ABB IRB 6620 Robot Modules IRB66203HAC057979-003 Motor Incl Pinion

Technical Dossier

Product Details And Specifications

ABB IRB 6620 Series Technical Notes

The ABB IRB 6620 is a high-payload industrial articulated robot engineered for demanding heavy-industry applications including automotive body-in-white assembly, foundry operations, chemical plant material handling, refinery maintenance robotics, and nuclear facility remote operations. With a payload capacity of 150 kg and a reach of 2.2 m, the IRB 6620 occupies a critical position in ABB's large-robot portfolio. Installed across thousands of production cells globally, this platform is characterized by its rigid cast-iron arm structure, IRC5 controller compatibility, and modular axis drive architecture — all of which make individual component replacement a viable long-term maintenance strategy rather than full-unit replacement.

The Evolution of IRB 6620 Architecture

The IRB 6620 architecture is built around a six-axis serial-link kinematic chain with a dedicated servo motor and gearbox assembly at each axis. The axis-1 through axis-3 drives handle the primary load-bearing motion (shoulder, lower arm, upper arm), while axis-4 through axis-6 manage wrist orientation. Each axis motor is paired with a resolver-based feedback encoder and communicates with the IRC5 drive module via the SREA (Serial Robot Electronics Architecture) backplane bus.

Early production units (pre-2010) used Axis Computer DSQC 668 and DSQC 679 variants for motion coordination. Post-2012 revisions introduced the DSQC 1000 main computer and updated SafeMove safety controller integration. This generational split creates a compatibility boundary: axis motors and gearboxes are mechanically interchangeable across the full production run, but electronic control modules require firmware version matching to the installed IRC5 cabinet generation. Technicians sourcing replacement parts must verify the IRC5 cabinet software version (RobotWare 5.x vs. 6.x) before ordering DSQC-series boards.

The pinion-integrated motor assembly — as represented by IRB66203HAC057979-003 — is specific to the axis-3 position. The integrated pinion eliminates a separate coupling component, reducing backlash and simplifying field replacement. This design was carried forward from the IRB 6600 and remains one of the most frequently replaced components due to its load exposure during heavy-payload cycles.

IRB 6620 Full Catalog & Functionalities (SKU List)

The following SKUs represent verified components within the ABB IRB 6620 spare parts ecosystem, classified by functional category:

Axis Motors & Drive Assemblies

IRB66203HAC057979-003: Axis-3 servo motor with integrated pinion, 150 kg payload variant, resolver feedback.
3HAC14550-1: Axis-1 motor unit, flange-mount, compatible with IRB 6620/6640 shared base frame.
3HAC14551-1: Axis-2 motor assembly, lower arm drive, high-torque winding configuration.
3HAC14552-1: Axis-4 wrist motor, compact form factor, resolver-encoded.
3HAC14553-1: Axis-5 wrist bend motor, dual-bearing preloaded shaft.
3HAC14554-1: Axis-6 wrist rotation motor, hollow-shaft design for cable routing.

Gearbox & Mechanical Transmission

3HAC025338-001: Axis-1 gearbox, RV-type cycloidal reducer, 1/105 ratio.
3HAC025339-001: Axis-2 gearbox assembly, pre-lubricated, sealed unit.
3HAC025340-001: Axis-3 gearbox, compatible with pinion-integrated motor interface.
3HAC025341-001: Axis-4 gearbox, wrist differential input stage.

IRC5 Controller Modules (DSQC Series)

DSQC 668 / 3HAC025917-001: Axis computer board, controls axes 1–6 motion interpolation, IRC5 single-cabinet.
DSQC 679 / 3HAC026254-001: Main teach pendant interface board, FlexPendant communication controller.
DSQC 1000 / 3HAC044168-001: Main computer unit, RobotWare 6.x platform, CompactFlash boot media.
DSQC 662 / 3HAC026253-001: I/O module, 16 DI / 16 DO, 24 VDC, DeviceNet compatible.
DSQC 663 / 3HAC025784-001: Analog I/O module, 4 AI / 4 AO, ±10 V range, IRC5 backplane mount.

Power Supply & Safety

3HAC024488-001: Drive system power supply unit, 3-phase 400 VAC input, 48 VDC bus output.
3HAC026254-002: SafeMove safety controller board, axis supervision and speed monitoring.
3HAC14565-1: Battery backup unit, SREA memory retention, 7.2 V NiMH, 72-hour hold.

Quality Control for the IRB 6620 Range

IRB 6620 components present specific QC challenges due to the platform's integrated backplane bus architecture and resolver-based feedback system. DriveKNMS applies the following test procedures to all IRB 6620 parts prior to shipment:

Motor & Pinion Assemblies (e.g., IRB66203HAC057979-003): No-load run-in test at rated speed for 30 minutes. Resolver signal integrity check (amplitude, phase offset, null voltage). Pinion gear mesh inspection under 10× magnification for pitting, spalling, or fretting corrosion. Bearing noise analysis via vibration spectrum (ISO 10816-3 reference band).

DSQC Controller Boards: Functional boot test in an IRC5 test cabinet with RobotWare 5.15 and 6.08 firmware images. SREA bus communication verification (all 6 axis channels active). Memory integrity check (CompactFlash read/write cycle test for DSQC 1000). I/O channel functional test for all digital and analog points (DSQC 662/663).

Gearbox Assemblies: Input/output backlash measurement against ABB tolerance specification (typically <1 arcmin for wrist axes). Leak test on sealed units (nitrogen pressure hold, 15 min). Lubricant sampling for metal particle content (ICP-OES analysis on request).