ABB IRB 4400/45 Product Specification Download Page 28

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1 Description

1.4.2 Absolute Accuracy calibration

Rev.N

3HAC9117-1

1.4.2 Absolute Accuracy calibration

General

Requires RobotWare option Absolute Accuracy, please see Product specification -

Controller software IRC5/RobotWare for more details.

The calibration concept

Absolute Accuracy (AbsAcc) is a calibration concept, which ensures a TCP absolute

accuracy of better than ±1 mm in the entire working range.

Absolute accuracy compensates for:

•

Mechanical tolerances in the robot structure

•

Deflection due to load

Absolute accuracy calibration focuses on positioning accuracy in the cartesian

coordinate system for the robot. It also includes load compensation for deflection

caused by the tool and equipment. Tool data from robot program is used for this

purpose. The positioning will be within specified performance regardless of load.

Calibration data

The user is supplied with robot calibration data (compensation parameters saved on

the manipulator SMB) and a certificate that shows the performance (Birth certifi-

cate). The difference between an ideal robot and a real robot without AbsAcc can

typically be 8 mm, resulting from mechanical tolerances and deflection in the robot

structure.

If there is a difference, at first start-up, between calibration data in controller and the

robot SMB, correct by copying data from SMB to controller.

Summary of Contents for IRB 4400/45

Page 1: ...Product specification Articulated robot IRB 4400 45 IRB 4400 60 IRB 4400 L30 IRB 4400 L10 IRB 4450 S M2004 ...

Page 2: ......

Page 3: ...Product specification Articulated robot 3HAC9117 1 Rev N IRB 4400 45 IRB 4400 60 IRB 4400 L30 IRB 4400 L10 IRB 4450 S M2004 ...

Page 4: ...ness 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 per mission and contents thereof must not be imparted to a third party nor be used for any unau thorized purpose Contravention will be prosec...

Page 5: ...uracy calibration 26 1 5 Load diagrams 28 1 5 1 Introduction 28 1 5 2 Diagrams 29 1 5 3 Maximum load and moment of inertia for full axis 5 movement 33 1 5 4 Wrist torque 34 1 6 Mounting equipment 35 1 6 1 Introduction 35 1 6 2 Robot tool flange 38 1 7 Maintenance and Troubleshooting 39 1 7 1 Introduction 39 1 8 Robot Motion 40 1 8 1 Introduction 40 1 8 2 Performance according to ISO 9283 48 1 8 3 ...

Page 6: ...Table of Contents 4 Rev N 3HAC9117 1 ...

Page 7: ...Marketing personnel Order and Customer Service personnel Contents Please see Table of Contents on page 3 Revisions Revision Description Revision 8 New values for Performance Acc to ISO 9283 added M2000 cancelled Revision J Foundry Prime added Option 287 5 Wash removed Revision K Text added to Clean room robots Footnote added to Pose accuracy Revision L Changes in chapter Standards Directions of fo...

Page 8: ...Complementary Product specifications Product specification Description Controller IRC5 with FlexPendant 3HAC021785 001 Controller Software IRC5 RobotWare 5 11 3HAC022349 001 Robot User Documen tation IRC5 and M2004 3HAC024534 001 ...

Page 9: ... Prime The robot version Foundry Prime is designed for water jet cleaning of casts and machined parts and similar very harsh environments The manipulator can withstand surrounding solvent based detergent max pH 9 0 and must contain rust inhibitor The detergent must be approved by ABB In addi tion the manipulator can withstand indirect spray from jet pressure max 600 bar and 100 humidity The manipu...

Page 10: ...nd robot control software RobotWare RobotWare supports every aspect of the robot system such as motion control development and execution of application programs communication etc See Product specification Controller IRC5 with FlexPendant Safety standards require a controller to be connected to the robot For additional functionality the robot can be equipped with optional software for application s...

Page 11: ...45 kg 1 96 m IRB 4400 60 60 kg 1 96 m IRB 4400 L30 30 kg 2 43 m IRB 4400 L10 10 kg 2 55 m IRB 4450S 30 kg 2 40 m Prefix description Robot type Description Version L S Long arm Shelf mounted manipulator Handling capacity Indicates the maximum handling capacity kg Robot type Weight IRB 4400 45 985 kg IRB 4400 60 1040 kg IRB 4400 L10 1040 kg IRB 4400 L30 1060 kg IRB 4450 S 1040 kg Data Description No...

