Product Specification

Product Specification
Product Specification
3HAC 13491-1/M2000/Rev. 3
IRB 7600 - 500/2.3
IRB 7600 - 400/2.55
IRB 7600 - 150/3.5
The information in this document is subject to change without notice and should not be construed as a
commitment by ABB Automation Technology Products AB, Robotics. ABB Automation Technology
Products AB, Robotics assumes no responsibility for any errors that may appear in this document.
In no event shall ABB Automation Technology Products AB, Robotics 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 Automation
Technology Products AB, Robotics’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 Automation Technology Products AB,
Robotics at its then current charge.
© Copyright 2001 ABB. All rights reserved.
Article number: 3HAC 13491-1
Issue: M2000/Rev. 3
ABB Automation Technology Products AB
Robotics
SE-721 68 Västerås
Sweden
Product Specification IRB 7600
CONTENTS
Page
1 Description ....................................................................................................................... 3
1.1 Structure.................................................................................................................. 3
Different robot versions ......................................................................................... 4
Definition of version designation........................................................................... 4
1.2 Safety/Standards ..................................................................................................... 7
1.3 Installation .............................................................................................................. 11
External Mains Transformer .................................................................................. 11
Operating requirements.......................................................................................... 11
Mounting the manipulator...................................................................................... 11
1.4 Load diagrams ........................................................................................................ 15
Maximum load and moment of inertia for full and limited axis 5
(centre line down) movement......................................................................... 22
Mounting equipment .............................................................................................. 23
Holes for mounting extra equipment ..................................................................... 24
1.5 Maintenance and Troubleshooting ......................................................................... 27
1.6 Robot Motion.......................................................................................................... 28
Performance according to ISO 9283...................................................................... 30
Velocity .................................................................................................................. 30
1.7 Cooling fan for axis 1-3 motor (option 113-115) ................................................... 30
1.8 DressPack for Material Handling ........................................................................... 31
DressPack options .................................................................................................. 31
Process cable package............................................................................................ 32
Communication...................................................................................................... 33
2 Specification of Variants and Options........................................................................... 37
3 Accessories ....................................................................................................................... 43
4 Index ................................................................................................................................. 45
Product Specification IRB 7600 M2000
1
Product Specification IRB 7600
2
Product Specification IRB 7600 M2000
Description
1 Description
1.1 Structure
A new world of possibilities opens up with ABB’s new Power Robot family. It comes
in three versions, 500 kg, 400 kg, and 150 kg handling capacities.
The IRB 7600 is ideal for heavy-weight applications, regardless of industry. Typical
areas can be handling of heavy fixtures, turning car bodies, lifting engines, handling
heavy parts, loading and unloading of machine cells, alternatively handling large and
heavy pallet layers.
There is more to this benchmark product than sheer power. We have added a range of
software products - all falling under the umbrella designation of Active Safety - to
protect not only personnel in the unlikely event of an accident, but also the robot itself.
When handling payloads of 500 kg, it is clear that safety features are vital in protecting
the new investment.
There are a large number of process options for spot welding and material handling
integrated in the robot. For a complete description of process options for spot welding
see the Product Specification SpotPack.
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 spot welding, communication features - network
communication - and advanced functions such as multi-tasking, sensor control, etc.
For a complete description on optional software, see the Product Specification
RobotWare Options.
Axis 3
Axis 4
Axis 6
Axis 5
Axis 2
Axis 1
Figure 1 The IRB 7600 manipulator has 6 axes.
Product Specification IRB 7600 M2000
3
Description
Different robot versions
The IRB 7600 is available in three versions. The following different robot types are
available:
Standard:
IRB 7600 - 500 kg / 2.3 m
IRB 7600 - 400 kg / 2.55 m
IRB 7600 - 150 kg / 3.5 m
Definition of version designation
IRB 7600 Mounting - Handling capacity / Reach
Prefix
Mounting
Floor-mounted manipulator
Handling capacity
yyy
Indicates the maximum handling capacity (kg)
Reach
x.x
Indicates the maximum reach at wrist centre (m)
Manipulator weight
4
-
Description
IRB 7600-500/2.32490 kg
IRB 7600-400/2.552500 kg
IRB 7600-150/3.52530 kg
Airborne noise level:
The sound pressure level outside
the working space
≤ 73 dB (A) Leq (acc. to
Machinery directive 98/37/EEC)
Power consumption at maximum load:
ISO Cube
Normal robot movements
3.4 kW
5.8 kW
Product Specification IRB 7600 M2000
Description
IRB 7600-500/2.3
7600-500/2.3
250
806
250
806
IRB 7600-400/2.55
IRB 7600-150/3.5
7600-400/2.55
1056
250
7600-150/3.50
2012
2012
250
250
Figure 2 View of the manipulator from the side and rear (dimensions in mm).
Allow 200 mm for cables behind the manipulator foot.
