Presented by:

Koti

Engineer Automation

What is a Robot ?

Robot Definition

A robot is a mechanical intelligent agent which can

perform tasks on its own, or with guidance. In practice a

robot is usually an electro-mechanical machine which is

guided by computer and electronic programming

Robots come in many designs. These are

determined primarily by the job they are

intended to perform. Most industrial robots are

fixed station units.

Industrial Robot Classification

Cartesian Robot

The first type of robot is called the

Cartesian robot. This type of robot

uses the X, Y, Z three dimensional

coordinate system to control

movement and location.

Gantry robots are Cartesian

robots that have been super-

sized! This structure minimizes

deflection along each axis.

Gantry Robots

Cylindrical Robots

Cylindrical robots have a main axis

that is in the centre of the operating

envelope. It can reach into tight

areas without sacrificing speed or

repeatability.

Spherical Robots

Spherical or polar robots are similar to

a cylindrical robot, but form a spherical

range of motion using a polar

coordinate system.

©Emil Decker, 2009

SCARA Robots

SCARA robots, or Selective Compliance Assembly Robot Arm, are

quite popular. It is a combination of the articulated arm and the

cylindrical robot.

Parallel Robots

Parallel Robots consist of a fixed base to a platform by means of a

number of legs. This type of robot is used to create realistic flight

simulators or rides in amusement parks.

Articulated Arm Robot

Articulated arm robots have at least three rotary joints. They are

frequently called an anthropomorphic arm because they closely

resemble a human arm.

Degrees of Freedom

Degrees of Freedom refer to the

movement range available for a

given piece of equipment within

three dimensions.

Degrees of Freedom

Basics Of ABB

Robots

DEFINITION OF AN INDUSTRIAL ROBOT

An industrial robot is a programmable multi-

functional,multi DOF manipulator powered by electricity.

MAJOR COMPONENTS OF ROBOT

Manipulator( body of robot )

Controller(computer +drives)

End-effector (tool)

Man Machine

Interface (TeachPendant/Laptop)

THE END_EFFECTOR

The tool that is attached to the Tool Mounting Flange of

the robot is known as the end_effector , it may be cutting

tool, drill bit, gripper (vacuum, pneumatic or servo),

welding gun, hemming tool, glue gun etc.

PNEUMATIC GRIPPER

A WELDING TORCH

A VACUUM GRIPPER

Block Diagram of Robot

CONTROLLER ROBOT MANIPULATOR

3 Phase 415VAC

R

Y B

Manipulator Power cable

SMB Cable

EXTERNAL AXIS

Ext Ax Power

Resolver Cable

DESCRIPTION OF A MANIPULATOR

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

Each joint is driven by an actuator (AC Servo motors in ABB

robots).

Actuators are coupled to joints via geared transmission.

An industrial manipulator has 4 OR 6 degrees of freedom.

Brakes are installed in every joint motor to hold the manipulator in

position against gravity in motors off state.

THE 6 AXES OF A ROBOT

Link 0 (Base)

Link 1

Link 2

Link 3

Link 4

Link 5

Link 6 (tool flange)

Manipulator Open Link Mechanism

Link 0 Link 1 Link 2 Link 3

Link 4 Link 5 Link 6

Base of robot

Tool Flange

Joint 1 Joint 2 Joint 3

Joint 4

Joint 5 Joint 6

Manipulator consists of Links (Rigid Arms)

Each link is connected to previous link by joints

USE OF RESOLVERS AND SMB

Every joint of a robot has a resolver , the resolver measures the position and velocity of a joint and sends

the data to the SMB (Serial Measurement Board) located at the base of the manipulator.

There is a separate battery for backing the SMB data in case of a power failure.

The SMB is connected to the controller via “resolver cable”.

DEGRES OF FREEDOM

The number of independent movements a robot can make is known as the degree of freedom of

the robot manipulator.

In other words the number of rotary axes a manipulator has is known as its degree

of freedom.

THE 6 AXES OF A ROBOT

THE MAJOR AND MINOR AXES OF A ROBOT

The first 3 axes (axis 1/2/3/) of a robot are known as the

major axes because they help in positioning the wrist

at a required point on the workpiece.

The last 3 axes (4/5/6) of a robot are called as the minor

axes because they allow the wrist to reorient in any

required direction without changing its position.