Page 12: ...ath E1 E2 E3 E4 in the ISO Cube maximum load IRB 4400 45 Cube side 630 mm IRB 4400 60 Cube side 630 mm Figure 2 Path E1 E2 E3 E4 in the ISO Cube maximum load Speed mm s Power consumption kW Max 1 36 1000 0 95 500 0 74 100 0 62 Speed mm s Power consumption kW Max 1 33 1000 0 99 500 0 78 100 0 66 ...

Page 13: ...gure 3 Path E1 E2 E3 E4 in the ISO Cube maximum load IRB 4450 S Cube side 1000 mm Speed mm s Power consumption kW Max 1 15 1000 0 86 500 0 73 100 0 64 Speed mm s Power consumption kW Max 1 28 1000 0 63 500 0 53 100 0 48 Speed mm s Power consumption kW Max Not yet available 1000 Not yet available 500 Not yet available 100 Not yet available ...

Page 14: ...finition of version designation 12 Rev N 3HAC9117 1 Dimensions IRB 4400 45 IRB 4400 60 IRB 4400 L30 Figure 4 View of the manipulator from the side dimensions in mm Pos Description A 880 for 4400 45 and 60 B 1380 for 4400 L30 ...

Page 15: ... Definition of version designation 3HAC9117 1 Rev N 13 Figure 5 View of the manipulator from the side dimensions in mm IRB 4400 45 IRB 4400 60 and IRB 4400 L30 Figure 6 View of the manipulator from above dimensions in mm ...

Page 16: ...1 Description 1 1 3 Definition of version designation 14 Rev N 3HAC9117 1 IRB 4400 L10 Figure 7 View of the manipulator from the side and above dimensions in mm ...

Page 17: ...1 Description 1 1 3 Definition of version designation 3HAC9117 1 Rev N 15 IRB 4450 S Figure 8 View of the manipulator from the side behind and above dimensions in mm ...

Page 18: ...y Electrical equipment of machines EN ISO 10218 1 2006a a There is a deviation from paragraph 6 2 in that only worst case stop distances and stop times are documented Robots for industrial environments Safety requirements EN 61000 6 4 option EMC Generic emission EN 61000 6 2 EMC Generic immunity Standard Description IEC 60529 Degrees of protection provided by enclosures Standard Description ISO 97...

Page 19: ...d speed In manual mode the speed is limited to a maximum of 250 mm s 600 inch min The speed limitation applies not only to the TCP Tool Center Point but to all parts of the robot It is also possible to monitor the speed of equipment mounted on the robot Three position enabling device The enabling device on the FlexPendant must be used to move the robot when in manual mode The enabling device consi...

Page 20: ...hanical disturbance like a collision electrode sticking etc the robot will stop and slightly back off from its stop position Restricting the working space The movement of each axis can be restricted using software limits Axes 1 2 can also be restricted by means of mechanical stops and axis 3 by an electrical switch option Hold to run control Hold to run means that you must depress the start button...

Page 21: ...ncluding payload can be mounted on the mounting flange axis 6 See section Load diagrams Other equipment Extra loads can be mounted on the upper arm and on the base There are holes for mounting extra equipment see section Mounting equipment Figure 19 and Figure 20 Working range The working range of axes 1 2 can be limited by mechanical stops and axis 3 by limit switches Electronic Position Switches...

Page 22: ...4 Foundry Manipulator IP67 steam washable Description Standard Option Temperature Manipulator during opera tion Standard 5 C 41 F to 45 C 113 F For the controller Standard Option See Product specification Con troller IRC5 with FlexPendant Complete robot during transportation and storage Standard 25 C 13 F to 55 C 131 F For short periods not exceeding 24 hours Standard up to 70 C 158 F Description ...

