ABB S4Cplus User manual

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S4Cplus/IRC5

© Copyright 2003-2007 ABB. All rights reserved.
Calibration Pendulum Instruction
Document ID: 3HAC 16578-1
Revision: E

© Copyright 2003-2007 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 of guarantee orwarranty by ABBfor losses,damagestopersons
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 2003-2007 ABB All rights reserved.
ABB Robotics
SE-721 68 Västerås
Sweden

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33HAC 16578-1 Revision: E
© Copyright 2003-2007 ABB. All rights reserved.
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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1.1 To what robots does this apply? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 When to calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Types of calibration procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Equipment for calibration pendulum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.6 Storage and warm up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Start up of Levelmeter 2000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3 Calibration of sensors (calibration pendulum) and Levelmeter 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.4 Checking of sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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3.1 Different functions in the calibration service routine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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3.2.1 About Calibration Pendulum II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2.2 Preparing the calibration procedure, CalPend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.2.3 Calibration, all axes, CalPend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.2.4 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.2.5 Calibration sensor mounting positions, CalPend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
3.2.6 Preparation for using sensor on axes 1 and 6, CalPend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.2.7 Calibration Pendulum II procedure on TPU, S4Cplus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.2.8 Calibration Pendulum II procedure on FlexPendant, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.2.9 Post calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.2.10 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
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3.3.1 About Reference Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.3.2 Preparation of reference surface at tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.3.3 Defining reference values for calibration of axes 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.3.4 Preparing the calibration procedure, RefCal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.3.5 Calibration of axes 2-6 using predefined reference values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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43HAC 16578-1 Revision: E
© Copyright 2003-2007 ABB. All rights reserved.

Overview
53HAC 16578-1 Revision: E
© Copyright 2003-2007 ABB. All rights reserved.
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This manual contains procedures for calibrating a robot, using the tool calibration pendulum.
Both the Calibration Pendulum II and Reference Calibration routine are described.
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This manual should be used during calibration with the calibration pendulum.
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This manual is intended for:
•installation personnel on the installation site.
•repairing personnel during repair or maintenace.
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The reader should have...
•the required knowledge of how the robot works
•a basic understanding of what calibration does and how it is performed.
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The manual is organized in the following chapters:
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1. General information about the calibration method, including information about
the required tools.
2. Information about how to prepare the equipment prior to calibration.
3. Procedures that detail how to perform the calibration. The chapter is divided in
two sections, one for each routine (Calibration Pendulum II and Reference Cal-
ibration). The sections specify to which robot system the routine is applicable.
5HYLVLRQ 'HVFULSWLRQ
0 First edition.
A Information on IRB 7600/2.3/500 added.
Paths to calibration software revised.
Minor editorial changes.
BMinor editorial changes.
Methods to calibrate the pendel tool added.
Changes in Information about IRB 7600/2.3/500.
CPendellum Calib II intrud.
Methods to calibrate the pendel tool added for IRC5.
Changes in Information about IRB 7600/2.3/500.
DReference Calibration introduced.
Manual restructured.
RobotmodelsIRB1600, IRB260,IRB660,IRB4450SandIRB6600ID/6650ID
added to the calibration procedure.
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Overview
3HAC 16578-1 Revision: E6
© Copyright 2003-2007 ABB. All rights reserved.
ERobot model IRB 1600ID added to the calibration procedure.
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1.1. To what robots does this apply?
73HAC 16578-1 Revision: E
© Copyright 2003-2007 ABB. All rights reserved.
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Robots, in general, may be calibrated using a number of methods. This manual describes
robot calibration using the Calibration Pendulum method, which is applicable to the
following ABB robots:
5RERWPRGHO 6HULDOQXPEHU
IRB 140 14M-21493
IRB 1400 14-26001
IRB 1600 All robots.
IRB 2400 M2000 24-23050 and on.
Robotswithserialnumbers 24-23051,24-23052, 24-23054,24-23055,
24-23056 and 24-23061 were not calibrated using the calibrations
pendulum method before delivery from ABB, but these robots are fully
compatible with this method.
IRB 260 All robots.
IRB 4400 M2000 44-21782 and on.
IRB 4450S All robots.
IRB 660 All robots.
IRB 6600/6650 All robots.
IRB 6600ID/6650ID All robots.
IRB 7600 76-20187 and on.
127( Robots 76-20190 and 76-20191 are H[FOXGHG!
IRC5 M2004 All robots using IRC5 controller.

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1.2. When to calibrate
3HAC 16578-1 Revision: E8
© Copyright 2003-2007 ABB. All rights reserved.
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The system must be calibrated if one or more of the listed failures below occurs.
Changed resolver values
Calibrate the measurement system carefully as detailed in chapter &DOLEUDWLRQRQSDJH if
any of the resolver values has been changed. This may occur when parts affecting the
calibration position have been replaced on the robot.
Contents of the revolution counter memory are lost
Calibrate the system roughly as detailed in section 8SGDWLQJUHYROXWLRQFRXQWHUVRQSDJH
if the contents of the revolution counter memory are lost. This may occur when:
•the battery has been discharged
•a resolver error occurs
•the signal between a resolver and measurement board interrupted
•a robot axis has been moved while the control system was disconnected.

