ABB IRC5机器人说明书 英文版

ABB IRC5机器人 说明书 房屋状态说明书下载罗氏说明书下载焊机说明书下载罗氏说明书下载GGD说明书下载 英文版 IRC5 Basic Operation And Programming Training IRC5 Basic Operation and Programming Training ABB Engineering(Shanghai)Ltd. 1 IRC5 Basic Operation And Programming Training Content 1Overview…………………………………………………………………………………………5 2Safety and environment protection…………………………… …………………………………6 3General……………………………………………………………………………….……………7 3.1 IRC5System……………………………………………………………………………………………….7 Consist of the system……………………………………………………………………………….…….8 4Start the controller…………………………………………………..………………………… ..10 4.1Buttons on the Control module………………………… ………….… …………………. ...10 4..2Buttons on the Drive module……………………………… ……………………………….12 4..3Start the controller…………… ……………………………………………………………..13 5Shut down the controller…………………………………………………………………… ..14 6FlexPendant…………………………………………………………………………………… ...15 6.1Buttons on the flexPendant……………………………………………………… ………….16 6.2 The ABB Menu……………………………………………………………………………………….…17 6.3 Close Button…………………………………………………………………………….....18 6.4 Task Bar……………………………………………………………………………….......19 6.5 Status Bar……………………………………………………………………………….....20 6.6 The Quickset menu………………………………………………… …………………. .....20 6.7 Soft keyboard……………………………………………………… ……………………...21 6.8 Scrolling and Zooming…………………………………………………… ……………......21 7Jogging the robot using the joystick……………………………………… …………………….23 8Precise positioning………………………………………………………………..……………...29 8.1Incremental movement………………………………………………………...………………………….29 9load a program…………………………………………………………………………………...31 9.1Load an existing program………………………………………………………...………………………..31 9.2Start and test a program in Manual mode………………………………………...………………………..31 10Stopping the program……………………………………….………………………………….38 11Running a program in Automatic mode……………………………………….……………….39 12Rapid Programming Rapid……………………………………………………………….…….41 12.1Consist of the program…………………………………………………………………………………...41 12.2Basic Movement Instruction…………………………………….…………………………...42 12.3Input/output Instructions………………………………………………………………………………..45 12.4Communication Insruction………………….…………………………………………………………..46 12.5Program Flow Control Instruction………………………………..……………………………………..46 12.6Other Common Instruction……………………………………..………………………………………..47 13Editing a program………………………………………………………………………………48 13.1Modify positions(tune with motions)………………………………………………...……….48 13.2Editing instruction arguments…………………………………………………………….....49 13.3Adding instructions……………………………………………………………………........52 13.4Programming a delay...………………………………….……………...…………………..54 2 IRC5 Basic Operation And Programming Training 14I/OSignals……………………………………………………………………………….……...57 14.1Programming and I/O instruction…….…………………………………………...……….…57 15Event Log……………………………………………………………………………………….60 15.1What is a log?…………………………………...………..…………………………………60 15.2 What is an event?....................................................................................................................60 15.3 What is an event message?.......................................................................................................60 15.4 What is an information message?...............................................................................................61 15.5 What is a warming?.................................................................................................................61 15.6 What is an error?....................................................................................................................61 15.7 What is an acknowledge?........................................................................................................61 15.8Open and close the event log?....................................................................................................61 15.9View a message?.....................................................................................................................62 16Emergency stop...………………………...……………………………………………………..64 17Operational modes………………………………………………………..………….…………65 17.1What is the manual mode?……………………………………………………………………65 17.2Manual mode 100%(Option，testing mode)…………………………………………………....65 17.3Automatic mode(production mode)………………………...………………………...………..66 18Maintenance……………………………………………………………………………...……..69 18.1Manipulator.……………………………………………………………………...……...….69 18.2Controller………………………………………………………………………………..…..69 18.3Other…………………………………………………………………………...…......…….69 3 IRC5 Basic Operation And Programming Training 1Overview 4 IRC5 Basic Operation And Programming Training 2 Safety and environment protection 5 IRC5 Basic Operation And Programming Training 3 General 3.1 IRC5 System 6 IRC5 Basic Operation And Programming Training 3.2 Consist of the system Part A---Manipulator PartB1---Control Module, IRC5, containing the control electronics of the robot system Part B2---Drive Module, IRC5, containing the power electronics of the robot system Part C---RobotWare CD, containing all robot software Part D---Documentation CD (option) Part E---Robot system software, being run by the robot controller. The system has been loaded into the controller from the server on the local area network. Part F---RobotStudioOnline PC software installed on PCx. RobotStudioOnline is used