Posts by Viperacebb

Did you have any software of backups with the system when you received it?

Hello! It would be great if you could include the controller (S4C, S4C +, IRC5, etc...). The year may be beneficial as well, so there's less confusion.

At this point, I would make sure that all the positions are using a work object for the weld area. Was it taught with a work object? Is there an extension after the tool (:\wobj_fixture; or something like this)?

Maybe check voltage at the motors for the brake released (you should see 24VDC). If you're not getting at least 22VDC, you may have something else dragging the voltage down. Check your electrical system out. Good luck!

Like Lemster68 has said, measure everything accurately and even make a routine for the robot to go to known points (edge 1, edge 2, edge 3) and move the positioner back to those positions taught versus where they were. You may still need to touch up a little bit, but hopefully not. Label and take a ton of pictures (they help more than you expect). If you could build a template out of wood as to the base of the robot to the base of the positioner, this may work very well too. Best of luck!

What setup do you have? Can you give a detailed description of the robot and system? There may be missing jumpers and you will need to check that the PLC is sending the correct signals to clear the safety circuit. From what I've seen, the PLC controls the SS1/SS2 circuit through SafeMove and drops that circuit when any of the ES,GS and AS are triggered (through the PLC).

Are you running any external axis? Can you check the cabling, pins, etc... Sounds like there's no feedback coming to the drives.

Good day! You will need to setup some basics in SafeMove via RobotStudio in order to start moving the robot. Take a look through the "Application manual - Functional safety and SafeMove2" and it will help guide you through the process a bit. You may need to add some jumpers into the SS1/SS2 if needed, prior to having a CIP Safety PLC hooked up (with a temporary safety bypass for development). Take your time and go through it. I also know that ABB likes to leave out some jumpers for the AS1/AS2 as well (usually found in a red bag inside the cabinets), to prevent you from going full auto without going through the safeties. I can appreciate this for newbies to be honest.

Sounds like the answers are here! Best of luck and if you need help, let me know. Done this at least a 1000 times (LOL)

Which controller do you have? S4C, IRC5, etc... Year would be helpful as well.

I've done this is the past to reduce the amount of play between the gears. You will need to create a "T" handle with a thread that mounts into the back side of the resolver (with the cap off). I would then release the brake and check the play between the gears (slight twisting motion in both directions via the "T" handle in the encoder while the brake is released). Make sure to not force the engagement between the gears too much or it may damage the gears. It takes a bit of time, but should be easier on the 1st axis. Then you mark the base at the sync mark and perform a "fine calibration". Check you program for variation and maybe test with a dial indicator for repeatability. I hope this helps!

You should definitely check those cables thoroughly. Based on those pictures and the wires being #22-#24AWG, it's very easy to pinch/break them. Those are the resolver cables and would give you all kinds of position or sync errors... I would check those cables first before ordering a ton of parts.

I've seen this before and it sounds like the base cable in the IRB6400. It's not too difficult to change, but you must be aware of all the screws holding the cable braces down on the inside (both on the floor and up on the rotating axis internally). It run in the base like an "S" shape and can be a pain at times. Invest in some short, hex bit set (I think it's a T25 in there) and a short driver for it. I found a small rachet style works best. Patience is what you will need to get through this. It's rare that a motor itself shorts out and seeing as it's bouncing from 1 and 2 axis... leads me to believe it's the base cable. Just my 2 cents.

If you can release the brake by pressing the #2 button at the base and the robot can move freely (be careful it doesn't fall down. Maybe secure it with a sling or post), it could be the brake release unit. If the robot still feels jammed, it most likely a failed brake in the motor itself. If you have a 24VDC power supply, you can connect directly with the 2 small wires (it will be polarity sensitive) on the larger square connector inside the motor itself (the one that supplies motor power, not the 9 pin D-sub connector for the resolver). If it allows free motion after the power supply is connected and powered up, it travels back to the brake release unit (or cabling going back). Find the route cause before switching out components. It will save you time and money in the long run.

I believe you would have a service routine called LoadID. I would recommend running this and follow the instructions. This would set the tool and/or load with the proper center of gravity (based on the robots calculations) and should run better following this. See if you have it by going to the service routines in the program editor screen. Keep in mind you will have to run this in manual mode and then auto mode. I always check in manual first (as it gives you the option to just do it in auto) as It will follow the same path in manual/auto. If you need to cancel and restart, you will need to cancel call routine, bring it back to the main and then try the service routine again. I recommend placing the robot in a safe place with a good amount of room before trying this. Good luck!

Good day! I've seen this happen in the past. I would put a meter on the 24VDC side of the contactor to see if it's maintaining the 24VDC, even once the contactor let's go. It's possible that the safety board is acting up, releasing the 24VDC from the contactor following the motors on request. Are all the safety chains illuminated? Are there any other faults coming up prior to this fault? Once you've verified the 24VDC, you should check the 0VDC side as well. This happened to me once and found a bad contact or a loss of 0VDC. Use a known 24VDC as a reference when checking. Just some things to try.

The software is very intuitive and helpful. It will make ease of programming to be honest. I found it extremely helpful (worth the money). Best of luck!

Hi!

If you're connected in WorkVisual, you should see a section on the lower left hand side of the screen (Workspace Selection). In this window, you should see Configuration and commissioning and Programming and diagnosis. If you click on Programming and diagnosis, it will bring you to a different screen all together. Here you will see different tabs at the top and on the right side, you should see the Cells tree. Here is where you should see the controller you are connected to. Make sure it's "checked" off or selected beside the name. On the top tabs, you should see 6 sections with multiple icons in each (this is fairly difficult to explain with showing pictures). The first icon in the 4th section from the left called "opens and edits for online systems" is the one you should select. The screen should show you the current status of the controller you are connected to. You will also see an "archive" towards the right of that screen. This will take a complete archive of the system and will allow you to restore from this as well. You can also take one from the USB as a secondary source to be on the safe side (until you gain comfort). Sorry for the long post, but hope it helps in some way. Good luck!

I have a couple of questions... Is this a used robot or new? Does it already have the integrated vision option as part of it's system? I can tell you first hand that integrating cognex vision camera's with ABB (with the option installed) is a lot easier than you think. The basic options are available through RobotStudio, but you can always modify an excel spreadsheet and import it for more complex programming.

Here's a link to RobInstall 4.0 Rev127. You will still need your key and any option disks/keys you may have had before. Good luck!