ROBOTICS

Operating manual
Machining Software
Trace back information:
Workspace Main version a627
Checked in 2024-11-05
Skribenta version 5.6.018
 Operating manual
Machining Software
1.4.1

Document ID: 3HAC080110-001

Revision: F

© Copyright 2021-2024 ABB. All rights reserved.

Specifications subject to change without notice.
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, damage 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.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.

© Copyright 2021-2024 ABB. All rights reserved.

Specifications subject to change without notice.
 Table of contents

Table of contents
Overview of the manual .................................................................................................................... 7
Network security ............................................................................................................................... 9
Safety ................................................................................................................................................ 10

1 Overview 11

2 Getting started 15

3 Creating, loading and exporting projects 19

4 Creating and tuning programs 21

4.1 Overview ......................................................................................................... 21
4.2 Defining path .................................................................................................... 23
4.3 Defining instructions .......................................................................................... 29

5 Auto-calibrating 33
5.1 Overview ......................................................................................................... 33
5.2 Calibrating toolkits ............................................................................................. 37
5.3 Calibrating cutters ............................................................................................. 42
5.4 Calibrating external axes and work objects ............................................................ 47

6 RAPID programming 53
6.1 RAPID exporting and reloading ............................................................................ 54
6.2 RAPID instructions ............................................................................................ 59
6.2.1 MachL - Moves linearly ............................................................................. 59
6.2.2 MachJ - Moves using joint movement ......................................................... 61
6.2.3 MachC - Moves circularly .......................................................................... 63
6.2.4 WaveLStartPoint - Moves to the wave start point ........................................... 65
6.2.5 WaveL - Moves along the wave path ........................................................... 66
6.3 RAPID data types .............................................................................................. 67
6.3.1 MachiningPose - Coordinate transformations in machining programs ............... 67
6.3.2 MachineProcess - Process definitions in machining programs ......................... 68
6.3.3 WaveDirection - Wave path processing directions ......................................... 69
6.3.4 WaveDistribution - Distribution information of wave nodes .............................. 70
6.3.5 WaveNode - wave nodes defined for wave paths ........................................... 71
6.3.6 WaveShape - wave patterns defined for wave paths ...................................... 72

7 Reference information 73
7.1 Messages and errors ......................................................................................... 73
7.2 Troubleshooting ................................................................................................ 76
7.3 Drawings ......................................................................................................... 77

Index 79

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 Overview of the manual

Overview of the manual

About this manual
This manual describes how to use Machining Software to work with machining
applications on the web user interface using PC or in the Machining application
using FlexPendant.

Usage
This manual should be used during the work with Machining Software.

Who should read this manual?

This manual is intended for application engineers, commissioning engineers and
operators.

Prerequisites
The reader should have basic knowledge of:
• Industrial robots and their terminology
• RAPID programming language
• RobotStudio
• Machining PowerPac add-in

References

Reference Document ID
Operating manual - IRC5 Integrator's guide 3HAC050940-001
Operating manual - Integrator's guide OmniCore 3HAC065037-001
Operating manual - Emergency safety information 3HAC027098-001
Safety manual for robot - Manipulator and IRC5 or OmniCore con- 3HAC031045-001
troller i
Operating manual - Machining PowerPac - Machining Functionality 3HAC054781-001
Technical reference manual - RAPID overview 3HAC050947-001
Technical reference manual - RAPID Instructions, Functions and 3HAC050917-001
Data types
Technical reference manual - System parameters 3HAC050948-001
Operating manual - RobotStudio 3HAC032104-001
Application manual - Force control with software and hardware 3HAC070206-001
i This manual contains all safety instructions from the product manuals for the manipulators and the
controllers.

Revision

Revision Description
A First edition

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Overview of the manual
Continued

Revision Description
B Published with version 1.1. The following updates are done in this re-
vision:
• Renamed the product from Machining Shopfloor HMI to Machin-
ing Software.
• Changed descriptions of option Shopfloor and Shopfloor Ad-
vanced to Machining Standard and Machining Premium, respect-
ively.
• Supported working with OmniCore controller.
• Supported working with projects using the MSF application on
FlexPendant.
• Added calibration procedure for crossbeam-type toolkit.
• Updated calibration procedure for cutters, separating cutters
into sander type and machining tool type.
• Added the wave path settings and related RAPID information.
• Added the multiple instruction exporting function.
• Added new error information.
C Published with version 1.2.0. The following updates are done in this
revision:
• Added calibration toolkit crossbeam and probe setup informa-
tion.
• Updated calibration procedure of probe-type toolkit.
D Published with version 1.3.0. The following updates are done in this
revision:
• Updated safety information.
• Added information about how to create new programs in Ma-
chining Software.
• Added the force control settings.
• Added a note for working with Machining application on Flex-
Pendant.
• Removed information about exporting programs to local file.
• Updated programming rules for modules CalibData_HMI and
Main_test_ProgramID.
E Published with version 1.4.0. The following updates are done in this
revision:
• Added a new calibration method Polyhedron for work object
calibration.
• Added a note to the required RobotWare, RobotStudio and
Machining PowerPac - Machining Functionality versions for
using the latest Machining Software.
• Added the drawing of polyhedron block as reference information.
• Added a troubleshooting for the reported error 40661 during
calibration using a probe.
F Published with version 1.4.1. The following updates are done in this
revision:
• Added a note about block preparation for the calibration of ex-
ternal axis or work objects.

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 Network security

Network security
Network security
This product is designed to be connected to and to communicate information and
data via a network interface. It is your sole responsibility to provide, and
continuously ensure, a secure connection between the product and to your network
or any other network (as the case may be).
You shall establish and maintain any appropriate measures (such as, but not limited
to, the installation of firewalls, application of authentication measures, encryption
of data, installation of anti-virus programs, etc) to protect the product, the network,
its system and the interface against any kind of security breaches, unauthorized
access, interference, intrusion, leakage and/or theft of data or information. ABB
Ltd and its entities are not liable for damage and/or loss related to such security
breaches, any unauthorized access, interference, intrusion, leakage and/or theft
of data or information.

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Safety

Safety
General
Machining Software is a product used for machining applications and shall be used
for setting, teaching, programming and operation phases during the lifecycle.
Machining Software is not a safety related part in a robot system. Using Machining
Software cannot reduce the safety risk level of the robot system. The integrator of
the robot system is required to perform an assessment of the hazards and risks,
and make sure using Machining Software will not increase the safety risk level of
the robot system.
Machining Software shall be used with robot systems that are designed and installed
in accordance with applicable standards.

Safety of personnel
When a robot is in automatic mode, the robot control system operates in accordance
with the robot program. The robot program can have a pause, long stop in
movement followed by a start of a movement. The robot program can also do
changes in operation, path and speed, of the manipulator through external signal(s).
The pattern of the behavior of a manipulator can therefore not be safely predicted
without the knowledge of the robot program. A deviation from an unsafe prediction
will be observed as an unexpected movement.
Therefore, a safety guard device (such as a safety fence) must be active in
automatic mode; and the operator must work outside the safety fence.
If the robot is operating in Auto mode, the users shall be close to a control panel
when using Machining Software from a browser so that the control panel can be
used to stop the robot system timely when needed.
It is the integrator's responsible for the safety of the robot system, and for that the
safety devices necessary to protect people working with the robot system are
designed and installed correctly.

Related information
Before beginning work with the robot, make sure you are familiar with all the general
safety aspects and specific safety information described in this manual as well as
safety manuals for manipulators and controllers.
You can find safety descriptions in following but not limited to following manuals:
• Operating manual - Emergency safety information (3HAC027098-001)
• Operating manual - General safety information (3HAC031045-001)
• Safety chapter in product manuals for manipulators and controllers

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 1 Overview

1 Overview
Introduction
Machining Software (previous known as Machining Shopfloor HMI) is a RobotWare
option that allows users to work with machining projects on site using PC or
FlexPendant.
With Machining Software, users can define machining processes by creating
programs using web browser on PC or in the dedicated Machining application on
FlexPendant. It is also possible to synchronize or load programs created in
Machining PowerPac - Machining Functionality (hereinafter referred as Machining
PowerPac) add-in in RobotStudio, and then tuning the programs in Machining
Software. Different from Machining PowerPac that provides offline programming
functions,Machining Software can load the created or tuned programs to the
connected controller (virtual or real) directly. This improves programming efficiency
and reduce the onsite commissioning time.
Machining Software also provides the auto-calibration function that allows users
to define calibration toolkits (eg. probe), cutters, external axis and work objects.
The calibrated data can be copied to and reused in RAPID for other projects, which
simplifies the calibration process.

Note

The Machining application on FlexPendant is only supported by OmniCore

controllers operating in RobotWare 7.X.

Key features
Machining Software provides the following main features:
• Web-based access to machining projects (using PC)
• Dedicated Machining application for working with machining projects (using
FlexPendant)
• Creating programs to define machining processes
• Tuning programs created by Machining PowerPac
• Auto-calibration on calibration toolkit, cutters, external axis and work objects

Versions
Machining Software provides two versions, Machining Standard (option 877-2 for
IRC5 and 3418-1 for OmniCore) and Machining Premium (option 877-3 for IRC5
and 3418-2 for OmniCore), with different user access to functions. The following
table lists the main functions to which the two options can access.
Function Standard Premium
File operations File loading X X
File export X X

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1 Overview
Continued

Function Standard Premium

Program operations Program creating X
Program synchronization and X
loading
Program tuning X
Auto-calibration Toolkit calibration X X
Cutter calibration X X
Work object calibration X X

Note

Only one Machining Software version can be installed on a controller at a time.

For the web-based Machining Software, if the version is changed, clean the
browser cache and restart the browser to make the new version take effect.
Otherwise, a version incompatibility message will be displayed.

Prerequisites
Hardware and software

Requiring... Note i
PC
Note

Required only for web-based Machining Software using

PC.
• OS: Windows 10, 64-bit
• CPU: 4x2.0Hz or faster processors
• RAM: 8GB at minimum
• Resolution: 1024 x 768 Pixels
• An account with administrator's privileges
Browser
Note

Required only for web-based Machining Software using

PC.
Google Chrome and Microsoft Edge are recommended.
Controller • IRC5 controller in RobotWare 6.15.04 or later
• OmniCore controller in RobotWare 7.14.2or later
FlexPendant ii FlexPendant must be connected and available to use.
RobotStudio RobotStudio 2022 or later
Machining PowerPac - Machining Machining PowerPac 2022.1 or later
Functionality Available in https://new.abb.com/products/robotics/ro-
botstudio/downloads.
i Listed versions of RobotWare, RobotStudio and Machining PowerPac- Machining Functionality are
the minimum versions required for the latest Machining Software version.
ii If the Machining application runs slowly when FlexPendant is used to work with machining projects,
it is recommended to use the web-based Machining Software on PC or use a FlexPendant with a
larger RAM.

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 1 Overview
Continued

License
Machining Software requires a license to activate. Contact ABB to order the option
Machining Standard or Machining Premium and obtain a license.

Note

If the option Machining Premium is selected, option Multitasking (option 623-1

for IRC5 and 3114-1 for OmniCore) will be selected together.