for loading the RobotWare software to the server as well as configuring the robot system and then loading the complete robot system into robot controller. Part G---Calibration data diskette for systems running the Absolute Accuracy option 7 IRC5 Basic Operation And Programming Training only. Calibration data for systems without this option is normally delivered on the Serial Measurement Board(SMB). Part H---FlexPendant, which is connected to the controller. Part J---Sever on network( not included in the delivery). This may be used for manually storing. Part PCK---RobotWare -complete robot system -documentation files In this context, the sever may be considered as a storage unit used by the PCx, and may even be the same unit! The server may be disconnected when not transferring data between the server and controller. Part M---RobotWare license key. The original key string are printed on two pieces of paper (one for the Control Module and one for the Drive Module) delivered inside the drive module. If ordered, the RobotWare license key is installed on delivery, so no further actions are required to get the system running. Part N---Serial Measurement board (SMB) handing resolver data and storing calibration data. For systems not running the Absolute Accuracy option, the calibration data is stored on the SMB on delivery. PCx PC(not included in the delivery), may even be the same unit as the sever J, shown above! The PC may be disconnected when not transferring data between the sever and controller! 8 IRC5 Basic Operation And Programming Training 4 Start the controller 4.1 Buttons on the Control module A---Main power ON/OFF B---Emergency stop C---Motor Enable/Disable ---Mode switch D Emergency stop: The robot stops-regardless of which state or mode the system is in-immediately when the emergency stop button is pressed. The button remains pressed in and, to turn to MOTORS ON again, must be returned to its original position. Motor Enable/Disable: In the MOTORS ON state, the motors of the robot are activated and the MOTORS ON button is continuously lit. Continuous light: Ready for program execution Fast flashing light: The robot is not calibrated or the revolution counters are not updated. The motors have been switched on. Slow flashing light: One of the safeguarded space stops is active. The motors have been switched off. 9 IRC5 Basic Operation And Programming Training Mode switch Function Info/Illustration A Two position mode switch B Three position mode switch C Automatic mode Used when running ready-made programs in production. It is not possible to move the robot with the joystick in this mode. D Manual reduced speed mode In manual mode the robot can only move in a reduced and safe speed, and only under manual control. You need to press the enabling switch to activate the robot’s motors. The manual mode is most often used when creating programs and when commissioning a robot system. E Manual mode 100% Use full speed manual mode when the program is to be tested in more natural conditions than the reduced speed that the manual mode offers, for instance to test synchronization between the robot and a conveyor or other external. The full speed manual mode allows you to run the program in full speed while still having access to all the available debugging functions of the program editor. 10 IRC5 Basic Operation And Programming Training 4.2Buttons on the Drive module 11 IRC5 Basic Operation And Programming Training 4.3 Start the controller Start the system in manual mode when there is no process or program to be resumed or started or when you need to perform operations not possible in automatic mode such as program editing and jogging. Step1---Set the mode switch in the manual mode reduced speed position. Step2---Turn on the main power by setting the switch in the on position. Step3---After being started, the system will be in a safe standby state awaiting further action 12 IRC5 Basic Operation And Programming Training 5Shut down the controller Step1---If the program is running, stop it by pressing the Stop button on the FlexPendant. Step2---Set the mode switch in the manual mode reduced speed position. Step3---Turn off the main power by setting the switch in the off position. 13 IRC5 Basic Operation And Programming Training 6 FlexPendant The FlexPendant(occasionally called TPU, or teach pendant unit) is a device for handling many of the functions involved with operating the robot system: running programs, jogging the manipulator, producing and editing application programs, etc. It is connected to the controller module through an integrated cable and connector. The illustration below shows the main parts of the FlexPendant. A---Connector B---Touch screen C---Emergency stop button D---Enabling device E---Joystick F---Hold-to-run button 14 IRC5 Basic Operation And Programming Training 6.1 Buttons on the FlexPendant Hold-to-run button: The two hold-to-run buttons on the rear of the FlexPendant are used differently depending on which operational mode the system is in and what function is desired. Operational mode: Manual Mode---Normally, the hold-to-run buttons have no effect while in the Manual Mode. However, it is possible to activate the function