ArcTechDigital Pro En

SOFTWAREKR C... ArcTechDigital 2.3 for power sources with program number control Configuration for KUKA.KR C 5.2, 5.3, 5.4, 5.5 Issued: 11 April 2006 ArcTechDig_P_R23 04.07.00 en Version: 00 1 of 68 e Copyright 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 ArcTechDig_P_R23 04.07.00 en 2 of 68 Contents 1 1.1 1.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System requirements, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of the configurable options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 8 9 2 2.1 2.1.1 2.1.2 2.1.3 2.2 2.2.1 2.2.2 2.3 2.3.1 2.3.2 2.4 2.4.1 2.4.2 Description of the “ArcTechDigital” commands . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Keyswitch for program execution without welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program run mode “GO” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switching on the welding process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start welding -- ARC ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic sequence diagram ARC ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal diagram ARC_ON and ARC_SWI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welding and ending seams -- ARC OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic sequence diagram ARC OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal diagram ARC_OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welding a seam in several sections -- ARC SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic sequence diagram ARC SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal diagram ARC_SWI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 11 11 11 11 11 12 13 13 14 15 15 16 17 3 3.1 3.2 Programs of the ArcTechDigital package . . . . . . . . . . . . . . . . . . . . . . . . . . Program structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of the “ArcTechDigital” files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 19 20 4 4.1 4.2 4.3 4.3.1 ArcTechDigital - basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activating the ARC 20 option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum configuration for power source interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum configuration for program number control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meaning of the variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 23 23 25 28 5 5.1 5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.2.2.1 5.3 5.3.1 5.3.2 Principles of the definable signal table . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview, definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index tables for configuring physical outputs and inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal tables for digital outputs and inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index table for physical digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal tables for digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definition of the signal states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index table for physical digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal tables for digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 29 29 29 30 30 31 31 32 32 33 6 6.1 Assignment of the signal grouping in normal operation . . . . . . . . . . . . Assignment of the outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 35 ArcTechDig_P_R23 04.07.00 en 3 of 68 . . . . . . . . . . . . . . . . . . . Output group O_STROB_PGNO [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Further options . . . . . . . . . Welding faults and robot faults . . . . . . . . . . . . . . . . . . . . . . . .6 9. . . . Reaction to robot faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 6. . . . . . .1. . . . . . . . . . . . .1 7. . . . . . . . . . . . . . . . . . . . . . . Signal APPL_RUN . . . . . . .3 6. .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . .00 en 4 of 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .1 6. . . . Output group O_FLT_CLEAN [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . . . . . . . . . . . . . . . . .2 6. . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output group O_SEAM_END [ ] . . . . . . . . .2 6. . . . . . . . . . . . Special feature IR_STOPMESS program . . . . . . . . . . . . . . . . . . .5 9.4 6. . . . . . . . . . . . . Setting -. . . . .6 Output group O_WELD_START [ ] . . . . . . . . . . Configurable fault service functions . . . . . . . . . . . . . . . .07. . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 47 47 48 8 8. . . . . . .1 8. . . . .3. . . . . . . .1 9. . . . . . . . . . . . . .3. . . . . . . .1 Enumeration of the signal groups for fault service functions . . . . . . . . . . . . . Timing diagram – program number interface (a) . . . . . . . .3. . . . . . Signal output group O_ACK_FLT [ ] . . . . Assignment of the inputs . . .parity bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 6. . . . . . . . .3 9. .3 Setting the restart options . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 49 49 50 50 50 9 9. . . . .1. . . . . . . . . . .1 9. .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 9. . . . . . . . . . . . . . .2 6. . . . . . . . . . . . . . . . . . . . Input group I_WELD_END [ ] . . . . . . . . . . . . . . . . . . . . . .2 7. . Ignition repetition monitoring . . . . . . . . . . . . . Types of faults and causes . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time_out when polling the inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 9. . . . . . . . .5. . . . . . . . . . .2 6. . . Joint activation/deactivation routines . . . . . . . . . . . . . . . . . . . . . . Signal output group O_FLT_WELD[ ] . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . Program test in manual mode . . . . . . . . . . . . . . . . . . .5 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Options for program number specification . . . . Output group O_FLT_ARC_ON [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 9. . . . . . . . . . . . . . . . . . . . . . . . . Output group O_ACK_WELD_E[ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 6. . . . . . . . . .1. . . . . . . .3 6. . .4 9. . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Polling of the external keyswitch (Hot/Cold) . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . .1 9. .5 9. . . . . . . . . . . .2. . . . . . . . . . . . . . . . 35 36 37 37 38 39 39 40 41 41 42 42 43 43 44 45 45 7 7. . . . . . . . . . . . . . . . . . RESTART_OPTION . . . .1 6. . . . . . . . Signal flow of the program numbers . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 6. . . . . . . . Input group I_START_MOVE [ ] . . . . . .4 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reaction to interpreter stop (STOP key) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal O_FLT_SIGNAL . . . . Fault service functions defined by the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . . . . . . . . . Output group O_ACK_START [ ] . . . . Input group I_WELD_COND [ ] . . . . . . . . .2. . .2 8. . 51 51 51 51 51 51 52 52 52 52 53 53 53 54 54 10 10. . . . . . . . . . . Input group I_WELD_FLT [ ] . . . . . . . . . . . . . . . . . . . 55 55 ArcTechDig_P_R23 04. . . . . . . . . . . . . . . . . . . Configuration in event of ignition faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output group O_FLT_WELD [ ] . . . Signal output group O_FLT_ARC_ON[ ] . . . . .4 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ArcTechDigital 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 8. Ignition faults . . . . . Output group O_ACK_FLT [ ] . . . . . . . . . . . . . EMERGENCY STOP and DRIVES OFF . . . . . . . . .2. . . . . . . . . . . . . . . Signal output groups for fault service function . . . . . . . . . . . . . . . . . . . . . .4 9. . . . . . . . . . . . . . . . . . . . .3 6. . . . . . .1 8. Signal output group O_FLT_CLEAN[ ] . . . . . . . . . . . . . . . . . . . .4. . Ignition fault message suppression option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Message text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 11. . . . . . . . . . . . . .1 11. . . . . . . . . . . .10. . . . . . . . . . . . 55 55 11 11. . .2 10. .00 en 5 of 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Block selection response . . . . . . . . . . . . . . . . . .2 12. . . . . . . . . . . . . . .2 11. . . .3 Ignition fault message suppression option . . . . . . . . . . . . Notes on mechanical weaving . . . . . . . Message time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Creating the “Spiral” weave pattern . . . . . . . . . . . . . Seam monitoring delay option . . . . . . . . . .4 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 12. . . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . “Figure--of--eight” weave pattern . . . . . . . . . . . . . . . . . . .3 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two--dimensional weaving . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . .5 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List of error messages . . . . 65 65 65 65 66 66 66 ArcTechDig_P_R23 04. . . . . . . . . . . . . . . . . . . . . . . .2 11. . . . . . . . . . . . . . . . . . . . . . . . .07. . . . . . . . . . . .1 11. . . . .2.2. . . . . . . . . . . . . . .5 Mechanical weaving . . . . . . . Changing and creating patterns for mechanical weaving .3 12. .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 11. . . Weave patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Creating your own weave patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Message groups . . . . . . . . . 56 56 57 59 59 61 62 62 63 64 12 12. . . . . . . . . . . Changing existing weave patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . .4. . . . . . . . . . . . .6 Error messages / troubleshooting . . . . .1 12. . . . . . Originator . . . . . . . . . . . . Message number . . . . . . . . . . . 