Product Specification IRB 7600 M2000
5
Description
R700
Robot power cable
200
R700
Fork
lift device für Gabelstapler
FHebevorrichtung
ork lift device
Figure 3 View of the manipulator from above (dimensions in mm)
6
Product Specification IRB 7600 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 9787
Manipulating industrial robots, coordinate systems
and motions
IEC 529
Degrees of protection provided by enclosures
EN 50081-2
EMC, Generic emission
EN 61000-6-2
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 Power Robot Generation is designed with a unique combination of robot power and
control system intelligence.
The Service Information System (SIS)
The service information system gathers information about the robot’s usage and by that
determines how hard the robot has been used. The usage is characterised by the speed,
the rotation angles and the load of every axis.
With this data collection, the service interval of every individual robot of this generation
can be predicted, optimising and planning ahead service activities. The collection data
is available via the teach pendant or the network link to the robot.
The Power Robot Generation is designed with absolute safety in mind. It is dedicated to
actively or passively avoid collisions and offers the highest level of safety to the
operators and the machines as well as the surrounding and attached equipment. These
features are presented in the active and passive safety system.
The Active Safety System
The active safety system includes those software features that maintain the accuracy of
the robot’s path and those that actively avoid collisions which can occur if the robot
leaves the programmed path accidentally or if an obstacle is put into the robot’s path.
Product Specification IRB 7600 M2000
7
Description
The Active Brake System (ABS)
All robots run with an active brake system that supports the robots to maintain the
programmed path even in an emergency situation.
The ABS is active during all stop modes, braking the robot to a stop with the power of
the servo drive system along the programmed path. After a specific time the mechanical
brakes are activated ensuring a safe stop.
The stopping process is in accordance with a class 1 stop. The maximal applicable torque
on the most loaded axis determines the stopping distance.
In case of a failure of the drive system or a power interruption, a class 0 stop turns out.
While programming the robot in manual mode, the enabling device has a class 0 stop.
ES and GS have still a class 1 stop.
The Self Tuning Performance (STP)
The Power Robot Generation is designed to run at different load configurations, many
of which occur within the same program and cycle.
The robot’s installed electrical power can thus be exploited to lift heavy loads, create a
high axis force or accelerate quickly without changing the configuration of the robot.
Consequently the robot can run in a “power mode” or a “speed mode” which can be
measured in the respective cycle time of one and the same program but with different
tool loads. This feature is based on QuickMoveTM.
The respective change in cycle time can be measured by running the robot in NoMotionExecution with different loads or with simulation tools, like RobotStudio.
The Electronically Stabilised Path (ESP)
The load and inertia of the tool have a significant effect on the path performance of a
robot. The Power Robot Generation is equipped with a system to electronically stabilise
the robot’s path in order to achieve the best path performance.
As the path performance as such is measured in a combination of speed and path accurac,
the user can choose himself the optimal configuration by applying the parameter “WorldAccLim” which can limit the linear acceleration along a programmed path.
This has an influence while accelerating and braking and consequently stabilises the
path during all motion operations with a compromise of the best cycle time. This feature
is secured through TrueMoveTM.
Over-speed protection
The speed of the robot is monitored by two independent computers.
Restricting the working space
The movement of each axis can be restricted using software limits.
As options there are safeguarded space stops for connection of limit switches to restrict
the working space.
Axes 1-3 can also be restricted by means of mechanical stops.
Collision detection (option)
In case an unexpected mechanical disturbance occurs, like a collision, electrode sticking,
etc., the robot will detect the collision, stop on the path and slightly back off from its stop
position, releasing tension in the tool.
The Passive Safety System
The Power Robot Generation has a dedicated passive safety system that by hardware
construction and dedicated solutions is designed to avoid collisions with surrounding
equipment. It integrates the robot system into the surrounding equipment safely.
8
Product Specification IRB 7600 M2000
Description
Compact robot arm design
The shape of the lower and upper arm system is compact, avoiding interference into
the working envelope of the robot.
The lower arm is shaped inward, giving more space under the upper arm to re-orientate
large parts and leaving more working space while reaching over equipment in front of
the robot.
The rear side of the upper arm is compact, with no components projecting over the edge
of the robot base even when the robot is moved into the home position.
Moveable mechanical limitation of main axes (option)
All main axes can be equipped with moveable mechanical stops, limiting the working
range of every axis individually. The mechanical stops are designed to withstand a
collision even under full load.
Zone switches on main axes (option)
All main axes can be equipped with zone switches. The double circuitry to the cam
switches is designed to offer personal safety according to the respective standards.
The Internal Safety Concept
The internal safety concept of the Power Robot Generation is based on a two-channel
circuit that 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
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.
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
Product Specification IRB 7600 M2000
9
Description
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 is shut off.
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.
