Unpacking the Potential
The ABB IRB 6700 family represents a significant evolution in heavy-payload industrial robotics, designed for high performance, reliability, and lower total cost of ownership. This article delves into the essential aspects covered in the product manual, offering practical insights and highlighting critical information for engineers, technicians, and integrators working with these powerful machines.
Whether you're involved in installation, commissioning, routine maintenance, or ensuring operational safety, understanding the nuances of the IRB 6700 is crucial. This guide synthesizes key information from the manual, particularly focusing on areas that require careful attention for optimal performance and longevity.
"The IRB 6700 isn't a single robot but a family with distinct payload and reach capabilities, allowing for tailored selection based on specific application demands."
| Model | Payload | Reach | Applications |
|---|---|---|---|
| IRB 6700 - 235/2.65 | 235 kg | 2.65 m | Heavy material handling |
| IRB 6700 - 205/2.80 | 205 kg | 2.80 m | Machine tending, heavy assembly |
| IRB 6700 - 175/3.05 | 175 kg | 3.05 m | Spot welding, material handling |
| IRB 6700 - 150/3.20 | 150 kg | 3.20 m | Extended reach applications |
Understanding the working range is fundamental during cell design. The manual provides detailed diagrams for each variant illustrating the operational envelope. Notably, Axis 1 offers a substantial ±170° rotation, while wrist axes (4, 5, and 6) provide significant dexterity.
Quick Facts
- IP67 protection standard for all variants
- Optional Foundry Plus protection for harsh environments
- LeanID option modifies Axis 5 and 6 working ranges
- Operating temperature range: +5°C to +50°C
- Foundation resonance frequency must be min. 22 Hz
Related Resources
Installation: Precision and Safety from the Start
Foundation First
The foundation must be level (max deviation 0.2mm) and rigid (min resonance frequency 22 Hz). Tilting the robot is generally not recommended without consulting ABB, as it impacts payload capacity.
Transportation
The manual strongly recommends transportation method 1 (tool removed, robot in transport position). Method 2 is acceptable only if method 1 is impossible. Incorrect transport can cause severe damage and void the warranty.
Stability is Key
An unsecured IRB 6700 is mechanically unstable. Do not change the robot's configuration from the shipping position before it's securely bolted to the foundation using M24 screws (625 Nm torque).
Installation Workflow
Lifting Procedures
Only use approved lifting methods for the IRB 6700. Incorrect lifting procedures can cause serious damage to the robot or risk personnel safety.
Forklift Method
- Requires the specific Fork Lift Device Set (3HAC047054-002)
- Must be fitted as per diagram xx1300001602
- Lift only with all four pockets fitted properly
- Follow path clearance requirements
Roundslings Method
- Requires specific configuration (xx1300001574)
- Uses M20 lifting eyes and multiple slings of defined lengths/capacities
- Careful sling placement to avoid interference
- Secure against brake release unit contact
Working Range Restriction
For safety or process needs, Axis 1's working range can be mechanically limited using optional stops (3HAC044287-001) fitted as shown in diagram xx1300001971.
Important Considerations
- Software parameters (system parameters manual 3HAC17076-1) must also be adjusted to match the mechanical limits.
- Incorrect load definition can lead to poor performance, operational stops, or even robot damage.
- Always define mass, center of gravity, and moments of inertia correctly in the IRC5 controller software.
Safety: Non-Negotiable Priority
Critical Safety Information
The manual dedicates significant attention to safety, reflecting the potential hazards of working with large industrial robots. The system integrator is responsible for ensuring the overall cell safety complies with local standards.
Emergency Stops
Understand the difference between uncontrolled (Category 0) and controlled (Category 1) emergency stops. Controlled stops are preferred to minimize wear. E-stops are for emergencies only, not routine program stops.
FlexPendant Usage
The enabling device (three-position switch) is critical for safe manual operation. Never bypass it. Always take the FlexPendant into the cell when working inside the safeguarded space. Reduced speed mode (max 250 mm/s) should be the default for manual intervention.
Specific Hazards
Moving Parts
Unexpected movements can be lethal. Ensure safety guards are active.
Hot Surfaces
Motors and gearboxes get hot during operation.
Electrical Hazards
High voltage (up to 800 VDC) is present. Always switch off and lock out main power before maintenance. Be aware of stored energy in capacitors.
Stored Energy (Balancing Device)
Contains high-tension springs. Never attempt to disassemble it yourself. Follow manual procedures strictly for removal and use designated tools for unloading.
Pneumatic/Hydraulic Systems
Residual pressure can exist after shutdown. Depressurize before work.
Safety Labels
Pay attention to the graphical safety labels on the manipulator. These include warnings for:
- Stored energy (xx1300001086)
- Tipping risk (xx1300001087)
- Lifting instructions (xx1300001084)
- Pinch points and crushing hazards
- Electrical shock warnings
Remember
Never disable safety features or attempt to override safety circuits. Always follow proper lockout/tagout procedures before maintenance.
Complete Safety GuideMaintenance: Ensuring Longevity and Performance
Regular maintenance is vital for the IRB 6700's lifespan and reliability. The manual provides a detailed schedule with intervals based on operating hours (Duty Time Counter - DTC) or calendar time.
Oil Level Inspections
Critical for gearbox health. The manual provides specific procedures and diagrams for checking levels in all six axes.
- • Different required levels (below plug hole vs. specific depth)
- • Use specific oil inspection tools
- • Check at regular intervals per maintenance schedule
Oil Changes
Required at longer intervals (e.g., 20,000 hours). Use the exact type of oil specified in the Technical reference manual.
- • Procedures detail using an oil dispenser
- • Safety precautions for hot oil and pressure
- • Specific oil types for each axis
Balancing Device
Requires inspection for noise, damage, leakage, and contamination. Lubrication of the front spherical roller bearing is also scheduled.
