ABB IRB 660 Product Manual
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ABB IRB 660 Product Manual

Flexgripper-vacuum
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FlexGripper-Vacuum
IRB 660

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  • Page 1 Product manual FlexGripper-Vacuum IRB 660...
  • Page 3 Product manual FlexGripper-Vacuum Document ID: 3HAC040633-002 Revision: -...
  • Page 4 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

    Table of Contents Overview ................5 1 Safety 1.1 Introduction .
  • Page 6 Table of Contents 2.6.6 Mechanical noise ............. . 70 2.6.7 Workpiece drop on power down .

  • Page 7: Overview

    Overview Overview About this manual This manual provides instructions for the FlexGripper-Vacuum. Each chapter concerning the FlexGripper-Vacuum contains information on: • mechanical structure & working principle • mechanical /electrical installation • maintenance • repair • trouble shooting • spare parts Read through this document carefully, especially the sections about safety, before you start to unpack, install and use the FlexGripper-Vacuum.
  • Page 8 Overview Continued Reference Reference Document ID Product manual - IRB 660 3HAC025755-001 Product manual - IRC5 Robot Controller 3HAC021313-001 Revision Revision Description First edition 3HAC040633-002 Revision: -...

  • Page 9: Safety

    1 Safety 1.1. Introduction 1 Safety 1.1. Introduction Overview The safety information in this manual is divided into two categories: • General safety aspects, important to attend to before performing any service work on the FlexGripper. These are applicable for all service work and are found in General safety information on page •...

  • Page 10: General Safety Information

    Limitation of liability Any information given in this manual regarding safety must not be construed as a guarantee by ABB that the industrial manipulator will not cause injury or damage, even if all safety instructions are complied with. Related information...

  • Page 11: Safety Risks

    Nation/region specific regulations To prevent injuries and damage during the installation of the manipulator system, the regulations applicable in the country concerned and the instructions of ABB manipulatorics must be complied with. 3HAC040633-002 Revision: -...

  • Page 12: Safety Risks Related To Tools/Workpieces

    1 Safety 1.2.2.2. Safety risks related to tools/workpieces 1.2.2.2. Safety risks related to tools/workpieces Safe handling It must be possible to safely turn off tools, such as milling cutters. Make sure that guards remain closed until the cutters stop rotating. It should be possible to release parts manually (valves).

  • Page 13: Safety Risks Related To High Speed

    1 Safety 1.2.2.3. Safety risks related to high speed 1.2.2.3. Safety risks related to high speed WARNING! Particular care must be taken with the FlexGripper-Vacuum. Risk of gripped workpiece uncontrolled gravity drop during high speed movement. 3HAC040633-002 Revision: -...

  • Page 14: Safety Risks During Operational Disturbances

    1 Safety 1.2.2.4. Safety risks during operational disturbances 1.2.2.4. Safety risks during operational disturbances General • The industrial manipulator is a flexible tool that can be used in many different industrial applications. • All work must be carried out professionally and in accordance with the applicable safety regulations.

  • Page 15: Risks Associated With Live Electric Parts

    1 Safety 1.2.2.5. Risks associated with live electric parts 1.2.2.5. Risks associated with live electric parts Voltage related risks, general • Although trouble shooting may, on occasion, have to be carried out while the power supply is turned on, the manipulator must be turne off(by setting the main switch to OFF)when repairing faults, disconnecting electric leads and disconnecting or connecting units.

  • Page 16: Safety Actions

    1 Safety 1.2.3.1. Safety fence dimensions 1.2.3. Safety actions 1.2.3.1. Safety fence dimensions General Install a safety cell around the manipulator and the FlexGripper to ensure safe FlexGripper installation and operation. Dimensioning Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the FlexGripper is dropped or released at maximum speed.

  • Page 17: Fire Extinguishing

    1 Safety 1.2.3.2. Fire extinguishing 1.2.3.2. Fire extinguishing NOTE! Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the manipulator system (manipulatoror controller)! 3HAC040633-002 Revision: -...

  • Page 18: Safe Use Of The Flexpendant

    1 Safety 1.2.3.3. Safe use of the FlexPendant 1.2.3.3. Safe use of the FlexPendant NOTE! The enabling device is a push-button located on the side of the FlexPendant which, when pressed half way in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the manipulator is taken to the MOTORS OFF state.

  • Page 19: Safety Related Instructions

    1 Safety 1.3.1. Safety signals, general 1.3 Safety related instructions 1.3.1. Safety signals, general General This section specifies all the dangers that may arise from performing the work detailed in the manual. Each danger is detailed in its own section consisting of: •...
  • Page 20 1 Safety 1.3.1. Safety signals, general Continued Symbol Designation Signification CAUTION Warns that an accident may occur if the instructions are not followed that can result in injury and/or damage to the product. It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height, etc.

