GRS
Global Robot Specifications
LMS # 34043
Module 1: Robot Processing
Fundamentals
Revision 6.2
© 2017 General Motors Company.
All Rights Reserved
1
Continuous Improvement Process
• If during this class you believe there is an error in the
wording used on a PowerPoint slide or the instructions
provided for an exercise/activity then please notify your
instructor of the exact slide number or exercise/activity
page at the next appropriate class break.
• Thanks for your help in continuously improving the
quality of the class training materials.
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Objectives
•
•
•
•
The student will be able to use robot path
rough cycle time estimation.
The student will be able to define DCS.
The student will know the robot rules of
process.
The student will know the details of path
control signals.
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Course Overview
• This course will provide participants with the ability to
explain the purpose of the GRS Common Global Robot
Specifications (GRS) including build and integration of
Robots and their applications.
• Remember to refer to the GRS Specifications found on
the GM intranet or www.gmsupplypower.com.
• The GRS standards are comprehensive and will have
the latest information. This training course is used as
an instructional guide and may not contain the absolute
latest information from the specifications.
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Global Robot Specifications Overview
GRS1 Robot Technical Specification
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–
–
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Out of the box content
Ethernet/IP communication for all control signals
Ethernet for upload/download support
Ethernet/IP communication for all safety signals
Ethernet/IP for I/O on end of arm tooling and legacy
interfaces
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GRS1
5
Global Robot Specifications Overview
GRS2 Robot Rules of Process Specification
– Sets the maximum limits for robot processing
– Rough cycle time rules
GRS2
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6
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GRS 2 Specification Overview
• This specification is intended to guide robot simulation
operators and process engineers in the standardization
of processing and designing robot applications.
• It provides robot processing requirements that promote
proper robot utilization and extend the life of robots,
robot dress and other associated equipment
• The “Rules of Process” were developed to ensure
common application of the standard interface in the
processing of robots.
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GRS2
7
Global Robot Specifications Overview
GRS3 Robot Integration
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–
GRS3
Path segment tables
Robot Dress
Robot Interference Zones
TCP Definition
Application Setup and Programming
Style and Option Code Usage
Buyoff Checklist
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Global Robot Specifications Overview
GRS4 Robot Interfaces
– Robot to cell controller interface
• Shop specific and user defined bits
– Robot to process equipment interface
• Shop specific and user defined bits
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GRS4
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Robot-Cell Controller Physical Interface (GRS-1)
The GRS-1 Robot Specification defines the basic
hardware and software capabilities of the robot.
This includes:
–
–
–
–
GRS1
Robot Arm Requirements
Robot Controller Requirements
Teach Pendant Requirements
Robot Software Requirements
• Instructions
• Utilities
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5
Robot-Cell Controller Physical Interface (GRS-1)
(cont’d)
Defines communication requirements (Ethernet/IP)
• Dedicated Ethernet/IP channel between robot and cell
controller
– Safe and non-safe signals over the same Ethernet
channel on the cell network
– Some process equipment may be on the cell network
• Ethernet for upload and download
• Additional Ethernet/IP channel(s)
– Robot to/from Process Equipment
– Controls EOAT IO
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GRS1
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GM GRS-2
Pre-tool design simulation is required and governed by the GM
Vehicle Systems GRS-2, Rules of Process Specification. The
simulation will include all facility features and equipment intended
in the Robot cell, including, but not limited to, the following:
•
•
•
•
•
•
•
GRS2
Perimeter guarding
Cell entrances
Operating spaces
Restricted spaces at operator load/unload stations
Auxiliary equipment located within the cell guarding
Facility equipment and/or obstructions in the cell
Tooling and transfer systems
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Robot Restricted Space and Dynamic Limiting
Devices (DLD)
• Through the use of DLDs, the robot’s restricted
space can be automatically changed during a
portion of the robot’s cycle to allow manual
loading/unloading tasks to be performed while the
moving robot is clear of the operator’s work area.
• DLD Device Examples:
– Base Limit Switch
– Light Curtain
– Dual Check Safety (DCS)
13
GRS3
13
Various Safety Devices Used in a Robotic Cell
Robot Cell With gate
GRS3
Robot Cell With Light Curtain
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Various Safety Devices Used in a Robotic Cell
Robot Cell With Safety Mat
Robot Cell With Area Scanner
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GRS3
15
Robot Restricted Space and
Dual Check Safety (DCS)
• Since Global 2, FANUC robots have certified
safety software systems that can be setup to
perform safety functions such as emergency stops,
general stops, teach T1 and T2 modes, as well as
safe monitoring of position and speed.
• Global 4 uses Ethernet/IP Safety I/O
• DCS position monitoring can be used for
redefining the robot’s restricted envelope or
dynamic limitation of the robot envelope (DLD).
GRS3
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Dual Check Safety (DCS) Zone Examples
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GRS3
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DCS Zone 1 and Zone 2 Layout
(Top View)
• DCS zones can be used
to replace other robot
DLD’s such as light
screens or axis switches.
• In this case DCS Zone 1
is configured as the
shared space, and as
safe OUTSIDE the
position zone.
GRS3
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9
DCS Zone 1 and Zone 2 Layout
(Side View)
• With zone 1 configured as a
shared space and as safe
OUTSIDE the position zone:
– The robot must operate outside
the defined space.
– If the robot enters Zone 1 while
the light screen is not reset, the
robot will E-stop.
– If the operator screen is reset
then the PLC will set the zone’s
disabling input active and the
robot will not be stopped.
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GRS3
19
DCS (continued)
• The robot DLD light screen and operator inside
light screen can be replaced with DCS Zones.
• Zone 1 replaces the robot light screen
• Zone 2 replaces the operator inside light
screen and restricts the robot at all times for
entering the operator area.
GRS3
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DCS Operator Zone
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GRS3
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DCS Operator Zones (continued)
GRS3
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DCS Fence Zones
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GRS3
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Validating DCS
•
•
Place temporary awareness barrier in operator station to
prevent anybody from entering the operator station.
Teach robot test path:
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•
•
•
•
•
GRS3
Teach path from robot Home position over the tool and through the
operator light screens as far as the robot can reach. No further testing is
required if the robot cannot reach beyond the outer operator light screen.
Moves taught with primary robot axis (i.e. Joints 1, 2 and 3)
Moves taught at 100% speed
Moves taught as CNT100 termination type
Moves taught as joint motion type
Ramp up test path to full speed in T1.
Test by ramping up to full speed in T2.
Verify that the robot stops before the robot. End effector,
or interrupts the outer operator light screen.
Adjust the DCS Zone and/or add hard stops if required.
Controls Engineer signs off Functional Buyoff checklist is
complete.
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Validating DCS (cont’d)
1. Select the DCS_Test program and skip to the moves to test the desired zone
2. If there is no DCS_Test program provided from simulation, create a short program
into the speed zone or jog the robot into the zone.
3. The robot will stop with a DCS fault
4. Measure the distance from the closest point of the EOAT to the fence.
5. Verify that the distance to the fence meets the minimum requirement in the
Perimeter and Operator Guard Guidelines document
6. If the distance is too small then increase the size of the zone
7. Redo steps 1-5 until the test passes
8. The 2nd test point should be used if a User Frame is used on the zone. The 2nd
test point should be as far away as possible from the 1st location to make sure the
DCS plane is not skewed. Repeat steps 1-7 for the second test point.
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GRS3
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Exercise 1.1
1. What is DCS?
2. Can DCS replace a light curtain or a robot axis
switch in an operator/robot station?
GRS4
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26
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Exercise 1.1
3. What will be the result if the operator light
curtain is reset and the robot enters the defined
shared space?
A. Robot is E-stopped
B. Robot is paused
C. Robot continues
D. Robot finishes segment and waits
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Exercise 1.1
4. What will be the result if the operator light
curtain is not reset and the robot enters the
defined shared space?
A.
Robot is E-stopped
B.
Robot is paused
C.
Robot continues
D.
Robot finishes segment and waits
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Exercise 1.1
5. Robots equipped with certified safety software
can be setup to perform which function(s) over
Integrated DeviceNet Safe (IDNS) or Ethernet/IP
Safety?
A. Position and Speed
B. Emergency Stops and General Stops
C. Teach T1 and T2 modes
D. All of the above
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Exercise 1.1
Exercise Solutions
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Exercise 1.1: Solution
1. What is DCS?
Dual Check Safety
2. Can DCS replace a light curtain or a robot axis
switch in an operator/robot station?
Yes, either one
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Exercise 1.1: Solution
3. What will be the result if the operator light
curtain is reset and the robot enters the defined
shared space?
A. Robot is E-stopped
B. Robot is paused
C. Robot continues
D. Robot finishes segment and waits
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Exercise 1.1: Solution
4. What will be the result if the operator light
curtain is not reset and the robot enters the
defined shared space?
A.
Robot is E-stopped
B.
Robot is paused
C.
Robot continues
D.
Robot finishes segment and waits
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Exercise 1.1: Solution
5. Robots equipped with certified safety software
can be setup to perform which function(s) over
Integrated DeviceNet Safe (IDNS) or Ethernet/IP
Safety?
A. Position and Speed
B. Emergency Stops and General Stops
C. Teach T1 and T2 modes
D. All of the above
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Robot Payload Analysis (Ref: GRS-2)
• During the early design of robot carried tooling, the
payload is analyzed to determine the correct robot
model.
• Payload analysis rules are found in the current version
of GMD-1.
• The “FANUC Payload Checker” Excel file should be
included with all EOAT designs.
Note: for more information see the Payload ID Application
Guidelines and the Payload Checker Tool on the next slide.
GRS2
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Robot Payload Analysis (Ref: GRS-2)
• For additional info, visit the Robotic Standards page:
https://supplier.body.gm.com/crw/production/main/globalStand
ards/roboticStandards.cfm
1. Click the link FANUC Payload ID Application Guidelines
2. Click the link FANUC Robotics Payload Checker Tool
2
2
1
1
GRS2
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Robot Payload Analysis (Ref: GRS-2)
Enter the values for
the mass, center of
gravity, and moments
of inertia for the
EOAT. Do the same
for the EOAT with
parts.
GRS2
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Robot Payload Analysis (Ref: GRS-2)
Has tab that shows a
screen similar to the
FAUNC Payload Entry
Screen with values
generated from the Excel
sheet
GRS2
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Rough Cycle Time Rules
• Many factors affect cycle time including access
to spots, metal types and stack ups.
• Rough cycle time calculations are used:
GRS2
– When little is known about the product or the tooling
in the robot’s path.
– Prior to simulation to obtain early estimates of cycle
time.
– Does not replace robot simulation cycle times.
– Most of the time they will only apply to Body Shop 39
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Rough Cycle Time Rules
Respot Robots
– Rough Cycle Time = 2.5 sec in + (# of Weld Spots X
2sec/spot) + 2.5 sec out
GRS2
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40
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Rough Cycle Time Rules
Framing or Geo-set Robots
– Rough Cycle Time = 2.5 sec in + (# of Weld Spots
X 3sec/spot) + 2.5 sec out
– Where, # of Weld Spots = the number of weld
spots planned for that robot
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GRS2
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Example: Respot Robot Analysis
Assume an engineer is analyzing a respot robot
application where it is uncertain if the robot will
have to reorient in order to get the estimated 12
welds. Also, the product data is not well defined.
The cycle time for that robot should be calculated
as follows:
GRS2
– Rough Cycle Time = 2.5 sec in + (12 Spots X
2sec/spot) + 2.5 sec Out
– Rough Cycle Time = 29 sec for Respot robot
– Rough Cycle Time = 41 sec for Geo-set robot
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Rough Cycle Time Rules
MH and Pedestal welding robots
– Rough Cycle Time = 6 to 9 sec pick & clear + (# of
Weld Spots X 2 sec) + 6 to 9 sec drop & clear
– Could apply the rough MH times to Powertrain
applications
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GRS2
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Example: MH Robot
Assume an engineer is analyzing a robot application
where a Fanuc robot will carry a long narrow part like a
Tie Bar. The robot will use 7 sec (in the range of 6 – 9
sec) to pick & clear and drop & clear. The robot has 12
Ped welding spots to do. The cycle time for this robot
should be calculated as follows:
– Rough MH Cycle Time = 7 sec Pick & Clear + (12
Ped Spots X 2 sec) + 7 sec Drop & Clear
– Rough Cycle Time = 38 sec for that robot
– Rough Cycle Time = 14 sec for just MH
GRS2
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Rough Cycle Time Rules
Carried stud welding robots
– Stud Weld Cycle Time = 2.5 sec In + (# of Studs X
[SWT + .5 per move]) + 2.5 sec Out
• Where: (# of Studs) = Number of stud welds for that robot
• And: (SWT) = Stud Weld Time for that type of weld.
• And: .5 sec per move between studs for studs within a few
inches on the same plane.
GRS2
– Consult a Vehicle Systems Robot engineer for
additional information regarding rough cycle times of
carried stud welders or other robot weld
applications.
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Example: Carried Stud Welder
Assume an engineer is analyzing a robot carried
stud weld application where the robot will have
an estimated 8 stud welds of type M6x25mm,
which welds take 2.2 seconds
– Stud Weld Robot Cycle Time = (2.5 sec in) + (8
Studs X (2.2 + .5) sec) + (2.5sec Out)
– Stud Weld Robot Cycle Time = 26.6 sec
GRS2
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Carried Dispense Robots
• Processing rule: Utilize this cycle time calculation to determine an
estimate of the length of the dispensing process based on the
available cycle time
𝐑𝐨𝐮𝐠𝐡 𝐂𝐲𝐜𝐥𝐞 𝐓𝐢𝐦𝐞
# of beads X
2.5 sec In
Bead Length in mm 200 mm
Robot Speed in mm/sec
2.5 sec Out
• 200 mm accounts for 100 mm before and after each continuous
bead do to sticky material and line straightening
• An estimate of the process cycle time based on the given length of
dispensing process
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GRS2
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Other Rough Cycle Time Calculations
• Carried arc welding robots
Rough Cycle Time
2.5 sec In
0.6 sec Arc Start
Bead Length in mm
Robot Speed in mm/sec
0.6 sec End Fill Delay
2.5 sec Out
• Projection nut welding robots
– Rough Cycle Time = 6 to 9 sec pick & clear + (# of Weld Spots X 3
sec/spot) + 6 to 9 sec drop & clear
– Project Nut welders are controlled by the cell controller
GRS2
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Other Rough Cycle Time Calculations
• Clinch nut welding robots
– Rough Cycle time = 2.5 sec in + (# Weld Spots X 2
sec/spot) + (2.5 sec out)
• Tool changer timing
– Tool Changer = (0.3 sec unlatch) + (0.3 sec latch) +
(6.0 sec concurrent with return to home motion)
•
NOTE: As a guideline in early processing, 12 seconds can be used to
estimate the total time to exchange tools
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GRS2
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Exercise 1.2
Exercise Solutions
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50
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Exercise 1.2: Rough Cycle Time Exercise
• Calculate the rough cycle time for a carried
stud welder that must make 11 stud welds.
– 2.5sec + [(2.2+0.5)*11] + 2.5 = 34.7
• Calculate the rough cycle time for a material
handler/ped welder. Assume the pick/clear
and drop/clear utilize 8 seconds each. There
will be 7 weld spots.
– 8 + (7*2) + 8 = 30
51
GRS2
51
Robot Rule of Process
Robot reach
Each robot shall be placed in simulation, and called
out in the system layout, such that the actual robot
can be misplaced on the floor by up to 100 mm in any
direction and still be able to reach all of its spots
Home and pounce
The home and pounce positions should be
programmed as close to the work position as possible
without interference with moving material or tooling.
GRS2
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52
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Robot Rules of Process
Robot clearances and tip wear
Clearances between the gun shanks and
product while welding or in motion shall be
greater than 5 mm before and after tip wear.
GRS2
Wearing of Weld Gun Tips (example only)
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Robot Rules of Process
End-effector mounting
1. It is square to the base of the robot when the robot’s joints are
centered at (zero degrees) synch position, minimizing the need
for angle brackets.
2. While the robot is running its path, joint 5 has a bend in it (near
90 degrees is preferred) to avoid singularities whenever
possible. Avoid key positions where joint 5 must be near zero
degrees. (ex., at spot welds, while dispensing, pick, drop, tip
dressing, etc.)
GRS2
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54
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Robot Rules of Process
End-effector mounting (cont’d)
3. There is as little rotation as possible from the robot’s home
position to the position where the joint angles of the robot are at
zero degrees—also taking items 1 and 2 above into account.
4. The CG is as close as possible to the centerline and surface of
the robot’s faceplate.
5. Joints 4 and 6 should be centered rather than turned one way at
home position and during its motion, if possible. This method of
programming will help when synchronizing the robot.
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GRS2
55
Robot Rules of Process
Weld spot distribution requirements
• Weld spots are grouped by gun orientation due to robot dress
• Minimize weld gun rotation
• The robot shall weld on no more than two grossly different weld
planes, where the angle difference is greater than 45 degrees
GRS2
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Tip Dressers
• Spot welding uses high
temperature and
pressure which alters the
copper weld tip shape
over a number of welds.
Tip dressing resets the
weld tip shape.
GRS2
Tip dresser (Picture is for example only)
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Tip Dressers
The following tip dress parameters shall be followed for robot carried gun tip
dressers within the cell. Place tip dresser in simulation following these
parameters:
•
The weld gun orientation at the tip dress position should be approximately
the same orientation utilized when welding
•
The robot shall be clear of the line transferring while moving to the tip
dress location to permit tip dressing while during line transfer.
•
The robot should be clear of the other robots’ paths (i.e., no interference
zones in the tip dress path)
•
One tip dresser per robot with carried gun(s)
GRS2
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Tip Dressing Process
Moveable Shank
Blade Holder
Weld gun must close in the
same direction as the springs
Moveable Shank must be on the
same side as the blade holder
GRS2
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Tip Dressing Process
GRS2
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60
30
Global 4 Tip Dress Document
For Tip Dress information visit the Robotic
Standards page to access the Global 4 Tip
Dress Document:
https://supplier.body.gm.com/crw/production/
main/globalStandards/roboticStandards.cfm
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Robot Control
The sharing of process-related devices,
controlled by a robot, is not permitted
Example: A ped welder controlled by one
robot and being used by another robot.
GRS2
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Two Process Rule
• A robot shall be limited to two processes based on
the use of two process controllers. (i.e. ped weld
and ped dispense)
– Material handling in conjunction with two processes is
permitted.
– MH is not a process
• A single end-effector shall be limited to two
functions.
– MH is a function
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GRS2
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Spot Weld Gun Combinations
The following table defines the number of guns that can
be used with 1 or 2 SCR’s
Note: See next
slide for Weld Gun
Combinations
DC Welding requires use of 1 SCR and 1 Weld Gun.
GRS2
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64
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Weld Gun Combinations
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Stud Weld Gun Combinations
The following table defines the number of carried or
pedestal guns that can be used
GRS2
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66
33
Stud Weld Gun
Stud Weld Gun (Picture is for example only)
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GRS2
67
Dispense Gun Combinations
The following table defines the number of dispense guns
that can be used with number of controllers
GRS2
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34
SCA Dispense Setup
Dispense Setup (Pictures are for example only)
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GRS2
69
Material Handling
Rules for Valves, Clamps, Electric Part Holders, Part
Present Switches and Vacuum Pumps
Device
Max Preferred Max allowed
(all)
(2004 Arch)
Max allowed
(2006 Global
Arch)
Max allowed Max allowed
Max allowed
(2009 Global 2 (2012 Global 3 (2016 Global 4
Arch)
Arch)
Arch)
Valves
Clamps
3
6
5
12
10
18
10
18
10
18
15
24
Electric Part
Holders
N/A
N/A
N/A
8
8
8
Part present
switches
3
6
9
9
9
16
Vacuum pump
channels
2
4
4
4
4
4
GRS2
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70
35
Tool Changers
GRS2
• The maximum number of tool changer stalls or
positions shall be four per robot. The tool changer
stalls may be arranged on single or separate
stands.
• Trans guns shall be used when spot weld gun
changes are required. Cable guns may not be
used with tool changers
• Use tool changers only when absolutely
necessary or in a tooling back-up situation
71
GRS2
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Tool Changers
GRS2
Tool Changers (Pictures are for example only)
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36
ATI Tool Changer Mechanism
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GRS2
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GRS2
GRS2 – Robot Rules of Process Summary
GRS2 sets the maximum limits for robot
processing. These limitations are critical to the
ability to purchase common equipment.
– Maximum of 24 Robots per Cell (Gated Area)
– Maximum of 2 process control panels per robot
– Maximum of 2 end effector functions
GRS2
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Path Control Signals (GRS-4)
The Path Control signals contain information on what program the
robot should run and control signals while running
Controller to Robot
Robot to Controller
Global Robot Specification
Global 4
Global 3
Prior
Style Number
0-255
0-127
0-31
Option Bits
A, B, C,
D, E
A, B, C,
D, E
A, B, C
Initiate Style
Global4
Global 3
Prior
Style Number Echo
0-255
0-127
0-31
Option Bits Echo
A, B, C,
D, E
A, B, C,
D, E
A, B, C
Manual Style Request
Decision Code
0-31
0-31
0-15
Decision Code Echo
0-31
0-31
0-15
Clear to Enter Zone
1-12
1-12
1-6
Clear Zone
1-12
1-12
1-6
0-255
0-63
Path Segment Ok to Continue
Path Segment Echo
0-255
Path Segment Request to Continue
0-255
0-63
Path Segment
0-255
In Cycle
75
Task OK
GRS4
75
Style
Style Number
0-255
Style Number Echo
0-255
• Style Numbers (1 to 24) identify different robot paths required by
the “style” of the part being operated on.
– Style Number (1 to 24) for Production Paths
– Style Numbers (25 to 34) for Special / Maintenance Paths
– Style Numbers (35 to 49) for Maintenance Styles
– Style Numbers (50 to 255) User Defined Styles
• The Style Number is read when the Initiate Style bit is turned on
GRS3
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38
Style Numbers
77
GRS3
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Style Numbers (cont’d)
GRS3
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78
39
Options
Option Bits
Global 3 and 4
Prior
A, B, C, D, E
A, B, C
Option Bits Echo
Global 3 and 4
Prior
A, B, C, D, E
A, B, C
• The option bits (A, B, C, D and E) identify minor
path variations within a given robot style program.
• The robot reads options once when “Initiate Style
Program” bit is ON from the controller and then it
(the robot) echoes the option bits to controller
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GRS3
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Path Segments
Global 3 and 4
Path Segment
0-255
Global 3 and 4
Path Segment
0-255
• The Path Segments numbers (0 to 255) from the robot identify the
location of a robot along its path within a style program
– For example: A robot with Path Segment number equal to 1
represents the robot “Moving to Pounce”
• The Path Segment numbers (0 to 255) from the PLC are used as
an echo of the robot Path Segment Number when the conditions
are met to move into the next segment, otherwise it will be zero
GRS3
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80
40
Path Segments
• Path Segment numbers shall be unique within a
style program
• Path Segment numbers are reused between
style programs
81
GRS3
81
Path Segments
• Path segments definitions
GRS3
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82
41
Path Segments
Path segments 10-59 and 110-149
Segment #
10-13
14-17
18-21
22-25
26-29
110-113
114-117
118-121
122-125
126-129
Usage
Segment # Usage
Pick 1
Pick 2
Pick 3
Pick 4
Pick 5
Pick 6
Pick 7
Pick 8
Pick 9
Pick 10
30-33
34-37
38-41
42-45
46-49
130-133
134-137
138-141
142-145
146-149
Segment #
Usage
50-54
55-59
Process 1
Process 2
Drop 1
Drop 2
Drop 3
Drop 4
Drop 5
Drop 6
Drop 7
Drop 8
Drop 9
Drop 10
• Pick/Drop 1-5 are used
in the Body Shop
• Pick/Drop 1-10 are
used for Powertrain
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GRS3
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Recovery Path Segments
• Path segments 201-210 are used for recovery from pick 211-220
are used for recovery from drop.
• This is currently only being used for Powertrain Advanced MH
Recovery
Segment #
201
202
203
204
205
206
207
208
209
210
GRS3
Recovery For
Segment #
(Original Segment #)
Pick 1 (10-13)
211
Pick 2 (14-17)
212
Pick 3 (18-21)
213
Pick 4 (22-25)
214
Pick 5 (26-29)
215
Pick 6 (110-113)
216
Pick 7 (114-117)
217
Pick 8 (118-121)
218
Pick 9 (122-125)
219
Pick 10 (126-129)
220
Recovery For
(Original Segment #)
Drop 1 (30-33)
Drop 2 (34-37)
Drop 3 (38-41)
Drop 4 (42-45)
Drop 5 (46-49)
Drop 6 (130-133)
Drop 7 (134-137)
Drop 8 (138-141)
Drop 9 (142-145)
Drop 10 (146-149)
84
84
42
Stamping Path Segments
Segment #
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
GRS3
Usage
Home/Unknown
Pick 1 Pounce/Enter Zone 1
Pick 1 Pounce
To Camera Calibration
To Repair
Brake Check
Approach Pick 1
At Pick 1
Lift Pick 1
Depart Pick 1
Clear Pick 1
Enter Zone 2
Auto Retry Pick 1
Drop Back to Pick 1
Drop 1 Pounce
Approach Pick 2
At Pick 2
Lift Pick 2
Depart Pick 2
Clear Pick 2
Segment #
28
29
30
31
32
33
34
35
36
37
38
39
40‐49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
Usage
Drop Back to Pick 2
Drop 2 Pounce
Drop Sneak
Drop 1 Approach and Drop
Drop 1 Depart and Clear
Enter Zone 1 Return
Return to Pick Pounce
Spare
To Tool Drop
From Tool Drop
To Tool Pick
From Tool Pick
Clear Press Access
Move to Show Part
Return to Home
85
Auto Retry Pick 2
85
“Continue” Signals
A “Request to Continue” (RTC) signal is required
when the robot needs to handshake with the
controller at a specific point in the path. Some of
these points may be:
–
–
–
–
GRS3
At pounce position always requires RTC
Clear to drop / pick
No part check / part check
Decision code point
86
86
43
Style Differences Between Shops
The structure of the style program differs depending on what shop
(body shop, powertrain, stamping) the robot is in. The differences are
detailed in the next few slides.
Body Shop
1.
Style program is called
2.
Robot moves to Pounce and RTC
3.
Then calls SXXPICK, SXXPROC, or SXXDROP programs as
needed
4.
Robot returns to home for next cycle
87
GRS3
87
Style Differences Between Shops (cont’d)
Powertrain
GRS3
1.
Style program is called
2.
Robot moves to Pounce and RTC
3.
The SXXDCDPK is called to choose the pick location
4.
RTC
5.
SXXPROC if needed
6.
RTC
7.
SXXDCDDP is called to choose drop location
8.
RTC
9.
Loops back to look for next pick without going home
88
88
44
Style Differences Between Shops (cont’d)
Stamping - Destacking
10. RTC – wait for drop
1.
Style program is called
11. Drop and move up
2.
Robot moves to Pounce and RTC
3.
Robot moves to pick in the style
program
12. RTC – check to go back to pick
pounce
4.
RTC
5.
Pick
6.
RTC – decide what to do with blank –
continue or return to stack
7.
Move up
8.
RTC – check for double blank
9.
Move Clear
13. Loops back to pick pounce without
going home
89
GRS3
89
Destacking Press Shop
GRS3
90
90
45
Weld Program RTC
R e q u e s t to C o n tin u e
“A t P ounce”
S e g 5 0 : W e ld
Seg 1: Pounce
“ R e q u e s t t o C o n t in u e ”
N o t A lw a y s R e q u ir e d !
S e g 6 3 : A ll C le a r
S e g 6 2 : T o o l C le a r
“ O p tio n a l”
91
GRS3
91
Robot Clear of Station
R e q u e s t to C o n tin u e
“A t P ounce”
S e g 5 0 : W e ld
Seg 1: Pounce
C le a r o f S ta tio n
N o t C le a r o f S ta tio n
S e g 6 3 : A ll C le a r
S e g 6 2 : T o o l C le a r
“ O p tio n a l”
GRS3
92
92
46
Weld Task OK - Successful Process
R e q u e s t to C o n tin u e
“A t P ounce”
T ask O K
V e r ifie d o ff a t p o u n c e
C o n tin u e O K
T a s k O K tu r n e d o n
Seg 1: Pounce
T a s k O K o ff
S e g 5 0 : W e ld
Task O K on
S e g 6 3 : A ll C le a r
I n itia te S ty le
T a s k O K , tu r n e d o ff
S e g 6 2 : T o o l C le a r
O p tio n a l
Automatically taken care of as part of the
ATPOUNCE program
GRS3
93
93
Weld Task OK - Incomplete Process
R e q u est to C o n tin u e
“ A t P o u n c e”
T a sk O K
V erified o ff a t p o u n ce
C o n tin u e O K
T a sk O K tu rn e d o n
S eg 1 : P o u n c e
Task O K on
T a s k O K o ff
S eg 6 3 : A ll C le ar
S e g 5 0 : W e ld
W eld fa u lt
S k ip p e d o n te a ch p en d a n t
T a sk O K , tu rn e d o ff
In itia te S ty le
T a sk O K , tu rn e d o ff
S eg 6 2 : T o o l C lea r
O p tio n a l
GRS3
94
94
47
Weld with Clamp Reposition
95
GRS3
95
Path Decision Control
Decision Code numbers
are used when different
paths are required within
the same robot style
program
Seg 31:Move clear of Drop
Request to Continue
“Are Drop 1 Part Switches On?”
Decision Code 1 sent to robot
Seg 30: Drop 1 & Clear Part
Seg 11: robot has part and moving
clear of pickup
Seg 12: robot is clear of pickup
Seg 63:Clear of All
Seg 35:Move clear of Drop
Request to Continue
“Are Drop 2 Part Switches On?”
GRS3
Request to Continue
“Which Drop is Ready”
Decision Code 2 sent to robot
Seg 34: Drop 2 & Clear Part
96
96
48
Path Decision Control
• Typical use: Multiple pick / drop locations for the
same style of part
• Requires robot to be at a “Request to Continue”
point
• Decision code is read by the robot when “Continue
Ok” bit is ON from the controller and is then
echoed back to controller
• Unlike decision code, the option bits (A-E) identify
minor path variations within a given robot style
program
97
GRS3
97
Path Decision Control
Predefined Decision Codes
– Decision 14, Cap Change Reset at Request Continue
– Decision 15, Return Home From Pounce
– Decision 16, Advanced MH Return Home From Pick
GRS3
98
98
49
Stamping Path Decision Control
99
GRS3
99
Body Shop/Powertrain MH Example
Seg11: At Pick 1
RTC
Seg31: At Drop1
RTC
Seg12: Clear Pick 1
DC =15
or 16
Seg10: To Pick 1
Seg63: All
Clear –
Powertrain
DC =2
DC =2
Seg14: To Pick 2
Seg34: To Drop 2
Seg36: Clear Drop 2
Seg16: Clear Pick 2
RTC
Seg63
RTC
Seg63: All Clear – Body Shop
GRS3
Seg30: To Drop 1
DC =1
DC =1
RTC
Seg1:Pounce
Seg32: Clear Drop 1
Seg15: At Pick 2
RTC
Seg35: At Drop 2
100
100
50
Stamping Example
101
GRS3
101
Stamping Example Press to Press Application
GRS3
102
102
51
Exercise 1.3: Draw a Robot Path
Layout the robot path with segment numbers in
the diagram in your exercise manual include the
request for continue points and decision codes
for the following operations:
– Weld
– Return home (Decision Code 15)
103
GRS3
103
Exercise 1.3: Draw a Robot Path
Layout the robot path with segment numbers in the
diagram in your exercise manual include the request for
continue points and decision codes for the following
operations:
–
–
–
–
Pick from either of two locations
Drop to a single location
Wait for station to clamp
Weld
– Return home
104
104
52
Exercise 1.3
Exercise Solutions
105
105
Exercise 1.3: Solution
Decision 15
1
RTC
Decision 0
50
63
GRS3
62
106
106
53
Exercise 1.3: Solution
Dec1
Dec15
RTC
1
63
62
GRS3
*No Part check
10 RTC*11
12
RTC Is Drop ready?
RTC* 16
30
14
15
RTC Part Check
31
Dec2
32
RTC Are Clamps
50
Closed?
107
107
Module 1: Review
• What tool can be used during early robot cell
design to approximate running time for various
robots?
– Rough Cycle Time Calculation
• What is DCS?
– Dual Check Safety. DCS position monitoring can be
used for redefining the robot’s restricted envelope or
dynamic limitation of the robot envelope (DLD).
• What is the maximum number of processes
allowed for a single robot?
– 2
108
108
54
Module 1: Review
• What are the path control signals used between
the PLC and robot?
– Robot uses Path Segment Request to Continue
– PLC responds with Path Segment Ok to Continue
109
109
55
GRS
Global Robot Specifications
LMS # 34043
Module 2: Robot Integration
Revision 6.2
© 2017 General Motors Company.
All Rights Reserved
1
Objectives
• The student will understand the phases of integration, the
hardware setup requirements, and the contents of the buyoff
checklist.
• The student will know how to setup the robot payload.
• The student will know the requirements for mastering.
• The student will be able to explain/setup Tool Center Point (TCP)
for multiple robot applications.
• The student will know program naming conventions and move
speed settings.
• The student will know robot interference zone rules.
• The student will define Collision Detection Setup.
2
2
1
SCS MPS Robotic Cell
• Review this video for proper use of the MPS
and SCS systems.
• If you have difficulty opening the video open
GM Supply Power then use this link
https://players.brightcove.net/5511551936001/HyxtG9kIb_default/index.html?
videoId=5976824853001
3
GRS3
3
Robot Integration
The responsible robot programmer shall document
completion of all Pre-Integration (Test Cell), On-Line
Integration (Including Home Line), and Re-Integration
(After Shipping) tasks using the appropriate columns of
the consolidated “GRS 3 Robot Buyoff Checklist”
GRS3
4
4
2
Pre-Integration
When the pre-integration (test cell) option is specified at
time of quote, the integrator shall be responsible to
complete all tasks that appear in Pre-Integration (Test
Cell) column of the “GRS 3 Robot Buyoff Checklist”
5
GRS3
5
On-line System Integration
• The integrator shall be responsible to complete all tasks
that appear in the On-Line Integration (Including Home
Line) column of the “GRS 3 Robot Buyoff Checklist”
• Any items not completed during pre-integration in the
test cell must be complete during on-line integration
Note: See next slide for the GRS Robot Buyoff Checklist
access.
GRS3
6
6
3
On-line System Integration
For Integration Buyoff information visit the Robotic
Standards page to access the GRS 3 Robot
Integration Buyoff Check list:
https://supplier.body.gm.com/crw/production/main/
globalStandards/roboticStandards.cfm
7
GRS3
7
Re-Integration
When plant startup assistance is specified at the time of
quote, the integrator shall be responsible to complete all
tasks that appear in the Re-Integration (After Shipping)
column of the “GRS 3 Robot Buyoff Checklist”
• For home-line integration, the Re-Integration is not
applicable
GRS3
8
8
4
Order Robots
• To order robots the integrator should submit the Robot
Order Form from SupplyPower to the GM Vehicle
Systems Engineer
• Accurately estimate cable lengths needed for the robot
9
GRS3
9
Robot Programming Safety
• Verify Teach Pendant length can safely reach
all areas of the cell
• Verify lag bolts are installed properly
• Verify Dual Check Safety (DCS) info sheets
from simulation
• Check for tool changer switch or jumper
• Verify SMC cylinders are set to the locking
position
GRS3
10
10
5
Robot Programming Safety (cont’d)
• Bypass DCS Common Industrial Protocol
(CIP) safety
• Verify presence and function of light curtains
• Reference Safe Operating Procedures (SOP)
11
GRS3
11
Configuration of Robot
• The latest version of core software should be loaded on the robot
• The integrator shall utilize the Set-up Wizard to achieve the
following deliverables at integration:
– Configure the robot software for proper control of the robot process
equipment
– Comment I/O points in the robot I/O map to match the wiring diagrams
• The integrator shall also configure the following during integration
– Define valves, valve types, sensor inputs, and associated feedback
devices – MH Valves
– Set up any associated delays and timeout value
– Setup all part present sensors for continuous checking as opposed to
discrete
GRS3
12
12
6
Configuration of Robot (cont’d)
• Set date/time
• Load offline programs and run the TOOLDATA program
• Verify EOAT operation
13
GRS3
13
Load Data Setup
• Load Data, encompasses both Payload and Armload.
• Payload is defined as the mass, center of gravity, and
mass moments of inertia for all EOAT and carried parts
manipulated by the robot.
• Armload is defined as the mass and center of gravity of
the dense pack and any other arm-mounted equipment
carried by the robot
GRS3
14
14
7
Load Data Setup (cont'd)
• Payload and Armload data shall be utilized in all
programming that contains motion
• A separate Payload shall be defined and utilized in the
robot program for each physical scenario in which there
is a unique payload characteristic *
* Exceptions to the above rule are allowed in cases where the
mass difference between two physical loading scenarios is less
than 5%
15
GRS3
15
Payload Definition
• Payload data from simulation contained in the Offline
Program (OLP) shall be utilized.
