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July 2011

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ACKNOWLEDGEMENT

Written words have an unfortunate tendency to degenerate genuine gratitude into a

formality. However it is the only way to record one's feelings permanently.

I was bestowed with the golden opportunity to undergo my summer training at ABB

ROBOTICS, Bangalore and hence take this opportunity to express my heartfelt thanks

to all those who have been associated with my training.

I express my special thanks to Mr. Rajneesh Arora Head of ABB Robotics Division, I

gained experience and knowledge about the importance of work culture and planning,

which is one of the best of the establishment; I had the privilege of working in the ABB

Robotics during my summer training. I had exposure to:

Knowledge about computer & various packages, which are used in an

organization for its efficient function.

Achieving goals and targets by proper planning & time management.

The importance of communication skill especially when having a group

discussion.

I express my heartfelt gratitude to Mr. Anand Gupta. For providing me with endless

support and encouragement in all my endeavors at every moment during my training.

This acknowledgement is really incomplete if I would fail to express my sincere thanks

to Mr.Kishan Cariappa, Human Resource department, ABB for giving the opportunity

of working in the ABB’s Robotics Division. Last but not the least I thank all my fellow

Trainees for their Co-operation and support.

SHAHID FAIZEE

Mentor

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INTRODUCTION

An industrial robot is defined by ISO as an automatically controlled, reprogrammable,

multipurpose manipulator programmable in three or more axes. The field of robotics

may be more practically defined as the study, design and use of robot systems

for manufacturing (a top-level definition relying on the prior definition of robot).

Typical applications of robots include welding, painting, assembly, pick and place (such

as packaging, palletizing and SMT), product inspection, and testing; all accomplished

with high endurance, speed, and precision.

The most commonly used robot configurations are articulated robots, SCARA robots

and Cartesian coordinate robots, (aka gantry robots or x-y-z robots). In the context of

general robotics, most types of robots would fall into the category of robotic

arms (inherent in the use of the word manipulator in the above-mentioned ISO

standard). Robots exhibit varying degrees of autonomy:

Some robots are programmed to faithfully carry out specific actions over and over

again (repetitive actions) without variation and with a high degree of accuracy.

These actions are determined by programmed routines that specify the direction,

acceleration, velocity, deceleration, and distance of a series of coordinated motions.

Other robots are much more flexible as to the orientation of the object on which they

are operating or even the task that has to be performed on the object itself, which

the robot may even need to identify. For example, for more precise guidance, robots

often contain machine vision sub-systems acting as their "eyes", linked to powerful

computers or controllers. Artificial intelligence, or what passes for it, is becoming an

increasingly important factor in the modern industrial robot.

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CHAPTER 1

COMPONENTS OF ROBOTS

MAJOR COMPONENTS OF ROBOTS:

Manipulator

(body of

robot) Controller

(Computer +

Drives

End-

effector(tool)

Man-Machine Interface(Laptop +

Teach Pendant)

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BLOCK DIAGRAM OF a ROBOT:

CONTROLLER

Laptop

Flexpendant

ROBOT MANIPULATOR

EXTERNAL

AXIS

3 Phase 415VAC

R

Y

Z

Manipulator Power

Cable

SMB

Cable

Ext Ax Power Resolver Cable

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Manipulator Open Link Mechanism:

DESCRIPTION OF MANIPULATOR:

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

Each Robot is driven by an actuator (A.C. Servo Motor for ABB Robots).

Actuators are coupled to joints via geared transmission.

An industrial manipulator has 4 or 6 Degree of Freedom.

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

against gravity in motors off state.

Link 0 Link 1 Link 2 Link 3

Link 4 Link 5 Link 6

Joint 1 Joint 2 Joint 3 Joint 4

Joint 5 Joint 6

BASE OF ROBOT

TOOL FLANGE

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VARIOUS KINDS OF ROBOTS:

The ABB Robots are designated by IRB (Industrial Robot Body)

ARTICULATED GANTRY PAINT PARALLEL

IRB 140

IRB 1400

IRB 1600

IRB 2400

IRB 6600

IRB 840

IRB 7600

IRB 510

IRB 540

IRB 5400

IRB 340

IRB 360

IRB 960

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CONTROLLER:

1. The controller is the brain behind the functioning of a robot. The pictures below depicts the IRC5 Controller.

SINGLE CABINET DUAL CABINET

CONTROL

MODULE

DRIVE

MODULE

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THE MAN-MACHINE INTERFACE:

Graphical Color Touch

Screen

Emergency Stop

Four hard keys

for fast access

3 way joystick

4 Hard Keys for running

program

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CHAPTER 2

OPERATING MODES OF A ROBOT

A Robot can be operated in three different modes:

Manual Mode

Manual 100% Mode

1) Manual Mode:

Robot can be jogged at less than 250 mm/sec.

