Arc Welding Operation Manual

Transcription

1 Kawasaki Robot Controller E Series Arc Welding Operation Manual Kawasaki Heavy Industries, Ltd DEA

2 PREFACE This manual describes operating instructions for arc welding specification of the Kawasaki Robot Controller E series. This manual is supplemental for standard Operation Manual. Read thoroughly the Safety Manual and other relevant manuals such as the Connection and Installation Manual for arc weld robot controlled via E series controller. Once the contents of these manuals are thoroughly read and understood the robot can be used. This manual provides as much detailed information as possible on the standard operating methods for arc welding specification of the Kawasaki robot. However, not every possible operation, condition or situation that should be avoided can be described in full. Therefore, should any unexplained questions or problems arise during robot operation, please contact Kawasaki Machine Systems. Refer to the contact information listed on the rear cover of this manual for the nearest Kawasaki Machine Systems office. The explanations in this manual include information on optional functions, but depending on the specification of each unit, not every optional function detailed here may be included with the robot. Also, note that figures given here may differ partially from actual screens. 1. This manual does not constitute a guarantee of the systems in which the robot is utilized. Accordingly, Kawasaki is not responsible for any accidents, damage, and/or problems relating to industrial property rights as a result of using the system. 2. It is recommended that all personnel assigned for activation of operation, teaching, maintenance or inspection of the robot attend the necessary education/training course(s) prepared by Kawasaki, before assuming their responsibilities. 3. Kawasaki reserves the right to change, revise, or update this manual without prior notice. 4. This manual may not, in whole or in part, be reprinted or copied without the prior written consent of Kawasaki. 5. Store this manual with care and keep it available for use at any time. If the robot is reinstalled or moved to a different side or sold off to a different use, attach this manual to the robot without fail. In the event the manual is lost or damaged severely, contact Kawasaki. Copyright 2011 Kawasaki Heavy Industries Ltd. All rights reserved. i

3 SYMBOLS The items that require special attention in this manual are designated with the following symbols. Ensure proper and safe operation of the robot and prevent physical injury or property damage by complying with the safety matters given in the boxes with these symbols.! DANGER Failure to comply with indicated matters can result in imminent injury or death.! WARNING Failure to comply with indicated matters may possibly lead to injury or death.! CAUTION Failure to comply with indicated matters may lead to physical injury and/or mechanical damage. [ NOTE ] Denotes precautions regarding robot specification, handling, teaching, operation and maintenance.! WARNING 1. The accuracy and effectiveness of the diagrams, procedures, and detail explanations given in this manual cannot be confirmed with absolute certainty. Accordingly, it is necessary to give one s fullest attention when using this manual to perform any work. Should any unexplained questions or problems arise, please contact Kawasaki Machine Systems. 2. Safety related contents described in this manual apply to each individual work and not to all robot work. In order to perform every work in safety, read and fully understand the safety manual, all pertinent laws, regulations and related materials as well as all the safety explanation described in each chapter, and prepare safety measures suitable for actual work. ii

4 INTRODUCTORY NOTES 1. HARDWARE KEYS AND SWITCHES (BUTTON) E series controller provides hardware keys and switches on the operation panel and the teach pendant for various kinds of operations. In this manual the names of the hardware keys and switches are enclosed with a square as follows. The terms key or switch which should follow the relevant names are sometimes omitted for simpler expression. When pressing two or more keys at the same time, the keys are indicated by + as shown in the example below. EXAMPLES TEACH/REPEAT: indicates the mode switch TEACH/REPEAT on the operation panel. A+MENU: indicates pressing and holding down A then pressing MENU. 2. SOFTWARE KEYS AND SWITCHES E series controller provides softw are keys and switches which appear on the screen of the teach pendant for various kinds of operations depending on specifications and situations. In this manual, the names of software keys and switches are enclosed by < > parentheses. The terms key or switch which should follow the relevant names are sometimes omitted for simpler expression. EXAMPLES <ENTER>: expresses an ENTER key that appears on the teach pendant screen. <NEXT PAGE>: expresses a NEXT PAGE key on the teach pendant screen. 3. SELECTION ITEMS Very often an item must be selected from a menu or pull-down menu on the teach pendant screen. In this manual the names of these menu items are enclosed in brackets [XXX]. EXAMPLES [Auxiliary Function]: Expresses the item Auxiliary Function in a menu. To select it, move the cursor to the relevant item by the arrow keys, and press the key. For detailed description, this procedure should be described every time, but select [XXX] item will be used instead for simpler expression. iii

5 CONTENTS 1.0 Overview of Arc Welding Control Configuration of Arc Welding Robot System E Controller Specifications for Arc Welding Hardware Keys on Teach Pendant Overview of Teach Pendant Hardware Keys on Teach Pendant Instructions for Operating Screen on Teach Pendant Status Area F keys (Function Keys) Monitor Screen PC Program Arc Status Screen Step Information (Auxiliary Data) Screen Manual Operation of Robot Manual Operation of Robot Aligning Operation Setting for Keeping Base +Z Direction Inching Operation for Weld Wire ON/OFF Operation for Supplying Shield Gas Teaching Overview of Teaching Operation Basic Flow of Teaching Operation Type of Teaching Points and Auxiliary Data Weld Condition How to Set Weld Condition Types of Weld Conditions Teaching for Arc Welding Creating a Program Sheet Preparation for Teaching Configuration of Teach Screen Teaching Operation Setting Other Auxiliary Data Setting Option Switches 5-18 iv

6 5.3.2 Setting Weld Conditions Setting Special Conditions Real Time Weld Condition Modification Function Repeat Operation Real Time Weld Condition Modification Function Program Modification Program Editing Screen Step Modification on Program Edit screen Pose Data and Auxiliary Data Modification Online Editing Function Screens that Can Use Online Editing Function Functions Used in Online editing Screen Auxiliary Functions Overview of Auxiliary Function Auxiliary Function List Touch Sensing Function (Option) Overview of Touch Sensing Function Features of Touch Sensing Option Function Sensing Patterns for Compensation of Workpiece Deviation Wire Check Function Teaching for Wire Check Function Wire Check Function at Repeat Operation Workpiece Detection Function Teaching for Workpiece Detection Function Workpiece Detection Function at Repeat Operation Compensation Function for Workpiece Deviation Combination of Sensing Patterns Teaching- Compensation Function for Workpiece Deviation- 1 (Teaching for Each Sensing Pattern) Teaching- Compensation Function for Workpiece Deviation- 2 (Teaching for Combination of Sensing Patterns) Compensation for Workpiece Deviation at Repeat Operation Continuation and Reset of Workpiece Deviation Compensation Continuation and Reset of Compensation Cases of Continuing/Resetting Compensation 9-35 v

7 9.5 Precautions on Teaching Error Handling when Operating Touch Sensing Function Error Message List Errors and Countermeasures Special Pattern Weaving Function (Option) Overview of Special Pattern Weaving Special Pattern Weaving Pendulum Weaving Weld Current/ Weld Voltage Boosts Flow Chart for Using Special Pattern Weaving Function Standard Weaving Patterns Registered for Robot Teaching Operation for Special Pattern Weaving Creating a New Weaving Pattern Coordinates System and Parameters when Creating Weaving Pattern Creating Weaving Patterns Servo Torch Function (Option) Overview of Servo Torch Function Procedure for Setting Servo Torch as External Axis Servo Torch Specification Auxiliary Functions for Servo Torch Differences: Servo Torch Spec. vs. Standard Arc Spec Error Handling when Operating Servo Torch Function Error Message List Errors and Countermeasures Error Message for Arc Weld Specification Error Message List Errors and Countermeasures 12-3 Appendix 1.0 Program Sheet A-1 Appendix 2.0 Weld Database A-3 Appendix 3.0 Pattern Example of Special Pattern Weaving (List) A-7 vi

8 1. Overview of Arc Welding Control 1.0 OVERVIEW OF ARC WELDING CONTROL The standard E series controller has been incorporated with control functions specific to arc welding. With these functions, the robot can be programmed to work flexibly and efficiently with weld machines to produce variety of high quality welds. 1.1 CONFIGURATION OF ARC WELDING ROBOT SYSTEM Arc welding robot system consists mainly of the following components. See the figure below. 1. Robot for arc welding (RA series robot, etc.) 2. E Series Controller for arc welding 3. Arc welding torch 4. Other devices for arc welding (weld power supply, wire feeder, gas supplying unit, cable, etc.) 5. Other optional devices (torch cleaner, etc.) This manual mainly focuses on No.2 above, regarding items relating to E Series Controller for arc welding. For details about other materials, see the standard operation manual, specification sheets, etc. Wire feeder E Series Controller for arc welding Robot main body for arc welding Weld power supply Arc welding torch 1-1

9 1. Overview of Arc Welding Control 1.2 E CONTROLLER SPECIFICATIONS FOR ARC WELDING Specifications for arc welding control are as follows. For details about other standard specifications, refer to the Operation Manual for E series controller. 1. Necessary boards: Arc welding interface board (1TW/1GN boards) Optional daughter boards (when using optional functions) 2. Arc welding control functions: Command of arc welding voltage/current to the weld power supply, motor control for wire feed (including inching/retract), gas supply ON/OFF, weld stuck detection 3. Optional control function: Touch sensing, special pattern weaving, etc. 1-2

10 2. Hardware Keys on Teach Pendant 2.0 HARDWARE KEYS ON TEACH PENDANT This chapter describes hardware keys on teach pendant specially for arc welding specification. For details about other standard keys, refer to Operation Manual for E series controller- 2.4 Switches on Teach Pendant and Functions of Hardware Keys. 2.1 OVERVIEW OF TEACH PENDANT Figure 2.1 shows the arrangement of the hardware keys on arc welding teach pendant. Figure

11 2. Hardware Keys on Teach Pendant 2.2 HARDWARE KEYS ON TEACH PENDANT This chapter describes the function of each of the hardware keys for arc welding closed by in Figure 2.1 Keys Function Feeds weld wire when pressed. See 4.2 Inching Operation for Weld Wire for more details. Pressing F key <Wire Inching> changes the speed at which wire is fed. Manually turns ON shield gas supply when pressing A + GAS ON. The gas is turned ON only while the key is pressed. Retracts weld wire when pressed. The wire is retracted only while the key is pressed. See 4.2 Inching Operation for Weld Wire for more details. Pressing F key <Wire Inching> changes the speed at which wire is pulled back. Pressing A + CND.CHG. displays Real Time Condition Modify screen in C area. A + WELD ON/OFF selects weld ON and OFF during repeat/check operations. A + INSTR. selects the instructions column under Mtd on block teaching screen. See Configuration of Teach Screen for picture. A + CND.NUM. selects the weld condition number column on block teaching screen. See Configuration of Teach Screen for picture. A + WELD CND. selects the weld conditions (Spd Amp Vlt Tmr Amp Vlt) set for the weld condition number on block teaching screen. See Configuration of Teach Screen for picture. A + SPEC.CND. selects the special condition column on block teaching screen. See Configuration of Teach Screen for picture. A + OPTION selects the option switch column on block teaching screen. See Configuration of Teach Screen for picture. A + JT6 +/- executes 45 align operation while in base mode. A + JT7 +/- executes 90 align operation while in base mode. 2-2

12 3. Instructions for Operating Screen on Teach Pendant 3.0 INSTRUCTIONS FOR OPERATING SCREEN ON TEACH PENDANT This chapter describes the screens on the teach pendant used for operating the arc welding functions. For details about other standard operating screens, the functions available on each screen and their operation procedures refer to Operation Manual for E series controller-2.4 Switches on Teach Pendant and Functions of Hardware Keys. 3-1

13 3. Instructions for Operating Screen on Teach Pendant 3.1 STATUS AREA When weld is set ON by pressing A + WELD ON/OFF, the following icon is displayed in the status (F) area as shown below. When Weld ON: Weld OFF :< Arc OFF> Weld ON:<Arc ON> When Weld OFF: Weld ON: Icon lights up 3-2

14 3. Instructions for Operating Screen on Teach Pendant 3.2 F KEYS (FUNCTION KEYS) The chart below shows the functions of the arc weld specification F keys (shown as 1 to 3 in figure below), displayed on teach mode screen. For other F keys, see the Operation Manual for E series controller 2.6 Operation Keys on Teach Pendant Screen No. Operation key Functions 1 Displays the arc status monitor (see for details on arc status monitor). When weld is ON, the icon lights up. 2 Displays the real time condition editing screen. For details on real time condition editing screen, see 5.4 and Sets the speed to feed or retract the wire via Wire Inching and Wire Retract. The speed changes in 3 levels from 1 to 3 every time the key is pressed. When pressed with A key Operation Functions Displays the arc status monitor (see for details on arc status monitor). When weld is ON, the icon lights up. Displays the real time condition editing screen. For details on real time condition editing screen, see 5.4 and 6.1. Sets the speed to feed or retract the wire via Wire Inching and Wire Retract. The speed changes in 3 levels from 1 to 3 every time the key is pressed. 3-3

15 3. Instructions for Operating Screen on Teach Pendant 3.3 MONITOR SCREEN In arc welding specification, the items below are added to the standard specification menu. 1. PC program (Monitor function no. 27) 2. Arc status (Monitor function no. 82) 3. Step information (Monitor function no. 83) Figure 3.1 For details on other monitor functions on the menu, see the Operation Manual for E series controller 2.9 Monitor Screen PC PROGRAM Selecting [PC Program] in Figure 3.1 displays the screen in C area similar to Figure 3.1 Figure 3.2 This screen displays the data of up to five PC programs. 3-4

16 3. Instructions for Operating Screen on Teach Pendant ARC STATUS SCREEN Selecting [Arc Status] in the screen shown in Figure 3.1 displays current robot status, arc weld conditions, etc. as shown in Figure 3.3. Figure 3.3 The following items are shown highlighted when the I/O signal is ON. Input Signal: Current Detect, Pole Stuck, Torch Interfere, Wire Touch, Wire Stuck Output Signal: Arc ON, Wire Inching*, Wire Retract*, Gas ON, Touch Sensor ON, Weld ON In Figure 3.3, Torch Interfere and Weld ON are ON. NOTE* For Wire Inching or Wire Retract, only one output signal can be ON. They cannot be ON simultaneously. In Curr. Comm. and Volt. Comm., the current command values are displayed. Current Command: V Voltage Command: V 3-5

17 3. Instructions for Operating Screen on Teach Pendant STEP INFORMATION (AUXILIARY DATA) SCREEN Selecting [Step (Aux)] in Figure 3.1 displays the screen in C area as shown in Figure 3.4. Figure 3.4 This screen displays all the auxiliary data for the selected step in the selected program. During repeat operation, etc., when a step moves forward, the contents of the currently running step are displayed. 3-6

18 4. Manual Operation of Robot 4.0 MANUAL OPERATION OF ROBOT When wire feeder or shield gas supplying unit are connected to E series controller, the teach pendant can be used to manually inch/retract weld wire or turn ON/OFF gas supply in addition to the normal robot operations by teach pendant. For details about connecting devices, see Installation and Connection Manual for arc welding E series controller. 4.1 MANUAL OPERATION OF ROBOT Same as standard specification robots, the arc welding robot can be driven manually in the desired mode: joint, base coordinate based, or tool coordinate based. For more details, see Operation Manual for E series controller- 4.0 Manual Operation of Robot. This section describes the align operation, a function useful for arc weld teaching. Instructions are also given for setting the robot installation posture in Aux. Function 0505 Robot Installation Posture. In addition, the fixing of the +Z base axis in vertical direction regardless of the posture set in Aux is explained in detail ALIGNING OPERATION Aligning function rotates the tool to make the Z axis of the tool coordinates parallel to the nearest base coordinate axis during teaching. This is convenient for aligning the tool direction with the Z axis of the base coordinates (especially when teaching downward welds) before teaching a weld line. RX and RY rotate parallel to Z axis. Base coordinate system 1. Press INTER and select base mode. [ NOTE ] Aligning operation is not possible in joint or tool modes. 4-1

