1
1
Introduction
Introduction
KUKA Schweissanlagen GmbH
KUKA Roboter GmbH
Augsburg Factory Site
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Introduction, Safety
Locations
USA
MEX
BR
S
UK
KUKA
Welding Systems
+ Robot Corp.
Sterling Heights
KUKA de México
Mexico City
UK
DV Automation
Ltd.
Chessington
B
KUKA do Brasil
Ltda.
São Paulo
KUKA
Svetsanläggningar
+Robotar AB
Västa Frölunda
KUKA
Welding Systems
+ Robot Ltd.
Halesowen
Thompson Friction
Welding Ltd.
Halesowen
F
E
KUKA
Automatisering
+ Robots N.V.
Houthalen
KUKA
Automatisme +
Robotique S.à.r.L.
Chilly Mazarin
KUKA
Sistemas de
Automatización,
S.A.
Vilanova i La
Geltrú
I
D
KUKA
Sistemi di Saldatura
+ Robot s.r.l.
Grugliasco/Torino
D
RUS
KUKA
Schweißanlagen
GmbH
Augsburg
H
KUKA
Werkzeugbau
Schwarzenberg
GmbH
Schwarzenberg
PRC
LSW
Maschinenfabrik
GmbH, Bremen
KUKA
Roboter GmbH
Augsburg
INDA GmbH
Industrie-- und
Akustikelektronik
Ichenhausen
LP Elektronik
GmbH
Weingarten
KUKA--VAZ
Engineering
Togliatti
INDA
Hungaria
KFT
Budapest
IWKA
Industrieanlagen
GmbH
Beijing
IWKA
Industrieanlagen
GmbH
Shanghai
IWKA
Industrieanlagen
GmbH
Hong Kong
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2
2
Safety
Safety
Valid for
all robot types KR ...
robot controller KR C1
The primary purpose of this Documentation Module is the safety of
the user and operating personnel when using the device described
below.
2.1
Liability
The device described in these operating instructions is an industrial robot -- called “robot
system”in the following text --, consisting of robot, connecting cables and control cabinet.
The robot system -- the subject matter of these operating instructions -- has been built
in accordance with state--of--the--art standards and the recognized safety rules.
Nevertheless, improper use of the robot system or its employment for a purpose
other than the intended one may constitute a risk to life and limb of operating
personnel or of third parties or cause damage to the robot system and to other
material property.
The robot system may only be used in technically perfect condition in accordance
with its designated use and only by safety--conscious persons who are fully aware
of the risks involved in its operation. Use of the robot system is subject to compliance
with these operating instructions and with the manufacturer’s declaration* supplied
together with the robot system. Any functional disorders affecting the safety of the
robot system must be rectified immediately.
The design and rating of the mechanical and electrical equipment of the robot system was
based on the EC machinery directives that came into force on 1 January 1993 (89/392 EEC
dated 14 June1989 and 91/368 EEC dated 20 June 1991) together with their annexes and
associated standards.
The following harmonized standards in particular were taken into account with regard to the
safety of the robot system:
EN 292
Part 1 and 2 (November 1991)
EN 60204 Part 1 (June 1993)
EN 775
EN 418
EN 614
Part 1
prEN 954 Part 1
EN 50081 Part 2
EN 50082 Part 2
The electrical part of the robot system additionally conforms to the “EC low voltage directive”
(73/23/EEC; EC file no. L 077) and the directive on “Electromagnetic compatibility”
(89/336/EEC; EC file no. L 139).
* The manufacturer’s declaration is to be found in the control cabinet.
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Introduction, Safety
D
Designated use
The robot system is designed exclusively for the applications specified in the robot
Doc. Module “Technical Data” (Section 1).
Using the robot system for any other or additional purpose is considered contrary
to its designated use. The manufacturer cannot be held liable for any damage resulting from such misuse. The risk of such misuse lies entirely with the user.
Operating the robot system within the limits of its designated use also involves
continuous observance of these operating instructions with particular reference to
the maintenance specifications.
The software employed is matched to the applications specified by the customer/
user and has been thoroughly tested. In the event that the functions contained in the
software are not executed without interruption, the Doc. Module “Error Messages/
Troubleshooting” must be consulted to remedy this condition. This also applies to
malfunctions occuring during service, set--up, programming and start--up activities.
The robot system may not be put into operation until it is ensured that the functional
machine or plant into which the robot system has been integrated conforms to the
specifications of the EC directives 89/392 EEC dated 14 June 1989 and 91/368 EEC
dated 20 June 1991.
No liability can be accepted if these directions are disregarded.
If the user provides items of equipment and the like which do not constitute part of
the KUKA contract and these parts are integrated into the periphery of the robot
system on behalf of the user, KUKA cannot be held liable for any resulting damage.
Any risk associated with these parts (mechanical, pneumatic and electrical) lies
entirely with the user.
These operating instructions consist of the following parts:
·robot
·control cabinet
·software
They constitute an integral part of the robot system supplied by KUKA, whose serial
numbers for robot and control cabinet can be noted from the manufacturer’s declaration.
2.2
Safety symbols
The following safety symbols are used in these operating instructions:
This symbol is used where failure to fully and accurately observe operating
instructions, work instructions, prescribed sequences and the like could
result in injury or a fatal accident.
This symbol is used where failure to fully and accurately observe operating
instructions, work instructions, prescribed sequences and the like could
result in damage to the robot system.
This symbol is used to draw attention to a particular feature. Observance of the note
will generally result in facilitation of the work concerned.
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2.3
Safety (continued)
General safety regulations
The mechanical and electrical equipment of the robot system for which these operating
instructions, prescribed by the manufacturer, have been issued meets the requirements of
the standard DIN EN 775 concerning the safety of industrial robots. The technical features
and possible mounting positions of this robot system are presented in detail in these
operating instructions and in the relevant specifications for the robot and control cabinet.
Improper use of the robot system or its employment for a purpose other
than the intended one may cause
-- danger to life and limb
-- danger to the robot system and other assets of the user and
-- danger to the efficient working of the robot system or its operator.
The associated operating instructions therefore contain numerous indications of danger,
which also apply to applications and to the use of accessories and supplementary equipment
supplied by KUKA.
Every person involved with installation or exchange, adjustment, operation, maintenance or
repair of the robot system must have read and understood these operating instructions,
particularly the Doc. Module “Safety, General”, paying special attention to the passages
marked with the symbol
, which are of paramount importance.
These passages contain switch--off procedures and other safety precautions serving to
protect operating personnel. Particular attention must be devoted to them when any work
concerning for example, transportation, installation, operation, conversion and adjustment,
adaptation, maintenance or repair is carried out.
Installation, exchange, adjustment, operation, maintenance and repair must be performed
only as specified in these operating instructions and only by personnel specially trained for
this purpose. The user is recommended to have personnel assigned for this work complete
an application--specific KUKA training course.
The user should check at specific intervals selected at his own discretion that the personnel
attend to their work in a safety--conscious manner, are fully aware of the risks involved during
operation and observe these operating instructions.
The responsibilities involved in operation of the robot system and in all other work performed
on the robot system or in its immediate vicinity must be clearly defined and observed by the
user in order to prevent any uncertainty regarding spheres of competence in matters of
safety.
The danger zones of the robot system, i.e. areas in which the robot together with tools,
accessories and additional equipment moves, must in all cases be safeguarded according
to DIN EN 775 to prevent persons or objects from entering these zones or to ensure that the
robot system is immediately shut down by an Emergency Stop system if a person or object
should nevertheless enter a danger zone. This safety facility is the responsibility of the
operator.
The switching times of the EMERGENCY STOP system must be taken into account
when determining the size of the danger zones.
The paint markings on the floor and signs indicating the danger zones must differ clearly in
form, color and style from other markings within the machine or plant in which the robot
system is integrated.
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Introduction, Safety
2.4
Particular safety measures for users and operating personnel
o
0
1
The robot system must be switched off before exchange, adjustment,
maintenance and repair in accordance with the regulations contained in
these operating instructions, i.e. the main switch on the robot control
cabinet must be turned to “OFF” and secured with a padlock to prevent
unauthorized persons from switching it on again.
Any method of working that impairs the functional and operating safety of the robot system
must be avoided.
The user and operating personnel must ensure that only authorized personnel are permitted
to work on the robot system. The user must clearly set out what the responsibilities of operating personnel actually entail and give them the authority to refuse to carry out instructions
from third parties which are contrary to safety procedures.
Do not allow personnel to be trained or instructed or personnel taking part in a general training
course to work on or with the robot system without being permanently supervised by an
experienced person.
Work on the electrical system or equipment of the robot system may only be carried out by
a skilled electrician himself or by specially instructed personnel under the control and supervision of such an electrician and in accordance with the applicable electrical engineering
rules.
Work on the hydropneumatic counterbalancing system (if present) may only be carried out
by persons having special knowledge and experience of hydraulic and pneumatic systems.
The operating personnel are obliged to inform the user immediately of any
changes to the robot system which impair its safety or give reason to
suspect that this might be the case.
The user must ensure that the robot system is only ever operated in
faultless condition.
The user must ensure, by means of appropriate instructions and checks, that the work station
and the environment of the robot system are kept in clean and orderly condition.
No functional safety equipment may be dismantled or taken out of operation
if this would directly or indirectly affect the robot system and if exchange,
adjustment, maintenance or repair is carried out on the robot system. This
would cause danger to life and limb, such as contusions, eye injuries,
fractures, serious internal and external injuries etc.
If it is necessary for such safety equipment nevertheless to be dismantled during the
above--mentioned work on the robot system, the machine or plant in which the robot system
is integrated must be shut down in the exact manner specified, with particular attention being
paid to the text passages of the operating instructions concerned marked with the symbol
, and measures must be taken to prevent unintentional or unauthorized start--up.
Immediately after completion of the exchange, adjustment, maintenance or repair work, the
safety equipment must be reinstalled and checked to ensure that it is functioning correctly.
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2
Safety (continued)
If it is essential for personnel to enter the working range of the robot system
for conversion, adjustment, maintenance or repair work on the machine or
plant in which the robot system is integrated, the safety measures must
always be designed in such a way (e.g. deadman safety switches) that the
robot system is switched off immediately should an unintended situation
arise.
Aspects requiring special consideration:
Only trained personnel familiar with the hazards may be entrusted with exchange, adjustment, maintenance and repair work on the robot system.
When work is carried out in the danger zone of the robot, the latter may only,
if absolutely essential, be operated at manual traversing speed at the most,
to allow the personnel enough time either to avoid dangerous movements
or to stop the robot.
All persons situated in the environment of the robot must be informed in good time that the
robot is about to move.
Wherever possible, only one person should work in the danger zone of the robot at any time,
with a second person remaining in visual contact outside the danger zone within reach of an
Emergency Stop pushbutton.
If two or more persons are working in the danger zone at the same time, they must also all
remain in constant visual contact. Responsibilities for each type of work and for each person
must be clearly and comprehensibly defined.
In sensor--assisted operation, the robot is liable to perform unexpected
movements and path corrections if the main switch on the control cabinet
has not been turned to “OFF”.
Components, tooling and other objects must not become jammed as a result of the robot
motion, nor must they lead to short--circuits or be liable to fall off.
Any motion of the robot that would cause indirect danger to persons or objects must be
avoided.
Due regard must be paid to hazards posed by the peripheral system components of the robot
such as grippers, conveyors, feed devices or other robots in a multi--robot system.
Any unauthorized conversion or modification of the robot system is not allowed.
The robot system including accessories and additional equipment may not be
equipped or operated with products of other manufacturers whose use is not
expressly permitted in these operating instructions or the parts catalog of the robot
system.
When using prescribed operating media which are specified as aggressive or toxic, appropriate protective clothing must be worn. Warning remarks must be observed.
The maintenance cycles prescribed in these operating instructions must be adhered to.
These operating instructions must always be kept ready to hand at the place of use of the
robot system (e.g. in the tool compartment or in the receptacle provided for them) -- whether
as a manual or CD--ROM.
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Introduction, Safety
2.5
Safety features on the robot system
2.5.1
Working space limitation
The means of limiting the working space of the robot comprise adjustable software limit
switches for all axes and for some axes mechanical limit stops with a buffer function, which
as the ”working range limitation”accessory are also adjustable (see also robot specification).
The working space of the robot can be restricted to the required minimum
by the travel limiting devices of the robot axes.
After unbraked impact of one or more of the robot axes against the respective limit stops at a speed higher than manual traversing speed, the buffers
which have absorbed the impact must be immediately replaced with new
ones. When this occurs on axis 1 of a wall--mounted robot, the rotating
column must be exchanged.
2.5.2
Load limitation
All robot axes are safeguarded by overload protection devices, which automatically switch
off the robot if the permissible power input is exceeded (overload protection of the drive
units). An overload can be caused by an excessive weight or by a hardware fault of the
associated servo power module.
2.5.3
Counterbalancing system
Some robot types are equipped with a hydropneumatic counterbalancing system.
When work is carried out on the hydropneumatic counterbalancing system,
the part of the robot assisted by this system must be secured to prevent it
from being able to move.
2.5.4
Motor monitoring
The motors are protected against overload by means of temperature sensors in the motor
windings.
2.5.5
Voltage monitoring
The servo power module is switched off if the voltage is too low or too high for the transistor
amplifiers.
2.5.6
Temperature monitoring
The temperatures inside the control cabinet (internal temperature) are monitored. The
controller is switched off if defined limits are exceeded.
2.5.7
Jog mode (deadman function)
All programs can be executed manually in the test modes at reduced velocity. However,
program execution is only possible as long as the “Start”key is depressed. As soon as it is
released, the robot stops. The program is continued only when the “Start”key is pressed
again.
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2.5.8
Safety (continued)
Other safety facilities
-- Safety switch on the KUKA Control Panel (KCP)
-- Operator mode selection by means of hardware
-- Connection for external safety equipment
-- Keyswitch
2.5.9
Safety functions of the controller
These safety functions concern:
-- Motion variables
-- Path, position
-- Working zone limits
-- Controller hardware
-- Peripheral devices and associated data transmission
-- Operator actions on the KCP
-- Programming, program organization, program execution
-- Admissibility of machine and user data
-- Implementation of DIN EN 775
More detailed descriptions of the functional areas mentioned above may be found in these
operating instructions.
2.6
Release device for robot axes
This device can be used to move the robot mechanically after a malfunction via the main axis
drive motors and, depending on the type of robot, also via the wrist axis drive motors in some
instances. It is intended exclusively for emergency use (e.g. rescuing people).
The release device may only be used if the main switch on the control
cabinet of the robot is turned to “OFF”and secured with a padlock to prevent
unauthorized persons from switching it on again.
If a robot axis has been moved by the release device, all robot axes must be
remastered.
By fitting the release device (reversible ratchet with size 12 socket wrench) onto the motor
shaft (remove protective cover!) the shaft can be turned manually. The resistance of the
mechanical motor brake and any additional axis loads have to be overcome when doing so.
The motors reach temperatures during operation which can cause burns to
the skin. Appropriate safety measures must be taken.
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Introduction, Safety
2.7
Planning and construction
The following safety measures must be implemented during the planning and construction
of a robotic installation.
2.7.1
Foundations and substructures
It must be ensured that the dimensions and qualities specified by KUKA for the foundations,
substructure or the ceiling construction have been adhered to. Deviations from these
dimensions or quality requirements are not permitted.
2.7.2
Load ratings of the robot
It must be checked that the torques, acceleration, weights and other mechanical and environmental conditions to be expected in operation of the robot system lie within the permissible
range for the robot.
