ABB FlexMT Product Manual Download Page 170

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8.3 Illumination

DANGER

Prior to work with the illumination: Safely shut the power to the FlexMT down
and lock against accidental turn-on.

Exchange of fluorescent tubes is described in the maintenance section.

In rare cases, the complete luminaires 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.

Layout of luminaires and smart camera

170

3HAC051768-001 Revision: -

8 Repair

8.3 Illumination

Summary of Contents for FlexMT

Page 1: ...Product manual FlexMT ...

Page 2: ...Trace back information Workspace Main version a80 Checked in 2014 10 08 Skribenta version 4 1 210 ...

Page 4: ...r 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 Additional copies of this manual may be obtained from ABB The original language for this publication is Swedish Any ...

Page 5: ...rn station 44 2 3 Electrical installation 45 2 3 1 Power supply 46 2 3 2 Earthing system 47 2 3 3 Potential equalization 48 2 4 Pneumatic installation 49 2 5 Machine tool connections 50 2 5 1 Machine tool safety interface 51 2 5 2 Machine tool functional interface 52 2 6 Network connections 52 2 6 1 Service port 53 2 6 2 WAN port 54 2 7 Licensing information 55 2 8 Moving the FlexMT 57 3 Commissio...

Page 6: ...he FlexMT 116 6 2 2 Shutting down the FlexMT 117 6 3 Starting and stopping 117 6 3 1 Standard start stop operation 117 6 3 1 1 Cycle start 118 6 3 1 2 Cycle stop 119 6 3 1 3 Quick stop 120 6 3 1 4 Restart after quick stop 121 6 4 Emergency and SafeMove stop 121 6 4 1 Emergency stop 122 6 4 2 Restart after emergency stop 123 6 4 3 SafeMove stop 124 6 4 4 Restart after SafeMove stop 125 6 5 Entry co...

Page 7: ...m 159 7 6 2 Backup of robot program 160 7 7 Other maintenance 160 7 7 1 Marking unit 161 7 7 2 Camera 162 7 7 3 PickMT Screen 163 8 Repair 164 8 1 Safety 165 8 2 Conveyors 166 8 2 1 Exchange of conveyor belt 169 8 2 2 Exchange of conveyor motor 170 8 3 Illumination 171 8 4 PickMT SmartCamera 171 8 4 1 Exchange of camera lens 172 8 4 2 Exchange of smart camera 174 8 5 Gripper 175 8 5 1 Exchange of ...

Page 8: ...3 2 2 Operation ABB ACS355 211 13 2 2 1 Key functions 213 13 2 2 2 Operation 214 13 2 3 Parameters 215 13 2 4 View and change parameters 216 13 2 5 Alarms 217 13 3 Pre configuration settings 218 13 3 1 Robot pre configuration 219 13 3 2 PickMT pre configuration 220 13 3 3 Marking unit pre configuration 221 13 3 4 Frequency inverter pre configuration 222 13 4 Known limitations and issues 222 13 4 1...

Page 9: ...rence 238 15 2 FlexMT core functionality reference 239 15 2 1 Control subsystem 240 15 2 2 Utility and assistance subsystem 241 15 3 FlexMT application functionality 243 16 Apendix D Own notes 3HAC051768 001 Revision 9 Copyright 2014 2014 ABB All rights reserved Table of contents ...

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Page 11: ...emark of ABB PickMT is a trademark of SVIA Svensk Industriautomation AB References Document ID Reference 3HAC049820 001 Product specification FlexMT 3HAC035504 001 Product manual IRB 2600 3HAC033453 001 Product manual IRB 4600 3HAC051771 001 Application manual PickMT 3HAC051769 001 Product manual Safety center for FlexMT 3HAC051770 001 Application manual PickMT with ABB robot 3HAC052311 001 Applic...

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Page 13: ...ccur if the instructions are not followed that can lead to serious injury pos sibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc WARNING xx0100000002 Warns for electrical hazards which could result in severe ...

Page 14: ...nd conditions NOTE xx0100000004 Describes where to find additional information or how to do an operation in an easier way TIP xx0100000098 14 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 1 Safety 1 1 Safety signals in the manual Continued ...

Page 15: ... that the safety laws and regulations that apply to their respective country are followed and that all safety devices that are required to guarantee the safety of those who work with the robot are installed correctly Only personnel with required training is authorized to use the system Trainee operators may only use the system under the supervision of a qualified experienced operator as follows Qu...

Page 16: ...er walls of the FlexMT and on any FlexMT option DANGER Ensure that nobody is within the machine enclosure during operation If the FlexMT is equipped with the turn station option an additional safety precaution might be necessary Depending on the length of parts to be turned an additional protective shield might become necessary DANGER When using the turn station option perform a complementary risk...

Page 17: ...and fully automatic operation DANGER The following must be ensured before commencing work on the FlexMT Emergency stop must be activated machine stationary Machine voltage must be disconnected Action must be taken so that machine voltage cannot be connected when work is carried out The air supply must be disconnected Action must be taken so that air supply cannot be connected when work is carried ...

Page 18: ... when working with the air cleaning box deburring unit for certain details The need will depend on the application and shall be risk assessed DANGER Pneumatic power to the grippers is not switched off neither during autostop nor in emergency state Be aware of crushing risk Normal precaution should be taken when working with the FlexMT 18 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights r...

Page 19: ...opriate risk assessment and validation DANGER The SafeMove configuration inside the machine tool must be adopted to the actual circumstances Risk assessment must be performed and the new SafeMove configuration must be validated Alternate mounting position The FlexMT mechanical configuration does allow an alternate mounting position of the robot This possibility is given for the integrators conveni...

Page 20: ...ration and validation of SafeMove configurations shall be followed DANGER It is the integrators responsibility to modify and validate the SafeMove configuration for the alternate mounting position in a suitable way 20 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 1 Safety 1 6 SafeMove Continued ...

Page 21: ... in another way than intended Operation of the machine when the safety devices are defective not in their intended location or in any other way not working When instructions for installation commissioning operation maintenance or repair are not followed Non authorised design modifications made in the FlexMT Maintenance or repair is carried out by inexperienced or non qualified personnel The machin...

Page 22: ...h the equipment is included has been determined to be in accordance with national and local laws and regulation Namely within the EU this refers to the machine directive 2006 42 EG with addition 22 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 1 Safety 1 8 Regulatory compliance ...

Page 23: ...te Read the safety precautions and other instructions carefully before unpacking and installing the equipment Continues on next page 3HAC051768 001 Revision 23 Copyright 2014 2014 ABB All rights reserved 2 Installation ...

Page 24: ...luding unloading and placing the FlexMT in relation to the machine tool If the installation contains further parts safety instructions may also be found in other documentation 24 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 2 Installation 2 1 General ...

Page 25: ...led from the chassis This section describes how to unpack the FlexMT step by step with text and pictures Always check the FlexMT for visible or suspected damages prior to unpacking Continues on next page 3HAC051768 001 Revision 25 Copyright 2014 2014 ABB All rights reserved 2 Installation 2 2 Mechanical installation ...

Page 26: ...T The surface of the floor shall be flat to within the equivalent of 1mm in 600mm 1 inch in 50 ft The floor and fastening elements shall withstand the forces originating from the robot according to the robot product manual Use at least bolts with minimum dimensions M20 3 4 26 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 2 Installation 2 2 1 Floor requirements ...

Page 27: ... a suspended load The FlexMT weight is 2500kg and shall be lifted off the transporter with a forklift from the side On the wooden pallet there are signs where to lift The FlexMT can be transported on the workshop floor with a forklift from the side with 3 handheld lifts as the pictures show or on appropriate skates Initial transport of the unit using handheld lifts 1 Look for fork lift signs Conti...

Page 29: ...delivered parts for unexpected damage If necessary take appropriate actions The FlexMT can be lifted using a fork lift with the provided fork lift slots placed on the bottom of the machine Lift of the FlexMT using fork lift Continues on next page 3HAC051768 001 Revision 29 Copyright 2014 2014 ABB All rights reserved 2 Installation 2 2 3 Unpacking and positioning ...

Page 30: ... Transport of the FlexMT using skates 2 CAUTION Do not lift the FlexMT to high in the back only It will damage the plates on the front door Continues on next page 30 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 2 Installation 2 2 3 Unpacking and positioning Continued ...

