IRC5 Basic Operations Revision d_5.pptx

IRC5

1. IRC5 Basic Operations ABB Robotics MYRO Training Centre

2. Regulation and Safety in ABB Malaysia Before entering our factory area, please ensure that you are briefed by your ABB host on the basic safety & health rules All visitors and guests must be accompanied by ABB employees while on a factory tour or testing Please ensure that your Visitor Pass is prominently displayed at all times Safety shoes must be worn at the factory area unless you are in the green zone Use of mobile phone is strictly prohibited when you are engaged in critical tasks such as testing Do not stand or cross underneath the overhead crane while it is in operation Do not smoke within the factory and warehouse area. Smoking is allowed at designated smoking areas only © ABB Robotic May 8, 2017

3. Regulation and Safety in ABB Malaysia For your safety, please do not tamper with any electrical equipment Visitors who are under the influence of drugs or alcohol are advised against entering the company’s premises Do not enter a “live” installation testing area without prior authorization Please ensure that you have been briefed on ABB’s emergency and evacuation plan Please exercise caution at blind corners Always observe and follow the traffic signs Please do not operate any equipment without the authorization ABB personnel Report all incidents, near misses, unsafe acts and unsafe condition to your ABB host © ABB Robotic May 8, 2017

4. Emergency procedure You are here © ABB Robotic May 8, 2017

5. Emergency procedure Upon hearing the first alarm - stop work or discussion Once you hear the second emergency alarm – follow your ABB host to evacuate the building Use the nearest exit Do not run or panic Use the staircase. Do not use the lift during an emergency Proceed to the emergency assembly area At the assembly area, please follow instructions of ABB personnel in-charge All clear signal – please wait for the all clear signal before re-entering the building Please dial 4816 for all emergencies © ABB Robotic May 8, 2017

6. INTRODUCTION ABB Robotics MYRO Training Centre

7. Course Content Section Description 1 Introduction 2 Safety 3 System Description 4 Getting Start 5 Jogging & Coordinate System 6 IO Signal 7 Handling Programming 9 Backup and Restore 10 Event Massage 11 Restarts 12 Calibration © ABB Robotic May 8, 2017

8. BASIC OPERATION Course time : 0900 - 1630 Breaks : Tea/Coffee : 1030 – 1050 Lunch : 1230 – 1330 Tea/Coffee:1500 - 1520 Day 1 Safety System Description General Controller Manipulator Operator’s Panel Teach Pendant Getting Start Starting the System Flex pendant Handling Robot Coordinate System Tool Coordinate System Work Object Coordinate System I/O Signal Day 2 Handling Program Program Data TCP Work object Load and Run Program - Program editing - Modify Position - Routine & data viewing and editing Programming - I/O Instruction - Movement Instruction - Circular movement Day 3 Save program and module Backup Event Message Restart Calibration © ABB Robotic May 8, 2017

9. Course Objectives Practice safety as it pertains to the robot system. Identify and use the Flex Pendant. Run the robot system in manual mode and automatic mode. Interpret and respond to event messages. Load, save, and edit basic programs using the Flex Pendant. Modifying movement instructions in a basic program. Understand the use of input and output instructions in a basic program. Manually manipulate I/O to release and activate tooling. Create and Define a tool center point Upon completion of this course the student will be able to successfully: © ABB Robotic May 8, 2017

10. Course Objectives Use movement instructions in a basic program .. Create routines, and use routine instructions in a basic program .. Understand and update Revolution Counters. Upon completion of this course the student will be able to successfully: © ABB Robotic May 8, 2017

11. SAFETY ABB Robotics MYRO Training Centre

12. © ABB Robotic May 8, 2017 Robot Safety during training course Keep fingers clear of gripper jaws when loading parts Stand clear of robot benches when running programs Test all program modifications in a manual mode first Full speed modes are permitted with instructors assistance Be cautious when releasing brakes When inside the robot cell, make sure you have control of Pendant

13. Safety Solutions – an Overview Pinch Points Lock Outs Emergency stop Operating mode Auto Manual < 250 mm/s Manual 100 % (Option) Enabling device (Dead mans grip) Hold-to-run Safeguard stop (Auto and Manual) Limiting the workspace Enabling device Hold-to-run buttons (for left or right hand)

14. Pinch Point © ABB Robotic May 8, 2017 Evaluate the machine and its movement to identify and avoid pinch points Pinch points are any areas where you can get caught between the moving parts of a robot and stationary object . Physical guards create a barrier to prevent you from getting trapped or injured in pinch point

15. LOCK OUT/TAG OUT © ABB Robotic May 8, 2017 Proper Lock Out /Tag Out practices and procedures safeguard yourself and other from release hazardous energy. To lock out turn the key switch to Manual Mode , then turn the rotary disconnect to the Off position . Open the locking mechanism on the disconnect & place your lock or a multiple “gang lock” device on the disconnect.

16. LOCK OUT /TAG OUT (LOTO) OBJECTIVE Preventing the unexpected start up or release of stored energy from equipment during maintenance and repairs to protect employees from injury To prevent equipment from unexpectedly being set in motion and endangering workers. Potential hazardous energy sources must be identified ,isolated and locked and tagged out before starting a service/ maintenance tasks © ABB Robotic May 8, 2017

17. Emergency Stop Pressing an Emergency Stop button will stop the robot motion immediately. Built-in emergency stop push buttons are found both on the FlexPendant and Control module. Additional emergency stops can be connected to the robot system’s safety chain. Recover by rotating pushbutton to reset and pressing the Motors On button. © ABB Robotic May 8, 2017

18. Operating Mode Automatic mode Production mode (no speed limit) Manual mode < 250 mm/s – max velocity 250 mm/s 100 % – Option, robot can be jogged/tested with no speed limit.