User grants
Machining Software requires a user account to log in, which must have been
granted access permission to the connected controller and corresponding grants
to specific functions. Refer to the following table for the required grants.
Functions Required grant... i
Access to the main page of Machining Software Read access to controller disks
New file, load file and save file Write access to controller disks
Synchronize programs created by Machining Power- I/O write access
Pac to Machining Software
Click Apply button to apply changes Load program
Request write access Program debug
Access to calibration functions Calibration
Access to program functions Edit RAPID code
Click Calibration button to start calibration • Load program
• Program debug
• Execute program
Selection of mechanical unit (Mechanism-type work Required only for RobotWare 6.X
object) • Remote restart
• Modify configuration
i For RobotWare 6.X, controller restart is required after grants are modified. For RobotWare 7.X,
grant modification takes effect in real time.
If the Default User is active, users can also use the user name Default User and
its password robotics to log in as the default user.
For details about user account management, see information about User
Authentication System (UAS) in the operation manual of the controller.

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 2 Getting started

2 Getting started
Installing
Generally, Machining Software is integrated in the controller system at delivery. It
is also available as an add-in RobotStudio. To add it to an existing controller or do
an update, use the following procedure to install:
1 Start RobotStudio and open the Add-Ins tab. The Gallery window is displayed.
2 In the displayed Gallery window, use the Search function or Common tags
to find the Machining Software add-in.
3 Click the displayed add-in icon.
4 In the right pane, click Add.
The package is automatically installed and listed in the Add-in navigation
tree in the left pane of the window.
5 In the Controller tab page, click the Modify Installation button in the
Configuration group.
6 In the Modify Installation dialogue, connect to a real controller or select/create
a virtual controller.
7 Follow the instructions in the installation wizard and add the Machining
Software add-in to the controller.

Note

You have to choose the Machining Software version in the Machining list
according to the license you obtained; otherwise, a warning message is
displayed.
Only one Machining Software version is allowed to be installed on the
controller at a time. To change the version, deselect the original version
and select the new one.
The Machining Software add-in is displayed in the controller overview if it is
successfully added to the controller.

Logging in
You can log in Machining Software in one of the following ways:
• Use web browser in PC
• Use the Machining application in FlexPendant
The modifications are automatically synchronized between the web-based
Machining Software and Machining application in FlexPendant, which are opened
for the same robot system. To view the latest modifications made in the other way,
refresh the web page or reopen the setting window in the application.

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2 Getting started
Continued

Detailed logging in procedures are as follows.

Using PC

Note

Before working with web-based Machining Software, make sure the PC opening
the Machining Software web page has connected to the required controller and
works in the same local subnet of the controller.
1 Start the browser.
Google Chrome and Microsoft Edge are recommended.
2 Enter the IP address of the connected controller in the Address bar.
Virtual controller Real controller
RobotWare http://127.0.0.1/docs/MSF.html http://Controller IP ad-
6.X dress/docs/MSF.html
RobotWare https://127.0.0.1:80/docs/MSF.html https://Controller IP ad-
7.X dress/docs/MSF.html

3 In the displayed window, enter the user name and password.

Make sure the account has the access permission to the connected controller.
You can also enter as the Default User.

Using FlexPendant

Note

The Machining application on FlexPendant is only supported by OmniCore

controllers operating in RobotWare 7.X.

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 2 Getting started
Continued

You can access the main window of Machining Software directly by tapping the
following application icon on the FlexPendant touch screen.

xx2200000576

The user interface

Home page

xx2100002395

Item Description
A Menu Displays the menu when clicking the hamburger button.

Note

The menu is available to use only when a project has

been created or loaded.

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2 Getting started
Continued

Item Description
B Status bar Shows the controller status.
You can click the icons to display the status details, in-
cluding controller name, controller status, operating mode
and motor status.
In the status details page, you can click Request Write
Access to get permission of program editing. Otherwise,
the program settings can only be viewed. After the write
access is granted, an Apply button is displayed next to
the status bar.

Note

The status bar is displayed only for web-based Machining

Software using PC. In the Machining application on
FlexPendant, only the Apply button is available.

C Start buttons Starts working with Machining Software by clicking New

File or Load File.
• New File: a new project is created and auto-calib-
ration function is available.
• Load File: an existing project can be loaded from
the controller or a local folder.

Note

If there is an unsaved project existing, a message window

is displayed before you can click the start buttons, urging
you to save or discard the previous editing.

Main working page

xx2100002396

Item Description
A 3D graphics window Shows the 3D graphics of the station and provides an
intuitive and realtime preview of the editings.
You can also drag the mouse to control the graphics view.
B Setting window Displays the detailed setting pages.

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 3 Creating, loading and exporting projects

3 Creating, loading and exporting projects

About Machining Software project
Machining Software project document is a .mpstn file that contains data of a
machining process. It stores information about operations, toolkits, cutters, work
objects and cell layout. A project can contain all or part of the information.
Users can create a new project or work on an existing project in Machining Software.
The generated or modified projects can be exported to local folder or the connected
controller.

Creating a new project

The following table lists the ways to create a new project in Machining Software.
Create project from... Description
Home page In the home page, click New File.
Menu 1 Click the hamburger button on the upper-left
corner of the window to display the menu.
2 Choose File > New File.
A message is displayed prompting you to save
any unsaved data.

Loading an existing project

The following table lists the ways to load an existing project to Machining Software.
Load project by... Description
Synchronizing from the Machining After programs are created in the Machining PowerPac
PowerPac add-in add-in in RobotStudio:
1 Click Sync in the Shopfloor Tool group.
2 Check the information shown in the displayed
window and click OK.
3 Choose the controller to which Machining Soft-
ware is connected and click OK.
The programs are automatically synchronized
to Machining Software.
4 Click Accept or Decline in the Machining Soft-
ware.
Loading from a local file 1 In the home page, click Load File and then
choose Load file, or in the main working page,
click the menu bar and then choose File > Load
file.
2 In the displayed window, choose the required
program file in .mpstn format from a local folder.
3 Click Open.
Loading from the controller 1 In the home page, click Load File and then
choose Load file from controller, or in the main
working page, click the menu bar and then
choose File > Load file from controller.
2 In the displayed window, choose the required
program file in .mpstn format.
Only the files saved in the HOME folder of the
controller system are displayed.
3 Click Load.

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3 Creating, loading and exporting projects
Continued

Exporting a project
The following table lists the ways to export a project.
Export project to... Description
Local folder
Note

Exporting project to local is valid only for web-based

Machining Software using PC.
1 In the main working page, click the menu bar
and then choose File > Save file.
2 In the displayed window, choose the items to
be downloaded.
By default, all the items are selected. You can
also select or remove a category in the left
pane, or choose or remove part of items in a
specified category.
3 Click Save.
A .mpstn project file is download to the specified
local folder.
Controller 1 In the main working page, click the menu bar
and then choose File > Save file to controller.
2 In the Contents area in the displayed window,
choose the items to be downloaded.
By default, all the items are selected and shown
by their categories in the Contents area. You
can click the drop-down arrow, and in the dis-
played window, select or remove a category in
the left pane, or choose or remove part of items
in a specified category.
3 Click OK.
4 Click Browse to select a folder in controller
system for download.
The HOME folder is selected by default.
5 Enter a name in the File Name text box.
6 Click Save.

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 4 Creating and tuning programs
4.1 Overview

4 Creating and tuning programs

4.1 Overview

Introduction
Machining processes are defined by programs and each program is a group of
operations with detailed path and instruction settings. Programs can be created
directly in Machining Software, synchronized from Machining PowerPac or loaded
from a Machining Software project file.
All the available programs are listed in the program setting window. You can click
the unfold button next to a program to expand or collapse the list of operations
that are included in the program.

Note

Only the Machining Software in advanced version (option Machining Premium)

supports the program creating, synchronization, loading and tuning.

Note

For web-based Machining Software, before working with the programs, make
sure the writing access to the controller has been requested and granted. To
request write access, click the icon on the status bar and then click Request
Write Access in the status details page.

Starting with programs and operations

If a project has available programs, the programs are listed in the program setting
window. You can click the required program and operation, and then start tuning
it.
To create new programs and operations, perform following procedure:
1 Click the menu bar in the main working page and then click Program.
This step is required only when the program setting window is not displayed.
2 In the program setting window in the right pane, click Add program.
3 In the displayed dialog box, specify the program name and then click OK.
The program is listed in the setting window. You can also rename or remove
the program by clicking the hamburger icon for the program and then
choosing Rename or Delete respectively.
4 Click the unfold button next to the required program to expand the program.
5 Click Add operation to add a new operation for the selected program.
After adding, the operation setting window is directly displayed for the
operation.
6 In the displayed window, further define paths and instructions.
Default operation name is OprX. You can rename the operation in the Name
text box, or click Delete to remove the operation from the program.

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4 Creating and tuning programs
4.1 Overview
Continued

Detailed procedures to define paths and instructions are specified in following

sections.

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 4 Creating and tuning programs
4.2 Defining path

4.2 Defining path

Procedure
Use the following procedure to define path properties:
1 Expand the required program and click the required operation.
The operation setting window is displayed.
2 In the Name text box on the Path tab page, keep the operation name or
rename the operation.
The name is allowed to be specified with a maximum of 10 characters.
3 Specify the path type, which can be set to Machining, Move and Force
Control.
This is a global setting for all the instructions associated with the operation.
4 If path type is set to Force Control, click the unfold button next to Force
Control Settings to display a new window and set force control parameters.
See details in Setting force control parameters on page 23.
5 Select the cutter to be used for processing and the work object to be
processed from the Tool and Wobj list, respectively.
6 For existing operations that already have target positions defined, perform
path smoothing or wave path setting if required.
See details in Smoothing path on page 24 and Setting wave path on page 25.
7 Click Apply in the status bar to apply the modifications to the connected
controller.

Setting force control parameters

If the path type is set to Force Control for an operation, you can click Force Control
Settings to enter a new window to set the force control parameters. Following table
lists the available parameters.
Parameter Description
FCStart
Force reference frame Defines which coordinate system the force control coordinate system
is related to. The parameter can be set to either the work object
coordinate system, the tool coordinate system or the path coordinate
system.
The default value is the tool coordinate system.
Force X(N) Defines the constant reference force in the x direction of the force
control coordinate system. If this parameter is omitted there will be
zero contact force in the x direction.
Default value is 0.
Force Y(N) Defines the constant reference force in the y direction of the force
control coordinate system. If this parameter is omitted there will be
zero contact force in the y direction.
Default value is 0.
Force Z(N) Defines the constant reference force in the z direction of the force
control coordinate system. If this parameter is omitted there will be
zero contact force in the z direction.
Default value is -10.

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4 Creating and tuning programs
4.2 Defining path
Continued

Parameter Description
Speed FFW If this parameter is enabled then feed forward regulation is used. If
this parameter is disabled then regulation in force direction is done
only with force control without help from programmed path. Enable
this parameter if path is complex and programmed path is close to
actual path.
This parameter is enabled by default.
Threshold(%) Percentage of the contact force that should be reached before move
toward the robtarget starts. TCP moves in force direction until this
percentage is reached. When percentage of force is reached, the
movement toward target starts.
Default value is 50.
Force Change Tuning parameter to ramp up force. This parameter overrides con-
Rate(N/s) figured value.
Default value is 50.
Damping(%) The relation value between the measured force and the applied
resulting force. By default the value are 100% (of system parameter
values), but it can be between 50% and infinity. Smaller values than
100% means that the robot is more sensitive to external force.
Timeout(s) If force hasn't build up before this time is reached then continue
with next instruction.
Default value is 5.
Supervision Distance The robot will stop if it has moved more than the distance Distance
away from the programmed path. Default value for Distance is
20mm.
This parameter is disabled by default.
FCEnd
Force Change Tuning parameter to ramp up force.
Rate(N/s) Default value is 50.
Zero Contact Force(N) Specifies a force limit and if the force is less than the specified value,
then force control is deactivated.
Default value is 50.

