The heart

of Robotics

Product Manual
Rail System
3HNA000254-001 en Rev.04
Product Manual
Rail System

3HNA000254-001 en Rev.04

First Edition: 08 June 2004

Last Revised 17 April 2008

Product Manual, Rail System

The information in this document is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that may
appear in this document.
Except as may be expressly stated anywhere in this document, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to persons or
property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from use of
this document or of the software and hardware described in this document.
We reserve all rights in this document and in the information contained therein.
Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Additional copies of this document may be obtained from ABB at its then current charge.

© Copyright 2007-2008 ABB All right reserved.

ABB AS Automation Technologies
Robotics
N-4341 Bryne
Norway
Product Manual, Rail System Table of Contents

Table of Contents

Product Manual, Rail System

1 Introduction 9

2 Safety 11

3 Installation and Commissioning 13

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 Description of Rail System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Preparing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4 Installing the Rails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5 Lifting the Rail Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.6 Install Gear Rack and Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.7 Rail Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.8 Install Front Covers and Cable Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.9 Guiding for Cable Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4 Calibration 25
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Calibrating Axis 7 to a Reference Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.3 Calibrating Axis 7 to Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.4 Optimize Calibration for Axis 1 - Trolley Robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Product Manual, Rail System 3HNA000254-001 en Rev.04 5

Table of Contents Product Manual, Rail System

6 3HNA000254-001 en Rev.04 Product Manual, Rail System

Product Manual, Rail System
This manual provides information for installing the rail system for the trolley.

The manual describes only the rail system. For information on the trolley to be
mounted on the rail, manipulator and control system, please refer to the standard
documentation for the robot.

WARNING! Before performing any work described in this manual, the Safety
Manual must be read and understood. Work must only be performed by skilled
personnel with the proper training.

The Safety Manual is shipped with the robot as paper copy, included in the control
cabinet.

Product Manual, Rail System 3HNA000254-001 en Rev.04 7

8 3HNA000254-001 en Rev.04 Product Manual, Rail System
 1 Introduction

1 Introduction

About This Manual This manual contains instructions for:

• Mechanical installation of the rail system for the trolley.

Usage This manual should be used during:

• Installation.

Who Should Read This This manual is intended for:

Manual?
• Installation personnel.

Prerequisites The reader should:

• Have the required knowledge of mechanical installation work.

Organization of The manual is organized in the following chapters:

Chapters
Chapter Description
Introduction This chapter.
Safety Information on safety.
Installation and Commissioning Information about design and installation of the trolley.
Calibration Information about calibration of axis 7 of the trolley unit.

References Following manuals are referred to in this manual:

Manual Description
Safety Manual This manual must be read before any work on the robot is
3HNA008924-001 performed.

Product Manual, T32 Trolley Information on the trolley.

3HNA010481-001

Operator’s Manual, IRC5P Includes description of the calibration function and

3HNA008861-001 procedure for entering calibration data etc.

Technical Reference Manual - Includes information on editing calibration offset.

System Parameters
3HAC17076

Product Manual, Rail System 3HNA000254-001 en Rev.04 9

1 Introduction

10 3HNA000254-001 en Rev.04 Product Manual, Rail System

 2 Safety

2 Safety

Safety Information Before performing any work described in this manual, it is extremely important that
all safety information is observed!

There are general safety aspects that must be read through, as well as more specific
safety information that describes danger and safety risks when performing the
procedures. Read the Safety Manual before performing any service work.

WARNING! Before performing any work described in this manual, the Safety
Manual must be read and understood. Work must only be performed by skilled
personnel with the proper training.

Observe Before Following points must be observed before any installation work is performed for the
Installation rail system:

• When working with rail system, extreme care must be exercised to prevent
injury by the heavy rail components.
• Attention must always be paid to prevent the elements from tilting during
handling and installation.
• If the spray booth has a risk of explosion hazard at this stage of the installation,
all information concerning spray booth safety must be read.

