Chrysler Cusw Fanuc Robot Standard Rel 1.3

Chrysler’s R o b o t i c s G r o u p A p p l ic i c a ti t i o n s S t an an d ar d s F o r

C o n t r o l l ed e d R o b o t s F o r Us Us e O n C US U S W N o r t h A m e r i c a Pr Pr o j e c t s

If you received this document by means other than a direct E -Mail from Chrysler AAME Robotics Group, you are not on the distribution list and you will not receive future updates. It is the user’s responsibility responsibility to obtain the latest updates to this document.

AS OF 1/12/2012 Printed copies are not source controlled

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CUSW REL1.3

TABLE OF CONTENTS RELEASE REVISION AND COMMENTS PAGE...................................................................................................... PAGE...................................................................................................... 5 PROCESS REQUIREMENTS TO ALLOW FOR ALIGNM ENT OF ROBOT ................. ................. .................. ........ 7 ROBOTIC BY-PASS CONCEPT ............................................................................................................................... 7 TEACH PENDANT USER KEY ASSIGNMENT ASSIGNMENT ................. .................. ................. .................. .................. ................ 7 USE OF PULSED OUTPUTS .................................................................................................................................... 7 USE OF ROBOT PROGRAM SPACE CHECK ........................................................................................................ 7 COORDINATED MOTION OF HORIZONTAL AXIS................ .................. ................. .................. .................. .......... 7 ROBOT DRESS REQUIREMENTS........................................................................................................................... 7 SEALER STYLE NUMBERS .................. ................. ................. .................. ................. .................. .................. .......... 7 SEALER SYSTEM CALIBRATION TO ROBOT ANALOG OUTPUT ...................................................................... 8 SEALER SCHEDULES ............................................................................................................................................. 8 NETWORK ADDRESSES ......................................................................................................................................... 8 FANUC ROBOTICS ROBOT SIGNALS AND MACHINE AUTOMATIC ................. .................. .................. ............. 8 ROBOT D-NET OUTPUT BIT MAP (ROBOT TO PLC)............................................................................................ 9 ROBOT D-NET INPUT BIT MAP (PLC TO ROBOT).............................................................................................. ROBOT).............................................................................................. 13 ROBOT IO MAP ASSIGNMENTS ........................................................................................................................... 18 ROBOT BIT MAP .................................................................................................................................................... 19 ROBOT APPLICATION ERROR TIMING ............................................................................................................... 41 ROBOT APPLICATION ERRORS .......................................................................................................................... 42 PLC LOGIC REFERENCE ...................................................................................................................................... 48 ROBOT PROGRAM NAMING ................ ................. ................. .................. ................. .................. .................. ........ 49 ROBOT INTERFERENCE ZONES................. ................. .................. ................. .................. ................. .................. 50

INTERFERENCE ZONE EXAMPLE 1 ............................................................................................................................ 51 INTERFERENCE ZONE EXAMPLE 2 ............................................................................................................................ 52 INTERFERENCE ZONE EXAMPLE 3.................................................................................................................... 53

PLC / ROBOT TIMING DIAGRAMS........................................................................................................................ 54 REGISTER USAGE ................................................................................................................................................. 57 NUMERICAL REGISTER USAGE .......................................................................................................................... 57 POSITION REGISTER USAGE ................. ................. ................. ................. .................. .................. .................. ..... 59 USER ALARMS ....................................................................................................................................................... 61


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TABLE OF CONTENTS RELEASE REVISION AND COMMENTS PAGE...................................................................................................... PAGE...................................................................................................... 5 PROCESS REQUIREMENTS TO ALLOW FOR ALIGNM ENT OF ROBOT ................. ................. .................. ........ 7 ROBOTIC BY-PASS CONCEPT ............................................................................................................................... 7 TEACH PENDANT USER KEY ASSIGNMENT ASSIGNMENT ................. .................. ................. .................. .................. ................ 7 USE OF PULSED OUTPUTS .................................................................................................................................... 7 USE OF ROBOT PROGRAM SPACE CHECK ........................................................................................................ 7 COORDINATED MOTION OF HORIZONTAL AXIS................ .................. ................. .................. .................. .......... 7 ROBOT DRESS REQUIREMENTS........................................................................................................................... 7 SEALER STYLE NUMBERS .................. ................. ................. .................. ................. .................. .................. .......... 7 SEALER SYSTEM CALIBRATION TO ROBOT ANALOG OUTPUT ...................................................................... 8 SEALER SCHEDULES ............................................................................................................................................. 8 NETWORK ADDRESSES ......................................................................................................................................... 8 FANUC ROBOTICS ROBOT SIGNALS AND MACHINE AUTOMATIC ................. .................. .................. ............. 8 ROBOT D-NET OUTPUT BIT MAP (ROBOT TO PLC)............................................................................................ 9 ROBOT D-NET INPUT BIT MAP (PLC TO ROBOT).............................................................................................. ROBOT).............................................................................................. 13 ROBOT IO MAP ASSIGNMENTS ........................................................................................................................... 18 ROBOT BIT MAP .................................................................................................................................................... 19 ROBOT APPLICATION ERROR TIMING ............................................................................................................... 41 ROBOT APPLICATION ERRORS .......................................................................................................................... 42 PLC LOGIC REFERENCE ...................................................................................................................................... 48 ROBOT PROGRAM NAMING ................ ................. ................. .................. ................. .................. .................. ........ 49 ROBOT INTERFERENCE ZONES................. ................. .................. ................. .................. ................. .................. 50

INTERFERENCE ZONE EXAMPLE 1 ............................................................................................................................ 51 INTERFERENCE ZONE EXAMPLE 2 ............................................................................................................................ 52 INTERFERENCE ZONE EXAMPLE 3.................................................................................................................... 53

PLC / ROBOT TIMING DIAGRAMS........................................................................................................................ 54 REGISTER USAGE ................................................................................................................................................. 57 NUMERICAL REGISTER USAGE .......................................................................................................................... 57 POSITION REGISTER USAGE ................. ................. ................. ................. .................. .................. .................. ..... 59 USER ALARMS ....................................................................................................................................................... 61


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CUSW REL1.3

REFERENCE POSITION USAGE ........................................................................................................................... 62 INTERCONNECTS .................................................................................................................................................. 63 MACROS ................................................................................................................................................................. 64 FLOW CHART EXAMPLES .................................................................................................................................... 66

M ATERIAL H ANDLING .............................................................................................................................................. 67 DISPENSE............................................................................................................................................................... 72 SPOT W ELDING ...................................................................................................................................................... 73 STUD W ELDING ...................................................................................................................................................... 75 TIP CHANGE (STYLE #3) ......................................................................................................................................... 76 PURGE (STYLE #4) ................................................................................................................................................. 77 TIP BURN IN (STYLE #5) .......................................................................................................................................... 78 SERVICE (STYLE #6) ............................................................................................................................................... 79 TIP DRESS GUN 1 (STYLE #7) ................................................................................................................................. 80 TIP DRESS GUN 2 (STYLE #8) ................................................................................................................................. 81 TOOL CHANGE (STYLE #9) ...................................................................................................................................... 82 SET APPLICATION IO (M ACRO) ................................................................................................................................ 83 CHECK ATI ERRORS (M ACRO) ................................................................................................................................ 84 CHECK TOOL (M ACRO) ........................................................................................................................................... 85 DROP TOOL NEST 1 (M ACRO) ................................................................................................................................. 86 ENTER ZONE 1 (M ACRO) ......................................................................................................................................... 88 HOME IO (M ACRO) ................................................................................................................................................. 88 MOVE HOME (M ACRO) ............................................................................................................................................ 88 MOVE HOME FROM POUNCE (M ACRO) .................................................................................................................... 88 PICK TOOL NEST 1 (M ACRO) ................................................................................................................................... 89 PROCESS APPLICATION M ACROS (SPOT, DISPENSE, STUD) ...................................................................................... 91 PURGE PED GUN (M ACRO) ..................................................................................................................................... 94 RESET STEPPER (M ACRO) ...................................................................................................................................... 94 TIP BURN IN (M ACRO) ............................................................................................................................................. 95 TIP DRESS GUN 1 (M ACRO) .................................................................................................................................... 97 TIP DRESS GUN 2 (M ACRO) .................................................................................................................................... 98 TIP DRESS PED GUN (M ACRO) ................................................................................................................................ 99 TOOL DROP PREPARATION (M ACRO) ..................................................................................................................... 100 TOOL PICK PREPARATION (M ACRO) ....................................................................................................................... 101 TEACH PENDANT LOGIC EXAMPLES ............................................................................................................... 102

M ATERIAL H ANDLING ............................................................................................................................................ 103 DISPENSE............................................................................................................................................................. 105 SPOT W ELDING .................................................................................................................................................... 106 STUD W ELDING .................................................................................................................................................... 107 TIP CHANGE (STYLE #3) ....................................................................................................................................... 108 PURGE (STYLE #4) ............................................................................................................................................... 108 TIP BURN IN (STYLE #5) ........................................................................................................................................ 109 SERVICE PROGRAM (STYLE #6)............................................................................................................................. 109 TIP DRESS GUN 1 (STYLE #7) ............................................................................................................................... 109 TIP DRESS GUN 2 (STYLE #8) ............................................................................................................................... 110 TOOL CHANGE (STYLE #9) .................................................................................................................................... 110 CHECK ATI ERRORS (M ACRO) .............................................................................................................................. 111 CHECK TOOL (M ACRO) ......................................................................................................................................... 112 DROP TOOL NEST 1 (M ACRO) ............................................................................................................................... 113 PICK TOOL NEST 1 (M ACRO) ................................................................................................................................. 114 ENTER ZONE 1 (M ACRO) ....................................................................................................................................... 116 HOME IO (M ACRO) ............................................................................................................................................... 116 PROCESS APPLICATION – PED SPOT (M ACRO) ....................................................................................................... 117 PROCESS APPLICATION – PED DISPENSE (M ACRO) ................................................................................................ 118 PROCESS APPLICATION – PED STUD (M ACRO) ....................................................................................................... 119 PURGE PED GUN (M ACRO) ................................................................................................................................... 119 RESET STEPPER (M ACRO) .................................................................................................................................... 119 TIP BURN IN (M ACRO) ........................................................................................................................................... 119 AS OF 1/12/2012 Printed copies are not source controlled

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CUSW REL1.3

TIP CHANGE PED GUN (M ACRO) ........................................................................................................................... TIP DRESS GUN 1 (M ACRO) .................................................................................................................................. TIP DRESS GUN 2 (M ACRO) .................................................................................................................................. TIP DRESS PED GUN (M ACRO) .............................................................................................................................. TOOL DROP PREPERATION (M ACRO) ..................................................................................................................... TOOL PICK PREPERATION (M ACRO) .......................................................................................................................

