ABB MultiMove Instructions for use

Application manual
MultiMove
Robot Controller
RobotWare 5.0

© Copyright 2004-2008 ABB. All rights reserved.
Application manual
MultiMove
RobotWare 5.0
Document ID: 3HAC021272-001
Revision: H

© Copyright 2004-2008 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
construedasany kind ofguaranteeor warrantyby ABB forlosses, 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, and contents thereof must not be imparted to a third party nor be used for
any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
© Copyright 2004-2008 ABB All rights reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden

Table of Contents
33HAC021272-001 Revision: H
© Copyright 2004-2008 ABB. All rights reserved.
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 Introduction 11
1.1 About MultiMove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Example applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.1 About the example applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3.2 Example "UnsyncArc" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.3 Example "SyncArc" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.4 Example "SyncSpot" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2 Installation 17
2.1 Hardware installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.1 About the hardware installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.2 Connections on the control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1.3 Connections on the drive module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2 Software installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2.1 Software installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 Configuration 25
3.1 Configuration overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 System parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.1 Controller topic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.2 Motion topic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2.3 I/O topic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3 Configuration examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3.1 Configuration example for "UnsyncArc". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3.2 Configuration example for "SyncArc" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.3.3 Configuration example for "SyncSpot" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.3.4 I/O configuration example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4 Calibration 39
4.1 Calibration overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2 Relative calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.3 Calibration chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.4 Examples of coordinate systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.4.1 Example "UnsyncArc" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.4.2 Example "SyncArc" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.4.3 Example "SyncSpot" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5 User interface specific for MultiMove 47
5.1 FlexPendant for MultiMove system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.2 Status bar indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.3 Opening the Program Editor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.4 Production Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.5 Mechanical unit menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.6 Select which tasks to start with START button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6 Programming 55
6.1 RAPID components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.2 Tasks and programming techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Table of Contents
43HAC021272-001 Revision: H
© Copyright 2004-2008 ABB. All rights reserved.
6.3 Coordinated work objects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.4 Independent movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.4.1 About independent movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.4.2 Example "UnsyncArc" with independent movements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.5 Semi coordinated movements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.5.1 About semi coordinated movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.5.2 Example "SyncArc" with semi coordinated movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.6 Coordinated synchronized movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.6.1 About coordinated synchronized movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.6.2 Example "SyncArc" with coordinated synchronized movement. . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.6.3 Example "SyncSpot" with coordinated synchronized movement . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.7 Program execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.7.1 Corner zones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.7.2 Synchronization behavior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.7.3 Dummy instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.7.4 Motion principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.7.5 Modify position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6.7.6 Moving a program pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.7.7 Tool orientation at circular movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
6.7.8 Applications affected by MultiMove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.8 Programming recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.8.1 Programming recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7 RAPID error recovery 91
7.1 Error recovery for MultiMove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.2 Simple error recovery example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7.3 Asynchronously raised errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.4 Example of creating asynchronously raised error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.5 Example with movements in error handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8 Running a subset of a MultiMove system 99
8.1 How to continue with one or more drive units inactive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
8.2 Running a subset in the “Unsync Arc” examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Index 105

Overview
53HAC021272-001 Revision: H
© Copyright 2004-2008 ABB. All rights reserved.
Overview
About this manual This manual contains information about the RobotWare options MultiMove Independent and
MultiMove Coordinated. The latter includes some extended functionality. Unless something
else is specified, MultiMove refers to both these options.
Usage This manual can be used either as a brief description to find out if MultiMove is the right
choice for solving a problem, or as a description of how to use it. This manual provides
information about system parameters and RAPID components related to MultiMove, and
many examples of how to use them. The details regarding syntax for RAPID components, and
similar, are not described here, but can be found in the respective reference manual.
Who should read this manual?
This manual is mainly intended for robot programmers.
Prerequisites The reader should...
•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
•be familiar with the option Multitasking (see Application manual - Engineering tools).
Organization of chapters
The manual is organized in the following chapters:
References
Chapter Contents
1. An introduction to what MultiMove is and how it can be used.
2. Installation information.
3. System parameters and how to configure a MultiMove System.
4. Coordinate systems and how to calibrate them.
5. The MultiMove user interface on the FlexPendant.
6. RAPID components and how to write program code for MultiMove.
7. Error handling for MultiMove, including asynchronously raised errors.
8. Disconnecting a drive unit and continue working
Reference Document Id
Technical reference manual - RAPID overview 3HAC16580-1
Technical reference manual - RAPID Instructions, Functions and
Data types 3HAC16581-1
Technical reference manual - RAPID kernel 3HAC16585-1
Operating manual - IRC5 with FlexPendant 3HAC16590-1
Continues on next page