19 4. Manual Operation of Robot 2. While pressing down the TRIGGER, press A + JT6 +/- for aligning at 45, and A + JT7 +/- for aligning at 90. For 90 alignment, robot arm stops and align is complete when Z axis of the tool becomes parallel to the base coordinates Z axis. Y Z X Base coordinates system 45 alignment 90 alignment Y Z X Base coordinates system [ NOTE ] Aligning operation can also be used for aligning the tool coordinates with the base coordinates X or Y axes. Before aligning, move the tool near the desired base coordinates axis and then execute the procedure described above. 4-2

20 4. Manual Operation of Robot SETTING FOR KEEPING BASE +Z DIRECTION The +Z direction of the base coordinate motion can be set perpendicular upwards during teaching, once the actual installation posture is made to match the posture set in the controller. The direction of robot s base coordinates is set as shown in the figure below. However, the value of the base coordinates must have O, A, and T set to 0(zero) in Aux. Function 0506 Base Coordinates. Floor Ceiling Wall Wall 2 4-3

21 4. Manual Operation of Robot Setting procedure 1. Display Aux. Function 0505 Robot Installation Posture. To display auxiliary function screens, refer to Operation Manual for E series controller- 8.2 How to Use Auxiliary Functions. 2. Move cursor to the desired item by pressing and if the setting is correct, press again. (Installation angle can be specified only in some models so normally, this should not be changed.) 4.2 INCHING OPERATION FOR WELD WIRE Press WIRE INCHING or WIRE RETRACT to feed or withdraw weld wire. Inching operation is possible when both weld power supply and controller power are ON regardless of ON/OFF status of TRIGGER, TEACH LOCK, RUN/ HOLD, etc. However, inching operation for servo torch spec. (Option) is possible only when TRIGGER, TEACH LOCK and MOTOR ON are ON and RUN/ HOLD is set to RUN in teach mode. 4.3 ON/OFF OPERATION FOR SUPPLYING SHIELD GAS Press A + GAS ON to turn ON/OFF shield gas supply. Gas ON/OFF operation is possible when both weld power supply and controller power are ON regardless of ON/OFF status of TRIGGER, TEACH LOCK, RUN/ HOLD, etc. 4-4

22 5. Teaching 5.0 TEACHING This chapter describes procedures for teaching and editing programs via the teach pendant using a simple arc welding program as an example. For details on programming via AS language, refer to Arc Welding AS Language Reference Manual for E series controller. 5-1

23 5. Teaching 5.1 OVERVIEW OF TEACHING OPERATION BASIC FLOW OF TEACHING OPERATION Teach horizontal fillet welding between P 1 and P 2 as shown below. Teaching point Teaching contents Step1 Starts operation from P 0. Step2 Starts welding from P 1. Step3 Completes welding at P 2. Step4 Evacuates robot to P 3. P 0 P 1 P 3 P 2 First enable manual operation of the robot, then start teaching by the following procedure with teach pendant. Move the tip of the torch to the point, P 0 /P 1 /P 2 /P 3 in the figure above manually. Select a type of teaching for points P 0 /P 1 /P 2 /P 3. Air Cut (AC) point (P 0 /P 3 ) Weld Start (WS) point (P 1 ) Weld Continue (WC) point Weld End (WE) point (P 2 ) Arc Spot (AS) point (Set weld condition.) (Set AS condition.) No Change auxiliary data. Set standard auxiliary data to the point? Yes Press to confirm. Final point? No To next point. 5-2 Yes End

24 5. Teaching TYPE OF TEACHING POINTS AND AUXILIARY DATA The table below shows the types of teaching points and auxiliary data which are set/modified for arc weld teaching. Set the teaching points with auxiliary data, instructions (Mtd). Types of teaching points Air cut point (no welding) Weld start point (to begin welding) Weld continue point (halfway through welding) Weld end point (to finish welding) Arc spot point (to weld by arc spot) Auxiliary data that can be set/modified Interpolation mode (joint, linear), Speed, Accuracy, Timer, OX, WX, J/E Interpolation mode (joint, linear), Speed, Timer, OX, WX Interpolation mode (linear, circular1, circular2) Weld data (Weld speed, Weld current, Weld voltage, Polarity Ratio*) Weaving data (Width, Frequency, Pattern*) OX Interpolation mode (linear, circular2) Weld data (Weld speed, Weld current, Weld voltage, Polarity Ratio*) Weaving data (Width, Frequency, Pattern*) Crater weld data (Time, Weld current, Weld voltage) OX Interpolation mode (joint, linear), Speed, Accuracy, Timer Arc spot weld data (Time, Weld current, Weld voltage, Polarity Ratio*) OX, WX NOTE* Polarity ratio and weaving pattern are options. 5-3

25 5. Teaching WELD CONDITION By itself pose data for P 0 to P 3 is insufficient for operating the robot arc welding functions. Additional data must also be taught to the robot, for example the speed for moving from P 0 to P 1, how closely the torch tip comes to the taught point when arriving at P 1 (accuracy), etc. This is called auxiliary data. Furthermore, data specifying the weld quality such as weld speed, weld current, weld voltage, etc. is also needed, which is called weld condition HOW TO SET WELD CONDITION Two methods for setting the weld conditions are available during teaching. 1. Weld condition: Indirect setting Store only the weld condition number in the program steps. During program execution, the weld conditions set to that number are used. (100 condition numbers 0 to 99 are available.) Useful when applying the same weld conditions at several steps, because: (1) it is simple to specify the condition number instead of specifying a lot of condition parameters. (2) weld condition change is reflected all at once in all steps taught by the same condition number. Convenient when setting same weld conditions to several steps. 2. Weld condition: Direct setting Store weld conditions directly to each step in a program. Use this method when changing the weld conditions in a step already taught by indirect setting of weld condition (per 1. above). Unlike indirect setting above, changing the weld conditions for blocks of steps is not possible. Weld conditions do not change unless step is modified/deleted, or the welding conditions are changed via Aux. Function 1406 Arc Weld Condition Modify or 1407 Arc Spot Weld Condition Modify. Convenient for setting the weld conditions to specific steps. For setting procedure, refer to 8.0 Auxiliary Functions. 5-4

26 5. Teaching TYPES OF WELD CONDITIONS The following weld conditions are available as shown in the table below. Parameter of weld condition Weld speed Arc spot condition Crater condition Weaving Condition Basic Condition Weld current Weld voltage Weaving width Weaving frequency Weaving pattern No. (Option) Crater stopping time Crater current Crater voltage Arc spot time Arc spot current Arc spot voltage Polarity Ratio (Option) Description Sets motion speed in welding. (Unit: cm/min) Sets weld current. (Unit: Ampere (A)) Sets weld voltage. (Unit: Volt (V)) Sets amplitude in weaving. (Unit: mm) Set 0 when not executing weaving. Sets frequency in weaving. (Unit: Hertz (Hz)) Set 0 when not executing weaving. Sets pattern in weaving. When option is not mounted, only simple harmonic motion is available and this parameter is not displayed. Sets stopping time in crater treatment. (Unit: Second (sec)) Set 0 when not executing crater treatment. Sets crater current in crater treatment. (Unit: Ampere (A)) Set 0 when not executing crater treatment. Sets crater voltage in crater treatment. (Unit: Volt (V)) Set 0 when not executing crater treatment. Sets arc spot time. (Unit: Second (sec)) Sets weld current in arc spot welding. (Unit: Ampere (A)) Sets weld voltage in arc spot welding. (Unit: Volt (V)) Sets ratio of negative-positive polarity energizing. (16 steps from 0 to 15) 5-5

27 5. Teaching 5.2 TEACHING FOR ARC WELDING This section describes teaching operations specific to arc welding application. For standard teaching methods, refer to Operation Manual for E series controller- 5.0 Teaching CREATING A PROGRAM SHEET Once the teaching contents are determined, fill in the auxiliary data on program sheet. The following sheet shows a sample program for teaching horizontal fillet welding. Teaching operation of this program is explained in Teaching Operation. A blank program sheet is attached in Appendix 1. Program Sheet; make copies of use for when planning programs. Program Name PG10 Machine No. Applicable Work work001 Date prepared: Prepared by: Taro Kawasaki Revision S T E P Teaching point 1 P 0 AC JOINT P 1 WS LINEAR P 2 WC LINEAR P 3 WE LINEAR P 4 AC LINEAR P 5 AC JOINT Timer OX WX Jump /End Welding Condition Direct Arc Spot Condition option Direct Type of of Interpolatiocuracy Speed Air- Accu- teaching point speed In- Indirect SP A V WV f PNCtCACVdirect t A V 0 0 [ NOTE ] When using RPS function, teach End at last step. 5-6

28 5. Teaching PREPARATION FOR TEACHING To teach a program, first determine the work to be performed, then create a program sheet. Before starting the teaching process, check the following two items. 1. Registration of tool transformation value for torch Set the tool transformation value for the torch. When using a standard torch, refer to Aux.1405 in 8.0 Auxiliary Functions. [ NOTE ] No registration is need when robot and torch are purchased together from Kawasaki, as tool transformation value is already registered at time of factory shipment. 2. Setting of wire extension When executing arc welding, set the wire extension length (mm) according to welding posture and leg length. For details, refer to Aux.1405 in 8.0 Auxiliary Functions. 5-7

29 5. Teaching CONFIGURATION OF TEACH SCREEN The configuration of the teach screen for arc welding is as shown in the figures below. To switch between screens, press A + or. For more details about using teaching screens, refer to Operation Manual for E series controller- 5.0 Teaching. 1. Displays weld condition No. (0-99) or D (Direct) per how weld conditions were set, indirect/direct. 2. Refer to Setting Option Switches. 3. Displays weld conditions. [PO] means Polarity Ratio. * * * 5-8

30 5. Teaching NOTE* [PO (Polarity Ratio)] and [Weaving Pattern] are Options. 5-9

31 5. Teaching TEACHING OPERATION This section describes how to teach the robot to perform horizontal fillet welding via the five points shown in Figure 5.1 below. P 4 Escape point (Air cut point) P 0 Work start point & P 5 Work end point P 2 (Weld continue point) P 3 (Weld end point) P 1 (Weld start point) Teaching procedure Figure First, set the program name to be edited. The teach screen in Figure 5.2 below displays the setting of program pg10. Figure

32 5. Teaching 2. The contents to be taught are listed in the table below. Teaching point Teaching contents Step1 Point for starting operations (P 0 ). Step2 Moves from P 0 to P 1 by linear interpolation. Generates arc at P 1 and starts welding. Step3 Moves from P 1 to P 2 welding horizontal fillet of 5 mm leg length. Arc is not OFF at P 2. Step4 Moves from P 2 to P 3 welding horizontal fillet of 5 mm leg length. Cuts OFF arc after crater operation at P 3. Step5 Moves from P 3 (Weld end point) to P 4 (Escape point) by linear interpolation. Step6 Moves from P 4 to P 5 (Work end point), and completes teaching. [ NOTE ] Conditions for teaching operation: 1. Work to be welded is set in a jig manually. 2. Input/output of signals between robot and welding devices are automatically set during the teaching process. 3. Teach step1. P 0 P 5 P 2 P 4 P 1 P 3 (1) Jog the torch tip to P 0 by +/

33 5. Teaching (2) Set the auxiliary data, the instruction* to AC, the interpolation to joint, the speed to 9, the accuracy to 2 and the timer to 0.** NOTE* To set the instruction: Move cursor to the auxiliary data title row by pressing either A + INSTR. or by or. Pressing changes the instruction setting on the edit row as AC (Air Cut point (point not welded)) WS (Weld Start point) WC (Weld Continue point) WE (Weld End point) AS (Arc Spot point). When the desired instruction appears (in this case, AC), then the instruction setting is complete. NOTE** To set the interpolation, speed, accuracy and timer, refer to Operation Manual for E series controller- 5.3 Element Instruction and Their Parameters. Note some interpolation modes may not be available for an instruction as shown below. Instruction AC, WS, AS WC WE Interpolation modes avail. to be set Joint Linear Joint Linear Circular 1 Circular 2 Linear Linear Circular 2 Linear (3) Press RECORD to teach the pose and the auxiliary data of step1 at the same time. The teach screen will appear as shown in Figure 5.3. Figure

34 5. Teaching 4. Teach step2. Set torch angle (θ 1 ) approx. 45 at P 1. P 1 θ 1 = approx. 45 Switch to inching mode when torch is set close to P 1. Keep approx. 1mm from corner. (1) Press INTER and select base mode, then TEACH SPEED to select desired speed. (2) Move torch tip near P 1 by +/-. Then press TEACH SPEED to select the inching mode (Speed 1), and move the robot at very slow speed to set the torch tip to P 1 accurately. (3) Set the auxiliary data, the instruction to WS, the interpolation to linear, the speed to 9, and the timer to 0. (4) Press RECORD to teach the pose and the auxiliary data of step2 at the same time. The teach screen will appear as shown in Figure 5.4. Figure Teach step3. P 2 Approx. 1mm P 1 P 1 Approx. 1mm P 2 θ 2 =approx. 45 θ 1 =approx. 45 At P 2, set torch posture by torch angle θ 1 and angle with vertical plate θ 2 to be approx. 45 respectively. 5-13

35 5. Teaching (1) Press INTER and select tool mode. (2) Press Z- to evacuate the torch from P 1 to P 1 temporarily. (3) Press INTER and select base mode. (4) Move the torch tip to P 2 near P 2 by +/-. Then press TEACH SPEED and select the inching mode (Speed 1). Move the robot at very slow speed to set the torch tip to P 2 accurately. (5) Set the auxiliary data, the instruction to WC, the interpolation to linear, and the weld condition number* to 0. (In this example, weld condition No. 0 contains the data for welding horizontal fillet with leg length/thickness of 5mm. For more details, refer to Aux.1401 (Arc Weld Condition in 8.0 Auxiliary Functions).) NOTE* To set the weld condition number, Move cursor to Weld Condition Number on the auxiliary data title row by pressing either A + CND.NUM. or by or. The screen below appears, so input the desired weld condition No. and press. Input range for weld condition No. is from 0 to 99. Input 100 to directly specify the weld condition. (In this example, 0 is specified). Pressing <Setting> in the above screen changes the display to screen for Aux Arc Weld Condition. The weld conditions can be set in that screen. (6) Press RECORD to teach the pose and the auxiliary data of step 3 at the same time. The teach screen will appear as shown in Figure 5.5. Figure

36 5. Teaching 6. Teach step4. Same as P 2, set the torch tip to P 3 accurately. This point is also welded P 2 by horizontal fillet. Set torch angle θ 1 to be approx. 45. θ 1 =approx. 45 P 3 Approx. 1mm (1) Set the auxiliary data, the instruction to WE, the interpolation to linear, and the weld condition number to 0. (In this example, weld condition No. 0 contains the data for welding horizontal fillet with leg length/thickness of 5mm, and crater condition. For more details, refer to Aux.1401 (Arc Weld Condition).) Weld condition numbers are the same for P 1 P 2 and P 2 P 3, thus step4 is automatically set with the same conditions as in step3. Take note that crater treatment condition is only reflected in weld end step. (2) Press RECORD to teach the pose and the auxiliary data of step4 at the same time. The teach screen will appear as shown in Figure 5.6. Figure

37 5. Teaching 7. Teach step5. Same as P 3, press Z- in tool mode to evacuate the torch and move it to the escape point P 4. P 4 P 3 (1) Set the auxiliary data, the instruction to AC, the interpolation to linear, the speed to 9, the accuracy to 2 and the timer to 0. (2) Press RECORD to teach the pose and the auxiliary data of step5 at the same time. The teach screen will appear as shown in Figure 5.7. Figure Teach step6 by following the same procedure used in 3. above where P 0 is taught. (See page 5-10 for procedure No. 3.) 5-16

38 5. Teaching 5.3 SETTING OTHER AUXILIARY DATA In arc welding specification, the following auxiliary data can be set in addition to those described above. J/E Option Switch Comment Weld Condition (Spd Amp Vlt PO* Tmr Amp Vlt PO*) WV (Width Frequency Pattern*) Special Condition OX WX Refer to Operation Manual for E series controller Jump/End (J /E) Instruction. Refer to Setting Option Switches. Comment can be input by moving the cursor to Comment on the auxiliary data title row by pressing or.the Refer to Operation Manual for E series controller PG Comment Input. Refer to Setting Weld Conditions. Refer to Setting Weld Conditions. Refer to Setting Special Conditions. Refer to Operation Manual for E series controller Output (O) Instruction. Refer to Operation Manual for E series controller Output (O) Instructions. NOTE* PO (polarity ratio) and weaving pattern are Options. 5-17

39 5. Teaching SETTING OPTION SWITCHES When Option functions are installed, option switches can be set in AC, WS and WE steps. For details about the setting of these switches, refer to related option manual and 9.0 Touch Sensing Function (Option) SETTING WELD CONDITIONS 1. In WC or WE steps press <Setting> in the screen that appears after pressing A + WELD CND., or move cursor to Weld Conditions (Spd Amp Vlt PO* Tmr Amp Vlt PO*) on the auxiliary data title row by pressing or, and press. Aux. Function 1401 Arc Weld Condition is displayed. For details about making settings on this screen, refer to Aux.1401 in 8.0 Auxiliary Functions. 2. In AS (Arc Spot) steps, press <Setting> in the screen that appears after pressing A + WELD CND., or move cursor to Weld Conditions (Spd Amp Vlt PO* Tmr Amp Vlt PO*) on the auxiliary data title row by pressing or, and press. Aux. Function 1402 Arc Spot Weld Condition is displayed. For details about making settings on this screen, refer to Aux in 8.0 Auxiliary Functions. NOTE* PO (polarity ratio) is Option SETTING SPECIAL CONDITIONS In WC or WE steps, move cursor to Special Condition on the auxiliary data title row by pressing either A + SPEC.CND. or by or, and press. Aux. Function 1401 Arc Weld Condition is displayed. For details about making settings on this screen, refer to Aux in 8.0 Auxiliary Functions. 5-18

40 5. Teaching 5.4 REAL TIME WELD CONDITION MODIFICATION FUNCTION Using the real time weld condition modification function, weld speed, current, and voltage can be changed during check operation. Any changes made to the weld conditions can then be overwritten onto taught data in check mode. This function is also available in repeat operation although overwriting is not allowed. 1. Press A + WELD ON/OFF to turn ON welding and start check operation. 2. In WC or WE steps, press A + CND.CHG. or F key <Real Time Condition> to display the real time condition modify screen in C area as shown in the figure below. Weld Speed (cm/min) Weld Curr. (A) Weld Volt (V) Sets speed in welding. Pressing <+> increases weld speed by 1cm/min increment. (Max.: 999cm/min) Pressing <-> decreases weld speed by 1cm/min increment. (Min.: 1cm/min) Sets current in welding. Pressing <+> increases weld current by 1A increment. (Max.: 999A) Pressing <-> decreases weld current by 1A increment. (Min.: 0A) Sets voltage in welding. Pressing <+> increases weld voltage 0.1V increment. (Max.: 99.9V) Pressing <-> decreases weld voltage 0.1V increment. (Min.: 0.0V) Press <Data Set> at check operation to record changes to weld speed, current, voltage and overwrite the weld condition data for that step. Press <Undo Data> to set back values to the currently registered weld conditions. 5-19

41 5. Teaching [ NOTE ] 1. During weld ON, weld speed, current, and voltage can be modified. To overwrite weld condition data with the current changes, press <Data Set>. During weld OFF, weld conditions cannot be modified. 2. When the taught data is overwritten in this manner, the weld condition is considered to be direct setting even though it was originally indirect setting. 3. Real time condition modification for crater treatment and arc spot welding is not possible at WE step.! WARNING If you watch the weld bead while using the real time weld condition modification function, use face shield without fail, and avoid looking directly at the arc. 5-20

42 6. Repeat Operation 6.0 REPEAT OPERATION Repeat operation plays back and executes the contents of a program that was taught to the robot. This chapter describes the functions available for arc welding application during repeat operation. For details about standard repeat operation procedure, refer to Operation Manual for E series controller- 6.0 Repeat Operation. 6.1 REAL TIME WELD CONDITION MODIFICATION FUNCTION Using the real time weld condition modification function, weld speed, current, and voltage can be changed during repeat operation. However, the changed weld conditions cannot be overwritten onto taught data. Overwriting is possible in check mode. Refer to 5.4 Real Time Weld Condition Modification Function for more details. [ NOTE ] 1. During weld ON, weld speed, current, and voltage can be modified. During weld OFF, only the weld speed can be changed. 2. Real time condition modification for crater condition and arc spot condition is not possible at WE step.! WARNING If you watch the weld bead while using the real time weld condition modification function, do not fail to use face shield, and avoid looking at the arc directly. 6-1

43 6. Repeat Operation 6-2

44 7.0 Program Modification 7.0 PROGRAM MODIFICATION This chapter explains about the program editing screen for arc welding specification. For general operations of the program editing screen, see the Operation Manual for E series controller- 7.3 Edit on the Program Edit Screen. 7.1 PROGRAM EDITING SCREEN STEP MODIFICATION ON PROGRAM EDIT SCREEN This section explains the procedures to edit the program steps POSE DATA AND AUXILIARY DATA MODIFICATION The taught data are modified via the edit screen as follows: 1. Pressing A+ / scrolls the page and displays the data as shown in the figures below. 7-1

45 7.0 Program Modification 2. Move the cursor to the item to modify. 3. Modify each data using the Number keys. Modification procedure differs according to the type of data as 1 and 2 below. 1. Entering values other than for option switch, weld condition, WV, special conditions, Output(O), input (I), and comment: 1) Move the cursor to the desired item. 2) Enter the necessary values according to the explanation in the chart below. Item Explanation Instruction Specify the instruction. (0:AC, 1:Start, 2:Midpoint, 3:End, 4:AS) Interpolation * Specify the interpolation mode. Refer to the Operation Manual for E Controller Step Data Modification on Edit Screen. No Specify the weld condition number. 0 99: Condition number, 100:Direct input. Speed Specify the speed. Refer to the Operation Manual for E Controller Step Data Modification on Edit Screen. Accuracy Specify the accuracy. Refer to the Operation Manual for E Controller Step Data Modification on Edit Screen. Timer Specify the timer. Refer to the Operation Manual for E Controller Step Data Modification on Edit Screen. J/E Specify the J/E instruction. Refer to the Operation Manual for E Controller Step Data Modification on Edit Screen. Pose data Specify the pose data. Refer to the Operation Manual for E Controller Step Data Modification on Edit Screen. 3) Press after entering each value. When all the necessary items are input, press <ENTER> to register. NOTE * Interpolation setting that can be used depend on the instruction mode, as shown below. Instruction AC, Start, AS Midpoint End Interpolation setting Joint Linear Joint Linear Circular 1 Circular 2 Linear Linear Circular 2 Linear 2. Entering values for option switch, weld condition, WV, special conditions, Output(O), input (I), and comment: 1) Move the cursor to the desired item and press. 7-2

46 7.0 Program Modification 2) The screen for data setting is display, so enter the values and comments to modify. See the table below for how to input the values. Item Option Switch Weld condition (Spd Amp Vlt PO* Tmr Amp Vlt PO*) WV (Width Frequency Pattern*) Special condition Explanation See Setting Option Switches. See Setting Weld Conditions. See Setting Weld Conditions. See Setting Special Conditions. Output (O) Input (I) Comment The current setting is displayed. Refer to the Operation Manual for E Controller Step Data Modification on Edit Screen. The current setting is displayed. Refer to the Operation Manual for E Controller Step Data Modification on Edit Screen. Pressing displays the comment input screen. Refer to the Operation Manual for E Controller Step Data Modification on Edit Screen. NOTE * PO (Polarity ratio) and weaving patterns are options. 3) Press after entering each value. When all the necessary items are input, press <ENTER> to register. 7-3

47 7.0 Program Modification 7.2 ONLINE EDITING FUNCTION Using this function enables modification of programs that are in repeat operation, although with some restrictions. This section explains about the online editing function for arc weld specification. For online operations common to all specifications, refer to the Operation Manual for E controller 7.3 Edit on the Program Edit Screen SCREENS THAT CAN USE ONLINE EDITING FUNCTION The following screens can be edited via the online editing function. 1.Programs that are already registered. 2.Subroutine programs that are being executed FUNCTIONS USED IN ONLINE EDITING SCREEN 1. Editing Basically is the same as explained in 7.1 Program Editing Screen, but there are few data that cannot be changed in online program editing. For details, see 2. Save as below. 2. Save as In online program editing, the following data cannot be modified: instruction. Interpolation, No, option switch, weld condition, WV, special condition, pose and comment. (Weld condition may be changed when specified in the program as weld condition number and not specified by direct number). When any of these are changed, save the program with a new name following the procedure described in the Operation Manual for E Controller Functions on Online Edit Screen. 7-4

48 8. Auxiliary Functions 8.0 AUXILIARY FUNCTIONS This chapter describes auxiliary functions specific to arc welding specification.! WARNING Auxiliary functions are a kind of teaching. Their usage is limited to only those who have completed special training and are qualified for teaching or supervising robot operations. 8.1 OVERVIEW OF AUXILIARY FUNCTION Use auxiliary functions for arc welding specification in the following cases. 1. Confirmation and setting of various kinds of data for arc welding. 2. Confirmation and setting of robot installation 3. Confirmation and setting of arc weld torch dimensions 4. Other settings Only auxiliary functions related arc welding are described here. For other auxiliary functions, refer to Operation Manual for E series controller- 8.0 Auxiliary Functions, and for methods on calling up the auxiliary function screen, see 8.2 How to Use Auxiliary Functions. Select [14. Arc Weld] in the auxiliary function screen to call up the arc welding auxiliary function list as shown below. 8-1

49 8. Auxiliary Functions 8.2 AUXILIARY FUNCTION LIST No. Function Name Function Description 1401 ARC WELD CONDITION Displays and sets arc weld condition data ARC SPOT WELD CONDITION ARC WELD CONDITION DATABASE Displays and sets arc spot weld condition data. Displays and sets arc weld condition database ARC WELD SETTING Displays and sets various kinds of data for arc welding ARC WELD TORCH DIMENSION ARC WELD CONDITION MODIFY ARC SPOT WELD CONDITION MODIFY Displays and sets arc weld torch dimensions. Changes arc weld conditions for specified steps. (direct teaching method) Changes arc spot weld conditions for specified steps. (direct teaching method) 8-2

50 8. Auxiliary Functions AUX.1401 ARC WELD CONDITION 1. Input desired weld condition number by Number (0-9) and press. 2. Move cursor to each item and input required data by Number (0-9). If the setting is correct, press. Press <Next Page> and <Prev Page> to display the setting screens for weld condition No. 0 to 99. To refer to the arc weld condition database screen, press <Auto Set>. For details about the screen, refer to Aux When Setting complete. is displayed, the setting is done. 8-3

51 8. Auxiliary Functions [ NOTE ] 1. [Pole Ratio] and [Weaving Data- Pattern] are displayed only when Option is installed. 2. Direct setting screen for arc weld conditions is not displayed. To specify or display the arc weld condition of direct setting, see 3. below and set by Aux.1401 or Aux In WC or WE steps, move cursor to No. on auxiliary data title row and press to display the weld condition number input screen as shown in (5). Enter 100 and press <Setting> to display the screen above. Directly input the condition number in this screen. To select the weld condition No., refer to Teaching Operation. (This method is also available for indirect setting.) (Auxiliary function screen is also called up by moving cursor to Weld Conditions (Spd Amp Vlt PO* Tmr Amp Vlt PO*) WV (Wid Freq Pat*), and then pressing.) At this time, (1) the screen can be called up only in teach mode with teach lock ON. (2) arc weld condition data set by direct method cannot be seen in repeat mode. NOTE* Displayed only when Option is installed. 8-4

52 8. Auxiliary Functions AUX.1402 ARC SPOT WELD CONDITION 1. Input desired arc spot weld condition number by Number (0-9) and press. 2. Move cursor to each item and input required data by Number (0-9). If the setting is correct, press. Press <Next Page> and <Prev Page> to display the setting screens for arc spot weld condition No. 0 to When Setting complete. is displayed, the setting is done. [ NOTE ] 1. [Pole Ratio] is displayed only when Option is installed. 2. Direct setting screen for arc spot weld condition is not displayed. To specify or display the arc spot weld condition of direct setting, see 3. below and set by Aux.1402 or Aux In AS (Arc Spot) steps, move cursor to No. on auxiliary data title row and press to display the weld condition number input screen as shown in (5). Enter 100 and press <Setting> to display the screen above. Directly input the condition number in this screen. To select the weld condition No., refer to Teaching Operation. (This method is also available for indirect setting.) (Auxiliary function screen is also called up by moving cursor to Weld Conditions (Spd Amp Vlt PO* Tmr Amp Vlt PO*), and then pressing.) At this time, (1) the screen can be called up only in teach mode with teach lock ON. (2) arc spot weld condition data set by direct method cannot be seen in repeat mode. NOTE* Displayed only when Option is installed. 8-5

53 8. Auxiliary Functions AUX.1403 ARC WELD CONDITION DATABASE In the arc weld condition database, weld data (speed, current, voltage, polarity ratio*), crater treatment data (time, current, voltage) and weaving data (width, frequency, pattern*) can be set and modified for each weld joint shape and leg length/thickness. This database provides a convenient means of calling up data when setting weld conditions by either the direct or indirect teaching Aux. screens. As shown in the figures below, move cursor to [Big Category] to display big category items and to [Small Category] to display small category items which correspond to the selected big category items. Select the desired item for each category by Number (0-9). Big category items Small category items Pressing <Display> displays the weld condition data for the selected big/small category items on the right half of the screen. In the figures above, weld condition data is for [1. H FILLET] of [Big Category] and [1. 3mm] of [Small Category]. 1. Horizontal fillet 2. Flat fillet 3. Lap fillet 4. Corner fillet 5. Butt I fillet 6. Downhill fillet 8-6

54 8. Auxiliary Functions 1. To change data, input required data and press to display the setting screen on the left. Move cursor to each item and input required data by Number (0-9). If the setting is correct, press. 2. When Setting complete. is displayed, the setting is done. NOTE* [Pole Ratio] and [Weaving Data- Pattern] are displayed only when Option is installed. Setting item Setting range Unit Speed 1 to 999 cm/min Weld data Current 0 to 999 A Voltage 0.0 to 99.9 V Polarity ratio (Option) 0 to 15 - Time 0.0 to 9.9 sec Crater weld data Current 0 to 999 A Voltage 0.0 to 99.9 V Width 0.0 to 40.0 mm Weaving data Frequency 0.0 to 4.0 Hz Pattern (Option) 0 to 10 -! CAUTION Database described in the Appendix is pre-installed at time of factory shipment. 8-7

55 8. Auxiliary Functions AUX.1404 ARC WELD SETTING This function sets various kinds of data for arc welding operation. Move the cursor to [1404. Arc Weld Setting] in the auxiliary function screen to display the auxiliary function list as shown in the figure below. Some menu items are Options and may not be shown depending on robot specification. Overview of each function is shown in the table on next page. The subsections hereafter describe each of these functions. 8-8