119 120 120 121 122 123

The flow charts and sample programs supplied in this document are in tended as a basic example and may not include all information required to properly control a robot in all applications. It is the build vendor's responsibility to provide robot programming required for proper system operation. The examples set forth in this document shall be followed. Any deviations will require approval by Chrysler Robot Specialist.


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CUSW REL1.3

RELEASE REVISION AND COMMENTS PAGE Release #

Release Date

Rel. 1.0

12/14/10

Rel. 1.1

2/4/11

REL. 1.2

REL1.3

-

Comments Initial Release

Adjusted Rbt/PLC bitmap to eliminate water saver control. DO[99], DI[7], DI[97], DI[98]. Update the Node Allocation – Eliminated the Water Savers, moved to PLC control. Updated Rbt/PLC Node descriptors per the bitmap. Spared out 4 Water Saver Nodes-I/O. Updated Safety I/O Added WaterOff to the bitmap DO[100] Removed reference to WK and WD in robot program naming Spared out DO91, 92, 95, 96 and 100 – Use Group Output [MaintReqBits1-8]. (TipChangeReq, ServiceReq, RbtTPPurgeGun1, RbtTPPurgeGun2, TipDressReq) Added air pressure master node and outputs to PLC DO[91] and [92] Added StepMode output DO[103] Added SignatureChgInd output DO[111] Updated Watersaver App Errors Updated Nordson App Errors to match new configuration Updated Nordson BitMap to match new configuration Added sealer style comment. Added sealer calibration requirement Added sealer schedule programming requirement Swapped air pressure inputs to match tooling Removed repo input bit 4 DI[84] Added General Communication Fault DeviceNet Master App Error [2] Added Low Battery Indicator App Error [4] Removed App Error [127] Dispense 1 Minor Alarm Removed App Error [128] Dispense 1 Communication Fault to Robot Removed App Error [137] Dispense 2 Minor Alarm Removed App Error [138] Dispense 2 Communication Fault to Robot Nordson app errors modifications Added Interference Zone 3 reference Added DO[107] – TipBurnInComp Added AtPurgePos to position register Added Tip Wear Update to Spotweld program Added PartPresent 7-10 on bit map sheet. Updated DI[121] Added RbtClrZone7 & 8 to DO[39], DO[40], Zone(7 & 8)ClrToEnter to DI[39], DI[40] and DO[908] PulseBatteryLow Updated Interconnects list Added IPG_Laser and HighYag Head I/O to nodes 17 and 18 Added LaserEnbld DO[87] and HYagEnbld DO[88] Added LaserEnable1 DI[6] and LaserGuideOn DI[7] Added LaserCut Head and Grinder to nodes 19 – 23 Changed the TipChange burn-in schedule from 58 to 62 per Welding CoC team P. 104. Updated the Nordson bitmaps per the requirements of the tech sealer document. Added DI[98:StartUpPurge] to PLC bitmap per tech requirements. Added DO[95:TipDressReq] to PLC bitm ap Updated Interconnect Table Added track lube faults to the application error list Added note indicating responsibility to set IP addresses and Node addresses. Added I/O map for the Precitec unit. Added DI127 Tip Dress Bypass Added DI768-775 and DO768-775 for Mig Weld Reamer Added DI776-783 and DO776-783 for Laser cutting field I/O Update Tip Dress Macro add DI127 TipDressInBypass Added RTU Auto Lube I/O


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CUSW REL1.3

PROCESS REQUIREMENTS TO ALLOW FOR ALIGNMENT OF ROBOT It is an AAME requirement that all Body shop and Assembly robots be capable of running an alignment program. This program will bring the robot into a position which will allow positioning of all axes to check robot alignment. The robot alignment position and path to reach this position must be considered when locating and processing the robot in the cell. Consideration must also be given when dressing out robot cables, hoses, end effectors and junction boxes on the robot arm so these items do not impede the robots ability to move t o the alignment position. Where possible, all axes should be aligned at the same time. In cases where cell layout would be affected or additional dress-out or safeties would be required to align all axes simultaneously, multiple alignment positions will be allowed. In addition to alignment program, all OEM‟S must verify that the robot is set to FANUC ROBOTICS factory values for alignment position prior to programming robot.

PROCESS CYCLE TIME REQUIREMENTS

It is an AAME requirement that all Body shop and Assembly robots be capable of meeting process cycle time without the presence of robot errors or warnings of any kind. ROBOTIC BY-PASS CONCEPT The Robot By-pass Mode is selected through the HMI screen associated with the specific robot. When in By-pass Mode, the PLC logic should allow t he following: In processes which allow a specific robot to be by-passed, (line capable of running without this specific robot with manual or automatic back up capabilities). A. B. C.

Allow the current part or job to transfer out of that station (if the robot is clear). Allow the line to continue to run while the robot is in by-pass and clear of all tooling. Send required back-up information to down stream robot(s) and/or FIS/AVI for downstream manual backup.

In processes which do not allow for the line to run with a specific robot in by-pass. A. Allow the current part or job to transfer out of that station (if the robot is clear). B. Stop further machine cycles if left in by-pass mode. C. Allow for easy changes to the PLC logic to override item “B” in the event that the plant provides temporary manual back -up for continued production. Note: Process Engineering, during the Design Phase of a project, will identify robots that can be by-passed while tooling continues to operate.

TEACH PENDANT USER KEY ASSIGNMENT The user definable keys on the robot t each pendants are to remain at FANUC ROBOTICS default settings unless a deviation is su bmitted by the Requestor and approved by a Chrysler Robotic Group representative.

USE OF PULSED OUTPUTS The use of pulsed outputs requires approval by a Chrysler Robot Specialist.

USE OF ROBOT PROGRAM SPACE CHECK The use of robot program space check requires approval by a Chrysler Robot Specialist.

COORDINATED MOTION OF HORIZONTAL AXIS All robots utilizing a horizontal slide axis shall be setup and programmed using coordinated motion with the other six axes of the robot arm.

ROBOT DRESS REQUIREMENTS FANUC robot dress packages for all spot welding and material handling robots will be supplied for installation. It is the responsibility of the build supplier (robot programmer) to adjust and validate all robot dress packages to meet the dress manufacturer‟s warranty. Robot programs must be considered when configuring the supplied dress package.

SEALER STYLE NUMBERS Sealer styles shall match the value of the robot program number. (i.e. If the sealer robot is executing program #30, the sealer style program shall utilize style #30).


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CUSW REL1.3

SEALER SYSTEM CALIBRATION TO ROBOT ANALOG OUTPUT -

It is the robot programmers responsibility to calibrate the Sealer System to the Robot System. Minimum and maximum speeds related to the robot analog output signal to produce required bead sizes must be established and verified at time of programming.

SEALER SCHEDULES -

It is the robot programmers responsibility to populate all sealer schedules with values appropriate for the working programs. All sealer schedules not utilized in a program shall be set t o the maximum flow rate available from the sealer system.

NETWORK ADDRESSES -

It is the robot programmers responsibility to set all IP addresses and Node addresses associated with the robot system.

FANUC ROBOTICS ROBOT SIGNALS AND MACHINE AUTOMATIC The PLC logic should monitor the following robot DeviceNet outputs. The “Robot Ready” signal should be true to achieve machine a utomatic but is not required to maintain machine automatic. Proper fault messages should be generated for each associated condition. “Robot Ready” DeviceNet - This signal is true when the f ollowing conditions are met:

CMDENBL SI[2]=ON CMDENBL SFSPD=ON CMDENBL ENBL=ON CMDENBL $RMT_MASTER=0 CMDENBL No active alarms CMDENBL Not in single step SYSRDY ENBL=ON SYSRDY GRP1 Servo ready SYSRDY GRP2 Servo ready GRP1 Motion enabled GRP2 Motion enabled Spot weld enabled Gun stroke enabled

(OK) (standard operator panel input 2, remote) (OK) (safety speed input signal) (OK) (OK) (no remote device in control of motion) (OK) (OK) (OK) (OK) (OK) (Spotweld only) (OK) (Robot motion group) (OK) (Servo motion group, spotweld only) (OK) (Weld status, welding applications only) (OK) (Gun stroke status, welding applications only)

The following signals are available through DeviceNet and should be displayed as faults or m essages when their appropriate state hinders achievement of the tooling system automatic: Robot System Ready for AUTO

RobotInAuto RbtReady IOSimulated 20HourRunModeAct Collision Guard Enabled TP Enabled Waiting for TP Input Robot E-Stop Enabled Weld Enabled (Spotweld only) STEP Mode


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CUSW REL1.3

ROBOT D-NET OUTPUT BIT MAP (ROBOT TO PLC) SIGNAL NAME

ROBOT OUTPUT

DESCRIPTION

RobotInAuto

1

RobotFaulted WaitForTPInput

2 3

InCycle

4

This robot output signal is used to inform switch is the auto position. This robot output signal is used to inform This robot output signal is used to inform the robot teach pendant. This robot output signal is used to inform

the PLC that the robot Auto/Teach key the PLC that the robot is in a faulted state. the PLC that a user response is required at the PLC that a robot program is executing.

