Product Manual

Positioner
 IRBP 500C/ 1000C
10
M2001
The information in this document is subject to change without notice and should be construed
as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in
this document.

In no event shall ABB be liable for damages of any nature from the use of this document.

This document and parts thereof must not be reproduced or copied without ABB´s written
permission, and the contents thereof must not be imparted to a third party nor be used for any
unauthorized purpose.

Copies of this document can be ordered from ABB.

© ABB Automation Technology Products AB

Artikelnummer: 504 846-102

Datum: 2002-05

ABB Automation Technology Products AB

Arc Welding & Application Equipment

S-695 82 Laxå

Sverige
 IRBP 500C/ 1000C

LIST OF CONTENTS
Page

1 Technical description .................................................................................................. 5

1.1 IRBP 500C/ 1000C ............................................................................................ 5
1.2 Technical data .................................................................................................... 6
1.3 Station switching unit MIC................................................................................ 7

2 Options ......................................................................................................................... 9
2.1 Option, Robot stand ........................................................................................... 9
2.2 Option, Swivels.................................................................................................. 10
2.3 Option, extra current collector for positioner types K/L/R/D............................ 15

3 Transport and unpacking ........................................................................................... 17

3.1 Lifting instructions............................................................................................. 17
3.2 Weights .............................................................................................................. 17

4 Foundation ................................................................................................................... 19
4.1 Installing the floor stand .................................................................................... 19

5 Maintenance................................................................................................................. 21

6 Loading table ............................................................................................................... 23

7 Integration of fixtures ................................................................................................. 25

7.1 IRBP 250R/ 500R/ 750R/ 250K/ 500K/ 750K/ 250L/ 500L/ 750L/ 2000L ...... 25
7.2 IRBP 250 C Index /500C /500 C Index/ 1000C/ 250A/ 500A/ 750A ............... 26

8 Measurement diagrams .............................................................................................. 27

8.1 IRBP 500C ......................................................................................................... 27
8.2 IRBP 1000C ....................................................................................................... 29

504 846-102 3
IRBP 500C/ 1000C

4 504 846-102
 Positioner IRBP
Technical description

1 Technical description

1.1 IRBP 500C/ 1000C

The positioner is designed to handle workpieces of a weight up to 500/1000 kg
(including the fixture) in connection with robot welding.
The positioner features a twin station solution where the robot welds on one side
and the operator loads and unloads on the other.
The modular design, few and heavy-duty moving parts as well as minimal
maintenance demands make the positioner extremely service friendly.
The positioner is designed with the following main sections (Figure 1):

1 Stand

2 Station switching unit MIC

2
504245A01

Figure 1 The positioner’s main sections.

On the outgoing shaft of the station switching unit MIC there is a frame on which
two fixed tables are fitted.
The tables have plain holes and guide holes for securing fixtures.
A screen is fitted between the two welding stations, which protects the operator
from arc-eye.
The drive equipment is placed in the system’s equipment cabinet.

5
Positioner IRBP
Technical description

1.2 Technical data

IRBP 500C IRBP 1000C

Max handling capacity 500 kg / side 1000 kg / side

Max load difference 350 kg 500 kg

between sides 1 and 2
(workpiece and fixture)

Centre of gravity See loading table See loading table

Repetition accuracy with ±0.1 mm ±0.1 mm

equal loads and radii 500
mm

Station switching time 180 º 3.3 - 4,0 s 3.1 - 4,0 s

Stop time with an < 0.5 s < 0.6 s

emergency stop

Max. welding power 600 Amp 600 Amp

60% duty cycle

Weight 360 kg 660 kg

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The station switching unit 0,&is a modular unit especially developed for robot
applications and is intended for indexed movement.
The station switching unit for 2 stations consists of following:

 Gear drive

 AC servo motor with integrated resolver and brake

 Limit Switch

 Limit position disc

2 4
mic

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A detailed description of the components parts is given below.

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The gearbox is a precision gear drive especially developed to withstand the high
demands placed on robot applications, among others, rigidity and torsional
strength, speed and accuracy.
The gearbox is virtually free of play and never needs to be adjusted; conforming to
requirements during its entire life.
The gearbox is maintenance free and the lubricant is sufficient for the gearbox’s
entire life, equivalent to 40,000 hours of operation.

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The AC-servo motor is a permanent magnetised 3-phase AC motor, which runs
smoothly throughout the entire speed range.
The rotor is equipped with high-grade permanent magnets that are not affected by
the temperature.
The motor is thermally protected (PTC-resistance), and has a resolver for motor
feedback and position indication.
The motor is equipped with a brake for locking when the station switching unit is
not actuated.
The brake is also activated with an emergency and operating stop.
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The motor is ground and electrically insulated from other parts in order to prevent
the weld current from being conducted through the motor’s protective conductor in
the event of a fault.
The motor is maintenance free.

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The station switching unit is equipped with two positive opening limit switches to
indicate effected station switching and for monitoring the position of the station
switching unit.

