ROBOTICS

Application manual
Controller software OmniCore
Trace back information:
Workspace Main version a678
Checked in 2025-06-12
Skribenta version 5.6.019
 Application manual
Controller software OmniCore
RobotWare 7.19

Document ID: 3HAC066554-001

Revision: T

© Copyright 2019-2025 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 2019-2025 ABB. All rights reserved.

Specifications subject to change without notice.
 Table of contents

Table of contents
Overview of this manual ................................................................................................................... 11
Open source and 3rd party components ......................................................................................... 15

1 Introduction to RobotWare 17
1.1 Products, classes, and options ............................................................................ 17
1.2 RAPID language and programming environment ..................................................... 19

2 RobotWare-OS, basic functionality in RobotWare 23

2.1 Motion settings and motion programming .............................................................. 23
2.2 Input and output signals ..................................................................................... 25
2.3 Functionality for user interaction .......................................................................... 26
2.4 File handling .................................................................................................... 27
2.5 Cyclic bool, cyclically evaluated logical conditions .................................................. 28
2.5.1 Cyclically evaluated logical conditions ........................................................ 28
2.5.2 Cyclic bool examples ............................................................................... 31
2.5.3 System parameters ................................................................................. 34
2.5.4 RAPID components ................................................................................. 35
2.6 File and I/O device handling ................................................................................ 36
2.6.1 Introduction to file and I/O device handling ................................................... 36
2.6.2 Binary and character based communication ................................................. 37
[Link] Overview ................................................................................... 37
[Link] RAPID components ...................................................................... 38
[Link] Code examples ........................................................................... 39
2.6.3 Raw data communication .......................................................................... 41
[Link] Overview ................................................................................... 41
[Link] RAPID components ...................................................................... 42
[Link] Code examples ........................................................................... 43
2.6.4 File and directory management .................................................................. 45
[Link] Overview ................................................................................... 45
[Link] RAPID components ...................................................................... 46
[Link] Code examples ........................................................................... 47
2.6.5 Device Command Interface, communicating with I/O devices .......................... 49
[Link] Introduction to Device Command Interface ....................................... 49
[Link] RAPID components and system parameters ..................................... 50
[Link] Code example ............................................................................. 51
2.7 Alias I/O signals ................................................................................................ 53
2.7.1 Overview ............................................................................................... 53
2.7.2 RAPID components ................................................................................. 54
2.7.3 Alias I/O functionality example ................................................................... 55
2.8 Logical Cross Connections ................................................................................. 56
2.8.1 Introduction to Logical Cross Connections ................................................... 56
2.8.2 Configuring Logical Cross Connections ....................................................... 57
2.8.3 Examples .............................................................................................. 58
2.8.4 Limitations ............................................................................................. 60
2.9 RAPID Message Queue ...................................................................................... 61
2.9.1 Introduction to RAPID Message Queue ....................................................... 61
2.9.2 RAPID Message Queue behavior ............................................................... 62
2.9.3 System parameters ................................................................................. 66
2.9.4 RAPID components ................................................................................. 67
2.9.5 Code examples ....................................................................................... 68
2.10 Socket Messaging ............................................................................................. 72
2.10.1 Introduction to Socket Messaging .............................................................. 72
2.10.2 Schematic picture of socket communication ................................................. 73
2.10.3 Technical facts about Socket Messaging ..................................................... 74
2.10.4 RAPID components ................................................................................. 75
2.10.5 Code examples for Socket Messaging ......................................................... 77

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2.11 Event logs for user actions .................................................................................. 79

2.11.1 Introduction to User logs .......................................................................... 79
2.12 Power failure functionality ................................................................................... 81
2.12.1 Overview ............................................................................................... 81
2.12.2 RAPID components and system parameters ................................................. 82
2.12.3 Power failure functionality example ............................................................ 83
2.13 Interrupt functionality ......................................................................................... 84
2.13.1 Overview ............................................................................................... 84
2.13.2 RAPID components ................................................................................. 85
2.13.3 Interrupt functionality examples ................................................................. 86
2.13.4 Analog Signal Interrupt ............................................................................. 87
[Link] Introduction to Analog Signal Interrupt ............................................ 87
[Link] RAPID components ...................................................................... 88
[Link] Code example ............................................................................. 89
2.14 Additional functions for motion control and motion programming ............................... 90
2.14.1 Fixed Position Events .............................................................................. 90
[Link] Overview ................................................................................... 90
[Link] RAPID components and system parameters ..................................... 91
[Link] Code examples ........................................................................... 94
2.14.2 Electronically Linked Motors ...................................................................... 96
[Link] Overview ................................................................................... 96
[Link] Configuration .............................................................................. 98
[Link] Managing a follower axis ............................................................... 101
[Link] Tuning a torque follower ............................................................... 106
[Link] Data setup .................................................................................. 110

3 Connectivity 115
3.1 Connected Services .......................................................................................... 115
3.1.1 Overview ............................................................................................... 115
3.1.2 Connected Services connectivity ................................................................ 117
3.1.3 Connected Services registration ................................................................ 119
3.1.4 Summary of Connected Services paths in FlexPendant .................................. 121
3.1.5 Summary of Connected Services paths in RobotStudio .................................. 122
3.1.6 Configuration of system parameters ........................................................... 123
3.1.7 Configuring Connected Services using FlexPendant ...................................... 125
[Link] Introduction ................................................................................ 125
[Link] Enable or disable Connected Services using FlexPendant .................. 126
[Link] Configure Connected Services based on connection type using
FlexPendant ............................................................................... 127
[Link] Configuration of public network using FlexPendant ............................ 130
[Link] Configure internet connection with proxy using FlexPendant ............... 131
3.1.8 Configuring Connected Services using RobotStudio ...................................... 132
[Link] Introduction ................................................................................ 132
[Link] Enable or disable Connected Services using RobotStudio ................... 133
[Link] Configure connected services based on connection type using
RobotStudio ............................................................................... 134
[Link] Configuration of public network using RobotStudio ............................ 137
[Link] Configure internet connection with proxy using RobotStudio ............... 138
3.1.9 Connected Services information ................................................................ 139
3.1.10 Troubleshooting ...................................................................................... 149
[Link] Server connectivity troubleshooting ................................................ 149
[Link] 3G Connectivity troubleshooting ..................................................... 150
[Link] 4G Connectivity troubleshooting ..................................................... 151
[Link] How to get Connected Services Embedded logs from the controller ...... 152
[Link] Connected Services Embedded troubleshooting logs ......................... 153
3.1.11 Network topology scenarios ...................................................................... 155

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4 Motion performance 165

4.1 Absolute Accuracy [3101-x] ................................................................................. 165
4.1.1 About Absolute Accuracy ......................................................................... 165
4.1.2 Useful tools ............................................................................................ 167
4.1.3 Configuration ......................................................................................... 168
4.1.4 Maintenance .......................................................................................... 170
[Link] Maintenance that affect the accuracy .............................................. 170
[Link] Loss of accuracy ......................................................................... 172
4.1.5 Compensation theory ............................................................................... 173
[Link] Error sources .............................................................................. 173
[Link] Absolute Accuracy compensation ................................................... 174
4.1.6 Preparation of Absolute Accuracy robot ...................................................... 176
[Link] ABB calibration process ................................................................ 176
[Link] Birth certificate ............................................................................ 178
[Link] Compensation parameters ............................................................ 179
4.1.7 Cell alignment ........................................................................................ 180
[Link] Overview ................................................................................... 180
[Link] Measure fixture alignment ............................................................. 181
[Link] Measure robot alignment .............................................................. 182
[Link] Frame relationships ..................................................................... 183
[Link] Tool calibration ........................................................................... 184
4.2 Ultra Accuracy [3101-10] ..................................................................................... 185
4.2.1 About Ultra Accuracy ............................................................................... 185
4.2.2 Configuration ......................................................................................... 187
4.2.3 Compensation parameters ........................................................................ 188
4.3 Advanced Robot Motion 3100-1 ........................................................................... 189
4.4 Advanced Shape Tuning [included in 3100-1] ......................................................... 190
4.4.1 About Advanced Shape Tuning .................................................................. 190
4.4.2 Automatic friction tuning ........................................................................... 191
4.4.3 Manual friction tuning .............................................................................. 193
4.4.4 System parameters ................................................................................. 195
[Link] System parameters ...................................................................... 195
[Link] Setting tuning system parameters ................................................... 196
4.4.5 RAPID components ................................................................................. 197
4.5 Motion Process Mode [included in 3100-1] ............................................................. 198
4.5.1 About Motion Process Mode ..................................................................... 198
4.5.2 User-defined modes ................................................................................ 200
4.5.3 General information about robot tuning ....................................................... 202
4.5.4 Additional information .............................................................................. 205
4.6 Wrist Move [included in 3100-1] ........................................................................... 206
4.6.1 Introduction to Wrist Move ........................................................................ 206
4.6.2 Cut plane frame ...................................................................................... 208
4.6.3 RAPID components ................................................................................. 210
4.6.4 RAPID code, examples ............................................................................. 211
4.6.5 Troubleshooting ...................................................................................... 213

5 Motion supervision 215

5.1 World Zones [3106-1] ......................................................................................... 215
5.1.1 Overview of World Zones .......................................................................... 215
5.1.2 RAPID components ................................................................................. 217
5.1.3 Code examples ....................................................................................... 219
5.2 Collision Detection [3107-1] ................................................................................. 221
5.2.1 Overview ............................................................................................... 221
5.2.2 Limitations ............................................................................................. 223
5.2.3 What happens at a collision ....................................................................... 224
5.2.4 Additional information .............................................................................. 226
5.2.5 Configuration and programming facilities ..................................................... 227
[Link] System parameters ...................................................................... 227

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[Link] RAPID components ...................................................................... 229

[Link] Signals ...................................................................................... 230
5.2.6 How to use Collision Detection .................................................................. 231
[Link] Set up system parameters ............................................................. 231
[Link] Adjust supervision from FlexPendant .............................................. 232
[Link] Adjust supervision from RAPID program .......................................... 233
[Link] How to avoid false triggering ......................................................... 234
5.3 Collision Avoidance [3150-1] ............................................................................... 235
5.4 SafeMove Assistant ........................................................................................... 238

6 Motor control 241

6.1 Independent Axis [3111-1] .................................................................................. 241
6.1.1 Overview ............................................................................................... 241
6.1.2 System parameters ................................................................................. 243
6.1.3 RAPID components ................................................................................. 244
6.1.4 Code examples ....................................................................................... 245
6.2 Tool Control [3109-1] ......................................................................................... 247
6.2.1 Overview ............................................................................................... 247
6.2.2 Servo tool movements ............................................................................. 248
6.2.3 Tip management ..................................................................................... 249
6.2.4 Supervision ............................................................................................ 251
6.2.5 RAPID components ................................................................................. 252
6.2.6 System parameters ................................................................................. 253
6.2.7 Commissioning and service ...................................................................... 258
6.2.8 Mechanical unit calibrations ...................................................................... 260
6.2.9 RAPID code example ............................................................................... 261

7 RAPID program features 263

7.1 Path Recovery [3113-1] ...................................................................................... 263
7.1.1 Overview ............................................................................................... 263
7.1.2 RAPID components ................................................................................. 264
7.1.3 Store current path ................................................................................... 265
7.1.4 Path recorder ......................................................................................... 271
7.2 Multitasking [3114-1] .......................................................................................... 279
7.2.1 Introduction to Multitasking ....................................................................... 279
7.2.2 System parameters ................................................................................. 281
7.2.3 RAPID components ................................................................................. 283
7.2.4 Communication between tasks .................................................................. 284
[Link] Persistent variables ..................................................................... 284
[Link] Waiting for other tasks .................................................................. 286
[Link] Synchronizing between tasks ......................................................... 288
[Link] Using a dispatcher ....................................................................... 290
7.2.5 Other programming issues ........................................................................ 292
[Link] Share resource between tasks ....................................................... 292
[Link] Test if task controls mechanical unit ................................................ 293
[Link] taskid ........................................................................................ 294
[Link] Avoid heavy loops ....................................................................... 295

8 Communication with remote mounted disks 297

8.1 FTP&SFTP client [3116-1] ................................................................................... 297
8.1.1 Introduction to FTP&SFTP client ................................................................ 297
8.2 NFS Client [3117-1] ........................................................................................... 299
8.2.1 Introduction to NFS Client ......................................................................... 299

9 Applications for user interaction 301

9.1 RobotStudio Connect [3119-1] ............................................................................. 301
9.2 FlexPendant Base Apps ..................................................................................... 302
9.3 FlexPendant Independent Apps ........................................................................... 303

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10 Engineering tools 305

10.1 RobotWare Add-In ............................................................................................. 305
10.2 Path Corrections [3123-1] ................................................................................... 306
10.2.1 Overview ............................................................................................... 306
10.2.2 RAPID components ................................................................................. 308
10.2.3 Related RAPID functionality ...................................................................... 309
10.2.4 Code example ........................................................................................ 310
10.3 Auto Acknowledge Input ..................................................................................... 311

11 Tool control options 313

11.1 Servo Tool Change [3110-1] ................................................................................ 313
11.1.1 Overview ............................................................................................... 313
11.1.2 Requirements and limitations .................................................................... 314
11.1.3 Configuration ......................................................................................... 316
11.1.4 Connection relay ..................................................................................... 317
11.1.5 Tool change procedure ............................................................................ 319
11.1.6 Jogging servo tools with activation disabled ................................................. 320

Index 321

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 Overview of this manual

Overview of this manual

About this manual
This manual explains the basics of when and how to use various RobotWare options
and functions.

Usage
This manual can be used either as a reference to find out if an option is the right
choice for solving a problem, or as a description of how to use an option. Detailed
information regarding syntax for RAPID routines, and similar, is not described here,
but can be found in the respective reference manual.

Who should read this manual?

This manual is intended for robot programmers.

Prerequisites
The reader should...
• be familiar with industrial robots and their terminology.
• be familiar with the RAPID programming language.
• be familiar with system parameters and how to configure them.

References

Tip

All documents can be found via myABB Business Portal, [Link]/myABB.

Reference Document ID
Product specification - OmniCore C line 3HAC065034-001
Product specification - OmniCore E line 3HAC079823-001
Product specification - OmniCore V line 3HAC074671-001
Operating manual - RobotStudio 3HAC032104-001
Operating manual - OmniCore 3HAC065036-001
Operating manual - Integrator's guide OmniCore 3HAC065037-001
Technical reference manual - RAPID Instructions, Functions and 3HAC065038-001
Data types
Technical reference manual - RAPID Overview 3HAC065040-001
Technical reference manual - System parameters 3HAC065041-001
Application manual - Additional axes 3HAC082287-001
Application manual - MultiMove 3HAC089689-001
Product manual - OmniCore C30 Type A 3HAC089064-001
Product manual - OmniCore C30 3HAC060860-001
Product manual - OmniCore C90XT 3HAC073706-001

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Overview of this manual
Continued

Reference Document ID
Product manual - OmniCore E10 3HAC079399-001
Product manual - OmniCore V250XT Type B 3HAC087112-001
Product manual - OmniCore V400XT 3HAC081697-001

Revisions

Revision Description
A Released with RobotWare 7.0.
B Released with RobotWare 7.01.
The following updates are made in this revision:
• "Cyber security" replaced by "Cybersecurity" in entire manual.
• Updated the section Connected Services on page 115.
C Released with RobotWare 7.0.2.
The following updates are made in this revision:
• FlexPendant terminology updated in entire manual.
• Updated the section Summary of Connected Services paths in Flex-
Pendant on page 121.
D Released with RobotWare 7.1.
The following updates are made in this revision:
• Updated the section Connected Services on page 115.
• Added information about YuMi robots and Collision Detection, see
Collision detection for YuMi robots on page 221.
• Updated limitations for SFTP client, see Limitations on page 298.
E Released with RobotWare 7.2.
The following updates are made in this revision:
• Updated the section Connected Services on page 115.
• Information about the digital output MotSupOn updated in section
Signals on page 230.
• Section System parameters on page 66 updated with information about
how to adjust the values of the attributes RMQ Max Message Size and
RMQ Max No Of Messages.
• Updated sections due to remote mounted disk/virtual root changes:
Limitations on page 298 (FTP&SFTP client) and Limitations on page 299
(NFS Client).
F Released with RobotWare 7.3.
The following updates are made in this revision:
• Updated the section Connected Services on page 115.
G Released with RobotWare 7.4.
The following updates are made in this revision:
• Added the section Connected Services Embedded troubleshooting
logs on page 153.
• Updated the section Connected Services on page 115.
• Updated information regarding UTF-8, in Raw data communication on
page 41.
H Released with RobotWare 7.5.
• Updated limitation for Collision Avoidance [3150-1] on page 235.

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Continued

Revision Description
J Released with RobotWare 7.6.
• Added the section Auto Acknowledge Input on page 311.
• Updated limitation regarding lead-through, see Overview of World
Zones on page 215.
• Added the section SafeMove Assistant on page 238.
K Released with RobotWare 7.10.
• Added the option Servo Tool Change [3110-1] on page 313.
• Minor corrections.
• Removed statement that the instructions StorePath and RestorePath
are included in RobotWare base. They require option Path Recovery.
• Added information about deactivation/deactivation and trigger signals,
see Collision Avoidance [3150-1] on page 235.
• Minor corrections in Network topology scenarios on page 155.
• Minor corrections in Auto Acknowledge Input on page 311.
L Released with RobotWare 7.12.
• Updated the section Connected Services information on page 139.
• The function Collision Avoidance is now available for delta robots,
seeLimitations on page 236.
M Released with RobotWare 7.13.
• ABB Connected Services is the new name for ABB Ability Connected
Services.
• Added section Electronically Linked Motors on page 96.
• Updated the section Connected Services on page 115.
N Released with RobotWare 7.14.
• Added section Tool Control [3109-1] on page 247.
P Released with RobotWare 7.15.
• Updated the server error details in the section Advanced page on
page 143.
• Updated the section Limitations on page 298 for FTP&SFTP Client.
Q Released with RobotWare 7.16.
• Added information about singularities and Absolute Accuracy in Robot-
Studio.
• Added information about user configuration files for Collision Avoid-
ance.
• Added limitation in Independent Axis regarding tool control.
R Released with RobotWare 7.17.
• Added section Ultra Accuracy [3101-10] on page 185.
• Added section RAPID language and programming environment on
page 19.
• Minor corrections.
• Added note in section FTP&SFTP client [3116-1] on page 297
• Added note in section on page 299

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Continued

Revision Description
S Released with RobotWare 7.18.
• List of event logs added to section Introduction to User logs on page 79.
• Restructured the chapter RobotWare-OS. The following functionality
is removed from this manual because it is described in more detail in
TRM - RAPID Overview.
- Bit functionality
- Data search functionality
- Configuration functionality
- Process support functionality
- User message functionality
- RAPID support functionality
• Updated section RAPID language and programming environment on
page 19.
• Minor improvements.
T Released with RobotWare 7.19.
• Information about NFS versions updated in Introduction to NFS Client
on page 299.
• Added example with TRAP routine, see Path recorder on page 271.
• Section System parameters on page 66 updated with allowed values
for RMQ Max Message Size.
• Information related to the option WiFi [3013-2] is removed.
• Updated the section SafeMove Assistant on page 238.

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 Open source and 3rd party components

Open source and 3rd party components

Open source and 3rd party components
ABB products use software provided by third parties, including open source
software. The following copyright statements and licenses apply to various
components that are distributed inside the ABB software. Each ABB product does
not necessarily use all of the listed third party software components. Licensee
must fully agree and comply with these license terms or the user is not entitled to
use the product. Start using the ABB software means accepting also referred
license terms. The third party license terms apply only to the respective software
to which the license pertains, and the third party license terms do not apply to ABB
products. With regard to programs provided under the GNU general public license
and the GNU lesser general public license licensor will provide licensee on demand,
a machine-readable copy of the corresponding source code. This offer is valid for
a period of three years after delivery of the product.
ABB software is licensed under the ABB end user license agreement, which is
provided separately.

RobotWare
For RobotWare, there is license information in the folder \licenses in the RobotWare
distribution package.

OpenSSL
This product includes software developed by the OpenSSL Project for use in the
OpenSSL Toolkit. ([Link]
This product includes cryptographic software written by Eric Young
(eay@[Link]).
This product includes software written by Tim Hudson (tjh@[Link]).

CTM
For OleOS, the Linux based operating system used on the conveyor tracking
module (CTM), a list of copyright statements and licenses is available in the file
/etc/[Link] located on the CTM board and accessible via the console port or
by downloading the file over SFTP.
For the CTM application, a list of copyright statements and licenses is available in
the file /opt/[Link]/ctm/[Link] located on the CTM board and accessible
via the console port or by downloading the file over SFTP.

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 1 Introduction to RobotWare
1.1 Products, classes, and options

1 Introduction to RobotWare
1.1 Products, classes, and options

Software products
RobotWare is a family of software products from ABB Robotics. The products are
designed to make you more productive and lower your cost of owning and operating
a robot. ABB Robotics has invested many years into the development of these
products and they represent knowledge and experience based on several thousands
of robot installations.

Product classes
Within the RobotWare family, there are different classes of products:
Product classes Description
RobotWare-OS This is the operating system of the robot. RobotWare-OS provides
all the necessary features for fundamental robot programming and
operation. It is an inherent part of the robot, but can be provided
separately for upgrading purposes.
For a description of RobotWare-OS, see the product specification
for the robot controller.
RobotWare options These products are options that run on top of RobotWare-OS. They
are intended for robot users that need additional functionality for
motion control, communication, system engineering, or applications.

Note

Not all RobotWare options are described in this manual. Some op-
tions are more comprehensive and are therefore described in sep-
arate manuals.

Process application These are extensive packages for specific process application like
options spot welding, arc welding, and dispensing. They are primarily de-
signed to improve the process result and to simplify installation and
programming of the application.
The process application options are all described in separate
manuals.
RobotWare Add-ins A RobotWare Add-in is a self-contained package that extends the
functionality of the robot system.
Some software products from ABB Robotics are delivered as Add-
ins. For example track motion (IRT), positioner (IRP), and standalone
controller. For more information see the product specification for
the robot controller.
The purpose of RobotWare Add-ins is also that a robot program
developer outside of ABB can create options for the ABB robots,
and sell the options to their customers. For more information on
creating RobotWare Add-ins, contact your local ABB Robotics rep-
resentative at [Link]/contacts.

Option groups
For OmniCore, the RobotWare options have been gathered in groups, depending
on the customer benefit. The goal is to make it easier to understand the customer

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1.1 Products, classes, and options
Continued

value of the options. However, all options are purchased individually. The groups
are as follows:
Option groups Description
Motion performance Options that optimize the performance of your robot.
Motion coordination Options that make your robot coordinated with external equipment
or other robots.
Motion Events Options that supervises the position of the robot.
Motion functions Options that control the path of the robot.
Motion Supervision Options that supervises the movement of the robot.
Communication Options that make the robot communicate with other equipment.
(External PCs etc.)
Engineering tools Options for the advanced robot integrator.
Servo motor control Options that make the robot controller operate external motors, in-
dependent of the robot.

Note

Not all RobotWare options are described in this manual. Some options are more
comprehensive and are therefore described in separate manuals.

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 1 Introduction to RobotWare
1.2 RAPID language and programming environment

1.2 RAPID language and programming environment

General
RAPID is the primary programming language used for ABB Robotics, designed to
facilitate the control and automation of industrial robots. It is a high-level language
that is both powerful and user-friendly, making it accessible for both novice and
experienced programmers. Its syntax and structure are designed to be intuitive,
reducing the learning curve for new users.
RAPID is suitable for a wide range of applications, from simple pick-and-place
tasks to complex assembly operations. The language is designed to be reliable
and robust, ensuring consistent performance in industrial environments.

Key features of RAPID

RAPID uses a structured text format similar to other programming languages like
Python or C, which includes loops, conditionals, and variable handling. It excels
in handling complex motion commands, allowing precise control over robot
movements.
RAPID supports various data types and operations, enabling efficient data handling
and processing. Users can create custom functions and procedures, enhancing
the flexibility and adaptability of the programming environment.
It allows seamless communication with external devices and systems, making it
ideal for integrated automation solutions.
Overall, RAPID is a versatile and powerful tool that enhances the capabilities of
ABB robots, making automation more efficient and accessible.

Summary of the RAPID concept

• Hierarchical and modular program structure to support structured
programming and reuse
• Routines can be Functions or Procedures
• Local or global data and routines
• Data typing, including structured and array data types
• User defined names on variables, routines, and I/O
• Extensive program flow control
• Arithmetic and logical expressions
• Interrupt handling
• Error handling
• User defined instructions (appear as an inherent part of the system)
• Backward handler (user definition of how a procedure should behave when
stepping backwards)
• Many powerful built-in functions, for example mathematics and robot specific
• Unlimited language (no maximum number of variables etc., only memory
limited). Built-in RAPID support in user interfaces, for example user defined
pick lists, facilitate working with RAPID.
• Support for Unicode symbols in strings and comments

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1.2 RAPID language and programming environment
Continued

Ease of use
Creating and editing RAPID programs is done using the integrated code editors
in RobotStudio or on the FlexPendant. Additionally, there is an app for the
FlexPendant called Wizard, where RAPID programming is further simplified to
block programming.
RAPID programs can range from simple movement procedures to complex
structures including sending and receiving data from sensors, cameras, I/O devices,
other machines, and more. This to enable a highly flexible automation, utilizing the
robot's capability.

Simple RAPID program examples

Hello world
MODULE HelloWorld
PROC main()
TPWrite "Hello, World!";
ENDPROC
ENDMODULE
In this example:
The module HelloWorld defines a module named HelloWorld.
PROC main() defines a procedure named main.
TPWrite "Hello, World!"; is the command that outputs "Hello, World!" to the
FlexPendant.

Displaying messages on the FlexPendant

MODULE MainModule
VAR num length;
VAR num width;
VAR num area;

PROC main()
length := 10;
width := 5;
area := length * width;
TPWrite "The area of the rectangle is " \Num:=area;
ENDPROC
ENDMODULE
This program will calculate the area of a rectangle and show the answer on the
FlexPendant.
The area of the rectangle is 50

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1.2 RAPID language and programming environment
Continued

Draw a square
The robot is holding a pen above a piece of paper on a table. This program will
make the robot move the tip of the pen down to the paper and then draw a square.

xx0700000362

PERS tooldata tPen := [ TRUE, [[200, 0, 30], [1, 0, 0 ,0]], [0.8,

[62, 0, 17], [1, 0, 0, 0], 0, 0, 0]];
CONST robtarget p10 := [ [600, -100, 800], [0.707170, 0, 0.707170,
0], [0, 0, 0, 0], [ 9E9, 9E9, 9E9, 9E9, 9E9, 9E9] ];
CONST robtarget p20 := [ [600, 100, 800], [0.707170, 0, 0.707170,
0], [0, 0, 0, 0], [ 9E9, 9E9, 9E9, 9E9, 9E9, 9E9] ];
CONST robtarget p30 := [ [800, 100, 800], [0.707170, 0, 0.707170,
0], [0, 0, 0, 0], [ 9E9, 9E9, 9E9, 9E9, 9E9, 9E9] ];
CONST robtarget p40 := [ [800, -100, 800], [0.707170, 0, 0.707170,
0], [0, 0, 0, 0], [ 9E9, 9E9, 9E9, 9E9, 9E9, 9E9] ];

PROC main()
MoveL p10, v200, fine, tPen;
MoveL p20, v200, fine, tPen;
MoveL p30, v200, fine, tPen;
MoveL p40, v200, fine, tPen;
MoveL p10, v200, fine, tPen;
ENDPROC

Draw an arc
To add a curve or arc to the previous program, the instruction MoveC is added.
MoveL p10, v500, fine, tPen;
MoveC p20, p30, v500, fine, tPen;
MoveL p40, v500, fine, tPen;

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1.2 RAPID language and programming environment
Continued

xx0700000364

References
The RAPID programming language is described in detail in the following documents.
What do you want to know Where to read about it
• More detailed information about the functionality Technical reference manual - RAP-
• What instructions are there for a specific cat- ID Overview
egory, for example, move instructions
• Descriptions of specific functionality, for example,
interrupts or error handling
• Information about a specific instruction, function, Technical reference manual - RAP-
or data type ID Instructions, Functions and
Data types
• Details about how the robot controller handles Technical reference manual - RAP-
different parts of RAPID ID kernel

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2.1 Motion settings and motion programming

2 RobotWare-OS, basic functionality in RobotWare

2.1 Motion settings and motion programming

Introduction
Point-to-point (PTP) motion programming involves moving the robot from one
specific pose to another. Each pose represents a precise position and orientation
in space. This method ensures high accuracy, and the detail level can be flexible
to adapt to the specific application.
The RAPID programming language offers both simple movement instructions and
combinations with setting I/O signals or triggering events. Many of the software
options include instructions, functions, and data types that simplify specific parts
of the programming.

Motion settings
Motion settings involve configuring parameters that define how the robot moves.
These settings include:
• Speed: Determines the velocity at which the robot's joints or end effector
move. It can be set globally or for specific motion instructions.
• Acceleration and Deceleration: Controls the rate at which the robot speeds
up or slows down. Proper settings ensure smooth transitions and prevent
mechanical stress.
• Zone Data: Defines the precision of the robot's path. Smaller zones result in
more accurate movements but may reduce speed, while larger zones allow
faster movements with less precision.
• Tool and Work Object Data: Specifies the dimensions and properties of the
tool attached to the robot and the work object being manipulated. Accurate
data ensures correct positioning and movement.

Motion programming
Key aspects for motion programming include:
• Move instructions: Commands that direct the robot to move to specific
positions. Common instructions include:
- MoveJ: Joint movement to a target position.
- MoveL: Linear movement to a target position.
- MoveC: Circular movement through intermediate points.
• Path and Positioning: Defining the robot's path involves specifying
coordinates and orientations. Positions can be absolute or relative to a
reference frame.
• Synchronization: Ensures coordinated movements between multiple robots
or external devices. Synchronization can be achieved using signals or shared
data.
• Error Handling: Implementing routines to manage and respond to errors
during motion execution. This includes retry mechanisms and safe stops.

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2.1 Motion settings and motion programming
Continued

Related information

Options Described in
Motion Technical reference manual - RAPID Over-
view
All RAPID instructions, functions, and data Technical reference manual - RAPID Instruc-
types tions, Functions and Data types

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2.2 Input and output signals

2.2 Input and output signals

Introduction
ABB robots can utilize both analog and digital I/O signals to interact with external
devices and systems.
The digital input (DI) signals receive binary data (0 or 1) from external sensors or
switches, indicating states such as on/off or open/closed. The digital output (DO)
signals send binary data to control external devices like relays, lights, or actuators.
The analog input (AI) signals receive continuous data from external sensors,
representing variables such as temperature, pressure, or position. The analog
output (AO) signals send continuous data to control external devices, allowing for
precise adjustments in operations like motor speed or valve position.
The I/O signals are mapped and configured using RobotStudio or directly on the
teach pendant. Each signal can be named and grouped for easier management.
Proper configuration ensures seamless integration with external systems, enabling
efficient communication and control.

Network protocols
A variety of network protocols can be used for I/O communication, ensuring
seamless integration with external systems. For example, PROFINET, EtherNet/IP,
DeviceNet, CC-link.
Safe communication is also possible, using PROFIsafe or CIP safety.
The specific network protocol options are described in their respective application
manual.

Related information

Options Described in
I/O principles Technical reference manual - RAPID Overview, section I/O principles

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2.3 Functionality for user interaction

2.3 Functionality for user interaction

Introduction
The RAPID programming language facilitates user interaction through instructions
and functions that allow the robot to communicate with the operator, gather input,
and display information. This can also include updating data or selecting alternatives
adapted to the final application.
Examples of user interaction instructions and functions:
• UIMsgBox - Write message to FlexPendant
• UIDnumEntry/UINumEntry - Read a numeric value from the FlexPendant
• UIListView - Select item in a list from the FlexPendant

Related information

Options Described in
I/O principles Technical reference manual - RAPID Over-
view, section Communication

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2.4 File handling

2.4 File handling

Introduction
RobotWare includes robust file handling capabilities that allow users to manage
and manipulate files efficiently. Key functionalities include:
• File transfer: Users can transfer files between the robot controller and external
devices such as PCs or network storage. This is essential for backing up
programs, updating software, and sharing data.
• File operations: RobotWare supports various file operations, including
creating, reading, writing, and deleting files. These operations can be
performed using RAPID commands, enabling automated file management
within robot programs.
• Data logging: Users can log data to files for monitoring and analysis purposes.
This includes recording operational parameters, error logs, and performance
metrics.
• Configuration files: RobotWare allows users to manage configuration files
that define system settings, I/O mappings, and other critical parameters.
These files ensure consistent and reliable robot operation.
• Integration with external systems: File handling in RobotWare facilitates
integration with external systems, enabling seamless communication and
data exchange. This is crucial for complex automation setups where multiple
devices need to interact.

Related information

Options Described in
File handling Technical reference manual - RAPID Over-
view, section File operation functions
File and I/O device handling File and I/O device handling on page 36

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2.5.1 Cyclically evaluated logical conditions

2.5 Cyclic bool, cyclically evaluated logical conditions

2.5.1 Cyclically evaluated logical conditions

Purpose
The purpose of cyclically evaluated logical conditions, Cyclic bool, is to allow a
RAPID programmer to connect a logical condition to a persistent boolean variable.
The logical condition will be evaluated every 12 ms and the result will be written
to the connected variable.

What is included
The RobotWare base functionality Cyclic bool includes:
• instructions for setting up Cyclic bool: SetupCyclicBool,
RemoveCyclicBool, RemoveAllCyclicBool
• functions for retrieving the status of Cyclic bool:
GetMaxNumberOfCyclicBool, GetNextCyclicBool,
GetNumberOfCyclicBool.

Basic approach
This is the general approach for using Cyclic bool. For more detailed examples of
how this is done, see Cyclic bool examples on page 31.
1 Declare a persistent boolean variable, for example:
PERS bool cyclicbool1;
2 Connect a logical condition to the variable, for example:
SetupCyclicBool cyclicbool1, doSafetyIsOk = 1;
3 Use the variable when programming, for example:
WHILE cyclicbool1 = 1 DO
! Do what’s only allowed when all safety is ok
...
ENDWHILE
4 Remove connection when no longer useful, for example:
RemoveCyclicBool cyclicbool1;

Restart and reset behavior

The table below describes the functionality of Cyclic bool when the program pointer
is moved or when the controller is restarted.
Action Description
Program pointer to The behavior when the program pointer is set to main is configur-
main able, see Configuration on page 29.
Restart or power fail This will have no effect.
All connected Cyclic bool conditions will remain and the evaluation
will be restarted immediately.
Reset RAPID This will remove all connected Cyclic bool conditions.
Reset system

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2.5.1 Cyclically evaluated logical conditions
Continued

Configuration
The following behavior of the Cyclic bool functionality can be configured:
Parameter Description
RemoveAtPpToMain It is possible to configure if the cyclically evaluated logical conditions
shall be removed or not when setting the program pointer to main.
• On - remove.
• Off - do not remove (default behavior).
ErrorMode It is possible to configure which error mode to use when the evalu-
ation of a Cyclic bool fails.
• SysStopError i - stop RAPID execution and produce an error
log (default behavior).
• Warning - produce a warning log.
• None - do nothing.
RecoveryMode It is possible to configure if a failing Cyclic bool shall be recovered
or not.
• On - try to recover the evaluation of a failing Cyclic bool (de-
fault behavior).
• Off - do not try to recover the evaluation of a Cyclic bool.
i Error mode SysStopError can only be combined with RecoveryMode - "On".
For more information, see System parameters on page 34.

Syntax
SetupCyclicBool Flag Cond [\Signal]
Flag shall be of:
• Data type: bool
- Object type: PERS or TASK PERS
Cond shall be a bool expression that may consist of:
• Data types: num, dnum and bool
- Object type: PERS, TASK PERS, or CONST
• Data types: signaldi, signaldo or physical di and do
- Object type: VAR
• Operands: 'NOT', 'AND', 'OR', 'XOR', '=', '(', ')'
\Signal shall be of:
• Object type: signaldo

RemoveCyclicBool Flag
Flag shall be of:
• Data type: bool
- Object type: PERS or TASK PERS

Limitations
• Records and arrays are not allowed in the logical condition.
• A maximum of 60 conditions can be connected at the same time.

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2.5.1 Cyclically evaluated logical conditions
Continued

• Any PERS num or dnum, CONST num or dnum or literal num or dnum used in a
condition must be of integer type. If using any decimal value this will cause
a fatal error.

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2.5.2 Cyclic bool examples

2.5.2 Cyclic bool examples

Using digital input and output signals

! Wait until all signals are set
PERS bool cyclicbool1 := FALSE;

PROC main()
SetupCyclicBool cyclicbool1, di1=1 AND do2=1;
WaitUntil cyclicbool1=TRUE;
! All is ok
...
! Remove connection when no longer in use
RemoveCyclicBool cyclicbool1;
ENDPROC

Using bool variables

! Wait until all flags are TRUE
PERS bool cyclicbool1 := FALSE;
TASK PERS bool flag1 := FALSE;
PERS bool flag2 := FALSE;

PROC main()
SetupCyclicBool cyclicbool1, flag1=TRUE AND flag2=TRUE;
WaitUntil cyclicbool1=TRUE;
! All is ok
...
! Remove connection when no longer in use
RemoveCyclicBool cyclicbool1;
ENDPROC

Using num and dnum variables

! Wait until all conditions are met
PERS bool cyclicbool1 := FALSE;
PERS bool cyclicbool2 := FALSE;
PERS num num1 := 0;
PERS dnum1 := 0;

PROC main()
SetupCyclicBool cyclicbool1, num1=7 OR dnum1=10000000;
SetupCyclicBool cyclicbool2, num1=8 OR dnum1=11000000;
WaitUntil cyclicbool1=TRUE;
...
WaitUntil cyclicbool2=TRUE;
...
! Remove all connections when no longer in use
RemoveAllCyclicBool;
ENDPROC

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2.5.2 Cyclic bool examples
Continued

Using alias variables

! Wait until all conditions are met
ALIAS bool aliasBool;
ALIAS num aliasNum;
ALIAS dnum aliasDnum;

PERS bool cyclicbool1 := FALSE;

PERS aliasBool flag1 := FALSE;
PERS aliasNum num1 := 0;
PERS aliasDnum dnum1 := 0;

PROC main()
SetupCyclicBool cyclicbool1, flag1=TRUE AND (num1=7 OR
dnum1=10000000);
WaitUntil cyclicbool1=TRUE;
! All is ok
...
! Remove connection when no longer in use
RemoveCyclicBool cyclicbool1;
ENDPROC

Using user defined constants for comparison

! Wait until all conditions are met
PERS bool cyclicbool1;
PERS bool flag1 := FALSE;
PERS num num1 := 0;
PERS dnum dnum1 := 0;
CONST bool MYTRUE := TRUE;
CONST num NUMLIMIT := 10;
CONST dnum DNUMLIMIT := 10000000;

PROC main()
SetupCyclicBool cyclicbool1, flag1=MYTRUE AND num1=NUMLIMIT AND
dnum1=DNUMLIMIT;
WaitUntil cyclicbool1=TRUE;
! All is ok
...
! Remove connection when no longer in use
RemoveCyclicBool cyclicbool1;
ENDPROC

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2.5.2 Cyclic bool examples
Continued

Handing over arguments by reference

If the instruction SetupCyclicBool is used inside a called procedure, it is possible
to hand over conditions as arguments to that procedure.
Using conditions passed by reference works only for SetupCyclicBool. Conditions
passed by reference has the same restrictions as conditions for SetupCyclicBool.
This functionality works regardless if the modules are Nostepin or has any other
module attributes.
MODULE MainModule
CONST robtarget p10 := [[600,500,225.3], [1,0,0,0], [1,1,0,0],
[11,12.3,9E9,9E9,9E9,9E9]];
PERS bool m1;
PERS bool Flag2 := FALSE;

PROC main()
! The Expression (di_1 = 1) OR Flag2 = TRUE shall be
! used by SetupCyclicBool
my_routine (di_1 = 1) OR Flag2 = TRUE;
ENDPROC

PROC my_routine(bool X)
! It is possible to pass arguments between several procedures
MySetCyclicBool X;
ENDPROC

PROC MySetCyclicBool (bool Y)

RemoveCyclicBool m1;
! Only SetupCyclicBool can pass arguments
SetupCyclicBool m1, Y;
! If conditions passed by reference shall be used by any other
! instruction, the condition must be setup with SetupCyclicBool
! before it can be used.
WaitUntil m1;
MoveL p10, v1000, z30, tool2;
ENDPROC
ENDMODULE

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2.5.3 System parameters

2.5.3 System parameters

About the system parameters

This is a brief description of the system parameters used by Cyclic bool. For more
information about the parameters, see Technical reference manual - System
parameters.

Type Cyclic bool settings

The system parameters used by Cyclic bool belong to the type Cyclic bool settings
in topic Controller.
Parameter Description
Name There can be only one instance of each allowed value, that
is a maximum of three instances in the system. All three in-
stances will be installed in the system (default) and cannot
be removed.
• RemoveAtPpToMain
• ErrorMode
• RecoveryMode
RemoveAtPpToMain The action value RemoveAtPpToMain is used to configure
if a connected Cyclic bool shall be removed or not when
setting the program pointer to Main.
ErrorMode The action value ErrorMode is used to configure which error
mode to use when evaluation fails.
RecoveryMode The action value RecoveryMode is used to configure which
recovery mode to use when evaluation fails.

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2.5.4 RAPID components

2.5.4 RAPID components

About the RAPID components

This is an overview of all RAPID instructions, functions, and data types in Cyclic
bool.
For more information, see Technical reference manual - RAPID Instructions,
Functions and Data types

Instructions

Instruction Description
SetupCyclicBool SetupCyclicBool connects a logical condition to a boolean
variable.
RemoveCyclicBool RemoveCyclicBool removes a specific connected logical con-
dition.
RemoveAllCyclicBool RemoveAllCyclicBool removes all connected logical condi-
tions.

Functions

Function Description
GetMaxNumberOfCyclicBool GetMaxNumberOfCyclicBool retrieves the maximum
number of cyclically evaluated logical condition that can
be connected at the same time.
GetNextCyclicBool GetNextCyclicBool retrieves the name of a connected
cyclically evaluated logical condition.
GetNumberOfCyclicBool GetNumberOfCyclicBool retrieves the number of a
connected cyclically evaluated logical condition.
IsCyclicBool IsCyclicBool is used to test if a persistent boolean is
a Cyclic bool or not, i.e. if a logical condition has been
connected to the persistent boolean variable with the
instruction SetupCyclicBool.

Data types
Cyclic bool includes no data types.

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2.6.1 Introduction to file and I/O device handling

2.6 File and I/O device handling

2.6.1 Introduction to file and I/O device handling

About file and I/O device handling

The RobotWare file and I/O device handling gives the robot programmer control
of files and fieldbuses from the RAPID code. This can, for example, be useful for:
• Reading from a bar code reader.
• Writing production statistics to a log file or to a printer.
• Transferring data between the robot and a PC.
The functionality for file and I/O device handling can be divided into groups:
Functionality group Description
Binary and character based commu- Basic communication functionality. Communication
nication with binary or character based files or I/O devices.
Raw data communication Data packed in a container. Especially intended for
fieldbus communication.
File and directory management Browsing and editing of file structures.

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[Link] Overview

2.6.2 Binary and character based communication

[Link] Overview

Purpose
The purpose of binary and character based communication is to:
• store information in a remote memory or on a remote disk
• let the robot communicate with other devices

What is included
To handle binary and character based communication, RobotWare gives you access
to:
• instructions for manipulations of a file or I/O device
• instructions for writing to file or I/O device
• instruction for reading from file or I/O device
• functions for reading from file or I/O device.

Basic approach
This is the general approach for using binary and character based communication.
For a more detailed example of how this is done, see Code examples on page 39.
1 Open a file or I/O device.
2 Read or write to the file or I/O device.
3 Close the file or I/O device.

Limitations
Access to files and I/O devices cannot be performed from different RAPID tasks
simultaneously. Such an access is performed by all instruction in binary and
character based communication, as well as WriteRawBytes and ReadRawBytes.
E.g. if a ReadBin instruction is executed in one task, it must be ready before a
WriteRawBytes can execute in another task.

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[Link] RAPID components

[Link] RAPID components

Data types
This is a brief description of each data type used for binary and character based
communication. For more information, see the respective data type in Technical
reference manual - RAPID Instructions, Functions and Data types.
Data type Description
iodev iodev contains a reference to a file or I/O device. It can be linked to the
physical unit with the instruction Open and then used for reading and
writing.

Instructions
This is a brief description of each instruction used for binary and character based
communication. For more information, see the respective instruction in Technical
reference manual - RAPID Instructions, Functions and Data types.
Instruction Description
Open Open is used to open a file or I/O device for reading or writing.
Close Close is used to close a file or I/O device.
Rewind Rewind sets the file position to the beginning of the file.
Write Write is used to write to a character based file or I/O device.
WriteBin WriteBin is used to write a number of bytes to a binary I/O device or
file.
WriteStrBin WriteStrBin is used to write a string to a binary I/O device or file.
WriteAnyBin WriteAnyBin is used to write any type of data to a binary I/O device or
file.
ReadAnyBin ReadAnyBin is used to read any type of data from a binary I/O device
or file.

