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 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
Unpacking and positioning ................ 2.2.4 Assemble corridor parts ................2.2.5 Assemble the vision tower ................ 2.2.6 Install the FlexMT to the machine ............... 2.2.7 Install FlexMT drop protection ..............2.2.8 Safety precautions for long parts in turn station ..........Electrical installation ..................
Page 6 6.7.1.1 Start in manual operating mode (Programming mode) ......6.7.1.2 Continuing work in automatic mode after manual mode operation ..6.7.2 Manually setting the belt speed (option) ............6.7.3 Manual cyclic brake check ................ 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 7 Exchange of valves ................. Grinding/Deburring units ..................8.9.1 Exchange of grinding/deburring unit ............8.9.2 Exchange of valves ................. 8.10 Marking unit ..................... 8.10.1 Exchange of marking unit ................. 8.11 Robot mounting/dismounting ................3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 8 14.1.5 Air cleaning box ..................14.1.6 Deburring ....................14.1.7 Marking unit ................... 14.1.8 Statistical outlet ..................14.2 Internal communication ..................14.2.1 PickMT <> Robot ..................14.2.2 Marking unit <> Robot ................3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 9 Table of contents 15 Apendix C: FlexMT RAPID reference 15.1 PickMT core functionality reference ..............15.2 FlexMT core functionality reference ..............15.2.1 Control subsystem .................. 15.2.2 Utility and assistance subsystem ............... 15.3 FlexMT application functionality ................16 Apendix D: Own notes 3HAC051768-001 Revision: - ©...
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Page 11: Overview Of This Manual
Product manual - IRB 2600 3HAC035504-001 Product manual - IRB 4600 3HAC033453-001 Application manual - PickMT 3HAC051771-001 Product manual - Safety center for FlexMT 3HAC051769-001 Application manual - PickMT with ABB robot 3HAC051770-001 Application manual - FeedLine Light 3HAC052311-001 Revisions...
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Page 13: Safety
ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. xx0200000023 Continues on next page 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 14 1.1 Safety signals in the manual Continued Symbol Designation Significance NOTE Describes important facts and conditions. xx0100000004 Describes where to find additional information or how to do an operation in an easier way. xx0100000098 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 15: General
Installation/commissioning personnel must be trained and thoroughly understand the principles of the FlexMT, to prevent risks to the operator and service personnel. Users of the FlexMT system must ensure that the safety laws and regulations that...
Page 16: Safety During Installation, Commissioning And Decommissioning
WARNING It is forbidden to step on the illumination roof, the outer walls of the FlexMT and on any FlexMT option. DANGER Ensure that nobody is within the machine enclosure during operation.
Page 17: Safety During Setup, Maintenance And Repair
The equipment can start without prior warning thus causing a crushing risk. Installed protection that belongs to the equipment must always be installed during semi-automatic and fully automatic operation. DANGER The following must be ensured before commencing work on the FlexMT: • Emergency stop must be activated (machine stationary) •...
Page 18: Safety During Operation And Teachin
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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 19: Safemove
1 Safety 1.6 SafeMove 1.6 SafeMove The robot working space in the FlexMT is restricted by the use of SafeMove. Due to space requirements, the SafeMove outer boundaries of restricted space are close to the FlexMT enclosure. In case of robot malfunction or erroneous programming leading to a movement out of the restricted space, the robot will begin to stop its movement.
Page 20 1.6 SafeMove Continued The SafeMove configuration must be changed accordingly to the new work space. The standard ABB guidelines for configuration and validation of SafeMove configurations shall be followed. DANGER It is the integrators responsibility to modify and validate the SafeMove configuration for the alternate mounting position in a suitable way.
Page 21: Limited Liability
In particular, liability cannot be accepted if injury/damage has been caused for any of the following reasons, for example (but not limited to): • Use of the FlexMT 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.
Page 23: Installation
2 Installation 2 Installation Note Read the safety precautions and other instructions carefully before unpacking and installing the equipment. Continues on next page 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 24: General
2.1 General This section describes the installation of the equipment, including 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. 3HAC051768-001 Revision: -...
Page 25: Mechanical Installation
2 Installation 2.2 Mechanical installation 2.2 Mechanical installation When the FlexMT arrives, it is bolted onto a wooden pallet with the vision tower dismantled from the chassis. This section describes how to unpack the FlexMT step-by-step with text and pictures.
Page 26: Floor Requirements
2 Installation 2.2.1 Floor requirements 2.2.1 Floor requirements The floor where the FlexMT becomes installed has to fulfill certain requirements: • Standard concrete industry floor is typically sufficient to install the FlexMT. • The surface of the floor shall be flat to within the equivalent of 1mm in 600mm (1 inch in 50 ft).