19. © ABB Robotic May 8, 2017 Manual Full Speed (Optional) Press and Hold down the play key, to run the program Press and Hold down the FWD or BWD key to step Releasing the pressed key to stops execution 1 2

20. © ABB Robotic May 8, 2017 Enabling Device (Dead Mans Grip) The enabling device is a press switch with three positions The switch must be in the middle position in order to activate the motors All robot movement will immediately stop if the switch is released or pressed to the bottom Enabling device

21. © ABB Robotic May 8, 2017 Safeguard Stops Your robot system can be equipped with a vast range of safeguards such as door interlocks, safety light curtains, laser scanners and pressure mats etc. A safeguard prevents hazardous situations by stopping the manipulator in a controlled manner when a mechanism such as a light curtain is activated The controller has three separate safeguarding mechanisms, General stop (GS) Always active regardless of operating mode Automatic stop (AS) Only active in auto mode Superior stop (SS). Always active regardless of operating mode

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

23. Working range of robot axis All Axis are software controlled to limit their rotational range The software stop should prevent collision at the end of axis rotational travel Axis 1–3 can on larger robots, can be fitted with adjustable mechanical stops Training robots axis are set to the default maximum range © ABB Robotic May 8, 2017

24. Electrical Safety A danger of high voltage is associated with, for example, the following parts: Be aware of stored electrical energy (DC link, Ultra capacitor bank unit) in the controller. Units such as I/O modules, can be supplied with power from an external source . The mains supply/mains switch The transformers The power unit The control power supply (230 VAC) The drive system power supply (230 VAC) The service outlets (115/230 VAC) The customer power supply (230 VAC) The power supply for the motors (up to 800 VDC ). The external voltage connected to the controller remains live even when the robot is disconnected from the mains. © ABB Robotic May 8, 2017

25. © ABB Robotic May 8, 2017 Brakes Release The brakes on the robot motors can be manually released Make sure the weight of the robot axis and tooling are supported Brakes are reapplied when button is released IRC5C controller brake release button

26. © ABB Robotic May 8, 2017 Safety Regarding Grip Device All grip devices must be designed so the work piece will be held even on power failure and other disturbances in the robot system There should be possibilities to loosen the work piece manually Familiarize yourself with operational buttons assigned to the gripper function

27. Personal Safety Principles should be followed in order to operate the robot system safely : Always operate the robot system in manual mode if personnel are inside safeguarded space. Always bring the Flex Pendant along when you enter safeguarded space so that robot control is in your hands . Watch out for rotating or moving tools such as milling cutters and saws. Make sure those are stopped before you approach the robot. Watch out for hot surfaces both on work pieces as well as on the robot system . The robot's motors can become fairly hot if run for a long time. Watch out for grippers and objects gripped. If the gripper is opened the work piece could fall and cause injuries or damage equipment. The gripper can be very powerful and can also cause injuries if not operated in a safe manner. Watch out for hydraulic and pneumatic systems and live electric parts. Even with power off residual energy in such circuits can be very dangerous. © ABB Robotic May 8, 2017

28. Accident Risks Fault tracing Repair Change of program Test run

29. Accident Risks Fault tracing Fault tracing and repair procedure go hand in hand .you are at your vulnerable when you’re fixing a robot. Never rush through the steps and try to work around the safety procedures .

30. Accident Risks Change Program A program change may mean what was safe space yesterday isn’t a safe space today Be sure you are following procedure and clear communicating information about any program changes

31. Accident Risks Change Program Anytime you change a program, make sure you perform a test run Check to make sure the robot moves the way you intended without any programming mistakes . Accidentally forgetting a clearance position in the robot’s program may cause someone serious harm and injury.  

32. SYSTEM DESCRIPTION ABB Robotics MYRO Training Centre

33. Robot System Manipulator IRB6700 Controller IRC5 Programming Unit FlexPendant © ABB Robotic May 8, 2017

34. Controller IRC5 - Single cabinet © ABB Robotic May 8, 2017 Main Switch E-Stop Motor on Button Selector Key Switch Ethernet Port Hour Meter

35. Controller IRC5 - Compact © ABB Robotic May 8, 2017 Main Switch Emergency Stop Button Motors on Selector Key Switch Brake Release Button

36. IRC5 Compact ( Controller Overview ) Main Power Connector Manipulator Connectors Operator´s Panel Digital I/O Safety Presently not used FlexPendant connector Brake Release (IRB120 only) Main Computer front with CF memory, ports and PCI slots DeviceNet TM Lean For external I/O units Customer 24 V Presently not used Main Switch

37. IRC5 Single Cabinet ( Controller Overview ) Main Computer Unit Field bus adapter: Ethernet I/P TM PROFIBUS DP PROFINET IO Compact Flash mass memory I/O units or PLC Main Drive Unit Additional Drive Unit Front connectors behind cove r UltraCap Main Computer Panel Unit Power Supply Axis Computer Hot Plug (option )

38. © ABB Robotic May 8, 2017 Example of Industrial Robot– IRB 6700 Large robot- 6 Axis

39. © ABB Robotic May 8, 2017 Example of Industrial Robot– IRB 140 Small Robot -6 Axis

40. © ABB Robotic May 8, 2017 Example of Industrial Robot– IRB 460 4 Axis Robot

41. © ABB Robotic May 8, 2017 Example of Industrial Robot– IRB 360 Parallel Robot- 4 Axis