Functions
This is a brief description of each function used for binary and character based
communication. For more information, see the respective instruction in Technical
reference manual - RAPID Instructions, Functions and Data types.
Function Description
ReadNum ReadNum is used to read a number from a character based file or I/O device.
ReadStr ReadStr is used to read a string from a character based file or I/O device.
ReadBin ReadBin is used to read a byte (8 bits) from a file or I/O device. This function
works on both binary and character based files or I/O devices.
ReadStrBin ReadStrBin is used to read a string from a binary I/O device or file.

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[Link] Code examples

[Link] Code examples

Communication with character based file

This example shows writing and reading to and from a character based file. The
line "The number is :8" is written to [Link]. The contents of [Link] is then
read and the output to the FlexPendant is "The number is :8" followed by "The
number is 8".
PROC write_to_file()
VAR iodev file;
VAR num number:= 8;
Open "HOME:" \File:= "[Link]", file;
Write file, "The number is :"\Num:=number;
Close file;
ENDPROC

PROC read_from_file()
VAR iodev file;
VAR num number;
VAR string text;

Open "HOME:" \File:= "[Link]", file \Read;

TPWrite ReadStr(file);
Rewind file;
text := ReadStr(file\Delim:=":");
number := ReadNum(file);
Close file;
TPWrite text \Num:=number;
ENDPROC

Communication with binary file

In this example, the string "Hello", the current robot position and the string "Hi" is
written to the binary file.
PROC write_bin_chan()
VAR iodev file1;
VAR num out_buffer{20};
VAR num input;
VAR robtarget target;

Open "HOME:" \File:= "[Link]", file1 \Bin;

! Write control character enq

out_buffer{1} := 5;
WriteBin file1, out_buffer, 1;

! Wait for control character ack

input := ReadBin (file1 \Time:= 0.1);
IF input = 6 THEN
! Write "Hello" followed by new line
WriteStrBin file1, "Hello\0A";

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Continued

! Write current robot position

target := CRobT(\Tool:= tool1\WObj:= wobj1);
WriteAnyBin file1, target;

! Set start text character (2=start text)

out_buffer{1} := 2;

! Set character "H" (72="H")

out_buffer{2} := 72;

! Set character "i"

out_buffer{3} := StrToByte("i"\Char);

! Set new line character (10=new line)

out_buffer{4} := 10;

! Set end text character (3=end text)

out_buffer{5} := 3;

! Write the buffer with the line "Hi"

! to the file
WriteBin file1, out_buffer, 5;
ENDIF
Close file1;
ENDPROC

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[Link] Overview

2.6.3 Raw data communication

[Link] Overview

Purpose
The purpose of raw data communication is to pack different type of data into a
container and send it to a file or I/O device, and to read and unpack data. This is
particularly useful when communicating via a fieldbus, such as DeviceNet.

What is included
To handle raw data communication, RobotWare gives you access to:
• instructions used for handling the contents of a rawbytes variable
• instructions for reading and writing raw data
• a function to get the valid data length of a rawbytes variable.

Basic approach
This is the general approach for raw data communication. For a more detailed
example of how this is done, see Write and read rawbytes on page 43.
1 Pack data into a rawbytes variable (data of type num, byte or string).
2 Write the rawbytes variable to a file or I/O device.
3 Read a rawbytes variable from a file or I/O device.
4 Unpack the rawbytes variable to num, byte or string.

Limitations
Device command communication also require the base functionality Device
Command Interface and the option for the industrial network in question.
Access to files and I/O devices cannot be performed from different RAPID tasks
simultaneously. Such an access is performed by all instruction in binary and
character based communication, as well as WriteRawBytes and ReadRawBytes.
For example, if a ReadBin instruction is executed in one task, then it must be ready
before a WriteRawBytes instruction can execute in another task.

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[Link] RAPID components

[Link] RAPID components

Data types
This is a brief description of each data type used for raw data communication. For
more information, see the respective data type in Technical reference
manual - RAPID Instructions, Functions and Data types.
Data type Description
rawbytes rawbytes is used as a general data container. It can be filled with any
data of types num, byte, or string. It also stores the length of the
valid data (in bytes).
rawbytes can contain up to 1024 bytes of data. The supported data
formats are listed in the instruction PackRawBytes, in Technical refer-
ence manual - RAPID Instructions, Functions and Data types.

Instructions
This is a brief description of each instruction used for raw data communication.
For more information, see the respective instruction in Technical reference
manual - RAPID Instructions, Functions and Data types.
Instruction Description
ClearRawBytes ClearRawBytes is used to set all the contents of a rawbytes variable
to 0. The length of the valid data in the rawbytes variable is set to 0.
ClearRawBytes can also be used to clear only the last part of a
rawbytes variable.
PackRawBytes PackRawBytes is used to pack the contents of variables of type num,
byte or string into a variable of type rawbytes.
UnpackRawBytes UnpackRawBytes is used to unpack the contents of a variable of type
rawbytes to variables of type byte, num or string.
CopyRawBytes CopyRawBytes is used to copy all or part of the contents from one
rawbytes variable to another.
WriteRawBytes WriteRawBytes is used to write data of type rawbytes to any binary
file or I/O device.
ReadRawBytes ReadRawBytes is used to read data of type rawbytes from any binary
file or I/O device.

Functions
This is a brief description of each function used for raw data communication. For
more information, see the respective function in Technical reference manual - RAPID
Instructions, Functions and Data types.
Function Description
RawBytesLen RawBytesLen is used to get the valid data length in a rawbytes vari-
able.

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[Link] Code examples

[Link] Code examples

About the examples

These examples are simplified demonstrations of how to use rawbytes. For a
more realistic example of how to use rawbytes in DeviceNet communication, see
Write rawbytes to DeviceNet on page 51.

Write and read rawbytes

This example shows how to pack data into a rawbytes variable and write it to a
device. It also shows how to read and unpack a rawbytes variable.
VAR iodev io_device;
VAR rawbytes raw_data;

PROC write_rawbytes()
VAR num length := 0.2;
VAR string length_unit := "meters";

! Empty contents of raw_data

ClearRawBytes raw_data;

! Add contents of length as a 4 byte float

PackRawBytes length, raw_data,(RawBytesLen(raw_data)+1) \Float4;

! Add the string length_unit

PackRawBytes length_unit, raw_data,(RawBytesLen(raw_data)+1)
\ISOLatin1Encoding;

Open "HOME:" \File:= "[Link]", io_device \Bin;

! Write the contents of raw_data to io_device

WriteRawBytes io_device, raw_data;

Close io_device;
ENDPROC

PROC read_rawbytes()
VAR string answer;

! Empty contents of raw_data

ClearRawBytes raw_data;

Open "HOME:" \File:= "[Link]", io_device \Bin;

! Read from io_device into raw_data

ReadRawBytes io_device, raw_data \Time:=1;

Close io_device;

! Unpack raw_data to the string answer

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Continued

UnpackRawBytes raw_data, 1, answer \ISOLatin1Encoding:=10;

ENDPROC

Copy rawbytes
In this example, all data from raw_data_1 and raw_data_2 is copied to
raw_data_3.
VAR rawbytes raw_data_1;
VAR rawbytes raw_data_2;
VAR rawbytes raw_data_3;
VAR num my_length:=0.2;
VAR string my_unit:=" meters";

PackRawBytes my_length, raw_data_1, 1 \Float4;

PackRawBytes my_unit, raw_data_2, 1 \ISOLatin1Encoding;

! Copy all data from raw_data_1 to raw_data_3

CopyRawBytes raw_data_1, 1, raw_data_3, 1;

! Append all data from raw_data_2 to raw_data_3

CopyRawBytes raw_data_2, 1, raw_data_3,(RawBytesLen(raw_data_3)+1);

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[Link] Overview

2.6.4 File and directory management

[Link] Overview

Purpose
The purpose of the file and directory management is to be able to browse and edit
file structures (directories and files).

What is included
To handle file and directory management, RobotWare gives you access to:
• instructions for handling directories
• a function for reading directories
• instructions for handling files on a file structure level
• functions to retrieve size and type information.

Basic approach
This is the general approach for file and directory management. For more detailed
examples of how this is done, see Code examples on page 47.
1 Open a directory.
2 Read from the directory and search until you find what you are looking for.
3 Close the directory.

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[Link] RAPID components

[Link] RAPID components

Data types
This is a brief description of each data type used for file and directory management.
For more information, see the respective data type in Technical reference
manual - RAPID Instructions, Functions and Data types.
Data type Description
dir dir contains a reference to a directory on disk or network. It can be linked
to the physical directory with the instruction OpenDir.

Instructions
This is a brief description of each instruction used for file and directory management.
For more information, see the respective instruction in Technical reference
manual - RAPID Instructions, Functions and Data types.
Instruction Description
OpenDir OpenDir is used to open a directory.
CloseDir CloseDir is used to close a directory.
MakeDir MakeDir is used to create a new directory.
RemoveDir RemoveDir is used to remove an empty directory.
CopyFile CopyFile is used to make a copy of an existing file.
RenameFile RenameFile is used to give a new name to an existing file. It can also be
used to move a file from one place to another in the directory structure.
RemoveFile RemoveFile is used to remove a file.

Functions
This is a brief description of each function used for file and directory management.
For more information, see the respective instruction in Technical reference
manual - RAPID Instructions, Functions and Data types.
Function Description
ReadDir ReadDir is used to retrieve the name of the next file or subdirectory under
a directory that has been opened with the instruction OpenDir.
Note that the first items read by ReadDir are . (full stop character) and ..
(double full stop characters) symbolizing the current directory and its parent
directory.
FileSize FileSize is used to retrieve the size (in bytes) of the specified file.
FSSize FSSize (File System Size) is used to retrieve the size (in bytes) of the file
system in which a specified file [Link] can either retrieve the total
size or the free size of the system.
IsFile IsFile test if the specified file is of the specified type. It can also be used
to test if the file exist at all.

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[Link] Code examples

[Link] Code examples

List files
This example shows how to list the files in a directory, excluding the directory itself
and its parent directory (. and ..).
PROC lsdir(string dirname)
VAR dir directory;
VAR string filename;

! Check that dirname really is a directory

IF IsFile(dirname \Directory) THEN
! Open the directory
OpenDir directory, dirname;

! Loop though the files in the directory

WHILE ReadDir(directory, filename) DO
IF (filename <> "." AND filename <> ".." THEN
TPWrite filename;
ENDIF
ENDWHILE

! Close the directory

CloseDir directory;
ENDIF
ENDPROC

Move file to new directory

This is an example where a new directory is created, a file renamed and moved to
the new directory and the old directory is removed.
VAR dir directory;
VAR string filename;

! Create the directory newdir

MakeDir "HOME:/newdir";

! Rename and move the file

RenameFile "HOME:/olddir/myfile", "HOME:/newdir/yourfile";

! Remove all files in olddir

OpenDir directory, "HOME:/olddir";
WHILE ReadDir(directory, filename) DO
IF (filename <> "." AND filename <> ".." THEN
RemoveFile "HOME:/olddir/" + filename;
ENDIF
ENDWHILE
CloseDir directory;

! Remove the directory olddir (which must be empty)

RemoveDir "HOME:/olddir";

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Continued

Check sizes
In this example, the size of the file is compared with the remaining free space on
the file system. If there is enough space, the file is copied.
VAR num freefsyssize;
VAR num f_size;

! Get the size of the file

f_size := FileSize("HOME:/myfile");

! Get the free size on the file system

freefsyssize := FSSize("HOME:/myfile" \Free);

! Copy file if enough space free

IF f_size < freefsyssize THEN
CopyFile "HOME:/myfile", "HOME:/yourfile";
ENDIF

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[Link] Introduction to Device Command Interface

2.6.5 Device Command Interface, communicating with I/O devices

[Link] Introduction to Device Command Interface

Purpose
Device Command Interface provides an interface to communicate with I/O devices
on industrial networks.
This interface is used together with raw data communication, see Raw data
communication on page 41.

What is included
The RobotWare base functionality Device Command Interface gives you access
to:
• Instruction used to create a DeviceNet header.

Basic approach
This is the general approach for using Device Command Interface. For a more
detailed example of how this is done, see Write rawbytes to DeviceNet on page 51.
1 Add a DeviceNet header to a rawbytes variable.
2 Add the data to the rawbytes variable.
3 Write the rawbytes variable to the DeviceNet I/O.
4 Read data from the DeviceNet I/O to a rawbytes variable.
5 Extract the data from the rawbytes variable.

Limitations
Device command communication require the option for the industrial network in
question.
Device Command Interface is supported by the following type of industrial networks:
• DeviceNet
• EtherNet/IP

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[Link] RAPID components and system parameters

[Link] RAPID components and system parameters

Data types
There are no RAPID data types for Device Command Interface.

Instructions
This is a brief description of each instruction in Device Command Interface. For
more information, see the respective instruction in Technical reference
manual - RAPID Instructions, Functions and Data types.
Instruction Description
PackDNHeader PackDNHeader adds a DeviceNet header to a rawbytes variable. The
header specifies a service to be done (e.g. set or get) and a parameter
on a DeviceNet I/O device.

Functions
There are no RAPID functions for Device Command Interface.

System parameters
There are no specific system parameters in Device Command Interface. For
information on system parameters in general, see Technical reference
manual - System parameters.

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[Link] Code example

[Link] Code example

Write rawbytes to DeviceNet

In this example, data packed as a rawbytes variable is written to a DeviceNet I/O
device. For more details regarding rawbytes, see Raw data communication on
page 41.
PROC set_filter_value()
VAR iodev dev;
VAR rawbytes rawdata_out;
VAR rawbytes rawdata_in;
VAR num input_int;
VAR byte return_status;
VAR byte return_info;
VAR byte return_errcode;
VAR byte return_errcode2;

! Empty contents of rawdata_out and rawdata_in

ClearRawBytes rawdata_out;
ClearRawBytes rawdata_in;

! Add DeviceNet header to rawdata_out with service

! "SET_ATTRIBUTE_SINGLE" and path to filter attribute on
! DeviceNet I/O device
PackDNHeader "10", "6,20 1D 24 01 30 64,8,1", rawdata_out;

! Add filter value to send to DeviceNet I/O device

input_int:= 5;
PackRawBytes input_int, rawdata_out,(RawBytesLen(rawdata_out) +
1) \IntX := USINT;

! Open I/O device

Open "/FCI1:" \File:="board328", dev \Bin;

! Write the contents of rawdata_out to the I/O device

WriteRawBytes dev, rawdata_out \NoOfBytes :=
RawBytesLen(rawdata_out);

! Read the answer from the I/O device

ReadRawBytes dev, rawdata_in;

! Close the I/O device

Close dev;

! Unpack rawdata_in to the variable return_status

UnpackRawBytes rawdata_in, 1, return_status \Hex1;

IF return_status = 144 THEN

TPWrite "Status OK from device. Status code:
"\Num:=return_status;
ELSE

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Continued

! Unpack error codes from device answer

UnpackRawBytes rawdata_in, 2, return_errcode \Hex1;
UnpackRawBytes rawdata_in, 3, return_errcode2 \Hex1;
TPWrite "Error code from device: " \Num:=return_errcode;
TPWrite "Additional error code from device: "
\Num:=return_errcode2;
ENDIF
ENDPROC

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2.7.1 Overview

2.7 Alias I/O signals

2.7.1 Overview

Purpose
The Alias I/O functionality gives the programmer the ability to use any name on a
signal and connect that name to a configured I/O signal.
This is useful when a RAPID program is reused between different systems. Instead
of rewriting the code, using a signal name that exist on the new system, the signal
name used in the program can be defined as an alias name.

What is included
Alias I/O functionality consists of the instruction AliasIO.

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2.7.2 RAPID components

2.7.2 RAPID components

Data types
There are no RAPID data types for the Alias I/O functionality.

Instructions
This is a brief description of each instruction used for the Alias I/O functionality.
For more information, see the respective instruction in Technical reference
manual - RAPID Instructions, Functions and Data types.
Instruction Description
AliasIO AliasIO is used to define a signal of any type with an alias name, or to
use signals in built-in task modules. The alias name is connected to a
configured I/O signal.
The instruction AliasIO must be run before any use of the actual signal.

Functions
There are no RAPID functions for the Alias I/O functionality.

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2.7.3 Alias I/O functionality example

2.7.3 Alias I/O functionality example

Assign alias name to signal

This example shows how to define the digital output signal alias_do to be
connected to the configured digital output I/O signal config_do.
The routine prog_start is connected to the START event.
This will ensure that "alias_do" can be used in the RAPID code even though there
is no configured signal with that name.
VAR signaldo alias_do;
PROC prog_start()
AliasIO config_do, alias_do;
ENDPROC

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2.8.1 Introduction to Logical Cross Connections

2.8 Logical Cross Connections

2.8.1 Introduction to Logical Cross Connections

Purpose
The purpose of Logical Cross Connections is to check and affect combinations of
digital I/O signals (DO, DI) or group I/O signals (GO, GI). This can be used to verify
or control process equipment that are external to the robot. The functionality can
be compared to the one of a simple PLC.
By letting the I/O system handle logical operations with I/O signals, a lot of RAPID
code execution can be avoided. Logical Cross Connections can replace the process
of reading I/O signal values, calculate new values and writing the values to I/O
signals.
Here are some examples of applications:
• Interrupt program execution when either of three input signals is set to 1.
• Set an output signal to 1 when both of two input signals are set to 1.

Description
Logical Cross Connections are used to define the dependencies of an I/O signal
to other I/O signals. The logical operators AND, OR, and inverted signal values
can be used to configure more complex dependencies.
The I/O signals that constitute the logical expression (actor I/O signals) and the
I/O signal that is the result of the expression (resultant I/O signal) can be either
digital I/O signals (DO, DI) or group I/O signals (GO, GI).

What is included
Logical Cross Connections allows you to build logical expressions with up to 5
actor I/O signals and the logical operations AND, OR, and inverted signal values.

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2.8.2 Configuring Logical Cross Connections

2.8.2 Configuring Logical Cross Connections

System parameters
This is a brief description of the parameters for cross connections. For more
information, see the respective parameter in Configuring Logical Cross Connections
on page 57.
These parameters belong to the type Cross Connection in the topic I/O System.
Parameter Description
Name Specifies the name of the cross connection.
Resultant The I/O signal that receive the result of the cross connection as its new
value.
Actor 1 The first I/O signal to be used in the evaluation of the Resultant.
Invert actor 1 If Invert actor 1 is set to Yes, then the inverted value of Actor 1 is used in
the evaluation of the Resultant.
Operator 1 Operand between Actor 1 and Actor 2.
Can be either of the operands:
• AND - Results in the value 1 if both input values are 1.
• OR - Results in the value 1 if at least one of the input values are 1.

Note

The operators are calculated left to right (Operator 1 first and Operator 4
last).

Actor 2 The second I/O signal (if more than one) to be used in the evaluation of the
Resultant.
Invert actor 2 If Invert actor 2 is set to Yes, then the inverted value of Actor 2 is used in
the evaluation of the Resultant.
Operator 2 Operand between Actor 2 and Actor 3.
See Operator 1.
Actor 3 The third I/O signal (if more than two) to be used in the evaluation of the
Resultant.
Invert actor 3 If Invert actor 3 is set to Yes, then the inverted value of Actor 3 is used in
the evaluation of the Resultant.
Operator 3 Operand between Actor 3 and Actor 4.
See Operator 1.
Actor 4 The fourth I/O signal (if more than three) to be used in the evaluation of the
Resultant.
Invert actor 4 If Invert actor 4 is set to Yes, then the inverted value of Actor 4 is used in
the evaluation of the Resultant.
Operator 4 Operand between Actor 4 and Actor 5.
See Operator 1.
Actor 5 The fifth I/O signal (if all five are used) to be used in the evaluation of the
Resultant.
Invert actor 5 If Invert actor 5 is set to Yes, then the inverted value of Actor 5 is used in
the evaluation of the Resultant.

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2.8.3 Examples

2.8.3 Examples

Logical AND
The following logical structure...

xx0300000457

... is created as shown below.

Resultant Actor 1 Invert Operator 1 Actor Invert Operator 2 Actor Invert
actor 1 2 actor 2 3 actor 3
do26 di1 No AND do2 No AND do10 No

Logical OR
The following logical structure...

xx0300000459

... is created as shown below.

Resultant Actor Invert Operator 1 Actor Invert Operator 2 Actor Invert
1 actor 1 2 actor 2 3 actor 3
do26 di1 No OR do2 No OR do10 No

Inverted signals
The following logical structure (where a ring symbolize an inverted signal)...

xx0300000460

... is created as shown below.

Resultant Actor Invert Operator 1 Actor Invert Operator 2 Actor Invert
1 actor 1 2 actor 2 3 actor 3
do26 di1 Yes OR do2 No OR do10 Yes

Several resultants
The following logical structure can not be implemented with one cross connection...

xx0300000462

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2.8.3 Examples
Continued

... but with three cross connections it can be implemented as shown below.
Resultant Actor 1 Invert actor 1 Operator 1 Actor 2 Invert actor 2
di17 di1 No AND do2 No
do26 di1 No AND do2 No
do13 di1 No AND do2 No

Complex conditions
The following logical structure...

xx0300000461

... is created as shown below.

Resultant Actor Invert Operator 1 Actor 2 Invert Operator 2 Actor Invert
1 actor 1 actor 2 3 actor 3
do11 di2 No AND do3 No
do14 di12 No AND do3 Yes
di11 di13 No AND do3 No
do23 di13 No AND do3 No
do17 di13 No AND do3 No
do15 do11 No OR do14 No OR di11 Yes
do33 di11 No AND do23 No
do61 do17 No AND do3 No
do54 do15 No OR do33 Yes

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2.8.4 Limitations

2.8.4 Limitations

Evaluation order
If more than two actor I/O signals are used in one cross connection, the evaluation
is made from left to right. This means that the operation between Actor 1 and Actor
2 is evaluated first and the result from that is used in the operation with Actor 3.
If all operators in one cross connection are of the same type (only AND or only
OR) the evaluation order has no significance. However, mixing AND and OR
operators, without considering the evaluation order, may give an unexpected result.

Tip

Use several cross connections instead of mixing AND and OR in the same cross
connection.

Maximum number of actor I/O signals

A cross connection may not have more than five actor I/O signals. If more actor
I/O signals are required, use several cross connections.

Maximum number of cross connections

The maximum number of cross connections handled by the robot system is 300.

Maximum depth
The maximum allowed depth of cross connection evaluations is 20.
A resultant from one cross connection can be used as an actor in another cross
connection. The resultant from that cross connection can in its turn be used as an
actor in the next cross connection. However, this type of chain of dependent cross
connections cannot be deeper than 20 steps.

Do not create a loop

Cross connections must not form closed chains since that would cause infinite
evaluation and oscillation. A closed chain appears when cross connections are
interlinked so that the chain of cross connections forms a circle.

Do not have the same resultant more than once

Ambiguous resultant I/O signals are not allowed since the outcome would depend
on the order of evaluation (which cannot be controlled). Ambiguous resultant I/O
signals occur when the same I/O signal is resultant in several cross connections.

Overlapping device maps

The resultant I/O signal in a cross connection must not have an overlapping device
map with any inverted actor I/O signals defined in the cross connection. Using I/O
signals with overlapping device map in a cross connection can cause infinity signal
setting loops.

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2.9.1 Introduction to RAPID Message Queue

2.9 RAPID Message Queue

2.9.1 Introduction to RAPID Message Queue

Purpose
The purpose of RAPID Message Queue is to communicate with another RAPID
task or PC application using PC SDK.
Here are some examples of applications:
• Sending data between two RAPID tasks.
• Sending data between a RAPID task and a PC application.
RAPID Message Queue can be defined for interrupt or synchronous mode. Default
setting is interrupt mode.

What is included
The RAPID Message Queue functionality is included in the RobotWare options:
• Multitasking
• RobotStudio Connect
RAPID Message Queue gives you access to RAPID instructions, functions, and
data types for sending and receiving data.

Basic approach
This is the general approach for using RAPID Message Queue. For a more detailed
example of how this is done, see Code examples on page 68.
1 For interrupt mode: The receiver sets up a trap routine that reads a message
and connects an interrupt so the trap routine is called when a new message
appears.
For synchronous mode: The message is handled by a waiting or the next
executed RMQReadWait instruction.
2 The sender looks up the slot identity of the queue in the receiver task.
3 The sender sends the message.

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2.9.2 RAPID Message Queue behavior

2.9.2 RAPID Message Queue behavior

Illustration of communication
The picture below shows various possible senders, receivers, and queues in the
system. Each arrow is an example of a way to post a message to a queue.

PC
PC SDK

Queue

Robot
controller
RAPID
task

Queue

RAPID
task

Queue

en0700000430

Creating a PC SDK client

This manual only describes how to use RAPID Message Queue to make a RAPID
task communicate with other RAPID tasks and PC SDK clients. For information
about how to set up the communication on a PC SDK client, see [Link]
[Link].

What can be sent in a message

The data in a message can be any data type in RAPID, except:
• non-value
• semi-value

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2.9.2 RAPID Message Queue behavior
Continued

• motsetdata
The data in a message can also be an array of a data type.
User defined records are allowed, but both sender and receiver must have identical
declarations of the record.

Tip

To keep backward compatibility, do not change a user defined record once it is

used in a released product. It is better to create a new record. This way, it is
possible to receive messages from both old and new applications.

Queue name
The name of the queue configured for a RAPID task is the same as the name of
the task with the prefix RMQ_, for example RMQ_T_ROB1. This name is used by
the instruction RMQFindSlot.

Queue handling
Messages in queues are handled in the order that they are received. This is known
as FIFO, first in first out. If a message is received while a previous message is
being handled, the new message is placed in the queue. As soon as the first
message handling is completed, the next message in the queue is handled.

Queue modes
The queue mode is defined with the system parameter RMQ Mode. Default behavior
is interrupt mode.

Interrupt mode
In interrupt mode the messages are handled depending on data type. Messages
are only handled for connected data types.
A cyclic interrupt must be set up for each data type that the receiver should handle.
The same trap routine can be called from more than one interrupt, that is for more
than one data type.
Messages of a data type with no connected interrupt will be discarded with only a
warning message in the event log.
Receiving an answer to the instruction RMQSendWait does not result in an interrupt.
No interrupt needs to be set up to receive this answer.

Synchronous mode
In synchronous mode, the task executes an RMQReadWait instruction to receive
a message of any data type. All messages are queued and handled in order they
arrive.
If there is a waiting RMQReadWait instruction, the message is handled immediately.
If there is no waiting RMQReadWait instruction, the next executed RMQReadWait
instruction will handle the message.

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2.9.2 RAPID Message Queue behavior
Continued

Message content
A RAPID Message Queue message consists of a header, containing receiver
identity, and a RAPID message. The RAPID message is a pretty-printed string with
data type name (and array dimensions) followed by the actual data value.
RAPID message examples:
"robtarget;[[930,0,1455],[1,0,0,0],[0,0,0,0],
[9E9,9E9,9E9,9E9,9E9,9E9]]"
"string;"A message string""
"stringarr:["string1","string2"]
"msgrec;[100,200]"
"bool{2,2};[[TRUE,TRUE],[FALSE,FALSE]]"

RAPID task not executing

It is possible to post messages to a RAPID task queue even though the RAPID
task containing the queue is not currently executing. The interrupt will not be
executed until the RAPID task is executing again.

Message size limitations

Before a message is sent, the maximum size (for the specific data type and
dimension) is calculated. If the size is greater than 5000 bytes, the message will
be discarded and an error will be raised. The sender can get same error if the
receiver is a PC SDK client with a maximum message size smaller than 400 bytes.
Sending a message of a specific data type with specific dimensions will either
always be possible or never possible.
When a message is received (when calling the instruction RMQGetMsgData), the
maximum size (for the specific data type and dimension) is calculated. If the size
is greater than the maximum message size configured for the queue of this task,
the message will be discarded and an error will be logged. Receiving a message
of a specific data type with specific dimensions will either always be possible or
never possible.

Message lost
In interrupt mode, any messages that cannot be received by a RAPID task will be
discarded. The message will be lost and a warning will be placed in the event log.
Example of reasons for discarding a message:
• The data type that is sent is not supported by the receiving task.
• The receiving task has not set up an interrupt for the data type that is sent,
and no RMQSendWait instruction is waiting for this data type.
• The interrupt queue of the receiving task is full

Queue lost
The queue is cleared at power fail.
When the execution context in a RAPID task is lost, for example when the program
pointer is moved to main, the corresponding queue is emptied.

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2.9.2 RAPID Message Queue behavior
Continued

Related information
For more information on queues and messages, see Technical reference
manual - RAPID kernel.

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2.9.3 System parameters

2.9.3 System parameters

About the system parameters

This is a brief description of each parameter in the functionality RAPID Message
Queue. For more information, see the respective parameter in Technical reference
manual - System parameters.

Type Task
These parameters belong to the type Task in the topic Controller.
Parameter Description
RMQ Type Can have one of the following values:
• None - Disable all communication with RAPID Message
Queue for this RAPID task.
• Internal - Enable the receiving of RAPID Message
Queue messages from other tasks on the controller,
but not from external clients (FlexPendant and PC ap-
plications). The task is still able to send messages to
external clients.
• Remote - Enable communication with RAPID Message
Queue for this task, both with other tasks on the con-
troller and external clients (FlexPendant and PC applic-
ations).
The default value is None.
RMQ Mode Defines the mode of the queue.
Can have one of the following values:
• Interrupt - A message can only be received by connect-
ing a trap routine to a specified message type.
• Synchronous - A message can only be received by
executing an RMQReadWait instruction.
Default value is Interrupt.
RMQ Max Message Size The maximum data size, in bytes, for a RAPID Message
Queue message.
An integer between 448 and 5000. The default value is 448.

Note

The value cannot be changed in RobotStudio or on the Flex-

Pendant. The only way to change the value is to edit the
[Link] file by adding the attribute RmqMaxMsgSize with the
desired value.

RMQ Max No Of Messages The maximum number of RAPID Message Queue messages
in the queue to this task.
An integer between 1 and 10. The default value is 5.

Note

The value cannot be changed in RobotStudio or on the Flex-

Pendant. The only way to change the value is to edit the
[Link] file by adding the attribute RmqMaxNoOfMsg with the
desired value.

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2.9.4 RAPID components

2.9.4 RAPID components

About the RAPID components

This is a brief description of each instruction, function, and data type in RAPID
Message Queue. For more information, see the respective parameter in Technical
reference manual - RAPID Instructions, Functions and Data types.

Instructions

Instruction Description
RMQFindSlot Find the slot identity number of the queue configured for a
RAPID task or Robot Application Builder client.
RMQSendMessage Send data to the queue configured for a RAPID task or Robot
Application Builder client.
IRMQMessage Order and enable cyclic interrupts for a specific data type.
RMQGetMessage Get the first message from the queue of this task. Can only
be used if RMQ Mode is defined as Interrupt.
RMQGetMsgHeader Get the header part from a message.
RMQGetMsgData Get the data part from a message.
RMQSendWait Send a message and wait for the answer. Can only be used
if RMQ Mode is defined as Interrupt.
RMQReadWait Wait for a message. Can only be used if RMQ Mode is defined
as Synchronous.
RMQEmptyQueue Empty the queue.

Functions

Function Description
RMQGetSlotName Get the name of the queue configured for a RAPID task or
Robot Application Builder client, given a slot identity number,
i.e. given a rmqslot.

Data types

Data type Description

rmqslot Slot identity of a RAPID task or Robot Application Builder
client.
rmqmessage A message used to store data in when communicating with
RAPID Message Queue. It contains information about what
type of data is sent, the slot identity of the sender, and the
actual data.
Note: rmqmessage is a large data type. Declaring too many
variables of this data type can lead to memory problems.
Reuse the same rmqmessage variables as much as possible.
rmqheader The rmqheader describes the message and can be read by
the RAPID program.

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2.9.5 Code examples

2.9.5 Code examples

Example using RMQSendMessage and RMQGetMessage with PC SDK

This is an example using RMQSendMessage and RMQGetMessage with PC SDK.
The PC SDK, creates data (a string) with a request to receive current position of
the mechanical unit. The T_ROB1 task receives the request and creates data
containing the position and sends it back to the PC SDK.

Example of RAPID with RMQ

MODULE MainModule
RECORD position
num x;
num y;
num z;
ENDRECORD

RECORD message
string msg1;
string msg2;
ENDRECORD
VAR position posData;
VAR message request;
VAR intnum rmqMsg;
VAR rmqslot clientSlot;
VAR pos currPosition;
CONST string unknownRequest := "Unknown request";
PROC main()
RMQFindSlot clientSlot, "RMQ_PC_SDK";
CONNECT rmqMsg WITH rmqMessageHandler;
IRMQMessage request, rmqMsg;
WHILE TRUE DO
...
currPosition := CPos(\Tool:=tool0 \WObj:=wobj0);
...
ENDWHILE
IDelete rmqMsg;
EXIT;
ENDPROC
TRAP rmqMessageHandler
VAR rmqmessage rmqMsg;
VAR rmqheader header;
RMQGetMessage rmqMsg;
RMQGetMsgHeader rmqMsg\Header := header\SenderId := clientSlot;
IF [Link] = "message" THEN
RMQGetMsgData rmqMsg, request;
IF request.msg1 = "Get current position" THEN
posData.x := currPosition.x;
posData.y := currPosition.y;
posData.z := currPosition.z;
RMQSendMessage clientSlot, posData;

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2.9.5 Code examples
Continued

ELSE
RMQSendMessage clientSlot, unknownRequest;
ENDIF
ENDIF
ENDTRAP
ENDMODULE

Example of PC SDK with RMQ

class Messaging
{
private static Controller ctrl;
private static IpcQueue pcsdkQueue;
private static IpcQueue trob1Queue;
private static float X;
private static float Y;
private static float Z;
private static string message1 = "\"Get current position\"";
private static string message2 = "\"\"";

static void Main(string[] args)

{
...
//Connect and login to selected controller.
...

if (ctrl != null)
{
trob1Queue = [Link]("RMQ_T_ROB1");

string pcsdkQueueName = "RMQ_PC_SDK";

if ([Link](pcsdkQueueName))
{
[Link]([Link](pcsdkQueueName));
}
pcsdkQueue = [Link](pcsdkQueueName, 16,
[Link]());

SendMessage(message1, message2);

...

[Link]([Link](pcsdkQueueName));
[Link]();

...
}

}
public static void SendMessage(string message1, string message2)
{

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2.9.5 Code examples
Continued

IpcMessage message = new IpcMessage();

byte[] data;
if (pcsdkQueue != null && trob1Queue != null)
{
data = new UTF8Encoding().GetBytes("message;[" + message1 +
" , " + message2 + "]");
[Link](data);
[Link] = [Link];
[Link](message);
[Link](() => { receiveMessage();
});
}
}
private static void receiveMessage()
{

IpcMessage message = new IpcMessage();

IpcReturnType ret;
int timeout = 5000;

if (pcsdkQueue != null)
{
ret = [Link](timeout, message);
if (ret == [Link])
{
string answer = new
UTF8Encoding().GetString([Link]);
string[] answerStructure = [Link](';');
if (answerStructure[0] == "position")
{
string pos = [Link](([Link]('[')) +
1, [Link](']') - (([Link]('['))
+ 1));
string [] array=[Link](',');
X = [Link](array[0]);
Y = [Link](array[1]);
Z = [Link](array[2]);
...
}
else if(answerStructure[0] == "string")
{
string valueCharacter = "\"";
int valueStartIndex = [Link](valueCharacter);
int valueEndIndex = [Link](valueCharacter,
valueStartIndex + 1);
string returnText = [Link](valueStartIndex
+ 1, valueEndIndex - (valueStartIndex + 1));
...
}
}
else

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2.9.5 Code examples
Continued

{
//No message recieved within time limit.
...
}
}
else
{
//No queue found
...
}
}
}
}

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2.10.1 Introduction to Socket Messaging

2.10 Socket Messaging

2.10.1 Introduction to Socket Messaging

Purpose
The purpose of Socket Messaging is to allow a RAPID programmer to transmit
application data between computers, using the TCP/IP network protocol. A socket
represents a general communication channel, independent of the network protocol
being used.
Socket communication is a standard that has its origin in Berkeley Software
Distribution Unix. Besides Unix, it is supported by, for example, Microsoft Windows.
With Socket Messaging, a RAPID program on a robot controller can, for example,
communicate with a C/C++ program on another computer.

What is included
The RobotWare functionality Socket Messaging gives you access to RAPID data
types, instructions and functions for socket communication between computers.

Basic approach
This is the general approach for using Socket Messaging. For a more detailed
example of how this is done, see Code examples for Socket Messaging on page 77.
1 Create a socket, both on client and server. A robot controller can be either
client or server.
2 Use SocketBind and SocketListen on the server, to prepare it for a
connection request.
3 Order the server to accept incoming socket connection requests.
4 Request socket connection from the client.
5 Send and receive data between client and server.

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2.10.2 Schematic picture of socket communication

2.10.2 Schematic picture of socket communication

Illustration of socket communication

en0600003224

Tip

Do not create and close sockets more than necessary. Keep the socket open
until the communication is completed. The socket is not really closed until a
certain time after SocketClose (due to TCP/IP functionality).

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2.10.3 Technical facts about Socket Messaging

2.10.3 Technical facts about Socket Messaging

Overview
When using the functionality Socket Messaging to communicate with a client or
server that is not a RAPID task, the following information can be useful.

No string termination
When sending a data message, no string termination sign is sent in the message.
The number of bytes sent is equal to the return value of the function strlen(str)
in the programming language C.

Unintended merge of messages

If sending two messages with no delay between them, the result can be that the
second message is appended to the first. The result is one big message instead
of two messages. To avoid this, use acknowledge messages from the receiver of
the data, if the client/server is just receiving messages.

Non printable characters

If a client that is not a RAPID task needs to receive non printable characters (binary
data) in a string from a RAPID task, this can be done by RAPID as shown in the
example below.
SocketSend socket1 \Str:="\0D\0A";
For more information, see Technical reference manual - RAPID kernel, section
String literals.

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2.10.4 RAPID components

2.10.4 RAPID components

Data types
This is a brief description of each data type in Socket Messaging. For more
information, see Technical reference manual - RAPID Instructions, Functions and
Data types.
Data type Description
socketdev A socket device used to communicate with other computers on a net-
work.
socketstatus Can contain status information from a socketdev variable.

Instructions for client

This is a brief description of each instruction used by the a Socket Messaging
client. For more information, see Technical reference manual - RAPID Instructions,
Functions and Data types.
Instruction Description
SocketCreate Creates a new socket and assigns it to a socketdev variable.
SocketConnect Makes a connection request to a remote computer. Used by the client
to connect to the server.
SocketSend Sends data via a socket connection to a remote computer. The data
can be a string or rawbytes variable, or a byte array.
SocketReceive Receives data and stores it in a string or rawbytes variable, or in
a byte array.
SocketClose Closes a socket and release all resources.

Tip

Do not use SocketClose directly after SocketSend. Wait for acknowledgement

before closing the socket.

Instructions for server

A Socket Messaging server uses the same instructions as the client, except for
SocketConnect. In addition, the server use the following instructions:

Instruction Description
SocketBind Binds the socket to a specified port number on the server.
Used by the server to define on which port (on the server) to
listen for a connection.
The IP address defines a physical computer and the port
defines a logical channel to a program on that computer.
SocketListen Makes the computer act as a server and accept incoming
connections. It will listen for a connection on the port specified
by SocketBind.
SocketAccept Accepts an incoming connection request. Used by the server
to accept the client’s request.

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2.10.4 RAPID components
Continued

Note

The server application must be started before the client application, so that the
instruction SocketAccept is executed before any client execute
SocketConnect.

Functions
This is a brief description of each function in Socket Messaging. For more
information, see Technical reference manual - RAPID Instructions, Functions and
Data types.
Function Description
SocketGetStatus Returns information about the last instruction performed on the socket
(created, connected, bound, listening, closed).
SocketGetStatus does not detect changes from outside RAPID (such
as a broken connection).

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2.10.5 Code examples for Socket Messaging

2.10.5 Code examples for Socket Messaging

Example of client/server communication

This example shows program code for a client and a server, communicating with
each other.
The server will write on the FlexPendant:
Client wrote - Hello server
Client wrote - Shutdown connection
The client will write on its FlexPendant:
Server wrote - Message acknowledged
Server wrote - Shutdown acknowledged
In this example, both the client and the server use RAPID programs. In reality, one
of the programs would often be running on a PC (or similar computer) and be
written in another program language.
Code example for client, contacting server with IP address [Link]:
! WaitTime to delay start of client.
! Server application should start first.
WaitTime 5;
VAR socketdev socket1;
VAR string received_string;
PROC main()
SocketCreate socket1;
SocketConnect socket1, "[Link]", 1025;
! Communication
SocketSend socket1 \Str:="Hello server";
SocketReceive socket1 \Str:=received_string;
TPWrite "Server wrote - " + received_string;
received_string := "";
! Continue sending and receiving
...
! Shutdown the connection
SocketSend socket1 \Str:="Shutdown connection";
SocketReceive socket1 \Str:=received_string;
TPWrite "Server wrote - " + received_string;
SocketClose socket1;
ENDPROC
Code example for server (with IP address [Link]):
VAR socketdev temp_socket;
VAR socketdev client_socket;
VAR string received_string;
VAR bool keep_listening := TRUE;
PROC main()
SocketCreate temp_socket;
SocketBind temp_socket, "[Link]", 1025;
SocketListen temp_socket;
WHILE keep_listening DO
! Waiting for a connection request
SocketAccept temp_socket, client_socket;

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Continued

! Communication
SocketReceive client_socket \Str:=received_string;
TPWrite "Client wrote - " + received_string;
received_string := "";
SocketSend client_socket \Str:="Message acknowledged";
! Shutdown the connection
SocketReceive client_socket \Str:=received_string;
TPWrite "Client wrote - " + received_string;
SocketSend client_socket \Str:="Shutdown acknowledged";
SocketClose client_socket;
ENDWHILE
SocketClose temp_socket;
ENDPROC

Example of error handler

The following error handlers will take care of power failure or broken connection.
Error handler for client in previous example:
! Error handler to make it possible to handle power fail
ERROR
IF ERRNO=ERR_SOCK_TIMEOUT THEN
RETRY;
ELSEIF ERRNO=ERR_SOCK_CLOSED THEN
SocketClose socket1;
! WaitTime to delay start of client.
! Server application should start first.
WaitTime 10;
SocketCreate socket1;
SocketConnect socket1, "[Link]", 1025;
RETRY;
ELSE
TPWrite "ERRNO = "\Num:=ERRNO;
Stop;
ENDIF
Error handler for server in previous example:
! Error handler for power fail and connection lost
ERROR
IF ERRNO=ERR_SOCK_TIMEOUT THEN
RETRY;
ELSEIF ERRNO=ERR_SOCK_CLOSED THEN
SocketClose temp_socket;
SocketClose client_socket;
SocketCreate temp_socket;
SocketBind temp_socket, "[Link]", 1025;
SocketListen temp_socket;
SocketAccept temp_socket, client_socket;
RETRY;
ELSE
TPWrite "ERRNO = "\Num:=ERRNO;
Stop;
ENDIF

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2.11.1 Introduction to User logs

2.11 Event logs for user actions

2.11.1 Introduction to User logs

Description
The RobotWare base functionality User logs generates event logs for the most
common user actions. The event logs are generated in the group Operational
events, number series 10xxx.
For more information on handling the event log, see Operating manual - OmniCore
and Technical reference manual - Event logs for RobotWare 7.

Purpose
The purpose of User logs is to track changes in the robot controller related to user
actions. This can for example be helpful to find the root cause if a production stop
occurs.

What is included
The RobotWare base functionality User logs generates event logs for the following
changes related to user actions. All event logs are described in Technical reference
manual - Event logs for RobotWare 7.
Topic User action Event logs
Program exe- Changing the speed or run mode (single cycle/continuous). 10140
cution Making changes to the task selection panel. Setting or reset- 10145
ting non motion execution mode.
10146
10153
10154
10284
10285
Simulate wait Simulating wait instructions, for example WaitTime, 10144
instructions WaitUntil, WaitDx, etc.
RAPID Opening or closing RAPID programs or modules, editing 10040
changes RAPID code, or modifying robot positions. 10041
10061
10062
10063
10064
10069
10078
10079
10147
Program Moving the program pointer to main, to a routine, to a posi- 10141
pointer move- tion, or to a service routine (call routine). 10142
ments
10143
10149

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2.11.1 Introduction to User logs
Continued

Topic User action Event logs

Changes on Updating the revolution counters or performing a calibration. 10205
the mechanic- 10206
al unit
10290
10292
Jogging Changing the tool, the work object, the payload, the coordin- 10280
ate system, or go to a position. 10281
10282
10283
10286
10287
10288
10289
10291
Supervision Setting or resetting the jog or path supervision. Setting the 10293
level of supervision. 10294
10295
10296
10297
10298
Change of Loading configuration data or changing a configuration at- 10250
configuration tribute.
System Clearing the event log or changing date and time. 10200
changes 10201
10202
Serial meas- Changing the data in the serial measurement board or 10115
urement changing the data in the robot memory. 10116
board
10117
10118
I/O Setting or pulsing I/O signals. 10148
10160
10161

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2.12.1 Overview

2.12 Power failure functionality

2.12.1 Overview

Purpose
If the robot was in the middle of a path movement when the power fail occurred,
some extra actions may need to be taken when the robot motion is resumed. The
power failure functionality helps you detect if the power fail occurred during a path
movement.

