Foundation & Mounting: Ensuring Peak Performance and Safety for Your ABB IRB 6700

A comprehensive guide to the critical foundation and mounting requirements for one of industry's most powerful robots.

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The ABB IRB 6700 is a powerhouse industrial robot, known for its high payload capacity, reach, and robustness. But like any high-performance machine, its ultimate effectiveness and safety hinge on a fundamental, often underestimated element: a properly prepared and secured foundation. This article delves into the critical foundation and mounting requirements detailed in the IRB 6700 product manual, translating technical specifications into practical insights for installation personnel, maintenance teams, and system integrators.

Going beyond simply listing numbers, we'll explore why these requirements exist, the potential consequences of neglecting them, and practical considerations for ensuring your IRB 6700 operates at its peak from day one.

Why a Rock-Solid Foundation is Non-Negotiable

Think of the foundation as the launching pad for your robot's operations. The IRB 6700 exerts significant forces and torques during its high-speed, high-payload movements. An inadequate foundation can lead to:

Reduced Accuracy and Repeatability

Vibrations or shifts in the base directly translate to deviations at the Tool Center Point (TCP), compromising task precision.

Increased Mechanical Stress & Wear

An unstable base forces the robot's internal components (gears, bearings) to compensate, leading to premature wear and potential failures.

Safety Hazards

In extreme cases, insufficient mounting can lead to instability or even tipping, especially during emergency stops or high-inertia movements.

Operational Faults

Excessive vibration can trigger protective stops, interrupting production.

"Investing time and resources in a proper foundation isn't just about meeting specs; it's about safeguarding your investment, ensuring operational reliability, and maintaining a safe working environment."

Decoding Foundation Requirements: What the Specs Mean

The IRB 6700 manual specifies several key parameters for the foundation. Understanding the rationale behind these specifications helps ensure your installation achieves optimal performance:

Maximum Deviation from Levelness

0.2 mm

Why it Matters:

This ensures the robot base sits perfectly flat, preventing stress on the frame casting and ensuring the initial calibration geometry is maintained. Better flatness contributes to better repeatability.

Practical Implication:

Use precision leveling tools. If the foundation isn't perfectly flat, shimming might be necessary, but be aware that significant deviations might necessitate recalibration for optimal absolute accuracy.

Maximum Tilt

0° (Perfectly Level)

Why it Matters:

The robot is designed and load-rated for a level installation. Any tilt changes the forces acting on the axes due to gravity, potentially exceeding design limits and affecting performance, especially at maximum payload and reach.

Practical Implication:

Ensure the mounting surface is truly horizontal. If tilting is unavoidable for a specific application, contact ABB to understand the implications on payload and performance.

Minimum Resonance Frequency

22 Hz

Why it Matters:

This refers to the foundation's stiffness and resistance to vibration. The robot itself has operational frequencies; if the foundation's natural frequency is too close to the robot's, vibrations can be amplified, drastically affecting performance and stability. 22 Hz ensures the foundation is sufficiently rigid to dampen robot-induced vibrations.

Practical Implication:

This typically requires a substantial, well-engineered concrete slab or a very rigid steel structure designed to avoid frequencies below 22 Hz under load.

Understanding Foundation Loads: Forces and Torques

The manual provides values for the forces and torques the robot exerts on its foundation. These are crucial for structural engineers designing the mounting base.

Robot foundation force diagram
  • Fxy: Horizontal force in any direction.
  • Fz: Vertical force (includes robot weight + dynamic forces).
  • Txy: Bending torque (tilting) around X or Y axis.
  • Tz: Rotational torque around the Z axis (axis 1).
Force/Torque Endurance Load
(Normal Operation)		 Max. Load
(Emergency Stop)
Force xy ± 7.4 kN ± 19.8 kN
Force z 14.6 ± 4.5 kN 14.6 ± 15.7 kN
Torque xy ± 21.0 kNm ± 37.1 kNm
Torque z ± 5.0 kNm ± 11.4 kNm

Crucial Insight

The manual correctly notes that these maximum values are extreme conditions (like a high-speed emergency stop with maximum payload) and rarely, if ever, occur simultaneously. Design calculations should account for these peaks, but understanding the context prevents over-engineering based on unrealistic simultaneous maximums.

