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ABB FlexLoader SC 6000, Product Manual

The ABB FlexLoader SC 6000 is a state-of-the-art automation system designed to optimize industrial production. With its advanced features, this product ensures superior efficiency and accuracy. For a seamless user experience, our website offers a comprehensive, free product manual for easy download at 88.208.23.73:8080.

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Common.sys

Data definitions, world zones, event routines and other stuff general to all cell types
is stored in Common.sys. This system module is accessible by all programs, and
by storing the data in this module all programs always have access to the right
data. Normally there is no additions to this module. When an integrator has general
definitions or other general data, that is preferably stored in CommonCell,
CommonSC3000 or CommonSC6000 depending on current cell type.

Description

Routine

Reads configured IO:s and loaded modules to set cell specific
configuration switches.

PROC AutoConfigura-
tion()

This routine checks if inconveyor is in position, i.e. ready to take
a new image. It is only to be used if the cell use a in and doesn't
use AUTO_GRAB of images.

FUNC bool CheckInPosi-
tion(num CameraNum-
ber)

Clears parta data for all tools for current calling robot.

PROC Clear-
ToolsPartInfo()

Activates a user-defined area where the robot may never be. This
must normally be positioned directly above the robot so that it
cannot make backward bending movements.

PROC DefForbidden-
Zone()

Activates a user-defined area where it is safe for the robot to start
its program from the start.

PROC DefSafeZone()

Called up automatically when the robot is switched on. From this
routine

DefForbiddenZone

,

DefSafeZone

and

DefMachineZone

are called up.

PROC DefWorldZones()

Finds the closest defined zone to where the robot is located right
now.

FUNC mttargetdata
getClosestZone()

This routine is called on power on event. Fill with suitable code if
needed in application.

PROC PowerOnEvent()

This routine is called on quick stop event. Fill with suitable code
if needed in application.

PROC QStopEvent()

This routine is called on restart event. Fill with suitable code if
needed in application.

PROC RestartEvent()

This routine is called on start event. Fill with suitable code if
needed in application.

PROC StartEvent()

This routine is called on stop event. Fill with suitable code if
needed in application.

PROC StopEvent()

CommonSC6000.sys

CommonSC6000.sys is supplied with FlexLoader. It handles data and routines
general to this machine type.

Standard functionality

Description

Routine

Setup of cell specific stuff.

PROC CellSetup()

Defines a zone inside machine. When the robot is inside this zone
the machine shall not be able to run because of output signal
DOF_LoaderOut.

PROC DefMa-
chineZone()

Calculate and set correct robot speed depending on weight of
part/parts in gripper.

PROC SetSpeed()

Continues on next page

Product manual - FlexLoader SC 6000

205

3HAC051768-001 Revision: D

© Copyright 2014-2020 ABB. All rights reserved.

F FlexLoader RAPID reference

F.3 FlexLoader application functionality

Continued

Summary of Contents for FlexLoader SC 6000

Page 1: ...ROBOTICS Product manual FlexLoader SC 6000 ...

Page 2: ...Trace back information Workspace Robots and Applications version a61 Checked in 2020 03 06 Skribenta version 5 3 033 ...

Page 3: ...Product manual FlexLoader SC 6000 R19D Document ID 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ...ty 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 Keep for future reference Additional copies of this manual may be obtained ...

Page 5: ...000 57 4 Commissioning 57 4 1 User accounts 58 4 2 Powering on the FlexLoader SC 6000 59 4 3 Vision system FlexLoader Vision 60 4 4 Robot system 60 4 4 1 Introduction 61 4 4 2 Calibration of the coordinate systems 72 4 4 3 Further integration steps 73 4 5 Machine tool 74 4 6 SafeMove 76 4 7 Marking unit 77 4 8 Deburring grinding unit 79 5 Interface 79 5 1 Safety interface 80 5 2 Function interface...

Page 6: ...3 10 Repair 143 10 1 Introduction 144 10 2 Conveyors 148 10 3 Illumination 149 10 4 FlexLoader Vision 151 10 5 Standard gripper 152 10 6 Re grip table 153 10 7 Turn station 155 10 8 Air cleaning box option 157 10 9 Grinding Deburring units option 160 10 10 Air preparation units 162 10 11 Marking unit 163 10 12 Robot mounting dismounting 164 10 13 Software 165 11 Troubleshooting 165 11 1 Alarms war...

Page 7: ...a specific alarm 243 G 1 16 MT_SetAlarm Sets an alarm to active 244 G 1 17 MT_SetPartInfo Sets part information of a part in a specific tracker 245 G 1 18 MT_UpdateMessageTextsIfNeeded Reads messages into message array if needed 246 G 2 Functions 246 G 2 1 MT_GetActiveAlarm Get an active alarm data 247 G 2 2 MT_GetCurrentZone Get zone where robot is positioned now 248 G 2 3 MT_GetMessage Get compl...

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Page 9: ... personnel working with an ABB robot must be trained by ABB and have the required knowledge of mechanical and electrical installation service and maintenance work Trademarks FlexLoader is a trademark of ABB References Document ID Reference 3HAA009719 001 Product specification FlexLoader SC 6000 3HAC051771 001 Product manual FlexLoader Vision 3HAC033453 001 Product manual IRB 2600 3HAC033453 001 Pr...

Page 10: ...escription and reference B Clarifications on PROFINET setup C Updated for R19D D Includes new RAPID program setup 10 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved Overview of this manual Continued ...

Page 11: ... Vision on page 59 and Product manual FlexLoader Vision Calibrate all camera work objects 5 See Product manual FlexLoader Vision Calibrate all robot work objects 6 See Calibration of the coordinate systems on page 61 Use a simple detail and perform a basic teachin 7 See Product manual FlexLoader Vision Adjust the robot program to fit the needs of the robot cell 8 See RAPID program on page 91 Perfo...

Page 12: ...This page is intentionally left blank ...

Page 13: ...nd installed correctly Personnel working with the robot must be familiar with the operation and handling of the robot as described in the applicable documents Only personnel with required training are authorized to use the system All received training must be documented in writing System integ rator Qualified elec trician Trained service and maintenance techni cian Trainedoperat or Activity X Comm...

Page 14: ...ssues WARNING Maintain established good work practices with regard to robot safety Ensure that nobody is within the safeguarded area during automatic operation CAUTION It is forbidden to enter the conveyor Ensure that nobody is on the conveyor especially when the belt is in motion CAUTION It is forbidden to step on the illumination roof the outer walls of the FlexLoader SC 6000 and on any FlexLoad...

Page 15: ...e conveyor belt Use the available lockout device The air supply must be disconnected Use the available lockout device The key for resetting the protective stop must be carried when working within the safeguarded area of FlexLoader SC 6000 Note that mechanical pneumatic or electrical energy may be stored in FlexLoader SC 6000 Take the necessary precautions when carrying out work in the robot cell A...

Page 16: ...n fall down after an extended period of depressurized state if the grippers are equipped with pressure retaining valves Be aware of crushing risk 16 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 2 Safety 2 3 Safety during setup maintenance service and repair Continued ...

Page 17: ...using can occur but will not lead to a personal hazard The working space is restricted by a set of FlexLoader SC 6000 internal zones and an additional set of FlexLoader SC 6000 external SafeMove zones DANGER The internal SafeMove configuration shall not be disabled or modified for any reason DANGER The external SafeMove configuration towards the machine tool must be adopted to the actual applicati...

Page 18: ...ser to the machine tool xx1900000185 Description Pos Standard mounting position A Alternative mounting position B The SafeMove configuration must be changed accordingly to the new work space The standard ABB guidelines for configuration and validation of SafeMove configurations shall be followed DANGER It is the integrators responsibility to modify and validate the SafeMove configuration for the a...

Page 19: ...jury or damage has been caused for any of the following reasons Use of FlexLoader SC 6000 in other ways than intended Incorrect operation or maintenance Operation of FlexLoader SC 6000 when the safety devices are defective not in their intended location or in any other way not working When instructions for operation and maintenance are not followed Non authorized design modifications made in or ar...

Page 20: ...ndustrial Robots and Robot Systems Safety Requirements and UL 1740 Standard for Robots and Robotic Equipment In Canada refer e g to CAN CSA Z434 03 Industrial Robots and Robot Systems General Safety Requirements Note The supplied equipment must not be operated until the processing machine or system in which the equipment is included has been approved according to national and regional laws and reg...

Page 21: ...and maintenance Where it is necessary to perform tasks within the safeguarded space there shall be safe and adequate access to the task locations Safety zones which must be crossed before admittance must be set up in front of the robot s working space Light beams or sensitive mats are suitable devices Turn tables or the like should be used to keep the operator out of the robot s working space A sa...

Page 22: ...nal safety center WARNING The Pluto program is a critical part of the automation cell s safety system Apart from configuration changes no other changes may be made without qualified review and validation regarding safety risks safety functions and the overall behavior of the safety system Changes to SafeMove configuration WARNING The SafeMove configuration is a critical part of the automation cell...

Page 23: ...ded will result in ser ious injury DANGER Signal word used to indicate a potentially hazardous situation which if not avoided could result in serious injury WARNING Signal word used to indicate a potentially hazardous situation related to electrical hazards which if not avoided could result in serious injury ELECTRICAL SHOCK Signal word used to indicate a potentially hazardous situation which if n...

Page 24: ... indicate where to find additional information or how to do an operation in an easier way TIP 24 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 2 Safety 2 8 Safety signals in the manual Continued ...

Page 25: ... safety instructions may also be found in other documentation Unpack the equipment and look for any signs of damage Prior to transportation untreated surfaces may have been rust proofed with a thin layer of oil which was applied before packing Wipe off any excess oil before installation using a lint free cloth Product manual FlexLoader SC 6000 25 3HAC051768 001 Revision D Copyright 2014 2020 ABB A...

Page 26: ...nd fastening elements must withstand the forces originating from the robot according to the robot product manual Use bolts with minimum dimensions M20 3 4 Unloading DANGER All lifting devices must be properly dimensioned FlexLoader SC 6000 weight is 2300 kg CAUTION When transporting using a forklift truck moving parts on or in the FlexLoader SC 6000 must not be touched or damaged The equipment mus...

Page 27: ...tes xx1900000186 xx1900000187 Initial transport of the unit using handheld lifts 1 Look for fork lift signs xx1900000188 Initial transport of the unit using handheld lifts 2 Continues on next page Product manual FlexLoader SC 6000 27 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 3 Installation 3 2 Mechanical installation Continued ...

Page 28: ...ses additional bolts can be used at positions A Note Check all delivered parts for damage If necessary take appropriate actions The FlexLoader SC 6000 can be lifted using a fork lift with the provided fork lift slots placed on the bottom of the machine xx1900000189 Lift of the FlexLoader SC 6000 using fork lift Continues on next page 28 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D C...

Page 29: ...sport of the FlexLoader SC 6000 using skates 1 xx1900000192 Transport of the FlexLoader SC 6000 using skates 2 Continues on next page Product manual FlexLoader SC 6000 29 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 3 Installation 3 2 Mechanical installation Continued ...

Page 30: ...0 at a suitable position relative to the machine tool Take especially the corridor between the FlexLoader SC 6000 and the machine tool into account If present remove all the absorb bags from the electrical cabinet and the rest of the machine Continues on next page 30 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 3 Installation 3 2 Mechanica...