Product Manual, Rail System 3HNA000254-001 en Rev.04 11

2 Safety

12 3HNA000254-001 en Rev.04 Product Manual, Rail System

 3 Installation and Commissioning
3.1 Introduction

3 Installation and Commissioning

3.1 Introduction

About this Chapter This chapter provides information on the installation of the rail system.

For information on how to install the trolley on the rail, please refer to the Product
Manual for the trolley.

Safety Information Before any work described in this chapter is commenced, it is extremely important
that all information concerning safety is carefully studied.

There are general safety aspects that must be read through, as well as more specific
safety information that describes danger and safety risks related to performing the
procedures. Read the ‘Safety Manual’ before performing any installation work.

WARNING! No installation work must be performed on the robot before the safety
guidelines in the ‘Safety Manual’ have been read and understood. Work must only
be performed by skilled personnel with the proper training.

Product Manual, Rail System 3HNA000254-001 en Rev.04 13

3 Installation and Commissioning
3.2 Description of Rail System

3.2 Description of Rail System

General The rail system is designed to enable motion of one or more robots in sideways
direction to increase the reach when processing larger objects such as automobile
bodies etc. The rail system is built up from a number of rail elements mounted
together end to end using screws and guide pins. Each rail element includes
attachment feet which are normally secured to foot plates which in turn are welded
to the floor. The rail system includes an upper and a lower rail and a gear rack.

Figure 1 The rail system

Rail system
Lower rail
Rail element Gear rack

Upper rail

Conveyor
center line

Upper guide pin

Rail segment
Front panel
Cable chain
Adjustment screws
Lower guide pin
Attachment screw
Cable chain base plate Rail foot Foot plate

Installation The rail system should be mounted on an iron plated floor or H-bar arrangement etc.
with positioning according to specified tolerances. One way to perform accurate
positioning of the rail system is to manufacture foot plates with the same
dimensions as the rail feet and place the rail elements on these plates. When the
final position of the rail system has been established, the base plates can be welded
to the floor structure to ensure an accurate and stable location of the rails. After the
foot plates have been welded to the floor, fine tuning of the rail position can be
performed.

Note: When installing the rail, make sure that a distance of minimum 100 mm is
free between each end of the rail and the spray booth wall or other type of
obstruction. This to prevent damage to the cable chain and cables when the trolley
reaches the end of the rail. For installation of the T32 trolley on the rail, a minimum
clearance above the rail is required. For detailed information, see ‘Product manual,
Trolley T32’.

14 3HNA000254-001 en Rev.04 Product Manual, Rail System

 3 Installation and Commissioning
3.2 Description of Rail System

Dual Rail Installation When two rail systems are to be installed, e.g. one on each side of the conveyor
(production line), and it is required to transfer programs between robots, the rail
systems must be installed parallel with each other on the same level and with the
same distance to the center line of the conveyor. To obtain close tolerances for the
transferred programs, it is critical that the rail systems are installed within close
tolerances.

Alignment Each rail system must be mounted horizontally in both length- and transversal
directions by adjusting levelling screws. The transversal tolerance can be measured
by a specially designed 90 degree levelling tool (shown in Figure 6), used directly
on the upper and lower rail. The rail systems must be installed parallel with the
production line (conveyor). The alignment of the rails can be performed using a
precision water leveller, teodolites or laser measuring equipment, depending on
requirements for accuracy in the installation.

Accuracy Requirements The accuracy of the installation will directly affect the accuracy of the paint result.
The accuracy level to be used in a particular installation depends on a number of
factors. If one robot is operating on a single rail and the object to be painted is
stationary in the same position each time, the rail accuracy is of no importance. If
the object is moving (tracking is used), programs need to be transferred from one
robot to another and/or programs need to be moved to robots on a rail on the
opposite side of the object (mirroring), higher accuracy is required. The tolerances
given in this document must be regarded as guidelines.

Rail Dimensions The rail elements are available in 2 meter and 1.5 meter lengths. The illustration
below shows the dimensions for the 2 meter and 1.5 meter rail elements and length
of rail rods and gear rack rods.