Installation Process Visualization

graph TD A[Prepare Foundation] -->|Meet 22 Hz requirement| B[Level Foundation] B -->|Max 0.2mm deviation| C[Position Base Plate] C --> D[Level Base Plate] D --> E[Anchor Base Plate] E --> F[Position Robot] F --> G[Guide with Sleeves] G --> H[Fasten Bolts] H -->|625 Nm torque
Criss-cross pattern| I[Final Check] style A fill:#e6f2fa,stroke:#0078d4,color:#005fa3 style B fill:#e6f2fa,stroke:#0078d4,color:#005fa3 style C fill:#e6f2fa,stroke:#0078d4,color:#005fa3 style D fill:#e6f2fa,stroke:#0078d4,color:#005fa3 style E fill:#e6f2fa,stroke:#0078d4,color:#005fa3 style F fill:#e6f2fa,stroke:#0078d4,color:#005fa3 style G fill:#e6f2fa,stroke:#0078d4,color:#005fa3 style H fill:#e6f2fa,stroke:#0078d4,color:#005fa3 style I fill:#e6f2fa,stroke:#0078d4,color:#005fa3 classDef critical fill:#f8d7da,stroke:#dc3545,color:#721c24 class H critical

The diagram above illustrates the complete installation process, with the critical fastening step highlighted in red.

The Base Plate: An Optional but Recommended Interface

ABB offers an optional base plate (P/N: 3HAC12937-7). While the robot can be mounted directly, the base plate offers advantages:

Simplified Leveling

Includes leveling bolts to precisely adjust the plate's flatness on a less-than-perfect foundation surface.

Accurate Positioning

Features orienting grooves and guide sleeve holes for precise robot placement.

Standardized Interface

Provides a well-defined mounting pattern.

Securing the Base Plate:

  1. Position: Place the base plate using the orienting grooves relative to the desired robot work location.
  2. Level: Use the integrated leveling bolts. Check flatness across the four robot contact surfaces (max deviation 0.2 mm). Use shims under the plate if necessary to fill gaps and achieve levelness.
  3. Anchor: Secure the plate to the foundation using appropriate anchor bolts (e.g., Hilti HDA-P M20 x 250/50 or /100, depending on plate thickness) as per the manufacturer's guidelines for the specific concrete grade (ABB recommends C25 or C30 minimum).

Securing the Robot: The Final Step to Stability

Once the foundation or base plate is prepared, the final step is mounting the robot itself. Remember: The IRB 6700 (approx. 1300 kg without DressPack/tooling) is inherently unstable until bolted down.

Safety Warning

The robot must remain in its stable shipping position until securely fastened to the foundation. Moving the axes can cause the robot to tip, creating a serious safety hazard.

ABB IRB 6700 robot

Mounting Procedure:

  1. Prepare: Ensure the robot is in its stable shipping position (or a similarly stable configuration) before lifting.
  2. Lift: Use appropriate lifting methods (forklift with ABB adapters, or roundslings as detailed in the manual). See Safe Lifting Techniques for the IRB 6700 for details.
  3. Position: Carefully lower the robot towards the foundation/base plate.
  4. Guide Sleeves: Fit two guide sleeves into the designated holes on the base plate or foundation template. These are crucial for accurate alignment as the robot is lowered.
  5. Lower: Gently lower the robot base onto the guide sleeves. Use M24 screws temporarily inserted into other holes to help guide it if needed.
  6. Fasten: Insert the four M24 x 100 (Quality 8.8) bolts with appropriate 4mm flat washers. Lightly lubricate the bolts before insertion.
  7. Torque: Tighten the bolts to the specified 625 Nm using a calibrated torque wrench. Crucially, tighten in a criss-cross pattern (like changing a car tire) to ensure even pressure and prevent distortion of the robot base.

