ABB IRB 640 User manual

Product Manual

3HAC 7579-1

IRB 640

M2000

The information in this document is subject to change without notice and should not be construed as a

commitment by ABB Robotics Products AB. ABB Robotics Products AB assumes no responsibility for

any errors that may appear in this document.

In no event shall ABB Robotics Products AB be liable for incidental or consequential damages arising

from use of this document or of the software and hardware described in this document.

This document and parts thereof must not be reproduced or copied without

ABB Robotics Products AB´s written permission, and contents thereof must not be imparted to a third

party nor be used for any unauthorized purpose. Contravention will be prosecuted.

Additional copies of this document may be obtained from ABB Robotics Products AB at its then current

charge.

Article number: 3HAC 7677-1

Issue: M2000/Rev.1

ABB Robotics Products AB

S-721 68 Västerås

Sweden

Installation and Commissioning

CONTENTS

Page

Product Manual IRB 640 1

1 Transporting and Unpacking......................................................................................... 3

1.1 Stability / risk of tipping......................................................................................... 4

1.2 System diskettes ..................................................................................................... 4

2 On-Site Installation.........................................................................................................5

2.1 Lifting the manipulator........................................................................................... 5

2.2 Assembling the robot.............................................................................................. 9

2.2.1 Manipulator.................................................................................................. 9

2.3 Stress forces............................................................................................................ 10

2.3.1 Stiffness........................................................................................................ 10

2.3.2 All versions.................................................................................................. 10

2.4 Amount of space required....................................................................................... 11

2.4.1 Manipulator.................................................................................................. 11

2.5 Manually engaging the brakes................................................................................ 12

2.6 Restricting the working space................................................................................. 13

2.6.1 Axis 1........................................................................................................... 13

2.6.2 Axes 2 and 3................................................................................................. 14

2.7 Mounting holes for equipment on the manipulator................................................ 15

2.7.1 Quality of screws for fitting extra equipment.............................................. 15

2.8 Loads ......................................................................................................................16

3 Customer connections on manipulator ......................................................................... 19

3.1 Connection of extra equipment to the manipulator................................................ 23

3.1.1 Connections on upper arm. .......................................................................... 23

3.1.2 Connections on upper arm with CanBus...................................................... 24

3.1.3 Connection of signal lamp on upper arm (option)....................................... 25

Installation and Commissioning

Page

2 Product Manual IRB 640

Installation and Commissioning Transporting and Unpacking

Product Manual IRB 640 3

1 Transporting and Unpacking

NB:

Before starting to unpack and install the robot, read the safety regulations and

other instructions very carefully. These are found in separate sections in the

User’s Guide and Product manual.

The installation shall be made by qualified installation personnel and should con-

form to all national and local codes.

When you have unpacked the robot, check that it has not been damaged during

transport or while unpacking.

Operating conditions:

Ambient temperature + 5° to + 45°C (manipulator)

Relative humidity Max. 95% at constant temperature

Storage conditions:

If the equipment is not going to be installed straight away, it must be stored in a dry

area at an ambient temperature between -25°C and +55°C.

When air transport is used, the robot must be located in a pressure-equalized area.

The net weight of the manipulator is approximately 1950 kg.

The control system weighs approximately 240 kg.

Whenever the manipulator is transported, axis 2 must be bent backwards 30° and

axis 3 must be moved down to a position against the rubber stops on axis 2.

Transporting and Unpacking Installation and Commissioning

4 Product Manual IRB 640

1.1 Stability / risk of tipping

When the manipulator is not fastened to the floor and standing still, the manipulator

is not stable in the whole working area. When the arms are moved, care must be

taken so that the centre of gravity is not displaced, as this could cause the manipula-

tor to tip over.

The following table shows the positions where there is a risk of tipping and refers to fig-

ures in chapter 3.8 in Product Specification IRB 640, for definition of position 0 and 5.

no = stable

yes = risk of tipping

1.2 System diskettes

The diskettes in the box, fixed to the shelf for the teach pendant, should be copied

(in a PC) before they are used. Never work with the original diskettes. When you have

made copies, store the originals in a safe place.

Do not store diskettes inside the controller due to the high temperatures there.