00 en 6 of 68 .3 ArcTechDig_P_R23 04.ArcTechDigital 2.07. Simple operation using application--specific softkeys and menus. Various routines used for ignition faults and monitoring of the number of ignition attempts. Use of the function generators for two--dimensional mechanical weaving as well as the possibility of configuring your own weave patterns. information on standard routines as well as specific “ArcTechDigital” applications have also been provided. The entire range of KRL commands are available to you at the expert level. “ARC OFF” and “ARC SWITCH” are described in Chapter 2. Restart options in case of faults. This requires sufficient knowledge of the KRL programming language. The transfer of program numbers is explained in Chapter 7. parameter and hardware configuration and programming of arc welding applications. The configuration of the digital input and output groups is dealt with in Chapter 6.00 en 7 of 68 . The entire range of KRL commands are available to you at the expert level. ArcTechDig_P_R23 04. Simple setting of variables. Prepared programs and subroutines. as well as uncomplicated handling of the “ArcTechDigital” technology package.1 General 1 General In the development of a welding robot that is easy and safe to use. Adaptation to various welding controllers with program number control and their different coding systems. entries required in files. In addition to fundamental descriptions accompanied by schematic sequence diagrams and screenshots of application tests. Chapter 5 explains adaptation to the peripheral equipment. Configuration requires sufficient knowledge of the KRL programming language. ArcTechDigital -. Further ArcTechDigital settings can be found in Chapter 10.07. and parameter lists. as well as uncomplicated handling of the ArcTechDigital technology package. This is intended to allow the trouble--free operation. information is provided on variable settings. top priority was given to the optimized adaptation of the operator interface and the interfacing capability to welding equipment with program number control. top priority was given to the optimized adaptation of the operator interface and the interfacing capability to welding equipment with program number control. Chapter 9 finally deals with fault situations and fault service functions. Adaptation to the peripheral equipment and configurable options of the digital outputs. their possible causes and appropriate corrective measures are described. ArcTechDigital features: G G G G G G G G G Menu--guided creation of programs at the user level. entries in files and parameter lists. Information and notes on “ArcTechDigital”--specific basic settings are provided in Chapter 4. Types of faults that can occur during the ignition and welding processes. The “ARC Tech 20” commands “ARC ON”. Chapter 3 provides information on the programs and files contained in the ArcTechDigital package. Among other things. Chapter 8 contains information on the restart options. This documentation has been created as a supplement to the documentation [Arc Welding.Operation] for the user group Expert. This is intended to make parameter and hardware configuration and the programming of arc welding applications easier. In the development of a welding robot that is easy and safe to use. KR C2ed05 -.1 onwards.00 en 8 of 68 . and the configuration of weave patterns. reinstallation and update of technology packages are described in detail in the documentation [Installation/Uninstallation/Update of Tech Packages]. 1.3. The installation.07.3 The mechanical weaving option included in the “ArcTechDigital” technology package is described in Chapter 11.Software Rel. 5. uninstallation. two--dimensional mechanical weaving.4. 5.KR C2. ArcTechDig_P_R23 04. 5.2.1 System requirements.ArcTechDigital 2. 5. Examples are used to show you how to change existing patterns and how to create your own patterns. These are available on CD--ROM. Installation The Software ArcTechDigital can be used with the following KRC--Software: -.5 From system software version 5. effects and remedial action. Chapter 12 contains a list of error messages along with their causes. There you will find fundamental information on the mode of operation of the function generators. technology packages are offered exclusively as ad--on software modules. DAT”. G Re--ignition after faults.1 General (continued) 1. G Selection of several defined patterns for mechanical weaving as well as the possibility of programming your own weave patterns.00 en 9 of 68 . G Configurable user--specific strategies and routines in case of faults. G Various routines used for ignition faults and monitoring of the number of ignition attempts. Most options are stored in variables that are defined in the files “$CONFIG.DAT” and “A20.2 Overview of the configurable options The ArcTechDigital technology package also provides a range of options in addition to the basic configuration: G Adaptation to various welding controllers with program number control and their different coding systems.07. Fundamental information on operator control as well as the menu--guided creation of programs at user level is provided in the documentation [Arc Welding. ArcTechDigital -Operation]. G Restart options in case of faults in the seam. ArcTechDig_P_R23 04. 00 en 10 of 68 .ArcTechDigital 2.07.3 ArcTechDig_P_R23 04. 00 en 11 of 68 . velocity.1. When the arc has been struck. More detailed information on selecting program run modes can be found in the chapter [Executing and stopping programs]. 2. the start parameters (start delay) and the program number. 2.1 Description of the “ArcTechDigital” commands General The general ArcTechDigital commands are described in this chapter.1.STATE” TRUE or FALSE according to the configuration). In order to be able to weld. Softkey assignments and their meaning. “MSTEP” and “ISTEP” do not allow the program to run properly. While the “ARC ON” program phase is being executed. ARC SWI and ARC OFF with sequence diagrams and signal diagrams. as is indicated by the welding torch being struck through on the left--hand status key bar.2 Program run mode “GO” Welding is only possible in the program run mode “GO”. the appropriate status must be active (“I_ENB_W_EXT.1. as a result of which the robot starts to move in accordance with the programmed path and velocity. the system scans the peripheral signal “I_WELD_COND” to check whether the welding controller is ready.ARC ON The command “ARC ON” contains the parameters for moving the welding torch (type of motion.1 Keyswitch for program execution without welding If the keyswitch function has been configured. this status key must be switched to the “HOT” position corresponding to the symbol shown on the left. The signal “O_ACK_START[ ]” informs the welding controller that the robot is moving. The movement from the home position to the start point of the seam can be executed as a “PTP”. Explanations of the main terms ARC ON. 2. 2. the welding power source supplies the signal “I_START_MOVE[ ]”.2 Start welding . When the welding torch reaches the ignition position. arc ignition is enabled by means of the signal “O_WELD_START[ ]”. “LIN” or “CIRC” motion. etc. (hot) welding is always deactivated.3 Switching on the welding process After the computer runs up.2 Description of the “ArcTechDigital” commands 2 2. the torch is stopped exactly at the start of the seam. Approximation is not possible for ARC ON. Otherwise welding is not possible. ArcTechDig_P_R23 04.) from the home position to the start point of the seam.07. 1 Schematic sequence diagram ARC ON For the purposes of simplicity.00 en 12 of 68 . not all options are illustrated.3 2. ARC ON Positioning motion to ignition position Initialization Standby test (Option polled) (Poll to see if power source ready) (Keyswitch polled) (Weld ON softkey) I_WELD_COND[ ] I_ENB_W_EXT [ ] Prg_ON_MODE <>0 Ignition program number output Ignition fault message N Y Weld start O_WELD_START[ ] Timeout Current flowing I_START_MOVE[ ] O_ACK_START[ ] Y Synchronization Activation of monitoring system End ARC ON Process continued with the next ARC OFF or ARC SWITCH command ArcTechDig_P_R23 04.07.ArcTechDigital 2.2. A single seam therefore requires at least two commands. can be “LIN” or “CIRC” motions. no.2.07. the motion parameters and. no. If a seam consists of several seam sections with different motion and/or weld parameters.2 Description of the “ArcTechDigital” commands (continued) 2. ArcTechDig_P_R23 04.ARC OFF The welding command “ARC OFF” contains the program number for the power source. Approximate positioning to the next motion block is not possible with “ARC OFF”.2 Signal diagram ARC_ON and ARC_SWI ARC_ON PRG_SWI_MODE = 1 P0 P1 P2 I_WELD_COND [ ] I_ENB_W_EXT [ ] O_WELD_START [ ] I_START_MOVE [ ] (O_ACK_START [ ] ) if PRG_ON_MODE<> 0 Prog. and also parameters for crater filling.00 en 13 of 68 . namely “ARC ON” and “ARC SWITCH”. or in case of several seam sections from the target point of the last section of an “ARC SWITCH” command to the end point of the seam. if relevant. = 2 Ignition time O_STROB_PGNO PRG_SWI_MODE = 2 P0’ P1’ P2’ Prog. Motions from the ignition point (ARC ON). = 1 Prog. = 1 ARC_SWI Prog. no. the command “ARC OFF” is used for the last seam section. = 2 Prog. the mechanical weaving parameters used for a single seam from a weld start (ARC ON) to the end of the seam. no. the motion concludes with the exact positioning at the target point (end of the seam). no. = 3 2.3 Welding and ending seams . 1 Schematic sequence diagram ARC OFF ARC OFF Positioning motion to the end point with weld velocity of the ARC_OFF command Program number output Program number transfer O_STROB_PGNO[ ] Cancel weld start signal at end position O_SEAM_END[ ] N Current off Y Synchronization I_WELD_END[ ] O_ACK_WELD_E[ ] End ARC OFF ArcTechDig_P_R23 04.00 en 14 of 68 .ArcTechDigital 2.3 2.07.3. 