Product Specification

Product Specification Track Motion IRBT 6002S/4002S 3HXD 7103-1 M99 February 1999 ABB Flexible Automation

The information in this document can be subject to change without prior notice and should not be regarded as an undertaking from ABB Flexible Automation AB. ABB Flexible Automation AB assumes no responsibility for errors that can appear in this document. ABB Flexible Automation AB is not responsible for damage incurred by the use of this document or software or hardware described in this document. The document, or parts there of, may not be reproduced or copied without prior permission from ABB Flexible Automation AB. It may neither be imparted to another nor otherwise used without authorisation. Infringement here of will be subjected to action in accordance with applicable laws. Further copies of this document can be obtained from ABB Flexible Automation AB at current prices. ABB Flexible Automation AB Article number: 3HXD 7103-1 Issue: February 1999 ABB Flexible Automation AB System Products S-721 81 Västerås Sweden

Product Specification CONTENTS Page 1 Introduction... 1 2 Description... 3 2.1 Automatic lubrication system (optional)... 4 2.2 Automatic lubrication system with timer (optional)... 4 3 Technical Specification... 5 3.1 Track Motion IRBT 6002... 5 3.1.1 Positioning times... 5 3.2 Track Motion IRBT 4002S... 6 3.2.1 Positioning times... 6 3.3 Principle build-up... 7 3.4 Dimensions... 8 3.4.1 Dimensions, cross section... 9 4 Variants and options... 11 4.1 Single carriage Track Motion IRBT 6002S/4002S (not for shelf mounted version)... 11 4.2 Dual carriage Track Motion IRBT 6002S/4002S (not for shelf mounted version)... 13 3HXD 7103-1 M99 i

Product Specification ii 3HXD 7103-1 M99

Product Specification Introduction 1 Introduction Thank you for your interest in the track motion IRBT 6002S/4002S. This description will give you an overview of the characteristics and performance of the track motion. Track Motion IRBT 6002S/4002S adds an extra programmable degree of freedom for the movement pattern of IRB 6400 and IRB 4400 respectively, and is to be connected to the robot control equipment, as an integrated seventh axis. Track Motion IRBT6002S/4002S has a compact design. The track motion is covered with top cover plates, that effectively protect the tracks and the cabling from dirt and falling objects. All driving parts are below the covers, which increases the safety for the personnel. The cable chain lies on the floor of the track motion and is covered by the top cover plates. As the track motion is fully adapted to the Robots, only very short installation time is needed before the system is ready for operation. The movements of the track motion are programmed using the robot s teach pendant in a similar way to other axes. In the event of a stoppage in operation, the entire work station can be restarted without any need for any calibration. The length of the track motion may be up to 45 m and can have several carriages. The IRBT 6002S/4002S is designed to work with all robot versions, except for the shelf-mounted IRB 6400. The IRBT 6001 track motion is used for shelfmounted IRB 6400. Figure 1. Track Motion IRBT 6002S/4002S 3HXD 7103-1 M99 1

Introduction Product Specification 2 3HXD 7103-1 M99

Product Specification Description 2 Description The track motion is primarily intended for the IRB 6400 and IRB 4400 but can as well be used for the smaller robots IRB 2400 and IRB 1400. The track motion consists of rail modules, carriage and drive package. The carriage is supported on four sealed ball bearing elements that run along hardened and ground linear bearings with high precision. It is powered by a hardened pinion which engages a rack of alloy steel. Figure 2. Track Motion 6002S/4002S The track motion is connected to the robot system as an integrated seventh axis and is programmed from the robot teach pendant. The travel length of the carriage, on which the robot is mounted, is specified in increments of 1 m from 1.7 m to 43.7 m. The total length of the track motion is 1.3 m longer than the travel length. Longer track motions are divided in several sections during transportation. The standard track motion is equipped with one or two carriages, but versions with more than two carriages are available on request. Track motion movements are programmed and controlled from the robots programming unit. This means programming/controlling the track motion is no different from any other robot axis. During assembly, the robot base can be positioned in one of two positions, with a 90 displacement. All cables for track motion and robot are routed through a cable chain below the cover plates. In the cable chain there is a free space available for process cables and hoses. As an option, a cable chain for spot welding with higher capacity can be delivered. This is then located externally, parallel to the track motion. 3HXD 7103-1 M99 3