10
Product Specification IRB 7600 M2000
Description
1.3 Installation
All versions of IRB 7600 are designed for floor mounting. Depending on the robot
version, an end effector with max. weight of 150 to 500 kg including payload, can be
mounted on the mounting flange (axis 6). See Load diagrams for IRB 7600 generation
robots from page 16 to page 21.
Extra loads (valve packages, transformers) can be mounted on the upper arm with a
maximum weight of 50 kg. On all versions an extra load of 500 kg can also be mounted
on the frame of axis 1. Holes for mounting extra equipment on page 24.
The working range of axes 1-3 can be limited by mechanical stops. Position switches
can be supplied on axes 1-3 for position indication of the manipulator.
External Mains Transformer
The robot system requires a 475 VAC power supply. Therefore an external transformer
will be included when a mains voltage other than 475V is selected.
Operating requirements
Protection standards
Standard and Foundry Manipulator
IP67
Explosive environments
The robot must not be located or operated in an explosive environment.
Ambient temperature
Manipulator during operation
For the controller: Standard
Option
+5oC (41oF) to +50oC (122oF)
+45oC (113oF)
+52oC (126oF)
Complete robot during transportation and storage,
for short periods (not exceeding 24 hours)up to
-25oC (13oF) to +55oC (131oF)
+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
Max. load at
emergency stop
Force xy
Force z
±14000 N
32000 ±10000 N
±31000 N
39000 ±16000 N
Torque xy
Torque z
±42000 Nm
±11000 Nm
±72000 Nm
±19500 Nm
Product Specification IRB 7600 M2000
11
88 ± 0.3
Description
Recommended screws for fastening
the manipulator to a base plate: M24 x 120 8.8 with 4 mm flat washer
Torque value 775 Nm
Figure 4 Hole configuration (dimensions in mm).
12
Product Specification IRB 7600 M2000
Description
B
5
325
D
B
37,5 o
A
C
15
o
A
C
o
10
50
522
1
A
0.1
A
A-A
1.5
B-B
C-C
D
Two guiding pins required, dimensions see Figure 6
Figure 5 Option Base plate (dimensions in mm).
Product Specification IRB 7600 M2000
13
Description
Protected from corrosion
Figure 6 Guide sleeves (dimensions in mm).
14
Product Specification IRB 7600 M2000
Description
1.4 Load diagrams
The load diagrams include a nominal payload inertia, J0 of 35 kgm2, and an extra load
of 50 kg at the upper arm housing, see Figure 7.
At different arm load, payload and moment of inertia, the load diagram will be
changed.
Centre of gravity 50 kg
400
200
Figure 7 Centre of gravity for 50 kg extra load at arm housing (dimensions i mm).
Product Specification IRB 7600 M2000
15
Description
Load diagram for IRB 7600-500/2.3
Z (m)
1,30
1,20
150 kg
1,10
1,00
200 kg
0,90
0,80
250 kg
0,70
300 kg
0,60
350 kg
0,50
425 kg
0,40
400 kg
450 kg
475 kg
500 kg
0,30
0,20
0,10
L (m)
250 mm
0,00
0,00
0,10
0,20
0,30
0,40
0,50
0,60
0,70
0,80
Figure 8 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity).
16
Product Specification IRB 7600 M2000
Description
Load diagram for IRB 7600-500/2.3 “Vertical Wrist” (±10o)
L
“Vertical wrist”
Pay
load
250 mm
10o 10o
Z
0,0
0,2
0,4
0,6
0,8
1,0
1,2
0,0
0,2
600 kg
550 kg
0,4
450 kg
300 kg
0,6
200 kg
0,8
1,0
1,2
Figure 9 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity) at “Vertical Wrist” (±10o), J0 =35 kgm2.
For wrist down (0o deviation from the vertical line).
Max load = 650kg, Zmax = 0,439m and Lmax = 0,096m
Product Specification IRB 7600 M2000
17
Description
Load diagram for IRB 7600-400/2.55
Z (m)
1,30
1,20
150 kg
1,10
1,00
200 kg
0,90
0,80
250 kg
0,70
300 kg
0,60
350 kg
0,50
400 kg
0,40
425 kg
0,30
0,20
250 mm
0,10
0,00
0,00
L (m)
0,10
0,20
0,30
0,40
0,50
0,60
0,70
0,80
Figure 10 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity).
18
Product Specification IRB 7600 M2000
Description
Load diagram for IRB 7600-400/2.55 “Vertical Wrist” (±10o)
L
“Vertical wrist”
Pay
load
10o 10o
250 mm
Z
0,0
0,2
0,4
0,6
0,8
1,0
1,2
1,4
0,0
0,2
500 kg
450 kg
0,4
400 kg
300 kg
0,6
200 kg
0,8
1,0
1,2
1,4
Figure 11 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity) at “Vertical Wrist” (±10o), J0 =35 kgm2.
For wrist down (0o deviation from the vertical line).
