Download
Share
Print this page
ABB IRB 660 Product Manual
  1. Manuals
  2. Brands
  3. ABB Manuals
  4. Robotics
  5. IRB 660
  6. Product manual
ABB IRB 660 Product Manual

ABB IRB 660 Product Manual

Flexgripper-clamp
Hide thumbs Also See for IRB 660:

Advertisement

Quick Links

Download this manual
Product manual
FlexGripper-Clamp
IRB 660/460

Advertisement

loading
Need help?

Need help?

Do you have a question about the IRB 660 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for ABB IRB 660

Summary of Contents for ABB IRB 660

  • Page 1 Product manual FlexGripper-Clamp IRB 660/460...
  • Page 3 Product manual FlexGripper-Clamp Document ID: 3HAC040630-002 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 Overview ................5 1 Safety 1.1 Introduction .
  • Page 6 Table of Contents 2.6.6 Oil stains on gripper ............67 2.6.7 Mechanical noise .
  • Page 7 Overview Overview About this manual This manual provides instructions for the FlexGripper-Clamp. Each chapter concerning the FlexGripper-Clamp 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-Clamp.
  • Page 8 Overview Continued Reference Reference Document ID Product manual - IRB 660 3HAC025755-001 Product manual - IRB 460 3HAC039611-001 Product manual - IRC5 Robot Controller 3HAC021313-001 Revision Revision Description First edition 3HAC040630-002 Revision: -...
  • Page 9 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 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 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. 3HAC040630-002 Revision: -...
  • Page 12 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 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-Clamp. Risk of gripped workpiece uncontrolled gravity drop during high speed movement. 3HAC040630-002 Revision: -...
  • Page 14 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 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 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 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)! 3HAC040630-002 Revision: -...
  • Page 18 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 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 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 1.3.3. Safety guidelines Safety guidelines while working with FlexGripper • See the IRB 660 or IRB 460 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 2 FlexGripper-Clamp 2.1. Specification NOTE! This section describes products the ABB FlexGripper-Clamps can lift and the ABB FlexGripper-Clamp specifications. Users can themselves judge if their products can be lifted by ABB FlexGripper-Clamps accordingly. This FlexGripper-Clamp handles cardboard boxes, paper tray packages, and buckets and so on.
  • Page 24 200 -1200 mm 200 - 500 mm 30 kg for IRB 460 1-5 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 product specifications. 3HAC040630-002 Revision: -...
  • Page 25 2 FlexGripper-Clamp 2.2.1. General 2.2 Mechanical structure & working principle 2.2.1. General The FlexGripper-Clamp lifts products using plates and a hook. It secures the products by pressing the moving plate towards the stationary plate and supporting the products bottom edge with the small hook. The action of the moving plate is controlled by a pneumatic cylinder with compressed air (4- 6 bar).
  • Page 26 2 FlexGripper-Clamp 2.2.2. Main frame 2.2.2. Main frame The FlexGripper-Clamp mainly consists of a flange, valve unit, terminal box, beam, the clamp unit and the hook unit. en1011028 Figure 2.1 Main frame of the FlexGripper-Clamp Part Description Valve unit Controls compressed air inlet and outlet of pneumatic cylinders.