The parameters in FCStart and FCEnd group are associated with the RAPID
instructions FCPress1LStart and FCPressEnd, respectively. See details in
Application manual - Force control with software and hardware.

Smoothing path
Use the following procedure to smooth target positions in a path or path segment:
1 Expand the required program and click the required operation.
On the Path tab page of the displayed window, information of the tool and
work object associated to the selected operation can be viewed.
2 Click Smooth.
The Smooth window is displayed.
3 Select a method from the Smooth Method list.
• Position: the path will be smoothed based on the X/Y/Z coordinates
of the targets.
• Orientation: the path with be smoothed based on the Rx/Ry/Rz
coordinates of the targets.

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4.2 Defining path
Continued

• Process: the path will be smoothed based on the axis settings of the
tool.
4 Select targets from the Segment list for defining a path or path segment.
By default, all the targets in the whole path are selected. You can also select
several targets to define a path segment. The number of selected targets
can be viewed.
In the Segment window,
• Click two targets as the first and last targets of the path/path segment.
All the targets in between will be selected.
• Click Select All to re-select all the targets. This button is available only
when part of targets are selected.
• Click OK to accept the selection or click Cancel to discard the selection.
5 Click the Local or Wobj tab to choose the reference coordinate system of
the targets, on which the path smoothing is based.
6 Modify target positions to smooth path.
• Only the positions of fixed targets can be modified. The first and last
targets in a path/path segment are fixed targets by default. For other
targets, turn the Fixed Target switch on to change the target
characteristics.
• You can drag the target to a required position in 3D graphics window
or type a value in the corresponding coordinates text box for a specific
target.
- If Position is selected in the Smooth Method list, the X(mm), Y(mm)
and Z(mm) parameters referring to the variations on the X, Y and Z
axis can be set.
- If Orientation is selected in the Smooth Method list, the Rx(deg),
Ry(deg) and Rz(deg) parameters referring to the variations on the
orientation rotating around the X, Y and Z axis can be set.
- If Process is selected in the Smooth Method list, the Indentation(mm),
Tilt Angle(deg) and Lead Angle(deg) parameters referring to the tool
position based on the TCP can be set.
7 Click Save to accept the settings.
You can also click Reset to cancel the settings.
8 Click Apply in the status bar to apply the modifications to the connected
controller.

Setting wave path

What is wave path?
Wave path settings are used to generate new paths based on the original machining
paths in operations generated by Machining PowerPac. Enabling wave path for a
specified machining path will wiggle the tool from side to side in the defined pattern
when the tool moves along the path. With wave path, better processing effects
could be achieved because it could provide sufficient processing on contact areas.
It especially benefits to deburring and grinding applications.

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4.2 Defining path
Continued

Wave path is available to use when:

• Target processing moves forward along X+ or Y+ directions of local coordinate
system of targets.
The processing direction can be set in target configuration for an operation
in Machining PowerPac.
• Distances between the targets in the original machining paths are even.
To obtain proper target distance, it is recommended to set interpolation
method to MaxLengthOnly when setting process move parameters for
operations in Machining PowerPac.
• Processing method is using tool tip.
In Machining PowerPac, the machining method for a tool shall be set to Face
Machining.

Procedure
Use the following procedure to enable and set wave path for the path in a specified
operation:
1 Expand the required program and click the required operation.
2 In the displayed new window, click Wave Path.
3 In the displayed Wave Path window, turn on the switch to enable wave path.
Detailed settings are displayed.
4 Choose the machining direction, Tool X+ or Tool Y+.
The tool will process along the selected direction based on the local
coordinate system of the tool.
5 Choose a wave pattern or create a new pattern.
• To use a predefined pattern or an existing pattern, select the desired
pattern from the list to apply the pattern. No further actions required.

Note

Three predefined patterns are available, square, circle and diamond.

The patterns are allowed to be duplicated or edited by clicking Edit
on the right corner of the window first and then clicking corresponding
button.
For detailed procedure of editing a pattern, proceed to 6. The edited
pattern will be applied to all the operations whose paths have enabled
wave path with this pattern.

• To create a new pattern, click New Pattern and proceed to 6.

6 In the Pattern Name area of the Edit Pattern or New Pattern window, keep
the automatically generated name or type another name as required.
7 Set the step for the pattern to loop.
The distance between two adjacent targets in the original machining path is
considered as one step. The pattern loops in a distance based on the defined
step. Default step is 3.
8 Set the basic source targets that could be used for setting the pattern.

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 4 Creating and tuning programs
4.2 Defining path
Continued

Source targets are the ones in the original path. They will be used as
reference to generate wave nodes that will be the new targets in wave path
for the tool to process. Default target number is 5.
9 Select the motion type that the tool moves from wave node to wave node.
• Linear: the tool moves using MoveL, that is, in linear movement.
• Circular: the tool moves along the path using MoveC, that is, in circular
movement.
10 In the pattern preview window:
a Click a source target in blue to generate one or more wave nodes.
Every wave node is shown with a number. The node numbers also
represent the processing sequence, that is, the tool will move in number
order.
b Click on the generated wave nodes and set the pattern with them.
• The tool processes along the wave path in the wave node number
order. The order could be changed by modifying the node number
in the Number text box of the quickset dialog box. The pattern
changes with the order change.
• The wave node position can be modified by dragging it to the
desired position or, in the quickset dialog box, setting the offsets
from the targets where the wave node generated in both the
machining direction and the direction perpendicular to the
machining direction.
• A single wave node can be deleted by clicking Delete Node in
the quickset dialog box. It is also possible to clear all the wave
nodes by clicking Delete All Nodes on the right upper corner of
the preview window.
The defined pattern is displayed as a blue path in real time, and other looped
patterns are displayed in grey.

Note

The final wave path depends on both the motion type and the way how the
pattern is defined. If a pattern contains N wave nodes and,
• the motion type is Linear, positions of all the N wave nodes will be
repeated in following looped patterns. That is, all the patterns contain
N wave nodes.
• the motion type is Circular, the first wave node in defined pattern
works as the wave start point but it is not repeated in the following
looped patterns. That is, the following patterns will contain only N-1
wave nodes (wave node in number 1 is excluded).

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4 Creating and tuning programs
4.2 Defining path
Continued

Note

For a circular pattern, it requires a minimum of 3 wave nodes and the total
node number should be 3+2N (N represents 0, 1, 2...). The wave node in
number 3+2N and 3+2(N+1) function as the StartPoint and ToPoint in a
circluar movement, and the wave node between them will be the CirPoint,
as shown in the following figure.

CirPoint

α
θ

start

ToPoint
xx1700001575

There are some limitations in how the CirPoint and the ToPoint can be
placed.
• Minimum distance between start and ToPoint is 0.1 mm
• Minimum distance between start and CirPoint is 0.1 mm
• Minimum distance between CirPoint and ToPoint is 0.1 mm
• If the system parameter Restrict placing of circle points is set to Yes,
then the following additional limitations are active:
- The angle of the circular path (θ in the picture above) may not
be larger than 240°.
- The circle point must be in the middle part of the circular path
(α must be 25-75% of θ, according to the picture above).
For more details, refer to the description of MoveC in Technical reference
manual - RAPID Instructions, Functions and Data types.

11 Click Save to return to the Wave Path window.

Note

Wave path settings could also be modified in RAPID programs. See RAPID
instructions on page 59 for more information.

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 4 Creating and tuning programs
4.3 Defining instructions

4.3 Defining instructions

Procedure
An instruction includes information such as movement mode and movement speed
on a specific target. Use the following procedure to define instructions:
1 Expand the required program and click the required operation.
2 In the displayed operation setting window, click the Instruction tab.
All the instructions associated with the selected operation are listed. If there
is no available instruction, click Add instruction to add new instructions.
3 Click the unfold button next to the instructions to be edited.

Tip

You can click the Filter button to filter instructions by types, approach,
process or depart.
• To edit a specific instruction, click it to enter the setting window.
• To edit a group of instructions as a whole, click Select in the right
corner of the window to select more than one instructions and then
click Edit at the bottom of the window to display the setting window.

Note

Instructions could also be selected and exported as arrays by clicking

the Export icon first and then choosing to save to local or controller.
Note that exporting to local is only available for web-based Machining
Software using PC.

Note

Available parameters for setting a specific instruction and setting a group

of instructions are similar. But you can only set position, start event and
end event for a specific instruction. Therefore, the following steps take the
setting of a specific instruction as an example.

4 If the path type is set to Force Control, click the unfold button next to Type,
and in the opened page, select a process type, FCStart, FCVia, FCEnd or
Move.
5 Select the motion type, Linear, Joint or Circular.

Note

The selection of global path type, process type (only for Force Control path
type) and motion type selected for the associated operation will define the
actual instruction that will be applied in the RAPID programs and used in
the process. See Reference information on page 31.

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4 Creating and tuning programs
4.3 Defining instructions
Continued

6 Select a movement speed (speed data) from the Speed list.

7 Select the position termination mode (zone data) from the Zone list.
8 If the path type is set to Force Control, specify the force size in the direction
defined in the coordinate system chosen in the Force Control Settings
window.
The Force value is set to 10 by default.
9 Click the unfold button next to TargetX.
10 In the displayed TargetX window:
a Click the Local, Wobj or Process tab to choose the reference coordinate
system on which the modification is based.
b Drag the coordinate axis to a required position in 3D graphics window
or type a value in the corresponding coordinates text box.
• In the Local and Wobj tab page,
- the X(mm), Y(mm) and Z(mm) parameters referring to the
variations on the X, Y and Z axis can be set;
- the Rx(deg), Ry(deg) and Rz(deg) parameters referring to the
variations on the orientation rotating around the X, Y and Z axis
can be set.
• In the Process tab page that is displayed for the Machining path
type, the Indentation(mm), Tilt Angle(deg) and Lead Angle(deg)
parameters referring to the tool position based on the TCP can
be set.
c Set external axis positions, if external axes exist.
If the value 9E+09 is displayed, it refers that no external axis is
connected and the positions cannot be set.
d Click Save to accept the settings.
11 If there are events defined and bound to the specified instruction, click the
unfold button next to Start Event or End Event to set the events.
Only bound events are displayed and available for setting. You can delete,
add or change event order for the instruction.
12 Click the unfold button next to Optional Arguments, and in the displayed
window, set values for the arguments.
• Offset: used to add a displacement in the work object coordinate
system to a robot position. The value is defined as [x,y,z] in unit of mm.
• RelEuler: used to add a displacement and/or a rotation in the active
tool object coordinate system to a robot position. The value is defined
as [x,y,z,Rx,Ry,Rz] in unit of mm.
• ID: specifies the synchronization id and is mandatory in the MultiMove
system if the movement is synchronized or coordinated synchronized.
By using the id number the movements are not mixed up at the runtime.
• T: used to specify the total time in seconds during which the robot
moves.

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 4 Creating and tuning programs
4.3 Defining instructions
Continued

The arguments will be used in the RAPID instruction. See RAPID instructions
on page 59 for more information.
13 Click Apply in the status bar to apply the modifications to the connected
controller.

Reference information
For path type Move and Machining, the actual instructions that will be applied in
RAPID program depend on the selection of motion type, that is
MoveJ/MoveL/MoveC and MachJ/MachL/MachC.
For path type Force Control, the actual instructions that will be applied in RAPID
program depend on the selection of both process type and motion type. The
following table lists the actual instructions will be used in different combinations.
For details about the instruction descriptions, see Technical reference
manual - RAPID Instructions, Functions and Data types, RAPID instructions on
page 59 and Application manual - Force control with software and hardware.

