVA is replaced with 7.2 kVA. 391 Drive unit T The drive unit is part of the DC-link. Recommended motor type see Figure 30. 392 Drive unit GT A separate drive unit including two drives. Recommended motor types see Figure 30. 394 Drive unit T+GT A combination of 391 and 392. 395 Drive unit C The drive unit is part of the DC-link. Recommended motor type see Figure 30. 396 Drive unit C+GT A combination of 395 and 392. 398 Prepared for GT Transformer 7.2 kVA. No drive units or cables are included.
385 EXTERNAL AXES MEASUREMENT BOARD The resolver can either be connected to a serial measurement board outside the controller, or to a measurement board inside the cabinet. 386 Serial measurement board inside cabinet Signal interface to external axes with absolute position at power on. The board is located in the cabinet and occupies one I/O unit slot. The resolvers are connected to a standard industrial 64-pin connector in accordance with DIN 43652, on the left-hand side of the cabinet. 387 Serial measurement board as separate unit
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Product Specification IRB 1400 M98/BaseWare OS 3.1
Specification of Variants and Options 370 EXTERNAL AXES DRIVES - SEPARATE CABINET If more external axes than in option 390 are to be used, an external cabinet can be supplied. The external cabinet is connected to one Harting connector (cable length 7 m) on the left-hand side of the robot controller. Door interlock, mains connection, mains voltage and mains filter according to the robot controller. One transformer and one mains switch are included. 37M-O
Drive unit GT, for 2, 4, or 6 motors. Recommended motor types see Figure 30.
37P-Q
Drive unit ECB, for 3 or 6 motors. Recommended motor types see Figure 30. Max current
Rated current
Motor type1
G
6 - 30A rms
16A rms
S, M, L
T
7,5 - 37A rms
20A rms
S, M, L
E
5,5 - 27Arms
8,4Arms
S, M
C
2,5 - 11A rms
5A rms
S
B
1,5 - 7A rms
4A rms
S
Drive unit data
1. Motors from ABB Flexible Automation/System Products. Types: S=small, M=medium, L=large Figure 30 Motor selecting table.
420 SERVICE OUTLET Any of the following standard outlets with protective earthing can be chosen for maintenance purposes. The maximum load permitted is 500 VA (max. 100 W can be installed inside the cabinet). 421* 230 V mains outlet in accordance with DIN VDE 0620; single socket suitable for Sweden, Germany and other countries. 422* 230 V in accordance with French standard; single socket. 423* 120 V in accordance with British standard; single socket. 424 120 V in accordance with American standard; single socket, Harvey Hubble. 425* Service outlet according to 421 and a computer connection on the front of the cabinet. The computer connection is connected to the RS232 serial channel. Cannot be used if option 142 is chosen.
Product Specification IRB 1400 M98/BaseWare OS 3.1
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Specification of Variants and Options 430 POWER SUPPLY TO SERVICE OUTLETS 431 Connection from the main transformer. The voltage is switched on/off by the mains switch on the front of the cabinet. 432 Connection before mains switch without transformer. Note this only applies when the mains voltage is 400 V, three-phase with neutral connection and a 230 V service socket. Note! Connection before mains switch is not in compliance with some national standards, NFPL 79 for example. 433 Connection before mains switch with an additional transformer for line voltages 400-500 V and with a secondary voltage of 115 V, 4 A or 230 V, 2A. Note! Connection before mains switch is not in compliance with some national standards, NFPL 79 for example. 439 Earth fault protection for service outlet. To increase personal safety, the service outlet can be supplied with an earth fault protection which trips at 30 mA earth current. The earth fault protection is placed next to the service outlet (see Figure 29). Voltage range: 110 - 240 V AC.
470 DISK DRIVE COOLING The disk drive normally works well at temperatures up to 40oC (104oF). At higher temperatures a cooling device for the drive is necessary to ensure good functionality. The disk drive will not deteriorate at higher temperatures but there will be an increase in the number of reading/writing problems as the temperature increases. 471 No 472 Yes
620 KIT FOR LIMITING WORKING SPACE To increase the safety of the robot, the working range of axes 1, 2 and 3 can be restricted. 621 Axis 1 The working range of axis 1 can be limited. Using restriction stops, the working range can be limited from +150o/-150o to the smallest working range which is +50o The restriction between 50o and 150o can be performed at any position by machining M10 holes and mounting the stops. The kit contains stops, screws and instructions. 622 Axis 2 By adding stop lugs, the working range of axis 2 can be restricted to +50o / -30o (for floor mounted version), -20o / -60o (for inverted mounted version). 623 Axis 3, Floor mounted (NOT inverted version) Axis 3 can be restricted so that it cannot move above the horizontal line, alternatively can move a maximum of 10o above the horizontal line.
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Product Specification IRB 1400 M98/BaseWare OS 3.1
Specification of Variants and Options 630 TEACH PENDANT LIGHTING The teach pendant is, as standard, equipped with a sharp and clear display without back lighting. Back lighting is available as an option. The cable lenght for the teach pendant is 10 m. For extension cable, see option 660. 632 Without back lighting 631 With back lighting
640 CABLE MANIPULATOR – CONTROLLER 64x Internal connectors The cables are connected directly to the drive units inside the cabinet via a cable gland on the left-hand side of the controller and to a connector inside the robot base. 65x External connectors The cables are connected to 64-pin Harting connectors in accordance with DIN 43652, located on the left-hand side of the controller and on the base of the manipulator. The cables are available in the following lengths: 7m 15 m 22 m 30 m
660 EXTENSION CABLE FOR THE TEACH PENDANT 66x 10 m This can be connected between the controller and the connector on the teach pendant’s cable. A maximum of two extension cables may be used; i.e. the total length of cable between the controller and the teach pendant should not exceed 30 m. If external control panel (option 182 or 183) with 15 m cable is used, an extension cable is allowed, and the total cable length can be up to 35 m.
680 ADDITIONAL I/O UNITS I/O units can be delivered separately. The units can then be mounted outside the cabinet or in the cabinet extension. These are connected in a chain to a connector (CAN 3 or CAN 2, see Figure 29) in the upper part of the cabinet. Connectors to the I/ O units and a connector to the cabinet (Phoenix MSTB 2.5/xx-ST-5.08), but no cabling, is included. Dimensions according to the figure below. For more details, see section Technical Specification 3.10. External enclosure must provide protection class IP 54 and EMC shielding. 68A-F
Digital I/O 24 V DC: 16 inputs/16 outputs.
68G-H
Analog I/O.
68I-L
AD Combi I/O: 16 digital inputs/16 digital outputs and 2 analog outputs (0-10V).
68M-P
Digital I/O 120 V AC: 16 inputs/16 outputs.
Product Specification IRB 1400 M98/BaseWare OS 3.1
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Specification of Variants and Options 68Q-T
Digital I/O with relay outputs: 16 inputs/16 outputs.
68U
Allen Bradley Remote I/O
68V-X
Interbus-S Slave
68Y-Z
Profibus DP Slave
69A-B
Encoder unit EN 50022 mounting rail
195
203
49
Figure 31 Dimensions for units 68A-68T.
EN 50022 mounting rail
170
49
115 Figure 32 Dimension for units 68U-Z and 69.
720 EXTRA DOCUMENTATION Gxy Product Manual IRB 1400, including Product Specification.
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Product Specification IRB 1400 M98/BaseWare OS 3.1
Accessories
5 Accessories There is a range of tools and equipment available, specially designed for the robot. Software options for robot and PC For more information, see Product Specification RobotWare. Robot Peripherals - Track Motion - Tool System - Motor Units
Product Specification IRB 1400 M98/BaseWare OS 3.1
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Accessories
56
Product Specification IRB 1400 M98/BaseWare OS 3.1
Product Specification RobotWare CONTENTS Page 1 Introduction ..................................................................................................................... 3 2 BaseWare OS ................................................................................................................... 5 2.1 The Rapid Language and Environment .................................................................. 5 2.2 Exception handling ................................................................................................. 6 2.3 Motion Control ....................................................................................................... 7 2.4 Safety ...................................................................................................................... 9 2.5 I/O System .............................................................................................................. 10 3 BaseWare Options ........................................................................................................... 11 3.1 Advanced Functions 3.1 ......................................................................................... 11 3.2 Advanced Motion 3.1 ............................................................................................. 16 3.3 Multitasking 3.1...................................................................................................... 19 3.4 FactoryWare Interface 3.1 ...................................................................................... 20 3.5 RAP Communication 3.1........................................................................................ 22 3.6 Ethernet Services 3.1 .............................................................................................. 23 3.7 Load Identification and Collision Detection 3.1 (LidCode)................................... 24 3.8 ScreenViewer 3.1.................................................................................................... 25 3.9 Conveyor Tracking 3.1 ........................................................................................... 27 3.10 I/O Plus 3.1 ........................................................................................................... 28 4 ProcessWare..................................................................................................................... 29 4.1 ArcWare 3.1............................................................................................................ 29 4.2 ArcWare Plus 3.1 ................................................................................................... 32 4.3 SpotWare 3.1.......................................................................................................... 33 4.4 SpotWare Plus 3.1................................................................................................... 37 4.5 GlueWare 3.1 ......................................................................................................... 38 4.6 PaintWare 3.1.......................................................................................................... 40 4.7 PalletWare............................................................................................................... 42 5 Memory and Documentation ......................................................................................... 45 5.1 Available memory................................................................................................... 45 5.2 Teach Pendant Language ........................................................................................ 46 5.3 Robot Documentation............................................................................................. 46 6 DeskWare ......................................................................................................................... 47 6.1 6.2 6.3 6.4 6.5
DeskWare Office 3.0 .............................................................................................. 47 Programming Station 3.0........................................................................................ 50 Training Center 3.0................................................................................................. 56 Library 3.0 .............................................................................................................. 58 Robot Lab 3.0 ......................................................................................................... 60
Product Specification RobotWare for BaseWare OS 3.1
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Product Specification RobotWare
7 FactoryWare .................................................................................................................... 7.1 RobComm 3.0 ........................................................................................................ 7.2 RobView 3.1 ........................................................................................................... 7.3 DDE Server 2.3 ...................................................................................................... 7.4 ScreenMaker 3.0..................................................................................................... 8 Index.................................................................................................................................
2
63 63 67 74 78 79
Product Specification RobotWare for BaseWare OS 3.1
Introduction
1 Introduction RobotWare is a family of software products from ABB Flexible Automation designed to make you more productive and lower your cost of owning and operating a robot. ABB Flexible Automation has invested many man-years into the development of these products and they represent knowledge and experience based on several thousand robot installations. Within the RobotWare family there are five classes of products: BaseWare OS - This is the operating system of the robot and constitutes the kernel of the RobotWare family. BaseWare OS provides all the necessary features for fundamental robot programming and operation. It is an inherent part of the robot but can be provided separately for upgrading purposes. BaseWare Options - These products are options that run on top of BaseWare OS of the robot. They represent functionality for robot users that need additional functionality, for example run multitasking, transfer information from file to robot, communicate with a PC, perform advanced motion tasks etc. ProcessWare - ProcessWare products are designed for specific process applications like welding, gluing and painting. They are primarily designed to improve the process result and to simplify installation and programming of applications. These products also run on top of BaseWare OS. DeskWare - This is a set of Windows-based PC products for a wide range of uses like: creating robot programs, training people on how to use robots, keeping track of robot programs and on-line documentation. The purpose is to lower the indirect cost of owning a robot. FactoryWare - By combining the power of PCs with robots, the possibilities are almost unlimited. The FactoryWare products are intended to be used in PCs connected to robots, on the factory floor or in the office. These tools can be typically used for such things as programmable operator interfaces, work monitoring or cell supervision.
Product Specification RobotWare for BaseWare OS 3.1
3
Introduction
4
Product Specification RobotWare for BaseWare OS 3.1
Rapid Language and Environment
2 BaseWare OS Only a very superficial overview of BaseWare OS is given here. For details, see references in Robot Documentation. The properties of BaseWare OS can be split up in five main areas: The Rapid Language and Environment; Exception handling; Motion Control; Safety; the I/O System.
2.1 The Rapid Language and Environment The Rapid language is a well balanced combination of simplicity, flexibility and powerfulness. It contains the following concepts: - Hierarchical and modular program structure to support structured programming and reuse. - Routines can be Functions or Procedures. - Local or global data and routines. - Data typing, including structured and array data types. - User defined names (shop floor language) on variables, routines and I/O. - Extensive program flow control. - Arithmetic and logical expressions. - Interrupt handling. - Error handling (for exception handling in general, see Exception handling). - User defined instructions (appear as an inherent part of the system). - Backward handler (user definition of how a procedure should behave when stepping backwards). - Many powerful built-in functions, e.g mathematics and robot specific. - Unlimited language (no max. number of variables etc., only memory limited). - Windows based man machine interface with built-in Rapid support (e.g. user defined pick lists).
Product Specification RobotWare for BaseWare OS 3.1
5
Exception handling
2.2 Exception handling Many advanced features are available to make fast error recovery possible. Characteristic is that the error recovery features are easy to adapt to a specific installation in order to minimise down time. Examples: - Error Handlers (automatic recovery often possible without stopping production). - Restart on Path. - Power failure restart. - Service routines. - Error messages: plain text with remedy suggestions, user defined messages. - Diagnostic tests. - Event logging.
6
Product Specification RobotWare for BaseWare OS 3.1
Motion Control
2.3 Motion Control TrueMoveTM Very accurate path and speed, based on advanced dynamic modelling. Speed independent path. Flexible and intuitive way to specify corner zones (e.g. possibility to have separate zone sizes for Tool Centre Point (TCP) path and for tool reorientation). QuickMoveTM By use of the dynamic model, the robot always and automatically optimises its performance for the shortest possible cycle time. No need for manual tuning! This is achieved without compromising the path accuracy. Coordinate Systems A very powerful concept of multiple coordinate systems that facilitates jogging, program adjustment, copying between robots, off-line programming, sensor based applications, external axes co-ordination etc. Full support for TCP attached to the robot or fixed in the cell (“Stationary TCP”). Note that also joint coordinate movements (MoveJ) are recalculated when a coordinate system is adjusted. Singularity handling The robot can pass through singular points in a controlled way, i.e. points where two axes coincide. Motion Supervision The behaviour of the motion system is continuously monitored as regards position and speed level to detect abnormal conditions and quickly stop the robot if something is not OK. A further monitoring function, Collision Detection, is optional (see option “Load Identification and Collision Detection”). External axes Very flexible possibilities to configure external axes. Includes for instance high performance coordination with robot movement and shared drive unit for several axes. Big Inertia One side effect of the dynamic model concept is that the system can handle very big load inertias by automatically adapting the performance to a suitable level. For big, flexible objects it is possible to optimise the servo tuning to minimise load oscillation.
Product Specification RobotWare for BaseWare OS 3.1
7
Motion Control Soft Servo Any axis (also external) can be switched to soft servo mode, which means that it will adopt a spring-like behaviour.
8
Product Specification RobotWare for BaseWare OS 3.1
Safety
2.4 Safety Many safety concepts reside in hardware and are not within the scope of this document. However, some important software contributions will be mentioned: Reduced Speed In the reduced speed mode, the controller limits all parts of the robot body, the TCP and one user defined point (attached to the upper arm) to 250 mm/s (can be set lower). This limitation also works in joint system motion. Motion Supervision See Motion Control. Authorisation It is possible to limit the access to certain commands by assigning different passwords to four different user levels (operator, service, programmer, service & programmer). It is possible to define the commands available at the different levels. Limited modpos It is possible to limit the allowed distance/rotation when modifying positions.
Product Specification RobotWare for BaseWare OS 3.1
9
I/O System
2.5 I/O System Elementary I/O Robust and fast distributed system built on CAN/DeviceNet with the following features: - Named signals and actions with mapping to physical signal (“gripper close” instead of “set output 1”). - Flexible cross connections. - Up to 512 signals available (one signal = single DI or DO, group of DI or DO, AI or AO). - Grouping of signals to form integer values. - Sophisticated error handling. - Selectable “trust level” (i.e. what action to take when a unit is “lost”). - Program controlled enabling/disabling of I/O units. - Scaling of analog signals. - Filtering. - Polarity definition. - Pulsing. - TCP-proportional analog signal. - Programmable delays. - Simulated I/O (for forming cross connections or logical conditions without need the for physical hardware). - Accurate coordination with motion. Serial I/O XON/XOFF or SLIP. Memory I/O RAM disk and floppy disk.
10
Product Specification RobotWare for BaseWare OS 3.1
Advanced Functions 3.1
3 BaseWare Options 3.1 Advanced Functions 3.1 Includes functions making the following possible: - Information transfer via serial channels or files. - Setting an output at a specific position. - Executing a routine at a specific position. - Defining forbidden areas within the robot´s working space. - Automatic setting of output when the robot is in a user-defined area. - Robot motion in an error handler or trap routine, e.g. during automatic error handling. - Cross connections with logical conditions. Transferring information via serial channels Data in the form of character strings, numeric values or binary information can be transferred between the robot and other peripheral equipment, e.g. a PC, bar code reader, or another robot. Information is transferred via an RS232 or RS485 serial channel. Examples of applications: - Printout of production statistics on a printer connected to the robot. - Reading part numbers from a bar code reader with a serial interface. - Transferring data between the robot and a PC. The transfer is controlled entirely from the robot’s work program. When it is required to control the transfer from a PC, use the option RAP Communication or FactoryWare Interface.
Product Specification RobotWare for BaseWare OS 3.1
11
Advanced Functions 3.1 Data transfer via files Data in the form of character strings, numerical values or binary information can be written to or read from files on a diskette or other type of mass storage/memory. Examples of applications: - Storing production statistics on a diskette or ramdisk. This information can then be read and processed by an ordinary PC. - The robot’s production is controlled by a file. This file may have been created in a PC, stored on a diskette, and read by the robot at a later time. Fixed position output The value of an output (digital, analog or a group of digitals) can be ordered to change at a certain distance before or after a programmed position. The output will then change at the same place every time, irrespective of the robot’s speed. Consideration can also be given to time delays in the process equipment. By specifying this time delay (max. 500 ms), the output is set at the corresponding time before the robot reaches the specified position. The distance can also be specified as a certain time before the programmed position. This time must be within the deceleration time when approaching that position. Examples of applications: - Handling press work, to provide a safe signalling system between the robot and the press, which will reduce cycle times. Just as the robot leaves the press, an output is set that starts the press. - Starting and finishing process equipment. When using this function, the start will always occur at the same position irrespective of the speed. For gluing and sealing, see GlueWare. Fixed position procedure call A procedure call can be carried out when the robot passes the middle of a corner zone. The position will remain the same, irrespective of the robot’s speed. Example of application: - In the press example above, it may be necessary to check a number of logical conditions before setting the output that starts the press. A procedure which takes care of the complete press start operation is called at a position just outside the press.
12
Product Specification RobotWare for BaseWare OS 3.1
Advanced Functions 3.1 World Zones A spherical, cylindrical or cubical volume can be defined within the working space. When the robot reaches this volume it will either set an output or stop with the error message “Outside working range”, both during program execution and when the robot is jogged into this area. The areas, which are defined in the world coordinate system, can be automatically activated at start-up or activated/deactivated from within the program. Examples of applications: - A volume is defining the home position of the robot. When the robot is started from a PLC, the PLC will check that the robot is inside the home volume, i.e. the corresponding output is set. - The volume is defining where peripheral equipment is located within the working space of the robot. This ensures that the robot cannot be moved into this volume. - A robot is working inside a box. By defining the outside of the box as a forbidden area, the robot cannot run into the walls of the box. - Handshaking between two robots both working in the same working space. When one of the robots enters the common working space, it sets an output and after that enters only when the corresponding output from the other robot is reset.
Product Specification RobotWare for BaseWare OS 3.1
13
Advanced Functions 3.1 Movements in interrupt routines and error handlers This function makes it possible to temporarily interrupt a movement which is in progress and then start a new movement which is independent of the first one. The robot stores information about the original movement path which allows it to be resumed later. Examples of applications: - Cleaning the welding gun when a welding fault occurs. When a welding fault occurs, there is normally a jump to the program’s error handler. The welding movement in progress can be stored and the robot is ordered to the cleaning position so that the nozzle can be cleaned. The welding process can then be restarted, with the correct parameters, at the position where the welding fault occurred. This is all automatic, without any need to call the operator. (This requires options ArcWare or ArcWare Plus.) - Via an input, the robot can be ordered to interrupt program execution and go to a service position, for example. When program execution is later restarted (manually or automatically) the robot resumes the interrupted movement. Cross-connections with logical conditions Logical conditions for digital input and output signals can be defined in the robot’s system parameters using AND, OR and NOT. Functionality similar to that of a PLC can be obtained in this way. Example: - Output 1 = Input 2 AND Output 5. - Input 3 = Output 7 OR NOT Output 8. Examples of applications: - Program execution to be interrupted when both inputs 3 and 4 become high. - A register is to be incremented when input 5 is set, but only when output 5=1 and input 3=0.
14
Product Specification RobotWare for BaseWare OS 3.1
Advanced Functions 3.1 RAPID instructions and functions included in this option Open Close Write WriteBin WriteStrBin ReadNum ReadStr ReadBin Rewind WZBoxDef WZCylDef WZLimSup WZSphDef WZDOSet WZDisable WZEnable WZFree StorePath RestoPath TriggC TriggL TriggJ TriggIO TriggEquip TriggInt MoveCSync MoveLSync MoveJSync
Opens a file or serial channel Closes a file or serial channel Writes to a character-based file or serial channel Writes to a binary file or serial channel Writes a string to a binary serial channel Reads a number from a file or serial channel Reads a string from a file or serial channel Reads from a binary file or serial channel Rewind file position Define a box shaped world zone Define a cylinder shaped world zone Activate world zone limit supervision Define a sphere shaped world zone Activate world zone to set digital output Deactivate world zone supervision Activate world zone supervision Erase world zone supervision Stores the path when an interrupt or error occurs Restores the path after an interrupt/error Position fix output/interrupt during circular movement Position fix output/interrupt during linear movement Position fix output/interrupt during joint movement Definition of trigger conditions for one output Definition of trigger conditions for process equipment with time delay Definition of trigger conditions for an interrupt Position fix procedure call during circular movement Position fix procedure call during linear movement Position fix procedure call during join movement
Product Specification RobotWare for BaseWare OS 3.1
15
Advanced Motion 3.1
3.2 Advanced Motion 3.1 Contains functions that offer the following possibilities: - Resetting the work area for an axis. - Independent movements. - Contour tracking. - Coordinated motion with external manipulators. Resetting the work area for an axis The current position of a rotating axis can be adjusted a number of complete turns without having to make any movements. Examples of applications: - When polishing, a large work area is sometimes needed on the robot axis 4 or axis 6 in order to be able to carry out final polishing without stopping. Assume that the axis has rotated 3 turns, for example. It can now be reset using this function, without having to physically rotate it back again. Obviously this will reduce cycle times. - When arc welding, the work object is often fitted to a rotating external axis. If this axis is rotated more than one turn during welding, the cycle time can be reduced because it is not necessary to rotate the axis back between welding cycles. Coordinated motion with multi-axis manipulators Coordinated motion with multi-axis manipulators or robot carriers (gantries) requires the Advanced Motion option. Note that simultaneous coordination with several single axis manipulators, e.g. track motion and workpiece manipulator, does not require Advanced Motion. Note! There is a built-in general method for defining the geometry for a manipulator comprising two rotating axes (see User’s Guide, Calibration). For other types of manipulators/robot carriers, comprising up to six linear and/or rotating axes, a special configuration file is needed. Please contact your nearest ABB Flexible Automation Centre.
16
Product Specification RobotWare for BaseWare OS 3.1
Advanced Motion 3.1 Contour tracking Path corrections can be made in the path coordinate system. These corrections will take effect immediately, also during movement between two positions. The path corrections must be entered from within the program. An interrupt or multitasking is therefore required to activate the correction during motion. Example of application: - A sensor is used to define the robot input for path correction during motion. The input can be defined via an analog input, a serial channel or similar. Multitasking or interrupts are used to read this information at specific intervals. Based on the input value, the path can then be adjusted. Independent movements A linear or rotating axis can be run independently of the other axes in the robot system. The independent movement can be programmed as an absolute or relative position. A continuous movement with a specific speed can also be programmed. Examples of applications: - A robot is working with two different stations (external axes). First, a work object located at station 1 is welded. When this operation is completed, station 1 is moved to a position where it is easy to change the work object and at the same time the robot welds the work object at station 2. Station 1 is moved independently of the robot’s movement, which simplifies programming and reduces the cycle time. - The work object is located on an external axis that rotates continuously at a constant speed. In the mean time, the robot sprays plasma, for example, on the work object. When this is finished the work area is reset for the external axis in order to shorten the cycle time. Friction Compensation During low speed (10-100 mm/s) cutting of fine profiles, in particular small circles, a friction effect, typically in the form of approximately 0.5 mm “bumps”, can be noted. Advanced Motion offers a possibility of compensating for these frictional effects. Typically a 0.5 mm “bump” can be reduced to about 0.1 mm. This, however, requires careful tuning of the friction level (see User’s Guide for tuning procedure). Note that even with careful tuning, there is no guarantee that “perfect” paths can always be generated. For the IRB 6400 family of robots, no significant effects can be expected by applying Friction Compensation.