4 Welding a seam in several sections .2 Signal diagram ARC_OFF ARC_SWI PRG_SWI_MODE = 1 ARC_OFF P0 P1 Crater time + Burnback time + Gas postflow time P2 Prog. ARC SWITCH contains the program number. = 5 O_STROB_PGN0 [ ] O_SEAM_END [ ] I_WELD_END [ ] O_ACK_WELD_E[ ] PRG_SWI_MODE = 2 P0’ P1’ P2’ Prog.00 en 15 of 68 . no.07. no.ARC SWITCH The command “ARC” (shown as “ARC SWITCH” in the menu) 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. In the interest of efficient operations.3. approximate positioning should be used for motions in “ARC SWITCH” commands if exact positioning between individual seam sections is not absolutely essential. the motion parameters for the current section of the seam. and also the parameters for the weld velocity and the mechanical weaving for the current section of the seam. ArcTechDig_P_R23 04. = 5 2. no. = 6 PRG_SWI_MODE = 1 Prog.2 Description of the “ArcTechDigital” commands (continued) 2. 3 2.07.ArcTechDigital 2.00 en 16 of 68 .1 Schematic sequence diagram ARC SWITCH ARC SWITCH Positioning motion to the end point with weld velocity of the ARC_SWI command Program number output Program number transfer O_STROB_PGNO[ ] End ARC SWITCH Process continued with the next ARC OFF or ARC SWITCH command ArcTechDig_P_R23 04.4. no.4.07. no.2 Signal diagram ARC_SWI ARC_ON PRG_SWI_MODE = 1 P0 P1 P2 I_WELD_COND [ ] I_ENB_W_EXT [ ] O_WELD_START [ ] I_START_MOVE [ ] (O_ACK_START [ ] ) if PRG_ON_MODE<> 0 Prog. = 1 Prog.2 Description of the “ArcTechDigital” commands (continued) 2. no. = 3 ArcTechDig_P_R23 04. no. = 1 ARC_SWI Prog. = 2 Prog. no.00 en 17 of 68 . = 2 PRG_SWI_MODE = 1 Ignition time O_STROB_PGNO PRG_SWI_MODE = 2 P0’ P1’ P2’ Prog. ArcTechDigital 2.3 ArcTechDig_P_R23 04.07.00 en 18 of 68 3 Programs of the ArcTechDigital package 3 3.1 Programs of the ArcTechDigital package Program structure In the following block diagram the program structure of the KR C1 robot controller is shown in the “Welding robot” configuration. The interface to the welding controller is implemented in the form of a configurable “handshake”. Settings for analog outputs as well as digital outputs and inputs are defined in the file “$Config.dat”. $Config.dat. A20 GLOBALS Global and application data Cell.src Autom./Ext. organization program IR_Stopm.src General handling of robot faults Bas.src Functions for robot motion P00.src Functions for Autom./Ext. Handshake Check Home Flt_serv_d.src User-definable fault service functions .dat Weav_def_d.src Definition and parameters for mechanical weaving A20.src Functions for arc welding .dat Sps.sub Switch--off routine after an interpreter stop Information about the hardware periphery of the robot controller can be found in the [Operating Handbook], chapter “Connector panel / Peripheral interfaces” and in the [Periphery] handbook. ArcTechDig_P_R23 04.07.00 en 19 of 68 ArcTechDigital 2.3 3.2 Overview of the “ArcTechDigital” files The files listed below are included in the “ArcTechDigital” package. To assist you in finding relevant information, you will always see the symbols shown on the left with their file names throughout this documentation wherever the corresponding file or parts of it are described. $Config.dat Contains data specific to ArcTechDigital within the section ;FOLD ARCTECHDIGITAL GLOBALS ; FOLD Structures and Definitions ... ; ENDFOLD (Structures and Definitions) ; FOLD Main Options ... ; ENDFOLD (Main Options) ; FOLD ArcTech Outputs ... ; ENDFOLD (ArcTech Outputs) ; FOLD ArcTech Inputs ... ; ENDFOLD (ArcTech Inputs) ; FOLD Default Datasets ... ; ENDFOLD (Default Datasets) ; FOLD Statuskey Variables ... ; ENDFOLD (Statuskey Variables) ; FOLD Peripheral Output groups ; outputs weld start ... ; outputs acknowledge start move ... ; strobe program number ... ; outputs weld end ... ; outputs acknowledge weld_end ... ; outputs fault while arc on ... ; outputs stop weld after interrupt on seam ... ; outputs stop cleaner after interrupt ... ; outputs acknowledge fault ... ; output for fault message ... ; Wirefeed control ... ; ENDFOLD (Peripheral Output groups) ArcTechDig_P_R23 04.07.00 en 20 of 68 inputs telling faults while welding . ENDFOLD (Internal System States) . Local data list for the program “A20. Program for fault strategies defined by the user.. . ENDFOLD (Peripheral Input groups) .. Within the section / block shown.dat Main program for arc welding with “ArcTechDigital”. including ignition faults.. the changes or entries described must be made.SRC”. .. . the section User--defined Variables in the file “$CONFIG... input for external enable weld .. ..ENDFOLD (ARCTECHDIGITAL GLOBALS) For additional entries. You will see the following symbols at various points in this documentation. . Counter for Interrupt definition . FOLD Internal System States . they indicate whether manual changes are permitted in the section of a file being described. A20.DAT” is available. . . inputs start moving .. no changes or entries may be made.src A20.. Programs of the ArcTechDigital package (continued) FOLD Peripheral Input groups inputs as condition befor weld can start . Fault service function (additional START error).00 en 21 of 68 ..src Definition of the patterns for mechanical weaving.07.. Contains local data list for the program “FLT_SERV.src Flt_serv_d. Weav_def_d..SRC”.dat Flt_serv_d. Within the section / block shown.3 . inputs weld is ended . ArcTechDig_P_R23 04.. . 3 ArcTechDig_P_R23 04.07.ArcTechDigital 2.00 en 22 of 68 . or check.basic settings Activating the ARC 20 option You must make. At the same time it must be ensured that the variable “A10_OPTION” is inactive (DISABLED).dat ArcTechDig_P_R23 04. except ArcTechDigital 4. Digital outputs Fold ArcTech Outputs in “$Config.00 en 23 of 68 .4 ArcTechDigital .basic settings 4 4. The “ARC20” option must always be activated (TRUE) when executing ArcTechDigital applications.dat” Digital outputs Configure physical output $Config. Corresponding entries using the menu function “Monitor -.Variable -. the basic settings described below for operation with “ARC Tech 20”.2 Minimum configuration for power source interface Signals for basic signal traffic are located in the configuration file.1 ArcTechDigital .07.Single” Variable ARC20 Value for ArcTechDigital TRUE FALSE (default) Characteristics ArcTechDigital applications Normal. 3 Digitale Eingänge Fold ArcTech Inputs in “$Config.ArcTechDigital 2.07.00 en 24 of 68 .dat” Digital inputs Configure physical input ArcTechDig_P_R23 04. 00 en 25 of 68 .dat.\R1\TP\ArcTechDigital”): Fold Main Options in “A20...dat” (in the directory “.dat” A20.basic settings (continued) 4. If they do not correspond. the program number output will not function.4 ArcTechDigital .07. ArcTechDig_P_R23 04.dat Info The signal declaration “SIGNAL ARCD_ProgNr $OUT[from] TO $OUT[to]” must correspond to the signal declaration of$Config. Some Folds from the file ”A20.3 Minimum configuration for program number control ArcTechDigital permits a variety of coding systems for program numbers for the purpose of ensuring compatibility with the various welding controllers that are used. ArcTechDigital 2.3 Fold Internal States in “A20.07.00 en 26 of 68 .dat” ArcTechDig_P_R23 04. basic settings (continued) Fold Internal States in “A20.07.4 ArcTechDigital .00 en 27 of 68 .dat” (Fortsetzung) ArcTechDig_P_R23 04. 07. Default = 4 Output number for the parity bit.dat” 4.PARITY PRG_NO.Coding 1 = dual -. Default = 0 Specification of the number of bits.ArcTechDigital 2. -.3 Fold ARC Messages in “A20. Coding of the program numbers.Coding 4 = BCD code Default = 1 ArcTechDig_P_R23 04.FIRST_BIT PRG_NO.00 en 28 of 68 .CODING Type INT INT INT INT Characteristics Represents the physical output number of the first bit.Coding 2 = 1 of n -.Coding 3 = 1 of (n--1)< -.3.LENGTH PRG_NO.1 Meaning of the variables Corresponding entry using the menu function “Monitor” → “Variable” → “Single”: Variable PRG_NO. Configuring peripheral outputs and inputs by means of signal tables (so--called “triple groups”) allows processes to run synchronously. For this purpose. it is merely necessary to alter the index tables accordingly. 5. “Weld start”.DAT” is provided in the descriptions of the various welding commands (ARC ON. Further information on the ARC 20 signal tables contained in “$CONFIG.DAT.1. Signal names of a group beginning with “O_. MIN and MAX values) when entries are made with the menu function “Monitor -.Single” or when the file is edited. “Weld end”. You can use the edit function to set or change the values of the variables in “$CONFIG. definition Index tables for configuring physical outputs and inputs For the purpose of configuring the physical outputs and inputs. and those with “I_. ArcTechDig_P_R23 04. Settings are stored in this file.Variable -.. ARC SWITCH) in Section 3..1 5. FOLD A20 GLOBALS..g.dat”. The capability of setting or scanning several signals makes it possible for various welding controllers to be adapted and the timing to be optimized.dat These options are stored in variables that are defined in the file $CONFIG. In addition.. G Digital outputs (DIGITAL OUTPUTS) G Digital inputs (DIGITAL INPUTS) Digital control signals from the robot controller to the welding controller -. “Arc struck”.e. $Config. Digital control signals from the welding controller to the robot controller -.07.e. two index tables are provided in the block “FOLD A20” in the file “$Config.dat In these index tables the assignment of the physical outputs and inputs is defined and references are made to the corresponding signal tables of the controller..” designate digital outputs. This has the advantage that if the terminal assignments for the periphery are changed.Single”.DAT”.2 Signal tables for digital outputs and inputs The interface concepts are variable. $Config.Variable -.” designate digital inputs.. their specific adaptation as well as configurable options: 5. ARC OFF. You change this value by entering a new value in the field “New value”. The current value is shown when the variable name is entered.1 Overview.00 en 29 of 68 . a list can be opened in the status window by means of the menu “Monitor -. menu--prompted viewing and alteration of the variable values is also possible.1.g.5 Principles of the definable signal table 5 Principles of the definable signal table This section describes the definition of the “ArcTechDigital” peripheral interfaces. A syntax check is not performed (for example. “Gas manual”. ArcTechDig_P_R23 04. Fold ArcTech Outputs in “$Config.”) whose content may be altered (while retaining the string length!).07..INI BOOL O_WELD_CTRL[1].00 en 30 of 68 .OUT_NR Type INT Characteristics Assignment of the physical output..2. any characters not overwritten (possibly because they are not visible in the window) will be retained. their physical assignment (OUT_NR n) is freely definable.NAME_NAT[ ] STRING All “O_WELD_CTRL[1]. O_WELD_CTRL[1]. The element “INI” defines the state to which the respective physical output “OUT_NR” is to be set on initialization.. meaning they are inactive.1 Digital outputs Index table for physical digital outputs Altogether 15 digital outputs (O_WELD_CTRL[1] . “10” (default: 0) State at initialization (default: FALSE) FALSE = LOW TRUE = HIGH 20 characters between “ ”. The value “FALSE” sets the output to “LOW”.ArcTechDigital 2. The “NAME_NAT[ ]” entries (signal name) are comments with a string length of 20 characters between the quotation marks (“.Variable -.3 5. the value “TRUE” to “HIGH”.OUT_NR” array elements are set to “0” at the factory. e.2 5.Single”: Variable O_WELD_CTRL[1]. [O_WELD_CTRL[15]) are available.dat” Physical outputs State at initialization Comment (signal name) Example of corresponding entries using the menu function “Monitor -. please note that if the string is changed..g. 00 en 31 of 68 .NAME_NAT[] “.0.STATE TRUE} {NO 1.2. use blanks if required.STATE FALSE} {NO 3.2. the index is deactivated and is ignored during execution of the program.DAT” please ensure that the length of the string between the quotation marks (“ ”) is exactly 20 characters long. an error message is displayed if the string exceeds 20 characters..PULS_TIME 0. Output parameters {NO 0.0.PULS_TIME 0.STATE TRUE} Characteristics Index disabled (ignored) Index NO 1 (refers to field 1 of the index table “O_WELD_CTRL[1]”) with static HIGH signal Index NO 2 (refers to field 2 of the index table “O_WELD_CTRL[2]”) with static LOW signal Index NO 3 (refers to field 3 of the index table “O_WELD_CTRL[3]”) with HIGH pulse (length: 1 s) {NO 2.PULS_TIME 1.2 5.Single” to make changes.”} Output 10 INI WELD START HIGH LOW Array “O_WELD_CTRL[n] INI” contains the initial value when the INIT routine is running before reaching the block coincidence movement. ArcTechDig_P_R23 04. If you use the menu function “Monitor -.STATE TRUE} If “NO” is set to “0” (zero)..07.0.0.2. The following example shows the assignment of the physical outputs and the signal states after initialization.5 Principles of the definable signal table (continued) If you make any changes to the comments (signal name) “NAME_NAT” directly in the file “$CONFIG. Index table DIGITAL OUTPUTS O_WELD_CTRL[1]={OUT_NR 10.PULS_TIME 0.Variable -.1 Signal tables for digital outputs Definition of the signal states Up to three outputs can be controlled and for each of these outputs the following parameters can be defined.INI FALSE. 5. Single”: Variable I_WELD_CTRL[1]. e. The following example illustrates the assignment of the physical inputs.IN_NR I_WELD_CTRL[1].dat” Physical inputs Comment (signal name) Example of corresponding entries using the menu function “Monitor -.1 Digital inputs Index table for physical digital inputs Altogether 15 digital inputs (I_WELD_CTRL[1] .3 5. I_WELD_CTRL[15]) are available. their physical assignment (IN_NRn) is freely definable.3.DAT”: Fold ArcTech Inputs in “$Config. All “IN_NR” array elements are set to “0” at the factory.NAME_NAT[ ] Type INT STRING Characteristics Assignment of the physical input.g. All “IN_NR” array elements are set to “0” at the factory.NAME_NAT[] “WELD SOURCE READY”} IN_NR 0 = input disabled Signals to: Input 2 ArcTechDig_P_R23 04. “I_WELD_CTRL[1]” is assigned to physical input no.ArcTechDigital 2. meaning they are inactive. meaning they are inactive. Also see the note in Section 5. any characters not overwritten will be retained.07.Variable -..00 en 32 of 68 ... FOLD A20 GLOBALS) DIGITAL INPUTS I_WELD_CTRL[1]={IN_NR 2. Index table “DIGITAL INPUTS” ($CONFIG.2.”) whose content may be altered while retaining the string length.DAT. For the purpose of assigning the physical inputs. The “NAME_NAT[ ]” entries (signal name) are comments with a string length of 20 characters between the quotation marks (”. 2..3 5. “2” (default: 0) 20 characters between “ ”.1. you can enter their corresponding numbers in the index table “DIGITAL INPUTS” of the file “$CONFIG. e.NO” with the value “2” refers to array 2 of the index table “DIGITAL INPUTS” (I_WELD_CTRL[15]) and thus to the physical input configured in it (see Section 5.STATE FALSE} I_WELD_COND[3]={NO 0. The following states can be checked for each of these inputs: Input parameter {NO 0.Variable -.2 Signal tables for digital inputs Up to three inputs can be scanned.STATE TRUE} I_WELD_COND[2]={NO 0.STATE FALSE} The following example shows a signal table from the file “$CONFIG.3. in this case “TRUE”. Information on the definition of the terms “index table” and “signal table” can be found in Section 6.1. ArcTechDig_P_R23 04.NAME_NAT[] “WELD SOURCE READY”} IN_NR 0 = Input disabled Signals to: Input 2 Example of corresponding entries using the menu function “Monitor -. FOLD A20 GLOBALS) DIGITAL INPUTS I_WELD_CTRL[1]={IN_NR 2. {NO 2.07. A LOW signal is awaited at the physical input referring to field 2 of the index table “I_WELD_CTRL[ ]”.Single”: Variable I_WELD_COND[1].DAT” for a digital input.NO I_WELD_COND[1].00 en 33 of 68 . The element “I_WELD_COND[1].DAT. . “2” (default: 0) Awaited state Default: FALSE Two other input signals are defined in this example as the second and third conditions that have to be met before welding can be started. inputs as condition before weld can start DECL FCT_IN_T I_WELD_COND[3] I_WELD_COND[1]={NO 1.g.STATE FALSE} Signal name Status (TRUE = HIGH) Index for addressing in index table “I_WELD_CTRL[1 ]” Index table “DIGITAL INPUTS” ($CONFIG.STATE TRUE} Characteristics NO 0: input disabled (ignored) A HIGH signal is awaited at the physical input referring to field 1 of the index table “I_WELD_CTRL[ ]”.3). The element “STATE” specifies the awaited state.5 Principles of the definable signal table (continued) 5.STATE Type INT BOOL Characteristics Assignment of the physical input.STATE TRUE} {NO 1. ArcTechDigital 2.3 ArcTechDig_P_R23 04.07.00 en 34 of 68 . For example. assign the value “1” to the variable “NO” in the first line “O_WELD_START[1]”. it is therefore advisable to check the setting of the variables before looking for faults in the hardware.2 Minimum configuration for power source interface.”} Output 10 INI WELD START HIGH LOW In the signal table “outputs weld start”. so enter the value “0. The signal level should be LOW at initialization and statically HIGH at the start of welding.07.0) or be output in the form of a pulse.INI FALSE.e. An output can be static (PULSE_TIME 0.3” corresponds to a pulse duration of 0. if they are not overwritten by the current programming by means of inline forms or parameter lists.0” for “PULS_TIME”.6 Assignment of the signal grouping in normal operation 6 Assignment of the signal grouping in normal operation The signal tables provide the capability of defining up to three signals. The element “PULSE_TIME” allows the programming of pulse times. of activating up to three different physical outputs with different signal levels by means of one event. i. 6.1 Assignment of the outputs The blocks with a gray background show the pre--configuration and do not normally need to be changed..NAME_NAT[] “.3 seconds. Index table DIGITAL OUTPUTS O_WELD_CTRL[1]={OUT_NR 10. this example is merely intended to illustrate that the reason for missing or incorrect peripheral signals can be an incorrect value assignment. the designation (NAME_NAT) “Weld Start” and “INI” = FALSE are already entered in the first line “O_WELD_CONTROL[1]”. See also Section 4. Assign the value “10” to the variable “OUT_NR”.00 en 35 of 68 . in which case the pulse duration is programmed in seconds. There is of course no practical application for this setting. ArcTechDig_P_R23 04. “PULSE_TIME 0. In the index table “Digital Outputs”. The signal level should be static..1 Output group O_WELD_START [ ] The “Weld Start” signal should be assigned to physical output 10.1. In such cases. 6. 5.00 en 36 of 68 .g.0 (static) Active state Default: FALSE 6.2 Output group O_ACK_START [ ] The “O_ACK_START[ ]” signal informs the welding controller that the robot has started to move. e. PULS_TIME 0.. Example: O_ACK_WELD_E[1]={NO 12.Single”: Variable O_WELD_START[1]. Assign the value “11” to the variable “OUT_NR” and set “INI” = TRUE.ArcTechDigital 2. “1” (default: 0) Pulse duration in seconds Default: 0.3 Entries made using the menu function “Monitor -.INI FALSE.NAME_NAT[] “.STATE TRUE} ArcTechDig_P_R23 04.Variable -.07. Index table DIGITAL OUTPUTS O_WELD_CTRL[2]={OUT_NR 11.”} Output 11 INI ACK START HIGH LOW Please note that “PULS_TIME” and “STATE” must be configured accordingly because the signal is not otherwise reset.1.PULS_TIME O_WELD_START[1]..STATE Type INT REAL BOOL Characteristics Assignment to element in index table.NO O_WELD_START[1]. 07. The configured signal cancels the WELD_START signal following the ARC_OFF command.INI FALSE.NAME_NAT[] “.NAME_NAT[] “. crater filling can begin -... Index table DIGITAL OUTPUTS O_WELD_CTRL[3]={OUT_NR 12..00 en 37 of 68 .1. Assign the value “10” to the variable “OUT_NR”.6 Assignment of the signal grouping in normal operation (continued) 6. Example: O_STROB_PGNO[1]={NO 3.1.O_SEAM_END[ ]. Index table DIGITAL OUTPUTS O_WELD_CTRL[1]={OUT_NR 10. Assign the value “12” to the variable “OUT_NR”.” signal to the welding controller defines the validity of the program number.INI FALSE.3 Output group O_STROB_PGNO [ ] The “TRIGGER PROGRAM NO.”