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INTRODUCTION TO ROBOTICS
ABB Robotics Division
Peenya,Bangalore
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DEFINITION OF AN INDUSTRIAL ROBOT
An industrial robot is a programmable multi-functional,multi DOF manipulator powered by electricity.
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MAJOR COMPONENTS OF ROBOT
Manipulator( body of robot )
Controller(computer +drives)
End-effector (tool) Man Machine
Interface (TeachPendant/Laptop)
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Block Diagram of Robot
CONTROLLERROBOT MANIPULATOR
3 Phase 415VAC
R
YB
Manipulator Power cable
SMB Cable
EXTERNAL AXIS
Ext Ax Power
Resolver Cable
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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.
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THE 6 AXES OF A ROBOT
Link 0 (Base)
Link 1
Link 2
Link 3
Link 4
Link 5
Link 6 (tool flange)
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Manipulator Open Link Mechanism
Link 0 Link 1 Link 2 Link 3
Link 4Link 5Link 6
Base of robot
Tool Flange
Joint 1 Joint 2Joint 3
Joint 4
Joint 5Joint 6
Manipulator consists of Links (Rigid Arms)
Each link is connected to previous link by joints
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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”.
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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 rotaryaxes a manipulator has is known as its degreeof freedom.
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THE 6 AXES OF A ROBOT
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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.
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BRAKE RELEASE BUTTON
The brake release buttons when pressed release the brakes.
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DESCRIPTION OF A CONTROLLER
A controller is the brain behind the functioning of a robot The picture below shows the IRC5 controller of ABB .It is a Dual cabinet controller.
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A SINGLE CABINET CONTROLLER
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MAJOR COMPONENTS OF AN IRC5 CONTROLLER
A main computer does all the primary computing job. Axis computers perform all the calculations of individual joints. Drive units control the torque , acceleration and speed of the joints. The SMPS (Switch Mode Power Supply) supplies 24 VDC to main
computer, axis computers, I/O Boards etc Contactors cut off supply from motors as and when required. Transformer steps down 415 VAC to 230 VAC. Rectifier converts AC to DC. I/O Boards are used for user signals.
IRC5 stands for Industrial Robot Controller (Fifth Generation)
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THE MAN_MACHINE INTERFACE
The FLEXPENDANT is the man_machine interface for an IRC5 controller , it is also known as GTPU (Graphical Teach Pendant Unit).
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BUTTONS ON A FLEXPENDANT
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MAIN MENU ON FLEXPENDANT
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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.
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PNEUMATIC GRIPPER
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A WELDING TORCH
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A VACUUM GRIPPER
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A WELDING ROBOT SYSTEM
Robot + Application Equipment+Work holding device+ EOAT+ peripheral equipments+interface/control panels+ safety= ROBOT SYSTEM
Positioner
Application Equipment
Peripheral Equipment
Robot Controller
Pedestal
EOAT
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MultiMove!
Drive Modules
Controller Module
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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 BodySome important specifications to look for in aSome important specifications to look for in aRobot are:Robot are:1.Payload 1.Payload 2.Reach 2.Reach 3.Supplementary load.3.Supplementary load.4.Speed 4.Speed
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TECHNICAL DATA FOR IRB 140
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TECHNICAL DATA FOR IRB140
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OPERATING MODES OF A ROBOT
Manual mode.
Manual 100% mode.
Automatic mode.
A robot can be operated in three different modes:A robot can be operated in three different modes:
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OPERATING MODES
MANUAL MANUAL 100% AUTOMATICMANUAL MANUAL 100% AUTOMATIC
Robot can be Robot can be Robot cannot be Robot can be Robot can be Robot cannot be jogged at less jogged at less jogged jogged at less jogged at less jogged than 250 mm/s than 250 mm/sthan 250 mm/s than 250 mm/s
Enabling device Enabling device No need of enabl_Enabling device Enabling device No need of enabl_needs to be pre_ and Hold to Run ing device or hold needs to be pre_ and Hold to Run ing device or hold _ssed button needs to to run button _ssed button needs to to run button be pressed be pressed Programmed Programmed speed Programmed Programmed speed speed is not Programmed speed is followed. speed is not Programmed speed is followed. followed. is followed. followed. is followed.
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COORDINATE SYSTEMS
THE BASE COORDINATE SYSTEM.
THE WORLD COORDINATE SYSTEM.
THE TOOL COORDINATE SYSTEM.
THE WORK OBJECT COORDINATE SYSTEM.
A coordinate system = origin O andA coordinate system = origin O and3 perpendicular axes X, Y, & Z.3 perpendicular axes X, Y, & Z.It is used to specify the position of a point in space.It is used to specify the position of a point in space.The various types of coordinate systems used in a The various types of coordinate systems used in a Robot are:Robot are:
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COORDINATE SYSTEMS
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TOOL COORDINATE SYSTEM
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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.