  • Page 21: Safety Symbols On The Flexgripper Labels

    1 Safety 1.3.2. Safety symbols on the FlexGripper labels 1.3.2. Safety symbols on the FlexGripper labels Introduction to labels This section describes safety symbols used on labels (stickers) on the FlexGripper. Symbols are used in combinations on the labels, describing each specific warning. The descriptions in this section are generic, the labels can contain additional information such as values.

  • Page 22: Safety Guidelines

    1.3.3. Safety guidelines Safety guidelines while working with FlexGripper • See the IRB 660 Product manual for information on safety. • All persons working in the system must be sufficiently trained. Incorrect installation and/or use can cause injuries to persons and/or damage to equipment.

  • Page 23: Flexgripper-Vacuum

    2 FlexGripper-Vacuum 2.1. Specification 2 FlexGripper-Vacuum 2.1. Specification The products to be lifted with the FlexGripper-Vacuum must have a dense and smooth surface and a rigid structure (for example a cardboard case) on which the vacuum cups can grip. Storage conditions The table below shows the allowed storage conditions for the FlexGripper-Vacuum: Parameter Value...
  • Page 24 Max: 1200 X 500 X 300mm NOTE! Due to variations in size, weight, design, surface, rigidity, porosity and centre of gravity, please judge if your products can be lifted by ABB FlexGrippers according to the above FlexGripper parameters and product specifications. 3HAC040633-002 Revision: -...

  • Page 25: Mechanical Structure & Working Principle

    2 FlexGripper-Vacuum 2.2.1. General 2.2 Mechanical structure & working principle 2.2.1. General The FlexGripper-Vacuum (see Figure 2.1) consists of two main components: the vacuum rails and the pallet hook. The vacuum rails are for picking up products and the pallet hook is used for lifting pallets.

  • Page 26: Vacuum Rails

    2 FlexGripper-Vacuum 2.2.2. Vacuum rails 2.2.2. Vacuum rails The two rails, which measure 1200 mm, consist of two beam plates mounted with vacuum units and photoelectric sensors (see figure 2.2). Each beam plate is equipped with ten vacuum units, which support two vacuum cups with a pitch of 60 mm each which generate the vacuum.
  • Page 27 2 FlexGripper-Vacuum 2.2.2. Vacuum rails Continued Individually controlled zones The vacuum rails are divided into ten separate controlled zones (see figure 2.3). en1011010 Figure 2.3 Vacuum cup and zone configration Each zone contains two vacuum units with four cups. On different rails, every two cups in the same zone share one vacuum generator, and every two vacuum generators in the same zone are controlled by one signal.

  • Page 28: Pallet Hook

    2 FlexGripper-Vacuum 2.2.3. Pallet hook 2.2.3. Pallet hook The pallet hook is used for lifting the pallet that is associated with the handling product. It includes two parts: a pneumatic search cylinder and two pairs of lifting fingers. Pneumatic search cylinder The pneumatic search cylinder on the FlexGripper (see figure 2.5) allows the robot to locate the top of the pallet stack, eliminating the need for external sensing to determine the exact height of the stack.
  • Page 29 2 FlexGripper-Vacuum 2.2.3. Pallet hook Continued Part Description Pneumatic cylinders Drive the hook to clamp the pallet. Lifting fingers Synchronous lever Operates the fingers synchronously Pallet size Different types of pallets are supported by the pallet hook as shown below. It is not required to make any change in the FlexGripper for working with these types of pallets.

  • Page 30: Installation And Commissioning

    2 FlexGripper-Vacuum 2.3.1. Overview 2.3 Installation and commissioning 2.3.1. Overview This instruction is primarily intended for use when unpacking and installing the grippr for the first time. It also contains information useful during later installation of the FlexGripper. The FlexGripper was packed by the standard of sea transportation, land transportation and air transportation on delivery.

  • Page 31: Unpacking

    The FlexGripper-Vacuum is wrapped in packing plastic foam loaded in a wooden package. Keep the package upwards. Unpack the package to check for any visible transport damage. If the FlexGripper-Vacuum is damaged, contact ABB. NOTE! Only 24V power is used in FlexGripper.
  • Page 32 2 FlexGripper-Vacuum 2.3.2. Unpacking Continued Recommended standard tightening torque For the torque values needed during installation, please see the following. The table below specifies the recommended standard tightening torque for oil-lubricated allen head screws (recommended class 12.9). Dimension Tightening torque(Nm) /Class 12.9, oil-lubricated 3HAC040633-002 Revision: -...

  • Page 33: Adjustment

    2 FlexGripper-Vacuum 2.3.3. Adjustment 2.3.3. Adjustment On delivery, the width is set wide enough to make mounting of the FlexGripper possible without the need to separate the vacuum rails and the pallet hook. The width between the two rails can be adjusted to fit different sized work pieces. If needed, please refer to the following instructions to adjust the width between the two rails according to the size of the product.