Product Manual, Rail System 3HNA000254-001 en Rev.04 15

3 Installation and Commissioning
3.2 Description of Rail System

Figure 2 Rail elements

2000 mm (1500 mm) gear rack

500 mm rail 1000 mm rail 1000 mm rail

816 mm

630 mm
249.75 mm 499.51 mm
3 meter lengths
1.5 m rail length = 1498.54 mm (cut to size at
ends)
2 m rail length = 1998.05 mm

16 3HNA000254-001 en Rev.04 Product Manual, Rail System

 3 Installation and Commissioning
3.3 Preparing Installation

3.3 Preparing Installation

Procedure Following points should be performed before starting the installation process of the
rail system.

1. Make necessary measurements, sketches, drawings etc. of the installation site

to determine position of rail(s).

Some installations use one rail system while other installations use one rail
system on each side of the conveyor. The following procedure covers both
these situations.

2. Make necessary number of foot plates according to drawing below (same

number as feet on the rail elements).

Figure 3 Base template for rail, top view

Washer 29 mm 570 mm

M16 attachment
screw
Threads for rail
attachment screws
Bushing
180 mm

28 mm

Rail foot

Foot plate M16

628 mm

Thickness of plate: t = min. 20 mm.

3. Make required number of bushings from steel, aluminium, plastic etc. to be

fitted into attachment holes on rail feet as shown in Figure 3. Make one bushing
for each foot for each side of the rail.

The bushings are only used during the installation phase and will be removed
before final alignment of the rail. The material from which they are made are
therefore of no significance. The length of the bushings is not critical but
should be made in a way which will make it easy to remove. An alternative to
making the bushings may be to use countersunk head screws instead of
bushings and replace the screws before final attachment.

Product Manual, Rail System 3HNA000254-001 en Rev.04 17

3 Installation and Commissioning
3.4 Installing the Rails

3.4 Installing the Rails

Procedure When the base plates or required base arrangements have been made, the rail system
should be installed as follows:

Note: The rail elements, upper- and lower rails and gear racks are marked A1, A2
etc. at each end. When lifting the elements into position, make sure that these
markings corresponds (A1-A1, A2-A2 etc.).

The rail elements are normally shipped with the upper rail and gear rack installed
and only the section overlapping the rail elements needs to be mounted after the
installation of the rail elements. This situation is the precondition for the following
procedure.

1. Check end surfaces of rail elements for cracks or damages caused by

transportation. Correct possible damages before lifting elements into position.
Clean end surfaces as required.

2. Install foot plates.

The foot plates may be placed on the floor at correct locations, 500 mm apart,
and the rails then placed on top of them. A more convenient way however is to
attach the foot plates to the rail feet before lowering the elements into position.
The latter method is the one described in the following.

3. Insert upper- and lower guide pins in element end. The location of the pins is
shown in Figure 1.

18 3HNA000254-001 en Rev.04 Product Manual, Rail System

 3 Installation and Commissioning
3.5 Lifting the Rail Elements

3.5 Lifting the Rail Elements

Procedure Lift the rail elements into position and join elements as follows:

1. Attach lifting straps as shown in Figure 4. Make sure that the straps are strong
enough to carry the weight of the element and that they are attached in a
manner that will prevent the element from dropping or tilting.

Weight of the elements are approximately 680 kg for a 2 meter element and
510 kg for a 1.5 meter element.

Figure 4 Lifting the rail elements

Attachment
screw
Bushing

Rail foot

Rail element markings Foot plate

A2 A3
Attach foot plates
to rail elements

Lift rail elements

into position
A1 A1 A2

WARNING! Do not walk under the hanging load.

2. Lift rail element to a height convenient for attaching the foot plates under the
rail feet.

WARNING! Make sure that a suitable support is placed under the rail element before
continuing to prevent person injury if the element should tilt or fall.