} Output 10 INI ARC_ON HIGH LOW ArcTechDig_P_R23 04.3.STATE TRUE} 6.”} Output 12 INI STROB_PGNO HIGH LOW Please note that “PULS_TIME” and “STATE” must be configured accordingly because the signal is not otherwise reset..4 Output group O_SEAM_END [ ] End of seam reached. PULS_TIME 0. 00 en 38 of 68 .STATE TRUE} ArcTechDig_P_R23 04.INI FALSE.ArcTechDigital 2.5..07. Assign the value “14” to the variable “OUT_NR”. Index table DIGITAL OUTPUTS O_WELD_CTRL[12]={OUT_NR 14. Example: O_ACK_WELD_E[1]={NO 12.5 Output group O_ACK_WELD_E[ ] Activated when the weld is finished and the crater has been filled. this output signal enables the program to be continued.NAME_NAT[] “.3 6.”} Output 14 INI ACK_WELD_E HIGH LOW Please note that “PULS_TIME” and “STATE” must be configured accordingly because the signal is not otherwise reset.1..PULS_TIME 0. INI FALSE.07.NAME_NAT[] “. Assign the value “15” or “10” to the variable “OUT_NR”.1 Signal output groups for fault service function Output group O_FLT_ARC_ON [ ] This output signal group means that a fault occurred during the ARC_ON command. An ignition fault output is set and.00 en 39 of 68 .6 Assignment of the signal grouping in normal operation (continued) 6. the “WELD_START” signal is cancelled.2.”} Output 15 INI FLT_ARC_ON ARC_ON HIGH LOW ArcTechDig_P_R23 04. at the same time.... Index table DIGITAL OUTPUTS O_WELD_CTRL[1]={OUT_NR 10.INI FALSE..2 6.NAME_NAT[] “.”} Output 10 INI Index table DIGITAL OUTPUTS HIGH LOW O_WELD_CTRL[13]={OUT_NR 15. NAME_NAT[] “..2.INI FALSE.”} Output 10 INI HIGH LOW Index table DIGITAL OUTPUTS O_WELD_CTRL[10]={OUT_NR 13.2 Output group O_FLT_WELD [ ] This output signal switches the welding off and sets an error message for the PLC.ArcTechDigital 2.INI FALSE. Assign the value “10” or “13” to the variable “OUT_NR”.NAME_NAT[] “.3 6.07..00 en 40 of 68 ..”} Output 13 INI FLT_WELD HIGH LOW ArcTechDig_P_R23 04. Index table DIGITAL OUTPUTS O_WELD_CTRL[1]={OUT_NR 10.. NAME_NAT[] “.INI FALSE.INI FALSE.. Example: O_ACK_FLT[1]={NO 4..PULS_TIME 1.3 Output group O_FLT_CLEAN [ ] These output signals are used to reset the outputs for torch cleaning.2. Index table DIGITAL OUTPUTS O_WELD_CTRL[6]={OUT_NR 9.4 Output group O_ACK_FLT [ ] These output signals are used to acknowledge error states.”} Output 8 INI ACK_FLT HIGH LOW Please note that “PULS_TIME” and “STATE” must be configured accordingly because the signal is not otherwise reset.”} Output 9 INI FLT_CLEAN HIGH LOW 6. Index table DIGITAL OUTPUTS O_WELD_CTRL[4]={OUT_NR 8.0.2...07.00 en 41 of 68 .STATE TRUE} ArcTechDig_P_R23 04. Assign the value “9” to the variable “OUT_NR”. Assign the value “8” to the variable “OUT_NR”.6 Assignment of the signal grouping in normal operation (continued) 6.NAME_NAT[] “. ”} Signals awaited at: Input 1 HIGH signal ArcTechDig_P_R23 04. The signal input groups with a gray background represent the pre--configuration from V2.NAME_NAT[] “.07. accordingly more signals must be configured.3 Assignment of the inputs The signal tables provide the capability of assigning up to three input signals to a condition.3 6. 6.ArcTechDigital 2. References to the index table “Digital Inputs” can of course also be made from other signal tables.1 Input group I_WELD_COND [ ] A precondition for welding is a successful check that the peripheral interface signal “WELDING SOURCE READY” is set.2 Minimum configuration for power source interface.3 onwards and do not normally need to be adapted.. If several conditions must be met.3.. See also Section 4. The inputs are polled using logical ANDing. The signal table for “I_WELD_COND[ ]” reads as follows: Index table DIGITAL INPUTS I_WELD_CTRL[1]={IN_NR 1.00 en 42 of 68 . This signal is a precondition for the robot to start moving along the path.3.3 Input group I_WELD_END [ ] The “WELD END” signal is issued on completion of welding and end crater filling..”} Signals awaited at: Input 3 HIGH signal 6..”} Signals awaited at: Input 2 LOW signal ArcTechDig_P_R23 04.e. for continuation of the process.NAME_NAT[] “.NAME_NAT[] “. The corresponding signal table for “I_WELD_END[ ]” is as follows: Index table DIGITAL INPUTS I_WELD_CTRL[2]={IN_NR 2.00 en 43 of 68 . i.3..2 Input group I_START_MOVE [ ] After successful ignition the welding source supplies the “ARC STRUCK” signal. The corresponding signal table for “I_START_MOVE[ ]” is as follows: Index table DIGITAL INPUTS I_WELD_CTRL[2]={IN_NR 3..07.6 Assignment of the signal grouping in normal operation (continued) 6. . I_WELD_FLT[2] and [3] generally monitor the following: shielding gas..NAME_NAT[] “.NAME_NAT[] “. The corresponding signal table for “I_WELD_FLT[ ]” is as follows: Index table DIGITAL INPUTS I_WELD_CTRL[2]={IN_NR 3. cooling or wire feed.NAME_NAT[] “.3.3 6..”} Signals awaited at: Input 4 HIGH signal Signals awaited at: Input 5 HIGH signal ArcTechDig_P_R23 04. the welding controller supplying a signal in the event of a welding fault or malfunction occurring. ARC SWITCH) is monitored..”} Signals awaited at: Input 3 HIGH signal Index table DIGITAL INPUTS I_WELD_CTRL[5]={IN_NR 5..4 Input group I_WELD_FLT [ ] The current welding process (ARC OFF.00 en 44 of 68 . Index table DIGITAL INPUTS I_WELD_CTRL[4]={IN_NR 4..”} I_WELD_FLT[1] generally monitors the current flow.07.ArcTechDigital 2. ..3) is required. input for external enable weld DECL FCT_IN_T I_ENB_W_EXT={NO 6..Single”: Variable I_ENB_W_EXT. Default: “6” Default: TRUE This entry must be made I_WELD_CTRL[6] = {IN_NR 7.3.STATE TRUE} Corresponding entry using the menu function “Monitor -.6 Assignment of the signal grouping in normal operation (continued) 6. as too is the reference to this input in the section “input for external enable weld” of the $CONFIG.3.Variable -. Entries made using the menu function “Monitor -. ArcTechDig_P_R23 04.6 Time_out when polling the inputs The wait time for digital input signals is limited by the variable . the program is stopped and a corresponding error message is displayed in the message window.0 . default = 3s A20.5 Polling of the external keyswitch (Hot/Cold) This keyswitch is used for executing programs without “hot” welding and can only be configured if the welding system is equipped accordingly.00 en 45 of 68 .Variable -.. .STATE Type INT BOOL Characteristics Reference to the physical input in the index table “DIGITAL INPUTS” I_WELD_CTRL[ ].Single”: Variable TIME_OUT1 Type REAL Characteristics Wait time in seconds.. time out while waiting (until fault message) REAL TIME_OUT1=3.DAT”.} 6..DAT If you receive the message “Object not found” (no. you must set the value of the variable $DATAPATH[] to “/R1/A20” (the “ ” characters are part of the string). For this purpose. [s] After this configurable wait time.07. 2047) while viewing or modifying variables in the file “A20.. configuration of the physical input in the index table “DIGITAL INPUTS” (see Section 5.NO I_ENB_W_EXT.DAT file. 07.3 ArcTechDig_P_R23 04.ArcTechDigital 2.00 en 46 of 68 . PRG_SWI_MODE=2: The program number is set before the point is reached.07.LENGTH = 4 Current program number PRG_ON_MODE INT PRG_SWI_MODE INT PRGNO_MIN PRGNO_MAX PRGNO INT INT INT PRG_ON_MODE and PRG_SWI_MODE are normally identical.DAT Parity 0 = default n = output number ⇒ positive ⇒ “even” ⇒ negative ⇒ “odd” ArcTechDig_P_R23 04. If PRG_ON_MODE=0. during the advance run. Default: 0 Defines the largest program number. -. 7. -. *) Default: 15 corresponding to PRG_NO.2 Setting . no O_ACK_START[ ] group is set.1 Options for program number specification Signal flow of the program numbers Variable Type Characteristics Function for ARC ON. during the advance run.parity bit A20.PRG_SWI_MODE=1: The program number is set when the point is reached. Default: 1 Defines the smallest program number.7 Options for program number specification 7 7. -.00 en 47 of 68 . Default: 1 Function for ARC SWITCH.PRG_ON_MODE=1: The program number is set when the point is reached.PRG_ON_MODE=2: The program number is set before the point is reached. -. no. = 4 Timing diagram – program number interface (a) P1 P2 Prog._E [ ] O_ACK_START [ ] P0 P1 P2 Prog. = 3 Prog.00 en . no. 3 is already set! PRG_SWI_MODE= 2 Prog. 4 is already set! ArcTechDig_P_R23 04. = 2 for SGL but prog.3 ARC_ON ARC_SWI ARC_SWI ARC_SWI ARC_OFF O_ACK_WELD. = 4 PRG_SWI_MODE=1 Default O_STROB _PGNO [ ] P0 Prog. = 2 Prog.07.7. = 3 Prog. = 3 for SGL but prog. = 2 Prog.3 48 of 68 Program number handshake ArcTechDigital 2. no. no. no. If welding is interrupted by pressing the STOP key (interpreter stop).Remedial action In the event of control or welding faults. Welding is subsequently restarted.07.1 Reaction to interpreter stop (STOP key) Pressing the STOP key triggers an interpreter stop.1 Setting the restart options RESTART_OPTION Possible reactions to welding faults on the seam are defined by means of the variable “RESTART_OPT”.Single” and characteristics: Variable Value 0 Characteristics -. the seam is completed without welding after a restart. the seam is completed without welding and a corresponding message is generated.DAT . with the restriction that the number of permissible welding interruptions is limited to a maximum value.Variable -. Remedy: release the Start key after releasing the enabling switch.3) Corresponding entries using the menu function “Monitor -. the program cannot be restarted.SUB”.00 en 49 of 68 .1. Users can define their own fault service functions in this program. After welding has been interrupted. This maximum value is defined in the variable “MAX_REA20”. the robot repositions the torch to the point of interruption.8 Setting the restart options 8 8. The welding process and torch cleaning station are switched off by the constantly--running parallel program “SPS. Variables: INT RESTART_OPT=1 Default: 1 (range 0 . 