IRC5 Controller

overview

Flexible Controller

Control module

Contains computer unit, safety

interface, control panel, space for

standard and customer options

Drive module

Contains drive system, axis computer,

transformer, mains connection & filter

Building block for MultiMove

application (up to 4 drive cabinets

connected to a single control cabinet)

Control Module

A. Customer I/O power

supply

B. Control panel

C. Main switch

D. System power supply

E. Computer unit

Drive Module: Small robot with external axes

Rectifier Drive units *Capacitor

Axes

computer

* Empty for small robots, if no external axes

Drive units

for ext axis

K42 K43

New Modules (”Design 2006”)

Single cabinet controller and process module added

Module range enables optimization for different customer needs

Single Cabinet Controller

90

0

Drive and control functions combined in

one cabinet

New ”Design 2006” encapsulation

Clean AluZinc cabinet

(only front painted)

resistant to environmental

influence

self healing if scratched

Dimensions 970 x 725 x 710 (H x D x W)

Full option range, including MultiMove

Max 2 internal I/O units (compared to 4)

Less connector space

Inside IRC5 Single Cabinet Controller

Power ON/OFF

Power supply units

Operator´s panel

Service ports USB (option)

Ethernet

Computer UltraCap

Duty Time Counter

Motors On contactors

and interface board (left inside wall)

Computer unit

Panel unit (safety interface) (right inside wall)

Customer (I/O) space

FlexPendant

connection Axis computer (right inside wall)

Drive unit

section

230/120 V service

outlet

Manipulator signal

interface

Power intake

Customer connections

Manipulator connections

(behind optional cover)

Options:

Single Cabinet Controller

Differentiation

Single Cabinet Controller

The ”standard” controller

Dual Cabinet Controller

Premium version for higher demands

Differentiating selling points vs. single cabinet and vs. competition

More connector space

More internal space

Distributability

Minimized height (with modules side by side)

Offers possibility to convert a MultiMove system to multiple single systems by adding control module

IRC5 HW Overview

MC

Panel

Safety

Power &

UPS Power

Drive

Safety

AXC

Drives I/O, Sensors and

Process equipments

USB LAN Service

Control module Drive module

SMB

Motor

S4CPlus

Carry over

IRB xxx

Block Diagram of Controller

Field buses

Fieldbuses

DeviceNet Master/Slave one or dual channel

Profibus DP Master/Slave

Interbus Master/Slave

Both copper-wire and fiber-optic interface available

EtherNet-IP slave

Communication

IRC5 FlexPendant continue

IRC5 FlexPendant

Intuitive standard screens

3 ax joystick

8 hard keys (4 customizable)

User Authorization System, allowing defined access levels for different user groups

Hot Plug - possibility to connect and disconnect during operation

Asian character support

Right and left-handed support

Swap HMI language without restart

IRC5 FlexPendant continue

Graphical colour touch screen

3-way joystick

Emergency stop

4 Hard keys for running programs

Start

Execute Backward/Forward

Stop program

4 Hard keys for fast access

Assignable

IRC5 FlexPendant continue

ABB Menu

Main menu Status bar

Quickset Menu

Windows style

“switch between

open windows/views”

IRC5 FlexPendant continue

ABB Main Menu

IRC5 FlexPendant continue

Inputs and Outputs (I/O Window).

IRC5 FlexPendant continue

Jogging window

IRC5 FlexPendant continue

Quickset Menu

Learning to Move a Robot

JOGGING

Jogging means manually moving a robot using the

joystick on the flexpendant.

The Robot gains more as per the Joystick Deflection.

Jogging cannot be done in auto mode.

Jogging is used while teaching a robot points in space.

Jogging can be done while programming.

JOGGING

From ABB main menu select jogging.

Operating Mode

Automatic mode

Production mode (programmed

speed)

Manual mode

< 250 mm/s – max velocity 250

mm/s

Manual 100 % – Option,

Robot program can execute in full

speed, (programmed speed).

