ABB IRB 2000 User manual

ABBProduct Manual, IRB 2000
ASEABROWNBOVERI
ConfigurationList
DescriptionIRB2000
Safety
InstallationIRB2000
InstallationS3
MaintenanceIRB2000
AdditionalDocuments(Option,RSI)
3HAB
3HAB
3HAB
3HAB
3HAB
3HAB
0007-2
0001-2
0001-8
0003-2
0003-8
0005-2

ProductManual
IRB2000
3HAB0007-2
January1993/M93
ABBRoboticsProducts
JkItIt
ASEABROWNBOVERI

Theinformationinthisdocumentissubjecttochangewithoutnoticeandshouldnotbeconstrued
asa commitmentbyABBRoboticsProductsAB.ABBRoboticsProductsABassumesno
responsibilityforanyerrorsthatmayappearinthisdocument.
InnoeventshallABBRoboticsProductsABbeliableforincidentalorconsequentialdamages
arisingfromuseofthisdocumentorofthesoftwareandhardwaredescribedinthisdocument.
ThisdocumentandpartsthereofmustnotbereproducedorcopiedwithoutABBRoboticsProducts
AB'swrittenpermission,andthecontentsthereofmustnotbeimpartedtoa thirdpartynorbeused
foranyunauthorizedpurpose.Contraventionwillbeprosecuted.
AdditionalcopiesofthisdocumentmaybeobtainedfromABBRoboticsProductsABatitsthen
currentcharge.
ABBRoboticsProductsAB1993
Articlenumber:3HAB0007-2
Issue:January1993
ABBRoboticsProductsAB
S-72168Vasteras
Sweden

ABBRoboticsProductsAB
ConfigurationlistIRB2000M93
RACRACRef.No.
Customer
OrderNo.
SerialNo.
CONTENTS
SpecificationformIR
Datasheet
Datasheet
DOCUMENTATION(70(
DESCRIPTION
ProductManualIRB2
ServiceManualIRB'<
ServiceManualS3
ProgrammingManual!
Computerlinkdocum
TotheUser
TheConfigurationListisanindividualspecifica-
tionoftherobotsystemdeliveredregardingcon-
figurationandextent.
Ondelivery,thecompletedocumentisplacedin
therobotcontrolcabinet.
Tillanvandaren
"ConfigurationList"arenindividuelispecifikation
avdetlevereraderobotsystemetavseendeupp-
byggnadochomfattning.
VidleveransenfranABBRoboticsfinnsdet
komplettadokumentetinlagti styrskapet.
INTHIS
DELIVERY
|I Testedaccordingtoinspectionprovision3HAA3916-B
Approved
Approved
DeliverySEROP
Delivery
Installation
Date
Date
Date
Date
Date
Name
Name
Name
Name
Name
IssuedbyDoc.No.LangRevDateSheetNo.
ABroberg/MT3HAB0105-2en092491/1

Description
IRB2000
3HAB0001-2
January1993/M93
ABBRoboticsProducts
AItIt
#*IPIP
ASEABROWNBOVERI

Theinformationinthisdocumentissubjecttochangewithoutnoticeandshouldnotbeconstruedasa
commitmentbyABBRoboticsProductsAB.ABBRoboticsProductsABassumesnoresponsibilityforany
errorsthatmayappearinthisdocument.
InnoeventshallABBRoboticsProductsABbeliableforincidentalorconsequentialdamagesarisingfrom
useofthisdocumentorofthesoftwareandhardwaredescribedinthisdocument.
ThisdocumentandpartsthereofmustnotbereproducedorcopiedwithoutABBRoboticsProductsAB's
writtenpermission,andthecontentsthereofmustnotbeimpartedtoa thirdpartynorbeusedforany
unauthorizedpurpose.Contraventionwillbeprosecuted.
AdditionalcopiesofthisdocumentmaybeobtainedfromABBRoboticsProductsABatitsthencurrent
charge.
©ABBRoboticsProductsAB1993
Articlenumber:3HAB0001-2
Issue:January1993
ABBRoboticsProductsAB
S-72168Vasteras
Sweden

