© Robotics - 1 -

01-10-24

overview
IRC5 Controller
 Flexible Controller

 Control module
 Contains computer unit, safety
interface, control panel, space for
standard and customer options
 Drive module
 Contains drive system, axis computer,
transformer, mains connection & filter
 Building block for MultiMove
application (up to 4 drive cabinets
connected to a single control cabinet)
© Robotics - 2
 Control Module

A. Customer I/O power

supply
B. Control panel
C. Main switch
D. System power supply
E. Computer unit
© Robotics - 3
 Drive Module: Small robot with external axes
K42 K43 Drive units Rectifier
*Capacitor

Axes
computer

Drive units
for ext axis
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* Empty for small robots, if no external axes

 Process Module (for Flexible controller)

 Integration of application
package, e g SpotWeld
 Installation of customer
equipment, e g extra I/O
 Integrated in the same
encapsulation family.
 Same interface layout as in
Control Module
© Robotics - 5
 New Module Family Concept (“Design 2006”)

 One size does not fit all!

 Flush sides for reduced floor space
 Front access
 All modules fit on top of each other
 No air filter
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 Full combined M2000 and M2000A capability

 New Modules (”Design 2006”)
 Single cabinet controller and process module added
 Module range enables optimization for different customer needs
 ONE IRC5 family! Not different controllers nor different positioning
© Robotics - 7
 Dual Cabinet Controller (”Design 2006”)

 Redesigned with the same encapsulation principles as the new Single

Cabinet Controller (=”Design 2006”)
 Minor changes to customer spec
 height increase 50 mm (for improved serviceability)
 new flexible internal fastening system
 new arrangement of I/O modules
 Replaces the previous design in January ‘06
© Robotics - 8
 Single Cabinet Controller
 Drive and control functions combined in one
cabinet
 New ”Design 2006” encapsulation
 Clean AluZinc cabinet
(only front painted)
 resistant to environmental
influence
 self healing if scratched
 Dimensions 970 x 725 x 710 (H x D x W)

900
 Full option range, including MultiMove
 Max 2 internal I/O units (compared to 4)
 Less connector space
© Robotics - 9
 Inside IRC5 Single Cabinet Controller
Power supply Computer unit
units Panel unit (safety interface)
Computer UltraCap
(right inside wall)

Power ON/OFF
Manipulator signal
interface

Operator´s panel

Service
ports Drive unit Customer (I/O) space
USB (option)
Ethernet
section
FlexPendant
connection
Axis computer
Options: (right inside wall)
Duty Time Counter
230/120 V service
outlet Power intake
Motors On contactors
Manipulator connections
and interface board
(left inside wall) Customer connections
(behind optional cover)
© Robotics - 10
 Single Cabinet Controller
© Robotics - 11
 Process Module

 Extension for more customer equipment space

 Common look and feel
 Fits on top of any other module (Control Module, Single
Cabinet Controller, Drive Module)
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 Other new HW options (design 2006)

 Inline wheels  Protection bar

 Air filter
 Metal grid stops
> 0.5 mm particles

 Cable gland
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 Other new HW options (design 2006) (cont.)
 Installation kit
 10 side mounting brackets + 30 screws

 3 floor mounting brackets

 1 cable protection for door cabling

 1 side mounting plate with terminal rail (fits left and

right)

 1 floor/door mounting plate

 1 dividable cable gland for connector hole

© Robotics - 14
 Differentiation

 Single Cabinet Controller

 The ”standard” controller
 Dual Cabinet Controller
 Premium version for higher demands
 Differentiating selling points vs. single cabinet and vs.
competition
 More connector space
 More internal space
 Distributability
 Minimized height (with modules side by side)
 Offers possibility to convert a MultiMove system to multiple
single systems by adding control module
© Robotics - 15
 3 Single Robot IRC5 Configurations

C
P C D

+ Distributed solutions

P C < 75m D
© Robotics - 16
 Example of a Multi Robot Configuration

R2

With external
operator panel
R1 R3

O Minimized
cable needs
C P P
FlexPendant
D1 D2 D3
© Robotics - 17
 IRC5 HW Overview

Control module Drive module

Power &
Power
UPS Panel IRB xxx
Drive
Safety Safety
USB
LAN
MC AXC SMB
Service

I/O, Sensors and Drives Motor

Process equipments

S4CPlus
© Robotics - 18

Carry over
 Field buses

 Fieldbuses
 DeviceNet Master/Slave one or dual channel
 Profibus DP Master/Slave
 Interbus Master/Slave
 Both copper-wire and fiber-optic interface available
 EtherNet-IP slave  
                                 
                                 
                                
                               
© Robotics - 19
 IRC5 SW Overview

Process support

Pendant
System
& Network Motion Axis
Resource Rapid
PC Com. control control
Manager
Applications

Win.Net Platform isolation layer and system architecture Blue S4

Carry over

HW Support
© Robotics - 20
 IRC5 FlexPendant

 Intuitive standard screens

 3 ax joystick
 8 hard keys (4 customizable)
 User Authorization System, allowing
defined access levels for different
user groups
 Hot Plug - possibility to connect and
disconnect during operation
 Asian character support
 Right and left-handed support
 Swap HMI language without restart
© Robotics - 21
 IRC5 FlexPendant continue
© Robotics - 22
 IRC5 FlexPendant continue

Emergency stop
Graphical colour touch screen

4 Hard keys for fast access

Assignable

3-way joystick

4 Hard keys for running programs

Start
Execute Backward/Forward
Stop program
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 IRC5 FlexPendant continue

ABB Menu Status bar

Main menu

Windows style
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“switch between
open windows/views” Quickset Menu
 IRC5 FlexPendant continue

 ABB Main Menu

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 IRC5 FlexPendant continue

 Inputs and Outputs (I/O Window).

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 IRC5 FlexPendant continue

 Jogging window
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 IRC5 FlexPendant continue

 Quickset Menu
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 IRC5 FlexPendant continue
 Ability to build custom applications  Online and offline
with full use of graphics and development with Virtual
controller information. IRC5.
 Microsoft Technologies with
powerful, standard, development
tools.
© Robotics - 29
 IRC5 FlexPendant & R.S.O

 FlexPendant and RobotStudioOnline work together

© Robotics - 30
 PC Appl. Example, RobotStudio-Online

 Install and configure the robot

controller to your needs
 Setup and download RobotWare
systems
 Easy and controlled change of system
parameters
 Monitor I/O signals
 Basic RAPID editing
 Touch up
 Managing production data
 Record events
 Backup and restore controller data
© Robotics - 31
 External Control Panel

 External Control Panel allow

easy access close to the cell

FlexPendant
© Robotics - 32