Turning a broken 2 ton robot into a CNC-machine | ABB IRB6400
Here’s an overview of the project I’ve been working on for the past few months: resurrecting this 2 ton cast iron beast from the dead and turning it into a CNC milling machine, mainly for foam.
The robot is an ABB IRB6400 / , manufactured in 1999.
The documents that were still with the robot state that the original customer was the Eurostar train factory located in Austria, where it served as a welding robot.
Upon the first startup attempt the controller wouldn’t perform a cold start and gave me : “Error 03:07003 Unexpected interrupt on MC“. After talking to some experts on the ABB robotics forum (thank you graemepaulin for your expertise) they pointed me in the right direction and told me to replace the main or robot computer. Replacing the Robot computer fixed te issue and the S4C controller was able to perform a cold start. I then installed Robotware OS 3.1 and after this i was able to get some movement out of the robot. Once the axis were callibrated again (because the backup battery inside the robot itself also died) i was able to make linear moves and start creating simple programs. Full thread on the ABB Robotics forum can be found here: #latest
Furthermore I replaced both backup batteries inside the S4C controller and swapped the Floppy drive for a USB one.
This whole process to get the robot up and running took about 2 weeks (had to wait for some parts to arrive). The rest of the time was spend on the development of a program to send coordinates directly to the S4C controller from a PC. Even with the floppy drive swapped for a USB one, the internal memory size was still about the size of a floppy disk (). Which means I was still only able to execute programs of max or around lines of code. Anyone who ever worked with CNC-machines know that even the simplest programs exceed lines. So that’s why i made the application. I’m now able to execute any file size that I need.
During the development of the program I used an Arduino Mega as an emulator for the S4C controller, to test out the serial communication protocols and handshakes.
---
Timestamps:
00:00 Intro
00:15 Transportation
00:30 Cleaning
00:52 First startup attempt
01:18 Fixing the robot
01:50 First movements
02:12 First program
02:38 Can test full program
03:01 Testing of repeatability
03:40 G-code to Rapid
03:54 3D-printed motor mount
04:10 TCP setup test
04:38 First milling test
05:04 Rapid2Serial Application
05:47 Fine tuning
06:32 Tesla Roadster wheel front
07:19 Tesla Roadster wheel back
08:07 Showcase
08:21 Outro
---
Music credit:
Outro song: Sustainable Dignity by Catalyst Belgium
Link to the video:
Link to their channel: Their website:
For use and licensing of this song, please contact Catalyst Belgium.
Song: Joakim Karud - Classic (Vlog No Copyright Music)
Music provided by Vlog No Copyright Music.
Video Link:
2 views
0
0
5 days ago 03:07:05 2
[BadComedian] - ПОСМОТРЕЛ ВСЕ СКАЗКИ (Волшебник изумрудного города, Бременские, Летучий корабль итд)
7 days ago 00:02:11 1
Mere Bete Ki Khushiyan Kha Gayi Tum || Mann Mast Malang || Har Pal Geo
7 days ago 00:03:33 0
Borrowed Time - R&B Cozy Chill Music
7 days ago 00:09:32 0
Making a Teddy Bear Keychain with Hair Rubber Bands and Sewing Thread / Incredibly Simple Steps
1 week ago 00:00:22 0
Turn Heads: The See-Through Long Sleeve Mini Dress
1 week ago 00:12:47 2
Mushoku Tensei: Blood Pact |12 Minutes Turning Point 4 Fan Animation
2 weeks ago 00:03:58 0
This Dual Monitor Arm Fixed My Productivity Issues– Ergotron LX Pro Review (Why Didn’t I Buy Sooner) - YouTube
2 weeks ago 00:03:49 0
Tori Amos - Professional Widow (Remix) (Official Music Video)
2 weeks ago 00:04:35 10
Jeff Bezos’ $10M Venice Wedding: Inside the Lavish Celebration & Celebrity Guest List | NEWSDRIFT
2 weeks ago 00:03:32 0
Why Your Back Hates You: FLYCAM Flowline Fixes It (Camera Rigs Just Got Comfy!) - YouTube
2 weeks ago 00:17:31 1
Meghan Markle CRIES As Viral Video BACKLASH Makes Her LOSE FANS
3 weeks ago 00:06:04 0
Cause of Starship Rocket Explosion During Test
3 weeks ago 00:04:15 4
Ronan Keating - When You Say Nothing At All (Lyrics)
3 weeks ago 00:00:18 0
A hippopotamus tries to escape from a lion’s den it accidentally entered #wildlife
3 weeks ago 00:00:39 0
The Blood of Dawnwalker — Gameplay Reveal Event Announcement
3 weeks ago 00:02:25 2
Greta’s Anatomy | Redneck AI Country Parody (Grey’s Anatomy)
3 weeks ago 00:00:15 0
A cheetah preys on a gaiter stuck in a tree #wildlife
4 weeks ago 00:06:40 7
English Christian Song | “You Should Understand God’s Intentions“
4 weeks ago 00:00:46 2
Get wet and wild (safely) with Helen Flanagan’s outrageously sexy pool rules - FHM (UK)