Abb BP Presentations4th

IRC5
Basic
Programming
IRC5 Programming Basic
Revised: 8-8-2011. REMAT L.L.C

Course Objectives
Course Objectives
Upon completion of this course the student will be able to
successfully:
 Practice safety as it pertains to the robot system.

 Identify and use the FlexPendant.
 Run the robot system in manual mode and automatic
mode.
 Interpret and respond to event messages.
Course Objectives
Course Objectives
successfully:
 Load, create, save, delete, check and edit basic Routines using the
FlexPendant and Robot Studio Online software, based on the BMW
Body Shop Standard.
 Verify robot synchronization using a calibration checking routine.
 ***Understand the creation and Definition of a tool center point, using
the 4 point method. And then the 5 point method with the Z elongator
and the X and Z elongator.
 *** Understand the creation and use of a Work Object, and its use in the
programs. The correct selection of a Work Object for motion, and its
assignment in a motion point.
Course Objectives
Course Objectives
successfully:
 Understand the use of different move instructions.

 Understand the differences with the BMW Body
Shop Move instructions and the ABB standard
motions.
 Use input and output instructions, and how to
interpret and react to them.
 Create routines, and the use routine instructions.
Modify these routines accordingly.
 Review the BMW ROBOT Standard.
Course Objectives
Course Objectives
successfully:
 Use decision making instructions depending on

different conditions of the Routines
 Use registers and math instructions to successfully
track portions of your programs.
 Use teach pendant communication instructions.
Course Objectives
Course Objectives
successfully:
 Use time instructions to help optimize your

routines.
 Use Offsets for movement instructions.
 Use work objects for position reference.
 Understand and update Revolution Counters.
Safety IRC5 Programming Basic
Introduction
 Students participating in courses

arranged by need to have
knowledge about safety
procedures from the Operator’s
Manual and Product Manual.
 In addition to instructor information,
students should study the
manuals. They must acknowledge
the understanding of safety
procedures and how to work with
robots on the training premises.
Accident Risks
 Fault tracing
 Repair
 Change of
program
 Test run
Always avoid Pinch POINTS

LOCK OUT
Use Lock out Devices.
Safety Solutions – an Overview
 Emergency stop
 Operating mode
 Auto
 Manual -< 250 mm/s
 Manual 100%
 Enabling device
(Dead mans grip)
 Safeguard stop
(Auto and Manual)
 Limiting the workspace
Law Demands
 The construct design for the robot is to comply with

requirements that are stated in i 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
Emergency Stop
 Built in emergency stop

pushbuttons are found both
on the FlexPendant and
Control module standard.
 Extra emergency stops can
be connected to the robot
systems safety chain.
Recover by resetting pushbutton and

pressing the Motors On button.
Operating Mode
 Automatic mode
 Production mode (no speed limit) max
7000 mm/s
 Manual mode
 < 250 mm/s – max velocity 250 mm/s
 100 % – Option, robot can be
jogged/tested with no speed limit.
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
released or pressed to the bottom
Enabling device
Safeguard Stop
 The connection of safeguard stop enables inter-locking

of external safety equipment, such as: doors, photo-
electric trip device, photo cells or sensible mats
 There are two categories of Safeguard stop:
 Manual – the safeguard stop is active regardless of operating
modes (Emergency Stop, General Stop, Superior Stop) (full
time stop)
 Auto – the safeguard is active when automatic mode is selected
(Auto Stop) (Part time stop)
 It is possible 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. After approx. 1
second the power supplied to the motors shuts off.
Limiting the Workspace
 To avoid the risk of getting

caught between the robot and
the perimeter safety
equipment, e.g. a fence, the
robot’s workspace can be
limited:
 All axis can be software limited
 On some robots Axis 1–3 can be
limited by adjustable mechanical
stops and controlled by limit
switches
Safety Regarding Grip Device
 All grip devices should be designed so the work piece

will be held even on power failure and other
disturbances in the robot system
 There should be possibilities to release the work piece
manually
Electrical Safety
 Hazardous power in both the cabinet and the robot

