Irc5 Programming and Operation2007

7/26/2019 IRC5 Programming and Operation_2007
IRC5
PROGRAMMING AND OPERATION
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http://slidepdf.com/reader/full/irc5-programming-and-operation2007 1/102
Facilities Guide
 Workshop Area
 Must be accompanied by a member of ABB staff
 Health & Safety / Customer confidentiality
 Please ask if you would like a guided tour

 Phones, Faxes and Internet access
 Outgoing calls - Phones available in training rooms and reception
–
relay
 Internet access - via terminal in main training area
 Password: Trainme2day11
 Contacting ABB personnel
 Please ask instructor if you would like to contact or meet up with
friends or acquaintances at ABB
 Smoking area
 Access via main entrance
Site Map
Fire Assembly point
Visitors
Parking
Smoking
Area
Employee parking
Auriga House Ground Floor Plan

Fire Exit
Mech Fire Exit

Training
Area
Workshop gangways
Room Paint
3 Training
Office Training Suite rooms
Room 1 Solutions
Centre Weld Training
rooms

Reception
Technical Robot Spare Parts Fire Exit
   Help desk
Main Entrance
Smoking shelter
Please use main entrance
IRC5 Training course scheme

Programming Programming &
Operator & Operation for
Operation Mig / Mag
2day 5 day 5 day
 
Mig Mag
RobotStudio 5 MultiMove
Electrical Process
Certified User Programming
Appreciation
4 da 3 da 3 da 3 da
 
Rotary
PickMaster Advanced External Axis
Mechanical
Stage1 Programming
4 day  5 day 5 day 2 day
  
WebWare Advanced SmarTac
Stage2
 2 day  3 day  2 day
Course Objectives
Safety requirements for basic programming and operation

System warm start up, shut down and error recovery
Basic program operation
Basic production programming techniques

Create and use routines
Use input output instructions
Flexpendant communication instructions
Numerical data instructions
Saving and opening programs
Potential Accident Risks

 Modifying program within robot cell
 Test run
 Fault tracing

Repair
 Process hazards
ABB Safety Solutions – an Overview
 Emergency stop
 Operating mode
 Auto
 Manual < 250 mm/s
 Manual 100%
 Enabling device

 Hold-to-run
 Safeguard stop
(Auto and Manual)
 Limiting the workspace

 Lockouts and Interlocks
Law Demands
 The construction design for the robot is to comply with
requirements that are stated in ISO 10218, Jan 1992,
industrial robot safety. Robot also comply with
requirements for ANSI/RIA 15.06-1999.

 Definition of safety function / regulations:
 Emergency stop – IEC 204-1, 10.7

Enabling device – ISO 11161, 3.4
 Safeguard – ISO 10218 (EN 775), 6.4.3
 Reduced speed – ISO 10218 (EN 775), 3.2.17
 Interlock – ISO 10218 (EN 775), 3.2.8
 Hold to run – ISO 10218 (EN 775), 3.2.7
ANSI: American National Standards Institute
RIA: Robotics Industries Association
ISO: International Standards Organisation
IEC: International Electrotechnical Commission
EN: European Normalisation
Emergency Stop
 Built in emergency stop

pushbuttons are found both
on the FlexPendant and
Controller-X-module as
default.

be connected to the robot
systems safety chain.
Operating Mode
 Automatic mode
 Production mode (no speed limit)
 Manual mode
 < 250 mm/s – max velocity 250 mm/s
 100 % – Option, robot can be
ogge teste w t no spee m t.
Enabling Device (Dead Mans Grip)
 The enabling device is a press switch with three

positions
 The switch must be in the middle positions in order to

activate the motors
 All robot movement will immediately stop if the switch is
re ease or presse o e o om
Enabling device
Hold-to-Run (Manual 100 %)
 Only found on Version 1 FlexPendant’s

