ABB IRB 360 Instructions Manual
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ABB IRB 360 Instructions Manual

ABB IRB 360 Instructions Manual

Robotic station for packing ffs1 dispensers
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ABB Sp. z o.o.
Branch in Warsaw
street Żegańska 1
04-713 Warsaw
Workplace instructions
Robotic station for packing FFS1 dispensers
Made for: GILLETTE
street Nowy Józefów, Łódź
DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03

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Summary of Contents for ABB IRB 360

  • Page 1 ABB Sp. z o.o. Branch in Warsaw street Żegańska 1 04-713 Warsaw Workplace instructions Robotic station for packing FFS1 dispensers Made for: GILLETTE street Nowy Józefów, Łódź DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 2: Table Of Contents

    GILLETTE ŁÓDŹ CONTENTS Robotic station for packing FFS1 dispensers CONTENTS: PURPOSE SECURITY DESIGN AND CONSTRUCTION OCCUPATIONAL HEALTH AND SAFETY USER MANUAL MAINTENANCE ATTACHMENTS ABB Sp. z o.o. Side 2/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 3 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers 1. DESTINY DESTINY PURPOSE OF THE POSITION TECHNICAL DATA RATING PLATE COMPLIANCE WITH STANDARDS ABB Sp. z o.o. Side 3/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 4: Purpose Of The Position

    ➢ Chain conveyors transporting dispensers to the packaging area. Zone 2 includes: ➢ ABB IRB 360 robot with two grippers (replaceable) - the task is to transfer dispensers from transporters to blisters located on an independent transporter. Depending on the desired configuration, a given gripper transports 8 or 16 dispensers per cycle (4s or 8s mode).
  • Page 5 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers ➢ A system that changes the orientation of dispensers (rotates the dispenser or 90°) Figure 1 Robotic dispenser packaging line. ABB Sp. z o.o. Side 5/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 6: Technical Data

    GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers Figure 2 Frame with the IRB 360 robot and control cabinets. TECHNICAL DATA 1.2.1 Technical data of the station: Table 1 Technical data of the station Supply voltage 3x400V +PE, 50Hz Compressed air...

  • Page 7: Rating Plate

    Security requirements. - PN-EN ISO 13857:2008 Machinery safety. Safety distances that prevent upper limbs from reaching danger zones. - PN-EN ISO 13850:2008: Machinery safety -- Emergency stop -- Design principles ABB Sp. z o.o. Side 7/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 8 - Regulation of the Ministry of Economy of October 30, 2002 on the minimum requirements for occupational health and safety in the use of machines and devices by employees during work (Journal of Laws No. 191, item 1596) Figure 4 CE marking ABB Sp. z o.o. Side 8/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 9 January 1, 1995, it is illegal in all European Union countries and economic areas of Europe to introduce new machines that do not have the CE mark. The remaining equipment has a Declaration of Conformity and CE marking issued by the manufacturers. ABB Sp. z o.o. Side 9/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 10: Security

    GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers 2 SECURITY SECURITY ENTRY 2.2 GENERAL SAFETY INFORMATION 2.3 SAFETY INSTRUCTIONS ABB Sp. z o.o. Side 10/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 11: Entry

    The method of avoiding and eliminating the threat is either described in detail in the procedure or described in detail in separate instructions given in the subsection“2.3 Safety Instructions” on page 16. ABB Sp. z o.o. Side 11/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 12: General Safety Information

    The dangers parts are divided into different categories) Security activities (describes in ● fire fighting detail the actions that can be ● safe use of FlexPendant taken to remove or avoid the threat) ABB Sp. z o.o. Side 12/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 13 Users of ABB industrial robots are responsible for ensuring that all applicable country-specific regulations and safety regulations are complied with and that the necessary safety devices are properly designed and installed to protect persons operating the robot system.
  • Page 14 Installation of safety Product manual for the robot Installation and devices acceptance Changing operating User manual – robot Modes of operation modes Limiting the workspace Product manual for the robot Installation and acceptance ABB Sp. z o.o. Side 14/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 15 _____________________________________________________________________ Voltage hazards - ABB IRC5 Compact controller The hazard due to high voltage is associated with, for example, the following parts: ● Please handle electrical power (DC connectors, ultracapacitor storage module) in the controller with care.