42. Product Range ABB Robotics MYRO Training Centre

43. The ABB robot family Reach up to 3.5m Payload up to 630kg © ABB Robotic May 8, 2017

44. Small robot family Payload 3kg to 10kg IRB 120 & 120T 3kg 0.58m 7kg 0.7m IRB 1200 5kg 0.9m IRB 1200 IRB 140 & 140T 6kg 0.81m IRB 1600 6kg &10kg 1.2m IRB 1600 6kg &10kg 1.45m IRB 1600ID 4kg 1.5m IRB 1520ID 4kg 1.5m © ABB Robotic May 8, 2017

45. Medium robot family Payload 8kg to 60kg IRB 2600ID IRB 2600ID 8kg 2.0m 15kg 1.85m IRB 2400 IRB 2600 IRB 2600 12kg 1.85m 12kg & 20kg 1.65m 12kg & 20kg 1.55m © ABB Robotic May 8, 2017

46. Medium robot family Payload 8kg to 60kg IRB 4400 IRB 4600 IRB 4600 IRB 4600 20kg 2.5m 60kg 1.96m 45kg & 60kg 2.05m 40kg 2.55m © ABB Robotic May 8, 2017

47. Large robot family Payload 90kg to 650kg IRB 6640 185kg 2.8m IRB 6640 205kg 2.75m IRB 6640 235kg 2.55m IRB 6640 130kg 3.2m IRB 6640ID 200kg 2.55m 180kg 2.55m IRB 6640 IRB 6640ID 170kg 2.75m © ABB Robotic May 8, 2017

48. Large robot family Payload 90kg to 630kg IRB 6660 Pre-machining IRB 6620 IRB 6660 Press Tending IRB 6650S IRB 6620LX 205kg 1.9m 130kg 3.1m 150kg 2.2m 90kg & 200kg 3.0m & 3.9m 150kg 1.9m © ABB Robotic May 8, 2017

49. The IRB 6700 Large Robot Family IRB 6700 175kg 3.05m 300kg 2.7m IRB 6700 240kg 3.00m IRB 6700 IRB 6700 150kg 3.2m IRB 6700 155kg 2.8m 200kg 2.6m IRB 6700 IRB 6700 205kg 2.8m IRB 6700 235kg 2.65m © ABB Robotic May 8, 2017

50. Large robot family Payload 90kg to 630kg 400kg 2.55m 340kg 2.8m 500kg* 2.55m IRB 7600 325kg 3.1m 150kg 3.5m IRB 7600 * 630kg capacity with wrist down IRB 7600 IRB 7600 IRB 7600 © ABB Robotic May 8, 2017

51. High speed pickers Palletizers Top loader and packer Dedicated 4 axis robot family Overview - picking, packing, palletizing Serving fully integrated packing lines © ABB Robotic May 8, 2017

52. Dedicated 4 axis FlexPicker family High speed pickers from 1kg to 8kg Stainless steel option Protection to IP55/67/IP69K Clean Room ISO Class 5-7 Wash Down 3kg 1,130mm 1kg 800mm 1kg 1,130mm 1kg 1,600mm 8kg 1,130mm 6kg 1,130mm © ABB Robotic May 8, 2017

53. Dedicated 4 axis robot family Top Loaders & Palletizers IRB 260 IRB 660 IRB 660 IRB 460 IRB 760 + Grippers 30kg 1.5m 110kg 2.4m 450kg 3.18m 180kg 3.15m 250kg 3.15m © ABB Robotic May 8, 2017

54. Compact version Panel mount version Robot control family Overview Multi-robot control, up to 36 axis, with MultiMove Programmable user interface with intuitive joystick control via FlexPendant World leading motion control with TrueMove and QuickMove “Next generation safety” with SafeMove Powerful connectivity through network interfaces Remote Service option Modular version © ABB Robotic May 8, 2017

55. Paint robot family With dedicated controller IRB 52 IRB 580 IRB 5400 IRB 5400 with Rail IRC5P All ABB paint robots, paint controllers and paint programming units are explosion protected. See data sheets for more information IRB 5500 13kg 3.0m & 5.8m 7kg 1.22m & 1.45m 10kg 2.2m & 2.6m 25kg 3.1m Paint Controller 25kg up to 20m © ABB Robotic May 8, 2017

56. Robot process and application equipment Fully integrated with your robot Dress Packs Painting Track Motions Process Cabinets Arc Welding Spot Welding © ABB Robotic May 8, 2017

57. Robot process and application equipment Fully integrated with your robot © ABB Robotic May 8, 2017 RTT tracks for small robots. IRBT 4004, 6004, 7004 tracks for large robots. IRT tracks for other objects.

58. Robot process and application equipment Fully integrated with your robot Motors Positioners Grippers Press tending tools Gearboxes Additional axis © ABB Robotic May 8, 2017

59. Robot process and application equipment Fully integrated with your robot L type positioner (5 sizes) C type positioner (2 sizes) R type positioner (3 sizes) K type positioner (3 sizes) A type positioner (3 sizes) B type positioner (3 sizes) D type positioner (2 sizes) © ABB Robotic May 8, 2017

60. Robot process and application equipment Fully integrated with your robot FlexLifter (3 models) FlexPLP (3 models) © ABB Robotic May 8, 2017

61. Robot process and application equipment Fully integrated with your robot Force control Vision Dispensing Dusting Press synchronization Door openers © ABB Robotic May 8, 2017

62. Getting Start ABB Robotics MYRO Training Centre

63. Starting the System Before switch ON the system, make sure that there is no one inside the safeguarded space around the robot. Switch ON the mains switch. The robot is then will automatically checked. Mains Switch OFF ON © ABB Robotic May 8, 2017

64. Starting the System Switch ON the Main Switch at the controller to power ON the system . MAIN SWITCH © ABB Robotic May 8, 2017

65. Starting the System (Welcome Screen) After the system has been checked and no errors are located, the welcome message appears on the display. Welcome Screen © ABB Robotic May 8, 2017