Note

For more information see the type Signal Safe Level, which belongs to the topic
I/O System, in Technical reference manual - System parameters.

What is included
The power failure functionality includes a function that checks for interrupted path:
PFRestart

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2.12.2 RAPID components and system parameters

2.12.2 RAPID components and system parameters

Data types
There are no RAPID data types in the power failure functionality.

Instructions
There are no RAPID instructions in the power failure functionality.

Functions
This is a brief description of each function in the power failure functionality. For
more information, see the respective function in Technical reference manual - RAPID
Instructions, Functions and Data types.
Function Description
PFRestart PFRestart (Power Failure Restart) is used to check if the path was inter-
rupted at power failure. If so it might be necessary to make some specific
actions. The function checks the path on current level, base level or on in-
terrupt level.

System parameters
There are no system parameters in the power failure functionality. However,
regardless of whether you have any options installed, you can use the parameter
Store signal at power fail.
For more information, see Technical reference manual - System parameters.

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2.12.3 Power failure functionality example

2.12.3 Power failure functionality example

Test for interrupted path

When resuming work after a power failure, this example tests if the power failure
occurred during a path (i.e. when the robot was moving).
!Test if path was interrupted
IF PFRestart() = TRUE THEN
SetDO do5,1;
ELSE
SetDO do5,0;
ENDIF

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2.13.1 Overview

2.13 Interrupt functionality

2.13.1 Overview

Interrupts
Interrupts are program-defined events, identified by interrupt numbers. An interrupt
occurs when an interrupt condition is true. Unlike errors, the occurrence of an
interrupt is not directly related to (synchronous with) a specific code position. The
occurrence of an interrupt causes suspension of the normal program execution
and control is passed to a trap routine.
A more extensive description of the interrupt functionality is found in Technical
reference manual - RAPID Overview.

Programming principles
Each interrupt is assigned an interrupt identity. It obtains its identity by creating a
variable (of data type intnum) and connecting this to a trap routine.
The interrupt identity (variable) is then used to order an interrupt, that is to specify
the reason for the interrupt. This may be one of the following events:
• An input or output is set to one or to zero.
• A given amount of time elapses after an interrupt is ordered.
• A specific position is reached.
When an interrupt is ordered, it is also automatically enabled, but can be temporarily
disabled. This can take place in two ways:
• All interrupts can be disabled. Any interrupts occurring during this time are
placed in a queue and then automatically generated when interrupts are
enabled again.
• Individual interrupts can be deactivated. Any interrupts occurring during this
time are disregarded.

Related information
Depending on the application, an interrupt can be resolved using the Path Recovery
functionality, see Path Recovery [3113-1] on page 263.

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2.13.2 RAPID components

2.13.2 RAPID components

Data types
This is a brief description of each data type in the interrupt functionality. For more
information, see the respective data type in Technical reference manual - RAPID
Instructions, Functions and Data types.
Data type Description
trapdata trapdata represents internal information related to the interrupt that caused
the current trap routine to be executed.
errdomain errdomain is used to specify an error domain. Depending on the nature
of the error, it is logged in different domains.
errtype errtype is used to specify an error type (error, warning, state change).

Instructions
This is a brief description of each instruction in the interrupt functionality. For more
information, see the respective instruction in Technical reference manual - RAPID
Instructions, Functions and Data types.
Instruction Description
IPers IPers (Interrupt Persistent) is used to order an interrupt to be generated
each time the value of a persistent variable is changed.
IError IError (Interrupt Errors) is used to order an interrupt to be generated each
time an error occurs.
GetTrapData GetTrapData is used in trap routines generated by the instruction IError.
GetTrapData obtains all information about the interrupt that caused the
trap routine to be executed.
ReadErrData ReadErrData is used in trap routines generated by the instruction IError.
ReadErrData read the information obtained by GetTrapData.
ErrRaise ErrRaise is used to create an error in the program and the call the error
handler of the [Link] can also be used in the error handler to
propagate the current error to the error handler of the calling routine.

Functions
There are no RAPID functions for the interrupt functionality.

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2.13.3 Interrupt functionality examples

2.13.3 Interrupt functionality examples

Interrupt when persistent variable changes

In this example, a trap routine is called when the value of the persistent variable
counter changes.
VAR intnum int1;
PERS num counter := 0;

PROC main()
CONNECT int1 WITH iroutine1;
IPers counter, int1;
...
counter := counter + 1;
...
Idelete int1;
ENDPROC

TRAP iroutine1
TPWrite "Current value of counter = " \Num:=counter;
ENDTRAP

Error interrupt
In this example, a trap routine is called when an error occurs. The trap routine
determines the error domain and the error number and communicates them via
output signals.
VAR intnum err_interrupt;
VAR trapdata err_data;
VAR errdomain err_domain;
VAR num err_number;
VAR errtype err_type;

PROC main()
CONNECT err_interrupt WITH trap_err;
IError COMMON_ERR, TYPE_ERR, err_interrupt;
...
a:=3;
b:=0;
c:=a/b;
...
IDelete err_interrupt;
ENDPROC

TRAP trap_err
GetTrapData err_data;
ReadErrData err_data, err_domain, err_number, err_type;
SetGO go_err1, err_domain;
SetGO go_err2, err_number;
ENDTRAP

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[Link] Introduction to Analog Signal Interrupt

2.13.4 Analog Signal Interrupt

[Link] Introduction to Analog Signal Interrupt

Purpose
The purpose of Analog Signal Interrupt is to supervise an analog signal and
generate an interrupt when a specified value is reached.
Analog Signal Interrupt is faster, easier to implement, and require less computer
capacity than polling methods.
Here are some examples of applications:
• Save cycle time with better timing (start robot movement exactly when a
signal reach the specified value, instead of waiting for polling).
• Show warning or error messages if a signal value is outside its allowed range.
• Stop the robot if a signal value reaches a dangerous level.

What is included
The RobotWare base functionality Analog Signal Interrupt gives you access to the
instructions:
• ISignalAI
• ISignalAO

Basic approach
This is the general approach for using Analog Signal Interrupt. For a more detailed
example of how this is done, see Code example on page 89.
1 Create a trap routine.
2 Connect the trap routine using the instruction CONNECT.
3 Define the interrupt conditions with the instruction ISignalAI or ISignalAO.

Limitations
Analog signals can only be used if you have an industrial network option (for
example DeviceNet).

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[Link] RAPID components

[Link] RAPID components

Data types
Analog Signal Interrupt includes no data types.

Instructions
This is a brief description of each instruction in Analog Signal Interrupt. For more
information, see the respective instruction in Technical reference manual - RAPID
Instructions, Functions and Data types.
Instruction Description
ISignalAI Defines the values of an analog input signal, for which an interrupt routine
shall be called.
An interrupt can be set to occur when the signal value is above or below a
specified value, or inside or outside a specified range. It can also be spe-
cified if the interrupt shall occur once or repeatedly.
ISignalAO Defines the values of an analog output signal, for which an interrupt routine
shall be called.
An interrupt can be set to occur when the signal value is above or below a
specified value, or inside or outside a specified range. It can also be spe-
cified if the interrupt shall occur once or repeatedly.

Functions
Analog Signal Interrupt includes no RAPID functions.

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[Link] Code example

[Link] Code example

Temperature surveillance
In this example a temperature sensor is connected to the signal ai1.
An interrupt routine with a warning is set to execute every time the temperature
rises 0.5 degrees in the range 120-130 degrees. Another trap routine, stopping the
robot, is set to execute as soon as the temperature rise above 130 degrees.
VAR intnum ai1_warning;
VAR intnum ai1_exeeded;

PROC main()
CONNECT ai1_warning WITH temp_warning;
CONNECT ai1_exeeded WITH temp_exeeded;
ISignalAI ai1, AIO_BETWEEN, 130, 120, 0.5, \DPos, ai1_warning;
ISignalAI \Single, ai1, AIO_ABOVE_HIGH, 130, 120, 0, ai1_exeeded;
...
IDelete ai1_warning;
IDelete ai1_exeeded;
ENDPROC

TRAP temp_warning
TPWrite "Warning: Temperature is "\Num:=ai1;
ENDTRAP

TRAP temp_exeeded
TPWrite "Temperature is too high";
Stop;
ENDTRAP

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[Link] Overview

2.14 Additional functions for motion control and motion programming

2.14.1 Fixed Position Events

[Link] Overview

Purpose
The purpose of Fixed Position Events is to make sure a program routine is executed
when the position of the TCP is well defined.
If a move instruction is called with the zone argument set to fine, the next routine
is always executed once the TCP has reached its target. If a move instruction is
called with the zone argument set to a distance (for example z20), the next routine
may be executed before the TCP is even close to the target. This is because there
is always a delay between the execution of RAPID instructions and the robot
movements.
Calling the move instruction with zone set to fine will slow down the movements.
With Fixed Position Events, a routine can be executed when the TCP is at a
specified position anywhere on the TCP path without slowing down the movement.

What is included
The RobotWare base functionality Fixed Position Events gives you access to:
• instructions used to define a position event
• instructions for moving the robot and executing the position event at the
same time
• instructions for moving the robot and calling a procedure while passing the
target, without first defining a position event

Basic approach
Fixed Position Events can either be used with one simplified instruction calling a
procedure or it can be set up following these general steps. For more detailed
examples of how this is done, see Code examples on page 94.
1 Declare the position event.
2 Define the position event:
• when it shall occur, compared to the target position
• what it shall do
3 Call a move instruction that uses the position event. When the TCP is as
close to the target as defined, the event will occur.

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[Link] RAPID components and system parameters

[Link] RAPID components and system parameters

Data types
This is a brief description of each data type in Fixed Position Events. For more
information, see the respective data type in Technical reference manual - RAPID
Instructions, Functions and Data types.
Data type Description
triggdata triggdata is used to store data about a position event.
A position event can take the form of setting an output signal or run-
ning an interrupt routine at a specific position along the movement
path of the robot.
triggdata also contains information on when the action shall occur,
for example when the TCP is at a defined distance from the target.
triggdata is a non-value data type.
triggios triggios is used to store data about a position event used by the
instruction TriggLIOs.
triggios sets the value of an output signal using a num value.
triggiosdnum triggiosdnum is used to store data about a position event used by
the instruction TriggLIOs.
triggiosdnum sets the value of an output signal using a dnum value.

Instructions
This is a brief description of each instruction in Fixed Position Events. For more
information, see the respective instruction in Technical reference manual - RAPID
Instructions, Functions and Data types.
Instruction Description
MoveLSync MoveLSync is a linear move instruction that calls a procedure in the
middle of the corner path.
MoveCSync MoveCSync is a circular move instruction that calls a procedure in
the middle of the corner path.
MoveJSync MoveJSync is a joint move instruction that calls a procedure in the
middle of the corner path.
TriggIO TriggIO defines the setting of an output signal and when to set that
signal. The definition is stored in a variable of type triggdata.
TriggIO can define the setting of the signal to occur at a certain
distance (in mm) from the target, or a certain time from the target. It
is also possible to set the signal at a defined distance or time from
the starting position.
By setting the distance to 0 (zero), the signal will be set when the TCP
is as close to the target as it gets (the middle of the corner path).
TriggEquip TriggEquip works like TriggIO, with the difference that TriggEquip
can compensate for the internal delay of the external equipment.
For example, the signal to a glue gun must be set a short time before
the glue is pressed out and the gluing begins.
TriggInt TriggInt defines when to run an interrupt routine. The definition is
stored in a variable of type triggdata.
TriggInt defines at what distance (in mm) from the target (or from
the starting position) the interrupt routine shall be called. By setting
the distance to 0 (zero), the interrupt will occur when the TCP is as
close to the target as it gets (the middle of the corner path).
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[Link] RAPID components and system parameters
Continued

Instruction Description
TriggCheckIO TriggCheckIO defines a test of an input or output signal, and when
to perform that test. The definition is stored in a variable of type
triggdata.
TriggCheckIO defines a test, comparing an input or output signal
with a value. If the test fails, an interrupt routine is called. As an option
the robot movement can be stopped when the interrupt occurs.
TriggCheckIO can define the test to occur at a certain distance (in
mm) from the target, or a certain time from the target. It is also possible
to perform the test at a defined distance or time from the starting po-
sition.
By setting the distance to 0 (zero), the interrupt routine will be called
when the TCP is as close to the target as it gets (the middle of the
corner path).
TriggRampAO TriggRampAO defines the ramping up or down of an analog output
signal and when this ramping is performed. The definition is stored
in a variable of type triggdata.
TriggRampIO defines where the ramping of the signal is to start and
the length of the ramping.
TriggL TriggL is a move instruction, similar to MoveL. In addition to the
movement the TriggL instruction can set output signals, run interrupt
routines and check input or output signals at fixed positions.
TriggL executes up to 8 position events stored as triggdata. These
must be defined before calling TriggL.
TriggC TriggC is a move instruction, similar to MoveC. In addition to the
movement the TriggC instruction can set output signals, run interrupt
routines and check input or output signals at fixed positions.
TriggC executes up to 8 position events stored as triggdata. These
must be defined before calling TriggC.
TriggJ TriggJ is a move instruction, similar to MoveJ. In addition to the
movement the TriggJ instruction can set output signals, run interrupt
routines and check input or output signals at fixed positions.
TriggJ executes up to 8 position events stored as triggdata. These
must be defined before calling TriggJ.
TriggLIOs TriggLIOs is a move instruction, similar to MoveL. In addition to the
movement the TriggLIOs instruction can set output signals at fixed
positions.
TriggLIOs is similar to the combination of TriggEquip and TriggL.
The difference is that TriggLIOs can handle up to 50 position events
stored as an array of datatype triggios, triggiosdnum, or
triggstrgo.

Functions
Fixed Position Events includes no RAPID functions.

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[Link] RAPID components and system parameters
Continued

System parameters
This is a brief description of each parameter in Fixed Position Events. For more
information, see the respective parameter in Technical reference manual - System
parameters.
Parameter Description
Event Preset Time TriggEquip takes advantage of the delay between the RAPID exe-
cution and the robot movement, which is about 70 ms. If the delay of
the equipment is longer than 70 ms, then the delay of the robot
movement can be increased by configuring Event preset time.
Event preset time belongs to the type Motion System in the topic
Motion.

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[Link] Code examples

[Link] Code examples

Example without Fixed Position Events

Without the use of Fixed Position Events, the code can look like this:
MoveJ p1, vmax, fine, tool1;
MoveL p2, v1000, z20, tool1;
SetDO do1, 1;
MoveL p3, v1000, fine, tool1;

Result
The code specifies that the TCP should reach p2 before setting do1. Because the
robot path is delayed compared to instruction execution, do1 is set when the TCP
is at the position marked with X (see illustration).

xx0300000151

Example with TriggIO and TriggL instructions

Setting the output signal 30 mm from the target can be arranged by defining the
position event and then moving the robot while the system is executing the position
event.
VAR triggdata do_set;
!Define that do1 shall be set when 30 mm from target
TriggIO do_set, 30 \DOp:=do1, 1;
MoveJ p1, vmax, fine, tool1;
!Move to p2 and let system execute do_set
TriggL p2, v1000, do_set, z20, tool1;
MoveL p3, v1000, fine, tool1;

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[Link] Code examples
Continued

Result
The signal do1 will be set when the TCP is 30 mm from p2. do1 is set when the
TCP is at the position marked with X (see illustration).

xx0300000158

Example with MoveLSync instruction

Calling a procedure when the robot path is as close to the target as possible can
be done with one instruction call.
MoveJ p1, vmax, fine, tool1;
!Move to p2 while calling a procedure
MoveLSync p2, v1000, z20, tool1, "proc1";
MoveL p3, v1000, fine, tool1;

Result
The procedure will be called when the TCP is at the position marked with X (see
illustration).

xx0300000165

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[Link] Overview

2.14.2 Electronically Linked Motors

[Link] Overview

Description
Electronically Linked Motors makes a master/follower configuration of motors (for
example two additional axes). The follower axis will continuously follow the master
axis in terms of position, velocity, and acceleration.
For stiff mechanical connection between the master and followers, the torque
follower function can be used. Instead of regulating to exactly the same position
for the master and follower, the follower axis will get its torque reference as a quota
of the torque of the master axis. A small position error between master and follower
will occur depending on backlash and mechanical misalignment.

Purpose
The primary purpose of Electronically Linked Motors is to replace driving shafts
of gantry machines, but the base functionality can be used to control any other set
of motors as well.

What is included
The RobotWare base functionality Electronically Linked Motors gives you access
to:
• a service routine for defining linked motor groups and trimming the axis
positions
• system parameters used to configure a follower axis

Basic approach
This is the general approach for setting up Electronically Linked Motors. For a
more detailed description of how this is done, see the respective section.
1 Configure the additional axes as a mechanical unit. See Application
manual - Additional axes.
2 Configure tolerance limits in the system parameters, in the types Linked M
Process, Process, and Joint.
3 Restart the controller for the changes to take effect.
4 Set values to data variables, defining the linked motor group and connecting
follower and master axes.
5 Use the service routine to trim positions or reset follower after position error.

Limitations
There can be up to 5 follower axes. The follower axes can be configured to follow
one master each, or several followers can follow one master, but the total number
of follower axes cannot be more than 5.
The follower axis cannot be an ABB robot. The master axis can be either an
additional axis or a robot axis.

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[Link] Overview
Continued

The RAPID instruction IndReset (Independent Reset) cannot be used in

combination with Electronically Linked Motors.

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[Link].1 System parameters

[Link] Configuration

[Link].1 System parameters

About the system parameters

This is a brief description of each parameter used for the option Electronically
Linked Motors. For more information, see the respective parameter in Technical
reference manual - System parameters.

Joint
These parameters belong to the topic Motion and the type Joint.
Parameter Description
Follower to Joint Specifies which master axis this axis shall follow. Refers to the parameter
Name in the type Joint. Robot axes are referred to as rob1 followed by
underscore and the axis number (for example rob1_6).
Use Process Id name of the process that is called. Refers to the parameter Name in
the type Process.
Lock Joint in Ipol A flag that locks the axis so it is not used in the path interpolation.
This parameter must be set to TRUE when the axis is electronically linked
to another axis.

Process
These parameters belong to the topic Motion and the type Process.
Parameter Description
Name Id name of the process.
Use Linked Motor Id name of electronically linked motor process. Refers to the parameter
Process Name in the type Linked M Process.

Linked M Process
These parameters belong to the topic Motion and the type Linked M Process.
Parameter Description
Name Id name for the linked motor process.
Offset Adjust Delay Time delay from control on until the follower starts to follow the
Time master.
This can be used to give the master time to stabilize before the
follower starts following.
Max Follower Offset The maximum allowed difference in distance (in radians or meters)
between master and follower.
If Max Follower Offset is exceeded, emergency stop is activated.
Max Offset Speed The maximum allowed difference in speed (in rad/s or m/s) between
master and follower.
If Max Offset Speed is exceeded, emergency stop is activated.
Offset Speed Ratio Defines how large part of the Max Offset Speed that can be used
to compensate for position error.
Ramp Time Time for acceleration up to Max Offset Speed.
The proportion constant for position regulation is ramped from zero
up to its final value (Master Follower kp) during Ramp Time.

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[Link].1 System parameters
Continued

Parameter Description
Master Follower kp The proportion constant for position regulation. Determines how
fast the position error is compensated.
Torque follower Set to True if the follower and master should share torque instead
of regulating on exact position.
Torque quota The follower axis will get its torque reference according to the
master axis torque multiplied with the quota.
If motors and gears are identical, it is recommend to set this value
a bit lower than 1, for example, 0.95.

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[Link].2 Configuration example

[Link].2 Configuration example

About this example

This is an example of how to configure the additional axis M8DM1 to be a follower
to the axis M7DM1 and axis M9DM1 to be a follower to robot axis 6.

Joint

Name Follower to Joint Use Process Lock Joint in Ipol

M7DM1
M8DM1 M7DM1 ELM_1 True
M9DM1 rob1_6 ELM_2 True

Process

Name Use Linked Motor Process

ELM_1 Linked_m_1
ELM_2 Linked_m_2

Linked M Process

Name Offset Adjust Max Follow- Max Offset Offset Ramp Master Fol-
Delay Time er Offset Speed Speed Ra- Time lower kp
tio
Linked_m_1 0.2 0.05 0.05 0.33 1 0.05
Linked_m_2 0.1 0.1 0.1 0.4 1.5 0.08

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[Link].1 Using the service routine for a follower axis

[Link] Managing a follower axis

[Link].1 Using the service routine for a follower axis

About the service routine

When the follower axis is configured as a mechanical unit and connected to a
master axis, the service routine can be used to:
• calibrate the follower axis
• reset follower after a position error
• tune a torque follower axis, see Tuning a torque follower on page 106.

Copy service routine file to HOME

Copy the file linked_m.sysx from the folder .../RobotControl_7.xxx/utility/, to the
HOME folder of the robot system.

Load cfg files

Load the configuration files LINKED_M_MMC.cfg and LINKED_M_SYS.cfg. These
are located in the directory:
...\utility\LinkedMotors.
Loading configuration files can be done with RobotStudio. How to do this is
described in:
Tool Description of loading cfg files
RobotStudio Section Loading a configuration file in Operating manual - RobotStudio.

Restart the controller after loading the configuration files.

Data variables
When the service routine starts, it will read values from system parameters and
set the values for a set of data variables used by the service routine. These variables
only need to be set manually if something goes wrong, see Data setup on page 110.

Start service routine

Note

The controller must be in manual or auto mode to run this service routine.

Step Action
1 On the start screen, tap Operate, and then select Service Routines from the menu.
2 Select Linked_m and tap Go to.
If Linked_m is not listed, browse to the folder where you placed it.
3 Press and hold the enabling device.
4 Press the RUN button to start the service routine.
5 Tap Menu 1.
The follower axes that are set up in the system are shown in the task bar.

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[Link].1 Using the service routine for a follower axis
Continued

Step Action
6 Tap the follower axis you want to use the service routine for.
The main menu of the service program is now shown.

Menu buttons

Button Description
AUTO Automatically moves the follower axis to the position corresponding to the
master axis, see Reset follower automatically on page 105.
STOP Stops the movement of the follower axis. Can be used when jogging or using
AUTO and the movement must be stopped immediately.
JOG Manual stepwise movement of the follower axis, see Jog follower axis on page 103.
If the follower axis is synchronized with the master axis, it will resume its position
when you tap AUTO or when you exit the service program.
UNSYNC Used to suspend the synchronization between follower axis and master axis,
see Unsynchronize on page 103.
HELP Show some help for how to use the service program. The button Next shows
the next help subject.

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[Link].2 Calibrate follower axis position

[Link].2 Calibrate follower axis position

Overview
Before the follower axis can follow the master axis, you must define the calibration
positions for both master and follower.

Master axis
calibrate position

Follower
position Desired
follower
position

en0400000963

This calibration is done by following the procedures below:

1 Jog the master axis to its calibration position.
2 Unsynchronize the follower and master axes. See Unsynchronize on page 103.
3 Jog the follower to the desired position. See Jog follower axis on page 103.
4 Fine calibrate follower axis. See Fine calibrate on page 104.

Unsynchronize

Step Action
1 In the main menu of the service routine, tap UNSYNC.
2 Confirm that you want to unsynchronize the axes by tapping YES.
3 Restart the controller when an information text tells you to do it.
After the restart the follower axis is no longer synchronized with the master axis.

Jog follower axis

Step Action
1 In the main menu of the service program, tap JOG.
2 Select the speed with which the follower axis should move when you jog it.
3 Select the step size with which the follower axis should move for each step you
jog it.
4 Tap on Positive or Negative, depending on in which direction you want to move
the follower axis.
Jog the follower axis until it is exactly in the calibration position (the position that
corresponds to the master axis calibration position).

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[Link].2 Calibrate follower axis position
Continued

Fine calibrate

Step Action
1 Open the Calibrate app.
2 Select the mechanical unit that the follower axis belongs to.
3 Tap the button Calib. Parameters.
4 Tap Fine Calibration....
5 In the warning dialog that appears, tap Yes.
6 Select the axis that is used as follower axis and tap Calibrate.
7 In the warning dialog that appears, tap Calibrate.
The follower axis is now calibrated. As soon as the follower is calibrated, it is also
synchronized with the master again.

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[Link].3 Reset follower axis

[Link].3 Reset follower axis

Overview
If the follower offset exceeds its tolerance limits (configured with the system
parameter Max follower offset), the service routine must be used to move the
follower back within the tolerance limits. This can be done automatically in the
service routine if the follower is within the AUTO range. Otherwise the follower
must be manually jogged.
The range where AUTO can be used is determined by the system parameter Max
Follower Offset multiplied with the data variable offset_ratio.

Range where AUTO in service program can be used

Range where follower

automatically follow master

Desired
follower
position

Max Follower
Master axis Offset
position
Max Follower Offset * offset_ratio

en0400000962

Reset follower automatically

Step Action
1 In the main menu of the service routine, tap AUTO.
2 Select the speed with which the follower axis should move to its desired position.

Reset follower by manual jogging

Step Action
1 In the main menu of the service routine, tap JOG.
2 Select the speed with which the follower axis should move when you jog it.
3 Select the step size with which the follower axis should move for each step you
jog it.
4 Tap on Positive or Negative, depending on which direction you want to move the
follower axis.
Jog the follower until it is within the tolerance of Max Follower Offset (or use AUTO
when you are close enough).

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[Link].1 Description of torque follower

[Link] Tuning a torque follower

[Link].1 Description of torque follower

About torque follower

The follower axis can be set up so that it gets its torque reference directly from the
master axis.
The following simplified graphics shows the control loop for both master and
follower axis.

Master axis

xx2300001589

Follower axis

xx2300001590

Description
The follower axis gets its torque feedforward according to a quota of torque ref on
the master axis.
When the follower axis is set as torque follower, the control parameters position
control gain (K) and speed loop integral part (Kv/Ti) is internally set to zero. It is
recommended to run the follower axis with a small value of Kv and FFW mode =
Spd.

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[Link].1 Description of torque follower
Continued

Torque quota
The sharing of torque is done so that the follower axis receives its torque reference
as the master reference multiplied with the torque quota. The setup is done with
equal motors and gears quota, and the ideal would be 1.0, but for stability reasons
it is recommended to set it to a value below that, for example, 0.95.
If motor and gearbox differs between master and follower, manual calculation is
required to achieve good sharing and stability.
The torque quota is configured with the system parameter Torque quota, see
Technical reference manual - System parameters, topic Motion, type Linked M
Process.

Example of torque follower configuration

An example of a torque follower configuration (part of [Link]):
LINKED_M_PROCESS:
-name "TorqueFollower" -offset_adj_delay_time 0.1 -max_offset
50\
-max_offset_speed 1 -offset_speed_ratio 0.3 -ramp_time 0.1\
-kp_offset 0.2 -torque_follower -torque_distribution 0.9

LCM0:
-name "MasterAxis" -Kp 10 -Kv 0.15 -Ti 0.2 -ffw_mode 1
-name " TorqueFollower " -Kp 10 -Kv 0.05 -Ti 0.2 -ffw_mode 1

When enabling torque_follower, the parameters marked with bold font in the
example, are no longer used. max_offset is still valid but should be increased.
Normally the follower axis should use a smaller value of Kv, but it is recommend
to still have some natural damping.

Note

It is highly recommended to use same type of motor and gearbox for the master
and follower.
When the torque follower is used with different motor types or gearboxes, the
quota must be set accordingly. The quota is shared on motor torque and does
not consider gear ratio.

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[Link].2 Using the service routine to tune a torque follower

[Link].2 Using the service routine to tune a torque follower

About the service routine for torque follower

The service routine Linked_M can be used to find suitable values of some
parameters for torque follower configuration. When the values are found, the system
parameters are updated and a new fine calibration is done. After that, there is no
need for any tuning of the torque follower.

Opening the tune torque follower menu

Action Illustration
1 Start the service routine (as described
by the first steps in Start service routine
on page 101).
2 Tap Menu 2.
3 Tap on the name of the follower axis to
tune.
4 Use the tune torque follower menu as
described below.

Tuning the torque quota

Use this procedure to change the torque quote for the follower axis.
Action Illustration
1 Tap Torque quota.
2 Type a number (between 0 and 10) for
the follower’s quota master torque.
For example, 0.95 will result in 95% of
the master torque will be set to the follow-
er.
Values above 1 should only be used in
case the follower axis is dimensioned
with higher torque possibilities.
3 To update the system parameters using
the new value, tap Store to cfg.
If not saved to cfg, the new value will be
used until the robot controller is restar-
ted, but the value will be lost at restart.

Tuning the temporary position delta

Use this procedure to tune the position delta of the torque follower axis. This delta
value is then used to adjust the fine calibration of the follower axis.
Action Illustration
1 Tap Temp. position delta.
2 Type a number (degrees on motor side)
that will be added to the position refer-
ence for the follower axis.

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[Link].2 Using the service routine to tune a torque follower
Continued

Action Illustration
3 Test which value results in the lowest
torque tension and make a fine calibra-
tion of the master axis. This will update
the follower axis with the current position
delta.

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[Link].1 Set up data for the service routine

[Link] Data setup

[Link].1 Set up data for the service routine

Overview
At start of the service routine for Electronically Linked Motors, some data variables
are read from the linked motor configuration. These variables are used by the
service routine. If they are not read correctly, the variables need to be edited in
the service routine.

Data descriptions

Data variable Description

l_f_axis_name A name for the follower axis that will be displayed on the FlexPendant.
String array with 5 elements, one for each follower axis. If you only have
one linked motor, use only the first element.
l_f_mecunt_n The name of the mechanical unit for the follower axis. Refers to the system
parameter Name in the type Mechanical Unit.
String array with 5 elements, one for each follower axis. If you only have
one linked motor, use only the first element.
l_f_axis_no Defines which axis in the mechanical unit (l_f_mecunt_n) is the follower
axis.
Num array with 5 elements, one for each follower axis. If you only have
one linked motor, use only the first element.
l_m_mecunt_n The name of the mechanical unit for the master axis. Refers to the system
parameter Name in the type Mechanical Unit.
String array with 5 elements, one for each master axis. If you only have
one linked motor, use only the first element.
l_m_axis_no Defines which axis in the mechanical unit (l_m_mecunt_n) is the master
axis.
Num array with 5 elements, one for each master axis. If you only have
one linked motor, use only the first element.
offset_ratio Defines the range where the AUTO function in the service program reset
the follower axis. offset_ratio defines this range as a multiple of the
range where the follower automatically follow the master (defined with
the parameter Max Follow Offset).
If the follower has a position error that is larger than Max Follower Offset
* offset_ratio, the follower must be reset manually. For more informa-
tion, see Reset follower axis on page 105.
speed_ratio Defines the speed of the follower axis when controlled by the service
program. The values are given as a part of the maximum allowed manual
speed (that is, the value 0.5 means half the max manual speed).
Num array with 20 elements. Elements 1-5 define the speed "very slow"
for each follower axis. Elements 6-10 define "slow", elements 11-15 define
"normal" and elements 16-20 define "fast". If you only have one linked
motor, use only elements 1, 6, 11 and 16.

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[Link].1 Set up data for the service routine
Continued

Data variable Description

displacement Defines the distance the follower axis will move for each tap on Positive
or Negative when jogging the follower axis from the service program. The
values are given in degrees or meters, depending on if the follower axis
is circular or linear.
Num array with 20 elements. Elements 1-5 define the displacement "very
short" for each follower axis. Elements 6-10 define "short", elements 11-
15 define "normal" and elements 16-20 define "long". If you only have one
linked motor, use only elements 1, 6, 11 and 16.

Edit data variables

If the data needs to be edited, use the Program Data app on the FlexPendant. See
Operating manual - OmniCore for more information on how to edit data.

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[Link].2 Example of data setup

[Link].2 Example of data setup

About this example

This is an example of how to set up the data variables for two follower axis. The
first follower axis is M8C1B1, which is a follower to the additional axis M7C1B1.
The second follower axis is M9C1B1, which is a follower to robot axis 6.

l_f_axis_name

Represented axis Element and value in l_f_axis_name

Follower 1 {1}: "follow_external"
Follower 2 {2}: "follow_axis6"
Follower 3 {3}: ""
Follower 4 {4}: ""
Follower 5 {5}: ""

l_f_mecunt_n

Represented axis Element and value in l_f_mecunt_n

Follower 1 {1}: "M8DM1"
Follower 2 {2}: "M9DM1"
Follower 3 {3}: ""
Follower 4 {4}: ""
Follower 5 {5}: ""

l_f_axis_no

Represented axis Element and value in l_f_axis_no

Follower 1 {1}: 1
Follower 2 {2}: 1
Follower 3 {3}: 0
Follower 4 {4}: 0
Follower 5 {5}: 0

l_m_mecunt_n

Represented axis Element and value in l_m_mecunt_n

Master 1 {1}: "M7DM1"
Master 2 {2}: "rob1"
Master 3 {3}: ""
Master 4 {4}: ""
Master 5 {5}: ""

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[Link].2 Example of data setup
Continued

l_m_axis_no

Represented axis Element and value in l_m_axis_no

Master 1 {1}: 1
Master 2 {2}: 6
Master 3 {3}: 0
Master 4 {4}: 0
Master 5 {5}: 0

offset_ratio

Represented axis Element and value in offset_ratio

Follower 1 {1}: 10
Follower 2 {2}: 15
Follower 3 {3}: 0
Follower 4 {4}: 0
Follower 5 {5}: 0

speed_ratio

Represented axis very slow slow normal fast

Follower 1 {1}: 0.01 {6}: 0.05 {11}: 0.2 {16}: 1
Follower 2 {2}: 0.01 {7}: 0.05 {12}: 0.2 {17}: 1
Follower 3 {3}: 0 {8}: 0 {13}: 0 {18}: 0
Follower 4 {4}: 0 {9}: 0 {14}: 0 {19}: 0
Follower 5 {5}: 0 {10}: 0 {15}: 0 {20}: 0

displacement

Represented axis very short short normal long

Follower 1 {1}: 0.001 {6}: 0.005 {11}: 0.02 {16}: 0.1
Follower 2 {2}: 0.01 {7}: 0.1 {12}: 1 {17}: 10
Follower 3 {3}: 0 {8}: 0 {13}: 0 {18}: 0
Follower 4 {4}: 0 {9}: 0 {14}: 0 {19}: 0
Follower 5 {5}: 0 {10}: 0 {15}: 0 {20}: 0

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 3 Connectivity
3.1.1 Overview

3 Connectivity
3.1 Connected Services

3.1.1 Overview

Note

ABB Connected Services is the new name for the functionality previously known
as ABB Ability. During a period of time, both names will appear in and on our
products.

Description
Connected Services is a functionality for ABB robot controllers to connect to ABB
Connected Services Cloud by using 3G/4G, or wired connectivity. Connected
Services collects the service information from the controller.

Purpose
The primary purpose of Connected Services is to collect service information from
the controller.
These service information will be available through MyRobot, Connected Services
portal, or pushed locally.

What is included
The RobotWare base functionality Connected Services gives you access to:
• a Connected Services agent software to manage the connectivity and the
service data collection.
• system parameters used to enable and configure the connectivity.
• status and information pages.
• dedicated event logs for key events of Connected Services.
• connectivity through Connected Services Gateway.
• connectivity through the public port.

Prerequisites
The Connected Services function requires that the controller is included in a service
agreement with ABB. Contact your local ABB office to create a service agreement
with Connected Services and get access to MyRobot website to perform the
registration after the connection.

Note

MyRobot is the ABB website which gives access to the service information of a
robot controller under a service agreement.

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3.1.1 Overview
Continued

Basic workflow
Connected Services is available natively as a plug and connect solution in
RobotWare. The setup concept is to:
1 Provides internet connectivity to the robot controller.
2 Configure connected services and startup the connection.
3 Register the controller through MyRobot registration page.
Once Connected Services is connected and registered, the data collection will run
transparently in the background.

Limitations
The controller identification is done using the controller serial number and must
match the serial number defined in the service agreement.

Power On Connect
Using a Connected Services Gateway 3G or 4G will provide automatic connectivity
after Power On of the controller without any configuration.

Production Registration
ABB will securely pre register Connected Services during production process to
avoid the manual registration.
The manual registration is still available when needed.

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 3 Connectivity
3.1.2 Connected Services connectivity

3.1.2 Connected Services connectivity

Connected Services connection concept

The concept of Connected Services is that a virtual Software Agent is implemented
inside the controller and it communicates securely with the ABB Connected Services
Cloud through internet.

Note

The connectivity of the controller through the public network requires a Firewall
provided by the customer.
The communication is secured and encrypted using HTTPS (secure HTTP). The
communication is possible only from the controller to ABB Cloud to keep the
customer network isolated from any external Internet access. The following figure
describe these concepts.
HTTPS:443

HTTPS:443

ABB ABB Customer

Connected Services firewall firewall
Public Connector OmniCore Controller
[Link]
Internet

Service
ABB Connected
Public/WAN information
Service Cloud

3G/4G Connected Connected

ABB Connect/LAN4
Services Services
MyRobot ABB & gateway agent
Wired
Website Customer Internal
firewall

xx1900000977

Disabling Connected Services

A robot controller can be delivered with Connected Services disabled by default,
by selecting the option 3013-99 No Connected Services when ordering.
If the option 3013-99 is selected when ordering the controller, then the following
apply:
• Connected Services embedded software is disabled.
• No Connected Services Gateway is installed.
• Detection of Connected Services Gateway is disabled.
A controller ordered with option 3013-99 can be retrofitted with Connected Services
with the following procedure.
1 Configure the software, see Enable or disable Connected Services using
FlexPendant on page 126 or Enable or disable Connected Services using
RobotStudio on page 133.
2 Order a Connected Services Gateway, see spare parts in the product manual
for the robot controller.

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3 Connectivity
3.1.2 Connected Services connectivity
Continued

3 Enable the detection of the gateway, by configuring the Connected Services

Gateway system parameters, see Technical reference manual - System
parameters.
• Enable 3G connection
• State (for wired connection)

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 3 Connectivity
3.1.3 Connected Services registration

3.1.3 Connected Services registration

Connected Services startup

The Connected Services startup is based on the following steps:
• (0) Connected Services preparation
• (1) Connected Services configuration
• (2) Connected Services connectivity
• (3) Connected Services registration
• (4) Connected Services connected and registered
When these steps are done, the software agent is securely connected and identified
with a client certificate. The following figure describes these concepts:

2d 2a
2b
2c
3d
Internet
4
ABB Connected
Services Center

Internet

3a 1a 0

3b 3c

Customer/ Customer/ My Robot

ABB CS Tech On Site ABB CS Admin

xx1500003226

Step Description
0 Check controller S/N and internet connectivity
1a Enable CSE and set up connectivity configuration
2a CS connectivity in place
2b Low poll for registration
2c Registration not trusted (get reg code)
2d Display registration code
3a Get registration code
3b Give controller S/N and registration code
3c Select controller S/N in SA and register with registration code
3d Registration trusted (client certificate)
4 Connected and registered secure CS session

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3 Connectivity
3.1.3 Connected Services registration
Continued

Connected Services preparation

1 Verify that the service agreement for this controller is available with ABB.
2 Verify the controller serial number with the serial number found in the
controller cabinet.
3 Verify and provide Internet connectivity to the robot controller.

Connected Services configuration

1 Configure the connectivity parameters based on connection type, see
Configuring Connected Services using FlexPendant on page 125.

Connected Services connectivity

1 The software agent connects to ABB Connected Services Cloud.
2 An initial registration process starts based on the selected polling rate.
3 The initial registration is incomplete and not yet fully trusted.
4 A registration code is received to finalize the trust relation.
5 The registration code is made available on the Connected Services
registration page.

Connected Services registration

1 The customer/ABB on site provides the controller serial number and
registration code to the Connected Services administrator for registration.
2 The Connected Services administrator validates this registration code in
MyRobot/Registration for ABB Connected Services on its service agreement.
3 The registration trust starts and implements a client certificate in the
controller.

Connected Services connected and registered

1 The controller is connected, registered, and identified as in the service
agreement.
2 The connection is trusted with a client certificate.
3 Connected Services is now actively running on the robot controller.

Note

In case of Power On Connect with 3G or 4G Connected Services Gateway and

production registration, all these process is done automatically when the controller
is powered.

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 3 Connectivity
3.1.4 Summary of Connected Services paths in FlexPendant

3.1.4 Summary of Connected Services paths in FlexPendant

Configuration
In Flexpendant the Connected Services configuration are available in:
• CS Gateway 3G: Settings > ABB Connected Services > 3G Connection
• CS Gateway Wired: Settings > ABB Connected Services > Wired Connection

Note

Connected Services Gateway 4G is configured through Wired Connection.

Status
In FlexPendant the Connected Services status are available in:
• Network: Settings > ABB Connected Services > Network Status
• CS Gateway: Settings > ABB Connected Services > Connectivity Status
• Connected Services summary: QuickSet > Connected Services
• Connected Services details: Settings > ABB Connected Services >
Connected Services Status
• Reset Connected Services: Operate > Service Routine

Logs
In Flexpendant the Connected Services logs are available in:
• Connection Logs (3G): Settings > Backup and Recovery > Connection Logs
• Details Logs: Settings > Backup and Recovery > System Diagnostic

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3.1.5 Summary of Connected Services paths in RobotStudio

3.1.5 Summary of Connected Services paths in RobotStudio

Configuration
In RobotStudio the Connected Services configuration are available in:
• CS Gateway 3G: Controller > Configuration > Communication > CS Gateway
3G
• CS Gateway Wired: Controller > Configuration > Communication > CS
Gateway Wired

Note

Connected Services Gateway 4G is configured through Wired Connection.

Status
In RobotStudio the Connected Services status are available in:
• Connected Services Summary/Details: Controller > Properties > Device
Browser > Software Resources > Connected Services
• Reset Connected Services: Not implemented

Logs
In RobotStudio the Connected Services logs are available in:
• Connection Logs (3G/4G): Not implemented
• Details Logs: Controller > Properties > Save Diagnostic

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 3 Connectivity
3.1.6 Configuration of system parameters

3.1.6 Configuration of system parameters

Introduction
This section provides a brief description of system parameters used for the
Connected Services. For more information see Technical reference manual - System
parameters.

Connected Services connection

The following parameters belong to the topic Communication, and the type
Connected Services. For more information, see the respective parameter in
Technical reference manual - System parameters.
Parameter Description
Enabled Enables or disables the Connected Services connection between
the controller and the server.
Connection Type Indicates if the communication is done on ABB Connect (ABB
Connected Services Gateway solution), Public, or Custom network.

Note

If the connection type is configured as Public or Custom, then en-

able Connected Services on Firewall Settings. For more details, see
the section Firewall settings in Operating manual - Integrator's
guide OmniCore.

Internet Gateway IP Defines the internet gateway IP of the connected network when the
connection type is private. This is valid for the Connection Type
Custom.
Forces the Internet Gateway to use for connectivity.
Internet DNS IP Defines the internet DNS IP of the connected network. This is valid
for the Connection Type Custom.
Forces the DNS to use for connectivity.

Note

The DNS can be set to blank if:

• the proxy is defined.
• the DNS resolution is done with the proxy.
• the proxy is provided as an IP address.

Proxy Used Defines if a proxy is used to access the internet and its name/ad-
dress, port, and authentication.
Proxy Auth Defines the proxy authentication type. Basic will use HTTP basic
authentication including user and password. None will not use any.
Server Polling Defines the frequency of polling for specific synchronization with
the sever. The available values are slow and fast.
For details about the behavior of events for server polling, see De-
scription of behavior of events for server polling on page 147.
Debug Mode Enables extensive logging for debugging the issues.
Trace Level Defines the level of logging if Debug Mode is enabled.

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3.1.6 Configuration of system parameters
Continued

Parameter Description
Connected Services Defines the compatibility for different robot controller's data format,
Mode cloud solution, and specific features. Following are the available
modes:
• Omnicore data collection.

Note

By default, the Omnicore data collection mode is enabled.

WAN configuration (Public connectivity)

The WAN IP/Mask/Gateway configuration is done in RobotStudio or on the
FlexPendant. The WAN Ethernet port configuration can give access to the Internet
on the controller without using the Connected Services Gateway. The port is defined
by its IP, Mask, and possible Gateway. For details about Public (WAN) configuration,
see the section Configuring Connected Service Gateway using FlexPendant in
Operating manual - Integrator's guide OmniCore.

Note

A firewall must be installed by the customer, if the Public/WAN port is connected

to Internet.

DNS configuration (Public connectivity)

These parameters belong to the topic Communication and the type DNS Client. A
DNS server need to be defined to resolve the name of the ABB Connected Services
connector ([Link]) to its IP address, if Public/WAN port is used for
internet connectivity. For more details, see Type DNS Client in Technical reference
manual - System parameters.

Note

For quick testing, use a temporary DNS defined as [Link] (Google DNS), then
switch to customer recommended DNS server IP.

