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ABB BullsEye 7 User Manual

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User's Guide
BullsEye®7
505 942-102
2004-02

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Summary of Contents for ABB BullsEye 7

  • Page 1 User’s Guide BullsEye®7 505 942-102 2004-02...
  • Page 2 ABB. ABB assumes no responsibility for errors that can appear in this document. ABB is not responsible for damage incurred by the use of this document or software or hardware des- cribed in this document.

  • Page 3: Table Of Contents

    BullsEye®7 TABLE OF CONTENTS Page Introduction ......................... How to use this Manual ..................What you must know before you use the Robot ..........Technical Specification....................Unit Specifications..................... Physical Dimensions..................Product Description ....................Tool Center Point (TCP) ..................Theory of Operation................... BullsEye®...
  • Page 4 BullsEye®7 505 942-102...

  • Page 5: Introduction

    BullsEye® 7 Introduction 1 Introduction 1.1 How to use this Manual This manual provides information on installation, preventive maintenance, trouble ® shooting and operation of the BullsEye product. 1.2 What you must know before you use the Robot The power supply must always be switched off whenever work is carried out in the controller cabinet.
  • Page 6 BullsEye® 7 Introduction 505 942-102...

  • Page 7: Technical Specification

    BullsEye® 7 Technical Specification 2 Technical Specification 2.1 Unit Specifications Electrical 40 mA, 24 VDC Robot Connections One sensor signal, 24 VDC, and 0 VDC Software Furnished with equipment (requires 250 kb free user memory) Repeatability ± 0.006" (0.163 mm) 2.2 Physical Dimensions For variant 501 527-880: Ø6 H8...
  • Page 8 BullsEye® 7 Technical Specification For variant: 550880-001: 114,50 Figure 2 505 942-102...

  • Page 9: Product Description

    BullsEye® 7 Product Description 3 Product Description 3.1 Tool Center Point (TCP) BullsEye® 7 provides completely automated Tool Center Point (TCP) definition for the S4C and S4Cplus models of IRB robots. TCP is defined as an invisible reference point in direct alignment and relationship to all axes of the robot arm and located at the precise point where the welding wire tip would touch the workpiece using a pre-determined wire stickout distance from the bottom of the gas nozzle.

  • Page 10: Theory Of Operation

    BullsEye® 7 Product Description 3.2 Theory of Operation When the robot is instructed to revolve around the TCP all robot axes will move accordingly to keep the TCP constant (See Figure 4 and Figure 5). If the torch is bumped and the program is run again, the robot repeats its same movements but it is possible that the TCP will no longer follow the same programmed path due to misalignment.

  • Page 11: Bullseye® Advantages

    Teach pendant text now resides in a separate system module. This change allows provision for the text to be translated into other languages by other ABB divisions. Version 7.0 is now compatible with Motion Supervision available in BaseWare 3.2 rev.20 and higher.
  • Page 12 BullsEye® 7 Product Description 505 942-102...

  • Page 13: Bullseye® Installation

    BullsEye® 7 BullsEye® Installation ® 4 BullsEye Installation 4.1 Mechanical Installation ® The BullsEye should be either bolted to the floor (freestanding) or in a position where the robot can reach it and where it is not in the way of personnel working around the robot.

  • Page 14: Electrical Installation

    BullsEye® 7 BullsEye® Installation ® The best procedure for installation is to place the Freestanding BullsEye in a desired position without securing it permanently. Perform the software installation ® and execute the BullsEye setup procedures as described in section 4.3. If the robot is able to complete the full TCP update process and successfully completes a Quick Check routine while meeting all other location requirements, then bolt it solidly in position.
  • Page 15 BullsEye® 7 BullsEye® Installation Connecting BullsEye, 501 527-880, new sensor with four cables (2004-02). The brown cable wire is connected to 24V DC, terminal 4 on the terminal block in TC 96 and 1 in Binzel BRS-LC. The blue wire is connected to 0V, terminal 8 on the terminal block in TC 96 and 3 in Binzel BRS-LC.