Max load = 540 kg, Zmax = 0,498m and Lmax = 0,103m
Product Specification IRB 7600 M2000
19
Description
Load diagram for IRB 7600-150/3.5
Z (m)
2,00
1,90
80 kg
1,80
1,70
90 kg
1,60
100 kg
1,50
1,40
1,30
110 kg
1,20
1,10
1,00
120 kg
0,90
0,80
0,70
130 kg
0,60
0,50
140 kg
0,40
0,30
150 kg
0,20
250 mm
0,10
0,00
0,00 0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80 0,90 1,00 1,10
L (m)
Figure 12 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity).
20
Product Specification IRB 7600 M2000
Description
Load diagram for IRB 7600-150/3.5 “Vertical Wrist” (±10o)
L
“Vertical wrist”
Pay
load
10o 10o
250 mm
Z
0,0
0,2
0,4
0,6
0,8
1,0
1,2
1,4
1,6
1,8
2,0
2,2
0,0
0,2
170 kg
150 kg
0,4
130 kg
0,6
110 kg
90 kg
0,8
1,0
Figure 13 Maximum permitted load mounted on the robot tool flange at different positions
(centre of gravity) at “Vertical Wrist” (±10o), J0 =35 kgm2.
For wrist down (0o deviation from the vertical line).
Max load = 180kg, Zmax = 0,337m and Lmax = 0,126m
Product Specification IRB 7600 M2000
21
Description
Maximum load and moment of inertia for full and limited axis 5 (centre line down)
movement.
Note. Load in kg, Z and L in m and J in kgm2
Full movement of axis 5 (±120o):
Axis 5
Maximum moment of inertia:
Ja5 = Mass • ((Z+0.250)2 +L2) + max J0L ≤ 500 kgm2
Axis 6
Maximum moment of inertia:
Ja6 = Mass • L2 + J0Z ≤ 315 kgm2
Z
X
Centre of gravity
J0L = Maximum own moment of inertia
around the maximum vector in the X-Y-plane
J0Z = Maximum own moment of inertia around Z
Figure 14 Own moment of inertia.
Limited axis 5, centre line down:
Axis 5
Maximum moment of inertia:
Ja5 = Load • ((Z+0.250)2 +L2) + J0L ≤ 550 kgm2
Axis 6
Maximum moment of inertia:
Ja6 = Load • L2 + J0Z ≤ 500 kgm2
Centre of gravity
J0L = Maximum own moment of inertia
around the maximum vector in the X-Y-plane
J0Z = Maximum own moment of inertia around Z
X
Z
Figure 15 Moment of inertia when axis 5 centre line down.
22
Product Specification IRB 7600 M2000
Description
Mounting equipment
Extra loads can be mounted on the upper arm housing, the lower arm, and on the frame.
Definitions of distances and masses are shown in Figure 16 and Figure 17.
The robot is supplied with holes for mounting extra equipment (see Figure 18).
Maximum permitted arm load depends on centre of gravity of arm load and robot
payload.
Upper arm
Permitted extra load on upper arm housing plus the maximum handling
weight (See Figure 16):
M1 ≤50 kg with distance a ≤500 mm, centre of gravity in axis 3 extension.
7600-500/2.3 /
250
806
M1
a
Mass
centre
M1
Figure 16 Permitted extra load on upper arm.
Frame (Hip Load)
Permitted extra load on frame is JH = 200 kgm2.
Recommended position (see Figure 17).
JH = JH0 + M4 • R2
where
JH0
R
M4
View from the rear
543
473
200
View from above
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 (≤500 kg)
View from the rear
800
600
600
View from above
1180
Figure 17 Extra load on the frame of IRB 7600 (dimensions in mm).
Mounting of hip load
The extra load can be mounted on the frame. Holes for mounting see Figure 20.
When mounting on the frame all the four holes (2x2, ∅16) on one side must be used.
Product Specification IRB 7600 M2000
23
Description
Holes for mounting extra equipment
(2012)
(1056)
806
0
165
250
50
777
1075
100
780
477
M12 (4x)
2512,5
M12 (4x)
150
Figure 18 Holes for mounting extra equipment on the upper and the lower arm (dimensions in mm).
24
Product Specification IRB 7600 M2000
Description
Figure 19 Holes for mounting of extra load on the upper arm (dimensions in mm).
240
240
50
60
290
290
M16(4x)
(4x)
M16
Figure 20 Holes for mounting of extra load on the frame, and for mounting of fork lift device
(dimensions in mm).
Product Specification IRB 7600 M2000
25
Description
31
A
1,6
0,04 A
12 H7 Depth 15
A
12 x
0,2 A B
B
(24)
15
12
x
30
12 H7 Depth 15
0,04 A
1,6
5
200
0,02 A
A
A-A
Figure 21 The mechanical interface; mounting flange (dimensions in mm).