2.7.3
Safety (exclusion) zones and working zones
Working zones are to be restricted to the necessary minimum size. In addition to software
limitation, they can also be safeguarded with adjustable mechanical stops (“working range
limitation”accessory). The working zones must meet the safety requirements, i.e. on no
account may persons or equipment be exposed to any danger.
Danger zones, i.e. areas in which robots move, must be safeguarded by means of protective
barriers. These can take the form of safety fences, light barriers, light curtains or zone
scanners, for example.
If safety fences are used, they must have a mesh size as specified in DIN EN 294, DIN EN
349 and DIN EN 811. They must also be high enough to prevent anybody from reaching over
them. The size of the fence sections must be selected in accordance with the strength of the
fencing; design measures must be taken to prevent them from bending. The number of
entrances (gates) in the fencing must be kept to a minimum. There should preferably be only
one gate. All entrances must be connected to the safety devices incorporated in the robot
and to the overall Emergency Stop system.
Shown below is an example illustrating the connection of gate position switches in combination with a pushbutton for enabling operation when the safety gate is closed.
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2
L+
Safety (continued)
A1 (+) Safety gate monitor
e.g. PST3, manuf.: Pilz
Ue
L --= safety gate open
A2 ( ---)
S11
= safety gate closed
= actuated element
S12
Gate position switches
S23
S24
X1
23
24
7
8
25
26
Safeguard channel 2 O
14
Safeguard channel 2 I
Peripheral connector
X11
13
Safeguard channel 1 O
This pushbutton must be located
outside the space limited by the
safeguards.
X2
Safeguard channel 1 I
Pushbutton for enable
with safety gate closed
KR C1
Light barriers, light curtains or zone scanners must be installed in addition to or instead
of safety fences. They must be connected to the overall Emergency Stop system.
Irrespective of these safeguarding measures, the danger zone is to be indicated by means
of paint markings on the floor. These markings must differ distinctly in form, color and style
from other markings within the machine or plant in which the robot system is integrated.
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Introduction, Safety
2.7.4
Collision protection
The robot can be equipped with a collision protection device (additional equipment). This
must in all cases be connected to the Emergency Stop circuit of the robot system or the PLC.
In the case of conveyor operation, additional precautions are required to ensure that the
conveyor cannot collide with the robot when the Emergency Stop function is triggered.
Appropriate measures must be taken to prevent the conveyor from continuing to move in
areas where a collision is possible after an Emergency Stop, e.g. by means of short systems
with transfer stations.
2.7.5
Tool change
Removal and installation stations must be provided to allow tools to be changed. These
stations must be accessible to the operator outside the danger zone and the robot must be
able to move to them by means of a special program step.
2.7.6
Safety mats
If the presence of operating personnel in the work envelope of the robot is unavoidable (e.g.
for loading components), the danger zone is to be isolated by means of a safety mat or light
curtain. This can be accomplished by connecting the safety mat or light curtain to range limit
switches (“working range monitoring” accessory) or a limit switch for the robot’s home
position and to the Emergency Stop circuit.
2.7.7
Interface characteristics
The voltage and output load capacity values of all signals corresponding with the robot
controller must lie within the permissible limits for the controller.
2.7.8
EMERGENCY STOP circuit (EN 418)
If the robot system is operated in conjunction with a higher--level controller, the two
Emergency Stop circuits must be interconnected. Both these circuits must be of failsafe
design (dual Emergency Stop contactors with reciprocal monitoring). In addition, every
operator station must be provided with an Emergency Stop device. This may take the form
of a pull cord or a mushroom--head pushbutton with a locking mechanism. It is particularly
important that a regular check is made to ensure that that the Emergency Stop devices are
functioning correctly.
2.7.9
Presetting of outputs
Outputs are to be preset in accordance with the main project file, i.e. signals for hold functions
must not be reset when the robot controller is switched off if personnel or equipment would
be endangered as a result.
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2.7.10
Safety (continued)
Tooling and additional equipment
If they have not been supplied by KUKA, tooling and additional equipment for the robot must
be designed to the same standard of safety as the robot system. The specifications valid for
the machine or plant into which the robot system is integrated must be applied analogously
to the tooling and equipment (e.g. fuses for the primary circuit of welding transformers).
2.7.11
Safety regulations
The machine or plant into which the robot system is integrated must be checked before the
robot system is installed to ensure that the user’s safety regulations, general accident
prevention rules and trade association regulations have been observed. Please observe
Section 2.8.9.
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Introduction, Safety
2.8
Installation, operation and other work
Personal protection:
All persons working within the danger zone of the robot system must wear
protective clothing. Of particular importance are safety helmets, safety footwear and closely fitting clothing. In addition, the safety regulations of the
relevant trade associations are to be observed.
The motors and the wrist of the robot system are liable to reach operating
temperatures that can cause burns to the skin. Work must not be carried out
on these components until they have cooled down sufficiently.
2.8.1
Mains connection conditions
The mains connection conditions specified by KUKA in respect of conductor cross--sections,
fuses, voltage and frequency must be adhered to. The pertinent regulations of the power
utilities concerned must be observed.
2.8.2
Transportation
The prescribed transport positions for the robot must be observed. All angle specifications
are referred to the mechanical zero of the robot axis concerned.
When being exchanged, individual parts and larger assemblies are to be fastened with care
to the lifting gear and secured so that they do not constitute a hazard. Only suitable and technically faultless lifting gear and load--bearing equipment with an adequate carrying capacity
may be used.
Do not work or stand under suspended loads!
The fastening of loads and the instructing of crane operators should be entrusted to experienced persons only. The marshaller giving the instructions must be within sight or sound of
the operator.
2.8.3
Protection from dirt and UV radiation
No welding may be carried out in the immediate vicinity of the open control
cabinet due to, amongst other factors, the risk of EPROMs being erased by
UV radiation.
Foreign matter (e.g. swarf, water, dust) must be prevented from entering the
control cabinet. If a particularly large amount of dirt or dust is created during
the installation phase, the control cabinet and robot must be covered.
2.8.4
Start--up
It must be ensured that all safety devices, limit switches and other protective measures are
installed completely and functioning correctly before the robot system is started up. The
system elements of the robot and the control cabinet must be checked for foreign bodies.
No persons or objects may be in the danger zone (work envelope of the robot) during the
start--up procedure. It must be ensured that the correct machine data have been loaded
before the system is put into operation for the first time.
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2.8.5
Safety (continued)
Software
Special software has been developed for the control computer. The
software detects most incorrect entries and operator errors. For further
information refer to the relevant parts of these operating instructions.
The hardware and software supplied have been checked for viruses. It is the user’s responsibility to make sure that the latest virus scanner is always used. Relevant details can be found
in the Chapter “Running Up / Shutting Down the Controller”.
2.8.6
Operation
All safety regulations must be adhered to while the robot system is in operation. No changes
may be made to safety measures or equipment. In the event of a malfunction, the robot must
be switched off immediately. Until the fault has been eliminated, measures must be taken
to prevent unauthorized start--up and to preclude any danger to persons or objects. Appropriate records are to be kept of malfunctions, their causes and the remedial action taken.
Check the robot system at least once per working shift for obvious damage and defects.
Report any changes, including changes in the robot system’s working behavior to the
competent department or person immediately. If necessary, stop the robot immediately and
lock it!
2.8.7
Shut--down
Before any exchange, adjustment, maintenance or repair work is carried out, the robot
system must be shut down as specified in these operating instructions and precautions must
be taken to prevent unauthorized start--up (e.g. padlock, keyswitch). If it is absolutely
essential for the robot to be moved during certain activities, special attention must be paid
to the relevant remarks in Section 3.2.
2.8.8
Additional remarks
Always tighten any screwed connections that have been loosened during maintenance and
repair as specified.
When carrying out overhead work always use safety--oriented ladders and working platforms. Never use the robot or the control cabinet as a climbing aid.
Ensure that all consumables, auxiliary substances and replaced parts are disposed of safely
and with minimum environmental impact!
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Introduction, Safety
2.8.9
Safety instruction
The personnel responsible for installation, exchange, adjustment, operation, maintenance
and repair must be instructed before any work is commenced in the type of work involved
and what exactly it entails as well as any hazards which may exist. Records are to be kept
of the content and extent of the instruction.
The above--mentioned personnel must be instructed orally every six months and in writing
every two years with regard to the observance of safety regulations and precautions. The
instruction may be carried out by safety officers of the user and/or within the framework of
the KUKA training program. Instruction is also required after particular incidents or technical
modifications.
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2.9
Safety labelling
2.9.1
General
Safety (continued)
Identification plates, warning labels and safety symbols are attached to the robot and to the
inside and outside of the control cabinet. The connecting cables between the robot and the
control cabinet as well as electric cables and other lines both in and on the robot and control
cabinet are provided with designation labels, many also with position marks.
All of these plates, labels, symbols and marks constitute safety--relevant parts of the robot
system. They must remain attached to the robot or control cabinet concerned for the whole
of their service lives in their specified, clearly visible positions.
It is forbidden to remove, cover, obliterate, paint over or alter in any other
way detracting from their clear visibility
-- identification plates,
-- warning labels,
-- safety symbols,
-- designation labels and
-- cable marks.
2.9.2
Robot
See robot Doc. Module “Technical Data”.
2.9.3
Control cabinet
The following plates and labels can be found inside and outside the control cabinet (Fig. 1):
1
Reference to operating instructions
2
Identification plate (2x)
3
Supply voltage warning
4
Reference to component fastening check
5
Reference to type of supply system
6
Production number of control cabinet
as well as
Ground conductor symbol (14x)
PE
PE symbol
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Introduction, Safety
Door, exterior
Door, interior
3
4
5
1
Side wall, exterior
righthand side
Side wall, interior
lefthand side
2
6
Fig. 1
Side wall, interior
righthand side
2
Plates and labels, control cabinet
Einleitung, Sicherheit R2.2.8 12.98.00 en
22 of 32
2
Safety (continued)
de Achtung!
Lesen Sie unbedingt die Gebrauchsanweisung vor Aufstellung, Installation, Inbetriebnahme.
Dadurch schützen Sie sich und vermeiden Schäden an
Ihrem Gerät.
el ..........!
............................................................................
............................................................................
nl Let op!
......................................................................................
..................................................................................
it Attenzione!
.............................................................................
.............................................................................
da OBS!
......................................................................................
..................................................................................
no NB!
.............................................................................
.............................................................................
es Atención!
......................................................................................
..................................................................................
pt Atenção!
.............................................................................
.............................................................................
fr Attention!
......................................................................................
..................................................................................
en Important!
Before installation and before using the appliance for
the first time read the operating instructions carefully.
This way you will avoid the risk of causing harm to
yourself or to your appliance.
Fig. 2
sv OBS!
.............................................................................
.............................................................................
fi Huomio!
.............................................................................
.............................................................................
1
Reference to operating instructions
KUKA
Roboter GmbH
Augsburg/Germany
Typ
Werk--Nr.
Artikel--Nr.
Type
Serial--No.
Artikel--No.
Type
No. de série
No. d’article
KR C1
01022
71051900
Baujahr
Plan--Nr.
Date
Plan--No.
Année de fabric.
No. de dessin
1997
392.707--85....
abcdef
Anschlußspg.
Netzfrequenz
Nennstrom
Netzsicherung
Supply Volt.
Frequency
Rated Current
Mainsfuse
Tension
Fréquence
Courant nominal
Fusible secteur
3x400V
50Hz
6A
16A
Gewicht
Weight
Poids
ca. 136kg
2
Fig. 3
Identification plate, control cabinet (example)
Einleitung, Sicherheit R2.2.8 12.98.00 en
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Introduction, Safety
Language combinations
ACHTUNG!
German/English
German/French
English/Dutch
German/Spanish
German/Swedish
German/Russian
German/Dutch
German/Italian
German/Turkish
English/Portuguese
German/Czech
German/Portuguese
Der Schrank darf nur mit
der dafür vorgesehenen
Netzspannung betrieben
werden.
3
ATTENTION
OPERATION OF CABINET
ONLY WITH APPROPRIATE
MAINS VOLTAGE
Fig. 4
Supplyvoltagewarning
ACHTUNG!
Vor Inbetriebnahme alle Schraub-- und
Klemmverbindungen auf Festsitz
überprüfen! Gem. VDE 0660/Teil 5
Par. 33 Absatz 2.
4
ATTENTION!
Before switching on the panel, please
check all connections
Fig. 5
Reference to component fastening check
ACHTUNG!
Dieses Gerät darf nur an Versorgungsnetzen mit
geerdetem Sternpunkt betrieben werden.
Attention!
Operation of this device only by supply unit
with grounded star point.
5
Attention!
Opération de set appareil seulement
par système avec neutre à la terre
Fig. 6
Reference to type of supply system
6
.........--...
Production number
Fig. 7
Serial number
Production number of control cabinet
Einleitung, Sicherheit R2.2.8 12.98.00 en
24 of 32
2
2.10
ESD directives
2.10.1
General
Safety (continued)
The ESD regulations (ESD: electrostatic sensitive devices) must be observed at all times
when handling modules for use in the (V) KR C1. These modules are fitted with high--quality
components and are very sensitive to electrostatic discharges (e.s.d.).
Partly through friction (triboelectricity) and partly through electrostatic induction, it is not rare
for objects, or even people under certain environmental conditions, to become charged to
very high voltages, up to several thousand volts.
The most common kind of electrostatic charging is caused by friction. This effect is
particularly encouraged by the combination of synthetic fibers and dry air and occurs as a
result of two fabrics with different dielectric constants rubbing together. This charges the
materials, i.e. one material gives electrons to the other, resulting in an accumulation of
charge carriers of one particular polarity. The same effect can also occur in people. Moving
in a dry atmosphere with well--insulated shoes on a synthetic carpet, you can build up a
charge of up to approximately 15 kV.
Even a fraction of this voltage (although imperceptible to a person) is enough to destroy
ESDs. It is possible to see from the following table that the voltage endurance of modern
semiconductor components, compared with the voltages which arise through electrostatic
charging, is alarmingly low.
U/kV
e.g. offices without humidity regulation
(in winter)
synthetic
Element
MOSFET
Voltage
EPROM
JFET
OP amplifiers
CMOS
wool
anti--static
Schottky diodes
Thick/thin-- film circuits
Bipolar transistors
Relative air humidity
a) average values for electrical voltages
to which a person can be charged
Fig. 8
Schottky TTL
b) e.s.d. vulnerability of semiconductor
elements
Electrostatic charges in people and e.s.d. vulnerability of semiconductors
Furthermore, as well as causing complete failure of components, e.s.d. can also be responsible for partial damage to an IC or component, which in turn reduces service life or leads
to sporadic faults of parts which are still, for the time being, able to function.
For these reasons, not only new modules, but also defective modules,
must be handled very carefully in a way suitable for ESDs.
Einleitung, Sicherheit R2.2.8 12.98.00 en
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Introduction, Safety
2.10.2
Handling ESD modules
G Components should only be unpacked and touched if
-- you are wearing ESD shoes or ESD shoe grounding strips, or
-- you are constantly grounded by means of an ESD armband through a 1 ? O protective
resistor
G Before touching an electronic module you should discharge the voltage from your own
body (by touching a grounded, electroconductive object)
G Surroundings: antistatic table surfaces, conductive floor coverings, high relative air
humidity, grounded tables and chairs (through 1MO protective resistor)
G Electronic modules must not be brought near VDUs, monitors or television sets
G Modules may only be measured if
-- the measuring instrument is grounded (e.g. by means of a protective conductor) or
-- before measuring with a potential--free measuring instrument, the measuring head is
briefly discharged (e.g. touched against an uncoated metallic section of the controller
casing).
G Only unpack and touch electronic components if it is absolutely necessary.
