Based on more than four decades of robotics experience, the IRC5 is the robotic industry's benchmark in robot controller technology. The IRC5 Compact variant delivers the full performance of the standard IRC5 controller in a significantly reduced footprint, making it ideal for applications where space is at a premium. In addition to ABB's unique motion control, it brings flexibility, safety, modularity, application interfaces, multi-robot control, and PC tool support to a compact form factor.

The IRC5 Compact combines the powerful performance of the standard IRC5 controller—including superior motion control and flexible RAPID language—with a compact design that enables easy integration into tight spaces. It is available with a range of small industrial robots including the IRB 120, IRB 140, and IRB 1410, providing a cost-effective and optimized solution for diverse automation needs.

Key Features & Advantages

Fast and Accurate Motion Control: The IRC5 Compact gives ABB robots the ability to perform tasks in a highly efficient manner. Based on advanced dynamic modeling, the controller automatically optimizes robot performance by reducing cycle times with QuickMove technology and providing precise path accuracy with TrueMove technology. QuickMove ensures maximum acceleration at every moment, delivering cycle times up to 25% shorter than competitors. TrueMove ensures that the motion path followed by the robot is identical to the programmed path regardless of robot speed.

Compact Design for Space-Constrained Applications: The IRC5 Compact features a significantly reduced footprint compared to standard IRC5 variants, making it suitable for installations where floor space is limited. With dimensions of 386 mm × 245 mm × 270 mm and a weight of only 12 kg, the controller can be easily integrated into compact robotic cells. The one-phase power input simplifies installation, while external connectors for all signals enable easy commissioning.

Flexible Programming with RAPID: All ABB robot systems are programmed with RAPID, ABB's flexible, high-level programming language. The IRC5 Compact supports the full RAPID programming environment, enabling complex automation tasks, error handling, and multi-tasking capabilities. Multi-tasking dialogue allows up to 14 RAPID programs to run simultaneously, enabling supervision of external equipment and advanced calculations.

Multi-Robot and Multi-Axis Control: The IRC5 Compact supports MultiMove technology, allowing up to four robots to run on one controller with a compact drive module added for each additional robot. The motion of the robots can be either coordinated or independent. The system can control up to 36 axes total, with robot main axes coordinated with external mechanical structures such as workpiece positioners, track-motion devices, and gantries.

Advanced I/O and Communication Capabilities: The controller supports the majority of state-of-the-art industrial networks for I/O, including DeviceNet, PROFINET, EtherCAT, and Ethernet/IP. The built-in I/O system features 16 inputs and 16 outputs that are expandable. The lean version of DeviceNet protocol supports up to 20 units and offers auto-configuration and bus scan tools for seamless communications with all connected devices. OPC UA support enables seamless data transmission from the factory floor to MES systems or the cloud.

TPU4 FlexPendant with Intuitive User Interface: ABB Robotics began delivering TPU4 for IRC5 controllers from March 2023. This fourth-generation Teach Pendant Unit is based on the design of the OmniCore FlexPendant and offers a more intuitive and efficient user interface for industrial applications. The TPU4 features an 8-inch screen with capacitive multi-touch interface supporting swipe and scroll gestures, delivering faster response times than previous resistive touch models. TPU4 comes with pre-installed software supporting the latest RobotWare versions, while older RobotWare versions continue to be supported via RobotStudio add-In.

Comprehensive Safety Features: The IRC5 Compact fulfills all relevant regulations and is certified by third-party inspectors worldwide. The controller includes SafeMove technology for advanced robot safety system capabilities, enabling leaner, less-restrictive safety systems with precise control of robot motion. Additional safety features include collision detection that stops the robot when motion torque values are exceeded, and user-authorization system that defines access rights for individual users.

Built-in Reliability and Diagnostics: Built-in diagnostic functions help ensure fast recovery and production restarts when operations are interrupted. Power failure support ensures that if power supply is cut off during operation, the robot restarts at the exact same position and system status as before the power failure. The Service Information System predicts robot service needs based on operating time, calendar time, and advanced algorithms for gearbox service calculation. Remote Service capability enables wireless alerting to ABB when maintenance is needed.

RobotStudio and Offline Programming Support: The IRC5 Compact supports RobotStudio for offline programming and online condition monitoring. The Installation Manager simplifies RobotWare installation and option management. RobotStudio App Connect allows the use of standard commercially available tablets for commissioning on the shop floor as an alternative to the FlexPendant.

Applications

• Material Handling: Pick and place, machine tending, palletizing, packaging
• Arc Welding: Dedicated RobotWare-Arc support with process equipment supervision and error recovery
• Spot Welding: Fast and accurate positioning with gun manipulation and process start control
• Assembly: Precision assembly operations requiring high accuracy and force control
• Dispensing: Gluing and sealing applications with dedicated RobotWare-Dispense support
• Cutting and Machining: Laser cutting and machining applications requiring advanced motion performance
• Laboratory Automation: Compact installations in research and testing environments