ABB BullsEye Instructions for use

ROBOTICS
Application manual
BullsEye

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Workspace R18-2 version a11
Checked in 2018-10-11
Skribenta version 5.3.008

Application manual
BullsEye
RobotWare 6.08
Document ID: 3HAC050989-001
Revision: C
© Copyright 2004-2018 ABB. All rights reserved.
Specifications subject to change without notice.

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.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.
© Copyright 2004-2018 ABB. All rights reserved.
Specifications subject to change without notice.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden

Table of contents
7Overview of this manual ...................................................................................................................
9Product documentation ....................................................................................................................
111 Safety
111.1 Safety signals in the manual ................................................................................
131.2 Make sure that the main power has been switched off ..............................................
141.3 Risks associated with live electric parts .................................................................
152 Introduction to BullsEye®
152.1 Product overview ..............................................................................................
172.2 Theory of operation ...........................................................................................
192.3 Limitations .......................................................................................................
212.4 Safety information .............................................................................................
233 Installation
274 Maintenance
295 User guide
305.1 Overview .........................................................................................................
315.2 Data storage .....................................................................................................
325.3 Using BullsEye .................................................................................................
335.3.1 The global methods of BullsEye .................................................................
345.3.2 Defining a tool ........................................................................................
375.3.3 Default BullsEye data ...............................................................................
385.3.4 Selecting different BullsEye data ................................................................
415.3.5 Creating new BullsEye data instances .........................................................
455.3.6 BullsEye data parameters .........................................................................
465.3.7 QuickCheck ...........................................................................................
475.4 BullsEye status codes ........................................................................................
515.5 Frequently asked questions ................................................................................
556 RAPID reference
556.1 Data types .......................................................................................................
556.1.1 be_device - Device data ...........................................................................
586.1.2 be_scan - Scan data ................................................................................
616.1.3 be_tooldesign - Tool design ......................................................................
656.2 Instructions ......................................................................................................
656.2.1 BECheckTcp - BullsEye check TCP ............................................................
686.2.2 BEDebugState - Debug state control ...........................................................
696.2.3 BERefPointer - BullsEye reference pointer ...................................................
726.2.4 BESetupToolJ - BullsEye setup tool joint move .............................................
776.2.5 BETcpExtend - BullsEye extend TCP ..........................................................
796.2.6 BEUpdateTcp - BullsEye update TCP ..........................................................
826.3 Functions ........................................................................................................
826.3.1 OffsToolXYZ - Offsets tool cartesian ...........................................................
836.3.2 OffsToolPolar - Offsets tool cartesian ..........................................................
857 Spare parts
87Index
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Table of contents

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Overview of this manual
About this manual
This manual explains the basics of when and how to use the option BullsEye®.
• Product overview
• Operation overview
• Requirements overview
• Software set-up
• Software reference, RAPID
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 intended for:
• installation personnel
• maintenance personnel
• repair personnel.
• robot programmers
Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
• 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.
Reference documents
Document IDReferences
3HAC031045-001Operating manual - General safety information i
3HAC050917-001Technical reference manual - RAPID Instructions, Functions
and Data types
3HAC050947-001Technical reference manual - RAPID Overview
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC050948-001Technical reference manual - System parameters
3HAC032104-001Operating manual - RobotStudio
3HAC052855-001Application manual - Production Manager
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
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Overview of this manual

Revisions
DescriptionRevision
Released with RobotWare 6.0.-
Released with RobotWare 6.04.
• BullsEye is now a separate RobotWare option.
A
Released with RobotWare 6.07.
• Added information about EIO configuration in section Installation on
page 23.
B
Released with RobotWare 6.08.
•Updated the example for argument [\UserInterface] for the RAPID
instructions BECheckTcp,BERefPointer and BEUpdateTcp.
C
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Overview of this manual
Continued

Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
All documents can be found via myABB Business Portal, www.myportal.abb.com.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
•Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Technical reference manuals
The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
Application manuals
Specific 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, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
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Product documentation

Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.
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Product documentation
Continued

1 Safety
1.1 Safety signals in the manual
Introduction to safety signals
This section specifies all safety signals used in the user manuals. Each signal
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 the danger is not eliminated.
• 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
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
Warns for electrical hazards which could result in
severe personal injury or death.
ELECTRICAL
SHOCK
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
Warns for electrostatic hazards which could result
in severe damage to the product.
ELECTROSTATIC
DISCHARGE (ESD)
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1 Safety
1.1 Safety signals in the manual

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

1.2 Make sure that the main power has been switched off
Description
Working with high voltage is potentially lethal. Persons subjected to high voltage
may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these
personal injuries, switch off the main power on the controller before proceeding
work.
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1 Safety
1.2 Make sure that the main power has been switched off