Page 31: ...he electrical cabinet and the rest of the machine Prior to transportation untreated surfaces may have been rust proofed with a layer of oil or grease which was applied before packing Wipe off any excess oil grease before installation using a lint free cloth Example of absorbtion bags in the control cabinet that must be removed 3HAC051768 001 Revision 31 Copyright 2014 2014 ABB All rights reserved ...

Page 32: ...By selecting a suitable amount of the flexible panels on the back side of the FlexMT various opening widths can be achieved 850mm 1300mm 1500mm Variable opening towards machine tool 850 mm Variable opening towards machine tool 1300 mm Continues on next page 32 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 2 Installation 2 2 4 Assemble corridor parts ...

Page 33: ...s needed for mechanical stability during transport Save the stabilization stag when disassembling it Transportation stability ensured by stag Continues on next page 3HAC051768 001 Revision 33 Copyright 2014 2014 ABB All rights reserved 2 Installation 2 2 4 Assemble corridor parts Continued ...

Page 34: ... corridor part If ordered with the extension panel door the FlexMT is delivered with the extension panel mounted in place The extension panel back has to be mounted on the FlexMT Select a suitable position along A and secure the extension panel back D by mounting it to the FlexMT outer shell screws on upper and lower rim of the FlexMT If the corridor part is a door that can be opened the safety sw...

Page 35: ...ably you will have to remove a plate to be able to reach the safety connection point 3HAC051768 001 Revision 35 Copyright 2014 2014 ABB All rights reserved 2 Installation 2 2 4 Assemble corridor parts Continued ...

Page 36: ...all be placed on top of the chassis and the camera shall be centered over the inconveyor The cables that need to be connected are put inside the tower see picture below The cables that they shall be connected to can be found in the vision tower The Continues on next page 36 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 2 Installation 2 2 5 Assemble the vision tower ...

Page 37: ...nside the electrical cabinet according to the circuit diagram Cable path from vision tower to FlexMT chassis Continues on next page 3HAC051768 001 Revision 37 Copyright 2014 2014 ABB All rights reserved 2 Installation 2 2 5 Assemble the vision tower Continued ...

Page 38: ...Internal connection of vision tower cables in control cabinet 38 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 2 Installation 2 2 5 Assemble the vision tower Continued ...

Page 39: ...h in the direction of movement and across it within 5 mm m 1 mm m for rolling parts Each deviation must be corrected If the wholes are drilled prior to putting the FlexMT into position use the following drilling plan Pay attention to distances implied by extension panel options FlexMT drilling template in mm seen from above 1 Continues on next page 3HAC051768 001 Revision 39 Copyright 2014 2014 AB...

Page 40: ...olling parts Each deviation must be corrected Drill holes and bolt the machine into the floor There are four brackets with holes where the machine shall be bolted around the robot The FlexMT shall be bolted with minimum bolt diameter M20 3 4 Use metal plates below the brackets to avoid air gaps between floor and FlexMT feet if necessary Continues on next page 40 3HAC051768 001 Revision Copyright 2...

Page 41: ... B FlexMT from below A Adjustable machine foot B Bolted to the floor Note Note that a tightening torque of 300 Nm 220 lb ft is required to ensure that the equipment is well secured 3HAC051768 001 Revision 41 Copyright 2014 2014 ABB All rights reserved 2 Installation 2 2 6 Install the FlexMT to the machine Continued ...

Page 42: ... position Start with putting the main part A into position and secure it to the FlexMT frame Thereafter hook the corridor part B into the main part and secure it FlexMT drop protection with main part A and corridor part B 42 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 2 Installation 2 2 7 Install FlexMT drop protection ...

Page 43: ...ed parts constitute a risk to the operator If risk assessment indicates a risk an extra vertical plate needs to be mounted close to the turn station on the FlexMT upper rim to avoid that the the risk area can be reached 3HAC051768 001 Revision 43 Copyright 2014 2014 ABB All rights reserved 2 Installation 2 2 8 Safety precautions for long parts in turn station ...

Page 44: ...according to specification Ensure that local rules and legislation is followed e g by setting a lockable main switch if needed Continues on next page 44 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 2 Installation 2 3 Electrical installation ...

Page 45: ... it shall be symmetrically designed Chose 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 POWER SUPPLY 3x 380 400V 50Hz Maximum short circuit current 10kA Required line fusing Circuit breaker with minimum characteristic C or better Max fuse 40A POWER SUPPLY 3x 440 480V 60Hz Maximum short ...

Page 46: ... earthing system shall be performed according to EN 60204 1 the PE conductor shall be dimensioned according to section 5 2 Table 1 46 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 2 Installation 2 3 2 Earthing system ...

Page 47: ...ted on the base frame to the left of the control panel this shall be connected to a separate functional earthing bonding circuit conductor NOTE Do not connect this to the PE system 3HAC051768 001 Revision 47 Copyright 2014 2014 ABB All rights reserved 2 Installation 2 3 3 Potential equalization ...

Page 48: ...atic installation Connect the incoming air connection Requirements are 6 bar 87 psi Dry air no oil 48 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 2 Installation 2 4 Pneumatic installation ...

Page 49: ...FlexMT connects to the machine tool by means of a safety interface and a functional interface Continues on next page 3HAC051768 001 Revision 49 Copyright 2014 2014 ABB All rights reserved 2 Installation 2 5 Machine tool connections ...

Page 50: ...rface Alternate autostop configuration The standard autostop safety interface connection puts the machine tool in autostop as soon as any FlexMT door is opened The FlexMT electrical cabinet does allow an alternate autostop configuration towards the machine tool autostop with override function This possibility is given for the integrators convenience and shall not be considered to be a standard opt...

Page 51: ...gital I O is working with the machine tools 24V Other physical interfaces are available by using optional IRC5 field bus or interface options to be ordered with robot The functional interface must be configured and commissioned prior to use of the FlexMT Please refer to the section Commissioning for details on functional interface setup 3HAC051768 001 Revision 51 Copyright 2014 2014 ABB All rights...

Page 52: ... Network connections to the robot controller can be established by means of the robots built in service port according to the robots manual 52 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 2 Installation 2 6 1 Service port ...

Page 53: ... strongly advised not to connect this network to any other network Under no circumstances shall ABB or ABB s suppliers be liable for incidental or consequential damages arising from connecting the vision system WAN port to any other network 3HAC051768 001 Revision 53 Copyright 2014 2014 ABB All rights reserved 2 Installation 2 6 2 WAN port ...

Page 54: ... the FlexMT and its PickMT SmartCamera you agree to Microsoft and Matrox licensing agreements These can be found on the PickMT SmartCamera 54 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 2 Installation 2 7 Licensing information ...

Page 55: ...ag close to the FlexMT s machine opening has to be fitted to the FlexMT prior to any transport This stag was delivered and fitted to the FlexMT for original delivery Transportation stability ensured by stag 3HAC051768 001 Revision 55 Copyright 2014 2014 ABB All rights reserved 2 Installation 2 8 Moving the FlexMT ...

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Page 57: ...3 Commissioning 3 1 Safety Carefully read the section on safety in this manual prior to commissioning 3HAC051768 001 Revision 57 Copyright 2014 2014 ABB All rights reserved 3 Commissioning 3 1 Safety ...

Page 58: ...ickMT password PickMT Robot Standard access is performed by the DefaultUser Please follow ABB s advice on user rights administration Safety related work i e SafeMove is performed with the SafetyUser account User SafetyUser password SafetyUser Pluto Normally the Pluto program must not be accessed nor the program changed However if re configuration or downloading of programs is necessary the passwor...

Page 59: ...y stop open door reset emergency stop close door reset door safety reset emergency stop Check the function of the external emergency stop DANGER Do not continue commissioning until the safety circuits are functioning 3HAC051768 001 Revision 59 Copyright 2014 2014 ABB All rights reserved 3 Commissioning 3 3 Basic steps ...

Page 60: ...ng to the maintenance section Keep in mind that the smart camera has limited system resources for non vision related tasks Do not strain neither memory nor hard disk space Tip Immediately after initial commissioning start maintaining your own system backups Now you can start teaching your first details Refer to the PickMT manual for detailed information on teachin configuration and problem solving...