66. © ABB Robotic May 8, 2017 FlexPendant Overview Status bar User defined keys Windows button Program execution keys E-Stop 3D Joystick Enabling device USB port Quickset menu Jogging keys

67. IRC5 – FlexPendant Main Menu © ABB Robotic May 8, 2017

68. © ABB Robotic May 8, 2017 QuickSet menu overview With the QuickSet menu you can access some often used settings Mechanical unit jogging mode (Not allowed in Auto) Incremental jogging (Not allowed in Auto) Running Mode Cycle or Continuous Step Mode (In, Out, Over, Next move) Override Speed (+/- 1%, 5%, 25%, 50%, 100%) Tasks (task activation / deactivation)

69. Mechanical Unit : A feature that allows the handler to choose between the robot and the motion modes for the robot and external axis, this is also where you can choose the coordinates and active tool, and active work object. When multiple Robots are on a system, the Blue Box indicates the current selection. Quickset Menu Description © ABB Robotic May 8, 2017

70. Show/Hide Details: By Tapping on the Show Details button, your current selections can be viewed. The button will change back to Hide Details if hit again allowing you to minimize that screen. The selected Coordinate system, and Motion Mode setting is displayed when Show Details is pressed. Tap on one of the other selections to change that property. Quickset Menu Description © ABB Robotic May 8, 2017

71. Increment: Use incremental movement to jog the robot in small steps, which enables very precise positioning. Each time the joystick is deflected, the robot moves one step(increment). If the joystick is deflected for one or more seconds, a sequence of steps, (at a rate of 10 steps per second), will be performed as long as the joystick is deflected. Default mode is no increment, then the robot move continuously when the joystick is deflected. Quickset Menu Description © ABB Robotic May 8, 2017

72. Run Mode: By setting run mode you define if the program execution should run once and then stop, or run continuously Single Cycle: Runs one cycle then stops execution. Continuous: Runs continuously.. Quickset Menu Description © ABB Robotic May 8, 2017

73. Step Mode: Selecting the different Step Mode features allows you to define how the Step-by-Step program execution will function. Step Into: Steps into called routines and executes them step-by-step. Step Out: Executes the remains of the current routine and then stops at the next instruction in the routine from which the current routine was called. Step Over: Called routines are executed in one single step. Next Move: Steps to the next move instruction. Stops before and after movement instructions, for example to modify positions. Quickset Menu Description © ABB Robotic May 8, 2017

74. Speed: The Speed settings apply to the current Operating Mode. But, if you decrease the speed in Automatic Mode, the setting also applies to Manual mode if you change back to that mode. The current running Speed, in relation to Max, is displayed above the buttons. -1% & +1%: Decrease & Increase running speed in steps of 1%. -5% & +5%: Decrease & Increase running speed in steps of 5%. 25%: Run at quarter speed (25%). 50%: Run at half speed (50%). 100%: Run at full speed (100%). Quickset Menu Description © ABB Robotic May 8, 2017

75. Tasks: If you have the option Multitasking installed there can be more than one Task. Otherwise there is only one Task. By default, only normal Tasks are possible to activate/deactivate in the Quickset menu. Using the Control Panel you can however change the settings so all Tasks are possible to activate & deactivate. Activated tasks are started and stopped with the Start and Stop buttons on the FlexPendant. The green checkmark indicates which Task is selected. Quickset Menu Description © ABB Robotic May 8, 2017

76. © ABB Robotic May 8, 2017 Exercise

77. Exercise Go to your assigned robots and practice jogging the robot using the Quick Set button and the joystick. What happens when you press the top center box on the Flex Pendant? Look at the Event Log. What was the last event that occurred? Challenge : Find and Change the FlexPendant display Brightness and contrast. Challenge : Find and Change the FlexPendant for either Right or Left handed users. Practice pressing buttons on the FlexPendant. If you have any questions ask the instructor. © ABB Robotic May 8, 2017

78. Jogging and Coordinate System ABB Robotics MYRO Training Centre

79. © ABB Robotic May 8, 2017 Jogging the robot

80. Jogging the robot Basic Setting for jogging Select Mechanical Unit Select Motion Mode Select Coordinate System Select Tool Select Work Object © ABB Robotic May 8, 2017

81. © ABB Robotic May 8, 2017 6 Axis Robot Axis 2 Axis 3 Axis 4 Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 +

82. © ABB Robotic May 8, 2017 4 Axis Robot (FlexPalletiser) A = Axis 1 B = Axis 2 C = Axis 3 D = Axis 6 A B C D +

83. © ABB Robotic May 8, 2017 3 / 4 Axis Robot (FlexPicker) 1 3 2 Y X 4 Z Base coordinate system

84. © ABB Robotic May 8, 2017 Jogging 6 axis robot 1 2

85. © ABB Robotic May 8, 2017 Jogging along Coordinate axis 1 2

86. © ABB Robotic May 8, 2017 Jogging Motion Keys Mechanical unit activation switch Linear / Reorient Group 1 / Group 2 Axis Activate / deactivate incremental jogging

87. © ABB Robotic May 8, 2017 Jogging External Axis Track

88. © ABB Robotic May 8, 2017 Jogging External Axis Positioner

89. © ABB Robotic May 8, 2017 Incremental Jogging Greater jogging control Small = 0.05mm Medium = 1mm Large 5mm User from 0 to 5mm Show values to edit User 2 1 3

90. © ABB Robotic May 8, 2017 Jogging collisions Disabling Jog supervision allows robot to be jogged after collision ‘Collision Detection’ Software option (613-1), required Path supervision is not effected only jog supervision Try before releasing brakes Disabled