  • Page 27 2 FlexGripper-Clamp 2.2.3. Clamp unit 2.2.3. Clamp unit The FlexGripper-Clamp uses one moving and one stationary plate (1-zone FlexGripper) or two moving and two stationary plates (2-zone FlexGripper) to grip products. en1011029 Figure 2.2 Bottom view of the clamp unit Part Description Base plate...
  • Page 28 2 FlexGripper-Clamp 2.2.3. Clamp unit Continued Part Description Linear guide The moving plates are mounted on it and move along it. Pneumatic cylinder Drives the moving plate. Adjustment holes of Can be used to adjust the mounting location of the stationary the stationary plate plate and then adjust the distance between two plates.
  • Page 29 2 FlexGripper-Clamp 2.2.4. Hook unit 2.2.4. Hook unit The cylinder on the moving plate can adjust the hook to open or close. When lifting products, the small hook is inserted under the product in order to hold it during the lift. Before the FlexGripper puts the product down, the hook pulls out from the bottom of the product.
  • Page 30 2 FlexGripper-Clamp 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 Cables Compressed air hose in blue. Signal cable in green. For IRB 460: circlar connector; For IRB 660: harting connector. Black corrugated pipe as cable protection Cable bracket Including: one product manual one spare parts list Continues on next page...
  • Page 32 Make sure that the power is off before starting any work. NOTE! ABB recommend that air connected to the FlexGripper should be: 4-6 bar, filtered, non- lubricated. Recommended standard tightening torque For the torque values needed during installation, please see the following.
  • Page 33 2 FlexGripper-Clamp 2.3.3. Adjustment 2.3.3. Adjustment On delivery, the width is set wide enough to make mounting of the FlexGripper possible. If needed, please refer to the following instructions to adjust the width between two plates according to the size of the product. For the correct torque values, see Recommended standard tightening torque on page Adjustment instructions...
  • Page 34 2 FlexGripper-Clamp 2.3.4. Mounting the FlexGripper-Clamp 2.3.4. Mounting the FlexGripper-Clamp DANGER! Before commencing any service work, be sure all the safety clauses have been strictly observed! Make sure that the power is off before starting any work. Mounting the FlexGripper-Clamp on robot No Action Info/Illustration 1.
  • Page 35 2 FlexGripper-Clamp 2.3.4. Mounting the FlexGripper-Clamp 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-Clamp 2.3.4. Mounting the FlexGripper-Clamp 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 2 FlexGripper-Clamp 2.3.5. Commissioning 2.3.5. Commissioning NOTE! ABB recommend that air connected to the FlexGripper should be: 4-6 bar and filtered (5µm). After the electrical and pneumatic connection of the FlexGripper, test if the FlexGripper operates correctly. NOTE! Only 24V power is used in FlexGripper.
  • Page 38 2 FlexGripper-Clamp 2.3.5. Commissioning Continued NOTE! The clamp is open, when ’DO10_02_ClampCylinder1_Close’ is set to be ’0’ and ’DO10_01_ClampCylinder1_Open’ is set to be ’1’. The clamp is close, when ’DO10_02_ClampCylinder1_Close’ is set to be ’1’ and ’DO10_01_ClampCylinder1_Open’ is set to be ’0’. PFPSClampCylinder PROC PFPSClampCylinder IF Present (Open) THEN...
  • Page 39 2 FlexGripper-Clamp 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, tPFPSClampGrip\WObj:=wobj0; TPWrite " Robot move to pick postion! "; MoveL Offs(pPick,-10,0,100), v100, z20, tPFPSClampGrip\WObj:=wobj0; MoveL pPick, v100, fine, tPFPSClampGrip\WObj:=wobj0;...
  • Page 40 2 FlexGripper-Clamp 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,-10,0,700), v500, z20, tPFPSClampGrip\WObj:=wobj0; MoveL Offs(pPlace,-10,0,30), v500, z20, tPFPSClampGrip\WObj:=wobj0; PFPSHookCylinder \Open;...
