ABB Robotics. Application manual Plastics Mould and DieCast

Transcription

1 ABB Robotics Application manual Plastics Mould and DieCast

2

3 Application manual Plastics Mould and DieCast RobotWare 5.0 Document ID: 3HAC Revision: E

4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like. In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein. This manual and parts thereof must not be reproduced or copied without ABB s written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted. Additional copies of this manual may be obtained from ABB at its then current charge. Copyright ABB All rights reserved. ABB Robotics SE Västerås Sweden

5 Table of Contents Overview...7 Product documentation, M Safety Introduction Overview Machine tending principle Position Path Cell path Cycle HomeRun How to work with RW Plastics Mould and RW DieCast Installation User authorization Program generation Run-time Back-up and I-start How to run normal RAPID program in robot system with RW Plastics Mould and RW DieCast additional option Remote control File structure Creating programs Overview Program wizard Creating programs Overview Program wizard - Name Program wizard - Gripper Program wizard - Cell Program wizard - Cycle Program wizard - Station Program wizard - Customize HomeRun Program wizard - Teach paths Program wizard - Position properties Program wizard - Test paths and stations Program wizard - Cell Path Program wizard - Save

6 Table of Contents 3 RAPID instructions Overview RAPID syntax Data types Overview Pointtype Propertytype IOMapping Instructions Overview xctmovein xctmoveout xctforcepart xctsetstatus xctsettoolstatus xctoffsetpath xcterrkeep xctsetuserstats xcttpwrite xctsetcycleend HR_MoveBackInPath HR_MoveForwardOutPath HR_MoveToStnAndExecute Functions Overview xctgetscrapstn xctgetcondition xctgettlstatus Stations Overview Station definition Station variables Overview IOMapping %STATION%_Xouts{} and IOMapping %STATION%_Xins{} propertytype %STATION%_Prop{} wobjdata w%station% pointtype%station%_mp{10} pointtype%station%_sp1{10} %STATION%_corner1 and %STATION%_corner

7 Table of Contents 4.4 Station procedures Overview DefEvents() CheckStatus() Execute() Initialize() RunWithoutRobot() RunWithRobot() LinkProcedure SetStationWobj() GetPath (string PathName, INOUT Path{*}) StationLib Overview BlankStn.lib IMM.lib (for RW Plastics Mould) DCM.lib (for RW DieCast) Conveyor.lib Vision.lib CoolingTower.lib PartCtrl.lib Home.lib Scrap.lib Station.xml Tools Overview Tool definition Tool variables Overview IOMapping %TOOL%_Xins{} and IOMapping %TOOL%_Xout{} tooldata t%tool% Tool procedures Overview DefEvents() CheckStatus() Open() Close() Initialize() SetToolTcp (string ToolTcpName)

8 Table of Contents 5.5 GripperLib Overview MechGrip.lib Grip2DO.lib Vacuum.lib (for RW Plastics Mould) LinkProcedures LinkProcedure.mod Configuring Overview Connecting hardware Configuring system Internal interfaces Configuring libraries Image Notice Appendix Signal interface (for RW Plastics Mould) Event log

9 Overview Overview About this manual This manual describes how to configure the RobotWare Plastics Mould and RobotWare DieCast. It is stated where a function is valid only for RobotWare Plastics Mould or RobotWare DieCast. Otherwise the information is valid for both RobotWare Plastics Mould and RobotWare DieCast. Usage This manual provides information about how to create a program and how to configure the RobotWare Plastics Mould and RobotWare DieCast library files that are then used by the program wizard. How to use RobotWare Plastics Mould and RobotWare DieCast to run production are described in the Operating manual - Plastics Mould and DieCast. Who should read this manual? This manual is mainly intended for the robot programmers in the foundry and plastics industry. Prerequisites The reader should... be familiar with industrial robots and their terminology. be familiar with the RAPID programming language. be familiar with system parameters and how to configure them. Organization of chapters The manual is organized in the following chapters: Chapter Contents 1. Introduction to RobotWare Plastics Mould and RobotWare DieCast tending principle and how to start. 2. Procedures for creating programs with RobotWare Plastics Mould and RobotWare DieCast. 3. about RAPID instructions in RobotWare Plastics Mould and RobotWare DieCast. Continues on next page 3HAC Revision: E 7

10 Overview Continued Chapter Contents 4. s of the station library. 5. s of the tool library. 6. s of the linkprocedure. 7. s of configuring information. 8. Appendix. References Reference Operating manual - IRC5 with FlexPendant Operating manual - RobotStudio Operating manual - Plastics Mould and DieCast Document Id 3HAC HAC HAC Revisions Revision B C RW DieCast added. Organization of chapters restructured. D Updated for RobotWare Plastics Mould 4.0 and RobotWare DieCast 4.0. Customized HomeRun added. E Minor corrections. 8 3HAC Revision: E

11 Product documentation, M2004 Product documentation, M2004 General The robot documentation may be divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems. Product manuals All hardware, robots and controllers, will be delivered with a Product manual that contains: Safety information Installation and commissioning (description of mechanical installation, electrical connections) Maintenance (description of all required preventive maintenance procedures including intervals) Repair (description of all recommended repair procedures including spare parts) Additional procedures, if any (calibration, decommissioning) Reference information (article numbers for documentation referred to in Product manual, procedures, lists of tools, safety standards) Part list Foldouts or exploded views Circuit diagrams Technical reference manuals The following manuals describe the robot software in general and contain relevant reference information: RAPID Overview: An overview of the RAPID programming language. RAPID Instructions, Functions and Data types: of all RAPID instructions, functions and data types. System parameters: of system parameters and configuration workflow. Continues on next page 3HAC Revision: E 9

12 Product documentation, M2004 Continued Application manuals Specific applications (for example, software or hardware options) are described in Application manuals. An application manual can describe one or several applications. An application manual generally contains information about: The purpose of the application (what it does and when it is useful) What is included (for example, cables, I/O boards, RAPID instructions, system parameters) How to use the application Examples of how to use the application Operating manuals This group of manuals is aimed at those having first hand operational contact with the robot, i.e. production cell operators, programmers and trouble shooters. The group of manuals include: IRC5 with FlexPendant RobotStudio Trouble shooting - IRC5 for the controller and robot 10 3HAC Revision: E

13 Safety Safety Safety of personnel A robot is heavy and extremely powerful regardless of its speed. A pause or long stop in movement can be followed by a fast hazardous movement. Even if a pattern of movement is predicted, a change in operation can be triggered by an external signal resulting in an unexpected movement. Therefore, it is important that all safety regulations are followed when entering safeguarded space. Safety regulations Before beginning work with the robot, make sure you are familiar with the safety regulations described in Operating manual - IRC5 with FlexPendant. 3HAC Revision: E 11

14 Safety 12 3HAC Revision: E

15 1 Introduction 1.1. Overview 1 Introduction 1.1. Overview Overview RW Plastics Mould and RW DieCast are software used for machine tending, especially for injection moulding and die casting. They provide an easy way for programming and production including safe HomeRun, user authorization, production statistics, and event log, as well as a standardized and structured way of machine tending programming. This chapter describes the principle of how RW Plastics Mould and RW DieCast programs are configured and created. Section This chapter contains the following sections: Overview on page 13 Machine tending principle on page 14 How to work with RW Plastics Mould and RW DieCast on page 25 Installation on page 26 User authorization on page 29 Program generation on page 32 Run-time on page 33 Back-up and I-start on page 34 How to run normal RAPID program in robot system with RW Plastics Mould and RW DieCast additional option on page 37 Remote control on page 38 File structure on page 40 3HAC Revision: E 13

16 1 Introduction Position 1.2 Machine tending principle Position Definition of position A position is a robot target. The possible position types are the following: Position In Target Out An In position belongs to the In path. The first In position of a path is the Entry position. A Target is the last position of the In path, where for examples: The robot picks/unloads, processes or releases/loads a part. The Target position of a main path is the Entry and Exit position of a sub path (It is highly recommended to teach the three positions as the same geometrical position). An Out position belongs to the Out path. The last Out position of a path is the Exit position. NOTE! A path has at least three positions, the Entry position, the Target position and the Exit position, and at most ten positions. Illustration of positions, main path and sub paths: pic HAC Revision: E

17 1 Introduction Path Path Definition of path A path is a robot track in a station, on which the robot moves along a sequence of positions. There are two types of paths: Path Main path Sub path The path on which the robot moves in and out of the station. Every station has one main path mandatory. The path on which the robot moves inside the station. Every station has 0-5 sub paths. A path is divided into two parts: Part of path In path Out path The robot moves in along the path starting from the Entry position. The robot moves out along the path ending with the Exit position. The robot tends the station in the following way: NOTE! In the following description, it is supposed that the Target position of the main path, the Entry position of the sub path and the Exit position of the sub path are taught as the same geometrical position. Action 1. The robot moves into the station. Moving along the main path. The robot moves into a station along the In path of the main path starting from the Entry position until it reaches the Target position. 3HAC Revision: E Continues on next page 15

18 1 Introduction Path Continued Action 2. The robot moves inside the station. 3. The robot moves out of the station. If there are sub paths, the robot will move on the sub path. 1. The robot moves in along the In path of the sub path starting from the Entry position of the sub path until it reaches the Target position. 2. In the Target position, the robot will pick, process or release a part. 3. The robot moves out along the Out path of the sub path until it reaches the Exit position of the sub path. Moving along the main path. The robot moves along the Out path of the main path ending with the Exit position. Illustration of a robot cycle including the Machine, Conveyor and Scrap: pic HAC Revision: E

19 1 Introduction Cell path Cell path Definition of cell path The cell path contains robot positions and determines the robot path between the stations. If the robot cannot move freely between the stations for some reasons, a cell path has to be defined: There are some obstacles between the stations. The robot will otherwise reach a singularity. NOTE! If no cell path is added, the robot can not move between stations in the current cell. You can add cell paths quickly by using the Default cell paths button. Refer to Program wizard - Cell Path on page 85 for detailed description. 3HAC Revision: E 17

20 1 Introduction Cycle Cycle Definition of cycle A cycle is a workflow in which the robot will tend the stations sequentially. Typical cycles include the filling cycle, clear cycle and production cycle. The production cycle is default and cannot be deleted. Some other cycles, such as the filling cycle and the clear cycle, are optional. The table below describes a typical cycle. Action 1. During a cycle, the robot will tend the first station in the cycle sequence. 2. If the status of the next station in cycle sequence is OK, the robot will move and tend the next station from the defined cell path. If the station shows status Busy, the robot will tend the alternative station, there may be: The alternative station belongs to the current cycle, then the robot will continue the cycle down stream to the alternative station. NOTE! If the alternative station is up-stream the busy station, a dead-loop may occur. The alternative station is not in the current cycle. Then after tending the alternative station, the robot will restart the cycle from the beginning. NOTE! In such a case all the tools must open in the alternative station to enable the robot to start cycle from the beginning. The alternative station is in Busy status, the robot will tend its alternative station. 3. Repeat step HAC Revision: E

21 1 Introduction HomeRun HomeRun Definition of HomeRun There are two kinds of HomeRun: Automatic HomeRun, after an instant stop on the path, tap HomeRun and press the Start button on the FlexPendant. The robot will find a way back to Home position following the default HomeRun rules that is defined in RAPID. If the customized HomeRun has been defined, the robot will execute the customized one. Direct HomeRun, after Move PP to Main or loading a program to the system, the robot can only make a direct HomeRun, when the distance between the robot current position and the robot stop position is less than 200 mm. When the distance between the current robot TCP and the Home position is less than 200 mm, the robot will move to Home as defined by the Entry position of Home. The default distance can be changed. Make sure that the way from the current position to Home is collision free. The robot should always be in Home position before starting any other cycle. The default HomeRun speed is 250 mm/s. The HomeRun speed can be set from the program wizard, see How to set general properties on page 48 for more information. Continues on next page 3HAC Revision: E 19

22 1 Introduction HomeRun Continued Automatic HomeRun When the robot comes to a station whose status is Not ok or the tool is Not ok, or the robot waits too long time for a signal, the error will be caught by the RAPID error handling. Then the robot stops. This default behavior is ruled by the RAPID error handling in every station and tool procedure defined by RAISE erhomepos;. This raise RAPID instruction can make sure the errors can be reachable by the error handling correctly. When some external events happen, such as push Hard stop button, Guard stop for the gate, or emergency stop, the robot stops immediately. The HomeRun button can be triggered to start a HomeRun from the Production window on the FlexPendant. The robot automatically returns to Home from anywhere on its path: To exit station: If the robot is on the In path of main or sub path, the robot will return out of the station the same way as it entered. If the robot is on the Out path of main or sub path, the robot will continue forward on the current path. If the robot is on a sub path, the robot will skip the following sub paths and move out directly on the main path. To return to Home position outside station: If the robot gripper does not hold any part, the robot will go straightly to Home. If the robot gripper holds a part, the robot will first go to the scrap station, leave the part, then go to Home. Continues on next page 20 3HAC Revision: E

23 1 Introduction HomeRun Continued Process description Cycle: Machine->Conveyor pic01005 Continues on next page 3HAC Revision: E 21

24 1 Introduction HomeRun Continued Station Path Position Home 1,2,3,4 Machine Main path 5, 6, 7, 8, 19, 20, 21 Sub path 1 9, 10, 11, 12, 13 Sub path 2 14, 15, 16, 17, 18 Conveyor Main path 22, 23, 24, 25, 31 Sub path 26, 27, 28, 29, 30 Scrap Main path 32, 33, 34, 35, 41, 42 From Machine to Conveyor From Scrap to Machine Sub path 36, 37, 38, 39, 40 Cell path 1 A->B Cell path 2 D->C Movement mode Robot movement/sequence of positions Direct HomeRun The robot movement will follow this sequence: 1->2->3->4 Production First cycle: From 4 ->5->6->7->8->9->10->11->12->13->14->15 ->16 ->17->18- >19->20->21->A->B->22->23->24->25->26->27 ->28 ->29 ->30->31 Second cycle: 31->5->6->7->8->9->10->11->12->13->14->15->16 ->17->18->19- >20->21->A-> B ->22->23->24->25->26->27->28->29->30->31 Stop After Cycle The robot will finish the current cycle first as described previously. Run the last cycle: 5 -> 6->7->8->9->10->11->12->13->14->15->16->17->18 ->19->20- >21->A->B->22->23->24->25->26->27->28->29 ->30 ->31 ->1->2- >3->4 Continues on next page 22 3HAC Revision: E

25 1 Introduction HomeRun Continued Robot stops at... Sub path Main path In path For example: between 10 and 11. Out path For example: between 12 and 13 In path For example: between 6 and 7 Out path For example: between 19 and 20 Robot movement /Sequence of positions The tools are closed in the position 11. The robot moves to Home following this sequence of positions: 10->9->8->7->6->5->21>1->2->3->4 The tools are closed in the position 11. If default cell paths have been defined (see Program wizard - Cell Path on page 85), the robot will move to Home following this sequence of positions. 13->19->20->21->32->33->34->35-> 36 ->37 ->38->39->40->41->42->1->2->3->4 NOTE! If there is no cell paths defined from the Machine to the Scrap, the robot will stop. A message will be displayed on the FlexPendant to inform that there is no cell path. The tools are closed in the position 11. The robot moves to Home following this sequence of positions: 6->5->21->1->2->3->4 The tools are closed in the position 11. If default cell paths have been defined (see Program wizard - Cell Path on page 85), the robot will move to Home following: 19->20->21->32->33->34->35->36->37->38- >39->40->41->42->1->2->3->4 NOTE! If there is no cell paths defined from the Machine to the Scrap, the robot will stop. A message will be displayed on the FlexPendant to inform that there is no cell path. 3HAC Revision: E Continues on next page 23

