ABB Robotics RobotWare 6 Applications Manual
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ABB Robotics RobotWare 6 Applications Manual

Servo gun setup
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Application manual
Servo Gun Setup

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  • Page 1 ROBOTICS Application manual Servo Gun Setup...
  • Page 2 Trace back information: Workspace 21A version a10 Checked in 2021-03-16 Skribenta version 5.4.005...
  • Page 3 Application manual Servo Gun Setup RobotWare 6 Document ID: 3HAC065014-001 Revision: E © Copyright 2021 ABB. All rights reserved. Specifications subject to change without notice.
  • Page 4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. 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, damage to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Table of contents Table of contents Overview of this manual ........................Product documentation ........................Introduction About Servo Gun Setup ..................Requirements ....................Preparations ....................Installation Servo Gun Setup wizard How to use the Servo Gun Setup wizard ..............Running the Servo Gun Setup wizard ..............Commissioning mode ..................
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  • Page 7: Overview Of This Manual

    Who should read this manual? The intended audience are servo gun manufacturers or advanced users, who need to tune a servo gun. Prerequisites The Servo Gun Setup wizard requires RobotWare 6.06 or later. The reader should be familiar with: • IRC5 programming and usage •...
  • Page 8 Max torque reduced at the end of tuning. • Added possibility to run force calibration again after completed tuning. • Other minor improvements. Released with RobotWare 6.12. • Added information about Movable Gun Arm Search. Application manual - Servo Gun Setup 3HAC065014-001 Revision: E...

  • Page 9: Product Documentation

    Product documentation Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
  • Page 10 Product documentation Continued Operating manuals The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters. Application manual - Servo Gun Setup 3HAC065014-001 Revision: E ©...

  • Page 11: Introduction

    1 Introduction 1.1 About Servo Gun Setup 1 Introduction 1.1 About Servo Gun Setup Basic approach For most servo guns it is enough to follow the Servo Gun Setup wizard, see Servo Gun Setup wizard on page 17. Here you can specify known data or, in many steps of the wizard, get recommended values for good performance.

  • Page 12: Requirements

    1 Introduction 1.2 Requirements 1.2 Requirements Requirements on motor and resolver The motor and resolver should comply with the requirements given in Application manual - Additional axes and stand alone controller. Spot Servo option required Use a system with the RobotWare Spot Servo option installed. Measuring equipment The following equipment is required: •...

  • Page 13: Preparations

    1 Introduction 1.3 Preparations 1.3 Preparations Tool and payload settings Before using Servo Gun Setup, the tool and the payload must be defined correctly. Basic verification Find out if there are any basic problems (i.e. bad parameters or ripple). These problems must be fixed before the tuning of force and position control is started.
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  • Page 15: Installation

    2 Installation 2 Installation Installing the Servo Gun Setup Add-in 1 In RobotStudio, click on the Add-Ins tab. 2 Select ServoGun Setup. 3 In the frame to the right, click Add. xx1800000408 Continues on next page Application manual - Servo Gun Setup 3HAC065014-001 Revision: E ©...
  • Page 16 2 Installation Continued Adding Servo Gun Setup to a system The product ServoGunSetup can be added when creating a new system, or added to an existing system. In both cases it is done in Installation Manager in RobotStudio. In the tab Products, add ServoGunSetup in the same way as RobotWare.

  • Page 17: Servo Gun Setup Wizard

    3 Servo Gun Setup wizard 3.1 How to use the Servo Gun Setup wizard 3 Servo Gun Setup wizard 3.1 How to use the Servo Gun Setup wizard The parts of Servo Gun Setup Servo Gun Setup is a wizard that step-by-step takes you through the following: •...
  • Page 18 3 Servo Gun Setup wizard 3.1 How to use the Servo Gun Setup wizard Continued Main view By going through the wizard, step by step, all these parts are being set up automatically. In some steps, there is a button Main view that takes you to an overview of the setup wizard: xx1700002044 Tapping on one of the parts will take you directly to that part of the wizard (if you...