 Hold-to-run buttons removed on Version 2 FlexPendant
 Option (this function can be selected in the parameters)
 The enabling device and one of the hold-to-run buttons
must be pressed simultaneously to start the motors
Enabling device
Hold-to-run buttons
(for left or right hand)
Version 2 FlexPendant Hold-to-Run
Hold-to-Run buttons and

prompt message removed
Hold down the play key, to run the program
Hold down the FWD or BWD key to step through program
Release the pressed key to stop execution
Safeguard Stop
 The connection of safeguard stop enables inter-locking

of external safety equipment, such as: doors, photo-
electric trip device, photo cells or pressure mats.
 Safeguard stop can be connected in two ways:
 Always active regardless of operating modes
 n y act ve w en automat c mo e s se ecte
 Possibility to activate Delayed Safeguard Stop.

A delayed stop gives a smooth stop. The robot stops in
the same way as at a normal program stop with no
deviation from the programmed path.
Limiting the Workspace
 To avoid the risk of getting

caught between the robot and
the outer safe equipment, e.g.
a fence, the robot’s workspace
can be limited:
 All axis can be software controlled

Axis 1–3 can be limited by
adjustable mechanical stops and
controlled by limit switches
Safety Regarding Grip Device
 All grip devices must be designed so the work piece will

be held on power failure and other disturbances in the
robot system
 Make yourself familiar with the output used to activate
the gripper
 n your ngers w en manua y opera ng gr pper rom
FlexPendant
Electrical Safety
 Hazardous power in both the cabinet and the robot

 Net power – 400 VAC

Transformer – 260 VAC
 Rectifier – 260 VAC and 370 VDC
 Power supply – 370 VDC
 Power supply to robot motors – up to 370 VDC

 Customer equipment – …
Safety Regarding Releasing the Breaks
 The breaks on the robot motors can be manually

released.

Before the breaks
of the robot arm is are released,
supported andbewont
surecause
that the weightto
damage
individual or equipment
Operational Exercise
 Execute program
 Manual reduced speed
 Enabling device
 Manual Full speed
 Enabling device and Hold-to-run
 Automatic
 Stepwise Operation
 Fwd Bwd and limitations

E-Stop and recovery
 Debug menu
 Starting program from cursors position
 Program Reset
Jogging the robot
Robot Axis
Axis 3
Axis 4
Axis 2
Axis 1
Jogging The Robot
Motion Types
 Robot
 Major Axes 1,2,3
 Minor Axes 4,5,6
 Line r / Reorient tion

 Base
 World
 Tool
 Workobject
 Can Jog the Robot in Incremental steps.
QuickSet menu
 With the QuickSet menu you can access some often

used settings
 Mechanical unit
 Jogging mode
 (1-3, 4-6, linear or reorient)

 Increment
 Running Mode
 Step Mode
 Override Speed
The Jogging Window
Exercise 1
Programming movements
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Programming with the FlexPendant IRC5 Programming and Operation_2007
 ABB Main Menu
7/26/2019
Creating a new Program File IRC5 Programming and Operation_2007
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Creating a new Program File IRC5 Programming and Operation_2007
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Programming Positions IRC5 Programming and Operation_2007
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Positional Movements Instructions IRC5 Programming and Operation_2007
MoveJ - moves the TCP in a way which is

easiest for the robot and not in a straight line
Speed Data ToolData
MoveJ *, v1000, z50, tool0;
Robot Position Zone Data
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Zone IRC5 Programming and Operation_2007
Zone data describes how close to the destination

position the axes must be before the next instruction
can be executed.
Robot path in automatic mode. Programmed

position.
Zone size.
MoveL p2, v100, z10, tool0;
7/26/2019 Joint & Linear Move IRC5 Programming and Operation_2007
P1 Joint Move
near ove
P2
7/26/2019 Positional Movements Instructions IRC5 Programming and Operation_2007
MoveL - moves the TCP in a Linear direction

or straight line
Speed Data ToolData
MoveL *, v1000, z50, tool0;
Robot Position Zone Data
7/26/2019 ModPos IRC5 Programming and Operation_2007
Modifying the position in a positioning instructions