during Manual Mode operation by setting a parameter. Manual Mode Full Speed---Pressing one of the hold-to-run buttons AND pressing the enabling switch enables running the manipulator. It may be run manually (by jogging) or automatically (execution of a program). Releasing the hold-to-run button in this mode immediately stops manipulator movement as well as program execution. When pressing it again, execution is resumed from that position. Automatic Mode---The hold-to-run buttons have no effect while in the Automatic Mode. 15 IRC5 Basic Operation And Programming Training Other hardware buttons 16 IRC5 Basic Operation And Programming Training 6.2 The ABB Menu Custom process applications may be started from the ABB menu. Each application will be listed as a menu item. Tap the ABB button to display the ABB menu: Each started application has a button in the taskbar. The buttons act as channel buttons on a radio. You tap the button to switch between the started applications. I/O Jogging Program data MAIN/Main module 17 IRC5 Basic Operation And Programming Training 6.3 Close Button The close button closes the current used window. The task bar displays quick-buttons to all opened views in the FlexPendant. 6.4Task bar 18 IRC5 Basic Operation And Programming Training 6.5 Status Bar 6.6 The Quickset menu The Quickset menu provides a quicker way to change jog properties rather than using the Jogging window. Each item of the menu uses a symbol to display the currently selected jogging property value or setting. Step1: Tap the Quickset button to access all functionality on the Quickset menu. The Quickset menu is displayed: A: Quickset button B: Mechanical unit C: Increment D: Run Mode E: Step Mode F: Speed Mode Step2: After selecting the appropriate function, changes may be introduced directly from the Quickset menu or through the Jogging button on the ABB menu. 19 IRC5 Basic Operation And Programming Training 6.7 Soft keyboard The Soft keyboard is used frequently when operating the system. The Soft keyboard works as an ordinary keyboard with which you can place the insertion point, type and correct typing errors. 6.8 Scrolling and Zooming The entire content of a screen may not be visible at the same time. To see the entire contents, you may: • Scroll up/down (and sometimes left/right) • Zoom in or out 20 IRC5 Basic Operation And Programming Training A Zoom in (larger text) B Scroll up (the height of one screen) C Scroll up (the height of one line) D Scroll left E Scroll right F Zoom out (smaller text) G Scroll down (the height of one screen) H Scroll down (the height of one line) 21 IRC5 Basic Operation And Programming Training 7 Jogging the robot using the Joystick To jog is the procedure to manually position or move robots or external axes by means of the FlexPendant joystick. You jog in manual mode. Jogging is possible regardless of what window is displayed on the FlexPendant, however you cannot jog during program execution. In most cases you select to have the robot move along straight lines in space, in a “move from point A to point B” fashion. This is called linear motion. Linear motion is relative to the selected coordinate system. Which coordinate system to select depends on what you want to do. You can also select to orient a tool for best operation performance or to move the robot axis by axis. Axis-by-axis motion is not relative to any coordinate system. You will also loose the tool orientation, which might affect any operations you would like to perform afterwards. The path you jog may not be the same path used by the robot program to move between target positions. The program will use the shortest and fastest straight or curved path possible between the two positions. If a straight or curved path will be used depends on how the operation is programmed. The selected motion mode and/or coordinate system determine the way the robot moves. In linear motion mode the tool center point moves along straight lines in space, in a “move from point A to point B” fashion. The tool center point moves in the direction of the selected coordinate system’s axes (1) Make sure that the operating mode selector is in the manual mode position. (2) Select mechanical unit. 22 IRC5 Basic Operation And Programming Training 7.2 Select mechanical Your robot system may not only consist of a single robot. There can also be other mechanical units such as work piece handlers or external axes mounted on the robot that you also want to jog. You don’t need to select what to jog if you only have a single robot. Each mechanical unit that can be jogged is represented by a symbol and a name. The symbol and name is decided when the robot system is configured. Please consult your plant or cell documentation to see which mechanical units are available in your robot system. Step 1: On the ABB menu, tap Jogging to display the jogging properties. Step 2: Tap Mechanical Unit. (A list of available mechanical units is displayed.) Step3: Tap the mechanical unit to be jogged, followed by OK. (The selected mechanical unit is used until you choose another even if you close the Jogging window.) 