91. © ABB Robotic May 8, 2017 Jogging Override Speed Used when the default 100% value feels to sensitive Value can be set to a percentage of the default jog speed Reduce percentage will be slower and less sensitive Jog speed is still proportional to joystick deflection

92. © ABB Robotic May 8, 2017 The Jogging Window

93. © ABB Robotic May 8, 2017 Jogging the Robot -Y +Y -X -Z +Z +X +X +Y +Z -Y +Y -X -Z +Z +X X Z Y -2 -1 +1 +2 -3 +3 +1 -1 +2 -2 +3 -3 -4 +4 -5 +5 -6 +6 -4 +4 +5 -5 +6 -6

94. © ABB Robotic May 8, 2017 Z X Y WorkObject Coordinate Coordinate System Base Coordinate Z Y X Tool Coordinate World) Z Y X Z Y X

95. © ABB Robotic May 8, 2017 Right Hand Rule The Right Hand Rule applies to all coordinate systems

96. © ABB Robotic May 8, 2017 Exercise Jogging the Robot Arm

97. © ABB Robotic May 8, 2017 Position the robot joints Major Axis Minor Axis Increments where required Position the tool using Linear relative to: World / Base coordinates Tool coordinates Work object coordinates Increments where required Position the tool using Orientation relative to: Tool / Base and Work object coordinates Practice Tool Alignment Jogging demonstration

98. Handling inputs and outputs, I/O ABB Robotics MYRO Training Centre

99. © ABB Robotic May 8, 2017 IRC5 – Flex Pendant (I/O Output) Inputs and Outputs Window I/O signal properties is used to view the input and output signals and their names, values and type Signals are configured with system parameters

100. © ABB Robotic May 8, 2017 IRC5 – Flex Pendant (I/O Output) I/O Unit status is recognized by the system ( Board ) Individual input/output signal characteristics can retrieval and manipulate. Manual operation is only allowable force for the individual signals. The output signal operation Off (value 0) and On (value 1) Input Signal Operation: First, press simulation, it can be operated via the same method.

101. © ABB Robotic May 8, 2017 IRC5 – Flex Pendant (I/O Output) Most Common I/O Signal type and relationship of critical signals it can be grouped into a separate group.

102. IRC5 – Flex Pendant (I/O Output) © ABB Robotic May 8, 2017 Viewing signal Tap Menu Tap Inputs and Outputs Tap View. Select signal type

103. Define and Using a Tool ABB Robotics MYRO Training Centre

104. © ABB Robotic May 8, 2017 Tool Centre Points (TCP) +X +Y +Z Wrist Coordinate system Tool Coordinate system

105. © ABB Robotic May 8, 2017 Tool Centre Point theory The position & movement of the robot is always relative to the active TCP. TCP’s are defined as being somewhere at the end of the tool. Many TCP’s may be defined, but only one active at any one time. Can be programmed manually but only if accurate TCP values are known. Normally the robot is used to define its TCP. If tool is damaged or replaced, don’t modify program positions, just redefine the tool.

106. © ABB Robotic May 8, 2017 Default Orientation (same direction as Wrist coordinate system) TCP & Z Just Z direction defined (X stays in same plane as wrist) TCP & Z, X both Z and X defined From 3 to 9 approach points Tool Centre Point Definition Methods

107. © ABB Robotic May 8, 2017 Example of TCP with default orient No rotational difference from the wrist coordinate system

108. © ABB Robotic May 8, 2017 Example of TCP with Z direction defined The TCP’s X&Z are in the same plane as the wrist

109. © ABB Robotic May 8, 2017 Example of TCP with Z&X directions defined The TCP’s X&Z directions are rotated differently to the wrist

110. © ABB Robotic May 8, 2017 1 2 3 4 1 2 3 Plan view 4 TCP Definition – Default Orient

111. © ABB Robotic May 8, 2017 1 3 6 5 4 Jog robot so the tool’s intended Z and X directions, visually align to the base coordinate’s Z and X axis. Jog along Base coordinate Z Axis to define tools Z direction Jog along Base coordinate X Axis to define tools X direction Z Elongator point 2 Tool orientations are defined by the direction the tool is positioned away from the datum point. X Elongator point TCP Definition – Z & X

112. © ABB Robotic May 8, 2017 Tool Centre Point Definition Method Menu Program data Select tooldata Show data New… Name tool Initial value or OK and then select tool in list and Edit Value Mass:= type in kg and Centre of Gravity Press OK Press Edit Select Define Select Method and number of Points Select Point 1, jog robot to calibration position and press Modify Position Repeat for remaining points Press OK You will need to activate your TCP in the jog window

113. © ABB Robotic May 8, 2017 Exercise Create a Tool Centre Point Exercise 2

114. Handling Program ABB Robotics MYRO Training Centre

115. © ABB Robotic May 8, 2017 Programming Introduction Load an existing program Introduction to basic move instructions and data Programming move instructions Modifying Instructions and data Save a program Rename a program Delete a program

116. © ABB Robotic May 8, 2017 Program Modules.mod Program Data Main Routine Routines <?xml version="1.0" encoding="ISO-8859-1" ?> <Program> <Module>MainModule.mod</Module> <Module>ModuleA.mod</Module> <Module>ModuleB.mod</Module> </Program> Program Data Routines Program Data Routines System Modules.sys Program Task Structure

117. Rapid Program © ABB Robotic May 8, 2017 A program is the list of command that tells robot what to do Programming language: RAPID (Robotics Application Programming Interactive Dialogue) - 4th generation language. RobotWare is written in C language, 3rd generation language. Program = data + Instruction/commands (Instruction/commands are handled in units of routines) A program operates in conjunction with a program module and a system module, and there is only one program in the program memory. (Extension: *. pgf )