Page 27: Unloading
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.
Page 29: Unpacking And Positioning
Check all 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...
Page 30 Transport of the FlexMT using skates (1) 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 3HAC051768-001 Revision: -...
Page 31 Continued Pay attention on inclination in order to avoid damages to front plates. Place the FlexMT at a suitable position relative to the machine tool. Take especially the corridor between the FlexMT and the machine tool into account. Remove all the absorb bags from the electrical cabinet and the rest of the machine.
Page 32: Assemble Corridor Parts
The width of the opening towards the machine tool can be adjusted according to the actual needs. 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):...
Page 33 The stabilization stag (se image below) is 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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 34 A ready made corridor part can be mounted on the side of the FlexMT, according to the image below. The extension panels consist of two parts, the extension panel door, and the extension panel back.
Page 35 2 Installation 2.2.4 Assemble corridor parts Continued Most probably, you will have to remove a plate to be able to reach the safety connection point. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 36: Assemble The Vision Tower
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 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 37 Continued rest of the cables need to be connected to the terminal inside the electrical cabinet according to the circuit diagram. Cable path from vision tower to FlexMT chassis. Continues on next page 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 38 2 Installation 2.2.5 Assemble the vision tower Continued Internal connection of vision tower cables in control cabinet. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 39: Install The Flexmt To The Machine
< 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.:...
Page 40 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.
Page 41 2.2.6 Install the FlexMT to the machine Continued The image below shows the FlexMT from below, pointing out the 4 machine foot positions (A) and the 4 bolting positions (B). FlexMT from below. A: Adjustable machine foot, B: Bolted to the floor.
Page 42: Install Flexmt Drop Protection
2.2.7 Install FlexMT drop protection 2.2.7 Install FlexMT drop protection After putting the FlexMT in position and securing it in place, the drop protection plates shall be put into position. Start with putting the main part A into position and secure it to the FlexMT frame.
Page 43: Safety Precautions For Long Parts In Turn Station
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.
Page 44: Electrical Installation
2.3 Electrical installation Connect the incoming power supply 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 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 45: Power Supply
C or better. Max. fuse 40A POWER SUPPLY 3x 440...480V 60Hz Maximum short-circuit current 10kA. Required line fusing: Circuit breaker with trip characteristic K. Max. fuse 35A (40A if power limiting switch is used). 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 46: Earthing System
2 Installation 2.3.2 Earthing system 2.3.2 Earthing system The protective earthing system shall be performed according to EN-60204-1, the PE conductor shall be dimensioned according to section 5.2, Table 1. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 47: Potential Equalization
2.3.3 Potential equalization 2.3.3 Potential equalization FlexMT is equipped with a earthing boss, the earthing boss is fitted on the base frame to the left of the control panel, this shall be connected to a separate functional earthing bonding circuit conductor.
Page 48: Pneumatic Installation
2 Installation 2.4 Pneumatic installation 2.4 Pneumatic installation Connect the incoming air connection. Requirements are 6 bar / 87 psi. Dry air, no oil. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 49: Machine Tool Connections
2 Installation 2.5 Machine tool connections 2.5 Machine tool connections FlexMT connects to the machine tool by means of a safety interface and a functional interface. Continues on next page 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 50: Machine Tool Safety Interface
2 Installation 2.5.1 Machine tool safety interface 2.5.1 Machine tool safety interface The equipment has a safety interface that makes connection of the FlexMT to the machine tool safety circuits possible. The safety interface handles the following aspects: • Bidirectional exchange of emergency stop between FlexMT and machine tool.
Page 51: Machine Tool Functional Interface
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: -...
Page 52: Network Connections
2.6.1 Service port 2.6 Network connections 2.6.1 Service port Network connections to the robot controller can be established by means of the robots built-in service port according to the robots manual. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 53: Wan Port
For security reasons, it is 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.
Page 54: Licensing Information
2 Installation 2.7 Licensing information 2.7 Licensing information By installing and using the FlexMT and its PickMT SmartCamera you agree to Microsoft and Matrox licensing agreements. These can be found on the PickMT SmartCamera. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 55: Moving The Flexmt
CAUTION Mechanically stabilize the FlexMT prior to transporting it again. The stabilizing stag 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.
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Page 57: Commissioning
3 Commissioning 3.1 Safety 3 Commissioning 3.1 Safety Carefully read the section on safety in this manual prior to commissioning. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 58: User Accounts
3 Commissioning 3.2 User accounts 3.2 User accounts CAUTION The FlexMT uses several standard user accounts.The user is strongly advised to change the standard passwords in order to reduce the risk of non-authorized access to important system parameters. PickMT Administrator account, which is used for all administrative purpose.