This includes Home I/O execution. “InCycle” remains high when the program is

CollisionDetd

5

IOSimulated WldEnabled

6 7

RobotReady

8

ActiveStyleBit1

9

paused. This robot output signal is used to inform the PLC that a collision was detected on the robot. This robot output signal is used to inform the PLC that a robot input is simulated. This robot output signal is used to inform the PLC that the weld mode is enabled at the weld controller. This robot output signal is used to inform the PLC that all conditions for robot ready are satisfied. This robot output along with the next six bits, grouped as “Group Outputs”, are used

to inform the PLC of the current style active. The group outputs are viewed as the binary bit weight viewed as a decimal value. ActiveStyleBit2 ActiveStyleBit4 ActiveStyleBit8 ActiveStyleBit16 ActiveStyleBit32 ActiveStyleBit64 PrgPaused

10 11 12 13 14 15 16

PrgRunning

17

RobotAtWork

18

WorkComplete

19

20HourRunModeAct

20

MaintReqBit1

21

MaintReqBit2 MaintReqBit4 MaintReqBit8 RobotAtPounce

22 23 24 25

RobotAtService

26

RobotAtHome

27

RobotInTipDress

28

TipDressComplt

29

RdyForTipChg

30

ClearToTransfer

31

WldInPrgrsActiv1

32


Reference Reference Reference Reference Reference Reference

description: “ActiveStyleBit1” description: “ActiveStyleBit1” description: “ActiveStyleBit1” description: “ActiveStyleBit1” description: “ActiveStyleBit1” description: “ActiveStyleBit1” This robot system output signal “UO[4: Paused]” is used to inform the PLC that the

robot program is in a paused condition. Signal is active in Auto and Teach modes. This robot system output signal “UO[3: Program Running]” is used to inform the PLC that the robot program is running. Signal is active in Auto and Teach modes. This robot output signal is used to inform the PLC that the robot has left the pounce position and is in the work portion of the robot program. This robot output signal is used to inform the PLC that the robot has completed the work program. Resets after WorkCompleteAck received from the PLC. This robot output signal is used to inform the PLC that the robot is in 20 hour run mode. This robot output signal along with the next 3 bits, grouped as “Group Outputs” are used to inform the PLC to execute the desired maintenance program 1-9. The group outputs are viewed as the binary bit weight viewed as a decimal value. Reference description: “MaintReqBit1” Reference description: “MaintReqBit1” Reference description: “MaintReqBit1”

This robot output signal is used to inform the PLC that the robot is at the pounce position. (Output set by user program) This robot output signal is used to inform the PLC that the robot is at the service position. This robot output signal is used to inform the PLC that the robot is at the home position. This robot output signal is used to inform the PLC that the robot is at the tip dress position. This robot output signal is used to inform the PLC that the tip dress procedure has completed. This robot output signal is used to inform the PLC that the robot is in tip change position. This robot output signal is used to inform the PLC that the robot is clear of the transfer. This robot output signal is used to inform the PLC that the weld controller 1 is executing a weld sequence. 9

CUSW REL1.3

RobotClrZone1

33

RobotClrZone2

34

RobotClrZone3

35

RobotClrZone4

36

RobotClrZone5

37

RobotClrZone6

38

RobotClrZone7

39

RobotClrZone8

40

UserOutput1 UserOutput2 UserOutput3 UserOutput4 UserOutput5 UserOutput6 UserOutput7 UserOutput8 ClrOfPickup1

41 42 43 44 45 46 47 48 49

AtPickup1

50

ClrOfDropoff1

51

AtDropoff1

52

ClrOfPickup2

53

AtPickup2

54

ClrOfDropoff2

55

AtDropoff2

56

ClrOfPickup3

57

AtPickup3

58

ClrOfDropoff3

59

AtDropoff3

60

ClrOfPickup4

61

AtPickup4

62

ClrOfDropoff4

63

AtDropoff4

64

Clr2UnclampEarly

65

RbtAtUserPos1 RbtAtUserPos2

66 67


This robot output signal is used to inform the PLC that the robot is clear of interference zone 1. This robot output signal is used to inform the PLC that the robot is clear of interference zone 2 This robot output signal is used to inform the PLC that the robot is clear of interference zone 3. This robot output signal is used to inform the PLC that the robot is clear of interference zone 4. This robot output signal is used to inform the PLC that the robot is clear of interference zone 5. This robot output signal is used to inform the PLC that the robot is clear of interference zone 6. This robot output signal is used to inform the PLC that the robot is clear of interference zone 7. This robot output signal is used to inform the PLC that the robot is clear of interference zone 8. This robot output signal is designated as user defined output 1. This robot output signal is designated as user defined output 2. This robot output signal is designated as user defined output 3. This robot output signal is designated as user defined output 4. This robot output signal is designated as user defined output 5. This robot output signal is designated as user defined output 6. This robot output signal is designated as user defined output 7. This robot output signal is designated as user defined output 8. This robot output signal is used to inform the PLC that the robot is clear of pickup 1 position. This robot output signal is used to inform the PLC that the robot is at the pickup 1 position. This robot output signal is used to inform the PLC that the robot is clear of dropoff 1 position. This robot output signal is used to inform the PLC that the robot is at the dropoff 1 position. This robot output signal is used to inform the PLC that the robot is clear of pickup 2 position. This robot output signal is used to inform the PLC that the robot is at the pickup 2 position. This robot output signal is used to inform the PLC that the robot is clear of dropoff 2 position. This robot output signal is used to inform the PLC that the robot is at the dropoff 2 position. This robot output signal is used to inform the PLC that the robot is clear of pickup 3 position. This robot output signal is used to inform the PLC that the robot is at the pickup 3 position. This robot output signal is used to inform the PLC that the robot is clear of dropoff 3 position. This robot output signal is used to inform the PLC that the robot is at the dropoff 3 position. This robot output signal is used to inform the PLC that the robot is clear of pickup 4 position. This robot output signal is used to inform the PLC that the robot is at the pickup 4 position. This robot output signal is used to inform the PLC that the robot is clear of dropoff 4 position. This robot output signal is used to inform the PLC that the robot is at the dropoff 4 position. This robot output signal is used to inform the PLC that the robot is clear to unclamp the tooling. This robot output signal is used to inform the PLC that the robot is at user position 1 This robot output signal is used to inform the PLC that the robot is at user position 2 10

CUSW REL1.3

RbtAtUserPos3 RbtAtUserPos4 Spare Req2EntrToolNest

68 69 70 71

ClearOfToolNest

72

ServiceComp

73

MajorMinorFlt

74

WaitingForPlcCmd

75

RemoveFault RobotPartPres1 RobotPartPres2 RobotPartPres3 RobotPartPres4 RobotPartPres5 RobotPartPres6 RobotPartPres7 RobotPartPres8 RobotPartPres9 RobotPartPres10 LaserEnbld HYagEnbld PickOverride

76 77 78 79 80 81 82 83 84 85 86 87 88 89

CollisGuardEnbld AIr OK AirPressAcptRng WetDryMode AbortPickReq

90 91 92 93 94

TipDressReq Spare ExtPurg1InProgrs

95 96 97

ExtPurg2InProgrs

98

WaterOn WaterOff TurnOnTipDresser StepperResetAck

99 100 101 102

StepMode RobotAtPurgePos RobotClrFixt1

103 104 105

RobotClrFixt2

106

TipBurnInComp Spare ReposTooling1

107 108 109

This robot output signal is used to inform the PLC that the robot is at user position 3 This robot output signal is used to inform the PLC that the robot is at user position 4 Spare This robot output signal is used as a request from the robot, entry to the tool nests to the PLC. This robot output signal is used to inform the PLC that the robot is clear of the tool nest. This robot output signal is used to signal the PLC that service is complete. This robot output signal is used to signal the PLC that the posted application error is a major fault This robot output signal is used to inform the PLC that the robot is waiting for a PLC command. (Active while in a user program – WaitDI or WaitGI) This robot output signal is used to inform the PLC to remove the application error. This robot output signal is used to inform the PLC that part present 1 is activated. This robot output signal is used to inform the PLC that part present 2 is activated. This robot output signal is used to inform the PLC that part present 3 is activated. This robot output signal is used to inform the PLC that part present 4 is activated. This robot output signal is used to inform the PLC that part present 5 is activated. This robot output signal is used to inform the PLC that part present 6 is activated. This robot output signal is used to inform the PLC that part present 7 is activated. This robot output signal is used to inform the PLC that part present 8 is activated. This robot output signal is used to inform the PLC that part present 9 is activated. This robot output signal is used to inform the PLC that part present 10 is activated. This robot output signal is used to inform the PLC that the Laser is enabled. This robot output signal is used to inform the PLC that the HighYag head is enabled. This robot output signal is used to inform the PLC that the robot is in a pick over ride process. This robot output signal is used to inform the PLC if collision guard is enabled. This robot output indicates the air pressure is OK This robot output indicates the air pressure is within acceptable range. This robot output signal is used to inform the PLC if the robot is in Wet mode. This robot output signal is used to inform the PLC that the robot is requesting the abort pick sequence. This robot output informs the PLC that the weld timer has issued a tip dress request. Spare This robot output signal is used to inform the PLC that dispenser 1 purge sequence is in progress. This robot output signal is used to inform the PLC that dispenser 2 purge sequence is in progress. This robot output signal is used to inform the PLC to turn the water saver on. This robot output signal is used to inform the PLC to turn the water saver off. This robot output signal is used to inform the PLC to turn on the tip dresser motor(s). This robot output signal is used to inform the PLC that the weld controller has reset stepper . This robot output signal is used to inform the PLC that the robot is in StepMode. This robot output indicates the robot is in position to purge. This robot output signal is used to inform the PLC that the robot is clear of fixture 1 (based on automatic zone/window definition in the robot). This robot output signal is used to inform the PLC that the robot is clear of fixture 2 (based on automatic zone/window definition in the robot). This robot output informs the PLC that the tip burn in is complete. Spare This robot output along with the next two bits, (ReposTooling2 – ReposTooling4) grouped as “Group Outputs”, are used to inform the PLC to reposition the tooling.

ReposTooling2 SignatureChgInd

110 111


The group outputs are viewed as the binary bit weight viewed as a decimal value. Reference description: “ReposTooling1” This robot output indicates to the PLC that the DCS signature current and previous match and have been verified. 11

CUSW REL1.3

RbtAtInspectPos

112

TeachPendantEnbd

113

StartExtApp1Proc StartExtApp2Proc ToolIDOnWrist1

114 115 116

ToolIDOnWrist2 ToolIDOnWrist4 ProcessFault AppErrorActive

117 118 119 120

AppErrorBit1

121

This robot output signal is used to inform the PLC that the robot is at the inspection position. This robot output signal is used to inform the PLC that the teach pendant switch is enabled. This robot output informs the PLC to start external application 1 process. This robot output informs the PLC to start external application 2 process. This robot output signal along with the next two bits, (ToolIDOnWrist2 ToolIDOnWrist4) grouped as “Group Outputs”, are used to inform the PLC which tool is on the robot wrist. The group outputs are viewed as the binary bit weight viewed as a decimal value. Reference description: “ToolIDOnWrist2” Reference description: “ToolIDOnWrist4”

This robot output signal is used to inform the PLC that a process fault is present. This robot output signal is used to inform the PLC that an application error is active. Reference: Robot input 8 as acknowledge to this bit. This robot output signal along with the next seven bits, (AppErrorBit2 AppErrorBit128) grouped as “Gr oup Outputs”, are used to inform the PLC of the

current value of the application error that is posted. The group outputs are viewed as the binary bit weight viewed as a decimal value. AppErrorBit2 AppErrorBit4 AppErrorBit8 AppErrorBit16 AppErrorBit32 AppErrorBit64 AppErrorBit128

122 123 124 125 126 127 128

Reference Reference Reference Reference Reference Reference Reference

description: description: description: description: description: description: description:

“AppErrorBit1” “AppErrorBit1” “AppErrorBit1” “AppErrorBit1” “AppErrorBit1” “AppErrorBit1” “AppErrorBit1”

Reference DCX Book of Implementation Guidelines for proper Tag and UDT Naming – Design standards for Control Logix AMS 0220 Section 9.3.2, 7.0 Tag – DeviceNet Tag Naming Guidelines, Starting on page 28.