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The robot stand consists of the following parts:

 Stand

 Pedestal

 Insulation

 Cover plate

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The pedestal can be placed in different hole groups on the stand.

• Exercise care to ensure the robot and positioner do not collide during station
switching. Recommended spacing, see the chapter 6WDWLRQOD\RXW

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The swivels can be combined in different configurations for different
requirements.

 Air swivel for 1 channel

 Electrical swivel.

 Air/water swivel for 2 channels.

 Air swivel for 1 channel and electrical swivel.

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The function is to transfer air between a fixed part and a moving part.
Technical specification, see table below.

Technical specification for 1-channel air swivel

&KDQQHOV 1
'LPHQVLRQV 1/4"
0HGLD Air, max 10 bar
0D[WHPSHUDWXUH 60°C
PHGLD

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The function is to transfer electrical signals between a fixed part and a moving
part, see the table below.
The electrical swivel can transfer different types of signals, e.g. 24 V DC and
different data bus systems. Technical specification, see table below.

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&KDQQHOV 24 *
&XUUHQW Max 2 A /channel
9ROWDJH Max 48 V DC
&RQGXFWRU 0.15 mm² AWG 26
FURVVVHFWLRQ
&$1EXV Max 500 KBit/s
3URILEXV'3 Max 12 MBit/s
,QWHUEXV6 Max 500 KBit/s
*. Of which 1 channel is a screen.

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The function is to transfer air/water between a fixed part and a moving part.
Technical specification, see table below.

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&KDQQHOV 1 or 2
'LPHQVLRQV 1 / 4"
0HGLD Air, max 10 bar
Coolant, max 10 bar
0HGLD
Type HFC , 35 % water 65% glycol
0D[WHPSHUDWXUH 60°C
PHGLD
Purity, media 16/13, ISO 4406

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&KDQQHOV 1 or 2
'LPHQVLRQV 3 / 8"
0HGLD Air, max 10 bar
Coolant, max 10 bar
0HGLD
Type HFC , 35 % water 65% glycol
0D[WHPSHUDWXUH 60°C
PHGLD
Purity, media 16/13, ISO 4406

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The function is to transfer air and electrical signals between a fixed part and a
moving part. Technical specification, see table below.

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&KDQQHOV 1
'LPHQVLRQV 1 / 4"
0HGLD Air, max 10 bar
0D[ 60°C
WHPSHUDWXUH
PHGLD

7HFKQLFDOVSHFLILFDWLRQIRUFKDQQHODLUVZLYHOIRU07&
&KDQQHOV 1
'LPHQVLRQV 3 / 8"
0HGLD Air, max 10 bar
0D[ 60°C
WHPSHUDWXUH
PHGLD
Purity, media 16/13, ISO 4406

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&KDQQHOV 24 *
&XUUHQW Max 2 A /channel
9ROWDJH Max 48 V DC
&RQGXFWRUFURVV 0.15 mm² AWG 26
VHFWLRQ
&$1EXV Max 500 KBit/s
3URILEXV'3 Max 12 MBit/s
,QWHUEXV6 Max 500 KBit/s
*. Of which 1 channel is a screen.

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Connection of the signals/media takes place via connection flanges, see figure below.

 Electrical signals are connected to a socket outlet (1). Suitable plugs are
supplied for fitting on the incoming cables.
Circuit diagram, see separate tab.

 Connection of the weld negative (2). The positioner chassis is to be

separated from the system ground, e.g. cable screen.

 Connect the air (3) to the connection nipple with dimensions set out in the
technical specification.

 On the rotary unit there is a free cable/hose for connection to the fixture.
3

2
connectio

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Connection of signals/media, see figure below:

 Electrical signals are connected to a

socket outlet (1). Suitable plugs are
supplied for fitting on the incoming
cables.
Circuit diagram, see separate tab.
2
 Connection of the weld negative (2).
The positioner chassis is to be 3
separated from the system ground,
e.g. cable screen.
503885883

 Connect the air to the connection

nipple (2) with dimensions set out in
the technical specification. 1

 On the rotary unit there is a free cable/hose for connection to the fixture.
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An extra current collector can be fitted if necessary, for example, with high weld
currents or with problems with the magnetic blow mechanism when welding.

 Contact bar

 Holder

 Return

2
current

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 Connect the return cable (3) on the current collector

 Lubricate the current collector with grease, our article number 501 869-001.
Also see the chapter “Maintenance”.

15
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16
 Transport and unpacking

3 Transport and unpacking

The safety instructions and other instructions should be studied carefully
before starting transport and unpacking. These can be found under a separate
tab in the System manual.
• Check that the equipment is not damaged in any way. Report any visible
transport damage immediately.

3.1 Lifting instructions

The positioner is fitted with lifting eyes in order for use when moving.
Lifting of the positioner may only:
- be carried out using equipment that corresponds with applicable lifting
standards.
- be carried out by authorised personnel.
Do not walk under a suspended load!

