P O SI TI O N KI N E MATI CS

O F TH E ABB I RB6400
PATRI CK WI LLO UG H BY
CO URSE 2. 05
D E CE MBE R 5, 2000


1
Figure 1- A x is N otation
I NTRODUCTI ON
The ABB IRB6400 robot is a large six-degree of freedom open loop robot. While the IRB6400
is used for a wide variety of applications, it is predominantly used for automotive applications such as
body painting and welding. The robot is capable of carrying up to a 200 kg load at the end of its 3-
meter maximum reach. Typically, the motors are constrained to have the tool center point (TCP)
move at a velocity around 2 meter per second, although the robot can travel at greater speeds.
As with most commercial robots, the forward and reverse kinematics are built into the controller
programming. For this project, some of the kinematics for the IRB 6400 will be calculated and
discussed. The goals of this project are:
To develop the basic vector equations that describe the position of the robots TCP
To assemble the transformation matrices for the robots six joint axes and to combine these
matrices to form the global transformation matrix for the robot base to the TCP
To construct a WorkingModel3D representation of the IRB 6400 and to compare some
position data from the model to the matrix method
To perform an inverse kinematics analysis of several points using the transformation matrix
to obtain joint angles and put these angles into the model to see the robot configuration
To describe some of the basic redundancies and singularities of the IRB 6400.

ANALYSI S AND DI SCUSSI ON
V ector Method
The first step for the project was to develop the vector equations to
describe the relationships of the different joints. Before writing these
equations, the presence of multiple loops in the robot had to be
considered. The IRB 6400 actually consists of two coupled loops: the
standard open loop that connect the base to the TCP and a parallel four
bar linkage that connects the axis three motor above the base to the
actual axis of revolution on the arm. As this parallel linkage is just a
standard double crank, the kinematic analysis was simple. This analysis
is shown in the Calculations section. The conclusion of this analysis was
2
that the double crank linkage has no effect on the kinematics of the robot.
For a change in the angle of the driving link, an equal change occurs at the
driven arm. Because the linkage has equal dimensions on opposite sides of
the linkage, the transmission ratio for torque is one, so every change in
input torque produces an equivalent output change. This statement neglects
friction and other losses for each of the joints, which would cause a
decrease in the ratio. By incorporating this linkage into the design of the
IRB 6400, the axis three motor can be located next to the axis two motor,
rather then extended out at the actual axis of revolution. This relocation
relieves the weight of the axis three motor off of the axis two motor,
allowing the robot to carry more weight. In addition, the robot can travel at
higher speeds (at axes one and two) without requiring additional brakes to
halt the increased momentum. The large mass at the end of the input
cranks arm is used to balance the robot and help tipping at full arm
extension.
After working through the vector analysis, it became obvious that the vector analysis was
extremely complex. The equations for the vector method are shown in the Calculations section. The
loop equation for the open loop consists of the link lengths multiplied with the unit vectors for each
joint in terms of the global coordinate system. For the first and second links, the vector equations
are relatively simple, however, the complexity increases drastically with each additional joint. Because
of the extremely complex nature of the vector equations, the vector analysis was stopped at this
point. The development of velocities or accelerations and the use of inverse kinematics are
extremely mathematically intensive and are beyond the scope of this project.

T ransformation M atrices
The next step for this project is to develop the homogeneous
transformation matrices for each joint and the global transformation
matrix to the end of the robot. The notation of axes for this
method remains consistent with the notation used for the vector
analysis above. As a starting point, the Denavit-Hartenberg
notation was investigated as a convention to use for describing the
kinematics of the IRB 6400. This convention was rejected, since the

