Frequently Asked Questions - ABB Remote Condition ...

What is ABB Ability Condition Monitoring for HV motors?
ABB Ability Condition Monitoring for HV motors is a service for monitoring the condition of motors and generators which is provided by ABB Local Service Centers. It is a remote monitoring service using sensors that feed signals to a fixed Data Analysis Unit installed either on or near the motor or generator. Data is collected continuously and transmitted wirelessly to an ABB server. The service aims to identify faults at a much earlier stage than previously possible so that the findings can be integrated into preventive maintenance schedules. The customer can access the server via the internet to view the overall status of the motor or generator, trend graphs, etc.

What is the output of ABB Ability Condition Monitoring for HV motors?
The measured data are analyzed to provide insight into the motor or generators condition from the viewpoint of:
1. Rotor bar defects (for squirrel cage induction motors)
2. Installation problems (mechanical condition - unbalance, misalignment, looseness, soft foot, etc.)
3. Bearing problems - anti-friction and sleeve
4. Operating parameters
5. Cooler fouling (if winding temperature is available for measurements)

Based on the findings, a preventive maintenance strategy can be prepared for the equipment in order to increase reliability and reduce costs.

What parameters are measured?
The system collects vibration data (four channels) and temperature data (five channels). Vibration is measured using accelerometers mounted at carefully selected locations (bearing housing, body, etc.) to ensure that the necessary signals are picked up. Temperature is measured using RTDs (resistance temperature detectors); in most cases three RTDs are mounted on the winding and two in the bearings. DAU will be able to receive signals from spare RTDs. It is not be able to share the signals from RTDs such as with PLC and others.

Will I have to open the motor or generator to install RTDs on the winding?
In the case of ABB motors and generators, most customers choose to order products with RTDs installed. The necessary signals can then be directly tapped from the RTDs into the Data Analysis Unit.
If the motor or generator whether supplied by ABB or another manufacturer does not have RTDs available, it may be possible to install them in the bearings and end windings, for example. Installation in the core will not be possible.

What happens if RTDs cannot be installed?
Even without RTDs, ABB Ability Condition Monitoring for HV motors will still be able to assess the condition of the motor or generator based on vibration measurements. However, without RTDs it will not be possible to detect fouling of the cooler.

How are the vibration sensors mounted?Steel blocks are fixed to the mounting location using high quality adhesive. The blocks are then drilled and tapped to mount the accelerometers.

How does the Data Analysis Unit work?
The Data Analysis Unit is a core element of the entire service. Its Linux-based embedded processor runs the complete ABB diagnostic software suite, monitoring the motor or generator and processing the vibration and temperature data on-board. Key Condition Parameters (KCPs) are generated for each different fault, and it is these KCPs that are transmitted to the server.

What do you mean by on-board processing? What are KCPs?
The software in the unit incorporates a number of algorithms developed by ABBs Corporate Research Centers. These algorithms process the raw signals to extract useful information.

Each KCP is a measure of a typical fault. It provides a direct understanding of the fault, rather than merely reflecting the overall amplitudes of the signals. To understand the rotor bar condition, for example, the algorithm assesses the specific location of the spectrum, spacing of the sidebands at slip frequency, etc. and converts them into numerical values. This data is normalized with respect to load by the Autoscan feature, and the normalized value is the KCP indicating the rotor bar condition.

