User manual ABB IRB 1400

Master's Thesis Vision-based control on an industrial robot with a webcam
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ABB IRB 1400 robot with corresponding S4-controller (M94A software) Sébastien Ducatteeuw Martijn Jaeken 2010-2011 Group T - Leuven Deze gebruikershandleiding is ook beschikbaar in het Nederlands en kan op de volgende plaats worden geraadpleegd: http://en.wikiversity.org/wiki/Gebruikershandleiding_ABB_IRB_1400

I made a movie of the working setup and can be downloaded here: http://dl.dropbox.com/u/6537121/demo.3gp

The paper and appendix (Dutch) can be downloaded here: http://dl.dropbox.com/u/6537121/paper.pdf http://dl.dropbox.com/u/6537121/appendix.pdf

CONTROLLER

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 * 1) Turn the drive's automatic circuit breaker in its upward position.  irb14003.jpg irb14004.jpg
 * 2) Turn on the controller by turning the big black button clockwise.  irb14005.jpg
 * 3) Make sure no emergency stop is pushed and the door of the safety cage is closed. Now press the O-button to reset all the emergency stops.  irb14006.jpg
 * 4) Press the start/stop button on the drive to remove the error.  irb14007.jpg irb14008.jpg
 * 5) Turn the key to the left so that the automatic mode becomes activated. This must be confirmed on the Teach Pendant (TP) by pressing OK.  irb14009.jpg irb140010.jpg
 * 6) Press the I-button to start the engines.  irb140011.jpg
 * 7) Load the program "LAURA" on the TP (File – 1 Load Program). Use the arrows and the enter key to select the right program.  irb140012.jpg
 * 8) When the program is loaded, start it by pressing the Start button on the TP.  irb140013.jpg irb140014.jpg
 * 9) It is best to execute the remark about the autofocus at this point (and after this ./PC on the computer).


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PC

 * 1) Turn on the PC in the Linux OS (Ubuntu 10.04 LTS with kernel version 2.6.32-29-generic)
 * 2) Open the terminal and go to the following directory where the program is located (cd Documents/libserial-0.6.0rc1/examples/thesis/)
 * 3) If necessary, compile the code by entering following command: gcc -ggdb -I/usr/local/include/opencv -o PC PC.cpp -L/usr/local/lib -lml -lcvaux -lhighgui -lcv -lcxcore -lserial
 * 4) Run the code with ./PC
 * 5) To terminate the program, press Ctrl+C.


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REMARKS

 * There may never, ever be someone inside the cage when the robot is operating.
 * There are three emergency stop buttons in the system: the big red button on the controller, the big red button on the TP and opening of the cage.
 * Do not forget to connect the serial cable to the parallel port on the controller before beginning..
 * Step 4 (PC) may only be done when step 8 (CONTROLLER) is executed. Beware that there is an integrated timeout and you will have to execute both steps within 60 seconds. If a timeout error does occur on the TP, you will have to press OK first and afterwards retry the last step.
 * When shutting down the entire setup, shut down the controller first before setting the drive's automatic circuit breaker in its downward position.
 * If one chooses not to integrate the conveyor belt in the emergency stop circuit, it can be disabled (or enabled) by following this procedure on the drive:
 * 1) menu
 * 2) LG – enter (long)
 * 3) =30= – enter
 * 4) 3003 – enter (long)
 * 5) 0 (disable) of 4 (enable) – enter
 * 6) 2x menu
 * By not integrating the conveyor belt in the emergency stop circuit, step 4 (CONTROLLER) can be skipped.


 * It is possible to disable the autofocus feature of the webcam. Go to Applications – Sound & Video – guvcview and let the webcam focus one last time on a block right below him (when the robot is in its starting position) such that the image is sharp in this position. Disable ‘Focus, Auto’ and press Quit. You will have to do this after every reboot to keep the autofocus disabled. In this tab you can also play with the settings for Brightness (118), Contrast (0) and Saturation (100).
 * Make sure that the webcam is facing downwards at all times. An error of just a single degree can be blown up enormously because of the height above the conveyor belt!
 * When the emergency button is pushed or the emergency circuit is activated, turn the key back into its middle position and follow controller step 3 until 6. It is best to let the program start from the beginning (Edit – 2 Start from Beginning – OK). Possible errors on the TP can be removed by pushing OK.
 * Please (if possible) do not stop the program (by pushing the red button on the TP) if the conveyor belt is still moving. If you do stop it at this moment, no command will be executed to stop the conveyor belt. When this scenario occurs, turn the key back into its middle position. Go to the I/O menu on the TP and put doStartConv1 to 0 manually. Step 5 and 6 (controller) should be executed again. Eventually start the program from the beginning.
 * The login details of the used Linux computer are the following:
 * User: robotuser
 * Password: irb1400