Page 31: ...that must be removed Assemble the vision tower If the FlexLoader SC 6000 was shipped in a container the vision tower has to be assembled Use straps to lift the vision tower The straps shall be fastened around the beams inside the tower See image below xx1900000196 Lifting of the vision tower Continues on next page Product manual FlexLoader SC 6000 31 3HAC051768 001 Revision D Copyright 2014 2020 A...

Page 32: ...ey shall be connected to can be found in the vision tower The rest of the cables need to be connected to the terminal inside the electrical cabinet according to the circuit diagram xx1900000198 Cable path from vision tower to FlexLoader SC 6000 chassis Continues on next page 32 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 3 Installation 3 ...

Page 33: ... connection of vision tower cables in control cabinet Continues on next page Product manual FlexLoader SC 6000 33 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 3 Installation 3 2 Mechanical installation Continued ...

Page 34: ... panels on the back side of the FlexLoader SC 6000 various opening widths can be achieved 850 mm 1300 mm 1500 mm xx1900000356 Variable opening towards machine tool 850 mm xx1900000357 Variable opening towards machine tool 1300 mm Continues on next page 34 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 3 Installation 3 2 Mechanical installati...

Page 35: ...nical stability during transport Save the stabilization support when disassembling it xx1900000359 Transportation stability ensured by support Continues on next page Product manual FlexLoader SC 6000 35 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 3 Installation 3 2 Mechanical installation Continued ...

Page 36: ...ording to the image below The extension panels consist of two parts the extension panel door and the extension panel back xx1900000360 Extension panel components Description Pos Extension panel door A Sliding door B Extension panel back C Continues on next page 36 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 3 Installation 3 2 Mechanical i...

Page 37: ...corridor part is a door that can be opened the safety switch has to be connected to the safety connection point hidden in the FlexLoader SC 6000 upper rim Install the FlexLoader SC 6000 to the machine Positioning and bolting Note The fastening elements are not part of the delivery as they must be selected with reference to the floor material Use only suitable fastening elements Pay attention to th...

Page 38: ...y attention to distances implied by extension panel options xx1900000362 FlexLoader SC 6000 drilling template in mm seen from above 1 Continues on next page 38 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 3 Installation 3 2 Mechanical installation Continued ...

Page 39: ...e levelled both in the direction of movement and across it within 1 mm m 0 5mm m for rolling parts Each deviation must be corrected Drill holes and bolt the machine onto the floor There are four brackets with holes where the machine shall be bolted around the robot Continues on next page Product manual FlexLoader SC 6000 39 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 3 In...

Page 40: ... checked after tightening the FlexLoader SC 6000 to the floor If swing door and FlexLoader SC 6000 upper rim do not align the height of the floor wheel shall be adjusted The securing hook tension shall be checked and if necessary adjusted tightening the FlexLoader SC 6000 to the floor Make sure that the swing door safety switch is working properly after adjustment Safety precautions for long parts...

Page 41: ...arings belts and shafts Short rigid belt type PVC 1000 mm Normal pre tension for a rigid belt type PVC is 0 3 regardless of location of the roller drives For long rigid belts the belt must be tensioned slightly more according to the table This pre tension is also valid for belts with steering profile 1000 700 400 250 Distance between the markings when the belt is not tensioned mm 1003 702 401 251 ...

Page 42: ...401 250 5 Roller drive at front edge distance between the markings when the belt is tensioned mm Belt adjustment The belt is adjusted when FlexLoader SC 6000 is tested at manufacturing but it may need to be readjusted after transportation or after repair Check that the support rollers are installed at exactly 90 in relation to the frame extension Tighten the adjustment screw that is located on the...

Page 43: ...se conductor area depending on your environment and cable routing Power supply cable is routed through a cable flange situated in the roof of the control cabinet 3x 380 400V 50Hz Maximum short circuit current 10kA Required line fusing Circuit breaker with minimum characteristic C or better Max fuse 40A 3x 440 480V 60Hz Maximum short circuit current 10kA Required line fusing Circuit breaker with tr...

Page 44: ... psi Dry air no oil xx1900000364 FlexLoader SC 6000 connection point compressed air Air preparation adjustment The pressure switch and the safety valve have been pre configured with suitable settings For detailed information see Air preparation units on page 160 44 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 3 Installation 3 4 Pneumatic i...

Page 45: ... connected to the valve package Valve outputs Six output signals are used for valve control two wire configuration For details on CS CP pin assignment see circuit diagrams Sensor inputs Two input signals for gripper sensors are available three wire configuration For details on CS CP pin assignment see circuit diagrams Product manual FlexLoader SC 6000 45 3HAC051768 001 Revision D Copyright 2014 20...

Page 46: ...than one external master Chained connection for two doors dynamic Eden signals with signals for door locking The physical interface is constituted by terminal blocks in the control cabinet The overall safety functions in FlexLoader SC 6000 fulfill the requirements for PLd according to EN ISO 13849 1 The overall safety function in the machine tool must fulfill the requirements for PLd according to ...

Page 47: ...B DC500 series I O node connected to the robot PROFINET network The functional interface must be configured and commissioned prior to use of the FlexLoader SC 6000 Product manual FlexLoader SC 6000 47 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 3 Installation 3 6 Machine tool installation Continued ...

Page 48: ...one by trained technicians Technicians shall have a good knowledge of I O settings both in general and in RobotStudio Action Set your PROFINET network in the robot to Private network in RobotStudio Use Controller Configuration Modify IP settings to fit the pricate network 1 Configure devices for your robot controller in RobotStudio I O configurator IOC Use Controller Configuration 2 Import all nec...

Page 49: ...es knobs on the module e g ci502 pn 01 if knobs are put in positions 0 x10H and 1 x01H A cold start is needed to read new name Do not use knob positions 0 and 0 as these are used for user defined names Robot PROFINET devices such as I O nodes and Pluto gateway will get their IP address as warm start as defined in robot I O configurator Internal cell network The internal cell network connects the F...

Page 50: ...to the robot controller through the service port of the robot controller For more information see the robot product manual Factory network The FlexLoader Vision PC can be connected to a factory network The PC network connection is named Factory on physical port PoE2 Please refer to the robot controller product manual for setting the robot IP configuration on the WAN port This network is controlled...

Page 51: ...68 125 160 Pluto gateway ci502 pn 01 192 168 125 1 192 168 125 161 I O board 1 e g ci502 pn 09 192 168 125 1 192 168 125 169 I O board 9 e g bufferbelt2 separ ationbelt camerabelt pallettipper 192 168 125 171 192 168 125 171 Frequency converter 1 192 168 125 179 192 168 125 179 Frequency converter 9 192 168 125 1 192 168 125 180 Project specific equipment 1 192 168 125 1 192 168 125 199 Project sp...

Page 52: ...e or standard cell A second robot controller can be connected through PROFINET by using a PROFINET fieldbus adapter in the second controller robot option 840 3 xx1800002906 A master PLC be connected through PROFINET by using a PROFINET fieldbus adapter in the first controller robot option 840 3 xx1800002905 Continues on next page 52 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyr...

Page 53: ...WAN port as well with all internal network components connected to WAN instead of LAN2 However this will expose all components to an external network We recommend to avoid this system setup Product manual FlexLoader SC 6000 53 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 3 Installation 3 7 Network connections Continued ...

Page 54: ...lls application of authentication measures encryption of data installation of anti virus programs etc to protect the product the network its system and the interface against any kind of security breaches unauthorized access interference intrusion leakage and or theft of data or information ABB Ltd and its entities are not liable for damages and or losses related to such security breaches any unaut...

Page 55: ... FlexLoader SC 6000 and its FlexLoader Vision you agree to Microsoft s and Matrox s license agreements Product manual FlexLoader SC 6000 55 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 3 Installation 3 9 Licensing ...

Page 56: ...achine opening has to be fitted to the FlexLoader SC 6000 prior to any transport This support was delivered and fitted to the FlexLoader SC 6000 for original delivery xx1900000359 Transportation stability ensured by support 56 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 3 Installation 3 10 Moving the FlexLoader SC 6000 ...

Page 57: ...Vision For adminstration Password User name FlexLoaderAdmin FlexLoaderAdmin Robot Default credentials according to ABB default settings Password User name robotics Default User Safety related work i e SafeMove is performed with the SafetyUser account Password User name SafetyUser SafetyUser Follow ABB s advice for administration of user permissions Pluto The Pluto program normally does not need to...

Page 58: ...set key Optionally if a light curtain is present a long light curtain reset may be needed 0 5 s first followed by a second reset for the whole cell Refer to the safety manual for more detailed information 3 Check the function of the external emergency stop 4 Check the function of the external protective stop if present DANGER Do not continue to work until the safety circuits are functioning correc...

Page 59: ...etails put the sheet on an appropriate height Adjust the lens focus ring and lock it For additional help use the focus value in the large view Normally a higher value indicates a better focus Adjust the lens aperture Set the exposure time in FlexLoader Vision to 20 of the maximum value Adjust the contrast to 50 of the slider maximum Place appropriate details on the belt and adjust the lens apertur...

Page 60: ...unted on an inclined pedestal for better reach and accessibility to the machine tool In order to simplify handling and jogging of the robot the robot base coordinate system shall be parallel to the floor not angled preferably with either the X or Y axis parallel with the front of the machine tool The following values can be changed in the robot configuration cf MOC CFG in order to take inclination...

Page 61: ...o the center of the circle as pointed out by the pointing mark xx1900000410 Figure 4 1 Appearance of a typical calibration mark Calibration tool fitting The following information applies to standard grippers only Place and grip the calibration tool in the gripper Make sure that the flat surface is firmly pressed on the contact points on the adjustable finger base as pointed out in the illustration...

Page 62: ...tion tools and work objects as described in the robot manuals General work object considerations Some standard work objects in the FlexLoader SC 6000 actively use both user frame and object frame When doing standard 3 point calibration the operator must calibrate by means of the user method The object frame is used internally in order to move work objects to specific points of interest Calibration...

Page 63: ...FlexLoader SC 6000 The position of the calibration points can be found in the images below Camera coordinate system wCamera1 Coordinate system for picking from inconveyor Follow the calibration instructions in the FlexLoader Vision manual Perform a standard 3 point calibration by use of the FlexLoader Vision calibration plate xx1800000260 Disturbing parts outside of the calibration plate image can...

Page 64: ...erOut Coordinate system for leaving on outconveyor The X axis is above the idler roller shaft the Y axis is at the left belt edge and in the direction of movement of the belt and the Z axis points upwards Perform a standard 3 point calibration Afterwards call the calibration routine CalibSpeedFeederOut Depending on the use of the system the point of interest pLeaveFeederOut is used differently In ...

Page 65: ...to be defined and displaced by user code xx1900000367 Approximate positioning of wFeederOut in the FlexLoader SC 6000 Continues on next page Product manual FlexLoader SC 6000 65 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 4 Commissioning 4 4 2 Calibration of the coordinate systems Continued ...

Page 66: ...rd 3 point calibration xx1900000368 Approximate positioning of wRegrip in the FlexLoader SC 6000 Continues on next page 66 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 4 Commissioning 4 4 2 Calibration of the coordinate systems Continued ...

Page 67: ...tandard 3 point calibration xx1900000369 Approximate positioning of wTurnStation in the FlexLoader SC 6000 Continues on next page Product manual FlexLoader SC 6000 67 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 4 Commissioning 4 4 2 Calibration of the coordinate systems Continued ...

Page 68: ...the tool is used in pre configured movements xx1900000370 Approximate positioning of wAirClean in the FlexLoader SC 6000 Deburring tools wDeburr The grinding and deburring tools are accessed from their own coordinate system wDeburr In the pre configured setup wDeburr is identical to wAirClean Standard 3 point calibration Continues on next page 68 Product manual FlexLoader SC 6000 3HAC051768 001 Re...

