IRC5 Programming and Operation - 2006 TKT

IRC5
PROGRAMMING AND OPERATION

ABB Automation Technologies
Course Objectives
Safety requirements for basic programming and operation

System warm start up, shut down and error recovery
Basic program operation
Basic production programming techniques
Editing program instructions to maximise efficiency
Create and use routines
Use input output instructions
Flexpendant communication instructions
ABB Automation Technologies - 2
Numerical data instructions

Saving and opening programs
Safety
Potential Accident Risks
Modifying program within robot cell
Test run
Fault tracing
Repair
Process hazards
ABB Safety Solutions an Overview
Emergency stop
Operating mode
Auto
Manual < 250 mm/s
Manual 100%
Enabling device
(Dead mans grip)
Hold-to-run
Safeguard stop
(Auto and Manual)
Limiting the workspace

Lockouts and Interlocks
Emergency Stop
Built in emergency stop

pushbuttons are found both
on the FlexPendant and
Controller-X-module as
default.
Extra emergency stops can
be connected to the robot
systems safety chain.
Operating Mode
Automatic mode
Production mode (no speed limit)
Manual mode
< 250 mm/s max velocity 250 mm/s
100 % Option, robot can be
jogged/tested with no speed limit.
Enabling Device (Dead Mans Grip)
The enabling device is a press switch with three

positions
The switch must be in the middle positions in order to
activate the motors
All robot movement will immediately stop if the switch is
released or pressed to the bottom
Enabling device
Hold-to-Run (Manual 100 %)
Option (this function can be selected in the

parameters)
The enabling device and one of the hold-to-run
buttons must be pressed simultaneously to
start the motors
Enabling device
Hold-to-run buttons
(for left or right hand)
Electrical Safety
Hazardous power in both the cabinet and the robot

Net power 400 VAC
Transformer 260 VAC
Rectifier 260 VAC and 370 VDC
Power supply 370 VDC
Power supply to robot motors up to 370 VDC

Customer equipment
Safety Regarding Releasing the Breaks
The breaks on the robot motors can be manually

released to release a caught individual
Before the breaks are released, be sure the weight of the
robot arms dont jam the individual even more
Stop the System
Stop the system immediately if
there is any personnel in the robot working area, while the robot
is working
the robot causes harm to personnel or mechanical equipment
Jogging the robot

Jogging The Robot
Motion Types
Robot
Major Axes 1,2,3
Minor Axes 4,5,6
Linear / Reorientation
Base
World
Tool
Workobject
Can Jog the Robot in Incremental steps.

QuickSet menu
With the QuickSet menu you can access some often

used settings
Mechanical unit
Jogging mode
(1-3, 4-6, linear or reorient)
Coordinate system
Increment
Running Mode
Step Mode
Override Speed
The Jogging Window

Exercise 1
Programming movements
Programming with the FlexPendant
ABB Main Menu

Creating a new Program File

Creating a new Program File

Programming Positions
Positional Movements Instructions
MoveJ - moves the TCP in a way which is

easiest for the robot and not in a straight line
Speed Data ToolData
MoveJ *, v1000, z50, tool0;

Robot Position Zone Data

Zone
Zone data describes how close to the destination
position the axes must be before the next instruction
can be executed.
Robot path in automatic mode. Programmed

position.
Zone size.
MoveL p2, v100, z10, tool0;

Joint & Linear Move
P1 Joint Move
Linear Move
P2
Positional Movements Instructions
MoveL - moves the TCP in a Linear direction

or straight line
Speed Data ToolData
MoveL *, v1000, z50, tool0;

Robot Position Zone Data

ModPos
Modifying the position in a positioning instructions
Move robot to desired position
Select the instruction or target to be changed
Press Modify position
Program Edit Menu

Tool Centre Point
Tool Mounting
Flange
+Y
+X +Z
Relative Directions X, Y & Z.
Tool Centre Point
Position & movement of robot always related to TCP.
Defined as being somewhere at the end of the tool.
Many can be defined but only one active at any one time.
Can be programmed manually but only if accurate data.