Product Specification RobotWare for BaseWare OS 3.1
17
Advanced Motion 3.1 External Drive System With Advanced Motion, the possibility to connect off-the-shelf standard drive systems for controlling external axes is available. This can be of interest, for example, when the power of the available S4C drives does not match the requirements. There are two alternatives: - The Atlas Copco Controls´ stand alone servo amplifier DMC. - The Atlas Copco Controls´ FBU (Field Bus Unit) that can handle up to three external drive units per FBU unit. These can be connected to analog outputs (+/- 10 V) or a field bus. The drive board can thus be of virtually any make and type. For further information about DMC and FBU, please contact Atlas Copco Controls. NOTE! The DMC/FBU must be equipped with Atlas Copco Controls option C. RAPID instructions and functions included in this option IndReset IndAMove IndDMove IndRMove IndCMove IndInpos IndSpeed CorrCon CorrWrite CorrRead CorrDiscon CorrClear
18
Resetting the work area for an axis Running an axis independently to an absolute position Running an axis independently for a specified distance Running an axis independently to a position within one revolution, without taking into consideration the number of turns the axis had rotated earlier Running an axis continuously in independent mode Checking whether or not an independent axis has reached the programmed position Checking whether or not an independent axis has reached the programmed speed Activating path correction Changing path correction Read current path correction Deactivating path correction Removes all correction generators
Product Specification RobotWare for BaseWare OS 3.1
Multitasking 3.1
3.3 Multitasking 3.1 Up to 10 programs (tasks) can be executed in parallel with the normal robot program. - These additional tasks start automatically at power on and will continue until the robot is powered off, i.e. even when the main process has been stopped and in manual mode. - They are programmed using standard RAPID instructions, except for motion instructions. - They can be programmed to carry out various activities in manual or automatic mode, and depending on whether or not the main process is running. - Communication between tasks is carried out via I/O or global data. - Priorities can be set between the processes. Examples of applications: - The robot is continuously monitoring certain signals even when the robot program has stopped, thus taking over the job traditionally allocated to a PLC. - An operator dialogue is required at the same time as the robot is doing, for example, welding. By putting this operator dialogue into a background task, the operator can specify input data for the next work cycle without having to stop the robot. - The robot is controlling a piece of external equipment in parallel with the normal program execution. Performance When the various processes are programmed in the correct way, no performance problems will normally occur: - When the priorities for the various processes are correctly set, the normal program execution of the robot will not be affected. - Because monitoring is implemented via interrupts (instead of checking conditions at regular intervals), processor time is required only when something actually happens. - All input and output signals are accessible for each process. Note that the response time of Multitasking does not match that of a PLC. Multitasking is primary intended for less demanding tasks. The available program memory can be divided up arbitrarily between the processes. However, each process in addition to the main process will reduce the total memory, see section 5.1.
Product Specification RobotWare for BaseWare OS 3.1
19
FactoryWare Interface 3.1
3.4 FactoryWare Interface 3.1 This option enables the robot system to communicate with a PC using RobComm 3.0 or later versions (see FactoryWare). The FactoryWare Interface 3.1 serves as a run-time license for RobComm, i.e. the PC does not require any license protection when executing a RobComm based application. However, when developing such an application, a hardware lock and password are needed in the PC (design time license). Older versions of RobComm will require RAP Communication in the robot and license protection in the PC (hardware lock and password for design and run-time, or only password for only run-time). This option will also work with RobView 3.1/1 or DDE Server 2.3/1 (or later versions). Older versions work only with RAP Communication. In all cases RobView and DDE Server will require the hardware lock and password. The Factory Ware Interface 3.1 includes the Robot Application Protocol (RAP), based on MMS functionality. The Robot Application Protocol is used for computer communication. The following functions are supported: - Start and stop program execution - Transfer programs to/from the robot - Transfer system parameters to/from the robot - Transfer files to/from the robot - Read the robot status - Read and write data - Read and write output signals - Read input signals - Read error messages - Change robot mode - Read logs RAP communication is available both for serial links and network, as illustrated by the figure below. RAP RPC (Remote Procedure Call) TCP/IP Standard protocols SLIP
Ethernet
RS232/RS422
20
Product Specification RobotWare for BaseWare OS 3.1
FactoryWare Interface 3.1 Examples of applications: - Production is controlled from a superior computer. Information about the robot status is displayed by the computer. Program execution is started and stopped from the computer, etc. - Transferring programs and parameters between the robot and a PC. When many different programs are used in the robot, the computer helps in keeping track of them and by doing back-ups. - Programs can be transferred to the robot’s ramdisk at the same time as the robot executes its normal program. When execution of this program has finished, the new program can be read very quickly from the ramdisk and program execution can continue. In this way a large number of programs can be handled and the robot’s memory does not have to be so big. RAPID instruction included in this option SCWrite
Sends a message to the computer (using RAP)
Product Specification RobotWare for BaseWare OS 3.1
21
RAP Communication 3.1
3.5 RAP Communication 3.1 This option is required for all communication with a superior computer, where none of the FactoryWare products RobComm, RobView, or DDE Server, are used. It includes the same functionality described for the option Factory Ware Interface 3.1. It also works for the FactoryWare products. For RobView and DDE Server, there is no difference from the FactoryWare Interface (except that the price is higher). For RobComm, in this case a license protection requirement in the PC is added. Note that both FactoryWare Interface and RAP Communication can be installed simultaneously.
22
Product Specification RobotWare for BaseWare OS 3.1
Ethernet Services 3.1
3.6 Ethernet Services 3.1 Information in mass storage, e.g. the hard disk in a PC, can be read directly from the robot. The robot control program can also be booted via Ethernet instead of using diskettes. This requires Ethernet hardware in the robot. Examples of applications: - All programs for the robot are stored in the PC. When a new part is to be produced, i.e. a new program is to be loaded, the program can be read directly from the hard disk of the PC. This is done by a manual command from the teach pendant or an instruction in the program. If the option RAP Communication or FactoryWare Interface is used, it can also be done by a command from the PC (without using the ramdisk as intermediate storage). - Several robots are connected to a PC via Ethernet. The control program and the user programs for all the robots are stored on the PC. A software update or a program backup can easily be executed from the PC.
Product Specification RobotWare for BaseWare OS 3.1
23
Load Identification and Collision Detection 3.1 (LidCode)
3.7 Load Identification and Collision Detection 3.1 (LidCode) This option is only available for the IRB 6400 family of robots. LidCode contains two very useful features: Load Identification To manually calculate or measure the load parameters accurately can be very difficult and time consuming. Operating a robot with inaccurate load parameters can have a detrimental influence on cycle time and path accuracy. With LidCode, the robot can carry out accurate identification of the complete load data (mass, centre of gravity, and three inertia components). If applicable, tool load and payload are handled separately. The identification procedure consists of limited predefined movements of axes 3, 5 and 6 during approximately three minutes. The starting point of the identification motion pattern can be chosen by the user so that collisions are avoided. The accuracy achieved is normally better than 5%. Collision Detection Abnormal torque levels on any robot axis (not external axes) are detected and will cause the robot to stop quickly and thereafter back off to relieve forces between the robot and environment. Tuning is normally not required, but the sensitivity can be changed from Rapid or manually (the supervision can even be switched off completely). This may be necessary when strong process forces are acting on the robot. The sensitivity (with default tuning) is comparable to the mechanical alternative (mechanical clutch) and in most cases much better. In addition, LidCode has the advantages of no added stick-out and weight, no need for connection to the e-stop circuit, no wear, the automatic backing off after collision and, finally, the adjustable tuning. Two system outputs reflect the activation and the trig status of the function. RAPID instructions included in this option MotionSup ParldRobValid ParldPosValid LoadId
24
Changing the sensitivity of the collision detection or activating/deactivating the function. Checking that identification is available for a specific robot type. Checking that the current position is OK for identification. Performing identification.
Product Specification RobotWare for BaseWare OS 3.1
ScreenViewer 3.1
3.8 ScreenViewer 3.1 This option adds a user window to display user defined screens with advanced display functions. The user window can be displayed at any time, regardless of the execution state of the RAPID programs. User defined screens The user defined screens are composed of: • A fixed background with a size of 12 lines of 40 characters each. These characters can be ASCII and/or horizontal or vertical strokes (for underlining, separating or framing). • 1 to 5 function keys. • 1 to 4 pop-up menus containing from 1 to 10 choices. • 1 to 30 display and input fields defined by: - Their position and size. - Their type (display, input). - Their display format (integer, decimal, binary, hexadecimal, text). - A possible boundary with minimum and maximum limits. Example of a user defined screen. The ### represent the fields. SpotTim Program number: ###
PHASES SQUEEZE PREHEAT COOLING ## HEAT COLD LASTCOLD POSTHEAT HOLD Next
View
File
| | | | | | | | |
XT ## ## ## ## ## ## ## ##
| | | | | | | | | |
CURENT (A) START | END | #### | | #### #### | | | #### | #### | Prev.
Heat stepper: ### interpolated: ## | | Tolerance: ###% | Force: ###daN | Forge: ###daN | | Fire chck: ### | | Err allow: ###% | Numb err: ###
(Copy)
Product Specification RobotWare for BaseWare OS 3.1
Valid
25
ScreenViewer 3.1 Advanced Display functions The user defined screens run independently of the RAPID programs. Some events occur on a screen (new screen displayed, menu choice selected, function key pressed, field modified, ...). A list of user screen commands can be associated with any of these events, then when the event occurs, the command list will be executed. A screen event can occur - When a new screen is displayed (to initialize the screen contents). - After a chosen interval (to refresh a screen). - When a menu choice or a function key is selected (to execute a specific action, or change the screen). - When a new value is entered in a field, or when a new field is selected (to execute some specific action). The commands that can be executed on screen events are - Reading/writing RAPID or I/O data. - Reading/writing fields contents. - Arithmetical (+, -, /, *, div) or logical (AND, OR, NOT, XOR) operations on the data read. - Comparing data read (=, ) and carrying out a command or not, depending on the comparison result. - Displaying a different screen. Capacities The user screens can be grouped in a screen package file under a specific name. Up to 8 packages can be loaded at the same time. A certain amount of memory (approx. 50 kbytes) is reserved for loading these screen packages. - The screen package to be displayed is selected using the far right hand menu “View” (which shows a list of the screen packages installed).
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Product Specification RobotWare for BaseWare OS 3.1
Conveyor Tracking 3.1
3.9 Conveyor Tracking 3.1 Conveyor Tracking (also called Line Tracking) is the function whereby the robot follows a work object which is mounted on a moving conveyor. While tracking the conveyor, the programmed TCP speed relative to the work object will be maintained, even when the conveyor speed is changing slowly. Note that hardware components for measuring the conveyor position are also necessary for this function. Please refer to the Product Specification for your robot. Conveyor Tracking provides the following features: - A conveyor can be defined as either linear or circular. - It is possible to have two conveyors connected simultaneously and to switch between tracking the one or the other. - Up to 254 objects can reside in an object queue which can be manipulated by RAPID instructions. - It is possible to define a start window in which an object must be before tracking can start. - A maximum tracking distance may be specified. - If the robot is mounted on a parallel track motion, then the system can be configured such that the track will follow the conveyor and maintain the relative position to the conveyor. - Tracking of a conveyor can be activated “on the fly”, i.e. it is not necessary to stop in a fine point. Performance At 150 mm/s constant conveyor speed, the TCP will stay within +/-2 mm of the path as seen with no conveyor motion. When the robot is stationary relative to the conveyor, the TCP will remain within 0.7 mm of the intended position. These values are valid as long as the robot is within its dynamic limits with the added conveyor motion and they require accurate conveyor calibration. RAPID instructions included in this option WaitWObj DropWObj
Connects to a work object in the start window Disconnects from the current object
Product Specification RobotWare for BaseWare OS 3.1
27
I/O Plus 3.1
3.10 I/O Plus 3.1 I/O Plus enables the S4C to use non-ABB I/O units. The following units are supported: - Wago modules with DeviceNet fieldbus coupler, item 750-306 revision 3. - Lutze IP67 module DIOPLEX-LS-DN 16E 744-215 revision 2 (16 digital input signals). - Lutze IP67 module DIOPLEX-LS-DN 8E/8A 744-221 revision 1 (8 digital input signals and 8 digital output signals). For more information on any of these untis, please contact the supplier. The communication between these units and S4C has been verified (this does not, however, guarantee the internal functionality and quality of the units). Configuration data for the units is included. In I/O Plus there is also support for a so-called “Welder”. This is a project specific spot welding timer, and is not intended for general use. In addition to the above units, the I/O Plus option also opens up the possibility to use other digital I/O units that conform with the DeviceNet specification. ABB Robotics Products AB does not assume any responsibility for the functionality or quality of such units. The user must provide the appropriate configuration data.
28
Product Specification RobotWare for BaseWare OS 3.1
ArcWare 3.1
4 ProcessWare 4.1 ArcWare 3.1 ArcWare comprises a large number of dedicated arc welding functions, which make the robot well suited for arc welding. It is a simple yet powerful program since both the positioning of the robot and the process control and monitoring are handled in one and the same instruction. I/O signals, timing sequences and weld error actions can be easily configured to meet the requirements of a specific installation. ArcWare functions A few examples of some useful functions are given below. Adaptation to different equipment The robot can handle different types of weld controllers and other welding equipment. Normally communication with the welding controller uses parallel signals but a serial interface is also available. Advanced process control Voltage, wire feed rate, and other process data can be controlled individually for each weld or part of a weld. The process data can be changed at the start and finish of a welding process in such a way that the best process result is achieved. Testing the program When testing a program, welding, weaving or weld guiding can all be blocked. This provides a way of testing the robot program without having the welding equipment connected. Automatic weld retry A function that can be configured to order one or more automatic weld retries after a process fault. Weaving The robot can implement a number of different weaving patterns up to 10 Hz depending on robot type. These can be used to fill the weld properly and in the best possible way. Weaving movement can also be ordered at the start of the weld in order to facilitate the initial striking of the arc.
Product Specification RobotWare for BaseWare OS 3.1
29
ArcWare 3.1 Wire burnback and rollback These are functions used to prevent the welding wire sticking to the work object. Fine adjustment during program execution The welding speed, wire feed rate, voltage and weaving can all be adjusted whilst welding is in progress. This makes trimming of the process much easier because the result can be seen immediately on the current weld. This can be done in both manual and automatic mode. Weld Guiding Weld guiding can be implemented using a number of different types of sensors. Please contact your nearest ABB Flexible Automation Centre for more information. Interface signals The following process signals are, if installed, handled automatically by ArcWare. The robot can also support dedicated signals for workpiece manipulators and sensors.
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Digital outputs Power on/off Gas on/off Wire feed on/off Wire feed direction Weld error Error information Weld program number
Description Turns weld on or off Turns gas on or off Turns wire feed on or off Feeds wire forward/backward Weld error Digital outputs for error identification Parallel port for selection of program number, or 3-bit pulse port for selection of program number, or Serial CAN/Devicenet communication
Digital inputs Arc OK Voltage OK Current OK Water OK Gas OK Wire feed OK Manual wire feed Weld inhibit Weave inhibit Stop process Wirestick error Supervision inhibit Torch collision
Description Arc established; starts weld motion Weld voltage supervision Weld current supervision Water supply supervision Gas supply supervision Wire supply supervision Manual command for wire feed Blocks the welding process Blocks the weaving process Stops/inhibits execution of arc welding instructions Wirestick supervision Program execution without supervision Torch collision supervision
Analog outputs Voltage Wire feed Current Voltage adjustment Current adjustment
Description Weld voltage Velocity of wire feed Weld current Voltage synergic line amplification Current synergic line amplification Product Specification RobotWare for BaseWare OS 3.1
ArcWare 3.1 Analog inputs (cont.)
Description (cont.)
Voltage
Weld voltage measurement for monitoring and supervision Weld current measurement for monitoring and supervision
Current
RAPID instructions included in this option ArcL ArcC
Arc welding with linear movement Arc welding with circular movement
Product Specification RobotWare for BaseWare OS 3.1
31
ArcWare Plus 3.1
4.2 ArcWare Plus 3.1 ArcWare Plus contains the following functionality: - ArcWare, see previous chapter. - Arc data monitoring. Arc data monitoring with adapted RAPID instructions for process supervision. The function predicts weld errors. - Contour tracking. Path corrections can be made in the path coordinate system. These corrections will take effect immediately, also during movement between two positions. The path corrections must be entered from within the program. An interrupt or multitasking is therefore required to activate the correction during motion. Example of application: A sensor is used to define the robot input for path correction during motion. The input can be defined via an analog input, a serial channel or similar. Multitasking or interrupts are used to read this information at specific intervals. Based on the input value, the path can then be adjusted. - Adaptive process control. Adaptive process control for LaserTrak and Serial Weld Guide systems. The tool provides the robot system with changes in the shape of the seam. These values can be used to adapt the process parameters to the current shape. RAPID instructions and functions included in this option ArcKill ArcRefresh CorrCon CorrWrite CorrRead CorrDiscon CorrClear SpcCon SpcWrite SpcDump SpcRead SpcDiscon
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Aborts the process and is intended to be used in error handlers Updates the weld references to new values Activating path correction Changing path correction Read current path correction Deactivating path correction Removes all correction generators Activates statistical process supervision Provides the controller with values for statistical process supervision Dumps statistical process supervision data to a file or on a serial channel Reads statistical process supervision information Deactivates statistical process supervision
Product Specification RobotWare for BaseWare OS 3.1
SpotWare 3.1
4.3 SpotWare 3.1 SpotWare comprises a large number of dedicated spot welding functions which make the robot well suited for spot welding. It is a simple yet powerful program since both the positioning of the robot and the process control and monitoring are handled in one and the same instruction. Cycle times can be shortened by means of closing the spot welding gun in advance, together with the fact that movement can commence immediately after a spot weld is completed. The robot’s self-optimising motion control, which results in fast acceleration and a quick approach to the spot weld, also contributes to making cycle times shorter. I/O signals, timing sequences and weld error actions can be easily configured to meet the requirements of a specific installation. SpotWare functions A few examples of some useful functions are given below. Adaptation to different welding guns Gun control (opening and closing) can be programmed freely to suit most types of guns, irrespective of the signal interface. Adaptation to different weld timers The robot can handle different types of weld timers. Normally communication with the weld timer uses parallel signals but a serial interface is also available for some types of weld timers. Continuous supervision of the welding equipment If the option Multitasking is added, supervision can be implemented irrespective of the spotweld instruction. For example, it is possible to monitor peripheral equipment even when program execution has been stopped. Closing the gun It is possible to start closing the spot welding gun before reaching the programmed point. By defining a time of closure, the gun can be closed correctly regardless of the speed of the robot. The cycle time is optimised when the gun is just about to close at the instant when the robot reaches the programmed point. Constant squeeze time Welding can be started directly as the gun closes, i.e. without waiting for the robot to reach its final position. This gives a constant time between gun closure and weld start. Customised Move enable The movement after a completed spot weld can be configured to start either on a user defined input signal or a delay time after weld ready.
Product Specification RobotWare for BaseWare OS 3.1
33
SpotWare 3.1 Immediate move after Move enable The robot moves immediately when enable is given. This is achieved by preparing the next action while waiting for the current weld to be completed. Gun control The system supports double guns, small and large strokes and gun pressure control. Several guns can be controlled in the same program. Testing the program The program can be run one instruction at a time, both forwards and backwards. When it is run backwards, only motion instructions, together with an inverted gun movement, are executed. The program can also be test run without connecting a weld timer or spot welding gun. This makes the program easier to test. Rewelds A function that can be configured to order one or more automatic rewelds or, when the program is restarted after an error, a manual reweld. Process error routines In the event of a process error, installation-specific routines, such as go-to-service position, can be ordered manually. When the appropriate routine has been performed, the weld cycle continues from where it was interrupted. Manual welding independent of positioning A spot weld can be ordered manually at the current robot position. This is implemented in a similar way as for program execution, i.e. with gun control and process supervision. It is also possible to order a separate gun control with full supervision. Interface signals The following process signals are, if installed, handled automatically by SpotWare. Digital outputs start 1 start 2 close tip 1 close tip 2 work select program parity reset fault process error current enable p2 request p3 request p4 request weld power water start
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Description start signal to the weld timer (tip 1) start signal to the weld timer (tip 2) close gun (tip 1) close gun (tip 2) select work or retract stroke of the gun weld program parity bit reset the weld timer operator request is set when an error occurs weld inhibit to the weld timer set pressure 2 set pressure 3 set pressure 4 activate the weld power unit contactor activate water cooling
Product Specification RobotWare for BaseWare OS 3.1
SpotWare 3.1 manual close gun manual open gun manual run process manual skip process manual new data process run inhibit move weld error
close gun manually open gun manually run a complete spot weld skip the ongoing action send data for the manual actions process is executed block spot welding movement weld ready timeout
Digital output groups program no. initiate
Description weld program number used for several weld timers
Digital inputs weld ready 1 weld ready 2 tip 1 open tip 2 open tip 1 retract tip 2 retract p1 OK p2 OK p3 OK p4 OK timer OK flow OK temp OK current OK
Description weld, started with start 1, is finished weld, started with start 2, is finished the gun (tip 1) is open the gun (tip 2) is open the gun (tip 1) opened to retract stroke the gun (tip 2) opened to retract stroke pressure 1 is reached pressure 2 is reached pressure 3 is reached pressure 4 is reached the weld timer is ready to weld no problem with the water supply no over-temperature the weld current is within permissible tolerances
User defined routines The following routines are predefined but can be adapted to suit the current installation. Routine preweld supervision postweld supervision init supervision motor on action motor off action process OK action process error action current enable action current disable action close gun open gun set pressure service close gun service open gun service weld fault
Description supervision to be done before welding supervision to be done after welding supervision to be done for a warm start action to be taken for Motors On action to be taken for Motors Off action to be taken for welding sensor OK action to be taken for a process error action to be taken for current enable action to be taken for current disable definition of gun closing definition of gun opening definition of gun pressure setting error handling when gun pressure is not achieved error handling at timeout for gun opening error handling at timeout for weld-ready signal
The option Advanced functions is included.
Product Specification RobotWare for BaseWare OS 3.1
35
SpotWare 3.1 RAPID instructions included in this option SpotL
36
Spot welding with linear movement
Product Specification RobotWare for BaseWare OS 3.1
SpotWare Plus 3.1
4.4 SpotWare Plus 3.1 In addition to the SpotWare functionality the robot can weld with up to four stationary welding guns simultaneously. RAPID instructions included in this option SpotML
Multiple spot welding with linear movement.
Product Specification RobotWare for BaseWare OS 3.1
37
GlueWare 3.1
4.5 GlueWare 3.1 GlueWare comprises a large number of dedicated gluing functions which make the robot well suited for gluing and sealing. It is a simple yet powerful program since both the positioning of the robot and the process control are handled in one and the same instruction. I/O signals and timing sequences can be easily configured to meet the requirements of a specific installation. GlueWare functions A few examples of some useful functions are given below. Adaptation to different gluing guns Both on/off guns and proportional guns can be handled. Furthermore, time delays can be specified for the gluing guns in order to obtain the correct thickness of glue or sealing compound and application at the specified time. Two gluing guns One or two gluing guns can be controlled. Up to two analog outputs can be controlled for each gun. Velocity independent glue string thickness The thickness of the glue string can be made independent on the robot’s velocity by controlling the gluing gun with a signal that reflects the robot’s velocity. When the robot velocity is reduced, the flow of glue will be automatically reduced. The robot can compensate for a gun delay of up to 500 ms, thanks to a proactive signal. Flow change at a specific position Flow changes (incl. start and stop) can be put into the programmed path, also where there are no programmed positions. These positions will remain fixed even when the velocity is changed, which makes the programming much simpler. Global flow changes The glue flow can be changed for the whole program just by changing one value. Program testing without glue Gluing can be temporarily blocked in order to be able to test the robot’s movements without any glue flow.
