Product manual

FlexGripper-Vacuum

IRB 660
 Product manual
FlexGripper-Vacuum

Document ID: 3HAC040633-002

Revision: -
The information in this manual 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 manual.
Except as may be expressly stated anywhere in this manual, 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 manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB’s written
permission.
Additional copies of this manual may be obtained from ABB.

© Copyright 2011 ABB All rights reserved.

ABB Robotics
CNAUS
Shanghai, China
 Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 Safety 7
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.1 Safety in the manipulator system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.2 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.2.1 Safety risks during installation and service work on the FlexGripper . . . . . . . . . . . . . . . . 9
1.2.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.2.3 Safety risks related to high speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2.2.4 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.2.5 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2.3 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.3.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.3.3 Safe use of the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3.2 Safety symbols on the FlexGripper labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3.3 Safety guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2 FlexGripper-Vacuum 21
2.1 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2 Mechanical structure & working principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2.2 Vacuum rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.2.3 Pallet hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3 Installation and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3.2 Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.3 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3.4 Mounting the FlexGripper-Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.3.5 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.4.2 Regular maintenance activities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.4.3 Changing/Replacement activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.5 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.5.1 Instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.5.2 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.5.2.1 Replacing the cylinder of the pallet picker unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.5.2.2 Replacing the cylinder on the pallet searcher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.5.3 Magnetic proximity switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.5.4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.5.5 Pneumatic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.5.6 Valve base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.5.7 Dress cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.6 Trouble shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.6.1 Start-up failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.6.2 Gripper not responding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.6.3 Wrong movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.6.4 Low performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.6.5 Problem jogging the gripper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

3
Table of Contents

2.6.6 Mechanical noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

2.6.7 Workpiece drop on power down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.6.8 No Input signal detected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.6.9 No Vacuum created . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.7 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.7.2 Environmental information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.8 Wear parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.9 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.10 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.10.1 Electrical circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.10.2 Pneumatic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

3 FlexGripper UI 87
3.1 Software installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.1.1 Installing FlexGripper UI FlexPendant application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.1.2 I/O signal configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.1.3 Back-up and I-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.2.1 FlexGripper UI main interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.2.2 Tool handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.2.2.1 FlexGripper function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.2.2.2 TCP edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.2.3 Tune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.2.3.1 Position Tune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.2.3.2 Work object tune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.2.3.3 Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.2.4 Production. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.2.4.1 Production monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.2.4.2 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.3 Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

4
 Overview

Overview

About this manual

This manual provides instructions for the FlexGripper-Vacuum. Each chapter concerning the
FlexGripper-Vacuum contains information on:
• mechanical structure & working principle
• mechanical /electrical installation
• maintenance
• repair
• trouble shooting
• spare parts
Read through this document carefully, especially the sections about safety, before you start to
unpack, install and use the FlexGripper-Vacuum.

Usage
This manual should be used during:
• installation
• operation
• maintenance work
• repair work

Who Should Read This Manual?

This manual is intended for:
• operators
• installation personnel
• repair and maintenance personnel

Prerequisites
The reader should be:
• familiar with industrial robots and the relevant terminology
• familiar with the equipment
• skilled in mechanical & electrical installation/maintenance/repairs

Oganization of Chapter
The manual is organized in to the following chapters:

Chapter Contents
1. Safety
2. FlexGripper-Vacuum
3. FlexGripper UI

Continues on next page

3HAC040633-002 Revision: - 5
Overview

Continued

Reference

Reference Document ID
Product manual - IRB 660 3HAC025755-001
Product manual - IRC5 Robot Controller 3HAC021313-001

Revision

Revision Description
- First edition

6 3HAC040633-002 Revision: -
 1 Safety
1.1. Introduction

1 Safety
1.1. Introduction

Overview
The safety information in this manual is divided into two categories:
• General safety aspects, important to attend to before performing any service work on
the FlexGripper. These are applicable for all service work and are found in General
safety information on page 8.
• Specific safety information, pointed out in the procedure when the danger is imminent.
How to avoid and eliminate the danger is either detailed directly in the procedure, or
further detailed in separate instructions, found in Safety related instructions on page
17.
NOTE!
This manual includes only the safety information related to this product.
The FlexGripper can be used together with IRB660. Please refer the Robot and IRC5
Controller manuals for more details on safety.

3HAC040633-002 Revision: - 7
1 Safety
1.2.1. Safety in the manipulator system

1.2 General safety information

1.2.1. Safety in the manipulator system

Validity and responsibility

The information does not cover how to design, install and operate a complete system, nor
does it cover all peripheral equipment, which can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the
manipulator is installed.
The users of ABB products are responsible for ensuring that the applicable safety laws and
regulations in the country concerned are observed, and that the safety devices necessary to
protect people working with the system are designed and installed correctly.
Personnel working with manipulators must be familiar with the operation and handling of the
industrial manipulator, as described in the following documents:
• Operating Manual - IRC5 with FlexPendant (M2004)
• Product Manual

Connection of external safety devices

Apart from the built-in safety functions, the manipulator is also supplied with an interface for
the connection of external safety devices. Via this interface, an external safety function can
interact with other machines and peripheral equipment. This means that control signals can
act on safety signals received from the peripheral equipment as well as from the manipulator.

Limitation of liability
Any information given in this manual regarding safety must not be construed as a guarantee
by ABB that the industrial manipulator will not cause injury or damage, even if all safety
instructions are complied with.

Related information

Type of information Detailed in document Section

Installation of safety Product manual for the Installation and commis-
devices manipulator sioning
Changing operating modes Operating manual - IRC5 with Operating modes
FlexPendant
Restricting the working Product manual for the Installation and commis-
space manipulator sioning

8 3HAC040633-002 Revision: -
 1 Safety
1.2.2.1. Safety risks during installation and service work on the FlexGripper

1.2.2. Safety risks

1.2.2.1. Safety risks during installation and service work on the FlexGripper

Overview
This section includes information on general safety risks to be considered when performing
installation and service work on the FlexGripper.

General risks during installation and service

• The instructions in the Product manual in the section Installation and commissioning
on page 28 must always be followed.
• Emergency stop buttons must be positioned in easily accessible places so that the
manipulator can be stopped quickly.
• Those in charge of operations must make sure that safety instructions are available for
the installation in question.
• Those who install the FlexGripper must have the appropriate training for the
manipulator system in question and in any safety matters associated with it.

Nation/region specific regulations

To prevent injuries and damage during the installation of the manipulator system, the
regulations applicable in the country concerned and the instructions of ABB manipulatorics
must be complied with.

3HAC040633-002 Revision: - 9
1 Safety
1.2.2.2. Safety risks related to tools/workpieces

1.2.2.2. Safety risks related to tools/workpieces

Safe handling
It must be possible to safely turn off tools, such as milling cutters. Make sure that guards
remain closed until the cutters stop rotating. It should be possible to release parts manually
(valves).

Safe design
FlexGrippers are designed so that they retain workpieces in the event of a power failure or a
disturbance to the controller.

10 3HAC040633-002 Revision: -
 1 Safety
1.2.2.3. Safety risks related to high speed

1.2.2.3. Safety risks related to high speed

WARNING!
Particular care must be taken with the FlexGripper-Vacuum.
Risk of gripped workpiece uncontrolled gravity drop during high speed movement.

3HAC040633-002 Revision: - 11
1 Safety
1.2.2.4. Safety risks during operational disturbances

1.2.2.4. Safety risks during operational disturbances

General
• The industrial manipulator is a flexible tool that can be used in many different
industrial applications.
• All work must be carried out professionally and in accordance with the applicable
safety regulations.
• Care must be taken at all times.

Qualified personnel
• Corrective maintenance must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated with its
different parts.

Extraordinary risks
If the working process is interrupted, extra care must be taken due to risks other than those
associated with regular operation. Such an interruption may have to be rectified manually.

12 3HAC040633-002 Revision: -
 1 Safety
1.2.2.5. Risks associated with live electric parts

1.2.2.5. Risks associated with live electric parts

Voltage related risks, general

• Although trouble shooting may, on occasion, have to be carried out while the power
supply is turned on, the manipulator must be turne off(by setting the main switch to
OFF)when repairing faults, disconnecting electric leads and disconnecting or
connecting units.
• The main supply to the manipulator must be connected in such a way that it can be
turned off outside the manipulator’s working space.

Voltage related risks, controller IRC5

A danger of high voltage is associated with the following parts:
• The mains supply/mains switch
• The transformers
• The power unit
• The control power supply (230 VAC)
• The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
• The drive unit (700 VDC)
• The drive system power supply (230 VAC)
• The service outlets (115/230 VAC)
• The customer power supply (230 VAC).
• The power supply unit for tools, or special power supply units for the machining
process.
• The external voltage connected to the control cabinet remains live even when the
manipulator is disconnected from the mains.
• Additional connections
• Be aware of stored electrical energy (DC link, Ultra Cap unit) in the controller.
• Units inside the controller, for example I/O modules, can be supplied with power from
an external source.

Voltage related risks, manipulator

A danger of high voltage is associated with the manipulator in:
• The power supply for the motors (up to 800 VDC)
• The user connections for tools or other parts of the installation (max.230 VAC, see
chapter Installation and commissioning in the Product manual).

Voltage related risks, tools, material handling devices and so on

Tools, material handling devices and so on may be live even if the manipulator system is in
the OFF position. Power supply cables which are in motion during the working process may
be damaged.

3HAC040633-002 Revision: - 13
1 Safety
1.2.3.1. Safety fence dimensions

1.2.3. Safety actions

1.2.3.1. Safety fence dimensions

General
Install a safety cell around the manipulator and the FlexGripper to ensure safe FlexGripper
installation and operation.

Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the FlexGripper is dropped or released at maximum speed.

14 3HAC040633-002 Revision: -
 1 Safety
1.2.3.2. Fire extinguishing

1.2.3.2. Fire extinguishing

NOTE!
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the manipulator
system (manipulatoror controller)!

3HAC040633-002 Revision: - 15
1 Safety
1.2.3.3. Safe use of the FlexPendant

1.2.3.3. Safe use of the FlexPendant

NOTE!
The enabling device is a push-button located on the side of the FlexPendant which, when
pressed half way in, takes the system to MOTORS ON. When the enabling device is released
or pushed all the way in, the manipulator is taken to the MOTORS OFF state.
To ensure safe use of the FlexPendant, the following must be implemented:
• The enabling device must never be rendered inoperative in any way. During
programming and testing, the enabling device must be released as soon as there is no
need for the manipulator to move. The programmer must always bring the
FlexPendant with them, when entering the manipulator's working space. This is to
prevent anyone else taking control of the manipulator without the programmer being
aware of it.

Enabling device
The enabling device is a manually operated constant pressure push-button which, when
continuously activated in one position only, allows potentially hazardous functions but does
not initiate them. In any other position, hazardous functions are stopped safely. The enabling
device is of a specific type where you must press the push-button only half-way to activate it.
In the fully in and fully out positions, manipulator operation is impossible.

Hold-to-run function
The hold-to-run function allows movement when a button connected to the function is
actuated manually, and immediately stops any movement when released. The hold-to-run
function can only be used in manual mode. How to operate the hold-to-run function is
detailed in the Operating manual - IRC5 with FlexPendant.

16 3HAC040633-002 Revision: -
 1 Safety
1.3.1. Safety signals, general

1.3 Safety related instructions

1.3.1. Safety signals, general

General
This section specifies all the dangers that may arise from performing the work detailed in the
manual. Each danger is detailed in its own section consisting of:
• A caption specifying the danger level (DANGER, WARNING or CAUTION) and the
type of danger.
• A brief description of what will happen if the operator/service personnel do not
eliminate the danger.
• An instruction of how to eliminate the danger to facilitate performing the activity at
hand.

Danger levels
The table below defines the captions specifying the danger levels used throughout this
manual.