Enabling device needs to be pressed.

Program speed is not followed.

2) Manual 100% Mode:

Robot can be jogged at less than 250 mm/sec.

Enabling device and Hold to Run button need to be pressed.

Program speed is followed.

3) Automatic Mode:

Robot cannot be jogged.

No need of enabling device or hold to run button.

Program speed is followed.

Co-ordinate System:

A Co-ordinate system = Origin O and 3 perpendicular axes X, Y & Z.

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It is used to specify the position of point in space. The various types of Co-ordinate

system used in a robot are:

The Base Co-Ordiante System

The World Co-Ordiante System

The Tool Co-Ordiante System

The Work Object Co-Ordiante System

JOGGING:

Jogging means manually moving a robot using the joystick on the Flexpendant. Jogging cannot be done in auto mode. Jogging is used while teaching a robot points in space. Jogging can be done while programming.

MODES OF JOGGING:

Jogging can be done in three modes:

1. Axes mode (joint by joint).

2. Linear mode (along X / Y / Z).

3. Reorient mode (changing orientation of tool).

1. 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.

2. 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 work object 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.

3. Reorientation Mode:

In reorientation mode the TCP of the selected tool remains at a fixed position in space.

However the orientation of the tool about that fixed point changes.

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JOYSTICK LOCK: The movements of the joystick can be restricted in few or all directions using the joystick lock. QUCKSET MENU: The quickset menu can be used for easy selection of jogging modes and setting the speed. LIMITING ROBOT WORKSPACE:

To avoid the risk of getting caught between the robot and outer safe equipment, e.g. a fence , the robot workspace can be limited:

All axis can be software limited.

Axis 1-3 can be limited by adjustable mechanical stops and controlled by

limit switches. TCP DEFINITION:

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CHAPTER 3

BASIC ROBOT PROGRAMMING

The programming language used by ABB robots is the RAPID programming language.

Programs can be accessed by going to the program editor window.

To start writing a new program click on “Tasks and Programs” then on “File” and then on “New”.

Type in your new program name using the soft keyboard and you are ready to start.

A RAPID PROGRAM: MoveJ Target _10 , v1500 , z100 , tool10 \ WObj : =

MoveJ Target _20 , v1500 , z100 , tool10 \ WObj : =

MoveJ Target _30 , v1500 , z100 , tool10 \ WObj : =

MoveJ Target _40 , v1500 , z100 , tool10 \ WObj : =

MoveJ Target _50 , v1500 , z100 , tool10 \ WObj : =

ENDPROC

PROC main ()

Path_10 ;

Path 10 ;

INSTRUCTION SET:

The common instructions available can be classified under the following categories:

1. Motion instructions. 2. Program flow instructions. 3. Assignment. 4. Communication instructions.

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1. MOTION INSTRUCTION:

a. MoveJ *,v500,z50,tool0;

b. MoveL *,v1000,z20,tool1;

c. MoveC *,*,v250,z40,gripper;

d. MoveC *,*,v250,z40,gripper;

e. MoveAbsJ *,v500,z40,torch;

a. MOVEJ:

MoveJ *, v500, z80, gripper;

* Represents the Robtarget where the TCP of the selected tool is to be moved.

V500 means that the TCP moves at a speed of 500 mm/s. Z80 is the zone error i.e. 80 mm, if instead of z80 we select “fine” the zone error is zero.

Gripper is the selected tool. TCP does not follow a straight line between initial position of robot and

the robtarget.

b. MOVEL:

MoveL *, v500, z20, torch; Rest is same as MoveJ only difference being that the TCP of the selected tool moves in a straight line from the initial position of the robot to the robtarget.

c. MOVEC:

MoveC *,*, v1000, z100, cutter; The TCP of the selected tool moves in a circular arc joining the initial TCP position to the two robtargets respectively.

d. MOVABSJ:

MoveAbsJ *; Here the * represents a joint-target that is the angular positions of the 6 joints.

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2. PROGRAM FLOW INSTRUCTIONS:

a. IF ELSE b. GOTO c. FOR d. COMPACT IF e. TEST CASE

a. IF ELSE:

IF reg2=10 THEN MoveJ *,v500,z80,tool0; MoveL *,v1000,z50,tool0; ELSE MoveL *,v500,z20,tool0; MoveC *,*, v500, z20, tool0; ENDFOR If a given condition is true it executes a set of instructions and if it is false then it executes another set of instructions.

b. GOTO:

GOTO start; …………. …………. …………. start: On seeing the instruction the program pointer goes to the line containing the label start.

c. FOR: FOR x FROM 1 TO 10 STEP1 DO ………… ………… …………. …………. ENDFOR It is used to repeat a given set of instructions a fixed number of times.

d. COMPACT IF:

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

It executes a single instruction if a given condition is found to be true.

