ABB TSC 2013 Assembly Instructions Manual
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ABB TSC 2013 Assembly Instructions Manual

ABB TSC 2013 Assembly Instructions Manual

Torch service center
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R O B OT I C S
Assembly instructions
Torch Service Center TSC 2013

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Summary of Contents for ABB TSC 2013

  • Page 1 — R O B OT I C S Assembly instructions Torch Service Center TSC 2013...

  • Page 2: Document:

    ABB for losses, damages to persons or property, fitness for a specific purpose or the like. In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein.

  • Page 3: Table Of Contents

    Non-designated use ............. Installation declaration for TC/TSC 2013....... . .
  • Page 4 2.4.3 Installation ..............2-12 2.4.4 Setting .
  • Page 5 Safety ..............Features of TCP gauging .

  • Page 6: Contents 3Hda000057A8519-001

    Contents 3HDA000057A8519-001...
  • Page 7 Area of use The TC/TSC 2013 is a tool of the robot and is controlled by the robot. It is used in robotic MIG/MAG welding units Torch Service Center - TSC 2013...
  • Page 8 The quality, performance and functionality of the TSC 2013 are only attained if it is used in welding units designed by ABB. The TC/TSC 2013 may only be used in the intended area of use (war- ranty!). ABB reserves the right to make technical modifications necessary to improve the TC/TSC 2013.
  • Page 9 Requirements Each person working on an ABB industrial robot must be trained by ABB and have the necessary knowledge on mechanical, pneumatic and electrical work, The robot manuals must therefore also be made available to the reader of these instructions.
  • Page 10 3HDA000057A8519-001 Torch Service Center - TSC 2013...

  • Page 11: Torch Service Center - Tsc 2013

    = Torch, S= Service, C= Center 1.1.1 Designated use The TSC 2013 is a compact, multi-functional torch service station and is used exclusively in auto- matic robot gas-shielded arc welding for torch cleaning, wire cutting and TCP gauging. Intended place of installation: In the working range of an industrial robot.

  • Page 12: Installation Declaration For Tc/Tsc 2013

    Installation declaration for TC/TSC 2013 Installation declaration for TC/TSC 2013 3HDA000057A8519-001 Torch Service Center - TSC 2013...

  • Page 13: Safety

    1.3.2 Sources of danger The TSC 2013 is installed in the working range of the industrial robot. Robots have a very high diversity of movement and operate with high accelerations. In automatic operation the robot is pro- gram-controlled and may also start up unexpectedly after being at rest for a prolonged period. Per- sons struck by the motion of a robot may suffer severe and fatal injuries.

  • Page 14: Possible Dangers Due To Fire

    There is a safety data sheet for the release agent for spraying the gas nozzle in accordance with Regulation (EC) No 1907/2006 (REACH) (Section 5 Appendix). NOTICE The release agent AS 72-K does not contain any chem- ical substances subject to the duty of notification under Regulation No 1907/2006 (REACH). 3HDA000057A8519-001 Torch Service Center - TSC 2013...

  • Page 15: Transport And Storage

    Do not throw, do not drop! 1.4.2 Transport and packaging Before dispatch by ABB, each TSC 2013 or separately ordered assembly is checked for damage and completeness. Protective packaging made of re-usable material is intended for transport. The transport packaging is selected depending on the assembly to be supplied and number of...

  • Page 16: Damage In Transport

    Pallet with wooden crate 1.4.3 Damage in transport If the TSC 2013 or separately ordered assemblies have been damaged in transport, the transport company must be informed immediately for an expert assessment and a concealed damage claim must be made.

  • Page 17: Structure And Function

    Structure and function Structure and function The TSC 2013 consists of three assemblies, which are also available separately. Torch cleaner TC 2013 Wire cutter TCP gauging The TSC 2013 fulfils the following functions: • cleaning the torch gas nozzle of weld spatter and spraying with release agent, •...