Motion type
Joint Linear Circular
Process type

FCStart - FCPress1LStart -
FCVia - FCPressL FCPressC
FCEnd - FCPressEnd -
Move MoveJ MoveL MoveC

It allows to change the path type for an operation. After changing, all the instructions
associated with this operation will change to the corresponding ones automatically,
depending on the selection of motion type.
If changing the path type from Move or Machining to Force control with process
type FCStart/FCVia/FCEnd, the instructions will change to FCPress1LStart,
FCPressL and FCPressEnd. If the process type is FCVia, you can further change
the motion type from Linear to Circular, and then the instruction will change to
FCPressC.

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 5 Auto-calibrating
5.1 Overview

5 Auto-calibrating
5.1 Overview

Introduction
If a Machining Software project file contains the information of toolkits, cutters and
work objects, users can define and calibrate their data with the auto-calibration
function. For a new project, it also allows users to define new toolkits and work
objects.
To calibrate cutters and work objects, a toolkit must be available to use and
calibrated first. The following table lists the required toolkit for each cutter and
workobject type.
Type Required toolkit
Cutter Orbit sander Probe
Random orbital sander Probe
Machining tool Crossbeam
Work object External axis (Mechanism) Probe
Wobjdata (work object) Probe

Note

A polyhedron or cube block shall also be prepared for the calibration of the
external axis or work objects, depending on the actual to-be-calibrated work
object shape.
To use the polyhedron block, refer to Drawing for polyhedron block on page 77
for its standard dimension. To customize the block, only the block length and
width are allowed to be changed. When designing, make sure the difference
between the block length and width is larger than 10 mm.
Every time the calibration is successfully performed, the calibration data is recorded.
A maximum of 10 latest records will be listed in the calibration history and available
for reuse. You can view the calibration history in the setting windows by clicking
the History icon on the right upper corner of the windows.

Note

For web-based Machining Software, before performing calibration, make sure

the writing access to the controller has been requested and granted. To request
write access, click the icon on the status bar and then click Request Write Access
in the status details page.

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5 Auto-calibrating
5.1 Overview
Continued

Toolkit setup
Crossbeam
Crossbeam is an optical sensor that radiates two perpendicular laser beams
(X-direction and Y-direction) within its inner for TCP measurement. By moving the
tool on a circular or square path within the crossbeam and interrupting the laser
beams, the TCP could be observed and then referenced for tool calibration. It is
also possible to determine the center point of the crossbeam where both laser
beams cross. At this center point, it can be checked whether the calibration was
correct since both laser beams are interrupted at the same time.
To calibrate cutters using a crossbeam in Machining Software, the crossbeam
must be available to use and calibrated first. Detailed procedures about how to set
up and configure a crossbeam, see the user manual from the vendor. Following
lists the necessary preparations of using the crossbeam with the Machining
Software:
• The crossbeam can have a circular inner, which is also recommended, or a
square inner. To calibrate the crossbeam with the Machining Software, the
Inner Radius parameter must be properly set according to the crossbeam
inner shape. For circular inner, it is set to the circle radius; for square inner,
it is set to the short diameter.
• The crossbeam shall connect to a controller with an I/O device, which could
provide 2 pins for power connection and 2 pins for signal connection.
The following figure illustrates a typical connection between the crossbeam
and OmniCore with the digital base device DSQC1030 supporting the
communication over Ethernet/IP.

Signal
PNP-NO (X) X1

Signal X2 I/O
PNP-NO (Y)
Crossbeam X3
Power DSQC 1030
+24 VDC

0V Power X45 Controller

xx2300001215

Note

If your controller is an IRC controller, the XS16 connector shall be used

for power connection. If your controller is installed with a DSQC652, the
X3 connector shall be used for signal connection.
For connections with other controllers or I/O boards, contact your local
ABB Robotics Service representative, see http://www.abb.com/.

• Signals for identifying the laser beams in X direction and Y direction are
configured using RobotStudio.
1 In the Controller ribbon tab in the RobotStudio, click Configuration
and then click I/O system.

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Continued

2 In the Type pane of the Configuration - I/O system window, right-click

Signal and choose New Signal.
3 In the displayed Instance Editor dialog box,
- specify a name to the x-direction or y-direction laser beam
- set Type of Signal to Digital Input
- select the connected IO board in the Assigned to Device
drop-down list
- set Default Value to 0
- remain default settings for other parameters

Probe
Probe is a displacement sensor that commonly consists of a sensor and a tooling
ball (or known as needle). The tooling ball can "feel" the contact surfaces and, by
measuring the displacement, feed back the position of the approached target.
To calibrate cutters or work objects using a probe in Machining Software, the probe
must be available to use and calibrated first. Detailed procedures about how to set
up and configure a probe, see the user manual from the vendor. Following lists
the necessary preparations of using the probe with the Machining Software:
• The tooling ball locates at the end of the probe and can be in any size. To
calibrate the probe with the Machining Software, the Ruby Ball Radius
parameter must be properly set according to the actual tooling ball radius.
• The probe shall connect to a relay first and then to a controller with an I/O
device, which could provide 2 pins for power connection and 1 pin for signal
connection..
The following figure illustrates a typical connection between the probe and
OmniCore with the digital base device DSQC1030 supporting the
communication over Ethernet/IP.

X1
Signal
PNP-NO X2 I/O

Probe Relay Power

X3
+24 VDC DSQC 1030

0V Power X45 Controller

xx2300001217

Note

If your controller is an IRC controller, the XS16 connector shall be used

for power connection. If your controller is installed with a DSQC652, the
X3 connector shall be used for signal connection.
For connections with other controllers or I/O boards, contact your local
ABB Robotics Service representative, see http://www.abb.com/.

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5 Auto-calibrating
5.1 Overview
Continued

• Signal for identifying the tooling ball is configured using RobotStudio.

1 In the Controller ribbon tab in the RobotStudio, click Configuration
and then click I/O system.
2 In the Type pane of the Configuration - I/O system window, right-click
Signal and choose New Signal.
3 In the displayed Instance Editor dialog box,
- specify a name to the tooling ball of the probe
- set Type of Signal to Digital Input
- select the connected IO board in the Assigned to Device
drop-down list
- set Default Value to 0
- remain default settings for other parameters

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 5 Auto-calibrating
5.2 Calibrating toolkits

5.2 Calibrating toolkits

Preparation procedure for new toolkit

For a new toolkit, perform the following preparation actions:
1 Click the hamburger button on the upper-left corner of the window to display
the menu.
2 Click Calibration.
3 In the displayed Toolkit setting window on the right, click New at the bottom
of the window.
4 Choose the required tool type, Probe or CrossBeam.

Preparation procedure for existing toolkit

For an existing toolkit, perform the following preparation actions:
1 Click the hamburger button on the upper-left corner of the window to display
the menu.
2 Click Calibration.
3 In the displayed Toolkit setting window on the right, click the More options
icon next to the required toolkit.
4 Click an icon according to your requirement.
• Edit: to edit basic information of the toolkit, such as name and trigger
signal.
• Define: to define the toolkit calibration settings and perform calibration.

Note

The Define item is available only when a trigger signal has been set
for the toolkit.

• Delete: to delete the toolkit.

Calibration procedure - toolkit (probe type)

Use the following procedure to define and calibrate a probe:
1 In the Probe Name area of the Probe setting window, keep the automatically
generated name or type another name as required.
2 Turn on/off the Robot Hold switch based on where the probe is installed.
• If the probe is hold by the robot, turn on the switch, that is, set it to
True.
• If the probe is stationary or hold by another robot, turn off the switch,
that is, set it to False.
3 In the tooldata area, check the current probe position and calibration status.
4 Choose a signal from the Trigger Signal drop-down list.
After a signal is chosen, the Define button at the bottom of the page is
available.
5 Set Trigger Value to 0 or 1.

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The trigger value represents the returned value when the probe contacts the
calibrating object.
6 Set Ruby Ball Radius (mm) to the actual radius of the tooling ball at the end
of the probe.
7 Click Define to enter the calibration process.
The Define ProbeName window is displayed.
8 Click Ball to enter the setting window for defining the calibrating ball that is
the calibration target for the probe to touch.
In the displayed Ball window,
• Set Ball Radius (mm) to the actual value.
The ball is automatically named with its radius.
• Set Accessible Offset (mm), which defines a safe area for the probe
to touch the ball.
This parameter defines a height from the top point of the ball. The safe
area refers to the ball surface covered by the projecting plane of the
height. You can also drag the arrow in the 3D graphics window to set
the safe area and the setting is displayed in real time.
The Accessible Offset (mm) value must be equal to or smaller than
the Ball Radius (mm) value.
Click Save to return.
9 Click Search Settings to enter the setting window for defining how the probe
goes to search.
In the displayed Search Settings window,
• Set Search Mode and Accuracy Level.
Five accuracy levels are predefined, with level 4 set by default.
The higher the level is selected, the more the touchpoints are defined
and the higher the calibration accuracy is, but the slower the calibration
process is. For example, in default level 4, nine touchpoints are defined
and the calibration is relatively more accurate, but it will take estimate
240 s for the calibration.
• Click the Advanced arrow to expand the settings and set Search Offset
and Approach Distance.

Tip

You can click the Information icon at the upper-right corner of the Search
Settings window to view the parameter definitions.

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5.2 Calibrating toolkits
Continued

10 Jog the probe to touch the ball at the Contact, Home and other four Pose
positions, and click Update Position to record corresponding values.

Note

The Contact position is the one where the probe touches the calibrating
ball, and must be updated before the probe is jogged to the Home position.
When jogging the probe to the four Pose positions, make sure the tooling
ball of the probe only rotates around the Home position without any
displacement.

11 Click Calibrate and then click Play.

• If the controller is in Auto mode, the calibration process runs
automatically.
• If the controller is in Manual mode, follow the instructions in the
displayed messages to perform the calibration.
12 Click Save to save the data after the calibration done.

Calibration procedure - toolkit (crossbeam type)

Note

Before calibration, make sure a valid cutter has been defined. See Calibration
procedure - cutters (machining tool type) on page 45.

Use the following procedure to define and calibrate a crossbeam:

1 In the Name area of the CrossBeam setting window, keep the automatically
generated name or type another name as required.
2 Turn on/off the Robot Hold switch based on where the crossbeam is installed.
• If the crossbeam is hold by the robot, turn on the switch, that is, set it
to True.
• If the crossbeam is stationary or hold by another robot, turn off the
switch, that is, set it to False.
3 In the Wobjdata area, check the crossbeam position and calibration status.
By default, the wobjdata wobj0 is displayed.
• If the crossbeam is installed with X and Y lasers whose directions close
to the X and Y directions of the coordination system for wobj0, remain
the wobjdata.
• If the crossbeam is defined with other wobjdata, click Copy wobjdata
from controller and select valid wobjdata for the crossbeam.
• If X and Y lasers of the crossbeam are not in the same X and Y
directions of the coordination system for wobj0 and no worbjdata is
valid for the crossbeam, define the crossbeam using the User defined
with 3 points method in FlexPendant.
4 Choose signals for both X and Y lasers from the Trigger Signal drop-down
lists.

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Continued

The Define button at the bottom of the page is available only after the signals
are selected.

Note

For crossbeam, the trigger value is always be 1, which represents the

returned value when the corresponding laser is interrupted by the calibrating
objects.

5 Set Inner Radius (mm) to the actual inner radius of the crossbeam.
6 Click Define to enter the calibration process.
The Define CrossbeamName window is displayed.
7 Select a cutter from the Cutter drop-down list.
Only cutters in machining tool type and in opposite robot-hold position to
the crossbeam are available to choose.
8 Click Search Settings to enter the setting window for defining how to search
with the crossbeam.
In the displayed Search Settings window,
• Set Search Direction and Search Speed.
• Click the Advanced arrow to expand the settings and set Search Depth
(mm) and Search Radius (mm).

