Operating Manual PowerPac

Operating manual
Machining PowerPac
RobotStudio 5.12
Document ID: 3HAC030420-001

Revision: B
© Copyright 2008-2009 ABB. All rights reserved.
The information in this manual is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that
may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB’s written
permission, and contents thereof must not be imparted to a third party nor be used for
any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
© Copyright 2008-2009 ABB All rights reserved. © Copyright 2008-2009 ABB. All rights reserved.
ABB Robotics
SE-721 68 Västerås
Sweden
Table of Contents
Overview .........................................................................................................................................5
1 Introduction 7
1.1 About Machining PowerPac.......................................................................................................7
1.2 Terms and Concepts ...................................................................................................................9
2 Installation 11
2.1 Installing ...................................................................................................................................11
2.2 Getting Started..........................................................................................................................13
3 Navigating Machining PowerPac 15

3.1 Overview ..................................................................................................................................15
3.2 The Machining Ribbon-tab ......................................................................................................17
3.3 The Machining Browser ...........................................................................................................20
3.4 The Path View ..........................................................................................................................24
3.5 The Solution Wizard ................................................................................................................28
4 Workflow for Machining PowerPac 29

4.1 Overview ..................................................................................................................................29
4.2 How to Create or Modify a Surface .........................................................................................31
4.3 How to Create Machining Solutions Based on Surface ......................................................34
4.3.1 Launching the Wizard ....................................................................................................34
4.3.2 Defining Machining Solution.........................................................................................35
4.3.3 Creating Machining Surface...........................................................................................37
4.3.4 Setting Machining Process Parameters ..........................................................................39

4.3.5 Setting Tool and Work Object .......................................................................................43
4.3.6 Setting Path Generation Pattern .....................................................................................45
4.3.7 Setting Target and Path ..................................................................................................54
4.3.8 Previewing the Trajectory of the Tool ...........................................................................57
4.4 How to Create Machining Solutions Based on Edge ...............................................................59
4.5 How to Set Schedule ................................................................................................................60
4.6 How to Modify Solutions, Paths and Targets.......................................................................61
4.6.1 Overview ........................................................................................................................61
4.6.2 Working with the Machining Browser...........................................................................62
4.6.3 Working with the Path View .........................................................................................64
4.6.3.1 Overview ...........................................................................................................64
4.6.3.2 The Create Menu...............................................................................................66
4.6.3.3 The Modify Menu .............................................................................................73
4.6.3.4 The Configuration Menu...................................................................................78
4.6.4 Working with the Machining Ribbon-tab ......................................................................80
3
Table of Contents
4.7 How to Set up a Simulation..................................................................................................... 88

4.8 How to Export Machining PowerPac Programs...................................................................... 89
4.9 How to Create or Modify Templates ..................................................................................... 91
4.9.1 Overview ....................................................................................................................... 91
4.9.2 Machining Templates .................................................................................................... 93
4.9.3 Approach/Departing Templates .................................................................................... 97
4.9.4 Solution Configuration Templates ................................................................................ 98
4.10 How to Create Calibrations ................................................................................................... 99
5 Trouble Shooting 101

5.1 About Path Generation Pattern.............................................................................................. 101
4
Overview
Overview
About This Manual

This manual describes how to use Machining PowerPac to create machining programs
offline. It also explains Machining PowerPac terms and concepts.
Usage
This manual should be used when working with Machining PowerPac.
Who Should Read This Manual?

This manual is intended for RobotStudio users, proposal engineers, mechanical designers,
offline programmers, robot technicians and service technicians.
Prerequisites
The reader should have basic knowledge of:
• Industrial robots and their terminology
• RAPID programming language
• RobotStudio
Organization of Chapters
The manual is organized in the following chapters:
Chapter Content
1. Introduction Describes terms and concepts of Machining PowerPac.
2. Installation Describes how to install Machining PowerPac.
3. Navigating Machining Describes the graphical user interface of Machining
PowerPac PowerPac.
4. Workflow for Machining Describes how to work with Machining PowerPac.
PowerPac
Continues on next page
3HAC030420-001 Revision: B 5
Overview
Continued
References
Reference Document Id
Operating manual - RobotStudio 3HAC032104-001
Application manual - Force Control for Machining 3HAC027595-001
Revision
Revision Description
- First edition
A Added information about new functions, for example, the
FC_SpeedChangeProcess template, the new pattern Edge that is used
to generate paths along the edges of the user-defined surface, and new
solution configuration templates for RW Machining FC.
B Minor corrections.
6 3HAC030420-001 Revision: B
1 Introduction
1.1. About Machining PowerPac
1 Introduction
Overview
Machining PowerPac is a process specific add-in to RobotStudio. This software product aims
to provide a new solution to solve difficulties in programming complex 3D paths offline for
the machining process.
Key Features
Key features of Machining PowerPac:
Function Description
Path generation based on All the machining paths are created based on a user-defined
surface surface or along the edges of the surface. Which means that a
surface must be created before creating machining paths.
NOTE! For creating path along edges, creating a surface is also
required. And makes sure that the edges you need are included
in the surface.
Wizard-based path Provides a wizard where the parameters regarding machining
generation process can be defined. After going through the wizard, a set of
machining paths will be created on the surface or along the
surface edges.
See How to Create Machining Solutions Based on Surface on
page 34 for how to use the wizard.
Saving and sharing Provides three types of templates to save the experiential data:
experience by templates • Machining template, contains machining process infor-
mation.
• Solution configuration template, contains solution con-
figuration parameters.
• Approach/Depart template, defines the approach/
departing styles.
All the templates can be shared between different Machining
PowerPac users by exporting and importing.
See How to Create or Modify Templates on page 91 for how to
export or import templates.
1 Introduction
Continued
Function Description
Target orientation optimiza- Provides functions to adjust target frame in both the single
tion target level and the multi-targets level.
NOTE! The multi-selected targets must be in the same path.
Multiple export The machining program in the Machining PowerPac can be
exported into different formats which can be recognized by
different user interfaces.
• RWM, exports the program as RobotWare Machining FC
project files which include taught targets to improve
learning speed and accuracy.
• RAPID, exports the program into RAPID program.
See How to Export Machining PowerPac Programs on page 89
for how to export a machining program.
1 Introduction
1.2. Terms and Concepts
Machining PowerPac Concepts

The table below describes the terminology and concepts that are used in Machining
PowerPac.
Term Explanation
Surface A machining surface is an area that consists of one or more
geometrical faces in a same part. In Machining PowerPac, a
surface is created to define an area to be machined, then the
machining paths can be generated on the surface or along the
edge of the surface.
Solution Represents the machining sequence.
The paths result in one pattern for a machining surface.
It’s possible to create more than one solution for the same
surface.
Schedule The entry point of the machining program.
Pattern An algorithm for generating paths on a surface.
It shows the idea to users in a user-friendly way and the users
do not need to know the details of an algorithm.
FC Acronym for Force Control.
RCS In Machining PowerPac, each target is combined with a local
reference coordinate system, which is named Reference

Coordinate System (RCS).
RCS is primarily used as a helper frame for making it easier to
create and manipulate targets.
The default RCS is defined
• X axis direction is along the path direction,
• Z axis direction is along the normal vector of the surface,
• Y axis direction follows the right hand rule.
Tool Working Range Tool working range defines a range of a tool that can be used to
machine a work piece.
Tool working range is expressed in degree as a angle.
Work Angle Defines how much a target can rotate around the X axis of the
RCS with the assumption that the original orientation of the
target is aligned with the RCS.
1 Introduction
Continued
Term Explanation
Travel Angle Defines how much a target can rotate around the Y axis of the
RCS after the target is already rotated within the defined work
angle.
Spin Angle Defines how much a target can rotate around the Z axis of the
RCS after the target is already rotated with the defined travel
angle.
2 Installation
2.1. Installing
2 Installation
2.1. Installing
Overview
This section describes the installation process.
Prerequisites
To start the installation process, the following must be available:
• A computer that meets or exceeds the system requirements.
• A log on account with administrator rights on the computer.
• RobotStudio installed on the computer.
• Machining PowerPac installation package.
System Requirements
To work with Machining PowerPac, the following is required:
Recommended Hardware
• CPU: 2.0 GHz Intel Pentium 4 or faster processor
• Memory: 1 GB RAM or more (More is recommended.)
• Available disk space: 5+ GB on the system disk, 250+ MB on the installation disk
• Graphics card: High performance OpenGL-compatible graphics card with the
corresponding up-to-date drivers installed
• Screen resolution: 1280 x 1024 pixels (Recommended)
• Colors: 256 or higher
• DPI: Normal size (96 dpi)
• Mouse: Three-button mouse
Software Requirements
• Microsoft Windows XP Professional with Service Pack 2, or
• Microsoft Windows Vista - Business or higher
• RobotStudio 5.11
2 Installation
2.1. Installing
Continued
Installing Machining PowerPac
Action
1. Browse to Machining PowerPac installation files and double-click the .exe file.
The installation wizard opens.
2. Follow the instructions in the installation wizard.
3. When the installation is finished, complete the installation wizard by clicking Finish.
NOTE! Machining PowerPac will be installed in the following location: C:\Program