The KCPs for other faults are generated in a similar way. They include:
Rotor bar damage: rotor bar index
Eccentricity: dynamic and static eccentricity values
Operating condition: slip versus load graph, line frequency, speed
Bearing: BeAM (Bearing Asset Monitor) and BeaCon (Bearing Condition), crest, etc.
Installation: Principal Component Analysis (measures unbalance, misalignment, looseness)
Cooler fouling: temperature versus load graph

How does ABB Ability Condition Monitoring for HV motors differ from other condition monitoring services?
ABB's solution is a unique tool for motor and generator analysis. Conventional remote or online condition monitoring systems transmit only raw data, which is input into a SCADA system. Trending of overall amplitude, such as vibration velocity, is computed and compared with a benchmark, usually the ISO standard. When the computed value exceeds the benchmark, an alarm or alert is activated.
With ABB Ability Condition Monitoring for HV motors it is the KCPs rather than the overall values that are monitored. If an alarm is triggered then the customer is given clear information on what fault has caused the alarm. In short, when an alarm is generated there is no need to do a detailed analysis to identify the fault.
Another major strength of the service is the web portal.

How does the ABB Ability Condition Monitoring for HV motors web portal work?
The KCPs generated within the Data Analysis Unit are transmitted wirelessly via GPRS or 3G to an ABB server. The web portal handles all data management tasks. The customer is authorized to log in to the portal to view data, trend graphs, operating parameters, health condition summaries, etc. The customer can also download reports directly from the portal.
An important advantage of this cloud based model is that the customer can access the data from anywhere in the world. Corporations with activities in different locations can quickly and conveniently monitor key performance indexes for critical motors and generators, no matter where in the world they are located.
Another key function of the portal is alarm management.

How does the portal manage alarms?
If a KCP exceeds the alarm limit, this indicates that something is no longer all right and action should be taken. As ABB Ability Condition Monitoring for HV motors can monitor performance on a continuous basis, any small deviation of the KCPs from normal observed values will be detected immediately. To prevent false alarms, however, a delay is provided to verify whether a fixed number of KCPs in series are above the threshold values. When an alarm is activated, the Data Analysis Unit uploads all the raw data to the server. The portal immediately sends SMS or messages to the customers registered contacts and, by default, to the nearest ABB Local Service Center (LSC). These messages contain detailed information about the motor or generator and type of KCPs which have triggered the alarm. This ensures that quick checks and, if required, corrective action can be carried out to prevent any unscheduled failure of the equipment.
The alarm is also notified to ABBs Regional Technical Center, which will generate a detailed report on the condition of the motor or generator and send it to the LSC. The customer will be approached by the LSC with the detailed report containing an analysis of the situation and a suggested action plan.

Alarms are also provided if there is a system fault ie, if data is not getting captured due to either cable, connector or sensor failure.

What are the key benefits of the ABB Ability Condition Monitoring for HV motors web portal?The web portal provides the following key benefits: 

1. Customers can quickly access all information via the internet at any time.
2. Easy-to-use, web based tool providing all the available information on the health of the motor or generator.
3. Displays available in the portal include:
· Summarized condition (for plants where multiple motors or generators are monitored)
· Overall vibration (velocity, acceleration and displacement)
· Line frequency and speed
· Slip versus load curve
· KCPs
4. Complete back up support available at time of alarm generation.

How are the alarms set for the KCPs?
ABBs solution treats each motor or generator as an individual unit. It therefore follows that common benchmark values provided in standards like ISO cannot hold good for all products. For this reason ABB Ability Condition Monitoring for HV motors starts from scratch to generate alarm levels for each motor or generator.

In addition, it is essential to know the operating slip parameter to analyze typical problems like rotor bar damage, eccentricity, etc. Conventional methods utilize nameplate slip, which introduces false positives and negatives into the analysis. To avoid these types of problem, when the ABB Ability Condition Monitoring for HV motors hardware is installed an ABB engineer will use ABB Ability Condition Monitoring for shaftlines to perform measurements on the motor or generator in its operating condition.

During installation, measurements are performed with ABB Ability Condition Monitoring for shaftlines to determine:

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1. Actual operating slip
2. Operating load
3. Operating speed and line frequency
4. Relationship between load and slip
5. Operating level of each KCP

The above results are used during configuration of the Data Analysis Unit and setting of the KCP alarm levels.