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 3 Connectivity
[Link] Introduction

3.1.7 Configuring Connected Services using FlexPendant

[Link] Introduction

Overview
This section explains how Connected Services is configured using the controller
FlexPendant based on the available internet connectivity. Internet connectivity can
be provided in multiple ways.
• Connected Services Gateway module (3G, 4G or wired)
• Direct internet connection on customer Public (WAN) network
• Direct internet connection on custom network

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3 Connectivity
[Link] Enable or disable Connected Services using FlexPendant

[Link] Enable or disable Connected Services using FlexPendant

Enabling or disabling Connected Services

This section provides information about enabling or disabling Connected Services
using FlexPendant.

Note

Connected Services is enabled by default.

Use the following procedure to enable or disable Connected Services on the
FlexPendant:
1 On the start screen, tap Settings, and then select ABB Connected Services
from the menu.
2 Tap Connected Services on the left pane.
3 In the Enable Connected Services field tap and select the value Yes or No.
4 Tap Apply.
The Restart confirmation message is displayed.
5 Tap OK.
The controller is restarted and Connected Services is enabled or disabled
based on the selection.

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[Link] Configure Connected Services based on connection type using FlexPendant

[Link] Configure Connected Services based on connection type using FlexPendant

Overview
Connected Services can be configured in the following ways depending on the
available connection type:
• ABB Connect
• Public
• Custom

Configuring the connection type ABB Connect

Connected Services is configured with the connection type ABB Connect when
the ABB Connected Services Gateway solution is connected.

Note

The connection type ABB Connect is enabled by default.

Use the following procedure to configure the connection type ABB Connect using
FlexPendant:
1 On the start screen, tap Settings, and then select ABB Connected Services
from the menu.
2 Tap Connected Services on the left pane.
The configuration parameters for Connected Services is displayed.
3 In the Connection Type list, tap and select ABB Connect.

Note

The ABB Connected Services network can be configured based on the

available CS Gateway (3G, 4G, or Wired). For details, see Operating
manual - Integrator's guide OmniCore.

4 Tap Apply.
The Restart confirmation message is displayed.
5 Tap Yes.
The controller is restarted.
Connected Services starts communicating to the server based on the
configuration.
Check the connectivity status or event logs. For more details, see Connected
Services information on page 139.

Configuring the connection type Public

Connected Services can be configured with the connection type Public when the
communication is done on customer Public (WAN) network using the IP, the default
gateway and DNS received through DHCP or statically configured.

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[Link] Configure Connected Services based on connection type using FlexPendant
Continued

Note

The Public network and DNS can be configured statically or automatically (via
DHCP). For more details, see Configuration of public network using FlexPendant
on page 130.

Note

If the connection type is configured as Public, then enable Connected Services

on Firewall Settings. For more details, see the section Firewall settings in
Operating manual - Integrator's guide OmniCore.
Use the following procedure to configure the public network using FlexPendant:
1 On the start screen, tap Settings, and then select ABB Connected Services
from the menu.
2 Tap Connected Services.
The configuration parameters for connected services are displayed.
3 In the Connection Type list, tap and select Public.
4 Tap Apply.
The Restart confirmation message is displayed.
5 Tap Yes.
The controller is restarted.
Connected Services starts communicating to the server based on the
configuration.
Check the connectivity status or event logs. For more details, see Connected
Services information on page 139.

Configuring the connection type Custom

Connected Services can be configured with the connection type Custom when the
controller has to specify a default Gateway and DNS available on the network.

Note

If the connection type is configured as Custom, then enable Connected Services

on Firewall Settings. For more details, see the section Firewall settings in
Operating manual - Integrator's guide OmniCore.
Use the following procedure to configure the connection type Custom using
FlexPendant:
1 On the start screen, tap Settings, and then select ABB Connected Services
from the menu.
2 Tap Connected Services on the left pane.
The configuration parameters for connected services is displayed.
3 In the Connection Type list, tap and select Custom.
4 In the Internet Gateway IP field, type the IP address of internet gateway.

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[Link] Configure Connected Services based on connection type using FlexPendant
Continued

5 In the Internet DNS IP field, type the IP address of Internet DNS.

6 Tap Apply.
The Restart confirmation message is displayed.
7 Click OK.
The controller is restarted.
Connected Services starts communicating to the server based on the
configuration.
Check the connectivity status or event logs. For more details, see Connected
Services information on page 139.

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[Link] Configuration of public network using FlexPendant

[Link] Configuration of public network using FlexPendant

Configuring IP and DNS Statically

Use the following procedure to statically configure IP and DNS using FlexPendant:
1 On the start screen, tap Settings, and then select Network from the menu.
2 Tap Public Network on the left pane.
3 Select the option Use the following IP Address or Use the following DNS
server addresses.
4 Enter the values in IP address, Subnet mask, Default gateway, Preferred
DNS server, and Alternate DNS server fields.
5 Tap Apply.
The IP and DNS are configured statically.

Configuring IP and DNS Automatically

Use the following procedure to automatically configure IP and DNS using
FlexPendant:
1 On the start screen, tap Settings, and then select Network from the menu.
2 Tap Public Network on the left pane.
3 Select the option Automatically get an IP Address or Automatically get
DNS server addresses.
The IP address and DNS server address is uploaded automatically.
4 Tap Apply.
The IP and DNS are configured automatic.

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[Link] Configure internet connection with proxy using FlexPendant

[Link] Configure internet connection with proxy using FlexPendant

Procedure
The following procedure provides information about configuring the Connected
Services from the FlexPendant when there is Internet connection with proxy.
1 On the start screen, tap Settings, and then select ABB Connected Services
from the menu.
2 Tap Connected Services.
The configuration parameters for Connected Services are displayed.
3 In the Proxy Used field, change the value to Yes.
The proxy parameters are displayed.
4 In the Proxy Name field, type a name for the proxy.
5 In the Proxy Port field, type the proxy port number.
6 In the Proxy Auth field, select Basic for basic authentication or select None
for no authentication from the drop-down list.

Note

Define the proxy user name and password for the basic authentication.
Even if a proxy is used, it is mandatory to define a DNS for name resolution.

Note

If your RobotWare version is between RW 7.8.1 and RW 7.10, it is

mandatory to define a username and password in proxy configuration,
even if is not used.

7 Tap Apply and restart the controller to take effect of the changes.

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[Link] Introduction

3.1.8 Configuring Connected Services using RobotStudio

[Link] Introduction

Overview
This section explains how the Connected Services is configured using RobotStudio
with the controller based on the available internet connectivity. Internet connectivity
can be provided in multiple ways.
• Connected Services Gateway Module (3G, 4G or wired)
• Direct internet connection on Customer Public (WAN) network
• Direct internet connection on custom network

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[Link] Enable or disable Connected Services using RobotStudio

[Link] Enable or disable Connected Services using RobotStudio

Enabling or disabling connected services

This section provides information about enabling or disabling Connected Services
using RobotStudio.

Note

Connected services is enabled by default.

Use the following procedure to manage the enabling or disabling of the connected
services feature:
1 Add controller in RobotStudio.
2 Click controller Configuration.
3 Right-click on Communication and select Configuration Editor.
The Configuration Editor is displayed.
4 Select Connected Services.
The configuration parameters for connected services is displayed.
5 Right-click on any field and select Edit Connected Services(s).
The Instance Editor is displayed.
6 In the Enabled field select the value Yes or No.
7 Click OK.
8 Restart the controller.
The connected services is enabled or disabled based on the selection.

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[Link] Configure connected services based on connection type using RobotStudio

[Link] Configure connected services based on connection type using RobotStudio

Overview
Connected services can be configured in the following three ways depending on
the available connection type:
• ABB Connect
• Public
• Custom

Configuring the connection type ABB Connect

Connected services is configured with the connection type ABB Connect when
the ABB Connected Services Gateway solution is connected.

Note

The connection type ABB Connect is enabled by default.

Use the following procedure to configure the connection type ABB Connect using
RobotStudio:
1 In the Controller tab, click Configuration.
2 Right-click on Communication and select Configuration Editor.
The Configuration Editor is displayed.
3 Select Connected Services.
The configuration parameters for connected services is displayed.
4 Right-click on any field and select Edit Connected Services(s).
The Instance Editor is displayed.
5 In the Connection Type field, select the value ABB Connect.

Note

Network can be configured based on the available CS Gateway (3G, 4G

or Wired). For details, see Operating manual - Integrator's guide OmniCore.

6 Click OK.
7 Restart the controller.
The connected services start communicating to the server based on the
configuration.
Check the connectivity status in the device browser. For more details, see
Connected Services information on page 139.
Also refer to the event logs generated. For more details, see Technical
reference manual - Event logs for RobotWare 7.

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[Link] Configure connected services based on connection type using RobotStudio
Continued

Configuring the connection type Public

Connected services can be configured with the connection type Public when the
communication is done on customer WAN network and when there is a default
gateway and DNS received.

Note

Public network and DNS can be configured statically or automatic (through

DHCP). For more details, see Configuration of public network using RobotStudio
on page 137.

Note

If the connection type is configured as Public, then enable Connected Services

on Firewall Settings. For more details, see the section Firewall settings in
Operating manual - Integrator's guide OmniCore.
Use the following procedure to configure the the connection type Public using
RobotStudio:
1 In the Controller tab, click Configuration.
2 Right-click on Communication and select Configuration Editor.
The Configuration Editor is displayed.
3 Click Connected Services.
The configuration parameters for connected services is displayed.
4 Right-click on any field and select Edit Connected Services(s).
The Instance Editor is displayed.
5 In the Connection Type field, select the value Public Network.
6 Click OK.
7 Restart the controller.
The connected services start communicating to the server based on the
configuration.
Check the connectivity status in the device browser. For more details, see
Connected Services information on page 139.
Also refer to the event logs generated. For more details, see Technical
reference manual - Event logs for RobotWare 7.

Configuring the connection type Custom

Connected services can be configured with the connection type Custom when the
controller has to specify a default gateway and DNS available on the network.

Note

If the connection type is configured as Custom, then enable Connected Services

on Firewall Settings. For more details, see the section Firewall settings in
Operating manual - Integrator's guide OmniCore.

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[Link] Configure connected services based on connection type using RobotStudio
Continued

Use the following procedure to configure the connection type Custom using
RobotStudio:
1 In the Controller tab, click Configuration.
2 Right-click on Communication and select Configuration Editor.
The Configuration Editor is displayed.
3 Click Connected Services.
The configuration parameters for connected services is displayed.
4 Right-click on any field and select Edit Connected Services(s).
The Instance Editor is displayed.
5 In the Connection Type field, select the value Private Network.
6 In the Internet Gateway IP field, type the IP address of internet gateway.
7 In the Internet DNS IP field, type the IP address of Internet DNS.
8 Click OK.
9 Restart the controller.
The connected services start communicating to the server based on the
configuration.
Check the connectivity status in the device browser. For more details, see
Connected Services information on page 139.
Also refer to the event logs generated. For more details, see Technical
reference manual - Event logs for RobotWare 7.

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[Link] Configuration of public network using RobotStudio

[Link] Configuration of public network using RobotStudio

Configuring IP Statically
Use the following procedure to configure statically IP using RobotStudio:
1 Right-click on the controller and select Properties > Network Settings.
The Network settings window is displayed.
2 Select the option Use following IP address.
3 Enter the values in IP address, Subnet mask, Default gateway fields.
4 Click OK and restart the controller
The IP is configured.

Configuring DNS Statically

The following procedure provides information about configuring the Connected
Services from RobotStudio when there is direct internet connection with statically
DNS.
1 In the Controller tab, click Configuration.
2 Right-click on Communication and select Configuration Editor.
The Configuration Editor is displayed.
3 Click DNS Client.
The configuration parameters for DNS Client is displayed.
4 Right-click on any field and select Edit DNS Client(s).
The Instance Editor is displayed.
5 In the Enabled field change the value to Yes.
6 In the 1st Name Server field type the server IP.
7 Click OK and restart the controller for the changes to take effect.

Configuring IP Automatic (DHCP)

Use the following procedure to configure IP automatic using RobotStudio:
1 Right-click on the controller and select Properties > Network Settings.
The Network settings window is displayed.
2 Select the option Obtain an IP address automatically.
The IP address is uploaded automatically.
3 Click OK and restart the controller
The IP and DNS shall be received automatically.

Note

It is still possible to define manual DNS with automatic IP. If there is conflict
between manual and automatic DNS, manual DNS has priority.

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[Link] Configure internet connection with proxy using RobotStudio

[Link] Configure internet connection with proxy using RobotStudio

Procedure
The following procedure provides information about configuring the Connected
Services from the RobotStudio when there is internet connection with proxy.
1 In the Controller tab, click Configuration.
2 Right-click on Communication and select Configuration Editor.
The Configuration Editor is displayed.
3 Select Connected Services.
The configuration parameters for connected services is displayed.
4 Right-click on any field and select Edit Connected Services(s).
The Instance Editor is displayed.
5 In the Proxy Used field, select the value Yes.
The proxy parameters are displayed.
6 In the Proxy Name field, type a name for the proxy.
7 In the Proxy Port field, type the proxy port number.
8 In the Proxy Auth field, from the drop-down list, select Basic for basic
authentication or select None for no authentication.

Note

Define the Proxy User and Proxy Password fields for the basic
authentication. Even if a proxy is used, it is mandatory to define a DNS for
name resolution.

Note

If your RobotWare version is between RW 7.8.1 and RW 7.10, it is

mandatory to define a username and password in proxy configuration,
even if is not used.

9 Click OK.
The controller is restarted and the changes are applied.

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 3 Connectivity
3.1.9 Connected Services information

3.1.9 Connected Services information

Connected Services pages

Introduction
The Connected Services information pages are available in FlexPendant under
Settings > ABB Connected Services > Connected Services Status. The following
Connected Services Status information pages are available:
• Overview
• Connectivity
• Registration
• Advanced

Note

The Connected Services information pages are available in RobotStudio under

Controller Properties > Device Browser > Software resources > Communication
> Connected Services.

Note

The information on a page can be refreshed by changing the page or by pressing

the Refresh button. The Refresh button also forces a connection with the server
if the software agent is waiting (for example, wait for registration
acknowledgement from MyRobot). This is useful in case of slow polling when
Server Polling is set to Slow.

Overview page
The Overview page provides a summary of the Connected Services status and
information. If the status is not active then the other pages provide more detailed
information.
Field Description Possible values Example
Property
Enabled Displays the value of the master Yes/No Yes
configuration switch for turning the
Connected Services on/off.
Status Displays the current status to see For a description Active
whether there is a need to navigate of values, see
to the Server connection page or CSE status on
Registration page. page 145.
Serial number Displays the identifier that is used Controller Serial 12-45678
to identify the controller in Connec- number
ted Services.
Robot OS Ver- Displays the Robot OS Version that Robot OS Ver- RobotOS_1.00.0-
sion is sent to the server. sion number 379
Robot Control Displays the Robot Control version Robot Control RobotCon-
version that is sent to the server. version name trol_7.[Link]-
ternal+405

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3.1.9 Connected Services information
Continued

Field Description Possible values Example

Service Agree- To verify that the controller is asso- "Name of the ser- SA_FR12_16
ment ciated to the expected service vice agreement"
agreement. "-"
Customer name To verify that the controller is asso- "Customer Name ABB Robotics
ciated to the expected service of the service
agreement. agreement"
"-"
Country To verify that the controller is asso- "Country of the France
ciated to the expected service service agree-
agreement. ment"
"-"
ABB server Displays the type of the server con- Robotics Cloud Robotics Cloud
nected services is connected.

Connectivity page
The Connectivity page provides a summary of the Connected Services connectivity
to the server.
Field Description Possible Example
values
Status Displays the current status to see For a de- Active
whether there is a need to navigate scription of
to the Connectivity page or Regis- values, see
tration page. CSE status
on page 145.
Connection Displays the status of communica- For a de- Connected
Status tion with the server and the type of scription of
error. values, see
CSE connec-
tion status
on page 145 .
Last updated Displays the relative time since the "HH:MM:SS ago"
information on the Connectivity
page has been generated.
Hardware gate- Displays the type of hardware gate- DSQC 1039 3G
way way and connection IP. Connected on IP:
[Link]
Note

4G Gateway is displayed as
DSQC1041 Wired.

Server name Displays the name of the server that "" Connected Services -
software agent is configured with. Server name [Link]

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3.1.9 Connected Services information
Continued

Field Description Possible Example

values
Server IP Displays the IP address of the serv- "" [Link] for
er and the port number used for Server IP [Link]
connection. The IP address is the
result of DNS name resolution done
by software agent.

Note

The IP address of [Link]

is displayed only if DNS is resolved
locally. If the system is unable to
resolve the IP, value displayed will
be "none".
If proxy is configured and the DNS
resolution is done by the proxy
server then the value displayed will
be "Proxy".

Server certific- Displays the server certificate name "" Connected Services -
ate name information. Server name [Link]
Untrusted
(Server)
Server certific- Displays the name of the server "" ABB issuing CA 6
ate issuer certificate issuer. Issuer DigiCert SHA2 Secure
Untrusted Server CA
(Issuer)
Server certific- Displays the server certificate date. "" Oct 02 [Link] 2020
ate valid from Issuer GMT
Issued
(Date)
Server certific- Displays the server certificate date. "" Nov 21 [Link] 2021
ate valid until Issuer GMT
Expired
(Date)
Client certificate Displays the name of the client cer- 07-000036
device tificate device.
Client Certificate Displays the name of the client cer- Remote-Service-
issuer tificate issuer. PROD-Issuing-CA-1
Client Certificate Displays from which date onwards Mar 15 [Link] 2019
valid from the client certificate is valid. GMT
Client Certificate Displays till which date the client Mar 15 [Link] 2020
valid until certificate is valid. GMT
Client Certificate Displays the serial number of the 15E37B17000100
serial number client certificate. 002D0B
Internet IP Displays the IP which is used to [Link]
connect to internet.

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Continued

Field Description Possible Example

values
Controller time Displays the controller date and 16-01-08 [Link]
time details.

Note

It is important to set the correct time

in the controller as this is needed
for the certificate process.

Connection type Displays the type of network connec- Public

tion used. ABB Con-
nect
Custom
Public network Displays the network information for NoIP DHCP: [Link]/
information the Public port. Static [Link]/
[Link]/ plugged
DHCP
ABB Connect Displays the network information for NoIP Static: [Link]/
network informa- the ABB Connect port. Static 255.255.255/ [Link]/
tion plugged
DHCP
System DNS Displays the DNS server informa- [Link]:53
tion.
Gateway used Displays the gateway used for creat- [Link]
ing the routes.
DNS used Displays the DNS values that are [Link]:53
currently used.
Route 1-8 Displays the routes created by Route 1 :
Connected Services. [Link]/32 =>
[Link]

Registration page
The Registration page provides a summary of the Connected Services registration.
Field Description Possible values Example
Status Displays the current status to see For a description Active
whether there is a need to navigate of values, see
to the Server connection page or CSE status on
Registration page. page 145.
Registration Displays the registration status. For a description Register with
Status of values, see code in MyRobot
CSE registration
status on
page 146.
Registration Displays the registration code. This "-" 456735
code code can be used to register using Code value
MyRobot.

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3.1.9 Connected Services information
Continued

Advanced page
The Advanced page provides advanced information about the dialog between
software agent and server.
Field Description Possible values Example
Last HTTP mes- Displays the last message sent. Register GetMessage
sage CheckRegistered
LogMessage
GetMessage
GetConfig
SendGetSpecific-
Code
DownLoadFile
AcknowledgeMes-
sage
BoxUpload
GetRSEAgree-
mentInformation
SendDeviceIn-
formation
RequestClientCer-
tificate
RenewClientCerti-
ficate
periodicDeviceUp-
dateInformation
Last HTTP mes- Displays the date and time when the Sent [Link]
sage time last message was sent. ago
Last HTTP error Displays the HTTP error when the Not Available - if Not Available
last message was sent and the no error
message ID if 4XX. Error HTTP XXX
+ Message
Next message Displays the next message to send GetMessage in
and the date to send the message. 70 seconds
Last command Displays the last command received Not Available Not Available
from server. Reboot
Reset
Ping
Diagnostic
...
Restart counter Displays the number of times the 0-N 2
software Agent been auto-restarted. If not Enabled,
This is used to see if watchdog has then display 0
restarted.
Connector ver- Displays the currently running con- 1.0.0
sion nector version information.

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Continued

Field Description Possible values Example

Data Collector Displays the status of the data col- Started Started
status lector. Not Started
None
Downloaded
Download Failed
Failed
Stopped
Disabled
Last registered Displays the last registration date
and time to server of controller.
Last connected Displays the last date and time on 11-07-2020
which the controller detects a suc- [Link]
cessful connection with the server.
Server polling Displays the Server polling configur- Fast Fast
ation. Server polling is related to the Slow
calculation of connection cost.
Bytes sent/re- Displays the number of bytes 17.0KB/24.17KB
ceived sent/received.
Connected Ser- Displays the status of the connected For a description Active Mode
vices mode services mode. of values, see
CSE mode on
page 147.
Server errors Displays a count of the following 0-N for each 5
servers errors: server error 0
1 Connection errors
1
2 Connection not available er-
rors 0
3 Authentication errors 1
4 Request errors 0
5 Timeout errors 0
6 Proxy errors 4
7 Unknown errors
8 Server errors
Root certificate Displays the name of the root certi- Baltimore Cyber-
issuer ficate issuer. Trust Root
DigiCert Global
Root CA
Root certificate Displays the name of the root certi- Baltimore Cyber-
subject ficate subject. Trust Root
DigiCert Global
Root CA
Root certificate Displays from which date onwards May 12 [Link]
valid from the root certificate is valid. 2000 GMT
May 12 [Link]
2006 GMT
Root certificate Displays till which date the root May 12 [Link]
valid until certificate is valid. 2025 GMT
May 12 [Link]
2031 GMT

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Continued

Data collectors page

The Data Collectors are the components used to collect the data required by ABB
Connected Services Cloud. The Data Collectors are updatable OTA (Over The Air)
from ABB Cloud.
The Data Collector page provides information about the state and version details
of different data collectors.
Field Description Possible values Example
OmniCore Con- Displays the status and version in- Disabled 1.0.4
nected Services formation of Connected Services Version informa-
data collector. tion

Description of values in Connected Services information

CSE status
The following table gives the information of CSE status:
Code Value Description
BASE_FAILED Failed Connected Services status is failed.
BASE_INITIALIZING Initializing Connected Services status is initializing.
BASE_ACTIVE Active Connected Services status is active.
BASE_CONNECT Trying to connect Connected Services status is trying to connect.
BASE_SHUTDOWN Shutdown mode Connected Services status is shutdown mode.
UNKNOWN_STATUS Unknown Connected Services status is unknown.
BASE_SLEEP Sleep Connected Services status is sleep mode.

CSE connection status

The following table gives the information of CSE connection status:
Code Value Description
SERVER_REQUEST_TIMEOUT_ERROR Request timed out Connection status request is
timed out.
SERVER_CONNECTED Connected Connection status in connected.
SERVER_NETWORK_ERROR Server not reach- Connection status server is not
able reachable.
SERVER_AUTH_ERROR Server not authen- Connection status server is not
ticated authenticated.
SERVER_CERT_ERROR Server certification Connection status server is
verification error certification verification error.
SERVER_HTTP_ERROR Server error (HTTP) Connection status server is HT-
TP error.
SERVER_PROXY_AUTH_ERROR Proxy Authentica- Connection status proxy authen-
tion Required tication error is required.
SERVER_REQUEST_ERROR Request error Connection status is request
error.
SERVER_PROXY_CONN_ERROR Proxy Connection Connection status proxy connec-
Error tion error.

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3.1.9 Connected Services information
Continued

Code Value Description

SERVER_GATEWAY_DISABLED CS Gateway dis- Connection status Gateway is
abled disabled.
SERVER_GATEWAY_WAITING Identifying CS Connection status Gateway is
Gateway identifying.
SERVER_GATEWAY_WAITING_3G Waiting 3G con- Connection status Gateway is
nectivity waiting for 3G connectivity.
SERVER_GATEWAY_CONNECTED CS Gateway con- Connection status Gateway is
nected connected.
SERVER_LOOKUP_IN_PROGRESS Host name lookup Connection status Gateway
in progress host name lookup in progress.
WAITING_GATEWAY_IP Waiting for Gate- Connection status Gateway is
way IP waiting for Gateway IP.
SERVER_DNS_RESOLUTION_FAIL DNS resolution Connection status Gateway has
failed server DNS resolution failure.
SERVER_GW_PING_TIMEOUT Gateway ping Connection status Gateway
timeout server ping is time out.
DNS_NOT_PINGABLE DNS not pingable Connection status Gateway has
DNS that is not pingable.
AUTHN_ERROR Authentication error Connection status Gateway
having authentication error.
RESTART_ERROR Waiting to start Connection status Gateway is
after restart error waiting to start after restart er-
ror.
CS_BLOCKED Blocked CSE is displaying this message
when CSE is not enabled in
Public or Private network. By
default CSE is enabled on
Private network.
For more details, see the para-
meter External Firewall Enabled
in Technical reference manu-
al - System parameters.
RESET_ERROR Waiting to start Connection status Gateway is
after reset error waiting to start after reset error.
CSE_SLEEP_MODE CSE in configured Connection status Gateway is
sleep mode in sleep mode.

CSE registration status

The following table gives the information of CSE registration status:
Code Value Description
REG_REGISTERED Registered Registration status is registered.
REG_IN_PROGRESS Registration in progress Registration status is in progress.
REG_REGISTER Registration with code in Registration status is registered with
MyRobot code in MyRobot.
REG_DISABLED Registration disabled Registration status is disabled.
REG_FAILED Failed Registration status is failed.

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 3 Connectivity
3.1.9 Connected Services information
Continued

CSE mode
The following table gives the information of CSE mode:
Code Value Description
CS_MODE_BOOT Boot Mode Connected Services during initialization.
CS_MODE_REGISTRATION Registration Mode Connected Services in registration mode.
CS_MODE_ACTIVE Active Mode Connected Services after registration is
successful.
CS_MODE_RESET Reset Mode Connected Services during reset of connec-
ted services.
CS_MODE_SLEEP Sleep Mode When there is a delay to perform operation.
CS_MODE_SHUTDOWN Shutdown Mode When suspend connected services until
revoke.

Data collection status

The following table gives the information of data collection status:
Code Value Description
SPECIFIC_STATUS_NONE None Data collection status is none.
SPECIFIC_STATUS_DOWNLOADED Download Data collection status is
downloaded.
SPECIFIC_STATUS_DOWNLOAD_FAILED Download Failed Data collection status down-
loaded failed.
SPECIFIC_STATUS_STARTED Started Data collection status is star-
ted.
SPECIFIC_STATUS_STOPPED Stopped Data collection status is
stopped.
SPECIFIC_STATUS_FAILED Failed Data collection status is failed.

Description of behavior of events for server polling

The following table gives information about the behavior of events for server polling:
Events Slow Fast
Check Registration 30 min 10 min
Send HardWare Information (before registra- 30 min 10 min
tion)
(Periodic polling is send only if there is any
change.)
Send HardWare Information (after registra- 24 h 24 h
tion)
Send Alive message 50 min 50 min
Check for Module Update 8h 4h
Send Dynamic Information 4h 4h
Internal Pending Command 10 min 1 min
Restart after Unregistration Restart watchdog (4 minutes)

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3.1.9 Connected Services information
Continued

Connected Services event logs

The software agent generates event logs in the central controller event log. Event
logs are generated during starting, registering, unregistering, losing connectivity,
and during other key events.
The events logs are in the range of 170XXX and are described with all the other
controller event logs documentation. For more details, see Technical reference
manual - Event logs for RobotWare 7.

Force a reset of the software agent

It is possible to reset the software agent. When you reset, the software agent erases
all its internal information including the registration information, the data collector
script, and all the locally stored service information. The configuration will not be
reset, but a new registration is required to reactivate the connected services.
Use the following procedure to reset the software agent using FlexPendant:
1 Open Operate.
2 Tap Service Routines.
3 Tap Connected Services Reset.
The ConnectedServiceReset window is displayed.
4 Tap Yes.
5 Press the START hard button on the FlexPendant.
A confirmation page is displayed with operator messages.
6 Tap Reset.
The software agent is reset.

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 3 Connectivity
[Link] Server connectivity troubleshooting

3.1.10 Troubleshooting

[Link] Server connectivity troubleshooting

Overview
From your location it is possible to verify the connectivity from the controller to the
Connected Services public connector server. This is done by connecting a PC
instead of the controller) with the same network configuration (WAN IP/Mask, DNS,
Route), and open the path to the root of the Connected Services server
([Link] in a browser. The connectivity is validated if the DNS
name has been resolved, the browser presents a page indicating the CS server,
and secured with an ABB certificate as shown in the following figures.

xx1500003225

Connected Services Gateway

For more details, see the section ABB Connected Services configuration in
Operating manual - Integrator's guide OmniCore.

Cybersecurity
For more details, see the section OmniCore Cybersecurity in Operating
manual - Integrator's guide OmniCore.

Time accuracy
It is important to set up the time correctly in the controllers including Time Zone,
either manually or with NTP. For more details, see the section Changing date and
time in Operating manual - OmniCore.

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3 Connectivity
[Link] 3G Connectivity troubleshooting

[Link] 3G Connectivity troubleshooting

Overview
This option is used to check the current connection state of the connectivity module
for troubleshooting.

Note

Connection log is available only for Connected Services Gateway 3G (not for
Wired).

Procedure
Use the following procedure to check the current connection state of the connectivity
module:
1 Open Settings.
2 Tap Backup & Recovery.
3 On the left sidebar tap Connection log.
The Connection log page is displayed and the logs are displayed on a
window.

Note

Tap on the refresh button to update the logs.

xx1900000976

4 Tap Export.
5 If required, in the File Name field edit the name of the file.
6 If required, to change the storage path, in the Folder Name field tap Browse
and select the required path.
7 Tap Create.
The current connection state of the connectivity module is saved in the
selected path.

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 3 Connectivity
[Link] 4G Connectivity troubleshooting

[Link] 4G Connectivity troubleshooting

Overview
It is possible to get some status information and logs from the Connected Services
Gateway 4G. This is done by using an external PC connected on port Eth 1 of the
4G Gateway.
For more information about troubleshooting, see the product manual for the
controller, listed in References on page 11.

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3 Connectivity
[Link] How to get Connected Services Embedded logs from the controller

[Link] How to get Connected Services Embedded logs from the controller

Procedure
Use the following procedure to retrieve the CSE logs from the controller:
1 Open RobotStudio, click the Controller tab, and add the controller.

Note

For more details about adding the controller, see Operating

manual - RobotStudio.

2 In the Configuration group, click Properties and select Save diagnostics.

The Save As window is displayed.
3 Click Save.
The file is saved in the selected location.
4 Send the full diagnostic file to ABB support for further processing.

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 3 Connectivity
[Link] Connected Services Embedded troubleshooting logs

[Link] Connected Services Embedded troubleshooting logs

Connected Services Embedded troubleshooting logs and description

Connected Services Embedded (CSE) sends some log messages to Connectivity
Management Secure Server (CMSS). These log messages are categorized into
two types, periodic logs and non-periodic logs. Periodic logs contain CSE heath
status. Non-periodic logs are sent when CSE enters a particular state like registered,
Data collector started, and so on. These logs messages are helpful in
troubleshooting CSE. The logs are accessible from internal ABB Connected Services
support tool.

Connected Services Embedded base logs

The following table provides the list of Connected Services Embedded base logs
and its description:
Log number Description
Log name
3000 Controller received unsupported reset command from
BASE_MODE_UNKNOWN external source.

3170 Omnicore data collection update has been failed.

BASE_MODE_FAIL_UPDATE
8000 Connected Services Embedded (CSE) is successfully
GLOBAL_INIT_OK registered with CMSS server.

8033 Connected Services Embedded (CSE) is unable to

INFO_JAVA_SPECIFIC_LOAD_NOK start Data collector.
8123 Connected Services Embedded (CSE) received reset
INFO_EXT_JAVARESET command from external source.

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[Link] Connected Services Embedded troubleshooting logs
Continued

Log number Description

Log name
8210 Connected Services Embedded (CSE) sends keep-
INFO_STAY_ALIVE alive messages to CMSS server at predefined intervals
(50 minutes) to indicate connected service is alive.
The alive message format is as below.
Note
Example:
INFO_STAY_ALIVE is a periodic message_count Alive Bytes:xx/yy
log. HTTP:p/q/r/s/t/u/v
Mem:7069164 Run:746 RC:0 LHE:
• message_count: Current alive message count.
• Bytes: Number of bytes of memory sent and
received by controller.
• HTTP: Different http errors occurred while con-
troller communicating with CMSS server.
Type of errors:
- p: Connection error count.
- q: Connection not available error count.
- r: Authentication related error count.
- s: Request error count.
- t: Timeout error count.
- u: Proxy error count.
- v: Unknown error count.
• Mem: Free memory available in bytes.
• Run: Controller's uptime in seconds.
• RC: Number of times CSE restarted since the
last boot.
• LHE: Information about last http error.
8213 Connected Services Embedded (CSE) will send keep
INFO_ALIVE_STARTED alive message once CSE registered. The message
format is same as 8210 INFO_STAY_ALIVE.
8214 Connected Services Embedded (CSE) will send this
INFO_ALIVE_ENDED alive message when Connected Services Embedded
stopped. The message format is same as 8210
INFO_STAY_ALIVE.
8700 Connected Services Embedded (CSE) module updated
INFO_MODULE_UPDATE_OK successfully.

8701 Connected Services Embedded (CSE) module update

INFO_MODULE_UPDATE_NOK failed.

8702 Connected Services Embedded (CSE) module update

INFO_MODULE_UPDATE_ERROR is failed.

8801 Connected Services Embedded (CSE) data collector

INFO_S24_STARTED module start.

8803 Connected Services Embedded (CSE) connect-

INFO_S2301_STARTED or(S2301) connector started.

9003 Connected Services Embedded (CSE) data collector

INFO_SPECIFIC_STOP stopped.

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 3 Connectivity
3.1.11 Network topology scenarios

3.1.11 Network topology scenarios

Connection Type – Connected Services with 4G module

In the following scenario the Controller 1 and Controller 2 are installed and
configured with ABB SIM. Refer to Connection Settings table in the following figure
for detailed configuration. Based on this configuration Connected Services Gateway
4G module will connect to the network.
Connected Services is configured with ABB Connect Connection Type, which
means all the communication to the ABB Cloud will pass and be routed through
the Connected Services Gateway 4G module.

ABB Connected Services

Controller 1 Controller 2

Network Switch

xx1900001182

4G connection settings for Controller 1 (NW1) Controller 2

controller 1 and 2
State Enabled Enabled
IP Address [Link] [Link]
Subnet mask [Link] [Link]
Default gateway [Link] [Link]
Preferred DNS [Link] [Link]
Secondary DNS [Link] [Link]

Connected services settings

State Enabled
Connection type ABB Connect
Proxy used No
Server polling Slow recommended
Connected services mode Omnicore data collection

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3.1.11 Network topology scenarios
Continued

Connection Type – Connected Services with 3G module

In the following scenario the Controller 1 and Controller 2 are installed and
configured with ABB SIM. Refer to Connection Settings table in the following figure
for detailed configuration. Based on this configuration Connected Services Gateway
3G module will connect to the network.
Connected Services is configured with ABB Connect Connection Type, which
means all the communication to the ABB Cloud will pass and be routed through
the Connected Services Gateway 3G module.

ABB Connected Services

Controller 1 Controller 2

Network Switch

xx1900001182

3G connection settings for controller 1 and 2

State Enabled
APN (Access point) [Link]
Operator Automatic
Band Automatic
Auth Automatic
Roaming Enabled
Idle 0
Delay 0

Connected services settings

State Enabled
Connection type ABB Connect
Proxy used No
Server polling Slow or Fast
Connected services mode Omnicore data collection

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 3 Connectivity
3.1.11 Network topology scenarios
Continued

Connection Type – Connected Services with Wired module

In the following scenario the Controller 1 and Controller 2 are connected with
Connected Services Gateway Wired module. Since it is a wired module it requires
a wired connection with internet access to reach ABB Cloud. Controller 1 and 2
are also connected to public network which could be a factory network.
Wired module always should be configured with static IP. Refer to the Connected
Services Gateway Wired settings table for a simple network configuration.
Connected Services is configured with the ABB Connect Connection Type, which
means all the communication to the ABB Cloud will pass and be routed through
the Connected Services Gateway Wired module and not on the public network.

ABB Connected Services

Controller 1 Controller 2
Internet Gateway

CS Gateway Wired Network with Internet Connection

Public Network

Network Switch

DHCP server DNS server User PC

xx1900001184

Wired connection settings Controller 1 (NW1) Controller 2

State Enabled Enabled
IP Address [Link] [Link]
Subnet mask [Link] [Link]
Default gateway [Link] [Link]
Preferred DNS [Link] [Link]
Secondary DNS [Link] [Link]

Controller 1 Controller 2 Internet DHCP serv- DNS server User PC

Gateway er
IP Address [Link] [Link] [Link] [Link] [Link] [Link]
Subnet [Link] [Link] [Link] [Link] [Link] [Link]
mask
Default [Link] [Link] [Link] [Link] [Link]
gateway

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Continued

Connected services settings

State Enabled
Connection type ABB Connect
Proxy used No
Server polling Fast
Connected services mode Omnicore data collection

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 3 Connectivity
3.1.11 Network topology scenarios
Continued

Connection Type – Public

If the factory network is enabled with internet access and firewalled, then the same
network which is connected to the public port of the controller can be used to
configure Connected Services.
In the following scenario the Controller 1 and Controller 2 are connected to public
network by using public port of the controller which is the factory network enabled
with internet. As a good practice the factory network must be firewalled for any
unwanted inbound and outbound accesses if connected to internet.
Connected Services with Public Connection Type is configured with the Connected
Services Settings in the following way:

OmniCore OmniCore
Controller 1 Controller 2

Public Network

Network switch ABB Connected Services

Firewall

Internet
Gateway

DHCP Server DNS Server

xx2300000120

Controller 1 Controller 2 Internet Gate- DHCP server DNS server

way
IP Address [Link] [Link] [Link] [Link] [Link]
Subnet mask [Link] [Link] [Link] [Link] [Link]
Default gate- [Link] [Link] [Link] [Link]
way
DNS [Link] [Link] [Link]

Connected services settings

State Enabled
Connection type Public
Proxy used No
Server polling Fast
Connected services mode Omnicore data collection

Note

Ensure that there is a Firewall setup on customer network for internet access
(outbound only). This needs to be confirmed also in the Omnicore Firewall
settings.

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3 Connectivity
3.1.11 Network topology scenarios
Continued

Connection Type – Public - With customer storage enabled

The following figure shows the scenario of using the customer storage to store
controller data. Customer storage could be a controller local disk, mapped network
disk (on ftp/sftp or nfs server) disk. In the following scenario we have used an
ftp/sftp server as a customer storage in the factory network. This ftp/sftp
server can be mounted as a local disk on the controller. So, during the Connected
Services configuration the disk path should be mentioned as the mounted ftp/sftp
disk. The disk path is ftp/sftp for mounted ftp/sftp disk and pc: for mounted
network disk on the controller.
Connected Services with Public Connection Type is configured with the Connected
Services Settings in the following way:

OmniCore OmniCore
Controller 1 Controller 2

Public Network

Network switch
DNS Server

ABB Connected Services

Firewall

Internet
Gateway

DHCP Server FTP Server

xx2300000122

Controller 1 Controller 2 Internet DHCP serv- DNS server FTP server

Gateway er
IP Address [Link] [Link] [Link] [Link] [Link] [Link]
Subnet [Link] [Link]
mask
Default [Link] [Link]
gateway
DNS [Link] [Link]

Connected services settings

State Enabled
Connection type Public
Proxy used No
Server polling Fast
Connected services mode Omnicore data collection
Customer storage Disk
Disk path ftp/

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 3 Connectivity
3.1.11 Network topology scenarios
Continued

Connected Services using ABB Gateway Service box

Overview
This section explains how Connected Services is configured using an external
Internet gateway (3G/4G) not defined as default gateway in the controller. In this
case connected services should be configured with the connection type custom.
The gateway service box can be connected on customer WAN port, management
port, or Connected Services Gateway wired port.

Controller with DHCP

Use the following procedure to configure the Connected Services from the
FlexPendant when there is controller with DHCP.
1 Open Settings.
2 Tap ABB Connected Services.
3 Tap Connected Services on the left pane.
The configuration parameters for connected services is displayed.
4 In the Connection Type list, tap and select Custom.
5 In the Internet Gateway IP field, type the IP address of internet gateway.
6 In the Internet DNS IP field, type the IP address of internet DNS.
7 Tap Apply.
The Restart confirmation message is displayed.
8 Click OK.
The controller is restarted.
The connected services start communicating to the server based on the
configuration.
Check the connectivity status in the event logs. For more details, see
Connected Services information on page 139.

Gateway box on customer network

When gateway box is configured for multiple controllers, then the LAN IP of the
gateway box must change according to the WAN IP network segment.
The gateway box should be connected to the customer network. And, the LAN IP
should be modified to match with the customer network IP segment.
The following figure and table show a typical network infrastructure:

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3 Connectivity
3.1.11 Network topology scenarios
Continued

DHCP Server DNS Server

[Link] [Link]
Connected Services 3G
Gateway Box
Controller 1

Customer WAN Network

Controller 2 Controller 3

xx1800002942

DHCP configuration Controller 1 Controller 2 Controller 3

IP [Link] [Link] [Link]
Mask [Link] [Link] [Link]
CSE Enabled Yes Yes Yes
Connection type Custom Custom Custom
Internet Gateway IP [Link] [Link] [Link]
Internet DNS IP [Link] [Link] [Link]

For more information about how to do setting for the gateway box for multiple
controllers, see Product manual - Connected Services.

Note

The network infrastructure is an example to demonstrate the network topology.

CAUTION

Ensure you always have Internet access with firewall.

Note

Using the ABB Service Box will allow Remote Access features. A standard 4G
router can also be used with same principles.

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 3 Connectivity
3.1.11 Network topology scenarios
Continued

Connected Services using customer Gateway

Overview
This section explains how Connected Services is configured using an external
Internet gateway (provided by the customer) not defined as default gateway in the
controller. In this case connected services should be configured with the connection
type custom.
The gateway service box can be connected on customer WAN port, management
port, or Connected Services Gateway wired port.

Controller with DHCP

Use the following procedure to configure the Connected Services from the
FlexPendant when there is controller with DHCP.
1 Open Settings.
2 Tap ABB Connected Services.
3 Tap Connected Services on the left pane.
The configuration parameters for connected services is displayed.
4 In the Connection Type list, tap and select Custom.
5 In the Internet Gateway IP field, type the IP address of internet gateway.
6 In the Internet DNS IP field, type the IP address of internet DNS.
7 Tap Apply.
The Restart confirmation message is displayed.
8 Click OK.
The controller is restarted.
The connected services start communicating to the server based on the
configuration.
Check the connectivity status in the event logs. For more details, see
Connected Services information on page 139.

Gateway box on customer network

When gateway box is configured for multiple controllers, then the LAN IP of the
gateway box must change according to the WAN IP network segment.
The gateway box should be connected to the customer network. And, the LAN IP
should be modified to match with the customer network IP segment.
The following figure and table show a typical network infrastructure:

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3 Connectivity
3.1.11 Network topology scenarios
Continued

DHCP Server DNS Server

[Link] [Link]
Customer Internet
Gateway Firewall
Controller 1

Customer WAN Network

Controller 2 Controller 3

xx2300001231

DHCP configuration Controller 1 Controller 2 Controller 3

IP [Link] [Link] [Link]
Mask [Link] [Link] [Link]
CSE Enabled Yes Yes Yes
Connection type Custom Custom Custom
Internet Gateway IP [Link] [Link] [Link]
Internet DNS IP [Link] [Link] [Link]

Note

The network infrastructure is an example to demonstrate the network topology.

CAUTION

Ensure you always have Internet access with firewall.

Note

It is possible to use an ABB Service Box which will also allow Remote Access
features. A standard 4G router can also be used with same principles.

Note

When you use an internet gateway make sure it is firewalled to allow only
minimum required outbound commands.

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 4 Motion performance
4.1.1 About Absolute Accuracy

4 Motion performance
4.1 Absolute Accuracy [3101-x]

4.1.1 About Absolute Accuracy

Purpose
Absolute Accuracy is a calibration concept that improves TCP accuracy. The
difference between an ideal robot and a real robot can be several millimeters,
resulting from mechanical tolerances and deflection in the robot structure. Absolute
Accuracy compensates for these differences.
Here are some examples of when this accuracy is important:
• Exchangeability of robots
• Offline programming with no or minimum touch-up
• Online programming with accurate movement and reorientation of tool
• Accurate cell alignment for MultiMove coordinated motion
• Programming with accurate offset movement in relation to eg. vision system
or offset programming
• Re-use of programs between applications
The option Absolute Accuracy is integrated in the controller algorithms and does
not need external equipment or calculation.

Note

The performance data is applicable to the corresponding RobotWare version of

the individual robot.

Note

Singularities might appear in slightly different positions on a real robot compared

to RobotStudio, where Absolute Accuracy is off compared to the real controller.

What is included
Every Absolute Accuracy robot is delivered with:
• compensation parameters saved in the robot memory
• a birth certificate representing the Absolute Accuracy measurement protocol
for the calibration and verification sequence.
A robot with Absolute Accuracy calibration has a label with this information on the
manipulator.
Absolute Accuracy supports floor mounted, wall mounted, and ceiling mounted
installations. The compensation parameters that are saved in the robot memory
differ depending on which Absolute Accuracy option is selected.