Page 69: ...should be in the center of the sample outlet surface where the sensor will detect details Note that orientation of the tool can be used xx1900000371 Approximate positioning of wSample in the FlexLoader SC 6000 Continues on next page Product manual FlexLoader SC 6000 69 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 4 Commissioning 4 4 2 Calibration of the coordinate systems ...

Page 70: ...ration routine CalibMarker The point of interest is where the calibration tool touches the marking needle with the marking needle at a suitable marking distance Note that orientation of the tool can be used Main and sub chuck of the machine tool When using FlexLoader Vision Lite the following machine tool coordinate systems have to be defined Coordinate system wMainChuckM1 and SubChuckM1 for the m...

Page 71: ... to the calibration routine From the current robot position the object frame of wMainChuckM1 is now moved to be located exactly in the center of the main chuck Call the routine CalibSubChuck and follow the instructions On request a cylindrical detail must be gripped with the sub chuck Position the robot so that the detail can be gripped by the machine tool chuck gripper precisely centered Confirm ...

Page 72: ...lexLoader Vision manual is strongly recommended Note Immediately after initial commissioning start maintaining your own system backups If you for some reason would lose the pre installation and pre configuration data of the robot system you can find a primary backup on the FlexLoader Vision system harddisk See Software on page 164 for detailed information 72 Product manual FlexLoader SC 6000 3HAC0...

Page 73: ...ls into a standardized set of commands to be understood by FlexLoader SC 6000 This standardized set of commands can be expanded and adapted Due to the large variety of machine tool interfaces and integrator needs it is the integrators responsibility to implement this interface module See RAPID program on page 91 for further implementation suggestions Product manual FlexLoader SC 6000 73 3HAC051768...

Page 74: ...st be adopted by the integrator The Stand Still Supervision zone SST ensures that the robot is kept at standstill when the statistical outlet is opened Opening the statistical outlet while the robot is moving leads to an immediate SaveMove safety violation SST is activated by an external sensor supervising the statistical outlet The global Tool Speed Supervison zone Global_TSP limits the maximum r...

Page 75: ...exLoader SC 6000 is changed a new risk assessment with regard to SafeMove configuration must be done DANGER SafeToolZones defined within the FlexLoader SC 6000 STZ4 STZ5 STZ6 STZ7 SST1 shall not be modified more than described above DANGER SafeToolZones depending on the machine tool must be adopted to the actual layout and machine too Risk assessment shall be performed Product manual FlexLoader SC...

Page 76: ...igured for use with the FlexLoader SC 6000 Configuration changes can be done by using the SIC controller configuration software delivered on the FlexLoader Vision storage to be installed on a separate PC communication with standard USB cable Typical changes might be modifications of the marking setup files FlexLoader SC 6000 is using three different marking files for different sizes SMALL MEDIUM L...

Page 77: ...e tools according to the customer needs DANGER The original risk assessment allows users to run the deburring grinding tools under the assumption that no irreversible damage can occur If other tools are used this risk assessment has to be re evaluated by the integrator user of the FlexLoader SC 6000 Product manual FlexLoader SC 6000 77 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights r...

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Page 79: ...ordance with EN ISO 13849 1 Machine tool Safety interface to machine tool The following standard connections are provided One machine tool Two channel potential free emergency stop from FlexLoader SC 6000 to machine tool Two channel potential free emergency stop from machine tool to FlexLoader SC 6000 Two channel potential free protective stop from FlexLoader SC 6000 to machine tool Two channel po...

Page 80: ...ion of inconveyor diFeeder1ManualForward Knob for backward operation of inconveyor diFeeder1ManualBackward Knob for selecting method of operation automatic manual of inconveyor diFeeder1SelectAutomatic Sensor that indicates that parts are at the end of outconveyor diOutFeeder1TooFar Knob for selecting method of operation automatic empty ing of outconveyor diFeeder1SelectEmptying Alarm from frequen...

Page 81: ...also set the signal Belt1AllowManualOperation without the request that Belt1AllowManualOperation can continue to be set to 1 even if the operator selects automatic operation and that the robot can set the signal to 0 without prior warning This can happen for example when the robot is stopped and started Continues on next page Product manual FlexLoader SC 6000 81 3HAC051768 001 Revision D Copyright...

Page 82: ...erface is constituted by terminal blocks in the control cabinet The I O node is physically located in the FlexLoader SC 6000 controller cabinet Optionally customer specific functional interface and I O solutions can be used The following signals are defined for general use Description Name Spare input signal diSpareInterface1 Spare input signal diSpareInterface16 Spare output signal doSpareInterfa...

Page 83: ...a conveyor belt that acts as a buffer The robot picks the parts from the conveyor belt A vision system with camera that is located above the conveyor belt guides the robot to the correct grip position After that all parts under the camera have been picked the conveyor belt feeds new parts forward FlexLoader SC 6000 can be configured with a variety of useful options Please refer to Product specific...

Page 84: ...r K Vision system and illumination F Retractable sliding door with entry control G xx1900000375 Component Pos Component Pos Outconveyor E Robot A Extension panel back K Inconveyor D Continues on next page 84 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 6 Function description 6 1 Overview Continued ...

Page 85: ...mponent Pos Component Pos Re grip table S Marking unit M Deburring Tools Q Air cleaning box P Turn unit T Continues on next page Product manual FlexLoader SC 6000 85 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 6 Function description 6 1 Overview Continued ...

Page 86: ... C Sensor that detects if a part has been placed on the statistical outlet A Inconveyor InPosition sensor detects that a part has been transported into the cameras field of view D Safety sensor that ensures that robot only can move when the statistical outlet is closed B Continues on next page 86 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserve...

Page 87: ... are situated at the start of the inconveyor below the vision system screen and at the sliding door towards the machine tool The operating panel at the start of the inconveyor controls basic conveyor operation xx1900000379 Continues on next page Product manual FlexLoader SC 6000 87 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 6 Function description 6 1 Overview Continued ...

Page 88: ...Pendant safety and motor controls and a USB connection for data transfer to and from the vision system xx1900000380 Component Pos Component Pos USB connector located below the vision system screen C Robot operator panel Emergency stop Motors On Operating mode witch Auto Manual with reduced speed A Robot service port located below the vision system screen D Illumination switch turns illumin ation o...

Page 89: ...s Door reset after cell entry D Emergency stop A Reset of emergency stop E Start robot if in home position B Request cell entry and request confirmation lamp C Product manual FlexLoader SC 6000 89 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 6 Function description 6 1 Overview Continued ...

Page 90: ...nveyor Two operation positions either automatic operation or emptying Changing operation mode via operator Sensor to stop the belt when the part reaches the end of the belt Time monitored belt stop with manual reset In order for outconveyor in emptying mode to start running after powering up or emergency stop a brief switch to automatic operation and back to emptying mode is required Functions for...

Page 91: ...e of the robot program More or less extensive additions and adjustments are required depending on the design and the functionality of the robot cell For more information on robot programming see the programming manual of the robot The FlexLoader RAPID code consists of several main blocks that supports the functionality of FlexLoader systems FlexLoader application functionality FlexLoader Vision in...

Page 92: ...he parts to be run Below these are called PartCamX for a general reference to any PartCam module or specifically PartCam1 for parts to be run using camera 1 PartCam2 for parts to be run using camera 2 and so on These files can be renamed according to project needs Cell definitions like tool data work objects and so on along with some event routines and help functions are placed in Common sys and C...

Page 93: ...n WaitTime 2 WHILE TRUE DO control end of cyle or entry requests CheckSystem see example codes below WaitTime 0 05 ENDWHILE ENDPROC Generic solution Many standard feeding solutions can be handled by the following schematic code This is the most simple code example It can be used for picking from up to four feeders e g FP 100 FP 300 and FP 400 or any FlexLoader function package loop through desired...

Page 94: ...EDER_NO_RETURN SetDOSignal DOF_AllowManualModeFeeder ValToStr CameraNumber 1 Nothing found in image even after potential retries MT_SetAlarm flv_NoPartFoundError Stop EXIT TODO ONLY FOR CELLS WITH NO BELT EXAMPLE PALLET PICKER REMOVE DOWN TO NEXT DASHED LINE IF NOT NEEDED CASE CHANGE_BIN No valid Pick position in pTarget TODO Make sure pallet is switched Stop Call ConfirmPick or RefPosOut to move ...

Page 95: ...amera setting grab images automatically or only from user program bAllowAutoGrab TRUE FALSE FALSE FALSE In order to take the post pick image use the prepared routines for this Note that the RAPID modules for this are optional and might not be included in the RAPID package if not asked for See comments in RAPID code for more information about the functions in the example code VAR visionres vrResult...

Page 96: ...et CAMERA_NO_1 handle that parts occasionally are not found WHILE nAction CAMERA_NO_1 NO_DETAIL DO change camera settings if necessary DiscardAndTakeNewImage CAMERA_NO_1 WaitUntil bCoordReceived CAMERA_NO_1 TRUE SetNextTarget CAMERA_NO_1 Incr nImageRetries CAMERA_NO_1 IF nImageRetries CAMERA_NO_1 MAX_IMAGE_RETRIES CAMERA_NO_1 THEN Create alarm or inform user in some other way EXIT ENDIF ENDWHILE I...

Page 97: ...d there is a MainRob2 pgf placed in robot HOME folder then it is loaded to T_ROB2 In the same way MainRob3 pgf is loaded to T_ROB3 if it exists and MainRob4 pgf to T_ROB4 if that task exists Some communication between robot and FlexLoader Vision is general and should be communicated once for one robot controller Most of the communication is done per camera and is communicated to the robot task tha...

Page 98: ...r for multiple picking In certain applications the robot is expected to pick more than one part in one pick cycle This can reduce cycle times FlexLoader Vision needs to be configured for multiple coordinate transfer see FlexLoader Vision ConfigurationEditor The main code uses following instructions to handle this case VAR num nPartsToPick This call will make the robot pick 3 parts from the same im...

Page 99: ...s held in gripper PickPartAt sdFeederIn dnGripper MT_Log MT_LVL_INFO PickMultiPartsCam_1 Picked part no ValToStr PartNo pos ValToStr Position TODO If several parts is picked the VisionResult will be overwritten between each one If the result for each part is needed later store it somewhere MoveL Offs VisionResult CAMERA_NO_1 Target 0 0 nPZ v1000 z10 tPickingGripper WObj wCamera1 ENDPROC RAPID exam...

Page 100: ...rogram bAllowAutoGrab CAMERA_NO_1 TRUE Set image grab delay after stop at sensor nImageGrabDelay CAMERA_NO_1 0 2 Initialization that is part specific is placed in the PartCam1 module if part is run at camera 1 in the InitializeCam1 This could include part dimensions weight and which options should be used for the part Options Set value TRUE for the options that should be used for this part bUseAir...

Page 101: ...standard parts as defined by the product specification and standard 3 finger grippers in the standard FlexLoader SC 6000 configuration When zones via positions parts grippers or any other conditions are changed the integrator has to ensure that the MT_MoveRobotTo routine can execute without risk for collisions The MT_MoveRobotTo routine is by default general But due to variations it might need to ...

