ABB BullsEye 7 User manual

User’s Guide
BullsEye®7
505 942-102
2004-02

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© ABB Automation Technology Products AB
Article number: 505 942-102
Date: 2004-02
ABB Automation Technology Products AB
Arc Welding & Application Equipment
S-695 82 Laxå
Sweden

BullsEye®7
TABLE OF CONTENTS
Page
505 942-102 3
1 Introduction ................................................................................................................. 5
1.1 How to use this Manual ..................................................................................... 5
1.2 What you must know before you use the Robot................................................ 5
2 Technical Specification................................................................................................ 7
2.1 Unit Specifications............................................................................................. 7
2.2 Physical Dimensions.......................................................................................... 7
3 Product Description .................................................................................................... 9
3.1 Tool Center Point (TCP) .................................................................................... 9
3.2 Theory of Operation........................................................................................... 10
3.3 BullsEye® Advantages..................................................................................... 11
4 BullsEye® Installation ................................................................................................ 13
4.1 Mechanical Installation...................................................................................... 13
4.2 Electrical Installation ......................................................................................... 14
4.3 Software Installation .......................................................................................... 16
5 Operation ..................................................................................................................... 25
5.1 Basic Operation.................................................................................................. 25
6 Advanced Setup Information ..................................................................................... 29
6.1 Global routines in the BullsEye.sys module:..................................................... 29
7 User’s Guide................................................................................................................. 33
7.1 Program execution ............................................................................................. 33
7.2 Fault management.............................................................................................. 33
8 Maintenance................................................................................................................. 39
9 Reservdelsförteckning/Spare parts list...................................................................... 41

BullsEye®7
4505 942-102

BullsEye® 7
Introduction
505 942-102 5
1 Introduction
1.1 How to use this Manual
This manual provides information on installation, preventive maintenance, trouble
shooting and operation of the BullsEye®product.
1.2 What you must know before you use the Robot
The power supply must always be switched off whenever work is carried out in the
controller cabinet.
NOTE! Even though the power is switched off at the robot controller, there may be
live cables which are connected to external equipment and are consequently not
affected by the mains switch on the controller.
Circuit boards - printed boards and components - should never be handled without
Electro-Static-Discharge (ESD) protection. Use the wrist strap located on the
inside of the controller door whenever handling any of these components.

BullsEye® 7
Introduction
6505 942-102

BullsEye® 7
Technical Specification
505 942-102 7
2 Technical Specification
2.1 Unit Specifications
Electrical 40 mA, 24 VDC
Robot Connections One sensor signal, 24 VDC, and 0 VDC
Software Furnished with equipment (requires 250 kb free user
memory)
Repeatability ± 0.006" (0.163 mm)
2.2 Physical Dimensions
For variant 501 527-880:
Figure 1 BullsEye®
bullseye_tysk.tif
248
Ø6 H8
M6
63
18 119,5 ±0,02

BullsEye® 7
Technical Specification
8505 942-102
For variant: 550880-001:
Figure 2
550880A01
26 89 77
676
38
57
150
160
12
20
215
255
Ø15(4x)
255
215
114,50
20

BullsEye® 7
Product Description
505 942-102 9
3 Product Description
3.1 Tool Center Point (TCP)
BullsEye® 7 provides completely automated Tool Center Point (TCP) definition
for the S4C and S4Cplus models of IRB robots.
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 workpiece using a pre-determined wire stickout distance from
the bottom of the gas nozzle.
Figure 3 Welding Torch Revolving Around A Set TCP
TCP Reference

BullsEye® 7
Product Description
10 505 942-102
3.2 Theory of Operation
When the robot is instructed to revolve around the TCP all robot axes will move
accordingly to keep the TCP constant (See Figure 4 and Figure 5). If the torch is
bumped and the program is run again, the robot repeats its same movements but it
is possible that the TCP will no longer follow the same programmed path due to
misalignment. You now have two choices:
1Physically move the torch back into alignment (a task that could be difficult
if not impossible)
2Adjust 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.
Figure 4 Robot Arm and Torch Movement With Correct TCP
Figure 5 Robot Arm Follows Same Path But Torch Path Has Changed

BullsEye® 7
Product Description
505 942-102 11
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.
3.3 BullsEye®Advantages
New for version 7.0 BullsEye®:
1Operation remains similar to predecessor, version 6.3 BullsEye®.
2Teach pendant text now resides in a separate system module. This change
allows provision for the text to be translated into other languages by other
ABB divisions.
3Version 7.0 is now compatible with Motion Supervision available in
BaseWare 3.2 rev.20 and higher.