  • Page 19: Running The Servo Gun Setup Wizard

    3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Start Servo Gun Setup On the FlexPendant, tap the ABB menu and select ServoGun Setup. xx1700002045 Continues on next page Application manual - Servo Gun Setup 3HAC065014-001 Revision: E ©...
  • Page 20 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued Load configuration Load a system parameter configuration file for a servo gun. Browse to select the desired template file. For more information about template files, see Application manual - Additional axes and stand alone controller. If you want to change the name of the servo gun, type the new name.
  • Page 21 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued Change motor type Load a file with the motor data. The motor type file can be on the controller or loaded from a USB. For information about the motor type file, see Motor type file on page 1 Browse to select the file for your servo gun motor, then tap OK.
  • Page 22 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued Change connection If previously loaded configuration file does not have the correct settings, change them to the values that apply to your servo gun. For information about the measurement system, see Application manual - Additional axes and stand alone controller.
  • Page 23 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued torque is not known, use the stall torque or the continuous torque from the motor data sheet. 1 If needed, change values. Then tap Next. xx1700002050 2 A restart is required for the changes to take effect. Tap Restart. xx1700002051 Continues on next page Application manual - Servo Gun Setup...
  • Page 24 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued Fine calibration After restart, the following page is shown if the servo gun is not already fine calibrated. Press Fine Calibrate to perform this calibration. xx1700002052 Tune servo gun 1 To start the routine that tunes the servo gun, press the enabling device on the FlexPendant and tap Tune Servo Gun.
  • Page 25 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued 2 Tap Continue. xx1700002054 3 If the correct tool and work object is used, tap Accept. xx1700002055 Continues on next page Application manual - Servo Gun Setup 3HAC065014-001 Revision: E ©...
  • Page 26 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued 4 To let the wizard perform a complete tuning, tap Complete. To manually perform selected steps of the tuning, tap Manually. xx1700002056 Tune transmission 1 If the transmission gear ratio is known, tap Modify and type the value. To automatically detect the transmission, tap Check.
  • Page 27 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued 2 Make sure the gun is opened approximately 20 mm. If not, open the Jogging window and jog the servo gun to 20 mm. Observe the servo gun when pressing OK. xx1700002058 3 Observe the direction of the movement.
  • Page 28 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued 4 Tap OK to do an STCalib with low force to find an initial value for the servo gun's zero position. xx1700002060 5 Type the upper limit of the servo gun opening and tap OK. xx1700002061 Continues on next page Application manual - Servo Gun Setup...
  • Page 29 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued 6 Measure the gun opening. If it is not exactly 50 mm, tap No and type the measured value. xx1700002062 7 Tap OK to continue. xx1700002063 Continues on next page Application manual - Servo Gun Setup 3HAC065014-001 Revision: E ©...
  • Page 30 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued 8 Measure the gun opening. If the measured value is not equal to the the value in the text (140 mm in our example), tap No and type the measured value. xx1700002064 Note X-guns are more or less non-linear.
  • Page 31 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued xx1700001574 The servo gun movement follows a circular arc path. The measured distance between the tips. The presented value is based on the servo gun movement which is longer (for example 140 mm) than the measured distance between the tips (for example 138 mm).
  • Page 32 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued Set alarm torque The gun will move slowly to measure the friction torque. An estimated alarm torque is then presented. Tap Accept to use the estimated value. Tap Change to type a value.
  • Page 33 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued Check delta position (initial value) The robot controller shall be in Manual speed mode. 1 Finding the servo gun's zero position is necessary to have an initial value for thickness estimation.
  • Page 34 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued 2 Look at the gap and tap the buttons to adjust the gap until it is closed without any force. Tip: If the gun is closed, tap +0.1 mm until there is a visible gap, then tap -0.1 mm to close the gap.
  • Page 35 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued 3 The gun opens and closes. If the tips are in contact after this, tap Yes. If the tips are not in contact, tap No to redo the check of delta collision position.