CONTENTS
ChapterPage
1INTRODUCTION3
2CHARACTERISTICS,IRB20005
3SYSTEMDESCRIPTION7
3.1Manipulator8
3.2Controlcabinet10
4OPERATION/PROGRAMMING15
4.1Controlpanel
4.1.1Remotecontrol16
17
5TECHNICALSPECIFICATION25
4.2
4.3Programmingunit
Programming
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
Programdesign
Movements
Programmablefunctions
Editingfunctions
Manuallycontrolledfunctions
Systemparameters
TECHNICALSPECIFICATION
5.1
5.2
5.3
5.4
Features
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
5.1.7
Performance
Programcapacity
Batterycapacity
Signalcapacity
Man- machinecommunication
Workingrange
Loaddiagram
Requirements
5.2.1
5.2.2Environmentalrequirements Electricalconnections
Physicaldata,dimensionaldrawings
5.3.1
5.3.2Physicaldata Dimensionaldrawings
Standards
31
31
35
37
6.1Manipulator37
6.2Controlsystem37
6.3Accessoriesmanipulatorunit48
6.4Accessoriescontrolsystem49
6.5Documentation50
DescriptionDIB2000

Description1KB2000

INTRODUCTION
1KB2000
isa six-axesrobotwitha largeworkvolumeandisprimarilyintendedforarc
weldingandglueing/sealing.IRB2000isalsosuitableforapplicationssuchas
assembly,waterjetcutting,lasercutting,materialhandlingandstudwelding.
Thehandlingcapacityis10kgandtheveryquickmovementsofthewristaxesare
otherimportantfeaturesfortheintendedapplications.
Tomakeitpossibletoadapttherobottovariousapplications,a rangeofperipheral
equipmentforvariousapplicationsisavailable.Theperipheralequipmentrange
includestoolexchangers,gripperholdersandseveraldifferentgripperunits.
Powerandairsupplyisavailableatthegrippers.
Description1KB2000

Description1KB2000

2CHARACTERISTICS,IRB2000
Capabilities
TheIRB2000handlesa loadofupto10kgwithina wideworkingrange,
accuratelyandrapidly.Theslendemessanddexterityofitsarmsystemgiveshigh
accessability.Itsdesignepermitsinstallationofthesamerobotontheflooror
inverted.
TheIRB2000robotisparticularysuitableforarcwelding,glueingandmaterial
handlingtasksbecauseofitsspeed,wideworkingrangeandtheflexibility
inherentinits6-axisdesign.
Speed
TheIRB2000robotperformsoutstandingly,bothinaccelerationandspeedforall
axes.Inarcweldingapplications,withmanyshortwelds,thehigheracceleration
canprovideshortestpossiblecycletime.
Inmachinetending,theworkpiecechangetimecanbecuttoa minimum.
Processinterface
TheIRB2000isa generalpurposerobotthatcanbeadaptedtovariouskindsof
applications.Therearesoftwarefunctionsadaptedforapplications,mounting
holesonthearmsystemforprocessequipmentanduserwiringsandpressurized
airsupplyroutedinsidetherobotarm.
Alltheseintegratedfeatures,whenconnectedtoperipheralequipment^like
grippers,toolexchangers,etc.),meana reliablesolutionwithhighproductivity.
Reliabilityandmaintenance
Highqualitycharacterizestheentiredesign,e.g.fewandrigidmovingparts,
minimalmaintenance,robotwiringroutedinsidetherobot,modulardesignforfast
andsimpleserviceanda minimumnumberofcircuitboards,circuitryand
components.
ThesefeaturesandmanymoremaketheIRB2000extremelyreliableandensurea
highproductivity.
Controlsystem
TheS3ControlSystemmakesuseofestablishedfeatureslikesoftkeys,joystick
andtherobot-languageARLAforsimpleandfastprogramming.IRB2000isinits
basicformequippedwithanabsolutemeasuringservosystem.Anotherimportant
factoristheinterfacecapacity.TheS3-controllerhastheabilitytoperforma
communicationinseveraldifferentways.ThesearedigitaloranalogueI/Os,
computerlinktoa superiorcontroooeravailableandcapabilitytocontrolupto6
externalaxes.
DescriptionIRB2000