Overview
3HAC021272-001 Revision: H6
© Copyright 2004-2008 ABB. All rights reserved.
Revisions
Operating manual - RobotStudio 3HAC032104-001
Product manual - IRC5 3HAC021313-001
Technical reference manual - System parameters 3HAC17076-1
Application manual - Engineering tools 3HAC020434-001
Application manual - Motion functions and events 3HAC18152-1
Application manual - Arc and Arc Sensor 3HAC16591-1
Application manual - Spot options 3HAC024762-001
Reference Document Id
Revision Description
-First edition
AThe software installation is handled different from earlier version. Maximum
number of motion tasks increased. Minor updates of the user interface on the
FlexPendant. Explanations added for modifying positions. Configuration
examples are more realistic.
BMore information about how to install a controller with several drive modules.
CAdded information about moving program pointer. Minor changes throughout the
document.
DAdded a section about running a subset of a Multimove system.
EMinor correction in description of modifying positions.
FSTATIC and SEMISTATIC tasks can now be started and stopped from the Flex-
Pendant. This leads to changes in the tasks panel in the QuickSet menu.
GAdded short piece about “Deselect task in synchronized mode”.
HMinor corrections.
Continued

Product documentation, M2004
73HAC021272-001 Revision: H
© Copyright 2004-2008 ABB. All rights reserved.
Product documentation, M2004
General The robot documentation is divided into a number of categories. This listing is based on the
type of information contained within the documents, regardless of whether the products are
standard or optional. This means that any given delivery of robot products will not contain all
documents listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Product manuals All hardware, robots and controllers, will be delivered with a Product manual that contains:
•Safety information
•Installation and commissioning (descriptions of mechanical installation, electrical
connections)
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
•Repair (descriptions of all recommended repair procedures including spare parts)
•Additional procedures, if any (calibration, decommissioning)
•Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
•Part list
•Foldouts or exploded views
•Circuit diagrams
Technical reference manuals
The following manuals describe the robot software in general and contain relevant reference
information:
•RAPID Overview: An overview of the RAPID programming language.
•RAPID Instructions, Functions and Data types: Description and syntax for all
RAPID instructions, functions and data types.
•System parameters: Description of system parameters and configuration workflows.
Application manualsSpecific 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, CD with PC software)
•How to use the application
•Examples of how to use the application
Continues on next page

Product documentation, M2004
3HAC021272-001 Revision: H8
© Copyright 2004-2008 ABB. All rights reserved.
Operating manuals This group of manuals is aimed at those having first hand operational contact with the robot,
that is production cell operators, programmers and trouble shooters. The group of manuals
includes:
•Emergency safety information
•General safety information
•Getting started, IRC5
•IRC5 with FlexPendant
•RobotStudio
•Introduction to RAPID
•Trouble shooting, for the controller and robot
Continued

Safety
93HAC021272-001 Revision: H
© Copyright 2004-2008 ABB. All rights reserved.
Safety
Safety of personnel A robot is heavy and extremely powerful regardless of its speed. A pause or long stop in
movement can be followed by a fast hazardous movement. Even if a pattern of movement is
predicted, a change in operation can be triggered by an external signal resulting in an
unexpected movement.
Therefore, it is important that all safety regulations are followed when entering safeguarded
space.
Safety regulations Before beginning work with the robot, make sure you are familiar with the safety regulations
described in Operating Manual - IRC5 With Flexpendant.

Safety
3HAC021272-001 Revision: H10
© Copyright 2004-2008 ABB. All rights reserved.

1 Introduction
1.1. About MultiMove
113HAC021272-001 Revision: H
© Copyright 2004-2008 ABB. All rights reserved.
1 Introduction
1.1. About MultiMove
Purpose The purpose of MultiMove is to let one controller handle several robots. This does not only
save on hardware costs, it also allows advanced coordination between different robots and
other mechanical units.
Here are some examples of applications:
•Several robots can work on the same moving work object.
•One robot can move a work object while other robots work on it.
•Several robots can cooperate to lift heavy objects.
Included functionality
MultiMove allows up to 6 tasks to be motion tasks (task that has move instructions). Since no
more than 4 drive modules can be used, a controller can handle up to 4 robots. However,
additional axes can be handled by separate tasks up to a total of 6 motion tasks.
Both MultiMove options allow you to implement:
•Independent movements (see Independent movements on page 60)
•Semi coordinated movements (see Semi coordinated movements on page 63)
In addition to what is mentioned above, the option MultiMove Coordinated allows you to
implement:
•Coordinated synchronized movements (see Coordinated synchronized movements on
page 69)
Included options If you have MultiMove, you automatically have access to some options that are necessary in
order to use MultiMove.
MultiMove always includes the option:
•Multitasking
In addition to what is mentioned above, MultiMove Coordinated includes the option:
•Multiple Axis Positioner
Basic approach This is the general approach for setting up a MultiMove system.
1. Install hardware and software (see Installation on page 17).
2. Configure system parameters (see Configuration on page 25).
3. Calibrate coordinate systems (see Calibration on page 39).
4. Write RAPID program for each task (see Programming on page 55).