Normally use robot to define TCP.
If tool is damaged or replaced, dont change program just

redefine the tool.
Tool Centre Point Definition Methods
Default Orientation (same direction as tool0)
TCP & Z Just Z direction defined (X stays in same plane as tool0)
TCP & Z, X both Z and X defined
From 3 to 9 approach points
TCP Default Orientation
No rotation about X, Y or Z
Y
Z
X
TCP & Z
Z direction defined
TCP Z & X - Welding gun
Both X and Z defined

TCP Definition Default Orient
1
1
4
3
2 4
3 2
Plan view
TCP Definition Z & X
5 Z Elongator Z
1 X
4 Y
3
6 Base
2 coordinate
X Elongator direction
Tool Centre Point Definition Method
ABB Menu
Program data
Select tooldata
Show data
New
Name tool
Initial value or OK and select tool in list and Edit Value
Mass:= type in kg
Press OK
Press and hold on tool in list to get context menu
Select Define
Select Method and number of Points

Select Point 1, jog robot to calibration position and press Modify Position
Repeat for remaining points
Press OK
You will need to activate your TCP in the jog window
Exercise 2
Create a Tool Centre Point
Work Object Coordinate System
All program positions are attached to a work object
Wobj0 is the default coordinate system
It is advisable to use custom work objects

z
p10
(900, 60, 500)
y
Base
(0,0,0)
Wobj0
x
Work Objects
Custom Work Object

X1
Object
frame
User
frame
World
Work Objects contain both User and Object Frames

Work Object Frames
p10
(200, 0, 450)
(400, 0, 50)
World User
(300, 60, 0)
Object
Defining a Work Object frames
World
World
User and Object Coordinate Systems are usually both defined

at the same position.
Work Object Definition Methods
User and Object Coordinate Systems are usually both defined

at the same position.
Jogging along axis Work Objects
X
X
Work Objects Summary
WObjData is used to describe the area that the robot welds, processes,
moves within etc.
If position Data is entered manually, the values can be taken from a

drawing.
Programs can be reused quickly following changes in the robot installation

e.g. if a fixture is moved, just redefine user coordinate system.
Variations in how the work object is attached can be compensated for. For
this, however, some sort of sensor will be required to position the work
object.
Robot can be jogged along the axes of the work object.

Work Object Definition Method
In the jogging window activate the TCP that you will use to define Workobject
ABB Menu
Program data
Select wobjdata and tap Show Data
Select New
Name work object
Press OK
Press and hold on the Workobject in list to get context menu
Select Define
Select 3 points for user frame and No Change for Object frame definition
Jog the tool to the User X1 point select and Modify Position
Repeat for User X2 and User Y1
Press OK and view the calculated result
Press OK to close
You will need to activate your workobject in the Jogging window
in order to program or jog relative to it.
Positional
MoveC - moves the TCP in a Circular

direction using the mid & end point of a semicircle
Speed Data ToolData
MoveC *, *, v1000, z10, tool0;

Robot Positions Zone Data

Circular Move
p1
Pick MoveC here
p4 p2
p3 ModPos MoveC here

MoveL p1, v100, fine, tool0;

MoveC p2, p3, v100, z1, tool0;
MoveC p4, p1, v100, fine, tool0;
Routines and program flow
main
outside circle oval
Main Outside Circle Oval

MoveJ pHome,v MoveJ pSafe,v MoveJ pSafe,v MoveJ pSafe,v
Outside; MoveJ v1000 MoveJ v1000 MoveJ v1000
Circle; MoveL v200, MoveL v200, MoveL v200,
Oval; MoveL v200, MoveC v20 MoveC v20
MoveC v20 MoveC v20 MoveC v20
MoveL v200, MoveL v200, MoveC v20
MoveC v20 MoveJ v1000 MoveC v20
MoveL v200, MoveC v20

MoveC v20 MoveC v20
MoveL v200, MoveL v200,
MoveC v20
MoveL v200,
Main routine Sub routines

Routines
Before you start to program, you should think out the structure first.
Repetitive instruction sequences that occur frequently in the program,

such as gripper handling, should form their own routines.
Routines separate the program into smaller more easily understood

parts that can then be called anywhere in the program.
You have a Max 16 characters allowed for naming a routine so you

should give them meaningful names such as DrawCircle, CutSquare

and Pick_Part etc.
Path Following Exercise
Start / Finish Start / Finish

Start / Finish
Direction
Example of main routine

Routines
There are three types of Routine:
Procedure - could be described as a number of instructions that
perform a specific task, such as welding a part or changing a tool.
These are put into your program by using ProcCall in the Pick List.
Function - returns a value and, for example, is used to displace a

