ABB IRC5 Compact Instructions for use

Application manual
Motion coordination and supervision
Controller software IRC5
Robotware 5.0

© Copyright 2004-2008 ABB. All rights reserved.
Application manual
Motion coordination and supervision
RobotWare 5.0
Document ID: 3HAC18154-1
Revision: F

© Copyright 2004-2008 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
construedasany kind ofguaranteeor warrantyby ABB forlosses, 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, and contents thereof must not be imparted to a third party nor be used for
any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
© Copyright 2004-2008 ABB All rights reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden

Table of Contents
33HAC18154-1 Revision: F
© Copyright 2004-2008 ABB. All rights reserved.
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Collision Detection 11
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1.2 Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1.3 What happens at a collision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Configuration and programming facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.1 System parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2 RAPID components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.3 Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3 How to use Collision Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3.1 Set up system parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3.2 Adjust supervision from FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3.3 Adjust supervision from RAPID program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
1.3.4 How to avoid false triggering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2 Machine Synchronization 23
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.1.2 What is needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.1.3 Synchronization features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.1.4 General description of the synchronization process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.1.5 Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Hardware configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.2.1 Sensor Synchronization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.2.1.1 Encoder specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.2.1.2 Encoder Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.2.1.3 Installation recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.2.1.4 Connecting encoder and encoder interface unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.2.2 Analog Synchronization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.2.2.1 Required hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.3 Software installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.3.1 Sensor installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.3.2 Reloading saved Motion parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.3.3 Installation of several sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.4 Programming the synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.4.1 General issues when programming with the synchronization option. . . . . . . . . . . . . . . . . . . . . . . 40
2.4.2 Programming examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.4.3 Entering and exiting coordinated motion in corner zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.4.4 Use several sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.4.5 Finepoint programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.4.6 Drop sensor object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.4.7 Information on the FlexPendant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.4.8 Programming considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.4.9 Modes of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.5 Robot to robot synchronization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.5.2 The concept of robot to robot synchronization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.5.3 Master robot configuration parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.5.4 Slave robot configuration parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Table of Contents
43HAC18154-1 Revision: F
© Copyright 2004-2008 ABB. All rights reserved.
2.5.5 Programming example for master robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.5.6 Programming example for slave robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.6 Synchronize with hydraulic press using recorded profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.6.2 Configuration of system parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.6.3 Program example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.7 Synchronize with molding machine using recorded profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.7.2 Configuration of system parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.7.3 Program example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.8 Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.8.1 Supervise movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.9 Programming and configuration data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.9.1 RAPID components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.9.2 System parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.9.3 I/O signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.10 RAPID reference information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.10.1 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.10.1.1 DropSensor - Drop object on sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.10.1.2 PrxActivAndStoreRecord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.10.1.3 PrxActivRecord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.10.1.4 PrxDbgStoreRecord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.10.1.5 PrxDeactRecord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.10.1.6 PrxResetPos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.10.1.7 PrxResetRecords. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.10.1.8 PrxSetPosOffset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.10.1.9 PrxSetRecordSampleTime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.10.1.10 PrxSetSyncalarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.10.1.11 PrxStartRecord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.10.1.12 PrxStopRecord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.10.1.13 PrxStoreRecord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.10.1.14 PrxUseFileRecord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.10.1.15 SupSyncSensorOff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.10.1.16 SupSyncSensorOn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.10.1.17 SyncToSensor - Sync to sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.10.1.18 WaitSensor - Wait for connection on sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.10.2 Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.10.2.1 PrxGetMaxRecordpos. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Index 105