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Product Specification RobotWare for BaseWare OS 3.1
GlueWare 3.1 Interface signals When installed, the following process signals are handled automatically by GlueWare. Analog outputs gun1 flow1 gun1 flow 2 gun2 flow1 gun2 flow 2
Description Glue flow reference gun 1 Glue flow reference gun 1 Glue flow reference gun 2 Glue flow reference gun 2
Digital outputs gun 1 on/off gun 2 on/off overspeed error
Description glue off/on gun1 glue off/on gun 2 the calculated value of an analog output signal is greater than its logical max. value error during gluing
process error User defined routines
The following routines are predefined but can be adapted to suit the current installation. Routine preglue actions postglue actions power on action restart action stop action emergency stop action
Description activity to be carried out in the beginning of the glue string activity to be carried out at the end of the glue string activity to be carried out at power-on activity to be carried out at program start activity to be carried out at program stop activity to be carried out in the event of an emergency stop or other safeguarded space stop
The option Advanced functions is included. RAPID instructions included in this option GlueL GlueC
Gluing with linear movement Gluing with circular movement
Product Specification RobotWare for BaseWare OS 3.1
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PaintWare 3.1
4.6 PaintWare 3.1 PaintWare comprises a large number of dedicated painting functions which make the robot well suited for painting and coating operations. It is powerful, yet simple since both the robot positioning and the paint events are handled in one and the same instruction. All phases of the paint process are controlled, such as start, change, and stop painting, due to trig plane events. The necessary structures for paint process data are predefined and organised as BrushData and BrushTables. PaintWare is only avaliable with painting robots. PaintWare functionality When painting, the fluid and air flow through the spray gun is controlled to suit the part being coated and the thickness requirements. These process parameters are changed along the path to achieve optimum control of the paint equipment along an entire path. The paint process is monitored continuously. A set of gun process parameters is called a Brush and it is possible to select different brushes during a linear paint instruction. A brush can contain up to five parameters: Paint Atom_air Fan_air Voltage Rotation
The Paint flow reference. The Atomising air reference. The Fan air reference. The Electrostatic voltage reference. The Rotation speed reference (for rotational applicators).
The five parameters may go directly to analog outputs controlling the spray gun in an open loop system, or may go to dedicated I/O boards for closed loop gun control (IPS). The Brushes are set up as an array, called a BrushTable. A specific BrushTable is selected with the instruction UseBrushTab. The changing of brushes along a path is done using events in the PaintL instruction. The event data describes how a trig plane is located in the active object coordinate system. It also describes which brush to use when the path crosses the plane. Event data is included in all linear paint instructions as optional arguments. A maximum of ten events can be held within one PaintL instruction. Data types included in this option BrushData EventData
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Data for one brush: flow, atomising air, fan air, etc. Data for one event: trig-plane (x, y or z), plane value and brush numberPaintL, PaintC, UseBrushTab,
Product Specification RobotWare for BaseWare OS 3.1
PaintWare 3.1 RAPID instructions included in this option PaintL PaintC UseBrushTab SetBrush
Paint along a straight path w/paint events Paint along a circular path Used to activate (select) a brush-table. Select a brush from the activated brush-table.
Product Specification RobotWare for BaseWare OS 3.1
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4.7 PalletWare General The PalletWare package is a set of Rapid modules and user screens, which perform basic operations related to a palletizing process. These operations include a number of services which can be called from a main program to perform pick and place operations for one or up to five palletizing tasks in parallel. For each such task a number of separate dynamic variables are used to describe and keep track of each on-going pallet operation. The PalletWare package is intended to work with Rapid modules generated from PalletWizard, a PC tool for off-line programming of pallet cycles. Pallet cycles Up to five different pallet cycles may be run in parallel, where a pallet cycle is the task to run a complete palletizing job for a pallet, i.e. to pick and place all products, including the pallet itself. Each pallet cycle includes a number of layer cycles, where each layer cycle is the task to complete one layer with all the parts to be picked and placed in this layer. Each layer cycle may further be broken down into a number of pick-place cycles, where each pick-place cycle is the task to pick one or several parts and place them on the pallet. Within each pick-place cycle there may be several pick operations, if parts must be picked in many separate operations. Similarly, there may be several place operations in each pick-place cycle. Each layer may be either an in-feeder layer, where the products, e.g. boxes, are picked from an in-feeder, or a stack layer, where the product, e.g. an empty pallet, is searched and picked from a stack. If several pallet cycles are run in parallel, then one complete pick-place cycle is always finished before a new one is started in another pallet cycle. Pallet cell The pallet cell may include any number of pallet stations, in-feeders and stacks for pallets, tier sheets or slip sheets. All such stations and stacks are defined as regards position, with an individual coordinate system (work object). The palletizing robot is normally an IRB 6400 or IRB 640 but any robot type may be used. The tool to use may be a mechanical gripper or a tool with suction cups, possibly with separate grip zones for multiple picking and placing. Several different tooldata may be defined and used depending on the product dimensions and number of products.
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Product Specification RobotWare for BaseWare OS 3.1
Products Any number of different products with different dimensions may be handled and placed in different patterns on the pallet. Each layer must have the same product only, but different layers on a pallet may have different products. Products may be delivered on one or several in-feeders and placed on one or several different pallets. For each separate product individual handling speeds and load data are used. The dimensions and speeds of the products may be changed in run time, thus affecting all pick and place positions. Movements, approach and retreat positions All movements are calculated in run time and relative to the different coordinate systems defined for each station. Between stations, e.g. moving from an in-feeder to a pallet station, the robot may be forced to move up to safety height and to retract before moving towards the new station. While moving to the pick or place position, the robot will first move to an approach position and then to a prepick/place position. These horizontal and vertical distances for the approach positions, relative to the pick or place position, may be individually defined per product or station. In addition, the approach direction may be individually defined per pick or place position. These approach data may be changed in run time. The picking and placing movements and the sequence to search different stacks for empty pallets or tier sheets may be customised if necessary. User routines A number of different user routines may be called at certain phases of the pallet cycle. These routines can be used for communication with external equipment, for error checking, for operator messages etc. Such user routines are grouped in three main groups according to when they are called in the pallet cycle. The groups are: - Cycle routines, connected to the different cycles, i.e. pallet cycle, layer cycle, pick and place cycle. Each such cycle may have its own individual user routine at the beginning, at the middle and at the end of the cycle. - Station access routines, connected to the different stations. A specific user routine may be called before (station-in routine) and after (station-out) a pick/place on a feeder or pallet station, e.g. to order the next products on the feeder. - Pick stack routines, connected to stacks. Such routines are called to search and pick a product on the stack.
Product Specification RobotWare for BaseWare OS 3.1
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User screens The user interacts with the program using menu driven screens on the teach pendant. These screens allow the following functions to be configured: - Station menu gives access to the robot default parameters, the tool information, the pallet stations, stack stations and feeder station information. - Product menu gives access to the information related to the different types of product: regular products, empty pallets. - Cycles menu gives access to the current production status for the different lines. PalletWare system modules PalletWare consists of a number of system modules as listed below. PalletWare Kernel:
PAL_EXE.sys PAL_DYN.sys PAL_SCR.sys
Generated from PalletWizard:
PAL_CELL.sys PAL_CYC.sys
Templates to be completed by the system integrator concerning work object data, tool data, user routines including communication with external equipment etc.: PAL_USRR.sys PAL_USRT.sys Modules and code not included in PalletWare In addition to the modules listed above, there are some modules which are not included in the PalletWare delivery, but which must be written by the system integrator for specific installations. These are: - The “main” module, including the main routine. In this routine all logic for working with parallel and simultaneous pallet cycles must be coded by the system integrator, including code required for operator messages, error handling and product changes. - A system module holding different operator dialogues, which may be called from the main routine in order to change or check pallet cycles or to handle error situations. System requirements for option PalletWare - Option ScreenViewer.
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Product Specification RobotWare for BaseWare OS 3.1
Available memory
5 Memory and Documentation 5.1 Available memory The available user memory for the different memory options is as follows: Extended memory
Standard
+8 MB
Total memory
8+8=16 MB (option 402)
8+16=24 MB (option 403)
Program memory without options
2.5 MB (ram disk=0.5 MB)
6.0 MB (ram disk=4.0 MB)
Other software options reduce the available program memory as follows. Options not mentioned have no or small memory consumption (less than 10 kB). All the figures are approximate. Option
Program memory
Base system
335 kB
Multitasking
80 kB/task (including task 1)
Advanced Functions
20 kB
GlueWare
125 kB
SpotWare
SpotWare Plus
370 kB
390 kB
Ram disk
Remark
145 kB (225 kB if memory option 403 is chosen)
30 kB
Including Advanced Functions
55 kB
Including Multitasking with two spotware tasks (one process and one supervision task).
75 kB
Including Multitasking with two spotware tasks (one process and one supervision task). Including Multitasking with five spotware tasks (four process and one supervision task).
SpotWare Plus
730 kB
75 kB
Load Identification and Collision Detection
80 kB
40 kB
Product Specification RobotWare for BaseWare OS 3.1
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Teach pendant language For RAPID memory consumption, see the RAPID Developer’s Manual. As an example, a MoveL or MoveJ instruction consumes 236 bytes when the robtarget is stored in the instruction (marked with ‘*’) and 168 bytes if a named robtarget is used. In the latter case, the CONST declaration of the named robtarget consumes an additional 280 bytes.
5.2 Teach Pendant Language The robot is delivered with the selected language installed. The other languages are also delivered and can be installed.
5.3 Robot Documentation A complete set of documentation consisting of: - User’s Guide, with step by step instructions on how to operate and program the robot. This manual also includes a chapter called Basic Operation, which is an introduction to the basic operation and programming of the robot, and is suitable as a tutorial. - RAPID Reference Manual, a description of the programming language. - Product Manual, a description of the installation of the robot, maintenance procedures and troubleshooting. The Product Specification is included. If the Danish language is chosen, the RAPID Reference Manual and parts of the Product Manual will be in English.
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Product Specification RobotWare for BaseWare OS 3.1
DeskWare Office 3.0
6 DeskWare 6.1 DeskWare Office 3.0 DeskWare Office is a suite of powerful PC applications designed to reduce the total cost of robot ownership. These applications are organized into four different rooms: • Programming Station • Training Center • Library • Robot Lab These rooms contain PC-based tools for training, programming, testing, and maintenance to address the fundamental needs of all robot owners. A comprehensive list of all applications in the DeskWare Office suite, organized by room, follows below. • Programming Station - ProgramMaker application - ConfigEdit application - Online version of the S4 RAPID Reference Manual • Training Center - QuickTeach application - QuickTeach Tutorial application - Online version of the S4 User’s Guide • Library - ProgramSafe application - ServiceLog application - Online versions of all S4 documentation • Robot Lab - VirtualRobot application To make navigating and launching applications easy, the graphical Office interface shown below was created. To launch applications, the user clicks on corresponding “hot spots,” enabled when the rooms are installed. When you launch DeskWare applications, you are in fact running the Virtual Controller - the actual S4 controller software - in your PC.
Product Specification RobotWare for BaseWare OS 3.1
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DeskWare Office 3.0
User Preferences
Library Training Center
Robot Lab
Programming Station
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Product Specification RobotWare for BaseWare OS 3.1
DeskWare Office 3.0 The “User Preferences” button is used to select robot and language options that apply to the entire application suite. Pressing this button displays the following dialog.
Select a robot
Configure the selected robot
The following sections contain more detailed descriptions of the applications available in each room of the DeskWare Office suite. PC System Requirements - Pentium processor. - 8 MB RAM memory, minimum for Windows 95; 16 MB RAM for Windows NT (32 MB RAM recommended). - Windows 95 or Windows NT 4.0. - 150 MB harddisk space. - VGA compatible display (1024 x 768 recommended). - CD-ROM drive. - Microsoft compatible mouse.
Product Specification RobotWare for BaseWare OS 3.1
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Programming Station 3.0
6.2 Programming Station 3.0 Programming Station is a collection of software applications that assist the user in constructing and editing robot programs and configuration files on a PC. Programming Station includes: - ProgramMaker application. - ConfigEdit application. - Online version of the S4 RAPID Reference Manual. ProgramMaker allows the user to create and edit robot programs on a PC, in the Windows environment. ProgramMaker is a complete system for creating and editing RAPID programs for the S4 robot controller. ProgramMaker is unique, compared to other offline programming systems, as it embeds the functionality of the S4 robot controller and uses this capability to perform all robot controller-specific tasks. For example, you can configure the embedded S4 controller within ProgramMaker so that it represents the same I/O setup as your real robot. Then, when you program I/O-based statements, ProgramMaker checks to ensure that you refer only to those signals that are defined on your robot. ProgramMaker can assume the functionality of different versions of the S4 controller, for example, V2.1 or V3.0, and behave in accordance with the features specific to that version of controller. This means you can see the same status and error messages in ProgramMaker as you see on the real robot. ProgramMaker implements an advanced Windows user interface that permits you to develop RAPID programs quickly, easily, and without error. Unlike using a conventional text editor, ProgramMaker helps you write RAPID programs by creating instructions with a single command, providing default parameters in many cases automatically. For beginning programmers, ProgramMaker provides instructionsensitive dialogs that make programming complex statements easy. For experts, ProgramMaker also offers the more conventional approach of text-based entry of RAPID program statements. Using either method, ProgramMaker guarantees that your programs will be valid when you load them into your robot. You can set up ProgramMaker to assume the configuration of a specific robot controller. You do this using the Preferences dialog of Office. Configuration includes, for example, the specific version (V2.1, V3.0, etc.) of the robot controller, the software options installed on that controller (ArcWare, SpotWare, Serial RAP, etc.), and the amount of memory installed (10MB, 12MB, etc.). The Preferences dialog can be used to select a predefined configuration, or it can be used to create entirely new configurations through user-assisted dialogs or through direct import from the floppy disks shipped with your robot. The following image illustrates some of the main features of the ProgramMaker user interface.
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Product Specification RobotWare for BaseWare OS 3.1
Programming Station 3.0
Editing of background tasks is supported with a tabbed Tree View.
Data View permits manipulation of program data in familiar “spreadsheet” context.
Code View allows creation and editing of user programs.
Tree View provides a hierarchical view of RAPID modules.
Graph View displays programmed points in a dynamic viewer.
Some of the main features of ProgramMaker include: - Ability to check for syntactic and semantic errors, as robot programs are created or edited. - Program data is displayed in a familiar “spreadsheet” format which is Microsoft Excel compatible. - Full support for RAPID array handling. - Automatic declaration of referenced data. - Positions can also be viewed as points in the Graph View. - The Tree View allows the user to view and navigate robot program structure in a simple, logical manner. - Syntax colorization in the Code View for enhanced usability. - Multiple routines can be viewed and edited at the same time. - Cut/Copy/Paste and Search/Replace features.
Product Specification RobotWare for BaseWare OS 3.1
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Programming Station 3.0 PalletWizard is a programming tool used for palletizing applications. It must be used in combination with PalletWare (i.e. the output generated from PalletWizard is used in conjunction with PalletWare). PalletWizard is an integrated component of ProgramMaker, invoked from the ‘Tools’ menu. PalletWizard allows the user to create and edit system modules, which define the layout of a palletizing robot cell with its different pallet stations, infeeders, stacks and tools, including the pallet composition (products, layers and layer patterns). A robot cell for palletizing incorporates one palletizing robot, one or several pallet stations where products are placed and one or several infeeders, from which products are picked. The cell may also include one or several stacks, from which empty pallets or tier sheets are drawn. Objects in a palletizing cell The following objects and properties for a palletizing cell may be defined using PalletWizard: • Robot - Speed without products - Acceleration without products • Pallet Stations Several pallet stations may be defined, each with the following properties - Maximum and minimum height - Approach height • Infeeders Several infeeders may be defined, each with the following properties - Maximum and minimum height - Approach height - Product alignment - Type of product • Stacks Several stacks may be defined, each with the following properties - Maximum and minimum height - Approach height - Product alignment - Type of product
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Product Specification RobotWare for BaseWare OS 3.1
Programming Station 3.0 • Products A number of different products, for example, boxes, pallets, tier sheets etc., may be defined, each with the following properties: - Size - Sides with labels - Robot speed and acceleration when carrying the product - Pick and place approach distances, vertically and horizontally Pallet cycles A number of different pallet cycles may be defined. A pallet cycle consists of palletizing a complete pallet (i.e. to pick and place all products, including the pallet itself). Each pallet cycle includes a number of layer cycles. Each layer cycle consists of one complete layer with all the products to be picked and placed in this layer. Each layer cycle may further be broken down in a number of pick-place cycles, where each pick-place cycle consists of picking one or several parts and placing them on the pallet. Within each pick-place cycle there may be several pick operations, if parts should be picked in separate operations. Similarly, there might be several place operations in each pick-place cycle. A number of different layer cycles may be defined, including pick-place cycles. These layer cycles may then be freely used and combined in different pallet cycles (pallet compositions). For each layer cycle the following properties may be defined: - The product to pick and place. - The infeeder to use. Several infeeders may be used, if necessary. - The pattern to use. - The pick-place cycles to use. For each pattern the following properties may be defined: - The number of parts to place. - The position and orientation of each part. Part positions are always related to reference lines, freely positioned on the pallet. Any number of reference lines and positions are allowed. Label sides of the articles may be placed facing out. - The envelope of the pattern (i.e. the outer borders of the pattern).
Product Specification RobotWare for BaseWare OS 3.1
53
Programming Station 3.0 For each pick-place operation the following properties may be defined: - The number of pick operations - The number of place operations - The tool to be used. Different tool definitions may be used depending on the article to pick and the number of articles. - The approach direction for pick and place operations - The pick and place positions, related to the used pattern For each pallet cycle the following properties may be defined: - The pallet station to use. Several pallet stations may be used, alternately, if necessary. - The pallet to use in the first layer. - Orientation of the pallet in the pallet station - Load alignment (i.e. alignment of the pattern envelope - front, center or back, left, center or right). - The pallet composition for a complete pallet (i.e. specification of layer cycles to use in each layer). User routines It is possible to call different user routines in different phases of the pallet cycle. These user routines may be used for installation specific tasks, for example, communication with external equipment, operator messages, intermediate positions, etc. In PalletWizard, only the declarations of these user routines are created. The routine body, or RAPID code, can then be completed within ProgramMaker. All routines are grouped in three main categories, according to when they are called in the pallet cycle. The groups are: - Cycle routines, connected to the different cycles (pallet cycle, layer cycle, pick and place cycle). Each such cycle may have its own individual user routine in the beginning, in the middle, and at the end of the cycle. - Station access routines, connected to the different stations. A specific user routine may be called before (station-in routine) and after (station-out) a pick/place action on a feeder or pallet station, for example, to order the next products on the feeder. - Pick stack routines, connected to stacks. Such routines are called to search and pick a product on the stack. Load data Load data (load, center of gravity, and moment of inertia) is automatically set up by PalletWizard depending on the article dimensions, weight and number of articles in the tool.
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Product Specification RobotWare for BaseWare OS 3.1
Programming Station 3.0 Output from PalletWizard PalletWizard generates three output files, which are loaded into a robot system running PalletWare. ConfigEdit allows users to create and edit robot configuration files on a PC, in the Windows environment.
Some of the main features of ConfigEdit include: - Support for all configuration domains. - Standard configuration templates which can be customized. - Cut/Copy/Paste functions. - Help feature to explain configuration parameters. PC System Requirements - Pentium processor. - 8 MB RAM memory, minimum for Windows 95; 16 MB RAM for Windows NT (32 MB RAM recommended). - Windows 95 or Windows NT 4.0. - 100 MB harddisk space. - VGA compatible display (1024 x 768 recommended). - CD-ROM drive. - Microsoft compatible mouse. Product Specification RobotWare for BaseWare OS 3.1
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Training Center 3.0
6.3 Training Center 3.0 Training Center is a collection of PC software applications that assist the user in learning how to use the robot. Training Center includes: - QuickTeach application. - QuickTeach Tutorial application. - Online version of the S4 User’s Guide. QuickTeach is the actual teach pendant software running on a PC under Windows. Most things that can be done on the real teach pendant can also be done with QuickTeach, making QuickTeach an excellent training tool and eliminating the need to dedicate a robot for most training purposes.
Some of the main features of QuickTeach include: - Supports all languages that are supported by the robot controller. - Can be configured to emulate the real robot (i.e. custom menus, software options, etc.). - Can be used to create and edit robot programs; however, Programming Station is more efficient for this purpose. QuickTeach Tutorial is a 45 minute tutorial that covers the basic operations of the teach pendant. The tutorial is supported in the following languages: - English, French, German, Italian, Spanish and Swedish. 56
Product Specification RobotWare for BaseWare OS 3.1
Training Center 3.0 PC System Requirements - Pentium processor. - 8 MB RAM memory, minimum for Windows 95; 16 MB RAM for Windows NT (32 MB RAM recommended). - Windows 95 or Windows NT 4.0. - 100 MB harddisk space. - VGA compatible display (1024 x 768 recommended). - CD-ROM drive. - Microsoft compatible mouse.
Product Specification RobotWare for BaseWare OS 3.1
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Library 3.0
6.4 Library 3.0 Library is a collection of PC software applications that allow the user to store and retrieve important documentation related to the robot and auxiliary equipment. Library includes: - ProgramSafe application. - ServiceLog application. Online versions of all S4 documentation. ProgramSafe allows the user to archive, catalog and retrieve robot programs and configuration files in the Windows environment.
Some of the main features of ProgramSafe include: - Associate RAPID program and configuration files with individual robots. - Compare feature to find the differences between files or different versions of the same file. - File printout feature.
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Product Specification RobotWare for BaseWare OS 3.1
Library 3.0 ServiceLog allows the user to archive, catalog and retrieve robot programs and configuration files in the Windows environment.
Some of the main features of ServiceLog include: - Store maintenance information about robots and other workcell equipment. - Store frequently used service-related names, addresses and phone numbers. - Schedule future maintenance with automatic notification when due. - ServiceLog data files are Microsoft Access compatible. - User definable password protection with two security levels. PC System Requirements - Pentium processor. - 8 MB RAM memory, minimum for Windows 95; 16 MB RAM for Windows NT (32 MB RAM recommended). - Windows 95 or Windows NT 4.0. - 30 MB harddisk space. - VGA compatible display (1024 x 768 recommended). - CD-ROM drive. - Microsoft compatible mouse.
Product Specification RobotWare for BaseWare OS 3.1
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Robot Lab 3.0
6.5 Robot Lab 3.0 Robot Lab includes a PC software application intended to assist the user in testing robot programs. Robot Lab includes: - VirtualRobot application. VirtualRobot simulates ABB S4 robots on desktop computers. VirtualRobot can be used to test robot programs without having to occupy a real robot system. The VirtualRobot application consists of three windows: the Teach Pendant, the I/O Simulator, and the Robot View. The Teach Pendant window simulates the S4 Controller Teach Pendant, the I/O Simulator window permits user manipulation of digital I/O signals, and the Robot View allows the user to observe the motion of the VirtualRobot as it executes robot programs. The user may choose to run VirtualRobot with or without the I/O Simulator and Robot View. The VirtualRobot application assumes the functionality of the embedded S4 controller and can be configured with various memory and software options just like a real S4 controller using the Preferences dialog. Configuration includes, for example, the software options available to the controller (ArcWare, SpotWare, Serial RAP, etc.), the robot model (IRB1400H CEILING/DCLinkB, IRB6400C/B-150, etc.), the amount of memory installed in the controller (10MB, 12MB, etc.), and several other parameters. It should be noted that the VirtualRobot is only available for robot controller versions 2.1 and later. However, it is possible to test many programs for earlier controller versions using VirtualRobot version 2.1. Robot Lab includes predefined configurations of the controller. The Preferences dialog can be used to select among defined configurations and to create entirely new configurations through user-assisted dialogs or direct import of configuration data from the floppy disks shipped with the robot. The VirtualRobot I/O Simulator can be used to view and manipulate digital input and output signals during program execution. This feature is useful for testing robot programs that may set outputs or wait on certain input states before continuing. The VirtualRobot I/O Simulator automatically configures itself with the I/O boards and signals used by the selected robot. In addition to dynamically displaying robot motion, the Robot View window includes a cycle time clock that displays time computed internally by the robot control system to provide an estimate of cycle time for the real robot. This estimate does not contain settling time at fine points. By adding 200 ms per fine point, the cycle time accuracy will normally be within ±2 %. The image below illustrates some features of the Robot View window.
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Product Specification RobotWare for BaseWare OS 3.1
Robot Lab 3.0
Cycle Time Clock controls
Dynamic display of robot in motion
Thumbwheels allow user control over 3-D viewing.
PC System Requirements - Pentium processor. - 8 MB RAM memory minimum, for Windows 95; 16 MB RAM for Windows NT (32 MB RAM recommended). - Windows 95 or Windows NT 4.0. - 100 MB harddisk space. - VGA compatible display (1024 x 768 recommended). - CD-ROM drive. - Microsoft compatible mouse.
Product Specification RobotWare for BaseWare OS 3.1
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Robot Lab 3.0
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Product Specification RobotWare for BaseWare OS 3.1
RobComm 3.0
7 FactoryWare 7.1 RobComm 3.0 RobComm is a powerful toolkit for developing PC-based user interfaces for robot systems. RobComm frees you from the underlying communication protocols, so you spend time designing a user interface, not writing communication software. Typical applications that would make use of RobComm include: - File servers. - Cell controllers. - Statistical process control supervisors. - Other applications where a graphical operator interface or remote process monitoring and control are desired. RobComm is a collection of ActiveX Controls (OCXs). The operation of these controls is configured via the control’s properties. RobComm includes three robot-specific OCXs: the Helper control, the ABB Button control, and the Pilot Light control. Together they present a flexible, comprehensive communication interface to the S4. In designing PC user screens, these RobComm controls may be used in combination with Microsoft ActiveX controls and the thousands of other ActiveX controls available from third-party suppliers. In addition, the user application can be tested using the DeskWare VirtualRobot application (see section 6.5), permitting off-line verification of the operator interface and rapid deployment into production. The User Application Designed to leverage industry standard development tools, RobComm supports 32-bit Windows applications created with Microsoft Visual Basic, Visual C++, or Wonderware InTouch 7.0. Thus, users benefit from the wide availability of third-party components (known as ActiveX controls) that support these development environments, further reducing development time and effort. Visual Basic is generally preferred for rapid development of user interface screens, whereas Visual C++ may be needed in complex installations that require integration with other programming libraries. RobComm is designed such that multiple applications, including multi-threaded applications, can communicate with multiple S4 controllers without conflict. Applications developed with RobComm will work over a serial line to one robot, or over Ethernet to multiple robots. Visual Basic source code for two sample applications is included to illustrate the use of RobComm and accelerate the learning curve.