 Control Module
 Power supply – 230 VAC
 Customer equipment – …
 Drive Module
 Power Source – 480 VAC
 Power supply – 230 VAC
 Power supply to robot motors – 370VDC up to 700 VDC
Safety Regarding Releasing the Brakes
 The brakes on the robot motors can be manually

released.
 Before the brakes are released, be sure the weight of
the robot arm is supported to avoid robot arm falling and
doing damage to equipment or people.
Safety Regarding Releasing the Brakes. TDC
 Here at the TDC: The Robots have a Collision protection

device at the Gripper; if the tooling is crashed, a
breakaway clutch will release the air; and an E-stop will
stop the Robot.
 In order to recover from the E-stop under a collision with
the Gripper is to re-locate the collision protection unit
back on its place. If it does not fit, the robot brakes must
be released in order to get the Gripper back in its place.
System Description IRC5 Basic Programming
Robot System
IRC5 Flexible Controller IRB 6600 Robot Manipulator

IRC 5 Controller
FlexPendant
Robot Studio Online
Main power switches

Control Module
Drive Module
Flexible Controller Outside

Main Disconnect
E-Stop
Motors On
Mode Selector
Run Chain Status

USB Port
Ethernet Service
Hour Meter
110 V Outlet
Six Axis Robot Movement

IRC5 – FlexPendant
Graphical color touch screen 4 Hard keys for fast access
Programmable
3-way joy stick
4 Hard keys for running programs

Start
Execute Backward/Forward
Stop program
Menu Status bar
Main menu
Windows style
Quickset
“switch between
open windows/views” Note: No more than 6 windows open in the bottom.
Quickset button
Quickset button- cont.

Jogging the robot
Remember that the joystick assumes you are facing the front of the robot.
Quickset button Show Details

Jogging the robot

-3 +4
CCW
-5
+6
CCW
+2
+3 CW
CW
-4 +5 -6
-2
-5
-2
-1 +1
+4 -4
-1 +1
+6 -6
-3 +3
+5
+2
+Z Z
Y
+Y
-X
-X
X
-Y +Y
-Y +Y
+Z -Z
+Z -Z +X
+X
+X
Coordinate Systems
TCP Z
Y
X
Tool coordinates
Z Z
Y Y
X WorkObject
Base coordinates
X
Z
Y
X
World coordinates
 Inputs and Outputs (I/O Window).
Output Output
Off On
 Jogging window
Event Messages IRC5 Controller
Maintenance
Handling Events
 When a problem or possible problem occurs in the robot an Event

Message is displayed and saved in an event log.
 To Clear the Event press “Acknowledge”

 If an event is ignored a message will stay in the Status bar.
Introduction
I Event Messages are divided into.
 Information
 E.g: Hold to run must be pressed.
Information of how to proceed
 Warning
 E.g: Manual movement full speed is selected.
The operator is informed about a potential risk.
 Error
 E.g: Motor On when Emergency Stop is active.
The system cannot operate before a measure is
carried out.
Information
 E.g. Information at program start:

Warning
 When the computer detects a situation that can cause a problem or

is a safety risk
Error Message
 When the computer detects a problem or possible problem, it

generates an error message with description and action.
 Unacknowledged message is displayed in red on the status bar
Unacknowledged
message displayed
Event Message Content

 An Event Message consists of
 Description
 Consequences (optional)
 Probable causes (optional)
 Action (optional)
Tap arrow to scroll down

in message!
Reading Event Logs on the FlexPendant
 Via - Main menu

 Tap status bar – Short cut
Tap on Status Bar to see

Event log.
Or Tap then Event Log

to see Event log.
Event Log
Symbol Code Title Time stamp

Event Log
 Scroll the list with the yellow arrows

 Tap on a specific message to get more information
 The time stamp is not reliable on hundredth of seconds
Event Log
 Logs are stored under different topics

 Tap view and select the topic of interest
 Topic common consist of a mixture of the last created loggs
Event Categories
Category Error number Area__________________
Operational 10xxx Operational Status

System 20xxx Panel unit
Hardware 30xxx Board Failure
Program 40xxx Programming
Motion 50xxx Movement problem
Operation 60xxx Flex Pendant Handling
I/O communication 70xxx I/O board communication errors
ArcWeld 11xxx Process

SpotWeld 12xxx Process
Paint 13xxx Process
 Refer to the error number when support is

needed!
Logs - Events in R.S.O
 The logs or events are avalible in R.S.O

 Refered to as Events in your RobotView
Exercise 1
 BMW_EXERCISES.ppt
The Fundamentals in IRC5 Basic Programming
Robot Programming
Topics
 Create and edit a ROUTINE

