Product Manual

Positioner
IRBP250K/ 500K/ 750K
M2003
506 180-102
2002-10
The information in this document is subject to change without notice and should be construed
as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in
this document.
In no event shall ABB be liable for damages of any nature from the use of this document.
This document and parts thereof must not be reproduced or copied without ABBs written per-
mission, and the contents thereof must not be imparted to a third party nor be used for any
unauthorized purpose.
Copies of this document can be ordered from ABB.
ABB Automation Technology Products AB
Artikelnummer: 506 180-102
Datum: 2002-10
ABB Automation Technology Products AB
Arc Welding Products
S-695 82 Lax
Sweden
IRBP250K/500/K/750K
LIST OF CONTENTS
Page
504 851-102 3
1 Technical description .................................................................................................. 5
1.1 IRBP 250K/ 500K/ 750K................................................................................... 5
1.2 Technical data for 250K..................................................................................... 6
1.3 The station switching unit MIC......................................................................... 9
1.4 Rotary unit......................................................................................................... 11
1.5 Support collar..................................................................................................... 12
2 Options ......................................................................................................................... 13
2.1 Option, Robot stand........................................................................................... 13
2.2 Option, Swivels.................................................................................................. 14
2.3 Option, extra current collector for positioner types K/L/R/D............................ 19
3 Transport and unpacking ........................................................................................... 21
3.1 Lifting instructions............................................................................................. 21
3.2 Weights.............................................................................................................. 21
4 Foundation................................................................................................................... 23
4.1 Installing the floor stand.................................................................................... 23
5 Maintenance................................................................................................................. 25
6 Loading diagram......................................................................................................... 27
6.1 IRBP 250K......................................................................................................... 27
6.2 IRBP 500K......................................................................................................... 28
6.3 IRBP 750K......................................................................................................... 29
7 Integration of fixtures ................................................................................................. 31
7.1 IRBP 250R/ 500R/ 750R/ 250K/ 500K/ 750K/ 250L/ 500L/ 750L/ 2000L/
250D/ 500D........................................................................................................ 31
7.2 IRBP 250 C Index /500C /500 C Index/ 1000C/ 250A/ 500A/ 750A/
250B/ 500B/ 750B............................................................................................. 32
8 Measurement diagrams .............................................................................................. 33
8.1 IRBP 250K......................................................................................................... 33
8.2 IRBP 500K/750K............................................................................................... 39
IRBP250K/500/K/750K
4 504 851-102
Positioner IRBP
Technical description
5
1 Technical description
1.1 IRBP 250K/ 500K/ 750K
The positioner is designed to handle workpieces of a weight up to 250/500/750 kg
including the fixture in connection with robot welding using the MIG/MAG
methods.
The positioner features a twin station solution where the robot welds on one side
and the operator loads and unloads on the other.
The modular design, few and heavy-duty moving parts as well as minimal
maintenance demands make the positioner extremely service friendly.
The positioner is designed with the following main sections (see Figure 1):
1 Stand
2 Rotary unit MTC
3 Station switching unit MIC
4 Support collar
Figure 1 The positioner's main sections.
On the outgoing shaft of the station switching unit MIC there is a frame on which
two rotary units MTC are fitted.
On the outgoing shaft of the rotary unit a faceplate is fitted. The faceplate has plain
holes and guide holes for securing fixtures. On the opposite side there is a support
collar used for fixture support.
A screen is fitted between the two welding stations, which protects the operator
from arc-eye.
The rotary unit is fitted with a current collector in the form of a slip ring in order to
transfer the weld current.