Overview
53HAC18154-1 Revision: F
© Copyright 2004-2008 ABB. All rights reserved.
Overview
About this manual This manual explains the basics of when and how to use the following RobotWare options:
•Collision Detection
•Sensor Synchronization
•Analog Synchronization
Usage This manual can be used either as a reference to find out if an option is the right choice for
solving a problem, or as a description of how to use an option. Detailed information regarding
syntax for RAPID routines, and similar, is not described here, but can be found in the
respective reference manual.
Who should read this manual?
This manual is mainly intended for robot programmers.
Prerequisites The reader should...
•be familiar with industrial robots and their terminology
•be familiar with the RAPID programming language
•be familiar with system parameters and how to configure them.
Organization of chapters
The manual is organized in the following chapters:
References
Chapter Contents
1. Describes the option Collision Detection.
2. Describes Machine Synchronization (the options Sensor Synchronization and
Analog Synchronization).
Reference Document Id
Technical reference manual - RAPID overview 3HAC16580-1
Technical reference manual - RAPID Instructions, Functions and
Data types 3HAC16581-1
Operating manual - IRC5 with FlexPendant 3HAC16590-1
Technical reference manual - System parameters 3HAC17076-1
Product manual - IRC5 3HAC021313-001
Application manual - DeviceNet 3HAC020676-001
Product Specification - Controller Software IRC5, RobotWare 5.0 3HAC022349-001
Continues on next page

Overview
3HAC18154-1 Revision: F6
© Copyright 2004-2008 ABB. All rights reserved.
Revisions
Revision Description
-First edition
ASensor Synchronization added
BCorrected errors in Sensor Synchronization, section slave robot configuration
parameters.
CAdded RAPID reference for Sensor Synchronization.
DMinor corrections.
EThe option Analog Synchronization has been added, which affects most parts of
the Machine Synchronization chapter.
Continued

Product documentation, M2004
73HAC18154-1 Revision: F
© Copyright 2004-2008 ABB. All rights reserved.
Product documentation, M2004
General The robot documentation is divided into a number of categories. This listing is based on the
type of information contained within the documents, regardless of whether the products are
standard or optional. This means that any given delivery of robot products will not contain
all documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Product manuals All hardware, robots and controllers, will be delivered with a Product manual that contains:
•Safety information
•Installation and commissioning (descriptions of mechanical installation, electrical
connections)
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
•Repair (descriptions of all recommended repair procedures including spare parts)
•Additional procedures, if any (calibration, decommissioning)
•Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
•Part list
•Foldouts or exploded views
•Circuit diagrams
Technical reference manuals
The following manuals describe the robot software in general and contain relevant reference
information:
•RAPID Overview: An overview of the RAPID programming language.
•RAPID Instructions, Functions and Data types: Description and syntax for all
RAPID instructions, functions and data types.
•System parameters: Description of system parameters and configuration workflows.
Application manualsSpecific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
•The purpose of the application (what it does and when it is useful)
•What is included (for example cables, I/O boards, RAPID instructions, system
parameters, CD with PC software)
•How to use the application
•Examples of how to use the application
Continues on next page

Product documentation, M2004
3HAC18154-1 Revision: F8
© Copyright 2004-2008 ABB. All rights reserved.
Operating manuals This group of manuals is aimed at those having first hand operational contact with the robot,
that is production cell operators, programmers and trouble shooters. The group of manuals
includes:
•Emergency safety information
•General safety information
•Getting started, IRC5
•IRC5 with FlexPendant
•RobotStudio
•Introduction to RAPID
•Trouble shooting, for the controller and robot
Continued

Safety
93HAC18154-1 Revision: F
© Copyright 2004-2008 ABB. All rights reserved.
Safety
Safety of personnel A robot is heavy and extremely powerful regardless of its speed. A pause or long stop in
movement can be followed by a fast hazardous movement. Even if a pattern of movement is
predicted, a change in operation can be triggered by an external signal resulting in an
unexpected movement.
Therefore, it is important that all safety regulations are followed when entering safeguarded
space.
Safety regulations Before beginning work with the robot, make sure you are familiar with the safety regulations
described in Operating Manual - IRC5 With Flexpendant.

Safety
3HAC18154-1 Revision: F10
© Copyright 2004-2008 ABB. All rights reserved.

