Mastering EOAT for Your ABB IRB 6700 Robot

The ABB IRB 6700 is a powerhouse in industrial robotics, renowned for its robustness and high performance. However, like any advanced robotic system, its true potential is unlocked through the correct selection and integration of End-of-Arm Tooling (EOAT). Choosing and mounting the right EOAT is not just a mechanical task; it's a critical engineering decision that directly impacts the robot's efficiency, lifespan, and safety.

This guide, drawing from the IRB 6700 product manual, aims to provide integrators, engineers, and technicians with practical insights and best practices for EOAT selection and mounting. We'll go beyond a simple feature list to explore why these considerations matter and how to apply them for optimal performance.

Understanding Load Capacity: The Cornerstone of EOAT Selection

Before you even consider a specific tool, understanding the IRB 6700's load capabilities is paramount. Section 2.4.7 of the manual, "Loads," emphasizes that any loads mounted on the robot must be defined correctly and carefully. This isn't just a recommendation; it's fundamental to preventing "jolting movements and overloading motors, gears and structure."

Key Load Parameters to Master:

Payload

The maximum weight the robot can handle at its tool flange, including the EOAT and the workpiece.

Center of Gravity (CoG)

The position of the EOAT and workpiece's combined CoG is crucial. An offset CoG can significantly reduce the effective payload and increase stress on the robot.

Mass Moments of Inertia

This defines how the mass is distributed around the CoG and affects the robot's ability to accelerate and decelerate the load smoothly.

CAUTION: Incorrectly defined loads may result in:

Operational stops or major damage to the robot
Reduced performance, sluggish movements, path deviations
Premature failure of motors, gears, and structural components
Safety hazards due to unpredictable movements or dropped parts

Finding the Data & Defining in Software:

Product Specification

The primary source for detailed load diagrams, permitted extra loads, and their specific positions for your IRB 6700 variant is the "Product specification - IRB 6700 (3HAC044265-001)."

This document is essential for proper EOAT selection and integration.

Software Configuration

Critically, these loads aren't just physical considerations. They must be accurately defined in the robot's software using the IRC5 FlexPendant.

The "Operating manual - IRC5 with FlexPendant (3HAC16590-1)" details this process. Failure to do so can negate even the most careful physical calculations.

"Robot motor brake performance depends on any loads attached." Heavier or more complex EOAT will affect stopping times and distances, a crucial factor for safety cell design and cycle time optimization.

IRB 6700 Variant Payload Capacities

Variant	Payload (kg)	Reach (m)	Upper Arm Load (max)	Frame Load (max)
IRB 6700-235/2.65	235	2.65	50 kg	250 kg
IRB 6700-205/2.80	205	2.80	50 kg	250 kg
IRB 6700-175/3.05	175	3.05	50 kg	250 kg

Note: Maximum allowed arm load depends on center of gravity of arm load and robot payload. Always consult the full product specification.

Beyond the Flange: Mounting Locations & Permissible Loads

While the primary EOAT attaches to the tool flange, the IRB 6700 allows for additional equipment to be mounted on the upper arm, lower arm, and frame (section 2.4.8 "Fitting equipment to the robot"). This is vital for integrating sensors, valve packs, or other auxiliary devices.

Important Note:

Always remember: "Maximum allowed arm load depends on center of gravity of arm load and robot payload." Both factors interact and must be considered together.

The Tool Flange: Your EOAT's Critical Interface

The tool flange is the physical connection point for your primary EOAT. The IRB 6700 offers different options to suit your application needs.

Standard Tool Flange

This is the default interface. Section 2.4.8 provides a detailed drawing with dimensions critical for designing your EOAT adapter plate.

Key features include bolt hole patterns, spigot diameter for centering, and overall dimensions. Always refer to the manual for exact specifications when designing your EOAT mounting plate.

LeanID Tool Flange (Option 780-4)

LeanID is an ABB solution for integrated dresspacks, routing cables and hoses through the robot's arm. If your IRB 6700 is equipped with LeanID (option 780-4), it will have a different tool flange, also detailed in section 2.4.8.