Symbol Designation Signification

DANGER Warns that an accident will occur if the instruc-
tions are not followed, resulting in a serious or
fatal injury and/or severe damage to the
product. It applies to warnings that apply to
danger with, for example, contact with high
voltage electrical units, explosion or fire risk,
risk of poisonous gases, risk of crushing,
impact, fall from height, etc.
WARNING Warns that an accident may occur if the
instructions are not followed, that can lead to
serious injury, possibly fatal, and/or great
damage to the product. It applies to warnings
that apply to danger, for example, contact with
high voltage electrical units, explosion or fire
risk, risk of poisonous gases, risk of crushing,
en1011002 impact, fall from height and so on.
ELECTRIC SHOCK The electrocution or electrical shock symbol
indicates electrical hazards which could result
in severe personal injury or death.

en1011003

Continues on next page

3HAC040633-002 Revision: - 17
1 Safety
1.3.1. Safety signals, general

Continued

Symbol Designation Signification

CAUTION Warns that an accident may occur if the
instructions are not followed that can result in
injury and/or damage to the product. It also
applies to warnings of risks that include burns,
eye injury, skin injury, hearing damage,
crushing or slipping, tripping, impact, fall from
height, etc. Furthermore, it applies to warnings
en1011004 that include function requirements when fitting
and removing equipment, where there is a risk
of damaging the product or causing a
breakdown.
ELECTROSTATIC DIS- The electrostatic discharge (ESD) symbol
CHARGE(ESD) indicates electrostatic hazards whichcould
result in severe damage to the product.

en1011005

NOTE Note symbols alert you to important facts and

conditions.

en1011006

TIP Tip symbols direct you to specific instructions,

where to find additional information or how to
perform a certain operation in an easier way.

en1011008

18 3HAC040633-002 Revision: -
 1 Safety
1.3.2. Safety symbols on the FlexGripper labels

1.3.2. Safety symbols on the FlexGripper labels

Introduction to labels
This section describes safety symbols used on labels (stickers) on the FlexGripper. Symbols
are used in combinations on the labels, describing each specific warning. The descriptions in
this section are generic, the labels can contain additional information such as values.

Types of labels
Both the manipulator and the FlexGripper are marked with several safety and information
labels, containing important information about the product. The information is useful for all
personnel handling the FlexGripper system, for example during installation, service, or
operation.The safety labels are language independent, they only use graphics.

Symbols on safety labels

Symbol Description
Heat
Risk of heat that can cause burns.

en1015001

3HAC040633-002 Revision: - 19
1 Safety
1.3.3. Safety guidelines

1.3.3. Safety guidelines

Safety guidelines while working with FlexGripper

• See the IRB 660 Product manual for information on safety.
• All persons working in the system must be sufficiently trained. Incorrect installation
and/or use can cause injuries to persons and/or damage to equipment.
• Damaged or broken equipment can result in a risk to safety.
• Do not continue to work with the FlexGripper if you find any fault in any parts of it.
• Do not over power the pneumatic devices.
• Use pressure relief valves.
• Repair any air leaks immediately.
• Wear safety glasses when working with pneumatic cylinders. Maintenance,
assembling, adjustments and other works on the FlexGripper, such as: replacement of
pneumatic cylinders , should only be implemented by skilled and qualified workers,
when the FlexGripper is not under air-pressure.
• It should be possible to release parts by manual operation (valves).
• Do not touch the FlexGripper while it is connected to air pressure.
• While assembling, adjusting and working on the FlexGripper, it is mandatory to
implement safety regulations so that no fingers or other body parts are in proximity to
the moving parts of the FlexGripper. There is risk and danger of injury.
• Do not use temporary arrangements to make the FlexGripper work. This may lead to
severe damage.
• Ensure all the bolts have been tightened before starting any operation after
maintenance work.
• Ensure no foreign material is lying on the FlexGripper before starting any operation.
• During operation the FlexGripper must be protected by fixed or interlocking guards
according to the safety laws and regulations in the country concerned.
• It should not be possible to reach any moving parts when the Flexgripper is operating
and the safety guards are fenced and interlocked.

20 3HAC040633-002 Revision: -
 2 FlexGripper-Vacuum
2.1. Specification

2 FlexGripper-Vacuum
2.1. Specification

The products to be lifted with the FlexGripper-Vacuum must have a dense and smooth surface
and a rigid structure (for example a cardboard case) on which the vacuum cups can grip.

Storage conditions
The table below shows the allowed storage conditions for the FlexGripper-Vacuum:
Parameter Value
Min ambient temperature 0° C
Max ambient temperature +55° C
Max ambient humidity Max. 90% at constant temperature
Explosive environments Not permitted

Operating conditions
The table below shows the allowed operating conditions for the FlexGripper-Vacuum:
Parameter Value
Min ambient temperature +5° C
Max ambient temperature +50° C
Max ambient humidity Max. 90% at constant temperature
Explosive environments Not permitted

FlexGripper-Vacuum weight
The table below shows the weights of the different variants :
FlexGripper-Vacuum Variants Weight
10 Zones Basic 2 X 20 65 kg
+Pallet Picker 2X2 75 kg

FlexGripper-Vacuum size

en100

Continues on next page

3HAC040633-002 Revision: - 21
2 FlexGripper-Vacuum
2.1. Specification

Continued

Product specification
Product capacity Product quantity Product size limit (LxMxH)
Max. 40 kg per lift 1-5 Min: 240 X 240 X100mm
Max: 1200 X 500 X 300mm

NOTE!
Due to variations in size, weight, design, surface, rigidity, porosity and centre of gravity,
please judge if your products can be lifted by ABB FlexGrippers according to the above
FlexGripper parameters and product specifications.

22 3HAC040633-002 Revision: -
 2 FlexGripper-Vacuum
2.2.1. General

2.2 Mechanical structure & working principle

2.2.1. General

The FlexGripper-Vacuum (see Figure 2.1) consists of two main components: the vacuum rails
and the pallet hook. The vacuum rails are for picking up products and the pallet hook is used
for lifting pallets.
The whole FlexGripper is connected to the robot manipulator by a flange.

en1011008

Figure 2.1 FlexGripper-Vacuum

Pos Part Description
A Valve unit The compressed air inlet and outlet, controlling the
air to the vacuum unit on the FlexGripper.
B Flange Connects the FlexGripper to the robot wrist.
C Cylinders of hook
D Terminal box Signals connections for the FlexGripper.
E Pallet hook Lifts the pallets
F Search cylinder
G Vacuum rails Picks up the products
H Beam plate Two plates, close to the vacuum cups

3HAC040633-002 Revision: - 23
2 FlexGripper-Vacuum
2.2.2. Vacuum rails

2.2.2. Vacuum rails

The two rails, which measure 1200 mm, consist of two beam plates mounted with vacuum
units and photoelectric sensors (see figure 2.2). Each beam plate is equipped with ten vacuum
units, which support two vacuum cups with a pitch of 60 mm each which generate the
vacuum. Photoelectric sensors are installed to detect if the products lift correctly.
The FlexGripper-Vacuum picks up the products using vacuum cups. The compressed air (4-
6 bar) is fed into a valve unit from the main inlet air cable. The 20 vacuum units are then
connected to the valve unit with 10 air cables.
The net height of the vacuum cups is designed to be higher than the beam plates. The vacuum
cups lift the products up until the upper-surface of the products touch with the plates. In this
way, the beam plates along with suction cups on the FlexGripper significantly reduce the
tendency of pendulum effects.

en1011009

Figure 2.2 Vacuum rails

Pos Part Description
A Vacuum generators 2 x 10
B Vacuum units
C Photoelectric Totally five sensors are installed on the FlexGripper
sensor by default. You can choose the mounting location
according to the size of the products.
D Suction cups 4 x 10

Continues on next page

24 3HAC040633-002 Revision: -
 2 FlexGripper-Vacuum
2.2.2. Vacuum rails

Continued

Individually controlled zones

The vacuum rails are divided into ten separate controlled zones (see figure 2.3).

en1011010

Figure 2.3 Vacuum cup and zone configration

Each zone contains two vacuum units with four cups. On different rails, every two cups in the
same zone share one vacuum generator, and every two vacuum generators in the same zone
are controlled by one signal. So there are four vacuum cups in one zone that are controlled
simultaneously, which also have integrated valves enabling individual control of different
zones.

Adjustable rails
The width between two rails can be adjusted from 210 to 360 mm measured from the center
of both rails, vacuum cups, center.

en1011012

Figure 2.4 Adjustment between the two rails

Adjustable widths(mm) 210 240 270 300 330 360

NOTE!
The distance from the center of the suction cup to the center of the FlexGripper should be
equal.

3HAC040633-002 Revision: - 25
2 FlexGripper-Vacuum
2.2.3. Pallet hook

2.2.3. Pallet hook

The pallet hook is used for lifting the pallet that is associated with the handling product. It
includes two parts: a pneumatic search cylinder and two pairs of lifting fingers.

Pneumatic search cylinder

The pneumatic search cylinder on the FlexGripper (see figure 2.5) allows the robot to locate
the top of the pallet stack, eliminating the need for external sensing to determine the exact
height of the stack.
As pallets are picked, the system keeps track of the theoretical top level of the pallet. If the
process is interrupted, for example if the cell is accessed by an operator, the robot will start
to seek from the absolute top level again to find the top surface of the pallet.

en1011013

Figure 2.5 Pneumatic search cylinder

Lifting fingers
Two pneumatic cylinders each control and adjust the tilting angle of the two pairs of fingers
(see figure 2.6). With one synchronous lever, the two pairs of fingers can be operated at the
same time.

en1011014

Figure 2.6 Pallet picker assembly details

Continues on next page
26 3HAC040633-002 Revision: -
 2 FlexGripper-Vacuum
2.2.3. Pallet hook

Continued

Pos Part Description

A Pneumatic cylinders Drive the hook to clamp the pallet.
B Lifting fingers 2x2
C Synchronous lever Operates the fingers synchronously

Pallet size
Different types of pallets are supported by the pallet hook as shown below. It is not required
to make any change in the FlexGripper for working with these types of pallets.

Pallet type Length x Width x Height MM/Inch

EUR pallet 1200 x 800 x 144 mm MM
GMA pallet 40" x 48" x Inch/(MM)
5.5"(1016*1219.2*139.7)
AUS pallet 1165 x 1165 x 150 mm MM
ISO pallet 1200 x 1000 x 144 mm MM

3HAC040633-002 Revision: - 27
2 FlexGripper-Vacuum
2.3.1. Overview

2.3 Installation and commissioning

2.3.1. Overview

This instruction is primarily intended for use when unpacking and installing the grippr for the
first time. It also contains information useful during later installation of the FlexGripper.
The FlexGripper was packed by the standard of sea transportation, land transportation and air
transportation on delivery.
NOTE!
Lifting should be done by four people or by a crane.
Do not hold the solenoid valves, terminal box or connectors when lifting the gripper.

28 3HAC040633-002 Revision: -
 2 FlexGripper-Vacuum
2.3.2. Unpacking

2.3.2. Unpacking

Inspection
The FlexGripper-Vacuum is wrapped in packing plastic foam loaded in a wooden package.
Keep the package upwards. Unpack the package to check for any visible transport damage. If
the FlexGripper-Vacuum is damaged, contact ABB.
NOTE!
Only 24V power is used in FlexGripper.

Short circuit protection should be implemented by a fuse in the control cabinet by the
customer.
NOTE!
If the FlexGripper is not to be installed directly, it must be stored. Refer to the specified
Storage conditions on page 21.

Contents
As standard the FlexGripper-Vacuum includes the following on delivery.

No. Item Description

A Flange
B Connecting screws For IRB660: 11x M12 screws and 16x M6
screws.
C Cable bracket Fixes the cables on the flange
D Preassembled
FlexGripper
E Cables Compressed air hose in blue
Power & signal cable in green
Plastic corrugated pipe in black
F CD Includes one product manual

Pre-requisites for mounting

The checklist below details what must be observed before proceeding with the actual
installation of the FlexGripper.
1. Visually inspect the FlexGripper to make sure it is not damaged.
2. Make sure the operating environment for the FlexGripper conforms to the
specifications, as described in Operating conditions on page 21.
3. Make sure that there is enough space around the robot wrist working range. Anything
that would hinder the installation of the FlexGripper or be dangerous to the operator
must be cleared away.
4. On delivery, the width is set wide enough to make mounting of the FlexGripper
possible without the need to separate the vacuum rails and the pallet FlexGripper. If
needed, refer to Adjustment on page 31to adjust the width between the two rails
according to the size of the product.

Continues on next page

3HAC040633-002 Revision: - 29
2 FlexGripper-Vacuum
2.3.2. Unpacking

Continued

Recommended standard tightening torque

For the torque values needed during installation, please see the following. The table below
specifies the recommended standard tightening torque for oil-lubricated allen head screws
(recommended class 12.9).

Dimension Tightening torque(Nm) /Class 12.9, oil-lubricated

M5 6
M6 10
M8 24
M10 47
M12 82
M16 200

30 3HAC040633-002 Revision: -
 2 FlexGripper-Vacuum
2.3.3. Adjustment

2.3.3. Adjustment

On delivery, the width is set wide enough to make mounting of the FlexGripper possible
without the need to separate the vacuum rails and the pallet hook.
The width between the two rails can be adjusted to fit different sized work pieces. If needed,
please refer to the following instructions to adjust the width between the two rails according
to the size of the product.