 Move robot to desired position
 Select the instruction or target to be changed

 Press Modify position
7/26/2019 Program Edit Menu IRC5 Programming and Operation_2007
7/26/2019 Tool Centre Point IRC5 Programming and Operation_2007
Tool Mounting
Flange
+Y
+X +Z
Relative Directions X, Y & Z.
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Tool Centre Point IRC5 Programming and Operation_2007
 Position & movement of robot always related to TCP.
 Defined as being somewhere at the end of the tool.
 Many can be defined but only one active at any one time.
 Can be programmed manually but only if accurate data.
 Normally use robot to define TCP.
 If tool is damaged or replaced, don’t change program just

redefine the tool.
7/26/2019
Tool Centre Point Definition Methods IRC5 Programming and Operation_2007
 Default Orientation (same direction as tool0)

 TCP & Z Just Z direction defined (X stays in same plane as tool0)
 TCP & Z, X both Z and X defined
 From 3 to 9 approach points
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TCP Default Orientation IRC5 Programming and Operation_2007
No rotation about X, Y or Z
Z
X
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TCP & Z IRC5 Programming and Operation_2007
Z direction defined

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TCP Z & X – Mag welding and Water cutting IRC5 Programming and Operation_2007
Both X and Z directions defined
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TCP Definition – Default Orient IRC5 Programming and Operation_2007
3 4 1
2 4
3 2
Plan view
TCP Definition – Z & X
Tool orientations are defined by the direction the tool is

positioned away from the datum point.
5
Z Elongator point
Jog robot so the tool’s intended Z and X
directions, visually align to the base
coordinate’s Z and X axis.
4 1 Jog along Base coordinate Z Axis to define

6 3 tools Z direction
2
Jog along Base coordinate X Axis to define
tools X direction
X Elongator point
Tool Centre Point Definition Method
 
Menu
 Program data
 Select tooldata
 Show data
 New…
 Name tool
 Initial value or OK and select tool in list and Edit Value
 ass:= type n g
 Press OK
 For RW5.06 Press and hold on tool in list to get context menu
 For RW5.07 Press Edit
 Select Define
 Select Method and number of Points
 Select Point 1, jog robot to calibration position and press Modify Position
 Repeat for remaining points
 Press OK
 You will need to activate your TCP in the jog window
Exercise 2
Create a Tool Centre Point
Logical
Set - turns ON a Digital Output .
Set doGripper;
- turns a
Reset OFF Digital Output.
Reset doGripper;
Logical
SetDO - changes the value of a Digital Output .
SetDO do15, 1;
or
SetDO \SDelay := 0.2, do15, 1;
SetDO \Sync do15, 1;
Routines and program flow example
main
PickPen PutPen
Main
PickPen;
MoveJ ,v200, 
,

MoveL
MoveL v100,
v300,

MoveJ ,v200, 
MoveJ ,v200,
MoveL v1000 MoveL v1000

MoveL v200, 
Set doGripper; Reset doGripper;
MoveL v200, 
MoveL v200, MoveL v200,

MoveJ ,v200, 
PutPen;
Main routine Sub routines
Routines
Repetitive instruction sequences, that occur frequently in the program,

should form their own routines.
Routines separate the program into smaller more easily understood

parts, these can then be called anywhere in the program using the
ProcCall instruction.
A Max of 16 characters are allowed for naming routines, meaningful

names such as PickBlock, CutSquare and Put_Part etc will make
the program easier to follow and operate.
Routines can be tested by moving the Program Pointer to a routine.
Routines Exercise
 Create a new routine called PickPen
 Activate your TCP

Program the robot to pick up the pen using the minimum amount of instructions
 Test this routine
 up ca e s rou ne an e e ou pu ns ruc on o pu e pen own
 Call these routines in your main routine
 Test your Main Routine