Page 23: ...in operation all IRB 4400 Max load at emergency stop all IRB 4400 Force xy 7500 N 9000 N Force z 9500 2000 N 9500 3000 N Torque xy 14000 Nm 16000 Nm Torque z 2000 Nm 4000 Nm Endurance load in operation all IRB 4450 S Max load at emergency stop all IRB 4450 S Force xy 7500 N 10000 N Force z 9500 2000 N 9500 4000 N Torque xy 14000 Nm 16000 Nm Torque z 2000 Nm 4000 Nm ...

Page 24: ...he manipulator 22 Rev N 3HAC9117 1 Figure 9 Direction of forces Note regarding Mxy and Fxy The bending torque Mxy can occur in any direction in the XY plane of the base coordinate system The same applies to the transverse force Fxy ...

Page 25: ...iption 1 3 3 Mounting the manipulator 3HAC9117 1 Rev N 23 Figure 10 Hole configuration dimensions in mm Pos Description A Z center line axis 1 B The same dimensions C View from the bottom of the base D Section ...

Page 26: ...tion 1 3 3 Mounting the manipulator 24 Rev N 3HAC9117 1 Mounting surface and bushings Figure 11 Mounting surface and bushings Pos Description A Surface treatment ISO 2081 Fe Zn 8 c2 Guide Bushings B Common zone ...

Page 27: ...ing the Calibration Pendulum please see Operating manual Calibration Pendulum Figure 12 All axes in zero position Calibration Position Calibration of all axes All axes are in zero position Calibration of axis 1 and 2 Axis 1 and 2 in zero position Axis 3 to 6 in any position Calibration of axis 1 Axis 1 in zero position Axis 2 to 6 in any position ...

Page 28: ...curacy in the cartesian coordinate system for the robot It also includes load compensation for deflection caused by the tool and equipment Tool data from robot program is used for this purpose The positioning will be within specified performance regardless of load Calibration data The user is supplied with robot calibration data compensation parameters saved on the manipulator SMB and a certificat...

Page 29: ... and includes an individual calibration of the robot mechanical arm Absolute Accuracy is a TCP calibration in order to Reach m a good positioning in the Cartesian coordinate system Figure 13 The Cartesian coordinate system Production data Typical production data regarding calibration are Robot Positioning accuracy mm Average Max Within 1 mm IRB 4400 45 60 L30 and L10 0 30 0 75 100 IRB 4450 S a a F...

Page 30: ...ng parts can be damaged due to overload motors gearboxes mechanical structure It is very important to always define correct actual load data and correct payload of the robot Incorrect definitions of load data can result in overloading of the robot Robots running with incorrect load data and or with loads outside load diagram will not be covered by the robot warranty ...

Page 31: ...d mounted on the mounting flange at different positions center of gravity Description Z See the above diagram and the coordinate system in the Product specification IRC5 with FlexPendant L Distance in X Y plane from Z axis to the center of gravity J Maximum own moment of inertia on the total handle weight max 2 5 kgm2 ...

Page 32: ...ed on the mounting flange at different positions center of gravity Description Z See the above diagram and the coordinate system in the Product specification IRC5 with FlexPendant L Distance in X Y plane from Z axis to the center of gravity J Maximum own moment of inertia on the total handle weight max 2 5 kgm2 ...

Page 33: ...ad mounted on the mounting flange at different positions center of gravity Description Z See the above diagram and the coordinate system in the Product specification IRC5 with FlexPendant L Distance in X Y plane from Z axis to the center of gravity J Maximum own moment of inertia on the total handle weight max 1 3 kgm2 ...

Page 34: ...d on the mounting flange at different positions center of gravity Description Z See the above diagram and the coordinate system in the Product specification IRC5 with FlexPendant L Distance in X Y plane from Z axis to the center of gravity J Maximum own moment of inertia on the total handle weight max 0 040 kgm2 ...

Page 35: ...B 4400 L10 J5 Mass x Z 0 085 2 L2 max J0x J0y 1 15 kgm2 6 IRB 4400 L10 J6 Mass x L2 J0Z 0 70 kgm2 Axis Robot Type Max value 5 IRB 4400 L30 IRB 4450S J5 Mass x Z 0 14 2 L2 max J0x J0y 22 0 kgm2 6 IRB 4400 L30 IRB 4450S J6 Mass x L2 J0Z 12 0 kgm2 Axis Robot Type Max value 5 IRB 4400 45 J5 Mass x Z 0 14 2 L2 max J0x J0y 25 0 kgm2 6 IRB 4400 45 J6 Mass x L2 J0Z 16 5 kgm2 Axis Robot Type Max value 5 IR...

