Professional Documents
Culture Documents
User Manual: Promia 50 Application - Material Handling
User Manual: Promia 50 Application - Material Handling
ABB
of Robotics
User Manual
Promia 50 application – Material Handling
IRC5
RDNU0006_F_MH-Promia50_Eng.doc
User Manual
Promia 50 application – Material Handling
Document ID: RDNU0006
Revision: F
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, 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.
© ABB
2 RDNU0006 Revision F
Table of Contents
Overview ......................................................................................................................................5
Product Documentation, M2004 ...................................................................................................7
Promia Documentation.................................................................................................................8
1 Safety 9
2 Welcome 13
4 Operating principles 33
5 Man-Machine Interface 51
RDNU0006 Revision F 3
Overview
6 Editing paths 83
4 RDNU0006 Revision F
Overview
Overview
Usage
This manual should be used during operator training workshops, and when creating
or modifying programs based on the Promia application software.
Prerequisites
The reader must:
• Be familiar with use of the IRC5 FlexPendant
• Be trained in basic robot programming.
Reference Document
Product Manual, procedures IRC5 3HAC 021313-001
Product Manual, references IRC5 3HAC 021313-001
Startup - IRC5 and RobotStudio Online 3HAC 021564-001
RDNU0006 Revision F 5
Overview
Revisions
Revision Description
A
First issue, December 2005
B Updated with new MMC interface, December 2006
C Update of master document 02/2007
Update of master document – Add new simplified backup
D
functionality. 11/2007
E Miscellaneous 04/2008
F Add warnings about B-Start et recycling 05/2008
6 RDNU0006 Revision F
Product Documentation, M2004
General information
The robot documentation is divided into different categories. The list is based on
the type of information contained in each document, whether the products are
optional or not. This means that each robot delivery will not contain all the
documents listed, but only those corresponding to the equipment supplied.
However, all the documents listed can be ordered from ABB. The documents listed
are valid for the M2004 robot systems.
Hardware Manuals
All hardware, robots and control cabinets will be delivered with a Product Manual,
which is divided into two parts:
Product manual, procedures
• Safety information
• Installation and commissioning (descriptions relative to mechanical
installation, electrical connections and loading system software)
• 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)
Product manual, reference information
• 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
RobotWare Manuals
The following manuals provide a general description of the robot software and
contain the applicable reference information.
• RAPID Overview: Overview of RAPID programming language
• RAPID Reference Manual, part 1: Description of all RAPID instructions.
• RAPID Reference Manual, part 2: Description of all RAPID functions, including
data types.
• Technical reference manual – System parameters: Description of system
parameters and configuration workflows.
RDNU0006 Revision F 7
Promia Documentation
Application manuals
Operator manuals
This group of manuals is aimed at those having first hand operational contact with
the robot, i.e. production cell operators, programmers and troubleshooters.
This group of manuals contains:
• Getting Started - IRC5 and RobotStudio Online
• Operator manual - IRC5 with FlexPendant
• Operator manual - RobotStudio Online
• Troubleshooting manual for the controller and robot
Promia Documentation
General information
Promia is a family of application software intended for the IRC5 robot systems.
All of these software applications include a common part, linked to the material
handling process, on which a part specific to a process can be added.
For each process, the Promia documentation includes a user manual and an
integration guide. The information supplied for a given process always includes
the information relative to the handling process.
8 RDNU0006 Revision F
1 Safety
1 Safety
1.1 About the Safety section
Introduction to Safety
This section details the safety principles and the procedures to be applied when a
robot or a robot system is in operation.
It does not cover how to design for safety nor how to install safety related
equipment. These topics are covered in the Product Manuals supplied with the
robot system.
Personnel safety
Any moving manipulator is a potentially lethal machine.
When running the manipulator, it may perform unexpected and sometimes
irrational movements. However, all movements are performed with great force and
may seriously injure any personnel and/or damage any piece of equipment located
within the manipulator working range.
Safety regulation
Before starting to work with the robot, make sure you are perfectly familiar with
the safety rules detailed in the Operator Manual – IRC5 with FlexPendant.
RDNU0006 Revision F 9
1 Safety
Safety standards
The robot fully complies with the safety standards specified in the European
machinery directives. The ABB robots controlled by the IRC5 comply with the
following standards:
Standard Description
EN ISO 12100-1 Safety of machinery, terminology
EN ISO 12100-2 Safety of machinery, technical specifications
Safety of machinery, safety related parts of control
EN 954-1
systems
EN 775 Manipulating industrial robots, safety
EN 60204 Electrical equipment of industrial machines
EN 61000-6-4
EMC, generic emission
(option)
EN 61000-6-2 EMC, generic immunity
Standard Description
IEC 204-1 Electrical equipment of industrial machines
IEC 529 Degrees of protection provided by enclosures
Standard Description
ISO 10218 Manipulating industrial robots, safety
Manipulating industrial robots, coordinate systems and
ISO 9787
motions
Standard Description
ANSI/RIA Safety requirements for industrial robots and robot
15.06/1999 systems
ANSI/UL 1740-1998
Safety standard for robots and robot equipment
(option)
CAN/CSA Z 434-03
Industrial robots and robot systems - General safety
(option)
10 RDNU0006 Revision F
1 Safety
Overview
This section describes the various types of warning which may be given during the
operations described in this manual. Each warning is explained in its own section
with:
• A symbol for each hazard level (DANGER, WARNING or CAUTION)
and the type of hazard
• A brief description of the result of the hazard if the operator/service
personnel does not eliminate the hazard
• An instruction enabling the personnel to eliminate the hazard and perform
the operation manually.
Hazard levels
The table below defines the hazard symbols used in this manual.
Electrical shock
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1 Safety
Note
12 RDNU0006 Revision F
2 Welcome
2 Welcome
Overview
This section describes the main Promia functions, as well as the concepts and
terms which will be used in this document.