Files\ABB Industrial IT\Robotics IT\RobotStudio\Bin\Addins.
Installing a License
Follow the procedure of installing a license the same as RobotStudio.
2 Installation
2.2. Getting Started
How to Start Machining PowerPac

Follow these steps to start Machining PowerPac:
1. Create a new station, or open an existing station by using RobotStudio basic function.
2. Click Machining in the PowerPacs group of the Add-ins tab on the Ribbon.
NOTE!
Machining PowerPac can not be started with an empty station.
How to Stop Machining PowerPac

To stop Machining PowerPac, click Machining again on the Add-ins tab or click Close
Machining in the Quick Access Toolbar.
2 Installation
3 Navigating Machining PowerPac
3.1. Overview

3.1. Overview
The Graphical User Interface

The graphical user interface of Machining PowerPac contains four main parts as shown in the
following pictures:
• The Machining Ribbon-tab on page 17
• The Machining Browser on page 20
• The Path View on page 24
• The Solution Wizard on page 28
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3.1. Overview
Continued
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3.2. The Machining Ribbon-tab
About the Machining Ribbon-tab

The Machining ribbon-tab contains the controls for creating machining surfaces, solutions
and calibrations, modifying machining solutions and paths, exporting, and checking/healing
imported parts.
Elements on the Machining Ribbon-tab
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Group Button Description

Create Solution Wizard Opens the Solution Wizard to create a machining
solution.
See How to Create Machining Solutions Based on
Surface on page 34 for a more detailed description.
Surface Opens the Create Machining Surface dialog box.
See How to Create or Modify a Surface on page 31for
a more detailed description.

Calibration Opens the Create Calibration dialog box.
See How to Create Calibrations on page 99 for more
information.
Continued

Modify Machining Opens a dialog box to change the machining
Template template for the selected path or solution.
See Machining Templates on page 93for more infor-
mation.
Approach/ Opens a dialog box to change the approach/
Departing departing template for the selected path or solution.
Template See Approach/Departing Templates on page 97 for
more information.
Machining Speed Opens a dialog box to set speed for the selected path
or solution.
See Machining Speed on page 82 for more informa-
tion.
Machining Force Opens a dialog box to set the machining force for the
selected path or solution which does support force
control process.
See Machining Force on page 84 for more informa-
tion.
Tool Compensa- Opens a dialog box to set the tool compensation for
tion the selected path or solution.
See Tool Compensation on page 85 for more informa-
tion.
Tool Working Opens a dialog box to set the tool working range for
Range the selected path or solution.

See Tool Working Range on page 86 for more infor-
mation.
Continued

Export RWM Abbreviation for RobotWare Machining Force Control
which is a controller software designed to address
challenges in machining uneven and unpredictable
heavy flashing and gating of castings. See
Application manual - Force Control for Machining for
detailed description.
Exports the current program as a file with specific
format that can be recognized by the RobotWare
Machining FC graphical user interface.
See How to Export Machining PowerPac Programs
on page 89 for more information.
RAPID Exports a complete RAPID program.
See How to Export Machining PowerPac Programs
on page 89 for more information.
Diagnostics Check/Heal Checks or heals the imported CAD models.
See Check/Heal on page 87 for more information.
General Help Provides information about help and product version.
3.3. The Machining Browser
Overview
The Machining browser is a hierarchical display of Machining PowerPac items, such as
surfaces, schedule, calibrations and templates.
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Continued
Icons in the Machining Browser
Icon Node Description

Task The current robot task.
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Surface collection Contains all the surfaces that are created with
Machining PowerPac in the current station.
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Surface A certain user-defined machining surface.
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Solution A set of result paths that are created on the surface.
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Unknown path A path for which the reachability check has not been
done.
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Verified path A path where all the targets are reachable for the
used robot.
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Failed path A path that contains at least one unreachable target.
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No configuration A path where no configuration solution can be found.

solution path
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Schedule The entry point for a machining program.
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Calibration Contains all calibration data.

collection
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Continued

Calibration The transformation method, with which you can
transform the programs created in the virtual
environment into the real cell.
en0814020010
Calibration point The points that are used for coordinates transforma-
tion.
en0814020011
Work object The work object that is used during calibration.
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Template Contains different types of templates.

collection
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Machining Contains all machining templates.

collection
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Machining A machining template.
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Approach/ Contains all approach/departing templates.

Departing

collection
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Approach/ Defines how a robot approaches or departs the

Departing machining surface.
template Contains both the approach targets and departing
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targets.
Approach target Contains all the approach targets in the current
list template.
en0814020017
Approach target A position and rotation defines how a robot

approaches a surface.
en0814020018
Departing target Contains all the departing targets in the current

list template.
en0814020019
Continued

Departing target A position and rotation defines how a robot departs a
surface.
en0814020020
Solution configu- Contains all templates of solution configuration.

ration collection
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Solution configu- A template contains all the information about solution

ration configuration.
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3.4. The Path View
3.4. The Path View
Overview
The Path View displays all targets in a path by representing them with instruction icons.
When a program contains several paths, the first instruction in the Path View is the last
instruction of the preceding path. This is used to verify that the robot can bridge these paths.
A robot icon, that is the robot cursor, sits on top of the targets to indicate the position of the
robot in the target sequence. Note how the cursor advances step-by-step when the path is
executed.
en0700000253
Path View Toolbar

The Path View holds the Path View Toolbar, which has menus and buttons for the most
frequently used commands.

Icon Description
View Center sets the view center automatically to the selected target in
the path view or the active TCP (if no target is selected).
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Select All selects all the paths in the Path View.
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The Create menu See The Create Menu on page 66.

The Modify menu See The Modify Menu on page 73.
3.4. The Path View
Continued
Icon Description
The Configura- Contains two commands:
tion menu • Check Reachability, displays whether the robot can reach a target
and motion instruction by changing the targets’ color. A
successful result turns the target yellow, while an unsuccessful
result turns it red.
• Set Configuration, see Set Configuration on page 78.
Arm Configuration opens a dialog box similar to the one opened by
clicking Configuration, Set Configuration.
en0700000209 See also Set Configuration on page 78.
The image on Arm Configuration also indicates the active arm config-
uration of the target.
Wrist Configuration opens a dialog box similar to the one opened by
en0700000210
See also Set Configuration on page 78.
The image on Wrist Configuration also indicates the active wrist con-
figuration of the target.
Tool Configuration opens a dialog box similar to the one opened by
en0700000211 See also Set Configuration on page 78.
The image on Tool Configuration also indicates the active tool configu-
ration of the target.
Jump to jumps the robot to the selected target and checks for reach. A
successful result turns the target yellow and moves the robot one
en0700000212 discrete step towards the target. An unsuccessful result turns the target
red and leaves the robot in its current position.
Move to moves the robot from the previous target to the selected target,
checks for reach and sets the robot configuration. A successful result
en0700000213 turns the target green and moves the robot continuously towards the
target. An unsuccessful result turns the target red and leaves the robot
in its current position.
NOTE! The virtual controller is not running when executing this
command.
Simulation synchronizes the selected targets to the virtual controller and
executes the selected targets in the virtual controller.
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3.4. The Path View
Continued
Icon Description
Stop stops the current robot motion.
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The Speed drop-down list applies only to Jump to and Move to. The
simulation speed is determined by the RAPID program.
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Instruction Icons
Object Description
Path Divider.
Indicates the start of a path.
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Approach Target
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Start Target
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Air/Via Target

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End Target
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Departing Target
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Linear Move
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Joint Move
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3.4. The Path View
Continued
The color coding:
Color Status
White Unknown status.
Green Target verified.
Yellow Solution found, but not verified.
Red No solution, or target out of reach.
3.5. The Solution Wizard
3.5. The Solution Wizard
How to Launch the Solution Wizard

To launch the Solution Wizard, click Solution Wizard on the Machining ribbon-tab.
Wizard Pages
The Solution Wizard is a 7-step wizard, where a machining solution can be quickly created.
Page Action
1. Machining Solution Select a controller, task, solution and configuration
template for the solution on this page.
2. Machining Surface Define a surface on which the machining paths will be
created. There are two ways:
• Select an existing surface from the drop-down list.
• Create a new surface by selecting faces in the 3D
view.
3. Machining Process Set parameters for generating robot targets and paths.
Parameters
4. Tool and Work Object Select and set a work object and tool data for the current
solution.
5. Path Generation Pattern Select a path generation pattern and set parameters for
the selected pattern.