1 RESTART_OPT 2 3 8.SRC”. ArcTechDig_P_R23 04. One or more user--defined fault service functions can be specified. A20. If this value is exceeded. Welding is not restarted when the Start key on the KCP is pressed. The same function as with “RESTART_OPT=1”. Occurrence of a fault triggers a branch to the program “FLT_SERV. The value specified in “MAX_REA20” (default = 3) is valid for the entire seam between the commands ARC ON and ARC OFF. Variable -.2. Number of user defined FLT_SERV-Subroutine The entry “A_FLT_SV_FCT=0” corresponds to the subroutine “CASE 0” in the file “FLT_SERV.1 Configuration in event of ignition faults Ignition repetition monitoring The following variables are available for repeat ignition attempts on a seam: The number of permissible restart attempts is programmed with the variable “MAX_AUTO_R”. for cutting through insulating oxide layers (for example during aluminum welding) when the wire contacts the workpiece in order to allow a fault--free ignition process in a restart.07.DAT .00 en 50 of 68 . The selection of the fault service subroutine to be used is made in the file “$CONFIG..DAT” by means of the variable “A_FLT_SV_FCT” (default setting: 0): INT A_FLT_SV_FCT=0 ..Single”: Variable MAX_AUTO_R Value 3 (default) Meaning for repeat ignition attempts Maximum number of restart attempts 8. ArcTechDig_P_R23 04. and the maximum number of welding faults per seam before an error message is generated is programmed with “MAX_REA20”. for instance.3 Ignition fault message suppression option The file “FLT_SERV. Variables: INT MAX_AUTO_R=3 Maximum number of ignition attempts Corresponding entries using the menu function “Monitor -.SRC” contains a fault service function with the designation “CASE 0” as well as five other examples (CASE 1 . This procedure is suitable.3 8.SRC”. 5) that can be freely configured.ArcTechDigital 2. A20.2 8. cooling).2.3 9.1 Types of faults and causes A distinction is made between application--specific seam faults caused by peripheral equipment (ignition faults.3. the corresponding outputs must be defined in the signal tables “O_FLT_WELD[ ]” and “O_FLT_CLEAN[ ]”. See also Sections 9. The descriptions and information in this chapter require the error--free installation. and correct programming and parameter settings. the user can configure his own fault service subroutines tailored to specific requirements. In addition to the standard measures included in the technology package. For this purpose. bus systems. 9. the welding process or torch cleaning station is switched off.g.g.3. for example: G Ignition and seam faults resulting from unreliable operating states of the torch and/or welding equipment. IR_STOPMESS faults. EMERGENCY STOP and DRIVES OFF The EMERGENCY STOP and DRIVES OFF states are monitored by means of the system variable “$STOPMESS”. ArcTechDig_P_R23 04.1 Ignition faults Signal output group O_FLT_ARC_ON[ ] If the “Arc struck” signal (I_START_MOVE[ ]) is missing after a weld start.1 Welding faults and robot faults Reaction to robot faults. oxidation). G Media faults (e. EMERGENCY STOP actuation). G Ignition and seam faults resulting from workpiece characteristics (e.3. the process is interrupted. Normally “$STOPMESS=FALSE”.2 9. etc.2 and 9. path faults). and faults attributable to the robot controller (e.00 en 51 of 68 . The possible causes of faults may be. the proper functioning of all peripheral equipment (welding controller.3.g. 9. G Operator control function “Interpreter STOP”. In the case of “$STOPMESS=TRUE”.9 Enumeration of the signal groups for fault service functions 9 Enumeration of the signal groups for fault service functions If a welding or robot fault occurs during ignition or welding.07. different fault service subroutines are required. Due to the variety of causes and types of faults. IR_STOPMESS faults). shielding gas. commissioning and configuration of the robot and the hardware and software of the robot controller. When this state occurs. welding wire.) according to their specifications.SRC for the programs “IR_STOPMESS” or “TECH_STOP1”. The following signal table is used for this purpose: 9.g. an interrupt call is made within A20. welding is switched off and an ignition fault signal is set. G Controller faults (e. 0.3.5 Signal O_FLT_SIGNAL This output signal is reset when the corresponding fault has been acknowledged.3.3 Signal output group O_FLT_CLEAN[ ] The torch cleaning process is switched off if interrupt functions are triggered.ArcTechDigital 2. ArcTechDig_P_R23 04. The signal table for this reads as follows: 9.07.3. The following signal table must be taken into account with regard to the torch cleaning device: 9. The ignition fault output can additionally be reset here.3.3 9.PULS_TIME 0. O_ACK_FLT[2] = {NO 13.2 Signal output group O_FLT_WELD[ ] Welding is stopped if a seam error is detected or an interrupt function is triggered.STATE FALSE} 9.00 en 52 of 68 . This reference manages general fault signals to the PLC.4 Signal output group O_ACK_FLT [ ] These output signals are used to reset the outputs for torch cleaning. 4 9.4.SRC file.07.9 Enumeration of the signal groups for fault service functions (continued) 9.00 en 53 of 68 . The signal state is managed exclusively in the IR_STROPMESS program.3.6 Signal APPL_RUN This output signal is defined and configured in the Fold AUTOEXT Globals. Default $OUT [34] 9. ArcTechDig_P_R23 04. The interrupt program is subsequently located in the Fold BASIS_STOP in the IR_STOPM.1 Special feature IR_STOPMESS program Joint activation/deactivation routines All technologies are deactivated. 5 9. Program continuation: the torch is moved back by X=50 mm.00 en 54 of 68 . 9.3 Once the causes have been eliminated. Opened Folds: The user must integrate his applications into the USER blocks in order to avoid impairing other technologies. the welding torch is moved back by X=100 mm. Torch is returned to its start position. ArcTechDig_P_R23 04.07.1 Configurable fault service functions Fault service functions defined by the user If ignition is not successful. the technologies are switched back on again one after the other.ArcTechDigital 2.5. 00 en 55 of 68 . This command can be used to optimize the ignition process reliability and always force an active edge for the seam fault monitoring interrupt. Monitoring is carried out using $TIMER[1] and $CYCFLAG[3].Modify”: Variable PROC_IN_T1 Type BOOL Characteristics Default: FALSE If a hot welding attempt is made with the setting FALSE. the message “Welding in operation mode T1 impossible!” appears in the message window. This time can be increased if ignition faults occur too often following an unstable ignition process.%CGLOBALS.2 Ignition fault message suppression option Default = 0 The ignition fault messages are suppressed if the condition START_CNT< MAX_AUTO_R is met and AUTO_RETRY = 1. If AUTO_RETRY = 0.%P in the file “$CONFIG.3 Seam monitoring delay option A_CTRL_DELAY= 800 [ms] means that the seam monitoring begins after a delay of 800 ms. 10.07. an error message appears in the message window after every ignition fault. the variable “PROC_IN_T1” (default value = FALSE) in the block .Variable -.10 Further options 10 10.0.%{E}%V2.DAT” can be set to TRUE. BOOL PROC_IN_T1=FALSE Corresponding entry using the menu function “Monitor -.%VGLOBALS.FOLD BAS GLOBALS .%MKUKATPBASIS. 10. ArcTechDig_P_R23 04.1 Further options Program test in manual mode For testing programs in manual mode “T1” under real welding conditions.3. the corresponding weld data set with its weave parameters is taken into consideration. the weaving function is independent of the position of the torch in relation to the seam and of the torch angle. to compensate for tolerances or to bridge gaps in a seam. Mechanical weaving is executed in the coordinate system “TTS” (tool--based technological system).1 Block selection response If a block selection is made to a motion command other than ARC_SWI or ARC_OFF.07. 11. It is also possible to rotate the torch in relation to the plane of the weld (direction of welding).00 en 56 of 68 . ArcTechDig_P_R23 04. for example.3 11 Mechanical weaving Mechanical weaving is used. This ensures the continuous monitoring of the torch motion to the component when moving in Test mode.ArcTechDigital 2. In the event of a weld command. The torch moves across the seam in this instance and the weave oscillation is thus superposed on the seam motion. In this way. mechanical weaving is switched off. and irrespective of whether welding is by the “pushing” or “dragging” technique. 