3.2 Weights
Weight of the positioner, see chapter 1 “Technical Data”.

17
Transport and unpacking

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The robot station requires a good foundation and a concrete floor with double
reinforcement and with a bearing capacity of at least 1000 kg/m2 is recommended.
The bolts need a cast steel plate of at least 150x150x10 mm. Other solutions, for
example, cast steel sections are also possible.
1RWHDQ\VXUIDFHXQHYHQQHVVDIODWQHVVRIPPLVQHFHVVDU\ If necessary,
use shims under the foundation on the robot and positioner.

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 Place the stand as set out in the chapter 6WDWLRQOD\RXW.

 Drill holes for the foundation bolts. For dimensions, see the chapter
6WDWLRQ OD\RXW.

 Use level bolts to adjust the height of the station.

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 Fit the foundation bolts.

 Remove the level bolts.

 Tighten all bolts.

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20
 Positioner IRBP
Maintenance

5 Maintenance
The welding robot station is intended for use in demanding working conditions
with a minimum of maintenance. However, to minimise downtime some preventive
maintenance and inspection, spread over different periods of time, is necessary (see
the table below).
The station should be cleaned if necessary:
• Use a vacuum cleaner of cloth.
Compressed air and/strong solvents can damage seals, bearings, etc.

Every six
Daily Every year
Maintenance 400h months 5 years Notes
checks (2000 h)
(1000 h)

Cables X1

Gearbox, X2 Positioner
oil leakage

Return cables X3

Current X5 X4 Positioner
collector

Series X6 Control
measurement Cabinet
card, battery
replacement

Inspection

X1 Ocular control of cables. Replace if damaged.

X2 With leakage, call service personnel.
X3 Check that there is good contact between the different
connections.
X4 Check that no damage has been caused by sparking
during the start of welding and that the surface of the shaft
is not rough.
X5 Lubricate the current collector
Use special grease, our article number 501 869-001.
X6 See the Product Manual for IRB 1400/2400.

21
Positioner IRBP
Maintenance

22
 Positioner IRBP
Loading table

6 Loading table
IRBP 500C
The table shows the limits for the position of the centre of gravity at different
loads.
If the load is 500 kg the centre of gravity for the workpiece including the fixture
must be within the area which is limited by the circle with a diameter of A.
If the load is, for example, 475 kg use the column immediately above, i.e. the
500 kg column.
The sides can be loaded with different weights as long as the load difference
between the side 1 and side 2 is less than 350 kg.

Weight of the workpiece 500 450 400 350 300 250

including fixture (kg)

Ø A (mm) 120 220 350 500 680 850

ØA
504249-2

Figure 12 Text IRBP 500C.

23
Positioner IRBP
Loading table

IRBP 1000C
The table shows the limits for the position of the centre of gravity at different
loads.
If the load is 1000 kg the centre of gravity for the workpiece including the fixture
must be within the area which is limited by the circle with a diameter of A.
If the load is, for example, 820 kg use the column immediately above, i.e. the 850
kg column.
The sides can be loaded with different weights as long as the load difference
between side 1 and side 2 is less than 500 kg.

Weight of the workpiece 1000 950 900 850 800 750 700 650
including fixture (kg)

Ø A (mm) 400 470 550 620 700 790 900 1000

ØA
504259-2

Figure 13 IRBP 1000C.

24
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An attempt should be made when designing fixtures to match the centre of gravity
for fixtures and workpieces with the centre of rotation. In doing so this will
minimise the positioning time between positions.
First calculate the position of the centre of gravity and after which the gravitational
torque can be calculated. The latter must not exceed the specified value of the
continuous torque.
See the dimensional drawings for the positioner, faceplate and support collar for
the fasteners’ installation measurements. The strength grade for the bolts in the
fixture should be 12.9 or the equivalent.
The fixture must conform to specific tolerances to maintain trueness and
parallelism in order to prevent clamping forces from occurring. See Figure 14.
integration of fixtures.tif

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With fixture weights exceeding the maximum permitted load difference between
side 1 and side 2 the rotary unit’s frame must be locked using an external aid, for
example, an overhead crane.


750K’s layout 1

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The position of the centre of gravity is to be calculated when designing fixtures.
After this check that the centre of gravity is within the permitted range (see the
chapter /RDGLQJGLDJUDP).
See the dimensional drawings for the positioner for the fasteners’ installation
measurements.
The strength grade for the bolts in the fixture should be 12.9 or the equivalent.

26
 IRBP 500C
Measurement diagrams

8 Measurement diagrams

8.1 IRBP 500C

504249A01-1

Figur 16

27
IRBP 500C
Measurement diagrams
504249A01-2

504249A01-3

Figur 17

28
 IRBP 1000C

8.2 IRBP 1000C

504259A01-1

Figur 18

29
30
504259A01-2
IRBP 1000C

504249A01-3

Figur 19
504 846-102