ABB FlexMT User manual

Product manual
FlexMT

Trace back information:
Workspace Main version a80
Checked in 2014-10-08
Skribenta version 4.1.210

Product manual
FlexMT
Document ID: 3HAC051768-001
Revision: -
© Copyright 2014-2014 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 Swedish. Any other languages that are
supplied have been translated from English.
© Copyright 2014-2014 ABB. All rights reserved.
ABB AB
Robotics Products
Se-721 68 Västerås
Sweden

Table of contents
11Overview of this manual ...................................................................................................................
131 Safety
131.1 Safety signals in the manual ................................................................................ 151.2 General ........................................................................................................... 161.3 Safety during installation, commissioning and decommissioning ................................ 171.4 Safety during setup, maintenance and repair .......................................................... 181.5 Safety during operation and teachin ...................................................................... 191.6 SafeMove ........................................................................................................ 211.7 Limited liability .................................................................................................. 221.8 Regulatory compliance .......................................................................................
232 Installation
242.1 General ........................................................................................................... 252.2 Mechanical installation ....................................................................................... 262.2.1 Floor requirements .................................................................................. 272.2.2 Unloading .............................................................................................. 292.2.3 Unpacking and positioning ........................................................................ 322.2.4 Assemble corridor parts ........................................................................... 362.2.5 Assemble the vision tower ........................................................................ 392.2.6 Install the FlexMT to the machine ............................................................... 422.2.7 Install FlexMT drop protection ................................................................... 432.2.8 Safety precautions for long parts in turn station ............................................ 442.3 Electrical installation .......................................................................................... 452.3.1 Power supply ......................................................................................... 462.3.2 Earthing system ...................................................................................... 472.3.3 Potential equalization ............................................................................... 482.4 Pneumatic installation ........................................................................................ 492.5 Machine tool connections ................................................................................... 502.5.1 Machine tool safety interface ..................................................................... 512.5.2 Machine tool functional interface ................................................................ 522.6 Network connections ......................................................................................... 522.6.1 Service port ........................................................................................... 532.6.2 WAN port ............................................................................................... 542.7 Licensing information ......................................................................................... 552.8 Moving the FlexMT ............................................................................................
573 Commissioning
573.1 Safety ............................................................................................................. 583.2 User accounts .................................................................................................. 593.3 Basic steps ...................................................................................................... 603.4 Vision system PickMT ........................................................................................ 613.5 Robot system ................................................................................................... 623.5.1 Robot base coordinate system ................................................................... 633.5.2 Calibration of coordinate systems .............................................................. 713.5.3 Further integration steps .......................................................................... 723.6 Machine tool .................................................................................................... 733.7 SafeMove ........................................................................................................ 753.8 Marking unit ..................................................................................................... 753.8.1 General ................................................................................................. 763.8.2 Configuration changes ............................................................................. 773.9 Deburring/grinding unit .......................................................................................
794 Function description
794.1 General ...........................................................................................................
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804.2 Overview ......................................................................................................... 814.2.1 Functional units ...................................................................................... 834.2.2 Sensors ................................................................................................. 844.2.3 Operator panels ...................................................................................... 874.3 General function description ................................................................................ 884.3.1 Functions for inconveyor .......................................................................... 894.3.2 Functions for outconveyor ........................................................................ 904.4 Functions for marking unit .................................................................................. 914.5 Functions for other options .................................................................................
935 Robot program
935.1 Safety ............................................................................................................. 945.2 Overview ......................................................................................................... 955.3 Machine interface module (TemplateMachine.sys) ................................................... 955.3.1 Overview ............................................................................................... 965.3.2 States and actions ................................................................................... 975.3.3 Procedures, functions and traps ................................................................. 985.3.4 Communication flow ................................................................................ 995.4 Main module (MainModule.mod) .......................................................................... 1005.5 Part specific modules (ModCam1.mod) ................................................................. 1015.5.1 FeedLine Light operation .......................................................................... 1045.5.2 Standard teachin operation ....................................................................... 1055.6 Option control ................................................................................................... 1065.7 User messaging ................................................................................................ 1085.8 Alarms and light tower ....................................................................................... 1095.9 WorldZones ..................................................................................................... 1105.10 Motion and zone overview ..................................................................................
1136 Operation
1146.1 Safety ............................................................................................................. 1156.2 Powering up / shutting down ............................................................................... 1156.2.1 Powering up the FlexMT ........................................................................... 1166.2.2 Shutting down the FlexMT ........................................................................ 1176.3 Starting and stopping ......................................................................................... 1176.3.1 Standard start/stop operation .................................................................... 1176.3.1.1 Cycle start .................................................................................. 1186.3.1.2 Cycle stop .................................................................................. 1196.3.1.3 Quick stop .................................................................................. 1206.3.1.4 Restart after quick stop ................................................................. 1216.4 Emergency and SafeMove stop ............................................................................ 1216.4.1 Emergency stop ...................................................................................... 1226.4.2 Restart after emergency stop .................................................................... 1236.4.3 SafeMove stop ........................................................................................ 1246.4.4 Restart after SafeMove stop ...................................................................... 1256.5 Entry control .................................................................................................... 1266.5.1 Manual operation of dangerous equipment .................................................. 1276.6 Conveyor operations .......................................................................................... 1276.6.1 Operator panel inconveyor ........................................................................ 1286.6.2 Loading inconveyor ................................................................................. 1296.6.3 Emptying in- or outconveyor ...................................................................... 1306.6.4 Automatic operation ................................................................................ 1306.6.4.1 Inconveyor ................................................................................. 1316.6.4.2 Outconveyor ............................................................................... 1326.7 Other operations ............................................................................................... 1326.7.1 Operation with robot in manual mode .......................................................... 1326.7.1.1 Start in manual operating mode (Programming mode) ........................ 1336.7.1.2 Continuing work in automatic mode after manual mode operation ........ 1346.7.2 Manually setting the belt speed (option) ...................................................... 1356.7.3 Manual cyclic brake check ........................................................................
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1366.7.4 Statistical outlet ......................................................................................
1377 Maintenance