  • Page 16: Software Installation

    BullsEye® 7 BullsEye® Installation 4.3 Software Installation With the Program Window of the Teach Pendant displayed, select FILE, then OPEN, and choose the "BullsEye" System Module from the floppy disk or other drive location where the module has been stored. This will load th program from the floppy into the robot controller where it will reside in memory.
  • Page 17 BullsEye® 7 BullsEye® Installation Program Waiting for Data! Present setup number 1. Degree of rotation =30/45 2. Robot mounting pos. =STAND/INVERTED 3. Gun alignment =NEVER/SETUP/ALWAYS 4. Stick-out distance (mm) =Min. 5 mm, Max. 30 mm Select which parameter to change to keep present values;...
  • Page 18 BullsEye® 7 BullsEye® Installation Gun alignment This parameter is for selecting when to align the welding gun to World Z (torch angle realignment) - Always is recommended. Program Waiting for Data! This parameter defines if and when the welding torch should be aligned with World Z (torch angle re-alignment) (ALWAYS is recommended if possible) Select robot mounting pos.
  • Page 19 BullsEye® 7 BullsEye® Installation Once all the set up questions have been answered, the next screen you will see is: Program Waiting for Data! Robot needs to be at a point where the gun is positioned straight up and down with the gas cup breaking the beam.
  • Page 20 BullsEye® 7 BullsEye® Installation If LAST was selected, the operator will be asked if the location that the robot ® moved to is indeed in correct orientation for the BullsEye to begin updating the TCP: Program Waiting for Data! Robot needs to be at a point where the gun is positioned straight up and down with the gas cup breaking the beam.
  • Page 21 BullsEye® 7 BullsEye® Installation Once an estimated TCP has been defined, a screen similar to the figure below will be displayed. Values can be altered if necessary. Tool load can also be entered here. Program Waiting for Data! Defined approximate TCP values Values for estimated tcp are: X value (mm) Y value (mm)
  • Page 22 BullsEye® 7 BullsEye® Installation The last screen of the setup procedure will appear once acknowledgment has been received that the robot was indeed at the pointer. Program Waiting for Data! The BullsEye setup is now complete Your TCP has been set to the following: X=123 Z=350 Press PROCEED to exit setup.
  • Page 23 BullsEye® 7 BullsEye® Installation Possible Error Messages Incurred During Setup: Invalid setup number is used Change setup number in instruction Valid setup numbers are normally 1-3. Change instruction and re-execute. The beam could not be found Check beam and/or change startpoint This comes up if the beam could not be found.
  • Page 24 BullsEye® 7 BullsEye® Installation 505 942-102...

  • Page 25: Operation

    BullsEye® 7 Operation 5 Operation 5.1 Basic Operation ® When the CheckTCP routine is called by the robot, the BullsEye will measure the TCP. A system with EasyArc installed will have menus which allow the operator to easily execute the procedure call and handle movements from the system’s safe ®...
  • Page 26 BullsEye® 7 Operation It is possible to change between day 1 TCP and present TCP. Present TCP is the TCP that was calculated the last time the GetNewTcpData was executed. In teach mode, the following result screen will appear: Program Waiting for Data! Difference from Day 1 x (mm) Y (mm)
  • Page 27 BullsEye® 7 Operation • If No is selected, the TCP will be re-measured and the values of the TCP will be updated to the new position. • If Yes is chosen, the robot will move to the original position that was programmed during setup for the pointer located at the bottom or the ®...
  • Page 28 BullsEye® 7 Operation If a search error occurs during TCP measurement, the following screen will appear: Program Waiting for Data! Tool measurement function failed. Check beam and/or wire stick-out. Check if gun is bent too much. POINTER: Robot will move to pointer POINTER RETRY EXIT...