The LeanID flange facilitates a cleaner setup with reduced risk of cable snagging. However, be aware of specific working range considerations for axes 5 and 6 with LeanID.

Working Range Considerations with LeanID

This diagram illustrates the allowed working area for axis 6 based on axis 5's position, which is crucial for path planning with LeanID.

Standard Working Range

Axis 5: ±130°
Axis 6: ±360° (±93.7 revolutions max)

LeanID Working Range

Axis 5: ±120°
Axis 6: ±220° (varies based on axis 5 position)

Practical Mounting: Holes, Modifications, and Best Practices

Section 2.4.8, "Holes for fitting extra equipment," provides visual guidance on where additional equipment can be attached to the upper arm, lower arm, and frame.

Utilizing Existing Holes

The manual shows predefined hole patterns (M10, M8, M6) on various parts of the robot structure. These are the preferred attachment points for any additional equipment.

Drilling New Holes – A Word of Caution

"Unauthorized modifications of the originally delivered manipulator are prohibited. Without the consent of ABB it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength could be affected."

— Section 1.2.3.3 of the IRB 6700 manual

However, section 2.4.8 also shows an "Allowed position for attachment holes, M12 through. Be careful not to touch the cables when drilling."

Interpretation: While general modification of castings is forbidden, there are specific, designated zones where through-holes might be permissible. Always consult ABB before drilling any holes.

Critical Torque Specifications

When mounting equipment to the IRB 6700, using the correct torque values is essential for safe and reliable operation. Below are some key torque specifications:

Connection Point	Bolt Size	Torque Value
Tool Flange Mounting	M6	10 Nm
Upper Arm Mounting	M10	47 Nm
Frame Mounting	M12	115 Nm

Always refer to the manual for the complete torque specifications based on the specific connection point and screw type.

Safety and Performance: Beyond Physical Mounting

Regular Inspections: Maintaining EOAT Performance

While not explicitly detailed for EOAT in this manual's maintenance schedule, it's best practice to regularly inspect the EOAT, its mounting hardware, and any associated cabling for wear, damage, or looseness.

Fasteners

Check for loose bolts, damaged threads, or signs of vibration-induced loosening. Re-torque as needed according to specifications.

Connections

Inspect electrical and pneumatic connections for secure attachment, proper strain relief, and signs of wear or damage.

Moving Parts

Check for smooth operation, proper lubrication, and absence of binding or excessive play in any moving components of the EOAT.

EOAT Selection and Integration Flowchart

                                    flowchart TD
                                        A["Start EOAT Selection"] --> B["Define Application Requirements"]
                                        B --> C["Determine Required Payload Capacity"]
                                        C --> D["Check Robot Variant Specifications"]
                                        D --> E{"Is Payload Within Robot Capacity?"}
                                        E -->|No| F["Reconsider EOAT Design or Robot Variant"]
                                        F --> B
                                        E -->|Yes| G["Select EOAT Type Based on Application"]
                                        
                                        G --> H["Calculate Total Weight and CoG of EOAT + Workpiece"]
                                        H --> I["Check for Additional Equipment Needs"]
                                        I --> J{"Additional Equipment Required?"}
                                        
                                        J -->|Yes| K["Select Mounting Location (Upper Arm, Frame)"]
                                        K --> L["Verify Location's Load Capacity"]
                                        L --> M{"Within Load Limits?"}
                                        M -->|No| N["Redesign or Relocate Equipment"]
                                        N --> K
                                        M -->|Yes| O["Plan Cable/Utility Routing"]
                                        J -->|No| O
                                        
                                        O --> P{"LeanID Option Installed?"}
                                        P -->|Yes| Q["Design for LeanID Tool Flange"]
                                        Q --> R["Consider Axis 5/6 Range Limitations"]
                                        P -->|No| S["Design for Standard Tool Flange"]
                                        R --> T["Physical Integration and Mounting"]
                                        S --> T
                                        
                                        T --> U["Configure Load Data in IRC5 Controller"]
                                        U --> V["Test and Validate Movements"]
                                        V --> W["Implement Safety Measures"]
                                        W --> X["Document TCP and Load Parameters"]
                                        X --> Y["End"]
                                        
                                        classDef blue fill:#0099D8,color:white;
                                        classDef yellow fill:#FFD700,color:black;
                                        
                                        class A,Y blue;
                                        class E,J,M,P yellow;

This flowchart illustrates the complete process for selecting, integrating, and configuring EOAT for the IRB 6700 robot.