 Program Move instructions
 Use velocity and zones
 Execute step-by-step
 Running in Manual mode
Sample Routine
Sample Routine
IRC5 Program File structure

Tap ABB
Tap Program Editor
Tap Debug
Tap PP to main
Or choose the pp to the
routine desired.
Notice that all the Jobs

are created under the
F25_XXX_XX module,
which will be called from
“MAIN” using the
JOBDATA
Configuration to talk to
the PLC.
 NOTE: At BMW, the MODULE with motion routines is usually
under the ROBOT’s name. The routines use F25 in front: E.g.
F25_FX10_WELD1
IRC5 Program File structure, EXAMPLE

Tasks found in backup example Module Routine
T_FAULT
T_GRIPPER
T_ROB1
UBG_20R3
DROP_GRIP1, DROP_GUN1
F25_ST20_BC2_DROP
F25_ST20_BC2_PICK
F25_ST20_FX20_WELD
F25_ST20_FX20_WELD
GET_GRIP1, GET_GUN1
UID_DATA
UIP_SPOT
DRESS_GUN1
MAINT_GUN1
MV000_HOME1EqSetup_FS1, ETC
TIP_CHANGE
TIPChangeALL
WELD_TEST_GUN1
UIP_TECH
HOME1, HOME2, HOME3
MAINT_GRIP1
MV_CALIB
MV_HOME1_HOME2, ETC
MvSynchSwitch
Creating a Module or a Routine
 To Create a new Routine: (BMW Standard)

-Tap ABB
-Tap Program Editor
Main or another
Routine is selected
-Tap Module
Find the module you
want to work on, and Show it
-Tap File/ New,
And type the correct name.
MoveJ or MoveL? And MoveJP or MoveLP?
MoveJP
Joint interpolation is often the fastest way to move between two points as
the robot axes follow the closest path between the start point and the
destination point (from the perspective of the axis angles). Use when in
open spaces such as moving from one fixture to another.
MoveLP
LINEAR interpolation is the most accurate motion between two points.

The robot will maintain a straight line of the TCP from the starting point to
the end point. If this is not possible an event will be generated. Use
when robot is moving close to other objects such as fixtures or
parts.
Ex. Move Instructions with BMW Standard
MoveJP p10, Job01, Seg01, v500, z5, tGripper\Wobj:= Fx10;

MoveLP *, Job01, Seg01, v500, z5, tGripper\Wobj:= Fx10;
In the 1st instruction above; fill in the blank:

The robot is moving to:___________in:________
P10 Joint
Which is Job #:______________________

01
And Segment #:______________________
01
At a speed of: ______________________
500 mm/sec
With a zone of: _____________________
5 mm
TCP: ______________________ tGripper
And a Work Object: ______________________
FX10
To change any part of an instruction double tap that part.

Changing a Program
Select item to
change by double
Tapping.
Then choose new

value and press
OK.
Move Instructions
Notice the differences

between the motion
points.
Note to the body shop:

Always use the
BMW Instructions,
unless they are not
Available.
Velocity and Zones
z
MoveLP p40, v1000, z40, tool0;
MoveLP p40, v1000, Fine, tool0; will

get you exactly to the point.
MoveLP p30, v300, z30, tool0;

Modifying a Position
Step to the move

to be modified.
Jog the robot to

the new position.
Tap
Modify Position
Debug option
Program
Pointer
(PP)
Checking Robot Calibration
 MoveAbsJP
 Create a new routine (GotoCalib)
 Insert MoveAbsJP instruction
 Choose star position, Debug / View Value, put all 6 axis to zero
Move Instructions
o position in air
x position on paper
ROBOT
o pHome
o p60
p40 x x p10
x p50
p30 x x p20
Inserting Move Instructions

 To add instructions to your program:
Tap Add Instruction
Jog robot into the desired position
Tap MoveJP or MoveLP
(Used at BMW)
To name the Position
Double tap the * and press new

Change the name by pressing
the … Box
Jog robot to next position
Repeat

Tap Add Instruction
Jog robot into position
Double tap the * and press new

the … Box
Repeat

Tap Add Instruction
Double tap the *and press new

the … Box
Repeat

Tap Add Instruction
Tap MoveJ or MoveL
Name the Position “*”
Tap the * and press new

the … Box
Repeat
Running Programs in Manual Mode

 Procedure
Step Action Info/Illustration
1 Switch the robot to Manual Mode. How can I see if the system is in
manual mode?
Switch from automatic to manual
mode.
xx
DANGER!
Before running the robot, please observe the safety
information in section DANGER – moving manipulators
are potentially lethal!
Running Programs in Manual Mode

 Procedure
3 Select the “program Editor” from the start menu.
4 Tap on Debug.
5 Choose the desired option. .

