KUKA.ServoGun TC 4.1. KUKA System Technology. For KUKA System Software 8.2. KUKA Roboter GmbH. Issued:

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1 KUKA System Technology KUKA Roboter GmbH KUKA.ServoGun TC 4.1 For KUKA System Software 8.2 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

2 Copyright 2013 KUKA Roboter GmbH Zugspitzstraße 140 D Augsburg Germany This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of KUKA Roboter GmbH. Other functions not described in this documentation may be operable in the controller. The user has no claims to these functions, however, in the case of a replacement or service work. We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a regular basis, however, and necessary corrections will be incorporated in the subsequent edition. Subject to technical alterations without an effect on the function. Translation of the original documentation KIM-PS5-DOC Publication: Pub KST ServoGun TC 4.1 (PDF) en Book structure: KST ServoGun TC 4.1 V1.6 Version: KST ServoGun TC 4.1 V1 en (PDF) 2 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

3 Contents Contents 1 Introduction Target group Industrial robot documentation Representation of warnings and notes Terms used Product description ServoGun TC overview Constant motion speed Overview of connecting cables Intended use of the technology package Safety Installation System requirements Installing or updating ServoGun TC Uninstalling ServoGun TC Operation Menus Status keys Manually opening / closing the gun Manually coupling / decoupling the gun Manually activating gun compensation Calling the variable overview Start-up and configuration Start-up and configuration overview Configuration in WorkVisual overview Configuring the gun Configuring ServoGun options in WorkVisual TCP calibration and tool direction Configuring the gun data and calibration Configuration screen Gun parameters screen Calibration 5 P screen Calibration 2 P screen Loading the gun and calibration data Saving the gun and calibration data Configuring variables in EG_EXTERN.DAT Configuring inputs/outputs Inputs Outputs Configuring timers, interrupts and cyclical flags Configuring ServoGun options in EG_EXTERN.DAT Configuring details for ServoGun options Details for Force from timer TRUE (ForceTimer TRUE) Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 3 / 125

4 Obtaining values from the weld timer without Valid bit sequence Details for Thickness from Timer TRUE (ThicknessTimer TRUE) Details for ThicknessTolTimer TRUE Details for WeldTimeTimer TRUE Manual gun mastering Determining the gear ratio Manually determining the thickness of the force gauge Calibration overview P calibration Coarse calibration with EG_1_Cal Fine calibration with EG_2_Recal Force test with EG_3_Force DualForce calibration DualForce calibration with EG_4_DF_Cal DualForce force test with EG_5_DF P calibration Fine calibration with EG_Recal_2_points Force test with EG_Force_2_points P calibration in T EG_1_Cal in T2 (without Warm-up, without Determine thickness ) EG_1_Cal in T2 (with Warm-up, without Determine thickness ) EG_1_Cal in T2 (without Warm-up, with Determine thickness ) EG_1_Cal in T2 (with Warm-up, with Determine thickness ) Determining the asymmetrical flexion of X guns Determining the sliding effect with X guns Setting the software limit switches Setting the negative software limit switch Setting the positive software limit switch Tip initialization overview First initialization via status key Cyclical initialization via status key Controller parameters overview Optimizing the parameters for the speed and position controllers Servo Gun parameter finding window Programming Inline forms overview Instructions for programming Instructions for use of stationary guns Programming a weld spot Inline form SPOT (Pneumatic option) Inline form SPOT (Robot compensation option) Programming a weld spot with EqualizingTech Inline form SPOT (EqualizingTech option) Programming a DualForce weld spot Inline form DualForce (Pneumatic option) Inline form DualForce (Robot compensation option) Programming a DualForce weld spot with EqualizingTech Inline form DualForce (EqualizingTech option) Programming tip initialization / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

5 Contents Programming first initialization (Pneumatic option with Ratio in %) Programming cyclical initialization (Pneumatic option with Ratio in %) Inline form INIT (Pneumatic option with Ratio in %) Programming first initialization (Individual measurement option) Programming cyclical initialization (Individual measurement option) Inline form INIT (Individual measurement option) Programming tip dressing Determining the thickness of the tip dresser Inline form TippDress (Pneumatic option) Inline form TippDress (Robot compensation option) Programming tip dressing with EqualizingTech Inline form TippDress (EqualizingTech option) Inline form ServoGun Decouple Inline form ServoGun Couple Programming background tip dressing or welding Inline form Background tip dressing Inline form Background welding Option window Frames Option window: Motion parameters (PTP) Option window: Motion parameters (LIN, CIRC) Option window Weld timer parameters Teach mode (reteaching weld spots) Correcting weld spots semi-automatically (ASA) User-specific subprograms EG_USER.SRC EG_PRE() (before welding) EG_POST_ERROR() (after welding and tip dressing) EG_PRED() (before tip dressing) EG_POSTD() (after tip dressing) EG_USERDRESS() (tip dressing) EG_USER_BG_TD_W.SRC Diagnosis Displaying and exporting data from the weld timer Displaying ServoGun I/Os Variables KUKA Service Requesting support KUKA Customer Support Index Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 5 / 125

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7 1 Introduction 1 Introduction 1.1 Target group This documentation is aimed at users with the following knowledge and skills: Advanced KRL programming skills Advanced knowledge of the robot controller system Knowledge of field bus interfaces Knowledge of spot welding For optimal use of our products, we recommend that our customers take part in a course of training at KUKA College. Information about the training program can be found at or can be obtained directly from our subsidiaries. 1.2 Industrial robot documentation The industrial robot documentation consists of the following parts: Documentation for the manipulator Documentation for the robot controller Operating and programming instructions for the KUKA System Software Documentation relating to options and accessories Parts catalog on storage medium Each of these sets of instructions is a separate document. 1.3 Representation of warnings and notes Safety These warnings are relevant to safety and must be observed. are taken. These warnings mean that it is certain or highly probable that death or severe injuries will occur, if no precautions These warnings mean that death or severe injuries may occur, if no precautions are taken. These warnings mean that minor injuries may occur, if no precautions are taken. These warnings mean that damage to property may occur, if no precautions are taken. These warnings contain references to safety-relevant information or general safety measures. These warnings do not refer to individual hazards or individual precautionary measures. This warning draws attention to procedures which serve to prevent or remedy emergencies or malfunctions: Procedures marked with this warning must be followed exactly. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 7 / 125

8 Notes These hints serve to make your work easier or contain references to further information. Tip to make your work easier or reference to further information. 1.4 Terms used Term Burn-off (tip wear) ASA Compensation (equalizing) Robot compensator (compensation-free gun) First initialization Mastering Calibration Tip dressing (TipDress) Force build-up Force gauge Robot compensation Weld timer Servo gun Water monitor Exchangeable gun Gun flexion Wear or deformation of the electrode tips caused by the welding process or by tip dressing Automatic Standoff Adjustment ASA can be used to correct weld spots semi-automatically. ASA can be used to adapt the position of a weld spot to the changed position of a workpiece. Pneumatic compensation cylinder for compensating the position of the gun: Compensation activated: soft gun position Compensation deactivated: exact gun position Gun without pneumatic compensation cylinder See also EqualizingTech and Robot compensation (>>> "EqualizingTech" Page 12) Pressing in the new electrode tips and remeasuring the tip burn-off (EG_WEAR[]) Definition of the zero point (closed position) of the weld gun Comparison of the force sensor with an external force gauge and calculation of the following characteristics: Force characteristic Gun flexion characteristic Restoring the profile of the electrode tips by cutting Generation of the closing force during gun closure Instrument for measuring the closing force of the weld gun For guns without pneumatic compensation cylinder: The gun position is compensated by the motion of the robot arm. (= weld controller) Device for controlling the welding time and welding current Weld gun with servomotor drive Monitoring unit in the cooling water circuit of the weld gun. The water monitor monitors the cooling water volume at the input and output of the cooling water circuit. Weld gun which is installed and removed on the robot flange via an automatic tool changing system. Deformation of the weld gun caused by the action of the closing force 8 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

9 1 Introduction Term Gear ratio Cyclical initialization Ratio between the motor stroke and gun opening Determination of the current electrode burn-off and adaptation of the closing position to the burn-off. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 9 / 125

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11 2 Product description 2 Product description 2.1 ServoGun TC overview Functions WorkVisual ServoGun TC is an add-on technology package for torque-controlled electric motor-driven spot welding. It offers the following functionalities: Defined build-up of gun force through constant motion and motor torque limitation Control of up to 6 electric motor-driven weld guns: Up to 6 exchangeable guns 1 stationary spot weld gun and up to 5 exchangeable guns 2 stationary spot weld guns If a linear unit is used: Up to 5 exchangeable guns Or 1 stationary spot weld gun Dual-force mode: The weld can be started with a defined force and finished with a different force at one and the same point. Compensation: Pneumatic compensation of the gun position on the workpiece possible Or: Compensation of the gun position on the workpiece through robot motion Force calibration of the gun: Possible in T1 and T2 The motor can be warmed up to process temperature before calibration. The thickness of the force sensor can be taken from the configuration parameters or determined during calibration. Selection of the weld program: Can be selected via the point name or separately via the program number The following data can be obtained from the weld timer or defined via inline forms: Welding force, workpiece thickness, thickness tolerance Background mode for stationary guns: The gun can be moved asynchronously during tip dressing or welding. At the same time, the robot axes can carry out other motions independently of the gun, e.g. fetching a new workpiece. For X guns: The sliding effect due to oblique electrode shanks and the asymmetrical flexion can be determined and compensated. Semi-automatic correction of workpiece position changes (ASA) Automatic point correction for compensating the electrode burn-off Correction can also be deactivated if necessary. Monitoring of various parameters Welding possible in all operating modes. In T1, welding can also be deactivated. For guns with pneumatic compensation: The gun can also be closed with process force in T1. The servo gun is implemented as an external axis. Every taught point contains the positions of the 6 robot axes and the opening width of the gun. The following software is required for configuring the servo guns: Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 11 / 125

12 WorkVisual 2.4 EqualizingTech The software KUKA.EqualizingTech is available as a supplement to Servo- Gun. With EqualizingTech, conventional gun compensation systems are no longer required. This makes it possible to dispense with e.g. the complicated start-up procedures for pneumatic compensation systems. EqualizingTech results in only minor changes in the operation of ServoGun for the user. Information about installing EqualizingTech is contained in the KU- KA.EqualizingTech documentation. Cell overview Fig. 2-1: Overview of a welding cell 1 KR C4 robot controller 2 Weld timer 3 Tool rack 4 Robot 5 Energy supply system 6 Stationary servo gun 7 Servo gun 8 Tip dresser 2.2 Constant motion speed ServoGun TC regulates the speed of motion in proportion with the target force. The larger the target force (= setpoint force), the higher the rotational speed. The time for the pressure build-up is dependent on the gun flexion and the target force. The proportionality is limited by the maximum speed of the constant motion phase. 12 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

13 2 Product description Fig. 2-2: Relationship between force and rpm 1 Rotational speed 2 Maximum speed of the constant motion phase 3 Force 2.3 Overview of connecting cables Fig. 2-3: Overview of connecting cables 1 Weld timer 2 Robot controller 3 Motor cable to the gun 4 Weld gun 5 Field bus module on the weld gun (Not necessary if EqualizingTech is used. Otherwise, depending on the weld gun used.) Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 13 / 125

14 6 Field bus connection between the following components: Weld timer Robot controller If used: Field bus module on the weld gun 7 Robot The following connections depend on the type of weld gun being used: Connection for water cooling of the weld gun and the motor Air connection for the gun compensation Connection for the weld current Further information about the connections on the weld gun can be obtained from the gun manufacturer. 2.4 Intended use of the technology package Use Misuse The ServoGun TC technology package is intended exclusively for spot welding with electric motor-driven guns and for use in an industrial environment. The technology package must only be operated in compliance with the specified system requirements. Operation in accordance with the intended use also involves observance of the configuration descriptions in this documentation and constant observance of the assembly and operating instructions for the cell components used. Any use or application deviating from the intended use is deemed to be impermissible misuse. The manufacturer cannot be held liable for any damage resulting from such use. The risk lies entirely with the user. Examples of such misuse include: Use in a cell which does not conform to the applicable safety regulations for spot welding. Use in a non-industrial environment 14 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

15 3 Safety 3 Safety This documentation contains safety instructions which refer specifically to the software described here. The fundamental safety information for the industrial robot can be found in the Safety chapter of the Operating and Programming Instructions for System Integrators or the Operating and Programming Instructions for End Users. The Safety chapter in the operating and programming instructions of the KUKA System Software (KSS) must be observed. Death to persons, severe injuries or considerable damage to property may otherwise result. The force signal is measured in analog form at the sensor box without electrically isolated voltage supply. This measurement can be disrupted by discharged currents from the welding process. Interference is particularly liable to occur if the following constellation is used in the cell: The secondary neutral of the welding transformer is grounded. And: the workpiece fixture (e.g. a clamping fixture) is grounded. It must be ensured that the force signal is transmitted to the sensor box without any interference. In particular, the constellation described above must not be used in the cell. If this precaution is not observed, the robot controller might receive corrupted force signals. Injuries or damage to property may result. If the secondary neutral of the welding transformer is not grounded, this will endanger persons working at the cell. In particular, a voltage of 500 V is liable to be generated on the gun and not discharged. To avoid this hazard, one of the following elements must be installed in the primary weld power supply: Isolating contactor Residual-current circuit-breaker matching the welding technology (medium frequency or mains frequency) Failure to observe this may result in severe injuries or death to persons. Calibration in T2 must only be carried out with a fixed force gauge. There must be no persons inside the safeguarded area during operation in T2 mode. Death to persons or severe injuries may otherwise result. If a number of robots work at a stationary gun, workspaces must be programmed to prevent more than one robot from moving to the gun at the same time. If no such workspaces are programmed, the robots can collide at the gun, resulting in damage to property. Weld spots and tip dressing points that were taught without Equalizing must not be used with Equalizing. Weld spots and tip dressing points that were taught with Equalizing must not be used without Equalizing. If such existing points are to be reused, they must be retaught. Damage to the gun or the workpiece may otherwise result. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 15 / 125

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17 4 Installation 4 Installation 4.1 System requirements Hardware KR C4 robot controller Servo gun with motor, without force sensor Recommendation: Motor from ARO, type S.DTE Software KUKA System Software 8.2 (Build 114 or higher) 4.2 Installing or updating ServoGun TC During installation of ServoGun, one gun is automatically installed as external axis E1. Any existing E1 is overwritten. If the gun is to be assigned to a different external axis number, this must be configured in WorkVisual. It is advisable to archive all relevant data before updating a software package. Preparation Copy software from CD to KUKA USB stick. The software must be copied onto the stick with the file Setup.exe at the highest level (i.e. not in a folder). Recommendation: Use a KUKA stick. Data may be lost if any other stick is used. Precondition User group Expert Operating mode T1 or T2. No program is selected. Procedure 1. Connect the USB stick to the robot controller or smartpad. 2. In the main menu, select Start-up > Additional software. 3. Click on New software. The entry ServoGun TC must be displayed in the Name column and drive E:\ or K:\ in the Path column. If not, click on Refresh. 4. If the specified entries are now displayed, continue with step 5. If not, the drive from which the software is being installed must be configured first: Click on the Configuration button. A new window opens. Select a line in the Installation paths for options area. Note: If the line already contains a path, this path will be overwritten. Click on Path selection. The available drives are displayed. Select E:\. (If stick connected to the robot controller.) Or select K:\. (If stick connected to the smartpad.) Click on Save. The window closes again. The drive only needs to be configured once and then remains saved for further installations. 5. Mark the entry ServoGun TC and click on Install. Answer the request for confirmation with Yes. 6. Confirm the reboot prompt with OK. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 17 / 125

18 7. Remove the stick. 8. Reboot the robot controller. Finishing work LOG file If ServoGun TC 4.0 has been updated to ServoGun TC 4.1, the following adaptations must be carried out afterwards: 1. Remove the old calibration programs manually. (4.1 has new, different calibration programs.) 2. Set EG_CAL_DIST[1] [6] to the value (Old value = 10.0) 3. Recalibrate the gun. 4. If user-specific routines are programmed in EG_USER.SRC: check EG_USER.SRC. A LOG file is created under C:\KRC\ROBOTER\LOG. 4.3 Uninstalling ServoGun TC It is advisable to archive all relevant data before uninstalling a software package. Precondition Expert user group Procedure 1. In the main menu, select Start-up > Additional software. 2. Mark the entry ServoGun_TC and click on Uninstall. Reply to the request for confirmation with Yes. Uninstallation is prepared. 3. Reboot the robot controller. Uninstallation is resumed and completed. LOG file A LOG file is created under C:\KRC\ROBOTER\LOG. 18 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

19 5 Operation 5 Operation 5.1 Menus The following menus and commands are specific to this technology package: Main menu: Configuration > Status keys > ServoTech Configuration > ServoGun Torque Control Configuration Gun parameters Calibration 5 P Calibration 2 P Load all Save all Configuration > ServoGun controller param. Diagnosis > ServoGun TC > Weld timer data Diagnosis > ServoGun TC > ServoGun I/Os Menu sequence Commands > ServoTech: SPOT PTP, LIN, CIRC DualForce PTP, LIN, CIRC INIT TippDress PTP, LIN ServoGun Decouple ServoGun Couple Background Background tip dressing, Background welding 5.2 Status keys Procedure Displaying the status keys: In the main menu, select Configuration > Status keys > ServoTech. Status key Name / description Toggle status keys Displays additional status keys. First initialization Cyclical initialization Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 19 / 125

20 Status key Name / description Decouple (>>> 5.4 "Manually coupling / decoupling the gun" Page 21) Couple (>>> 5.4 "Manually coupling / decoupling the gun" Page 21) Gun Gun to which the status keys refer Only with the option Pneumatic: Status key Name / description Compensator 1 Close gun with compensator 1 (>>> 5.5 "Manually activating gun compensation" Page 21) Compensator 2 Close gun with compensator 2 (>>> 5.5 "Manually activating gun compensation" Page 21) Compensators 1 and 2 Close gun with compensator 1 and compensator 2. Only with the option Robot compensation: Status key Name / description Teach mode off Teach mode is deactivated. Pressing the status key switches Teach mode on. Teach mode on Teach mode is activated. Pressing the status key switches Teach mode off. 5.3 Manually opening / closing the gun Precondition Operating mode T1 Settings on the Keys tab in the Jog options window: The check box Activate keys is activated. Under Key groups, a group is selected that contains the external axis, e.g. External axes. The type and number of kinematics groups available depend on the system configuration. Under Coordinate system, the option Axes is selected. 20 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