RDNU0006 Revision F 13
2 Welcome
Promia Description
The software applications derived from the common base include interfaces with
different processes and/or different specific equipments.
User
Screens Gripper
Material &
Handling Tool
Tooling Tooling Functions
Control Commands
Cabinet and Events
The basic application software manages the interface with an industrial PLC in
order to handle the part codes, synchronizations through commands and events,
and error reporting through monitoring functions.
It also manages the interface with the grippers and tools through « handling
sequences », also called "gripper actions" and « part detection monitoring »
functions.
Exchanges with a tooling control cabinet are managed by tooling commands and
events.
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2 Welcome
The applicative functions are the management of the movements to the "safe" and
"home" positions, and the management of the service requests that are local to the
robot controller.
The user screens display the information relative to the application software
functions. These screens are detailed later in this document.
In a multi-robot environment, the management of the part codes and the error
reporting are common and global for all the robots. On the other hand, the
commands, events and the handling interface are specific to each robot.
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2 Welcome
Integrator tasks
Promia is not directly operational in the form in which it is delivered and installed.
Promia is a programming frame, not an end-user application.
Promia becomes a customer final application once it has been customized by the
integrator; it is their job to define the robot paths and adapt the Promia functions to
the specific requirements of the user site.
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2 Welcome
Overview
This section describes the main concepts and terms used in this manual.
The description starts with the general concepts related to execution of the robot
paths and to the continuous monitoring performed by the application software,
followed by the terms related to the dialogue with the PLC, and finally, the terms
related to the various processes.
The robot controller can receive work requests from different components:
The first three cases are handled on a standard basis by Promia. The fourth case
can be implemented by an “internal code” mechanism described below in the
manual.
Each requested task is executed as a « robot program » which is itself divided into
« paths ».
To facilitate installation control and maintenance, the various paths begin and end
by a fine point. They also include an "anti-loop" mechanism to ensure that they are
not executed as a loop without returning to the main robot program.
In principle, the various robot programs begin and end by a specific position
referred to as "home" position. The new program codes are only taken into account
on this point. The organization of the various robot programs then takes the form
of a "daisy" with the home position at its center.
It is also possible to terminate the robot programs outside this point; this function
is described in the Basic handling application software integration guides.
RDNU0006 Revision F 17
2 Welcome
T_Service1
T_MoveToHome
Traj1
Traj2
Program n°1
Home Traj3
Safe
Position Position
a fe
T_MoveToSafe
oS Traj5
ctT
Traj4
e
Dir
ve
Mo
T_
Program n°2
18 RDNU0006 Revision F
2 Welcome
Description
When a robot has been stopped during its execution, there are two different ways
to resume the execution sequence:
• The robot resumes its path, after possible physical repositioning toward
the position where the stop took place. This procedure is called "path
regain" or “repositioning”,
• The robot does not resume the normal path, either because the operator,
after some manual jogging, is aiming directly at the next programmed
position, or because the operator, using the Debug menu in the Program
editor window, has placed the program pointer on an instruction
different from the current instruction. In both cases, the recovery
procedure is referred to as “recycling”.
Programmed
position n+1
Progarmmed
position n+2
Recycling
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2 Welcome
Current position
Recycling
Jogging (1)
Repositioning
Programmed
position n+1
Programmed
Programmed Position where
position n+2
position n the robot stopped
The behavior of the active outputs and monitoring functions will differ according
to the procedure (repositioning or recycling) used when resuming work. These are
documented in the Operating Principles detailed in this User Manual.
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2 Welcome
Description
The synchronization with the cell environment is made through digital
inputs/outputs that are exchanged with the PLC and referred to as « commands and
events ».
The commands are information signals sent by the robot to the environment. The
events are information signals expected by the robot from the environment.
Commands
Events
Description
The synchronization with a tooling controller is made through digital
inputs/outputs that are exchanged with the tooling controller and referred to as
« tooling commands and events ».
The « tooling commands » are information signals sent by the robot to the tool
cabinet. The “tooling events” are information signals expected by the robot from
the tool cabinet.
The tool commands and events can be programmed on positions when creating or
modifying paths. Appropriate instructions enable them to be programmed either a
fine point or on a fly-by point.
Tooling Commands
Tooling Events
RDNU0006 Revision F 21
2 Welcome
Overview
The clamping components, whether these are fixed or integrated in a gripper, are
made of monostable or bistable actuators, associated with sensors used to check
their position. The actions on these components are referred to as « Handling
sequences », or "Gripper actions".
Some sensors are also used to detect the part picked up in the gripper. These
signals are referred to as “Part detection” signals.
Note: The handling sequences can also be used to control other components than
the grippers. These are used for example to manage the tip extractors and the tip
dresser flaps operated by the Spot Welding process.
Depending on the complexity of the site, the handling sequences and the part
detection sensors can be managed either by the robot or by the PLC. The two
management modes can be used together (example: material handling managed by
the PLC, but tip dresser flaps managed by robot sequences).
In this configuration, the PLC manages the actuators and monitors the sensors.
Programming in the robot paths is done through specific PLC commands and
events.
The management of the part sensors is in this mode entirely unknown from
Promia. If so defined by the integrator, the handling sequences managed by the
PLC can be controlled manually on the robot teach pendant when the robot is not
executing any motion program.
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2 Welcome
Definition
The debug mode is used to test the robot programs, without a part, when the
installation is not yet complete.
This mode can be activated both in manual mode and in automatic mode and is
used, among others, to verify the program structure, the accessibilities and the
movements of the cables.
In the mode:
• the processes are inactive,
• if material handling is managed by the robot, the part detection functions
are replaced by wait times. The values of these times can be configured
by the integrator,
• if handling is managed by the robot, the handling sequence checks can
be activated or inhibited in accordance with a specific configuration for
each sequence. If inhibited, they are replaced by wait times. The values
of these times can be configured by the integrator.
The transition from debug mode to real mode is immediate for the handling
sequences and part detection functions. Reactivating the process is generally
performed when the next program code is received.