Description1KB2000
6

DESCRIPTION
Therobotconsistsofa manipulatoranda controlunitconnectedby2 cables.
Variousoptionsandvariantsareavailable.Thesearedescribedindetailinchapter6.
Thecontrolunitcontainsthetotalsystemelectronics,andoffersmany
opportunitiesforexternalcommunicationandcontrolofperipheralequipment.
Operatorcommunication,programmingandmanualrunningisperformedviaa
portableprogrammingunit.Programmingcanalsobeperformedoff-lineviaa
terminalandanABBRoboticsOff-lineProgrammingPackage.
CONTROLUNIT
Programmingunit
Floppydiskunit
Computerlink
Printout
Power
supply
Power
supply
ExternalI/O
Externalaxes
Trackmotion
\Toolinterfacej
Manipulator
PERIPHERALEQUIPMENTANDTOOLS
Conveyer
iToolsystem2000!
Etc.
1
1
1
1
1
>
1
Fig.3.1Principlediagram1KB2000
Description
1KB2000

3.1Manipulator
TheManipulatorcaninoneversionbeusedforeitherfloormountingorinverted
sustpension.
Exeptionalforthisdesignis:
•smallpedestalturningradius
*slenderarmsystem.
Serviceability
Extensiveefforthasbeenputintomakingtheroboteasilyserviceableandtherefore
faultcanbedoneinminutesbyservicepersonnel.Onlyafewspecialtoolsare
required.
Drivesystem
Allmotorsareservo-controlled,brushlessACmotors,speciallyadaptedforeachaxis.
Boththemotorsandthefeedbackunitsaremaintenancefree.
Brakes
Therobotissuppliedwithbrakesonall axes.Therobotisautomaticallybrakedat
emergencystops,powerfailureorwhenthesystemistakendowntoMOTOROFFIf
therobotareinMOTORONmode,brakesareactivatedafter10seconds(automatic
operation)orafter5 minutes(manualoperation).
Thebrakescan,individually,bemanuallyreleasedbyswitchedlocatedonthesideof
therobot.Thebrakesrequirenomaintenance.
Whenthebrakesarereleased,thearmsystemmaycollapse!Armcanmake
asudden,uncontrolledmovement.
Gearboxes
Allgearboxesaremadewithveryhighaccuracyandarespeciallyadaptedforeach
axisfunction.
Allgearsarelubricated,withliquidgreaseandoil.
Cabling
Thecablingishighlymodularisedandthereforeeasytoreplaceascompleteunits.
Thecablesarearrangedformaximumlifetime.
Measurementsystemandaccumulatorunit
Themeasurementsystemconsistsofoneresolveroneachmotorshaftanda
measurementboardmountedontherobot.
Theresolverisusedforgatheringspeedandpositiondata.Themeasurementboard
readstheresolverfeedbacksignalsandgeneratespositioninformationforeachaxis.
Therechargablebatteryisusedforsupplybackuptothemeasurementboard
duringpoweroff.Thispreventsthedataregardingthenumberofturnseach
resolverhasmadetobeerasedduetopowerfailure.Thebatteryischarged
continouslyatpoweron.
Thismeans thattherobotmayberestarteddirectlyfromitspresentpositionaftera
systemshutdown.
Description1KB2000
8

Movementstructure
Therobot'smovementpatterncanbrieflybedescribedasfollows(seealsothe
figurebelow).
Axisl(C)
Turningofthecompletemechanicalunitarmsystem.
Axis2 (B)
Forwardandreversemovementofthelowerarm.
Axis3 (A)
Upanddownmovementoftheupperarm.
Axis4 (D)
Turningofthecompletewristcentre.
Axis5 (E)
Bendingofwristaroundthewristcentre.
Axis6 (P)
Turningofmountingflange(robotturningdisc)
3rd(A)axisMotorunitSthand
6thaxes
Motorunit4thaxis6th(E)axis
6th(PJaxis
Wrist
Motorunitand
gearbox3rdaxisMotorunitand
gear box2ndaxis
1st<C)axis
Base
Gearbox1staxis
Description
1KB2000
9

3.2Controlsystem
Controlpanel
Programmingunit
Floppydiskunit
Winchestermemory
(option)
Dutytimecounter
Monitor,LCD
(Option)
Coolingdevice(option)
Connections
Mainsswitch
Controlpanel
Floppydiskunit
Dutytimecounter
Connections
Mainfunctionsforrobotoperation.
Allfunctionsforrobotoperationandprogramming.
Built-insystemtest.
Handlesstoring/loadingofdataonfloppydisk.
Handlesstoring/loadingofdataina massmemory.
Recordingdutytime.
Additionaldisplayofuserprogramandprocess
messages.
Coolingoftheelectronic.
Controlcableconnection,processcommunication,computer
link(option),programprintout(option).
Coolingdevice
onitor
Programmingunit
Fig3.4ControlcabinetThelookofthecabinetdiffers,
dependingondesign
Description10
1KB2000