– OLP is the output from simulation that is loadable and on the
robot.
• If OLP is not used, the integrator shall be responsible for
calculating and implementing Payload data for all
programming that contains motion.
GRS3
– (Note: The integrator shall utilize Roboload Payload information
wherever Roboload has been provided by the mechanical design
source.)
– Armload data for manual entry will be provided by GM Vehicle
Systems
16
16
8
Payload Naming Convention
• Payload1, or the first available payload data, shall be
used for the primary EOAT without carried parts
• Primary EOAT is defined as the EOAT that the robot is
holding at the Home position.
• For carried process equipment without material
handling or tool changing, only Payload1 is typically
necessary. For material handling or tool changing,
additional payload definitions are usually required
17
GRS3
17
Payload Naming Convention (cont'd)
• Payload2, shall be used for the primary EOAT with its
carried part for Style 1. For tool changing, Payload2
shall be used for the second carried tool
• Subsequent payloads are named in sequential order
as they are encountered in the robot’s process
sequence, beginning with Style 1, until all unique
loading scenarios are defined.
• For tool changing, the robot-without-tool loading
scenario shall be defined as the last payload
GRS3
18
18
9
Mastering
• Mastering defines the location of the robot by
synchronizing the mechanical unit’s position with the
robot controller’s stored positional data.
• In order for the robot motion to behave properly the
robot must be properly mastered. Prior to performing
any path teaching or setup (e.g. teaching frames)
the robot’s mastering shall be verified
19
GRS3
19
Verify Mastering
• The integrator shall be responsible to review and follow
the appropriate manufacturer’s procedure to master the
robot
• The integrator shall also verify that the appropriate
mastering values are recorded on a print out or a
sticker placed inside the robot controller cabinet
• Any problems with mastering that are encountered
during system integration shall be reported to the GM
Vehicle Systems Robots engineer
GRS3
20
20
10
Verify Mastering (cont'd)
• Mastering will be reviewed at the time of robot
buyoff
– For FANUC robots, the witness marks specify the
mastered position when aligned
21
GRS3
21
Zero Position Mastering
• If zero position mastering was possible then
the mastering position will coincide with the
zero position and should be directly entered
to assure that all joints are at precisely zero
• Once the integrator has completed the
manufacturer’s procedure they shall create
a program called “MASTERPS”
• Running this routine and checking the
physical position of the arm by examining
the witness marks can verify the robot
mastering
GRS3
22
22
11
Zero Position Mastering (cont'd)
• A safe path (avoiding any dress problems/tooling
collisions) from the home position to the mastering
position.
• An instruction to PAUSE program execution.
• A safe path to home
GRS3
23
23
Zero Position Mastering Not Possible
• If zero position mastering was NOT possible then the
responsible GM Vehicle Systems engineer shall be
contacted to provide direction
• Mastering of the robot will have to be completed in 2
steps. The first step shall involve aligning axis 1, 2, and 3
to zero, with the wrist axes in such a position as to avoid
any collisions
• The second step shall involve aligning axis 4, 5, and 6 to
zero, with the major axes in such a position as to avoid
any collisions
GRS3
24
24
12
Zero Position Mastering Not Possible (cont'd)
• Once the integrator has completed the manufacturer’s
procedure they shall create a program called
“MASTERPS”. Running this routine and checking the
physical position of the arm by examining the witness
marks can verify the robot mastering
25
GRS3
25
Zero Position Mastering Not Possible (cont'd)
• A safe path (avoiding any tooling collisions) from the
home position to the mastering position for axis 1, 2,
and 3
• An instruction to PAUSE program execution
• A safe path (avoiding any dress problems/tooling
collisions) from the mastering position for axis 1, 2, and
3 to the mastering position for axis 4, 5, and 6
• An instruction to PAUSE program execution
• A safe path to home
GRS3
26
26
13
Setup Weld Gun and Accessory Weld Equipment
• Set up the Servo Gun based on the Servo Gun Setup
Manual
• Setup Water Saver
• Setup Tip Dresser
• Verify Tip Dresser motor and blow off functionality
27
GRS3
27
Tool Center Point (TCP)
• A tool center point shall be defined for each process
and material handling end-effector to facilitate path
teaching and recovery.
• Each individual process feature of a dual or multiple
function end-effector shall have a unique TCP defined.
• Remote TCPs are required for any robot controlled or
PLC-controlled process equipment with which the robot
interacts that are not physically mounted to the robot
arm.
For more information on TCP see next slide.
GRS3
28
28
14
Robot Frames
World frame
GRS3
Tool frame
User frame
29
29
Tool Center Point (TCP) (cont'd)
• Tool center point location, orientation, and
naming convention shall follow the standard
defined in GRS3
• TCP verification shall immediately follow TCP
definition or updating, and will be rechecked as
part of the GM Vehicle Systems buyoff checklist
GRS3
30
30
15
Teach TCP
• If an offline program is provided, the X-Y-Z of the tool
center point that is provided from simulation shall be
updated prior to path touchup
• If an offline program is not provided, a new TCP shall
be defined according to the standard documented in
this Section, prior to path teaching
• For pedestal applications, a remote TCP coordinate
system for the pedestal portion of the path shall be
defined
31
GRS3
31
Verify TCP Location - Carried Applications
• Using the teach pendant, set the robot jog
mode to tool coordinates and jog the robot so
that it rotates around the tool X, Y, and Z axes
• The TCP shall not move more than 2 mm in
any direction during a 45-degree rotation about
any axis
GRS3
32
32
16
Verify TCP Location - Pedestal Applications
The location of each remote TCP shall be verified in the following
manner:
•
•
Pick a stationary point on the End of Arm Tooling (EOAT) or process part (if
carried by robot) and jog the robot so that the point lines up with the pedestal
TCP
Place the robot in remote tool coordinates and rotate the EOAT or carried part
around the X, Y, and Z axes
• The EOAT or carried part shall not move more than 2mm in any direction relative to
the pedestal TCP during a 45-degree rotation about any axis
33
GRS3
33
Verify TCP Orientation - Carried Applications
With the robot jog mode set to tool coordinates,
jog the robot in the positive directions of the X, Y,
and Z axes. The tool center point shall move
linearly in the positive direction of each axis
GRS3
34
34
17
Verify TCP Orientation - Pedestal Applications (cont'd)
The orientation of each remote TCP shall be verified in the
following manner:
• Pick a stationary point on the EOAT or process part if carried by
robot and jog the robot so that the point lines up with the pedestal
TCP
• Place the robot in remote tool coordinates and move the EOAT or
carried part in the X, Y, and Z directions
–
–
The EOAT or carried part shall move linearly in the positive direction of each
axis.
For pedestal spot welding, jogging in the remote tool +X direction swallows
the metal and jogging in the remote tool +Z direction brings the
stationary tip closer to the metal
35
GRS3
35
TCP Naming Convention
• Robot programs originating from Offline Programming (OLP) shall
maintain the TCP names established by the GM Robot download
translator
• Robot programs not originating from OLP shall follow the following
standard for TCP naming
– Robots with a single carried TCP shall be programmed using TCP 1. Robots
with more than one carried TCP shall be programmed with TCP’s numbered in
ascending order based on the process sequence for each robot.
– Robots that are processed to use different TCPs (or in a different sequence)
based on Style program shall be programmed using TCPs in ascending order
starting with Style 1 and continuing until all TCPs are named
GRS3
36
36
18
TCP Naming Convention (cont'd)
• Robots with pedestal applications shall use the standard
above for naming of carried TCPs.
• Stationary TCPs (FANUC UFRAME/RTCP) shall be
numbered in ascending order beginning with the
process sequence of Style 1 and continuing until all
stationary TCPs are named
37
GRS3
37
Material Handling Application
• A TCP shall be created for each part that is handled
• The origin of the TCP coordinate system shall be located at the
EOAT 4-way locating pin
• If the EOAT does not have a locating pin, the drop off TCP shall be
set in the center of the locating hole in the part that corresponds to
the 4 way locating pin in the drop off station
• In this case, the TCP orientation shall be aligned with the pin in the
station and is not always aligned with the surface of the clamp
detail. For the pick up path, the TCP shall be set on the corner of
one of the clamp details
• Note that multiple TCP should be created (i.e. one for the pick up
path and one for the drop off path) to make programming quicker
and easier.
38
GRS3
38
19
Material Handling Application (cont'd)
• As a general rule, a TCP should be created for each
location that the robot must rotate about. For example,
a robot that picks up a door inner and marries it to a
door outer, will have two TCP
– One TCP will be used for most of the path and will be set at the
EOAT 4 way pin
– A second TCP will be located along one edge of the part.
During the marriage process, the part will be rotated about this
second TCP to snap the two parts together
39
GRS3
39
Material Handling Application (cont'd)
• In cases with no pins on the EOAT or in the
tooling, the TCP shall also be set to the corner
of one of the clamp details
• In cases with no pins or details on the EOAT or
in the station (i.e. suction cups or magnets
only), the TCP shall be set in the center of each
set of suction cups or magnets
GRS3
40
40
20
Material Handling Application (cont'd)
The orientation of the TCP shall be defined
according to the following rules
– The +Z direction is defined as the direction the end-effector will
approach the part
– The X and Y directions are defined square to the part and
according to the right hand rule
GRS3
41
41
MH TCP Definition for robots With Pin
GRS3
42
42
21
MH TCP Definition for robots Without Pin
43
GRS3
43
Standard TCP Definitions - Weldgun Application
For servo weld guns, the origin of the TCP shall
be centered on a new cap attached to the
stationary weld arm
GRS3
44
44
22
Spot Weld Guns (Pictures are for Examples Only)
Small Frame
GRS3
Light Weight C Gun
Light Weight X-Gun
Medium Frame
Large Frame
45
45
Spot Weld Guns (Pictures are for Examples Only)
GRS3
46
46
23
Spot Weld Setup
47
GRS3
47
Servo Weld Gun Types
GRS3
48
48
24
Servo Gun Setup Manual
• For servo gun setup information, visit the
Robotic Standards page:
https://supplier.body.gm.com/crw/production/main
/globalStandards/roboticStandards.cfm
• Navigate to User Guides and Manuals then
Global 4 User Guides and Manuals
GRS3
49
49
Pedestal Spot Weld TCP Definition for Fanuc
GRS3
50
50
25
Standard TCP Definitions - Weldgun Application (cont'd)
For rocker-type guns, the origin of the TCP shall be the
point in space where the weld tips meet the metal
– The +X direction shall be out of the throat of the gun in the
plane of the sheet metal
– The +Z direction shall be out of the stationary weld shank and
normal to the plane of the metal that is welded by the gun. The
“movable” tip is generally connected to the cylinder rod and the
“stationary tip” is the other tip
– The +Y direction follows from the right hand rule
51
GRS3
51
Rocker-Type Guns
• Definition of TCP for rocker-type guns: First,
determine where gun tips will meet on metal
• Next draw a line from the pivot point between
the 2 gun arms through the point of contact of
the tips on metal.
GRS3
52
52
26
Rocker-Type Guns (cont'd)
• Draw the +Z vector normal to metal (pointing
away from the stationary tip) and the +X vector
outward from the throat of the gun
• The TCP may be defined in space for guns
where both tips move to meet metal
53
GRS3
53
Stud Welding
• For stud welding, the origin of the TCP shall be 1.5
times the stud length off the stud gun collet with the +Z
direction out of the collet
•
GRS3
The +X and +Y direction shall be square to the stud
gun following the right hand rule, with a minimum of
rotation from the robot default TCP
54
54
27
Stud Welding (cont'd)
Carried Stud TCP Definition for ALL robots
55
GRS3
55
Stud Welding (cont'd)
Pedestal Stud TCP Definition for Fanuc.
Z
GRS3
56
56
28
Sealing Application
• For sealing, the origin of the TCP coordinate system
shall be defined 1/4 inch off the nozzle, with the +Z
direction out of the nozzle
• The +X and +Y direction shall be defined square to the
nozzle parallel to the world coordinate system, if
possible, and follow the right hand rule
57
GRS3
57
Sealing Application (cont'd)
• Carried Sealing TCP Definition for ALL robots
GRS3
58
58
29
Sealing Application (cont'd)
• Pedestal Sealing TCP Definition for Fanuc
– Note that +X points toward the pedestal sealer base
59
GRS3
59
Program Naming Convention
• Common paths that can be called from multiple styles will use the
following naming convention
– S01PICKy
– S01DROPy
– S01PROCy
• y represents the pick/drop location number, or the process number (1-2)
• Style specific paths will use the following naming convention
– SxxPICKy
– SxxDROPy
– SxxPROCy
GRS3
• xx represents the style number that the path is used for (i.e. STYLE02 pick 1 would
be S02PICK1)
• y represents the pick/drop location number, or the process number (1-2)
60
60
30
Recommended Move Speeds
61
GRS3
61
Recommended Move Speeds (Cont’d)
GRS3
62
62
31
Programming Paths
•
•
•
•
•
•
•
•
•
Add path segment numbers and comments as needed
Add comments before MH instructions
Verify weld/joint numbers
Teach home to pounce and pounce to home
Teach pick, drop, and process paths based on the templates
Teach fast fault recovery paths
Teach tool changer paths
Setup style, option bits, and decision codes
Teach repair/service paths (tip dress, purge, etc.)
63
GRS3
63
MOV_POUNCE (Power Train (PT) Only)
•
•
Used to move from pounce to pounce without going home (similar to old
powertrain router)
Uses two arguments – CALL MOV_POUNCE(Arg1, Arg2)
–
–
Arg 1 – What pounce to go to? – uses PR[1] – PR[10] which are also tied to reference positions 1‐10
Arg 2 – Is the robot at a known pounce? – Yes = 1, No = 2
•
•
•
•
1 is used when you should be at a pounce – at the top of a pick or drop – verifies that it is at a valid pounce
2 is used when moving to a pounce – at the end of a pick or drop
Will perform a joint move from current location to the selected pounce position
If the robot cannot go from pounce to pounce then a linking program can be
used that has via points between pounces. This is setup under DATA – F1[TYPE] –
Pounce Data
64
64
32
Multiple Pounce Data (PT Only)
•
•
A program can be assigned with the linking moves between two pounces
It must be enabled for the MOV_POUNCE program to check and run the
program
65
65
Path Recorder (PT Only)
•
•
•
Path recorder is used to record the path
moving to a pick or drop.
It will periodically store the robot joint
positions while the path is running.
This is used as part of recovery to back
the robot out of the path.
–
–
–
–
–
•
Rec Path Start – starts recording
Rec Path Pause – pauses recording
Rec Path Resume – resumes recording
Rec Path End – stops recording
Do Bwd Exit – runs the recorded path backward
If the pick or drop has happened it will
continue forward through the path
66
66
33
Path Recovery (PT Only)
•
•
•
Path recovery is based off the skip
condition of DI[521:diMHRecoveryReq] =
ON
The points going to the pick or the drop
should end with SkipJump, LBL[999] –
When DI[521] turns on from the PLC the
robot will stop the current motion and
jump to label 999 to recover
MOV_RCVY will then set the recovery
path segment (201‐220) and will move
back to pounce
67
67
Review 2-1
• Once the integrator has completed the manufacturer’s
procedure for mastering they shall create a program
called?
MASTERPS
• Why is a tool center point defined for each process and
material handling end-effector?
To facilitate path teaching and recovery
• For a common path give the name for the first pick
position?
68
S01PICK1
68
34
Interference Zones
An interference zone between two robots exists if,
at any time, the path of one robot causes a
potential interference with the path of another
robot. An interference zone shall be used when
any part of the robot (wrist, upper arm, weldgun /
EOAT, motor housing, cables, etc.) could collide
with any part of another robot that crosses its
path
69
GRS3
69
Robot Interference Zones
GRS3
70
70
35
When to Use Interference Zones
• The purpose of an interference zone is to protect the
robot and robot equipment from colliding with another
robot under any possible condition. The integrator shall
properly implement interference zones to avoid
damaging GM’s equipment
• Interference zones are not to be used between material
handling robots when passing parts from one robot to
another via a rest fixture.
– Collisions shall be avoided using PLC control of path
segments.
71
GRS3
71
Setting Up Interference Zones
• Each robot has 12 pre-defined interference zones
available (defined by R1 through R12). If robot R5 has
an interference zone with robot R3, then at the position
before entering that zone, robot R5 must call “Enter
Interference Zone 3” and once robot R5 is clear of the
zone it calls “Exit Interference Zone 3”
• In each station, note which robot has the longest
individual cycle time and set up the interference zones
such that this robot never pauses during normal
operation
GRS3
72
72
36
Interference Zone Rules
1. The home position shall be clear of all potential
interferences
2. Multiple interference zones between two robots shall
be avoided whenever possible
3. Use the interfering robot number as the zone number
whenever possible
4. If a robot interferes with two robots of the same
number, use the next available zone number for the
interference with the robot that is down stream (based
on part flow)
73
GRS3
73
Interference Zone Rules (cont'd)
5. The programmer shall include a comment for each
interference zone in the path program which includes
robot number and zone number.
COMMENT “********************************”
COMMENT “STYLE XX PROCESS 1”
COMMENT “********************************” ;
SET SEGMENT(50) ;
MOVE J P1 100% CONT100 ;
COMMENT “Enter I-Zone with F120-R4 in Z1”
ENTER INTERFERENCE ZONE(4) ;
MOVE L P2 100mm/s CONT100
GRS3
74
74
37
Interference Zone Numbering Example 1
10R2
Flow
Zone 1
5R2
Zone 1
Zone 4
Zone 2
STA. 5
Zone 3
Zone 1
5R1
Zone 1
Zone 2
Zone 3
*The zone between 5R1 and
5R2 is not normally needed.
Requires Vehicle Systems
approval when used.
STA. 10
Zone 2
Zone 2
Zone 1
10R3
Zone 4
10R1
Zone 1
STA. 20
20R2
Zone 3
*The zone between 10R1 and
20R1 is not normally needed.
Requires Vehicle Systems
approval when used.
Zone 3
* Path segment control from the PLC is preferred.
75
GRS3
75
Interference Zone Numbering Example 2
Flow
Zone 1
STA. 5
GRS3
5R1
Zone 2
Zone 1
STA. 10
10R1
STA. 20
Zone 1
20R1
76
76
38
Interference Zone Numbering Example 3
R2
R4
R6
Flow
R1
R3
Interference with Robot #
Use zone number
R1
1
R2
2
R3
3
R4
4
R5
5
R6
6
R5
77
GRS3
77
Procedure for Implementing Interference Zones
The programmer will set the “Enter Interference Zone”
and “Exit Interference Zone” instructions for all robots in
every station
– Program each robot to minimize potential interferences with
other robots
– Run each robot individually, noting areas where interference
zones may be needed
– Determine where each robot enters and leaves the
interference zone and insert the appropriate programming
instructions into the program
GRS3
78
78
39
Teaching Interference Zones
79
GRS3
79
Teaching Interference Zones Entering Zone
To determine the interference zone locations in the path
programs for the drawing above:
1. Move robot R2 to the node immediately before
entering the estimated interference zone
2. Run robot R4 through its entire path if possible. If an
interference still exists, move to a previous node
3. Set the “Enter Interference Zone 4” signal at this
node for robot R2
GRS3
80
80
40
Teaching Interference Zones Exiting Zone
1. Move robot R2 to the node immediately after leaving
the estimated interference zone
2. Run robot R4 through its entire path if possible. If an
interference still exists, move to the next node (or
adjust the position of this node) until robot R4 can run
through its entire path cleanly
3. Set the “Exit Interference Zone 4” signal at this node
for robot R2
81
GRS3
81
Procedure for Testing Interference Zones
• After properly programming the interference zone
instructions, the programmer will verify that PLC logic
for the station has been set up to work with the
interference zones that were used.
• Interference zone interlocks are typically added to the
PLC logic at the request of the robot programmers. This
procedure is required to avoid accidental robot crashes
during integration.
GRS3
82
82
41
Test Robot R2
• Let robot R2 move inside its interference zone with
robot R4 and stop the program.
• Run robot R4. Robot R4 should proceed up to the node
where “Enter Interference Zone 2” is called and then
should stop, waiting for the clear to proceed input from
the PLC.
• Continue robot R2's program. Once R2 executes the
“Exit Interference Zone 4” instruction, robot R4 should
receive the PLC input and be capable of continuing its
program to completion.
83
GRS3
83
Test Robot R4
• Let robot R4 move inside its interference zone with
robot R2 and stop the program.
• Run robot R2. Robot R2 should proceed up to the node
where “Enter Interference Zone 4” is called and then
should stop, waiting for the clear to proceed input from
the PLC.
• Continue robot R4's program. Once R4 executes the
“Exit Interference Zone 2” instruction, robot R2 should
receive the PLC input and be capable of continuing its
program to completion.
GRS3
84
84
42
Test Instructions
The integrator shall be responsible for the following
deliverables at integration:
– Verify that software is properly configured by exercising all
process instructions under normal circumstances
– Verify cycle time for all styles
– Check that the proper diagnostic messages are reported by
inducing faults into the system
85
GRS3
85
Software Housekeeping
•
•
•
•
•
Delete temporary programs
Remove unused macros from the macro table
Remove temporary tools and frames
Remove temporary payload settings
Enable prompts and alerts – Simulated IO, Machine Lock,
Production Speed
• Backup robots (see Module 4)
• Setup Upload, Download & Compare (UD&C)
GRS3
86
86
43
Hardware Housekeeping
• Verify robot is dressed properly – cables do not rub, service loops
on cables, welding equipment isolated from the robot
• Stencil number on robot arm
• Stencil number on controller
• Install dust cover on unused receptacles
GRS3
Note: See next slide for more information
about Dress Pack
87
87
Leoni Dress Pack
GRS3
88
88
44
Electrical and Pneumatic Connections
The integrator shall be responsible for performing the
following electrical and pneumatic deliverables at
integration:
– Connect and verify the electrical and pneumatic connections
per the end-effector wiring diagrams
– Correctly set dip switches on any peripheral equipment
– Correctly set adjustable levels on all equipment
– Mark-up all wiring diagrams during build
– Update all drawings such that the documentation matches the
build
89
GRS3
89
Tagging
The integrator shall be responsible for the following
deliverables at integration:
Tag and label all cords, sensors, grippers and Ethernet/IP nodes
per GCCB-1
GRS3
90
90
45
Robot Limiting Hardware and Software
•
•
•
•
Set soft limits and hard stops
Verify soft limit and hard stop settings
Verify light curtain locations
Validate DCS per GRS3 Appendix A
91
GRS3
91
Collision Detection Setup
• The integrator shall be responsible for implementing
collision detection on all General Motors’ robots that are
equipped with the collision detection software option.
• Collision detection must be on at all times during
program execution. Exceptions to this standard shall
require written approval from the GM Vehicle Systems
Robots Engineer
GRS3
92
92
46
Collision Detection Setup (cont'd)
• Accurately set Load Data, including Payload and
Armload
• Do not utilize any external reporting that the collision
detection software provides
• Optimize global sensitivity. While running continuously
cycling with carried parts, increase the global sensitivity
by increments of 10% until collision detection faults
occur. Then decrease the global sensitivity by 10%
93
GRS3
93
Collision Detection Setup (cont'd)
• Optimize local pickup and dropoff sensitivities (material
handling robots only). The programmer shall include
instructions in the path program to change the collision
detection sensitivity several moves before each pickup
and dropoff location
• Optimize pedestal welding sensitivity to avoid nuisance
faults
GRS3
94
94
47
Integration Documentation
The integrator shall complete the following from
the “GRS Robot Buyoff Checklist”
1a. New Robot Tasks or 1b. Existing Robot Tasks
2. Controller Data
3. DCS Tasks – DCS Validation in Appendix A of GRS3
95
GRS3
95
Prepare for Shipping
• Block and band Robot Arm
• Band Robot Controller
• Mount robot and controller to pallet
– Steel OEM pallets should be used when possible
GRS3
96
96
48
Module 2
Exercise Solutions
97
97
Exercise 2.1: Solution
10R2
Flow
Zone 1
5R2
Zone 2
STA. 5
Zone 4
5R1
Zone 1
Zone
STA. 10
1
Zone 3
Zone 1
The zone between 5R1 and
5R2 is not normally needed.
Requires Vehicle Systems
approval when used.
Zone 2
Zone 3
Zone
1
Zone 2
Zone 2
10R1
a
b
c
d
e
f
g
h
i
j
k
l
1
3
2
1
2
3
4
1
3
2
1
3
Zone 3
Zone 3
10R3
98
98
49
Exercise 2.2: Solution
Carried Spot Weld TCP for all C guns
99
GRS3
99
Exercise 2.2: Solution
Material Handling TCP with pin
GRS3
100
100
50
Module 2: Review
1. What is the purpose of an interference zone?
The purpose of an interference zone is to protect the entire
robot, dress, arm, EOAT, etc., and the robot equipment from
colliding with another robot under any possible condition.
101
GRS3
101
Module 2: Review (cont’d)
2. Define TCP tool data set up.
A tool center point will be defined for each process and
material handling end-effector to facilitate path teaching and
recovery. Each individual process feature of a dual or
multiple function end-effector will have a unique TCP defined.
GRS3
102
102
51
Module 2: Review (cont’d)
3. Define the Collision Detection setup procedure.
GRS3
• Accurately set Load Data, including Payload and Armload.
• Do not utilize any external reporting that the collision detection software
provides; i.e. do not attempt to map any collision detection related outputs
to the PLC that may be supported in the software.
• Optimize global sensitivity. While running continuously cycling with carried
parts, increase the global sensitivity by increments of 10% until collision
detection faults occur. Then decrease the global sensitivity by 10%.
Collision guard sensitivity should be set at the highest possible value
where nuisance trips are not present.
• Optimize local pickup and dropoff sensitivities (material handling robots
only).
• Optimize pedestal-welding sensitivity. As needed, the programmer will
include sensitivity instructions in the path program immediately before and
after pedestal welding in order to avoid any nuisance tripping that occurs
during the welding operation.
103
103
Module 2: Review (cont’d)
4. What is the purpose of mastering a robot?
Mastering defines the location of the robot by synchronizing
the mechanical unit’s position with the robot controller’s
stored positional data so that the robot can be programmed
to accurate positions.
GRS3
104
104
52
GRS
Global Robot Specifications
LMS # 34043
Module 3: Robot Interfaces
Revision 6.2
© 2017 General Motors Company.
All Rights Reserved
1
Objectives
• The student will explain the different robot to PLC interfaces and
the appropriate I/O signals.
• The student will explain the following robot to equipment Interfaces
and define I/O signals:
–
–
–
–
–
–
–
Resistance weld water saver and tip dress interface
Resistance weld controller interface.
Integrated servo gun controller interface.
Dispense tool controller interface.
Stud weld interface.
Flow drill screw and self piercing rivets
Material handling interface.
Note: See slide 4 for more Robot Interface information
2
2
1
Robot Mechanical Unit
3
3
Robot Interface Overview
GRS4
4
4
2
Cell Controller
• The system level signals between the robot and the cell
controller are limited to eight inputs and eight outputs
• The vendor and Vehicle Systems will determine which
eight inputs and outputs are to be used from the
available signals
5
GRS4
5
Robot IO
• For more information about Robot I/O consult the
appropriate document bellow:
Global 2 Robot IO
Global 3 Robot IO
Global 4 Robot IO
6
6
3
Robot Inputs
Initiate Style Program: This signal goes high to indicate to the robot that the
style bits are valid and can be read.
Style Bits (1,2,4,8,16,32,64,128): The style bits form a binary number that
indicates the style of part. The eight signals are combined to indicating up
to 255 styles possible styles.
Option Bits (A, B, C, D, E): The option bits are discrete signals that allow up
to five individual options to be applied to the style selected.
Decision Code Bits (1,2,4,8,16): The decision code bits form a binary
number indicating up to 31 specific operations within the style that are to
be performed.
7
GRS4
7
Robot Inputs
Interference Zone (1,2,3,4,5,6,7,8,9,10,11,12) Clear To Enter: The
interference zone clear to enter are discrete signals that go high to indicate
a specific interference zone is clear to enter.
Path Segment Request Bits (1,2,4,8,16,32, 64,128): The path segment bits
are a binary combination of 8 bits that are used as handshakes with the
portion of the robot path being executed.
Path Segment Request to Continue: The path segment continue signal goes
high to indicate the robot is clear to proceed into the next path segment.
GRS4
8
8
4
Robot Inputs
Tryout Mode Request: The tryout mode signal goes high to indicate the robot
should run in the tryout mode.
Fast Stop Request: Used to pause the robot after an operation has occurred.
Used for applications like flow drills screw and self-piercing rivets
Equipment Remote Reset: A signal indicating a cell level reset is requested
for approved equipment faults such as water saver faults.
9
GRS4
9
Robot Inputs
Process 1/Process 2 On Request: Indicates to the robot that the process
should be performed. When the signal is low, the robot will place the
process equipment in “off” mode.
Process 1/Process 2 Bypass Request: Request that the process be
bypassed. This ignores the process and allows MH to continue.
Shop Specific Bits (128 available): The Shop Specific bits are used
differently depending on what area is chosen (Body Shop, Powertrain,
Stamping, Paint Shop). For example:
Stamping uses bits for stack searching
Powertrain uses bits for interference checking
Paint uses bits for raising the hood and deck lid
GRS4
10
10
5
Robot Outputs
Home 1 – Home 10: Tied to reference positions that turn on a digital output
when the robot is within the specified range of joint values for all joints.
In Cycle: The “In Cycle” signal indicates that the robot is operating and the
style program is being performed. This signal is set as an
acknowledgment that a valid style has been received. This signal will be
set until the style program is complete, aborted or returned from pounce.
Manual Style Request: The “Manual Style Request” signal causes the cell
controller to read the manual style bits, manual option bits and manual
decision codes to determine which style is being requested from the robot.
11
GRS4
11
Robot Outputs (cont’d)
Manual Style Bits (1,2,4,8,16,32,64,128): The ‘Manual Style Bits’ form a
binary number that allows up to 255 styles to be requested in the isolate
mode. In the interlock mode the robot uses these bits to echo the style
selected to the cell controller. The robot is programmed to set the manual
style bits from within execution of the style program.
Manual Option Bits (A, B, C, D, E): The manual option bits are discrete
signals that select a specific option under the selected style in the isolate
mode. In the interlock mode the robot uses these bits to echo the option to
the cell controller.
GRS4
12
12
6
Robot Outputs (cont’d)
Manual Decision Code Bits (1,2,4,8,16): The ‘Manual Decision Code Bits’
form a binary number that selects a specific operation within the style.
Robot In Interlock: The ‘Robot in Interlock’ signal indicates that the robot is
in Interlock mode.
Robot In Isolate: The ‘Robot in Isolate’ signal indicates that the robot is in
Isolate mode.
Tryout Mode: The Tryout Mode’ signal indicates that the robot is in Tryout
(Dry Cycle) mode.
13
GRS4
13
Robot Outputs (cont'd)
Robot Clear Of Interference Zone (1,2,3,4,5,6,7,8,9,10,11,12): These
discrete signals are used individually to indicate the robot is clear of the
interference zone the bit represents.
Path Segment Bits (1,2,4,8,16,32, 64,128): The path segment bits are a
binary combination of 8 bits that indicate which portion of the robot path is
being executed.
Path Segment Request To Continue: This signal is a request to the cell
controller for permission to continue onto the next path segment.
GRS4
14
14
7
Robot Outputs (cont'd)
Manual Intervention: This signal indicates that robot needs attention at the
teach pendant
Fast Fault Recovery Active: This signal indicates that the Fast Fault
Recovery mode is active and that the robot may be moving to a service
location.
Fast Stop Acknowledge: This signal is used in response to a Fast Stop
Request to tell the cell controller that the signal has been received
Simulated I/O: Indicates that at least one input or output has been simulated
on the teach pendant
Tool Changer Safe Switch Missing: Indicates that the tool changer unlatch
safety switch is disconnected
15
GRS4
15
Robot Outputs (cont’d)
Process 1/Process 2 Enabled: Indicates that the robot has placed the
process equipment into the “on” mode.
Process 1/Process 2 Bypassed: Indicates that the process has been
bypassed.
Process 1/Process 2 Fault: Indicates that a major error has occurred within
the process.
Process 1/Process 2 Alert: This signal indicates that a minor error has
occurred within the process.
Process 1/Process 2 Alert 2: This signal indicates that maintenance is
required on the process equipment.
GRS4
16
16
8
Robot Outputs (cont’d)
Process 1/Process 2 Out Of Tolerance: This signal indicates that the
process has detected an out of tolerance condition. This signal is used in
dispense applications to indicate that the process flow measurement is
bypassed.
Process 1/Process 2 Task OK: The “Task OK” signal indicates that the
processing of the part is OK. This signal will be set low upon a style initiate
as an anti tie-down measure. It will be set when the 'continue from pounce'
signal is received. This signal will be set low when the process is disabled
or has encountered a questionable state (e.g. a skipped weld, continue
dry).