  • Page 41 2 FlexGripper-Clamp 2.3.5. Commissioning Continued Routines Description PFPS_PlaceDownBox() This routine is called when the robot goes to place down boxes. exePickPlace() This routine is called when the robot goes to pick up and place down boxes. The two routines ’PFPS_PickUpBox()’ and ’PFPS_PlaceDownBox()’...
  • Page 42 2 FlexGripper-Clamp 2.3.5. Commissioning Continued PFPSHookCylinder() PROC PFPSHookCylinder() IF Present (Open) THEN SetDO DO10_06_HookCylinder1_Close,0; SetDO DO10_05_HookCylinder1_Open,1; SetDO DO10_08_HookCylinder2_Close,0; SetDO DO10_07_HookCylinder2_Open,1; WaitDI DI10_05_HookCylinder1_Opened, 1; WaitDI DI10_07_HookCylinder2_Opened, 1; ENDIF IF Present (Close) THEN SetDO DO10_05_HookCylinder1_Open,0; SetDO DO10_06_HookCylinder1_Close,1; SetDO DO10_07_HookCylinder2_Open,0; SetDO DO10_08_HookCylinder2_Close,1; WaitDI DI10_06_HookCylinder1_Closed, 1; WaitDI DI10_08_HookCylinder2_Closed, 1;...
  • Page 43 2 FlexGripper-Clamp 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, tPFPSClampGrip\WObj:=wobj0; TPWrite " Robot move to pick postion! "; MoveL Offs(pPick,-10,0,100), v100, z20, tPFPSClampGrip\WObj:=wobj0; MoveL pPick, v100, fine, tPFPSClampGrip\WObj:=wobj0;...
  • Page 44 2 FlexGripper-Clamp 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,-10,0,700), v500, z20, tPFPSClampGrip\WObj:=wobj0; MoveL Offs(pPlace,-10,0,30), v500, z20, tPFPSClampGrip\WObj:=wobj0; PFPSHookCylinder \Open;...
  • Page 45 2 FlexGripper-Clamp 2.3.5. Commissioning Continued Reference Rapid codes for 2-zone FlexGripper MODULE MainModule CONST robtarget pPick:=[[2094.58,-1118.54,1240.28],[6.7435E-07,0.64016,-0.768242,- 1.6648E-06],[-1,0,-2,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]]; PERS tooldata tPFPSClampGrip:=[TRUE,[[0,0,439],[1,0,0,0]],[45,[0,0,200],[1,0,0,0],0,0,4.097]]; PERS Loaddata PFPSLoadFull:=[40,[0,0,-150],[1,0,0,0],2,4,7]; PERS Loaddata PFPSLoadEmpty:=[0.001,[0,0,0.001],[1,0,0,0],0,0,0]; PERS num cycletime:=3.111; PERS num pace:=0; PROC main() var clock MyClock; MoveJ pPick, vmax, fine,tPFPSClampGrip\WObj:=wobj0; ConfJ \off;...
  • Page 46 2 FlexGripper-Clamp 2.3.5. Commissioning Continued SetDO DO10_02_ClampCylinder1_Close,0; SetDO DO10_01_ClampCylinder1_Open,1; WaitDI DI10_01_ClampCylinder1_Opened,1; ENDIF IF Present (Close) THEN SetDO DO10_01_ClampCylinder1_Open,0; SetDO DO10_02_ClampCylinder1_Close,1; WaitDI DI10_02_ClampCylinder1_Closed,1; ENDIF ENDPROC PROC PFPSHookCylinder(\switch Open | switch Close) IF Present (Close) THEN SetDO DO10_05_HookCylinder1_Open,0; SetDO DO10_06_HookCylinder1_Close,1; WaitDI DI10_06_HookCylinder1_Closed, 1; ENDIF IF Present (Open) THEN SetDO DO10_06_HookCylinder1_Close,0;...
  • Page 47 2 FlexGripper-Clamp 2.3.5. Commissioning Continued Reference Rapid codes for 2-zone FlexGripper MODULE MainModule CONST robtarget pPick:=[[2094.58,-1118.54,1240.28],[6.7435E-07,0.64016,-0.768242,- 1.6648E-06],[-1,0,-2,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]]; PERS tooldata tPFPSClampGrip:=[TRUE,[[0,0,539],[1,0,0,0]],[80,[0,0,200],[1,0,0,0],0,0,4.097]]; PERS Loaddata PFPSLoadFull:=[60,[0,0,-150],[1,0,0,0],3.7,7.7,15]; PERS Loaddata PFPSLoadEmpty:=[0.001,[0,0,0.001],[1,0,0,0],0,0,0]; PERS num cycletime:=3.111; PERS num pace:=0; PROC main() var clock MyClock; MoveJ pPick, vmax, fine,tPFPSClampGrip\WObj:=wobj0; ConfJ \off;...
  • Page 48 2 FlexGripper-Clamp 2.3.5. Commissioning Continued PROC PFPSClampCylinder(\switch Open | switch Close) IF Present (Open) THEN SetDO DO10_02_ClampCylinder1_Close,0; SetDO DO10_04_ClampCylinder2_Close,0; SetDO DO10_01_ClampCylinder1_Open,1; SetDO DO10_03_ClampCylinder2_Open,1; WaitDI DI10_01_ClampCylinder1_Opened,1; WaitDI DI10_03_ClampCylinder2_Opened,1; ENDIF IF Present (Close) THEN SetDO DO10_01_ClampCylinder1_Open,0; SetDO DO10_03_ClampCylinder2_Open,0; SetDO DO10_02_ClampCylinder1_Close,1; SetDO DO10_04_ClampCylinder2_Close,1; WaitDI DI10_02_ClampCylinder1_Closed,1;...