3. Attach foot plates to underside of rail feet using prepared bushings and
attachment screws, see Figure 4 inset.

4. Lower rail element into position as close as possible to final position.

5. Lift next rail element and place it beside the first one (watch markings A1-A1
etc.). Press into position on the guide pins. You may have to knock the lower
pin into position from the underside.

6. Screw rail elements together using the M12x50 attachment screws (5/2). Do not
tighten screws. (Allow a small gap between the rail elements).

Product Manual, Rail System 3HNA000254-001 en Rev.04 19

3 Installation and Commissioning
3.6 Install Gear Rack and Rails

3.6 Install Gear Rack and Rails

Procedure Install gear rack and rail as follows:

1. Remove the 4 attachment screws (5/1) at the ends of the gear rack and press the
rail rod (5/5) overlapping the two rail elements into position. Re-install
attachment screws but do not tighten.

Figure 5 Installing rails and gear rack

Gear rack
6
Upper rail
5
1
Rail distance bar

Lower rail
2

3 4

2. Place the ‘small gear rack part’ (5/6) upside down on top of the gear racks with
its half length on each side of the split between two racks. This gear rack part
will serve as a tool to ensure correct pitch between the gear rack sections.

Note: The ‘small gear rack part’ is made with the gear teeth in opposite angle
so it will match the teeth of the gear rack on the rail. The gear rack part is
supplied with the rail levelling tool. (For trolleys older than T32, the gear rack
has straight teeth and the special ‘small gear rack part’ is not required).

3. Tighten the rail attachment screws and gear rack attachment screws.

As part of this activity, some of the rail feet may be raised from the floor. In this
case, loosen attachment screws and adjust adjustment screws until the foot plate
rests on the floor. Depending on the floor, it may be required to place distance
pieces between the floor and some of the foot plates.

4. Repeat operation for all rail elements, placing them side by side, installing rail
rod and securing rail rod and elements.

5. Install lower rail in the same way as the upper rail. Make sure that there is no
clearance between the rail rods. Make sure that all rail rods and mounting
surfaces are undamaged, clean and lubricated for corrosion prevention.

6. Install missing rail rods (5/3) (rods across the element junction) using M12x120
screws with washers (5/4).

20 3HNA000254-001 en Rev.04 Product Manual, Rail System

 3 Installation and Commissioning
3.7 Rail Alignment

3.7 Rail Alignment

Procedure When the rail elements, gear rod and rails have been installed, adjust rail system as
follows:

1. Adjust levelling screws on the rail feet until all rail elements are horizontal
within ±0.2 mm per meter for the length of the rail and ±0.2 mm per meter
transversal.

Figure 6 Rail levelling, front- and end view

Precision leveller Max. ±0.2mm/meter Max. ±1mm

(both rails) (both ends)

±0.2mm/meter
transversal
tolerance

A=B ±1mm
(both ends)

Levelling tool

Rail system
end view

2. Measure distances from upper- and lower rail to center line of conveyor at both
ends of the rail. Adjust position of rail until these distances are the same within
±1 mm. If two rails are installed, the distances should be the same for both rails.

3. If two rail systems are installed, measure the horizontal alignment of the rails.
The rails should be level within ±1 mm per meter.

4. Repeat measurements above and adjust until alignment is as close to the

tolerances as practical possible.

5. Weld foot plates to floor.

6. Unscrew rail attachment screws from foot plates and remove bushings. Re-
install screws but do not tighten. Lubricate screws for corrosion protection.

7. Fine tune adjustments of rail(s) using precision leveller, teodolites or laser as

required.

8. When the final alignment is within tolerances, secure attachment screws.

Product Manual, Rail System 3HNA000254-001 en Rev.04 21

3 Installation and Commissioning
3.8 Install Front Covers and Cable Chain

3.8 Install Front Covers and Cable Chain

Procedure Following procedure describes how to install the rail covers and cable chain system.

1. Install trolley robot as described in the Product Manual for the trolley.

2. Install upper front cover support (7/1) using M8x12 attachment screws. These
supports have elongated holes. Lift supports to upper position and tighten
screws. Also install left out section of lower front cover support (7/2).

Figure 7 Rail front covers, rail system end view

3. Hook upper front cover (7/3) in place and install lower front cover (7/4) using
M8x12 attachment screws.

4. Install cable chain resting plates on the lower part of the rail. Start with the plate
at the right side, as indicated in Figure 8. At last, install the cable chain resting
plate with the lower end of the cable chain attached, so that the cable chain
unrolls to the right.

Figure 8 Trolley rail, rear view

Cable chain Trolley

Cable chain starting point Cable chain resting plates

5. Attach the other end of the cable chain to the trolley.

Note: If the length of the rail exceeds 8 meter, special cable chain guiding must
be installed. See ’Guiding for Cable Chain’ on page 23 for procedure.

6. Lead the cables into the trolley and connect the cables as described in the
Product Manual for the trolley.

22 3HNA000254-001 en Rev.04 Product Manual, Rail System

 3 Installation and Commissioning
3.9 Guiding for Cable Chain

3.9 Guiding for Cable Chain

General When the rail exceeds a certain length a guiding for the cable chain needs to be
installed. The guiding prevents the cable chain from hanging down.

Description One guiding for the cable chain must be installed when the trolley rail is between 8
and 11 meters long. Two guidings must be installed when the trolley rail is between
11 and 15 meters.

The guiding(s) must be placed in such a way that the left half of the rail will be
divided in more or less equal sections, as shown in Figure 9. The cable chain must
not be obstructed by the guiding in any position of the trolley.

Figure 9 Cable chain guiding location

Trolley position A Guiding Cable chain Trolley position B

A A A

The guiding is to be installed between two holes in the rail (two holes with the
longest distance between them). The guiding must be installed a few centimeters
below the horizontally stretched cable chain, as shown in Figure 9 inset. Insert the
mounting bar through one of the holes and mount the guiding between two holes.

Product Manual, Rail System 3HNA000254-001 en Rev.04 23

3 Installation and Commissioning
3.9 Guiding for Cable Chain

24 3HNA000254-001 en Rev.04 Product Manual, Rail System

 4 Calibration
4.1 Introduction

4 Calibration
4.1 Introduction

About this Chapter This chapter describes the calibration of axis 7 of the trolley unit.

Safety Information Before any work described in this chapter is commenced, it is extremely important
that all information concerning safety is carefully studied.

There are general safety aspects that must be read through, as well as more specific
safety information that describes danger and safety risks related to performing the
procedures. Read the ‘Safety Manual’ before performing any installation work.

WARNING! No installation work must be performed on the robot before the safety
guidelines in the ‘Safety Manual’ have been read and understood. Work must only
be performed by skilled personnel with the proper training.

Calibrating the Robots Each robot in the installation is calibrated individually for axes 1-6. The trolley
on the Rail System motion (axis 7) for the robot must be calibrated in relation to the object and to the
robot on the opposite side of the object.

Calibrating robot axis 7 may be made to a reference point in the booth or with
reference to rail system end.

The calibration operation is normally performed by establishing a reference point in

the installation and all robots are calibrated in relation to this point. How to perform
this type of calibration is described under ’Calibrating Axis 7 to a Reference Point’
on page 26 in the following.

If this procedure for some reason can not be used, e.g. it is difficult to establish a
reference point, procedure ’Calibrating Axis 7 to Rail’ on page 28 can be used as an
alternative.

Product Manual, Rail System 3HNA000254-001 en Rev.04 25

4 Calibration
4.2 Calibrating Axis 7 to a Reference Point

4.2 Calibrating Axis 7 to a Reference Point

General Following procedure describes how calibration is performed by establishing a

reference point in the installation and all robots are calibrated in relation to this
point.

Procedure Perform following points to calibrate the robot.

1. Establish a reference point in the center of the installation which can be reached
by all robots. Make sure that axis 1, 4, 5 and 6 are in calibration position.