BullsEye® 7
Product Description
12 505 942-102

BullsEye® 7
BullsEye® Installation
505 942-102 13
4 BullsEye®Installation
4.1 Mechanical Installation
The BullsEye®should be either bolted to the floor (freestanding) or in a position
where the robot can reach it and where it is not in the way of personnel working
around the robot.
Figure 6 Base Coordinates
When the software is installed and executed (see Section 4.3), the robot will swivel
around the weld wire plus and minus 30 or 45 degrees (See Figure 7). Forty-five
(45) degrees will achieve the best accuracy. The position chosen for mounting the
BullsEye®must not only allow the robot to reach it, but this position must also
allow the robot to easily maneuver around its TCP within the BullsEye®work
envelope without causing the robot to exceed its joint limits.
Figure 7 Alignment Angle Of 45° Works Best

BullsEye® 7
BullsEye® Installation
14 505 942-102
The best procedure for installation is to place the Freestanding BullsEye®in a
desired position without securing it permanently. Perform the software installation
and execute the BullsEye®setup procedures as described in section 4.3. If the
robot is able to complete the full TCP update process and successfully completes a
Quick Check routine while meeting all other location requirements, then bolt it
solidly in position.
Side Mount BullsEye’s must also be mounted in a manner to allow unrestricted
robot access.
4.2 Electrical Installation
The BullsEye® is pre-wired at the factory for easy assembly. Connect the cable
provided from the receptacle on the BullsEye® unit to the controller cabinet.
Use the following diagram for installation.
Figure 8 shows the termination points for the wires in the robot controller cabinet
at the I/O Module and 24VDC terminal blocks.
Figure 8 Wiring Diagram for Male Receptacle on BullsEye, 550 880-001.
Connecting BullsEye, 550 880-001.
1The white cable (2014045) wire goes to 24 VDC
2The black cable (2014045) wire (signal to sensor 1) goes to I/O
3The green cable (2014045) wire goes to 0 VDC
Connecting BullsEye, 501 527-880, with three cables.
1The blue cable wire is connected to 24V DC, terminal 4 on the terminal
block in TC 96 and 1 in Binzel BRS-LC.
2The brown wire is connected to 0V, terminal 8 on the terminal block in TC
96 and 3 in Binzel BRS-LC.
3The black wire to the sensor input, connection 16 on the terminal block in
TC 96 and 10 in Binzel BRS-LC.
12
3

BullsEye® 7
BullsEye® Installation
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Connecting BullsEye, 501 527-880, new sensor with four cables (2004-02).
1The brown cable wire is connected to 24V DC, terminal 4 on the terminal
block in TC 96 and 1 in Binzel BRS-LC.
2The blue wire is connected to 0V, terminal 8 on the terminal block in TC 96
and 3 in Binzel BRS-LC.
3The white wire to the sensor input, connection 16 on the terminal block in
TC 96 and 10 in Binzel BRS-LC.
When the BullsEye® is correctly wired, the sensor light and input on the I/O in the
robot control cabinet should be illuminated only when the light beam of the
BullsEye® is broken.

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BullsEye® Installation
16 505 942-102
4.3 Software Installation
With the Program Window of the Teach Pendant displayed, select FILE, then
OPEN, and choose the "BullsEye" System Module from the floppy disk or other
drive location where the module has been stored. This will load th program from
the floppy into the robot controller where it will reside in memory. Acknowledge
any reference errors displayed on the Teach Pendant and follow the same
procedurees to load the "TCPData" Program Module from the floppy disk.
(EasyArc users will load TCP_Data Program Module.) Finally load the BE_text
System Module in the same way. Alteratively, BE_text may be installed as a Build-
in module. Note that the system must have at least 250 kb free memory to run this
software.
Required modules:
BullsEye.sys, BE_text.sys, and one of the following: TCPdata.mod or
TCP_Data.mod.
Module Details:
BullsEye.sys Loaded Task 0 noview/encrypted
BE_text.sys Loaded of Built-in Task 0 noview/encrypted
TCPdata.mod Loaded Task 0 open (non-EasyArc)
TCP_Data.mod Loaded Task 0 open (EasyArc)
Software Setup:
Prepare the robot, the torch and BullsEye®for use. With the Program Window
visible on the Teach Pendant, select the VIEW Menu Key, select MODULE,
highlight "BULLSEYE" and press ENTER. Now highlight the routine
“SetupBullsEye” and press ENTER. Press the TEST Function Key. With the
robot ready to operate and the enabling devise activated, you may begin the
program by pressing the START Function Key.
The BullsEye® setup routines can also be called from the EasyArc program. Refer
to the appropriate EasyArc instructions for starting and running this program.
Upon starting the setup program, the first screen displayed will tell you the module
version number and that the program running is “...for setting up the BullsEye".
Press PROCEED.
The next screen is regarding Copyright and Patent information concerning the
BullsEye®software. Press PROCEED.
Now the Teach Pendant will display the Present Selections Screen. To change any
of the parameters shown, select the corresponding Function Key. To keep the
parameters shown press OK.