Product Specification RobotWare for BaseWare OS 3.1
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RobComm 3.0 The two screens shown below, are examples of a Visual Basic application that uses RobComm to collect and display process statistics, error messages, and robot I/O and to enable remote program modification. Pilot Light Controls
ABB Button Controls
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Product Specification RobotWare for BaseWare OS 3.1
RobComm 3.0 Following is a brief description of each ActiveX control included the RobComm toolkit. The Helper Control This is the primary communication interface for RobComm. The Helper control is an invisible control that provides methods, properties, and events to expose the entire S4 communication interface. The ABB Button Control The ABB Button control is a derivative of the standard Windows button control. An ABB Button can be connected directly to a specific digital I/O signal in an S4 control. The Button control provides a simple way to view and modify a digital signal, and, in most cases, can be used without adding code to your application. The display of the button can be configured via property settings to automatically update itself based on the current state of the communication link to the robot control and the state of the digital signal assigned to the button control. Optionally, you can display bitmaps, text strings, text colors, and/or background colors based on the signal state (on or off). The button action can be configured to turn a signal on, turn a signal off, toggle a signal, pulse a signal, or do nothing in response to a mouse click. The Pilot Light Control The Pilot Light control tracks the state of a specific digital signal. This control is configured via properties and requires no additional code. The display of the Pilot Light is modeled after status lamps commonly used in hardwired operator panels. The Pilot Light displays bitmaps to represent the on and off states of the associated signal. The user selects the on and off colors via properties. A Caption Property is used to label the Pilot Light. When the communication link to the robot control is down, the Pilot Light automatically disables itself and re-enables itself when the communication link is restored. PC System Requirements - Pentium processor. - 8 MB RAM memory minimum for Windows 95, 16 MB RAM for Windows NT (32 MB RAM recommended). - Windows 95 or Windows NT 4.0. - Microsoft Visual Basic, Visual C++, or Wonderware InTouch 7.0 (for application development). - 20 MB free hard disk space. - VGA compatible display (1024 x 768 recommended).
Product Specification RobotWare for BaseWare OS 3.1
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RobComm 3.0 - CD-ROM drive. - One or more network interfaces - any NDIS or ODI network adapter (for ethernet) or a serial port (for serial connection to one S4). - A terminal server with SLIP protocol support is required for connections to multiple S4 controllers not equipped with an ethernet interface. - Microsoft compatible mouse. Robot Controller Requirements - FactoryWare Interface (or RAP communication) installed. FactoryWare Interface is preferred as RAP communication requires run-time licensing on the PC. - Ethernet interface hardware (optional). - RobComm 3.0 can be used with all versions of BaseWare OS.
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Product Specification RobotWare for BaseWare OS 3.1
RobView 3.1
7.2 RobView 3.1 RobView is an end-user application that lets the customer visualise robot data in a PC. It also lets the user remotely operate robots from a PC and provides access to robot files for simple file transfer and back-up. RobView is Windows-based and easy to use.
RobView comes as a ready to use application and is typically run in a PC on the factory floor, connected to one or more robots. RobView takes care of the PC to robot communication. The user can start working immediately, using the pre-defined features and buttons. He can also define his own buttons and signals. A built-in user security system can be used to prevent accidental use by unauthorized persons. Pre-defined controls In RobView there are several pre-defined objects. They are configured for the user to operate robots, look at various robot status and perform file operations. Each robot is represented by a small robot-box on the screen.
Product Specification RobotWare for BaseWare OS 3.1
67
RobView 3.1 The Robot Box The ready-made robot-box provides the user with instant information about the most important status of the robot, like Motor power on, Program running and Robot mode. It also allows the user to remotely operate the robot with buttons for Motor Power On/Off, Load program, Run and Halt the program, and Start from the top of program. A robot box may also be dragged out of the RobView window and made to float freely on the windows desktop, always visible to the user. The user can ask for more detailed status by clicking on one of the buttons in the bottom row in the robot-box. He can also start the RobView File manager. The detailed status information that the user can ask for is presented in pre-defined windows as shown below. Controller Information A click on the Info button displays the system information. Here the user can see the available buffer space in the robot and information about the robot and its software. I/O status A click on the I/O status button displays the digital I/O boards with their input and output signals. The user can select I/O board by clicking on the left and right arrowbuttons at the bottom. The I/O signals are “alive” on the screen and follow the changes in the robot. The user can give the I/O signals his own names - specified for each card and for each robot.
Robot position A click on the Position button displays the position status. The current position of the robot is displayed as well as the name of the selected tool and work object. The position data is updated as the robot moves.
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Product Specification RobotWare for BaseWare OS 3.1
RobView 3.1 File manager When the user clicks on the File manager button in the Robot Box, the RobView File Manager window is displayed. With the RobView File Manager, maintaining the files in the robots and making back-up copies of programs is simple.
In the RobView File Manager, the user can see both the hierarchy of folders and files on the PC, and the files in the selected robot. This is especially useful for copying files using the familiar Windows “drag-and-drop” interface. The user can copy files and programs back and forth between the robot and the PC without interrupting production. Files can be renamed and deleted. Batch operation In the RobView File Manager there is a Batch menu where the user can make batch files for file-operations that are tedious and repetitive. A batch file can contain Put-, Get- and Delete-commands. This is useful for example for back-up purposes - a batch file can be started from a user defined button. User defined controls In addition to the robot box control that is ready to use, the user can customise RobView by defining his own views with lamps, signals, command buttons, etc. on the screen and link them to variables or I/O in the robot. If the user, for example, wants to keep track of a RAPID variable in the robot, for example “PartsProduced”, he just defines it on his screen and it will always be updated and display the correct value. The user can also edit a data field on the PC screen and have the value sent to the robot. In this way the user can prepare and send production data to his robots, e.g. number of parts to produce, type of part, etc., without interrupting production. The user can build complete screens containing customised views of the production cell, including robots and external equipment with layout-drawings, command buttons, signals and display of data.
Product Specification RobotWare for BaseWare OS 3.1
69
RobView 3.1 The layout drawings of the production-cell are made with a standard drawing program like Windows PaintBrush, or a drawing coming from for example AutoCad. These bitmap drawings are displayed in each view in RobView as a “background” for the robot boxes, buttons, data fields, etc. The screen is split in two parts: the main part and the project part. The user can design his own controls in both parts of the window. The “main” part of the window contains one view that is active all the time. The “project” part of the window can have up to 32 different “pages” or views (screens), where one is visible at a time. The user can switch between the views by selecting them from a list or at the push of a button (the user can specify which button to press for which view). A view can also be selected automatically, based on a variable or I/O in a robot. Controls are defined in easy to use dialogue boxes where the user selects how the controls will look on the screen. The same dialogues (under the Triggers tab) are also used to link the controls to variables in the robot. Shape By simple click-and-select, the user can define a rectangle, square, oval, circle, rounded rectangle, etc., set it to be filled or transparent, set the thickness of the border, set the colours, etc. More importantly, the shape can be linked to variables or digital I/O in the robot and made to change its colour, become invisible, etc., dependent on the value in the robot. The shape can even be made to move on the PC screen, dependent on the value of variables in the robot. Label A label can be a lot of different things: It can be as simple as plain text on the screen, or it can be an edit field displaying a value from the robot with the ability for the operator to edit the value and send it back to the robot. The user can define labels in any view. The label can be linked to a variable or digital I/O in the robot to display the value (be that numbers or text) and can also change its fill colour, text colour or become invisible. The user-input on a label (edit-field) can be protected, so that only qualified users are allowed to change data in the robot. Command button A command button can be used for a lot of different things: set or reset I/O’s, clear a value of a variable, start a program, start a file transfer - its up to the imagination of the user. The user can define command buttons in any view and specify one or more actions that is to occur when the button is operated. Command buttons can be protected, so that only qualified operators are allowed to operate them. A button can have a text and/or a bitmap.
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Product Specification RobotWare for BaseWare OS 3.1
RobView 3.1 In addition, also a button can be linked to variables or I/O in the robot and made to change its bitmap picture, the colour of the text or become invisible, dependent on the value in the robot. Grid A grid can be connected to both complex variables or arrays. It will dynamically updated the data field displaying the value of a robot variable, and has the ability to edit the value and send it back to the robot. The user can define grids in any view. It is easy to set the size of the grid from the Grid property page. You may also define column and row header texts. The user-input on a grid can be protected, so that only qualified users are allowed to change data in the robot. Icon The icon control is used for drawing a picture on any of the views. The picture files are typically bitmap files (.bmp) or icon (.ico) files that you for example have prepared with the Windows Paint application, or have exported from some other drawing program. The icon can be linked to a variable or digital I/O in the robot and made to change picture or become invisible dependent on the value of the robot variable. Hot-Spot Select the Hot-spot control to draw a hot-spot in any of the views. It is usually placed on top of other controls (e.g. Icon), to make RobView change view when you click on the hot-spot. The hot-spot is invisible in run mode. Peripheral equipment The user defined controls can also be linked to signals in peripheral equipment. This can be done in two ways: 1) By using spare I/O in the robot where signals from the peripheral equipment are connected so that RobView can reach them or 2) by using a dedicated DDE Server if one is available for the equipment in question, so that RobView can connect to the variables of that DDE Server and in this way be able to control and monitor the external equipment. Multiple robots RobView can be supplied with support for one or multiple robots. For use with one robot, the robot is connected directly to the serial port in the PC. If the robots are equipped with a network option, they can be connected directly by ethernet to the networked PC.
Product Specification RobotWare for BaseWare OS 3.1
71
RobView 3.1 For use with more than one robot with serial connections, a “terminal server” is needed in the set-up. This is a box with eight or more serial ports and an ethernet port. The robots are connected to the serial ports and the PC (with an ethernet board) to the ethernet port. The “ShivaPort” from Shiva (used to be called “SpiderPort”) is an example of a good terminal server for this use. PC System Requirements The requirements for RobView will depend on the size of the installation and the number of robots. The descriptions below are recommendations only. RobView for one robot 486 DX-66 minimum (Pentium recommended). 16 MB RAM memory or more. 10 MB free harddisk space. Windows-95 or Windows/NT installed. VGA compatible display (higher resolution recommended). 3.5” 1.44 MB diskette drive or CD rom. Serial port or Network board. RobView for multiple robots Pentium 75 MHz (minimum). 16 MB RAM memory min. (more recommended). 10 MB free harddisk space. Windows-95 or Windows/NT installed. VGA compatible display (higher resolution and large screen strongly recommended). 3.5” 1.44 MB diskette drive or CD rom. Network board (e.g. 3COM EtherLink III 3C509). Alternatively a terminal server may be used. Robot Controller Requirements FactoryWare Interface 3.1 (or RAP Communication 3.1) installed. Ethernet interface hardware (optional). RobComm 3.1 can run with all versions of BaseWare OS. 72
Product Specification RobotWare for BaseWare OS 3.1
RobView 3.1 Technical specification Platform:
IBM/Intel based PC and compatibles
Operating system:
Microsoft Windows-95 or Windows/NT 4.0 (not included)
TCP/IP stack:
The generic Microsoft winsock.dll (not included, comes with Windows)
RPC:
Public domain Sun rpc.dll, ported to Windows/NT (included)
Software protection:
Access key, placed in printer port, with keypassword. (Will run for five hour intervals without password or key)
User security:
Optional Log In functionality with user-id and user-password. Four user levels: View, Safe, Expert and “Programmer”
Product Specification RobotWare for BaseWare OS 3.1
73
DDE Server 2.3
7.3 DDE Server 2.3 The DDE Server is a software building block that provides reliable, quick and accurate flow of information between robots and a PC. This is what the user needs if he wants to build his own customised user interface, using visualisation packages like for example “InTouch” from Wonderware. The S4 DDE Server takes care of the communication with the robot, and presents the data in the industry standard DDE communication protocol. DDE stands for Dynamic Data Exchange. It is a communication protocol designed by Microsoft to allow Windows applications to send and receive data to/from each other. It is implemented as a client/server mechanism. The server application (like the ABB S4 DDE Server) provides the data and accepts requests from any other application that is interested in its data. An application that can “talk” the DDE “language” can communicate with the ABB robots via the S4 DDE Server. Examples of applications that do DDE communication are Microsoft “Excel” and “InTouch” from Wonderware. The S4 DDE Server communicates with robots using the ABB RAP protocol. The S4 DDE Server maintains a database of the relevant variables in the robot and makes sure that these DDE variables are kept updated at all times. The application using the DDE Server can concentrate on the user interface and rely on the updated DDE variables. If new RAPID variables are introduced in the robot program, the DDE Server is able to create corresponding DDE variables “on-the-fly”. Functionality The S4 DDE Server provides reading and writing of I/O, RAPID variables and robot system variables. It supports spontaneous messages from the robot (SCWrite), error messages, as well as file operations. A file batch functionality is also included. Digital I/O The user can read or write to the digital I/O signals in the robot. The S4 DDE Server supports both group-I/O and block-I/O transfer. This improves the speed significantly. RAPID variables The user can read or write to RAPID variables that are defined and declared as persistent (PERS). The S4 DDE Server supports strings and numbers as well as more complex data types like wobjdata, pos, speeddata and tooldata. The names of the variables are defined by the user.
74
Product Specification RobotWare for BaseWare OS 3.1
DDE Server 2.3 SCWrite The user can address persistent RAPID variables that are written by the robot to the DDE Server (using the SCWrite RAPID instruction). The S4 DDE Server supports strings and numbers as well as more complex data types like wobjdata, pos, speeddata and tooldata. The name of the variables are defined by the user. A superior-computer-write variable is only updated when the SCWrite RAPID instruction is executed in the robot. The user includes the SCWrite instruction at points in his RAPID program where he wants this update to take place. System variables With the system variables the user can read various status of the robot controller (controller ready/executing, program loaded, the position of the robot, etc.). Writing to the system variables will turn the motor power on/off, load a program, run it, etc. The system variables are pre-defined in the S4 DDE Server. Program variables With the program variables the user can control the loading and execution of programs in the robot. The variables are pre-defined in the S4 DDE Server. Error variables With the error variables the user can read the various error messages generated by the robot. The variables are pre-defined in the S4 DDE Server. File operations With the file operation variables the user can perform the following file operations: get file, put file, delete file, rename file, get directory listing and batch operation. These are pre-defined in the S4 DDE Server. Batch operation The S4 DDE Server offers a batch facility for file operations. The user can specify several file operations in a batch file (text file) and the DDE Server will execute this file to do multiple file-upload, download, delete, etc. This is a feature that is used for performing repetitive, regular file operations like back-up. A log-file reports how the file operations went.
Product Specification RobotWare for BaseWare OS 3.1
75
DDE Server 2.3 Communication link The user can read the communication variable to get information about the communication link to the robot. It will tell the user if the robot is up and running and communicating with the PC. It is pre-defined in the S4 DDE Server. Addressing the DDE variables You may think of a DDE variable (item) as a placeholder for a variable in the S4 robot controller. An example: To connect a cell in an MS Excel worksheet to a digital output (ex: do1) in the S4 robot controller, you type: =ABBS4DDE|ROB1!a_digio_raplong_do1 in the formula bar in Excel, and press enter. From now on the cell in Excel will show a “1” when do1 is on and a “0” when do1 is off. Multiple robots The DDE Server can be supplied with support for one or multiple robots. For use with one robot, the robot is connected directly to the serial port in the PC. If the robots are equipped with a network option, they can be connected directly by ethernet to the networked PC. For use with more than one robot with serial connections, a “terminal server” is needed in the set-up. This is a box with eight or more serial ports and an ethernet port. The robots are connected to the serial ports and the PC (with an ethernet board) to the ethernet port. The “ShivaPort” from Shiva (used to be called “SpiderPort”) is an example of a good terminal server for this use. PC System Requirements The requirements for the DDE Server will depend on the size of the installation and the number of robots. The descriptions below are recommendations only. DDE Server for one robot 486 DX-66 minimum (Pentium recommended). 16 MB RAM memory or more. 10 MB free harddisk space. Windows-95 or Windows/NT installed. VGA compatible display (higher resolution recommended). 3.5” 1.44 MB diskette drive or CD rom. Serial port or Network board.
76
Product Specification RobotWare for BaseWare OS 3.1
DDE Server 2.3 DDE Server for multiple robots Pentium 75 MHz (minimum). 16 MB RAM memory min. (more recommended). 10 MB free harddisk space. Windows-95 or Windows/NT installed. VGA compatible display (higher resolution and large screen strongly recommended). 3.5” 1.44 MB diskette drive or CD rom. Network board (e.g. 3COM EtherLink III 3C509) Alternatively a terminal server may be used. Robot Controller Requirements FactoryWare Interface 3.1 (or RAP Communication 3.1) installed. Ethernet interface hardware (optional). RobComm 3.1 can run with all versions of BaseWare OS. Technical specification Platform:
IBM/Intel based PC and compatibles
Operating system:
Microsoft Windows-95 or Windows/NT 4.0 (not included)
TCP/IP stack:
The generic Microsoft winsock.dll (not included, comes with Windows)
RPC:
Public domain Sun rpc.dll, ported to Windows/NT (included)
Software protection:
Access key, placed in printer port, with key-password. (Will run for five hour intervals without password or key)
Product Specification RobotWare for BaseWare OS 3.1
77
ScreenMaker 3.0
7.4 ScreenMaker 3.0 ScreenMaker is a software product that assists the user in creating and editing user screen package files in a PC. See the ScreenViewer option for description of the user screens. This product offers the advantages of the Windows environment. Some of the main features of ScreenMaker include: - Easy to edit representation of user screens (using a tree and a list view). - User friendly modification commands (rename, properties, insert, delete, etc.) via toolbar, shortcuts and mouse right click menu. - Preview of a screen as it will be displayed on the teach pendant (including the strokes and the fields). - Gives exact memory size that the screen package takes up when loaded onto the controller. - Ability to check the syntax of display commands. - Standard cut, copy and paste functions. PC System Requirements - 486 DX-33 minimum (Pentium recommended). - 8 MB RAM memory minimum for Windows 95, 12 MB RAM for Windows NT(16 MB RAM recommended). - Windows 95 or Windows NT 4.0. - 5 MB free harddisk space. - VGA compatible display (1024 x 768 recommended). - Microsoft compatible mouse. - 3.5" 1.44 MB diskette drive.
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Product Specification RobotWare for BaseWare OS 3.1
Safety CONTENTS Page 1 General ............................................................................................................................. 3 1.1 Introduction ........................................................................................................... 3 2 Applicable Safety Standards .......................................................................................... 3 3 Fire-Extinguishing........................................................................................................... 4 4 Definitions of Safety Functions ...................................................................................... 4 5 Safe Working Procedures ............................................................................................... 5 5.1 Normal operations ................................................................................................. 5 6 Programming, Testing and Servicing ............................................................................ 5 7 Safety Functions .............................................................................................................. 6 7.1 The safety control chain of operation .................................................................... 6 7.2 Emergency stops.................................................................................................... 7 7.3 Mode selection using the operating mode selector................................................ 7 7.4 Enabling device ..................................................................................................... 8 7.5 Hold-to-run control................................................................................................ 8 7.6 General Mode Safeguarded Stop (GS) connection................................................ 9 7.7 Automatic Mode Safeguarded Stop (AS) connection ........................................... 10 7.8 Limiting the working space ................................................................................... 10 7.9 Supplementary functions ....................................................................................... 10 8 Safety Risks Related to End Effectors........................................................................... 10 8.1 Gripper................................................................................................................... 10 8.2 Tools/workpieces ................................................................................................... 11 8.3 Pneumatic/hydraulic systems ................................................................................ 11 9 Risks during Operation Disturbances........................................................................... 11 10 Risks during Installation and Service ......................................................................... 11 11 Risks Associated with Live Electric Parts ................................................................... 12 12 Emergency Release of Mechanical Arm ..................................................................... 13 13 Limitation of Liability................................................................................................... 13 14 Related Information...................................................................................................... 13
Product Manual
1
Safety
2
Product Manual
Safety
Safety 1 General This information on safety covers functions that have to do with the operation of the industrial robot. The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment, which can influence the safety of the total system. To protect personnel, the complete system has to be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed. The users of ABB industrial robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that the safety devices necessary to protect people working with the robot system have been designed and installed correctly. People who work with robots must be familiar with the operation and handling of the industrial robot, described in applicable documents, e.g. Users’s Guide and Product Manual. The diskettes which contain the robot’s control programs must not be changed in any way because this could lead to the deactivation of safety functions, such as reduced speed.
1.1 Introduction Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot. In the Product Manual/Installation, instructions are provided for connecting safety devices between the robot and the peripheral equipment.
2 Applicable Safety Standards The robot is designed in accordance with the requirements of ISO10218, Jan. 1992, Industrial Robot Safety. The robot also fulfils the ANSI/RIA 15.06-1992 stipulations.
Product Manual
3
Safety
3 Fire-Extinguishing Use a CARBON DIOXIDE extinguisher in the event of a fire in the robot (manipulator or controller).
4 Definitions of Safety Functions Emergency stop – IEC 204-1,10.7 A condition which overrides all other robot controls, removes drive power from robot axis actuators, stops all moving parts and removes power from other dangerous functions controlled by the robot. Enabling device – ISO 11161, 3.4 A manually operated device which, when continuously activated in one position only, allows hazardous functions but does not initiate them. In any other position, hazardous functions can be stopped safely. Safety stop – ISO 10218 (EN 775), 6.4.3 When a safety stop circuit is provided, each robot must be delivered with the necessary connections for the safeguards and interlocks associated with this circuit. It is necessary to reset the power to the machine actuators before any robot motion can be initiated. However, if only the power to the machine actuators is reset, this should not suffice to initiate any operation. Reduced speed – ISO 10218 (EN 775), 3.2.17 A single, selectable velocity provided by the robot supplier which automatically restricts the robot velocity to that specified in order to allow sufficient time for people either to withdraw from the hazardous area or to stop the robot. Interlock (for safeguarding) – ISO 10218 (EN 775), 3.2.8 A function that interconnects a guard(s) or a device(s) and the robot controller and/or power system of the robot and its associated equipment. Hold-to-run control – ISO 10218 (EN 775), 3.2.7 A control which only allows movements during its manual actuation and which causes these movements to stop as soon as it is released.
4
Product Manual
Safety
5 Safe Working Procedures Safe working procedures must be used to prevent injury. No safety device or circuit may be modified, bypassed or changed in any way, at any time.
5.1 Normal operations All normal operations in automatic mode must be executed from outside the safeguarded space.
6 Programming, Testing and Servicing The robot is extremely heavy and powerful, even at low speed. When entering into the robot’s safeguarded space, the applicable safety regulations of the country concerned must be observed. Operators must be aware of the fact that the robot can make unexpected movements. A pause (stop) in a pattern of movements may be followed by a movement at high speed. Operators must also be aware of the fact that external signals can affect robot programs in such a way that a certain pattern of movement changes without warning. If work must be carried out within the robot’s work envelope, the following points must be observed: • The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel. • The robot’s speed is limited to max. 250 mm/s (10 inches/s) when the operating mode selector is in position < 250 mm/s. This should be the normal position when entering the working space. The position 100% – full speed – may only be used by trained personnel who are aware of the risks that this entails. Do not change “Transm gear ratio” or other kinematic parameters from the teach pendant or a PC. This will affect the safety function Reduced speed 250 mm/s. • During programming and testing, the enabling device must be released as soon as there is no need for the robot to move. The enabling device must never be rendered inoperative in any way. • The programmer must always take the teach pendant with him/her when entering through the safety gate to the robot’s working space so that no-one else can take over control of the robot without his/her knowledge.
Product Manual
5
Safety
7 Safety Functions
7.1 The safety control chain of operation The safety control chain of operation is based on dual electrical safety chains which interact with the robot computer and enable the MOTORS ON mode. Each electrical safety chain consist of several switches connected in such a way that all of them must be closed before the robot can be set to MOTORS ON mode. MOTORS ON mode means that drive power is supplied to the motors. If any contact in the safety chain of operation is open, the robot always reverts to MOTORS OFF mode. MOTORS OFF mode means that drive power is removed from the robot’s motors and the brakes are applied. K2
K1
K1
Drive Unit
M
K2
Interlocking
EN RUN
&
&
Man2
Man1
+
+ LIM1
Auto1
TPU En1
ES1 GS1
AS1
LIM2 External contactors
TPU En2
ES2 GS2
Auto2 AS2
The status of the switches is indicated by LEDs on top of the panel module in the control cabinet and is also displayed on the teach pendant (I/O window). After a stop, the switch must be reset at the unit which caused the stop before the robot can be ordered to start again. The time limits for the central two channel cyclic supervisions of the safety control chain is between 2 and 4 second. The safety chains must never be bypassed, modified or changed in any other way.