21 5 Operation Procedure 1. Set jog override. 2. Hold down the enabling switch. 3. The axes of the selected kinematics group are displayed next to the jog keys. Press the plus key of the external axis to close the gun. Press the minus key of the external axis to open the gun. If the functions of the status keys are interchanged (i.e. if the gun opens when plus is pressed), the sign of the configuration parameter Gear ratio must be changed. 5.4 Manually coupling / decoupling the gun The gun is coupled or decoupled by the software. The opening width of the gun must be identical in both the coupling and decoupling position. Recommendation: The gun should be open at least 10 mm. Do not decouple the gun if it is in the mastering position, since the mastering would otherwise be lost when the gun is recoupled. Procedure 1. Select the gun using the Gun status key. 2. Couple the gun with the Couple status key, or decouple it using Decouple. 5.5 Manually activating gun compensation This function is not required if EqualizingTech is installed. This functionality can be used to check the pneumatic compensation. Precondition T1 or T2 operating mode The gun is coupled. Procedure 1. Move the gun to the panel/position where the check is to be carried out. 2. Select the gun using the Gun status key. 3. Press the status key for the desired compensator, e.g. Compensator 1. The gun closes and opens again after 0.5 s. 4. If the panel deforms in an undesired manner, change the setting of the pneumatic compension on the gun. 5. Repeat steps 3 and 4 until compensation is carried out as desired. 5.6 Calling the variable overview The variable overview displays the different ServoGun parameters and the corresponding values. Procedure In the main menu, select Display > Variable > Overview > Display. The variable overview is opened. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 21 / 125

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23 6 Start-up and configuration 6 Start-up and configuration 6.1 Start-up and configuration overview Step 1 Mount the gun. 2 Connect the connecting cables. 3 Enter the weld parameters in the weld timer. Note: Information can be found in the documentation for the weld timer. If the robot controller is to obtain the force value from the weld timer, the desired force in kn must be entered in the weld timer for every program number used. 4 Install ServoGun TC. 5 If required: Install EqualizingTech. 6 Transfer the project to WorkVisual and carry out configuration via WorkVisual. Then transfer the project from WorkVisual back to the robot controller. (>>> 6.2 "Configuration in WorkVisual overview" Page 24) 7 Calibrate the gun as the tool. Note: Observe the information about calibration in this documentation: (>>> 6.3 "TCP calibration and tool direction" Page 29) 8 Configure the inputs/outputs in the file EG_EXTERN.DAT. (>>> "Configuring inputs/outputs" Page 36) 9 Configure the timer, interrupts and cyclical flags in the file EG_EXTERN.DAT. (>>> "Configuring timers, interrupts and cyclical flags" Page 40) 10 Configure the following additional parameters in the file EG_EXTERN.DAT: (>>> "Configuring ServoGun options in EG_EXTERN.DAT" Page 41) (>>> "Configuring details for ServoGun options" Page 42) 11 Set the parameters on the configuration screen Configuration (except for: Thickness, X-Compensation and Asym- Bend compensation) Also enter and save the gun name(s). (>>> 6.4 "Configuring the gun data and calibration" Page 30) 12 Master the gun. (>>> 6.6 "Manual gun mastering" Page 46) 13 Determine the gear ratio. (>>> 6.7 "Determining the gear ratio" Page 47) Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 23 / 125

24 Step 14 Determine the thickness of the force gauge. (>>> 6.8 "Manually determining the thickness of the force gauge" Page 48) 15 Calibrate the gun. (>>> 6.9 "Calibration overview" Page 49) 16 Only for X guns with the option Robot compensation: determine the offset due to asymmetrical flexion. (>>> 6.10 "Determining the asymmetrical flexion of X guns" Page 67) 17 Only for X guns with oblique electrode shanks: determine the offset. (>>> 6.11 "Determining the sliding effect with X guns" Page 68) 18 Set the software limit switches for the gun. (>>> 6.12 "Setting the software limit switches" Page 69) 19 Carry out first initialization of the electrode tips. (>>> 7.7 "Programming tip initialization" Page 87) 20 Optimize the controller parameters. If a different motor is used instead of the default motor: optimization must be carried out. If the default motor is used: optimization is recommended. (>>> 6.14 "Controller parameters overview" Page 71) If a number of robots work at a stationary gun, workspaces must be programmed to prevent more than one robot from moving to the gun at the same time. If no such workspaces are programmed, the robots can collide at the gun, resulting in damage to property. 6.2 Configuration in WorkVisual overview Step 1 Transfer the project from the robot controller to WorkVisual. 2 Configure the field bus. 3 Configure the gun. (>>> "Configuring the gun" Page 25) 4 Select the ServoGun options. (>>> "Configuring ServoGun options in WorkVisual" Page 27) 5 If required: perform further settings in WorkVisual. 6 Transfer the project from WorkVisual to the robot controller. Information about bus configuration and project deployment can be found in the WorkVisual documentation. 24 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

25 6 Start-up and configuration Configuring the gun During installation of ServoGun, one gun is automatically installed as external axis E1. Any existing E1 is overwritten. If the gun is to be assigned to a different external axis number, this must be configured in WorkVisual. The following guns/combinations can be configured: Up to 6 exchangeable guns 1 stationary spot weld gun and up to 5 exchangeable guns 2 stationary spot weld guns If a linear unit is used: Up to 5 exchangeable guns Or 1 stationary spot weld gun Preparation 1. Copy the file ServoGunTC.afc from the CATALOGS folder on the Servo- Gun CD. 2. Copy the file to the following folder on the PC on which WorkVisual is installed: C:\Progam Files\KUKA\WorkVisual \Catalogs 3. Remove the write protection: a. Right-click on the file ServoGunTC.afc and select Properties from the context menu. The Properties [ ] window is opened. b. Deactivate the Write-protected check box and confirm with OK. The Properties [ ] window is closed again. 4. Import the catalog in WorkVisual via File > Catalog management... The catalog is now displayed in the Catalogs window. If motors are to be used that are not contained in the catalog Servo- GunTC.afc, use the catalog from the gun supplier (file [ ].afc). If no catalog was supplied with the gun, please contact the gun supplier. If a motor supplied by KUKA is not included in the catalog ServoGunTC.afc, please contact KUKA Roboter GmbH. Precondition The robot controller has been set as the active controller. Procedure 1. Select the gun in the ServoGun [ ] catalog in the Catalogs window. The guns are named after their motors. If the name does not contain any specification of the gun type, then it does not matter which gun type the motor is combined with in reality. 2. Drag the gun into the Project structure window: into the Hardware tab, onto the robot controller there. (Not onto the node Unassigned active devices.) 3. If the gun is used as a stationary gun, continue directly with step 4. If it is used on the robot flange, select the Geometry tab. There, drag the gun onto the Flange Base node of the robot. (This specifies that the gun may be coupled to this robot. It does not specify whether the gun is actually coupled, but merely that coupling is possible.) 4. Select the gun and select the menu sequence Editors > Machine data configuration. The Machine data configuration window is opened. 5. Only if this ServoGun project has already been transferred 2 or more times to WorkVisual: Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 25 / 125

26 Click on the following button: Import axis-specific machine data of the kinematic system from external files If the data are not imported in the specified case, configuration data may be lost, resulting in a faulty project being transferred to the robot controller. This may result in damage to property or necessitate extensive corrective measures. 6. If the tab [Axis_name] (e.g. Joint 1) is closed, click on it. The tab is opened. 7. In the Axis ID box in the area General axis-specific machine data, specify which drive the gun is assigned to in the real cell. 8. Fill out the Supply channel box. 9. Set the check mark in the box Axis decouplable. 10. If required: edit the other parameters. 11. Repeat steps 1 to 9 for all the guns used. 12. Only with stationary guns: The gun must be linked to the robot with which it is to be kinematically coupled in the real cell. a. Select the cell on the Hardware tab and select the menu sequence Editors > Configure kinematic relations. An editor opens. (If couplable guns are used, these are linked to their robot in the editor by means of arrows. This is only a display and cannot be changed here.) b. Right-click in the empty space in the editor and select from the context menu. c. Click on the stationary gun. Hold down the mouse button, drag the mouse pointer to the robot and release the mouse button. In the editor, the link is now displayed by an arrow line. The designation of the gun is now displayed in the node of the robot on the Hardware tab. d. Repeat these steps for all stationary guns used. 13. Switch back to the Machine data configuration window. 14. Only perform in the following case: If this project has been configured in WorkVisual for the first time. And if one or more guns had already been configured manually on the robot controller before the project was transferred to WorkVisual. Click on the following button: Import axis-specific machine data of the kinematic system from external files If the data are not imported in the specified case, configuration data may be lost, resulting in a faulty project being transferred to the robot controller. This may result in damage to property or necessitate extensive corrective measures. ServoGun variables The following ServoGun variables are adapted by the configuration in WorkVisual: INT EG_EXTAX_ACTIVE = 1 INT EG_GUN_NBR = 2 GlOBAL INT EG_SERVOGUN_EXAXIS[6] EG_SERVOGUN_EXAXIS[1] = 1 EG_SERVOGUN_EXAXIS[2] = 2 EG_SERVOGUN_EXAXIS[3] [6]= 0 INT EG_COUPLE_AXIS = 'B00011' 26 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

27 6 Start-up and configuration GlOBAL INT EG_DRIVE_CHANNEL[6] EG_DRIVE_CHANNEL[1] [6] = Configuring ServoGun options in WorkVisual Limitations The following options were developed for the weld timer family PSI 63Cx (with firmware 729) from BOSCH: Force from timer TRUE (ForceTimer TRUE) Thickness from Timer TRUE (ThicknessTimer TRUE) Part thickness tolerance TRUE (ThicknessTolTimer TRUE): Can only be selected in EG_EXTERN.DAT! (>>> "Configuring ServoGun options in EG_EXTERN.DAT" Page 41) The options can also be used with other timers if these use the same communication principle. Communication principle: 1. Robot controller requests program from weld timer (data bit & Valid bit). 2. Weld timer responds with the following data: ForceTimer, ThicknessTimer, ThicknessTolTimer. 3. When all the data are present at the interface, the weld timer sends the Valid bit to the robot controller. 4. The robot controller reads the data and executes the weld. The transmission of the values from the weld timer to the robot controller takes time. In the following cases, this can mean that the robot controller has to wait for the values and is therefore unable to approximate the gun motions: With very small distances between points With a very small opening of the gun In the following cases it is not possible to obtain the values from the weld timer: The configuration parameter Timer type is set to TEST. The robot controller instead uses the values last received for this point from a weld timer. In Office mode Precondition A robot controller is selected in the Project structure window. Or: A gun is selected in the Project structure window. Procedure 1. Select the menu sequence Editors > ServoGun TC Editor. The ServoGun TC Editor window is opened. It displays the options for the selected gun. If a robot controller is selected, all the guns assigned to this robot controller are displayed one under the other. 2. Select the options. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 27 / 125

28 Fig. 6-1: ServoGun options Parameter Weld program selection type These parameters apply to the entire cell. Method used by the robot controller to select the weld program: Point name The weld program is selected via the name of the weld spot. Program number The weld program is selected via a number. The number is specified by the user in the inline form. Number of entities This box is only visible if Point name is selected. The user defines the name of the weld spot or tip dressing point in the inline forms SPOT and TippDress on the robot controller. The last x characters of the name (default = 7 characters) must be digits. The robot controller communicates these digits to the weld timer as the program number. The number of relevant final characters can be configured here in Number of entities (>>> "Point name as program number" Page 29) Weld Timer Options These parameters apply to the individual gun. Force from timer Where is the value for the closing force of the gun to come from? Thickness from Timer TRUE: The robot controller obtains the value from the weld timer. Note: If TRUE is selected, additional settings must be made in EG_EXTERN.DAT. (>>> "Configuring details for ServoGun options" Page 42) FALSE: The user defines the value via the inline form. Where is the value for the overall thickness of the parts to be welded to come from? TRUE: The robot controller obtains the value from the weld timer. Note: If TRUE is selected, additional settings must be made in EG_EXTERN.DAT. (>>> "Configuring details for ServoGun options" Page 42) FALSE: The user defines the value via the inline form. Gun Options These parameters apply to the individual gun. 28 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

29 6 Start-up and configuration Parameter Compensation Burn-off management Point name as program number Type of equalization: Pneumatic: The gun position is corrected pneumatically. Robot compensation: The gun position is corrected by means of compensation motion by the robot. EqualizingTech: Must be selected if KUKA.EqualizingTech is to be used on the robot controller. Is only available if the project comes from a robot controller on which EqualizingTech is installed. Method for determining the tip burn-off: Ratio in %: The overall burn-off is calculated. The robot controller assigns the burn-off to the two electrodes using a defined ratio. (Default = 50:50). The ratio can be configured in EG_WEAR_RATIO[ ]. Individual measurement: The overall burn-off is calculated. After this, the precise burn-off is determined for the moving electrode. The burn-off of the fixed electrode is derived from the difference. Can only be combined with Robot compensation. Example: In WorkVisual, the option Point name has been selected. In WorkVisual, the default value 7 has been left in the Number of entities box. The following point name is defined in the inline form: SG The robot controller communicates the last 7 characters (counting from the right) to the weld timer as the program number: These characters must be digits. All characters located further to the left are irrelevant for the program number; these may be digits or any other characters. 6.3 TCP calibration and tool direction When calibrating the servo gun, the TCP must always be positioned on the fixed electrode. Recommendation: Define the tool direction as shown in the illustration (>>> Fig. 6-2 ): Plus points in the direction of the fixed electrode. Minus points in the opposite direction from the fixed electrode. The direction defined must then entered on the Configuration configuration screen under the parameter TCP orientation. Information about calibration and definition of the tool direction is contained in the operating and programming instructions for the KUKA System Software (KSS). Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 29 / 125

30 Fig. 6-2: TCP and tool direction 6.4 Configuring the gun data and calibration Precondition Expert user group Procedure 1. In the main menu, select Configuration > ServoGun Torque Control and then one of the following menu items: Configuration Gun parameters Calibration 2 P Calibration 5 P The corresponding configuration screen is opened. 2. If there is more than one gun configured: In the Gun selection box, select the gun (no.) to which the settings are to apply. 3. In the Gun description box, enter a distinctive name for the gun. This needs to be done only once per gun, on one of the screens. 4. Configure the parameters as required on the selected screen. 5. Press Save. The changes are saved. 6. Close the screen via the Close icon. 7. Configure the parameters as required on the other screens. Alternative procedure Buttons The parameters can also be loaded from a data medium. The parameters can be loaded for each screen. (>>> "Buttons" Page 30) The parameters can be loaded for a number of screens at once. (>>> "Loading the gun and calibration data" Page 35) The following buttons are available on the configuration screens: 30 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

31 6 Start-up and configuration Button Import Export Load Save Calculate If the data for this screen are available in a TXT file, they can be loaded using this button. Precondition: The TXT file is located on a drive to which the robot controller has access. Or a USB stick with the TXT file is connected. Saves the data in this screen to a TXT file. A name can be assigned to the file. As the memory location, it is possible to select a drive to which the robot controller has access, or a USB stick. Updates the data in this screen in accordance with the current state of the robot controller. If changes have been entered but not yet saved on this screen, the initial state can be restored in this way. Saves the changes on this screen. Only available in the screens Calibration 2 P and Calibration 5 P. Calculates the current calibration of the gun on the basis of the values Force 1 in kn, etc. The calibration is not saved Configuration screen Parameter Timer type Manufacturer of the weld timer used TEST (default), ARO, BOSCH, FASE, SERRA For the setting TEST, the following applies: The gun is closed for 0.5 s with the defined force and then opened again. No welding is carried out. If Force from timer TRUE is configured, the robot controller uses the force value last received for this point from a weld timer. This also applies to other values that are obtained from the timer. If Force from timer TRUE is configured, then the values in the Weld timer parameters option window can additionally be changed. Gun type X: X gun (default) TCP orientation C, G, J: C gun The working direction of the tool (TCP) must be specified here. -X (default), -Y, -Z, +X, +Y, +Z The choice of X, Y or Z depends on the value defined in $TOOL_DIRECTION. The same value must be selected here. The choice of plus or minus depends on the definition of the direction: Plus points in the direction of the fixed electrode, minus points in the opposite direction: select Plus Minus points in the direction of the fixed electrode, plus points in the opposite direction: select Minus (>>> 6.3 "TCP calibration and tool direction" Page 29) Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 31 / 125

32 Parameter TCP correction Tip detection Calibration method X-Compensation Only relevant for X guns with oblique electrode shanks Thickness Automatic correction of the point coordinates in order to compensate for the current tip burn-off On (default): The point coordinates are corrected, i.e. they are adapted in accordance with the tip wear determined during tip initialization. Off: The point coordinates are not corrected. If the burn-off has been determined, this is ignored. The system checks for the presence of tips on the gun. On (default): Tip detection activated. If an electrode tip falls off, this is detected and an error message is generated. After force build-up, the closing width of the gun is measured. This value is compared with the value entered under Part in the inline form TippDress, taking into account the flexion. Off: Tip detection deactivated Desired calibration method 5 P (default) 2 P: Can only be selected if a calibration with 5 P has already been carried out. Maximum comp.: enter the offset determined with the program EG_7_Sliding mm Default: 0.00 Direction: enter the direction of the determined offset. -X (default), -Y, -Z, +X, +Y, +Z Compensation active: activate/deactivate offset compensation Off (default), On Thickness of the force gauge mm Default: First Init force Maximum tip wear Distance (>>> 6.8 "Manually determining the thickness of the force gauge" Page 48) The force with which the gun is closed during the first motion during first initialization. Note: Suitable values are values from 2.5 kn. 0 kn max. gun force Default: 2.50 Maximum permissible value of the tip burn-off (both tips together) 0 20 mm Default: 8.00 Length of the constant motion distance The force build-up after the electrodes have made contact with the workpiece must be executed within the constant motion distance. In the case of small differences between the positions of the individual workpieces, a lower value can be selected. In the case of larger differences, a higher value must be selected. 0 5 mm Default: / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

33 6 Start-up and configuration Parameter AsymBend compensation Only relevant for X guns with the option Robot compensation Maximum comp.: enter the offset determined with the program EG_6_Asym_Bend. The direction of the offset must be specified via the sign: If the closing point has shifted in the TCP direction: Enter the value without sign. If the closing point has shifted in the opposite direction from the TCP direction: Enter the value with negative sign. Compensation active: activate/deactivate offset compensation Off (default), On Gun parameters screen Input Motor file Servo file Position control file Gear ratio The files currently used are displayed here. (display only) If other files are to be loaded, this must be done in WorkVisual. Distance moved by electrodes in [mm] per revolution of the motor mm Default: 5.00 Note: Enter the value without sign, or with a positive sign. Max. opening (mm) (>>> 6.7 "Determining the gear ratio" Page 47) Enter the negative software limit switch mm Default: Software limit (mm) (>>> "Setting the negative software limit switch" Page 69) Enter the positive software limit switch mm Default: Max. flexion (mm) Max. speed (rpm) (>>> "Setting the positive software limit switch" Page 69) Maximum flexion of the gun (calculated from the calibration) + 5 mm reserve (display only) Revolutions per minute of the gun motor (display only) Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 33 / 125