  • Page 49 2 FlexGripper-Clamp 2.3.5. Commissioning Continued Software commissioning For detailed software commissioning procedure, see FlexGripper-Clamp (FlexGripper- Clamp 1) function test on page 104 FlexGripper-Clamp (FlexGripper-Clamp 2) function test on page 105. 3HAC040630-002 Revision: -...
  • Page 50 2 FlexGripper-Clamp 2.4.1. General 2.4 Maintenance 2.4.1. General This chapter details all maintenance activities recommended for the FlexGripper-Clamp. For the torque values needed during maintenance, please see Recommended standard tightening torque on page WARNING! During maintenance, disconnect the mains voltage before any work is started. Even if the voltage is switched off there still remains a safety risk.
  • Page 51 2 FlexGripper-Clamp 2.4.2. Regular Inspection of FlexGripper-Clamp 2.4.2. Regular Inspection of FlexGripper-Clamp Perform general visual system inspection regularly before starting an operation. Parts that need to be visually inspected with a more regular interval (less than a half year and so on) are: Type Action Fastener...
  • Page 52 2 FlexGripper-Clamp 2.4.3. Regular replacement 2.4.3. Regular replacement In any of the following situations, the corresponding component should be replaced: • The hook unit/hook finger is distorted • The corrugated pipe has worn out • The rubber pad has worn down seriously and has affected the gripping capacity •...
  • Page 53 2 FlexGripper-Clamp 2.5.1. Instruction 2.5 Repair 2.5.1. Instruction This chapter details all repair activities recommended for the FlexGripper-Clamp. Safety information Before any service work is started, it is extremely important that all safety information is read! There are general safety aspects that must be read through, as well as more specific safety information that describes the danger and safety risks when performing specific steps in a procedure.
  • Page 54 2 FlexGripper-Clamp 2.5.2.1. Replacing the moving plate cylinder 2.5.2. Cylinder 2.5.2.1. Replacing the moving plate cylinder The cylinder is located as shown in the figure below. en1012001 Position Part Spherical hinge Pneumatic cylinder Quick connector Flow valve Base of pneumatic cylinder Use this procedure to remove the cylinder.
  • Page 55 2 FlexGripper-Clamp 2.5.2.1. Replacing the moving plate cylinder 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 rod 5.
  • Page 56 2 FlexGripper-Clamp 2.5.2.2. Replacing the cylinder of hook 2.5.2.2. Replacing the cylinder of hook The cylinder is located as shown in the figure below. en1012006 Position Part Pin1 for 40 cylinder 40 cylinder bracket 1 Split pin 1.6X32 Quick connector Flow valve Limit switch strap Magnetic proximity switch...
  • Page 57 2 FlexGripper-Clamp 2.5.2.2. Replacing the cylinder of hook Continued Use this procedure to remove the cylinder. DANGER! Turn off all electric power and pneumatic pressure supplies to the gripper! Action Note 1. Drain the air from the cylinder. Disconnect air cable on the cylinder. 2.
  • Page 58 2 FlexGripper-Clamp 2.5.2.2. Replacing the cylinder of hook Continued Action Note 5. Remove the split pin and then remove pin1 for 40cylinder. en1012010 Parts: A: Split pin, B: Pin1 for 40cylinder 6. Remove the split pin and then remove pin2 for 40cylinder. en1012011 Parts: A: Split pin, B: Pin2 for 40cylinder 7.
  • Page 59 2 FlexGripper-Clamp 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 Limit switch strap Pneumatic cylinder Pneumatic cylinder Position 1 Use this procedure to remove the magnetic proximitycswitch.
  • Page 60 2 FlexGripper-Clamp 2.5.3. Magnetic proximity switch Continued Position 2 Use this procedure to remove the magnetic proximityswitch. DANGER! Turn off all electric power, pneumatic pressure supplies to the gripper! Action Note 1. Loosen the small bolt and pull out the magnetic proximity switch from the limit switch strap.