RDNU0006 Revision F 23
2 Welcome
24 RDNU0006 Revision F
3 Organization of application software
Section content
This section describes the architecture of the application software, the organization
of the RAPID files and the organization of the memory.
ABB supply
The robot controller supplied by ABB contains the pre-installed Promia
application software.
Reinstallation of the application software is described in the Promia integration
guide.
P-Start
When a user module common to several tasks has been modified, the application
software must be reinitialized by a P-Start command.
Select "Advanced…"
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3 Organization of application software
Initiate by P-Start
26 RDNU0006 Revision F
3 Organization of application software
Once the Promia application has been installed, the software in the robot controller
has the following architecture:
Trajectories
Integrator Process
Integrator Common Base Modules
Modules
ProcessWare BaseWare
ABB RobotWare
PROMIA internal software (cannot be modified)
PROMIA customization
RDNU0006 Revision F 27
3 Organization of application software
Task implementation
Each of these tasks contains specific modules and modules which are shared
between the 2 tasks.
The non-modifiable modules of the common base of Promia are the same for each
mechanical unit. The non-customizable process modules are only included in the
tasks related to the mechanical units which use this process.
If we consider a system with 3 mechanical units (3 robots) with the first one using
a process 1 and the 2nd and 3rd tasks using a process 2, the configuration will be as
follows:
Mechanical Unit 1
Foreground+
Foreground Background
Background
Common Base Common Base
Common Base
Foreground+
Foreground Background
Background
Process 1 Process 1
Process 1
Foreground+
Foreground Background
Background
Common Base Common Base
Common Base
Foreground+
Foreground Background
Background
Process 1 Process 1
Process 1
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3 Organization of application software
Mechanical Unit 2
Foreground+
Foreground Background
Background
Common Base Common Base
Common Base
Foreground+
Foreground Background
Background
Process 2 Process 2
Process 2
Foreground+
Foreground Background
Background
Common Base Common Base
Common Base
Foreground+
Foreground Background
Background
Process 2 Process 2
Process 2
Mechanical Unit 3
Foreground+
Foreground Background
Background
Common Base Common Base
Common Base
Foreground+
Foreground Background
Background
Process 2 Process 2
Process 2
Foreground+
Foreground Background
Background
Common Base Common Base
Common Base
Foreground+
Foreground Background
Background
Process 2 Process 2
Process 2
RDNU0006 Revision F 29
3 Organization of application software
hd0a/
RobotWare_x.yy.zzzz
APPL-PROMIA50.xx
Backup
home
Site x
Syspar
In a single robot system, there is only one site sub-directory, called “Site”.
30 RDNU0006 Revision F
3 Organization of application software
Module name
Module name
(multi-robot
(single robot Main purpose of module
environment –
environment)
mechanical unit ‘n’)
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3 Organization of application software
3.6 Contents of the Site directories
32 RDNU0006 Revision F
4 Operating principles
4.1 General controls of the robot controller
4 Operating principles
4.1 General controls of the robot controller
FlexPendant
Main switch
Emergency Stop
Motors On light & button
Mode selector (Manual/Auto)
Programmables
Keys
Start
Stop
RDNU0006 Revision F 33
4 Operating principles
4.2 Main menu of FlexPendant
Windows accessed from the ABB main menu are described in the IRC5 product
documentation.
34 RDNU0006 Revision F
4 Operating principles
4.3 Considerations related to single and multi-robot environments
Promia is an application software designed to operate in both single and multi-robot environments.
Some of the screen snapshot examples in this document are taken from a system
with three robots controlled by the same robot controller. However, the principles
described are also valid in a single-robot environment.
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4 Operating principles
4.3 Considerations related to single and multi-robot environments
• The Production window displays several vertical tabs; there is one tab
for each foreground task.
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4 Operating principles
4.3 Considerations related to single and multi-robot environments
RDNU0006 Revision F 37
4 Operating principles
4.4 Running the program
• In the ABB menu, select the Production Window in the left part of
the menu. If the program pointer was previously reinitialized at the start
of the program, the window displayed is as follows :
• If this is not the case, reinitialize the program using the PP to Main
command. This command reinitializes the program pointers of all the
foreground tasks and requests a confirmation :
38 RDNU0006 Revision F
4 Operating principles
4.4 Running the program
If all the robots are at the safe or home position, the program can be initiated in
automatic mode:
If the robot controller is connected to a PLC, the Motors On and start of execution
can be initiated from the PLC; see next section.
RDNU0006 Revision F 39
4 Operating principles
4.5 Production modes
This section starts with a description of the « production enabled » and « production disabled » modes, and the
way the corresponding PLC information are managed. This is followed by a detailed description the start of
production and the end of production operations. Finally, this section explains the way program codes are
managed by the application.
Via a digital input, ENPRO, the robot is informed by the PLC if it is integrated, or
not, in the production stream.
When set, this input informs the robot controller that it is in the "PRODUCTION
ENABLED" mode. When it is reset, the robot controller has to be in the
"PRODUCTION DISABLED" state.
The use of this function is optional and has to be defined in accordance with the
needs of your site. If the Production enabled /disabled feature is not used, the
“ENPRO” input must be declared as inverted in the I/O signal parameters.
The local and remote commands (Motors On (DMSP), start cycle (DDCY), move
to safe, stop …) are active.
The movement programs generated by the external code management system are
executed.
Only the "move to safe" request is active. The remote commands (Motors On
(DMSP), start cycle (DDCY), Service request) are ignored.
The robot terminates the ongoing movement program, but does not read the
external or internal program code which may be present on dedicated inputs. This
will usually leave the robot at home position, unless a "move to safe" request is
issued.
Once at the safe position, there is no automatic selection of the production startup
program (T_MoveToHome path).
When the production disabled mode is detected by the robot (ENPRO input off),
the « Production Disabled » message is displayed in the « Production » screen of
the application.
