Product Short Description
Product Introduction
The ABB 3HAC026272-001, also known as the DSQC 647 SafeMove Unit, is a dedicated safety controller module designed exclusively for integration with ABB IRC5 series industrial robot controllers. It functions as the core safety intelligence component within robotic automation systems, implementing advanced safety monitoring, safe motion control, and emergency response functions to protect personnel, equipment, and work environments. This unit operates in conjunction with the main robot controller to execute safety-critical tasks such as safe speed limitation, safe position monitoring, safe torque off, and collision prevention.
Description
Technical Specifications
| Parameter | Value |
|---|---|
| Product Type | Safety Controller Module / SafeMove Unit |
| Compatible Controllers | ABB IRC5, IRC5 Compact, IRC5 Single Robot ControllersABB Group |
| Safety Standard Compliance | EN ISO 13849-1 (PL e), IEC 61508 (SIL 3), EN 61800-5-2 (STO) |
| Input Voltage | 24 V DC (19.2 V DC – 30 V DC operating range) |
| Input Current | Maximum 0.5 A |
| Digital Inputs | 16 x safe digital inputs (single-ended/differential, optically isolated) |
| Digital Outputs | 16 x safe digital outputs (relay type) |
| Communication Interfaces | Safe EtherCAT, Ethernet, Serial communication, internal IRC5 bus |
| Protection Features | Over-voltage protection, over-current protection, EMC protection, reverse polarity protection |
| Environmental Rating | IP20 (enclosure) |
| Operating Temperature | -20 °C to +60 °C |
| Storage Temperature | -40 °C to +85 °C |
| Relative Humidity | 5% – 95% (non-condensing) |
| Vibration Resistance | 10 – 500 Hz, 5G rms (IEC 60068-2-6) |
| Dimensions (W × H × D) | 263 mm × 58 mm × 28 mm |
| Weight | 1.62 kg |
| Mounting | Standard rack mounting for IRC5 controller cabinets |
| Certifications | CE, UL, TÜV, RoHS compliant |
| Country of Origin | Germany |
Functional Features
Advanced Safety Monitoring & Control
- Safe Motion Supervision: Executes real-time monitoring of robot speed, position, acceleration, and torque, enforcing safe operating limits to prevent hazardous movements.
- Safe Torque Off (STO): Provides instant, fail-safe removal of motor torque upon safety signal activation, ensuring immediate, safe robot stop without power disconnection.
- Safe Speed Reduction (SSR): Automatically reduces robot speed to predefined safe limits when operators enter predefined zones, enabling safe human-robot collaboration.
- Safe Position Monitoring (SPM): Restricts robot movement within programmed safe work zones, preventing collisions with fixtures, peripherals, or personnel.
- Safety Input/Output Management: Processes 16 safe digital inputs from safety devices (e.g., light curtains, emergency stops, safety scanners) and triggers 16 safe digital outputs to control safety-related actuators.
High Safety Integrity & Reliability
- Dual-Channel Safety Architecture: Implements redundant, cross-monitored safety circuits to ensure fail-safe operation and eliminate single-point failures.
- Certified Safety Performance: Meets EN ISO 13849-1 Performance Level e (PL e) and IEC 61508 Safety Integrity Level 3 (SIL 3) for the highest safety classification.
- Continuous Self-Diagnostics: Performs constant internal self-testing of safety functions, circuits, and communication, detecting faults and initiating safe responses instantly.
- Industrial-Grade Durability: Constructed with high-quality components to withstand extreme temperatures, vibration, and electrical interference in industrial environments.
Seamless System Integration
- Plug-and-Play with IRC5: Directly integrates into ABB IRC5 controller racks with standardized connectors and communication interfacesABB Group.
- Safety PLC Compatibility: Interfaces seamlessly with external safety PLCs, enabling coordinated safety logic across entire automation cells.
- Multi-Protocol Communication: Supports Safe EtherCAT, Ethernet, and serial communication for flexible integration with higher-level factory automation systems.
- Modular Design: Compact form factor optimizes cabinet space, supports easy installation, replacement, and system expansion without full controller shutdown.
Intelligent Safety Functions
- Collision Detection & Prevention: Monitors motor torque and motion feedback to detect unexpected collisions, triggering immediate safe stops to minimize damage.
- Programmable Safety Zones: Allows configuration of multiple, customizable safe work zones, speed limits, and access permissions via robot programming software.
- Status Indication: Features dedicated LED indicators for real-time visualization of safety input/output status, active safety functions, and fault conditions.
- Remote Safety Monitoring: Enables remote access to safety system status, diagnostics, and event logs for predictive maintenance and troubleshooting.
Flexible Configuration & Compatibility
- Retrofit Capability: Compatible with SafeMove retrofit kits (3HAC032934-001) for upgrading existing IRC5 controller-based robot systemsABB Group.
- Multi-Robot Coordination: Supports safety monitoring and coordination for multiple interconnected robots within shared work cells.
- User-Friendly Programming: Configurable via ABB RobotStudio and IRC5 teach pendant, with pre-defined safety function templates for simplified setup.
- Wide Robot Compatibility: Compatible with all ABB IRB series industrial robots controlled by IRC5 controllers, from small payload to heavy-duty modelsABB Group.
Application Scenarios
Collaborative Robotics & Human-Robot Interaction
- Collaborative Assembly Stations: Enables safe, direct human-robot collaboration in assembly tasks without full physical guarding.
- Operator-Assisted Material Handling: Allows operators to work alongside robots for loading/unloading with automatic speed reduction when personnel are present.
- Flexible Manufacturing Cells: Supports dynamic reconfiguration of work zones and safety parameters for mixed-model production with frequent human intervention.
Automotive Manufacturing
- Body-in-White Assembly: Provides safety supervision for robotic welding, fastening, and material handling in high-volume automotive production.
- Powertrain Assembly Lines: Ensures safe operation of robots handling heavy engine and transmission components with collision prevention.
- Paint Shop Automation: Monitors safe motion and zone restrictions for painting robots in confined spray booth environments.
Metalworking & Fabrication
- Welding Automation: Implements safe speed and zone control for arc welding robots, protecting operators during process intervention.
- Laser/Plasma Cutting Cells: Prevents unauthorized access and ensures safe robot paths in precision cutting applications.
- Press & Forging Operations: Delivers emergency stop and safe torque off functions for robots handling hot, heavy materials in metal forming.
Electronics & Semiconductor Manufacturing
- PCB Assembly & Handling: Provides ultra-precise safety monitoring for robots handling delicate electronic components in cleanroom environments.
- Semiconductor Wafer Processing: Enforces strict safe position limits to prevent damage to fragile wafers during robotic transfer.
Logistics & Warehouse Automation
- Robotic Palletizing/Depalletizing: Manages safe speed and zone control for high-speed palletizing robots in distribution centers.
- Automated Storage & Retrieval: Ensures safe operation of robotic cranes and shuttles in high-bay warehouse systems.
Aerospace & Defense
- Aircraft Component Assembly: Delivers high-integrity safety for large robots handling precision aerospace structures and composite materials.
- Drilling & Fastening Systems: Enforces ultra-precise safe position and torque limits for robotic aircraft assembly.
General Industrial Automation
- Packaging & Food Processing: Provides safety supervision for pick-and-place robots in food, beverage, and consumer goods packaging lines.
- CNC Machine Tending: Enables safe operator access to CNC machines during robot loading/unloading operations.
- Textile & Printing Machinery: Ensures safe motion control for automated textile and printing equipment with frequent operator interaction.
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