1 Introduction
1.2. Terminology
3HAC021272-001 Revision: H12
© Copyright 2004-2008 ABB. All rights reserved.
1.2. Terminology
About these terms Some words have a specific meaning when used in this manual. It is important to understand
exactly what is meant by these words. This manual's definition of these words are listed
below.
Term list
Term Explanation
Coordination A robot that is coordinated to a work object will follow the
movements of that work object.
Synchronization Movements that are simultaneous. Synchronization refers to
a similarity in time, not in room coordinates.
Positioner A mechanical unit without TCP, which can only handle joint
movements. A positioner is a mechanical unit, with one or
several axes, that holds and moves a work object.
Robot A mechanical unit with TCP, which can be programmed in
Cartesian coordinates (x, y and z).
Task program The same as a program. It is just a way of specifying that it is
a program for one specific task.

1 Introduction
1.3.1. About the example applications
133HAC021272-001 Revision: H
© Copyright 2004-2008 ABB. All rights reserved.
1.3 Example applications
1.3.1. About the example applications
Three consistent examples
In this manual there are many examples (for configuration, RAPID code etc.). Every example
is created for one of three physical robot systems. These example robot system setups are
called "UnsyncArc", "SyncArc" and "SyncSpot" and will help you understand what kind of
robot system an example is made for. The examples are also consistent, i.e. the RAPID code
example for "SyncSpot" is made for a robot system configured as the configuration example
for "SyncSpot".

1 Introduction
1.3.2. Example "UnsyncArc"
3HAC021272-001 Revision: H14
© Copyright 2004-2008 ABB. All rights reserved.
1.3.2. Example "UnsyncArc"
About example "UnsyncArc"
In this example, two robots work independently on one work piece for each robot. They do
not cooperate in any way and do not have to wait for each other.
Illustration
xx0300000590

1 Introduction
1.3.3. Example "SyncArc"
153HAC021272-001 Revision: H
© Copyright 2004-2008 ABB. All rights reserved.
1.3.3. Example "SyncArc"
About example "SyncArc"
In this example, two robots perform arc welding on the same work piece. The work object is
rotated by a positioner.
Illustration
xx0300000594

1 Introduction
1.3.4. Example "SyncSpot"
3HAC021272-001 Revision: H16
© Copyright 2004-2008 ABB. All rights reserved.
1.3.4. Example "SyncSpot"
About example "SyncSpot"
In this example, one robot handles the work piece that the other robot is working on.
Illustration
xx0300000592

2 Installation
2.1.1. About the hardware installation
173HAC021272-001 Revision: H
© Copyright 2004-2008 ABB. All rights reserved.
2 Installation
2.1 Hardware installation
2.1.1. About the hardware installation
Overview A controller that handles several robots needs extra drive modules (one drive module per
robot). Up to four drive modules can be used, including the one assembled with the control
module.
xx0400001042
One Ethernet cable and one safety signal cable for each additional drive module must be
connected to the control module. A MultiMove control module is equipped with an extra
Ethernet card to communicate with the additional drive modules.
This manual only describes what is specific for a MultiMove installation. For more
information about installation and commissioning of the controller, see Product manual -
IRC5.

2 Installation
2.1.2. Connections on the control module
3HAC021272-001 Revision: H18
© Copyright 2004-2008 ABB. All rights reserved.
2.1.2. Connections on the control module
Connect drive modules to the control module
xx0400001294
At delivery, both the Ethernet cable and the safety signal cable are connected to the drive
module. They are also attached to a shield plate that fits in the slot of the control module.
Remove the cover from an empty slot and fit the shield plate of the communication cables in
its place. Connect the Ethernet cable according to Ethernet connections on page 19and safety
signal cable according to Safety signal connections on page 20.
AFront view of single cabinet controller
BBack view of single cabinet controller
CRobot communication card
DEthernet card (only present if more than one drive module is used)
EPanel board
FSlots for inserting communication cables into the control cabinet
Continues on next page