Slip is calculated for every measurement and compared to the slip versus load curve. Deviations are immediately detected. Any variation in slip indicates a variation in load. This is used along with temperature measurements to determine whether cooler fouling has occurred.

What about security? How safe is the web portal?The portal is hosted on an ABB owned server with secure VPN (virtual private network) access and it is well protected from viruses, bugs, spam and other unauthorized interference. Only authorized personnel can access the portal, and each customer is given access only to the equipment in their own plant. This means that no-one is able to view any information on other customers equipment or plants.

What methods are available for transferring data to the server?
The Data Analysis Unit supports various options for transferring data to the web portal. The recommended transfer method is GPRS or 3G by means of a SIM card installed in the unit. Data communication costs can be kept to a minimum as only the KCPs are transferred and the amount of data involved is very low. Another benefit of this method is that it avoids the need for data to pass through firewalls at the customer site.

For those cases (expected to be fairly rare) where network coverage is not available, the hardware supports other options:

1. WiFi transfer via WiFi to an internet-connected computer, which transfers data to the portal
2. Ethernet cable transfer via ethernet cable to an internet-connected computer.
In both of these cases permission is required from the local IS team to allow data through firewalls.

How does the analysis performed by ABBs software compare with conventional methods?

1. Conventional methods use nameplate information for calculating slip. ABBs solution estimates the actual operating slip from measured data.
2. In the case of rotor bar defects, the operating load is taken into account to normalize the data before the severity is determined.
3. Better signal processing techniques help to correctly locate the sideband amplitude and frequency.
4. Vibration data effectively confirm any mechanical issues.
5. Unique bearing analysis algorithms help to detect any impending faults well in advance.
6. The slip versus load curve helps to determine any abnormalities in the functioning of the cooler.

Hello everyone. I hope you don't mind some very basic questions. My company builds robotic welding cells for general industry. My next project will be using an ABB IRB and a 2-axis positioner. I need to learn as much as I can in advance of the delivery of the robot (due in late August). Because I don't have a robot yet, I'm learning what I can from pdf's. In no particular order, here are my questions.

1) Mastering (calibrating) the arm - KUKA uses an EMD and software on the controller to move each motor into the mastering position. Does ABB have anything like this? What I have seen so far are some marks on the arm that you line up by eye and then update the revolution counters. Are there also some alignment pins or something?
2) Mastering (calibrating) external motors - When mastering an external motor gear unit with KUKA, we use an EMD. How do you master (calibrate) an ABB MGU?
3) Virtual PLC - KUKA has a virtual PLC which we use to monitor the state of some pushbutton switches the operator uses to control the robot while running in AUTO mode. Does ABB have a virtual PLC? How do I monitor mechanical pushbuttons while the robot is busy executing a welding program?
4) Safety chain - KUKA has a built-in Safety Interface Board that I wire up the safety chain (a string of 2-channel switches/outputs). So far in my early ABB education, I've been lead to believe that I need to add my own safety PLC the output of which is wired to the controller (somehow).
5) Digital I/O - It looks like ABB uses their own DIO modules that communicate with the controller PC using DeviceNet(?) and are setup/configured (mapped into memory?) using RobotStudio. Is this correct? In KUKA, WorkVisual is the configuration software where DIO modules (we have used Beckoff) are mapped into controller memory space.

Thanks.....Matt

1) Mastering (calibrating) the arm - KUKA uses an EMD and software on the controller to move each motor into the mastering position. Does ABB have anything like this? What I have seen so far are some marks on the arm that you line up by eye and then update the revolution counters. Are there also some alignment pins or something?

ABB robots normally have calibration marks and aligment with eyes. Jog the robot to line up the calibration marks on each axis, then through the service menu update the rev counters. if battery is dead use Fine calibration and type calibration offsets number. (Numbers on manupulator label). Another way you can use Calibration Pendulum.

https://library.e.abb.com/public/5c031eeHAC-en.pdf

2) Mastering (calibrating) external motors - When mastering an external motor gear unit with KUKA, we use an EMD. How do you master (calibrate) an ABB MGU?