Page 59: Basic Steps
(press emergency 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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 60: Vision System Pickmt
3.4 Vision system PickMT FlexMT is delivered with PickMT pre-installed and pre-configured on the PickMT SmartCamera. Do not install any updates or patches if not advised from ABB or ABB:s subsupplier. • Visually check that the all parts of the illumination system are working. If not, replace illumination according to the maintenance section.
Page 61: Robot System
3.5 Robot system 3.5 Robot system FlexMT is delivered with a pre-installed and pre-configured robot gripper system and robot program. For details on the structure of the FlexMT robot software refer to section on robot programming. Commissioning includes the following main steps: •...
Page 62: Robot Base Coordinate System
• 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 configuration. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 63: Calibration Of Coordinate Systems
3 Commissioning 3.5.2 Calibration of coordinate systems 3.5.2 Calibration of coordinate systems All robot coordinate systems that are used in the FlexMT are pre-defined from factory. However, they should be redefined to compensate for possible changes due to transportation and setup.
Page 64 In most cases, the tool orientation in the point-of-interest will be used during later movements. Refer to each work object for more detailed information. Continues on next page 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 65 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.
Page 66 Z-axis points upwards. Follow the calibration instructions 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.
Page 67 Turning station wTurnStation The turning station coordinate system wTurnStation is oriented as follows. Standard 3-point calibration. Approximate positioning of wTurnStation in the FlexMT Air cleaning box wAirClean The air cleaning box coordinate system wAirClean is oriented as follows. Standard 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.
Page 68 Note that orientation of the tool is used in pre-configured movements. Approximate positioning of wSample in the FlexMT Continues on next page 3HAC051768-001 Revision: -...
Page 69 (X1, X2, Y1) and lower the calibration tool into the holes. No exact positioning of this coordinate system is necessary due to the nature of the marking process. Approximate positioning of wMarker in the FlexMT Afterwards, call the calibration routine CalibMarker. The point of interest is where the calibration tool touches the marking needle.
Page 70 If the chucks are movable, the calibration must be checked, so that the z-axis in wMainChuckM1 and wSubChuckM1 is in line with actual chuck movement (even for long movements). 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 71: Further Integration Steps
3 Commissioning 3.5.3 Further integration steps 3.5.3 Further integration steps The pre-configured robot software for FlexMT contains suggestions for a working application skeleton. Note Please follow suggestions in the section about robot program for building your own applications. Further in-depth reading of the PickMT manual with its section on robot integration and FeedLine Light is strongly recommended.
Page 72: Machine Tool
3 Commissioning 3.6 Machine tool 3.6 Machine tool The FlexMT system provides a framework for handling the most common machine tool interface types. Interaction with the machine tool is handled by a machine tool specific module (Machine.sys). This module translates actual machine tool communication signals into a standardized set of commands to be understood by FlexMT.
Page 73: Safemove
• STZ4, ST5, ST6, and ST7 define forbidden areas based on the contours of the FlexMT shell. At the same time, they limit the maximum robot speed to 1200 mm/s (-> use max v1000 in robot). •...
Page 74 Continued Follow standard SafeMove configuration routines as described 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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 75: Marking Unit
3.8 Marking unit 3.8.1 General The marking unit is a standard FlexMT option. The hardware consists of a SIC marking equipment, i.e. an i52 marking head with an E10 controller unit. During operation, the robot communicates by means of serial communication with the controller unit.
Page 76: Configuration Changes
SmartCamera storage, to be installed on a separate PC, 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.
Page 77: Deburring/Grinding Unit
3 Commissioning 3.9 Deburring/grinding unit 3.9 Deburring/grinding unit The deburring/grinding unit is a standard FlexMT option. The hardware 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.
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Page 79: Function Description
After that all parts under the camera have been picked, the conveyor belt feeds new parts forward. FlexMT can be configured with a variety of useful options. Please refer to the product specification for further details.
Page 80: Overview
4 Function description 4.2 Overview 4.2 Overview FlexMT contains numerous mechanical devices and sensors that are important to know about in order to understand the function. Continues on next page 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 81: Functional Units
4 Function description 4.2.1 Functional units 4.2.1 Functional units The FlexMT consists of the following main parts: Schematic overview with FlexMT functional units (1) B Operators panel, C Electrical cabinet with IRC5 panel mounted controller, F Vision system and illumination, G Retractable sliding door with entry control, H Swing door, J Statistical outlet, K Extension panel door.
Page 82 4 Function description 4.2.1 Functional units Continued The main options the FlexMT can be equipped with are: Schematic overview with FlexMT functional options M Marking unit, P air cleaning box, T Turn unit, S re-grip table, Q Deburring Tools 3HAC051768-001 Revision: -...