-PP to Main
-PP to Routine
-PP to Cursor
-Cursor to PP
-Or Call Routine
6 -In order to move, remember to press the “dead Start
man”, and then the desired start Key
Stop program
Stepping Instruction by Instruction

 In Manual Mode, the program may be executed step-by-step Line
by Line forwards or backwards.
 There are number of dedicated hardware buttons on the FlexPendant
Programmable button 1. How to define it's function is

detailed in section Hardware buttons and buttons in
Operator's manual – IRC5 with FlexPendant.



RUN button. Starts program execution.
STEP BACKWARDS button. Steps the program one

instruction backwards.
STEP FORWARDS button. Steps the program one
instruction forwards.
STOP button. Stops the program execution.
Stepping Instruction by Instruction (2)

 Select stepping mode
1 Selection of step mode. Described in Make run mode
properties selection.
 Stepping forward
1 Press the FWD button on the FlexPendant as
shown in the illustration on earlier page.
 Stepping backward
1 Press the BWD button on the FlexPendant as
shown in the illustration on earlier page.
Stopping Execution
 Procedure
2 During operation without hold-to-run control:

Press the STOP button on the FlexPendant unit.
3 When running in step-by-step mode, the robot will

stop after executing each instruction.
Program Select, Job Select
From the “Program Editor”,

After having selected PP to
Main, if running the program
with the DEAD MAN and the
Start key, there will be
several choices to select:
Start
Stop program
Exercise 2
Backup & Restore IRC5
IRC5 Programming
Basic Programming
Basic
Topics
 Backup
 Why?
 When?
 How?
 Precautions
 What is stored
Backup
 Having a valid backup is necessary for fast recovery:
 If the system behaves differently. (Other than normal)
 After software upgrades
or replacement
 Tap ABB
 Tap Backup and Restore
 Tap Backup Current
System
Backup
 What does a backup contain?
 All of the files/folders stored under Home directory in your
system on your flash drive.
 The system parameters (e.g naming of I/O signals)
 All current programs, modules, and tasks currently in memory.
 A backup contains the info that allows your system to go back to
behave as it did when the backup was taken.
Backup
 Always
 Give your backup a good name.
 Pay attention to the Path/ Location. …

 Store the finished Backup in a safe place. Like a Backup folder.
Backup and Restore – Backup the System

Use the green arrow up folder to go up a level till you get to the hdoa, or bd0.

Use the green arrow up folder to go up a level till you get to the hdoa, or bd0.
Then Pick what location you want.
To create a
new folder

Restore
 Remember
 Always check if you are restoring the correct Backup Folder.
 recommends performing a backup:

 Before installing new RobotWare
 Before making any major changes to instructions and/or
parameters to facilitate the previous setting
 After making any changes to instructions and/or parameters and
testing the new settings to retain the new successful settings
Backup
 Procedure
1 Tap .
2 Tap Backup and Restore.
xx0300000469
Backup
 Procedure
3 Tap Backup.
Xx0300000440
The set backup directory is displayed.

Backup
 Procedure
Info/
Step Action Illustration
4 Is the displayed directory the correct one?
If YES: Tap Backup at the bottom of the screen to perform
the backup to the selected directory.
If NO: Tap … to the right of the directory and proceed below.
xx0300000441
A backup file named according to the current date is created.

Backup
 Procedure
Info/
Step Action
Illustration
5 Select the desired directory.
6 When the desired directory is shown, tap OK.
xx0300000443
Backup and Restore – Restore the System
 recommends performing a restore:

 If, for any reason you suspect the program is corrupt
 If any changes made to the instructions’ and/or parameters’
settings did not prove successful, and the previous settings is
desired
 During the restore, all system parameters are replaced
and all modules from the backup directory are loaded
 The Home directory is copied back to the new systems
HOME directory during the warm start
Restore
 Procedure
1 Tap .
2 Tap Backup and Restore.
xx0300000439
Restore
 Procedure
3 Tap Restore.
Xx0300000440
The set backup directory is displayed.