1 Collision Detection
1.1.1. Overview
113HAC18154-1 Revision: F
© Copyright 2004-2008 ABB. All rights reserved.
1 Collision Detection
1.1 Introduction
1.1.1. Overview
Purpose Collision Detection is a software option that reduces collision impact forces on the robot. This
helps protecting the robot and external equipment from severe damage.
WARNING!
Collision Detection cannot protect equipment from damage at a full speed collision.
Description The software option Collision Detection identifies a collision by high sensitivity, model based
supervision of the robot. Depending on what forces you deliberately apply on the robot, the
sensitivity can be tuned as well as turned on and off. Because the forces on the robot can vary
during program execution, the sensitivity can be set on-line in the program code.
Collision detection is more sensitive than the ordinary supervision and has extra features.
When a collision is detected, the robot will immediately stop and relieve the residual forces
by moving in reversed direction a short distance along its path. After a collision error message
has been acknowledged, the movement can continue without having to press Motors on on
the controller.
What is included The RobotWare option Collision Detection gives you access to:
•system parameters for defining if Collision Detection should be active and how
sensitive it should be (without the option you can only turn detection on and off for
Auto mode)
•instruction for on-line changes of the sensitivity:MotionSup
Basic approach Collision Detection is by default always active when the robot is moving. In many cases this
means that you can use Collision Detection without having to take any active measures.
If necessary, you can turn Collision Detection on and off or change its sensitivity in two ways:
•temporary changes can be made on-line with the RAPID instruction MotionSup
•permanent changes are made through the system parameters.
For detailed descriptions of how this is done, see How to use Collision Detection on page 18.

1 Collision Detection
1.1.2. Limitations
3HAC18154-1 Revision: F12
© Copyright 2004-2008 ABB. All rights reserved.
1.1.2. Limitations
Load definition In order to detect collisions properly, the payload of the robot must be correctly defined.
TIP!
Use Load Identification to define the payload. For more information, see Operating manual
- IRC5 with FlexPendant.
Robot axes only Collision Detection is only available for the robot axes. It is not available for track motions,
orbit stations, or any other external axes.
Independent joint The collision detection is deactivated when at least one axis is run in independent joint mode.
This is also the case even when it is an external axis that is run as an independent joint.
Soft servo The collision detection may trigger without a collision when the robot is used in soft servo
mode. Therefore, it is recommended to turn the collision detection off when the robot is in
soft servo mode.
No change until the robot moves
If the RAPID instruction MotionSup is used to turn off the collision detection, this will only
take effect once the robot starts to move. As a result, the digital output MotSupOn may
temporarily have an unexpected value at program start before the robot starts to move.
Reversed movement distance
The distance the robot is reversed after a collision is proportional to the speed of the motion
before the collision. If repeated low speed collisions occur, the robot may not be reversed
sufficiently to relieve the stress of the collision. As a result, it may not be possible to jog the
robot without the supervision triggering. In this case, turn Collision Detection off temporarily
and jog the robot away from the obstacle.
Delay before reversed movement
In the event of a stiff collision during program execution, it may take a few seconds before
the robot starts the reversed movement.
Robot on track motion
If the robot is mounted on a track motion the collision detection should be deactivated when
the track motion is moving. If it is not deactivated, the collision detection may trigger when
the track moves, even if there is no collision.

1 Collision Detection
1.1.3. What happens at a collision
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1.1.3. What happens at a collision
Overview When the collision detection is triggered, the robot will stop as quickly as possible. Then it
will move in the reverse direction to remove residual forces. The program execution will stop
with an error message. The robot remains in the state motors on so that program execution
can be resumed after the collision error message has been acknowledged.
A typical collision is illustrated below.
Collision illustration
xx0300000361
Robot behavior after a collision
This list shows the order of events after a collision. For an illustration of the sequence, see the
diagram below.
When ... then ...
the collision is detected the motor torques are reversed and the mechanical brakes
applied in order to stop the robot
the robot has stopped the robot moves in reversed direction a short distance along
the path in order to remove any residual forces which may be
present if a collision or jam occurred
the residual forces are
removed the robot stops again and remains in the motors on state
Continues on next page