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4.1.1 About Absolute Accuracy
Continued

When is Absolute Accuracy being used

Absolute Accuracy works on a robot target in Cartesian coordinates, not on the
individual joints. Therefore, joint based movements (e.g. MoveAbsJ) will not be
affected.
If the robot is inverted, the Absolute Accuracy calibration must be performed when
the robot is inverted.

Absolute Accuracy active

Absolute Accuracy will be active in the following cases:
• Any motion function based on robtargets (e.g. MoveL) and ModPos on
robtargets
• Reorientation jogging
• Linear jogging
• Tool definition (4, 5, 6 point tool definition, room fixed TCP, stationary tool)
• Work object definition

Absolute Accuracy not active

The following are examples of when Absolute Accuracy is not active:
• Any motion function based on a jointtarget (MoveAbsJ)
• Independent joint
• Joint based jogging
• Additional axes
• Track motion

Note

In a robot system with, for example, an additional axis or track motion, the
Absolute Accuracy is active for the manipulator but not for the additional axis or
track motion.

RAPID instructions
There are no RAPID instructions included in this option.

Absolute Accuracy and MultiMove

If the main robot in a MultiMove system has the Absolute Accuracy option, it opens
up Absolute Accuracy capability for all the robots in the system. However, each
robot needs to be calibrated individually.

Note

Note that this is the only RobotWare option that is relevant for an additional robot.

Note

It is possible to mix robots with and without the option Absolute Accuracy
arbitrarily in a MultiMove system.

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 4 Motion performance
4.1.2 Useful tools

4.1.2 Useful tools

Overview
The following products are recommended for operation and maintenance of
Absolute Accurate robots:
• Load Identification
• CalibWare (Absolute Accuracy calibration tool)

Load Identification
Absolute Accuracy calculates the robot's deflection depending on payload. It is
very important to have an accurate description of the load.
Load Identification is a tool that determines the mass, center of gravity, and inertia
of the payload.
For more information, see Operating manual - OmniCore.

CalibWare
CalibWare, provided by ABB, is a tool for calibrating Absolute Accuracy. The
documentation to CalibWare describes the Absolute Accuracy calibration procedure
in detail.
CalibWare is used at initial calibration and when servicing the robot.

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4 Motion performance
4.1.3 Configuration

4.1.3 Configuration

Activate Absolute Accuracy

Use RobotStudio and follow these steps (see Operating manual - RobotStudio for
more information):
1 If you do not already have write access, click Request Write Access and
wait for grant from the FlexPendant.
2 Click Configuration Editor and select Motion.
3 Click the type Robot.
4 For the parameter Use Robot Calibration, change the value to r1_calib.
5 For a MultiMove system, configure the parameter Use Robot Calibration for
each robot. It should be set to r2_calib for robot 2, r3_calib for robot 3, and
r4_calib for robot 4.
6 No restart is required.

Deactivate Absolute Accuracy

Use RobotStudio and follow these steps (see Operating manual - RobotStudio for
more information):
1 If you do not already have write access, click Request Write Access and
wait for grant from the FlexPendant.
2 Click Configuration Editor and select the topic Motion.
3 Click the type Robot.
4 Configure the parameter Use Robot Calibration and change the value to
"r1_uncalib".
5 For a MultiMove system, repeat step 3 and 4 for each robot. Use Robot
Calibration is then set to "r2_uncalib" for robot 2, "r3_uncalib" for robot 3
and "r4_uncalib" for robot 4.
6 No restart is required.

Change calibration data

If you exchange the manipulator, the calibration data for the new manipulator must
be loaded. This is done by copying the calibration data from the robot memory to
the robot controller.
Use the FlexPendant and follow these steps (for more information, see Operating
manual - OmniCore):
1 On the start screen, tap Calibrate, and then select Calibration from the menu.
2 Tap on the robot you wish to update.
3 Tap the tab Robot Memory.
4 Tap Advanced.
5 Tap Clear Controller Memory.
6 Tap Clear and then confirm by tapping Yes.
7 Tap Close.
8 Tap Update.

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4.1.3 Configuration
Continued

9 Tap Cabinet or robot has been exchanged and confirm by tapping Yes.

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[Link] Maintenance that affect the accuracy

4.1.4 Maintenance

[Link] Maintenance that affect the accuracy

Overview
This section will focus on those maintenance activities that directly affect the
accuracy of the robot, summarized as follows:
• Tool recalibration
• Motor replacement
• Wrist replacement (large robots)
• Arm replacement (lower arm, upper arm, gearbox, foot)
• Manipulator replacement
• Loss of accuracy

Note

If the RobotWare version on the controller must be downgraded, then contact

your local ABB for support regarding compatible versions of Absolute Accuracy.

Tool recalibration
For information about tool recalibration, see Tool calibration on page 184.

Motor replacement
Replacement of all motors requires a re-calibration of the corresponding resolver
offset parameter using the standard calibration method for the respective robot.
This is described in the product manual for the robot.
If the motor replacement requires disassembly of the arm, then see Arm
replacement or disassembly on page 170.

Wrist replacement
Replacement of the wrist unit requires a re-calibration of the resolver offsets for
axes 5 and 6 using the standard calibration method for the respective robot.

Arm replacement or disassembly

Replacement of any of the robot arms, or other mechanical structure (excluding
wrist), changes the structure of the robot to the extent that a robot recalibration is
required. It is recommended that, after an arm replacement, the entire robot should
be recalibrated to ensure optimal Absolute Accuracy functionality. This is typically
performed with CalibWare and a separate measurement system. CalibWare can
be used together with any generic 3Dmeasurement system.
For more information about the calibration process, see documentation for
CalibWare.

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[Link] Maintenance that affect the accuracy
Continued

A summary of the calibration process is presented as follows:

Action
1 Replace the affected component.
2 Perform a resolver offset calibration for all axes. See the product manual for the
respective robot.
3 Recalibrate the TCP.
4 Check the accuracy by comparison to a fixed reference point in the cell.
5 Check the accuracy of the work objects.

Note

An update of the defined work objects will make the deviation less in positioning.

6 Check the accuracy of the positions in the current application.

7 If the accuracy still is unsatisfactory, perform an Absolute Accuracy calibration of
the entire robot. See documentation for CalibWare.

Manipulator replacement
When a robot manipulator is replaced without replacing the controller cabinet, it
is necessary to update the Absolute Accuracy parameters in the controller cabinet
and realign the robot to the cell. The Absolute Accuracy parameters are updated
by loading the replacement robot’s calibration parameters into the controller as
described in Change calibration data on page 168. Ensure that the calibration data
is loaded and that Absolute Accuracy is activated.
The alignment of the replacement robot to the cell depends on the robot alignment
technique chosen at installation. If the robot mounting pins are aligned to the cell
then the robot need only be placed on the pins - no further alignment is necessary.
If the robot was aligned using a robot program then it is necessary to measure the
cell fixture(s) and measure the robot in several positions (for best results use the
same program as the original robot). See Measure robot alignment on page 182.

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[Link] Loss of accuracy

[Link] Loss of accuracy

Cause and action

Loss of accuracy usually occur after robot collision or large temperature variations.
It is necessary to determine the cause of the errors, and take adequate action.
If... ...then...
the tool is not prop- recalibrate if the TCP has changed.
erly calibrated
the tool load is not run Load Identification to ensure correct mass, centre of gravity and
correctly defined inertia for the active tool.
the resolver offsets 1 Check that the axis scales show that the robot stands correctly
are no longer valid in the home position.
2 If the indicators are not aligned, move the robot to correct posi-
tion and update the revolution counters.
3 If the indicators are close to aligned but not correct, re-calibrate
with the standard calibration for the robot.
the robot’s relation- 1 Check by moving the robot to a predefined position on the fix-
ship to the fix- ture(s).
ture(s) has 2 Visually assessing whether the deviation is excessive.
changed 3 If excessive, realign robot to fixture(s).
the robot structure 1 Visually assess whether the robot is damaged.
has changed 2 If damaged then replace entire manipulator -or- replace affected
arm(s) -or- recalibrate affected arm(s).

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 4 Motion performance
[Link] Error sources

4.1.5 Compensation theory

[Link] Error sources

Types of errors
The errors compensated for in the controller derive from the mechanical tolerances
of the constituent robot parts. A subset of these are detailed in the illustration
below.
Compliance errors are due to the effect of the robot’s own weight together with the
weight of the current payload. These errors depend on gravity and the
characteristics of the load. The compensation of these errors is most efficient if
you use Load Identification (see Operating manual - OmniCore).
Kinematic errors are caused by position or orientational deviations in the robot
axes. These are independent of the load.

Illustration
There are several types of errors that can occur in each joint.

en0300000232

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[Link] Absolute Accuracy compensation

[Link] Absolute Accuracy compensation

Introduction
Both compliance and kinematic errors are compensated for with "fake targets".
Knowing the deflection of the robot (i.e. deviation from ordered position), Absolute
Accuracy can compensate by ordering the robot to a fake target.
The compensation works on a robot target in cartesian coordinates, not on the
individual joints. This means that it is the position of the TCP (marked with an arrow
in the following illustrations) that is correctly compensated.

Desired position
The following illustration shows the position you want the robot to have.

xx0300000225

Position due to deflection

The following illustration shows the position the robot will get without Absolute
Accuracy. The weight of the robot arms and the load will make a deflection on the
robot. Note that the deflection is exaggerated.

xx0300000227

Fake target
In order to get the desired position, Absolute Accuracy calculates a fake target.
When you enter a desired position, the system recalculates it to a fake target that
after the deflection will result in the desired position.

xx0300000226

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[Link] Absolute Accuracy compensation
Continued

Compensated position
The actual position will be the same as your desired position. As a user you will
not notice the fake target or the deflection. The robot will behave as if it had no
deflection.

xx0300000224

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[Link] ABB calibration process

4.1.6 Preparation of Absolute Accuracy robot

[Link] ABB calibration process

Overview
This section describes the calibration process that ABB performs on each Absolute
Accuracy robot, regardless of robot type or family, before it is delivered.
The process can be divided in four steps:
1 Resolver offset calibration
2 Absolute Accuracy calibration
3 Calibration data stored in the robot memory
4 Absolute Accuracy verification
5 Generation of a birth certificate

Resolver offset calibration

The resolver offset calibration process is used to calibrate the resolver offset
parameters.
For information on how to do this, see the product manual for the respective robot.

Absolute Accuracy calibration

The Absolute Accuracy calibration is performed on top of the resolver offset
calibration, hence the importance of having repeatable methods for both processes.
Each robot is calibrated with maximum load to ensure that the correct compensation
parameters are detected (calibration at lower load might not result in a correct
determination of the robot flexibility parameters.) The process runs the robot to
100 jointtarget poses and measures each corresponding measurement point
coordinate. The list of poses and measurements are fed into the CalibWare
calibration core and a set of robot compensation parameters are created.
For information on how to do this, see documentation for CalibWare.
CalibWare
Robot joint angle
Set (~100 points)
Robot
controller

z
Measured positions AbsAcc
parameters
(Robot base frame)
y
Measurement
x system

xx1900001203

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[Link] ABB calibration process
Continued

Absolute Accuracy verification

The parameters are loaded onto the controller and activated. The robot is then run
to a set of 50 robtarget poses. Each pose is measured and the deviation from
nominal determined.
For information on how to do this, see documentation for CalibWare.
The requirements for acceptance vary between robot types, see typical performance
data in the product specification for the respective robot.

Compensation parameters and birth certificate

The compensation parameters are saved in the robot memory (see Compensation
parameters on page 179).
A birth certificate is created representing the Absolute Accuracy measurement
protocol for the calibration and verification sequence (see Birth certificate on
page 178).

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[Link] Birth certificate

[Link] Birth certificate

About the birth certificate

All Absolute Accuracy robots are shipped with a birth certificate. It represents the
Absolute Accuracy measurement protocol for the calibration and verification
sequence.
The birth certificate contains the following information:
• Robot information (robot type, serial number, version of Absolute Accuracy)
• Accuracy information (maximum, average and standard deviation for finepoint
error distribution)
• Tool information (TCP, mass, center of gravity)
• Description of measurement protocol (measurement and calibration system,
number of points, measurement point location)

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[Link] Compensation parameters

[Link] Compensation parameters

About the compensation parameters

All Absolute Accuracy robots are shipped with a set of compensation parameters,
as part of the system parameters (configuration). As the resolver offset calibration
is integral in the Absolute Accuracy calibration, the resolver offset parameters are
also stored in the robot memory.

The compensation parameters

The compensation parameters are defined in the following configuration types:
• ROBOT_CALIB
• ARM_CALIB
• JOINT_CALIB
• PARALLEL_ARM_CALIB
• TOOL_INTERFACE
• MOTOR_CALIB
The type ROBOT_CALIB defines the top level of the calibration structure. The
instance r1_calib activates the Absolute Accuracy functionality by specifying the
flag -absacc. See Activate Absolute Accuracy on page 168.
The types ARM_CALIB, JOINT_CALIB, PARALLEL_ARM_CALIB, and
MOTOR_CALIB are reserved by the system and are only shown when the Absolute
Accuracy option is selected in the Modify Installation dialog. The parameter values
can be changed by importing a new configuration file.
The compensation parameters are included in a backup, in the file [Link].

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[Link] Overview

4.1.7 Cell alignment

[Link] Overview

About cell alignment

The compensation parameters for the Absolute Accuracy robot are determined
from the physical base plate to the robot tool. For many applications this is enough,
the robot can be used as any other robot. However, it is common that Absolute
Accuracy robots are aligned to the coordinates in their cells. This section describes
this alignment procedure. For a more detailed description, see documentation for
CalibWare.

Alignment procedure
In order for the robot to be accurate with respect to the entire robot cell, it is
necessary to install the robot correctly. In summary, this involves:
Action Description
1 Measure fixture alignment Determine the relationship between the measurement
system and the fixture. See Measure fixture alignment
on page 181.
2 Measure robot alignment Determine the relationship between the measurement
system and the robot. See Measure robot alignment
on page 182.
3 Calculate frame relationships Determine the relationship between, for example, the
robot and the fixture. See Frame relationships on
page 183.
4 Calibrate tool Determine the relationship between the robot tool and
other cell components. See Tool calibration on
page 184.

Illustration
=Robtargets
Z
Z
Y
Y
3.
Work object
transformation X
=Mounting pins
X User (Fixture) =Reference points
Robot base
X
Z
3. 1.
Base frame Z 2.
transformation
Y
Y

Measurement
X system base

World

=Reference points
1.

en0300000239

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[Link] Measure fixture alignment

[Link] Measure fixture alignment

About fixture alignment

A fixture is defined as a cell component that is associated with a particular
coordinate system. The interaction between the robot and the fixture requires an
accurate relationship in order to ensure Absolute Accuracy.
Absolute Accuracy fixtures must be equipped with at least three (preferably four)
reference points, each with clearly marked position information.

Fixture measurement procedure

The alignment of the fixture is done in the following steps:
1 Enter the reference point names and positions into the alignment software.
2 Measure the reference points and assign the same names.
3 Use the alignment software to match the reference to measured points and
determine the relationship frame. All measurement systems support this
form of transformation.

Illustration
Z
Y

Z
X
Y

2
Measurement 3
system base
X
1 4
User (Fixture)

=Reference points

en0300000237

Measurement positions Reference positions Frame relationship

Pos1: 100, 100, 200 Pos1: 100, 100, 100 1) RobotStudio work object
Pos2: 100, 200, 200 Pos2: 100, 200, 100 (0,0,-100,0,0,0)
(x,y,z,roll,pitch,yaw
Pos3: 200, 200, 200 Pos3: 200, 200, 100
Pos4: 200, 100, 200 Pos4: 200, 100, 100

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[Link] Measure robot alignment

[Link] Measure robot alignment

Select method
The relationship between the measurement system and the robot can be determined
in the following ways:
Alignment procedure Description
Alignment to physical base The equivalent to the fixture alignment in which the physical
base pins are measured and aligned with respect to the ref-
erence positions detailed in the product manual for the re-
spective robot.
Alignment to theoretical base Measuring several robot poses and letting the alignment
software determine the robot alignment.

Alignment to physical base

The advantage of aligning the robot as a fixture is in its simplicity - the robot is
treated as another fixture in the cell and its base points measured accordingly.
The disadvantage is that small errors in the subsequent placement of the robot on
the pins can result is large TCP errors due to the reach of the robot (i.e. the
placement of the robot is not calibrated.)
In order to determine the reference point coordinates, it is necessary to consult
the product manual for that robot type.
Once the correct point have been measured, the alignment software is used to
determine the frame relationship between the measurement system and robot
base.

Alignment to theoretical base

The advantage of aligning the robot to a theoretical base is that any errors resulting
from mounting the robot can be eliminated. Furthermore, the alignment process
details the robot accuracy at the measured points, confirming correct Absolute
Accuracy functionality. The disadvantage is that a robot program must be created
(either manually or automatically from CalibWare) and the robot measured (ideally
with correct tool however the TCP can also be calibrated as a part of this procedure.)
Once the correct point is measured, the alignment software is used to determine
the frame relationship between the measurement system and robot base.

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[Link] Frame relationships

[Link] Frame relationships

About frame relationships

Once the relationships between the measurement system and all other cell
components are measured, the relationships between cell components can be
determined.
The relationship between the world coordinate system and the robot shall be stored
in the robot base. The relationship between the robot and the fixture shall be stored
in the workobject data type.
The measurement system is initially the active coordinate system as both world
and robot are measured relative to the measurement system.

Determine robot base

Use a standard measurement system software to determine the robot base in world
coordinates:
1 Set the world coordinate system to be active (the origin).
2 Read the coordinates of the robot base frame (now relative to the world).
The fixture relationship is similarly determined by setting the robot to be
active and reading the coordinates of the fixture frame.

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[Link] Tool calibration

[Link] Tool calibration

About tool calibration

The Absolute Accuracy robot compensation parameters are calculated to be tool
independent. This allows any tool with a correctly pre-defined TCP to be connected
to the robot flange and used without requiring a tool re-calibration. In practice,
however, it is difficult to perform a correct TCP calibration with, for example, a
Coordinate Measurement Machine (CMM) as this does not take into account the
connection of the tool to the robot nor the tool flexibility.
Each tool should be calibrated on a regular basis to ensure optimal robot accuracy.

Tool calibration procedures

Suggested tool recalibration procedures are detailed as follows:
• SBCU (Single Beam Calibration Unit) such as the ABB BullsEye for
arc-welding or spot-welding applications.
• Geometry calibration such as the 4, 5 or 6 Point tool center point calibration
routine available in the controller. A measurement system can be used to
ensure that the single point used is accurate.
• RAPID tool calibration routines: MToolTCPCalib (calibration of TCP for moving
tool), SToolTCPCalib (calibration of TCP for stationary tool), MToolRotCalib
(calibration of rotation for moving tool), SToolRotCalib (calibration of TCP
and rotation for stationary tool.)
• Using theoretical data, for example from a CAD model.

Tip

As the tool load characteristics are used in the Absolute Accuracy models, it is
essential that all parameters be as accurate as possible. Use of Load Identification
is an efficient method of determining tool load characteristics.

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4.2.1 About Ultra Accuracy

4.2 Ultra Accuracy [3101-10]

4.2.1 About Ultra Accuracy

Purpose
Ultra Accuracy is a control concept for GoFa CRB 15000 robots that improves the
TCP path accuracy even further.
Here are some examples of when this kind of accuracy is important:
• Gluing extremely small electronics components.
• Laser welding of car body parts in automotive.
• Positioning of composite material layup in aircraft manufacturing.
• High fidelity 3D printing.
• High precision laser cutting of small metal shapes.
The option Ultra Accuracy is integrated in the controller algorithms and does not
need external equipment.

Note

The performance data is applicable to the corresponding RobotWare version of

the individual robot.

What is included
A robot with the option Ultra Accuracy is delivered with:
• compensation parameters saved in the robot memory
• a birth certificate representing the Ultra Accuracy measurement protocol for
the calibration and verification sequence.
A robot with Ultra Accuracy capability has a label with this information on the
manipulator.
Ultra Accuracy supports floor mounted, wall mounted, and ceiling mounted
installations.

When is Ultra Accuracy being used

Ultra Accuracy works on a all robot target in Cartesian coordinates and also on
the individual joints. Therefore, joint based movements, for example, MoveAbsJ,
are also affected.

Ultra Accuracy active

Ultra Accuracy is active in the following cases:
• Any motion function based on robtarget or jointtarget (for example,
MoveL and MoveAbsJ) and ModPos on robtargets.
• Reorientation jogging
• Linear jogging
• Tool definition (4, 5, 6 point tool definition, room fixed TCP, stationary tool)
• Work object definition
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4.2.1 About Ultra Accuracy
Continued

Ultra Accuracy not active

The following are examples of when Ultra Accuracy is not active:
• Independent joint
• Applications such as Force Control and SoftMove

RAPID instructions
There are no RAPID instructions included in this option.

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4.2.2 Configuration

4.2.2 Configuration

Overview
Use RobotStudio to activate and deactivate Ultra Accuracy or to change the stability
margin.
See Operating manual - RobotStudio.

Activate Ultra Accuracy

1 On the Controller tab, click Request Write Access and wait for grant from
the FlexPendant.
2 Click Configuration Editor and select Motion.
3 Click the type Robot.
4 For the parameter Ultra Accuracy, change the value to Active.
No restart of the controller is needed.

Deactivate Ultra Accuracy

1 On the Controller tab, click Request Write Access and wait for grant from
the FlexPendant.
2 Click Configuration Editor and select the topic Motion.
3 Click the type Robot.
4 For the parameter Ultra Accuracy, change the value to Inactive.
No restart of the controller is needed.

Change the stability margin

If vibrations are seen on the robot there might be a need to change the stability
margin. This can be the case if a special tool is used, etc.
1 On the Controller tab, click Request Write Access and wait for grant from
the FlexPendant.
2 Click Configuration Editor and select the topic Motion.
3 Click the type Arm.
4 Select the arm that needs a lower stability margin for Ultra Accuracy.
5 For the parameter Ultra Accuracy stability margin, change the value.
Recommended step size is 0.1.
No restart of the controller is needed.

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4.2.3 Compensation parameters

4.2.3 Compensation parameters

About the compensation parameters

All Ultra Accuracy robots are shipped with a set of compensation parameters apart
from the Absolute Accuracy parameters, as part of the system parameters
(configuration). These are identified with a service routine.

The compensation parameters

The compensation parameters are defined in the following configuration types:
• HD_KINEMATIC_ERROR_COMP
• SECONDARY_ENCODER_ERROR_COMP
• DISTRIBUTED_FRICTION_COMP
They are all automatically created and should not be manually changed.
The compensation parameters are included in a backup, in the file [Link] and
are also stored in robot memory.

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4.3 Advanced Robot Motion 3100-1

4.3 Advanced Robot Motion 3100-1

About Advanced Robot Motion

The option Advanced Robot Motion gives you access to:
• Advanced Shape Tuning, see Advanced Shape Tuning [included in 3100-1]
on page 190.
• Changing Motion Process Mode from RAPID, see Motion Process Mode
[included in 3100-1] on page 198.
• Wrist Move, see Wrist Move [included in 3100-1] on page 206.

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4.4.1 About Advanced Shape Tuning

4.4 Advanced Shape Tuning [included in 3100-1]

4.4.1 About Advanced Shape Tuning

Purpose
The purpose of Advanced Shape Tuning is to reduce the path deviation caused
by joint friction of the robot.
Advanced Shape Tuning is useful for low speed cutting (10-100 mm/s) of, for
example, small circles. Effects of robot joint friction can cause path deviation of
typically 0.5 mm in these cases. By tuning parameters of a friction model in the
controller, the path deviation can be reduced to the repeatability level of the robot,
for example, 0.1 mm for a medium sized robot.

What is included
Advanced Shape Tuning is included in the RobotWare option Advanced robot
motion and gives you access to:
• Instructions FricIdInit, FricIdEvaluate and FricIdSetFricLevels
that automatically optimize the joint friction model parameters for a
programmed path.
• The system parameters Friction FFW On, Friction FFW level and Friction
FFW Ramp for manual tuning of the joint friction parameters.
• The tune types tune_fric_lev and tune_fric_ramp that can be used
with the instruction TuneServo.

Basic approach
This is a brief description of how Advanced Shape Tuning is most commonly used:
1 Set system parameter Friction FFW On to TRUE. See System parameters
on page 195.
2 Perform automatic tuning of the joint friction levels using the instructions
FricIdInit and FricIdEvaluate. See Automatic friction tuning on
page 191.
3 Compensate for the friction using the instruction FricIdSetFricLevels.

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4.4.2 Automatic friction tuning

4.4.2 Automatic friction tuning

About automatic friction tuning

A robot’s joint friction levels are automatically tuned with the instructions
FricIdInit and FricIdEvaluate. These instructions will tune each joint’s
friction level for a specific sequence of movements.
The automatically tuned levels are applied for friction compensation with the
instruction FricIdSetFricLevels.

Program execution
To perform automatic tuning for a sequence of movements, the sequence must
begin with the instruction FricIdInit and end with the instruction
FricIdEvaluate. When program execution reaches FricIdEvaluate, the robot
will repeat the movement sequence until the best friction level for each joint axis
is found. Each iteration consists of a backward and a forward motion, both following
the programmed path. Typically the sequence has to be repeated approximately
20-30 times, in order to iterate to correct joint friction levels.
If the program execution is stopped in any way while the program pointer is on the
instruction FricIdEvaluate and then restarted, the results will be invalid. After
a stop, friction identification must therefore be restarted from the beginning.
Once the correct friction levels are found they have to be set with the instruction
FricIdSetFricLevels, otherwise they will not be used. Note that the friction
levels are tuned for the particular movement between FricIdInit and
FricIdEvaluate. For movements in another region in the robot’s working area,
a new tuning is needed to obtain the correct friction levels.
For a detailed description of the instructions, see Technical reference
manual - RAPID Instructions, Functions and Data types.

Limitations
There are the following limitations for friction tuning:
• Friction tuning cannot be combined with synchronized movement. That is,
SyncMoveOn is not allowed between FricIdInit and FricIdEvaluate.
• The movement sequence for which friction tuning is done must begin and
end with a finepoint. If not, finepoints will automatically be inserted during
the tuning process.
• Automatic friction tuning works only for TCP robots.
• Automatic joint friction tuning can only be done for one robot at a time.
• Tuning can be made to a maximum of 500%. If that is not enough, set a higher
value for the parameter Friction FFW Level, see Starting with an estimated
value on page 196.
• It is not possible to view any test signals with TuneMaster during automatic
friction tuning.
• The movement sequence between FricIdInit and FricIdEvaluate
cannot be longer than 10 seconds.

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4.4.2 Automatic friction tuning
Continued

Note

To use Advanced Shape Tuning, the parameter Friction FFW On must be set to
TRUE.

Example
This example shows how to program a cutting instruction that encapsulates the
friction tuning. When the instruction is run the first time, without calculated friction
parameters, the friction tuning is done. During the tuning process, the robot will
repeatedly move back and forth along the programmed path. Approximately 25
iterations are needed.
At all subsequent runs the friction levels are set to the tuned values identified in
the first run. By using the instruction CutHole, the friction can be tuned individually
for each hole.
PERS num friction_levels1{6} := [9E9,9E9,9E9,9E9,9E9,9E9];
PERS num friction_levels2{6} := [9E9,9E9,9E9,9E9,9E9,9E9];

CutHole p1,20,v50,tool1,friction_levels1;
CutHole p2,15,v50,tool1,friction_levels2;

PROC CutHole(robtarget Center, num Radius, speeddata Speed, PERS

tooldata Tool, PERS num FricLevels{*})
VAR bool DoTuning := FALSE;

IF (FricLevels{1} >= 9E9) THEN

! Variable is uninitialized, do tuning
DoTuning := TRUE;
FricIdInit;
ELSE
FricIdSetFricLevels FricLevels;
ENDIF

! Execute the move sequence

MoveC p10, p20, Speed, z0, Tool;
MoveC p30, p40, Speed, z0, Tool;

IF DoTuning THEN
FricIdEvaluate FricLevels;
ENDIF
ENDPROC

Note

A real program would include deactivating the cutting equipment before the
tuning phase.

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 4 Motion performance
4.4.3 Manual friction tuning

4.4.3 Manual friction tuning

Overview
It is possible to make a manual tuning of a robot's joint friction (instead of automatic
friction tuning). The friction level for each joint can be tuned using the instruction
TuneServo. How to do this is described in this section.
There is usually no need to make changes to the friction ramp.

Note

To use Advanced Shape Tuning, the parameter Friction FFW On must be set to
TRUE.

Tune types
A tune type is used as an argument to the instruction TuneServo. For more
information, see tunetype in Technical reference manual - RAPID Instructions,
Functions and Data types.
There are two tune types that are used expressly for Advanced Shape Tuning:
Tune type Description
TUNE_FRIC_LEV By calling the instruction TuneServo with the argument
TUNE_FRIC_LEV the friction level for a robot joint can be adjusted
during program execution. A value is given in percent (between 1
and 500) of the friction level defined by the parameter Friction FFW
Level.
TUNE_FRIC_RAMP By calling the instruction TuneServo with the argument
TUNE_FRIC_RAMP the motor shaft speed at which full friction com-
pensation is reached can be adjusted during program execution. A
value is given in percent (between 1 and 500) of the friction ramp
defined by the parameter Friction FFW Ramp.
There is normally no need to tune the friction ramp.

Configure friction level

The friction level is set for each robot joint. Perform the following steps for one
joint at a time:
Action
1 Test the robot by running it through the most demanding parts of its tasks (the most
advanced shapes). If the robot shall be used for cutting, then test it by cutting with the
same tool as at manufacturing.
Observe the path deviations and test if the joint friction levels need to be increased
or decreased.
2 Tune the friction level with the RAPID instruction TuneServo and the tune type
TUNE_FRIC_LEV. The level is given in percent of the Friction FFW Level value.
Example: The instruction for increasing the friction level with 20% looks like this:
TuneServo MHA160R1, 1, 120 \Type:= TUNE_FRIC_LEV;
3 Repeat step 1 and 2 until you are satisfied with the path deviation.

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4 Motion performance
4.4.3 Manual friction tuning
Continued

Action
4 The final tuning values can be transferred to the system parameters.
Example: The Friction FFW Level is 0.5 and the final tune value (TUNE_FRIC_LEV) is
120%. Set Friction FFW Level to 0.6 and tune value to 100% (default value), which is
equivalent.

Tip

Tuning can be made to a maximum of 500%. If that is not enough, set a higher
value for the parameter Friction FFW Level, see Setting tuning system parameters
on page 196.

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 4 Motion performance
[Link] System parameters

4.4.4 System parameters

[Link] System parameters

About the system parameters

This is a brief description of each parameter in the option Advanced Shape Tuning.
For more information, see the respective parameter in Technical reference
manual - System parameters.

Friction Compensation / Control Parameters

These parameters belong to the type Friction Compensation in the topic Motion,
except for the robots IRB 1400 and IRB 1410 where they belong to the type Control
Parameters in the topic Motion.
Parameter Description
Friction FFW On Advanced Shape Tuning is active when Friction FFW On is set to
TRUE.
Friction FFW Level Friction FFW Level is the friction level for the robot joint. See illustra-
tion below.
Friction FFW Ramp Friction FFW Ramp is the speed of the robot motor shaft, at which
the friction has reached the friction level defined by Friction FFW
Level. See illustration below.
There is normally no need to make changes to Friction FFW Ramp.

Illustration

en0900000117

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4 Motion performance
[Link] Setting tuning system parameters

[Link] Setting tuning system parameters

Automatic tuning rarely requires changes in system parameters

For automatic tuning, if the friction levels are saved in a persistent array, the tuning
is maintained after a power failure. The automatic tuning can also be used to set
different tuning levels for different robot movement sequences, which cannot be
achieved with system parameters. When using automatic tuning, there is no need
to change the system parameters unless the default values are very much off, see
Starting with an estimated value on page 196.

Transfer tuning to system parameters

When using manual tuning, the tuning values are reset to default (100%) at power
failure. System parameter settings are, however, permanent.
If a temporary tuning is made, that is only valid for a part of the program execution,
it should not be transferred.
To transfer the friction level tuning value (TUNE_FRIC_LEV) to the parameter
Friction FFW Level follow these steps:
Action
1 In RobotStudio, open the Configuration Editor, Motion topic, and select the type
Friction comp (except for the robots IRB 1400 and IRB 1410 where they belong to the
type Control parameters).
2 Multiply Friction FFW Level with the tuning value. Set this value as the new Friction
FFW Level and set the tuning value (TUNE_FRIC_LEV) to 100%.
Example: The Friction FFW Level is 0.5 and the final tune value (TUNE_FRIC_LEV) is
120%. Set Friction FFW Level to 0.6 (1.20x0.5) and the tuning value to 100% (default
value), which is equivalent.
3 Restart the controller for the changes to take effect.

Starting with an estimated value

The parameter Friction FFW Level will be the starting value for the tuning. If this
value is very far from the correct value, tuning to the correct value might be
impossible. This is unlikely to happen, since Friction FFW Level is by default set
to a value approximately correct for most situations.
If the Friction FFW Level value, for some reason, is too far from the correct value,
it can be changed to an new estimated value.
Action
1 In RobotStudio, open the Configuration Editor, Motion topic, and select the type
Friction comp (except for the robots IRB 1400 and IRB 1410 where they belong to the
type Control parameters).
2 Set the parameter Friction FFW Level to an estimated value. Do not set the value 0
(zero), because that will make tuning impossible.
3 Restart the controller for the changes to take effect.

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 4 Motion performance
4.4.5 RAPID components

4.4.5 RAPID components

About the RAPID components

This is an overview of all instructions, functions, and data types in Advanced Shape
Tuning.
For more information, see Technical reference manual - RAPID Instructions,
Functions and Data types.

Instructions

Instructions Description
FricIdInit Initiate friction identification
FricIdEvaluate Evaluate friction identification
FricIdSetFricLevels Set friction levels after friction identification

Functions
Advanced Shape Tuning includes no functions.

Data types
Advanced Shape Tuning includes no data types.

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4 Motion performance
4.5.1 About Motion Process Mode

4.5 Motion Process Mode [included in 3100-1]

4.5.1 About Motion Process Mode

Purpose
The purpose of Motion Process Mode is to simplify application specific tuning, i.e.
to optimize the performance of the robot for a specific application.
For most applications the default mode is the best choice.

Tip

If the default mode does not give sufficient accuracy, first test to use Accuracy
mode, and if that is not sufficient, use Low speed accuracy.

Available motion process modes

A motion process mode consists of a specific set of tuning parameters for a robot.
Each tuning parameter set, that is each mode, optimizes the robot tuning for a
specific class of applications.
There following modes are predefined:
• Optimal cycle time mode – this mode gives the shortest possible cycle time
and is normally the default mode.
• Accuracy mode – this mode improves path accuracy. The cycle time will be
slightly increased compared to Optimal cycle time mode.
• Low speed accuracy mode – this mode improves path accuracy. The cycle
time will be slightly increased compared to Accuracy mode.
• Low speed stiff mode - this mode is recommended for contact applications
where maximum servo stiffness is important. Could also be used in some
low speed applications, where a minimum of path vibrations is desired. The
cycle time will be increased compared to Low speed accuracy mode.
• Press tending mode – Changes the Kv Factor, Kp Factor and Ti Factor in
order to mitigate tool vibrations. This mode is primarily intended for use in
press tending applications where flexible grippers with a large extension in
the y-direction are used.
• Collaborative mode – This mode is recommended for collaborative
applications where robot should run smoothly. The cycle time will be
increased compared to optimal cycle time mode. This will only have any
effect on GoFa CRB 15000 and CRB 1810.
There are also four modes available for application specific user tuning:
• MPM User mode 1 – 4

Selection of mode
The default mode is automatically selected and can be changed by changing the
system parameter Use Motion Process Mode for type Robot.

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4.5.1 About Motion Process Mode
Continued

Changing the Motion Process Mode from RAPID is only possible if the option
Advanced Robot Motion is installed. The mode can only be changed when the
robot is standing still, otherwise a fine point is enforced.
The following example shows a typical use of the RAPID instruction
MotionProcessModeSet.
MotionProcessModeSet OPTIMAL_CYCLE_TIME_MODE;
! Do cycle-time critical movement
MoveL *, vmax, ...;
...

MotionProcessModeSet ACCURACY_MODE;
! Do cutting with high accuracy
MoveL *, v50, ...;
...

Limitations
• The Motion Process Mode concept is currently available for all six- and
seven-axes robots except paint robots with TrueMove1.
• The Mounting Stiffness Factor parameters are only available for the following
robots:
IRB 120, IRB 140, IRB 1200, IRB 1520, IRB 1600, IRB 2600, IRB 4600, IRB
6620 (not LX), IRB 6640, IRB 6700.
• For IRB 1410, only the Accset and the geometric accuracy parameters are
available.
• The following robot models do not support the use of World Acc Factor (i.e.
only World Acc Factor = -1 is allowed):
IRB 340, IRB 360, IRB 540, IRB 1400, IRB 1410

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4 Motion performance
4.5.2 User-defined modes

4.5.2 User-defined modes

Available tune parameters

If a more specific tuning is needed, some tuning parameters can be modified in
each motion process mode. The predefined modes and the user modes can all be
modified. In this way, the user can create a specific tuning for a specific application.
The following list contains a short description of the available tune parameters.
• Use Motion Process Mode Type - selects predefined parameters for a user
mode.
• Accset Acc Factor – changes acceleration
• Accset Ramp Factor – changes acceleration ramp
• Accset Fine Point Ramp Factor – changes deceleration ramp in fine points
• Joint Acc Factor - changes acceleration for a specific joint.
• World Acc Factor - activates dynamic world acceleration limitation if positive,
typical value is 1, deactivated if -1.
• Geometric Accuracy Factor - improves geometric accuracy if reduced.
• Dh Factor – changes path smoothness (effective system bandwidth)
• Df Factor – changes the predicted resonance frequency for a particular axis
• Kp Factor – changes the equivalent gain of the position controller for a
particular axis
• Kv Factor – changes the equivalent gain of the speed controller for a particular
axis
• Ti Factor – changes the integral time of the controller for a particular axis
• Mounting Stiffness Factor X – describes the stiffness of the robot foundation
in x direction
• Mounting Stiffness Factor Y – describes the stiffness of the robot foundation
in y direction
• Mounting Stiffness Factor Z – describes the stiffness of the robot foundation
in z direction
For a detailed description, see Motion Process Mode in Technical reference
manual - System parameters.

Tuning parameters from RAPID

Most parameters can also be changed using the TuneServo and AccSet
instructions.

Note

All parameter settings are relative adjustments of the predefined parameter

values. Although it is possible to combine the use of motion process modes and
TuneServo/Accset instructions, it is recommended to choose either motion
process modes or TuneServo/AccSet.

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4.5.2 User-defined modes
Continued

Example 1
Relative adjustment of acceleration = [Predefined AccSet Acc Factor] * [AccSet
Acc Factor] * [AccSet instruction acceleration factor / 100]

Example 2
Relative adjustment of Kv = [Predefined Kv Factor] * [Kv Factor] * [Tune value of
TuneServo(TYPE_KV) instruction / 100]

Predefined parameter values

The predefined parameter values for each mode varies for different robot types.
Generally, all predefined parameters are set to 1.0 for Optimal cycle time mode.
For Low speed accuracy mode and Low speed stiff mode, the AccSet and Dh
parameters are lowered for a smoother movement and a more accurate path, and
the Kv Factor, Kp Factor, and Ti Factor are changed for higher servo stiffness.
For some robots, it might not be possible to increase the Kv Factor in Low speed
accuracy mode and Low speed stiff mode. Always be careful and be observant for
increased motor noise level when adjusting Kv Factor and do not use higher values
than needed for fulfilling the application requirement. A Kp Factor which is too
high, or a Ti Factor which is too low, can also increase vibrations due to mechanical
resonances.
Accuracy Mode uses a dynamic world acceleration limitation (World Acc Factor)
and increased geometric accuracy (Geometric Accuracy Factor) to improve the
path accuracy.
The Df Factor and the Mounting Stiffness Factors are always set to 1.0 in the
predefined modes, since the optimal values of these parameters depends the
specific installation, for example, the stiffness of the foundation on which the robot
is mounted. These parameters can be optimized using TuneMaster. More
information can be found in the TuneMaster application. Also note the limitations
of Mounting Stiffness Factor.

WARNING

Incorrect setting of the Motion Process Mode parameters can cause oscillating
movements or torques that can damage the robot.

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4 Motion performance
4.5.3 General information about robot tuning

4.5.3 General information about robot tuning

Minimizing cycle time

For best possible cycle time, the motion process mode Optimal cycle time mode
should be used. This mode is normally the default mode. The user only needs to
define the tool load, payload, and arm loads if any. Once the robot path has been
programmed, the ABB QuickMove motion technology automatically computes the
optimal accelerations and speeds along the path. This results in a time-optimal
path with the shortest possible cycle time. Hence, no tuning of acceleration is
needed. The only way to improve the cycle time is to change the geometry of the
path or to work in another region of the work space. This type of optimization, if
needed, can be performed by simulation in RobotStudio.

Increasing path accuracy and reducing vibrations

For most applications, the Optimal cycle time mode will result in a satisfactory
behavior in terms of path accuracy and vibrations. This is due to the ABB TrueMove
motion technology. However, there are applications where the accuracy needs to
be improved by modifying the tuning of the robot. This tuning has previously been
performed by using the TuneServo and AccSet instructions in the RAPID program.
The concept of motion process modes will simplify this application specific tuning
and the four predefined modes should be useful in many cases with no further
adjustments needed.
Here follows some general advice for solving accuracy problems, assuming that
the default choice Optimal cycle time mode has been tested and that accuracy
problems have been noticed:
1 Verify that tool load, payload, and arm loads are properly defined.
2 Inspect tool and process equipment attached to the robot arms. Make sure
that everything is properly fastened and that rigidity of the tool is adequate.
3 Inspect the foundation on which the robot is mounted, see Compensating
for foundation flexibility on page 202.

Compensating for foundation flexibility

If the foundation does not fulfill the stiffness requirement of the robot product
manual, then the foundation flexibility should be compensated for. See section
Requirements on foundation, Minimum resonance frequency in the robot product
manual.
This is performed by Df Factor for axis 1 and 2 or Mounting Stiffness Factor
depending on robot type, see Limitations on page 205.
TuneMaster is used for finding the optimal value of Df Factor / Mounting Stiffness
Factor. The obtained Df Factor / Mounting Stiffness Factor is then defined for the
Motion Process Modes used.

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4.5.3 General information about robot tuning
Continued

Note

A foundation that does not fulfill the requirements always impairs the accuracy
to some extent, even if the described compensation is used. If the foundation
rigidity is very low, there might not be possible to solve the problem using Df
Factor / Mounting Stiffness Factor.
In this case, the foundation must be improved or any of the solutions below used,
for example, Optimal cycle time mode with a low Dh Factor, Accset Acc Factor,
or Accset Fine Point Ramp Factor depending on the application.

WARNING

Incorrect tuning for a very low mounting stiffness can cause oscillating
movements or torques that can damage the robot.

If accuracy still needs to be improved

• For applications with high demands on path accuracy, for example cutting,
Advanced Shape Tuning and Accuracy mode/Low speed accuracy mode
should be used. The choice of motion mode depends both on the robot type
and the specific application. In general, Accuracy mode is recommended for
small and medium size robots (up to IRB 2400/2600) and Low speed accuracy
mode is recommended for larger robots.
• If the path accuracy still needs improvement, the accuracy modes can be
adjusted with the tune parameters, some examples:
- Tuning of Accuracy mode for improved accuracy:
1) Reduce World Acc Factor, for example from 1 to 0.5.
2) Reduce Dh Factor to 0.5 or lower. Note that a low value of Dh factor
can change the corner zones at high speed.
- Tuning of Low speed accuracy mode for improved accuracy:
1) Set World Acc Factor to 1, and set Geometric Accuracy Factor to
0.1.
2) Reduce Dh Factor to 0.5 or lower.
• The programmed speed must sometimes be reduced for best possible
accuracy, e.g. in cutting applications. For example, a circle with radius 1 mm
should not be programmed with a higher speed than 20 mm/s.
• For contact applications, for example milling and pre-machining, Low speed
stiff mode is recommended. This mode can also be useful for large robots
in some low speed applications (up to 100 mm/s) where a minimum of path
vibrations is required, for example below 0.1 mm. Note that this mode has a
very stiff servo tuning and that there may be cases where the Kv Factor
needs to be reduced due to motor vibrations and noise.
• If overshoots and vibrations in fine points needs to be reduced. Use Optimal
cycle time mode and decrease the value of Accset Fine Point Ramp Factor
or Dh Factor until the problem is solved.

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4.5.3 General information about robot tuning
Continued

• If accuracy problems occur when starting or ending reorientation. Define a

new zone with increased pzone_ori and pzone_eax. These should always
have the same value, even if there are no external axes in the system. Also
increase zone_ori. Always strive for smooth reorientations when
programming.
• Finally, if the cycle time needs to be reduced after the tuning for accuracy is
finished. Use different motion process modes in different sections of the
RAPID program.