Note

The larger the search radius is, the higher the search precision is
and the less the possibility of reporting search error messages is.
However, a larger search radius may also cause collisions. Always
set the search radius properly.

Tip

You can click the Information icon at the upper-right corner of the Search
Settings window to view the parameter definitions.

9 Jog the cutter to approach the inner circle of the crossbeam at the Home,
ContactXY and other four Pose positions, and click Update Position to record
corresponding values.

Note

The positions are related to both the workobject coordinate system of the
crossbeam and the tool coordinate system of the selected cutter.

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 5 Auto-calibrating
5.2 Calibrating toolkits
Continued

Note

The ContactXY position is the one where the cutter reaches the crosspoint
of the X and Y lasers, that is, the center point of the crossbeam inner circle.
When jogging the cutter to the four Pose positions, make sure the cutter
only rotates around the center point of the crossbeam inner circle.

10 Click Calibrate and then click Play.

• If the controller is in Auto mode, the calibration process runs
automatically.
• If the controller is in Manual mode, follow the instructions in the
displayed messages to perform the calibration.
11 Click Save to save the data after the calibration done.

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5 Auto-calibrating
5.3 Calibrating cutters

5.3 Calibrating cutters

Preparation procedure for new cutters

For a new cutter, perform the following preparation actions:
1 Click the hamburger button on the upper-left corner of the window to display
the menu.
2 Click Calibration.
3 In the displayed Cutter setting window on the right, click New at the bottom
of the window.

Preparation procedure for existing cutters

For an existing cutter, perform the following preparation actions:
1 Click the hamburger button on the upper-left corner of the window to display
the menu.
2 Click Calibration.
3 In the displayed Cutter setting window on the right, click the More options
icon next to the required cutter.
4 Click an icon according to your requirement.
• Edit: to edit basic information of the cutter, such as name and tool type.
• Define: to define the cutter calibration settings and perform calibration.
• Delete: to delete the cutter.

Calibration procedure - cutters (sander type)

Setting basic cutter information
Use the following procedure to set basic information of the cutter:
1 In the Name area of the Cutter setting window, keep the automatically
generated name or type another name as required.
2 Turn on/off the Robot Hold switch based on where the cutter is installed.
• If the cutter is hold by the robot, turn on the switch, that is, set it to
True.
• If the cutter is stationary or hold by another robot, turn off the switch,
that is, set it to False.
3 In the tooldata area, check the current cutter position and calibration status.
By default, the tooldata tool0 is displayed.
• If the TCP of the cutter is at position of tool0, remain the tooldata.
• If the cutter is defined with other tooldata, click Copy tooldata from
controller and select valid tooldata for the cutter.
• If the TCP of the cutter is not at position of tool0 and no tooldata is
valid for the cutter, create tooldata for the cutter in FlexPendant.
4 Choose the sander-type cutter from the Tool Type list.
• Orbital Sander: choose this type if the sanding paper is square.
• Random Orbital Sander: choose this type if the sanding paper is circle.

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 5 Auto-calibrating
5.3 Calibrating cutters
Continued

5 Click Define to enter the calibration process.

The Define CutterName window is displayed.

Defining and calibrating the cutter

In the Define CutterName window, use the following procedure to define and
calibrate the sander:
1 Click Calibration Method to select the required method.
• DOF3: calibration will be performed on the surface of sanding paper
on the sander.
• DOF6: calibration will be performed on the sander.
Click Save to return.
2 Click Shape to enter the page for setting the shape of the sanding paper or
sander based on the previous selection of the sander type and calibration
method.
Cutter type Calibration Shape type Parameter description
method
Orbital DOF3 Default Pad • Length/Width/Height
sander Defines the shape of square sand-
ing paper.
• Rotation
Defines a degree based on which
the XY plane of the sanding paper
or sander rotates around the Z dir-
ection.
CAD • Load Sander Model
Click to upload a 3D model from
local PC. Make sure the Z direction
of the model is the same as the
polishing direction.
• Rotation
Defines a degree based on which
the XY plane of the sanding paper
or sander rotates around the Z dir-
ection.
DOF6 CAD • Load Sander Model
Click to upload a 3D model from
local PC. Make sure the Z direction
of the model is the same as the
polishing direction.
• Rotation
Defines a degree based on which
the XY plane of the sanding paper
or sander rotates around the Z dir-
ection.

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5 Auto-calibrating
5.3 Calibrating cutters
Continued

Cutter type Calibration Shape type Parameter description

method
Random or- DOF3 Default Pad • Radius
bital sander Defines the shape of circle sanding
paper.
• Rotation
Defines a degree based on which
the XY plane of the sanding paper
or sander rotates around the Z dir-
ection.
DOF6 CAD • Load Sander Model
Click to upload a 3D model from
local PC. Make sure the Z direction
of the model is the same as the
polishing direction.
• Rotation
Defines a degree based on which
the XY plane of the sanding paper
or sander rotates around the Z dir-
ection.

Note

To ensure the calibration validity, the defined shape shall not be larger
than the actual shape of the sanding paper or sander.
Click Save to return.
3 Click Touchpoints to add the touchpoints used for calibration.
• If the calibration method is DOF3, add touchpoints directly by clicking
on the surface of the model shown in the 3D view.
• If the calibration method is DOF6, choose a plane first and then add
touchpoints on the selected plane.

Note

If there are steps on a plane, adding touchpoints in different steps

may affect the final calibration result slightly.

Effective Touchpoints in Total shows the quantity of effective touchpoints.

You could also remove the selection by clicking Clear Points.
After selection, click Save to return.
4 Choose a calibrated probe from the Probe list.
5 Click Search Settings to enter the setting window for defining how the probe
goes to search.
In the displayed Search Settings window,
• Set Search Mode and Search Speed.
• Click the Advanced arrow to expand the settings and set Search Offset
and Approach Distance.

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 5 Auto-calibrating
5.3 Calibrating cutters
Continued

Tip

You can click the Information icon at the upper-right corner of the Search
Settings window to view the parameter definitions.

6 Jog the probe to touch the sanding paper surface or sander at the required
position and click Update Position to record the value.
• If the calibration method is DOF3, the Home position is required.
• If the calibration method is DOF6, the Home, Home_X+, Home_Y+,
Home_X- and Home_Y- positions are required.

Note

The positions are related to both the tool coordinate system of the selected
probe and the tool coordinate system of the sander itself. At the same time,
the sander tooldata will be referred as wobjdata.

7 Click Calibrate and then click Play.

• If the controller is in Auto mode, the calibration process runs
automatically.
• If the controller is in Manual mode, follow the instructions in the
displayed messages to perform the calibration.
8 Click Save to save the data after the calibration done.

Calibration procedure - cutters (machining tool type)

Setting basic cutter information
Use the following procedure to set basic information of the cutter:
1 In the Name area of the Cutter setting window, keep the automatically
generated name or type another name as required.
2 Turn on/off the Robot Hold switch based on where the cutter is installed.
• If the cutter is hold by the robot, turn on the switch, that is, set it to
True.
• If the cutter is stationary or hold by another robot, turn off the switch,
that is, set it to False.
3 In the tooldata area, check the current cutter position and calibration status.
By default, the tooldata tool0 is displayed.
• If the TCP of the cutter is at position of tool0, remain the tooldata.
• If the cutter is defined with other tooldata, click Copy tooldata from
controller and select valid tooldata for the cutter.
• If the TCP of the cutter is not at position of tool0 and no tooldata is
valid for the cutter, use the tooldata tool0.
4 Choose the machining tool-type cutter from the Tool Type list.
5 Click Define to enter the calibration process.
The Define CutterName window is displayed.

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5.3 Calibrating cutters
Continued

Defining and calibrating the cutter

In the Define CutterName window, use the following procedure to define and
calibrate the cutter:
1 Choose a calibrated crossbeam from the CrossBeam list.
2 Click Search Settings to enter the setting window for defining how the probe
goes to search.
In the displayed Search Settings window,
• Set Search Mode and Search Speed.
• Click the Advanced arrow to expand the settings and set Search Offset
and Approach Distance.

Tip

You can click the Information icon at the upper-right corner of the Search
Settings window to view the parameter definitions.

3 Jog the cutter to approach the inner circle of the crossbeam at the Home
and ContactXY positions, and click Update Position to record corresponding
values.

Note

The positions are related to both the workobject coordinate system of the
selected crossbeam and the tool coordinate system of the cutter itself.

Note

The ContactXY position is the one where the cutter reaches the crosspoint
of the X and Y lasers, that is, the center point of the crossbeam inner circle.

4 Click Calibrate and then click Play.

• If the controller is in Auto mode, the calibration process runs
automatically.
• If the controller is in Manual mode, follow the instructions in the
displayed messages to perform the calibration.
5 Click Save to save the data after the calibration done.

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 5 Auto-calibrating
5.4 Calibrating external axes and work objects

5.4 Calibrating external axes and work objects

Preparation procedure for new external axis/work object

For a new external axis/work object, perform the following preparation actions:
1 Click the hamburger button on the upper-left corner of the window to display
the menu.
2 Click Calibration.
3 In the displayed Wobj setting window on the right, click New at the bottom
of the window.
4 Click the Mechanism or Wobj icon as required.

Preparation procedure for existing external axis/work object

For an existing toolkit, perform the following preparation actions:
1 Click the hamburger button on the upper-left corner of the window to display
the menu.
2 Click Calibration.
3 In the displayed Wobj setting window on the right, click the More options
icon next to the required external axis/work object.
4 Click an icon according to your requirement.
• Edit: to edit basic information of the external axis/work object, such as
name.
• Define: to define the external axis/work object calibration settings and
perform calibration.
• Delete: to delete the external axis/work object

Calibration procedure - external axis

Use the following procedure to define and calibrate an external axis:
1 In the Name area of the Mechanism setting window, keep the automatically
generated name or type another name as required.
2 Select an external axis from the Mechanism Unit list.
A message will be displayed if the base frame of the selected external axis
is different in the Machining Software and in the controller, prompting you
to load data from controller or overwrite the data in the controller.
• If loading from the controller, the axis information and base frame of
the external axis are displayed automatically.
• If overwriting, you will be promoted to restart the controller. The data
takes effect only after the controller is restarted. After the controller
restarts, you can view the updated axis information in the Machining
Software by reselecting the external axis.
3 Click Define to enter the calibration process.
The Define ExternalAixsName window is displayed.
4 Choose a calibrated probe from the Probe list.

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5 Auto-calibrating
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Continued

5 Click Ball to enter the setting window for defining the calibrating ball that is
placed on the external axis and the calibration target for the probe to touch.
In the displayed Ball window,
• Set Ball Radius (mm) to the actual value.
The ball is automatically named with its radius.
• Set Accessible Offset (mm), which defines a safe area for the probe
to touch the ball.
This parameter defines a height from the top point of the ball. The safe
area refers to the ball surface covered by the projecting plane of the
height.
The Accessible Offset (mm) value must be equal to or smaller than
the Ball Radius (mm) value.
• Move the Number of touchpoints slider to set the quantity of points
on the ball for the probe to touch.
Click OK to return.
6 Click Search Direction to select a direction for the probe to touch the
calibrating ball.
The direction could be based on the probe coordinate system (Tool tab) or
work object coordinate system (Wobj tab).
7 Click Search Settings to enter the setting window for defining how the probe
goes to search.
In the displayed Search Settings window,
• Set Search Mode and Search Speed.
• Click the Advanced arrow to expand the settings and set Search Offset
and Approach Distance.