Restore
 Procedure
Info/
4 Is the displayed directory the correct one?
If YES: Tap Restore at the bottom of the screen to perform
the backup to the selected directory.
If NO: Tap … to the right of the directory and proceed below.
xx0300000441
Restore
 Procedure
Info/
5 Select the desired directory.
6 When the desired directory is shown, select the

correct backup file and tap OK. Then tap Restore.
xx0300000444
The Restore is performed, and the system is warm

started automatically.
Exercise 3
Rev.Count update IRC5
IRC5 Programming
Basic Programming
Basic
Topics
 Revolution counters
 Fine calibration
Calibration – IRC5
 Fine Calibrate or Rev.Count update?

 Rev.Count update can easily be made with no special tools.
 Fine calibration needs special tools.
Rev. Counters
 Rev.Counter
 Tells how many turns the motor has rotated in the gearbox.
 If value is lost the robot cannot run any programs.
 A message notifies that the Rev.Counters need to be updated.
(e.g. If battery in SMB is drained)
Updating Rev. Counters
1. Use the Joy stick and

Move the Robot to
the Calibration
Position and align
the witness marks.
Updating Rev. Counter Procedure

1. Jog the robot to the witness marks / Calibration
position.
2. Tap : Calibration
3. Select the robot to be calibrated.
4. Tap Update Revolution Counter
5. Tap YES to confirm this is what you want to do.
6. If needed select the axes to be updated.
7. Tap Update and Update again.
Checking Robot Calibration
 MoveAbsJ
 Create a new routine (GotoCalib)
 Insert MoveAbsJ instruction
 Choose star position, Debug / View Value, put all 6 axis to zero
Fine Calibration
 Fine Calibration
 Tells the current angle of motor shaft when robot is in sync
position
 Is tuned in by or on site with special equipment
 Only needs to be retuned if a motor / gearbox is replaced
Requires special tools!

Cannot be made correctly
by eye Measurement.
Edit Motor Calibration Offsets
 Type in the fine calibration values manually

 Use moc.cfg values from Backup, Silver label in back of
manipulator with 6 values, or original Motor Calibration
values on floppy shipped with system.
Exercise 4
Tool Center Points IRC5
IRC5 Programming
Basic Programming
Basic
Tool Coordinate System
 Tool coordinate system
Tool coordinates
Y
Tool0
X Z
 Benefits using Tool:
 Jogging
 Re-orientation
 Easy to change
Z
Y  Control Speed
 Follow Path
Base coordinates
X
Coordinate System
 Different examples of tools and TCPs.
TCP
TCP
TCP
TOOL0
TCP
Tool0 is always the

ref.point for the other tools
Defining and Using a Tool
YFlange
ZFlange X Tool
XFlange
YTool
TCP with
tool calibration
Z Tool
Defining a Tool
 Create a Tooldata on FlexPendant
 Tap on ABB : Program Data : ToolData : Show Data : New
 Give tool a name.

 Tap Initial Value.
Define a Tool Center point, 4-point Method
 Tap the new tool name then press

Edit.
 Tap Define.
 Choose Method.
 No. of points if applicable.
 Choose Point1.
 Jog robot to
reference pointer.
 Tap Modify Position.
 Reposition robot.
 Repeat for all four Points.
 Tap OK.
Define a Tool Center point, 4-point Method
 Tap the new tool name then press

Edit.
 Tap Define.
 Choose Point1.
 Jog robot to
reference pointer.
 Reposition robot.
 Repeat for all four Points.
 Tap OK.
How to Define the working direction of a tool

How to Define the working direction of a tool
Choose 4 Point & Z method. To

4 3 create the fifth point for the z-
elongator move the tool so that it
2
is in perfect alignment with the
1 forth point of the 4 point method,
with a raised z value. You may
lock the joystick to allow
movement only in Z.
Define a Tool, 3-point Method, then the elongator

 tPen calibration example
Exercise 5
Defining a Tool Load
Every IRC5 has a service routine called LoadIdentify. It is

used to define the mass and center of gravity of a tool
and/or a part that the tool picks up (Payload or Loaddata).
Arm Load
PayLoad
Tool Load
ManLoadIdentify is used to define external axis loads.