The best protection against the effects of electrostatic discharges is not letting these charges
build up in the first place. For this reason, the grounding of all possible electric potential
carriers is absolutely vital for the optimal handling of ESDs (see diagram).
Module
Work surface
(conductive)
Person
Module
packaging
Instruments,
tools
R: protective resistor 1 MOhm
Fig. 9
2.10.3
Handling ESD modules
Packaging suitable for ESDs
When packaging ESD modules and components, care should always be taken to use only
conductive and antistatic packaging materials, e.g. metallized or graphite--containing
packaging, antistatic plastic bags, etc.
Einleitung, Sicherheit R2.2.8 12.98.00 en
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3
3
About this documentation
3.1
General information
<Function>
About this documentation
Your new KR C1 controller comes complete with this operator handbook. In it, you will find
a general description of the robot system, the hand programming unit and the graphic user
interface. Furthermore, the clear, practical instructions and tips are designed to help you
work more effectively and safely with our industrial robot.
As is known, there are usually several means of achieving a particular end. The procedures
described in this handbook show the way that our experience has found to be optimal.
When creating this documentation, great care has been taken to ensure conformity with the
current hardware and software. Discrepancies cannot always be precluded, however, for
which reason total conformity can unfortunately not be guaranteed. The contents are
checked on a regular basis, though, and any identified discrepancies immediately corrected
(see also Section 3.4).
In addition to the functions described in this handbook (e.g. menu options, function keys,
etc.), further operator control possibilities that are not documented may be available. The
proper, problem--free operation of such non--documented functions can unfortunately not,
however, be guaranteed.
For emphasizing important, often safety--relevant, text passages, various symbols and
words are displayed on the lefthand side of the page. For descriptions of procedures and
individual job steps, you will also find in this area illustrations of function keys and menu
options. These illustrations are used to facilitate rapid visual assignment of the functions on
the graphic user interface.
3.2
Meaning of symbols, words
3.2.1
Safety instructions
This symbol is used where failure to fully and accurately observe operating instructions, work instructions, prescribed sequences and the like could result in injury
or a fatal accident.
The symbol “CAUTION”is used where failure to fully and accurately observe operating
instructions, work instructions, prescribed sequences and the like could result in damage
to the robot system.
3.2.2
Other information and symbols
...is used to emphasize general or additional information on a particular subject or highlights special features.
...is used to identify text passages containing recommendations and advice to make your
work easier.
...is used to introduce descriptions and illustrations of practical examples.
Einleitung, Sicherheit R2.2.8 12.98.00 en
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Introduction, Safety
...within the section or block shown, the changes or entries described should or must be
made.
...within the section or block shown, no changes or entries should or may be made.
...information which is of particular significance or is useful for greater understanding.
...cross--reference to other sections or chapters in the handbook containing further information and explanations.
Example
Detailed information on the function of the “Space Mouse”may be found in the chapter
[Manual traversing of the robot].
<Function>
...refers to a program key (menu key or softkey) that can be pressed on the KCP, with the
appropriate <Function> appearing on the display.
...refers to the possibility of using menus to alter or enter values for system variables
mentioned in the text.
3.3
Meaning of the font styles used in this documentation
Font style
Content
Text in [square brackets]
Titles of other documents
Text in “quotation marks”
Names of specific terms, softkeys, status keys, keys and
boxes (e.g. in forms)
Bold
Emphasis for particular attention
Italic
Explanations of program listings
Serif
Extracts from program files
Serif bold or underlined
Entries or alterations made by the user in the program listings
Einleitung, Sicherheit R2.2.8 12.98.00 en
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3
3.4
About this documentation (continued)
Your opinion counts!
Your opinion counts!
If you are not satisfied with these
operating instructions or with a
part of them, please write to us.
Please also let us know about any
errors that you come across. This
is the only way in which the quality of this documentation can be
continually adapted to your needs.
Suggestions for improvements will
also be gratefully received.
Please send your comments to:
KUKA Roboter GmbH
Abt. R13--T
Subject Documentation
Blücherstr. 144
D -- 86 165 Augsburg
Fax: (0821) 797 -- 2340
Einleitung, Sicherheit R2.2.8 12.98.00 en
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Index
A
S
About this documentation, 27
Safety, 7
C
Safety features, 12
Collision protection, 16
Connection conditions, 18
Counterbalancing system, 12
Safety functions of the controller, 13
Safety instruction, 20
E
Safety labelling, 21
EMERGENCY STOP circuit, 16
ESD directives, 25
Safety symbols, 8
Serial number, 30
G
Shut--down, 19
General safety regulations, 9
Start--up, 18
I
Identification plate, 30
Installation, 18
Introduction, 5
T
J
Jog mode, 12
Temperature monitoring, 12
L
Tool change, 16
Liability, 7
Load limitation, 12
Locations, 6
Transport, 18
M
Motor monitoring, 12
V
O
Operation, 19
Voltage monitoring, 12
P
Particular safety measures, 10
Planning and construction, 14
Protection from dirt, 18
R
Release device for robot axes, 13
W
Words, 27
Index -- i
Index
A
S
About this documentation, 27
Safety, 7
C
Safety features, 12
Collision protection, 16
Connection conditions, 18
Counterbalancing system, 12
Safety functions of the controller, 13
Safety instruction, 20
E
Safety labelling, 21
EMERGENCY STOP circuit, 16
ESD directives, 25
Safety symbols, 8
Serial number, 30
G
Shut--down, 19
General safety regulations, 9
Start--up, 18
I
Identification plate, 30
Installation, 18
Introduction, 5
T
J
Jog mode, 12
Temperature monitoring, 12
L
Tool change, 16
Liability, 7
Load limitation, 12
Locations, 6
Transport, 18
M
Motor monitoring, 12
V
O
Operation, 19
Voltage monitoring, 12
P
Particular safety measures, 10
Planning and construction, 14
Protection from dirt, 18
R
Release device for robot axes, 13
W
Words, 27
Index -- i
Introduction, Safety
4
Service
4.1
Procedure for dealing with queries or problems
If any questions or problems arise while using the robot or the hand programming unit, please
first try to solve them with the aid of these operating instructions.
Should this not bring the desired success, please contact one of our Service Centers. So that
the situation can be resolved easily and quickly, it is advisable for you to be at the robot with
access to the control panel when you call.
You should also have the following information at hand:
G The robot’s serial number
You will find this on the robot’s identification plate, which is attached to the rotating column
axis 2.
Serial number
G
The control cabinet’s serial number
The number is located on the righthand side of the control cabinet (see the following
illustration).
Einleitung, Sicherheit R2.2.8 12.98.00 en
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4
Service (continued)
Serial number
G
Version number of the installed software
The version number of the installed software is called up on the display when you press
the menu key ”Help”on the operational hand programming unit and then, using the “¯”
arrow key, select the menu option ”Version”from the menu that is opened.
More detailed information on handling the hand programming unit and using the graphic
user interface can be found in the chapter [The KUKA Control Panel KCP].
The following information is also useful:
G
a description of the problem, as detailed as possible;
G
a description of the attempts so far to solve the problem;
G
the exact wording and originator of the messages displayed in the message window.
With this information, please contact the appropriate Service Center, the address, telephone
and fax numbers of which are given in the following list.
Einleitung, Sicherheit R2.2.8 12.98.00 en
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Introduction, Safety
4.2
Worldwide service centers
D
Germany
KUKA Roboter GmbH
Blücherstr. 144
D -- 86 165 Augsburg
Tel.:
0821 / 797 -- 1926
Fax:
0821 / 797 -- 1792
KUKA Roboter GmbH
Roboterzentrum Volkswagen--Werk
Hall14, Eingang 62, EG
Postfach
D -- 38 436 Wolfsburg
Tel.:
05361 / 97 56 94
Fax:
05361 / 97 56 97
KUKA Roboter GmbH
Büro Köln
Maarweg 27
D -- 50 933 Köln
Tel.:
0221 / 49 94 61 7
Fax:
0221 / 49 94 61 7
B
I
E
Belgium
KUKA Automatisering + Robots N.V.
Meerstraat 41
Industrieterrein Centrum Zuid 1031
B -- 3530 Houthalen
Tel.:
0032--11 / 52 50 50
/ 52 50 51
Fax:
0032--11 / 52 67 94
Italy
KUKA Sistemi di Saldatura
+ Robot s.r.l.
Via Camerana, 23
I -- 10 095 Grugliasco / Torino
Tel.:
0039--11 / 411 29 66
/ 411 03 75
Fax:
0039--11 / 411 16 45
P
S
F
RUS
UK
USA
Spain
KUKA Sistemas de Automatización,
S.A.
Pol. Industrial Torrent de la Pastera
Carrer del Bages s/n
E -- 08 800 Vilanova i La Geltrú
(Barcelona)
Tel.:
0034--3 / 8 14 23 53
Fax:
0034--3 / 8 14 29 50
Portugal
KUKA Sistemas de Automatizacion S.A.
Av. Alexandre Herculano 75, R/C, DTO.
P -- 29 55 PINHAL NOVO
Portugal
Tel.:
00351--1 / 238 80 83
Fax:
00351--1 / 238 80 86
Sweden
KUKA Svetsanläggningar + Robotar AB
E A Rosengrens Gata 22
S -- 42 131 Västa Frölunda
Tel.:
0046--31 / 89 12 80
Fax:
0046--31 / 45 08 96
France
KUKA Automatisme + Robotique S.à.r.L.
1, Rue Blaise Pascal
F -- 91 380 Chilly Mazarin
Tel.:
0033--1 / 69 09 03 93
Fax:
0033--1 / 69 09 00 05
Russia
KUKA--VAZ Engineering
44 56 33 Togliatti
Jushnoje Chaussee, 36 VAZ, PTO
Tel.:
007--8482 / 39 12 49
/ 37 05 64
Fax:
007--8482 / 39 12 49
Tx:
007--214 106
UK
KUKA Welding Systems + Robot Ltd.
Hereward Rise
Halesowen
West Midlands B62 8AN UK
Tel.:
0044--121 / 58 50 800
Fax:
0044--121 / 58 50 900
USA
KUKA Welding Systems
+ Robot Corp.
6600 Center Drive
Sterling Heights
Michigan 48 312 USA
Tel.:
001--810 / 795 20 00
Fax:
001--810 / 978 04 29
1
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SOFTWARE
KR C1
Arc Welding ARC Tech 10 E
for power sources with analog reference voltage
Operation
Release 2.2
ARC Tech 10_B R2.2.8 01.99.00 en
1 of 66
eCopyright
KUKA Roboter GmbH
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.
PD Interleaf
ARC Tech 10_B R2.2.8 01.99.00 en
2 of 66
Contents
1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
1.1
1.1.1
1.1.2
Software settings at a glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Settable options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
9
1.2
Brief description of the commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
1.3
ARC Tech 10 program structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
2
The graphic user interface of the KUKA Control Panel (KCP) . . . . . . . .
11
2.1
2.1.1
2.1.2
Function of the menu keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
“Configure”menu -- “Status keys” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying variables and altering values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
11
2.2
2.2.1
2.2.2
2.2.3
The display during programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The programming window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The status window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The message window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
13
13
14
2.3
2.3.1
2.3.2
2.3.3
2.3.3.1
2.3.3.2
Key functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function of the menu key “Technology” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function of the softkeys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function of the left status keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual control of the wire feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controlling welding (HOT/COLD) and the “dry run”(DRY) . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
15
17
18
18
19
3
Programming and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
3.1
3.1.1
3.1.2
Basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A10_OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The entry “ARCSPS.SUB”in the file “$CUSTOM.DAT” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
20
20
3.2
3.2.1
3.2.2
3.2.3
Adaptation to the periphery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating mode (W_Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burnback mode (A_BB_MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burnback channel for the KUKA SSDV8 controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
21
21
21
3.3
Entering commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
3.4
3.4.1
3.4.2
Variables in input boxes of the inline forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Explanation of the inline forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program run mode for welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
23
23
3.5
3.5.1
3.5.2
3.5.2.1
3.5.2.2
3.5.2.3
3.5.3
3.5.3.1
3.5.3.2
3.5.3.3
3.5.3.4
Start welding (ARC ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Types of motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Point--to--point (PTP) motions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motion along a straight line (LIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motion along a circular path (CIRC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming the start of welding (ARC ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inline form and parameter lists for the command “ARC ON”, “PTP” . . . . . . . . . . . . . . . . . . .
Inline form and parameter lists for the command “ARC ON”, “LIN” . . . . . . . . . . . . . . . . . . . .
Inline form and parameter lists for the command “ARC ON”, “CIRC” . . . . . . . . . . . . . . . . . .
24
24
24
24
24
24
24
24
25
27
29
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3.5.3.5
Parameter list for the start parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
3.6
3.6.1
3.6.2
3.6.3
3.6.3.1
3.6.3.2
3.6.3.3
3.6.3.4
3.6.3.5
3.6.4
3.6.4.1
3.6.4.2
3.6.4.3
3.6.4.4
3.6.4.5
3.6.4.6
3.6.4.7
3.6.4.8
3.6.4.9
3.6.5
3.6.5.1
3.6.5.2
Welding and ending a seam (ARC OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Types of motion for the command “ARC OFF” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming “ARC OFF” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inline form and parameter lists for the command “ARC OFF”, “LIN” . . . . . . . . . . . . . . . . . . .
Inline form and parameter lists for the command “ARC OFF”, “CIRC” . . . . . . . . . . . . . . . . .
Inline form and parameter lists for “ARC OFF”, weld and end parameters . . . . . . . . . . . . . .
Inline form with “TRACK”function when LIBO sensor is active (A50) . . . . . . . . . . . . . . . . . .
Parameter list for the weld parameters (W) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weave frequency, weave length, path velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotation of the weave angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combining mechanical and thermal weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ramp function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Extended weld parameter lists for special applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameter list for the end parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Extended end parameter lists for special applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
31
31
31
31
32
33
33
35
36
36
37
39
40
41
42
44
46
46
47
47
48
3.7
3.7.1
3.7.2
3.7.3
3.7.3.1
3.7.3.2
3.7.3.3
3.7.3.4
Welding several seam sections -- “ARC SWITCH” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Types of motion for the command “ARC SWITCH” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming “ARC SWITCH” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inline form and parameter lists for the command “ARC SWITCH”, “LIN” . . . . . . . . . . . . . . .
Inline form and parameter lists for the command “ARC SWITCH”, “CIRC” . . . . . . . . . . . . .
Inline form and parameter lists for “ARC SWITCH”, weld parameters . . . . . . . . . . . . . . . . . .
50
50
50
50
50
51
52
53
3.8
Motion commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54
4
Program example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
4.1
Creating a new program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
4.2
Starting welding of seam 1 -- “ARC ON” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
4.3
Ending welding of seam 1 -- “ARC OFF” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
4.4
4.4.1
4.4.2
Moving to seam 2 (PTP) and starting welding -- “ARC ON”. . . . . . . . . . . . . . . . . . . . . . . . . . .
Moving to the point in space P3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting welding of seam 2 -- “ARC ON” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
59
59
4.5
4.5.1
4.5.2
4.5.3
Welding seam 2 (up to P8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section P4 ... P5 -- “ARC SWITCH”-- “LIN” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section P5 ... P6 ... P7 -- “ARC SWITCH”-- ”CIRC” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ending welding of seam 2 -- “ARC OFF” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60
60
61
61
5
Altering existing programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
5.1
Altering command lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
5.2
Deleting program lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
5.3
Adding commands to an existing program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
Description of the alteration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Altering the command “Motion”(to P3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inserting the start of welding for the new seam -- “ARC ON” . . . . . . . . . . . . . . . . . . . . . . . . .