Adjustment instructions
DANGER!
Turn off all electric power and pneumatic pressure supplies to the gripper!

No Action Info/Illustration
1. Release the air pipe from the
compressed air hose.

en1917001

2. Loosen the screws holding the

rails, the width between the
two rails can be adjusted
depending on the size of the
products.

en1011011

3. Adjust the length of the air

pipe and reconnect them with
the compressed air hose.

3HAC040633-002 Revision: - 31
2 FlexGripper-Vacuum
2.3.4. Mounting the FlexGripper-Vacuum

2.3.4. Mounting the FlexGripper-Vacuum

DANGER!
Before any service work is started, make sure all the safety guidelines have been strictly
observed!
Make sure that the power is off before starting any work.

Mounting the FlexGripper-Vacuum on the robot

No Action Info/Illustration
1. Place the wooden package so that the
robot can reach it.
Jog the robot wrist to the correct working
height for the operators.
2. Insert the robot pin in the non-threaded
hole on the robot wrist.(seeFigure).

en1011031

3. Mount the flange on the robot wrist using

the 6 supplied M10 screws Moment 47 Nm
(or 11x M12 Moment 80 Nm) from below
upward.

NOTE!
Locate the previously inserted robot pin in
to the non-threaded hole in the flange plate
to guarantee the FlexGripper's orientation.

en1011015.

4. Jog robot to find the location of the

FlexGripper. Set the robot wrist to a low
position (see Robot User’s Guide).

Continues on next page

32 3HAC040633-002 Revision: -
 2 FlexGripper-Vacuum
2.3.4. Mounting the FlexGripper-Vacuum

Continued

No Action Info/Illustration
5. Mount the flange to the FlexGripper beam
using the supplied 16×M6 bolts Moment
10Nm from above downward.

NOTE!
The labels on the flange and the
FlexGripper indicate the directions of
mounting.

Make sure the locking groove on the

flange engages with the frame of the en1011016
FlexGripper.

en1011017

6. Attach the cable bracket on the flange and

the cable routing to the robot wrist.

NOTE!
Pass the cables through the plastic
corrugated pipe which is used as the cable
protection.

en1011018

en1011019

Continues on next page

3HAC040633-002 Revision: - 33
2 FlexGripper-Vacuum
2.3.4. Mounting the FlexGripper-Vacuum

Continued

No Action Info/Illustration
7. Connect the power and air cables to the
manipulator wrist.

en1011020

8. Connect the compressed air supply cable

to the vavle unit and the power & signal
cable to the terminal box.

en1011023

9. Jog the robot wrist to lift the FlexGripper

package, then pull down the wooden box
and separate it from the FlexGripper.
10. Set axis 4 to zero angle position.
Manipulate the robot to check if axis 4 can
rotate to the position of angle 180
clockwise and anticlockwise without
tensioning of the cables and distortion of
the corrugated pipe.

NOTE!
Make sure that the standard tool kit and attached screws, washers and dowels be used during
the mounting.

34 3HAC040633-002 Revision: -
 2 FlexGripper-Vacuum
2.3.5. Commissioning

2.3.5. Commissioning

NOTE!
ABB recommend that air connected to the FlexGripper should be: 4-6 bar, filtered (5ym),
1600 L/min and non-lubricated.
After the electrical and pneumatic connection of the FlexGripper, commissioning must be
done to test if the FlexGripper operates correctly.
NOTE!
Only 24V power is used in FlexGripper.
Short circuit protection should be implemented by a fuse in the control cabinet by the
customer.
CAUTION!
Hot parts may cause burns!

Mechanical commissioning
1. Manually test ten zones separately to check that each zone works individually. If not,
check the connection of the air cables..
2. Operate the pallet hook manually to check the lifting fingers move smoothly and reach
the predetermined position. If not, adjust the fixing location of the cylinder rod.

Rapid routines

Routines Description
Init_Interrupt() This routine is called to initialize the interrupt program.
According to your using of the sensors, Please modify this routine.
Totally five sensors are installed on the FlexGripper-Vacuum by
default.
PFPS_MainEntry() This routine is the main entry of the ‘Test run’ process.
It can not be renamed, modified or deleted.
PFPS_PalletPicker() This routine is called when the pallet hook is set to be open or
close.
PFPS_PalletSeacher() This routine is called when the search cylinder goes forward and
backward to search the pallet.
PFPS_PickUpBox() This routine is called when the robot goes to pick up boxes.
PFPS_PlaceDownBox() This routine is called when the robot goes to place down boxes.
exePickPlace() This routine is called when the robot goes to pick up and place
down boxes.
The two routines ’PFPS_PickUpBox()’ and
’PFPS_PlaceDownBox()’ are called during the process.
exePallet() This routine is called when the robot picks up the pallet for testing
the vacuum hook.

Continues on next page

3HAC040633-002 Revision: - 35
2 FlexGripper-Vacuum
2.3.5. Commissioning

Continued

NOTE!
The hook is open, when ’DO10_02_PalletPicker_Close’ is 0 and
’DO10_01_PalletPicker_Open’ is 1. While the hook is close, when
’DO10_02_PalletPicker_Close’ is 1 and ’DO10_01_PalletPicker_Open’ is 0.

PFPS_PalletPicker()
PROC PFPS_PalletPicker()
IF Present (Open) THEN
SetDO DO10_02_PalletPicker_Close,0;
SetDO DO10_01_PalletPicker_Open,1;
ENDIF
IF Present (Close) THEN
SetDO DO10_01_PalletPicker_Open,0;
SetDO DO10_02_PalletPicker_Close,1;
ENDIF
ENDPROC
NOTE!
The pneumatic search cylinder is forward when ’DO10_14_PostionSeacher_Backward’ is 0
and ’DO10_13_PostionSeacher_Forward’ is 1. The pneumatic search cylinder is backward
when ’DO10_14_PostionSeacher_Backward’ is 1 and ’DO10_13_PostionSeacher_Forward’

Continues on next page

36 3HAC040633-002 Revision: -
 2 FlexGripper-Vacuum
2.3.5. Commissioning

Continued

is 0. While ’DO10_14_PostionSeacher_Backward’ is 0 and

’DO10_13_PostionSeacher_Forward’ is also 0, there is no pressure in the cylinder which
means a pallet is searched.

PFPS_PalletSeacher()
PROC PFPS_PalletSeacher()
IF Present (Forward) THEN
SetDO DO10_14_PostionSeacher_Backward, 0;
SetDO DO10_13_PostionSeacher_Forward, 1;
WaitDI DI10_03_PostionSeacher_Searched, 1;
ENDIF
IF Present (Back) THEN
SetDO DO10_13_PostionSeacher_Forward, 0;
SetDO DO10_14_PostionSeacher_Backward, 1;
WaitDI DI10_04_PostionSeacher_Backed, 1;
ENDIF
IF Present (Search) THEN
SetDO DO10_14_PostionSeacher_Backward, 0;
SetDO DO10_13_PostionSeacher_Forward, 1;
WaitDI DI10_03_PostionSeacher_Searched, 1;
SetDO DO10_13_PostionSeacher_Forward, 0;
WaitDI DI10_03_PostionSeacher_Searched, 1;
ENDIF
ENDPROC

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3HAC040633-002 Revision: - 37
2 FlexGripper-Vacuum
2.3.5. Commissioning

Continued

NOTE!
The target points ’pHome’, ’pPick’ and its offsets must be defined and taught firstly.

PFPS_PickUpBox()
PROC PFPS_PickUpBox()
MoveJ pHome, v100, fine, tPFPSVacGrip\WObj:=wobj0;
TPWrite " Robot move to pick postion! ";
MoveL Offs(pPick,-10,0,100), v100, z20, tPFPSVacGrip\WObj:=wobj0;
TriggIO tTrigger1, 20\GOp:=GoVacuume, 0;
TriggL pPick, v100, tTrigger1, fine, tPFPSVacGrip;
IWatch PFPSVacuumMonitor1;
IWatch PFPSVacuumMonitor2;
IWatch PFPSVacuumMonitor3;
IWatch PFPSVacuumMonitor4;
bPartPicked:=TRUE;
TPWrite " Robot start to pick up box! ";
MoveL Offs(pPick,0,0,50), v50, z10, tPFPSVacGrip\WObj:=wobj0;
WaitTime\InPos, 0;
MoveJ pHome, v100, fine, tPFPSVacGrip\WObj:=wobj0;
ENDPROC

Continues on next page

38 3HAC040633-002 Revision: -
 2 FlexGripper-Vacuum
2.3.5. Commissioning

Continued

NOTE!
The target points ’pHome’, ’pPlace’ and its offsets must be defined and taught firstly.

PFPS_PlaceDownBox()
PROC PFPS_PlaceDownBox()
TPWrite " Robot move to place postion! ";
MoveL Offs(pPlace,-10,0,100), v100, z20, tPFPSVacGrip\WObj:=wobj0;
ISleep PFPSVacuumMonitor1;
ISleep PFPSVacuumMonitor2;
TriggIO tTrigger2, 0\GOp:=GoVacuume, 992;
TriggL pPlace, v50, tTrigger2, fine, tPFPSVacGrip\WObj:=wobj0;
WaitTime\InPos, 0.2;
WaitTime\InPos, 2.0;
ISleep PFPSVacuumMonitor3;
ISleep PFPSVacuumMonitor4;
TriggIO tTrigger2, 0\GOp:=GoVacuume, 1023;
TriggL pPlace, v50, tTrigger2, fine, tPFPSVacGrip\WObj:=wobj0; bPartPicked:=FALSE;
WaitTime\InPos, 0.2;
TPWrite " Robot finish to place box! ";
MoveL Offs(pPlace,-10,0,100), v100, z20, tPFPSVacGrip\WObj:=wobj0;
TPWrite " Robot move to home postion! ";
MoveJ pHome, v100, fine, tPFPSVacGrip\WObj:=wobj0;
ENDPROC

Continues on next page

3HAC040633-002 Revision: - 39
2 FlexGripper-Vacuum
2.3.5. Commissioning

Continued

NOTE!
The target points ’pSearch’ and its offsets, ’pPickPallet’ and its offsets, ’pHome’, ’pPlace’
and its offsets, ’pPick’ and its offsets must be defined and taught firstly.

exePallet()
During the process, first the robot with the FlexGripper-Vacuum goes to search the pallet,
then pick up the pallet, finally place down the pallet.
PROC exePallet()
TPWrite " Robot move to test vacuum postion! ";
MoveJ pSearch, v100, fine, tPFPSVacGrip\WObj:=wobj0;
TPWrite " Robot ready to search pallet! ";
PFPS_PalletPicker \Open;
PFPS_PalletSeacher \Search;
IWatch PFPSPosSeachMonitor;
MoveL Offs(pSearch,0,0,-480), v100, fine, tPFPSVacGrip\WObj:=wobj0;
ISleep PFPSPosSeachMonitor;
PFPS_PalletSeacher \Search;
TPWrite " Robot start to search pallet! ";
SearchL\Stop, DI10_03_PostionSeacher_Searched\Flanks, pPickPallet, pSearchEnd,
v10, tPFPSVacGrip\WObj:=wobj0;
PFPS_PalletSeacher \Back;
MoveL Offs(pPickPallet,0,0,-13), v30, fine, tPFPSVacGrip\WObj:=wobj0;
WaitTime\InPos, 0.2;
TPWrite " Robot start to pick up pallet! ";
PFPS_PalletPicker \Close;
MoveL Offs(pSearch,0,0,-480), v30, fine, tPFPSVacGrip\WObj:=wobj0;
MoveJ pSearch, v100, fine, tPFPSVacGrip\WObj:=wobj0;
WaitTime\InPos, 2;
TPWrite " Robot start to place down pallet! ";
MoveL Offs(pSearch,0,0,-480), v100, fine, tPFPSVacGrip\WObj:=wobj0;
MoveL Offs(pPickPallet,0,0,-18), v30, fine, tPFPSVacGrip\WObj:=wobj0;
PFPS_PalletPicker \Open;
MoveL Offs(pPickPallet,0,0,-480), v30, fine, tPFPSVacGrip\WObj:=wobj0;
MoveJ pSearch, v100, fine, tPFPSVacGrip\WObj:=wobj0;
TPWrite " Robot finish pick pallet test! ";
WaitTime\InPos, 2;
PFPS_PalletPicker\Close;
ERROR
IF ERRNO=ERR_WHLSEARCH THEN
TPErase;
TPWrite " Warning!the pallet's position or the Forward sensor of ";
Continues on next page
40 3HAC040633-002 Revision: -
 2 FlexGripper-Vacuum
2.3.5. Commissioning

