ABB Robot Basic Training

Introduction

ABB robots are appearing throughout the plant. They are in use as painters, waterjets,
pushnut insertion, riveters, routers, sonic welders, and laser scoring – to name but a few uses. It
is important for the Facilities group to be able to support these machines. Therefore, Facilities
(maintenance) personnel must be familiar with the safe operation of these robots.
This course is intended to give a basic working knowledge of ABB robots. It is not
intended to teach advanced programming technique nor systems integration, but will (hopefully)
provide enough information to comfortably move a robot around and recover from common
problems.
Much of the information included in this guide has been duplicated from the RPT Student
Guide. It provides most of the basic information necessary… and bears no copyright notice.
Nothing has been copied directly from ABB’s (copyrighted) manuals.

Safety

Safety devices
 Safety fences, barriers, and chains
 Light curtains
 Pressure mats
 Vision systems
 RF area guards
 Interlocks
 Mechanical stops
 EMERGENCY STOP buttons/switches
 ENABLING DEVICE switches
 Floor markings
 Warning lights
Teaching or Manual Operation Safety

 Visually inspect the robot, tooling fixtures, and work envelope to make sure that no
potentially hazardous conditions exist.
 The area around the robot must be clean and free of slip/trip hazards (grease, oil, water,
and debris such as pushnuts).
 Verify all safeguards are in place.
 Check for proper operation of the ENABLING DEVICE switch.
 Place the robot MODE select switch in T1 position.
 If you must enter the workcell, take the teach pendant with you. Only the person with the
teach pendant should be in the workcell.
 Use reduced speeds to manually move the robot.

Workcell safety

Safety is essential whenever robots are used. Keep in mind the following factors with regard to
safety:
 Never rely on software as the primary safety element.
 Clearly identify the work envelope of each robot in the system with floor markings, signs,
and special barriers. The work envelope is the area defined by the maximum motion
range of the robot – including any tooling attached to the wrist flange.
 Arrange the work cell so the operator faces the work cell and can see what is going on
inside the cell.
 Position all controllers outside the robot work envelope.
 Mount an adequate number of EMERGENCY STOP buttons/switches within easy reach
of the operator(s) and at critical points inside and around the work cell.
 Whenever possible, install safety fences to protect against unauthorized entry by
personnel into the work envelope.
 Install special guarding to prevent the operator(s) from reaching into restricted areas of
the work envelope.
 Use interlocks.
 Use presence or proximity sensing devices such as light curtains, mats, and vision
systems to enhance safety.
 Make sure all external devices are properly filtered, grounded, shielded, and suppressed
to prevent hazardous motion due to the effects of electromagnetic interference (EMI),
radio frequency interference (RFI), and electrostatic discharge (ESD).
 Make provisions for power lockout/tagout at the controller.
 Eliminate pinch points. Pinch points are areas where personnel could get trapped
between a moving robot and other equipment. Consider that a safety fence could also be a
pinch point.
 Install lights and/or audible indicators that activate when the robot is active (power is
applied to the servo drive system). Audible indicators should exceed ambient noise level.
 Provide adequate room inside the workcell to permit safe maintenance and programming.
 Robot System
- -
Axis 5 Axis 4
1. Manipulator + +
- -
A. Axis offsets Axis Axis 3
6 on a tag at rear of vertical arm.
usually
B. +
Provides connections for air/signal to EOAT (End+ of Arm Tooling).
C. Six axis
Minor axes Major axes
 Major axes
(Group 2) (Group 1)
 Axis1 (base), axis 2 (waist), axis- 3 (elbow)
 Establish shape of work envelope. Axis 2
 Control position of EOAT within + work envelope.
 Define location of frames of motion.
 Minor axes
 Axis 4 (forearm), axis 5 (wrist fold), axis 6 (wrist rotate)
 Control orientation of EOAT.
D. Each axis can move independently of the other five.
E. Axes can make coordinated moves.
F. All six axes rotate (on our units).- Axis 1 +
G. Optional external axes (axis 7 – 12 )
H. Each axis is driven by a servomotor.
 Uses two encoders for positioning.
 Servo motors are not user serviceable.
I. Each motor has an internal (integral) brake.
 Mechanically applied, electrically released via servo amplifier signal.
 Can be damaged by improper robot lubrication.
 Failure is typically loss of brake current (signal) rather than failure of the
brake itself.
 Entire motor must be replaced if the brake fails.
 Manipulators