34 6.4.3 Calibration 5 P screen Parameter Force 1 in kn Force 5 in kn Motor torque 1 in kn Motor torque 5 in kn Calibration position 1 in degrees Calibration position 5 in degrees Position / Force Maximum gun force in kn Enter here the forces that were measured with the force gauge during 5 P calibration. Default: 0.00 Torques used to perform the 5 gun closures during 5 P calibration. Either: use the default values. Or: enter the tip dressing force (approx. 1 kn) as value 1. Then distribute the values 2-5 linearly over the welding range. Default: Value 1: 1.00 kn Value 2: 2.50 kn Value 3: 4.00 kn Value 4: 5.50 kn Value 5: 7.00 kn Gun position after force build-up (display only) (display only) Maximum closing force of the gun in kn. Refer to the gun data sheet and enter the relevant value Default: 4.00 Note: This value is identical with the value of the same name in the screen Calibration 2 P. If the value is changed in one screen, it is automatically transferred to the other screen. The values for the motor torques can be entered manually in the screen Calibration 5 P. If the values entered are too high, the gun could be damaged Calibration 2 P screen Precondition 5P calibration has been carried out. The value 2 P has been entered under Calibration method in the configuration screen Configuration. Operating mode T1 Expert user group 34 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

35 6 Start-up and configuration Parameter Measure 1 Measure 2 Maximum gun force in kn Maximum closing force of the gun in kn. Refer to the gun data sheet and enter the relevant value Default: 4.00 Note: This value is identical with the value of the same name in the screen Calibration 5 P. If the value is changed in one screen, it is automatically transferred to the other screen. Target force in kn Setpoint for the 1st target force Setpoint for the 2nd target force Calculated torque in kn Calibrated torque in kn Value from the 5P calibration for the 1st target force Torque for the 1st target force, finely adapted in the 2P calibration Value from the 5P calibration for the 2nd target force Torque for the 2nd target force, finely adapted in the 2P calibration Loading the gun and calibration data If the data for the following configuration screens are available in a TXT file, they can be loaded: Configuration Gun parameters Calibration 2 P Calibration 5 P On loading the data, the gun name stored in the TXT file overwrites the name configured in the ServoGun software. TXT files created in ServoGun TC 4.0 can be loaded in 4.1. The existing data are accepted. For every parameter that is missing in the file, the robot controller displays an error message. This applies to parameters which are new in 4.1 and thus not available in the file from 4.0. This is also the case with any parameters that have been manually deleted from the file. Precondition The TXT file is located on a drive to which the robot controller has access. Or: A USB stick with the TXT file is connected. Expert user group Procedure 1. In the main menu, select Configuration > ServoGun Torque Control > Load all. 2. In the Gun selection box, select the gun for which the data are to be loaded. 3. Navigate to the TXT file and select it. 4. Press Load. 5. A request for confirmation is displayed, asking if the existing data should be overwritten. Confirm with Yes. The data are loaded and the following message is displayed: Data successfully imported. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 35 / 125

36 6.4.6 Saving the gun and calibration data This procedure saves the data in the following configuration screens to a TXT file: Configuration Gun parameters Calibration 2 P Calibration 5 P Precondition Expert user group Procedure 1. If data are to be saved to a USB stick, this must be connected. 2. In the main menu, select Configuration > ServoGun Torque Control > Save all. 3. Select the desired gun in the Gun selection box. Only data for one gun can be saved in a file. 4. The name of the selected gun is displayed in the Gun description box. The name can be changed. This has no effect on the name of the gun in the ServoGun software. Only the data in the TXT file are saved under this name. 5. Navigate to the desired memory location and select it. 6. A default name for the file is displayed in the Select file box. Change the name if required. 7. Press Save. The data are saved and the following message is displayed: Saving successful 6.5 Configuring variables in EG_EXTERN.DAT Variables in EG_EXTERN.DAT can be changed via the variable correction function or directly in the file. Information about the variable correction function can be found in the operating and programming instructions for the KUKA System Software (KSS) Configuring inputs/outputs The numbers for inputs/outputs, interrupts, timers and cyclical flags must only be assigned once in the entire robot controller. Precondition Expert user group Procedure 1. In the Navigator, open the file EG_EXTERN.DAT in the directory R1\TP\ServoGun_TC. 2. Open the fold Signals. 3. Configure the inputs/outputs as required in this fold. 4. Close the file. Respond to the request for confirmation asking whether the changes should be saved by pressing Yes. The window I/Os for weld timer / PLC displays the states of the inputs and outputs. (>>> 8.2 "Displaying ServoGun I/Os" Page 107) 36 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

37 6 Start-up and configuration Inputs Inputs from the weld timer: Input EG_ERROR_IN[1] [6] EG_TIMER_READY_IN[1] [6] EG_VALID_IN[1] [6] EG_CURRENT_IN[1] [6] EG_CYC_END_IN[1] [6] EG_THERMO_CONTACT_IN[1] [6] EG_WATCH_PROCESS_IN[1] [ 6] HIGH = Weld timer signals an error LOW = Weld timer signals no error Status of weld timer HIGH = Weld timer ready LOW = Weld timer not ready Weld timer confirms program number. HIGH = Weld timer confirms program number LOW = No confirmation from the weld timer Switch current on/off HIGH = Switches the current on LOW = Switches the current off HIGH = End of weld reached LOW = End of weld not reached Monitoring of the temperature of the transformer on the gun HIGH = Transformer has normal operating temperature LOW = Transformer is overheating HIGH = External error LOW = No external error Inputs from the media supply unit: Input EG_WATER_SAVER_IN_1[1] [6] EG_WATER_SAVER_IN_2[1] [6] Monitoring of the cooling water volume at the gun intake HIGH = No alarm LOW = Alarm triggered Monitoring of the cooling water volume at the gun outflow HIGH = No alarm LOW = Alarm triggered Inputs from the PLC: Input EG_STOP_POINT_END_IN EG_NO_PART_IN Request for the robot to stop after welding at the next weld spot HIGH = Request LOW = No request Motion with/without closing HIGH = Gun remains open at the weld spot LOW = Gun closes at the weld spot Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 37 / 125

38 Input EG_QUIT_RESUME_IN EG_QUIT_REPEAT_IN Certain dialog messages can also be answered by the PLC instead of the user. These two inputs receive the answer from the PLC. (>>> "Acknowledgement by PLC" Page 38) HIGH on EG_QUIT_RESUME_IN = NO The program is continued without repeating the point. HIGH on EG_QUIT_REPEAT_IN = YES The last point is repeated. Both inputs must not be HIGH at the same time. If both inputs are LOW, this means no answer, and the message remains in the message window. Note: After the dialog message has been answered, the input must be reset by the PLC for the program to be resumed. Acknowledgement by PLC The following dialog messages can be acknowledged by the PLC: No cycle end signal, input..., repeat point? Welding controller error, input..., repeat point? No TIMER READY signal, input..., repeat point? Inputs for background tip dressing: Input EG_BG_TD_REQ_IN EG_BG_TD_GUN_MINI_IN EG_BG_TD_GUN_MAXI_IN Request to start background tip dressing HIGH = Request LOW = No request Input range for the dresser number Inputs for background welding: Input EG_BG_W_REQ_IN EG_BG_W_GUN_MINI_IN EG_BG_W_GUN_MAXI_IN EG_BG_W_PGNO_MINI_IN EG_BG_W_PGNO_MAXI_IN EG_BG_W_FORCE_MINI_IN EG_BG_W_FORCE_MAXI_IN EG_BG_W_THICK_MINI_IN EG_BG_W_THICK_MAXI_IN EG_BG_W_COMP_MINI_IN EG_BG_W_COMP_MAXI_IN Request to start background welding HIGH = Request LOW = No request Input range for gun number Input range for program number Input range for welding force Unit: N Input range for part thickness Unit: mm Input range for specifying which compensator should be activated Outputs Outputs to the weld timer: 38 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

39 6 Start-up and configuration Outputs EG_QUIT_OUT[1] [6] EG_INDEX_MINI_OUT[1] [6] EG_INDEX_MAXI_OUT[1] [6] EG_VALID_OUT[1] [6] EG_NOCURRENT_OUT[1] [6] EG_START_OUT[1] [6] Reset errors currently active in the weld timer. HIGH = Reset the errors. LOW = Do not reset the errors. Address range for transfer of the program number. The bit width must not exceed 32 bits. Confirmation that the signal EG_VALID_IN has been received HIGH = Confirmation LOW = No confirmation Request to close the gun with the correct force and time, but without current HIGH = Request LOW = No request Start the welding process (also start of cycle). HIGH = Start of welding LOW = No start of welding Outputs to the gun: Outputs EG_COMP_OUT[1,1] [6,1] EG_COMP_OUT[1,2] [6,2] EG_COMP_OUT[1,3] [6,3] Only effective for gun with pneumatic compensation: activate compensator 1. HIGH = Compensation activated LOW = Compensation deactivated Only effective for gun with pneumatic compensation: activate compensator 2. HIGH = Compensation activated LOW = Compensation deactivated Only effective for gun with pneumatic compensation: activate compensator 1 and compensator 2. HIGH = Compensation activated LOW = Compensation deactivated Outputs to PLC: Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 39 / 125

40 Outputs EG_EL_NEW_OUT[1] [6] EG_WELD_ERROR_DIALOG_O UT EG_STOP_POINT_END_OUT Request indicating that new electrodes are required HIGH = Request LOW = No request Certain dialog messages can also be answered by the PLC instead of the user. This output signals to the PLC when the message window displays a message of this kind. (The PLC can then send its answer.) (>>> "Acknowledgement by PLC" Page 38) HIGH = Dialog message is present LOW = No dialog message present Note: The signal should be set for at least 1 second. For the robot to resume motion, the signal must then be reset. Confirmation of the request EG_STOP_POINT_END_IN HIGH = End of weld reached LOW = End of weld not yet reached Outputs for background tip dressing: Outputs EG_BG_TD_RDY_OUT EG_BG_TD_BSY_OUT EG_BG_TD_SUCCESS_OUT HIGH = Ready for background tip dressing LOW = Not ready HIGH = Background tip dressing running HIGH = Background tip dressing has been performed successfully Outputs for background welding: Outputs EG_BG_W_RDY_OUT EG_BG_W_BSY_OUT EG_BG_W_SUCCESS_OUT HIGH = Ready for background welding LOW = Not ready HIGH = Background welding running HIGH = Background welding has been performed successfully Configuring timers, interrupts and cyclical flags The numbers for inputs/outputs, interrupts, timers and cyclical flags must only be assigned once in the entire robot controller. Precondition Expert user group Procedure 1. In the Navigator, open the file EG_EXTERN.DAT in the directory R1\TP\ServoGun_TC. 2. Open the fold Error handling. 3. The fold contains the following sections (among others): ; Used Timers ; Used interrupts ; Used cycflags Configure the variables as required in these sections. 40 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

41 6 Start-up and configuration 4. Close the file. Respond to the request for confirmation asking whether the changes should be saved by pressing Yes. Variable / default value EG_TIMER_12=12 EG_TIMER_13=13 EG_INTERRUPT_1=1 EG_INTERRUPT_11=11... EG_INTERRUPT_16=16 EG_INTERRUPT_21=21 EG_CYCFLAG1=1 EG_CYCFLAG2=2 Only used if the inline forms Background tip dressing or Background welding are used. For timeouts during the welding process For calibration and for ASA Only used for the Pneumatic option. Which interrupts are required for the specific application depends on how many guns are used and which external axis number these are assigned to. E1 = INTERRUPT_11,, E6 = INTERRUPT_16 Only used if the inline form DualForce is used. Only used if the inline form DualForce is used. For ASA Configuring ServoGun options in EG_EXTERN.DAT Precondition Expert user group Procedure 1. In the Navigator, open the file EG_EXTERN.DAT in the directory R1\TP\ServoGun_TC. 2. Open the fold Gun typ. 3. The fold contains the variables ServogunTC[1] to ServogunTC[6]. Configure each gun used. 4. Close the file. Respond to the request for confirmation asking whether the changes should be saved by pressing Yes. ServoGun options Fig. 6-3: Excerpt from the open fold Gun typ The parameters from the fold which are not described here are to be configured in WorkVisual. (>>> "Configuring ServoGun options in WorkVisual" Page 27) Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 41 / 125

42 Parameter ThicknessTolTimer WeldTimeTimer Where is the value for the permissible thickness tolerance to come from? TRUE: The robot controller obtains the value from the weld timer. Note: If TRUE is selected, additional settings must be made in EG_EXTERN.DAT. (>>> "Configuring details for ServoGun options" Page 42) FALSE: The user defines the value via the inline form. Meaning of the tolerance: for example, if the thickness is 20 mm and the tolerance is 3 mm, then the total thickness may lie between 17 and 23 mm. Note: This parameter is reserved for future use in combination with KUKA.RoboSpin. KUKA.RoboSpin is not yet available for use with ServoGun TC. The parameter is currently without meaning. Where is the value for the spin time to come from? FALSE: The user defines the value via the inline form. TRUE: The robot controller obtains the value for the duration of the welding process from the weld timer. An offset is added to this value. This results in the spin time. Note: If TRUE is selected, additional settings must be made in EG_EXTERN.DAT. (>>> "Configuring details for ServoGun options" Page 42) Configuring details for ServoGun options If one or more of the following settings were made, further details must be configured here: Force from timertrue (ForceTimer TRUE) Thickness from Timer TRUE (ThicknessTimer TRUE) ThicknessTolTimer TRUE WeldTimeTimer TRUE Precondition Expert user group Procedure 1. In the Navigator, open the file EG_EXTERN.DAT in the directory R1\TP\ServoGun_TC. 2. Open the fold Data from timer. 3. Configure the variables as required. 4. Close the file. Respond to the request for confirmation asking whether the changes should be saved by pressing Yes. 42 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

43 6 Start-up and configuration Details for Force from timer TRUE (ForceTimer TRUE) Variable EG_NEW_TIMER EG_INVALID_PRGNR EG_INVALID_FORCE EG_FORCE_TMR_START_ IN EG_FORCE_TMR_END_IN EG_FORCE_TMR_IN_ EG_FORCE_TMR_SCALE Type: BOOL It must be specified here whether the weld timer supplies a Valid bit. TRUE (default): Valid bit FALSE: No Valid bit (>>> "Obtaining values from the weld timer without Valid bit sequence" Page 44) Type: INT Only relevant if EG_NEW_TIMER == FALSE. Dummy program number. Must not be identical to any of the real program numbers in the weld timer. Default: 0 Type: REAL Only relevant if EG_NEW_TIMER == FALSE. Reference force for the dummy force Must be greater than the dummy force. Must be less than the smallest real force. Default: 0.1 (kn) Type: INT The weld timer documentation must be consulted to determine the outputs used for communicating the force values. The input range of the robot controller that is assigned to these outputs must be specified for each gun: EG_FORCE_TMR_START_IN[x]: Start bit for gun number x EG_FORCE_TMR_END_IN[x]: End bit for gun number x Type: Signal The weld timer documentation must be consulted to determine the outputs available for communicating the forces. The input range of the robot controller that is assigned to these outputs must be specified in EG_FORCE_TMR_IN_. Type: REAL Scale factor for the force values The robot controller always interprets the force values as values in kn. The scale factor enables the values supplied by the weld timer to be correctly converted if this is necessary. The value of the scale factor depends on the transmission width of the signal, the scale factor of the weld timer, and the unit for values in the weld timer. Default: Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 43 / 125

44 Variable EG_FORCE_TMR_OFFSE T EG_FORCE_MAX EG_FORCE_MIN Type: REAL The robot controller adds this value to the force value supplied by the weld timer. Sequence: 1. The robot controller first adds the offset (EG_FORCE_TMR_OFFSET) to the value from the timer. 2. It then converts the result using the scale factor (EG_FORCE_TMR_SCALE). Default: 0.0 Type: REAL Maximum value for the force Default: 4,000 N Type: REAL Minimum value for the force Default: 500 N ForceTimer TRUE with DualForce The robot controller checks whether the force value supplied by the timer changes between the start and end of welding. If so, it adapts the gun force to the second value. This is done provided that a DualForce inline form has been used in the program. If the force from the timer changes, but an inline form for a regular weld spot has been used in the program, then the robot controller ignores the change and maintains the first force until the end of welding Obtaining values from the weld timer without Valid bit sequence The following sequence applies if EG_NEW_TIMER == FALSE. 1. In the advance run, the robot controller sends a dummy program number to the weld timer before each weld spot. A dummy force must be defined for this number in the weld timer. 2. The weld timer sends the dummy force to the robot controller. 3. The robot controller compares the dummy force with the reference force. If the reference force is greater, the robot controller sends the real program number to the weld timer. 4. The weld timer sends the real force to the robot controller (and any further values obtained from the weld timer). 5. The robot controller compares the real force with the reference force. If the reference force is smaller, the robot controller reads in the real force. 6. The robot controller compares the real force with the permissible maximum force (= value of the configuration parameter Maximum gun force in kn). If the maximum force is greater or equal, the robot controller uses the real force (and any further values obtained) for this weld spot. The exchange and comparison of the dummy values serves to avoid communication errors between the robot controller and the weld timer, e.g. due to transmission delays. 44 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

45 6 Start-up and configuration Details for Thickness from Timer TRUE (ThicknessTimer TRUE) Variable EG_THICK_TMR_START_I N EG_THICK_TMR_END_IN EG_THICK_TMR_SCALE EG_THICK_MAX EG_THICK_MIN Type: INT The weld timer documentation must be consulted to determine the outputs used for communicating the thickness values. The input range of the robot controller that is assigned to these outputs must be specified for each gun: EG_THICK_TMR_START_IN[x]: Start bit for gun number x EG_THICK_TMR_END_IN[x]: End bit for gun number x Type: REAL Scale factor for the thickness values The robot controller always interprets the thickness values as values in mm. The scale factor enables the values supplied by the weld timer to be correctly converted if this is necessary. The value of the scale factor depends on the transmission width of the signal, the scale factor of the weld timer, and the unit for values in the weld timer. Default: 0.1 Type: REAL Maximum value for the thickness Default: 25.0 mm Type: REAL Minimum value for the thickness Default: 0.1 mm Details for ThicknessTolTimer TRUE Variable EG_THICKTOL_TMR_STA RT_IN EG_THICKTOL_TMR_END _IN Type: INT The weld timer documentation must be consulted to determine the outputs used for communicating the thickness tolerance values. The input range of the robot controller that is assigned to these outputs must be specified for each gun: EG_THICKTOL_TMR_START_IN[x]: Start bit for gun number x EG_THICKTOL_TMR_SCA LE EG_THICKTOL_TMR_END_IN[x]: End bit for gun number x Type: REAL Scale factor for the thickness tolerance values The robot controller always interprets the values as values in mm. The scale factor enables the values supplied by the weld timer to be correctly converted if this is necessary. The value of the scale factor depends on the transmission width of the signal, the scale factor of the weld timer, and the unit for values in the weld timer. Default: 1.0 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 45 / 125

46 Variable EG_THICKTOL_MIN EG_THICKTOL_MAX Type: REAL Minimum value for the thickness tolerance Default: 0.1 mm Type: REAL Maximum value for the thickness tolerance Default: 25.0 mm Details for WeldTimeTimer TRUE These parameters are reserved for future use in combination with KUKA.RoboSpin. KUKA.RoboSpin is not yet available for use with ServoGun TC. The parameters is currently without meaning. Variable EG_WELDTIME_TMR_STA RT_IN EG_WELDTIME_TMR_EN D_IN EG_WELDTIME_TMR_SC ALE EG_WELDTIME_MIN EG_WELDTIME_MAX EG_WELDTIME_OFFSET Type: INT The weld timer documentation must be consulted to determine the outputs used for communicating the weld time values. The input range of the robot controller that is assigned to these outputs must be specified for each gun: EG_WELDTIME_TMR_START_IN[x]: Start bit for gun number x EG_WELDTIME_TMR_END_IN[x]: End bit for gun number x Type: REAL Scale factor for the weld time values The robot controller always interprets the values as values in ms. The scale factor enables the values supplied by the weld timer to be correctly converted if this is necessary. The value of the scale factor depends on the transmission width of the signal, the scale factor of the weld timer, and the unit for values in the weld timer. Default: 1.0 Type: REAL Minimum value for the weld time Default: 100 ms Type: REAL Maximum value for the weld time Default: 4600 ms Type: REAL Default: -96 ms 6.6 Manual gun mastering A gun must be mastered in the following cases: Commissioning a gun (first mastering) After exchanging gun components After a loss of mastering Precondition Operating mode T1 46 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

47 6 Start-up and configuration New electrode tips are fitted on the gun. damage the gun. Used electrodes must not be used in this case, as this would result in an incorrect mastering value. This could Procedure 1. Close the gun manually with the jog keys until the electrodes are just touching. The gun must not exert any force, otherwise it may become damaged. Whether or not the electrodes are just touching can be ascertained by a visual check, or using a strip of paper held between the electrodes. (Close the gun until the strip of paper is lightly clamped.) 2. In the main menu, select Start-up > Master > Dial. A window opens. 3. In this window, select the external axis to be mastered and press the Master softkey. The axis is removed from the window. 4. Close the window. 6.7 Determining the gear ratio Precondition The gun is mastered. Operating mode T1 Procedure For C guns: The gear ratio generally corresponds to the screw pitch of spindle. 1. Consult the gun manufacturer s data sheet to find out the value for the screw pitch of spindle. 2. Enter the value in the Gear ratio box in the Gun parameters configuration screen and save. If no value for the spindle screw pitch is available from the manufacturer, the gear ratio can be determined using the same method as for X guns. For X guns: The gear ratio is the change in the opening width over 1 motor revolution. 1. Close the gun without exerting any force. 2. In the main menu, select Display > Actual position. The Cartesian actual position is displayed. 3. Press Axis-specific to display the axis-specific actual position. The gun position is displayed as 0 in the Motor [deg] column. 4. Open the gun manually until the value 360 is displayed in the Motor [deg] column. 5. Measure the distance between the electrodes. 6. Enter the distance in the Gear ratio box in the Gun parameters configuration screen and save. If the opening width of the gun is not large enough to be measured after one motor revolution, open the gun 2 or 3 motor revolutions before taking the measurement. Then divide the measured distance by the number of revolutions. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 47 / 125

48 6.8 Manually determining the thickness of the force gauge For correct calibration of a gun, the robot controller needs to know the thickness of the sensor plate on the force gauge used. The following methods can be used for determining the thickness and communicating it to the robot controller: Determine the thickness manually and enter the value in the configuration. Determine the thickness with the calibration program. (>>> "Determing the thickness of the force gauge" Page 49) Fig. 6-4: Measuring with the force gauge (example) Precondition The gun is mastered. Operating mode T1 Accessories Force gauge (if necessary, consult gun manufacturer for a suitable model.) Procedure 1. Set jog override to 3%. 2. Open the gun manually. 3. Place the force gauge on the fixed electrode. 4. Close the gun until the moving electrode just touches the sensor plate. 5. In the main menu, select Display > Actual position. A window opens. Then press the Axis-specific button. 6. In the Pos. [deg, mm] column, read off the position of the gun and note the value. 7. Open the gun and remove the force gauge. 8. Enter the value in the Thickness box on the configuration screen Configuration. 48 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

49 6 Start-up and configuration 6.9 Calibration overview Methods Programs Calibration Is used for 5P Initial calibration of the gun Can be used for recalibration, e.g. if the gun has been damaged and needs to be recalibrated. (>>> "5P calibration" Page 49) DualForce Initial calibration if DualForce commands are to be used during programming. DualForce calibration must be carried out after the 5P calibration. Recalibration: If DualForce commands are used and if the gun is recalibrated with 5P, another DualForce calibration must be carried out afterwards. (>>> "DualForce calibration" Page 55) 2P Recalibration Recalibration with 2P is faster than with 5P. 2P can also be used for recalibration if DualForce commands are used. Precondition: 2P can only be used, however, if the gun operates with a maximum of 2 different forces. If more forces are used, 5P calibration must be used. (>>> "2P calibration" Page 58) All calibration programs are located in the directory R1\Program\Calibration. Force gauge A force gauge is required for executing all calibration programs. (If necessary, consult the gun manufacturer for a suitable model.) T1/T2 All calibration programs can be executed in T1. If a fixed force gauge is used, 5P calibration can also be carried out in T2. (>>> "5P calibration in T2" Page 59) Warming up the motor The calibration programs start by displaying the temperature of the gun motor and offer the option of warming up the motor. Whether it is necessary to warm up the motor, and to what temperature, depends on the specific application. Recommendation: Warm the motor up to the temperature that it has during the welding process. Determing the thickness of the force gauge The calibration programs offer the option of determining the thickness of the force gauge. This is done before the actual calibration. If the user selects No, the robot controller uses the value of Thickness which is saved on the configuration screen Configuration. If the user selects Yes, the program determines the thickness. After this, it displays both the newly determined value and the value saved in the configuration. The user must then choose which value is to be used P calibration Step 1 Execute EG_1_Cal. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 49 / 125

50 Step 2 Execute EG_2_Recal. 3 Execute EG_3_Force Coarse calibration with EG_1_Cal The EG_1_Cal program calculates 2 characteristics on the basis of predefined motor torque values: Torque / force characteristic Force / gun flexion characteristic The EG_1_Cal program closes the gun and limits the motor torque to the predefined value M x. The resulting force is measured by the user with a force gauge. In a total of 5 measurements with values M 1 to M 5, 5 torque/force pairs are determined. These pairs are saved and added to the torque/force characteristic M/F, with interpolation of the intermediate values. Fig. 6-5: Torque / force characteristic M max M 1 M 5 F 1 F 5 F max M / F Maximum motor torque Predefined motor torques Forces F 1 to F 5 generated after force build-up for motor torques M 1 to M 5 Maximum closing force Torque / force characteristic The force / gun flexion characteristic is calculated from the force values, the motor position and the gear ratio. 50 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

51 6 Start-up and configuration Fig. 6-6: Force / gun flexion characteristic G F Gun flexion in mm Force in kn Precondition The value 5 P has been entered under Calibration method in the configuration screen Configuration. All values have been entered in the configuration screen Gun parameters. On the configuration screen Calibration 5 P, the desired values have been entered under Motor torque 1 in kn to Motor torque 5 in kn. The value Maximum gun force in kn has been entered in the configuration screen Calibration 5 P. The gun is mastered. Operating mode T1 Only necessary if the thickness of the force gauge is not to be determined using the program: The value Thickness has been entered in the configuration screen Configuration. Procedure If it becomes apparent during the measuring process that the maximum gun force will be exceeded at the next measuring step, the program must be aborted. If this is not done, the force gauge and/or gun may be damaged. On the configuration screen Calibration 5 P, lower values must be entered under Motor torque 1 in kn to Motor torque 5 in kn. Then restart the program. 1. Select and start the program EG_1_Cal. 2. If more than one gun is configured, the following message is displayed: Please select the gun number. Select the gun. 3. The following message is displayed: The temperature of the ServoGun motor is {Current temperature} Celsius. Warm up? If No: Continue with step 4. If Yes: a. The message Programmed path reached (BCO) is displayed. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 51 / 125

52 Press the Start key. The gun closes to the mastering position and opens again. This is done 10 times in succession. b. The message Warm up? is displayed again with the current temperature that the motor has reached. Either select Yes again, if necessary. Or select No and continue with step The following message is displayed: Determine the thickness of the force gauge? If No: a. If the message Programmed path reached (BCO) is displayed: Press the Start key. b. Continue with step 5. If Yes: a. If the message Programmed path reached (BCO) is displayed: Press the Start key. b. The following message is displayed: Please insert the force sensor and press the Start key again. Confirm the message with OK and insert the force gauge. c. Press the Start key. The gun closes. When it detects the force gauge, it stops briefly and then opens again. d. A message displays the measured and the configured values. Select which value is to be used. 5. The following message is displayed: Please insert the force sensor and press the Start key again. Confirm the message with OK, insert the force gauge and press the Start key. The gun closes. 6. Follow the dialog messages and note the values of the 5 measurements. If the question as to whether the measurement is OK is answered with No, the controller repeats the measurement. 7. After the 5th measurement, the following message is displayed: Please remove the force sensor and press the Start key again. Confirm the message with OK, remove the force gauge and press the Start key. 8. The gun closes to the mastering position and the following message is displayed: Please check the gun mastering. Carry out a visual inspection of the mastering position and confirm the message with OK. The message must always be confirmed with OK. If the visual inspection was negative, e.g. because the position of the electrode tips has shifted, the gun must be remastered. 9. Press the Start key. The following message is displayed: Force calibration completed! 10. Confirm the message with OK and deselect the program. 11. The values noted must be entered on the Calibration 5 P configuration screen in Force 1 in kn to Force 5 in kn. The measured values should cover the force range of the gun. This is dependent on the gun. Guide values: Force 1 in kn: 0.7 kn 1.2 kn Force 5 in kn: Maximum force If the measured values are too low, EG_1_Cal must be restarted with higher motor torques. 52 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

53 6 Start-up and configuration Fine calibration with EG_2_Recal The EG_2_Recal program performs the same 5 measurements as EG_1_Cal, but closes the gun at a constant velocity. Fig. 6-7: Torque / force characteristic: F 5 now close to F max M max M 1 M 5 Maximum motor torque Predefined motor torques F 1 F 5 Resultant forces F 1 to F 5 F max M / F Maximum closing force Torque / force characteristic Precondition Calibration with EG_1_Cal has been carried out. Operating mode T1 Procedure 1. Select and start the program EG_2_Recal. 2. Continue in the same way as for EG_1_Cal. 3. After entering and saving the noted values on the Calibration 5 P configuration screen, repeat EG_2_Recal at least 2 more times. EG_2_Recal must be executed at least 3 times. Exception: If ServoGun TC 4.0 has been updated to ServoGun TC 4.1, then EG_2_Recal needs to be executed only once Force test with EG_3_Force This program checks the torque / force characteristic. A force sensor is placed in the gun. The user selects the force with which the gun is to be closed. The robot controller calculates the corresponding torque value from the torque / force characteristic, and closes the gun. When the electrodes touch the force gauge, the motor torque increases up to the permissible value and is limited to this value. The user now compares the measured force with the previously selected setpoint force. If the forces differ, the user must decide whether or not the deviation is acceptable for the given application. If not, another calibration must be carried out with EG_2_Recal. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 53 / 125

54 When assessing the deviation, the maximum forces that may be applied to the gun and the force gauge must also be taken into account. If the actual force is so much higher than the setpoint force that the force limits of the gun and/or the force gauge could be exceeded, then the gun must not be used with this calibration. Damage to property may otherwise result. Precondition Calibration with EG_1_Cal has been carried out. Operating mode T1 Procedure 1. Select and start the program EG_3_Force. 2. If more than one gun is configured, the following message is displayed: Please select the gun number. Select the gun. 3. The following message is displayed: The temperature of the ServoGun motor is {Current temperature} Celsius. Warm up? If No: Continue with step 4. If Yes: a. The message Programmed path reached (BCO) is displayed. Press the Start key. The gun closes to the mastering position and opens again. This is done 10 times in succession. b. The message Warm up? is displayed again with the current temperature that the motor has reached. Either select Yes again, if necessary. Or select No and continue with step The following message is displayed: Determine the thickness of the force gauge? If No: a. If the message Programmed path reached (BCO) is displayed: Press the Start key. b. Continue with step 5. If Yes: a. If the message Programmed path reached (BCO) is displayed: Press the Start key. b. The following message is displayed: Please insert the force sensor and press the Start key again. Confirm the message with OK and insert the force gauge. c. Press the Start key. The gun closes. When it detects the force gauge, it stops briefly and then opens again. d. A message displays the measured and the configured values. Select which value is to be used. 5. The following message is displayed: Enter the force, position the force sensor and press Start. Select a force using the corresponding button. Recommendation: Select the force which is closest to the process force. 6. Insert the force gauge and press the Start key. 7. The gun closes. Use the force gauge to measure the actual force exerted. 8. The following message is displayed again: Enter the force, position the force sensor and press Start.. 54 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

55 6 Start-up and configuration Either: If necessary, select and test another force. If necessary, test further forces in the same way. Or: To close the program, select any force (in order to clear the message). Then deselect the program DualForce calibration Step 1 Execute EG_4_DF_Cal. 2 Execute EG_5_DF DualForce calibration with EG_4_DF_Cal During welding in DualForce mode, the second force is addressed with position control (not torque control). To be able to calculate the position for the second force, the robot controller must know the spindle backlash. The program EG_4_DF_Cal is used to determine the spindle backlash. Precondition 5P calibration has been carried out. Operating mode T1 Procedure If it becomes apparent during the measuring process that the maximum gun force will be exceeded at the next measuring step, the program must be aborted. If this is not done, the force gauge and/or gun may be damaged. On the configuration screen Calibration 5 P, lower values must be entered under Motor torque 1 in kn to Motor torque 5 in kn. Then restart the program. 1. Select and start the program EG_4_DF_Cal. 2. If more than one gun is configured, the following message is displayed: Please select the gun number. Select the gun. 3. The message Programmed path reached (BCO) is displayed. Press the Start key. 4. The following message is displayed: The temperature of the ServoGun motor is {Current temperature} Celsius. Warm up? If No: Continue with step 5. If Yes: The gun closes to the mastering position and opens again. This is done 10 times in succession. The message Warm up? is displayed again with the current temperature that the motor has reached. Either select Yes again, if necessary. Or select No and continue with step The following message is displayed: Determine the thickness of the force gauge? If No: Continue with step 6. If Yes: a. The following message is displayed: Please insert the force sensor and press the Start key again. Confirm the message with OK and insert the force gauge. b. Press the Start key. The gun closes. When it detects the force gauge, it stops briefly and then opens again. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 55 / 125

56 c. A message displays the measured and the configured values. Select which value is to be used. d. Press Start. 6. The following message is displayed: Please insert the force gauge and press the Start key again. Note the value of the force gauge. Confirm the message with OK and insert the force gauge. 7. Press the Start key. The gun closes with 40% of the maximum force. Note the measured value. 8. The following message is displayed: Open the menu => Variable => Single and assign the measured force [kn] to the variable EG_FORCE_MEAS_1. Confirm the message with OK. 9. Assign the noted value to the variable EG_FORCE_MEAS_1 using the variable correction function. Enter the value in kn! 10. The following message is displayed again: Please insert the force gauge and press the Start key again. Note the value of the force gauge. Confirm the message with OK and insert the force gauge. 11. Press the Start key. The gun closes with 80% of the maximum force and then reduces the force to 40% (without any visible opening or closing). Measure and note the value for 40%. 12. The following message is displayed: Open the menu => Variable => Single and assign the measured force [kn] to the variable EG_FORCE_MEAS_2. Confirm the message with OK. 13. Assign the noted value to the variable EG_FORCE_MEAS_2 using the variable correction function. Enter the value in kn! 14. Press the Start key. The following message is displayed: The spindle backlash on reversal is {x} mm 15. Confirm the message with OK and press the Start key again. The program is finished and can be deselected DualForce force test with EG_5_DF The EG_5_DF program checks the torque / force characteristic for dual-force mode. The user selects the force with which the gun is to be closed. The user measures the force at the closed gun and compares the measured force with the previously selected setpoint force. If the forces differ, the user must decide whether or not the deviation is acceptable for the given application. If not, another calibration must be carried out with EG_4_DF_Cal. When assessing the deviation, the maximum forces that may be applied to the gun and the force gauge must also be taken into account. If the actual force is so much higher than the setpoint force that the force limits of the gun and/or the force gauge could be exceeded, then the gun must not be used with this calibration. Damage to property may otherwise result. Precondition Calibration with EG_4_DF_Cal has been carried out. Operating mode T1 Procedure 1. Select and start the program EG_5_DF. 2. If more than one gun is configured, the following message is displayed: Please select the gun number. 56 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

57 6 Start-up and configuration Select the gun. 3. The message Programmed path reached (BCO) is displayed. Press the Start key. 4. The following message is displayed: The temperature of the ServoGun motor is {Current temperature} Celsius. Warm up? If No: Continue with step 5. If Yes: The gun closes to the mastering position and opens again. This is done 10 times in succession. The message Warm up? is displayed again with the current temperature that the motor has reached. Either select Yes again, if necessary. Or select No and continue with step The following message is displayed: Determine the thickness of the force gauge? If No: Continue with step 6. If Yes is selected: a. The following message is displayed: Please insert the force sensor and press the Start key again. Confirm the message with OK and insert the force gauge. b. Press the Start key. The gun closes. When it detects the force gauge, it stops briefly and then opens again. c. A message displays the measured and the configured values. Select which value is to be used. d. Press Start. 6. The following message is displayed: Enter the desired higher force for the dual-force test. Select a force using the corresponding button. Recommendation: Select the force which is closest to the process force. 7. The following message is displayed: Enter the desired lower force for the dual-force test. Select a force using the corresponding button. 8. The following message is displayed: Please insert the force sensor and press the Start key again. Confirm the message with OK, insert the force gauge and press the Start key. The gun closes with the higher force. 9. The following message is displayed: Is the actual force {x} kn? Compare the value in the message with the value measured by the force gauge: If the values are the same or if the deviation is acceptable, confirm the message with Yes. Continue with step 10. If the deviation is not acceptable, select No and deselect the program. The gun must be recalibrated. 10. The gun now switches from the higher to the lower force (without any visible opening or closing). The following message is displayed: Is the actual force {x} kn? Once again, compare the value in the message with the value measured by the force gauge: If the values are the same or if the deviation is acceptable: Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 57 / 125

58 Hold on to the force gauge, as the gun opens during the next step. Confirm the message with Yes. The gun opens. Remove the force gauge. If the deviation is not acceptable, select No and deselect the program. The gun must be recalibrated P calibration Step 1 Execute EG_Recal_2_points. 2 Execute EG_Force_2_points Fine calibration with EG_Recal_2_points Precondition 5P calibration has been carried out. The value 2 P has been entered under Calibration method in the configuration screen Configuration. Operating mode T1 Expert user group Preparation 1. Enter the following values in the configuration screen Calibration 2 P: Maximum gun force in kn Target force in kn for Measure 1 and Measure 2 2. Press the Calculate button. In the two boxes Calculated torque in kn, the values are entered automatically from the torque / force characteristic. 3. Save changes and close the configuration. Procedure 1. Select and start the program EG_Recal_2_points. 2. If more than one gun is configured, the following message is displayed: Please select the gun number. Select the gun. 3. The message Programmed path reached (BCO) is displayed. Press the Start key. 4. Follow the dialog messages. The gun is closed at a constant velocity. During the force build-up, the motor torque is limited to the value in the box Calculated torque in kn. 5. Compare the value measured by the force gauge with the value from Target force in kn/measure 1. If the values match, confirm with OK. If the values do not match, modify the torque using the button + (plus) or - (minus) in order to approximate the actual force and target force. When the values match, confirm with OK. 6. Repeat step 5 for Target force in kn/measure Force test with EG_Force_2_points This program checks the torque / force characteristic. A force sensor is placed in the gun. The user selects the force with which the gun is to be closed. The robot controller calculates the corresponding torque value from the torque / force characteristic, and closes the gun. When the electrodes touch the force gauge, the motor torque increases up to the permissible value and is limited to this value. 58 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

59 6 Start-up and configuration The user now compares the measured force with the previously selected setpoint force. If the forces differ, the user must decide whether or not the deviation is acceptable for the given application. If not, another calibration must be carried out with EG_Recal_2_points. When assessing the deviation, the maximum forces that may be applied to the gun and the force gauge must also be taken into account. If the actual force is so much higher than the setpoint force that the force limits of the gun and/or the force gauge could be exceeded, then the gun must not be used with this calibration. Damage to property may otherwise result. Precondition Calibration with EG_Recal_2_points has been carried out. Operating mode T1 Procedure 1. Select and start the program EG_Force_2_points. 2. If more than one gun is configured, the following message is displayed: Please select the gun number. Select the gun. 3. The message Programmed path reached (BCO) is displayed. Press the Start key. 4. Follow the dialog messages. 5. Select the lowest force using the corresponding button. Use the force gauge to measure the actual force exerted. 6. Repeat step 5 for all forces P calibration in T2 If a fixed force gauge is used, 5P calibration can also be carried out in T2, instead of in T1. Advantage: Unlike in T1, the velocity is not limited in T2; this makes the calibration more precise. Disadvantage: As certain calibration steps have to be performed nonetheless in T1, it is necessary to switch to and fro between T2 and T1. Calibration in T2 is described below, using EG_1_Cal as an example. If the other 5P calibration programs are executed in T2, the switch between T1 and T2 must also be made accordingly. Calibration in T2 must only be carried out with a fixed force gauge. There must be no persons inside the safeguarded area during operation in T2 mode. Death to persons or severe injuries may otherwise result EG_1_Cal in T2 (without Warm-up, without Determine thickness ) Precondition As described for EG_1_Cal or the corresponding calibration program. In addition: EG_CAL_T1 = FALSE Accessories Fixed force gauge with portable stand (if necessary, consult gun manufacturer for a suitable model.) Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 59 / 125

60 Install the force gauge so that it has slight freedom of movement and can adapt its position to the gun when it closes. It is also possible to use a force gauge with a stand that has a fixed position in the cell (i.e. not portable). The procedure must then be checked and modified accordingly. Particular attention must be paid to the following points: The warm-up procedure and the checking of the mastering position must not be carried out at the force gauge. Damage to the gun and/or the force gauge may otherwise result. To move the gun to or from the force gauge, it is necessary to switch to T1 mode. Procedure If it becomes apparent during the measuring process that the maximum gun force will be exceeded at the next measuring step, the program must be aborted. If this is not done, the force gauge and/or gun may be damaged. On the configuration screen Calibration 5 P, lower values must be entered under Motor torque 1 in kn to Motor torque 5 in kn. Then restart the program. In addition to the messages cited in the procedure, the following messages are also displayed at a number of steps: Ackn. In T2 the robot can move faster than 250 mm/s Acknowledge to resume T2 operation with the set velocity. These messages must be acknowledged with OK. 1. Position the gun and the force gauge ready for the force measurement. 2. Select the program EG_1_Cal. 3. Set T2. a. The following message is displayed: Cartesian velocity is still limited in T2 b. Set the program override to 100%. The message is cleared. 4. Press the Start key. 5. If more than one gun is configured, the following message is displayed: Please select the gun number. Select the gun. 6. The following message is displayed: The temperature of the ServoGun motor is {Current temperature} Celsius. Warm up? Answer with No. 7. The following message is displayed: Determine the thickness of the force gauge? Answer with No. 8. The message Programmed path reached (BCO) is displayed. Press the Start key. 9. The following message is displayed: Please insert the force sensor and press the Start key again. Confirm the message with OK and press the Start key. The gun closes. 10. Follow the dialog messages and note the values of the 5 measurements. If the question as to whether the measurement is OK is answered with No, the controller repeats the measurement. 11. After the 5th measurement, the following message is displayed: Please remove the force sensor and press the Start key again. 60 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

61 6 Start-up and configuration 12. Remove the stand with the force gauge. 13. Confirm the message Please remove the force sensor and press the Start key again. with OK and press the Start key. The gun closes to the mastering position. 14. The message Please check the gun mastering. is displayed. Carry out a visual inspection of the mastering position and confirm the message with OK. The message must always be confirmed with OK. If the visual inspection was negative, e.g. because the position of the electrode tips has shifted, the gun must be remastered. 15. Press the Start key. The message Force calibration completed! is displayed. 16. Confirm the message with OK and deselect the program. 17. The values noted must be entered on the Calibration 5 P configuration screen in Force 1 in kn to Force 5 in kn. The measured values should cover the force range of the gun. This is dependent on the gun. Guide values: Force 1 in kn: 0.7 kn 1.2 kn Force 5 in kn: Maximum force If the measured values are too low, EG_1_Cal must be restarted with higher motor torques EG_1_Cal in T2 (with Warm-up, without Determine thickness ) Precondition As described for EG_1_Cal or the corresponding calibration program. In addition: EG_CAL_T1 = FALSE Accessories Fixed force gauge with portable stand (if necessary, consult gun manufacturer for a suitable model.) Install the force gauge so that it has slight freedom of movement and can adapt its position to the gun when it closes. It is also possible to use a force gauge with a stand that has a fixed position in the cell (i.e. not portable). The procedure must then be checked and modified accordingly. Particular attention must be paid to the following points: The warm-up procedure and the checking of the mastering position must not be carried out at the force gauge. Damage to the gun and/or the force gauge may otherwise result. To move the gun to or from the force gauge, it is necessary to switch to T1 mode. Procedure If it becomes apparent during the measuring process that the maximum gun force will be exceeded at the next measuring step, the program must be aborted. If this is not done, the force gauge and/or gun may be damaged. On the configuration screen Calibration 5 P, lower values must be entered under Motor torque 1 in kn to Motor torque 5 in kn. Then restart the program. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 61 / 125

62 In addition to the messages cited in the procedure, the following messages are also displayed at a number of steps: Ackn. In T2 the robot can move faster than 250 mm/s Acknowledge to resume T2 operation with the set velocity. These messages must be acknowledged with OK. 1. In T1, move the gun to a position that meets the following requirements: The gun can close here to the mastering position. The stand with the force gauge can be moved here later in order to carry out the force measurement. The force gauge must not yet be positioned at the gun. Damage to the gun and/or the force gauge may otherwise result. 2. Select the program EG_1_Cal. 3. Set T2. a. The following message is displayed: Cartesian velocity is still limited in T2 b. Set the program override to 100%. The message disappears. 4. Press the Start key. 5. If more than one gun is configured, the following message is displayed: Please select the gun number. Select the gun. 6. The following message is displayed: The temperature of the ServoGun motor is {Current temperature} Celsius. Warm up? Answer with Yes. The controller saves the current position of the gun and displays the message Programmed path reached (BCO). 7. Press the Start key. The gun closes to the mastering position and opens again to the saved position. This is done 10 times in succession. 8. The message Warm up? is displayed again with the current temperature that the motor has reached. Either select Yes again, if necessary. The motor continues to be warmed up. Or select No and continue with the next step. 9. The following message is displayed: Determine the thickness of the force gauge? Answer with No. 10. The following message is displayed: Please insert the force sensor and press the Start key again. Bring the stand with the force gauge to the gun. 11. Confirm the message with OK and press the Start key. The gun closes. 12. Follow the dialog messages and note the values of the 5 measurements. If the question as to whether the measurement is OK is answered with No, the controller repeats the measurement. 13. After the 5th measurement, the following message is displayed: Please remove the force sensor and press the Start key again. 14. Remove the stand with the force gauge. 15. Confirm the message Please remove the force sensor and press the Start key again. with OK and press the Start key. The gun closes to the mastering position. 62 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

63 6 Start-up and configuration 16. The message Please check the gun mastering. is displayed. Carry out a visual inspection of the mastering position and confirm the message with OK. The message must always be confirmed with OK. If the visual inspection was negative, e.g. because the position of the electrode tips has shifted, the gun must be remastered. 17. Press the Start key. The message Force calibration completed! is displayed. 18. Confirm the message with OK and deselect the program. 19. The values noted must be entered on the Calibration 5 P configuration screen in Force 1 in kn to Force 5 in kn. The measured values should cover the force range of the gun. This is dependent on the gun. Guide values: Force 1 in kn: 0.7 kn 1.2 kn Force 5 in kn: Maximum force If the measured values are too low, EG_1_Cal must be restarted with higher motor torques EG_1_Cal in T2 (without Warm-up, with Determine thickness ) Precondition As described for EG_1_Cal or the corresponding calibration program. In addition: EG_CAL_T1 = FALSE Accessories Fixed force gauge with portable stand (if necessary, consult gun manufacturer for a suitable model.) Install the force gauge so that it has slight freedom of movement and can adapt its position to the gun when it closes. It is also possible to use a force gauge with a stand that has a fixed position in the cell (i.e. not portable). The procedure must then be checked and modified accordingly. Particular attention must be paid to the following points: The warm-up procedure and the checking of the mastering position must not be carried out at the force gauge. Damage to the gun and/or the force gauge may otherwise result. To move the gun to or from the force gauge, it is necessary to switch to T1 mode. Procedure If it becomes apparent during the measuring process that the maximum gun force will be exceeded at the next measuring step, the program must be aborted. If this is not done, the force gauge and/or gun may be damaged. On the configuration screen Calibration 5 P, lower values must be entered under Motor torque 1 in kn to Motor torque 5 in kn. Then restart the program. In addition to the messages cited in the procedure, the following messages are also displayed at a number of steps: Ackn. In T2 the robot can move faster than 250 mm/s Acknowledge to resume T2 operation with the set velocity. These messages must be acknowledged with OK. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 63 / 125

64 1. Set T1. 2. Position the gun and the force gauge ready for the force measurement. 3. Select the program EG_1_Cal and press the Start key. 4. If more than one gun is configured, the following message is displayed: Please select the gun number. Select the gun. 5. The following message is displayed: The temperature of the ServoGun motor is {Current temperature} Celsius. Warm up? Answer with No. 6. The following message is displayed: Determine the thickness of the force gauge? Answer with Yes. 7. The message Programmed path reached (BCO) is displayed. Press the Start key. 8. The following message is displayed: Please insert the force sensor and press the Start key again.. Confirm the message with OK. 9. Press the Start key. The gun closes. When it detects the force gauge, it stops briefly and then opens again. 10. A message displays the measured and the configured values. Select which value is to be used. 11. The following message is displayed: Please insert the force sensor and press the Start key again.. Confirm the message with OK and press the Start key. 12. The following message is displayed: Please switch to 100% OV and T2 13. Set T2. a. The following message is displayed: Cartesian velocity is still limited in T2 b. Set the program override to 100%. The message disappears. 14. Confirm the message Please switch to 100% OV and T2 with OK and press the Start key. 15. Follow the dialog messages and note the values of the 5 measurements. If the question as to whether the measurement is OK is answered with No, the controller repeats the measurement. 16. After the 5th measurement, the following message is displayed: Please remove the force sensor and press the Start key again. 17. Remove the stand with the force gauge. 18. Confirm the message Please remove the force sensor and press the Start key again. with OK and press the Start key. The gun closes to the mastering position. 19. The message Please check the gun mastering. is displayed. Carry out a visual inspection of the mastering position and confirm the message with OK. The message must always be confirmed with OK. If the visual inspection was negative, e.g. because the position of the electrode tips has shifted, the gun must be remastered. 20. Press the Start key. The message Force calibration completed! is displayed. 21. Confirm the message with OK and deselect the program. 64 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

65 6 Start-up and configuration 22. The values noted must be entered on the Calibration 5 P configuration screen in Force 1 in kn to Force 5 in kn. The measured values should cover the force range of the gun. This is dependent on the gun. Guide values: Force 1 in kn: 0.7 kn 1.2 kn Force 5 in kn: Maximum force If the measured values are too low, EG_1_Cal must be restarted with higher motor torques EG_1_Cal in T2 (with Warm-up, with Determine thickness ) Precondition As described for EG_1_Cal or the corresponding calibration program. In addition: EG_CAL_T1 = FALSE Accessories Fixed force gauge with portable stand (if necessary, consult gun manufacturer for a suitable model.) Install the force gauge so that it has slight freedom of movement and can adapt its position to the gun when it closes. It is also possible to use a force gauge with a stand that has a fixed position in the cell (i.e. not portable). The procedure must then be checked and modified accordingly. Particular attention must be paid to the following points: The warm-up procedure and the checking of the mastering position must not be carried out at the force gauge. Damage to the gun and/or the force gauge may otherwise result. To move the gun to or from the force gauge, it is necessary to switch to T1 mode. Procedure If it becomes apparent during the measuring process that the maximum gun force will be exceeded at the next measuring step, the program must be aborted. If this is not done, the force gauge and/or gun may be damaged. On the configuration screen Calibration 5 P, lower values must be entered under Motor torque 1 in kn to Motor torque 5 in kn. Then restart the program. In addition to the messages cited in the procedure, the following messages are also displayed at a number of steps: Ackn. In T2 the robot can move faster than 250 mm/s Acknowledge to resume T2 operation with the set velocity. These messages must be acknowledged with OK. 1. In T1, move the gun to a position that meets the following requirements: The gun can close here to the mastering position. The stand with the force gauge can be moved here later in order to carry out the force measurement. The force gauge must not yet be positioned at the gun. Damage to the gun and/or the force gauge may otherwise result. 2. Select the program EG_1_Cal. 3. Set T2. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 65 / 125

66 a. The following message is displayed: Cartesian velocity is still limited in T2 b. Set the program override to 100%. The message disappears. 4. Press the Start key. 5. If more than one gun is configured, the following message is displayed: Please select the gun number. Select the gun. 6. The following message is displayed: The temperature of the ServoGun motor is {Current temperature} Celsius. Warm up? Answer with Yes. The controller saves the current position of the gun and displays the message Programmed path reached (BCO). 7. Press the Start key. The gun closes to the mastering position and opens again to the saved position. This is done 10 times in succession. 8. The message Warm up? is displayed again with the current temperature that the motor has reached. Either select Yes again, if necessary. The motor continues to be warmed up. Or select No and continue with the next step. 9. The following message is displayed: Determine the thickness of the force gauge? Answer with Yes. 10. The following message is displayed: Please switch to 100% OV and T1. Set T Press OK to confirm the message Please switch to 100% OV and T1 and press the Start key. 12. The following message is displayed: Please insert the force sensor and press the Start key again.. Bring the stand with the force gauge to the gun. 13. Confirm the message with OK and press the Start key. The gun closes. When it detects the force gauge, it stops briefly and then opens again. 14. A message displays the measured and the configured values. Select which value is to be used. 15. Press the Start key. The following message is displayed: Please insert the force sensor and press the Start key again.. Caution! Do not press OK and do not press the Start key! 16. Set T2. a. The following message is displayed: Cartesian velocity is still limited in T2 b. Set the program override to 100%. The message disappears. 17. Press the Start key. 18. Follow the dialog messages and note the values of the 5 measurements. If the question as to whether the measurement is OK is answered with No, the controller repeats the measurement. 19. After the 5th measurement, the following message is displayed: Please remove the force sensor and press the Start key again. Caution! Do not press OK and do not press the Start key! 20. Remove the stand with the force gauge. 66 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

67 6 Start-up and configuration 21. Confirm the message Please remove the force sensor and press the Start key again. with OK and press the Start key. The gun closes to the mastering position. 22. The message Please check the gun mastering. is displayed. Carry out a visual inspection of the mastering position and confirm the message with OK. The message must always be confirmed with OK. If the visual inspection was negative, e.g. because the position of the electrode tips has shifted, the gun must be remastered. 23. Press the Start key. The message Force calibration completed! is displayed. 24. Confirm the message with OK and deselect the program. 25. The values noted must be entered on the Calibration 5 P configuration screen in Force 1 in kn to Force 5 in kn. The measured values should cover the force range of the gun. This is dependent on the gun. Guide values: Force 1 in kn: 0.7 kn 1.2 kn Force 5 in kn: Maximum force If the measured values are too low, EG_1_Cal must be restarted with higher motor torques Determining the asymmetrical flexion of X guns It is only necessary to determine the offset for X guns with the option Robot compensation. With X guns, it is possible that the upper and lower gun arms may have different flexion rates when the gun is closed under force. This means that the point at which welding is carried out no longer corresponds to the taught point. So that the software can compensate for this, the offset must be measured and entered in the configuration. Precondition New electrode tips are fitted on the gun. Means of marking the position of the closing point Operating mode T1 Procedure There must be nothing between the electrodes. 1. Close the gun manually, ensuring that no force is exerted. 2. Mark the height at which the closing point of the electrodes lies. 3. Select the program EG_6_Asym_Bend. 4. Start the program. The gun closes with the maximum force. 5. Measure how far the closing point has moved from the mark. At the same time, hold down the enabling switch! Also note whether it has shifted in the TCP direction or in the opposite direction. 6. Enter the distance value in the Maximum comp. box in the AsymBend compensation area of the configuration screen Configuration. The direction of the offset must be specified via the sign: If the closing point has shifted in the TCP direction: Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 67 / 125