Working area, position 0

load = 0 kg load = max

Working area, position 5

load = 0 kg load = max

no no no yes

Installation and Commissioning On-Site Installation

Product Manual IRB 640 5

2 On-Site Installation

2.1 Lifting the manipulator

The following lifting instructions are valid for a “naked” robot. Whenever

additional equipment is put on the robot, the centre of gravity can change and

make lifting dangerous.

Never walk under a suspended load.

If the integrated lifting ears on the front cannot be reached, the manipulator must be

reoriented to the sync position.

The best way to lift the manipulator is to use lifting straps and a traverse crane.

Attach the straps to the integrated lifting eyes on both sides of the frame (see

Figure 2). The lifting strap dimensions must comply with the applicable standards

for lifting. It is also possible to use two lifting devices (option) for use with a fork

lift truck (see Figure 4).

NB!

The right lifting device, the robot seen from behind, must be removed before

start-up, see Figure 1.

Figure 1 Lifting device that must be removed.

View from behind

Lifting device

On-Site Installation Installation and Commissioning

6 Product Manual IRB 640

Figure 2 Lifting the manipulator using a traverse crane.

Length=1150

Length=950

Crane lift

240

700

Installation and Commissioning On-Site Installation

Product Manual IRB 640 7

Figure 3 Lifting the manipulator with the arm system in the calibration position.

Crane lift, in calibration position

Length=1150

Length=950

On-Site Installation Installation and Commissioning

8 Product Manual IRB 640

Figure 4 Lifting the manipulator using a fork lift truck.

Crane lifting is not permitted using the fork lift arrangement.

Fork lift

1120

400

Installation and Commissioning On-Site Installation

Product Manual IRB 640 9

2.2 Assembling the robot

2.2.1 Manipulator

The three support points of the manipulator foot shall be mounted on three flat surfaces

with a flatness within the specification. Use shims if necessary. The rest of the surface

must be flat within ± 2 mm. Footprint diagram, see Figure 5. Floor mounted models

can be tilted max. 5

o

.

The levelness requirement for the surface is as follows:

Figure 5 Bolting down the manipulator (dimensions in mm).

The manipulator is fixed with three M30 bolts, tightened alternately.

Suitable bolts: M30x160 8.8 Socket screw with washer

Tightening torque: 1000 Nm

Two guide sleeves can be added to two of the bolt holes, to allow the same manipulator

to be re-mounted without program adjustment (see Figure 5).

When bolting a mounting plate or frame to a concrete floor, follow the general

instructions for expansion-shell bolts. The screw joint must be able to withstand the

stress loads defined in Chapter 2.3 Stress forces .

0.5

D=64 H9 (3x)

Support surface D=85 (3x)

A

0.2

720

480±0.1

A

∅

415.7

D=32(3x)

D=48(3x)

A - A

X

Y

Z

100 ±0,5

15

+2

0

Guide sleeve

On-Site Installation Installation and Commissioning

10 Product Manual IRB 640

2.3 Stress forces

2.3.1 Stiffness

The stiffness of the foundation must be designed to minimize the influence on the

dynamic behaviour of the robot. For optimal performance the frequency of the founda-

tion with the robot weight must be higher than 22 Hz.

TuneServo can be used for adapting the robot tuning to a non-optimal foundation.

2.3.2 All versions

Endurance load Max. load

(In operation) (Emergency stop)

Force xy ±12 000 N ±18 000 N

Force z 21 000 ±5 500 N 21 000 ±10000 N

Torque xy ± 32 000 Nm ±39 000 Nm

Torque z ±6 000 Nm ±13 000 Nm

Force xy and torque xy are vectors that can have any direction in the xy plane.

Figure 6 The directions of the stress forces.

Y

X

Z

Installation and Commissioning On-Site Installation

Product Manual IRB 640 11

2.4 Amount of space required

The amount of working space required to operate the manipulator and controller is

illustrated in Figure 7.

The working range for axis 1 is +/- 180°.

NB: There are no software or mechanical limits for the working space under the

base of the manipulator.

2.4.1 Manipulator

Figure 7 The working space required for the manipulator.