26 1 Introduction HomeRun Continued Robot stops at... Cell path 1 For example: between A and B. The tools are closed. For example: between A and B All the tools are opened. Robot movement /Sequence of positions If default cell paths have been defined (see Program wizard - Cell Path on page 85), the robot moves to Home following this sequence of positions: A->21->32->33->34->35->36->37->38->39- >40->41->42->1->2->3->4 NOTE! If there is no cell paths defined from the Machine to the Scrap, the robot will stop. A message will be displayed on the FlexPendant to inform that there is no cell path. The robot moves to Home following this sequence of positions: A->21->1->2->3->4 For all the positions in the station, the default movement is MoveL. On the cell path, the movement is always MoveJ. All paths should be tested backward and forward to make sure that the movement and HomeRun are safe in any situation. 24 3HAC Revision: E

27 1 Introduction 1.3. How to work with RW Plastics Mould and RW DieCast 1.3. How to work with RW Plastics Mould and RW DieCast Overview RW Plastics Mould and RW DieCast should be used in the following ways: 1. Installation. RW Plastics Mould and RW DieCast are installed with RobotWare. Controller key, drive key and additional option keys are needed. (see Installation on page 26). 2. Signal interface. Robot and machine communicate with each other via signals to run synchronously when the robot enters, unloads part and exits the machine (see Signal interface (for RW Plastics Mould) on page 185). 3. Configuring. RW Plastics Mould and RW DieCast provide the general station and tool templates, which can be modified to suit more specific tools and stations (see Configuring libraries on page 179). 4. Programming. The programs can be created on FlexPendant using RW Plastics Mould and RW DieCast program wizard. The program is named, stations and tools are chosen, robot cycles are defined, robot paths are taught and gripper and link procedures are set in robot positions (see Creating programs on page 43). 5. Commissioning. Each station should be tested in the RW Plastics Mould and RW DieCast program wizard. The entire program should be tested carefully, including HomeRun, all the cycles, the robot-machine interaction and RunWithoutRobot, etc. (see Program wizard - Test paths and stations on page 81). 6. Running in production. Run the program in production from the Production window of the RW Plastics Mould and RW DieCast (see Operating manual - Plastics Mould and DieCast). NOTE! Do not connect different applications, for example, RobotStudio, FTP Client and other PC applications to a controller at the same time, make sure only one application at a time. If more than one applications have to be connected to the controller at the same time, the RW Plastics Mould and RW DieCast should be in the main menu. 3HAC Revision: E 25

28 1 Introduction 1.4. Installation 1.4. Installation Overview This section explains how to install RW Plastics Mould and RW DieCast by using RobotStudio. Required RobotWare options The following RobotWare options are needed to run RW Plastics Mould and RW DieCast: RobotWare Plastics Mould or RobotWare DieCast. Or all of the four options: World zones, FlexPendant Interface, Advanced RAPID and Fixed Position Events. Continues on next page 26 3HAC Revision: E

29 1 Introduction 1.4. Installation Continued Install RW Plastics Mould and RW DieCast The following table describes how to install RW Plastics Mould and RW DieCast by using RobotStudio. Action Note/illustration 1. Click the installation script Setup.exe in the folder Additional option/robotware Plastics Mould or RobotWare DieCast on the RobotWare CD to install RW Plastics Mould or RW DieCast option folder into the Media pool. 2. Build a system by using the system builder on the Offline ribbon-tab of RobotStudio. In the step - Additional option, add the RW Plastics Mould or RW DieCast key (see Operating manual - RobotStudio). pic01006 pic01007 Continues on next page 3HAC Revision: E 27

30 1 Introduction 1.4. Installation Continued Action 3. In system builder option list, make sure that the following options are selected: RobotWare Plastics Mould or RobotWare Plastics Mould, or all of: World zone, FlexPendant Interface, Advanced RAPID and Fixed Position Events. Note/illustration 4. Download the system to the IRC5 controller and make an I-start. pic01008 See Back-up and I-start on page HAC Revision: E

31 1 Introduction 1.5. User authorization 1.5. User authorization Overview This section explains how to set up the user authorization by using RobotStudio. User authorization The following levels are set up by default. User Default Group Operator Grants: UAS_RWP_IOSIGNALSETTING UAS_RWP_MACHINEINTERFACECONFIGURE UAS_RWP_RUN UAS_RWP_HOMERUNSETTING UAS_RWP_RESETSTATISTICS UAS_RWP_HOTEDIT UAS_RWP_MODIFY FP_UAS_ABB_MENU_ACCESS UAS_RWP_CYCLESETTING UAS_RWP_TESTSTATION UAS_RWP_LOAD UAS_RWP_CREATE UAS_RWP_SERVICEROUTINE Access to running everything in Production, for example, starting and stopping the robot, running user defined cycles and controlling production statistics. Grants: FR_UAS_ABB_MENU_ACCESS UAS_RWP_RUN UAS_RWP_LOAD 3HAC Revision: E Continues on next page 29

32 1 Introduction 1.5. User authorization Continued User Machine handler Programmer Access to running and resetting everything in Production, configuring machine interface and loading programs. Grants: UAS_RWP_IOSIGNALSETTING UAS_RWP_RUN UAS_RWP_HOMERUNSETTING UAS_RWP_RESETSTATISTICS UAS_RWP_HOTEDIT FP_UAS_ABB_MENU_ACCESS UAS_RWP_CYCLESETTING UAS_RWP_TESTSTATION UAS_RWP_LOAD UAS_RWP_SERVICEROUTINE Access to all parts of RW Plastics Mould and RW DieCast including creating and modifying programs, loading programs and running production. Grants: UAS_RWP_IOSIGNALSETTING UAS_RWP_MACHINEINTERFACECONFIGURE UAS_RWP_RUN UAS_RWP_HOMERUNSETTING UAS_RWP_RESETSTATISTICS UAS_RWP_HOTEDIT UAS_RWP_MODIFY FP_UAS_ABB_MENU_ACCESS UAS_RWP_CYCLESETTING UAS_RWP_TESTSTATION UAS_RWP_LOAD UAS_RWP_CREATE UAS_RWP_SERVICEROUTINE The function buttons that the user does not have access to will be invisible. Continues on next page 30 3HAC Revision: E

33 1 Introduction 1.5. User authorization Continued Set up user authorization The following table describes how to set up the user authorization with RobotStudio. Action Note/illustration 1. Select the controller on which you want to set the grants. Request writing access to the controller. On the controller menu, point to UAS Settings and click UAS Administration Tool. 2. The default user groups are: Programmer Machine Handler Operator These groups grants are described previously. 3. Set up users and add them to a group (see Operating manual - RobotStudio). 4. Warm start the controller and log in as the authorized user. pic01009 pic HAC Revision: E 31

34 1 Introduction 1.6. Program generation 1.6. Program generation Overview When a program is generated by using the program wizard, library files are copied to the newly created program directory and the user input data are added to these files. Illustration of program generation. pic01011 For example, when Program01 is created and saved by using the program wizard, the files from GripperLib and StationLib are transformed to module files and copied to the directory \Programs\Program01. For the station and tool modules, keywords such as %station% or %tool% will be replaced by the station or tool names which are set from the program wizard. For example, the conveyor.lib work object definition: PERS wobjdata w%station%:=[false,true,"", [[0,0,0],[1,0,0,0]],[[ , , ], [ , , , ]]]; will be replaced when it is transformed to conveyor.mod by: PERS wobjdata wconveyor:=[false,true,"", [[0,0,0],[1,0,0,0]],[[ , , ], [ , , , ]]]; 32 3HAC Revision: E

35 1 Introduction 1.7. Run-time 1.7. Run-time Overview A RW Plastics Mould and RW DieCast program mainly consists of: a main program, the kernel (xctjob.mod, xctdata.sys etc.). The kernel handles the scheduling of different stations and error handling. modules that represents the stations (for example, IMM.mod, DCM.mod) and the tools (for example, Vacuumtool.mod) in a cell. The station module defines the robot movement and logic in a certain station. RW Plastics Mould and RW DieCast RAPID instructions and functions (see RAPID instructions on page 89) are used in the station and tool modules to implement robot movement and logic. In run-time the kernel communicates with the station and tool modules via certain stations and tools procedures that the kernel calls. Interrupts and traps are used to catch events. 3HAC Revision: E 33

36 1 Introduction 1.8. Back-up and I-start 1.8. Back-up and I-start Overview This section describes the Back-up and I-start procedures. Back-up Back-up is performed as a usual procedure with FlexPendant or RobotStudio. Everything in the system folder will be backed up. Restart and return to default settings (I-start) At I-start, all the default files will be copied from the additional option folder to the system folder. If the user defined files, including configuration files, have the same name with the default files in the additional option folder, the user defined files will be replaced and lost. Therefor it is important to always make a back-up before performing I-start. The following table describes how to make an I-start. Action 1. Make a back-up of the system. 2. Make an I-start. 3. Restore the system back-up. Continues on next page 34 3HAC Revision: E

37 1 Introduction 1.8. Back-up and I-start Continued Signal configuration of the eio.cfg If the configuration files of the current system are empty, the eio.cfg file with mandatory system signals will be automatically loaded to the program after an I-start. There is a virtual board named "Cell" in the eio.cfg. The signals defined for "Cell" are for RW Plastics Mould and RW DieCast internal use. The mandatory signals must not be set/reset out of RW Plastics Mould and RW DieCast. Signal name didummysignal/ didummysiglow/ dodummysignal/ dodummysiglow doupdatepf/ do_rststatistic xdoprogramrunning Reserved signal. If a logical alias signal is not used in a station, keep it to this signal. didummysignal/dodummysignal stands for virtual input/output signals which stay high in program running. didummysiglow/dodummysiglow stands for virtual input/ output signals which stay low in program running. Reserved signal. The signals represent the running status of RW Plastics Mould and RW DieCast. When the program is running, this signal is high; when the program is stopped, this signal is low. This signal can be used to control the safe gate. Configuring signals The following table describes how to configure the signals. Action 1. Change the signal definitions from virtual to physical IO board on the FlexPendant (see Operating manual - IRC5 with FlexPendant) or using RobotStudio (see Operating manual - RobotStudio). 2. Rename and add signals if necessary. 3. With the RW Plastics Mould and RW DieCast program wizard, map the signals in the eio.cfg to the signals used in the tool and station modules. Continues on next page 3HAC Revision: E 35

38 1 Introduction 1.8. Back-up and I-start Continued Events configuration of Sys.cfg In RW Plastics Mould and RW DieCast application, the Start and Restart, Stop and QStop events are mandatory used in the program. CAB_EXEC_HOOKS: -Routine "xctstart" -Shelf "START" -Task "T_ROB1" -Routine "xctrestart" -Shelf "RESTART" -Task "T_ROB1" -Routine "xctqstop" -Shelf "QSTOP" -Task "T_ROB1" -Routine "xctstop" -Shelf "STOP" -Task "T_ROB1" These event routines are automatically loaded to the program after an I-Start. When starting running RAPID, the four event routines are executed automatically according to the specified actions. The four event routines are used for initializing and executing status recovery, which are from RW Plastics Mould and RW DieCast and should not be used out of RW Plastics Mould and RW DieCast. 36 3HAC Revision: E

39 1 Introduction 1.9. How to run normal RAPID program in robot system with RW Plastics Mould and RW DieCast additional option 1.9. How to run normal RAPID program in robot system with RW Plastics Mould and RW DieCast additional option Overview Since the RW Plastics Mould and RW DieCast additional options add some specified configuration into the system, the normal RAPID program can not be executed without starting RW Plastics Mould and RW DieCast. If a normal RAPID program execution is required, please follow the procedures. Action 1. Make an P-start, make sure that all RW Plastics Mould and RW DieCast related RAPID modules are deleted from memory, including both system modules and program modules. 2. Load a normal RAPID program. 3. Add a new program module to memory, add the following four empty routines into the program module: xctstart(); xctrestart(); xctstop(); xctqstop(). Note/illustration System modules: plastbase, xcttypes, xctdata, xctcommunic, xct- ServiceTP. Program modules: All modules start with xct, all station modules, all tool modules, LinkProcedure, CAction and CHomeRun. Example: Proc xctstart() EndProc Proc xctrestart() EndProc Proc xctstop() EndProc Proc xctqstop() EndProc 4. Run the normal RAPID program. The system will first execute xctstart() or xctre- Start() after pressing the start button on the Flex- Pendant. The system will execute xctstop or xctqstop after the robot stops. All these functions can be left empty if the program does not need. 3HAC Revision: E 37

40 1 Introduction Remote control Remote control Overview Remote control is used to distribute the control of the cell to a machine control panel or some other remote control panels. Start, stop, and HomeRun of the robot can be distributed. When the robot system is under remote control, the remote control panel can handle only one function at each time. The following is remote control xml config. <ConfigFile name="machine Control Remote Command"> <RemoteCommand name="homerun"> <DiSignal name="" VoltageLevel="" /> </RemoteCommand> <RemoteCommand name="runwithrobot"> <DiSignal name="" VoltageLevel="" /> </RemoteCommand> <RemoteCommand name="runwithoutrobot"> <DiSignal name="" VoltageLevel="" /> </RemoteCommand> <RemoteCommand name="stopaftercycle"> <DiSignal name="" VoltageLevel="" /> </RemoteCommand> <RemoteCommand name="stopcurrentcycle"> <DiSignal name="" VoltageLevel="" /> </RemoteCommand> <RemoteCommand name="continue"> <DiSignal name="" VoltageLevel="" /> </RemoteCommand> <RemoteCommand name="instantstop"> Continues on next page 38 3HAC Revision: E

41 1 Introduction Remote control Continued <DiSignal name="" VoltageLevel="" /> </RemoteCommand> <RemoteCommand name="production"> <DiSignal name="" VoltageLevel="" /> </RemoteCommand> </ConfigFile> NOTE! All these items are default and can not be deleted. Never change the sequence! How to trigger remote control There are two ways to trigger remote control: Action Switch to remote control manually Configure special signals In the Production window, tap Menu and then Machine Control to distribute the control of the cell to a remote control panel. The detailed procedures are described in Operating manual - Plastics Mould and DieCast, section Machine control The robot is in local control. When the signal mapped to StopCurrentCycle or StopAfterCycle or InstantStop is caught by the robot, the remote control is triggered automatically, the relevant action is executed and the control from the FlexPendant is disabled. The following procedure details how to configure the special signals: In the Production window, tap Menu and then Machine Control to open the Machine Control page. Tap Configure Machine Interface... directly without tapping Remote Control. Configure signals from the Machine Interface Configuration page. NOTE! Only the signals mapped to StopCurrentCycle, StopAfterCycle and InstantStop can automatically trigger remote control. 3HAC Revision: E 39

42 1 Introduction File structure File structure RW Plastics Mould and RW DieCast file structure In a system, the RW Plastics Mould and RW DieCast files are located in Home\DieCast or in Home\Plastic. The DieCast or Plastic directory contains the following files: Directory/Files Modifications BaseLib Contains the main program files. These files will be copied to the program directory by default when a program is created using the program wizard. BaseLib contains: default.pgf - will become the ProgramXX.pgf. default.detail - contains the information about the program and defines the images in the user interface. xctjob.mod - contains the main program that calls the kernel. xctpara.mod - contains the parameters. xctcellpaths.mod - stores the cell paths. Scrap.mod - contains the parameters of the default station Scrap. Home.mod - contains the parameters of the default station Home. RemoteCommand.xml - contains the signal declarations for remote control. CAction - contains all the combined Linkprocedures and toolmethods CHomeRun - contains all the customized HomeRun. Do not change anything in BaseLib. Continues on next page 40 3HAC Revision: E