Page 36: ... load diagram since those also are lim ited by main axes torques as well as dynamic loads Also arm loads will influence the per mitted load diagram For finding the absolute limits of the load diagram please contact your local ABB organization Robot type Max wrist torque axis 4 and 5 Max wrist torque axis 6 Max torque valid at load IRB 4400 L10 20 6 Nm 9 81 Nm 10 kg RB 4400 L30 IRB 4450S 155 0 Nm 6...

Page 37: ...ndicates the permitted positions center of gravity for any extra equipment mounted in the holes dimensions in mm Pos Description A M8 2x Used if option 218 6 is chosen Depth of thread 9 B M8 3x Depth of thread 14 200 110 106 144 115 25 50 77 38 5 300 340 150 300 150 390 20o B B B B A A A 250 175 A Max 15 kg 54 D D D D 15 29 5 29 5 120o 3x 15o C C C C D 100 195 A B C D E F G ...

Page 38: ...071 for 4400L 30 D M6 2x tapped depth 12 E Max 5 kg for 4400 45 and 60 at max handling weight 5 kg for 4400L 30 and 4450S if handling weight is max 25 kg 0 kg if handling weight is 30 kg F M8 3x R 92 Depth 16 If option 34 1 is chosen these holes are occupied G Max 35 kg Pos Description ...

Page 39: ...ra equipment mounted in the holes dimensions in mm Pos Description A M6 2x Depth of thread 9 B M8 3x Depth of thread 14 E M8 3x R 92 Depth 16 If option 34 1 is chosen these holes are occupied 110 115 77 38 5 150 300 150 390 20o B B B B A A A 250 175 A Max 15 kg 54 Max 2 kg 110 25 43 D 240 22 78 300 1221 M5 2x 120o 3x 15o C C C C D 100 195 Max 35 kg A B C ...

Page 40: ... Rev N 3HAC9117 1 1 6 2 Robot tool flange IRB 4400 45 IRB 4400 60 IRB 4400 L30 and IRB 4450 S Figure 21 The mechanical interface mounting flange dimensions in mm IRB 4400 L10 Figure 22 The mechanical interface mounting flange dimensions in mm ...

Page 41: ...e as possible Maintenance free AC motors are used Oil is used for the gear boxes The cabling is routed for longevity and in the unlikely event of a failure its modular design makes it easy to change Maintenance The maintenance intervals depend on the use of the robot the required maintenance activities also depend on selected options For detailed information on maintenance procedures see Maintenan...

Page 42: ... 70 Axis 3 Arm motion 65 to 60 Axis 4 Wrist motion 200 to 200 Axis 5 Bend motion 120 to 120 Axis 6 Turn motion 400 to 400 200 rev a to 200 rev Max b a rev Revolutions b The default working range for axis 6 can be extended by changing parameter values in the software Option 610 1 Independent axis can be used for resetting the revolution counter after the axis has been rotated no need for rewinding ...

Page 43: ...B 4400 45 and 60 dimensions in mm Positions mm and Angles degrees for IRB 4400 45 and IRB 4400 60 Position No see Figure 23 Position mm X Position mm Z Angle degrees Axis 2 Angle degrees Axis 3 0 1080 1720 0 0 1 887 2140 0 30 2 708 836 0 65 3 1894 221 95 60 4 570 126 95 40 5 51 1554 70 40 6 227 1210 70 65 ...

Page 44: ...to 60 Axis 4 Wrist motion 200 to 200 Axis 5 Bend motion 120 to 120 Axis 6 Turn motion 400 to 400 200 rev a to 200 rev Max b a rev Revolutions b The default working range for axis 6 can be extended by changing parameter values in the software Option 610 1 Independent axis can be used for resetting the revolution counter after the axis has been rotated no need for rewinding the axis ...