BullsEye® 7
BullsEye® Installation
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Present setup number
This value represents which tool is selected, and therefore which TCP is going to
be updated. Changing this value must be performed off-line on a text editor.
1 Degree of rotation
Making this selection elicits the following menu:
The robot will calculate the TCP by finding the welding wire at different
rotation locations of the welding gun. A larger rotation will result in slightly
better accuracy in the measurement (See Figure 7).
2 Robot mounting position
Making this selection elicits the following menu:
This parameter defines how the robot and BullsEye® are mounted in
relation to each other, either STANDING or INVERTED. If the base of
both the robot and the BullsEye® are mounted on the same plane, select
STANDING. If for example the robot is hanging upside down from a tower
and the BullsEye® is mounted conventionally on the floor, or visa versa,
select INVERTED.
Program Waiting for Data!
Present setup number =1
1. Degree of rotation =30/45
2. Robot mounting pos. =STAND/INVERTED
3. Gun alignment =NEVER/SETUP/ALWAYS
4. Stick-out distance (mm) =Min. 5 mm, Max. 30 mm
Select which parameter to change to
keep present values; Press OK
1 2 3 4 OK
Program Waiting for Data!
This parameter defines how much the
welding torch will rotat between
each measurement
(Try to use 45 degree if possible)
Select degree of rotation
30 45
Program Waiting for Data!
This parameter defines how the robot
is mounted, STANDING or INVERTED
Select robot mounting pos.
STAND INV

BullsEye® 7
BullsEye® Installation
18 505 942-102
3 Gun alignment
This parameter is for selecting when to align the welding gun to World Z
(torch angle realignment) - Always is recommended.
NEVER - If torch is difficult to align.
SETUP - Aligns during setup only.
ALWAYS - Recommended method.
4 Stick-out distance
Allows you to indicate stick-out distance from bottom of the gas cup to the
TCP in millimeters. Use the keypad to input the desired length.
Figure 9 Defining The TCP
Program Waiting for Data!
This parameter defines if and when
the welding torch should be aligned
with World Z (torch angle re-alignment)
(ALWAYS is recommended if possible)
Select robot mounting pos.
NEVER SETUP ALWAYS
Program Waiting for Data!
Stick-out is the distance between the
bottom of the gas cup and the TCP.
Min.5 mm, Max.30 mm
Select stick-out distance (mm)
X
Z
Y
Robot Arm
TCP
Face Plate

BullsEye® 7
BullsEye® Installation
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Once all the set up questions have been answered, the next screen you will see is:
To continue with the set up, the robot needs to be moved to a point were the
welding gun is positioned straight up and down with the gas cup breaking the
beam. The beam needs to be placed a location were the robot is able to rotate the
welding gun around its gas cup axis +/- 45 or 30 and make a 30 tilt motion
without running out of reach (See Figure 7 and Figure 10). Also, the beam needs to
be parallel to the plane of the robot base.
STOP
STOP allows the operator to manually jog the robot to a point where the
torch is positioned straight up and down with the gas cup breaking the beam
of the BullsEye®. Once the robot is in a correct position. the operator then
presses START on the Teach Pendant to resume the program.
LAST
LAST causes the robot to move to the last point defined as the Startup
position. This position is stored in the TCPData module and is inaccessible
to edit except through the Setup routine. It is not recommended that the
operator chose LAST, if it is the first time for the BullsEye®to be set up on
that particular system.
Caution:
The robot is not able to verify that the last setup location can be reached before
trying to go there
.
Figure 10 30° tilting motion.
Program Waiting for Data!
Robot needs to be at a point where the
gun is positioned straight up and down
with the gas cup breaking the beam.
STOP, Jog robot manually, start again
LAST, Moves to last Setup position
Make a selection please
STOP LAST

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BullsEye® Installation
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If LAST was selected, the operator will be asked if the location that the robot
moved to is indeed in correct orientation for the BullsEye®to begin updating the
TCP:
YES will stop the program and allows the operator to manually jog the robot to a
correct position. Once the robot is in a correct position, the operator then presses
START on the Teach Pendant to resume the program.
Pressing NO allows the program to continue with the tool center point set up.
The above screen would also appear had STOP been chosen instead of selecting
LAST at the previous screen. In either case if the torch is not breaking the beam
when the program is allowed to resume with the set up, the following message and
request for action appears:
The robot is now ready to begin calculating the TCP for the welding gun. The first
step is to determine the beam orientation and generate an approximate TCP.
The approximate TCP measurement is excluded if the SKIPTCP button is pressed.
If the system has a MIG weld gun, use the wire feeder manual button to increase
the wire stick-out, cut to length as required and then press PROCEED. Note that on
some plasma cutting torches a special extension needs to be added to the torch to
simulate a wire. Now the BullsEye®begins automatic estimation of the TCP.
Program Waiting for Data!
Robot needs to be at a point where the
gun is positioned straight up and down
with the gas cup breaking the beam.
YES, Program will stop, you can then
jog robot manually, start again
NO, Program will continue
Is adjustment needed ?
YES NO
Program Waiting for Data!
The system has detected that the beam
is not broken.
Program will move to previous screen.
PROCEED
Program Waiting for Data!
The Robot is now ready to search
for the beam orientation and
approximate TCP values.
Select SKIPTCP If you already have
good TCP values.
If your using a MIG weld gun, make
sure that 15 mm wire is fed out.
SKIPTCP PROCEED