  • Page 16: Safety Instructions

    Applies to warnings having connection, for example, with contact with devices under high voltage, risk of fire or explosion, risk of poisonous gases, risk of crushing, impact, falling from height etc. ABB Sp. z o.o. Side 16/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 17 Attention symbols call attention to important facts and conditions. Tip symbols direct the reader to detailed instructions where they can be found additional information about the execution of the given activities in an easier way. ABB Sp. z o.o. Side 17/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 18 Table 5 Eliminating the threat, controller in the +P1 cabinet Action Comment/Illustration Turn off the main switch on the frame Turn off the main A - main switch switch - A on the controller cabinet. ABB Sp. z o.o. Side 18/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 19 _____________________________________________________________________ Location of the wrist strap latch The electrostatic wristband connection is located in the right corner as shown in the illustration below. Connecting the electrostatic wristband ABB Sp. z o.o. Side 19/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 20 When the robot system performs production activities, the cabinet doors must be closed properly. Otherwise, the cabinet will not meet the requirements of the IP54 protection level. The degree of protection against electromagnetic interference will also be limited. ABB Sp. z o.o. Side 20/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 21: Design And Construction

    GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers 3 CONSTRUCTION AND CONSTRUCTION DESIGN AND CONSTRUCTION SECURITY SYSTEM CONSTRUCTION OF THE STATION JOB LOCATION WORK CYCLE OF THE JOB HUMAN-MACHINE INTERFACE ABB Sp. z o.o. Side 21/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 22: Security System

    MECHANICAL The robotic cell is secured on two sides with PMMA walls and on both sides with glass service doors in the IRB 360 robot working area, while the box exchange/unloading area is secured with a 2.3 m high protective fence with a service door.
  • Page 23 - a box on a post next to the service door outside zone 1 - +P7 control cabinet - programming panel – FlexPendant ABB Each time any emergency stop button is pressed, the entire system including the robot stops immediately. This is done in...
  • Page 24 Robotic station for packing FFS1 dispensers Any modifications to the safety systems are prohibited. Improper operation of safety systems may pose a threat to life and health and may damage the device. DANGER ABB Sp. z o.o. Side 24/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 25: Construction Of The Station

    GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers CONSTRUCTION OF THE STATION The robotic dispenser packaging station provided by ABB includes the following elements: Table 8 Construction of the stand Zone 1 Gravity roller Two gravity roller feeders feeder piece...
  • Page 26 ● System IRC5 cabinets (high Compact voltage +P1 ● Signal, power and user and low connector cable voltage +P2) between the IRB 360 robot and the IRC5 Compact control cabinet. ● Robot control cabinet. IRC5 operating system. Panel operatora robota FlexPendant ●...
  • Page 27 Enables repeated gripping (8s) piece and carrying of 16 dispensers. A system that The task of the system is changes the piece to rotate the dispensers by orientation of 90°. dispensers - lifted ABB Sp. z o.o. Side 27/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 28: Job Location

    The hall should meet the following parameters: - temperature: 5°C -25°C. - general lighting >250 Lux The IRB 360 robot is suspended on a frame at a Robot height of ~2.3 m in a place enabling optimal process operation. The robot is an integral part of the application and is located in the cell.

  • Page 29: Work Cycle Of The Job

    When the recipe is changed, the gripper needs to be replaced. The sequence of ABB robot movements includes: retrieving dispensers (8 or 16) from a belt conveyor, ensuring the distance between dispensers (using a gripper) and placing the dispensers into blisters located on an independent transporter.

  • Page 30: Human-Machine Interface

    PLC panel is provided later in the manual. Additionally, there are Operator Panels within the station, the functions of which are described inchapter 5.2 of the manual. ABB Sp. z o.o. Side 30/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 31 ● Program the robot; ● Correct the robot's trajectory points. Messages about operating irregularities of the IRC5 control system and the IRB 360 robot are also displayed on the FlexPendant operator panel and on the PLC control panel. ABB Sp. z o.o.