43 1 Introduction File structure Continued Directory/Files Modifications ImageLib Contains images that are shown in the Production window, including customized stations, cycle icons etc. Add product images, station and cycle icons to this file. GripperLib Contains gripper tool library files. Configure this file if necessary. StationLib LinkProcLib Programs Contains station library files. Station.xml specify the icons and station background images that are used to represent the stations. Contains the LinkProcedure.mod with procedures that can be linked to and triggered in a certain position. Contains a directory for a program created in the program wizard. A ProgramXX directory contains: ProgramXX.pgf ProgramXX.detail -contains information about the program and defines the images in the user interface. xctjob.mod - calls the kernel. xctpara.mod - parameters. xctcellpaths.mod - stores the cell paths. Scrap.mod - contains the parameters of the default station Scrap. Home.mod - contains the parameters of the default station Home. station modules tool modules LinkProcedure.mod CAction.mod CHomerun.mod RemoteCommand.xml - contains the signal declarations for remote control. Configure this file if necessary. Configure this file if necessary. Can be created and modified in the program wizard. 3HAC Revision: E 41

44 1 Introduction File structure 42 3HAC Revision: E

45 2 Creating programs 2.1. Overview 2 Creating programs 2.1. Overview Overview This chapter provides the description of the program wizard and how to create programs. Sections This chapter is divided into the following sections: Overview on page 43 Program wizard on page 44 Creating programs on page 47 User authorization To access Create Program, the user authorization must be Programmer. 3HAC Revision: E 43

46 2 Creating programs 2.2. Program wizard 2.2. Program wizard Overview The program wizard contains all necessary operations for user to create a program. After going through all the steps that the program wizard contains, the program will be ready to run. It is also possible to save an uncompleted program and continue the program wizard later by using Modify Program. NOTE! When the program is running, it is not possible to access Modify Program. Program wizard steps Tap Create Program in RW Plastics Mould and RW DieCast main menu. The welcome page will open. Wizard overview From the wizard, you can... 1 Name Enter the names of program, mould/die and gripper, enter the program description and load the picture of the part that will be produced. See Program wizard - Name on page Gripper Select the gripper tools that will be used in the cell. See Program wizard - Gripper on page Cell Add stations to the program, for example, the moulding/ die casting machine. Place these stations in the cell. See Program wizard - Cell on page Cycle Define the robot cycles, for example, production, warmup, scrap, quality check etc. Define cycle types (i.e. start cycle and action cycle). See Program wizard - Cycle on page 56. Continues on next page 44 3HAC Revision: E

47 2 Creating programs 2.2. Program wizard Continued Wizard overview From the wizard, you can... 5 Station Teach all the positions in the station paths with correct tool data. Set parameters for each position (for example, name, speed, move, zone value). Select to trigger link procedures and/or tool method in the position. Set alternative stations Set station properties. Test the stations. See Program wizard - Station on page Cell Path Teach positions on the cell paths to avoid collision if necessary. See Program wizard - Cell on page Save Check the check list to make sure all the steps in the wizard are completed. Save or cancel the program. See Program wizard - Save on page 87. Continues on next page 3HAC Revision: E 45

48 2 Creating programs 2.2. Program wizard Continued Browse the program wizard There are two ways to browse the program wizard: Button Action Note/illustration Next and back buttons (A) Tap Next and Back that are displayed in the bottom of the program wizard to browse the wizard step by step. Numbered tabs (B) Tap the numbered tabs on the top of the program wizard. pic HAC Revision: E

49 2 Creating programs Overview 2.3 Creating programs Overview Overview This section describes how to create a program by using the 7-step program wizard. Preparations The RW Plastics Mould and RW DieCast programs are based on the machine tending principle (see Machine tending principle on page 14). To create a program with the RW Plastics Mould and RW DieCast program wizard, the following are required: Station library, see Stations on page 113 for detailed information. Gripper library, see Tools on page 159 for detailed information. LinkProcedrue.mod, see LinkProcedures on page 171 for detailed information. 3HAC Revision: E 47

50 2 Creating programs Program wizard - Name Program wizard - Name Overview The first step of the program wizard is used to set the general properties. How to set general properties The table below describes the operation on this page. Action Note/illustration 1. To open the program wizard: Tap Create Program from the RW Plastics Mould and RW DieCast main menu. 2. The welcome page opens to show the wizard description. To enter the program wizard, tap Next. To go back to the main menu, tap Back. pic02202 Continues on next page 48 3HAC Revision: E

51 2 Creating programs Program wizard - Name Continued Action 3. The Name tab page is the first page of the program wizard. To name the program, tap Program text box under the Program data. Note/illustration 4. To open the soft keyboard, tap ABC... Tap the letters, numbers and special characters to type the program name and tap OK. pic Type the names of the gripper and die/mould and the program description with the ABC To load a product picture, tap Load Image... to browse and load the image from the ImageLib folder. To remove the image, tap Unload Image. pic03004 The product picture will be displayed in the Production window. The product pictures are saved in directory \Home\Plastic\ImageLib, or \Home\DieCast\ImageLib. 3HAC Revision: E Continues on next page 49

52 2 Creating programs Program wizard - Name Continued Action 7. To set advanced mode, tap Advanced Mode. In the Advanced Mode page the following settings can be done: Set HomeRun max speed. Select or clear the check boxes to enable or disable different functions. To quit this page and make all the changes take effect, tap OK. To quit this page without any changes, tap Cancel. Note/illustration 8. To enter the second step of the program wizard, tap Next. pic HAC Revision: E

53 2 Creating programs Program wizard - Gripper Program wizard - Gripper Overview In the second program wizard step, the gripper tools for the program are selected. Tool library The tool library contains general and user defined tools. SeeTools on page 159for how to configure a tool. How to select tools The following table describes how to select tools that will be used in the cell. Action Note/illustration 1. To add a tool to the cell, tap a tool name in the list of Tool Library, and tap arrow to copy the selected one to the Tools for Program. The tools in the list of Tools for Program will be used in the new program. pic03005 Continues on next page 3HAC Revision: E 51

54 2 Creating programs Program wizard - Gripper Continued Action 2. To edit the tool data: Select a tool form the Tools for Program and tap Set Tool data... Type all necessary values in the Tool Data page. Confirm the changes with OK. Note/illustration 3. To map signals: Tap a tool from Tool for Program, then tap Map Signals... Select the matching Physical signal (defined in the eio.cfg file see Configuring signals on page 35) from the list. Confirm all the settings with OK. 4. Repeat step 1-3 to add all desired tools to the program. 5. To remove a tool, tap a tool in the list of Tools for Program and then tap the cross. 6. To enter the third step, tap Next. pic03006 pic HAC Revision: E

55 2 Creating programs Program wizard - Cell Program wizard - Cell Overview The third step of the program wizard is used to setup a cell. In this step, the stations for program will be chosen and placed as the real world production cell. This step constitutes the layout of the Production window. Station library The station library contains the general and user defined stations. How to configure a station is described in How to configure the StationLib on page 179. Default stations Some mandatory stations are added to the cell by default. These stations cannot be deleted. Default station Home Scrap In Home station, the robot is free from all physical obstacles in the cell. HomeRun means the robot goes to the Home position. Criterion: Never add Home to the cycle. Make sure all tools are opened before the robot goes to Home. See Home.lib on page 157. When some errors occur in the cell, the robot will leave the current part in the Scrap station. Criterion: If the cycle includes the Scrap station, the Scrap station must be the last station in the cycle. In the Scrap station, all the tools must be opened to release all the things that the gripper holds. See Scrap.lib on page HAC Revision: E Continues on next page 53

56 2 Creating programs Program wizard - Cell Continued How to define the cell layout The table below describes how to define the cell layout. Action Note/illustration 1. To add a station to the cell, tap a station from the station list on the left side of the window. The Add Station page opens. 2. Select an icon to represent the selected station and rename the station with ABC... Tap OK to add this station to the program and place this station icon on the screen. The station is represented by a circle icon. 3. Repeat step 1-2 to add all required stations to the program. pic03008 pic03009 NOTE! The station name must be less than or equal to 8 characters. NOTE! The station name can not be changed after the station has been added to the program. NOTE! The maximum number of stations in a program is twelve. Continues on next page 54 3HAC Revision: E

57 2 Creating programs Program wizard - Cell Continued Action 4. To place the icons on the screen. 1. Tap a station icon to highlight it. The icon will turn green. 2. Tap on the area where the station should be placed. Note/illustration 5. To delete a station. Tap a station to highlight it, tap Delete. 6. To enter the fourth step of the program wizard, tap Next. pic HAC Revision: E 55

58 2 Creating programs Program wizard - Cycle Program wizard - Cycle Overview The fourth step of the program wizard is used to define the robot cycles. Start and Action cycles There are two types of cycles: Action cycles, an action cycle can not be started directly from the start menu. It can be triggered when another type of cycle is running. Then the robot will finish its current cycle and switch to the action cycle. Start cycles, a start cycle can be started when there is no cycle running. The production cycle is a mandatory start cycle. Some recommended cycles are: Cycle Cycle Type Production Mandatory start The main cycle running for production cycle Warm-up/Start Start cycle Run this cycle when the machine is warming-up. Make sure all parts have been released before starting this cycle. Scrap Action cycle When the offgrade parts are detected, this cycle will be triggered. The offgrade parts will be released to the scrap station during this cycle. Quality Action cycle Run this cycle to place the part on a quality control station. Fill cycle Run this cycle to fill up the cooling tower station. Clear cycle Run this cycle to empty the cooling tower station. Continues on next page 56 3HAC Revision: E

59 2 Creating programs Program wizard - Cycle Continued How to set the robot cycles The table below describes how to set the robot cycles. Action Note/illustration 1. To add new cycles to the program: Tap Edit and then Add... The Add Cycle page opens. Select an icon and name the new cycle from the Add cycle page. The Production cycle is the default start cycle and has been added to the program by default. All the cycles in the current program are listed on the left side of the window. 2. To set Cycle type: Tap Start or Action option button. See Start and Action cycles on page To set the stations sequence in the cycle: When the Add to Cycle command appears, tap the stations on the screen one after the other. The station will get a sequence number automatically. pic03011 NOTE! Max 9 cycles can be added to a program. NOTE! If the Scrap is included in a cycle, the scrap station must be the last station. NOTE! It is possible enter a station more than one time, just tap the station again (maximum four reentries). Continues on next page 3HAC Revision: E 57

60 2 Creating programs Program wizard - Cycle Continued Action 4. To define multiple entries for a station with different cases, for example, the Cooling Tower station: Tap the CL Tower on the screen, the Multiple Entries page will open automatically. Select in which case the robot will tend the Cooling Tower. Tap OK to confirm the settings. Note/illustration 5. To remove a station from the cycle: Tap the Add to Cycle, the menu label will turn to Reset Cycle. Tap a station. The circle around the station icon will turn grey to indicate that the robot will not tend the station in the current cycle. pic03012 NOTE! Removing a station from a cycle means the robot will not tend the station during the current cycle. The station still exists in the program. The description about how to delete a station from the program is in Program wizard - Cell on page 53. NOTE! According to the previous setting, after removing a station from the cycle, The stations that the robot tends before the removed station will keep their previous sequence. For the stations that the robot tends after the removed station, their sequence will be lost. Continues on next page 58 3HAC Revision: E

61 2 Creating programs Program wizard - Cycle Continued Action 6. To view the cycle details. Tap a cycle, tap Edit and then Cycle Details... The Cycle Details page opens. Note/illustration 7. To rename a cycle. Tap a cycle, tap Edit and then Rename To delete a cycle. Tap a cycle, tap Edit and then Delete. 9. To enter the fifth program wizard step, tap Next. pic HAC Revision: E 59

62 2 Creating programs Program wizard - Station Program wizard - Station Overview The fifth step of the program wizard is used to configure various settings that are related to the stations in the program. Position and path color code The positions are visualized as colorful spheres. The following color code is used in both cases, positions and paths. Color Grey Yellow Status Untaught Taught How to browse and edit paths The following table describes how to browse and edit the paths. Action Note/illustration 1. To browse between the stations, do one of the following: Tap Next and Back. Select a station from the drop down list. Continues on next page 60 3HAC Revision: E

63 2 Creating programs Program wizard - Station Continued Action 2. To view the positions defined on each path, tap the plus signs next to the paths. To view the linkprocedure and tool method defined in each position, tap the plus signs next to the positions. Note/illustration 3. To switch between the two dimensional views, tap X-Y/Y-Z/X- Z. The station paths are visualized in the coordinate system on the right side of the screen. 4. To add a sub path before the selected one: Select a sub path. Tap Edit and then Insert... To add a sub path as the last sub path: Tap Add last To rename a path: Select a path. Tap Edit and then Rename... Rename the path with the soft keyboard. 6. To delete a path Select a path, tap Edit and then Delete. pic03015 NOTE! The maximum number of sub paths that can be added to a station is 5. NOTE! Some paths cannot be deleted (see Pointtype on page 92), for example, the sub paths of the die casting machine station or the injection moulding station. 3HAC Revision: E Continues on next page 61

64 2 Creating programs Program wizard - Station Continued How to edit station properties The table below describes how to browse and edit the station properties, alternative station, work object, safety zone, signals mapping and allow HomeRun of the station: Action Note/illustration 1. To set station properties: Tap the plus sign next to the Properties to expand the properties. Select a property and then tap Set Property... to open the Property page. Set necessary values. pic03021 pic03016 Continues on next page 62 3HAC Revision: E

65 2 Creating programs Program wizard - Station Continued Action 2. To set the alternative station: Tap Alternative Station on the screen and then tap Set Alternative Station... Select a station and tap OK. When the status of the current station is Busy, the robot will tend the alternative station instead. Note/illustration 3. To set the work object of the station: Tap Work Object and tap Set Work Object... In the Work Object Data window, type all necessary work object data. Confirm with OK. The work object data can also be taught in the Program Data using datatype wobj data. The work object is the local coordinate system of a station. pic03017 pic03018 Continues on next page 3HAC Revision: E 63

66 2 Creating programs Program wizard - Station Continued Action Note/illustration 4. To set safety zone of the station: Tap Safety Zone and tap Set Safety Zone... Type all necessary values. Confirm with OK. 5. To map signals: Tap Signal Mapping and then tap Map Signals... Select matching Physical signals (defined in the eio.cfg file). Confirm with OK. pic03019 NOTE! Safety zone (World zone) is the safety area where the robot can move with collision free. The function of the safety zone must be set and enabled in each station module. pic03020 Continues on next page 64 3HAC Revision: E

67 2 Creating programs Program wizard - Station Continued Action Note/illustration 6. To enable HomeRun in a station: Tap Allow HomeRun. Select or clear the check boxes of Allow HomeRun in auto mode and Allow HomeRun in manual mode to turn on or off the options. The Allow HomeRun in manual mode is selected by default. 7. To enable check station status: Tap Check Station Status. Select the check box of the Enable Check Current Station Status. pic03022 pic03039 If Enable Check Current Station Status has been selected, the station status will be checked before the robot tends this station. If Enable Check Current Station Status has been cleared, this station status will not be checked during production. This function is used to save RAPID execution time. 3HAC Revision: E 65

68 2 Creating programs Program wizard - Customize HomeRun Program wizard - Customize HomeRun Overview In normal process, when there are some errors, the robot will move to Home following the default HomeRun rules. A useful function is provided in this step, with which you can add your own HomeRun strategy. Continues on next page 66 3HAC Revision: E

69 2 Creating programs Program wizard - Customize HomeRun Continued Customized HomeRun strategy The table below describes HomeRun strategies. Condition HomeRun strategies The robot stops in a station In path of sub path in a station Out path of sub path in a station Target position of sub path Main path Cell path Robot moves to another station When the robot stops on the In path of the sub path in a station, the robot will move to the Entry position of the sub path and executes the strategy defined in the Entry position. Then the robot moves to the Target position of the main path and executes the strategy defined in this position. If the robot moves back to the Entry position of the main path, the Entry position of the main path strategy will be executed. If the robot moves forward to the Exit position of the main Path, the Exit position of the main Path strategy will be executed. When the robot stops on the Out path of sub path in a station, the robot will move to the Exit position of the sub path and executes the strategy defined in this position. Then the robot moves to the Out path of the main path and executes the strategy defined in the Exit position of the main path. NOTE! The robot will not move to the Target position of main path, the Target position of main path strategy will not be executed. Depending on the movement defined in this position, the robot will move backward or forward, see previous description for reference. All the customized HomeRun will be executed. The robot will move back to the previous station Exit position, and execute the customized HomeRun strategy defined in this position. The robot will do customized HomeRun in a station following the rule. If the robot already moves out of current station and moves to the next station, only the Customized HomeRun that is defined in the Exit position of the next station will be done. 3HAC Revision: E Continues on next page 67

70 2 Creating programs Program wizard - Customize HomeRun Continued Condition Special interface HomeRun strategies All the HomeRun strategy procedures are included in the CHomeRun module, and one special entry routine called HR_EntryProc will be executed before all the strategy. PROC HR_EntryProc() EndPROC NOTE! All the customized HomeRun procedures contents can be modified by using the Program Editor or RobotStudio, but if the grammar is not recognized by the graphical user interface, it can not be modified by the graphical user interface any more. If the movement has been defined, and the movement instructions are not the HomeRun move instructions. The robot will not know the actual position until it moves to Home. Continues on next page 68 3HAC Revision: E

71 2 Creating programs Program wizard - Customize HomeRun Continued How to customize HomeRun Select a position from the station tab page, tap Customize HomeRun... to open the Customize HomeRun page which contains of three tab pages, Condition, Action for True Condition and Action for False Condition. NOTE! Only in Entry, Target and Exit positions, the customized HomeRun can be defined. The table below describes how to define the condition. Action Note/illustration 1. To add an item. Tap Add and then tap Add Tool Check, Add DInput Signal Check or Add DOutput Signal Check. If you need more than one items to define the condition. Tap Insert to add an item before the one selected currently. Or tap Add to add an item at the end of the list. 2. To edit the item: Tap each column of the item and select proper options for the item. 3. To delete an item: Tap an item, then tap Delete, the item will be deleted from this list. pic03045 Continues on next page 3HAC Revision: E 69

72 2 Creating programs Program wizard - Customize HomeRun Continued The table below describes the operation for the Action for True Condition and Action for False Condition. Action Note/illustration 1. Set actions in True or False condition. When the linkprocedures and toolmethods have been added, the up and down arrows are enabled. Tap up or down arrows to sort the sequence of the linkprocedures and tool methods. 2. Execute Movement below. Tap the drop-down arrow and select the desired option from the list. 3. Station case. Tap the drop-down arrow and select an option from the list. pic03046 The procedure is almost the same as setting linkprocedure or toolmethod at a position. See How to set linkprocedures at a position on page 79 and How to set toolmethods at a position on page 80 for reference. For the Entry and Exit position of a sub path, it s no necessary to set this option. For the Target position of a sub path or main path, you should decide the robot will move backward to the Entry position or move forward to the Exit position. For the Entry and Exit position of the main path, you should decide the robot will move to Home, Scrap or other stations in the cell. This step should be done only for the Entry and Exit position of main path when selecting Move to station with different cases, for example, the Cooling Tower Station. Continues on next page 70 3HAC Revision: E

73 2 Creating programs Program wizard - Customize HomeRun Continued After all the tab pages have been modified, tap OK to quit this page and make all the settings take effect, or tap Cancel to go back to the station tab page without any changes. NOTE! If you just set the condition without setting any actions for the true or false condition, when you tap OK, there will be a message page to warn you about this. Tap OK to quit this page discarding all your settings, or tap Cancel to go back to the page and continue the modification. 3HAC Revision: E 71

74 2 Creating programs Program wizard - Teach paths Program wizard - Teach paths Overview This section describes how to teach a robot path. Recommended Not recommended Teach the following positions as the same geometrical position using Paste Main Target: Target position of the main path Entry position of the sub path Exit position of the sub path These positions are not taught as the same geometrical position. In such a case, it is important to test that the robot carrying a part can move without any collisions: from the Entry position of the sub path to the Target position of the main path. and from the Exit position of the sub path to the Target position of the main path. pic03023 Continues on next page 72 3HAC Revision: E

75 2 Creating programs Program wizard - Teach paths Continued NOTE! The robot must be in manual mode when jogging the robot to the teach positions. How to teach a path The following procedure details how to teach a path. Action Note/illustration 1. To open the Path page: Tap a path that should be taught. Tap Teach The Path page will open. All the positions on that path can be seen in this page. Tap a position, the position will be marked with a square pointer. pic03024 pic03025 Continues on next page 3HAC Revision: E 73

76 2 Creating programs Program wizard - Teach paths Continued Action Note/illustration 3. Before teaching positions, make sure the following options have been set correctly from the QuickSet menu: the TCP the work object They will be used when jogging the robot and storing robot positions. NOTE! Only the tool data and work objects related to the tools and stations that RW Plastics Mould and RW DieCast contains can be used, for example, tmechgrip and wdcm or tvacuum and wimm. 4. To add a position to the path: Tap a position, tap Insert to add a position before the selected one. or tap Add Last to add a position as the last position of the path. 5. To delete a position: Tap a position and then tap Delete. 6. To teach a path: Tap a position. Jog the robot to the desired position. Tap Teach on the screen. The color of the position will turn to yellow to indicate that the position is taught. pic03026 Detailed description about how to use the QuickSet menu is described in Operating manual - IRC5 with FlexPendant. The max. number of positions in a path is 10. It is impossible to delete the Target, Entry and Exit position of the path. The positions can be fine tuned in x-,y- and z- coordinates. See Program wizard - Position properties on page 76. Continues on next page 74 3HAC Revision: E

77 2 Creating programs Program wizard - Teach paths Continued Action 7. To reuse the positions: Tap Copy, Paste. For example, Tap the position Home_p1, then tap Copy, the massage Home_p1 in Buffer will be displayed on the screen. Tap the position Home_p2 to activate it, then tap Paste. Now Home_p1 and Home_p2 are exactly the same geometrical position. 8. To reuse the Target position of the main path in the sub paths, tap Paste Main Target. 9. Repeat step 6, 7 or 8 to teach all the positions in the path. Tap Next Path and repeat for all paths in the station. 10. Repeat step 1-9 for all stations in the cell. Note/illustration pic03040 It is recommended to reuse the Target position of the main path when teaching the sub paths. 3HAC Revision: E 75

78 2 Creating programs Program wizard - Position properties Program wizard - Position properties Overview The position properties specify the robot movement at a certain position. Position properties The table below describes the position properties: Position property Work object Tool data Coordinate value Display Name Section Speed Move instruction Zone The work object is the local coordinate system of a station. See Program wizard - Station on page 60 for how to defined the work object. A robot uses several work objects, each suitable for specific types of jogging or programming. The suitable work object can be selected from the QuickSet menu. The tool data defines the coordinates of the gripper. See Program wizard - Gripper on page 51 for how to define the tool data. The suitable tool data can be selected from the QuickSet menu. The robot positions are represented in x-, y- and z- coordinates. The position name displayed on the screen. NOTE! Sometimes the same position may have different names displayed on the screen and in the RAPID. The sections define where the position is located. In - positions on the In path and Target position Out - positions on the Out path The speed of the robot movement in mm/s. The robot movement type: MoveJ = Moves the robot by joint movement. MoveL = Moves the robot linearly. MoveJ Synch = Moves the robot by joint movement and executes a RAPID procedure synchronize. MoveL Synch = Moves the robot linearly and executes a RAPID procedure synchronize. Fine or zone value of the robot movement. Continues on next page 76 3HAC Revision: E

79 2 Creating programs Program wizard - Position properties Continued Position property Concurrent Link Procedure Execute one or more logical instructions at the same time as the robot moves in order to reduce the cycle time (e.g. used when communicating via serial channels). No synchronization required. See Technical reference manual - RAPID Instructions, Functions and Data types. A linkprocedure is the procedure that will be triggered when the robot reaches the position, for example, Wait10s, move conveyor belt, cut sprue etc. The procedures are defined in LinkProcedure.mod. For further description see LinkProcedure on page 128. Select a position in the program wizard - Station and tap Set Position... button to view the linkprocedures attached to the position. The machine tending logic is by default defined with linkprocedures. NOTE! To execute the procedure in the exact position zone data MoveLsync of fine position should be used. Tool method A toolmethod is the procedure that will be triggered when the robot reaches a Target position, for example, Open Grip Detail or Close Grip Detail. The toolmethods are defined in the Tool Library. For further description see Tools on page 159. The tool wait time starts when the tool is triggered. Select a position in the program wizard - Station and tap Set Position... button to view the toolmethod attached to the position. When the robot starts a new cycle, all tools need to be opened. NOTE! To execute the procedure in the exact position zone data MoveLsync of fine position should be used. Continues on next page 3HAC Revision: E 77

80 2 Creating programs Program wizard - Position properties Continued How to set position properties The table below describes how to set position properties. Action Note/illustration 1. To open the Set Position page: Tap a position in the fifth page of the program wizard or in the Path page. Tap Set Position To modify the following settings: Tap the up or down arrow to change the coordinate values of the selected position. Tap the Display Name text box, rename the position with the soft keyboard. Under Movement, tap the text box to expand the lists, select desired value from the list for Speed, Move type and Zone. 3. To sort the sequence of linkprocedures and toolmethods: Tap an item and then tap up or down arrow under Actions 4. To confirm all the changes: Tap OK. pic03027 How to trigger linkprocedures/toolmethods is described in How to set linkprocedures at a position on page 79 and How to set toolmethods at a position on page 80. Continues on next page 78 3HAC Revision: E

81 2 Creating programs Program wizard - Position properties Continued How to set linkprocedures at a position The following procedure details how to set a linkprocedure. Action Note/illustration 1. Tap Select LinkProcedure... from the Set position page. The Trigger Link procedure at: page will open. 2. To add a procedure: Tap a procedure in the Library, for example, Wait1second, and tap the arrow.the selected procedure is copied to Trigger at Position. 3. To remove a linkprocedure from the position, select a linkprocedure and tap the cross. 4. Tap OK. pic03028 NOTE! Be careful to change the linkprocedures related to the machine tending logic. 3HAC Revision: E Continues on next page 79

82 2 Creating programs Program wizard - Position properties Continued How to set toolmethods at a position The following procedure describes how to trigger a toolmethod. Action Note/illustration 1. Tap Select ToolMethod... from the Set position page. The Trigger Tool at: window will open. 2. To add a tool: Tap a tool in the Tool list, for example, MechGrip, tap the arrow. The tool is copied to the tools to be triggered in the position. 3. To set a method: Tap Open/Close and then select Open or Close from the list. 4. To specify the wait time: Tap the tool wait time area and tap the up/down arrow. 5. To remove a toolmethod from the position: Tap a toolmethod and tap the cross. 6. Repeat step 1-4 for all tools needed in the program. 7. Tap OK. pic HAC Revision: E

83 2 Creating programs Program wizard - Test paths and stations Program wizard - Test paths and stations Overview After a path has been taught, the path and the relevant station are ready for testing. Test type Set the testing type: Direction Forward. Do the test from the first position. The robot will move forward according to the positions sequence. Backward. Do the test from the last position. The robot will move backward according to the positions sequence. Mode Single step test. Do the test step by step. It s safer to test path in single step mode when testing a path for the first time. Continuous test. All positions in the path are tested continuously. The robot will move continuously. Auto/Manual mode All tests can be done in either auto or manual mode. It is recommended to test paths/stations in manual mode for safety. Continues on next page 3HAC Revision: E 81

84 2 Creating programs Program wizard - Test paths and stations Continued How to test paths Action 1. Turn the robot to manual mode. Hold the guard stop to enable motors on. 2. To open the test path page: Tap Test in the Path page. Note/illustration 3. Move the square pointer to the first position for Forward test or last position for Backward test. 4. To choose test mode: Tap Single step or Continuous. pic03030 Continues on next page 82 3HAC Revision: E

85 2 Creating programs Program wizard - Test paths and stations Continued Action 5. Press the Start button on the Flex- Pendant: In Single step test, the robot will run to the next position and stop. Repeat the operation until all positions are tested. In Continuous test, the robot will test to run the entire path and stop. 6. To go back to the teach page of the current path, tap Teach. To go to the teach page of the previous/next path, tap Prev./Next. To go back to the Station tab page, tap OK. Note/illustration Continues on next page 3HAC Revision: E 83

86 2 Creating programs Program wizard - Test paths and stations Continued How to test stations Action 1. Turn the robot to manual mode. Hold the guard stop to enable motors on. 2. To open the Test Station page: Select a station that should be tested from the dropdown list box. Tap Test Station... Note/illustration 3. To select test types from the following options: Test Movement With Logic. Test Station Case. Test Only Movements. Test Shortcut Path. After tap an item, the detailed description about the test type will be displayed on the screen. 4. Press the Start button on the Flex- Pendant, the robot will start testing according to the selected test type. pic03043 pic HAC Revision: E

87 2 Creating programs Program wizard - Cell Path Program wizard - Cell Path Overview In the sixth step of the program wizard, the robot positions between stations are defined and taught i.e. the cell path. NOTE! If there are some obstacles between the stations, it is very important to define cell paths to avoid the collisions. If no cell path has been added to the cell, it is not possible to make the robot move from one station to another. NOTE! There are two positions on the cell path that can not be modified: the Exit position of the main path in the previous station, and the Entry position of the main path in the next station. How to define and teach cell paths The following table describes how to define and teach cell paths. Action Note/illustration 1. To add cell paths: To define between which stations the cell path should be created, select stations from the drop-down lists. Tap arrow, the cell path Station 1 -> Station2 is created and displayed in the Cell Path List. pic03034 Continues on next page 3HAC Revision: E 85

88 2 Creating programs Program wizard - Cell Path Continued Action 2. To add default cell paths: Tap Default cell paths to open the Setting page. Select/clear check boxes to decide what kind of cell paths should be added to the cell. Tap OK to confirm the settings, all the selected cell paths will de displayed in the Cell Path List. Note/illustration 3. To teach cell paths: Teaching cell paths is almost the same as teaching paths in station, see Program wizard - Teach paths on page 72 for detailed description. pic HAC Revision: E

89 2 Creating programs Program wizard - Save Program wizard - Save Overview A check list of the program is provided in the last step of the program wizard. How to check and save program The table below describes how to check and save the program. Action Note/illustration 1. To check the program: Tap Check. If all the necessary operations have been done, all the steps will be marked with a check mark. Otherwise go back to the unfinished steps to complete the settings. 2. Set the program status with Set to Ready/Set to Untested. pic03036 Continues on next page 3HAC Revision: E 87

90 2 Creating programs Program wizard - Save Continued Action 3. Tap Finish, a message page opens up. From this page, Tap Save to save the program in the default folder. Tap Save as... to save the program with new name. Tap Discard to discard the new program and go back to the main menu. Tap Cancel to go back to the program wizard. Note/illustration 4. After save the program, the main menu will open. And the newly created program will be loaded as the current program automatically. pic HAC Revision: E

91 3 RAPID instructions 3.1. Overview 3 RAPID instructions 3.1. Overview Overview Sections This chapter describes the syntax, data types, constants, instructions and functions unique for RW Plastics Mould and RW DieCast. It should be seen as a complement to the Technical reference manual - RAPID Instructions, functions and data types. The sections of the chapter are: Overview on page 89 RAPID syntax on page 90 Data types on page 91 Instructions on page 96 Functions on page 109 3HAC Revision: E 89

92 3 RAPID instructions 3.2. RAPID syntax 3.2. RAPID syntax Overview Besides the normal RAPID syntax, the following syntax is used: The RW Plastics Mould and RW DieCast RAPID instructions are case sensitive. In the tool and station modules, it is strongly recommended to use local variable data (LOCAL VAR) instead of persistent data (PERS) to limit the variable life period. In station and tool library files, %station% and %tool% should be used as the station and tool names (see Program generation on page 32). 90 3HAC Revision: E