Continued

TPWrite " pallet picker may be wrong ! ";

TPWrite " ";
TPWrite " Robot stop to test,and need checking parts or sensor! ";
StopMove;
WaitTime 0.2;
ENDIF
ENDPROC

Continues on next page

3HAC040633-002 Revision: - 41
2 FlexGripper-Vacuum
2.3.5. Commissioning

Continued

Reference Rapid codes

Gripper function is checked with the following rapid codes. Please modify the data in rapid
codes as needed before using it. The rapid codes are as follows:
MODULE MainModule
Local PERS robtarget
pPick:=[[1908.03,-446.57,1007.54],[1.72802E-06,0.0867458,-0.996231,-5.63714E-07],[-
1,0,-1,0],[9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]];
PERS tooldata
tPFPSVacGrip:=[TRUE,[[0,0,439],[1,0,0,0]],[80,[0,0,200],[1,0,0,0],0,0,4.097]];
PERS Loaddata PFPSLoadEmpty:=[0.001,[0,0,0.001],[1,0,0,0],0,0,0];
PERS num cycletime:=3.111;
PERS num pace:=0;

PROC main()
var clock MyClock;
MoveJ pPick, vmax, fine,tPFPSVacGrip\WObj:=wobj0;
ConfJ \off;
confl \off;
pace:=0;
clkreset MyClock;
clkstart MyClock;
for i from 1 to 5 do
StartVaccum 1, \ZoneNo2:=2, \ZoneNo3:=3, \ZoneNo4:=4, \ZoneNo5:=5, \ZoneNo6:=6,
\ZoneNo7:=7, \ZoneNo8:=8, \ZoneNo9:=9, \ZoneNo10:=10;
WaitTime 0.2;
GripLoad PFPSLoadFull;
MoveL Offs(pPick,0,0,400),vmax,z200, tPFPSVacGrip\WObj:=wobj0;
MoveL Offs(pPick,0,2000,400), vmax, z200, tPFPSVacGrip\WObj:=wobj0;
MoveL Offs(pPick,0,2000,0), vmax, fine, tPFPSVacGrip\WObj:=wobj0;
StopVaccum 1, \ZoneNo2:=2, \ZoneNo3:=3, \ZoneNo4:=4, \ZoneNo5:=5, \ZoneNo6:=6,
\ZoneNo7:=7, \ZoneNo8:=8, \ZoneNo9:=9, \ZoneNo10:=10;
WaitTime 0.1;
GripLoad PFPSLoadEmpty;
!Gripper start to back!
MoveL Offs(pPick,0,2000,400), vmax, z200, tPFPSVacGrip\WObj:=wobj0;
MoveL Offs(pPick,0,0,400),vmax,z200, tPFPSVacGrip\WObj:=wobj0;
MoveL pPick,vmax,fine, tPFPSVacGrip\WObj:=wobj0;
endfor
waituntil\inpos,true;
clkStop MyClock;
Continues on next page
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 2 FlexGripper-Vacuum
2.3.5. Commissioning

Continued

cycletime:=clkRead(MyClock)/5;
pace:=3600/cycletime;
ENDPROC

PROC StartVaccum(num ZoneNo1, \num ZoneNo2, \num ZoneNo3, \num ZoneNo4, \num
ZoneNo5, \num ZoneNo6, \num ZoneNo7, \num ZoneNo8, \num ZoneNo9, \num
ZoneNo10)
SetZone(ZoneNo1);
if Present(ZoneNo2) then
SetZone(ZoneNo2);
endif
if Present(ZoneNo3) then
SetZone(ZoneNo3);
endif
if Present(ZoneNo4) then
SetZone(ZoneNo4);
endif
if Present(ZoneNo5) then
SetZone(ZoneNo5);
endif
if Present(ZoneNo6) then
SetZone(ZoneNo6);
endif
if Present(ZoneNo7) then
SetZone(ZoneNo7);
endif
if Present(ZoneNo8) then
SetZone(ZoneNo8);
endif
if Present(ZoneNo9) then
SetZone(ZoneNo9);
endif
if Present(ZoneNo10) then
SetZone(ZoneNo10);
endif
ENDPROC
PROC StopVaccum(num ZoneNo1, \num ZoneNo2, \num ZoneNo3, \num ZoneNo4, \num
ZoneNo5, \num ZoneNo6, \num ZoneNo7, \num ZoneNo8, \num ZoneNo9, \num
ZoneNo10)
ResetZone(ZoneNo1);
Continues on next page
3HAC040633-002 Revision: - 43
2 FlexGripper-Vacuum
2.3.5. Commissioning

Continued

if Present(ZoneNo2) then
ResetZone(ZoneNo2);
endif
if Present(ZoneNo3) then
ResetZone(ZoneNo3);
endif
if Present(ZoneNo4) then
ResetZone(ZoneNo4);
endif
if Present(ZoneNo5) then
ResetZone(ZoneNo5);
endif
if Present(ZoneNo6) then
ResetZone(ZoneNo6);
endif
if Present(ZoneNo7) then
ResetZone(ZoneNo7);
endif
if Present(ZoneNo8) then
ResetZone(ZoneNo8);
endif
if Present(ZoneNo9) then
ResetZone(ZoneNo9);
endif
if Present(ZoneNo10) then
ResetZone(ZoneNo10);
endif
ENDPROC
PROC SetZone(num zone)
TEST zone
CASE 1:Set DO10_03_Zone1;
CASE 2:Set DO10_04_Zone2;
CASE 3:Set DO10_05_Zone3;
CASE 4:Set DO10_06_Zone4;
CASE 5:Set DO10_07_Zone5;
CASE 6:Set DO10_08_Zone6;
CASE 7:Set DO10_09_Zone7;
CASE 8:Set DO10_10_Zone8;
CASE 9:Set DO10_11_Zone9;

Continues on next page

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2.3.5. Commissioning

Continued

CASE 10:Set DO10_12_Zone10;

ENDTEST
ENDPROC
PROC ResetZone(num zone)
TEST zone
CASE 1:Reset DO10_03_Zone1;
CASE 2:Reset DO10_04_Zone2;
CASE 3:Reset DO10_05_Zone3;
CASE 4:Reset DO10_06_Zone4;
CASE 5:Reset DO10_07_Zone5;
CASE 6:Reset DO10_08_Zone6;
CASE 7:Reset DO10_09_Zone7;
CASE 8: Reset DO10_10_Zone8;
CASE 9:Reset DO10_11_Zone9;
CASE 10:Reset DO10_12_Zone10;
ENDTEST
ENDPROC
PROC PFPS_PalletPicker(\switch Open | switch Close)
IF Present (Open) THEN
SetDO DO10_02_PalletPicker_Close,0;
SetDO DO10_01_PalletPicker_Open,1;
ENDIF
IF Present (Close) THEN
SetDO DO10_01_PalletPicker_Open,0;
SetDO DO10_02_PalletPicker_Close,1;
ENDIF
ENDPROC
PROC PFPS_PalletSeacher(\switch Forward | switch Back | switch Search)
IF Present (Forward) THEN
SetDO DO10_14_PostionSeacher_Backward, 0;
SetDO DO10_13_PostionSeacher_Forward, 1;
WaitDI DI10_03_PostionSeacher_Searched, 1;
ENDIF
IF Present (Back) THEN
SetDO DO10_13_PostionSeacher_Forward, 0;
SetDO DO10_14_PostionSeacher_Backward, 1;
WaitDI DI10_04_PostionSeacher_Backed, 1;
ENDIF
IF Present (Search) THEN

Continues on next page

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2 FlexGripper-Vacuum
2.3.5. Commissioning

Continued

SetDO DO10_14_PostionSeacher_Backward, 0;
SetDO DO10_13_PostionSeacher_Forward, 1;
WaitDI DI10_03_PostionSeacher_Searched, 1;
SetDO DO10_13_PostionSeacher_Forward, 0;
WaitDI DI10_03_PostionSeacher_Searched, 1;
ENDIF
ENDPROC
ENDMODULE

Software commissioning
For the detailed software commissioning procedure, see FlexGripper-Vacuum function test
on page 93.

46 3HAC040633-002 Revision: -
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2.4.1. General

2.4 Maintenance

2.4.1. General

This chapter details all the maintenance activities recommended for the FlexGripper. It
contains two types of maintenance: regular maintenance activities and changing activities.
The procedures are gathered in different sections and divided according to the maintenance
activity.
WARNING!
During maintenance, disconnect the mains voltage before work on the equipment is started.
Even if the voltage is switched off there still remains a safety risk. Pneumatic and Electric
connection should be disconnected before performing any maintenance activity in the
FlexGripper.

Safety information
Before any service work is started, 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 chapter Safety on page 7 before performing any service work.

3HAC040633-002 Revision: - 47
2 FlexGripper-Vacuum
2.4.2. Regular maintenance activities

2.4.2. Regular maintenance activities

To help prevent accidents, the pneumatic system must be regularly inspected. Regular visual
inspections must be carried out before operating the FlexGripper.
The main parts to be inspected at regular intervals are:

Maintenance
Equipment Action
activity
Inspection Fastener Check that the fastener is not loose.
Rubber pad Check the wear extent of the rubber pad.
Pneumatic cylinders Regularly check that the piston rods of cylinders
are free from dust particles and that there is no air
leakage.
Vacuum generators Check for air leakage.
Suction cups Regularly check that the suction cups are
undamaged and free from dirt and other particles
(at least one time per month)
Valve unit Ensure all the connectors are tightened properly.
Cleaning Suction cups Clean the cups with soap and water.

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2.4.3. Changing/Replacement activities

2.4.3. Changing/Replacement activities

In any of the following situations, the corresponding component should be replaced:

• The valve unit/vacuum generator is distorted
• The congressed pipe is worn out
• Pins in the FlexGripper-Vacuum are worn out
• The vacuum rails are distorted
• Any component that has exceeded it’s lifetime
See the expected component life time in the table below:

Maintenance activity Equipment Expected life

Changing Complete suction cups 6 months

3HAC040633-002 Revision: - 49
2 FlexGripper-Vacuum
2.5.1. Instruction

2.5 Repair

2.5.1. Instruction

This chapter details all the repair activities recommended for the FlexGripper-Vacuum.

Safety information
Before any service work is started, 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 chapter Safety on page 7 before performing any service work.
NOTE!
Make sure that the power is off before starting any work.

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2.5.2.1. Replacing the cylinder of the pallet picker unit

2.5.2. Cylinder

2.5.2.1. Replacing the cylinder of the pallet picker unit

The cylinder is located as shown in the figure below.

en1012001

Position Part
A Spring hoop
B Spherical hinge
C Pneumatic cylinder
D Bracket
E Pin
F Bracket

Use this procedure to remove the cylinder.

DANGER!
Turn off all electric power and pneumatic pressure supplies to the gripper!

Action Note
1. Drain the air from the cylinder. Disconnect the air cable on the cylinder.
2. Remove the air control valve and joint.

en1012002

Parts: A: air control valve, B: joint

Continues on next page

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2 FlexGripper-Vacuum
2.5.2.1. Replacing the cylinder of the pallet picker unit

Continued

Action Note
3. Remove the sensors from the cylinder.

en1012003

Parts: A: sensor
4. Remove the joint from the piston rod of
the cylinder.

en1012004

Parts: A: joint, B: piston rob

5. Remove the bracket from the cylinder.

en1012005

Parts: A: cylinder, B: bracket

6. Remove the cylinder.

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2.5.2.2. Replacing the cylinder on the pallet searcher

2.5.2.2. Replacing the cylinder on the pallet searcher

The cylinder is located as shown in the figure below.

en1012006

Position Part
A Cylinder connect plate
B Magnetic proximity switch
C Quick connector
D Flow valve

Use this procedure to remove the cylinder.

DANGER!
Turn off all electric power and pneumatic pressure supplies to the gripper!

Action Note
1. Drain the air from the cylinder. Disconnect the air cable on the cylinder.
2. Remove the flow valve and quick
connector.

en1012007

Parts: A: Flow valve, B: Quick connector

Continues on next page

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2 FlexGripper-Vacuum
2.5.2.2. Replacing the cylinder on the pallet searcher

Continued

Action Note
3. Remove the magnetic proximity switch
from the pneumaticcylinder.

en1012008

Parts: A: Magnetic proximity switch

4. Remove the press plate from the
pneumatic cylinder.

en1012009

Parts: A: Press plate

5. Loosen the bolts on the cylinder connect
plate.

en1012010

Parts: A: Bolt
6. Remove the pneumatic cylinder.