Inserting the first section of the new seam -- “ARC SWITCH”. . . . . . . . . . . . . . . . . . . . . . . . .
Inserting the second section of the new seam -- “ARC OFF” . . . . . . . . . . . . . . . . . . . . . . . . .
Inserting a point in space -- “Motion” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64
64
65
65
65
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1
1
General
General
This documentation has been created for the user group User. It contains the description of
the graphic user interface of the KUKA Control Panel and illustrates the operator actions
necessary for creating, testing, correcting, altering and optimizing programs of the
“ARC Tech 10 E ”technology. Explanatory information on the technology commands and the
associated parameters is also included.
The functions that are specific to “ARC Tech 10”, the operator control elements, the menus
and the various inline forms of the KUKA Control Panel are described in Section 2 -- Graphic
user interface of the KUKA Control Panel.
Section 3 -- Programming and operation -- contains the description of the individual
“ARC Tech 10”commands together with various tables and information on programming.
The command--specific overviews showing the parameter lists that are assigned to the inline
forms, together with a brief description of the parameters and of the frequently required
operator control elements can be useful -- especially to the less experienced user.
By using the simple examples given in both Section 4 -- Program example -- and Section
5 -- Altering an existing program -- where the individual steps required for creating and
altering programs are illustrated, even less experienced users can quickly familiarize
themselves with programming.
As a user, you should have adequate knowledge regarding the creation of motion
programs. More detailed information on this can be found in the chapter [Motion
programming].
The chapter [ARC Tech 10 -- Configuration] contains detailed information on
programming and setting parameters for the user group “Expert”.
The meaning of the symbols, icons and particular font styles is explained in the chapter
[About this documentation].
It is assumed that the robot system is prepared for production operation and that the technology package is loaded. Information on this can be found in the chapter [Start--up].
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1.1
Software settings at a glance
An overview of the important software settings for the configuration of the ARC Tech 10 E
technology package.
Unless otherwise stated, settings and changes to the variable values only become
active after the system is restarted. The following procedure is carried out:
G
When configuration is complete, save the data on the hard disk.
Menu function: ?File ?Save all to Floppy
G
Once the data have been saved, shut the system down.
G
Restart the system.
1.1.1
Basic settings
The file “IOSYS.INI”(directory “...\KRC\DRIVERS”) must contain the following entries:
IOSYS.INI
...
[DRIVERS]
...
LIBO=10,liboInit,libodrv.o
...
IIn the file “$CUSTOM.DAT”(in the directory “...\KRC\MADA\STEU”)
the line
$CUSTOM.DAT
must be changed to:
...
$PRO_I_O[]=”/R1/SPS()”
...
...
$PRO_I_O[]=”/R1/ARCSPS()”
...
"""(entries)
This change only takes effect when the Submit interpreter is restarted.
Menu function: ?Configure ? SUBMIT interpreter ? Stop and then
?Configure ? SUBMIT interpreter ? Start.
The following variable settings must be made:
Variable
Value
Attributes
A10_OPTION
#ACTIVE
ARC Tech 10 activated
ARC20
FALSE
ARC Tech 20 deactivated
See
Section
3.1.1
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1.1.2
General (continued)
Settable options
The following variable settings must be made:
Variable
(Function)
Value
1
Mode 1 PULSE (PS)
2
Mode 2 MIGMAG (MM)
#ACT_PAR
Standard setting (default)
#SSDV8_
MODE
KUKA SSDV8 controller
A_ACT_W_MODE
(Welding mode)
A_BB_MODE
(Burnback mode)
#COMPLETE
A_BB_CHANNEL
(Burnback channel)
A_RAMP_OPTION
A_TH_WEAVE_OPT
(Thermal weaving)
1.2
Characteristics
3
See
Section
Special burnback and crater filling
parameters
Value for SSDV8_MODE only
(KUKA welding controller)
FALSE
TRUE
FALSE
Thermal weaving deactivated
TRUE
Thermal weaving activated
3.6.4.5
Brief description of the commands
An initialization command and three program commands, which are used to control the welding equipment, are basically available for gas metal--arc welding with an analog reference
voltage. These are:
G INI
This initialization command is automatically entered at the beginning of the skeleton program
when a new program is created. This sets the basic parameters for the robot and the application program and initializes the welding and motion commands and approximate positioning.
The parameters can only be changed by the user group “Expert”.
G ARC ON
The command “ARC ON”contains the parameters for moving the welding torch (type of
motion, velocity, etc.) from the home position to the start point of the seam, and all the start
and ignition parameters. “ARC ON”ends after ignition has been successfully completed.
G ARC OFF
The welding command “ARC OFF” contains the motion and weld parameters (including
mechanical and thermal weaving) and the end parameters for the seam, or for the last
section of the seam if it is divided into several sections.
“ARC OFF”ends the welding process by filling the crater and burning back excess wire, so
that the correct free wire length and wire form are available for the ignition process at the start
of the next seam.
G ARC SWITCH
The command “ARC SWITCH”is used where the seam is divided into several sections. It
contains the motion and weld parameters (including mechanical and thermal weaving) for
the current section of the seam.
The set weld parameters are used as a default setting for all of the following “ARC SWITCH”
commands.
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A command belonging to the “Motion”group is used for moving the welding torch, e.g. from
the end of a seam (ARC OFF) to the home position of a following “ARC ON”command, and
for reorientating it.
Detailed information on motion programming can be found in the chapter
[Motion programming].
1.3
ARC Tech 10 program structure
The structure of the ARC Tech 10 commands is illustrated in the following sketch by means
of a simple example. You can see how the motion and welding commands and the start and
end parameters are assigned to the individual sections of the seam.
ARC SWITCH
ARC ON
Motion
parameters
Motion
parameters
ARC OFF
Motion
parameters
Start
parameters
Weld
parameters
P1
P2
Weld
parameters
End
parameters
P3
Home
position
Section 1
Section 2
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2
2
The graphic user interface of the KUKA Control Panel (KCP)
The graphic user interface of the KUKA Control Panel (KCP)
This section is intended to familiarize you with the graphic user interface of the KUKA Control
Panel (KCP), in particular with the possibilities offered by it in the framework of ARC Tech
10 programming.
A basic description of the graphic user interface can be found in the chapter [The KUKA
Control Panel KCP].
The creation and selection of a program that is to be altered is described in the chapter
[Program creation].
2.1
Function of the menu keys
2.1.1
“Configure” menu -- “Status keys”
The configuration menu allows part of both the left status key bar and the softkey bar to be
assigned specific arc welding functions by means of the menu item “Status keys”. A graphic
user interface optimized for the current application is thus available for the purpose of entering program commands and function calls.
The status keys for “GRIPPER Tech”are displayed when the controller is first started, i.e.
after the software hs been installed. Once “ARC Tech 10”has been selected, this configuration is saved, so that it is loaded at every subsequent restart.
More detailed information on the method of operation of the ARC Tech 10 status keys
can be found in Section 2.3.3 (Function of the left status keys).
2.1.2
Displaying variables and altering values
Depending on the configuration, it may be necessary to alter variables or to check the settings. The menu item “Variable”, followed by “Modify”, can be selected in the ”Monitor”menu
for this purpose.
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More detailed information on this can be found in Sections 3.1 and 3.2, and in the
documentation [ARC Tech 10 -- Configuration].
Only alter variables if you have adequate knowledge of the function, and of the
possible consequences!
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2.2
The graphic user interface of the KUKA Control Panel (KCP) (continued)
The display during programming
The following diagram shows the KCP display configured for ARC Tech 10 applications after
a new program has been selected. A skeleton program with four predefined lines can be seen
in the programming window.
Edit cursor
The next program line entered will be
inserted as a new line after the cursor
position.
Please always remember that the edit cursor (the blinking vertical line in the second line
of the screenshot above) must always be in the line after which the next program line is
to be inserted. The user group ”User”cannot write or alter command lines directly.
2.2.1
The programming window
The programming window is the main monitor. It is normally active and in focus, this being
indicated by the light blue background. In this window it is used, for example, for displaying
directories and program lists. For the purpose of entering commands and parameters, generated inline forms are also inserted into the programming window.
2.2.2
The status window
If a box of the inline form is assigned a parameter list (motion or weld parameters), this will
be opened on the right of the status window as soon as this box is in focus (white lettering
on a blue background). The status window is not active (gray background) if the monitor or
message windows are in focus.
The status window becomes active when the ”Window selection”key is pressed. The right
status keys that are assigned to the input boxes of the parameter lists are not activated either
until the status window is in focus.
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The status window is active in the adjacent
screenshot (light blue background color).
The status keys (--/+) on the right next to the
input boxes are used for altering default
values. Pressing the status key next to one
of the input boxes automatically activates
this box.
2.2.3
The message window
Operational and error messages are displayed in the message window. More detailed information on this can be found in the chapter [The KUKA Control Panel KCP].
For safety reasons, the display of messages always has priority. It is therefore possible for
an open parameter list to be partially covered by the message window -- as shown in the lefthand screenshot below.
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The graphic user interface of the KUKA Control Panel (KCP) (continued)
Covered by the message
window
To eliminate this overlap, press the “Window selection”key (top left on the operator control
unit). This activates the message window, which is closed by pressing the softkey “Ack All”.
2.3
Key functions
A range of “softkeys” is available for operating the robot and entering commands. A
distinction is made between menu keys, softkeys and status keys. The functions of the keys
specific to ARC Tech 10 are described below.
2.3.1
Function of the menu key “Technology”
After pressing the menu key “Technology”, the following menu is displayed:
The menu item “ARC Tech 10 E ”can be selected by using the arrow key or by pressing “0”
on the numeric keypad.
After pressing the Enter key or the (right) arrow key, a further pulldown menu is opened. You
can now select between the welding commands “ARC ON”, “ARC SWITCH”and “ARC OFF”
by using the arrow keys or by entering the underlined number.
Finally, a menu for selecting the type of motion is opened:
G “PTP”, “LIN”or “CIRC”for the welding command “ARC ON”,
G ”LIN”or ”CIRC”for the welding commands ”ARC SWITCH”and ”ARC OFF”.
In the following example, ”ARC ON, PTP”has been selected.
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After pressing the Enter key, an inline form is opened in the programming window:
If the programming window is active (in focus), the input boxes can be selected by means
of the arrow keys. The selected box appears in white lettering on a blue background. The
functions of the individual boxes are described in Section 3.
The arrow keys have the following functions here:
-- - The cursor moves one box to the left
-- ¯ The cursor moves one box to the right
-- ¬ The cursor moves one character to the left
-- ® The cursor moves one character to the right
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2.3.2
The graphic user interface of the KUKA Control Panel (KCP) (continued)
Function of the softkeys
The welding commands can not only be selected by means of the menu key “Technology”
using the procedure described above, but also by means of the softkey bar. If the status key
bar “ARC Tech 10”has been selected in the menu “Configure”, the softkey bar has the following assignment after the skeleton program has been opened:
The function of these softkeys is as follows:
The inline form in which the edit cursor (vertical line) is positioned is opened by means of the
softkey “Change”.
The softkey “Motion”opens an inline form for a motion command moving the welding torch
from the end of one seam to the start point of the next, for example.
The command for starting a seam is entered by means of the softkey “ARC ON”. An inline
form for entering the appropriate instructions and parameters is opened in the programming
window.
The softkey “ARC OFF”allows you to enter the command for ending a seam.
Pressing the softkey “Line Sel.”moves the program pointer (yellow arrow) to the line in which
the edit cursor is positioned. The program pointer indicates the program line where the
program is to be continued when the Start key is pressed.
The softkey “File”opens the program directory, thus allowing you to select another program.
The softkey “Program”returns you to the program that was selected before the softkey “File”
was pressed.
After selecting the welding command “ARC ON”by means of the menu key “Technology”-“ARC Tech 10”-- “ARC ON”-- “PTP”or by pressing the appropriate softkey and opening a
corresponding inline form, the assignment of the softkey bar changes to that shown in the
following example:
If the command “ARC OFF”has been selected, the assignment of the softkey bar changes
to that shown below:
You can change both the welding command that has been entered and the type of motion
by means of the softkey bar. When making such a change, the inline form is also automatically adapted, just like the assignment of the softkey bar.
When the motion type “CIRC”is selected, the softkey bar is assigned an additional function
for teaching the intermediate point (midpoint), the key “Touchup MP”. The softkey “Touch Up”
is then assigned the designation “Touchup EP”for teaching the destination point (end point).
If the status window (parameter list) is active, the softkey bar appears as follows:
The softkeys have the following functions:
It is possible to abort programming at any time by means of the softkey “Cmd Abort”. In this
case, none of the data are saved and the inline form is closed. The “ESC”key has the same
function.
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This softkey displays the types of motion that are not currently selected; in this example, PTP
motion is selected. Pressing this softkey changes the type of motion to the one which
appears first (“LIN”in this example). The changed type of motion is automatically entered
into the input box of the inline form, the inline form is updated and the assignment of the
softkey changes accordingly at the same time.
It is possible to change the selected welding command (“ARC ON”in this case) by means
of the softkeys “ARC SWI”and “ARC OFF”. The inline form that is currently open is closed
and a form corresponding to the new command is opened. The assignment of this softkey
changes accordingly at the same time.
The current robot coordinates are saved by pressing the softkey “Touch Up”.
The following only applies when programming “CIRC”motions: the current robot coordinates
for the intermediate point (MP) are saved by pressing the softkey “Touchup MP”.
The intermediate point (MP) must always be taught manually by means of the softkey
“Touchup MP”; it is not possible to automatically save the robot coordinates for the
intermediate point when this command is ended.
The following only applies when programming “CIRC”motions: the current robot coordinates
for the destination point (EP) are saved by pressing the softkey “Touchup EP”.
The current robot coordinates are not saved by means of the commands “Touch Up”,
Touchup MP”and “Touchup EP”until you have confirmed that you want to save them.
For this purpose, a relevant dialog is displayed in the message window.
This softkey is only available if a parameter list is open and the status window is active. The
softkey “Command”is used to exit the parameter list and activate the appropriate input box
in the inline form.
After the parameters have been set, save the data and close the form by pressing the
softkey “Cmd Ok”. The newly created command line appears in the program list and the edit
cursor is moved to this line.
The Enter key has the same function.
If the current robot coordinates have not been touched up during programming, this will
be done automatically. After entering “Cmd Ok”, the following hint message is displayed
in the message window.
Should command lines subsequently be altered, the current robot coordinates will not
be automatically saved.
2.3.3
Function of the left status keys
Provided that the status key bar “ARC Tech”has been selected in the “Configure”menu, four
“ARC Tech 10”--specific control keys for manual wire feed, manually controlled welding and
“DRY”(“dry run”) are available in the left status key bar.
2.3.3.1
Manual control of the wire feed
These two status keys allow wire feed to be controlled manually. The following possibilities
are available:
Status key “+”: wire is fed..
Status key “--”: wire is retracted.
These two functions cannot be used during an active welding process.
The KUKA “SSDV8”controller allows wire to be fed manually at two speeds. Depending on
the default setting, the wire is first fed or retracted slowly and then fed or retracted more
quickly if the key is held down for longer.
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2.3.3.2
The graphic user interface of the KUKA Control Panel (KCP) (continued)
Controlling welding (HOT/COLD) and the “dry run” (DRY)
The two status keys “HOT/COLD”and “DRY”have a toggle function with reciprocal lockout.
It is not possible to switch directly from “HOT”(Welding on) to “DRY”and vice versa.
The screenshot on the left shows the status “Welding and DRY switched off”, which is recognizable by the fact that each of the welding torch icons is struck through. In this position, only
the motions of a welding program can be executed; there is no welding. The wire feed and
the shielding gas are switched off.
