ABB - Training Generalr PDF

ABB Robotics Division INTRODUCTION TO
Peenya,Bangalore ROBOTICS
© BAU ATMA India - 1 -
01-11-2005
DEFINITION OF AN INDUSTRIAL ROBOT
An industrial robot is a re-programmable multi-functional

manipulator resembling a human arm but powered by
electricity.
© BAU ATMA India - 2
MAJOR COMPONENTS OF ROBOT
Manipulator( body of
robot )
Controller(computer
+drives)
End-effector (tool)
Man Machine
Interface
(TeachPendant/Lapt
op)
Block Diagram of Robot
Laptop
Flexpendant
Manipulator Power cable

CONTROLLER
ROBOT MANIPULATOR
SMB Cable
Ext Ax Power
Resolver Cable
EXTERNAL AXIS
R
Y
B 3 Phase 415VAC
Manipulator Open Link Mechanism
Manipulator consists of Links (Rigid Arms)
Base of robot
Each link is connected to previous link by joints
Link 1 Link 2 Link 3

Link 0 Joint 2
Joint 1 Joint 3
Joint 4
Link 5 Link 4
Link 6 Joint 6
Joint 5
Tool Flange
DESCRIPTION OF A MANIPULATOR
A manipulator is an assemblage of rigid links connected by joints.

Each joint is driven by an actuator (AC Servo motors in ABB
robots).
Actuators are coupled to joints via geared transmission.
An industrial manipulator has 4 OR 6 degrees of freedom.
Brakes are installed in every joint motor to hold the manipulator in
position against gravity in motors off state.
THE 6 AXES OF A ROBOT
Link 4
Link 3
Link 2 Link 6 (tool flange)
Link 5
Link 1
Link 0 (Base)
Can you number the Links?????
Base 1 2 3 4 5 ToolFlange
The various ABB Robots:
ABB Robots are designated by IRB (Industrial Robot

Body).
Articulated Paint Parallel
Gantry
IRB140
IRB2400 IRB510 IRB340
IRB1400 IRB360
IRB6600 IRB540
IRB1600 IRB940
IRB840 IRB5400
IRB7600
Robot Models: 6 axis 4 axis
What is a CONTROLLER???
The controller is the brain behind the functioning of a

robot The pictures below depicts the IRC5 Controller.
Dual Cabinet
Single Cabinet
Control Module
Drive Module
THE MAN_MACHINE INTERFACE
The FLEXPENDANT is the man_machine interface for

an IRC5 controller , it is also known as GTPU (Graphical
Teach Pendant Unit).
BUTTONS ON A FLEXPENDANT
A WELDING TORCH
A VACUUM GRIPPER
A WELDING ROBOT SYSTEM
Robot + Application Equipment+

Work holding device+ EOAT+
peripheral equipments
+interface/control panels+ safety
= ROBOT SYSTEM EOAT
Robot
Application Controller
Equipment
Peripheral
Equipment
Positioner
Pedestal
ROBOT SPECIFICATION
ABB robots are specified using a designation IRB say for example,
IRB140, IRB1400, IRB2400, IRB1600, IRB6600, IRB340 etc.
Some important specifications to look for in a

Robot are:
o1.Payload
2.Reach
3.Supplementary load.
4.Speed
TECHNICAL DATA SHEET FOR IRB 140
TECHNICAL DATA SHEET FOR IRB 140
OPERATING MODES OF A ROBOT
A robot can be operated in three different modes:

Manual mode.
Manual 100% mode.
Automatic mode.
OPERATING MODES
MANUAL MANUAL 100% AUTOMATIC
Robot can be Robot can be Robot cannot be

jogged at less jogged at less jogged
than 250 mm/s than 250 mm/s
Enabling device Enabling device No need of enabl_

needs to be pre_ and Hold to Run ing device or hold
_ssed button needs to to run button
be pressed
Programmed Programmed speed
speed is not Programmed speed is followed.

followed. is followed.
COORDINATE SYSTEMS
A coordinate system = origin O and

3 perpendicular axes X, Y, & Z.
It is used to specify the position of a point in space.
The various types of coordinate systems used in a
Robot are:
THE BASE COORDINATE SYSTEM.
THE WORLD COORDINATE SYSTEM.
THE TOOL COORDINATE SYSTEM.
THE WORK OBJECT COORDINATE SYSTEM.