6
Product Manual
Safety
7.2 Emergency stops An emergency stop should be activated if there is a danger to people or equipment. Built-in emergency stop buttons are located on the operator’s panel of the robot controller and on the teach pendant. External emergency stop devices (buttons, etc.) can be connected to the safety chain by the user (see Product Manual/Installation). They must be connected in accordance with the applicable standards for emergency stop circuits. Before commissioning the robot, all emergency stop buttons or other safety equipment must be checked by the user to ensure their proper operation. Before switching to MOTORS ON mode again, establish the reason for the stop and rectify the fault.
7.3 Mode selection using the operating mode selector The applicable safety requirements for using robots, laid down in accordance with ISO/DIS 10218, are characterised by different modes, selected by means of control devices and with clear-cut positions. One automatic and two manual modes are available: Manual mode: < 250 mm/s - max. speed is 250mm/s 100% - full speed Automatic mode: The robot can be operated via a remote control device The manual mode, < 250 mm/s or 100%, must be selected whenever anyone enters the robot’s safeguarded space. The robot must be operated using the teach pendant and, if 100% is selected, using Hold-to-run control. In automatic mode, the operating mode selector is switched to , and all safety arrangements, such as doors, gates, light curtains, light beams and sensitive mats, etc., are active. No-one may enter the robot’s safeguarded space. All controls, such as emergency stops, the control panel and control cabinet, must be easily accessible from outside the safeguarded space. Programming and testing at reduced speed Robot movements at reduced speed can be carried out as follows: • Set the operating mode selector to 500 V max voltage 125 V nominal voltage
Figure 25 Examples of clamping circuits to suppress voltage transients.
3.4 Connection types I/O, external emergency stops, safety stops, etc., can be supplied on screwed connections or as industrial connectors. Designation
32
X(T)
Screwed terminal
XP
Male (pin)
XS
Sockets (female)
Product Manual IRB 1400
Installation and Commissioning
Connecting Signals
3.5 Connections Detailed information about connection locations and functions will be found in chapter 11, Circuit Diagram.
3.5.1 To screw terminal Panel unit and I/O units are provided wiyh keyed screw terminals for cables with an area between 0.25 and 1.5 mm2. A maximum of two cables may be used in any one connection. The cable screen must be connected to the cabinet wall using EMC. It should be noted that the screen must continue right up to the screw terminal. The installation should comply with the IP54 (NEMA 12) protective standard. Bend unused conductors backwards and attach them to the cable using a clasp, for example. In order to prevent interference, ensure that such conductors are not connected at the other end of the cable (antenna effect). In environments with much interference, disconnected conductors should be grounded (0 V) at both ends. 3.5.2
To connectors (option) Industrial connectors with 4x16 pins for contact crimping (complies with DIN 43652) can be found on the left-hand side or front of the cabinet (depending on the customer order) See Figure 26 and Figure 17. In each industrial connector there is space for four rows of 16 conductors with a maximum conductor area of 1.5 mm2. The pull-relief clamp must be used when connecting the shield to the case. The manipulator arm is equipped with round Burndy/Framatome connectors (customer connector not included). Bend unused conductors backwards and attach them to the cable using a clasp, for example. In order to prevent interference, ensure that such conductors are not connected at the other end of the cable (antenna effect). In environments with much interference, disconnected conductors should be grounded (0 V) at both ends. When contact crimping industrial connectors, the following applies: Using special tongs, press a pin or socket on to each non-insulated conductor. The pin can then be snapped into the actual contact. Push the pin into the connector until it locks. Also, see instructions from contact supplier. A special extractor tool must be used to remove pins from industrial connectors. When two conductors must be connected to the same pin, both of them are pressed into the same pin. A maximum of two conductors may be pressed into any one pin.
Product Manual IRB 1400
33
Connecting Signals
Installation and Commissioning
Space for cable glands XS 3 (safety) Prepared for further connectors XS 5 (customer signals) XS17, CAN bus connector
XS 6 (customer power) XS 7 (external axes)
XS 8, Position switch XS 1, Motor cable XS 2, Measurement system cable
Figure 26 Positions for connections on the left-hand side of the controller.
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Product Manual IRB 1400
Installation and Commissioning
Connecting Signals
3.6 Customer connections on manipulator N.B. When option 04y is chosen, the customer connections are available at the front of the upper arm. Connections: R1/4” in the upper arm housing and R1/4” at the base. Max. 8 bar. Inner hose diameter: 6.5 mm. For connection of extra equipment on the manipulator, there are cables integrated into the manipulator’s cabling and one Burndy 12-pin UTG 014-12S connector on the upper arm housing. Number of signals: 12 signals 60 V, 500 mA.
R2.CS
R1.CS
Figure 27 Location of customer connections.
Product Manual IRB 1400
35
Connecting Signals
Installation and Commissioning
To connect to power and signal conductors from the connection unit to the manipulator base and on the upper arm, the following parts are recommended:
Connector R2.CS. Signals, on upper arm. (Regarding Pos see Figure 28) Pos
Name
ABB art. no.
Type
Comments
1
Socket connector
3HAA 2613-2
UTO 014 12 SHT
Burndy
2
Gasket
5217 649-64
UTFD 13B
Burndy
3
Socket
See below
4
Pin connector 12p
3HAA 2602-2 5217 649-7
UTO 61412PN04 UTO 61412PN
Burndy EMC Burndy
5
Pin
See below
6
Adaptor
3HAA 2601-2 5217 1038-3
URG 14 ADT UTG 14 AD
Burndy EMC Burndy
7
Cable clamp
5217 649-8
UTG 14 PG
Burndy
8
Shrinking hose Shrinking hose
3HAA 2614-2 5217 1032-4
Bottled shaped Angled
Connector R1CS. Signals, on the manipulator base. (Regarding Pos see Figure 28)
36
Pos
Name
ABB art. no.
Type
Comments
1
Pin connector 12p
3HAA 2599-2
UTG 014 12 P
Burndy
2
Gasket
5217 649-64
UTFD 14 B
Burndy
3
Pin
See below
4
Socket con. 12p
3HAA 2600-2
UTO 61412 S
Burndy EMC
5
Sockets
See below
6
Adaptor
3HAA 2601-2 5217 1038-3
URG 14 ADT UTG 14 PG
Burndy EMC Burndy
7
Cable clamp
5217 649-8
UTG 14 PG
Burndy
8
Shrinking hose Shrinking hose
3HAA 2614-2 5217 1032-4
Bottled shaped Angled
Product Manual IRB 1400
Installation and Commissioning
Connecting Signals
Name
ABB part no.
Type
Comments
Pin
5217 649-72 5217 649-25 5217 649-70 5217 649-3 5217 649-68 5217 649-10 5217 649-31
24/26 24/26 20/22 20/22 16/20 24/26 16/20
Burndy Machine tooling Burndy Hand tooling Burndy Machine tooling Burndy Hand tooling Burndy Machine tooling Burndy Ground Burndy Ground
Socket
5217 649-73 5217 649-26 5217 649-71 5217 649-69 5217 1021-4
24/26 24/26 20/22 16/18 DIN 43 652
5217 1021-5
DIN 43 652
Burndy Machine tooling Burndy Hand tooling Burndy Machine tooling Burndy Machine tooling Tin bronze (CuSu) 0.14 - 0.5mm2 AWG 20-26 Tin bronze (CuSu) 0.5 - 1.5mm2 AWG 16-20
Customer side
4, 5
Manipulator side 1, 3
8 6 2 7 Figure 28 Burndy connector
Product Manual IRB 1400
37
Connecting Signals
Installation and Commissioning
3.7 Connection to screw terminal Sockets with screwed connections for customer I/O, external safety circuits, customer sockets on the robot, external supply to electronics. Signal identification
Location
Safeguarded stop Digital I/O Combi I/O Relay I/O RIO I/O SIO 1, SIO 2 CAN1 (internal unit) CAN 2 (manipulator, I/O units) CAN 3 (external I/O units) 24 V supply (2 A fuse) 115/230 V AC supply
Panel unit I/O unit I/O unit I/O unit I/O unit Backplane Panel unit Backplane Backplane
Terminals X1 - X4 X1 - X4 X1 - X4, X6 X1 - X4 X1, X2 X1, X2 X9 X16 X10 XT31 XT21
Location of socket terminals are shown below. See also circuit diagram, “View of control cabinet”, for more details.
X1 (SIO1)
Backplane
X2 (SIO2) X10 (CAN3)
I/O units (x4)
X16 (CAN2) alt. D-sub
Panel unit WARNING REMOVE JUMPERS BEFORE CONNECTING ANY EXTERNAL EQUIPMENT MS NS
EN
ES1 ES2 GS1 GS2 AS1 AS2
X1 - 4 X5
XT5, customer signals XT6, customer power XT8, position switch
X8
X6 CONTROL PANEL
X9 (CAN1)) XT21 (115/230 V ACsupply) XT31 (24V supply)
Figure 29 Screw terminal locations.
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Product Manual IRB 1400
Installation and Commissioning
Connecting Signals
3.8 The MOTORS ON / MOTORS OFF circuit To set the robot to MOTORS ON mode, two identical chains of switches must be closed. If any switch is open, the robot will switch to MOTORS OFF mode. As long as the two chains are not identical, the robot will remain in MOTORS OFF mode. Figure 30 shows an outline principal diagram of the available customer connections, AS, GS and ES.
LS
Solid state switches
Contactor
ES 2nd chain interlock
GS
TPU En
& EN RUN Computer commands
AS
Auto Operating mode selector
Drive unit
Manual
M
LS = Limit switch AS = Automatic mode safeguarded space Stop TPU En= Enabling device, teach pendant unit GS = General mode safeguarded space Stop ES = Emergency Stop
Figure 30 MOTORS ON /MOTORS OFF circuit.
Product Manual IRB 1400
39
Connecting Signals
Installation and Commissioning
3.9 Connection of safety chains 24 V * X3:12 X4:12
24 V
Ext LIM1 X1:4 3
K1 0V
see 3.9.1 ES1
X3:10
8
+ Opto isol. -
GS1
&
TPU En1
11 9
+ Opto isol. -
EN RUN
AS1 Auto1
K1 Interlocking
K2
Man1
External contactors X2:5 6 CONT1
0V
X1:5
24 V
6
CONT2
Ext LIM2 X2:4 3
0V
K2 24V
see 3.9.1
8
Drive unit
ES2
X4:10 + Opto isol. -
GS2 M
&
TPU En2
11 + 9
-
Opto AS2 isol.
Technical data per chain Auto2
Man2
X3:7 * X4:7 0V
*) Supply from internal 24V (X3/X4:12) and 0 V (X3/ X4:7) is displayed. When external supply of GS and AS, X3/X4:10,11 is connected to 24 V and X3/X4:8,9 is connected to external 0 V X1-X4 connection tables, see section 3.10.
Limit switch: load max. V drop
300 mA 1V
External contactors: load max. V drop
10 mA 4V
GS/AS load at 24V
25 mA
GS/AS closed “1”
> 18 V
GS/AS open “0”
AXC AM test # T1067: IOC IOC->AXC Memory test (RWM) # T1068: IOC IOC->AXC Memory test (RWM) R6 Global # T1069: IOC IOC->AXC Memory test (RWM) DSP # T1070: IOC Enable AXC->IOC Interrupts # T1061: IOC IOC->AXC Load AXC # T3001: AXC RWM test Dist. # T3002: AXC R6 Global RWM test # T3003: AXC DSP Double access RWM test # T3004: AXC DSP Data RWM test # T3020: AXC VME interrupt test # T3023: AXC Test channels output test # T1071: IOC Disable AXC->IOC Interrupts # T1046: IOC IOC->MC Access test # T1048: IOC IOC->MC AM test Product Manual
5
Troubleshooting Tools # T1050: IOC IOC->MC Memory test Destructive, Low win # T1506: IOC IOC->MC LED off # T1508: IOC IOC->ERWM LED off # T1512: IOC IOC->MC Load MC # T1509: IOC IOC->MC Release MC # T2002: MC Memory test (RWM) Destructive # T2010: MC Memory test (RWM) BM Destructive # T1510: IOC IOC->MC Reset MC Warm start tests in consecutive order. IOC = Robot computer At every “power on”, the IOC makes a destructive RWM test. If it fails, the IOC will flash the NS and MS front LEDs and stop the program running. # T1504: IOC LED off # T1005: IOC Memory test (RWM) Non Destructive # T1018: IOC Battery test
1.2 Monitor Mode 2 When the system is in Monitor Mode 2, a large number of tests can be run. These tests must be performed only by authorised service personnel. It should be noted that some of the tests will cause activity on customer connections and drive systems, which can result in damage, accidents etc. unless suitable precautionary measures are taken. It is advisable to disconnect all the connections involved during these tests. To ensure that all memory addresses are resetted after testing shall the system be cold started. The test mode Monitor mode 2 can be run from the teach pendant and/or a connected PC/terminal.
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Product Manual
Troubleshooting Tools 1.2.1 Entering the test mode from the teach pendant 1. Press the backplane TEST button, see section 3. 2. Keep the button depressed. 3. Push the INIT button, see section 3 (keep the TEST button pressed in). 4. Keep the TEST button depressed for at least 5 sec. (after releasing of the INIT button). 5. The display will show the following: MONITOR MODE 2 if you proceed, system data will be lost! Press any key to accept. 6. Then enter the password: 4433221.
1.2.2 Console connected to a PC A PC with terminal emulation (see PC manual). The PC shall be set up for 9600 baud, 8 bits, no parity, and shall be connected to the Console terminal on the front of the robot computer board. Connection table: Console terminal on robot and main computer Console Pin
Signal
Description
2
RXD
Serial receive data
3
TXD
Serial transmit data
5
GND
Signal ground (0V)
Start up: 1. Connect the PC. 2. Turn on the power to the robot. Entering the test mode from a PC/terminal: 1. Press the backplane TEST button, see section 3. 2. Keep the button depressed. 3. Push the INIT button, see section 3 (keep the TEST button pressed in). 4. Keep the TEST button depressed for at least 5 sec. (after release of the INIT button). 5. The display will show the following: Product Manual
7
Troubleshooting Tools MONITOR MODE 2 if you proceed, system data will be lost! Press any key on the PC to accept. 6. Then enter the password: ROBSERV. When the password has been entered (see above), a menu will be displayed, as shown below: Welcome to Monitor Mode 2 1. Memory IO 2. Serial IO 3. Elementary IO 4. DSQC 3xx (IOC) 5. DSQC 3xx (AXC) 6. DSQC 3xx (MC, ERWM) 7. System tests (MISC) 8. Auxiliary 9. Specific test
(Tests the memory) (Tests the serial channels) (Tests the IO units) Not yet implemented (Tests the IO computer) (Tests the axes computer) (Tests the main computer and external memory boards) (System-related tests) (Special tests) Not yet implemented (Specific tests that can be run separately)
10. T1060 IOC System reset Select test group and the test group menu will be displayed. 1. T9901 Memory IO 1. Up one level 2. FLOPPY 1. Up one level 2. T1039 IOC Floppy Format Test 3. T1040 IOC Floppy Write/Read Test 3. IOC RWM 1. Up one level 2. T1516 TIOC RWM size 3. T1005 IOC Memory test (RWM) Non destructive 4. AXC RWM 1. Up one level 2. T1067 IOC->AXC Memory test (RWM) 3. T1068 IOC->AXC Memory test (RWM) R6 Global 4. T1069 IOC->AXC Memory test (RWM) DSP 5. T3001 AXC RWM test Destr 6. T3002 AXC R6 Global RWM test 7. T3003 AXC DSP Double access RWM test 8. T3004 AXC DSP Data RWM test
8
Product Manual
Troubleshooting Tools 5. MC/ERWM RWM 1. Up one level 2. T1517 MC/ERWM RWM size 3. T1047 IOC IOC->MC Memory test Destructive 4. T2002 MC Memory test (RWM) Destructive 5. T2010 MC Memory test (RWM) BM Destructive 6. PROM (Not yet implemented) 2. T9902 Serial I/O 1. Up one level 2. SIO 1 (Not yet implemented) 3. SIO 2 1. Up one level 2. T1029 IOC SIO2 RS422 loopback test 3. T1033 IOC SIO2 RS422 JUMPER test (Requires special hardware jumpers) 4. CONSOLE (Not yet implemented) 5. TPUNIT (Not yet implemented) 3. T9903 Elementary I/O (Not yet implemented) 4. T9911 DSQC 3xx (IOC) 1. Up one level 2. IOC CPU (Not yet implemented) 3. PROM (Not yet implemented) 4. RWM 1. Up one level 2. T1516 IOC RWM size 3. T1005 IOC Memory test (RWM) Non Destructive 5. RTC (Not yet implemented) 6. FDC 1. T9800 Up one level 2. T1039 IOC Floppy Format Test 3. T1040 IOC Floppy Write/Read Test
Product Manual
9
Troubleshooting Tools 7. UART 1. T9800 Up one level 2. T1029 IOC SIO2 RS422 loopback test 3. T1013 IOC TPUNIT RS422 loopback test 4. T1033 IOC SIO2 RS422 JUMPER test (requires special hardware jumpers) 5. T1022 IOC TPUNIT RS422 JUMPER test (Requires special hardware jumpers and must be run from terminal) 8. DMA (Not yet implemented) 9. VME (Not yet implemented) 10. Miscellaneous 1. Up one level 2. T1018 IOC Battery test startup 3. T1060 IOC System Reset 11. LED 1. Up one level 2. T1503 IOC LED on 3. T1504 IOC LED off 4. T1518 IOC CAN LEDs sequence test 5. DSQC 3xx (AXC) 1. Up one level 2. AXC CPU (Not yet implemented) 3. RWM 1. T9800 Up one level 2. T1067 IOC IOC->AXC Memory test (RWM) 3. T1068 IOC IOC->AXC Memory test (RWM) R6 Global 4. T1069 IOC IOC->AXC Memory test (RWM) DSP 5. T3001 AXC RWM test Dstr 6. T3002 AXC R6 Global RWM test 7. T3003 AXC DSP Double access RWM test 8. T3004 AXC DSP Data RWM test 4. VME 1. Up one level 2. T1053 IOC IOC->AXC Access test 3. T1062 IOC IOC->AXC AM test 4. T3020 AXC VME interrupt test
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Product Manual
Troubleshooting Tools 5. Miscellaneous 1. Up one level 2. T1072 IOC IOC->AXC Reset AXC 3. T1071 IOC Enable AXC->IOC Interrupts 4. T1061 IOC IOC->AXC Load AXC 5. T3018 AXC ASIC ID number 6. T3019 AXC Board ID number 7. T3023 AXC Test channels output test 8. T1071 IOC Disable AXC->IOC Interrupts 6. DSQC 3xx (MC, ERWM) 1. Up one level 2. MC CPU (Not yet implemented) 3. RWM 1. Up one level 2. T1517 MC/ERWM RWM size 3. T1047 IOC IOC->MC Memory test Destructive 4. T2002 MC Memory test (RWM) Destructive 5. T2010 MC Memory test (RWM) BM Destructive 4. LED 1. Up one level 2. T1505 IOC IOC->MC LED on 3. T1506 IOC IOC->MC LED off 4. T1507 IOC IOC->ERWM LED on 5. T1508 IOC IOC->ERWM LED off 6. T2501 MC LED on 7. T2502 MC LED off 5. Duart (Not yet implemented) 6. VME 1. Up one level 2. T1048 IOC IOC->MC AM test 3. T1046 IOC IOC->MC Access test 7. DMA (Not yet implemented) 8. Miscellanous 1. Up one level 2. T1512 LOAD MC DIAG 3. T1509 ENABLE MC 4. T1510 DISABLE (RESET) MC
Product Manual
11
Troubleshooting Tools 7. System tests (Misc.) 1. Up one level 2. Battery 1. Up one level 2. T1018 IOC Battery test startup 3. IOC->MC 1. Up one level 2. T1046 IOC IOC->MC Access test 3. T1048 IOC IOC->MC AM test 4. T1505 IOC IOC->MC LED on 5. T1506 IOC IOC->MC LED off 6. T1507 IOC IOC->ERWM LED on 7. T1508 IOC IOC->ERWM LED off 8. T1512 LOAD MC DIAG 9. T1509 ENABLE MC 10. T1510 DISABLE (RESET) MC 11. T2501 MC LED on 12. T2502 MC LED off 4. IOC->AXC 1. T9800 Up one level 2. T1062 IOC IOC->AXC AM test 3. T1053 IOC IOC->AXC Access test 4. T1072 IOC IOC->AXC Reset AXC 5. T1070 IOC Enable AXC->IOC Interrupts 6. T1061 IOC IOC->AXC Load AXC 7. T3018 AXC ASIC ID number 8. T3019 AXC Board ID number 9. T3020 AXC VME interrupt test 10. T3023 AXC Test channels output test 11. T1071 IOC Disable AXC->IOC Interrupts 5. MC->AXC (Not yet implemented) 6. AXC->IOC (Not yet implemented) 7. VME (Not yet implemented) 8. RTC (Not yet implemented) 9. Reset password (Re-boot required) 10. Cold start (Not yet implemented) 8. Auxiliary (Not yet implemented)
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Product Manual
Troubleshooting Tools 9. Specific test Specific test Txxxx or < > to quit Enter test number Txxxx: T 10. IOC System reset (Not yet implemented) All available tests have been defined in Chapter 1.1.
Product Manual
13
Troubleshooting Tools
2 Indication LEDs on the Various Units
IRB 1400
IRB 2400
IRB 4400
IRB 6400
IRB 640
IRB 840/A
Axes
Axes
Axes
Axes
Axes
Axes
1
1, 2, 4
1, 2, 4
1, 6
1, 6
1, 6
1(X), 6(C)
2
3, 5, 6
3, 5, 6
2, 4
2, 4
2, 3
2(Y), 3(Z)
3, 5
3, 5
Drive unit
3
Optional board
Optional board
Transformer
Main computer
Supply unit
Memory board
Robot computer
Drive unit 1
Drive unit 2
Drive unit 3
DC link
2.1 Location of units in the cabinet
2.2 Robot computer DSQC 363/373 SIO1 TxD RxD
Designation
Colour
Description/Remedy
F
Red
Turns off when the board approves the initialisation.
TxD
Yellow
See section 2.14.
RxD
Yellow
See section 2.14.
NS
Green/red
See section 2.14.
MS
Green/red
See section 2.14.
SIO2 TxD RxD
CAN NS MS DSQC 322
F
C O N S O L E
14
Product Manual
Troubleshooting Tools
2.3 Main computer DSQC 361 Designation
Colour
Description/Remedy
F
Red
Turns off when the board approves the initialisation.
DSQC 361
F
2.4 Memory board DSQC 324/16Mb, 323/8Mb Designation F
Colour
Description/Remedy
Red
Turns off when the board approves the initialisation.
DSQC 3xx
F
Product Manual
15
Troubleshooting Tools
2.5 Ethernet DSQC 336 Designation
Colour
Description/Remedy
TxD
Yellow
Indicates data transmit activity. If no light when transmission is expected, check error messages and check also system boards in rack.
RxD
Yellow
Indicates data receive activity. If no light, check network and connections.
NS
Green/red
See section 2.14.
MS
Green/red
See section 2.14.
F
Red
Lit after reset. Thereafter controlled by the CPU. Light without message on display indicates a hardware fault preventing system from strating. By light and message on display, check message.
LAN TXD RXD
CAN NS MS A U I
DSQC 336 F
T P E
C O N S O L E
16
Product Manual
Troubleshooting Tools
2.6 Power supply units DSQC 334 X1
X5
AC OK
X2 X3
Designation
Colour
Description/Remedy
AC OK
Green
3 x 55V supply OK (start of ENABLE chain)
DSQC 374/365 New “standard” power supply unit DSQC 374, introduced week 826 (M98 rev. 1) New “extended” power supply unit DSQC 365 introduced week 840.
Product Manual
17
Troubleshooting Tools
X1
X3
X5
AC OK 24 V I/O
X7
Only DSQC 365
X2
18
Designation
Colour
Description/Remedy
AC OK
Green
3 x 55V supply OK (start of ENABLE chain)
24 V I/O
Green
24 V I/O OK
Product Manual
Troubleshooting Tools
2.7 Panel unit DSQC 331 WARNING! REMOVE JUMPERS BEFORE CONNECTING ANY EXTERNAL EQUIPMENT
EN
MS NS
ES1 ES2 GS1 GS2 AS1 AS2
Status LED’s
Product Manual
Designation
Colour
Description/Remedy
EN
Green
Enable signal from power supply and computers
MS/NS
Green/red
See section 2.14.