26
Product Specification IRB 7600 M2000
Description
1.5 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 batteries every third year.
The maintenance intervals depend on the use of the robot. For detailed information on
maintenance procedures, see Maintenance section in the Product Manual.
Product Specification IRB 7600 M2000
27
Description
1.6 Robot Motion
Type of motion
Axis 1
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
Rotation motion
Arm motion
Arm motion
Wrist motion
Bend motion
Turn motion
Range of movement
+180oto-180o
+85oto-60o
+60oto-180o
+300oto-300o
+100oto-100o
+300oto -300o
IRB 7600-500/2.3
Figure 22 The extreme positions of the robot arm specified at the wrist centre
(dimensions in mm).
28
Product Specification IRB 7600 M2000
Description
IRB 7600-400/2.55
IRB 7600-150/3.5
Figure 23 The extreme positions of the robot arm specified at the wrist centre (dimensions in mm).
Product Specification IRB 7600 M2000
29
Description
Velocity
Maximum axis speeds.
IRB 7600
Axis no.
1
2
3
4
5
6
-400/2.55
-500/2.3
-150/3.5
75°/s
60°/s
60°/s
100°/s
100°/s
160°/s
75°/s
60°/s
60°/s
100°/s
100°/s
160°/s
100°/s
60°/s
60°/s
100°/s
100°/s
160°/s
Accuracy according to ISO 9283
Position accuracy:
0.10 mm
Position repeatability: 0.19 mm
Path repeatability:
1.27 mm
(IRB 7600-400/2.55)
(IRB 7600-400/2.55)
(IRB 7600-400/2.55)
1.7 Cooling fan for axis 1-3 motor (options 113-115)
A motor of the robot needs a fan to avoid overheating if the average speed over time
exceeds the value given in Table 1. The maximum allowed average speed is depending
on the load.
The average speed can be calculated with the following formula:
Average speed =
Total axis movement, number of degrees, in one cycle
360 x cycle time (minutes) incl. waiting time
The maximum allowed average speed depends on the ambient temperature according
to Table 1 and can be interpolated linearly between 40-50oC.
IP 54 for cooling fan.
Table 1
Variant
30
Maximum ambient
temp. (oC)
Maximum
average speed
axis 1 (rpm)
Maximum
average speed
axis 2 (rpm)
Maximum
average speed
axis 3 (rpm)
IRB 7600500/2.3
40
50
7.6 - 9.9
5.4 - 7.0
2.2 - 2.4
1.4 - 1.5
2.9 - 3.8
1.2 - 1.6
IRB 7600400/2.55
40
50
7.6 - 9.9
5.4 - 7.0
2.2 - 2.4
1.4 - 1.5
2.9 - 3.8
1.2 - 1.6
IRB 7600150/3.5
40
50
5.0 - 6.5
4.1 - 5.3
2.5 - 2.8
1.3 - 1.4
3.7 - 4.8
2.2 - 2.9
Product Specification IRB 7600 M2000
Description
1.8 DressPack for Material Handling
DressPack options
Dress Pack options include options for Upper arm harness, Lower arm harness and
Floor harness. These are described separately below but are designed and meant to be
seen as a complete package for either Material handling or Spot welding application.
The Upper Arm Harness consists of a process cable package and supports, clamps,
brackets, and a retractor arm. The process cable package contains special designed
cables and hoses that have been long term tested. The cables and hoses are partly
placed in a protective hose to extend the lifetime.
The Upper Arm Harness is designed to follow the robot arm movements and minimise
damages to the harness or the manipulator. The interface to the lower arm harness is
located well protected below the motor for axis 3.
The complete harness is tested and proven to be well suited for both spot welding
applications and other applications with the same type of movements and very high
requirements. The cable and hose package has a 1000-mm free length at axis 6 for
connection to a robot tool. A tension arm unit keeps hose package in the right position
for the robot arm movement approved for the DressPack. An arm protection will
prevent wearing on the protective hose and on the robot itself. Please note that when
the robot is operating, some multiply axis movement might end up with an
overstraining of the hose package. These movements must be avoided.
For more information see the Installation and Maintenance Manual.
Option 2205
Process Cable package
Harness support axis 6
Tension arm unit
Arm protection
Figure 24 Mechanical equipment upper arm harness.
Note. The upper arm harness specification is based on the selection of lower arm
harness.
The Lower Arm Harness consists of a process cable package and supports, clamps
and brackets. The process cable package, containing special designed cables and hoses,
has been long term tested.
Product Specification IRB 7600 M2000
31
Description
The process cable package is routed along the lower arm to minimize space required
and to give no limitation in the robot working envelope. The cables and hoses are partly
placed in a protective hose to extend the lifetime.
The lower arm harness is connected to the upper arm harness at the connection point
under the axis 3 motor. The interface plate at the manipulator base is the place where
the floor harness and the process media are connected.