Tip

You can click the Information icon at the upper-right corner of the Search
Settings window to view the parameter definitions.

8 Jog the probe to touch the ball at AngleX+, Angle2, Angle3 and Angle4
positions, and click Update Position to record corresponding values.
More positions can be added by clicking the + button.

Note

The positions are related to both the workobject coordinate system of the
wobj0 (robot base frame) and the tool coordinate system of the selected
probe.

Note

Before jogging the probe to the AngleX+ position, make sure that the
external axis is in 0° position.

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 5 Auto-calibrating
5.4 Calibrating external axes and work objects
Continued

9 Click Calibrate and then click Play.

• If the controller is in Auto mode, the calibration process runs
automatically.
• If the controller is in Manual mode, follow the instructions in the
displayed messages to perform the calibration.
10 Click Save to save the data after the calibration done.
A message displays, promoting you to restart the controller. The calibration
data takes effect only after the controller restarts.

Calibration procedure - work object

Use the following procedure to define and calibrate a work object:
1 In the Wobj Name area of the Wobj setting window, keep the automatically
generated name or type another name as required.
2 Turn on/off the Robot Hold switch based on where the work object is installed.
• If the work object is hold by the robot, turn on the switch, that is, set it
to True.
• If the work object is stationary, or hold by another robot or external
axis, turn off the switch, that is, set it to False.
3 Click External Axis to enable or disable the external axis. If enabled, select
the valid external axis from the list.

Note

External Axis is valid for setting only when Robot Hold is set to False.

4 In the Wobjdata area, check the current work object position and calibration
status.
5 Click Define to enter the calibration process.
The Define WobjName window is displayed.
6 Choose the calibration method, Polyhedron or Cube, based on the work
object shape from the Calibration Method list.
Following figures illustrate the shapes of the polyhedron and cube.
Polyhedron Cube

xx2400000697 xx2400000698

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5 Auto-calibrating
5.4 Calibrating external axes and work objects
Continued

Note

Calibration method Polyhedron is available from Machining Software version

1.4.0. Using the Polyhedron calibration mode will obtain a higher accuracy
calibration result but it consumes more time.

7 Choose a calibrated probe from the Probe list.

Tip

Only probes whose robot-hold status is opposite to the to-be-calibrated

work object are available to choose.

8 Click Polyhedron or Cube to enter the setting window for defining the
calibration target for the probe to touch.
Method Action
Polyhedron a Set Length(mm) and Width(mm) to the actual values.
You can prepare a standard polyhedron block by referring to the
drawing with predefined dimensions. The standard block is in
120 mm length and 100 mm width. See Drawing for polyhedron
block on page 77.
You can also customize a block as required. When designing the
block, make sure that the difference between the length value
and width value is larger than 10 mm.
b View other parameters.
Top Height(mm), Mid Height(mm) and Concave Depth(mm) are
in fixed value; Mid Width(mm) is half of the defined Width(mm)
value.
c Click Save to return.
Cube a Set Length (mm), Width (mm) and Height (mm) to the actual
values.
b Click the Touchpoint Layout arrow to display the panel for se-
lecting point matrix.
At least a 2x2 matrix, that is, 4 points, must be selected.
c Click Save to return.

9 Click Search Settings to enter the setting window for defining how the probe
goes to search.
In the displayed Search Settings window,
• Set Search Mode.
• If it is Cube, set Search Speed.
• If it is Polyhedron, set Accuracy.
Five accuracy levels are available for choose. Number of touchpoints
on each block surface for each level can be previewed in 3D graphics
window in real time, and the estimated calibration time is also presented
for reference. The higher the accuracy level is, the more calibration
time is taken.
• Click the Advanced arrow to expand the settings and set Search Offset
and Approach Distance.

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5.4 Calibrating external axes and work objects
Continued

Tip

You can click the Information icon at the upper-right corner of the Search
Settings window to view the parameter definitions.

10 Select a corner on the work object as the origin point in the 3D graphics
window.
Only after the origin point is selected, the position information can be
displayed and target updating can be performed. You can click Change
Origin to change an origin point.

Note

The coordination system is based on whether the work object is hold by

the robot. If yes, the tool coordinate system is used; otherwise, the work
object coordinate system is used.

11 Jog the probe to touch the work object at the Origin, X and Y positions, and
click Update Position to record corresponding values.

Note

If the external axis is enabled, before jogging the probe to the Origin
position, make sure that the external axis is in 0°.

Note

The Origin, X and Y positions are related to both wobj0 (robot base frame)
and the tool coordinate system of the selected probe.
The Home, XOYHome, XOZHome and YOZHome positions are related to
the workobject coordinate system of the work object, which has been
calculated based on the Origin, X and Y positions.

Note

The Origin position is the one where the probe touches the origin point.
The X position is the corner point where the probe touches after moving
along the X axis direction of the origin point. The Y position is a point on
the positive Y-axis side.
The Home, XOYHome, XOZHome and YOZHome positions are valid for
updating only after the Origin, X and Y positions are updated.
After the Home position is updated, the XOYHome, XOZHome and
YOZHome positions update automatically. You can further update the three
positions separately.

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5 Auto-calibrating
5.4 Calibrating external axes and work objects
Continued

12 Click Calibrate and then click Play.

• If the controller is in Auto mode, the calibration process runs
automatically.
• If the controller is in Manual mode, follow the instructions in the
displayed messages to perform the calibration.
13 Click Save to save the data after the calibration done.

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 6 RAPID programming

6 RAPID programming
Overview
RAPID programming is supported only by Machining Software in advanced version
(option Machining Premium).

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6 RAPID programming
6.1 RAPID exporting and reloading

6.1 RAPID exporting and reloading

RAPID exporting
Machining Software allows users to apply the created or tuned programs to the
connected controller. When the program is ready, click the Apply button to apply
the programs.

Note

The Apply button is valid only when the writing access has been requested and
granted. If the controller is in Auto mode, the writing access will be automatically
granted to Machining Software; if the controller is in Manual mode, the writing
access have to be granted in FlexPendant.
If the writing access is held by another client, release the access first and request
from Machining Software again.
A main module and several related modules will be generated.
Module Description
CalibData_HMI Includes the tool data, work object data, speed data, zone
data and calibration result data.
EventDefGroup_ProgramID If events are specified for instructions, the event data will
be loaded in the EventDefGroup_ProgramID module.
ProgramID specifies the program to which the events be-
long.
Group_ProgramID_Opera- Includes the path data.
tionID_000 ProgramID and OperationID specify the program and op-
eration to which the instruction belongs.
Main_test_ProgramID The main module of the Machining Software program.
ProcessDefGroup_Program- Includes the machining process data.
ID_OperationID_000 ProgramID and OperationID specify the program and op-
eration to which the machining process belongs.
TargetDefGroup_ProgramID_Op- Includes the target point data.
erationID_000 ProgramID and OperationID specify the program and op-
eration to which the target point belong.
WaveGroup_ProgramID_Opera- Includes the wave path data, including wave pattern, speed
tionID_000 data, zone data, tool data and work object data.
ProgramID and OperationID specify the program and op-
eration that enables wave path.

Note

The speed data and zone data are not defined for wave
paths in Machining Software. They are set to v50 and z0
respectively by default and allow users to modify in RAPID
editor.

InstructionName_T Includes the point array data for wave paths.

InstructionName specifies the name of the instruction that
enables wave path.

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6.1 RAPID exporting and reloading
Continued

Module Description
PatternName_NodeMod Includes the wave path pattern data.
PatternName starts with "C" or "L" that specifies the mo-
tion type, circular or linear and follows with the user-
defined pattern name.

Exporting RAPID to controller

The modules are loaded into the T_ROB1 task of the controller after clicking Apply.

RAPID reloading
The applied Machining Software modules must be edited based on programming
rules to ensure successful reloading to Machining Software.

Note

Wave path modules could be edited in RAPID editor without programming

limitations and applied to the controller directly, but they could not be reloaded
from the controller to Machining Software.

In module, Programming rule

CalibData_HMI • Values of the tooldata and wobjdata can be modified.
• Do not modify the names of the tooldata or wobjdata.
Values of the tooldata or wobjdata whose name is modified cannot
be reloaded to Machining Software.
EventDefGroup_ProgramID • Events included in a procedure (between PROC and ENDPROC)
can be modified, either the complete event routine or the parameters
defined in the event routine.
• Do not insert new event routines in an event routine.
• Do not modify the procedure name.
Event routines in the procedure cannot be reloaded to Machining
Software even the events are modified.
• Do not delete event routines.
Deleted events will not be deleted from Machining Software and
will be exported again when program download/export is executed
in Machining Software.
Group_ProgramID_OperationID_000 • Values of the speeddata and zonedata in the instructions can be
modified, but only predefined values are allowed.
• Do not modify the names of the robtarget, RCS, tooldata, wobjdata
or process in the instructions.
Values of the robtarget, RCS, tooldata, wobjdata or process whose
name is modified cannot be reloaded to Machining Software.
• Do not delete instructions.
Deleted instructions will not be deleted from Machining Software
and will be exported again when program download/export is ex-
ecuted in Machining Software.
Main_test_ProgramID Not allowed to be edited.

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6 RAPID programming
6.1 RAPID exporting and reloading
Continued

In module, Programming rule

ProcessDefGroup_ProgramID_Opera- • Values of the EngageDistance, TiltAngle and LeadAngle compon-
tionID_000 ents in MachineProcess data type can be modified.
• Do not modify the names of the PreRoutine or PostRoutine com-
ponents in MachineProcess data type.
Values of the components whose name is modified cannot be re-
loaded to Machining Software.
• Do not modify the names of processes in MachineProcess data
type.
Values of the EngageDistance, TiltAngle and LeadAngle compon-
ents cannot be reloaded to Machining Software even they are
modified.
• Do not add new processes in MachineProcess data type.
Values of the new processes cannot be reloaded to Machining
Software.
• Do not delete processes in MachineProcess data type.
Deleted processes will not be deleted from Machining Software
and will be exported again when program download/export is ex-
ecuted in Machining Software.
TargetDefGroup_ProgramID_Opera- • Value of the robtarget can be modified.
tionID_000 • Do not modify RCS values.
Modified RCS values cannot be reloaded to Machining Software.
• Do not modify the target names.
Value of the target whose name is modified cannot be reloaded to
Machining Software.
• Do not add new robtarget or RCS.
Values of the new robtarget and RCS cannot be reloaded to Machin-
ing Software.
• Do not delete robtarget or RCS.
Deleted robtarget and RCS will not be deleted from Machining
Software and will be exported again when program download/export
is executed in Machining Software.

All the Machining Software modules (wave path related modules excluded) are
also declared with "! Generated by ABB Machining Software HMI -
Machining Functionality for ABB Robot xxx", which cannot be removed.
Before reloading the modules to the Machining Software, verify that the declaration
remains and the modules are programmed following the rules.

Reloading from controller

When reloading the modules from the controller to the Machining Software,
• if there is no modification made in the Machining Software, the programs will
be reloaded to Machining Software directly.
• if there is modifications made in the Machining Software, a message will be
displayed, prompting you to synchronize from the controller or keep the
modification in Machining Software.

Reloading from local file

The modules saved to the local folder must be loaded to the T_ROB1 task of the
controller first, and then be programmed and reloaded to Machining Software.

