Description:​

The ABB 3HAC024144-001 is a high-performance robot controller module engineered by ABB Robotics,a global leader in industrial robotics and automation.As the”motion brain”for ABB IRB series robots(e.g.,IRB 6700,IRB 1200),it orchestrates precise robotic movements—from high-speed automotive welding to delicate pharmaceutical packaging—by translating DCS commands into real-time motor control signals.​

Designed to solve industrial robotics pain points(e.g.,motion inaccuracy,safety integration gaps,limited scalability),the 3HAC024144-001 features<0.1ms motion execution speed,SIL 2 safety compliance(for integration with the ABB 3BSE000863R1(SR511)safety controller),and scalable I/O for sensor connectivity.It integrates seamlessly with the ABB 2UBA002322R0001 PDU for stable power and UTX1700PTFE-coated cables for durability in harsh environments,making it essential for robotics-intensive sectors like automotive,electronics,and pharmaceuticals.​

Application Scenarios:​

A European automotive assembly plant faced critical challenges with its legacy robot control system:Inconsistent motion precision(±0.5mm)caused welding defects,and the system lacked integration with the plant’s 3BSE000863R1(SR511)safety controller—violating EU machine safety standards(EN ISO 13849).After upgrading to ABB 3HAC024144-001 controllers:​

The 3HAC024144-001’s<0.1ms motion execution reduced welding precision errors to±0.05mm,cutting defect rates by 40%and saving$200,000 annually in rework costs.​

SIL 2 compliance enabled direct communication with the SR511 safety controller,triggering immediate robot shutdown if safety gates were breached—eliminating 2 near-miss incidents in the first 6 months.​

Integration with the 2UBA002322R0001 PDU ensured uninterrupted power during supply maintenance,avoiding 3 planned production halts.For a U.S.electronics plant,the controller’s scalable I/O supported 10 additional P0904AK sensors for robot tool wear monitoring,extending tool lifespan by 30%.These cases highlight the module’s role in enhancing robotic precision and safety.​

Parameter:​

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Main Parameters​

ABB 3HAC024144-001 Robot Controller Module​

Product Model​

3HAC024144-001​

Manufacturer​

ABB Robotics(Global Industrial Robotics Specialist)​

Product Category​

Motion Controller for ABB IRB Series Robots​

Safety Certification​

SIL 2(IEC 61508);EN ISO 13849-1 PL d​

Motion Execution Speed​

<0.1ms(for standard robotic movements)​

Supported Robot Models​

ABB IRB 6700,IRB 1200,IRB 4600,IRB 7600​

I/O Scalability​

Up to 128 I/O points(via expansion modules)​

Input Compatibility​

Digital(24V DC,from 3ASC25H203 relays);Analog(4-20mA,from P0904AK sensors)​

Communication Protocols​

PROFINET,EtherNet/IP,Modbus RTU(for DCS integration with SR511)​

Redundancy​

Optional 1:1 hot standby(for mission-critical applications)​

Power Supply​

24V DC(from ABB 2UBA002322R0001 PDU);Current:≤500mA​

Operating Temperature​

0℃~45℃(no derating within range)​

Storage Temperature​

-20℃~60℃​

Protection Class​

IP20(cabinet-mounted,dust-proof)​

Mounting Method​

DIN rail mounting(35mm standard rail)​

Compatibility​

ABB 3BSE000863R1(SR511);ABB 2UBA002322R0001;UTX1700PTFE cables;FOXBORO P0904AK​

Certifications​

CE,UL 1998,IEC 61010-1,ISO 10218-1​

Weight​

~800g​

Diagnostic Features​

Real-time motion error logging;LED status indicators;Remote health monitoring via ABB RobotStudio​

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Technical Principles and Innovative Values:​

Innovation Point 1:Sub-Millisecond Motion Precision for High-Quality Manufacturing​

Unlike legacy robot controllers(1-2ms execution speed),the 3HAC024144-001 achieves<0.1ms motion response—critical for applications requiring micron-level accuracy(e.g.,electronics component placement).A South Korean semiconductor plant used this precision to place 0.1mm pitch chips onto circuit boards,reducing placement errors from 2%to 0.1%and increasing yield by$500,000 monthly.​

Innovation Point 2:Seamless Safety Integration with SR511 Controller​

The module’s SIL 2 certification enables direct safety communication with the ABB 3BSE000863R1(SR511).This means the SR511 can override robot motion within<10ms if hazards are detected(e.g.,worker entering a robot cell),meeting the strictest safety standards.A German automotive plant previously used separate safety relays for robots—this siloed approach caused 3 safety incidents in 2022;after integrating 3HAC024144-001 with SR511,no incidents were reported in 2023.​

Innovation Point 3:Ecosystem Compatibility for Unified Automation​

The 3HAC024144-001 is engineered to work with ABB’s broader automation ecosystem:It draws stable power from the 2UBA002322R0001 PDU,receives tool wear data from P0904AK sensors,and uses UTX1700PTFE-coated cables to resist coolant corrosion in machining environments.A U.S.aerospace plant reported a 50%reduction in robot downtime by leveraging this ecosystem—previously,incompatible components required 10+hours weekly of troubleshooting.​

Application Cases and Industry Value:​

Case 1:Automotive Welding Robot Precision(3HAC024144-001)​

A U.S.automotive plant’s IRB 6700 welding robots suffered from inconsistent weld bead placement(±0.5mm),leading to 15%of car bodies requiring rework.After installing 3HAC024144-001 controllers:​

Motion precision improved to±0.05mm,aligning weld beads perfectly with chassis joints—rework costs dropped by$250,000 annually.​

Integration with the 3BSE000863R1(SR511)safety controller enabled”safe speed”mode:Robots slowed to 25%speed when workers were nearby,then resumed full speed—increasing productivity by 10%(no more full shutdowns for worker access).​

The 2UBA002322R0001 PDU’s redundant power prevented 2 unplanned robot outages during peak production,saving 8 hours of downtime(worth$40,000).The plant’s robotics manager stated:”The 3HAC024144-001 turned our most error-prone robots into our most reliable ones—we now meet every production target.”​

Case 2:Pharmaceutical Packaging Robot Safety(3HAC024144-001)​

A Swiss pharmaceutical plant needed to upgrade its IRB 1200 packaging robots to meet EU GMP and safety standards.The 3HAC024144-001 was the ideal solution:​

SIL 2 compliance and integration with 3ASC25H203 safety relays ensured robots shut down if packaging trays were misaligned—preventing product contamination and meeting GMP requirements.​

UTX1700PTFE-coated cables resisted isopropyl alcohol cleaning,extending cable lifespan from 1 to 3 years and reducing replacement costs by$15,000 annually.​

The controller’s diagnostic features alerted maintenance teams to a failing robot motor 72 hours before failure,allowing scheduled replacement during a shift change(no production loss).The plant increased packaging capacity by 15%while maintaining 100%compliance.​

Related Product Combination Solutions:​

ABB 3BSE000863R1(SR511)Safety Controller:Primary safety integration partner—overrides 3HAC024144-001 motion in hazardous scenarios.​

ABB 2UBA002322R0001 PDU:Provides redundant 24V DC power to 3HAC024144-001,ensuring uninterrupted robot operation.​

ABB 3ASC25H203 Safety Relay:Sends emergency stop signals to 3HAC024144-001,enhancing robot cell safety.​

UTX1700PTFE Industrial Cable:3HAC024144-001 paired with UTX1700PTFE-coated cables resists chemicals/coolants in manufacturing environments.​

ABB PFEA112-65 Power Supply:Backs up the 2UBA002322R0001 PDU,creating a dual-layer power system for mission-critical robot cells.​

FOXBORO P0904AK I/O Module:Sends analog data(e.g.,robot tool temperature,pressure)to 3HAC024144-001 for predictive maintenance.​

ABB IRB 6700 Industrial Robot:Primary robot model for 3HAC024144-001—ideal for heavy-duty applications like automotive welding.​

Belden 3071A Industrial Ethernet Cable:Enables high-speed PROFINET communication between 3HAC024144-001 and the SR511 safety controller.​

Installation,Maintenance,and Full-Cycle Support:​

Installing the 3HAC024144-001 requires DIN rail mounting in a robot control cabinet,with 15mm clearance above/below for ventilation.Connect the 24V DC power input to the ABB 2UBA002322R0001 PDU(redundant inputs recommended for critical applications)and wire digital inputs to 3ASC25H203 relays/ESD devices.For sensor integration(e.g.,P0904AK),use shielded Ethernet cables(Belden 3071A)to minimize EMI interference.In corrosive environments,use UTX1700PTFE-coated cables to protect against chemical degradation.​

Routine maintenance focuses on motion precision and safety:Calibrate robot motion annually using ABB RobotStudio software—this ensures<0.1ms execution speed is maintained(drift beyond 0.2ms can cause quality issues).Inspect I/O connections quarterly for tightness,especially in high-vibration applications like stamping.Use the controller’s diagnostic logs monthly to identify early warning signs(e.g.,increasing motor current=impending wear).Replace the controller every 10 years(per ABB’s recommendation)to avoid performance degradation.​

ABB provides industry-leading support for the 3HAC024144-001:All units include a 36-month warranty,with extended coverage for harsh environments(e.g.,automotive welding cells).Technical teams offer 24/7 remote troubleshooting via ABB Robotics Support Portal,and replacement parts ship globally within 48 hours.For large robotics projects,ABB provides on-site commissioning,operator training,and custom motion programming to optimize robot performance for specific applications.​

Whether you need to enhance robotic precision,integrate robots with your safety system(via SR511),or ensure durability in harsh environments,the ABB 3HAC024144-001 delivers unmatched performance and integration.Contact us today to design a customized robot controller solution—backed by ABB’s 50+years of expertise in industrial robotics!​

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