The Floor Harness consists of signal cables for customer signals. The floor harness is
connected to the lower arm harness at the interface plate at the manipulator base and to
the left side of the control cabinet. The signal connection inside the control cabinet
depends on chosen options. As example bus option and parallel option mean different
connections.
The cables and hose which are used to form the DressPack for the Material Handling
application has the following specification and capacity:
Table 2
Type
Pcs
Area
Allowed capacity
Customer Power (CP)
Utility Power
Protective Earth
2+2
1
0,5 mm2
1,0 mm2
500 VAC, 5 A rms
500 VAC
19
4
0,23 mm2
0,23 mm2
50 VAC/DC, 1 A rms
50 VAC/DC, 1 A rms
Customer Bus (CBus)
Bus signals
Bus signals
Bus signals
Bus utility signals
2
2
4
4
0,18 mm2
0,18 mm2
0,18 mm2
0,23 mm2
Profibus 12 Mbit/s spec*
Can/DeviceNet spec*
Interbus spec*
50 VAC/DC, 1 A rms
Media
Air (PROC 1)
1
12,5 mm
inner
diameter
Max. pressure 16 bar / 230
PSI
Customer Signals (CS)
Signals twisted pair
Signals twisted pair and
separate shielded
*
Quad twisted under separate screen. Can also be used for very sensitive signals
Process cable package
For material handling the DressPack can be chosen in different configurations, where
details of the signals and media are added.
Option 056 Connection to manipulator
No floor cables for the DressPack are chosen. The connector at the base for interfacing
is specified in the installation and maintenance manual. Terminal connections could be
found in the circuit diagrams.
32
Product Specification IRB 7600 M2000
Description
Option 057 Connection to cabinet
Floor cables for the DressPack are chosen. The number of cables and cable type
depends on chosen options. The length of the process cable package at the floor is
specified under the options below:
- Option 675-678 for parallel communication
- Option 660-663 for bus communication with CANDeviceNet
- Option 665-668 for bus communication with Profibus
- Option 670-673 for bus communication with Interbus
The connection inside the cabinet depends on communication type.
- If parallel communication is chosen, signals are found at terminals inside the
cabinet (XT5.1, XT5.2 and XT6)
- If bus communication is chosen, signals are both routed to valid bus card. The
remaining are found at terminals inside the cabinet (XT5.1, XT5.2 and XT6).
Communication
Option 2063 Parallel communication
The process cable package has been chosen for parallel communication. The number
as well as the type of signals are defined under Material handling application, Option
2204, 2205.
Option 2064 Bus communication
The process cable package has been chosen for bus communication. This alternative
includes both the signals for the bus communication as well as some parallel signals.
The number as well as the type of signals are defined under Material handling
application, Option 2204, 2205. The type of bus is defined by the choice of floor
cabling (see also option 057)
Option 2204 Material Handling axis 1 to axis 3
The Lower arm harness for the Material Handling has been chosen. This includes the
process cable package as well as brackets, connectors etc. to form a complete dressing
package from manipulator base to connectors on axis 3. Depending on the choice
above the process cable package will have different content. See tables below.
For all process cable packages some of the content are common. These common parts
for Material Handling application are shown in Table 3 below. Unique parts for
different option combinations are shown in Table 4, Table 5 and Table 6. These tables
are valid for option 2204 and 2205.
Product Specification IRB 7600 M2000
33
Description
option 2204
Figure 25 Material Handling from foot to axis 3
Table for Common content Material Handling (with option 2063/2064)
Table 3
Type
Pieces at
Connection point
Note
Allowed capacity
1
12,5 m inner
diameter
Max pressure 16 bar / 230 PSI
Media
Air (PROC 1)
Table for Material Handling with option 2063
Table 4
Type
Customer Power (CP)
Utility Power
Protective earth
Customer Signals (CS)
Signals twisted pair
Signals twisted pair and
separate shielded
Pieces at
Terminal*
Pieces at
Connection point**
Allowed capacity
2+2
1
2+2
1
500 VAC, 5 A rms
500 VAC
19
4
19
4
50 VAC, 5 A rms
50 VAC, 5 A rms
* Terminals inside the cabinet if option 057 is chosen
** At manipulator base or axis 3 interface (or axis 6 under option 2205)
34
Product Specification IRB 7600 M2000
Description
Table for Material Handling with option 2064 and Can/DeviceNet
Table 5
Type
Customer Power (CP)
Utility Power
Protective earth
Customer Bus (CBus)
Bus signals
Bus signals
Signals twisted pair
Utility signals
Pieces at
Terminal*
Pieces at
Connection point**
Allowed capacity
2+2
1
2+2
1
500 VAC, 5 A rms
500 VAC
4
4
2
2
4
4
Can/DeviceNet spec
50 VAC, 1 A rms
50 VAC, 1 A rms
50 VAC, 1 A rms
* Terminals inside the cabinet if option 057 is chosen
** At manipulator base or axis 3 interface (or axis 6 under option 2205)
Table for Material Handling with option 2064 and Interbus
Table 6
Type
Customer Power (CP)
Utility Power
Protective earth
Customer Bus (CBus)
Bus signals
Bus signals
Signals twisted pair
Utility signals
Pieces at
Terminal*
Pieces at
Connection point**
Allowed capacity
2+2
1
2+2
1
500 VAC, 5 A rms
500 VAC
4
3
4
1
4
3
Interbus spec
50 VAC, 1 A rms
50 VAC, 1 A rms
50 VAC, 1 A rms
* Terminals inside the cabinet if option 057 is chosen
** At manipulator base or axis 3 interface (or axis 6 under option 2205)
Option 2205 Material Handling axis 3 to axis 6
The Upper arm harness for the Material Handling has been chosen. This includes the
process cable package as well as brackets, connectors etc. to form a complete dressing
package from interface at axis 3 to the connectors at axis 6. Depending on the earlier
choice (see option 2204) the process cable package will have different content.