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6.1 RAPID exporting and reloading
Continued

Multiple instruction exporting

Introduction
If the targets in a program is more than 2000, it is recommended to enable the
multiple instruction exporting function. With the function enabled, every 200
instructions will be grouped and included in a separate module in the T_Large task.
The modules in the T_Large task will be further called by the main routine in the
T_ROB1 task. This facilitates program programming and reading.
The multiple instruction exporting function is supported only by Machining Software
in advanced version (option Machining Premium). To enable the function, make
sure the Multitasking option is selected and then select option Machining Premium
> More than 2000 instructions > Add T_large task in the Modify Installation
dialogue.

Working with multiple instruction exporting function

1 Open RobotStudio.
2 In the Add-Ins tab, click Machining 202X.X.
3 In the Machining tab, choose Export Settings from the Export list in the
Path Tools group.
4 In the displayed Export Settings window, choose
Large_Export_Rules_Library.yml from the Active Template drop-down list
in the Export template library area, and then click OK.
5 In the Program tab page on the left pane of the window, right-click the
required program and choose Export RAPID from the shortcut menu.
• Information of every 200 targets is included in an LN file. If less than
200 targets are left for the last file, default data will be added to make
sure 200 target items are included in the file.
• The LN files are named with suffix "_LN_{index}", in which "index"
refers to the file number.
• The LN files are generated and exported to directory
$HOME/LN{ProgramName}/Opr_{ProgramID}_{Operation_ID}.
6 Click the Controller tab and, in the RAPID category in the Controller
navigation tree in the displayed window:
• Right-click the T_Large task, choose Load Module from the shortcut
menu and load modules BackgroundCalibData.mod and
BackgroundMain.mod.
• Right-click the T_ROB1 task, choose Load Module from the shortcut
menu and load modules MotionCalibData.mod, MotionMain.mod
and, if any, MotionEventDefGroup.
7 Click the RAPID tab and remove the selection of the T_ROB1 task from the
Selected tasks list in the Test and Debug group.
8 Set the program pointer to the GenerateModules_Opr routine in the T_Large
task.
9 Run the program to start RAPID compiling.
Corresponding binary files are generated for the LN files in the same directory.

Continues on next page

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6 RAPID programming
6.1 RAPID exporting and reloading
Continued

10 Click the RAPID tab and select the T_ROB1 task from the Selected tasks
list in the Test and Debug group.
11 Set the program pointer to the main routine in the T_ROB1 task.
12 Run the program.

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 6 RAPID programming
6.2.1 MachL - Moves linearly

6.2 RAPID instructions

6.2.1 MachL - Moves linearly

Usage
In machining programs, MachL is used to move the tool center point (TCP) linearly
to a given destination.
This instruction can only be used in the main task T_ROB1 or, if in a MultiMove
System, in Motion tasks.

Arguments
offset
Data type: pose
offset is used to add an offset to the robot position in the object coordinate
system.

RelEuler
Data type: MachiningPose (See MachiningPose - Coordinate transformations in
machining programs on page 67)
RelEuler is used to add a displacement and/or a rotation, expressed in the active
tool coordinate system, to a robot position.

ToPoint
Data type: robtarget
ToPoint defines the destination point of the robot and external axes.

\RCS
Data type: pose
RCS defines the coordinate system for machining the contact point. The Z-axis
direction is the same as the normal vector. The value of the this argument is
generated automatically in Machining PowerPac and not allowed to be changed.

\ID
Data type: identno
The argument \ID is mandatory in the MultiMove systems, if the movement is
synchronized or coordinated synchronized. This argument is not allowed in any
other case. The specified id number must be the same in all the cooperating
program tasks. By using the id number the movements are not mixed up at the
runtime.

Speed
Data type: speeddata
The speed data that applies to movements. Speed data defines the velocity for the
tool center point, the tool reorientation, and external axes.

Zone
Data type: zonedata
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6 RAPID programming
6.2.1 MachL - Moves linearly
Continued

Zone data for the movement. Zone data describes the size of the generated corner
path.

Tool
Data type: tooldata
The tool in use when the robot moves. The tool center point is the point moved to
the specified destination position.

\WObj
Data type: wobjdata
The work object (coordinate system) to which the robot position in the instruction
is related.
This argument can be omitted and if so then the position is related to the world
coordinate system. If, on the other hand, a stationary tool or coordinated external
axes are used then this argument must be specified to perform a linear movement
relative to the work object.

\Corr
Data type: switch
Correction data written to a corrections entry by the instruction CorrWrite will be
added to the path and destination position if this argument is present.
The RobotWare option Path Offset is required when using this argument.

\TLoad
Data type: loaddata
The \TLoad argument describes the load attached to the tool flange of the robot.

process
Data type: MachineProcess (See MachineProcess - Process definitions in
machining programs on page 68)
The process argument describes the required process parameters and other
necessary information for machining applications.

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 6 RAPID programming
6.2.2 MachJ - Moves using joint movement

6.2.2 MachJ - Moves using joint movement

Usage
In machining programs, MachJ is used to move quickly from one point to another
when that movement does not have to be in a straight line.
The robot and external axes move to the destination position along a non-linear
path. All axes reach the destination position at the same time.
This instruction can only be used in the main task T_ROB1 or, if in a MultiMove
system, in Motion tasks.

Arguments
offset
Data type: pose
offset is used to add an offset to the robot position in the object coordinate
system.

RelEuler
Data type: MachiningPose (See MachiningPose - Coordinate transformations in
machining programs on page 67)
RelEuler is used to add a displacement and/or a rotation, expressed in the active
tool coordinate system, to a robot position.

ToPoint
Data type: robtarget
ToPoint defines the destination point of the robot and external axes.

\RCS
Data type: pose
RCS defines the coordinate system for machining the contact point. The Z-axis
direction is the same as the normal vector. The value of the this argument is
generated automatically in Machining PowerPac and not allowed to be changed.

\ID
Data type: identno
The argument \ID is mandatory in the MultiMove systems, if the movement is
synchronized or coordinated synchronized. This argument is not allowed in any
other case. The specified id number must be the same in all the cooperating
program tasks. By using the id number the movements are not mixed up at the
runtime.

Speed
Data type: speeddata
The speed data that applies to movements. Speed data defines the velocity for the
tool center point, the tool reorientation, and external axes.

Zone
Data type: zonedata
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6 RAPID programming
6.2.2 MachJ - Moves using joint movement
Continued

Zone data for the movement. Zone data describes the size of the generated corner
path.

Tool
Data type: tooldata
The tool in use when the robot moves. The tool center point is the point moved to
the specified destination position.

\WObj
Data type: wobjdata
The work object (coordinate system) to which the robot position in the instruction
is related.
This argument can be omitted and if so then the position is related to the world
coordinate system. If, on the other hand, a stationary tool or coordinated external
axes are used then this argument must be specified to perform a linear movement
relative to the work object.

\TLoad
Data type: loaddata
The \TLoad argument describes the load attached to the tool flange of the robot.

process
Data type: MachineProcess (See MachineProcess - Process definitions in
machining programs on page 68)
The process argument describes the required process parameters and other
necessary information for machining applications.

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 6 RAPID programming
6.2.3 MachC - Moves circularly

6.2.3 MachC - Moves circularly

Usage
In machining programs, MachC is used to move the tool center point (TCP) circularly
to a given destination. During the movement the orientation normally remains
unchanged relative to the circle.
This instruction can only be used in the main task T_ROB1 or, if in a MultiMove
system, in Motion tasks.

Arguments
offset
Data type: pose
offset is used to add an offset to the robot position in the object coordinate
system.

RelEuler
Data type: MachiningPose (See MachiningPose - Coordinate transformations in
machining programs on page 67)
RelEuler is used to add a displacement and/or a rotation, expressed in the active
tool coordinate system, to a robot position.

CirPoint
Data type: robtarget
The circle point of the robot. The circle point is a position on the circle between
the start point and the destination point.

\RCS_Cir
Data type: pose
RCS defines the coordinate system for circle point.

ToPoint
Data type: robtarget
ToPoint defines the destination point of the robot and external axes.

\RCS_To
Data type: pose
RCS defines the coordinate system for destination point.

\ID
Data type: identno
The argument \ID is mandatory in the MultiMove systems, if the movement is
synchronized or coordinated synchronized. This argument is not allowed in any
other case. The specified id number must be the same in all the cooperating
program tasks. By using the id number the movements are not mixed up at the
runtime.

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6 RAPID programming
6.2.3 MachC - Moves circularly
Continued

Speed
Data type: speeddata
The speed data that applies to movements. Speed data defines the velocity for the
tool center point, the tool reorientation, and external axes.

Zone
Data type: zonedata
Zone data for the movement. Zone data describes the size of the generated corner
path.

Tool
Data type: tooldata
The tool in use when the robot moves. The tool center point is the point moved to
the specified destination position.

\WObj
Data type: wobjdata
The work object (coordinate system) to which the robot position in the instruction
is related.
This argument can be omitted and if so then the position is related to the world
coordinate system. If, on the other hand, a stationary tool or coordinated external
axes are used then this argument must be specified to perform a linear movement
relative to the work object.

\TLoad
Data type: loaddata
The \TLoad argument describes the load attached to the tool flange of the robot.

process
Data type: MachineProcess (See MachineProcess - Process definitions in
machining programs on page 68)
The process argument describes the required process parameters and other
necessary information for machining applications.

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 6 RAPID programming
6.2.4 WaveLStartPoint - Moves to the wave start point

6.2.4 WaveLStartPoint - Moves to the wave start point

Usage
In machining programs, WaveLStartPoint is used to specify the position of the
wave start point. If the motion type is circular, this instruction is operated and the
robot moves to the specified wave start point first to process. If the motion type is
linear, this instruction is skipped and the robot directly moves to the next wave
node to process.
This instruction can only be used in the main task T_ROB1 or, if in a MultiMove
System, in Motion tasks.

Arguments
WShape
Data type: WaveShape (See WaveShape - wave patterns defined for wave paths
on page 72)
WShape specifies the wave pattern, circular or linear.

ToTarget
Data type: robtarget
ToTarget specifies the sourcing target generated by Machining PowerPac, which
is used as reference for generating the wave start node.

Speed
Data type: speeddata
The speed data that applies to movements. Speed data defines the velocity for the
tool center point, the tool reorientation, and external axes.

Zone
Data type: zonedata
Zone data for the movement. Zone data describes the size of the generated corner
path.

Tool
Data type: tooldata
The tool in use when the robot moves. The tool center point is the point moved to
the specified destination position.

\WObj
Data type: wobjdata
The work object (coordinate system) to which the robot position in the instruction
is related.
This argument can be omitted and if so then the position is related to the world
coordinate system. If, on the other hand, a stationary tool or coordinated external
axes are used then this argument must be specified to perform a linear movement
relative to the work object.

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6 RAPID programming
6.2.5 WaveL - Moves along the wave path

6.2.5 WaveL - Moves along the wave path

Usage
In machining programs, WaveLStartPoint is used to specify the position of the
wave start point. If the motion type is circular, this instruction is operated and the
robot moves to the specified wave start point first to process. If the motion type is
linear, this instruction is skipped and the robot directly moves to the next wave
node to process.
This instruction can only be used in the main task T_ROB1 or, if in a MultiMove
System, in Motion tasks.

Arguments
WShape
Data type: WaveShape (See WaveShape - wave patterns defined for wave paths
on page 72)
WShape specifies the wave pattern, circular or linear.

ToTarget
Data type: robtarget
ToTarget specifies the sourcing target generated by Machining PowerPac, which
is used as reference for generating the wave start node.

Speed
Data type: speeddata
The speed data that applies to movements. Speed data defines the velocity for the
tool center point, the tool reorientation, and external axes.

Zone
Data type: zonedata
Zone data for the movement. Zone data describes the size of the generated corner
path.