  • Page 61 2 FlexGripper-Clamp 2.5.4. Sensors 2.5.4. Sensors The sensors are located as shown in the figure below. en1012017 Position Part Sensor (there are 2 sensors on gripper) Use this procedure to remove the sensors. DANGER! Turn off all electric power, pneumatic pressure supplies to the gripper! Action Note 1.
  • Page 62 2 FlexGripper-Clamp 2.5.5. Solenoid valve 2.5.5. Solenoid valve The solenoid valves are located as shown in the figure below. en1012019 Position Part Power supply One way valve Quick connector Bolt Use this procedure to remove the solenoid valve. DANGER! Turn off all electric power and pneumatic pressure supplies to the gripper! Action Note 1.
  • Page 63 2 FlexGripper-Clamp 2.5.6. Dress cable 2.5.6. 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 64 2 FlexGripper-Clamp 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 65 2 FlexGripper-Clamp 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 66 2 FlexGripper-Clamp 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 67 2 FlexGripper-Clamp 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 68 2 FlexGripper-Clamp 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. 3HAC040630-002 Revision: -...
  • Page 69 2 FlexGripper-Clamp 2.6.6. Oil stains on gripper 2.6.6. Oil stains on gripper Consequences In some cases the oil may contaminate the workpiece. Symptoms and causes Too much oil for the linear guild. Recommended actions Action Info/illustration 1. Clean up the redundant oil. 3HAC040630-002 Revision: -...
  • Page 70 2 FlexGripper-Clamp 2.6.7. Mechanical noise 2.6.7. 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 71 2 FlexGripper-Clamp 2.6.8. Workpiece drop on power down 2.6.8. 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 72 2 FlexGripper-Clamp 2.6.9. Workpiece drop on air down 2.6.9. Workpiece drop on air 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 73 2 FlexGripper-Clamp 2.6.10. No Input signal detected 2.6.10. 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 74 2 FlexGripper-Clamp 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 75 2 FlexGripper-Clamp 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 76 2 FlexGripper-Clamp 2.8. Ware part 2.8. Ware part FlexGripper Part No. Description type 1-zone 3HAC040555-001 Move plate with rubber 2-zone 3HAC040556-001 Move plate with rubber 3HAC040630-002 Revision: -...
  • Page 77 2 FlexGripper-Clamp 2.9. Spare parts 2.9. Spare parts 1-zone FlexGripper en1016001 Continues on next page 3HAC040630-002 Revision: -...
  • Page 78 2 FlexGripper-Clamp 2.9. Spare parts Continued en1016001 Continues on next page 3HAC040630-002 Revision: -...
  • Page 79 Description Note / Dimension 3HAC040415-001 Flange plate for 460 Product in IRB 460 3HAC040417-001 Flange plate for 660 Product in IRB 660 3HAC040416-001 Shaft fitting for 460 Product in IRB 460 3HAC040418-001 Shaft fitting for 660 Product in IRB 660 3HAC038579‐001...
  • Page 80 2 FlexGripper-Clamp 2.9. Spare parts Continued Part No. Description Note / Dimension 3HAC040801‐001 basic module 3HAC040802‐001 terminal module 3HAC040803‐001 pipe joint 3HAC040804‐001 solenoid valve 3HAC040805‐001 socket 3HAC040806‐001 Quick twist joint  3HAC040807‐001 muffle 3HAC040808‐001 quick connector 3HAC040809‐001 quick connector 3HAC040810‐001 sealed valve 3HAC040811‐001 quick connector 3HAC040812‐001 quick connector 3HAC040813‐001 quick connector(plastic) 3HAC040820‐001 magnetic proximity switchs  3HAC039438‐001 Gripper terminal box unit 3HAC040872‐001...
  • Page 81 2 FlexGripper-Clamp 2.9. Spare parts Continued 2-zone FlexGripper en1016001 Continues on next page 3HAC040630-002 Revision: -...
  • Page 82 2 FlexGripper-Clamp 2.9. Spare parts Continued en1016001 Continues on next page 3HAC040630-002 Revision: -...
