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Product Specification
IRB 6400PE
3HAC 9120-1 / M2000
ABB Flexible Automation
The information in this document is subject to change without notice and should not be construed as a
commitment by ABB Robotics AB. ABB Robotics AB assumes no responsibility for any errors that may
appear in this document.
In no event shall ABB Robotics 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 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 AB at its then current charge.
© ABB Robotics AB
Article number: 3HAC 9120-1
Issue: M2000
ABB Robotics AB
S-721 68 Västerås
Sweden
Product Specification IRB 6400PE
CONTENTS
Page
1 Description ....................................................................................................................... 3
1.1 Structure.................................................................................................................. 3
1.2 Safety/Standards ..................................................................................................... 5
1.3 Installation .............................................................................................................. 7
Operating requirements.......................................................................................... 7
Mounting the manipulator...................................................................................... 7
Load diagram ......................................................................................................... 8
Process forces......................................................................................................... 9
Mounting equipment .............................................................................................. 10
Holes for mounting equipment .............................................................................. 11
1.4 Maintenance and Troubleshooting ......................................................................... 12
1.5 Robot Motion.......................................................................................................... 13
Performance according to ISO 9283...................................................................... 14
Velocity .................................................................................................................. 14
Resolution .............................................................................................................. 14
1.6 Signals .................................................................................................................... 14
Signal connections on robot arm............................................................................ 14
2 Specification of Variants and Options........................................................................... 15
3 Accessories ....................................................................................................................... 19
4 Index ................................................................................................................................. 21
Product Specification IRB 6400PE M2000
1
Product Specification IRB 6400PE
2
Product Specification IRB 6400PE M2000
Description
1 Description
1.1 Structure
IRB 6400PE is a 6-axis industrial robot, designed specifically for poke welding at
manufacturing industries that use flexible robot-based automation. The robot has an
open structure that is specially adapted for flexible use, and can communicate
extensively with external systems.
The robot is equipped with the operating system BaseWare OS. BaseWare OS controls
every aspect of the robot, like motion control, development and execution of
application programs communication etc. See Product Specification S4Cplus.
For additional functionality, the robot can be equipped with optional software for
application support - for example gluing and arc welding, communication features network communication - and advanced functions such as multitasking, sensor control
etc. For a complete description on optional software, see the Product Specification
RobotWare Options.
Axis 3
Axis 4
Axis 5
Axis 6
Axis 2
Axis 1
Figure 1 The IRB 6400PE manipulator has 6 axes.
Manipulator weight
1590 kg
Airborne noise level:
The sound pressure level outside
the working space
Product Specification IRB 6400PE M2000
< 70 dB (A) Leq (acc. to
Machinery directive 89/392 EEC)
3
Description
1221
1750
1150
200
724
246
225
1175
2240
900
188
922
1044
R 660
322
Figure 2 View of the manipulator from the side, rear and above (dimensions in mm).
4
Product Specification IRB 6400PE M2000
Description
1.2 Safety/Standards
The robot conforms to the following standards:
EN 292-1
Safety of machinery, terminology
EN 292-2
Safety of machinery, technical specifications
EN 954-1
Safety of machinery, safety related parts of control
systems
EN 60204
Electrical equipment of industrial machines
IEC 204-1
Electrical equipment of industrial machines
ISO 10218, EN 775
Manipulating industrial robots, safety
ANSI/RIA 15.06/1999
Industrial robots, safety requirements
ISO 9409-1
Manipulating industrial robots, mechanical
interface
ISO 9787
Manipulating industrial robots, coordinate systems
and motions
IEC 529
Degrees of protection provided by enclosures
EN 50081-2
EMC, Generic emission
EN 50082-2
EMC, Generic immunity
ANSI/UL 1740-1996 (option) Standard for Industrial Robots and Robotic
Equipment
CAN/CSA Z 434-94 (option) Industrial Robots and Robot Systems - General
Safety Requirements
The robot complies fully with the health and safety standards specified in the EEC’s
Machinery Directives.
The robot is designed with absolute safety in mind. It has a dedicated safety system
based on a two-channel circuit which is monitored continuously. If any component
fails, the electrical power supplied to the motors shuts off and the brakes engage.
Safety category 3
Malfunction of a single component, such as a sticking relay, will be detected at the next
MOTOR OFF/MOTOR ON operation. MOTOR ON is then prevented and the faulty
section is indicated. This complies with category 3 of EN 954-1, Safety of machinery
- safety related parts of control systems - Part 1.
Selecting the operating mode
The robot can be operated either manually or automatically. In manual mode, the robot
can only be operated via the teach pendant, i.e. not by any external equipment.