Page 83: Sensors
4 Function description 4.2.2 Sensors 4.2.2 Sensors The main sensors the FlexMT can be equipped with are: Schematic overview with sensors (1) • A Sensor that detects if a part has been placed on the statistical outlet. • B Safety sensor that ensures that statistical outlet is closed when the robot moves inside this area.
Page 84: Operator Panels
4.2.3 Operator panels 4.2.3 Operator panels The main operator panels of FlexMT are situated at the start of the inconveyor, below the vision system screen, and at the sliding door towards the machine tool. The operating panel at the start of the inconveyor controls basic conveyor operation.
Page 85 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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 86 4 Function description 4.2.3 Operator panels Continued The operator panel at the sliding door combines the following elements: FlexMT operator panel at sliding door • A Emergency stop • B Start robot (if in home position) • C Request cell entry and request confirmation lamp •...
Page 87: General Function Description
4.3 General function description 4.3 General function description The purpose of FlexMT is to feed parts to the cameras field of view where they are to be identified by a camera and picked by a robot. The inconveyor is filled with parts manually.
Page 88: Functions For Inconveyor
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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 89: Functions For Outconveyor
• 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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 90: Functions For 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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 91: Functions For Other Options
4.5 Functions for other options 4.5 Functions for other options Functions for other options, 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: - © Copyright 2014-2014 ABB. All rights reserved.
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Page 93: Robot Program
Applicable training is required in order to use the product. Incorrect use of the product can lead 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.
Page 94: Overview
5 Robot program 5.2 Overview 5.2 Overview The FlexMT RAPID code consists of three main blocks, all of which are necessary to run the FlexMT: • PickMT core code. This code handles the interface and the communication to and from PickMT.
Page 95: Machine Interface Module (Templatemachine.sys)
5.3 Machine interface module (TemplateMachine.sys) 5.3.1 Overview The FlexMT standard modules communicate 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.
Page 96: States And Actions
This module contains a number of predefined states and actions that are consistently used throughout the FlexMT. If needed, new values can be added. However, do not remove existing values, as they are used in the FlexMT core functionality. Examples for predefined values are: •...
Page 97: Procedures, Functions And Traps
NEEDED: Define signals and communicate with machine tool. FUNC bool MachineWait Waits for machine condition to be ok within nMaxTime. Returns (string sWait,num nMax- false if nMaxTime elapses. Time) NEEDED: Define signals and communicate with machine tool. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 98: Communication Flow
MachineAction CLOSE_DOOR; MachineAction CYCLE_START; Different machine tools have different behavior. As described in the previous section, FlexMT supplies a comprehensive set of tools and adoption possibilities to handle these behaviors. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 99: Main Module (Mainmodule.mod)
5 Robot program 5.4 Main module (MainModule.mod) 5.4 Main module (MainModule.mod) The main module contains the overall logic within the FlexMT. It contains the following procedures and functions: Name Description FUNC bool CheckInPosi- This routine checks if the feeder subsystem is in position for tion() taking a new image.
Page 100: Part Specific Modules (Modcam1.Mod)
DANGER These routines are provided as example code. You have to ensure that they are working with the actual parts and process. Continues on next page 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 101: Feedline Light Operation
Example code for leaving the finished detail in the statistical let() outlet. PROC MarkDetail() Example code for marking detail. PROC TurnDetail() Example code for turning detail before loading machine. Continues on next page 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 102 This procedure is for first unloading and then loading the main chine_MAIN_Load_MAIN() chuck in machine tool. PROC UnLoadMa- This procedure is for unloading the sub chuck in machine tool. chine_SUB() Continues on next page 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 103 Z is calculated with help from PickMT values. To change the unload position, the work object has to be adjusted until the position is correct. In this case adjust “wSubChuckM1” by run- ning the procedure “CalibSubChuck” 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 104: Standard Teachin Operation
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.
Page 105: Option Control
The module Options.sys contains useful code to control the options within the FlexMT. Examples are: • Marking Unit: InitMarker, LoadMarkerFile, ChangeMarkerString, StartMarker • AirCleanBox: StartAirClean, StopAirClean Check Options.sys for more usable functions. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 106: User Messaging
CONST num LOW_AIR_PRESSURE:=3; If needed, new values can be added. However, do not remove or change values, as they are used in the FlexMT core functionality. • A number of predefined procedures/functions for interacting with the operator:...