Page 102: ...0 CameraContrast CAMERA_NO_3 30 Positions for the currently used part can be switched on and off if required by the application enable all positions for camera 1 EnablePosition CAMERA_NO_1 1000 disable position 1 for camera 1 DisablePosition CAMERA_NO_1 1 disable all positions for camera 1 DisablePosition CAMERA_NO_1 1000 enable position 1 for camera 1 EnablePosition CAMERA_NO_1 1 Set alarm warnin...

Page 103: ...lity alarms handling initiating image acquisition or setting other parameters in such system event RAPID code Non compliance may result in undesired system behavior Note Please note that some code relies on predefined I O signal names If any of those signal names is renamed the code can t execute as desired If a signal name should change always search the code and make sure it is possible first Pr...

Page 104: ...ork objects and configurations needs to be handled The module contains parametric movement instructions option handling and machine tool handling In this case the LitePartCam1 mod is used for all parts and only parametrized code can be executed It is located in HOME FlexLoaderVisionLite Note The handling routines are called for each part Make sure your code works with all parts If not activate the...

Page 105: ...ads for this detail program lPartLite nRawDetailWeight 0 0 nGripHeightRawDetail nRawDetailHeight 2 1 0 0 0 0 0 0 Calculations for positions pLoadMachine1_MAIN trans calcPosLoadMachine pLoadMachine1_SUB trans calcPosLoadMachine nSpindleOffset nUnloadSubSpindleOffset pUnLoadMachine1_MAIN trans calcPosUnloadMachine pUnLoadMachine1_SUB trans calcPosUnloadMachine nSpindleOffset nUnloadSubSpindleOffset ...

Page 106: ...xpendant The source files for English are found under HOME Language en If the FlexPendant language is changed to Swedish the files are expected to be in the folder HOME Language sv If the standard text files don t exist for the selected language a translation must be done and new files must be created Possible languages are the same as the languages that can be used for the FlexPendant itself The ...

Page 107: ...rds can be used A wild card is a place holder that later can be changed to wanted text through RAPID code For example Header Emergency stop 1 machine number 2 The placeholder numbers can be replaced by customer defined text when RAPID calls are made in the program If the example has the identifier EMStop then a call in the program might look like this Creating alarm Emergency stop from machine num...

Page 108: ...le is also read upon restart and your new application text will also be updated now Note that if the correct language file for the application texts was not found the system will search for and use the English file instead There will be a log in the FlexPendant of that in the case this happens Stations Stations enable a good object oriented structure of the cell They open possibilities to visualiz...

Page 109: ... detailed information about the instructions see appendix MoveVia The MoveVia functionality helps to move the robot between different stations in the cell Normally in every cell there is one robot position in front of each station where robot is doing some kind of work Those points in front of the different stations in the cell are used when navigating between the different stations and are define...

Page 110: ...ore moving directly to the via position This added code must be created by the integrator who have knowledge of the specific cell ENDPROC In the mv instructions define how to navigate from any other position to this position zone Note that the routine name must be mv followed by the exact name of the corresponding mttargetdata mvZONE_HOME could in this example look like this Note that there also m...

Page 111: ...that has to be inserted to the robot controller computer before starting to log If no USB memory is inserted user will be notified of this Note The USB port in the FlexPendant is not usable for this logging purpose Use the USB ports on the main computer unit instead The log message created with a call to MT_Log will include date and time robot task log level source and message Each log will occupy...

Page 112: ...Gripper0 default to use data for tGripper1 TODO If necessary modify those cog and mass data to something that fits even better for tGripper0 tGripper0 tload cog tGripper1 tload cog tGripper0 tload mass tGripper1 tload mass TODO modify gripper setups to fit the current cell Read comments in ToolSetup for more information about this ClearToolData ToolSetup GRIPPER_0 Gripper 0 tGripper0 sdRobot StnIn...

Page 113: ...feeder handling Feeder handling includes in feeder control in cases no PLC is taking care of it and some help functions to handle leaving and running the out belt It also includes additional functions to monitor if camera belt has been in manual mode since this might indicate someone entered the cell and might have touched parts which was already found and prepared for robot picking RAPID example ...

Page 114: ...dedicated signals force alarm indication on Set DOF_Alarm switch back to automatic control Reset DOF_Alarm force warning indication on Set DOF_Warning switch back to automatic control Reset DOF_Warning force information indication on Set DOF_Information switch back to automatic control Reset DOF_Information force question indication on Set DOF_Question switch back to automatic control Reset DOF_Qu...

Page 115: ...re possible A typical machine tool communication flow for a load unload sequence as realized in the standard setup could be as follows Note that no movement is included in this schematic code Prepare for machine tool interaction Machine1Action INIT_MACHINE WaitUntil Machine1Check LOAD_MAIN_OK TRUE Machine1Action OPEN_DOOR WaitUntil Machine1Wait DOOR_OPENED 10 Enter machine tool and load part in ma...

Page 116: ...Reset doMachineSpare03 CASE CLOSE_DOOR TODO Send signal to machine CASE PREPARE_LOAD_MAIN TODO Send signal to machine WaitUntil Machine1Wait MAIN_CHUCK_OPENED 30 TRUE CASE PREPARE_UNLOAD_MAIN TODO Send signal to machine CASE PREPARE_UNLOAD_SUB TODO Send signal to machine CASE OPEN_DOOR TODO Send signal to machine CASE CYCLE_START TODO Send signal to machine PulseDO High PLength 0 5 doMachineSpare0...

Page 117: ...leaning movements if necessary StopAirClean ALL_NOZZLES Continue process Marking unit option Move robot to suitable position SetMarker Medium ExampleText StartMarker Continue process Statistical outlet The statistical outlet is most often used in FlexLoader Vision Lite applications The outlet handling is based on a few RAPID calls based on predefined cycles and sample frequency LeaveSamplePartIfNe...

Page 118: ... the robot from moving through the forbidden volume The following zones are predefined for integrator convenience and can be configured during commissioning safeVolume The robot could be started from here directly Connected to DOF_SafeZone machineVolume Robot is outside of machine tool Connected to DOF_LoaderOut The definition of these WorldZones can be changed by geometrical data defined in Commo...

Page 119: ...ired knowledge of the functions and risks related to FlexLoader SC 6000 DANGER Before FlexLoader SC 6000 is started or restarted always check that all safety devices are working properly and that no damage can be caused at startup DANGER Make sure that the air pressure to the gripper is safely shut down before replacing or repositioning the gripping fingers Product manual FlexLoader SC 6000 119 3H...

Page 120: ...eset key Optionally if a light curtain is present a long light curtain reset may be needed 0 5 s first followed by a second reset for the whole cell Refer to the safety manual for more detailed information 3 Check the function of the external emergency stop 4 Check the function of the external protective stop if present DANGER Do not continue to work until the safety circuits are functioning corre...

Page 121: ...t a complete cycle stop 2 Exit the FlexLoader Vision application 3 Turn off the computer 4 Turn off the main switch Product manual FlexLoader SC 6000 121 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 8 Operation 8 3 Shutting down the FlexLoader SC 6000 ...

Page 122: ...Note that clicking Stop will not make the robot stop immediately It will stop at the end of the cycle or after a certain maximum time Clicking Stop a second time will make the robot stop immediately See FlexLoader Vision product manual for details If an emergency situation has arisen use the emergency stop Robot stop Perform a robot stop by pressing the stop button on the robot FlexPendant The rob...

Page 123: ... the robot program if you have made any changes to it 2 Reset the cell safety see Entry control on page 125 3 Set the robot operating mode selector to automatic 4 Acknowledge the message on the FlexPendant 5 Press Motors On on the robot operating panel 6 Press the start button on the FlexPendant Note When you have made changes to the system we recommend running the first production cycles with red...

Page 124: ...or pull out depending on button model all activated emergency stop buttons to reset them The blue reset button on the operating panel starts flashing 2 Reset the emergency stop mode by pressing the blue reset button so that the flashing blue light goes off 3 Acknowledge the emergency stop message on the robot FlexPendant 4 Ensure that the external equipment is ready for automatic operation 5 If th...

Page 125: ...xample below describes operator interaction with the operator panel Standard operation The entry control to the cell during automatic operation works as follows Stop the system in a controlled way by pressing the button for an entry request C at the door The green lamp C starts to flash The system stops at a suitable moment so that the restart can occur without problems As soon as the entry is per...

Page 126: ...ally opened when the robot program has stopped As soon as the door has been unlocked the green lamp is lit without flashing Manual operation of dangerous equipment By default the protective stop is activated as soon as any FlexLoader SC 6000 door is opened This deactivates dangerous equipment in the cell Sometimes such equipment must be activated for test operation Therefore the FlexLoader SC 6000...

Page 127: ...sh the statistical outlet back in place Acknowledge error message on FlexPendant and press Motors On Press Motors On once more Press the start button on the FlexPendant As soon as the operating mode switch is set to manual mode the SafeMove manual operation override is enabled Cyclic brake check The FlexLoader SC 6000 is programmed to automatically perform the cyclic brake check that is needed for...

Page 128: ...how to perform a software synchronization In short move the robot to a suitable position preferably its home position Then call the service routine SoftwareSync 128 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 8 Operation 8 7 SafeMove operation Continued ...

Page 129: ...lose gripper 2 Open or close the turn station option gripper Toggle turn station option rotation between rotated and non rotated If the installation is equipped with an air vent valve the air supply is checked at every system startup and every time the gripper is opened or closed manually If the door is opened or the safety chain is interrupted for some reason the air supply has to be reactivated ...

Page 130: ...operating mode must be turned to manual operation This requests permission for manual operation from the robot and the lamp in the knob starts to flash The lamp lights continuously as soon as FlexLoader SC 6000 can be run in manual mode WARNING If you have stopped the robot in the middle of a started gripping manoeuvre then run the belt manually and then allow the robot to continue the grip manoeu...

Page 131: ...uld lead to unidentified parts or parts that are not picked due to false identified gripper collision Emptying in or outconveyor The inconveyor can be emptied in manual operation mode If the operator does not reach all parts on the conveyor the belt can be run backwards using the backward operation button The outconveyor must be emptied in emptying operation mode This is selected via the associate...

Page 132: ... must then pick off the parts The belt either starts automatically when the parts are picked off or the operating mode knob must be turned briefly 1s to emptying and back 132 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 8 Operation 8 9 Conveyor operations Continued ...

Page 133: ...has occurred in the system Example of possible causes Unlocked door s at startup The robot cannot leave details on the outconveyor Low air pressure A detail has been transported too far on the inconveyor Yellow light Warning The indicator lamps are yellow when there is a warning message for the operator on the FlexPendant e g there are no details on the inconveyor White light Question The indicato...

Page 134: ... so on If the robot is waiting to be able to place the next sample part it already is at standstill thus the sample outlet can be opened directly Order new sample anytime In order to take a sample part independently of the specified sampling frequency press function key on the FlexPendant The robot will place the next part in the statistical outlet and come to standstill and the sample outlet can ...

Page 135: ...l cleaning Clean the air cleaning box option Check the oil level of the compressed air lubricator option Check the electrical functions Every month Check the gripper system Clean marking unit stylus pin guide and assembly Check the safety functions Check the cables and the cable rack Every 3 months Check the connections Replace the compressed air filter cartridge Every 6 months Adjust the conveyor...

Page 136: ... week How Run the conveyor belt and check that the belt does not slip at the motor drum nor moves sideways Adjust the conveyor belt What Adjust the conveyor belt When When it starts to move sideways or slacken How Refer to the installation sections for belt adjustment and belt tension Clean the air cleaning box option What Clean the air cleaning box When Every week More often if needed for example...