ES1 and 2
Yellow
Emergency stop chain 1 and 2 closed
GS1 and 2
Yellow
General stop switch chain 1 and 2 closed
AS1 and 2
Yellow
Auto stop switch chain 1 and 2 closed
19
Troubleshooting Tools
2.8 Digital and Combi I/O units All the I/O units have the same LED indications. The figure below shows a digital I/O unit, DSQC 328. The description below is applicable for the following I/O units: Digital I/O DSQC 328, Combi I/O DSQC 327, Relay I/O DSQC 332 and 120 VAC I/O DSQC 320.
Status LED’s
1
2
3
4
5
6
7
8
OUT
MS
IN
NS
X1
X3
OUT 9
10
11
12
13
14
15
16
IN
X2 1
1
10
1
10
X4 1
10
10
1
12
X5
20
Designation
Colour
Description/Remedy
IN
Yellow
Lights at high signal on an input. The higher the applied voltage, the brighter the LED will shine. This means that even if the input voltage is just under the voltage level “1”, the LED will glow dimly.
OUT
Yellow
Lights at high signal on an output. The higher the applied voltage, the brighter the LED will shine.
MS/NS
Green/red
See section 2.14.
Product Manual
Troubleshooting Tools
2.9 Analog I/O, DSQC 355
Bus status LED’s Bus staus LED’s
X8
X7
S2 S3 X2 X5 X3
MS
Analog I/O
DSQC 355
N.U RS232 Rx CAN Rx +5V +12V
N.U RS232 Tx CAN Tx -12V NS
ABB flexible Automation
Designation
Colour
Description/Remedy
NS/MS
Green/red
See section 2.14.
RS232 Rx
Green
Indicates the state of the RS232 Rx line. LED is active when receiving data. If no light, check communication line and connections.
RS232 Tx
Green
Indicates the state of the RS232 Tx line. LED is active when tranceiving data. If no light when transmission is expected, check error messages and check also system boards in rack.
Green
Indicates that supply voltage is present and at correct level. Check that voltage is present on power unit. Check that power is present in power connector. If not, check cables and connectors. If power is applied to unit but unit does not work, replace the unit.
+5VDC / +12VDC / -12VDC
Product Manual
21
Troubleshooting Tools
2.10 Remote I/O DSQC 350, Allen Bradley
POWER NS MS CAN Tx CAN Rx NAC STATUS
Bus status LED’s POWER NS MS CAN Tx CAN Rx
X5 X9
X3
22
X8 DSQC 350
NAC STATUS
ABB Flexible Atomation
Designation
Colour
Description/Remedy
POWER-24 VDC
Green
Indicates that a supply voltage is present, and has a level above 12 VDC. If no light, check that voltage is present on power unit. That power is present in power connector. If not, check cables and connectors. If power is applied to unit but unit does not work, replace unit.
NS/MS
Green/red
See section 2.14.
CAN Tx/CAN Rx Yellow
See section 2.14.
NAC STATUS
Steady green indicates RIO link in operation. If no light, check network, cables and connections. Check that PLC is operational. Flashing green, communication established, but INIT_COMPLETE bit not set in NA chip, or configuration or rack size etc. not matching configuration set in PLC. If LED keeps flashing continuously, check setup
Green
Product Manual
Troubleshooting Tools
2.11 Interbus-S, slave DSQC 351
X21
RC BA RBDA POWER
Interbus-S
CAN Rx CAN Tx MS NS POWER
X5
Product Manual
DSQC 351
X20
ABB Flexible Automation
Bus status LED’s POWER NS MS CAN Tx CAN Rx
POWER RBDA BA RC
X3
Designation
Colour
Description/Remedy
POWER-24 VDC
Green
Indicates that a supply voltage is present, and has a level above 12 VDC.
NS/MS
Green/red See section 2.14.
CAN Tx/CAN Rx
Green/red See section 2.14.
POWER- 5 VDC
Green
Lit when both 5 VDC supplies are within limits, and no reset is active.
RBDA
Red
Lit when this Interbus-S station is last in the Interbus-S network. If not as required, check parameter setup.
BA
Green
Lit when Interbus-S is active. If no light, check network, nodes and connections
RC
Green
Lit when Interbus-S communication runs without errors.
23
Troubleshooting Tools
PROFIBUS ACTIVE
Profibus
NS MS CAN Tx CAN Rx POWER
X5
Bus status LED’s Profibus active NS MS CAN Tx CAN Rx
DSQC 352
X20
ABB Flexible Automation
2.12 Profibus-DP, DSQC352
Power
X3
Designation
Colour
Description/Remedy
Profibus active with
Green
Lit when the node is communicating the master. If no light, check system messages in robot and in Profibus net.
24
NS/MS
Green/red See section 2.14.
CAN Tx/CAN Rx
Green/red See section 2.14.
POWER, 24 VDC
Green
Indicates that a supply voltage is present, and has a level above 12 VDC. If no light, check that voltage is present in power unit.Check that power is present in the power connector. If not, check cables and connectors. If power is available at the unit but the unit does not function, replace the unit
Product Manual
Troubleshooting Tools
2.13 Encoder interface unit, DSQC354
ABB Flexible Automation
Status LED’s X20
Encoder
CAN Rx CAN Tx MS NS POWER
X5
Product Manual
ENC 1A ENC 1B DIGIN 1
DSQC 354
Digin 2 Enc 2B Enc 2A Digin 1 Enc 1B Enc 1A
POWER NS MS CAN Tx CAN Rx
X3
Designation
Colour
Description/Remedy
POWER, 24 VDC
Green
Indicates that a supply voltage is present, and has a level above 12 VDC. If no light, check that voltage is present on power unit. That power is present in connector X20. If not, check cables and connectors.If power is applied to unit but unit does not work, replace unit.
NS/MS
Green/red
See section 2.14.
CAN Tx/CAN Rx
Yellow
See section 2.14.
ENC 1A/1B
Green
Indicates phase 1 and 2 from encoder. Flashes by each Encoder pulse. By frequencies higher than a few Hz, flashing can no longer be observed (light will appear weaker). If no light, faulty power supply for input circuit (internal or external). Defective input circuit on board. External wiring or connectors, short circuit or broken wire. Internal error in unit. Constant light indi cates constant high level on input and vice versa. No light in one LED indicates fault in one encoder phase.
25
Troubleshooting Tools DIGIN1
26
Green
Digital input. Lit when digital input is active. The input is used for external start signal/conveyor synchronization point. If no light, faulty limit switch, photocell etc. External wiring or connectors, short circuit or broken wire. Faulty power supply for input circuit (internal or external). Defective input circuit on board.
Product Manual
Troubleshooting Tools
2.14 Status LEDs description Each of the units connected to the CAN bus includes 2 or 4 LED indicators which indicate the condition (health) of the unit and the function of the network communication. These LEDs are: All units MS - Module status NS - Network status Some units: CAN Tx - CAN network transmit CAN Rx - CAN network receive MS - Module status This bicolour (green/red) LED provides device status. It indicates whether or not the device has power and is operating properly. The LED is controlled by software. The table below shows the different states of the MS LED.
Description
Remedy / Source of fault
Off No power applied to the device.
Check power supply.
Green If no light, check other LED modes. Device is operating in a normal condition. Flashing green Device needs commissioning due to configuration missing, incomplete or incorrect. The device may be in the Stand-by state.
Check system parameters. Check messages.
Flashing red Recoverable minor fault.
Check messages.
Red The device has an unrecoverable fault.
Device may need replacing.
Flashing red/green The device is running self test.
If flashing for more than a few seconds, check hardware.
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Troubleshooting Tools NS - Network status The bicolour (green/red) LED indicates the status of the communication link. The LED is controlled by software. The table below shows the different states of the NS LED.
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Description
Remedy / Source of fault
Off Device has no power or is not on-line. The device has not completed the Dup_MAC_ID test yet.
Check status of MS LED. Check power to affected module.
Flashing green Device is on-line, but has no connections in the established state. The device has passed the Dup_MAC_ID test, is on-line, but has no established connections to other nodes. For a group 2 only device it means that the device is not allocated to a master. For a UCMM capable device it means that the device has no established connections.
Check that other nodes in network are operative. Check parameter to see if module has correct ID.
Green The device is on-line and has connection in the established state. For a group 2 only device it means that the device is allocated to a master. For a UCMM capable device it means that the device has one or more established connections.
If no light, check other LED modes.
Flashing red One or more I/O connections are in the Time-Out state.
Check system messages.
Red Failed communication device. The device has detected an error that has rendered it incapable of communicating on the network. (Duplicate MAC_ID, or Bus-off).
Check system messages and parameters.
Product Manual
Troubleshooting Tools Module- and network status LEDs at power-up The system performs a test of the MS and NS LEDs during start-up. The purpose of this test is to check that all LEDs are functioning properly. The test runs as follows: - - NS LED is switched Off. - - MS LED is switched On green for approx. 0.25 seconds. - - MS LED is switched On red for approx. 0.25 seconds. - - MS LED is switched On green. - - NS LED is switched On green for approx. 0.25 seconds. - - NS LED is switched On red for approx. 0.25 seconds. - - NS LED is switched On red. If a device has other LEDs, each LED is tested in sequence. CAN Tx - CAN network transmit Description
Remedy / Source of fault
Green LED. Physically connected to the Can Tx line. Flashes when the CPU is receiving data on the CAN bus.
If no light when transmission is expected, check error messages. Check system boards in rack.
CAN Rx - CAN network receive Description
Remedy / Source of fault
Green LED. Physically connected to the Can Rx line. Flashes when the CPU is transmitting data on the Can bus.
If no light, check network and connections.
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Troubleshooting Tools
3 Measuring Points 3.1 Back plane The backplane contains a maintenance plug (X9) for signals that are hard to reach. Other signals are measured at their respective connection points, which can come in very handy when troubleshooting (see Figure 1). SIO1 and SIO 2 can also be D-sub contacts, both variants will exist. alt. Serial ports SIO 1 RS 232 SIO2 RS 422
Battery
1
2
Test points X5-X8
Maintenance plug, X9
CAN3 (ext. I/O) CAN2 (manip. I/O) CAN1 (panel unit)
Drive units, X14 (ext. axes) Serial meas. board 2, X12 (ext. axes)
Disk drive - data - supply
Accessible from cabinet top Accessible by cabinet door
S1 = INIT button S2 = TEST button Drive units, X22 (manipulator)
Serial meas. board 1, X23 (manipulator)
Power supply
Power contact can also be a 15-pole contact, both variant will exsist
Figure 1 Back plane
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3.2 Signal description, RS 232 and RS 422 RS 232 Signal
Explanation
TXD
Transmit Data
RXD
Receive Data
DSR
Data Set Ready
DTR
Data Terminal Ready
CTS
Clear To Send
RTS
Request To Send
Stop bit (“1”) Start bit (“0”) 10 V
0V Byte 1
Byte 2
f=9600/19200 baud
Figure 2 Signal description for RS 232.
The transmission pattern can be single or bursts of 10 bit words, with one start bit “0”, eight data bits (MSB first) and lastly one stop bit “1”.
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Troubleshooting Tools RS 422 Signal
Explanation
TXD4/TXD4 N
Transmit Data in Full Duplex Mode
RXD4/RXD4 N
Receive Data in Full Duplex Mode
DATA4/DATA4 N
Data Signals in Half Duplex Mode
DCLK4/DCLK4 N
Data Transmission Clock
N.B! Only full duplex is supported.
Signal XXX 5V
5V
Signal XXX N
f= 9600 38400 baud Figure 3 Signal description for RS 422, differential transmission.
When measuring the differential RS 422 signals, the oscilloscope should be set for AC testing. The data transmission has the same structure as RS 232, i.e. 1 start bit + 8 data bits + 1 stop bit, but the signals are differential. By looking at the “true” channel, it is possible to read the data. If the types of signal as shown in the above diagram are obtained when measuring, this means that the drive circuits and lines are OK. If one or both of the signals do not move, it is likely that one or several line(s) or one or several drive circuit(s) is/are faulty.
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3.3 X1 and X2 Serial links: SIO 1 and SIO 2 General serial interfaces: SIO 1 (X1) is an RS232 interface and SIO 2 (X2) is an RS422 interface. Explanation of signals see 3.2. Screw terminals X1
X2
Pin
Signal
Pin
Signal
1
TXD
1
TXD
2
RTS N
2
TXD N
3
0V
3
0V
4
RXD
4
RXD
5
CTS N
5
RXD N
6
0V
6
0V
7
DTR
7
DATA
8
DSR
8
DATA N
9
0V
9
0V
10
10
DCLK
11
11
DCLK N
12
12
0V
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Troubleshooting Tools D-sub connector X1 Pin
X2 Signal
1
Pin
Signal
1
TXD
2
RXD
2
TXD N
3
TXD
3
RXD
4
DTR
4
RXD N
5
0V
5
0V
6
DSR
6
DATA
7
RTS N
7
DATA N
8
CTS N
8
DCLK
9
DCLK N
9
3.4 X9 Maintenance plug
3.4.1 Power supply Supply voltages can be measured at the following points: X9 Pin
Row A
Row C
28
Aco*k
Dco*k
29
+ 5V_TST
0V
30
+ 15V_TST
0V
31
15V_TST
0V
32
+ 24V_TST
0V
There is a 10 kΩ resistor between each power supply line and the test terminal to prevent damage by a short circuit. Aco*k: Follows the AC power input without delay. High (= 5V) when power is OK. Dco*k: Follows the supply unit energy buffer. After power on, Dco*k goes high (=5 V) when output voltages are stable.
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3.4.2 X9 VBATT 1 and 2 Battery back-up for the computer memory and the real time clock. Voltage of batteries 1 and 2; the voltage must be between 3.3 V and 3.9 V. X9 Pin
Row A
Row C
7
VBATT1
VBATT2
8
0V
0V
3.4.3 Drive system The signal interface with the drive system. It complies with the EIA RS 422 standard, which means that signal transmission is differential. See 3.2 (Figure 3). X9 Pin
A
C
16
DRCI1
DRCI1 N
17
DRCO1
DRCO1 N
18
DRCI2
DRCI2 N
19
DRCO2
DRCO2 N
20
0V
The DRCO signals travel from the robot computer to the drive units. The DRCI signals enter the robot computer from the drive units. DRCI1/DRCO1 signals are connected to the internal drive system (backplane connector X22, see 3.1). DRCI2/DRCO2 are connected to external placed drive units (backplane connector X14, see 3.1).
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Troubleshooting Tools
3.4.4 Measuring system The signal interface with the serial measuring system. It complies with the EIA RS 422 standard, which means that signal transmission is differential, see 3.2 (Figure 3). X9 Pin
A
20
C 0V
21
MRCI1
MRCI1 N
22
MRCO1
MRCO1 N
23
MRCI2
MRCI2 N
24
MRCO2
MRCO2 N
The MRCO signals travel from the robot computer to the measuring boards. The MRCI signals enter the robot computer from the measuring boards. MRCI1/MRCO1 signals are connected to the IRB axes (backplane connector X23, see 3.1). MRCI2/MRCO2 are used for external axes (backplane connector X12, see 3.1).
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3.4.5 Disk drive The signal interface with the disk drive; TTL levels “0” 0V, “1” +5V. X9 Pin
A
Explanation
9
RD N
Read Data, pulses. Data pulses when reading the diskette
10
WP N
Write Protect, static active low. Indicates whether or not the diskette is write protected.
11
DSKCHG N
Disk Change, static active low. Indicates whether or not there is a diskette in the unit.
12
WD N
Write Data, pulses. Data pulses when writing to the diskette.
13
SSO N
Side Select, static active low. Indicates which side of the diskette is active.
14
DIRC N
Direction in, static active low. Indicates that the heads are to move inwards.
15
0V
X9 Pin
C
Explanation
9
IP N
Index, pulses. One pulse per cycle, c. every 200 milliseconds.
10
TR00 N
11
MO N
Motor on, static low. Starts the motor in the selected unit.
12
WG N
Write Gate, pulses. Enables writing.
13
STEP N
14
HD N
15
0V
Product Manual
Track 00, active low. Indicates that the heads are located at track 0 of the diskette.
Step, pulses. Steps the heads in the direction indicated by DIRC N. High Density, static active low. Indicates that a 1.44 MB diskette is in the unit.
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Troubleshooting Tools
MOTOR ON DRIVE SELECT STEP WRITE GATE WRITE DATA Write frequency
MOTOR ON DRIVE SELECT STEP WRITE GATE READ DATA Read frequency Figure 4 Diagram of write and read frequencies.
3.4.6 Teach pendant The data transmission signal complies with the EIA RS 422 standard, see 3.2 (Figure 3).
X9
38
Pin
A
C
6
DATA4=TP
DATA4-N=TP-N
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Troubleshooting Tools
3.4.7 CAN
X9 Pin
A
C
25
CANRLY2 N
CANRLY3 N
26
CAN_H
CAN_L
CANRLY2 N and CANRLY3 N respectively: 0V when CAN 2 or CAN 3 is active (see Installation and Commissioning, section 3.17.3). 24V when CAN 2 and CAN 3 are disconnected (see Installation and Commissioning, section 3.17.3). In this case the backplane fixed termination resistor is connected in.
3.4.8 Safety
X9 Pin
A
C
27
ENABLE9
SPEED
ENABLE 9: 5V when supply voltage is OK and the computers are OK (output from the robot computer to the panel unit; LED EN). SPEED: 5V when one of the modes AUTO or MANUAL FULL SPEED is active (input to the robot computer from the panel unit).
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Troubleshooting Tools
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Product Manual
Fault tracing guide CONTENTS Page 1 Fault tracing guide .......................................................................................................... 3 1.1 Starting Troubleshooting Work........................................................................... 3 1.1.1 Intermittent errors ........................................................................................ 3 1.1.2 Tools............................................................................................................. 3 1.2 Robot system ......................................................................................................... 4 1.3 Main computer DSQC 361 and memory board DSQC 323/324 ...................... 4 1.4 Robot computer DSQC 363 ................................................................................. 5 1.5 Panel unit DSQC 331............................................................................................ 5 1.5.1 Status of the Panel unit, inputs and outputs, displayed on the teach pendant 6 1.6 Distributed I/O...................................................................................................... 8 1.7 Serial Communication.......................................................................................... 9 1.8 Drive System and Motors..................................................................................... 9 1.9 Teach Pendant....................................................................................................... 10 1.10 Measurement System ......................................................................................... 10 1.11 Disk Drive ............................................................................................................ 11 1.12 Fuses..................................................................................................................... 11
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Fault tracing guide
1 Fault tracing guide Sometimes errors occur which neither refer to an error message nor can be remedied with the help of an error message. To make a correct error diagnosis of these particular cases, you must be very experienced and have an in-depth knowledge of the control system. This section of the Product Manual is intended to provide support and guidance in any diagnostic work.
1.1 Starting Troubleshooting Work Always start off by consulting a qualified operator and/or check any log books available to get some idea of what has happened, to note which error messages are displayed, which LEDs are lit, etc. If possible, look at the control system’s error log; if there are any error messages there, it can be accessed from the Service menu. On the basis of this error information, you can start your analysis using the various tools, test programs, measuring points, etc., available. Never start off by wildly replacing boards or units since this can result in new errors being introduced into the system. When handling units and other electronic equipment in the controller, the wrist strap in the controller must be used to avoid ESD damage. 1.1.1 Intermittent errors Unfortunately, intermittent errors sometimes occur and these can be difficult to remedy. This problem can occur anywhere in the robot and may be due to external interference, internal interference, loose connections, dry joints, heating problems, etc. To identify the unit in which there is a fault, note and/or ask a qualified operator to note the status of all the LEDs, the messages on the teach pendant, the robot’s behaviour, etc., each time that type of error occurs. It may be necessary to run quite a number of test programs in order to pinpoint the error; these are run in loops, which should make the error occur more frequently. If an intermittent error occurs periodically, check whether something in the environment in which the robot is working also changes periodically. For example, it may be caused by electrical interference from a large electric plant which only operates periodically. Intermittent errors can also be caused by considerable temperature changes in the workshop, which occur for different reasons. Disturbances in the robot environment can affect cabling, if the cable screen connections are not intact or have been incorrectly connected. 1.1.2
Tools Usually, the following tools are required when troubleshooting: - Normal shop tools - Multimeter - Oscilloscope - Recorder
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Fault tracing guide 1.2 Robot system In this instance the robot system means the entire robot (controller + manipulator) and process equipment. Errors can occur in the form of several different errors where it is difficult to localise one particular error, i.e. where it is not possible to directly pinpoint the unit that caused the problem. For example, if the system cannot be cold-started, this may be due to several different errors (the wrong diskette, a computer fault, etc.).
1.3 Main computer DSQC 361 and memory board DSQC 323/324 The main computer, which is connected to the VME bus and the local bus of the memory board, looks after the higher-level administrative work in the control system. Under normal operating conditions, all diagnostic monitoring is controlled by the main computer. At start-up, irrespective of whether a cold or warm start is performed, the robot computer releases the main computer when the robot computer’s diagnostics allows it and, following this, the main computer takes over the control of the system. The read and write memories of the main computer are battery-backed. If the red LEDs on the main computer light up (or do not turn off at initialisation), either a critical system failure has occurred or the main computer board or memory board is faulty. The memory board is an extension of the main computer memory. The memory board has a LED, F, which is lit and turned off by the main computer. If there is a memory error on one of these boards, an error code will be shown on the display, T1047 or T2010. These error codes also include a field called the At address, which in turn contains an hexadecimal code that indicates on which board the erroneous memory circuit is located. When the error is in the main computer, the hexadecimal code is in the following range: 0 X 000000 - 0 X 7FFFFF When the error is in the memory board, the code is above 0 X 800 000.
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1.4 Robot computer DSQC 363 The robot computer, which controls the system’s I/O, axis control, serial communication and teach pendant communication, is the first unit to start after a cold or warm start. The red LED on the front of the board goes off immediately when the system is reset and goes on again if an error is detected in the tests. As mentioned above, the robot computer releases the main computer when the preliminary diagnostics have given the go ahead-signal. The read and write memories of the robot computer are battery-backed. If the system does not start at all, and the LED on the robot computer goes on, the error is probably in the robot computer.
1.5 Panel unit DSQC 331 The DSQC 331 Panel unit controls and monitors the dual operation chain. Its status is also indicated by LEDs at the upper part of the unit. Over temperature of the motors is monitored by PTC inputs to the board. LED indications for DSQC 331 Marking
Colour
Meaning
EN
Green
Indicates “go ahead” from the control system
MS NS ES 1 and 2 GS 1 and 2 AS 1 and 2
Green/red Green/red Yellow Yellow Yellow
Module status, normally green, see also section 1.6 Network status, normally green, see also section 1.6 EMERGENCY STOP, chain 1 and 2 closed GENERAL STOP switch, chain 1 and 2 closed AUTO STOP switch, chain 1 and 2 closed
The LEDs are very useful when trying to locate errors in the operation chain. Unlit LEDs indicate the whereabouts of an error in the operation chain, making the error easy to locate in the system circuit diagram.
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1.5.1
Status of the Panel unit, inputs and outputs, displayed on the teach pendant • Select the I/O window. • Call up the Units list by choosing View. • Select the Safety unit. The location of the status signals are found in the circuit diagram, regarding Panel unit, where outputs are marked with and inputs with See the table below. Outputs DO
6
Name
Meaning when “1” is displayed
BRAKE
Energise brake contactor (i.e. release brakes) and turn on duty time counter
MONLMP
Turn on LED in motor-on push button
RUN CH1
Energise motor contactor chain 1
RUN CH2
Energise motor contactor chain 2
SOFT ASO
Choose delayed turn off of auto stop
SOFT ESO
Choose delayed turn off of emergency stop
SOFT GSO
Choose delayed turn off of general stop
Product Manual
Fault tracing guide Inputs DI Name
Meaning when “1” is displayed
AS1
Auto stop chain 1 closed
AS2
Auto stop chain 2 closed
AUTO1
Mode selector chain 1; Auto operation
AUTO2
Mode selector chain 2; Auto operation
CH1
All switches in chain 1 closed
CH2
All switches in chain 2 closed
EN1
Enabling device chain 1 closed
EN2
Enabling device chain 2 closed
ES1
Emergency stop chain 1 closed
ES2
Emergency stop chain 2 closed
ENABLE
Enable from backplane
EXTCONT
External contactors closed
FAN OK
Fan in power supply running
GS1
General stop chain 1 closed
GS2
General stop chain 2 closed
K1
Motor contactor, chain 1, closed
K2
Motor contactor, chain 2, closed
LIM1
Limit switch chain 1 closed
LIM2
Limit switch chain 2 closed
MAN2
Mode selector chain 2; Manual operation
MANFS2
Mode selector chain 2; Manual full speed operation
MANORFS1
Mode selector chain 1; Manual or manual full speed operation
MON PB
Motor-On push button pressed
PTC
Over temperature in motors of manipulator
PTC Ext.
