Master-Control Communication Setup (RobotWare 7)

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Preparation

Check Controller and Software Compatibility

Controller: OmniCore
Controller system software version: RobotWare 7.3 or higher
Control module option: 3114-1 Multitasking

The detailed instructions are as follows.

In the Home interface of the teach pendant, select Settings System to check the RobotWare version.
Tap About and you can confirm the RobotWare version, which should be above 7.3, in System Details.
Check whether 3114-1 Multitasking is in the System Options.

The robot cannot be connected by using Master-control if the system version does not meet the requirement.

Set up the Network Connection

Connect the Hardware

Plug the Ethernet cable of the IPC into the WAN port of the robot controller, as shown below.

Set the IP Address

The Ethernet cable must be connected to the WAN port. When setting the IP address, be careful to distinguish between the robot IP address of the WAN port and that of the LAN port.

Tap to open Control Panel, and then select Control Manual.
In the Home interface of the teach pendant, select Settings Network Public Network.
Select Use the following IP address, and enter the IP Address, Subnet mask, and Default Getaway. The IP address of the robot should be in the same subnet as that of the IPC.

Load the Program Files to the Robot (Auto)

After you set parameters in the Robot Program Loader tool, the tool auto-loads files to the ABB robot. Follow the steps below to allow the tool to auto-load files.

If the auto-load process fails and you cannot resolve the issue, proceed to Load the Program Files to the Robot (Manual).

Tap to open the Control Panel, and select Control Auto.

Navigate to the installation directory of Mech-Vision and Mech-Viz, go to the Robot Program Loader folder by using the Communication Component\tool\Robot Program Loader path, and then double-click the Robot Program Loader program to open the loader. The main interface of the loader appears.

To switch languages in Robot Program Loader, select a different language from the drop-down list in the upper-right corner of the main interface and restart Robot Program Loader for the new language to take effect.

Select the ABB robot brand, enter the actual robot IP address, and then click Connect.

If the connection fails, click Test network connection in the lower-right corner to troubleshoot the issue.

In the ABB Program Loading interface, select a folder to store the backup files and then click Back up. If the files are backed up, a message that indicates the backup is successful is displayed in the Log section.

If errors occur in the subsequent loading process, the files can be used to reset the robot system.
If you have loaded master-control programs to the robot, you can load master-control programs again only after you reset the robot system.

After the backup succeeds, select Load the Master-Control program(s) to confirm the folder that stores the program files and then select the IO card type of the robot. In this example, No IO card is selected. Your card type may be different from the card type that is used in this example. Set the card type based on your actual scenario. After you set the preceding parameters, click Load with one-click. If a message that indicates the program files are successfully loaded appears in the Log section, the files are loaded to the robot.

If the auto-load process succeeds, the controller restarts. After the auto-load process succeeds, proceed to Test Master-Control Communication.

Load the Program Files to the Robot (Manual)

If the auto-load process succeeds, skip this section.

Before you manually load files to the robot, we recommend that you perform a backup. This way, you can reset the robot system if an incorrect operation occurs.
If you have loaded master-control programs to the robot, you can load master-control programs again only after you reset the robot system.

Prepare the Files

Navigate to Communication Component/Robot_Server/Robot_FullControl/abb/RobotWare 7 from the installation directory of Mech-Vision & Mech-Viz. Copy the folders below and paste it into the USB flash drive.

Folder	Description
config_robware7	Robot configuration file that defines the signals required by the master-control, the auto-loaded module, and task types
MM_robware7	The robot program module

Folder

Description

config_robware7

Robot configuration file that defines the signals required by the master-control, the auto-loaded module, and task types

MM_robware7

The robot program module

Backup

Before operating the robot, please follow the backup instructions below to back up the system so that the robot system can be restored if an incorrect operation occurs.

Select Settings Backup & Recovery in the Home interface.
In the Backup window, modify the Backup Name and Location and then tap Backup.
Click OK in the pop-up window to complete the backup.

Resetting

Two types of resetting exist: resetting RAPID and resetting the system.

Resetting the system restores the default system parameters and RAPID program, and resets the I/O settings. If a communication board or other communication devices are used, you must re-configure the board and devices after the system is reset.
Resetting RAPID deletes the current RAPID program and data and retains system parameter settings.