COORDINATE SYSTEMS
TOOL COORDINATE SYSTEM
JOGGING
Jogging means manually moving a robot using the

joystick on the flexpendant.
Jogging cannot be done in auto mode.
Jogging is used while teaching a robot points in space.
Jogging can be done while programming.
JOGGING
From ABB main menu select jogging.

JOGGING WINDOW
MODES OF JOGGING
Jogging can be done in three modes:
Axes mode (joint by joint )

Linear mode (along X / Y / Z)
Reorient mode (changing orientation of tool)
AXIS MODE
We can jog axes 1-3 or axes 4-6 at one go.

The position format shows the angular position of each
joint in degrees or radians.
LINEAR MODE
In linear mode the TCP moves in a straight line.
The TCP can move parallel to either the x-axis or the y-axis or the
z-axis of the selected coordinate system of the robot which can
be the base,world,tool or workobject coordinate system.
The position format shows the position of the TCP w.r.t the
coordinate system selected in mm and orientation of tool in
Quaternions or Euler Angles.
During linear jogging orientation of tool remains same.
REORIENTATION MODE
In reorientation mode the TCP of the selected tool

remains at a fixed positon in space.
However the orientation of the tool about that fixed point
changes.
INCREMENTAL MODE
JOYSTICK LOCK
The movements of the joystick can be restricted in few

or all directions using the joystick lock.
QUICKSET MENU
The quickset menu can be used for easy selection of
jogging modes and setting the speed.
SPEED AND RUN MODE

LIMITING ROBOTS WORKSPACE
TOOL DEFINITION
TCP DEFINITION
WORK OBJECT DEFINITION
BASIC ROBOT PROGRAMMING
The programming language used by ABB robots is the

RAPID programming language.
Programs can be accessed by going to the program
editor window.
To start writing a new program click on “Tasks and
Programs” then on “File” and then on “New”.
Type in your new program name using the soft keyboard
and you are ready to start.
HOW TO WRITE A NEW PROGRAM
SOFT KEYBOARD
A RAPID Program
INSTRUCTION SET
To add a new instruction click on “Add Instruction”.

The common instructions available can be classified under
the following categories:
Motion instructions.
Program flow instructions.
Assignment.
Communication instructions.
INSTRUCTION SET
MOTION INSTRUCTIONS
MoveJ *,v500,z50,tool0;
MoveL *,v1000,z20,tool1;
MoveC *,*,v250,z40,gripper;
MoveAbsJ *,v500,z40,torch;
MOVEJ
MoveJ *,v500,z80,gripper;
* Represents the Robtarget where the TCP of the selected tool is to
be moved.
V500 means that the TCP moves at a speed of 500 mm/s
Z80 is the zone error i.e. 80 mm, if instead of z80 we select “fine” the
zone error is zero.
Gripper is the selected tool.
TCP doesnot follow a straight line between initial position of robot
and the robtarget.
MOVEL
MoveL *,v500,z20,torch;
Rest is same as MoveJ only difference being that the TCP

of the selected tool moves in a straight line from the
initial position of the robot to the robtarget.
MOVEC
MoveC *,*,v1000,z100,cutter;
The TCP of the selected tool moves in a circular arc joining

the initial TCP position to the two robtargets
respectively.
MOVEABSJ
MoveAbsJ *;
Here the * represents a joint-target that is the angular

positions of the 6 joints.
PROGRAM FLOW INSTRUCTIONS
IF ELSE
GOTO
FOR
COMPACT IF
TEST CASE
COMPACT IF
IF reg1=1 MoveJ *,v500,z20,tool0;