  • Page 18: Torch Cleaner Tc 2013

    TCP measurement is used to measure and adjust the robot tool center point (TCP) It is available as an add-on module for the TC 2013 or a standalone version (with stand). NOTICE A detailed description can be found in Chapter 4 TCP ® gauging (BullsEye 1-12 3HDA000057A8519-001 Torch Service Center - TSC 2013...

  • Page 19: Technical Data Of Tsc 2013

    34 kg Rating plate There is a rating plate on the TC 2013 with the following particulars: * Note: This number of sequential and is issued individually for each delivered TC 2013. Torch Service Center - TSC 2013 3HDA000057A8519-001 1-13...

  • Page 20: Torch Cleaner Tc 2013

    A-A ( 1 : 5 ) Spacer plate Milling cutter Clambing cylinder Wire cutter Spray head Pos. Assembly Article No Torch cleaner TC 2013 3HDA000057A5527 Wire cutter 3HDA000000A9289 TCP measurement 3HDA000000A9324 Weight: 32 kg without release agent 1-14 3HDA000057A8519-001 Torch Service Center - TSC 2013...

  • Page 21: Torch Cleaner Tc 2013

    Torch cleaner TC 2013 TC 2013 means T = Torch; C = Cleaner; 2013 = Generation 2013 The TC 2013 torch cleaner is an assembly which, unlike the TSC 2013, is supplied without a wire cutter and TCP gauging. 2.1.1 Designated use...

  • Page 22: Technical Data Of Tc 2013

    Technical data of TC 2013 Technical data of TC 2013 Control voltage 24VDC Max. current consumption 0,4 A Air connection G 1/8" at 5-10 bar Clamping cylinder Ø 65 x 34 mm stroke F = 1227N at 5 bar Gas nozzle external diameter min.

  • Page 23: Torch Cleaning Device Tc 2013

    Technical data of TC 2013 2.2.1 Torch cleaning device TC 2013 Figure 2-1 Dimensions TC 2013 Protective sleeve Adjusting tip Spacer plate Milling Clambing Spray head cylinder cutter Torch cleaner TC 2013 3HDA000057A8519-001...

  • Page 24: Milling Cutter

    Figure 2-1 for removing welding spatters is selected into depen- dence of the type of the gas nozzle. NOTICE In principle, the TSC 2013 is delivered without milling cutter. This must separately be ordered from ABB as a spare part. NOTICE...

  • Page 25: Spacer Plates

    Figure 2-1 is selected into dependence of the used gas nozzle diameter. NOTICE The gas nozzle diameter has to be transmitted to ABB Automation GmbH as in Section 2.2.2 "Milling cutter" described. Spacer plates are available in the following strengths:...

  • Page 26: Structure And Function

    Structure and function Structure and function The function of the TC 2013, unlike the complete TSC 2013, contains only the cleaning/milling of the torch and subsequent spraying of liquid weld spatter release agent. The wire-cutting and TCP gauging functions are included in the basic unit.

  • Page 27: Function

    Structure and function 2.3.2 Function Torch cleaning is performed fully automatically by a rotating tool (milling cutter). The welding torch is clamped in a holding mechanism (V-block) for this purpose. The external surface of the contact tip nozzle and the internal surface of the gas nozzle are then cleared of weld spatter in one oper- ation.
  • Page 28 Structure and function Height adjustment without TCP gauging* It is recommended that the optimum height is determined depending on the center of the ful- crum of robot axis 2 (guide value). Optimum height means that the robot arm reaches the TC2013 by the shortest route and can swivel in horizontally with minimal height movement.
  • Page 29 Structure and function 2.3.2.5 Spray device (Pos. 5) The spray device consists of a 3/2-way valve, the spray head and a release agent tank with liquid sensor. The spray device wets the cleaned gas nozzle with release agent free of silicone and sol- vent.

  • Page 30: Replacement Parts

    Structure and function 2.3.3 Replacement parts The replacement parts include: • Milling cutter (can be ordered individually) • Replacement spacer plate for the clamping V-block (can be ordered individually) • Release agent tank (1 litre silicone-free weld spatter release agent) 2.3.3.1 Replacing milling cutter Remove protective cover (1).