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e. TEST:

TEST reg1 Case 1: …………………… Case 2: ………….………… Case 3: …………………… ENDTEST Executes set of instructions based on the integer values of a variable e.g. reg1.

3. COMMUNICATION INSTRUCTIONS:

a. TPWrite “TIME FOR THE CYCLE IS”,reg1; b. TPErase; c. TPReadNum reg2;

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CHAPTER 4

CALIBRATION

REVOLUTION COUNTER :

Tells us how many turns he engine shaft has rotated in the gearbox. If the value is lost the robot cannot run any program.. A message notifies that the Rev. Counters needs to be updated. (e.g. when battery in

SMB is drained).

UPDATE REV. COUNTERS:

Jog all of the 6 axis to the sync mark.

Update Rev. Counter.

Check if Rev. Counter are correctly updated.

Possible to update the axis one by one, if the cell is cramped.

MOTOR CALIBRATION VALUES:

Type in the fine calibration value manually.

Use moc.cfg values from Backup, Silver label in the back of manipulator with 6

values, or original motor calibration values floppy shipped with the system.

WHEN TO CALIBRATE:

The system must be calibrated if one or more of the listed failures below occurs.

Changed resolver values

Calibrate the measurement system carefully, if any of the resolver values have been

changed. This can occur when parts affecting the calibration position have been

replaced on the robot.

Contents of the revolution counter memory are lost.

Calibrate the system roughly, if the contents of the revolution counter memory are lost.

This can occur when:

The battery has been discharged.

A resolver error occurs.

The signal between a resolver and measurement board is interrupted.

A robot axis has been moved while the control system was disconnected.

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CHAPTER 5

A.C. SERVO MOTOR

5.1 WHAT IS A SERVO?

This is not easily defined or self-explanatory since a servomechanism, or servo

drive, does not apply to any particular device. It is a term which applies to a

function or a task.

The function, or task, of a servo can be described as follows. A command signal

which is issued from the user's interface panel comes into the servo's

"positioning controller". The positioning controllers the device which stores

information about various jobs or tasks. It has been programmed to activate the

motor/load, i.e. change speed/position.

The signal then passes into the servo control or "amplifier" section. The servo

control takes this low power level signal and increases, or amplifies the power

up to appropriate levels to actually result in movement of the servo motor/load.

These low power level signals must be amplified: Higher voltage levels are

needed to rotate the servo motor at appropriate higher speeds and higher

current levels are required to provide torque to move heavier loads.

This power is supplied to the servo control (amplifier) from the "power supply"

which simply converts sac power into the required DC level. It also supplies any

low level voltage required for operation of integrated circuits.

As power is applied onto the servo motor, the load begins to move . . . speed and

position changes. As the load moves, so does some other "device" move. This

other "device" is a tachometer, resolver or encoder (providing a signal which is

"sent back" to the controller). This "feedback" signal is informing the positioning

controller whether the motor is doing the proper job.

The positioning controller looks at this feedback signal and determines if the

load is being moved properly by the servo motor; and, if not, then the controller

makes appropriate corrections. For example, assume the command signal was to

drive the load at 1000 rpm. For some reason it is actually rotating at 900 rpm.

The feedback signal will inform the controller that the speed is 900rpm. The

controller then compares the command signal (desired speed) of 1000 rpm and

the feedback signal (actual speed) of 900 rpm and notes an error. The controller

then outputs a signal to apply more voltage onto the servo motor to increase

speed until the feedback signal equals the command signal, i.e. there is no error.

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Therefore, a servo involves several devices. It is a system of devices for

controlling some item (load). The item (load) which is controlled (regulated) can

be controlled in any manner, i.e. position, direction, speed. The speed or position

is controlled in relation to reference (command signal), as long as the proper

feedback device (error detection device) is used. The feedback and command

signals are compared, and the corrections made. Thus, the definition of a servo

system is, that it consists of several devices which control or regulate

speed/position of a load.

5.2 Types of Servo Motors

There are two types of servo motors--AC and DC. AC servos can handle higher

current surges and tend to be used in industrial machinery. DC servos are not

designed for high current surges. Generally speaking, DC motors are less

expensive than their AC counterparts.