Procedure is same. Positioner have calibration mark.

3) Virtual PLC - KUKA has a virtual PLC which we use to monitor the state of some pushbutton switches the operator uses to control the robot while running in AUTO mode. Does ABB have a virtual PLC? How do I monitor mechanical pushbuttons while the robot is busy executing a welding program?

You don't need Soft PLC. Buy multitasking option and you can run a few modüle simultaneous. e.g. KUKA using "SPS.sub" or Proconos. If you using complex logic of course you can get Soft PLC option from ABB just like KUKA.

4) Safety chain - KUKA has a built-in Safety Interface Board that I wire up the safety chain (a string of 2-channel switches/outputs). So far in my early ABB education, I've been lead to believe that I need to add my own safety PLC the output of which is wired to the controller (somehow).

ABB have panel board and safety signal can connect to interface. E.g GS(General Stop), ES(Emergency Stop), AS (Automatic Stop) etc. already defined on panel board. Make jumper or apply external circuit.

5) Digital I/O - It looks like ABB uses their own DIO modules that communicate with the controller PC using DeviceNet(?) and are setup/configured (mapped into memory?) using RobotStudio. Is this correct? In KUKA, WorkVisual is the configuration software where DIO modules (we have used Beckoff) are mapped into controller memory space.

ABB using pre-defined or user defined modüle and bus types. You can define new modüle types or bus with robot studio or Pendant. Bus types is optional and you must select better option. E.g if you using Profinet you must to buy Profinet card from ABB and Profinet option key (Licence Option)

1) So it sounds like the Calibration Pendulum is used to determine the calibration offset numbers recorded on the manipulator label? Is there anyway the numbers on the label can become obsolete and new numbers need to be determined?

4) By "external circuit" do you mean my string of 2-channel switches (i.e. door switches & safety relays)?

5) We will be using DeviceNet to communicate with a welding power supply. Does that suggest that we should also be using DIO modules that communicate using DeviceNet?

Just for added clarification....
The robot controller itself determines the cal-offset when you fine calibrate the motor, cal pendelum "only" establishes the "0-position" (it basically makes sure that the robot is level).
With an external axis you don't have any means of using cal pendelum so on a track you determine the 0-pos yourself and on a positioner/orbital I typically used a spirit level to make sure it was somewhat leveled.
Once the fine calibration is done, updating the revolution counters will compensate for any slight misalignment when eying in the calibration marks.

Basically the only time you need to use cal pendelum to fine calibrate the robot if you ever change robot hardware, e.g. motors or gearboxes

If your power source (assuming arc welding, not spot welding?) is interfaced through DNET then I'd stick with DNET for the IO's as well since you'd have to pay for any additional interfaces (EthernetIP, ProfiNet/BUS should you choose those for IO's).
You don't necessarily have to go with ABB IO modules, you can choose any DNET compliant I/O module, Beckhoff, AB, Wago, etc. but if this is your first ABB system then I'd reccomend using ABB modules and power supplies since they're not that expensive and they're pre-installed/wired which saves you some time/hassle.

ABB contains other products and information you need, so please check it out.

I saw incorrect information, so some clarification and news:

1 - ABB robots have two different procedures:
-Revolution counter update. Update the revolution of the motor in relation to the zero position of the axis. There's a battery that backup this in the manipulator. If this battery is empty you loose revolution counter when you turn off controller. Revolution counter update is a simple and fast procedure, don't need any special equipment. Just align some marks manually by eye and enter in a menu option to update.