For content see Table 3, Table 4, Table 5 and Table 6. See also Figure 24.
The connector type at the manipulator base, at axis 3 and axis 6 is specified in the
installation and maintenance manual.
Product Specification IRB 7600 M2000
35
Description
36
Product Specification IRB 7600 M2000
Specification of Variants and Options
2 Specification of Variants and Options
The different variants and options for the IRB 7600 are described below.
The same numbers are used here as in the Specification form. For controller options,
see Product Specification S4Cplus, for software options, see Product Specification
RobotWare Options, and for SpotPack options, see Product Specification SpotPack.
1 MANIPULATOR
VARIANTS
021 IRB 7600-150/3.5
024 IRB 7600-400/2.55
025 IRB 7600-500/2.3
Manipulator colour
330 Standard
The manipulator is painted in ABB orange.
352 Ral code
Colours according to RAL-codes. Not available for Foundry.
Protection
035 Standard (IP 67)
036 Foundry
Robot adapted for foundry or other harsh environments.
The robot has the FoundryPlus protection which means that the whole manipulator is
IP67 classified and steam washable. An excellent corrosion protection is obtained by a
special coating. The connectors are designed for severe environment, and bearings,
gears and other sensitive parts are highly protected.
Only available colour is ABB orange Foundry.
PROCESS CABLE PACKAGE
For more information see chapter 1.8 DressPack for Material Handling.
Regarding DressPack for spot welding see Product Specification SpotPack.
2204 Material Handling from foot to axis 3
Requires Communication Parallel or Bus option 2063/2064.
See Figure 25, and chapter1.8 DressPack for Material Handling and Table 2 - Table 6.
2205 Material Handling from axis 3 to axis 6
Requires Material Handling from foot to axis 3 option 2204 and Communication
Parallel or Bus option 2063/2064.
See Figure 25, and chapter1.8 DressPack for Material Handling and Table 2 - Table 6.
Product Specification IRB 7600 M2000
37
Specification of Variants and Options
Communication
2063 Parallel
Includes customer power CP, customer signals CS and Air for MH-process cable
package.
2064 Bus
Includes CP, Air and CAN/DeviceNet, Interbus or Profibus for MH-process cable
package.
R1.SW1
R1.SW2/3
7th Axis
R1.MP
R1.SMB
R1.PROC1 1 x 1/2”
R1.CP/CS
Figure 26 Location of MH connections on the foot.
R2.CP/CS
R2.PROC1 1 x 1/2”
R2.MP 5/6
Figure 27 Location of MH connections on axis 3.
38
Product Specification IRB 7600 M2000
Specification of Variants and Options
Connection to
056 Manipulator
The signals are connected directly to the manipulator base to one heavy duty industrial
housing with a Harting modular connector R1.CP/CS, see Figure 26.
The cables from the manipulator base are not supplied.
057 Cabinet
The signals CP/CS 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.
For information about the limited number of signals available,
see DressPack options on page 31.
Connection to cabinet (Cable lengths)
Parallel/CANDeviceNet/Interbus/Profibus
675/660/670/665 7m
676/661/671/666 15m
678/663/673/668 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.
092 Fork lift device
Lifting device on the manipulator for fork-lift handling.
Note. When Cooling Fan for axis 1 motor unit is used, this must be disassembled in
order to use fork lift device.
087 Base plate
See chapter 1.3 Installation, for dimension drawing.
091 Brake release cover
A cover for the break release buttons.
113 Cooling fan for axis 1 motor (IP 54)
Cannot be combined with Cooling fan for axis 2 motor option 114.
For in use recommendations see 1.7 Cooling fan for axis 1-3 motor (options 113-115).
See Figure 28.
Not for protection Foundry.
114 Cooling fan for axis 2 motor (IP 54)
For in use recommendations see 1.7 Cooling fan for axis 1-3 motor (options 113-115).