6. Target and Path Set the target orientation and select a path connection
type.
7. Preview Preview the trajectory of the tool.
Related Information
How to Create Machining Solutions Based on Surface on page 34.
4 Workflow for Machining PowerPac
4.1. Overview

4.1. Overview
Overview
The following is a recommended flow for working with Machining PowerPac. After you
complete the workflow, you can perform these task in any order.
NOTE!
The machining station (contains at least one robot system) should be set up by using
RobotStudio basic function before starting Machining PowerPac, as the Machining PowerPac
provides only a method for creating paths but not functions for building stations.
Workflow for Machining PowerPac

After starting Machining PowerPac, follow these steps:
Task Description
1. Create a surface to be See How to Create or Modify a Surface on page 31.
machined. NOTE! For creating path along edges, creating a
surface is also required. Define a surface that
includes the edges you need before creating paths.
2. Create a machining solution. Create a set of machining paths with the Solution
Wizard.
NOTE! A solution must be created for a certain
surface. You can choose to create a surface by
clicking Surface on the Machining ribbon-tab, or to
create a surface within the wizard.
For more information, see How to Create Machining
Solutions Based on Surface on page 34 and How to
Create Machining Solutions Based on Edge on page
59.
3. Configure paths. Open paths in the Path View, select all targets and
click Move to to find configurations for all targets, and
execute the whole path.
If any target can not be executed, manually adjust the
target.
For more information, see How to Modify Solutions,
Paths and Targets on page 61.
4.1. Overview
Continued
Task Description
4. Synchronize to virtual controller. Synchronize all the paths in the current station to the
virtual controller.
For more information, see How to Set up a Simulation
on page 88.
5. Run simulation. Run simulation to make sure that all paths can be
executed in the virtual controller.
For detailed information, see How to Set up a
Simulation on page 88.
6. Export the whole program. The program can be exported in two different
formats.
For detailed information, see How to Export
Machining PowerPac Programs on page 89.
4.2. How to Create or Modify a Surface
Overview
This section describes how to create a machining surface.
Creating a Surface
Click Surface on the Machining ribbon-tab, the Create Surface dialog box opens as
illustrated below.
en0700000207
Item Description
Name The name of the new surface.

Select Faces from 3D All the faces that are selected by clicking in the 3D view are
view displayed in the box. The new surface is made of these faces.
Clear Clears all the faces in the Select Faces list box.
Create Creates a new surface according to the settings in this dialog
box.
Close Closes this dialog box.
To create a surface, follow these steps:

1. Click Surface on the Machining ribbon-tab to open the Create Surface dialog box.
2. Enter a name in the Name text box or use the default one for the new surface.
Continued
3. Select a face by clicking in the 3D view. It is also possible to multi-select faces by

pressing SHIFT while dragging the mouse device to select an area in the 3D view. The
faces that meet the following condition, the angle between the view vector and the
normal vector of the face is less than 90 degrees, in the selected area will be added to
the list under Select Faces from 3D view.
4. Click a face or multi-select faces in the face list to highlight the faces in the 3D view.
It is also possible to view a face in the center of the 3D view by right-clicking each
face name in the face list and clicking Examine from the shortcut menu. If you are not
satisfied with the face, click Remove from the shortcut menu to remove the selected
face from the face list.
5. Click Create, the surface that consists of all the faces in the list will be created. You
may then browse the new surface in the Machining browser.
You can also create a surface when using Solution Wizard. For more information, see How
to Create Machining Solutions Based on Surface on page 34.
Continued
Modifying a Surface
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Item Description
Name Displays the name of the selected surface.
NOTE! Unable to rename an already created surface.
Faces Lists all the faces that the selected surface contains.
Examine Shortcut menu item.
Displays the selected face in the center of the 3D view.
Remove Shortcut menu item.
Removes the selected face.

Apply Makes the changes take effect.
Close Close this dialog box.
To modify a surface, follow these steps:

1. Right-click a surface in the Machining browser and click Properties... to open the
Properties: Surface dialog box.
2. Add new faces to the Faces list by clicking in the 3D view, or remove faces by right-
clicking a face and clicking Remove from the shortcut menu.
3. Click Apply.
The changes will take effect.
NOTE! The changes will not make any influence on the solutions and paths that were created
based on the previous surface.
4.3.1. Launching the Wizard
4.3 How to Create Machining Solutions Based on Surface
4.3.1. Launching the Wizard
Overview
Machining PowerPac provides a wizard that contains all necessary parameters for creating
machining solutions. After you go through the wizard, a machining solution is created.
How to Launch the Wizard

Click Solution Wizard on the Machining ribbon-tab to launch the wizard.
TIP!
When editing parameters in this wizard, an indicator appears indicating which item is being
edited, and the illustration and description for the current edited item will be displayed on the
right side of the wizard.
4.3.2. Defining Machining Solution
Description
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Item Description
Controller Select a controller in which the solution will be located.

Task Select a task in which the solution will be located.
Solution Configuration Select a solution configuration template to load the parameters
Template that were set previously for creating a solution. If no template is
selected, all the parameters will have the default value.
Solution Name Enter a name for the new solution in the text box.
Continued
Follow these steps:

1. Select a controller that will be used for the solution from the Controller drop-down
menu.
2. Select a task from the Task drop-down menu.
3. Select a solution configuration template to load and reuse the values and settings that
are defined in the selected template or select Empty then enter value for each
parameter manually.
4. Enter a name for the solution or use the default name.
5. Click Next to continue to the next page.
4.3.3. Creating Machining Surface
Description
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Item Description
Machining surface Select an existing surface or create a new surface.

See How to Create or Modify a Surface on page 31.
Name New surface name.
Select Faces from 3D view A list of faces selected from the 3D view. The new surface
consists of these faces.
Follow these steps:

1. Click the drop-down menu and select an existing surface name or select Create New
Surface.
Continued
If you choose to use an existing surface you can directly go to the next page. If you want to
create a new surface within this page, follow these steps:
1. Click the drop-down menu and select Create New Surface.
2. Enter a name in the Name text box or use the default one for the new surface.
3. Select a face by clicking in the 3D view. It is also possible to multi-select faces by
pressing SHIFT while dragging the mouse device to select an area in the 3D view. The
faces that meet the following condition, the angle between the view vector and the
normal vector of the face is less than 90 degrees, in the selected area will be added to
the list under Select Faces from 3D view.
4. Click a face or multi-select faces in the face list to highlight the faces in the 3D view.
It is also possible to view a face in the center of the 3D view by right-clicking each
face name in the face list and clicking Examine from the shortcut menu. If you are not
satisfied with the face, click Remove from the shortcut menu to remove the selected
face from the face list.
5. Click Create, the surface that consists of all the faces in the list is created.
4.3.4. Setting Machining Process Parameters
Description
en0823030003
Item Description
Tolerance (mm) Controls how the generated path fits with the surface.
A set of polygon lines corresponding to a set of move instruc-
tions are used to fit the surface. The value defines the maximum
distance between a polygon line and the surface. If the value is
0, this parameter is ignored.
This value should be 0 - 1000 mm.
Deviation Angle (deg) Controls the fitness of the robot path with the surface.
The maximum allowable angle between the tangent lines of 2
adjacent points in a path.
If the value is 0, this parameter is ignored.
The value should be 0 - 360 degree.
Continued
Item Description
Machining Overlap The overlapping strip between two adjacent paths which is
Rate(%) defined as the percentage of the used tool width.
The minimum value is 0 which means no overlap between two
adjacent paths. The maximum is 99 which means 99%
overlapped between two adjacent paths.
Machining Template Defines a set of specific move instructions. The template can be
customized in terms of machining process related properties,
such as properties of each included move instruction and
number of move instructions of different parts of a path.
See Machining Templates on page 93 for more information.
Set Force Control Opens a dialog box containing force control parameters.
Parameters
Enable Optimize Speed Enables or disables the function of setting optimal speed.
Maximum speed on The maximum speed will be applied to the machining point on
surface the surface with the largest curvature.
Minimum Speed on surface The minimum speed will be applied to the machining point on
the surface with the smallest curvature.
Follow these steps:

1. Click the up/down arrow to set a desired value or enter a desired value for each
parameter according to the real working condition.
2. Select a machining template for the solution.