  • Page 32: Occupational Health And Safety

    GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers 4 SECURITY AND OCCUPATIONAL HYGIENE OCCUPATIONAL HEALTH AND SAFETY INTENDED USE INCOMPATIBLE USE THREATS COUNTERACTIONS TAKEN INFORMATION ABOUT THE POSITION AND TRAINING GENERAL THOUGHTS ABB Sp. z o.o. Side 32/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 33: Intended Use

    Intended use also includes reading and understanding of this manual, in particular the chapters on occupational health and safety. ABB Sp. z o.o. Side 33/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 34: Incompatible Use

    4.3.2. Danger resulting from the movement of the robot manipulator and gripper - possibility of crushing. 4.3.3. Danger resulting from the need for the staff to enter the working zone of the IRB 360 robot, the zone of replacing/unloading boxes and operated devices for setup and maintenance purposes.

  • Page 35: Information About The Position And Training

    7 EMERGENCY STOP buttons at the station and additional buttons within the station, which, when pressed, immediately stop the moving elements of the system. Persons working as Operators should undergo on-the-job training in operating the station. ABB Sp. z o.o. Side 35/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 36: General Thoughts

    GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers Persons changing settings or programs should undergo operator training in the operation and programming of ABB robots. GENERAL THOUGHTS Safe operation can only be guaranteed if: the system is used, maintained and kept in good...
  • Page 37 Table 10 Occupational health and safety symbols To ensure safe work, all service personnel should be familiar with the area's operation and health and safety instructions Maintenance and adjustment work should be performed by qualified personnel. ABB Sp. z o.o. Side 37/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 38 It is prohibited to make repairs or mechanical adjustments while the device is in use moving. It is forbidden to work with covers removed and safety systems disabled. ABB Sp. z o.o. Side 38/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 39 GILLETTE must be observed. When operating the system, health and safety instructions must be strictly followed, especially regarding restrictions on entering the robot's work zone. ABB Sp. z o.o. Side 39/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 40 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers ABB Sp. z o.o. Side 40/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 41: User Manual

    MANUAL PACKING MODE ROBOT SETTING MODE TRAFFIC LIGHTS AT THE STATION BACKUP COPY 5.10 TURNING THE SYSTEM OFF 5.11 BOX SETTING 5.12 PROCEDURE FOR REMOVING THE DEVICE 5.13 TRANSPORT RECOMMENDATIONS 5.14 EMERGENCY SITUATIONS ABB Sp. z o.o. Side 41/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 42: Preparing The System For Work

    Operator Operator panels should have all panels buttons in working order. Check the correct installation of the buttons and their functionality (e.g. whether the emergency stop buttons ABB Sp. z o.o. Side 42/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 43: Functions Of Operator Panels

