ABB Project

Robotics & Industrial Automation

(Conestoga College)

Introduction to Robotics

Working with

ABB IRB 120

Robot

Submitted To: Mr. Jason Wilson Pranav Sharma 7157118

3 July 2015 Nitin Bhardwaj 7145139

Contents1. Equipment List.....................................................................................................................................2

2. Work cell task description...................................................................................................................2

3. Program Listing....................................................................................................................................4

3.1 Session 1………………………………………………………………………………………………………………………………………….5

3.2 Session 2………………………………………………………………………………………………………………………………………….6

3.3 Session 3………………………………………………………………………………………………………………………………………..10

4. Coordinates……………………………………………………………………………………………………………………………………….18

5. Subroutines……………………………………………………………………………………………………………………………………….18

5. Problems……………………………………………………………………………………………………………………………………………19

6. Improvements……………………………………………………………………………………………………………………………………20

1. Equipment List1.1. ABB 120 robot

1.2. Robot controller

1.3. Pendant(MCP)

1.4. Marker

1.5. Paper

1.6. ABB Robotics RobotStudio 5.61 software

2. Work cell task description2.1. Session One

Session one involved familiarizing ourselves with the ABB teach pendant, teaching points and

creating a simple program that will write the letter “R” using a marker attached as the end

effector for the ABB robot. RobotStudio 5.61 was used to run the simulation, and create a relation

between the virtual robot and the actual robot controller so that we could exchange data

between each other.

2.2. Session TwoIn Session two, we were asked to modify the program in such a way that the operator will be

prompted at the beginning about which letter he wanted to be drawn. Organizing the code for

this session in separate subroutines was mandatory. After completing the relative programming

code, the operator had an option to either select a desired single letter from the word “ROBOT”

using the teach pendant or the letter “w” which would make the robot draw the full word

“ROBOT”.

2.3. Session ThreeBased on Session two, Session three included further modifications to the program to get further

information for the operator before the program ran. This time after entering the desired letter

that the operator wanted to be printed, he would be prompted again to enter an a whole number

between 1 to 5 where the number signifies how many times the letter should be printed.

3. Program Listing 3.1. Session One

MODULE MainModule

//Define the positions of the points for letter “R”

CONST robtarget r1:=[[520.58,-144.96,226.97],[0.0110613,-0.157066,0.987502,0.00691692],[-

1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];

PROC main()

// Move quickly to the position above point r1 at speed 1000mm/s without cutting any corners, and

vertical distance between the target position and r1 is 20.

MoveJ Offs(r1,0,0,20), v1000, fine, tool0;

// Move linearly to point r1 at speed 1000mm/s without cutting any corners.

MoveL r1, v1000, fine, tool0;





// Move circularly from current position to r5 through r4 at speed 1000mm/s.

MoveC r4, r5, v1000, fine, tool0;



// Move quickly to the position above point r6 at speed 1000mm/s without cutting any corners,

and vertical distance between the target position and r6 is 20.

MoveL Offs(r6,0,0,20), v1000, fine, tool0;











ENDPROC

ENDMODULE

3.2. Session Two(Based on the code of Session one)

MODULE MainModule

//Define the positions of the points for letter “R”


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];

//Define the positions of the points for letter “O”

CONST robtarget o1:=[[485.07,-64.03,232.41],[0.0112717,-0.156964,0.987516,0.00694745],[-

1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];

CONST robtarget o3:=[[486.05,-12.03,224.37],[0.0112138,-0.156962,0.987516,0.00694],[-1,0,-

5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];

//Define the positions of the points for letter “B”

CONST robtarget b1:=[[520.97,11.97,227.27],[0.0111344,-0.156945,0.98752,0.00697157],[0,0,-

5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];

CONST robtarget b2:=[[451.97,10.09,227.24],[0.0111576,-0.156888,0.987529,0.00697767],

[0,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


[0,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


[0,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


[0,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];

//Define the positions of the points for letter “O”


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];

//Define the positions of the points for letter “T”

CONST robtarget t1:=[[519.14,-99.55,249.49],[0.0109924,-0.157003,0.987512,0.00700935],[-

1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];


1,0,-5,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];

VAR string answer; //define a string variable answer

PROC main()

// Get the letter that the operator entered and store that string into “answer”.

answer := UIAlphaEntry (\Header:= " "

\Message:= "Enter the Letter: "

\Icon:= iconInfo

\InitString:= "signal.log"

\MaxTime:= 60

\BreakFlag:= err_var);

IF answer = "r" THEN // if operator enters “r”, call subroutine LETTER_R

LETTER_R;

ELSEIF answer = "o" THEN // if operator enters “o”, call subroutine LETTER_O

LETTER_O;

ELSEIF answer = "b" THEN // if operator enters “b”, call subroutine LETTER_B

Letter_B;

ELSEIF answer = "t" THEN // if operator enters “t”, call subroutine LETTER_T

Letter_T;

ELSEIF answer = "W" THEN // if operator enters “W”, call subroutine LETTER_R,

LETTER_O, LETTER_B, LETTER_O1, Letter_T

LETTER_R;

LETTER_O;

LETTER_B;

LETTER_O1;

Letter_T;

ELSE //else, teach pendant will show the message “INVALID ENTRY!”

TPWrite "INVALID ENTRY!";

ENDIF

ENDPROC

PROC LETTER_R() //subroutine to draw letter “R”












ENDPROC

PROC LETTER_O() //subroutine to draw letter “O”

//Move to the position above point o4 at speed 1000mm/s and vertical distance between the target

position and o4 is 10

MoveJ Offs(o4, 0, 0, 10), v1000, fine, tool0;

// Move linearly to point o4 at speed 1000mm/s without cutting any corners.

MoveL o4, v1000, fine, tool0;

// Move circularly from current position to o2 through o1 at speed 1000mm/s.

MoveC o1, o2, v1000, fine, tool0;


MoveC o3, o4,v1000, fine, tool0;

//Move to the position above point o4 at speed 1000mm/s and vertical distance between the target

position and o4 is 10

MoveL Offs(o4, 0, 0, 10), v1000,fine, tool0;

ENDPROC

PROC Letter_B() //subroutine to draw letter “B”

//Move to the position above point b1 at speed 1000mm/s and vertical distance between the target

position and b1 is 10

MoveJ Offs(b1,0,0,10), v1000, fine, tool0;

// Move linearly to point b1 at speed 1000mm/s without cutting any corners.

MoveL b1, v1000, fine, tool0;





// Move circularly from current position to b5 through b4 at speed 1000mm/s.

MoveC b4, b5, v1000, fine, tool0;





// Move circularly from current position to b8 through b7 at speed 1000mm/s.




//Move to the position above point b1 at speed 1000mm/s

MoveL Offs(b1, 0, 0, 10), v1000,fine, tool0;

ENDPROC

PROC LETTER_O1() //subroutine to draw the 2nd letter “O”

//Move to the position above point o8 at speed 1000mm/s


// Move linearly to point o8 at speed 1000mm/s without cutting any corners.






//Move to the position above point o8 at speed 1000mm/s


ENDPROC

PROC Letter_T() //subroutine to draw letter “T”

//Move to the position above point t1 at speed 1000mm/s

MoveJ Offs(t1, 0, 0, 10), v1000, fine, tool0;

// Move linearly to point t1 at speed 1000mm/s without cutting any corners.

MoveL t1, v1000, fine, tool0;







//Move to the position above point t4 at speed 1000mm/s

MoveL Offs(t4, 0, 0, 10), v1000, fine, tool0;

ENDPROC

ENDMODULE

3.3. Session Three(Based on the code of Session two)

MODULE MainModule

VAR string answer; //define a string variable answer

VAR dnum numeric; //define a dnum variable numeric

VAR errnum err_var; //define a errnum variable err_var

PROC main()

// Get the letter that the operator entered and store that string into “answer”.

answer := UIAlphaEntry (\Header:= " "

\Message:= "Enter the Letter: "

\Icon:= iconInfo

\InitString:= "signal.log"

\MaxTime:= 60

\BreakFlag:= err_var);

//Get the number of times that operator wants to draw the selected letter

numeric := UIDnumEntry(

\Header:= ""

\Message:= "How many times you want to write this letter?"

\Icon:= iconInfo

\InitValue:= 3 //initiate the value as 3

\MinValue:=1 //min value is 1

\MaxValue:=5 //max value is 5

\AsInteger);

IF answer = "r" THEN // “r” is selected, then draw it certain times depending on numeric

TEST numeric

CASE 1: //numeric = 1

LETTER_R; //call subroutine LETTER_R, draw “R” once


LETTER_R; LETTER_R1; // draw “R” twice


LETTER_R; LETTER_R1; LETTER_R2; // draw “R” 3 times


LETTER_R; LETTER_R1; LETTER_R2; LETTER_R3; // draw “R” 4 times

CASE 5: //numeric = 5, draw “R” 5 times

LETTER_R; LETTER_R1; LETTER_R2; LETTER_R3; LETTER_R4;

ENDTEST

ELSEIF answer = "o" THEN // “o” is selected

TEST numeric // draw “o” certain times depending on numeric


LETTER_OPrev; //call subroutine LETTER_ OPrev, draw “O” once


LETTER_OPrev; LETTER_O; //draw “O” twice


LETTER_OPrev; LETTER_O;LETTER_O2; //draw “O” 3 times


LETTER_OPrev; LETTER_O; LETTER_O2; LETTER_O3; //draw “O” 4 times

CASE 5: //numeric = 5,draw “O” 5 times

LETTER_OPrev;LETTER_O;LETTER_O2;LETTER_O3;LETTER_O4;

ENDTEST

ELSEIF answer = "b" THEN // “b” is selected

TEST numeric //draw “b” certain times depending on numeric


Letter_B1; //draw “B” 1 time


Letter_B1;Letter_B2; //draw “B” 2 times


Letter_B1;Letter_B2;Letter_B; //draw “B” 3 times


Letter_B1;Letter_B2;Letter_B;Letter_B3; //draw “B” 4 times


Letter_B1;Letter_B2;Letter_B;Letter_B3;Letter_B4; //draw “B” 5 times

ENDTEST

ELSEIF answer = "t" THEN // “t” is selected

TEST numeric //draw “t” certain times depending on numeric


Letter_T1; //draw “T” 1 time


Letter_T1;Letter_T2; //draw “T” 2 times


Letter_T1;Letter_T2;Letter_T3; //draw “T”3 times


Letter_T1;Letter_T2;Letter_T3;Letter_T4; //draw “T” 4 times


Letter_T1;Letter_T2;Letter_T3;Letter_T4;Letter_T; //draw “T” 5 times

ENDTEST

ELSEIF answer = "W" THEN // “W” is selected

TEST numeric

CASE 1: //draw word “ROBOT”

LETTER_R;LETTER_O;LETTER_B;LETTER_O1;Letter_T;

ENDTEST

Else //else, the teach pendant will display the message below:

TPWrite "INVALID ENTRY!";

ENDIF

ENDPROC

PROC LETTER_R() //subroutine to draw letter “R”












ENDPROC

PROC LETTER_R1() //subroutine to draw letter “R”, use offs() to adjust the position of R


MoveL Offs(r1, 0, 30, 0), v1000, fine, tool0;

MoveL Offs (r2, 0, 30, 0), v1000, fine, tool0;

MoveL offs (r3, 0, 30, 0), v1000, fine, tool0;

MoveC offs (r4, 0,30, 0), Offs( r5, 0, 30, 0), v1000, fine, tool0;

MoveL Offs (r6,0, 30, 0), v1000, fine, tool0;



MoveL offs (r5,0, 30, 0), v1000, fine, tool0;

MoveL Offs ( r7,0, 30, 0), v1000, fine, tool0;


ENDPROC




MoveL Offs (r2, 0,60, 0), v1000, fine, tool0;


MoveC offs (r4, 0, 60, 0), Offs( r5, 0, 60, 0), v1000, fine, tool0;







ENDPROC



MoveL Offs(r1, 0,90, 0), v1000, fine, tool0;



MoveC offs (r4, 0, 90, 0), Offs( r5, 0,90, 0), v1000, fine, tool0;







ENDPROC






MoveC offs (r4, 0, 120, 0), Offs( r5, 0, 120, 0), v1000, fine, tool0;







ENDPROC

PROC LETTER_OPrev() //subroutine to draw letter “O”, use offs() to adjust the position of O

MoveJ Offs(o4, 0, -30, 10), v1000, fine, tool0;

MoveL offs (o4,0, -30, 0), v1000, fine, tool0;

MoveC offs (o1,0, -30, 0), offs (o2,0, -30, 0), v1000, fine, tool0;

MoveC offs (o3,0, -30, 0), offs (o4,0, -30, 0),v1000, fine, tool0;

MoveL Offs(o4, 0, -30, 10), v1000,fine, tool0;

ENDPROC

PROC LETTER_O() //subroutine to draw letter “O”






ENDPROC

PROC LETTER_O2()//subroutine to draw letter “O”, use offs() to adjust the position of O


MoveL Offs(o4, 0, 30, 0), v1000, fine, tool0;

MoveC Offs(o1, 0, 30, 0), Offs(o2, 0, 30, 0), v1000, fine, tool0;

MoveC Offs(o3, 0, 30, 0), Offs(o4, 0, 30, 0),v1000, fine, tool0;


ENDPROC




MoveC Offs(o1, 0, 60, 0), Offs(o2, 0, 60, 0), v1000, fine, tool0;



ENDPROC




MoveC Offs(o1, 0, 90, 0), Offs(o2, 0,90, 0), v1000, fine, tool0;



ENDPROC

PROC Letter_B()//subroutine to draw letter “B”











ENDPROC

PROC Letter_B1()//subroutine to draw letter “B”, use offs() to adjust the position of B

MoveJ Offs(b1,0,-60,10), v1000, fine, tool0;

MoveL Offs(b1,0,-60,0), v1000, fine, tool0;



MoveC Offs(b4,0,-60,0), Offs(b5,0,-60,0), v1000, fine, tool0;





MoveL Offs(b1, 0, -60, 10), v1000,fine, tool0;

ENDPROC


MoveJ Offs(b1,0,-30,10), v1000, fine, tool0;









MoveL Offs(b1, 0, -30, 10), v1000,fine, tool0;

ENDPROC



MoveL Offs(b1,0,30,0), v1000, fine, tool0;



MoveC Offs(b4,0,30,0), Offs(b5,0,30,0), v1000, fine, tool0;





MoveL Offs(b1, 0,30, 10), v1000,fine, tool0;

ENDPROC












ENDPROC

PROC Letter_T1()//subroutine to draw letter “T”, use offs() to adjust the position of T

MoveJ Offs(t1, 0, -120, 10), v1000, fine, tool0;

MoveL Offs(t1, 0, -120, 0), v1000, fine, tool0;





ENDPROC








ENDPROC








ENDPROC








ENDPROC

PROC Letter_T()//subroutine to draw letter “T”

MoveJ Offs(t1, 0, 0, 10), v1000, fine, tool0;





MoveL Offs(t4, 0, 0, 10), v1000, fine, tool0;

ENDPROC

PROC LETTER_O1()//subroutine to draw the 2nd letter “O”