56 8. Auxiliary Functions Linearization Offset/Gain Weld current/voltage characteristics in arc weld machines differ depending on its manufacturer/model, weld gas, wire type, etc. To match these characteristics, linearization table is prepared inside the robot controller. By editing this table, it is possible to match the set current/voltage with actual current/voltage and to make control of weld conditions easier. For example, when a weld machine breaks, some characteristics between old and new machines may differ. Use Offset/Gain to correct these differences instead of re-editing the linearization set above. Weld machine command Set current/voltage Weld Start Sequence Software Slow Down Weld Stuck Cancel Sequence Arc Spot Sequence Preflow/Afterflow Wire Inching/Retract Weld ON/OFF in Check Touch Sensing (Option) Special Pattern Weaving (Option) Servo Torch (Option) Sets various kinds of data for arc weld sequence and enables changing of the weld sequence. Sets weld conditions for the time up until arc is generated at arc start. Enables superior arc start settings. Sets various kinds of data to automatically release when weld wire is stuck. Sets various kinds of data for arc spot weld sequence. Sets time for preflow/afterflow. Sets speed for inching/retracting weld wire. Sets weld ON/OFF at check operation. Sets various kinds of data for touch sensing function. For more details, see also 8.0 Touch Sensing Function (Option). Enables registration of special weaving patterns for reference during program execution. For more details, see also 9.0 Special Pattern Weaving Function (Option). Sets various kinds of data for servo torch function. For more details, see also 10.0 Servo Torch Function (Option). 8-9

57 8. Auxiliary Functions AUX LINEARIZATION This function calibrates the absolute values for current/voltage for each weld method, wire diameter, wire extension length, wire type, and weld machine with the voltage that is actually commanded to weld machine. Setting item Description Setting range Weld Current Sets the command voltage (mv) from controller to 0 to 999A weld machine necessary for realizing command weld current. 0 to 15000mV Weld Voltage Sets the command voltage (mv) from controller to 0 to 99.9V weld machine necessary for realizing command 0 to 15000mV weld voltage. Maximum Output Voltage Some weld machines receive only 15V or less of output voltage as a command value from robot controller. For these machines, the max. voltage output value from controller can be restricted. 0.0 to 15.0V! CAUTION 1. No adjustment is needed when both robot and weld machine are purchased from Kawasaki, as correct values are already registered at time of factory shipment. 2. Consult Kawasaki before changing these set values. 8-10

58 8. Auxiliary Functions Weld current 1. Move cursor to each item and input required data by Number (0-9). If the setting is correct, press. Press <Graph> to display the graph showing the set data. 2. When Setting complete. is displayed, the setting is done. Weld voltage 1. Move cursor to each item and input required data by Number (0-9). If the setting is correct, press. Press <Graph> to display the graph showing the set data. 2. When Setting complete. is displayed, the setting is done. Once setting is complete, weld current/voltage values are sorted in ascending order when the setting screen is displayed again. 8-11

59 8. Auxiliary Functions Maximum output voltage 1. Input required data by Number (0-9), and if the setting is correct, press. 2. When Setting complete. is displayed, the setting is done. When current/voltage are set for the weld condition, the voltage value to be sent to weld machine is then determined by linearization as per the linearization data. For example, the command value to weld machine is as follows when setting the weld current/voltage value in the figure on the previous page (outputs 4.74V by 224A and 7.967V by 19.2V, and outputs 3.53V by 192A and 6.639V by 16V) and executing welding of 210A and 18V. Current ( ) = 4210mV Voltage (18-16) = 7469mV 8-12

60 8. Auxiliary Functions Aux OFFSET/GAIN In order to realize the specified current/voltage during actual welds, this function sets offset and gain values for adjusting the standard linearization characteristics. Setting item Description Setting range Current/Voltage offset Sets constant value (mv) to be added to command value from controller to weld machine to 9999 Current/Voltage gain Sets a multiplier value (unit 0.001) to command value (mv) from controller to weld machine. 0 to 9.999! CAUTION 1. No adjustment is needed when both robot and weld machine are purchased from Kawasaki, as correct values are already registered at time of factory shipment. 2. Consult Kawasaki before changing these set values. 1. Move cursor to each item and input required data by Number (0-9). If the setting is correct, press. 2. When Setting complete. is displayed, the setting is done. [ NOTE ] Command voltage output from controller Value calculated = by linearization Gain + Offset 8-13

61 8. Auxiliary Functions Aux WELD START SEQUENCE Setting item Description Setting range Threshold for scratch/ Standstill start Sets threshold distance for switching scratch/standstill start. When the distance between real taught points is larger than the set value, scratch start is selected, and if not, stand still is selected. 0 to 999 Scratch start Keep welding distance Scratch start Turn back distance Sets distance/area in which robot will not move back to weld start point even after arc generation at scratch start. Sets distance/area in which robot moves back to weld start point after arc generation at scratch start. 0 to 99 0 to 99 Standstill start Sets standstill time at stand still start. 0.0 to 9.9 Standstill time Weld start retry Sets No. of times for retrying weld start sequence 0 to 9 Number of times Weld start retry when arc is not generated. Sets time for retracting wire before performing arc 0.0 to 9.9 Retract time Weld start retry start retry. Sets speed for retracting wire before performing arc 0 to 100 Retract speed start retry by ratio to the Aux Maximum Output Voltage. For servo torch spec. (Option), sets the speed by ratio to the max. rotation speed set in Aux Linearization. Turn back speed Sets speed by which the torch moves back to weld start point at scratch start, arc start retry, etc. 1 to 999 Overlap distance in restart Sets distance for overlap weld at restart. Setting -1 automatically calculates the distance according to the weld conditions. -1 to Move cursor to each item and input required data* by Number (0-9). If the setting is correct, press. 2. When Setting complete. is displayed, the setting is done. NOTE* Values set here are standard parameter values of Kawasaki. 8-14

62 8. Auxiliary Functions REMARKS: Weld Start Sequence 1. Weld start sequence To start welding more smoothly, the following two types of weld start sequences have been provided. (1) Scratch start Robot moves to the next teach point from weld start point during which time arc is generated. This is called scratch start as it looks like the torch scratches the work, and it is used mainly for welding a long weld line. This robot motion is further classified into two types depending on the distance between taught weld start point and the point the arc is actually generated. Weld start point (A) (B) Weld continue point Weld end point 1) Distance from start point to arc generating point is less than [Keep Welding Distance (A)] If arc is generated within (A) distance, welding continues toward the next weld continue (end) point. Arc generating point Weld start point (A) (B) Weld continue point Weld end point 8-15

63 8. Auxiliary Functions 2) Distance to arc generating point after passing (A) is less than [Turn Back Distance (B)] If arc is generated within (B) distance, robot welds moving backwards to the weld start point, and continues welding toward the next weld continue (end) point. When no arc is generated even after passing (B) distance, error occurs. Arc generating point Weld start point (A) (B) Weld continue point Weld end point (2) Standstill start Robot stops at weld start point until arc is generated. After arc generation, welding continues toward the next weld continue (end) point. Standstill time is variable and when arc is not generated within the set time, an error occurs. 2. Restart sequence This sequence is used for restarting the welding after robot stops welding for some reason. e.g.) After arc deficiency by tip friction, etc. After holding. Scratch start or standstill start can be executed in restart sequence. However, in order to bury the crater caused by the weld stop, robot moves back to the point where welding stops after arc generation and to restart welding with an overlap welding. e.g.) After calculating remaining distance and restarting by a scratch start Weld start point Arc generating point 3. Arc start retry Overlap welding distance Normally when No. of times for retry is not set, an error occurs if arc is not generated. However, if set, the weld start sequence (scratch start/standstill start) will be attempted the set No. of times. Wire can be retracted before the retry, and retract time and No. of times for retract can be set or modified. 8-16

64 8. Auxiliary Functions AUX SOFTWARE SLOW DOWN This function changes weld conditions for the time up until arc is generated. For example, when the base metal surface is resistant to current flow and generation of arc is difficult, weave for increased generation until the arc is actually applied to the surface. Setting item Description Setting range Software slow down Enable Disable Weld current Sets weld current (A) at arc start until arc is 0 to 999 generated. Weld voltage Sets weld voltage (V) at arc start until arc is 0 to 99.9 generated. Pre-heat time Sets for the time (s) to operate keeping the conditions set in this screen after arc is generated at arc start. Polarity ratio (Option) Sets polarity ratio at arc start until arc is 0 to 15 generated. Weaving width Sets weaving width (mm) at arc start until arc is 0 to 40.0 generated. Weaving frequency Sets weaving frequency (Hz) at arc start until arc 0 to 4.0 is generated. Weaving pattern (Option) Sets weaving pattern at arc start until arc is generated. 0 to Move cursor to each item and input required data* by Number (0-9). If the setting is correct, press. ([Pole Ratio] and [Weaving Data- Pattern] are displayed only when Option is installed. 2. When Setting complete. is displayed, the setting is done. NOTE* Values set here are standard parameter values of Kawasaki. 8-17

65 8. Auxiliary Functions AUX WELD STUCK CANCEL SEQUENCE After crater treatment or arc spot welding at weld end point, weld stuck detecting is executed automatically. When wire is stuck, this condition is automatically released by arc generation under the crater/arc spot conditions (Weld Stuck Cancel Sequence). When weld stuck cancel does not succeed after attempting sequence set No. of Detecting Times, error occurs. Note that cancel sequence is not possible if crater treatment was not executed. Setting item Description Setting range Number of detecting times Set No. of times for repeating detecting wire stuck arc ON after arc OFF. 0 to 9 Detecting wire Sets waiting time for detecting weld stuck after arc OFF. 0.0 to 9.9 stuck waiting time Detecting wire Sets time for detecting wire stuck. Receiving stuck 0.0 to 9.9 stuck time signal within this time, it is considered as weld stuck. Welding time Sets arc ON time to cancel weld stuck. 0.0 to Move cursor to each item and input required data* by Number (0-9). If the setting is correct, press. 2. When Setting complete. is displayed, the setting is done. NOTE* Values set here are standard parameter values of Kawasaki. Crater treatment/arc spot weld Detecting Wire Stuck Waiting Time Weld stuck? (Detecting) No Yes To next step Detecting times set detecting times Yes No Arc ON Error 8-18

66 8. Auxiliary Functions AUX ARC SPOT SEQUENCE This function sets various parameters for arc spot welding. Setting item Description Retry Number of times Sets max. No. of times for repeating arc spot when current detect signal is not returned from weld machine at time of arc spot weld (that is, weld is not executed). Wire retract time Sets time for retracting wire until arc spot weld is executed at retry. Wire retract speed Sets speed for retracting wire before performing arc spot weld at retry by ratio to the Aux Maximum Output Voltage. For servo torch spec. (Option), sets the speed by ratio to the max. rotation speed set in Aux Linearization. After arc spot Wire retract time Sets time for retracting wire after arc spot weld was executed. Wire retract speed Sets speed for retracting wire after performing arc spot weld by ratio to the Aux Maximum Output Voltage. For servo torch spec. (Option), sets the speed by ratio to the max. rotation speed set in Aux Linearization. Setting range 0 to to to to to Move cursor to each item and input required data* by Number (0-9). If the setting is correct, press. 2. When Setting complete. is displayed, the setting is done. NOTE* Values set here are standard parameter values of Kawasaki. 8-19

67 8. Auxiliary Functions AUX PREFLOW/AFTERFLOW Setting item Description Setting range Preflow time Sets time to turn Arc ON ON gas before arc generation. Gas ON Preflow time Afterflow time Sets delay time for turning OFF gas after arc generation. Arc ON Gas ON Afterflow time 1. Move cursor to each item and input required data* by Number (0-9). If the setting is correct, press. 2. When Setting complete. is displayed, the setting is done. NOTE* Values set here are standard parameter values of Kawasaki. 1. Preflow Air cut point When preflow time is set, shield gas is turned ON for the set time before robot arrives at weld start point. If weld start point and its previous taught point are close and robot moves within the set time, preflow is executed only during the time robot moves. Moving distance determined by the set time Weld start point Weld continue (end) point 2. Afterflow When afterflow time is set, robot stops and shield gas is turned ON for the set time after crater treatment at weld end point. Afterflow is not executed if crater treatment is not executed. Air cut point Weld start point 8-20 Weld continue (end) point

68 8. Auxiliary Functions AUX WIRE INCHING/RETRACT This function inches/retracts wire during air cut operation. This is executed in 0.5 sec increments as robot moves per the air cut instruction taught this setting. Setting item Description Setting range Wire retract speed Sets speed at time of wire retract by ratio to the 0 to 100 Aux Maximum Output Voltage. For servo torch spec. (Option), sets the speed by ratio to the max. rotation speed set in Aux Linearization Wire inching speed Sets speed at time of wire inching by ratio to the Aux Maximum Output Voltage. For servo torch spec. (Option), sets the speed by ratio to the max. rotation speed set in Aux Linearization. 0 to Move cursor to each item and input required data* by Number (0-9). If the setting is correct, press. 2. When Setting complete. is displayed, the setting is done. NOTE* Values set here are standard parameter values of Kawasaki. Air cut point Inching Air cut point Air cut point Retract Air cut point 8-21

69 8. Auxiliary Functions AUX WELD ON/OFF IN CHECK This switch enables execution of real welding during check operation. Setting item Weld in check ON Weld in check OFF Description Welding can be executed during check operation when weld status is ON. Welding cannot be executed during check operation regardless of weld ON/OFF status. 1. Select [ON] or [OFF] of [Weld in Check] and press.* 2. When Setting complete. is displayed, the setting is done. NOTE* Values set here are standard parameter values of Kawasaki. 8-22

70 8. Auxiliary Functions AUX TOUCH SENSING (OPTION) Setting item Description Setting range Touch sensing Distance* Sets wire sensing distance. 0 to 300 Speed* Sets wire sensing speed. 0 to 100 Wire check Retract speed Sets retract speed at wire check. 0 to 100 Inching speed Sets inching speed at wire check. 0 to 100 NOTE* For touch sensing distance and speed. Teach point A Touch sensing speed Sensing start point B Teach point B Sensing end point B Touch sensing distance (1) In the setting above, distances between B and B, and B and B are both 20mm. (2) The faster the sensing speed, the greater the weld wire bends at touch and then correcting accuracy becomes decreased. However, wire bend varies depending on sensing direction, wire diameter, material, etc. (3) These parameters are provided for the work detection and work position compensation functions. For more details, see 8.3 Work Detection Function and 8.4 Compensation Function for Work Deviation. 1. Move cursor to each item and input required data** by Number (0-9). If the setting is correct, press. 2. When Setting complete. is displayed, the setting is done. NOTE** Values set here are standard parameter values of Kawasaki. 8-23

71 8. Auxiliary Functions AUX SPECIAL PATTERN WEAVING (OPTION) Setting item Description Setting range Time Sets time ratio. 0 to 100 X Sets robot motion increment ratio for back and forth to 100 Y Sets robot motion increment ratio for right and left to 100 Z Sets robot motion increment ratio for upper and lower to 100 Angle Sets posture changing angle for pendulum weaving to 10.0 Current Sets current increment ratio for boost to 100 Voltage Sets voltage increment ratio for boost to Input desired weaving pattern number by Number (0-9) and press. 2. Move cursor to each item and input required data by Number (0-9). If the setting is correct, press. Press <Next Page> to display the setting screen for patterns 9 to When Setting complete. is displayed, the setting is done. 8-24

72 8. Auxiliary Functions AUX SERVO TORCH (OPTION) This function sets various kinds of data for servo torch function. Select [16. Servo torch] in [1404. Arc Weld Setting] to display the auxiliary function list shown in the figure below. Overview of each function is shown in the table below. The subsections hereafter describe each of these functions. Linearization Torch data Servo adjustment Inching speed Start/End sequence Sets the relation between weld current command values (A) and wire feeding speeds (rpm). Sets the speed reduction ratio, number of bits changed per encoder rotation and direction of motor rotation for the servo torch. Adjusts the servo parameters that control the feeding. Registers the wire inching/retract speed that corresponds to each teach speed, set by pressing TEACH SPEED. Sets the parameters that control the wire feeding at weld start/end. 8-25