position or read an input. Not in the Pick List.
Trap - is used to deal with interrupts. These routines are run when
something happens e.g. when a sensor tells you your weld gun has
no gas so an error is reported by the trap routine. Can only be
connected to an interrupt.
What is a module
The Internal Structure of Modules
%%%
VERSION:1
LANGUAGE:ENGLISH
%%%
MODULE MainModule
CONST robtarget p3:=[[1266.11,-44.68,379.91],[0.567059,0.054467,0.821577,0.022118],[0,0,-
CONST robtarget p2:=[[1270.77,-93.78,386.13],[0.567071,0.054457,0.82157,0.02211],[-1,0,-
CONST robtarget p1:=[[1312.4,-132.16,381.39],[0.567077,0.054431,0.821568,0.02209],[-1,0,-
PROC main()
MoveL p1,v1000,fine,tool0;
ENDPROC
ENDMODULE
IRC5 Task Structure
Robot Task
Program File.pgf
<?xml version="1.0" encoding="ISO-8859-1" ?>
<Program>
<Module>MainModule.mod</Module>
</Program>
MainModule.mod System Modules.sys
Program Data Program Data

Main
Routines Routines
Routine
IRC5 Task Structure
Robot Task
Program File.pgf
<?xml version="1.0" encoding="ISO-8859-1" ?>
<Program>
<Module>ModuleA.mod</Module>
<Module>ModuleB.mod</Module>
<Module>MainModule.mod</Module>
</Program>
Program Modules.mod System Modules.sys
Program Data Program Data Program Data

Main
Routines Routines Routines
Routine
Creating a new program in IRC5
A new program file is created (.pgf)

A MainModule with main routine is created
Saving program in IRC5
A folder with the same name as the program is created

This folder contains the MainModule, Sub modules and the
program file
The program file (.pgf),is an extensible mark-up language,
XML, file that lists all program modules in the task
System Modules are NOT saved
Folder created with

same name
What are Modules
A module is a group of routines and data.
The module that contains the main routine is the MainModule
System modules are always present in memory and can be used to save
your default data
Filename extensions are
XXXXX.mod Module
XXXXX.sys System Module
XXXXX.cfg Parameter File
XXXXX.pgf Program File
Saving Individual Modules
Individual, Program or System modules can be saved
Select in Program Editor and Save Module As from File menu
IRC5 System backup
Backup_20050117
BACK INFO HOME RAPID SYSPAR System.xml
System ID Most files off System parameters

Text information, Flash disk from
programme.id, Active system
key.id,
keystr.txt, TASK 0 TASK
TASK 111
Multitasking
system.guid,
template.guid
TASK
TASK 1
PROGMOD SYSMOD PROGMOD

PROGMOD SYSMOD
SYSMOD
Empty Empty PROGMOD
PROGMOD SYSMOD
SYSMOD
Program modules System modules
Used by system only!
Loading Programs
Loading whole programs will overwrite existing programs

Each task will have its own program
Loading Modules
Loading Program and System modules from the Program Editor
1
2
Logical
Set - turns ON a Digital Output.
Set doGripper;
Reset - turns OFF a Digital Output.
Reset doGripper;
Logical
SetDO - changes the value of a Digital Output.
SetDO do15, 1;
or
SetDO \SDelay := 0.2, do15, 1;
SetDO \Sync do15, 1;

WaitDI
WaitDI - Waits until a Digital Input is set to either

high or low.
WaitDI di1, 1;
Logical
WaitUntil - Waits until 1 or several Inputs have

been set.
WaitUntil di1=1;
WaitUntil di1=1 AND di2=1;

AND, OR, XOR & NOT

Logical
WaitTime - Waits a set amount of time.
WaitTime 0.5;
(Waits 0.5 seconds)
WaitTime \InPos, 0.5 ;

(Optional Argument wait in position)
Logical
Stop - is used to stop program execution.
Move J pTCPcheck, v100,fine,tGun;

Stop;
TPWrite
TPWrite - writes Text/Data to FlexPendant.
TPWrite Execution Started;

TPWrite Num of produced parts= \Num:=reg1;
TPWrite String [\Num] | [\Bool] | [\Pos] | [\Orient]
TPErase
TPErase - is used to clear the display of the FlexPendant.
TPErase;
TPWrite Execution Started;
TPShow
TPShow - is used to switch the window on the FlexPendant.
TPShow TP_PROGRAM;
The Production Window will be active if the system is in AUTO mode.
Or
The Program Window will be active if the system is in MAN mode.
TPShow TP_LATEST;
Show the previous FlexPendant Window before the current one.

