ABB Levelmeter 2000 User manual


Instructions for Levelmeter calibration (alternative method)
Calibration equipment
Levelmeter 2000
IRB 140 / IRB 1400 / IRB 2400 / IRB 4400
IRB 6600 / IRB 6650 / IRB 6650S / IRB 7600 / IRB 6400R

Instructions for Levelmeter calibration
(alternative method)
Levelmeter 2000
IRB 140
IRB 1400
IRB 2400
IRB 4400
IRB 6600
IRB 6650
IRB 6650S
IRB 7600
IRB 6400R
Document ID: 3HAC 022907-001
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.
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will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then
current charge.
© Copyright 2004 ABB All right reserved.
ABB Automation Technologies AB
Robotics
SE-721 68 Västerås
Sweden

Table of Contents
33HAC 022907-001 Revision: -
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 Overview 7
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 How and when to calibrate the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Calibration, prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Calibration movement directions for all axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Reference information 13
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Calibration equipment, axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Calibration equipment, axes 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5 Initialization of Levelmeter 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.6 Checking the calibration position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.7 Positions and directions of sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3 Calibration 37
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2 Calibration, axis 1, IRB 140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.3 Calibration, axis 1, IRB 1400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.4 Calibration axis 1, IRB 2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.5 Calibration, axis 1, IRB 4400. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.6 Calibration, axis 1, IRB 6600 / IRB 6650 / IRB 6650S / IRB 7600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.7 Calibration, axis 1, IRB 7600 (early design) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.8 Calibration, axis 1, IRB 6400R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.9 Calibration, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.10 Calibration, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.11 Calibration, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.12 Calibration, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.13 Calibration, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.14 Fine calibration procedure on TPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.15 Fine calibration procedure on FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.16 Resetting of Levelmeter 2000 and sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.17 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4 After calibration 77
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.2 Post calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Table of Contents
3HAC 022907-001 Revision: -4

Overview
53HAC 022907-001 Revision: -
Overview
About this manual This manual contains instructions for calibrating a robot, using the alternative method with
Levelmeter calibration equipment.
Usage This manual should be used during calibration with the Levelmeter (alternative method).
Who should read this manual?
This manual is intended for:
• installation personnel on the installation site
• repairing personnel during repair or maintenace.
Prerequisites The reader should have...
• the required knowledge of how the robot works
• a basic understanding of what calibration does and how it is performed.
Organization of chapters
The manual is organized in the following chapters:
Revisions
Chapter Contents
Overview General information about when to calibrate the robot and a
brief description of how the alternative method works. Also
general facts that may be useful during calibration of the robot.
Reference information Lists of required calibration tools. Information about how to
prepare for calibration and how to check the calibration
position prior to and after calibration.
Calibration Instructions for calibrating the robot, axis by axis. Procedures
to be performed on the TPU / FlexPendant.
After calibration Information about how to check that the calibration is done
correctly.
Revision Description
-First edition.

Overview
3HAC 022907-001 Revision: -6

1 Overview
1.1. Introduction
73HAC 022907-001 Revision: -
1 Overview
1.1. Introduction
General This chapter contains a brief description of how to calibrate a robot, using the alternative
method with the Levelmeter 2000.
This chapter also includes facts useful before comissioning the actual calibration procedure.

1 Overview
1.2. How and when to calibrate the robot system
3HAC 022907-001 Revision: -8
1.2. How and when to calibrate the robot system
General This section provides an overview of the procedures to perform when calibrating the robot
system with the alternative method, using Levelmeter 2000. The steps in this overview are
detailed in other sections to which references are given.
When to calibrate The system must be calibrated if any of the below occurs:
Changed resolver values
Calibrate the measurement system carefully as detailed in section Calibration on page 37 if
any of the resolver values have changed. This may occur when parts affecting the calibration
position are replaced on the robot.
Contents of the revolution counter memory are lost
Calibrate the system roughly as detailed in section Updating revolution counters on page 72
if the contents of the revolution counter memory are lost. This may occur when:
• the battery is discharged
• a resolver error occurs
• the signal between a resolver and measurement board is interrupted
• a robot axis is moved with the control system disconnected.
Overview - Levelmeter Calibration
The calibration procedure with Levelmeter 2000 may be performed with either one or two
sensors. The procedure detailed here is performed with only one sensor and may be described
as checking a pre-adjusted sensor, trying to obtain the same measurement value on every axis
as when adjusted at the reference plane.
Overview - calibration procedure
The procedure below is a brief overview of the complete calibration procedure.
Step Action Note
1. Check that all required hardware is available
for calibrating the robot. Requiredhardware is specified in the calibration procedures for each axis
and also gathered in section
Calibration equipment, axis 1 on
page 14 and Calibration equipment,
axes 2-6 on page 15.
2. Manually run the robot axes to a position
close to the correct calibration position. Use the calibration scales fitted to each robot axis to locate this
position. These are shown in the
section Calibration scales and
correct axis position on page 16.
3. Initialize the Levelmeter. Detailed in section Initialization of
Levelmeter 2000 on page 21.