IRB 2400 IRB 2400L

IRB 4400

IRB 6400
IRB 6600
2. Software
A. Defines the function of the robot (welding, painting, palletizing, etc.).
B. “Lives” inside the controller.
C. Contains core operating system.
D. User programs
E. Fault isolation and diagnostics
F. User defined parameters
 Frames
 System variables
 I/O configuration
G. Communication protocols

3. Controller

A. The “brains” of the system.

B. Converts program data into servo drive signals.
C. Contains hardware to work with peripheral communications devices.
D. Interface with work cell.
 Emergency stop connections
 Communications ports
 Discrete I/O
E. Directs/coordinates motion for the six mechanical unit and any external axes (up
to six additional axes).
F. Two sizes of cabinets.
 Tall cabinet – C5.3 painters, S4 (6400), PLC (waterknife).
 Short cabinet – S4C(+) & S4P(+) – most of ours.
 Controllers

Paint robots
Pictured above are the three kinds of paint robot controllers in use:
 C5.3 – used with the 510 robots
 S4P – Development cell and Cell 22.
 S4P+ - Cell 33 spray robots

Other robots
 S4 (tall cabinet) – Ex-welders (now FIP and “spare”)
 S4C (disconnect handle)
 S4CPLUS (rotary disconnect)
4. Operator Panel

A. MODE SELECT keyswitch

 AUTO (Production) mode
 ENABLING DEVICE must be released or an error will occur.
 Cannot start programs using the teach pendant.
 Safety fence is monitored.
 Key may be removed in the Auto position.
 Manual Reduced Speed (Programming) mode(<250 mm/s):
 Programs can be activated only from teach pendant, and only when
ENABLING DEVICE is activated (center position).
 Sets MOTORS OFF state unless ENABLING DEVICE is active.
 TCP speed is less than 250 mm/s during jogging.
 During program test, robot will move at program speed or 250
mm/s – whichever is less.
 Safety fence is bypassed.
 Key may be removed in the Manual Reduced Speed position.
 Manual Full Speed (Testing) mode (100%):
 Common on paint robots.
 Very few of our other short cabinet robots have this option.
 Programs can be activated only from teach pendant, and only when
ENABLING DEVICE is activated (center position).
 TCP speed is less than 250 mm/s during jogging.
 During program test, full program speed is allowed – controlled by
the override. Full speed button (near ENABLING DEVICE) must
be held.
 Key may not be removed in the Manual Full Speed position.

B. MOTORS ON button
 Usually a white, illuminated pushbutton.
  Doubles as fault acknowledge/reset button.
 Illuminated when drives are on.
 Blinks in manual when drives are ready, but not on.
 Fast-blinks to indicate Rev counter problem.

C. Emergency Stop button

 Immediately stops the robot – regardless of state or mode. Detented
button must be returned to its original position before MOTORS ON is
allowed.

D. Optional Operator Panel controls

 MOTORS OFF button
 Hour meter
 Servo disconnect
 Paint system controls (purge, status)
Operator panels
5. Teach pendant
A. An operator interface device which can either be considered as part of the
controller – or as a peripheral device.
 Connected to the controller via a cable.
 Moves (jogs) the robot.
 Create/edit/test programs
 Loads/saves/backs up files
 Checks status
 Performs manual functions
 Configures applications
 Adjusts system parameters
 Sets up production

B. Control components
 Joystick
Controls up to three elements of motion at a time.
 EMERGENCY STOP Button
Press to stop robot, twist to reset.
 ENABLING DEVICE Switch
Also called a DEADMAN, this switch allows robot motion only when
the switch is gripped to the center position. If the switch is released or
clenched to the fully depressed position, the robot stops immediately.
 Full Speed Enable Button
On controllers equipped with a Manual Full Speed (100%) position on
the Mode Select keyswitch, this button must be pressed to enable the
robot to run at 100% speed.
 User defined buttons
Two buttons (located above ENABLING DEVICE switch)
C. Teach pendant keys
 Window (Four keys - located at left edge of screen)
Jog
Program
I/O
Miscellaneous
 Menu (Five keys above top edge of screen)
Contrast
 Motion (Four keys - located at right edge of screen)
Robot/external axis
Reorient/Cartesian
Joint Base/Wrist
Incremental mode

 Data entry and Navigation

7 8 9

4 5 6
Numbers (also used for text)
1 2 3

- 0 .