_________________
Defining a Tool Load

Activate the tool and in the jog window, then. To go to the
LoadIdentify routine tap Debug : Call Routine. Select
LoadIdentify then tap “Go to”. Then hold the enable device
and start the program. In auto, press the “Drives On”
Then follow the directions as they appear on the screen.
Things to Remember
Before using Load Identification (LoadID) make sure the following

conditions are met:
Tool is correctly mounted.

Remember:
Axis 6 is not near limits. Should be “0” Create Tooldata before
Tool Load.
Axis 4 is at 0. Create LoadData before

Payload.
Arm load defined. (If it is used)
Speed override set to 100%.

Responses and Results

When asked to run in slow speed respond NO because nothing is
calculated at slow speed. However, if unsure about tool cable length
then slow speed can be used. Follow all instructions as requested.
When asked about the mass for known or unknown choose unknown
and the system will do a fine tune of the tool weight.
When asked about the angle that axis 6 is to move while performing
the test it is best to select +90 or -90 degrees. This will give the best
results. If the tooling is unable to make this amount of rotation choose
other. A minimum of 30 degrees must be specified.

At the end of the procedure the following information is given:

Mass (kg)= 2.3 Kg
Centrer of Gravity(mm) X= -87.5
Centrer of Gravity(mm) Y= 2.6
Centrer of Gravity(mm) Z= 89.1
Measurement Accuracy = (Should be greater than 80%)
(If not then run again)
Exercise 6
Create a Work Object
Figure drawn in a work object

Work Object Coordinate System
 User Coordinate System

 Object Coordinate System
Z
Y
TCP Z WorkObject
Y
X X
Tool coordinates
Z
Y
X
Base coordinates
Work Object Coordinate System
 Define coordinate systems
Object
User User
Create a Work Object
 Activate the measuring tool

(tPen)
 Create the work object
 Define the coordinates
Origin y1
x1 Work object axis Y
x2
wobjA4
Work object axis X

Activating a Work Object





Using a Work Object
MoveAbsJp pHome, v1000 , z50 , tPen;

MoveJ pTri10, v1000, z50, tPen \ WObj := wobjA4;
.... ;
o pHome
o position in air
x position on paper
Origin o pTri10 y1
/
work object axis Y
x1 --
x pTri20
pTri40 x
x pTri30
x2 --
work object
work object axis X

Exercise 7
Structured Programming IRC5
IRC5 Programming
Basic Programming
Basic
Topics
 Program I/O instructions

 Create structurized Routines
 Test your Routines
Basic I/O Instruction Choices.

To Turn Outputs on or off:
Set _____________________________
Turns output on and leaves it on
Reset ______________________________
Turns output off and leaves it off
SetDo Turns
__________________________________________
output on or off plus the optional argument
of a delay
To just change the status of an output use
_______________.
InvertDO
To turn an output on for a short time, then off again

use _____________.
PulseDo
To change the amount of Pulse time go into
____________.
Opt. Arg.
Basic I/O Instructions
The ______________
WaitDI instruction is used for waiting
for a single input.
The ______________
WaitUntil instruction is used to wait for a
complicated condition.
The ______________
Waittime instruction is used for waiting
for an amount of time.
I/O Instructions
I/O Timing
P50 p10
P20
P40
DT
P30
DT is a time dependant on processor load.

I/O Timing
p10
P50
P40
P20
P30
Structured Programming
 Structured
 Well defined routines
- easy to test TDC Example Module Routine
T_FAULT
- easy to re-use T_GRIPPER
- easy to trace faults T_ROB1
TDC_F25_R01
 Easy to read

F25_AIR
F25_PICK_CUBE
F25_DROP_CUBE
F25_TABLE_SIM1 AND 2
F25_DROP_CUBE_ON_TABLE
UID_DATA
UIP_TECH
HOME1, HOME2, HOME3
MV_CALIB
MV_HOME1_HOME2, ETC
MvSynchSwitch
Creating Routines
 How to create and program routines.
 Must be in the Program Editor.
 Tap Routines : File
 New Routine : Tap “ABC…”
to change the name.
 Tap OK.
 Select the routine.
 Tap Show routine.
Exercise 9
Program Flow IRC5
IRC5Basic Programming
Programming
Basic
Control with I/O Signals
 House keeping routine.