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1.3. Types of calibration procedures
93HAC 16578-1 Revision: E
© Copyright 2003-2007 ABB. All rights reserved.
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The routine Calibration Pendulum II (CalPend) is used to move the robot to zero position for
fine calibration of motor calibration offset. The calibration is fully automatic and will move
the robot to the position read from the sensors.
Read more about the routine in section $ERXW&DOLEUDWLRQ3HQGXOXP,,RQSDJH.
If the second generation of tool set is available it is always recommended to use the flip-flop
variant (option available for IRB 6600/6650 and IRB 7600). (In the second generation of tool
set the calibration pendulum housing is equipped with an extra pin on the side, next to the
attachment screw.Theserviceroutinewillaskthe operator whether to use theflip-flopvariant
or not.)
From RobotWare 4.0.100 (M2000) and 5.07 (M2004) automatic fine calibration is available
in the service routine.
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With the routine Reference Calibration (RefCal) references are taken of the robots zero
position once the robot is installed. These reference values are then used when the robot needs
to be recalibrated at future service occasions, i.e. recalibration of the motor calibration offset
is required.
Read more about the routine in section $ERXW5H HUHQFH&DOLEUDWLRQRQSDJH.
The Reference Calibration includes features regarding:
•axis 1 position. The user may put the axis 1 in any position, to avoid obstacles.
•tool and process equipment. All tool and process equipment may stay fitted during
calibration.
•hanging robot. A reference may be used on hanging robots as well.
These features are not available in Calibration Pendulum II.

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1.4. Calibration scales and correct axis position
3HAC 16578-1 Revision: E10
© Copyright 2003-2007 ABB. All rights reserved.
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This section specifies the calibration scale positions and/or correct axis position for all robot
models.
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The illustration below shows the calibration scale positions on IRB 140:
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1.4. Calibration scales and correct axis position
113HAC 16578-1 Revision: E
© Copyright 2003-2007 ABB. All rights reserved.
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The illustration below shows the calibration scale positions on IRB 1400:
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1.4. Calibration scales and correct axis position
3HAC 16578-1 Revision: E12
© Copyright 2003-2007 ABB. All rights reserved.
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The illustration below shows the calibration marks and correct positions of the six axes of the
robot. The marks shown in the figure are numbered according to the number of the axes.
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1.4. Calibration scales and correct axis position
133HAC 16578-1 Revision: E
© Copyright 2003-2007 ABB. All rights reserved.
xx0600002876
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1.4. Calibration scales and correct axis position
3HAC 16578-1 Revision: E14
© Copyright 2003-2007 ABB. All rights reserved.
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The illustration below shows the calibration marks and correct positions of the six axes of the
robot. The marks shown in the figure are numbered according to the number of the axes.
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1.4. Calibration scales and correct axis position
153HAC 16578-1 Revision: E
© Copyright 2003-2007 ABB. All rights reserved.
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The illustration below shows the calibration marks on all axes of the robot.
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1.4. Calibration scales and correct axis position
3HAC 16578-1 Revision: E16
© Copyright 2003-2007 ABB. All rights reserved.
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When axis 3 is put in calibration position, the mark on the calibration plate is visible above
the mechanical stop, as shown in the figure below.
xx0500002485
AMechanical stop of axis 3
BCalibration mark on calibration plate, axis 3
CCalibration plate and marking, axis 6
DPunch, axis 1, 3HAB8223-1
EPunch, axis 2, 3HAB8223-1 (1 marking)
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1.4. Calibration scales and correct axis position
173HAC 16578-1 Revision: E
© Copyright 2003-2007 ABB. All rights reserved.
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The illustration below shows the calibration scale positions on IRB 4450S.
The calibration marks for axes 2, 3, 4 and 5 are marked using punch mark tools.
xx0500002239
APunch axis 2, 3HAB 1521-1
BPunch axis 3, 3HAB 1522-1
CPunch axis 4, 3HAB 1523-1 (there are two different versions of the marks, as
shown in the figure)
DPunch axis 5, 3HAB 1524-1
EAxes 5 and 6, IRB 4400/L10
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1.4. Calibration scales and correct axis position
3HAC 16578-1 Revision: E18
© Copyright 2003-2007 ABB. All rights reserved.
&DOLEUDWLRQVFDOHV,5%
The illustration below shows the calibration scale positions on IRB 4400.
The calibration marks for axes 2, 3, 4 and 5 are marked using punch mark tools.
xx0300000209
APunch, axis 2, 3HAB 1521-1
BPunch, axis 3, 3HAB 1522-1
CPunch, axis 4, 3HAB 1523-1 (there are two different versions of the marks,as shown
in the figure)
DPunch, axis 5, 3HAB 1524-1
EAxes 5 and 6, IRB 4400/L10
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