23 IRC5 Basic Operation And Programming Training ? TIP! Use the Quickset Menu to switch between mechanical units faster. Step 1: Tap the Quickset Menu button. Step 2: Tap the Mechanical unit button. Step 3: After tapping Mechanical unit, the following buttons are displayed: A: Mechanical unit menu button B: Selected mechanical unit C: Motion Mode Setting D: Tool Setting E: Work Object Setting F: Coordinate System Setting Step 4: Select mechanical unit. Step 5: Tap the Quickset Menu button to close the window. 7.3Select motion mode The Joystick Directions area shows how joystick axes correspond to the selected coordinate system’s axes. The significance of the joystick directions depends on what mode has been selected. 24 IRC5 Basic Operation And Programming Training ? CAUTION The Directions properties are not intended to show the direction in which the mechanical unit will move. Always try out jigging with small joystick movements so that you learn the true directions of the mechanical unit. Step 1: Tap ABB, then Jogging to display the jogging properties. Step 2: Tap Motion Mode, and then Linear followed by OK. 7.4Set up the coordinate system, the tool and the speed. The coordinate systems, used to make jogging and off-line programming easier. 25 IRC5 Basic Operation And Programming Training 7.5Jog the robot Step 1: Press and hold the enabling button halfway in. (If the enabling button is not pressed the unit’s motors will not be activated. Step 2: Move the joystick to make the mechanical unit to move. (The greater the deflection of the joystick, the faster the unit moves.) If you want to move the robot along the X axis, then move the joystick towards or from you. If you want to move the robot along the Y axis, then move the joystick to the left or right. If you want to move the robot along the Z axis, then twist the joystick to the left or right. As a safety precaution the mechanical unit can’t go faster than 250mm/s 26 IRC5 Basic Operation And Programming Training 27 IRC5 Basic Operation And Programming Training 8 Precise positioning 8.1 Incremental movement Incremental movement may be used to adjust the position of the robot. This means that each time the joystick is deflected; the robot moves one step (increment). If the joystick is deflected for one or more seconds, a sequence of steps, (at a rate of 10 steps per second), will be generated as long as the joystick is deflected. Procedure: Step 1: On the ABB menu, tap Jogging to display the jogging properties. Step 2: Tap Increment. Step 3: Select the desired function key, and tap OK. Step 4: Try operating the robot using the joystick and note how the robot moves. Step 5: Switch to continuous movement. Choose between small, medium and large increments or define your own custom size. 28 IRC5 Basic Operation And Programming Training 8.1 TIP! Use the Quickset Menu to switch between continuous and incremental movement and to select increment size faster. Fig. 7 Step 1: Tap the Quickset Menu button. Step 2: Tap the Increment button. Step 3: After tapping Increment, the following buttons are displayed: A: No movement increments. B: Small movement increments. C: Medium movement increments. D: Large movement increments. E: Movement increments to be defined by the user. Step 4: Select increment size. Step 5: Tap the Quickset Menu button to close the window. 29 IRC5 Basic Operation And Programming Training 9 Load a program A program is usually made up of three different parts, one main routine (always present), a number of subroutines and program data. Only one main routine is permitted per program. If you lode a program, that program replaces the program in the robot’s memory. When a program is loaded, the main routine will be shown on the display with the first instruction in the main routine selected. 9.1Load an existing program 1 On the ABB menu,tap Program Editor 2 Tap Task and program 3 If no program is loaded into the task,a dialog box is displayed.Tap New ifno program is available and one is to be created.Tap Loaded if apreviously written program is to be used. Aftertapping Load, a file-searching tool is displayed. 4 In order to make room for the new program,first delect any previously loaded program 5 Use the file-searching tool to locate the program file to be loaded.Then tap OK.The program is loaded and the following screen is displayed 30 IRC5 Basic Operation And Programming Training The main routine for the selected program is displayed The routine consist of different types of instruction. Such as move instruction, wait instructins.etc.Each instruction is followed by different arguments. Argumentscan, depending on their type,be changed or omitted altogether. A The name of the instruction which moves the robot linearly B Hide the values of the instruction’s position C Determines the velocity of the robot D Determines the precision of the robot’s position E Specifies which tool is active 31 IRC5 Basic Operation And Programming Training 9.2Start and test a program in manual mode You are now going to start the program you just opened.it should first be run step-by-step using reduced velocity then continuously The program consists off our motionin structions and position near the robot’scalibration position 1 switch the robot to Manual Mode 2 before starting the program