Over temperature in external device
SOFT ASI
Delayed turn off of auto stop (read back of digital output)
SOFT ESI
Delayed turn off of emergency stop (read back of digital output)
SOFT GSI
Delayed turn off of general stop (read back of digital output)
TRFOTMP
Over temperature in main transformer
24V panel
24V panel is higher than 22V
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Fault tracing guide 1.6 Distributed I/O I/O units communicate with the I/O computer, located on the robot computer board, via the CAN bus. To activate the I/O units they must be defined in the system parameters. The I/O channels can be read and activated from the I/O menu on the teach pendant. In the event of an error in the I/O communication to and from the robot, check as follows: 1. Is I/O communication programmed in the current program? 2. On the unit in question, the MS (Module status) and NS (Network status) LEDs must be lit with a fixed green colour. See the table below regarding other conditions: MS LED is:
To indicate
Action
Off
No power
Check 24 V CAN
Green
Normal condition
Flashing green
Software configuration missing, standby state
Configure device
Flashing red/green
Device self testing
Wait for test to be completed
Flashing red
Minor fault (recoverable)
Restart device
Red
Unrecoverable fault
Replace device
NS LED is:
To indicate
Action
Off
Not powered/not on-line
Flashing green
On-line, not connected
Green
On-line, connections established
Red
Critical link failure, incapable of communicating (duplicate MAC ID, or bus-off)
Wait for connection
Change MAC ID and/ or check CAN connection/cables
3. Check that the current I/O signal has the desired status using the I/O menu on the tech pendant display. 4. Check the I/O unit’s LED for the current input or output. If the output LED is not lit, check that the 24 V I/O power supply is OK. 5. Check on all connectors and cabling from the I/O unit to the process connection.
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1.7 Serial Communication The most common causes of errors in serial communication are faulty cables (e.g. mixed-up send and receive signals) and transfer rates (baud rates), or data widths that are incorrectly set. If there is a problem, check the cables and the connected equipment before doing anything else. The communication can be tested using the integral test-program, after strapping the input to the output. See chapter 9.
1.8 Drive System and Motors The drive system, which consists of rectifier, drive unit and motor, is controlled by the axis computer, located on the robot computer board.
Computer
Rotor position
DC link
Serial measurement board
Torque reference
Drive Unit
M
R
Figure 1 A schematic description of the drive system.
The drive system is equipped with internal error supervision. An error is sent on via the robot computer and can be read on the teach pendant display as an error message. An explanation of the available error messages can be found in the User’s Guide, System and error messages, section 3, error no. 39XXX. If a drive unit or rectifier is faulty, the unit should be replaced. Internal troubleshooting cannot be performed in the operating environment.
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1.9 Teach Pendant The teach pendant communicates with the robot computer via a cable. This cable is also used for the +24 V supply and the dual operation chain. If the display is not illuminated, try first adjusting the contrast, and if this does not help check the 24 V power supply. Communication errors between the teach pendant and the I/O computer are indicated by an error message on the teach pendant. For measuring points for the teach pendant communication signals, see chapter 9.
1.10 Measurement System The measurement system comprises an axis computer, one or more serial measurement boards and resolvers. The serial measurement board is used to collect resolver data. The board is supplied from 24 V SYS via a fuse on the back plane. The board is located in the manipulator and is battery-backed. Communication with the axis computer takes place across a differential serial link (RS 485). The measurement system contains information on the position of the axes and this information is continuously updated during operation. If the resolver connections are disconnected or if the battery goes dead after the robot has been stationary for a long period of time, the manipulator’s axis positions will not be stored and must be updated. The axis positions are updated by manually jogging the manipulator to the synchronised position and then, using the teach pendant, setting the counters to zero. If you try to start program execution without doing the above, the system will give an alarm to indicate that the system is not calibrated. Measuring points for the measurement system are located on the backplane, X9 Maintenance plug, see chapter 9 for more detailed information. Note that it is necessary to re-calibrate after the resolver lines have been disconnected. This applies even if the manipulator axes have not been moved. Transmission errors are detected by the system’s error control, which alerts and stops program execution if necessary. Common causes of errors in the measurement system are line breakdown, resolver errors and measurement board interference. The latter type of error relates to the 7th axis, which has its own measurement board. If it is positioned too close to a source of interference, there is a risk of an error.
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1.11 Disk Drive The disk drive is controlled by the I/O computer via a flat cable. The power is supplied by a separate cable. Common types of error are read and write errors, generally caused by faulty diskettes. In the event of a read and/or write error, format a new, high quality diskette in the robot and check to see whether the error disappears. If the error is still present, the disk drive will probably have to be replaced. However, check the flat cable first. NB: Never use diskettes without a manufacturer’s mark. Unmarked, cheap diskettes can be of very poor quality. If the disk drive is completely dead, check the supply voltage connection to the disk drive to see that it is +5 V, before replacing the drive. Measuring points are available on the backplane: X9 Maintenance plug, see chapter 9. When replacing the disk drive, check that the strapping is set correctly on the unit. Compare with the faulty drive being replaced.
1.12 Fuses There is one automatic three-phase 20 A fuse that supplies the DC-link in the MOTORS ON state, on the transformer. There is also a automatic three-phase 10 A fuse that supplies the power supply unit. There are also two fuses for customer AC supplies, one 3.15 A and one 6.3 A. The backplane has four PTC resistance fuses: - Serial measurement board 1 - Serial measurement board 2 - CAN2, manipulator I/O - CAN3, external I/O The fuses protect against 24 V short-circuits and return to the normal state when there is no longer a risk of short-circuiting. The panel unit has one PTC fuse to protect the motor on chains. An open fuse is indicated on the teach pendant, see Status of the Panel unit, inputs and outputs, displayed on the teach pendant side 6, 24 panel. The cabling from customer 24 V supply is protected by a 2A fuse on terminal XT31 in the upper compartment of the controller. Note that the power supply unit DSQC 374 is provided with a short circuit energy limitation which makes the fuse unnecessary.
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ABB Flexible Automation AB
This chapter is not included in the On-line Manual.
Click on the Main menu button below to continue to the front page. Main menu
Repairs CONTENTS Page 1 General Description ........................................................................................................ 3 1.1 Instructions for reading the following sections ...................................................... 5 1.2 Caution.................................................................................................................... 6 1.3 Fitting new bearings and seals................................................................................ 6 1.3.1 Bearings ....................................................................................................... 6 1.3.2 Seals ............................................................................................................. 7 1.4 Instructions for tightening screw joints .................................................................. 9 1.5 Tightening torques .................................................................................................. 10 2 Axis 1 ................................................................................................................................ 11 2.1 Changing the motor of axis 1 ................................................................................. 11 2.2 Changing the gearbox............................................................................................. 12 2.3 Position indicator in axis 1 (optional)..................................................................... 13 2.4 Replacing the mechanical stop ............................................................................... 14 3 Axis 2 ................................................................................................................................ 15 3.1 Changing the motor of axis 2 ................................................................................. 15 3.2 Changing the gearbox............................................................................................. 16 3.3 Dismantling the lower arm ..................................................................................... 16 3.4 Changing the bearings in the upper arm................................................................. 17 3.5 Dismantling the balancing springs ......................................................................... 18 4 Axis 3 ................................................................................................................................ 19 4.1 Changing the motor of axis 3 ................................................................................. 19 4.2 Changing the gearbox............................................................................................. 20 4.3 Dismantling the parallel arm .................................................................................. 20 4.4 Changing the tie rod ............................................................................................... 21 4.5 Dismantling the complete upper arm...................................................................... 22 5 Axis 4 ................................................................................................................................ 25 5.1 Changing the motor ................................................................................................ 25 5.2 Changing the intermediate gear including sealing ................................................. 26 5.3 Dismantling the drive gear on the tubular shaft ..................................................... 27 5.4 Dismantling the tubular shaft and changing bearings ............................................ 29 6 Cabling and Serial Measuring board ............................................................................ 31 6.1 Changing serial measuring boards.......................................................................... 31 6.2 Changing the cabling in axes 1, 2 and 3 ................................................................. 31 6.3 Changing the cabling in axes 4, 5 and 6 ................................................................. 32 7 The Wrist and Axes 5 and 6 ........................................................................................... 33 7.1 Dismantling the wrist.............................................................................................. 33 7.2 Dismantling the complete drive mechanism of axes 5 and 6 ................................. 34 Product Manual IRB 1400
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Repairs CONTENTS Page 7.3 Changing the motor or driving belt of axes 5 and 6............................................... 7.4 Measuring play in axes 5 and 6 .............................................................................. 8 Motor Units...................................................................................................................... 9 Calibration....................................................................................................................... 9.1 Adjustment procedure using calibration equipment (fine calibration)................... 9.2 Setting the calibration marks on the manipulator................................................... 9.3 Checking the calibration position........................................................................... 9.4 Alternative calibration positions ............................................................................ 9.5 Calibration equipment ............................................................................................ 9.6 Operating the robot.................................................................................................
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Repairs
General Description
1 General Description The industrial robot system comprises two separate units: the control cabinet and the manipulator. The IRB 1400 is also available in a suspended version, IRB 1400H. Servicing the mechanical unit is described in the following sections. Servicing the manipulator is described in this manual. When service on the IRB1400H is contemplated, a decision must be made in each particular case whether the work can be carried out with the manipulator suspended or whether it must be removed and the work done on the floor. Lifting and turning the manipulator is described in the Chapter entitled, Installation and commissioning. When servicing the manipulator, it is helpful to service the following parts separately: • The Electrical System • The Motor Units • The Mechanical System The Electrical System is routed through the entire manipulator and is made up of two main cabling systems: the power cabling and signal cabling. The power cabling feeds the motor units of the manipulator axes. The signal cabling feeds the various control parameters, such as axis positions, motor revs, etc. The AC Motor Units provide the motive power for the various manipulator axes by means of gears. Mechanical brakes, electrically released, lock the motor units when the robot is inoperative for more than 3 minutes during both automatic and manual operation. The manipulator has 6 axes which makes its movements very flexible.
Product Manual IRB 1400
3
General Description
Repairs
Axis 1 rotates the manipulator. Axis 2 provides the lower arm’s reciprocating motion. The lower arm, together with the parallel arm and the parallel bracket, forms a parallelogram relative to the upper arm. The parallel bracket is mounted on bearings in the parallel arm and in the upper arm. Axis 3 raises the upper arm of the manipulator. Axis 4, located on the side of the upper arm, rotates the upper arm. The wrist is bolted to the tip of the upper arm and includes axes 5 and 6. These axes form a cross and their motors are located at the rear of the upper arm. Axis 5 is used to tilt and axis 6 to turn. A connection is supplied for various customer tools on the tip of the wrist in the turn disc. The tool (or manipulator) can be pneumatically controlled by means of an external air supply (optional extra). The signals to/ from the tool can be supplied via internal customer connections (optional extras). Note that the control cabinet must be switched off during all maintenance work on the manipulator. The accumulator power supply must always be disconnected before performing any work on the manipulator measurement system (measurement boards, cabling, resolver unit). When any type of maintenance work is carried out, the calibration position of the manipulator must be checked before the robot is returned to the operational mode. Take special care when manually operating the brakes. Make sure also that the safety instructions described in this manual are followed when starting to operate the robot.
4
Product Manual IRB 1400
Repairs
General Description
1.1 Instructions for reading the following sections The subsequent sections describe the type of on-site maintenance that can be performed by the customer’s own maintenance staff. Some maintenance jobs require special experience or specific tools and are therefore not described in this manual. These jobs involve replacing the faulty module or component on-site. The faulty component is then transported to ABB Flexible Automation for service. Calibration: The robot must be re-calibrated when a mechanical unit or part of one is replaced, when the motor and feedback unit is disconnected, when a resolver error occurs, or when the power supply between a measurement board and resolver is interrupted. This procedure is described in detail in Chapter 9, Calibration. Any work on the robot signal cabling may cause the robot to move to the wrong positions. After performing such work, the calibration position of the robot must be checked as described in Chapter 9, Calibration. Tools: Two types of tools are required for the various maintenance jobs. It may be necessary to use conventional tools, such as sockets and ratchet spanners, etc., or special tools, depending on the type of servicing. Conventional tools are not discussed in this manual, since it is assumed that maintenance staff have sufficient basic technical competence. Maintenance jobs which require the use of special tools are, on the other hand, described in this manual. Foldouts: The chapter on spare parts comes with a number of foldouts which illustrate the parts of the robot. These foldouts are provided in order to make it easier for you to quickly identify both the type of service required and the make-up of the various parts and components. The item numbers of the parts are also shown on the foldouts. In the subsequent sections, these numbers are referred to in angle brackets < >. If a reference is made to a foldout, other than that specified in the paragraph title, the foldout’s number is included in the numeric reference to its item number; for example: or . The digit(s) before the stroke refer to the foldout number. The foldouts also include other information such as the article number, designation and related data. NB: This manual is not considered as a substitute for a proper training course. The information in the following chapters should be used only after an appropriate course has been completed.
Product Manual IRB 1400
5
General Description
Repairs
1.2 Caution The mechanical unit contains several parts which are too heavy to lift manually. As these parts must be moved with precision during any maintenance and repair work, it is important to have a suitable lifting device available. The robot should always be switched to MOTORS OFF before anybody is allowed to enter its working space.
1.3 Fitting new bearings and seals
1.3.1 Bearings 1.
Do not unwrap new bearings until just before assembly, in order to prevent dust and grit getting into the bearing.
2.
Make sure that all parts of the bearing are free from burr dust, grinding dust and any other contamination. Cast parts must be free from foundry sand.
3.
Bearing rings, races and roller parts must not under any circ*mstances be subjected to direct impact. The roller parts must not be subjected to any pressure that is created during the assembly.
Tapered bearings 4.
The bearing should be tightened gradually until the recommended pre-tensioning is attained.
5.
The roller parts must be rotated a specified number of turns both before pretensioning and during pre-tensioning.
6.
The above procedure must be carried out to enable the roller parts to slot into the correct position with respect to the racer flange.
7.
It is important to position the bearings correctly, because this directly affects the service life of the bearing.
Greasing bearings 8.
Bearings must be greased after they are fitted. Extreme cleanliness is necessary throughout. High quality lubricating grease, such as 3HAB 3537-1, should be used.
9.
Grooved ball bearings should be greased on both sides.
10. Tapered roller bearings and axial needle bearings should be greased when they are split. 6
Product Manual IRB 1400
Repairs
General Description 11. Normally the bearings should not be completely filled with grease. However, if there is space on both sides of the bearing, it can be filled completely with grease when it is fitted, as surplus grease will be released from the bearing on start up. 12. 70-80% of the available volume of the bearing must be filled with grease during operation. 13. Make sure that the grease is handled and stored correctly, to avoid contamination.
1.3.2 Seals 1.
The most common cause of leakage is incorrect mounting.
Rotating seals 2.
The seal surfaces must be protected during transportation and assembly.
3.
The seals must either be kept in their original packages or be protected well.
4.
The seal surfaces must be inspected before mounting. If the seal is scratched or damaged in such a way that it may cause leakage in the future, it must be replaced.
5.
The seal must also be checked before it is fitted to ensure that: • the seal edge is not damaged (feel the edge with your finger nail), • the correct type of seal is used (has a cut-off edge), • there is no other damage.
6.
Grease the seal just before it is fitted – not too early as otherwise dirt and foreign particles may stick to the seal. The space between the dust tongue and sealing lip should 2/3-filled with grease of type 3HAB 3537-1. The rubber coated external diameter must also be greased.
7.
Seals and gears must be fitted on clean workbenches.
8.
Fit the seal correctly. If it is fitted incorrectly, it may start to leak when pumping. starts.
9.
Always use an assembling tool to fit the seal. Never hammer directly on the seal because this will cause it to leak.
10. Use a protective sleeve on the sealing edge during assembly, when sliding over threads, key-ways, etc. Flange seals and static seals 11. Check the flange surfaces. The surface must be even and have no pores. The evenness can be easily checked using a gauge on the fitted joint (without sealing compound). Product Manual IRB 1400
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General Description
Repairs
12. The surfaces must be even and free from burr dust (caused by incorrect machining). If the flange surfaces are defective, they must not be used as they will cause leakage. 13. The surfaces must be cleaned properly in the manner recommended by ABB ROBOTICS. 14. Distribute the sealing compound evenly over the surface, preferably using a brush. 15. Tighten the screws evenly around the flange joint. 16. Make sure that the joint is not subjected to loading until the sealing compound has attained the hardness specified in the materials specification. O-rings 17. Check the O-ring grooves. The grooves must be geometrically correct, without pores and free of dust and grime. 18. Check the O-ring for surface defects and burrs, and check that it has the correct shape, etc. 19. Make sure the correct O-ring size is used. 20. Tighten the screws evenly. 21. Defective O-rings and O-ring grooves must not be used. 22. If any of the parts fitted are defective, they will cause leakage. Grease the O-ring with 3HAB 3537-1 before fitting it.
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Product Manual IRB 1400
Repairs
General Description
1.4 Instructions for tightening screw joints General It is extremely important that all screw joints are tightened using the correct torque. Application The following tightening torques must be used, unless otherwise specified in the text, for all screw joints made of metallic materials. The instructions do not apply to screw joints made of soft or brittle materials. For screws with a property class higher than 8.8, the same specifications as for class 8.8. are applicable, unless otherwise stated. Screws treated with Gleitmo All screws in the manipulator that are tightened to a specified torque are treated with Gleitmo. When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used. Screws treated with Gleitmo can be unscrewed and screwed in again 3-4 times before the slip coating disappears. Screws can also be treated with Molycote 1000. When screwing in new screws without Gleitmo, these should first be lubricated with Molycote 1000 and then tightened to the specified torque. Assembly Screw threads sized M8 or larger should preferably be lubricated with oil. Molycote 1000 should only be used when specified in the text. Screws sized M8 or larger should be tightened with a torque wrench, if possible. Screws sized M6 or smaller may be tightened to the correct torque by personnel with sufficient mechanical training, without using torque measurement tools.
Product Manual IRB 1400
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General Description
Repairs
1.5 Tightening torques Screws with slotted or cross recessed head, property class 4.8 Dimension
Tightening Torque - Nm
without oil
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
Screws with hexagon socket head, property class 8.8 Dimension
10
Tightening Torque - Nm
without oil
with oil
M3
1
1
M4
2
2
M5
5.5
4
M6
10
9
M8
24
22
M10
48
45
M12
83
78
M16
200
190
M20
410
400
M24
750
740
Product Manual IRB 1400
Repairs
Axis 1
2 Axis 1 2.1 Changing the motor of axis 1 See foldouts 1 and 5 (6 for IRB 1400H) in the list of spare parts. The motor and the drive gear constitute one unit. To dismantle: 1.
Remove the cover of the motor.
2.
Loosen connectors R4.MP1 and R4.FB1.
3.
Remove the connection box by unscrewing .
4.
Note the position of the motor before removing it.
5.
Loosen the motor by unscrewing .
To assemble: 6.
Check that the assembly surfaces are clean and the motor unscratched.
7.
Release the brake, apply 24V DC to terminals 7 and 8 in the 4.MP1 connector.
8.
Install the motor, tighten screws using a torque of approximately 2 Nm. Note the position of the motor
9.
Adjust the motor in relation to the gear in the gearbox.
10. Screw the 3HAB 1201-1 crank tool into the end of the motor shaft. 11. Make sure there is very small play by turning axis 1 at least 45o. 12. Tighten screws using a torque of 8.3 Nm ±10%. 13. Connect the cabling. 14. Calibrate the robot as specified in Chapter 9, Calibration. Tightening torque: The motor attaching screws, item10:
Product Manual IRB 1400
8.3 Nm ±10%
11
Axis 1
Repairs
2.2 Changing the gearbox Axis 1 gearbox is of the conventional type, manufactured with a high degree of precision and, together with the gearboxes for axes 2 and 3, forms a complete unit. The gearbox is not normally serviced or adjusted. Note: If the gearbox on any of the axes 1, 2 or 3 is changed, the whole unit must be changed. See foldout 1 (6 for IRB 1400H) in the list of spare parts. To dismantle: 1.
Remove the motors in axes 1, 2 and 3 as in sections 2.1, 3.1 and 4.1.
2.
Remove the cabling and serial measuring boards as in Chapter 6, Cabling.
3.
Remove the tie rod as in Chapter 4.4, Changing the tie rod.
4.
Remove the radius rod as in Chapter 4.3, Dismantling the radius rod.
5.
Remove the equalizer springs as in Chapter 3.5, Dismantling the equalizer springs (not valid for IRB 1400H).
6.
Dismantle the upper arm as in Chapter 4.5, Dismantling the complete upper arm.
7.
Dismantle the lower arm as in Chapter 3.3, Dismantling the lower arm.
8.
Place the remaining parts of the manipulator upside-down on a table or similar surface and remove the bottom plate . See Figure 1.
Make sure that the foot is stable.
Figure 1 How to position the foot when dismantling axes 1, 2 and 3.
9.
Undo screws .
10. Separate the base from the gear unit.
12
Product Manual IRB 1400
Repairs
Axis 1 To assemble: 11. Place a new gear unit on the table. 12. Raise the base. 13. Screw in the screws together with their washers . Tighten using a torque of 68 Nm ±10%. 14. Replace the bottom plate using screws . 15. Turn the foot. 16. Replace the lower arm as in Chapter 3.3, Dismantling the lower arm 17. Replace the radius rod as in Chapter 4.3, Dismantling the radius rod. 18. Replace the upper arm as in Chapter 5.4, Dismantling the tubular shaft and changing bearings. 19. Replace the cabling as in Chapter 6, Cabling and Serial Measurement Boards. 20. Replace the tie rod as in Chapter 4.4, Changing the tie rod. 21. Replace the equalizer springs as in chapter 3.5, Dismantling the equalizer springs (not valid for IRB 1400H). 22. Calibrate the robot as in Chapter 9, Calibration. Tightening torque: Screwed joint of base/gear unit, item :
68 Nm ±10%
2.3 Position indicator in axis 1 (optional) See foldouts 3 and 4 (6 for IRB 1400H) in the list of spare parts. To dismantle: 1.
Remove the flange plate .
2.
Loosen the connector R1.LS.
3.
Dismantle the two limit switches .
4.
Loosen the cables from the switches.
5.
Remove the cabling through the base.
To assemble: 6.
Assemble in the reverse order.
Product Manual IRB 1400
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Axis 1
Repairs
2.4 Replacing the mechanical stop See foldout 1 in the list of spare parts. If the stop pins are bent, they must be replaced. Remove the old stop pin.
68 ± 1
Fit the new pin as illustrated in the diagram below.
Loctite 242 or 243
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Product Manual IRB 1400
Repairs
Axis 2
3 Axis 2 3.1 Changing the motor of axis 2 See foldouts 1 and 5 (6 for IRB 1400H) in the list of spare parts. The motor and the drive gear constitute one unit. To dismantle: Lock the arm system before dismantling the motor; the brake is located in the motor. 1.
Remove the cover of the motor.
2.
Loosen connectors R3.MP2 and R3.FB2.
3.
Remove the connection box by unscrewing .
4.
Note the position of the motor before removing it.
5.
Loosen the motor by unscrewing . N.B. The oil will start to run out.
To assemble: 6.
Check that the assembly surfaces are clean and the motor unscratched.
7.
Release the brake, apply 24 V DC to terminals 7 and 8 on the R3.MP2 connector.
8.
Install the motor, tighten screws to a torque of approximately 2 Nm. Note the position of the motor
9.
Adjust the motor in relation to the drive in the gearbox.
10. Screw the 3HAB 1201-1 crank tool into the end of the motor shaft. 11. Make sure there is no play. 12. Tighten screws to a torque of 8.3 Nm ±10%. 13. Fill with oil. See Chapter 8, Maintenance. 14. Connect the cabling. 15. Calibrate the robot as specified in Chapter 9, Calibration. Tightening torque: The motor’s fixing screws, item10: 8.3 Nm ±10%
Product Manual IRB 1400
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Axis 2
Repairs
3.2 Changing the gearbox Axis 2 gearbox is of a conventional type, manufactured with a high degree of precision and, together with the gearbox for axes 1 and 3, forms a complete unit. The gearbox is not normally serviced or adjusted. Note: If the gearbox of any of the axes 1, 2 or 3 needs to be changed, the whole unit must be changed. See foldout 1 in the list of spare parts. To dismantle: See Chapter 2.1.
3.3 Dismantling the lower arm See foldouts 1 (6 for IRB 1400H) in the list of spare parts. To dismantle: 1.
Remove the equalizer springs as in Chapter 3.5, Dismantling the equalizer springs (not valid for IRB 1400H).
2.
Remove the cabling down to axis 1 as in Chapter 6, Cabling and Serial Measuring Boards.
3.
Dismantle the upper arm as in Chapter 4.5, Dismantling the complete upper arm.
4.
Attach the crane to the lower arm.
5.
Remove the radius rod as in Chapter 4.3, Dismantling the radius rod.
6.
Loosen screws .
7.
Take off the lower arm.
To assemble: 8.
Transfer the damping element and calibration marking to the new lower arm.
9.
Lift the lower arm into position.