Reduced speed
In manual mode, the speed is limited to a maximum of 250 mm/s (600 inch/min.).
The speed limitation applies not only to the TCP (Tool Centre point), but to all parts of
the robot. It is also possible to monitor the speed of equipment mounted on the robot.
Three position enabling device
The enabling device on the teach pendant must be used to move the robot when in
manual mode. The enabling device consists of a switch with three positions, meaning
Product Specification IRB 6400PE M2000
5
Description
that all robot movements stop when either the enabling device is pushed fully in, or when
it is released completely. This makes the robot safer to operate.
Safe manual movement
The robot is moved using a joystick instead of the operator having to look at the teach
pendant to find the right key.
Over-speed protection
The speed of the robot is monitored by two independent computers.
Emergency stop
There is one emergency stop push button on the controller and another on the teach
pendant. Additional emergency stop buttons can be connected to the robot’s safety chain
circuit.
Safeguarded space stop
The robot has a number of electrical inputs which can be used to connect external safety
equipment, such as safety gates and light curtains. This allows the robot’s safety
functions to be activated both by peripheral equipment and by the robot itself.
Delayed safeguarded space stop
A delayed stop gives a smooth stop. The robot stops in the same way as at a normal
program stop with no deviation from the programmed path. After approx. 1 second the
power supplied to the motors shuts off.
Collision detection (option)
In case an unexpected mechanical disturbance like a collision, electrode stik etc appears,
the robot will stop and slightly back off from its stop position.
Restricting the working space
The movement of each axis can be restricted using software limits.
There are safeguarded space stops for connection of limit switches to restrict the
working space.
Axes 1-3 can also be restricted (option).
Hold-to-run control
“Hold-to-run” means that you must depress the start button in order to move the robot. When
the button is released the robot will stop. The hold-to-run function makes program testing
safer.
Fire safety
Both the manipulator and control system comply with UL’s (Underwriters Laboratory)
tough requirements for fire safety.
Safety lamp (option)
As an option, the robot can be equipped with a safety lamp mounted on the manipulator.
This is activated when the motors are in the MOTORS ON state.
6
Product Specification IRB 6400PE M2000
Description
1.3 Installation
The IRB 6400PE is designed for floor mounting. An end effector of max. weight 75 kg,
including payload, can be mounted on the mounting flange (axis 6). Load diagram, see
page 8.
Extra loads (valve packages, transformers) can be mounted on the upper arm. An extra
load can also be mounted on the frame of axis 1. Holes for extra equipment see page 11.
The working range of axes 1-3 can be limited by mechanical stops. Position switches
can be supplied on axis 1 and axis 2 for position indication of the manipulator.
Operating requirements
Protection standards
IEC529
IP54
IP55
Manipulator
Wrist
Explosive environments
The robot must not be located or operated in an explosive environment.
Ambient temperature
Manipulator during operation
+5oC (41oF) to +45oC (117oF)
Complete robot during transportation and storage, -25oC (13oF) to +55oC (131oF)
for short periods (not exceeding 24 hours)
up to +70oC (158oF)
Relative humidity
Complete robot during transportation and storage Max. 95% at constant temperature
Complete robot during operation
Max. 95% at constant temperature
Mounting the manipulator
Maximum load in relation to the base coordinate system.
Endurance load
in operation
± 12000 N
21000 ± 5500 N
Force xy
Force z
Torque xy
Torque z
± 32000 Nm
±12000 Nm
Max. load at
emergency stop
± 18000 N
21000 ± 10000 N
± 39000 Nm
± 13000 Nm
Y
∅ 0.2 (3x)
D=48 (3x)
D=32 (3x)
415.7
720
100 ±0,5
Z
X
D=64 H9 (3x)
A
15
+2
0
A
Support surface D=85 (3x)
480 ±0.1
A-A
Figure 3 Hole configuration (dimensions in mm).
Product Specification IRB 6400PE M2000
7
Description
Load diagram
Load diagram for IRB 6400PE
Z (m)
30 kg
0.7
0.6
45 kg
0.5
60 kg
0.4
75 kg
0.3
0.2
0.1
L (m)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
The load diagram is valid for J0 ≤10 kgm2.
J0 = the maximum component (JX0, JY0, JZ0) of the moment
of inertia of the handling weight at its centre of gravity.
Figure 4 Maximum weight permitted for load mounted on the mounting flange at different positions
(centre of gravity).
8
Product Specification IRB 6400PE M2000
Description
Process forces
Max. force through the wrist centre:
- 0 to 65o relative to the vertical line, F = 5000 N
- 65 to 90o relative to the vertical line, F = 4500 N
- 90 to 115o relative to the vertical line, F = 3500 N
Max. offset force from the wrist centre:
- 3500 N when r = 100 mm.