move axis5 ,manually with the joystick 3 select the program to be started 32 IRC5 Basic Operation And Programming Training A Program pointer The program point(pp) indicates the instruction with which the program will start when you press one of the function keys on the FlexPendant:RUN.FWDorBWD 33 IRC5 Basic Operation And Programming Training Before we start the program we need to reduce the speed to 75% 1 Tap the Quickset Menu button 2 Tap the speed Mode button 3 After tapping Speed Mode,the following buttons are displayed: A:Actual running speed (in relation to max) B:Decrease running speed in steps of 1% C:Increase running speed in step of 1% D:Increase running speed in step of 5% E: Decrease running speed in steps of 5% F:Run at quarter speed G:Run at half speed H:Run at full speed 4Reduce the speed to 75% 5Tap the Quickset Menu button to close the window 34 IRC5 Basic Operation And Programming Training The program can now be started. Make sure that no one is inside the safeguarded space around the robot 1 press the enabling device on the FlexPendant 2 press the function key FWD(step-by-step program execution forward) 3 Go through all the program instructions step by step.pressFWD 4 Let the robot move to position number4 35 IRC5 Basic Operation And Programming Training You are now going to change from continuous to single cycle execution 1 Tap the Quickset Menu button 2 Tap the Run Mode button After trapping Run Mode,the following buttons are displayed A Single cycle running B Continuous running 4 Tap the Single Cycle button 5 Tap the Quickset Menu button to close the window 6 Press the enabling device on the FlexPendant 7 Start the program by pressing the Run button on the FlexPendant 8 Select Continuous running again 36 IRC5 Basic Operation And Programming Training 10Stopping the program Program execution may be stopped in a number of ways depending on the operational mode. Step1: When running in continuously mode: Press the STOP button on the FlexPendant. Step2: When running in step-by-step mode, the robot will stop after executing each instruction. (Execute next instruction by pressing FWD or BWD again.) 37 IRC5 Basic Operation And Programming Training 11Running a grogram in Automatic mode Automatic mode is used to execute ready-made programs. Step1: Set the mode switch in the automatic position. A mode change dialog is displayed on the FlexPendant. Step2: Tap OK to close the dialog. (If you change the switch back to manual mode the dialog will be closed automatically.) Step3: You have now changed to automatic mode and Production window appears on the FlexPendant. Step4: Press the Motors Enable/Disable button on the Controller module to activate the robot. 38 IRC5 Basic Operation And Programming Training Step5: Press the RUN button on the FlexPendant to start the program. Step6: Press the STOP button on the FlexPendant to stop the program. Step7: Switch back to Manual mode. 39 IRC5 Basic Operation And Programming Training 12 Rapid Programming 12.1 Consist of the program Program memory Program data Program Main routine Routine 1 Main module Routine 2 Module 1 Routine 3 Module 2 Module 3 Module 4 Program data Routine 4 Routine 5 System module 1 Program data Routine 6 System module 2 Routine 7 40 IRC5 Basic Operation And Programming Training 12.2 Basic Movement Instruction 41 IRC5 Basic Operation And Programming Training 42 IRC5 Basic Operation And Programming Training 12.3Input/Output instruction 12.4Conmmunication Instruction 12.5Program Flow Control Instruction 43 IRC5 Basic Operation And Programming Training 12.6Other Common Instruction 44 IRC5 Basic Operation And Programming Training 13Editing a program This chapter explains some of the ways in which you can change the program you opened and started in the preceding chapters you will Run the program step by step until you get to the position you want to modify Modify this position Change an argument in an instruction Enter a new instruction(position) Program a time delay(Wait Time) 13.1 Editing a program) Use this procedure to tune the single position argument of instruction such as Move L and Move J or individual position arguments of instructions such as Move C and have the robot positioned at all positions to be tuned. Step1: On the ABB menu, tap Program Editor. Step2: Stop the program if running. Step3: Signal step the program so that the robot or external axis reaches the position you want to change. Step4: Jog the robot or external axis to the new position or change orientation. (The work object and tool of the instruction whose argument you want to change is automatically selected for jogging.) Step5: Tap Modify Position. A confirmation dialog appears. Step6: Tap Modify to use the new position. Tap Cancel to keep the original. 45 IRC5 Basic Operation And Programming Training Step7: Repeat step 3 through 6 for each position argument you want to change. Step8: Test running the program step-by-step. Step9: Tap Close to close the program editor. 13.2Editing Routine instruction argument You are now going to change one of the arguments of the first move instruction (Move L), which should be highlighted. . You are going to change the precision of the position fine to z10 Step1: On the ABB menu, tap Program Editor. Step2: Tap Edit. (Tap to select the program step you want to change.) 