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4 Operating principles
4.5 Production modes
Automatic Automatic
mode, mode,
Command Manual mode
"production "production
disabled" enabled"
Motors On button on robot
Inactive Active Active
cabinet
The "Move to Safe" command is used, as a general rule, to bring the robots to their
safe positions by pressing
• the « Move to Safe » pushbutton on the front panel of the robot cabinet,
when this button exists,
• the graphic button on the operator panel when this button does not
physically exist (see 5.5 Operator panel screen) :
The "Move to Safe" command can also be run through a specific program code
which can be sent by the PLC, like any other program code, to request the end of
production.
RDNU0006 Revision F 41
4 Operating principles
4.5 Production modes
When starting up programs, from the beginning, after having chosen for example
"PP to Main" in the production window, the application software sends first all
the robots to their safe positions in order to initiate production under known
conditions, using the production startup program and the T_MoveToHome path.
The production startup program is automatically selected once all the controlled
robots are at their safe positions.
• If the robot is already at its safe position, the "Move to Safe" phase is
unnecessary and the robot waits there until the other robots have reached
their own safe positions.
• If the robot is not at its safe position, a message on the « Production »
screen of the application informs the operator that he must press the
"Safe" pushbutton to initiate a movement to the safe position:
The operator has to order the movement to safe position (no other command is
active). Depending on the hardware configuration, he can use either the “Safe”
pushbutton on the controller or the dedicated button on the “Operator Panel”
screen.
• Either the robot is at its home position; in this case, the movement to the
safe position is performed by the T_MoveToSafe path routine. This
movement to the safe position can be executed in automatic mode
provided all the robots are either at their home or at their safe position.
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4 Operating principles
4.5 Production modes
• The robot is not at its home position and not at its safe position (position
is considered as unknown). The movement to the safe position will run
the T_MoveDirectToSafe path and must then be performed in
manual mode.
If necessary, a message in the production screen will request the operator
to switch to manual mode; when this is done, the application displays a
direct "move to safe" dialog. This dialog must be acknowledged for each
robot requiring a direct movement to its safe position.
Figure 20. Switch to manual mode to initiate direct move to safe operation.
Figure 21. Direct move to safe dialog to be acknowledged for robots 1 and 2.
When the robot controller is equipped with a lighted "safe" pushbutton, the
indicator light flashes until all the controlled robots have reached their safe
positions. The "safe" indicator light on the virtual operator panel (see 5.5 Operator
panel screen) acts in the same way.
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4 Operating principles
4.5 Production modes
When all the robots controlled by the robot controller have reached their safe
positions, the production startup internal program is automatically selected and
will run the T_MoveToHome path.
At the end of this path, the application is ready to accept any kind of program code
requests.
End of production
44 RDNU0006 Revision F
4 Operating principles
4.5 Production modes
When the robot controller is equipped with a lighted Safe pushbutton, the indicator
light flashes until all the robots have reached their safe position, or until the end of
production request has been cancelled. The safe indicator light on the virtual
operator panel (see 5.5 Operator panel screen) acts in the same way.
The program codes are caught at the end of the preceding program. Though reset
of the preceding external code may have been anticipated, the external code is only
read at this moment.
If several work requests occur simultaneously, the choice is made in accordance
with the priority algorithm defined below.
Reading of the program code can sometimes be inhibited. This is the case when
the system has gone into “production disabled” mode. This is also the case when
the process has been temporarily deactivated. The deactivation is used to terminate
a part which may have presented a problem, but does not allow any execution of
new parts. The process must therefore be reactivated in order to allow catching of
new program codes.
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4 Operating principles
4.5 Production modes
The program codes are managed in accordance with the following priority levels
(indicated in decreasing order of priority):
46 RDNU0006 Revision F
4 Operating principles
4.6 Principles relative to actions and checks attached to a position
As a general rule, any moment the robot waits for a feedback signal on a
programmed position, a message is displayed on the TPU to inform the operator
and the reason why the robot is waiting is also sent to the PLC.
By default, no Stop is generated; the movements of the involved robot are
automatically stopped since execution of the program is blocked as long as the
information is not present. When the expected information appears, the program
resumes its normal sequence.
The PLC can however decide to generate a Stop via the robot controller
inputs/outputs. In this case, the error must be acknowledged on the PLC and
program execution must be restarted from the PLC.
The list of error messages is given in section 5.4 Error messages. The list of
corresponding codes sent to the PLC is given in the PROMIA integration guide.
RDNU0006 Revision F 47
4 Operating principles
4.7 Continuous monitoring
This behavior may be disturbing for certain process phases and the dynamic
monitoring functions can therefore be enabled or disabled by programming during
execution of certain sections of a path.
The integrator can modify this configuration of the default states. For each of the
variables, TRUE means enabled by default, and FALSE means disabled by default.
The state of the enabled monitoring tasks can be modified in the robot programs
using the MonitorInputs instruction.
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4 Operating principles
4.7 Continuous monitoring
4.7.2 Error management
The application displays and erases messages during execution of the programs
and paths.
Robot behavior
The robot movement will be blocked since an error message is displayed. This
blocked condition will only end when the message has been erased, and therefore
after the end of the movement … which will never take place … A program
sequence of this type will therefore lead to complete blockage of the robot.
RDNU0006 Revision F 49
4 Operating principles
4.8 Behaviors in cases of exception
The behavior of the application software will vary according to the complexity of the exception. On a simple
exception, such as a stop or an emergency stop, followed by a restart with no jogging or modification, the
application software does not take any special action.
On the other hand, when restarting after manual jogging or modification of the program pointer, the behavior
will be very different depending on how the work will be resumed: repositioning or recycling. For the
meaning of these terms, refer to 2.4.2 Repositioning and recycling principles.
During repositioning
While the robot regains its path, the behavior is similar to the one during manual
jogging: no check will block the repositioning operation and, if any sequences are
controlled, they are monitored, but only for the purpose of displaying possible
errors.
