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ABB Levelmeter 2000, Instructions Manual

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ABB Levelmeter 2000 Instructions Manual Download Page 12

1 Overview

1.3. Calibration, prerequisites

   

3HAC 022907-001 Revision: -

10

1.3. Calibration, prerequisites

Peripheral equipment

The robots upper arm must be free from any peripheral equipment during calibration. Fitted 

tools and similar will cause erroneous calibration positions.

Calibration order

The axes must be adjusted in increasing sequence, i.e. 1 - 2 - 3 - 4 - 5 - 6. 

Summary of Contents for Levelmeter 2000

Page 1: ...Instructions for Levelmeter calibration alternative method Calibration equipment Levelmeter 2000 IRB 140 IRB 1400 IRB 2400 IRB 4400 IRB 6600 IRB 6650 IRB 6650S IRB 7600 IRB 6400R...

Page 2: ......

Page 3: ...Instructions for Levelmeter calibration alternative method Levelmeter 2000 IRB 140 IRB 1400 IRB 2400 IRB 4400 IRB 6600 IRB 6650 IRB 6650S IRB 7600 IRB 6400R Document ID 3HAC 022907 001 Revision...

Page 4: ...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...

Page 5: ...25 3 Calibration 37 3 1 Introduction 37 3 2 Calibration axis 1 IRB 140 38 3 3 Calibration axis 1 IRB 1400 40 3 4 Calibration axis 1 IRB 2400 42 3 5 Calibration axis 1 IRB 4400 44 3 6 Calibration axis...

Page 6: ...Table of Contents 3HAC 022907 001 Revision 4...

Page 7: ...bration does and how it is performed Organization of chapters The manual is organized in the following chapters Revisions Chapter Contents Overview General information about when to calibrate the robo...

Page 8: ...Overview 3HAC 022907 001 Revision 6...

Page 9: ...1 Overview 1 1 Introduction General This chapter contains a brief description of how to calibrate a robot using the alternative method with the Levelmeter 2000 This chapter also includes facts useful...

Page 10: ...a resolver and measurement board is interrupted a robot axis is moved with the control system disconnected Overview Levelmeter Calibration The calibration procedure with Levelmeter 2000 may be perfor...

Page 11: ...otWare 4 0 Detailed in section Fine calibration procedure on FlexPendant on page 67 RobotWare 5 0 5 Calibrate each axis Detailed in each axis calibration instruction 6 Verify that the calibration was...

Page 12: ...bration prerequisites Peripheral equipment The robots upper arm must be free from any peripheral equipment during calibration Fitted tools and similar will cause erroneous calibration positions Calibr...

Page 13: ...towards the calibration position in the same direction in order to avoid position errors caused by backlash in gears etc Positive directions are shown in the figure below This is normally handled by t...

Page 14: ...1 Overview 1 4 Calibration movement directions for all axes 3HAC 022907 001 Revision 12...

Page 15: ...information 2 1 Introduction 13 3HAC 022907 001 Revision 2 Reference information 2 1 Introduction General This chapter contains necessary reference information for performing the actual calibration o...

Page 16: ...equipment such as cleaning agents etc IRB 140 IRB 1400 IRB 2400 IRB 4400 IRB 6600 6650 6650S 7600 IRB 6400R Equipment Art no Calibration tool 3HAC 0181 1 Equipment Art no Calibration tool 3HAB 1378 1...

Page 17: ...With sensor Sensor fixture 6808 0011 GM All At reference plane Angle bracket 6808 0011 LP All Axis 2 Turning disk fixture 6808 0011 GU All Axes 3 4 5 and 6 Guide pins included Sync adapter 3HAB 7981...

Page 18: ...evision 16 2 4 Calibration scales and correct axis position Introduction This section specifies the calibration scale positions and or correct axis position for all robot models Calibration scales IRB...

Page 19: ...ence information 2 4 Calibration scales and correct axis position 17 3HAC 022907 001 Revision Calibration scales IRB 1400 The illustration below shows the calibration scale positions on IRB 1400 en020...

Page 20: ...ence information 2 4 Calibration scales and correct axis position 3HAC 022907 001 Revision 18 Calibration scales IRB 2400 The illustration below shows the calibration scale positions on IRB 2400 en020...