3. If the force control process type is applied to the current solution, click Set Force
Control Parameters to open a dialog box to set values for force control parameters
as displayed below.
Continued
If you select FC_PressureProcess template, after click Set Force Control Parameters, the
dialog box opens.
See Application manual - Force Control for Machining FC, section FCPress1LStart, for the
description about the parameters of FC Pressure Start, section FCPressL and FCPressC for
the description about the parameters of FC Pressure Via, and section FCPressEnd for the
description about the parameters of FC Pressure End.
NOTE! If you want to export the current program as a RobotWare Machining FC program,
we recommend that you select PATH FRAME as the Force Frame Reference, and do NOT
set the direction of force the same as the path direction.
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Continued
If you select FC_SpeedChangeProcess template, after click Set Force Control Parameters,
the dialog box opens.
See Application manual - Force Control for Machining, section FCSpdChgAct, for the
description about the parameters.
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4.3.5. Setting Tool and Work Object
Description
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Item Description
Work Object Defines the work object to be used for this path.
An existing work object can be selected from this list, or a new
work object can be created as the default one, which will be
attached to the current part.
NOTE! If you select an existing work object from the drop down
list that is not attached to the current work piece, when you
change the position of the current work piece, the paths on the
work piece can not be updated correspondingly.
Tool Type Defines the type of circular tool according to its working area.
Two types of tools are supported:
• Side working, the surrounding face will be used.
• Face working, the top face will be used.
Tool Data Defines the tool data that is used for all move instructions in the
path.
Continued
Item Description
Tool Working Width (mm) Defines the working range of the tool, which means the
contacting length of the tool’s working face with the machined
face.
The value should be from 1 to 10000.
Tool Compensation (mm) For side working tool, tool compensation means the radius of
the tool wheel. This is because the TCP is defined to align with
the rotating axis of the tool, while the contacting points of the
tool are located at the surrounding face;
For face working tool, tool compensation means the distance
from the top face of the tool to the machining face. Value equal
to zero means the tool face will be in contact with the machined
face. The value can only be zero or positive.
Path Merging Gap (mm) Path Merging Gap means that two robot motion segments will
be integrated as one if the gap between them is less than the
specified value.
Follow these steps:

1. Enter a desired value for each parameter.
4.3.6. Setting Path Generation Pattern
Description
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Item Description
Select Pattern drop-down Provides six different patterns for creating machining paths.
list When creating paths with targets based on the object
geometries, curves are the geometrical objects that
RobotStudio uses. Five patterns are provided on this page to
create curves that generate paths along the curves, instead of
manually finding and creating the necessary targets.
Editing area Contains the related parameters for each patterns.
Continued
Cutting Plane Along Straight Line
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First specify a straight line, then generate a set of planes that run perpendicular to the straight
line with a constant gap which are defined by the tool working width and overlap rate. These
planes will be used to intersect with the machining surface to generate a set of curves. Targets
and machining paths will then be generated from these curves.
Continued
If one of the generated plane covers the machining surface, the machining targets and paths
will be generated along the surface edge.
Object Description
Direction (In Part Defines the direction of the straight line where a set of cutting
Coordinate) plane are created.
Select a direction from the drop-down list.
If you are not satisfied with the result, click the left/right arrow or
enter a value in each box to adjust the rotation around the X, Y
or Z axis.
The result can be viewed from the 3D view.
Start and End Point Defines a range in the line alone which the cutting planes can
be created.
Click left/right arrow or enter desired values to define the start
point and end point.
Cutting Plane Along Customized Line

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First specify a feature line, which can be a straight line or a line with several straight line
segments, by creating at least two points in 3D view. A set of planes will be generated that
run perpendicular with the feature line with a constant gap which are defined by the tool
Continued
working width and overlap rate. These planes will be used to intersect with the machining
surface to generate a set of curves. Targets and machining paths will then be generated from
these curves.
Object Description
Feature Line Points (In Part To add points to the feature line points list:
Coordinate) • Click on the surface from the 3D view.
To set point sequence:
• Select a point, and click up/down arrow.
To highlight points:
• Click a point name in the point list, or multi-select by
pressing SHIFT or CTRL while clicking each point in the
list.
To examine a point:
• Right click a point, then click Examine on the shortcut
menu, the selected point is displayed in the center of the
3D view.
To delete points:
• Click the "×" to delete the selected point.
• or click Clear All Points to delete all the points.
Change Customized Line Select this check box to make the customized line flat and
as Spline pliable.
Change Customized Line Select this check box to make the customized line as a loop.
as Loop
Continued
Circular Cutting Planes
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Use a Group of raying planes that cut the machining surface to create some curves. Create
targets and paths on these curves. These paths are machining paths. Here you need to specify
the planes’ common axis.
Object Description
Axis Direction (In Part Defines the direction of the axis.

Coordinate) Select an item from the drop-down list to quick adjust the
direction.
If you are not satisfied with the result, click the left/right arrow or
enter a value to adjust the rotation around the X, Y or Z axis.
Axis Point (In Part Click in the 3D view or enter desired value to set the position of
Coordinate) the axis point.
Radius Enter a value.
Continued
ISO Parametric Lines
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The machined surface can be regarded as a spine face represented by U and V curves. Where
a U curve or a V curve will be located is determined by the value of the parameter that ranges
from 0 to 1. A U curve or a V curve can be regarded as a feature line. A set of planes that runs
perpendicular to the feature line will be generated with a constant gap which is defined by the
tool working width and overlap rate. These planes will then be used to intersect with

machining surface to generate a set of curves. Targets and machining paths will be generated
from these curves.Two curves that stay in different faces will be integrated as one if the
distance between them is less than the defined merging gap. This will be enabled when the
check box is marked.
Object Description
Feature Line Parameter All the faces that the surface contains are displayed here.
The
V direction Select the check box of V direction, the V direction should be
used.
Clear the check box, the U direction will be used.
Location Enter a desired value for each face. The range should be from
0 to 1.
Continued
Customized Points
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Generate targets on the surface at the place you clicked and generate a path with all these
targets according to the clicking sequence.
A machining path will be created by tracing the points in sequence.
Continued
Object Description
Customized Points (In Part To add points to the points list:
Coordinate) • Click on the surface from the 3D view.
To set point sequence:
• Select a point, and click up/down arrow.
To highlight points:
• Click a point name in the point list, or multi-select by
pressing SHIFT or CTRL while clicking each point in the
list.
To examine a point:
• Right click a point, then click Examine on the shortcut
menu, the selected point is displayed in the center of the
3D view.
To delete points:
• Click the "×" to delete the selected point.
• or click Clear All Points to delete all the points.
Change Customized Line Select this check box to make the generated path flat and
as Spline pliable.
Change Customized Line Select this check box to make the generated path as a loop.
as Loop
Continued
Edges
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Generate targets on the surface along the selected edge and generate a path with all these
targets according to the edge sequence.
Object Description
Select edge from 3D view To add edges to the list:
• Click to select edges from the 3D view.