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2.5.3. Magnetic proximity switch

2.5.3. Magnetic proximity switch

The magnetic proximity switch is located as shown in the figure below.

Position 1

en1012013

Position 2

en1012013

A Magnetic proximity switch

Position 1
Use this procedure to remove the magnetic proximity switch.
DANGER!
Turn off all electric power and pneumatic pressure supplies to the gripper!

Action Note
1. Loosen the small bolt.

en1012015

Parts: A: Small bolt

2. Open the terminal box and remove the See the circuit diagram for details.
cable.
3. Remove the magnetic proximity switch.

Continues on next page

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2 FlexGripper-Vacuum
2.5.3. Magnetic proximity switch

Continued

Position 2
Use this procedure to remove the magnetic proximity switch.
DANGER!
Turn off all electric power and pneumatic pressure supplies to the gripper!

Action Note
1. Loosen the small bolt.

en1012016

Parts: A: Small bolt

2. Open the terminal box and remove the See the circuit diagram for details.
cable.
3. Remove the magnetic proximity switch.

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2.5.4. Sensors

2.5.4. Sensors

The sensor is located as shown in the figure below. (There are 5 sensors mounted on the
gripper.)

en1012017

Position Part
A Sensor

Continues on next page

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2 FlexGripper-Vacuum
2.5.4. Sensors

Continued

Removing the sensor

Use this procedure to remove the sensor.
DANGER!
Turn off all electric power and pneumatic pressure supplies to the gripper!

Action Note
1. Loosen the small bolt.

en1012018

Parts: A: Small bolt

2. Loosen the small bolt.

en1012018

Parts: A: Small bolt

3. Open the terminal box and remove the See the circuit diagram for details.
cable.
4. Remove the sensor.

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2.5.5. Pneumatic unit

2.5.5. Pneumatic unit

The pneumatic units are located as shown in the figure below.

en1012019

Position Part
A Pneumatic unit
B Pneumatic cup
C Vacuum ejector
D One way valve
E Quick connector
F Pneumatic block
G Compressed air hose

Removing the pneumatic cup lip

Use this procedure to remove the pneumatic cup lip.
DANGER!
Turn off all electric power and pneumatic pressure supplies to the gripper!

Action Note
1. Remove the cup lip using your hands.

en1012018

Parts: A: Cup lip

Continues on next page

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2 FlexGripper-Vacuum
2.5.5. Pneumatic unit

Continued

Removing the pneumatic cup lip

Use this procedure to remove the whole pneumatic cuplip.
DANGER!
Turn off all electric power and pneumatic pressure supplies to the gripper!

Action Note
1. Loosen the bolts.

en1012018

Parts: A: Bolt
2. Remove the cup.

Removing the vacuum ejector

Use this procedure to remove the vacuum ejector.

Continues on next page

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2.5.5. Pneumatic unit

Continued

DANGER!
Turn off all electric power and pneumatic pressure supplies to the gripper!

Action Note
1. Loosen the bolts.

en1012018

Parts: A: Bolt
2. Remove the compressed air hose.

en1012018

Parts: A: Compressed air hose

3. Remove the quick connector.

en1012018

Parts: A: Quick connector

4. Remove the vacuum ejector.

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2 FlexGripper-Vacuum
2.5.6. Valve base

2.5.6. Valve base

The valve base is located as shown in the figure below.

en1012017

Position Part
A Power supply
B Valve base
C Muffler
D Quick connector

Removing the pneumatic cup lip

Use this procedure to remove the pneumatic cup lip.
DANGER!
Turn off all electric power and pneumatic pressure supplies to the gripper!

Action Note
1. Drain the air from the gripper. Disconnect the air cable.
2. Remove the power supply.
3. Disconnect the air cable.
4. Remove the quick connector.
5. Remove the muffler.

Continues on next page

62 3HAC040633-002 Revision: -
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2.5.6. Valve base

Continued

Action Note
6. Loosen the bolts.

en1012018

Parts: A: Bolt
7. Remove the valve base.

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2 FlexGripper-Vacuum
2.5.7. Dress cable

2.5.7. Dress cable

The dress cable is located as shown in the figure below.

en1012020

Position Part
A Electrical cable
B Main compressed air hose
C Corrugated pipe clip
D Dress cable

Use this procedure to remove the dress cable magnetic proximity switch.
DANGER!
Turn off all electric power and pneumatic pressure supplies to the gripper!

Action Note
1. Drain the air from the cylinder. Disconnect the air
cable
2. Pull out the main compressed air hose from the two sidequick
connectors.
3. Pull out the electrical cable from both side( one side-Gripper
terminal box, the other side-Robot axis 6).
4. Open the corrugated pipe clip.
5. Remove the dress cable.

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2.6.1. Start-up failures

2.6 Trouble shooting

2.6.1. Start-up failures

Consequences
Problem starting the system

Symptoms and causes

• LEDs not lit on the sensors.
• Air hose hangs loosely on the gripper.

Recommended actions

Action Info/illustration
1. Make sure the robot system has started up and is correctly
connected.
2. Make sure the air source is open.
3. Make sure the gripper cable and air hose are correctly
connected to the dress cable.
4. Make sure the gripper cable is correctly connected to the
terminal box on the gripper.

3HAC040633-002 Revision: - 65
2 FlexGripper-Vacuum
2.6.2. Gripper not responding

2.6.2. Gripper not responding

Consequences
The gripper cannot be operated using the FlexPendant.

Recommended actions

Action Info/illustration
1. Make sure the gripper system has started up.
2. Make sure the connection to the I/O board is correct.
3. Make sure that there is no air leakage.

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2.6.3. Wrong movement

2.6.3. Wrong movement

Consequences
The fault can cause severe injuries or death to personnel in the area or severe damage to the
manipulator and/or surrounding equipment.

Symptoms and causes

The movement of the gripper part is not as expected during commissioning.

Recommended actions

Action Info/illustration
1. Make sure the connection to the I/O board is correct.
2. Check the connection in the terminal box.

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2 FlexGripper-Vacuum
2.6.4. Low performance

2.6.4. Low performance

Consequences
Clamp or hook movement is sluggish and sometimes stalls.

Symptoms and causes

• Connection error
• Low air pressure
• Excessive friction

Recommended actions

Action Info/illustration
1. Make sure the electrical and air connections are correctly and
firmly connected.
2. Make sure the air pressure is between 4 bar and 6 bar.
3. Make sure there is not excessive friction between moving parts
(See section Mechanical noise).

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2.6.5. Problem jogging the gripper

2.6.5. Problem jogging the gripper

Consequences
Gripper can not reach the rotation range.

Symptoms and causes

Cable or air hose routing.

Recommended actions

Action Info/illustration
1. Make sure the cable and air hose are correctly routed.

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2 FlexGripper-Vacuum
2.6.6. Mechanical noise

2.6.6. Mechanical noise

Consequences
• Failing bearings cause the palletizing accuracy, and in severe cases, the workpiece
may fall down uncontrolly
• The gripper part or workpiece may fall down

Symptoms and causes

• Loose bolts

Recommended actions

Action Info/illustration
1. Determine which bearing is emitting the noise.
2. Make sure the bearing has sufficient lubrication.
3. Replace the bearing with a new one.

Action Info/illustration
1. Determine which bearing is emitting the noise.
2. Tighten the bolts to the recommended torque.

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2.6.7. Workpiece drop on power down

2.6.7. Workpiece drop on power down

Consequences
The fault can cause severe injuries or death to personnel in the area or severe damage to the
manipulator and/or surrounding equipment.

Symptoms and causes

• Faulty valve
• Faulty air connection or air leakage

Recommended actions

Action Info/illustration
1. Determine which valve causes the workpiece to drop.
2. Check the air hose connection.

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2 FlexGripper-Vacuum
2.6.8. No Input signal detected

2.6.8. No Input signal detected

Consequences
Can not run work program.

Symptoms and causes

• No signal detected in UI. LEDs not lit on the I/O board.
• Faulty connection.

Recommended actions

Action Info/illustration
1. Make sure the LED sensors are lit and all the connections are
firmly connected.
2. Check the connection on the I/O board.

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 2 FlexGripper-Vacuum
2.6.9. No Vacuum created

2.6.9. No Vacuum created

Consequences
Can not use vacuum gripper.

Symptoms and causes

• Wrong voltage levelAir leakage
• Faulty vacuum pump or terminal valve

Recommended actions

Action Info/illustration
1. Make sure low level is used to activate the vacuum.
2. Make sure there is no air leakage or air connection error.
3. Replace the faulty vacuum pump or the terminal valve.

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2 FlexGripper-Vacuum
2.7.1. Introduction

2.7 Decommissioning

2.7.1. Introduction

Introduction
This section contains information to consider when taking a product, FlexGripper, out of
operation. It deals with how to handle potentially dangerous components and potentially
hazardous materials.

General
All used grease, oils and dead batteries must be disposed of in accordance with the current
legislation of the country in which the FlexGripper units are installed. If the FlexGripper units
are partially or completely disposed of, the various parts must be grouped together according
to their nature (that is, all iron together and all plastic together), and disposed of accordingly.
These parts must also be disposed of in accordance with the current legislation of the country
in which the FlexGripper units are installed.

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 2 FlexGripper-Vacuum
2.7.2. Environmental information

2.7.2. Environmental information

Hazardous material
The table specifies some of the materials in the FlexGripper and their respective use
throughout the product.
Dispose of the components properly to prevent health or environmental hazards.

Material Example application

Copper Cables
Steel Screws, base-frame, and so on
Plastic/rubber (PVC) Cables, connectors, and so on
Oil, grease Gear boxes
Aluminium Flange

Oil and grease

Where possible, arrange for the oil and grease to be recycled. Dispose of via an authorized
person/contractor in accordance with local regulations. Do not dispose of oil and grease near
lakes, ponds, ditches, down drains or onto soil. Incineration must be carried out under
controlled conditions in accordance with local regulations.
Also note that:
• Spills may form a film on water surfaces causing damage to organisms. Oxygen
transfer could also be impaired. Spillage may penetrate the soil causing ground water
contamination.

3HAC040633-002 Revision: - 75
2 FlexGripper-Vacuum
2.8. Wear parts

2.8. Wear parts

Part No. Description

3HAC040869-001 Vacuum cup

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2.9. Spare parts

2.9. Spare parts

Mechanical parts

en1016001

Continues on next page

3HAC040633-002 Revision: - 77
2 FlexGripper-Vacuum
2.9. Spare parts

Continued

Pneumatic & electric parts

en1016001

Continues on next page

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2.9. Spare parts

Continued

Spare parts list

Pos Part No. Description Qty Note / Dimension

1 3HAC040417‐001 Flange plate for 660 1
2 3HAC040418‐001 Shaft fitting for 660 1
3 3HAC040469‐001 frame machining 1
4 3HAC040472‐001 electric box bracket 2
5 3HAC040588‐001 valve bracket A 2
6 3HAC040474‐001 beam welding1 2
7 3HAC040526‐001 cable protect plate 2
8 3HAC040527‐001 sensor bracket 5
9 3HAC040528‐001 hook block 8
10 3HAC040529‐001 hook 4
11 3HAC040533‐001 cylinder pin 4
12 3HAC040535‐001 hollow shaft pin 4
13 3HAC040536‐001 shaft 2
14 3HAC040538‐001 pneumatic block left 10
15 3HAC040589‐001 pneumatic block right 10
16 3HAC040539‐001 bearing house 4
17 3HAC040540‐001 plastic sleeve 4
18 3HAC040542‐001 synchronize rod 1
19 3HAC040543‐001 cylinder washer 1
20 3HAC040544‐001 cylinder connect plate 1
21 3HAC040545‐001 press plate 1
22 3HAC040698‐001 Wafer for hook 4
23 9ABA135‐10 spring ring 4
24 9ABA142‐62 pin 4
25 3HAC040844-001 Valve base 1
26 3HAC040851-001 fitting 8
27 3HAC040854-001 Cylinder 1
28 3HAC040855-001 Flow contral valve 2
29 3HAC040856-001 fitting 2
30 3HAC040857-001 Accessory of cylinder 2
31 3HAC040858-001 Pin 2
32 3HAC040859-001 cylinder 2
33 3HAC040860-001 Accessory of cylinder 2
34 3HAC040800-001 spherical hinge 4
35 3HAC040861-001 Flow vavle 4
36 3HAC040862-001 fitting 4
37 3HAC040867-001 Vacuum ejector 20
37 3HAC040868-001 One way valve 20
40 3HAC040872-001 photoelectric sensor 5

en1016001

3HAC040633-002 Revision: - 79
2 FlexGripper-Vacuum
2.10.1. Electrical circuit

2.10 Circuit diagram

2.10.1. Electrical circuit

Power supply circuit

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. © Copyright 2003 ABB
Prepared by, date: CNYAWU2

Latest revision:

1
Approved by, date:

2
XT31

3
G2
-XP6

1
3

-X4

6;7 / -24V
-XP6

5
4

4
6;7 7;8 / -0V
Lab/Office:
POWER SUPPLY

5
6
Document no.