  • Page 83 Description Note / Dimension 3HAC040415-001 Flange plate for 460 Product in IRB 460 3HAC040417-001 Flange plate for 660 Product in IRB 660 3HAC040416-001 Shaft fitting for 460 Product in IRB 460 3HAC040418-001 Shaft fitting for 660 Product in IRB 660 3HAC040429‐001...
  • Page 84 2 FlexGripper-Clamp 2.9. Spare parts Continued Part No. Description Note / Dimension 3HAC040801‐001 basic module 3HAC040803‐001 terminal module 3HAC040804‐001 pipe joint 3HAC040805‐001 solenoid valve 3HAC040806‐001 socket 3HAC040807‐001 Quick twist joint  3HAC040808‐001 muffle 3HAC040809‐001 quick connector 3HAC040810‐001 quick connector 3HAC040811‐001 sealed valve 3HAC040812‐001 quick connector 3HAC040812‐001 quick connector 3HAC040813‐001 quick connector(plastic) 3HAC040820‐001 magnetic proximity switchs  3HAC039438‐001 Gripper terminal box unit 3HAC040872‐001...
  • Page 85 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 8;7 11;7 8;7 9;8 11;7 12;8...
  • Page 86 Continued FlexGripper-Clamp 1 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 3HAC040149-003-8 Continues on next page 3HAC040630-002 Revision: -...
  • Page 87 Continued FlexGripper-Clamp 1 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 3HAC040149-003-9 Continues on next page 3HAC040630-002 Revision: -...
  • Page 88 Continued FlexGripper-Clamp 1 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 3HAC040149-003-20 Continues on next page 3HAC040630-002 Revision: -...
  • Page 89 2.10.1. Electrical circuit Continued FlexGripper-Clamp 1 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 15;6 -DI_CLAMP_OPEN 15;6 -DI_CLAMP_CLOSE 15;6...
  • Page 90 Continued FlexGripper-Clamp 2 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 3HAC040149-003-11 Continues on next page 3HAC040630-002 Revision: -...
  • Page 91 Continued FlexGripper-Clamp 2 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 3HAC040149-003-12 Continues on next page 3HAC040630-002 Revision: -...
  • Page 92 Continued FlexGripper-Clamp 2 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 3HAC040149-003-23 Continues on next page 3HAC040630-002 Revision: -...
  • Page 93 2.10.1. Electrical circuit Continued FlexGripper-Clamp 2 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 18;6 -DI_CLAMP1_OPEN 18;6 -DI_CLAMP1_CLOSE 18;6...
  • Page 94 2 FlexGripper-Clamp 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 95 2.10.1. Electrical circuit Continued DRESSPACK IRB460 only for FlexGripper-Clamp 1 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...
  • Page 96 2.10.2. Pneumatic circuit 2.10.2. Pneumatic circuit FlexGripper-Clamp 1 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_PRE1 -AIR_RET1 3HAC040149-003-22...
  • Page 97 2.10.2. Pneumatic circuit Continued FlexGripper-Clamp 2 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_PRE2 11;7 -AIR_RET2 12;8...
  • Page 98 2 FlexGripper-Clamp 2.10.2. Pneumatic circuit 3HAC040630-002 Revision: -...
  • Page 99 3 FlexGripper UI 2.10.2. Pneumatic circuit 3 FlexGripper UI 3HAC040630-002 Revision: -...
  • Page 100 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 101 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 102 3 FlexGripper UI 3.1.2. I/O signal configuration 3.1.2. I/O signal configuration FlexGripper-Clamp 1 signal configration I/O signal I/O board Controller Electric box Signal DO1001(DO10_01_ClampC XT5.1.1 ylinder1_Open) DO1002(DO10_02_ClampC XT5.1.2 ylinder1_Close) Spare XT5.2.1 Spare XT5.2.2 DO1005(DO10_05_HookCyl XT5.2.3 inder1_Open) DO1006(DO10_06_HookCyl XT5.2.4 inder1_Close) Spare XT5.1.9 Spare XT5.1.10...