    Check the correct installation of the buttons and their functionality (e.g. whether the emergency stop button is not loose/damaged and whether it can be pressed out freely after pressing it). 5.2 FUNCTIONS OF OPERATOR PANELS ABB Sp. z o.o. Side 43/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 44 The location of all EMERGENCY STOP buttons can be found in the SAFETY ELEMENTS MAP appendix and on the HMI panel. RESET button– the reset button should be +P6 PANEL OPERATORSKI pressed and held for approximately 1 second ABB Sp. z o.o. Side 44/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 45 1 second. STOP button– pressing the button stops the machine after the work cycle is completed. The machine will stop only when the robot completes the packaging cycle and moves to its home position. ABB Sp. z o.o. Side 45/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 46 The machine for robotic packaging of dispensers is divided into several hardware modules from EM_00 to EM_03: EM_00 – Robot, transporters, EM_01 – Box feeders #1 and #2, EM_02 – Grinder #1, EM_03 – Grinder #2. ABB Sp. z o.o. Side 46/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 47 After starting the station, operator mode is activated. To change the user, press the LOG IN button on the main screen. To return to operator mode, log out the current user. Figure 6 HMI login window ● Main screen of the HMI +P0 operator panel. ABB Sp. z o.o. Side 47/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 48 - CLEAR ERRORS – Button that allows you to clear errors. Error deletion is only possible when the cause of the error has been eliminated. The buttons will be inactive if the current machine condition does not allow their use. ABB Sp. z o.o. Side 48/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 49 - EMERGENCY STOP button status indicator (OFF – plug pressed, ON – plug pressed) - door locking status indicator light (green - door closed and locked, red - door unlocked or open) ● Screen – Machine State Model ABB Sp. z o.o. Side 49/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 50 If the operator tries to change the recipe and the current state of the machine does not allow it, the following message will be displayed: "Recipe change not allowed". ● EM Diagnostics screen ABB Sp. z o.o. Side 50/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 51 The hardware module diagnostics screen allows you to observe errors that occur. If an error assigned to one of the modules occurs, it flashes red. Clicking opens a screen showing the type of error. ABB Sp. z o.o. Side 51/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 52 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers Figure 10 Diagnostics screens showing the type of error ABB Sp. z o.o. Side 52/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 53 Status and error indicators are described in the table below. Table 13 Status and error indicators Status Status Status OFF Error rates Mistake No error indicators I dare state Module error Drive status Green Gray Gray Drive error Status ruchu ABB Sp. z o.o. Side 53/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 54 Figure 12 EM Screen Operation The EM Operation screen also allows you to change the recipe. Additionally, this screen displays a graphic indicating which recipe is active. Functional buttons: - EM Manual Jog ABB Sp. z o.o. Side 54/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 55 - Command – condition Figure 14 Command window - conditions The window presents individual program commands and the conditions for their execution; if any condition is not met, it is displayed on the screen. ABB Sp. z o.o. Side 55/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 56 ● EM Configuration screen Figure 15 EM Configuration window The screen allows you to change the parameters of individual hardware modules. Changes to the configuration can only be made by authorized persons - "mechanic" or "service". ABB Sp. z o.o. Side 56/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 57 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers Figure 16 EM 00 Robot configuration Figure 17 EM 01 Feeders configuration ABB Sp. z o.o. Side 57/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 58 PICK READY – causes the dispensers to be grabbed and moved over the blister PLACE READY – puts the dispensers back in the blister MILLS OFF/ON – allows you to manually raise or lower the mechanism of the grinders to rotate the dispensers ABB Sp. z o.o. Side 58/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 59 (equalizing the number of dispensers on the conveyors) 3. After the specified number of robot cycles - sending the "EMPTY" command to FFS1 4. After the specified number of robot cycles - STOP the cell ABB Sp. z o.o. Side 59/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 60 The Clear History button clears the screen and deletes visible information about fixed errors. ABB Sp. z o.o. Side 60/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 61: Starting The System

    HMI screen or press the RESET button on the HMI panel. Confirm the Press and hold the RESET button error has been on the HMI cabinet for approx. 1 cleared. second. ABB Sp. z o.o. Side 61/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 62: Automatic Operation Mode

    The lock is closed - the door is locked. Interrupting the safety circuit, i.e. opening the door, pressing the safety stop switch, causes the robot to stop immediately. The system can be resumed after closing safety circuit ABB Sp. z o.o. Side 62/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 63 Preparatory Make sure that all steps activities described in sections 5.1 and 5.3 of the manual have been completed. Switch the Turn the key to the left to the operating mode AUTO position. ABB Sp. z o.o. Side 63/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 64 Holding the RESET button for about 1 second causes the machine's units to be homed and ready for operation. To start production, hold down the START button for about 1 second. ABB Sp. z o.o. Side 64/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 65: Manual Mode

    GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers 5.5 MANUAL MODE In manual mode, the operator can manually move the IRB 360 robot. The procedure for switching the robot to manual operation mode is presented below: Table 17 Switching to manual operation mode...
  • Page 66 Attention! Before releasing the robot's brakes, the operator must support the robot using the robot's middle arm. If the button is not held and pressed, a collision may occur. Figure 21 Key and robot brake release button ABB Sp. z o.o. Side 66/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 67 Step 7: The operator prepares the station by placing a stack of crates in the cell and then takes a position to retrieve dispensers from the crates and pack them into blisters. Figure 22 Manual packing scheme ABB Sp. z o.o. Side 67/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 68: Robot Setting Mode