Page 45: ...bot arm IRB 4400 L30 dimensions in mm Positions mm and Angles degrees for IRB 4400 L30 Position No see Figure 24 Position mm X Position mm Z Angle degrees Axis 2 Angle degrees Axis 3 0 1580 1720 0 0 1 1320 2390 0 30 2 919 383 0 65 3 2303 66 95 60 4 180 448 95 42 5 484 1804 70 40 6 725 1254 70 65 ...

Page 46: ...to 60 Axis 4 Wrist motion 200 to 200 Axis 5 Bend motion 120 to 120 Axis 6 Turn motion 400 to 400 183 rev a to 183 rev Max b a rev Revolutions b The default working range for axis 6 can be extended by changing parameter values in the software Option 610 1 Independent axis can be used for resetting the revolution counter after the axis has been rotated no need for rewinding the axis ...

Page 47: ...ot arm IRB 4400 L10 dimensions in mm Positions mm and Angles degrees for IRB 4400 L10 Position No see Figure 25 Position mm X Position mm Z Angle degrees Axis 2 Angle degrees Axis 3 0 1700 1720 0 0 1 1424 2450 0 30 2 970 274 0 65 3 2401 135 95 60 4 500 786 95 24 5 588 1864 70 40 6 845 1265 70 65 ...

Page 48: ...o 60 Axis 4 Wrist motion 200 to 200 Axis 5 Bend motion 120 to 120 Axis 6 Turn motion 400 to 400 200 rev a to 200 rev Max b a rev Revolutions b The default working range for axis 6 can be extended by changing parameter values in the software Option 610 1 Independent axis can be used for resetting the revolution counter after the axis has been rotated no need for rewinding the axis ...

Page 49: ...obot arm IRB 4450 S dimensions in mm Positions mm and Angles degrees for IRB 4450 S Position No see Figure 26 Position mm X Position mm Z Angle degrees Axis 2 Angle degrees Axis 3 0 2006 556 0 0 1 2190 978 0 30 2 1437 1054 95 60 3 294 303 95 40 4 1101 239 0 65 5 1058 847 70 65 6 1195 1208 70 40 ...

Page 50: ...al path at program execution AP Mean distance from programmed position AT Max deviation from E RP Tolerance of posiotion B at repeated positioning RT Tolerance of the path at repeated program execution Description Values IRB 4400L 10 4400 30 4400 45 4400 60 4450S Pose accuracy APa mm a AP according to the ISO test above is the difference between the teached position position manually modified in t...

Page 51: ...vision is required to prevent overheating in applications with intensive and frequent movements Resolution Approx 0 01o on each axis Axis no IRB 4400 45 60 L30 and IRB 4450 S IRB 4400 L10 1 150 s 150 s 2 120 s 150 s 3 120 s 150 s 4 225 s 370 s 5 250 s 330 s 6 330 s 381 s ...

Page 52: ...7 2 17 0 2 28 0 3 25 0 3 3 13 0 2 27 0 3 26 0 3 Robot Type Category 0 Category 1 Main power failure Axis A B A B A B IRB 4400L 30 1 68 0 9 95 1 2 n a n a 2 15 0 3 22 0 4 20 0 3 3 21 0 4 35 0 6 30 0 4 Robot Type Category 0 Category 1 Main power failure Axis A B A B A B IRB 4400 45 1 60 0 9 73 0 9 46 0 9 2 15 0 3 25 0 4 24 0 3 3 13 0 2 22 0 3 22 0 3 Robot Type Category 0 Category 1 Main power failur...

Page 53: ...e manipulator s cabling one FCI UT07 14 12SH44N connector and one FCI UT07 18 23SH44N connector on the rear part of the upper arm Hose for compressed air is also integrated into the manipulator There is an inlet R1 4 at the base and an outlet R1 4 on the rear part of the upper arm Number Value Signals 23 50 V 250 mA Power 10 250 V 2 A Air 1 Max 8 bar inner hose diameter 8 mm ...

Page 54: ...1 Description 1 8 5 Signals 52 Rev N 3HAC9117 1 ...