  • Page 36 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued Do not expect good repeatability in this initial force calibration. A more precise force calibration is made later in the wizard. 1 Tap OK to continue with the force calibration. xx1700002069 2 Tap Setup.
  • Page 37 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued 3 By default, the force calibration is performed by doing two force measurements (typically at half max force and at max force). To change number of measurements, tap 1 and then enter the number of measurements. To change the max force that the servo gun shall reach, tap 2 and then enter the new value.
  • Page 38 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued 6 The default force for the first measurement is half the max force. To change it, type a new value. Hold the force sensor between the gun tips. Tap OK and read the measured force on the force sensor.
  • Page 39 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued 8 Type the measured value and tap OK. xx1700002075 9 Repeat step for the second measurement, but with max force. (If more than two measurements are used, repeat for each measurement with increasing force.) 10 Tap OK.
  • Page 40 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued 11 The torque and force of the measurements are presented. Tap Next. xx1700002077 12 Tap OK to update the servo gun's force calibration with the new measurements. xx1700002078 13 Repeat step until the max force has been reached (typically 2-3 times).
  • Page 41 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued 14 Confirm that the desired max force was reached by tapping Yes. xx1700002079 Tune speed limit A recommendation is to use TuneMaster to view relevant signals during the speed tuning.
  • Page 42 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued 2 Tap OK to perform an automatic tuning of the speed limit. xx1700002080 3 The servo gun will close to force mode several times to test the speed limitation during force mode.
  • Page 43 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued Tune acceleration A recommendation is to use TuneMaster to view relevant signals during the acceleration tuning. If any problems occur, this can help you study the course of events in detail.
  • Page 44 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued 2 If there is a known upper limit from data sheet or mechanical design, tap Change and enter the value. If the acceleration limit is unknown, tap OK to detect it automatically. xx1700002083 3 Tap OK to start the tuning.
  • Page 45 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued 4 The servo gun opens and closes to test the acceleration. A suggested acceleration limit is presented. Tap Yes to set this value as acceleration limit. xx1700002085 Check delta position (final value) Now that force, speed and acceleration are calibrated, the servo gun's zero position has probably changed.
  • Page 46 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued Force calibration (final value) Now that the delta position is definitively defined, a final force calibration can be made. Perform this calibration just like Force calibration (initial value) on page 35 with the difference that this time it is more important with the accuracy of the force calibration.
  • Page 47 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued Tune gun deflection parameters Place dial indicators that measures the servo gun deflection in z and x direction. Normally there is no deflection in y direction, but if there is, measure this too. xx1700001573 Dial indicator for detecting movement in x direction Dial indicator for detecting movement in z direction...
  • Page 48 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued 1 Tap OK to perform the gun deflection tuning. xx1700002086 2 The suggested force for the gun deflection tuning is the max force. To change this, tap Change and enter desired force value. Observe the dial indicators and tap Check to start the gun deflection tuning.
  • Page 49 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued 3 Read the deflection values from the dial indicators. The current deflection values are presented. If these values are correct, tap Save. To change the values, tap Change. xx1700002088 4 Type the measured deflection in Z direction and tap OK.
  • Page 50 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued 7 The default deflection time is 0.1 mm. If the time it takes to build up the deflection differ from this, type the correct value and tap OK. xx1700002090 8 Tap Save to save the deflection values you have entered.
  • Page 51 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued Save the configuration 1 Tap Save to save the configuration. xx1700002093 2 To save only the servo gun data to file, tap Save Servo Gun Types and select name and location for the file.
  • Page 52 3 Servo Gun Setup wizard 3.2 Running the Servo Gun Setup wizard Continued If the gun should be used in many configurations, it is recommended to use the tool Mechanical Unit Manager to create variants of this configuration file. See Application manual - Mechanical Unit Manager.

