3HAC055902 - Machining PowerPac Tutorials

Directions for use
Machining PowerPac
Trace back information:
Workspace Main version a182 (not checked in)
Published 2016-09-27 at 09:29:37
Skribenta version 4.6.320
Directions for use
Machining PowerPac
RobotStudio 6.04
Document ID: 3HAC055902-001

Revision: B
© Copyright 2016 ABB. All rights reserved.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.

ABB AB
Robotics Products
Se-721 68 Västerås
Sweden
Table of contents
Table of contents
Overview of the manual .................................................................................................................... 7
1 Simple polishing - flat surface polishing with robot-hold tool 9

1.1 General ........................................................................................................... 9
1.2 Procedure ........................................................................................................ 11
2 Tool axis control - dispensing with robot-hold work piece 43

2.1 General ........................................................................................................... 43
2.2 Procedure ........................................................................................................ 45
3 Path Editor - lid deburring with robot-hold work piece 77

3.1 General ........................................................................................................... 77
3.2 Procedure ........................................................................................................ 79
4 Robot configuration - freeform surface polishing with robot-hold work piece 123
4.1 General ........................................................................................................... 123
4.2 Procedure ........................................................................................................ 125
5 Robot on track with robot-hold tool 165

5.1 General ........................................................................................................... 165
5.2 Procedure ........................................................................................................ 167
Directions for use - Machining PowerPac 5

3HAC055902-001 Revision: B
This page is intentionally left blank
Overview of the manual
Overview of the manual

About this manual
This manual uses typical cases to describe how to use Machining PowerPac -
Machining to create RAPID machining programs based on CAD models in specific
application scenarios.
Usage
This manual should be used during the work with Machining PowerPac - Machining.
Who should read this manual?

This manual is intended for RobotStudio users, proposal engineers, mechanical
designers, offline programmers, robot technicians, and service technicians.
Prerequisites
RobotStudio and Machining PowerPac have been successfully installed, and the
reader should have basic knowledge of:
• Industrial robots and their terminology
• RAPID programming language
• RobotStudio
References
Reference Document ID
Operating manual - RobotStudio 3HAC032104-001
Technical reference manual - RAPID overview 3HAC050947-001
Operating manual - Machining PowerPac - Machining Functionality 3HAC054781-001
Revision
Revision Description
- First edition
A Changes made in this revision:
• Added a step describing how to create a new station in the
RobotStudio for each case.
• Modified substeps about specifying process areas when creating
geometries in each case because of GUI redesign.
• Minor corrections.
B-ongoing Changes made in this revision:
• Added substeps about tool axis setting when creating operation
for the intersection geometry in the path editor case.
• Modified the orientation values of the model tap_03_Position1
when creating a new station in the robot configuration case.

1 Simple polishing - flat surface polishing with robot-hold tool
1.1 General
1 Simple polishing - flat surface polishing with

robot-hold tool
1.1 General
Objectives
Users will be able to complete polishing tasks on 3C work pieces by:
• Creating face-machining tool and side-machining tool
• Creating intersection geometry on to-be-machined work pieces
• Generating robot path in zigzag pattern and direct transfer type
• Simulating the path and exporting the path as RAPID files
By following the instructions of this tutorial, final paths shown in the following
figures can be generated.
xx1500001366
Continues on next page

1.1 General
Continued
xx1500001367
Required equipment
Note
The following equipment is dedicated for this case and only for reference. They
could be changed to other equipment with similar functions as required to fulfill
the task.
Type Description Note

Robot IRB 2600-12/1.65
CAD model Mobile phone shell
Tool Polishing tool Robot-hold tool
10 Directions for use - Machining PowerPac

1.2 Procedure
1.2 Procedure
Step 1: Opening RobotStudio and starting with a preset or new station
Note
Before using the Machining PowerPac, a station must be prepared. You can
either get a quick start by loading a preset station or create a new station based
on actual requirements.
Loading a preset station

1 Open the RobotStudio programme and load the preset station Case 1 - Simple
polishing.
Note
The preset station is saved in C:\Program Files (x86)\ABB Industrial

IT\Robotics IT\Machining PowerPac 6.0X\Tutorials\Samples. This directory
may vary according to the actual installation folder on your PC. The station
includes the settings of the robot, CAD model of the to-be-machined cell
phone shell, and polishing tool.
xx1500001060

1.2 Procedure
Continued
Creating a new station

1 Double-click the RobotStudio programme to open it and then choose New
> Empty Station > Create to create a new station with empty settings.
xx1500001622
An empty station is displayed in the 3D graphics window.
xx1500001623

1.2 Procedure
Continued
2 On the Home ribbon tab of RobotStudio, click ABB Library in the Build
Station group and then choose IRB 2600 from the robot list.
xx1500001624
3 In the displayed dialog box, select 12 kg and 1.65 m from the Capacity and
Reach drop-down lists, respectively, and then click OK.
xx1500001695

1.2 Procedure
Continued
The robot is displayed in the 3D graphics window.
xx1500001696
4 Choose Browse for Geometry from Import Geometry in the Build Station
group.
xx1500001697

1.2 Procedure
Continued
5 In the displayed window, select the CAD models of the cell phone and tool
(named as our cell phone-1 and spindle respectively in this case) from the
folder where they are saved to import them to the station.
Note
The CAD models are saved in C:\Program Files (x86)\ABB Industrial

may vary according to the actual installation folder on your PC.
The models are displayed in the 3D graphics window and listed under the
Components node in the Layout tab page.
6 Make sure the robot is at the home position. If not, right-click the robot node
in the Layout tab page and choose Jump home from the context menu.
7 Attach the tool to the robot by dragging the tool node to the robot node.
An Update position dialog box is displayed. In this case, click No for manually
setting the model position later.
xx1600000621
Tip
To attach the tool to the robot, you can also right-click the tool node and
choose the robot from the list under Attach to.
8 Right-click each required node and choose Position > Set Position to set
their positions based on the following data.
When setting the position, make sure World is chosen in the Reference
drop-down list so that the world reference coordinate system is used.
Model Position Position Position Orienta- Orienta- Orienta-
X (mm) Y (mm) Z (mm) tion X tion Y tion Z
(deg) (deg) (deg)
our cell phone-1 1025.85 0 688.41 90 0 90
spindle 1087.53 0 1176.87 180 60 180
9 After the setting, click Apply to accept and then Close to return.

1.2 Procedure
Continued
10 Choose From Layout from Robot System in the Build Station group to create
system based on the layout.
xx1500001699
11 In the displayed Create System From Layout dialog box, remain the default
settings and click Next in each page, and then click Finish in the last page.
After the system is created, the station is set up successfully.
Step 2: Opening Machining PowerPac

1 On the Add-Ins ribbon tab of RobotStudio, click Machining 6.0X in the
PowerPacs group.
xx1500001061

1.2 Procedure
Continued
Step 3: Creating workobject

1 Select Create WorkObject from the Geometry category in the ribbon tab.
xx1500001062
2 In the WorkObject area of the displayed Create WorkObject window, click

New.
xx1500001096
Note
Attributes of the work object, such as user frame and object frame, could
be edited in the Create WorkObject window. However, note that the
modifications will also affect the RobotStudio work objects because the
work objects in Machining PowerPac use the RobotStudio work object
settings as the basis.