12

CUSW REL1.3

ROBOT D-NET INPUT BIT MAP (PLC TO ROBOT) SIGNAL NAME

ROBOT INPUT #

NoHold

1

Resume FaultReset

2 3

20HourRunMode ReqToEnter

4 5

LaserEnable1 LaserGuideOn AppErrorAck

6 7 8

STYLEBit1

9

DESCRIPTION This robot system input “UI[2:Hold]” is used to decelerate and stop the robot. This

signal is held high for normal operation of the robot. This robot system input “UI[6:Start]” is used to resume a paused style program. This robot system input “UI[5:Fault Reset]” is used to reset robot and robot controlled peripheral device faults. This robot input is used to put the robot into 20 hour run mode. This robot input is used to pause the robot program after it has completed the current task and/or motion. This robot input is used to signal the robot to activate the Laser system This robot input is used to signal the robot to activate the Laser Guide This robot input is used as an acknowledgment from the PLC that the application error has been read. This robot system input “UI[9:RSR1/PNS1/STYLE1]” along with the next six bits, grouped as “Group Inputs”, are used for style selection inputs from the PLC. The

STYLEBit2 STYLEBit4 STYLEBit8 STYLEBit16 STYLEBit32 STYLEBit64 WeldGunForceChk

10 11 12 13 14 15 16

InterferenceClr1 InterferenceClr2 AcceptVolume

17 18 19

VolumeFltReset

20

PPOK_ClrToGrip GripOK_ClrToExit AbortExitPick AbortExitDrop RetFromPounce

21 22 23 24 25

group inputs are viewed as the binary bit weight in a decimal fashion. System input “UI[10:RSR2/PNS2/STYLE2]” Reference description: “Style1” System input “UI[11:RSR3/PNS3/STYLE3]” Reference description: “Style1” System input “UI[12:RSR4/PNS4/STYLE4]” Reference description: “Style1” System input “UI[13:RSR5/PNS5/STYLE5]” Reference description: “Style1” System input “UI[14:RSR6/PNS6/STYLE6]” Reference description: “Style1” System input “UI[15:RSR7/PNS7/STYLE7]” Reference description: “Style1” This robot input is used to initiate the weld gun force check from a style program at the wait for dropoff position. This robot input is used to signal the robot that interference is clear at area 1. This robot input is used to signal the robot that interference is clear at area 2. This robot input is used to externally accept the sealer bead from the PLC if a volume fault was issued. This robot input is used to externally tell the robot from the PLC to reset a volume fault on the dispense unit. This robot input is used to signal the robot to grip the part. (Used for Clr to Grip part) This robot input is used to signal the robot to exit the position. (Used for Clmp&Hold) This robot input is used to signal the robot to Abort Exit Pick . This robot input is used to signal the robot to Abort Exit Drop . This robot input is used to signal the robot to return from the pounce position back to the home position. When executed, the robot program will return to the home position and mainline program without issuing a “WorkComplete”.

ServiceCompltReq

26

ServiceRequest

27

TipDressGunReq

28

ProdStart

29

Spare GoToWork

30 31

WorkCompleteAck Zone1ClrToEnter

32 33

Zone2ClrToEnter

34

Zone3ClrToEnter

35

Zone4ClrToEnter

36


This robot input is used to signal the robot to complete the service program and return to home position and mainline program from the service position. This robot input is used to signal the robot to execute a maintenance routine when the robot is at the Waiting for Dropoff# position. (M/H robots only) This robot input is used to signal the robot to initiate the tip dress procedure from a style program. This robot system input “UI[18:Prod Start]” is used to initiate a new style program. When this bit is high and a style number has been set, the robot will start executing the selected style program. [Go to pounce position of selected program] This robot input is not used. This robot input is used to signal the robot to leave “Pounce Position” and execute the work portion of the robot program. This robot input is used to signal that “WorkComplete” was received by the PLC.

This robot input is used to inform the robot that interference zone 1 is clear to enter. Reference the AME zone logic standard for further information. This robot input is used to inform the robot that interference zone 2 is clear to enter. Reference the AME zone logic standard for further information. This robot input is used to inform the robot that interference zone 3 is clear to enter. Reference the AME zone logic standard for further information. This robot input is used to inform the robot that interference zone 4 is clear to enter. 13

CUSW REL1.3

Zone5ClrToEnter

37

Zone6ClrToEnter

38

Zone7ClrToEnter

39

Zone8ClrToEnter

40

UserInput1

41

UserInput2

42

UserInput3

43

UserInput4

44

UserInput5

45

UserInput6

46

UserInput7

47

UserInput8

48

GoToPickup1

49

ExitPickup1

50

GoToDropoff1

51

ExitDropoff1

52

GoToPickup2

53

ExitPickup2

54

GoToDropoff2

55

ExitDropoff2

56

GoToPickup3

57

ExitPickup3

58

GoToDropoff3

59

ExitDropoff3

60

GoToPickup4

61

ExitPickup4

62

GoToDropoff4

63

ExitDropoff4

64

Part1InFixture Part2InFixture Part3InFixture

65 66 67


Reference the AME zone logic standard for further information. This robot input is used to inform the robot that interference zone 5 is clear to enter. Reference the AME zone logic standard for further information. This robot input is used to inform the robot that interference zone 6 is clear to enter. Reference the AME zone logic standard for further information. This robot input is used to inform the robot that interference zone 7 is clear to enter. Reference the AME zone logic standard for further information. This robot input is used to inform the robot that interference zone 8 is clear to enter. Reference the AME zone logic standard for further information. This robot input is designated as a user defined input. If used, the robot program must be annotated to identify the use of this user input. This robot input is designated as a user defined input. If used, the robot program must be annotated to identify the use of this user input. This robot input is designated as a user defined input. If used, the robot program must be annotated to identify the use of this user input. This robot input is designated as a user defined input. If used, the robot program must be annotated to identify the use of this user input. This robot input is designated as a user defined input. If used, the robot program must be annotated to identify the use of this user input. This robot input is designated as a user defined input. If used, the robot program must be annotated to identify the use of this user input. This robot input is designated as a user defined input. If used, the robot program must be annotated to identify the use of this user input. This robot input is designated as a user defined input. If used, the robot program must be annotated to identify the use of this user input. This robot input is used to signal the robot to continue its program to the pickup 1 position. This robot input is used to signal the robot to continue its program from the pickup 1 position. This robot input is used to signal the robot to continue its program to the dropoff 1 position. This robot input is used to signal the robot to continue its program from the dropoff 1 position. This robot input is used to signal the robot to continue its program to the pickup 2 position. This robot input is used to signal the robot to continue its program from the pickup 2 position. This robot input is used to signal the robot to continue its program to the dropoff 2 position. This robot input is used to signal the robot to continue its program from the dropoff 2 position. This robot input is used to signal the robot to continue its program to the pickup 3 position. This robot input is used to signal the robot to continue its program from the pickup 3 position. This robot input is used to signal the robot to continue its program to the dropoff 3 position. This robot input is used to signal the robot to continue its program from the dropoff 3 position. This robot input is used to signal the robot to continue its program to the pickup 4 position. This robot input is used to signal the robot to continue its program from the pickup 4 position. This robot input is used to signal the robot to continue its program to the dropoff 4 position. This robot input is used to signal the robot to continue its program from the dropoff 4 position. This robot input is used to signal the robot that part 1 is present in the tooling fixture. This robot input is used to signal the robot that part 2 is present in the tooling fixture. This robot input is used to signal the robot that part 3 is present in the tooling fixture. 14

CUSW REL1.3

Part4InFixture Part5InFixture Part6InFixture App1ClrToEnter

68 69 70 71

App2ClrToEnter

72

ToolInNest1 ToolInNest2 ToolInNest3 ToolInNest4 PickTool1

73 74 75 76 77

This robot input is used to signal the robot that part 4 is present in the tooling fixture. This robot input is used to signal the robot that part 5 is present in the tooling fixture. This robot input is used to signal the robot that part 6 is present in the tooling fixture. This robot input is used to signal the robot that the process application 1 fixture/area is clear for the robot to enter. This robot input is used to signal the robot that the process application 2 fixture/area is clear for the robot to enter. This robot input is used to inform the robot there is a tool present in nest 1. This robot input is used to inform the robot there is a tool present in nest 2. This robot input is used to inform the robot there is a tool present in nest 3. This robot input is used to inform the robot there is a tool present in nest 4. This robot input along with the next three bits, (PickTool2 – PickTool8) grouped as “Group Inputs”, are used to signal the robot to pick up a specific tool. The group

inputs are viewed as the binary bit weight in a decimal fashion. PickTool2 PickTool4 PickTool8 Clr2EntToolNest ToolingRepod1

78 79 80 81 82

Reference description: “PickTool1” Reference description: “PickTool1” Reference description: “PickTool1”

This robot input is used to signal the robot that the tool nest(s) is clear to enter. This robot input along with the next two bits, (ToolingRepod2 – ToolingRepod4) grouped as “Group Inputs”, are used to signal the robot that the tooling/fixture/dumps

are repositioned. The group inputs are viewed as the binary bit weight in a decimal fashion. ToolingRepod2 Spare PalletPosBit1

83 84 85

Reference description: “ToolingRepod1”

This robot input is not currently used. This robot input along with the next seven bits, (PalletPosBit2 – PalletPosBit128) grouped as “Group Inputs”, are used to signal the robot to move to a specific pallet

position. PalletPosBit2 PalletPosBit4 PalletPosBit8 PalletPosBit16 PalletPosBit32 PalletPosBit64 PalletPosBit128 WetDryMode AbortReq PurgeGun1Req