Eletroniccomponents
Computerboard
Systemboard
DigitalI/Oboards
(option)
AnalogueI/Oboards
(option)
Powerunit
Rectifier
Supplyunit
Driveunits
Controlboardfor
externalaxis(option).
Mainstransformer
•Containsfourmicroprocessors:
Maincomputer- foroverallcontrol.
Servocomputer- forcontrolofservofunctions
androbotmovements.
-Axiscomputer- forindividualcontrolofrobotaxes.
I/Ocomputer- forcontrolofcommunicationwith
operatorunit,peripheralequipment,hostcomputer
(option)andfloppydiscunit.
•Containsallrobotprimarymemory.
•Containscircuitsforpersonalsafetyfunctions
emergencystop;
safeguardedstops;
limitswitches;
etc.
Digitalprocesscommunication.
Analogueprocesscommunication.
Contactorsforpowertotherectifierforthedriveunits
andpowerforthebrakes.
Voltagesupplytodriveunits.
Stabilizedvoltagesupplytoallelectronics,andI/O
andbrakes.
Poweramplificationforcontrolofmotortorque.One
axisperdriveunit.(Upto7 unitsincl.oneintegrated
axis.)
Speedreferencesignalsandconnetion
ofresolversfor1-6externalaxes.
Description 1KB2000
11

Processconnections(option)
Thesystemcanhandlethefollowinginputandoutputsignalsfromtheperipheral
equipment:
•DigitalI/O
-upto96inputsand96outputs
Requires1-6digitalI/Oboards(option)
•AnalogueI/O
-upto4 inputsand4 outputs
Requires1 analogueI/Oboard(option)
•CombiI/O
-16digitalin-and16outputs+ 2 analogueoutputs
Requires1 ADcombiI/Oboard(option)
•ComputercommunicationviaRS232interface.
Requires"Computerlink"(option).
•I/OremotebusforAllenBradly1771RIOlink,upto128in/ 128out(option)
•Controlsignalsfor1-6externalaxes.
Requiresoneextraboard(option).
Drivesystem
Thedrivesystem,fortherobotmotorsandoneintegratedaxis7 (option),consists
ofthefollowingunits.
•Computerboard
•Rectifierunit
•Driveunit
Serialmeasumentboard
Controlsystem
foroverallcontrol.
forpowersupplytothedriveunits.
receivescurrentreferencesfromthecomputer
board.Thecurrentreferencescontrolthe
poweramplifiersupplyingcurrenttothemotor.
readstheresolver
Manipulator
A» A Curren
TRotorangle-
Fig.3.5ACdrivesystem,robotaxesandintegratedaxis7.
Driveunitforoptionalexternalaxesislocatedoutsidethecontrolsystem.
Thesedriveunitsareprovidedwithspeedreferensebythecontrolsystem.
ControlcabinetSeparatedriveunit
outsidecontrolsystem
t
'osition>.Controlboard,
externalaxesSpeed
Position
Fig.3.6Drivesystemexternalaxis.
Description
1KB2000
12

Diagnostics
Thecontrolsystemisprovidedwithitsownbuilt-indiagnosticswiththefollowing
characteristics:
•Testonstart-up:
-computerboard;
-programmingunit;
-monitor(option);
-voltagesupplyunit;
-rectifierunit.
-locationcontrolofI/Oboardsanddriveunits
•Duringtestrunning,a redLEDonthecomputerboardwillswitchfroma
continuouslighttoa flashinglight.
•Successfultestrunningindicatedby:
-noredLEDsonallunits;
-a greenLEDlightsuponthecomputerboard.
•Unsuccessfultestrunningindicatedby:
-a redLEDlightsuponthefaultyboard;
-ifpossible,a faultmessageappearsontheprogrammingunitandonthe
monitor(ifinstalled).
•Runningofthecontrolsystemina specialtestmodeduringservice,withthe
followingfunctions:
-start-uptest;
-fulltestoftheI/Oboards,jumpersincluded;
-testrunningofthedriveunitsatfullvoltage;
-programforcleaningthefloppydiskunitread/writeheads.
DescriptionIBB2000
13

Description1KB2000
14