1.2 Procedure
Continued
3 In the Create Workobject window, remain the default settings and then click
Create.
The workobject is namesd as Workobject_1 by default.
4 Click the Home tab in the menu bar to enter the Home ribbon tab.
xx1500001300

1.2 Procedure
Continued
5 In the Path&Targets view pane, right-click the Workobject_1 node and

choose Attach to from the context menu to attach the workobject to the
required CAD model.
xx1500001386

1.2 Procedure
Continued
6 Click Yes in the displayed Update position dialog box.
xx1500001387
7 Click the Machining tab in the menu bar to return to the Machining tab page.
Step 4: Creating face-machining tool

1 Select Create Tool from the Tool category in the ribbon tab.
xx1500001064
Tip
You can also click Tool directly in the ribbon tab.
2 In the Tooldata area of the displayed Create Tool window, click New.
Note
You could also select the existing tooldata or edit the parameters of the
existing tooldata.
The settings of tooldata defines the tool position, that is, the tool tip locates
at the position set in tooldata.
xx1500001090

1.2 Procedure
Continued
3 In the Create Tooldata window:

• Click the drop-down arrow next to Position x,y,z in the Tool Frame
area.
• Activate the displayed combo box by clicking it.
• Choose the Snap Center mode in the 3D graphics window and click
the central point of the robot-hold polishing tool in the 3D graphics
window.
• The coordinate of the selected point is displayed in the text box. Click
Accept and then click Create.
xx1500001065
4 In the Shape Definition area of the Create Tool window, choose T_Cutter
from the Type drop-down list.
xx1500001116

1.2 Procedure
Continued
5 In the Process Setting area, remain the default choice Face Machining for
Machining Method.
xx1500001115
6 Modify the tool shape parameters as follows:

• Enter 100 in the Tip Diameter (mm) text box.
• Enter 20 in the Tip Length (mm) text box.
• Enter 0 in the Contact Diameter (mm) text box.

1.2 Procedure
Continued
xx1500001066
Note
Definitions of tool shape parameters are as follows:

• Tip Diameter: Specifies the diameter of the entire tool tip.
• Tip Length: Specifies the length of the tool tip.
• Contact Diameter: Available to face-machining tools for specifying the
diameter of tool face that is actually used to process.

1.2 Procedure
Continued
The tool with modified shape parameters is displayed in the 3D graphics

window.
xx1500001349
7 Click OK.
A tool node is displayed in Tool view pane.
Step 5: Creating program group

1 Select Create Program Group from the Program category in the ribbon tab.
xx1500001067
Tip
You can also click Program directly in the ribbon tab.

1.2 Procedure
Continued
2 In the displayed Create Program Group window, remain the default settings
and click OK.
xx1500001068
A program node is displayed in Program view pane.
Step 6: Creating intersection geometry for the shell backplane

1 Select Create Geometry from the Geometry category in the ribbon tab.
xx1500001069
Tip
You can also click Geometry directly in the ribbon tab.

1.2 Procedure
Continued
2 In the displayed Create Geometry window, choose Intersection Geometry

from the Type drop-down list in the Settings area.
Note
The created workobject is selected for the WorkObject drop-down list in

the Basic area by default. You can also select another workobject to which
the geometry is to be belonged. All geometry settings related to the
coordinate system is based on the properties of the belonged workobject.
xx1500001070
3
Click the icon next to Specify Process Area, and then click the Specify
Area icon in the displayed Process Area window.

4 Select the backplane surfaces of the mobile phone shell in the 3D graphics
window.

1.2 Procedure
Continued
The selected surfaces are highlighted and also listed in the Selected Faces
area of the Process Area window.
xx1500001071
5 Click OK to accpet the selection and also OK to return to the Create Geometry
window.
6
Click the icon next to Specify Cutting Plane.
7 In the displayed Specify Cutting Plane window, make sure that Parallel
Planes is chosen in the Type area and set the parameters as follows:
• Enter 30 in the Interval (mm) text box.
• Enter 6 in the Count (xN) text box.
xx1500001072

1.2 Procedure
Continued
8 In the 3D graphics window, use the free hand to drag the axes of the plane
frame to move the plane to a proper position.
xx1500001357
Tip
The free hand may hide after you click another position in the 3D graphics
window. To display it again, click any Position (mm) combo box in the
Specify Frame area to activate.
9 Click OK to return and then click Preview.

1.2 Procedure
Continued
The path is highlighted in the 3D graphics window.
xx1500001073
10 Click OK.
A geometry node is displayed under the created workobject node in the
Geometry view pane.
Step 7: Creating operation

1 Select Create Operation from the Operation category in the ribbon tab.
xx1500001075
Tip
You can also click Operation directly in the ribbon tab.

1.2 Procedure
Continued
2 In the displayed Create Operation window, make sure the created geometry,
tool, and program group are selected in the Basic area.
xx1500001076
3 Click Preview.
The path can be previewed on the mobile phone shell in the 3D graphics
window and an estimated reachable target rate of 100.00% is displayed in
the Create Operation window.
xx1500001074
4 Choose Zigzag from the Pattern drop-down list in the Path Setting area and
then click Preview again.
Note
For zig pattern, the tool processes in a one-way direction with the approach
each time in the same direction. For zigzag pattern, the tool processes
forth and back with consecutive approach and departing.

1.2 Procedure
Continued
The path in zigzag pattern can be previewed in the 3D graphics window and
the estimated reachable target rate is also 100.00%.
xx1500001077
5 Click the Non-process Move Setting icon and in the displayed Non-Process
Move Setting window, choose Direct from the Transfer Type drop-down list
in the Transfer area.
xx1500001087

1.2 Procedure
Continued

The path with direct transfer type can be previewed in the 3D graphics window
and the estimated reachable target rate is also 100.00%.
xx1500001094
7 Click OK.
An operation node is displayed under the related geometry node in the
Geometry view pane.
Step 8: Simulating the path

1 With the created operation node being selected, choose Simulate from the
Simulation category in the ribbon tab.
xx1500001078
Tip
You can also click Simulation directly in the ribbon tab.

1.2 Procedure
Continued
2 Click the Start icon in the simulation window to run the quick simulation.
xx1500001079
3 Select VC simulation and click the Start icon again to run the simulation with
virtual controller.
xx1500001080
4 Click Close to exit the simulation.
Step 9: Exporting RAPID files

1 With the program group node being selected, choose Export RAPID from
the Export category in the ribbon tab.
xx1500001081
Tip
You can also click Export directly in the ribbon tab, or right-click the
program group node and choose Export RAPID from the context menu.

1.2 Procedure
Continued
2 Click Open Export Location in the Export Result dialog box.
xx1500001082
The directory where the RAPID files are saved is displayed.
Tip
The preceding eight steps provide a complete workflow for you to fulfill a polishing
task on specific surfaces of a work piece. If more surfaces need to be polished
on one work piece during a polishing task, you could proceed with the following
steps.
Step 10: Creating intersection geometry for the shell edges

1 Click Geometry in the ribbon tab and also choose Intersection Geometry
2

3 Select the edge surfaces of the mobile phone shell in the 3D graphics window.
xx1500001083

1.2 Procedure
Continued
4 Click OK to accept the selection and also OK to return to the Create Geometry
window.
5
6 In the displayed Specify Cutting Plane window, make sure that Parallel
Planes is chosen in the Type area.
7 In the Specify Frame area, remain the default frame type SurfaceNormal
and click a combo box to activate the setting.
8 Choose the Snap Mid mode in the 3D graphics window and click a point on
one shared edge of the selected surface.
xx1500001117
The coordinate information of the point is filled automatically in the Position

and Orientation combo boxes.
9 Modify the parameters as follows:
• Enter 0 in the red combo box under Orientation.
Note
The red, green, and blue combo box represents x, y, and z axis of
the coordinate, respectively.
• Enter 1 in the Count (xN) text box.

1.2 Procedure
Continued
xx1500001084

1.2 Procedure
Continued
xx1500001085
11 Click OK.
A new geometry node is displayed under the workobject node in the
Geometry view pane.
Step 11: Creating side-machining tool

1 Click Tool in the ribbon tab.
2 In the Basic area of the displayed Create Tool window, specify the tool name
as Cutter_2 to distinguish from the face-machining tool.
3 In the Shape Definition area, choose T_Cutter from the Type drop-down
list.
4 In the Process Setting area, choose Side Machining for Machining Method.
• Enter 10 in the Contact Height (mm) text box.