  • Page 31: Assembly And Disassembly

    Assembly and disassembly Assembly and disassembly 2.4.1 General The TC 2013 is supplied fully assembled. Each individual unit is tested after manufacturing and provided with a serial number. The test results are recorded. After receipt of the delivery, the TC 2013 is to be examined for any damage in transport and for completeness on the basis of the delivery note.

  • Page 32: Installation

    Assembly and disassembly 2.4.3 Installation 2.4.3.1 Electrical installation WARNING Electrical installation must only be performed by qual- ified personnel! NOTICE The attached electrical circuit diagram must be observed in installation! (see Chapter 2.10 Electrical circuit diagram) The grounding actions performed must be checked by measurements and recorded.

  • Page 33: Setting

    Assembly and disassembly Air quality The compressed air must comply with „class 4“ or better in accordance with to ISO 8573-1:2010. Operating pressure The operating pressure for the TC 2013 must be at least 5 bar and must not exceed 10 bar. It acts in the same way for all air consumers on the unit.

  • Page 34: Setting Of Spray Mechanism

    Assembly and disassembly 2.4.5 Setting of spray mechanism Check level of liquid in release agent tank (1) and if necessary top up or replace bottle. Set system pressure of 6 bar in the pressure control valve (2) . The degree of nebulisation is set on the set- ting screw (3).

  • Page 35: Disassembly

    Assembly and disassembly 2.4.6 Disassembly CAUTION Before the TC 2013 is disassembled the unit must be completely switched off and protected against being turned back on! All lines must be pressureless and empty. Disconnect power supply. Disconnect compressed air connection. Detach grounding cable.

  • Page 36: Commissioning

    Commissioning Commissioning 2.5.1 Instructions for commissioning Before operating for the first time it should be checked that • all components are correctly assembled and attached, • all electrical connections are correctly made, • all pneumatic connections are correctly dimensioned and connected, •...

  • Page 37: Switching On

    Commissioning 2.5.3 Switching on The TC 2013 is ready for operation when the robot control is switched on. CAUTION Danger of electric shock! Make sure that all live components are properly cov- ered. 2.5.4 Modes The welding system is designed for automatic operation. The program specified for the TC 2013 is designed for automatic operation.
  • Page 38 Commissioning • The spraying device wets the torch head with an anti-adhesion fluid which prevents early depo- sition of new weld spatter. • The period of spraying is fixed in the program. Two short sprays is better than one long spray. The spraying process is over when the time runs out.

  • Page 39: Program Sequence For Torch Cleaning

    • digital output spraying The software option "653-1 ABB TC96" makes separate rapid instructions available for torch cleaning, torch blow-out/spraying and shortening of the welding wire. The operator or program- mer does not have to take account of the activation of inputs and outputs. This is taken over by rapid instructions.

  • Page 40: Program Examples

    Program sequence for torch cleaning 2.6.2 Program examples Program example Torch cleaning/Torch spraying: Program example Welding wire shortening: 2-20 3HDA000057A8519-001 Torch cleaner TC 2013...

  • Page 41: Configuration For Tc 2013

    Program sequence for torch cleaning 2.6.3 Configuration for TC 2013 2.6.3.1 Configuration for torch cleaning The configuration for torch cleaning can take place via RobotStudio or directly via the FlexPendant of robot control. The configuration is produced in the process configuration database (Proc.cfg). RobotStudio - view of the configuration for torch cleaning (Torch services mech clean properties) Parameter view in a text editor: Torch cleaner TC 2013...
  • Page 42 Program sequence for torch cleaning 2.6.3.2 Configuration for wire cutting RobotStudio - view of the configuration for wire cutting (Torch services wirecut properties) Parameter view in a text editor: 2-22 3HDA000057A8519-001 Torch cleaner TC 2013...
  • Page 43 Program sequence for torch cleaning 2.6.3.3 Configuration torch spraying RobotStudio - view of the configuration for torch spraying (Torch services spray properties) Parameter view in a text editor: Torch cleaner TC 2013 3HDA000057A8519-001 2-23...