The status key “HOT/COLD” must always be switched on (HOT) for welding.
This status key can also be used for manually switching between “HOT” (welding) and
“COLD”(robot motion only), so--called “flying”on/off.
The status key “DRY”is disabled when the status key “HOT”is switched on.
When the status key “DRY”is switched on, the robot moves at a higher velocity (in accordance with the default setting in CONFIG.DAT). In this instance, the welding process, the
wire feed and the shielding gas are switched off and any mechanical weaving that has been
programmed is not executed.
When the system is started up, (hot) welding is always deactivated, as can be seen from the
crossed--out torch symbol in the lefthand status key bar. Before welding can begin, this status
key must be switched to the position “HOT”as illustrated here by the symbol on the left.
The function of both the top left status key “Manual traversing mode”(manual traversing of the robot using the Space Mouse or the right status keys) and the status key
“Program execution mode”, which is situated beneath it, is described in the chapter
[The KUKA Control Panel KCP].
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3
Programming and operation
This section describes how to create new programs and how to program welding and motion
commands. It also contains information on everything that has to be taken into account when
setting individual parameters.
To ensure satisfactory operation, the “ARC Tech 10”package must be configured appropriately. As a user, you are able to retrieve and alter the values of variables with the aid of menus.
For this purpose, an input form can be opened in the status window by means of the menu
“Monitor”-- “Variable”-- “Modify”(see also Section 2.1.2).
Only alter variables if you have adequate knowledge of the function, and of the
possible consequences!
3.1
Basic settings
Detailed information and instructions on these can be found in the documentation
[ARC Tech 10 Ó -- Configuration].
3.1.1
A10_OPTION
The A10_OPTION must always be activated when executing ARC Tech 10 Ó applications.
Appropriate entry by means of the menu function “Monitor”-- “Variable”-- “Modify”:
Variable
Value for ARC Tech
Possible Values
A10_OPTION
#ACTIVE
#ACTIVE, #DISABLED
The setting “A10_OPTION=#DISABLED”causes the error message “Missing ARCSPS or
A_A10_OPTION disabled”to be displayed when the command “ARC ON”is executed.
3.1.2
The entry “ARCSPS.SUB” in the file “$CUSTOM.DAT”
The subprogram “ARCSPS.SUB”must be entered in the file “$CUSTOM.DAT”, which is
located in the directory “...\KRC\MADA\STEU”. This can be checked by means of the menu
function “Monitor” -- “Variable” -- “Modify”. Modifications can only be made in the file
“$CUSTOM.DAT”.
Variable
Value for ARC Tech
Possible Values
$PRO_I_O[]
“/R1/ARCSPS()”
“/R1/ARCSPS()”; “/R1/SPS()”
The setting “$PRO_I_O[]=“/R1/SPS()”” causes an appropriate error message to be
displayed when the command “ARC ON”is executed.
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3.2
Programming and operation (continued)
Adaptation to the periphery
The default variables may have to be changed in order to adapt them to the periphery (welding controller, welding mode, number of analog channels, burnback mode). A brief overview
is given in the following subsections -- detailed information can be found in the documentation
[ARC Tech 10 Ó -- Configuration].
3.2.1
Operating mode (W_Mode)
The ARC Tech 10 Ó package supports two welding processes (modes), “PULSE” and
“MIGMAG”, which are assigned as follows:
Variable
Value
A_ACT_W_MODE
3.2.2
1
Mode 1
PULS
(PS)
2
Mode 2
MIGMAG (MM)
Burnback mode (A_BB_MODE)
It is possible to select between various burnback modes by means of the variable
“A_BB_MODE”.
DECL A_BB_TYPE A_BB_MODE=#ACT_PAR ;#SSDV8_MODE,ACT_PAR,COMPLETE
The manufacturer‘s default setting for “A_BB_MODE”is “#ACT_PAR”.
Appropriate entry by means of the menu function “Monitor”-- “Variable”-- “Modify”:
3.2.3
Variable
Value
Possible values
A_BB_MODE
#ACT_PAR
Default setting
A_BB_MODE
#SSDV8_MODE
KUKA SSDV8 controller
A_BB_MODE
#COMPLETE
Special applications (e.g. other burnback and
crater filling parameters)
Burnback channel for the KUKA SSDV8 controller
When using the KUKA SSDV8 welding controller (A_BB_MODE=#SSDV8_MODE), the
variable “A_BB_CHANNEL”must be assigned a value n that is greater than the value for
“A_ACT_AN_MAX”.
Appropriate entry by means of the menu function “Monitor”-- “Variable”-- “Modify”:
Variable
A_BB_CHANNEL
3.3
Value for “SSDV8”MODE”
3
Entering commands
For a number of commands, the KUKA Control Panel provides several methods of entering
them. For example, the command for opening an inline form for “ARC ON”can be entered
by means of the menu key “Technology”.
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After pressing the menu key “Technology”, it is possible to select options from the menus by
means of the arrow keys.
Provided that the status key option “ARC Tech 10”has been selected from the “Configure”
menu, the key “ARC ON”is available in the softkey bar.
Selecting this option also opens the inline form. Please note that in this case the type of
motion that is displayed corresponds to the setting used for the last command. The desired
motion type can be selected by means of the softkey (the assignment of the softkey bar
changes when the inline form is opened). It is also possible to correct the welding command
“ARC SWI” or “ARC OFF” before programming is completed by entering “Cmd
Ok”.
It is also possible to change the type of motion at any time directly in the inline form, provided
that the box ”Type of motion”is in focus.
-- By opening a submenu using the bottom right status key, the desired type of motion
can be selected by means of the status keys “+”or “--”. The menu is automatically
closed after a short time and the selected motion type is entered into the inline form.
-- By using the keypad, it is possible to change the type of motion by entering the first
letter of the respective command designation (e.g. “P”for PTP).
Precondition: the box
“Type of motion” in
the inline form is in
focus.
Inline form
Bottom right
softkey
Entry by means of
the keypad:
ILF submenu
PTP
LIN
CIRC
3.4
Variables in input boxes of the inline forms
The inline forms contain a series of input boxes, whose designations are freely selectable.
This applies to the boxes
P1 ...
Designation of the destination point
PDAT1 ..., CPDAT1 ...
Designation of the “Movement parameters”data set
S1 ...
Designation of the “Start parameters”data set
W1 ...
Designation of the “Weld parameters”data set
E1 ...
Designation of the “End parameters”data set
SEAM2
Comment
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Programming and operation (continued)
The following must always be observed:
-- The designation can consist of letters and numbers. Special characters are not
allowed. Only the underscore “_”can be used.
-- The first character of a designation must always be a letter.
-- The designation for the boxes mentioned above may consist of a maximum of 11
characters. This limit does not apply to the comment box “SEAM2”.
-- The designation is entered unchanged as a pure character string into all of the subsequent program lines.
-- If the last character is a number, the value of this number is automatically incremented
(n+1), e.g. “W1”, “W2” ... “Wn” or “SEAM_FRONT1”, “SEAM_FRONT2” ...
“SEAM_FRONT99”, in the subsequent commands.
Please remember that the number of characters increases by 1 when going from 9 to
10. Should this lead to the designation exceeding 11 characters, which is not permitted,
an error message will be displayed in the message window.
3.4.1
Explanation of the inline forms
The following sections contain screenshots of the inline forms assigned to each of the “ARC”
commands, showing both the input boxes and the parameter lists that can be opened in the
status window if the cursor is moved to the appropriate box in the inline form.
The operator control elements and symbols that are used here are explained below:
If the inline form is active, the desired input box can be selected by means of the arrow keys.
The selected box is displayed in white lettering on a blue background.
The operator control elements given below the inline form are intended to be an additional
aid to familiarize you with the various possibilities of making entries in inline forms and parameter lists. These have the meanings described below:
If the cursor is positioned in the appropriate box of the inline form, the bottom right status key
can be used to alter the parameters or to select data sets that have already been defined.
It is possible to both enter and alter commands and parameters by means of the keypad (by
pressing the initial letter of the command/parameter).
This symbol indicates that a parameter list (motion or weld parameters) is assigned to the
input box in the inline form. The status window together with the appropriate parameter list
is activated when the “Window selection”key on the graphic user interface is pressed.
This softkey (which is only visible when a parameter list is active in the status window) is used
to exit the status window and activate the corresponding input box in the inline form.
3.4.2
Program run mode for welding
Welding is only possible in the program run mode “GO”. It would not be possible to satisfactorily execute the program in the run modes “MSTEP”and ”ISTEP”. More detailed information
on selecting program run modes can be found in the documentation [Executing and stopping
programs].
When the system is started up, (hot) welding is always deactivated, as can be seen from the
crossed--out torch symbol in the lefthand status key bar. Before welding can begin, this status
key must be switched to the position “HOT”as illustrated here by the symbol on the left.
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3.5
Start welding (ARC ON)
3.5.1
General information
The command “ARC ON”contains the parameters for moving the welding torch (type of
motion, velocity, etc.) from the home position to the start point of the seam, and all the start
and ignition parameters, including options that have been selected (e.g. aluminum ignition
process).
While the program phase “ARC ON” is being executed, the system constantly checks
whether the ignition conditions are satisfied. “ARC ON”ends after ignition has been successfully completed.
3.5.2
Types of motion
The robot can be moved from the home position to the start point of the seam using PTP,
LIN or CIRC motions. Approximate positioning is not possible; the robot is exactly positioned
to each point.
3.5.2.1
Point--to--point (PTP) motions
PTP (point--to--point) motions offer the quickest way of moving the robot to the destination
position and are thus the most efficient.
The path cannot be predicted exactly for PTP motions. The motion characteristics of the robot near obstacles should therefore be checked in a test run.
3.5.2.2
Motion along a straight line (LIN)
LIN (linear) motions are used whenever the robot has to follow an exact path to the destination point (the start of the seam in this case).
3.5.2.3
Motion along a circular path (CIRC)
In the case of CIRC motions, the welding torch is moved along a circular path. This type of
motion is useful for the command “ARC ON”if the welding torch cannot be positioned to the
destination point using a linear motion.
3.5.3
Programming the start of welding (ARC ON)
3.5.3.1
Menu
After selecting the relevant option by means of the menu key “Technology”(”ARC ON -- PTP”
in this example), the inline form described in the next section is opened.
If the status key option “ARC Tech 10”has been selected in the “Configure”menu, the key
“ARC ON”is available in the softkey bar. Selecting this option also opens the inline form.
Please note that in this case the type of motion that is displayed corresponds to the setting
for the last command. The desired motion type can be selected by means of an additional
softkey or in the inline form.
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3.5.3.2
Programming and operation (continued)
Inline form and parameter lists for the command “ARC ON”, “PTP”
Frames
Start parameters
Start Parameter
Tool coordinate
system (1...16 or
NULLFRAME)
Pre Flow Time
Base coordinate
system (1...16 or
NULLFRAME)
Start Time
External TCP
“True”or “False”
Gas preflow time
(0 to 1.5 sec)
Start time
(0 to 1.5 sec)
Voltage
Start voltage
at start (13 to 39V)
Wire Feed
Wire feed rate
(0 to 20 m/min)
Movement
Acceleration
(1 to 100%)
Start Parameter
Only if the number of
analog channels > 2
Reserved for an
additional analog
channel
Softkey bar when the inline form is active
Softkey bar when a parameter list is active
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Brief description of the input boxes of the inline form (from left to right), their functions and
their range of values where applicable:
Box
Function
Range of values, Comments
PTP
Type of motion
Change using bottom right status
key, softkey bar or keypad.
P1
Designation of the end point
(teach using softkey “Touch Up”)
Freely selectable (see Section 3.4)
Change the designation Pn by
using the keypad or the bottom
right status key.
Vel =100%
Path velocity
1 to 100% of the maximum value
(default setting: 100%)
Change by entering a value by
means of the numeric keypad or
the bottom right status key.
PDAT1
Designation of the movement
parameters.
Freely selectable (see Section 3.4)
PS
Welding process
PS = Pulse
MM = MIGMAG
S1
Designation of the start
parameters.
Freely selectable (see Section 3.4)
Seam 2
Comment
Freely selectable (see Section 3.4)
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3.5.3.3
Programming and operation (continued)
Inline form and parameter lists for the command “ARC ON”, “LIN”
After selecting the command “ARC ON -- LIN”, the inline form shown below is opened.
Frames
Start Parameter
Tool coordinate
system (1...16 or
NULLFRAME)
Pre Flow Time
Base coordinate
system (1...16 or
NULLFRAME)
Start Time
External TCP
“True”or “False”
Voltage
Start parameters
Gas preflow time
(0 to 1.5 sec)
Start time
(0 to 1.5 sec)
Start voltage
at start (13 to 39V)
Wire Feed
Wire feed rate
(0 to 20 m/min)
Movement
Acceleration
(1 to 100%)
Start Parameter
Only if the number of
analog channels > 2
Reserved for an
additional analog
channel
Softkey bar when the inline form is active
Softkey bar when a parameter list is active
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Brief description of the input boxes of the inline form (from left to right), their functions and
their range of values where applicable:
Box
Function
Range of values, comments
LIN
Type of motion
Change using bottom right status
key, softkey bar or keypad.
P1
Designation of the endpoint (teach
using softkey “Touch Up”)
Freely selectable (see Section 3.4)
Change the designation Pn by using the keypad or the bottom right
status key.
Vel =1.25m/s
Path velocity
0.001 to 2 m/s
(default setting: 2 m/s)
Change by entering a value by
means of the numeric keypad or
the bottom right status key.
CPDAT1
Designation of the movement
parameters.
Freely selectable (see Section 3.4)
PS
Welding process
PS = Pulse
MM = MIGMAG
S1
Designation of the start
parameters
Freely selectable (see Section 3.4)
Seam 2
Comments
Freely selectable (see Section 3.4)
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3.5.3.4
Programming and operation (continued)
Inline form and parameter lists for the command “ARC ON”, “CIRC”
After selecting the command “ARC ON -- CIRC”, the inline form shown below is opened.
Frames
Start parameters
Start Parameter
Tool coordinate
system (1...16 or
NULLFRAME)
Base coordinate
system (1...16 or
NULLFRAME)
External TCP
“True”or “False”
Pre Flow Time
Start Time
Voltage
Wire Feed
Movement
Acceleration
(1 to 100%)
Start Parameter
Gas preflow time
(0 to 1.5 sec)
Start time
(0 to 1.5 sec)
Start voltage
at start (13 to 39 V)
Wire feed rate
(0 to 20 m/min)
Only if the number of
analog channels > 2
Reserved for an
additional analog
channel
Softkey bar when the inline form is active
Softkey bar when a parameter list is active
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Brief description of the input boxes of the inline form (from left to right), their functions and
their range of values where applicable:
Box
Function
Range of values, Comments
CIRC
Type of motion
Change using bottom right status
key, softkey bar or keypad.
P1
Designation of the midpoint (teach
using softkey “Touchup MP”)
Freely selectable (see Section 3.4)
Change the designation by using
the keypad or the bottom right
status key.
P2
Designation of the end point
(teach using softkey “Touchup
EP”)
Freely selectable (see Section 3.4)
Change the designation by using
the keypad or the bottom right
status key.
For information on the other parameters, see Section 3.5.3.3. Detailed information on
motion programming can be found in the chapter [Motion programming].
3.5.3.5
Parameter list for the start parameters
The values for the start time, the gas preflow time, the ignition voltage and the wire feed rate
at the start are defined in the parameter list “Start parameter”.