Page 107 1;Message1Row1 2;Message2Row1; Message2Row2 6;Message6Row1 Certain ranges are reserved for specific purposes: 1-99: FlexMT core messages. These are defined in FeedLineAlarmsToPV.sys, too, in order to enable inter-task data exchange. 100-299: Application messages 300-499: User dialog messages 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 108: Alarms And Light Tower
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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 109: Worldzones
Some users prefer the use of WorldZones to verify the robots presence in certain areas/volumes, and/or to block certain movements. FlexMT offers predefined WorldZone handling in the module Common.sys. The FlexMT defined WorldZones are active in jogging mode and automatic mode. The following zone is predefined and must be configured during commissioning. •...
Page 110: Motion And Zone Overview
(viaPositions), movement 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.
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Page 113: Operation
The FlexMT:s work place during operation is at the beginning of the inconveyor, where the operator adds new material and unloads the outconveyor. For ”Teachin” there is a work place in front of FlexMT, at the vision system screen location. The inconveyor has two operation modes.
Page 114: Safety
DANGER When the operator replaces or repositions the gripping fingers, the air pressure to the gripper must be safely shut down. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 116: Shutting Down The Flexmt
6 Operation 6.2.2 Shutting down the FlexMT 6.2.2 Shutting down the FlexMT • Stop the FlexMT as described below and await complete cycle stop. • Exit the PickMT application. • Turn off the main switch. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 117: Starting And Stopping
• Click ”Start” in the PickMT user interface. • The selected robot program for the part will now be loaded in the robot and the FlexMT will start. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 118: Cycle Stop
Please note: 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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 119: Quick Stop
In the event of a quick stop, the robot will stop 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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 120: Restart After Quick Stop
6 Operation 6.3.1.4 Restart after quick stop 6.3.1.4 Restart after quick stop Press ”Start” on the robots FlexPendant. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 121: Emergency And Safemove Stop
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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 122: Restart After Emergency Stop
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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 123: Safemove Stop
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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 124: Restart After Safemove Stop
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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 125: Entry Control
The lock opens even in the event of manual operation when the robot program has stopped. As soon as the door is unlocked, the green lamp illuminates continuously. Continues on next page 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 126: Manual Operation Of 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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 127: Conveyor Operations
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...
Page 128: Loading Inconveyor
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 continue the grip manoeuvre, there is a large risk of a collision. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 129: Emptying In- Or Outconveyor
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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 130: Automatic Operation
6 Operation 6.6.4.1 Inconveyor 6.6.4 Automatic operation 6.6.4.1 Inconveyor During automatic operation, the inconveyor is controlled based on the robots requirement. Parts can be place on the outconveyor during operation. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 131: Outconveyor
(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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 132: Other Operations
DANGER Running the machine in manual mode with an operator close to robot, machine tool and FlexMT options leads to increased risks for the operator.Be carefull and observant to potential risks. The equipment can be run with open doors in manual operating mode. The robot operation mode must be Manual with reduced speed.
Page 133: Continuing Work In Automatic Mode After Manual Mode Operation
• 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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 134: Manually Setting The Belt Speed (Option)
6.7.2 Manually setting the belt speed (option) Using the potentiometer mounted on the side of the controller cabinet the belts speed can be manually set to a speed appropriate to the product. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 135: Manual Cyclic Brake Check
6.7.3 Manual cyclic brake check 6.7.3 Manual cyclic brake check The FlexMT is programmed to automatically perform the cyclic brake check that is needed for the secure operation with SafeMove. Sometimes, it can become necessary to perform this procedure manually. Please adhere to the robots guidelines in how to perform a cyclic break check.
Page 136: Statistical Outlet
As soon as the sample outlet is closed again, the operator can confirm, and the robot will continue. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 137: Maintenance
7 Maintenance 7.1 Safety 7 Maintenance 7.1 Safety DANGER Always adhere to the general safety instructions as described in chapter ”Safety”. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 138: General
Note Maintenance procedures for the robot are described in the robots product manual. Most maintenance of the FlexMT is obvious to perform, even if not listed in this section. This sections covers both maintenance of equipment and options that are not included in all installations.
Page 139: Mechanical Maintenance
7.3.1 FlexMT overall cleaning 7.3 Mechanical maintenance 7.3.1 FlexMT overall cleaning What: Overall cleaning of the FlexMT. When: Once / week. More often if needed. How: Let the robot move to its home position (-> entry request). Clean all surfaces from chips, oil and other material that might disturb correct function.