  • Page 44: Sequence Of Torch Cleaning

    Program sequence for torch cleaning 2.6.4 Sequence of torch cleaning The instruction "MoveMechCleanL" moves the robot via a preliminary position directly to the cleaning position and checks whether the milling cutter in the lower end position and the clamping element is open. In the case of incorrect signal states an operator dialogue is automatically opened on the FlexPendant and operator interaction is necessary.
  • Page 45 Program sequence for torch cleaning 2.6.4.1 Sequence of torch cleaning without software option "653-1 ABB TC96" Example of a possible sequence for torch cleaning without software option "653-1 ABB TC96": Robot runs into a safe position close to the cleaning position.
  • Page 46 Program sequence for torch cleaning 2.6.4.3 Sequence of spraying without software option "653- ABB TC96" Example of a possible sequence for spraying of the release agent without software option "653-1 ABB TC96": Robot runs into a safe position close to the spraying position.

  • Page 47: Maintenance

    TC 2013. We recommend the following maintenance plan to guarantee perfect functioning of the TC 2013. Interval Machine part Activity Remark daily TSC 2013 Visual inspection weekly Spray nozzle - Test, - Clean when required Milling cutter unit...

  • Page 48: Spare And Wearing Parts For Tc 2013

    Spare and wearing parts for TC 2013 Spare and wearing parts for TC 2013 2.8.1 TC 2013 without wire cutter 2-28 3HDA000057A8519-001 Torch cleaner TC 2013...
  • Page 49 Spare and wearing parts for TC 2013 Pos. Name ABB Article No Spare part Wearing part Spray head TC 2013 3HDA000000A9271 Motor pack for milling cutter 3HDA000000A9277 Clamping unit TC 2013 3HDA000057A6670 V-block TC 2013 0.743.800.040 spacer plate torch-dependent replacement part Gas nozzle Ø...
  • Page 50 Spare and wearing parts for TC 2013 Pos. Name ABB Article No Spare part Wearing part Miniature silencer "Legris" G1/8 - 0677 00 10 3HDA000057A5155 Parker Hannifin GmbH Cable 14G 0.5mm² 3HDA000057A5224 HELUKABEL GmbH 1 litre Release agent - 3850 0.743.505.003...

  • Page 51: Tc 2013 With Wire Cutter

    Spare and wearing parts for TC 2013 2.8.2 TC 2013 with wire cutter Torch cleaner TC 2013 3HDA000057A8519-001 2-31...
  • Page 52 ABB Article No Spare part Wearing part Spray head TC 2013 3HDA000000A9271 Motor pack for milling cutter 3HDA000000A9277 Wire cutter - TSC 2013 3HDA000000A9289 V-block TC 2013 0.743.800.040 spacer plate torch-dependent replacement part Gas nozzle Ø 16 mm 0.746.124.001 Gas nozzle Ø 16 mm 0.746.124.019...
  • Page 53 Spare and wearing parts for TC 2013 Pos. Name ABB Article No Spare part Wearing part Cable 14G0.5mm² 3HDA000057A5224 HELUKABEL GmbH 1 litre Weld spatter release agent 0.743.505.003 (in original container) Torch cleaner TC 2013 3HDA000057A8519-001 2-33...

  • Page 54: Pneumatic Plan

    Pneumatic plan Pneumatic plan Clambing cylinder and Wire cutter (optionally) Feed cylinder Air motor Spray device 2-34 3HDA000057A8519-001 Torch cleaner TC 2013...

  • Page 55: Electrical Circuit Diagram

    Electrical circuit diagram 2.10 Electrical circuit diagram Torch cleaner TC 2013 3HDA000057A8519-001 2-35...
  • Page 56 Electrical circuit diagram 2-36 3HDA000057A8519-001 Torch cleaner TC 2013...

  • Page 57: Wire Cutter

    The wire cutter is an option for the TC 2013 and can be retrofitted at any time. A wire cutter con- version cut – Article No 3HDA000057A8405 is needed for this purpose. Note: The wire cutter is already contained in the TSC 2013 (Torch Service Center). Figure 3-1 TC 2013 with wire cutter...