Not for protection Foundry.
115 Cooling fan for axis 3 motor (IP 54)
For in use recommendations see 1.7 Cooling fan for axis 1-3 motor (options 113-115).
See Figure 28.
Not for protection Foundry.
Product Specification IRB 7600 M2000
39
Specification of Variants and Options
088 Upper arm covers
See Figure 29.
Option 115
Option 113
Figure 28 Cooling fan for axis 1 motor and axis 3 motor.
Option 088
Figure 29 Upper arm covers.
1300 Axis 1 cover
A leather cover around the cables in the central hole at axis 1.
1301 Piston cover
A leather bellow for the balancing cylinder piston.
POSITION SWITCHES
Position switches indicating the position of the three 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. No machining operation of the cams is necessary for the adaptation, simple
hand tools can be used.
For axis 1, there are three redundant position zones available, each with two independent
40
Product Specification IRB 7600 M2000
Specification of Variants and Options
switches and cams. For axes 2 and 3, two redundant position zones are available, each
with two independent switches and cams.
For axis 1 it is possible to mount a second set of position switches, doubling the number
of redundant zones to six.
Each position zone consists of two switches mechanically operated by separate cams.
Each switch has one normally open and one normally closed contact. See Product
Specification S4Cplus.
The design and components fulfil the demands to be used as safety switches.
These options may require external safety arrangements, e.g. light curtains, photocells
or contact mats.
The switches can be connected either to the manipulator base (R1.SW1 and R1.SW2/
3, see Figure 26), or to the controller. In the controller the signals are connected to
screw terminal XT8 Phoenix MSTB 2.5/12-ST-5.08.
Switch type Balluff Multiple position switches BNS, according to EN 60947-5-1 and
EN 60947-5-2.
Connection to
075 Manipulator
Connection on the manipulator base with one/two FCI Sealok 32-pin connector.
076 Cabinet
Connected to 12-pole screw terminals, Phoenix MSTB 2.5/12-ST-5.08, in the
controller. Position switch cables are included.
Position switches axis 1
071 Three redundant position zones are available, each with two independent switches and
cams.
Connection of signals axis 1 (cable lengths)
078 7m
079 15m
081 30m
072 Position switches axis 2
Two redundant position zones are available, each with two independent switches and
cams.
073 Position switches axis 3
Two redundant position zones are available, each with two independent switches and
cams.
Connection of signals axes 2 and 3 (cable lengths)
083 7m
084 15m
086 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.
Product Specification IRB 7600 M2000
41
Specification of Variants and Options
Axis 1
061 Four stops which allow the working range to be restricted in increments of 7,5o.
062 Two stops which allow the working range to be restricted in increments of 15o.
063 Axis 2
Six stops which allow the working range to be restricted in increments of 15o at both
end positions. Each stop decreases the motion by 15o.
064 Axis 3
Six stops which allow the working range to be restricted in increments of 20o at both
end positions. Each stop decreases the motion by 20o.
42
Product Specification IRB 7600 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
Tools
Brake release box
Includes six brake release buttons and 24V battery unit which can be connected to
R1.BU on the manipulator frame. The brake release box can be ordered from
ABB Automation Technology Products AB, Robotics, department S.
Calibration Cube
This calibration tool can be ordered from ABB Automation Technology Products AB,
Robotics, department S.
Product Specification IRB 7600 M2000
43
Accessories
44
Product Specification IRB 7600 M2000
Index
4 Index
A
accessories 43
Active Brake System 8
Active Safety System 7
motion 28
mounting
extra equipment 23
robot 11
mounting flange 26
N
C
noise level 4
Collision detection 8
colours 37
cooling device 4
O
E
Electronically Stabilised Path 8
emergency stop 9
enabling device 9
equipment
mounting 23
permitted extra load 23
F
fire safety 10
fork lift device 39
H
hold-to-run control 10
hole configuration 12
holes for mounting extra equipment 24
humidity 11
I
installation 11
Internal Safety Concept 9
L
lifting device 39
load 11
load diagrams 15
operating requirements 11
options 37
overspeed protection 8
P
Passive Safety System 8
payload 11
performance 30
position switches 40
protection 37
protection standards 11
R
range of movement 28
reduced speed 9
Robot Peripherals 43
robot versions 4
S
safeguarded space stop 10
delayed 10
safety 7
Safety category 3 9
safety lamp 10, 39
Self Tuning Performance 8
service 27
Service Information System 7
space requirements 4
standards 7
structure 3
M
T
maintenance 27
manipulator colour 37
mechanical interface 26
Product Specification IRB 7600 M2000
temperature 11
troubleshooting 27
45
Index
V
variants 37
W
weight 4
working space
restricting 8, 11, 41
Z
zone switches 9
46
Product Specification IRB 7600 M2000
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement