Fundamentals

of

Industrial Robotics
Online Training Course for Students 2019 (4)
 Industrial Robots

Robot
Source: New Age Robotics
Programming
 Industrial Robots
 The most popular method of robot programming is probably the
use of the teach pendant. Over 90% of robots are programmed
by this method.

 Robot teach pendants have changed a lot throughout the years.

Early teach pendants looked like a large calculator with many buttons
and small displays.

ABB
KUKA Reis Robotics
KUKA
 Industrial Robots

 Nowadays, modern teach pendants are more like a touchscreen tablet.

They combine the evolving technical solutions with ergonomical demands
of the robot users.

FANUC KUKA ABB

 Industrial Robots
The Design of Teach Pendants is a compromise between functionality and physical size
and weight.
Typical features are:
 Large Graphical Touch Display  Start /Stop buttons for automatic program run

 Operation mode selection  Right and left hand support

 Emergency Stop button  Connection to Robot controller via cable

 3D Joystick or 6D Mouse to enable easy jogging

 Axis Motion control buttons ( 6 to 8 buttons)

 Soft Keys (function keys) to activate functionalities

presented by the implemented programming software

Source: KUKA KRC 2

 Teach Pendants of Industrial Robots
Modern design of Teach Pendants:

DENSO Robotics
UNIVERSAL Robot

KAWASAKI

PANASONIC
YASKAWA
COMAU
 Industrial Robots
Programming of Industrial Robots requires a high amount of skills and
technical expertise:

 Knowledge how to operate the Teach Pendant;

 Jogging of the robot in multiple coordinate systems;
 Trajectory planning and commanding robot motion;
 Process technology and justification of process behavior;
 Structuring of Robot Programs to optimize program flow;
 Create, modify, load, save, and store robot programs;
 Planning of workflow; consideration of time constraints;
 Safety measures to consider while working with a robot.

 Programming robot operations by means of Offline

Programming & Simulation Tools (if relevant).

Source: robotmaster.com
 Industrial Robots
ABB FlexPendant represents:
 3D Joystick

 4 Hard keys (customizable)

 4 Hard keys for Automatic program run

 Large touch screen ( 7.7 inch, 640x480 pixels)

 4 Hard keys to select operation modes

 IRC 5 concept: FlexPendant and RobotStudioOnline work together; same accessibility of data
on FlexPendant as on RobotStudioOnline

 FlexPendant is using an independant computer  independant from main robot computer

 OP system is WINDOWS CE.net,

 RobotWare supports functionalities and processes (i.e. RobotWare ARC)

Source: ABB
 Industrial Robots
 Graphic Operator Menus (GUI) provided by System Software
make it easier to work with industrial robots.

 The User interacts with the GUI application by:

- Clicking a button
- Selecting from a menu
- Typing text into a text box, and
- Scrolling.

 Each user action on the GUI creates events. Events are

executed by an Event Handler.

 Two different levels are availale to control a robot station:

- by Event Handler running on the FlexPendant,
- by RAPID instructions executed by the controller.

ABB RobotWare
Source: ABB
 Industrial Robots

Jogging the robot in different coordinate systems

Cartesian world Joint world

Source: robotmaster.com
 Industrial Robots
Coordinate systems are in use to make jogging and offline programming easier:
World coordinates: to relate any TCP position
of the robot to a fixed point in the workshop.
Of particular use if two robots work together.

Base coordinates: attached to the base plate of

the robot.

Tool coordinates: specifies the TCP position of

the tool and the tool orientation.

User coordinates: specifies the position of a

fixture or of a workpiece positioner.

Object coordinates: specifies how a workpiece

is positioned in a fixture or on a positioner.
Coordinates can be specified by
numerical values or by jogging the
Source: ipacv.ro robot through a number of positions.
 Industrial Robots
Tool Coordinate system makes jogging and programming easier:

Moves are relative to the axis system defined by the tool coordinates.

Robot can move a tool straight forword towards a destination along one axis
of the tool coordinate system. No reorientation of the tool during this movement
is necessary!

Often used for applications where the robot arm has to approach parts
or pick up parts out of fixtures.

Tool can be rotated easily around its TCP.

Also applied at stationary tools where the robot will manipulate a workpiece.
Workpiece is always moved towards the stationary TCP.

Source: ipacv.ro
 Industrial Robots
Use of Object Coordinates can make programming easier:

Tool can be programmed to move parallel to object coordinates. Each position

the tool has to move is specified in object coordinates.

Often in use when numerous workpieces of same series for instance have to be
welded at different stations surrounding the robot. The workpieces can change
their orientations, but the program is always the same, because all target
positions defined in the program are related to the object coordinate system
once defined for this workpieces.

Source: ipacv.ro
 Industrial Robots

Each definition of robot motion should avoid singularity positions!