3500 N
Centre axis 5
4500 N
o
Y
±115
X
5000 N
F
Centre axis 6
±90o
r ≤ 100 mm
o
±65
Z
Z
Figure 5 Max. force through the wrist centre.
The direction of force F must be parallel to the z-axis in the tool coordinate system.
Time at max. force:
- < 1 second excluding rewelds
- < 3 seconds for rewelds
Due to the dynamic forces and the backward elastic deflection in the robot, the rise time
for rebuilding the forces in the air cylinder must comply with the values below:
- Min. time to achieve 90% of max force:
F > 3500 N
F ≤ 3500 N
- Min. time to go from 100% load to 0% load: F > 3500 N
F ≤ 3500 N
> 0.15 sec.
> 0.03 sec.
> 0.1 sec.
> 0.03 sec.
The angular fault from the z-axis must be less than 5o.
The distance between the weld cylinder and weld plate: 15 mm.
The number of poke points permitted per minute:
The force contact surface = 1 sec. (Cabinet temperature 45o C).
The number of points can be increased if the cabinet temperature can be decreased.
Axis
1
2 and 3
1
2
% Torque1
Number of points/minute2
100
3-5
75
6-8
50
15-20
100
12-25
75
26-40
100% = maximum torque load on current axis.
The lower value applies when the current robot axis is executing large
movements. The higher value applies for small movements of the current axis.
Product Specification IRB 6400PE M2000
9
Description
Mounting equipment
Extra loads can be mounted on the upper arm and the frame. Definitions of distances
and masses are shown in Figure 6 (upper arm) and in Figure 7 (frame).
The robot is supplied with holes for mounting extra equipment (see Figure 8).
Upper arm
Permitted extra load on upper arm plus the maximum handling weight
(See Figure 6):
M1 ≤ 35 kg with distance a ≤ 500 mm, centre of gravity in axis 3 extension
or
M2 ≤ 35 kg with distance b ≤ 400 mm
or
M3 ≤ 10 kg with distance c ≥300 mm
If the handling weight is lower than the maximum weight, M1 alt. M2 can be
increased as follows:
M1 (alt. M2) + handling weight ≤ 35 kg + max. handling weight
For example, if the handling weight for 2.4-120 is only 80 kg, M2 can be 75 kg.
M1
M2
a
M3
b
c
Mass
centre
M1
Figure 6 Permitted extra load on upper arm.
Frame (Hip Load)
Permitted extra load on frame is JH = 120 kgm2.
Recommended position (see Figure 7).
JH = JH0 + M4 • R2
where
is the moment of inertia of the equipment
is the radius (m) from the centre of axis 1
is the total mass (kg) of the equipment including
bracket and harness (≤ 320 kg)
JH0
R
M4
362
R
M4
JH0
188
504
Figure 7 Extra load on frame of IRB 6400PE (dimensions in mm).
10
Product Specification IRB 6400PE M2000
Description
Holes for mounting equipment
A
A
D
E
D
E
M10 (2x) See E-E
B
M10 (4x)
B
104 for “Hole 1”
93 for “Hole 2”
See E-E
50
C
175
C
810 (/2.4-x)
A-A
F
112
80
282
M10 (2x)
M10 (2x)
B-B
260
F
378
C-C
15
M10 (4x) Depth 20
93
150
75
200
D-D
M10 (2x)
“Hole 2”
“Hole 1”
180 175
E-E
Figure 8 Holes for mounting extra equipment (dimensions in mm).
Product Specification IRB 6400PE M2000
11
Description
30o
D=10 H7 depth 10
8
M10 (6x) depth 18
D=80 H7
D=160 h7
60o
D=125
F-F
8
Figure 9 The mechanical interface (mounting flange) ISO 9409-1-A125 (dimensions in mm).
As an option there is an electrically insulated tool flange.
For more information see Figure 13.
1.4 Maintenance and Troubleshooting
The robot requires only a minimum of maintenance during operation. It has been
designed to make it as easy to service as possible:
- Maintenance-free AC motors are used.
- Liquid grease or oil is used for the gear boxes.
- The cabling is routed for longevity, and in the unlikely event of a failure, its
modular design makes it easy to change.
The following maintenance is required:
- Changing filter for the transformer/drive unit cooling every year.
- Changing grease and oil every third year.
- Changing batteries every third year.
- Some additional checks every year.
The maintenance intervals depends on the use of the robot. For detailed information on
maintenance procedures, see Maintenance section in the Product Manual.