To set edge sequence:
• Select an edge, and click the up/down arrow.
To highlight edges:
• Click an edge name in the edge list, or multi-select by
pressing SHIFT while clicking each edge in the list.
To examine an edge:
• Right click an edge, then click Examine on the shortcut
menu, the selected edge is displayed in the center of the
3D view.
To delete edges:
• Click the "×" to delete the selected edge.
• or click Clear All Edges to delete all the edges.
4.3.7. Setting Target and Path
Description
en0823030006
Item Description

Work Angle (deg) Defines targets orientation.
See Terms and Concepts on page 9.
Travel Angle (deg) Defines targets orientation.
See Terms and Concepts on page 9.
Auto Calculate Spin Angle The Machining PowerPac will find a spin angle automatically.
Spin Angle (deg) See Terms and Concepts on page 9.
Offset (mm) The distance in axis direction between the target location and
the reference coordination frame.
Continued
Item Description
Path Connection Type Defines how different paths can be connected.
Three types are provided:
• Clipping
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• Sweeping
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• Miniclipping
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Approach/Departing A template that defines how a robot approaches/leaves a part.

Template NOTE! The approach points are relative to the first machining
point and the departing points are relative to the last machining
point.
Continued
Item Description
Protect Distance in Path Distance between the first machining target and the surface
Start (mm) edge.
Protect Distance in Path Distance between the last machining target and the surface
End (mm) edge.
Follow these steps:

1. Enter a desired value for each parameter.
4.3.8. Previewing the Trajectory of the Tool
Description
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Item Description
Merge into One Path Merges the generated paths into one machining path which
contains all the targets and instructions and keeps the same
targets sequence.
Auto Path Configuration Configures the paths automatically after clicking Finish.
Synchronize to Virtual Synchronizes the current solution to the virtual controller auto-
Controller matically after clicking Finish.
When the check box of Synchronize to Virtual Controller is
selected, the Auto Path Configuration is selected automatically,
which means that you cannot synchronize all your settings in
the wizard before configuring the paths correctly.
Save Setting as Template Saves all the settings and parameters in the current solution as
a template.
Continued
Follow these steps:

1. If there are some settings that do not meet your requirements, click Back to the relative
page.
2. If you want to reuse all the settings for other solutions, click Save Settings As
Template... .
3. Click Finish.
After clicking Finish, the solution will be created and the wizard will be closed. You can
modify the solution with the Machining ribbon-tab, the Machining browser, and the Path
View. See Working with the Machining Ribbon-tab on page 80,Working with the Machining
Browser on page 62, and Overview on page 64.
4.4. How to Create Machining Solutions Based on Edge
4.4. How to Create Machining Solutions Based on Edge
Launching the Solution Wizard

Click Solution Wizard on the Machining ribbon-tab to launch the Solution Wizard.
Setting Parameters
See How to Create Machining Solutions Based on Surface on page 34 for how to use the
wizard creating solutions.
NOTE! The only difference is that creating solution based on edge must use the Edges
pattern. See Edges on page 53for the detailed information.
4.5. How to Set Schedule
4.5. How to Set Schedule
Overview
This section describes how to organize all solutions in a schedule.
Schedule is the entry point for a machining program. The new created solution will be added
under the schedule node automatically.
Organizing Solutions in a Schedule

When a solution is created by the Solution Wizard, this solution will be added under the
Schedule node automatically.
To reset the schedule:
• Right-click the Schedule node, click Clear to remove all the solutions. Or right-click
the solution that you want to remove from the schedule, and click Delete.
• Add solutions to the schedule by dragging a solution under the surface node and
dropping.
• Set solution sequence by right-clicking the solution under the Schedule node and
clicking Move up and Move down on the shortcut menu.
4.6.1. Overview
4.6 How to Modify Solutions, Paths and Targets
4.6.1. Overview
Overview
This section describes how to modify solutions, paths and targets. Frequently used functions
are provided, such as delete, rename, reverse and so on. You can modify an element by right-
clicking the element node or clicking the button on the Machining ribbon-tab.
4.6.2. Working with the Machining Browser
Overview
The machining solution is automatically displayed in the Machining browser after finishing
the Solution Wizard. You can directly synchronize the solution to virtual controller and run
simulation, or do some modification with the shortcut menu by right-clicking the solutions
and paths in the browser.
Shortcut Menu from the Task Node
Item Description
Refresh Refreshes the display of the task node.
Clean VC Removes all user modules from the virtual controller.
Synchronize to VC Synchronizes the current program to the virtual controller.
Shortcut Menu from the Solution Node
Item Description
Open In Path View Displays all the paths of this solution in both the path view and
the 3D view.
Auto Path Configuration Configures paths automatically.

Reverse All Reverses the paths sequence.
Show All in 3D Displays all the paths in the 3D view.
Rename Prompts you to rename the selected solution.
Delete Deletes the selected solution from the current surface node.
Properties... Displays the properties of the selected solution.
Close Path View Closes the paths in the path view.
Only available when there are paths opened in the path view.
Hide All Hides paths of the selected solution that were highlighted in the
3D view.
Only available on the solution that contains several highlighted
paths.
Continued
Shortcut Menu from the Path Node
Item Description
Open in Path View Displays the selected path in both:
• path view. See Overview on page 64for more informa-
tion.
• 3D view, all the targets in the path will be displayed with
reference frames. A tool indicator will show how the tool
reaches the targets.
Not available on an open path.
Auto Path Configuration Configures the selected path automatically.
Reverse Reverses the targets sequence in the selected path, and inter-
changes target types accordingly.
The following targets are interchanged:
• the start and end targets
• the approach and departing targets
NOTE! When reversing targets sequence for a force control
path, you should modify the start and end targets to meet the
requirement for these targets in force control process. See
Application manual - Force Control for Machining for a detailed
description.
Show in 3D Highlights the selected path in the 3D view.
Rename Allows you to rename the selected path.
Delete Deletes the selected path.

Hide Hides the path that was highlighted in the 3D view.
Only available on the highlighted path.
Close Path View Closes the path from the path view.
Only available on an open path.
4.6.3.1. Overview
4.6.3. Working with the Path View
4.6.3.1. Overview
Overview
The path view displays the targets in a path by representing them with instruction icons.
These target can be modified by using commands from the shortcut menus or the buttons in
the path view tool bar.
You can choose to modify:
• An individual target
• An entire path
• Multi-selected targets
Shortcut Menu from the Path View

Right-click an instruction icon in the Path View to open the shortcut menu. The contents of
the shortcut menu will change depending on selected target.
The table below shows all the commands in the menu.
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4.6.3.1. Overview
Continued
Object Description
Create Creates paths, instructions and procedure calls. The content will change
depending on selected target.
Not available for the approach target, departing target, end target and
multi-selected targets.
See The Create Menu on page 66 for detailed description.
Modify Modifies targets, instructions and motion type. The content will change
depending on selected target.
See The Modify Menu on page 73.
Configuration Contains the following commands:
• Check Reachability on page 78
• Set Configuration on page 78
Jump to See Path View Toolbar on page 24.
Move to See Path View Toolbar on page 24.
Set target Sets the target referenced in the instruction as the User Coordinate
reference as UCS System.
Not available for the multi-selected targets.
Remove Configu- Removes the configuration of the currently selected targets.
ration
Delete Deletes the selected item.
Select this path Selects the entire pat.
Only available for the path divider.
Path View Toolbar

The path view holds the path view toolbar, which has menus and buttons for the most
frequently used commands.
See The Path View on page 24 for detailed description.
Related Information
The Path View on page 24
4.6.3.2. The Create Menu
Overview
This menu contains the following commands:
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Continued
Command Description
New Path Only available for the path divider.
Create a New Path on page 68
Machining Instruction Only available for the Start or Via target.
Create a Machining Instruction on page 69
Air Instruction Only available for a path divider, action instruction, or ABS joint
instruction.
Create an Air Instruction on page 70
ABS Joint Instruction Only available for a path divider, action instruction, or ABS joint
instruction.
Create an ABS Joint Instruction on page 71
Action Instruction Only available for a path divider, action instruction, or ABS joint
instruction.
Create an Action Instruction on page 72
Procedure Call Only available for a path divider, action instruction, or ABS joint
instruction.
Create a Procedure Call on page 72
Add Approach Instruction Only available for the Start target when the path does not
contain approach targets.
Adds approach targets before the Start target according to the
current used Approach/Departing template.
Add Departing Instruction Only available for the End target when the path does not contain
departing targets.
Adds departing targets after the End target according to the
current used Approach/Departing template.
NOTE!
• The contents of the Create menu will change depending on selected target.
• Save the parameters and settings in the present tool window before clicking the Create
menu, otherwise all these settings will be lost. Because to open any Create dialog box
will close all other dialog boxes that were previously opened.
• Save the parameters in the Create dialog box before opening other dialog boxes,
otherwise the Create dialog box will close and all the parameters in the Create dialog
box will be lost.
Continued
Create a New Path
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To create a new path, follow these steps:

1. Right-click a path in the Path View, in the Create menu, click New Path.
2. Name the new path or use the default name in the Name text box.
3. Select a Machining template and an approach/departing template for the path.
4. Set work angle, travel angle and spin angle for the path.
5. Click in the 3D view to add points to the new path.
6. Click Create, the new path will be created.
Continued
Create a Machining Instruction
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Machining instruction defines how the robot moves to the via target which must locate on the
surface to be machined.
To create a Machining instruction, follow these steps:
1. Select a reference frame from the drop-down list.
2. Click in the 3D view to set a To Point, the position value of the selected target is
displayed in the dialog box.