  • Page 34: Mounting The Flexgripper-Vacuum

    2 FlexGripper-Vacuum 2.3.4. Mounting the FlexGripper-Vacuum 2.3.4. Mounting the FlexGripper-Vacuum DANGER! Before any service work is started, make sure all the safety guidelines have been strictly observed! Make sure that the power is off before starting any work. Mounting the FlexGripper-Vacuum on the robot No Action Info/Illustration 1.
  • Page 35 2 FlexGripper-Vacuum 2.3.4. Mounting the FlexGripper-Vacuum Continued No Action Info/Illustration 5. Mount the flange to the FlexGripper beam using the supplied 16×M6 bolts Moment 10Nm from above downward. NOTE! The labels on the flange and the FlexGripper indicate the directions of mounting.
  • Page 36 2 FlexGripper-Vacuum 2.3.4. Mounting the FlexGripper-Vacuum Continued No Action Info/Illustration 7. Connect the power and air cables to the manipulator wrist. en1011020 8. Connect the compressed air supply cable to the vavle unit and the power & signal cable to the terminal box. en1011023 9.

  • Page 37: Commissioning

    2.3.5. Commissioning 2.3.5. Commissioning NOTE! ABB recommend that air connected to the FlexGripper should be: 4-6 bar, filtered (5ym), 1600 L/min and non-lubricated. After the electrical and pneumatic connection of the FlexGripper, commissioning must be done to test if the FlexGripper operates correctly.
  • Page 38 2 FlexGripper-Vacuum 2.3.5. Commissioning Continued NOTE! The hook is open, when ’DO10_02_PalletPicker_Close’ is 0 and ’DO10_01_PalletPicker_Open’ is 1. While the hook is close, when ’DO10_02_PalletPicker_Close’ is 1 and ’DO10_01_PalletPicker_Open’ is 0. PFPS_PalletPicker() PROC PFPS_PalletPicker() IF Present (Open) THEN SetDO DO10_02_PalletPicker_Close,0; SetDO DO10_01_PalletPicker_Open,1;...
  • Page 39 2 FlexGripper-Vacuum 2.3.5. Commissioning Continued is 0. While ’DO10_14_PostionSeacher_Backward’ is 0 and ’DO10_13_PostionSeacher_Forward’ is also 0, there is no pressure in the cylinder which means a pallet is searched. PFPS_PalletSeacher() PROC PFPS_PalletSeacher() IF Present (Forward) THEN SetDO DO10_14_PostionSeacher_Backward, 0; SetDO DO10_13_PostionSeacher_Forward, 1; WaitDI DI10_03_PostionSeacher_Searched, 1;...
  • Page 40 2 FlexGripper-Vacuum 2.3.5. Commissioning Continued NOTE! The target points ’pHome’, ’pPick’ and its offsets must be defined and taught firstly. PFPS_PickUpBox() PROC PFPS_PickUpBox() MoveJ pHome, v100, fine, tPFPSVacGrip\WObj:=wobj0; TPWrite " Robot move to pick postion! "; MoveL Offs(pPick,-10,0,100), v100, z20, tPFPSVacGrip\WObj:=wobj0; TriggIO tTrigger1, 20\GOp:=GoVacuume, 0;...
  • Page 41 2 FlexGripper-Vacuum 2.3.5. Commissioning Continued NOTE! The target points ’pHome’, ’pPlace’ and its offsets must be defined and taught firstly. PFPS_PlaceDownBox() PROC PFPS_PlaceDownBox() TPWrite " Robot move to place postion! "; MoveL Offs(pPlace,-10,0,100), v100, z20, tPFPSVacGrip\WObj:=wobj0; ISleep PFPSVacuumMonitor1; ISleep PFPSVacuumMonitor2; TriggIO tTrigger2, 0\GOp:=GoVacuume, 992;...
  • Page 42 2 FlexGripper-Vacuum 2.3.5. Commissioning Continued NOTE! The target points ’pSearch’ and its offsets, ’pPickPallet’ and its offsets, ’pHome’, ’pPlace’ and its offsets, ’pPick’ and its offsets must be defined and taught firstly. exePallet() During the process, first the robot with the FlexGripper-Vacuum goes to search the pallet, then pick up the pallet, finally place down the pallet.
  • Page 43 2 FlexGripper-Vacuum 2.3.5. Commissioning Continued TPWrite " pallet picker may be wrong ! "; TPWrite " "; TPWrite " Robot stop to test,and need checking parts or sensor! "; StopMove; WaitTime 0.2; ENDIF ENDPROC Continues on next page 3HAC040633-002 Revision: -...
  • Page 44 2 FlexGripper-Vacuum 2.3.5. Commissioning Continued Reference Rapid codes Gripper function is checked with the following rapid codes. Please modify the data in rapid codes as needed before using it. The rapid codes are as follows: MODULE MainModule Local PERS robtarget pPick:=[[1908.03,-446.57,1007.54],[1.72802E-06,0.0867458,-0.996231,-5.63714E-07],[- 1,0,-1,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];...
  • Page 45 2 FlexGripper-Vacuum 2.3.5. Commissioning Continued cycletime:=clkRead(MyClock)/5; pace:=3600/cycletime; ENDPROC PROC StartVaccum(num ZoneNo1, \num ZoneNo2, \num ZoneNo3, \num ZoneNo4, \num ZoneNo5, \num ZoneNo6, \num ZoneNo7, \num ZoneNo8, \num ZoneNo9, \num ZoneNo10) SetZone(ZoneNo1); if Present(ZoneNo2) then SetZone(ZoneNo2); endif if Present(ZoneNo3) then SetZone(ZoneNo3); endif if Present(ZoneNo4) then SetZone(ZoneNo4);...
  • Page 46 2 FlexGripper-Vacuum 2.3.5. Commissioning Continued if Present(ZoneNo2) then ResetZone(ZoneNo2); endif if Present(ZoneNo3) then ResetZone(ZoneNo3); endif if Present(ZoneNo4) then ResetZone(ZoneNo4); endif if Present(ZoneNo5) then ResetZone(ZoneNo5); endif if Present(ZoneNo6) then ResetZone(ZoneNo6); endif if Present(ZoneNo7) then ResetZone(ZoneNo7); endif if Present(ZoneNo8) then ResetZone(ZoneNo8); endif if Present(ZoneNo9) then ResetZone(ZoneNo9);...
  • Page 47 2 FlexGripper-Vacuum 2.3.5. Commissioning Continued CASE 10:Set DO10_12_Zone10; ENDTEST ENDPROC PROC ResetZone(num zone) TEST zone CASE 1:Reset DO10_03_Zone1; CASE 2:Reset DO10_04_Zone2; CASE 3:Reset DO10_05_Zone3; CASE 4:Reset DO10_06_Zone4; CASE 5:Reset DO10_07_Zone5; CASE 6:Reset DO10_08_Zone6; CASE 7:Reset DO10_09_Zone7; CASE 8: Reset DO10_10_Zone8; CASE 9:Reset DO10_11_Zone9;...
  • Page 48 2 FlexGripper-Vacuum 2.3.5. Commissioning Continued SetDO DO10_14_PostionSeacher_Backward, 0; SetDO DO10_13_PostionSeacher_Forward, 1; WaitDI DI10_03_PostionSeacher_Searched, 1; SetDO DO10_13_PostionSeacher_Forward, 0; WaitDI DI10_03_PostionSeacher_Searched, 1; ENDIF ENDPROC ENDMODULE Software commissioning For the detailed software commissioning procedure, see FlexGripper-Vacuum function test on page 3HAC040633-002 Revision: -...