Kinematic singularity means that the robot is losing

its ability to move the end-effector in expected directions.
The robot controller fails in executing motion because
of infinitely growing speed values. Two degrees of freedom
degenerate into only one.

Typically is for instance Wrist Singularity. Here, axes 4

and 6 line up with each other. Controller does not know
which axis should be moved. Some controllers stop
program execution. Others move axis 4 instead of
axis 6 or continue to move both.
This can create serve problems and damage.

Therefore: Robot programmers should know about the singularity problem and take care
of singularities during programming!

Source: robotmaster.com
 Industrial Robots

Instructions to program Industrial Robots:

 Main basic entities being considered during robot programming are:

- Position data (to define trajectories);

- Procedures and Process data
- Instruction to organize Program flow .

 Robot software (robotware) will facilitate these programming tasks.

Source: robotmaster.com
 Industrial Robots
Selection of main Instructions being used to program Industrial Robots
 Motion commands (Move Joints, Move Line, Move Circ, Move Offset [Relative Motion],
Move AbsJ jpos10 [position=numerical value] )
 Positioning accuracy (FINE, ZONE)
 Velocity instruction (mm/s)
 Tool specification (TCP)
 Workobject (coordinate system)
 Input/Output commands (DI, DO, AI, AO)
 Logic commands (WAIT, WAIT time)
 Program flow instructions (IF THEN ELSE, FOR, WHILE,….)
 Control of external devices:
Close gripper  SetDO do1,1;
Open gripper  SetDO do1, 0;
 Program Stop
Source: robotmaster.com
 Industrial Robots
Some additional Instructions for Programming of Industrial Robots

 Interrupt instructions (to deal directly with an event [interrupt] regardles which command is
executed at the time)

 Mathematical instructions (to calculate and change values of data)

 Process-related instructions (Spot welding, Arc welding, etc.) SpotL, Spotdata, ArcL, ArcC,
weavedata, welddata, etc.

 ! [Comment]

Source: robotmaster.com
 Industrial Robots

Modes of Programming Industrial Robots:

 Online Programming
- TeachPendant programming

- Lead-through programming

 Offline Programming

Source: robotmaster.com
 Industrial Robots

Teach-In Programming:
 To program the robot, the operator moves it from point-to-point, using
the buttons on the pendant to move it around and saves each position
individually.

 When the whole program has been learned, the robot controller can
play back the programmed points at full speed.

 Teach-in programming takes time and needs programming skills and

training.
 Industrial Robots
Teach-In: Check the need of auxiliary positions before programming
A) B)

Collision

Task: Move from Start-Position to Target-position Programmed: PTP-Move directly towards Target-position
C) AUX2
AUX D) AUX3

AUX1

Programmed: LINE-Move via Auxiliary Position towards Target Programmed: PTP-Move via Auxiliary Positions towards Target

Source: THM Giessen, K.Wüst

 Industrial Robots
Recommendations to consider in robot programming:
1. Any movement of the tool in the free working space of the robot can be programmed with PTP mode.
2. Position selected close to a Start Position of a Work Task should be reached by PTP but already with
required orientation for the work task.
3. Closest position before START does not need any stop of the TCP movement use fly-over function or
ZONE function.
4. START position should be reach at low speed and by means of CP motion.
5. Begin of process execution  motion with selected velocitiy until the end position is reached.
6. After END of process execution: move always towards a safe position at low speed and by means of CP mode.

P50 PTP P90

PTP AUX
AUX
CP CP
START Work Task END

Workpiece
 Industrial Robots

Recommendations to consider in robot programming:

7. Use different coordination systems.

Movement parallel to axes of the coordinate system makes programming easier.

8. Use of Tool Coordinates for instance may help to move gripper, welding gun, drilling tool,
etc. with a defined orientation along straight direction without any reorientation needs.
Tool is aligned with the workpiece and will keep this orientation while moving towords target!

9. Use of Object Coordinates if only one program shall be applied for multiple workpieces
of similar type which have to be welded at different tables surrounding the robot.
 Industrial Robots

Recommendations to consider in robot programming:

10. Be clear about the work flow before starting with robot program generation.

11. Are there any time constraints to consider?  for instance cycle times;

12. Are there technological aspects to consider?  for instance heat distortion
during welding which has impact on the sequence of welds

13. Are there any geometrical tolerances to consider?  for instance related to the pre-preparation
of workpieces;

14. Is full accessibility of the tool guaranteed? for instance in terms of fixtures or clamping devices

15. Use auxiliary positions to avoid any collision  but consider: too much auxiliary positions
will extend cycle times.
 Industrial Robots

Safety Standards to consider during Online Programming and Program Run:

 Online programming near the robot only at reduced TCP speed ( 250mm/s)
 Safety switch (enabling device) at Teach Pendant 3 positions: OFF-ON-OFF
 Operation mode switch (Test and automatic program run)
 Electric Limit switches (to define range of operation at each axis)
 Mechanical Stops in axis 1, 2 and 3
 Emergency Stop ( push button on controller and on tech pendant)
Additional emergency stops can be connected to the robot‘s safety chain circuit.