At end of repositioning
At the end of the regain operation, the dynamic monitoring tasks are restarted in
the same condition as they were prior to the exception, and any active checks made
on position are reinitiated.
The sequences are monitored in accordance with the control state programmed in
the paths.
Re-initialization of checks
50 RDNU0006 Revision F
5 Man-Machine Interface
5.1 General description of the screen container
5 Man-Machine Interface
The screens of the Promia application software are not initiated from the ABB menu, but from a tab in the
task bar, known as the Screen Container, which is always visible. The container starts up automatically at
controller startup.
General aspect
The container gives access to the application screens through a floating panel,
located by default at the top right corner of the screen.
Floating panel
The floating panel can be moved from top to bottom and from bottom to top to
allow reading the screens which it covers with no interference.
It comprises three elements:
• The right hand part acts as a « handle » to move the floating panel :
RDNU0006 Revision F 51
5 Man-Machine Interface
5.1 General description of the screen container
• The top button, to the left, displays a blue command bar used to select
the screen of the application software to be displayed.
• The lower button, to the left, is used to toggle between the current screen
and the « Operator Panel » screen ; it is thus possible, using this button,
to call up, at any time, the Operator Panel screen which contains a
virtual « button set » used to request "Move to Safe position" or for
service requests:
Figure 26. Button used to toggle between current screen and Operator Panel
screen.
Selecting a screen
When the screen selection button is pressed, a blue command bar appears (over the
current command, if one is displayed):
The selection button aspect changes; when the button is pressed again, the blue
command bar disappears.
52 RDNU0006 Revision F
5 Man-Machine Interface
5.2 Choice of "Common Features" screens
5.2 Choice of "Common Features" screens
The elements displayed in this blue command bar depend on the processes
managed by the application software, especially in a multi-robot environment,
where several processes are implemented.
The command bar always contains however a first item used to select the screens
of the common base application, and is referred to as the “Common Features”.
This menu has three sub-menus which gives access respectively to the production
screen, the information screens common to all the processes, and to a simplified
backup screen:
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5.3 Production screen
This screen contains a command bar and a display with two separate areas:
• the upper half, called the Program area, displays the state of the current
programs and paths,
• the lower half, called the Message area, displays the application software
messages.
Program area
Messages area
Command bar
The command bar is used to control the display in the Messages area; it is
described in the corresponding section.
The first line indicates the version of the application software installed and the
processes controlled by the various robots of the cabinet. In the example below,
robot 1 is a handling robot and robots 2 and 3 are arc welding robots:
The second line displays the external code present on the inputs of the robot
controller, "xCode" and the program codes currently accepted by the application
software
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5.3 Production screen
In the example above, no external code is present and the codes executed by the
application are a normal "Move to Safe", performed from home position, for robot
1, and a direct move to Safe for robots 2 and 3.
Lines 3 to 6 contain, for each of the robots (4 maximum), the names of the current
programs and paths, as defined by the integrator; see instructions
DisplayProgram and DisplayPath in section 7.2 Giving information
about active path and active robot program.
The Message Area has two operating modes: a "snapshot" mode and a "history" mode. The two modes are
controlled from the command bar of the production screen.
The command bar contains 3 icons used to control the display in the Message area:
• the icon indicates that the current mode is the « history » mode.
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The Message area contains an instant view or a history of the application software
messages.
The messages are time-stamped and the order of appearance of the messages is
preserved.
Format of messages
The movement tasks have a name which begins by « T_ ». This must not be
confused with the path names which also traditionally begin by « T_ »
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5.3 Production screen
Validation of messages
A message validation request is only displayed when the cause of the error has
disappeared.
The movements of the robot(s) only resume after this dialog has been
acknowledged by the operator.
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5.4 Error messages
The error messages are presented here according to their source (common base or process), then according to
their seriousness.
Type of
Wording Description
message
Type of
Wording Description
message
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5.4 Error messages
Type of
Text Description
message
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List of information messages
Type of
Text Description
message
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5.4 Error messages
Type of
Text Description
message
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5.4 Error messages
Type of
Text Description
message
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5.4 Error messages
Type of
Text Description
message
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5.5 Operator panel screen
This screen replaces a set of physical buttons and lamps; it includes, by default, a lighted “safe” pushbutton
and 4“service” pushbuttons. These 4 buttons are used to request the corresponding service routines.
The operator panel screen can be customized in accordance with the installed processes.
Access
This screen is accessed using the key at the bottom left of the floating panel of the
screen container:
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5.6 Promia information screens
These screens are accessed from the blue command bar which is called up by
pressing the button at the top left of the floating panel of the screen container, and
then through the Common Features Menu:
5 parts of screen
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5.6 Promia information screens
tab to select
mechanical unit
Screen title
Additionnal
information or
instruction
Page,
information displayed
Menu,
screen selection
Information displayed
The 5th screen displays the execution context and, especially, the state of the
active dynamic monitoring functions.
Accessing from the “Common Features” screen selection menu always calls up the
first screen (part detection).
The change of screen is performed from the « Menu » area.
The change of mechanical unit using the « Tabs » area preserves the current type
of information and therefore the current screen; only the contents of the page is
changed to reflect the information related to the selected mechanical unit.
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5.6 Promia information screens
The names displayed in these pages are read from the DEF_SITn modules as
entered by the integrator.
These modules are supplied by ABB with default names which are not necessarily
relevant for a given site.
The relevance of the display names is therefore strictly dependent on the
customization defined by the integrator.
Content of pages
The part detection screen includes only one page displaying the expected state of
the 8 part detection sensors available for a mechanical unit.
Each part detection sensor is represented by its name and a pictogram indicating
the compliance of its actual state with respect to its expected state.
If no name has been defined for a part detection sensor, the corresponding fields
remain empty. In the examples below, only part detection sensor 1 name has been
filled in.
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When a CheckPart instruction is executed, the expected state of the part
detection sensors involved by this instruction is known. A pictogram is displayed
to the left of their names to indicate compliance (green colour) or non-compliance
(red colour) of the actual signal compared with its expected state.