Criss-Cross Torque Pattern

graph TD subgraph "Robot Base (Top View)" A((1)) --- B((3)) A --- D((4)) B --- C((2)) C --- D style A fill:#e6f2fa,stroke:#0078d4,color:#005fa3,stroke-width:4px style B fill:#e6f2fa,stroke:#0078d4,color:#005fa3,stroke-width:4px style C fill:#e6f2fa,stroke:#0078d4,color:#005fa3,stroke-width:4px style D fill:#e6f2fa,stroke:#0078d4,color:#005fa3,stroke-width:4px end T1[Step 1:
Tighten bolt 1] --> T3[Step 2:
Tighten bolt 3] T3 --> T2[Step 3:
Tighten bolt 2] T2 --> T4[Step 4:
Tighten bolt 4] T4 --> T5[Repeat pattern
to final torque] style T1 fill:#e6f2fa,stroke:#0078d4,color:#005fa3 style T2 fill:#e6f2fa,stroke:#0078d4,color:#005fa3 style T3 fill:#e6f2fa,stroke:#0078d4,color:#005fa3 style T4 fill:#e6f2fa,stroke:#0078d4,color:#005fa3 style T5 fill:#e6f2fa,stroke:#0078d4,color:#005fa3

Beyond the Manual: Practical Installation Tips

Concrete Curing

If installing on new concrete, ensure it has fully cured according to the engineer's specifications before drilling and mounting. Premature loading can compromise foundation integrity.

Shimming

If minor leveling adjustments are needed directly under the robot base (when not using a base plate), use high-quality, non-compressible metal shims. Ensure full contact and support.

Re-Torque

Especially on new installations, consider re-checking the M24 bolt torque after a short initial operating period (e.g., after a few days or a week) as components settle.

Environmental Vibrations

Consider external sources of vibration (nearby heavy machinery, presses) during foundation design. Isolation pads or more robust foundation designs might be needed.

Recalibration

If significant shimming was required or if there's any doubt about the final flatness/levelness, consider performing a robot mastering (calibration) check after installation to ensure optimal accuracy. Refer to Chapter 5 of the manual.

Before the Bolts: Essential Pre-Mounting Steps

While the foundation provides the critical stability, several essential steps must occur before you lower the IRB 6700 onto its mounting points. Proper preparation, inspection, and handling during unpacking and transport are vital to prevent damage and ensure a successful installation.

Unpacking and Initial Visual Inspection

  • Inspect for Transit Damage: Carefully examine the packaging and the visible parts of the robot for any signs of damage that might have occurred during shipping (dents, scratches, broken components). Document any findings immediately.
  • Verify Contents: Check the delivery manifest against the received components. Ensure all ordered options, manuals, and accessories are present.
  • Protection Type: Confirm the robot's protection class (e.g., Standard IP67, Foundry Plus IP67) from the rating label. This dictates handling and cleaning procedures later on.

Pre-Installation Checks

  • Operating Environment: Ensure the ambient temperature will remain within the operational range (+5°C to +50°C / 41°F to 122°F). Note that operating below 10°C may require a warm-up routine.
  • Humidity: Maximum 95% relative humidity at a constant temperature. Condensation should be avoided.
  • Foundation Ready: Double-check that the prepared foundation meets the flatness, levelness, and minimum resonance frequency requirements discussed previously.
  • Lifting Equipment: Confirm that the available lifting equipment (overhead crane, forklift) and accessories (slings, lifting eyes, fork adapters) are rated significantly higher than the robot's weight (approx. 1300 kg plus any fitted DressPack or tooling).

Understanding Stability and Transportation

Crucially, the IRB 6700 is mechanically unstable when not bolted down.

  • Shipping Position: The robot is typically shipped in a specific, balanced position (often with axes near their calibration marks, as shown in the manual). Do not significantly move the robot arms before it is securely mounted. Moving the arms drastically shifts the center of gravity, creating a serious tipping hazard.
  • ABB Recommended Transport:
    • Method 1 (Preferred): Transport the robot without tooling attached, keeping it in the stable shipping position.
    • Method 2 (If Tool Attached): Use the specific transport position and the recommended transport support bracket detailed in the manual (Section 2.3). This provides additional stability when moving the robot with an end-effector already mounted. Failure to use the correct method can damage the robot and void the warranty.
Robot in shipping position

Robot in shipping position

Safe Lifting onto the Foundation

Once the site is ready, the robot needs to be lifted onto its mounting points. The manual details two primary methods:

Using a Forklift (Section 2.4.1):