ENDPROC

ENDMODULE

4. Coordinates:

5. Subroutines:Subroutines with Coordinates Offset

LETTER_R: r1, r2, r3, r4, r5, r6, r7 Z-axis = 10

LETTER_R1: r1, r2, r3, r4, r5, r6, r7 Z-axis = 10, Y-axis = 30




LETTER_OPrev: o1, o2, o3, o4 Z-axis = 10, Y-axis = -30

LETTER_O: o1, o2, o3, o4 Z-axis = 10

LETTER_O2: o1, o2, o3, o4 Z-axis = 10, Y-axis = 30



LETTER_B: b1, b2, b3, b4, b5, b6, b7, b8 Z-axis = 10

LETTER_B1: b1, b2, b3, b4, b5, b6, b7, b8 Z-axis = 10, Y-axis = -60

LETTER_B2: b1, b2, b3, b4, b5, b6, b7, b8 Z-axis = 10, Y-axis = -30

LETTER_B3: b1, b2, b3, b4, b5, b6, b7, b8 Z-axis = 10, Y-axis = 30

LETTER_B4: b1, b2, b3, b4, b5, b6, b7, b8 Z-axis = 10, Y-axis = 50

LETTER_T1: t1, t2, t3, t4 Z-axis = 10, Y-axis = -120




LETTER_T: t1, t2, t3, t4 Z-axis = 10

LETTER_O1: o5, o6, o7, o8 Z-axis = 10

6. Problems:Session 1

We were not able to find the “Dead man Switch”, because of which we get delayed from starting the

lab.

All the E-stops were pressed by the previous group. Even the one down the robot where all the

machinery is present. Because of that e-switch we again got delayed from starting our lab.

Both of the above problems were rectified by the help of lab instructor, Mr. Wilson.

One major problem was when we need to transfer the code from the PC to the robot. Initially it was

tricky but after couple of times we figured that out easily. Mr. Wilson recorded a video of ours doing

that.

Session 2

We were supposed to enter the letter and the how many number of times you want to print this

letter. Searching the commands for the same was a bit tricky part because there were various

commands for the same commands mentioned in the user manual of ABB.

For the last session we needed to write the same letter for some number of times. How to use the

same written code with the same teach points (without teaching the new teach points). We had an

idea of doing offset but we confirmed that with Mr. Wilson and then we did it by using offset in Y

axis.

Session 3

We almost completed our last session in our second lab itself. We were planning to do something

more creative in the last session which was not mentioned in the lab manual like writing a letter in

Chinese or in Hindi language. But when we started doing our lab, as usual all the e-stop buttons

were pressed and the moment I released the last e-stop robot gets down and touched the surface of

the table. Mr. Wilson helped us getting it up in normal position.

We were not able to figure what was wrong with the robot was at that moment but Mr. Wilson

came and played with the robot for a little bit and started working (NOT PERFECTLY).

Then we restarted the robot and it started showing the error “Robot is in Singularity State”. Which

our instructor Mr. Wilson explained that it’s because of the robot doesn’t know where to go. This

happens because if something happens with the robot’s memory. Again Mr. Wilson helped us to

overcome this.

7. But something was wrong with the robot’s axis. +Y and –Y axis was not behaving as they were

supposed to. Because of that we were only able to complete our last session. If this wouldn’t

happened we could have done something new.

6. Improvements The manual could have been more object-oriented and informatory.

Whoever works on the robot should properly shut it down and bring it to the home position so

that it would be easier for the following group to start- up.

We could have completed all of the session earlier than we did (2 days), if we could have done

some research prior to the lab sessions.

There should be proper highlighted guidelines for the restricted areas of the lab so that students

wouldn’t reach places they are not supposed to as the lab group ahead of ours did. They pressed

the e-stop on the main controller which gave us a huge mess to deal with at the start of the lab

every time.

ABB Project

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