Delete
List On/Off (AKA “Jump the fence”)
Page Up/Down
Enter

Arrows

 P1 P2 P3 User defined
 Function (Five keys below bottom edge of screen)
Stop
 Teach Pendant

7 8 9

4 5 6

1 2 3

- 0 .

P1 P2

P3
6. Peripheral Equipment

Any item which is not part of the mechanical unit, software, or controller.
A. PLC

B. Operator Interface Panel – usually a PanelView on our machines

C. End-of-Arm Tooling (EOAT)

D. Fixtures

E. Communications
 RS-232-C and RS-422 serial ports
 Ethernet connections
 USB connection* (not currently available)
 Allen-Bradley Remote I/O
 System Startup and Shutdown

1. Power up
 Before turning on the power, inspect the robot, workcell, and surrounding area to
verify that it is safe. Remove slip/trip hazards or other debris. Make sure the
safeguards are in place and the work envelope is clear of personnel.
 Activate disconnect handle at main control cabinet.
 Move the robot controller circuit breaker disconnect switch to the ON position.

 Turning on the power disconnect warm-boots the robot controller, which in turn
powers the robot and performs the following activities:
o Self-test for pendant, batteries, and other system components.
o Verifies Rev(olution) counter status.
o Initializes any changes to I/O and/or system parameters.
 Some machines (Kimastle, Flow) require machine control power to be on before the
robot can be driven. Others generate an E-stop (drop control power) whenever a
robot is in manual mode – but allow the robot to move. The laser score machines have
a separate mode switch, which must be in the “Robot” position to allow the robot to
be manually driven.

2. Power down
 Press the Stop button on the teach pendant if a program is running or if the robot is
moving – or move the keyswitch to the MANUAL position.
 The PLUS-series controllers provide a gentle, soft shutdown procedure:
o Press the MISC key.
o Select SERVICES option.
o Pull-down the FILE menu.
o Select Shutdown.
o Confirm decision to shut down the controller, and wait for prompt.
 Move the circuit breaker disconnect switch to the OFF position.
 Power down the robot when performing maintenance on the robot or controller.
 Jogging the Robot

Jogging is moving the robot at a (relatively) slow speed via the joystick. To add a motion
instruction to a teach pendant program, the robot must first be moved (jogged) to the
intended position. Jogging can also be used to modify existing positions.

Jogging is affected by:

 Jog speed (feed rate override) – how fast the robot moves.
 Coordinate system – the direction the robot moves.
 Motion type – joint, linear, re-orient, external
 Major/minor axis jogging – which 3 axes the joystick controls.

Jog speed
Displayed in the top right corner of the teach pendant, jog speed is a percentage of the
maximum speed you can jog the robot. 100% is the maximum jog speed (varies depending
on robot model). Maximum jog speed is defined by the tool center point (TCP) moving at or
below 250 mm/s. The Incremental key moves the robot one step for each joystick deflection.

The joystick
C5.3 paint robots and early S4 robots had a (heavy) teach pendant with the joystick
coming out of the right side. The old weld robots (now FIP robots) had this style, but somewhere
along the way, they were converted to the new style (joystick mounted on top).
Paint robot teach pendants are made intrinsically safe. They are not backlit and can be
identified by their blue cord (at least until the cords get discolored by paint, solvent, etc.).
As far as driving is concerned, one of the major differences between painters and “others”
is that paint robots follow the joystick when driver is standing beside the robot, other robots
follow the teach pendant when driver is facing the robot.
 Coordinate systems
Base
This is the way the robot would see things. It is normally the
same as World – unless robot is inverted (or mounted on a sloped or
vertical base – only newer robots can accommodate). Z+
World
This is the way the programmer would (ordinarily) see things.
X+ is forward (away from the power connector on the robot), Y+ is to
the robot’s left, and Z+ is up. (Right-hand rule – thumb up, pointer
forward, “the” finger left).

X+
Y+

Work Object
If the work object has been built on a slope (GMX base panel, GBD, 272TC) or vertical
(SCC, new consoles), the robot will track (move) accordingly. It should also be pointed out that
points are based on the work object coordinate system, so Z+ on a vertical work object is
probably toward the robot (what would ordinarily be X-).