  • Page 103 3 FlexGripper UI 3.1.2. I/O signal configuration Continued DO1001(DO10_01_ClampC XT5.1.1 ylinder1_Open) DO1002(DO10_02_ClampC XT5.1.2 ylinder1_Close) DO1003(DO10_03_ClampC XT5.2.1 ylinder2_Open) DO1004(DO10_04_ClampC XT5.2.2 ylinder2_Close) DO1005(DO10_05_HookCyl XT5.2.3 inder1_Open) DO1006(DO10_06_HookCyl XT5.2.4 inder1_Close) DO1007(DO10_07_HookCyl XT5.1.9 inder2_Open) DO1008(DO10_08_HookCyl XT5.1.10 inder2_Close) DI1001(DI10_01_ClampCyli XT5.1.11 nder1_Opened) DI1002(DI10_02_ClampCyli XT5.1.12 nder1_Closed) DI1003(DI10_03_ClampCyli XT5.1.3 nder2_Opened) DI1004(DI10_04_ClampCyli XT5.1.4...
  • Page 104 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 105 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 3HAC040630-002 Revision: -...
  • Page 106 3 FlexGripper UI 3.2.2.1. FlexGripper function test 3.2.2. Tool handle 3.2.2.1. FlexGripper function test FlexGripper-Clamp (FlexGripper-Clamp 1) function test Touch the Tool handle button, the following interface shows. en1011053 You can operate the functions displayed to check if the corresponding signals status is correct. The functions displayed are Clamp open, Clamp close, Hook open and Hook close.
  • Page 107 3 FlexGripper UI 3.2.2.1. FlexGripper function test Continued NOTE! After entering the main interface and touching any of the buttons, a warning message shows prompting converting to manual mode. Switch the control mode from auto mode to manual mode, the operations are now available. Touch Back to Main button, the interface returns to the main interface.
  • Page 108 3 FlexGripper UI 3.2.2.1. FlexGripper function test Continued Users can operate the functions displayed and check if the corresponding signals status is correct. With the Clamp zone dropdown list, users can choose Zone1, Zone2 or Both zones to do the corresponding function test. Function and signal status table (FlexGripper-Clamp 2) Func- Function...
  • Page 109 3 FlexGripper UI 3.2.2.1. FlexGripper function test Continued Func- Function Action description Signal status tion type name Both Clamp open Both clamp cylinders pull out and DO10_01_ClampCylinder zones both clamps open. 1_Opened DO10_03_ClampCylinder 2_Opened turn to 1 and lights up Clamp close Both clamp cylinders pull back DO10_02_ClampCylinder...
  • Page 110 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 111 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 112 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 113 3 FlexGripper UI 3.2.2.2. TCP edit Continued Default TCP of FlexGrippers FlexGri pper Default TCP value Default TCP location illustration type FlexGrip [TRUE, [[0,0,551], [1,0,0,0]], per- [39.7, [-15.5,-3.7,167.5], Clamp 1 [1,0,0,0],0,0,0.973]] en1011078 FlexGrip [TRUE, [[0,0,539], [1,0,0,0]], per- [74.9, [-18,-7.7,180.8], Clamp 2 [1,0,0,0],6.152,0.557,7.603]] en1011079 NOTE!
  • Page 114 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 115 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 116 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 117 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-Clamp, after entering the Test run interface, the following interface shows: en1011065 Continues on next page...
  • Page 118 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 119 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 120 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 3HAC040630-002 Revision: -...
  • Page 121 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 122 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 123 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 124 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 125 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 126 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\Sys- par\Clamp\EIO.cfg. 3HAC040630-002 Revision: -...
  • Page 128 ABB Robotics S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592...

This manual is also suitable for:

Irb 460