Page 137: ... HLT 2 or equivalent All seals Schunk Renolit HLT 2 or equivalent Bores on the piston In addition to the described maintenance the guides of the gripper can be re lubricated as needed by means of lubricating nipples The lubricating nipples can be used instead of the air purge connection Remove the two adjustment screws for the air purge connection and replace them with two conical grease nipples F...

Page 138: ...ng on the amount of dirt that comes from the details and the surrounding Replace if necessary Check the safety functions What Check all emergency stops and emergency and safety switches When Check every month and fix when necessary Electrical function check What Check all electrical functions breakers and limit position functions When Once month Check the cables and cable racks What Check the cabl...

Page 139: ...e filter bowl in an anti clockwise direction as seen from below 4 Pull the filter bowl away from the unit 5 Turn the filter plate in an anti clockwise direction 6 Replace the filter cartridge if the pores are dirty Grasp the filter cartridge only at the lower end when it is new 7 Clean the bowl with water soap solution max 60 C or petroleum ether free of aromatic compounds 8 Fit the individual par...

Page 140: ...ont of the air cleaning box It has an inspection window that shows the oil level If the oil level is below the minimum level mark refill it by pulling the blue slider down and turn the bowl clockwise until it is loose Refill with a suitable oil until the oil level is above minimum level The recommended oil is Festo special oil as per ISO VG 32 type Festo OFSW 32 140 Product manual FlexLoader SC 60...

Page 141: ...ackup of the robot program When When you have made a program change How Follow the robot manual and save the copy onto a secure media Recovery image of the vision system What Do a complete recovery image of the vision system When After major system changes upgrades or updates How Follow instructions in the FlexLoader Vision product manual Product manual FlexLoader SC 6000 141 3HAC051768 001 Revisi...

Page 142: ...parts and remove the grease Lubricate the stylus and the stylus pin guide using the oil supplied with the marking unit Reassemble the machine and manually fasten the stylus pin guide Note please pay attention to the direction when reassembling the core see marking unit manual Avoid dust and abrasive particles on the guiding and driving elements Windows updates What Download and install of Windows ...

Page 143: ...re relatively straightforward to carry out The most important procedures can be found in this section Minor repairs that can be performed with common industry methods are not described in this manual WARNING Always follow the general safety instructions see Safety on page 13 Note How to repair the robot is described in the robot product manual Product manual FlexLoader SC 6000 143 3HAC051768 001 R...

Page 144: ...suitable exchange position The belt splice should be close to the end of the conveyor xx1900000385 Remove the relevant protection cover at the end of the belt see illustrations below Reduce belt tension by releasing the tensioning screws see illustrations below Remove the idler drum below the middle of the conveyor see illustrations below Continues on next page 144 Product manual FlexLoader SC 600...

Page 145: ...ddle of conveyor Description Pos In conveyor points of interest A Out conveyor points of interest B Continues on next page Product manual FlexLoader SC 6000 145 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 10 Repair 10 2 Conveyors Continued ...

Page 146: ...old belt splice Drag the new belt with the help of the old belt through the FlexLoader SC 6000 Remove old belt then connect and lock the new belt splice Refit the idler drum below the middle of the conveyor Take special care to the belt path below the conveyor Continues on next page 146 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 10 Repai...

Page 147: ... belt side position and stability according to instructions in the maintenance section Mount the protection cover Exchange of conveyor motor Disconnect the motor cable in the electrical cabinet Follow the instructions for belt exchange When the belt is opened replace the conveyor motor Refit the belt and check belt adjustment and stability according to instructions in the maintenance section Produ...

Page 148: ...aires have to be exchanged Use the following procedure Identify the defect luminaires Remove the fluorescent tube and the reflector Remove the inner protection housing Loosen the power cables Remove the luminaires Replace by the new luminaires and assemble in reverse order xx1900000390 Layout of luminaires and camera 148 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 20...

Page 149: ...exLoader Vision manual 6 Run the system at a slow speed for the first few picks Replacing the camera To replace the camera with the least possible impact on existing detail teachin use the following procedure WARNING Before replacing the camera Switch off the current to FlexLoader SC 6000 and lock the switch to prevent unintentional switching on 1 Disconnect the camera cable 2 Remove the screws ho...

Page 150: ...000 8 Adjust the position of the camera mounting plate Use an existing teachin as a reference The camera image field of view should look the same as in the existing teachin 9 Tighten the screws holding the camera mounting plate 10 Calibrate the vision system with robot according to the FlexLoader Vision manual 11 Run the system at a slow speed for the first few picks 150 Product manual FlexLoader ...

Page 151: ...Unscrew the gripper module 7 Fit the new gripper pneumatic connections and pneumatic tubing 8 Fit the gripper fingers 9 Restore the pneumatic supply to FlexLoader SC 6000 10 Test the new gripper Replacing the gripper valves To replace one or more valve modules Festo 1 Mark the signal cables if necessary 2 Loosen the signal connectors if necessary 3 Unscrew the two screws holding the control valve ...

Page 152: ...owed However check if the robots work object has to be redefined or if picking positions have to be adjusted xx1900000393 xx1900000394 FlexLoader SC 6000 re grip table in two different configurations 152 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 10 Repair 10 6 Re grip table ...

Page 153: ...pper Mount gripper fingers Restore pneumatic supply to FlexLoader SC 6000 Test the new gripper xx1900000395 FlexLoader SC 6000 turn station with axis in gripper Exchange of rotation module The rotation module can be exchanged by the following procedure Remove electrical and pneumatic connections to the turn station Remove turn station from holding panel by unscrewing the six holding screws Follow ...

Page 154: ...lexLoader SC 6000 turn station showing the rotation module and the valve positioning Exchange of valves For exchange of valve modules in the turn station follow the first steps of instructions above exchange of rotation module in order to obtain access to the valve package Then follow the procedure for changing valves on the gripper The valves are positioned in the turn station housing as seen in ...

Page 155: ...ool 1 D Deburring tool 2 E Valves controlling the deburring tools F Replacing the flexblow hoses If a flexblow hose holding a blowing nozzle gets unstable it can be replaced the following way 1 Use a wrench to hold the pneumatic connection Turn the flexblow hose counterclockwise until it is loose 2 Turn the blowing nozzle counterclockwise to release it from the hose 3 Replace the flexblow hose 4 A...

Page 156: ... the valves controlling the air cleaning nozzles To replace one or more valve modules Festo use the same procedure as for the gripper valves see Standard gripper on page 151 156 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 10 Repair 10 8 Air cleaning box option Continued ...

Page 157: ...escription Pos Flexblow hoses A Valves controlling the air cleaning nozzles B Signal splitter box C Deburring tool 1 D Deburring tool 2 E Valves controlling the deburring tools F Replacing the grinding deburring unit To replace the grinding deburring unit 1 Disconnect the pneumatic connection to the grinding deburring unit Continues on next page Product manual FlexLoader SC 6000 157 3HAC051768 001...

Page 158: ...r more valve modules Festo can be replaced by the following procedure 1 Disconnect the pneumatic connections that connects the valves to FlexLoader SC 6000 2 Disconnect the electrical connection to the distributor box 3 Disconnect the pneumatic connections and the two M4 screws placed underneath holding the valve 4 Replace the valve with a new one 5 Reinstall the air cleaning box in reverse order ...

Page 159: ...st be updated CAUTION Run the system at a reduced speed during the first cycles to ensure that the air cleaning box is in the correct position Product manual FlexLoader SC 6000 159 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 10 Repair 10 9 Grinding Deburring units option Continued ...

Page 160: ...ar 7 psi Pressure switch on safety valve right Switching pressure set point 4 bar 58 psi Hysteresis 0 0 bar 0 psi Make sure that the earthing strap is electrically connected to the outer housing To change the values do as follows 1 Press EDIT on the pressure switch 2 Press EDIT button until the display says SP 3 Use the UP DOWN button to set the the correct value 4 Press EDIT button once and the d...

Page 161: ... valve fully situated on top of the safety valve 2 From this position close the valve by turning the screw five turns clockwise 3 If the valve opens too fast or too slow adjust the valve by half a turn at the time until the system operates correctly 4 Make sure the pressure switch is adjusted as described above Product manual FlexLoader SC 6000 161 3HAC051768 001 Revision D Copyright 2014 2020 ABB...

Page 162: ...nit Replace with a new marking unit in reverse order CAUTION If there are any changes in position design between the new and old unit the robot positions need to be updated CAUTION Run system at slow speed for the first cycles to ensure the air cleaning box is in correct position 162 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 10 Repair 1...

Page 163: ...of the hanging robot Mount the robot to FlexLoader SC 6000 by the following procedure Use a fork lift and place the pallet with the robot as close as possible to the FlexLoader SC 6000 robot pedestal Attach straps to robot Attach the straps to a forklift with enough handling weight to handle the robots weight Place the robot at the FlexLoader SC 6000 robot pedestal Secure the robot by mounting the...

Page 164: ...der Vision PC hard disk Copy this backup to a USB memory stick and restore it with standard robot backup restore procedures see the robot product manual FlexLoader Vision backup and recover A FlexLoader Vision backup that restores the system to its factory settings is saved on a separate USB drive See the backup and recovery information in the FlexLoader Vision manual for more information 164 Prod...

Page 165: ...n zone of the robot cannot be determined Jog robot to suitable position PRESENT_POSITION_UNIDEN TIFIED 91 207 R Wrong signal specification when calling configuration routines Check I O configura tion and signal names CANT_FIND_SIGNAL_NAME 91 208 R No image coordinate received from FlexLoad er Vision IMAGE_GRABBING_PROBLEM 91 300 Check FlexLoader Vision status B No detail found by FlexLoader Vision...

Page 166: ...tical outlet Wait until robot is in SafeStandStill STATISTICAL_OUTLET_AC CESS 91 404 B Detail in statistical outlet Open statistical outlet and remove detail STATISTICAL_OUTLET_RE MOVE 91 405 Restart robot with button 4 on the FlexPend ant R No detail in the statistical outlet when expec ted Check the statistical outlet sensor SAMPLE_OUT LET_SENSOR_ERROR 91 406 B Detail ready in statistical outlet...

Page 167: ...conveyor with outconveyor auto manual switch R Faulty signal from TooFar sensor outconvey or ALARM_TOO_FAR_FAULTY_OUT BELT1 91 320 Check sensor function R Inconveyor is in manual mode and cannot be controlled by robot when necessary ALARM_IN_BELT_MANU AL_MODE 91 321 R Robot is blocking possibility for emptying mode Wait for robot block signal to reset or reset it manually ALARM_RO BOT_BLOCK_EMPTYI...

Page 168: ... necessary be reset by shortly pressing the red button in the control cabinet It is located directly on the side of the marking unit control unit 168 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 11 Troubleshooting 11 1 Alarms warnings and informations and troubleshooting Continued ...

Page 169: ...ing of the robot according to the robot product manual Disposal of storage media Before disposal of any storage equipment anything from an SD card to a complete controller make sure that all sensitive information has been deleted Tip To remove all data from the SD card use the Clean Disk function part of Recovery Disk function in RobotStudio See Operating manual RobotStudio Product manual FlexLoad...

Page 170: ...EE should not be mixed with general household waste If you wish to discard electrical and electronic equipment EEE please contact your dealer or supplier for further information Disposing of this product correctly will help save valuable resources and prevent any potential negative effects on human health and the environment which could otherwise arise from inappropriate waste handling For disposa...

