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System DescriptionArc Welding Products
IRC5M20043HEA801213-001 Rev. A 2005-05
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© 2005 ABB Automation Technologies AB
ABB Automation Technologies ABArc Welding Products
SE-69582 LaxåSweden
3HEA801213-001 Rev. A 2005-05 i
Contents
System Description 3HEA801213-001 Rev. A 2005-05
1 System Description 1
1.1 General 1
1.2 Welding robot system 2
1.3 Control systems adapted for peripheral equipment 31.3.1 Variants 31.3.2 Single robot systems 41.3.3 Multiple robot system 6
1.4 Robot with welding equipment 71.4.1 Welding power source 81.4.2 Welding torches 91.4.3 Torch service units 101.4.4 Sensors 10
1.5 IRBP positioner 11
1.6 Travel Track for robot 14
1.7 Operator panel 15
1.8 Safety equipment 161.8.1 Safety functions 16
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System DescriptionGeneral
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1 System Description
1.1 GeneralThis document describes ABB’s standard assortment of arc-welding robot systems. The document is included in the System Manual (binder) supplied with the welding robot system. The System Manual corresponds to the system ordered by the customer and contains detailed descriptions of the component products.
System Description
Welding robot system
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1.2 Welding robot system
Delivery
The welding robot system is delivered in its standard design in sections. Everything included in the delivery is fitted to the respective sections.
Example
The component parts that can make up a welding robot system are described below.
Figure 1 Complete welding robot station with robot
Item Name
1 Positioner
2 Safety equipment
3 Robot, wire feed, welding torch and hose bundle
4 Welding power source
5 Robot Controller
6 Operator panel
7 Travel track (not shown, see Figure 6)
Accessories: cooling unit, mechanical torch cleaning unit, wire cutter, unit for checking TCP (Tool Center Point), joint locator and joint tracker
1
3 4
5
6
2
System DescriptionControl systems adapted for peripheral equipment
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1.3 Control systems adapted for peripheral equipment
Description
The control system is used to control the robot, welding equipment, positioner, safety equipment and all other peripheral equipment.
1.3.1 Variants
The IRC5 control system is complemented with control equipment for positioners, welding equipment and safety equipment. The control system consists of:
• One control module (CM).
• One or more drive modules (DM). The total number of drive modules depends on the total number of robots in the system.
• A process module is included in systems that have:
The product is produced for the following robot types:
• IRB 1400/1600/2400, AW design.
Control systems for robot are described in the product manual Robot ControllerControl systems for peripheral equipment are described in the product manual: Control Equipment for Positioner/Welding Equipment/Safety Equipment.
1. Multiple robots systems with A314E/A316E/A324E-L welding equipment.
2. Single robot systems with welding equipment and AWC joint tracking equipment.
System Description
Single robot systems
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1.3.2 Single robot systems
Single robots systems with A314E/A316E/A324E-L welding equipment and positioner
Example
Figure 2 Overview of single robot system
Item Name Item Name
1 Control module (CM) 3 Positioner
2 Drive module 1 (DM1) 4 Robot
1
2
3 4
System DescriptionSingle robot systems
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Single robot system with welding equipment, positioner and AWC
Example
Figure 3 Overview of single robot system with AWC
Item Name Item Name
1 Process module (PM) 4 Positioner
2 Control module (CM) 5 Robot
3 Drive module 1 (DM1)
1
3
4 5
2
System Description
Multiple robot system
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1.3.3 Multiple robot system
Multiple robots system with A314E/A316E/A324E-L welding equipment and positioner
Figure 4 Overview of multiple robot system with two robots
Item Name Item Name
1 Control module (CM) 5 Positioner
2 Drive module 1 (DM1) 6 Robot 1
3 Drive module 2 (DM2) 7 Robot 2
4 Process module
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2
3 4 5
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7
Robot with welding equipment
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1.4 Robot with welding equipment
Arc-welding
In an arc-welding robot system, an IRB1400, IRB1600 or IRB2400 robot is normally used. In certain systems, other types can be included, such as welding, handling or machining robots.In an arc-welding system, the robot is equipped with welding equipment consisting of the following units.
Example
Figure 5 IRB 2400 with installed welding equipment
Item Description Item Description
1 Welding power source 5 Insulator/Collision sensor (option)
2 Welding gun 6 Wire cutter
3 Hose bundle 7 TCP calibration unit
4 Wire feed equipment 8 Torch cleaner
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2
8
6
7
Welding power source
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1.4.1 Welding power source
The following power source standard alternatives are available:
Description Illustration
RPB 320/420/520
LRC 430
TPS 4000/5000 Fronius
MigRob 500
Other power sources can be connected to the system, e.g., LAF 635.
Welding torches
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1.4.2 Welding torches
The following welding torch standard alternatives are available:
Description Illustration
PKI 250/500/630/300 SPKI 250/500/630/300 D
PSF 315/500MPSF 315/500ME
WH Binzel
1. Collision sensor (option)
1
Torch service units
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1.4.3 Torch service units
The following torch service unit standard alternatives are available:
1.4.4 Sensors
The following sensor standard alternatives are available:
Description Illustration
TSC Torch Service Center, based on the TC96/TSC Torch Service Center, based on the BRS-LC, consisting of:1. Torch cleaner2. Wire cutter3. TCP calibration unit
• Component parts can be purchased separately.
2
3
1
Description
Joint locator
• SmarTac
• Touch sense (for Fronius only)
Joint tracker
• AWC
IRBP positioner
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1.5 IRBP positioner
Description
A positioner is used to position work pieces optimally for welding joints and robots. The IRBP positioner is equipped with maintenance-free AC motors with electro-magnetic brakes.
• The numbers in the positioner name indicate maximum handling capacity.
• The letters in the positioner name indicate the positioner type.
The following positioner type standard alternatives are available:
Description Illustration
IRBP 500/1000C
IRBP 250/500C Index
IRBP positioner
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IRBP 250/500/750/2000/5000L
IRBP 250/500/750K
IRBP 250/500/750R
Description Illustration
IRBP positioner
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IRBP 250/500/750A
IRBP 250/500/750B
IRBP 250/500D
Description Illustration
Travel Track for robot
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1.6 Travel Track for robot
Description
A Travel track is used to position a robot at different work stations or within a large work area.
Figure 6 Travel track
Item Description
1 Travel track, Bobin 3.7m
2 Travel track, Marathon 3.7m
Travel length
1.7m 7.7m
2.7m 8.7m
3.7m 9.7m
4.7m 10.7m
5.7m 11.7m
6.7m 12.7m
1
2
Operator panel
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1.7 Operator panel
Operator communication
There is an operator panel with a number of button functions to enable the operator to communicate with the arc-welding system. The following operator panel standard alternatives are available:
Description Illustration
Operator panel for one work area
Operator panel for two work areas
Safety equipment
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1.8 Safety equipmentFor personnel to work safely with an arc-welding robot system, the system must be equipped with a number of safety components, which are integrated into the control cabinet’s safety system.
1.8.1 Safety functions
Safety functions
Working area surveillance with light barriers
Time resetting for light barriers
Working area indication for:
• Robot or track motion
• Positioner
Gate surveillance
Reset unit for gate surveillance
Figure 7 Welding robot station with safety equipment
3HEA801213-001 Rev. A 2005-05
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