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5.6 Promia information screens
Content of pages
• A page displaying the detailed state of the selected sequence and used to
control it.
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General state of sequences
Each sequence is represented by its name, its programmed state (state requested by
program during execution), its actual state (state currently controlled) and by a
pictogram indicating compliance of its actual state with respect to its expected
state.
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5.6 Promia information screens
Once the movement program is reinitialized (pp->Main, Exec), the control state of
the sequences which have been used in the program is displayed and monitored by
the application software. The pictograms indicating the state of the sequences are
refreshed.
The « Programmed State » and « Actual state » fields of the defined sequences, but
which are not used on the path, remain empty.
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5.6 Promia information screens
The second tap on the line opens the detail screen showing the state of the sensors
related to the sequence and identifies, if relevant, the faulty sensor.
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5.6 Promia information screens
For each sensor, the screen displays its name, its expected status and, in real time,
its physical state. It also displays the control state of the actuators controlled by the
selected sequence.
The “Sequence details” screen includes a specific command bar used for manual
control of the sequence: the first two selections are used respectively to activate
and deactivate the sequence. Their wordings correspond to those entered in by the
integrator for this sequence.
These controls are greyed in (see figure above) when manual control of the
sequence is not enabled (individual inhibition of this sequence, program execution
in progress, automatic operating mode, motors off or enabling device released).
Note: In this screen, it is possible to manually control all the sequences defined,
whether they are declared, or not, as usable in the path. You may, for instance,
control a sequence trhat is managed by the PLC.
When manual control of the sequence is possible (program stopped, manual mode,
motors powered up, enabling device pressed, no specific inhibition for this
sequence), the control keys become active:
The current control state is indicated at the top right of the screen. The state of the
sensors is refreshed in real time, even if the enabling device is released.
Before controlling the sequence, make sure the operation is safe for personnel and
equipment.
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Select « Close » to return to the general sequence screen.
Any possible inconsistency between the programmed state and the state actually
controlled is displayed as a warning:
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Content of pages
The events screen includes two pages respectively displaying the state of the 16
PLC events and the 16 tool events related to the selected mechanical unit.
The choice between « PLC events » and « tool events » is made in the « Events »
sub-menu:
The two pages are similar. Only the screen title is different. Each event is
represented by its number and its name:
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Only the events which are expected and not present, either in a path action, or in
the dynamic monitoring, are indicated by an error pictogram:
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Content of pages
The Commands screen includes two pages respectively displaying the states of the
16 PLC commands and the 16 tool commands related to the selected mechanical
unit.
The choice between « PLC commands » and « tool commands » is made in the
« Commands » sub-menu.
The two pages are similar. Only the screen title is different. Each command is
represented by its number, its name and a LED when the command is set:
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5.7 Backup screen
5.7 Backup screen
This screen is used to perform a simplified backup of the complete application.
The backup is identical to the one performed in the standard ABB screen, but the backup paths are predefined
by the integrator for 3 types of media: flashdisk, USB port and network.
Caution: EACH NEW BACKUP ON A MEDIA OVERRIDES THE PREVIOUS BACKUP MADE ON THIS
MEDIA.
Note: These screens do not allow any access path modification. If the operator wishes to perform a backup out
of the predefined paths, he must use the standard backup procedure, accessible from the ABB menu.
Access
This screen is accessed from the blue command bar, which is displayed by
pressing the button at the top left of the floating panel of the screen container , and
then through the Common Features Menu:
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5.7 Backup screen
This screen includes a menu bar used to select the media on which the backup will
be performed, a reminder of the action to be performed, a reminder of the path of
the directory on which the backup will be performed, and an action button to
initiate the backup operation.
The 3 pictograms on the command bar are used respectively to select the
FlashDisk, the USB port or a remote computer.
If not customized by the integrator, the application software creates backups in the
default directories for the FlashDisk (directory: REST_ABB) and the USB key
(BACKUP_, followed by current date, for example Backup_2007_04_06). If the
path for backup on a remote computer is not defined, the button in the
corresponding screen is greyed in and disabled.
( ).
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5.7 Backup screen
Summary:
Corresponding
Pictogram Media Default directory
button
FlashDisk /hd0a/systemName/REST_ABB
USB /bd0/Backup_CurrentDate
Network None
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6 Editing paths
6.1 General information
6 Editing paths
6.1 General information
General procedure
It is also possible to edit the program line currently executed from the Production
window. In this case, select ‘Debug’, then ‘Edit Program’:
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6.2 Insertion of a specific instruction of the application
The specific instructions of the application are located in the Most Common list 1
and 2 of the instruction panel that appears when using the ‘Add Instruction’
menu.
The « PROMIA » list contains the actions which are common to all the processes.
The « PROCESS » list gives access to the actions specific to the process.
Note:
When opening the program editor, a button is displayed in the task bar with the
name of the movement task and the name of the module currently being edited
(here, T_ROB1, PRG_MVT).
The movement tasks have a name which begins by « T_ ». Do not confuse this
with the paths names which also traditionally begin by « T_ »
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6.3 Inserting a « Common base » instruction
The actions common to all the processes, also called « common base » actions are
displayed on 2 pages:
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7.1 Programming anti-loop functions
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7.1 Programming anti-loop functions
PROC Programme(
num prog)
TEST prog
CASE 1:
DisplayProgram prog,"Prog 1";
! pulse code acknowledge signal
PulseDO\PLength:=1,ACQ_CODE1;
EnablePath;
Traj1; ….
Example of path:
PROC Traj1()
DisplayPath "Traj 1";
PreventLoop;
MoveL *, …
….
MoveJ *,…
ENDPROC
Syntax:
EnablePath
No parameter
Syntax:
PreventLoop
No parameter
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7.2 Giving information about active path and active robot program
7.2 Giving information about active path and active robot program
In order to display the names of the current robot programs and paths, this
information must be given at the right moment.