Create Routine to pick and place
Pen
Work Object Coordinate System

All program positions are attached to a work object
Wobj0 is the default coordinate system
It is advisable to use custom work objects z

p10
(900, 60, 500)
Base (0,0,0)
Wobj0
Work Objects
Custom Work Object

X1
Object
frame
User
frame
World
Work Objects contain both User and Object Frames
Work Object Frames

p10
(200, 0, 450)
(400, 0, 50)
World User
(300, 60, 0)
Object
Work Objects and External Axis

Workobject disconnected from robot world

and attached to mechanical unit
Object frame may be transposed

Defining a Work Object frames

World
World
User and Object Coordinate Systems are usually both defined

at the same position.
Work Object Definition Methods

User and Object Coordinate Systems are usually both defined

at the same position.
Jogging along axis Work Objects

Work Objects Summary

 WObjData is used to describe the area that the robot welds, processes,
moves within etc.
 If position Data is entered manually, the values can be taken from a

drawing.
 Programs can be reused quickly following changes in the robot installation

e.g. a x ure s move , us re e ne user coor na e sys em.
 Variations in how the work object is attached can be compensated for. For
this, however, some sort of sensor will be required to position the work
object.
 Robot can be jogged along the axes of the work object.
Work Object Definition Method

7/26/2019
 In the jogging window activate the TCP that you will use to define Workobject
IRC5 Programming and Operation_2007
  Menu
 Program data
 Select wobjdata and tap Show Data
 Select New…
 Name work object
 Press OK
.
 For RW5.07 Press Edit

 Select Define
 Select ‘3 points’ for user frame and ‘No Change’ for Object frame definition
 Jog the tool to the User X1 point select and Modify Position
 Repeat for User X2 and User Y1
 Press OK and view the calculated result
 Press OK to close
 You will need to activate your workobject in the Jogging window
in order to program or jog relative to it.
Exercise 4
Create a Work Object
Positional
MoveC - moves the TCP in a Circular

direction using the mid & end point of a semicircle
Speed Data ToolData
MoveC *, *, v1000, z10, tool0;
Robot Positions Zone Data
Circular Move
p1
Pick MoveC here
p4 p2
p3 ModPos MoveC here
MoveL p1, v100, fine, tool0;

MoveC p2, p3, v100, z1, tool0;
MoveC p4, p1, v100, fine, tool0;
Path Following Exercise

Start / Finish Start / Finish
Start / Finish
Direction

 Example of main routine
Exercise 5
Programming with Routines
What is a module
The Internal Structure of Modules

%%%
VERSION:1
LANGUAGE:ENGLISH
%%%
MODULE EX1
= - -
CONST robtarget p2:=[[1270.77,-93.78,386.13],[0.567071,0.054457,0.82157,0.02211],[-1,0,-
CONST robtarget p1:=[[1312.4,-132.16,381.39],[0.567077,0.054431,0.821568,0.02209],[-1,0,-
PROC main()
MoveL p1,v1000,fine,tool0;
ENDPROC
ENDMODULE
IRC5 Task Structure

Robot Task
Program File.pgf
<?xml version="1.0" encoding="ISO-8859-1" ?>
<Program>
<Module>MainModule.mod</Module>
</Program>
MainModule.mod System Modules.sys

Program Data Program Data
Main
Routine Routines Routines
IRC5 Task Structure

Robot Task
Program File.pgf
<?xml version="1.0" encoding="ISO-8859-1" ?>
<Program>
<Module>ModuleA.mod</Module>
<Module>ModuleB.mod</Module>
<Module>MainModule.mod</Module>
</Program>
Program Modules.mod System Modules.sys

Program Data Program Data Program Data
Main
Routine Routines Routines Routines
What are Modules

 A module is a group of routines and data.
 The module that contains the main routine is the MainModule

 System modules are always present in memory and can be used to save
your default data
 Filename extensions are
 XXXXX.mod Module
 XXXXX.sys System Module
 XXXXX.cfg Parameter File
 XXXXX.pgf Program File
Creating a new program in IRC5

 A new program file is created (.pgf)