1377.1 Safety ............................................................................................................. 1387.2 General ........................................................................................................... 1397.3 Mechanical maintenance .................................................................................... 1397.3.1 FlexMT overall cleaning ............................................................................ 1407.3.2 Air cleaning box cleaning .......................................................................... 1417.3.3 Conveyor belt cleaning ............................................................................. 1427.3.4 Conveyor belt check ................................................................................ 1437.3.5 Belt tension ............................................................................................ 1457.3.6 Conveyor belt adjustment ......................................................................... 1467.3.7 Gripper system check .............................................................................. 1477.3.8 Gripper system lubrication ........................................................................ 1487.4 Electrical maintenance ....................................................................................... 1487.4.1 Robot, control cabinet .............................................................................. 1497.4.2 Illumination ............................................................................................ 1507.4.3 Reflectors/sensors .................................................................................. 1517.4.4 Electrical function check ........................................................................... 1527.4.5 Checking cables and cable racks ............................................................... 1537.4.6 Checking electrical connections ................................................................. 1547.5 Pneumatic maintenance ..................................................................................... 1547.5.1 Air preparation condensate drain ............................................................... 1557.5.2 Filter cartridge replacement ....................................................................... 1577.5.3 Compressed air lubricator ......................................................................... 1587.6 Backup ............................................................................................................ 1587.6.1 Backup of vision system ........................................................................... 1597.6.2 Backup of robot program .......................................................................... 1607.7 Other maintenance ............................................................................................ 1607.7.1 Marking unit ........................................................................................... 1617.7.2 Camera ................................................................................................. 1627.7.3 PickMT Screen .......................................................................................
1638 Repair
1648.1 Safety ............................................................................................................. 1658.2 Conveyors ....................................................................................................... 1668.2.1 Exchange of conveyor belt ........................................................................ 1698.2.2 Exchange of conveyor motor ..................................................................... 1708.3 Illumination ...................................................................................................... 1718.4 PickMT SmartCamera ........................................................................................ 1718.4.1 Exchange of camera lens .......................................................................... 1728.4.2 Exchange of smart camera ........................................................................ 1748.5 Gripper ............................................................................................................ 1758.5.1 Exchange of gripping module on gripper ..................................................... 1768.5.2 Exchange of valves ................................................................................. 1778.6 Re-grip table .................................................................................................... 1788.7 Turn station ...................................................................................................... 1798.7.1 Exchange of gripping module on turn station ................................................ 1808.7.2 Exchange of rotation module ..................................................................... 1818.7.3 Exchange of valves ................................................................................. 1828.8 Air cleaning box ................................................................................................ 1838.8.1 Exchange of flexblow hoses ...................................................................... 1848.8.2 Exchange of valves ................................................................................. 1858.9 Grinding/Deburring units .................................................................................... 1868.9.1 Exchange of grinding/deburring unit ........................................................... 1878.9.2 Exchange of valves ................................................................................. 1898.10 Marking unit ..................................................................................................... 1898.10.1 Exchange of marking unit ......................................................................... 1908.11 Robot mounting/dismounting ...............................................................................
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1918.12 Robot fine calibration ......................................................................................... 1928.13 Software repair ................................................................................................. 1938.13.1 Robot repair ........................................................................................... 1948.13.2 PickMT SmartCamera repair ......................................................................
1959 Troubleshooting
1959.1 Alarms, warnings and informations ....................................................................... 1959.1.1 FlexMT .................................................................................................. 1979.1.2 PickMT .................................................................................................. 1989.2 PickMT troubleshooting ...................................................................................... 1999.3 Robot troubleshooting ........................................................................................ 2009.4 Marking unit .....................................................................................................
20110 Decommissioning
20210.1 Environmental information .................................................................................. 20210.1.1 Hazardous material ................................................................................. 20310.1.2 Oil and grease ........................................................................................ 20410.2 Scrapping of FlexMT ..........................................................................................
20511 Spare parts
20712 Diagrams
20712.1 Circuit diagram ................................................................................................. 20812.2 Pneumatic diagram ............................................................................................
20913 Appendix A: Configuration
20913.1 Conveyor system parameters that can be set by PickMT .......................................... 21013.2 Setting the frequency inverter .............................................................................. 21013.2.1 General ................................................................................................. 21113.2.2 Operation ABB ACS355 ............................................................................ 21113.2.2.1 Key functions .............................................................................. 21313.2.2.2 Operation ................................................................................... 21413.2.3 Parameters ............................................................................................ 21513.2.4 View and change parameters .................................................................... 21613.2.5 Alarms .................................................................................................. 21713.3 Pre-configuration settings ................................................................................... 21813.3.1 Robot pre-configuration ............................................................................ 21913.3.2 PickMT pre-configuration .......................................................................... 22013.3.3 Marking unit pre-configuration ................................................................... 22113.3.4 Frequency inverter pre-configuration .......................................................... 22213.4 Known limitations and issues .............................................................................. 22213.4.1 RobotWare 5.15.06 .................................................................................. 22313.4.2 RobotWare 5.60 ......................................................................................
22514 Appendix B: Communication
22514.1 Inputs and outputs ............................................................................................ 22514.1.1 Conveyor system .................................................................................... 22614.1.2 Entry control and safety ............................................................................ 22714.1.3 Gripper .................................................................................................. 22814.1.4 Turn station ............................................................................................ 22914.1.5 Air cleaning box ...................................................................................... 23014.1.6 Deburring .............................................................................................. 23114.1.7 Marking unit ........................................................................................... 23214.1.8 Statistical outlet ...................................................................................... 23314.2 Internal communication ...................................................................................... 23414.2.1 PickMT <> Robot ..................................................................................... 23514.2.2 Marking unit <> Robot ..............................................................................
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23715 Apendix C: FlexMT RAPID reference
23715.1 PickMT core functionality reference ...................................................................... 23815.2 FlexMT core functionality reference ...................................................................... 23915.2.1 Control subsystem .................................................................................. 24015.2.2 Utility and assistance subsystem ............................................................... 24115.3 FlexMT application functionality ...........................................................................
24316 Apendix D: Own notes
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Overview of this manual
About this manual
This manual describes the option FlexMT.
Usage
User manuals are used to understand how to use the product, for example to install,
configure, or operate.
Users
This manual is intended for:
• Personnel that are responsible for installation and configuration of robot
systems
• Programmers
• Service engineers
Trademarks
FlexMT is a trademark of ABB.
PickMT is a trademark of SVIA, Svensk Industriautomation AB.
References
Document IDReference
3HAC049820-001Product specification - FlexMT
3HAC035504-001Product manual - IRB 2600
3HAC033453-001Product manual - IRB 4600
3HAC051771-001Application manual - PickMT
3HAC051769-001Product manual - Safety center for FlexMT
3HAC051770-001Application manual - PickMT with ABB robot
3HAC052311-001Application manual - FeedLine Light
Revisions
DescriptionRevision
First edition.-
3HAC051768-001 Revision: - 11
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Overview of this manual