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JOGGING
From ABB main menu select jogging.From ABB main menu select jogging.
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JOGGING WINDOW
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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)
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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.
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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.
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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.
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INCREMENTAL MODE
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JOYSTICK LOCK
The movements of the joystick can be restricted in few or all directions using the joystick lock.
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QUICKSET MENU
The quickset menu can be used for easy selection of jogging modes and setting the speed.
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SPEED AND RUN MODE
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LIMITING ROBOTS WORKSPACE
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Tool Definition :
The attachment at the flange or 6th axis is what we call as the tool .
A tool needs to be defined before it can be used for Jogging or Program purposes .
Every tool has to have a imaginary Coordinate attached to it .
The origin of this coordinate is called as TCP (Tool Center Point) it can be the Tip of a tool.
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Tool Definition Contd…
Tool
Attached to Robot Flange
Stationary in world
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Tool Definition Contd…
Normal Tools are always defined w.r.t to the “tool0” Frame which is attached to the Flange plate.
The TCP x,y,z of the tool are measured from the flange center or tool0 center.
It is not necessary that x,y,z axes of a tool be same as tool0 directions.
Apart from the coordinates , certain other Physical parameters of the tool are also essential to be defined such as Mass, COG, Moment of Inertia etc.
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Tool Definition Contd…
Tool Definition
TCP Default Orient
TCP & Z
TCP & Z,X
“Keeps Tool Frame Directions same as Tool0
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TOOL DEFINITION
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TCP DEFINITION
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Type of TCP Definition/Quaternions
1 0 0 0
x x 0 0
x x x x
TCP Default Orient
TCP & Z
TCP Z & X
q1 q2 q3 q4
(q1)2+(q2) 2+(q3) 2+(q4) 2=1
-1≤ X ≤ 1
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Manual Entry of ToolData
Tool Name
robhold
tframe
tload
trans
rot
cog
aom
TRUE x
y
zq1
q2
q3
q4Mass(Kg) x
yz
q1q2
q3
q4ix iy
iz
(mm)
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WorkObject :
A coordinate frame that is attached to a Physical object such as Table /Fixture / Plate is a WorkObject .
Utility is that : If by any chance the object gets shifted we just need to reteach where the Workobject is …….. The rest of the program needs no modification .
For defining a frame in space perfectly we need 3 distinct points on the physical object (which should not be in a straight line)
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WORK OBJECT DEFINITION
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Origin & Frame Orientation
The X axis can be got by joining X1 & X2 and points towards X2.
The Y axis can be got by dropping a perpendicular on X axis from Y1 ,and points towards Y1.
The origin is the point where the perpendicular meets X axis.
The Z axis is perpendicular to both X & Y axis and can be obtained using Right Hand Thumb Rule .
---- 1st Finger = X axis
---- 2nd Finger = Y axis
Then , Thumb points towards Z axis!!!!!!!
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Origin & Frame Orientation contd…
X1
X2
Y1
90°
Y axis
X axis
Origin
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BASIC ROBOT PROGRAMMING
ABB robots use the RAPID programming language. Programs can be accessed by going to the “Program
Editor” window. It works on the OS “RobotWare” Programs can be written either from the Flexpendant or
using RobotStudio Online.
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Programs/Routines/Modules Structure
X Y
Mainmodule
Mainmodule
P QM N
Main()
Main()
R1( )
R2 ( )
R3( )
R4( )
R5( )
R6( ) R7( )
R1( )
R2( )
R3( )
R4( )
R5( )
R6( )R7( )
Created By Default
PROGRAMS
MODULES
ROUTINES
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NEW PROGRAM SELECTION
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SOFT KEYBOARD
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Zoom In
Zoom Out
Page Scroll
Line Scroll
Command MenuCut/Copy/Del/ABC
Prog PointerRecord Point
Motors State
Load/Create New Program Create Modules
Create Routines
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INSTRUCTION SET
To add a new instruction click on “Add Instruction”.
The common instructions available can be classified under the following categories:
Motion instructions.
Program flow instructions.
Assignment.
Communication instructions.
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INSTRUCTION SET
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MOTION INSTRUCTIONS
MoveJ *,v500,z50,tool0;
MoveL *,v1000,z20,tool1;
MoveC *,*,v250,z40,gripper;
MoveAbsJ *,v500,z40,torch;
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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 doesnot follow a straight line between initial position of robot and the robtarget.
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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.
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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.
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CALIBRATION
An uncalibrated system.
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REVOLUTION COUNTER
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UPDATE REV. COUNTERS
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MOTOR CALIBRATION VALUES