The drive equipment for the positioner is placed in the system's equipment cabinet
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Positioner IRBP
Technical description
6
1.2 Technical data for 250K
IRBP 250 K
( 1000
IRBP 250K
( 1200)
Max. handling
capacity
250 kg 250 kg
Max load difference between
sides 1 and 2 (workpiece and
fixture)
140 kg 120 kg
Max. continuous torque 350 Nm 350 Nm
Centre of gravity
See loading
diagram
See loading
diagram
Max bending moment 600 Nm 600 Nm
Positioning time 90 degrees 0.8 -1.2 s 0.8 -1.2 s
Positioning time 180 degrees 1.4 -1.9 s 1.4 -1.9 s
Positioning time 360 degrees 2.3 -2.7 s 2.3 -2.7 s
Repetition accuracy with equal
loads and radius 500 mm
0.1 mm 0.1 mm
Max. speed of rotation 30 rpm 30 rpm
Station switching time 3,2 - 3,9 s 3,2 - 3,9 s
Stop time with an emergency
stop
<0.5 s <0.5 s
Max welding current, 60%
duty cycle
600 Amp 600 Amp
Weight 930 -1200 kg 970 -1250 kg
Positioner IRBP
Technical description
7
1.2.1 Technical data for 500K
IRBP 500K
( 1000
IRBP 500K
( 1200)
IRBP 500K
( 1400)
Max. handling
capacity
500 kg 500 kg 500 kg
Max load difference
between sides 1 and
2 (workpiece and
fixture)
300 kg 250 kg 220 kg
Max. continuous
torque
650 Nm 650 Nm 650 Nm
Centre of gravity
See loading
diagram
See loading
diagram
See loading
diagram
Max bending
moment
3300 Nm 3300 Nm 3300 Nm
Positioning time 90
degrees
1.2 -1.6 s 1.2 -1.6 s 1.2 -1.6 s
Positioning time 180
degrees
1.8 -2.5 s 1.8 -2.5 s 1.8 -2.5 s
Positioning time 360
degrees
3.1 -3.4 s 3.1 -3.4 s 3.1 -3.4 s
Repetition accuracy
with equal loads and
radii 500 mm
0.1 mm 0.1 mm 0.1 mm
Max. speed of
rotation
25 rpm 25 rpm 25 rpm
Station switching
time
3,3 - 4,5 s 3,3 - 4,5 s 3,3 - 4,5 s
Stop time with an
emergency stop
<0.5 s <0.5 s <0.5 s
Max welding
current, 60% duty
cycle
600 Amp 600 Amp 600 Amp
Weight 1700 -2150 kg 1750 -2200 kg 1850 -2300 kg
Positioner IRBP
Technical description
8
1.2.2 Technical data for 750K
IRBP 750K
( 1000
IRBP 750K
( 1200)
IRBP 750K
( 1400)
Max. handling
capacity
750 kg 750 kg 750 kg
Max load difference
between sides 1 and
2 (workpiece and
fixture)
250 kg 220 kg 200 kg
Max. continuous
torque
900 Nm 900 Nm 900 Nm
Centre of gravity
See loading
diagram
See loading
diagram
See loading
diagram
Max bending
moment
5000 Nm 5000 Nm 5000 Nm
Positioning time 90
degrees
1.3 -1.7 s 1.3 -1.7 s 1.3 -1.7 s
Positioning time 180
degrees
1.9 -2.6 s 1.9 -2.6 s 1.9 -2.6 s
Positioning time 360
degrees
3.2 -3.5 s 3.2 -3.5 s 3.2 -3.5 s
Repetition accuracy
with equal loads
and radii 500 mm
0.1 mm 0.1 mm 0.1 mm
Max. speed of
rotation
25 r/m 25 r/m 25 r/m
Station switching
time
3,3 - 4,6 s 3,3 - 4,6 s 3,3 - 4,6 s
Stop time with an
emergency stop
<0.6 s <0.6 s <0.6 s
Max welding
current, 60% duty
cycle
600 Amp 600 Amp 600 Amp
Weight 1700 -2150 kg 1750 -2200 kg 1850 -2300 kg
IRBP
Positioner IRBP
9
1.3 The station switching unit MIC
The station switching unit MIC is a modular unit especially developed for robot
applications and is intended for indexed movement.
The station switching unit for 2 stations consists of the following:
1 Gear drive
2 AC servo motor with integrated resolver and brake
3 Limit Switch
4 Limit position faceplate
5 Cable reel
Figure 2 The station switching unit MIC
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IRBP
Positioner IRBP
10
1.3.1 Components
A detailed description of the component parts is given below.
Gearbox
The gearbox is a precision gear drive especially developed to withstand the high
demands placed on robot applications, among others, rigidity and torsional
strength, speed and accuracy.
The gearbox is virtually free of play and never needs to be adjusted; conforming to
requirements during its entire life.
The gearbox is maintenance free and the lubricant is sufficient for the gearbox's
entire life, equivalent to 40000 hours of operation.