  • Page 53: Commissioning Mode

    3 Servo Gun Setup wizard 3.3 Commissioning mode 3.3 Commissioning mode About commissioning mode If you already have a file with configured servo gun data (button Save Servo Gun Types, see Save the configuration on page 51), a special commissioning mode allows for a shortcut through the Servo Gun Setup wizard.
  • Page 54 3 Servo Gun Setup wizard 3.3 Commissioning mode Continued If previously loaded configuration file does not have the correct settings, change them to the values that apply to your servo gun. For information about the measurement system, see Application manual - Additional axes and stand alone controller.
  • Page 55 3 Servo Gun Setup wizard 3.3 Commissioning mode Continued 6 If you want to change anything in the configuration, press the enabling device on the FlexPendant and tap Tune Servo Gun (see Tune servo gun). Configure the steps necessary and skip the steps that are not needed. xx1700002093 7 Tap Save to save the configuration.
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  • Page 57: System Parameters

    4 System parameters 4 System parameters About this section This section only describes the system parameters that are most important for servo guns. How to configure additional axis in general is described in Application manual - Additional axes and stand alone controller. All system parameters are described in Technical reference manual - System parameters.
  • Page 58 4 System parameters Continued Parameter name Description Ramp when In- Parameter is kept for backward compatibility. ramp_torque_ref_ crease Force Should not be used. closing Ramp Time Determines how fast force is built up while ramp_time closing the tool. This should normally be between 0.050 and 0.090 s.
  • Page 59 4 System parameters Continued Parameter name Description Search reverse dis- When search for plate is activate in a spot search_reverse_dist tance welding instruction, the servo gun will perform a movement towards the plate and stops im- mediately when the plate is found. To reduce search impact as much as possible the gun will automatically move in the opposite direc- tion directly after the plate is found.
  • Page 60 4 System parameters Continued Cfg name Parameter name Description Kv, Gain speed loop The amplification of the velocity control. A high value gives better high frequency stiffness, better response speed and low overshoot. If the value is too high the servo gun will vibrate.
  • Page 61 4 System parameters Continued Cfg name Parameter name Description Phase inductance Stator phase inductance at zero cur- l_stator rent. The value should be measured at a frequency of about 120Hz to cor- respond to what the drive expects. If the inductance is measured phase-to- phase, the value should be divided by 2.
  • Page 62 4 System parameters Continued SG Process Cfg name Parameter name Description Close Time Adjust Constant time adjustment (s), positive or min_close_time_adjust negative, of the moment when the gun tips reach contact during a gun closure. This value is normally zero. May be used to delay the closing slightly when the synchronized pre closing is used for welding.
  • Page 63 4 System parameters Continued Cfg name Parameter name Description Calibration Time The wait time (s) during a calibration before calib_time the positional gun tip correction is done. Re- commended value ca: 0.5 s. Number of Stored Number of stored forces in the force VS motor no_of_active_db_posts Forces torque table.
  • Page 64 4 System parameters Continued Cfg name Parameter name Description Forced off Position The lower limit for forced gain control. Kp_forced_off_limit Limit Normally not used for servo gun. Keep at default value. Supervision Type Cfg name Parameter name Description Static power up position error limit static_power_up_position_ at zero speed.The unit is radians, limit...
  • Page 65 4 System parameters Continued Cfg name Parameter name Description Teach Max Speed Maximum supervision speed ratio in teach_mode_speed_max_dsp teach mode for axis computer (% max speed). Min.=0, Max.= 1, De- fault=0.28. Take the value from teach_mode_speed_max_mainand add a margin for noise and vibra- tions.
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  • Page 67: Tunemaster And Tuning

    5 TuneMaster and tuning 5.1 TuneMaster 5 TuneMaster and tuning 5.1 TuneMaster About TuneMaster TuneMaster can be used to study signals for position, speed, torque, etc. TuneMaster can be downloaded from: http://new.abb.com/products/robotics/robotstudio For more information about TuneMaster, see Application manual - TuneMaster. Define test signals with TuneMaster The following test signals should be defined for the servo gun: Signal...
  • Page 68 5 TuneMaster and tuning 5.1 TuneMaster Continued Speed limit tuning When tuning the speed limit, you want to allow as fast speed as possible without getting a pushback from the servo gun that can severely reduce the accuracy of the force control. Example of bad speed limit xx1700001576 Speed limit signal...
  • Page 69 5 TuneMaster and tuning 5.1 TuneMaster Continued Example of good speed limit xx1700001577 Torque signal Force control mode signal Speed limit signal Speed signal No pushback from the servo gun. A reduction in the torque when the speed reach the speed limit is per- fectly normal.
  • Page 70 5 TuneMaster and tuning 5.1 TuneMaster Continued Example of acceleration tuning xx1700001578 Positive torque limit signal Speed signal Torque signal Negative torque limit signal Torque during acceleration when opening the gun Torque during deceleration when closing the gun Application manual - Servo Gun Setup 3HAC065014-001 Revision: E ©...