Page 61: ... robot coordinate systems establishing the FlexMT machine tool communication interface and adopting the robot program to the individual automation needs Note FlexMT commissioning uses standard robot functionality for maintaining work objects tool data and other settings Please refer to the robot product manual for this standard functionality Continues on next page 3HAC051768 001 Revision 61 Copyri...

Page 62: ...of the machine tool The following values were changed in the robot configuration cf MOC CFG in order to take inclination into account gravity_alpha gravity_beta base_frame_orient_u0 base_frame_orient_u1 base_frame_orient_u2 base_frame_orient_u3 base_frame_x base_frame_y base_frame_z DANGER Do not change position or orientation of robot base coordinate system as this will affect the SafeMove config...

Page 63: ...setup Calibration point markers Most calibration points are represented by circles with a pointing mark The tip of the calibration tool should be as close as possible to the center of the circle as pointed out by the pointing mark Appearance of a typical calibration mark Continues on next page 3HAC051768 001 Revision 63 Copyright 2014 2014 ABB All rights reserved 3 Commissioning 3 5 2 Calibration ...

Page 64: ... a well defined position Suitably this can be done by reorienting the robot around a sharp tip If necessary redefine the tool definition for the calibration tool Tip Follow well established guidelines for calibration tools and work objects as described in the robot manuals Calibration aiding procedures All of the work objects below shall be calibrated by standard 3 point work object calibration So...

Page 65: ...s the current position The following coordinate systems shall be redefined if the corresponding option is present on the FlexMT The position of the calibration points can be found in the images below Camera coordinate system wCamera Coordinate system for picking from inconveyor Follow the calibration instructions in the PickMT manual Standard 3 point calibration Approximate positioning of wCamera ...

Page 66: ...tructions in the PickMT manual section FeedLine Light Standard 3 point calibration Approximate positioning of wOutBelt in the FlexMT Re grip table wRegrip The re grip table coordinate system wRegrip is oriented as follows Standard 3 point calibration Approximate positioning of wRegrip in the FlexMT Continues on next page 66 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 3 Comm...

Page 67: ...d 3 point calibration Afterwards call the calibration routine CalibAirClean The point of interest should be in the middle of the air cleaning box at the height where the air cleaning starts Note that orientation of the tool is used in pre configured movements Approximate positioning of wAirClean in the FlexMT Deburring tools wDeburr Continues on next page 3HAC051768 001 Revision 67 Copyright 2014 ...

Page 68: ...s Standard 3 point calibration Afterwards call the calibration routine CalibSampleOutlet The point of interest should be in the center of the sample outlet surface where the sensor will detect parts Note that orientation of the tool is used in pre configured movements Approximate positioning of wSample in the FlexMT Continues on next page 68 3HAC051768 001 Revision Copyright 2014 2014 ABB All righ...

Page 69: ...ol touches the marking needle Note that orientation of the tool is used in pre configured movements Machine tool main and sub chuck wMainChuckM1 wSubChuckM1 Coordinate system for the machine tools main chuck and sub chuck The coordinate systems X Y plane for a chuck must be at the front plane of the main and sub chuck with x 0 y 0 at the chuck s rotation shaft The typical machine tool for this app...

Page 70: ...ons On request a cylindrical part must be gripped with the sub chuck Position the robot so that this part can be gripped by the machine tool chuck gripper precisely centered Confirm to the calibration routine From the current robot position the object frame of wSubChuckM1 is now moved to be located exactly in the main chucks center If the chucks are movable the calibration must be checked so that ...

Page 71: ...its section on robot integration and FeedLine Light is strongly recommended Immediately after initial commissioning start maintaining your own system backups If pre installation and pre configuration data of the robot system should get lost for any reason you can find a primary backup on the PickMT system harddisk Refer to the repair section for detailed information 3HAC051768 001 Revision 71 Copy...

Page 72: ... set of commands to be understood by FlexMT This standardized set of commands can be expanded and adopted Due to the large variety of machine tool interfaces and integrator needs it is the integrators responsibility to implement this interface module Refer to section on machine tool connection for hardware information and section on robot program for further implementation suggestions 72 3HAC05176...

Page 73: ...aced out of reach for the operator i e inside the control cabinet i order to minimize abuse and to protect the equipment Schematic positions of SafeMove zones within the FlexMT The marked areas are forbidden zones When delivered all SafeToolZones are activated If the opening towards the machine tool is enlarged by removing one of the flexible panels the corresponding SafeToolZone should be deactiv...

Page 74: ...bed in the robot manual DANGER If the intended use of the FlexMT is changed a new risk assessment with regard to SafeMove configuration must be done 74 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 3 Commissioning 3 7 SafeMove Continued ...

Page 75: ...E10 controller unit During operation the robot communicates by means of serial communication with the controller unit The robot must thus be equipped with the serial communication option For in depth information refer to the section on pre configuration data 3HAC051768 001 Revision 75 Copyright 2014 2014 ABB All rights reserved 3 Commissioning 3 8 1 General ...

Page 76: ...C communication with standard USB cable Typical changes might be modifications of the marking setup files FlexMT is using three different marking files for different sizes SMALL MEDIUM LARGE For in depth information refer to the section on pre configuration data especially if you intend to modify the marking units configuration 76 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved...

Page 77: ...e consists of an Atlas Copco pneumatic die grinder LSF28 ST030E and a Nitto pneumatic filer ASH 900 These units can be equipped by any suitable tools according to the customer needs 3HAC051768 001 Revision 77 Copyright 2014 2014 ABB All rights reserved 3 Commissioning 3 9 Deburring grinding unit ...

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Page 79: ...to the requirements of the customer In a typical application FlexMT is integrated with a machine tool The operator places parts on 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 ...

Page 80: ...rous mechanical devices and sensors that are important to know about in order to understand the function Continues on next page 80 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 4 Function description 4 2 Overview ...

Page 81: ...controller F Vision system and illumination G Retractable sliding door with entry control H Swing door J Statistical outlet K Extension panel door Schematic overview with FlexMT functional units 2 D Inconveyor E Outconveyor L Extension panel back Continues on next page 3HAC051768 001 Revision 81 Copyright 2014 2014 ABB All rights reserved 4 Function description 4 2 1 Functional units ...

Page 82: ...chematic overview with FlexMT functional options M Marking unit P air cleaning box T Turn unit S re grip table Q Deburring Tools 82 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 4 Function description 4 2 1 Functional units Continued ...

Page 83: ...rea C Inconveyor TooFar sensor detects if parts on the inconveyor have been transported to far This is usually due to unidentified parts D Inconveyor InPosition sensor detects that a part has been transported into the cameras field of view Schematic overview with sensors 2 A Outconveyor ToFarOutbelt sensor detects when a part arrives at the end of the outconveyor 3HAC051768 001 Revision 83 Copyrig...

Page 84: ...yor operation Operator panel at start of inconveyor A Move inconveyor forward and backward reset errors by shortly switching the knob to Move Forward B Function selector inconveyor Manual or Automatic with visual indicator C Function selector for OutConveyor Automatic mode or emptying mode D Emergency stop button Continues on next page 84 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights ...

Page 85: ... system FlexMT main operator panel A Robot operator panel Emergency stop Motors On Operating mode witch Auto Manual with reduced speed B Illumination switch turns illumination on or off C USB connector located below the vision system screen Continues on next page 3HAC051768 001 Revision 85 Copyright 2014 2014 ABB All rights reserved 4 Function description 4 2 3 Operator panels Continued ...

Page 86: ... sliding door A Emergency stop B Start robot if in home position C Request cell entry and request confirmation lamp D Door reset after cell entry E Reset of emergency stop 86 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 4 Function description 4 2 3 Operator panels Continued ...

Page 87: ...onveyor is filled with parts manually Finished parts are left on the outconveyor These are then picked manually by the operator The belt system of the FlexMT is controlled by a number of background tasks FlexMT core functions Continues on next page 3HAC051768 001 Revision 87 Copyright 2014 2014 ABB All rights reserved 4 Function description 4 3 General function description ...

Page 88: ... the belt when the part reaches the cameras field of view Sensor to stop the belt when the part reaches the end of the belt Adjustable belt speed changed at frequency inverter Time monitored belt stop with manual reset After powering FlexMT and after emergency stop the inconveyor is stationary 88 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 4 Function description 4 3 1 Funct...

Page 89: ...t 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 3HAC051768 001 Revision 89 Copyright 2014 2014 ABB All rights reserved 4 Function description 4 3 2 Functions for outconveyor ...