1.2 Procedure
Continued
xx1500001086
Note

• Contact Height: Available to side-machining tools for specifying the
height from the tool tip to the tool part that is actually used to process.

1.2 Procedure
Continued

window.
xx1500001350
6 Click OK.
A new tool node is displayed in Tool view pane.
Step 12: Creating operation for the second geometry

1 Click Operation in the ribbon tab.
2 In the displayed Create Operation window, make sure the newly created
geometry and tool are selected in the Basic area.
3 In the Path Setting area, click the icon next to the Tool Axis drop-down list.

1.2 Procedure
Continued
4 In the displayed Tool Axis Setting window, clear the Reverse Contact Point
check box and then click OK to return.
xx1500001089
5 Click Preview.
xx1500001088
6 Click OK.
A new operation node is displayed under the related geometry and tool nodes.

1.2 Procedure
Continued
Step 13: Simulating the path and exporting RAPID files

Repeat the operations described in Step 8: Simulating the path on page 32 and
Step 9: Exporting RAPID files on page 33 to perform path simulation and file export.

2 Tool axis control - dispensing with robot-hold work piece
2.1 General
2 Tool axis control - dispensing with robot-hold work

piece
2.1 General
Objectives
Users will be able to complete dispensing tasks on 3C work pieces by:
• Creating edge curve geometry on to-be-machined work pieces
• Setting tilt angle and interpolation for a created operation
• Inserting a target at the beginning of a path using the path editor to change
the approach position of the fixed tool
• Splitting path into several segments by editing feature curves.
xx1500001368
Required equipment
Note
the task.

Robot IRB 1200-5/0.9
Gripper Gripper of IRB 5350 For holding the tool
CAD model Mobile phone shell Robot-hold work piece

2.1 General
Continued

Tool Dispensing tool Fixed tool

2.2 Procedure
2.2 Procedure
Note

1 Open the RobotStudio programme and load the preset station Case 2 - Tool
axis control.
Note

includes the settings of the robot, CAD model of the to-be-machined cell
phone shell, and dispensing tool.
xx1500001095

2.2 Procedure
Continued

xx1500001622
xx1500001623

2.2 Procedure
Continued
Station group and then choose IRB 1200 (or any other required robot model)
from the robot list.
xx1500001702

2.2 Procedure
Continued
3 In the displayed dialog box, select 5 kg and Standard from the Capacity and
Connectors drop-down lists, respectively, and then click OK.
xx1500001701
xx1500001703

2.2 Procedure
Continued
4 On the Home ribbon tab of RobotStudio, click Import Library in the Build
Station group. Choose Equipment > Tools and then IRB 5350 Gripper from
the tool list.
xx1500001704
The tool is displayed in the 3D graphics window.

group.
xx1500001697

2.2 Procedure
Continued
6 In the displayed window, select the CAD model of the cell phone (named as
our cell phone-1 in this case) from the folder where it is saved to import it
to the station.
Note

The model is displayed in the 3D graphics window and listed under the
8 Attach the cell phone model to the robot by dragging the cell phone node to
the robot node.
setting the model position later.
xx1500001700
Tip
To attach the cell phone to the robot, you can also right-click the cell phone
node and choose the robot from the list under Attach to.
(deg) (deg) (deg)
IRB 5350 Gripper 876.096 0 751.78 0 0 180
our cell phone-1 559.25 0 826.60 90 60 180

2.2 Procedure
Continued
xx1500001699

PowerPacs group.
xx1500001061

2.2 Procedure
Continued

xx1500001062

New.
xx1500001096
Note

2.2 Procedure
Continued
3 In the Create Workobject window, set Robot holds workobject in the Misc
data area to True and then click Create.
xx1500001097
4 In the Create WorkObject window, click OK.

A workobject node is displayed in Geometry view pane.
Note
The created workobject will be used to create geometries. Only geometries

associated to a workobject can generate paths. The workobject also defines
the base coordinate system of operations.
Step 4: Creating fixed tool

xx1500001064

2.2 Procedure
Continued
Tip
Note
existing tooldata.
xx1500001090

• Set Robot holds tool in the Misc data area to False.
xx1500001119
area.
• Activate the displayed combo box by clicking it.

2.2 Procedure
Continued
• Choose the Snap Center mode in the 3D graphics window and click
the central point of the tool tip in the 3D graphics window.
xx1500001352
The coordinate of the selected point is displayed in the text box, then,
click Accept.
xx1500001120
• Click the drop-down arrow next to Rotation x,y,z in the Tool Frame
area.
• Enter 180 in the red Rotation (deg) combo box and click Accept.
Note

2.2 Procedure
Continued
xx1500001098
• Click Create.
A fixed tool is displayed in the 3D graphics window.
xx1500001353
4 In the Shape Definition area of the Create Tool window, modify the following
tool shape parameters:

2.2 Procedure
Continued

• Enter 6 in the Holder Diameter (mm) text box.
• Enter 50 in the Holder Length (mm) text box.
xx1500001100
Note

• Contact Diameter: Specifies the diameter from the tool tip to the tool
part that is actually used to process.
• Holder Diameter: Specifies the diameter of the tool holder.
• Holder Length: Specifies the length of the tool holder.

2.2 Procedure
Continued

window.
xx1500001351
5 Click OK.

xx1500001067
Tip

2.2 Procedure
Continued
and click OK.
xx1500001068
Step 6: Creating edge curve geometry

xx1500001069
Tip

2.2 Procedure
Continued
2 In the displayed Create Geometry window, choose Edge Curve from the
Type drop-down list in the Settings area.
Note

xx1500001101
3
Click the icon next to Specify Process Area.
4 Select the inner edge surfaces of the mobile phone shell in the 3D graphics
window.
xx1500001103
5
Click OK to return and then click the icon next to Specify Edge.
2.2 Procedure
Continued
6 In the displayed Edge window, click the Delete selected edge(s) icon to
remove all default selected edges in the list.
xx1500001104
Note
Listed default edges include all boundaries of the selected surfaces.
7 Choose Boundary from the Selection Mode drop-down list.
xx1500001105
8 Click a point on an outer edge of the mobile phone shell in the 3D graphics
window.

2.2 Procedure
Continued
A Confirm Edges dialog box listing all edges that smoothly connects to the
selected outer edge is displayed.
xx1500001106
9 Select all the edges in the list and then click OK to return.
The path with edges to be machined is highlighted in the 3D graphics window.
xx1500001121
10 Click OK.
Geometry view pane.
Step 7: Creating operation

xx1500001075

2.2 Procedure
Continued
Tip
tool, and program group are selected in the Basic area.
xx1500001107
4 In the displayed Tool Axis Setting window, set Tilt Angle (deg) in the Angle
Setting area to -60, and then click OK to return.
xx1500001108
5 Click Preview.

2.2 Procedure
Continued
xx1500001109
6 Click the Target Configuration icon .
xx1500001110
7 In the displayed Axis Settings tab page, click Activate Local Settings to
activate the setting.
xx1500001122
Note
The axis settings of an operation inherit the settings of the parent node to
which the operation belongs by default and are unavailable for modification
when the Axis Settings tab page is opened. To modify the settings, always
click Activate Local Settings. To remain the default settings inherited from
the parent node, click Inherit Parent Settings.

2.2 Procedure
Continued
8 Set Rotate all targets around z axis to 0 and then click Reachability to verify
the estimated reachable target rate.
xx1500001111

10 Click OK.
Geometry view pane.

2.2 Procedure
Continued

xx1500001078
Tip
xx1500001079
visual controller.
xx1500001080

2.2 Procedure
Continued
Step 9: Editing path using Path Editor
Note
This procedure is required when collision occurs during the path simulation or
the path is improper.
In this case, collision occurs when the tool approaches the mobile phone shell
during the simulation so that the following steps are performed.
1 Click Path Editor in the ribbon tab.
xx1500001123
Tip
You can also open the path editor by right-clicking the operation node and
choosing Edit Path from the context menu.
2 In the displayed Instructions window, right-click the first instruction node

and choose Copy > Insert above from the context menu.
xx1500001112
3 In the displayed Set Position window, set the following parameters:

• Enter -80 in the blue Position X,Y,Z (mm) combo box.
• Enter 30 in the green Orientation (deg) combo box.

2.2 Procedure
Continued
Note
The red, green, and blue combo box represents x, y, and z axis of the
coordinate, respectively.
4 Click Apply and then Close to return.
xx1500001113
The tool originally approaches at the following position.
xx1500001358

2.2 Procedure
Continued
The modified approach position is as follows.
xx1500001359
5 Close the Instructions window and then perform VC simulation to check

whether the modified path settings are proper.
6 Since the path settings are still improper during the VC simulation, open the
path editor to have a fine-tuning.

2.2 Procedure
Continued
7 Right-click the first instruction node and choose Set Position from the context
menu.
xx1500001124
8 In the displayed Set Position window, set the following parameters:

• Choose World from the Reference drop-down list.
• Enter 486 and 1064 in the red and blue Position X,Y,Z (mm) combo
box, respectively.
Note
xx1500001118

2.2 Procedure
Continued
The modified approach position is as follows.
xx1500001360
10 Perform VC simulation again to confirm the settings.

The collision does not occur any more.
Note
You can repeat sub-steps 3 to 7 for several times until a proper path is achieved.
The reference frame is also chosen based on actual requirements.

2.2 Procedure
Continued

xx1500001081
Tip
xx1500001082
Note
You can also open the Export Result dialog box by right-clicking the
program node and choosing Export RAPID from the context menu.

2.2 Procedure
Continued
Tip
The preceding nine steps provide a complete workflow for you to fulfill a
dispensing task on specific edges of a work piece. If the path is required to be
split or re-ordered, or the tool approach position is required to be modified, you
could proceed with the following steps.
Step 11: Editing feature curves
Note
This procedure is required when the tool approaches or departs the

to-be-machined work pieces in an improper way or at an improper position, which
may cause collisions or overcut.
In this case, the tool approach position is improper so that the following steps
are performed.
1 Right-click the geometry node and choose Edit Feature Curves from the
context menu.
xx1500001114

2.2 Procedure
Continued
2 In the displayed Edit Feature Curves window, select the last wire of the path
(or another wire you want to split) from the list.
xx1500001126
3 Click any one of the combo boxes above the list to activate the splitting point
selection.
4 Select a point on the selected wire in the 3D graphics window.
The coordinate of the selected point is filled automatically in the combo
boxes. The wire will be split at this point.
xx1500001127
5 Click the Split the selected wire icon.

2.2 Procedure
Continued
The selected wire will be split into two wires in the list.
xx1500001132
6 Click the Move up icon to move the last wire to the top of the list.
Tip
The moving of the wires is used for adjusting wire sequence. After the
preceding operation, the last wire will become the first wire to be machined
on the path.
7 Click OK to return.
8 Right-click the operation node and choose Regenerate Path from the context
menu.
xx1500001130

2.2 Procedure
Continued
9 Click OK in the displayed confirmation box.
xx1500001131
The path is successfully regenerated.

Repeat the operations described in Step 8: Simulating the path on page 66 to
perform path simulation.
Step 13: Editing the path for split path
Note
This procedure is required when collision occurs during the path simulation or
the path is improper.
In this case, collision occurs when the tool approaches the mobile phone shell
during the simulation so that this procedure is performed.
Repeat the operations described in Step 9: Editing path using Path Editor on
page 67 to edit path using the path editor.
Step 14: Simulating the path and exporting RAPID files

Repeat the operations described in Step 10: Exporting RAPID files on page 72 to
perform file export.

3 Path Editor - lid deburring with robot-hold work piece
3.1 General

3.1 General
Objective
Users will be able to complete deburring tasks by:
• Creating intersection and edge curve geometries on to-be-machined work
pieces
• Splitting path into several segments by editing feature curves.
• Specifying flexible contact point and smoothing tool contact height using
path editor
• Setting tool path by editing tool positions using path editor
xx1500001369

3.1 General
Continued
xx1500001370
Required equipment
Note
the task.

Robot IRB 4400/60
CAD model Lid Robot-hold work piece
Tool Deurring tool Fixed tool

3.2 Procedure
3.2 Procedure
Note

1 Open the RobotStudio programme and load the preset station Case 3 - Path
Editor.
Note

includes the settings of the robot, CAD model of the to-be-machined lid,
and deburring tool.
xx1500001133

3.2 Procedure
Continued

xx1500001622
xx1500001623

3.2 Procedure
Continued
xx1500001707

3.2 Procedure
Continued
3 In the displayed dialog box, select IRB 4400 from the Version drop-down
list, and then click OK.
xx1500001708

3.2 Procedure
Continued
xx1500001709

3.2 Procedure
Continued
4 On the Home ribbon tab of RobotStudio, click Import Library in the Build
Station group. Choose Equipment > Training Objects and then propeller
table from the list.
xx1500001725
The table is displayed in the 3D graphics window.

group.
xx1500001697

3.2 Procedure
Continued
6 In the displayed window, select the CAD model of the lid (named as toilet
lid in this case) from the folder where it is saved to import it to the station.
Note

8 Attach the lid to the robot by dragging the lid node to the robot node.
setting the model positions later.
xx1500001698
Tip
To attach the lid to the robot, you can also right-click the lid node and
choose the robot from the list under Attach to.
(deg) (deg) (deg)
table_and_fix- 1292.35 -175 301.94 0 0 0
ture_140
toilet lid 1201.24 0 1650 180 60 180

3.2 Procedure
Continued
xx1500001699

PowerPacs group.
xx1500001061

3.2 Procedure
Continued

xx1500001062

New.
xx1500001096
Note

3.2 Procedure
Continued
xx1500001097

Note

Step 4: Creating fixed tool

xx1500001064

3.2 Procedure
Continued
Tip
Note
existing tooldata.
xx1500001090

xx1500001119
area.

3.2 Procedure
Continued
• Activate the displayed combo box by clicking it and click the center
point of the tool tip with the Snap Center mode chosen in the 3D
graphics window.
xx1500001354

3.2 Procedure
Continued
click Accept.
xx1500001134
• Click Create.

3.2 Procedure
Continued
A fixed tool is displayed in the 3D graphics window.
xx1500001355
4 In the Shape Definition area, choose T_Cutter from the Type drop-down
list.
xx1500001135

3.2 Procedure
Continued
5 In the Process Setting area, choose Side Machining for Machining Method.
xx1500001388
6 Modify the following tool shape parameters:

• Enter 30 in the Contact Height (mm) text box.
xx1500001389
Note

• Contact Height: Available to side-machining tools for specifying the
height from the tool tip to the tool part that is actually used to process.

3.2 Procedure
Continued

window.
xx1500001356
7 Click OK.

xx1500001067
Tip

3.2 Procedure
Continued
and click OK.
xx1500001068
Step 6: Creating intersection geometry

xx1500001069
Tip

3.2 Procedure
Continued

Note

xx1500001070
3

4 Select the required surfaces of the lid in the 3D graphics window.

3.2 Procedure
Continued
xx1500001136
window.
6
7 In the displayed Specify Cutting Plane window, choose Body_Z in the
Specify Frame area.
xx1500001137

3.2 Procedure
Continued
Note
Specify Frame defines the type of a coordinate direction that will be used
as the Z axis of the frame based on which the intersection curves are
generated.
In this case, Body_Z is chosen so that the Z axis of the part frame is used.
8 In the Parameters area, set Count (xN) to 1.
xx1500001138
9 In the 3D graphics window, use the free hand to drag the z axis of the plane
frame, moving the plane to a proper position for generating the required
curve.
xx1500001139
Tip
The plane frame may hide after you click another position in the 3D graphics
3.2 Procedure
Continued

xx1500001140
11 Click OK.
Geometry view pane.
Step 7: Editing feature curves
Note
This procedure is required when the tool approaches or departs the

to-be-machined work pieces in an improper way or at an improper position, which
may cause collisions or overcut.
In this case, the tool will overcut the lid during approaching and departing so
that the following steps are performed.

3.2 Procedure
Continued
1 Right-click the geometry node and choose Edit Feature Curves from the
context menu.
xx1500001114
2 In the displayed Edit Feature Curves window, select one of the two wires of
the path from the list (the first wire is chosen in this case).
xx1500001141
3 Click any one of the combo boxes above the list to activate the splitting point
selection.

3.2 Procedure
Continued
4 Select a point near the spindle of the lid on the selected wire in the 3D
graphics window.
The coordinate of the selected point is filled automatically in the combo
boxes. The wire will be split at this point.
xx1500001143
5 Click the Split the selected wire icon.
The selected wire will be split into two wires in the list.
6 Click the Delete icon to remove the wire that is close to the spindle.
7 Select the other of the two wires of the path mentioned in sub-step 2 from
the list and then repeat sub-steps 3 to 6 to obtain the new wire.
8 Click OK to return.
The new path is generated.

3.2 Procedure
Continued
Step 8: Creating operation for the intersection geometry

xx1500001075
Tip
2 In the displayed Create Operation window, choose

FlexibleContactPoint_Default from the Select Template drop-down list in
the Template area.
xx1500001154
Note
The settings of contact height and tool rotation in the path editor can be
enabled only for operations using the FlexibleContactPoint_ Default
template.
3 In the Basic area, make sure the created geometry, tool, and program group
are selected and modify the operation name.
xx1500001145

3.2 Procedure
Continued
5 In the displayed Tool Axis Setting window, click to clear the Reverse Contact
Point check box in the Contact Position area.
xx1600001340
6 Click Preview to preview the current path in the 3D graphics window.
xx1500001146
Tip
To show the frame of each target in the path, enable Frame in the Path
Preview group in the ribbon tab.

3.2 Procedure
Continued
7 In the Path Setting area, click the Non-process Move Setting icon.
8 In the displayed Non-Process Move Setting window, set Ry (deg) in the

Approach area to 90 to prevent the interference that may occur during tool
approach with default settings.
xx1500001147
The tool approach position changes as follows (A is original, B is with modified

setting):
xx1500001361

The path with modified settings can be previewed in the 3D graphics window.

3.2 Procedure
Continued
10 Click OK.
Geometry view pane.

xx1500001078
Tip
xx1500001079
visual controller.
xx1500001080

3.2 Procedure
Continued
Step 10: Smoothing tool contact height using Path Editor

1 Since collision occurs during the simulation, click Path Editor in the ribbon
tab to enter the path editor to edit tool path.
xx1500001123
Tip
You can also open the path editor by right-clicking the operation node and
choosing Edit Path from the context menu.
2 In the displayed Instructions window, go through instruction nodes to view

the tool position at each target point.
3 Select the target points (nodes 6 to 20 in this case) on which smoothing tool
contact height is to be applied by dragging the mouse.

3.2 Procedure
Continued
The selected nodes are highlighted in the list.
xx1500001149

3.2 Procedure
Continued
4 Right-click the nodes and choose Smooth Tool Contact Height from the
context menu.
xx1500001148

3.2 Procedure
Continued
5 In the displayed Smooth Tool Contact Height window, drag the dotted line
that representing the target points to the required one (instruction node 8 in
this case).
xx1500001150
6 Modify the contact height at this target point to 4.73 by dragging the slider
in the Target contact height scrollbar.
xx1500001151

3.2 Procedure
Continued
The tool contact height changes as follows (A is original, B is with modified

settings.)
xx1500001363
7 Drag the dotted line again to the other required target point (instruction node
16 in this tutorial).

3.2 Procedure
Continued
8 Modify the contact height at this target point to 4.73 by dragging the slider
in the Target contact height scrollbar too.
xx1500001152
9 Click Dynamic Preview to preview the tool path on the selected target points.
10 Click Apply and then click Close to return.

3.2 Procedure
Continued
The tool path changes as follows (A is original, B is with modified setting):
xx1500001362
11 Repeat sub-steps 3 to 10 to smooth tool contact height at another group of

target points (instruction nodes 39 to 54 in this case) along the path.

3.2 Procedure
Continued
The tool contact height of both instruction nodes 42 and 51 is modified to

4.73.
xx1500001155
12 Close the Instructions window.

13 Repeat the operations described in Step 9: Simulating the path on page 105
to perform path simulation.
Tip
The preceding nine steps provide a complete workflow for generating path for
processing the outer edge of the lid. To continue processing the inner edge of
the lid, you could proceed with the following steps.
Step 11: Creating edge curve geometry

1 Click Geometry in the ribbon tab and choose Edge curve from the Type
drop-down list in the Settings area.
Note

the geometry is to be belonged.

3.2 Procedure
Continued
xx1500001101
2
Click the icon next to Specify Process Area.
3 Select the required surfaces of the lid, whose edges will be machined, in the
3D graphics window.
xx1500001136
4
Click OK to return and then click the icon next to Specify Edge.
5 In the displayed Edge window, click the Delete selected edge(s) icon to
remove all default selected edges in the list.

3.2 Procedure
Continued
Note
Listed default edges include all boundaries of the selected surfaces.
6 Choose Boundary from the Selection Mode drop-down list.
xx1500001105
7 Click a point on the inner edge of selected surfaces on the lid in the 3D
graphics window.
A Confirm Edges dialog box listing all edges that smoothly connects to the
selected outer edge is displayed.
xx1500001157
8 Select all the edges in the list and then click OK.

3.2 Procedure
Continued
The curve with edges to be machined is highlighted in the 3D graphics

window.
xx1500001156
10 Click OK.
A new geometry node is displayed under the workobject node in the
Geometry view pane.
Step 12: Creating operation for the edge curve geometry

1 Click Operation in the ribbon tab and modify the operation name in the Basic
area with other parameters remaining default values.

3.2 Procedure
Continued
3 In the displayed Tool Axis Setting window, choose Fixed_Axis from the
Type drop-down list in the Tool Axis area.
xx1500001165
4 Enter -1000 in the blue Direction Vector (mm) combo box.
xx1500001158

3.2 Procedure
Continued
The path can be previewed in the 3D graphics window.
xx1500001159
6 Click the Reverse Path icon to reverse the sequence of target points in the
path. Then, click Preview to preview the modified path.
xx1500001161
7 Click OK.
Geometry view pane.
Step 13: Editing the path

1 Since collision occurs during the simulation, click Path Editor in the ribbon
tab to enter the path editor to edit tool path.
2 Go through instruction nodes to view the tool position at each target point.

3.2 Procedure
Continued
3 Right-click the instruction nodes with all nodes in the list selected and choose
Set Position from the context menu.
xx1500001162
4 In the displayed Set Position window, enter -15 in the blue Position X/Y/Z
(mm) combo box.
Note
xx1500001163

3.2 Procedure
Continued
Tip
You can use the Set Position function to tune the tool position for several
times to make sure the path meets the machining requirements.

6 Click the Start icon in the Instruction window to preview the modified tool
position at each target.
xx1500001164
7 Close the Instruction window.

The collision does not occur any more.

3.2 Procedure
Continued

xx1500001081
Tip
xx1500001082
Note

4 Robot configuration - freeform surface polishing with robot-hold work piece
4.1 General
4 Robot configuration - freeform surface polishing with

robot-hold work piece
4.1 General
Objective
Users will be able to complete polishing tasks by:
• Creating projection, intersection and UV curve geometries on to-be-machined
work pieces
• Creating tools on existing tool machines and changing tools for an operation
• Setting and adjusting robot orientation by choosing between different
interpolation strategies
• Changing vision status of work pieces
xx1500001371

4.1 General
Continued
xx1500001372
Required equipment
Note
the task.

Robot IRB 4400
CAD model Tap Robot-hold work piece
The tap has two positions. This
tutorial focuses on the path gen-
eration for the tap in different po-
sitions and does not concern how
to change tap positions.
Tool Sand belt machine Fixed tool
Several tools will be created on
different sand belts in this case.

4.2 Procedure
4.2 Procedure
Note

1 Open the RobotStudio programme and load the preset station Case 4 - Robot
configuration.
Note

includes the settings of the robot, CAD model of the to-be-machined tap,
and sand belt machines.
xx1500001166

4.2 Procedure
Continued

xx1500001622
xx1500001623

4.2 Procedure
Continued
xx1500001707

4.2 Procedure
Continued
3 In the displayed dialog box, select IRB 4400 from the Version drop-down
xx1500001708

4.2 Procedure
Continued
xx1500001709
group.
xx1500001697
5 In the displayed window, select the CAD models of the tap, sand machine,
and tool gripper (named as tap_03_Position1, SandMachineA, and
4.2 Procedure
Continued
ToolGripper respectively in this case) from the folder where they are saved
to import them to the station.
Note

The models are displayed in the 3D graphics window and listed under the
Components node in the Layout tab page. Two sand machines are required
so that the CAD model of the sand machine has to be imported twice.
7 Attach the tap and tool gripper to the robot by dragging the tap and tool
gripper nodes to the robot node.
setting the model positions later.
xx1500001705
Tip
You can also right-click the tap and tool gripper nodes and choose the
robot from the list under Attach to.
(deg) (deg) (deg)
tap_03_Position1 1527.51 0 1475.10 0 -30 180
SandMachineA 750 1299.04 600 0 90 -30
SandMachineA_2 1409.54 513.03 600 0 90 -70
ToolGripper 1201.24 0 1650 180 60 180

4.2 Procedure
Continued
xx1500001699

PowerPacs group.
xx1500001061

4.2 Procedure
Continued

xx1500001062

New.
xx1500001096
Note

4.2 Procedure
Continued
xx1500001097
4 Click the Target Configuration icon in the Target area.
xx1500001110

4.2 Procedure
Continued
5 In the displayed Robot Configuration tab page, remain the default

configurations or change the positions of robot arm, elbow, and wrist as
required.
xx1500001365

Note


4.2 Procedure
Continued
Step 4: Creating the first tool

xx1500001064
Tip
as Tool1 to distinguish it from the tool set later.
3 In the Tooldata area, click New.
Note
existing tooldata.
xx1500001090

4.2 Procedure
Continued

xx1500001119
area.
• Enter 1311.061, 488.58, and 1400 in the combo boxes successively to
specify the coordinate of the tool position, and then click Accept.
Note
xx1500001167
• Click the drop-down arrow next to Rotation rx,ry,rz.

4.2 Procedure
Continued
• Enter 0, -86.12, and 18.92 in the combo boxes successively to specify

the deviation degree of the tool position, and then click Accept.
Note
xx1500001168
• Click Create.
5 In the Shape Definition area, choose None from the Type drop-down list.
xx1500001169
6 Click OK.

4.2 Procedure
Continued
A fixed tool is displayed at the defined position on one sand belt in the 3D
graphics window and a tool node is displayed in Tool view pane.
xx1500001170
Step 5: Creating the second tool

1 Click Tool in the ribbon tab to create the second tool.
as Tool2.
3 In the Tooldata area, click New.
area.

4.2 Procedure
Continued
• Enter 679.81, 1223.86, and 1138.84 in the combo boxes successively

to specify the coordinate of the tool position, and then click Accept.
Note
xx1500001171
• Click the drop-down arrow next to Rotation rx,ry,rz.

• Enter -90, 0.92, and 149.24 in the combo boxes successively to specify
the deviation degree of the tool position, and then click Accept.
Note

4.2 Procedure
Continued
xx1500001172
• Click Create.
5 In the Shape Definition area, choose None from the Type drop-down list.
6 Click OK.

4.2 Procedure
Continued
The second fixed tool is displayed at the defined position on another sand
belt in the 3D graphics window and a new tool node is displayed in Tool view
pane.
xx1500001173

xx1500001067

4.2 Procedure
Continued
Tip
and click OK.
xx1500001068
Step 7: Creating the intersection geometry

xx1500001069

4.2 Procedure
Continued
Tip

Note

xx1500001070
3

4 Select the required surfaces of the tap in the 3D graphics window.

4.2 Procedure
Continued
xx1500001174
window.
6
7 In the displayed Specify Cutting Plane window, choose Body_X in the
Specify Frame area.
xx1500001175
Note
Specify Frame defines the type of a coordinate direction that will be used
as the Z axis of the frame based on which the intersection curves are
generated.
In this case, Body_X is chosen so that the X axis of the part frame is used.

4.2 Procedure
Continued
8 In the Parameters area, set Interval and Count (xN) to 20 and 3, respectively.
xx1500001176
9 In the 3D graphics window, use the free hand to drag the z axis of the plane
frame to move the plane to a proper position.
xx1500001177
Tip
The free hand may hide after you click another position in the 3D graphics

4.2 Procedure
Continued
10 In the Specify Frame area of the Specify Plane window, tune the plane
position manually by modifying the values in the Position (mm) combo boxes
to -55.67, -27, 448.57 successively.
Note
xx1500001178

xx1500001179
12 Click OK.
Geometry view pane.

4.2 Procedure
Continued
Step 8: Creating operation for the intersection geometry

Setting basic information
xx1500001075
Tip
2 In the Basic area, make sure the created geometry and program group are
selected, and choose Tool1 from the Tool drop-down list to use the first tool
for machining.
xx1500001180
3 Select Zigzag from the Pattern drop-down list in the Path Setting area and
then click Preview.
Note

4.2 Procedure
Continued
The path in zigzag pattern can be previewed in the 3D graphics window.
xx1500001181
Setting and adjusting robot orientation
Note
Machining PowerPac - Machining provides several strategies for setting the robot
orientation. In the Tool rotation method area of the Axis Settings window, you
can choose one of three options to define a rotation method first. When the
Spherical interpolation option is selected, another two option buttons With Z
Axis Rotation and Without Z Axis Rotation are available. In addition, the Rotate
all targets around z axis parameter is provided to define a specific angle of
targets rotating around the z axis. You can choose among the previous strategies
to make the robot work at an optimal orientation.
1 Click the Target Configuration icon in the Target area.
xx1500001110

4.2 Procedure
Continued
2 In the displayed Axis Settings tab page, click Reachability to obtain the
estimated reachable target rate diagram.
xx1500001182
The diagram shows that the estimated reachable target rate is 100% with
this orientation strategy.
Tip
If the rate is 100%, it means all targets are reachable when the robot is at
the orientation defined by the strategy. You can drag the dotted line in the
diagram to view the rates at different robot orientations. The lower the rate
is, the fewer the targets can be reached.
3 Click OK to return the Create Operation window and then click OK to close
the window.
Geometry view pane.
4 With the created operation node selected, click Simulation in the ribbon tab.
5 Drag the slider on the result scrollbar to preview the path and browse the
robot position at each target.
Tip
You can also click the Start icon in the simulation window to run the quick
simulation.

4.2 Procedure
Continued
xx1500001183
6 If the robot orientation with the original strategy is improper, perform the
following sub-steps to change the strategy to adjust the robot orientation.
7 Right-click the operation node and choose Edit from the context menu.
xx1500001186

4.2 Procedure
Continued
8 In the displayed Axis Settings tab page, click Reachability to obtain a new
estimated reachable target rate diagram.
xx1500001185
Tip
You can also drag the dotted line in the diagram to modify the rotation
angle. The reachable target rate changes with the rotation angle when
dragging the dotted line, providing you a reachability reference.