Status: 6/20/2011
3HAC040633-004

Approved

7
Sublocation:+
Location: +
Plant:
Rev. Ind Page 5

=
00 Total 11

8
Next 6

3HAC040149-003-7

Continues on next page

80 3HAC040633-002 Revision: -
2 FlexGripper-Vacuum

Continued

Continues on next page

81
2.10.1. Electrical circuit

1 2 3 4 5 6 7 8
-ROBOTCABINET -MANIPULATOR BASE -AXIS 3 -AXIS 6 -Terminal box
*
DUAL
*
SINGLE
-XS13
-XP6 -R1.CP/CS -R2CP/CS -R3.CP/CS -G.CP/CS
1 670 BK A1 a1 1 D1 d1 4 D1 d1 4 C4 E
- BN 24V 24V
2 A2 a2 2 D6 d6 5 D6 d6 5 C5 c5 F
671 RD 0V 0V
- OG
3 672 YE A3 a3 3 D3 d3 6 D3 d3 6 C6 c6 V
- GN 24V 24V
4 A4 a4 4 D4 d4 7 D4 d4 7 C7 c7 W
673 BU 0V 0V
- VT
GN/YE GN/YE GN/YE GN/YE GN/YE
PE
-XP5.1
1 677 BK B1 b1 WH B1 B1 WH/BK B1 b1 WH/BK B18 A
2 678 BN B2 b2 BU B2 b2 BK B2 b2 BK B19 B
We reserve all rights in this document and in the information contained therein.Reproduction, use or

-XP5.2
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

1 WH/GN WH/GN B3 b3 WH/GN B3 b3 WH/BN B3 b3 WH/BN B20 C

2 GN GN B4 b4 GN B4 b4 BN B4 b4 BN B21 D
3 WH/BN WH/BN B5 b5 WH/BN B5 b5 WH/RD B5 b5 WH/RD B22 H
4 BN BN B6 b6 BN B6 b6 RD B6 b6 RD B23 J
-XP5.1
9 WH/BU WH/BU B7 b7 WH/BU B7 b7 WH/OG B7 b7 WH/OG B24 K
KSR KSR
10 BU BU B8 b8 BU B8 b8 OG B8 b8 OG B25 L
KSR KSR
11 WH/OG WH/OG B9 b9 WH/OG B9 b9 WH/YE B9 b9 WH/YE B16 M
12 OG OG B10 b10 OG B10 b10 YE B10 b10 YE B17 N
3 679 RD B11 b11 WH B11 b11 WH/GN B11 b11 WH/GN B1 P
4 680 OG B12 b12 OG B12 b12 GN B12 b12 GN B2 R
5 681 YE B13 b13 WH B13 b13 WH/BU B13 b13 WH/BU B3 S
6 682 GN B14 b14 GN B14 b14 BU B14 b14 BU B4 T
-XP5.3
1 693 GY B15 b15 WH B15 b15 WH/VT B15 b15 WH/VT B5 U

3HAC040149-003-17
2 694 WH B16 b16 BN B16 b16 VT B16 b16 VT B6 X
3 695 WH/BK B18 b18 WH B18 b18 WH/GY B18 b18 WH/GY B7 Y
4 696 WH/BN B19 b19 GY B19 b19 GY B19 b19 GY B8 Z
5 697 WH/RD B20 b20 RD B20 b20 WH/BK B20 b20 WH/BK B9 a

3HAC040633-002 Revision: -
6 698 WH/OG B21 b21 BU B21 b21 BK B21 b21 BK B10 b
-XP5.2
5 685 GY C16 c16 RD C16 c16 WH/OG C16 c16 WH/OG B11 c
DRESSPACK IRB660

6 686 WH C17 c17 OG C17 c17 OG C17 c17 OG B12

101/3

101/4

101/5

101/6

101/7

101/8

101/8

101/8
Latest revision: Lab/Office: Status: 6/20/2011 Plant: =
Approved Location: +
DRESSPACK IRB660 Sublocation:+
Document no. Rev. Ind Page 8
3HAC040633-004 Next 9
Prepared by, date: CNYAWU2 Approved by, date: 00 Total 11
 3HAC040633-002 Revision: -
Continues on next page
1 2 3 4 5 6 7 8
-I/O Unit
DSQC 652
OUTPUT CH 1-8
XTXX.X1
<1 =CAB-I/O 1
OUTPUT CH.1 -XP5.1
2 2
1 1
2
3 -XP5.2
4 2
3 3
4
5
6 4
5 9
6
7 -XP5.1
8 10
We reserve all rights in this document and in the information contained therein.Reproduction, use or

7
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

0V 8 -0V / 5;4
9 -24V / 5;4
24V 10
OUTPUT CH 9-16
XTXX.X2
<1 =CAB-I/O 11
OUTPUT CH.9 -XP5.1
0V
10 12
1 3
2
11
12 4
3 5
4
13
14 6
5
6
7
8
9 -AIR_PRE / 11;1
10

3HAC040149-003-15
2 FlexGripper-Vacuum

FlexGripper-Vacuum DO
2.10.1. Electrical circuit

Latest revision: Lab/Office: Status: 6/20/2011 Plant: =

Approved Location: +
VACUUM DO Sublocation:+
Document no. Rev. Ind Page 6
3HAC040633-004 Next 7
Prepared by, date: CNYAWU2 Approved by, date: 00 Total 11
Continued

82
2 FlexGripper-Vacuum

Continued

Continues on next page

83
2.10.1. Electrical circuit

1 2 3 4 5 6 7 8
-I/O Unit DSQC 652
XTXX.X3
-I/O 1
INPUT CH.1 -XP5.3
2 2
1 3
2
3 -XP5.3
4 4
=CAB-I/O 3 5
/ -V-,1 5
We reserve all rights in this document and in the information contained therein.Reproduction, use or

4 6
-CAN_L,1 6
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

/ 1 5 5
/ -CAN_H,1 2 6
7 -XP5.2
/ -V+,1 8 1 -XP6
4 7
5 8 -0V / 5;4
/ -DRAIN,1 9
0V 3 10
NA0 6
NA1 7
1) NA2 8 0V
NA3 9
NA4 10 XTXX.X4
NA5 11 -I/O 2
12 INPUT CH.9 -XP6
1
2
3
4
5
6
1) THE DEFAULT NODE ADDRESS IS 10. 7 -AIR_RET / 11;2
8
9
10

3HAC040149-003-16

3HAC040633-002 Revision: -
FlexGripper-Vacuum DI

Latest revision: Lab/Office: Status: 6/20/2011 Plant: =

Approved Location: +
VACUUM DI Sublocation:+
Document no. Rev. Ind Page 7
3HAC040633-004 Next 8
Prepared by, date: CNYAWU2 Approved by, date: 00 Total 11
 3HAC040633-002 Revision: -
Continues on next page
1 2 3 4 5 6 7 8
-G.CP/CS
A 1
WH -DO_PALLET_OPEN / 11;7
B 2
GN -DO_PALLET_CLOSE / 11;8
C 3
YE -DO_POS_F / 11;2
D 4
GY -DO_POS_B / 11;2
H 5
PK -ZONE1 / 11;3
J 6
BU -ZONE2 / 11;3
K 7
RD -ZONE3 / 11;4
L 8
VT -ZONE4 / 11;4
M 9
GY/PK -ZONE5 / 11;5
N 10
RD/BU -ZONE6 / 11;5
P 11
WH/GN -ZONE7 / 11;5
R 12
BN/GN -ZONE8 / 11;6
S 13
WH/YE -ZONE9 / 11;6
T 14
YE/BN -ZONE10 / 11;7
We reserve all rights in this document and in the information contained therein.Reproduction, use or

U 15
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB

-DI_PALLET_OPEN / 10;3
X 16
-DI_PALLET_CLOSE / 10;3
Y 17
-DI_POS_F / 10;4
Z 18
-DI_POS_B / 10;4
a 19
-VACUUM_DET1 / 10;6
b 20
-VACUUM_DET2 / 10;6
c 21
-VACUUM_DET3 / 10;7
E 22
-VACUUM_DET4 / 10;7 10;8
F 23
-VACUUM_AIR_RETURN /
V 25
24V -VACUUM_AIR /
27
29
-VACUUM_24V_3 / 10;1
31
-VACUUM_24V_4 / 10;1
FlexGripper-Vacuum terminal connection

33
-VACUUM_24V_5 / 10;1
35
-VACUUM_24V_6 / 10;1
37
-VACUUM_24V_7 / 10;1
39
-VACUUM_24V_8 / 10;1
W 26

3HAC040149-003-29
0V
28
-VACUUM_0V_2 / 11;8 11;8 11;8
30
-VACUUM_0V_3 / 10;2
32
-VACUUM_0V_4 / 10;2
2 FlexGripper-Vacuum

34
-VACUUM_0V_5 / 10;2
36
-VACUUM_0V_6 / 10;2
38
-VACUUM_0V_7 / 10;2
2.10.1. Electrical circuit

40
-VACUUM_0V_8 / 10;2
Latest revision: Lab/Office: Status: 6/20/2011 Plant: =
Approved Location: +
TERMINAL CONN. VACUUM Sublocation:+
Document no. Rev. Ind Page 9
3HAC040633-004 Next 10
Prepared by, date: CNYAWU2 Approved by, date: 00 Total 11
Continued

84
2 FlexGripper-Vacuum

Continued

85
2.10.1. Electrical circuit

1 2 3 4 5 6 7 8

-VACUUM_DET1

-VACUUM_DET2

-VACUUM_DET3

-VACUUM_DET4

-VACUUM_DET4
9;6 10;8

9;6 10;7
-DI_PALLET_CLOSE
-DI_PALLET_OPEN

9;6

9;6

9;6
-DI_POS_B
-DI_POS_F
9;6

9;6

9;6

9;6
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. © Copyright 2003 ABB

4 4 4 4 4 4 4 4 4
S1 S2 S3 S4 L1 L2 L3 L4 L5
- + - + - + - + - + - + - + - + - +
2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1
9;6 / -VACUUM_0V_3
9;6 / -VACUUM_0V_4
9;6 / -VACUUM_0V_5
9;6 / -VACUUM_0V_6
9;6 / -VACUUM_0V_7
FlexGripper-Vacuum sensor connection

9;6 / -VACUUM_0V_8
9;6 / -VACUUM_24V_3
9;6 / -VACUUM_24V_4

3HAC040149-003-30
9;6 / -VACUUM_24V_5
9;6 / -VACUUM_24V_6
9;6 / -VACUUM_24V_7

3HAC040633-002 Revision: -
9;6 / -VACUUM_24V_8
/ -VACUUM_24V_9
Latest revision: Lab/Office: Status: 6/20/2011 Plant: =
Approved Location: +
VACUUM SENSORS Sublocation:+
Document no. Rev. Ind Page 10
3HAC040633-004 Next 11
Prepared by, date: CNYAWU2 Approved by, date: 00 Total 11
2 FlexGripper-Vacuum
2.10.2. Pneumatic circuit

2.10.2. Pneumatic circuit

FlexGripper-Vacuum pneumatic circuit

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. © Copyright 2003 ABB
Prepared by, date: CNYAWU2

Latest revision:

Option

1
10P-18-8A-MP-N-U-C5NLJ ZWRA-E
I/O board

-AIR_PRE
6;7
-AIR_RET
7;8
Approved by, date:

?2
11

12/14

82/84
3/5

(VL)
V
1

2
-DO_POS_F
C
3

9;6

?
4

-DO_POS_B
4

9;6 ?
2

-ZONE1 VGS 3010 VGS 3010

N

?0
5

9;6

3
AQR AQR
4

-ZONE2 VGS 3010 VGS 3010

6

9;6
AQR AQR
2

?0

-ZONE3 VGS 3010 VGS 3010

N
7

?0

9;6
AQR AQR
4

4
-ZONE4 VGS 3010 VGS 3010
8

9;6
AQR AQR
2

?0
Lab/Office:

-ZONE5 VGS 3010 VGS 3010

N
9

?0

9;6
AQR AQR
4
VACUUM PNEUMATICS

-ZONE6
5

VGS 3010 VGS 3010

10

9;6
AQR AQR
2

?0

-ZONE7 VGS 3010 VGS 3010

N
11

9;6
?0

AQR AQR
4

-ZONE8 VGS 3010 VGS 3010

12

9;6
6

AQR AQR
2

?0

-ZONE9 VGS 3010 VGS 3010

N
13

?0

9;6
AQR AQR
4

-ZONE10
Document no.