Page 21: ...low shows the calibration scale positions on IRB 4400 The calibration marks for axes 2 3 4 and 5 are marked using punch mark tools xx0300000209 A Punch axis 2 3HAB 1521 1 B Punch axis 3 3HAB 1522 1 C...

Page 22: ...at axes 2 and 3 The calibration marks at axes 2 and 3 shown in the figure above consist of two single marks that should be positioned opposite to one another when the robot is standing in its calibra...

Page 23: ...Detailed procedures are given further down 1 Select the correct filter type as detailed in Illustration Levelmeter 2000 on page 21 2 Set the measuring unit as detailed in Measuring units on page 22 3...

Page 24: ...5 does not flash press ZERO SELECT to select filter type 5 and press ENTER Step Action Info Illustration 1 Press ON MODE until the dot flashes under UNIT Shown in the figure Illustration Levelmeter 20...

Page 25: ...0 0 0 0 0 9E9 9E9 9E9 9E9 9E9 9E9 NoEOffs v1000 z50 Tool0 4 Run the program in manual mode 5 Check that the calibration marks for the axes align correctly If they do not update the revolution counter...

Page 26: ...s for the axes align correctly If they do not update the revolution counters The calibration marks are shown in section Calibration scales and correct axis position on page 16 Detailed in section Upda...

Page 27: ...axes of the robot The reference sensor and the calibration sensor is consequently the same sensor used at different locations When using the sensor as a reference at the base it is fitted to a sensor...

Page 28: ...irections of sensor 3HAC 022907 001 Revision 26 Calibration sensor axis 1 IRB 140 xx0200000140 Calibration sensor axis 2 IRB 140 xx0200000144 1 Reference surface 2 Calibration tool on axis 1 A Calibra...

Page 29: ...ections of sensor 27 3HAC 022907 001 Revision Calibration sensor axis 3 IRB 140 xx0200000145 Calibration sensor axis 4 IRB 140 xx0200000146 A Calibration sensor position and orientation axis 3 A Calib...

Page 30: ...ections of sensor 3HAC 022907 001 Revision 28 Calibration sensor axis 5 IRB 140 xx0200000147 Calibration sensor axis 6 IRB 140 xx0200000148 A Calibration sensor position and orientation axis 5 A Calib...

Page 31: ...his section specifies the position and alignment of the calibration sensor at the reference plane and on each axis of IRB 1400 xx0400001019 A Axis 2 sensor B Axis 3 sensor C Axis 4 sensor D Axis 5 sen...

Page 32: ...tion specifies the position and alignment of the calibration sensor at the reference plane and on each axis of IRB 2400 xx0300000218 A View from above Axis 2 B View from above Axis 6 C View from above...

Page 33: ...alignment of the calibration sensor at the reference plane and on each axis of IRB 4400 xx0300000204 A Flange plate B Axis 2 sensor B1 Axis 2 sensor view from above C Axis 3 sensor D Axis 4 sensor E...

Page 34: ...nd IRB 7600 The figures show IRB 7600 but the positions and alignments are the same for IRB 6600 6650 6650S Calibration sensor at reference plane IRB 6600 IRB 6650 IRB 6650S IRB 7600 The reference sen...

Page 35: ...3 3HAC 022907 001 Revision Calibration sensor at axes IRB 6600 IRB 6650 IRB 6650S IRB 7600 The calibration sensor is positioned and aligned on the axes as shown in the figures below xx0200000091 xx020...

Page 36: ...2 Reference information 2 7 Positions and directions of sensor 3HAC 022907 001 Revision 34 xx0200000093 A Calibration sensor axis 4...

Page 37: ...2 Reference information 2 7 Positions and directions of sensor 35 3HAC 022907 001 Revision xx0200000094 xx0200000095 A Calibration sensor axis 5 A Calibration sensor axis 6...

Page 38: ...on specifies the position and alignment of the calibration sensor at the reference plane and on each axis of IRB 6400R xx0400001134 A Reference plane B Direction for sensor at reference plane axes 2 3...

Page 39: ...native method with the Levelmeter 2000 The chapter is divided so that calibration of each axis is detailed in separate sections Only calibration of axis 1 is unique for each robot model otherwise the...