Page 171: ...rdous material The table specifies some of the materials in the FlexLoader function package and their respective use throughout the product Dispose of the components properly to prevent health or environmental hazards Example application Material Main computer Batteries Lithium Serial measurement board Cables Copper Motors Cabinet structure plates screws etc Steel Cables connectors etc Plastic rub...

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Page 173: ...rts Spare part list is not included in the manual but is delivered as a separate document Product manual FlexLoader SC 6000 173 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 13 Spare parts ...

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Page 175: ...is manual but delivered as separate document Pneumatic diagram The pneumatic diagram is not included in this manual but delivered as separate document Product manual FlexLoader SC 6000 175 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved 14 Diagrams ...

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Page 177: ...outconveyor 1 during emptying nTimeoutEmptyingOut belt1 If this flag is set to 1 the sensor diOutFeeder1TooFar is ignored nDisableTooFarOutbelt1 The time which the outconveyor must run in order to allow new details to be put on the outconveyor nRunTimeFeederOut Description General parameters Delay time for the signal DOF_AllowRobotLeaveFeederOut1 which takes into account ramp down time of the belt...

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Page 179: ...requency inverter outconveyor diAlarmU12FeederOUT Runs inconveyor forward doRunForwardBelt1 Runs inconveyor backward doRunBackwardBelt1 Indication for operator when running inconveyor manually is permitted doManualLampFeeder1 Run outconveyor doRunFeederOut1 Entry control and safety The following signals are defined for entry and safety related tasks e g operator panels located at gates Description...

Page 180: ...r doValve3Gripper Spare signal on robot arm connected to valve Can be used by integrator doValve4Gripper Spare signal on robot arm connected to valve Can be used by integrator doValve5Gripper Spare signal on robot arm connected to valve Can be used by integrator doValve6Gripper Turn station Description Name Open gripper doTurnStationGripperOpen Rotate turn station doTurnStationRotate Air cleaning ...

Page 181: ...x is in position and ready to receive parts diSampleOutletInPosition Sensor Light signals The following signals are defined for signaling operation status to the operator Description Name Controls the red component of RGB signal light doRedRGB Controls the green component of RGB signal light doGreenRGB Controls the blue component of RGB signal light doBlueRGB Controls the lightning for the vision ...

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Page 183: ...D code for in depth information WriteStrBin ioSicMarker LOADFILE MEDIUM 0D 0A Response LOADFILE OK 0D 0A WriteStrBin ioSicMarker SETVAR STRING example text 0D 0A Response SETVAR OK 0D 0A WriteStrBin ioSicMarker RUN 0D 0A Response RUN OK 0D 0A WriteStrBin ioSicMarker RUN SIMULATION 0D 0A RUN OK 0D 0A Response RUN OK 0D 0A A number of advanced commands can be issued to the marking unit controller Pl...

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Page 185: ... pre configured for use with FlexLoader SC 6000 There are three pre configured marking files that are used with FlexLoader Vision SMALL MEDIUM LARGE These files can if needed be changed by the use of the marking units configuration software se reference section on auxiliary software When changing marking files keep the following information in mind The part specific marking string is written to th...

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Page 187: ...ns of the manual on the ABB website Overview of the frequency inverter ACS355 xx1800001095 Figure E 1 Overview of the frequency inverter ACS355 1 LCD display divided into five areas a Upper left Control location LOC drive control is local that is from the control panel REM drive control is remote such as the drive I O or fieldbus b Upper right the unit of the displayed value c Center variable Gene...

Page 188: ... local and remote control of the drive 7 DIR Changes the direction of the motor rotation 8 STOP Stops the drive in local control 9 START Starts the drive in local control Operating the frequency inverter You operate the frequency inverter with the help of menus and keys Select an option e g operation mode or parameter by scrolling the or keys until the desired option is visible in the display and ...

Page 189: ...arameter with underneath This indic ates that you can now change the value of the parameter Note When is visible pressing and simultaneously changes the dis played value to the default value of the parameter 6 Use and to modify the parameter value When you have changed the paramet er value starts flashing To save the displayed parameter value press To cancel the new value and keep the origin al pr...

Page 190: ... BRAKING DC HOLD CTL 2104 3 3 s DC BRAKE TIME 2104 0 Not Selected ACC DEC 1 2 SEL 2201 0 5 0 5 s ACCELER TIME 1 2202 0 1 0 1 s DECELER TIME 1 2203 103 OUTPUT FREQ SIGNAL 1 PARAM 3401 5 THERM 0 SENSOR TYPE 3501 7 DI5 INPUT SELECTION 3502 User adjustable parameter settings The following parameter settings are typically adjusted by the user User value U12 User value U11 Default Description Parameter ...

Page 191: ...r a while When the problem has been resolved the motor can be restarted Alarm codes 2001 Current limit 2002 Overvoltage 2003 Undervoltage 2009 High temp frequency inverter Error codes 0001 Current limit exceeded 0002 Overvoltage 0003 High temperature frequency inverter 0004 Short circuit in motor cables or motor 0006 Undervoltage 0009 High motor temperature Product manual FlexLoader SC 6000 191 3H...

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Page 193: ...nFeederOut t tooldata e g tCalibTool1 v speeddata e g vLowSpeed w wobjdata e g wCamera1 Several seldom used data types do not obtain their own prefix e g shapedata errnum wzstationary Variables inside records do not use prefixes either Variables are named with prefix and a descriptive name where start of new words is indicated with capital letters see examples above Constant prefixes and naming Co...

Page 194: ...unctions for using the original camera to grab a second control image and then return settings to normal again Loaded in all motion tasks VisionControlImage sys VisionCom mod This module contains routines needed for background communication between the robot and FlexLoader Vision and must not be changed VisionCom synchronizes the vision system and conveyor events with robot program execution It re...

Page 195: ...et according to the desired system behavior for each camera Normally set from InitializeCamX in ModCamX TRUE When the belt has been run and the InPosition sig nal set a new image is taken by the automatic device FALSE Imaging must be explicitly initiated by the robot program by calling up GrabImage AL LOW_AUTO_GRAB 4 Important routines Description Routine If SetNextTarget returns valid grip inform...

Page 196: ...uation of what to do If user wants this routine could do image retires too FUNC visionres GetNew VisionResult num Cam era num DesiredPosi tion num MaxImageRe tries num TimeoutTime Vision Called up by the user to take a new image with the selected camera The routine waits until the accompanying signal InPosi tion is 1 and sends a command to FlexLoader Vision to take a new image with nCamera Note Do...

Page 197: ...et For system internal usage PROC ClearCoordin ates Called up to deactivate a certain teachin position in FlexLoader Vision All positions can be locked at the same time by specifying a value nPosition 999 PROC DisablePosi tion nCamera nPosi tion Called up to activate a certain teachin position in FlexLoader Vis ion All positions can be enabled at the same time by specifying a value nPosition 999 P...

Page 198: ...nCamera sGroupName sDetail Name Called up to set a new edge height in the selected camera Usually used when running stacks on the belt PROC SendEdge Height nCamera nEdgeHeight For system internal usage PROC SendGrab nCam era For system internal usage PROC SendStop Called up to set an alarm in FlexLoader Vision from the robot PROC SetAlarm sMes sage Called up to set an information message in FlexLo...

Page 199: ...t as master directly to FlexLoader Vision The routines in this modules connects to VisionSlave functionality to handle this Important routines Description Routine Starts FlexLoader Vision PROC VisionControl Start Stops FlexLoader Vision PROC VisionControl Stop Changes part selection for a selected camera in FlexLoader Vision This routine only changes part in one selected camera PROC VisionControl ...

Page 200: ...es robot to camera X second image position and a MoveFromControlImageX that moves away out of camera X area after image These instructions should be purely movements X is the number of the camera which should be used for the second image FUNC visionres Con trolImage num Camer aNumber num Con trolImagePosi tions num NormalIm agePositions camera setting CameraSetting sControl camerasetting CameraSet...

Page 201: ...d is always supplied with FlexLoader Vision It is the main robot program of the system MainModule mod provides the following routines Description Routine Checks whether anyone has requested entry to the cell or has been inside the cell The routine also ensures that new images are taken when the cell is started after someone has been inside This happens as it can no longer be guaranteed that the pa...

Page 202: ...iply routine if several machines PROC LoadMachine Handles the main flow of the cell together with main This include to check status of machines and so on to figure out what to do next All these kind of selections and checks that are part specific is placed in this routine The rest is placed in either of the routines depending on how the integrator wants the structure PROC MainRoutine1 Template rou...

Page 203: ...h the part prior to loading into the machine tool Change according application PROC PerformPrepare Options Machine tool handling procedures and functions Note that the GLOBAL procedures like LoadMachine_MAIN are called from the MainRoutine and perform logical work whereas the LOCAL routines like LoadMAIN perform the actual movement work Description Name This procedure is for moving the robot into ...

Page 204: ...t unloading and then loading the main chuck in machine tool PROC UnloadMa chine_MAIN_Load_MAIN This procedure is for unloading the sub chuck in the machine tool PROC UnLoadMa chine_SUB This procedure unloads the part in the main chuck Make sure to use EnterMachine before all loading unloading and ExitMa chine after all loading unloading LOCAL PROC Unload MAIN The unload position is always calculat...

Page 205: ...bot is switched on From this routine DefForbiddenZone DefSafeZone and DefMachineZone are called up PROC DefWorldZones Finds the closest defined zone to where the robot is located right now FUNC mttargetdata getClosestZone This routine is called on power on event Fill with suitable code if needed in application PROC PowerOnEvent This routine is called on quick stop event Fill with suitable code if ...

Page 206: ...ment User could add own code for special cases for example if robot is inside a machine a couple of extra positions might be needed first before moving to via position Also called from built in FlexLoader Library Add in routines PROC MT_MoveToVia mttar getdata Target Help user solve problem if robot is standing in an undefined zone Also called from built in FlexLoader Library Add in routines PROC ...

Page 207: ...e figure thereafter xx1900000400 Schematic motion overview Continues on next page Product manual FlexLoader SC 6000 207 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved F FlexLoader RAPID reference F 3 FlexLoader application functionality Continued ...

Page 208: ...9 Schematic zone overview 208 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved F FlexLoader RAPID reference F 3 FlexLoader application functionality Continued ...

Page 209: ...ad Compensation PROC CalibLoadCom pensation Calculate load position inside machine FUNC pos calcPosLoad Machine num nSpindleOffset Calculate grip position for left over part FUNC pos calcPosUn loadLeftOverPart num nSpindleOffset Calculate unload position inside machine FUNC pos calcPosUn loadMachine num nSpindleOffset Checks if current light branch has been tested and validated FUNC bool Check IfL...

Page 210: ... tion sensor This module is loaded into a separate background task FeedLineInPosition mod Specialized task for handling start and stop of inconveyor with short response time regular operation with ToFar sensor This module is loaded into a separate background task FeedLineToFar mod Specialized task for checking if operator has manually oper ated any conveyor This module is loaded into a separate ba...

Page 211: ... indic ation light handling Indication Lights_shared sys Module for improved and safe handling of gripping functions by the operator Loaded into own background task ToolControlMenu mod Module for convenient and common tool handling Loaded into all motion tasks Tools_base sys Shared module for some task shared data and routines for tool handling Tools_shared sys EntryControl mod This background tas...

Page 212: ...t num feederNo If selected it will also check if feeder out has moved and in that case re initialize the feeder This procedure runs feeder one part length desired space space between parts Also resets and initializes variables for feeder PROC RunFeed erOut num feed erNo num run Length num runTime Setup restrictions for out feeder belt and part This procedure should be called once before start usin...