3. Click Create, the new machining instruction is created.
Continued
Create an Air Instruction
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Air instruction defines how the robot moves to an air target which is the intermediate target
between path section.
To create an Air Instruction, follow these steps:
1. Select a desired item from the Reference drop-down list.
2. In the 3D view, move the robot TCP to the desired position and click Present. A new
target is displayed in the graphics window, and an instruction icon is added to the path
view.
3. To set the position manually, select a reference coordinate system, enter a desired

value.
4. In the dialog box, click OK. If the Auto Create check box is selected, the air
instruction is automatically created when a valid input has been entered. A new target
is displayed in the 3D view, and an instruction icon is added to the path view. Click
OK, all the changes will take effect.
5. Click Close to close this dialog box without any changes.
Continued
Create an ABS Joint Instruction

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Absolute joint instructions may be added to a path.

To create a jointtarget, follow these steps:
1. Jog the robot to an arbitrary position and then click OK.
2. A new jointtarget is displayed in the 3D view, and an instruction icon is added to the
path view.
Continued
Create an Action Instruction
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To create an action instruction:

1. Select an instruction from the drop-down list.
2. Click OK, a blue instruction is add to the path view.
Create a Procedure Call
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To set procedure call:

1. Select a path procedure name from the drop-down list.
2. Click OK to make the changes take effect.
4.6.3.3. The Modify Menu
Overview
This menu contains the following commands:
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Command Description
Instruction Not available for the path divider.
Modify Instruction on page 74
Target Not available for a path divider, ABS joint target, or action
instruction.
Modifying Target on page 75
Convert to Linear Move Only available for a Approach, Departing or air target with joint
motion.
Convert to Joint Move Only available for a Approach, Departing or air target with joint
motion.
Convert to Air Instruction Only available for the first Approach target or the last Departing
target.
Convert to Approach Only available for an air target, after which the target must not
Instruction be air.
Convert to Departing Only available for an air target, before which the target must not
Instruction be air.
Continued
The Modify menu for the multi-selected targets contains the following command:
Command Description
Target Reference Position Target Reference Position on Selection on page 76
on Selection
Target Reference Target Reference Orientation on Selection on page 77
Orientation on Selection
Target Offset/Angle on Target Offset/Angle on Selection on page 77
Selection
Convert to Circular Only available when two Via targets are selected.
Convert to Linear Only available when two Via targets are selected.
NOTE!
The contents of the Modify menu will change depending on selected target.
Modify Instruction
Most instructions have arguments that specify how the instruction must be performed. For
example, the arguments of the MoveL instruction specify the speed and accuracy with which
the robot moves to the target. In the Modify Instruction dialog box, you can display and
change these arguments.
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Enter the desired value, or select a value from the drop-down menu. Click Apply to make all
changes take effect.
Continued
Modifying Target
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To modify the selected target:

1. Reference, the coordinate system of the target reference. All available frames in the
station are listed.
2. Target reference, marks the start or end position and rotation.
3. Target, normally linked to the target reference coordinate system. The offset values
are relative to the target reference.
Convert to Joint Move

Convert a MoveJ instruction to a MoveL instruction.
Convert to Linear Move

Convert a MoveL instruction to a MoveJ instruction.
Convert to Air Instruction

Switch the motion type of the selected target to Air Instruction.
Continued
Target Reference Position on Selection
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Modify menu on the multi-selected targets.

To modify the selected targets:
1. Reference, the coordinate system of the target reference. All available frames in the

system are listed here. Select a desired item from the drop-down list.
2. Position, enter desired values. If you want to move the selected target in just one
direction, clear the check boxes of the other axes on the left side.
Continued
Target Reference Orientation on Selection
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Target Offset/Angle on Selection

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This command offsets of rotates the selected targets of process instructions a given distance
or angle. This offset or angles is in relation to the target reference coordinate system.
4.6.3.4. The Configuration Menu
Check Reachability
Click this item to check whether the robot can reach a target. A successful result turns the
target yellow, while an unsuccessful result turns it red.
Set Configuration
Robot configuration may be set for individual targets. The system calculates a configuration
based on your selections, after which values are displayed.
Click Configuration -> Set configuration..., the following box appears:
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Item Description
Arm The group is used to specify whether the robot wrist is in front of
or behind axis 1, and whether the elbow is up or down.
Wrist This group is used to specify whether axis 4 will be turned
positive or negative.
Continued
Item Description
Tool This group is used to specify whether axis 6 will be turned
positive or negative. If neutral is selected, the configuration of
axis 6 will be determined by the arm and wrist selections.
New This list displays the configuration and joint values for a selected
configuration, as well as alternatives.
Current This box displays the configuration currently stored in the
selected target.
Change This box calculates the difference in joint values between the
currently selected target and the preceding target in the path.
To set configuration, follow these steps:

1. Right-click a target in the Path View, and click Configuration -> Set configuration...
from the shortcut menu to start the Set Configuration dialog box.
2. Select a configuration in the New drop-down list or click items in the Arm, Wrist and
Tool groups to set configuration manually. An available configuration will turn the
corresponding item to white, while the unavailable configuration appears shades.
3. Click Apply.
The configuration will be applied to the selected target.
4.6.4. Working with the Machining Ribbon-tab
Overview
The frequently used commands for modifying solutions or paths are provided on the
Machining ribbon-tab.
This section introduces the functions that are provided in the Modify group and Diagnostics
group.
See How to Create Machining Solutions Based on Surface on page 34, How to Create or
Modify a Surface on page 31 and How to Create Calibrations on page 99 for the descriptions
about the Create group, and How to Export Machining PowerPac Programs on page 89for
the description about the Export group.
Machining Template

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To change the Machining template of a path or a solution, follow these steps:

1. In the Machining browser, click a solution that needs to be modified.
2. Click Machining Template on the Machining ribbon-tab to open the dialog box.
NOTE! When the dialog box opens, the corresponding values of the selected path or
the first path in the selected solution (depending on what you select) will be loaded
and displayed in the dialog box.
3. Select a desired template from the Machining Template drop-down list.
4. Click Apply.
Continued
The RAPID instructions of the corresponding targets in the selected path will be changed
according to the new Machining Template. For example, if you change the machining
template from NormalProcess to FC_PressureProcess, the instruction for the process start
target will be changed from MoveL to FCPress1LStart.
See Machining Templates on page 93 for the definition for Machining Template.
NOTE!
A Machining template should be applied to an entire solution. After the FC_PressureProcess
or FC_SpeedChangeProcess template is applied to the selected solution, the force control
parameters in the selected solution will be set to default values.
Approach/Departing Template
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To change the Approach/Departing Template of a path or a solution, follow these steps:

1. In the Machining browser, click a path or a solution that needs to be modified.

2. Click Approach/Departing Template on the Machining ribbon-tab to open the
dialog box. NOTE! When the dialog box opens, the corresponding values of the
selected path or the first path in the selected solution (depending on what you select)
will be loaded and displayed in the dialog box.
3. Select a desired template from the drop-down list.
4. Click Apply.
See Approach/Departing Templates on page 97 for the definition for Approach/Departing
Template.
Continued
NOTE!
• Changing the Approach/Departing Template will delete the approach/departing
targets in the selected path, then insert new approach/departing targets using the new
template.
• If the Start/End targets in the path or solution are deleted, changing the Approach/
Departing Template will delete the approach/departing targets but the new ones can
not be added, since the approch/departing targes should be created relative to the start/
end targets.
• In general, the new approach targets are inserted before the start target. However, if
FCSpdChgAct is added before the start target, the new approach targets are inserted
before FCSpdChgAct instead of the start target.
Machining Speed
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Continued
To modify the speed for a path or a solution, follow these steps:

2. Click Machining Speed on the Machining ribbon-tab to open the dialog box. NOTE!
When the dialog box opens, the corresponding values of the selected path or the first
path in the selected solution (depending on what you select) will be loaded and
3. Select a desired speed value for each phase.
4. Click Apply.
The new values are applied to the corresponding targets in the selected paths.
See Machining Templates on page 93 for the detailed explanation about the targets
classification.
NOTE!
Not every paths contains all the types of targets. The speed values can only be applied to the
targets that exist in the selected path. For the target type that does not exist in the select path,
nothing will be changed in the path even if you set a new speed value.
Continued
Machining Force
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When the Machining FC option is active in the current controller system, the machining force
needs to be set.
To modify the machining force for a path or solution, follow these steps:
1. In the Machining browser, click a solution that needs to be modified.
2. Click Machining Force on the Machining ribbon-tab to open the dialog box.NOTE!
When the dialog box opens, the corresponding values of the selected path or the first
path in the selected solution (depending on what you select) will be loaded and
3. Enter a desired value under Machining force.
4. Click Apply.

The new value of machining force is applied to the selected path. This value is used in
FCPressL or FCPressC when the FC_PressureProcess is selected, or FCSpdChgAct when
the FC_SpeedChangeProcess is selected.
NOTE! This command is available only when the FC_PressureProcess or
FC_SpeedChangeProcess template is applied to the current solution.
Continued
Tool Compensation
en0700000234
To modify the tool compensation for a path or a solution, follow these steps:
2. Click Tool Compensation on the Machining ribbon-tab to open the dialog
box.NOTE! When the dialog box opens, the corresponding values of the selected path
or the first path in the selected solution (depending on what you select) will be loaded
3. Enter a desired value under the Tool compensation (mm).
4. Click Apply.
The new value is applied to the selected path and is used to change the offset in Z direction
of all the targets in the selected path.
See Setting Tool and Work Object on page 43for the explanation for what the tool
compensation is.
Continued
Tool Working Range
en0700000224
To modify the tool working range for a path or a solution, follow these steps:
2. Click Tool Working Range on the Machining ribbon-tab to open the dialog
box.NOTE! When the dialog box opens, the corresponding values of the selected path
or the first path in the selected solution (depending on what you select) will be loaded
3. Select the check boxes of Tool Working Range (deg) and Rotate Tool Working
Point (deg), and enter desired values.
4. Click Apply.

The new value is applied to the selected path. Consequently, the spin angles for all the targets
in the selected path are changed according to the changes.
See Terms and Concepts on page 9 for the definition of tool working range.
Check/Heal
This tool is used to check whether the imported part is valid, and furthermore, to heal the
damaged part in the current station. And this function can be available whenever working
with Machining PowerPac.
en0700000258
To check an imported part, follow these steps:

• Click Check/Heal on the Machining ribbon-tab to open the dialog box.
• Select a part that you want to check from the Part drop-down list. All the parts that
are imported to the current station will be displayed in the list.
• Click Check.
The check result is displayed in the Output window.
To heal an imported part, follow these steps:
• Click Check/Heal on the Machining ribbon-tab to open the dialog box.

• Select a part that you want to heal from the Part drop-down list. All the parts that are
imported in the current station will be displayed in the list.
• Click Heal.
The result is displayed in the Output window.
4.7. How to Set up a Simulation
4.7. How to Set up a Simulation
How to run a simulation

To run a simulation follow these steps:
1. Synchronize the current program to virtual controller. This can be done by right-
clicking the task node in the Machining browser and selecting Synchronize to VC
from the shortcut menu, or selecting the check box Synchronize to VC in the last page
of the wizard.
2. Click the Simulation tab in the Ribbon, and click Play to start the solution. Or click
Simulation in the Path View toolbar.
NOTE! Before the synchronization, make sure that all the paths in the current program are
configured correctly.
How to prepare for a force control simulation

When the Machining FC option is active in the current controller system, some special
settings are required.
Before simulating a program that contains force control instructions, you should:
1. Press F5 to launch the virtual FlexPendant.
2. Click the ABB logo at the upper-right corner to open the ABB main menu.
3. Click Control Panel.

4. Click Configuration. From the Topics list which is located at the bottom of the virtual
FlexPendant, select Motion. Double-click Robot. Select the currently used robot task,
click Edit.
5. Double-click Use FC Master, select a FC Master for the robot.
6. Click OK to confirm, a warm start is required.
7. After the warm start, all the changes will take effect.
4.8. How to Export Machining PowerPac Programs
Continued
How to Export a Machining Program

You can choose to export the current work with Machining PowerPac as a RAPID program,
or a RobotWare Machining Force Control program.
en0700000232
To export a RAPID program:

1. Synchronize the current program to the virtual controller.
2. Select the task node in the Machining browser.
3. Click RAPID on the Machining ribbon-tab. A dialog box displays.
4. Specify the location where you want to save the program, and enter a name for the
program.
5. Click OK, the RAPID program will be saved in the specified location.
en0700000230
To export a RWM program:

1. Select the task node in the Machining browser.
2. Click the RWM on the Machining ribbon-tab. A dialog box displays.
3. Select a process type from the FC Process Type drop-down list, specify a location
where the export program will be stored and give a new name or use the default name
for the export program.
4. Click OK, the program will be saved in the specified location.

Copy the exported file to the controller project folder "\HOME\MachiningFC\MFC
Projects\", the file can be recognized by the RobotWare Machining FC graphical user
interface. The RobotWare Machining FC is a controller software designed for high quality
surface finishing and cast cleaning with Force Control option. All the exported paths from
RobotStudio Machining PowerPac are taught paths. A learning process can be preformed
based on the exported paths. See Application manual - Force Control for Machining.
4.9.1. Overview
Continued
4.9 How to Create or Modify Templates
4.9.1. Overview
Overview
Three predefined templates are provided:
• Machining template, a template defining a set of specific move instructions, which can
be customized in terms of machining process related properties.
• Approach/Departing template, a template defining how the robot moves close to a
surface and withdraws from a surface. For approaching targets, their translation and
orientation is referenced to the first target located in the surface. For the departing
targets, their translation and orientation is referenced to the End target.
• Solution Configuration Template, a template defining all the parameters to be used to
generate paths from a surface.
en0700000245
4.9.1. Overview
Importing or Exporting Templates

Machining PowerPac enables you to export and import templates. With this function you can
backup the customized templates and share these templates with other Machining PowerPac
users.
Template Exported file

Machining Templates .prt
Approach/Departing Templates .adt
Solution configuration Templates .pgs
Example
To export Machining templates:
1. Right-click the Machining node in the Machining browser and click Export... on the
shortcut menu to start the Export Machining Template dialog box.
2. Specify a location in Save in, enter a name for the new prt file in the File Name text
box and click Save. All the templates under the Machining node will be saved as a prt
file, which means an exported file may contain more than one machining template.
To import a prt file to Machining PowerPac:
1. Right-click the Machining node in the Machining PowerPac browser and click
Import... on the shortcut menu to open the Import Machining Template dialog box.

2. In Look in browse to the location where the prt file is stored, select the desired file,
and click Open.
3. All the Machining templates in the imported prt file will be displayed under the
Machining node.
4.9.2. Machining Templates
Continued
Overview
A machining template is a collection of instruction settings and process parameters. Before
creating paths in Machining PowerPac, a machining template should be selected and the
corresponding instructions will be applied to the path.
Machining PowerPac provides the following templates by default:
Template Description
NormalProcess Always available.
Includes the normal move instructions: MoveL, MoveJ and
MoveC.
FC_PressureProcess Available when the Force Control option is selected in the
current system.
Includes force control instructions and supports the pressure
process.
FC_SpeedChangeProcess Available when the Force Control option is selected in the
current system.
Includes force control instructions and supports the speed
change process.
NOTE!
If the Force Control option is not selected in the current system, the FC_PressureProcess and
FC_SpeedChangeProcess are not available and it is not possible to import a template with
force control instructions.
Continued
Machining Modeling
A machining process model in RobotStudio Machining PowerPac is given as below:
en0700000239
Machining Motion Part Description

Air Intermediate targets between path sections.
A collection of robot targets where the robot will move fast and
the motion type of the robot can be linear or joint.