  • Page 49: Maintenance

    2 FlexGripper-Vacuum 2.4.1. General 2.4 Maintenance 2.4.1. General This chapter details all the maintenance activities recommended for the FlexGripper. It contains two types of maintenance: regular maintenance activities and changing activities. The procedures are gathered in different sections and divided according to the maintenance activity.

  • Page 50: Regular Maintenance Activities

    2 FlexGripper-Vacuum 2.4.2. Regular maintenance activities 2.4.2. Regular maintenance activities To help prevent accidents, the pneumatic system must be regularly inspected. Regular visual inspections must be carried out before operating the FlexGripper. The main parts to be inspected at regular intervals are: Maintenance Equipment Action...

  • Page 51: Changing/Replacement Activities

    2 FlexGripper-Vacuum 2.4.3. Changing/Replacement activities 2.4.3. Changing/Replacement activities In any of the following situations, the corresponding component should be replaced: • The valve unit/vacuum generator is distorted • The congressed pipe is worn out • Pins in the FlexGripper-Vacuum are worn out •...

  • Page 52: Repair

    2 FlexGripper-Vacuum 2.5.1. Instruction 2.5 Repair 2.5.1. Instruction This chapter details all the repair activities recommended for the FlexGripper-Vacuum. Safety information Before any service work is started, it is extremely important that all safety information is observed! There are general safety aspects that must be read through, as well as more specific safety information that describes danger and safety risks when performing the procedures.

  • Page 53: Cylinder

    2 FlexGripper-Vacuum 2.5.2.1. Replacing the cylinder of the pallet picker unit 2.5.2. Cylinder 2.5.2.1. Replacing the cylinder of the pallet picker unit The cylinder is located as shown in the figure below. en1012001 Position Part Spring hoop Spherical hinge Pneumatic cylinder Bracket Bracket Use this procedure to remove the cylinder.
  • Page 54 2 FlexGripper-Vacuum 2.5.2.1. Replacing the cylinder of the pallet picker unit Continued Action Note 3. Remove the sensors from the cylinder. en1012003 Parts: A: sensor 4. Remove the joint from the piston rod of the cylinder. en1012004 Parts: A: joint, B: piston rob 5.