86 87 88 89 90 91 92 93 94 95

PurgeGun2Req

96

WaterFlowOK StartUpPurge

97 98

TipDressDumpExtd TipDrsDumpRetrct TipDrsMotorOn ExtStepperReset1 ExtStepperReset2 TipBurnInReq

99 100 101 102 103 104

TipChgReq

105

InspectRequired InspectComplete ClrToExitUsrPos1 ClrToExitUsrPos2

106 107 108 109


Reference Reference Reference Reference Reference Reference Reference

description: description: description: description: description: description: description:

“PalletPosBit1” “PalletPosBit1” “PalletPosBit1” “PalletPosBit1” “PalletPosBit1” “PalletPosBit1” “PalletPosBit1”

This robot input is used to signal the robot to go into Wet mode. This robot input is used to signal the robot to run an Abort routine. This robot input is used to signal the robot to execute a purge sequence for dispenser 1. This robot input is used to signal the robot to execute a purge sequence for dispenser 2. This robot input is used to signal the robot that water flow is OK. This robot input is used during the sealer purge process to instruct the robot to execute a longer purge time due to the enabling of the sealer unit from conservation mode. This robot input is used to signal the robot that the tip dresser dump is extended. This robot input is used to signal the robot that the tip dresser dump is retracted. This robot input is used to signal the robot that the tip dresser motor is running. This robot input is used to signal the robot to reset weld controller stepper 1. This robot input is used to signal the robot to reset weld controller stepper 2. This robot input is used to call the tip burn in program from the work program while the robot is at home position and from the wait for dropoff position. (Requires input looping) This robot input is used to call the tip change program from the work program while the robot is at home position and from the wait for dropoff position. (Requires input looping) This robot input is used to signal the robot to execute the inspection process. This robot input is used to signal the robot to return from inspection position. This robot input is used to signal the robot that it is clear to exit user position 1. This robot input is used to signal the robot that it is clear to exit user position 2. 15

CUSW REL1.3

ClrToExitUsrPos3 ClrToExitUsrPos4 ClrToExitUsrPos5 ExtApp1StartReq

110 111 112 113

ExtApp1Complete ExtApp2StartReq

114 115

ExtApp2Complete Reseal RejectPart NoSafeSpeed1 ReweldStud

116 117 118 119 120

AcceptStud/Part

121

RejectStud

122

ChangedHead StudSlide1InPos StudSlide2InPos PickOverrideReq

123 124 125 126

TipDressBypass NoSafeSpeed2

127 128

This robot input is used to signal the robot that it is clear to exit user position 3. This robot input is used to signal the robot that it is clear to exit user position 4. This robot input is used to signal the robot that it is clear to exit user position 5. This robot input is used to signal the robot to tell dispense controller 1 to initiate a remote start. This robot input is used to signal the robot that external application 1 is complete. This robot input is used to signal the robot to tell dispense controller 2 to initiate a remote start. This robot input is used to signal the robot that external application 2 is complete. This robot input is used to execute a Reseal process. This robot input is used to execute a Reject Part process This robot input is used to drop the robot into a slow speed during part inspection. This robot input is used to command the robot to issue a Reweld Stud command. (Fault Ack and Start1 or Start2 to ST/W. This robot input is used to comm and the robot to issue a Accept Stud comm and. (Fault Ack to ST/W and Weld Complete to robot) Accept Part (MH application) This robot input is used to command the robot to issue a Reject Stud command. (Fault Ack to ST/W and Weld Complete and JumpLbl to Dropoff to the robot. This robot input is used to instruct the robot that the ST/W head has been changed. This robot input indicates to the robot, that studwelder 1 is in the weld position. This robot input indicates to the robot, that studwelder 2 is in the weld position. This robot input indicates to the robot to execute the pick override section of the program This robot input indicates to the robot that the tip dresser is in bypass. This robot input is used to drop the robot into a slow speed during part inspection.

Reference DCX Book of Implementation Guidelines for proper Tag and UDT Naming – Design standards for Control Logix AMS 0220 Section 9.3.2, 7.0 Tag – DeviceNet Tag Naming Guidelines, Starting on page 28.


16

CUSW REL1.3

ROBOT OUTPUTS

ROBOT INPUTS

SAFETY PLC COMMUNICATIONS

SAFETY PLC COMMUNICATIONS

NODE ADDRESS

ROBOT ADDRESS

NODE ADDRESS

ROBOT ADDRESS

1

CSO 1

ESPB

1

CSI 1

EES

1

CSO 2

RB MTR OFF

1

CSI 2

EGS

1

CSO 3

AUTO

1

CSI 3

SW24V

1

CSO 4

AXP1 MON

1

CSI 4

TC24V

1

CSO 5

TC24V MON

1

CSI 5

spare

1

CSO 6

spare

1

CSI 6

spare

1

CSO 7

DM MON

1

CSI 7

spare

1

CSO 8

CSBP

1

CSI 8

spare

1

CSO 9

spare

1

CSI 9

spare

1

CSO 10

Joint 1 Zone Disabled

1

CSI 10

Joint 1 Zone Disable

1

CSO 11

Joint 2 Zone Disabled

1

CSI 11

Joint 2 Zone Disable

1

CSO 12

spare

1

CSI 12

spare

1

CSO 13

spare

1

CSI 13

spare

1

CSO 14

spare

1

CSI 14

spare

1

CSO 15

spare

1

CSI 15

spare

1

CSO 16

spare

1

CSI 16

spare

SIGNAL NAME

RTU Auto Lube I/O Robot Input #

1 2 3 4 5 6 7 8

RTU Auto Lube I/O

Name

Robot Output #

PinionCRMon BearingCRMon Pinion24VOkMon Bearing24VOkMon Pinion24VOk Bearing24VOk


SIGNAL NAME

1 2 3 4 5 6 7 8

17

Name

PinionLubeOn BearingLubeOn

CUSW REL1.3

ROBOT IO MAP ASSIGNMENTS INPUT ASSIGNMENTS

NODE NUMBER

DO [1 - 128]

DI [1 - 128]

1

SPARES PRECITEC SPOT WELD SCR#1 SPOT WELD SCR#2 SPOT WELD SCR#3 SPOT WELD SCR#4

DO [129 - 192] DO [193 - 352] DO [193 - 224] DO [225 - 256] DO [257 - 288] DO [289 - 320]

DI [129 - 192] DI [193 - 352] DI [193 - 224] DI [225 - 256] DI [257 - 288] DI [289 - 320]

10 11 12 13 14

NELSON STUD WELDER

DO [321 - 384]

DI [321 - 384]

16

DISPENSE #1 DISPENSE #2

DO [385 - 448] DO [449 - 512]

DI [385 - 448] DI [449 - 512]

25 26

DI [513 - 528] DI [529 - 544] DI [545 - 560] DI [561 - 576] DI [577 - 592]

31 32 33 34 35

ROBOT COMMUNICATION PLC COMMUNICATIONS

OUTPUT ASSIGNMENTS

MH EOAT MODULE #1 INPUT MH EOAT MODULE #2 INPUT MH EOAT MODULE #3 INPUT MH EOAT MODULE #4 INPUT MH EOAT MODULE #5 INPUT MH EOAT MODULE #1 OUTPUT MH EOAT MODULE MISC OUTPUT

DO [513 - 544] DO [545 - 576]

SPARE

DO [577 - 585]

MH EOAT VAC MODULE #1 MH EOAT VAC MODULE #2 USER DEFINABLE IO #1 USER DEFINABLE IO #2

DO [593 DO [601 DO [609 DO [617 -

600] 608] 616] 624]

DI [593 - 600] DI [601 - 608] DI [609 - 616] DI [617 - 624]

SPARE

DO [625 - 631]

DI [625 - 631]

ATI TOOLCHANGER ATI TOOLCHANGER (Robot Internal)

DO [632 - 639] DO [640 - 654]

DI [632 - 695]

54

SPARES

DO [640 - 695]

FORM & PIERCE MOOG FORM & PIERCE CLINCH NUT-FEEDER FORM & PIERCE CLINCH NUT-TOOL FORM & PIERCE PUMP Mig Weld Reamer SPARES TOOLCHANGER COVER / NEST #1 TOOLCHANGER COVER / NEST #2 TOOLCHANGER COVER / NEST #3 TOOLCHANGER COVER / NEST #4

DO [696 - 727] DO [728 - 743] DO [744 - 759] DO [760 - 767] DO (768- 775) DO [776 - 784]

DI [696 - 727] DI [728 - 743] DI [744 - 759] DI [760 - 767] DI (768 - 775) DI [776 - 784]

48 49 50 51 46

IPG_LASERWELD_GENERATOR (ASME) HIGHYAG_HEAD (ASME)

DO [785 - 800] DO [817 - 848]

DI [785 - 800] DI [817 - 848]

17 18

LaserCut Head GrinderMod1 GrinderMod2 GrinderAnalogMod1 GrinderAnalogMod2 Laser Cut Field I/O ISRA OR OTHER VISION

DO [849 - 856] DO [857 - 864] DO [865 - 872] AL 1-1 AL 2-2 AL 1-1 AL 2-2 DO (776- 783) DO [913 - 944]

DO [849 - 856] DO [857 - 864] DO [865 - 872] AL 1-1 AL 2-2 AL 1-1 AL 2-2 DI (776 - 783) DI [913 - 1024]

19 20 21 22 23 24 60

APP ERROR SPARES


39 36

37 38 43 44

55 56 57 58

DO [945 - 1024]

