ABB is a leader in the development of robot software, and has recently introduced a range of functions to simplify and shorten the time required for programming.
Online programming
The most common method of robot programming remains online, via a robot controller teach pendant. ABB’s FlexPendant, supplied with the ABB IRC5 robot controller, is characterised by its clean, touch screen-based design and 3D joystick for intuitive interaction. Powerful customised application support enables loading of tailor-made applications, such as operator screens, eliminating the need for a separate HMI.
The ABB controller is supplied with RobotWare software. The heart of this powerful and configurable software is ABB’s robot language, RAPID, a highly flexible programming tool. RobotWare has a range of additional functions and process specific applications to simplify programming (Machining FC, Assembly FC, DieCast, Plastic Mould, Dispense and Spot). On RobotWare Plastic Mould for example, the program wizard guides the inexperienced user to create an injection moulding machine tending program in just a few steps.
The software is built with symbol programming that hides programming language (RAPID) from the user. The experienced programmer can utilise the advanced programming possibilities to create and modify unique stations and grippers. The combination of symbol programming and RAPID modifications offers a very powerful and flexible tool to program and modify machine tending programs.
ABB has also recently introduced Force Control for machining applications (grinding, deflashing, polishing and deburring), saving up to 90% of the programming time. The traditional way in which a user programs a robot is to define the path and the speed. These are constant, independent of the process forces. If the path does not coincide with the surface and dimensions of the part, quality problems and potential damage to tooling can result. Users have spent a lot of time trying to correct these deficiencies, often requiring additional flexible toolings and servo axes. With the FC (Force Control) Graphical Programming Interface, the robot is made “soft”, and the operator can move the robot by hand to the correct positions, avoiding these traditional problems. The correct positions on the work piece only need to be accurate within a few millimetres. These manually taught paths are used as the basis for Automatic Path Learning. The robot runs FCPressure functionality, following the surface/edge, and recording the accurate path. All of these features are designed to shorten the programming time.
Offline programming
There is also a big push for offline programming, especially for manufacturers working two or three shifts. Offline programming can be used as a risk assessment tool by visualising and confirming solutions and layouts before the actual robot is installed, and by creating more accurate paths.
RobotStudio 5 is ABB’s leading product for offline programming. It can easily import data in major CAD formats. By working with this very exact data, the robot programmer is able to generate more accurate robot programs, yielding higher product quality. Some of the smart RobotStudio features are AutoPath and AutoReach. By using a CAD model of the part to be processed, AutoPath automatically generates the robot positions needed to follow the curve in just a few minutes — a task that would otherwise take hours or days. AutoReach automatically analyses reachability, enabling the user to move the robot or work piece around until all positions are reachable.
Learning the languages
ABB Australia is running several programming courses throughout 2008. The basic programming course is held over four days. A Robotstudio course has also been introduced to meet the manufacturing industry’s growing demand for offline programming. For more information contact the number below.
www.abb.com/robotics
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