ABB Robotics. Product manual BullsEye

Transcription

1 ABB Robotics Product manual BullsEye

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3 Product Manual BullsEye IRC5 3HAC Rev. A

4 The information in this document is subject to alteration without prior notice and should not be regarded as an undertaking from ABB Automation Technologies AB. ABB Automation Technologies AB assumes no responsibility for errors that may occur in this document. ABB Automation Technologies AB bears no responsibility for damage that is a consequence of using this document or the software or hardware described in this document. The document, or parts of it, may not be reproduced or copied without prior permission from ABB Automation Technologies AB. It may neither be imparted to a third party nor otherwise be used without authorization. Infringement hereof will be subject to action in accordance with applicable laws. Further copies of this document can be obtained from ABB Automation Technologies AB at current prices ABB Automation Technologies AB ABB Automation Technologies AB Robotics & Manufacturing SE Laxå Sweden

5 Table of contents Product documentation, M Introduction General Safety instructions Description Warning symbols (signals) DANGER Ensure that the main power switch is turned off WARNING The unit is sensitive to ESD Overview Product Overview BullsEye New for Version 10 BullsEye Theory of Operation Example of operation Requirements Overview System Prerequisites Installation Components List BullsEye Yoke Specifications Dimensions Hardware set-up Placing Setup Attaching Installation procedure Electrical installation Assembly Start-up Test Before running BullsEye Maintenance General Spare parts list TCP gauging unit BullsEye complete HAC Rev. A i

6 Table of contents ii 3HAC Rev. A

7 Product documentation, M2004 Product documentation, M2004 Overview The robot documentation may be divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems. Hardware manuals All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts: Product manual, procedures Safety information Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software) Maintenance (descriptions of all required preventive maintenance procedures including intervals) Repair (descriptions of all recommended repair procedures including spare parts) Additional procedures, if any (calibration, decommissioning) Product manual, reference information Reference information (article numbers for documentation referred to in Product manual, procedures, lists of tools, safety standards) Part list Foldouts or exploded views Circuit diagrams RobotWare manuals The following manuals describe the robot software in general and contain relevant reference information: RAPID Overview: An overview of the RAPID programming language. RAPID Instructions, functions and data types: Description of all RAPID instructions, functions and data types. System parameters: Description of system parameters and configuration workflow. Application manuals Specific applications (e.g. software or hardware options) are described in Application manuals. An application manual can describe one or several applications. 3HAC Rev.A 1

8 Product documentation, M2004 An application manual generally contains information about: The purpose of the application (what it does and when it is useful) What is it included (e.g. cables, I/O boards, RAPID instructions, system parameters) How to use the application Examples of how to use the application Operating manuals This group of manuals is aimed at those having first hand operational contact with the robot, i.e. production cell operators, programmers and trouble shooters. The group of manuals include: IRC5 with FlexPendant RobotStudio Online Trouble shooting - IRC5 for the controller and robot 2 3HAC Rev.A

9 Introduction General 1 Introduction 1.1 General About this manual This manual explains the basics of when and how to use the following BullsEye options: Product overview Operation overview Requirements overview Hardware set-up Electrical installation Start-up Test Usage This manual is intended for use in conjunction with: Installation Operation Maintenance and repairs Who should read this manual? This manual is intended for: Operators Installation personnel Repair and maintenance personnel Basic skills Readers of this manual should: be familiar with industrial robots and their terminology be familiar with the equipment be skilled in mechanical and electrical installation/maintenance/repairs 3HAC Rev.A 3

10 Introduction General User s qualifications Operator The Operator requires very little instruction to take advantage of BullsEye. Programmer The Programmer must be well versed in RAPID programming. He/She should understand: What a TCP is. How to save a module. How to modify a RAPID instruction s interface including adding and removing optional arguments. How to create new data instances of tooldata, jointtargets, etc. Reference documents Document Operating manual - Getting started, IRC5 and Robot- Studio Online Operating manual - IRC5 with FlexPendant Application manual - BullsEye (software) Application manual - Production manager Document Id 3HAC HAC HAC HAC HAC Rev.A

11 Safety instructions 2 Safety instructions A robot is heavy and extremely powerful regardless of its speed. A stoppage or longer stop can be followed by rapid, dangerous movements. Even if the robot's pattern of movement is predetermined, an external signal can affect the movement sequence, resulting in unanticipated movement. It is therefore important that all safety instructions are observed when entering a safety supervised area. 2.1 Description Safety instructions can be found under tab 1 in the AW system manual for all steps that involve risk for personal injury or material damage. In addition, they are included in the instructions for each step. General warnings, where the intention is to avoid problems, are only included in the pertinent instructions. All personnel working with the welding robot system must have full understanding of the applicable safety instructions. Reference document Document Related safety instructions. Described in: AW System manual, chapter introduction and safety 3HAC Rev.A 5

12 Safety instructions Warning symbols (signals) 2.2 Warning symbols (signals) Symbol explanations The different types of warnings are set out in the following chapters according to the table below: Symbol Name! Danger Warning Electric shock Caution Meaning Warning that serious or life-threatening personal injury and/or serious damage to the product will occur if the instructions are not followed. Warns of the risk of personal injury or serious damage to the product. Always follow the instructions that accompany this symbol. Warns of possible electric shock that can cause life-threatening or serious personal injury. Always follow the instructions that accompany this symbol. Draws your attention to the fact that damage to the product may occur if an action is not performed or is performed incorrectly. Static electricity ESD The ESD symbol indicates a risk of static electricity that may cause serious damage to the product. Note Information about important parts. Tips This symbol refers to an instruction providing further information on a particular step. 6 3HAC Rev.A

13 Safety instructions DANGER Ensure that the main power switch is turned off DANGER Ensure that the main power switch is turned off. Description Work with high voltage entails a potential lethal hazard. Persons subjected to high voltages can suffer heart failure, burns or other serious injuries. To avoid such injuries, never begin a job without first eliminating the risks to safety. These are descried below. Elimination Action 1. Turn off the main power switch at the control module. The main power switch on the control module switches off the control voltage to all the drive modules. 2. Turn off the main power switch (work switch) on the respective drive module to switch off the feed voltage. 1 Info/Illustration 2 3. Single robot stations All voltage is lost when the main switch on the drive module (DM1) is switched off. 3HAC Rev.A 7

14 Safety instructions WARNING The unit is sensitive to ESD WARNING The unit is sensitive to ESD. Description ESD (electrostatic discharge) is the transfer of electrostatic charges between two objects with varying charges, either through direct contact or through an electrical field. The discharge contains very little electricity and is therefore not hazardous to humans, however, electronics can be damaged by the high voltages. Elimination Action Info/Illustration 1. Use an ESD bracelet. The bracelet must be regularly tested to ensure that it is undamaged and functions properly. 2. Use an ESD-protected floor mat. The mat must be grounded through a voltage regulating resistor. 3. Use an ESD-protected table mat. The mat shall produce a controlled discharge of static electricity and must be grounded. Location of attachment point for ESD bracelet Button (A) for the ESD bracelet is located on the computer unit in the control module/drive module. The location is shown in the following figure. A B Drivmodul, bild på knapp för ESD Figure 1 Location of attachment point for ESD bracelet xx HAC Rev.A

15 Safety instructions WARNING The unit is sensitive to ESD. Item A B Name Attachment point for ESD bracelet in the control module. Attachment point for ESD bracelet in the drive module. 3HAC Rev.A 9

16 Safety instructions WARNING The unit is sensitive to ESD. 10 3HAC Rev.A

17 Overview Product Overview 3 Overview 3.1 Product Overview BullsEye BullsEye version 10 provides completely automated Tool Center Point (TCP) definition for the IRC5 robot controller. TCP TCP is defined as an invisible reference point in direct alignment and relationship to all axes of the robot arm and located at the precise point where the welding wire tip would touch the work-piece using a pre-determined wire stick-out distance from the bottom of the gas nozzle. Illustration TCP Reference Figure 2 Welding Torch Revolving Around A Set TCP New for Version 10 BullsEye 1. Full MultiMove compatibility. 2. Improved joint limit checking to detect out-of-reach errors early in the setup. 3. Fully integrated with RobotWare delivery. 3HAC Rev.A 11

18 Overview Theory of Operation 3.2 Theory of Operation Example of operation When the robot is instructed to revolve around the TCP all robot axes will move accordingly to keep the TCP stationary (See Figure 3 and Figure 4). If the torch is damaged and the program is run again, the robot repeats the same movements, but the TCP will no longer follow the same path due to the misalignment. You now have two choices: 1. Physically move the torch back into alignment (a task that could be difficult if not impossible) 2. Adjust for the misalignment automatically by redefining the TCP to the new torch position using the BullsEye. After the BullsEye system updates the current TCP definition, the torch will rotate around the TCP as before because the robot arm has adjusted its path to compensate for the torch misalignment. Once a point has been programmed, the robot remembers the tool center point location, not what the angles of the robot joints are. When the robot replays the programmed path, it calculates what the joint angles should be to get the TCP back to where it was when the path was programmed initially. As long as the robot controller is kept informed about where the tool center point is, it will always keep the paths properly adjusted. 12 3HAC Rev.A

19 Overview Example of operation Illustration Figure 3 Robot Arm and Torch Movement With Correct TCP Figure 4 Robot Arm Follows Same Path But Torch Path Has Changed 3HAC Rev.A 13

20 Overview Requirements Overview 3.3 Requirements Overview System Prerequisites BaseWare requirements: Controller requirements: Digital input RobotWare options: 5.06 or higher IRC5 At least one free Arc, BullsEye 14 3HAC Rev.A

21 Installation Components List 4 Installation 4.1 Components List BullsEye consists of the following components: Application mnaual - BullsEye. This will be distributed in electronic format, unless a printed version is purchased. BullsEye scanning device. Typically this will be the standard BullsEye yoke described below. BullsEye RAPID robot software. Software may be delivered as a separate product bundled on a CD-ROM with documentation, or as part of cell management software like GPP and EasyArc BullsEye Yoke Specifications Technical data Electrical 40 ma, 24 VDC Robot Connections One digital input, 24 VDC, and 0 VDC Repeatability ± 0.006" (0.163 mm) 3HAC Rev.A 15

22 Installation Dimensions Dimensions Variant : M ,5 ±0,02 Figure 5 Standard BullsEye Yoke Ø6 H8 bullseye_tysk.tif 16 3HAC Rev.A

23 Installation Hardware set-up 4.2 Hardware set-up Placing The BullsEye scanning device must be placed in a location that allows the robot to move freely about the TCP without reaching its joint limits and without causing undesirable cable tension. Illustration Setup Attaching Figure 6 Figure IN.2 Scan Device Location Although BullsEye can be configured to handle any scan device orientation, it is easiest to setup BullsEye when the beam of the scanning device is in a plane parallel to the plane of the robot s base. The BullsEye should be either bolted securely in a position where the robot can reach it and where it is not in the way of personnel working around the robot. 3HAC Rev.A 17

24 Installation Installation procedure Illustration Figure 7 Figure IN.3 Base Coordinates Installation procedure Figure 8 Figure IN.4 Alignment Angle Of 45 Works Best Action Info/Illustration 1. The best procedure for installation is to place the BullsEye in a desired position without securing it permanently. 2. Perform the software installation. See Application manual - BullsEye 3. Execute the BullsEye setup procedures See Application manual - BullsEye as described in Section 4.3. If the robot is able to complete the full TCP update process and successfully completes a Quick- Check routine while meeting all other location requirements, 4. Bolt it solidly in position. 18 3HAC Rev.A

25 Installation Electrical installation 4.3 Electrical installation Assembly The BullsEye is pre-wired at the factory for easy assembly. Connect the cable provided from the Robot controller to the connector on the BullsEye unit. Installation diagram The installation of the BullsEye is described in Circuit diagram - Process Options Torch Equipment, 3HEA Installation check When the BullsEye is correctly wired, the LED on the I/O board corresponding to the input should be illuminated only when the beam is broken. 3HAC Rev.A 19

26 Installation Start-up Test 4.4 Start-up Test Before running BullsEye Perform a start-up test before running BullsEye. Instruction Action 1. Check that the digital input connected to the scanning device is responding correctly. To do this, verify that the signal is defined as an input on an I/O board. 2. Pass your hand through the BullsEye yoke beam to break the beam. The LED on the I/O board corresponding to the input should turn on when the beam is broken. If it does not, verify that the I/O board is configured properly and that the wiring is correct. 20 3HAC Rev.A

27 Maintenance General 5 Maintenance 5.1 General The BullsEye is shipped complete and requires very little maintenance aside from keeping the unit clean. Refer to Section 4.2 for wiring information. Replacement parts Replacement parts may be obtained from ABB Automation Technologies AB. Be prepared to provide complete information on the part(s) you need as well as robot serial number. 3HAC Rev.A 21

28 Maintenance General 22 3HAC Rev.A

29 Spare parts list 6 Spare parts list Spare parts are to be ordered from ABB Automation Technologies AB. Kindly indicate type of unit, serial number, denominations and ordering number according to the spare parts list. Rights to reserved to alter specifications without notice. The spare parts list contains all information required for ordering special parts of the TCP gauging unit. Please ensure that you give us the precise description of the part which you require. A pair of special-purpose pliers is absolutely essential for fitting the fibre-optic cable (Item 2). 3HAC Rev.A 23

30 Spare parts list TCP gauging unit 6.1 TCP gauging unit Item Qty Art. no Description Remark Complete for TC-96 BullsEye Measuring pin BullsEye fiber optic incl. special tool Optoelectronic sensor HAC Rev.A

31 Spare parts list BullsEye complete 6.2 BullsEye complete Pos Item Antal Qty Art. nr Art. no Description BullsEye stand alone, complete Anmärkning Remark BullsEye upper pole BullsEye pole foot Ext. cable 7 m Ext. cable 10 m Ext. cable 15 m 3HAC Rev.A 25

32 Spare parts list BullsEye complete 26 3HAC Rev.A

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34 Contact us ABB AB Discrete Automation and Motion Robotics S VÄSTERÅS SWEDEN Telephone +46 (0) HAC Rev A, en