Enabling Device

The enabling device is a switch with three positions

The switch must be in the middle position in order to

activate the motor on contactors and drives

All robot movement will immediately stop if the switch is

released or pressed to the bottom

Enabling device

Hold-to-Run (Manual 100 %)

Option (3-mode selector)

The Enabling device and one of the hold-to-run

buttons must be pressed simultaneously to

start the motors. Or Start/Step button

constantly pressed (FlexPendant gen2,

supported from RW5.06.04)

Enabling device

Hold-to-run buttons

(for left or right hand)

Safeguarded Stop

The connection of safeguarded stops enables inter-lock of external

safety equipment, such as: doors, photo-electric trip device, photo

cells or sensible mats

Safeguarded stop can be connected in three ways:

Auto Stop (AS) – active when automatic mode is selected. Possible to

jog and run program in Manual Mode

General Stop (GS) – active regardless of operating mode

Superior Stop (SS) – the safeguard stop is active regardless of

operating mode

Possibility to activate Delayed Safeguarded Stop and Emergency

Stop. Delayed stop gives a smooth stop. The robot stops in the

same way as at a normal program stop with no deviation from the

programmed path. After approx. 1 second the power supplied to the

motors shuts off

JOGGING WINDOW

MODES OF JOGGING

Jogging can be done in three modes:

Axes mode (joint by joint )

Linear mode (along X / Y / Z)

Reorient mode (changing orientation of tool)

AXIS MODE

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

The position format shows the angular position of each

joint in degrees or radians.

LINEAR MODE

In linear mode the TCP moves in a straight line.

The TCP can move parallel to either the x-axis or the y-axis or the

z-axis of the selected coordinate system of the robot which can be

the base,world,tool or workobject coordinate system.

The position format shows the position of the TCP w.r.t the

coordinate system selected in mm and orientation of tool in

Quaternions or Euler Angles.

During linear jogging orientation of tool remains same.

REORIENTATION MODE

In reorientation mode the TCP of the selected tool

remains at a fixed positon in space.

However the orientation of the tool about that fixed point

changes.

INCREMENTAL MODE

JOYSTICK LOCK

The movements of the joystick can be restricted in few

or all directions using the joystick lock.

QUICKSET MENU

The quickset menu can be used for easy selection of

jogging modes and setting the speed.

SPEED AND RUN MODE

MultiMove!

ROBOT SPECIFICATION

ABB robots are specified using a designation IRB say for example,

IRB140, IRB1400, IRB2400, IRB1600, IRB6600, IRB340 etc.

IRB stands for Industrial Robot Body

Some important specifications to look for in a

Robot are:

1.Payload 2.Reach 3.Supplementary load. 4.Speed

TECHNICAL DATA FOR IRB 140

TECHNICAL DATA FOR IRB140

OPERATING MODES OF A ROBOT

Manual mode.

Manual 100% mode.

Automatic mode.

A robot can be operated in three different modes:

OPERATING MODES

MANUAL MANUAL 100% AUTOMATIC

Robot can be Robot can be Robot cannot be

jogged at less jogged at less jogged

than 250 mm/s than 250 mm/s

Enabling device Enabling device No need of enabl_

needs to be pre_ and Hold to Run ing device or hold

_ssed button needs to to run button

be pressed

Programmed Programmed speed

speed is not Programmed speed is followed.

followed. is followed.

COORDINATE SYSTEMS

THE BASE COORDINATE SYSTEM.

THE WORLD COORDINATE SYSTEM.

THE TOOL COORDINATE SYSTEM.

THE WORK OBJECT COORDINATE SYSTEM.

A coordinate system = origin O and

3 perpendicular axes X, Y, & Z.

It is used to specify the position of a point in space.

The various types of coordinate systems used in a

Robot are:

COORDINATE SYSTEMS

TOOL COORDINATE SYSTEM

IRC5 Safety

Emergency Stop

Emergency stop pushbuttons

as default on FlexPendant

and Control module

Additional emergency stops

to be connected to IRC5

safety chain on Panel unit by

the integrator

External Operators panel with

Emergency stop (Option)

Safety Regarding Releasing the Brakes

Emergency release of the robot’s arm In an emergency situation, any of the robot’s axes may be released

manually by pushing the brake release buttons on the robot

The robot arm may be moved manually on smaller robot models, but larger models may require using an overhead crane or similar

Increased injury

Before releasing the brakes, make sure that the weight of the arms does not increase the pressure on the trapped person, further increasing any injury!

Recover from Emergency stop

Action

Make sure the hazardous situation that resulted in the

emergency stop condition no longer exists

Locate and reset the device or devices that gave the

emergency stop condition

Acknowledge the emergency stop event (20202) in the

event log

Press the Motors On button to recover from the

emergency stop condition

BRAKE RELEASE BUTTON

The brake release buttons when pressed release the

brakes.