17
GRS4
17
Robot Outputs (cont’d)
Process 1/Process 2 One Joint Made: This signal indicates that a
successful joint has been made (spot weld, rivet, or screw)
Process 1/Process 2 Equipment Messages (56 available): Depending on
the chosen process there are 56 bits allocated for messages from the
process equipment. For example, spot welding has messages for tip
change required and tip maintenance(tip dress) required. Dispense has a
message for purge request. A self piercing rivet application has a
message for rivets low. Flow drill screw uses a message for screws low
GRS4
18
18
9
Robot Outputs (cont’d)
Shop Specific Bits (128 available): The Shop Specific bits are used
differently depending on what area is chosen (Body Shop, Powertrain,
Stamping, Paint Shop). For Example:
Stamping uses bits for racking
Powertrain uses bits for interference checking status
Paint uses bits for pressure and temperature output
19
GRS4
19
Cell Controller / Robot Inputs
Robot Input
Signal Name
In01
System Level Signals—Robot Specific*
*IMSTP
In02
System Level Signals—Robot Specific*
*Hold
In03
System Level Signals—Robot Specific*
*SFSPD
In04
System Level Signals—Robot Specific*
Cycle Stop
In05
System Level Signals—Robot Specific*
Fault reset
In06
System Level Signals—Robot Specific*
Start
In07
System Level Signals—Robot Specific*
Home
In09
System Level Signals—Robot Specific*
(Reserved)
Enable
(Reserved)
In10
Tryout Mode Request
TryoutModeReq
In11
(Reserved)
(Reserved)
In08
GRS4
Description
20
20
10
Cell Controller / Robot Inputs (cont’d)
Robot Input
Description
Signal Name
In12
(Reserved)
(Reserved)
In13
(Reserved)
(Reserved)
In14
(Reserved)
(Reserved)
In15
(Reserved)
(Reserved)
In16
(Reserved)
(Reserved)
In17
(Reserved)
(Reserved)
In18
(Reserved)
(Reserved)
In19
(Reserved)
(Reserved)
In20
Option Bit A
OptionBitA
In21
Option Bit B
OptionBitB
In22
Option Bit C
OptionBitC
21
GRS4
21
Cell Controller / Robot Inputs (cont’d)
Robot Input
GRS4
Description
Signal Name
In23
Option Bit D
OptionBitD
In24
Option Bit E
OptionBitE
In25
Style (Bit 1)
StyleBit1
In26
Style (Bit 2)
StyleBit2
In27
Style (Bit 4)
StyleBit4
In28
Style (Bit 8)
StyleBit8
In29
Style (Bit 16)
StyleBit16
In30
Style (Bit 32)
StyleBit32
In31
Style (Bit 64)
StyleBit64
In32
Style (Bit 128)
StyleBit128
In33
Fast Stop Request
FastStopRequest
22
22
11
Cell Controller / Robot Inputs (cont’d)
Robot Input
Description
Signal Name
In34
(Reserved)
(Reserved)
In35
Initiate Style Program (Cycle Start)
InitiateStyle
In36
Equipment Remote Reset
EqptRemoteRes
In37
Interference Zone 1 Clear to Enter
ClearToEntrZone1
In38
Interference Zone 2 Clear to Enter
ClearToEntrZone2
In39
Interference Zone 3 Clear to Enter
ClearToEntrZone3
In40
Interference Zone 4 Clear to Enter
ClearToEntrZone4
In41
Interference Zone 5 Clear to Enter
ClearToEntrZone5
In42
Interference Zone 6 Clear to Enter
ClearToEntrZone6
In43
Interference Zone 7 Clear to Enter
ClearToEntrZone7
In44
Interference Zone 8 Clear to Enter
ClearToEntrZone8
23
GRS4
23
Cell Controller / Robot Inputs (cont’d)
Robot Input
GRS4
Description
Signal Name
In45
Interference Zone 9 Clear to Enter
ClearToEntrZone9
In46
Interference Zone 10 Clear to Enter
ClearToEntrZone10
In47
Interference Zone 11 Clear to Enter
ClearToEntrZone11
In48
Interference Zone 12 Clear to Enter
ClearToEntrZone12
In49
Decision code (Bit 1)
DecisionCodeBit1
In50
Decision code (Bit 2)
DecisionCodeBit2
In51
Decision code (Bit 4)
DecisionCodeBit4
In52
Decision code (Bit 8)
DecisionCodeBit8
In53
In54
Decision code (Bit 16)
(Reserved) Decision code (Bit 32)
DecisionCodeBit16
(Reserved) DecisionCodeBit32
In55
(Reserved) Decision code (Bit 64)
(Reserved) DecisionCodeBit64
24
24
12
Cell Controller / Robot Inputs (cont’d)
Robot Input
Description
Signal Name
In56
Path Segment Continue OK
PathSegContOK
In57
Path Segment (Bit 1)
PathSegmentBit1
In58
Path Segment (Bit 2)
PathSegmentBit2
In59
Path Segment (Bit 4)
PathSegmentBit4
In60
Path Segment (Bit 8)
PathSegmentBit8
In61
Path Segment (Bit 16)
PathSegmentBit16
In62
Path Segment (Bit 32)
PathSegmentBit32
In63
Path Segment (Bit 64)
PathSegmentBit64
In64
Path Segment (Bit 128)
PathSegmentBit128
25
GRS4
25
Cell Controller / Robot Inputs (cont’d)
Robot Input
Signal name
In65
Process 1 On Request
Process1OnReq
In66
Process 1 Bypass Request
Proc1BypassReq
Process 1 (Reserved)
Proc1 (Reserved)
In67 – In128
Robot Input
Description
Signal name
In129
Process 2 On Request
Process2OnReq
In130
Process 2 Bypass Request
Proc2BypassReq
Process 2 (Reserved)
Proc2 (Reserved)
In131 – In192
GRS4
Description
26
26
13
Cell Controller / Robot Inputs (cont’d)
Robot Input
Description
In257 – In416
Shop Specific Inputs
In417 – In432
Robot Option Bits
In433 – In448
Multi Home
In449 – In496
Advanced MH
In498 – In512
In513 – In520
Vision Bits
Tool Number
In521 – In528
Common MH Bits
In529 – In640
Reserved
In641 – In672
User Defined
In673 – In800
Reserved
Signal name
diShopSpec
(Reserved)
(Reserved)
(Reserved)
(Reserved)
27
GRS4
27
Cell Controller / Robot Group Inputs
GRS4
GIN#
Signals
Description
Signal Name
1
In25 to In32
Style
Style
2
In49 to In53
Decision Code
DecisionCode
3
26
In57 to In64
In657 to In672
Path Segment Select
User Defined
PathSegmentSelec
UserDefined
GIN#
8
Signals
In385 to In392
Description
Decision Code 2
Signal Name
DecisionCode2
9
In393 to In400
Decision Code 3
DecisionCode3
28
28
14
Cell Controller / Robot Outputs
Robot output
GRS4
Description
Signal name
Out01
System Level Signals—Robot Specific
Out02
System Level Signals—Robot Specific
Out03
System Level Signals—Robot Specific
Out04
System Level Signals—Robot Specific
Out05
System Level Signals—Robot Specific
Out06
System Level Signals—Robot Specific
Out07
System Level Signals—Robot Specific
Out08
System Level Signals—Robot Specific
Out09
Out10
Out11
(Reserved)
Tryout Mode
In Cycle
Housekeeping
State
-
Cmd enable
-
System ready
-
Prg running
-
Prg paused
-
Motion held
-
Fault
-
BatteryLowAlert
TP enabled
(Reserved)
TryoutMode
InCycle
Low
29
29
Cell Controller / Robot Outputs (cont’d)
Robot output
Out12
Out13
Out14
Out15
Out16
Out17
Out18
Out19
Out20
Out21
Out22
GRS4
Description
Signal name
Robot In Interlock
InInterlock
Robot In Isolate
InIsolate
Manual Style Request
ManualStyleReq
(Reserved)
(Reserved)
(Reserved)
(Reserved)
Manual Intervention
ManInterventReq
Fast Fault Recovery Active
FFRActive
(Reserved)
Manual Option Bit A
Manual Option Bit B
Manual Option Bit C
(Reserved)
ManualOptionBitA
ManualOptionBitB
ManualOptionBitC
Housekeeping State
Low
Low
Low
Low
Low
Low
30
30
15
Cell Controller / Robot Outputs (cont’d)
Robot output
Out23
Out24
Out25
Out26
Out27
Out28
Out29
Out30
Out31
Out32
Out33
Description
Signal name
Manual Option Bit D
Manual Option Bit E
Manual Style (Bit 1)
Manual Style (Bit 2)
Manual Style (Bit 4)
Manual Style (Bit 8)
Manual Style (Bit 16)
Manual Style (Bit 32)
Manual Style (Bit 64)
Manual Style (Bit 128)
Fast Stop Acknowledge
ManualOptionBitD
ManualOptionBitE
ManualStyleBit1
ManualStyleBit2
ManualStyleBit4
ManualStyleBit8
ManualStyleBit16
ManualStyleBit32
ManualStyleBit64
ManualStyleBit128
FastStopAck
Housekeeping State
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
31
GRS4
31
Cell Controller / Robot Outputs (cont’d)
Robot output Description
Out34
Out35
Out36
GRS4
Simulated I/O
(Reserved)
Signal name
SimulatedIO
(Reserved)
Housekeeping State
Low
Tool Changer Safe Switch Missing Alert TCSafeSwMissing
Low
Out37
Robot Clear of Interference Zone 1
ClearOfZone1
High
Out38
Robot Clear of Interference Zone 2
ClearOfZone2
High
Out39
Robot Clear of Interference Zone 3
ClearOfZone3
High
Out40
Robot Clear of Interference Zone 4
ClearOfZone4
High
Out41
Robot Clear of Interference Zone 5
ClearOfZone5
High
Out42
Robot Clear of Interference Zone 6
ClearOfZone6
High
Out43
Robot Clear of Interference Zone 7
ClearOfZone7
High
Out44
Robot Clear of Interference Zone 8
ClearOfZone8
High
32
32
16
Cell Controller / Robot Outputs (cont’d)
Robot output Description
Signal name
Housekeeping State
ClearOfZone9
High
Out45
Robot Clear of Interference Zone 9
Out46
Robot Clear of Interference Zone 10 ClearOfZone10
High
Out47
Robot Clear of Interference Zone 11 ClearOfZone11
High
Out48
Robot Clear of Interference Zone 12 ClearOfZone12
High
Out49
Manual Decision code (Bit 1)
ManDecCodeBit1
Low
Out50
Manual Decision code (Bit 2)
ManDecCodeBit2
Low
Out51
Manual Decision code (Bit 4)
ManDecCodeBit4
Low
Out52
Manual Decision code (Bit 8)
ManDecCodeBit8
Low
Out53
Manual Decision code (Bit 16)
(Reserved)
Manual Decision code (Bit 32)
(Reserved)
Manual Decision code (Bit 64)
ManDecCodeBit16
Low
Out54
Out55
Low
(Reserved)ManDecCodeBit32
Low
(Reserved)ManDecCodeBit64
33
GRS4
33
Cell Controller / Robot Outputs (cont’d)
Robot output
Out56
GRS4
Description
Signal name
Housekeeping State
Path Segment Request to Continue
PathSegReqToCont
Low
Out57
Path Segment (Bit 1)
PathSegmentBit1
Low
Out58
Path Segment (Bit 2)
PathSegmentBit2
Low
Out59
Path Segment (Bit 4)
PathSegmentBit4
Low
Out60
Path Segment (Bit 8)
PathSegmentBit8
-Low
Out61
Path Segment (Bit 16)
PathSegmentBit16
Low
Out62
Path Segment (Bit 32)
PathSegmentBit32
Low
Out63
Path Segment (Bit 64)
PathSegmentBit64
Low
Out64
Path Segment (Bit 128)
PathSegmentBit128
Low
34
34
17
Cell Controller / Robot Outputs (cont’d)
Robot Output
Description
Signal name
Out65
Process 1 Enabled
Process1On
Out66
Process 1 Bypassed
Process1Bypassed
Out67
Process 1 Fault
Process1Fault
Out68
Process 1 Alert
Process1Alert
Out69
Process 1 Alert2
Process1Alert2
Out70
Out71
Process 1 Out of Tolerance
Process 1 Task OK
Process1OutOfTol
Proc1TaskOK
Out72
Process 1 One Joint Made
Proc1OneJntMade
Process1 Equipment Messages
doProc1EqMsg
Out73 – Out128
35
GRS4
35
Cell Controller / Robot Outputs (cont’d)
Robot Output
Signal name
Out129
Process 2 Enabled
Process2On
Out130
Process 2 Bypassed
Process2Bypassed
Out131
Process 2 Fault
Process2Fault
Out132
Process 2 Alert
Process2Alert
Out133
Process 2 Alert2
Process2Alert2
Out134
Out135
Process 2 Out of Tolerance
Process 2 Task OK
Process2OutOfTol
Proc2TaskOK
Out136
Process 2 One Joint Made
Proc2OneJntMade
Process2 Equipment Messages
doProc2EqMsg
Out137 – Out192
GRS4
Description
36
36
18
Cell Controller / Robot Outputs (cont’d)
Robot Output
Description
Signal name
Out257 – Out384
Shop Specific
doShopSpec
Out385 – Out416
(Reserved)
(Reserved)
Out417 – Out432
Robot Option Bits
Out433 – Out448
Home 1 -10
Out449 – Out496
Out497 – Out512
Advanced MH
Vision Bits
Out513 – Out520
Tool Number
Out521 – Out528
Common MH Bits
Out529 – Out640
EOAT Status
Out641 – Out672
User Definable
Out673 - Out800
DCS Safety Signatures
doHome
37
GRS4
37
Cell Controller / Robot Group Outputs
GOUT#
GRS4
Signals
Description
Signal Name
1
Out25 to Out32
Manual Style Select
ManualStyle
2
Out49 to Out53
Manual Decision Code
ManDecCode
3
26
Out57 to Out64
Out657 to Out672
Path Segment
User Defined
PathSegment
UserDefined
GOUT#
8
Signals
Out385 to Out392
Description
Signal Name
Manual Decision Code 2 ManDecCode2
9
Out393 to Out400
Manual Decision Code 3 ManDecCode3
38
38
19
Module 3 Review – Robot Inputs/Outputs
This signal goes high to indicate the robot should run in the tryout
mode?
Tryout Mode Request
This signal is a request to the cell controller for permission to
continue onto the next path segment?
Path Segment Request To Continue
Who determines what system level signals between the robot and the
cell controller are used?
The vendor and Vehicle Systems
39
39
Modes
There are three types of modes the robot can use. They
are :
– Process Enable/Disable
– Tryout
– Interlock/Isolate
GRS4
40
40
20
Process Enabled/Disabled
This mode includes the ‘Process On
Request’ inputs from the cell controller
– In Interlock mode, the robot will use the
status of these signals to place the
process equipment in the appropriate
mode
– In “Interlock” mode with “Process Off”, a
“Major Fault” from the process equipment
will not prevent execution of the robot
style program
41
GRS4
41
Tryout
This mode indicates that no part is to be processed and
that the robot will not check the status of part present
input(s)
– In Interlock mode, the cell controller selects the tryout mode
using the ‘Tryout Mode Request’ bit
GRS4
42
42
21
Interlock/Isolate
Interlock and Isolate are valid modes only when the robot
is in Automatic
– In Interlock mode the robot will respond to initiate signals from
the cell controller.
– In Isolate mode the cell controller will only initiate a robot as a
result of a request from the robot. Process modes for peripheral
equipment may be selected from the teach pendant
43
GRS4
43
Mainline Shell Program
When the robot is at the home position and in automatic it
will perform the following functions:
– Execute the Home Check to verify it is at a home position
– Execute the Housekeeping functions which resets the robot
outputs
– Execute the Special Functions
– Execute the Run Style program that monitors the signals from
the controller
– Return to the top of the list
GRS4
44
44
22
Home Check Program
The home check routine will verify the robot is at a home
position. It will:
1. Compare the current position of the robot with the taught home
positions and calculate the difference in position and orientation.
2. If the difference in position and orientation are within the
definable limits, the robot will set the ‘Home 1-10’ bit to the
controller.
3. If distance or orientation difference is greater than the
definable limits, the robot will prompt the user to jog to the home
position.
45
GRS4
45
Housekeeping
• The robot will set the outputs to the cell controller to the
“Housekeeping State”.
• A separate routine will be provided for any additional
user selected I/O initialization
GRS4
46
46
23
Special Functions
• Special functions allow the user to execute specific
routines or commands from the shell loop.
• It is possible to insert any user-defined routine or
programming instruction into the special functions
portion of the shell loop
47
GRS4
47
Run Style
• In automatic and interlock modes the robot will monitor
the initiate signal from the cell controller.
• If an invalid style is selected by the cell controller the
robot will indicate a fault.
• A fault reset will take the robot back to the Mainline
Shell.
GRS4
48
48
24
Robot Mode
A means will be provided to select between Interlock and
Isolate line modes when the robot is in Automatic.
– Upon transition to Automatic, the robot will default to Interlock
mode.
– Upon transition to T1 or T2, the robot will default to Isolate
mode.
49
GRS4
49
Style Table
The robot will map the cell controller initiated style number
to any valid robot style program
GRS4
50
50
25
Style Program Structure
Program style structure will be implemented in a modular format
A template will be provided containing the standard logic
There will be provisions for a common pounce to be shared between all styles
If a style program is selected in teach mode and the robot is placed back in automatic,
upon completion of the style program, the robot will return to the MAINLINE shell
51
GRS4
51
Repair (Style 31) Sequence
The Repair Sequence routine is executed to move the robot to the repair position
1. Echo Style 31 (move to repair) to the cell controller
2. SetSegment [2]
3. <User to program the path from home to repair here>
4. Wait for continue (cell controller or user input to the robot)
5. SetSegment [3]
6. <User to program the path from repair to home here>
GRS4
52
52
26
Cap Change (Style 27) Sequence
This routine will resets the steppers and water savers
1. Echo Style 27 to cell controller
2. Set Segment [6]
3. Check for water saver tripped or bypassed. If neither is detected, generate a fault and prompt the user for acknowledgement prior to continuing.
4. <Automatically reset steppers>
5. <Automatically reset water savers>
6. <Automatically request tip dress style from cell controller if “tip dress on cap change” has been configured and use “New Cap TD Schedule”>
7. <Automatically reset cap change request bits>
8. <Automatically initiate tip wear measurement for servo guns>
For more Cap Changer Information see the next slide.
53
GRS4
53
Cap Changers
Pneumatic Cap Changer
GRS4
Servo Cap Changer
54
54
27
Pedestal Cap Change at the End of a Path Segment
The robot will respond to a cap change command at any
time the robot is waiting for a “Path Segment Continue”
Decision code 14 has been allocated for this purpose. This
routine resets steppers and resets water savers.
If the “Tipdress on Cap Change” signal is set it also sets the
request for tipdress for all spot welding equipment
55
GRS4
55
Pedestal Cap Change at the End of a Path
Segment (cont’d)
1. <save current path segment>
2. Set Segment [6]
3. Check for water saver tripped or bypassed. If neither is detected, generate a fault
and prompt the user for acknowledgement prior to continuing.
4. <Automatically reset steppers>
5. <Automatically reset water savers>
6. <Automatically request tip dress style from cell controller if “tip dress on cap change”
has been configured and use “New Cap TD Schedule”>
7. <Automatically reset the cap change request bits>
8. <Automatically initiate tip wear measurement for the servo guns>
9. SetSegment [saved segment]
10. RequestContinue
GRS4
56
56
28
Purge Sequence
• Style 29 is used for Dispense Process 1 purge
sequence
• Style 30 is used for Dispense Process 2 purge
sequence
1. Set Segment [4(Process 1) or 5 (Process 2)]
2. <user to program a path from home to purge position here>
3. Purge
4. <user to program a path from purge position to home here>
GRS4
57
57
Tip Cleaning Sequence Style 29, Process 1
This routine is programmed by the user to implement the tip dressing
routine for the spot welding robots
1. Set Segment 4
2. StartTDMotor
3. <User to program path from home to tip dress position here or advance dump for
pedestal(s)>
4. TipDress [gun#X]
5. <User to program path from tip dress to home here or retract dump for pedestal(s)>
6. StopTDMotor
7. <Automatically initiate tip wear measurement for servo guns>
GRS4
58
58
29
Tip Cleaning Sequence Style 30, Process 2
This routine is programmed by the user to implement the tip dressing
routine for the spot welding robots
1. Set Segment 5
2. StartTDMotor
3. <User to program path from home to tip dress position here or advance dump for
pedestal(s)>
4. TipDress [gun#X]
5. <User to program path from tip dress to home here or retract dump for pedestal(s)>
6. StopTDMotor
7. <Automatically initiate tip wear measurement for servo guns>
GRS4
59
59
Enter Interference Zone
This is the request to enter the interference zone and the
cell controller signal clear to enter the interference zone
1. Reset ClearOfZone#
2. Post the message “Waiting for Interference Zone <Zone #> Clear to Enter”
on the teach pendant
3. Wait for Zone#Clear to be set by the cell controller
4. Post the message “Robot in Interference Zone <Zone #>” on the teach
pendant
GRS4
60
60
30
Exit Interference Zone
This is the request to exit the interference zone and zone
clear signal to be sent by the controller
1. Set ClearOfZone#
2. Post the message ”Robot Clear of Interference Zone <Zone #>” on the
teach pendant.
GRS4
61
61
Set Path Segment
A means will be provided to guarantee this instruction is
executed within a programmable distance of the
proceeding programmed position regardless of
programmed termination type
1. Set PathSeg equal to Segment #
2. Reset PathSegReqToCont
3. Post the message: ”Entering Path Segment <Segment #>” on the teach
pendant
GRS4
62
62
31
Request Continue
• A means will be provided to execute this instruction
within a programmable time of reaching the proceeding
programmed position such that path program
hesitation can be eliminated
• If the Continue OK indication is not received, path
motion will stop at the programmed position regardless
of the programmed termination type
GRS4
63
63
Request Continue (cont’d)
1. Reset the PathSegReqToCont
2. Wait for the PathSegContOK to be reset
3. Set PathSegReqToCont
4. Post the message ”Waiting for Continue” on the teach pendant
5. Wait for the PathSegContOK to be set by the cell controller
6. Capture the Decision Code and echo to cell controller using the ManDecisionCode
7. Post the message “Decision Code <DecisionCode> Received” on the teach pendant
8. If the Decision Code is 14 (cap change) then execute the pedestal cap change and return to the top of the program.
9. If the Decision Code is 15, (return home from pounce) and the robot is in path segment 1, return home.
10. If the Decision Code not valid stop and display fault message.
GRS4
64
64
32
Early Request to Continue
•
•
The REQ_ERLY program allows the
robot to request to continue earlier
in the path without having to wait
for the Path Segment Continue OK
In the program R[159] is used as a
flag to indicate that the request
was made
65
GRS4
65
Early Request to Continue (cont’d)
•
•
GRS4
In the REQ_CONT program the
robot will skip the request portion
of the code if R[159]=1
This can help save cycle time by
starting the handshake and check
earlier
66
66
33
Fault and Alert Handling
Upon the detection of a major fault (either by the process
equipment or by the robot application package), the robot
will:
1. Set the ‘Process # Fault’ signal to the PLC
2. When in ‘Interlock’ mode with ‘Process On Request’ input from the cell
interface on, halt robot motion and process
3. Display and indicate the major fault(s) and recovery options on the teach
pendant
4. Log the faults
GRS4
67
67
Fault and Alert Handling (cont’d)
• Faults and alerts will be handled on a first-come first-served basis.
• A fault will occur when the expected handshaking between the
robot controller and peripheral equipment is disrupted.
• For material handling faults, the user will be presented with the
option of disabling the checking of the input signal that caused the
fault for a maximum of 20 job cycles.
GRS4
68
68
34
Fault and Alert Handling (cont’d)
• Remote recovery will be available for process faults or when
waiting for the correct state of a proximity sensor / cylindicator
input (such as part present, clamp or gun retract).
–
The remote recovery option will retry the action or retest the fault condition
upon receiving a robot system input from the cell controller.
– Remote recovery will not be available for some functions, which could result in
equipment damage, such as stud weld faults or water saver faults. These
cases are explicitly stated in the process sections of GRS-4.
GRS4
69
69
Fast Fault Recovery
An FFR option will be presented for process faults that occur during style
execution. When the FFR option is selected the robot will move through the
programmed path in no-process mode to a user defined position.
Once the fault has been corrected the robot will re-run the taught path and
complete the process. During the FFR, the robot will set the ‘FFRActive’
output on the cell interface.
GRS4
70
70
35
Fast Fault Recovery
No-Process Modes
Application
FFR Application Mode
Comments
Spot Welding
No-stroke & No-Weld
Activate Retract normally,
as per program instructions
Dispensing
Dry
Stud Welding
No-stroke & No-Weld
Arc Welding
No-weld & No-weave
GRS4
71
71
Recovery Sequence
It will be possible for the user to implement FFR for an entire process or for
individual segments of a process path
FFR will be supported for either dual carried or dual pedestal processes
independently
For a combination of material handling with a carried process, FFR will be
supported whether material handling occurs before or after the process
GRS4
72
72
36
FFR Structure Program - Single Carried Weld
GO[1:Manual Style]=8 ;
ECHO OPTION ;
CALL STPR_CHK ;
CALL SPOUNCE ;
MAINT_PROG[1]=MOV_REPR;
CALL S08PROC1 ;
RUN CAPWEAR ;
MOVE TO HOME ;
WAIT(F1:CapWearComp);
GRS4
73
73
FFR Structure Program Material Handler with Pedestal Weld Process
GO[1:Manual Style]=8 ;
ECHO OPTION ;
!FFR HANDLER ;
IF DO[43:FFRActive]=ON, JMP LBL[R[160]] ;
CALL STPR_CHK ;
CALL SPOUNCE ;
CALL S06PICK1 ;
LBL[10:PROCESS 1] ;
R[160:FFR Process LBL]=10 ;
MAINT_PROG[1]=S06_FFR1;
CALL TDDMPCHK(1) ;
CALL S08PROC1 ;
GRS4
CALL TD_PD_CK ;
IF DO[43:FFRActive]=ON, JMP LBL[99] ;
REQUEST CONTINUE ;
CALL S06DROP1 ;
MOVE TO HOME ;
WAIT(F1:CapWearComp);
LBL[99:PROG END] ;
74
74
37
FFR Structure Program –
Multi-Part Carried Weld Gun
GO[1:Manual Style]=8 ;
ECHO OPTION ;
!FFR HANDLER ;
IF DO[43:FFRActive]=ON, JMP LBL[R[160]] ;
CALL SPOUNCE ;
CALL STPR_CHK ;
LBL[10:PART 1] ;
R[160:FFR Process LBL]=10 ;
MAINT_PROG[1]=MOV_REPR ;
CALL S08PART1 ;
IF DO[43:FFRActive]=ON, CALL
S08PRT1TOHOM ;
IF DO[43:FFRActive]=ON, JMP LBL[99] ;
REQUEST CONTINUE ;
LBL[20:PART 2] ;
IF (!DO[43:FFRActive]),DO[41:TaskOK]=ON ;
R[160:FFR Process LBL]=20 ;
MAINT_PROG[1]=MOV_REPR ;
IF DO[43:FFRActive]=ON,CALL
S08HOMTOPRT2 ;
CALL S08PART2 ;
IF DO[43:FFRActive]=ON, CALL
S08PRT2TOHOM ;
IF DO[43:FFRActive]=ON, JMP LBL[99] ;
REQUEST CONTINUE ;
GRS4
75
75
FFR Structure Program –
Multi-Part Carried Weld Gun
LBL[30:PART 3] ;
IF (!DO[43:FFRActive]),DO[41:TaskOK]=ON ;
R[160:FFR Process LBL]=30 ;
MAINT_PROG[1]=MOV_REPR ;
IF DO[43:FFRActive]=ON,CALL
S08HOMTOPRT3 ;
CALL S08PART3 ;
RUN CAPWEAR ;
MOVE TO HOME ;
WAIT(F1:CapWearComp);
LBL[99:PROG END] ;
GRS4
76
76
38
Student Exercise 3.1
Robot Cell Interface
Complete the exercise in your book.
77
77
Exercise 3.1
Exercise Solutions
78
78
39
Exercise 3.1: Robot Cell Interface: Solutions
1. Complete
the table.
Description
Signal Name
Robot Input
Style (bit 1)
StyleBit1
In25
Style (bit 2)
StyleBit2
In26
Style (bit 8)
StyleBit8
In28
Tryout Mode Request
TryoutModeReq
In10
Initiate Style Program
InitiateStyle
In35
Path Segment Continue OK
PathSegContOk
In56
Interference Zone 1 Clear to
Enter
ClearToEntrZone1
In37
Decision Code (Bit 1)
DecisionCodeBit1
In49
Process 1 On Request
Process1OnReq
In65
79
79
Exercise 3.1: Robot Cell Interface: Solutions
(cont’d)
2. Complete
the table.
Description
Signal Name
Robot Output
Manual Style (Bit 1)
ManualStyleBit1
Out25
Simulated I/O
SimulatedIO
Out34
Tryout Mode
TryoutMode
Out10
In Cycle
InCycle
Out11
Path Segment (Bit1)
PathSementBit1
Out57
Robot Clear of Interference
Zone 1
ClearOfZone1
Out37
Robot in Isolate
InIsolate
Out13
80
80
40
Exercise 3.1: Robot Cell Interface: Solutions
(cont’d)
2. (Continued)
Description
Signal Name
Robot Output
Process 1 One Joint Made
Proc1OneJntMade
Out72
Fast Fault Recovery Active
FFRActive
Out18
Process 1 Fault
Process1Fault
Out67
81
81
Exercise 3.1: Robot Cell Interface: Solutions
(cont’d)
3. Write the steps used to request to enter interference
zone 1.
1. Reset ClearOfZone1
2. Post the message “Waiting for Interference Zone 1 Clear to
Enter” on the teach pendant
3. Wait for ClearToEntrZone1 to be set by the cell controller
4. Post the message “Robot in Interference Zone 1” on the
teach pendant
82
82
41
Exercise 3.1: Robot Cell Interface: Solutions
(cont’d)
4. Write the steps used to exit interference zone 1.
1. Set ClearOfZone1
2. Post the message ”Robot Clear of Interference Zone 1” on
the teach pendant.
83
83
Exercise 3.1: Robot Cell Interface: Solutions
(cont’d)
5. What signal is required at the robot to leave the
pounce position?
The controller sends the “Decision Code Bits” (if required) and
sets the “Path Segment Continue OK” bit.
84
84
42
Exercise 3.1: Robot Cell Interface: Solutions
(cont’d)
6. What signal indicates to the robot that the style select
and option bits are valid?
Initiate Style
85
85
Exercise 3.1: Robot Cell Interface: Solutions
(cont’d)
7. When the robot returns home position what should
the clear of interference zone bits be set to?
On
86
86
43
Exercise 3.1: Robot Cell Interface: Solutions
(cont’d)
8. What are the steps the robot should complete upon
returning to the home position?
–
–
–
–
–
Execute the Home Check to verify it is at the home position
Execute the Housekeeping functions which resets the robot
outputs
Execute the Special Functions
Execute the Run Style program that monitors the signals
from the controller
Return to the top of the list
87
87
Exercise 3.1: Robot Cell Interface: Solutions
(cont’d)
9. When the robot is switched to Automatic, what mode
should it default to?
Interlock Mode
88
88
44
Exercise 3.1: Robot Cell Interface: Solutions
(cont’d)
10. What style is used for:
Repair –
Style 31
Cap Change –
Style 27
Purge Dispense 1 –
Style 29
Purge Dispense 2 –
Style 30
Tip Maintenance –
Style 29 Proc.1, Style 30 Proc. 2
89
89
Module 3: Review - Robot cell Interface
Identify 5 of the robot to PLC interface signals.
1.
2.
3.
4.
5.
GRS4
Tryout Mode
Interlock/Isolate
Process Enable/Disable
System Level Signals, is limited to 8in/8out
Interference Zones
90
90
45
Robot Software Requirements
Resistance Weld Controllers
91
91
Overall Mapping Assignment
Slot #
Address: 120.xxx.yyy.zzz
Type
1
ADP
PLC
2
3
SCN
SCN
Weld Controller 1
Weld Controller 2
4
SCN
Dispense Controller
5
SCN
Dispense Controller
6
SCN
Stud Welder
DESCRIPTION
7
8
9
SCN
Self Piercing Rivet 1
10
SCN
Self Piercing Rivet 2
11
SCN
FDS Weber 1
12
13
14
15
16
17
GRS4-B1
18
19
92
92
46
Overall Mapping Assignment
Address 192.168.1.(Slot #)
Type
45
SCN
Spot Weld Carried Integrated Gun 1/ PW Gun1
20
SCN
Tip Dresser Gun 1/Servo Dresser
46
SCN
Spot Weld Carried/Pedestal Integrated Gun 1
21
SCN
Spot Weld Pedestal Gun 1
DESCRIPTION
47
SCN
Spot Weld Carried Gun 1
22
SCN
Spot Weld Pedestal Gun 2
48
SCN
Watersaver1
23
SCN
Spot Weld Pedestal Gun 3
49
SCN
24
SCN
Spot Weld Pedestal Gun 4
50
SCN
Watersaver2
51
SCN
Spot Weld Carried Integrated Gun 2/ PW Gun2
52
25
26
Spot Weld Carried Gun 2
SCN
Spot Weld Pedestal Integrated Gun 2
53
SCN
Vision
28
SCN
Carried Cap Changer
54
SCN
Tool Changer End Of Arm (Robot End)
29
SCN
Material Handling Vacuum Pump 1
55
30
SCN
Material Handling Vacuum Pump 2
56
SCN
Tool Changer Nest 1
31
SCN
Material Handling Valve Manifold 1
57
SCN
Tool Changer Nest 2
32
SCN
Material Handling Valve Manifold 2
58
SCN
Tool Changer Nest 3
33
SCN
Material Handling Valve Manifold 3 (new for G4)
59
SCN
Tool Changer Nest 4
34
SCN
Material Handling Input Block 1
60
SCN
Analog Input Block
35
SCN
Material Handling Input Block 2
61
SCN
Balluff Analog Input Block
36
SCN
Material Handling Input Block 3
37
SCN
Material Handling Input Block 4 (new for G4)
62
63
38
SCN
Tip Dresser Gun 2
39
SCN
Tip Dresser Gun 3
40
SCN
Tip Dresser Gun 4
41
SCN
Integrated vision I/O Block 1
42
SCN
Integrated vision I/O Block 2
43
SCN
44
SCN
27
GRS4-B1
93
93
Resistance Weld Controller Interface
• These signals are the communication between the
robot/ PLC and the resistance weld controller
• The vendor and the GM Vehicle Systems Engineers
will determine which inputs and outputs are to be used
from the available signals
GRS4-B1
94
94
47
Robot / PLC Inputs (Weld Controller Outputs)
The following signals are outputs from the weld controller to the robot or PLC
1. No Alert: The “No Alert” signal is set to indicate that there are no alerts present. If an
alert occurs the welder control will continue to operate.
The No Alert is reset by the ‘Fault Reset’ signal or when the condition that
prompted the alert clears.
2. No Fault: The “No Fault” signal is set to indicate that there are no faults present.
If the cause of the fault has not been removed after the ‘Fault Reset’ input has been
received, the weld controller will reset the fault after the release of the ‘Fault Reset’
signal.
If a fault(s) is present, the welder control will not cycle until all fault(s) are cleared.
GRS4-B1
95
95
Robot / PLC Inputs (Weld Controller Outputs)
(cont’d)
3. Weld Mode On: The “Weld Mode On’
signal is set to indicate the weld controller
is in the weld mode and it will pass
current. The robot will check this signal
prior to an initiate weld and will not review
the signal during that weld.
• The robot will compare the ‘Weld Mode On’
signal to its output (weld mode) to confirm that
the weld controller is in the correct mode.
4. Process Complete: The “Process
Complete” signal is set to indicate the
requested schedule was completed and
no faults were generated. This signal also
• This signal remains high until the ‘Initiate
Weld‘ signal goes low.
needs to functions in the ‘no weld’ mode.
GRS4-B1
96
96
48
Robot / PLC Inputs (Weld Controller Outputs)
(cont’d)
5. Schedule In Progress: This signal is set to indicate a weld schedule is being executed. The signal drops
low after a ‘Process Complete’ signal or a fault is detected.
• This signal is a response to an initiate signal. While ‘Schedule In Progress’ is high and a schedule is being executed the weld mode
from the robot will be ignored by the weld controller.
6. All Steppers Reset: This signal indicates that the steppers have been reset. The robot will echo the reset
signal for Stepper Weld Controller to the cell controller using the ‘Process X Alert 2’ output.
7. Approaching Cap Change: This signal is an alert from the weld controller indicating that one or more of
the steppers are approaching a cap change or that the maximum number of tip dresses has been
achieved.
GRS4-B1
97
97
Robot / PLC Inputs (Weld Controller Outputs)
(cont’d)
8. Tip Dress Request: This signal is set to indicate the weld controller is requesting a tip dress.
The weld controller sets this signal after a successful weld, in conjunction with ‘Process Complete’
signal. It is set when the stepper has entered the preset step number defined for requesting a tip
dress. This request will not inhibit further welding cycles. This signal is reset upon the next initiate.
9. Cap Change Request: This signal indicates a request from the weld controller to perform a cap
change on all guns. The weld controller will set a ‘Cap Change Request’ after a successful weld.
This request will not inhibit further welding cycles (within a preset limit) or indicate a fault to the
robot controller.
GRS4-B1
98
98
49
Robot / PLC Inputs (Weld Controller Outputs)
(cont’d)
10. Contactor Open: The “Contactor Open” signal indicates that the isolation contactor in
the weld controller is in the open state. It is not necessary to monitor the ‘contactor open’
signal at the robot. In the weld controller this signal is a pass-through from the isolation
contactor - auxiliary contact block.
11. Not Control Stopped: This signal indicates the weld controller is not in a control-stopped
state. The ‘Not Control Stopped’ signal is determined by the status of the hardware affected
by the 24V Control Stop input to the weld controller.
• The robot will communicate this signal for SWC 1 and SWC 2 to the cell controller using a
Process Equipment Message (for Process 1 – DO[105:doP1EqNotCtrlStopped]).
GRS4-B1
99
99
Robot / PLC Outputs (Weld Controller Inputs)
1. Binary Select Bits (1,2,4,8,16,32,64,128, 256, 512, 1024, 2048, 4096, 8192, 16384, 32768, 65536, 131072,
262144, 524288): The “Binary Select Bits” form a binary number between 1 and 1,048,575 used to select the weld
schedule. These bits will be set before or at the same time the “initiate weld” or “request pressure” input is received.
2. Initiate Weld: This signal is used to initiate the weld schedule after the binary bits have been set.
3. Weld Mode: This signal indicates the weld controller is requesting weld mode. The weld mode sent from the robot
will be read by the weld controller upon an initiate (and not reviewed until ‘Process Complete’).
•If ‘Weld Mode’ is low and a weld is initiated, the weld controller will execute a normal weld sequence (with the exception of
passing current) and with the isolation contactor open. If the robot detects a mismatch between this signal and the ‘Weld Mode’
input, a process fault will be set.
GRS4-B1
100
100
50
Robot / PLC Outputs (Weld Controller Inputs)
(cont’d)
4. Fault Reset: This signal resets the weld controller faults. If the cause of the fault has not been
removed, then the weld controller will reassert the fault after the release of the ‘fault reset’ signal.
5. Enable Contactor Saver: The “Enable Contactor Saver” signal is set to indicate to the weld
controller to hold the contactor closed for the time configured in the weld controller.
•This signal does not have to be set to initiate a weld. If ‘Enable Contactor Saver’ is low at the end of a schedule, the
contactor is opened.
•The weld control will not have any faults or alerts associated with this item. If this signal goes low after a successful weld
but prior to the isolation contactor saver timer timing out, the weld controller will open the contactor immediately.
GRS4-B1
101
101
Robot / PLC Outputs (Weld Controller Inputs)
(cont’d)
6. Caps Changed: This signal to the weld controller indicates that
all the steppers should be reset. The output remains on until the ‘All
Steppers Reset’ signal is received from the weld controller.
• Note: The tips dressed indication will be made through the use of schedules to the
weld controller. Schedules 61 and 62 are used for signaling that the respective tip
has been dressed. Use schedule 61 for gun 1 and schedule 62 for gun 2.
GRS4-B1
102
102
51
Hardwire Outputs
(Weld Controller Inputs)
1. Control Stop: When the “Control Stop” signal is set the welder control is allowed to operate.
When it resets the control will immediately stop all welds and open the isolation contactor. When a
control stop is received, the welder control will perform a safe and orderly shutdown, stopping all
welding current within one line cycle.