1 Overview
1.2. How and when to calibrate the robot system
93HAC 022907-001 Revision: -
Additional information
In addition to the basic calibration procedure detailed above, a number of calibration related
actions may be performed:
4. Start the calibration procedure on the TPU /
FlexPendant. Detailed in section Fine calibration procedure on TPU on page 65
(RobotWare 4.0).
Detailed in section Fine calibration
procedure on FlexPendant on page
67 (RobotWare 5.0).
5. Calibrate each axis. Detailed in each axis’ calibration
instruction.
6. Verify that the calibration was successfully
carried out. Detailed in section Post calibration procedure on page 78.
Step Action Note
Action Detailed in section:
How to update the robot revolution counter
without performing a complete calibration. Updating revolution counters on page 72.
Howto manually checkthecurrentcalibration
position. Checking the calibration position on page 23

1 Overview
1.3. Calibration, prerequisites
3HAC 022907-001 Revision: -10
1.3. Calibration, prerequisites
Peripheral equipment
The robots upper arm must be free from any peripheral equipment during calibration. Fitted
tools and similar will cause erroneous calibration positions.
Calibration order The axes must be adjusted in increasing sequence, i.e. 1 - 2 - 3 - 4 - 5 - 6.

1 Overview
1.4. Calibration movement directions for all axes
113HAC 022907-001 Revision: -
1.4. Calibration movement directions for all axes
Calibration movement directions
When calibrating, the axis must consistently be run towards the calibration position in the
same direction, in order to avoid position errors caused by backlash in gears etc. Positive
directions are shown in the figure below.
This is normally handled by the robot calibration software.
Note! The figure shows an IRB 7600, but the positive direction is the same for all robots,
except the positive direction of axis 3 for IRB 6400R which is in the opposite direction!
xx0200000089

1 Overview
1.4. Calibration movement directions for all axes
3HAC 022907-001 Revision: -12

2 Reference information
2.1. Introduction
133HAC 022907-001 Revision: -
2 Reference information
2.1. Introduction
General This chapter contains necessary reference information for performing the actual calibration
of the robot.

2 Reference information
2.2. Calibration equipment, axis 1
3HAC 022907-001 Revision: -14
2.2. Calibration equipment, axis 1
General Axis 1 is calibrated mechanically without use of the Levelmeter. The special calibration
equipment is listed in this section and also in the procedure for axis 1 calibration of each
robot. Notice that the procedures may list additional equipment, such as cleaning-agents etc.
IRB 140
IRB 1400
IRB 2400
IRB 4400
IRB 6600, 6650, 6650S, 7600
IRB 6400R
Equipment Art. no.
Calibration tool 3HAC 0181-1
Equipment Art. no.
Calibration tool 3HAB 1378-1
Measuring pin 6808 0011-GR
Equipment Art. no.
Calibration tool 3HAB 8064-1
Equipment Art. no.
Calibration tool 3HAB 1526-1
Measuring pin 6808 0011-GR
Equipment Art. no.
Calibration tool 3HAC 13908-4
Measuring pin 3HAC 13908-5
Calibration bracket 3HAC 13908-9
Equipment Art. no.
Calibration tool 3HAB 7477-1
Calibration fixture 3HAC 8851-1
Measuring pin 6896 0011-YN

2 Reference information
2.3. Calibration equipment, axes 2-6
153HAC 022907-001 Revision: -
2.3. Calibration equipment, axes 2-6
General Axes 2-6 are calibrated with the alternative method, using Levelmeter 2000, including one
sensor. The calibration equipment is gathered in the table below as well as in the procedures
for calibration of each axis.
Notice the differences between different robot models!
Calibration equipment
Marking equipment
Equipment Art. no. Valid for
robots: Usage
Levelmeter 2000 6369 901-347 (incl. one sensor)
6369 901-348 (incl. two sensors) All
Sensor plate 3HAC 0392-1 All With sensor
Sensor fixture 6808 0011-GM All At reference plane
Angle bracket 6808 0011-LP All Axis 2
Turning disk fixture 6808 0011-GU All Axes 3, 4, 5 and 6
Guide pins included
Sync adapter 3HAB 7981-1 IRB 2400/10
IRB 2400/16 Axes 3, 4, 5 and 6
Sync adapter 3HAB 1525-1 IRB 4400 Axes 3, 4, 5 and 6
Sync adapter 3HAC13908-1 IRB 6600
IRB 6650
IRB 6650S
IRB 7600
Axes 3, 4, 5 and 6
Sync adapter 6896 134-GZ IRB 6400R Axes 3, 4, 5 and 6
Equipment Art. no. Valid for robots:
Marking equipment, axis 4 3HAC 8481-1 IRB 140
Marking equipment, axes 1-4 3HAB 8223-1 IRB 2400
Marking equipment, axis 6 3HAB 8184-1 IRB 2400
Marking equipment, axis 2 3HAB 1521-1 IRB 4400
Marking equipment, axis 3 3HAB 1522-1 IRB 4400
Marking equipment, axis 4 3HAB 1523-1 IRB 4400
Marking equipment, axis 5 3HAB 1524-1 IRB 4400

2 Reference information
2.4. Calibration scales and correct axis position
3HAC 022907-001 Revision: -16
2.4. Calibration scales and correct axis position
Introduction This section specifies the calibration scale positions and/or correct axis position for all robot
models.
Calibration scales, IRB 140
The illustration below shows the calibration scale positions on IRB 140:
xx0200000157

2 Reference information
2.4. Calibration scales and correct axis position
173HAC 022907-001 Revision: -
Calibration scales, IRB 1400
The illustration below shows the calibration scale positions on IRB 1400:
en0200000272

2 Reference information
2.4. Calibration scales and correct axis position
3HAC 022907-001 Revision: -18
Calibration scales, IRB 2400
The illustration below shows the calibration scale positions on IRB 2400:
en0200000273