12
Product Specification IRB 6400PE M2000
Description
1.5 Robot Motion
Type of motion
Range of movement
Axis 1
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
+180o
+70o
+105o
+200o
+120o
+300o
Rotation motion
Arm motion
Arm motion
Wrist motion
Bend motion
Turn motion
-180o
-70o
-28o
-200o
-120o
-300o
to
to
to
to
to
to
6
1
ϕ3
ϕ2/ϕ3
0
2
5
ϕ2
2589
3
900
4
53
878
2253
Positions at wrist centre (mm)
pos.
X
0
1
2
3
4
5
6
1338
205
421
718
1000
2246
1669
Z
2075
1963
1549
459
56
1349
2397
Angle ϕ2, ϕ3 (degrees)
pos.
0
1
2
3
4
5
6
axis 2
(ϕ2)
0
-70
-70
40
70
70
37
axis 3
(ϕ3)
Angle 2/3 (ϕ2/ϕ3)
Min. 25o Max. 155o
90o at pos. 0
0
-28
-5
105
105
5
-28
All dimensions refer to the wrist centre (mm)
Figure 10 The extreme positions of the robot arm (dimensions in mm).
Product Specification IRB 6400PE M2000
13
Description
Performance according to ISO 9283
At rated load and 1 m/s velocity on the inclined ISO test plane with all six robot axes
in motion.
Unidirectional pose repeatability:
RP = 0.2 mm
Linear path accuracy:
AT = 2.5 - 3.0 mm
Linear path repeatability:
RT = 0.8 - 1.4 mm
Minimum positioning time, to within 0.4 mm of the position:
0.3 - 0.5 sec. (on 35 mm linear path)
0.7 - 0.9 sec. (on 350 mm linear path)
The above values are the range of average test-results from a number of robots. If
guaranteed values are required, please contact your nearest ABB Flexible Automation
Centre.
Velocity
Axis no. 1
2
3
4
5
6
70o/s
70o/s
70o/s
210o/s
150o/s
210o/s
There is a supervision function to prevent overheating in applications with intensive
and frequent movements.
Resolution
Approx. 0.01o on each axis.
1.6 Signals
Signal connections on robot arm
For connection of extra equipment on the manipulator there are cables integrated into
the manipulator’s cabling, and two connectors, one Burndy 23-pin UTG 018-23S and
one Burndy 12-pin UTG 014-12S, on the moveable part of the upper arm.
Signals
Power
Air
14
23
10
1
50 V, 250 mA
250 V, 2 A
Max. 10 bar, inner hose diameter 11 mm
Product Specification IRB 6400PE M2000
Specification of Variants and Options
2 Specification of Variants and Options
The different variants and options for the IRB 6400PE are described below.
The same numbers are used here as in the Specification form. For controller options,
see Product Specification S4Cplus, and for software options, see Product Specification
RobotWare Options.
1 MANIPULATOR
VARIANT
022 IRB 6400PE/2.25-75
IRB 6400 Application, Mounting / Reach-Handling capacity
Application:
Mounting:
Reach:
Handling capacity:
PE
-
Robot adapted for poke welding.
Floor-mounted manipulator.
Specifies the max. reach at the wrist centre.
Specifies the max. handling capacity.
Manipulator colour
330 The manipulator is painted with ABB orange.
331- Colours according to RAL-codes.
348
Protection
035 Standard
APPLICATION INTERFACE
Air supply and signals for extra equipment to upper arm
042 Integrated hose for compressed air. There is an inlet at the base (see Figure 11) and an
outlet on the upper arm (see Figure 12). Connections: R1/2”.
For connection of extra equipment on the manipulator there are cables integrated into
the manipulator’s cabling, and two connectors, one Burndy 23-pin UTG 018-23S and
one Burndy 12-pin UTG 014-12S, on the moveable part of the upper arm.
This option is standard on 6400PE.
Option 056/057
R1.CP/CS
Air R1/2”
Product Specification IRB 6400PE M2000
15
Specification of Variants and Options
Figure 11 Option 042, connection of signals and air to the base.
042
Figure 12 Connection of signals on the upper arm.
Connection of signals to
056 Manipulator
The signals are connected directly to the robot base to one Harting 40-pin connector
(see Figure 11). The cables from the manipulator base are not supplied.
057 Cabinet
The signals are connected to 12-pole screw terminals, Phoenix MSTB 2.5/12-ST-5.08,
in the controller.
The cable between R1.CP/CS and the controller is supplied.
675
676
677
678
Connection to cabinet (Cable lengths)
7m
15m
22m
30m
EQUIPMENT
691 Safety lamp
A safety lamp with an orange fixed light can be mounted on the manipulator.