- • Expected life around 40,000 hours
- • Depends heavily on usage patterns
- • Never disassemble without proper training
Cable Harness
Inspect regularly for wear, especially around axes 2 and 3. Replace if damage or excessive wear is found.
- • Life expectancy varies with usage
- • Refer to diagram xx1300001095 for inspection points
- • Check for abrasion and fatigue
SMB Battery
Replace at scheduled intervals or when the "Battery charge low" alert (38213) appears. Keep the controller powered on until replacement to avoid losing revolution counter data. Update revolution counters after replacement.
Pro Tip: Consider keeping a spare SMB battery on hand to minimize downtime during replacement.
Maintenance Schedule
Daily/Weekly
- • Visual inspection
- • Cleaning as needed
- • Check for unusual noise
6 Months / 4,000 Hours
- • Check oil levels
- • Inspect cable harness
- • Check all connections
12 Months / 10,000 Hours
- • Lubricate balancing device bearing
- • Check brake function
- • Replace SMB battery (if needed)
36 Months / 20,000 Hours
- • Change gearbox oil
- • Inspect balancing device
- • Replace critical seals
Cleaning
Methods depend on the protection type (Standard vs. Foundry Plus - IP67 for both, but Foundry Plus allows steam cleaning).
Do:
- • Use mild detergents
- • Ensure protective covers are fitted before cleaning
- • Allow to dry completely before operation
Don't:
- • Use high-pressure water on Standard robots
- • Use harsh solvents or abrasives
- • Point water jets at seals/connectors
Consumables
Treat consumables as integral parts of the repair. Replacing O-rings and gaskets during major component overhauls is inexpensive insurance against future leaks and downtime.
| Item | Part Number |
|---|---|
| O-ring (Axis 1 Motor) | 3HAB3772-111 |
| Gasket (Axis 6 Motor) | 3HAC033489-001 |
| SMB Battery | 3HAC17824-1 |
Calibration: Restoring Precision
Calibration ensures the robot knows its exact position. It's required after replacing components affecting joint position (motors, gearboxes), losing revolution counter memory (e.g., SMB battery replacement), or after major structural repairs.
Updating Revolution Counters
The simplest form of calibration, needed after battery loss or if an axis was moved manually with power off. Uses calibration marks and the FlexPendant.
Crucial: Ensure axes 4 and 6 are returned to the correct turn before updating, especially on certain robot models.
Standard Calibration
Resets the robot to its nominal zero position using resolver values stored on the Serial Measurement Board (SMB). The Calibration Pendulum method is the standard and most accurate way.
Absolute Accuracy Calibration (Optional)
Compensates for mechanical tolerances and deflection for higher Cartesian accuracy. Requires CalibWare software. Standard calibration is often sufficient after component replacement if the robot structure isn't altered.
Calibration Workflow
Checking Calibration
Always verify the calibration position using MoveAbsJ or the jogging window after updates or calibration procedures.
Critical Procedures and Considerations
Advanced Repairs
Repairs range from simple battery replacement to major overhauls like replacing arm segments or core gearboxes.
Balancing Device
The balancing device contains high-tension springs and requires extreme caution during maintenance.
Electrical Connections
Proper connection and management of the robot's cabling are essential for communication, power delivery, and signal integrity.
Operating Environment and Protection
Environmental Limits
Temperature
Operating Range: +5°C to +50°C
Storage Range: -25°C to +55°C (short term up to +70°C)
Operating below +10°C may require a warm-up routine to counteract increased lubricant viscosity.
Humidity
Maximum 95% at constant temperature
High humidity, especially with temperature fluctuations causing condensation, can increase the risk of corrosion or electrical issues over time, even with IP67 protection.
IP67 Rating
Dust-tight and protected against temporary immersion in water.
Withstands typical industrial dust and coolant splashes well. However, it does not mean it's designed for continuous high-pressure washing or permanent submersion.
Protection Options
Standard Protection
- IP67 rated
- Suitable for general industrial environments
- Withstands standard cleaning procedures
- Not for high-pressure washing
Foundry Plus Protection
Premium- IP67 rated with enhanced materials
- Designed for harsh environments
- Withstands heat, spatter, aggressive cleaning
- Allows careful steam/high-pressure washing
Environment Assessment
Assess the intended operating environment carefully when selecting the robot variant and protection type. Operate within the specified temperature and humidity ranges. Implement cleaning procedures appropriate for the robot's protection level.
Conclusion
The ABB IRB 6700 is a powerful and versatile industrial robot designed for demanding applications. As highlighted throughout its comprehensive product manual, realizing its full potential requires meticulous attention to detail during installation, strict adherence to safety protocols, and a commitment to the prescribed maintenance schedule.
Understanding the specific requirements for transportation, foundation preparation, load definition, and the handling of critical components like the balancing device are paramount. Furthermore, regular inspections, timely lubrication using correct materials, and proper calibration procedures are essential for maximizing uptime and ensuring the robot's longevity.
By leveraging the insights provided in the manual and elaborated upon here, users can effectively deploy, operate, and maintain their IRB 6700 robots, ensuring safe, reliable, and efficient production for years to come. Always refer to the full product manual (3HAC044266-001) and its referenced documents for complete, step-by-step procedures and specifications.
Related Articles
Getting Started: IRB 6700 Unboxing & Initial Installation Checklist
Practical first steps for new users/installers.
IRB 6700 Variants Deep Dive: Payload, Reach & Performance
Detailed comparison of all IRB 6700 models from 150/3.20 to 235/2.65.
Diagnosing and Fixing Common IRB 6700 Problems
Solutions for frequently encountered issues including SMB communication errors.