73 8. Auxiliary Functions AUX LINEARIZATION This function sets the relation between weld current command values (A) and wire feeding speeds (rpm) for each weld method, wire diameter, wire extension length, wire type, and weld machine. Setting item Description Setting range Linearization Sets the value to transform weld current 0 to 999A command value (A) to wire feeding speed (rpm). 0 to 999rpm! CAUTION 1. No adjustment is needed when both robot and weld machine are purchased from Kawasaki, as correct values are already registered at time of factory shipment. 2. Consult Kawasaki before changing these set values. 1. Move cursor to each item and input required data by Number (0-9). If the setting is correct, press. Press <Graph> to display the graph showing the set data. 2. When Setting complete. is displayed, the setting is done. 8-26

74 8. Auxiliary Functions When current/voltage are set for the weld condition, the rotation speed to be sent to servo torch motor is then determined by linearization as per the linearization data. For example, the command rotation speed to servo torch is as follows when setting the weld current value in the figure on the previous page (outputs 102rpm by 250A and 81rpm by 200A) and executing welding of 210A and 18V. Rotation speed ( ) =85.2rpm Note that max. command rotation speed cannot exceed the max. value set in this linearization table. 8-27

75 8. Auxiliary Functions AUX TORCH DATA This function sets the speed reduction ratio, number of bits changed per encoder rotation and direction of motor rotation for servo torch. Setting item Description Setting range Reduction ratio Sets the speed reduction ratio for the servo torch. n1: 1 to n2: 1 to 1000 Bits per encoder Sets number of bits per one encoder rotation. 1 to 9999 rotation Rotary direction of motor Sets plus or minus for direction of motor rotation. 1. Move cursor to each item and input required data* by Number (0-9). If the setting is correct, press. 2. When Setting complete. is displayed, the setting is done. NOTE* Values set here are standard parameter values of Kawasaki. 8-28

76 8. Auxiliary Functions AUX SERVO ADJUSTMENT This function adjusts the servo parameters that control the wire feeding. The following three setting items can also be set in Aux External Axis Servo Parameter- Full Spec Tuning. In that auxiliary function screen, Servo gain is KVP, Torque limit (plus direction) is IQCLP, and Torque limit (minus direction) is IQCLM. Setting item Description Setting range Servo gain Sets the feedback gain of servo torch motor. 0 to Torque limit Sets the upper limit of max. output current of servo 0 to (plus direction) torch motor. Torque limit (minus direction) Sets the upper limit of max. output current of servo torch motor. 0 to Move cursor to each item and input required data by Number (0-9). If the setting is correct, press. 2. When Setting complete. is displayed, the setting is done. 8-29

77 8. Auxiliary Functions AUX INCHING SPEED This function registers the wire inching/retract speed that corresponds to each teach speed, set by pressing TEACH SPEED. Setting item Description Setting range Inching/Retract Sets the rotation speed when inching at wire inching 1 to 100 speed 1 speed 1. Inching/Retract Sets the rotation speed for wire inching speed 2. 1 to 100 speed 2 Inching/Retract speed 3 Sets the rotation speed for wire inching speed 3. 1 to Move cursor to each item and input required data* by Number (0-9). If the setting is correct, press. 2. When Setting complete. is displayed, the setting is done. NOTE* Values set here are standard parameter values of Kawasaki. 8-30

78 8. Auxiliary Functions AUX START/END SEQUENCE This function sets the parameters that control the wire feeding at weld start/end. Start End Setting item Description Setting range Wire feeder on delay After Arc ON signal turns ON, delays the start 0 to 999 of the wire feeding by set value. Slow down speed Sets wire feeding speed to turn WCR signal ON 1 to 999 after Arc ON signal turns ON. Hot start 1 Sets the wire feeding time at slow down speed 0 to 999 after WCR signal turns ON. Hot start 2 Sets the time to change from slow down speed 0 to 999 to wire feeding speed at welding after Hot start 1 described above. Wire feeder off delay After Arc ON signal turns OFF, delays the start 0 to 999 of the deceleration of the wire feeding by set value. Flare up time Sets time to decelerate from wire feeding speed 0 to 999 to 0, after Wire feeder off delay has elapsed. Feeder waiting time Sets the time to start wire feeding after wire is 0 to 999 after Stuck cancel detected not to be stuck. Time of wire feed Sets the wire feeding time after weld stuck is 0 to 999 after Stuck cancel canceled. Feeder speed after Stuck cancel Sets the wire feeding speed after wire stuck is canceled. 1 to Move cursor to each item and input required data* by Number (0-9). If the setting is correct, press. 2. When Setting complete. is displayed, the setting is done. NOTE* Values set here are standard parameter values of Kawasaki. 8-31

79 8. Auxiliary Functions Wire feeding speed (rpm) Wire feeding speed at welding Slow down speed Wire feeder on delay Waiting WCR detection Hot start 1 Hot start 2 Weld in progress Time (t) WCR Arc ON signal At start of welding 8-32

80 8. Auxiliary Functions Wire feeding speed (rpm) Wire feeding speed at welding Arc ON signal Wire feeder off delay Flare up time (1) When wire stuck is not detected. Time t Wire feeding speed (rpm) Speed at welding Time1: Wire feeder off delay Time2: Flare up time Time3: Feeder waiting time after Stuck cancel Time4: Time of wire feed after Stuck cancel Speed: Feeder speed after Stuck cancel Speed Detecting weld stuck Arc ON signal Time1 Time2 Time3 Time4 Time t Weld stuck detected Weld stuck not detected (2) When wire stuck is detected. At end of welding 8-33

81 8. Auxiliary Functions AUX.1405 ARC WELD TORCH DIMENSION When using a standard arc weld torch as shown below, tool transformation values can be set by registering length of the weld torch, torch installation angle and wire extension length. 1. Move cursor to each item and input required data by Number (0-9). If the setting is correct, press. 2. When Setting complete. is displayed, the setting is done. (B) (A) Tool Y direction Tool X direction Tool Z direction End of tool (C) Rotation center of JT6 Setting item Description Setting range Length Length (A) in 0 to 999 the figure left Angle Angle (B) in 0 to 180 the figure left Wire extension Length (C) in the figure left 0 to 999 No registration is needed when robot and torch are purchased together from Kawasaki, as the values are already registered at time of factory shipment.! CAUTION Attach the torch to the robot by setting wire extension length to 15 mm and the wire end to be on the rotation center of JT6 as shown above. If wire extension length is not 15 mm, set the torch by the same procedure above. Then, register the desired wire extension length and cut the wire to that length. 8-34

82 8. Auxiliary Functions AUX.1406 ARC WELD CONDITION MODIFY This function changes the weld conditions for a block of weld continue or weld end points that were taught by direct teaching method. To change the weld conditions for a range of points taught by indirect method, use Aux Move cursor to <Program Name> and set the desired program name. For more details about selecting a program name, refer to Operation Manual for E series controller Program/ Comment Area. 2. Input required data, and press. [ NOTE ] Designation of step No.; When the end step is 0, only start step is processed. When 0 is designated for start step, input error is returned. When specified number of steps is greater than the last step of designated program, changes are applied up until the last step. Example of input: Start step No End step No Error Error Execute only Execute only step1 step

83 8. Auxiliary Functions 3. Condition setting screen* as shown on left is displayed. Move cursor to each item and input required data by Number (0-9). If the setting is correct, press. 4. When Setting complete. is displayed, the setting is done. NOTE* From the range of selected steps, the data of the step first taught by direct teaching method is displayed in this screen. Press <Auto Set> to refer to the arc weld condition database screen. For details about this screen, refer to Aux [Pole Ratio] and [Weaving Data- Pattern] are displayed only when Option is installed. [ NOTE ] 1. Changes apply only to the weld continue or weld end points in the specified range that were taught by direct teaching method. Data of other steps in the range are not affected. 2. To change weld conditions in weld continue or end points taught by indirect method, see Aux.1401 Arc Weld Condition. 8-36

84 8. Auxiliary Functions AUX.1407 ARC SPOT WELD CONDITION MODIFY This function changes the weld conditions for a block of arc spot weld points that were taught by direct teaching method. To change the arc spot weld conditions for a range of points taught by indirect method, use Aux Move cursor to <Program Name> and set the desired program name. For more details about selecting a program name, refer to Operation Manual for E series controller Program/ Comment Area. 2. Input required data, and press. [ NOTE ] Designation of step No.; When the end step is 0, only start step is processed. When 0 is designated for start step, input error is returned. When specified number of steps is greater than the last step of designated program, changes are applied up until the last step. Example of input: Start step No End step No Error Error Execute only Execute only step1 step

85 8. Auxiliary Functions 3. Condition setting screen* as shown on left is displayed. Move cursor to each item and input required data by Number (0-9). If the setting is correct, press. 4. When Setting complete. is displayed, the setting is done. NOTE* From the range of selected steps, the data of the arc spot step first taught by direct teaching method is displayed in this screen. [Pole Ratio] is displayed only when Option is installed. [ NOTE ] 1. Changes apply only to the arc spot points in the specified range that were taught by direct teaching method. Data of other arc spot steps in the range are not effected. 2. To change AS (Arc Spot) weld conditions in arc spot points taught by indirect method, see Aux.1402 Arc Spot Weld Condition. 8-38

86 9. Touch Sensing Function (Option) 9.0 TOUCH SENSING FUNCTION (OPTION) This chapter describes touch sensing function by optional specification and the teaching operation. 9.1 OVERVIEW OF TOUCH SENSING FUNCTION FEATURES OF TOUCH SENSING OPTION FUNCTION When using the robot to weld, good positioning accuracy is required for both workpiece and for arc torch relative to the workpiece. However, at the weld production site, perfect accuracy cannot always be guaranteed. Thus, to achieve better, more consistent accuracy, use the touch sensing function in the following situations. 1. When wire extension length must be accurate. Wire check function 2. When confirmation is needed to check if workpiece is set correctly. Workpiece detection function 3. When positioning accuracy of the workpiece is not ensured. Compensation for workpiece deviation 1. Wire check function In automatic weld operation, wire extension length may vary from the set length after welding. This function can be used to keep the wire length constant. To check if wire is the set length, robot stops and only wire is inched. 2. Workpiece detection function Weld wire is inched as robot stops. Typically in auto weld operation, workpiece placement is checked via sensors (limit switches, photocells). Touch sensing eliminates the need for sensors. Robot checks correct placement automatically before welding by moving torch from its position and using the torch tip to detect presence of the workpiece. Workpiece Workpiece Starts detecting workpiece from this point. 9-1

87 9. Touch Sensing Function (Option) 3. Compensation for workpiece deviation In robot weld operation, this function compares taught point with the point where workpiece was detected at repeat operation, and automatically corrects for differences; weld can be executed accurately considering workpiece set deviation. Torch tip moves according to the set sensing pattern. Corrects tip pose automatically when workpiece is not set correctly. Workpiece SENSING PATTERNS FOR COMPENSATION OF WORKPIECE DEVIATION When planning a weld operation, determine beforehand the direction in which the workpiece may deviate. In addition, one must be considered the kind of workpiece to be welded, and workpiece deviation amount. This section describes seven kinds of sensing patterns by which workpiece deviation compensation are made. Sensing patterns can be used alone or in combination (max. of three patterns). 9-2

88 9. Touch Sensing Function (Option) Item Pattern Pattern 1 Pattern 2 Pattern 3 Pattern 4 Pattern 5 Pattern 6 Pattern 7 Types of sensing No. of sensing pts (teaching points) Direction of Translational Translational Translationa workpiece deviation movement in movement in l movement Movement Movement Movement on Movement 1 direction 2 directions in 3 on surface on surface surface on surface directions Shape of workpiece control surface Relation between No need to be flat Flat Flat Flat Flat Cylinder Flat workpiece deviation direction and control No need to be vertical Vertical Vertical No need to be vertical No need to be vertical No need to be vertical No need to be vertical surface Relation between Center line of control surface and set surface No need to be vertical Vertical Vertical Vertical Vertical cylinder vertical to set Vertical surface Relation between 1 st surface: 1 st surface: 1 st surface: 1 st surface: 1 st surface: Outer or inner 1 st surface: control surface and 1 point 1 point 1 point 2 points 2 points surfaces of 2 points sensing point 2 nd surface: 2 nd surface: 2 nd surface: 2 nd surface: cylinder 2 nd surface: (teaching point) 1 point 1 point 1 point 2 points whose section 1 point 3 rd surface: becomes 1 point perfect circle: 3 points Relative relation of 2 control surfaces 2 orthogonal flat surfaces 3 orthogonal flat surfaces orthogonal flat 2 orthogonal flat surfaces surfaces Order of teaching points Specified Specified Specified Specified 9-3

89 BB E Series Controller 9. Touch Sensing Function (Option) Each sensing pattern is described below. 1. Pattern 1: Workpiece may deviate in only one direction Workpiece (1) Condition of workpiece Workpiece moves to only one direction parallel. A 1 BB1 Stopper (2) Sensing point Execute sensing of one point which the workpiece moves toward, B 1 in left figure. Direction of workpiece deviation Control surface (3) Teaching point Teach A 1 and B 1 as line A 1 B1 parallel to the direction in which workpiece deviates. 2. Pattern 2: Workpiece may deviate parallel to flat surface. Control surface 1 Control surface 2 Direction of workpiece deviation A 1 A 2 B B2 1 Workpiece Stopper (1) Condition of workpiece 1) Workpiece moves parallel to the flat surface. 2) Control surfaces (1 and 2) are flat and intersect at 90. 3) Directions in which workpiece deviates are vertical to each control surface. (2) Sensing point Execute sensing of two points which the workpiece moves toward, B 1 and B 2 in left figure. Direction of workpiece deviation B 1 A 1 Deviation direction Control surface (3) Teaching point Teach A 1, B 1, A 2, and B 2 as lines A 1 B1 and A 2 B 2B parallel to the directions in which workpiece deviates. 9-4

90 B E Series Controller 9. Touch Sensing Function (Option) 3. Pattern 3: Workpiece may deviate parallel in space. Control surface 3 A 3 Direction of workpiece deviation Direction of workpiece deviation Direction of workpiece deviation A 1 A 2 BB2B 2 B B3 B B1 Control surface 1 B 1 Control surface 2 Workpice Deviation direction Control surface A 1 (1) Condition of workpiece 1) Workpiece moves parallel in space (in three directions). 2) Control surfaces (1, 2 and 3) are flat and orthogonal to each other. 3) Directions in which workpiece deviates are vertical to each control surface. (2) Sensing point Execute sensing of three points which the workpiece moves toward, B 1, B 2 and B 3 in left figure. (3) Teaching point Teach A 1, B 1, A 2, B 2, A 3, and B 3 as lines A 1 B1, A 2 B 2B and A 3 B3 parallel to the directions in which workpiece deviates. 9-5

91 9. Touch Sensing Function (Option) 4. Pattern 4: Workpiece may deviate arbitrarily on a flat surface. Work (1) Condition of workpiece 1) Workpiece moves parallel to the flat surface on which it is placed. 2) Control surfaces (1 and 2) are flat and intersect at 90. 3) The two control surfaces are vertical to the flat surface on which the workpiece moves. A 1 B 1 A 2 B 2 Control surface 1 B 3 Control surface 2 A 3 Control surface B 1 Deviation direction Set surface A 1 (2) Sensing point 1) Execute sensing of two points on one sensing surface and one point on the other surface, B 1, B 2, and B 3 in left figure. 2) B 1 and B 2 are on the same surface. (3) Teaching point Teach the points in order of A 1, B 1 A 2, BB2 A 3, B 3 with the following conditions. 1) Lines A 1 B1, A 2 B 2B, and A 3 B3 are parallel to the workpiece setting surface. 2) Angle between lines A 1 B1 and A 3 B 3B is 30 to 150 (90 is desirable). 3) Distance between B 1 and B 2 is 10mm or more. 9-6