AC servo motor
The AC-servo motor is a permanent magnetised 3-phase AC motor, which runs
smoothly throughout the entire speed range.
The rotor is equipped with high-grade permanent magnets that are not affected by
the temperature.
The motor is thermally protected (PTC-resistance), and has a resolver for motor
feedback and position indication.
The motor is equipped with a brake for locking when the station switching unit is
not actuated.
The brake is also activated with an emergency and operating stop.
NOTE! This brake is not an operating brake.
This means that with normal operations the p-box or operator's panel are to be
used to stop.
The motor is grounded and electrically insulated from other parts in order to
prevent the weld current from being conducted through the motor's protective
conductor in the event of a fault.
The motor is maintenance free.
Limit switch/Limit position disc
The station switching unit is equipped with two positive opening limit switches to
indicate effected station switching and for monitoring the position of the station
switching unit.
IRBP
Positioner IRBP
11
1.4 Rotary unit
The rotary unit MTC is a modular unit, developed especially for robot applications
when welding and is intended for positioning the workpiece.
The rotary unit consists of the following parts:
1 Gearbox
2 AC motor with integrated brake and resolver
3 Current collector
4 Rotary unit faceplate
Figure 3 Rotary unit MTC.
1.4.1 Components
A detailed description of the component parts is given below.
Gearbox
The gearbox is a precision gear drive especially developed to withstand the high
demands placed on robot applications, among others, rigidity and torsional
strength, speed and accuracy.
The gearbox is virtually free of play and never needs to be adjusted; conforming to
requirements during its entire life.
The gearbox is maintenance free and the lubricant is sufficient for the gearbox's
entire life, equivalent to 40000 hours of operation.
AC servo motor
The AC-servo motor is a permanent magnetised 3-phase AC motor and runs
smoothly throughout the entire speed range.
The rotor is equipped with high-grade permanent magnets that are marginally
affected by the temperature.
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IRBP
Positioner IRBP
12
The motor is thermally protected (PTC-resistance), and has a resolver for motor
feedback and position indication.
The motor is equipped with a brake for locking in a position when the rotary unit is
not actuated and to provide braking with an emergency or operating stop.
NOTE! This brake is not an operating brake.
This means that with normal operations the p-box or operator's panel are to be
used to stop.
The motor is grounded and electrically insulated from other parts in order to
prevent the weld current from being conducted through the motor's protective
conductor in the event of a fault.
The motor is maintenance free.
Current collector
The function of the current collector is to transfer the weld current through the
rotary unit. This takes place through a spring-loaded contact bar against the shaft.
The contact bar needs to be lubricated after approximately 400 hours of operation.
This should be done using a special grease, article number 501 869-001.
1.5 Support collar
The support collar consists of two parts:
1 Shaft with the mounting flange
2 Flange bearing with spherical bearing position
The support collar allows axial movement during rotation.
Figure 4
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IRBP
Options
13
2 Options
2.1 Option, Robot stand
The robot stand consists of the following parts:
1 Stand
2 Pedestal
3 Insulation
4 Cover plate
Figure 5 Robot stand for positioners of the types C and R
Figure 6 Robot stand for positioner of the type K
The pedestal can be placed in different hole groups on the stand.
Exercise care to ensure the robot and positioner do not collide during station
switching. Recommended spacing, see the chapter Station layout.
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IRBP
Options
14
2.2 Option, Swivels
The swivels can be combined in different configurations for different
requirements.
1 Air swivel for 1 channel
2 Electrical swivel.
3 Air/water swivel for 2 channels.
4 Air swivel for 1 channel and electrical swivel.
2.2.1 Air swivel for 1 channel
Figure 7 Air swivel
The function is to transfer air between a fixed part and a moving part.
Technical specification, see table below.
Technical specification for 1-channel air swivel
Channels 1
Dimensions 1 / 4 "
Media Air, max 10 bar
Max. temperature
media
60C
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IRBP
Options
15
2.2.2 Electrical swivel.
Figure 8 Electrical swivel
The function is to transfer electrical signals between a fixed part and a moving
part, see the table below.
The electrical swivel can transfer different types of signals, e.g. 24 V DC and
different data bus systems. Technical specification, see table below.