 A MainModule with main routine is created
Saving program in IRC5

 A folder with the same name as the program is created
 This folder contains the MainModule, Sub modules and the
program file
 The program file (.pgf),is an extensible mark-up language,
‘XML’, file that lists all program modules in the task
 System Modules are NOT saved
Folder created with

same name
Saving Individual Modules


7/26/2019
Individual, Program or System modules can be saved
 Select in ‘Program Editor’ and ‘Save Module As…’ from File menu
Loading Programs
7/26/2019
 Loading whole programs willIRC5
overwrite existing programs
Programming and Operation_2007
 Each task will have its own program
Loading Modules

7/26/2019
Loading Program and System modules from the Program Editor
IRC5 System backup

7/26/2019
Backup_20050117
System.xml
BACK INFO
System ID
HOME
Most files off
RAPID SYSPAR
System parameters
Text information, Flash disk from
programme.id, Active system
ey. ,
keystr.txt, TASK 0 TASK 1 Multitasking
system.guid,
template.guid TASK
TASK111
TASK
PROGMOD SYSMOD PROGMOD

PROGMOD SYSMOD
SYSMOD
Empty Empty
PROGMOD
PROGMOD SYSMOD
SYSMOD
Program modules System modules
Used by system only!
Backed up regularly !!!
Exercise 6
Backup and Restore
Logical
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WaitDI - Waits until a Digital Input is set to either
high or low.
WaitDI di1, 1;
Logical
7/26/2019
WaitUntil - Waits until 1 or several Inputs have IRC5 Programming and Operation_2007
been set.
WaitUntil di1=1;
WaitUntil di1=1 AND di2=1;
AND, OR
Logical
7/26/2019
WaitTime - Waits a set amount of time.
WaitTime 0.5;
(Waits 0.5 seconds)
WaitTime \ InPos, 0.5 ;

(Optional Argument wait in position)
Logical
7/26/2019 Stop - is used to stop program execution.
Move J pTCPcheck, v100,fine,tGun;

Stop;
Exercise 7
Waiting for Inputs and Time
TPWrite
7/26/2019 TPWrite - writes Text/Data to FlexPendant.
TPWrite “Execution Started”;

TPWrite “Num of produced parts=” \Num:=reg1;
TPWrite String [\Num] | [\Bool] | [\Pos] | [\Orient]
TPErase
7/26/2019
TPErase - is used to clear the display of the FlexPendant.
TPErase;
TPWrite “Execution Started”;
TPShow
7/26/2019
TPShow - is used to switch the window on the FlexPendant.
TPShow TP_PROGRAM;
The Production Window will be active if the system is in AUTO mode.
Or
The Program Editor will be active if the system is in MAN mode.
TPShow TP_LATEST;
Show the previous FlexPendant Window before the current one.
Exercise 8
Operators Log Messages
Comment
Comment - Inserts a line of text so as to make it easier to understand
7/26/2019
the program.
Comment / Uncomment Row

Comment Row – Disabling Instructions, sometimes better than delete!
CompactIF
7/26/2019
Compact IF - where a single instruction is executed
depending on whether a condition is met or not.
IF di1 = HIGH WaitTime 0.5;

or
IF di1 = HIGH PickPart;
The instruction may be a ProcCall which calls a

routine
IF
7/26/2019
IF - where different instructions are executed
depending on whether a condition is met or not.
IF di1 = HIGH THEN IF di1 = HIGH THEN

Circle; Circle;
va ;
ELSEIF di2 = HIGH THEN
ENDIF
Outside;
ELSE
Oval;
ENDIF
Exercise 9
Decision making with ‘IF’
TPReadNum
TPReadNum - writes Text on FlexPendant and records
7/26/2019
which Numbers are pressed.
TPReadNum reg1, “How many Outsides should be produced?…”;
While
While - is used when a number of instructions are to be
7/26/2019
repeated as long as a given condition is met. IRC5 Programming and Operation_2007
WHILE reg1> 0 DO
Outside;
Decr reg1;
ENDWHILE
Repeats the instructions in the WHILE loop as long as

reg1 > 0
WHILE Condition DO... ENDWHILE
Exercise 10
Loops
Cycle Timing Instructions