  • Page 71: Tuning With Movable Gun Arm Search

    5 TuneMaster and tuning 5.2.1 Movable gun arm search 5.2 Tuning with movable gun arm search 5.2.1 Movable gun arm search About the functionality The tuning of moveable gun arm search is done by repeating search movements and changing system parameters. Run the RAPID instruction SearchMoveCheck to perform a test run while finding values for parameters.
  • Page 72 5 TuneMaster and tuning 5.2.1 Movable gun arm search Continued Search Ti is active during ramp and search and Search Kv is active during the search. xx2000001903 2 Check and tune the speed error filter. Run the search movement with selected values of Search Kv and Search Ti from the previous step.
  • Page 73 5 TuneMaster and tuning 5.2.1 Movable gun arm search Continued An example of a correctly tuned gun can be seen in the following figure, note that even though Kv is increased by about 200% an oscillatory behavior is seen and this is probably due to ripple effects in the motor. xx2000001904 In the figure above, about 50% of the samples in the search signal are equal to zero.

  • Page 74: Rapid References For Mgas

    5 TuneMaster and tuning 5.2.2.1 SearchMoveCheck 5.2.2 RAPID references for MGAS 5.2.2.1 SearchMoveCheck Usage SearchMoveCheck is used to do search movements without any contact to repeat movements during tuning procedures. A tuning procedure is typically used to find an optimal value for a parameter. A test movement (that is, a program execution with a SearchMoveCheck) is repeated when using different parameter tune values set up by TuneDetectionParams.

  • Page 75: Tunedetectionparams

    5 TuneMaster and tuning 5.2.2.2 TuneDetectionParams 5.2.2.2 TuneDetectionParams Usage TuneDetectionParams is used to change search parameters during tuning procedures. A tuning procedure is typically used to find an optimal value for a parameter. A test movement (that is, a program execution with a SearchMoveCheck) is repeated when using different parameter tune values set up by TuneDetectionParams.
  • Page 76 5 TuneMaster and tuning 5.2.2.2 TuneDetectionParams Continued \SearchSpeed Data type: num Speed during search movement mm/s. \FilterCoeff Data type: num Cut off frequency for the speed error filter (Hz). Syntax TuneDetectionParams [gunnum ':='] <expression (IN) of num> ['\' Threshold ':=' <expression (IN) of num>] ['\' LeakSubtrahend ':=' <expression (IN) of num>] ['\' SearchKv ':=' <expression (IN) of num>] ['\' SearchTi ':=' <expression (IN) of num>]...

  • Page 77: Motor Type File

    6 Motor type file 6 Motor type file Content of motor type file The motor type file must include the types: • MOTOR_TYPE • STRESS_DUTY_CYCLE If not using the default values for standard ABB motors, the motor type file can include (for example): •...
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  • Page 79: Index

    Index Index Main view, 18 motor type, 21 motor type file, 77 acceleration, 43 alarm torque, 32 Next button, 18 non-linear guns, 30 Back button, 18 buttons, 18 requirements, 12 RobotStudio, 12 Change button, 18 commissioning mode, 53 connection, 22 save configuration, 51 Servo Gun Setup wizard, 17 Skip button, 18...
  • Page 82 ABB AB Robotics & Discrete Automation S-721 68 VÄSTERÅS, Sweden Telephone +46 (0) 21 344 400 ABB AS Robotics & Discrete Automation Nordlysvegen 7, N-4340 BRYNE, Norway Box 265, N-4349 BRYNE, Norway Telephone: +47 22 87 2000 ABB Engineering (Shanghai) Ltd. Robotics &...

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