Page 90: ...n in the manual of the marking unit This manual can be found in the documentation folder on the SmartCamera During automatic operation the robot controls the start and stop of marking Communication is performed by means of standard serial channel communication 90 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 4 Function description 4 4 Functions for marking unit ...

Page 91: ...ions e g air cleaning box deburring turn station and re grip table are controlled by various output signals directly from the robot 3HAC051768 001 Revision 91 Copyright 2014 2014 ABB All rights reserved 4 Function description 4 5 Functions for other options ...

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Page 93: ...d to personal injury and material damage Before programming the FlexMT it is your responsibility to carefully read the chapter on safety to become familiar with the FlexMT and its options and to become familiar with the safety devices 3HAC051768 001 Revision 93 Copyright 2014 2014 ABB All rights reserved 5 Robot program 5 1 Safety ...

Page 94: ...order to match the actual application However the basic structure should be followed to ensure smooth operation The FlexMT application code contains also a template for a machine tool interface which must be modified and adopted to the actual machine tool by the integrator The provided application code offers two possibilities Application code for parameter based simplified TeachIn for upright sta...

Page 95: ...ommunicate with the machine tool by means of the interface module TemplateMachine sys Read this module and the comments to each function in order to add machine tool specific code where needed 3HAC051768 001 Revision 95 Copyright 2014 2014 ABB All rights reserved 5 Robot program 5 3 1 Overview ...

Page 96: ...fined values are Predefined machine checks waits DOOR_OPENED PREPICK_OK LOAD_SUB_OK LOAD_MAIN_OK UNLOAD_SUB_OK UNLOAD_MAIN_OK HOME_POSITION_OK Predefined machine actions CLOSE_CHUCK_MAIN CLOSE_CHUCK_SUB CLOSE_DOOR OPEN_CHUCK_MAIN OPEN_CHUCK_SUB PREPARE_LOAD_MAIN PREPARE_LOAD_SUB PREPARE_UNLOAD_MAIN PREPARE_UNLOAD_SUB OPEN_DOOR CYCLE_START INIT_MACHINE STOP_MACHINE 96 3HAC051768 001 Revision Copyri...

Page 97: ...unctions for communication with machine tool Description Name Initiate whats neccessary for machine handling Sets up traps NEEDED Set up correct signals for interrupt handling PROC InitMachine Performs desired machine tool action NEEDED Define signals and communicate with machine tool PROC MachineAction string sAction Checks machine tool and conditions and returns correct state for use in main flo...

Page 98: ...K TRUE MachineAction PREPARE_LOAD_MAIN MachineAction OPEN_DOOR Await MachineWait DOOR_OPENED 10 Enter machine tool and load part MachineAction CLOSE_CHUCK_MAIN MachineAction PREPARE_UNLOAD_SUB grip detail MachineAction OPEN_CHUCK_SUB leave machine MachineAction CLOSE_DOOR MachineAction CYCLE_START Different machine tools have different behavior As described in the previous section FlexMT supplies ...

Page 99: ...ppers add or replace conditions in this procedure for nLoadGripperNumber nLoadGripperNumber is changed from PickMT in case of FeedLine Light detail PROC InitGrippers This procedure holds all initialization made when starting the robot program from the beginning Add all initialization for the current application here PROC InitializeMain Loads camera modules as specified by PickMT Check com ments in...

Page 100: ...ight A generic robot program based on geometrical part data is executed No robot programming is necessary for different parts and teachin is reduced to entering a few geometrical parameters Application code for parameter based simplified TeachIn but with modified robot program Both approaches can be combined where picking parts and tending the machine is handled as in Standard FeedLine Light but t...

Page 101: ...on the active tool PROC GripDetail switch Left_over_part This procedure releases the gripper on the active tool It will also set correct information for gripper what is carried mass and center of gravity Also it will call load compensation calcula tion PROC ReleaseDetail Checks setup and machine condition and selects correct state in main program flow I e this function handles the main program flo...

Page 102: ...Load_SUB This procedure loads detail in main chuck Make sure to use EnterMachine before all loading unloading and ExitMachine after all loading unloading LOCAL PROC Load MAIN The load position is always calculated X and Y is set to 0 and Z is calculated with help from PickMT values To change the leave position adjust wMainChuckM1 by running the procedure CalibMainChuck This procedure unloads sub c...

Page 103: ...huckM1 by running the procedure CalibMainChuck This procedure unloads detail in sub chuck Make sure to use EnterMachine before all loading unloading and ExitMachine after all loading unloading LOCAL PROC Unload SUB The unload position is always calculated X and Y is set to 0 and Z is calculated with help from PickMT values To change the unload position the work object has to be adjusted until the ...

Page 104: ... handling We recommend to use the FeedLine Light code as template and modify it to your needs For programming of standard teachin robot code refer also to the PickMT ABB integration manual All assistant code from the FlexMT system can of course be used e g the LeaveFeederOut routine for leaving parts ordered on the outconveyor 104 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved...

Page 105: ...ithin the FlexMT Examples are Marking Unit InitMarker LoadMarkerFile ChangeMarkerString StartMarker AirCleanBox StartAirClean StopAirClean Check Options sys for more usable functions 3HAC051768 001 Revision 105 Copyright 2014 2014 ABB All rights reserved 5 Robot program 5 6 Option control ...

Page 106: ...curred ERR_TP_DOBREAK If Do break signal occurred NOTE If ShowInPickMT TRUE all other arguments except TextNumber will NOT have any effect Write error message to FlexPendant event log and PickMT if wanted Also set error flag for correct indication at light tower Program execution then stops directly after home run or continue in user program depending on switch settings PROC WriteError num TextNum...

Page 107: ...Header MessageRow2 MessageRow11 NOTE The number first in every row points to which message also look at to CONSTANT declarations in this file It s not neces sary to write all lines for every message one row could be good enough 1 Message1Row1 2 Message2Row1 Message2Row2 6 Message6Row1 Certain ranges are reserved for specific purposes 1 99 FlexMT core messages These are defined in FeedLineAlarmsToP...

Page 108: ... user decisions If the user wants to light a certain color the variables bUserDefinedRedLight bUserDefinedYellowLight bUserDefinedBlueLight or bUserDefinedWhiteLight can be set to TRUE in the users code Light indications should always be accompanied with user messages for explanation 108 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 5 Robot program 5 8 Alarms and light tower ...

Page 109: ...ot moving through this zone The following zones are predefined for the user convenience and can be configured during commissioning SafeZone The robot could be started from here directly Connected to DOF_SafeZone HomeZone Indicates robot home position Connected to DOF_HomeZone MachineZone Robot is outside of machine tool Connected to DOF_LoaderOut The geometrical definition of these WorldZones can ...

Page 110: ...ovement within certain areas of the FlexMT can be initiated A schematic view of the principle motion within the FlexMT is shown and main positions is shown in the next figure The pre configured setup of FlexMT zones is shown in the figure thereafter Schematic motion overview Continues on next page 110 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 5 Robot program 5 10 Motion a...

Page 112: ...This page is intentionally left blank ...

Page 113: ...run forward and backward manually In the automatic operation position the inconveyor is run forward automatically when there are no more parts in the picking area If the inconveyor is not refilled in time the conveyor stops after a set monitoring period The outconveyor has two operation modes In automatic operation mode the conveyor is controlled by the robot The outconveyor is moved forward at ne...

Page 114: ... are fault free and that no damage can be caused when the machine is started DANGER When the operator replaces or repositions the gripping fingers the air pressure to the gripper must be safely shut down 114 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 6 Operation 6 1 Safety ...

Page 115: ... check Press and restore at least one emergency stop button open and close at least one door reset door status by shortly activating the reset key and finally reset emergency stop condition Refer to the safety manual for more detailed information 3HAC051768 001 Revision 115 Copyright 2014 2014 ABB All rights reserved 6 Operation 6 2 1 Powering up the FlexMT ...

Page 116: ...Stop the FlexMT as described below and await complete cycle stop Exit the PickMT application Turn off the main switch 116 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 6 Operation 6 2 2 Shutting down the FlexMT ...

Page 117: ...stop is not deployed If necessary acknowledge any remaining error messages on the robots FlexPendant If necessary turn the robots operating mode selector to automatic Confirm mode change with OK Select correct part in the PickMT user interface by choosing correct group and detail Click Start in the PickMT user interface The selected robot program for the part will now be loaded in the robot and th...

