System Description. Arc Welding Products IRC5 M2004 3HEA Rev. A

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1 System Arc Welding Products IRC5 M2004 3HEA Rev. A

2 The information in this document is subject to alteration without prior notice and should not be regarded as an undertaking from ABB Automation Technologies AB. ABB Automation Technologies AB assumes no responsibility for errors that may occur in this document. ABB Automation Technologies AB bears no responsibility for damage that is a consequence of using this document or the software or hardware described in this document. The document, or parts of it, may not be reproduced or copied without prior permission from ABB Automation Technologies AB. It may neither be imparted to a third party nor otherwise be used without authorization. Infringement hereof will be subject to action in accordance with applicable laws. Further copies of this document can be obtained from ABB Automation Technologies AB at current prices ABB Automation Technologies AB ABB Automation Technologies AB Arc Welding Products SE Laxå Sweden

3 Contents System 3HEA Rev. A System General Welding robot system Control systems adapted for peripheral equipment Variants Single robot systems Multiple robot system Robot with welding equipment Welding power source Welding torches Torch service units Sensors IRBP positioner Travel Track for robot Operator panel Safety equipment Safety functions 16 3HEA Rev. A i

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5 System General 1 System 1.1 General This document describes ABB s standard assortment of arc-welding robot systems. The document is included in the System Manual (binder) supplied with the welding robot system. The System Manual corresponds to the system ordered by the customer and contains detailed descriptions of the component products. 3HEA Rev. A

6 System Welding robot system 1.2 Welding robot system Delivery The welding robot system is delivered in its standard design in sections. Everything included in the delivery is fitted to the respective sections. Example The component parts that can make up a welding robot system are described below Figure 1 Complete welding robot station with robot Item Name 1 Positioner 2 Safety equipment 3 Robot, wire feed, welding torch and hose bundle 4 Welding power source 5 Robot Controller 6 Operator panel 7 Travel track (not shown, see Figure 6) Accessories: cooling unit, mechanical torch cleaning unit, wire cutter, unit for checking TCP (Tool Center Point), joint locator and joint tracker 2 3HEA Rev. A

7 System Control systems adapted for peripheral equipment 1.3 Control systems adapted for peripheral equipment The control system is used to control the robot, welding equipment, positioner, safety equipment and all other peripheral equipment Variants Control systems for robot are described in the product manual Robot Controller Control systems for peripheral equipment are described in the product manual: Control Equipment for Positioner/Welding Equipment/Safety Equipment. The IRC5 control system is complemented with control equipment for positioners, welding equipment and safety equipment. The control system consists of: One control module (CM). One or more drive modules (DM). The total number of drive modules depends on the total number of robots in the system. A process module is included in systems that have: 1. Multiple robots systems with A314E/A316E/A324E-L welding equipment. 2. Single robot systems with welding equipment and AWC joint tracking equipment. The product is produced for the following robot types: IRB 1400/1600/2400, AW design. 3HEA Rev. A

8 System Single robot systems Single robot systems Single robots systems with A314E/A316E/A324E-L welding equipment and positioner Example Figure 2 Overview of single robot system Item Name Item Name 1 Control module (CM) 3 Positioner 2 Drive module 1 (DM1) 4 Robot 4 3HEA Rev. A

9 System Single robot systems Single robot system with welding equipment, positioner and AWC Example Figure 3 Overview of single robot system with AWC 4 5 Item Name Item Name 1 Process module (PM) 4 Positioner 2 Control module (CM) 5 Robot 3 Drive module 1 (DM1) 3HEA Rev. A

10 System Multiple robot system Multiple robot system Multiple robots system with A314E/A316E/A324E-L welding equipment and positioner Figure 4 Overview of multiple robot system with two robots Item Name Item Name 1 Control module (CM) 5 Positioner 2 Drive module 1 (DM1) 6 Robot 1 3 Drive module 2 (DM2) 7 Robot 2 4 Process module 6 3HEA Rev. A

11 Robot with welding equipment 1.4 Robot with welding equipment Arc-welding In an arc-welding robot system, an IRB1400, IRB1600 or IRB2400 robot is normally used. In certain systems, other types can be included, such as welding, handling or machining robots. In an arc-welding system, the robot is equipped with welding equipment consisting of the following units. Example Figure 5 IRB 2400 with installed welding equipment Item Item 1 Welding power source 5 Insulator/Collision sensor (option) 2 Welding gun 6 Wire cutter 3 Hose bundle 7 TCP calibration unit 4 Wire feed equipment 8 Torch cleaner 3HEA Rev. A

12 Welding power source Welding power source The following power source standard alternatives are available: RPB 320/420/520 Illustration LRC 430 TPS 4000/5000 Fronius MigRob 500 Other power sources can be connected to the system, e.g., LAF HEA Rev. A

13 Welding torches Welding torches The following welding torch standard alternatives are available: PKI 250/500/630/300 S PKI 250/500/630/300 D Illustration PSF 315/500M PSF 315/500ME WH Binzel 1. Collision sensor (option) 1 3HEA Rev. A

14 Torch service units Torch service units The following torch service unit standard alternatives are available: TSC Torch Service Center, based on the TC96/ TSC Torch Service Center, based on the BRS-LC, consisting of: 1. Torch cleaner 2. Wire cutter 3. TCP calibration unit Component parts can be purchased separately. Illustration Sensors The following sensor standard alternatives are available: Joint locator SmarTac Touch sense (for Fronius only) Joint tracker AWC 10 3HEA Rev. A

15 IRBP positioner 1.5 IRBP positioner A positioner is used to position work pieces optimally for welding joints and robots. The IRBP positioner is equipped with maintenance-free AC motors with electromagnetic brakes. The numbers in the positioner name indicate maximum handling capacity. The letters in the positioner name indicate the positioner type. The following positioner type standard alternatives are available: IRBP 500/1000C Illustration IRBP 250/500C Index 3HEA Rev. A

16 IRBP positioner IRBP 250/500/750/2000/5000L Illustration IRBP 250/500/750K IRBP 250/500/750R 12 3HEA Rev. A

17 IRBP positioner IRBP 250/500/750A Illustration IRBP 250/500/750B IRBP 250/500D 3HEA Rev. A

18 Travel Track for robot 1.6 Travel Track for robot A Travel track is used to position a robot at different work stations or within a large work area. 1 2 Figure 6 Travel track Item 1 Travel track, Bobin 3.7m 2 Travel track, Marathon 3.7m Travel length 1.7m 7.7m 2.7m 8.7m 3.7m 9.7m 4.7m 10.7m 5.7m 11.7m 6.7m 12.7m 14 3HEA Rev. A

19 Operator panel 1.7 Operator panel Operator communication There is an operator panel with a number of button functions to enable the operator to communicate with the arc-welding system. The following operator panel standard alternatives are available: Operator panel for one work area Illustration Operator panel for two work areas 3HEA Rev. A

20 Safety equipment 1.8 Safety equipment For personnel to work safely with an arc-welding robot system, the system must be equipped with a number of safety components, which are integrated into the control cabinet s safety system Safety functions Safety functions Working area surveillance with light barriers Time resetting for light barriers Working area indication for: Robot or track motion Positioner Gate surveillance Reset unit for gate surveillance Figure 7 Welding robot station with safety equipment 16 3HEA Rev. A

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