Description Product Specification The track motion is fitted with a measurement board which converts the resolver signals of the track motion drive system to digital signals. The board uses a battery backup, and this enables the robot to be restarted without any synchronization or similar after a power break-down. The digital signal transmission is also less sensitive to radio interference than the traditional analog transmission. This ensures safe operation, even with very long travel lengths. At the centre of one side of the track motion, there is a junction point for connection of robot and control cabinet. 2.1 Automatic lubrication system (optional) The system distributes lubricant to all four ball elements and to the rack at regular intervals. The grease injector contains 125 ml grease. The equipment has the following parts: 5 grease injectors (for the rack and the 4 ball elements) Hoses to the ball elements and the rack The driver is an electrolyte genererating gas, that makes the piston protrude. The driver is adjustable 1 to 12 months depending on piston speed. It is possible to turn the driver off completely, and then turn it on again. When the grease is all used up, the driver is exchanged and the container is refilled with new grease. Driver Piston Container Grease Thread 2.2 Automatic lubrication system with timer (optional) If the track motion is moving more than 40% of the total cycle time, its recommended to use the automatic lubrication system with timer. This system reduces the need for maintenance significantly. The system distributes lubricant to all four ball elements and to the rack/pinion at regular intervals. The intervals can be adjusted to optimize the lubrication for each particular case. The autolub system comprises: A container for 2.75 kg lubricant A programmable timer A valve package distributing lubricant to the ball elements and the pinion 5 feeding hoses A special cover for the pinion with built-in lubrication brush 4 3HXD 7103-1 M99

Product Specification Technical Specification 3 Technical Specification 3.1 Track Motion IRBT 6002 Travel length Travel speed Rail length 1.7-43.7 in steps of 1 m 1.0 m/s travel length + 1.3 m Acceleration with IRB 6400 + 300 kg 1.4 m/s 2 Retardation 1,6m/s 2 Repeatability, repeated stops in the same direction towards the same position Maximum load Track Motion weight Protection Class ±0.2 mm robot weight + 300 kg 800 kg + 200 kg/m IP54 3.1.1 Positioning times The diagram is valid for fine points from still standing to still standing Distance (m) Time (s) Figure 3. Positioning times, IRBT 6002S 3HXD 7103-1 M99 5

Technical Specification Product Specification 3.2 Track Motion IRBT 4002S Travel length Rail length Travel speed 1.7-43.7 in steps of 1 m travel length + 1.3 m 1.6 m/s Acceleration with IRB 4400 + 100 kg 1.4 m/s 2 Retardation with IRB 4400 + 100 kg 1.9 m/s 2 Repeatability, repeated stops in the same direction towards the same position Maximum load Track Motion weight Protection Class ±0.2 mm robot weight + 100 kg 800 kg + 200 kg/m IP54 3.2.1 Positioning times Travel length (m) 5,2 5,0 4,8 4,6 4,4 4,2 4,0 3,8 3,6 3,4 3,2 3,0 2,8 2,6 2,4 2,2 2,0 1,8 1,6 1,4 1,2 1,0 0,8 0,6 0,4 0,2 0,0 0,0 0,4 0,8 1,2 1,6 2,0 2,4 2,8 3,2 3,6 4,0 Positioning time(s) Figure 4. Positioning times, IRBT 4002S 6 3HXD 7103-1 M99

Product Specification Technical Specification 3.3 Principle build-up 11 3 2 4 10 1 9 7 6 5 8 Figure 5. Principle build-up 1. Rail module 7. Motor 2. Guide rail 8. Limit and zone switch plate 3. Ball element 9. Cable chain 4. Rack 10. Limit switch (option) 5. Hole for anchorbolt 11. Serial Measurement Box 6. Gear box 3HXD 7103-1 M99 7

Technical Specification Product Specification 3.4 Dimensions Single carriage Track Motion ACTUAL BEAM LENGTH TRAVEL LENGTH SW channel, detail External cable chain (alt. location) Connection point external cable chain The dimension between the socket beams at the rail varies Connection point internal cable chain Figure 6. Dimensions, Single carriage Travel length 1,7 2,7 3,7 4,7 5,7 6,7 7,7 Number of increments, N 2 3 4 5 6 7 8 Dual carriage Track Motion Figure 7. Dual carriage 8 3HXD 7103-1 M99

Product Specification Technical Specification 3.4.1 Dimensions, cross section External cable chain 900 544 240 Figure 8. External cable chain, cross section Internal cable chain 1172 450 1000 1060 Figure 9. Internal cable chain, cross section 3HXD 7103-1 M99 9