1.3 Risks associated with live electric parts
Voltage related risks, general
Work on the electrical equipment of the robot must be performed by a qualified
electrician in accordance with electrical regulations.
Although troubleshooting may, on occasion, need to be carried out while the power
supply is turned on, the robot must be turned off (by setting the main switch to
OFF) when repairing faults, disconnecting electric leads, and disconnecting or
connecting units.
The main supply to the robot must be connected in such a way that it can be turned
off from outside the working space of the robot.
Make sure that no one else can turn on the power to the controller and robot while
you are working with the system. A good method is to always lock the main switch
on the controller cabinet with a safety lock.
The necessary protection for the electrical equipment and robot during installation,
commissioning, and maintenance is guaranteed if the valid regulations are followed.
Voltage related risks, manipulator
A danger of low voltage is associated with the manipulator in:
• The power supply for the motors (up to 800 VDC).
• The user connections for tools or other parts of the installation (max. 230
VAC).
Voltage related risks, tools, material handling devices, etc.
Tools, material handling devices, etc., may be live even if the robot system is in
the OFF position. Power supply cables which are in motion during the working
process may be damaged.
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1 Safety
1.3 Risks associated with live electric parts

2 Introduction to BullsEye®
2.1 Product overview
Introduction to BullsEye
BullsEye® 10 provides completely automated Tool Center Point (TCP) definition
for the IRC5 robot controller and introduces support of new tools in addition to
MIG welding torch configurations. Concentric cutting tools may also be used where
the stick-out is defined as the distance from the cutting tip to the part surface.
TCP
TCP is defined as an invisible reference point in direct alignment and relationship
to all axes of the robot arm and located at the precise point where the welding wire
tip would touch the work piece using a pre-determined wire stick-out distance from
the bottom of the gas nozzle.
Illustration: Welding torch revolving around a defined TCP
xx1400001210
BullsEye features
• Scanning behavior that can be configured for:
- Scan lengths
- Scan speeds
- Tool dimensions
• Historical log file.
• Fully compatible with MultiMove systems.
• Accommodates RobotStudio.
• Simultaneous support for up to five unique tools per robot task.
• Integrated error handling.
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2 Introduction to BullsEye®
2.1 Product overview

• Optimized update times.
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2 Introduction to BullsEye®
2.1 Product overview
Continued

2.2 Theory of operation
Example of operation
When the robot is programmed to revolve around the TCP all robot axes will move
accordingly to keep the TCP stationary (see the following figures). If the torch is
damaged and the program is run again, the robot repeats the same movements,
but the TCP will no longer follow the same path due to the misalignment. You now
have two choices:
1 Physically move the torch back into alignment (a task that could be difficult
if not impossible) or
2 Adjust for the misalignment automatically by redefining the TCP to the new
torch position using the BullsEye. After the BullsEye system updates the
current TCP definition, the torch will rotate around the TCP as before because
the robot arm has adjusted its path to compensate for the torch misalignment.
Once a point has been programmed, the robot remembers the tool center point
location, not what the angles of the robot joints are. When the robot replays the
programmed path, it calculates what the joint angles should be to get the TCP back
to where it was when the path was programmed initially. As long as the robot
controller is kept informed about where the tool center point is, it will always keep
the paths properly adjusted.
Robot arm and torch movement with correct TCP
xx1400001211
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2 Introduction to BullsEye®
2.2 Theory of operation

Robot arm follows same path but torch path has changed
xx1400001212
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2.2 Theory of operation
Continued

2.3 Limitations
System complexity
At the time of this printing, version 10.0, build 2, is the released build. It has not
been tested in implementations that incorporate complex multi-axis robot carriers.
For this reason, version 10 will not be supported on these applications until further
notice.
Limitations for calibration
BullsEye 10 can be used to calibrate tools of a variety of shapes. While earlier
versions of BullsEye were restricted to welding MIG tool designs, BullsEye 10 is
also suited to cutting tools that do not have a consumable wire electrode like a
MIG tool.
Here is a list of limitations:
1The tool must be concentric along its centerline. Cylindrical and conical tools
meet this criterion.
2 There may not be any obstructions on the scanned portion of the tool.
Typically, the BullsEye is set up to make scans along the last several inches
of the tool body. There can be no fittings, clamps, set screws, wires, hoses,
or other features extending from the tool body in this section.
3If the tool does not have a consumable wire electrode, or a wire-like extension,
it must be assumed that the TCP will be inline with the centerline of the tool
body.
4 The tool must have adequate clearance to allow the program to complete all
moves without colliding with the BullsEye scanning device.
Typical tool designs
Here are some typical tool designs suited to BullsEye®:
Welding MIG tool
xx1400001214
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2 Introduction to BullsEye®
2.3 Limitations

Hypothetical laser cutting tool
xx1400001215
Water-jet cutting tool
xx1400001216
TCP z-axis inline with mounting surface z-axis not supported
BullsEye is incapable of defining a tool that has the TCP centered along the z-axis
of the robot 6th axis mounting surface, and the z-axis of the tool perpendicular to
the mounting surface. Said another way, you cannot have the tool pointing straight
out from the center of the mounting plate.
BE_Data.sys is a reserved module name
BullsEye uses a temporary system module called BE_Data to store and recover
setup information. For this reason, it is not permitted to have another module loaded
in the robot motion task called BE_Data, or BullsEye will be unable to save and
retrieve data.
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2 Introduction to BullsEye®
2.3 Limitations
Continued