92 9. Touch Sensing Function (Option) 5. Pattern 5: Workpiece may deviate arbitrarily on a flat surface. B 1 Work B 3 B 4 A 4 (1) Condition of workpiece 1) Workpiece moves parallel to the flat surface on which it is placed. 2) Control surfaces (1 and 2) are flat. 3) The two control surfaces are vertical to the flat surface on which the workpiece moves. B 2 A 1 A 2 Control surface 1 Control surface B 1 Control surface 2 Deviation direction Set surface A 3 (2) Sensing point 1) Execute sensing of four points (two points on each surface), B 1, B 2, B 3, and B4 in left figure. 2) B 1 and B 2 are on control surface 1 and BB3 and B 4, on control surface 2, as in left figure. (3) Teaching point Teach the points in order of A 1, B 1 A 2, BB2 A 3, B 3 A 4, B 4 with the following conditions. 1) Lines A 1 B1 and A 3 B 3B are parallel to the workpiece setting surface. 2) Angles between lines A 1 B1 and A 3 B 3B / lines A 2 B2 and A 4 B 4B are 30 to 150 (90 is desirable). 3) Distances between B 1 and B 2 /B 3 and B 4 are 10 mm or more. 9-7

93 9. Touch Sensing Function (Option) 6. Pattern 6: Cylinder workpiece may deviate on a flat surface. Centerline of cylinder Workpiece A 3 (1) Condition of workpiece 1) Workpiece is cylinder. 2) Workpiece moves parallel on a flat surface which is 90 to the centerline of the cylinder. B B3 A 1 BB1 BB2 A 2 (2) Sensing point 1) Execute sensing of three points. 2) Execute sensing on outer or inner points of the cylinder whose section becomes a perfect circle, B 1, B 2, and B3 in left figure. Centerline of cylinder Set surface Deviation direction (3) Teaching point Teach the points in order of A 1, B 1 A 2, BB2 A 3, B 3 with the following conditions. 1) Lines A 1 B1, A 2 B 2B, and A 3 B3 are parallel to the workpiece setting surface. 2) Angles between lines A 1 B1 and A 2 B 2B / lines A 2 B2 and A 3 B 3B are 30 to 150 (90 is desirable). 9-8

94 9. Touch Sensing Function (Option) 7. Pattern 7: Workpiece may deviate arbitrarily on a flat surface. B 1 A 1 (1) Condition of workpiece 1) Workpiece moves parallel to the flat surface on which it is placed. 2) Control surfaces (1 and 2) are flat and intersect at 90. 3) The two control surfaces are vertical to the flat surface on which the workpiece moves. A 3 B 3 B 2 Control surface 2 Control surface 1 Control surface B 1 A 2 Deviation direction Set surface (2) Sensing point 1) Execute sensing of two points on one sensing surface and one point on the other surface, B 1, B 2, and B 3 in left figure. 2) B 1 and B 2 are on the same surface. (3) Teaching point Teach the points in order of A 1, B 1 A 2, BB2 A 3, B 3 with the following conditions. 1) Lines A 1 B1, A 2 B 2B, and A 3 B3 are parallel to the workpiece setting surface. 2) Angle between lines A 1 B1 and A 3 B 3B is 30 to 150 (90 is desirable). 3) Distance between B 1 and B 2 is 10 mm or more. [ NOTE ] Pattern 7 is different from pattern 4 in that A 3 and B 3 are compensated by detecting B 1 and B 2 ; pattern 7 is suitable for sensing a thin work. 9-9

95 9. Touch Sensing Function (Option) 9.2 WIRE CHECK FUNCTION! WARNING Torch Weld machine Voltage Work Insulating sheet + - Set table/base material Working table When wire check function is working, a constant voltage (DC15V standard, DC400V as Option) is applied between torch and base material as shown on the left so that the contact position can be detected the instant a touch has been made. Thus, beware the following items: 1. Avoid touching the base material or wire during touch sensing. 2. Do not fail to connect the work to be touched and the set table to the earth side. Furthermore, the position to be touched should not be deviated and select the forged surface. Execute the touch sensing on a firmly fixed set table. Wire check function can be used in the following cases. 1. To keep a constant wire extension length without using wire cutter devices, etc. 2. At pre welding points, set the wire to the desired length in 1. above. The following subsection describes the teaching operations. For standard teaching methods, refer to 5.0 Teaching and Operation Manual for E series controller- 5.0 Teaching TEACHING FOR WIRE CHECK FUNCTION Teach the movement in the right figure. Point A Inch wire and touch the workpiece here. Point B Set length Point C Workpiece 9-10

96 9. Touch Sensing Function (Option) [ NOTE ] 1. Only air cut points can be taught the wire check function. 2. Teach the wire check to the point where the wire is inched to the desired length (Point B in figure on previous page). A 1. Teach point A. As a general point previous to teaching the wire check function, move the torch tip to point A and then teach air cut (AC) for instruction. If setting is correct, press. Work Workpiece B 2. Teach point B; after moving the torch tip to the point B, teach [Wire Check]. Set the desired wire length and touch it to point B. As exact positioning is required to point B, set the accuracy to 1. Then move cursor under Option Switch on the auxiliary data title row by pressing A + OPTION or by or, and press. Nozzle Extension length Workpiece Tip Wire To set the desired wire extension length, use a scale as shown here. 9-11

97 9. Touch Sensing Function (Option) The setting screen appears as in Figure 8.1. Select [3. Wire Check] to [Touch Sensing] and press. Figure 9.1 Press RECORD to teach the wire check in the Option Switch field. The teach screen appears as in Figure 9.2. Figure Teach point C; move torch tip to point C after touching the workpiece, and then teach air cut (AC) for instruction. As exact positioning is not required, set the accuracy to 4 (2 or 3 is also possible). If setting is correct, press RECORD. C Work The setting of wire check function is complete. 9-12

98 9. Touch Sensing Function (Option) WIRE CHECK FUNCTION AT REPEAT OPERATION! CAUTION Wire check function is possible only when repeat mode and continuous step are selected. Wire check function does not operate under any other conditions. (Doing so only plays back taught contents.) Robot moves as shown below when the program taught in Teaching for Wire Check Function is executed in repeat mode. Point A Point C Point B 0.5 sec ON Work Work Set length Wire retract signal OFF at the moment of touch Wire inching signal ON for max. of 5 sec 1. When [Wire Check] is taught at point B, wire is retracted for 0.5 sec when robot starts moving from point A to point B. 2. When arriving at point B, robot stops and inches the wire for 5 sec at a constant speed. 3. When wire tip touches the workpiece during wire inching, robot stops inching the wire and starts moving to point C. 4. If wire tip does not touch the workpiece within 5 sec, robot outputs error- E6516 Wire check failure.- and stops. 5. The speed for inching/retracting wire can be changed. (The time cannot be changed.) For more details, refer to Aux in 8.0 Auxiliary Functions. 9-13

99 9. Touch Sensing Function (Option) 9.3 WORKPIECE DETECTION FUNCTION! WARNING Torch Workpiece Voltage Insulating sheet Set table/base material Working table Weld machine + - When workpiece detection function is working, a constant voltage (DC15V standard, DC400V as Option) is applied between torch and base material as shown on the left so that the contact position can be detected the instant a touch has been made. Thus, beware the following items: 1. Avoid touching the base material or wire during touch sensing. 2. Do not fail to connect the work to be touched and the set table to the earth side. Furthermore, the position to be touched should not be deviated and select the forged surface. Execute the touch sensing on a firmly fixed set table. Workpiece detection function can check for presence of a workpiece on the set table thus eliminating the need for sensors, switches, etc. The following subsection describes the teaching operations. For standard teaching methods, refer to 5.0 Teaching and Operation Manual for E series controller- 5.0 Teaching TEACHING FOR WORKPIECE DETECTION FUNCTION Teach the movement in the figure below. Point A Point C Point B Touch the workpiece here. Point B Workpiece 9-14

100 9. Touch Sensing Function (Option) [ NOTE ] 1. Only air cut points can be taught the workpiece detection function. 2. Teach the workpiece detection to the point where the wire touches the work (Point B in figure on previous page). A Workpiece 1. Teach point A. As a general point previous to teaching the workpiece detection function, move the torch tip to point A and then teach air cut (AC) for instruction. Note that point A defines the sensing direction to the sensing point B where workpiece detection is taught (that is, robot moves A to B when sensing). Recommended distance between A and B is 100mm or more. If setting is correct, press RECORD. Case A Extension length (No need to be accurate) Case B B 2. Teach point B; after moving the torch tip to the point B, teach [Workpiece Detect]. When touching the torch tip to the workpiece, the desired torch angle can be selected as in case A, B and C on the left. In case A, extension length need not be accurate. In cases B and C, however, the extension length must correctly match the set length. B Extension length (Needs to be accurate) Case C Extension length (Needs to be accurate) B 9-15 As exact positioning is required to point B, set the accuracy to 1. Then move cursor under Option Switch on the auxiliary data title row by pressing A + OPTION or by or, and press. The setting screen appears as in Figure 8.1. Select [4. Workpiece Detect] to [Touch Sensing] and press. Press RECORD to teach the workpiece detection in the Option Switch field. The teach screen appears as in Figure 9.3.

101 9. Touch Sensing Function (Option) Figure 9.3 A Sensing start point When point B was taught by joint interpolation. B Note that robot moves on line A to B at sensing as on the left even when point B was taught by joint interpolation. C 3. Teach point C; move torch tip to point C after touching the workpiece, and then teach air cut (AC) for instruction. As exact positioning is not required, set the accuracy to 4 (2 or 3 is also possible). If setting is correct, press. Workpiece The setting of workpiece detection function is complete. 9-16

102 9. Touch Sensing Function (Option) WORKPIECE DETECTION FUNCTION AT REPEAT OPERATION! CAUTION Workpiece detection function is possible only when repeat mode and continuous step are selected. Workpiece detection function does not operate under any other conditions. (Doing so only plays back taught contents.) Robot moves as shown below when the program taught in Teaching for Workpiece Detection Function is executed in repeat mode. Point C Detect the work B Point A Point B Work B Sensing start point B Sensing end point Detection range 1. Register beforehand the distances between points B and B and points B and B by Aux in 8.0 Auxiliary Functions. 2. When [Workpiece Detect] is taught at point B, robot moves from point A to point B at the air cut speed. 3. The wire tip moves detecting the workpiece at a constant speed from the point B to the point B. Set this speed by Aux in 8.0 Auxiliary Functions. 4. When wire tip touches the workpiece (that is, workpiece detection) at point B during motion from B to B, the robot moves to point C at the air cut speed. 5. When workpiece detection did not succeed even after arriving at point B, robot outputs error- E6509 No work detected.- and stops. 9-17

103 9. Touch Sensing Function (Option) 9.4 COMPENSATION FUNCTION FOR WORKPIECE DEVIATION COMBINATION OF SENSING PATTERNS When compensating for deviations in workpiece position, the deviation amount must be acquired correctly. In arc weld specification robot, sensing patterns for compensation are classified into seven types as in the table below depending on shape of workpiece, deviate direction, etc. For details on each pattern, see Sensing Patterns for Compensation of Workpiece Deviation. Pattern 1 Pattern 2 Pattern 3 Pattern 4 Pattern 5 Pattern 6 Pattern 7 It may be necessary to use a combination of two or three of the patterns above in order to correctly acquire the deviation amounts. Apply any combination (max. of three patterns) as needed to accommodate workpiece shape/size. Two sample combining cases are described below. 1. Case 1 When the condition of the workpiece is as follows, combine pattern 1 (compensation in direction) and pattern 6 (compensation for cylinder). Then, compensate the deviation by the following procedure and execute welding. Executes circumferential fillet weld of the cylinder pipe to the square pipe as shown on the left. Height of the square pipe deviates a max. of ± 3mm. Placing position of the cylinder deviates a max. of ± 5mm. Weld line Cylinder pipe (2) (2) (1) (2) Square pipe Compensating procedure (1) Compensate the deviation (height of square pipe) by pattern 1. (2) Compensate the deviation (height of cylinder pipe) by pattern 6. (3) Execute welding. Working table 9-18

104 9. Touch Sensing Function (Option) 2. Case 2 When the condition of the workpiece is as follows, combine pattern 1 (compensation in direction) and pattern 4 (compensation on flat surface) to ensure accurate compensation for each workpiece. Weld workpiece B to workpiece A, and then workpiece C to workpiece B as shown below. Workpiece B deviates a max. of ± 2 mm up and down. Placing position for workpiece C deviates a max. of ± 1 mm. Compensate by the following procedure and then execute welding. Compensating procedure Weld line 1 (1) Compensate the deviation in workpiece B by pattern 1. (2) Keep weld line 1 between the workpieces A and B. (3) Compensate the deviation of workpiece C on the flat surface by pattern 4. (4) Keep weld line 2 between workpieces B and C. (1) (3) Work A Weld line 2 Work C (3) (3) Work B Weld line 1 Using multiple patterns to compensate for workpiece deviation as above is called compensation by combination of sensing patterns. The relation between patterns is explained below. Work to be welded Baby work Third compensation Daughter work Second compensation Mother work First compensation Base To combine patterns, first compensate to the base, then distinguish second/third compensations. These are called: mother workpiece compensation, daughter workpiece compensation and baby workpiece compensation, respectively. Their relationships are demonstrated here, with mother on base, daughter on mother, baby on daughter, and the workpiece on the baby s back. 9-19

105 9. Touch Sensing Function (Option) As shown in figure above, the workpiece to be welded can be compensated only after the deviation of mother workpiece, daughter workpiece and baby workpiece are compensated in this order. [ NOTE ] Compensation by combination X Z Y Base coordinates X M X D Z M X B Mother work coordinates Y M Z D Daughter work coordinates Y D Z B Baby work coordinates Y B Compensation by combination of sensing patterns can be mathematically explained as follows. To compensate the deviation of coordinates systems, assume mother work coordinates system (X M, Y M, Z M ) relative to the robot base coordinates system (X, Y, Z), daughter work coordinates system (X D, Y D, Z D ) relative to the mother work coordinates system (X M, Y M, Z M ), and baby work coordinates system (X B, Y B, Z B ) relative to the daughter work coordinates system (X D, Y D, Z D ) shown on left. Then obtain the deviation of the coordinates systems and compensate the deviation. That is, compensation can be performed correctly during repeat operation by executing touch sensing to the coordinates systems (X M, Y M, Z M ), (X D, Y D, Z D ) and (X B, Y B, Z B ) specified at teaching, obtaining the deviated coordinates systems (X M, Y M, Z M ), (X D, Y D, Z D ) and (X B, Y B, Z B ), and compensating each of the deviations in order of mother, daughter and baby. 9-20

106 9. Touch Sensing Function (Option) TEACHING- COMPENSATION FUNCTION FOR WORKPIECE DEVIATION- 1 (TEACHING FOR EACH SENSING PATTERN)! WARNING Torch Weld machine Voltage Work Insulating sheet + - Set table/base material Working table When deviation compensation function is working, a constant voltage (DC15V standard, DC400V as Option) is applied between torch and base material as shown on the left so that the contact position can be detected the instant a touch has been made. Thus, beware the following items: 1. Avoid touching the base material or wire during touch sensing. 2. Do not fail to connect the work to be touched and the set table to the earth side. Furthermore, the position to be touched should not be deviated and select the forged surface. Execute the touch sensing on a firmly fixed set table. This section describes the teaching operations. For standard teaching methods, refer to 5.0 Teaching and Operation Manual for E series controller- 5.0 Teaching. Teach the movement in the figure below. Deviation direction of cylinder work (7) (5) (2) (6) (4) (1) Cylinder work (Mother work) (3) Part to be welded 9-21