  • Requires the optional Fork Lift Device Set (4 pockets, P/N: 3HAC047054-002).
  • These four pockets bolt securely onto the robot base (M20x60 bolts, torque 280 Nm).
  • Crucially, all four pockets *must* be used. Lifting with fewer creates an unstable and dangerous situation.
  • Lift slowly and carefully, ensuring the forks are fully engaged.
Fork lift pockets illustration

Using Roundslings and Crane (Section 2.4.4):

  • Requires specific robot positioning (Axis 1: 0°, Axis 2: -45°, Axis 3: +65°, Axis 5: +70°).
  • Uses four M20 lifting eyes (minimum 2000 kg capacity each) bolted into the base.
  • Requires four 2.5m roundslings (2000 kg capacity) attached to the lifting eyes and the crane hook.
  • Additional securing roundslings (2m or 2.5m depending on variant) are used front and rear to prevent tipping during the lift – these should not be strained but act as safety tethers.
Roundsling attachment illustration

Universal Lifting Safety

NEVER allow personnel under a suspended load. Ensure the lifting path is clear.

Connecting the Nerve Center: Power and Signal Cabling

With the robot mechanically secured, it's time to connect it to its controller (IRC5). This establishes the vital communication and power pathways necessary for operation. The cabling is standardized and designed for straightforward connection, but precision is still key.

Robot-Controller Cable Connections

graph LR subgraph "IRC5 Controller" XS1[XS1
Drive Unit Output] XS2[XS2
Signal Input] end subgraph "IRB 6700 Robot" R1MP[R1.MP
Motor Power] R1SMB[R1.SMB
Serial Measurement Board] end XS1 -- "Robot Power Cable
(7m, 15m, 22m, 30m)" --> R1MP XS2 -- "Robot Signal Cable
(7m, 15m, 22m, 30m)" --> R1SMB style XS1 fill:#e6f2fa,stroke:#0078d4,color:#005fa3 style XS2 fill:#e6f2fa,stroke:#0078d4,color:#005fa3 style R1MP fill:#e6f2fa,stroke:#0078d4,color:#005fa3 style R1SMB fill:#e6f2fa,stroke:#0078d4,color:#005fa3

Cable Categories

  1. Robot Cables (Standard Delivery):

    • Power Cable: Delivers high-voltage DC drive power from the IRC5 drive units to the robot's axis motors.
    • Signal Cable: Transmits crucial position feedback data from the robot's Serial Measurement Board (SMB) unit back to the controller, and provides power to the SMB. This cable is shielded to protect against electrical noise.

  2. Customer Cables (Optional/Application Specific):

    • Low-voltage signal wires (e.g., for sensors, gripper actuation).
    • High-voltage power supply for tooling (e.g., welding guns, spindles).
    • Protective earth connections for tooling.
    • Databus communication lines (e.g., DeviceNet, Profibus) integrated into the robot's DressPack options.

Connection Best Practices

  • Verify Ports

    Double-check that you are connecting the correct cable to the corresponding ports on both the robot and the controller.

  • Clean Connectors

    Ensure connectors are free of dirt, dust, or moisture before mating.

  • Secure Connection

    Fully seat the connectors and secure any locking mechanisms. A loose connection can cause intermittent faults or power issues.

  • Cable Routing

    Route cables carefully to avoid pinching, sharp bends, or interference with moving parts or personnel traffic. Use appropriate cable management systems.

Customer Cabling Note

Connecting customer cabling, especially if integrated with an ABB DressPack (like LeanID), follows specific procedures outlined in the Product manual - DressPack/SpotPack IRB 6700 (3HAC044270-001). Key aspects include proper strain relief, routing through designated channels, and connecting to the appropriate interfaces within the controller or robot base connection area.

Outfitting Your Robot: Fitting Equipment and Managing Loads

The IRB 6700 is designed to carry significant payloads, but adding extra equipment (tooling, DressPacks, sensors) requires careful consideration of weight, center of gravity, and mounting locations to maintain performance and avoid overloading.

Frame (Hip Load)

Frame load area illustration

Capacity: Defined by a moment of inertia limit (JH = 100 kgm²). This calculation considers both the mass (M4 ≤ 250 kg) and its distance (R) from the axis 1 center (JH = JHo + M4 x R²).