4.2 Procedure
Continued
9 To change to another robot orientation strategy, select the Without Z Axis

Rotation option button and modify the value of Rotate all targets around z
axis to 96.
xx1500001184
Tip
With the Rotate all targets around z axis value changing, the robot
orientation at the first target point is dynamically shown in the 3D graphics
window. You can have a rough preview of the robot orientation along the
path with the current setting.
10 When a satisfied robot orientation with 100% reachable target rate is

determined, click OK to return to and then close the Create Operation
window.
11 Perform simulation again.
Tip
You can repeat the preceding sub-steps until a proper robot orientation is
obtained.

4.2 Procedure
Continued
Step 9: Creating the projection geometry

1 Click Geometry in the ribbon tab and choose Projection geometry from the
Type drop-down list in the Settings area.
Note

the geometry is to be belonged.
xx1500001187
2

3 Select the required surfaces of the tap in the 3D graphics window.
xx1500001188
window.
5
Click the icon next to Specify Project Curve.

4.2 Procedure
Continued
6 In the displayed Specify Project Curve window:

• Choose Manual Pattern from the drop-down list at the top of the
window.
xx1500001190
• Choose the Spline option button in the Type area.
xx1500001283
• In the 3D graphics window, use the free hand to drag the z axis of the
plane frame to move the plane to a proper position.
Tip
The free hand may hide after you click another position in the 3D
graphics window. To display it again, click any Position (mm) combo
box in the Specify Frame area to activate.
You can also modify the values in the Position (mm) combo boxes
in the Specify Frame area directly to obtain the proper position.

4.2 Procedure
Continued
xx1500001364
• In the Specify Points area, click a Point (mm) combo box to activate
the point choosing.
• In the 3D graphics window, double-click on the selected surface to
select points one by one.
The coordinate of each point is automatically listed in the Specify
Points area. When selecting a new point, a line is generated between
this point and its previous point. After all points are selected, a curve
is displayed.
xx1500001191
• Click the first point set in the list and use the free hand to drag the
coordinate axes in the 3D graphics window to tune the point position.

4.2 Procedure
Continued
Repeat this operation until all points are set to a proper position for
generating a curve path.
xx1500001284
• Click OK to return.
7 Click Preview.
xx1500001285
8 Click OK.
A new geometry is displayed under the created workobject in the Geometry
view pane.
Step 10: Creating operation for the projection geometry

Setting basic information
1 With the newly created geometry selected, click Operation in the ribbon tab.
2 In the Basic area, make sure the newly created geometry and program group
are selected, and choose Tool1 from the Tool drop-down list to use the first
tool for machining.
3 Click Preview.

4.2 Procedure
Continued
The path can be previewed in the 3D graphics window.
xx1500001286
4 Click OK.
An operation node is displayed under the newly created geometry node in
the Geometry view pane.
Setting and adjusting robot orientation

1 With the created operation node selected, click Simulation in the ribbon tab
2 If collision occurs or the robot orientation/position is improper, perform the
following sub-steps to set robot orientation strategy for obtaining optimal
robot orientation during the machining.
3 Right-click the operation node and choose Edit from the context menu.
xx1500001287

4.2 Procedure
Continued
4 In the displayed Edit Operation window, click the Target Configuration icon
in the Target area.
xx1500001110
5 In the displayed Axis Settings tab page, click Activate Local Settings to
xx1500001122
Note
The axis settings of an operation inherit the settings of the parent node to
which the operation belongs by default and are unavailable for modification
when the Axis Settings window is opened. To modify the settings, always
click Activate Local Settings. To remain the default settings inherited from
the parent node, click Inherit Parent Settings.
6 Choose Spherical interpolation from the drop-down list in the Tool rotation
method area and then click Reachability to obtain the estimated reachable
target rate diagram.
xx1500001289

4.2 Procedure
Continued
7 Drag the dotted line in the diagram to view the reachable rate in a specific
angle and preview the robot orientation at the first target point with this angle
setting in the 3D graphics window.
xx1500001290
xx1500001291

4.2 Procedure
Continued
8 If the robot orientation with this strategy is unsatisfied, change to another

strategy by choosing Fixed tool orientation from the drop-down list in the
Tool rotation method area.
xx1500001292
9 Click Reachability again to obtain the estimated reachable target rate diagram
with the new strategy. Drag the dotted line also in the diagram to preview
the robot orientation at the first target point in the 3D graphics window.
determined, click OK to return the Edit Operation window and then click OK
to close the window.
xx1500001294
11 With the created operation node selected, click Simulation in the ribbon tab.
12 Drag the slider on the result scrollbar to preview the path and browse the
robot position at each target.
Tip
You can also click the Start icon in the simulation window to run the quick
simulation.

4.2 Procedure
Continued
Tip
You can repeat the preceding sub-steps until a proper robot orientation is
obtained.
Changing tool for the operation
Note
This procedure is required when a tool has already been set for an operation
and needs to be replaced by another tool for the operation.
1 In the Tool view pane, click and drag the required operation node (second
node in this case) under Tool1 node (when creating the operation, Tool1 is
set as the tool for the operation) to Tool2 node.
xx1500001295
The status of the operation node changes from Up to date to Out of date.
xx1500001296
Note
An operation node has the following three statuses:

• Error: Parameters of the operation are invalid so that the path cannot
be generated.
• Out of date: Some settings have been modified and the robot path is
out of time. You should regenerate the path.
• Up to date: Latest parameters have been updated in the path. The
nodes in this status are available for use.

4.2 Procedure
Continued
2 Right-click the operation node and choose Regenerate Path from the context
menu.
xx1500001297
3 Click OK in the displayed Regeneration Done dialog box.

The status of the operation node is updated to Up to date.
xx1500001298
4 Perform simulation again to preview the path and robot orientation.

5 If collision occurs or robot orientation is improper, edit the operation and
change to another strategy to adjust the robot orientation by referring to
Setting and adjusting robot orientation on page 157.

4.2 Procedure
Continued

xx1500001081
Tip
xx1500001082
Note

5 Robot on track with robot-hold tool
5.1 General

5.1 General
Objective
Users will be able to complete polishing tasks by:
• Creating intersection and UV curve geometries on to-be-machined work
pieces
• Creating a tool on an existing robot-hold tool and setting tooldata to make
the tool be properly attached to the existing tool
• Setting and adjusting track configuration using different strategies
• Setting and adjusting robot orientation by choosing between different
interpolation strategies
• Modifying robot configuration
By following the instructions of this tutorial, final path shown in the following figure
can be generated.
xx1500001374

5.1 General
Continued
Required equipment
Note
the task.

Robot IRB 6640
Track IRBT 6004
CAD model Ship body
Tool Polishing tool Robot-hold tool

5.2 Procedure
5.2 Procedure
Note

1 Open the RobotStudio programme and load the preset station Case 5 - Robot
on track.
Note

includes the settings of the robot, CAD model of the to-be-machined ship
body, and polishing tool.
xx1500001314

5.2 Procedure
Continued

xx1500001622
xx1500001623

5.2 Procedure
Continued
xx1500001717

5.2 Procedure
Continued
3 In the displayed dialog box, select IRB 6640-180 from the Version drop-down
xx1500001706

5.2 Procedure
Continued
xx1500001718

5.2 Procedure
Continued
Station group and then choose IRBT 6004 from the track list.
xx1500001716

5.2 Procedure
Continued
5 In the displayed dialog box, select Standard, 8, and 90 from the Type, Track
length (m), and Robot angle (deg) drop-down list, and then click OK.
xx1500001720
The track is displayed in the 3D graphics window.
xx1500001721

5.2 Procedure
Continued
6 On the Home ribbon tab of RobotStudio, choose Import Library > User
Library > MillingTool in the Build Station group.
xx1500001710
xx1500001719

5.2 Procedure
Continued
group.
xx1500001697
8 In the displayed window, select the CAD model of the canoe (named as
canoe(6000mm) in this case) from the folder where it is saved to import it to
the station.
Note

9 Drag the attaching nodes to the corresponding nodes to be attached.
• Attach the robot to the track
• Attach the milling tool to the robot
An Update position dialog box is displayed. Click Yes to accept the position
update.
xx1500001715

5.2 Procedure
Continued
Tip
You can also right-click the attaching node and choose the to-be-attached
node from the list under Attach to.
10 Right-click the canoe node and choose Position > Set Position to set its
position based on the following data.
(deg) (deg) (deg)
Canoe 3527.63 3077.24 1524.24 180 0 0
xx1500001699

5.2 Procedure
Continued

PowerPacs group.
xx1500001061

xx1500001062

5.2 Procedure
Continued

New.
xx1500001096
Note
3 In the Create Workobject window:

• Click the drop-down arrow next to Position x,y,z in the User Frame
area.
• Activate the displayed combo box by clicking it and then click a point
on the ship body in the 3D graphics window.

5.2 Procedure
Continued
click Accept.
xx1500001315
• Click Create.
A work object node is displayed in Geometry view pane.
Note

Step 4: Creating tool

xx1500001064

5.2 Procedure
Continued
Tip
Note
existing tooldata.
xx1500001090

area.

5.2 Procedure
Continued
• Activate the displayed combo box by clicking it and then click the center
point of the tool tip with the Snap Center mode chosen in the 3D
graphics window.
xx1500001316

5.2 Procedure
Continued
The coordinate of the selected point is displayed in the text box.
xx1500001348
• Modify the value in the red combo box to 250.
Note
xx1500001317
• Click Accept.

5.2 Procedure
Continued
• Click the drop-down arrow next to Rotation rx,ry,rz in the Tool Frame
area and enter 90 in the green combo box.
xx1500001319
• Click Accept and then click Apply.

xx1500001320

5.2 Procedure
Continued
4 In the Shape Definition area of the Create Tool window, choose T_Cutter
from the Type drop-down list.
xx1500001116

• Enter 50 in the Holder Diameter (mm) text box.
• Enter 200 in the Holder Length (mm) text box.
xx1500001321
Note

• Contact Diameter: Specifies the diameter from the tool tip to the tool
part that is actually used to process.
• Holder Diameter: Specifies the diameter of the tool holder.
• Holder Length: Specifies the length of the tool holder.

5.2 Procedure
Continued

window.
xx1500001322
6 Click OK.

xx1500001067
Tip

5.2 Procedure
Continued
and click OK.
xx1500001068
Step 6: Creating UV curve geometry

xx1500001069
Tip

5.2 Procedure
Continued
2 In the displayed Create Geometry window, choose UV Curve from the Type
drop-down list in the Settings area.
Note

xx1500001305
3

4 Select the to-be-machined surface of the ship body in the 3D graphics window.

5.2 Procedure
Continued
xx1500001323
window.
6
Click the icon next to Specify UV Parameter.
7 In the displayed Specify UV Parameter window, remain the default settings
and click OK to return.
xx1500001324
8 Click Preview.

5.2 Procedure
Continued
xx1500001325
9 Click OK.
Geometry view pane.
Step 7: Creating operation for the UV curve geometry

xx1500001075
Tip

5.2 Procedure
Continued
tool, and program group are selected in the Basic area, and modify the
operation name to OPR to distinguish from the operation set later.
xx1500001326
3 In the Path Setting area, choose Zigzag from the Pattern drop-down list.
Note
xx1500001327
4 Click the Process Move Setting icon.
5 In the displayed Process Move Setting window, modify the value of Max
Length (mm) to 0.
Tip
The Max Length (mm) parameter is disabled when being set to 0.

5.2 Procedure
Continued
xx1500001329
6 Click OK to return and click Preview.

xx1500001330
7 Since the target rate is not 100% which means not all targets can be
processed, click the Target Configuration icon in the Target area to modify
track configuration and robot orientation.
xx1500001110

5.2 Procedure
Continued
8 In the displayed External Axis tab page, click Activate Local Settings to
xx1500001122
Note
The external axis settings of an operation inherit the settings of the parent
node to which the operation belongs by default and are unavailable for
modification when the External Axis tab page is opened. To modify the
settings, always click Activate Local Settings. To remain the default
settings inherited from the parent node, click Inherit Parent Settings.
9 Choose Distance from the Strategy drop-down list to specify the strategy.
xx1500001331

5.2 Procedure
Continued
10 Drag the slider to a desired value (-523 in this case) on the scrollbar under
Offset distance (mm) or enter the value directly in the text box.
xx1500001332
11 Enter the Axis Settings tab page, remain the default strategy settings, that
is, the With Z Axis Rotation option button is selected under the Spherical
interpolation option.
xx1500001344

5.2 Procedure
Continued
12 Click Reachability again to obtain the estimated reachable target rate

diagram. Drag the dotted line in the diagram to preview the robot orientation
in the 3D graphics window.
xx1500001345

determined (in this case, Rotates all target around z axis is 105), click OK
to return the Create Operation window and then click OK to close the window.
An operation node is displayed under the created geometry node in the
Geometry view pane.

xx1500001078

5.2 Procedure
Continued
Tip
xx1500001079

xx1500001081
Tip

5.2 Procedure
Continued
xx1500001082
Note

Contact us
3HAC055902-001, Rev B, en
ABB AB
Discrete Automation and Motion
Robotics
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400
ABB AS, Robotics

Discrete Automation and Motion
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 51489000
ABB Engineering (Shanghai) Ltd.

No. 4528 Kangxin Highway
PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
www.abb.com/robotics

3HAC055902 - Machining PowerPac Tutorials

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3HAC055902 - Machining PowerPac Tutorials

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© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

1 Simple polishing - flat surface polishing with robot-hold tool 9

2 Tool axis control - dispensing with robot-hold work piece 43

3 Path Editor - lid deburring with robot-hold work piece 77

5 Robot on track with robot-hold tool 165

Directions for use - Machining PowerPac 5

Overview of the manual

Who should read this manual?

Directions for use - Machining PowerPac 7

1 Simple polishing - flat surface polishing with

Continues on next page

Type Description Note

10 Directions for use - Machining PowerPac

Step 1: Opening RobotStudio and starting with a preset or new station

Loading a preset station

The preset station is saved in C:\Program Files (x86)\ABB Industrial

Continues on next page

Creating a new station

An empty station is displayed in the 3D graphics window.

Continues on next page

Continues on next page

The robot is displayed in the 3D graphics window.

Continues on next page

The CAD models are saved in C:\Program Files (x86)\ABB Industrial

Continues on next page

Step 2: Opening Machining PowerPac

Continues on next page

Step 3: Creating workobject

2 In the WorkObject area of the displayed Create WorkObject window, click

Continues on next page

Continues on next page

5 In the Path&Targets view pane, right-click the Workobject_1 node and

Continues on next page

6 Click Yes in the displayed Update position dialog box.

Step 4: Creating face-machining tool

You can also click Tool directly in the ribbon tab.

Continues on next page

3 In the Create Tooldata window:

Continues on next page

6 Modify the tool shape parameters as follows:

Continues on next page

Definitions of tool shape parameters are as follows:

Continues on next page

The tool with modified shape parameters is displayed in the 3D graphics

Step 5: Creating program group

You can also click Program directly in the ribbon tab.

Continues on next page

A program node is displayed in Program view pane.

Step 6: Creating intersection geometry for the shell backplane

You can also click Geometry directly in the ribbon tab.

Continues on next page

2 In the displayed Create Geometry window, choose Intersection Geometry

The created workobject is selected for the WorkObject drop-down list in

Area icon in the displayed Process Area window.

Continues on next page

Continues on next page

9 Click OK to return and then click Preview.

Continues on next page

The path is highlighted in the 3D graphics window.

Step 7: Creating operation

You can also click Operation directly in the ribbon tab.