2. Transformer Overtemp: This signal is set to indicate that the transformer is operating within its
temperature range. When it is reset it will prevent the initiation of the weld schedules and
annunciate a fault. If it turns off during a weld schedule, the weld schedule will be completed and
then the fault will be set, prohibiting further welding.
• Note: this input is typically wired to the weld controller only in the case of manual welding.
GRS4-B1
103
103
Robot Inputs: SW 1
EIP Scanner ‐ Slot 2
Description
DI[#]
Signal Name
EIP Scanner ‐ Slot 2
Description
DI[#]
Signal Name
1025
1026
1027
1028
1029
1030
1031
1032
SW1 No Alert
SW1 No Fault
SW1 Weld Mode On
SW1 Process Complete
SW1 Schedule In Progress
(Reserved)
SW1 Contactor Open
SW1 No Control Stop
diSW1NoAlert
diSW1NoFault
diSW1WeldModeOn
diSW1ProcCmplt
diSW1InProgrss
(Reserved)
diSW1ContctrOpn
diSW1NoCtrlStop
1042
1043
1044
1045
1046
1047
1048
1049
SW1 Stepper Is Reset For GUN4
(Reserved)
(Reserved)
SW1 Tip Dress Request Gun 1
SW1 Tip Dress Request Gun 2
SW1 Tip Dress Request Gun 3
SW1 Tip Dress Request Gun 4
(Reserved)
diSW1StepResetG4
(Reserved)
(Reserved)
diSW1TDRequestG1
diSW1TDRequestG2
diSW1TDRequestG3
diSW1TDRequestG4
(Reserved)
1033
1034
1035
1036
SW1 Approaching Cap Change Gun 1
SW1 Approaching Cap Change Gun 2
SW1 Approaching Cap Change Gun 3
SW1 Approaching Cap Change Gun 4
diSW1ApprCpChgG1
diSW1ApprCpChgG2
diSW1ApprCpChgG3
diSW1ApprCpChgG4
1050
1051
1052
1053
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
1037
1038
1039
1040
(Reserved)
(Reserved)
SW1 Stepper Is Reset For GUN1
SW1 Stepper Is Reset For GUN2
(Reserved)
(Reserved)
diSW1StepResetG1
diSW1StepResetG2
1054
1055
1056
1057
(Reserved)
(Reserved)
(Reserved)
SW1 Cap Change Request for Gun1
(Reserved)
(Reserved)
(Reserved)
diSW1CChngeReqG1
1041 SW1 Stepper Is Reset For GUN3
diSW1StepResetG3
1058 SW1 Cap Change Request for Gun2
diSW1CChngeReqG2
GRS4-B1
104
104
52
Robot Inputs: SW 1 (cont’d)
EIP Scanner ‐ Slot 2
Description
DI[#]
Signal Name
EIP Scanner ‐ Slot 2
Description
DI[#]
Signal Name
1059
1060
1061
1062
1063
1064
1065
1066
SW1 Cap Change Request for Gun3
SW1 Cap Change Request for Gun4
(Reserved)
(Reserved)
SW1 Pressure Bit 1
SW1 Pressure Bit 2
SW1 Pressure Bit 4
SW1 Pressure Bit 8
diSW1CChngeReqG3
diSW1CChngeReqG4
(Reserved)
(Reserved)
diSW1Pressure1
diSW1Pressure2
diSW1Pressure4
diSW1Pressure8
1076 SW1 End of Part Reply
1077 SW1 Adaptive Capable
diSW1EndPrtReply
diSW1AdaptiveCap
1078 (Reserved)
1079 (Reserved)
(Reserved)
(Reserved)
1080 (Reserved)
1081 (Reserved)
1082 (Reserved)
(Reserved)
(Reserved)
(Reserved)
1083 (Reserved)
(Reserved)
1067
1068
1069
1070
SW1 Read Pressure
(Reserved)
(Reserved)
(Reserved)
diSW1ReadPrssre
(Reserved)
(Reserved)
(Reserved)
1084 (Reserved)
(Reserved)
1085 (Reserved)
1086 (Reserved)
1087 (Reserved)
(Reserved)
(Reserved)
(Reserved)
1071
1072
1073
1074
(Reserved)
(Reserved)
SW1 Weld Process Stop
SW1 Adaptive Reguation Off
(Reserved)
(Reserved)
diSW1ProcessStop
diSW1AdaptRegOff
1088 (Reserved)
(Reserved)
1075 SW1 Adaptive Monitoring Off
diSW1AdaptMtrOff
105
GRS4-B1
105
Robot Inputs: SW 2
EIP Scanner ‐ Slot 3
Description
DI[#]
Signal Name
DI[#]
EIP Scanner ‐ Slot 3
Description
Signal Name
1153
1154
1155
1156
1157
1158
1159
1160
SW2 No Alert
SW2 No Fault
SW2 Weld Mode On
SW2 Process Complete
SW2 Schedule In Progress
(Reserved)
SW2 Contactor Open
SW2 No Control Stop
diSW2NoAlert
diSW2NoFault
diSW2WeldModeOn
diSW2ProcCmplt
diSW2InProgrss
(Reserved)
diSW2ContctrOpn
diSW2NoCtrlStop
1170
1171
1172
1173
1174
1175
1176
1177
SW2 Stepper Is Reset For GUN4
(Reserved)
(Reserved)
SW2 Tip Dress Request Gun 1
SW2 Tip Dress Request Gun 2
SW2 Tip Dress Request Gun 3
SW2 Tip Dress Request Gun 4
(Reserved)
diSW2StepResetG4
(Reserved)
(Reserved)
diSW2TDRequestG1
diSW2TDRequestG2
diSW2TDRequestG3
diSW2TDRequestG4
(Reserved)
1161
1162
1163
1164
SW2 Approaching Cap Change Gun 1
SW2 Approaching Cap Change Gun 2
SW2 Approaching Cap Change Gun 3
SW2 Approaching Cap Change Gun 4
diSW2ApprCpChgG1
diSW2ApprCpChgG2
diSW2ApprCpChgG3
diSW2ApprCpChgG4
1178
1179
1180
1181
(Reserved)
SW2 Gun1 Is Tip Dress Reset
SW2 Gun2 Is Tip Dress Reset
SW2 Gun3 Is Tip Dress Reset
(Reserved)
diSW2G1TDReset
diSW2G2TDReset
diSW2G3TDReset
1165
1166
1167
1168
(Reserved)
(Reserved)
SW2 Stepper Is Reset For GUN1
SW2 Stepper Is Reset For GUN2
(Reserved)
(Reserved)
diSW2StepResetG1
diSW2StepResetG2
1182
1183
1184
1185
SW2 Gun4 Is Tip Dress Reset
(Reserved)
(Reserved)
SW2 Cap Change Request for Gun1
diSW2G4TDReset
(Reserved)
(Reserved)
diSW2CChngeReqG1
1169 SW2 Stepper Is Reset For GUN3
diSW2StepResetG3
1186 SW2 Cap Change Request for Gun2
diSW2CChngeReqG2
GRS4-B1
106
106
53
Robot Inputs: SW 2 (cont’d)
EIP Scanner ‐ Slot 3
Description
DI[#]
Signal Name
EIP Scanner ‐ Slot 3
Description
DI[#]
Signal Name
1187
1188
1189
1190
1191
1192
1193
1194
SW2 Cap Change Request for Gun3
SW2 Cap Change Request for Gun4
(Reserved)
(Reserved)
SW2 Pressure Bit 1
SW2 Pressure Bit 2
SW2 Pressure Bit 4
SW2 Pressure Bit 8
diSW2CChngeReqG3
diSW2CChngeReqG4
(Reserved)
(Reserved)
diSW2Pressure1
diSW2Pressure2
diSW2Pressure4
diSW2Pressure8
1204 SW2 End of Part Reply
1205 SW2 Adaptive Capable
1206 (Reserved)
diSW2EndPrtReply
diSW2AdptCapable
(Reserved)
1207 (Reserved)
1208 (Reserved)
(Reserved)
(Reserved)
1209 (Reserved)
1210 (Reserved)
1211 (Reserved)
(Reserved)
(Reserved)
(Reserved)
1195
1196
1197
1198
SW2 Read Pressure
(Reserved)
(Reserved)
(Reserved)
diSW2ReadPrssre
(Reserved)
(Reserved)
(Reserved)
1212 (Reserved)
1213 (Reserved)
(Reserved)
(Reserved)
1214 (Reserved)
1215 (Reserved)
(Reserved)
(Reserved)
1199
1200
1201
1202
(Reserved)
(Reserved)
SW2WeldProcessStop
SW2 Adaptive Reguation Off
(Reserved)
(Reserved)
diSW2ProcessStop
diSW2AdaptRegOff
1216 (Reserved)
(Reserved)
1203 SW2 Adaptive Monitoring Off
diSW2AdaptMtrOff
107
GRS4-B1
107
Robot Outputs: SW 1
EIP Scanner ‐ Slot 2
Description
DO[#]
Signal Name
DO[#]
EIP Scanner ‐ Slot 2
Description
Signal Name
1025
1026
1027
1028
1029
1030
1031
1032
SW1 Weld Mode
SW1 Fault Reset
SW1 Enable Contactor Saver
(Reserved)
(Reserved)
SW1 Request Pressure
SW1 Initiate Weld
(Reserved)
doSW1WeldMode
doSW1FaultReset
doSW1EnContact
(Reserved)
(Reserved)
doSW1ReqPrssre
doSW1InitWeld
(Reserved)
1042
1043
1044
1045
1046
1047
1048
1049
SW1 Binary Select 512
SW1 Binary Select 1028
SW1 Binary Select 2048
SW1 Binary Select 4096
SW1 Binary Select 8192
SW1 Binary Select 16384
SW1 Binary Select 32768
SW1 Binary Select 65536
goSW1BinS512
goSW1BinS1024
goSW1BinS2048
goSW1BinS4096
goSW1BinS8192
goSW1BinS16384
goSW1BinS32768
goSW1BinS65536
1033
1034
1035
1036
SW1 Binary Select 1
SW1 Binary Select 2
SW1 Binary Select 4
SW1 Binary Select 8
goSW1BinS1
goSW1BinS2
goSW1BinS4
goSW1BinS8
1050
1051
1052
1053
SW1 Binary Select 131072
SW1 Binary Select 262144
SW1 Binary Select 524288
SW1 Weld BodyID 1
goSW1BnS131072
goSW1BnS262144
goSW1BnS524288
goSW1WeldID1
1037
1038
1039
1040
SW1 Binary Select 16
SW1 Binary Select 32
SW1 Binary Select 64
SW1 Binary Select 128
goSW1BinS16
goSW1BinS32
goSW1BinS64
goSW1BinS128
1054
1055
1056
1057
SW1 Weld BodyID 2
SW1 Weld BodyID 4
SW1 Weld BodyID 8
SW1 Weld BodyID 16
goSW1WeldID2
goSW1WeldID4
goSW1WeldID8
goSW1WeldID16
1041 SW1 Binary Select 256
goSW1BinS256
1058 SW1 Weld BodyID 32
goSW1WeldID32
GRS4-B1
108
108
54
Robot Outputs: SW 1 (cont’d)
EIP Scanner ‐ Slot 2
Description
DO[#]
1059
1060
1061
1062
1063
1064
1065
1066
1067
1068
1069
1070
1071
1072
1073
1074
1075
SW1 Weld BodyID 64
SW1 Weld BodyID 128
SW1 Stepper Reset Gun 1
SW1 Stepper Reset Gun 2
SW1 Stepper Reset Gun 3
SW1 Stepper Reset Gun 4
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
SW1 Part Finished
SW1 Gun Resistance Check
SW1 Reweld‐Turn Off Adaptive
Signal Name
EIP Scanner ‐ Slot 2
DO[#] Description Signal Name
goSW1WeldID64
goSW1WeldID128
doSW1StprRstGn1
doSW1StprRstGn2
doSW1StprRstGn3
doSW1StprRstGn4
(Reserved)
(Reserved)
1076 (Reserved) (Reserved)
1077 (Reserved) (Reserved)
1078 (Reserved) (Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
1084 (Reserved) (Reserved)
1085 (Reserved) (Reserved)
(Reserved)
(Reserved)
doSW1PrtFinished
doSW1GnResistChk
1088 (Reserved) (Reserved)
1079 (Reserved) (Reserved)
1080 (Reserved) (Reserved)
1081 (Reserved) (Reserved)
1082 (Reserved) (Reserved)
1083 (Reserved) (Reserved)
1086 (Reserved) (Reserved)
1087 (Reserved) (Reserved)
doSW1Reweld
109
GRS4-B1
109
Robot Outputs: SW 2
EIP Scanner ‐ Slot 3
Description
DO[#]
Signal Name
DO[#]
EIP Scanner ‐ Slot 3
Description
Signal Name
1153
1154
1155
1156
1157
1158
1159
1160
SW2 Weld Mode
SW2 Fault Reset
SW2 Enable Contactor Saver
(Reserved)
(Reserved)
SW2 Request Pressure
SW2 Initiate Weld
(Reserved)
doSW2WeldMode
doSW2FaultReset
doSW2EnContact
(Reserved)
(Reserved)
doSW2ReqPrssre
doSW2InitWeld
(Reserved)
1170
1171
1172
1173
1174
1175
1176
1177
SW2 Binary Select 512
SW2 Binary Select 1028
SW2 Binary Select 2048
SW2 Binary Select 4096
SW2 Binary Select 8192
SW2 Binary Select 16384
SW2 Binary Select 32768
SW2 Binary Select 65536
goSW2BinS512
goSW2BinS1024
goSW2BinS2048
goSW2BinS4096
goSW2BinS8192
goSW2BinS16384
goSW2BinS32768
goSW2BinS65536
1161
1162
1163
1164
SW2 Binary Select 1
SW2 Binary Select 2
SW2 Binary Select 4
SW2 Binary Select 8
goSW2BinS1
goSW2BinS2
goSW2BinS4
goSW2BinS8
1178
1179
1180
1181
SW2 Binary Select 131072
SW2 Binary Select 262144
SW2 Binary Select 524288
SW2 Weld BodyID 1
goSW2BnS131072
goSW2BnS262144
goSW2BnS524288
goSW2WeldID1
1165
1166
1167
1168
SW2 Binary Select 16
SW2 Binary Select 32
SW2 Binary Select 64
SW2 Binary Select 128
goSW2BinS16
goSW2BinS32
goSW2BinS64
goSW2BinS128
1182
1183
1184
1185
SW2 Weld BodyID 2
SW2 Weld BodyID 4
SW2 Weld BodyID 8
SW2 Weld BodyID 16
goSW2WeldID2
goSW2WeldID4
goSW2WeldID8
goSW2WeldID16
1169 SW2 Binary Select 256
goSW2BinS256
1186 SW2 Weld BodyID 32
goSW2WeldID32
GRS4-B1
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110
55
Robot Outputs: SW 2 (cont’d)
EIP Scanner ‐ Slot 3
Description
DO[#]
Signal Name
EIP Scanner ‐ Slot 3
DO[#] Description Signal Name
1187
1188
1189
1190
1191
1192
1193
1194
SW2 Weld BodyID 64
SW2 Weld BodyID 128
SW2 Stepper Reset Gun 1
SW2 Stepper Reset Gun 2
SW2 Stepper Reset Gun 3
SW2 Stepper Reset Gun 4
(Reserved)
(Reserved)
goSW2WeldID64
goSW2WeldID128
doSW2StprRstGn1
doSW2StprRstGn2
doSW2StprRstGn3
doSW2StprRstGn4
(Reserved)
(Reserved)
1204 (Reserved) (Reserved)
1195
1196
1197
1198
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
1212 (Reserved) (Reserved)
1199
1200
1201
1202
(Reserved)
(Reserved)
SW2 Part Finished
SW2 Gun Resistance Check
(Reserved)
(Reserved)
doSW2PrtFinished
doSW2GnResistChk
1216 (Reserved) (Reserved)
1203 SW2 Reweld-Turn Off Adaptive
1205 (Reserved) (Reserved)
1206 (Reserved) (Reserved)
1207 (Reserved) (Reserved)
1208 (Reserved) (Reserved)
1209 (Reserved) (Reserved)
1210 (Reserved) (Reserved)
1211 (Reserved) (Reserved)
1213 (Reserved) (Reserved)
1214 (Reserved) (Reserved)
1215 (Reserved) (Reserved)
doSW2Reweld
GRS4-B1
111
111
Robot Software Requirements
The following software requirements and specifications
have been developed for GM.
• Change between Process modes
• Weld Controller Checking
GRS4-B1
112
112
56
Process Modes
1. The ability to change the process mode between Process On (Weld) and Process Off (NoWeld) modes.
2. In Teach or Isolate mode of operation the Process On/Off mode will be selectable from the teach pendant.
3. In Interlock mode the status of the ‘Process X On Request’ input on the cell interface determines the process
mode. The ‘Process X On Request’ bit will be set to 1 for Process On (Weld) mode. The ‘Process X On Request’ bit
will be set to 0 for Process Off (No Weld) mode.
4. The ‘Weld Mode On’ bit will be set according to the ‘Process X On Request’ bit and sent to the weld controller.
5. In No Weld Mode, a means will be provided to select between Stroke and No Stroke modes.
GRS4-B1
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113
Process Modes (cont’d)
When the robot is in No Stroke mode it will:
•
Open to the backup distance stroke (if specified)
•
Resuming path execution.
No Stroke will be utilized in Interlock mode during Fast Fault Recovery.
GRS4-B1
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114
57
Process Equipment Check
1. The robot will check the status of the weld controller prior to
the start of any non-utility style program.
• It will verify weld controller is not faulted
2. If a fault is detected the controller will display an appropriate
message for the fault signal and allow for the following options.
• Retry
• Disable and continue
GRS4-B1
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115
Programming Instructions
The following programming instructions need to conform to
specifications set forth by GM:
Spot Weld Instructions
Cap Loss Detection
Gun Parameters
Flow Monitoring
Welding Cycle Parameters
Manual Functions
Pre-, In-, and Post- Weld Functions
Reset Stepper
One Joint Made
GRS4-B1
116
116
58
Spot Weld
• The spot weld instruction moves the robot to a
specific position and applies a spot weld.
• Parameters associated with motion for this instruction
will have the ability to be edited according to GM
GRS-1
• The termination type for this command will be
“CNTxxx” for ServoGuns
GRS4-B1
117
117
Body Shop Robot Spot Weld Application
GRS4-B1
118
118
59
Gun # and Schedule Parameters
• The user will be able to specify one schedule per gun
for up to two guns.
• The following parameters can be set for each weld
location
– Weld Identification - Each spot will have a minimum of eight ASCII characters
that are used to identify the weld.
– Starting Distance – Distance the gun should be opened going to the weld
– Pressure – Pressure schedule number to use from the pressure table
– Weld Schedule – Schedule number to send to the weld controller
– Thickness – Used for thickness verification
– Ending Distance – Distance the gun should open after the weld
GRS4-B1
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119
Spot Welding Cycle
1. The robot will be able to control up to two SCR’s and four weld guns. The program will be able to
simultaneously weld with two guns on separate SCR’s in a single spot welding instruction.
2. When two welds are required sequentially at a given path location, the program will be able to
execute the spot welding cycle in a single spot instruction or in two separate spot instructions.
• The amount of time it takes to complete these two welds will be no more than 50ms greater
than the larger single spot welding cycle (providing no faults occur).
3. The gun will close as the robot approaches the weld location. After the weld is complete the
robot will wait for the servo gun to open the proper distance before continuing.
GRS4-B1
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120
60
Pre-Weld Functions
The gun will start to close as the robot is moving toward the position. The following will also be
checked while moving to the weld location:
1.Water saver
2. Transformer
3. Enable contactor
4. Close gun. The following steps are included in closing the gun:
:
• Close gun
• Set weld schedule
GRS4-B1
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121
In-Weld Functions
During the weld the robot will perform the following steps:
1. Initiate the weld
2. Verify the weld schedule is in progress
3. Reset the weld schedule
4. Verify the process completed
5. Check the weld alert
GRS4-B1
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122
61
Post-Weld Functions
The robot will perform the following steps after the weld is completed:
1. Check stepper status – Signal the cell controller if required.
2. Check the tip dress – Signal the cell controller if required.
3. Reset the ‘Initiate Weld’ bit
4. Reset the ‘Process Fault’ bit
5. Open the gun.
GRS4-B1
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123
One Joint Made
The signal ‘OneJointMade’ is to be set after the first 'successful' weld, rivet, or screw is
made in a style.
This signal is only to be set if the weld controller is in weld mode and the ‘Process Complete’
signal is received from the weld controller and no faults occur during the weld.
The signal is reset during the 'Housekeeping Routine'.
GRS4-B1
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124
62
Cap Loss Detection and Flow Monitoring
The ‘Cap Loss Detection’ bit will be checked prior to every
weld, with the exception of when the water saver is
bypassed.
The ‘Flow Ok to Weld’ bit is to be checked prior to every
weld.
GRS4-B1
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125
Manual Functions
Manual functions will be available to allow the user the
appropriate control of the configured peripheral
equipment for the purposes of programming and
troubleshooting.
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126
63
Manual Spot Weld
• The manual spot weld feature allows the operator to
initiate a particular spot weld schedule on the selected
gun
• The user selections will be retained for repeated
execution of this feature
GRS4-B1
127
127
Reset Stepper
This feature will reset a stepper for the selected SCR(s)
by executing the appropriate weld sequence (61 for Gun
1, 62 for Gun 2) without closing the gun.
GRS4-B1
128
128
64
Fault Handling and Recovery-Auto Retry
The robot will be able to automatically open the gun and retry a
faulted weld up to three times
The default retries will be 0 and the maximum number of retries
will be 3
The robot will communicate each retry to the PLC via the ‘Process
X Alert’ signal and post a message to the teach pendant
GRS4-B1
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129
Fault Handling and Recovery - Weld Fault
The following recovery options will be available when a fault or weld complete timeout
occurs during the spot weld sequence:
1. Retry – Selecting Retry will initiate a new weld cycle.
2. Skip – Selecting Skip will drop ‘Task OK’, and move to the next weld location.
3. FFR – Refer to the FFR section below.
4. Abort – Selecting Abort will cancel any user program execution, robot motion,
or process execution.
Remote recovery capability will be supported for this type of fault. The response to a
robot specific remote input on the cell controller interface will be to retry the current weld
GRS4-B1
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130
65
Fast Fault Recovery
The recovery sequence will begin when Fast Fault Recovery (FFR) is
active and the robot has finished moving through the programmed path
in ‘No-Process’ mode.
Carried applications will be handled differently than pedestal applications
during the FFR.
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131
Carried Application
If the application is carried only:
1. The robot starts at the home position.
2. Execute the style program Repair. When the robot is in the repair position the process mode will
default to “ON” to allow full functionality to execute and test the results of repair operations.
3. The robot will be in a state where a ‘Remote Reset’ and ‘Cycle Start’ from the cell controller will
cause the robot to execute the path from repair to home.
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132
66
Carried Application (cont'd)
4. The user will be able to turn process mode “OFF” and have the following process
options when the repair style has been completed:
• Continue Last – Begin the re-weld process with the faulted weld
• Continue Next – Drop the ‘Task OK’ bit and begin the re-weld process with the first spot after the faulted weld.
• Abort – Cancel any user program execution, robot motion, or process execution.
5. The robot will restart the application process path and finish the process according
to the user-selected option.
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133
Pedestal Application
If the application is pedestal:
1. Execute a user-defined path that moves the robot from the final position in the process path to a repair position for
service.
2. Turn process mode “ON”
3. Present the following options to operator:
• Continue Last – Begin the re-weld process with the faulted weld.
• Continue Next – Drop the ‘Task OK’ bit and begin the re-weld process with the first spot after the faulted weld.
• Abort – Cancel any user program execution, robot motion, or process execution.
4. Turn process mode “OFF” and execute the user-defined path that moves the robot from the repair position to the
starting position of the process path and execute the process path according to the user-selected option.
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134
67
FFR with Dual Pedestal Process
GRS4-B1
135
135
Exercise 3.2: Resistance Weld Controller
Resistance Weld
– Complete the Exercise in your book.
136
136
68
Exercise 3.2
Exercise Solutions
137
137
Exercise 3.2: Resistance Weld Controller:
Solutions
1. Complete the Table
GRS4-B1
Description
Signal Name
Robot Input
SW1 No Alert
diSW1NoAlert
1025
SW1Stepper is Reset for GUN 1
diSW1StepResetG1
1039
SW1 Cap Change Request for Gun 2 diSW1CChngeReqG2
1058
SW1 No Fault
diSW1NoFault
1026
SW1 Weld Mode On
diSW1WeldModeOn
1027
SW1 Process Complete
diSW1ProcCmplt
1028
SW1 Schedule in Progress
diSW1InProgrss
1029
SW1 Tip Dress Request Gun 1
diSW1TDRequestG1
1045
SW1 Contactor Open
diSW1ContctrOpn
1031
138
138
69
Exercise 3.2: Resistance Weld Controller:
Solutions (cont’d)
2. Complete the Table
Description
Signal Name
Robot Output
SW2 Weld Mode
doSW2WeldMode
1153
SW2 Fault Reset
doSW2FaultReset
1154
SW2 Binary Select 4096
goSW2BinS4096
1173
SW2 Initiate Weld
doSW2InitWeld
1159
SW2 Binary Select 1
goSW2BinS1
1161
SW2 Enable Contactor Saver doSW2EnContact
1155
SW2 Stepper Reset Gun 1
1189
doSW2StprRstGn1
GRS4-B1
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139
Exercise 3.2: Resistance Weld Controller:
Solutions (cont’d)
3. Write a subroutine to move the robot with a carried
weld gun to the Repair Position. Wait for a repair
complete signal from the operator to return to home.
Don’t forget to add the segment path values.
1.
2.
3.
4.
5.
6.
GRS4-B1
Echo Style 31 (move to repair) to the cell controller
SetSegment [2]
<User to program the path from home to repair here>
Wait for continue (cell controller or user input to the robot)
SetSegment [3]
<User to program the path from repair to home here>
140
140
70
Exercise 3.2: Resistance Weld Controller:
Solutions (cont’d)
4. Write the steps that are in the Request to Continue
macro
–
–
–
–
–
–
–
–
Reset PathSegReqToCont
Wait for the PathSegContOK to be reset
Set PathSegReqToCont
Post Message “Waiting for Continue”
Wait for PathSegContOK
Capture Decision Code and echo to cell controller using ManDecisionCode
Post Message “Decision Code Received”
Reset PathSegReqToCont
GRS4-B1
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141
Exercise 3.2: Resistance Weld Controller:
Solutions (cont’d)
5. What robot input signal indicates the weld was
completed without errors?
Process Complete
GRS4-B1
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142
71
Exercise 3.2: Resistance Weld Controller:
Solutions (cont’d)
6. Which robot controller outputs are used to set the
weld schedule?
–
–
Binary Select Bits
Initiate Weld
GRS4-B1
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143
Exercise 3.2: Resistance Weld Controller:
Solutions (cont’d)
7. What will be the state of the ‘No Fault’ bit from the
controller after a fault reset from the robot is received
but the fault still exists?
No Fault will be low
GRS4-B1
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144
72
Exercise 3.2: Resistance Weld Controller:
Solutions (cont’d)
8. What are the 4 steps that should be performed before
the weld position?
–
–
–
–
Check Water saver
Check Transformer
Enable contactor
Close gun.
GRS4-B1
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145
Exercise 3.2: Resistance Weld Controller:
Solutions (cont’d)
9. What are the 5 steps that should be performed after
the weld is completed?
–
–
–
–
–
GRS4-B1
Check stepper status – Determine if the cell controller is
requesting a cap change.
Check the tip dress – Determine if the cell controller is
requesting a tip dress.
Reset the ‘Initiate Weld’ bit
Reset the ‘Process Fault’ bit
Open the gun.
146
146
73
Exercise 3.2: Resistance Weld Controller:
Solutions (cont’d)
10. What is the purpose of the One Joint Made signal?
This signal indicates the robot has successfully completed a weld
spot in weld mode.
GRS4-B1
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147
Module 3: Review – Robot to Resistance Weld
Controller
Identify 4 of the robot to resistance weld
controller interface signals.
1.
2.
3.
4.
GRS4-B1
Process Complete
Weld Mode On
All Steppers Reset
Tip dress request
148
148
74
Robot Software Requirements
Resistance Weld Water Saver
and Tip Dress Interface
149
149
Water Saver Outputs / Robot Inputs
1. Water Saver Aux Power OK: This signal indicates that auxiliary power for output(s) is available.
2. Flow OK To Weld: This signal indicates that the water saver is reset and has adequate flow.
3. Minimal Flow: This signal indicates that the water saver is reset and there is minimal flow at the tips.
4. Water Saver Tripped: This signal indicates that the weld water saver has detected a cap loss.
5. Water Valve Closed: This signal indicates that the weld water valve is in the “off” position.
6. Water Saver Bypassed: This signal indicates that the weld water saver is in the bypass state.
GRS4-B2
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150
75
Water Saver Inputs / Robot Outputs
1. Reset Water Saver: This signal resets the water saver.
2. Water Off: This signal shuts the water off at the water saver.
3. Bypass Water Saver: This signal puts the water saver in bypass.
GRS4-B2
151
151
Robot Inputs and Outputs: Water Saver 1 and 2
EIP Scanner ‐ Slot 48
Description
DI[#]
1441
1442
1443
1444
1445
1446
1447
Signal Name
EIP Scanner ‐ Slot 48
Description
DO[#]
Spot Weld Gun 1 W/S Flow OK to Weld
Spot Weld Gun 1 W/S Valve Closed
Spot Weld Gun 1 W/S Bypass on
Spot Weld Gun 1 W/S Minimal flow
Spot Weld Gun 1 W/S Tripped/Cap Loss
(Reserved)
(Reserved)
diG1WS_OktoWeld
diG1WS_ValveClsd
diG1WS_Bypassed
diG1WS_MinFlow
diG1WS_CapLoss
(Reserved)
(Reserved)
1441
1442
1443
1444
1445
1446
1447
1448 Spot Weld Gun 1 Water Saver Aux. Power OK
diG1WS_PowerOK
1448 (Reserved)
EIP Scanner ‐ Slot 50
Description
DI[#]
1449
1450
1451
1452
1453
1454
1455
Signal Name
Reset water saver G1 (flow on)
Water off G1 (flow off)
Bypass Water saver G1 (flow on)
(Reserved)
(Reserved)
(Reserved)
(Reserved )
Spot Weld Gun 2 W/S Flow OK to Weld
Spot Weld Gun 2 W/S Valve Closed
Spot Weld Gun 2 W/S Bypass on
Spot Weld Gun 2 W/S Minimal flow
Spot Weld Gun 2 W/S Tripped/Cap Loss
(Reserved)
(Reserved)
diG2WS_OktoWeld
diG2WS_ValveClsd
diG2WS_Bypassed
diG2WS_MinFlow
diG2WS_CapLoss
(Reserved)
(Reserved)
1449
1450
1451
1452
1453
1454
1455
1456 Spot Weld Gun 2 Water Saver Aux. Power OK
diG2WS_PowerOK
1456 (Reserved)
GRS4-B2
(Reserved)
EIP Scanner ‐ Slot 50
Description
DO[#]
Signal Name
doRstG1WaterSvr
doG1Wateroff
doG1WSBypass
(Reserved)
(Reserved)
(Reserved)
(Reserved)
Reset water saver G2 (flow on)
Water off G2 (flow off)
Bypass Water saver G2 (flow on)
(Reserved)
(Reserved)
(Reserved)
(Reserved )
Signal Name
doRstG2WaterSvr
doG2Wateroff
doG2WSBypass
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
152
152
76
Tip Dresser Outputs– Robot Inputs
Each robot will control its own tip dressers(s). Robots cannot share the same tip
dresser(s)
1. Motor Running: This signal indicates that the tip dress motor is
running.
2. Motor Current: Group of16 bits that represent the motor current.
3. Phase Lost: This signal indicates that the tip dress motor starter has
detected a fault on the power feed to the motor.
4. Trip: This signal indicates that the overload has tripped.
5. Overload: An overload condition on the motor starter.
6. Phase Imbalance: This signal indicates that there is a current
imbalance between the three phase motor power.
GRS4-B2
153
153
Tip Dresser Signal Definitions - Robot Outputs
1. Tip Dress Motor Start: This signal initiates the tip dress motor starter and starts the motor.
An auxiliary contact off of the motor starter is used to energize the blow off valve.
2. Tip Dress Trip Reset: This signal resets the overload/ trip fault in the motor starter.
3. Blow Off On: Turns on the blow off to keep the cutter clean.
GRS4-B2
154
154
77
Robot Inputs: Tip Dresser 1
EIP Scanner ‐ Slot 20
DI[#]
Description
EIP Scanner ‐ Slot 20
Signal Name
DI[#]
Description
EIP Scanner ‐ Slot 20
Signal Name
DI[#]
Description
1505 Motor Current Bit 1
Signal Name
1473 Trip
diTD1Tripped
1489 Short Circuit
diTD1ShortCrt
diTD1Current
1474 (Reserved)
(Reserved)
1490 Overload
diTD1Overload
1506 Motor Current Bit 2
diTD1Current
1475 Motor Running
diTD1RunningFWD
1491 Phase Loss
diTD1PhaseLost
1507 Motor Current Bit 3
diTD1Current
diTD1Current
1476 (Reserved)
(Reserved)
1492 (Reserved)
(Reserved)
1508 Motor Current Bit 4
1477 Ready
diTD1Ready
1493 (Reserved)
(Reserved)
1509 Motor Current Bit 5
diTD1Current
1478 (Reserved)
(Reserved)
1494 Control Power Lost
diTD1CntPwrLoss
1510 Motor Current Bit 6
diTD1Current
1479 (Reserved)
(Reserved)
1495 Fault
diTD1Fault
1511 Motor Current Bit 7
diTD1Current
1480 (Reserved)
(Reserved)
1496 (Reserved)
(Reserved)
1512 Motor Current Bit 8
diTD1Current
diTD1Current
1481 (Reserved)
(Reserved)
1497 Phase Imbalance
diTD1PhaseImb
1513 Motor Current Bit 9
1482 (Reserved)
(Reserved)
1498 (Reserved)
(Reserved)
1514 Motor Current Bit 10
diTD1Current
1483 (Reserved)
(Reserved)
1499 (Reserved)
(Reserved)
1515 Motor Current Bit 11
diTD1Current
1484 (Reserved)
(Reserved)
1500 (Reserved)
(Reserved)
1516 Motor Current Bit 12
diTD1Current
1485 Keypad On
diTD1KeyPadOn
1501 (Reserved)
(Reserved)
1517 Motor Current Bit 13
diTD1Current
1486 Disconnect On
diTD1DiscOn
1502 Hardware Fault
diTD1HWFault
1518 Motor Current Bit 14
diTD1Current
1487 (Reserved)
(Reserved)
1503 (Reserved)
(Reserved)
1519 Motor Current Bit 15
diTD1Current
1488 (Reserved)
(Reserved)
1504 (Reserved)
(Reserved)
1520 Motor Current Bit 16
diTD1Current
GRS4-B2
155
155
Robot Inputs: Servo Tip Dresser
Servo Tip Dresser
Servo Tip Dresser for Pedestal
EIP Scanner ‐ Slot 20
DI[#]
Description
Signal Name
EIP Scanner ‐ Slot 21
DI[#]
Description
Signal Name
1473
(Reserved)
(Reserved)
1681
Spot Weld Gun1Aux. Power OK
diG1PowerOK
1474
(Reserved)
(Reserved)
1682
Spot Weld Gun 1 Retract Closed
diG1RetClosed
1475
(Reserved)
(Reserved)
1683
Spot Weld Gun1 Backup Retract
diG1RetOpened
1476
(Reserved)
(Reserved)
1684
Spot Weld Gun1 Transformer Over Temp diG1TransOT
1477
(Reserved)
(Reserved)
1685
Tip Dress dump AdvancedG1
diG1TDDumpAdv
1478
(Reserved)
(Reserved)
1686
Tip Dress dump retractedG1
diG1TDDumpRet
1479
(Reserved)
(Reserved)
1687
Weld Gun Pressure AchievedG1
diG1PresAchieved
1480
(Reserved)
(Reserved)
1688
Tip Dress Dump Pin
diG1TDDumpPin
GRS4-B2
156
156
78
Robot Outputs: Tip Dresser 1-4
EIP Scanner ‐ Slot 20
DO[#]
Description
EIP Scanner ‐ Slot 38
Signal Name
DO[#]
Description
1521 Motor On
doTD1MotorOn
1474 (Reserved)
(Reserved)
1522 (Reserved)
(Reserved)
1475 Fault Reset
doTD1FaultReset
1523 Fault Reset
doTD2FaultReset
1476 (Reserved)
(Reserved)
1524 (Reserved)
(Reserved)
1477 (Reserved)
(Reserved)
1525 (Reserved)
(Reserved)
1478 (Reserved)
(Reserved)
1526 (Reserved)
(Reserved)
1479 Blow Off On
doTD1BlowOffOn
1527 Blow Off On
doTD2BlowOffOn
1480 (Reserved)
(Reserved)
1528 (Reserved)
(Reserved)
EIP Scanner ‐ Slot 39
DO[#]
GRS4-B2
Signal Name
1473 Motor On
Description
doTD2MotorOn
EIP Scanner ‐ Slot 40
Signal Name
DO[#]
Description
1617 Motor On
Signal Name
1569 Motor On
doTD3MotorOn
doTD4MotorOn
1570 (Reserved)
(Reserved)
1618 (Reserved)
(Reserved)
1571 Fault Reset
doTD3FaultReset
1619 Fault Reset
doTD4FaultReset
1572 (Reserved)
(Reserved)
1620 (Reserved)
(Reserved)
1573 (Reserved)
(Reserved)
1621 (Reserved)
(Reserved)
1574 (Reserved)
(Reserved)
1622 (Reserved)
(Reserved)
1575 Blow Off On
doTD3BlowOffOn
1623 Blow Off On
doTD4BlowOffOn
1576 (Reserved)
(Reserved)
1624 (Reserved)
(Reserved)
157
157
Robot Outputs: Servo Tip Dresser
Servo Tip Dresser
EIP Scanner ‐ Slot 20
DO[#]
GRS4-B2
Description
Signal Name
1473
doTdBlowoffG1
doTdBlowoffG1
1474
doTdBlowoffG2
doTdBlowoffG2
1475
doTdBlowoffG3
doTdBlowoffG3
1476
doTdBlowoffG4
doTdBlowoffG4
1477
(Reserved)
(Reserved)
1478
(Reserved)
(Reserved)
1479
(Reserved)
(Reserved)
1480
(Reserved)
(Reserved)
158
158
79
Module 3: Review – Water Saver Interface
Identify 5 of the water saver outputs – robot
inputs
1.
2.
3.
4.
5.
6.
Water Saver Aux Power
Flow OK To Weld
Minimum Flow
Water Saver Tripped
Water Valve Closed
Water Saver Bypassed
GRS4-B2
159
159
Robot Software Requirements
Servo Guns
160
160
80
Integrated Servo Gun
The integrated servo gun manual (GRS4-B3)
contains the GM standard for the robot seventh-axis
It covers the standard interface between robots and
all OEM equipment
GRS4-B3
161
161
Drive System Requirements
Compatibility
1. The seventh-axis robot control system will interface with all GM
approved servo weld gun suppliers per MD-1 and WG-001.
2. The seventh-axis drive will be compatible with:
a. Tol-O-Matic HT and SW series servo systems
b. Aro water-cooled servos
c. Robot manufacturer servos (e.g. Fanuc, ABB, Kuka)
3. Seventh-axis system will interface to the robot Auto Stop, General
Stop, E-Stop, and enabling device in the same manner as primary
axes.
GRS4-B3
162
162
81
Drive System Requirements
Tip Forces
1.
2.
3.
The servo gun system will be able to handle all gun forces required by
the WS-1 and WG-01 specifications.
The gun tip force will not deviate more than 2% of the programmed gun
force (for direct acting gun, i.e. the actuator is solely responsible for tip
force).
The drive system will be able to handle forces ranging from 890 – 8450
Newtons (200lb –1900lb).
GRS4-B3
163
163
Drive System Requirements
Configurations
1. Configurations for carried and pedestal pneumatic weld guns will
be supported for servo guns.
2. Single point (pogo) servo guns will be supported.
3. Hard automatic (nobot) servo guns will be supported. The nobot
will have the capability to control at least 6 guns individually or
simultaneously in any combination.
GRS4-B3
164
164
82
Seventh-Axis Control Software Requirements
Gun Setup
1. Robot servo gun software will provide a setup utility for the creation of new servo
gun definitions.
2. The minimum gun parameters for a new servo gun definition are:
a. Gun opening distance
b. Gun closing distance
c. Servomotor rotation to gun tip displacement ratio
d. Maximum gun force
3. The typical gun mastering position is with gun tips closed but other conditions can
be supported.
4. Robot will maintain gun mastering position and parameters during a robot
controller power failure.
GRS4-B3
165
165
Seventh-Axis Control Software Requirements
Tip Force and Velocity
1. The servo gun software will provide a gun calibration utility for proper
gun force calibration. The gun calibration must increase tip force
accuracy to within 2% deviation or less.
2. Servo gun system will dynamically maintain and monitor gun force
during weld execution.
3. The robot will coordinate the seventh-axis electrode velocity to meet the
metal at the programmed position without decreasing the maximum
robot speed.
4. The seventh-axis servo must match the maximum robot speed.
GRS4-B3
166
166
83
Seventh-Axis Control Software Requirements
Programmable Gun Opening Distance
1.
2.
3.
4.
5.
6.
The servo drive system and actuator will handle the full gun open and closed positions.
The gun opening will be able to be programmable at any point within the robot program.
The gun open and close positions will be within 1 cm of the maximum mechanical actuator
unit over-travel position. This distance will prevent the opening or closing of the gun to the
mechanical limit of the gun actuator.
Pre-programmed gun openings should be listed in a table for later use during robot
programming.
Pre-programmed gun openings are to be manually entered by the robot programmer.
Gun openings must be individually labeled in the gun-opening table.
GRS4-B3
167
167
Seventh-Axis Control Software Requirements
Software Gun Centering
1. Gun centering is defined as the automatic process in which both
gun arms (stationary and movable) travel with coordinated
motion to the programmed metal surface (taught position).
2. The travel distance of the stationary arm (distance from metal to
stationary cap) can be unique and programmed for each weld
pressure in the pressure table.
3. The robot software must provide the option to enable or disable
automatic software gun centering.
GRS4-B3
168
168
84
Seventh-Axis Control Software Requirements
Software Gun Equalization
1. Gun equalization is defined as the automatic process in which the stationary gun
arm will search for the actual metal position within the programmed metal surface.
2. The robot will close the gun at the location where stationary gun finds the actual
metal position and initiate the weld sequence.
3. Software gun equalization will be available as an option. With the option, the
Servo Gun Control System will be configurable to enable or disable software
equalization.
GRS4-B3
169
169
Seventh-Axis Control Software Requirements
Gun Deflection Compensation
• Robot servo gun software will have the ability to compensate for elasticity that is present in the
stationary gun arm of the servo weld gun moving “into the metal” while closing the gun.
• The deflection distance will be either a measured value for each weld force, or an interpolated
value based on a curve that is established during a calibration procedure.
GRS4-B3
170
170
85
Seventh-Axis Control Software Requirements
Tip Wear Compensation
1. Robot servo gun software must offset the “Fixed Weld Tip Position” relative to the
gun TCP to allow for cap wear or cap change.
2. The system should provide more than one method of measuring cap wear in order
to optimize accuracy.
3. The software will provide a programming instruction to initiate the measurement of
worn caps and offset the gun TCP accordingly.
4. The software will provide a programming instruction to initiate the measurement of
new caps and offset the gun TCP accordingly.
GRS4-B3
171
171
Seventh-Axis Control Software Requirements
Tip Wear Compensation (cont’d)
5. A servo gun status screen will be provided to display current cap wear amounts
on both gun arms.
6. Cap wear and cap change offset ratios will be manually adjustable. The user will
be able to change cap wear ratios from 50/ 50 Top / Bottom Cap to a user defined
ratio.
7. The software will provide automatic calculation of actual wear by comparison to a
reference surface.
8. The software will provide a means to initiate the “cap wear” instruction based on a
user programmable cumulative number of welds. This will occur while the robot is
at the home position and running Mainline Shell (refer to GRS-4A).
GRS4-B3
172
172
86
Seventh-Axis Control Software Requirements
Tip Wear Compensation (cont'd)
9. The software will provide a user programmable value for maximum cap wear
that generates an error when exceeded. The error detection will be
configurable to:
a. Alarm – Set a warning that there are out of tolerance values.
b. Fault – Stop the process because of out of tolerance values.
c. None – Do nothing for out of tolerance.
GRS4-B3
173
173
Seventh-Axis Control Software Requirements
Measurement of Part Thickness
1. The servo gun will be able to detect part thickness +/- 0.1mm.
2. Thickness detection will be programmable for each weld.
3. Thickness detection will also be provided as a program instruction or a
user initiated function. (e.g. THICKNESS [1.5] for a 1.5mm thickness
detection).
4. Thickness error detection will be configurable to:
a. Alarm – Set a warning that there are out of tolerance values.
b. Fault – Stop the process because of out of tolerance values.
c. None – Do nothing for out of tolerance.
GRS4-B3
174
174
87
Seventh-Axis Control Software Requirements
Measurement of Part Thickness (cont’d)
5. An error will be generated for a reading that is less than or
greater than programmed dimension.
6. Out of tolerance values will be user programmable.
GRS4-B3
175
175
Seventh-Axis Control Software Requirements
Soft Touch
1. Servo gun must automatically decelerate the electrode speed to
be no greater than 10% at a 2mm-creep distance.
2. The servo gun software, using the metal thickness as a reference
value, must automatically generate a creep distance of 2mm.
3. Soft Touch creep distance for each gun arm will be manually
adjustable and programmable for each weld.
GRS4-B3
176
176
88
Seventh-Axis Control Software Requirements
Jogging and Programming
1. The gun electrode will be jogged from the robot teach pendant.
2. The servo gun software will prevent the gun from jogging outside the gun
opening or closing limits.
3. The software will prevent the gun from exceeding the maximum gun force
when being closed. The software will monitor servo torque to avoid gun
damage due to excessive gun pressure outside designed gun limits.
4. The gun will maintain selected teach speed T1 or T2 per GRS-1.
5. The spot weld positions will be taught with the stationary tip touching the
metal at the weld location. The software will automatically compensate for
the taught position via creep distance during path execution.
GRS4-B3
177
177
Process Software Requirements
The servo gun system will be compatible with the
requirements of GRS-4 Section B1 (Resistance Weld
Controller Interface) and GRS-4 Section B2 (Resistance
Weld Dense Pack Interface) with the additions/exceptions
described in this section.
GRS4-B3
178
178
89
Spot Weld Cycle
1. Tip force will be programmable for each weld.
2. The gun tip force settings will be listed in a pressure table at the robot. The GRS-4 B1 weld pressure
interface does not apply to servo gun applications.
3. It will be possible to manually label the gun forces with a description.
4. The system will initiate the weld cycle when the pressure and metal thickness are both achieved.
5. If there is a fault during the weld sequence the robot will generate an error. During the error recovery
process, the gun will re-open and then reinitiate the weld sequence.
GRS4-B3
179
179
Process Modes
Tryout Mode
1. A means will be provided to select tryout mode when welding
is performed without metal.
2. In Teach or Isolate the tryout mode will be selectable from the
teach pendant.
3. In Interlock the status of the ‘Tryout Mode Request’ input on
the cell interface will select the tryout mode.
4. The tryout mode status will be communicated to the cell
controller using the ‘Tryout Mode’ output.
5. In Tryout Mode the system will ignore the metal thickness
condition but still keep the programmed gun force and initiate
the weld sequence when gun force is achieved.
GRS4-B3
180
180
90
Process Modes
Weld / No Weld
• Weld and No Weld modes, as defined in GRS-4 Section B, will apply to servo
gun operation.
• In No Weld the robot will maintain all servo gun functions including software
equalization or gun centering and programmed gun force.
GRS4-B3
181
181
Process Modes
Stroke / No Stroke
1. Stroke and No Stroke modes, as defined in GRS-4 Section
B1, will apply to servo gun operation.
2. In No Stroke the robot will temporary disable the software
equalization or the gun centering and execute the
programmed path.
3. In No Stroke, the stationary gun arm will move to the taught
point (stationary cap touching the metal surface).
GRS4-B3
182
182
91
Process Modes
Tip Dressing
1. A program instruction will be provided to close the servo gun at the tip
dress cutter using software equalization or gun centering and the selected
tip dress pressure.
2. Both gun tips must close at the tip dress cutter without executing a weld
sequence or sending a non-weld schedule.
3. The gun close instruction can be used as a discrete robot operation or
included in a robot move instruction.
GRS4-B3
183
183
Module 3: Review – Servo Guns
Identify 4 of the robot to integrated servo gun
controller requirements.
GRS4-B3
1. The integrated servo gun contains the GM standard for
the robot seventh-axis. It covers the standard interface
between robots and all OEM equipment.
2. The servo gun system will be able to handle all gun forces
required by the WS-1 and WG-01 Specifications.
3. The gun tip force will not deviate more than 2% of the
programmed gun force (for direct acting gun, i.e. the
actuator is solely responsible for tip force).
4. The drive system will be able to handle forces ranging
184
from 890 – 8450 Newton’s (200lb –1900lb).
184
92
Robot Software Requirements
Dispense Interface
185
185
Robot Inputs - Dispense Controller Outputs
1. Dispenser Ready: This signal indicates that the dispenser is functioning properly with no faults
and ready for a dispense cycle. This signal requires the dispenser to be in the automatic mode and
at the proper temperature (if applicable). The “Dispenser Ready’ signal will be reset during a
remote start, when a fault occurs, or when the system is depressurized.
•When the system is not ready the ‘Dispense Ready’ signal will be reset. The not ready condition will be sent to the cell
controller using the ‘Process X Tip Maintenance Request’ signal.
2. No Fault: This signal is reset when a fault has occurred within the dispensing equipment.
GRS4-C
186
186
93
Robot Inputs - Dispense Controller Outputs
(cont’d)
3. No Alert: This signal is reset when an alert has occurred within the dispense equipment.
The dispenser tracks alerts and they may result in a major fault after a specified number of
occurrences.
• When an alert is detected the robot will set the ‘Process X Alert 1’ output on the cell interface. An alert will not
override processing of the ‘Volume OK’ signal or prevent by itself the setting ‘Task OK’ high.
4. Dispense In Process: This signal indicates that the dispense system has received a valid
style and is in the dispensing process. Resetting this signal while the ‘Dispense Complete’
robot output is set causes the robot to read the ‘Volume OK’, ‘No Fault’ and ‘No Alert’
signals from the dispenser.
GRS4-C
187
187
Robot Inputs - Dispense Controller Outputs
(cont’d)
5. Area Volume OK: This signal indicates that the volume dispensed for the given area was completed within the
defined limits
6. Total Volume OK: This signal indicates that the volume dispensed for the given style was completed within the
defined limits of the dispense controller. ‘Total Volume OK’ is reset when the robot turns off the ‘Style Strobe’
output. The ‘OFF’ state of this signal will be checked by the robot prior to setting ‘Style Strobe’ at the beginning of a
dispense sequence.
7. Remote Start / Purge In Process: This signal indicates that a remote start has been initiated by the dispense
controller. The ‘Remote Start’ remains set until the dispense equipment has achieved ‘Dispense Ready’ status. The
remote start process includes performing a metered or non-metered purge according to parameters defined within
the dispense controller.
GRS4-C
188
188
94
Robot Inputs - Dispense Controller Outputs
(cont’d)
8. Drum Empty: This signal indicates that one or both material supply drums are
empty. The ‘Drum Empty’ signal will be interconnected to the appropriate
‘Process X Alert 2’ robot output on the cell interface.
9. Purge Request: This signal is a request to purge the system due to dispense
inactivity. A user definable time set in the dispense controller determines when a
purge is necessary. ‘Purge Request’ status will be communicated to the cell
controller using the ‘Process X Tip Maintenance Request’ signal.
GRS4-C
189
189
Robot Outputs - Dispense Controller Inputs
1. Style ID Bits (1,2,4,8,16,32,64,128): This group of signals form an eight-bit binary number output that is used to
relay the style information to the dispenser. The style ID bits will be set before the ‘Style Strobe’ is set and drop low
after the ‘Dispense In Process’ is received. A volume target with tolerance limits will be associated with each style
in the dispenser. A fault will be sent to the robot if the volume is not within the specified limits.
2. Style Strobe: A signal indicating that the style bits are set, per body style, and ready for the dispenser to read
them. This bit will remain high until after volume and fault information are read at the end of the dispense cycle. The
robot will reset this signal when a dispense sequence is interrupted.
3. Gun X On (1,2,3,4,): The ‘Gun X On’ signals are discreet signals to the dispenser to turn on guns one through
four. Any combination of the guns may be on at any given time.
GRS4-C
190
190
95
Robot Outputs - Dispense Controller Inputs
(cont’d)
4. Total Dispense Complete: This signal is set when the dispense cycle is completed. This
signal will initiate the dispense controller to perform the volume calculations for the current
job. Based on the volume dispensed, the ‘Volume OK’ signal and/or the ‘Alert’ signal may
be set.
• A fault could be reported based upon the volume dispensed. The ‘Dispense Complete’ signal will be reset after
the ‘Volume OK’ signal is set or a fault signal is detected.
5. Area Volume Complete: This signal is set to check the volume of a certain area that was
just completed
GRS4-C
191
191
Robot Outputs - Dispense Controller Inputs
(cont’d)
6. Dispense Material Flow Command (1,2,4,8,16,32,64,128,256,512,1024,2048) - Analog:
This 12 bit binary output represents an analog signal between 0 to 10 V. The analog signal
controls the dispense flow rate.
• This is a binary representation of an analog signal that is proportional to the TCP speed of the robot.
7. Bead Shaping Command (1,2,4,8,16,32,64,128,256,512,1024,2048) - Analog: This 12 bit
binary output represents an analog signal between 0 to 10 V. This signal controls the bead
shaping of the dispensed material. It is possible to control the bead-shaping signal by direct
entry (straight voltage) or as a TCP speed proportional signal.
GRS4-C
192
192
96
Robot Outputs - Dispense Controller Inputs
(cont’d)
8. Remote Start: This signal restarts the dispense system from any “not-ready”
state.
9. Purge: This signal initiates a purge according to parameters in the dispense
controller.
10. Shutdown Command: This command will shutdown the dispense controller
and put it in an idle state. It can be awakened using the remote start command
GRS4-C
193
193
Robot Outputs - Dispense Controller Inputs
(cont’d)
11. Fault Reset: The fault reset starts the fault recovery procedure and
attempts to reset a fault condition. If the cause of the fault has not been
removed, then the fault will be resent after the release of the ‘Fault Reset’
signal. The dispense controller also uses this signal to cancel an abandoned
style sequence and reinitialize itself for the next cycle. The dispense controller
checks that this signal is low prior to setting ‘Dispense in Process’ at the
beginning of a dispense sequence. If the fault reset is in the incorrect state
(set), the dispenser will report the fault.
GRS4-C
194
194
97
Dispense Controller 1 Outputs / Robot Inputs
EIP Scanner ‐ Slot 4
DI[#]
Description
EIP Scanner ‐ Slot 4
Signal Name
DI[#]
Description
1025 Dispense1 Ready
diSL1Ready
1041 (Reserved)
1026 Dispense1 NO Fault
diSL1NOFault
1042 (Reserved)
1027 Dispense1 NO Alert
diSL1NOAlert
1043 (Reserved)
1028 Dispense1 In Process
diSL1InProcess
1044 Dispense1 Shutdown Status
1029 Dispense1 TOTAL Volume OK
diSL1VolumeOK
1030 Dispense1 Area Volume OK
EIP Scanner ‐ Slot 4
Signal Name
(Reserved)
DI[#]
Description
Signal Name
1057 Process1 Data Total Volume Bit 1
diSL1TotalVolB1
(Reserved)
1058 Process1 Data Total Volume Bit 2
diSL1TotalVolB2
(Reserved)
1059 Process1 Data Total Volume Bit 3
diSL1TotalVolB3
diSL1ShutDwnStat
1060 Process1 Data Total Volume Bit 4
diSL1TotalVolB4
1045 (Reserved) for 2k Mi1er Change Req
diSL1_2KMi1erChgR
1061 Process1 Data Total Volume Bit 5
diSL1TotalVolB5
diSL1AreaVolOK
1046 (Reserved) for 2k 2k in Mi1er
diSL1_2KinMi1er
1062 Process1 Data Total Volume Bit 6
diSL1TotalVolB6
1031 Dispense1 Purge Request
Dispense1 Remote Start In
1032 Progress
diSL1PurgeReq
1047 (Reserved) for 2k
diSL1_2K
1063 Process1 Data Total Volume Bit 7
diSL1TotalVolB7
diSL1RmtStartInp
1048 (Reserved) for 2k
diSL1_2K
1064 Process1 Data Total Volume Bit 8
diSL1TotalVolB8
1033 Dispense1 Barrel 1 Low
diSL1Barel1Low
1049 Dispense1 Meter is Full
diSL1MeterFull
1065 Process1 Data Total Volume Bit 9
diSL1TotalVolB9
1034 Dispense1 Barrel 1 Empty
diSL1Barel1Empty
1066 Process1 Data Total Volume Bit 10
diSL1TotalVolB10
diSL1Barel2Low
1050 Dispense1 Fill Requested
Dispense1 Meter in Re-Fill Station
1051 Ready
diSL1FillRequest
1035 Dispense1 Barrel 2 Low
diSL1MtrRSRdy
1067 Process1 Data Total Volume Bit 11
diSL1TotalVolB11
1036 Dispense1 Barrel 2 Empty
diSL1Barel2Empty
1052 Dispense1 Meter at Robot Dock Ready diSL1MtrDockRdy
1068 Process1 Data Total Volume Bit 12
diSL1TotalVolB12
1037 Dispense1 Barrel 2K 1 Low
diSL1Barl2K1Low
1053 Dispense1 Fill Valve Refill Station
1069 Process1 Data Total Volume Bit 13
diSL1TotalVolB13
1038 Dispense1 Barrel 2K 1 Empty
diSL1Barl2K1Empt
1054 Dispense1 Meter in Circulate
diSL1Circulate
1070 Process1 Data Total Volume Bit 14
diSL1TotalVolB14
1039 Dispense1 Barrel 2K 2 Low
diSL1Barl2K2Low
1055 Dispense1 Temp Zone XX Disabled
diSL1TmpZnDsbled
1071 Process1 Data Total Volume Bit 15
diSL1TotalVolB15
1040 Dispense1 Barrel 2K 2 Empty
diSL1Barl2K2Empt
1056 Dispense1 Process Data Acknowledge XData_Ack
1072 Process1 Data Total Volume Bit 16
diSL1TotalVolB16
diSL1Fill_Inter
GRS4-C
195
195
Dispense Controller 1 Outputs / Robot Inputs
(cont’d)
EIP Scanner ‐ Slot 4
Description
EIP Scanner ‐ Slot 4
Description
Signal Name
1089 Process1 Data System Pressure Bit 1
diSL1PressureB1
1105 Process1 Data Temp Set Point Bit 1
diSL1TempSetB1
1090 Process1 Data System Pressure Bit 2
diSL1PressureB2
1106 Process1 Data Temp Set Point Bit 2
diSL1TempSetB2
1091 Process1 Data System Pressure Bit 3
diSL1PressureB3
1107 Process1 Data Temp Set Point Bit 3
diSL1TempSetB3
1092 Process1 Data System Pressure Bit 4
diSL1PressureB4
1108 Process1 Data Temp Set Point Bit 4
diSL1TempSetB4
1093 Process1 Data System Pressure Bit 5
diSL1PressureB5
1109 Process1 Data Temp Set Point Bit 5
diSL1TempSetB5
1094 Process1 Data System Pressure Bit 6
diSL1PressureB6
1110 Process1 Data Temp Set Point Bit 6
diSL1TempSetB6
1095 Process1 Data System Pressure Bit 7
diSL1PressureB7
1111 Process1 Data Temp Set Point Bit 7
diSL1TempSetB7
1096 Process1 Data System Pressure Bit 8
diSL1PressureB8
1097 Process1 Data System Pressure Bit 9
diSL1PressureB9
1098 Process1 Data System Pressure Bit 10
diSL1PressureB10
1112 Process1 Data Temp Set Point Bit 8
Process1 Data Actual Temp Set Point
1113 1
Process1 Data Actual Temp Set Point
1114 2
Process1 Data Actual Temp Set Point
1115 3
Process1 Data Actual Temp Set Point
1116 4
Process1 Data Actual Temp Set Point
1117 5
Process1 Data Actual Temp Set Point
1118 6
Process1 Data Actual Temp Set Point
1119 7
Process1 Data Actual Temp Set Point
1120 8
DI[#]
1080 Process1 Data Area Volume Bit 8
Signal Name
diSL1AreaVolB1
diSL1AreaVolB2
diSL1AreaVolB3
diSL1AreaVolB4
diSL1AreaVolB5
diSL1AreaVolB6
diSL1AreaVolB7
diSL1AreaVolB8
1081 Process1 Data Area Volume Bit 9
diSL1AreaVolB9
DI[#]
1073 Process1 Data Area Volume Bit 1
1074 Process1 Data Area Volume Bit 2
1075 Process1 Data Area Volume Bit 3
1076 Process1 Data Area Volume Bit 4
1077 Process1 Data Area Volume Bit 5
1078 Process1 Data Area Volume Bit 6
1079 Process1 Data Area Volume Bit 7
1082 Process1 Data Area Volume Bit 10 diSL1AreaVolB10
1083 Process1 Data Area Volume Bit 11 diSL1AreaVolB11
1099 Process1 Data System Pressure Bit 11
diSL1PressureB11
1084 Process1 Data Area Volume Bit 12 diSL1AreaVolB12
1100 Process1 Data System Pressure Bit 12
diSL1PressureB12
1085 Process1 Data Area Volume Bit 13 diSL1AreaVolB13
1101 Process1 Data System Pressure Bit 13
diSL1PressureB13
1086 Process1 Data Area Volume Bit 14 diSL1AreaVolB14
1102 Process1 Data System Pressure Bit 14
diSL1PressureB14
1087 Process1 Data Area Volume Bit 15 diSL1AreaVolB15
1103 Process1 Data System Pressure Bit 15
diSL1PressureB15
1088 Process1 Data Area Volume Bit 16 diSL1AreaVolB16
1104 Process1 Data System Pressure Bit 16
diSL1PressureB16
GRS4-C
DI[#]
EIP Scanner ‐ Slot 4
Description
Signal Name
diSL1TempSetB8
Bit
diSL1ActTempB1
Bit
diSL1ActTempB2
Bit
diSL1ActTempB3
Bit
diSL1ActTempB4
Bit
diSL1ActTempB5
Bit
diSL1ActTempB6
Bit
diSL1ActTempB7
Bit
diSL1ActTempB8
196
196
98
Dispense Controller 1 Outputs / Robot Inputs
(cont’d)
EIP Scanner ‐ Slot 4
Description
DI[#]
Signal Name
EIP Scanner ‐ Slot 4
Description
DI[#]
Signal Name
1121 Dispense1 Fault Data Bit 1
diSL1FaultBit1
1137 (Reserved)
(SL1 Reserved)
1122 Dispense1 Fault Data Bit 2
diSL1FaultBit2
1138 (Reserved)
(SL1 Reserved)
1123 Dispense1 Fault Data Bit 3
diSL1FaultBit3
1139 (Reserved)
(SL1 Reserved)
1124 Dispense1 Fault Data Bit 4
diSL1FaultBit4
1140 (Reserved)
(SL1 Reserved)
1125 Dispense1 Fault Data Bit 5
diSL1FaultBit5
1141 (Reserved)
(SL1 Reserved)
1126 Dispense1 Fault Data Bit 6
diSL1FaultBit6
1142 (Reserved)
(SL1 Reserved)
1127 Dispense1 Fault Data Bit 7
diSL1FaultBit7
1143 (Reserved)
(SL1 Reserved)
1128 Dispense1 Fault Data Bit 8
diSL1FaultBit8
1144 (Reserved)
(SL1 Reserved)
1129 Dispense1 Fault Data Bit 9
diSL1FaultBit9
1145 (Reserved)
(SL1 Reserved)
1130 Dispense1 Fault Data Bit 10
diSL1FaultBit10
1146 (Reserved)
(SL1 Reserved)
1131 Dispense1 Fault Data Bit 11
diSL1FaultBit11
1147 (Reserved)
(SL1 Reserved)
1132 Dispense1 Fault Data Bit 12
diSL1FaultBit12
1148 (Reserved)
(SL1 Reserved)
1133 Dispense1 Fault Data Bit 13
diSL1FaultBit13
1149 (Reserved)
(SL1 Reserved)
1134 Dispense1 Fault Data Bit 14
diSL1FaultBit14
1150 (Reserved)
(SL1 Reserved)
1135 Dispense1 Fault Data Bit 15
diSL1FaultBit15
1151 (Reserved)
(SL1 Reserved)
1136 Dispense1 Fault Data Bit 16
diSL1FaultBit16
1152 (Reserved)
(SL1 Reserved)
GRS4-C
197
197
Dispense Controller 2 Outputs / Robot Inputs
EIP Scanner ‐ Slot 5
DI[#]
Description
EIP Scanner ‐ Slot 5
Signal Name
DI[#]
Description
1153 Dispense2 Ready
diSL2Ready
1169 (Reserved)
1154 Dispense2 NO Fault
diSL2NOFault
1170 (Reserved)
1155 Dispense2 NO Alert
diSL2NOAlert
1171 (Reserved)
1156 Dispense2 In Process
diSL2InProcess
1172 Dispense2 Shutdown Status
1157 Dispense2 TOTAL Volume OK
diSL2VolumeOK
1158 Dispense2 Area Volume OK
EIP Scanner ‐ Slot 5
Signal Name
(Reserved)
DI[#]
Description
Signal Name
1185 Process2 Data Total Volume Bit 1
diSL2TotalVolB1
(Reserved)
1186 Process2 Data Total Volume Bit 2
diSL2TotalVolB2
(Reserved)
1187 Process2 Data Total Volume Bit 3
diSL2TotalVolB3
diSL2ShutDwnStat
1188 Process2 Data Total Volume Bit 4
diSL2TotalVolB4
1173 (Reserved) for 2k Mi1er Change Req
diSL2_2KMi1erChgR
1189 Process2 Data Total Volume Bit 5
diSL2TotalVolB5
diSL2AreaVolOK
1174 (Reserved) for 2k 2k in Mi1er
diSL2_2KinMi1er
1190 Process2 Data Total Volume Bit 6
diSL2TotalVolB6
1159 Dispense2 Purge Request
Dispense2 Remote Start In
1160 Progress
diSL2PurgeReq
1175 (Reserved) for 2k
diSL2_2K
1191 Process2 Data Total Volume Bit 7
diSL2TotalVolB7
diSL2RmtStartInp
1176 (Reserved) for 2k
diSL2_2K
1192 Process2 Data Total Volume Bit 8
diSL2TotalVolB8
1161 Dispense2 Barrel 1 Low
diSL2Barel1Low
1177 Dispense2 Meter is Full
diSL2MeterFull
1193 Process2 Data Total Volume Bit 9
diSL2TotalVolB9
1162 Dispense2 Barrel 1 Empty
diSL2Barel1Empty
1194 Process2 Data Total Volume Bit 10
diSL2TotalVolB10
diSL2Barel2Low
1178 Dispense2 Fill Requested
Dispense2 Meter in Re-Fill Station
1179 Ready
diSL2FillRequest
1163 Dispense2 Barrel 2 Low
diSL2MtrRSRdy
1195 Process2 Data Total Volume Bit 11
diSL2TotalVolB11
1164 Dispense2 Barrel 2 Empty
diSL2Barel2Empty
1180 Dispense2 Meter at Robot Dock Ready diSL2MtrDockRdy
1196 Process2 Data Total Volume Bit 12
diSL2TotalVolB12
1165 Dispense2 Barrel 2K 1 Low
diSL2Barl2K1Low
1181 Dispense2 Fill Valve Refill Station
1197 Process2 Data Total Volume Bit 13
diSL2TotalVolB13
1166 Dispense2 Barrel 2K 1 Empty
diSL2Barl2K1Empt
1182 Dispense2 Meter in Circulate
diSL2Circulate
1198 Process2 Data Total Volume Bit 14
diSL2TotalVolB14
1167 Dispense2 Barrel 2K 2 Low
diSL2Barl2K2Low
1183 Dispense2 Temp Zone XX Disabled
diSL2TmpZnDsbled
1199 Process2 Data Total Volume Bit 15
diSL2TotalVolB15
1168 Dispense2 Barrel 2K 2 Empty
diSL2Barl2K2Empt
1184 Dispense2 Process Data Acknowledge XData_Ack
1200 Process2 Data Total Volume Bit 16
diSL2TotalVolB16
GRS4-C
diSL2Fill_Inter
198
198
99
Dispense Controller 2 Outputs / Robot Inputs
(cont’d)
EIP Scanner ‐ Slot 5
DI[#]
Description
1201 Process2 Data Area Volume Bit 1
EIP Scanner ‐ Slot 5
Signal Name
diSL2AreaVolB1
diSL2AreaVolB2
diSL2AreaVolB3
diSL2AreaVolB4
DI[#]
EIP Scanner ‐ Slot 5
Description
Signal Name
DI[#]
Description
Signal Name
1217 Process2 Data System Pressure Bit 1
diSL2PressureB1
1233 Process2 Data Temp Set Point Bit 1
diSL2TempSetB1
1218 Process2 Data System Pressure Bit 2
diSL2PressureB2
1234 Process2 Data Temp Set Point Bit 2
diSL2TempSetB2
1219 Process2 Data System Pressure Bit 3
diSL2PressureB3
1235 Process2 Data Temp Set Point Bit 3
diSL2TempSetB3
1220 Process2 Data System Pressure Bit 4
diSL2PressureB4
1236 Process2 Data Temp Set Point Bit 4
diSL2TempSetB4
1221 Process2 Data System Pressure Bit 5
diSL2PressureB5
1237 Process2 Data Temp Set Point Bit 5
diSL2TempSetB5
1222 Process2 Data System Pressure Bit 6
diSL2PressureB6
1238 Process2 Data Temp Set Point Bit 6
diSL2TempSetB6
1223 Process2 Data System Pressure Bit 7
diSL2PressureB7
1239 Process2 Data Temp Set Point Bit 7
diSL2TempSetB7
1208 Process2 Data Area Volume Bit 8
diSL2AreaVolB5
diSL2AreaVolB6
diSL2AreaVolB7
diSL2AreaVolB8
1224 Process2 Data System Pressure Bit 8
diSL2PressureB8
1209 Process2 Data Area Volume Bit 9
diSL2AreaVolB9
1225 Process2 Data System Pressure Bit 9
diSL2PressureB9
1240 Process2 Data Temp Set Point Bit 8
Process2 Data Actual Temp Set Point
1241 1
Process2 Data Actual Temp Set Point
1242 2
Process2 Data Actual Temp Set Point
1243 3
Process2 Data Actual Temp Set Point
1244 4
Process2 Data Actual Temp Set Point
1245 5
Process2 Data Actual Temp Set Point
1246 6
Process2 Data Actual Temp Set Point
1247 7
Process2 Data Actual Temp Set Point
1248 8
1202 Process2 Data Area Volume Bit 2
1203 Process2 Data Area Volume Bit 3
1204 Process2 Data Area Volume Bit 4
1205 Process2 Data Area Volume Bit 5
1206 Process2 Data Area Volume Bit 6
1207 Process2 Data Area Volume Bit 7
1210 Process2 Data Area Volume Bit 10 diSL2AreaVolB10
1226 Process2 Data System Pressure Bit 10 diSL2PressureB10
1211 Process2 Data Area Volume Bit 11 diSL2AreaVolB11
1227 Process2 Data System Pressure Bit 11 diSL2PressureB11
1212 Process2 Data Area Volume Bit 12 diSL2AreaVolB12
1228 Process2 Data System Pressure Bit 12 diSL2PressureB12
1213 Process2 Data Area Volume Bit 13 diSL2AreaVolB13
1229 Process2 Data System Pressure Bit 13 diSL2PressureB13
1214 Process2 Data Area Volume Bit 14 diSL2AreaVolB14
1230 Process2 Data System Pressure Bit 14 diSL2PressureB14
1215 Process2 Data Area Volume Bit 15 diSL2AreaVolB15
1231 Process2 Data System Pressure Bit 15 diSL2PressureB15
1216 Process2 Data Area Volume Bit 16 diSL2AreaVolB16
1232 Process2 Data System Pressure Bit 16 diSL2PressureB16
diSL2TempSetB8
Bit
diSL2ActTempB1
Bit
diSL2ActTempB2
Bit
diSL2ActTempB3
Bit
diSL2ActTempB4
Bit
diSL2ActTempB5
Bit
diSL2ActTempB6
Bit
diSL2ActTempB7
Bit
diSL2ActTempB8
GRS4-C
199
199
Dispense Controller 2 Outputs / Robot Inputs
(cont’d)
DI[#]
EIP Scanner ‐ Slot 5
Description
Signal Name
DI[#]
EIP Scanner ‐ Slot 5
Description
Signal Name
1249 Dispense2 Fault Data Bit 1
diSL2FaultBit1
1265 (Reserved)
(SL2 Reserved)
1250 Dispense2 Fault Data Bit 2
diSL2FaultBit2
1266 (Reserved)
(SL2 Reserved)
1251 Dispense2 Fault Data Bit 3
diSL2FaultBit3
1267 (Reserved)
(SL2 Reserved)
1252 Dispense2 Fault Data Bit 4
diSL2FaultBit4
1268 (Reserved)
(SL2 Reserved)
1253 Dispense2 Fault Data Bit 5
diSL2FaultBit5
1269 (Reserved)
(SL2 Reserved)
1254 Dispense2 Fault Data Bit 6
diSL2FaultBit6
1270 (Reserved)
(SL2 Reserved)
1255 Dispense2 Fault Data Bit 7
diSL2FaultBit7
1271 (Reserved)
(SL2 Reserved)
1256 Dispense2 Fault Data Bit 8
diSL2FaultBit8
1272 (Reserved)
(SL2 Reserved)
1257 Dispense2 Fault Data Bit 9
diSL2FaultBit9
1273 (Reserved)
(SL2 Reserved)
1258 Dispense2 Fault Data Bit 10
diSL2FaultBit10
1274 (Reserved)
(SL2 Reserved)
1259 Dispense2 Fault Data Bit 11
diSL2FaultBit11
1275 (Reserved)
(SL2 Reserved)
1260 Dispense2 Fault Data Bit 12
diSL2FaultBit12
1276 (Reserved)
(SL2 Reserved)
1261 Dispense2 Fault Data Bit 13
diSL2FaultBit13
1277 (Reserved)
(SL2 Reserved)
1262 Dispense2 Fault Data Bit 14
diSL2FaultBit14
1278 (Reserved)
(SL2 Reserved)
1263 Dispense2 Fault Data Bit 15
diSL2FaultBit15
1279 (Reserved)
(SL2 Reserved)
1264 Dispense2 Fault Data Bit 16
diSL2FaultBit16
1280 (Reserved)
(SL2 Reserved)
GRS4-C
200
200
100
Dispense Controller 1 Inputs / Robot Outputs
EIP Scanner ‐ Slot 4
DO[#]
EIP Scanner ‐ Slot 4
Description
Signal Name
DO[#]
Description
EIP Scanner ‐ Slot 4
Signal Name
DO[#]
Description
Signal Name
1025 Dispense1 Style Bit 1
doSL1StyleBit1
1041 Dispense1 Material Flow Command Bit 1 goSL1MatFlow1
1057 Not @ Purge Position Tooling Fixture doNotATPurgePos
1026 Dispense1 Style Bit 2
doSL1StyleBit2
1042 Dispense1 Material Flow Command Bit 2 goSL1MatFlow2
1058 (Reserved)
1027 Dispense1 Style Bit 4
doSL1StyleBit4
1043 Dispense1 Material Flow Command Bit 3 goSL1MatFlow3
1059 Dispense1 Area Volume Complete
diSL1AreaVolCmp
1028 Dispense1 Style Bit 8
doSL1StyleBit8
1044 Dispense1 Material Flow Command Bit 4 goSL1MatFlow4
1060 Dispense1 Purge
doSL1Purge
(Reserved)
1029 Dispense1 Style Bit 16
doSL1StyleBit16
1045 Dispense1 Material Flow Command Bit 5 goSL1MatFlow5
1061 Dispense1 Shut down Command
doSL1ShutDwnCmd
1030 Dispense1 Style Bit 32
doSL1StyleBit32
1046 Dispense1 Material Flow Command Bit 6 goSL1MatFlow6
1062 Dispense1 Fault Reset
doSL1FaultReset
doSL1RemoteStart
1031 Dispense1 Style Bit 64
doSL1StyleBit64
1047 Dispense1 Material Flow Command Bit 7 goSL1MatFlow7