Page 140: Air Cleaning Box Cleaning
When: Once / week. More often if needed, e.g. when 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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 141: Conveyor Belt Cleaning
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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 142: Conveyor Belt Check
7.3.4 Conveyor belt check What: Checking the 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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 143: Belt Tension
1004mm after tensioning the lower conveyor belt. • Clean off the marks. • Mount the protection cover. Screws holding protection cover. Continues on next page 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 145: Conveyor Belt Adjustment
The belt is adjusted when test operation is performed at the manufacturer, however, it may need to be readjusted after transportation or after repair. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 146: Gripper System Check
What: Check gripper system When: Once / month How: Visually check the gripper system, including gripper holder, gripper finger holders and gripper fingers, for signs of mechanical wear. Replace damaged or worn parts. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 147: Gripper System Lubrication
Remove the two set screws for the air purge connection and replace them with two conical grease nipples. For in-depth information, follow original Schunk manuals. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 148: Electrical Maintenance
7 Maintenance 7.4.1 Robot, control cabinet 7.4 Electrical maintenance 7.4.1 Robot, control cabinet What: See ABB robot product manual. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 149: Illumination
How: Turn the fluorescent lamp a ¼ 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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 150: Reflectors/Sensors
What: Always check that all reflectors and sensors 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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 151: Electrical Function Check
7 Maintenance 7.4.4 Electrical function check 7.4.4 Electrical function check What: Check all electrical functions, breakers and limit position functions When: Once / month 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 152: Checking Cables And Cable Racks
When: Every 3 months 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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 153: Checking Electrical Connections
7 Maintenance 7.4.6 Checking electrical connections 7.4.6 Checking electrical connections What: Checking electrical connections When: Every 3 months How: Inspect all electrical contacts and make sure that they are secured properly. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 154: Pneumatic Maintenance
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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 155: Filter Cartridge Replacement
Cleaning; Use only the following cleaning agents: Water or soap suds (max. +60 °C), or petroleum ether (free of aromatic compounds). Service unit - Open filter housing Continues on next page 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 157: Compressed Air Lubricator
7.5.3 Compressed air lubricator 7.5.3 Compressed air lubricator What: If a deburring/grinding unit is used the FlexMT is equipped with a lubricator placed in front of the air cleaning unit. When: Depending on usage of the deburring/grinding unit. Typical 1 time/week.
Page 158: Backup
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). 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 159: Backup Of Robot Program
What: Make a backup of the robot program When: When you have made a program change How: Follow the robot manual and save the copy onto a secure media (i.e. not the robot itself). 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 160: Other Maintenance
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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 161: Camera
How: Wipe the front of the object clean 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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 162: Pickmt Screen
7 Maintenance 7.7.3 PickMT Screen 7.7.3 PickMT Screen What: Carefully wipe off using a damp cloth. When: As necessary 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 163: Repair
Note Repair procedures for the robot are described in the robots 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.
Page 164: Safety
8 Repair 8.1 Safety 8.1 Safety DANGER Always adhere to the general safety instructions as described in chapter ”Safety”. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 165: Conveyors
8.2 Conveyors 8.2 Conveyors DANGER Prior to all work with the conveyors: 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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 166: Exchange Of Conveyor Belt
• 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 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 167 Open the belt splice by straightening the lock wire. • 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. •...
Page 168 Adjust belt tension according to instructions in the maintenance section. DANGER Power to the FlexMT has to be restored prior to mounting the protection caps, in order to perform the belt adjustment. Be careful when adjusting the belt. Risk for finger squeeze.
Page 169: Exchange Of Conveyor Motor
Follow the instructions for belt exchange. • When the belt is opened, replace the conveyor motor. • Refit the belt and check belt adjustment and stability according to instructions in the maintenance section. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 170: Illumination
8.3 Illumination 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: •...
Page 171: Pickmt Smartcamera
• 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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 172: Exchange Of Smart Camera
8.4.2 Exchange of smart camera Change of camera shall be performed with as little impact as possible on existing teach-In. Use the following procedure: CAUTION: Safely shut the power to the FlexMT down and lock against accidental turn-on. • Loosen the three cables connecting the smart camera •...
Page 173 The camera image (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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 174: Gripper
8 Repair 8.5 Gripper 8.5 Gripper DANGER Prior to work with the gripper: Safely shut the pneumatic supply to the FlexMT down and lock against accidental turn-on. Continues on next page 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 175: Exchange Of Gripping Module On Gripper
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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 176: Exchange Of Valves
• 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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 177: Re-Grip Table
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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 178: Turn Station
8 Repair 8.7 Turn station 8.7 Turn station DANGER Prior to work with the turn station: Safely shut the pneumatic supply to the FlexMT down and lock against accidental turn-on. Continues on next page 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 179: Exchange Of Gripping Module On Turn Station
• 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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 180: Exchange Of Rotation Module
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 positioning 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 181: Exchange Of Valves
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: -...
Page 182: Air Cleaning Box
8.8 Air cleaning box DANGER Prior to work with the air cleaning box: Safely shut the pneumatic supply to the FlexMT down and lock against accidental turn-on. Continues on next page 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 183: Exchange Of Flexblow Hoses
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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 184: Exchange Of Valves
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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 185: Grinding/Deburring Units
8.9 Grinding/Deburring units DANGER Prior to work with the grinding deburring units: 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: -...