It executes a single instruction if a given condition is
found to be true.
IF ELSE
IF reg2=10 THEN
MoveJ *,v500,z80,tool0;
ELSE
MoveC *,*,v500,z20,tool0;
ENDFOR
If a given condition is true it executes a set of instructions and if it is false then

it executes another set of instructions.
GOTO
GOTO start;
………….
………….
………….
start:
On seeing the instruction the program pointer goes to the
line containing the label start.
FOR
FOR x FROM 1 TO 10 STEP1 DO

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

TEST
TEST reg1
Case 1: …………
…………
Case 2: ………….
…………
Case 3: …………
…………
ENDTEST
Executes set of instructions based on the integer values of a variable eg. reg1.
COMMUNICATION INSTRUCTIONS
TPWrite “TIME FOR THE CYCLE IS”,reg1;

TPErase;
TPReadNum reg2;
ROUTINES
I/O BOARDS
The following picture shows an i/o board.

I/O UNITS SUPPORTING DEVICENET
COMMUNICATION
DSQC 327A
TECHNICAL DATA DSQC327A
CONNECTOR X1
Connector X1 is for digital outputs.

CONNECTOR X2
Connector X2 is for digital outputs.

CONNECTOR X3
Connector X3 is for digital inputs.

CONNECTOR X4
Connector X4 is for digital inputs.

PROCEDURE OF CONNECTING DIGITAL INPUTS
INPUT MAPPING
OUTPUT MAPPING
ANALOG OUTPUTS
CALIBRATION
An uncalibrated system.
REVOLUTION COUNTER
UPDATE REV. COUNTERS

MOTOR CALIBRATION VALUES
CONNECTING A LAPTOP TO CONTROLLER
TAKING A BACKUP??
BACKUP

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ABB Robotics Division INTRODUCTION TO

 An industrial robot is a re-programmable multi-functional

Manipulator Power cable

Link 1 Link 2 Link 3

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

Link 2 Link 6 (tool flange)

 ABB Robots are designated by IRB (Industrial Robot

 The controller is the brain behind the functioning of a

 The FLEXPENDANT is the man_machine interface for

Robot + Application Equipment+

Some important specifications to look for in a

A robot can be operated in three different modes:

MANUAL MANUAL 100% AUTOMATIC

Robot can be Robot can be Robot cannot be

Enabling device Enabling device No need of enabl_

speed is not Programmed speed is followed.

A coordinate system = origin O and

 THE WORK OBJECT COORDINATE SYSTEM.

 Jogging means manually moving a robot using the

From ABB main menu select jogging.

Jogging can be done in three modes:

 Axes mode (joint by joint )

 We can jog axes 1-3 or axes 4-6 at one go.

 In reorientation mode the TCP of the selected tool

 The movements of the joystick can be restricted in few

SPEED AND RUN MODE

 The programming language used by ABB robots is the

To add a new instruction click on “Add Instruction”.

Rest is same as MoveJ only difference being that the TCP

The TCP of the selected tool moves in a circular arc joining

Here the * represents a joint-target that is the angular

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

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

FOR x FROM 1 TO 10 STEP1 DO

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

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

 The following picture shows an i/o board.

 Connector X1 is for digital outputs.

 Connector X2 is for digital outputs.

 Connector X3 is for digital inputs.

 Connector X4 is for digital inputs.

UPDATE REV. COUNTERS

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An industrial robot is a re-programmable multi-functional

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

ABB Robots are designated by IRB (Industrial Robot

The controller is the brain behind the functioning of a

The FLEXPENDANT is the man_machine interface for

THE WORK OBJECT COORDINATE SYSTEM.

Jogging means manually moving a robot using the

Axes mode (joint by joint )

We can jog axes 1-3 or axes 4-6 at one go.

In reorientation mode the TCP of the selected tool

The movements of the joystick can be restricted in few

The programming language used by ABB robots is the

TPWrite “TIME FOR THE CYCLE IS”,reg1;

The following picture shows an i/o board.

Connector X1 is for digital outputs.

Connector X2 is for digital outputs.

Connector X3 is for digital inputs.

Connector X4 is for digital inputs.