Tool
tool0 is the system default, and cannot be changed.
Origin (0,0,0) is at faceplate center, Z+ points away, Y+ is
toward alignment notch, making X+ point down. Commonly,
the TCP (tool) is taught with X+ away from faceplate, Z+ is
Y+
toward the part – which makes Y+ point the opposite
direction.

Z+ X+
 Motion Type

Robot/External axis

Selection is fixed on robot (upper) unless an external axis is present and enabled.
Although an external axis (e.g. the rotating wall on most waterjets) can be manually driven, it’s
usually easier to step into a routine and let it move the axis to a specific point.

Reorient

The tool rotates around the TCP. The position remains constant – only the angle is
affected. This mode is most useful for changing tool angles on cuts, etc.

Linear

Motion is up/down, left/right, in/out. The robot tries to keep the tool at the same
orientation. Large lateral motion can result in the head trying to exceed its limits. Linear mode is
also (especially) affected by singularity.

Axis by axis (joint move)

1=axis 1-3
Group 1 is the primary/major (heavy) axes. Axis 1 rotates left/right, axis 2 rotates fore/aft, and
axis 3 rotates up/down. Axes 2 and 3 are mechanically connected - moving axis 2 will make
axis 3 move with respect to axis 2. Moving axis 3 does not affect axis 2.

2=axis 4-6
Group 2 is the secondary/minor (wrist?) axes. On a hollow-wrist painter, these are all together,
most other robots have axis 4 as forearm roll, rotating most of the horizontal arm. Axis 5 is the
wrist fold, axis 6 is wrist roll.

Incremental

AKA “inch” mode, the incremental mode makes the robot take “baby steps” – the size of
which is selectable on the JOG page. The TCP position monitor (also on the JOG page) shows
that it is changing. This mode is valuable for highly accurate positioning. If left in incremental
mode (especially with fine increment selected), the robot will appear to be unresponsive to the
joystick. If the robot won’t respond to the joystick, and doesn’t display any error messages (like
E-stop, or other runchain messages), verify that the increment mode is not selected

Singularity

Definition
 Singularity is a point at which an infinite number of joint angles can generate the
same set of Cartesian data (X,Y,Z).
 Singularity occurs in a linear coordinate system – joint mode is unaffected.
 Singularity can cause unexpected, rapid wrist motion (rotation)
 A singularity exists when Axis 5 is at zero degrees.
 With axis 5 near zero (AKA “singularity”), axes 4 and 6 interact – axes spin opposite
directions. There are software options to get around the singularity, but it’s usually
easier to flex axis 5 via a joint move.
 Sample Procedures (Routines)
PROC GoHome()
MoveJ Offs(pHome,0,200,-25),v500,z50,tFLAME;
MoveJ Offs(pHome,0,25,-25),v300,z80,tFLAME;
MoveJ pHome,v150,fine,tFLAME;
RETURN;
ENDPROC

PROC Water_Jet(
\switch On
|switch Off)

IF Present(On) THEN
IF DOutput(roHIGH_PRE_REQ)=low THEN
WaitDI riHIGH_PRESSURE,0;
Set roNOZZLE_ON;
ELSEIF DOutput(roHIGH_PRE_REQ)=high THEN
WaitDI riHIGH_PRESSURE,1;
Set roNOZZLE_ON;
ENDIF
ELSEIF Present(Off) THEN
Reset roNOZZLE_ON;
ENDIF
WaitTime 0.5;
ENDPROC

PROC rSWD_S2()
MoveJDO *,v300,z0,tJet\WObj:=woTC_S2,roNOZZLE_ON,1;
PDispSet fSWD_S2;
!SWD
V.v_tcp:=42;
MoveL pSWD2,V,z0,tJet\WObj:=woTC_S2;
MoveC *,*,V,z20,tJet\WObj:=woTC_S2;
MoveC *,*,V,z5,tJet\WObj:=woTC_S2;
MoveC *,*,V,z15,tJet\WObj:=woTC_S2;
MoveL Offs(pSWD2,-1,-1,0),V,fine,tJet\WObj:=woTC_S2;
Water_Jet\Off;
PDispOff;
ENDPROC