18

CUSW REL1.3

ROBOT BIT MAP ROBOT OUTPUTS PLC COMMUNICATIONS NODE ROBOT PMC ADDRESS ADDRESS ADDRESS 1 DO 1 Y 0.0

ROBOT INPUTS PLC COMMUNICATIONS

GROUP ASSIGNMENT

SIGNAL NAME RobotInAuto

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 1 DI 1 X 0.0 NOHold

1

DO 2

Y 0.1

RobotFaulted

1

DI 2

X 0.1

Resume

1

DO 3

Y 0.2

WaitForTPInput

1

DI 3

X 0.2

FaultReset

1

DO 4

Y 0.3

InCycle

1

DI 4

X 0.3

20HourRunMode

1

DO 5

Y 0.4

CollisionDetd

1

DI 5

X 0.4

ReqToEnter

1

DO 6

Y 0.5

IOSimulated

1

DI 6

X 0.5

LaserEnable1

1

DO 7

Y 0.6

WldEnabled

1

DI 7

X 0.6

LaserGuideOn

1

DO 8

Y 0.7

1

DO 9

Y 1.0

1

DO 10

Y 1.1

1

DO 11

Y 1.2

1

DO 12

Y 1.3

1

DO 13

Y 1.4

1

DO 14

Y 1.5

1

DO 15

Y 1.6

1

DO 16

Y 1.7

1

DO 17

1 1

RobotReady

1

DI 8

X 0.7

ActiveStyBit1

1

DI 9

X 1.0

ActiveStyBit2

1

DI 10

X 1.1

ActiveStyBit4

1

DI 11

X 1.2

ActiveStyBit8

1

DI 12

X 1.3

ActiveStyBit16

1

DI 13

X 1.4

ActiveStyBit32

1

DI 14

X 1.5

ActiveStyBit64

1

DI 15

X 1.6

PrgPaused

1

DI 16

X 1.7

WeldGunForceChk

Y 2.0

PrgRunning

1

DI 17

X 2.0

InterferenceClr1

DO 18

Y 2.1

RobotAtWork

1

DI 18

X 2.1

InterferenceClr2

DO 19

Y 2.2

WorkComplete

1

DI 19

X 2.2

AcceptVolume

1

DO 20

Y 2.3

1

DO 21

Y 2.4

1

DO 22

Y 2.5

1

DO 23

Y 2.6

1

DO 24

Y 2.7

1

DO 25

1

GO[1] GO[1] GO[1] GO[1] GO[1] GO[1] GO[1]

AppErrorAck

GI[1] GI[1] GI[1] GI[1] GI[1] GI[1] GI[1]

STYLEBit1 STYLEBit2 STYLEBit4 STYLEBit8 STYLEBit16 STYLEBit32 STYLEBit64

20HourRunModeAct

1

DI 20

X 2.3

VolumeFltReset

MaintReqBit1

1

DI 21

X 2.4

PPOK_ClrToGrip

MaintReqBit2

1

DI 22

X 2.5

GripOK_ClrToExit

MaintReqBit4

1

DI 23

X 2.6

AbortExitPick

MaintReqBit8

1

DI 24

X 2.7

AbortExitDrop

Y 3.0

RobotAtPounce

1

DI 25

X 3.0

RetFromPounce

DO 26

Y 3.1

RobotAtService

1

DI 26

X 3.1

ServiceCompltReq

1

DO 27

Y 3.2

RobotAtHome

1

DI 27

X 3.2

ServiceRequest

1

DO 28

Y 3.3

RobotInTipDress

1

DI 28

X 3.3

TipDressGunReq

1

DO 29

Y 3.4

TipDressComplt

1

DI 29

X 3.4

ProdStart

1

DO 30

Y 3.5

RdyForTipChg

1

DI 30

X 3.5

Spare

1

DO 31

Y 3.6

CleartoTransfer

1

DI 31

X 3.6

GoToWork

1

DO 32

Y 3.7

WldInPrgrsActiv1

1

DI 32

X 3.7

WorkCompleteAck

1

DO 33

Y 4.0

RbtClrZone1

1

DI 33

X 4.0

Zone1ClrToEnter

1

DO 34

Y 4.1

RbtClrZone2

1

DI 34

X 4.1

Zone2ClrToEnter

1

DO 35

Y 4.2

RbtClrZone3

1

DI 35

X 4.2

Zone3ClrToEnter

1

DO 36

Y 4.3

RbtClrZone4

1

DI 36

X 4.3

Zone4ClrToEnter

1

DO 37

Y 4.4

RbtClrZone5

1

DI 37

X 4.4

Zone5ClrToEnter

1

DO 38

Y 4.5

RbtClrZone6

1

DI 38

X 4.5

Zone6ClrToEnter

1

DO 39

Y 4.6

RbtClrZone7

1

DI 39

X 4.6

Zone7ClrToEnter

1

DO 40

Y 4.7

RbtClrZone8

1

DI 40

X 4.7

Zone8ClrToEnter

1

DO 41

Y 5.0

UserOutput1

1

DI 41

X 5.0

UserInput1

1

DO 42

Y 5.1

UserOutput2

1

DI 42

X 5.1

UserInput2

1

DO 43

Y 5.2

UserOutput3

1

DI 43

X 5.2

UserInput3

1

DO 44

Y 5.3

UserOutput4

1

DI 44

X 5.3

UserInput4

1

DO 45

Y 5.4

UserOutput5

1

DI 45

X 5.4

UserInput5

1

DO 46

Y 5.5

UserOutput6

1

DI 46

X 5.5

UserInput6

1

DO 47

Y 5.6

UserOutput7

1

DI 47

X 5.6

UserInput7

1

DO 48

Y 5.7

UserOutput8

1

DI 48

X 5.7

UserInput8

1

DO 49

Y 6.0

ClrOfPickup1

1

DI 49

X 6.0

GoToPickup1

1

DO 50

Y 6.1

AtPickup1

1

DI 50

X 6.1

ExitPickup1

1

DO 51

Y 6.2

ClrOfDropoff1

1

DI 51

X 6.2

GoToDropoff1

1

DO 52

Y 6.3

AtDropoff1

1

DI 52

X 6.3

ExitDropoff1

1

DO 53

Y 6.4

ClrOfPickup2

1

DI 53

X 6.4

GoToPickup2

1

DO 54

Y 6.5

AtPickup2

1

DI 54

X 6.5

ExitPickup2

1

DO 55

Y 6.6

ClrOfDropoff2

1

DI 55

X 6.6

GoToDropoff2

1

DO 56

Y 6.7

AtDropoff2

1

DI 56

X 6.7

ExitDropoff2

1 1

DO 57 DO 58

Y 7.0 Y 7.1

ClrOfPickup3 AtPickup3

1 1

DI 57 DI 58

X 7.0 X 7.1

GoToPickup3 ExitPickup3

1

DO 59

Y 7.2

ClrOfDropoff3

1

DI 59

X 7.2

GoToDropoff3

1

DO 60

Y 7.3

AtDropoff3

1

DI 60

X 7.3

ExitDropoff3

1

DO 61

Y 7.4

ClrOfPickup4

1

DI 61

X 7.4

GoToPickup4

1

DO 62

Y 7.5

AtPickup4

1

DI 62

X 7.5

ExitPickup4

1

DO 63

Y 7.6

ClrOfDropoff4

1

DI 63

X 7.6

GoToDropoff4

1

DO 64

Y 7.7

AtDropoff4

1

DI 64

X 7.7

ExitDropoff4

1

DO 65

Y 8.0

Clr2UnclampEarly

1

DI 65

X 8.0

Part1InFixture

1

DO 66

Y 8.1

RbtAtUserPos1

1

DI 66

X 8.1

Part2InFixture

1

DO 67

Y 8.2

RbtAtUserPos2

1

DI 67

X 8.2

Part3InFixture

1

DO 68

Y 8.3

RbtAtUserPos3

1

DI 68

X 8.3

Part4InFixture

1

DO 69

Y 8.4

RbtAtUserPos4

1

DI 69

X 8.4

Part5InFixture

1

DO 70

Y 8.5

Spare

1

DI 70

X 8.5

Part6InFixture

1

DO 71

Y 8.6

Req2EntrToolNest

1

DI 71

X 8.6

App1ClrToEnter

GO[5] GO[5] GO[5] GO[5]


19

CUSW REL1.3

ROBOT OUTPUTS PLC COMMUNICATIONS

ROBOT INPUTS PLC COMMUNICATIONS

1

DO 72

Y 8.7

ClearOfToolNest

1

DI 72

X 8.7

App2ClrToEnter

1

DO 73

Y 9.0

ServiceComp

1

DI 73

X 9.0

ToolInNest1

1

DO 74

Y 9.1

MajorMinorFlt

1

DI 74

X 9.1

ToolInNest2

1

DO 75

Y 9.2

WaitingForPlcCmd

1

DI 75

X 9.2

ToolInNest3

1

DO 76

Y 9.3

RemoveFault

1

DI 76

X 9.3

1

DO 77

Y 9.4

RobotPartPres1

1

DI 77

X 9.4

1

DO 78

Y 9.5

RobotPartPres2

1

DI 78

X 9.5

1

DO 79

Y 9.6

RobotPartPres3

1

DI 79

X 9.6

1

DO 80

Y 9.7

RobotPartPres4

1

DI 80

X 9.7

1

DO 81

Y 10.0

RobotPartPres5

1

DI 81

X 10.0

1

DO 82

Y 10.1

RobotPartPres6

1

DI 82

X 10.1

1

DO 83

Y 10.2

RobotPartPres7

1

DI 83

X 10.2

1

DO 84

Y 10.3

RobotPartPres8

1

DI 84

X 10.3

1

DO 85

Y 10.4

RobotPartPres9

1

DI 85

X 10.4

1

DO 86

Y 10.5

RobotPartPres10

1

DI 86

X 10.5

1

DO 87

Y 10.6

LaserEnbld

1

DI 87

X 10.6

1

DO 88

Y 10.7

HYagEnbld

1

DI 88

X 10.7

1

DO 89

Y 11.0

PickOverride

1

DI 89

X 11.0

1

DO 90

Y 11.1

CollisGuardEnbld

1

DI 90

X 11.1

1

DO 91

Y 11.2

AirOK

1

DI 91

X 11.2

1

DO 92

Y 11.3

AirPressAcptRng

1

DI 92

X 11.3

1

DO 93

Y 11.4

WetDryMode

1

DI 93

X 11.4

WetDryMode

1

DO 94

Y 11.5

AbortPickReq

1

DI 94

X 11.5

AbortReq

1

DO 95

Y 11.6

TipDressReq

1

DI 95

X 11.6

PurgeGun1Req

1

DO 96

Y 11.7

Spare

1

DI 96

X 11.7

PurgeGun2Req

1

DO 97

Y 12.0

ExtPurg1InProgrs

1

DI 97

X 12.0

WaterFlowOK

1

DO 98

Y 12.1

ExtPurg2InProgrs

1

DI 98

X 12.1

StartUpPurge

1

DO 99

Y 12.2

WaterOn

1

DI 99

X 12.2

TipDressDumpExtd

1

DO 100

Y 12.3

WaterOff

1

DI 100

X 12.3

TipDrsDumpRetrct

1

DO 101

Y 12.4

TurnOnTipDresser

1

DI 101

X 12.4

TipDrsMotorOn

1

DO 102

Y 12.5

StepperRstAck

1

DI 102

X 12.5

ExtStepperReset1

1

DO 103

Y 12.6

StepMode

1

DI 103

X 12.6

ExtStepperReset2

1

DO 104

Y 12.7

RobotAtPurgePos

1

DI 104

X 12.7

TipBurnInReq

1

DO 105

Y 13.0

RobotClrFixt1

1

DI 105

X 13.0

TipChgReq

1

DO 106

Y 13.1

RobotClrFixt2

1

DI 106

X 13.1

InspectRequired

1

DO 107

Y 13.2

TipBurnInComp

1

DI 107

X 13.2

InspectComplete

1

DO 108

Y 13.3

1

DO 109

Y 13.4

1

DO 110

Y 13.5

1

DO 111

Y 13.6

1

DO 112

1

ToolInNest4

GI[4] GI[4] GI[4] GI[4]