  • Page 55: Replacing The Cylinder On The Pallet Searcher

    2 FlexGripper-Vacuum 2.5.2.2. Replacing the cylinder on the pallet searcher 2.5.2.2. Replacing the cylinder on the pallet searcher The cylinder is located as shown in the figure below. en1012006 Position Part Cylinder connect plate Magnetic proximity switch Quick connector Flow valve Use this procedure to remove the cylinder.
  • Page 56 2 FlexGripper-Vacuum 2.5.2.2. Replacing the cylinder on the pallet searcher Continued Action Note 3. Remove the magnetic proximity switch from the pneumaticcylinder. en1012008 Parts: A: Magnetic proximity switch 4. Remove the press plate from the pneumatic cylinder. en1012009 Parts: A: Press plate 5.

  • Page 57: Magnetic Proximity Switch

    2 FlexGripper-Vacuum 2.5.3. Magnetic proximity switch 2.5.3. Magnetic proximity switch The magnetic proximity switch is located as shown in the figure below. Position 1 en1012013 Position 2 en1012013 Magnetic proximity switch Position 1 Use this procedure to remove the magnetic proximity switch. DANGER! Turn off all electric power and pneumatic pressure supplies to the gripper! Action...
  • Page 58 2 FlexGripper-Vacuum 2.5.3. Magnetic proximity switch Continued Position 2 Use this procedure to remove the magnetic proximity switch. DANGER! Turn off all electric power and pneumatic pressure supplies to the gripper! Action Note 1. Loosen the small bolt. en1012016 Parts: A: Small bolt 2.

  • Page 59: Sensors

    2 FlexGripper-Vacuum 2.5.4. Sensors 2.5.4. Sensors The sensor is located as shown in the figure below. (There are 5 sensors mounted on the gripper.) en1012017 Position Part Sensor Continues on next page 3HAC040633-002 Revision: -...
  • Page 60 2 FlexGripper-Vacuum 2.5.4. Sensors Continued Removing the sensor Use this procedure to remove the sensor. DANGER! Turn off all electric power and pneumatic pressure supplies to the gripper! Action Note 1. Loosen the small bolt. en1012018 Parts: A: Small bolt 2.

  • Page 61: Pneumatic Unit

    2 FlexGripper-Vacuum 2.5.5. Pneumatic unit 2.5.5. Pneumatic unit The pneumatic units are located as shown in the figure below. en1012019 Position Part Pneumatic unit Pneumatic cup Vacuum ejector One way valve Quick connector Pneumatic block Compressed air hose Removing the pneumatic cup lip Use this procedure to remove the pneumatic cup lip.
  • Page 62 2 FlexGripper-Vacuum 2.5.5. Pneumatic unit Continued Removing the pneumatic cup lip Use this procedure to remove the whole pneumatic cuplip. DANGER! Turn off all electric power and pneumatic pressure supplies to the gripper! Action Note 1. Loosen the bolts. en1012018 Parts: A: Bolt 2.
  • Page 63 2 FlexGripper-Vacuum 2.5.5. Pneumatic unit Continued DANGER! Turn off all electric power and pneumatic pressure supplies to the gripper! Action Note 1. Loosen the bolts. en1012018 Parts: A: Bolt 2. Remove the compressed air hose. en1012018 Parts: A: Compressed air hose 3.

  • Page 64: Valve Base

    2 FlexGripper-Vacuum 2.5.6. Valve base 2.5.6. Valve base The valve base is located as shown in the figure below. en1012017 Position Part Power supply Valve base Muffler Quick connector Removing the pneumatic cup lip Use this procedure to remove the pneumatic cup lip. DANGER! Turn off all electric power and pneumatic pressure supplies to the gripper! Action...
  • Page 65 2 FlexGripper-Vacuum 2.5.6. Valve base Continued Action Note 6. Loosen the bolts. en1012018 Parts: A: Bolt 7. Remove the valve base. 3HAC040633-002 Revision: -...

  • Page 66: Dress Cable

    2 FlexGripper-Vacuum 2.5.7. Dress cable 2.5.7. Dress cable The dress cable is located as shown in the figure below. en1012020 Position Part Electrical cable Main compressed air hose Corrugated pipe clip Dress cable Use this procedure to remove the dress cable magnetic proximity switch. DANGER! Turn off all electric power and pneumatic pressure supplies to the gripper! Action...

  • Page 67: Trouble Shooting

    2 FlexGripper-Vacuum 2.6.1. Start-up failures 2.6 Trouble shooting 2.6.1. Start-up failures Consequences Problem starting the system Symptoms and causes • LEDs not lit on the sensors. • Air hose hangs loosely on the gripper. Recommended actions Action Info/illustration 1. Make sure the robot system has started up and is correctly connected.

  • Page 68: Gripper Not Responding

    2 FlexGripper-Vacuum 2.6.2. Gripper not responding 2.6.2. Gripper not responding Consequences The gripper cannot be operated using the FlexPendant. Recommended actions Action Info/illustration 1. Make sure the gripper system has started up. 2. Make sure the connection to the I/O board is correct. 3.

  • Page 69: Wrong Movement

    2 FlexGripper-Vacuum 2.6.3. Wrong movement 2.6.3. Wrong movement Consequences The fault can cause severe injuries or death to personnel in the area or severe damage to the manipulator and/or surrounding equipment. Symptoms and causes The movement of the gripper part is not as expected during commissioning. Recommended actions Action Info/illustration...

