In the field of industrial automation, especially in the coating industry, the precise operation of the robot plays a vital role in ensuring the quality of the final product. As an efficient and reliable solution, the ABB spray robot 5500/5510 series is widely used in various spraying operations. Among them, gap detection technology is an important function of these robots, which is directly related to the spraying quality and production safety. 1. The importance of gap detection
The gap detection function of ABB painting robots 5500/5510 is crucial for ensuring high-quality painting results. These robots are equipped with sensors and advanced algorithms to detect the gaps between the spray gun and the workpiece surface.
During operation, the sensors continuously measure the distance to accurately determine the gap. By analyzing this data, the robot can adjust its position and orientation in real-time. This adjustment ensures that the spray pattern remains consistent and the coating is evenly applied, avoiding issues like uneven thickness or overspray.
The gap detection also helps in preventing collisions. When the gap deviates from the preset value, the robot can take immediate corrective actions. This function significantly improves the precision and efficiency of the painting process, making ABB 5500/5510 robots highly reliable for industrial painting tasks.
During the use of the spray robot, the spline between the brake disc and the motor shaft will wear normally. Tests must be performed to determine the amount of clearance between the gears on axes 1, 2 and 3.
When is the test required: The manual requires inspection every 2500 hours.
To check the backlash (gap between teeth), a quick service procedure is used. This procedure can measure the rebound clearance at any position on axes 1, 2 and 3. This test can be performed without removing any equipment from the robot arm.
Accurate detection of gap detection
(1) Ensure spraying quality: Gap detection ensures that the robot maintains a consistent distance between the spray gun and the workpiece during the spraying process, thereby ensuring the uniformity and quality of the coating. This is particularly critical to meeting high quality standards.
(2) Preventing mechanical collisions: On complex production lines, gap detection can also help avoid accidental collisions between the robot and surrounding equipment or workpieces, reducing potential damage and downtime.
- Test method
- Set the operation mode selector to manual low-speed mode.
- Move the robot axes 1, 2, and 3 to a position where it will move 5 degrees for each axis.
- Select the “Editor” menu on the TPU main menu to open the “Quick Editor”.
- Load the service routine BrakeBacklash view from the serv route button in the editor.
- Activate the enable device on the teach pendant and keep it activated during the test program.
- Press the play button on the teach pendant.
- Result judgment
The robot will perform multiple rounds of inspections for each axis. After each axis test is completed, its results will be displayed on the screen in real time. If the test result exceeds the 1-degree threshold, the system will issue a warning message, indicating that the motor needs to be replaced.
The system will automatically generate and update a log file to record the information and running time of each test. The log file is stored in HOME:/logs/backlash_Check.log. - Notes
Since robotware 6.10.01, the relevant modules have been integrated into robotware. For systems using earlier versions of robotware, you need to manually add a test program to detect the gap.
Manual addition method: Place the BrakeBacklash file in the home-programs folder (imported through robotstudio connection). If you need to obtain the BrakeBacklash file, you can call ABB after-sales service for consultation.
In short, the gap detection system of ABB spraying robot 5500/5510 is a key technology to ensure the quality of spraying and the safe operation of the robot. Train operators and maintenance personnel to understand the working principle and operation method of the gap detection system to ensure that they can correctly handle daily problems and intervene quickly when necessary. Through correct configuration, maintenance and operation, this system can not only significantly improve production efficiency, but also extend the service life of the equipment, bringing greater value to the enterprise.