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: -

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.

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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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 .................................................................................
Robot program
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 ..................................................................................
Operation
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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12 Robot fine calibration ......................................................................................... 1928.13 Software repair ................................................................................................. 1938.13.1 Robot repair ........................................................................................... 1948.13.2 PickMT SmartCamera repair ......................................................................
Troubleshooting
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 .....................................................................................................
Decommissioning
1 Environmental information .................................................................................. 20210.1.1 Hazardous material ................................................................................. 20310.1.2 Oil and grease ........................................................................................ 20410.2 Scrapping of FlexMT ..........................................................................................
Spare parts
Diagrams
1 Circuit diagram ................................................................................................. 20812.2 Pneumatic diagram ............................................................................................
Appendix A: Configuration
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 ......................................................................................
Appendix B: Communication
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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Table of contents