Status: 6/20/2011

VGS 3010 VGS 3010

3HAC040633-004

Approved

14

9;6
AQR AQR
2

?0

7
L

-DO_PALLET_OPEN
J
1

9;6
?0
Sublocation:+
Location: +
Plant:

4
2

?0

-DO_PALLET_CLOSE
2

9;6
Rev. Ind Page 11

-VACUUM_0V_2
(VR)
V
00 Total 11

8
WH/BK

23

9;6

-VACUUM_0V_2
Next

BN

24

9;6
-VACUUM_0V_2
BK

25

9;6

3HAC040149-003-31

86 3HAC040633-002 Revision: -
 3 FlexGripper UI
2.10.2. Pneumatic circuit

3 FlexGripper UI

3HAC040633-002 Revision: - 87
3 FlexGripper UI
3.1.1. Installing FlexGripper UI FlexPendant application

3.1 Software installation

3.1.1. Installing FlexGripper UI FlexPendant application

NOTE!
Only 24V power is used in FlexGripper.

Short circuit protection should be implemented by a fuse in the control cabinet by the
customer.

Robot controller configuration requirement

Hardware DSQC 652 board
RobotWare RobotWare 5.13.02, includes the following options:
• 617-1 FlexPendant Interface

FlexGripper UI FlexPendant application installation

Use the following procedure:
NOTE!
Before installing FlexGripper UI FlexPendant application, make sure that you have
RobotStudio installed on your laptop.
1.Copy the FlexGripperUI folder into the mediapool folder of your laptop. Copy the
MULTIFLEXGRIPPERUI folder from the FlexGripperUI FlexPendant GUI installation CD
to C:\Program Files\ABB Industrial IT\Robotics IT\Mediapool on your laptop (If the path to
mediapool folder is not as above, find the mediapool folder on your PC).
2.Create a robot controller system for FlexGripperUI with RobotStudio.
• On the Online ribbon-tab of RobotStudio, click System Builder to bring up a dialog
box.
• In the Actions group click Create New... to start the wizard.
• Follow the instructions on the wizard to enter a name and path of the system, then enter
a controller key and a drive key for the system.
• In the Add Additional Options page, browse and select the FlexGripperUI option key
from C:\Program Files\ABB Industrial IT\Robotics
IT\Mediapool\MULTIFLEXGRIPPERUI\Internal_Use_Key. Then click the arrow to
add the FlexGripperUI option key to the Added options list. Click Next to go to the
next page.
• In the Modify Options page, make sure the following options are selected: a
DeviceNet option (according to your hardware configuration), 616-1 PC Interface,
617-1 FlexPendant Interface and MULTIFLEXGRIPPERUI.
• Click Finish. The controller system is created. See Operating manual - RobotStudio
for more detailed information.

Continues on next page

88 3HAC040633-002 Revision: -
 3 FlexGripper UI
3.1.1. Installing FlexGripper UI FlexPendant application

Continued

3. Download the system to robot controller.

4. Warm start the controller.
The FlexGripperUI application icon is shown on the ABB main menu on the FlexPendant.

Note: For the FlexGripper UI option, Singleclamp option represents FlexGripper-Clamp 1,

Twoclamp option represents FlexGripper-Clamp 2, Vacuum option represents FlexGripper-
Vacuum, Claw option represents FlexGripper-Claw.

en1011047

3HAC040633-002 Revision: - 89
3 FlexGripper UI
3.1.2. I/O signal configuration

3.1.2. I/O signal configuration

FlexGripper-Vacuum signal configration

I/O signal I/O board Controller Electric box
Signal 24V 0V
DO1001(DO10_01_PalletPic DO1 XT5.1.1 1 - 28
ker_Open)
DO1002(DO10_02_PalletPic DO2 XT5.1.2 2
ker_Close)
DO1003(DO10_03_Postion DO3 XT5.2.1 3
Seacher_Forward)
DO1004(DO10_04_Postion DO4 XT5.2.2 4
Seacher_Backward)
DO1005(DO10_05_Zone1) DO5 XT5.2.3 5
DO1006(DO10_06_Zone2) DO6 XT5.2.4 6
DO1007(DO10_07_Zone3) DO7 XT5.1.9 7
DO1008(DO10_08_Zone4) DO8 XT5.1.10 8
DO1009(DO10_09_Zone5) DO9 XT5.1.11 9
DO1010(DO10_10_Zone6) DO10 XT5.1.12 10
DO1011(DO10_11_Zone7) DO11 XT5.1.3 11
DO1012(DO10_12_Zone8) DO12 XT5.1.4 12
DO1013(DO10_13_Zone9) DO13 XT5.1.5 13
DO1014(DO10_14_Zone10) DO14 XT5.1.6 14
DI1001(DI10_01_PalletPicke DI1 XT5.3.1 15 29 30
r1_Open)
DI1002(DI10_02_PalletPicke DI2 XT5.3.2 16 29 30
r1_Close)
DI1003(DI10_03_PostionSe DI3 XT5.3.3 17 31 32
acher_Searched)
DI1004(DI10_04_PostionSe DI4 XT5.3.4 18 31 32
acher_Backed)
DI1005(DI10_05_PartCheck DI5 XT5.3.5 19 33 34
1), for photoelectrical sensor
1
DI1006(DI10_06_PartCheck DI6 XT5.3.6 20 35 36
2), for photoelectrical sensor
2
DI1007(DI10_07_PartCheck DI7 XT5.2.5 21 37 38
3), for photoelectrical sensor
3
DI1008(DI10_08_PartCheck DI8 XP6.1 22 39 40
4), for photoelectrical sensor
4 and 5
DI1009(DI10_09_AirPressur DI9 XP6.2 23 25
e),for compressed air source
pressure detection
24V XP6.3
0V XP6.4

90 3HAC040633-002 Revision: -
 3 FlexGripper UI
3.1.3. Back-up and I-Start

3.1.3. Back-up and I-Start

Back up the system

Use this procedure to back up your system:
NOTE!
We recommend performing a backup:
• Before installing a new RobotWare.
• Before making any major changes to instructions and/or parameters to make it
possible to return to the previous settings.
• After making any major changes to instructions and/or parameters and testing the new
settings to retain the new successful setting.
1. Tap the ABB menu and then tap Backup and Restore.
2. Tap Backup Current System....A page showing the selected path opens.
3. Specify a backup folder name and path.
4. Tap Backup.
A backup folder is created according to your settings.

Restart and return to default setting (I-start)

Use this procedure to make an I-start
NOTE!
After I-start, the system’s state will be resumed but any changes done to system parameters
and other settings will be lost. Instead, system parameters and other settings are read from the
originally installed system on delivery. Therefore it is important to always make a back up
before I-start.
1. Make a backup of the system.
2. On the ABB menu, tap Restart. The restart page is displayed.
3. Tap Advanced... to select restart method. The select restart method dialog is displayed.
4. Tap I-start, then tap OK.
5. Restore the backup system.

3HAC040633-002 Revision: - 91
3 FlexGripper UI
3.2.1. FlexGripper UI main interface

3.2 Operation

3.2.1. FlexGripper UI main interface

Enter FlexGripper UI

en1011048

The FlexGripper UI has three function blocks: Tool handle, TCP edit and Production which
you can see after entering the main interface.

en1011049

92 3HAC040633-002 Revision: -
 3 FlexGripper UI
3.2.2.1. FlexGripper function test

3.2.2. Tool handle

3.2.2.1. FlexGripper function test

FlexGripper-Vacuum function test

Touch Tool handle button, the following interface would show up

en1011050

Continues on next page

3HAC040633-002 Revision: - 93
3 FlexGripper UI
3.2.2.1. FlexGripper function test

Continued

Users can operate functions displayed and check if the corresponding signals status right. By
the FlexGripper function dropdown list, users can choose Vacuums, PalletPicker or
PalletSearch to do the corresponding function test.

Function and signal status table (FlexGripper-Vacuum)

Function Function
Action description Signal status
type name
Vacuums Vacuum On Turn on the vacuum source of all DO10_05_Zone1
the vacuum cups at the same DO10_06_Zone2
time. DO10_07_Zone3
DO10_08_Zone4
DO10_09_Zone5
DO10_10_Zone6
DO10_11_Zone7
DO10_12_Zone8
DO10_13_Zone9
DO10_14_Zone10
all turn to 0 and
extinguish
Vacuum Off Turn off the vacuum source of all DO10_05_Zone1
the vacuum cups at the same time DO10_06_Zone2
DO10_07_Zone3
DO10_08_Zone4
DO10_09_Zone5
DO10_10_Zone6
DO10_11_Zone7
DO10_12_Zone8
DO10_13_Zone9
DO10_14_Zone10
all turn to 1 and light up
Group Vacuum Group vacuum cups into groups Refer to Group activity
and on different vacuum rails
PalletPicker Close Close pallet picker DO10_02_PalletPicker1
_Close turns to 1 and
lights up
Open Open pallet picker DO10_01_PalletPicker1
_Open turns to 1 and
lights up

Continues on next page

94 3HAC040633-002 Revision: -
 3 FlexGripper UI
3.2.2.1. FlexGripper function test

Continued

Function Function
Action description Signal status
type name
Palle- Forward Search cylinder move forward DO10_03_PositionSear
tSearch cher_Forward turns to 1
and lights up
Backward Search cylinder move backward DO10_04_PositionSear
cher_Backward turns to
1 and lights up
Product To detect if the product drop down. If one of the products
drop When the product is gripped, the drops, the correspond-
detection corresponding photoelectric ing signal in
sensor would keep light on. DI10_05_PartCheck1
DI10_06_PartCheck2
DI10_07_PartCheck3
DI10_08_PartCheck4
would turn to 0 and turn
off.

Group activity
Group function is used for build vacuum groups. Every two adjacent vacuum cups share a
vacuum generator. Every vacuum cup pair and the opposite vacuum cup pair on the other
vacuum rail form one control zone. There are totally ten vacuum zones which can be
controlled separately.
Touch Group vacuum button, the following interface shows up:

en1011051

Continues on next page

3HAC040633-002 Revision: - 95
3 FlexGripper UI
3.2.2.1. FlexGripper function test

Continued

Select the desired group, tap Vacuum on or Vacuum off button, the vacuum source of selected
vacuum groups would be turn on or shut down accordingly. Users can operate functions
displayed and check if the corresponding signals status right. Function and signal status table
for default vacuum group:

Group
Button name Action description Signal status
name
Group 1 Vacuum On Turn on the vacuum source of all DO10_05_Zone1
vacuum cups in group 1 at the DO10_06_Zone2
same time. DO10_07_Zone3
DO10_08_Zone4
DO10_09_Zone5
DO10_10_Zone6
DO10_11_Zone7
DO10_12_Zone8
DO10_13_Zone9
DO10_14_Zone10
all turn to 0 and turn off
Vacuum off Cut off the vacuum source of all DO10_05_Zone1
vacuum cups in group 1 at the DO10_06_Zone2
same time. DO10_07_Zone3
DO10_08_Zone4
DO10_09_Zone5
DO10_10_Zone6
DO10_11_Zone7
DO10_12_Zone8
DO10_13_Zone9
DO10_14_Zone10
all turn to 1 and light up

Users can edit the vacuum group. Following is the action list that could be executed when
selecting a group:

Action Description Procedure

Add Add new groups Touch Action -> Add group, a soft keyboard would
Group show up. Input the group name. The name can only
contains numbers, letters and underline signals with
name length no more than 25 characters.
Delete Delete vacuum groups Select the group to be deleted, touch Action ->
Group Delete Group, A message window would pop up
confirming the action. Click OK to confirm the
deletion. Click Cancel to cancel the edition.
Zone edit Add or delete a vacuum Select the group to which a vacuum zone would be
zone to the selected group added. A vacuum zone list would show up in the
right in which selected cups would be marked with a
tick and unselected cups would leave unmarked.
Select or deselect the vacuum zone that to be
added or deleted, and touch OK.Click Back to
cancel the edition.

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3.2.2.1. FlexGripper function test

Continued

Users can edit the vacuum zone. Following is the action list that could be executed when
selecting a zone:

Action Description Procedure

Zone edit Add or delete a vacuum zone to Select the vacuum zone to be added or
the selected group deleted. A vacuum zone list would show up
in the right in which selected cups would be
marked with a tick and unselected cups
would leave unmarked. Select or deselect
the vacuum zone that to be added or
deleted, and touch OK. Click Back to
cancel the edition.

