ABB Robotics FlexGripper User manual

ROBOTICS
Product Manual
FlexGripper-Claw

Trace back information:
Workspace Robots and Applications version a56 (not checked in)
Published 2019-11-15 at 05:15:13
Skribenta version 5.3.033

Product Manual
FlexGripper-Claw
Document ID: 4GAA40401009901-001
Revision: A
© Copyright 20132019 ABB. All rights reserved.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.
Original instructions.
© Copyright 20132019 ABB. All rights reserved.
Robotics and Motion
Robotics
ABB Pte. Ltd.
2 Ayer Rajah Crescent
Singapore 139935

Table of contents
7Overview of this manual ...................................................................................................................
91 Safety
91.1 Introduction ......................................................................................................
101.2 General safety information ..................................................................................
101.2.1 Safety in the robot ...................................................................................
121.2.2 Safety risks ............................................................................................
121.2.2.1 Safety risks during installation and service work on the FlexGripper .....
131.2.2.2 Safety risks related to tools/workpieces ...........................................
141.2.2.3 Safety risks related to high speed ...................................................
151.2.2.4 Safety risks during operational disturbances .....................................
161.2.2.5 Risks associated with live electric parts ...........................................
181.2.3 Safety actions .........................................................................................
181.2.3.1 Safety fence dimensions ...............................................................
191.2.3.2 Fire extinguishing ........................................................................
201.2.3.3 Enabling device and hold-to-run functionality ....................................
211.3 Safety related instructions ..................................................................................
211.3.1 Safety signals in the manual ......................................................................
231.3.2 Safety symbols on the FlexGripper labels ....................................................
241.3.3 Safety guidelines ....................................................................................
252 FlexGripper-Claw
252.1 Specification ....................................................................................................
302.2 Mechanical structure & working principle ...............................................................
302.2.1 General .................................................................................................
322.2.2 Claw unit ...............................................................................................
332.2.3 Push plate unit ........................................................................................
352.3 Installation and Commissioning ...........................................................................
352.3.1 Overview ...............................................................................................
362.3.2 Unpacking .............................................................................................
382.3.3 Adjustment ............................................................................................
392.3.4 Mounting the new gripper .........................................................................
422.3.5 Commissioning .......................................................................................
482.4 Maintenance ....................................................................................................
482.4.1 General .................................................................................................
492.4.2 Regular Inspection of new gripper ..............................................................
502.4.3 Regular replacement ................................................................................
512.4.4 Regular adjustment .................................................................................
532.5 Repair .............................................................................................................
532.5.1 Instruction .............................................................................................
542.5.2 Pneumatic cylinder ..................................................................................
542.5.2.1 Replacing the cylinder of the claw ...................................................
572.5.2.2 Replacing the cylinder of the top press plate .....................................
602.5.2.3 Replacing the cylinder of push plates ..............................................
622.5.3 Magnetic proximity switch .........................................................................
662.5.4 Solenoid valve ........................................................................................
682.5.5 Dress cable ............................................................................................
702.6 Trouble shooting ...............................................................................................
702.6.1 Start-up failures ......................................................................................
712.6.2 Gripper not responding ............................................................................
722.6.3 Wrong movement ....................................................................................
732.6.4 Low performance ....................................................................................
742.6.5 Problem jogging the gripper ......................................................................
752.6.6 Mechanical noise and vibration ..................................................................
762.6.7 Workpiece drop down ..............................................................................
772.6.8 No Input signal detected ...........................................................................
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Table of contents

782.6.9 Package displacement .............................................................................
792.7 Decommissioning ..............................................................................................
792.7.1 Introduction ............................................................................................
802.7.2 Environmental information ........................................................................
812.7.3 Environmental information ........................................................................
822.8 Spare parts ......................................................................................................
842.9 Circuit diagram .................................................................................................
853 FlexGripper UI
853.1 Software installation ..........................................................................................
853.1.1 Installing FlexGripper UI Flexpendant application ..........................................
883.1.2 I/O signal configuration ............................................................................
893.1.3 Back-up and Reset System .......................................................................
913.2 Operation ........................................................................................................
913.2.1 FlexGripper UI main interface ....................................................................
923.2.2 Tool handle ............................................................................................
923.2.2.1 FlexGripper Claw function test .......................................................
953.2.2.2 TCP edit ....................................................................................
1003.2.3 Tune .....................................................................................................
1003.2.3.1 Position Tune .............................................................................
1023.2.3.2 Work object tune ........................................................................
1033.2.3.3 Test run .....................................................................................
1043.2.4 Production .............................................................................................
1043.2.4.1 Production monitor ......................................................................
1053.2.4.2 Setup ........................................................................................
1083.3 Trouble shooting ...............................................................................................
113Index
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Table of contents