Page 118: ...e Pressing Stop will not make the robot stop immediately It will only stop at the end of the cycle or after a certain maximum time If an emergency situation has arisen use the emergency stop 118 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 6 Operation 6 3 1 2 Cycle stop ...

Page 119: ...p immediately in the position it is in whilst the external equipment completes its started work cycle Perform a quick stop by pressing Stop on the robots FlexPendant 3HAC051768 001 Revision 119 Copyright 2014 2014 ABB All rights reserved 6 Operation 6 3 1 3 Quick stop ...

Page 120: ...6 3 1 4 Restart after quick stop Press Start on the robots FlexPendant 120 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 6 Operation 6 3 1 4 Restart after quick stop ...

Page 121: ...ations and not to stop the machine normally The robot cell stops as quickly as possible and unwanted unexpected situations can occur where there may be a risk when restarting the robot cell without manual intervention Please note Grippers will remain pressurized 3HAC051768 001 Revision 121 Copyright 2014 2014 ABB All rights reserved 6 Operation 6 4 1 Emergency stop ...

Page 122: ...equipment is ready for automatic operation If the robot cannot be automatically run back to a safe position e g while loading unloading the machine tool Switch the robot operating mode switch to manual Jog the robot close to its safe position Switch back to automatic mode Press Motors on on the operator panel Perform a standard cycle start 122 3HAC051768 001 Revision Copyright 2014 2014 ABB All ri...

Page 123: ...e SafeMove supervision is active in both automatic mode and in manual operation The two main reasons for SafeMove stop are Jogging the robot manually out of the safe areas Pulling out the statistical outlet while robot is accessing this area 3HAC051768 001 Revision 123 Copyright 2014 2014 ABB All rights reserved 6 Operation 6 4 3 SafeMove stop ...

Page 124: ... press Motors On Press Motors On once more Press Start on FlexPendant SafeMove stop occurred due to jogging out of the safe areas Acknowledge error message on FlexPendant Jog robot back into safe area If the SafeMove override switch is needed it can be found inside the FlexMT electrical cabinet 124 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 6 Operation 6 4 4 Restart after ...

Page 125: ...he confirmation of the protection door with them This is to prevent unintentional confirmation and restart of the machine There must only be one key for the entire cell After work has been carried out in the cell the operator closes the door and confirms using the key switch D The system can then be restarted with the start button B or from the robots FlexPendant Upon restart the door is locked ag...

Page 126: ...bling device on the robots FlexPendant The robot can now be started The key to reset door safety is used to enable start special dangerous equipment As soon as the reset key was activated for a short period special dangerous equipment can be started When the operator releases the enabling device on the robots control panel the special dangerous equipment also stops 126 3HAC051768 001 Revision Copy...

Page 127: ... selecting 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 FlexMT 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 manoeuv...

Page 128: ...ntil the belt can be filled with further parts Otherwise the belt runs automatically until the first parts reach the cameras field of view During manual operation the conveyor can be run forward until the sensor at the cameras field of view is affected WARNING If you have stopped the robot in the middle of a started gripping manoeuvre then run the belt manually and then allowed the robot to contin...

Page 129: ...eyor must be emptied in emptying operation mode This is selected via the associated operation mode knob WARNING If you have stopped the robot and then run the outconveyor manually and then let the robot continue this may cause a collision risk depending on which position pattern is used on the outconveyor 3HAC051768 001 Revision 129 Copyright 2014 2014 ABB All rights reserved 6 Operation 6 6 3 Emp...

Page 130: ... During automatic operation the inconveyor is controlled based on the robots requirement Parts can be place on the outconveyor during operation 130 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 6 Operation 6 6 4 1 Inconveyor ...

Page 131: ...parts have reached the end of the outconveyor the belt stops and the yellow lamp warning is switched on The operator 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 3HAC051768 001 Revision 131 Copyright 2014 2014 ABB All rights reserved 6 Operation 6 6 4 2 Outconveyor ...

Page 132: ...the manual mode However the following restrictions do apply No automatic robot program loading will take place when PickMT is started with robot in manual mode Do not forget to save the robot program after making changes If the machine starts in automatic mode the robot program is reloaded and any changes made are lost MainModule com and part specific modules Note A convenient way to automatically...

Page 133: ... reset safety circuits Set the robot operating mode to automatic Acknowledge the message on the FlexPendant Press Motors on on the robot operation panel Press Start on the FlexPendant 3HAC051768 001 Revision 133 Copyright 2014 2014 ABB All rights reserved 6 Operation 6 7 1 2 Continuing work in automatic mode after manual mode operation ...

Page 134: ...entiometer mounted on the side of the controller cabinet the belts speed can be manually set to a speed appropriate to the product 134 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 6 Operation 6 7 2 Manually setting the belt speed option ...

Page 135: ...e Sometimes it can become necessary to perform this procedure manually Please adhere to the robots guidelines in how to perform a cyclic break check In short move the robot to a suitable position Then call the service routine CyclicBrakeCheck 3HAC051768 001 Revision 135 Copyright 2014 2014 ABB All rights reserved 6 Operation 6 7 3 Manual cyclic brake check ...

Page 136: ...dstill and the sample outlet can be opened When the sample outlet is closed again the operator can confirm and the robot will continue 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 In order to take a sample part directly i e prior to the specified sampling frequency press function key on the FlexPendant Th...

Page 137: ...aintenance 7 1 Safety DANGER Always adhere to the general safety instructions as described in chapter Safety 3HAC051768 001 Revision 137 Copyright 2014 2014 ABB All rights reserved 7 Maintenance 7 1 Safety ...

Page 138: ...is off Below is a summary of maintenance intervals and corresponding corrective actions Corrective action Maintenance intervals Conveyor belt cleaning Daily Conveyor belt check Every week FlexMT overall cleaning Air cleaning box cleaning Compressed air lubricator Electrical function check Every month Gripper system check Checking cables and cable racks Checking contacts Every 3 months Filter cartr...

Page 139: ... the robot move to its home position entry request Clean all surfaces from chips oil and other material that might disturb correct function Vacuum clean with industrial grade vacuum cleaner Be careful when cleaning inside 3HAC051768 001 Revision 139 Copyright 2014 2014 ABB All rights reserved 7 Maintenance 7 3 1 FlexMT overall cleaning ...

Page 140: ...en performing intense deburring How Remove all chips and material from deburring units Vacuum clean with industrial grade vacuum cleaner Remove oil and dirt from deburring tools and their holders 140 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 7 Maintenance 7 3 2 Air cleaning box cleaning ...

Page 141: ... from the belt Use Induren A or soap solution and cloth for PVC belts When Once day Vacuum the felt belt at least once week How Clean vacuum surface of the belt Run the belt to be able to clean the entire belt 3HAC051768 001 Revision 141 Copyright 2014 2014 ABB All rights reserved 7 Maintenance 7 3 3 Conveyor belt cleaning ...

Page 142: ...he conveyor belt When Once week How Run the conveyor belt and check that the belt does not slip at the motor drum nor move sideways 142 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 7 Maintenance 7 3 4 Conveyor belt check ...

Page 143: ...en tensioned before and is now installed without tension Measure a distance of 1000mm in the middle of the belt and make a mark at 0 and 1000mm Using both adjustment screws see figure 15 tension the belt until the distance between the marks is 1005mm If a PVC belt is used the distance between the marks should be 1003mm after tensioning the upper conveyor belt and 1004mm after tensioning the lower ...

Page 145: ...es sideways Wait until the belt has gone around 10 times before the next adjustment Note After each adjustment the belt must be run for approximately 30 minutes at the same time while being monitored as it takes some time for the belt to react to the new settings The belt is adjusted when test operation is performed at the manufacturer however it may need to be readjusted after transportation or a...

Page 146: ... Visually check the gripper system including gripper holder gripper finger holders and gripper fingers for signs of mechanical wear Replace damaged or worn parts 146 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 7 Maintenance 7 3 7 Gripper system check ...

Page 147: ... equivalent All seals Schunk Renolit HLT 2 or equivalent bores on the piston Schunk Renolit HLT 2 or equivalent 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 set screws for the air purge connection and replace them with two conic...