118. © ABB Robotic May 8, 2017 Internal Structure of Module

119. © ABB Robotic May 8, 2017 Modules A module contains routines and data’s. The module that contains the main routine is the MainModule System modules are always present in memory and can be used to save your default data Filename extensions are XXXXX.mod Program Module XXXXX.sys System Module XXXXX.pgf Program File

120. © ABB Robotic May 8, 2017 Routines Repetitive instruction sequences, that occur frequently in the program, should form their own routines. Routines separate the program into smaller more easily understood parts, these can then be called anywhere in the program using the ProcCall instruction. A Max of 16 characters are allowed for naming routines, meaningful names will make the program easier to follow and operate. Routines can be tested by moving the Program Pointer to a routine. (Debug) Routines are called within the program using the instruction ‘Procall’

121. © ABB Robotic May 8, 2017 Routines and program flow example The Main Procedure controls the flow of the entire program Sub Procedure routines do the jobs The ProCall Instruction is used to program the call of the routines

122. © ABB Robotic May 8, 2017 Instructions An instruction defines a specific task that is to be carried out when instruction is executed, for example Moving the robot Setting an output Changing data Jumping within the program Instructions comprise an instruction name and a number of arguments. The name specifies the principal task of the instruction and the arguments specify the characteristics Example: MoveL p1,v500,fine,tool1 Moves the TCP linearly to the position p1 . The arguments, v500, fine and tool1 , specify the current speed, position accuracy and tool.

123. © ABB Robotic May 8, 2017 Introduction to Joint & Linear Motion Move L Move J

124. MoveJ is used to move the robot quickly from point to point The movement will not be in a straight line. © ABB Robotic May 8, 2017 Positional Movements Instructions (Common Picklist) Robtarget Speed Zone Tool

125. © ABB Robotic May 8, 2017 Positional Movements Instructions (Common Picklist) MoveL moves the TCP in a Linear direction or straight line. Robtarget Speed Zone Tool

126. Zones © ABB Robotic May 8, 2017 z MoveL p40 , v1000 , z50 , tool0; MoveL p30 , v400 , z20 , tool0; Zone data describes how close to the destination position the axes must be before the next instruction can be executed Zone size

127. © ABB Robotic May 8, 2017 Moving Circular MoveC - moves the TCP in a Circular direction using the mid & end point of a semicircle MoveL *, v100, fine, tPen \ WObj :=wobj1; MoveC * , * , v100, z10, tPen \ WObj :=wobj1; mid end

128. © ABB Robotic May 8, 2017 Programming MoveC p1 p2 p3 p4 ModPos End target here Pick MoveC here MoveL p1 , v100, fine, tPen \WObj:=wobj1; MoveC p2 , p3 , v100, z1, tPen \WObj:=wobj1; MoveC p4 , p1 , v100, fine, tPen \WObj:=wobj1;

129. Input Instruction © ABB Robotic May 8, 2017 Input processing instructions are to wait until you are satisfied the specified conditions. Conditions can be such signal conditions, the time, the logical operation. WaitDI di05_AutoReady, 1 ; WaitTime 0.5 ; WaitUntil di06_Ready = 1 ; WaitUntil di05=1 AND di07=0 ; WaitUntil di02=1 OR di03=1... ; Signal state Signal Name

130. Set do03_Clamp; Reset do03_Clamp; Signal t 1 Signal t 1 0.2s 1.0s PulseDO \ PLength := 0.2 , do12; PulseDO \ PLength := 1.0 , do12; SetDO \ SDelay := 1.5 , do04, 1; SetDO do04, low; Output Instruction Signal t 1 1.5s © ABB Robotic May 8, 2017

131. I/O Timing DT is a time dependant on processor load. p10 © ABB Robotic May 8, 2017

132. I/O Timing P20 p10 © ABB Robotic May 8, 2017

133. © ABB Robotic May 8, 2017 Creating New programs New Programs can be created in the Program Editor Program names can not start with a number If a program allready exists, it will be overwritten New programs are temporaraly called ’NewProgramName’ A ‘main’ routine is created within a ‘MainModule’

134. Loading Programs Loading whole programs will overwrite existing programs Each task will have its own program © ABB Robotic May 8, 2017

135. Loading Modules Loading Program and System modules from the Program Editor © ABB Robotic May 8, 2017

136. Creating a new Module ABB menu Tap Program Editor . Tap Modules . Tap File , then tap New Module . Tap ABC... and use the soft keyboard to enter the new module's name. Then tap OK Select which type of module to be created: • Program • System Then tap OK . © ABB Robotic May 8, 2017

137. Creating a new Module © ABB Robotic May 8, 2017

138. How to create and program routines. Must be in the Program Editor. Tap Routines : File New Routine : Tap “ABC…” to change the name. Tap OK. Select the routine. Tap Show routine . Creating Routines © ABB Robotic May 8, 2017

139. To add instructions to your program: Tap Add Instruction Jog robot into position Tap MoveJ or MoveL Jog robot to next position Repeat Inserting Move Instructions © ABB Robotic May 8, 2017

140. Exercise Programming movements Exercise 1 © ABB Robotic May 8, 2017

141. Select the instruction or target to be changed (Step is recommended) Jog robot to the desired position Press Modify Position Modify Position © ABB Robotic May 8, 2017

142. Changing a Program Select item to change by double Tapping. Then choose new value and press OK. © ABB Robotic May 8, 2017

143. Program Edit © ABB Robotic May 8, 2017

144. Debug Program Pointer (PP) © ABB Robotic May 8, 2017

145. Exercise Programming with Routines Exercise 5 © ABB Robotic May 8, 2017

146. Create a new routine called PickPen Activate your TCP Program the robot to pick up the pen Test this routine (debug ‘PP to routine’) Copy this routine and edit the output instruction to put the pen down Test the duplicated routine (debug ‘PP to routine’) Call these routines within your main routine (ProCall instruction) Test your Main Routine (debug ‘PP to main’) Save your program as ‘Exercise_3’ Routines Exercise © ABB Robotic May 8, 2017