IRB 640

All dimensions refer to TCP 0 (mm)

+1

-1

1220

2905

+2-2

+3

-3

2/3

+6

-6

TCP 0

2310

599

On-Site Installation Installation and Commissioning

12 Product Manual IRB 640

2.5 Manually engaging the brakes

All axes come equipped with holding brakes. When the position of a manipulator axis

needs to be changed without connecting the controller, an external voltage supply

(24 V DC) must be connected to enable engagement of the brakes. The voltage supply

should be connected to the connector at the base of the manipulator (see Figure 8).

Figure 8 Connection of external voltage to enable engagement of the brakes.

External power must be connected according to Figure 8. Incorrectly connected

power can release all brakes, causing simultaneously movement of all axes.

When the controller or the voltage device is connected, illustrated above, the brakes can

be engaged separately by means of the push-buttons on the brake release unit on the

exterior of the axis 3 gear box. The push-buttons are marked with the appropriate axis

name. The names of the axes and their motion patterns are illustrated in Figure 9.

WARNING: Be very careful when engaging the brakes. The axes become acti-

vated very quickly and may cause damage or injury.

Figure 9 The robot axes and motion patterns.

0 V B14

+24 V B16

Brake release unit

1

6

5

4

3

2

Axis 3

Axis 2

Axis 1

Axis 6

NB!

Buttons 4 and 5

are not connected.

Installation and Commissioning On-Site Installation

Product Manual IRB 640 13

2.6 Restricting the working space

When installing the manipulator, make sure that it can move freely within its entire

working space. If there is a risk that it may collide with other objects, its working space

should be limited, both mechanically and using software. Installation of an optional

extra stop for the main axes 1, 2 and 3 is described below.

Limiting the working space using software is described in the chapter System Param-

eters in the User’s Guide.

2.6.1 Axis 1

The range of rotation for axis 1 can be limited mechanically by fitting extra mechanical

stop arms.

Instructions for doing this are supplied with the kit.

IMPORTANT! The mechanical stop pin and the extra moveable mechanical stop

arm for axis 1 must absolutely be replaced after a hard collision, if the pin or arm

has been deformed.

On-Site Installation Installation and Commissioning

14 Product Manual IRB 640

2.6.2 Axes 2 and 3

The working range of axes 2 and 3 is limited by mechanical stops and can be reduced

by adding fixed mechanical stops.

The stops are mounted on the inside of the frame to each axis.

Extra stops must be mounted in a row, starting at the fixed stop.

Figure 10 Mechanically limiting axes 2 and 3.

NB!

The robot is always delivered with one extra mechanical stop mounted for axis 3.

It is not allowed to remove it.

Holes for extra stops

Installation and Commissioning On-Site Installation

Product Manual IRB 640 15

2.7 Mounting holes for equipment on the manipulator

NB: Never drill a hole in the manipulator without first consulting maintenance

staff or the design department at ABB Flexible Automation.

Figure 11 Holes for mounting extra equipment (dimensions in mm).

Figure 12 The mechanical interface (mounting flange) ISO 9409 (dimensions in mm).

2.7.1 Quality of screws for fitting extra equipment

When fitting tools on the manipulator’s mounting flange (see above), use only screws

with quality of 12.9. When fitting other equipment, standard screws with quality 8.8

can be used.

M10 (2x)

200

6069

220

411

486

8

0

depth 25

99

126

Limit for M10 surfaces

45

M10 (2x) through

M10 (4x) through

260

130

230

100

35

30

o

60

o

D=10 H7 depth 10

M10 (6x) depth 18

D=160 h7

D=80 H7

D=125

8

F - F

On-Site Installation Installation and Commissioning

16 Product Manual IRB 640

2.8 Loads

It is important to define the loads properly (with regard to the position of centre of grav-

ity and inertia factor) in order to avoid jolting movements and unnecessary stops due to

overloaded motors.

For more information see chapter 3.4 in Product Specification IRB 640 (Technical

specification) for load diagrams, permitted extra loads (equipment) and their positions.

The loads must also be defined in the software, see User´s Guide.

Installation and Commissioning On-Site Installation

Product Manual IRB 640 17

On-Site Installation Installation and Commissioning

18 Product Manual IRB 640

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