Figure 10 Calibration against a reference point

Reference point

Conveyor center line

Pointer on wrist

Fixture for
witness point

2. Install a pointer on the front of the wrist.

3. Move the robot along the rail until the pointer on the robot is pointing exactly at
the established point by moving axis 7, 2 and 3 only.

4. Enter calibration data for axis 7.

For information on how to enter calibration data etc., see ‘Operator’s Manual ,
IRC5P’ (S4P+: ‘PaintWare User’s Guide, Rev.13 or later).

26 3HNA000254-001 en Rev.04 Product Manual, Rail System

 4 Calibration
4.2 Calibrating Axis 7 to a Reference Point

Establish a Witness After the calibration data has been entered, the robot can be moved to a specified
Point position, called witness point, and then make a note of the calibration values in this
position. Later, if the calibration data for some reason should be lost, the robot can
be moved to the witness point and the calibration data can be re-entered.

The witness point must be an accurate point and can be established by

manufacturing a fixture to be used from end of the rail, or by placing a mark on the
rail etc. The rear rollers on the trolley are fitted with high tolerance and should be
used as reference point on the robot.

Fixture(s) to be used for establishing of witness points can be supplied on request.

Product Manual, Rail System 3HNA000254-001 en Rev.04 27

4 Calibration
4.3 Calibrating Axis 7 to Rail

4.3 Calibrating Axis 7 to Rail

General As an alternative to calibrating the robot to a reference point, the robots can be
calibrated to the end of the rail.

Description To be able to perform this type of calibration, a calibration fixture must be installed
on the end of the rail, and the robot calibrated against this fixture. If more than one
robot is operating on the rail, an additional calibration fixture must be available to
determine the position of the other robot(s).

If rails are installed on both sides of the conveyor, the end positions of the rails must
be accurately measured so that the difference (offset) from robots on one side is
known.

To be able to perform this type of calibration, calibration fixture R-12267 may be

used. If more than one robot is operating on the rail, control rod R-32755 or
R-32634 must be used. Fixture and control rod can be supplied on request.

Rails are to be installed and measured according to the zero point (reference point)
in the booth. The distance from the zero point to the end of the rail is to be noted in
the measuring protocol. End of rail closest to the zero point is to be used as
reference for calibration of axis 7. The distance x (mm) between the zero point and
the end of rail is to be added to the fixed installation distances during calibration.

When using cartesian coordinates, ensure that all robots are referring to the same
zero point.

Procedure Perform following steps to calibrate axis 7 to the rail.

1. Remove the stopper on the end of the rail.

2. Install calibration fixture R-12267 on the end of the rail. The distance from the
end of the rail to the contact point is 110 mm.

3. First move the robot manually into contact with the fixture (contact between
trolley rear roller and fixture). Center of robot is Δx1 = 600 mm from end of the
rail. Enter calibration offset (cartesian coordinates) for axis 7.

4. If two robots on rail:

Keep the first robot in position. Place the control rod (R-32755 or R-32634) in
contact with the second wheel. Move the second robot manually into contact
with the control rod.

Distance from end of rail to center of second robot:

4.1 Control rod R-32755 (620 mm) Δx2 = 2200 mm
4.2 Control rod R-32634 (1000 mm) Δx2 = 2580 mm

Enter respective calibration offset for axis 7 for the second robot.

28 3HNA000254-001 en Rev.04 Product Manual, Rail System

 4 Calibration
4.3 Calibrating Axis 7 to Rail

5. Remove the calibration fixture and control rod.

6. Install the stopper on the end of the rail.

7. The maximum working area of the trolley depends on the length of the track.
Mechanical stops are mounted at each end. The software limits must be set
slightly before the mechanical limits. To do this, move the trolley close to the
mechanical stop at each end, and read the value of axis 7. Then insert this value
(in meters) into the parameter, which is found under Topics: Manipulator,
Types: Arm. On most models, the trolley axis is called irb_7R or irb_7L,
depending on installation settings. Press Enter, then find and adjust
Upper/Lower joint bound.

Note: This way of calibration is to be used when all robots in the paint booth are to
be working in the same coordinate system. This requires accurate alignment of all
the robots and rails in the booth.