147. Start / Finish Direction Start / Finish Start / Finish Path Following Exercise Path Following Exercise © ABB Robotic May 8, 2017

148. Running Program ABB Robotics MYRO Training Centre

149. Running Programs in Manual Mode Procedure Step Action Info/Illustration 1 Switch the robot to Manual Mode. 2 DANGER! Before running the robot, please observe the safety information in section DANGER – moving manipulators are potentially lethal! © ABB Robotic May 8, 2017

150. Running Programs in Manual Mode Procedure Step Action Info/Illustration 3 Press Enable Device. 4 Press the Start button on the Flex Pendant. Run / Start Program Execute Backward/Forward Stop program © ABB Robotic May 8, 2017

151. Starting Execution Procedure Step Action Info/Illustration 1 To run a selected execution use the “Run" button on the Flex Pendant's hardware button key set. Run / Start Program Execute Backward/Forward Stop program © ABB Robotic May 8, 2017

152. Stepping Instruction by Instruction In Manual Mode, the program may be executed step-by-step forwards or backwards There are number of dedicated hardware buttons on the FlexPendant Programmable button 1. How to define it's function is in the IRC5 Pocket Guide. Programmable button 2. How to define it's function is in the IRC5 Pocket Guide. Programmable button 3. How to define it's function is in the IRC5 Pocket Guide. Programmable button 4. How to define it's function is in the IRC5 Pocket Guide. RUN button. Starts program execution. STEP BACKWARDS button. Steps the program one instruction backwards. STEP FORWARDS button. Steps the program one instruction forwards. STOP button. Stops the program execution. © ABB Robotic May 8, 2017

153. Stepping Instruction by Instruction (2) Select stepping mode Step Action Info/Illustration 1 Selection of step mode. Stepping forward Step Action Info/Illustration 1 Press the FWD button on the FlexPendant as shown in the illustration on earlier page. Stepping backward Step Action Info/Illustration 1 Press the BWD button on the FlexPendant as shown in the illustration on earlier page. © ABB Robotic May 8, 2017

154. Stopping Execution Procedure Step Action Info/Illustration 1 During operation with hold-to-run control: Release the hold-to-run button. 2 During operation without hold-to-run control: Press the STOP button on the FlexPendant unit. 3 When running in step-by-step mode, the robot will stop after executing each instruction. Execute next instruction by pressing FWD or BWD again. © ABB Robotic May 8, 2017

155. Saving Program ABB Robotics MYRO Training Centre

156. Saving program in IRC5 A folder with the same name as the program is created This folder contains the MainModule, Sub modules and the program file The program file (.pgf),is an extensible mark-up language, ‘XML’, file that lists all program modules in the task System Modules are NOT saved © ABB Robotic May 8, 2017

157. Saving Program Robot Task MainModule.mod System Modules.sys Program File.pgf Program Data Routines Program Data Main Routine Routines © ABB Robotic May 8, 2017

158. Saving Individual Modules Individual, Program or System modules can be saved Select in ‘Program Editor’ and ‘Save Module As…’ from File menu © ABB Robotic May 8, 2017

159. Program Data Routines Saving Module Robot Task System Modules.sys Program File.pgf Program Data Routines Program Data Main Routine Routines MainModule.mod Module1.mod © ABB Robotic May 8, 2017

160. Exercise Go to your assigned robots and create a simple program as described in this section. Then test your program. Each student should make their own program. (Do not use I/O until all participants have created and tested their programs.) What happens when you press the E-Stop button while the robot is running? Can you restart the robot from where it stopped? Save the program to the Flash Drive. Practice pressing buttons on the FlexPendant. If you have any questions ask the instructor. © ABB Robotic May 8, 2017

161. Backup and Restore ABB Robotics MYRO Training Centre

162. Backup Having a valid backup is necessary for fast recovery: If the system behaves differently. (Other than normal) After software upgrades or reinstallation. What does a backup contain? All of the files/folders stored under Home directory in your system on your flash drive. The system parameters ( e.g naming of I/O signals) All current programs, modules, and tasks currently in memory. A backup contains the info that allows your system to go back to behave as it did when the backup was taken. © ABB Robotic May 8, 2017

163. Backup Structure TASKS Copy of Systems ‘home’ folder © ABB Robotic May 8, 2017

164. Backup and Restore – Backup the System ABB recommends performing a backup: Before installing new Robot Ware Before making any major changes to instructions and/or parameters to facilitate the previous setting After making any changes to instructions and/or parameters and testing the new settings to retain the new settings Remarks: Always Give your backup a good name. Push to go to the key board to type the name of the backup. Pay attention to the Backup Path, this is the location where the backup will be stored. Push the … to change the location. You should create a Backup folder to store the file in. © ABB Robotic May 8, 2017

165. Backup Perform Backup © ABB Robotic May 8, 2017

166. Exercise 6 Backup and Restore System Backup and Restore Exercise © ABB Robotic May 8, 2017

167. Even Messages ABB Robotics MYRO Training Centre

168. Event Messages are divided into. Information Example: Hold to run must be pressed. Information is stored in the log. Warning Example : Manual movement full speed is selected. The operator is informed about a potential risk. Error Example : Motor On when Emergency Stop is active. The system cannot operate before a measure is carried out. Introduction © ABB Robotic May 8, 2017

169. Information Example: Information at program start:

170. Warning Example: When the computer detects a situation that can cause a problem or is a safety risk

171. Error Message Example: When the computer detects a problem or possible problem, it generates an error message with description and action. Unacknowledged message is displayed in red on the status bar Unacknowledged message displayed

172. Event Message Content An Event Message consists of Description Consequences (optional) Probable causes (optional) Action (optional) Tap arrow to scroll down in message! © ABB Robotic May 8, 2017

173. Reading Event Logs on the FlexPendant Via ABB - Main menu Tap status bar – Short cut Tap on Status Bar to see Event log. Or Tap ABB then Event Log to see Event log.