ClkReset is used to reset a clock that functions as a stop
7/26/2019 watch, it sets it to 0. IRC5 Programming and Operation_2007
ClkReset clock1;
ClkStart - is used to start a clock that functions as a stop

.
ClkStart clock1;
ClkStop - is used to stop a clock that functions as a stop

watch.
ClkStop clock1;
ClkRead()
ClkRead() is a function that reads a timing clock and
7/26/2019 returns its value. IRC5 Programming and Operation_2007
ClkReset clock1;
ClkStart clock1;
MoveJ *, v1000, fine, tool0;
ClkStop clock1;
TPWrite “Cycle Time=”\Num:=ClkRead(clock1);
TPReadFK
TPReadFK - writes text on the FlexPendant and records a number.
TPReadFK nPress, “Choose?…”, “Outside”, “Circle”, “Oval” ,“”,“”;
TEST
- where different instructions are executed

TEST where different instructions are executed
7/26/2019 depending on the value of an expression or data.
TEST nPress
CASE 1:
Outside;

Circle;
CASE 3:
Oval;
DEFAULT:
TPWrite “Illegal choice”;
Stop;
ENDTEST
Programming
Practice
Course Objectives
Safety requirements for basic programming and operation
System warm start up, shut down and error recovery

Basic program operation
Basic production programming techniques


Create and use routines
Use input output instructions
Flexpendant communication instructions
Numerical data instructions

Saving and opening programs

Irc5 Programming and Operation2007

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7/26/2019 IRC5 Programming and Operation_2007

 Please ask if you would like a guided tour

Fire Assembly point

Auriga House Ground Floor Plan

Mech Fire Exit

IRC5 Training course scheme

Safety requirements for basic programming and operation

Potential Accident Risks

ABB Safety Solutions – an Overview

 Limiting the workspace

requirements for ANSI/RIA 15.06-1999.

 Built in emergency stop

Enabling Device (Dead Mans Grip)

 The enabling device is a press switch with three

 The switch must be in the middle positions in order to

Hold-to-Run (Manual 100 %)

 Only found on Version 1 FlexPendant’s

(for left or right hand)

Version 2 FlexPendant Hold-to-Run

Hold-to-Run buttons and

Hold down the play key, to run the program

Hold down the FWD or BWD key to step through program

Release the pressed key to stop execution

 The connection of safeguard stop enables inter-locking

 Possibility to activate Delayed Safeguard Stop.

Limiting the Workspace

 To avoid the risk of getting

Safety Regarding Grip Device

 All grip devices must be designed so the work piece will

 Hazardous power in both the cabinet and the robot

 Power supply to robot motors – up to 370 VDC

Safety Regarding Releasing the Breaks

 The breaks on the robot motors can be manually

 Starting program from cursors position

Jogging the robot

Jogging The Robot

 Line r / Reorient tion

 Can Jog the Robot in Incremental steps.

 With the QuickSet menu you can access some often

The Jogging Window

 ABB Main Menu

MoveJ - moves the TCP in a way which is

Speed Data ToolData

MoveJ *, v1000, z50, tool0;

Robot Position Zone Data

Zone data describes how close to the destination

Robot path in automatic mode. Programmed

MoveL p2, v100, z10, tool0;

MoveL - moves the TCP in a Linear direction

Speed Data ToolData

MoveL *, v1000, z50, tool0;

Robot Position Zone Data

Modifying the position in a positioning instructions

 Select the instruction or target to be changed

 Position & movement of robot always related to TCP.

 Defined as being somewhere at the end of the tool.

 Can be programmed manually but only if accurate data.

 Normally use robot to define TCP.

 If tool is damaged or replaced, don’t change program just

 Default Orientation (same direction as tool0)

Both X and Z directions defined

Tool orientations are defined by the direction the tool is

4 1 Jog along Base coordinate Z Axis to define

MoveC , , v1000, z10, tool0;