ABB Commissioning A New Robot

This blog post aims to provide you with a step-by-step tutorial to follow when commissioning a brand new robot.

 

Initial Backup

The first step is to create a backup of the initial state. To do so, you can use RobotStudio or the Teach Pendant.

On RobotStudio, connect to the robot then select "Create Backup" from the Controller tab.

On the Teach Pendant, open the menu then select "Backup and Restore". You can save the backup onto a usb key.

This will save a backup that can later be used for restoring your robot to its original state if you mess with something.

 

Checking the 0 Mark on Each Joint

Ensuring proper calibration of the axes is an important step. It would be unfortunate to invest effort in other aspects only to discover later that the calibration is incorrect.

• Jog each axis to approximately 0 degree.

• Check the zero marks on the robot.

If an axis position deviates significantly from the zero mark, calibration becomes necessary. Fortunately, this process is relatively simple. 

• Jog each axis to their zero mark.

• Open the menu. Select "Calibration".

• Click on "ROB_1".

• Click on "Manual Method (Advanced)".

• On "Rev. Counters" tab, click on "Update Revolution Counters...".

• Next, proceed to update the revolution counters for all axes or solely for the one that was not within the desired range.

Loading the Program

Follow this blog post to load the program : ABB Robot Tutorial : Load Program to the Robot.

 

Inputs & Outputs

Once the program is loaded, configuring and checking inputs and outputs is necessary.

• Set up the local IO device.
• Adjust fieldbus settings for IO communication with the PLC.
• Perform tests on local IO and remote IO to check that everything is mapped properly. 

 

Defining Tool Data

If you have already defined tool data (geometry, mass, center of gravity) in your program, you can skip this step.

Otherwise, it's time to do it.

If all these informations are already known, input the revelant values into the tooldata. 

If you don’t know the Tool Center Point (TCP), you can follow a procedure on the Teach Pendant to teach it.

• Open the menu. Select "Program Data".

• Select "tooldata".

• Select the tool, then "Edit" and "Define".

•  Choose a method, then teach the tool frame. Look at the manuals for more informations about teaching methods.

If the mass or center of gravity is unknown, particularly when dealing with a heavy tool, you have the option to utilize the automated load identification feature.

To start this procedure:

• Open the menu. Select "Program Editor".
• Click on "Debug", then "Call Routine...".

• Choose "LoadIdentify".

• Start this routine and follow the instructions.

 

Teaching Frames

It’s time to defines the work objects of your application.

Install the reference tool on the robot’s wrist, then follow these steps for each frame.

• Open the menu. Select "Program Data".
• Select "wobjdata".
• Select the work object, then "Edit" and "Define".

•  Choose user or object method, then teach the 3 points to define Origin, X-axis and Y-axis point.

Lastly, jog the robot with this frame selected to check that the robot moves according to the frame.  

 

Teaching Positions

First, teach general positions of your application (home, maintenance, etc.).
Then teach every position specific to your application (pick-up, drop-off, etc.).

 

Adjusting Trajectories

While in manual mode, navigate the Program Pointer through each motion routine. Utilize the step-by-step button to carefully examine the trajectories. If needed, make adjustments to waypoints or offsets.

 

Worldzones

If this option is installed in the robot, you need to define and check the worldzones.

Verify that the output values are adjusted to match the robot's position in relation to the defined zones.

 

Auto Mode at Low Speed

Set a very low speed and initiate program execution in automatic mode using the PLC.  Keep the Teach Pendant close to you to halt the robot or modify the speed as needed. 

 

Optimization

To improve cycle time, you can adjust trajectories, speed and smoothing.

To simplify you can :

• Reduce offset values when entering or exiting the part.
• Change speed.
• Adjust zone data.
• Use MoveJ instead of MoveL whenever feasible.
• Improve the handshakes with the PLC to avoid downtime.

Final Backup

Once everything is set up, you can make a final backup.