93 3 RAPID instructions Overview 3.3 Data types Overview Overview The data types described in this section are used to define positions, stations, tools, etc. Pointtype on page 92 Propertytype on page 95 IOMapping on page 95 3HAC Revision: E 91

94 3 RAPID instructions Pointtype Pointtype Pointtype Pointtype is used to describe a position on a path, for example, an Entry position. Example pointtype ptarget:= [17,1,1,[[1515, , ], [ , , , ], [0,0,-1,0], [9E+09,9E+09,9E+09,9E+09,9E+09,9E+09]], [200,500,5000,1000],[TRUE,0,0,0,0,0,0], "IMM:L_IMM_p5","","tGrip2DO","wIMM","IMM_p5",0,2,3,"IMM_SP1 IM M_p5","",0,""], Structure pointtype ptarget:= [ TeachFlag; Section; MvMnt; robtarget RtPos; speeddata SdSpeed; zonedata ZdZone; LinkProcedure; ToolMethod; tltcp; stnwobj; RealName; ConcMode; TargetPositionIndex; ExitPositionIndex; DisplayName; CustomizedHomeRun; nfutureuse; strfutureuse]; Continues on next page 92 3HAC Revision: E

95 3 RAPID instructions Pointtype Continued Pointtype Components byte TeachFlag Can be assigned to the following constants: 0 - The position is not taught and can be deleted from the program wizard. 1 - The position is not taught and can not be deleted from the program wizard The position is taught and can be deleted from the program wizard. 17- The position is taught and cannot be deleted from the program wizard. byte Section Definition of the In path position or Out path position. Can be assigned to the following constants: 0 - Undefined section 1 - In path including the Target position 2 - Out path position num MvMnt Defines how the robot moves to the position, i.e. in linear motion or joint motion. Can be assigned to the following constants: 0 - undefined movement 1 - linear movement 2 - joint movement 3 - MoveL Sync 4 - MoveJ Sync robtarget RtPos Position as the robtarget Continues on next page 3HAC Revision: E 93

96 3 RAPID instructions Pointtype Continued Pointtype Components speeddata SdSpeed zonedata ZdZone string LinkProcedure string ToolMethod string tltcp string stnwobj string RealName byte ConcMode byte TargetPositionIndex byte ExitPositionIndex string DisplayName string CustomizedHomeRun num nfutureuse string strfutureuse Robot movement speed when moving to the position Zone in the position CAction module name and procedure Empty string, keep for future use. Tool data Work object data Every position has an unique name. This name is generated when you add a path or add a position in the program wizard. This name can not be changed manually. The real name is extremely important for logic execution. Conc flag. 0=no ConCurrent, 1= with ConCurrent. This option only can be selected when the movement and logic synchronization is not important, and the conc can not be selected above 4 in execution continuosly. Target position index in the current path. It is automatically generated by the program wizard and can not be modified manually. Exit position index in the current path. It is automatically generated by the program wizard and can not be modified manually. Displayed name. This position name can be seen from the program wizard. Customized HomeRun procedure Keep for future use. Keep for future use. 94 3HAC Revision: E

97 3 RAPID instructions Propertytype Propertytype See propertytype %STATION%_Prop{} on page IOMapping See IOMapping %STATION%_Xouts{} and IOMapping %STATION%_Xins{} on page HAC Revision: E 95

98 3 RAPID instructions Overview 3.4 Instructions Overview Overview This section describes the instructions used in RW Plastics Mould and RW DieCast. The instructions are used to move the robot and set status of stations and tools. xctmovein on page 97 xctmoveout on page 98 xctforcepart on page 99 xctsetstatus on page 100 xctsettoolstatus on page 100 xctoffsetpath on page 101 xcterrkeep on page 102 xctsetuserstats on page 103 xcttpwrite on page 104 xctsetcycleend on page 105 HR_MoveBackInPath on page 106 HR_MoveForwardOutPath on page 107 HR_MoveToStnAndExecute on page HAC Revision: E

99 3 RAPID instructions xctmovein xctmovein xctmovein This instruction is used to move the robot from the Entry position of the path to the Target position of the path. This instruction is used only in the station Execute() procedure and should be used with xctmoveout in pair. Example PERS pointtype DCM_mp{10}:=*; xctmovein RbtOnMainPath, DCM_mp;! xctmovein moves the robot from DCM_mp Entry position to DCM_mp Target position. Structure xctmovein PathID, Path{*}; Argument num PathID Defines path type. Can be assigned to the following values: RbtOnCellPath - The robot moves between the stations on the cell path. RbtOnMainPath - The robot moves in a station on the main path. RbtOnSubPath - The robot moves inside a station on the sub path. pointtype Path{*} Array with 10 positions data (see Pointtype on page 92). 3HAC Revision: E 97

100 3 RAPID instructions xctmoveout xctmoveout xctmoveout This instruction is used to move the robot from the Target position of the path to the last defined position on the path.this instruction is used only in the station Execute() procedure and should be used with xctmovein in pair. Example PERS pointtype DCM_mp{10}:=*; xctmoveout RbtOnSubPath, DCM_mp;! xctmoveout moves the robot from DCM_mp Target-position to the Exit position. Structure xctmoveout PathID, Path{*}; Arguments num PathID Defines path type. Can be assigned to the following values: RbtOnCellPath - The robot moves between the stations on the cell path. RbtOnMainPath - The robot moves in a station on the main path. RbtOnSubPath - The robot moves in a station on the sub path. pointtype Path{*} Array with 10 positions data (see Pointtype on page 92). 98 3HAC Revision: E

101 3 RAPID instructions xctforcepart xctforcepart xctforcepart This instruction is used to force the robot to digress the normal cycle sequence and move to a requested station (the forced station) where the part will be processed after the robot exits the current station. The instruction is mainly used in the station Execute() procedure. For example, xctforcepart is used to force the robot to scrap the part according to an input signal that could come from a vision control. NOTE! If the forced station is in the current cycle, after tending the forced station, the robot will continue the cycle down stream. NOTE! If the forced station is up-stream the current station, a dead-loop may occur. If the forced station is not in the current cycle, after tending the forced station, the robot will restart the cycle from the beginning. NOTE! In the whole case, tools must be opened in the forced station. Example WaitDI di_ejector,1\maxtime:=waitt\timeflag:=btimeout; If btimeout Then xctforcepart "Scrap";! Forces robot to Scrap station, after DCM is!executed. Endif xctmoveout RbtOnMainPath,DCM_mp; Structure xctforcepart Station Arguments string Name The name of the forced station, where the robot is forced to and processes the part instead of following the normal cycle sequence. 3HAC Revision: E 99

102 3 RAPID instructions xctsetstatus xctsetstatus xctsettoolstatus xctsetstatus This instruction is used to set station status. This instruction is mainly used in the station CheckStatus() procedure. Example xctsetstatus "Conveyor",stnOk;!Station's status is set, depending on logical condition. Structure xctsetstatus Name, Status; Arguments string Name Name of station num Status The station status should be: stnok - the robot will tend the station. stnbusy - the robot will tend the alternative station of the station. stnnok - the robot will not tend the station, make a HomeRun instead. xctsettoolstatus This instruction is used to set the current tool status. The instruction is mainly used in the tool CheckStatus() procedure. Example If DOUTPUT(doGrip) =1 then xctsettoolstatus "MechGrip", tlopen;! Set tool status to open. EndIf Structure xctsettoolstatus Name, Status; Arguments string Name Name of the current tool num Status The tool status should be: tlopen - the tool is opened. tlclosed - the tool is closed. tlnok - the tool is not key HAC Revision: E

103 3 RAPID instructions xctoffsetpath xctoffsetpath Example Structure xctoffsetpath This instruction is used to move a complete path in three dimensions, which is useful to set offset value for a palletizing pattern. The instruction is mainly used in the station Execute() procedure. NOTE! The xctoffsetpath can be used for the subpath only. After offsetting a subpath, when an error happens: the robot can follow the offset path to move forward or backward, moving from the offset path to the main path is not verified by default. To ensure a safe HomeRun, you should test the path in production window. xctoffsetpath Conveyor_sp1, nconveyor_xoff, nconveyor_yoff, nconveyor_zoff;!moves Conveyor_sp1 in three dimensions. xctmovein RbtOnSubPath,Conveyor_sp1; xctoffsetpath Path{*}, xoff, yoff, zoff; Arguments pointtypepath{*} An array with position data (see Pointtype on page 92). num xoff, yoff, Offset value of the path zoff 3HAC Revision: E 101

104 3 RAPID instructions xcterrkeep xcterrkeep xcterrkeep Example Structure Arguments This instruction is used to write the user defined messages to the Event log, which is mainly used in the procedure error handling. CheckStatus() xctsetstatus "Conv1", stnok; ERROR xcterrkeep "Error in Conveyor CheckStatus", ERRNO;! Error message written to the Event log. RAISE erhomepos; ENDPROC xcterrkeep "Error string",errno; string "Error Contains the error description. Max 50 characters. string" errnum ERRNO Error number written to the Event log HAC Revision: E

105 3 RAPID instructions xctsetuserstats xctsetuserstats xctsetuserstats Example This instruction is used to write user defined statistics to RW Plastics Mould and RW DieCast statistics window.!to measure the machine process time: clkstart clkdcmstopwatch{1}; clkstart clkdcmstopwatch{2}; nkptcurtimepoint{1}:= clkread(clkdcmstopwatch{1}); nkptpretimepoint{1}:= clkread(clkdcmstopwatch{2}); stdcmprocesstime:=nkptcurtimepoint{1}-nkptpretimepoint{1}; Structure xctsetuserstats 14, stdcmprocesstime,"processing Time in %STA- TION%(s)"; xctsetuserstats ID, data, description; Arguments byte ID Statistics ID number The ID must be unique in a program. num Data Statistics variable string of the statistics variable 3HAC Revision: E 103

106 3 RAPID instructions xcttpwrite xcttpwrite Example Structure xcttpwrite This instruction is used to write cycle information to the RW Plastics Mould and RW DieCast cycle information window. xcttpwrite "Waiting for Mould Open Position signal"; xcttpwrite string;!as Same as Tpwrite Arguments string of the robot current position. Max 80 characters. tmpnum The data whose numeric value should be written after the text string. tmpbool The data whose logical value should be written after the text string. tmppos The data whose position should be written after the text string. tmporient The data whose orientation should be written after the text string HAC Revision: E

107 3 RAPID instructions xctsetcycleend xctsetcycleend xctsetcycleend Example This instruction is used to set a flag to allow the robot to finish current cycle and stop. Local Proc Execute() xctmovein RbtOnMainPath, IMM_MP, xctmovein RbtOnSubPath,IMM_SP1; xctmoveout RbtOnSubPath,IMM_SP1; xctmoveout RbtOnMainPath,IMM_MP; If dinosprueinpart=1 then xctsetcycleend; else LK1_SetMldClose; endif Structure Arguments Endproc xctsetcycleend() No parameters 3HAC Revision: E 105

108 3 RAPID instructions HR_MoveBackInPath HR_MoveBackInPath HR_MoveBackInPath This instruction is used to make the robot move along the In path back to the Entry position of the current path. Example HR_MoveBackInPath RbtOnSubPath, IMM_SP1; Structure!Customized HomeRun FunctionPROC HR_MoveBackInPath( num PathID,pointtype Path{*}) Arguments num PathID Defines the path type that the robot will move on. PathID can be assigned to the following values: RbtOnCellPath - the robot moves between the stations on the cell path. RbtOnMainPath - the robot moves in the station on the main path. RbtOnSubPath - the robot moves inside the station on the sub path. pointtype Path{*} The path is an array with 10 positions data (see Pointtype on page 92) HAC Revision: E

109 3 RAPID instructions HR_MoveForwardOutPath HR_MoveForwardOutPath Example Structure HR_MoveForwardOutPath This instruction is used to make the robot move along the Out path forward to the Exit position of the current path. HR MoveForwardOutPath RbtOnSubPath, IMM SP1;!Customized HomeRun Function PROC HR_MoveBackInPath(num PathID, pointtype Path{*}) Arguments num PathID Defines the path type that the robot will move on. PathID can be assigned to the following values: RbtOnCellPath - the robot moves between the stations on the cell path. RbtOnMainPath - the robot moves in the station on the main path. RbtOnSubPath - the robot moves inside the station on the sub path. pointtype Path{*} The path is an array with 10 positions data (see Pointtype on page 92). 3HAC Revision: E 107

110 3 RAPID instructions HR_MoveToStnAndExecute HR_MoveToStnAndExecute HR_MoveToStnAndExecute This instruction is used to move the robot from the current station to the next station and execute the procedure defined in the next station. Example HR_MoveToStnAndExecute "IMM", "Blank01"; HR_MoveToStnAndExecute "IMM", "CLTower",\stationcase:="FillingAndProductionOperation"; Structure PROC HR_MoveToStnAndExecute (string FromStation, string ToStation \string StationCase) Arguments FromStation Current station name ToStation Next station name StationCase If the next station has been defined with different cases, the cases should be specified HAC Revision: E

111 3 RAPID instructions Overview 3.5 Functions Overview Overview The functions are used to get information from the station and tool modules. xctgetscrapstn on page 110 xctgetcondition on page 110 xctgettlstatus on page 111 3HAC Revision: E 109

112 3 RAPID instructions xctgetscrapstn xctgetscrapstn xctgetcondition string xctgetscrapstn Returns the name of the Scrap station as a string. Example WaitDI di_ejector,1\maxtime:=waitt\timeflag:=btimeout; If btimeout Then! Returns Scrap station name, and forces robot to go to! Scrap station. xctforcepart xctgetscrapstn(); EndIf xctmoveout RbtOnMainPath,DCM_mp; Return Value string Name Name of the Scrap station string xctgetcondition(string) Example Argument Return Value Returns the re-entry cases of the current station. The station re-entry case is set in the program wizard - cycle tab page.!two cases to choose between two sub paths in Execute(): stentrycondition:=xctgetcondition("%station%"); Test stentrycondition CASE "FillingAndProductionCycle": xctmovein RbtOnSubPath,%STATION%_SP1; CASE "ClearCycle": xctmovein RbtOnSubPath,%STATION%_SP2; ENDTEST string "%station%" string "station case" 110 3HAC Revision: E

113 3 RAPID instructions xctgettlstatus xctgettlstatus xctgettlstatus Example Structure Argument Return Value Returns the specific tool status as a byte. The tool status has three status:tlopen, tlnok, tlclosed. VAR byte currenttoolstatus:=0; currenttoolstatus:=xctgettlstatus("vacuum") FUNC num xctgettlstatus(string toolname) string "%station%" num tool status: tlopen tlclosed tlnok 3HAC Revision: E 111

114 3 RAPID instructions xctgettlstatus 112 3HAC Revision: E

115 4 Stations 4.1. Overview 4 Stations 4.1. Overview Overview Sections This chapter explains the station module. For explanation of %STATION% syntax, see RAPID syntax on page 90. The sections of this chapter are: Station definition on page 114 Station variables on page 115 Station procedures on page 120 StationLib on page 131 Station.xml on page 158 3HAC Revision: E 113

116 4 Stations 4.2. Station definition 4.2. Station definition Definition A station is the special work place, where the robot picks or leaves a part or where a part is processed, for example, the injection/die casting machine or conveyor. Every station contains predefined paths, procedures and logic statements. A station is modelled as an object independent of other stations in the cell. In RAPID code a station object will be a program module i.e. a.mod file. To enable the main program to interact with the station, the station needs to support the properties, procedures and events described below. Station status The station can have these statuses: Status Ok Busy Not Ok The station is ready for tending. The station is busy with some processes. The station is in failure state HAC Revision: E