1 Collision Detection
1.1.3. What happens at a collision
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Speed and torque diagram
en0300000360
Continued

1 Collision Detection
1.2.1. System parameters
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1.2 Configuration and programming facilities
1.2.1. System parameters
About system parameters
The parameters for Collision Detection do not require a warm start to take effect.
For more information about the parameters, see Technical reference manual - System
parameters.
Motion Supervision These parameters belong to the type Motion Supervision in the topic Motion.
Motion System These parameters belong to the topic Motion and the type Motion System.
Parameter Description
Path Collision Detection Turn the collision detection On or Off for program execution.
Path Collision Detection is by default set to On.
Jog Collision Detection Turn the collision detection On or Off for jogging.
Jog Collision Detection is by default set to On.
Path Collision Detection
Level Modifies the Collision Detection supervision level for program execution by the specified percentage value. A large
percentage value makes the function less sensitive.
Path Collision Detection Level is by default set to 100%.
Jog Collision Detection
Level Modifies the Collision Detection supervision level for jogging by the specified percentage value. A large percentage value
makes the function less sensitive.
Jog Collision Detection Level is by default set to 100%.
Collision Detection Memory Defines how much the robot moves in reversed direction on
the path after a collision, specified in seconds. If the robot
moved fast before the collision it will move away a larger
distance than if the speed was slow.
Collision Detection Memory is by default set to 75 ms.
Manipulator Supervision Turns the supervision for the loose arm detection on or off for
IRB 340 and IRB 360. A loose arm will stop the robot and
cause an error message.
Manipulator Supervision is by default set to On.
Manipulator Supervision
Level Modifies the supervision level for the loose arm detection for the manipulators IRB 340 and IRB 360. A large value makes
the function less sensitive.
Manipulator Supervision Level is by default value set to 100%.
Parameter Description
Motion Supervision Max
Level Set the maximum level to which the total collision detection tune level can be changed. It is by default set to 300%.
Motion Supervision Max Level is only available if the system is
installed in Service mode.

1 Collision Detection
1.2.2. RAPID components
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1.2.2. RAPID components
Instructions This is a brief description of the instructions in Collision Detection. For more information,
see respective instruction in Technicalreferencemanual-RAPIDInstructions,Functionsand
Data types.
Instruction Description
MotionSup MotionSup is used to:
• activate ordeactivateCollisionDetection.This can only bedone
if the parameter Path Collision Detection is set to On.
• modify the supervision level with a specified percentage value
(1-300%). A large percentage value makes the function less
sensitive.

1 Collision Detection
1.2.3. Signals
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1.2.3. Signals
Digital outputs This is a brief description of the digital outputs in Collision Detection. For more information,
see respective digital output in Technical reference manual - System parameters.
Digital output Description
MotSupOn MotSupOn is high when Collision Detection is active and low when it is
not active.
Note that a change in the state takes effect when a motion starts. Thus,
if Collision Detection is active and the robot is moving, MotSupOn is
high. If the robot is stopped and Collision Detection turned off,
MotSupOn is still high. When the robot starts to move, MotSupOn
switches to low.
MotSupTrigg MotSupTrigg goes high when the collision detection triggers. It stays
high until the error code is acknowledged from the FlexPendant.

1 Collision Detection
1.3.1. Set up system parameters
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© Copyright 2004-2008 ABB. All rights reserved.
1.3 How to use Collision Detection
1.3.1. Set up system parameters
Activate supervisionTo be able to use Collision Detection during program execution, the parameter Path Collision
Detection must be set to On.
To be able to use Collision Detection during jogging, the parameter Jog Collision Detection
must be set to On.
Define supervision levels
Set the parameter Path Collision Detection Level to the percentage value you want as default
during program execution.
Set the parameter Jog Collision Detection Level to the percentage value you want as default
during jogging.