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1 Safety
1.1 Safety signals in the manual
Introduction to safety signals
This section specifies all dangers that can arise when doing the work described
in this manual. Each danger consists of:
• A caption specifying the danger level (DANGER, WARNING, or CAUTION)
and the type of danger.
• A brief description of what will happen if the operator/service personnel do
not eliminate the danger.
• Instruction about how to eliminate danger to simplify doing the work.
Danger levels
The table below defines the captions specifying the danger levels used throughout
this manual.
SignificanceDesignationSymbol
Warns that an accident will occur if the instructions
are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
or fire risk, risk of poisonous gases, risk of crushing,
impact, fall from height, and so on.
DANGER
xx0200000022
Warns that an accident may occur if the instructions
are not followed that can lead to serious injury, pos-
sibly fatal, and/or great damage to the product. It
applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
explosion or fire risk, risk of poisonous gases, risk
of crushing, impact, fall from height, etc.
WARNING
xx0100000002
Warns for electrical hazards which could result in
severe personal injury or death.
ELECTRICAL
SHOCK
xx0200000024
Warns that an accident may occur if the instructions
are not followed that can result in injury and/or
damage to the product. It also applies to warnings
of risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping, im-
pact, fall from height, etc. Furthermore, it applies to
warnings that include function requirements when
fitting and removing equipment where there is a risk
of damaging the product or causing a breakdown.
CAUTION
xx0100000003
Warns for electrostatic hazards which could result
in severe damage to the product.
ELECTROSTATIC
DISCHARGE (ESD)
xx0200000023
Continues on next page
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1 Safety
1.1 Safety signals in the manual