10. Fix the lower arm to gear 2 using screws and tighten them to a torque of 68 Nm ±10%. To prevent clicking during operation of the robot, grease the bearing seating of the radius rod in the lower arm. 16
Product Manual IRB 1400
Repairs
Axis 2 11. Replace the radius rod as in Chapter 4.3, Dismantling the radius rod. 12. Replace the upper arm as in Chapter 4.5, Dismantling the complete upper arm. 13. Replace the equalizer springs as in chapter 3.5, Dismantling the equalizer springs (not valid for IRB 1400H). 14. Replace the cabling as in Chapter 6, Cabling and Serial Measurement Boards. 15. Calibrate the robot as in Chapter 9, Calibration. Tightening torque: Screwed joint of lower arm/gear 2, item :
68 Nm ±10%
3.4 Changing the bearings in the upper arm See foldout 1 (6 for IRB 1400H) in the list of spare parts. To dismantle: 1.
Loosen the upper bracket of the tie rod as in Chapter 4.4, Changing the tie rod.
2.
Unscrew screws which hold the radius rod to gear 3.
3.
Remove the bearings from the radius rod.
To assemble: 4.
Fit new bearings to the radius rod.
5.
Replace the radius rod using screws and tighten to a torque of 68 Nm ±10%.
6.
Attach the upper bracket of the tie rod as in Chapter 4.4, Changing the tie rod.
7.
Calibrate the robot as in Chapter 9, Calibration.
Tightening torque: Screwed joint of radius rod/gear 3, pos. :
Product Manual IRB 1400
68 Nm ±10%
17
Axis 2
Repairs
3.5 Dismantling the balancing springs See foldouts 1 and 2 in the list of spare parts. NOTE! Not valid for IRB 1400H. To dismantle: 1.
Place the lower arm in a vertical position.
2.
Loosen the locking nut .
3.
Release the spring using tool 3HAB 1214-6 and undo screw at the same time.
If the tool 3HAB 1214-6 is not available, but there are two persons, then the spring can be released manually. 4.
Unscrew in the upper bracket of the spring.
5.
Remove the springs.
To assemble: 6.
Before installing new springs, make sure that the distance between the attachment points is correct, see Figure 2. Lock the link heads using Loctite 242 or 243. C C 377
Figure 2 Distance between the attachment points.
7.
Lubricate the link heads with grease.
8.
Attach the springs to the top bracket using screws and tighten to a torque of 68 Nm ±10%.
9.
Pull the springs down using tool 3HAB 1214-6 and attach screws , together with lifting lug and washer .
10. Attach the locking nut . Tightening torque: Screws of upper bracket, position : 18
68 Nm ±10%. Product Manual IRB 1400
Repairs
Axis 3
4 Axis 3 4.1 Changing the motor of axis 3 See foldouts 1 and 5 (6 for IRB 1400H) in the list of spare parts. The motor and the drive gear constitute one unit. To dismantle: 1.
Remove the cover of the motor.
2.
Loosen connectors R5.MP3 and R5.FB3.
3.
Remove the connection box by unscrewing .
4.
Note the position of the motor before removing it.
5.
Loosen the motor by unscrewing . N.B. The oil will start to run out.
To assemble: 6.
Check that the assembly surfaces are clean and the motor unscratched.
7.
Release the brake, apply 24 V DC to terminals 7 and 8 on the 4.MP1 connector.
8.
Install the motor, tighten screws to a torque of approximately 2 Nm. Note the position of the motor
9.
Adjust the motor in relation to the drive in the gearbox.
10. Screw the 3HAB 1201-1 crank tool into the end of the motor shaft. 11. Make sure there is no play. 12. Tighten screws to a torque of 8.3 Nm ±10%. 13. Fill with oil. See Chapter 8, Maintenance. 14. Connect the cabling. 15. Calibrate the robot as specified in Chapter 9, Calibration. Tightening torque: The motor’s fixing screws, item 10:
Product Manual IRB 1400
8.3 Nm ±10%
19
Axis 3
Repairs
4.2 Changing the gearbox Axis 3’s gearbox is of a conventional type, manufactured with a high degree of precision and, together with the gearbox for axes 1 and 2, forms a complete unit. The gearbox is not normally serviced are adjusted. Note: If the gearbox of any of the axes 1, 2 or 3 needs to be changed, the whole unit must be changed. See foldout 1 in the list of spare parts.
To dismantle: See Chapter 2.1.
4.3 Dismantling the parallel arm See foldout 1 (6 for IRB 1400H) in the list of spare parts. To dismantle: 1.
Loosen the upper bracket of the tie rod as in Chapter 4.4, Changing the tie rod.
2.
Unscrew screws which fix the parallel arm to gear 3.
3.
Remove the bearings from the parallel arm.
To assemble: 4.
Fit the bearings on the parallel arm.
5.
Replace the parallel arm using screws and tighten to a torque of 68 Nm ±10%.
6.
Attach the upper bracket of the tie rod as in Chapter 4.4, Changing the tie rod.
7.
Calibrate the robot as in Chapter 9, Calibration.
Tightening torque: Screwed joint of parallel arm/gear 3,item :
20
68 Nm ±10%
Product Manual IRB 1400
Repairs
Axis 3
4.4 Changing the tie rod See foldout 2 in the list of spare parts. To dismantle: Lock the upper arm in a horizontal position with the help of a crane or similar. 1.
Unscrew screw .
2.
Undo the two screws for fixing the cabling bracket of the upper arm housing. Fold back the cabling bracket.
3.
Screw the screw back into the shaft .
4.
Carefully knock the shaft out.
5.
Remove housing .
6.
Unscrew on the lower bracket.
7.
Carefully tap the rod off the shaft.
8.
Change the bearings.
To assemble: 9.
Fit bearings on the parallel arm.
10. Make sure you replace the rod the correct way up. See foldout 1 (1:1). 11. Install grommets: (3 x) and (1 x) . Note: grommet is bevelled and must be inserted the right way up in the lower bearing. 12. Place the lower bearing of the tie rod on the parallel arm. 13. Screw in screw and its washer . Lock using Loctite 242 or 243. 14. Replace shaft . N.B. Do not forget the sleeve . 15. Mount washer and tighten the shaft using a temporary screw, M8x35. 16. Replace this screw by screw and mount the cable bearer . Lock using Loctite 242 or 243.
Product Manual IRB 1400
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Axis 3
Repairs
4.5 Dismantling the complete upper arm See foldout 2 in the list of spare parts. To dismantle: Attach a crane to the upper arm. 1.
Unscrew the upper bracket of the tie rod as in Chapter 4.4, Changing the tie rod.
2.
Loosen the connectors of the motors of axes 4, 5 and 6.
3.
Disconnect the connection box from the motors.
4.
Detach the equalizer springs as in Chapter 3.5, Dismantling the balancing springs (not valid for IRB 1400H).
5.
Undo the KM nuts .
6.
Remove washers and shims on the same side as axis 3.
7.
Attach the withdrawing tool 3HAB 1259-1 and pull the axes off.
To assemble: 8.
Raise the upper arm into assembly position.
9.
Install shaft spindles (both sides), use two temporary screws M10x90.
10. Insert bearings (both sides) using tool 3HAB 1200-1 and screws . 11. Detach the tool and tighten the screws once more, only to prevent rotation of the axis when the KM nut is tightened. N.B. Assemble the same side as axis 2 first. 12. Mount two washers and calibration washer . 13. Tighten using the KM nut . 14. Attach the measuring instrument 3HAB 1205-1 to the shaft spindle on axis 3. N.B. If measuring instrument 3HAB 1205-1 is not available, you can use a micrometer thickness gauge. 15. Hold the tool against the shoulder of the shaft spindle and measure the dimension “A”. See Figure 3. (If you are not using the measuring instrument, tighten using the KM nut and, before measuring with the micrometer thickness gauge, then undo it again.)
22
Product Manual IRB 1400
Repairs
Axis 3
Figure 3 Measuring the shim thickness when preloading the bearing.
16. Make a note of the dimension “A”. Fit one washer and shims and, using the micrometer, measure the thickness so that the total thickness is 0.10 0.20 mm more than the noted dimension “A”. This will result in a preloading of the bearing of 0.10 - 0.20 mm. 17. Fit the shims and washer and tighten the KM nut . 18. Replace the upper attachment of the tie rod as in Chapter 4.4, Changing the tie rod. 19. Replace the equalizer springs as in Chapter 3.5, Dismantling the balancing springs (not valid for IRB 1400H). 20. Reconnect the connection boxes and the cabling. 21. Calibrate the robot as in Chapter 9, Calibration. 22. Undo the KM-nut on the axis 2 side, just to be able to adjust the calibration washer . 23. If the old armhouse is mounted, adjust the calibration washer according to the punch mark. If the armhouse is new adjust the washer according to Figure 4 and make a new punch marks for axes 3 and 4, according to chapter 9.2.
Product Manual IRB 1400
23
Axis 3
Repairs
105o
Figure 4 Calibraion mark for axis 3.
Tools:
24
Pressing tool for bearings:
3HAB 1200-1
Measuring instrument:
3HAB 1205-1
Withdrawing tool for shaft spindles:
3HAB 1259-1
Product Manual IRB 1400
Repairs
Axis 4
5 Axis 4 5.1 Changing the motor See foldouts 5 and 8 in the list of spare parts. The motor and the drive gear constitute one unit. Position the arm system in such a way that the motor of axis 4 points upwards. To dismantle: 1.
Remove the cover of the motor.
2.
Loosen connectors R3.MP4 and R3.FB4.
3.
Remove the connection box by unscrewing .
4.
Note the position of the motor before removing it.
5.
Loosen the motor by unscrewing .
To assemble: 6.
Check that the assembly surfaces are clean and the motor unscratched.
7.
Put O-ring on the motor.
8.
Release the brake, apply 24 V DC to terminals 7 and 8 on theR3.MP4 connector.
9.
Install the motor, tighten screws to a torque of approximately 2 Nm. Note the position of the motor
10. Adjust the position of the motor in relation to the drive in the gearbox. 11. Screw the 3HAB 1201-1 crank tool into the end of the motor shaft. 12. Make sure there is a small clearance. 13. Unscrew one screw at a time, apply Loctite 242 or 243 and tighten to a torque of 4.1 Nm ±10%.
Product Manual IRB 1400
25
Axis 4
Repairs 14. Connect the cabling. 15. Calibrate the robot as in Chapter 9, Calibration. Tightening torque: The motor’s fixing screws, item :
4.1 Nm ±10%
Tool: Crank tool for checking the play:
3HAB 1201-1
5.2 Changing the intermediate gear including sealing See foldout 8 in the list of spare parts. To dismantle: 1.
Dismantle the wrist as in Chapter 7, The Wrist and Axes 5 and 6.
2.
Dismantle the drive mechanism as in Chapter 7.2, Dismantling the complete drive mechanism of axes 5 and 6.
3.
Dismantle the motor of axis 4 as in Chapter 5.1, Changing the motor.
4.
Remove the cover .
5.
Undo screws fixing the large drive gear and dismantle it. N.B. Put the shims in a safe place.
6.
Undo screws .
7.
Push the intermediate gear out of the arm housing.
To assemble: 8.
Grease the seating of the arm housing to provide radial sealing.
9.
Push the gear unit down into the arm housing.
10. Screw in screws together with their washers and pull the gear down. 11. Mount the drive gear using screws and tighten to a torque of 8.3 Nm ±10%. N.B. Do not forget to insert shims under the drive gear. 12. Tighten screws to a torque of approximately 5 Nm. 13. Bend the pinion towards the large drive gear and then rotate it around the tubular shaft a couple of times so that the clearance in the gears can adjust itself in relation 26
Product Manual IRB 1400
Repairs
Axis 4 to the highest point of the large drive gear. 14. Then tighten screws to a torque of 20 Nm ±10%. 15. Check the clearance in relation to the tightening torque. 16. Replace the cover using screws . Use a drop of Loctite 242 or 243. 17. Position the manipulator so that the tubular shaft points upwards. 18. Fill (30 ml) oil into the gear of axis 4. See Maintenance of IRB 1400. 19. Install the motor of axis 4 as in Chapter 5.1, Changing the motor. 20. Install drive mechanism as in Chapter 7.2, Dismantling the complete drive mechanism of axes 5 and 6. 21. Replace the wrist as in Chapter 7, The Wrist and Axes 5 and 6. 22. Calibrate the robot as in Chapter 9, Calibration. Tightening torque: Screws for the large drive gear, item :
8.3 Nm ±10%
Screws for the intermediate gear of axis 4, item :
20 Nm ±10%
5.3 Dismantling the drive gear on the tubular shaft See foldout 8 in the list of spare parts. To dismantle: 1.
Dismantle the wrist as in Chapter 7, The Wrist and Axes 5 and 6.
2.
Dismantle the drive mechanism as in Chapter 7.2, Dismantling the complete drive mechanism of axes 5 and 6.
3.
Dismantle the motor of axis 4 as in Chapter 5.1, Changing the motor.
4.
Remove the cover .
5.
Unscrew screws that hold the intermediate gear in place.
6.
Unscrew screws that hold the large drive gear and then dismantle it. N.B. Put the shims from under the drive gear in a safe place.
Product Manual IRB 1400
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Axis 4
Repairs To assemble: Shim between drive gear and the rear bearing . Shim thickness = B - A + 0.05 mm, see Figure 5.
Figure 5 Measuring the shim thickness of the drive gear of axis 4.
7.
Install the drive gear using screws and tighten to a torque of 8.3 Nm ±10%. N.B. Do not forget the shims.
8.
Screw screw and 2 washers into the drive gear. Lock using Loctite 242 or 243.
9.
Mount the intermediate gear as in Chapter 5.2, Changing the intermediate gear including sealing.
10. Lubricate the drive gear with grease (30 g). 11. Install the motor of axis 4 as in Chapter 5.1, Changing the motor. 12. Replace the cover using screws . Lock using a drop of Loctite 242 or 243. 13. Mount the drive mechanism as in Chapter 7.2, Dismantling the complete drive mechanism of axes 5 and 6. 14. Mount the wrist as in Chapter 7.1, Dismantling the wrist. 15. Calibrate the robot as in Chapter 9, Calibration. Tightening torque: Screws of drive gear, item :
28
8.3 Nm ±10%
Product Manual IRB 1400
Repairs
Axis 4
5.4 Dismantling the tubular shaft and changing bearings See foldout 8 in the list of spare parts. To dismantle: 1.
Dismantle the drive gear as in Chapter 5.3, Dismantling the drive gear on the tubular shaft.
2.
Push out the tubular shaft.
To assemble: 3.
Fit a new bearing on the tubular shaft using tool 6896 134-V.
4.
Push the tube into the housing of the upper arm.
5.
Insert the rear bearing using tool 6896 134-JB.
6.
Mount the drive gear as in Chapter 5.3, Dismantling the drive gear on the tubular shaft.
7.
Calibrate the robot as in Chapter 9, Calibration.
Tools: Pressing tool for front bearing:
6896 134-V
Pressing tool for rear bearing:
6896 134-JB
Product Manual IRB 1400
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Axis 4
30
Repairs
Product Manual IRB 1400
Repairs
Cabling and Serial Measuring board
6 Cabling and Serial Measuring board 6.1 Changing serial measuring boards See foldout 4 in the list of spare parts. To dismantle: 1.
Remove flange plate .
2.
Cut tie around bundle .
3.
Unscrew the serial measuring board using screws .
4.
Remove the board and loosen the contacts.
To assemble: 5.
Assemble in the reverse order.
6.2 Changing the cabling in axes 1, 2 and 3 See foldouts 3 and 4 (7 for IRB 1400H) in the list of spare parts. To dismantle: 1.
Remove the cover of the motors.
2.
Remove the flange plate .
3.
Loosen connectors R1.MP, R2.FB1-3.
4.
Cut tie around bundle and detach the cable brackets.
5.
Detach the cable guides and undo screws .
6.
Loosen the connectors in the motors.
7.
Disconnect the connection boxes in the motors.
8.
Feed the cabling up through the middle of axis 1.
To assemble: 9.
Assemble in the reverse order.
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Cabling and Serial Measuring board
Repairs
6.3 Changing the cabling in axes 4, 5 and 6 See foldouts 2, 3 and 4 (6 for IRB 1400H) in the list of spare parts. To dismantle: 1.
Remove the cover of the motors.
2.
Remove the flange plate .
3.
Loosen connectors R2.MP4-6 and R2.FB4-6, including customer connector R1.CS (if there is one) and the air hose.
4.
Detach the cable guides .
5.
Loosen the cable brackets between gears 2 and 3 and cut the tie around them.
6.
Feed the cabling and air hose up through axis 1.
7.
Loosen the cable bracket on the lower arm and undo screws .
8.
Undo screw which fixes the shaft of the tie rod.
9.
Disconnect the connection boxes in the motors.
10. Loosen the remaining cable brackets and remove the cabling. To assemble: 11. Assemble in the reverse order.
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Product Manual IRB 1400
Repairs
The Wrist and Axes 5 and 6
7 The Wrist and Axes 5 and 6 The wrist, which includes axes 5 and 6, is a complete unit, comprising drive units and gears. It is of such a complex design that it is not normally serviced on-site, but should be sent to ABB Flexible Automation to be serviced. ABB ROBOTICS recommends its customers to carry out only the following servicing and repair work on the wrist. • Grease the wrist according to the table in the chapter on maintenance.
7.1 Dismantling the wrist See foldouts 1 (6 for IRB 1400H) and 9 in the list of spare parts. To dismantle: 1.
Remove the 2 plastic plugs on the rear of the wrist.
2.
Release the brake in axes 5 and 6.
3.
Rotate axes 5 and 6 so that you can see screws in the clamping sleeve through the hole.
4.
Disconnect the clamping sleeve.
5.
Undo screws and remove the wrist.
To assemble: 6.
Mount the wrist, tighten screws to a torque of 8.3 Nm ±10%. Note! The grease nipple on the tilt house should be pointing against the base when the axis 4 is in the calibration position.
7.
Screw the clamping sleeves together using screws .
8.
Replace the plastic plugs.
9.
Calibrate the robot as in Chapter 9, Calibration.
Tightening torque: Screwed joint of wrist/tubular shaft, item : 8.3 Nm ±10%
Product Manual IRB 1400
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The Wrist and Axes 5 and 6
Repairs
7.2 Dismantling the complete drive mechanism of axes 5 and 6 See foldouts 8 and 9 in the list of spare parts. To dismantle: 1.
Dismantle the wrist as in section 7.1.
2.
Loosen the connectors on the motors of axes 5 and 6.
3.
Undo screws .
4.
Squeeze the drive shafts () together at the tip of the tubular shaft, in order that they can pass through the tube.
5.
Pull out the complete drive mechanism of axes 5 and 6.
To assemble: 6.
Install the drive mechanism in the tubular shaft.
7.
Tighten screws to a torque of 8.3 Nm ±10%.
8.
Insert the cabling.
9.
Mount the wrist as in section 7.1.
Tightening torque: Screwed joint of the drive mechanism, item : 8.3 Nm ±10%
7.3 Changing the motor or driving belt of axes 5 and 6 See foldout 9 in the list of spare parts. To dismantle:
34
1.
Dismantle the wrist as in section 7.1.
2.
Dismantle the drive mechanism as in 7.2.
3.
Undo screws and remove the appropriate motor.
4.
If the driving belt is to be changed, both motors must be removed.
5.
Undo screws and remove plate .
Product Manual IRB 1400
Repairs
The Wrist and Axes 5 and 6 To assemble: 6.
Install the driving belts.
7.
Mount the plate using screws . N.B. Do not forget the nuts of the motors.
8.
Install the motors.
9.
Push the motors in sideways to tension the belts. Use tool 3HAA 7601-050. Tighten screws to a torque of 4.1 Nm.
10. Rotate the drive shafts. Check the tension on the belt. 11. Install the drive mechanism as in section 7.2. 12. Mount the wrist as in section 7.1. 13. Calibrate the robot as in Chapter 9, Calibration. Tightening torque: Screws for motors and plate, item : 4.1 Nm. Tool: To adjust the belt tension:
3HAA 7601-050
7.4 Measuring play in axes 5 and 6 Axis 5. Axis 4 shall be turned 90o. The maximum accepted play in axis 5 is 4.7 arc.minutes when loading axis 5 with a moment of 4.8 Nm in one direction, unloading to 0.24 Nm and start measuring the play, loading in the other direction with 4.8 Nm unloading to 0.24 Nm and reading the play. This correspond to play of 0.27 mm on a radius of 200 mm when the load is F=40 N and 2 N on radius 120 mm. 120 35
F 200
Product Manual IRB 1400
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The Wrist and Axes 5 and 6
Repairs
Axis 6. The maximum accepted play in axis 6 is 12.8 arc.minutes when loading axis 6 with a moment of 4.2 Nm in one direction, unloading to 0.2 Nm and start measuring the play, loading in the other direction with 4.2 Nm unloading to 0.2 Nm and reading the play. This correspond to a play of 0.37 mm on a radius of 100 mm when the load is F=42 N and 2 N.
100
36
F
Product Manual IRB 1400
Repairs
Motor Units
8 Motor Units General Each axis of the manipulator has its own motor unit, comprising: - a synchronous motor - a brake (built into the motor) - a feedback device. There are a total of six motors mounted in the manipulator. The power and signal cables are run to the respective motor from the cable connector points on the manipulator. The cables are connected to the motor units by connectors. The drive shaft of the electric motor forms a part of the gearbox of the manipulator axis. A brake, operated electromagnetically, is mounted on the rear end of the motor shaft and a pinion is mounted on its drive end. The brake releases when power is supplied to the electromagnets. N.B. There is a feedback device mounted on each motor unit. The device is installed by the supplier of the motor and should never be removed from the motor. The motor need never be commutated. The commutation value of the motors is: 1.570800. The motor, resolver and brakes are regarded as one complete unit.
Product Manual IRB 1400
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Motor Units
38
Repairs
Product Manual IRB 1400
Repairs
Calibration
9 Calibration General The robot measurement system consists of one feedback unit for each axis and a measurement board which keeps track of the current robot position. The measurement board memory is battery-backed. The measurement system needs to be carefully calibrated (as in Chapter 9.1) if any of the resolver values change. Resolver values change when any - part of the manipulator that affects the calibration position is replaced. The system needs to be coarsely calibrated (as in Chapter 9.2) if the contents of the revolution counter memory are lost. The memory may be lost if: - the battery is discharged. - a resolver error occurs - the signal between the resolver and measurement board is interrupted.
9.1 Adjustment procedure using calibration equipment (fine calibration) The axes are calibrated in numerical order, i.e. 1 - 2 - 3 - 4 - 5 - 6. 1.
Move the robot to the calibration position, corresponding to the calibration marks, as shown in Figure 17.
2.
Calibrate all the axes as described below.
3.
Press the Misc. window key (see Figure 6).
1 2
P1
7
8
9
4 1
5 2 0
6 3
P2 P3
Figure 6 The Misc. window key.
4.
Choose Service from the dialog box that appears on the display.
Product Manual IRB 1400
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Calibration
Repairs
5.
Press Enter
6.
Choose View: Calibration. The window shown in Figure 7 appears. File
.
Edit
View
Com
Service Commutation Mech Unit
Status 1(4)
Robot
Not Calibrated
Figure 7 The window shows whether or not the robot system units are calibrated.
The calibration status can be any of the following: - Synchronized All axes are calibrated and their positions are known. The unit is ready for use. - Not updated Rev. Counter All axes are fine-calibrated but the counter on one (or more) of the axes is NOT updated. That axis or axes must therefore be updated as described in Chapter 9.2. - Not calibrated One (or more) of the axes is NOT fine-calibrated. That axis or axes must therefore be fine-calibrated as described in Chapter 9.1. 7.
If there is more than one unit, select the desired unit in the window in Figure 7. Choose Calib: Calibrate and the window shown in Figure 8 will appear.
. Calibration! Robot To calibrate, include axes and press OK. Axis X X
X X
Status
1 2 3 4 5 6
Incl
Not Fine Calibrated Not Fine Calibrated Fine Calibrated Fine Calibrated Not Fine Calibrated Not Fine Calibrated
All
Cancel
1(6)
OK
Figure 8 The dialog box used to calibrate the manipulator.
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Product Manual IRB 1400
Repairs
Calibration 8.
Press the function key All to select all axes, if all axes are to be calibrated. Otherwise, select the desired axis and press the function key Incl (the selected axis is marked with an x).
9.
Confirm your choice by pressing OK. The window shown in Figure 9 appears. Calibration! Robot - - - - - WARNING - - - - The calibration for all marked axes will be changed. It cannot be undone. OK to continue?
Cancel
OK
Figure 9 The dialog box used to start the calibration.
10. Start the calibration by pressing OK. An alert box is displayed during the calibration. The Status window appears when the fine calibration is complete. The revolution counters are always updated at the same time as the calibration is performed. The robot is now roughly calibrated. 11. Remove the protective plate from the reference surface on the manipulator base. 12. Attach the calibration tool for axis 1 on the guide pin underneath the gearbox, see Figure 10. Tool no. 6808 0011-GR Tool no. 3HAB 1378-1
Guide pin in gearbox
Figure 10
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