Approach A collection of robot targets that leads the robot to move to the
surface smoothly and safely.
Start The first target that locates on the surface, where some signals
or events can be triggered.
Via A collection of robot targets that locate on the surface, and the
motion type for Via targets is defined by the machining template.
End Normally, the end part is the first retract target where the robot
can safely move to from the last target on the surface, and it’s
also a synchronization point to trigger signals and events.
Currently, the End target follows close behind the last Via target
and locates in the position that is 3 mm in both the X and Z
positive direction of the last Via target.
Departing A collection of robot targets that leads the robot to withdraw from
the surface.
Continued
Differences on Machining Template

About the machining template, there are different convention to describe the targets between
RobotStudio Machining PowerPac and RobotWare Machining FC.
See the following pictures and table for the detailed information.
Machining Template in RobotStudio Machining PowerPac
en0902040001
Machining Template in RobotWare Machining FC
en0902040002
RobotStudio Air Approach Start Via End Departing

Machining optional 3 (Template) 1 (The first >=1 1 (Create 3

PowerPac target on Via on the last (Template)
the via target)
surface)
RobotWare - Approach Process Process Withdraw Withdraw
Machining >=3 1 (The first >=2 1 (The first >=2
FC Process Process withdraw
target) target)
Shortcut Menu from a Machining Template Node
Item Description
Create Copy Creates a copy template.
Rename Allows you to rename the selected template.
Item Description
Delete Deletes the selected template.
Properties... Opens a dialog box with which you can view and edit the
properties of the selected template.
4.9.3. Approach/Departing Templates
4.9.3. Approach/Departing Templates
Overview
Each Approach/Departing template has two parts to define the approaching section and the
departing section of a machining path.
NOTE! Machining PowerPac defines special Approach/Departing templates with prefix FC
as default for the learning process of RobotWare Machining FC. For example, if the
FC_ObetuseAngle_135_deg is selected, the approach/departing targets expected relative
position and orientation to Start target and End target is shown in the following figure. The
Approach2, Approach3 and Start targets should be along the x axis in an almost straight line,
and the approach angle to the surface is less than 20 degree. The End, Departing1 and
Departing2 should be along the x axis in an almost straight line.
en0700000257
Adding Approach/Departing Targets

1. Right-click the Approach Target List or Departing Target List, click Add
Approach Target/Add Departing Target on the shortcut menu. A new target will be
displayed in the browser with default position and orientation values.

2. Right-click the new target, click Properties... to start a dialog box.
3. Define the position and orientation in the dialog box.
4. Click Apply to apply the new values to the target.
4.9.4. Solution Configuration Templates
4.9.4. Solution Configuration Templates
Overview
Defines all parameters for generating a solution.
NOTE! SolutionConfiguration_RWMFC is provided by Machining PowerPac as default for
RobotWare Machining FC.
Showing the Properties of a Template

Right-click a template, and click Properties..., the dialog box with four tabs will open.
• Edit the parameters in this dialog box.
• Click Apply to make all changes take effect.
See How to Create Machining Solutions Based on Surface on page 34 for the detailed
descriptions of the parameters.
4.10. How to Create Calibrations
Continued
Overview
In most of cases, the part positions are different between the virtual cell and the real cell.
Machining PowerPac provides an easy way to adjust the positions by calibrating work object
since all the robot targets are relative to the work object.
After creating all the paths offline, the calibration for paths should be done before applying
the paths to work.
How to Create Calibration Data

5 points calibration method is recommended.
en0700000231
To create calibration in virtual world:

1. Click Calibration on the Machining ribbon-tab to open the dialog box.
2. Enter a name for the calibration in the text box.
3. Click in the 3D view to select 5 points not in a line or type values in the spin box under
Point Position.
4. Select the check box of the work object to decide which work object in the list will be
the reference work object.
5. Click Create, the new created calibration will be displayed in the Machining browser.
The Machining PowerPac will generate a RAPID procedure for this calibration.
How to Calibrate in Real World

To calibrate in real cell:
1. In real cell, select 5 points at almost the same positions as in the virtual world.
2. Call the generated RAPID procedure to update the work object. This will affect the
value of the oframe, that is, the object frame of the work object.

5 Trouble Shooting
5.1. About Path Generation Pattern
5 Trouble Shooting
What to do...
Troubleshooting when using path generation patterns in the solution wizard:
When using... Trouble Description Try this ...

Cutting Planes The generated paths can Probable cause: The cutting planes are
Along Straight not be seen from the parallel with the surface.
Line Preview page of the Try this: Adjust the orientation of the cutting
Cutting Planes Solution Wizard. planes to ensure that the cutting planes
Along intersect with the surface.
Customized Probable cause: The part is invalid.
Line Try this: Close the wizard, use Check/Heal on
Circular the Machining ribbon-tab to heal the imported
Cutting Planes part.
ISO Parametric There is no curve Close the wizard, use Check/Heal on the
Lines generated. Machining ribbon-tab to heal the imported
part.
If there is still no curve generated after
running Heal, the surface may not be the
supported format for this pattern.
Edges Edges can not be selected From the selection level toolbar of RobotStu-
from the 3D view. dio, make sure that Surface and Snap Edge
are selected.
If you still can not select the edges, close the
wizard. Use Check/Heal on the Machining
ribbon-tab to heal the imported part.

5 Trouble Shooting

Index
A
Approach/Departing Template 97
E
Edge 53
M
Machining Template 93
FC_PressureProcess 93
FC_SpeedChangeProcess 93
NormalProcess 93
R
RWM 19
S
Schedule 9
Solution 9
Solution Configuration Template 98
Spin Angle 10
Surface 9
T
Tool Compensation 44
Tool Working Range 9
Travel Angle 10
W
Work Angle 9
103
104
Index

Operating Manual PowerPac

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Operating manual

Document ID: 3HAC030420-001

3 Navigating Machining PowerPac 15

4 Workflow for Machining PowerPac 29

4.3.4 Setting Machining Process Parameters ..........................................................................39

4.7 How to Set up a Simulation..................................................................................................... 88

5 Trouble Shooting 101

© Copyright 2008-2009 ABB. All rights reserved.

About This Manual

Who Should Read This Manual?

Continues on next page

© Copyright 2008-2009 ABB. All rights reserved.

Continues on next page

© Copyright 2008-2009 ABB. All rights reserved.

1.2. Terms and Concepts

Machining PowerPac Concepts

reference coordinate system, which is named Reference

Continues on next page

© Copyright 2008-2009 ABB. All rights reserved.

Continues on next page

Installing Machining PowerPac

NOTE! Machining PowerPac will be installed in the following location: C:\Program

© Copyright 2008-2009 ABB. All rights reserved.

2.2. Getting Started

How to Start Machining PowerPac

How to Stop Machining PowerPac

© Copyright 2008-2009 ABB. All rights reserved.

3 Navigating Machining PowerPac

The Graphical User Interface

Continues on next page

© Copyright 2008-2009 ABB. All rights reserved.

3.2. The Machining Ribbon-tab

About the Machining Ribbon-tab

Elements on the Machining Ribbon-tab

Group Button Description

a more detailed description.

Continues on next page

Group Button Description

© Copyright 2008-2009 ABB. All rights reserved.

Continues on next page

Group Button Description

3.3. The Machining Browser

© Copyright 2008-2009 ABB. All rights reserved.

Continues on next page

Icons in the Machining Browser

Icon Node Description

Surface A certain user-defined machining surface.

Solution A set of result paths that are created on the surface.

Failed path A path that contains at least one unreachable target.

No configuration A path where no configuration solution can be found.

Schedule The entry point for a machining program.

Calibration Contains all calibration data.

Continues on next page

Icon Node Description

Work object The work object that is used during calibration.

Template Contains different types of templates.

Machining Contains all machining templates.

Machining A machining template.

Approach/ Contains all approach/departing templates.

© Copyright 2008-2009 ABB. All rights reserved.

Approach/ Defines how a robot approaches or departs the

Approach target A position and rotation defines how a robot

Departing target Contains all the departing targets in the current

Continues on next page