 Check Calibration Routine.
 Run the Table Routines depending on the decision
asked.
Program Flow – Decision Making Instructions

 In previous exercises we have been programming using
line by line execution. This is extremely limiting when
creating bigger programs.
IF Class_input6=1 THEN
Get_cube ;
ELSE
return ;
ENDIF
IF
THEN Class_input6=1
ELSE
Get_cube Return_cube
ENDIF
More Complicated Decision Making

IF Class_input1=1 THEN
Table1 ;
Optional Argument ELSEIF Class_input2=1 THEN
Table2 ;
ELSE
return ;
ENDIF IF
THEN ELSE
Class_input1=1
Table1
THEN ELSE
Class_input2=1
Table2 Return
ENDIF
Program flow IF
 To add Else and Elseif Double tap just the word IF.
Program flow IF
 The screen changes to this
Program flow IF
 And now your ready to plug in the data
Program flow IF
 Double tap the EXP
Program flow IF
 Select change data type Select Signaldi
Select the signal to use and add the expression Pick the appropriate Expression
Program flow IF
 Select Edit, Only selected for just the Highlighted cursor
Program flow IF
 Then type a 1 or 0 for on and off
WaitUntil
 To get the optional arguments Double tap the instruction
Program flow IF
 Then optional argument
Program flow IF
 Select the argument and touch use
Program flow IF
 Select the argument to use. Then close
Program flow IF
 OK
Program flow IF
 Now enter the data to use with the arguments
Exercise 10
Working with Numbers IRC5
Programming
Basic
Working with Numbers

When working with numbers use the data type ________.
num
It will usually be a ______________

Variable type of data.
This data type is designated by the letter ____

n or the letters _____
reg before
the name.
Example: nCount, reg1, reg2, nCycles, nParts
The robot has the following instructions that can be used when
working with numbers:
:= (Assign) _______________________
ADD, Clear, r, Decr Remember to create
the data you need
Example: nCounter := nCounter+1;
before you start or
r nCount;
with the instruction.
nCount:=0;
Clear nCount;
Add nCount, 1;
More Numbers
The Assign (:=)instruction can also do other mathematics such as:
___________________
ADD
___________________
Subtract
___________________
Multiply and more
IF
To make decisions using a number, use the ___________ or
Compact IF instructions.
__________
Example: IF nCount>=10 rTipClean;

or
IF nCount>=10 THEN
rTipClean
ENDIF;
Inspect every third part
 Inspect every third part

F25_TDC_R01
Get_cube Return_cube
nCount=3
di1=1 di2=1 Inspect
Table1 Table2
Good Part Bad Part
Return_cube Reject_On_table
GotoCalib
Exercise 11
Operator IRC5
Programming
Communications Basic
Communicate with Operator

Messages can be written to the screen to make a robot
program more operator friendly.

 TPWrite instruction is used to write messages to the screen.
Certain data values can also be written.
 TPErase instruction is used to clear the message from the screen.
The decision is made by the operator/inspector.

 TPReadFK
TPReadFK nFKey, “Is this a GOOD or BAD part?”, stEmpty, “GOOD”, stEmpty, “BAD”, stEmpty;
(1) 2 (3) 4 (5)
The TEST instruction can be used to make decisions.

 Select num data by Tapping “Insert Expression”


The TEST instruction is quite similar to an IF instruction.
Double Tap
the
instruction

Choose the DEFAULT and how many CASE segments you
need.

Now just tap the EXP and enter the expression
Then tap SMT and select instruction (PROCALL).
 TPReadNum TPReadNum nfigures, “How many figures do you want?