Page 148: ...7 4 Electrical maintenance 7 4 1 Robot control cabinet What See ABB robot product manual 148 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 7 Maintenance 7 4 1 Robot control cabinet ...

Page 149: ... stops working all the remaining ones must be replaced at the same time How Turn the fluorescent lamp a turn until the contact grooves are free If only one lamp stops working after a maximum of six months it is enough to only replace that particular lamp 3HAC051768 001 Revision 149 Copyright 2014 2014 ABB All rights reserved 7 Maintenance 7 4 2 Illumination ...

Page 150: ...sors are intact and clean and are secured properly When As necessary Depends on surroundings and amount of dirt from parts handled in the FlexMT and surroundings 150 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 7 Maintenance 7 4 3 Reflectors sensors ...

Page 151: ...nction check What Check all electrical functions breakers and limit position functions When Once month 3HAC051768 001 Revision 151 Copyright 2014 2014 ABB All rights reserved 7 Maintenance 7 4 4 Electrical function check ...

Page 152: ...How Inspect the entire cable rack mounting points dirt deposits wear and remedy any breaks Check all cables Replace damaged cables Extend cables that rub against sharp edges 152 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 7 Maintenance 7 4 5 Checking cables and cable racks ...

Page 153: ...ng electrical connections When Every 3 months How Inspect all electrical contacts and make sure that they are secured properly 3HAC051768 001 Revision 153 Copyright 2014 2014 ABB All rights reserved 7 Maintenance 7 4 6 Checking electrical connections ...

Page 154: ...on as seen from below The condensate will then flow out When Depending on quality of the compressed air generally 1 2 times year How For further cleaning pull the blue button downwards and turn the bowl clockwise until it is loose See figures below Replace the filter and clean the bowl Assemble in reverse order 154 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 7 Maintenance 7...

Page 155: ...tridge if the pores are dirty Grasp the filter cartridge only at the lower end when it is new Fit the individual parts again in the reverse sequence The following checks must then be made The locking pinof the filter bowl must face the large recess in the housing The unlocking slide must be heard to clip into place when the end stop is reached Cleaning Use only the following cleaning agents Water ...

Page 157: ...f the air cleaning box It has an inspection window where the oil level is visible If oil level is below the minimum level mark refill it by pulling the blue button down and turn the bowl clockwise until it is loose Refill with a suitable oil so the oil level is above minimum level Recommended oil is Festo special oil as per ISO VG 32 type Festo OFSW 32 3HAC051768 001 Revision 157 Copyright 2014 20...

Page 158: ...tem When When you have made a change or as necessary How Create a backup under the tab settings service and save it onto a secure media i e not the PickMT SmartCamera itself 158 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 7 Maintenance 7 6 1 Backup of vision system ...

Page 159: ...bot program When When you have made a program change How Follow the robot manual and save the copy onto a secure media i e not the robot itself 3HAC051768 001 Revision 159 Copyright 2014 2014 ABB All rights reserved 7 Maintenance 7 6 2 Backup of robot program ...

Page 160: ...pring and the core Clean all 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 160 3HAC051768 001 Revis...

Page 161: ...lean using a clean cloth If this is not sufficient use pure alcohol or similar Ensure not to leave a film on the lens If the cameras position is changed perform a new calibration according to the PickMT manual 3HAC051768 001 Revision 161 Copyright 2014 2014 ABB All rights reserved 7 Maintenance 7 7 2 Camera ...

Page 162: ...7 7 3 PickMT Screen What Carefully wipe off using a damp cloth When As necessary 162 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 7 Maintenance 7 7 3 PickMT Screen ...

Page 163: ... product manual Most repairs of the FlexMT are relatively obvious to perform The most important procedures are listed in this section Minor repairs that can be performed with standard industry procedures are not listed here Continues on next page 3HAC051768 001 Revision 163 Copyright 2014 2014 ABB All rights reserved 8 Repair ...

Page 164: ...8 1 Safety DANGER Always adhere to the general safety instructions as described in chapter Safety 164 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 8 Repair 8 1 Safety ...

Page 165: ...veyors After positioning the belts in suitable positions safely shut the power to the FlexMT down and lock against accidential turn on Continues on next page 3HAC051768 001 Revision 165 Copyright 2014 2014 ABB All rights reserved 8 Repair 8 2 Conveyors ...

Page 166: ...on 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 Protective caps and release points idler drum in middle of conveyor Continues on next page 166 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 8 Repair 8 2 1 Exchange...

Page 167: ...e Connect the new belt to the old belt splice Drag the new belt with the help of the old belt through the FlexMT 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 3HAC051768 001 Revision 167 Copyright 2014 2014 ABB All rights reserved 8 Repair 8 2 1 Exchange of...

Page 168: ... to mounting the protection caps in order to perform the belt adjustment Be careful when adjusting the belt Risk for finger squeeze Adjust belt side position and stability according to instructions in the maintenance section Mount the protection cover 168 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 8 Repair 8 2 1 Exchange of conveyor belt Continued ...

Page 169: ...structions 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 3HAC051768 001 Revision 169 Copyright 2014 2014 ABB All rights reserved 8 Repair 8 2 2 Exchange of conveyor motor ...

Page 170: ...e complete luminaires 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 Layout of luminaires and smart camera 170 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved ...

Page 171: ... smart camera Adjust focus of the new lens Observe an existing image e g one of the existing teach in and compare image brightness Try to adjust aperture to match the previous appearance with the old lens Mount the protection cover Calibrate vision system with robot according to PickMT manual Run system at slow speed for the first few picks 3HAC051768 001 Revision 171 Copyright 2014 2014 ABB All r...

Page 172: ...smart camera mounting plate screws view from below Location of smart camera mounting plate screws view from side Remove camera from camera mounting plate and replace by new camera Move lens from the old smart camera to the new smart camera Follow the procedure for exchange of the camera lens Assemble camera mounting plate into FlexMT frame Do not tighten screws firmly yet Attach the three cables c...

Page 173: ...ge field of view should look the same as in an existing teachin Calibrate vision system with robot according to PickMT manual Run system at slow speed for the first few picks 3HAC051768 001 Revision 173 Copyright 2014 2014 ABB All rights reserved 8 Repair 8 4 2 Exchange of smart camera Continued ...

Page 174: ...o work with the gripper Safely shut the pneumatic supply to the FlexMT down and lock against accidental turn on Continues on next page 174 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 8 Repair 8 5 Gripper ...

Page 175: ... gripper fingers Loosen pneumatic tubes Remove pneumatic connections Unscrew gripper module Mount new gripper pneumatic connections and pneumatic tubing Mount gripper fingers Restore pneumatic supply to FlexMT Test the new gripper FlexMT standard gripper 3HAC051768 001 Revision 175 Copyright 2014 2014 ABB All rights reserved 8 Repair 8 5 1 Exchange of gripping module on gripper ...

Page 176: ...lding the control valve See figure below Pull the control valve straight up Assemble in reverse order Demount control valves DANGER Safely shut the pneumatic supply to the FlexMT down and lock against accidental turn on 176 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 8 Repair 8 5 2 Exchange of valves ...

Page 177: ...ts No special procedure has to be followed However check if the robots work object has to be redefined or if picking positions have to be adjusted FlexMT re grip table in two different configurations 3HAC051768 001 Revision 177 Copyright 2014 2014 ABB All rights reserved 8 Repair 8 6 Re grip table ...

Page 178: ...work with the turn station Safely shut the pneumatic supply to the FlexMT down and lock against accidental turn on Continues on next page 178 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 8 Repair 8 7 Turn station ...

Page 179: ...ice position Unscrew gripper fingers Remove pneumatic connections Unscrew gripper module Mount new gripper Mount gripper fingers Restore pneumatic supply to FlexMT Test the new gripper FlexMT turn station with axis in gripper 3HAC051768 001 Revision 179 Copyright 2014 2014 ABB All rights reserved 8 Repair 8 7 1 Exchange of gripping module on turn station ...

Page 180: ...tic connections to the rotation module Dismount and exchange the rotation module Assemble in reverse order Be sure to adjust the angular stop positions to the desired range Test the turn station gripper CAUTION If there are any changes in position design between the new and old unit the robot positions need to be updated FlexMT turn station from behind showing the rotation module and the valve pos...