68 Enter the value without sign. If the closing point has shifted in the opposite direction from the TCP direction: Enter the value with negative sign. 7. Activate or deactivate compensation, as required, in the Compensation active box. Example Fig. 6-8: Example: Without force with force Item 1 Closed electrodes, without force 2 Moving electrode 3 Mark The mark is at the same height as the closing point. 4 Closed electrodes, now with force In this example, the closing point has shifted in the negative TCP direction due to the application of the force. (>>> 6.3 "TCP calibration and tool direction" Page 29) 5 Caliper gauge The caliper gauge is used to measure the difference between the mark and the current height of the closing point Determining the sliding effect with X guns The offset can be determined for X guns with oblique electrode shanks. This offset does not occur with other guns. On X guns with oblique electrode shanks, the electrodes can shift when the gun is closed under force. This means that the point at which welding is carried out no longer corresponds to the taught point. So that the software can compensate for this, the offset must be measured and entered in the configuration. Precondition New electrode tips are fitted on the gun. Means of marking the position of the closing point Operating mode T1 Procedure There must be nothing between the electrodes. 1. Close the gun manually, ensuring that no force is exerted. 2. Mark the position of the closing point. 68 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

69 6 Start-up and configuration 3. Select the program EG_7_Sliding. 4. Start the program. The gun closes with the maximum force. 5. Measure how far the closing point has moved from the mark. At the same time, hold down the enabling switch! In addition, note the direction in which it has moved (relative to the TOOL coordinate system). 6. Enter the values in the boxes Maximum comp. and Direction in the X- Compensation area of the configuration screen Configuration. 7. Activate or deactivate compensation, as required, in the Compensation active box Setting the software limit switches The positive and negative software limit switches for the gun (external axis) must be set. This limits the stroke of the gun Setting the negative software limit switch Precondition Expert user group The gun is mastered. The gear ratio has been entered. The gun is calibrated. New electrode tips Do not open the gun all the way. If in doubt, stop a little earlier. Damage to property may otherwise result. Procedure 1. Determine the value for the negative software limit switch: a. Open the gun until it is almost completely open. b. In the main menu, select Display > Variable > Overview > Display. Note the value of the Position variable. c. Value sought = value of Position variable + reserve (recommended: height of 2 motor revolutions) 2. Enter this value in the Gun parameters configuration screen under Software limit (mm) and save. Alternative procedure 1. Take the value from the gun data sheet, and enter and save it in the Gun parameters configuration screen under Software limit (mm). 2. Check that the value is correct. To do this, open the gun manually and observe whether it stops automatically at the point corresponding to the entered value, before reaching the stop. If the gun does not stop automatically, stop manual motion before the stop is reached. The value from the data sheet is not correct. The positive limit switch must be determined as described in the first procedure Setting the positive software limit switch Precondition Expert user group The gun is mastered. The gear ratio has been entered. The gun is calibrated. New electrode tips Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 69 / 125

70 Procedure 1. Calculate the value for the positive software limit switch: Max. flexion (mm) + Tip wear (burn-off) + reserve (approx. 3 mm) The values can be taken from the following sources: Max. flexion (mm): configuration screen Gun parameters Tip wear (burn-off): configuration screen Configuration Reserve: This value can be chosen freely as required. Guide value: 3 mm 2. Enter the calculated value in the Gun parameters configuration screen under Software limit (mm) and save Tip initialization overview During tip initialization, the current electrode burn-off is measured and saved. This enables the gun opening to be automatically adapted to the burn-off. The gun opening is adapted to the current burn-off if the parameter TCP correction is set to On in the configuration screen Configuration. There are 2 types of tip initialization: First initialization Must be carried out in the following cases: During commissioning Every time the electrode tips are exchanged Cyclical initialization Cyclical initialization must be carried out after tip dressing. Overview Initialization is performed via a KRL program. Depending on the ServoGun option selected in WorkVisual, it can also be performed via status key instead. ServoGun option First initialization Cyclical initialization Pneumatic Robot compensation (>>> "First initialization via status key" Page 70) with Ratio in % Robot compensation with Individual measurement (>>> "Programming first initialization (Pneumatic option with Ratio in %)" Page 87) (>>> "Programming first initialization (Individual measurement option)" Page 89) (>>> "Cyclical initialization via status key" Page 71) (>>> "Programming cyclical initialization (Individual measurement option)" Page 91) If EqualizingTech is installed, the descriptions for the Pneumatic option must be used First initialization via status key Precondition Operating mode T1 or T2 The gun is mastered. The gun is calibrated. New electrode tips are fitted on the gun. The value First Init force has been entered in the configuration screen Configuration. 70 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

71 6 Start-up and configuration Procedure 1. Set program override to 100%. 2. Open the gun manually at least 10 mm. 3. Hold down the enabling switch. 4. Press the status key First initialization. First initialization is performed: Sequence With this first initialization, the following occurs: The gun closes at a constant velocity until the first initialization force is reached. The electrode tips are pressed firmly onto the electrodes. The gun opens. The gun closes twice with initialization force. The robot controller saves the current tip wear in EG_WEAR[]. The variable EG_WORN is set to FALSE. The output New electrodes is set and reset Cyclical initialization via status key Precondition T1 or T2 operating mode The gun is mastered. The gun is calibrated. First initialization has been performed. Procedure 1. Set program override to 100%. 2. Open the gun manually at least 10 mm. 3. Hold down the enabling switch. 4. Press the Cyclical initialization status key. Cyclical initialization is carried out. Sequence With this cyclical initialization, the following occurs: The gun closes twice with initialization force. The robot controller saves the current tip wear in EG_WEAR[]. It generates a message if the current wear is greater than the maximum permissible wear (EG_WEAR_MAX). The electrode tips must then be exchanged Controller parameters overview The controller tool can be used to determine and optimize the motor-specific and gun-specific controller parameters for PTP and CP motions. The parameters must be determined in the following order: Step Parameter / description 1 Proportional factor of the speed controller for PTP and CP motions VEL GAIN (Speed controller gain) 2 Integration time constant of the speed controller for PTP and CP motions VEL INT TIME (Reset time of speed controller) 3 Position control gain for PTP and CP motions POS GAIN (Position controller gain) Sequence The controller tool calls up programs which execute a defined motion profile cyclically with the active weld gun. At each program cycle, the parameter is increased by the defined increment ( step size ), starting from the lower limit and Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 71 / 125

72 continuing until the upper limit is reached. The entire sequence for a parameter is recorded as a measurement curve (trace). While the parameters for the position and speed controllers are being determined, the axis of the active gun moves between a position before the negative software limit switch and the mastering position Optimizing the parameters for the speed and position controllers Precondition The weld gun is fully configured. The software limit switches have been set. The weld gun is mastered. The gun has been calibrated. The gear ratio has been entered. Operating mode T2 Procedure 1. In the main menu, select Configuration > ServoGun controller param.. The Servo Gun parameter finding window is opened. (>>> " Servo Gun parameter finding window" Page 73) 2. Fill out the following boxes: Gun number:, Motor type, Gun type and Stiffness. 3. Fill out the following boxes: Lower limit, Upper limit and Steps. 4. Press button Motor param.. The program EG_SET_MOTOR_PARAM is selected. 5. Set program override to 100% and execute the program up to the first HALT. If the program override is not set to 100%, the measurements will be incorrect. 6. In the main menu, select Configuration > ServoGun controller param.. 7. Select the menu sequence Trace > VEL GAIN. The measurement curve for VEL GAIN opens. 8. Read and note the value of VEL GAIN from the measurement curve. (VEL GAIN = half the value at which the motor current begins to oscillate.) 9. Close the measurement curve and enter the determined value in the Servo Gun parameter finding in the following box: VEL GAIN (Speed controller gain). Then press Save values. 10. Close the Servo Gun parameter finding window and execute the selected program until the next HALT. 11. In the main menu, select Configuration > ServoGun controller param Select the menu sequence Trace > VEL INT TIME. The measurement curve for VEL INT TIME opens. 13. Read and note the value of VEL INT TIME from the measurement curve. (VEL INT TIME = value with the smallest following error at standstill.) 14. Close the measurement curve and enter the determined value in the Servo Gun parameter finding in the following box: VEL INT TIME (Reset time of speed controller). Then press Save values. 15. Close the Servo Gun parameter finding window and execute the selected program until the next HALT. 16. In the main menu, select Configuration > ServoGun controller param Select the menu sequence Trace > POS GAIN. The measurement curve for POS GAIN opens. 18. Read and note the value of POS GAIN from the measurement curve. (POS GAIN = half the value at which the motor current begins to oscillate.) 72 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

73 6 Start-up and configuration 19. Close the measurement curve and enter the determined value in the Servo Gun parameter finding in the following box: POS GAIN (Position controller gain). Then press Save values. 20. Close the Servo Gun parameter finding window and execute the selected program through to the end. The PTP parameters are automatically saved in addition as CP parameters. The values are also displayed in the configuration screen Gun parameters. If the values are changed there, the change is transferred to the Servo Gun parameter finding window, and vice versa Servo Gun parameter finding window Fig. 6-9: Servo Gun parameter finding window 1 Table 2 Enter the determined parameters here. The following buttons are available: Button Motor param. Trace > [controller_parameter] Selects the program EG_SET_MOTOR_PARAM. This program is used to determine the parameters for the speed and position controllers. Only available to the user group Expert or higher. Opens the measurement curve for the selected parameter. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 73 / 125

74 Button Table > Load table Table > Discard table Save table Save values Only available to the user group Expert or higher. Loads the default values for the following parameters: Lower limit, Upper limit, Steps The default values depend on what is selected in the following boxes: Motor type, Gun type, Stiffness Only available to the user group Expert or higher. Discards the current entries in the following boxes: Lower limit, Upper limit, Steps. Instead, the most recently saved values are displayed. Saves the following values: Lower limit, Upper limit, Steps Saves the entered values. 74 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

75 7 Programming 7 Programming 7.1 Inline forms overview Inline form SPOT DualForce INIT TippDress ServoGun Decouple ServoGun Couple Background tip dressing Background welding Programming a weld spot with/without EqualizingTech (>>> 7.3 "Programming a weld spot" Page 76) (>>> 7.4 "Programming a weld spot with EqualizingTech" Page 80) Programming a dual-force weld spot: The weld is started with a defined force and finished with a different force. (>>> 7.5 "Programming a DualForce weld spot" Page 81) (>>> 7.6 "Programming a DualForce weld spot with Equalizing- Tech" Page 85) Measuring and saving the current wear. (>>> 6.13 "Tip initialization overview" Page 70) Tip dressing with/without EqualizingTech (>>> 7.8 "Programming tip dressing" Page 92) (>>> 7.9 "Programming tip dressing with EqualizingTech" Page 96) Decoupling the gun (>>> 7.10 "Inline form ServoGun Decouple" Page 97) Coupling the gun (>>> 7.11 "Inline form ServoGun Couple" Page 98) Only with stationary guns: Enabling asynchronous tip dressing Enabling asynchronous welding (only for test welding without a real workpiece) (>>> 7.12 "Programming background tip dressing or welding" Page 98) 7.2 Instructions for programming General Welding is possible in all modes. Welding in T1 can be deactivated via EG_T1_OPEN_MOVE if necessary. (>>> 9 "Variables" Page 109) In T1, the velocity is reduced. For this reason, the forces attained during welding in T1 may fall significantly below the target force. This is especially the case with low target forces. Exception: With the Pneumatic option, the gun is closed asynchronously in T1. It closes with the same velocity as in T2; this ensures that the target force is also achieved in T1. If required, this functionality can be deactivated via EG_SPOT_ASYNC_T1 = FALSE. In all operating modes, an override less than 100% can cause the attained forces to fall significantly below the target force. The program override is automatically 100%, however, when the gun is closed under force, i.e. the gun reaches its target force. If required, this functionality can be deactivated via EG_SET_OV_100 = FALSE. In this case, the set program override applies even when the gun is closed under force. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 75 / 125

76 Weld programs can only be executed in the program run mode #GO. #MSTEP and #ISTEP are not possible. Equalizing Collision detection == FALSE RoboTeam Weld spots and tip dressing points that were taught without Equalizing must not be used with Equalizing. Weld spots and tip dressing points that were taught with Equalizing must not be used without Equalizing. If such existing points are to be reused, they must be retaught. Damage to the gun or the workpiece may otherwise result. With the following points, the value False must be selected for Collision detection: All weld spots All tip dressing points All PTP, LIN or CIRC points followed by an INIT New or INIT Same. Point INIT New (Individual measurement option) The following settings are recommended for working with RoboTeam. EG_SET_OV_100 = FALSE EG_SPOT_ASYNC_T1 = FALSE EG_T1_OPEN_MOVE =TRUE Instructions for use of stationary guns The descriptions regarding programming refer to guns mounted on the robot flange. For stationary guns, the programming must be adapted accordingly. Aspects requiring special consideration: In the option window Frames the interpolation mode must be set to True, indicating that a stationary gun is being used. This concerns the following inline forms: SPOT DualForce INIT, New (Individual measurement option) TippDress With the Individual measurement option, it must be taken into account for first initialization that the plate has to be brought to the gun. 7.3 Programming a weld spot This description refers to ServoGun without EqualizingTech. If EqualizingTech is installed, the relevant description must be used: (>>> 7.4 "Programming a weld spot with EqualizingTech" Page 80) Distances The following distances are required for the position of the gun during teaching. For the Pneumatic option: Electrode Moving electrode Fixed electrode Gun opening Distance from workpiece Min. 15 mm Max. 5 mm Must be at least 4 mm away from the negative software limit switch. 76 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

77 7 Programming For the Robot compensation option: Electrode Moving electrode Fixed electrode Gun opening Distance from workpiece Min. 15 mm 0 mm The fixed electrode must be in direct contact with the workpiece, without exerting any force on it. Must be at least 4 mm away from the negative software limit switch. Procedure 1. Position the gun on the desired weld spot. Observe the required distances. 2. Select the menu sequence Commands > ServoTech > SPOT and then select the desired motion type. 3. Set the parameters in the inline form. (>>> "Inline form SPOT (Pneumatic option)" Page 77) (>>> "Inline form SPOT (Robot compensation option)" Page 78) 4. Press Cmd OK to save the instruction Inline form SPOT (Pneumatic option) Item 1 Motion type Fig. 7-1: SPOT (Pneumatic option) PTP, LIN or CIRC 2 Only for CIRC motions: Auxiliary point 3 Name of the end point (>>> 7.13 "Option window Frames " Page 99) Only with the option Point name: The last 7 characters (= default number) must be digits. The robot controller communicates these digits to the weld timer as the program number. The number of relevant final characters can be configured in the parameter Number of entities. Vel [ ] [ ] Velocity PTP: % For LIN or CIRC: m/s 4 Name for the motion data set. The system automatically generates a name. The name can be overwritten. (>>> 7.14 "Option window: Motion parameters (PTP)" Page 100) (>>> 7.15 "Option window: Motion parameters (LIN, CIRC)" Page 101) Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 77 / 125

78 Item ProgNr Program number for the weld timer ServoGun This box is only displayed if the Program number option is configured. Active gun 1 6 Cont CLS OPN: Approximate positioning during closing and opening motions Part Force OPN: Approximate positioning during opening motion CLS: Approximate positioning during closing motion [blank]: Without approximate positioning Total thickness of the workpieces to be welded mm This box is only displayed if the option Thickness from Timer FALSE is configured. Closing force of the gun Maximum value: Value of the configuration parameter Maximum gun force in kn This box is only displayed if the option Force from timer FALSE is configured. Comp 0: Without compensation Trigger WeldTimer 1: Compensator 1 2: Compensator 2 1+2: Compensators 1 and 2 Distance after which compensation is deactivated on opening the gun Weld parameters (>>> 7.16 "Option window Weld timer parameters " Page 102) This box is only displayed if at least one of the following options has been configured: Force from timer TRUE, Thickness from Timer TRUE, Thickness- TolTimer TRUE, WeldTimeTimer TRUE Inline form SPOT (Robot compensation option) Fig. 7-2: SPOT (Robot compensation option) Item 1 Motion type PTP, LIN or CIRC 2 Only for CIRC motions: Auxiliary point 78 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

79 7 Programming Item 3 Name of the end point (>>> 7.13 "Option window Frames " Page 99) Only with the option Point name: The last 7 characters (= default number) must be digits. The robot controller communicates these digits to the weld timer as the program number. The number of relevant final characters can be configured in the parameter Number of entities. Vel [ ] [ ] Velocity PTP: % For LIN or CIRC: m/s 4 Name for the motion data set. The system automatically generates a name. The name can be overwritten. (>>> 7.14 "Option window: Motion parameters (PTP)" Page 100) (>>> 7.15 "Option window: Motion parameters (LIN, CIRC)" Page 101) ProgNr Program number for the weld timer ServoGun This box is only displayed if the Program number option is configured. Active gun 1 6 Cont CLS OPN: Approximate positioning during closing and opening motions Part OPN: Approximate positioning during opening motion CLS: Approximate positioning during closing motion [blank]: Without approximate positioning Total thickness of the workpieces to be welded mm Force ApproxDist This box is only displayed if the option Thickness from Timer FALSE is configured. Closing force of the gun Maximum value: Value of the configuration parameter Maximum gun force in kn This box is only displayed if the option Force from timer FALSE is configured. Correction of the gun position by the robot between the weld spots. This means of compensation can be used, for example, if the gun would scratch the panel when moving from one weld spot to the next. The position is corrected in the negative tool direction mm Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 79 / 125

80 Item SpotOffset WeldTimer Correction of the gun position by the robot at the weld spot. This means of compensation can be used, for example, if the original panel thickness has changed due to molten material. Positive value: The position is corrected in the tool direction. Negative value: The position is corrected in the negative tool direction mm Weld parameters (>>> 7.16 "Option window Weld timer parameters " Page 102) This box is only displayed if at least one of the following options has been configured: Force from timer TRUE, Thickness from Timer TRUE, Thickness- TolTimer TRUE, WeldTimeTimer TRUE 7.4 Programming a weld spot with EqualizingTech Distances The following distances are required for the position of the gun during teaching: Distance Fixed electrode Gun opening Value No distance from the workpiece; must be in contact with the workpiece. Must be at least 4 mm away from the negative software limit switch. Procedure 1. Position the gun on the desired weld spot. Observe the required distances. 2. Select the menu sequence Commands > ServoTech > SPOT and then select the desired motion type. 3. Set the parameters in the inline form. (>>> "Inline form SPOT (EqualizingTech option)" Page 80) 4. Press Cmd OK to save the instruction. Sequence Program sequence for welding: When approaching points, the robot maintains a certain distance from the workpiece so that the fixed electrode does not scrape against the workpiece. The user can configure this distance (for all weld spots for the gun) via the REAL variable EG_TOUCH_DIFF[] in the file EG_EXTERN.DAT. Default setting: 3 mm. The actual opening width of the gun at the point is the sum of the taught opening width and this distance Inline form SPOT (EqualizingTech option) Fig. 7-3: SPOT (EqualizingTech option) 80 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