Technical specification for the electrical swivel
Channels
24
*
*. Of which 1 channel is a screen.
Current Max 2 A /channel
Voltage Max 48 V DC
Conductor
cross-section
0.15 mm AWG 26
CAN-bus Max 500 KBit/s
Profibus DP Max 12 MBit/s
Interbus-S Max 500 KBit/s
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8
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IRBP
Options
16
2.2.3 Air/water swivel for 2 channels.
Figure 9 Air/water swivel
The function is to transfer air/water between a fixed part and a moving part.
Technical specification, see table below.
Technical specification for 1/2 channels air/water swivel for MTC 250
Technical specification for 1/2 channels air/water swivel for MTC 500/750/2000/5000
Channels 1 or 2
Dimensions 1 / 4"
Media 1 Air, max 10 bar
Media 2
Coolant, max 10 bar
Type HFC , 35 % water 65% glycol
Max. temperature
media
60C
Purity, media 16/13, ISO 4406
Channels 1 or 2
Dimensions 1 / 2"
Media 1 Air, max 10 bar
Media 2
Coolant, max 10 bar
Type HFC , 35 % water 65% glycol
Max. temperature
media
60C
Purity, media 16/13, ISO 4406
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8
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8
2
IRBP
Options
17
2.2.4 Air swivel for 1 channel and electrical swivel.
Figure 10 Air and electrical swivel
The function is to transfer air and electrical signals between a fixed part and a
moving part. Technical specification, see table below.
Technical specification for 1 channel air swivel for MTC 250
Technical specification for 1 channel air swivel for MTC 500/750/2000/5000
Technical specification for the electrical swivel
Channels 1
Dimensions 1 / 4"
Media 1 Air, max 10 bar
Max.
temperature
media
60C
Channels 1
Dimensions 1 / 2"
Media 1 Air, max 10 bar
Max.
temperature
media
60C
Purity, media 16/13, ISO 4406
Channels
24
*
*. Of which 1 channel is a screen.
Current Max 2 A /channel
Voltage Max 48 V DC
Conductor cross-
section
0.15 mm AWG 26
CAN-bus Max 500 KBit/s
Profibus DP Max 12 MBit/s
Interbus-S Max 500 KBit/s
5
0
3
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8
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8
8
3
IRBP
Options
18
2.2.5 Installation of the swivels
Positioner types A / B / C / D / K / R
Connection of the signals/media takes place via connection flanges, see figure below.
1 Electrical signals are connected to a socket outlet (1). Suitable plugs are
supplied for fitting on the incoming cables.
Circuit diagram, see separate tab.
2 Connection of the weld negative (2). The positioner chassis is to be
separated from the system ground, e.g. cable screen.
3 Connect the air (3) to the connection nipple with dimensions set out in the
technical specification.
4 On the rotary unit there is a free cable/hose for connection to the fixture.
Figure 11 Terminal box for connection of the swivel
Positioner type L
Connection of signals/media, see figure below:
1 Electrical signals are connected to a
socket outlet (1). Suitable plugs are
supplied for fitting on the incoming
cables.
Circuit diagram, see separate tab.
2 Connection of the weld negative (2).
The positioner chassis is to be
separated from the system ground,
e.g. cable screen.
3 Connect the air to the connection
nipple (2) with dimensions set out in
the technical specification.
4 On the rotary unit there is a free cable/hose for connection to the fixture.
Figure 12 Connection of the swivel for positioner type L
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IRBP
Options
19
2.3 Option, extra current collector for positioner types K/L/R/D
An extra current collector can be fitted if necessary, for example, with high weld
currents or with problems with the magnetic blow mechanism when welding.
1 Contact bar
2 Holder
3 Return
Figure 13 Extra current collector
2.3.1 Technical data
600 Amp at 60% duty cycle.
2.3.2 Installation of the extra current collector for positioner type L
1 Connect the return cable (3) on the current collector
2 Lubricate the current collector with grease, our article number 501 869-001.
Also see the chapter Maintenance.
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IRBP
Options
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Transport and unpacking
21
3 Transport and unpacking
The safety instructions and other instructions should be studied carefully
before starting transport and unpacking. These can be found under a separate
tab in the System manual.
Check that the equipment is not damaged in any way. Report any visible
transport damage immediately.