Page 40: ...ral This section details how to perform the mechanical calibration of axis 1 using special calibration equipment without sensors Required equipment Location of calibration tools axis 1 xx0200000140 Eq...

Page 41: ...n section Required equipment on page 38 2 Attach the calibration tool to the flat surface Shown in section Location of calibration tools axis 1 on page 38 3 Turn the operating mode selector to MANUAL...

Page 42: ...alibration equipment without sensors Required equipment Location of calibration tools axis 1 The special calibration equipment is fitted to the base of the robot as shown in the figure below xx0400001...

Page 43: ...in Required equipment on page 40 3 Fit the calibration tool axis 1 on the guide pin underneath the gearbox Art no is specified in Required equipment on page 40 Shown in the figure Location of calibrat...

Page 44: ...echanical calibration of axis 1 using special calibration equipment without sensors Required equipment Location of calibration equipment axis 1 The special calibration equipment for axis 1 is fitted t...

Page 45: ...on tool on the guide pin underneath the gearbox Art no is specified in Required equipment on page 42 5 Release the brakes and move the robot manually so that the calibration tool can be fixed to the b...

Page 46: ...ut sensors Required equipment Location of calibration tool axis 1 The special calibration equipment is fitted to the base of the robot as shown in the figure below xx0300000202 Equipment etc Art no No...

Page 47: ...age 44 3 Fit the calibration tool on the guide pin underneath the gearbox Art no is specified in Required equipment on page 44 Shown in the figure Location of calibration tool axis 1 on page 44 4 Fit...

Page 48: ...rated differently as detailed in section Calibration axis 1 IRB 7600 early design on page 48 Equipment Calibration tool position The calibration bracket calibration tool and measuring pin are position...

Page 49: ...n tab frame Shown in the figure Calibration tool position on page 46 6 Fit the measuring pin to the base of the robot Shown in the figure Calibration tool position on page 46 7 Fit the calibration too...

Page 50: ...designs of the calibration tabs on the base This section details how to calibrate axis 1 when the robot has the earlier design of the tabs Required equipment Calibration tool position early design The...

Page 51: ...nd base according to the figure Calibration tool position early design on page 48 If the tool fits over both tabs alt over the pin and the bracket simultaneously axis 1 is correctly If not manually ru...

Page 52: ...pin 6896 0011 YN Calibration tool 3HAB 7477 1 Step Action Note 1 Remove the cover plate from the reference surface on the base of the robot Clean the surface with isopropanol and deburr it 2 Fit the...

Page 53: ...1 is calibrated correctly If not manually run axis 1 with the joystick until the tool may be fitted over both the pin and the fixture Art no is specified in Equipment on page 50 xx0400001129 7 Update...

Page 54: ...tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Step Action Note 1 Reset the l...

Page 55: ...mm m IRB 6600 IRB 6650 IRB 6650S IRB 7600 0 0 05 mm m 7 Update only axis 2 Detailed in sections Fine calibration procedure on TPU on page 65 RobotWare 4 0 Fine calibration procedure on FlexPendant on...

Page 56: ...1 1 Required for robots IRB 2400 10 IRB 2400 16 Sync adapter 3HAB 1525 1 Required for robot IRB 4400 Sync adapter 3HAC13908 1 Required for robots IRB 6600 IRB 6650 IRB 6650S IRB 7600 Sync adapter 6896...

Page 57: ...e time as the screws are tightened 4 Run the program SYSTEM UTILITY SERVICE CALIBRAT CALxx xx xxxx robot model e g 7600 in the system and select Calib CAL3 The robot moves to the position for calibrat...

Page 58: ...on FlexPendant on page 67 RobotWare 5 0 10 Remove the sensor 11 Check the calibration according to section Post calibration procedure on page 78 or continue with calibration of next axis 12 Refit the...

Page 59: ...1 1 Required for robots IRB 2400 10 IRB 2400 16 Sync adapter 3HAB 1525 1 Required for robot IRB 4400 Sync adapter 3HAC13908 1 Required for robots IRB 6600 IRB 6650 IRB 6650S IRB 7600 Sync adapter 6896...

Page 60: ...s the screws are tightened 4 Run the program SYSTEM UTILITY SERVICE CALIBRAT CALxx xx xxxx robot model e g 7600 in the system and select Calib CAL4A The robot moves to the position for calibration of...