117 4 Stations Overview 4.3 Station variables Overview Overview This section describes the mandatory variables of a station. Station variables The variables determine the station representation in Production window or program wizard, or the robot path in station. Data PERS string %STATION%_Xins{} PERS string %STATION%_Xouts{} PERS propertytype %STATION%_Prop{} PERS wobjdata w%station%j PERS pointtype%station%_mp{10} PERS pointtype%station%_sp1{10} PERS %STATION%_corner1 PERS %STATION%_corner2 A station module may also contain other variables. Input signals for the Production window. Output signals for the Production window. Station properties - variables that are displayed and modified from the program wizard. Work object of a station. Array with main path positions. The size of array is fixed 10. Array with sub path positions.the size of array is fixed 10. Definition of safety zone box left corner. Definition of safety zone box right corner. 3HAC Revision: E 115

118 4 Stations IOMapping %STATION%_Xouts{} and IOMapping %STATION%_Xins{} IOMapping %STATION%_Xouts{} and IOMapping %STATION%_Xins{} PERS IOMapping %Station%_Xouts{} PERS IOMapping %Station%_Xins{} Data type Example Modify IOMapping array Defines which physical In and Out signals defined in the eio.cfg will trigger a logical signal of the station or tool. AliasIO is used for mapping. The physical signals will be displayed for the station in the Production window. %Station%_Xouts{} and %Tool%_Xouts{} for digital Out signals %Station%_Xins{} and %Tool%_Xins{} for digital In signals The default physical signals are do_dummysignal and di_dummysignal. The dummy signals have no influence on the program logic. NOTE! Do not delete IOmapping only! If IOmapping is deleted, the code using these signals should be deleted as well. Max 50 signals. RECORD IoMapping:=[ string strphysicalname;! Physical signal as defined in the eio.cfg. Max 16 characters. string straliasname;!logical aliasio signal name of the station or tool!module. Max 16 characters. string str;! of the signal. Max 80 characters. Cannot include comma. ENDRECORD]; PERS IoMapping %STATION%_XIns{2}:=[ ["didummysiglow","sdi%station%mvin","control signal before robot enters the station"], ["didummysiglow","sdi%station%mvout","control signal after robot exits the station"] ]; Add more logical signals and their descriptions if necessary. The physical signals are set in the program wizard HAC Revision: E

119 4 Stations propertytype %STATION%_Prop{} propertytype %STATION%_Prop{} PERS propertytype %STATION%_Prop{} Array that is used to enable RAPID variables to be displayed and modified in the program wizard - station. It is very useful for the variables that needs to be modified frequently, such as time and palletizing parameters. The properties provide the flexibility to modify RAPID parameters during production through HotEdit. Max 1000 properties. Data type ["property variable", "datatype", min value, max value, "value", "string description"]. The data type can be num, bool or string. Example PERS propertytype %STATION%_Prop{10} := [ ["n%station%_ct", "num",0.5,500,"100","%station% Cycle Time"], ["","",0,0,"",""], ["","",0,0,"",""], ["","",0,0,"",""], ["","",0,0,"",""], ["","",0,0,"",""], ["","",0,0,"",""], ["","",0,0,"",""], ["","",0,0,"",""], ["","",0,0,"",""] ]; Modify The propertytype can be modified from: the program wizard - station, see Program wizard - Station on page 60. the Program Data window, see Operating manual - IRC5 with Flex- Pendant. 3HAC Revision: E 117

120 4 Stations wobjdata w%station% wobjdata w%station% PERS wobjdata w%station% Data type Example Modify The work object coordinate system of the station, i.e. the local coordinate system for this station. Wobjdata PERS wobjdata w%station%:= [FALSE,TRUE,"",[[0,0,0],[1,0,0,0]],[[ , , ],[ , , , ]]]; The wobjdata can be modified from: the program wizard - station, see Program wizard - Station on page 60. the Program Data window for wobjdata, see Operating manual - IRC5 with FlexPendant pointtype%station%_mp{10} PERS pointtype%station%_mp{10} Array with the positions of the main path. 10 positions in each path. Data type pointtype (see Pointtype on page 92). Modify These data are set from the program wizard. Do not modify manually HAC Revision: E

121 4 Stations pointtype%station%_sp1{10} pointtype%station%_sp1{10} PERS pointtype%station%_sp1{10 Array with the positions of the sub path. 10 positions in each path. The maximum number of sub path that a station can have is 10, the default is 5. Data type pointtype (see Pointtype on page 92). Modify These data are set from the program wizard. Do not modify manually %STATION%_corner1 and %STATION%_corner2 PERS pos %STATION%_corner1 PERS pos %STATION%_corner2 Data type Modify The positions define the corners of the world zone box. If another type of world zone is used, for example, Sphere, modify the positions for similar definition. pos These data are set from the program wizard. Do not modify manually. 3HAC Revision: E 119

122 4 Stations Overview 4.4 Station procedures Overview Overview This section describes the required station procedures. Station procedures The station procedures are called when the relevant operation should be done, such as checking the station status, unloading a part, initializing output signal, etc. The logic of the procedures are implemented with the RAPID instructions on page 89. To enable the RW Plastics Mould and RW DieCast kernel to interact with the station, the station must support the following local procedures: Procedure Type DefEvents() Defines interrupts and connects Contains station logic. interrupts to trap routines. CheckStatus() Sets the status of a station. Contains station logic. Execute() Defines the robot movement in a station. Contains station logic. InitializeIO Initializes out signals to initial value. Output signal RunWithoutRobot() Configure output signals, then the station Output signal can work independently of the robot. RunWithRobot() Configure output signals, then the station Output signal works together with the robot. GetPath() Gets a path from a station. Do not modify this procedure. SetStationWobj() Sets the wobjdata of the station. Do not modify this procedure. LKx_Procedure Linkprocedures that will be executed in a specific position. Other procedures may be added to the station modules. It is preferred to define all the variables and procedure as LOCAL except for station properties (see propertytype %STATION%_Prop{} on page 117) HAC Revision: E

123 4 Stations DefEvents() DefEvents() DefEvents() Example Defines all events related to a station. The interrupts belonging to the station are connected to a trap routine and tied to be triggered on a certain signal change. DefEvents() is executed once only at the direct HomeRun after the program has been loaded or Move PP to main. DefEvents() IDelete intdcm_start_1;!dcm_ejector forward CONNECT intdcm_start_1 WITH Eject_Forward; ISignalDI diejectorforwpos,1,intdcm_start_1; ENDPROC Modify LOCAL TRAP Eject_Forward setdo, doeject_backward,1; setdo, doeject_forward,0; ENDTRAP Add necessary interrupts and traps. 3HAC Revision: E 121

124 4 Stations CheckStatus() CheckStatus() CheckStatus() Example Defines the condition for a station status. CheckStatus() is used either internally (trap routine) or externally to test and set station status. Each time the robot enters or exits a station, CheckStatus() is called. The station status can be: stnok - the robot will tend the station. stnbusy - the robot will tend the alternative station. stnnok - the robot will not tend the station, make a HomeRun instead. There are two conveyors, Conv_1 and Conv_2. Conv_2 is the alternative station of Conv_1. When Conv_1 is full, Conv_2 will be used in the current cycle without defining another cycle. Conv_1 has two signals to indicate its status. diconv_ok and diconv_full. Modify CheckStatus() if diconv_ok=1 then if diconv_full=1 then xctsetstatus Conv_1, stnbusy; else xctsetstatus Conv_1, stnok; endif else xctsetstatus Conv_1, stnok; endif ENDPROC Add conditions for the station status HAC Revision: E

125 4 Stations Execute() Execute() Execute() Defines the robot movements related to a station, i.e. moving into station, setting inputs and outputs, loading a part with the tool, etc. When a station is scheduled as the next station that the robot will tend, Execute() of that station is called. The robot actions are triggered in a position by setting linkprocedures in that position (see LinkProcedures on page 171). Continues on next page 3HAC Revision: E 123

126 4 Stations Execute() Continued Execute() Example Execute()! Execute of Injection Moulding Machine!Move in of the machine xctmovein RbtOnMainPath,%STATION%_MP; stentrycondition:=xctgetcondition("%station%"); Test stentrycondition CASE "UseSubPath1":!Move in on subpath1 xctmovein RbtOnSubPath,%STATION%_SP1;!Move out on subpath1 xctmoveout RbtOnSubPath,%STATION%_SP1; CASE "UseSubPath2"!Move in on subpath1 xctmovein RbtOnSubPath,%STATION%_SP2;!Move out on subpath1 xctmoveout RbtOnSubPath,%STATION%_SP2; Default: Modify ENDTEST!Move out of the machine xctmoveout RbtOnMainPath,%STATION%_MP; ERROR!Error handling including HomeRun. xcterrkeep "Problem in the machine",errno; Raise erhomepos; ENDPROC Add logic to robot movement if necessary, such as conditions to call the error handling and station cases (see xctgetcondition on page 110) etc HAC Revision: E

127 4 Stations Initialize() Initialize() Initialize() Example Modify Initializes output signals or some variable in the station. This procedure can be called only when the robot is in Home position. NOTE! Triggering the Initialize button might mean that the gripper will lose the parts or the machine will move. InitializeIO() SETDO doen_ejecforw,0; SETDO doen_ejecback,0; SETDO doen_mould,0; SETDO doirb_opmode,0; SETDO doen_cpullpos1,0; SETDO doen_cpullpos2,0; SETDO doen_fmouldop,0; ENDPROC Set output signals to initial value when the station contains some signals or variables that need to be initialized. 3HAC Revision: E 125

128 4 Stations RunWithoutRobot() RunWithoutRobot() RunWithoutRobot() Example Modify Configure the output signals then the station can work independently of the robot. This procedure is called when the RunWithRobot button is tapped in the Production window. RunWithoutRobot() SETDO doen_ejecforw,1; SETDO doen_ejecback,1; SETDO doen_mould,1; SETDO doirb_opmode,1; SETDO doen_cpullpos1,1; SETDO doen_cpullpos2,1; SETDO doen_fmouldop,1; ENDPROC Set output signals to required value (often high) if the station requires running in RunWithoutRobot mode HAC Revision: E

129 4 Stations RunWithRobot() RunWithRobot() RunWithRobot() Example Modify Configure the output signal then the robot can work with the stations. This procedure should be the inverse of the RunWithoutRobot(). The procedure is called when the RunWithRobot button is tapped in the Production window. RunWithRobot() SETDO doen_ejecforw,0; SETDO doen_ejecback,0; SETDO doen_mould,0; SETDO doirb_opmode,0; SETDO doen_cpullpos1,0; SETDO doen_cpullpos2,0; SETDO doen_fmouldop,0; ENDPROC Set output signals to required value (often low) if the station requires running in RunWithRobot mode. 3HAC Revision: E 127

130 4 Stations LinkProcedure LinkProcedure LinkProcedure Example Separate linkprocedure in a specific station. If the procedure name starts with LKx_, it will be consider as a link procedure. LK0_ means this link procedure is only used in the current station, LK1_ means this procedure can also be used for other stations. LK0_ChkMldOpn() LK0_ChkMachAuto() LK0_ChkEjctForw() LK0_ChkEjctBack() LK0_ChkCor1Pos1() LK0_ChkCor1Pos2() LK0_ChkCor2Pos1() LK0_ChkCor2Pos2() LK1_ChkPart() LK1_SetMldClose() LK1_RstMldClose() LK0_SetEjctBack() LK0_SetCore1Pos1() LK0_SetCore1Pos2() LK0_SetCore2Pos1() LK0_SetCore2Pos2() LK0_ChkMvInHigh() LK0_ChkMvInLow() LK0_ChkMvOutHigh() LK0_ChkMvOutLow() LK0_Axis1SoftAct() LK0_Axis4SoftAct() LK0_Axis5SoftAct() LK0_Axis6SoftAct() Continues on next page 128 3HAC Revision: E

131 4 Stations LinkProcedure Continued LinkProcedure Example Modify LK0_SoftDeact() LK0_WaitDelay_01() LK0_WaitDelay_02() LK0_SetSig1High() LK0_RstSig1Low() LK0_SetSig2High() LK0_RstSig2Low() LK0_SetSig3High() LK0_RstSig3Low() LK0_SetSig4High() LK0_RstSig4Low() LK0_CHKSig1High() LK0_CHKSig1Low() LK0_CHKSig2High() LK0_CHKSig2Low() LK0_CHKSig3High() LK0_CHKSig3Low() LK0_CHKSig4High() LK0_CHKSig4Low() LK1_GrpHeavyLoad() LK1_GrpLightLoad() Add linkprocedures if necessary. 3HAC Revision: E 129

132 4 Stations SetStationWobj() SetStationWobj() SetStationWobj() Modify Sets wobjdata as StationWobj. Do not modify this procedure GetPath (string PathName, INOUT Path{*}) GetPath (string PathName, INOUT Path{*}) Modify GetPath() is used to get a path from a station. Assigns input argument Path to either main path or correct sub path depending on argument Path Name. Do not modify this procedure HAC Revision: E

133 4 Stations Overview 4.5 StationLib Overview Overview This section describes the standard station in the StationLib. Default station library General and typical stations are predefined in the station library. It is also possible to create new library stations based on the general stations. BlankStn.lib on page 132 IMM.lib (for RW Plastics Mould) on page 133 DCM.lib (for RW DieCast) on page 144 Conveyor.lib on page 151 Vision.lib on page 153 CoolingTower.lib on page 154 PartCtrl.lib on page 156 Home.lib on page 157 Scrap.lib on page 157 3HAC Revision: E 131

134 4 Stations BlankStn.lib BlankStn.lib BlankStn.lib Signals Properties Modify General station prepared for the station where the robot unloads or loads parts. Used for insert feeder, sprue cut etc. This blank station is for general use only including the path and movement without extra logic. This station can be used to create a new library station as a template, or used for a station without complex IO handshaking logic. No signals predefined No properties predefined Add necessary signals, properties and logic HAC Revision: E

135 4 Stations IMM.lib (for RW Plastics Mould) IMM.lib (for RW Plastics Mould) IMM.lib Signals This file is the template of Injection moulding machine station. Characteristics of the IMM station: Predefined signal interface between machine and robot, which is based on Euromap 12/67 and SPI. The Execute() procedure includes all the sequence logic needed. The handshaking with the machine is triggered by linkprocedures. Traps are used for signals that need immediate response, for example, you can create a trap to change the "enable mould close" signal in case that the robot moves to the conveyor meanwhile the mould is closed. ABB standard based on Euromap 12, 67 and SPI: dimouldopenpos diejec_backpos diejec_forwpos direject dien_opmode dimouldclosed diintermouldpos dinopartavaible dicorepullpos1 dicorepullpos2 doen_mould doirb_opmode doen_ejecback doen_ejecforw doen_fmouldop doen_cpullpos1 doen_cpullpos2 doen_fmouldop domouldareafree 3HAC Revision: E Continues on next page 133

136 4 Stations IMM.lib (for RW Plastics Mould) Continued IMM.lib Properties Modify "n%station%_ct", "HotEdit %STATION% Max Work Time", This value is used to define max. wait time in this station, for example, wait for mould open, if wait time is above the value, the logic will raise an erhomepos error and cause a HomeRun. "n%station%_ejtt","%station% Ejector Maximum Move Time" This value is used to define ejector max. movement time, if ejector can not move to the expected position within this time limitation, the logic will raise an erhomepos error and cause a HomeRun. "n%station%_delay1","hotedit Wait time delay " It's related to a Link- Procedure called LK0_WaitDelay_01(). The value is used to adjust the wait time. "%STATION%_ForcStn","Scrap station if part rejected" This is a station name. When a bad part is detected in the machine, the robot will move to this station. NOTE! The station name is case sensitive. "%STATION%_X1_Soft", "Axis 1 Softness factor 0=min softness/ 100=max softness" Softness value in percent (0-100%). 0% denotes min. softness (max. stiffness), and 100% denotes max. softness. "%STATION%_X1_Rate","Axis 1 Ramp Factor In Percent" Ramp factor in percent (>=100%). The ramp factor is used to control the engagement of the soft servo. A factor 100% denotes the normal value; with greater values the soft servo is engaged more slowly (longer ramp). The default value for ramp factor is 100%. "%STATION%_X4_Soft","Axis 4 Softness factor 0=min softness/ 100=max softness" "%STATION%_X4_Rate","Axis 1 Ramp Factor In Percent" "%STATION%_X5_Soft","Axis 5 Softness factor 0=min softness/ 100=max softness" "%STATION%_X5_Rate","Axis 1 Ramp Factor In Percent" "%STATION%_X6_Soft","Axis 6 Softness factor 0=min softness/ 100=max softness" "%STATION%_X6_Rate","Axis 1 Ramp Factor In Percent" "%STATION%PartLoad","The weight of load in kg" This and the following three properties are used for LK1_GrpHeavyLoad. "%STATION%PartX","centre of gravity X Direction" centre of gravity "%STATION%PartY","centre of gravity Y Direction" "%STATION%PartZ","centre of gravity Z Direction" Optional logic needs to be added. Continues on next page 134 3HAC Revision: E