46 IRC5 Basic Operation And Programming Training Step3: Tap Change Selected to access the Current instruction menu. Step4: Tap Zone to access the Current argument menu. Step5: Tap z10 to change the argument. Step6: When the arguments are changed tap OK. Step7: Tap OK. 13.3 Adding instructions You are now going to add a movement instruction to the program after the first instruction. Step1: On the ABB menu, tap Program Editor. Step2: Tap Edit. Step3: Tap on the argument or instruction you want to copy and then copy. Step4: Tap Paste to insert the copied instruction. (The new instruction will be inserted directly under the instruction that was highlighted.) Step5: Using the joystick, move the robot to the position which you want it moved. Step6: Tap Modify Position. Step7: Tap Modify to use the new position. Tap Cancel to keep the original. Step8: Test running the program in the continuously mode. 47 IRC5 Basic Operation And Programming Training 13.4 Programming a delay You are now going to program a delay, i.e. make the robot wait a specified amount of time. The new instruction will be inserted after the fourth instruction. Step1: On the ABB menu, tap Program Editor. Step2: Tap Add Instruction. (Tap the fourth instruction in the program.) Step3: Tap Next at the bottom of the list of instruction. (Tap Common to display a scrollable list of the available categories.) Step4: Tap WaitTime. Step5: Tap Show123 and then 3 on the numeric soft keyboard. Step6: Tap OK and the Add Instruction to close the Add Instruction menu. Step7: A delay of 3 seconds is now added to the program. Step8: Test running the program in continuously mode. 48 IRC5 Basic Operation And Programming Training 14 I/O Signals After you have test running the program, you will manually open the I/O list and look at the signal in question. 14.1Programming an I/O instruction Step1: On the ABB menu, tap Program Editor. Step2: Tap Add Instruction. (Tap the third instruction in the program.) 49 IRC5 Basic Operation And Programming Training Step3: Tap Common to display a scrollable list of the available categories. (A large number of instructions, divided into several categories, are available.) Step4: Tap I/O and then Set. (All instructions are listed in RAPID reference manual-part1, Instruction A-Z.) Step5: After you have selected the function Set, the dialog box appears. Step6: Tap USERDO4 in the list and then OK. Step7: Close the Add Instruction menu. 50 IRC5 Basic Operation And Programming Training Step8: Test running the program, one instruction at a time, so that the program can read the “Set USERDO4” instruction. You are now going to manually check the state of the signal. Step1: On the ABB menu, tap Inputs and Outputs. Step2: Tap on the USERDO4 to view the state of the signal. (You can change the value by tap on 0 or 1.) Step3: Change the value of the signal. Step4: Test running the program once more and check the value of the signal again. 51 IRC5 Basic Operation And Programming Training 15Event log 15.1 What is a log? A log is a written account of events within the robot system. A log has entries, one for each event, tagged with the time of its occurrence. A: The event type (error, warning, information). B: The event code. C: The event title. D: The date and time of occurrence. 15.2What is an event? An event is a specific occurrence, which generates an item in the log. For instance, if the manipulator collides with an obstacle, this will cause a message to be sent to the log. A message of the occurrence is displayed along with a time marker, etc. This is the event. 15.3What is an event message? An event message is the actual wording, describing what has happened, what consequences this will have on the system, etc. Event message are divided into three categories: information, warning and error. 52 IRC5 Basic Operation And Programming Training 15.4What is an information message? An information message is an entry in the log corresponding to normal system events such as: ?Starting and stopping programs. ?Change in operational mode. ?Motors on and off. 15.5What is a warning? A warning is an event that you need to be aware of but is not so severe that the process or RAPID program needs to be stopped. Warning must sometimes be acknowledged. Warnings often indicate underlying problems that sooner or later need to be solved. 15.6What is an error? An error is an event that prevents the robot system from processing. The running process or RAPID program cannot continue and is stopped. All errors must be acknowledged. Most errors also require some immediate action from you in order to be solved. 15.7What is “acknowledge”? Certain events, mainly errors, require the operator to acknowledge them, before being able to proceed with the program execution. This is done by tapping Acknowledge or OK on the FlexPendant. 