Understanding the Challenge
Moving and installing a heavy-duty industrial robot like the ABB IRB 6700 requires precision, planning, and an unwavering commitment to safety. Weighing approximately 1300 kg (excluding tooling and DressPack), improper lifting can lead to severe equipment damage, costly delays, and, most importantly, serious personnel injury.
This guide dives deep into the two ABB-approved methods for lifting the IRB 6700 on-site: using a forklift with a dedicated device set and using roundslings. We'll go beyond simply listing steps, providing practical insights and emphasizing the critical safety precautions detailed in the official product manual.
Target Audience
Installation technicians, maintenance crews, system integrators, and anyone involved in the physical setup or relocation of an IRB 6700 robot.
Critical Specifications
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Base Weight: Approximately 1300 kg
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Manual Reference: Document ID: 3HAC044266-001
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Required Torque: 280 Nm (forklift method)
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Foundation Resonance: Minimum 22 Hz
Safety First: Non-Negotiable Prerequisites
Before attempting any lift, internalize these fundamental safety principles that must be followed without exception. These are the critical foundations that ensure both equipment integrity and personnel safety.
Weight Awareness
The IRB 6700 base robot weighs 1300 kg. Always ensure your lifting equipment (forklift, crane, slings, shackles, lifting eyes) is rated significantly above this weight, accounting for potential dynamic forces.
Stability is Paramount
An unsecured IRB 6700 is mechanically unstable. Do not change the robot's configuration from its stable shipping position until it is securely fastened to its foundation or a proper transport fixture. Moving the arms can shift the center of gravity and cause tipping.
Power Down Completely
Always turn off all electrical power, hydraulic pressure, and air pressure supplies to the robot and controller before entering the workspace or beginning lifting procedures. Lock out the main power switch.
Clear the Zone
NO PERSONNEL should be under or near the suspended load at any time during the lift. Establish clear safety zones before beginning the operation.
Certified Equipment Only
Use only ABB-approved or certified lifting accessories designed for the task. Inspect all equipment for wear or damage before use to prevent lifting failures.
Remove Tooling
Unless using Method 2 with the approved transport support, always remove the end-of-arm tooling (EOAT) before transport to maintain proper balance and weight distribution.
Method 1: Forklift Lifting (ABB Recommended)
ABB strongly recommends using a forklift with the dedicated lifting device set for maximum stability and safety during on-site transport. This is the preferred method whenever feasible.
Required Equipment
Forklift
Adequate lifting capacity (>1300 kg)
Fork Lift Device Set
ABB Art. No. 3HAC047054-002
(Includes 4 lifting pockets)
Attachment Screws
M20x60, Quality Steel 8.8-A3F
(8 pcs total, 2 per pocket)
Torque Wrench
Capable of 280 Nm torque application
Step-by-Step Procedure
Prepare the Robot
- Ensure the robot is in its shipping position (Manual Section 2.2.3). If not, carefully jog it into position.
- Confirm all power sources (electric, hydraulic, air) are OFF and locked out.
- Verify no load/tooling is attached to the robot.
Attach Lifting Pockets
- Securely attach all four fork lift pockets to the robot base using the specified M20x60 screws.
- Crucially: Tighten the attachment screws to 280 Nm using a calibrated torque wrench. Ensure original or equivalent quality screws are used.
- WARNING: Lifting with fewer than four pockets is unsafe and risks accidents.
Position the Forklift
Carefully align the forklift tines with the attached pockets, ensuring they are fully inserted before attempting to lift.
Perform the Lift
- Slowly and carefully lift the robot straight up.
- Maintain low speed during transport.
- Ensure no personnel are under the suspended robot.
Transport and Placement
Move the robot to its installation site and gently lower it into position. Maintain control of the robot during descent and ensure precise alignment with foundation points.
Forklift Method Process Flow
flowchart TB
A[Prepare Robot] -->|Shipping Position| B[Attach 4 Lifting Pockets]
B -->|Torque to 280 Nm| C[Position Forklift]
C -->|Align Tines| D[Perform Lift]
D -->|Slow & Careful| E[Transport to Site]
E -->|Maintain Low Speed| F[Lower into Position]
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classDef warning fill:#fff3cd,stroke:#ffc107,color:#856404;
class B warning
Key Insights (Forklift Method)
Why Preferred?
This method utilizes dedicated, engineered attachment points on the robot base, offering superior stability compared to slings.
Torque is Critical
The 280 Nm torque ensures the pockets are securely fastened to handle the robot's weight. Under-tightening is dangerous.
Shipping Position
This is generally the most stable configuration for the robot when unsecured, minimizing the risk of tipping.
Method 2: Roundsling Lifting (Alternative)
This method is approved by ABB but should only be used if forklift lifting (Method 1) is not possible. It requires careful positioning and correct sling application.
Required Equipment
Overhead Crane
Or similar lifting device with adequate capacity (>1300 kg)
Lifting Eyes
M20 (4 pcs), Working Load Limit (WLL) ≥ 2000 kg each
Roundsling (Lifting)
2.5 m length, WLL ≥ 2000 kg (4 pcs)
Roundsling (Securing - Rear)
2 m length, WLL ≥ 2000 kg (1 pc)
Roundsling (Securing - Front)
Length varies by variant, WLL ≥ 2000 kg (1 pc):
IRB 6700 - 235/2.65 & 205/2.80: 2 m length
IRB 6700 - 175/3.05 & 150/3.20: 2.5 m length
Lifting Shackles
Optional but Recommended: If lifting eyes have sharp edges that could damage slings
Step-by-Step Procedure
Prepare the Robot
Carefully jog the robot into the specific lifting position:
Confirm all power sources are OFF and locked out.