137 4 Stations IMM.lib (for RW Plastics Mould) Continued How to use IMM.lib This section describes how to use IMM.lib. How to use IMM without insert To use the IMM without inserts, there are two different status: NOTE! Before running production, make sure the machine is ready to start production with the robot. NOTE! When switching the operation mode from manual to auto mode, make sure the status is RunWithRobot. The status is... Action RunWithRobot First start the robot using the FlexPendant. Then start the machine. RunWithoutRobot Start the machine at any time depending on the mode of the machine. When the robot is required to join the production, the robot will first check whether the machine is ready to allow the robot enter before going to enter the machine. If the IMM is closed when the robot moves to the first position of IMM, the robot will join current cycle, otherwise it will join next cycle. Normally, there is only one ejector in the default IMM.lib. If several ejectors or core pullers are required, configure the signals of IMM in the program wizard. The concept of core and ejector is described in the standard Euromap12/67. NOTE! There are some status variables used with the IMM: Variable bfirstexeflag is used when the robot and the machine start the first time. bfirstexeflag is always TRUE when the robot is in Home position. Variable bmachinealwaysopen is used to check whether the machine has made a part or not (i.e. the machine is opened or closed). bmachinealwaysopen is TRUE when robot is in Home position. Variable bcontinuerun represents the production cycle settings. bcontinuerun is TRUE when production is not in its last cycle. bcontinuerun is TRUE when robot is in Home position. Continues on next page 3HAC Revision: E 135

138 4 Stations IMM.lib (for RW Plastics Mould) Continued Machine and robot logic timing diagram pic03001 Continues on next page 136 3HAC Revision: E

139 4 Stations IMM.lib (for RW Plastics Mould) Continued How to use IMM with insert To use IMM with inserts, there are two ways: Put the first insert into the IMM station manually. Then run production the same as the IMM without insert. If you want the robot to put the first insert into the IMM, follow these description to configure the program: Action 1. Configure the IMM station In the first cycle, the robot moves to the IMM station to put the insert in without picking up any parts from the IMM or palletizing parts on the conveyor. When xdofirstcycle is high, the robot is running the first cycle which you can configure to make all desired settings take effect. In the last cycle, the robot may pick up a part without putting a new insert into the machine. When xdolast- Cycle is high, the robot is running the last cycle. This configuration is based on the internal interface (See Internal interfaces on page 177). 2. Configure cycles In the program wizard, define at least three cycles, a start cycle, a production cycle and an action cycle: Start cycle - set the start cycle as the first cycle and the robot will run this cycle one time. Production cycle - after the start cycle, the robot will run the production cycle continuously or as the number of cycles set in the Production window. Action cycle - set the action cycle as the last cycle and the robot will run the cycle once. After the last cycle, the robot will return to Home. NOTE! In such a case never tap Stop current cycle or Stop after cycle. LinkProcedure in IMM The linkprocedures defined for the IMM are related to the IOMapping. The alias signals should be mapped to the physical I/O signals. The linkprocedure can be added to a specified position. Continues on next page 3HAC Revision: E 137

140 4 Stations IMM.lib (for RW Plastics Mould) Continued Some general logic already connected to the specific position. The linkprocedures for machine tending logic are linked to some positions by default based on Euromap 12,67 and SPI. For example: In the first position of the main path, LK0_ChkMldOpn, LK0_ChkMachAuto and LK1_RstMldClose are set. In the Target position of the sub path, LK0_SetEjctForw and LK0_SetEjctBack are set. It is also possible to set linkprocedures to a position in the machine station besides the default linkprocedures. NOTE! After IOMapping the linkprocedures can be enabled. LinkProcedures Signals Alias LK0_ChkMldOpn() LK0_ChkMachAuto() LK0_ChkEjctForw() LK0_ChkEjctBack() LK0_ChkCor1Pos1() LK0_ChkCor1Pos2() LK0_ChkCor2Pos1() LK0_ChkCor2Pos2() LK1_ChkPart() dimouldopenpos dien_opmo de diejec_forw Pos diejec_back Pos dicorepullp os1 dicorepullp os2 didummysignal didummysignal sdiimmmldop sdiimmauto sdiimmejfwd sdiimmejbck Check Machine Open Position signal high Check Machine in Auto Mode Check Ejector Forward Position Check Ejector Backward Position sdiimmcr1p1 Check Core Puller 1 in Position 1 sdiimmcr1p2 Check Core Puller 1 in Position 2 sdiimmcr2p1 Check Core Puller 2 in Position 1 sdiimmcr2p2 Check Core Puller 2 in Position 2 direject sdiimmrjct Check Reject part signal high, if it is high, robot will moves to IMM_ForcStn which is defined in the property. Continues on next page 138 3HAC Revision: E

141 4 Stations IMM.lib (for RW Plastics Mould) Continued LinkProcedures Signals Alias LK1_SetMldClose() LK1_RstMldClose() LK0_SetEjctForw() LK0_SetEjctBack() LK0_SetCore1Pos1() doen_mould sdoimmenmld Enable Closure, Set it high xctbtnpushed() is true, stop after cycle has been pushed. xctmachcycend, set the flag to kernel machine has finished the cycle. xctmachcycbegin, set the flag to kernel machine start a new cycle. These function make the stop after cycle function. Example: LK1_SetMldClose() if bcontinuerun then if Not xctbtnpushed() then setdo sdoimmenmld,1; endif xctmachcycend; endif ERROR xcterrkeep "Error in IMM:LK1_SetMldClose", ERRNO; RAISE erhomepos; ENDPROC doen_mould sdoimmenmld Disable Closure, Set it low doen_ejecb ack doen_ejecf orw doen_ejecb ack doen_ejecf orw doen_cpull Pos1 doen_cpull Pos2 sdoimmejbck sdoimmejfwd sdoimmejbck sdoimmejfwd sdoimmcr1p1 sdoimmcr1p2 Set Enable Ejector Backward High, Reset Enable Ejector Forward Low Set Enable Ejector Backward High Reset Enable Ejector Forward Low Set Enable Core Pullers 1 to Position 1 High Reset Enable Core Pullers 1 to Position 2 Low 3HAC Revision: E Continues on next page 139

142 4 Stations IMM.lib (for RW Plastics Mould) Continued LinkProcedures Signals Alias LK0_SetCore1Pos2() LK0_SetCore2Pos1() LK0_SetCore2Pos2() LK0_ChkMvInHigh() LK0_ChkMvInLow() LK0_ChkMvOutHigh() LK0_ChkMvOutLow() LK0_Axis1SoftAct() LK0_Axis4SoftAct() doen_cpull Pos1 doen_cpull Pos2 dodummysiglow dodummysiglow dodummysiglow dodummysiglow didummysiglow didummysiglow didummysiglow didummysiglow sdoimmcr1p1 sdoimmcr1p2 sdoimmcr2p1 sdoimmcr2p2 sdoimmcr2p1 sdoimmcr2p2 sdiimmmvin sdiimmmvin sdiimmmvout sdiimmmvout Reset Enable Core Pullers 1 to Position 1 Low Set Enable Core Pullers 1 to Position 2 High Set Enable Core Pullers 2 to Position 1 High Reset Enable Core Pullers 2 to Position 2 Low Reset Enable Core Pullers 2 to Position 1 Low Set Enable Core Pullers 2 to Position 2 High Check Control signal before robot enters high Check Control signal before robot enters Low Check Control signal after robot exits High Check Control signal after robot exits Low Set the Axis 1 softness, the softness value is defined in the property. IMM_X1_Soft Axis 1 Softness factor 0=min softness/100=max softness IMM_X1_Rate,Axis 1 Ramp Factor In Percent Set the Axis 4softness, the softness value is defined in the property. IMM_X4_Soft Axis 1 Softness factor 0=min softness/100=max softness IMM_X4_Rate,Axis 1 Ramp Factor In Percent Continues on next page 140 3HAC Revision: E

143 4 Stations IMM.lib (for RW Plastics Mould) Continued LinkProcedures Signals Alias LK0_Axis5SoftAct() Set the Axis 5 softness, the softness value is defined in the property. IMM_X5_Soft Axis 1 Softness factor 0=min softness/100=max softness IMM_X5_Rate,Axis 1 Ramp Factor In Percent LK0_Axis6SoftAct() Set the Axis 6 softness, the softness value is defined in the property. IMM_X6_Soft Axis 1 Softness factor 0=min softness/100=max softness IMM_X6_Rate,Axis 1 Ramp Factor In Percent LK0_SoftDeact() Softness Deact LK0_WaitDelay_01() LK0_SetSig1High() LK0_RstSig1Low() LK0_SetSig2High() LK0_RstSig2Low() LK0_SetSig3High() dodummysiglow dodummysiglow dodummysiglow dodummysiglow dodummysiglow sdoimmsig1 sdoimmsig1 sdoimmsig2 sdoimmsig2 sdoimmsig3 WaitTime Setting, if some position need wait some time, and the time can be adjusted by the property, unit is second nimm_delay1 Wait time delay 1 spare signal can be used in advanced application. Setting Signal /1 spare signal can be used in advanced application. Setting Signal /1 spare signal can be used in advanced application. Setting Signal /2 spare signal can be used in advanced application. Setting Signal /2 spare signal can be used in advanced application. Setting Signal /3 Continues on next page 3HAC Revision: E 141

144 4 Stations IMM.lib (for RW Plastics Mould) Continued LinkProcedures Signals Alias LK0_RstSig3Low() dodummysiglow sdoimmsig3 spare signal can be used in advanced application. Setting Signal /3 LK0_SetSig4High() dodummysiglow sdoimmsig4 spare signal can be used in advanced application. Setting Signal /4 LK0_RstSig4Low() dodummysiglow sdoimmsig4 spare signal can be used in advanced application. Setting Signal /4 LK0_CHKSig1High() didummysiglow sdiimmsig1 spare signal can be used in advanced application. Check Signal /1 LK0_CHKSig1Low() didummysiglow sdiimmsig1 spare signal can be used in advanced application. Check Signal /1 LK0_CHKSig2High() didummysiglow sdiimmsig2 spare signal can be used in advanced application. Check Signal /2 LK0_CHKSig2Low() didummysiglow sdiimmsig2 spare signal can be used in advanced application. Check Signal /2 LK0_CHKSig3High() LK0_CHKSig3Low() LK0_CHKSig4High() LK0_CHKSig4Low() didummysiglow didummysiglow didummysiglow didummysiglow sdiimmsig3 sdiimmsig3 sdiimmsig4 sdiimmsig4 spare signal can be used in advanced application. Check Signal /3 spare signal can be used in advanced application. Check Signal /3 spare signal can be used in advanced application. Check Signal /4 spare signal can be used in advanced application. Check Signal /4 Continues on next page 142 3HAC Revision: E

145 4 Stations IMM.lib (for RW Plastics Mould) Continued LinkProcedures Signals Alias LK1_GrpHeavyLoad() LK1_GrpLightLoad() Setting the heavy part load and centre of gravity. It is defined in the property. IMMPartLoad The weight of load in kg IMMPartX,centre of gravity X Direction, IMMPartY centre of gravity Y Direction IMMPartZ, centre of gravity Z Direction Remove the part load, part load is load0 3HAC Revision: E 143

146 4 Stations DCM.lib (for RW DieCast) DCM.lib (for RW DieCast) DCM.lib The template of die casting machine station is provided in this file. Characteristics of DCM: The Execute() procedure includes all the sequence logic needed. The handshaking with the machine is triggered by the linkprocedures. Traps are used for signals that need immediate response. For example, you can create a trap to change the "enable mould close" signal in case that the robot moves to the conveyor meanwhile the mould is closed. The general solution for how to operate the machine and robot is described below: 1. Make sure that the machine is ready to start production with robot. 2. Switch the machine to auto mode. NOTE! Make sure the robot is not in RunWithoutRobot status when switching operation mode to auto mode. 3. Start production using RW DieCast, then start the machine. Status variables: bfirstexeflag is used when the robot and the machine starts the first time. bfirstexeflag is always TRUE when the robot is in Home. bmachinealwaysopen is used to make sure that the machine has made a part (i.e. been opened and closed). bmachinealwaysopen is TRUE when robot is in Home. bcontinuerun represents the production cycle settings. bcontinuerun is TRUE when production is not in its last cycle. bcontinuerun is TRUE when robot is in Home Signals For detailed description see Linkprocedures in DCM.lib on page 145. Properties Modify See IMM.lib (for RW Plastics Mould) on page 133 as reference. Optional logic needs to be added. Continues on next page 144 3HAC Revision: E

147 4 Stations DCM.lib (for RW DieCast) Continued Linkprocedures in DCM.lib Some general logic has already been connected to the specific positions. And it is also possible to set linkprocedures to a position besides the default linkprocedures. For example: In the main path first position, Check the Mould Open, Check the door Open, and check the machine in Auto. In the Target position of the sub path, set ejector forward, then Check the ejector forward, then operate tool. If the application needs different logic, modify the linkprocedures. NOTE! All the linkprocedures are enabled after the IOMapping is done to the real signals. LinkProcedures Signals Alias LK0_ChkMldOpn() didummysignal sdi%sta- TION%MldOp Check Machine Open Position signal high LK0_ChkMldOpn_2() didummysignal sdi%sta- TION%M_Op2 Check Machine Open Position 2 signal high LK0_ChkDoorOpen() didummysignal sdi%sta- TION%D_Op Check Door Open Position signal high LK0_ChkCylStart() didummysignal sdi%sta- TION%CylST Check Permit robot start Cycle LK0_ChkMachAuto() LK0_ChkEjctForw() LK0_ChkEjctBack() LK0_ChkCor1Pos1() LK0_ChkCor1Pos2() LK0_ChkCor2Pos1() LK0_ChkCor2Pos2() didummysignal didummysignal didummysignal didummysignal didummysignal didummysignal didummysignal sdi%sta- TION%Auto sdi%sta- TION%EjFwd sdi%sta- TION%EjBck sdi%sta- TION%Cr1P1 sdi%sta- TION%Cr1P2 sdi%sta- TION%Cr2P1 sdi%sta- TION%Cr2P2 Check Machine in Auto Mode. Check Ejector Forward Position. Check Ejector Backward Position. Check Core Puller 1 in Position 1. Check Core Puller 1 in Position 2 Check Core Puller 2 in Position 1 Check Core Puller 2 in Position 2 Continues on next page 3HAC Revision: E 145