Overview of this manual
About this manual
This manual provides instructions for the FlexGripper-Claw. Each chapter
concerning the FlexGripper-Claw contains information on:
• mechanical structure & working principle
• mechanical /electrical installation
• maintenance
• repair
• trouble shooting
• spare parts
Read through this document carefully, especially the sections about safety, before
you start to unpack, install and use the FlexGripper-Claw.
Usage
This manual should be used during:
• installation
• operation
• maintenance work
• repair work
Who should read this manual?
This manual is intended for:
• operators
• installation personnel
• repair and maintenance personnel
Prerequisites
The reader should be:
• familiar with industrial robots and the relevant terminology
• familiar with the equipment
• skilled in mechanical & electrical installation/maintenance/repairs
Organization of chapters
The manual is organized in to the following chapters:
ContentsChapter
Safety
FlexGripper-Claw
FlexGripper UI
Continues on next page
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Overview of this manual

References
Document IDReference
3HAC025755-001Product manual - IRB 660
3HAC039611-001Product manual - IRB 460
3HAC021313-001Product manual - IRC5
Revision
DescriptionRevi-
sion
First edition-
Restart information is updated to the latest restart mode, such as replacing I-start
with Reset System.
A
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Overview of this manual
Continued

1 Safety
1.1 Introduction
Overview
The safety information in this manual is divided into two categories:
• General safety aspects, important to attend to before performing any service
work on the FlexGripper. These are applicable for all service work and are
found in General safety information on page 10.
• Specific safety information, pointed out in the procedure when the danger is
imminent. How to avoid and eliminate the danger is either detailed directly
in the procedure, or further detailed in separate instructions, found in Safety
related instructions on page 21.
Note
This manual includes only the safety information related to this product.
The FlexGripper can be used together with IRB 660 or IRB 460. See the robot
and IRC5 controller manuals for more details on safety.
Before beginning work with the robot, make sure you are familiar with the safety
regulations described in the manual Operating manual - General safety
information.
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1 Safety
1.1 Introduction

1.2 General safety information
1.2.1 Safety in the robot
Validity and responsibility
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system. To protect personnel, the complete system must be designed
and installed in accordance with the safety requirements set forth in the standards
and regulations of the country where the robot is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the
safety devices necessary to protect people working with the robot system are
designed and installed correctly. Personnel working with robot must be familiar
with the operation and handling of the industrial robot as described in the applicable
documents, for example:
•Operating manual - IRC5 with FlexPendant
•Operating manual - General safety information I
•Product manual
IThis manual contains all safety instructions from the product manuals for the robots and the
controllers.
The robot system shall be designed and constructed in such a way as to allow safe
access to all areas where intervention is necessary during operation, adjustment,
and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.
Connection of external safety devices
Apart from the built-in safety functions, the robot is also supplied with an interface
for the connection of external safety devices. An external safety function can
interact with other machines and peripheral equipment via this interface. This
means that control signals can act on safety signals received from the peripheral
equipment as well as from the robot.
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
Related information
SectionDetailed in documentType of information
Installation and
commissioning
Product manual for the robotInstallation of safety devices
Continues on next page
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1 Safety
1.2.1 Safety in the robot

SectionDetailed in documentType of information
Operating modesOperating manual - IRC5 with FlexPend-
ant
Changing operating modes
Installation and
commissioning
Product manual for the robotRestricting the working space
Load diagramsProduct specification for the robotLoad limits for tools and
workpieces
Application manual - Functional safety
and SafeMove2
Configuration of safety mod-
ule (requires Functional safety
options)
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1 Safety
1.2.1 Safety in the robot
Continued

1.2.2 Safety risks
1.2.2.1 Safety risks during installation and service work on the FlexGripper
Overview
This section includes information on general safety risks to be considered when
performing installation and service work on the FlexGripper.
General risks during installation and service
• The instructions in the Product manual in the section Installation and
Commissioning on page 35 must always be followed.
• Emergency stop buttons must be positioned in easily accessible places so
that the manipulator can be stopped quickly.
• Those in charge of operations must make sure that safety instructions are
available for the installation in question.
• Those who install the FlexGripper must have the appropriate training for the
manipulator system in question and in any safety matters associated with it.
Nation/region specific regulations
To prevent injuries and damage during the installation of the manipulator system,
the regulations applicable in the country concerned and the instructions of ABB
manipulatorics must be complied with.
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1 Safety
1.2.2.1 Safety risks during installation and service work on the FlexGripper