The current robot program name is typically given using the DisplayProgram
instruction in the corresponding “CASE” to the Programme routine.
The current path name is typically given through a DisplayPath instruction at
the beginning of the routine dedicated to this path.
Syntax:
DisplayPath pathName
Mandatory parameter
Name : Meaning :
Syntax:
DisplayProgram programNumber programName
Mandatory parameters
Name : Meaning :
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7.3 Programming PLC commands
PLC commands are information signals sent by the robot to its environment (via a
PLC). This logic information can be programmed on positions when creating or
modifying paths.
The PLC commands are only sent during program execution. They are generated
when a SendPlc action is programmed on a fine point or a MoveSendPlc
instruction is programmed on a fly-by point:
• The commands are reset during path teaching, in case of recycling, when
a movement program is aborted or after having moved the robot to its
safe position.
• The commands are programmed by blocks of 16. The commands not
programmed in one instruction are reset. You must the re-program on an
instruction all the commands previously set that you want to remain set.
This path instruction entitles you to send up to 16 PLC commands on the same
position.
Generation of the commands may be delayed by using an optional argument
\Delay. This parameter defines the value of the delay in seconds. If this argument
is used, generation of all the programmed commands is delayed.
Example:
SendPlc \O1;
Syntax:
SendPlc
[\Delay][\O1][\O2][\O3][\O4][\O5][\O6][\O7][\O8]
[\O9][\O10][\O11][\O12][\O13][\O14][\O15][\O16]
Optional parameters:
Name : Meaning :
\O1 ... \O16 Specifies that the corresponding command (1 to 16) must be
set.
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7.3 Programming PLC commands
7.3.2 MoveSendPlc instruction
Example:
MoveSendPlc \L,*\O1,v1000,z20,tool0,wobj0;
Syntax:
MoveSendPlc
[\L] ToPoint [\Id] [\O1][\O2][\O3][\O4][\O5][\O6]
[\O7][\O8][\O9][\O10][\O11][\O12][\O13][\O14]
[\O15][\O16] speed zone tool wobj
Mandatory parameters :
Name : Meaning :
Optional parameters :
Name : Meaning :
\O1 ... \O16 Specifies that the corresponding command (1 to 16) must be
set.
The position is stored when creating the instruction and can subsequently be
modified using the “Modify Position” command of the program editing window.
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7.4 Programming events
Events are information expected by the robot from its environment. This logic
information can be programmed on positions when creating or modifying paths.
The events are only expected during program execution. They are expected as
soon as a PlcEvent action is programmed on a fine point, or a
MovePlcEvent instruction is programmed on a fly-by point:
This path instruction entitles you to wait for up to 16 PLC events on the same
position.
Example:
PlcEvent \E1;
Syntax:
PlcEvent [\E1][\E2][\E3][\E4][\E5][\E6][\E7][\E8]
[\E9][\E10][\E11][\E12][\E13][\E14][\E15][\E16]
Optional parameters :
Name : Meaning :
\E1 ... \E16 Specifies that the corresponding event (1 to 16) is expected
to be set.
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7.4 Programming events
The test of events can also be programmed in the fly-by point area using the
MovePlcEvent movement instruction.
If the tested events are present at the end of the movement, the robot continues its
path normally; otherwise, it stops on its path while waiting for the programmed
events to be set.
Example:
MovePlcEvent \L,*\E1,v1000,z20,tool0,wobj0;
Syntax :
MovePlcEvent
[\L] ToPoint [\E1][\E2][\E3][\E4][\E5][\E6][\E7]
[\E8][\E9][\E10][\E11][\E12][\E13][\E14][\E15]
[\E16] speed zone tool wobj
Mandatory parameters :
Name : Meaning :
ToPoint Position, target of the movement, and where events test will
be performed
Optional parameters :
Name : Meaning :
\E1 ... \E16 Specifies that the corresponding event (1 to 16) is expected
to be set.
The position is stored when creating the instruction and can subsequently be
modified using the “Modify Position” command of the program editing window.
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7.5 Programming tool commands
The tool commands are information signals sent by the robot to a tooling control
cabinet. This logic information can be programmed on positions when creating or
modifying paths.
Note: Tool commands can also be used as an extension of the PLC commands.
The tool commands are only set during program execution. These commands are
generated when a SendTooling action is programmed on a fine point or when
a MoveSendTooling instruction is programmed on a fly-by point:
• The tool commands are reset during path teaching, in case of recycling,
when a movement program is aborted or after having moved the robot to
its safe position.
• The tool commands are programmed by blocks of 16. The tool
commands not programmed in one instruction are reset. You must the
re-program on an instruction all the commands previously set that you
want to remain set.
This path instruction entitles you to send up to 16 tool commands on the same
position.
Generation of the commands can be delayed using the optional \Delay argument.
This parameter defines the value of the delay in seconds. If this argument is used,
generation of all the programmed commands is delayed.
Example:
SendTooling\O1;
Syntax:
SendTooling
[\O1][\O2][\O3][\O4][\O5][\O6][\O7][\O8]
[\O9][\O10][\O11][\O12][\O13][\O14][\O15][\O16]
Optional parameters:
Name : Meaning :
\O1 ... \O16 Specifies that the corresponding command (1 to 16) must be
set.
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7.5 Programming tool commands
Syntax:
MoveSendTooling
[\L][\Id] ToPoint [\O1][\O2][\O3][\O4][\O5][\O6]
[\O7][\O8][\O9][\O10][\O11][\O12][\O13][\O14]
[\O15][\O16] speed zone tool wobj
Mandatory parameters:
Name : Meaning :
Optional parameters :
Name : Meaning :
\O1 ... \O16 Specifies that the corresponding command (1 to 16) must be
set.
The position is stored when creating the instruction and can subsequently be
modified using the “Modify Position” command of the program editing window.
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7.6 Programming tool events
The tool events are information signals expected by the robot and generated by a
tool control cabinet. This logic information can be programmed on positions when
creating or modifying paths.