-Calibration. Is the zero fine position. It's made on robot factory and is not normally done at the customer. You only make a new calibration if you disassembly a motor. For calibration you need special equipment (to be done the right way). For older robots, and some paint robots it's some device that lock the axis in position. For IRC5 robots, we use Calibration Pendulum, a special device with sensor that calibrate the robot with a routine. It's not easy like Kuka one. Last year ABB developed a new calibration method, but only for new robot models. I think this method is better than Kuka because it's automatic, fast, simple and cheap. You only need a pin that is put on the robot and the axis touch the pin, no special sensors needed.

2 - For external motors depends on the kind. Positioners have a built in routine that recalculate the positions for the interchange, track motions have mechanical devices. In resume you need something to lock the axis in position.

3 - We don't have Soft PLC option, we use multitask for that. It's the same language the robot use, but running in parallel and without motion instructions. With this option you can have up to 20 tasks running in parallel.

4 - We have a board called Panel board with discrete dual channel safety signals, you can attach any safety device here to stop the robot. There's is two inputs for global stop (GS and SS), one for automatic mode (AS) and one for emergency stop buttons (ES).
This year ABB launched SafeMove2 with Profisafe and CIPis planned in the future.

5 - If you buy IO with the robot it will come with a DeviceNet interface card, a harness for DeviceNet inside the controller and a ABB DeviceNet board.
ABB robots can also have, Ethernet/IP, Profinet and ProfiBus. DeviceNet and Profibus need special inteface card connected to the CPU, Profinet and Ethernet/IP can be connected directly to the the CPU. IO is configured with RobotStudio or in directly in robot using FlexPendant. For Profinet and Profibus you need additional software to configure network.

Thanks Roulv.

I work for a system integrator that builds arc welding cells. Typically, we design and build the cell, install the robot and welding torch, and program the customer's parts to be welded. Once the welding programs are finished, the cell gets disassembled, shipped to the customer's location, and reassembled.

My main concern is if a robot loses it's calibration for some reason (say during shipping), how does the robot get re-calibrated at the customer's location so that all of the previously programmed robot moves (points) are still correct?

With KUKA, it is not unusual for 1 or more axis to lose mastering during shipping (the arm moves slightly while powered off). With KUKA, use the EMD at the customer's location to re-establish mastering and all of the previously programmed position (points) are still correct. How is the same thing accomplished with ABB?

You mentioned that the new robots use pins and some software routines to calibrate the robot. Do you know which robots use pins?

I don't understand the reason for updating the 'revolution counters'. If all of the robot positions are keyed off of the zero point calibration (done with either with the Calibration Pendulum or with pins), what are the revolution counters used for?

You will not loose any point. This is the main difference between Kuka and ABB.

In Kuka, if your robot move slight while off you have to put the device in the the robot and master.

In ABB you don't need it, because you are not calibrating zero, you are just setting the revolution of the motor. You can do that by eye because you have a full revolution of the motor to say that is the revolution zero.
You only need the special device to recalibrate when you disassemble the robot.

More technical view:
All robots have a feedback device in each axis. This devices read the motor position.

The problem is after motor there's a gear box with some reduction. This mean that one revolution of the motor is not one revolution of the axis.
When you turn one revolution of the motor you get just a small movement of the axis.

So to calculate the correct axis position, you need more information, which is the current revolution of the motor.

Some robot brands use encoders that can give you the current revolution of the motor. ABB and Kuka use one single resolver where we don't have this information. So in ABB and Kuka the controller is continuous monitoring the resolver and every time the motor turn one revolution, the controller increment or decrement a variable with the current revolution. This way the controller know the current position of the axis and is called revolution counter.

But if you turn off your controller and release brakes, axis motor have been turned one or more revolutions and the controller is not monitoring. Because of that you lose revolution counter when you turn controller on again.

In ABB you only need to move axis to a mark and say to the controller that this position is within one revolution of the zero position. This is done by eye, there's no problem because if you put axis a bit to one side or to the other side, it's still inside the first revolution.

In Kuka you have to put the mastering device even if you only lost revolution counter, this means more time.

If you are looking for more details, kindly visit Abb Motor Suppliers.