    1. Log in to the MECHANIC or SERVICE level. 2. Activate the program / 8s, the one which you want to modify. 3. Reset the machine. 4. Enter the screenEM Configuration. Figure 23 HMI main screen ABB Sp. z o.o. Side 68/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 69 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers 5. Enter the screen IN 00 Robot Konfig. Figure 24 EM Configuration (HMI) screen 6. Press the buttonROBOT ADJUSTMENT MODE OFF. ABB Sp. z o.o. Side 69/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 70 If the setting mode is started correctly, the button will turn red and the text will appearROBOT SETTING MODE ENABLED, and the following window will appear on the FlexPendant panel screen: Figure 26 Settings menu (FlexPendant) Then follow the instructions that will be displayed on the FlexPendant screen. ABB Sp. z o.o. Side 70/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 71 8. A warning window will appear on the FlexPendant screen. Figure 27 Settings menu - download (FlexPendant) Read the warning and confirm with the buttonOK. 9. A window will appear on the FlexPendant screen. ABB Sp. z o.o. Side 71/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 72 The directions of axis shifts are marked in the drawing displayed on the HMI panel -Z axis – values >0 move up, values <0 move down. X and Y axes - as in the drawing. Figure 29 Pickup Position Adjustment (HMI) ABB Sp. z o.o. Side 72/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 73 10. If there is no visible risk of collision, press the buttonSo on the FlexPendant panel - the robot will go to the dispenser collection point. And it will display the screen: ABB Sp. z o.o. Side 73/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 74 After setting the correct download position, confirm the changes by pressing the buttonNO and we move on to the next step. 11. After confirming the download position, the following window will appear on the FlexPendant panel: ABB Sp. z o.o. Side 74/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 75 The robot will then catch the dispensers and lift them up. 12. Then the Select line number window will appear: Figure 34 Select Line No. (FlexPendant) Select the line number you want to modify. ABB Sp. z o.o. Side 75/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 76 14. Then the following window will appear on the FlexPendant screen: Figure 36 Settings menu - placement adjustment (FlexPendant) ABB Sp. z o.o. Side 76/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 77 Figure 37 Visualization of placement slots and robot coordinate system (HMI) If there is no visible risk of collision, press the buttonSo, and then the robot will move down to the position of placing the dispensers in a given slot. ABB Sp. z o.o. Side 77/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 78 If the placement position in a given slot is correct, press the buttonNO, which will cause you to pass over the next nest. Then you should repeat the steps for modifying the offsets for a given socket. ABB Sp. z o.o. Side 78/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 79 If there is a need to adjust another line, press the buttonSo and repeat the offset modification steps as with the previous line. If there is no need to check subsequent placement points, the following window will appear: ABB Sp. z o.o. Side 79/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 80 Pressing the buttonSo will open the grippers and place the dispensers in a given slot. After opening the grippers, the following window will appear on the FlexPendant screen: Figure 42 Setup menu - Pick-up and put-down position adjustment completed (FlexPendant) ABB Sp. z o.o. Side 80/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 81: Traffic Lights At The Station

    (Zone 1). The signal column consists of five elements - four light elements and a sound signal. Below is a description of the individual elements of the column: ABB Sp. z o.o. Side 81/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 82: Backup Copy

    Green light: Continuous green color – the line is working, auto mode. 5.9 BACKUP COPY The ABB IRC5 robot system allows you to make copies. The backup copy contains all system parameters and programs. ABB Sp. z o.o. Side 82/135...
  • Page 83 ● BACKUP BACKUP Table 18 Creating a backup copy of the robot program 1.Select ABB Menu 2.Backup and Restore ABB Sp. z o.o. Side 83/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 84 - Flash memory – PenDrive Computer- RobotStudio On-line Use the navigation buttons to select the name and path By default, the name is: Backup_Data Data - current data Press: Backup ● RESTORE BACKUPS ABB Sp. z o.o. Side 84/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 85 You can restore a copy from: - robot diskhdOa - Type memoryFlash – PenDrive Computer-RobotS tudio On-line Use the navigation buttons to select the name and path The backup copy we want to restore. Press: Restore ABB Sp. z o.o. Side 85/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 86: Turning The System Off

    Press the STOP button and wait until the robot Press one of the STOP completes the cycle and stops in the safe buttons position. Turn the operating mode selection key to the position: MANUAL ABB Sp. z o.o. Side 86/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 87 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers To choose: ABB Menu Restart To choose: Advanced To choose: Shutdown Press: ABB Sp. z o.o. Side 87/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 88 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers Press: Shutdown After the no connection message appears on the Programming Panel Turn off the main switch Close the compressed air supply valve ABB Sp. z o.o. Side 88/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 89: Box Setting