Attach Lifting Eyes
Securely screw the four M20 lifting eyes into the designated outer holes on the robot base (refer to manual figure in section 2.4.4 for exact locations).
Position Lifting Slings
- Run the four 2.5m roundslings (A) through the lifting eyes (D).
- Critical Check: Inspect lifting eyes for sharp edges. If present, use shackles to connect the slings to the eyes to prevent sling damage. Ensure slings are not rubbing against sharp robot parts.
Attach Securing Slings
- Attach the rear securing sling (B - 2m) around the robot frame as shown in the manual figure. This sling should not be strained during the lift; it's for stability.
- Attach the front securing sling (C - 2m or 2.5m depending on variant) as shown. This sling also should not be strained during the lift.
Connect to Crane
Attach all slings to the overhead crane hook, ensuring they are properly positioned and not twisted.
Perform the Lift
- Slowly raise the crane hook, taking up slack evenly.
- Critical Check: As tension increases, verify the roundsling running from the front, left corner (when facing the robot) passes correctly relative to the brake release unit plate (see manual section 2.4.4 figure). Misrouting could damage components.
- Lift the robot carefully, keeping the load balanced.
- Maintain low speed during transport.
- Ensure no personnel are under the suspended robot.
Transport and Placement
Move the robot to its installation site and gently lower it. Maintain even tension on all slings during descent.
Roundsling Method Process Flow
flowchart TB
A[Position Robot] -->|Specific Angles| B[Attach Lifting Eyes]
B --> C[Position Lifting Slings]
C -->|Check for Sharp Edges| D[Attach Securing Slings]
D -->|Front & Rear| E[Connect to Crane]
E --> F[Perform Lift]
F -->|Verify Sling Routing| G[Transport to Site]
G --> H[Lower into Position]
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classDef critical fill:#FFEBEE,stroke:#F44336,color:#B71C1C;
class A,C,F critical
Key Insights (Roundsling Method)
Robot Position is Mandatory
The specified axis configuration (-45°/65°/70°) is essential for balance. Deviating from this position could lead to unstable lifting.
Securing Slings are Vital
Although not taking the primary load, the front and rear securing slings prevent tipping during the lift. Ensure they are attached correctly but remain slack.
Inspect Edges
Sharp edges on lifting eyes will damage slings under load, leading to failure. Always check and use shackles if necessary.
Supporting Procedures: Manual Brake Release
During positioning for lifting or placement after lifting (before securing), you might need finer control than jogging allows. The manual brake release buttons can be used.
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Location: Internal brake release unit on the robot (see manual section 2.4.5).
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Power: If the controller is disconnected, 24VDC must be supplied to connector R1.MP (Pins 11 & 12) as detailed in the manual.
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Procedure: Press the button corresponding to the axis requiring release. The brake re-engages when the button is released.
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DANGER: Releasing brakes allows axes to move rapidly due to gravity or stored energy in the balancing system. Ensure personnel are clear and anticipate movement. Never release brakes unnecessarily.
Beyond the Manual: Practical Considerations
A successful lift requires more than just following the basic procedure. These additional practical insights, based on real-world experience, will help ensure a smooth operation.
Plan Your Path
Before lifting, survey the transport route. Ensure adequate clearance (height, width), floor load capacity, and no obstructions. A quick walk-through can prevent discovering problems mid-transport.
Team Communication
Clear communication between the crane/forklift operator and spotters is essential. Use standard hand signals if necessary to ensure coordination during the entire lifting operation.
Gentle Handling
Avoid sudden starts, stops, or jerky movements during the lift and transport. Smooth, controlled movements reduce the risk of dynamic loading and potential damage to the robot.
Pre-Lift Check
Always double-check sling attachments, shackle pins, forklift pocket torque, and personnel clearance immediately before the load leaves the ground. This final verification can prevent accidents.
Expanding on IRB 6700 Handling
Complete IRB 6700 handling involves more than just the lift itself. These sections cover critical adjacent topics for a successful installation.
Pre-Lift Site Preparation & Verification
Before the IRB 6700 arrives or is even unpacked, meticulous site preparation is essential. This goes beyond just having a foundation ready.
Foundation Levelness & Flatness
The manual specifies a maximum deviation from levelness of only 0.2 mm across the robot's anchoring points. Verify this before installation. An uneven foundation compromises stability, repeatability, and potentially robot accuracy. Shimming might be required during the securing phase if the foundation isn't perfect.
Clearance Checks
Walk the entire planned transport path from unloading point to final installation site. Check for overhead clearance, width clearance, and obstructions like low-hanging pipes, conduits, support columns, or other machinery that could interfere.
Floor Load Capacity
Confirm the floor along the transport path and at the installation site can support the combined weight of the robot (approx. 1300 kg + tooling/DressPack) and the transport vehicle (forklift). Point loads under forklift wheels can be significant.
Foundation Resonance
The foundation must have a minimum resonance frequency of 22 Hz. While typically an engineering design consideration, be aware that an inadequate foundation can lead to vibration issues during operation.
Conclusion
Safely lifting the ABB IRB 6700 is a critical first step in its installation or relocation. By strictly adhering to ABB's approved methods – preferably the forklift method with the dedicated device set, or alternatively the roundsling method with precise positioning – and prioritizing all safety precautions, you can ensure the integrity of the equipment and the well-being of personnel.
Always consult the official ABB IRB 6700 Product Manual for complete details and diagrams before undertaking any lifting operation. Remember: planning, correct equipment, and vigilance are key to a successful lift.