This parameter list offers the following ranges of values:
Start Parameter
Pre Flow Time
Start Time
Start parameters, Page 1
Gas preflow time
0 to 1.5 sec
Start time
(delay of weld start)
0 to 1.5 sec
Voltage
Start voltage
13 to 39 V
Wire Feed
Wire feed rate at the start
0 to 20 meters per minute
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Start Parameter
Programming and operation (continued)
Start parameters, page 2
Only if the number of analog channels > 2
(e.g. A_ACT_AN_MAX=3)
Reserved for the parameters of an additional analog channel
3.6
Welding and ending a seam (ARC OFF)
3.6.1
General information
The welding command “ARC OFF”contains the motion and weld parameters for
-- the seam from after welding has been successfully started (ARC ON) up to the end
of the seam, provided that the same motion and weld parameters are used for the
entire seam,
-- the last section of the seam from the command “ARC SWITCH”up to the end of the
seam when the seam is divided into several sections with different motion and/or weld
parameters,
and the end parameters for crater filling, the gas postflow time and burnback of excess wire.
3.6.2
Types of motion for the command “ARC OFF”
Two types of motion can be selected for the command “ARC OFF”:
“LIN”-- linear motion -- and “CIRC”-- motion along a circular path. Approximate positioning
is not possible; the robot is exactly positioned to each point.
3.6.3
Programming “ARC OFF”
3.6.3.1
Menu
After selecting the relevant option by means of the menu key “Technology”(ARC Tech 10 E
-- ARC OFF -- LIN in this example), the inline form described in the next section is opened.
If the status key option “ARC Tech”has been selected in the “Configure”menu, the key “ARC
OFF”is available in the softkey bar. Selecting this option also opens the inline form. Please
note that in this case the type of motion that is displayed corresponds to the setting for the
last command. The desired motion type (“LIN”or “CIRC”) can be selected by means of an
additional softkey or in the inline form.
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3.6.3.2
Inline form and parameter lists for the command “ARC OFF”, “LIN”
Frames
Movement
Tool coordinate
system (1...16 or
NULLFRAME)
Acceleration
(1 to 100%)
Base coordinate
system (1...16 or
NULLFRAME)
External TCP
“True”or “False”
Softkey bar when the inline form is active
Softkey bar when a parameter list is active
Brief description of the input boxes of the inline form (from left to right), their functions and
their range of values where applicable:
Box
Function
Range of values, Comments
LIN
Type of motion
Change using bottom right status
key, softkey bar or keypad.
P2
Designation of the end point
(teach using softkey “Touchup
EP”)
Freely selectable (see Section 3.4)
Change the designation by using
the keypad or the bottom right
status key.
CPDAT1
Designation of the movement
parameters
Freely selectable (see Section 3.4)
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3.6.3.3
Programming and operation (continued)
Inline form and parameter lists for the command “ARC OFF”, “CIRC”
After selecting the command “ARC OFF -- CIRC”, the inline form given below is opened.
Frames
Movement
Acceleration
(1 to 100%)
Tool coordinate
system (1...16 or
NULLFRAME)
Base coordinate
system (1...16 or
NULLFRAME)
External TCP
“True”or “False”
Softkey bar when the inline form is active
Softkey bar when a parameter list is active
Brief description of the input boxes of the inline form (from left to right), their functions and
their range of values where applicable:
Box
Function
Range of values, Comments
CIRC
Type of motion
Change using bottom right status
key, softkey bar or keypad.
P2
Designation of the midpoint (teach
using softkey “Touchup MP”)
Freely selectable (see Section 3.4)
Change the designation by using
the keypad or the bottom right
status key.
P3
CPDAT1
3.6.3.4
Designation of the end point
(teach using softkey “Touchup
EP”)
Designation of the movement
parameters
Freely selectable (see Section 3.4)
Change the designation by using
the keypad or the bottom right
status key.
Freely selectable (see Section 3.4)
Inline form and parameter lists for “ARC OFF”, weld and end parameters
The part of the inline form and the parameter lists for the weld and end parameters of the
command “ARC OFF”are described below.
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Primary Weld
Travel Speed
Primary weld
Ramp function
Welding
velocity
Ramp length
(0 to 2 m/min)
Voltage
Wire Feed
Burnback Time
Mechanical Weaving
Welding voltage
(13 to 39 Volt)
End Set
Voltage (Burnback)
Burnback time
(0 to 1.5 sec)
Wire Feed
Weave Type
Weave pattern
Weave Length
Weave length
(1.5 to 12 mm)
Weave Amplitude(zero to peak)
Weave amplitude
(1 to 15 mm)
Wire feed rate
(0 to 20 m/min)
3) Only for “A_BB_MODE = #COMPLETE”.
End Set
Crater Time
Voltage (Crater Filling)
Weave angle
(--90 to 90 degrees)
Burnback Time
Thermal Weaving
Thermal
weaving 1)
Weave Type
Weave pattern
Voltage
Welding voltage
(0 to 39 Volt)
Post Flow Time
Wire Feed
Wire feed rate
(0 to 20 m/min)
Voltage (Burnback)
Thermal Length
Thermal
weave length
(1.5 to 12 mm)
1) Only for “A_TH_WEAVE_OPT = TRUE”.
End Set 3)
Burnback voltage
(13 to 39 Volt)
Wire Feed
Weave Angle
Ramp length
(0 to 25 mm)
2) Only for “A_RAMP_OPTION = TRUE”.
Wire feed rate
(0 to 20 m/min)
Mechanical
weaving
Ramp function 2)
End Set
End Set
Crater time
(0 to 1.5 sec)
Crater voltage
(13 to 39 V)
Wire feed rate
(0 to 20 m/min)
Burnback time
(0 to 1.5 sec)
End Set
Gas postflow time
(0 to 1.5 sec)
Burnback voltage
(13 to 39 V) 4)
Wire Feed
Wire feed rate
(0 to 20 m/min)4)
4) Only for “A_BB_MODE = #COMPLETE”.
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Programming and operation (continued)
Brief description of the input boxes of the inline form (from left to right), their functions and
their range of values where applicable:
3.6.3.5
Box
Function
Range of values, Comments
PS/MM
Welding process
PS = Pulse
MM = MIGMAG
W1
Designation of the weld
parameters
Freely selectable (see Section 3.4)
E1
Designation of the end parameters Freely selectable (see Section 3.4)
Seam2
Comment
Freely selectable (see Section 3.4)
Inline form with “TRACK” function when LIBO sensor is active (A50)
The inline form illustrated below also contains the selection box “TRACK”. The “TRACK”
function is only available if the LIBO sensor of the A50 technology package has been installed
and activated.
Once “TRACK”has been selected, another box, “T”, is added.
If box “T”has the focus, the parameter list “Tracking Conditions”is opened in the status
window offering the possibility of adjusting the LIBO sensor settings.
Tracking Conditions
Detailed information on the functions and configuration of the LIBO sensor software
package may be found in the chapter [LIBO Sensor A50].
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3.6.4
Parameter list for the weld parameters (W)
The parameter list “Primary Weld”consists of four pages. The parameters entered here are
saved in the data set “Wn”.
3.6.4.1
Primary Weld
This page contains the parameters for the welding voltage and the wire feed rate. If the option
“Thermal weaving”is selected, the values for the welding voltage and the wire feed rate that
are set in this parameter list are the maximum values for each. For information on this, see
Section 3.3.4.3.
This parameter list offers the following ranges of values:
Primary Weld
Travel Speed
Primary Weld
Welding velocity
0 to 2 meters per minute
Voltage
Welding voltage *)
13 to 39 V
Wire Feed
Wire feed rate
0 to 20 meters per minute
Burnback Time
Burnback time
0 to1.5 sec
*) Information about applications in which
thermal and mechanical weaving are
combined can be found in Sections
3.6.4.5 and 3.6.4.6.
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3.6.4.2
Programming and operation (continued)
Mechanical weaving
Mechanical weaving is used, for example, to compensate for component tolerances or to
bridge gaps in a seam.The torch moves across the seam in this instance and the weave oscillation is thus superposed on the seam motion.It is also possible to rotate the torch in relation to the component plane.
The parameter list for mechanical weaving:
Mechanical Weaving
Weave pattern
No weaving,
7 patterns as shown in table
1 freely definable pattern
Weave length *)
1.5 to 12 mm
Weave amplitude
Half the total weave width, from peak to
zero.
1 to 15 mm
Weave angle
--90 to 90 degrees
*) Information about applications in
which thermal and mechanical weaving
are combined can be found in Section
3.6.4.6.
With mechanical weaving -- depending on the weave amplitude and weave length -- the
effective welding velocity is greater than the travel speed.
Weave seam
(Triangle)
Welding torch
Weave amplitude*)
Weave width
1) Weave amplitude = half the weave width
Trapezoidal, spiral and figure--of--eight weave patterns result in a non--uniform effective
welding velocity. This can vary between the set path velocity and a multiple of it during one
period, depending on the relation of the lateral deflection (amplitude) to the weave length.
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Seven weave patterns are predefined by the manufacturer:
s
s
Weave
amplitude
Weave length
Direction
of welding
No weaving
(No Weave)
Triangular weaving
(Triangle)
Triangular weaving
double frequency
(Dbl Triangle)
Trapezoidal
weaving
(Sgl Trapec)
Trapezoidal
weaving
double frequency
(Dbl Trapec)
Trapezoidal
weaving
asymmetric
(Uns Trapec)
Spiral weaving
(Spiral)
Figure--of--eight
weaving
(Double 8)
The lateral deflection (amplitude), the weave length (the length over which a pattern is
executed) and the angle of the torch to the welding plane can be set for each weave pattern.
In the user group “Expert”, one further weave pattern with the name “Usr_define”can
be defined in the file “WEAV DEF.SRC”and existing patterns can be modified.
Information on this can be found in the documentation [ARC Tech 10 E -- Configuration].
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3.6.4.3
Programming and operation (continued)
Weave frequency, weave length, path velocity
Of significance for the correct functioning of the robot is the weave frequency, which
results from the programmed path velocity (travel speed) and weave length. The following relationships exist between these parameters:
Weave frequency f
=
travel speed [m/min] ¯1000
weave length [mm] ¯60
[Hz]
Weave length s
=
travel speed [m/min] ¯1000
weave frequency [Hz] ¯60
[mm]
Travel speed v
=
weave frequency [Hz] ¯weave length [mm] ¯60 [m/min]
1000
These relationships are depicted graphically in the following nomogram.
Weave length s
[mm]
0.3 0.5
12
Weave frequency f [Hz]
0.75 1.0
1.25
1.5
2.0
2.5
3.0
11
10
3.5
4.0
9
8
7
5.0
6
6.5
5
4
3
2
1.5
0
.1
.2
.3
0
Travel speed v
m/min
.4
.6
0.5
.7
.8
.9
.1
.2
.3
.4
1.0
For weave frequencies > 4 Hz
see explanation in text.
.6
.7
1.5
.8
.9
2.0
Non--permissible range
The maximum weave frequency for mechanical weaving is influenced by several factors,
depending on the robot type concerned, for example by the resonant frequency of the
“robot/tool”unit. Weave frequencies of up to 4 Hz (corresponding, for example, to a weave
length of 2.5 mm at a travel speed of 0.6 m/min) are considered safe according to previous
experience.
With higher frequencies, undesirable effects are liable to result in certain conditions
(depending on the tool design and/or tool orientation). With weave frequencies > 4 Hz, the
motion characteristics of the robot should therefore be individually tested in each case.
Further information on Mechanical Weaving can be found in the chapter
[ARC Tech 10 E -- Configuration].
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3.6.4.4
Rotation of the weave plane
In certain applications, it may be necessary to rotate the weave plane. The range of possible
settings is --90 to +90 degrees.
90 degrees
Weave amplitude
Torch plane
Welding torch
Mechanical Weaving
Weave Angle
Component
plane
Weave plane
Weave plane 0 degrees
+ 90 degrees
Weave
plane
0 degrees
Torch plane
Weave
amplitude
-- 90 degrees
Weave
plane
Weave
amplitude
Torch plane
0 degrees
Weave plane +90 degrees
Weave plane --90 degrees
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3.6.4.5
Programming and operation (continued)
Thermal weaving
In conventional welding processes, the values for the welding voltage and the wire feed rate
remain constant. Thermal weaving can be used for certain applications (e.g. for reducing the
welding distortion).
The welding voltage and the wire feed rate are periodically altered in this instance, thus producing a seam with weld metal that varies periodically in relation to these changes.
The robot--specific operating mode “Thermal weaving”has nothing in common with the
“Pulsing”option of welding equipment.
A precondition for the “Thermal weaving” function is that the value of the variable
“A_TH_WEAVE_OPT”is set to TRUE.
Variable
A_TH_WEAVE_OPT
Value
Characteristics
FALSE
Thermal weaving deactivated (default).
TRUE
Thermal weaving activated.
The parameter list for thermal weaving:
Thermal Weaving
Weave Type
Thermal weaving
Weave pattern
without weaving
Triangle
Trapezoid
Voltage
Welding voltage *)
(min. voltage, see Section
3.3.4.1 and the above diagram)
Wire Feed
0 to 39 Volt
Wire feed rate *)
(min. wire feed rate, see Section 3.3.4 and
the above diagram)
0 to 20 meters per minute
Thermal Length
Thermal weave length
1.5 to 12 mm
*) Information about applications in which
thermal and mechanical weaving are combined can be found in Section 3.6.4.6.
The parameter list “Thermal weaving”is only displayed if the value of the variable
“A_TH_WEAVE_OPT”has been set to TRUE.
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Two patterns are predefined by the manufacturer:
Thermal weaving
Triangle
Welding voltage
(volts)
Trapezoid
Thermal
weave
length
Welding voltage
(volts)
Max. voltage *)
(Parameter list
“Primary Weld“)
Max. voltage *)
(Parameter list
“Primary Weld”)
Min. voltage *)
(Parameter list
“Thermal Weaving“)
Min. voltage *)
(Parameter list
“Thermal Weaving“)
Direction of welding
Direction of welding
Wire feed rate
(meters per minute)
Wire feed rate
(meters per minute)
Max. feedrate *)
(Parameter list
“Primary Weld”)
Max. feedrate *)
(Parameter list
“Primary Weld”)
Min. feedrate *)
(Parameter list
“Thermal Weaving“)
Min. feedrate *)
(Parameter list
“Thermal Weaving“)
Direction of welding
Thermal
weave
length
Direction of welding
*) The maximum values for welding voltage and wire feed are normally entered in the
parameter list “Primary Weld”, Page 1, and the minimum values in the parameter list
“Thermal Weaving”.
Applications in which mechanical and thermal weaving are combined are described in
the next section 3.6.4.6.
Detailed information on thermal weaving can be found in the chapter [ARC Tech 10 E
-- Configuration].
3.6.4.6
Combining mechanical and thermal weaving
The options of mechanical and thermal weaving can also be combined for certain
applications.
The following diagram shows an example of the combination of mechanical and thermal
triangular weaving. By synchronizing the mechanical and thermal weave curves – the values
for the mechanical and thermal weave must be the same – the welding voltage and the wire
feed rate are greater on the side of the thicker sheet than on that of the thin sheet.
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Programming and operation (continued)
Maximum values for welding
voltage and wire feed are entered
in the parameter list “Primary
Weld”, Page 1.
+
max. voltage,
max. wire feed
min. voltage,
min. wire feed
--
0°
90°
180°
270° 360°
Minimum values for welding
voltage and wire feed are
entered in the parameter list
“Thermal Weaving”.
Mechanical: Triangle j = 0°
Thermal:
Triangle j = 0°
Mechanical weaving
Thermal weaving
The precondition for synchronization is that the values for the “thermal weave length”
(parameter list “Thermal Weaving”) and the “weave length”in the parameter list
“Mechanical Weaving”are the same.