Lifecycle Management and Long-Term Considerations

The design and implementation of your EOAT play a significant role in achieving the expected operational lifespans of robot components.

Meeting Expected Component Life

IRB 6700 Component Lifespans

Cable Harness: 20,000 to 40,000 hours (depending on usage)
Gearboxes: 40,000 hours
Balancing Device: 40,000 hours

Adhering to the load, CoG, and inertia specifications for your EOAT is not just about immediate performance; it's about minimizing undue stress that could shorten these lifespans.

Accelerated Wear from Poor EOAT Design

An EOAT that is excessively heavy, has a CoG far from the flange, or introduces high vibrational loads can significantly accelerate wear on:

Gearboxes: Increased backlash, premature wear of gear teeth, and potential seal failure.
Motors: Overheating and increased strain, leading to reduced efficiency and lifespan.
Cable Harness: Excessive or erratic movements due to poorly damped EOAT can lead to premature wear on the internal cabling, especially around axes 2 and 3.
Balancing Device: Consistently operating with an unbalanced or overly heavy EOAT can lead to increased stress on its components.

EOAT-Specific Maintenance

The EOAT, being a custom or third-party component, requires its own dedicated maintenance plan beyond the robot's standard schedule.

Key EOAT Inspection Points:

Fasteners: Check torque of bolts securing the EOAT to the robot flange
Actuators: Inspect pneumatic cylinders for leaks, electric motors for unusual noise
Gripper Fingers/Surfaces: Check for wear, damage, or material buildup
Sensors: Clean lenses/faces, verify alignment and functionality
Cabling & Hoses: Look for chafing, kinking, loose connections
Lubrication: Apply as needed per manufacturer specifications

Documentation and Change Management

In a dynamic production environment, EOAT might be modified, swapped for different tasks, or replaced due to wear. Proper documentation is vital.

Essential Documentation:

Detailed design drawings and bill of materials (BOM)
TCP coordinates and tool load data records
Program backups including tool data files (.TDM)
Maintenance checklists and schedules
Change management procedures for EOAT modifications

The "Total Cost of Ownership" Perspective

When selecting or designing EOAT, consider these factors beyond the initial purchase price:

Initial Cost

Purchase price or fabrication cost

Integration Cost

Time and effort to mount, cable, program, and calibrate

Maintenance Cost

Spare parts, labor, consumables

Downtime Cost

Lost production due to EOAT failure

Performance Impact

Effect on cycle time, accuracy, and product quality

Longevity

Durability and expected service life

Environmental Considerations and EOAT Material Selection

Conclusion: Precision and Diligence are Key

Effectively choosing and mounting End-of-Arm Tooling for your ABB IRB 6700 is a blend of understanding its mechanical capabilities, adhering to safety principles, and meticulously configuring its control system.

Key Takeaways:

Consult the Product Specification

This is your ultimate guide for load capacities, CoG limits, and inertia for your specific IRB 6700 variant.

Accurate Software Definition

Physical mounting is only half the battle; loads must be correctly defined in the IRC5 software.

Respect Mounting Guidelines

Utilize designated mounting points and understand the implications of any modifications.

Prioritize Safety

Design EOAT to fail-safe and consider the impact of loads on robot dynamics and stopping.

Choose the Right Flange

Understand if the standard or LeanID flange better suits your application and dresspack needs.

Document Everything

Maintain detailed records of EOAT design, TCP values, load data, and maintenance procedures.

By diligently applying the information found in the IRB 6700 manual and its associated documents, you can ensure your robot and its EOAT work harmoniously, delivering the performance, reliability, and safety expected from an ABB robotic solution.

Load Capacity

Tool Flange

Safety & Longevity