Program Documentation
All your programs, and documentation should be well looked

after. At the very least your programs should be:
Backed up regularly
Master
copies on CD or USB Memory stick in
Company safe
Shop floor copies on USB Memory stick or robots

Hd0a
Comment
Comment - Inserts a line of text so as to make it easier to understand
the program.
Comment / Uncomment Row
Comment Row Disabling Instructions, sometimes better than delete!
IF
IF - where different instructions are executed

depending on whether a condition is met or not.
IF di1 = HIGH THEN IF di1 = HIGH THEN

Circle; Circle;
Oval;
ELSEIF di2 = HIGH THEN
ENDIF
Outside;
ELSE
Oval;
ENDIF
CompactIF
Compact IF - where a single instruction is executed

depending on whether a condition is met or not.
IF di1 = HIGH WaitTime 0.5;

or
IF di1 = HIGH Oval;
The instruction may be a ProcCall which calls a

routine
TPReadNum
TPReadNum - writes Text on FlexPendant and records
which Numbers are pressed.
TPReadNum reg1, How many Outsides should be produced?;
While
While - is used when a number of instructions are to be

repeated as long as a given condition is met.
WHILE reg1> 0 DO
Outside;
Decr reg1;
ENDWHILE
Repeats the instructions in the WHILE loop as long as

reg1 > 0
WHILE Condition DO... ENDWHILE
Cycle Timing Instructions
ClkReset - is used to reset a clock that functions as a stop

watch, it sets it to 0.
ClkReset clock1;
ClkStart - is used to start a clock that functions as a stop

watch.
ClkStart clock1;
ClkStop - is used to stop a clock that functions as a stop

watch.
ClkStop clock1;
ClkRead()
ClkRead() - is a function that reads a timing clock and

returns its value.
ClkReset clock1;
ClkStart clock1;
MoveJ *, v1000, fine, tool0;
ClkStop clock1;
TPWrite Cycle Time=\Num:=ClkRead(clock1);
TPReadFK
TPReadFK - writes text on the FlexPendant and records a number.
TPReadFK nPress, Choose?, Outside, Circle, Oval ,,;

TEST
TEST - where different instructions are executed depending

on the value of an expression or data.
TEST nPress
CASE 1:
Outside;
CASE 2:
Circle;
CASE 3:
Oval;
DEFAULT:
TPWrite Illegal choice;
Stop;
ENDTEST
Course Objectives
Safety requirements for basic programming and operation

System warm start up, shut down and error recovery
Basic program operation
Basic production programming techniques
Editing program instructions to maximise efficiency
Create and use routines
Use input output instructions
Flexpendant communication instructions

Numerical data instructions
Saving and opening programs

IRC5 Programming and Operation - 2006 TKT

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IRC5

PROGRAMMING AND OPERATION

Safety requirements for basic programming and operation

Numerical data instructions

Limiting the workspace

Built in emergency stop

The enabling device is a press switch with three

Option (this function can be selected in the

Hazardous power in both the cabinet and the robot

Power supply to robot motors up to 370 VDC

The breaks on the robot motors can be manually

Jogging the robot

Can Jog the Robot in Incremental steps.

With the QuickSet menu you can access some often

The Jogging Window

ABB Main Menu

Creating a new Program File

Creating a new Program File

MoveJ - moves the TCP in a way which is

Speed Data ToolData

MoveJ *, v1000, z50, tool0;

Robot Position Zone Data

Robot path in automatic mode. Programmed

MoveL p2, v100, z10, tool0;

MoveL - moves the TCP in a Linear direction

Speed Data ToolData

MoveL *, v1000, z50, tool0;

Robot Position Zone Data

Program Edit Menu

Position & movement of robot always related to TCP.

Defined as being somewhere at the end of the tool.

Can be programmed manually but only if accurate data.

Normally use robot to define TCP.

If tool is damaged or replaced, dont change program just

Both X and Z defined

Select Method and number of Points

All program positions are attached to a work object

Wobj0 is the default coordinate system

It is advisable to use custom work objects

Custom Work Object

Work Objects contain both User and Object Frames

User and Object Coordinate Systems are usually both defined

User and Object Coordinate Systems are usually both defined

If position Data is entered manually, the values can be taken from a

Programs can be reused quickly following changes in the robot installation

Robot can be jogged along the axes of the work object.

MoveC - moves the TCP in a Circular

Speed Data ToolData

MoveC *, *, v1000, z10, tool0;

Robot Positions Zone Data

p3 ModPos MoveC here

MoveL p1, v100, fine, tool0;

outside circle oval

Main Outside Circle Oval

MoveL v200, MoveC v20

Main routine Sub routines

Repetitive instruction sequences that occur frequently in the program,

Routines separate the program into smaller more easily understood

You have a Max 16 characters allowed for naming a routine so you

should give them meaningful names such as DrawCircle, CutSquare

Start / Finish Start / Finish

Path Following Exercise

Example of main routine

MoveC , , v1000, z10, tool0;