11 Mechanical weaving (continued) 11.07.00 en 57 of 68 .2 Weave patterns The following weave patterns are included in the ArcTechDigital package: s Lateral deflection (amplitude) Direction of welding s Weave length 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 unsymmetrical (Uns Trapec) Spiral weaving (Spiral) Figure-of-eight weaving (Double 8) ArcTechDig_P_R23 04. CPS1.src”.CPS1. Xn=1.CPS1.07.FCT.triangle CASE 2 .CPS1.trapezoid CASE 4 . ArcTechDigital -. double frequency (DBL_TRP) Trapezoidal weaving.Y2=1.double triangle CASE 3 .triangle IF FG_NR1>0 THEN $TECH[FG_NR1]. The weave length X.0 corresponds to the lateral deflection (weave amplitude -.X1=0.e.X2=0. The value for Y can be between --1...0 and 1.3 These weave patterns are defined in the file “Weav_def_d. double frequency (DBL_TRI) Trapezoidal weaving (SGL_TRP) Trapezoidal weaving.0 $TECH[FG_NR1]. the length over which a pattern is executed. CASE 1 .0 corresponds to the weave length entered in the W--parameter list 2 (Mechanical Weaving).spiral CASE 7 .0 $TECH[FG_NR1].0 $TECH[FG_NR1].FCT. 4) with the corresponding X and Y values. and on the right is the assignment to the individual control points (1 .Y4=0.CPS1.. on the left is the entry taken from the file “Weav_def_d.ArcTechDigital 2.zero to peak) entered in the W--parameter list 2 (Mechanical Weaving).0.Y1=0. Additional information on menu--guided programming can be found in the documentation [Arc Welding. DEF WEAV_DEF (GENERATOR :IN.CPS1. Yn=1.double trapezoid CASE 5 .FCT. ArcTechDig_P_R23 04.0.FCT.5 0.0 X 4 --1 3 The value for X can be between 0.CPS1. unsymmetrical (UNSYM_TRP) Spiral weaving (SPIRAL) Figure-of-eight weaving (DBL_8) .FCT.unsymmetrical trapezoid CASE 6 .0 1 0.0 ENDIF 0.25 0.CPNUM=4 $TECH[FG_NR1].00 en 58 of 68 .X3=0.Operation].0 $TECH[FG_NR1].CPS1. Weav_def_d.FIGUR :IN ) Triangular weaving (SGL_TRI) Triangular weaving.75 1.src SWITCH FIGUR n = control points (CPNUM) Y 1 2 CASE 1 .25 $TECH[FG_NR1].FCT. i.0 and 1.X4=1.eight The “Triangle” weave pattern (SGL_TRI) is described in the following example.FCT. the lateral deflection Y and the angle of the torch in relation to the welding plane (weave angle) can be programmed for each weave pattern in the W--parameter list 2 “Mechanical Weaving” with menu prompting.75 $TECH[FG_NR1].Y3=-1.FCT.ORDER=1 $TECH[FG_NR1]..0 $TECH[FG_NR1].FCT.FCT.src”. FCT.FCTCTRL.src $TECH[N]..2.0 .1 Two-dimensional weaving Weave patterns such as triangular and trapezoidal patterns result from the lateral deflection of the torch during motion along the seam.Xn=x (0.0 .FCTRL..FCTCTRL. A20.CPS1.SCALE_OUT) corresponds to the value set for the half weave width (W. 1.Xn=x (0. i.0 . Complex patterns are possible by means of a second function generator that causes the torch to weave in the welding direction (X--axis)..SCALE_IN) to the weave length (A. 1. the torch describes a motion in the form of a circle (with the same amplitude) or of an ellipse (with different amplitudes).. The following diagram illustrates the mode of operation of the function generator using the example of spiral weaving..src Lateral deflection (amplitude) 1) $TECH[FG_NR1].FCTRL. for example).WEAVLEN_MECH) is 1:1. As a result of the superposition of a lateral weave motion “sin(x)” with an orthogonally--acting weave motion of the same frequency in the welding direction “cos(x)”.WEAVAMP_MECH).07..FCT..0) Lateral deflection (amplitude) 1) (-Y’) (Y) (Y’) (-Y) Torch Weave width 1) Lateral deflection (amplitude) = half weave width 2) Deflection in direction of path= ¦ weave length The ratio of the deflection in the welding direction (.SCALE_IN) in relation to the weave length (W. The magnitude of the deflection in the welding direction (. Weav_def_d. You can also develop your own patterns. The lateral deflection (. 1..SCALE_OUT) corresponds to the value set for half the weave width (A.0) Deflection in direction of path 2) $TECH[FG_NR2]. are already included in the technology package. The lateral deflection (.Yn=x (0.2 Creating the “Spiral” weave pattern The following illustration depicts the development of the “Spiral” weave pattern.0 .e..FCT. it corresponds to half the weave width (peak to peak).CPS1.FCTCTRL. Two practical functions (for thin sheet welding. namely spiral weaving and figure--of--eight weaving.00 en 59 of 68 .2.FCT..WEAVLEN_MECH) is set in the file “A20.0) $TECH[FG_NR2].FCTCTRL.Yn=x (0..WEAVAMP_MECH)..CPS1. ArcTechDig_P_R23 04. 1.0) $TECH[FG_NR1].. 11. The spiral form results because the torch is moved by the amount of the weave length (from X=0 to X=1) during one period (360˚) in the direction of welding..11 Mechanical weaving (continued) 11.SCALE_OUT=1 The “Weave amplitude” value is defined as “zero to peak”.CPS1...SCALE_IN=1 $TECH[N].SRC” at a ratio of 1:1. ”) and a cosine for the deflection in the direction of the path (”$TECH[FG_NR2].NR1..0 Y 1 Deflection in direction of path 3’ 4’ 0 1 $TECH[FG_NR2]. 6’ 5’ 3 (Y’) 3’ X 4’ 5 4 --1 1’ 2’ 5’ 6’ --1 Weave length The control points for the “Spiral” weave pattern are defined in the file “Weav_def_d.spiral” in the file “Weav_def_d.00 en 60 of 68 . 6. The figure of a spiral results from the superpositioning of these two motions... (X 1 .. 6) 6 X 1. (X 1 ..).3 Superposition of cosine on sine Without path motion 0 1 sin(x) cos(x) With path motion Welding direction 1 0 The following diagram shows the curve shapes of the function generators derived from the sine function. ArcTechDig_P_R23 04.... 6.0 --1 Y 1 2’ 0 1 1’ 4 5 Resultant: spiral 2 (--Y’) 6.ArcTechDigital 2.. The parameters for the lateral deflection are stored in the first block (..src”.... The corresponding control point parameters are stored under “CASE 6 ..src”. This is approximately a sine for the lateral deflection (”$TECH[FG_NR1]... 6) 0 X 1.”). Y 1 .07.. Y 1 .. Y 1 Lateral deflection (amplitude) 2 3 $TECH[FG_NR1]... Y2=1..X5=0.FCT.CPS1.CPS1.0 $TECH[FG_NR1].Y5=-1.X6=1.FCT.CPS1.CPNUM=6 $TECH[FG_NR2].X2=0.CPNUM=6 $TECH[FG_NR1].0 $TECH[FG_NR2].0 $TECH[FG_NR2].FCT.FCT.CPS1.CPS1.11 Weav_def_d.0 $TECH[FG_NR1]. IF FG_NR2>0 THEN $TECH[FG_NR2].666666 $TECH[FG_NR1].FCT..X2=0..0 $TECH[FG_NR2].FCT. is defined in the file “Weav_def_d.X3=0.FCT. (X 1 .CPS1.333333 $TECH[FG_NR1].CPS1. 6.) contains the parameters for the deflection in the direction of the path.00 en $TECH[FG_NR2].CPS1.FCT.0 $TECH[FG_NR2].FCT.3 “Figure-of-eight” weave pattern An additional weave pattern.0 $TECH[FG_NR1].FCT.. Y 1 .spiral IF FG_NR1>0 THEN $TECH[FG_NR1]..CPS1.. 6) Weave length 61 of 68 .FCT.Y5=-1.Y6=0..FCT.CPS1.FCT.Y6=-1.CPS1.FCT.FCT.07.FCT.Y3=1..ORDER=1 $TECH[FG_NR1].X4=0.0 $TECH[FG_NR2].Y3=1..FCT.FCT.FCT.5 4 8 --1 3 0.Y1=-1.CPS1.0 $TECH[FG_NR1].0 $TECH[FG_NR2].083333 $TECH[FG_NR2].X3=0.CPS1..FCT.CPS1.eight”.Y4=1.CPS1.Y1=0.416666 $TECH[FG_NR2]. (X 1 .CPS1.CPS1.CPS1.0 ENDIF Mechanical weaving (continued) The second block (A_FG_MECH2..0 ENDIF 11.916666 $TECH[FG_NR2].FCT.FCT.FCT.X1=0.X6=1.2.CPS1.ORDER=1 $TECH[FG_NR2].0 $TECH[FG_NR1].CPS1.0 $TECH[FG_NR1].src CASE 6 .CPS1.CPS1.FCT. This pattern results from the superposition of a lateral weave motion with an orthogonally--acting weave motion in the direction of welding with double frequency.X1=0.X4=0.0 $TECH[FG_NR1]. Y 1 .Y2=-1..FCT.833333 $TECH[FG_NR1].FCT. 6.5 4 5 9 X 0 3 1 5 7 9 X Deflection in Y direction of path 2 6 1 3 0 Resultant: “eight” Y 4 2 5 1 8 7 9 X 6 $TECH[FG_NR1]. 6) ArcTechDig_P_R23 04.CPS1.166666 $TECH[FG_NR1].FCT.src” under the designation “CASE 7 . Lateral deflection Y (amplitude) 1 2 0 1 6 --1 7 8 --0.0 $TECH[FG_NR2]...Y4=-1.CPS1.FCT. an asymmetrical “figure--of--eight”.58 $TECH[FG_NR2].X5=0. FCT.CPNUM=4 $TECH[FG_NR1].FCT.25 $TECH[FG_NR1]. The required changes have been made in the following list and are underlined for ready identification. ArcTechDig_P_R23 04.3 11.CPS1.by 180˚ in the phase angle.Y3=-1.FCT.Y2=1. You want to shift the “Triangle” pattern -.src CASE 1 .2. and new patterns can be created.ORDER=1 $TECH[FG_NR1].FCT.CPS1.75 $TECH[FG_NR1].src” to your own requirements by changing the number of control points and their parameters.0 4 X 3 --1 n = control points (CPNUM) In order to achieve a phase shift of 180˚.CPS1.FCT.X2=0.FCT.Y1=0.5 0.2. 11.FCT.0 $TECH[FG_NR1].1 Changing existing weave patterns You can adapt the weave patterns defined in the file “Weav_def_d.CPS1.FCT.ArcTechDigital 2.4.0 $TECH[FG_NR1].75 1.0 0.src”.X4=1.00 en 62 of 68 .0 $TECH[FG_NR1].25 1 0.Y4=0.FCT.CPS1.0 $TECH[FG_NR1].triangle IF FG_NR1>0 THEN $TECH[FG_NR1].4 Changing and creating patterns for mechanical weaving The weave patterns defined by the manufacturer can be changed by the user.contained in the file “Weav_def_d. The settings for the “Triangle” weave pattern are contained in the file “Weav_def_d.FCT.0 $TECH[FG_NR1].X3=0.src” -.CPS1. Weav_def_d.CPS1.CPS1.07.0 ENDIF Represented graphically: Y 1 2 0. it is merely necessary to change the parameters for control points Y2 and Y3.X1=0. FCT.CPNUM=4 $TECH[FG_NR1].default as minimums and flag for beginning” of the file “Weav_def_d.X4=1.X2=0.2 Creating your own weave patterns The following example shows the practical approach for creating your own weave patterns.FCT. Y 1 0.CPS1.CPS1.FCT.0 $TECH[FG_NR1].CPS1.Y1=0.Y4=0. Multiple X values that are identical cannot be used.00 en 63 of 68 . ArcTechDig_P_R23 04.2.0 $TECH[FG_NR1].FCT.0 $TECH[FG_NR1].25 $TECH[FG_NR1].CPS1.0 6 X --1 5 n = control points (CPNUM) The first value for X must be 0 (zero) and the last value must be 1.CPS1.0 for the path “X” covered within a period and  1 for the lateral deflection “Y” are predefined.75 1.FCT.4. A weave pattern is to be created as a combination of a trapezoid and a triangle.25 0.FCT.0 $TECH[FG_NR1].triangle (phi = 180 degrees) IF FG_NR1>0 THEN $TECH[FG_NR1].0 0. It is recommendable to start by drawing the desired pattern. A range from 0.0 to 1.8 1.X3=0.FCT.src”. in the block “CASE 8 .Y2=-1.X1=0.0 4 X --1 2 n = control points (CPNUM) 11.75 $TECH[FG_NR1].07.FCT.FCT.0 $TECH[FG_NR1].0 ENDIF Y 1 1 0.4 0.Y3=1.2 0.FCT.6 4 0.CPS1.11 Weav_def_d. as shown in the following.src CASE 1 . The number of control points determined (CPNUM) as well as the X and Y values can be entered.CPS1.5 3 Mechanical weaving (continued) 0. for example.ORDER=1 $TECH[FG_NR1].0 1 2 3 0.CPS1. FCT.X2=.src CASE 8 .ArcTechDigital 2.ORDER=1 $TECH[FG_NR1].CPS1. With higher weave frequencies.Y6=.FCT. for example.0 $TECH[FG_NR1].Y4=. This can vary between the set path velocity and a multiple of it.4 $TECH[FG_NR1].FCT..FCT.Y1=. The maximum weave frequency for mechanical weaving is – depending on the robot type concerned – influenced by several factors.FCT.FCT.CPS1.CPS1.CPS1. etc.FCT...CPS1.2.0 ENDIF Number of control points Value X for control point 1 Value X for control point 1 Value X for control point 2 Value Y for control point 2 .0 $TECH[FG_NR1]. The weave motion is superposed on the path motion.CPS1. Weave frequencies of up to 3 Hz (corresponding. . this leads to an irregular welding speed during a period.2 $TECH[FG_NR1].6 m/min) are possible without causing problems according to previous experience. to a weave length of 3. axis torsion.5 Notes on mechanical weaving The quality of a seam welded with mechanical weaving is influenced by a variety of physical and mechanical factors.Y5=-1.CPS1. undesirable effects are liable to result in certain conditions (depending on the tool design and/or tool orientation).FCT.00 en 64 of 68 .CPS1.FCT. depending on the relation of the weave length (frequency) to the lateral deflection (amplitude). for example by the resonant frequency of the “robot/tool” mechanical unit.FCT.0 $TECH[FG_NR1].X3=.X6=1.3 Weav_def_d.CPS1.0 $TECH[FG_NR1].8 $TECH[FG_NR1].CPS1. path tangent.CPNUM=6 $TECH[FG_NR1].X5=. With weave frequencies > 3 Hz. such as the mechanical play in the gears.33 mm at a travel speed of 0. In addition.CPS1..Y2=1. the motion characteristics of the robot should therefore be individually tested in each case.Trapez .X4=. interdependencies with the interpolation cycle as well as the set robot--specific $Filter value also exist.FCT.CPS1. 