Page 61: ...position 12 Update only axis 4 Detailed in sections Fine calibration procedure on TPU on page 65 RobotWare 4 0 Fine calibration procedure on FlexPendant on page 67 RobotWare 5 0 13 Check the calibrati...

Page 62: ...1 1 Required for robots IRB 2400 10 IRB 2400 16 Sync adapter 3HAB 1525 1 Required for robot IRB 4400 Sync adapter 3HAC13908 1 Required for robots IRB 6600 IRB 6650 IRB 6650S IRB 7600 Sync adapter 6896...

Page 63: ...as the screws are tightened 4 Run the program SYSTEM UTILITY SERVICE CALIBRAT CALxx xx xxxx robot model e g 7600 in the system and select Calib CAL5 The robot will now move to the position for calibr...

Page 64: ...on FlexPendant on page 67 RobotWare 5 0 10 Remove the sensor 11 Check the calibration according to section Post calibration procedure on page 78 or continue with calibration of next axis 12 Refit the...

Page 65: ...1 1 Required for robots IRB 2400 10 IRB 2400 16 Sync adapter 3HAB 1525 1 Required for robot IRB 4400 Sync adapter 3HAC13908 1 Required for robots IRB 6600 IRB 6650 IRB 6650S IRB 7600 Sync adapter 6896...

Page 66: ...he securing screws with approximately the same tightening torque used at the reference plane Shown in section Positions and directions of sensor on page 25 4 Tip Reduce the jogging velocity in order t...

Page 67: ...Calibration from the View menu The Calibration window appears If multiple units are connected to the robot they will be listed in the window xx0100000201 The calibration status can be any of the foll...

Page 68: ...w appears xx0100000204 6 Select the desired axis and press Incl to include it it will be marked with an x or press All to select all axes 7 Press OK when all axes that are to be updated are marked wit...

Page 69: ...instruction for the axis Fine calibration procedure The procedure below details how to perform the fine calibration procedure on the FlexPendant Step Action 1 Warning Do not fine calibrate the robot...

Page 70: ...hange programmed robot positions is also displayed Tap Yes to proceed Tap No to cancel Tapping Yes results in displaying a new screen 5 Select the axis to calibrate by Checking the box to the left 6 T...

Page 71: ...0 and sensor General The equipment must first be reset before calibrating each axis This section details how to reset the Levelmeter 2000 and make the one sensor ready for calibration Levelmeter 2000...

Page 72: ...100000207 Required equipment NOTE Always secure the sensor to the sensor fixture using screws and with approximately the same torque each time NOTE Always fit the sensor in the same direction when res...

Page 73: ...e on the robot base Shown in the section Positions and directions of sensor on page 25 4 Clean the area where the sensor fixture is fitted with isopropanol 5 Fit the sensor fixture on the reference su...

Page 74: ...either on the lower arm or underneath the flange plate on the base At delivery the robot is in the correct position do NOT rotate axis 4 or 6 at power up before the revolution counters are updated If...

Page 75: ...window xx0100000194 2 Select Calibration from the View menu The Calibration window appears If there is more than one unit connected to the robot they will be listed in the window xx0100000201 3 Select...

Page 76: ...ended that the revolution counter values are saved to a diskette Not required 8 Caution If a revolution counter is incorrectly updated it will cause incorrect robot positioning which in turn may cause...

Page 77: ...ox to the left Tapping Select all to update all axes Then tap Update 5 A dialog box is displayed warning that the updating operation cannot be undone Tap Update to proceed with updating the revolution...

Page 78: ...3 Calibration 3 17 Updating revolution counters 3HAC 022907 001 Revision 76...

Page 79: ...on 4 1 Introduction 77 3HAC 022907 001 Revision 4 After calibration 4 1 Introduction General This chapter details the final step in the calibration procedure how to verify that the calibration of the...

Page 80: ...6400R Check the calibration positions of axes 2 5 and 6 If axes 5 and 6 are within the tolerances given below then axes 3 and 4 do not need to be checked The acceptable accuracy is IRB 4400 IRB 6400R...

Page 81: ...C Calibration position 72 calibration position checking 23 calibration position jog to 24 D direction of axes 11 N negative directions axes 11 P positive directions axes 11 R Revolution counters 72 U...

Page 82: ......

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