    Additionally, a protection has been introduced to detect a dispenser that is turned 180° (bottom surface up). Sensors performing this function are located above the conveyors at the exit from the feeder zone. ABB Sp. z o.o. Side 89/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 90: Procedure For Removing The Device

    ● Replacing the gripper Attention! The concept of color marking tools was adopted. Blue color – 4s recipe Red color – Recipe 8s ABB Sp. z o.o. Side 90/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 91 The pneumatic lines of both grippers are also marked to simplify and improve machine setup. The cables should be attached carefully, but remember not to obstruct the air flow when clamping them to the robot arm. ABB Sp. z o.o. Side 91/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 92 Figure 48 Fixing the pneumatic lines Step 6: Unscrew the gripper from the robot flange using the knobs marked in the figure below. When unscrewing the gripper, be especially careful to prevent the gripper from falling. ABB Sp. z o.o. Side 92/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 93 All guide bands are mounted on positioning pins, which allows for quick retooling of the device. For the recipe8s bands 1, 2, 3 and 4 are used for recipe4s bandy 3, 4, 5 and 6. ABB Sp. z o.o. Side 93/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 94 Only after setting the 4s recipe on the HMI panel should you start retooling the guide bands. The bands are being re-equippedimpossible when the grinders are in the down position (recipe 8s). ATTENTION! ABB Sp. z o.o. Side 94/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 95 After stopping the process and retooling the device, the operator can start changing the control program (4s or 8s). Step 1: On the main screen, press the "Machine State Model" button Figure 52 HMI main screen ABB Sp. z o.o. Side 95/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 96 If the conveyors in the grinder area are not cleaned, changing the procedure from 4s to 8s will result in a collision and damage to the grinders!! ABB Sp. z o.o. Side 96/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 97: Transport Recommendations

    The handles intended for carrying the cell are marked in the drawing below. The frame must be lifted and transported using an overhead crane. Weight of the frame with the robot ~2 tons. ABB Sp. z o.o. Side 97/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 98 Figure 54 Frame transport handles Transport of feeders The conveyors should be moved using a forklift. The forklift should be placed halfway along the feeder as shown in the figure below. Feeder weight ~600kg. ABB Sp. z o.o. Side 98/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 99: Emergency Situations

    Take the robot out of the collision situation with extreme caution and remove the consequences of the collision. Move the robot to a safe position (HOME), lock the door and start the system in automatic mode (Detailedly described in point 5.4) ABB Sp. z o.o. Side 99/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 100 EMERGENCY STOP. Consequences No action will be possible until the circuit of the switched on motors is closed. The robot's axes are kept in the same position by brakes. ABB Sp. z o.o. Side 100/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 101 1) Make sure the system is MOTOR ON. 2) Check the cable connections. 20205, Automatic Stop Chain interrupted Specification The Automatic Stop chain has been broken. Consequences The system will enter the Automatic Stop state. Possible causes ABB Sp. z o.o. Side 101/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 102 1 second. 2) Check the security system wiring. 3) Check for other errors that appeared at the same time. 4) Check the system settings related to the Motors ON button. ABB Sp. z o.o. Side 102/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 103 Recommended actions Check whether the arm is stuck in another object or machine. Check the equipment. 50240, Torque exceeded ABB Sp. z o.o. Side 103/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 104: Maintenance