Reset RAPID

Determine whether you need to reset RAPID based on the following flowchart.

Select Settings Backup & Recovery in the Home interface.
In the Reset user data window, select Reset RAPID, and then tap Reset.
Click OK in the pop-up window.

Reset the System (use with caution)

Select Settings Backup & Recovery in the Home interface.
In the Reset user data window, select Reset RAPID and System Parameters, and then tap Reset.
Click OK in the pop-up window.

Load the Files to the Robot

Before starting, ensure that the robot system does not have programs created with Wizard. Wizard is a graphical programming tool, which enables users to create programs by dragging and dropping graphic blocks. If a Wizard program exists in the robot system, you should reset RAPID. Besides, do not program with Wizard after loading the program files.

The Ethernet cable is connected to the WAN port of the controller. To add the controller, you can open RobotStudio, click Add Controller, and then select the controller and click OK. After the controller is added, the controller management port will be connected automatically.
Import the two configuration files in the config_robware7 folder as shown below.

If a DSQC 1030 I/O unit is used, please select DSQC1030.cfg and SYS.cfg.
Select Confirm in the pop-up windows.
Follow the steps as shown in the figure below to copy the entire MM_robware7 folder and paste it to the HOME directory of the robot system.
Follow the steps as shown in the figure below to enable the RapidSockets network service.
Modify the safe zone threshold (in mm) in the safe_area.mod program based on the actual on-site work space of the robot.
Click Restart to complete loading the program files.

Test Master-Control Communication

Please ensure that:

The robot system does not have a Main program. If a Main program already exists in the robot system, modify the name of the program.
The StopMove function does not have the Quick property.

Reset the Program Pointer

In the Home interface, tap Operate.
Tap Tasks on the left and the list of tasks will be expanded. Tap Advanced on the right and the advanced settings will appear.
In the list of tasks, select T_ROB1, and then select Reset Program Pointer to Main.
Select Yes in the pop-up window.

Run the Program

Tap to open the Control Panel, and select Control Auto.
Select Confirm in the pop-up window.
Select Motors on Play to run the program.
Tap Messages in the upper left corner to view the Operator Messages. If messages as shown below appear, the program has been successfully loaded on the robot side.

Create a Mech-Viz Project

Open Mech-Viz, press Ctrl+N on the keyboard to create a new project. Select the robot model corresponding to your real robot brand and model on the interface as shown below.
Press Ctrl+S and create or select a folder to save the project.
Right-click the project name in the left panel in Mech-Viz and select Autoload Project.

Connect to the Robot

Click Master-Control Robot on the toolbar of Mech-Viz.
Input the IP address of the real robot in Robot IP address (the IP address in the picture is only an example). Click Connect the robot.

If Mech-Viz successfully connects the real robot, the current status will change to Connected. Meanwhile, the icon in the toolbar will turn from blue to green.

If the connection fails, please double-check the robot IP address.

Move the Robot

In the toolbar of Mech-Viz, change the “Vel.” (velocity) and “Acc.” (acceleration) parameters to 5%.
Click Sync Robot in the toolbar, and you can synchronize the poses of the simulated robot in the 3D simulation space with the poses of the real robot. Then click Sync Robot again to unselect it.
In the Robot tab, slightly adjust the value of “J1”, for example, from 0˚ to 3˚. This operation will move the simulated robot.
Click Move real robot and check if the real robot has moved. If the real robot has reached the JPs set for the simulated robot, the master-control communication is working.

When moving the robot, please ensure the safety of personnel. In the case of an emergency, press the emergency stop button on the teach pendant!

Troubleshooting

If the program has been loaded but the robot cannot be connected successfully, please check whether the following requirements have been met.

IPC side:
- The firewall is turned off.
- The IPC can ping the robot IP address in the command prompt.
- Antivirus software does not affect the connection.
- Two network ports of the IPC belong to different subnets.
- If the IPC is connected by using a router, other network cables do not affect the connection.
Robot side:
- The Ethernet cable is connected to the WAN port of the controller properly.
- The correct robot IP address is set. Please ensure that the IP address of the WAN port, instead of other ports, is modified.
- The program is run on the robot side.