3.1 Lifting instructions
The positioner is fitted with lifting eyes in order for use when moving.
Lifting of the positioner may only:
- be carried out using equipment that corresponds with applicable lifting
standards.
- be carried out by authorised personnel.
Do not walk under a suspended load!
3.2 Weights
Weight of the positioner, see chapter 1 Technical Data.

Transport and unpacking
22
Positioner IRBP
Foundation
23
4 Foundation
The robot station requires a good foundation and a concrete floor with double
reinforcement and with a bearing capacity of at least 1000 kg/m
2
is recommended.
The bolts need a cast steel plate of at least 150x150x10 mm. Other solutions, for
example, cast steel sections are also possible.
Note any surface unevenness, a flatness of 0.5 mm is necessary. If necessary,
use shims under the foundation on the robot and positioner.
4.1 Installing the floor stand
1 Place the stand as set out in the chapter Station layout.
2 Drill holes for the foundation bolts. For dimensions, see the chapter
Station layout.
3 Use level bolts to adjust the height of the station.
4 Use shims if necessary.
5 Fit the foundation bolts.
6 Remove the level bolts.
7 Tighten all bolts.
Positioner IRBP
Foundation
24
Positioner IRBP
Maintenance
25
5 Maintenance
The welding robot station is intended for use in demanding working conditions
with a minimum of maintenance. However, to minimise downtime some preventive
maintenance and inspection, spread over different periods of time, is necessary (see
the table below).
The station should be cleaned if necessary:
Use a vacuum cleaner of cloth.
Compressed air and/strong solvents can damage seals, bearings, etc.
X1 Ocular control of cables. Replace if damaged.
X2 With leakage, call service personnel.
X3 Check that there is good contact between the different
connections.
X4 Check that no damage has been caused by sparking
during the start of welding and that the surface of the shaft
is not rough.
X5 Lubricate the current collector
Use special grease, our article number 501 869-001.
X6 See the Product Manual for IRB 1400/2400.
Maintenance
Daily
checks
400h
Every six
months
(1000 h)
Every year
(2000 h)
5 years Notes
Cables X1
Gearbox,
oil leakage
X2 Positioner
Return cables X3
Current
collector
X5 X4 Positioner
Series
measurement
card, battery
replacement
X6 Control
Cabinet
Positioner IRBP
Maintenance
26
Positioner IRBP
Loading diagram
27
6 Loading diagram
The diagrams (Figure 14, Figure 16) show the maximum permitted centre of
gravity displacement from the centre of rotation at different loads.
For the maximum load difference between side 1 and side 2, see the technical data
in the chapter Positioner.
The load refers to the workpiece including the fixture. Also refer to the value for
the max. continuous torque.
6.1 IRBP 250K
Example: If the centre of gravity is placed 276 mm from the centre of rotation the
load may not be greater than: 129 kg.
Figure 14 Limits for the position of the centre of gravity at different loads.
Avstnd i mm
R
Tyngdpunkt
k
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50
100
150
200
250
300
0 50 100 150 200 250 300 350 400 450 500
Weight (kg)
R (mm)
129 kg
276 mm
MTC 250
Positioner IRBP
Loading diagram
28
6.2 IRBP 500K
Example: If the centre of gravity is placed 276 mm from the centre of rotation the
load may not be greater than: 240 kg. The load refers to the workpiece including
the fixture.
Also refer to the value for the max. continuous torque.
.
Figure 15 Limits for the position of the centre of gravity at different loads.
Avstnd i mm
R
Tyngdpunkt
4
1
8
9
8
1
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MTC 500
0
100
200
300
400
500
600
0 50 100 150 200 250 300 350 400 450 500
276 mm
240 kg
R (mm)
Weight (kg)
Positioner IRBP
Loading diagram
29
6.3 IRBP 750K
Example: If the centre of gravity is placed 276 mm from the centre of rotation the
load may not be greater than: 333kg. The load refers to the workpiece including the
fixture.
Also refer to the value for the max. continuous torque.
.
Figure 16 Limits for the position of the centre of gravity at different loads.
