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Just like with a newly purchased mobile phone, the first thing we do isn't to make calls, but to install the apps we need. The same applies to industrial robots, but their installation and setup are far more complex than those of a mobile phone.
Based on relevant technical manuals, and taking the ABB palletizing robot as an example, we will introduce 13 steps for the installation and commissioning of industrial robots.
1
Installing robots
Before installing the robot, first check that all parts are intact and inspect the robot visually to ensure it is undamaged. Then install the control cabinet and use a forklift or crane to lift the robot body. Finally, connect the robot body to the control cabinet. The connection between the robot and the control cabinet mainly involves connecting the motor power cable, the speed counter cable, and the user cable.
control cabinet
2
Set language
When you power on the device for the first time, the default language is English. You need to change it to Chinese for easier operation.
1. Click the "ABB" icon in the upper left corner.
2. Click "Control Panel"
3. Click "language"
4. Select "Chinese" and click "OK".
5. After selecting "Yes", wait for the robot to restart. The language setting is now complete.
Teach pendant main interface
3
Backup and restore
Regularly backing up the robot is a good habit to ensure its normal operation. Backup files can be stored on the robot's internal storage or backed up to a USB drive.
Backup files contain running programs and system configuration parameters. When the robot system malfunctions, the backup file can be used to quickly restore the robot to its previous state. It is essential to perform backups before making any program changes. It is important to note that backup data is unique; backup data from one robot cannot be restored to another.
4
calibration
Each joint axis of an ABB robot has a mechanical origin position. The rotation counter needs to be updated to update the mechanical origin position in the following situations:
1. After replacing the battery in the servo motor speed counter
2. When the speed counter malfunctions, after repair...
3. After the speed counter is disconnected from the measuring plate
4. After the power was cut off, the robot's joint axes moved.
5. When the system alarm prompts "10036 RPM counter not updated"
5
System I/O configuration and wiring
The following is an explanation using the electrical schematic diagram of a certain gripper wiring.
The schematic diagram of the robot signal input section shows that there are 704 bits of 24V+ and 703 bits of 24V-. The input signals are from five positions: gripper start position, gripper end position, pressure plate end position, gripping roller ready, and pallet ready.
The first three are detection signals from the cylinder magnetic switch, and the last two are signals transmitted from the PLC to the robot indicating that the large bag and pallet are ready. In order to achieve electrical isolation, the level signal from the PLC to the robot needs to be converted into the robot's own level, which needs to be achieved through a relay.
The schematic diagram of the output section is as follows, which also has five outputs: gripper solenoid valve, pressing solenoid valve, gripping completion signal, palletizing completion signal, and robot operation signal.
Typically, the DSQC652 communication board provides us with a communication interface, with each interface corresponding to an input or output.
The diagram shows the DSQC652 communication board. It has two rows of terminals on the top and bottom, containing 16 digital inputs and 16 digital outputs. Each interface corresponds to an address. For example, X1.1 corresponds to digital output address 0 (do0), X1.2 corresponds to digital output address 1 (do1), X3.1 corresponds to digital input address 0 (di0), X3.2 corresponds to digital input address 1 (di1), and so on. Terminal 9 of each terminal block connects to line 703 (COM), and terminal 10 connects to line 704 (+24V).
First, we need to configure a unique name for each of the five input signals and five output signals in the robot control system, used within the robot program. For example, the gripper start bit is di0JiaZhuaStart, and the gripper end bit is di1JiaZhuaEnd. Since the program cannot recognize Chinese characters, these signals must also be combinations of letters and numbers. Then, we need to map these names to the physical addresses of our communication board.
1. Configure I/O units
1) Click Control Panel
2) Click Configuration
3) Click "Theme" and confirm that I/O has been selected.
4) Select Unit
5) Select "Show all"
6) Select "Add"
7) Set the value
8) Click the scroll down arrow
9) Set the DN address according to the line.
10) Click "OK", then click "Yes".
2. Set the digital input di1
1) Select "Signal" in the configuration.
2) Select "Show all"
3) Select "Add"
4) Set the value, click "OK", then click "Yes".
Simply follow the steps above to change di1 to di0JiaZhuaStart.
Once all signals have been configured, connect the corresponding signal lines to the communication board.
In addition, there is another communication method between the robot and the PLC: PROFIBUS.
1. Click "ABB" on the main touchscreen screen.
2. Click "Control Panel"
3. Click "Configuration"
4. Click "Bus"
5. Click "Add" to enter the add page and modify the parameters.
6. After returning to the I/O page from step 3, click "Unit Type".
7. Locate "DP_INTERNAL_SLAVE_FA" and click to enter.
8. After entering the product ID number, scroll down to find "Input Size" and "Output Size," and change both to 64. Click OK. If a pop-up window asks "Restart now?", click "No" and wait for the configuration to complete before restarting.
9. After returning to the I/O page from step 3, click "Unit", create a new "profibus1" unit, and modify the parameters.
10. After returning to the I/O page in step 3, click "Signal" to enter the interface for configuring each I/O signal. The parameter design is basically similar to that of di1 above; simply change "Assigned to Unit" to "profibus1".
6
Check signal
1. Click the "ABB" icon to enter the system menu.
2. Click "Input/Output" to monitor the I/O signals. 0 indicates no signal, and 1 indicates a signal. Check if the configured signals correspond correctly to the actual signals.
3. doGripperA and doGripperB represent the robot's two gripper cylinders. Click on one of them.
4. Click 0 or 1 again to change the clamp status, force the clamp to open and close, and check if the solenoid valve wiring is incorrect.