  • Page 58: Safety Instructions

    Safety instructions Safety instructions Proceed with the utmost caution when work has to be carried out on the wire cutter (cleaning, replacement of the blades etc.). Very high forces act in wire cutting as the blades are pressed together using clamping cylinders. CAUTION Danger of injury! Do not place fingers in blades!

  • Page 59: Assembly Of The Wire Cutter On The Tc 2013

    Assembly of the wire cutter on the TC 2013 • The welding torch runs to the desired wire length distance (e.g. 10 mm) above the knife into the wire- cutting position of the torch cleaner. • The wire feed advances a welding wire surplus length of at least 20 mm! Wire length distance (A surplus wire length of at least 20 mm is neces-...

  • Page 60: Disassembly Of Clamping Cylinder

    Assembly of the wire cutter on the TC 2013 3.6.2 Disassembly of clamping cylinder Slight reconstructions are to be carried out in order to be able to install the wire cutter on the TC 2013. Existing components are partly replaced by new ones. The following steps are to be performed: Figure 3-2 Disassembly of clamping cylinder Make system pressureless and secure against switching back on.

  • Page 61: Assembly Of Wire Cutter

    Assembly of the wire cutter on the TC 2013 3.6.3 Assembly of wire cutter Figure 3-3 Assembly of wire cutter Guide piston rod (6) and shaft (10) lightly oiled into the cylinder tube (8) and through the adapter with wiper and O-ring. Push cushion disc (5) and lid (11) into the cylinder tube.

  • Page 62: Corrective And Preventive Maintenance

    Corrective and preventive maintenance Figure 3-4 Setting aid for sensors (view from below) Sensors fastened in this orientation Setting aid 14. Assemble push-in fitting (1) and insert air hose. 15. Screw in screws M5x10 (15) into the housing of the wire cutter but tighten only such that the wire capture container can be suspended.

  • Page 63: Tcp Gauging

    – individual device (for ceiling assembly or as option for retrofitting on TC 2013), – as individual device with stand (standalone version), – integrated in the TC 2013 or – integrated in the TSC 2013. 4.1.1 Designated use The TCP gauging unit is intended solely to measure and adjust the robot tool center point (TCP) 4.1.2...

  • Page 64: Technical Data

    Technical data Technical data 4.2.1 Dimensions Protective sleeve Adjusting tip 4.2.2 Connection data electrics Electrical connection 40mA, at 24VDC Connection of robot digital sensor input ® 3HDA000057A8519-001 TCP gauging (BullsEye...

  • Page 65: System Requirements

    Arc, BullsEye ® RobotWare options Safety WARNING Observe the safety instructions in Chapter 1 Torch Service Center - TSC 2013. CAUTION Danger due to piercing! The protective sleeve must always be placed on the adjusting tip in work on TCP gauging.

  • Page 66: Structure And Function

    Structure and function Structure and function 4.5.1 TCP gauging as standalone device Standalone TCP gauging can be installed either on the ceiling of a robot cell or retrofitted as an addition to the TC 2013. TCP gauging consists of the following components: adjusting tip protective sleeve for adjusting syringe fibre-optic sensor...

  • Page 67: Functional Description

    Functional description Functional description ® TCP gauging with BullsEye version 10 allows completely automatic definition of the tool center point (TCP) for IRC robot control. 4.6.1 Examples of operation When a robot receives the command to rotate about the TCP all the robot axes are moved such that the TCP remains stationary.

  • Page 68: Tcp Deviation

    Functional description 4.6.2 TCP deviation Component programming is normally undertaken with an adjusted TCP. The adjusted TCP may deviate from the actual TCP due to faults in operating sequence. TCP deviations may have the following causes: – collision with a component clamp, –...
  • Page 69 Functional description Figure 4-5 Deviation from the programmed trajectory New path of the welding torch Same path of th robot Workpiece Robot arm The tool is re-measured by the automatic TCP gauging. The welding gun then runs the correct trajectory on the component. Figure 4-6 The TCP was corrected Path of the welding torch (once again correctly on he trajectory)

  • Page 70: Assembly

    Assembly Assembly 4.7.1 Subsequent assembly on the TC 2013 The TCP gauging can be retrofitted on the TC 2013 at any time. WARNING Before assembly and installation work the system must be electrically dead and pressureless and pro- tected against being switched back on. 1.