Page 186: Exchange Of Grinding/Deburring 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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 187: Exchange Of Valves
• Remove the protective 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°.
Page 188 • Mount the air cleaning box in 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.
Page 189: Marking Unit
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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 190: Robot Mounting/Dismounting
Below specifies required bolts and washers for securing the robot at Flex MT. • ABB 4600: 6 bolts M16 x 60, 6 washers 17 x 30 x 3, quality 8.8 • ABB 2600: 3 bolts M16 x 60, 3 washers 17 x 30 x 3, quality 8.8...
Page 191: Robot Fine Calibration
8 Repair 8.12 Robot fine calibration 8.12 Robot fine calibration When fine-calibrating the robot, it must be on flat level surface. Thus it must be dismounted from the FlexMT. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 192: Software Repair
When delivered, a backup of the robot and 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 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 193: Robot Repair
A robot backup that restores the robot system to its factory settings is 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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 194: Pickmt Smartcamera Repair
A smart camera backup that restores the smart camera to its factory settings is 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). 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 195: Troubleshooting
Switch to normal mode. 91 102 LOW_AIR_PRESSURE Low air pressure detected in CheckSystem. Check air preparation. 91 103 NOT_VALID_GRIPPER No valid gripper number. Check user RAPID code. Continues on next page 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 196 MAX_HEIGHT_EX- Maximum part height for loading exceeded. CEEDED_LOAD Reduce height or check value of FEED- ER_MAX_HEIGHT. 91 124 TOO_SMALL_DETAIL_DIAMET- Minimum part diameter reached. Increase diameter or check value of MIN_RAW_DETAIL_DIAMETER. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 198: Pickmt Troubleshooting
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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 199: Robot Troubleshooting
9 Troubleshooting 9.3 Robot troubleshooting 9.3 Robot troubleshooting Troubleshooting information concerning the robot can be found in the robot manuals. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 200: Marking Unit
The marking unit can - if in rare cases 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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 201: Decommissioning
10 Decommissioning 10 Decommissioning When decommissioning the FlexMT, start with decommissioning of the robot according to the robot product 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.
Page 202: Environmental Information
Batteries, NiCad or Lithium Serial measurement board Copper Cables, Motors Cast iron/nodular iron Steel Neodymium Brakes Motors Plastic/rubber Oil, grease Gearboxes Aluminium Dispose components properly to prevent health or environmental hazards. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 203: Oil And Grease
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: - © Copyright 2014-2014 ABB. All rights reserved.
Page 204: Scrapping Of Flexmt
10 Decommissioning 10.2 Scrapping of FlexMT 10.2 Scrapping of FlexMT When a FlexMT is disassembled while being scrapped, it is very important to remember the following before disassembling starts, in order to prevent injuries: • Start with scrapping/disassembling the robot according to the robots product manual.
Page 205: Spare Parts
11 Spare parts 11 Spare parts Spare part list is not included in the manual but are delivered as a separate documents. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
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Page 207: Diagrams
12 Diagrams 12.1 Circuit diagram 12 Diagrams 12.1 Circuit diagram The circuit diagram is not included in this manual, but delivered as separate document. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 208: Pneumatic Diagram
12 Diagrams 12.2 Pneumatic diagram 12.2 Pneumatic diagram The pneumatic diagram is not included in this manual, but delivered as separate document. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 209: Appendix A: Configuration
These parameters are defined as a user defined PLC in PickMT. Parameters can be changed, renamed, added. Refer to PickMT manual for in-depth information on user defined PLC. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 210: Setting The Frequency Inverter
ACS355-01E-04A7-2 (CE) and 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. 3HAC051768-001 Revision: -...
Page 211: Operation Abb Acs355
Resets faults in the Output and Fault modes. 3. MENU/ENTER – Enters deeper into menu level. In the Parameter mode, saves the displayed value as the new setting. Continues on next page 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 212 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. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 214: Parameters
13 Appendix A: Configuration 13.2.3 Parameters 13.2.3 Parameters Factory parameters settings are found in the electrical documentation. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 215: View And Change Parameters
When you have changed the parameter value, starts flashing. • To save the displayed parameter value, press • To cancel the new value and keep the ori- ginal, press . 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 216: Alarms
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 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 217: Pre-Configuration Settings
13 Appendix A: Configuration 13.3 Pre-configuration settings 13.3 Pre-configuration settings The FlexMT is pre-configured when delivered. 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: -...
Page 218: Robot Pre-Configuration
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 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 219: Pickmt Pre-Configuration
13.3.2 PickMT pre-configuration 13.3.2 PickMT pre-configuration PickMT has been pre-configured with the options that are 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: -...