Product Manual, Rail System 3HNA000254-001 en Rev.04 29

4 Calibration
4.4 Optimize Calibration for Axis 1 - Trolley Robots

4.4 Optimize Calibration for Axis 1 - Trolley Robots

General The calibration value for axis 1 on a trolley robot obtained by using the calibration
clamp (tool) may be further optimized regarding small inaccuracy related to the rail.

Procedure The accuracy can be checked and, if necessary, corrected as follows: A precondition
for performing this test is that the wrist is in calibration position.

1. Remove axis 1 calibration fixture.

2. Turn mode switch to manual mode and jog manipulator so that the measuring
tool point is in height with the vertical side of the upper rail of the track.

3. If not already done, open the jog window on the teach pendant. Select jog mode
‘axis-by-axis’ for the main axes.

4. Release brakes on axis 1 and push the manipulator very slowly until the
measuring tool touches the vertical surface of the rail. Note the value shown for
axis 1 (ex. 90.23 degree).

Note: The robot has a speed supervision which engage the brakes if the speed
exceeds the manual mode speed limit. The manipulator must be moved very
slowly in order not to engage the brake.

WARNING! Do not release brakes on any other axis than axis 1. If the robot arm is
equipped with any heavy load, the manipulator may be impossible to handle
manually and may cause safety hazard.

5. Rotate axis 1 until it hits the rail on the other side of the robot. Note value for
axis 1 in this position (ex. -89.90 degree).

CAUTION! Be careful not to disturb the position of the other axes when moving axis
1 from one side of the rail to the other.

6. Find the mean error value by subtracting one angle from the other
(ex. 90.23 + (-89.90) = 0.33). Divide result by 2 (ex. 0.33 / 2 = 0.165).

7. All parameters are entered in SI-units. The error angle must therefore be
calculated in radians by the formula:

phi_par (rad) = phi_err (deg) * π/180 = 0.165 * 3.14159265/180 = 0.002880

radians

8. Correct the parameter ‘Calibration offset’ for axis 1 by adding the value found
above to the offset (ex. 6.083669 + 0.002880 = 6.086549).

For editing the calibration offset, refer to ‘Technical Reference Manual, System
Parameters’ / Topic Motion / Type Motor Calibration / Calibration Offset. For
information on how to enter the parameters, see ‘Operator’s Manual, IRC5P’.

30 3HNA000254-001 en Rev.04 Product Manual, Rail System

 4 Calibration
4.4 Optimize Calibration for Axis 1 - Trolley Robots

(For S4P+: ‘User’s Guide’ / System Parameters / topic Manipulator ).

9. Verify the result of the optimizing by resetting the robot and repeat operation. If
it is correct, the values will be the same in both positions (ex. 90.07 / -90.07).

Product Manual, Rail System 3HNA000254-001 en Rev.04 31

4 Calibration
4.4 Optimize Calibration for Axis 1 - Trolley Robots

32 3HNA000254-001 en Rev.04 Product Manual, Rail System

 Manual Status

Manual Status

Product Manual
Rail System
3HNA000254-001 en Rev.04
Documents included in manual:
Chp.: Subject: File Identification: Page:
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A000254.fm 7
1 Rail System. file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T02521 Rev.05 9

Product Manual, Rail System 3HNA000254-001 en Rev.04 31

Manual Status

32 3HNA000254-001 en Rev.04 Product Manual, Rail System

 List of Imported Graphics

List of Imported Graphics

Product Manual
Rail System
3HNA000254-001 en Rev.04
Graphic files imported in manual:
Pg.: Illustration: Pg.: Illustration: Pg.: Illustration:
1 FrontPict.jpg @ 275 dpi
14 T0252101.wmf
16 T0252102.wmf
17 T0252103.wmf
19 T0252104.wmf
20 T0252105.wmf
21 T0252106.wmf
22 T0252107.wmf
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23 T0252110.jpg @ 300 dpi
26 T0252111.wmf

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