Avstnd i mm
R
Tyngdpunkt
0
100
200
300
400
500
600
700
800
0 50 100 150 200 250 300 350 400 450 500 550 600 650
4
1
8
9
8
1
1
276 mm
333 kg
R (mm)
Weight (kg)
MTC 750
Positioner IRBP
Loading diagram
30
IRBP
Integration of fixtures
31
7 Integration of fixtures
7.1 IRBP 250R/ 500R/ 750R/ 250K/ 500K/ 750K/ 250L/ 500L/ 750L/ 2000L/
250D/ 500D
An attempt should be made when designing fixtures to match the centre of gravity
for fixtures and workpieces with the centre of rotation. In doing so this will
minimise the positioning time between positions.
First calculate the position of the centre of gravity and after which the gravitational
torque can be calculated. The latter must not exceed the specified value of the
continuous torque.
See the dimensional drawings for the positioner, faceplate and support collar for
the fasteners' installation measurements. The strength grade for the bolts in the
fixture should be 12.9 or the equivalent.
The fixture must conform to specific tolerances to maintain trueness and
parallelism in order to prevent clamping forces from occurring. See Figure 17.
Figure 17
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IRBP
Integration of fixtures
32
7.1.1 Assembling/dismantling the fixtures 250K/ 500K/ 750K
With fixture weights exceeding the maximum permitted load difference between
side 1 and side 2 the rotary unit's frame must be locked using an external aid, for
example, an overhead crane.
Figure 18 750K
7.2 IRBP 250 C Index /500C /500 C Index/ 1000C/ 250A/ 500A/ 750A/
250B/ 500B/ 750B
The position of the centre of gravity is to be calculated when designing fixtures.
After this check that the centre of gravity is within the permitted range (see the
chapter Loading diagram).
See the dimensional drawings for the positioner for the fasteners' installation
measurements.
The strength grade for the bolts in the fixture should be 12.9 or the equivalent.
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IRBP 250K
Measurement diagrams
33
8 Measurement diagrams
8.1 IRBP 250K
Figur 19 IRBP 250K, 1000 mm
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IRBP 250K
Measurement diagrams
34
Figur 20 IRBP 250K, 1200 mm
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IRBP 250K
Measurement diagrams
35
Figur 21 IRBP 250K, 1000 mm, 1200 mm
IRBP 250K 1000/ 1200
A (mm) B (mm) C (mm)
1600 706 2960
2000 840 3360
2500 1006 3860
3150 1223 4510
3500 1340 4860
4000 1507 5360
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IRBP 250K
Measurement diagrams
36
Figur 22 IRBP 250K, 1000 mm, 1200 mm
IRBP 250K 1000/ 1200
A (mm) B (mm) C (mm)
1600 706 2960
2000 840 3360
2500 1006 3860
3150 1223 4510
3500 1340 4860
4000 1507 5360
IRBP 250K D (mm) E (mm)
1000 930 601
1200 1030 664
5
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D
E
IRBP 250K
Measurement diagrams
37
Figur 23
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IRBP 250K
Measurement diagrams
38
IRBP 500K/750K
39
8.2 IRBP 500K/750K
Figur 24 IRBP 500K/750K, 1000 mm
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IRBP 500K/750K
40
Figur 25 IRBP 500K/750K, 1200 mm
5
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IRBP 500K/750K
41
Figur 26 IRBP 500K/750K, 1400 mm
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IRBP 500K/750K
42
Figur 27 IRBP 500K/750K, 1000, 1200, 1400 mm
IRBP 500K/750K 1000/ 1200/ 1400
A (mm) B (mm) C (mm)
1600 816 3409
2000 950 3809
2500 1116 4309
3150 1333 4959
3500 1450 5309
4000 1616 5809
5
0
4
2
8
4
A
0
1
-
1
IRBP 500K/750K
43
Figur 28 IRBP 500K/750K, 1000, 1200, 1400 mm
IRBP 500K/750K 1000/ 1200/ 1400
A (mm) B (mm) C (mm)
1600 816 3409
2000 950 3809
2500 1116 4309
3150 1333 4959
3500 1450 5309
4000 1616 5809
IRBP 500K/750K D (mm) E (mm)
1000 1030 678
1200 1130 748
1400 1230 813
5
0
4
2
8
4
A
0
1
-
3
D
E
IRBP 500K/750K
44
Figur 29
5
0
4
2
6
9
A
0
1
-
4
5
0
4
2
6
9
B
0
1
-
3
506 180-102