Page 220: Marking Unit Pre-Configuration
13.3.3 Marking unit pre-configuration 13.3.3 Marking unit pre-configuration The marking unit has been pre-configured for use with FlexMT. There are three pre-configured marking files that are used with PickMT (SMALL, MEDIUM, LARGE). These files can - if needed - be changed by the use of the marking units configuration software (se reference section on auxiliary software).
Page 221: Frequency Inverter Pre-Configuration
13 Appendix A: Configuration 13.3.4 Frequency inverter pre-configuration 13.3.4 Frequency inverter pre-configuration The frequency inverter units have been pre-configured for use with FlexMT. Se section below for parameter handling of these devices. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 222: Known Limitations And Issues
13.4 Known limitations and issues 13.4.1 RobotWare 5.15.06 • The cyclic break 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.
Page 223: Robotware 5.60
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: - © Copyright 2014-2014 ABB. All rights reserved.
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Page 225: Appendix B: Communication
Alarm from frequency inverter inconveyor diAlarmU12FeederOUT Alarm from frequency inverter outconveyor doRunForwardBelt1 Runs inconveyor forward doRunBackwardBelt1 Runs inconveyor backward doManualLampFeeder1 Indication for operator when running inconveyor manually is permitted doRunFeederOut1 Run outconveyor 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 226: Entry Control And Safety
Signal from air preparation unit that air pressure is ok. doGreenLamp Turn on green light in RGB signal lamp doBlueLamp Turn on blue light in RGB signal lamp doRedLamp Turn on red light in RGB signal lamp 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 227: Gripper
Spare signal on robot arm connected to valve. Can be used by integrator doValve7Gripper Spare signal on robot arm connected to valve. Can be used by integrator 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 228: Turn Station
14 Appendix B: Communication 14.1.4 Turn station 14.1.4 Turn station Name Description doTurnStationGripperOpen Open gripper doTurnStationRotate Rotate turn station 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 229: Air Cleaning Box
Activate valve 3 on air cleaning box doValve4BlowBox Activate valve 4 on air cleaning box doValve5BlowBox Activate valve 5 on air cleaning box doValve6BlowBox Activate valve 6 on air cleaning box 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 230: Deburring
14 Appendix B: Communication 14.1.6 Deburring 14.1.6 Deburring Name Description doValve1Deburr Activate grinding/deburring tool 1 doValve2Deburr Activate grinding/deburring tool 1 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 231: Marking Unit
14 Appendix B: Communication 14.1.7 Marking unit 14.1.7 Marking unit No digital I/O is used for the marking unit. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 232: Statistical Outlet
14.1.8 Statistical outlet Name Description diDetailInBoxSensor Sensor that indicates that parts are placed in the statistical outlet. diBoxInPositionSensor Sensor that indicates that the box is in position and ready to receive parts. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 233: Internal Communication
14.2 Internal communication 14.2 Internal communication The FlexMT has a function interface that makes communication of the equipment with corresponding robot 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.
Page 234: Pickmt <> Robot
14 Appendix B: Communication 14.2.1 PickMT <> Robot 14.2.1 PickMT <> Robot For details on communication between PickMT and robot refer top the PickMT manual. 3HAC051768-001 Revision: - © Copyright 2014-2014 ABB. All rights reserved.
Page 235: Marking Unit <> Robot
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: - © Copyright 2014-2014 ABB. All rights reserved.
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Page 237: Apendix C: Flexmt Rapid Reference
The PickMT core consists of two modules, PvCom.mod which is running in a 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: -...
Page 238: Flexmt Core Functionality Reference
15.2 FlexMT core functionality reference 15.2 FlexMT core functionality reference The FlexMT core functionality is structured according to the following overviews. Some modules relevant for commissioning have been described in the robot program section. All other modules are described below.
Page 239: Control Subsystem
15 Apendix C: FlexMT RAPID reference 15.2.1 Control subsystem 15.2.1 Control subsystem FlexMT core functionality - control tasks (1) FlexMT core functionality - control tasks (2) FeedLine.mod Overal handling of conveyors and alarms connected to conveyor system. FeedLineInPosition.mod Specialized task for handling start and stop of inconveyor with short response time, regular operation with InPosition-sensor.
Page 240: Utility And Assistance Subsystem
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).
Page 241: Flexmt Application Functionality
15.3 FlexMT application functionality 15.3 FlexMT application functionality The FlexMT application functionality handles machine tool and part specific aspects of the FlexMT. The integrator is fully responsible for adopting this functionality to the actual application. FlexMT core functionality - main task TemplateMachine.sys...
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Page 246 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...

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