Note: The tool events can also be used as an extension to the PLC events.
The tool events are only expected during program execution. These events are
expected as soon as a ToolingEvent action is programmed on a fine point, or
when a MoveToolingEvent instruction is programmed on a fly-by point :
This path instruction entitles you to wait for up to 16 tool events on the same
position.
Example:
ToolingEvent\E1;
Syntax:
ToolingEvent
[\E1][\E2][\E3][\E4][\E5][\E6][\E7][\E8]
[\E9][\E10][\E11][\E12][\E13][\E14][\E15][\E16]
Optional parameters :
Name : Meaning :
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7.6 Programming tool events
The tool events test can also be programmed in the fly-by point zone using the
MoveToolingEvent movement instruction.
If the tested events are present at the end of the movement, the robot continues its
path normally; otherwise, it stops on its path while waiting for the programmed
events to be set.
Example:
MoveToolingEvent\L,*\E1,v1000,z20,tool0,wobj0;
Syntax:
MoveToolingEvent
[\L] ToPoint [\E1][\E2][\E3][\E4][\E5][\E6][\E7]
[\E8][\E9][\E10][\E11][\E12][\E13][\E14][\E15]
[\E16] speed zone tool wobj
Mandatory parameters:
Name : Meaning :
ToPoint Position, target of the movement, and where events test will
be performed
Optional parameters :
Name : Meaning :
\E1 ... \E16 Specifies that the corresponding event (1 to 16) is expected
to be set.
The position is stored when creating the instruction and can subsequently be
modified using the “Modify Position” command of the program editing window.
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7.7 Programming handling sequences
The handling sequences have two states: « activated » and « deactivated ». They
are controlled (actuator signals are set or reset) and monitored (feedback signals
are checked) according to their desired state. The signals used to control and
monitor the sequences are defined by the integrator.
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7.7 Programming handling sequences
• \S1_A or \S1_D
• …
• \S16_A or \S16_D
Without an optional argument, this instruction can be used to reinitialize the state
of the programmed sequences (to be used, for example, when dropping the tool if a
tool changer is used).
Example:
GripperAction\S1_A;
Optional parameters :
Name : Meaning :
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7.8 Programming part detection functions
These signals are monitored with respect to their expected state: idle, set or reset.
The expected states of all the part detection functions are placed in the idle state on
program start up from its ‘Main’ routine. They are then positioned in accordance
with the path programs.
This instruction is used to program the expected state for the 8 part detection
signals and to wait for the signals to match the expected states.
This means that when the expected state of a part detection sensor is modified, the
programming for the other part detection sensors must be repeated in order to
continue to monitor them if so desired.
Example:
CheckPart \CPP1_1;
Syntax:
CheckPart
[\DET1_1][\DET1_0][\DET2_1][\DET2_0]
[\DET3_1][\DET3_0][\DET4_1][\DET4_0]
[\DET5_1][\DET5_0][\DET6_1][\DET6_0]
[\DET7_1][\DET7_0][\DET8_1][\DET8_0]
Optional parameters :
Name : Meaning :
The application software does not monitor the state of the part detection sensors
not specified in the instruction. Use of the instruction without optional argument
thus results in inhibiting dynamic monitoring of the part detection sensors.
This function ensures continuous (between points) monitoring of the states of the
signals corresponding to the part detection sensors, the handling sequences and the
events. For more information, see 4.7.1 Dynamic monitoring.
Two optional argument families can be used: two exclusive general arguments and
3 basic arguments whose effects are cumulative:
Syntax:
MonitorInputs
[\NONE] [\BY_DEFAULT]
[\GRIPPER] [\PART] [\PLC] [\TOOLING]
Optional parameters:
Name : Meaning :
8 Service programs
8.1 General information
The Promia application software manages 4 service programs, each of which can result from a request internal
to the process (example: spot welding), a service frequency (example: arc welding), or a request generated by
an external signal (pushbutton …).
At a given moment, several service requests may be active. The 4 service requests
are managed in accordance with a specific priority:
Service request 1 priority > Service request 2 priority > Service request 3 priority
> Service request 4 priority
9.1 Index
A PLC Events
Anti-loop function Definition ....................................................... 21
Principle and management..............................87 Programming .................................................. 92
D Promia window .............................................. 76
Debugging Program
Definition........................................................23 Display in Production screen.......................... 55
Dynamic monitoring Robot program and path principle.................. 17
Description .....................................................48 Running program in automatic mode ............. 39
Programming ................................................102 Running program in manual mode ................. 38
Types of monitoring .......................................48 Program code
E Program code priority..................................... 46
Errors and messages sources of program codes ............................... 45
Displaying ......................................................57 Promia
List of common base errors requiring a Customizable modules ................................... 31
validation ....................................................59 Description ..................................................... 14
List of common base simple errors.................59 Organization of memory ................................ 28
List of simple common base messages ...........61 Software architecture...................................... 27
F R
FlexPendant Recycling
Basic menu .....................................................34 Application software behavior ....................... 50
Dedicated buttons ...........................................33 Definition ....................................................... 19
H Repositioning
Handling sequences Application software behavior ....................... 50
Definition........................................................22 Definition ....................................................... 19
Manual control................................................73 S
Programming ..................................................98 Safe
Promia window...............................................70 end of production request ............................... 44
Hazard levels ......................................................11 Safe position
Home position definition of safe position............................... 18
definition ........................................................17 Startup
I Execution of start program ............................. 44
IRC5 Move to safe request....................................... 42
Control devices ...............................................33 Safe and home requests .................................. 41
P T
Part Detection Tool Commands
Definition........................................................22 Definition ....................................................... 21
Programming ................................................100 Programming .................................................. 94
Promia window...............................................68 Promia window .............................................. 78
PLC Commands Tool Events
Definition........................................................21 Definition ....................................................... 21
Programming ..................................................90 Programming .................................................. 96
Promia window...............................................78 Promia window .............................................. 76