Page 55: ...roller IRC5 with FlexPendant and for software options see Product specification Controller software IRC5 RobotWare 2 1 2 Manipulator Variants Manipulator color Option IRB Type Handling capacity kg Reach m 435 37 IRB 4000 45 45 1 96 435 38 IRB 4400 60 60 1 96 435 42 IRB 4400 L30 30 2 43 435 41 IRB 4400 L10 10 2 55 435 62 IRB 4450S 30 2 40 Option Description 209 1 Protection Standard and Foundry hav...

Page 56: ...ry Primea Robots adapted for water jet cleaning of casts and machined parts and similar very harsh environments The manipulator can withstand surrounding solvent based detergent max pH 9 0 and must contain rust inhibitor The detergent must be approved by ABB In addition the manipulator can withstand indirect spray from jet pressure max 600 bar and 100 humidity The manipulator can work in an enviro...

Page 57: ...hose and cables Figure 29 Hose and cables Option Description 218 8 Integrated hose and cables for connection of extra equipment on the manipu lator to the rear end of the upper arm Option Description 218 6 Hose and cables for connection of extra equipment are continuing to the wrist on the outside of the upper arm Not available for options 435 41 435 42 435 43 287 3 and 287 5 ...

Page 58: ...internal cabling are then delivered separately to be mounted in the main robot Control Module or in another encapsulation for example a PLC cabinet Cabinet The signals are connected to 12 pole screw terminals Phoenix MSTB 2 5 12 ST 5 08 to the the controller Pos Description A If 218 6 B If 16 1 Option Lengths 94 1 7 m 94 2 15 m 94 3 22 m 94 4 30 m Option Description 213 1 Safety lamp A safety lamp...

Page 59: ...duct specification Controller IRC5 with FlexPendant and Application Manual Electronic Position Switches art No 3HAC0277709 001 Connector kit Detached connectors suitable to the connectors for the application interface and position switches The kit consists of connectors pins and sockets Option Description 431 1 For the connectors on the upper arm 239 1 For the connectors on the foot if connection ...

Page 60: ...0 60 IRB 4400 L30 IRB 4400 L10 Figure 32 Mounting positions of the stops axis 2 Option Description 28 1 Axis 1 Two extra stops for restricting the working range The stops can be mounted within the area from 65 to 125 See Figure 31 Option Description 32 1 Axis 2 Stop lugs for restricting the working range Figure 33 illustrates the mounting positions of the stops ...

Page 61: ...ranty Standard warranty is 18 months 1 1 2 years 438 2 Standard 12 months 18 12 months 2 1 2 years 438 4 Standard 18 months 18 18 months 3 years 438 5 Standard 24 months 18 24 months 3 1 2 years 438 6 Standard 6 months 18 6 months 2 years 438 8 Stock Warranty Maximum 6 months postponed warranty starting from shipment date ABB Robotics Production unit PRU Option 438 1 Warranty commences automatical...

Page 62: ...or cable length Connection of parallel communication 2 1 4 Documentation DVD User Documentation Option Lengths 210 2 7 m 210 3 15 m 210 4 22 m 210 5 30 m Option Lengths 94 1 7 m 94 2 15 m 94 3 22 m 94 4 30 m Option Type Description 808 1 Documentation on DVD See Product specification Robot User Documentation ...

Page 63: ...ories Basic software and software options for robot and PC For more information see Product specification Controller IRC5 with Flex Pendant and Product specification Controller software IRC5 RobotWare Robot Peripherals Track Motion Motor Units ...

Page 64: ...3 Accessories 62 Rev N 3HAC9117 1 ...

Page 65: ...nting extra equipment 35 robot 21 mounting flange 38 N noise level 9 O operating requirements 20 options 53 overspeed protection 17 P path 48 payload 19 performance 48 pose 48 protection standards 20 R range of movement working space 40 42 44 46 reduced speed 17 repeatability 48 Robot Peripherals 61 robot versions 9 S safeguarded space stop 18 delayed 18 safety 16 safety lamp 18 56 service 39 serv...

Page 66: ...Index 64 Rev N 3HAC9117 1 ...

Page 67: ......

Page 68: ...ABB AB Robotics Products S 721 68 VÄSTERÅS SWEDEN Telephone 46 0 21 344000 Telefax 46 0 21 132592 3HAC 9117 1 Revision N en ...

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