SignificanceDesignationSymbol
Describes important facts and conditions.NOTE
xx0100000004
Describes where to find additional information or
how to do an operation in an easier way.
TIP
xx0100000098
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1 Safety
1.1 Safety signals in the manual
Continued

1.2 General
This sections covers safety precautions regarding the standard equipment as well
as options that are not included in all installations. If the installation contains further
parts, safety instruction may also be found in other documentation.
General safety precautions for all procedures where there is a risk of personal
injury or damage to property can be found in this chapter. Additional instructions
can also be found close to the instructions for each procedure.
Equipment that is part of a fully- or semi-automatic system must always be treated
with care regarding safety during the installation phase, during operation as well
as during maintenance and repair.
Installation/commissioning personnel must be trained and thoroughly understand
the principles of the FlexMT, to prevent risks to the operator and service personnel.
Users of the FlexMT system must ensure that the safety laws and regulations that
apply to their respective country are followed and that all safety devices that are
required to guarantee the safety of those who work with the robot are installed
correctly.
Only personnel with required training is authorized to use the system.
Trainee operators may only use the system under the supervision of a qualified,
experienced operator as follows:
Qualified electricianTrained service and
maintenance techni-
cians
Trained operatorActivity
x×Installation/commis-
sioning
××Operation
××Fault tracing
×Correction of mechan-
ical fault
×Correction of electric-
al fault
××Service
××Maintenance
x = Authorized to perform the activity
Received training must be documented in writing.
Always check that the installation and maintenance instructions are supplied.
DANGER
Be aware of inherent risks of robot systems ! Safety information for the robot
system is supplied in the robots product manual. Ensure that you have read
these instructions and follow them.
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1 Safety
1.2 General