15.8Open and close the event log Step1: Tap the statue bar. (The statue window is displayed.) Step2: Tap Event Log. (The event log is displayed.) Step3: If the log contents do not fit into a single screen, it can be scrolled and/or zoomed. Step4: Tap a log entry to view the event message. (How to do this is detailed in section (9) View a message.) Step5: Tap the statue bar again to close the log. 53 IRC5 Basic Operation And Programming Training 15.9View a message Each entry is accompanied by a message that describes the event in detail and often contains advice on how to solve the problem. A: Event number. All error events are listed in accordance with this number. B: Event title. Briefly states what has happened. C: Event time marker. Specifies exactly when the event occurred. D: Description. A brief description of the event. Intended to assist in understanding the causes and implications of the event. E: Consequences. A brief description of any consequences inflicted on the system, transition to other operation mode, emergency stop caused by the particular event. Intended to assist in understanding the causes and implications of the event. F: Problem causes. A list of problem causes, listed in order of probability G: Recommended actions. A list of the recommended correcting actions, based on the “Probable causes” specified above. These may range from “Replace the xx…” to “Run testing program xx…” i.e. may be actions to isolate the problem as well as correcting it. H: Acknowledge or OK button. 54 IRC5 Basic Operation And Programming Training Step1: Tap a log entry to view its message. Step2: Tap Next to view the subsequent message in the list. Step3: Tap Previous to view the previous message in the list. Step4: Tap Close to close the message. 55 IRC5 Basic Operation And Programming Training 16Emergency stop Emergency stop buttons are located on the FlexController panel and on the FlexPendant. There are often other ways of activating an emergency stop, but these depend on the robot installation. When the emergency stop button is activated, the power supply to the motors is shut off and program execution stops. ?Recover from Emergency stops: Recover from an emergency stop condition is a simple but important procedure. This procedure ensures that the robot system is not returned to production while maintaining a hazardous condition. ?Reset the latch of emergency stop buttons: All push-button style emergency stop devices have a latching feature that must be released in order to remove the emergency stop condition of the device. In many cases twisting the push-button as marked does this, but there are also devices where you pull the button to release the latch. ?Reset automatic emergency stop device: All automatic emergency stop devices have also some kind of latching feature that must be released. Please consult your plant or cell documentation to see how your robot system is configured. ?Procedure: Step1: Make sure the hazardous situation that resulted in the emergency stop condition no longer exists. Step2: Locate and reset the device or devices that gave the emergency stop condition. Step3: Acknowledge the emergency stop event (20202) in the event log. Step4: Press the Motors On button to recover from the emergency stop condition. 56 IRC5 Basic Operation And Programming Training 17Operational modes 17.1What is the manual mode? In manual mode the robot can only move in a reduced and safe speed, and only under control. You need to press the enabling switch to activate the robot’s motors. The manual mode is most often used when creating programs and when commissioning a robot system. In manual mode you normally: ? Jog the robot back on its path when you return to operation after an emergency stop. ? Correct the value of I/O signals after error conditions. ? Create and edit RAPID programs. ? Tune programmed positions. Procedure: Set the mode switch in the manual position. 17.2Manual mode 100% (Option, testing mode) Use full speed manual mode when the program is to be tested in more natural conditions than the reduced speed that the manual mode offers, for instance to test synchronization between the robot and a conveyor or other external equipment. The full speed manual mode allows you to run the program in full speed while still having access to all the available debugging functions of the program editor. 17.3Automatic mode (production mode) In automatic mode the enabling switch is disconnected so that the robot can move without human intervention. A robot system in production normally runs in the automatic mode. This mode enables controlling the robot system remotely, for instance by using the controller’s I/O signals. An input signal may be used to start and stop a RAPID program, another to activate the robot’s motors. There are also additional safeguarding mechanisms active in automatic mode, not used in manual mode, to increase safety. Limitations: Jogging is not possible in automatic mode. There may also be other specific tasks that you should perform in manual mode to make sure only you are in control of the robot and its movements. In automatic mode you normally: ?Start and stop processes. ?Load, start and stop RAPID programs. ?Return the robot to it’s path when you return to operation after an emergency stop. ?Backup the system. ?Restore backups. ?Tune paths. ?Clean tools. ?Prepare or replace work objects. 57 IRC5 Basic Operation And Programming Training ?Perform other process-oriented tasks. 58