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 4 Motion performance
4.5.4 Additional information

4.5.4 Additional information

Motion Process Mode compared to TuneServo and AccSet

Motion process modes simplifies application specific tuning and makes it possible
to define the tuning by system parameters instead of the RAPID program.
In general, motion process modes should be the first choice for solving accuracy
problems. However, application specific tuning can still be performed using the
TuneServo and AccSet instructions in the RAPID program.
There are a few situations where TuneServo and AccSet might be a better choice.
One example of this is if an acceleration reduction in a section of the RAPID
program solves the accuracy problem and the cycle time is to be optimized. In this
case it might be better to use AccSet which can be changed without fine point
whereas change of motion process mode requires a fine point.

Limitations
• The Motion Process Mode concept is currently available for all six- and
seven-axes robots except paint robots.
• The Mounting Stiffness Factor parameters are only available for the following
robots:
IRB 120, IRB 140, IRB 1200, IRB 1520, IRB 1600, IRB 2600, IRB 4600, IRB
6620 (not LX), IRB 6640, IRB 6700.
• For IRB 1410, only the Accset and the geometric accuracy parameters are
available.
• The following robot models do not support the use of World Acc Factor (i.e.
only World Acc Factor = -1 is allowed):
IRB 340, IRB 360, IRB 540, IRB 1400, IRB 1410

Related information

For information about See

Configuration of Motion Process Mode Technical reference manual - System paramet-
parameters. ers
RAPID instructions: Technical reference manual - RAPID Instruc-
• AccSet - Reduces the acceleration tions, Functions and Data types
• MotionProcessModeSet - Set mo-
tion process mode
• TuneServo - Tuning servos

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4 Motion performance
4.6.1 Introduction to Wrist Move

4.6 Wrist Move [included in 3100-1]

4.6.1 Introduction to Wrist Move

Purpose
The purpose of Wrist Move is to improve the path accuracy when cutting geometries
with small dimensions. For geometrical shapes like small holes, friction effects
from the main axes (1-3) of the robot often degrade the visual appearance of the
shape. The key idea is that instead of controlling the robot's TCP, a wrist movement
controls the point of intersection between the laser beam (or water jet or routing
spindle, etc) and the cutting plane. For controlling the point of intersection, only
two wrist axes are needed. Instead of using all axes of the robot, only two wrist
axes are used, thereby minimizing the friction effects on the path. Which wrist axis
pair to be used is decided by the programmer.

Using Wrist Move

Wrist Move is included in the RobotWare option Advanced robot motion.
Wrist Move is used together with the RAPID instruction CirPathMode and
movement instructions for circular arcs, that is, MoveC, TrigC, CapC etc. The wrist
movement mode is activated by the instruction CirPathMode together with one
of the flags Wrist45, Wrist46, or Wrist56. With this mode activated, all
subsequent MoveC instructions will result in a wrist movement. To go back to
normal MoveC behavior, then CirPathMode has to be set with a flag other than
Wrist45, Wrist46, and Wrist56, for example, PathFrame.

Note

During a wrist movement, the TCP height above the surface will vary. This is an
unavoidable consequence of using only two axes. The height variation will depend
on the robot position, the tool definition, and the radius of the circular arc. The
larger the radius, the larger the height variation will be. Due to the height variation
it is recommended that the movement is run at a very low speed the first time to
verify that the height variation does not become too large. Otherwise it is possible
that the cutting tool collides with the surface being cut.

Limitations
The Wrist Move option cannot be used if:
• The work object is moving
• The robot is mounted on a track or another manipulator that is moving
The Wrist Move option is only supported for robots running QuickMove, second
generation.
The tool will not remain at right angle against the surface during the cutting. As a
consequence, the holes cut with this method will be slightly conical. Usually this
will not be a problem for thin plates, but for thick plates the conicity will become
apparent.

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4.6.1 Introduction to Wrist Move
Continued

The height of the TCP above the surface will vary during the cut. The height variation
will increase with the size of the shape being cut. What limits the possible size of
the shape are therefore, beside risk of collision, process characteristics like focal
length of the laser beam or the water jet.
WristMove cannot be used on robots with non-spherical wrist, for example, GoFa,
CRB 1810, or YuMi.

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4 Motion performance
4.6.2 Cut plane frame

4.6.2 Cut plane frame

Defining the cut plane frame

Crucial to the wrist movement concept is the definition of the cut plane frame. This
frame provides information about position and orientation of the object surface.
The cut plane frame is defined by the robot's starting position when executing a
MoveC instruction. The frame is defined to be equal to the tool frame at the starting
position. Note that for a sequence of MoveC instructions, the cut plane frame stays
the same during the whole sequence.

Illustration, cut plane

The left illustration shows how the cut plane is defined, and the right illustration
shows the tool- and cut plane frames during cutting.

en0900000118

Prerequisites
Due to the way the cut plane frame is defined, the following must be fulfilled at the
starting position:
• The tool must be at right angle to the surface
• The z-axis of the tool must coincide with the laser beam or water jet
• The TCP must be as close to the surface as possible
If the first two requirements are not fulfilled, then the shape of the cut contour will
be affected. For example, a circular hole would look more like an ellipse. The third
requirement is normally easy to fulfill as the TCP is often defined to be a few mm
in front of, for example, the nozzle of a water jet. However, if the third requirement
is not fulfilled, then it will only affect the radius of the resulting circle arc. That is,
the radius of the cut arc will not agree with the programmed radius. For a linear
segment, the length will be affected.

Tip

In the jog window of the FlexPendant there is a button for automatic alignment
of the tool against a chosen coordinate frame. This functionality can be used to
ensure that the tool is at a right angle against the surface when starting the wrist
movement.
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 4 Motion performance
4.6.2 Cut plane frame
Continued

Tip

Wrist movement is not limited to circular arcs only: If the targets of MoveC are
collinear, then a straight line will be achieved.

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4 Motion performance
4.6.3 RAPID components

4.6.3 RAPID components

Instruction
This is a brief description of the instruction used in Wrist Move. For more
information, see the description of the instruction in Technical reference
manual - RAPID Instructions, Functions and Data types.
Instruction Descriptions
CirPathMode CirPathMode makes it possible to select different modes to
reorientate the tool during circular movements.
The arguments Wrist45, Wrist46, and Wrist56 are used
specifically for the Wrist Move option.

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 4 Motion performance
4.6.4 RAPID code, examples

4.6.4 RAPID code, examples

Basic example
This example shows how to do two circular arcs, first using axes 4 and 5, and then
using axes 5 and 6. After the two arcs, wrist movement is deactivated by
CirPathMode.
! This position will define the cut plane frame
MoveJ p10, v100, fine, tWaterJet;

CirPathMode \Wrist45;
MoveC p20, p30, v50, z0, tWaterJet;

! The cut-plane frame remains the same in a sequence of MoveC

CirPathMode \Wrist56;
MoveC p40, p50, v50, fine, tWaterJet;

! Deactivate Wrist Movement, could use \ObjectFrame

! or \CirPointOri as well
CirPathMode \PathFrame;

Advanced example
This example shows how to cut a slot with end radius R and length L+2R, using
wrist movement. See Illustration, pSlot and wSlot on page 212. The slot both
begins and ends at the position pSlot, which is the center of the left semi-circle.
To avoid introducing oscillations in the robot, the cut begins and ends with
semi-circular lead-in and lead-out paths that connect smoothly to the slot contour.
All coordinates are given relative the work object wSlot.
! Set the dimensions of the slot
R := 5;
L := 30;

! This position defines the cut plane frame, it must be normal

! to the surface
MoveJ pSlot, v100, z1, tLaser, \wobj := wSlot;
CirPathMode \Wrist45;

! Lead-in curve
MoveC Offs(pSlot, R/2, R/2, 0), Offs(pSlot, 0, R, 0), v50, z0,
tLaser, \wobj := wSlot;

! Left semi-circle
MoveC Offs(pSlot, -R, 0, 0), Offs(pSlot, 0, -R, 0), v50, z0, tLaser,
\wobj := wSlot;

! Lower straight line, circle point passes through the mid-point

! of the line
MoveC Offs(pSlot, L/2, -R, 0), Offs(pSlot, L, -R, 0), v50, z0,
tLaser, \wobj := wSlot;

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4 Motion performance
4.6.4 RAPID code, examples
Continued

! Right semi-circle
MoveC Offs(pSlot, L+R, 0, 0), Offs(pSlot, L, R, 0), v50, z0, tLaser,
\wobj := wSlot;

! Upper straight line, circle point passes through the mid-point

! of the line
MoveC Offs(pSlot, L/2, R, 0), Offs(pSlot, 0, R, 0), v50, z0, tLaser,
\wobj := wSlot;

! Lead-out curve back to the starting point

MoveC Offs(pSlot, -R/2, R/2, 0), pSlot, v50, z1, tLaser, \wobj :=
wSlot;

Deactivate Wrist Movement

CirPathMode \ObjectFrame;

Illustration, pSlot and wSlot

wSlot

pSlot

xx0900000111

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 4 Motion performance
4.6.5 Troubleshooting

4.6.5 Troubleshooting

Unexpected cut shape

If the cut shape is not the expected, then check the following:
• The tool z-axis coincides with the laser beam or the water jet
• The tool z-axis is at right angle to the surface at the starting position of the
first MoveC
• If you have the option Advanced Shape Tuning, then try tuning the friction
for the involved wrist axes.

Mismatching radius
If the radius of the circular arc does not agree with the programmed radius, then
check that the TCP is as close to the surface as possible at the starting position.

Impossible movement with chosen axis pair

If the movement is not possible with the selected axis pair, then try activating
another pair by using one of the flags Wrist45, Wrist46, or Wrist56. As a last
resort, try reaching the starting position with another robot configuration.

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 5 Motion supervision
5.1.1 Overview of World Zones

5 Motion supervision
5.1 World Zones [3106-1]

5.1.1 Overview of World Zones

Purpose
The purpose of World Zones is to stop the robot or set an output signal if the robot
is inside a special user-defined zone. Here are some examples of applications:
• When two robots share a part of their respective work areas. The possibility
of the two robots colliding can be safely eliminated by World Zones
supervision.
• When a permanent obstacle or some temporary external equipment is located
inside the robot’s work area. A forbidden zone can be created to prevent the
robot from colliding with this equipment.
• Indication that the robot is at a position where it is permissible to start program
execution from a Programmable Logic Controller (PLC).
A world zone is supervised during robot movements both during program execution
and jogging. If the robot’s TCP reaches the world zone or if the axes reaches the
world zone in joints, the movement is stopped or a digital output signal is set.

WARNING

For safety reasons, this software shall not be used for protection of personnel.
Use hardware protection equipment for that.

What is included
The RobotWare option World Zones gives you access to:
• instructions used to define volumes of various shapes
• instructions used to define joint zones in coordinates for axes
• instructions used to define and enable world zones

Basic approach
This is the general approach for setting up World Zones. For a more detailed
example of how this is done, see Code examples on page 219.
1 Declare the world zone as stationary or temporary.
2 Declare the shape variable.
3 Define the shape that the world zone shall have.
4 Define the world zone (that the robot shall stop or that an output signal shall
be set when reaching the volume).

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5.1.1 Overview of World Zones
Continued

Limitations
Supervision of a volume only works for the TCP. Any other part of the robot may
pass through the volume undetected. To be certain to prevent this, you can
supervise a joint world zone (defined byWZLimJointDef or WZHomeJointDef).
A variable of type wzstationary or wztemporary can not be redefined. They
can only be defined once (with WZLimSup or WZDOSet).
World Zones supervision is not accessible when lead-through is active.

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 5 Motion supervision
5.1.2 RAPID components

5.1.2 RAPID components

Data types
This is a brief description of each data type in World Zones. For more information,
see respective data type in Technical reference manual - RAPID Instructions,
Functions and Data types.
Data type Description
wztemporary wztemporary is used to identify a temporary world zone and can be
used anywhere in the RAPID program.
Temporary world zones can be disabled, enabled again, or erased
via RAPID instructions. Temporary world zones are automatically
erased when a new program is loaded or when program execution
start from the beginning in the MAIN routine.
wzstationary wzstationary is used to identify a stationary world zone and can
only be used in an event routine connected to the event POWER ON.
For information on defining event routines, see Operating manual - Om-
niCore.
A stationary world zone is always active and is reactivated by a restart
(switch power off then on, or change system parameters). It is not
possible to disable, enable or erase a stationary world zone via
RAPID instructions.
Stationary world zones shall be used if security is involved.
shapedata shapedata is used to describe the geometry of a world zone.
World zones can be defined in 4 different geometrical shapes:
• a straight box, with all sides parallel to the world coordinate
system
• a cylinder, parallel to the z axis of the world coordinate system
• a sphere
• a joint angle area for the robot axes and/or external axes

Instructions
This is a brief description of each instruction in World Zones. For more information,
see respective instruction in Technical reference manual - RAPID Instructions,
Functions and Data types.
Instruction Description
WZBoxDef WZBoxDef is used to define a volume that has the shape of a straight
box with all its sides parallel to the axes of the world coordinate sys-
tem. The definition is stored in a variable of type shapedata.
The volume can also be defined as the inverse of the box (all volume
outside the box).
WZCylDef WZCylDef is used to define a volume that has the shape of a cylinder
with the cylinder axis parallel to the z-axis of the world coordinate
system. The definition is stored in a variable of type shapedata.
The volume can also be defined as the inverse of the cylinder (all
volume outside the cylinder).
WZSphDef WZSphDef is used to define a volume that has the shape of a sphere.
The definition is stored in a variable of type shapedata.
The volume can also be defined as the inverse of the sphere (all
volume outside the sphere).

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5 Motion supervision
5.1.2 RAPID components
Continued

Instruction Description
WZLimJointDef WZLimJointDef is used to define joint coordinate for axes, to be
used for limitation of the working area. Coordinate limits can be set
for both the robot axes and external axes.
For each axis WZLimJointDef defines an upper and lower limit. For
rotational axes the limits are given in degrees and for linear axes the
limits are given in mm.
The definition is stored in a variable of type shapedata.
WZHomeJointDef WZHomeJointDef is used to define joint coordinates for axes, to be
used to identify a position in the joint space. Coordinate limits can be
set for both the robot axes and external axes.
For each axis WZHomeJointDef defines a joint coordinate for the
middle of the zone and the zones delta deviation from the middle. For
rotational axes the coordinates are given in degrees and for linear
axes the coordinates are given in mm.
The definition is stored in a variable of type shapedata.
WZLimSup WZLimSup is used to define, and enable, stopping the robot with an
error message when the TCP reaches the world zone. This supervision
is active both during program execution and when jogging.
When calling WZLimSup you specify whether it is a stationary world
zone, stored in a wzstationary variable, or a temporary world zone,
stored in a wztemporary variable.
WZDOSet WZDOSet is used to define, and enable, setting a digital output signal
when the TCP reaches the world zone.
When callingWZDOSet you specify whether it is a stationary world
zone, stored in a wzstationary variable, or a temporary world zone,
stored in a wztemporary variable.
WZDisable WZDisable is used to disable the supervision of a temporary world
zone.
WZEnable WZEnable is used to re-enable the supervision of a temporary world
zone.
A world zone is automatically enabled on creation. Enabling is only
necessary after it has been disabled with WZDisable.
WZFree WZFree is used to disable and erase a temporary world zone.

Functions
World Zones does not include any RAPID functions.

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 5 Motion supervision
5.1.3 Code examples

5.1.3 Code examples

Create protected box

To prevent the robot TCP from moving into stationary equipment, set up a stationary
world zone around the equipment.
The routine my_power_on should then be connected to the event POWER ON.
For information on how to do this, read about defining event routines in Operating
manual - OmniCore.

xx0300000178

VAR wzstationary obstacle;

PROC my_power_on()
VAR shapedata volume;
CONST pos p1 := [200, 100, 100];
CONST pos p2 := [600, 400, 400];

!Define a box between the corners p1 and p2

WZBoxDef \Inside, volume, p1, p2;

!Define and enable supervision of the box

WZLimSup \Stat, obstacle, volume;
ENDPROC

Signal when robot is in position

When two robots share a work area it is important to know when a robot is out of
the way, letting the other robot move freely.
This example defines a home position where the robot is in a safe position and
sets an output signal when the robot is in its home position. The robot is standing
on a travel track, handled as external axis 1. No other external axes are active.
The shadowed area in the illustration shows the world zone.

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5.1.3 Code examples
Continued

xx0300000206

VAR wztemporary home;

PROC zone_output()
VAR shapedata joint_space;

!Define the home position

CONST jointtarget home_pos := [[0, -20, 0, 0, 0, 0], [0, 9E9,
9E9, 9E9, 9E9, 9E9]];

!Define accepted deviation from the home position

CONST jointtarget delta_pos := [[2, 2, 2, 2, 2, 2], [10, 9E9,
9E9, 9E9, 9E9, 9E9]];

!Define the shape of the world zone

WZHomeJointDef \Inside, joint_space, home_pos, delta_pos;

!Define the world zone, setting the

!signal do_home to 1 when in zone
WZDOSet \Temp, home \Inside, joint_space, do_home, 1;
ENDPROC

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 5 Motion supervision
5.2.1 Overview

5.2 Collision Detection [3107-1]

5.2.1 Overview

Purpose
Collision Detection is a software option that reduces collision impact forces on the
robot. This helps protecting the robot and external equipment from severe damage.

WARNING

Collision Detection cannot protect equipment from damage at a full speed

collision.

Description
The software option Collision Detection identifies a collision by high sensitivity,
model based supervision of the robot. Depending on what forces you deliberately
apply on the robot, the sensitivity can be tuned as well as turned on and off.
Because the forces on the robot can vary during program execution, the sensitivity
can be set on-line in the program code.
Collision detection is more sensitive than the ordinary supervision and has extra
features. When a collision is detected, the robot will immediately stop and relieve
the residual forces by moving in reversed direction a short distance along its path.
After a collision error message has been acknowledged, the movement can continue
without having to press Motors on on the controller.

What is included
The RobotWare option Collision Detection gives you access to:
• system parameters for defining if Collision Detection should be active and
how sensitive it should be (without the option you can only turn detection on
and off for Auto mode)
• instruction for on-line changes of the sensitivity:MotionSup

Basic approach
Collision Detection is by default always active when the robot is moving. In many
cases this means that you can use Collision Detection without having to take any
active measures.
If necessary, you can turn Collision Detection on and off or change its sensitivity
in two ways:
• temporary changes can be made on-line with the RAPID instruction
MotionSup
• permanent changes are made through the system parameters.

Collision detection for YuMi robots

As default YuMi will have collision detection active at stand still. It also has another
stop ramp compared to other robots to be able to release clamping forces.

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5.2.1 Overview
Continued

Note

If the tool data is wrong, false collisions might be triggered and the robot arm
might drop a short distance during the stop ramp.

Collision detection for MultiMove robots

The default behavior when a collision is detected for one robot in a MultiMove
configuration is that all robots are stopped.
One reason for this behavior is that when a collision is detected, there is a big risk
that it was two robots that collided. Another reason is that if one robot stops and
another continues, this might cause another collision.
This behavior can be changed with the system parameter Ind collision stop without
brake. If this parameter is set to TRUE and the robots are running in independent
RAPID tasks when a collision is detected, only the robot that detected the collision
will be stopped.

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 5 Motion supervision
5.2.2 Limitations

5.2.2 Limitations

Load definition
In order to detect collisions properly, the payload of the robot must be correctly
defined.

Tip

Use Load Identification to define the payload. For more information, see Operating
manual - OmniCore.

Robot axes only

Collision Detection is only available for the robot axes. It is not available for track
motions, orbit stations, or any other external axes.

Independent joint
The collision detection is deactivated when at least one axis is run in independent
joint mode. This is also the case even when it is an external axis that is run as an
independent joint.

Soft servo
The collision detection may trigger without a collision when the robot is used in
soft servo mode. Therefore, it is recommended to turn the collision detection off
when the robot is in soft servo mode.

No change until the robot moves

If the RAPID instruction MotionSup is used to turn off the collision detection, this
will only take effect once the robot starts to move. As a result, the digital output
MotSupOn may temporarily have an unexpected value at program start before the
robot starts to move.

Reversed movement distance

The distance the robot is reversed after a collision is proportional to the speed of
the motion before the collision. If repeated low speed collisions occur, the robot
may not be reversed sufficiently to relieve the stress of the collision. As a result,
it may not be possible to jog the robot without the supervision triggering. In this
case, turn Collision Detection off temporarily and jog the robot away from the
obstacle.

Delay before reversed movement

In the event of a stiff collision during program execution, it may take a few seconds
before the robot starts the reversed movement.

Robot on track motion

If the robot is mounted on a track motion the collision detection should be
deactivated when the track motion is moving. If it is not deactivated, the collision
detection may trigger when the track moves, even if there is no collision.

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5 Motion supervision
5.2.3 What happens at a collision

5.2.3 What happens at a collision

Overview
When the collision detection is triggered, the robot will stop as quickly as possible.
Then it will move in the reverse direction to remove residual forces. The program
execution will stop with an error message. The robot remains in the state motors
on so that program execution can be resumed after the collision error message
has been acknowledged.
A typical collision is illustrated below.

Collision illustration

xx0300000361

Robot behavior after a collision

This list shows the order of events after a collision. For an illustration of the
sequence, see the diagram below.
When ... then ...
the collision is detected the motor torques are reversed and the mechanical brakes
applied in order to stop the robot
the robot has stopped the robot moves in reversed direction a short distance along
the path in order to remove any residual forces which may
be present if a collision or jam occurred
the residual forces are re- the robot stops again and remains in the motors on state
moved

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 5 Motion supervision
5.2.3 What happens at a collision
Continued

Speed and torque diagram

en0300000360

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5 Motion supervision
5.2.4 Additional information

5.2.4 Additional information

Motion error handling

For more information regarding error handling for a collision, see Technical
reference manual - RAPID kernel.

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 5 Motion supervision
[Link] System parameters

5.2.5 Configuration and programming facilities

[Link] System parameters

About system parameters

Most of the system parameters for Collision Detection do not require a restart to
take effect.
For more information about the parameters, see Technical reference
manual - System parameters.

Motion Supervision
These parameters belong to the type Motion Supervision in the topic Motion.
Parameter Description
Path Collision Detection Turn the collision detection On or Off for program execution.
Path Collision Detection is by default set to On.
Jog Collision Detection Turn the collision detection On or Off for jogging.
Jog Collision Detection is by default set to On.
Path Collision Detection Modifies the Collision Detection supervision level for program
Level execution by the specified percentage value. A large percent-
age value makes the function less sensitive.
Path Collision Detection Level is by default set to 100%.
Jog Collision Detection Level Modifies the Collision Detection supervision level for jogging
by the specified percentage value. A large percentage value
makes the function less sensitive.
Jog Collision Detection Level is by default set to 100%.
Collision Detection Memory Defines how much the robot moves in reversed direction on
the path after a collision, specified in seconds. If the robot
moved fast before the collision it will move away a larger
distance than if the speed was slow.
Collision Detection Memory is by default set to 75 ms.
Manipulator Supervision Turns the supervision for the loose arm detection on or off
for IRB 340 and IRB 360. A loose arm will stop the robot and
cause an error message.
Manipulator Supervision is by default set to On.
Manipulator Supervision Modifies the supervision level for the loose arm detection for
Level the manipulators IRB 340 and IRB 360. A large value makes
the function less sensitive.
Manipulator Supervision Level is by default value set to 100%.

Motion Planner
These parameters belong to the type Motion Planner in the topic Motion.
Parameter Description
Motion Supervision Max Set the maximum level to which the total collision detection
Level tune level can be changed. It is by default set to 300%.

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[Link] System parameters
Continued

Motion System
This parameter belongs to the type Motion System in the topic Motion.
Parameter Description
Ind collision stop without This parameter is only valid for systems using the MultiMove
brake option. If this parameter is set to TRUE, detected collisions will
be handled independently in RAPID tasks that are executed
independently.
A restart is required for this parameter to take effect.

General RAPID
These parameters belong to the type General RAPID in the topic Controller.
Parameter Description
Collision Error Handler Enables RAPID error handling for collision. Collision Error
Handler is default set to Off.
For more information regarding error handling for a collision,
see Technical reference manual - RAPID kernel

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 5 Motion supervision
[Link] RAPID components

[Link] RAPID components

Instructions
This is a brief description of the instructions in Collision Detection. For more
information, see respective instruction in Technical reference manual - RAPID
Instructions, Functions and Data types.
Instruction Description
MotionSup MotionSup is used to:
• activate or deactivate Collision Detection. This can only be done
if the parameter Path Collision Detection is set to On.
• modify the supervision level with a specified percentage value
(1-300%). A large percentage value makes the function less
sensitive.

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5 Motion supervision
[Link] Signals

[Link] Signals

Digital outputs
This is a brief description of the digital outputs in Collision Detection. For more
information, see respective digital output in Technical reference manual - System
parameters.
Digital output Description
MotSupOn MotSupOn is high when Collision Detection is active and low when it
is not active.
Note that a change in the state takes effect when a motion starts. Thus,
if Collision Detection is active and the robot is moving, MotSupOn is
high. If the robot is stopped and Collision Detection is turned off, Mot-
SupOn is still high. When the robot starts to move, MotSupOn switches
to low.
Before the first Motors On order after a restart of the robot controller,
MotSupOn will reflect the value of the corresponding system parameter
Path Collision Detection:
• If Path Collision Detection is set to On, MotSupOn will be high.
• If Path Collision Detection is set to Off, MotSupOn will be low.
MotSupTrigg MotSupTrigg goes high when the collision detection triggers. It stays
high until the error code is acknowledged from the FlexPendant.

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 5 Motion supervision
[Link] Set up system parameters

5.2.6 How to use Collision Detection

[Link] Set up system parameters

Activate supervision
To be able to use Collision Detection during program execution, the parameter
Path Collision Detection must be set to On.
To be able to use Collision Detection during jogging, the parameter Jog Collision
Detection must be set to On.

Define supervision levels

Set the parameter Path Collision Detection Level to the percentage value you want
as default during program execution.
Set the parameter Jog Collision Detection Level to the percentage value you want
as default during jogging.

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5 Motion supervision
[Link] Adjust supervision from FlexPendant

[Link] Adjust supervision from FlexPendant

Speed adjusted supervision level

Collision Detection uses a variable supervision level. At low speeds it is more
sensitive than at high speeds. For this reason, no tuning of the function should be
required by the user during normal operating conditions. However, it is possible
to turn the function on and off and to tune the supervision levels.
Separate tuning parameters are available for jogging and program execution. These
parameters are described in System parameters on page 227.

Set jog supervision on FlexPendant

On the FlexPendant, select Control from the QuickSet window and then tap Jog.
On the Jog Settings, tap Jog Supervision.
Supervision can be turned on or off and the sensitivity can be adjusted for both
programmed paths and jogging. The sensitivity level is set in percentage. A large
value makes the function less sensitive.
If the motion supervision for jogging is turned off in the dialog box and a program
is executed, Collision Detection can still be active during execution of the program.

Note

The supervision settings correspond to system parameters of the type Motion

Supervision. These can be set using the supervision settings on the FlexPendant,
as described above. They can also be changed using RobotStudio or FlexPendant
configuration editor or Quickset Mechanical unit menu.

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 5 Motion supervision
[Link] Adjust supervision from RAPID program

[Link] Adjust supervision from RAPID program

Default values
If Collision Detection is activated with the system parameters, it is by default active
during program execution with the tune value 100%. These values are set
automatically:
• when using the restart mode Reset system.
• when a new program is loaded.
• when starting program execution from the beginning.

Note

If tune values are set in the system parameters and in the RAPID instruction,
both values are taken into consideration.
Example: If the tune value in the system parameters is set to 150% and the tune
value is set to 200% in the RAPID instruction the resulting tune level will be 300%.

Temporarily deactivate supervision

If external forces will affect the robot during a part of the program execution,
temporarily deactivate the supervision with the following instruction:
MotionSup \Off;

Reactivate supervision
If the supervision has been temporarily deactivated, it can be activated with the
following instruction:
MotionSup \On;

Note

If the supervision is deactivated with the system parameters, it cannot be activated

with RAPID instructions.

Tuning
The supervision level can be tuned during program execution with the instruction
MotionSup. The tune values are set in percent of the basic tuning where 100%
corresponds to the basic values. A higher percentage gives a less sensitive system.
This is an example of an instruction that increase the supervision level to 200%:
MotionSup \On \TuneValue:=200;

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5 Motion supervision
[Link] How to avoid false triggering

[Link] How to avoid false triggering

About false triggering

Because the supervision is designed to be very sensitive, it may trigger if the load
data is incorrect or if there are large process forces acting on the robot.

Actions to take

If ... then ...

the payload is incorrectly use Load Identification to define it. For more information, see
defined Operating manual - OmniCore.
the payload has large mass increase supervision level
or inertia
the arm load (cables or simil- manually define the arm load or increase supervision level
ar) cause trigger
the application involves increase the supervision level for jogging and program exe-
many external process cution in steps of 30 percent until you no longer receive the
forces error code.
the external process forces use the instruction MotionSup to raise the supervision level
are only temporary or turn the function off temporarily.
everything else fails turn off Collision Detection.

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 5 Motion supervision
5.3 Collision Avoidance [3150-1]

5.3 Collision Avoidance [3150-1]

Introduction
The function Collision Avoidance monitors a detailed geometric model of the robot.
By defining additional geometrical models of bodies in the robot workarea, the
controller will warn about a predicted collision and stops the robot if two bodies
come too close to each other. The system parameter Coll-Pred Safety Distance
determines at what distance the two objects are considered to be in collision.
The function Collision Avoidance is useful for example when setting up and testing
programs, or for programs where positions are not static but created from sensors,
such as cameras (non-deterministic programs). By using trigger-signals (see Trigger
signals on page 236), Collision Avoidance can be used for implementing safe
workspace sharing between multiple robots.
Besides the robot itself the function will monitor up 10 objects that is created via
the configurator in RobotStudio. Typical objects to be monitored are tool mounted
on the robot flange, additional equipment mounted on the robot arm (typically axis
3) or static volume around the robot.
The geometric models are set up in RobotStudio.
The functionality is activated by the system input Collision Avoidance. A high signal
will activate the functionality and a low signal will deactivate the functionality. The
functionality is by default active if no signal has been assigned to the system input
Collision Avoidance.
Collision Avoidance is active both during jogging and when running programs.
Also, the RAPID function IsCollFree provides a way to check possible collisions
before moving to a position.

CAUTION

Always be careful to avoid collisions with external equipment, since a collision

could damage the mechanical structure of the arm.
Collision Avoidance is no guarantee for avoiding collisions.

Tip

How to configure Collision Avoidance is described in Operating

manual - RobotStudio.

Tip

Collision Avoidance adds the user configuration in the folder CA under the HOME
folder. This is created when adding a configuration in RobotStudio.
If disk space is needed, the rsgfx files can be removed.

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5.3 Collision Avoidance [3150-1]
Continued

False collision warning

There are different ways to lower the sensitivity of the function Collision Avoidance
to avoid false warnings.
• Temporarily disable Collision Avoidance, see Disabling Collision Avoidance
on page 237.
• Decrease the general safety distance with the system parameter Coll-Pred
Safety Distance.

Activation/deactivation of objects
By default, a defined collision object is active all the time. However, it is possible
to configure a collision object with an activation signal, which basically connects
it to a digital input that determines whether the object is active or not. This is useful,
for example, for modelling multiple tools, where only one tool at a time is active.
Another use case is modelling of objects that can be present or absent in the robot
cell, for example a pallet.
Note that changing the state of an activation signal will immediately change the
activation state of the connected collision object, and no synchronization to the
robot path planning is made. Activating a collision object while the robot is moving
towards the object can thus lead to a collision because the planned path may
already have passed by the collision object while it was inactive. If synchronization
is important, then activation signals should either be changed in finepoints when
the robot is standing still or using trigg instructions like TriggL or TriggJ.

Trigger signals
A non-moving collision object can be configured with a trigger signal. The value
of the trigger signal reflects which robots are in contact with the collision object.
More specifically, the value of a trigger signal should be interpreted as a bit pattern,
where bit k is high if robot k is in contact with the collision object. For example, if
the trigger signal has the value 6, which is 110 in binary, it means that ROB_2 and
ROB_3 are in contact with the collision object. Trigger signals can be used to
implement safe workspace sharing between multiple robots.
A trigger signal can be configured with two timing behaviors: immediate or
on-arrival. If configured with immediate behavior, then the trigger signal is changed
as quickly as possible, well before the robot has physically reached the position
where it comes into contact with the collision object. If configured with on-arrival
behavior, then the trigger signal changes state when the robot physically reaches
the position where it comes in contact with the zone.

Limitations

CAUTION

Collision Avoidance shall not be used for safety of personnel.

• Paint robots are not supported.
• Collision Avoidance cannot be used in manual mode together with responsive
jogging. The system parameter Jog Mode must be changed to Standard.

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Continued

• Only stationary/non-moving objects can be configured with a trigger signal.

A trigger signal must correspond to a group signal. Furthermore, each
collision object must have its own trigger signal.
• There is no support for applications that do corrections to the path, such as
conveyor tracking, WeldGuide, Force Control, SoftMove, SoftAct etc.
• The Collision Avoidance functionality between 2 robots (or more) can only
be achieved when using a MultiMove system.

Disabling Collision Avoidance

It is possible to temporarily disable the function Collision Avoidance if the robot
has already collided or is within the default safety distance, or when the robot arms
need to be very close and the risk of collision is acceptable.
Set the system input signal Collision Avoidance to 0 to disable Collision
Avoidance. It is recommended to enable it (set Collision Avoidance to 1) as
soon as the work is done that required Collision Avoidance to be disabled.

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5 Motion supervision
5.4 SafeMove Assistant

5.4 SafeMove Assistant

Purpose
SafeMove Assistant is a functionality in RobotWare that helps users to program
their application when there is an active SafeMove configuration. The assistant
will read the active configuration and plan the trajectories according to the limits
and settings in that configuration. It will set the speed so that SafeMove will not
trigger violations etc. It will also stop with error message in case the robot is
programmed to enter a forbidden zone etc.
SafeMove Assistant will automatically adjust robot behavior to adopt to the active
SafeMove configuration, the robot will adopt to speed limited zones and stop before
entering forbidden zones.

CAUTION

SafeMove Assistant is not a safety function.

For example, if using a fence, then a safety distance is required between the
safe cartesian zone and the fence.

Note

In case of SafeMove Assistant fails, the SafeMove supervision will trigger an

emergency stop.

Description
SafeMove Assistant will check if any SafeMove speed limit is active for any
Cartesian speed checkpoint (TCP, tool points, and elbow). If this is the case, a
corresponding speed limit is applied in the path planner. If SafeMove Assistant in
some special case does not reduce the speed enough, the system parameter
SafeMove assistance speed factor can be decreased.
In manual mode, SafeMove Assistant will reduce the TCP speed according to the
active tool in the safety configuration.
SafeMove Assistant does not take path corrections generated at lower level into
account. It is therefore an increased risk of SafeMove violations when running
applications like Externally Guided Motion or conveyor tracking.

SafeMove Assistant zone margin

When the robot is running on a zone border there is a small risk that SafeMove
can trigger violations when going in and out of the zone. It determines roughly how
far before a speed-limited zone the robot will have reached the actual speed limit.
Likewise, when the robot is moving out of a speed-limited zone, it will not start
accelerating towards the programmed speed until it has moved this distance outside
the zone.
The parameter SafeMove Assistant zone margin can be increased to reduce that
risk but can in most cases be left at default value. If robot has reduced performance
with low acceleration, it might also be a need to increase this parameter.

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5.4 SafeMove Assistant
Continued

System parameters
SafeMove Assistant can be disabled for the SafeMove validation etc. This is done
with the parameter Disable SafeMove Assistance, in the type in Motion System.
There are some parameters that can be changed in case robot system has minor
overshoot or in any other way triggers SafeMove violations.
Parameter Description
SafeMove Assist- That has a default setting of 0.96 which corresponds to 96% of speed
ance Speed supervision will be the speed that path planner will use. This parameter
Factor can be decreased to reduce that risk but can in most cases be left at
default value.
SafeMove assist- When robot is running on a zone border there is a small risk that Safe-
ance zone mar- Move can trigger violations when going in and out of the zone. This
gin parameter can be increased to reduce that risk but can in most cases
be left at default value.

For more information, see the parameters in the type Motion System described in
Technical reference manual - System parameters.

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 6 Motor control
6.1.1 Overview

6 Motor control
6.1 Independent Axis [3111-1]

6.1.1 Overview

Purpose
The purpose of Independent Axis is to move an axis independently of other axes
in the robot system. Some examples of applications are:
• Move an external axis holding an object (for example rotating an object while
the robot is spray painting it).
• Save cycle time by performing a robot task at the same time as an external
axis performs another.
• Continuously rotate robot axis 6 (for polishing or similar tasks).
• Reset the measurement system after an axis has rotated multiple revolutions
in the same direction. Saves cycle time compared to physically winding back.
An axis can move independently if it is set to independent mode. An axis can be
changed to independent mode and later back to normal mode again.

What is included
The RobotWare option Independent Axis gives you access to:
• instructions used to set independent mode and specify the movement for an
axis
• an instruction for changing back to normal mode and/or reset the
measurement system
• functions used to verify the status of an independent axis
• system parameters for configuration.

Basic approach
This is the general approach for moving an axis independently. For detailed
examples of how this is done, see Code examples on page 245.
1 Call an independent move instruction to set the axis to independent mode
and move it.
2 Let the robot execute another instruction at the same time as the independent
axis moves.
3 When both robot and independent axis has stopped, reset the independent
axis to normal mode.

Reset axis
Even without being in independent mode, an axis might rotate only in one direction
and eventually loose precision. The measurement system can then be reset with
the instruction IndReset.
The recommendation is to reset the measurement system for an axis before its
motor has rotated 10000 revolutions in the same direction.

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6.1.1 Overview
Continued

Limitations
A mechanical unit may not be deactivated when one of its axes is in independent
mode.
Axes in independent mode cannot be jogged.
The only robot axis that can be used as an independent axis is axis number 6. On
IRB 1600, 2600 and 4600 models (except ID version), the instruction IndReset
can also be used for axis 4.
Internal and customer cabling and equipment may limit the ability to use
independent axis functionality on axis 4 and 6.
The option is not possible to use in combination with:
• SafeMove I
• Track Motion (IRBT)
• Positioners (IRBP) on Interchange axes
• Tool change
I Independent Axis can in some cases be combined with SafeMove2 if the additional axis does not
move the robot, and the additional axis is not monitored by SafeMove. Contact your local ABB
sales office team for additional information.
The following is deactivated when option Independent Axes is used:
• Collision detection

Note

The collision detection is deactivated on all axes in a motion planner if one

of them is run in independent mode.

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6.1.2 System parameters

6.1.2 System parameters

About the system parameters

This is a brief description of each parameter in the option Independent Axis. For
more information, see the respective parameter in Technical reference
manual - System parameters.

Arm
These parameters belongs to the type Arm in the topic Motion.
Parameter Description
Independent Joint Flag that determines if independent mode is allowed for the axis.
Independent Upper Defines the upper limit of the working area for the joint when operating
Joint Bound in independent mode.
Independent Lower Defines the lower limit of the working area for the joint when operating
Joint Bound in independent mode.

Transmission
These parameters belong to the type Transmission in the topic Motion.
Parameter Description
Transmission Gear Independent Axes requires high resolution in transmission gear ratio,
High which is therefore defined as Transmission Gear High divided by
Transmission Gear Low. If no smaller number can be used, the
transmission gear ratio will be correct if Transmission Gear High is
set to the number of cogs on the robot axis side, and Transmission
Gear Low is set to the number of cogs on the motor side.
Transmission Gear See Transmission Gear High.
Low

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6.1.3 RAPID components

6.1.3 RAPID components

Data types
There are no data types for Independent Axis.

Instructions
This is a brief description of each instruction in Independent Axis. For more
information, see respective instruction in Technical reference manual - RAPID
Instructions, Functions and Data types.
An independent move instruction is executed immediately, even if the axis is being
moved at the time. If a new independent move instruction is executed before the
last one is finished, the new instruction immediately overrides the old one.
Instruction Description
IndAMove IndAMove (Independent Absolute position Movement) change an
axis to independent mode and move the axis to a specified position.
IndCMove IndCMove (Independent Continuous Movement) change an axis to
independent mode and start moving the axis continuously at a spe-
cified speed.
IndDMove IndDMove (Independent Delta position Movement) change an axis to
independent mode and move the axis a specified distance.
IndRMove IndRMove (Independent Relative position Movement) change a rota-
tional axis to independent mode and move the axis to a specific pos-
ition within one revolution.
Because the revolution information in the position is omitted,
IndRMove never rotates more than one axis revolution.
IndReset IndReset is used to change an independent axis back to normal
mode.
IndReset can move the measurement system for a rotational axis a
number of axis revolutions. The resolution of positions is decreased
when moving away from logical position 0, and winding the axis back
would take time. By moving the measurement system the resolution
is maintained without physically winding the axis back.
Both the independent axis and the robot must stand still when calling
IndReset.

Functions
This is a brief description of each function in Independent Axis. For more
information, see respective function in Technical reference manual - RAPID
Instructions, Functions and Data types.
Function Description
IndInpos IndInposindicates whether an axis has reached the selected position.
IndSpeed IndSpeed indicates whether an axis has reached the selected speed.

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6.1.4 Code examples

6.1.4 Code examples

Save cycle time

An object in station A needs welding in two places. The external axis for station A
can turn the object in position for the second welding while the robot is welding
on another object. This saves cycle time compared to letting the robot wait while
the external axis moves.
!Perform first welding in station A
!Call subroutine for welding
weld_stationA_1;

!Move the object in station A, axis 1, with

!independent movement to position 90 degrees
!at the speed 20 degrees/second
IndAMove Station_A,1\ToAbsNum:=90,20;

!Let the robot perform another task while waiting

!Call subroutine for welding
weld_stationB_1;

!Wait until the independent axis is in position

WaitUntil IndInpos(Station_A,1 ) = TRUE;
WaitTime 0.2;

!Perform second welding in station A

!Call subroutine for welding
weld_stationA_2;

Polish by rotating axis 6

To polish an object the robot axis 6 can be set to continuously rotate.
Set robot axis 6 to independent mode and continuously rotate it. Move the robot
over the area you want to polish. Stop movement for both robot and independent
axis before changing back to normal mode. After rotating the axis many revolutions,
reset the measurement system to maintain the resolution.
Note that, for this example to work, the parameter Independent Joint for rob1_6
must be set to Yes.
PROC Polish()
!Change axis 6 of ROB_1 to independent mode and
!rotate it with 180 degrees/second
IndCMove ROB_1, 6, 180;

!Wait until axis 6 is up to speed

WaitUntil IndSpeed(ROB_1,6\InSpeed);
WaitTime 0.2;

!Move robot where you want to polish

MoveL p1,v10, z50, tool1;
MoveL p2,v10, fine, tool1;

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6.1.4 Code examples
Continued

!Stop axis 6 and wait until it's still

IndCMove ROB_1, 6, 0;
WaitUntil IndSpeed(ROB_1,6\ZeroSpeed);
WaitTime 0.2;

!Change axis 6 back to normal mode and

!reset measurement system (close to 0)
IndReset ROB_1, 6 \RefNum:=0 \Short;
ENDPROC

Reset an axis
This is an example of how to reset the measurement system for axis 1 in station
A. The measurement system will change a whole number of revolutions, so it is
close to zero (±180°).
IndReset Station_A, 1 \RefNum:=0 \Short;

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 6 Motor control
6.2.1 Overview

6.2 Tool Control [3109-1]

6.2.1 Overview

Purpose
Tool Control can be used to control a servo tool, for example in a spot weld
application. Tool Control makes it possible to close the tool to a specific plate
thickness and force, and maintain the force during the process until the tool is
requested to be opened.

What is included
Tool Control gives you access to:
• RAPID instructions to open, close and calibrate servo tools
• RAPID instructions for tuning system parameter values
• RAPID functions for checking status of servo tools
• system parameters to configure servo tools

Basic approach
This is the general approach for using Tool Control.
1 Configure and calibrate the servo tool.
2 Perform a force calibration.
3 Create the RAPID program.

Prerequisites
A servo tool is an additional axis. Required hardware, such as drive module and
measurement board, is specified in Application manual - Additional axes.

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6 Motor control
6.2.2 Servo tool movements

6.2.2 Servo tool movements

Closing and opening of a servo tool

The servo tool can be closed to a predefined thickness and tool force. When the
tool reaches the programmed contact position, the movement is stopped and there
is an immediate switch from position control mode to force control mode. In the
force control mode a motor torque will be applied to achieve the desired tool force.
The force remains constant until an opening is ordered. Opening of the tool will
reduce the tool force to zero and move the tool arm back to the pre-close position.

Synchronous and asynchronous movements

Normally a servo tool axis is moved synchronous with the robot movements in
such a way that both movements will be completed exactly at the same time.
However the servo tool may be closed asynchronously (independent of current
robot movement). The closing will immediately start to run the tool arm to the
expected contact position (thickness). The closing movement will interrupt an
on-going synchronous movement of the tool arm.
The tool opening may also take place while the robot is moving. But it is not possible
if the robot movement includes a synchronized movement of the servo tool axis.
A motion error, "tool opening could not synchronize with robot movement", will
occur.