107 9. Touch Sensing Function (Option) [ NOTE ] 1. Only air cut points can be taught the deviation compensation function. 2. Teach points in order of (1) (2) (6) (7). Execute the sensing to the mother workpiece (cylinder workpiece) by pattern Teach angle made by lines (1)(2) and (3)(4) to be 30 to150 (90 is desirable). [ NOTE ] Direction of torch at teaching 1. Parallel to sensed surface 2. Oblique to sensed surface 3. Vertical to sensed surface て垂直 Workpiece Workpiece Workpiece When torch direction is parallel to the sensed surface, wire extension length need not be accurate. However, when it is oblique or vertical, wire length must correctly match the set length. Teach the following data. (Weld conditions, OX, WX, etc. are omitted.) Step (Teaching point) Type of teaching point Inter- polation Speed Accuracy Timer Touch sensing Contents of teaching point Motion coordinates of robot 1 Air cut Linear Workpiece reset mother 2 Air cut Linear Workpiece mother Pattern 6 Create mother workpiece coordinates by sensing pattern 6. (1 st point) Base 3 Air cut Linear Air cut Linear Workpiece mother Pattern 6 Create mother workpiece coordinates by sensing pattern 6. (2 nd point) 5 Air cut Joint

108 9. Touch Sensing Function (Option) 6 Air cut Linear Workpiece mother Pattern 6 Create mother workpiece coordinates by sensing pattern 6. (3 rd point) 7 Air cut Linear Mother workpiece (1) Cylinder work 1. Teach point (1). As a general point previous to teaching the deviation compensation function, move the torch tip to point (1) and then teach air cut (AC) for instruction, linear for interpolation, 9 for speed, and 4 for accuracy. Note that point (1) defines the sensing direction to the sensing point (2) where compensation deviation is taught (that is, robot moves (1) to (2) when sensing). Recommended distance between (1) and (2) is 100mm or more. Then move cursor under Option Switch on the auxiliary data title row by pressing A + OPTION or by or, and press. The setting screen appears as in Figure 8.1. Select [6. Workpiece Reset] to [Touch Sensing]. Then move cursor to [Work] by to display the setting screen as in Figure 8.4. Select [1. Mother] and press. Press RECORD to teach the workpiece reset (Mother) in the Option Switch field. The teach screen appears as in Figure 8.5. Figure 9.4 Figure

109 9. Touch Sensing Function (Option)! CAUTION When teaching a program using combination of sensing patterns for the workpiece deviation compensation function, be sure to set Work Reset Mother in the first step for safety. (This clears all workpiece coordinates systems and resets them to base coordinates system.) This prevents robot from moving per the last workpiece coordinates set. Attempting to execute the program from the beginning step after robot stops without workpiece reset at the first step causes an error. (2) (1) Direction to touch the workpiece is (1) (2) Cylinder workpiece 2. Teach point (2). Move the torch tip to the point (2) and then teach [Workpiece Modify]. Teach air cut (AC) for instruction, linear for interpolation, 9 for speed. As exact positioning is required to point (2), set the accuracy to 1. Then move cursor under Option Switch on the auxiliary data title row by pressing A + OPTION or by or, and press. The setting screen appears as in Figure 9.1. Select [5. Work(piece) Modify] for [Touch Sensing]. Then move cursor to [Work] by to display the setting screen as in Figure 9.6. Select [1. Mother]. Move cursor to [Pattern] by to display the setting screen as in Figure 9.7. Select reset pattern [6] and press. Press RECORD to teach the workpiece modify (Mother, 6) in the Option Switch field. The teach screen appears as in Figure 9.8. Figure

110 9. Touch Sensing Function (Option) Figure 9.7 Figure Continue teaching points (3) to (7) following the same procedure described above. Note that points (3) and (5) define the sensing direction to the sensing points (4) and (6) respectively where deviation compensation is taught (that is, robot moves (3) to (4) and (5) to (6) when sensing). Be sure to teach workpiece mother, pattern 6 to points (2), (4), (6). 9-25

111 9. Touch Sensing Function (Option) TEACHING- COMPENSATION FUNCTION FOR WORKPIECE DEVIATION- 2 (TEACHING FOR COMBINATION OF SENSING PATTERNS)! WARNING Torch Voltage Workpiece Insulating sheet Set table/base material Working table Weld machine + - When deviation compensation function is working, a constant voltage (DC15V standard, DC400V as Option) is applied between torch and base material as shown on the left so that the contact position can be detected the instant a touch has been made. Thus, beware the following items: 1. Avoid touching the base material or wire during touch sensing. 2. Do not fail to connect the workpiece to be touched and the set table to the earth side. Furthermore, the position to be touched should not be deviated and select the forged surface. Execute the touch sensing on a firmly fixed set table. This section describes the teaching operations. For standard teaching methods, refer to 5.0 Teaching and Operation Manual for E series controller- 5.0 Teaching. Teach the movement in the figure below. Deviation direction of cylinder workpiece (9) (7) (8) (1) (3) (6) (4) Cylinder workpiece (Daughter workpiece) (5) Deviation direction of square pipe (2) Part to be welded Square workpiece (Mother workpiece) Working table 9-26

112 9. Touch Sensing Function (Option) [ NOTE ] 1. Only air cut points can be taught the deviation compensation function. 2. Teach points in order of (1) (2) (8) (9). 3. Execute the sensing to the mother workpiece (square workpiece) by pattern Execute the sensing to the daughter workpiece (cylinder workpiece) by pattern Teach angle made by lines (3)(4) and (5)(6) to be 30 to 150 (90 is desirable). [ NOTE ] Understanding of sensing patterns Deviation Deviation Cylinder pipe Square pipe Up down deviation occurs in the square pipe. Compensate the height by pattern 1. Height compensation of a square pipe should be executed first, thus select [Mother work]. Horizontal deviation occurs in the cylinder pipe. Compensate the deviation by pattern 6. The square pipe on which cylinder pipe is placed is compensated as mother workpiece, thus the cylinder pipe becomes the second compensation, then select [Daughter work]. 9-27

113 9. Touch Sensing Function (Option) Teach the following data. (Weld conditions, OX, WX, etc. are omitted.) Step (Teaching point) Type of teaching point Inter- polation Speed Accuracy Timer Touch sensing Contents of teaching point Motion coordinates of robot 1 Air cut Linear Workpiece reset mother 2 Air cut Linear Workpiece mother Pattern 1 Create mother workpiece coordinates by sensing pattern 1. Base 3 Air cut Linear Air cut Linear Workpiece daughter Pattern 6 Create daughter workpiece coordinates by sensing pattern 6. (1 st point) Mother workpiece 5 Air cut Linear Air cut Linear Workpiece daughter Pattern 6 Create daughter workpiece coordinates by sensing pattern 6. (2 nd point) 7 Air cut Joint Air cut Linear Workpiece daughter Pattern 6 Create daughter workpiece coordinates by sensing pattern 6. (3 rd point) 9 Air cut Linear Daughter workpiece (1) Cylinder pipe Square pipe 1. Teach point (1). As a general point previous to teaching the deviation compensation function, move the torch tip to point (1) and then teach air cut (AC) for instruction, linear for interpolation, 9 for speed, and 4 for accuracy. Note that point (1) defines the sensing direction to the sensing point (2) where compensation deviation is taught (that is, robot moves (1) to (2) when sensing). Recommended distance between (1) and (2) is 100mm or more. 9-28

114 9. Touch Sensing Function (Option) Then move cursor under Option Switch on the auxiliary data title row by pressing A + OPTION or by or, and press. The setting screen appears as in Figure 9.1. Select [6. Workpiece Reset] for [Touch Sensing]. Then move cursor to [Work] by to display the setting screen as in Figure 9.4. Select [1. Mother] and press. Press RECORD to teach the workpiece reset (Mother) in the Option Switch field. The teach screen appears as in Figure 9.5.! CAUTION When teaching a program using combination of sensing patterns for the workpiece deviation compensation function, be sure to set Work Reset Mother in the first step for safety. (This clears all workpiece coordinates systems and resets them to base coordinates system.) This prevents robot from moving per the last workpiece coordinates set. Attempting to execute the program from the beginning step after robot stops without workpiece reset at the first step causes an error. Direction to touch the workpiece (square pipe) is (1) (2). 2. First create mother workpiece coordinates by sensing pattern 1. (1) Cylinder pipe Teach point (2). Move the torch tip to the point (2) and then teach [Work Modify]. (2) Square pipe Teach air cut (AC) for instruction, linear for interpolation, 9 for speed. As exact positioning is required to point (2), set the accuracy to 1. Then move cursor under Option Switch on the auxiliary data title row by pressing A + OPTION/C or by or, and press. The setting screen appears as in Figure 9.1. Select [5. Work(piece) Modify] for [Touch Sensing]. Then move cursor to [Work] by to display the setting screen as in Figure 9.6. Select [1. Mother]. Move cursor to [Pattern] by to display the setting screen as in Figure 9.7. Select reset pattern [1] and press. Press RECORD to teach the workpiece modify (Mother, 1) in the Option Switch field. The teach screen appears as in Figure

115 9. Touch Sensing Function (Option) Figure 9.9 Creating the mother workpiece coordinates by sensing pattern1 is complete. 3. Next create daughter workpiece coordinates by sensing pattern 6. (2) (3) Cylinder pipe Square pipe Teach point (3). As a general point, move the torch tip to point (3) and then teach air cut (AC) for instruction, linear for interpolation, 9 for speed, and 4 for accuracy. Note that point (3) defines the sensing direction to the sensing point (4) where compensation deviation is taught (that is, robot moves (3) to (4) when sensing). Recommended distance between (3) and (4) is 100 mm or more. If setting is correct, press. 4. Teach point (4). Move the torch tip to the point (4) and then teach [Work Modify]. Direction to touch the workpiece (cylinder pipe) is (3) (4) (3) (4) Cylinder pipe Square pipe Teach air cut (AC) for instruction, linear for interpolation, 9 for speed. As exact positioning is required to point (4), set the accuracy to

116 9. Touch Sensing Function (Option) Then move cursor under Option Switch on the auxiliary data title row by pressing A + OPTION or by or, and press. The setting screen appears as in Figure 9.1. Select [5. Work(piece) Modify] for [Touch Sensing]. Then move cursor to [Work] by to display the setting screen as in Figure 9.6. Select [2. Daughter]. Move cursor to [Pattern] by to display the setting screen as in Figure Select reset pattern [6] and press. Press RECORD to teach the workpiece modify (Daughter, 6) in the Option Switch field. The teach screen appears as in Figure Figure 9.10 Figure Continue teaching points (5) to (9) following the same procedure described above. Note that points (5) and (7) define the sensing direction to the sensing points (6) and (8) respectively where deviation compensation is taught (that is, robot moves (5) to (6) and (7) to (8) when sensing). Be sure to teach workpiece daughter, pattern 6 to points (4), (6), (8). The procedure is now complete. The teaching performed here creates the mother workpiece coordinates by sensing pattern 1 and the daughter workpiece coordinates by sensing pattern

117 9. Touch Sensing Function (Option) COMPENSATION FOR WORKPIECE DEVIATION AT REPEAT OPERATION! CAUTION Deviation compensation function is possible only when repeat mode and continuous step are selected. Deviation compensation does not operate under any other conditions. (Doing so only plays back taught contents.) Robot moves as shown below when the program taught in Teaching- Compensation Function for Workpiece Deviation- 1 (Teaching for Each Sensing Pattern) is executed in repeat mode. Point (3) Point (1) Sensing the workpiece Point (2) Cylinder workpiece Touch sensing distance 1. Register beforehand the touch sensing distance by Aux in 8.0 Auxiliary Functions. 2. The wire tip moves detecting the workpiece at a constant speed within the touch sensing distance (sensing range). Set this speed by Aux in 8.0 Auxiliary Functions. 3. When wire tip touches the workpiece (that is, sensing) within the touch sensing distance (sensing range), the robot moves to the next teaching point (point (3) in the figure above). 9-32

118 9. Touch Sensing Function (Option) CONTINUATION AND RESET OF WORKPIECE DEVIATION COMPENSATION CONTINUATION AND RESET OF COMPENSATION The difference between continuation and reset of compensation are described in this section by Figures 9.12 and 9.13 which demonstrates the welding a pipe on an iron plate. In Figure 9.12, pipes are placed on the same iron plate and are considered to deviate in one direction on the plate. In Figure 9.13, each pipe is on a separate iron plate but deviates in the same direction. In the case of Figure 9.12, execute one direction compensation by pattern 1 before welding pipe No.1, then weld No.1 No.2 No.3 in that compensated state. In the case of Figure 9.13, on the other hand, weld pipe No.1 by executing one direction compensation by pattern 1, and reset the compensation (that is, reset compensation when robot moves to next teaching point.). Execute compensation by pattern 1 again before welding pipe No.2, and then execute the same procedure to pipe No. 3. Based on these examples, the compensation function can be performed once, compensating the same deviation distance on multiple workpieces Continuous Compensated state, or compensation can be performed independently for each workpiece Reset Compensation state. (See program examples on next page.) 9-33

119 9. Touch Sensing Function (Option) Guide Deviation No.1 No.2 No.3 No.1 No.2 No.3 Deviation Guide Iron plate Guide Iron plate Figure 9.12 Figure 9.13 Flow of program (Continuous compensation) Flow of program (Reset compensation) Work reset mother Work mother pattern 1 Weld pipe No.1. Sets initialization (Same state at teaching) Work reset mother Work mother pattern 1 Weld pipe No.1. Sets initialization (Same state at teaching) Compensated state Weld pipe No.2. Weld pipe No.3. Continuous compensated state Work reset mother Work mother pattern 1 Reset compensation Compensated state Weld pipe No.2. Work reset mother Reset compensation Work mother pattern 1 Compensated state Weld pipe No

120 9. Touch Sensing Function (Option) CASES OF CONTINUING/RESETTING COMPENSATION Cases for using continuous or reset compensation are classified in the table below. Operation on program Others When continuing use of same compensation amt. If nothing is done on program (not teaching reset of workpiece mother, daughter, baby), the previous compensation continues. When resetting the compensation amt. Select compensation data to reset: workpiece mother, daughter or baby on program. Workpiece mother reset: All compensations are reset. Workpiece daughter reset: Only daughter workpiece and baby workpiece compensations are reset. Workpiece baby reset: Only baby workpiece compensation is reset. Reset compensation data when: 1. Selecting a program by teach pendant, etc. 2. Selecting a step by teach pendant, etc. 3. Inserting, deleting or changing program by teach pendant, etc. 4. External program reset is input by interlock, etc. from outside. 9-35

121 9. Touch Sensing Function (Option) 9.5 PRECAUTIONS ON TEACHING This section describes precautions when teaching a program that uses the touch sensing functions, wire check, workpiece detection, and compensation for workpiece deviation. Note that incorrect operation causes sensing error or defect.! WARNING Torch Voltage Insulating sheet Weld machine Workpiece + - Set table/base material Working table When touch sensing function is working, a constant voltage (DC15V standard, DC400V as Option) is applied between torch and base material as shown on the left. Avoid touching the base material or the wire during teaching. 1. If tool dimensions are registered incorrectly, error results from the workpiece coordinates acquired by sensing, even if workpiece is set correctly with no deviation. For more details, see Aux.1405 in 8.0 Auxiliary Functions. Dimensions for torch installation Registered torch dimensions 55 15mm 404mm Different! Aux Arc Weld Torch Dimension Length 404mm Angle 55deg Wire Extension 15mm One or some of these registered values are incorrect. 9-36

