Hello again.
The S4c+ systems are nice and bullet proof but they are getting quite old. The problem with that is that most of the tuning possibilities that exist in a modern controller where not implemented yet. Pretty sure tune master won't work for that old controller.
The 4400/L10 is a good robot and normally has some really good path performance. I am actually getting nostalgic thinking about tuning those old systems and robots. Now most likely you are having some issues with friction or axis resonance. I am thinking that you cant use tune master to fix any of that so instead i have something you can try.
Copy paste this code into the start of your cutting routine.
WaitTime\InPos,0.01;
PathResol 70;
AccSet 50,50;
TuneServo ROB_ID,1,60\Type:=TUNE_DH;
WaitTime\inpos will force the robot to be in compleate stop for 0.01 seconds. This is important, the robot will not like it if you tune servo parameters when its moving. (it wont break, but it will hate you).
PathResol will change the path resolution time to 70% of its original value, this will increase the path resolution. If this value is to low you might se an error saying something along the lines of "corner path failure", you can ignore that error as long as the path is good.
AccSet lowers acceleration and acceleration ramp. Instead of using PathAccLim it is better to use AccSet on a 4400 robot since they respond really well to the increased ramp. Values are %.
Tuneservo command is used to change servo parameters, this is ok to do and it is well documented in the manual. "DH" tuning is the robots finite impulse respons filter, lowering the value will increase the amount of filtering, This should smooth out your path a lot. If the value is to low you will see the robot taking smal shortcuts in zones.
This tuning is 100% safe and won't damage anything.
As for the zones, this is data declarations.
CONST zonedata zone0:=[FALSE,0.3,20,0.3,0.03,0.3,0.03];
CONST zonedata zone1:=[FALSE,1,20,1,0.1,1,0.1];
You can copy these lines into your base modules in your tasks. This will make them available to all programs in the system.
This will allow you to use these custom zones in you movement instructions.
! Go from this
MoveL p10,v200,z0,tool0;
! To this
MoveL p10,v200,zone0,tool0;
It should help you keep the speed up int he small zones.
The abb robot will let you create custom data of more or less anything so you can get it to do exactly what you want it to do.
And as you stated the abb "fine" zone is the one that will force the robot to stop completely, all the other zones including z0 will not force the robot to stop. But z0 is a zone of 0,3mm and the robot is quite big so its hard for it to maintain speed through the zone.
Don't worry about your lack of experience, everyone in this forum was in your shoes at some point. Just see every day as a chance to learn something new and you will ace your job.