148 4 Stations DCM.lib (for RW DieCast) Continued LinkProcedures Signals Alias LK1_ChkPart() didummysiglow sdi%sta- TION%Rjct Check Reject part signal high, if it is high, robot will moves to IMM_ForcStn which is defined in the property. LK1_ChkTolerance() didummysiglow sdi%sta- TION%Toler Check signal/tolerance LK1_ChkQuality() didummysiglow sdi%sta- TION%Qalty Check Signal/Quality LK1_ChkMaterial() didummysiglow sdi%sta- TION%Matl Check signal/material LK0_SetSprayUnit() dodummysiglow sdo%sta- TION%S_Spy Start Spray unit LK0_RstSprayUnit() dodummysiglow sdo%sta- TION%S_Spy Start Spray unit LK1_SetMldClose() dodummysiglow sdo%sta- TION%EnMld Disable Closure, Set it low LK1_RstMldClose() dodummysiglow sdo%sta- TION%EnMld Disable Closure, Set it low LK0_SetEjctForw() LK0_SetEjctBack() LK0_SetCore1Pos1() LK0_SetCore1Pos2() dodummysiglow dodummysiglow sdo%sta- TION%EjBck sdo%sta- TION%EjFwd dodummysiglow dodummysiglow sdo%sta- TION%EjBck sdo%sta- TION%EjFwd dodummysiglow sdo%sta- TION%Cr1P1 dodummysiglow sdo%sta- TION%Cr1P2 Set Enable Ejector Backward High, Reset Enable Ejector Forward Low Set Enable Ejector Backward High Reset Enable Ejector Forward Low Set Enable Core Pullers 1 to Position 1 High Reset Enable Core Pullers 1 to Position 2 Low Reset Enable Core Pullers 1 to Position 1 Low Set Enable Core Pullers 1 to Position 2 High Continues on next page 146 3HAC Revision: E

149 4 Stations DCM.lib (for RW DieCast) Continued LinkProcedures Signals Alias LK0_SetCore2Pos1() dodummysiglow sdo%sta- TION%Cr2P1 Set Enable Core Pullers 2 to Position 1 High Reset Enable Core Pullers 2 to Position 2 Low LK0_SetCore2Pos2() dodummysiglow sdo%sta- TION%Cr2P2 Reset Enable Core Pullers 2 to Position 1 Low Set Enable Core Pullers 2 to Position 2 High LK0_ChkMvInHigh() dodummysiglow sdi%sta- TION%MvIn Check Control signal before robot enters high LK0_ChkMvInLow() didummysiglow sdi%sta- TION%MvIn Check Control signal before robot enters Low LK0_ChkMvOutHigh() didummysiglow sdi%sta- TION%MvOut Check Control signal after robot exits High LK0_ChkMvOutLow() didummysiglow sdi%sta- TION%MvOut Check Control signal after robot exits Low LK0_SetRobInDag() dodummysiglow sdo%sta- TION%R_Dag Robot is in Dangerous area LK0_RstRobInDag() dodummysiglow sdo%sta- TION%R_Dag Robot is in Dangerous area LK0_SetRobInSafe() LK0_RstRobInSafe() LK0_SetNotInSpy() LK0_RstInSpray() LK0_Axis1SoftAct() dodummysiglow dodummysiglow dodummysiglow dodummysiglow sdo%sta- TION%pSafe sdo%sta- TION%pSafe sdo%sta- TION%S_Fr sdo%sta- TION%S_Fr Robot is in the initialize position Robot is in the initialize position Robot is not the collision area for Spray Robot is not the collision area for Spray Set the Axis 1 softness, the softness value is defined in the property. IMM_X1_Soft Axis 1 Softness factor 0=min softness/100=max softness IMM_X1_Rate,Axis 1 Ramp Factor In Percent Continues on next page 3HAC Revision: E 147

150 4 Stations DCM.lib (for RW DieCast) Continued LinkProcedures Signals Alias LK0_Axis4SoftAct() Set the Axis 4softness, the softness value is defined in the property. IMM_X4_Soft Axis 1 Softness factor 0=min softness/100=max softness IMM_X4_Rate,Axis 1 Ramp Factor In Percent LK0_Axis5SoftAct() Set the Axis 5 softness, the softness value is defined in the property. IMM_X5_Soft Axis 1 Softness factor 0=min softness/100=max softness IMM_X5_Rate,Axis 1 Ramp Factor In Percent LK0_Axis6SoftAct() LK0_SoftDeact() LK0_WaitDelay_01() LK0_WaitDelay_02() LK0_SetSig1High() dodummysiglow sdo%sta- TION%Sig1 [Set the Axis 6 softness, the softness value is defined in the property. IMM_X6_Soft Axis 1 Softness factor 0=min softness/100=max softness IMM_X6_Rate,Axis 1 Ramp Factor In Percent Softness Deact WaitTime Setting, if some position need wait some time, and the time can be adjusted by the property, unit is second nimm_delay1 Wait time delay 1 WaitTime Setting, if some position need wait some time, and the time can be adjusted by the property, unit is second nimm_delay2 Wait time delay 2 spare signal can be used in advanced application. Setting Signal /1 Continues on next page 148 3HAC Revision: E

151 4 Stations DCM.lib (for RW DieCast) Continued LinkProcedures Signals Alias LK0_RstSig1Low() dodummysiglow sdo%sta- TION%Sig1 spare signal can be used in advanced application. Setting Signal /1 LK0_SetSig2High() dodummysiglow sdo%sta- TION%Sig2 spare signal can be used in advanced application. Setting Signal /2 LK0_RstSig2Low() dodummysiglow sdo%sta- TION%Sig2 spare signal can be used in advanced application. Setting Signal /2 LK0_SetSig3High() dodummysiglow sdo%sta- TION%Sig3 spare signal can be used in advanced application. Setting Signal /3 LK0_RstSig3Low() dodummysiglow sdo%sta- TION%Sig3 spare signal can be used in advanced application. Setting Signal /3 LK0_SetSig4High() dodummysiglow sdo%sta- TION%Sig4 spare signal can be used in advanced application. Setting Signal /4 LK0_RstSig4Low() dodummysiglow sdo%sta- TION%Sig4 spare signal can be used in advanced application. Setting Signal /4 LK0_CHKSig1High() LK0_CHKSig1Low() LK0_CHKSig2High() LK0_CHKSig2Low() LK0_CHKSig3High() didummysiglow sdi%sta- TION%sig1 didummysiglow sdi%sta- TION%sig1 didummysiglow sdi%sta- TION%sig2 didummysiglow sdi%sta- TION%sig2 didummysiglow sdi%sta- TION%sig3 spare signal can be used in advanced application. Check Signal /1 spare signal can be used in advanced application. Check Signal /1 spare signal can be used in advanced application. Check Signal /2 spare signal can be used in advanced application. Check Signal /2 spare signal can be used in advanced application. Check Signal /3 Continues on next page 3HAC Revision: E 149

152 4 Stations DCM.lib (for RW DieCast) Continued LinkProcedures Signals Alias LK0_CHKSig3Low() LK0_CHKSig4High() LK0_CHKSig4Low() LK1_GrpHeavyLoad() LK1_GrpLightLoad() didummysiglow sdi%sta- TION%sig3 didummysiglow sdi%sta- TION%sig4 didummysiglow sdi%sta- TION%sig4 spare signal can be used in advanced application. Check Signal /3 spare signal can be used in advanced application. Check Signal /4 spare signal can be used in advanced application. Check Signal /4 Setting the heavy part load and centre of gravity. It is defined in the property. IMMPartLoad The weight of load in kg IMMPartX,centre of gravity X Direction, IMMPartY centre of gravity Y Direction IMMPartZ, centre of gravity Z Direction Remove the part load, part load is load HAC Revision: E

153 4 Stations Conveyor.lib Conveyor.lib Conveyor.lib Signals The station is used when the robot loads parts in a palletizing pattern. In each cycle the robot will release a part in a new position (i.e. all the sub paths are offset). With the sub paths in one cycle, a smaller palletizing pattern can be made. For next cycle this pattern will be repeated in an offset position. The palletizing is reset when the program is loaded. To be used for output stations, for example, conveyor, tray, rack, etc. Set a physical signal to move the conveyor, and the signal will be used in LK0_PulseDoMove. Continues on next page 3HAC Revision: E 151

154 4 Stations Conveyor.lib Continued Conveyor.lib Properties Properties to set up palletizing pattern: "%STATION%_Xnum", "Cycle times in x direction" "%STATION%_Ynum", "Cycle times in Y direction" "%STATION%_Znum", "Cycle times in Z direction" "%STATION%_XOff", Distance between parts in X direction "%STATION%_YOff", Distance between parts in Y direction, "%STATION%_ZOff", Distance between parts in Z direction], "%STATION%_Dir", "0 X-Y-Z or 1 Y-X-Z ",0=Palletize order X-Y-Z; 1=Palletize order Y-X-Z %STATION%_TDelay:=0;! After the palletize, make the conveyor move time. It is used in LK0_PulseDoMove "%STATION%_MoveNum","count Number conveyor start to move", This is used with LK0_PulseDoMove, only this LK0_PulseDoMove is used in the position, "n%station%_ct", "HotEdit %STATION% Max Work Time", This value is used to define max. wait time in this station. Modify pic03002 Configure signals to start conveyor. Modify palletizing pattern if needed HAC Revision: E

155 4 Stations Vision.lib Vision.lib Vision.lib Signals Properties Modify The station is prepared for showing parts for vision control. If the part quality is not good, the robot is forced to release the part in the scrap station (see xctforcepart on page 99). The file is used for the station in which certain conditions shall make the robot change the normal cycle. Set signals to check if the part quality is ok or not. "%STATION%_ForcStn", The station where the robot shall leave a part. "n%station%_ct","hotedit %STATION% Max Work Time". This value is used to define max. wait time in this station. Add conditions for the robot to change the cycle. 3HAC Revision: E 153

156 4 Stations CoolingTower.lib CoolingTower.lib CoolingTower.lib Signals Properties Modify The Cooling Tower is used for cooling parts during production. NOTE! The Cooling Tower supports only one tool. The Cooling Tower counter will be reset after a program has been loaded into the system or Move PP to main. No signals TASK PERS propertytype %STATION%_Prop{10} :=[["%STA- TION%_Xnum","NUM",1,100,"1","Number in x direction"], ["%STATION%_Ynum","NUM",0,100,"1","Number in Y direction"], ["%STATION%_Znum","NUM",0,100,"1","Number in Z direction"], ["%STATION%_XOff","NUM",-1000,1000,"0","Offset in x axis"], ["%STATION%_YOff","NUM",-1000,1000,"0","Offset in y axis"], ["%STATION%_ZOff","NUM",-1000,1000,"0","Offset in z axis"], ["%STATION%_Dir","NUM",0,1,"0","0 X-Y 1 X-Z "], ["n%station%_ct","num",0.5,500,"30","hotedit %STATION% Max Work Time"], ["%STATION%FirstStn","",1,8,"","The First Station Name in Production Cycle"], ["","",0,0,"",""] ]; NOTE! The property FirstStn is very useful in the first n-1 cycles (Suppose that the cooling tower has n cooling places). Detailed explanation is described below. No Continues on next page 154 3HAC Revision: E

157 4 Stations CoolingTower.lib Continued Examples There is a typical work cell with a cooling tower station in it. Suppose that the cooling tower has n cooling places. The following table describes the robot operations. Before running in production Production cycles Clear cycle The cooling tower station is empty. The first n-1 cycles After n-1 cycles Filling in operation When running the first n-1 cycles, the robot can not run the complete production cycle. In each cycle, after the robot puts a part in the cooling tower, the robot will be forced to the first station and start the next production cycle. NOTE! Make sure that FirstStn has been defined correctly from the program wizard, otherwise the cycle can not be run. Production After n-1 cycles, the robot will run the complete production cycle. The robot will put a part in the cooling tower and take a part that has been put in the cooling tower previously. Then the robot will go on doing other production procedures according to the cycle settings. Run the clear cycle to empty the cooling tower. In each cycle, the robot will take a part from the cooling tower without putting new one. 3HAC Revision: E 155

158 4 Stations PartCtrl.lib PartCtrl.lib PartCtrl.lib Signals Properties Modify Part control is the station in which the part should be checked by a sensor. The name and number of control signals can be flexible chosen by activating signals for the station in the program wizard. If all the activated control signals are high, the part is okay. Otherwise the part is NOK. Then an error will be reported and the robot will make a HomeRun. Max 16 control signals can be defined. The 16 signals can be separately activated or not for one specific part. "%STATION%Sensor01","%STATION% Sensor 01 1=Enable 0=Disable" "%STATION%Sensor02","%STATION% Sensor 02 1=Enable 0=Disable" "%STATION%Sensor03","%STATION% Sensor 03 1=Enable 0=Disable" "%STATION%Sensor04","%STATION% Sensor 04 1=Enable 0=Disable" "%STATION%Sensor05","%STATION% Sensor 05 1=Enable 0=Disable" "%STATION%Sensor06","%STATION% Sensor 06 1=Enable 0=Disable" "%STATION%Sensor07","%STATION% Sensor 07 1=Enable 0=Disable" "%STATION%Sensor08","%STATION% Sensor 08 1=Enable 0=Disable" "%STATION%Sensor09","%STATION% Sensor 09 1=Enable 0=Disable" "%STATION%Sensor10","%STATION% Sensor 10 1=Enable 0=Disable" "%STATION%Sensor11","%STATION% Sensor 11 1=Enable 0=Disable" "%STATION%Sensor12","%STATION% Sensor 12 1=Enable 0=Disable" "%STATION%Sensor13","%STATION% Sensor 13 1=Enable 0=Disable" "%STATION%Sensor14","%STATION% Sensor 14 1=Enable 0=Disable" "%STATION%Sensor15","%STATION% Sensor 15 1=Enable 0=Disable" "%STATION%Sensor16","%STATION% Sensor 16 1=Enable 0=Disable" The 16 signals can be enabled or disable in the part control, but must be define real IO in the IOMapping first. No 156 3HAC Revision: E

159 4 Stations Home.lib Home.lib Scrap.lib Home.lib Mandatory station that contains the robot Home position. All tools should be opened before the robot goes to Home. If there are some variables or signals that should always be initialized after production is stopped, they can be initialized in Home Execute(). Signals - Properties - Modify Add variables that need to be initialized after stopping the production. Scrap.lib Mandatory station where the robot leaves all parts before moving to Home during the HomeRun cycle. If the Scrap station is included in the current cycle, it should be the last station of the cycle. NOTE! All tools should be opened in the Scrap station. If the robot can not open the tools because of some errors, the robot will try to open the tools five times. After that, if the tools still can not be opened, the robot will wait in the Entry position of the Scrap station. Signals - Modify - 3HAC Revision: E 157

160 4 Stations 4.6. Station.xml 4.6. Station.xml Overview The station.xml file are described below: File station.xml Makes the station visible in the program wizard. Defines which icons and station images should be used for the stations. The image formats are described in Image on page 181. Declaration Example Modify <station> <text>name of station</text>! name displayed in the program wizard. max 8 characters <name>name of station.lib file</name> <imgfile>icon image file</imgfile> <imgsize>size of icon, use normal </imgsize> <bkimgfile></bkimgfile>! NOTE! Leave empty! </station> <station> <text>dcm3000</text> <name>dcmnoist</name> <imgfile>pla-station-dcm.png</imgfile> <imgsize>normal</imgsize> <bkimgfile></bkimgfile> </station> Modify this file when adding new icons HAC Revision: E

161 5 Tools 5.1. Overview 5 Tools 5.1. Overview Overview Sections This chapter explains the standard tool modules in GripperLib. For explanation of %TOOL% syntax, see RAPID syntax on page 90. The sections of the chapter are: Tool definition on page 160 Tool variables on page 161 Tool procedures on page 163 GripperLib on page 168 3HAC Revision: E 159

162 5 Tools 5.2. Tool definition 5.2. Tool definition Tool definition A physical gripper may contain one or several mechanical grips. In a program, every grip is represented by a tool. Hence, one gripper can contain many tools. The maximum number of tools that the gripper can hold is 12. A tool is represented by a RAPID module. The tool data describes the physical dimensions of the tool. A tool interacts with the surrounding via its properties, procedures and events. The tools must follow these rules: The tools can be opened or closed only in the Target position of the path (to ensure a safe HomeRun). Several tools can be triggered in the same position. In the default scrap station, all tools must be opened to release everything the gripper holds. When the robot starts a new cycle, all tools need to be opened. Illustration of gripper and tool. pic HAC Revision: E