Robotic Arc Welding Interfacing

Transcription

1 Robotic Arc Welding Interfacing Josh Williamson Fronius USA LLC 6797 Fronius Drive Portage, IN 46368

2 Presentation Topics / What is a Robotic Interface??? / Interface History / Communication Protocols / Smart Interfaces / Overview of a robotic shipbuilding project. 2

3 What is a Robotic Interface??? The connection and interaction between the robot, the welding hardware, and the user. 3

4 What is a Robotic Interface The connection and interaction between the robot, the welding hardware, and the user. Robot and Positioning Equipment Robot Technician Robot Controller and Teach Pendant Welding Power Source & Interface 4

5 Interface Basic Signals

6 Presentation Topics / What is a robotic interface??? / Interface History / Communication Protocols / Smart Interfaces / Overview of a robotic shipbuilding project. 6

7 Interface History 1982 Motoman System 7

8 General Interface trends Interfaces progression over the last 25 years: Relays and discrete i/o Discrete i/o with 2 or 3 analog channels Increased functionality and process control Improved user interfaces (4 digits Windows type indefinite) Increased communication interfaces (16 in/out 1024 signals, field buses, Ethernet) Increased computational power (8 kb 13 Mb) Easier to setup and diagnose

9 Interface History Early 80 s Motoman RX Controller Current Motoman DX Controller 9

10 Interface History ABB S1 Controller ABB IRC5 Controller 10

11 Presentation Topics / What is a robotic interface??? / Interface History / Communication Protocols / Smart Interfaces / Overview of a robotic shipbuilding project. 11

12 Interface Communication Protocols Profi-Bus EtherNet IP IP Industrial Protocol Developed by Rockwell 1990 Based on Common Industrial Protocol (CIP) DeviceNet Developed by Rockwell Based on CIP Noise Sensitive Profi-Net Developed 1989 in Germany Software necessary to create network GSD file (general station description) Ethernet (Modbus) UDP Maintained by a community (PI) Uses ethernet cables Energy savings Developed in 1979 GSD file (general station description) No Royalty-Fee Wireless Discrete I/O Troubleshooting physical signals Time consuming setup Additional i/o boards sometimes needed EDS file (electronic data sheet) 12

13 Simple Interface 13

14 Ethernet Interface BitMap 14

15 Troubleshooting (error codes) EFD xxx Error with the wire feed system, refer to wire feeder error codes for more details Err 049, 051, and 052 Error detected in mains power input (phase missing or voltage too low/high). Check mains. Err PE Voltage detected on earth ground. Check for isolation between welding ground points and earth ground points. No H2O Error with the coolant system, check cooler for operation and system for good flow. STOP Communication or E-Stop condition with robot. Check for Robot Ready and Error Reset signals from robot.

16 Weld Process The flow rate of the shielding gas is a critical aspect of the welding process. Too high OR too low will have a serious impact on weld results. Fronius Options Typically, the weld system opens and closes the gas valve. If flow monitoring is desired within the system, the following options are available. Rule of thumb for the flow rate: times the diameter in l/min of flow - 1.2mm x 10 = 12 l/min - 1 l/min = 2.1 CFH - 12 l/min x 2.1 = 25 CFH Helium and Hydrogen require about 50% more flow than other gases due to their lighter weights. Correct flow rate Excessive flow rate Gas Pressure Sensor Manually set gas valve that reports a gas error to the weld system when flow is too low. Only errors out for low flow and doesn t report specific flow information. Digital Gas Sensor The specific gas flow is set, regulated, and monitored using this device. Not only is a low or high flow rate detected, but the system also reports back specific gas flow data.

17 Presentation Topics / What is a robotic interface??? / Interface History / Communication Protocols / Smart Interfaces / Overview of a robotic shipbuilding project. 17

18 Smart Interfaces 18

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30 Smart Interfaces 30

31 Presentation Topics / What is a robotic interface??? / Interface History / Communication Protocols / Smart Interfaces / Overview of a robotic shipbuilding project. 31

32 Tech Support USA Service & Application Support Weld Testing & Development 32 Fronius USA /Product Overview / 6/11/2013

33 All information is without guarantee in spite of careful editing - liability excluded. Intellectual property and copyright: all rights reserved. Copyright law and other laws protecting intellectual property apply to the not otherwise marked content of this presentation respectively documents (texts, pictures, graphics, animations etc.). It is not permitted to use, copy or alter the content of this presentation for private or commercial purposes without express authorisation from Fronius.