NOTE!
After entering the main interface and touch any of the buttons, a warning message would
show up prompting converting to the manual mode.

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3.2.2.2. TCP edit

3.2.2.2. TCP edit

Note: The TCP configuration includes three elements: TASK, Storage type and Scope.
Their scopes are:
Task: T_ROB1
Storage type: Persistent and variable
Scope: Task, Global and Local
If the scope and storage type of the TCP is not correct it can not be monitored.
Touch TCP tab, the following interface would shows:

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The grey column indicates data columns are not editable. The white columns indicate they
are in editable mode.

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3.2.2.2. TCP edit

Continued

TCP operation

Action Procedure
Select TCP Touch Select TCP button, then the TCP list shows.

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Select the TCP needed, and touch OK. The related parameters of the TCP
are automatically loaded into the Tool field on the left and the Load field on
the right.
Edit TCP Choose the “Edit TCP” button, the column turns from grey to white
indicating the content is editable. Choose one field, a soft keyboard shows
which is used to input TCP data.

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The soft keyboard consists of 0-9 numbers, positive/negative sign (+/-),

decimal point, and an arrow left/right symbol used to move cursor left/right.
The cross button has the function of backspace. For data description and
valid data scope, see Table TCP Parameter description, After the editing,
touch OK to confirm the editing. Then touch Apply, the editing is saved
which is indicated by the data input columns turning grey.

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3.2.2.2. TCP edit

Continued

TCP Parameter description

Type Parameter Description

Tool trans x The X-value of TCP position in mm
trans y The Y-value of TCP position in mm
trans z The Z-value of TCP position in mm
rot q1 The q1 value in the quaternion (q1, q2, q3, q4) of
the orientation of the tool coordinate system
rot q2 The q2 value in the quaternion (q1, q2, q3, q4) of
the orientation of the tool coordinate system
rot q3 The q3 value in the quaternion (q1, q2, q3, q4) of
the orientation of the tool coordinate system
rot q4 The q4 value in the quaternion (q1, q2, q3, q4) of
the orientation of the tool coordinate system
Load mass The weight of the tool in kg.
cog x The X-value of the center of gravity of the tool
load (x, y and z) in mm
cog y The Y-value of the center of gravity of the tool
load (x, y and z) in mm
cog z The Z-value of the center of gravity of the tool
load (x, y and z) in mm
inertia x The X-value of the moments of inertia of the tool
relative to its center of mass around the tool load
coordinate axes in kgm2
inertia y The Y-value of the moments of inertia of the tool
relative to its center of mass around the tool load
coordinate axes in kgm2
inertia z The Z-value of the moments of inertia of the tool
relative to its center of mass around the tool load
coordinate axes in kgm2

Default TCP of FlexGrippers

FlexGri
pper Default TCP value Default TCP location illustration
type
FlexGrip [TRUE, [[0,0,158], [1,0,0,0]],
per- [64, [-10.5,12.8,59.8],
Vacuum [1,0,0,0],4.817,0,8.722]]

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NOTE!
The default TCP is only valid with no prodcut is gripped by the FlexGripper. After the product
is gripped, the TCP location should be adjusted according to the new center of gravity.
If the user want to add TCP themselves, they can add TCP in the program. Then the newly
added TCP can be shown in the TCP list when tapping Select TCP in the TCP interface.

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3.2.3.1. Position Tune

3.2.3. Tune

3.2.3.1. Position Tune

The position tune function is used to fine tune the robot target location as the pick/place
location and home location.
Note: The robot target configuration includes three elements: TASK, Storage type and Scope.
Their scopes are:
Task: T_ROB1
Storage type: Persistent and variable
Scope: Task, Global and Local
If the scope and storage type of the robot target is not correct it can not be monitored.

Touch the Tune button in the FlexGripper UI main interface, and enter the Tune interface. By
default, there are three robot targets listed: pPick, pPlace and pHome (For FlexGripper-
Vacuum, there are three more targets: pPickPallet, pSearch and pSearchEnd).

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3.2.3.1. Position Tune

Continued

Robot target edit

Action Procedure
Add target Touch the Add target button, in the screen shown, the left side shows the
target contribution, ie Task, Type, the right side shows the target list with
the module described. Select the target needed, which is then ticked in
the square before its name.

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The targets listed are selected by default. Touch the target to remove the
tick and deselect a target. Select OK, the selected targets are added to
the Choose robot target column.
Teach target Touch the Teach button, the selected robot target position is taught.
Meanwhile the corresponding parameters of the TCP are automatically
loaded into the Pos offset column.
Target position After target teach, if the robot doesn’t reach the exact position, the offset
offset function can be used to fine tune the robot target.
In the Pos offset column, touching the plus sign increases the position in
mm and the minus sign decreases it. The increment unit can be adjusted
in 0.1mm, 0.5mm, 1mm or 5mm. After the offset, touch Apply, the offset
target is saved.

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3.2.3.2. Work object tune

3.2.3.2. Work object tune

A work object is a coordinate system used to describe the position of a work piece. The work
object consists of two frames: a user frame and an object frame. All programmed positions
will be related to the object frame. The object frame is related to the user frame and the user
frame is related to the world coordinate system.

Note: The work object configuration includs three elements: TASK, Storage type and Scope.
Their scopes are:
Task: T_ROB1
Storage type: Persistent and variable
Scope: Task, Global
If the scope and storage type of the work object is not correct it can not be monitored.

Touch the Work object tune tab to enter the work object tune interface.

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Work object tune operation

Action Procedure
Choose work Choose work object from the drop down list on the left. The work object (x,
target y, z) in mm shows up on the right.
Tune the work Touch the minus button to decrease the value and the plus button to
object increase the value. The tuning unit can be 0.1mm, 0.5mm, 1mm or 5 mm.
After editing, touch Apply, the modification is saved.

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3.2.3.3. Test run

3.2.3.3. Test run

After the TCP edit, Position tune and work object tune, the functions defined in the Template
system module can be tested in Test run. For FlexGripper-Vacuum, after entering the Test run
interface, the following interface shows:

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3.2.3.3. Test run

Continued

Press the Product Pick&place button, the robot implements the exePickPlace routing which
includes a part pick and place cycle. Press the Pallet pick&place button, the robot will
implement the exePallet routing which includes a series action: pallet search, pick pallet and
place.
NOTE!
when pressing any of the test buttons, a message shows prompting you to press the run button.
Press the run button. Before the test, the TCP should be edited according to the real payload
in testrun.
In the pick operation and place operation, the loads of the FlexGripper are different. So the
user must set the new TCP, payload and work object according to the different load situation.

For FlexGripper-Clamp (FlexGripper-Clamp 1, FlexGripper-Clamp 2) and FlexGripper-

Claw, after entering the Test run interface:

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Press the Pick&place test button, the robot implements the exePickPlace routing which
includes a part pick and place cycle.
Note: when pressing any of the test buttons, a message shows prompting you to press the run
button. Press the run button. Before the test, the TCP should be edited according to the real
payload in test run, and all the robot target positions must be accurate.
In the pick operation and place operation, the loads of the FlexGripper are different. So the
user must set the new TCP, payload and work object according to the different load situation.

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3.2.4.1. Production monitor

3.2.4. Production

3.2.4.1. Production monitor

The production interface shows monitor signals on the left and monitor variables on the right.
Users can monitor the production by the status of signals and variables. Users can check if
the signal status or variable status is correct. If it is not in the right condition, check the
corresponding equipment.

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3.2.4.2. Setup

3.2.4.2. Setup

The production interface shows monitor signals on the left and monitor variables on the right.
The monitoring signals and variables shown can be set by the Setup function.

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Touch the Setup button, the following interface with signal list shows.

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3.2.4.2. Setup

Continued

After selecting one of the signals, using the two arrows buttons (see picture above) on the
right to choose former signals or signals below.
Use the yellow double triangle/single triangle buttons to go to the first/last page or to move
the page up/down.

Signal edit
Action Procedure
Add signal Touch Add button, then choose signal type, the signal to be added and edit
its shown name by touching the button with an ellipsis sign.

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A soft keyboard shows. Choose signal type for the signal to be added, edit
its name by touching the button with an ellipsis. Type in the signal name.
The signal name should be no longer than 25 characters which can only
include numbers, letters and underline sign.
Note: No more than 12 signals can be added.
Modify signal Select the signal to be modified and press the Modify button. You can then
modify its type, signal and name in the dropdown list or the soft keyboard.
Press cancel if no modification is needed.
Delete signal Select the signal to be deleted and press delete. The signal is then deleted
from the monitor signal list.

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3.2.4.2. Setup

Continued

Variable edit
Action Procedure
Add variable Touch Add button, the following interface shows:

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Choose the module followed by the variable type to be added from the
dropdown list. You can edit its name by selecting the button with the
ellipsis. A soft keyboard shows with which you can enter the variable
name.
Note: The variable shown name should be no longer than 25 characters
which can include numbers, letters and the underline sign.
Note: No more than 12 variables can be added.
Modify variable Select the variable to be modified and press the modify button. The
variable, its module, type and name can be modified in the drop dropdown
list or by using the soft keyboard. Select cancel if no modification is
needed.
Delete variable Select the variable to be deleted and press delete. The variable is deleted
from the monitor variable list.

When you have finished editing, select Save to save any changes. Press the Back to
Production button to return to the Production main interface.
NOTE!
The variable configuration includes three elements: TASK, Storage type and Scope.
Their scopes are:
Task: T_ROB1;
Scope: Global, Task and local
Storage type: only Persistent
If the scope and storage type of the variable is not correct it can not be monitored.

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3 FlexGripper UI
3.3. Trouble shooting

3.3. Trouble shooting

Variable can not be monitored

Description Can not monitor the variables
Possible reason • The scope of variable is not correct
• The storage type of variable is not correct
Solution • Make sure the variable and the storage type are correct

The valid scope of variables is:

Task: T_ROB1;
Scope: Global, Task and local
Storage type: Persistent

TCP can not be edited

Description Can not edit the TCP
Possible reason • The scope of the TCP is not correct
• The storage type of the TCP is not correct
Solution • Make sure the scope and the storage type are correct

The valid scope of TCP is:

Task: T_ROB1;
Scope: Global, Task and local
Storage type: Persistent and Variable

Robot target can not be edited

Description Can not edit the robot target
Possible reason • The scope of the robot target is not correct
• The storage type of the robot target is not correct
Solution • Make sure the scope and the storage type are correct

The valid scope of robot target is:

Task: T_ROB1;
Scope: Global, Task and local
Storage type: Persistent and Variable

Work object can not be edited

Description Can not edit the work object
Possible reason • The scope of the work object is not correct
• The storage type of the robot target is not correct
Solution • Make sure the scope and the storage type are correct

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Continued

The valid scope of the work object is:

Task: T_ROB1;
Scope: Global, Task
Storage type: Persistent and Variable

FlexGripper UI icon can not be displayed on the ABB main menu of the FlexPendant
Description Can not display FlexGripper UI icon on FlexPendant
Possible reason • The FlexGripper UI FlexPendant application is installed incor-
rectly.
• The FlexPendant Interface option is not selected when creating
a robot system.
Solution Check if the FlexGripper UI option is selected for the current system from
ABB main menu->SystemInfo->SystemProperties->Additional Option
on the FlexPendant. If the option is not displayed in the list, reinstall the
TrueView application.

Position out of reach

Description

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Possible reason Robot target position is out of reach of the robot.

Solution Check and change the robot target position to a valid scope.

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3.3. Trouble shooting

Continued

Active view no valid test view

Description

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Possible reason The current test view is not a valid test view.
Solution Enter Control panel->Flexpendant-> AdditionalTestView, check if the
test view of the FlexGripper UI is selected.

Two many views

Description When all the 6 places of the task bar are occupied by views, a warning
message box will pop up when clicking on the GUI icon.
Possible reason Too many views are opened at the same time.
Solution Close one or more of the views not in use.

Duplicated adress
Description

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Possible reason Two I/O units with the same addresses name'BOARD10'.

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 3HAC040633-002, Revision -, en

ABB Robotics
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax: +46 (0) 21 132592
 3 FlexGripper UI
3.3. Trouble shooting

Continued

Solution Enter Control panel->Configration-> Unit->BOARD10, edit the

addresses name to BOARD11.
Before software installation, edit the content ’DN_Address 10’ to
’DN_Address 11’ in EIO.cfg. For example, C:\Program Files\ABB
Industrial IT\Robotics IT\MediaPool\FlexGripperUI\Syspar\Vac-
uum\EIO.cfg.

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3.3. Trouble shooting

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