Technical Specification Product Specification 10 3HXD 7103-1 M99

Product Specification Variants and options 4 Variants and options IRBT 6002S/4002S works as an integrated 7th axis and requires option 391, Drive unit T, on the robot specification form. The robots standard cables are used from controller to track motion. The length of the 7th axis motor cable is 15 m, measured from the junction point at the middle of the track motion. When dual carriage Track Motion is ordered all ordered options will automatically be doubled. N.B! To have the correct length of the cables at the carriage it is important to specify on the specification form (ordering form) if the robotposition is in-line or 90. 4.1 Single carriage Track Motion IRBT 6002S/4002S (not for shelf mounted version) 3HXD 1262-2xx 3HXD 1263-2xx 3HXD 1262-4xx 3HXD 1263-4xx 3HXD 1262-xx 3HXD 1263-xx 3HXD 1262-6xx 3HXD 1263-6xx 3HXD 1262-7xx 3HXD 1263-7xx Track Motion IRBT 4002S (internal cable chain), for IRB2400 Track Motion IRBT 4002S (external cable chain), for IRB2400 Track Motion IRBT 4002S (internal cable chain), for IRB4400 Track Motion IRBT 4002S (external cable chain), for IRB4400 Track Motion IRBT 6002S (internal cable chain), for IRB6400/M97A-M98 Track Motion IRBT 6002S (external cable chain), for IRB6400/M97A-M98 Track Motion IRBT 6002S (internal cable chain), for IRB6400R/M99 Track Motion IRBT 6002S (external cable chain), for IRB6400R/M99 Track Motion IRBT 6002S (internal cable chain), for IRB640/M97A-M98 Track Motion IRBT 6002S (external cable chain), for IRB640/M97A-M98 3HXD 7103-1 M99 11

Variants and options Product Specification Options 3HXD 1277-70 3HXD 1277-150 7th axis power floor cable, 7 m 7th axis power floor cable, 15 m 3HXD 1143- Customer signal and power cable, IRB 6400, IRB 4400 3HXD 1187- Customer signal and power cable, IRB 2400 3HXD 1216/1217 3HXD 1144-xx 3HXD 1145-xx CAN-bus cable Position switch cable axis 1, IRB4400, IRB2400 Position switch cable axis 1, IRB6400 3HXD 1279-xx Customer power vacuum cable for IRB 640 3HXD 0100-42 3HXD 0100-143 3HXD 0100-213 3HXD 1104- and 3HXD 1146-3HXD 1175-70 OR 3HXD 1175-150 3HXD 1264- Two Automatic lubrication systems (five small grease injectors) Automatic lubrication system with timer (one large grease container (Trabon) Electrical working range limit switch Zone division (two switches) and zone division cable in cable chain Zone division floor cable, 7m Zone division floor cable, 150m Spot welding media for IRB 6400 with Spot Welding System 6000TG (requires external cable chain) 12 3HXD 7103-1 M99

Product Specification Variants and options 4.2 Dual carriage Track Motion IRBT 6002S/4002S (not for shelf mounted version) 3HXD 1264-2xx 3HXD 1265-2xx 3HXD 1264-4xx 3HXD 1265-4xx 3HXD 1264-xx 3HXD 1265-xx 3HXD 1264-6xx 3HXD 1265-6xx 3HXD 1264-7xx 3HXD 1265-7xx Track Motion IRBT 4002S (internal cable chain), for IRB2400 Track Motion IRBT 4002S (external cable chain), for IRB2400 Track Motion IRBT 4002S (internal cable chain), for IRB4400 Track Motion IRBT 4002S (external cable chain), for IRB4400 Track Motion IRBT 6002S (internal cable chain), for IRB6400/M97A-M98 Track Motion IRBT 6002S (external cable chain), for IRB6400/M97A-M98 Track Motion IRBT 6002S (internal cable chain), for IRB6400R/M99 Track Motion IRBT 6002S (external cable chain), for IRB6400R/M99 Track Motion IRBT 6002S (internal cable chain), for IRB640/M97A-M98 Track Motion IRBT 6002S (external cable chain), for IRB640/M97A-M98 Options: 3HXD 1277-70 3HXD 1277-150 Two 7th axis power floor cables, 7 m Two 7th axis power floor cables, 15 m 3HXD 1143- Two Customer signal and power cables, IRB 6400, IRB 4400 3HXD 1187- Two Customer signal and power cables, IRB 2400 3HXD 1216/1217 3HXD 1144-xx 3HXD 1145-xx Two CAN-bus cables Two Position switch cable axis 1, IRB4400, IRB2400 Two Position switch cable axis 1, IRB6400 3HXD 1279-xx Two Customer power vacuum cable for IRB 640 3HXD 7103-1 M99 13

Variants and options Product Specification 3HXD 0100-42 3HXD 0100-143 3HXD 0100-212 3HXD 0100-213 3HXD 1104- and 3HXD 1175-70 OR 3HXD 1175-150 3HXD 1264- Two Automatic lubrication systems (five small grease injectors/carriage) Two Automatic lubrication system with timer (one large grease container (Trabon) Electrical collision limit switches Two Electrical working range limit switches Two Zone division (two switches/carriage) and zone division 3HXD 1146- cable in cable chain Two Zone division floor cable, 7m Two Zone division floor cable, 15m Two Spot welding media for IRB 6400 with Spot Welding System 6000TG (requires external cable chain) 14 3HXD 7103-1 M99

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