The lamp is active in MOTORS ON mode.
The safety lamp is required on a UL/UR approved robot.
058 Dressing
Mounting of extra equipment, e.g. tool system on robot before delivery, ordered from
ABB Flexible Automation/Dpt U.
092 Fork lift device
Lifting device on the manipulator for fork-lift handling is mounted at delivery.
Lifting eyes for use with an overhead crane are integrated as standard.
091 Brake release cover
Protective cover over push-buttons on brake release unit.
089 Insulated flange
Electrically insulated tool flange. In case of an electrical fault in the spot welding
equipment mounted on the tool flange, the tool flange withstands dangerous
voltage (100V AC during 60 seconds or 300V AC during 10 seconds) in non water
applications without passing it further to electronics in the robot and controller.
See Figure 13.
16
Product Specification IRB 6400PE M2000
Specification of Variants and Options
30o
D=10 H7 Depth 10
8
M10 (6x) Depth 18
D=80 H7
D=160 h7
60o
D=125
10o
D=10 H7 Depth 10
8
Figure 13 The mechanical interface of the insulated flange (dimensions in mm).
POSITION SWITCH
Position switches indicating the position of one or two of the main axes. Rails with
separate adjustable cams are attached to the manipulator. The cams, which have to be
adapted to the switch function by the user, can be mounted in any position in the
working range for each switch.
The position switch device is delivered as a kit to be assembled when installing the
robot. Assembly instruction is included.
Note! This option may require external safety arrangements, e.g. light curtains,
photocells or contact mats.
Note The switches are not recommended to be used in severe environment with sand or
chips.
1, 2 or 3 switches indicating the position of axis 1.
Switch type: Telemecanique XCK-M1/ZCK-D16, 2 pole N/C + N/O, according to
IEC 947-5-1.
069 1 switch, axis 1
070 2 switches, axis 1
071 3 switches, axis 1
072 1 switch, axis 2
Connection to
075 Manipulator
Connection on the manipulator base with one FCI 23-pin connector.
076 Cabinet
The signals are connected to 12-pole screw terminals, Phoenix MSTB 2.5/12-ST5.08,in the controller. The cable between the manipulator base R1.SW and the
controller, is included.
Product Specification IRB 6400PE M2000
17
Specification of Variants and Options
Connection of signals (Cable lengths)
083
084
085
086
7m
15m
22m
30m
WORKING RANGE LIMIT
To increase the safety of the robot, the working range of axes 1, 2 and 3 can be restricted
by extra mechanical stops.
621 Axis 1
2 stops which allow the working range to be restricted in any increment of 20o.
622 Axis 2
6 stops which allow the working range to be restricted in increments of 20o. Each stop
decreases the motion by 20°. This means that the motion can be decreased by
6 x 20° from the maximum axis motion.
623 Axis 3
6 stops which allow the working range to be restricted in increments of 20o. Each stop
decreases the motion by 20°. This means that the motion can be decreased by
6 x 20° from the maximum axis motion.
18
Product Specification IRB 6400PE M2000
Accessories
3 Accessories
There is a range of tools and equipment available, specially designed for the robot.
Basic software and software options for robot and PC
For more information, see Product Specification S4Cplus, and Product Specification
RobotWare Options.
Robot Peripherals
- Track Motion
- Tool System
- Motor Units
- Spot welding system for transformer gun
Product Specification IRB 6400PE M2000
19
Accessories
20
Product Specification IRB 6400PE M2000
Index
4 Index
N
A
noise level 3
accessories 19
air supply 15
O
C
cooling device 3
E
emergency stop 6
enabling device 5
equipment
mounting 10
permitted extra load 10
extra equipment
connections 15
F
fire safety 6
fork lift device 16
H
hold-to-run control 6
humidity 7
I
installation 7
L
load 7
load diagrams 8
operating requirements 7
options 15
overspeed protection 6
P
payload 7
performance 14
position switch 17
protection standards 7
R
range of movement 13
reduced speed 5
repeatability 14
Robot Peripherals 19
robot versions 15
S
safeguarded space stop 6
delayed 6
safety 5
Safety lamp 6, 16
service 12
service position indicator 17
signal connections 15
space requirements 3
standards 5
structure 3
T
M
maintenance 12
mechanical interface 12
motion 13
mounting
extra equipment 10
robot 7
mounting flange 12
temperature 7
troubleshooting 12
V
variants 15
W
working space
restricting 6, 7, 18
Product Specification IRB 6400PE M2000
21
Index
22
Product Specification IRB 6400PE M2000
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