Page 213: ...C num cal cInchToMM Calculates Kg value from Lb FUNC num calcLb ToKg This function returns a new tooldata updated with a TCP matching position of currently found object in FlexLoader Vision FUNC tooldata calcToolData robtarget pickPos wobjdata pick WorkObject num Robot Number Use this procedure first before teaching or using positions that need a TCP that is attached to the FlexLoader Vision posit...

Page 214: ...dex Sets a configuration value depending on if passed IO exists in system or not PROC SetConfiguration Variable INOUT bool ConfiguratioValue string SignalName switch OutputSignal switch In putSignal Set a digital output signal with signal name passed as a string PROC SetDOSig nal string Signal Name dionum Value Returns tooldata value with offsets according to optional argu ments If no optional arg...

Page 215: ...message type PROC IndicationLights SetupLightTower Assign correct color to each message type PROC IndicationLights SetupRGBLights ToolControlMenu mod The module ToolControlMenu mod handles the FlexPendant menu for manual control of tool signals This module depends on the use of Tools_shared sys to declare all tools in the system As long as this is done no further input is needed in ToolControlMenu...

Page 216: ...d from all loads currently held by robot PROC AddToSumGrip Load INOUT loaddata pSumLoad tooldata ActiveTool loaddata ThisLoad tooldata This Tool Checks if a specific tool is defined in system FUNC bool CheckVal idTool num RobotNum ber dnum ToolNumber Clears tooldefinition data If using optional argument only remove that specific data else remove all PROC Clear ToolData bool Rob Hold num RobotNum b...

Page 217: ...OpenOrOn string CloseOrOffSignal num WaitTimeCloseOr Off string LabelCloseOr Off string BlockManual Control Updates tooldefinition data Finds the robot tool through it s ToolNumber and updates all data for that tool which is passed in the arguments Data which is not passed as argument will not be touched PROC ToolUpdate bool RobHold num Robot Number dnumToolNum ber string La bel tooldata Tool_Data...

Page 218: ... interface to a lathe machine tool TemplateMa chine_Lathe sys Note If more machine tools is used than what is handled by the template then the functionality can be enhanced by the integrator TemplateMachine_CNC sys This module contains a number of predefined procedures or functions for communication with the machine tool Description Name Intended use is for index table machines to keep track of pa...

Page 219: ...ote We recommend the use of an additional background task if the robot cell requires time critical machine tool communication Note Operation with more than two machines requires the creation of these routines with equivalent names e g Machine3Action and Machine4Wait TemplateMachine_Lathe sys This module contains a number of predefined traps for information transfer with machine tool Description Na...

Page 220: ...dard features in Machine1Action Machine1Check and Machine1Wait are correctly implemented Malfunction and collisions might otherwise occur Note We recommend the use of an additional background task if the robot cell requires time critical machine tool communication Note Operation with more than one machine requires the creation of these routines with equivalent names e g Machine2Action and Machine3...

Page 221: ...B CYCLE_START INIT_MACHINE STOP_MACHINE There are further predefined values in GlobalCodeAndConfig sys that can be implemented in machine communication modules Product manual FlexLoader SC 6000 221 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved F FlexLoader RAPID reference F 7 FlexLoader machine tool interface functionality Continued ...

Page 222: ... for turn station Could be loaded in all motion tasks but currently only prepared for T_ROB1 TurnStation sys Contains helper functions for setting up and controlling the washer unit Could be loaded in all motion tasks but currently only prepared for T_ROB1 Washer sys Contains helper function for cyclic break check Could be loaded in all motion tasks but currently only prepared for T_ROB1 SafeMove ...

Page 223: ...k if needed to leave sample part and call routine to do so if true PROC LeaveSamplePar tIfNeeded Prepares everything for robot to leave in statistical outlet PROC PrepareLeaveIn StatisticalOutlet Make sure robot stops and then tells operator to fetch part from statistical outlet PROC PrepareSample PartRemoval Washer sys The module Washer sys handles functionality related to the washing unit Descri...

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Page 225: ...mples The following example illustrates the instruction MT_ClearAllPartInfo Example 1 MT_ClearAllPartInfo This will clear all part info in the all trackers defined in the program Product manual FlexLoader SC 6000 225 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved G FlexLoader Library Add in reference G 1 1 MT_ClearAllPartInfo Clears all part tracker information RobotWare OS ...

Page 226: ...arPartInfo Station StationName Index Station Data type mtstationdata The station data which part tracker data should be cleared in StationName Data type string Name of the station data declaration as a string Through this name the correct mtstationdata definition will be found and the corresponding part tracker where part data should be cleared Index Data type num Index number of the part tracker ...

Page 227: ...ex 1 will be used internally Arguments MT_CopyPartInfo FromStation FromStationName FromIndex ToStation ToStationName ToIndex FromStation Data type mtstationdata The station to copy part tracker data from FromStationName Data type string The station to copy part tracker data from In this argument the name of the mtstationdata definition is passed as a string FromIndex Data type num Specifies which ...

Page 228: ... in ToStation to copy part info to 228 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved G FlexLoader Library Add in reference G 1 3 MT_CopyPartInfo Copies part info between trackers RobotWare OS Continued ...

Page 229: ...Arguments MT_CreateAlarm Identifier Header Text Category ErrorNumber Domain Identifier Data type string System unique string that gives the possibility to point to a specific message Header Data type string Header text for the message Text Data type string array Up to 8 strings could be passed in this message body text Category Data type icondata Defines the category of an alarm If not used this w...

Page 230: ...type The text will appear with wildcard 1 replaced with AddText Example 1 PROC ErrWriteExample VAR mtmsgdata Alarm Alarm MT_GetMessage myAlarm MT_ErrWrite Alarm WildCardTexts AddText ENDPROC Arguments MT_ErrWrite Message WildCardTexts Message Data type mtmsgdata The message data that should be used to write message to error log WildCardTexts Data type string array String array of wild card text to...

Page 231: ...lCode MachineCode Routine Part Tool PLoad State UserDef Station Data type mtstationdata The station to fetch part tracker data from StationName Data type string The station to fetch part tracker data from In this argument name of the mtstationdata definition is passed as a string Index Data type num Specifies which part tracker index to fetch part info from ProgCode Data type dnum Stores ProgCode ...

Page 232: ...pe tooldata Stores Tool into this INOUT argument PLoad Data type loaddata Stores PLoad into this INOUT argument State Data type mtpartstate Stores State into this INOUT argument See mtparttracker UserDef Data type string Stores UserDef into this INOUT argument See mtparttracker 232 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved G FlexLoader ...

Page 233: ...g example illustrates the instruction MT_GoHome Example 1 MT_GoHome Moves robot to position in the mttargetdata ZONE_HOME Product manual FlexLoader SC 6000 233 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved G FlexLoader Library Add in reference G 1 7 MT_GoHome Moves robot to home zone RobotWare OS ...

Page 234: ...ding of all texts from csv files even if the language selection didn t change since last time All current messages will be removed first Example 1 MT_InitializeMessageHandling ForceLoading Arguments MT_InitializeMessageHandling ForceLoading ForceLoading Data type switch Forces loading of all messages even if there hasn t been a language change or text file changes 234 Product manual FlexLoader SC ...

Page 235: ...utput in the csv file could look like below Arguments MT_Log Level Source Msg Level Data type mtloglevel Specifies the log level of this log message Source Data type string Specifies the source of this log message for normally routine name Free for user to use it as something else than routine name msg Data type string array An array of log message lines Product manual FlexLoader SC 6000 235 3HAC0...

Page 236: ...mtloglevel for more information about the different log levels Arguments MT_LogEnable Enabled Level Enabled Data type bool Set to TRUE to activate logging Set to deactivate logging Level Data type mtloglevel Specifies which kind of log level which should be turned on or off If argument not used turn on or off all kind of log levels 236 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Co...

Page 237: ... the FromStation tracker will have empty part data information Arguments MT_MovePartInfo FromStation FromStationName FromIndex ToStation ToStationName ToIndex FromStation Data type mtstationdata The station to move part tracker data from FromStationName Data type string The station to move part tracker data from In this argument the name of the mtstationdata definition is passed as a string FromIn...

Page 238: ... ToStation to move part info to 238 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved G FlexLoader Library Add in reference G 1 11 MT_MovePartInfo Moves part info between part trackers RobotWare OS Continued ...

Page 239: ...eName CheckStart Data type switch Use switch if the robot should first move to the current zone via position Normally the robot is in the current zone via position when calling this and in that case don t use this switch If using this argument the user will first get a question if robot should start moving straight for the via position TargetZone Data type mttargetdata The mttargetdata of the zone...

Page 240: ...e Data type switch Only usable in virtual controller If not used in virtual mode robot will always go directly to closest without any checks If used robot will act as in auto and check distance to closest position and if too far away ask the operator if movement to that position is ok or not 240 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved...

Page 241: ...pendant and allow it only in manual mode Basic examples The following example illustrates the instruction MT_MoveToZoneMenu Example 1 MT_MoveToZoneMenu If robot is in manual mode the selection list of possible zones to move to will show on Flexpendant Product manual FlexLoader SC 6000 241 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved G FlexLoader Library Add in reference G ...

Page 242: ... card number 1 myWildCard Note that if more than one wild card was used in the alarm creation or if more was passed to the reset above it is not an exact wild card match and the reset would not be done Arguments MT_ResetAlarms Identifier WildCardTexts Identifier Data type string System unique string that gives the possibility to point to a specific message to reset WildCardTexts Data type string a...

Page 243: ...xt 1 text 2 myAlarm is set to active with the wild card texts text 1 and text 2 Arguments MT_SetAlarm Identifier WildCardTexts Identifier Data type string System unique string that gives the possibility to point to a specific message WildCardText Data type string array String array of wild cards text to use for this message Product manual FlexLoader SC 6000 243 3HAC051768 001 Revision D Copyright ...

Page 244: ...on to set part tracker data to StationName Data type string The station to set part tracker data to In this argument name of the mtstationdata definition is passed as a string Index Data type num Specifies which part tracker index to set part info to ProgCode Data type dnum ProgCode to set to the specified part tracker See mtpartdata State Data type mtpartstate State to store in the specified part...

Page 245: ...Example 1 MT_UpdateMessageTextsIfNeeded ForceLoading This will always update message texts from files to RAPID system Arguments MT_UpdateMessageTextsIfNeeded ForceLoading ForceLoading Data type switch Use if texts always should be updated independent of changes to language settings or file modifications Product manual FlexLoader SC 6000 245 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rig...

Page 246: ...T_GetActiveAlarm Index 1 This will fetch the complete active alarm data for message with index 1 latest alarm created and store it into Alarm Return value Data type mtactivealarmdata Arguments MT_GetMessage Index Index Data type num Index of the alarm that should be returned from the active alarm list If not used index 1 latest created alarm will be returned 246 Product manual FlexLoader SC 6000 3...

Page 247: ...re the robot is positioned right now and returns matching mttargetdata which is stored in Current Return value Data type mttargetdata Target data matching the current position of the robot Arguments MT_GetCurrentZone INOUT ZoneName ZoneName Data type string Name as a string of the returned zone Product manual FlexLoader SC 6000 247 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reser...

Page 248: ...entifier myAlarm and store it into Alarm Example 1 VAR mtmsgdata Alarm Alarm MT_GetMessage myAlarm Return value Data type mtmsgdata Arguments MT_GetMessage Identifier Identifier Data type string System unique string that gives the possibility to point to a specific message 248 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved G FlexLoader Libra...