81 7 Programming Item 1 Motion type PTP, LIN or CIRC 2 Only for CIRC motions: Auxiliary point 3 Name of the end point (>>> 7.13 "Option window Frames " Page 99) Only with the option Point name: The last 7 characters (= default number) must be digits. The robot controller communicates these digits to the weld timer as the program number. The number of relevant final characters can be configured in the parameter Number of entities. Vel [ ] [ ] Velocity PTP: % For LIN or CIRC: m/s 4 Name for the motion data set. The system automatically generates a name. The name can be overwritten. (>>> 7.14 "Option window: Motion parameters (PTP)" Page 100) (>>> 7.15 "Option window: Motion parameters (LIN, CIRC)" Page 101) ProgNr Program number for the weld timer ServoGun This box is only displayed if the Program number option is configured. Active gun 1 6 Cont CLS OPN: Approximate positioning during closing and opening motions Part OPN: Approximate positioning during opening motion CLS: Approximate positioning during closing motion [blank]: Without approximate positioning Total thickness of the workpieces to be welded mm Force WeldTimer This box is only displayed if the option Thickness from Timer FALSE is configured. Closing force of the gun Maximum value: Value of the configuration parameter Maximum gun force in kn This box is only displayed if the option Force from timer FALSE is configured. Weld parameters (>>> 7.16 "Option window Weld timer parameters " Page 102) This box is only displayed if at least one of the following options has been configured: Force from timer TRUE, Thickness from Timer TRUE, Thickness- TolTimer TRUE, WeldTimeTimer TRUE 7.5 Programming a DualForce weld spot This description refers to ServoGun without EqualizingTech. If EqualizingTech is installed, the relevant description must be used: (>>> 7.4 "Programming a weld spot with EqualizingTech" Page 80) Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 81 / 125

82 Distances The same distances apply as for a normal weld spot. (>>> "Distances" Page 76) Procedure 1. Position the gun on the desired weld spot. Observe the required distances. 2. Select the menu sequence Commands > ServoTech > DualForce and then select the desired motion type. 3. Set the parameters in the inline form. (>>> "Inline form DualForce (Pneumatic option)" Page 82) (>>> "Inline form DualForce (Robot compensation option)" Page 83) 4. Press Cmd OK to save the instruction Inline form DualForce (Pneumatic option) Item 1 Motion type Fig. 7-4: DualForce (Pneumatic option) PTP, LIN or CIRC 2 Only for CIRC motions: Auxiliary point 3 Name of the end point (>>> 7.13 "Option window Frames " Page 99) Only with the option Point name: The last 7 characters (= default number) must be digits. The robot controller communicates these digits to the weld timer as the program number. The number of relevant final characters can be configured in the parameter Number of entities. Vel [ ] [ ] Velocity PTP: % For LIN or CIRC: m/s 4 Name for the motion data set. The system automatically generates a name. The name can be overwritten. (>>> 7.14 "Option window: Motion parameters (PTP)" Page 100) (>>> 7.15 "Option window: Motion parameters (LIN, CIRC)" Page 101) ProgNr Program number for the weld timer DF ServoGun This box is only displayed if the Program number option is configured. Active gun / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

83 7 Programming Item Cont CLS OPN: Approximate positioning during closing and opening motions Part Force1 OPN: Approximate positioning during opening motion CLS: Approximate positioning during closing motion [blank]: Without approximate positioning Total thickness of the workpieces to be welded mm This box is only displayed if the option Thickness from Timer FALSE is configured. First closing force of the gun Maximum value: Value of the configuration parameter Maximum gun force in kn The boxes Force1, HoldTime and Force2 are only displayed if the option Force from timer FALSE is configured. (>>> "ForceTimer TRUE with DualForce" Page 44) HoldTime When the gun has reached the first closing force, it maintains this force for the time specified here. After this, it switches to the second closing force (without opening and closing). Force2 Second closing force of the gun When the gun has reached the second closing force, it maintains this force until the weld end signal comes from the weld timer. Comp 0: Without compensation Trigger WeldTimer 1: Compensator 1 2: Compensator 2 1+2: Compensators 1 and 2 Distance after which compensation is deactivated on opening the gun Weld parameters (>>> 7.16 "Option window Weld timer parameters " Page 102) This box is only displayed if at least one of the following options has been configured: Force from timer TRUE, Thickness from Timer TRUE, Thickness- TolTimer TRUE, WeldTimeTimer TRUE Inline form DualForce (Robot compensation option) Fig. 7-5: DualForce (Robot compensation option) Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 83 / 125

84 Item 1 Motion type PTP, LIN or CIRC 2 Only for CIRC motions: Auxiliary point 3 Name of the end point (>>> 7.13 "Option window Frames " Page 99) Only with the option Point name: The last 7 characters (= default number) must be digits. The robot controller communicates these digits to the weld timer as the program number. The number of relevant final characters can be configured in the parameter Number of entities. Vel [ ] [ ] Velocity PTP: % For LIN or CIRC: m/s 4 Name for the motion data set. The system automatically generates a name. The name can be overwritten. (>>> 7.14 "Option window: Motion parameters (PTP)" Page 100) (>>> 7.15 "Option window: Motion parameters (LIN, CIRC)" Page 101) ProgNr Program number for the weld timer DF ServoGun This box is only displayed if the Program number option is configured. Active gun 1 6 Cont CLS OPN: Approximate positioning during closing and opening motions Part OPN: Approximate positioning during opening motion CLS: Approximate positioning during closing motion [blank]: Without approximate positioning Total thickness of the workpieces to be welded mm Force1 HoldTime Force2 This box is only displayed if the option Thickness from Timer FALSE is configured. First closing force of the gun Maximum value: Value of the configuration parameter Maximum gun force in kn The boxes Force1, HoldTime and Force2 are only displayed if the option Force from timer FALSE is configured. (>>> "ForceTimer TRUE with DualForce" Page 44) When the gun has reached the first closing force, it maintains this force for the time specified here. After this, it switches to the second closing force (without opening and closing). Second closing force of the gun When the gun has reached the second closing force, it maintains this force until the weld end signal comes from the weld timer. 84 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

85 7 Programming Item ApproxDist SpotOffset WeldTimer Correction of the gun position by the robot between the weld spots. This means of compensation can be used, for example, if the gun would scratch the panel when moving from one weld spot to the next. The position is corrected in the negative tool direction mm Correction of the gun position by the robot at the weld spot. This means of compensation can be used, for example, if the original panel thickness has changed due to molten material. Positive value: The position is corrected in the tool direction. Negative value: The position is corrected in the negative tool direction mm Weld parameters (>>> 7.16 "Option window Weld timer parameters " Page 102) This box is only displayed if at least one of the following options has been configured: Force from timer TRUE, Thickness from Timer TRUE, Thickness- TolTimer TRUE, WeldTimeTimer TRUE 7.6 Programming a DualForce weld spot with EqualizingTech Procedure 1. Position the gun on the desired weld spot. Observe the required distances. 2. Select the menu sequence Commands > ServoTech > DualForce and then select the desired motion type. 3. Set the parameters in the inline form. (>>> "Inline form DualForce (EqualizingTech option)" Page 85) 4. Press Cmd OK to save the instruction Inline form DualForce (EqualizingTech option) Fig. 7-6: DualForce (EqualizingTech option) Item 1 Motion type PTP, LIN or CIRC 2 Only for CIRC motions: Auxiliary point Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 85 / 125

86 Item 3 Name of the end point (>>> 7.13 "Option window Frames " Page 99) Only with the option Point name: The last 7 characters (= default number) must be digits. The robot controller communicates these digits to the weld timer as the program number. The number of relevant final characters can be configured in the parameter Number of entities. Vel [ ] [ ] Velocity PTP: % For LIN or CIRC: m/s 4 Name for the motion data set. The system automatically generates a name. The name can be overwritten. (>>> 7.14 "Option window: Motion parameters (PTP)" Page 100) (>>> 7.15 "Option window: Motion parameters (LIN, CIRC)" Page 101) ProgNr Program number for the weld timer DF ServoGun This box is only displayed if the Program number option is configured. Active gun 1 6 Cont CLS OPN: Approximate positioning during closing and opening motions Part OPN: Approximate positioning during opening motion CLS: Approximate positioning during closing motion [blank]: Without approximate positioning Total thickness of the workpieces to be welded mm Force1 HoldTime Force2 WeldTimer This box is only displayed if the option Thickness from Timer FALSE is configured. First closing force of the gun Maximum value: Value of the configuration parameter Maximum gun force in kn The boxes Force1, HoldTime and Force2 are only displayed if the option Force from timer FALSE is configured. (>>> "ForceTimer TRUE with DualForce" Page 44) When the gun has reached the first closing force, it maintains this force for the time specified here. After this, it switches to the second closing force (without opening and closing). Second closing force of the gun When the gun has reached the second closing force, it maintains this force until the weld end signal comes from the weld timer. Weld parameters (>>> 7.16 "Option window Weld timer parameters " Page 102) This box is only displayed if at least one of the following options has been configured: Force from timer TRUE, Thickness from Timer TRUE, Thickness- TolTimer TRUE, WeldTimeTimer TRUE 86 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

87 7 Programming 7.7 Programming tip initialization Overview Initialization is performed via a KRL program. Depending on the ServoGun option selected in WorkVisual, it can also be performed via status key instead. ServoGun option First initialization Cyclical initialization Pneumatic Robot compensation (>>> "First initialization via status key" Page 70) with Ratio in % Robot compensation with Individual measurement (>>> "Programming first initialization (Pneumatic option with Ratio in %)" Page 87) (>>> "Programming first initialization (Individual measurement option)" Page 89) (>>> "Cyclical initialization via status key" Page 71) (>>> "Programming cyclical initialization (Individual measurement option)" Page 91) If EqualizingTech is installed, the descriptions for the Pneumatic option must be used Programming first initialization (Pneumatic option with Ratio in %) 1 position must be taught for initialization. This is taught as a normal motion point. Precondition Operating mode T1 or T2 The gun has been calibrated as a tool. This tool is currently selected. The gun is mastered. The gun is calibrated. New electrode tips are fitted on the gun. The following values have been entered in the configuration screen Configuration. First Init force, TCP orientation The software limit switches have been set. Procedure 1. Move the gun to the position at which initialization is to be performed. The position must be at least 4 mm away from the negative software limit switch. 2. Teach a conventional PTP, LIN or CIRC point at this position. With this point, the value False must be selected for Collision detection (in the Frames option window). 3. Select the menu sequence Commands > ServoTech > INIT. 4. Select the gun in the inline form. 5. Select New in the inline form. (>>> "Inline form INIT (Pneumatic option with Ratio in %)" Page 88) 6. Press Cmd OK to save the instruction. Sequence With this first initialization, the following occurs: The gun closes at a constant velocity until the first initialization force is reached. The electrode tips are pressed firmly onto the electrodes. The gun opens. The gun closes twice with initialization force. The robot controller saves the current tip wear in EG_WEAR[]. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 87 / 125

88 The gun moves to the initialization position. The moving gun arm performs a motion with initialization force. The variable EG_WORN is set to FALSE. The output New electrodes is set and reset Programming cyclical initialization (Pneumatic option with Ratio in %) 1 position must be taught for initialization. This is taught as a normal motion point. Precondition T1 or T2 operating mode The gun has been calibrated as a tool. This tool is currently selected. The gun is mastered. The gun is calibrated. The software limit switches have been set. First initialization has been performed. Procedure 1. Move the gun to the position at which initialization is to be performed. The position must be at least 4 mm away from the negative software limit switch. 2. Teach a conventional PTP, LIN or CIRC point at this position. With this point, the value False must be selected for Collision detection (in the Frames option window). 3. Select the menu sequence Commands > ServoTech > INIT. 4. Select the gun in the inline form. 5. Select Same in the inline form. (>>> "Inline form INIT (Pneumatic option with Ratio in %)" Page 88) 6. Press Cmd OK to save the instruction. Sequence With this cyclical initialization, the following occurs: The gun closes twice with initialization force. The robot controller saves the current tip wear in EG_WEAR[]. It generates a message if the current wear is greater than the maximum permissible wear (EG_WEAR_MAX). The electrode tips must then be exchanged Inline form INIT (Pneumatic option with Ratio in %) The inline form does not contain any position data; the preceding point is used. The point must be at least 4 mm away from the negative software limit switch. Fig. 7-7: INIT (Pneumatic option with Ratio in %) 88 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

89 7 Programming Item 1 Select the active gun New: First initialization Same: Cyclical initialization Programming first initialization (Individual measurement option) First the overall burn-off is determined. After this, the precise burn-off is determined for the moving electrode. The burn-off of the fixed electrode is derived from the difference. 2 positions must be taught for initialization: 1st position: The overall burn-off is determined at this position. It is taught freely in space as a normal motion point. It may be no further than 100 mm from the 2nd position. (The robot controller does not check the distance as a vector but checks the change of the X, Y and Z coordinates.) 2nd position: The burn-off of the moving electrode is measured at this position. The position is taught with the inline form INIT NEW. The position must be taught on a fixed plate, e.g. a plate on the tip dresser. Both electrodes must be in contact with the plate. No force must be applied. Fig. 7-8: Example: Determining the burn-off using a plate 1 1st position 2 2nd position Recommendation: Set EG_ASA_WEAR_SINGLE to TRUE. Advantages: Initialization is more precise. The force applied to the plate is less than 500 N. The exact force is dependent on the gun. Precondition Operating mode T2 The gun has been calibrated as a tool. This tool is currently selected. The gun is mastered. The gun is calibrated. New electrode tips are fitted on the gun. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 89 / 125

90 The following values have been entered in the configuration screen Configuration. First Init force, TCP orientation A suitable plate is available for teaching the 2nd position. If EG_ASA_WEAR_SINGLE == TRUE: The plate must be able to withstand the force applied. The force is below 500 N. The exact force is dependent on the gun. If EG_ASA_WEAR_SINGLE == FALSE: The plate must be able to withstand a force of at least 500 N. Procedure 1. Move the gun to the desired 1st position. 2. Teach a conventional PTP, LIN or CIRC point at this position. With this point, the value False must be selected for Collision detection (in the Frames option window). 3. Move the gun to the 2nd position. 4. Select the menu sequence Commands > ServoTech > INIT. 5. In the inline form, edit the point data and select the gun. 6. Select New in the inline form. (>>> "Inline form INIT (Individual measurement option)" Page 91) 7. Click on Touch Up to save the current position as the initialization position. Do not click on Cmd OK. In this case, the initialization position is not saved. It is not essential for a separate point to be taught as the 1st position. The 2nd position can be addressed from any point, subject to the following preconditions: The gun can be opened and closed at the point. The point is no further than 100 mm from the 2nd position. With this point, the value False is selected for Collision detection (in the Frames option window). The BASE coordinate systems of all points from which the 2nd position is addressed must be identical. It is nevertheless advisable for a separate point to be taught as the 1st position in order to ensure that the preconditions are always satisfied. Sequence With this first initialization, the following occurs: The gun moves to the 1st position. The gun closes at a constant velocity until the first initialization force is reached. The electrode tips are pressed firmly onto the electrodes. The gun opens. The gun closes twice with initialization force. The robot controller saves the current tip wear in EG_WEAR. The gun moves to the 2nd position. The moving gun arm performs a motion with initialization force. The variable EG_WORN is set to FALSE. The output New electrodes is set and reset. EG_WEAR_FLEX and EG_WEAR_FIX are set to / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

91 7 Programming Programming cyclical initialization (Individual measurement option) Cyclical initialization is always performed at the position taught as the 2nd position for first initialization. Precondition Operating mode T2 The gun has been calibrated as a tool. This tool is currently selected. The gun is mastered. The gun is calibrated. First initialization has been performed. Procedure 1. Select the menu sequence Commands > ServoTech > INIT. 2. Select the gun in the inline form. 3. Select Same in the inline form. (>>> "Inline form INIT (Individual measurement option)" Page 91) Sequence With this cyclical initialization, the following occurs: The gun moves to the 1st position. The gun closes twice with initialization force. The robot controller saves the current tip wear in EG_WEAR. The gun moves to the 2nd position. The moving gun arm performs a motion with initialization force Inline form INIT (Individual measurement option) Fig. 7-9: INIT New (Individual measurement) Fig. 7-10: INIT Same (Individual measurement) Item 1 Only displayed if New is selected: Point name. The system automatically assigns the name. It cannot be changed. (>>> 7.13 "Option window Frames " Page 99) Note: With this point, the value False must be selected for Collision detection in the option window. 2 Select the active gun New: First initialization Same: Cyclical initialization Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 91 / 125

92 7.8 Programming tip dressing This description refers to ServoGun without EqualizingTech. If EqualizingTech is installed, the relevant description must be used: (>>> 7.9 "Programming tip dressing with EqualizingTech" Page 96) TippDress executes a weld spot without approximate positioning. The following parameters must be set in the weld timer: Dressing time (complete cycle time) Cycle without current Dressing must be performed without weld current. If dressing is carried out with weld current, damage to property is liable to occur. Fig. 7-11: Tip dressing Distances The same distances apply as for a normal weld spot. (>>> "Distances" Page 76) Precondition The thickness of the tip dresser has been determined. (>>> "Determining the thickness of the tip dresser" Page 93) Procedure 1. Position the gun on the desired tip dressing point. Observe the required distances. 2. Select the menu sequence Commands > ServoTech > TippDress and then select the desired motion type. 3. Set the parameters in the inline form. (>>> "Inline form TippDress (Pneumatic option)" Page 93) (>>> "Inline form TippDress (Robot compensation option)" Page 94) 4. Press Cmd OK to save the instruction. 92 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