  • Page 70: Low Performance

    2 FlexGripper-Vacuum 2.6.4. Low performance 2.6.4. Low performance Consequences Clamp or hook movement is sluggish and sometimes stalls. Symptoms and causes • Connection error • Low air pressure • Excessive friction Recommended actions Action Info/illustration 1. Make sure the electrical and air connections are correctly and firmly connected.

  • Page 71: Problem Jogging The Gripper

    2 FlexGripper-Vacuum 2.6.5. Problem jogging the gripper 2.6.5. Problem jogging the gripper Consequences Gripper can not reach the rotation range. Symptoms and causes Cable or air hose routing. Recommended actions Action Info/illustration 1. Make sure the cable and air hose are correctly routed. 3HAC040633-002 Revision: -...

  • Page 72: Mechanical Noise

    2 FlexGripper-Vacuum 2.6.6. Mechanical noise 2.6.6. Mechanical noise Consequences • Failing bearings cause the palletizing accuracy, and in severe cases, the workpiece may fall down uncontrolly • The gripper part or workpiece may fall down Symptoms and causes • Loose bolts Recommended actions Action Info/illustration...

  • Page 73: Workpiece Drop On Power Down

    2 FlexGripper-Vacuum 2.6.7. Workpiece drop on power down 2.6.7. Workpiece drop on power down Consequences The fault can cause severe injuries or death to personnel in the area or severe damage to the manipulator and/or surrounding equipment. Symptoms and causes •...

  • Page 74: No Input Signal Detected

    2 FlexGripper-Vacuum 2.6.8. No Input signal detected 2.6.8. No Input signal detected Consequences Can not run work program. Symptoms and causes • No signal detected in UI. LEDs not lit on the I/O board. • Faulty connection. Recommended actions Action Info/illustration 1.

  • Page 75: No Vacuum Created

    2 FlexGripper-Vacuum 2.6.9. No Vacuum created 2.6.9. No Vacuum created Consequences Can not use vacuum gripper. Symptoms and causes • Wrong voltage levelAir leakage • Faulty vacuum pump or terminal valve Recommended actions Action Info/illustration 1. Make sure low level is used to activate the vacuum. 2.

  • Page 76: Decommissioning

    2 FlexGripper-Vacuum 2.7.1. Introduction 2.7 Decommissioning 2.7.1. Introduction Introduction This section contains information to consider when taking a product, FlexGripper, out of operation. It deals with how to handle potentially dangerous components and potentially hazardous materials. General All used grease, oils and dead batteries must be disposed of in accordance with the current legislation of the country in which the FlexGripper units are installed.

  • Page 77: Environmental Information

    2 FlexGripper-Vacuum 2.7.2. Environmental information 2.7.2. Environmental information Hazardous material The table specifies some of the materials in the FlexGripper and their respective use throughout the product. Dispose of the components properly to prevent health or environmental hazards. Material Example application Copper Cables Steel...

  • Page 78: Wear Parts

    2 FlexGripper-Vacuum 2.8. Wear parts 2.8. Wear parts Part No. Description 3HAC040869-001 Vacuum cup 3HAC040633-002 Revision: -...

  • Page 79: Spare Parts

    2 FlexGripper-Vacuum 2.9. Spare parts 2.9. Spare parts Mechanical parts en1016001 Continues on next page 3HAC040633-002 Revision: -...
  • Page 80 2 FlexGripper-Vacuum 2.9. Spare parts Continued Pneumatic & electric parts en1016001 Continues on next page 3HAC040633-002 Revision: -...
  • Page 81 2 FlexGripper-Vacuum 2.9. Spare parts Continued Spare parts list Part No. Description Note / Dimension 3HAC040417‐001 Flange plate for 660 3HAC040418‐001 Shaft fitting for 660 3HAC040469‐001 frame machining 3HAC040472‐001 electric box bracket 3HAC040588‐001 valve bracket A 3HAC040474‐001 beam welding1 3HAC040526‐001 cable protect plate 3HAC040527‐001 sensor bracket...

  • Page 82: Circuit Diagram

    2.10 Circuit diagram 2.10.1. Electrical circuit Power supply circuit We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB -24V 6;7 7;8 3HAC040149-003-7...
  • Page 83 2 FlexGripper-Vacuum 2.10.1. Electrical circuit Continued DRESSPACK IRB660 We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB 101/3 101/4 101/5 101/6...
  • Page 84 Continued FlexGripper-Vacuum DO We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB 3HAC040149-003-15 Continues on next page 3HAC040633-002 Revision: -...
  • Page 85 Continued FlexGripper-Vacuum DI We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB 3HAC040149-003-16 Continues on next page 3HAC040633-002 Revision: -...
  • Page 86 Continued FlexGripper-Vacuum terminal connection We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB 3HAC040149-003-29 Continues on next page 3HAC040633-002 Revision: -...
  • Page 87 2.10.1. Electrical circuit Continued FlexGripper-Vacuum sensor connection We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB -DI_PALLET_OPEN -DI_PALLET_CLOSE -DI_POS_F -DI_POS_B...