 Override Function (to adjust TCP speed during manual test and automatic run)
 Industrial Robots
Safety Standards to consider during Online Programming:

 Safety switch (enabling device) at Teach Pendant 3 positions: OFF-ON-OFF

- Robot movement stops when either the enabling device is pressed fully in
or it is released completely.

Denso Robotics

ABB FlexPendant
 Industrial Robots

Operation mode switch

I) Manual testing with Reduced speed :
Hold-to-run function is used. Press Safety switch (enabling device)
and START button. Keep pressing both!!

II) Full speed manual testing mode (100%):

Hold-to-run function is used. Press Safety switch (enabling device)

and START button. Keep pressing both!!

III) Automatic mode:

Hold-to run function is not used. Press only START button!
Press STOP-button to stop the program execution.!
 Industrial Robots

Online Progragramming – a summary:

Source : YouTube
Industrial Robots

Offline Programming
 Industrial Robots
Offline Programming and Simulation of Industrial Robots
 Offline programming (OLP) is applied to generate and simulate robot programs based on virtual
models of robots, workpieces (often 3D CAD models), and other cell components.

 OLP is widely used for automation systems with

large product volume.
 OLP programs are typically generated on an external
computer in the office. They will be tested and
simulated before they are downloaded to the real
physical robot cell in the workshop.
 With OLP robot programs can be developed earlier in the design or production cycle.
 Quality of OLP programs is related to the models being used and on the skills of the programmer.
 Program generation with OLP tools requires high level programming skills.

Source: Univ. of Wollongong/Australia, ks-iss.com

 Industrial Robots

Advantages of Offline Programming

• Reduces downtimes for robot programming,
• Reduces risk by visualisation and confirming solutions,
• Introduce new parts and methods without interrupting
production,
• Optimize robot programs to increase productivity,

• Generate higher part quality through creation of more accurate

paths,
• Check for and avoid singularities.
Source: ABB
 Industrial Robots

Disadvantages of Offline Programming

• Virtual models will (probably) never be able to represent the
real world with 100% accuracy.
• Programs may still need to be altered after they are applied to
the real robot.
• Might take longer overall. Although offline programming
reduces the downtime of the robot, it means that someone
has to spend extra time developing the simulation, as well as
testing it on the robot.
• Can sometimes end up wasting time sorting out simulator
issues instead of solving production challenges. This could be
related to the quality of the simulator.
 Industrial Robots

ROBOT STUDIO
Offline Programming and Simulation Tool

Source: ABB
 Industrial Robots

Offline Programming with RobotStudio:

User Interface

1. Menus
2. Toolbars
3. Browser
4. Property Browser
5. Status Bar
6. Output window
7. Graphics window

Source: ABB
 Industrial Robots

Set-up of a Robot Cell by means of Design Libraries

We have to assemble the tool onto the robot during the design phase.

Robot with Tool

Source: ABB
 Industrial Robots

Functions offered by RobotStudio

Modeling of robots ( from library) and positioning Import of geometries (CAD models)

Application of Virtual Robot Controller Create RAPID code

Selection of tools ( from Library) and integration into Collision checks

robot system
Work with virtual FlexPendant
Definition of workobjects (coordinate systems)
Design of conveyor systems
Definition of target positions
Creating of Smart Components (finger gripper,
Definition of paths vacuum gripper, sensors, etc.)

Simulation Loading and saving programs

 Industrial Robots

Simulation with RobotStudio

Source : YouTube
 Industrial Robots

Offline Programming & Simulation

Start to learn programming with ROBOT STUDIO !

 Industrial Robots

Links to learn programming with RobotStudio

Operating manual
https://library.e.abb.com/public/244a8a5c10ef8875c1257b4b0052193c/3HAC032104-001_revD_en.pdf

A Guide for ABB Robot Studio RobotStudio Tutorials

www2.dem.uc.pt/pedro.neto/PUB/BC/M_1.pdf https://new.abb.com/products/robotics/robotstudio/tutorials

Getting started 1 RobotStudio Tutorial

https://www.youtube.com/watch?v=bm-Tyz4Gmzw https://www.youtube.com/watch?v=pqUGWgK9lhQ
Getting started 2
https://www.youtube.com/watch?v=zYS__OluiXw
Getting started 3
https://www.youtube.com/watch?v=cR3-bhILuqg
Getting started 4
https://www.youtube.com/watch?v=8o-thxZeeMk
Getting started 5
https://www.youtube.com/watch?v=q25LbS9fd1s
 Industrial Robots

End of Online Session 4 !

Thank you for your interest!