    Exceeding the torque caused the engine to enter the Stop State Recommended actions Check the Load Data parameter. 6 MAINTENANCE MAINTENANCE SYSTEM OPERATION INSPECTION AND TECHNICAL INSPECTIONS 6.3. MAINTENANCE AND LUBRICATION 6.4. CHECKING THE GEOMETRY OF THE GRIPPER 6.5. SETTING THE ADJUSTABLE ELEMENTS ABB Sp. z o.o. Side 104/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 105 ▪ Frame for mounting the robot with control cabinets (+P1 and +P2),supplier: ABB ▪ IRB 360 industrial robot and controller –supplier and specification: ABB company. They include: - industrial robotIRB 360 – 120kg - controllerIRC5 Compact2ndGeneration ▪...
  • Page 106 ▪ Box feeders –supplier: ABB ▪ Fence - supplier: AXELENT ▪ Control cabinet +P7 –supplier: ABB 6.2 INSPECTION AND TECHNICAL INSPECTIONS To ensure reliable operation of the system, periodic inspection and maintenance of its components is required. TECHNICAL INSPECTIONS ● DAILY MAINTENANCE INCLUDES: Note: Daily inspection should be carried out with the machine operating in automatic mode.
  • Page 107 STOP button. 1. EMERGENCY STOP switches – visual inspection and functional test. The location of the EMERGENCY STOP switches is located SAFETY ELEMENTS MAP in the attachment. ABB Sp. z o.o. Side 107/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 108 ● REPLACING AIR FILTERS There are 6 ventilation grills in the cell. Replacing 4 filters takes place from the outside of the cell, while replacing the remaining 2 filters must be done inside the cell. ABB Sp. z o.o. Side 108/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 109 Lubrication points Type of grease Quantity Frequency Guides around Mobilgrease FM Thin layer Once a month bearings: 222/Dynalub 510 ● GRIPPER1 (4s) (DIN Performance ● GRIPPER2 (8s) Claim KP2K-20) ABB Sp. z o.o. Side 109/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 110 It is recommended that the guides be covered with a thin lubricant filter at all times. Only the guides should be lubricated - the actuator piston rod does not require lubrication. Lubrication points Type of grease Quantity Frequency ABB Sp. z o.o. Side 110/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 111 Each box positioning trolley has two bearings. Lubrication points Type of grease Quantity Frequency Positioning carriage KYODO YUSHI To sail Once a month bearings: Multemp SRL ● 2 bearings – FEEDER 1 ● 2 bearings – FEEDER 2 ABB Sp. z o.o. Side 111/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 112 Lubrication points Type of grease Quantity Frequency Carriage guides at the Mobilgrease Thin layer Once a month actuators: 222/Dynalub 510 ● PS1_PULLER (DIN Performance ● PS1_EVACCUATOR1 Claim KP2K-20) ● PS2_PULLER ● PS2_EVACCUATOR1 ABB Sp. z o.o. Side 112/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 113 Figure 62 Lubrication points for the guides of moving trolleys Conducting daily inspections and keeping a log of their results according to the above list is a condition for maintaining the warranty for the station. 6.4. CHECKING THE GEOMETRY OF THE GRIPPER ABB Sp. z o.o. Side 113/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 114 Releasing the button re-engages the robot's brakes and the robot remains in the desired position. ABB Sp. z o.o. Side 114/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 115 4. Checking the parallelism of the installation of the gripping lugs. When performing this operation, use the attached flat bar and millimeter scale. When applying the flat bar, check whether all gripping lugs are mounted ABB Sp. z o.o. Side 115/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 116 In case of any irregularities, the clamp mounting should be adjusted. Figure 66 Checking the parallelism of the mounting of the gripping lugs Figure 67 Checking the parallelism of the mounting of the gripping lugs ABB Sp. z o.o. Side 116/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 117 The sensors are only active for the 8s recipe. Below is how to properly set up the sensors +P2-76S1 (MILL TRIGGER 1) and +P2-76S2 (MILL TRIGGER 2). MILL TRIGGER 1 Figure 69 Setting the grinder trigger sensor 1 ABB Sp. z o.o. Side 117/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 118 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers Figure 70 Setting the grinder trigger sensor 1 MILL TRIGGER 2 Figure 71 Setting the grinder trigger sensor 2 ABB Sp. z o.o. Side 118/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 119 "pocket" rises up, so for stable operation of the sensor, the sensor must be positioned so that the spot hits the lower edge of the raised dispenser. ABB Sp. z o.o. Side 119/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 120 4s recipe. Their task is to count dispensers located in the collection zone. The correct positioning of the sensors is shown below. Figure 73 Setting the dispenser counting sensors Figure 74 Setting the dispenser counting sensors ABB Sp. z o.o. Side 120/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 121 If an incorrect feed is detected, the belt will be emptied. The correct positioning of the sensors is shown below. Figure 75 Setting of sensors detecting incorrect dispenser collection Figure 76 Setting of sensors detecting incorrect dispenser collection ABB Sp. z o.o. Side 121/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 122 The same effect will occur if the gripper does not pick up the dispenser from the belt. Figure 77 Setting of sensors detecting correct picking and rotation Figure 78 Setting of sensors detecting correct picking and rotation ABB Sp. z o.o. Side 122/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...