  • Page 29: Advanced Setup Information

    BullsEye® 7 Advanced Setup Information 6 Advanced Setup Information NOTE! The information in this section is typically used only by ABB technicians setting up a system with unique properties. 6.1 Global routines in the BullsEye.sys module: IsTCPOK Function for TCP quick check Function that performs a quick check of the tool.
  • Page 30 BullsEye® 7 Advanced Setup Information GetNewTCPData: Instruction used for TCP check ® The instruction returns TCP values calculated by the BullsEye routine. The new TCP values are returned in the INOUT variable YourTool. _______________________________________________________________ Arguments GetNewTCPData YourTool SetupNo [\DoSetup] [\MaxQChkErr] [\MaxFrDay1] [\GasCupAlign] [\GasCupMinDia] [\GasCupOffs][\DistGasCup] [\InitMove] [\SliceGap] [\ForceTcpQuat] [\WireScanLngth] [\CupScanLngth] [\Wobj]...
  • Page 31 BullsEye® 7 Advanced Setup Information [\GasCupOffs] Data type: num Min 3 Max 10 Default 6 (unit mm) Defines the forward movement between the center of the wire and the vertical search location for the gas cup. If a thick wire is used this parameter might need to be changed.
  • Page 32 BullsEye® 7 Advanced Setup Information 505 942-102...

  • Page 33: User's Guide

    BullsEye® 7 User’s Guide 7 User’s Guide 7.1 Program execution This procedure is designed to give access to a number of parameters that affect how the BullsEye program runs. The parameters can be changed to adapt the program to tools that do not resemble a standard MIG gun (a plasma cutter, for example).
  • Page 34 BullsEye® 7 User’s Guide Example Normal setup Stationary robot with the bullseye mounted to the floor. The SetupBullsEye procedure is used when the BullsEye® needs to be setup. After execution, the tWeldGun variables will have new values. The tWeldGun variable can be replaced with your tcp name if different. PROC SetupBullsEye() GetNewTCPDatatWeldGun,1\DoSetup ERROR...
  • Page 35 BullsEye® 7 User’s Guide Robot on a gantry system The BullsEye® is mounted to a moving part of the gantry system. With a gantry system there is not a coordinate system that is referenced to the base of the robot. In this case a work object has to be created every time the BullsEye®...
  • Page 36 BullsEye® 7 User’s Guide GetGantryFrame Calculates a new frame The GetGantryFrame instruction is basically an encapsulated MoveAbsJ instruction “MoveAbsJ ToJointPos,Speed,fine,tool0” that returns the frame of tool0 when the location is reached. The procedure can be used to calculate a frame based on a robot joint move. This is needed when the robot is mounted on a gantry system and the Bullseye moves with the gantry.
  • Page 37 BullsEye® 7 User’s Guide Tool orientation The BullsEye program always defines the tool z-axis as straight out from the torch gas nozzle. The tool x-axis will be oriented in such as way that it is parallel with tool0 z-axis. The positive direction will be towards the robot face plate. In most cases the orientation will be the same as doing a manual 5-point calibration.
  • Page 38 BullsEye® 7 User’s Guide 505 942-102...

  • Page 39: Maintenance

    BullsEye® 7 Maintenance 8 Maintenance ® The BullsEye is shipped complete and requires very little maintenance aside from keeping the unit clean. Refer to Section 4.2 for wiring information. Replacements parts may be obtained from After Sales at +46 584 81666. Be prepared to provide complete information on the part(s) you need.
  • Page 40 BullsEye® 7 Maintenance 505 942-102...

  • Page 41: Reservdelsförteckning/Spare Parts List

    Rätt till ändring av specifikationer utan avisering förbehålles. Spare parts are to be ordered from ABB Flexible Automation AB. Kindly indicate type of unit, serial number, denominations and ordering number according to the spare parts list.
  • Page 42 BullsEye®7 Reservdelsförteckning/Spare parts list Reservdelslistan innehåller all information som behövs för beställning av speciella delar till modulen för mätning av TCP. Var vänlig kontrollera att de uppgifter som lämnas är korrekta och motsvarar den önskade reservdelen. En specialtång är absolut nödvändig för montering av den fiberoptiska ledaren. The spare parts list contains all information required for ordering special parts of the TCP gauging unit.
  • Page 43 BullsEye®7 Reservdelsförteckning/Spare parts list Positions- nummer Antal Beställningsnummer Anmärkningar Benämning Denomination Position Qty. Ordering number Remarks number 550 880-001 BullsEye, kompl. BullsEye, compl. 200 44 14 BullsEye-ram BullsEye frame 200 14 30 Kabeladapter, skarv Adapter, cable 706-034-011 Uttag, hona Receptacle 706-034-013 Kabel Cable...
  • Page 44 BullsEye®7 Reservdelsförteckning/Spare parts list 505 942-101...
  • Page 46 505 942-102...

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