  • Page 88: Pneumatic Circuit

    2.10.2. Pneumatic circuit 2.10.2. Pneumatic circuit FlexGripper-Vacuum pneumatic circuit We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB -AIR_PRE -AIR_RET -DO_POS_F...

  • Page 89: Flexgripper Ui

    3 FlexGripper UI 2.10.2. Pneumatic circuit 3 FlexGripper UI 3HAC040633-002 Revision: -...

  • Page 90: Software Installation

    1.Copy the FlexGripperUI folder into the mediapool folder of your laptop. Copy the MULTIFLEXGRIPPERUI folder from the FlexGripperUI FlexPendant GUI installation CD to C:\Program Files\ABB Industrial IT\Robotics IT\Mediapool on your laptop (If the path to mediapool folder is not as above, find the mediapool folder on your PC).
  • Page 91 3. Download the system to robot controller. 4. Warm start the controller. The FlexGripperUI application icon is shown on the ABB main menu on the FlexPendant. Note: For the FlexGripper UI option, Singleclamp option represents FlexGripper-Clamp 1, Twoclamp option represents FlexGripper-Clamp 2, Vacuum option represents FlexGripper- Vacuum, Claw option represents FlexGripper-Claw.

  • Page 92: I/O Signal Configuration

    3 FlexGripper UI 3.1.2. I/O signal configuration 3.1.2. I/O signal configuration FlexGripper-Vacuum signal configration I/O signal I/O board Controller Electric box Signal DO1001(DO10_01_PalletPic XT5.1.1 ker_Open) DO1002(DO10_02_PalletPic XT5.1.2 ker_Close) DO1003(DO10_03_Postion XT5.2.1 Seacher_Forward) DO1004(DO10_04_Postion XT5.2.2 Seacher_Backward) DO1005(DO10_05_Zone1) XT5.2.3 DO1006(DO10_06_Zone2) XT5.2.4 DO1007(DO10_07_Zone3) XT5.1.9 DO1008(DO10_08_Zone4) XT5.1.10 DO1009(DO10_09_Zone5)

  • Page 93: Back-Up And I-Start

    I-start. 1. Make a backup of the system. 2. On the ABB menu, tap Restart. The restart page is displayed. 3. Tap Advanced... to select restart method. The select restart method dialog is displayed. 4. Tap I-start, then tap OK.

  • Page 94: Operation

    3 FlexGripper UI 3.2.1. FlexGripper UI main interface 3.2 Operation 3.2.1. FlexGripper UI main interface Enter FlexGripper UI en1011048 The FlexGripper UI has three function blocks: Tool handle, TCP edit and Production which you can see after entering the main interface. en1011049 3HAC040633-002 Revision: -...

  • Page 95: Tool Handle

    3 FlexGripper UI 3.2.2.1. FlexGripper function test 3.2.2. Tool handle 3.2.2.1. FlexGripper function test FlexGripper-Vacuum function test Touch Tool handle button, the following interface would show up en1011050 Continues on next page 3HAC040633-002 Revision: -...
  • Page 96 3 FlexGripper UI 3.2.2.1. FlexGripper function test Continued Users can operate functions displayed and check if the corresponding signals status right. By the FlexGripper function dropdown list, users can choose Vacuums, PalletPicker or PalletSearch to do the corresponding function test. Function and signal status table (FlexGripper-Vacuum) Function Function...
  • Page 97 3 FlexGripper UI 3.2.2.1. FlexGripper function test Continued Function Function Action description Signal status type name Palle- Forward Search cylinder move forward DO10_03_PositionSear tSearch cher_Forward turns to 1 and lights up Backward Search cylinder move backward DO10_04_PositionSear cher_Backward turns to 1 and lights up Product To detect if the product drop down.
  • Page 98 3 FlexGripper UI 3.2.2.1. FlexGripper function test Continued Select the desired group, tap Vacuum on or Vacuum off button, the vacuum source of selected vacuum groups would be turn on or shut down accordingly. Users can operate functions displayed and check if the corresponding signals status right. Function and signal status table for default vacuum group: Group Button name...
  • Page 99 3 FlexGripper UI 3.2.2.1. FlexGripper function test Continued Users can edit the vacuum zone. Following is the action list that could be executed when selecting a zone: Action Description Procedure Zone edit Add or delete a vacuum zone to Select the vacuum zone to be added or the selected group deleted.