5.3 Principle of operation of A.C. Servo Motor

AC Motors are the first choice for constant speed applications and where large

starting torque is not required. They are available in three or single phase. The

smaller motors are for household applications and they are made for single

phase operation. For industrial application, AC motors are available from a

fraction to a hundred horse power output. The principle of operation is that the

rotor is made of laminated steel. And bars of conducting material such as

aluminum and copper are buried in the motor which are short circuited at both

ends.

The stator is made of laminated steel with properly designed slots. In the slots a

well designed number of windings is located which is connected to the power

supply. The power supply generates a rotating magnetic field. When the motor is

connected to the power supply, a voltage is induced in the bars located in the

rotor which causes a current flow through them. As a result of the current, an

electromotive torque is developed which accelerates the motor. As the speed

increases the induced voltage reduces because the rotor approaches the

synchronous speed. At the synchronous speed, the torque becomes zero.

Therefore, AC motors always rotate at a speed lower than the synchronous

speed. The synchronous speed is determined by the frequency of the power

supply and number of poles in the stator.

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5.4 Working of A.C. Servo Motor

A servo motor operates on the principal

of "proportional control." This means the motor will only run as hard as

necessary to accomplish the task at hand. If the shaft needs to turn a great deal,

the motor will run at full speed. If the movement is small, the motor will run

more slowly.

A control wire sends coded signals to the shaft using "pulse coded modulation."

With pulse-coded modulation, the shaft knows to move to achieve a certain

angle, based on the duration of the pulse sent via the control wire. A 1.5

millisecond pulse will make the motor turn to the 90-degree position. Shorter

than 1.5 moves it to 0 degrees, and longer will turn it to 180 degrees.

5.5 Applications of A.C. Servo Motor

5.5.1 Commercial Application

A.C. Servo Motors for Toy Enthusiasts

A.C. Servo motors can be found in radio-controlled toy cars. Servos are used in radio-controlled airplanes to position the rudders, in radio-controlled cars to move the wheels and in other remote-controlled toys like puppets.

5.5.2 Industrial Application

In food services and pharmaceuticals, the tools are designed to be used in harsher environments, where the potential for corrosion is high due to being washed at high pressures and temperatures repeatedly to maintain strict hygiene standards.

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CHAPTER 6

APPLICATIONS OF ROBOTS

1) Electrical and Electronics:

ABB large robots are used in machine tending for injection molding machines

(IMM) & die casting machines that produce covers & chassis parts for electrical

and electronic (3C) products. They are also used in the handling of flat panel

displays (FPD)

Our painting robots have become the industry standard for coating a wide range

of device covers; including laptop computers and mobile phones.

Our medium sized robots, combined with Force Control technology, have

provided competitive advantage in the finishing of parts through high quality

grinding, deburring, deflashing & polishing applications.

Our new small robot family & our FlexPicker are hard at work every day in

assembly, small part material handling, inspection & testing facilities throughout

the world.

ABB robots in electrical & electronic (3C) industries will ensure you achieve

higher quality products with the required cosmetic finishing, while improving

your up-time and providing the flexibility needed for both short & high volume

production runs.

ABB robots and controllers optimized for small parts assembly

2) Metal Fabrication Processes:

a) Cutting

The 6-axis robots are ideal for complex cutting operations using laser,

oxygene, plasma or traditional mechanical tools. ABB's Mechanical Cut

PowerPac ensures easy programming and great performance.

Main cutting processes in Metal Fabrication:

Oxy Cutting

Plasma Cutting

Laser Cutting

Mechanical Cutting

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b) Welding and Joining:

The Robots can be used in the following areas of Welding & Joining:

Arc Welding

Laser Welding

Plasma Welding

Poke Welding

Spot Welding

Stud Welding

Brazing

Clinching

Hemming

Gluing

c) Surface Treatment & Finishing:

The Robots can be used in the following areas of Surface Treatment &

Finishing:

Deburring/Grinding/Cleaning

Plasma Coating

Polishing/Finishing

Enameling

Painting

Sealing

d) Material Handling:

The Robots can handle upto 500kg of payload with ease and precision. These Robots can be used in the following areas:

Holding and manipulating workpieces while processing Material handling between operations Stacking/de-stacking Picking Palletizing/De-Palletizing CNC Machine Tending

e) Plastics:

Easy-to-use, 6-axis robots are accessible to plastics moulders. With their built-in flexibility, these machines are the perfect complement to traditional 3-axis linear gantry automation.Traditional, fixed automation is time-consuming and costly.. Catering to every conceivable need, these machines perform a variety of tasks during the production cycle. Which means you can look forward to a far more. flexible and cost-efficient operation.