1063 Dispense1 Remote Start
1032 Dispense1 Style Bit 128
doSL1StyleBit128
1048 Dispense1 Material Flow Command Bit 8 goSL1MatFlow8
1064 (Reserved)for 2k
do2kRepairPosE1
1033 Dispense1 Style Strobe
doSL1StyleStrobe
1049 Dispense1 Material Flow Command Bit 9 goSL1MatFlow9
1065 (Reserved)for 2k
do2kMi1erChgE1
1034 Dispense1 Total Dispense Complete
doSL1TotVolComp
1050 Dispense1 Material Flow Command Bit 10 goSL1MatFlow10
1066 (Reserved)for 2k
do2kPurgePBE1
1035 Dispense1 Gun 1 ON
doSL1Gun1On
1051 Dispense1 Material Flow Command Bit 11 goSL1MatFlow11
1067 (Reserved)for 2k
(Reserved)
1036 Dispense1 Gun 2 ON
doSL1Gun2On
1052 Dispense1 Material Flow Command Bit 12 goSL1MatFlow12
1068 Dispense1 Meter in Re-Fill Station
doSL1StaRefRdy
1037 Dispense1 Gun 3 ON
doSL1Gun3On
1053 Dispense1 Material Flow Command Bit 13 goSL1MatFlow13
1069 Dispense1 Meter in Docked Position doSL1MtrDocked
1038 Dispense1 Gun 4 ON
doSL1Gun4On
1054 Dispense1 Material Flow Command Bit 14 goSL1MatFlow14
1070 (Reserved)
(Reserved)
1039 (Reserved) Swirl Enable
(Reserved)
1055 Dispense1 Material Flow Command Bit 15 goSL1MatFlow15
1071 Dispense1 Circulate Meter
doSL1Circulate
1040 (Reserved) Pre-pressue Trigger
(Reserved)
1056 Dispense1 Material Flow Command Bit 16 goSL1MatFlow16
1072 Dispense1 Fill Meter
doSL1FillMeter
GRS4-C
201
201
Dispense Controller 1 Inputs / Robot Outputs
(cont’d)
EIP Scanner ‐ Slot 4
DO[#]
Description
EIP Scanner ‐ Slot 4
Signal Name
1073 Dispense1 Bead Shaping Command (bit 1) goSL1BeadShp1
DO[#]
Description
1089 AreaNumberBit1
EIP Scanner ‐ Slot 4
Signal Name
goSL1AreaNum1
DO[#]
1105 (Reserved)
Description
Signal Name
(SL1 Reserved)
1074 Dispense1 Bead Shaping Command (bit 2) goSL1BeadShp2
1090 AreaNumberBit2
goSL1AreaNum2
1106 (Reserved)
(SL1 Reserved)
1075 Dispense1 Bead Shaping Command (bit 3) goSL1BeadShp3
1091 AreaNumberBit3
goSL1AreaNum3
1107 (Reserved)
(SL1 Reserved)
1076 Dispense1 Bead Shaping Command (bit 4) goSL1BeadShp4
1092 AreaNumberBit4
goSL1AreaNum4
1108 (Reserved)
(SL1 Reserved)
1077 Dispense1 Bead Shaping Command (bit 5) goSL1BeadShp5
1093 AreaNumberBit5
goSL1AreaNum5
1109 (Reserved)
(SL1 Reserved)
1078 Dispense1 Bead Shaping Command (bit 6) goSL1BeadShp6
1094 (Reserved)
(Reserved)
1110 (Reserved)
(SL1 Reserved)
1079 Dispense1 Bead Shaping Command (bit 7) goSL1BeadShp7
1095 (Reserved)
(Reserved)
1111 (Reserved)
(SL1 Reserved)
1080 Dispense1 Bead Shaping Command (bit 8) goSL1BeadShp8
1096 AreaNumber1Act
doSL1AreaActive
1112 (Reserved)
(SL1 Reserved)
1081 Dispense1 Bead Shaping Command (bit 9) goSL1BeadShp9
1097 1Data_Strobe process data to robot
doSL1DataStrobe
1113 (Reserved)
(SL1 Reserved)
1082 Dispense1 Bead Shaping Command (bit 10) goSL1BeadShp10
1098 (Reserved)
(SL1 Reserved)
1114 (Reserved)
(SL1 Reserved)
1083 Dispense1 Bead Shaping Command (bit 11) goSL1BeadShp11
1099 (Reserved)
(SL1 Reserved)
1115 (Reserved)
(SL1 Reserved)
1084 Dispense1 Bead Shaping Command (bit 12) goSL1BeadShp12
1100 (Reserved)
(SL1 Reserved)
1116 (Reserved)
(SL1 Reserved)
1085 Dispense1 Bead Shaping Command (bit 13) goSL1BeadShp13
1101 (Reserved)
(SL1 Reserved)
1117 (Reserved)
(SL1 Reserved)
1086 Dispense1 Bead Shaping Command (bit 14) goSL1BeadShp14
1102 (Reserved)
(SL1 Reserved)
1118 (Reserved)
(SL1 Reserved)
1087 Dispense1 Bead Shaping Command (bit 15) goSL1BeadShp15
1103 (Reserved)
(SL1 Reserved)
1119 (Reserved)
(SL1 Reserved)
1088 Dispense1 Bead Shaping Command (bit 16) goSL1BeadShp16
1104 (Reserved)
(SL1 Reserved)
1120 (Reserved)
(SL1 Reserved)
GRS4-C
202
202
101
Dispense Controller 1 Inputs / Robot Outputs
(cont’d)
EIP Scanner ‐ Slot 4
Description
DO[#]
EIP Scanner ‐ Slot 4
Description
Signal Name
DO[#]
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
1137
1138
1139
1140
1141
1142
1143
1144
1145
1146
1147
1148
1149
1150
1151
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
(SL1 Reserved)
1136 (Reserved)
(SL1 Reserved)
1152 (Reserved)
(SL1 Reserved)
1121
1122
1123
1124
1125
1126
1127
1128
1129
1130
1131
1132
1133
1134
1135
Signal Name
GRS4-C
203
203
Dispense Controller 2 Inputs / Robot Outputs
EIP Scanner ‐ Slot 5
DO[#]
Description
EIP Scanner ‐ Slot 5
Signal Name
DO[#]
Description
EIP Scanner ‐ Slot 5
Signal Name
DO[#]
Description
Signal Name
1153 Dispense2 Style Bit 1
doSL2StyleBit1
1169 Dispense2 Material Flow Command Bit 1 goSL2MatFlow1
1185 Not @ Purge Position Tooling Fixture doNotATPurgePos
1154 Dispense2 Style Bit 2
doSL2StyleBit2
1170 Dispense2 Material Flow Command Bit 2 goSL2MatFlow2
1186 (Reserved)
1155 Dispense2 Style Bit 4
doSL2StyleBit4
1171 Dispense2 Material Flow Command Bit 3 goSL2MatFlow3
1187 Dispense2 Area Volume Complete
diSL2AreaVolCmp
1156 Dispense2 Style Bit 8
doSL2StyleBit8
1172 Dispense2 Material Flow Command Bit 4 goSL2MatFlow4
1188 Dispense2 Purge
doSL2Purge
(Reserved)
1157 Dispense2 Style Bit 16
doSL2StyleBit16
1173 Dispense2 Material Flow Command Bit 5 goSL2MatFlow5
1189 Dispense2 Shut down Command
doSL2ShutDwnCmd
1158 Dispense2 Style Bit 32
doSL2StyleBit32
1174 Dispense2 Material Flow Command Bit 6 goSL2MatFlow6
1190 Dispense2 Fault Reset
doSL2FaultReset
doSL2RemoteStart
1159 Dispense2 Style Bit 64
doSL2StyleBit64
1175 Dispense2 Material Flow Command Bit 7 goSL2MatFlow7
1191 Dispense2 Remote Start
1160 Dispense2 Style Bit 128
doSL2StyleBit128
1176 Dispense2 Material Flow Command Bit 8 goSL2MatFlow8
1192 (Reserved)for 2k
do2kRepairPosE1
1161 Dispense2 Style Strobe
doSL2StyleStrobe
1177 Dispense2 Material Flow Command Bit 9 goSL2MatFlow9
1193 (Reserved)for 2k
do2kMi1erChgE1
1162 Dispense2 Total Dispense Complete
doSL2TotVolComp
1178 Dispense2 Material Flow Command Bit 10 goSL2MatFlow10
1194 (Reserved)for 2k
do2kPurgePBE1
1163 Dispense2 Gun 1 ON
doSL2Gun1On
1179 Dispense2 Material Flow Command Bit 11 goSL2MatFlow11
1195 (Reserved)for 2k
(Reserved)
1164 Dispense2 Gun 2 ON
doSL2Gun2On
1180 Dispense2 Material Flow Command Bit 12 goSL2MatFlow12
1196 Dispense2 Meter in Re-Fill Station
doSL2StaRefRdy
1165 Dispense2 Gun 3 ON
doSL2Gun3On
1181 Dispense2 Material Flow Command Bit 13 goSL2MatFlow13
1197 Dispense2 Meter in Docked Position doSL2MtrDocked
1166 Dispense2 Gun 4 ON
doSL2Gun4On
1182 Dispense2 Material Flow Command Bit 14 goSL2MatFlow14
1198 (Reserved)
(Reserved)
1167 (Reserved) Swirl Enable
(Reserved)
1183 Dispense2 Material Flow Command Bit 15 goSL2MatFlow15
1199 Dispense2 Circulate Meter
doSL2Circulate
1168 (Reserved) Pre-pressue Trigger
(Reserved)
1184 Dispense2 Material Flow Command Bit 16 goSL2MatFlow16
1200 Dispense2 Fill Meter
doSL2FillMeter
GRS4-C
204
204
102
Dispense Controller 2 Inputs / Robot Outputs
(cont’d)
EIP Scanner ‐ Slot 5
DO[#]
Description
EIP Scanner ‐ Slot 5
Signal Name
1201 Dispense2 Bead Shaping Command (bit 1) goSL2BeadShp1
DO[#]
Description
EIP Scanner ‐ Slot 5
Signal Name
DO[#]
Description
Signal Name
1217 AreaNumberBit1
goSL2AreaNum1
1233 (Reserved)
(SL2 Reserved)
(SL2 Reserved)
1202 Dispense2 Bead Shaping Command (bit 2) goSL2BeadShp2
1218 AreaNumberBit2
goSL2AreaNum2
1234 (Reserved)
1203 Dispense2 Bead Shaping Command (bit 3) goSL2BeadShp3
1219 AreaNumberBit3
goSL2AreaNum3
1235 (Reserved)
(SL2 Reserved)
1204 Dispense2 Bead Shaping Command (bit 4) goSL2BeadShp4
1220 AreaNumberBit4
goSL2AreaNum4
1236 (Reserved)
(SL2 Reserved)
(SL2 Reserved)
1205 Dispense2 Bead Shaping Command (bit 5) goSL2BeadShp5
1221 AreaNumberBit5
goSL2AreaNum5
1237 (Reserved)
1206 Dispense2 Bead Shaping Command (bit 6) goSL2BeadShp6
1222 (Reserved)
(Reserved)
1238 (Reserved)
(SL2 Reserved)
1207 Dispense2 Bead Shaping Command (bit 7) goSL2BeadShp7
1223 (Reserved)
(Reserved)
1239 (Reserved)
(SL2 Reserved)
1208 Dispense2 Bead Shaping Command (bit 8) goSL2BeadShp8
1224 AreaNumber1Act
doSL2AreaActive
1240 (Reserved)
(SL2 Reserved)
1209 Dispense2 Bead Shaping Command (bit 9) goSL2BeadShp9
1225 1Data_Strobe process data to robot
doSL2DataStrobe
1241 (Reserved)
(SL2 Reserved)
1210 Dispense2 Bead Shaping Command (bit 10) goSL2BeadShp10
1226 (Reserved)
(SL2 Reserved)
1242 (Reserved)
(SL2 Reserved)
1211 Dispense2 Bead Shaping Command (bit 11) goSL2BeadShp11
1227 (Reserved)
(SL2 Reserved)
1243 (Reserved)
(SL2 Reserved)
(SL2 Reserved)
1212 Dispense2 Bead Shaping Command (bit 12) goSL2BeadShp12
1228 (Reserved)
(SL2 Reserved)
1244 (Reserved)
1213 Dispense2 Bead Shaping Command (bit 13) goSL2BeadShp13
1229 (Reserved)
(SL2 Reserved)
1245 (Reserved)
(SL2 Reserved)
1214 Dispense2 Bead Shaping Command (bit 14) goSL2BeadShp14
1230 (Reserved)
(SL2 Reserved)
1246 (Reserved)
(SL2 Reserved)
1215 Dispense2 Bead Shaping Command (bit 15) goSL2BeadShp15
1231 (Reserved)
(SL2 Reserved)
1247 (Reserved)
(SL2 Reserved)
1216 Dispense2 Bead Shaping Command (bit 16) goSL2BeadShp16
1232 (Reserved)
(SL2 Reserved)
1248 (Reserved)
(SL2 Reserved)
GRS4-C
205
205
Dispense Controller 2 Inputs / Robot Outputs
(cont’d)
EIP Scanner ‐ Slot 5
Description
DO[#]
EIP Scanner ‐ Slot 5
Description
Signal Name
DO[#]
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
1265
1266
1267
1268
1269
1270
1271
1272
1273
1274
1275
1276
1277
1278
1279
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
(SL2 Reserved)
1264 (Reserved)
(SL2 Reserved)
1280 (Reserved)
(SL2 Reserved)
1249
1250
1251
1252
1253
1254
1255
1256
1257
1258
1259
1260
1261
1262
1263
GRS4-C
Signal Name
206
206
103
Robot Software Requirements
Process Modes
1. The system will be able to toggle between the Process On (wet) mode
and the Process Off (dry) mode. In Process Off mode, all I/O on the
robot-dispense interface will be ignored.
2. In Teach or Isolate the dispense mode will be selectable from the teach
pendant.
3. In Interlock mode the status of the ‘Process X On Request’ input on the
cell interface will dictate the dispense mode. When the ‘Process X On
Request’ bit is set the Process On (wet) mode is selected for the
dispenser.
4. The status of dispense mode will be reflected to the PLC with the
‘Process X Enabled’ output.
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Programming Instructions
Flow On – Seal Start
1. The ‘Flow On’ instruction actuates the dispense applicator and starts the dispensing.
2. When used in conjunction with motion, the robot will move to a specified location
according to the motion parameters and start dispensing:
a. It will turn on the ‘Gun On’ and ‘Material Flow Command’ signals with respect to
the taught point and use anticipation time for the ‘Gun On’ signal.
b. It will turn on the ‘Bead Shaping Command’ signals with respect to the taught
point using the bead shaping anticipation time.
c. It will set pre-pressure time, which defines the relative timing between the analog
‘Material Flow Command’ and the digital ‘Gun On’ signals, when the dispensing
starts.
3. When used independent of the motion, the ‘Flow On’ instruction will turn the dispense
applicator on.
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Programming Instructions
Flow Off – Seal End
1. This instruction stops the dispensing process.
2. When used in conjunction with motion, the robot will move to a specified location
according to the motion parameters and stop dispensing.
a. It will turn off the ‘Gun On’ and ‘Material Flow Command’ signals with respect to
the taught point using gun off anticipation time.
b. It will turn off the ‘Bead Shaping Command’ signals with respect to the taught
point using the bead shaping off anticipation time.
c. It will apply the de-pressure time from the last executed Flow On command, which
defines the relative timing between the analog ‘Material Flow Command’ and the
digital ‘Gun On’ signals, when the dispensing ends.
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Programming Instructions
Begin Process
1.
GRS4-C
The Begin Process contains all pre-application checks of the dispense equipment. It initializes the
dispense process by setting the appropriate Style ID and the Style Strobe bit. At any point during
the sequence, if an incorrect I/O state is detected, the robot generates the appropriate fault. This
is run automatically before entering the dispense process
a. Check for ‘Dispense Ready’. If not detected, perform the ‘Remote Start / Purge’ sequence
b. Check for the ‘No Fault’ high, ‘Volume OK’ low, and ‘In Process’ low. Use the ‘Fault Reset’ if
any incorrect state is detected
c. Ensure the ‘Fault Reset’ bit is low
d. Set the ‘Task OK’ bit low
e. Set the ‘Style ID’ per style table
f. Set the ‘Style Strobe’ bit
g. Wait for the ‘In Process’ input
h. Reset the ‘Style ID’ bits
210
210
105
Programming Instructions
Begin Process (cont'd)
2. The pre-application instruction is called prior to executing the dispense process
routine.
3. The following fault condition will be detected by this instruction. For each fault,
the recovery options ‘Recheck’ and ‘Abort’ will be available.
Major Fault from Dispenser: This fault occurs if the dispenser is ‘Ready’ and a
fault is detected after a ‘Fault Reset’ sequence has been attempted.
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Programming Instructions
Area Start (EQx, AreaNum)
Area Start is a macro that sends the PLC and process controller a specific number for dispensing a process into
32 potential individual areas. This gives the user the ability to check critical area’s with multiple Volume Checks
in the robotic process path. This macro is called in the dispense process path.
The Area Start (EQx, AreaNum) system function:
- Verify the Equipment and Area Number are valid
- Verify tryout mode and or process mode is requested
- Assert to the PLC the area number
- Reset TASK_OK for Process(X)
- Verify the Area Volume / Total Volume are low, signal sequence check
- Enable / Disable the area based on PLC command
Area Enabled = DISP Process <WET>
Area Disabled = DISP Process <DRY>
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106
Programming Instructions
Area Complete (EQx, AreaNum)
This instruction indicates the dispense area is completed and will check the Area Volume OK
-
Verify equipment and area numbers are valid
Verify tryout and process mode requests
Set the doSLXAreaVolComp signal
Wait for diSLXAreaVolOK for up to 200ms
If OK, set TASK_OK = ON, turn off doSLXAreaVolComp, send AREADATA(x) for
process data to the PLC, turn off goSLXAreaNumber to the process controller
If not OK, set TASK_OK = OFF, turn off doSLXAreaVolComp, send AREADATA(x) for
process data to the PLC, turn off goSLXAreaNumber to the process controller
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Programming Instructions
Total Dispense Complete (EQx)
1.
This instruction indicates the total dispense cycle is completed and handles all the post
dispensing handshakes with the dispense controller. It is not associated with any motion
instructions or parameters.
- Verify the equipment number is valid.
- Check for the ’In Process’ bit to be high and the ‘Volume OK’ bit to be low. The robot will
generate a fault if the wrong state is detected on either bit.
- Set the doSLXTotVolComp signal.
- Look for ‘Total Volume OK’ signal or a fault indication from the dispensing equipment.
The maximum wait time is 100 ms.
- If OK, set TASK_OK=ON, turn off doSLXTotVolComp, send TOTALDTA(x) to PLC, clear
the part ID, turn off the style strobe, reset process data sent to PLC.
- The ‘In Process’ bit will be reset when the robot output signals are turned off
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107
Programming Instructions
Total Dispense Complete (EQx) (cont’d)
2.
3.
4.
The ‘Total Dispense Complete’ signal is set upon the completion of the dispense process
routine.
The following fault conditions will be detected by this instruction. For each fault the recovery
options will be available.
a. Program Interrupted while Dispensing: This signal occurs if any external condition causes the
robot motion to stop during the dispensing process.
b. Major Fault from Dispenser: This signal occurs if a fault is detected from the dispenser in
conjunction with a ‘Volume OK’ signal.
c. Dispense Volume Out Of Range: This signal occurs if a ‘Volume OK’ signal is not received
from the dispenser in conjunction with a fault.
d. Dispenser Not Responding: This signal occurs if neither a ‘Volume OK’ nor a ‘Fault’ is
detected from the dispenser.
There will be no remote recovery operation for faults occurring at dispense complete.
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Programming Instructions
Remote Start / Purge
1.
2.
This instruction handles the remote start and purge functionality.
This instruction is called from Utility Style 29 (Process 1) and /or Style 30 (Process 2) to
initiate a remote start and/or purge by the PLC.
a. The robot will set the ‘Remote Start’ output to the dispense controller.
b. The robot will receive the ‘Remote Start In Process’ bit from the dispense controller
within a configurable amount of time or generate a fault.
c. The dispense controller will re-pressurize or re-heat as required then execute the
purge operation per its configuration information.
d. The robot controller will wait until either the ‘Dispense Ready’ or fault indication are
received from the dispense controller. If neither is received within a configurable
amount of time the robot will generate a fault
Note: All purge characteristics (e.g. interval, duration, repetition, metered Vs. non-metered)
will be configured and stored within the dispense controller. A purge will be initiated
remotely from the robot by the ‘Remote Start’ input to the dispense controller.
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108
Programming Instructions
Remote Start / Purge (cont’d)
3. The following fault conditions will be detected by this instruction.
Dispenser Not Responding:
This signal occurs if:
The ‘Remote Start in Process’ signal is not received from the dispense controller
within a specified amount of time after the robot sends the ‘Remote Start’ output,
or the ‘Dispense Ready’ signal is not received within a specified amount of time after
the robot receives the ‘Remote Start in Process’ input.
Major Fault From Dispenser: This signal occurs if the robot receives a fault
indication (‘No Fault’ drops low) during the remote start operation.
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Programming Data
Flow Schedule
All parameters that affect timing will be capable of both positive and
negative timing shifts. Positive values imply triggering before the
taught point, whereas negative values imply triggering after the
taught point
GRS4-C
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109
Flow Schedule
1. Flow type - 2 flow types are supported:
• a. Tool Center Point (TCP) and speed (bead width, volume)
• b. Direct Voltage
2. Flow rate - The units are dictated by the flow type selection.
3. Gun number - Up to 4 guns will be supported.
4. Flow control equipment delay –The time variable applies a time shift to the analog signal with respect to actual tool speed. It does not affect the ‘Gun On’
and ‘Gun Off’ signal trigger timing. It only affects the analog material flow command timing around the corners and applies to all the flow types.
5. Gun on anticipation time - Gun on anticipation time is in respect to the taught point. This variable applies to all digital ‘Gun On’ signals activated when the
gun is turned on.
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Flow Schedule (cont'd)
6. Gun off anticipation time - Gun off anticipation time is in respect to the taught point. This variable applies to all digital ‘Gun
Off’ signals activated when the gun is turned off. The effect is similar to the gun on anticipation time except that it applies to the
gun off point.
7. Pre-pressure time - This parameter determines the relative timing between the analog flow command signal and the digital
gun on signal when the flow is turned on.
8. De-pressure time - This parameter determines the relative timing between the analog flow command signal and the digital
gun off signal when the flow is turned off. The effect of this parameter is similar to the pre-pressure time shown in , except that
it applies to the gun off point.
9. Bead shaping command - This analog signal is used for atomizing air for dispense applications in the Paint Shops or
swirling in the Body Shops.
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110
Flow Schedule (cont'd)
10. Bead shaping on anticipation time - Bead shaping on
anticipation time is in respect to the taught point.
11. Bead shaping off anticipation time - Bead shaping off
anticipation time is in respect to the taught point. The timing is
similar to bead shaping on anticipation time.
GRS4-C
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Style ID Table
A means will be provided to associate a style input from
the PLC with any desired style output to the dispense
controller
Default values will be 1=1, 2=2, etc
GRS4-C
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111
Fault Handling and Recovery
1. Upon the detection of a fault, the robot will perform the following:
• Halt robot motion and process.
• Set the ‘Process # Fault’ signal to the PLC.
• Display and indicate the major fault(s) and recovery options on the teach pendant.
• Log all faults.
2. Upon the detection of an alert, the robot will perform the following:
• Continue execution of motion and process.
• Set the ‘Process # Alert’ signal to the PLC.
• Display and indicate minor fault(s) on the teach pendant.
• Log all alerts.
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Recovery Before Total Dispense Complete
Execution
Faults occurring during the dispense path will not require
intervention until the ‘Total Dispense Complete’ signal is
received
In cases where an interruption of the dispense program
has occurred, the robot will automatically continue with
process off until dispense complete execution
GRS4-C
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224
112
Recovery At Total Dispense Complete
FFR is no longer used for dispense recovery on global 4 robots. Faults
will be evaluated after Total Dispense complete. The following options
will be available from the HMI:
a.
b.
c.
Start Rerun – reruns faulted area. Select and press the DO button
Rerun All – reruns all areas in the process. Select Rerun All, Select Start
Rerun and press the DO button
Accept Part – sets process complete for that process and sends the part
to the next stage. Select and press the DO button
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Exercise 3.3: Dispense Interface
Dispense Interface
Complete the exercise in your book.
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113
Exercise 3.3
Exercise Solutions
GRS4-C
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Exercise 3.3: Dispense Interface: Solutions
1. What is the signal response (two signals) from the
dispense controller to the robot, when
doSLXTotVolComp is turned on by the robot and the
process was completed successfully?
TOTAL Volume OK is set
Dispense in Process is reset
GRS4-C
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228
114
Exercise 3.3: Dispense Interface: Solutions
(cont’d)
2. What signal is set from the robot controller to the
dispense unit to clear a fault?
Fault Reset
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Exercise 3.3: Dispense Interface: Solutions
(cont’d)
3. What is the purpose of the anticipation on the
material flow?
Compensates for delay in dispense equipment and process.
GRS4-C
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230
115
Exercise 3.3: Dispense Interface: Solutions
(cont’d)
4. When a fault or alert is detected, what four things
should the robot do?
For Faults:
• Halt robot motion and process.
• Set the ‘Process # Fault’ signal to the PLC.
• Display and indicate the major fault(s) and recovery options on the teach
pendant.
• Log all faults.
For Alerts:
• Continue execution of motion and process.
• Set the ‘Process # Alert’ signal to the PLC.
• Display and indicate minor fault(s) on the teach pendant.
• Log all alerts.
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Exercise 3.3: Dispense Interface: Solutions
(cont’d)
5. Which signal indicates the robot has been idle too
long and needs to be purged?
Purge Request
GRS4-C
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232
116
Exercise 3.3: Dispense Interface: Solutions
(cont’d)
6. What is the bit name and state of the bit that indicates
that the dispense controller should read the style
group output from the robot?
Style Strobe will be turned on
GRS4-C
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233
Robot Software Requirements
Stud Weld Interface
234
234
117
Robot Inputs - Weld Controller Outputs
1. No Fault: This signal is set to indicate that there are no faults present. When the bit goes
low, the signal indicates a fault from the weld controller (A no-weld indication is not a fault).
The robot will read this signal after the ‘Weld In Progress’ bit goes low.
2. Weld Complete: This signal is normally low and indicates the requested schedule has
been completed and no faults were generated. The robot will read this bit after ‘Weld in
Progress’ bit goes low. The signal remains high until the ‘Initiate Head‘ signal goes low.
3. Weld In Progress: This signal is normally low and goes high to indicate a schedule is
being run. This signal drops low again after a ‘Weld Complete’ signal or a fault is detected.
This signal is a response to an initiate head signal.
GRS4-D
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Robot Inputs - Weld Controller Outputs (cont'd)
4. Head Back: This signal indicates that the stud head is in the retracted position. The head
back signal for all valid stud heads will be checked at the beginning of the process
sequence and prior to robot motion after a stud weld (faulted or not faulted) has been
completed.
5. Weld Ready: This signal indicates the weld controller is in weld mode and ready to weld
in automatic. The robot will check the signal prior to an initiate weld, and it will not review
the signal during the weld. The robot will compare the signal to its output (weld mode) to
confirm that the weld controller is in the correct mode. The status of this bit will be
communicated to the cell controller by the ‘Process X Enabled’ output on the cell interface.
GRS4-D
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118
GRS4-D
Robot Inputs - Weld Controller Outputs (cont'd)
6. Stud Low: This signal indicates that the feeder(s) is low. The ‘Stud Low’ signal is set to activate the ‘Process X
Alert’ signal on the cell controller interface.
7. No Alert: This signal goes low to indicate that one or more stud heads requires preventive maintenance, or that
the stud controller has detected an abnormal condition. The alert signal will not immediately halt or prevent the
welding operation. The ‘No Alert’ signal goes low to activate the ‘Process X Alert’ signal on the cell controller
interface.
8. In Tolerance: This signal goes low at the end of a invalid weld sequence. It indicates that the weld controller has
detected parameters outside programmable limits. The robot will read this bit after ‘Weld In Progress’ bit goes low.
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Robot Outputs - Weld Controller Inputs
1. Initiate Head: This signal is used to start the weld schedule and indicate that the schedule
data bits are valid.
2. Manual Advance Head: The weld controller extends the stud gun when the ‘Manual
Advance Head’ bit is high and returns the gun when the ‘Manual Advance Head’ bit is reset.
3. Schedule Bits (1,2,4,8,16,32): These six bit form a binary number that selects one of the
63 individual weld schedules at the weld controller.
4. Fault Reset: This signal resets the weld controller faults. If the cause of the fault has not
been removed then the fault will be re-sent after the release of the ‘Fault Reset’ signal.
GRS4-D
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238
119
Robot Outputs - Weld Controller Inputs (cont’d)
5. Select Weld Mode: This signal indicates a request of
weld mode to the weld controller.
6. Select Part Mode: This signal specifies the operating
mode of the weld controller when Weld Mode is not
selected.
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Hardware Interlocks
1. Control Stop: The ‘Control Stop’ signal is a 24V signal from the robot indicating motion power is
enabled for the cell. When the signal goes low the stud controller will remove all feeder, head, and
welding power over 50V and remove all motion power within 50ms
2. Feeder Power Interrupt: The feeder power interrupt is a stand-alone interface connector that
interrupts the power to each feeder (and therefore each head) independently. When the external
contacts are open for a given output device, the stud controller will remove all feeder, head, and
welding power over 50V, and all motion power within 50ms for the given output device.
GRS4-D
240
240
120
Stud Weld Controller/ Robot Inputs
EIP Scanner ‐ Slot 6
DI[#]
EIP Scanner ‐ Slot 6
Description
1025 NO Fault Head #1
Signal Name
diST1NoFaultHd1
DI[#]
Description
Weld Complete Head
1041 #4
EIP Scanner ‐ Slot 6
Signal Name
diST1WeldComp4
DI[#]
Description
1057 (Reserved)
Signal Name
(Reserved)
EIP Scanner ‐ Slot 6
DI[#]
Description
Signal Name
1073 (Reserved)
(Reserved)
1026 Weld Complete Head #1 diST1WeldComp1
1042 Weld In Progress #4
diST1InProg4
1058 (Reserved)
(Reserved)
1074 (Reserved)
(Reserved)
1027 Weld In Progress #1
diST1InProg1
1043 Head Back #4
diST1HdBackHd4
1059 (Reserved)
(Reserved)
1075 (Reserved)
(Reserved)
1028 Head Back #1
diST1HdBackHd1
1044 (Reserved)
(Reserved)
1060 (Reserved)
(Reserved)
1076 (Reserved)
(Reserved)
1029 (Reserved)
(Reserved)
1045 (Reserved)
(Reserved)
1061 (Reserved)
(Reserved)
1077 (Reserved)
(Reserved)
1030 NO Fault Head #2
diST1NoFaultHd2
1046 (Reserved)
(Reserved)
1062 (Reserved)
(Reserved)
1078 (Reserved)
(Reserved)
1031 Weld Complete Head #2 diST1WeldComp2
1047 (Reserved)
(Reserved)
1063 (Reserved)
(Reserved)
1079 (Reserved)
(Reserved)
1032 Weld In Progress #2
diST1InProg2
1048 (Reserved)
(Reserved)
1064 (Reserved)
(Reserved)
1080 (Reserved)
(Reserved)
1033 Head Back #2
diST1HdBackHd2
1049 (Reserved)
(Reserved)
1065 (Reserved)
(Reserved)
1081 (Reserved)
(Reserved)
1034 (Reserved)
(Reserved)
1050 Weld Mode On
diST1WeldMode
1066 (Reserved)
(Reserved)
1082 (Reserved)
(Reserved)
1035 NO Fault Head #3
diST1NoFaultHd3
1051 Stud Low
diST1StudLow
1067 (Reserved)
(Reserved)
1083 (Reserved)
(Reserved)
1036 Weld Complete Head #3 diST1WeldComp3
1052 No Alert
diST1NoAlert
1068 (Reserved)
(Reserved)
1084 (Reserved)
(Reserved)
1037 Weld In Progress #3
diST1InProg3
1053 In Tolerance
diST1InTol
1069 (Reserved)
(Reserved)
1085 (Reserved)
(Reserved)
1038 Head Back #3
diST1HdBackHd3
1054 (Reserved)
(Reserved)
1070 (Reserved)
(Reserved)
1086 (Reserved)
(Reserved)
1039 (Reserved)
(Reserved)
1055 (Reserved)
(Reserved)
1071 (Reserved)
(Reserved)
1087 (Reserved)
(Reserved)
1040 NO Fault Head #4
diST1NoFaultHd4
1056 (Reserved)
(Reserved)
1072 (Reserved)
(Reserved)
1088 (Reserved)
(Reserved)
GRS4-D
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Stud Weld Controller/ Robot Outputs
EIP Scanner ‐ Slot 6
DO[#]
Description
1025 Initiate Head #1
EIP Scanner ‐ Slot 6
Signal Name
doST1CycleHd1
DO[#]
Description
1041 (Reserved)
Signal Name
(Reserved)
EIP Scanner ‐ Slot 6
DO[#]
Description
Signal Name
EIP Scanner ‐ Slot 6
DO[#]
Description
Signal Name
1057 (Reserved)
(Reserved)
1073 (Reserved)
(Reserved)
1026 Initiate Head #2
doST1CycleHd2
1042 Reset Fault
doST1FaultRes
1058 (Reserved)
(Reserved)
1074 (Reserved)
(Reserved)
1027 Initiate Head #3
doST1CycleHd3
1043 (Reserved)
(Reserved)
1059 (Reserved)
(Reserved)
1075 (Reserved)
(Reserved)
1028 Initiate Head #4
doST1CycleHd4
1044 Select Weld Mode doST1WeldMode
1060 (Reserved)
(Reserved)
1076 (Reserved)
(Reserved)
1029 (Reserved)
(Reserved)
1045 Select Part Mode doST1PartMode
1061 (Reserved)
(Reserved)
1077 (Reserved)
(Reserved)
1030 Manual Advance Head #1 doST1ManAdvHd1
1046 (Reserved)
(Reserved)
1062 (Reserved)
(Reserved)
1078 (Reserved)
(Reserved)
1031 Manual Advance Head #2 doST1ManAdvHd2
1047 (Reserved)
(Reserved)
1063 (Reserved)
(Reserved)
1079 (Reserved)
(Reserved)
1032 Manual Advance Head #3 doST1ManAdvHd3
1048 (Reserved)
(Reserved)
1064 (Reserved)
(Reserved)
1080 (Reserved)
(Reserved)
1033 Manual Advance Head #4 doST1ManAdvHd4
1049 (Reserved)
(Reserved)
1065 (Reserved)
(Reserved)
1081 (Reserved)
(Reserved)
1034 (Reserved)
(Reserved)
1050 (Reserved)
(Reserved)
1066 (Reserved)
(Reserved)
1082 (Reserved)
(Reserved)
1035 Schedule Bit 1
doST1Sched1
1051 (Reserved)
(Reserved)
1067 (Reserved)
(Reserved)
1083 (Reserved)
(Reserved)
1036 Schedule Bit 2
doST1Sched2
1052 (Reserved)
(Reserved)
1068 (Reserved)
(Reserved)
1084 (Reserved)
(Reserved)
1037 Schedule Bit 4
doST1Sched4
1053 (Reserved)
(Reserved)
1069 (Reserved)
(Reserved)
1085 (Reserved)
(Reserved)
1038 Schedule Bit 8
doST1Sched8
1054 (Reserved)
(Reserved)
1070 (Reserved)
(Reserved)
1086 (Reserved)
(Reserved)
1039 Schedule Bit 16
doST1Sched16
1055 (Reserved)
(Reserved)
1071 (Reserved)
(Reserved)
1087 (Reserved)
(Reserved)
1040 Schedule Bit 32
doST1Sched32
1056 (Reserved)
(Reserved)
1072 (Reserved)
(Reserved)
1088 (Reserved)
(Reserved)
GRS4-D
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Process Modes
Robot / PLC Interface
Robot / Stud Weld Interface
Weld Control Operation
Process
On
Request
(robot
input)
Tryout
Mode
Request
(robot
input)
Process
Enabled
(robot
output)
Select
Weld
Mode
(robot
output)
Select Part
Mode
(robot
Output)
Weld
Ready
(robot
input)
High
Low
High
High
High
High
Full automatic weld mode.