122 9. Touch Sensing Function (Option) 2. During workpiece detection/compensation, if wire extension length is incorrect, error results from the workpiece coordinates acquired by sensing regardless of the workpiece deviation. However, if torch is parallel to the control surface when touching, error does not occur. Therefore, ensure the same extension length in teaching and repeat operations using wire check function, wire cutter, etc. Extension length at teaching Extension length in repeat operation Different! E.g. 15mm 10mm 3. Confirm wire touches the control surface correctly and that there is conduction. Correct teaching state Incorrect teaching state Wire touches surface, and there is a conduction. No conduction as wire does not touch surface or due to forged surface even when touched. 4. When condition of wire tip is not good, wire check, workpiece detection, compensation for workpiece deviation may not be performed correctly. Desirable wire tip Undesirable wire tip The tip is cut by wire cutter, etc. and there is a good electrical contact. Wire tip has a lump, or spatter, etc. adheres to the wire. 9-37

123 9. Touch Sensing Function (Option) 5. In order to compensate correctly, execute touch sensing to the surface which deviates the same as the weld line. Incorrect touch sensing (1) Correct touch sensing 6. When sensing pattern and sensing order are not matched, an error occurs. Incorrect touch sensing (2) Correct sensing pattern and sensing order [ NOTE ] To compensate work deviations correctly, touch sensing function assumes that the weld line on the work surface/area to be sensed is taught with a sufficiently high accuracy level. 9-38

124 9. Touch Sensing Function (Option) 9.6 ERRORS AND COUNTERMEASURES FOR TOUCH SENSING FUNCTION This section describes errors occurring during touch sensing operation and the error handling ERROR MESSAGE LIST Error Error message code E6509 No work detected. E6510 Undefined sensing direction. E6511 Insufficient sensing points. E6512 Undefined mother or daughter work. E6513 Too many sensing points. E6514 Work specification incorrect. E6515 Incorrect sensing point specified. E6516 Wire check failure. Main cause When sensing for workpiece detection or compensation, wire did not touch the workpiece after moving the touch sensing distance. When sensing for workpiece detection or compensation, no point was taught prior to the sensing point, or Air Cut (defining the sensing direction) was not taught in the prior point/step. Weld was started before acquiring the No. of sensing points specified by the pattern. Attempted to execute daughter or baby workpiece before mother workpiece was specified. Or, attempted to execute baby workpiece before daughter workpiece was specified. Without reset, executed the same sensing to workpiece for which sensing was already complete. Or, executed sensing at more points than the No. of sensing points specified by the pattern. Before completing sensing of all the sensing points of the specified pattern, a different sensing pattern was processed. During deviation compensation, sensing order or sensing locations were incorrect. During wire check, wire did not touch the workpiece after inching the wire for 5 sec. 9-39

125 9. Touch Sensing Function (Option) ERRORS AND COUNTERMEASURES If the program taught with the touch sensing function suffers an error while it is running, execute the recovery procedures detailed here and on the following pages. 1. E6509: No work detected. When an error occurs, robot holds detection of the workpiece and stops at the place the error occurred. Main cause: 1. Workpiece deviated more than touch sensing distance registered in Aux. Function Workpiece is not set. Countermeasure: Touch sensing distance may be short, set again with a longer touch sensing distance in Aux. Function (Beware that setting a longer distance lengthens the touch sensing time.) Or, when workpiece deviates too much, reset it to its set place. Trajectory of robot torch tip from time of error occurrence to error handling Error occurrence B A B (Sensing start point) P Torch tip motion Torch evacuation point B B A P Cycle start B B A B (Sensing end point) Place error occurred B B 9-40

126 9. Touch Sensing Function (Option) Remarks: If robot is stopped by turning RUN /HOLD to HOLD during sensing, the trajectory of the robot torch tip is as shown below when restarting. Pausing A Cycle start A A Pausing location B B (Sensing start point) B (Sensing end point) B B B Pausing location Returns to B once. B B B Then moves B B.! CAUTION If this error occurs when sensing the workpiece by deviation compensation function, and then if the workpiece was moved for the error recovery, be sure to execute sensing of the workpiece coordinates from the first compensation (for mother workpiece, daughter workpiece, etc.). Also beware that when selecting a particular step, all compensation amounts are reset. 2. E6510: Undefined sensing direction. When an error occurs, robot holds detection of the workpiece and stops in that step. Main cause: For example, when the error occurred in step 4 of the program below, the following are considered probable causes. 1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET 2. WS LINEAR SPEED9 TIMER0 3. WE LINEAR WELD_CONDO 4. AC LINEAR SPEED9 ACCU4 TIMER0 WORK_DETECT : 1. The previous step (step 3) is not an air cut point, which is necessary for using the workpiece detection function in step When selecting a particular step as the start step wherein the sensing function is specified, for 9-41

127 9. Touch Sensing Function (Option) example, if only step4 in the above program is selected for execution. Countermeasure: 1. In the case of the program above, inset a new step containing an Air Cut point before step4 (which includes workpiece detection). (Sensing direction is determined by the point taught sensing function and the air cut point.) 2. When selecting a particular step for execution, specify the step that precedes the step taught workpiece detection function as a start step. For programs that frequently use touch sensing functions, be sure to execute the program from the first step. 3. E6511: Insufficient sensing points. When an error occurs, robot holds creation of the workpiece coordinates and stops in that step. Main cause: For example, when the error occurred in step2 of the program below, the following are considered probable causes. 1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET 2. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK2 3. WS LINEAR SPEED9 TIMER0 : 1. Although pattern 2 (with 2 sensing points) was set in step2 above, sensing was executed for only one of the two sensing points, also a non-air Cut instruction was specified in the next step (step3). Countermeasure: 1. In the case of the program above, insert new steps (steps 3, 4) for sensing the second of the two sensing points as below. Ensure the number of steps used to execute workpiece deviation compensation corresponds with the number of sensing points. (As in program example each sensing point is taught by two steps, the first being an Air Cut step and the second being MOTHER_WORK#, DAUGHTER_WORK#, etc.) 2. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK2 3. AC LINEAR SPEED9 ACCU4 TIMER0 4. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK2 5. WS LINEAR SPEED9 TIMER0 9-42

128 9. Touch Sensing Function (Option) 4. E6512: Undefined mother or daughter work. When an error occurs, robot holds creation of the workpiece coordinates and stops in that step. Main cause: For example, when the error occurred in step2 of the program below, the following are considered probable causes. 1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET 2. AC LINEAR SPEED9 ACCU4 TIMER0 DAUGHTER_WORK2 : 1. Attempted creation of daughter workpiece coordinates in step2 without first making the mother workpiece coordinates. Or, although mother workpiece is taught in the previous step, attempted to start execution in repeat mode from the step containing daughter workpiece. Countermeasure: 1. In the case of the program above, edit the step so as to ensure mother workpiece coordinates are created first. Or, insert a new step creating mother workpiece coordinates. 1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET 2. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK1 When selecting a step from which to begin in repeat mode, avoid starting from step with daughter workpiece or baby workpiece. 9-43

129 9. Touch Sensing Function (Option) 5. E6513: Too many sensing points. When an error occurs, robot stops in the place the error occurred. Main cause: For example, when the error occurred in step7 of the program below, the following are considered probable causes. 1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET 2. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK1 3. AC LINEAR SPEED9 ACCU4 TIMER0 4. WS LINEAR SPEED9 TIMER0 5. WE LINEAR WELD_COND0 6. AC LINEAR SPEED9 ACCU4 TIMER0 7. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK1 1. Although workpiece coordinates have already been created (step 2), the workpiece coordinates were to be created again (step 7). Or, the sensing was to be executed at a higher No. of sensing points than specified in sensing pattern. Countermeasure: 1. In the case of the program above, reset the workpiece coordinates (step6), and edit the step so as to create the workpiece coordinates again. See below. 6. AC LINEAR SPEED9 ACCU4 TIMERO MOTHER_RESET 7. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK1 6. E6514: Work specification incorrect. Robot stops in the step where error occurred. Main cause: For example, when the error occurred in step4 of the program below, the following are considered probable causes. 1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET 2. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK2 3. AC LINEAR SPEED9 ACCU4 TIMER0 4. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK1 9-44

130 9. Touch Sensing Function (Option) 1. After specifying the first point of two point sensing pattern in step3, different sensing pattern was specified in step4. Countermeasure: 1. In the case of the program above, specify the same sensing pattern to complete the workpiece coordinates as below. 4. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK2 7. E6515: Incorrect sensing point specified. Robot stops in the step where error occurred. Main cause: 1. Teaching order was incorrect, for example did not follow A 1 B1 A 2 B 2 B A3 B3. 2. The distance between two points taught on the same control surface was less than 10mm. Or, angle made from the sensing directions for two different control surfaces was not within Countermeasure: 1. Clear the error cause and teach again correctly. 8. E6516: Wire check failure. Robot stops in the step where error occurred. Main cause: 1. The workpiece was too far from the teaching point. 2. Wire feeder did not inch weld wire due to cut OFF of power supply in weld machine, etc. Countermeasure: 1. When teaching point and the workpiece are located far apart, teach again with the position closer to the workpiece. 2. When weld wire was not inched, adjust and check the devices and press CYCLE START button. Then, confirm wire is inched for the full 5 sec. 9-45

131 9. Touch Sensing Function (Option) 9-46

132 10. Special Pattern Weaving Function (Option) 10.0 SPECIAL PATTERN WEAVING FUNCTION (OPTION) This section describes special pattern weaving function, an optional specification OVERVIEW OF SPECIAL PATTERN WEAVING SPECIAL PATTERN WEAVING By using this special pattern weaving function, weaving shapes which are normally simple harmonic can be created or changed freely. 1. Standard registration Pattern No. (PN): Standard 2. Available only when Option (Special pattern weaving) is installed Pattern No. (PN): 1 10 PN=1 to PN=5: These patterns are already registered at time of factory shipment. Original, newly created patterns can be also registered here. PN=6 to PN=10: Registers original, newly created patterns. (1) Pattern examples listed in this manual Select and register the desired pattern from Appendix 3. Pattern Example of Special Pattern Weaving (List). (2) Register the newly created weaving patterns. 10-1

133 10. Special Pattern Weaving Function (Option) Pattern No. Pattern name Motion Motion of torch tip Standard Simple harmonic 1 Simple harmonic both ends stop 2 Triangular 3 Reciprocating triangular 4 Circular (Clockwise) 5 Circular (Counterclockwise) 6 to 0 Unregistered 10-2

134 10. Special Pattern Weaving Function (Option) PENDULUM WEAVING For weaving in a narrow groove, the torch posture often needs to be changed during weaving operation. With the special pattern weaving function, torch posture can be changed a max. of ±10. This is called pendulum weaving % -50%! CAUTION Note that pendulum weaving sometimes induces large motions in the robot even though the motion of the torch tip is small. Or, speed abnormality may occur. In these cases, set pendulum angle smaller, or modify teaching contents to make the motion of each robot axis smaller WELD CURRENT/ WELD VOLTAGE BOOSTS For weaving in a narrow groove, etc., weld current or weld voltage often need to be changed to enable high quality penetrating at both ends of the weave. Via the special pattern weaving function, weld current or weld voltage can be changed a max. of ±100%. This is called weld current/weld voltage boosts. (%) % Weld condition set value -100% 10-3

135 10. Special Pattern Weaving Function (Option) FLOW CHART FOR USING SPECIAL PATTERN WEAVING FUNCTION To use special pattern weaving function, follow the flow chart described below. Decide weaving pattern type to use. Use a standard pattern. Use a pattern example listed in Make and use a new (See 10.2 Standard this manual. (See Aux pattern. (See Weaving Patterns Registered for Robot.) Special Pattern Weaving (Option) in 8.0 Auxiliary Functions). Creating Weaving Patterns.) (Specify one pattern from the five kinds of weaving patterns.) (Pattern example can be modified.) Fill in sheet used for registering pattern data. Draw a figure of the movement in created pattern. Determine a position for defining teaching origin and weaving width. Create expansion pattern diagrams for back/forth, lateral, and vertical directions of the torch. Based on pattern diagrams, fill in sheet used for registering pattern data. Determine weaving pattern No. and register required data. Specify weaving pattern No. when teaching the program. 10-4

136 10. Special Pattern Weaving Function (Option) 10.2 STANDARD WEAVING PATTERNS REGISTERED FOR ROBOT The standard weaving patterns registered in this function include: simple harmonic both ends stop weaving, triangular weaving, reciprocating triangular weaving, circular weaving, etc. This section describes the motion using solid figures and the expansion patterns for the weaving patterns in back/forth, lateral, and vertical directions. Vertical direction Vertical plate Lateral direction 1 cycle (sec) Horizontal plate Motion direction Back/forth direction Amplitude (WV) Motion of torch tip Vertical direction: Torch direction (+ moves upwards.) Lateral direction: Direction vertical to torch and traveling direction (+ moves towards vertical plate (left)) Back/forth direction: Motion direction of weld (+ moves forward) Relation between frequency and cycle is as shown in the graph below. 1 cycle Frequency f=0.5hz 1 sec 2 sec 1 cycle f=1hz 1 sec 2 sec 1 cycle f=2hz 1 sec 2 sec 10-5

137 10. Special Pattern Weaving Function (Option) 1. Pattern No. 1 (PN=1): Simple harmonic both ends stop weaving pattern Motion of torch tip Motion direction Amplitude (WV) Forth Time ratio in a cycle Back Lateral Lateral Up Down Time ratio in a cycle (Torch moves left and right at amplitude 100%. Pause at both ends.) Time ratio in a cycle (Torch does not move in vertical direction.) 10-6

138 10. Special Pattern Weaving Function (Option) 2. Pattern No. 2 (PN=2): Triangular weaving pattern Motion of torch tip Amplitude (WV) Motion direction Forth Time ratio in a cycle Back Lateral Lateral Time ratio in a cycle (Torch moves at amplitude 100 %.) Up Down Time ratio in a cycle (Torch also moves in vertical direction.) 10-7

139 10. Special Pattern Weaving Function (Option) 3. Pattern No. 3 (PN=3): Reciprocating triangular weaving pattern- both ends stop, center stop Motion of torch tip Motion direction Amplitude (WV) Forth Time ratio in a cycle Back Lateral Lateral Up Down Time ratio in a cycle (Torch moves left and right at amplitude 100 %. Pause at both ends and center.) Time ratio in a cycle (Torch also moves in vertical direction.) 10-8

140 10. Special Pattern Weaving Function (Option) 4. Pattern No. 4 (PN=4): Circular weaving pattern (1)- from vertical plate direction Motion of torch tip Amplitude (WV) Motion direction Forth Back Time ratio in a cycle (Torch displacement changes back and forth.) Lateral Lateral Time ratio in a cycle (Torch moves left and right at amplitude 100%.) Up Down Time ratio in a cycle (Torch does not move in vertical direction.) 10-9

141 10. Special Pattern Weaving Function (Option) 5. Pattern No. 5 (PN=5): Circular weaving pattern (2)- from horizontal plate direction Motion of torch tip Amplitude (WV) Motion direction Forth Back Lateral Lateral Up Down Time ratio in a cycle (Torch displacement changes back and forth.) Time ratio in a cycle (Torch moves left and right at amplitude 100%.) Time ratio in a cycle (Torch does not move in vertical direction.) 10-10

142 10. Special Pattern Weaving Function (Option) 10.3 TEACHING OPERATION FOR SPECIAL PATTERN WEAVING Point at teaching Weaving motion in repeat operation Weld end point Weld line Weld start point Teach the motion pattern at weld end or weld continue points. Welding executed by repeating the specified motion pattern. When using registered weaving patterns, there is no additional teaching procedure to use special weaving function. Simply set the desired weaving pattern No. in the weld conditions. For example, to use weaving pattern 4 in the arc spot weld condition of direct setting, set the pattern No. as in Figure ([Pole Ratio] shown only when Option is installed.) Figure 10.1 Weaving patterns can be also set in the weld condition by the following auxiliary functions. For details about the setting procedures of each function, see 8.0 Auxiliary Functions. 1. Aux. Function 1403: Arc Weld Condition Database 2. Aux. Function : Software Slow Down 3. Aux. Function 1406: Arc Weld Condition Modify 10-11