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 6 Motor control
6.2.3 Tip management

6.2.3 Tip management

About tip management

The tip management functionality will find and calibrate the contact position of the
tool tips automatically. It will also update and monitor the total tip wear of the tool
tips.
The tips can be calibrated using the RAPID instruction STCalib (see Instructions
on page 252). Typically, two tool closings will be performed during a calibration.
Three different types of calibrations are supported: tip wear, tip change and tool
change. All three will calibrate the contact position of the tips. The total tip wear
will, however, be updated differently by these methods.

Tip wear calibration

As the tips are worn down, for example when spot welding, they need to be dressed.
After the tip dressing, a tip wear calibration is required. The tool contact position
is calibrated and the total tip wear of the tool is updated. The calibration movements
are fast and the switch to force control mode will take place at the zero position.
This method must only be used to make small position adjustments (< 3 mm)
caused by tip wear/tip dressing.

Tip

A variable in your RAPID program can keep track of the tip wear and inform you
when the tips needs to be replaced.

Tip change calibration

The tip change calibration is to be used after mounting a new pair of tips, for
example when spot welding. The tool contact position is calibrated and the total
tip wear of the tool is reset. The first calibration movement is slow in order to find
the unknown contact position and switch to force control. The second calibration
movement is fast. This calibration method will handle big position adjustments of
the servo tool.
This calibration may be followed by a tool closing in order to squeeze the tips in
place. A new tip change calibration is then done to update possible position
differences after the tip squeeze.

Tool change calibration

The tool change calibration is to be used after reconnecting and activating a servo
tool. The tool contact position is calibrated and the total tip wear of the tool remains
unchanged. The first calibration movement is slow in order to find the unknown
tip collision position and switch to force control. The second calibration movement
is fast. This calibration method will handle big position adjustments of the tool.
The method should always be used after reconnecting a tool since the activation
will restore the latest known position of the tool, and that position may be different
from the actual tool position; the tool arm may have been moved when

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6.2.3 Tip management
Continued

disconnected. This calibration method will handle big position adjustments of the
tool.

Tip

Tool change calibration is most commonly used together with the RobotWare
option Servo Tool Change.

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 6 Motor control
6.2.4 Supervision

6.2.4 Supervision

Max and min stroke

An out of range supervision will stop the movement if the tool is reaching max
stroke or if it is closed to contact with the tips (reaching min stroke). See Upper
Joint Bound and Lower Joint Bound in Arm on page 255.

Motion supervision
During the position control phase of the closing/opening, motion supervision is
active for the servo tool to detect if the arm collides or gets stuck. A collision will
cause a motion error and the motion will be stopped.
During the force control phase, the motion supervision will supervise the tool arm
position not to exceed a certain distance from the expected contact position. See
parameter Max Force Control Position Error in Supervision Type on page 256.

Maximum torque
There is a maximum motor torque for the servo tool that never will be exceeded
in order to protect the tool from damage. If the force is programmed out of range
according to the tools force-torque table, the output force will be limited to this
maximum allowed motor torque and a motion warning will be logged. See parameter
Max Force Control Motor Torque in SG Process on page 253.

Speed limit
During the force control phase there is a speed limitation. The speed limitation will
give a controlled behavior of the tool even if the force control starts before the tool
is completely closed. See Speed limit 1- 6 in Force Master Control on page 254.

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6 Motor control
6.2.5 RAPID components

6.2.5 RAPID components

About the RAPID components

This is an overview of all instructions, functions, and data types in Tool Control.
For more information, see Technical reference manual - RAPID Instructions,
Functions and Data types.

Instructions

Instruction Description
STClose Close the servo tool with a predefined force and thickness.
STOpen Open the servo tool.
STCalib Calibrate the servo tool.
An argument determines which type of calibration will be performed:
• \ToolChg for tool change calibration
• \TipChg for tip change calibration
• \TipWear for tip wear calibration
STTune Tune motion parameters for the servo tool. A temporary value can be
set for a parameter specified in the instruction.
STTuneReset Reset tuned motion parameters for the servo tool. Cancel the effect of
all STTune instructions.

Functions

Function Description
STIsClosed Test if the servo tool is closed.
STIsOpen Test if the servo tool is open.
STIsCalib Tests if a servo tool is calibrated.
STCalcTorque Calculate the motor torque for a servo tool.
STCalcForce Calculate the force for a servo tool.
STIsServoTool Tests if a mechanical unit is a servo tool.
STIsIndGun Tests if servo tool is in independent mode.

Data types
Tool Control includes no RAPID data types.

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 6 Motor control
6.2.6 System parameters

6.2.6 System parameters

About the system parameters

When using a servo tool, a motion parameter file for the tool is normally installed
on the controller. A servo tool is a specific variant of an additional axis and the
description of how to configure the servo tool is found in Application
manual - Additional axes.
In this section, the parameters used in combination with Tool Control is briefly
described. For more information, see the respective parameter in Technical
reference manual - System parameters.

SG Process
These parameters belong to the type SG Process in the topic Motion.
SG Process is used to configure the behavior of a servo gun (or other servo tool).
Parameter Description
Close Time Adjust Adjustment of the ordered minimum close time of the gun.
Close Position Adjust Adjustment of the ordered position (plate thickness) where force
control should start, when closing the gun.
Force Ready Delay Delays the close ready event after achieving the ordered force.
Max Force Control Max allowed motor torque for force control. Commanded force will
Motor Torque be reduced, if the required motor torque is higher than this value.
Post-synchronization Anticipation of the open ready event. This can be used to synchron-
Time ize the gun opening with the next robot movement.
Calibration Mode Defines the number of times the servo gun closes during a tip wear
calibration.
Calibration Force Low The minimum tip force used during a tip wear calibration.
Calibration Force High The maximum tip force used during a tip wear calibration.
Calibration Time The time that the servo gun waits in closed position during calibra-
tion.
Number of Stored Defines the number of points in the force-torque relation specified
Forces in Tip Force 1 - 10 and Motor Torque 1 - 10.
Tip Force 1 - 10 Tip Force 1 defines the tip force that corresponds to the motor torque
in Motor Torque 1.
Tip Force 2 corresponds to Motor Torque 2, etc.
Motor Torque 1- 10 Motor Torque 1 defines the motor torque that corresponds to the
tip force in Tip Force 1.
Motor Torque 2 corresponds to Tip Force 2, etc.
Squeeze Position 1 - Defines the joint position at each force level in the force calibration
10 table.
Soft Stop Timeout Defines how long the force will be maintained if a soft stop occurs
during constant force.

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6.2.6 System parameters
Continued

Force Master
These parameters belong to the type Force Master in the topic Motion.
Force Master is used to define how a servo tool, typically a servo gun, behaves
during force control. The parameters only affect the servo tool when it is in force
control mode.
Parameter Description
References Bandwidth The frequency limit for the low pass filter for reference values.
Use ramp time Determines if the ramping of the tip force should use a constant
time or a constant gradient.
Ramp when Increase Determines how fast force is built up while closing the tool when
Force Use ramp time is set to No.
Ramp time Determines how fast force is built up while closing the tool when
Use ramp time is set to Yes.
Collision LP Bandwidth Frequency limit for the low pass filter used for tip wear calibration.
Collision Alarm Torque Determines how hard the tool tips will be pressed together during
the first gun closing of new tips calibrations and tool change cal-
ibrations.
Collision Speed Determines the servo gun speed during the first gun closing of
new tips calibrations and tool change calibrations.
Collision Delta Position Defines the distance the servo tool has gone beyond the contact
position when the motor torque has reached the value specified
in Collision Alarm Torque.
Max pos err. closing Determines how close to the ordered plate thickness the tool tips
must be before the force control starts.
Delay ramp Delays the starting of torque ramp when force control is started.
Ramp to real contact Determines if the feedback position should be used instead of
reference position when deciding the contact position.

Force Master Control

These parameters belong to the type Force Master Control in the topic Motion.
Force Master Control is used to set the speed limit and speed loop gain as functions
of the torque.
Parameter Description
No. of speed limits The number of points used to define speed limit and speed loop gain
as functions of the torque. Up to 6 points can be defined.
torque 1 - torque 6 The torque levels, corresponding to the ordered tip force, for which
the speed limit and speed loop gain values are defined.
Speed Limit 1 - 6 Speed Limit 1 to Speed Limit 6 are used to define the maximum speed
depending on the ordered tip force.
Kv 1 - 6 Kv 1 to Kv 6 are used to define the speed loop gain for reducing the
speed when the speed limit is exceeded.

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6.2.6 System parameters
Continued

Arm
These parameters belong to the type Arm in the topic Motion.
The type Arm defines the characteristics of an arm.
Parameter Description
Upper Joint Bound Defines the upper limit of the working area for the joint.
Lower Joint Bound Defines the lower limit of the working area for the joint.

Acceleration Data
These parameters belong to the type Acceleration Data in the topic Motion.
Acceleration Data is used to specify some acceleration characteristics for axes
without any dynamic model.
Parameter Description
Nominal Acceleration Worst case motor acceleration.
Nominal Deceleration Worst case motor deceleration.
Acceleration Derivate Ratio Indicates how fast the acceleration can be increased.
Deceleration Derivate Ratio Indicates how fast the deceleration can be increased.

Motor Type
These parameters belong to the type Motor Type in the topic Motion.
Motor Type is used to describe characteristics for a motor.
Parameter Description
Pole Pairs Defines the number of pole pairs for the motor.
Inertia The inertia of the motor, including the resolver but excluding the
brake.
Stall Torque The continuous stall torque, i.e. the torque the motor can produce at
no speed and during an infinite time.
ke Phase to Phase Nominal voltage constant. The induced voltage (phase to phase) that
corresponds to the speed 1 rad/s.
Max Current Max current without irreversible magnetization.
Phase Resistance Nominal winding resistance per phase at 20 degrees Celsius.
Phase Inductance Nominal winding inductance per phase at zero current.

Motor Calibration
These parameters belong to the type Motor Calibration in the topic Motion.
Motor Calibration is used to calibrate a motor.
Parameter Description
Commutator Offset Defines the position of the motor (resolver) when the rotor is in the
electrical zero position relative to the stator.
Calibration Offset Defines the position of the motor (resolver) when it is in the calibration
position.

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6.2.6 System parameters
Continued

Stress Duty Cycle

These parameters belong to the type Stress Duty Cycle in the topic Motion.
Stress Duty Cycle is used for protecting axes, gearboxes, etc.
Parameter Description
Speed Absolute Max The absolute highest motor speed to be used.
Torque Absolute Max The absolute highest motor torque to be used.

Supervision Type
These parameters belong to the type Supervision Type in the topic Motion.
Supervision Type is used for continuos supervision of position, speed and torque.
Parameter Description
Max Force Control When a servo gun is in force control mode it is not allowed to move
Position Error more than the distance specified in Max Force Control Position Error.
This supervision will protect the tool if, for instance, one tip is lost.
Max Force Control Speed error factor during force control.
Speed Limit If the speed limits, defined in the type Force Master Control, multiplied
with Max Force Control Speed Limit is exceeded, all movement is
stopped.

Transmission
These parameters belong to the type Transmission in the topic Motion.
Transmission is used to define the transmission gear ratio between a motor and
its axis.
Parameter Description
Rotating Move Defines if the axis is rotating or linear.
Transmission Gear Ratio Defines the transmission gear ratio between motor and joint.

Lag Control Master 0

These parameters belong to the type Lag Control Master 0 in the topic Motion.
Lag Control Master 0 is used for regulation of axes without any dynamic model.
Parameter Description
FFW Mode Defines if the position regulation should use feed forward of speed
and torque values.
Kp, Gain Position Loop Proportional gain in the position regulation loop.
Kv, Gain Speed Loop Proportional gain in the speed regulation loop.
Ti Integration Time Integration time in the speed regulation loop.
Speed Loop

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6.2.6 System parameters
Continued

Uncalibrated Control Master 0

These parameters belong to the type Uncalibrated Control Master 0 in the topic
Motion.
Uncalibrated Control Master 0 is used to regulate uncalibrated axes.
Parameter Description
Kp, Gain Position Loop Proportional gain in the position regulation loop.
Kv, Gain Speed Loop Proportional gain in the speed regulation loop.
Ti Integration Time Speed Loop Integration time in the speed regulation loop.
Speed Max Uncalibrated The maximum allowed speed for an uncalibrated axis.
Acceleration Max Uncalibrated The maximum allowed acceleration for an uncalibrated
axis.
Deceleration Max Uncalibrated The maximum allowed deceleration for an uncalibrated
axis.

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6 Motor control
6.2.7 Commissioning and service

6.2.7 Commissioning and service

Commissioning the servo tool

For a new servo tool, follow these steps for installing and commissioning:
Step Action
1 Install the servo tool according to the description in Application manual - Additional
axes.
2 Load a .cfg file with the servo tool configuration. For detailed description on how
to do this, see Operating manual - RobotStudio.
If you do not have any .cfg file for the servo tool, you can load a template file and
configure the system parameters with the values of your servo tool. Template files
are found in the RobotWare distribution, see Template file locations on page 258.
3 Use the RAPID instruction STTune and iterate to find the optimal parameter values.
Once found, these optimal values should be written to the system parameters to
be permanent.
4 Fine calibrate the servo tool, see Fine calibration on page 260.
5 Unless force calibration was included in a loaded .cfg file, perform a force calibra-
tion.

Template file locations

The template files can be obtained from the PC or the IRC5 controller.
• In the RobotWare installation folder in RobotStudio: ...\RobotPackages\
RobotWare_RPK_<version>\utility\AdditionalAxis\
• On the IRC5 Controller:
<SystemName>\PRODUCTS\<RobotWare_xx.[Link]>\utility\AdditionalAxis\

Note

Navigate to the RobotWare installation folder from the RobotStudio Add-Ins tab,
by right-clicking on the installed RobotWare version in the Add-Ins browser and
selecting Open Package Folder.

Disconnect/reconnect a servo tool

If the servo tool is deactivated, using the DeactUnit instruction, it may be
disconnected and removed. The tool position at deactivation will be restored when
the tool is connected and reactivated. Make a tool change calibration to make sure
the tip position is OK.
The whole process of changing a tool can be performed by a RAPID program if
you use the RobotWare option Servo Tool Change and the instruction STCalib.

Recover from accidental disconnection

If the motor cables are disconnected by accident when the servo tool is active, the
system will go into system failure state. After restart of the system the servo tool
must be deactivated in order to jog the robot to a service position.
Deactivation may be performed from the Jogging window. Tap on Activate..., select
the servo tool and tap on Deactivate.

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6.2.7 Commissioning and service
Continued

After service / repair the revolution counter must be updated since the position
has been lost, see Update revolution counter on page 260.

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6 Motor control
6.2.8 Mechanical unit calibrations

6.2.8 Mechanical unit calibrations

Fine calibration
Fine calibration must be performed when installing a new servo tool, or if the servo
tool axis is in state ‘Not Calibrated’.
For this, it is recommended to create a service routine using the following
instructions:
STCalib "ToolName" \TipChg;
STCalib "ToolName" \TipWear;

Update revolution counter

An update of the revolution counter must be performed if the position of the axis
is lost. If this happens, this is indicated by the calibration state ‘Rev. Counter not
updated’.
For this, it is recommended to use the same service routine as for the fine
calibration.

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6.2.9 RAPID code example

6.2.9 RAPID code example

How to use the code package

The normal programming technique for Tool Control is to customize shell routines
based on the example code below. These shell routines are then called from your
program.

Using shell routines

This example shows a main routine in combination with a customized routine
(rMoveSpot) that uses the standard servo tool instructions. The external process
(for example a weld timer) is indicated with the routine rWeld.
PROC main()
MoveJ p1, v500, z50, weldtool;
MoveL p2, v1000, z50, weldtool;
! Perform weld process
rMoveSpot weldpos1, v2000, curr_gun_name, 1000, 2, 1,
weldtool\WObj:=weldwobj;
rMoveSpot weldpos2, v2000, curr_gun_name, 1000, 2, 1,
weldtool\WObj:=weldwobj;
rMoveSpot weldpos3, v2000, curr_gun_name, 1500, 3, 1,
weldtool\WObj:=weldwobj;
MoveL p3, v1000, z50, weldtool;
ENDPROC

PROC rMoveSpot (robtarget ToPoint,

speeddata Speed,
gunname Gun,
num Force,
num Thickness,
PERS tooldata Tool
\PERS wobjdata WObj)
! Move the gun to weld position.
! Always use FINE point to prevent too early closing.
MoveL ToPoint, Speed, FINE, weldtool \WOIbj=WObj;
STClose Gun, Thickness;
rWeld;
STOpen Gun;
ENDPROC

PROC rWeld()
! Request weld start from weld timer
SetDO doWeldstart,1;
! Wait until weld is performed
WaitDI diWeldready,1;
SetDO doWeldstart,0;
ENDPROC

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 7 RAPID program features
7.1.1 Overview

7 RAPID program features

7.1 Path Recovery [3113-1]

7.1.1 Overview

Purpose
Path Recovery is used to store the current movement path, perform some robot
movements and then restore the interrupted path. This is useful when an error or
interrupt occurs during the path movement. An error handler or interrupt routine
can perform a task and then recreate the path.
For applications like arc welding and gluing, it is important to continue the work
from the point where the robot left off. If the robot started over from the beginning,
then the work piece would have to be scrapped.
If a process error occurs when the robot is inside a work piece, moving the robot
straight out might cause a collision. By using the path recorder, the robot can
instead move out along the same path it came in.

What is included
The RobotWare option Path Recovery gives you access to:
• instructions to suspend and resume the coordinated synchronized movement
mode on the error or interrupt level.
• a path recorder, with the ability to move the TCP out from a position along
the same path it came.

Limitations
The instructions StorePath and RestoPath only handles movement path data.
The stop position must also be stored.
Movements using the path recorder has to be performed on trap-level, i.e.
StorePath has to be executed prior to PathRecMoveBwd.

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7.1.2 RAPID components

7.1.2 RAPID components

Data types
This is a brief description of each data type in Path Recovery. For more information,
see the respective data type in Technical reference manual - RAPID Instructions,
Functions and Data types.
Data type Description
pathrecid pathrecid is used to identify a breakpoint for the path recorder.

Instructions
This is a brief description of each instruction in Path Recovery. For more
information, see the respective instruction in Technical reference manual - RAPID
Instructions, Functions and Data types.
Instruction Description
StorePath StorePath is used to store the movement path being executed when
an error or interrupt occurs.
RestoPath RestoPath is used to restore the path that was stored by StorePath.
PathRecStart PathRecStart is used to start recording the robot’s path. The path
recorder will store path information during execution of the robot
program.
PathRecStop PathRecStop is used to stop recording the robot's path.
PathRecMoveBwd PathRecMoveBwd is used to move the robot backwards along a recor-
ded path.
PathRecMoveFwd PathRecMoveFwd is used to move the robot back to the position
where PathRecMoveBwd was executed.
It is also possible to move the robot partly forward by supplying an
identifier that has been passed during the backward movement.
SyncMoveSuspend SyncMoveSuspend is used to suspend synchronized movements
mode and set the system to independent movement mode.
SyncMoveResume SyncmoveResume is used to go back to synchronized movements
from independent movement mode.

Functions
This is a brief description of each function in Path Recovery. For more information,
see the respective function in Technical reference manual - RAPID Instructions,
Functions and Data types.
Function Description
PathRecValidBwd PathRecValidBwd is used to check if the path recorder is active and
if a recorded backward path is available.
PathRecValidFwd PathRecValidFwd is used to check if the path recorder can be used
to move forward. The ability to move forward with the path recorder
implies that the path recorder must have been ordered to move
backwards earlier.

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7.1.3 Store current path

7.1.3 Store current path

Why store the path?

The simplest way to use Path Recovery is to only store the current path to be able
to restore it after resolving an error or similar action.
Let's say that an error occur during arc welding. To resolve the error the robot
might have to be moved away from the part. When the error is resolved, the welding
should be continued from the point it left off. This is solved by storing the path
information and the position of the robot before moving away from the path. The
path can then be restored and the welding resumed after the error has been
handled.

Basic approach
This is the general approach for storing the current path:
1 At the start of an error handler or interrupt routine:
stop the movement
store the movement path
store the stop position
2 At the end of the error handler or interrupt routine:
move to the stored stop position
restore the movement path
start the movement

Example
This is an example of how to use Path Recovery in error handling. First the path
and position is stored, the error is corrected and then the robot is moved back in
position and the path is restored.
MoveL p100, v100, z10, gun1;
...
ERROR
IF ERRNO=MY_GUN_ERR THEN
gun_cleaning();
ENDIF
...
PROC gun_cleaning()
VAR robtarget p1;

!Stop the robot movement, if not already stopped.

StopMove;

!Store the movement path and current position

StorePath;
p1 := CRobT(\Tool:=gun1\WObj:=wobj0);

!Correct the error

MoveL pclean, v100, fine, gun1;

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7.1.3 Store current path
Continued

...
!Move the robot back to the stored position
MoveL p1, v100, fine, gun1;

!Restore the path and start the movement

RestoPath;
StartMove;
RETRY;
ENDPROC

Store path in a MultiMove system

In a MultiMove system the robots can keep the synchronized movement mode
after StorePath with the argument KeepSync. However the robots can’t switch
from independent mode to synchronized mode, only the other way around.
After a Multimove system is set with the argument KeepSync, the system can
change between synchronized, semi coordinated and independent mode on the
StorePath level. The changes are made with the instructions SyncMoveResume
and SyncMoveSuspend.

SyncArc example with coordinated synchronized movement

This is an example on how to use Path Recovery and keep synchronized mode in
the error handler for a MultiMove system. Two robots perform arc welding on the
same work piece. To make the example simple and general, we use move
instructions instead of weld instructions. The work object is rotated by a positioner.
For more information on the SyncArc example, see Application manual - MultiMove.

T_ROB1 task program

MODULE module1
VAR syncident sync1;
VAR syncident sync2;
VAR syncident sync3;
PERS tasks all_tasks{3} := [["T_ROB1"],["T_ROB2"],["T_STN1"]];
PERS wobjdata wobj_stn1 := [ FALSE, FALSE, "STN_1", [ [0, 0, 0],
[1, 0, 0 ,0] ], [ [0, 0, 250], [1, 0, 0, 0] ] ];
TASK PERS tooldata tool1 := ...
CONST robtarget p100 := ...
CONST robtarget p199 := ...
PROC main()
...
SyncMove;
ENDPROC

PROC SyncMove()
MoveJ p100, v1000, z50, tool1;
WaitSyncTask sync1, all_tasks;
MoveL p101, v500, fine, tool1;
SyncMoveOn sync2, all_tasks;
MoveL p102\ID:=10, v300, z10, tool1 \WObj:=wobj_stn1;
MoveC p103, p104\ID:=20, v300, z10, tool1 \WObj:=wobj_stn1;
MoveL p105\ID:=30, v300, z10, tool1 \WObj:=wobj_stn1;

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7.1.3 Store current path
Continued

MoveC p106, p101\ID:=40, v300, fine, tool1 \WObj:=wobj_stn1;

SyncMoveOff sync3;
MoveL p199, v1000, fine, tool1;
ERROR
IF ERRNO = ERR_PATH_STOP THEN
gun_cleaning();
ENDIF
UNDO
SyncMoveUndo;
ENDPROC

PROC gun_cleaning()
VAR robtarget p1;
!Store the movement path and current position
! and keep syncronized mode.
StorePath \KeepSync;
p1 := CRobT(\Tool:=tool1 \WObj:=wobj_stn1);
!Correct the error
MoveL pclean1 \ID:=50, v100, fine, tool1 \WObj:=wobj_stn1;
...
!Move the robot back to the stored position
MoveL p1 \ID:=60, v100, fine, tool1 \WObj:=wobj_stn1;
!Restore the path and start the movement
RestoPath;
StartMove;
RETRY;
ENDPROC
ENDMODULE

T_ROB2 task program

MODULE module2
VAR syncident sync1;
VAR syncident sync2;
VAR syncident sync3;
PERS tasks all_tasks{3};
PERS wobjdata wobj_stn1;
TASK PERS tooldata tool2 := ...
CONST robtarget p200 := ...
CONST robtarget p299 := ...
PROC main()
...
SyncMove;
ENDPROC
PROC SyncMove()
MoveJ p200, v1000, z50, tool2;
WaitSyncTask sync1, all_tasks;
MoveL p201, v500, fine, tool2;
SyncMoveOn sync2, all_tasks;
MoveL p202\ID:=10, v300, z10, tool2 \WObj:=wobj_stn1;
MoveC p203, p204\ID:=20, v300, z10, tool2 \WObj:=wobj_stn1;
MoveL p205\ID:=30, v300, z10, tool2 \WObj:=wobj_stn1;

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7.1.3 Store current path
Continued

MoveC p206, p201\ID:=40, v300, fine, tool2 \WObj:=wobj_stn1;

SyncMoveOff sync3;
MoveL p299, v1000, fine, tool2;
ERROR
IF ERRNO = ERR_PATH_STOP THEN
gun_cleaning();
ENDIF
UNDO
SyncMoveUndo;
ENDPROC
PROC gun_cleaning()
VAR robtarget p2;
!Store the movement path and current position.
StorePath \KeepSync;
p2 := CRobT(\Tool:=tool2 \WObj:=wobj_stn1);
!Correct the error
MoveL pclean2 \ID:=50, v100, fine, tool2 \WObj:=wobj_stn1;
...
!Move the robot back to the stored position.
MoveL p2 \ID:=60, v100, fine, tool2 \WObj:=wobj_stn1;
!Restore the path and start the movement
RestoPath;
StartMove;
RETRY;
ENDPROC
ENDMODULE

T_STN1 task program

MODULE module3
VAR syncident sync1;
VAR syncident sync2;
VAR syncident sync3;
PERS tasks all_tasks{3};
CONST jointtarget angle_neg20 :=[ [ 9E9, 9E9, 9E9, 9E9, 9E9,
9E9], [ -20, 9E9, 9E9, 9E9, 9E9, 9E9] ];
...
CONST jointtarget angle_340 :=[ [ 9E9, 9E9, 9E9, 9E9, 9E9, 9E9],[
340, 9E9, 9E9, 9E9, 9E9, 9E9] ];
PROC main()
...
SyncMove;
...
ENDPROC
PROC SyncMove()
MoveExtJ angle_neg20, vrot50, fine;
WaitSyncTask sync1, all_tasks;
! Wait for the robots
SyncMoveOn sync2, all_tasks;
MoveExtJ angle_20\ID:=10, vrot100, z10;
MoveExtJ angle_160\ID:=20, vrot100, z10;
MoveExtJ angle_200\ID:=30, vrot100, z10;

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7.1.3 Store current path
Continued

MoveExtJ angle_340\ID:=40, vrot100, fine;

SyncMoveOff sync3;
ERROR
IF ERRNO = ERR_PATH_STOP THEN
gun_cleaning();
ENDIF
UNDO
SyncMoveUndo;
ENDPROC
PROC gun_cleaning()
VAR jointtarget resume_angle;
!Store the movement path and current angle.
StorePath \KeepSync;
resume_angle := CJointT();
!Correct the error
MoveExtJ clean_angle \ID:=50, vrot100, fine;
...
!Move the robot back to the stored position.
MoveExtJ resume_angle \ID:=60, vrot100, fine;
!Restore the path and start the movement
RestoPath;
StartMove;
RETRY;
ENDPROC
ENDMODULE

Suspend and resume synchronized movements in the SyncArc example

SyncMoveSuspend is used to suspend synchronized movements mode and set
the system to independent or semi coordinated movement mode.
SyncMoveResume is used to go back once more to synchronized movements.
These instructions can only be used after StorePath\KeepSync has been
executed.

T_ROB1
PROC gun_cleaning()
VAR robtarget p1;
!Store the movement path and current position
! and keep syncronized mode.
StorePath \KeepSync;
p1 := CRobT(\Tool:=tool1 \WObj:=wobj_stn1);
!Move in synchronized motion mode
MoveL p104 \ID:=50, v100, fine, tool1 \WObj:=wobj_stn1;
SyncMoveSuspend;
!Move in independent mode
MoveL pclean1, v100, fine, tool1;
...
!Move the robot back to the stored position
SyncMoveResume;
MoveL p1 \ID:=60, v100, fine, tool1 \WObj:=wobj_stn1;
!Restore the path and start the movement

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7.1.3 Store current path
Continued

RestoPath;
StartMove;
RETRY;
ENDPROC

T_ROB2
PROC gun_cleaning()
VAR robtarget p2;
!Store the movement path and current position.
StorePath \KeepSync;
p2 := CRobT(\Tool:=tool2 \WObj:=wobj_stn1);
!Move in synchronized motion mode
MoveL p104 \ID:=50, v100, fine, tool2 \WObj:=wobj_stn1;
SyncMoveSuspend;
!Move in independent mode
MoveL pclean2 v100, fine, tool2;
...
!Move the robot back to the stored position.
SyncMoveResume;
!Move in synchronized motion mode
MoveL p2 \ID:=60, v100, fine, tool2 \WObj:=wobj_stn1;
!Restore the path and start the movement
RestoPath;
StartMove;
RETRY;
ENDPROC

T_STN1
PROC gun_cleaning()
VAR jointtarget resume_angle;
!Store the movement path and current angle.
StorePath \KeepSync;
resume_angle := CJointT();
!Move in synchronized motion mode
MoveExtJ p1clean_angle \ID:=50, vrot100, fine;
SyncMoveSuspend;
! Move in independent mode
MoveExtJ p2clean_angle,vrot, fine;
...
!Move the robot back to the stored position.
SyncMoveResume;
! Move in synchronized motion mode
MoveExtJ resume_angle \ID:=60, vrot100, fine;
!Restore the path and start the movement
RestoPath;
StartMove;
RETRY;
ENDPROC

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 7 RAPID program features
7.1.4 Path recorder

7.1.4 Path recorder

What is the path recorder

The path recorder can memorize a number of move instructions. This memory can
then be used to move the robot backwards along that same path.

How to use the path recorder

This is the general approach for using the path recorder:
1 Start the path recorder
2 Move the robot with regular move, or process, instructions
3 Store the current path
4 Move backwards along the recorded path
5 Resolve the error
6 Move forward along the recorded path
7 Restore the interrupted path

Lift the tool

When the robot moves backward in its own track, you may want to avoid scraping
the tool against the work piece. For a process like arc welding, you want to stay
clear of the welding seam.
By using the argument ToolOffs in the instructions PathRecMoveBwd and
PathRecMoveFwd, you can set an offset for the TCP. This offset is set in tool
coordinates, which means that if it is set to [0,0,10] the tool will be 10mm from the
work object when it moves back along the recorded path.

xx0400000828

Note

When a MultiMove system is in synchronized mode all tasks must use ToolOffs
if a tool is going to be lifted.
However if you only want to lift one tool, set ToolOffs=[0,0,0] in the other
tasks.

Simple example
If an error occurs between p1 and p4, the robot will return to p1 where the error
can be resolved. When the error has been resolved, the robot continues from where
the error occurred.
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7.1.4 Path recorder
Continued

When p4 is reached without any error, the path recorder is switched off. The robot
then moves from p4 to p5 without the path recorder.
...
VAR pathrecid start_id;
...
MoveL p1, vmax, fine, tool1;
PathRecStart start_id;
MoveL p2, vmax, z50, tool1;
MoveL p3, vmax, z50, tool1;
MoveL p4, vmax, fine, tool1;
PathRecStop \Clear;
MoveL p5, vmax, fine, tool1;

ERROR
StorePath;
PathRecMoveBwd;
! Fix the problem
PathRecMoveFwd;
RestoPath;
StartMove;
RETRY;
ENDIF
...

Complex example
In this example, the path recorder is used for two purposes:
• If an error occurs, the operator can choose to back up to p1 or to p2. When
the error has been resolved, the interrupted movement is resumed.
• Even if no error occurs, the path recorder is used to move the robot from p4
to p1. This technique is useful when the robot is in a narrow position that is
difficult to move out of.
Note that if an error occurs during the first move instruction, between p1 and p2,
it is not possible to go backwards to p2. If the operator choose to go back to p2,
PathRecValidBwd is used to see if it is possible. Before the robot is moved forward
to the position where it was interrupted, PathRecValidFwd is used to see if it is
possible (if the robot never backed up it is already in position).
...
VAR pathrecid origin_id;
VAR pathrecid corner_id;
VAR num choice;
...
MoveJ p1, vmax, z50, tool1;
PathRecStart origin_id;
MoveJ p2, vmax, z50, tool1;
PathRecStart corner_id;
MoveL p3, vmax, z50, tool1;
MoveL p4, vmax, fine, tool1;

! Use path record to move safely to p1

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7.1.4 Path recorder
Continued

StorePath;
PathRecMoveBwd \ID:=origin_id
\ToolOffs:=[0,0,10];
RestoPath;
PathRecStop \Clear;
ClearPath;
StartMove;

ERROR
StorePath;

! Ask operator how far to back up

TPReadFK choice,"Extract to:", stEmpty, stEmpty,
stEmpty, "Origin", "Corner";

IF choice=4 THEN
! Back up to p1
PathRecMoveBwd \ID:=origin_id
\ToolOffs:=[0,0,10];
ELSEIF choice=5 THEN
! Verify that it is possible to back to p2,
IF PathRecValidBwd(\ID:=corner_id) THEN
! Back up to p2
PathRecMoveBwd \ID:=corner_id
\ToolOffs:=[0,0,10];
ENDIF
ENDIF

! Fix the problem

! Verify that there is a path record forward

IF PathRecValidFwd() THEN
! Return to where the path was interrupted
PathRecMoveFwd \ToolOffs:=[0,0,10];
ENDIF

! Restore the path and resume movement

RestoPath;
StartMove;
RETRY;
...

Resume path recorder

If the path recorder is stopped, it can be started again from the same position
without loosing its history.
In the example below, the PathRecMoveBwd instruction will back the robot to p1.
If the robot had been in any other position than p2 when the path recorder was
restarted, this would not have been possible.
For more information, see the section about PathRecStop in Technical reference
manual - RAPID Instructions, Functions and Data types.
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7.1.4 Path recorder
Continued

...
MoveL p1, vmax, z50, tool1;
PathRecStart id1;
MoveL p2, vmax, z50, tool1;
PathRecStop;
MoveL p3, vmax, z50, tool1;
MoveL p4, vmax, z50, tool1;
MoveL p2, vmax, z50, tool1;
PathRecStart id2;
MoveL p5, vmax, z50, tool1;
StorePath;
PathRecMoveBwd \ID:=id1;
RestoPath;
...

Example with TRAP routine

Below is an example where an error is managed using a TRAP routine instead of
an error handler. During a movement sequence, the signal ProcessErr is monitored.
If ProcessErr is set to 1, the robot returns to the StartPos position and stops. Upon
restarting the RAPID program, it waits for ProcessErr to reset to 0. Once this occurs,
the robot resumes its movement from the position where ProcessErr was initially
triggered, continuing the sequence.
VAR pathrecid Id1;
VAR pathrecid Id2;
VAR intnum intErrProcess;

PROC main()
Init;
WHILE TRUE DO
DoMovement;
ENDWHILE
ENDPROC

PROC Init()
CONNECT intErrProcess WITH Surveil;
ISignalDO ProcessErr, 1, intErrProcess;
ENDPROC

! TRAP that is executed if signal ProcessErr is set to 1

TRAP Surveil
StopMove\Quick;
StorePath;
PathRecMoveBwd\ID:=Id1\Speed:=v200;
TPWrite "Do Maintenance";
Stop;
!Maintenance
PathRecMoveFwd\Speed:=v200;
RestoPath;

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7.1.4 Path recorder
Continued

WaitUntil ProcessErr=0 \Visualize \Header:="ProcessErr signal

is 1" \MsgArray:=["Movement will not start until",
"condition below is TRUE"];
StartMove;
RETURN;
ENDTRAP

PROC DoMovement()
MoveL StartPos,v200,fine,Tooldata_1;
PathRecStart Id1;
MoveL Target_20,v100,z0,Tooldata_1;
MoveL Target_30,v100,z0,Tooldata_1;
MoveL Target_50,v100,z0,Tooldata_1;
MoveL Target_70,v100,z0,Tooldata_1;
MoveL Target_80,v100,z0,Tooldata_1;
MoveL Target_100,v100,z0,Tooldata_1;
MoveL Target_110,v100,z0,Tooldata_1;
ENDPROC

SyncArc example with coordinated synchronized movement

This is an example on how to use Path Recorder in error handling for a MultiMove
system.
In this example two robots perform arc welding on the same work piece. To make
the example simple and general, we use move instructions instead of weld
instructions. The work object is rotated by a positioner.
For more information on the SyncArc example, see Application manual - MultiMove.

T_ROB1 task program

MODULE module1
VAR syncident sync1;
VAR syncident sync2;
VAR syncident sync3;
PERS tasks all_tasks{3} := [["T_ROB1"],["T_ROB2"],["T_STN1"]];
PERS wobjdata wobj_stn1 := [ FALSE, FALSE, "STN_1",[ [0, 0, 0],
[1, 0, 0 ,0] ], [ [0, 0,250], [1, 0, 0, 0] ] ];
TASK PERS tooldata tool1 := ...
CONST robtarget p100 := ...
CONST robtarget p199 := ...
PROC main()
...
SyncMove;
ENDPROC

PROC SyncMove()
WaitSyncTask sync1, all_tasks;
MoveJ p100, v1000, z50, tool1;
! Start recording
PathRecStart HomeROB1;
MoveL p101, v500, fine, tool1;
SyncMoveOn sync2, all_tasks;
MoveL p102\ID:=10, v300, z10, tool1 \WObj:=wobj_stn1;
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7.1.4 Path recorder
Continued

MoveC p103, p104\ID:=20, v300, z10, tool1 \WObj:=wobj_stn1;

MoveL p105\ID:=30, v300, z10, tool1 \WObj:=wobj_stn1;
MoveC p106, p101\ID:=40, v300, fine, tool1 \WObj:=wobj_stn1;
!Stop recording
PathRecStop \Clear;
SyncMoveOff sync3;
MoveL p199, v1000, fine, tool1;
ERROR
! Weld error in this program task
IF ERRNO = AW_WELD_ERR THEN
gun_cleaning();
ENDIF
UNDO
SyncMoveUndo;
ENDPROC
PROC gun_cleaning()
VAR robtarget p1;
!Store the movement path
IF IsSyncMoveOn() THEN
StorePath \KeepSync;
ELSE
StorePath;
ENDIF
!Move this robot backward to p100.
PathRecMoveBwd \ID:=HomeROB1 \ToolOffs:=[0,0,10];
!Correct the error
MoveJ pclean1 ,v100, fine, tool1;
...
!Move the robot back to p100
MoveJ p100, v100, fine, tool1;
PathRecMoveFwd \ToolOffs:=[0,0,10];
!Restore the path and start the movement
RestoPath;
StartMove;
RETRY;
ENDPROC
ENDMODULE

T_ROB2 task program

MODULE module2
VAR syncident sync1;
VAR syncident sync2;
VAR syncident sync3;
PERS tasks all_tasks{3};
PERS wobjdata wobj_stn1;
TASK PERS tooldata tool2 := ...
CONST robtarget p200 := ...
CONST robtarget p299 := ...
PROC main()
...
SyncMove;

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7.1.4 Path recorder
Continued

ENDPROC
PROC SyncMove()
WaitSyncTask sync1, all_tasks;
MoveJ p200, v1000, z50, tool2;
PathRecStart HomeROB2;
MoveL p201, v500, fine, tool2;
SyncMoveOn sync2, all_tasks;
MoveL p202\ID:=10, v300, z10, tool2 \WObj:=wobj_stn1;
MoveC p203, p204\ID:=20, v300, z10, tool2 \WObj:=wobj_stn1;
MoveL p205\ID:=30, v300, z10, tool2 \WObj:=wobj_stn1;
MoveC p206, p201\ID:=40, v300, fine, tool2 \WObj:=wobj_stn1;
PathRecStop \Clear;
SyncMoveOff sync3;
MoveL p299, v1000, fine, tool2;
ERROR
IF ERRNO = ERR_PATH_STOP THEN
gun_move_out();
ENDIF
UNDO
SyncMoveUndo;
ENDPROC
PROC gun_move_out()
IF IsSyncMoveOn() THEN
StorePath \KeepSync;
ELSE
StorePath;
ENDIF
! Move this robot backward to p201
PathRecMoveBwd \ToolOffs:=[0,0,10];
! Wait for the other gun to get clean
PathRecMoveFwd \ToolOffs:=[0,0,10];
!Restore the path and start the movement
RestoPath;
StartMove;
RETRY;
ENDPROC
ENDMODULE

T_STN1 task program

MODULE module3
VAR syncident sync1;
VAR syncident sync2;
VAR syncident sync3;
PERS tasks all_tasks{3};
CONST jointtarget angle_neg20 :=[ [ 9E9, 9E9, 9E9, 9E9, 9E9,
9E9], [ -20, 9E9, 9E9, 9E9, 9E9, 9E9] ];
...
CONST jointtarget angle_340 :=[ [ 9E9, 9E9, 9E9, 9E9, 9E9, 9E9],[
340, 9E9, 9E9, 9E9,9E9, 9E9] ];
PROC main()
...

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7.1.4 Path recorder
Continued

SyncMove;
...
ENDPROC
PROC SyncMove()
WaitSyncTask sync1, all_tasks;
MoveExtJ angle_neg20, vrot50, fine;
PathRecStart HomeSTN1;
SyncMoveOn sync2, all_tasks;
MoveExtJ angle_20\ID:=10, vrot100, z10;
MoveExtJ angle_160\ID:=20, vrot100, z10;
MoveExtJ angle_200\ID:=30, vrot100, z10;
MoveExtJ angle_340\ID:=40, vrot100, fine;
PathRecStop \Clear;
SyncMoveOff sync3;
ERROR
IF ERRNO = ERR_PATH_STOP THEN
gun_move_out();
ENDIF
UNDO
SyncMoveUndo;
ENDPROC
PROC gun_move_out()
!Store the movement
IF IsSyncMoveOn() THEN
StorePath \KeepSync;
ELSE
StorePath;
ENDIF
!Move the manipulator backward to angle_neg 20
PathRecMoveBwd \ToolOffs:=[0,0,0];
...
!Wait for the gun to get clean
PathRecMoveFwd \ToolOffs:=[0,0,0];
RestoPath;
StartMove;
RETRY;
ENDPROC

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 7 RAPID program features
7.2.1 Introduction to Multitasking

7.2 Multitasking [3114-1]

7.2.1 Introduction to Multitasking

Purpose
The purpose of the option Multitasking is to be able to execute more than one
program at a time.
Examples of applications to run in parallel with the main program:
• Continuous supervision of signals, even if the main program has stopped.
This can in some cases take over the job of a PLC. However, the response
time will not match that of a PLC.
• Operator input from the FlexPendant while the robot is working.
• Control and activation/deactivation of external equipment.

Basic description
Up to 20 tasks can be run at the same time. This includes tasks from add-ins and
options, that might be running in the background.
Each task consists of one program (with several program modules) and several
system modules. The modules are local in the respective task.

en0300000517

Variables and constants are local in the respective task, but persistents are not.
Every task has its own trap handling and event routines are triggered only on its
own task system states.

What is included
The RobotWare option Multitasking gives you access to:
• The possibility to run up to 20 programs in parallel (one per task).
• The system parameters: The type Task and all its parameters.
• The data types: taskid, syncident, and tasks.
• The instruction: WaitSyncTask.

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Continued

• The functions: TestAndSet, TaskRunMec, and TaskRunRob.

Note

TestAndSet, TaskRunMec, and TaskRunRob can be used without the option

Multitasking, but they are much more useful together with Multitasking.

Basic approach
This is the basic approach for setting up Multitasking. For more information,
seeRAPID components on page 283.
1 Define the tasks you need.
2 Write RAPID code for each task.
3 Specify which modules to load in each task.

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7.2.2 System parameters

7.2.2 System parameters

About the system parameters

This is a brief description of each parameter in the option Multitasking. For more
information, see the respective parameter in Technical reference manual - System
parameters.

Task
These parameters belongs to the type Task in the topic Controller.
Parameter Description
Task The name of the task.
Note that the name of the task must be unique. This means that it cannot
have the same name as the mechanical unit, and no variable in the
RAPID program can have the same name.
Note that editing the task entry in the configuration editor and changing
the task name will remove the old task and add a new one. This means
that any program or module in the task will disappear after a restart with
these kind of changes.
Task in fore- Used to set priorities between tasks.
ground Task in foreground contains the name of the task that should run in the
foreground of this task. This means that the program of the task, for which
the parameter is set, will only execute if the foreground task program is
idle.
If Task in foreground is set to empty string for a task, it runs at the highest
level.
Type Controls the start/stop and system restart behavior:
• Normal (NORMAL) - The task program is manually started and
stopped (e.g. from the FlexPendant). The task stops at emergency
stop.
• Static (STATIC) - At a restart the task program continues from
where the it was. The task program is normally not stopped by the
FlexPendant or by emergency stop.
• Semistatic (SEMISTATIC) - The task program restarts from the
beginning at restart. The task program is normally not stopped by
the FlexPendant or by emergency stop.
A task that controls a mechanical unit must be of the type normal.
Main entry The name of the start routine for the task program.
Check unre- This parameter should be set to NO if the system is to accept unsolved
solved refer- references in the program while linking a module, otherwise set to YES.
ences
TrustLevel TrustLevel defines the system behavior when a static or semistatic task
program is stopped (e.g. due to error):
• SysFail - If the program of this task stops, the system will be set
to SYS_FAIL. This will cause the programs of all NORMAL tasks
to stop (static and semistatic tasks will continue execution if pos-
sible). No jogging or program start can be made. A restart is re-
quired.
• SysHalt -If the program of this task stops, the programs of all
normal tasks will be stopped. If "motors on" is set, jogging is
possible, but not program start. A restart is required.
• SysStop - If the program of this task stops, the programs of all
normal tasks will be stopped but are restartable. Jogging is also
possible.
• NoSafety - Only the program of this task will stop.