Figure 2 Parallel L ink age

Figure 3: Coordinate S ystmes
3
axis 5
X
6
tool flange
formulaic version presented in class cannot accommodate the translations in directions other than
the current z direction and the following x direction. Instead, the standard homogenous
transformation matrix procedure given earlier in the course was used. This procedure consists of
combining a rotation matrix Qi with a translation matrix qi in a four by four, homogeneous matrix.
Applying this procedure to the robot creates a total of seven transformation matrices, with one
matrix for each joint and an extra translation out to the tool center point. Figure 3 shows the
directions of the unit vectors for the starting configuration of the robot. For this configuration, the
coordinate systems for each joint have the same directions, but are translated to each joint axis. The
following list shows all transformations:
T1 Translation on Z1 and Rotation on Z1
T2 Translation on X2 and Rotation on Y2
T3 Translation on Z3 and Rotation on Y3
T4 Translation on Z4 and Rotation on X4
T5 Translation on X5 and Rotation on Y5
T6 Translation on X6 and Rotation on X6
Tp Translation on X6
The coordinate systems and corresponding matrices
are shown in the Calculations section, while one example
of a transformation, T6, is shown here. This
transformation consists of a translation from axis five to
the end of the tool flange along axis six (x6) and a
rotation of the flange, also about axis six. The assembled
matrix for this transformation contains a standard
homogenous rotation transformation matrix around an x-
axis combined with a translation of h5 in the x direction. The matrix for T6 is shown in equation 1.
The result for the complete transformation matrix
analysis has the same conclusion as the vector analysis
method. The matrices for the individual transformations
from joint to joint are simple, as they are only functions of
the joint angle and distance. The combined matrices for
multiple joints become increasingly complex as joints are
added, while the global transformation becomes so complex that MathCAD refuses to symbolically
display the formula for an individual cell in the matrix. The global matrix can be solved numerically
Figure 4 T
6
T ransformation D iagram
T
6
1
0
0
0
0
cos
6
( )
sin
6
( )
0
0
sin
6
( )
cos
6
( )
0
h
5
0
0
1

,
:
E quation 1: T
6
M atrix
4
in MathCAD by inputting angles to obtain the position and orientation of a vector extending from
the flange to the TCP. A printed copy of the MathCAD worksheet is included in the Calculations
section. To match the angle values used by ABB, 3 is defined as - 2 + 3. This constraint allows
the robots arm to remain horizontal after a rotation on axis two, but has no effect on the kinematics.
Because of the complexity of the matrices, further analysis was stopped, although forward kinematics
in the MathCAD worksheet will be used to compare the WorkingModel3D model to the matrices.

W ork ing M odel 3D R epresentation
The next section of the project was to develop an accurate kinematic model of the IRB 6400 in
Working Model 3d. To ensure the validity of the decision not to model the parallel linkage, two
models were constructed to observe its effect: one with and one without the parallel linkage. In both
cases, the resulting TCP data and orientation data matched for all joint angles attempted. A
screenshot of the Working Model window for the parallel version of the robot is shown at the end of
this report. In the simulation, accurate length dimensions were used as described in the ABB
manual. Accurate data for the radius, mass, etc of the links were not required so a diameter of 25
mm was assumed for all links and the default density was used. For all joints, revolute motors were
used with the rotational axis aligned to the robots motion. Motion of the joints was specified by
inputting the angular orientation of the joints. The block of six sliders on the right side of the
window was used to input the angle values into the robot. Design limits were built into the sliders to
simulate physical stops put on the robot by ABB to prevent motor damage or dangerous motions.
Three digital meters are shown on the lower right to measure the orientation and position of the
TCP and the position of axis five. ABB commonly uses the position of axis five to set the working
space limits and describe motion of the significantly larger section of the robot.
After building the model, several joint angle set were put into the model. This variety of
positions was compared to data from the transformation matrices and ABB data to validate the
model. Since the data points, matrix values, and ABB data values correlated for all points, lengthy
tables of data points were not included in this report. Examples of working plane data are shown
below.
The next step was to plot the working volume of the model using WorkingModel3D. Since the
physical limits of the joints were provided by ABB, the working volume was determined using these
numbers rather than a generic kinematic analysis without regard to the robots physical presence.
This generic analysis would only show that the robots working space could be contained within a
complete sphere with center at axis two. After observing the motion of the IRB 6400, it is clear that
5
this could be the desired range of the robot, but this motion is physically impossible with current
geometry. Table 1 shows joint values for axes two and three at their physical limits. Since these two
axes give the major component of motion for the robot, they are the only values that need to be
simulated for the working plane. The axis one angle can be varied to rotate the working plane into a
working volume.
Position
Number
Axis 2 Angle
(deg)
Axis 3 Angle
(deg)
X Value of TCP
(mm)
Z Value of TCP
(mm)
0 0 0 1415 2075
1 -70 -28 185 1909
2 -70 -3 415 1445
3 43 110 766 387
4 85 110 1096 -290
5 85 20 2467 701
6 37 -28 1804 2389

T able 1: W ork ing S pace L imits on A x es 2 and 3 and Corresponding Position

The result of inputting these
values into WorkingModel3D was an
animation that shows the robot
moving through the 2D working
plane. This animation cannot be
shown in this report, although a
rough sketch of the working plane is
shown in figure 5. This Lima beanish
shape can be rotated around the joint
one axis to give its complete working
volume, which would appear like a
very strange doughnut.

