System DescriptionArc Welding Products

IRC5M20043HEA801213-001 Rev. A 2005-05

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© 2005 ABB Automation Technologies AB

ABB Automation Technologies ABArc Welding Products

SE-69582 LaxåSweden

3HEA801213-001 Rev. A 2005-05 i

Contents

System Description 3HEA801213-001 Rev. A 2005-05

1 System Description 1

1.1 General 1

1.2 Welding robot system 2

1.3 Control systems adapted for peripheral equipment 31.3.1 Variants 31.3.2 Single robot systems 41.3.3 Multiple robot system 6

1.4 Robot with welding equipment 71.4.1 Welding power source 81.4.2 Welding torches 91.4.3 Torch service units 101.4.4 Sensors 10

1.5 IRBP positioner 11

1.6 Travel Track for robot 14

1.7 Operator panel 15

1.8 Safety equipment 161.8.1 Safety functions 16

ii 3HEA801213-001 Rev. A 2005-05

System DescriptionGeneral

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1 System Description

1.1 GeneralThis 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.

System Description

Welding robot system

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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

1

3 4

5

6

2

System DescriptionControl systems adapted for peripheral equipment

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1.3 Control systems adapted for peripheral equipment

Description

The control system is used to control the robot, welding equipment, positioner, safety equipment and all other peripheral equipment.

1.3.1 Variants

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:

The product is produced for the following robot types:

• IRB 1400/1600/2400, AW design.

Control systems for robot are described in the product manual Robot ControllerControl systems for peripheral equipment are described in the product manual: Control Equipment for Positioner/Welding Equipment/Safety Equipment.

1. Multiple robots systems with A314E/A316E/A324E-L welding equipment.

2. Single robot systems with welding equipment and AWC joint tracking equipment.

System Description

Single robot systems

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1.3.2 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

1

2

3 4

System DescriptionSingle robot systems

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Single robot system with welding equipment, positioner and AWC

Example

Figure 3 Overview of single robot system with AWC

Item Name Item Name

1 Process module (PM) 4 Positioner

2 Control module (CM) 5 Robot

3 Drive module 1 (DM1)

1

3

4 5

2

System Description

Multiple robot system

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1.3.3 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

1

2

3 4 5

6

7

Robot with welding equipment

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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 Description Item Description

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

34

51

2

8

6

7

Welding power source

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1.4.1 Welding power source

The following power source standard alternatives are available:

Description Illustration

RPB 320/420/520

LRC 430

TPS 4000/5000 Fronius

MigRob 500

Other power sources can be connected to the system, e.g., LAF 635.

Welding torches

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1.4.2 Welding torches

The following welding torch standard alternatives are available:

Description Illustration

PKI 250/500/630/300 SPKI 250/500/630/300 D

PSF 315/500MPSF 315/500ME

WH Binzel

1. Collision sensor (option)

1

Torch service units

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1.4.3 Torch service units

The following torch service unit standard alternatives are available:

1.4.4 Sensors

The following sensor standard alternatives are available:

Description Illustration

TSC Torch Service Center, based on the TC96/TSC Torch Service Center, based on the BRS-LC, consisting of:1. Torch cleaner2. Wire cutter3. TCP calibration unit

• Component parts can be purchased separately.

2

3

1

Description

Joint locator

• SmarTac

• Touch sense (for Fronius only)

Joint tracker

• AWC

IRBP positioner

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1.5 IRBP positioner

Description

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 electro-magnetic 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:

Description Illustration

IRBP 500/1000C

IRBP 250/500C Index

IRBP positioner

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IRBP 250/500/750/2000/5000L

IRBP 250/500/750K

IRBP 250/500/750R

Description Illustration

IRBP positioner

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IRBP 250/500/750A

IRBP 250/500/750B

IRBP 250/500D

Description Illustration

Travel Track for robot

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1.6 Travel Track for robot

Description

A Travel track is used to position a robot at different work stations or within a large work area.

Figure 6 Travel track

Item Description

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

1

2

Operator panel

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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:

Description Illustration

Operator panel for one work area

Operator panel for two work areas

Safety equipment

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1.8 Safety equipmentFor 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.

1.8.1 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

3HEA801213-001 Rev. A 2005-05

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