Practical Use: Mounting process controllers, valve packs, or other auxiliary equipment near the robot base.

Mounting Points: Designated tapped holes are provided on the frame (see manual illustrations).

Upper Arm

Upper arm load CG illustration

Capacity: Allows an additional load of up to 50 kg, provided its center of gravity is within 500 mm of the axis 3 extension center. This is in addition to the robot's rated payload at the tool flange.

Practical Use: Mounting tooling components, valve islands closer to the tool, vision systems, or DressPack elements.

Mounting Points: Specific tapped holes (M12) are provided. The manual also shows areas where drilling additional M12 through-holes is permissible, but extreme care must be taken not to damage internal cabling.

Tool Flange

This is where the primary payload (gripper, welding gun, etc.) attaches.

The manual shows the standard ISO flange pattern and the specific flange for the LeanID option (780-4).

Payload capacity varies significantly by IRB 6700 variant (150 kg to 235 kg) and is detailed in the Product Specification.

Always verify the maximum payload rating for your specific robot variant before mounting tooling.

Defining Loads in Software: The Critical Step

Physically mounting equipment is only half the battle. You MUST accurately define all loads (tool, upper arm loads, frame loads) in the robot's software (IRC5 controller). This involves specifying:

Mass

The weight of the equipment

Center of Gravity (CoG)

X, Y, Z coordinates relative to the mounting point

Moments of Inertia

How the mass is distributed around the CoG

Why is this critical?

  • Performance: The controller uses this data to calculate motor torques and optimize path accuracy and speed. Incorrect data leads to sluggish or jerky movements.
  • Safety/Protection: Accurate load data prevents overloading motors and gearboxes, extending component life and preventing faults.
  • Collision Avoidance: If using advanced functions like SafeMove, accurate tooling geometry is essential.

Refer to the Operating manual - IRC5 with FlexPendant for instructions on defining TCP (Tool Center Point) and payload data.

Setting Boundaries: Restricting the Working Range

Sometimes, the robot's full reach needs to be limited to prevent collisions with fixtures, walls, or other machinery within the cell. The IRB 6700 allows restriction on:

Axis 1 (Rotation)

Axis 1 mechanical stop illustration
  • Mechanical Stops (Option): Additional physical stop blocks can be bolted onto the robot base. These provide a hard, physical limit to rotation in 15° increments (between ±5° and ±125°). This is the most robust way to guarantee a limit.
  • Software Limits: System parameters (Upper Joint Bound, Lower Joint Bound) can define a narrower software-controlled working range. Crucially, if mechanical stops are fitted, the software limits must be set to correspond to, or be narrower than, the physical limits.

Axis 2 & 3 (Arm Motion)

graph TD A[Software Limits Only] A --> B[System Parameters] B --> C[Upper Joint Bound] B --> D[Lower Joint Bound] style A fill:#e6f2fa,stroke:#0078d4,color:#005fa3 style B fill:#e6f2fa,stroke:#0078d4,color:#005fa3 style C fill:#e6f2fa,stroke:#0078d4,color:#005fa3 style D fill:#e6f2fa,stroke:#0078d4,color:#005fa3

These axes can only be restricted using software parameters in the controller configuration. Unlike Axis 1, there are no optional mechanical stops available for these axes.

Important Note

Modifying working ranges, especially adding mechanical stops, requires updating the robot's system parameters. Refer to the Technical reference manual - System parameters. Incorrect configuration can lead to unexpected behavior or faults.

Conclusion: Get the Foundation Right

Installing an ABB IRB 6700 is a significant undertaking. While cabling, programming, and tooling are often in the spotlight, the foundation is the literal base upon which the robot's performance, reliability, and safety are built. By carefully understanding and meticulously implementing the foundation and mounting requirements outlined in the manual – paying close attention to levelness, stiffness, and correct fastening procedures – you ensure your IRB 6700 can deliver its full potential reliably and safely for years to come. Don't cut corners here; a solid foundation is the best start for a successful robot installation.

Need Further Information?

For more detailed guidance on your ABB IRB 6700 installation, maintenance, or troubleshooting, explore our complete series of technical guides.

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