1.2.2.2 Safety risks related to tools/workpieces
Safe handling
It must be possible to safely turn off tools, such as milling cutters. Make sure that
guards remain closed until the cutters stop rotating. It should be possible to release
parts manually (valves).
Safe design
FlexGrippers are designed so that they retain workpieces in the event of a power
failure or a disturbance to the controller.
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1 Safety
1.2.2.2 Safety risks related to tools/workpieces

1.2.2.3 Safety risks related to high speed
WARNING
Particular care must be taken with the FlexGripper-Claw.
Risk of gripped workpiece uncontrolled gravity drop during high speed movement.
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1 Safety
1.2.2.3 Safety risks related to high speed

1.2.2.4 Safety risks during operational disturbances
General
• The industrial robot is a flexible tool that can be used in many different
industrial applications.
• All work must be carried out professionally and in accordance with the
applicable safety regulations.
• Care must be taken at all times.
Qualified personnel
Corrective maintenance must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated with its
different parts.
Extraordinary risks
If the working process is interrupted, extra care must be taken due to risks other
than those associated with regular operation. Such an interruption may have to be
rectified manually.
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1 Safety
1.2.2.4 Safety risks during operational disturbances

1.2.2.5 Risks associated with live electric parts
Voltage related risks, general
Work on the electrical equipment of the manipulator must be performed by a
qualified electrician in accordance with electrical regulations.
• Although troubleshooting may, on occasion, need to be carried out while the
power supply is turned on, the robot must be turned off (by setting the mains
switch to OFF) when repairing faults, disconnecting electric leads and
disconnecting or connecting units.
• The mains supply to the robot must be connected in such a way that it can
be turned off from outside the robot’s working space.
• Make sure that one else can turn on the power to the controller and
manipulator while you are working with the system. A good method is to
always lock the main switch on the controller cabinet with a safety lock.
The necessary protection for the electrical equipment and manipulator system
during construction, commissioning, and maintenance is guaranteed if the valid
regulations are followed.
All work must be performed:
• by qualified personnel
• on machine/manipulator system in deadlock
• in an isolated state, disconnected from power supply, and protected against
reconnection
Voltage related risks, IRC5 controller
A danger of high voltage is associated with, for example, the following parts:
• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in
the controller.
• Units such as I/O modules, can be supplied with power from an external
source.
• The mains supply/mains switch
• The transformers
• The power unit
• The control power supply (230 VAC)
• The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: Capacitors!)
• The drive unit (400/700 VDC)
• The drive system power supply (230 VAC)
• The service outlets (115/230 VAC)
• The customer power supply (230 VAC)
• The power supply unit for additional tools, or special power supply units for
the machining process.
• The external voltage connected to the controller remains live even when the
robot is disconnected from the mains.
• Additional connections.
Continues on next page
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1 Safety
1.2.2.5 Risks associated with live electric parts

Voltage related risks, manipulator
A danger of high voltage is associated with the manipulator in:
• The power supply for the motors (up to 800 VDC).
• The user connections for tools or other parts of the installation (max. 230
VAC).
Voltage related risks, tools, material handling devices, etc.
Tools, material handling devices, etc., may be live even if the robot system is in
the OFF position. Power supply cables which are in motion during the working
process may be damaged.
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1 Safety
1.2.2.5 Risks associated with live electric parts
Continued

1.2.3 Safety actions
1.2.3.1 Safety fence dimensions
General
Install a safety cell around the manipulator and the FlexGripper to ensure safe
FlexGripper installation and operation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the
load being handled by the FlexGripper is dropped or released at maximum speed.
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1 Safety
1.2.3.1 Safety fence dimensions

1.2.3.2 Fire extinguishing
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the
manipulator or controller.
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1 Safety
1.2.3.2 Fire extinguishing

1.2.3.3 Enabling device and hold-to-run functionality
Three-position enabling device
The three-position enabling device is a manually operated, constant pressure
push-button which, when continuously activated in one position only, allows
potentially hazardous functions but does not initiate them. In any other position,
hazardous functions are stopped safely.
The three-position enabling device is of a specific type where you must press the
push-button only half-way to activate it. In the fully in and fully out positions,
operating the robot is impossible.
Note
To ensure safe use of the teach pendant, the following must be implemented:
• The enabling device must never be rendered inoperational in any way.
• During programming and testing, the enabling device must be released as
soon as there is no need for the robot to move.
• Anyone entering the working space of the robot must always hold the teach
pendant. This is to prevent anyone else from taking control of the robot
without his/her knowledge.
Hold-to-run function
The hold-to-run function allows movement when a button connected to the function
is actuated manually and immediately stops any movement when released. The
hold-to-run function can only be used in manual mode.
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1 Safety
1.2.3.3 Enabling device and hold-to-run functionality