7
Import program
1. Click the "ABB" icon, select "Program Editor", and then click "Modules".
2. In the module interface, select "Load Module" to load the required program module from the path where program modules are stored. Modules are usually stored in the PROGMOD folder and can be opened with Notepad.
8
Workpiece coordinate system setting
1. Robot's coordinate system
Setting the workpiece coordinates is a prerequisite for teaching; all teaching points must be established within the corresponding workpiece coordinates. If teaching points are established on WOB J0, all points must be re-taught after the robot moves the robot. If teaching points are established on the left side of the corresponding workpiece, only the workpiece coordinates need to be modified, without re-teaching all points.
2. The necessity of correctly setting workpiece coordinates
Inaccurate workpiece coordinates make it difficult for the robot to move in the X/Y directions on the workpiece.
3. Set coordinates
1) Create a wobj1 project on the teach pendant.
2) Define workpiece coordinates
3) Verify the accuracy of workpiece coordinates
9
Comparison with reference point
1. Click the "ABB" icon to enter the main system interface, then click "Program Data".
2. Click “robtarget”
3. Select the workstation that needs to be modified. pPick1 and pPkck2 correspond to the basic positions of workstation 1 and workstation 2, respectively.
4. After clicking on the workstation, a drop-down menu will appear. Select "Edit," and then select "Modify Position" from the edit options. After modification, the robot will automatically record the new position.
10
Adjust parameters
1. Fine-tune the length, width, and height of the cardboard box.
If the newly arrived cartons have slight changes that affect the stacking effect, or if the carton packing effect is not very good, adjustments need to be made.
1) Click the "ABB" icon to enter the main system interface, then click "Program Data".
2) Click "num" and find the three variables "nBoxH", "nBoxW", and "nBoxH". They correspond to the length, width, and height of the cardboard box, respectively.
3) Click on the variable you want to modify and enter the value.
4) After making the changes, click "OK" and then "OK Input".
2. Modify the number of cardboard boxes that have already been stacked.
This adjustment may be necessary after the robot malfunctions and the cardboard boxes have been sorted.
1) Click the "ABB" icon to enter the main system interface, then click "Program Data".
2) Click "ncount" to enter the array. Components {1} and {2} correspond to the number of items already stacked at workstations 1 and 2, respectively. Click the corresponding value to modify it.
3. Fine-tune the gripping position
1) Click the "ABB" icon to enter the main system interface, then click "Program Data".
2) Click “robtarget”
3) Select the workstation that needs to be modified. "pPick1" and "pPick2" correspond to the basic positions of workstation 1 and workstation 2, respectively.
4) Locate and modify the x, y, and z parts.
4. Fine-tune the placement of palletizers
After setting the position of each reference point, some fine-tuning may be needed during the stacking process. This adjustment can only be done manually.
1) Click the "ABB" icon to enter the main system interface, then click "Program Editor".
2) Click "Modules" at the top, find the program module that stores the palletizing address, click "Show Modules," and find the program location where the number of packages to be changed is located.
3) Select the part that needs to be adjusted, then click "Edit" below, and then click the "ABC..." button to enter the modification interface.
4) Enter the information directly on the keyboard and click "OK" when finished. After making changes, be sure to check for any errors. Before starting automatic palletizing, always run a low-speed test run to ensure safety.
11
Manual debugging
1. Set button 4 on the controller panel to manual mode, which is the middle position of the three-position switch.
2. Click "ABB" > "Program Editor" to enter the program editor.
3. Click "Move PP to Main"
4. Reduce the robot's speed to a very low level.
5. Press and hold the enable controller.
6. Press the "Start" button to begin.
During the debugging process, if a problem is found, the robot will stop immediately when the controller is released.
12
Automatic operation
It can only run automatically after debugging is complete and without errors, and the speed must be set to a low level in the early stages.
1. Switch 4 on the control panel to automatic mode.
2. Click "Confirm" once (if the speed is 100%, it will only confirm once). Pay close attention to the robot speed settings, especially during debugging. It is recommended to manually debug the entire palletizing cycle first, and then start automatic operation at a slightly slower speed.
3. If a fault is found, identify and repair it.
4. Press button 3 on the control panel. If everything is normal, the white indicator light will illuminate, and the TP display will show that the motor is on.
5. Press the start button to start the robot. The robot will then continue following the program from where it stopped last time.
6. To start the program from the beginning, move the motor "PP" to "Main" and press the start button again.
7. Pressing the pause button will stop the robot from running. The motors will still be running. Pressing the start button will resume the robot's operation.
Note: If the motor "PP moves to Main" while paused, the number of stacked items and the stacking position calculation information will be cleared. When running again, the robot will start from the main program again, and you will need to re-enter the number of stacked items.
13
Precautions
1. Before powering on, ensure that the power supply wiring is correct, secure, and effectively grounded.
2. The teach pendant must be powered off before plugging and unplugging.
3. After a power outage and restart, be sure to wait approximately one minute after the device has completely shut down before starting it to prevent data loss.
4. After modifying the program content, be sure to review it again.
5. After modifying the palletizing position, parameters, etc., you must first manually run the program at low speed, and then run it automatically.
Make sure to back up your data before making any changes.
After completing all the above steps, you can test the effectiveness through on-site inspections and even during delivery! If the test results are off, you'll need to find the cause, and you can ask an experienced technician for help. After all, robot debugging is highly dependent on the experience and technical skills of the debugger. Let's work together to become debugging masters as soon as possible!