Tool
Data type: tooldata
The tool in use when the robot moves. The tool center point is the point moved to
the specified destination position.

\WObj
Data type: wobjdata
The work object (coordinate system) to which the robot position in the instruction
is related.
This argument can be omitted and if so then the position is related to the world
coordinate system. If, on the other hand, a stationary tool or coordinated external
axes are used then this argument must be specified to perform a linear movement
relative to the work object.

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 6 RAPID programming
6.3.1 MachiningPose - Coordinate transformations in machining programs

6.3 RAPID data types

6.3.1 MachiningPose - Coordinate transformations in machining programs

Usage
Data of the type MachiningPose describes how a coordinate system is displaced
and rotated.

Components
x
Data type: num
The displacement in X-axis position of the coordinate system.

y
Data type: num
The displacement in Y-axis position of the coordinate system.

z
Data type: num
The displacement in Z-axis position of the coordinate system.

Rx
Data type: num
The orientation in X-axis position of the coordinate system.

Ry
Data type: num
The orientation in Y-axis position of the coordinate system.

Rz
Data type: num
The orientation in Z-axis position of the coordinate system.

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6 RAPID programming
6.3.2 MachineProcess - Process definitions in machining programs

6.3.2 MachineProcess - Process definitions in machining programs

Usage
Data of the type MachiningProcess describes parameters specially used during
machining process.

Components
EngageDistance
Data type: num
The pressure amount with which the tool will move a further distance towards to
the work object.

TiltAngle
Data type: num
The angle (inclined right or left) that the tool will rotate along the forward direction
of the machining path.

LeadAngle
Data type: num
The angle (inclined forward or backward) that the tool will rotate along the tangent
direction to the forward direction of the machining path.

PreRoutine
Data type: string
The component PreRoutine defines the event that is executed before a motion
instruction.

PostRoutine
Data type: string
The component PostRoutine defines the event that is executed after a motion
instruction.

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 6 RAPID programming
6.3.3 WaveDirection - Wave path processing directions

6.3.3 WaveDirection - Wave path processing directions

Usage
Data of the type WaveDirection describes the coordinate system of the wave
nodes and the processing forward direction of the wave paths.

Components
CoordinateSystem
Data type: num
Value of TOOLSYSTEM is 0, indicating the tool coordinate system is used.

Direction
Data type: string
Processing forward direction of the wave path.

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6 RAPID programming
6.3.4 WaveDistribution - Distribution information of wave nodes

6.3.4 WaveDistribution - Distribution information of wave nodes

Usage
Data of the type WaveDistribution describes the node array, that is, how the
nodes distribute.

Components
Nodes
Data type: string
Name of the node array.

NodeCount
Data type: num
Quantity of nodes in the node array.

StartPoint
Data type: pos
Wave start point of the wave path. This parameter works only for the wave path in
circular pattern.

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 6 RAPID programming
6.3.5 WaveNode - wave nodes defined for wave paths

6.3.5 WaveNode - wave nodes defined for wave paths

Usage
Data of the type WaveNode describes how the wave nodes are defined based on
the sourcing targets generated by Machining PowerPac.

Components
Offset
Data type: pos
Displacement offset of wave nodes from the sourcing targets based on which the
nodes are generated.

Index
Data type: num
Index indicating the sourcing target from which the wave node is generated.

MotionType
Data type: string
The robot motion type, linear or circular.

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6 RAPID programming
6.3.6 WaveShape - wave patterns defined for wave paths

6.3.6 WaveShape - wave patterns defined for wave paths

Usage
Data of the type WaveShape describes the wave pattern of the wave path.

Components
WType
Data type: string
Name of the wave path.

WaveDistribution
Data type: WaveDistribution
Distribution information of nodes in the wave path.

WaveDirection
Data type: WaveDirection
Coordinate system of nodes and processing forward direction of the wave path.

nStep
Data type: num
Step for the wave pattern to repeat.

WMotion
Data type: string
Wave motion function, whose default value is WaveMotionCustomDefault. It
allows users to customize motion functions as requires. The function is available
in the system module WaveMotionModule.

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 7 Reference information
7.1 Messages and errors

7 Reference information
7.1 Messages and errors

Message list

ID Message
118001 Calibration Process Information
118002 TouchMotion Information
118003 Parameter error

Error list
118004 Array Length is too short

Description The array length is too short.

Consequence The program is stopped.
Causes None
Actions None

118005 Distance is zero

Description The distance between the home point and the contact point is 0.
Consequence The program is stopped.
Causes The home point is too close to the contact point.
Actions None

118006 Tool and Wobj are wrong

Description Active tool and active work object cannot have the RobHold para-
meter set to the same value, no matter both True or both False.
Consequence The program is stopped.
Causes The setting of the robhold component in the tooldata and
wobjdata instructions is conflict.
Actions Change the setting of the RobHold parameter for the active tool and
active work object to different value.

118007 External Axis is not at Zero position

Description The axis is not at zero position.

Consequence The program is stopped.
Causes The external axis is found not at the zero position.
Actions Jog the external axis to the zero position.

118008 Array length mismatch

Description The size of the array does not match the size used.
Consequence The program is stopped.
Causes The length of the array is less than the number of elements used.

Continues on next page

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7 Reference information
7.1 Messages and errors
Continued

Actions Modify the number of elements used.

118009 Precision is not enough

Description Data or position is not defined accurately.

Consequence The program is stopped.
Causes No enough data or the positions do not have the required relations
or not specified with enough accuracy.
Actions Increase the number of data and improve the data correlation.

118010 Collision occurred during probe movement

Description Collision occurs during probe movement.

Consequence The program is stopped.
Causes The probe has collided with an obstacle in the cell during its move-
ment.
Actions 1 Check the probe retraction status, succeeded or failed.
2 If failed, go to Manual mode.
3 Manually run the robot to move the probe away from the ob-
ject.
4 Resume operation by restarting the program.

118011 Probe retraction succeeded

Description The manipulator has attempted to move the probe back away from
the obstacle, into which it collided, and succeeded.
Consequence The system is ready to go back to normal operation.
Causes None
Actions None

118012 Probe retraction failed

Description The manipulator has attempted to move the probe back away from
the obstacle, into which it collided, and failed
Consequence The system is NOT ready to go back to normal operation.
Causes This may be caused by the probe being stuck to the object into
which it collided.
Actions 1 Go to Manual mode.
2 Manually run the robot to move the probe away from the ob-
ject.
3 Resume operation by restarting the program.

118100 Robot-hold status confliction for crossbeam and its related tool

Description Robot-hold status of the tool and crossbeam (or the wobjdata defined
for the crossbeam) conflict.
Consequence The program is stopped.
Causes The tool selected for crossbeam calibration and the crossbeam (or
the wobjdata defined for the crossbeam) are both set as in fixed
position or hold by the robot.
Actions 1 Check the robot-hold status of each item.
2 Modify the required one.

Continues on next page

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 7 Reference information
7.1 Messages and errors
Continued

118101 Robot-hold status confliction for original and calibrated tooldata

Description Robot-hold status included in the original tooldata and calibrated

tooldata of the tool conflict.
Consequence The program is stopped.
Causes The robot-hold status in the calibrated tooldata of the tool is different
from that in the original tooldata used for the tool.
Actions • Check the robot-hold status in the original and calibrated
tooldata.
• Modify the required one.

118610 Rapid module is missing

Description The specified RAPID module cannot be found.

Consequence The program is stopped.
Causes The RAPID module is missing.
Actions • Check the file path and file name.
• Check whether the file exist.

118611 LN file is missing

Description The specified LN file cannot be found.

Consequence The program is stopped.
Causes The LN file is missing.
Actions • Check the file path and file name.
• Check whether the file exist.

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7 Reference information
7.2 Troubleshooting

7.2 Troubleshooting

Robot stops and reports 40661, Search Error during probe searching
Description
During the calibration using a probe, the robot stops and event 40661 Search Error
is reported when the probe moves to search towards the calibration target.

Possible causes
When the probe starts search towards a surface of the calibration target, the robot
will turn its position to the same as the home position defined for this surface. With
this position, if the searching target is around the singularity or the boundary of
robot working range, the error is reported.

Action
In the defining window, jog the robot to another position and update the Home
position to this new position. Then, start the calibration process again.

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7 Reference information
7.3 Drawings

77
1 2 3 4 5 6
Supplementary document Doc. type Document Description
A 0.025 A B A
10°
30 ±0.015

M3 THRU
0.025 C

3.2 X 90°, Near Side 6

4
4x C0.5 C 1.6 2x C0.5
0.025 A 1.6 A

50

60
0.025 B

© Copyright 2021-2024 ABB. All rights reserved.

0.012
50

1.6
1.6

B 100 ±0.015 B
165
We reserve all rights in this document and in the in-

disclosure to third parties without express authority

formation contained therein. Reproduction, use or

is strictly forbidden. © Copyright 2020 ABB

0.025 A
8x C0.5 0.025 B 1.6
4x 5.5 THRU ALL Material: AL6061-T6

8.5
Weight: About 1.6Kg

120 ±0.015

Operating manual - Machining Software

8.5
C There shall be no scratches or scratches on the surface C
Unmarked surface roughness Ra3.2

100
Unnoted rounded corner R0.5
Drawing for polyhedron block

Unnoted chamfer C0.5

2x R1 2x R1 Sharp edge blunted
Surface color anodizing
ᶀᯉ˖ AL6061-T6
䟽䟿˖ 㓖1.6Kg
㺘䶒нᗇᴹࡂⰅᬖՔㅹ㕪䲧

3HAC080110-001 Revision: F
+0.018 ᵚ⌘㺘䶒㋇㌉ᓖ Ra3.2
6 H8 0 12 6 B 1.6 0.025 A 4x R10 ᵚ⌘ശ䀂 R0.5 General tolerance class 䙊⭘‫ޜ‬ᐞㅹ㓗
7 X 90°, Near Side 150 ᵚ⌘‫ق‬䀂 C0.5 Machined parts / Metal sheet ᵪ࣐ᐕԦ / 䫓䠁Ԧ
䭀䗩‫ق‬䫍
7.3 Drawings

㺘䶒ᵜ㢢䱣ᶱ≗ॆ Fine Medium Coarse Very Coarse

acc. to ISO 2768-1
Prepared Responsible Department Description
D Approved Take over department Sheet
D
1
Status ECO number No. of sh.
1
Document no. Rev. ind.
Latest Revision
1 2 3 4 5 6
This page is intentionally left blank
 Index

Index P
path
smooth path, 24
A wave path, 25
authentication
user grant, 13 S
safety, 10
C smooth path, 24
calibration
cutter, 42 T
external axis, 47 toolkit, 37
toolkit, 37 crossbeam type, 39
work object, 47 probe type, 37
cutter, 42
machining tool type, 45 V
sander type, 42 version, 11
license, 13
E
external axis, 47 W
wave path, 25
L work object
license, 13 cube, 49
polyhedron, 49
N
network security, 9

Operating manual - Machining Software 79

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© Copyright 2021-2024 ABB. All rights reserved.
ABB AB
Robotics & Discrete Automation
S-721 68 VÄSTERÅS, Sweden
Telephone +46 10-732 50 00

ABB AS
Robotics & Discrete Automation
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000

ABB Engineering (Shanghai) Ltd.

Robotics & Discrete Automation
No. 4528 Kangxin Highway
PuDong New District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666

ABB Inc.
Robotics & Discrete Automation
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000

abb.com/robotics
3HAC080110-001, Rev F, en

© Copyright 2021-2024 ABB. All rights reserved.

Specifications subject to change without notice.