High
High
Low
High
Low
Low
Invalid state.
Low
Low
Low
Low
High
Low
Dry Cycle With Part: Weld control
cycles the stud gun, verifies stud
on work, performs all I/O
handshaking, and performs all
weld functions with the exception
of passing current.
Low
High
Low
Low
Low
Low
Dry Cycle Without Part: Weld
control cycles the stud gun and
performs all I/O handshaking.
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Process Modes
1. The system will be able to select between the Weld/No Weld and Part/No Part process modes as described in above.
2. In Teach or Isolate the process modes will be selectable from the teach pendant. In Interlock the status of the ‘Process X On
Request’ and ‘Tryout Mode Request’ inputs on the cell interface will dictate the process mode.
3. The status of the ‘Weld Ready’ signal from the weld controller will be sent to cell controller using the ‘Process X Enabled’
output.
4. In No Weld mode, the system will be able to select between Stroke and No Stroke modes. In No Stroke, all I/O on the stud
controller interface except ‘Head Back’ will be ignored. No Stroke will be used in interlock mode during Fast Fault Recovery.
GRS4-D
244
244
122
Programming Instructions
Stud Weld
1. This instruction will move the robot to a specified position and initiate a
stud weld.
2. Motion parameters for this instruction will have the ability to be edited
according to GM GRS-1, Technical Specifications for Production Robots.
The termination type for this command will always be “fine.”
3. The following parameters will be available:
a. Head / Head Set (if hot backup configured) selection
b. Weld schedule
GRS4-D
245
245
Programming Instructions (cont'd)
4. The stud weld instruction will perform the interface handshaking.
a. Set the weld schedule.
b. Initiate the weld by setting the appropriate ‘Initiate Head’ signal on.
c. Wait for the appropriate ‘Weld In Progress’ signal. If not received within a
configurable timeout, perform the error recovery routine.
d. Wait for the appropriate ‘Weld In Progress’ signal to drop low.
e. Read the status of ‘Weld Complete’, ‘No Fault’, and ‘In Tolerance’ signals.
5. When hot backup is used, the robot will determine which head (stud
welder channel) is active and fire the appropriate ‘Initiate Head’ signal.
For the carried process, the identification is based on tool ID from the tool
changer interface. For the pedestal process, the ID is based on the ‘Gun
Ready’ signal from the cell interface.
GRS4-D
246
246
123
Manual Functions
Manual Stud Weld
– This feature allows the operator to select a stud head and
manually initiate a weld sequence
– In Teach or Isolate the function will allow the user to select a
weld schedule. In Interlock, the function will not manipulate the
schedule outputs or any head that is not currently in the
backup position
GRS4-D
247
247
Fault Handling and Recovery
Out of Tolerance Handling
If Out of Tolerance is detected at the end of a weld (‘In Tolerance’
bit is low), the cell interface ‘Process X Out of Tolerance’ signal
will be set high until the beginning of the next style sequence
GRS4-D
248
248
124
Fault Handling and Recovery
Head Fault Recovery
On a head fault or timeout the following fault recovery
options will be supported:
1. Retry – The Retry selection will drop the ‘Initiate Head,’ signal, pulse the
‘Fault Reset’ signal and initiate a new weld cycle.
2. Skip – The Skip selection will drop ‘Initiate Head’ signal, pulse ‘Fault
Reset’ signal, drop ‘Task OK’ signal and move to the next stud location.
3. FFR – See the following section.
4. Abort – The Abort will cancel any user program execution, robot motion, or
process execution. No remote recovery capability will be provided for this
type of fault.
GRS4-D
249
249
Fault Handling and Recovery
Fast Fault Recovery Without Hot Backup
Prior to re-running the process cycle, the following process
specific recovery options will be available:
1. Continue Last – resume by placing stud at the point the fault has occurred.
2. Continue Next – resume by placing stud at the next point following the one
where the fault has occurred, with ‘Task OK’ signal low.
3. Abort – cancel any user program execution, robot motion, or process
execution.
GRS4-D
250
250
125
FFR with Carried Process, No Hot Backup
GRS4-D
251
251
FFR with Pedestal Process, No Hot Backup
GRS4-D
252
252
126
FFR with Carried Process, With Hot Backup
GRS4-D
253
253
FFR with Pedestal Process with Hot Backup
GRS4-D
254
254
127
Robot Software Requirements
Flow Drill Screw and Self Piercing Rivets
255
255
Flow Drill Screw Outputs – Robot Inputs
EIP Scanner ‐ Slot 11
DI[#]
Description
Spindle in Home
1025 Position
EIP Scanner ‐ Slot 11
Signal Name
diFDS1SpindHome
DI[#]
Description
EIP Scanner ‐ Slot 11
Signal Name
1041 FDS1 Error Code Bit9 diFDS1ErrCodeB9
DI[#]
1057
Description
(Reserved)
Signal Name
(Reserved)
EIP Scanner ‐ Slot 11
DI[#]
1073
Description
(Reserved)
Signal Name
(Reserved)
1026 System OK
diFDS1SysOK
1042 FDS1 Error Code Bit10 diFDS1ErrCodeB10
1058
(Reserved)
(Reserved)
1074
FDS1 Last Step Bit1 diFDS1LastStepB1
1027 Ready to Start
diFDS1Ready
1043 FDS1 Error Code Bit11 diFDS1ErrCodeB11
1059
(Reserved)
(Reserved)
1075
FDS1 Last Step Bit2 diFDS1LastStepB2
1028 OK Signal
diFDS1OK
1044 FDS1 Error Code Bit12 diFDS1ErrCodeB12
1060
(Reserved)
(Reserved)
1076
FDS1 Last Step Bit3 diFDS1LastStepB3
1029 NOK Signal
diFDS1NOK
1045 FDS1 Error Code Bit13 diFDS1ErrCodeB13
1061
(Reserved)
(Reserved)
1077
FDS1 Last Step Bit4 diFDS1LastStepB4
1030 Level Control
diFDS1LevelCntrl
1046 FDS1 Error Code Bit14 diFDS1ErrCodeB14
1062
(Reserved)
(Reserved)
1078
FDS1 Last Step Bit5 diFDS1LastStepB5
1031 Part Ejected
FDS1 Maintenace
1032 Request
diFDS1PartEjectd
1047 FDS1 Error Code Bit15 diFDS1ErrCodeB15
1063
(Reserved)
(Reserved)
1079
FDS1 Last Step Bit6 diFDS1LastStepB6
diFDS1MaintReq
1048 FDS1 Error Code Bit16 diFDS1ErrCodeB16
1064
(Reserved)
(Reserved)
1080
FDS1 Last Step Bit7 diFDS1LastStepB7
1033 FDS1 Error Code Bit1
diFDS1ErrCodeB1
1049 (Reserved)
(Reserved)
1065
(Reserved)
(Reserved)
1081
FDS1 Last Step Bit8 diFDS1LastStepB8
1034 FDS1 Error Code Bit2
diFDS1ErrCodeB2
1050 (Reserved)
(Reserved)
1066
(Reserved)
(Reserved)
1082
(Reserved)
(Reserved)
1035 FDS1 Error Code Bit3
diFDS1ErrCodeB3
1051 (Reserved)
(Reserved)
1067
(Reserved)
(Reserved)
1083
(Reserved)
(Reserved)
1036 FDS1 Error Code Bit4
diFDS1ErrCodeB4
1052 (Reserved)
(Reserved)
1068
(Reserved)
(Reserved)
1084
(Reserved)
(Reserved)
1037 FDS1 Error Code Bit5
diFDS1ErrCodeB5
1053 (Reserved)
(Reserved)
1069
(Reserved)
(Reserved)
1085
(Reserved)
(Reserved)
1038 FDS1 Error Code Bit6
diFDS1ErrCodeB6
1054 (Reserved)
(Reserved)
1070
(Reserved)
(Reserved)
1086
(Reserved)
(Reserved)
1039 FDS1 Error Code Bit7
diFDS1ErrCodeB7
1055 (Reserved)
(Reserved)
1071
(Reserved)
(Reserved)
1087
(Reserved)
(Reserved)
1040 FDS1 Error Code Bit8
diFDS1ErrCodeB8
1056 (Reserved)
(Reserved)
1072
(Reserved)
(Reserved)
1088
(Reserved)
(Reserved)
GRS4
256
256
128
Flow Drill Screw Inputs – Robot Outputs
EIP Scanner ‐ Slot 11
DO[#]
EIP Scanner ‐ Slot 11
Description
Signal Name
doFDS1Auto
1041
(Reserved) (Reserved)
1057
(Reserved)
(Reserved)
1073
(Reserved)
(Reserved)
1026 Error Acknowledge
doFDS1ErrorAck
1042
(Reserved) (Reserved)
1058
(Reserved)
(Reserved)
1074
(Reserved)
(Reserved)
1027 Start Signal
doFDS1StartSignal
1043
(Reserved) (Reserved)
1059
(Reserved)
(Reserved)
1075
(Reserved)
(Reserved)
1028 Start Nullification
doFDS1StartNull
1044
(Reserved) (Reserved)
1060
(Reserved)
(Reserved)
1076
(Reserved)
(Reserved)
1029 Simulation Mode
doFDS1DryCycle
1045
(Reserved) (Reserved)
1061
(Reserved)
(Reserved)
1077
(Reserved)
(Reserved)
1030 Change Direction of Motor Rotation doFDS1ChngMtrRot
1046
(Reserved) (Reserved)
1062
(Reserved)
(Reserved)
1078
(Reserved)
(Reserved)
1031 Start Part Eject
1047
(Reserved) (Reserved)
1063
(Reserved)
(Reserved)
1079
(Reserved)
(Reserved)
doFDS1PartEject
DO[#]
Description
EIP Scanner ‐ Slot 11
Description
1025 Automatic Signal
Signal Name
EIP Scanner ‐ Slot 11
DO[#]
Signal Name
DO[#]
Description
Signal Name
1032 Move Blank Holder in Work Position doFDS1MvWorkPos
1048
(Reserved) (Reserved)
1064
(Reserved)
(Reserved)
1080
(Reserved)
(Reserved)
1033 Code Number Bit 1
doFDS1CodeBit1
1049
(Reserved) (Reserved)
1065
(Reserved)
(Reserved)
1081
(Reserved)
(Reserved)
1034 Code Number Bit 2
doFDS1CodeBit2
1050
(Reserved) (Reserved)
1066
(Reserved)
(Reserved)
1082
(Reserved)
(Reserved)
1035 Code Number Bit 3
doFDS1CodeBit3
1051
(Reserved) (Reserved)
1067
(Reserved)
(Reserved)
1083
(Reserved)
(Reserved)
1036 Code Number Bit 4
doFDS1CodeBit4
1052
(Reserved) (Reserved)
1068
(Reserved)
(Reserved)
1084
(Reserved)
(Reserved)
1037 Code Number Bit 5
doFDS1CodeBit5
1053
(Reserved) (Reserved)
1069
(Reserved)
(Reserved)
1085
(Reserved)
(Reserved)
1038 Code Number Bit 6
doFDS1CodeBit6
1054
(Reserved) (Reserved)
1070
(Reserved)
(Reserved)
1086
(Reserved)
(Reserved)
1039 Code Number Bit 7
doFDS1CodeBit7
1055
(Reserved) (Reserved)
1071
(Reserved)
(Reserved)
1087
(Reserved)
(Reserved)
1040 Code Number Bit 8
doFDS1CodeBit8
1056
(Reserved) (Reserved)
1072
(Reserved)
(Reserved)
1088
(Reserved)
(Reserved)
257
GRS4
257
Self Piercing Rivets Outputs – Robot Inputs
EIP Scanner ‐ Slot 9
DI[#]
Description
EIP Scanner ‐ Slot 9
Signal Name
DI[#]
Description
EIP Scanner ‐ Slot 9
Signal Name
DI[#]
Description
(Reserved)
Signal Name
(Reserved)
EIP Scanner ‐ Slot 9
DI[#]
1073
Description
(Reserved)
Signal Name
1025 Ready TO Cycle
diSPR1RdyToCycle
1041 (Reserved)
(Reserved)
1057
(Reserved)
1026 In Cycle
diSPR1InCycle
1042 Auto Mode Selecter
diSPR1AutoMode
1058
(Reserved)
(Reserved)
1074
(Reserved)
(Reserved)
1027 Finished
diSPR1Finished
1043 Punch Maintenance Request diSPR1PunchMtn
1059
(Reserved)
(Reserved)
1075
(Reserved)
(Reserved)
1028 Fault
diSPR1Faulted
1060
(Reserved)
(Reserved)
1076
(Reserved)
(Reserved)
diSPR1RivMonON
1044 Die Maintenance Request
Cleaning Maintenance
1045 Request
diSPR1DieMtn
1029 RivMon ON
diSPR1CleanMtn
1061
(Reserved)
(Reserved)
1077
(Reserved)
(Reserved)
1030 Tool Off
diSPR1ToolOff
1046 Million Cycle PM Request
diSPR1_1M_CycMtn
1062
(Reserved)
(Reserved)
1078
(Reserved)
(Reserved)
1031 Rivets Low
diSPR1RivetsLow
1047 Alert
diSPR1Alert
1063
(Reserved)
(Reserved)
1079
(Reserved)
(Reserved)
1032 Tool Home
diSPR1ToolHome
1048 Heartbeat
diSPR1Heartbeat
1064
(Reserved)
(Reserved)
1080
(Reserved)
(Reserved)
1033 Tool Open
diSPR1ToolOpen
1049 FaultCodeBit1
diSPR1FaultBit1
1065
(Reserved)
(Reserved)
1081
(Reserved)
(Reserved)
1034 Rivet Set
diSPR1RivetSet
1050 FaultCodeBit2
diSPR1FaultBit2
1066
(Reserved)
(Reserved)
1082
(Reserved)
(Reserved)
1035 (Reserved)
(Reserved)
1051 FaultCodeBit4
diSPR1FaultBit4
1067
(Reserved)
(Reserved)
1083
(Reserved)
(Reserved)
1036 (Reserved)
(Reserved)
(Reserved)
1052 FaultCodeBit8
diSPR1FaultBit8
1068
(Reserved)
(Reserved)
1084
(Reserved)
1037 Fault - Before Riveting diSPR1BfrRivetFlt
1053 FaultCodeBit16
diSPR1FaultBit16
1069
(Reserved)
(Reserved)
1085
(Reserved)
(Reserved)
1038 Fault - During Riveting diSPR1DurRivetFlt
1054 FaultCodeBit32
diSPR1FaultBit32
1070
(Reserved)
(Reserved)
1086
(Reserved)
(Reserved)
1039 Fault - After Riveting
diSPR1AftRivetFlt
1055 FaultCodeBit64
diSPR1FaultBit64
1071
(Reserved)
(Reserved)
1087
(Reserved)
(Reserved)
1040 Fault - System
diSPR1SystemFlt
1056 FaultCodeBit128
diSPR1FaultBit128
1072
(Reserved)
(Reserved)
1088
(Reserved)
(Reserved)
GRS4
258
258
129
Self Piercing Rivets Inputs – Robot Outputs
EIP Scanner ‐ Slot 9
DO[#]
Description
1025 Tool Select Bit1
Signal Name
doSPR1ToolSelct1
EIP Scanner ‐ Slot 9
DO[#]
Description
1041 Dry Cycle
EIP Scanner ‐ Slot 9
Signal Name
DO[#]
doSPR1DryCycle
1057
Description
(Reserved)
Signal Name
(Reserved)
EIP Scanner ‐ Slot 9
DO[#]
1073
Description
(Reserved)
Signal Name
(Reserved)
1026 Tool Select Bit2
doSPR1ToolSelct2
1042 No Home Allowed
doSPR1NoHmAlowed
1058
(Reserved)
(Reserved)
1074
(Reserved)
(Reserved)
1027 Tool Select Bit4
doSPR1ToolSelct4
1043 Tool Moved
doSPR1ToolMoved
1059
(Reserved)
(Reserved)
1075
(Reserved)
(Reserved)
1028 Tool Select Bit8
(Reserved)
doSPR1ToolSelct8
1044 EqualizerBit1
doSPR1Equalizer1
1060
(Reserved)
(Reserved)
1076
(Reserved)
1029 Manual Slow Close doSPR1SlowClose
1045 EqualizerBit2
doSPR1Equalizer2
1061
(Reserved)
(Reserved)
1077
(Reserved)
(Reserved)
1030 Manual Slow Open doSPR1SlowOpen
1046 No Man Cycle
doSPR1NoManCycle
1062
(Reserved)
(Reserved)
1078
(Reserved)
(Reserved)
1031 Gun Opening Bit1 doSPR1GunOpen1
1047 (Reserved)
(Reserved)
1063
(Reserved)
(Reserved)
1079
(Reserved)
(Reserved)
1032 Gun Opening Bit2 doSPR1GunOpen2
1048 Heartbeat
doSPR1Heartbeat
1064
(Reserved)
(Reserved)
1080
(Reserved)
(Reserved)
1033 (Reserved)
(Reserved)
1049 JointNumber1
doSPR1JntNum1
1065
(Reserved)
(Reserved)
1081
(Reserved)
(Reserved)
1034 (Reserved)
(Reserved)
1050 JointNumber2
doSPR1JntNum2
1066
(Reserved)
(Reserved)
1082
(Reserved)
(Reserved)
1035 Cycle Tool
doSPR1CycleTool
1051 JointNumber4
doSPR1JntNum4
1067
(Reserved)
(Reserved)
1083
(Reserved)
(Reserved)
1036 Goto Opening
doSPR1GotoOpn
1052 JointNumber8
doSPR1JntNum8
1068
(Reserved)
(Reserved)
1084
(Reserved)
(Reserved)
1037 (Reserved)
(Reserved)
1053 JointNumber16
doSPR1JntNum16
1069
(Reserved)
(Reserved)
1085
(Reserved)
(Reserved)
1038 Cut Tape
doSPR1Cut Tape
1054 JointNumber32
doSPR1JntNum32
1070
(Reserved)
(Reserved)
1086
(Reserved)
(Reserved)
1039 Fault Acknowledge doSPR1FltAck
1055 JointNumber64
doSPR1JntNum64
1071
(Reserved)
(Reserved)
1087
(Reserved)
(Reserved)
1040 (Reserved)
1056 JointNumber128
doSPR1JntNum128
1072
(Reserved)
(Reserved)
1088
(Reserved)
(Reserved)
(Reserved)
259
GRS4
259
Robot Software Requirements
Material Handling Interface
260
260
130
Material Handling Configuration Items
The following options will be configurable for material handling robots:
1. Specify the size of the input module
2. Select if a vacuum pump is being used
3. Select if the vacuum valves are being used
a. Specify the number of valves
b. Specify if vacuum feedback is available
4. Select if the cylinder valves are used
a. Specify the number of valves
b. Specify which cylinders (2-position devices) are controlled by which
valve
c. Specify if cylinder position feedback is available
GRS4-E
261
261
MH Valves Setup
MH Valves are
used on FANUC
Robots to
associate clamps
and part presents
with valves.
Valve 1 – Common - Clamps 1-4 and PP 1-2
Valve 2 – Style 1 Specific – Clamp 5 and PP 3
Valve 3 – Style 2 Specific – Clamp 6 and PP 4
C
5
PP3
C
1
C
2
PP1
C
3
GRS4
PP4
C
6
PP2
C
4
262
262
131
MH Valves Setup (cont’d)
Press MENU – 6: Setup – MH Valves
To setup the valves:
Select the tool to setup and press F2 Detail
Select the valve number and press F2 Detail
263
GRS4
263
MH Valves Setup (cont’d)
•
•
•
Enter a name for the valve – VALVE 1
Choose the Valve Type – Clamp
Set the number of clamps – 4
Choose to check the open and closed states and
set timeout values – YES, 750ms
•
Choose the number of part presents – 2
Set Continuous Checking – NO
•
Toggle Retry Enabled (Grip or Release) – YES
– allows the auto retry option for that valve
and sets the number of retries
Auto Retry (Grip or Release) – 2
•
GRS4
Cancel/Recover Option (Grip or Release) –
YES – allows the Cancel/Recover option for
the valve gripping or releasing
Make Sure to Press F3 APPLY
when Finished
264
264
132
MH Valves Setup (cont’d)
•
•
Press NEXT and Choose Signals to setup input
numbers for clamps, part presents, and
vacuums. Valve outputs can also be set. Press
F2 DETAIL to bring up the association screen.
The association screen ties an input or output
to a signal description.
For example, di801PH01PX1 is the clamp open
cylindicator for part holder 1 that is tied to DI[801]
265
GRS4
265
MH Valves Setup (cont’d)
Press PREV to return to the Valve Setup screen. Scroll to No of Clamps and
press F5 Config.
Highlight the input signal for clamp one and press F4 [CHOICE] to choose
what input the clamp open signal is tied to.
The clamp closed should automatically populate.
Continue until all clamp inputs are defined
Do the same for part presents
Press F3 IN/OUT to set the valve outputs
Repeat the process for the remaining valves to be configured
GRS4
266
266
133
MH Valves Setup (cont’d)
If vacuum is being used, choose vacuum on the
valve setup screen
• Enter the name for the valve – VALVE4
• Choose the Valve Type – Vacuum
–
–
–
–
•
Set the number of vacuum sensor – 1
Set if there is Vac Feedback, how long to delay before
checking and if the check is continuous
Set the Max Feedback Delay
Set the Blow off time
Set the number of part present switches
–
Set if the part presents are continuously monitored
Make Sure to Press F3 APPLY
when Finished
267
GRS4
267
Fault Handling
The following requirements apply to both
Material Handling and Tool Changing:
• A fault will be generated whenever an expected input state
is not detected within a configurable amount of time.
• Faults will be indicated to the cell controller using the
‘Material Handling Fault’ output.
GRS4-E
268
268
134
MH Recovery
Can recover from TP and HMI
–
–
–
–
Check I/O Again – recheck signal, no movement
Disable Alarm: 20 Cycles
Disable Alarm: 1 Cycle
Toggle Gripper and Retry – toggles states and rechecks
– Cancel and Recover – will un-grip and recover if
gripping or will grip and recover if un-gripping
269
GRS4
269
Material Handling Input Block 1-4 / Robot Inputs
DI[#]
MH Input Block 1
EIP Scanner ‐ Slot 34
Description
Signal Name
DI[#]
MH Input Block 2
EIP Scanner ‐ Slot 35
Description
Signal Name
DI[#]
MH Input Block 3
EIP Scanner ‐ Slot 36
Description
Signal Name
801
Cylinder 01 PX1 di801PH01PX1
817
Cylinder 07 PX1 di817PH07PX1
833
Cylinder 13 PX1 di833PH13PX1
802
Cylinder 01 PX2 di802PH01PX2
818
Cylinder 07 PX2 di818PH07PX2
834
Cylinder 13 PX2 di834PH13PX2
803
Cylinder 02 PX1 di803PH02PX1
819
Cylinder 08 PX1 di819PH08PX1
835
Cylinder 14 PX1 di835PH14PX1
804
Cylinder 02 PX2 di804PH02PX2
820
Cylinder 08 PX2 di820PH08PX2
836
Cylinder 14 PX2 di836PH14PX2
805
Cylinder 03 PX1 di805PH03PX1
821
Cylinder 09PX1
d821PH09PX1
837
Cylinder 15 PX1 di837PH15PX1
806
Cylinder 03 PX2 di806PH03PX2
822
Cylinder 09PX2
di822PH09PX2
838
Cylinder 15 PX2 di838PH15PX2
807
Cylinder 04 PX1 di807PH04PX1
823
Cylinder 10 PX1 di823PH10PX1
839
Cylinder 16 PX1 di839PH16PX1
808
Cylinder 04 PX2 di808PH04PX2
824
Cylinder 10 PX2 di824PH10PX2
840
Cylinder 16 PX2 di840PH16PX2
809
Cylinder 05 PX1 di809PH05PX1
825
Cylinder 11 PX1 di825PH11PX1
841
Cylinder 17 PX1 di841PH17PX1
810
Cylinder 05 PX2 di810PH05PX2
826
Cylinder 11 PX2 di826PH11PX2
842
Cylinder 17 PX2 di842PH17PX2
811
Cylinder 06 PX1 di811PH06PX1
827
Cylinder 12 PX1 di827PH12PX1
843
Cylinder 18 PX1 di843PH18PX1
812
Cylinder 06 PX2 di812PH06PX2
828
Cylinder 12 PX2 di828PH12PX2
844
Cylinder 18 PX2 di844PH18PX2
813
Part Present 01
di813PartPres01
829
Part Present 05
di829PartPres05
845
Part Present 09
di845PartPres09
814
Part Present 02
di814PartPres02
830
Part Present 06
di830PartPres06
846
Part Present 10
di846PartPres10
815
Part Present 03
di815PartPres03
831
Part Present 07
di831PartPres07
847
Part Present 11
di847PartPres11
816
Part Present 04
di816PartPres04
832
Part Present 08
di832PartPres08
848
Part Present 12
di848PartPres12
GRS4-E
MH Input Block 4
EIP Scanner ‐ Slot 37
DI[#]
Description
Signal Name
849 Cylinder 19 PX1 di849PH19PX1
850 Cylinder 19 PX2 di850PH19PX2
851 Cylinder 20 PX1 di851PH20PX1
852 Cylinder 20 PX2 di852PH20PX2
853 Cylinder 21 PX1 di853PH21PX1
854 Cylinder 21 PX2 di854PH21PX2
855 Cylinder 22 PX1 di855PH22PX1
856 Cylinder 22 PX2 di856PH22PX2
857 Cylinder 23 PX1 di857PH23PX1
858 Cylinder 23 PX2 di858PH23PX2
859 Cylinder 24 PX1 di859PH24PX1
860 Cylinder 24 PX2 di860PH24PX2
861 Part Present 13 di861PartPres13
862 Part Present 14 di862PartPres14
863 Part Present 15 di863PartPres15
864 Part Present 16 di864PartPres16
270
270
135
Material Handling Vacuum Pump 1-2 /
Robot Inputs
MH Vacuum Pump 1
MH Vacuum Pump 2
EIP Scanner ‐ Slot 29
DI[#]
Description
EIP Scanner ‐ Slot 30
Signal Name
DI[#]
Description
Signal Name
865
VP Vacuum Made 1
di865VPVacMade1
873
VP Vacuum Made 3
866
VP Vacuum Made 2
di866VPVacMade2
di873VPVacMade3
874
VP Vacuum Made 4
di874VPVacMade4
867
(Reserved)
(Reserved)
875
(Reserved)
(Reserved)
868
(Reserved)
(Reserved)
876
(Reserved)
(Reserved)
869
(Reserved)
(Reserved)
877
(Reserved)
(Reserved)
870
(Reserved)
(Reserved)
878
(Reserved)
(Reserved)
871
(Reserved)
(Reserved)
879
(Reserved)
(Reserved)
872
(Reserved)
(Reserved)
880
(Reserved)
(Reserved)
GRS4-E
271
271
Material Handling Valve Block 1-3 / Robot
Outputs
MH Valve Block 1
EIP Scanner ‐ Slot 31
Description
DO[#]
Signal Name
809
Valve 5 to A Position / Vacuum 5 On
810
Valve 5 to B Position / Vacuum 5 Blow-Off
do801Valve01T
oA
do802Valve01T
oB
do803Valve02T
oA
do804Valve02T
oB
do805Valve03T
oA
do806Valve03T
oB
do807Valve04T
oA
do808Valve04T
oB
do809Valve05T
oA
do810Valve05T
oB
811
(Reserved)
812
(Reserved)
813
801
Valve 1 to A Position / Vacuum 1 On
802
Valve 1 to B Position / Vacuum 1 Blow-Off
803
Valve 2 to A Position / Vacuum 2 On
804
Valve 2 to B Position / Vacuum 2 Blow-Off
805
Valve 3to A Position / Vacuum 3 On
806
Valve 3 to B Position / Vacuum 3 Blow-Off
807
Valve 4 to A Position / Vacuum 4 On
808
Valve 4 to B Position / Vacuum 4 Blow-Off
MH Valve Block 2
EIP Scanner ‐ Slot 32
Description
DO[#]
Signal Name
do817Valve06ToA
DO[#]
MH Valve Block 3
EIP Scanner ‐ Slot 33
Description
Valve 6 to A Position / Vacuum 1 On
818
Valve 6 to B Position / Vacuum 1 Blow-Off do818Valve06ToB
834 Valve 11 to B Position / Vacuum 1 Blow-Off do834Valve11ToB
819
Valve 7 to A Position / Vacuum 2 On
835 Valve 12 to A Position / Vacuum 2 On
820
Valve 7 to B Position / Vacuum 2 Blow-Off do820Valve07ToB
836 Valve 12 to B Position / Vacuum 2 Blow-Off do836Valve12ToB
821
Valve 8 to A Position / Vacuum 3 On
837 Valve 13 to A Position / Vacuum 3 On
822
Valve 8 to B Position / Vacuum 3 Blow-Off do822Valve08ToB
838 Valve 13 to B Position / Vacuum 3 Blow-Off do838Valve13ToB
823
Valve 9 to A Position / Vacuum 4 On
839 Valve 14 to A Position / Vacuum 4 On
824
Valve 9 to B Position / Vacuum 4 Blow-Off do824Valve09ToB
840 Valve 14 to B Position / Vacuum 4 Blow-Off do840Valve14ToB
841 Valve 15 to A Position / Vacuum 5 On
do819Valve07ToA
do821Valve08ToA
do823Valve09ToA
do833Valve11ToA
do835Valve12ToA
do837Valve13ToA
do839Valve14ToA
825
Valve 10 to A Position / Vacuum 5 On
826
Valve 10 to B Position / Vacuum 5 Blow-Off do826Valve10ToB
842 Valve 15 to B Position / Vacuum 5 Blow-Off do842Valve15ToB
(Reserved)
827
(Reserved)
(Reserved)
843 (Reserved)
(Reserved)
(Reserved)
828
(Reserved)
(Reserved)
844 (Reserved)
(Reserved)
(Reserved)
(Reserved)
829
(Reserved)
(Reserved)
845 (Reserved)
(Reserved)
814
(Reserved)
(Reserved)
830
(Reserved)
(Reserved)
846 (Reserved)
(Reserved)
815
(Reserved)
(Reserved)
831
(Reserved)
(Reserved)
847 (Reserved)
(Reserved)
816
(Reserved)
(Reserved)
832
(Reserved)
(Reserved)
848 (Reserved)
(Reserved)
GRS4-E
do825Valve10ToA
833 Valve 11 to A Position / Vacuum 1 On
Signal Name
817
do841Valve15ToA
272
272
136
Material Handling Vacuum Pump 1-2 / Robot
Outputs
MH Vacuum Pump 1
MH Vacuum Pump 2
EIP Scanner ‐ Slot 29
DO[#]
Description
EIP Scanner ‐ Slot 30
Signal Name
DO[#]
Description
Signal Name
865
Vacuum 1 On
do865Vacuum1on
873
Vacuum 3 On
do873Vacuum3on
866
Vacuum 1 Blow-Off
do866Vac1BlowOn
874
Vacuum 3 Blow-Off
do874Vac3BlowOn
867
Vacuum 2 On
do867Vacuum2on
875
Vacuum 4 On
do875Vacuum4on
868
Vacuum 2 Blow-Off
do868Vac2BlowOn
876
Vacuum 4 Blow-Off
do876Vac4BlowOn
869
(Reserved)
(Reserved)
877
Reserved)
(Reserved)
870
(Reserved)
(Reserved)
878
Reserved)
(Reserved)
871
(Reserved)
(Reserved)
879
Reserved)
(Reserved)
872
(Reserved)
(Reserved)
880
Reserved)
(Reserved)
GRS4-E
273
273
Material Handling Robot Software Requirements
Tryout Mode
1. The system will be able to change between Part and No Part mode.
2. In Teach or Isolate, the Part/No Part mode will be selectable from the teach pendant.
3. In Interlock the ‘Tryout Mode Request’ bit on the cell interface will determine Part/No Part mode.
Selecting ‘Tryout Mode’ will select No Part mode.
4. The status of Part/No Part Mode will be sent to the cell controller using the ‘Tryout Mode’ output.
GRS4-E
274
274
137
Programming Instructions -Cylinders
Prepare To Pickup
This instruction verifies that all cylinders of the selected
valves are in the B (Opened) position and that no part is
detected at the associated part present inputs.
GRS4-E
275
275
Programming Instructions - Cylinders
Grip Part
1. Setting the ‘Grip Part’ instruction will shift the selected valves to the A (Closed)
position.
2. Feedback from any of the 24 available cylinders and/or 16 available part present
inputs will be used with the specified valve(s) to verify successful completion of
the gripping operation.
3. Program execution will resume when the “closed” state of all associated clamps
are detected or after the programmable time delay (if clamp feedback is not
assigned).
4. The ‘Grip Part’ instruction will support both discrete and continuous checking of
the part present input(s). If continuous monitoring is selected, the monitoring will
remain in effect until a ‘Release Part’ instruction is executed for the associated
input.
276
5.
In
GRS4-E No Part mode the robot will ignore the state of all part present inputs.
276
138
Programming Instructions - Cylinders
Release Part
1. The ‘Release Part’ instruction will shift one or more of the 15 available
valves to the B (Opened) position.
2. Feedback from any of the 24 available cylinders and/or 16 available part
present inputs will be used with the specified valve(s) to verify
successful completion of the gripping operation.
3. Program execution will resume when the “open” state of all associated
clamps are detected or after the programmable time delay if clamp
feedback is not assigned.
4. The ‘Release Part’ instruction will terminate continuous monitoring of
any associated part present input(s).
GRS4-E
277
277
Programming Instructions - Cylinders
Vacuums
• The vacuum on, vacuum off, and blow off instructions will support both
simple vacuum and vacuum pump systems
• The vacuum remains on as long as the ‘Vacuum On’ signal is set and
blow-off remains on as long as the ‘Blow-Off On’ signal is set
• Up to five total valves including clamp and simple vacuum will be
supported
• Vacuum pumps do not limit the number of available cylinder valves
GRS4-E
278
278
139
Programming Instructions - Cylinders
Vacuum On
• This instruction will turn on the vacuum to pick-up the part.