1.3 Safety during installation, commissioning and decommissioning
Carefully read the safety precautions, before unpacking and installing the
equipment.
Personnel who are involved in the installation and commissioning must have
relevant training for the respective robot and corresponding safety issues.
WARNING
It is forbidden to step on the part of the conveyors that is outside of the
machineEnsure that nobody is on the conveyor, especially when the belt is in
motion.
WARNING
It is forbidden to step on the illumination roof, the outer walls of the FlexMT and
on any FlexMT option.
DANGER
Ensure that nobody is within the machine enclosure during operation.
If the FlexMT is equipped with the turn station option, an additional safety precaution
might be necessary. Depending on the length of parts to be turned, an additional
protective shield might become necessary.
DANGER
When using the turn station option, perform a complementary risk analysis with
respect to the length of the part and height of the risk zone. See section on
mechanical installation.
DANGER
The SafeMove configuration shall not be disabled for any reason.
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1 Safety
1.3 Safety during installation, commissioning and decommissioning

1.4 Safety during setup, maintenance and repair
Work on mechanical systems must only be carried out by qualified personal or by
an instructed person under guidance and supervision of a qualified person
according to the applicable technical regulations
Work on electrical systems or operating material must only be carried out by a
qualified electrician or by an instructed person under guidance and supervision of
a qualified electrician according to the applicable electrical technical regulations.
The equipment can start without prior warning thus causing a crushing risk. Installed
protection that belongs to the equipment must always be installed during
semi-automatic and fully automatic operation.
DANGER
The following must be ensured before commencing work on the FlexMT:
• Emergency stop must be activated (machine stationary)
• Machine voltage must be disconnected
• Action must be taken so that machine voltage cannot be connected when
work is carried out.
• The air supply must be disconnected.
• Action must be taken so that air supply cannot be connected when work is
carried out.
• The key for resetting the safety stop must be carried when working within
the FlexMT housing.
Mechanical, pneumatic or electrical energy may be stored in the machine, which
may cause a risk when carrying out work inside the FlexMT.
The function of safety devices must be checked after all work that might have an
impact on the safety arrangements.
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1 Safety
1.4 Safety during setup, maintenance and repair

1.5 Safety during operation and teachin
WARNING
Ear protection shall be used when working with the air cleaning box/deburring
unit for certain details. The need will depend on the application and shall be risk
assessed.
WARNING
Eye protection shall be used when working with the air cleaning box/deburring
unit for certain details. The need will depend on the application and shall be risk
assessed.
DANGER
Pneumatic power to the grippers is not switched off neither during autostop nor
in emergency state. Be aware of crushing risk.
Normal precaution should be taken when working with the FlexMT.
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1 Safety
1.5 Safety during operation and teachin

1.6 SafeMove
The robot working space in the FlexMT is restricted by the use of SafeMove. Due
to space requirements, the SafeMove outer boundaries of restricted space are
close to the FlexMT enclosure.
In case of robot malfunction or erroneous programming leading to a movement
out of the restricted space, the robot will begin to stop its movement. Minor
collisions with the outer FlexMT housing can occur, but will not lead a personal
hazard.
DANGER
The SafeMove configuration shall not be disabled for any reason. Modifications
of the SafeMove configuration shall not be done without appropriate risk
assessment and validation.
DANGER
The SafeMove configuration inside the machine tool must be adopted to the
actual circumstances. Risk assessment must be performed, and the new
SafeMove configuration must be validated.
Alternate mounting position.
The FlexMT mechanical configuration does allow an alternate mounting position
of the robot. This possibility is given for the integrators convenience and shall not
be considered to be a standard option.
If the wall towards the machine tool is (partly) removed, the alternate mounting
position of the robot will move the robot ~100mm closer to the machine tool.
Standard mounting position A, alternate mounting position B
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1 Safety
1.6 SafeMove

The SafeMove configuration must be changed accordingly to the new work space.
The standard ABB guidelines for configuration and validation of SafeMove
configurations shall be followed.
DANGER
It is the integrators responsibility to modify and validate the SafeMove
configuration for the alternate mounting position in a suitable way.
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1 Safety
1.6 SafeMove
Continued