You can also shift the phase of the thermal weave curve by 180°in relation to the mechanical
weave curve without difficulty. This is done by entering the maximum values for the voltage
and wire feed in the parameter list “Thermal weaving”, and the minimum values in the parameter list “Primary Weld”, Page 1.
As can be seen in the following diagram, the welding voltage and the wire feed rate are, again
in this example, greater on the side of the thicker sheet than on that of the thin sheet.
min. voltage,
min. wire feed
+
Maximum values for welding
voltage and wire feed are entered
in the parameter list “Thermal
Weaving”.
Minimum values for welding
voltage and wire feed are
entered in the parameter list
“Primary Weld”.
max. voltage,
max. wire feed
--
0°
90°
180°
270° 360°
Mechanical: Triangle j = 0°
Thermal:
Triangle j = 0°
Mechanical weaving
Thermal weaving
Further information on mechanical and thermal weaving can be found in the
documentation [ARC Tech 10 E -- Configuration].
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3.6.4.7
Ramp function
The switch from ignition parameters to weld parameters (start or welding voltage and wire
feed) at the end of the start time, i.e. the moment the robot motion begins, normally occurs
without a transition. The switching of weld parameters occurs equally abruptly between
individual ARC SWITCH commands and between ARC SWITCH and ARC OFF.
In certain welding applications – for example aluminum welding – a gradual transition can
improve the welding results. The ramp function makes it possible to increase or decrease
the welding voltage and wire feed within a specified distance – the ramp length – according
to the parameters set.
If, for example, the start voltage is 30 volts and the welding voltage is 26 volts, the voltage
in the ramp length entered in the parameter list “Ramp function”is changed linearly from 30
to 26 volts.
A precondition for the ramp function is that the value of the variable “A_RAMP_OPTION”is
set to TRUE.
Variable
Value
Characteristics
FALSE
Ramp function for welding voltage and wire
feed switched off (default).
TRUE
Ramp function for welding voltage and wire
feed switched on.
A_RAMP_OPTION
The parameter list for the ramp function:
Ramp function
Ramp function
Ramp length
Ramp length
0 to 25 mm
The ramp function is not available if the LIBO sensor (A50 option) is being used. In this
case, the variable must be set to A_RAMP_OPTION = FALSE.
The following diagram illustrates the ramp function.
In the first seam section (ARC SWITCH P1 -- P2) the welding voltage changes, after P1 and
within the ramp length (12 mm), from the value set in the start parameter list to the value (26
volts) set in the welding parameter list (ARC SWITCH). The wire feed changes in the same
way.
In the second seam section (ARC SWITCH P2 -- P3) the welding voltage can be seen to
change from 26 volts to 23 volts within the ramp length (5 mm) after P2. The wire feed value
changes from 15 to 8 m/min.
In the third seam section (ARC OFF P3 -- P4), the ramp length value is 0 mm. The switch
from the weld parameters for the second seam section to those for the third occurs at P3
without a transition.
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1st seam section
ARC SWITCH
2nd seam section
ARC SWITCH
Welding voltage
26
26
Wire feed rate
m/min
15
Ramp length
mm
Start parameters
(ARC ON)
Weld parameters
5
m/min
Ramp length
mm
0
mm
P4
P3
P2
volts
Wire feed rate
m/min
8
Ramp length
P1
Welding voltage
volts
23
Wire feed rate
12
3rd seam section
ARC OFF
Welding voltage
volts
15
Programming and operation (continued)
Welding voltage
+
--
Wire feed rate
+
--
P4
P2
P3
P1
Ramp length
Ramp length
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3.6.4.8
End Set
Burnback is used for burning off excess wire and ensures that the correct free wire length
and an ideal form for the end of the wire are again given for the start process for the following
welding cycle.
This parameter list is only present when the burnback option
“A_BB_MODE=#COMPLETE”is set. It offers the following ranges of values:
End Set
End Set
Voltage (Burnback)
Burnback voltage
13 to 39 V
Wire feed rate
Wire Feed
0 to 20 meters per minute
The parameters for burnback are only effective when the burnback time is greater than
0.
3.6.4.9
Extended weld parameter lists for special applications
Two analog channels, one for the welding voltage and one for the wire feed, are available
as standard for controlling the welding controller. For special applications, the number of
analog channels can be increased by changing the value of the variable “A_ACT_AN_MAX”
accordingly. The burnback option “A_BB_MODE=#COMPLETE”can also be set.
Detailed information on this can be found in Section 2.1.2, and in the documentation
[ARC Tech 10 Ó -- Configuration].
The weld parameter lists (Wn) for applications with three analog channels are given overleaf.
If the number of analog channels is increased further, the number of additional input boxes,
and thus the structure of the parameter lists, is also increased.
Primary Weld
2/5
Primary Weld, Page 2
Reserved for parameters for
an additional analog channel
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End Set
Voltage (Burnback)
Programming and operation (continued)
End Set, Page 5
Burnback voltage
13 to 39 V
Wire Feed
Wire feed rate
0 to 20 meters per minute
Reserved for parameters for
an additional analog channel
3.6.5
Parameter list for the end parameters
3.6.5.1
Standard
The parameter list “End set”consists of two pages. The settings for crater filling, the gas postflow time and burnback are defined here. Burnback is used for burning off excess wire and
ensures that the correct free wire length and an ideal form for the end of the wire are again
given for the start process for the following welding cycle.
Both pages of the parameter list together with the respective ranges of settings are shown
below.
End Set
Crater Time
End Set, Page 1
Crater time
0 to 1.5 seconds
Voltage (Crater Filling)
Crater voltage
0 to 39 V
Wire Feed
Wire feed rate
0 to 20 meters per minute
Burnback Time
Burnback time
0 to 1.5 seconds
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End Set
End Set, Page 1
Post Flow Time
Gas postflow time
0 to 1.5 seconds
Voltage (Burnback)
Burnback voltage *)
13 to 39 V
Wire Feed
Wire feed rate *)
0 to 20 meters per minute
*) The input boxes “Voltage (Burnback) and “Wire Feed (Burnback)”are only available if the
burnback option “A_BB_MODE=#COMPLETE”is set.
The burnback parameters are only effective when the crater fill time (Crater Time) is
greater than zero. If the value for the crater fill time is zero, the burnback parameters
for the last command to be executed are used.
Further information on crater filling and burnback is contained in the documentation
[ARC Tech 10 E -- Configuration].
3.6.5.2
Extended end parameter lists for special applications
Just as with the welding parameter lists, the end parameter lists also change when more than
two analog channels are used.
Detailed information on this can be found in Section 2.1.2, and in the documentation
[ARC Tech 10 Ó -- Configuration].
The welding parameter lists (En) for applications with three analog channels are given overleaf. If the number of analog channels is increased further, the number of additional input
boxes, and thus the structure of the parameter lists, is also increased.
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End Set
Crater Time
Voltage (Crater filling)
Programming and operation (continued)
End Set, Page 1
Crater time
0 to 1.5 seconds
Crater voltage
13 to 39 Volt
Wire Feed
Wire feed rate *)
0 to 20 meters per minute
Burnback Time
Burnback time
0 to 1.5 seconds
End Set
Post Flow Time
End Set, Page 2
Gas postflow time
0 to 1.5 seconds
Reserved for the end parameters of an
additional channel
Voltage (Burnback)
Burnback voltage
13 to 39 Volt
Wire Feed
Wire feed rate
0 to 20 meters per minute
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End Set
End Set, Page 3
Reserved for the burnback
parameters of an additional
channel
3.7
Welding several seam sections -- “ARC SWITCH”
3.7.1
General information
The command “ARC SWITCH”is used between the commands “ARC ON”and “ARC OFF”
when the seam is divided into several sections with different motion and/or weld parameters.
It contains the motion and weld parameters for the current section of the seam, including the
parameters for mechanical and thermal weaving. The set weld parameters are used as a
default setting for all of the following “ARC SWITCH”commands.
3.7.2
Types of motion for the command “ARC SWITCH”
Two types of motion can be selected for the command “ARC SWITCH”:
“LIN”-- linear motion -- and “CIRC”-- motion along a circular path. While the robot is always
exactly positioned in the case of “ARC ON” and “ARC OFF”, approximate positioning is
possible with “ARC SWITCH”.
3.7.3
Programming “ARC SWITCH”
3.7.3.1
Menu
After selecting the relevant option by means of the menu key “Technology”(“ARC SWITCH
-- LIN”in this example), the inline form described in the next section is opened.
Alternatively, you can also press the softkey “ARC ON”or “ARC OFF”and -- after the inline
form has been opened -- the new softkey “ARC SWI”. To do so, the status key option “ARC
Tech”must have been selected in the “Configure”menu.
Again, please remember that the type of motion that is displayed corresponds to the setting
for the last command. The desired motion type (“LIN”or “CIRC”) can be selected by means
of an additional softkey or in the inline form.
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3.7.3.2
Programming and operation (continued)
Inline form and parameter lists for the command “ARC SWITCH”, “LIN”
Frames
Movement
Tool coordinate
system (1...16 or
NULLFRAME)
Acceleration
(1 to 100%)
Base coordinate
system (1...16 or
NULLFRAME)
Only when “CONT”
is used (approximate positioning):
start of approximate positioning
(1 to 100 mm)
External TCP
“True”or “False”
Softkey bar when the inline form is active
Softkey bar when a parameter list is active
Brief description of the input boxes of the inline form (from left to right), their functions and
their range of values where applicable:
Box
Function
Range of values, Comments
LIN
Type of motion
Change using bottom right status
key, softkey bar or keypad.
P2
Designation of the end point
(teach using softkey “Touch Up”)
Freely selectable (see Section 3.4)
Change the designation by using
the keypad or the bottom right
status key.
CONT
Approximate positioning
no entry = without approximate
positioning
CONT = with approximate
positioning
CPDAT1
Designation of the movement
parameters
Freely selectable (see Section 3.4)
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3.7.3.3
Inline form and parameter lists for the command “ARC SWITCH”, “CIRC”
After selecting the command “ARC ON -- CIRC”, the inline form given below is opened.
Frames
Movement
Tool coordinate
system (1...16 or
NULLFRAME)
Acceleration
(1 to 100%)
Base coordinate
system (1...16 or
NULLFRAME)
Ext. TCP
“True”or “False”
Only when
”CONT”is used
(approximate
positioning):
start of approxi-mate positioning
(1 to 100 mm)
Softkey bar when the inline form is active
Softkey bar when a parameter list is active
Brief description of the input boxes of the inline form (from left to right), their functions and
their range of values where applicable:
Box
Function
Range of values, Comments
CIRC
Type of motion
Change using bottom right status
key, softkey bar or keypad.
P2
Designation of the midpoint (teach
using softkey “Touchup MP”)
Freely selectable (see Section 3.4)
Change the designation by using
the keypad or the bottom right
status key.
P3
Designation of the end point
(teach using softkey “Touchup
EP”)
Freely selectable (see Section 3.4)
Change the designation by using
the keypad or the bottom right
status key.
CONT
Approximate positioning
No entry = without approximate
positioning
CONT = with approximate
positioning
CPDAT1
Designation of the movement
parameters
Freely selectable (see Section 3.4)
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Programming and operation (continued)
Detailed information on motion programming can be found in the chapter [Motion
programming].
3.7.3.4
Inline form and parameter lists for “ARC SWITCH”, weld parameters
The part of the inline form and the parameter lists for the weld parameters of the command
“ARC SWITCH”are described below.
Primary Weld
Primary Weld
1) Only if “A_TH_WEAVE_OPT = TRUE”.
Thermal Weaving
Travel Speed
Welding velocity
(0 to 2 m/min)
Thermal
Weaving 1)
Weave Type
Voltage
Weave pattern
Welding voltage
(13 to 39 Volt)
Voltage
Wire Feed
Wire feed rate
(0 to 20 m/min)
Wire Feed
Burnback Time
Burnback time
(0 to 1.5 sec)
Thermal Length
Mechanical Weaving
Mechanical
Weaving
Weave Type
Weave pattern
Weave Length
Weave length
(1.5 to 12 mm)
Weave Amplitude(zero to peak)
Weave Angle
Weave amplitude
(1 to 15 mm)
Weave angle
Ramp function
Ramp length
Welding voltage
(0 to 39 Volt)
Wire feed rate
(0 to 20 m/min)
Thermal
weave length
(1.5 to 12 mm)
Ramp function 2)
Ramp length
(0 to 25 mm)
2) Only if “A_RAMP_OPTION = TRUE”.
End Set
Voltage (Burnback)
(--90 to 90 degrees)
Wire Feed
End Set 3)
Burnback voltage
(13 to 39 V)
Wire feed rate
(0 to 20 m/min)
3) Only if “A_BB_MODE = #COMPLETE”.
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Brief description of the input boxes of the inline form (from left to right), their functions and
their range of values where applicable:
Box
Function
Range of values, Comments
PS/MM
Welding process
PS = Pulse
MM = MIGMAG
W1
Designation of the weld parameters
Freely selectable (see Section 3.4)
Seam2
Comment
Freely selectable (see Section 3.4)
Information on the parameter list “Primary Weld”and explanations of mechanical and
thermal weaving can be found in Section 3.3.4.
3.8
Motion commands
The command “Motion”from the menu “Commands”is used for moving the welding torch,
e.g. from the end of a seam (ARC OFF) to the home position of a subsequent “ARC ON”
command, and for reorientating it when necessary.
Information on motion programming can be found in the chapter
[Motion programming].
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4
4
Program example
Program example
The use of the individual “ARC Tech 10”commands will now be described step by step on
the basis of a simple program example. The welded assembly shown below, consisting of
three individual parts, is to be fabricated by means of two seams.
Welding torch
Home position
Seam 2/3
Seam 1
Seam 2/2
Motion
--PTP
Seam 2/1
ARC (SWI) -- CIRC
4.1
Creating a new program
To create a new program, press the softkey “New”and enter a program name (e.g. “Test”)
in the input box.
Further information on creating and altering programs can be found in the chapter
[Program creation]. Details on motion commands can be found in the chapter [Motion
programming].
Now press the softkey “Select”. The following skeleton program is displayed in the programming window:
Pay attention to the position of the edit cursor. The following program line created by you will
be inserted as a new line after the cursor.
Alternatively, you can program in offline mode by means of the softkey “Edit”. The syntax will
not be checked, however.
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4.2
Starting welding of seam 1 -- “ARC ON”
Home
position
ARC ON -- PTP
P1
Seam 1
Press the menu key “Technology”and select the options shown below (menu items in white
lettering on a blue background):
This command can also be entered by means of the softkey “ARC ON”if the status key option
“ARC Tech”has been selected.
After selecting the command “ARC ON -- PTP”, the inline form for setting the parameters that
is shown below is opened on the display. If this command has been selected by means of
the softkey “ARC ON”, the motion type (in the first box of the inline form) must be changed
to “PTP”using the procedure described earlier.
You can also correct your original selection (ARC command/motion command, type of
motion ...) by means of this softkey bar. The inline form changes accordingly when a selection
is made. The softkey “Cmd Abort”can be used to abort the command without saving data.
Now enter the motion and welding parameters into both the inline form and the corresponding
parameter lists.
An overview of both the inline input boxes and the parameter lists can be found in
Section 3.5.3.
For the purpose of positioning the welding torch, move it to the position P1 by means of the
Space Mouse or the traversing keys. Information on controlling motions of the robot manually
can be found in the chapter [Manual traversing of the robot].