Page 181: ...cess 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 the figure above DANGER Safely shut the pneumatic supply to the FlexMT down and lock against accidential turn on 3HAC051768 001 Revision 181 Copyright 2014 2014 ABB All rights reserved 8 Repair 8 7 3 Exchange of valves ...

Page 182: ...rk with the air cleaning box Safely shut the pneumatic supply to the FlexMT down and lock against accidental turn on Continues on next page 182 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 8 Repair 8 8 Air cleaning box ...

Page 183: ...eplace the flexblow hose and assemble in reverse order CAUTION If there are any changes in position design between the new and old unit the robots position need to be updated Components of the air cleaning box and deburring tools A Flexblow hoses B Valves controlling air cleaning C Signal splitter box D Deburring tool 1 E Deburring tool 2 F Valves controlling deburring tools G Protective cover 3HA...

Page 184: ...lve modules Festo can be exchanged by the following procedure Pull the statistic outlet to its outer position Remove the cover hiding the valves For exchange of valve modules follow the procedure as for changing valves on the gripper 184 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 8 Repair 8 8 2 Exchange of valves ...

Page 185: ...nits Safely shut the pneumatic supply to the FlexMT down and lock against accidential turn on Components of the air cleaning box and deburring tools Continues on next page 3HAC051768 001 Revision 185 Copyright 2014 2014 ABB All rights reserved 8 Repair 8 9 Grinding Deburring units ...

Page 186: ...igure below Grinding deburring unit fastening system Pull the unit backwards Mount the new unit Connect the pneumatic connection to the grinding deburring unit Restore pneumatic supply to FlexMT CAUTION If there are any changes in position design between the new and old unit the robot positions need to be updated 186 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 8 Repair 8 9 ...

Page 187: ...ive cover over the valves G Air cleaning box valve section cover Disconnect the pneumatic connections that connects the valves to FlexMT Disconnect the electrical connection to the distributor box Pull the two bayonet fastenings placed in front of the air cleaning box and twist them 90 Bayonet fastenings holding the air cleaning box in place Drag the air cleaning box out of FlexMT Continues on nex...

Page 188: ...reverse order make sure the air cleaning box connects correct to the pins placed in the FlexMT frame 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 188 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved...

Page 189: ...ing the marking unit 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 3HAC051768 001 Revision 189 Copyright 2014 2014 ABB All rights reserved 8 Repair 8 10 1 Exchange of ma...

Page 190: ... account the center of mass of the hanging robot Mount the robot to FlexMT by the following procedure Use a fork lift and place the pallet with the robot as close as possible to the FlexMT 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 FlexMT robot pedestal Secure the robot by mounting the M16 bol...

Page 191: ...ration When fine calibrating the robot it must be on flat level surface Thus it must be dismounted from the FlexMT 3HAC051768 001 Revision 191 Copyright 2014 2014 ABB All rights reserved 8 Repair 8 12 Robot fine calibration ...

Page 192: ...d the PickMT is included The robot backup is saved on the PickMT SmartCamera and a backup of the PickMT SmartCamera is saved on the robot Continues on next page 192 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 8 Repair 8 13 Software repair ...

Page 193: ... saved on the smart camera harddisk location D SystemRepair RobotBackup Copy this backup to a USB memory stick and restore it with standard robot backup restore procedures refer to robot manual 3HAC051768 001 Revision 193 Copyright 2014 2014 ABB All rights reserved 8 Repair 8 13 1 Robot repair ...

Page 194: ... saved on the robot hard disk location BACKUP SystemRepair SmartCameraBackup Copy this backup to a USB memory stick and restore it with standard smart camera restore procedures refer to PickMT manual 194 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 8 Repair 8 13 2 PickMT SmartCamera repair ...

Page 195: ... belt with run forward knob TIMEOUT_MANUAL_FOR WARD_BELT1 91 007 R Timeout manual run backward inconveyor Restart belt with run backward knob TIMEOUT_MANUAL_BACK WARD_BELT1 91 008 R Timeout emptying outconveyor Restart outconveyor with outconveyor auto manual switch TIMEOUT_EMPTYING_OUT BELT1 91 009 R Part reached end of outconveyor Remove part Restart outconveyor with outconveyor auto manual swit...

Page 196: ...D 91 114 B No parts on inconveyor Load more parts NO_DETAIL_IN_POSITION 91 115 R Machine door tool was not opened within time limit Check machine tool MA CHINE_DOOR_NOT_OPENED 91 116 B Marker unit text could not be changed Check communication status Reset marker unit MARK_TEXT_CHANGE_PROB LEM 91 117 R Marker unit text to long Shorten text to be written MARK_TEXT_TOO_LONG 91 118 B Marker unit file ...

Page 198: ... can be found in the PickMT manual Other PickMT related problems can often be solved by checking the PickMT generated log file Refer to the PickMT manual for information on extended logging 198 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 9 Troubleshooting 9 2 PickMT troubleshooting ...

Page 199: ...roubleshooting Troubleshooting information concerning the robot can be found in the robot manuals 3HAC051768 001 Revision 199 Copyright 2014 2014 ABB All rights reserved 9 Troubleshooting 9 3 Robot troubleshooting ...

Page 200: ... necessary be resetted by shortly pressing the red button in the control cabinet It is located directly on the side of the marking unit control unit 200 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 9 Troubleshooting 9 4 Marking unit ...

Page 201: ...uct manual Allways follow the relevant countries regulations for removing and recycling mechanical electrical and electronic material Take into account oil and grease that can be found inside the equipment Continues on next page 3HAC051768 001 Revision 201 Copyright 2014 2014 ABB All rights reserved 10 Decommissioning ...

Page 202: ...ication Material Serial measurement board Batteries NiCad or Lithium Motors Copper Cables Cast iron nodular iron Steel Motors Neodymium Brakes Plastic rubber Gearboxes Oil grease Aluminium Dispose components properly to prevent health or environmental hazards 202 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 10 Decommissioning 10 1 1 Hazardous material ...

Page 203: ...own drains or onto soil Incineration must be carried out under controlled conditions in accordance with local regulations Also note that Spills can form a film on water surfaces causing damage to organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination 3HAC051768 001 Revision 203 Copyright 2014 2014 ABB All rights reserved 10 Decommissioni...

Page 204: ...portant to remember the following before disassembling starts in order to prevent injuries Start with scrapping disassembling the robot according to the robots product manual 204 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 10 Decommissioning 10 2 Scrapping of FlexMT ...

Page 205: ...11 Spare parts Spare part list is not included in the manual but are delivered as a separate documents 3HAC051768 001 Revision 205 Copyright 2014 2014 ABB All rights reserved 11 Spare parts ...

Page 206: ...This page is intentionally left blank ...

Page 207: ... 12 1 Circuit diagram The circuit diagram is not included in this manual but delivered as separate document 3HAC051768 001 Revision 207 Copyright 2014 2014 ABB All rights reserved 12 Diagrams 12 1 Circuit diagram ...

Page 208: ...umatic diagram The pneumatic diagram is not included in this manual but delivered as separate document 208 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 12 Diagrams 12 2 Pneumatic diagram ...

Page 209: ...running time for outconveyor1 during emptying nTimeoutEmptyingOut belt1 DisableTooFarOutbelt1 If this flag is set to 1 sensor Outbelt1Too Far is ignored nDisableTooFarOutbelt1 The time which the outconveyor must run in order to allow new details to be put on the outconveyor nRunTimeFeederOut General Delay time for signal AllowRobotLeaveOutbelt1 which takes into account ramp down time of the belt M...

Page 210: ...ACS355 03U 04A7 2 E200 UL which is used in FlexMT The document reports settings of the essential parameters that are required for tuning the FlexMT Further optimization and settings can be done for this refer to ABB ACS355 documentation 210 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 13 Appendix A Configuration 13 2 1 General ...

Page 211: ...e PAR Parameter mode MENU Main menu FAULT Fault mode e Lower right Indicators FWD forward REV reverse direction of the motor rotation Flashing slowly stopped Flashing rapidly running not at setpoint Steady running at setpoint SET Displayed value can be modified in the Parameter and Reference modes 2 RESET EXIT Exits to the next higher menu level without saving changed values Resets faults in the O...

Page 212: ... parameter is selected Decreases the reference value in the Reference mode Holding the key down changes the value faster 6 LOC REM Changes between 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 212 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 13 Appendix...