93 7 Programming After tip dressing, cyclical initialization must be performed. Sequence The default sequence for tip dressing corresponds to the sequence for welding. The gun closes until the defined force is reached. The robot controller then sets the output Weld start and waits for the input Weld end. If a different sequence is required for tip dressing, this can be programmed in the subprogram EG_USERDRESS. In order for the robot controller to perform this different sequence, the variable EG_NON_KUKA_DRESS must be set to TRUE Determining the thickness of the tip dresser The thickness of the tip dresser is required for the inline form TippDress. Precondition The gun is mastered. New electrode tips are fitted on the gun. T1 or T2 operating mode Procedure 1. Position the gun with both electrodes on the the tip dresser. 2. Close the gun until build-up of tip dressing force. 3. In the main menu, select Display > Variable > Overview > Display. The Variable overview Display window is opened. 4. Read and note the value of the Position variable Inline form TippDress (Pneumatic option) Item 1 Motion type Fig. 7-12: TippDress (Pneumatic option) PTP or LIN 2 Name of the end point (>>> 7.13 "Option window Frames " Page 99) Only with the option Point name: The last 7 characters (= default number) must be digits. The robot controller communicates these digits to the weld timer as the program number. The number of relevant final characters can be configured in the parameter Number of entities. Vel [ ] [ ] Velocity PTP: % LIN: m/s Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 93 / 125

94 Item 4 Name for the motion data set. The system automatically generates a name. The name can be overwritten. (>>> 7.14 "Option window: Motion parameters (PTP)" Page 100) (>>> 7.15 "Option window: Motion parameters (LIN, CIRC)" Page 101) ProgNr Program number for the weld timer ServoGun Part This box is only displayed if the Program number option is configured. Active gun 1 6 Thickness of the tip dresser mm Force This box is only displayed if the option Thickness from Timer FALSE is configured. Closing force of the gun Maximum value: Value of the configuration parameter Maximum gun force in kn This box is only displayed if the option Force from timer FALSE is configured. Comp 0: Without compensation Trigger WeldTimer 1: Compensator 1 2: Compensator 2 1+2: Compensators 1 and 2 Distance after which compensation is deactivated on opening the gun Weld parameters (>>> 7.16 "Option window Weld timer parameters " Page 102) This box is only displayed if at least one of the following options has been configured: Force from timer TRUE, Thickness from Timer TRUE (ThicknessTolTimer and WeldTimeTimer are not relevant for tip dressing.) Inline form TippDress (Robot compensation option) Fig. 7-13: Tip dressing (Robot compensation option) 94 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

95 7 Programming Item 1 Motion type PTP or LIN 2 Name of the end point (>>> 7.13 "Option window Frames " Page 99) Only with the option Point name: The last 7 characters (= default number) must be digits. The robot controller communicates these digits to the weld timer as the program number. The number of relevant final characters can be configured in the parameter Number of entities. Vel [ ] [ ] Velocity PTP: % For LIN or CIRC: m/s 3 Name for the motion data set. The system automatically generates a name. The name can be overwritten. (>>> 7.14 "Option window: Motion parameters (PTP)" Page 100) (>>> 7.15 "Option window: Motion parameters (LIN, CIRC)" Page 101) ProgNr Program number for the weld timer ServoGun Part Force ApproxDist SpotOffset WeldTimer This box is only displayed if the Program number option is configured. Active gun 1 6 Thickness of the dresser mm This box is only displayed if the option Thickness from Timer FALSE is configured. Closing force of the gun Maximum value: Value of the configuration parameter Maximum gun force in kn This box is only displayed if the option Force from timer FALSE is configured. Correction of the gun position by the robot between the weld spots. This means of compensation can be used, for example, if the gun would scratch the panel when moving from one weld spot to the next. The position is corrected in the negative tool direction mm Correction of the gun position by the robot at the weld spot. This means of compensation can be used, for example, if the original panel thickness has changed due to molten material. Positive value: The position is corrected in the tool direction. Negative value: The position is corrected in the negative tool direction mm Weld parameters (>>> 7.16 "Option window Weld timer parameters " Page 102) This box is only displayed if at least one of the following options has been configured: Force from timer TRUE, Thickness from Timer TRUE (ThicknessTolTimer and WeldTimeTimer are not relevant for tip dressing.) Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 95 / 125

96 7.9 Programming tip dressing with EqualizingTech TippDress executes a weld spot without approximate positioning. The following parameters must be set in the weld timer: Dressing time (complete cycle time) Cycle without current Dressing must be performed without weld current. If dressing is carried out with weld current, damage to property is liable to occur. Distances The following distances are required for the position of the gun during teaching: Distance Fixed electrode Gun opening Value No distance from the workpiece; must be in contact with the workpiece. Must be at least 4 mm away from the negative software limit switch. Precondition The thickness of the tip dresser has been determined. (>>> "Determining the thickness of the tip dresser" Page 93) Procedure 1. Position the gun on the desired tip dressing point. Observe the required distances. 2. Select the menu sequence Commands > ServoTech > TippDress > ServoTech or LIN. 3. Set the parameters in the inline form. Also enter the thickness of the tip dresser. (>>> "Inline form TippDress (EqualizingTech option)" Page 96) 4. Press Cmd OK to save the instruction. After tip dressing, cyclical initialization must be performed. Sequence Program sequence for tip dressing: The default sequence corresponds to the sequence for welding. If a different sequence is required for tip dressing, this can be programmed in the subprogram EG_USERDRESS. In order for the robot controller to perform this different sequence, the variable EG_NON_KUKA_DRESS must be set to TRUE Inline form TippDress (EqualizingTech option) Fig. 7-14: TippDress (EqualizingTech option) 96 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

97 7 Programming Item 1 Motion type PTP or LIN 2 Name of the end point (>>> 7.13 "Option window Frames " Page 99) Only with the option Point name: The last 7 characters (= default number) must be digits. The robot controller communicates these digits to the weld timer as the program number. The number of relevant final characters can be configured in the parameter Number of entities. Vel [ ] [ ] Velocity PTP: % For LIN or CIRC: m/s 3 Name for the motion data set. The system automatically generates a name. The name can be overwritten. (>>> 7.14 "Option window: Motion parameters (PTP)" Page 100) (>>> 7.15 "Option window: Motion parameters (LIN, CIRC)" Page 101) ProgNr Program number for the weld timer ServoGun Part Force WeldTimer This box is only displayed if the Program number option is configured. Active gun 1 6 Thickness of the tip dresser mm This box is only displayed if the option Thickness from Timer FALSE is configured. Closing force of the gun Maximum value: Value of the configuration parameter Maximum gun force in kn This box is only displayed if the option Force from timer FALSE is configured. Weld parameters (>>> 7.16 "Option window Weld timer parameters " Page 102) This box is only displayed if at least one of the following options has been configured: Force from timer TRUE, Thickness from Timer TRUE (ThicknessTolTimer and WeldTimeTimer are not relevant for tip dressing.) 7.10 Inline form ServoGun Decouple This command decouples within the software the gun currently in use. The inline form does not control any hardware, inputs or outputs. The opening width of the gun must be identical in both the coupling and decoupling position. Recommendation: The gun should be open at least 10 mm. Do not decouple the gun if it is in the mastering position, since the mastering would otherwise be lost when the gun is recoupled. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 97 / 125

98 Fig. 7-15: ServoGun Decouple Item 1 Select the active gun Inline form ServoGun Couple This command couples within the software the gun currently in use. The inline form does not control any hardware, inputs or outputs. The opening width of the gun must be identical in both the coupling and decoupling position. Recommendation: The gun should be open at least 10 mm. Fig. 7-16: ServoGun Couple Item 1 Select the active gun Programming background tip dressing or welding Precondition While tip dressing is being carried out with a stationary gun, the robot is normally not available for other work (e.g. fetching a new workpiece). The reason for this is that the robot axes and the external axis (= gun) are moved synchronously. This means they perform common motions that start and finish simultaneously. Even though the robot axes are usually stationary during dressing, this is nevertheless part of the overall motion. With the Background commands, however, it is possible to move the stationary gun asynchronously. At the same time, the robot axes are able to execute other movements independently of the gun. The asynchronous gun motion is not only possible during tip dressing, but also during welding. However, this only applies to test welding where no real workpiece is used. To enable the robot controller to execute background commands, the corresponding inputs and outputs must be configured in EG_EXTERN.DAT. Procedure 1. Select the menu sequence Commands > ServoTech > Background. Then select either Background tip dressing or Background welding. 2. Set the parameters in the inline form. (>>> "Inline form Background tip dressing " Page 99) (>>> "Inline form Background welding " Page 99) 98 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

99 7 Programming 3. Press Cmd OK to save the instruction Inline form Background tip dressing Fig. 7-17: Background tip dressing Item 1 Enable: Asynchronous motion of the stationary gun during tip dressing is possible. Disable: Not possible. 2 Select the gun number Inline form Background welding Fig. 7-18: Background welding Item 1 Enable: Asynchronous motion of the stationary gun during welding is possible. Disable: Not possible. 2 Select the active gun Option window Frames Fig. 7-19: Option window: Frames Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 99 / 125

100 With the following points, the value False must be selected for Collision detection: All weld spots All tip dressing points All PTP, LIN or CIRC points followed by an INIT New or INIT Same. Point INIT New (Individual measurement) Item 1 Tool selection. If True in the box External TCP: workpiece selection. Range of values: [1] [16] 2 Base selection. If True in the box External TCP: fixed tool selection. Range of values: [1] [32] 3 Interpolation mode False: The tool is mounted on the mounting flange. True: The tool is a fixed tool. 4 True: For this motion, the robot controller calculates the axis torques. These are required for collision detection. False: For this motion, the robot controller does not calculate the axis torques. Collision detection is thus not possible for this motion Option window: Motion parameters (PTP) Fig. 7-20: Option window: Motion parameters (PTP) 100 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

101 7 Programming Item 1 Acceleration Refers to the maximum value specified in the machine data. The maximum value depends on the robot type and the selected operating mode % 2 This box is only displayed if it is specified in the inline form that the point is to be approximated. Furthest distance before the end point at which approximate positioning can begin. Maximum distance 100%: half the distance between the start point and the end point relative to the contour of the PTP motion without approximate positioning % 7.15 Option window: Motion parameters (LIN, CIRC) Fig. 7-21: Option window: Motion parameters (LIN, CIRC) Item 1 Path acceleration Refers to the maximum value specified in the machine data. The maximum value depends on the robot type and the selected operating mode. 2 This box is only displayed if it is specified in the inline form that the point is to be approximated. Furthest distance before the end point at which approximate positioning can begin The maximum permissible value is half the distance between the start point and the end point. If a higher value is entered, this is ignored and the maximum value is used. 3 Orientation control selection. Standard Wrist PTP Constant orientation control Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 101 / 125

102 7.16 Option window Weld timer parameters The values in this window come from the weld timer. They are only displayed and cannot be modified. Exception: If the configuration parameter Timer type is set to TEST, the values can be edited. The values displayed are those which the robot controller last received from a weld timer. Fig. 7-22: Option window Weld timer parameters Item 1 Welding force Note: This box is only displayed if the option Force from timer TRUE has been configured. 2 Total thickness of the workpieces to be welded Note: This box is only displayed if the option Thickness from Timer TRUE has been configured. 3 Amount by which the actual total thickness may deviate (in both directions) from the value in Part thickness Example: If Part thickness is set to 20 mm and Part thickness tolerance to 3 mm, then the total thickness may lie between 17 and 23 mm. Note: This box is only displayed if the option ThicknessTolTimer TRUE has been selected. ThicknessTolTimer is not relevant for tip dressing. 4 Note: This parameter is reserved for future use in combination with KUKA.RoboSpin. KUKA.RoboSpin is not yet available for use with ServoGun TC. The parameter is currently without meaning. Weld time (duration of the welding process) This box is only displayed if the option WeldTimeTimer TRUE has been selected. This value plus the value of EG_WELDTIME_OFFSET[axis no.] results in the spin time. WeldTimeTimer is not relevant for tip dressing Teach mode (reteaching weld spots) Teach mode is only available for the Robot compensation option. 102 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

103 7 Programming In Teach mode, the gun moves to the points taught in KUKA.ServoGun TC and stops there. This allows the user to check the position and to reteach it if necessary. The gun does not stop at points which are not specific to ServoGun (e.g. at conventional PTP points). (Without Teach mode, guns without pneumatic compensation are moved not to the originally taught weld spots, but to corrected points.) Precondition A program is selected. Operating mode T1 or T2 Procedure 1. Hold down the enabling switch. 2. Press the Toggle status keys status key until the Teach Mode Off status key is displayed. 3. Press the Teach Mode Off status key. Teach mode is now activated. 4. Hold down the Start key. The gun stops at the taught position. 5. Check the position and reteach it if necessary. 6. Hold down the Start key. The gun closes to the programmed force and then moves to the next taught position, where it stops. 7. Repeat steps 5 and 6 until all points that are to be checked have been executed. 8. Press the Teach Mode On status key in order to deactivate Teach mode again Correcting weld spots semi-automatically (ASA) Weld spots can be corrected semi-automatically by means of ASA (= Automatic Standoff Adjustment). ASA can be used to adapt a weld program to the changed position of a workpiece. The user executes the welding program in ASA mode. Program execution is as usual apart from the weld spots: At these points the gun determines the position of the workpiece. The user then has the option of adapting the weld spot to the current workpiece. Precondition Operating mode T1 The variable EG_ASA_ON is TRUE. Procedure 1. Select and execute the welding program. On reaching a weld spot, the gun stays open further than originally taught (EG_ET_DIST). Among other things, this serves the purpose of avoiding a collision with the workpiece. The gun closes at constant velocity. When the moving electrode contacts the workpiece, the motion stops and the following query is displayed: Do you want to move to the calculated position? 2. Answer the query with YES. The fixed electrode now moves to the workpiece and the gun opens to the width originally taught. 3. The robot controller checks the deviation of the fixed electrode from the position originally taught (taking into account the current tip wear). If the deviation is greater than EG_ET_MAX_DIFF, the following message is displayed: The difference is... mm too high! If the current position is to be taught, press Touch Up. Then press the Start key to continue the program. If the original position is to be retained, continue the program by pressing the Start key. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 103 / 125

104 If the deviation is less than or equal to EG_ET_MAX_DIFF, the robot controller automatically continues the program. 4. Repeat steps 2 and 3 for all points of the welding program. 5. Set the variable EG_ASA_ON to FALSE. Only for the Robot compensation option: If the gun causes the workpiece to bend, this can be offset by entering a corresponding value in the box SpotOffset in the inline form. Variables The variables are located in the file EG_EXTERN.DAT in the directory R1\TP\ServoGun_TC. Variable EG_ASA_ON EG_ET_DIST[gun no.] EG_ET_MAX_DIFF Type: BOOL FALSE (default): ASA mode is switched off. TRUE: ASA mode is switched on. Type: REAL Opening of the gun at the weld spot, additionally to the width originally taught Default: 10.0 (mm) Type: REAL Maximum deviation allowed between the current position of the TCP (taking the current tip wear into account) and the position originally taught Default: 3.0 (mm) 7.19 User-specific subprograms ServoGun TC contains subprograms that the user can adapt individually to his requirements. No parameters can be transferred in the subprograms. The adaptations in these subprograms are preserved if the technology package is updated. If the package is uninstalled, the adaptations will be lost. The data must therefore be backed up beforehand if required. The subprograms are located in the following programs in the directory R1\TP\SERVOGUN_TC: EG_USER.SRC EG_USER_BG_TD_W.SRC (for background welding and background tip dressing) Precondition Expert user group EG_USER.SRC Subprograms which are not listed below are primarily intended for use by KUKA employees. They may only be modified after consultation with KUKA Roboter GmbH. 104 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

105 7 Programming EG_PRE() (before welding) The necessary input/output signals can be programmed, in order to poll the welding power source, for example, or to verify certain states. Instructions that trigger an advance run stop are allowed. Precondition The gun is closed under pressure. The weld start signal has not yet been given EG_POST_ERROR() (after welding and tip dressing) Process errors can be evaluated. The program can evaluate user-specific monitoring signals. Instructions that trigger an advance run stop are allowed. Precondition End of weld signal is set EG_PRED() (before tip dressing) This program is called before tip dressing. It can be used to switch on the tip dresser, for example, or wait for an enable signal from the PLC. Instructions that trigger an advance run stop are allowed EG_POSTD() (after tip dressing) This program is called after tip dressing. Instructions that trigger an advance run stop are not allowed EG_USERDRESS() (tip dressing) If the programs EG_PRED() and EG_POSTD() are not sufficient for tip dressing, the user must program the specific tip dressing process in the EG_USERDRESS() program. EG_USERDRESS() consists of 3 programs: Close gun under pressure Gun_to_pressure() Open gun in order to close it again without robot motion Gun_open_repeat() Open gun with subsequent robot motion Gun_open_not_repeat() It is also possible to access the 3 Gun_ () programs from outside of EG_USERDRESS(), i.e. it is not absolutely necessary to execute EG_USERDRESS() in order to execute one of these programs. Precondition In order for the robot controller to execute EG_USERDRESS(), the variable EG_NON_KUKA_DRESS must be set to TRUE. EG_PRED() and EG_POSTD() are always executed, irrespective of the state of the variable EG_NON_KUKA_DRESS. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 105 / 125

106 EG_USER_BG_TD_W.SRC Program EG_PRE_BG_TD EG_POST_BG_TD EG_PRE_BG_W EG_POST_BG_W When does the robot controller call the program? Before background tip dressing After background tip dressing Before background welding After background welding 106 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)

107 8 Diagnosis 8 Diagnosis 8.1 Displaying and exporting data from the weld timer This overview displays the weld spots of a program, together with all the values which the robot controller has received from the weld timer for each point. Which values these are depends on the configuration of the ServoGun options. All programs that have been executed are available for selection. The values displayed are always those from the last program execution. Precondition Expert user group The program whose data are to be displayed has been executed. Procedure 1. In the main menu, select Diagnosis > ServoGun TC > Weld timer data. The Overview of weld timer data window is opened. 2. In the Module name box, select the program whose data are to be displayed. 3. If required: To export the displayed data, press Export. The data are exported to a CSV file in the directory C:\KRC\USER\Weld- Data\WeldTimerData. Fig. 8-1: Overview of weld timer data 8.2 Displaying ServoGun I/Os Precondition Expert user group Procedure In the main menu, select Diagnosis > ServoGun TC > ServoGun I/Os. The I/Os for weld timer / PLC window is opened. Issued: Version: KST ServoGun TC 4.1 V1 en (PDF) 107 / 125

108 The I/Os for weld timer / PLC window contains 2 tabs: one shows the I/O configuration between the robot controller and the weld timer, the other shows the I/O configuration between the robot controller and the PLC. Lamps indicate the states of the I/Os. Lamps State / description Green HIGH HIGH = normal or desired state Green and gray LOW LOW = abnormal or undesired state Red HIGH HIGH = abnormal or undesired state Red and gray LOW LOW = normal or desired state Fig. 8-2: Weld timer tab Fig. 8-3: PLC tab 108 / 125 Issued: Version: KST ServoGun TC 4.1 V1 en (PDF)