You can now press the softkey “Touchup”. In this case, press the softkey “Yes”to confirm
the query “Touchup really?”that is displayed in the message window. Alternatively, press the
softkey “Cmd Ok”or the Enter key. The current robot coordinates are automatically saved.
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4
Program example (continued)
The command is ended by pressing the softkey “Cmd Ok”or the Enter key. If the point P1
has not yet been touched up, the current robot coordinates are now automatically saved. The
information message “Point P1 created automatically”is displayed in the message window.
After that the inline form is closed and the generated program line is inserted into the program
form. The numbers of the following program lines are automatically updated.
4.3
Ending welding of seam 1 -- “ARC OFF”
As only a straight seam, with the motion and welding parameters remaining the same, is to
be welded in this example, only one “ARC OFF” command is required. This command
contains the motion, welding and end parameters for the seam.
P1
Seam 1
ARC OFF -- LIN
P2
After pressing the menu key “Technology”, select the options shown below:
This command can also be entered by means of the softkey “ARC OFF”if the status key
“ARC Tech”has been selected.
After selecting the command “ARC OFF -- LIN”, the inline form for setting the parameters
that is given below is opened on the display. If this command has been selected by means
of the softkey “ARC OFF”, the motion type (in the first box of the inline form) must be changed
to “LIN”using the procedure described earlier.
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Now enter the motion and welding parameters into both the inline form and the corresponding
parameter lists.
Overviews of both the inline input boxes and the parameter lists for the command “ARC
OFF”can be found in Section 3.6.3 of this chapter.
To position the welding torch, move it to the position P2 by means of the Space Mouse or
the traversing keys.
You can now save the coordinates for this point by means of the softkey “Touch Up”or you
can automatically save them by pressing the softkey “Cmd Ok”or the Enter key.
Pressing “Cmd Ok”or the Enter key closes the inline form and the created program line is
inserted into the program form. The numbers of the following program lines are automatically
updated.
4.4
Moving to seam 2 (PTP) and starting welding -- “ARC ON”
In order to move from the end point of seam 1 (P2) to the start point of seam 2 (P4) via the
intermediate point (P3), you can, for example, enter the command “ARC ON -- CIRC”. Positioning the welding torch directly by means of a PTP motion might involve the risk of it colliding
with the workpiece.
In this example, the path is covered by means of two PTP motions, as this type of motion
is normally the quickest. A motion command (PTP with approximate positioning) is used for
the path P2 -- P3 and the path P3 -- P4 is covered by means of the command “ARC ON -PTP”.
P1
ARC ON -- PTP
Seam 1
ARC ON -CIRC
P3
P4
Seam 2
P2
Motion
--PTP
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4.4.1
Program example (continued)
Moving to the point in space P3
Press the softkey “Motion”. The displayed (default) type of motion must be changed to “PTP”
in the inline form, if necessary.
After selecting the command “Motion -- PTP”, the inline form for setting the parameters given
below is opened on the screen:
Position the welding torch to the point in space P3. You can define this point in any way you
like but it should ensure an optimal path. During this motion, also orientate the torch in
accordance with the opposite direction of welding used for the second seam. If desired, the
robot coordinates can be saved by means of the softkey “Touch Up”.
Finally, press the softkey “Cmd Ok”. If the robot coordinates have not yet been saved, this
is done automatically and the program form is updated accordingly.
4.4.2
Starting welding of seam 2 -- “ARC ON”
Select the command “ARC ON”-- “PTP”. The following new inline form is opened:
The new designations of the motion parameters (PDAT3), the start parameters (S2) and the
numbering for the comment (Seam3) have automatically been generated.
Use the procedure described in Section 4.4. After all of the commands have been entered,
the program form contains the motion command (to point P3) in line 6 and the welding
command “ARC ON”-- “PTP”(to point P4) in line 7.
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4.5
Welding seam 2 (up to P8)
Seam 2 contains a straight section (from P4, where welding starts, to point P5), followed by
a circular section (to point P7 via point P6) and finally a straight section (to the end of the seam
P8).
P1
P8
Seam 2/3
ARC OFF
--LIN
P7
Seam 2/2
P4
P6
P5
Seam 2/1
P2
ARC(SWI)
CIRC
LIN
The first section of the seam is programmed as “ARC SWITCH”with the motion type “LIN”
and the second section as “ARC SWITCH”with the motion type “CIRC”. The command “ARC
OFF”with the motion type “LIN”ends the seam.
4.5.1
Section P4 ... P5 -- “ARC SWITCH” -- “LIN”
After pressing the menu key “Technology”, select the options shown below:
“ARC Tech10 E ”-- “ARC SWITCH”-- “LIN”.
Alternatively, you can also press the softkey “ARC ON”or “ARC OFF”and -- after the inline
form has been opened -- the new softkey “ARC SWI”. To do so, the status key option “ARC
Tech”must have been selected in the “Configure”menu.
Again, please remember that the type of motion that is displayed corresponds to the setting
for the last command. The desired motion type (“LIN”or “CIRC”) can be selected by means
of an additional softkey or in the inline form.
The following inline form appears on the screen:
After entering the motion and welding parameters, press the softkey “Cmd Ok”. The program
form is updated accordingly.
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4.5.2
Program example (continued)
Section P5 ... P6 ... P7 -- “ARC SWITCH” -- ”CIRC”
The following section of the seam also requires the command “ARC SWITCH”. As the seam
does not run in a straight line, however, but is circular, the motion type “CIRC” must be
selected.
Select the command “ARC SWITCH” -- “CIRC”using the menu key “Technology” or the
appropriate softkeys. The following inline form appears on the screen:
This form, with which you will already be familiar from the “LIN”command, contains the
midpoint P6 which is required for the CIRC motion. The additional softkey “Touchup MP”can
also be seen in the softkey bar.
Unlike seams along a straight line, whose destination point coordinates are automatically
saved when the command is ended, the intermediate point coordinates must be saved by
means of “Touchup MP”for a CIRC motion.
For this purpose, position the welding torch to the intermediate point P6 (pay attention to the
orientation during this motion) and press the softkey “Touchup MP”. Use the softkey “Yes”
to respond to the query “Touchup really?”.
Then move the torch to the end point P7 of this seam section, again paying attention to the
orientation. You can save the current robot coordinates straight away by means of the softkey
“Touchup EP”or by pressing the softkey “Cmd Ok”or the Enter key.
4.5.3
Ending welding of seam 2 -- “ARC OFF”
The welding command “ARC OFF”is used for the last section. Use the procedure described
in Section 4.3.
The three commands that were entered last are shown in lines 8, 9 and 10 of the following
screenshot.
The motion command “PTP HOME”in the twelfth line (automatically generated as part of
the program) returns the welding torch to its home position. This concludes programming for
this program example.
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5
Altering existing programs
It is possible to alter commands and/or parameters and to delete command lines in an existing program at any time. Two examples are given below.
5.1
Altering command lines
The procedure for altering command lines is demonstrated below by using a different type
of motion from the end of the first seam (P2) to the point in space P3 from that used in the
program example given above.
The type of motion is to be changed from “PTP”to “LIN”.
Move the edit cursor to line 6 (P3) by means of the arrow keys.
Press the softkey “Change”. The inline form for this command line is opened.
Press the softkey “LIN/CIRC”. Alternatively, the motion type “LIN”can also be selected by
means of the bottom right status key if the first box on the left (type of motion “PTP”) is active.
The inline form changes accordingly.
Enter the new parameters and then press the softkey “Cmd Ok”or the Enter key. The inline
form is closed and the program form is updated accordingly.
5.2
Deleting program lines
In the following example, a “SPOT Tech”command, which now appears as line 10 in the
program form, has been entered by mistake.
This command line is to be deleted. To do so, move the edit cursor to line 10 and press the
menu key “Program”.
Select “Delete Line”by using the arrow key or press the key “1”on the numeric keypad (do
not press Enter). If you press “Yes”to respond to the request for confirmation in the message
window, the selected line is deleted and the program form is updated accordingly.
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5.3
Altering existing programs (continued)
Adding commands to an existing program
The procedure for adding commands to an existing program is given below. A further part
is added to the welded assembly described in Section 4.
(P3)
P12
Motion
-- PTP
ARC ON
--PTP
P4
P3
P2
P9
P10
Motion
-- PTP
P11
ARC ON
--PTP
NEUES TEIL = NEW PART
ARC (SWI)
--LIN
ARC (SWI)
--LIN
For design reasons, this seam for the new part must be welded using different parameters:
it is to be welded as a normal straight seam in the first section and mechanical triangular
weaving is to be used in the second.
There are several ways of achieving this, e.g. the new seam could be welded last. However,
this would not be an efficient procedure for the entire sequence. To optimize execution and
the time taken to perform the operation, it is better to execute the welding process for this
new part immediately after seam 1 has been welded.
The following changes, therefore, have to be made to the program:
-- Alter the command “Motion”(P3)
-- Insert the command “ARC ON”(P9)
-- Insert the command “ARC SWITCH”(P10)
-- Insert the command “ARC OFF”(P11)
-- Insert the command “Motion”(P12)
The modified welded assembly is illustrated in the following diagram.
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Home position
ARC ON -- PTP
P1
P8
Seam 3/3
ARC OFF
--LIN
P7
Seam 1
Seam 3/2
ARC (SWI)
--CIRC
P6
Motion
-- PTP
ARC OFF
--LIN
Seam 3/1
P5
P3
P2
P12
P9
P10
Seam 2/1
P4
ARC (SWI)
--LIN
P11
ARC ON
--PTP
Motion
-- PTP
Seam 2/2
ARC ON
--PTP
NEUES TEIL = NEW PART
5.3.1
ARC (SWI)
--LIN
ARC (SWI)
--LIN
Description of the alteration
To alter the program, open the program form from the previous section.
5.3.2
Altering the command “Motion” (to P3)
Move the edit cursor (the blinking vertical line) to line 6 (P3).
Move the welding torch to the new position of the point in space P3 and press the softkey
“Touch Up”. When asked if you want to touch this point, answer “Yes”.
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5.3.3
Altering existing programs (continued)
Inserting the start of welding for the new seam -- “ARC ON”
Before opening the menu, ensure that the edit cursor (the blinking vertical line) is positioned
in line 6. Insert the command “ARC ON -- PTP”for the new point P9. Use the procedure
described in Section 3.5.
5.3.4
Inserting the first section of the new seam -- “ARC SWITCH”
Select the command “ARC SWITCH”-- “LIN”from the menu “Motion”as the option for the
first section (from P9 to P10) of the new seam.
After entering the motion and weld parameters press the softkey “Cmd Ok”or the Enter key.
The program form is updated accordingly.
5.3.5
Inserting the second section of the new seam -- “ARC OFF”
The second section (from P10 to P11) is executed using “mechanical weaving”. As this seam
ends at P11, the command “ARC OFF”is used. Select the command “ARC OFF”-- “LIN”from
the menu “Technology”or by means of the softkey bar.
Enter the motion and weld parameters into both the inline form and the corresponding
parameter lists. To enter the parameters for mechanical weaving, open the parameter list
“Mechanical Weaving”.
Mechanical Weaving
Weave Type
Weave Length
Weave Amplitude(zero to peak)
Weave Angle
Select the desired weave pattern (“Triangular weaving” -- “SGL_TRI” in our example) by
means of the bottom right status key. To do so, the input box “Type”must be active. Then
enter the values for the weave length, the lateral deflection (weave amplitude) and the angle
of the torch (weave angle).
Detailed information on thermal weaving can be found in Section 3.6.4.2.
Press the softkey “Cmd Ok”. The program form is updated accordingly.
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5.3.6
Inserting a point in space -- “Motion”
Finally, the motion from the end point of the new seam (P11) to the start of the next seam
(P4) must be programmed. A further point in space (P12) is required between P11 and P4
for this purpose.
Insert this command following the description given in Section 4.4.1. After ending this command, alteration of the program is completed. The new commands appear in lines 7 to 10
of the program form.
1
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Index
Symbols
#ACT_PAR, 21
#COMPLETE, 21
#SSDV8_MODE, 21
$CUSTOM.DAT, 8, 20
$PRO_I_O[ ], 20
Controlling welding, 19
Crater time, 34, 47, 49
Crater voltage, 34
D
Delay of weld start, 30
Deleting program lines, 62
Displaying variables, 11
DRY, 19
A
A_ACT_AN_MAX, 21, 46
A_ACT_W_MODE, 21
A_BB_CHANNEL, 21
A_BB_MODE, 21
A_BB_MODE = #COMPLETE, 34, 46, 53
A_RAMP_OPTION = TRUE, 34, 53
A10_OPTION, 8, 20
A50, 35
Adding commands to an existing program, 63
Altering command lines, 62
Amplitude, weaving, 38
ARC OFF, 9, 31, 57
ARC OFF CIRC, 33
ARC OFF LIN, 32
ARC OFF weld and end parameters, 33
ARC ON, 9, 24, 56
ARC ON CIRC, 29
ARC ON LIN, 27
ARC ON PTP, 25
ARC SWITCH, 9, 50, 60
ARC SWITCH CIRC, 52
ARC SWITCH LIN, 51
ARC SWITCH weld parameters, 53
ARC Tech 10 program structure, 10
ARC20, 8
ARCSPS, 20
ARCSPS.SUB, 20
E
E..., 22
End Set, 47
End Set (seam--specific burnback data), 34
Exact stop, 24
Executing and stopping programs, 23
F
Figure--of--eight weaving, 38
G
Gas postflow time, 48, 49
Gas preflow time, 25, 27, 29, 30
H
HOT/COLD, 19
I
INI, 9
Inline form, 16, 23
IOSYS.INI, 8
L
LIBO sensor (A50), 35
LIN, 24
B
Basic settings, 8, 20
Burnback mode, 21
Burnback time, 36, 46, 47, 49
Burnback voltage, 34, 46, 47, 53
C
CIRC, 24
Combining mechanical and thermal weaving,
42
M
Maximum weave frequency, 39
Mechanical weaving, 37, 65
Menu keys, 11, 15
Message window, 14
MIGMAG, 21
MM, 21
Modes, 21
Motion characteristics of the robot, 39
Index -- i
Index
T
P
P..., 22
Parameter list for the end parameters, 47
Parameter list for the start parameters, 30
Parameter list for the weld parameters (W), 36
Parameter lists, weld parameters, 53
PDAT..., 22
Periphery, 21
Primary Weld (weld parameters), 36
Program run mode, 23
Programming window, 13
PS, 21
PTP, 24
PULSE, 21
Technology, 15
Thermal weaving, 41
TRACK, 35
Trapezoidal weaving, 38
Travel speed, 39
Triangular weaving, 38
Type of motion, 15, 22
Types of motion, 24
V
R
Variables in input boxes of the inline form, 22
Ramp function, 44
Resonant frequency, 39
Rotation of the weave plane, 40
S
W
W..., 22
S..., 22
SEAM..., 22
Softkey ARC OFF, 17
Softkey ARC ON, 17
Softkeys, 17
Spiral weaving, 38
SSDV8, 21
SSDV8 controller, 21
Start time (ignition time), 25, 27, 29, 30
Start voltage, 25, 27, 29, 30
Start welding, 24
Status key ”+”, 18
Status key ”--”, 18
Status key ”DRY”, 19
Status key ”HOT/COLD”, 19
Status keys, 11
Status window, 13
Weave amplitude, 37
Weave angle, 37
Weave frequency, 39
Weave length, 38, 39
Weaving, mechanical, 37
Weaving, thermal, 41
Welding and ending a seam, 31
Welding processes, 21
Welding several seam sections, 50
Welding velocity, 36
Welding voltage, 36
Wire feed, 18
Wire feed rate, 25, 27, 29, 36, 46
Wire feed rate at the start, 30
Index -- ii