Exercise 12
Work object and More IRC5
IRC5 Programming
Basic Programming
Basic
Topics
 Clock instructions.
 Repeating a section of a program
 Understand the “For Endfor” loop.
Clock Instructions
 Clock Instructions
When using a clock as a stop watch:
ClkReset - used to set clock value to 0
ClkStart - used to begin a clock functioning as a

stopwatch
ClkStop - used to stop a clock functioning as a

stopwatch
Clock Functions
 Clock Functions
ClkRead - reads clock stopwatch value
Cdate - reads current system date
Ctime - reads current system time
 Example:
Repeat Routine/Instruction
 FOR is used when something (instruction/routine) needs

to be repeated a number of times. Either with a fixed
value or with a variable value.
 For, makes it easier to change the number of times
something needs to be repeated.
Repeat Routine/Instruction
 FOR FOR i FROM 1 TO 5 DO

5 rutin1;
ENDFOR
FOR i FROM 1 TO nReps DO

MoveJ ..... ;
MoveJ ..... ;
nReps WaitTime..... ;
MoveJ ..... ;
... ;
ENDFOR
Programming with Offsets IRC5
IRC5 Programming
Basic Programming
Basic
Circular Movement
 MoveC
pStart
p10
p20
Circular Movement
 Circle with MoveC’s
pStart
This robtarget can be copied and pasted
p30 p10
p20
Press Modify pos
Function Offset
Function Offset
In the Move command position definition, choosing
function will enable move with offset (Offs). A
displacement of the robot position.
Example
Used to displace a position
Move type Speed
from original position
C, J, L Accuracy
Move_ Offs(pStart,-100,0,0), v500, fine, toolx;

Z Offset
Position data to
Y Offset
be displaced
X Offset
Making a Perfect Circle
To Make a Perfect Circle

MoveL pStart, v500, fine, toolx;
MoveC Offs(pStart,-100,-100,0),Offs(pStart,-200,0,0),v500,z1,toolx;
MoveC Offs(pStart,-100,100,0), pStart,v500,z1,toolx;
Which direction will

the circle be drawn?
CW or CCW
Offset Example
Example
Square with Offsets
MM X
Example 100
Which quadrant will
the square be drawn?
75
1 2
50 1 2 3 4
25
100 75 50 25 -25 -50 -75 -100
Y MM
-25
pSTART
-50
3 -75 4
-100
From the previous example program:

_____________is
pSTART the FIRST point of drawing a square
and also the ____________point
LAST of the square.
Exercise 13

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IRC5

Revised: 8-8-2011. REMAT L.L.C

 Practice safety as it pertains to the robot system.

 Understand the use of different move instructions.

 Use decision making instructions depending on

 Use time instructions to help optimize your

 Students participating in courses

Always avoid Pinch POINTS

Safety Solutions – an Overview

 The construct design for the robot is to comply with

 Built in emergency stop

Recover by resetting pushbutton and

Enabling Device (Dead Mans Grip)

 The enabling device is a press switch with three

 The connection of safeguard stop enables inter-locking

Limiting the Workspace

 To avoid the risk of getting

Safety Regarding Grip Device

 All grip devices should be designed so the work piece

 Hazardous power in both the cabinet and the robot

Safety Regarding Releasing the Brakes

 The brakes on the robot motors can be manually

Safety Regarding Releasing the Brakes. TDC

 Here at the TDC: The Robots have a Collision protection

IRC5 Flexible Controller IRB 6600 Robot Manipulator

Main power switches

Flexible Controller Outside

Run Chain Status

Six Axis Robot Movement

3-way joy stick

4 Hard keys for running programs

Quickset button- cont.

Jogging the robot

Quickset button Show Details

Jogging the robot

 Inputs and Outputs (I/O Window).

 When a problem or possible problem occurs in the robot an Event

 To Clear the Event press “Acknowledge”

I Event Messages are divided into.

 E.g. Information at program start:

 When the computer detects a situation that can cause a problem or

 When the computer detects a problem or possible problem, it

Event Message Content

Tap arrow to scroll down

Reading Event Logs on the FlexPendant

 Via - Main menu

Tap on Status Bar to see

Or Tap then Event Log

Symbol Code Title Time stamp

 Scroll the list with the yellow arrows

 Logs are stored under different topics

Operational 10xxx Operational Status

ArcWeld 11xxx Process

 Refer to the error number when support is

Logs - Events in R.S.O

 The logs or events are avalible in R.S.O

 Create and edit a ROUTINE

IRC5 Program File structure

Notice that all the Jobs

IRC5 Program File structure, EXAMPLE

Creating a Module or a Routine

 To Create a new Routine: (BMW Standard)

MoveJ or MoveL? And MoveJP or MoveLP?