  • Page 100: Tcp Edit

    3 FlexGripper UI 3.2.2.2. TCP edit 3.2.2.2. TCP edit Note: The TCP configuration includes three elements: TASK, Storage type and Scope. Their scopes are: Task: T_ROB1 Storage type: Persistent and variable Scope: Task, Global and Local If the scope and storage type of the TCP is not correct it can not be monitored. Touch TCP tab, the following interface would shows: en1011057 The grey column indicates data columns are not editable.
  • Page 101 3 FlexGripper UI 3.2.2.2. TCP edit Continued TCP operation Action Procedure Select TCP Touch Select TCP button, then the TCP list shows. en1011058 Select the TCP needed, and touch OK. The related parameters of the TCP are automatically loaded into the Tool field on the left and the Load field on the right.
  • Page 102 3 FlexGripper UI 3.2.2.2. TCP edit Continued TCP Parameter description Type Parameter Description Tool trans x The X-value of TCP position in mm trans y The Y-value of TCP position in mm trans z The Z-value of TCP position in mm rot q1 The q1 value in the quaternion (q1, q2, q3, q4) of the orientation of the tool coordinate system...

  • Page 103: Tune

    3 FlexGripper UI 3.2.3.1. Position Tune 3.2.3. Tune 3.2.3.1. Position Tune The position tune function is used to fine tune the robot target location as the pick/place location and home location. Note: The robot target configuration includes three elements: TASK, Storage type and Scope. Their scopes are: Task: T_ROB1 Storage type: Persistent and variable...
  • Page 104 3 FlexGripper UI 3.2.3.1. Position Tune Continued Robot target edit Action Procedure Add target Touch the Add target button, in the screen shown, the left side shows the target contribution, ie Task, Type, the right side shows the target list with the module described.

  • Page 105: Work Object Tune

    3 FlexGripper UI 3.2.3.2. Work object tune 3.2.3.2. Work object tune A work object is a coordinate system used to describe the position of a work piece. The work object consists of two frames: a user frame and an object frame. All programmed positions will be related to the object frame.

  • Page 106: Test Run

    3 FlexGripper UI 3.2.3.3. Test run 3.2.3.3. Test run After the TCP edit, Position tune and work object tune, the functions defined in the Template system module can be tested in Test run. For FlexGripper-Vacuum, after entering the Test run interface, the following interface shows: en1011065 Continues on next page...
  • Page 107 3 FlexGripper UI 3.2.3.3. Test run Continued Press the Product Pick&place button, the robot implements the exePickPlace routing which includes a part pick and place cycle. Press the Pallet pick&place button, the robot will implement the exePallet routing which includes a series action: pallet search, pick pallet and place.

  • Page 108: Production

    3 FlexGripper UI 3.2.4.1. Production monitor 3.2.4. Production 3.2.4.1. Production monitor The production interface shows monitor signals on the left and monitor variables on the right. Users can monitor the production by the status of signals and variables. Users can check if the signal status or variable status is correct.

  • Page 109: Setup

    3 FlexGripper UI 3.2.4.2. Setup 3.2.4.2. Setup The production interface shows monitor signals on the left and monitor variables on the right. The monitoring signals and variables shown can be set by the Setup function. en1011067 Touch the Setup button, the following interface with signal list shows. en1011068 Continues on next page 3HAC040633-002 Revision: -...
  • Page 110 3 FlexGripper UI 3.2.4.2. Setup Continued After selecting one of the signals, using the two arrows buttons (see picture above) on the right to choose former signals or signals below. Use the yellow double triangle/single triangle buttons to go to the first/last page or to move the page up/down.
  • Page 111 3 FlexGripper UI 3.2.4.2. Setup Continued Variable edit Action Procedure Add variable Touch Add button, the following interface shows: en1011074 Choose the module followed by the variable type to be added from the dropdown list. You can edit its name by selecting the button with the ellipsis.

  • Page 112: Trouble Shooting

    3 FlexGripper UI 3.3. Trouble shooting 3.3. Trouble shooting Variable can not be monitored Description Can not monitor the variables Possible reason • The scope of variable is not correct • The storage type of variable is not correct Solution •...
  • Page 113 The valid scope of the work object is: Task: T_ROB1; Scope: Global, Task Storage type: Persistent and Variable FlexGripper UI icon can not be displayed on the ABB main menu of the FlexPendant Description Can not display FlexGripper UI icon on FlexPendant Possible reason •...
  • Page 114 3 FlexGripper UI 3.3. Trouble shooting Continued Active view no valid test view Description en1011075 Possible reason The current test view is not a valid test view. Solution Enter Control panel->Flexpendant-> AdditionalTestView, check if the test view of the FlexGripper UI is selected. Two many views Description When all the 6 places of the task bar are occupied by views, a warning...
  • Page 116 ABB Robotics S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592...
  • Page 117 3 FlexGripper UI 3.3. Trouble shooting Continued Solution Enter Control panel->Configration-> Unit->BOARD10, edit the addresses name to BOARD11. Before software installation, edit the content ’DN_Address 10’ to ’DN_Address 11’ in EIO.cfg. For example, C:\Program Files\ABB Industrial IT\Robotics IT\MediaPool\FlexGripperUI\Syspar\Vac- uum\EIO.cfg. 3HAC040633-002 Revision: -...
  • Page 118 3 FlexGripper UI 3.3. Trouble shooting 3HAC040633-002 Revision: -...

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