Page 213: ...meter mode Copy mode and Fault mode When a fault or alarm occurs the panel goes automatically to the Fault mode showing the fault or alarm code You can reset the fault or alarm in the Output or Fault mode After the power is switched on the panel is in the Output mode where you can start stop change the direction switch between local and remote control and monitor up to three actual values one at a...

Page 214: ... 2 3 Parameters Factory parameters settings are found in the electrical documentation 214 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 13 Appendix A Configuration 13 2 3 Parameters ...

Page 215: ...group 4 Use keys and to find the desired parameter 5 Press and hold for about two seconds until the display shows the value of the parameter with underneath indicating that changing of the value is now possible Note When is visible pressing keys and simultaneously changes the displayed value to the default value of the parameter 6 Use keys and to modify the parameter value When you have changed th...

Page 216: ...the supply voltage off for a while When the fault has been removed the motor can be restarted Alarm messages 2001 Current limit 2002 Overvoltage 2003 Undervoltage 2009 High temp frequency inverter Fault messages 0001 Current limit exceeded 0002 Over voltage 0003 High temperature frequency inverter 0004 Short circuit in motorcables or motor 0006 Under voltage 0009 High motor temperature 216 3HAC051...

Page 217: ...ered This section describes some pre configuration data that might be needed for in depth technical use of the FlexMT Continues on next page 3HAC051768 001 Revision 217 Copyright 2014 2014 ABB All rights reserved 13 Appendix A Configuration 13 3 Pre configuration settings ...

Page 218: ...rlier in this manual Serial port setting for communication with the marking unit are as follows Name COM1 Connector COM1 Baud rate 9600 Parity None Number of bits 8 Number of stop bits 1 Flow control None Duplex Full 218 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 13 Appendix A Configuration 13 3 1 Robot pre configuration ...

Page 219: ...e present in the delivered FlexMT If needed this pre configuration can be changed Please consult the PickMT manual for detailed information on configuration 3HAC051768 001 Revision 219 Copyright 2014 2014 ABB All rights reserved 13 Appendix A Configuration 13 3 2 PickMT pre configuration ...

Page 220: ...written to the text variable PICKMT with a constant length that is defined in the PickMT setup files The serial communication of the SIC controller is set to match the standard setting for COM1 on the robot Baud rate 9600 Parity None Number of bits 8 Number of stop bits 1 Only RC NO Type RS232 No further configuration of the SIC controller is necessary if desired most advanced options of the marki...

Page 221: ...inverter units have been pre configured for use with FlexMT Se section below for parameter handling of these devices 3HAC051768 001 Revision 221 Copyright 2014 2014 ABB All rights reserved 13 Appendix A Configuration 13 3 4 Frequency inverter pre configuration ...

Page 222: ... check functionality on a robot as used in the FLexMT is subject to an internal error Due to not yet known reasons RW 15 15 06 can therefore not be used 222 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 13 Appendix A Configuration 13 4 1 RobotWare 5 15 06 ...

Page 223: ...re off Operator presses Run button on FlexPendant An error message about safety mechanism intervention is displayed and acknowledged From this point onwards the communication channel to the robot is broken until the robot system is restarted warm start 3HAC051768 001 Revision 223 Copyright 2014 2014 ABB All rights reserved 13 Appendix A Configuration 13 4 2 RobotWare 5 60 ...

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Page 225: ...ic 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 frequency inverter inconveyor diAlarmU11FeederIN Alarm from frequency inverter outconveyor diAlarmU12FeederOUT Runs inconveyor forward doRunForwardBelt1 Runs in...

Page 226: ... holder doLockGate Turn on lamp in entry request button on door operator panel doEntryRequestControlLamp Signal from air preparation unit that air pressure is ok diAirPressureOK Turn on green light in RGB signal lamp doGreenLamp Turn on blue light in RGB signal lamp doBlueLamp Turn on red light in RGB signal lamp doRedLamp 226 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 14 ...

Page 227: ...d by integrator diGripperSensor6 Open gripper 1 doValve1Gripper Open gripper 2 doValve2Gripper Spare signal on robot arm connected to valve Can be used by integrator 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...

Page 228: ...ion Description Name Open gripper doTurnStationGripperOpen Rotate turn station doTurnStationRotate 228 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 14 Appendix B Communication 14 1 4 Turn station ...

Page 229: ...lowBox Activate valve 3 on air cleaning box doValve3BlowBox Activate valve 4 on air cleaning box doValve4BlowBox Activate valve 5 on air cleaning box doValve5BlowBox Activate valve 6 on air cleaning box doValve6BlowBox 3HAC051768 001 Revision 229 Copyright 2014 2014 ABB All rights reserved 14 Appendix B Communication 14 1 5 Air cleaning box ...

Page 230: ...tion Name Activate grinding deburring tool 1 doValve1Deburr Activate grinding deburring tool 1 doValve2Deburr 230 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 14 Appendix B Communication 14 1 6 Deburring ...

Page 231: ...14 1 7 Marking unit No digital I O is used for the marking unit 3HAC051768 001 Revision 231 Copyright 2014 2014 ABB All rights reserved 14 Appendix B Communication 14 1 7 Marking unit ...

Page 232: ...e placed in the statistical outlet diDetailInBoxSensor Sensor that indicates that the box is in position and ready to receive parts diBoxInPositionSensor 232 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 14 Appendix B Communication 14 1 8 Statistical outlet ...

Page 233: ...bot and the rest of the robot cell possible The structure of the robot cells function interface e g to the principal machine can be found in the robot cells interface description Continues on next page 3HAC051768 001 Revision 233 Copyright 2014 2014 ABB All rights reserved 14 Appendix B Communication 14 2 Internal communication ...

Page 234: ...kMT Robot For details on communication between PickMT and robot refer top the PickMT manual 234 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 14 Appendix B Communication 14 2 1 PickMT Robot ...

Page 235: ...ult RAPID code for in depth information WriteStrBin ioSicMarker LOADFILE MEDIUM 0D 0A WriteStrBin ioSicMarker SETVAR PICKMT example text 0D 0A WriteStrBin ioSicMarker RUN 0D 0A A number of advanced commands can be issued to the marking unit controller Please refer to the marking units manual for in depth information 3HAC051768 001 Revision 235 Copyright 2014 2014 ABB All rights reserved 14 Appendi...

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Page 237: ... background task and PvMcSys mod which is the interface towards the application RAPID code FlexMT core functionality control tasks 2 These two modules are documented in more detail in the PickMT manual 3HAC051768 001 Revision 237 Copyright 2014 2014 ABB All rights reserved 15 Apendix C FlexMT RAPID reference 15 1 PickMT core functionality reference ...

Page 238: ...ng overviews Some modules relevant for commissioning have been described in the robot program section All other modules are described below Continues on next page 238 3HAC051768 001 Revision Copyright 2014 2014 ABB All rights reserved 15 Apendix C FlexMT RAPID reference 15 2 FlexMT core functionality reference ...

Page 239: ...h short response time regular operation with ToFar sensor FeedLineAlarmsToPV mod Specialized task for checking and communicating alarms to PickMT EntryControlLamp mod Specialized task responsible for handling entry request confirmation lamp EntryControl mod Specialized task responsible for handling entry request autostop reset and door lock signals RGBLightTower mod Specialized task responsible fo...

Page 240: ...tional equipment UserCommunication sys Contains helper functions for localizable user interaction and information Refer to chapter on robot program MainModule mod Main module controlling FlexMT function Refer to chapter on robot program Common sys Contains tool data work object data and world zone information refer to chapter on world zones FeedLineLight sys Refer to PickMT manual FeederOut sys Re...

Page 241: ...al functions within the FlexMT application and physical interface to the machine tool ModCam1 mod ModCam1 mod handles the part specific programming e g loading unloading marking air cleaning Two example modules are delivered one for operation with simplified TeachIn FeedLine Light the other for standard operation with standard TeachIn Refer to chapter on robot program 3HAC051768 001 Revision 241 C...

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Page 246: ...0 ABB AS Robotics Discrete Automation and Motion Nordlysvegen 7 N 4340 BRYNE Norway Box 265 N 4349 BRYNE Norway Telephone 47 51489000 ABB Engineering Shanghai Ltd 5 Lane 369 ChuangYe Road KangQiao Town PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 www abb com robotics 3HAC051768 001 Rev en ...

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Summary of Contents for FlexMT

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