174. Event Log Code Title Time stamp Symbol © ABB Robotic May 8, 2017

175. Scroll the list with the yellow arrows Tap on a specific message to get more information Event Log © ABB Robotic May 8, 2017

176. Event Log Logs are stored under different topics Tap view and select the topic of interest Topic common consist of a mixture of the last created logs Log Messages Common 150 All others 20

177. Event Categories Category Error number Area__________________ Operational 10xxx Operational Status System 20xxx Panel unit Hardware 30xxx Board Failure Program 40xxx Programming Motion 50xxx Movement problem Operation 60xxx Flex Pendant Handling I/O communication 70xxx I/O board communication errors ArcWeld 11xxxx Process SpotWeld 12xxxx Process Paint 13xxxx Process Refer to the error number when support is needed! © ABB Robotic May 8, 2017

178. Restarts ABB Robotics MYRO Training Centre

179. Restart In ABB/Main menu select restart

180. Restart Advanced Menu If another restart than Warm Start is required Tap Advanced © ABB Robotic May 8, 2017

181. Restart (Warm Start) When: New hardware, SYSFAIL or change in configuration Result: Current system is restarted. Program pointer are restored Reset System (I- start) When: Add RobWare for a new process All saved, Restart with default parameters. Modules & program not loaded Reset Rapid (P-Start) When: E.g. Changing data in parallel tasks All data saved on image file for loading purpose RAPID programs not reloaded Summary of Restart Alternatives © ABB Robotic May 8, 2017

182. Summary of Restart Alternatives Start Boot Application (E-start) When: Change to an existing system: E.g: Glue to Arcweld All data are saved on an image file, for loading purpose only C-Start (Cold start) Removes all user inputs and the robot software When: E.g: A new BaseWare for a system shall be loaded All data is erased. A boot is necessary if no other system exists in the controller © ABB Robotic May 8, 2017

183. Special Restart Alternatives Shutdown When: The UPS system is not working An image file is carried out as a normal Power Off To start: Turn Power Off & On to restart the system Revert to last Auto Saved (B-Start) When: E.g. Recommend action from an error message Returns the system to the state after the most recent shutdown by either Power Off or Shutdown In this case no saving is carried out as for Warm Start Note! These alternatives are intended for special use only! © ABB Robotic May 8, 2017

184. Calibration ABB Robotics MYRO Training Centre

185. Fine Calibrate or Rev.Count update? Rev.Count update can easily be made with no special tools. Fine calibration needs special tools. Calibration – IRC5 © ABB Robotic May 8, 2017

186. Rev.Counter Tells how many turns the motor has rotated in the gearbox. If value is lost the robot cannot run any programs. A message notifies that the Rev.Counters need to be updated. (e.g. If battery in SMB is drained) Rev. Counters If Event message The system informs about difference: Update so that the robot and the controller have the same calibration values © ABB Inc.-184 © ABB Robotic May 8, 2017

187. Updating Rev. Counters 1. Use the Joy stick and Move the Robot to the Calibration Position and align the witness marks. © ABB Robotic May 8, 2017

188. Synchronization Marks IRB120 A: Axis1, B: Axis2, C: Axis3, D: Axis4, E: Axis5, F: Axis6

189. Synchronization Marks IRB2400, 4400

190. Synchronization Marks IRB2600, 4600 A: Axis1, B: Axis2, C: Axis3, D: Axis4, E: Axis5, F: Axis6

191. Synchronization Marks IRB6640 A: Axis1, B: Axis2, C: Axis3, D: Axis4, E: Axis5, F: Axis6

192. Synchronization Marks IRB6660 A: Axis1, C: Axis2, D: Axis3 E: Axis4, F: Axis5, G: Axis6 A D

193. Synchronization Marks IRB6700

194. Synchronization Marks IRB660,760 A: Axis1, C: Axis2, D: Axis3, E: Axis6

195. Synchronization Marks IRB360 A: Axis4, B: Axis1-3

196. Updating Rev. Counter Procedure Jog the robot to the witness marks / Calibration position. Tap ABB : Calibration Select the robot to be calibrated. Tap Update Revolution Counter Tap YES to confirm this is what you want to do. If needed select the axes to be updated. Tap Update and Update again. © ABB Robotic May 8, 2017

197. MoveAbsJ Create a new routine (GotoCalib) Insert MoveAbsJ instruction Choose star position, Debug / View Value, put all 6 axis to zero Checking Robot Calibration © ABB Robotic May 8, 2017

198. Fine Calibration Tells the current angle of motor shaft when robot is in sync position Is tuned in by ABB or on site with special equipment Only needs to be retuned if a motor / gearbox is replaced Fine Calibration Requires special tools! Cannot be made correctly by eye Measurement. © ABB Robotic May 8, 2017

199. Type in the fine calibration values manually Use moc.cfg values from Backup, Silver label in back of manipulator with 6 values, or original Motor Calibration values on floppy shipped with system. Edit Motor Calibration Offsets © ABB Robotic May 8, 2017

200. Post Assessment & Evaluation © ABB Robotic May 8, 2017

201. For Emergency Service, Spare Parts, Tech Support, Questions, Comments, Complaints…. [phone] © ABB Robotic May 8, 2017

202. © ABB Robotic May 8, 2017