Figure 5 W ork ing Plane for R obot
6
R edundancies and S ingularities
The final part of this project was to describe the redundancies and singularities of the system.
No redundancies were built into the IRB 6400, as all six degrees of freedom are needed to completely
position and orient the end effector. If any one of the joints were immobilized, the robot could still
operate, but it could not locate or orient properly. Quite a bit of research is under way at ABB to
make the robot joints easier to maintain, so that they can be replaced or repaired quickly if they fail.
One critical singularity exists for the robot when the axis five angle is set to zero. By setting joint
five to zero in the MathCAD worksheet, this singularity can be observed by changing the joint four
and six angles. In this case, either axis four or six can rotate and identical motions can occur. To
remove this singularity, ABB has included programming in the controller system to prevent the robot
from becoming locked in this position.


RESULTS
Results for the vector and transformation matrix methods are shown in the Calculations section.
In addition, a screenshot of the WorkingModel3D simulation is shown in the Calculations section.
Copies of both the WorkingModel3D simulations and the MathCAD worksheet can be provided
electronically, if desired or required.


CONCLUSI ON
In conclusion, much was learned about the process of kinematically describing the position of a
robot. Primarily, a large lesson was learned about the mathematical complexity involved with
working on even a relatively simple robot, without involving dynamics. By adding any number of
joints, the complexity of the mathematics increases drastically. The incorporation of dynamics into
the IRB 6400 control system must be a mathematical monster. Another learning experience was the
development of the WorkingModel3D representation of the robot. Not only was the process of
creating the model educational, it was rather entertaining to run the simulation and send the robot all
over the screen. It was interesting to note that WorkingModel3D simulates the dynamics of the
motion, even though it is not requested. Finally, it was interesting to have the opportunity to do a
moderate level of research on the object of thesis study, yet in a very different area.
7









C AL C U L AT I O N S
8
T
0.66
0.047
0.75
0
0.683
0.377
0.625
0
0.313
0.925
0.217
0
1.147 10
3

991.436
2.432 10
3

,
T
wrist
0.66
0.047
0.75
0
0.436
0.789
0.433
0
0.612
0.612
0.5
0
1.002 10
3

1.002 10
3

2.597 10
3

T T
1
T
2
T
3
T
4
T
5
T
6
T
TCP
: T
wrist
T
1
T
2
T
3
T
4
T
5
:
T
TCP
1
0
0
0
0
1
0
0
0
0
1
0
h
p
0
0
1

,
:
T
6
1
0
0
0
0
cos
6
( )
sin
6
( )
0
0
sin
6
( )
cos
6
( )
0
h
5
0
0
1

,
: T
5
cos
5
( )
0
sin
5
( )
0
0
1
0
0
sin
5
( )
0
cos
5
( )
0
h
4
0
0
1

,
:
T
4
1
0
0
0
0
cos
4
( )
sin
4
( )
0
0
sin
4
( )
cos
4
( )
0
0
0
h
3
1

,
: T
3
cos
3
( )
0
sin
3
( )
0
0
1
0
0
sin
3
( )
0
cos
3
( )
0
0
0
h
2
1

,
:
T
2
cos
2
( )
0
sin
2
( )
0
0
1
0
0
sin
2
( )
0
cos
2
( )
0
L
1
0
0
1

,
: T
1
cos
1
( )
sin
1
( )
0
0
sin
1
( )
cos
1
( )
0
0
0
0
1
0
0
0
h
1
1

,
:

3

2

3d
+ :
L
1
240 : h
1
800 :
1
45deg :
h
2
1050 :
2
15deg :
h
3
225 :
3d
30 deg :
h
4
1175 :
4
150deg :
h
5
200 :
5
90 deg :
h
p
20 :
6
30 deg :

9
atan
T ( )
2 0 ,
T
0 0 ,
( )
2
T
1 0 ,
( )
2
+

1
1
1
]
:
atan
T
1 0 ,
T
0 0 ,

,
:
atan
T
2 1 ,
T
2 2 ,

,
:
If , , and are reported to be singular, then the Euler
ZYX angles are:
90 deg
= 0 deg
= Shown Below
48.59deg
4.107 deg
70.893 deg

singular
atan
T
0 1 ,
T
1 1 ,

,
:

singular
1.066
10

Figure 6 S creenshot of W ork ing M odel 3D S imulation