• This instruction will initiate continuous monitoring of the
‘Vacuum Made’ input after a configurable time delay.
• In No Part mode the specified vacuum channels are not
activated and no feedback will be monitored from the
specified vacuum channels.
GRS4-E
279
279
Programming Instructions - Cylinders
Vacuum Off
• This instruction will turn off the vacuum and turn on the blow-off function.
• This instruction will terminate continuous monitoring of the ‘Vacuum
Made’ input.
• In No Part mode, the specified vacuum channels will not be activated,
blow-off will not be activated, and no feedback will be monitored from the
specified vacuum channels.
GRS4-E
280
280
140
Programming Instructions - Cylinders
Check Part Present
• This instruction will check that state of the part present switch at one or more of the 16
available inputs.
• This instruction will support both discrete and continuous checking of the specified
input(s) as a programming option. If continuous monitoring is selected, the monitoring
will remain in effect until a ‘Release Part’ instruction is executed for the associated input.
Check No Part Present
• This instruction will check that no part is present at the specified switches.
GRS4-E
281
281
Module 3 Review – Material Handling
• A MH robot can be recovered from TP and HMI, what
actions can be done?
–
–
–
–
–
GRS4-E
Check I/O Again – recheck signal, no movement
Disable Alarm: 20 Cycles
Disable Alarm: 1 Cycle
Toggle Gripper and Retry – toggles states and re-checks
Cancel and Recover – will un-grip and recover if gripping or
will grip and recover if un-gripping
282
282
141
Module 3 Review – Material Handling
• This instruction verifies that all cylinders of the selected
valves are in the B (Opened) position and that no part
is detected at the associated part present inputs.
Prepare to Pickup
GRS4-E
283
283
Tool Change Configuration Items
The following options will be configurable
for tool changing robots:
• Specify the number of tools that will be used
• Select if the tool changer nests will utilize lids
• Select if the nest in position signals will be used
GRS4-E
284
284
142
Tool Changer Interface Signals
Robot Inputs (Robot End)
• Tool Plate Latched: This signal indicates that the tool changer’s engagement mechanism
is latched.
• Tool Plate Unlatched: This signal indicates that the tool changer’s engagement
mechanism is unlatched.
• Unlatch Solenoid Energized: This signal is set to indicate the unlatch tool switch is made
and the unlatch output is energized. If the unlatch switch jumper is installed, this signal
will be true whenever the unlatch output is true.
• Aux Power Available: This signal indicates that auxiliary power (24VDC) is available.
GRS4-E
285
285
Tool Changer End Of Arm (Tool End)
Robot Inputs (Tool End)
• Tool Number: An 8 bit binary number that indicates the tool number. It is
used to identify the number of the end effector (1,2,3, etc).
• Robot Number: A 4 bit binary number that indicates the robot number. It
is used to identify robot so that the end effector is not inadvertently
swapped between robots.
• Line Number: A 4 bit binary number that indicates the application type
being used. (1-MH, 2-Spot, 3-Spot/MH, 4-Stud, 5-SPR)
GRS4-E
286
286
143
GRS4-E
Tool Changer End of Arm / Robot Inputs
DI[#]
Tool Changer Robot End
EIP Scanner ‐ Slot 54
Description
Signal Name
DI[#]
905
906
907
908
Tool Plate Latched
Tool Plate Unlatched
Ok to Latch
Ok to Unlatch
diToolLatched
diToolUnlatched
diOktoLatch
diOktoUnlatch
913
914
915
916
909
910
911
Tool Plate Found
Safe Switch Missing
(Reserved)
diToolPresent
diSafeSwMissing
(Reserved)
917
918
919
912
(Reserved)
(Reserved)
920
921
922
923
924
925
926
927
928
Tool Changer Tool End
EIP Scanner ‐ Slot 54
Description
Signal Name
giToolNumber
Tool Number (bit 1)
giToolNumber
Tool Number (bit 2)
giToolNumber
Tool Number (bit 4)
giToolNumber
Tool Number (bit 8)
giToolNumber
Tool Number (bit 16)
giToolNumber
Tool Number (bit 32)
giToolNumber
Tool Number (bit 64)
Tool Number (bit 128) giToolNumber
giRobotNumber
Robot Number (bit 1)
giRobotNumber
Robot Number (bit 2)
giRobotNumber
Robot Number (bit 4)
giRobotNumber
Robot Number (bit 8)
giLineNumber
Line Number (bit 1)
giLineNumber
Line Number (bit 2)
giLineNumber
Line Number (bit 4)
giLineNumber
Line Number (bit 8)
GRS4-E
287
287
Tool Changer End of Arm / Robot Outputs
Tool Changer Robot End
EIP Scanner ‐ Slot 54
Description
DO[#]
GRS4-E
Signal Name
905
906
Latch Tool Plate
Unlatch Tool Plate
doLatchTool
doUnlatchTool
907
908
Tool Changer Fault Reset
(Reserved)
doTCFaultReset
(Reserved)
909
(Reserved)
(Reserved)
910
911
(Reserved)
(Reserved)
(Reserved)
(Reserved)
912
(Reserved)
(Reserved)
288
288
144
Tool Changer Robot Software Requirements
Latch Tool Plate
The ‘Latch Tool Plate’ instruction cycles the tool changer
to the latched position and verifies the correct state of
the associated feedback.
Unlatch Tool Plate
The ‘Unlatch Tool Plate’ instruction cycles the tool
changer to the unlatched position and verifies the correct
state of the associated feedback.
GRS4-E
289
289
Tool Changer Robot Software Requirements
Check For Head Present
• This instruction will check if a particular head is present on the
tool changer.
Check For No Head Present
• This instruction will verify that there is no head present on the
tool changer.
GRS4-E
290
290
145
Tool Changer Nest (Robot Controlled)
Robot Inputs
• Nest Closed: This signal indicates that the tool changer nest is closed.
• Nest Open: This signal indicates that the tool changer nest is open.
• Head In Nest: This signal indicates that there is an end-effector in the
nest.
• Nest In Position: This signal indicates the tool nest is in position and
locked.
GRS4-E
291
291
Tool Changer Nest (Robot Controlled)
Robot Outputs
• Close Nest: This signal commands the tool nest to close the lid.
• Open Nest: This signal commands the tool nest to open the lid.
GRS4-E
292
292
146
GRS4-E
Tool Changer Nest / Robot Inputs
DI[#]
Tool Change Nest 1
Tool Change Nest 2
Tool Change Nest 3
Tool Change Nest 4
EIP Scanner ‐ Slot 56
EIP Scanner ‐ Slot 57
EIP Scanner ‐ Slot 58
EIP Scanner ‐ Slot 59
Description
Signal Name
DI[#]
Description
Signal Name
DI[#]
Description
929
Nest 1 Open
diNest1Open
937
Nest 2 Open
930
Nest 1 Closed
diNest1Closed
938
Nest 2 Closed
diNest2Closed
946
Nest 3 Closed
931
Head 1 In Nest
diHead1InNest
939
Head 2 In Nest
diHead2InNest
947
Head 3 In Nest
diNest2Open
945
Nest 3 Open
Signal Name
diNest3Open
DI[#]
Description
Signal Name
953
Nest 4 Open
diNest4Open
diNest3Closed
954
Nest 4 Closed
diNest4Closed
diHead3InNest
955
Head 4 In Nest
diHead4InNest
932
Nest 1 In Position diNest1InPos
940
Nest 2 In Position diNest2InPos
948
Nest 3 In Position diNest3InPos
956
Nest 4 In Position
diNest4InPos
933
(Reserved)
(Reserved)
941
(Reserved)
(Reserved)
949
(Reserved)
(Reserved)
957
(Reserved)
(Reserved)
934
(Reserved)
(Reserved)
942
(Reserved)
(Reserved)
950
(Reserved)
(Reserved)
958
(Reserved)
(Reserved)
935
(Reserved)
(Reserved)
943
(Reserved)
(Reserved)
951
(Reserved)
(Reserved)
959
(Reserved)
(Reserved)
936
(Reserved)
(Reserved)
944
(Reserved)
(Reserved)
952
(Reserved)
(Reserved)
960
(Reserved)
(Reserved)
GRS4-E
293
293
Tool Nest 1- 4 / Robot Outputs
DO[#]
929
Tool Change Nest 1
Tool Change Nest 2
Tool Change Nest 3
Tool Change Nest 4
EIP Scanner ‐ Slot 56
EIP Scanner ‐ Slot 57
EIP Scanner ‐ Slot 58
EIP Scanner ‐ Slot 59
Description
Signal Name
DO[#]
Open Nest 1
doOpenNest1
937
930
Close Nest 1
doCloseNest1
931
(Reserved)
(Reserved)
932
(Reserved)
933
Description
Signal Name
DO[#]
Description
Signal Name
DO[#]
Description
Signal Name
Open Nest 2
doOpenNest2
945
Open Nest 3
doOpenNest3
953
Open Nest 4
doOpenNest4
938
Close Nest 2
doCloseNest2
946
Close Nest 3
doCloseNest3
954
Close Nest 4
doCloseNest4
939
(Reserved)
(Reserved)
947
(Reserved)
(Reserved)
955
(Reserved)
(Reserved)
(Reserved)
940
(Reserved)
(Reserved)
948
(Reserved)
(Reserved)
956
(Reserved)
(Reserved)
(Reserved)
(Reserved)
941
(Reserved)
(Reserved)
949
(Reserved)
(Reserved)
957
(Reserved)
(Reserved)
934
(Reserved)
(Reserved)
942
(Reserved)
(Reserved)
950
(Reserved)
(Reserved)
958
(Reserved)
(Reserved)
935
(Reserved)
(Reserved)
943
(Reserved)
(Reserved)
951
(Reserved)
(Reserved)
959
(Reserved)
(Reserved)
936
(Reserved)
(Reserved)
944
(Reserved)
(Reserved)
952
(Reserved)
(Reserved)
960
(Reserved)
(Reserved)
GRS4-E
294
294
147
Robot Controlled Tool Nests
Check For Nest Empty
• This instruction will verify that a specific tool changer nest is empty.
Check For Head In Nest
• This instruction will verify that a specific tool changer nest is occupied.
Open Nest
• This instruction will open a tool changer nest.
Close Nest
• This instruction will close a tool changer nest.
GRS4-E
295
295
Tool Changer Nest (Robot Controlled)
The maximum number of robot controlled nests is 4.
The robot will control nests where the end-effector can not be serviced
without entering the cell. The robot will not control the tool nests in
applications where tool changers are implemented as a means of backup,
and a faulted end effector can be removed from the nest without entering
the cell.
Instead, the robot will communicate with the cell controller for indication of
nest empty and related signals using the path segments.
GRS4-E
296
296
148
Robot Controlled Tool Nests
Pickup/Dropoff Routines
• Path routines will be provided for the exchange of tool changer
heads during both in-path and back-up tool changing situations.
• These routines will initiate the proper checks for dropping or
picking up a tool changer head.
• It will be possible to utilize these routines to send the robot to
exchange tools automatically.
GRS4-E
297
297
Tool Exchange Utility (Style 26)
While the robot is in interlock mode, selecting Style 26
from the cell controller will execute the functions described
below.
The Pick Tool function drops off the currently installed gun
in the appropriate nest before picking up the requested
tool.
GRS4-E
298
298
149
Tool Change Decisions
DECISION CODE AT POUNCE
FUNCTION
0
1
2
Swap with backup
pick tool from nest 1
pick tool from nest 2
3
4
5
pick tool from nest 3
pick tool from nest 4
Drop tool in nest
GRS4-E
299
299
Path Segments for PLC Operated
Tool Nests
HOME TO
PRE-NEST
GRS4-E
PRE-NEST TO
LIFT
LIFT TO EXIT
NEST
ROBOT INPUT TO
CHECK
Head 1 pickup
10
11
12
diGun1Rdy (In61)
Head 2 pickup
14
15
16
diGun2Rdy (In62)
Head 3 pickup
18
19
20
diGun3Rdy (In63)
Head 4 pickup
22
23
24
diGun4Rdy (In64)
300
300
150
Path Segments for PLC Operated
Tool Nests (cont’d)
HOME TO
PRE-NEST
PRE-NEST TO
LIFT
LIFT TO EXIT
NEST
Head 1 dropoff
30
31
32
Head 2 dropoff
34
35
36
Head 3 dropoff
38
39
40
Head 4 dropoff
42
43
44
ROBOT INPUT TO
CHECK
GRS4-E
301
301
Module 3: Review – Tool Change Configuration Items
What options will be configurable for tool changing robots?
1. Specify the number of tools that will be used
2. Select if the tool changer nests will utilize lids
4. Select if the nest in position signals will be used
For both material handling and tool changing, what is generated
whenever an expected input state is not detected within a
configurable amount of time?
A Fault
GRS4-E
302
302
151
GRS
Global Robot Specifications
LMS # 34043
Module 4: Robot Set-up Procedures
Revision 6.2
© 2017 General Motors Company.
All Rights Reserved
1
Objectives
•
•
•
•
•
•
The student will explain the “Cold Start” and “Controlled Start”
procedure.
The student will define the Fanuc Setup Wizard use.
The student will explain the “Backup All” procedure.
The student will define the “Create and restore a backup image”
procedures.
The student will explain the “Robot Held Servo Wizard” setup
procedure.
Understand GM Custom Screens
2
2
1
Robot Teach Pendent
3
3
Controlled Start
The Controlled Start procedure is similar to booting in Safe Mode on
a windows PC. It allows the user to load software options and
configure the robot's settings. Use the following steps to perform the
Controlled Start:
1.
2.
GRS4
Turn off the Power to the Robot Controller.
– If the controller is on. Press the "on/off" button to select "off". (Make
sure robot and cell are at the end of cycle)
Perform Controlled Start.
– Press and hold the "PREV" button and "NEXT" keys on the teach
pendent while you press the "On/Off" button on the controller.
– Press the "3" button to select menu option "3 Controlled Start".
– Press the Enter button.
4
4
2
Controlled Start (cont’d)
On the FANUC R-30iB Controller, a controlled start can also be done
from the cycle power menu.
1.
2.
3.
Press FCTN – 0: Next – 8: Cycle Power
Select OPTIONS from the pop up menu
Choose Controlled Start
5
GRS4
5
Cold Start
Cold Start:
Used to initialize changes to I/O and System Variable
Boots back up with the program aborted
Use the following steps to perform a Cold Start:
1.
2.
GRS4
Turn off the Power to the Robot Controller.
– If the controller is on. Press the "on/off" button to select "off". (Make
sure robot and cell are at the end of cycle)
Perform Cold Start.
– Press and hold the "PREV" button and "NEXT" keys on the teach
pendent while you press the "On/Off" button on the controller.
– Press the “2" button to select menu option “2 Cold Start".
– Press the Enter button.
6
6
3
Cold Start (cont’d)
On the FANUC R-30iB Controller, a cold start can also be done from
the cycle power menu.
1.
2.
3.
Press FCTN – 0: Next – 8: Cycle Power
Select OPTIONS from the pop up menu
Choose Cold Start
7
GRS4
7
GM Setup Wizard - Overview
• The Fanuc Setup Wizard aids the user in setting up
robots used at General Motors for all projects using
Global 4 generation of Fanuc robots with SpotTool+
8.33 with the GRS4 Customization.
• Typically, the wizard needs to be executed only when
the robot is first installed or if the robot has to be
configured for a different application.
– Depending on the application change, software may need to
be reloaded.
For more G4 Setup Wizard information see next slide.
GRS4
8
8
4
GM Setup Wizard – Additional Information
• For GM Setup Wizard information, visit the
Robotic Standards page:
https://supplier.body.gm.com/crw/production/main
/globalStandards/roboticStandards.cfm
• Navigate to User Guides and Manuals then
Global 4 User Guides and Manuals
9
GRS4
9
What Does the Setup Wizard Do?
Provides the programmer menus to aid in configuration and setup of
FANUC robots with GM GRS4 customization during a controlled
start. It prompts the user with an intuitive series of questions about
the robots application, and based on the user’s input to the questions
the Wizard will:
• Map and configure I/O for the application.
• Set GM customized variables.
• Load standard and application specific programs/templates.
GRS4
10
10
5
What the Wizard Does Not Do?
The Wizard will not:
• Reconfigure the core software personality (this is not a normal
procedure as robots are delivered with the correct software
personality for their hardware configurations). If reconfiguring a
robot, users need to be educated to determine what software
personality is required.
• Add software options.
• Perform Servo Gun Setup (calibration, parameter setting)
11
GRS4
11
GRS-4 Global 4 Customization Menu
Select from the Customization Steps listed below:
12
12
6
Select English, German
• This section allows the Setup Wizard utility to be run in
various languages (English, Spanish, German).
• Current supported languages are English and German.
– The default language for all controllers loaded from FRA or
FANUC is English.
– If the user would like to have the Setup Wizard utility run in
another language, execute this step first.
• In order to change the language, “Select English,
German” before “Run Robot Configuration Tool”.
13
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13
Select English, German (cont’d)
• Then select under SETUP/General to change base
controller language.
– The secondary language will be changed here.
• All changed language components have been agreed
to by FANUC Robotics America and GM N/A MAAC to
cover a complete GRS-4 software option set.
• Please note NOT all WIZARD items or CORE
Spottool+ v8.33 items are translated.
GRS4
14
14
7
Display Current Robot Configuration
Displays the current configuration of the robot
• What manufacturing area is it in? – Body shop, Metal
Forming, Powertrain, Paint shop
• What application is it running? – Spot Welding, MH,
etc.
Note: Feature to be included in the next robot
software release.
15
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15
Run Robot Configuration Tool
• This selection is used to setup of the robot. Under this selection
the wizard will prompt the user for the IP address, manufacturing
area, number of processes, and what each process is (Spot, Stud,
Dispense, Multi-Process or Material Handling).
• Depending on the robot configuration the wizard will go through a
variety of questions asking for user input for setup questions.
• These questions will configure system settings, system variables,
robot I/O, and load application specific template TP programs and
Macros.
GRS4
16
16
8
Load Configuration
Allows for the configuration file to be loaded to
multiple robots
Note: Feature to be included in the next robot
software release.
17
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17
Exit
• Exit will exit the Setup Wizard and finish any GRS4
Customized settings.
• Once the Wizard is finished setting parameters perform
a Cold Start.
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18
18
9
Robot Held Servo Gun Welding Example
This is a complete example of running the setup wizard
Robot Held Servo Gun.
– The user should only select the equipment relevant to the
application.
– If your application requires a language other than English, set
the Wizard language first, and then move to “Run Robot
Configuration Tool ”.
– NOTE: If your setup will require more than 1 SERVO GUN the
FULL LOAD Media Card must be inserted in the robot
controller prior to RUNNING THE SETUP WIZARD.
19
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19
Robot Held Servo Gun Welding Example (cont’d)
1. Select 3. Run Robot Configuration Tool
GRS4
20
20
10
Robot Held Servo Gun Welding Example (cont’d)
2. If running for the first time this menu may not appear.
If running it again it will ask to clear the configuration
GRS4
21
21
Robot Held Servo Gun Welding Example (cont’d)
3. Select 1 to setup the Safe I/O
GRS4
22
22
11
Robot Held Servo Gun Welding Example (cont’d)
4. Select 1 to set the IP address of the robot
GRS4
23
23
Robot Held Servo Gun Welding Example (cont’d)
5. Select the Manufacturing area, <BodyShop>.
GRS4
24
24
12
Robot Held Servo Gun Welding Example (cont’d)
6. Select the number of robot processes. <1>.
25
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25
Robot Held Servo Gun Welding Example (cont’d)
7. Select the robot process. <Spotwelding>.
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26
26
13
Robot Held Servo Gun Welding Example (cont’d)
8. Preset GLOBAL 3/4
Equipment EIP Settings. If
the devices are not
GLOBAL 3/4 STANDARD
the user should answer
NO.
Note: This does set the
device EIP address, as the
watersaver is on the robot
LOCAL network.
27
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27
Robot Held Servo Gun Welding Example (cont’d)
9. Select the weld gun configuration. <Robot Held Gun>
GRS4
28
28
14
Robot Held Servo Gun Welding Example (cont’d)
10. Select Servo Gun welding application <Servo Gun
YES>
GRS4
29
29
Robot Held Servo Gun Welding Example (cont’d)
11. Select Axis Data Step
<YES>.
Note: A selection of
<NO> will be required
only if the wizard is run
and the user does not
want to modify gun setup
parameters.
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30
30
15
Robot Held Servo Gun Welding Example (cont’d)
12. Select the motor type from the list.
<5 GSWA/XXX/XXX/IMA44 – Tol >.
Note: If the user motor
selection is not listed, select
motor number 1. Then
change the motor type
following the Spottool +
Setup and operations menu
at CONTROLLED START
menus.
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31
31
Robot Held Servo Gun Welding Example (cont’d)
13. From the servo gun tag, Enter the maximum pressure for the servo gun
<XXXX nwt> from the gun tag and NOT the motor tag.
Note: This value will
be used to determine
servo gun calibration
table and pressure
table settings.
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32
32
16
Robot Held Servo Gun Welding Example (cont’d)
14.Select the gun design type or shape
< C-Gun >
C - Gun
X - Gun
33
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33
Robot Held Servo Gun Welding Example (cont’d)
15. Default Press/Bkup/Distance Setup <1 = YES>
Usually answer yes if this is
a first time setup
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34
34
17
Robot Held Servo Gun Welding Example (cont’d)
16. Select Tip Dresser option.
35
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35
Robot Held Servo Gun Welding Example (cont’d)
17. Select if dress verification is used
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36
36
18
Robot Held Servo Gun Welding Example (cont’d)
18. Select if Servo Tip Dresser is used. If no is selected the default
electric dresser is configured
37
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37
Robot Held Servo Gun Welding Example (cont’d)
19. Select transformer over-temp switch, if present. Typically NO.
GRS4
38
38
19
Robot Held Servo Gun Welding Example (cont’d)
20. Is a Tool Changer(s) Present? Typically NO.
39
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39
Robot Held Servo Gun Welding Example (cont’d)
21. Press 1 to Execute Setup
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40
40
20
Robot Held Servo Gun Welding Example (cont’d)
22. If the setup has already been run it will ask if you want to
acknowledge each change or accept all changes. In this case
enter 1 to RESET
41
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41
Robot Held Servo Gun Welding Example (cont’d)
23. The screen will flash as the changes are being made and it will
return to the Wizard Menu. Select 5 and press enter to Exit. Then
Press FCTN – 1 Cold Start to return to reboot the robot
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42
21
Storage Devices
43
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43
MD Backup Procedure
• Set device as where USB/MC is loaded & Create a
new directory with folder name as robot name
• Set device to ‘MD’ & *.* , press ‘enter’
• Select ‘all files’ by moving curser up or down
• Press ‘prev’ or ‘next button’ & press ‘copy’
• Verify the origin / destination files are correct
• Confirm to copy
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44
44
22
Backup All
The Backup All procedure should be performed
every time you reprogram the robot. This is an
archive procedure that allows you to retrieve the
current settings.
45
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45
Backup All (cont’d)
Step 1. Access File Screen
1.
2.
3.
4.
5.
GRS4
Turn on the robot controller by pressing the on/off switch.
Press the "MENU" button on the teach pendent after boot is
complete.
Select "7 File".
Press the "ENTER" button.
The File screen will appear.
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46
23
Backup All (cont’d)
Step 2. Set up the backup device.
6. Insert a Memory Card into the PCMCIA slot inside the
controller, a USB Drive into the port on the front of the
controller or into the port on the TP
7. Press "F5 [UTIL]". The backup device menu will appear.
8. Select "1 Set Device".
9. Press the "ENTER" button.
10. Select “Mem Card (MC:)“, “USB Disk (UD1:)” or press 8 to go
to the next page to access “USB on TP (UT1:)”.
11. Press the "ENTER" button.
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47
Backup All (cont’d)
Step 3. Start the backup
12. Press "F4 [BACKUP]". The file type menu will appear.
13. Select "All of the above".
14. Press the "ENTER" button.
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48
24
Backup All (cont’d)
Step 4. Maintenance and back up files.
15. Answer On-Screen question "Delete MC: \\ before backup
files?"
16. Press "F4" for Yes. Files are deleted on memory card.
17. Press "F5" for No. Will not delete files on memory card
You have completed the Backup All procedure. Your current
settings are saved for future reference on the memory card.
49
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49
MD: Copy
An MD: Copy backup copies both compiled and
non-compiled files from the robot to the backup
device. This is helpful for viewing files offline in a
text editor.
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50
50
25
MD: Copy (cont’d)
Step 1. Access File Screen
1.
2.
3.
4.
5.
Turn on the robot controller by pressing the on/off switch.
Press the "MENU" button on the teach pendent after boot is
complete.
Select "7 File".
Press the "ENTER" button.
The File screen will appear.
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MD: Copy (cont’d)
Step 2. Set up the backup device.
6. Insert a Memory Card into the PCMCIA slot inside the
controller, a USB Drive into the port on the front of the
controller or into the port on the TP
7. Press "F5 [UTIL]". The backup device menu will appear.
8. Select "1 Set Device".
9. Press the "ENTER" button.
10. Select “Mem Card (MC:)“, “USB Disk (UD1:)” or press 8 to go
to the next page to access “USB on TP (UT1:)”.
11. Press the "ENTER" button.
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52
52
26
MD: Copy (cont’d)
Step 3. Set the MD:
12.
13.
14.
15.
16.
Press "F5 [UTIL]". The backup device menu will appear.
Select "1 Set Device".
Press the "ENTER" button.
Select “Mem Device (MD:)“
Press the "ENTER" button.
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53
MD: Copy (cont’d)
Step 4. Start the backup
16.
17.
18.
19.
20.
GRS4
Press NEXT to change the function key options
Press F2 COPY
Scroll down to the To Device: field and press F4 [CHOICE]
Choose the device to copy to. Usually MC: or UD1:
Press F1 DO_COPY
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27
MD: Copy (cont’d)
Step 5. Maintenance and back up files.
21. Answer On-Screen question “Overwrite?"
22. Press "F4" for Yes or "F5" for No.
You have completed the MD: Copy procedure. Compiled and noncompiled files should be stored to the selected removable memory
device.
55
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Controller Image - Backup
Use this procedure to backup the controller as an image.
1. Turn off power to the robot controller
2. Press and hold F1 and F5 keys on the teach pendant
3. Continue to hold F1 and F5. Turn the power back on to the
robot controller. The robot will boot to the BMON menu on
the teach pendant.
4. Release all the keys when the BMON menu appears.
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28
Controller Image – Backup (cont’d)
5. From the BMON menu, select Controller backup/restore
(press the 4 button then the ENTER button).
57
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Controller Image – Backup (cont’d)
6. Select Backup controller as Images (press 2 then press
Enter).
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58
58
29
Controller Image – Backup (cont’d)
7. Select Memory Card (MC:) or USB (UD1:) and press ENTER.
59
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Controller Image – Backup (cont’d)
8. Insert a memory card or USB flash drive with enough free
space to hold the full controller image.
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30
Controller Image – Backup (cont’d)
9. Type 1 and press ENTER. The memory files will
be written to the memory card. You should see
messages similar to the following:
61
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Controller Image – Backup (cont’d)
10. When the backup is complete, press ENTER to
display the BMON menu.
11.Press 1 to return to the Configuration Menu
12.Select Cold Start to boot back into the normal
mode
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31
Controller Image – Backup (cont’d)
On newer software versions an Image Backup can be
taken from the normal file menu:
– Press MENU – 7 File – F4 [BACKUP] – select Image Backup
– The controller will then cycle power, go into boot monitor,
backup the image files, and re-boot into normal mode
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Controller Image – Restore
1. Turn off power to the robot controller
2. Press and hold F1 and F5 keys on the teach pendant
3. Continue to hold F1 and F5. Turn the power back on to
the robot controller. The robot will boot to the BMON
menu on the teach pendant.
4. Release all the keys when the BMON menu appears.
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32
Controller Image – Restore (cont’d)
5. Select Controller backup/restore and press the 4 button
then the ENTER button.
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65
Controller Image – Restore (cont’d)
6. Select restore controller images press the 3 button then
press Enter.
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33
Controller Image – Restore (cont’d)
7. Insert a memory card or USB flash drive with the
controller image.
8. Select (1) Memory Card (MC:) or (3) USB (UD1:) and
press ENTER.
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Controller Image – Restore (cont’d)
9. Type 1 and press ENTER. The memory card files will be
written to the robot memory.
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34
Controller Image – Restore (cont’d)
10. When the restore is complete, press ENTER to display the
BMON menu.
11. Press 1 to return to the Configuration Menu
12. Select Cold Start to boot back into the normal mode
13. Load the “Backup All” files from the file menu to restore the
latest TP programs.
The image should be restored.
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GM Customized Screens
GM has created customized screens to assist with robot
programming and troubleshooting. These screens include:
• Production Home, GM Manuals, Production Speed
• Servo Gun Hints
• Tip Dress Status
• Tool Changer Status
• Proteus Web Application
• WTC Weld Controller WebDep
• GM Setup Top Menu – Wizard Top Menu
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35
Production Home, GM Manuals, Production Speed
The Production Home screen is accessed from the Menu
Favorites bar. Press MENU button for the bar to appear and
select PROD HOME
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71
Production Home, GM Manuals, Production Speed
(cont’d)
The Production Home screen gives information on the IP
address, style, segments, decision codes, and the status of the
robot. It also give access to the Production Speed Page and GM
Robot Manual page
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72
36
Production Home, GM Manuals, Production Speed
(cont’d)
The Production Speed Control Page summarizes robot speed settings. It gives the
selection to allow the PLC to control the speed after the paths have been validated
at 100%. For continuous processes the speed override will be set to 100% all the
time. This is used for dispense robots.
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Production Home, GM Manuals, Production Speed
(cont’d)
The Manuals page gives links to the GM Setup guides. The documents can be saved
to Memory Card or USB drives so they can be viewed on a PC. The application
specific documents are loaded based on the application selected in the wizard.
Pressing the Production Home button takes you back.
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37
Servo Gun Setup Hints
This screen gives a reference for servo gun activities.
This page is accessed by pressing MENU – UTILITIES –
F1 [TYPE] – Servo Gun Hints
75
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75
Tip Dresser Status
This screen gives a summary of the tip dresser data. To access this page press STATUS –
F1[Type] – Tip dresser #1.
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38
Tool Changer Status
This screen gives a summary of the I/O used for tool changing. To access this page press
STATUS – F1[Type] – Tool Change Status.
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77
Proteus Web Application
This screen connects to the water saver’s device web page. The communication should
be setup through Ethernet port #2. To access this page press MENU ‐ BROWSER –
F1[Type] – PROTEUS #1 or PROTEUS #2. It can be used to setup dual water savers. See
the Wizard Manual for more details.
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39
WTC Weld Controller WebDep
This screen connects to the weld controller’s device web page. The communication
should be setup through Ethernet port #1 of the PLC switch. To access this page press
MENU ‐ BROWSER – F1[Type] – WTC1 or WTC2. It can be used to setup dual water
savers. See the Wizard Manual for more details.
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GM Setup Top Menu
1.
2.
By pressing the i‐key and the MENU
button at the same time the GM
Setup menu will appear. This
provides links to the menus that are
necessary for setting up a robot with
the GM customization.
It also has a link the Wizard Top
Menu which gives information on 2
how to get to the setup wizard.
1
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40
Wizard Top Menu
3.
Wizard Top Menu
3
81
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81
Module 4: Review
How do you perform the “Cold Start” procedure?
–
–
–
Step 1: Press PREV and NEXT while rebooting
Step 2: Select “2 Cold Start” from the configuration menu
Step 3: Press the "ENTER" button.
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Module 4: Review
How do you backup the controller as an image?
1. Turn off power to the robot controller
2. Press and hold F1 and F5 keys on the teach pendant
3. Continue to hold F1 and F5. Turn the power back on to the
robot controller. The robot will boot to the BMON menu on
the teach pendant.
4. Release all the keys when the BMON menu appears.
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Module 4: Review
How do you backup the controller as an image? (cont’d)
5. From the BMON menu, select Controller backup/restore
(press the 4 button then the ENTER button).
6. Select Backup controller as Images (press 2 then press
Enter).
7. Select Memory Card (MC:) or USB (UD1:) and press ENTER.
8. Insert a memory card or USB flash drive with enough free
space to hold the full controller image.
9. Type 1 and press ENTER. The memory files will be written to
the memory card.
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42
Module 4: Review
How do you restore the controller image?
1. Turn off power to the robot controller
2. Press and hold F1 and F5 keys on the teach pendant
3. Continue to hold F1 and F5. Turn the power back on to the robot
controller. The robot will boot to the BMON menu on the teach
pendant.
4. Release all the keys when the BMON menu appears.
5. Select Controller backup/restore and press the 4 button then the
ENTER button.
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Module 4: Review
How do you restore the controller image? (cont’d)
GRS4
6.
Select restore controller images press the 3 button then press
Enter.
7.
Select (1) Memory Card (MC:) or (3) USB (UD1:) and press ENTER.
8.
Insert a memory card or USB flash drive with the controller image.
9.
Type 1 and press ENTER. The memory card files will be written to
the robot memory.
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43
Module 4: Review
How do you restore the controller image? (cont’d)
10. When the restore is complete, press ENTER to display the BMON
menu.
11.Press 1 to return to the Configuration Menu
12. Select Cold Start to boot back into the normal mode
13. Load the “Backup All” files from the file menu to restore the latest
TP programs.
The image should be restored.
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87
Module 4: Review
What are some guidelines for Robot Held Servo Gun Setup?
– The user should only select the equipment relevant to the
application.
– If your application requires a language other than English, set the
Wizard language first, and then move to “Run Robot Configuration”
– NOTE: If your setup will require more than 1 SERVO GUN the
FULL LOAD Media Card must be inserted in the robot controller
prior to RUNNING THE SETUP WIZARD.
– Use the wizard as shown in the Robot Held Servo Gun Setup
procedure to setup for your application.
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44
Module 4: Review
How do you perform a Backup all procedure?
Step 1. Access File Screen
Step 2. Set up the backup device.
Step 3. Start the backup
Step 4. Maintenance and back up files
89
89
Module 4: Review
What does the Setup Wizard do?
Provides the programmer menus to aid in configuration and setup of
FANUC robots with GM GRS4 customization during a controlled
start. It prompts the user with an intuitive series of questions about
the robots application, and based on the user’s input to the questions
the Wizard will:
• Map and configure I/O for the application.
• Set GM customized variables.
• Load standard and application specific programs/templates.
90
90
45
Module 4: Review
What does the Wizard not do?
The Wizard will not:
• Reconfigure the core software personality (this is not a normal
procedure as robots are delivered with the correct software
personality for their hardware configurations). If reconfiguring a
robot, users need to be educated to determine what software
personality is required.
• Add software options.
• Add Ethernet/IP devices to the scan list
• Perform Servo Gun Setup (calibration, parameter setting)
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46
GRS
Global Robot Specifications
LMS # 34043
Review
Revision 6.2
© 2017 General Motors Company.
All Rights Reserved
1
Review
What is the rough cycle time for a carried stud
welder that must make 9 stud welds with a SWT
of 2.2?
A.
B.
C.
D.
19 seconds
23.4 seconds
29.3 seconds
34.7 seconds
2
2
1
Review
What decision code returns the robot to the home
position from pounce?
A.
B.
C.
D.
12
13
14
15
3
3
Review
The option bits are transferred between the cell
controller and the robot are used to:
A. Select the program style
B. Determine which of two pick up points to select
the part from
C. Modify the program to perform backup routines
D. Run a variation of a style program based on
features unique to this part
4
4
2
Review
What bit to the robot indicates that the PLC is
sending valid style and option bits?
A.
B.
C.
D.
Initiate style bit
Start bit
Select bit
Option bit
5
5
Review
What are the steps the robot should complete
upon returning to the home position?
A.
B.
C.
D.
Execute the home check
Execute the housekeeping function
Terminate the style program
All of the above
6
6
3
Review
What style is used for moving the robot to the
repair position?
A.
B.
C.
D.
29
30
31
25
7
7
Review
At the end of a normal cycle, what two signals should be
received from dispense controller 1 at the robot?
A.
Dispense 1 TOTAL Volume OK is On and Dispense 1 in
Process is Off
B. Dispense 1 Fault is On and Dispense 1 Area Volume OK is
On
C. Dispense 1 Process Alert is On and Dispense Complete is
Off
D. Dispense 1 TOTAL Volume OK is On and Dispense 1 End of
Cycle is On
8
8
4
Review
If Decision Code 3 is sent, the tool will be picked out of
what nest?
A.
B.
C.
D.
Nest 1
Nest 2
Nest 3
Nest 4
9
9
Review
What signal will the robot wait for from the cell controller
when at the pounce position?
A.
B.
C.
D.
Start
Decision code
Path segment 1
Ok to Continue
10
10
5
Review
Which of the following is not a choice when running Fast
Fault Recovery?
A.
B.
C.
D.
Re-Weld
Abort
Continue Last
Continue Next
11
11
6