  • Page 71: Assembly Of Tcp Gauging With Stand

    Assembly 4.7.2 Assembly of TCP gauging with stand NOTICE In assembling the TCP gauging unit with stand (stand- alone version), proceed as described in Section 2.4 Assembly and disassembly of the TC 2013. 4.7.3 Assembly site and alignment Assemble the welding gun on the robot so that the torch axis points in the X-direction of the wrist. The installation site of the TCP gauging unit must be in the working range of the robot so that no singularity and end positions of the robot are reached.
  • Page 72 Assembly 4.7.3.1 Electrical installation WARNING Electrical installation must only be performed by qual- ified personnel! To simplify assembly, the TCP gauging unit is supplied pre-assembled and with a connecting cable. Connect the cable supplied from the robot control with the connection on the TCP gauging ®...

  • Page 73: Using For The First Time

    How do I set up a non-ABB supplied I/O device? Only ABB I/O devices are guaranteed to work with BullsEye. Many I/O devices from other vendors are too slow or too unrepeatable to allow BullsEye to work correctly. When using non-ABB devices, you may need to slow the scan speed substantially to improve accuracy.

  • Page 74: Operation

    Operation Operation TCP gauging is controlled by the robot. The program sequence for TCP gauging is contained in the robot program. 4.9.1 Switching on When robot control is switched on, the TCP gauging unit is also ready for operation. CAUTION Danger of electric shock! Make sure that all live components are properly cov- ered.

  • Page 75: Spare Parts

    Spare parts Replacement of the sensor If the fibre-optic sensor of TCP gauging is to be replaced due to a defect, it should be ensured that the 3 switches on the senor are in the illustrated position. Pos. Switch position Standard T.Off 4.11...
  • Page 76 Spare parts Pos. Quantity Name ABB article number TCP gauging (BullsEye ® ) 3HDA000000A9324 Adjusting tip for reference points 0.746.335.025 Protective sleeve 0.746.335.026 Fibre-optic sensor SU18-40A/110/115/126A 3HDA000057A5166 Pepperl+Fuchs GmbH Fibre-optic KLE-C01-2,2-2,0-K103 3HDA000057A5175 Pepperl+Fuchs GmbH Optional: TCP gauging 3HDA000057A5435 complete with stand ®...

  • Page 77: Appendix

    Dimension sheet Gas nozzle Appendix Dimension sheet Gas nozzle Appendix 3HDA000057A8519-001...
  • Page 78 Dimension sheet Gas nozzle 3HDA000057A8519-001 Appendix...

  • Page 79: Safety Data Sheet Release Agent As 72-K

    Safety Data Sheet Release Agent AS 72-K Safety Data Sheet Release Agent AS 72-K After cleaning, the gas nozzle should be sprayed with the release agent AS 72K. NOTICE No safety data sheet is required for this product in accordance with article 31 of the REACH ordinance (EC) No 1907/2006.
  • Page 80 Safety Data Sheet Release Agent AS 72-K 3HDA000057A8519-001 Appendix...
  • Page 81 Safety Data Sheet Release Agent AS 72-K Appendix 3HDA000057A8519-001...
  • Page 82 Safety Data Sheet Release Agent AS 72-K 3HDA000057A8519-001 Appendix...
  • Page 83 Safety Data Sheet Release Agent AS 72-K Appendix 3HDA000057A8519-001...
  • Page 84 Safety Data Sheet Release Agent AS 72-K 3HDA000057A8519-001 Appendix...
  • Page 85 Safety Data Sheet Release Agent AS 72-K Appendix 3HDA000057A8519-001...
  • Page 86 Safety Data Sheet Release Agent AS 72-K 5-10 3HDA000057A8519-001 Appendix...
  • Page 88 Robotics and Motion No. 4528 Kangxin Highway PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2018 ABB. All rights reserved.

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