Page 249: ...ActiveAlarms This will fetch the number of active alarms in the system and store it into NumberOfAlarms Example 1 VAR num NumberOfAlarms NumberOfAlarms MT_GetNumberOfActiveAlarms Return value Data type num Product manual FlexLoader SC 6000 249 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved G FlexLoader Library Add in reference G 2 4 MT_GetNumberOfActiveAlarms Gets number of ...

Page 250: ...lue Data type mtpartstate Arguments MT_GetPartState Station StationName Index Station Data type mtstationdata The station data which part state data should be fetched in StationName Data type string Name of the station data declaration as a string Through this name the correct mtstationdata definition will be found and the corresponding part tracker where part state data should be fetched Index Da...

Page 251: ...der Text1 Text2 Text3 Text4 Text5 Text6 Text7 Text8 Identifier Data type string System unique string that gives the possibility to point to a specific message Header Data type switch Gets the header text line Text1 Data type switch Gets the body text number 1 Text2 Data type switch Gets the body text number 2 Text3 Data type switch Gets the body text number 3 Text4 Data type switch Gets the body t...

Page 252: ...text number 7 Text8 Data type switch Gets the body text number 8 252 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved G FlexLoader Library Add in reference G 2 6 MT_GetText Gets a selected text line from a message RobotWare OS Continued ...

Page 253: ...CHINE v500 fine tTool0 Moves robot to the via position connected to ZONE_MACHINE Return value Data type robtarget Arguments MT_GetViaPosition Target Target Data type mttargetdata The mttargetdata for the target for which the robtarget should be fetched Product manual FlexLoader SC 6000 253 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved G FlexLoader Library Add in reference G...

Page 254: ...ategory StationName Identifier Data type string System unique string that gives the possibility to point to a specific message WildCardTexts Data type string array String array of wild cards text to look for All text must match to get a result 1 back This argument only has a meaning if used at the same time as the identifier argument Category Data type icondata Only return result 1 if an alarm mat...

Page 255: ... and one with text No If the True button is pressed function will return TRUE Return value Data type bool Arguments MT_UIBoolEntry Identifier WildCardTexts Wrap TrueButtonText FalseButtonText DefaultBtn Icon Image MaxTime DIBreak DIPassive DOBreak DOPassive PersBoolBreak PersBoolPassive BreakFlag UIActiveSignal Identifier Data type string System unique string that gives the possibility to point to...

Page 256: ...and then the FlexPendant loads the images The image that will be shown can have the width of 185 pixels and the height of 300 pixels If the image is bigger only 185 300 pixels of the image will be shown starting at the top left of the image No exact value can be specified on the size that an image can have or the amount of images that can be loaded to the FlexPendant It depends on the size of othe...

Page 257: ...t Passive Data type switch This switch overrides the default behavior when using DOBreak optional argument Instead of reacting when signal is set to 1 or already 1 the instruction should continue in the error handler if no BreakFlag is used when the signal DOBreak is set to 0 or already is 0 The constant ERR_TP_DOBREAK can be used to test whether or not this has occurred PersBoolBreak Persistent B...

Page 258: ...LBREAK can be used to select the reason UIActiveSignal Data type signaldo The digital output signal used in optional argument UIActiveSignal is set to 1 when the message box is activated on the FlexPendant When the user selection has been done and the execution continue the signal is set to 0 again No supervision of stop or restart exist The signal is set to 0 when the function is ready or when PP...

Page 259: ...sInteger MaxTime DIBreak DIPassive DOBreak DOPassive PersBoolBreak PersBoolPassive BreakFlag UIActiveSignal Identifier Data type string System unique string that gives the possibility to point to a specific message WildCardTexts Data type string array String array of wild cards text to use for this message Wrap Data type switch If selected all the specified strings in the argument MsgArray will be...

Page 260: ...perator dialog If the OK button is not pressed before the signal is set to 1 or is already 1 then the program continues to execute in the error handler unless the BreakFlag is used see below The constant ERR_TP_DIBREAK can be used to test whether or not this has occurred DIPassive Digital Input Passive Data type switch This switch overrides the default behavior when using DIBreak optional argument...

Page 261: ...ve Data type switch This switch overrides the default behavior when using PersBoolBreak optional argument Instead of reacting when persistent boolean is set to TRUE or already TRUE the instruction should continue in the error handler if no BreakFlag is used when the persistent boolean PersBoolBreak is set to FALSE or already is FALSE The constant ERR_TP_PERSBOOLBREAK can be used to test whether or...

Page 262: ...CONST icondata iconWarning 2 CONST icondata iconError 3 262 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved G FlexLoader Library Add in reference G 2 10 MT_UIDNumEntry Shows a localized dnum entry RobotWare OS Continued ...

Page 263: ...rn value Data type btnres Arguments UIMessageBox Identifier WildCardTexts Wrap Buttons BtnArray DefaultBtn Icon Image MaxTime DIBreak DIPassive DOBreak DOPassive PersBoolBreak PersBoolPassive BreakFlag UIActiveSignal Identifier Data type string System unique string that gives the possibility to point to a specific message WildCardTexts Data type string array String array of wild cards text to use ...

Page 264: ...he images has to be placed in the HOME directory in the active system or directly in the active system The recommendation is to place the files in the HOME directory so that they are saved if a Backup and Restore is done A Restart is required and then the FlexPendant loads the images The image that will be shown can have the width of 185 pixels and the height of 300 pixels If the image is bigger o...

Page 265: ...set to 1 or is already 1 then the program continues to execute in the error handler unless the BreakFlag is used see below The constant ERR_TP_DOBREAK can be used to test whether or not this has occurred DOPassive Digital Output Passive Data type switch This switch overrides the default behavior when using DOBreak optional argument Instead of reacting when signal is set to 1 or already 1 the instr...

Page 266: ...t UIActiveSignal is set to 1 when the message box is activated on the FlexPendant When the user selection has been done and the execution continue the signal is set to 0 again No supervision of stop or restart exist The signal is set to 0 when the function is ready or when PP is moved Predefined data Icons CONST icondata iconNone 0 CONST icondata iconInfo 1 CONST icondata iconWarning 2 CONST icond...

Page 267: ...eger MaxTime DIBreak DIPassive DOBreak DOPassive PersBoolBreak PersBoolPassive BreakFlag UIActiveSignal Identifier Data type string System unique string that gives the possibility to point to a specific message WildCardTexts Data type string array String array of wild cards text to use for this message Wrap Data type switch If selected all the specified strings in the argument MsgArray will be con...

Page 268: ...dialog If the OK button is not pressed before the signal is set to 1 or is already 1 then the program continues to execute in the error handler unless the BreakFlag is used see below The constant ERR_TP_DIBREAK can be used to test whether or not this has occurred DIPassive Digital Input Passive Data type switch This switch overrides the default behavior when using DIBreak optional argument Instead...

Page 269: ... type switch This switch overrides the default behavior when using PersBoolBreak optional argument Instead of reacting when persistent boolean is set to TRUE or already TRUE the instruction should continue in the error handler if no BreakFlag is used when the persistent boolean PersBoolBreak is set to FALSE or already is FALSE The constant ERR_TP_PERSBOOLBREAK can be used to test whether or not th...

Page 270: ...condata iconWarning 2 CONST icondata iconError 3 270 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved G FlexLoader Library Add in reference G 2 12 MT_UINumEntry Shows a num entry box in localized language RobotWare OS Continued ...

Page 271: ...nts The data type mtaxisrange has the following components Axis Data type num Number of the robot axis to use 1 6 normal robot axis 7 12 external axis Range Data type mtrange The range for this axis Product manual FlexLoader SC 6000 271 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved G FlexLoader Library Add in reference G 3 1 mtaxisrange specifies an axis with an axis range ...

Page 272: ...ctions MT_Log and MT_LogEnable Comment Symbolic constant Value MT_LVL_ERROR 1 MT_LVL_WARNING 2 MT_LVL_INFO 3 MT_LVL_DEBUG 4 MT_LVL_USER 5 Characteristics mtloglevel is an alias data type for num and consequently inherits its characteristics 272 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved G FlexLoader Library Add in reference G 3 2 mtlogle...

Page 273: ... Message number will be shown as part of the alarm number in alarm lists Can also be a way to keep structure of the messages but not mandatory to use this Domain Data type num Message domain number This is not mandatory could be used to group alarms in a different way maybe a bigger type of group than station level Header Data type string Header text for the message Text1 Data type string First te...

Page 274: ...dy text for the message Text7 Data type string Seventh text line of body text for the message Text8 Data type string Eighth text line of body text for the message 274 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved G FlexLoader Library Add in reference G 3 3 mtmsgdata alarm and message definition data RobotWare OS Continued ...

Page 275: ...ly not used MachineCode Data type dnum Code for a machine served by robot for example form code of an Injection Moulding Machine Only use if it makes sense in the project RoutineName Data type string Currently not used RunInTasks Data type string Currently not used Tool Data type string Currently not used PartLoad Data type string Name of the predefined loaddata associated with this part This can ...

Page 276: ...tructions like MT_SetPartState and MT_GetPartState Comment Symbolic constant Value psEMPTY 0 psRAW 500 psMACHINED 501 psFINISHED 502 psCOOLED 503 Characteristics mtpartstate is an alias data type for num and consequently inherits its characteristics 276 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved G FlexLoader Library Add in reference G 3 ...

Page 277: ...ld be blank those are filled later on when using the part tracker instructions Components The data type mtparttracker has the following components Station Data type string Name of the mtstationdata declaration where the part tracker belongs to Part Data type string Name of the mtpartdata declaration which is currently connected to the part tracker State Data type string Name of the mtpartstate dec...

Page 278: ...ra The content is as the name says user defined and so must be parsed by the application program 278 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved G FlexLoader Library Add in reference G 3 6 mtparttracker describes all data for a part tracker RobotWare OS Continued ...

Page 279: ...The data type mtrange has the following components Min Data type num Start value of the range Max Data type num Stop value of the range Product manual FlexLoader SC 6000 279 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved G FlexLoader Library Add in reference G 3 7 mtrange describes a robot axis range RobotWare OS ...

Page 280: ...gh which the station is selected or deselected Here the high state of the signal means Station selected and the low state means Station deselected IOInvert Data type bool Inversion flag which will invert the meaning of the value in arguments IOEnabled HMIEnabled Data type bool Station has been selected TRUE or deselected FALSE by the HMI Only if no signal name is defined then the station can be se...

Page 281: ...dex number 1 and connects to via position pHome To be considered in the zone the robot must have axis 1 between 80 and 70 degrees And axis 3 between 30 to 30 degrees and axis 4 between 10 to 40 degrees Components The data type mttargetdata has the following components Index Data type num Unique index number for this mttargetdata the number doesn t matter as long as it s unique PosName Data type st...

Page 282: ...owing symbolic constants of the data type mttargetdata are predefined and can be used when specifying a condition for instructions like MT_GetCurrentZone Comment Symbolic constant Value ZONE_UNDEFINED 9999 9E9 9E9 0 0 0 0 0 0 0 0 0 0 0 0 282 Product manual FlexLoader SC 6000 3HAC051768 001 Revision D Copyright 2014 2020 ABB All rights reserved G FlexLoader Library Add in reference G 3 9 mttargetda...

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Page 284: ...Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC051768 001 Rev D en Copyright 2014 2020 ABB All rights reserved Specifications subject to change without notice ...

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