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7.2.2 System parameters
Continued

Parameter Description
MotionTask Indicates whether the task program can control robot movement with
RAPID move instructions.
Only one task can have MotionTask set to YES unless the option Mul-
tiMove is used.

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7.2.3 RAPID components

7.2.3 RAPID components

Data types
This is a brief description of each data type in Multitasking. For more information,
see the respective data type in Technical reference manual - RAPID Instructions,
Functions and Data types.
Data type Description
taskid taskid identify available tasks in the system.
This identity is defined by the system parameter Task, and cannot be
defined in the RAPID program. However, the data type taskid can be
used as a parameter when declaring a routine.
For code example, see taskid on page 294.
syncident syncident is used to identify the waiting point in the program, when
using the instruction WaitSyncTask.
The name of the syncident variable must be the same in all task pro-
grams.
For code example, see WaitSyncTask example on page 288.
tasks A variable of the data type tasks contains names of the tasks that will
be synchronized by the instruction WaitSyncTask.
For code example, see WaitSyncTask example on page 288.

Instructions
This is a brief description of each instruction in Multitasking. For more information,
see the respective instruction in Technical reference manual - RAPID Instructions,
Functions and Data types.
Instruction Description
WaitSyncTask WaitSyncTask is used to synchronize several task programs at a special
point in the program.
A WaitSyncTask instruction will delay program execution and wait for
the other task programs. When all task programs have reached the point,
the respective program will continue its execution.
For code example, seeWaitSyncTask example on page 288.

Functions
This is a brief description of each function in Multitasking. For more information,
see the respective function in Technical reference manual - RAPID Instructions,
Functions and Data types.
Function Description
TestAndSet TestAndSet is used, together with a boolean flag, to ensure that only one
task program at the time use a specific RAPID code area or system re-
source.
For code example, seeExample with flag and TestAndSet on page 292.
TaskRunMec Check if the task program controls any mechanical unit (robot or other
unit).
For code example, seeTest if task controls mechanical unit on page 293.
TaskRunRob Check if the task program controls any robot with TCP.
For code example, seeTest if task controls mechanical unit on page 293.

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7 RAPID program features
[Link] Persistent variables

7.2.4 Communication between tasks

[Link] Persistent variables

About persistent variables

To share data between tasks, use persistent variables.
A persistent variable is global in all tasks where it is declared. The persistent
variable must be declared as the same type and size (array dimension) in all tasks.
Otherwise a runtime error will occur.
It is sufficient to specify an initial value for the persistent variable in one task. If
initial values are specified in several tasks, only the initial value of the first module
to load will be used.

Tip

When a program is saved, the current value of a persistent variable will be used
as initial value in the future. If this is not desired, reset the persistent variable
directly after the communication.

Example with persistent variable

In this example the persistent variables startsync and stringtosend are
accessed by both tasks, and can therefore be used for communication between
the task programs.
Main task program:
MODULE module1
PERS bool startsync:=FALSE;
PERS string stringtosend:="";
PROC main()
stringtosend:="this is a test";
startsync:= TRUE
ENDPROC
ENDMODULE
Background task program:
MODULE module2
PERS bool startsync;
PERS string stringtosend;
PROC main()
WaitUntil startsync;
IF stringtosend = "this is a test" THEN
...
ENDIF
!reset persistent variables
startsync:=FALSE;
stringtosend:="";
ENDPROC
ENDMODULE

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[Link] Persistent variables
Continued

Module for common data

When using persistent variables in several tasks, there should be declarations in
all the tasks. The best way to do this, to avoid type errors or forgetting a declaration
somewhere, is to declare all common variables in a system module. The system
module can then be loaded into all tasks that require the variables.

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[Link] Waiting for other tasks

[Link] Waiting for other tasks

Two techniques
Some applications have task programs that execute independently of other tasks,
but often task programs need to know what other tasks are doing.
A task program can be made to wait for another task program. This is accomplished
either by setting a persistent variable that the other task program can poll, or by
setting a signal that the other task program can connect to an interrupt.

Polling
This is the easiest way to make a task program wait for another, but the performance
will be the slowest. Persistent variables are used together with the instructions
WaitUntil or WHILE.
If the instruction WaitUntil is used, it will poll internally every 100 ms.

CAUTION

Do not poll more frequently than every 100 ms. A loop that polls without a wait
instruction can cause overload, resulting in lost contact with the FlexPendant.

Polling example
Main task program:
MODULE module1
PERS bool startsync:=FALSE;
PROC main()
startsync:= TRUE;
...
ENDPROC
ENDMODULE

Background task program:

MODULE module2
PERS bool startsync:=FALSE;
PROC main()

WaitUntil startsync;
! This is the point where the execution
! continues after startsync is set to TRUE
...
ENDPROC
ENDMODULE

Interrupt
By setting a signal in one task program and using an interrupt in another task
program, quick response is obtained without the work load caused by polling.
The drawback is that the code executed after the interrupt must be placed in a trap
routine.

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[Link] Waiting for other tasks
Continued

Interrupt example
Main task program:
MODULE module1
PROC main()
SetDO do1,1;
...
ENDPROC
ENDMODULE

Background task program:

MODULE module2
VAR intnum intno1;

PROC main()
CONNECT intno1 WITH wait_trap;
ISignalDO do1, 1, intno1;
WHILE TRUE DO
WaitTime 10;
ENDWHILE
ENDPROC

TRAP wait_trap
! This is the point where the execution
! continues after do1 is set in main task
...
IDelete intno1;
ENDTRAP
ENDMODULE

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7 RAPID program features
[Link] Synchronizing between tasks

[Link] Synchronizing between tasks

Synchronizing using WaitSyncTask

Synchronization is useful when task programs are depending on each other. No
task program will continue beyond a synchronization point in the program code
until all task programs have reached that point in the respective program code.
The instruction WaitSyncTask is used to synchronize task programs. No task
program will continue its execution until all task programs have reached the same
WaitSyncTask instruction.

WaitSyncTask example
In this example, the background task program calculates the next object's position
while the main task program handles the robots work with the current object.
The background task program may have to wait for operator input or I/O signals,
but the main task program will not continue with the next object until the new
position is calculated. Likewise, the background task program must not start the
next calculation until the main task program is done with one object and ready to
receive the new value.
Main task program:
MODULE module1
PERS pos object_position:=[0,0,0];
PERS tasks task_list{2} := [["MAIN"], ["BACK1"]];
VAR syncident sync1;

PROC main()
VAR pos position;
WHILE TRUE DO
!Wait for calculation of next object_position
WaitSyncTask sync1, task_list;
position:=object_position;
!Call routine to handle object
handle_object(position);
ENDWHILE
ENDPROC

PROC handle_object(pos position)

...
ENDPROC
ENDMODULE

Background task program:

MODULE module2
PERS pos object_position:=[0,0,0];
PERS tasks task_list{2} := [["MAIN"], ["BACK1"]];
VAR syncident sync1;

PROC main()
WHILE TRUE DO

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[Link] Synchronizing between tasks
Continued

!Call routine to calculate object_position

calculate_position;

!Wait for handling of current object

WaitSyncTask sync1, task_list;
ENDWHILE
ENDPROC

PROC calculate_position()
...
object_position:= ...
ENDPROC
ENDMODULE

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7 RAPID program features
[Link] Using a dispatcher

[Link] Using a dispatcher

What is a dispatcher?
A digital signal can be used to indicate when another task should do something.
However, it cannot contain information about what to do.
Instead of using one signal for each routine, a dispatcher can be used to determine
which routine to call. A dispatcher can be a persistent string variable containing
the name of the routine to execute in another task.

Dispatcher example
In this example, the main task program calls routines in the background task by
setting routine_string to the routine name and then setting do5 to 1. In this
way, the main task program initialize that the background task program should
execute the routine clean_gun first and then routine1.
Main task program:
MODULE module1
PERS string routine_string:="";

PROC main()
!Call clean_gun in background task
routine_string:="clean_gun";
SetDO do5,1;
WaitDO do5,0;

!Call routine1 in background task

routine_string:="routine1";
SetDO do5,1;
WaitDO do5,0;
...
ENDPROC
ENDMODULE

Background task program:

MODULE module2
PERS string routine_string:="";

PROC main()
WaitDO do5,1;
%routine_string%;
SetDO do5,0;
ENDPROC

PROC clean_gun()
...
ENDPROC

PROC routine1()
...

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[Link] Using a dispatcher
Continued

ENDPROC
ENDMODULE

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7 RAPID program features
[Link] Share resource between tasks

7.2.5 Other programming issues

[Link] Share resource between tasks

Flag indicating occupied resource

System resources, such as FlexPendant, file system and I/O signals, are available
from all tasks. However, if several task programs use the same resource, make
sure that they take turns using the resource, rather than using it at the same time.
To avoid having two task programs using the same resource at the same time, use
a flag to indicate that the resource is already in use. A boolean variable can be set
to true while the task program uses the resource.
To facilitate this handling, the instruction TestAndSet is used. It will first test the
flag. If the flag is false, it will set the flag to true and return true. Otherwise, it will
return false.

Example with flag and TestAndSet

In this example, two task programs try to write three lines each to the FlexPendant.
If no flag is used, there is a risk that these lines are mixed with each other. By using
a flag, the task program that first execute the TestAndSet instruction will write all
three lines first. The other task program will wait until the flag is set to false and
then write all its lines.
Main task program:
PERS bool tproutine_inuse := FALSE;
...
WaitUntil TestAndSet(tproutine_inuse);
TPWrite "First line from MAIN";
TPWrite "Second line from MAIN";
TPWrite "Third line from MAIN";
tproutine_inuse := FALSE;

Background task program:

PERS bool tproutine_inuse := FALSE;
...
WaitUntil TestAndSet(tproutine_inuse);
TPWrite "First line from BACK1";
TPWrite "Second line from BACK1";
TPWrite "Third line from BACK1";
tproutine_inuse := FALSE;

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 7 RAPID program features
[Link] Test if task controls mechanical unit

[Link] Test if task controls mechanical unit

Two functions for inquiring

There are functions for checking if the task program has control of any mechanical
unit, TaskRunMec, or of a robot, TaskRunRob.
TaskRunMec will return true if the task program controls a robot or other mechanical
unit. TaskRunRob will only return true if the task program controls a robot with
TCP.
TaskRunMec and TaskRunRob are useful when using MultiMove. With MultiMove
you can have several tasks controlling mechanical units, see Application
manual - MultiMove.

Note

For a task to have control of a robot, the parameter Type must be set to normal,
and the type MotionTask must be set to YES. See System parameters on page 281.

Example with TaskRunMec and TaskRunRob

In this example, the maximum speed for external equipment is set. If the task
program controls a robot, the maximum speed for external equipment is set to the
same value as the maximum speed for the robot. If the task program controls
external equipment but no robot, the maximum speed is set to 5000 mm/s.
IF TaskRunMec() THEN
IF TaskRunRob() THEN
!If task controls a robot
MaxExtSpeed := MaxRobSpeed();
ELSE
!If task controls other mech unit than robot
MaxExtSpeed := 5000;
ENDIF
ENDIF

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7 RAPID program features
[Link] taskid

[Link] taskid

taskid syntax
A task always has a predefined variable of type taskid that consists of the name
of the task and the suffix "Id". For example, the variable name of the MAIN task is
MAINId.

Code example
In this example, the module PART_A is saved in the task BACK1, even though the
Save instruction is executed in another task.
BACK1Id is a variable of type taskid that is automatically declared by the system.
Save \TaskRef:=BACK1Id, "PART_A"
\FilePath:="HOME:/DOORDIR/PART_A.MOD";

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 7 RAPID program features
[Link] Avoid heavy loops

[Link] Avoid heavy loops

Background tasks loop continuously

A task program is normally executed continuously. This means that a background
task program is in effect an eternal loop. If this program does not have any waiting
instruction, the background task may use too much computer power and make the
controller unable to handle the other tasks.

Example
MODULE background_module
PROC main()
WaitTime 1;
IF di1=1 THEN
...
ENDIF
ENDPROC
ENDMODULE
If there was no wait instruction in this example and di1 was 0, then this background
task would use up the computer power with a loop doing nothing.

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 8 Communication with remote mounted disks
8.1.1 Introduction to FTP&SFTP client

8 Communication with remote mounted disks

8.1 FTP&SFTP client [3116-1]

8.1.1 Introduction to FTP&SFTP client

Purpose
The purpose of FTP&SFTP Client is to enable the robot to access remote mounted
disks, for example a hard disk drive on a PC.
Here are some examples of applications:
• Backup to a remote computer.
• Load programs from a remote computer.

Note

The controller has no antivirus software to check the data transferred to/from
the controller via the remote mounted disk. It is up to the customer to secure the
external data storage.

Network illustration

External computer

Ethernet TCP/IP

xx1900001202

Description
Several robots can access the same computer over an Ethernet network.
The FTP/SFTP mounted device is accessed by its name, as specified in the system
parameter Name.
Once the FTP/SFTP protocol is configured, the remote computer can be accessed
in the same way as the controller's internal hard disk.

What is included
The RobotWare option FTP&SFTP client gives you access to the system parameter
types FTP Client and SFTP Client.

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8.1.1 Introduction to FTP&SFTP client
Continued

Basic approach
This is the general approach for using FTP&SFTP client.
1 Configure an FTP/SFTP protocol to point out a disk or directory on a remote
computer that will be accessible from the robot.
2 Read and write to the remote computer in the same way as with the
controller's internal hard disk.
SFTP supports the following servers:
• Rebex version 1.0.3
• CompleteFTP version 11.0.0
• Cerberus version [Link]
In certain SFTP servers, as Complete SFTP server, there is a configuration setting,
Timeout for idle sessions, which defines the time that the connection can be idle.
If no client requests are made during this time interval, the connection is closed.
Setting the value as No timeout will keep the connection alive, even though client
requests are not made.

Requirements
The external computer must have:
• TCP/IP stack
• FTP Server or SFTP Server

Directory listing style on FTP server

The FTP server must list directories in a UNIX style.
Example:
drwxrwxrwx 1 owner group 25 May 18 16:39 backups
The MS-DOS style does not work.

Tip

For Internet Information Services (IIS) in Windows, the directory listing style is
configurable.

Limitations
• The maximum length of the path is 248 characters. Note that for backup and
restore, the names of all the created directories have to be included in the
max path.

System parameters
See Technical reference manual - System parameters.

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 8 Communication with remote mounted disks
8.2.1 Introduction to NFS Client

8.2 NFS Client [3117-1]

8.2.1 Introduction to NFS Client

Purpose
NFS Client allows the robot to access remote mounted disks, such as a hard disk
drive on a PC. Supported NFS versions are 2 and 3.
Here are a few application examples:
• Backup to a remote computer.
• Load programs from a remote computer.

Note

The controller has no antivirus software to check the data transferred to/from
the controller via the remote mounted disk. It is up to the customer to secure the
external data storage.

Description
Several robots can access the same computer over an Ethernet network.
The NFS mounted device is accessed by its name, as specified in the Name system
parameter.
Once the NFS application protocol is configured, the remote computer can be
accessed in the same way as the controller's internal hard disk.

What is included
The RobotWare option NFS Client gives you access to the system parameter type
Application protocol and its parameters: Name, Type, Transmission protocol, Server
address, Server type, NFS version,Trusted, Local path, Server path, User ID, Group
ID, and Show Device.

Basic approach
This is the general approach for using NFS Client.
1 Configure an NFS protocol to point out a disk or directory on a remote
computer that will be accessible from the robot.
2 Read and write to the remote computer in the same way as with the
controller's internal hard disk.

Prerequisites
The external computer must have:
• TCP/IP stack
• NFS Server

Limitations
When using the NFS Client the maximum length for a file path including the file
name is 248 characters. The whole path is included in the 248 characters, not only

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8.2.1 Introduction to NFS Client
Continued

the server path. When ordering a backup towards a mounted disk all the directories
created by the backup has to be included in the max path.

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 9 Applications for user interaction
9.1 RobotStudio Connect [3119-1]

9 Applications for user interaction

9.1 RobotStudio Connect [3119-1]

Overview
RobotStudio is the programming, configuration and commissioning tool for
OmniCore controllers. RobotStudio acts directly on the active data in the controller
and enables activities like RAPID programming, update/booting of the systems
software and system configuration. Connecting RobotStudio directly to the local
management port is enabled by default, but connecting RobotStudio over a public
network requires this option RobotStudio Connect.

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9 Applications for user interaction
9.2 FlexPendant Base Apps

9.2 FlexPendant Base Apps

Limited App Package [3120-1]

The option Limited App Package contains base functionality to operate the robot
system. This base version of software for the FlexPendant allows for the most
crucial functionality, like jogging the robot, calibration of the robot, basic operation
(start, stop, loading programs), read and write I/O signals, event log and operator
messages.

Essential App Package [3120-2]

The option Essential App Package includes features that will make it easier and
more efficient to work with the robot system. The jog functionality is improved with
3D illustrations, and dashboards makes it easy to view the system status at a
glance. This includes the option Limited App Package.

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 9 Applications for user interaction
9.3 FlexPendant Independent Apps

9.3 FlexPendant Independent Apps

Program Package [3151-1]

The option Program Package is required in order to create new and edit existing
RAPID programs on the FlexPendant. If the program package is not selected with
the FlexPendant, RobotStudio must instead be used on a separate PC to create
and edit RAPID programs.
The FlexPendant options are not tied to the FlexPendant hardware, but instead to
OmniCore controller. This means a FlexPendant runs the apps that are licensed
to the controller it is connected to. A shared FlexPendant can accordingly have
different apps on different robots.

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 10 Engineering tools
10.1 RobotWare Add-In

10 Engineering tools
10.1 RobotWare Add-In

Purpose
The option RobotWare Add-In is required for licensed Add-Ins.
See Application manual - RobotWare add-ins.

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10 Engineering tools
10.2.1 Overview

10.2 Path Corrections [3123-1]

10.2.1 Overview

Purpose
The purpose of Path Corrections is to be able to make online adjustments of the
robot path according to input from sensors. With the set of instructions that Path
Corrections offers, the robot path can be compared and adjusted with the input
from sensors.

What is included
The RobotWare option Path Corrections gives you access to:
• the data type corrdescr
• the instructions CorrCon, CorrDiscon, CorrClear and CorrWrite
• the function CorrRead

Basic approach
This is the general approach for setting up Path Corrections. For a detailed example
of how this is done, see Code example on page 310.
1 Declare the correction generator.
2 Connect the correction generator.
3 Define a trap routine that determines the offset and writes it to the correction
generator.
4 Define an interrupt to frequently call the trap routine.
5 Call a move instruction using the correction. The path will be repeatedly
corrected.

Note

The instruction CorrWrite is intended with low speed and moderate values of
correction. Too aggressive values will be clamped. The correction values should
be tested in RobotStudio to confirm the performance.

Note

If two or more move instructions are called after each other with the \Corr switch,
it is important to know that all \Corr offsets are reset each time the robot starts
from a finepoint. So, when using finepoints, on the second Move instruction the
controller does not know that the path already has an offset. To avoid any strange
behavior it is recommended only to use zones together with the \Corr switch
and avoid finepoints.

Limitations
It is possible to connect several correction generators at the same time (for instance
one for corrections along the Z axis and one for corrections along the Y axis).

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 10 Engineering tools
10.2.1 Overview
Continued

However, it is not possible to connect more than 5 correction generators at the

same time.
After a controller restart, the correction generators have to be defined once again.
The definitions and connections do not survive a controller restart.
The instructions can only be used in motion tasks.

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10 Engineering tools
10.2.2 RAPID components

10.2.2 RAPID components

Data types
This is a brief description of each data type in the option Path Corrections. For
more information, see the respective data type in Technical reference
manual - RAPID Instructions, Functions and Data types.
Data type Description
corrdescr corrdescr is a correction generator descriptor that is used as the
reference to the correction generator.

Instructions
This is a brief description of each instruction in the option Path Corrections. For
more information, see the respective instruction in Technical reference
manual - RAPID Instructions, Functions and Data types.
Instruction Description
CorrCon CorrCon activates path correction. Calling CorrCon will connect a
correction generator. Once this connection is made, the path can be
continuously corrected with new offset inputs (for instance from a
sensor).
CorrDiscon CorrDiscon deactivates path correction. Calling CorrDiscon will
disconnect a correction generator.
CorrClear CorrClear deactivate path correction. Calling CorrClear will dis-
connect all correction generators.
CorrWrite CorrWrite sets the path correction values. Calling CorrWrite will
set the offset values to a correction generator.

Functions
This is a brief description of each function in the option Path Corrections. For more
information, see the respective function in Technical reference manual - RAPID
Instructions, Functions and Data types.
Function Description
CorrRead CorrRead reads the total correction made by a correction generator.

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 10 Engineering tools
10.2.3 Related RAPID functionality

10.2.3 Related RAPID functionality

The argument \Corr

The optional argument\Corrcan be set for some move instructions. This will enable
path corrections while the move instruction is executed.
The following instructions have the optional argument\Corr:
• MoveL
• MoveC
• SearchL
• SearchC
• TriggL (only if the controller is equipped with the base functionality Fixed
Position Events)
• TriggC (only if the controller is equipped with the base functionality Fixed
Position Events)
• CapL (only if the controller is equipped with the option Continuous Application
Platform)
• CapC (only if the controller is equipped with the option Continuous Application
Platform)
• ArcL (only if the controller is equipped with the option RobotWare Arc)
• ArcC (only if the controller is equipped with the option RobotWare Arc)
For more information on these instructions, see respective instruction in Technical
reference manual - RAPID Instructions, Functions and Data types.

Interrupts
To create programs using Path Corrections, you need to be able to handle
interrupts. For more information on interrupts, see Technical reference
manual - RAPID Overview.

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10 Engineering tools
10.2.4 Code example

10.2.4 Code example

Linear movement with correction

This is a simple example of how to program a linear path with online path correction.
This is done by having an interrupt 5 times per second, calling a trap routine which
makes the offset correction.

Program code
VAR intnum int_no1;
VAR corrdescr id;
VAR pos sens_val;
PROC PathRoutine()
!Connect to the correction generator
CorrCon id;

!Setup a 5 Hz timer interrupt.

CONNECT int_no1 WITH UpdateCorr;
ITimer\Single, 0.2, int_no1

!Position for start of contour tracking

MoveJ p10,v100,z10,tool1;

!Run MoveL with correction.

MoveL p20,v100,z10,tool1\Corr;

!Remove the correction generator.

CorrDiscon id;

!Remove the timer interrupt.

IDelete int_no1;
ENDPROC
TRAP UpdateCorr
!Call a routine that read the sensor
ReadSensor sens_val.x, sens_val.y, sens_val.z;

!Execute correction
CorrWrite id, sens_val;

!Setup interrupt again

IDelete int_no1;
CONNECT int_no1 WITH UpdateCorr;
ITimer\Single, 0.2, int_no1;
ENDTRAP

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 10 Engineering tools
10.3 Auto Acknowledge Input

10.3 Auto Acknowledge Input

Description
The RobotWare base functionality Auto Acknowledge Input is an option that enables
a system input which will acknowledge the dialog presented on the FlexPendant
when switching the operator mode from manual to auto with the key switch on the
robot controller.

WARNING

Note that using such an input will be contrary to the regulations in the safety
standard ISO 10218-1 chapter 5.3.5 Single point of control with following text:
"The robot control system shall be designed and constructed so that when the
robot is placed under local pendant control or other teaching device control,
initiation of robot motion or change of local control selection from any other
source shall be prevented."
Thus it is absolutely necessary to use other means of safety to maintain the
requirements of the standard and the machinery directive and also to make a
risk assessment of the completed cell. Such additional arrangements and risk
assessment is the responsibility of the system integrator and the system must
not be put into service until these actions have been completed.

Limitations
The system parameter cannot be defined using the FlexPendant or RobotStudio,
only with a text string in the configuration file.

Activate Auto Acknowledge Input

The robot system must be installed with the option Auto Acknowledge Input using
the Modify Installation function.
Use the following procedure to activate the system input for Auto Acknowledge
Input.
Action
1 Save a copy of the configuration file [Link], using the FlexPendant or RobotStudio.
2 Edit the configuration file [Link], using a text editor. Add the following line in the
group SYSSIG_IN:
-Name "my_signal_name" -Action "AckAutoMode"
my_signal_name is the name of the configured digital input signal that should be
used as the system input.
3 Save the file and reload it to the controller.
4 Restart the system to activate the signal.

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 11 Tool control options
11.1.1 Overview

11 Tool control options

11.1 Servo Tool Change [3110-1]

11.1.1 Overview

Purpose
The purpose of Servo Tool Change is to be able to change tools online.
With the option Servo Tool Change it is possible to disconnect the cables to the
motor of an additional axis and connect them to the motor of another additional
axis. This can be done on the run, in production.
This option is designed with servo tools in mind, but can be used for any type of
additional axes.
Examples of advantages are:
• One robot can handle several tools.
• Less equipment is needed since one drive-measurement system is shared
by several tools.

What is included
The RobotWare option Servo Tool Change enables:
• changing tool online
• up to 8 different servo tools to change between.
Note that the option Servo Tool Change only provides the software functionality.
Hardware, such as a tool changer is not included.

Basic approach
This is the general approach for using Servo Tool Change. For a more detailed
description of how this is done, see Tool change procedure on page 319.
1 Deactivate the first tool.
2 Disconnect the first tool from the cables.
3 Connect the second tool to the cables.
4 Activate the second tool.

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11 Tool control options
11.1.2 Requirements and limitations

11.1.2 Requirements and limitations

Additional axes
To use Servo Motor Control, you must have the option Additional Axes. All additional
axes used by servo motor control must be configured according to the instructions
in Application manual - Additional axes.

Tool changer
To be able to change tools in production with a plug-in mechanism, a mechanical
tool changer interface is required.

en0300000549

All cables are connected to the tool changer. The tool changer interface includes
connections for signals, power, air, water, or whatever needs to be transmitted to
and from the tool.

Up to 8 tools
Up to 8 additional axes (servo tools or other axes) can be installed simultaneously
in one robot controller. Some of them (or all) may be servo tools sharing a tool
changer.

Moving deactivated tool

The controller remembers the position of a deactivated tool. When the tool is
reconnected and activated this position is used.
If the servo tool axis is moved during deactivation, the position of the axis might
be wrong after activation, and this will not be detected by the controller.
The position after activation will be correct if the axis has not been moved, or if
the movement is less than 0.5 motor revolutions.

Continues on next page

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 11 Tool control options
11.1.2 Requirements and limitations
Continued

Tip

If you have the Spot Servo option you can use tool change calibration.
After a tool is activated, use the instruction STCalib to calibrate the tool. This
will adjust any positional error caused by tool movements during deactivation.

Activating wrong tool

It is important to only activate a mechanical unit that is connected.
An activation of the wrong mechanical unit may cause unexpected movements or
errors. The same errors occur if a tool is activated when no tool at all is connected.

Tip

A connection relay can be configured so that activation of a mechanical unit is

only allowed when it is connected. See Connection relay on page 317.

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11 Tool control options
11.1.3 Configuration

11.1.3 Configuration

Configuration overview
The option Servo Tool Change allows configuration of several tools for the same
additional axis.
One individual set of parameters is installed for each gun tool.

How to configure each tool

Each tool is configured the same way as if it was the only tool. For information on
how to do this, see Application manual - Additional axes.
The parameter Deactivate PTC superv. at disconnect, in the type Mechanical Unit,
must be set to Yes.
The parameter Disconnect at Deactivate, in the type Measurement Channel, must
be set to Yes.
The parameter Logical Axis, in the type Joint, can be set to the same number for
several tools. Since the tools are never used at the same time, the tools are allowed
to use the same logical axis.
The parameter allow_activation_from_any_motion_task, in the type Mechanical
Unit, must be set for the specific servo gun. The servo gun .cfg files are created
by the servo gun manufacturer.
For a detailed description of the respective parameter, see Technical reference
manual - System parameters.

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 11 Tool control options
11.1.4 Connection relay

11.1.4 Connection relay

Overview
To make sure a disconnected mechanical unit is not activated, a connection relay
can be used. A connection relay can prevent a mechanical unit from being activated
unless a specified digital signal is set.
Some tool changers support I/O signals that specify which gun is currently
connected. Then a digital input signal from the tool changer is used by the
connection relay.
If the tool changer does not support I/O signals, a similar behavior can be created
with RAPID instructions. Set a digital output signal to 1 with the instruction SetDO
each time the tool is connected, and set the signal to 0 when the tool is
disconnected.

System parameters
This is a brief description of each parameter used to configure a connection relay.
For more information, see Technical reference manual - System parameters.
The following parameters have to be set for the type Mechanical Unit in the topic
Motion:
Parameter Description
Use Connection The name of the relay to use.
Relay Corresponds to the name specified in the parameter Name in the type
Relay.

The following parameters must be set for the type Relay in the topic Motion:
Parameter Description
Name Name of the relay.
Used by the parameter Use Connection Relay in the type Mechanical Unit.
Input Signal The name of the digital signal used to indicate if it should be possible to
activate the mechanical unit.

Example of connection relay configuration

This is an example of how to configure connection relays for two gun tools. gun1
can only be activated when signal di1 is 1, and gun2 can only be activated when
di2 is 1.
If the tool changer sets di1 to 1 only when gun1 is connected, and di2 to 1 only
when gun2 is connected, there is no risk of activating the wrong gun.
The following parameter values are set for gun1 and gun2 in the type Mechanical
Unit:
Name Use Connection Relay
gun1 gun1_relay
gun2 gun2_relay

Continues on next page

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11 Tool control options
11.1.4 Connection relay
Continued

The following parameter values are set for gun1 and gun2 in the type Relay:
Name Input Signal
gun1_relay di1
gun2_relay di2

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 11 Tool control options
11.1.5 Tool change procedure

11.1.5 Tool change procedure

How to change tool

This is a description of how to change from gun1 to gun2.
Step Action
1 Deactivate gun1 with the instruction:
DeactUnit gun1;
2 Disconnect gun1 from the tool changer.
3 Connect gun2 to the tool changer.
4 Activate gun2 with the instruction:
ActUnit gun2;
5 Optional but recommended:
Calibrate gun2 with the instruction:
STCalib gun1 \ToolChg;
Note that this calibration requires option Servo Tool Control or Spot Servo.

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11 Tool control options
11.1.6 Jogging servo tools with activation disabled

11.1.6 Jogging servo tools with activation disabled

Overview
Only one of the servo tools used by the tool changer may be activated at a time,
the others are set to activation disabled. This is to make sure that the user is jogging
the servo tool presently connected with right configuration.

What to do when Activation disabled appears

Follow these steps when you need to jog a servo tool but cannot activate the unit
because activation is disabled.
Step Action
1. Make sure that the right servo tool is mounted on the tool changer. If the wrong
tool is mounted, see Tool change procedure on page 319.
2. If no tool is activated, open the RAPID execution and activate the right tool.
3. If the right tool is mounted on the tool changer, deactivate the wrong tool and ac-
tivate the right tool from RAPID execution.

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 Index

Index Collision Avoidance, 235

Collision Delta Position, 254
collision detection
3 MultiMove, 222
3rd party software, 15
YuMi robots, 221
A Collision Detection Memory, 227
Absolute Accuracy, 165 Collision Error Handler, 228
MultiMove, 166 Collision LP Bandwidth, 254
Absolute Accuracy calibration, 176 Collision Speed, 254
Absolute Accuracy compensation, 174 commissioning, 258
Absolute Accuracy verification, 177 common data, 285
Acceleration Data, 255 communication, 36
Acceleration Derivate Ratio, 255 Commutator Offset, 255
Acceleration Max Uncalibrated, 257 compensation, 174
accidental disconnection, 258 compensation parameters, 165, 179
acknowledge messages, 74 compliance errors, 173
activate Absolute Accuracy, 168 configuration
activate supervision, 233 Absolute Accuracy, 168
activation disabled, 320 configure Collision Detection, 231
actor signals, 56–57 connection relay, 317
additional axes, 247 coordinate systems, 180
Advanced Shape Tuning, 190 CopyFile, 46
AliasIO, 53–54 CopyRawBytes, 42
alignment, 180 Corr argument, 309
analog signal, 87 CorrClear, 308
Analog Signal Interrupt, 87 CorrCon, 308
AND, 57 corrdescr, 308
Arm, 255 CorrDiscon, 308
arm replacement, 170 correction generator, 306
asynchronous movements, 248 CorrRead, 308
Auto acknowledge input, 13, 311 CorrWrite, 308
automatic friction tuning, 191 cross connections, 56
axis, 241 cut plane, 208
axis reset, 241 cut shape, 213
Cyclic bool, 28
B Cyclic bool settings, 34
binary communication, 37 Cyclic bool system parameters, 34
binary data, 74
birth certificate, Absolute Accuracy, 178 D
data, 62
C data types
calibrate follower axis, 103 Multitasking, 283
calibrate tool, 184 data variable example
calibration data, 168 Electronically Linked Motors, 112
Calibration Force High, 253 data variables
Calibration Force Low, 253 Electronically Linked Motors, 110
Calibration Mode, 253 Deactivate PTC superv. at disconnect, 316
Calibration Offset, 255 deactivate supervision, 233
calibration process, 176 Deceleration Derivate Ratio, 255
Calibration Time, 253 Deceleration Max Uncalibrated, 257
calibration tools, 167 declarations, 285
CalibWare, 167 deflection, 174
cell alignment, 180 Delay ramp, 254
certificate, Absolute Accuary, 178 digital I/O signals, 56
change calibration data, 168 dir, 46
character based communication, 37 directory management, 45
Check unresolved references, Task type, 281 discarded message, 64
CirPathMode, 210 Disconnect at Deactivate, 316
ClearRawBytes, 42 disconnection, 258
Close, 38 dispatcher, 290
CloseDir, 46 displacement, 111
Close position adjust, 253
Close time adjust, 253 E
code example, 261 Electronically Linked Motors, 96
collision, 224 errdomain, 85
Collision Alarm Torque, 254 error sources in accuracy, 173
ErrRaise, 85

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Index

errtype, 85 Multitasking, 283

Ethernet, 297, 299 interrupt, 63, 87, 286
Event Preset Time, 93 iodev, 38
external axes, 223 IPers, 85
external axis, 241 IRMQMessage, 67
IsCyclicBool, 35
F IsFile, 46
fake target, 174 ISignalAI, 88
false triggering, 234 ISignalAO, 88
FFW Mode, 256
Fieldbus Command Interface, 49 J
FIFO, 63 Jog Collision Detection, 227, 231
file communication, 36 Jog Collision Detection Level, 227
file management, 45 Jog Collision Detection Level, 231
FileSize, 46 Joint, 98
file structures, 45 joint zones, 215
fine calibration, 260
fixed position events, 90 K
fixture alignment, 181 ke Phase to Phase, 255
FlexPendant, 292 kinematic errors, 173
follower, 96 Kp, Gain Position Loop, 256–257
Follower to Joint, 98 Kv 1 - 6, 254
Force Master, 254 Kv, Gain Speed Loop, 256
Force Master Control, 254 Kv, Gain Speed Loop, 257
Force Ready Delay, 253
frame relationships, 183 L
frames, 180 l_f_axis_name, 110
FricIdEvaluate, 197 l_f_axis_no, 110
FricIdInit, 197 l_f_mecunt_n, 110
FricIdSetFricLevels, 197 l_m_axis_no, 110
friction compensation, 190 l_m_mecunt_n, 110
Friction FFW Level, 195 Lag Control Master 0, 256
Friction FFW On, 195 licenses, 15
Friction FFW Ramp, 195 Linked M Process, 98
friction level tuning, 191 load calibration data, 168
FSSize, 46 Load Identification, 167
functions Lock Joint in Ipol, 98
Multitasking, 283 logical AND, 58
Logical Axis, 316
G Logical Cross Connections, 56
General RAPID, 228 logical operations, 56
GetMaxNumberOfCyclicBool, 35 logical OR, 58
GetNextCyclicBool, 35 loss of accuracy, 172
GetNumberOfCyclicBool, 35 lost message, 64
GetTrapData, 85 lost queue, 64
group I/O signals, 56 Lower Joint Bound, 255

I M
IError, 85 Main entry, Task type, 281
IndAMove, 244 maintenance, 170
IndCMove, 244 MakeDir, 46
Ind collision stop without brake, 228 manipulator replacement, 171
IndDMove, 244 Manipulator Supervision, 227
Independent Axes, 241 Manipulator Supervision Level, 227
independent joint, 223 manual friction tuning, 193
Independent Joint, 243 master, 96
Independent Lower Joint Bound, 243 Master Follower kp, 99
independent movement, 241 Max Current, 255
Independent Upper Joint Bound, 243 Max Follower Offset, 98
IndInpos, 244 Max Force Control Motor Torque, 253
IndReset, 244 Max Force Control Position Error, 256
IndRMove, 244 Max Force Control Speed Limit, 256
IndSpeed, 244 Max Offset Speed, 98
Inertia, 255 Max pos err. closing, 254
Input Signal, 317 measurement system, 244
installation, 258 mechanical unit, 293
instructions merge of messages, 74

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 Index

Motion Planner, 227 position event, 90

Motion Process Mode, 198 Post-synchronization Time, 253
MotionSup, 229, 233 power failure functionality, 82
Motion Supervision, 227 Process, 98
Motion Supervision Max Level, 227
Motion System, 228 Q
MotionTask, Task type, 282 queue handling, 63
Motor Calibration, 255 queue name, 63
motor replacement, 170
Motor Torque 1- 10, 253 R
Motor Type, 255 r1_calib, 168
MotSupOn, 230 Ramp time, 254
MotSupTrigg, 230 Ramp Time, 98
MoveCSync, 91 Ramp to real contact, 254
MoveJSync, 91 Ramp when Increase Force, 254
MoveLSync, 91 RAPID, 19
MultiMove RAPID components
collision detection, 222 Multitasking, 283
Multitasking, 279 RAPID Message Queue, 61
rawbytes, 42
N RawBytesLen, 42
NFS Client, 14, 299 raw data, 41
No. of speed limits, 254 ReadAnyBin, 38
Nominal Acceleration, 255 ReadBin, 38
Nominal Deceleration, 255 ReadDir, 46
non printable characters, 74 ReadErrData, 85
NORMAL, 281 ReadNum, 38
NoSafety, 281 ReadRawBytes, 42
NOT, 58 ReadStr, 38
Not Calibrated, 260 ReadStrBin, 38
Number of Stored Forces, 253 reconnect a servo tool, 258
record, 62
O recorded path, 271
offset_ratio, 110 recover path, 263
Offset Adjust Delay Time, 98 References Bandwidth, 254
Offset Speed Ratio, 98 relay, 317
Open, 38 RemoveAllCyclicBool, 35
OpenDir, 46 RemoveCyclicBool, 35
open source software, OSS, 15 RemoveDir, 46
OR, 57 RemoveFile, 46
RenameFile, 46
P replacements, 170
PackDNHeader, 50 reset, 244
PackRawBytes, 42 reset axis, 241
parameters reset follower axis, 105
accuracy compensation, 179 resolver offset calibration, 176
path, 82 RestoPath, 264
Path Collision Detection, 227, 231 resultant signal, 56–57
Path Collision Detection Level, 227, 231 Rev. Counter not updated, 260
path correction, 306 reversed movement, 224
pathrecid, 264 Rewind, 38
PathRecMoveBwd, 264 RMQEmptyQueue, 67
PathRecMoveFwd, 264 RMQFindSlot, 67
path recorder, 271 RMQGetMessage, 67
Path Recovery, 263 RMQGetMsgData, 67
PathRecStart, 264 RMQGetMsgHeader, 67
PathRecStop, 264 RMQGetSlotName, 67
PathRecValidBwd, 264 rmqheader, 67
PathRecValidFwd, 264 RMQ Max Message Size, 66
PC SDK client, 62 RMQ Max No Of Messages, 66
persistent variables, 284 rmqmessage, 67
PFRestart, 82 RMQ Mode, 66
Phase Inductance, 255 RMQReadWait, 67
Phase Resistance, 255 RMQSendMessage, 67
pitch, 173 RMQSendWait, 67
Pole Pairs, 255 rmqslot, 67
polling, 286 RMQ Type, 66

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Index

robot alignment, 182 SysHalt, 281

roll, 173 SysStop, 281
Rotating Move, 256 system parameters
routine call, 290 Multitasking, 281
system resources, 292
S
SafeMove Assistant, 238 T
SEMISTATIC, 281 Task, Task type, 281
sensor, 306 Task, type, 281
service, 258 taskid, 283, 294
service routines taskid, data type, 283
Electronically Linked Motors, 101 Task in foreground, Task type, 281
Servo Tool Change, 313 TaskRunMec, 293
set up Collision Detection, 231 TaskRunMec, function, 283
SetupCyclicBool, 35 TaskRunRob, 293
SG Process, 253 TaskRunRob, function, 283
shapedata, 217 tasks, 279, 288
shared resources, 292 data type, 283
signal, 286, 290 tasks, data type, 283
SocketAccept, 75 temporary world zone, 217
SocketBind, 75 TestAndSet, 292
SocketClose, 75 TestAndSet, function, 283
SocketConnect, 75 Ti Integration Time Speed Loop, 256–257
SocketCreate, 75 tip change calibration, 249
socketdev, 75 Tip Force 1 - 10, 253
SocketGetStatus, 76 tip wear calibration, 249
SocketListen, 75 tool calibration, 184
Socket Messaging, 72 tool change calibration, 249
SocketReceive, 75 tools, 167
SocketSend, 75 torque, 225
socketstatus, 75 torque 1 - torque 6, 254
soft servo, 223 Torque Absolute Max, 256
Soft Stop Timeout, 253 torque follower, 106
software licenses, 15 track motion, 223
speed, 225 Transmission, 256
speed_ratio, 110 Transmission Gear High, 243
Speed Absolute Max, 256 Transmission Gear Low, 243
Speed Limit 1 - 6, 254 Transmission Gear Ratio, 256
Speed Max Uncalibrated, 257 trapdata, 85
Squeeze Position 1 -10, 253 trap routine, 63
Stall Torque, 255 trap routines, 84
STATIC, 281 TriggC, 92
stationary world zone, 217 TriggCheckIO, 92
STCalcForce, 252 triggdata, 91
STCalcTorque, 252 TriggEquip, 91
STCalib, 252 triggering, 234
STClose, 252 TriggInt, 91
STIsCalib, 252 TriggIO, 91
STIsClosed, 252 triggios, 91
STIsIndGun, 252 triggiosdnum, 91
STIsOpen, 252 TriggJ, 92
STIsServoTool, 252 TriggL, 92
STOpen, 252 TriggLIOs, 92
StorePath, 264 TriggRampAO, 92
Stress Duty Cycle, 256 TrustLevel, Task type, 281
string termination, 74 TUNE_FRIC_LEV, 193
STTune, 252 TUNE_FRIC_RAMP, 193
STTuneReset, 252 TuneServo, 193
supervision level, 227, 229, 233 tuning, 233
Supervision Type, 256 tuning, automatic, 191
synchronizing tasks, 288 tuning, manual, 193
synchronous movements, 248 Type, Task type, 281
syncident, 288
syncident, data type, 283 U
SyncMoveResume, 264 uncalib, 168
SyncMoveSuspend, 264 Uncalibrated Control Master 0, 257
SysFail, 281 Unicode, 19

324 Application manual - Controller software OmniCore

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© Copyright 2019-2025 ABB. All rights reserved.
 Index

UnpackRawBytes, 42 WriteAnyBin, 38
unsynchronize, 103 WriteBin, 38
Update revolution counter, 260 WriteRawBytes, 42
Upper Joint Bound, 255 WriteStrBin, 38
Use Connection Relay, 317 WZBoxDef, 217
Use Linked Motor Process, 98 WZCylDef, 217
Use Process, 98 WZDisable, 218
Use ramp time, 254 WZDOSet, 218
Use Robot Calibration, 168 WZEnable, 218
WZFree, 218
V WZHomeJointDef, 218
verification, 177 WZLimJointDef, 218
WZLimSup, 218
W WZSphDef, 217
waiting for tasks, 288 wzstationary, 217
WaitSyncTask, 288 wztemporary, 217
WaitSyncTask, instruction, 283
WaitUntil, 286 Y
world zones, 215 yaw, 173
Wrist Move, 206
wrist replacement, 170 Z
Write, 38 zones, 215

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© Copyright 2019-2025 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 201315, China
Telephone: +86 21 6105 6666

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

[Link]/robotics
3HAC066554-001, Rev T, en

© Copyright 2019-2025 ABB. All rights reserved.

Specifications subject to change without notice.