11. ArcTechDig_P_R23 04.Dreieck $TECH[A_FG_MECH1].0 $TECH[FG_NR1].0 $TECH[FG_NR1].FCT. robot position.FCT.6 $TECH[FG_NR1].0 $TECH[FG_NR1]. In case of weave patterns such as “Trapezoid” or “Spiral”.FCT.07.X1=.Y3=1. a secondary signal that has to be acknowledged is set for reasons of safety.00 en 65 of 68 . for example: Message group Message time Message number Originator Message text COMMAND ACCELERATION EXCEEDED A2 ACTIVE COMMANDS INHIBITED 12. Dialog messages require confirmation by the operator (“Yes” or “No” softkeys). 12.1 Message groups Hint messages provide the operator with explanatory information. the corresponding cause. The message is cleared after it has been confirmed. Operational messages signal the status of the system that has led to a control reaction. 12. effect and remedy can quickly be located in the list of error messages.g. A message consists of the following items of information. for example.2 Message time The message time indicates the time at which the message was generated.12 Error messages / troubleshooting 12 Error messages / troubleshooting Messages of all categories are displayed in the message window. ArcTechDig_P_R23 04. Acknowledgement messages indicate a situation that must in all instances be recognized and acknowledged with the acknowledge key. The message is cleared once its cause has been eliminated. if an illegal key has been pressed. In some cases. These can be either informative messages that do not need to be acknowledged or messages that have to be acknowledged. They are often a consequence of a status (operational) message. e.07. An acknowledgement message stops a movement or prevents further operation. Emergency Stop.3 Message number With the aid of the message number. ArcTechDig_P_R23 04. Effect describes how the controller reacts to the error.6 List of error messages To make it easier to find error messages in the following list. the message number is shown first.5 Message text The text of the error message is shown here.00 en 66 of 68 . Cause gives a detailed description of the cause of the error. Monitor indicates when the conditions for generation of the message are checked.3 12.4 Originator The origin of the error is indicated in this field. 12. In the case of ArcTechDigital. Remedy describes what action the user can take to eliminate the error. the entry is TPA20. it is possible to obtain further information on an error and the appropriate remedial action. 12. This information is subdivided into: Message text is the actual text of the error message as displayed. By referring to this message number.ArcTechDigital 2. unlike on the display.07. no arc -.Configured signals not returned to input group I_START_MOVE [ ] Current flow not established Power source sends this output too late or not at all Weld current connections broken -.In ARC ON command -.ARC_ON command -. as deactivation not otherwise possible in event of interpreter stop -.Submit interpreter has been stopped.In ARC ON command -.12 1 Message text Cause Monitor Effect Remedy 2 Message text Cause Monitor Effect Remedy 3 Message text Cause Monitor Effect Remedy 4 Message text Cause Error messages / troubleshooting (continued) Option bit ARC20 not set -.For test purposes or start--up. stop and restart Submit interpreter.Endless loop always with this message -. etc.Switch on power source (I_WELD_COND [ ]) Ignition failure.In ARC ON command -.Ignition process is cancelled and restarted.The inputs configured in the signal input group I_WELD_COND [ ] are missing when welding is activated -.Set ARC20 to TRUE.Endless loop with this message -.Restart Submit interpreter Wrong submit routine selected -.Endless loop always with this message -.ARC20 = FALSE -. in accordance with configured option and number of ignition attempts set -.Endless loop with this message. -.No SPS.During initialization of A20_INIT commands -. data backup Submit is not running -. the I_START_MOVE [ ] condition may be deactivated Monitor Effect Remedy 5 Message text Cause Monitor Effect Remedy ArcTechDig_P_R23 04.SUB submit program running while ARC20=TRUE -.Position of the keyswitch (incorrect status for welding) -.$PRO_I_O[ ] = “R1/SPS ( )” Weld controller not ready -.Move the keyswitch to the correct position -.00 en 67 of 68 . once message acknowledged.07. Too many ignition attempts.Program remains in this loop after message acknowledged -.Seam not welded -.In ARC ON command -.07.Set the above variable to TRUE ($config.Periphery error: robot waiting for the inputs expected in I_WELD_FLT [ ].Incorrect burnback parameters -.dat) Monitor Effect Remedy 8 Message text Cause Monitor Effect Remedy 9 Message text Cause Monitor Effect Remedy 1 ArcTechDig_P_R23 04.ArcTechDigital 2.Clean ignition position and make new block selection to ARC_ON position Switch off welding -.In ARC OFF command -. weld process is restarted.3 6 Message text Cause Monitor Effect Remedy 7 Message text Cause Continue without welding -.Complete the configuration Reconnect gas.Incorrect configuration -. water.In advance run section of ARC ON command -.T1 mode and PROC_IN_T1 = FALSE -.Configuration error (OK state configured) -.Power source does not switch welding off or does so too late -. Normally configured as current flow “Gas present”. depending on RESTART_OPTION -. once message acknowledged. etc.Continuous between ignition process and ARC_OFF command if welding -.Single message for user -.00 en 68 of 68 . too many seam faults or interruption with RESTART_OPT = 0 (continue “Cold”) -. coolant monitoring -.Optimization of the burnback parameters Weld controller fault -. or check respective sensor Welding in operation mode T1 impossible! -.Welding is switched off. WEAVAMP_MECH. 13. 32 Fold ArcTech Outputs in $Config. 21 A20. 16 ARC20.i . 21 Fold ARC Messages in A20. 42 Input group I_WELD_END [ ].dat. 21 Activating. 43 Input group I_WELD_COND [ ]. 23 Block selection response. 58 Coordinate system ”TTS”.dat. 37 Creating your own weave patterns. 30 Fold Internal States in A20. 20 $STOPMESS. 50 A10.dat. 26. 20 Flt_serv_d. 30.dat. 21 Flt_serv_d. 19. 29 Digital outputs (physical). 25 Motion characteristics of the robot. 32 Ignition faults. 64 Mechanical weaving. 32 Digital outputs. 51 L Lateral deflection (weave amplitude). 27 Fold Main Options in A20. 14 ARC ON. 32 Digital inputs.STATE. 29 Digital inputs (physical). 49 IR_STOPMESS program.dat.DAT. 23.NO. 23. 11. 24. 57 Files for ”ARC Tech 20”. 61 Figure--of--eight weaving. 62 Control points (CPNUM). 45 N NAME_NAT[ ]. 51 Figure--of--eight weave pattern. 59 A20. 32 Index table for physical digital outputs. 45 I_ENB_W_EXT. 51 A A. 44 Installation. 53 B Basic settings. 64 F FAULT SERVICE FUNCTION. 25 I I_ENB_W_EXT. 29 $Config. 43 Input group I_WELD_FLT [ ]. 54 Fault situations and fault service functions. 58 M MAX_AUTO_R.dat. 51 Ignition repetition.dat. 56 Crater filling. 30 Digitale Eingänge. 51 External keyswitch. 15. 28 Fold ArcTech Inputs in $Config.WEAVLEN_MECH. 64 E EMERGENCY STOP.SRC.src. 50 O Index -. 56 C Changing existing weave patterns. 56 Minimum configuration. 8 Interpreter stop (STOP key). 63 D DIGITAL INPUTS. 23 Fault service functions. 29 ARC OFF. 59 A. 12 ARC SWITCH. 50 Maximum weave frequency. 45 I_WELD_CTRL[ ]. 32 Notes on mechanical weaving.dat.Index Zeichen $CONFIG.src. 24 DRIVES OFF. 29 Input group I_START_MOVE [ ]. 32 Index table for physical digital inputs. 50 IN_NR. 59 A_FLT_SV_FCT. 30 Index tables. 23 Adaptation to the periphery. 23. changing of. 62 Weave patterns. 29 Spiral weave pattern. 39 Signal tables for digital inputs.ARC SWITCH.ARC ON. 45 Timing diagram. 57 Start welding -. 52 Signal output groups for fault service function. 51 R Resonant frequency. 28 PRG_NO. 17 Signal flow of the program numbers. 25 Program number specification. 47 PROC_IN_T1. 58 Weave patterns.PARITY. 14 Schematic sequence diagram ARC ON.Index O_SEAM_END[ ]. 63 Weaving. 28 PRG_NO. 52 Signal output group O_ACK_FLT [ ].ARC OFF. 64 RESTART_OPT. 52 Signal APPL_RUN.FIRST_BIT. 30 Output group O_ACK_FLT [ ]. 59 Types of faults. 47 . 28 PRG_ON_MODE. 19 Program test.SRC. creating of. 37 O_WELD_CTRL[ ]. 21 Weave length. 49 Switching on the welding process. 52 Signal output group O_FLT_CLEAN[ ].ii S Schematic sequence diagram ARC OFF. 58. 36 Output group O_ACK_WELD_E[ ]. 30 OUT_NR. 55 Program number control. 49 RESTART_OPTION. 62 Weav_def_d. 40 Output group O_SEAM_END [ ]. 48 Trapezoidal weaving. 29 Two--dimensional weaving.CODING. 47 PRG_SWI_MODE. 53 Signal diagram ARC_OFF. 15 Signal diagram ARC_ON. 13 Index -. 12 Schematic sequence diagram ARC SWITCH. 49 W WEAV_DEF. 37 Output group O_STROB_PGNO [ ]. 15 Welding and ending seams -. 55 PULS_TIME. 31 STATE. 59 Spiral weaving. 57 Triangular weaving. 47 PRGNO_MAX. 41 Output group O_ACK_START [ ]. 39 Output group O_FLT_CLEAN [ ]. 28 PRG_NO. two--dimensional. 33 Signal tables for digital outputs. 38 Output group O_FLT_ARC_ON [ ]. 41 Output group O_FLT_WELD [ ]. 47 Program run mode ”GO”. 57 Triple groups. 57 Weave patterns. 56 Weaving. 35 Signal O_FLT_SIGNAL. 11 Program structure. 16 Seam error. 8 P T Time_out. 37 Output group O_WELD_START [ ].src. 35 Signal grouping in normal operation. 13 Signal diagram ARC_SWI. 31 Signal tables for digital outputs and inputs. 11 Power source interface. 23 PRG_NO. 47 PRGNO_MIN. 59 Welding a seam in several sections -. 11 System requirements. 31 STOP key.LENGTH.