  • Page 123: Attachments

    2. Annex 2 FFS1 – Electrical and pneumatic diagrams 3. Annex 3 FFS1 – Documentation of elements supplied by sub-suppliers –NOT APPLICABLE 4. Appendix 4 FFS1 – Instructions for the IRB 360 robot and IRC5 Compact controller 5. Annex 5 FFS1 – Layout of the stand 6.
  • Page 124 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers ABB Sp. z o.o. 04-713 WARSAW street Żegańska 1 Robotics Division tel.: (0-22) 220 23 20 fax.: (0-22) 222 20 99 Robotic station for packing FFS1 dispensers Appendix 1 EC declarations of conformity ABB Sp.
  • Page 125 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers ABB Sp. z o.o. 04-713 WARSAW street Żegańska 1 Robotics Division tel.: (0-22) 220 23 20 fax.: (0-22) 222 20 99 Robotic station for packing FFS1 dispensers ANNEX No. 2 Electrical and pneumatic diagrams ABB Sp.
  • Page 126 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers ABB Sp. z o.o. 04-713 WARSAW street Żegańska 1 Robotics Division tel.: (0-22) 220 23 20 fax.: (0-22) 222 20 99 Robotic station for packing FFS1 dispensers ANNEX No. 3 –NOT APPLICABLE...
  • Page 127 Żegańska 1 Robotics Division tel.: (0-22) 220 23 20 fax.: (0-22) 222 20 99 Robotic station for packing FFS1 dispensers ANNEX No. 4 Instructions for the IRB 360 robot and IRC5 Compact controller ABB Sp. z o.o. Side 127/135 DTR_GILLETTE_ZSDPD_Farmores1_IRB360_2015_v03...
  • Page 128 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers ABB Sp. z o.o. 04-713 WARSAW street Żegańska 1 Robotics Division tel.: (0-22) 220 23 20 fax.: (0-22) 222 20 99 Robotic station for packing FFS1 dispensers ANNEX No. 5 Layout of the position ABB Sp.
  • Page 129 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers ABB Sp. z o.o. 04-713 WARSAW street Żegańska 1 Robotics Division tel.: (0-22) 220 23 20 fax.: (0-22) 222 20 99 Robotic station for packing FFS1 dispensers ANNEX No. 6 Map of sensors and actuators with description ABB Sp.
  • Page 130 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers ABB Sp. z o.o. 04-713 WARSAW street Żegańska 1 Robotics Division tel.: (0-22) 220 23 20 fax.: (0-22) 222 20 99 Robotic station for packing FFS1 dispensers ANNEX No. 7 Spare parts list ABB Sp.
  • Page 131 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers ABB Sp. z o.o. 04-713 WARSAW street Żegańska 1 Robotics Division tel.: (0-22) 220 23 20 fax.: (0-22) 222 20 99 Robotic station for packing FFS1 dispensers ANNEX No. 8 Security elements map ABB Sp.
  • Page 132 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers ABB Sp. z o.o. 04-713 WARSAW street Żegańska 1 Robotics Division tel.: (0-22) 220 23 20 fax.: (0-22) 222 20 99 Robotic station for packing FFS1 dispensers ANNEX No. 9 Checking emergency stop switches inside covers ABB Sp.
  • Page 133 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers ABB Sp. z o.o. 04-713 WARSAW street Żegańska 1 Robotics Division tel.: (0-22) 220 23 20 fax.: (0-22) 222 20 99 Robotic station for packing FFS1 dispensers ANNEX No. 10 Safety assessment ABB Sp.
  • Page 134 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers ABB Sp. z o.o. 04-713 WARSAW street Żegańska 1 Robotics Division tel.: (0-22) 220 23 20 fax.: (0-22) 222 20 99 Robotic station for packing FFS1 dispensers ANNEX No. 11 Security processor algorithm and signature ABB Sp.
  • Page 135 GILLETTE ŁÓDŹ Robotic station for packing FFS1 dispensers ABB Sp. z o.o. 04-713 WARSAW street Żegańska 1 Robotics Division tel.: (0-22) 220 23 20 fax.: (0-22) 222 20 99 Robotic station for packing FFS1 dispensers ANNEX No. 12 SCCR calculations ABB Sp.

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