PickTool1

GI[5] GI[5]

ToolingRepod1

GI[6] GI[6] GI[6] GI[6] GI[6] GI[6] GI[6] GI[6]

PalletPosBit1

PickTool2 PickTool4 PickTool8 Clr2EntToolNest ToolingRepod2 Spare PalletPosBit2 PalletPosBit4 PalletPosBit8 PalletPosBit16 PalletPosBit32 PalletPosBit64 PalletPosBit128

Spare

1

DI 108

X 13.3

ClrToExitUsrPos1

ReposTooling1

1

DI 109

X 13.4

ClrToExitUsrPos2

ReposTooling2

1

DI 110

X 13.5

ClrToExitUsrPos3

SignatureChgInd

1

DI 111

X 13.6

ClrToExitUsrPos4

Y 13.7

RbtAtInspectPos

1

DI 112

X 13.7

ClrToExitUsrPos5

DO 113

Y 14.0

TeachPendantEnbd

1

DI 113

X 14.0

ExtApp1StartReq

1

DO 114

Y 14.1

StartExtApp1Proc

1

DI 114

X 14.1

ExtApp1Complete

1

DO 115

Y 14.2

StartExtApp1Proc

1

DI 115

X 14.2

ExtApp2StartReq

1

DO 116

Y 14.3

ToolIDOnWrist1

1

DI 116

X 14.3

ExtApp2Complete

1

DO 117

Y 14.4

ToolIDOnWrist2

1

DI 117

X 14.4

Reseal

1

DO 118

Y 14.5

ToolIDOnWrist4

1

DI 118

X 14.5

RejectPart

1

DO 119

Y 14.6

ProcessFault

1

DI 119

X 14.6

NoSafeSpeed1

1

DO 120

Y 14.7

AppErrorActive

1

DI 120

X 14.7

ReweldStud

1

DO 121

Y 15.0

AppErorrBit1

1

DI 121

X 15.0

AcceptStud/Part

1

DO 122

Y 15.1

AppErrorBit2

1

DI 122

X 15.1

RejectStud

1

DO 123

Y 15.2

AppErrorBit4

1

DI 123

X 15.2

ChangedHead

1

DO 124

Y 15.3

AppErrorBit8

1

DI 124

X 15.3

StudSlide1InPos

1

DO 125

Y 15.4

AppErrorBit16

1

DI 125

X 15.4

StudSlide2InPos

1

DO 126

Y 15.5

AppErrorBit32

1

DI 126

X 15.5

PickOverrideReq

1

DO 127

Y 15.6

AppErrorBit64

1

DI 127

X 15.6

TipDressBypass

1

DO 128

Y 15.7

AppErrorBit128

1

DI 128

X 15.7

NoSafeSpeed2

GO[2] GO[2]

GO[3] GO[3] GO[3]

GO[4] GO[4] GO[4] GO[4] GO[4] GO[4] GO[4] GO[4]


20

CUSW REL1.3

ROBOT OUTPUTS

ROBOT INPUTS

PLC COMMUNICATIONS Precitec

PLC COMMUNICATIONS Precitec

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 1 DO 129 Part OK

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 1 DI 129 Part No Bit 0 Part No Bit 1 1 DI 130

1

DO 130

Part Not OK

1

DO 131

Inspection Incomplete

1

DI 131

Part No Bit 2

1

DO 132

Line Stop

1

DI 132

Part No Bit 3

1

DO 133

Not OK Left Side

1

DI 133

Part No Bit 4

1

DO 134

Not OK Right Side

1

DI 134

Part No Bit 5

1

DO 135

Reserved

1

DI 135

Part No Bit 6

1

DO 136

Reserved

1

DI 136

Part No Bit 7

1

DO 137

1

DI 137

Part No Bit 8

1

DO 138

Seam Fault Generic Term A Seam Fault Generic Term B

1

DI 138

Part No Bit 9

1

DO 139

Seam Fault Generic Term C

1

DI 139

Part No Bit 10

1

DO 140

Reserved

1

DI 140

Part No Bit 11

1

DO 141

Reserved

1

DI 141

Part No Bit 12

1

DO 142

Reserved

1

DI 142

Part No Bit 13

1

DO 143

Reserved

1

DI 143

Part No Bit 14

1

DO 144

Reserved

1

DI 144

Part No Bit 15

1

DO 145

System Ready

1

DI 145

Part No Bit 16

1

DO 146

Spare

1

DI 146

Part No Bit 16

1

DO 147

Spare

1

DI 147

Part No Bit 18

1

DO 148

Spare

1

DI 148

Part No Bit 19

1

DO 149

Spare

1

DI 149

Part No Bit 20

1

DO 150

Spare

1

DI 150

Part No Bit 21

1

DO 151

Spare

1

DI 151

Part No Bit 22

1

DO 152

Spare

1

DI 152

Part No Bit 23

1

DO 153

Spare

1

DI 153

Part No Bit 24

1

DO 154

Spare

1

DI 154

Part No Bit 25

1

DO 155

Spare

1

DI 155

Part No Bit 26

1

DO 156

Spare

1

DI 156

Part No Bit 27

1

DO 157

Spare

1

DI 157

Part No Bit 28

1

DO 158

Spare

1

DI 158

Part No Bit 29

1

DO 159

Spare

1

DI 159

Part No Bit 30

1

DO 160

Spare

1

DI 160

Part No Bit 31

1

DO 161

Spare

1

DI 161

1

DO 162

Spare

1

DI 162

Part Type Bit 0 Part Type Bit 1

1

DO 163

Spare

1

DI 163

Part Type Bit 2

1

DO 164

Spare

1

DI 164

Part Type Bit 3

1

DO 165

Spare

1

DI 165

Part Type Bit 4

1

DO 166

Spare

1

DI 166

Part Type Bit 5

1

DO 167

Spare

1

DI 167

Part Type Bit 6

1

DO 168

Spare

1

DI 168

Part Type Bit 7

DO 169

Spare

DI 169

Spare

DO 170

Spare

DI 170

Spare

DO 171

Spare

DI 171

Spare

DO 172

Spare

DI 172

Spare

DO 173

Spare

DI 173

Spare

DO 174

Spare

DI 174

Spare

DO 175

Spare

DI 175

Spare

DO 176

Spare

DI 176

Spare

DO 177

Spare

DI 177

Spare

DO 178

Spare

DI 178

Spare

DO 179

Spare

DI 179

Spare

DO 180

Spare

DI 180

Spare

DO 181

Spare

DI 181

Spare

DO 182

Spare

DI 182

Spare

DO 183

Spare

DI 183

Spare

DO 184

Spare

DI 184

Spare

DO 185

Spare

DI 185

Spare

DO 186

Spare

DI 186

Spare

DO 187

Spare

DI 187

Spare

DO 188

Spare

DI 188

Spare

DO 189

Spare

DI 189

Spare

DO 190

Spare

DI 190

Spare

DO 191

Spare

DI 191

Spare

DO 192

Spare

DI 192

Spare


21

CUSW REL1.3

ROBOT OUTPUTS

ROBOT INPUTS

PRECITEC COMMUNICATIONS NODE ADDRESS 10

ROBOT ADDRESS DO 193

10

DO 194

10

DO 195

10

DO 196

10

DO 197

10

DO 198

10

DO 199

10 10

PMC ADDRESS Y 0.0

PRECITEC COMMUNICATIONS GROUP ASSIGNMENT

SIGNAL NAME Seam Sequence number Bit 0

NODE ADDRESS 10

ROBOT PMC GROUP ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME System fault: no laserlines DI 193 X 0.0

10

DI 194

10

DI 195

10

DI 196

10

DI 197

10

DI 198

10

DI 199

DO 200

Seam Sequence number Bit 1 Seam Sequence number Bit 2 Seam Sequence number Bit 3 Seam Sequence number Bit 4 Seam Sequence number Bit 5 Seam Sequence number Bit 6 Seam Sequence number Bit 7

10

DI 200

DO 201

Seam number Bit 0

10

DI 201

10

DI 202

Seam number Bit 2 Seam number Bit 3 Seam number Bit 4

10

DI 203

10

DI 204

10

DI 205

Seam number Bit 5 Seam number Bit 6 Seam number Bit 7

10

DI 206

10

DI 207

10

DI 208

Inspection part active Take-over Seam Seq. No Inspection seam active Linelaser on No images Air nozzle on Select inkjet reserved Error code left Error code right reserved reserved reserved reserved reserved reserved Quit system fault reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved Calibration active reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved

10

DI 209

10

DI 210

10

DI 211

10

DI 212

10

DI 213

10

DI 214

10

DI 215

10

DI 216

10

DI 217

10

DI 218

10

DI 219

10

DI 220

10

DI 221

10

DI 222

10

DI 223

10

DI 224

10

DI 225

10

DI 226

10

DI 227

10

DI 228

10

DI 229

10

DI 230

10

DI 231

10

DI 232

10

DI 233

10

DI 234

10

DI 235

10

DI 236

10

DI 237

10

DI 238

10

DI 239

10

DI 240

10

DI 241

10

DI 242

10

DI 243

10

DI 244

10

DI 245

10

DI 246

10

DI 247

10

DI 248

10

DI 249

10

DI 250

10

DI 251

10

DI 252

10

DI 253

10

DI 254

10

DI 255

10

DI 256

10

DI 257

10

DI 258

10

DI 259

10

DI 260

10

DI 261

10

DI 262

10

DI 263

10

DO 202

10

DO 203

10

DO 204

10

DO 205

10

DO 206

10

DO 207

10

DO 208

10

DO 209

10

DO 210

10

DO 211

10

DO 212

10

DO 213

10

DO 214

10

DO 215

10

DO 216

10

DO 217

10

DO 218

10

DO 219

10

DO 220

10

DO 221

10

DO 222

10

DO 223

10

DO 224

10

DO 225

10

DO 226

10

DO 227

10

DO 228

10

DO 229

10

DO 230

10

DO 231

10

DO 232

10

DO 233

10

DO 234

10

DO 235

10

DO 236

10

DO 237

10

DO 238

10

DO 239

10

DO 240

10

DO 241

10

DO 242

10

DO 243

10

DO 244

10

DO 245

10

DO 246

10

DO 247

10

DO 248

10

DO 249

10

DO 250

10

DO 251

10

DO 252

10

DO 253

10

DO 254

10

DO 255

10

DO 256

10

DO 257

10

DO 258

10

DO 259

10

DO 260

10

DO 261

10

DO 262

10

DO 263


Seam number Bit 1

22

System fault: no flash t System fault: camera problem System fault: reserved System fault: internal software problem System fault: autofocus-axis System fault: reserved System fault: reserved System fault: wrong position of sensor head System fault: seam start/seam end not detected System fault: reserved System fault: reserved System fault: Air conditioner / cabinet emperature System fault: inkjet has fault System fault: inkjet has warning System fault: reserved Part OK (OK=1) Part NOK (NOK = 1) Inspection incomplete Linestop (Stop = 1) NOK left side NOK right side reserved reserved Seam fault generic term A Seam fault generic term B Seam fault generic term C reserved reserved reserved reserved reserved System ready (collective signal) Sensor ready Inkjet ready reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved Calibration request Calibration finished Calibration OK Calibration NOK reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved

CUSW REL1.3

10

DO 264

10

DO 265

10

DO 266

10

DO 267

10

DO 268

10

DO 269

10

DO 270

10

DO 271

10

DO 272

10

DO 273

10

DO 274

10

DO 275

10

DO 276

10

DO 277

10

DO 278

10

DO 279

10

DO 280

10

DO 281

10

DO 282

10

DO 283

10

DO 284

10

DO 285

10

DO 286

10

DO 287

10

DO 288

10

DO 289

10

DO 290

10

DO 291

10

DO 292

10

DO 293

10

DO 294

10

DO 295

10

DO 296

10

DO 297

10

DO 298

10

DO 299

10

DO 300

10

DO 301

10

DO 302

10

DO 303

10

DO 304

10

DO 305

10

DO 306

10

DO 307

10

DO 308

10

DO 309

10

DO 310

10

DO 311

10

DO 312

10

DO 313

10

DO 314

10

DO 315

10

DO 316

10

DO 317

10

DO 318

10

DO 319

10

DO 320

10

DO 321

10

DO 322

10

DO 323

10

DO 324

10

DO 325

10

DO 326

10

DO 327

10

DO 328

10

DO 329

10

DO 330

10

DO 331

10

DO 332

10

DO 333

10

DO 334

10

DO 335

10

DO 336

10

DO 337

10

DO 338

10

DO 339


reserved reserved reserved reserved reserved reserved reserved reserved reserved Part-No Bit 0 (Year Bit 0) Part-No Bit 1 (Year Bit 1) Part-No Bit 2 (Year Bit 2) Part-No Bit 3 (Year Bit 3) Part-No Bit 4 (Day Bit 0) Part-No Bit 5 (Day Bit 1) Part-No Bit 6 (Day Bit 2) Part-No Bit 7 (Day Bit 3) Part-No Bit 8 (Day Bit 4) Part-No Bit 9 (Day Bit 5) Part-No Bit 10 (Day Bit 6) Part-No Bit 11 (Day Bit 7) Part-No Bit 12 (Day Bit 8) Part-No Bit 13 (Day Bit 9) Part-No Bit 14 (Day Bit 10) Part-No Bit 15 (Day Bit 11)

10

DI 264

10

DI 265

10

DI 266

10

DI 267

10

DI 268

10

DI 269

10

DI 270

10

DI 271

10

DI 272

10

DI 273

10

DI 274

10

DI 275

10

DI 276

10

DI 277

10

DI 278

10

DI 279

10

DI 280

10

DI 281

10

DI 282

10

DI 283

10

DI 284

10

DI 285

10

DI 286

10

DI 287

10

DI 288

Part-No Bit 16 (Current no Bit 0) Part-No Bit 17 (Current no Bit 1) Part-No Bit 18 (Current no Bit 2) Part-No Bit 19 (Current no Bit 3) Part-No Bit 20 (Current no Bit 4) Part-No Bit 21 (Current no Bit 5) Part-No Bit 22 (Current no Bit 6) Part-No Bit 23 (Current no Bit 7) Part-No Bit 24 (Current no Bit 8) Part-No Bit 25 (Current no Bit 9) Part-No Bit 26 (Current no Bit 10) Part-No Bit 27 (Current no Bit 11) Part-No Bit 28 (Current no Bit 12) Part-No Bit 29 (Current no Bit 13) Part-No Bit 30 (Current no Bit 14) Part-No Bit 31 (Current no Bit 15) Part-No Bit 32 Part-No Bit 33 Part-No Bit 34 Part-No Bit 35 Part-No Bit 36 Part-No Bit 37 Part-No Bit 38 Part-No Bit 39 Part-No Bit 40 Part-No Bit 41 Part-No Bit 42 Part-No Bit 43 Part-No Bit 44 Part-No Bit 45 Part-No Bit 46 Part-No Bit 47 Part-Type Bit 0 Part-Type Bit 1 Part-Type Bit 2 Part-Type Bit 3 Part-Type Bit 4 Part-Type Bit 5 Part-Type Bit 6 Part-Type Bit 7 reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved

10

DI 289

10

DI 290

10

DI 291

10

DI 292

10

DI 293

10

DI 294

10

DI 295

10

DI 296

10

DI 297

10

DI 298

Part-No Bit 16 (Current no Bit 0) Part-No Bit 17 (Current no Bit 1) Part-No Bit 18 (Current no Bit 2) Part-No Bit 19 (Current no Bit 3) Part-No Bit 20 (Current no Bit 4) Part-No Bit 21 (Current no Bit 5) Part-No Bit 22 (Current no Bit 6) Part-No Bit 23 (Current no Bit 7) Part-No Bit 24 (Current no Bit 8) Part-No Bit 25 (Current no Bit 9)

10

DI 299

Part-No Bit 26 (Current no Bit 10)

10

DI 300


10

DI 301


10

DI 302


10

DI 303


10

DI 304


10

DI 305

10

DI 306

10

DI 307

10

DI 308

10

DI 309

10

DI 310

10

DI 311

10

DI 312

10

DI 313

10

DI 314

10

DI 315

10

DI 316

10

DI 317

10

DI 318

10

DI 319

10

DI 320

Part-No Bit 32 Part-No Bit 33 Part-No Bit 34 Part-No Bit 35 Part-No Bit 36 Part-No Bit 37 Part-No Bit 38 Part-No Bit 39 Part-No Bit 40 Part-No Bit 41 Part-No Bit 42 Part-No Bit 43 Part-No Bit 44 Part-No Bit 45 Part-No Bit 46 Part-No Bit 47 Part-Type Bit 0 Part-Type Bit 1 Part-Type Bit 2 Part-Type Bit 3 Part-Type Bit 4 Part-Type Bit 5 Part-Type Bit 6 Part-Type Bit 7 reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved

23

10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

reserved reserved reserved reserved reserved reserved reserved reserved reserved Part-No Bit 0 (Year Bit 0) Part-No Bit 1 (Year Bit 1) Part-No Bit 2 (Year Bit 2) Part-No Bit 3 (Year Bit 3) Part-No Bit 4 (Day Bit 0) Part-No Bit 5 (Day Bit 1) Part-No Bit 6 (Day Bit 2) Part-No Bit 7 (Day Bit 3) Part-No Bit 8 (Day Bit 4) Part-No Bit 9 (Day Bit 5) Part-No Bit 10 (Day Bit 6) Part-No Bit 11 (Day Bit 7) Part-No Bit 12 (Day Bit 8) Part-No Bit 13 (Day Bit 9) Part-No Bit 14 (Day Bit 10) Part-No Bit 15 (Day Bit 11)

CUSW REL1.3

10

DO 340

10

DO 341

10

DO 342

10

DO 343

10

DO 344

10

DO 345

10

DO 346

10

DO 347

10

DO 348

10

DO 349

10

DO 350

10

DO 351

10

DO 352

reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved

10 10 10 10 10 10 10 10 10 10 10 10 10

reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved reserved

Note: Configuration of the Precitec must done manually by the robot programmer. The robot must be set up with the custo as a material handling robot and spotwelding and studwelding cannot be configured.


24

CUSW REL1.3

ROBOT OUTPUTS

ROBOT INPUTS

SPOT WELD SCR#1 COMMUNICA TIONS

SPOT WELD SCR#1 COMMUNICATIONS

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 11 DO 193 Y 0.0 W1EnableWld

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 11 DI 193 X 0.0 W1WeldEnabled

11

DO 194

W1FaultRst

11

DI 194

W1NoFault

11

DO 195

W1WldFltAck

11

DI 195

W1NoAlert

11

DO 196

W1PrgBit1

11

DI 196

11

DO 197

W1PrgBit2

11

DI 197

11

DO 198

W1PrgBit4

11

DI 198

11

DO 199

W1PrgBit8

11

DI 199

11

DO 200

W1PrgBit16

11

DI 200

11

DO 201

W1PrgBit32

11

DI 201

11

DO 202

W1InitiateWld

11

DI 202

W1WeldComplete

11

DO 203

W1PressTest

11

DI 203

W1WeldInProgres

11

DO 204

W1InitRet

11

DI 204

W1SteppersReset

11

DO 205

W1RstStepper

11

DI 205

W1NearEndOfStep

11

DO 206

W1IsoContSvrEnb

11

DI 206

W1EndOfStepper

11

DO 207

W1ControlStop

11

DI 207

W1ReadyToWeld

11

DO 208

11

DO 209

11

DO 210

11

DO 211

11

DO 212

11

DO 213

11

DO 214

11

DO 215

11

DO 216

11

DO 217

11

DO 218

11

DO 219

11

DO 220

11

DO 221

11

DO 222

11 11

GO[11] GO[11] GO[11] GO[11] GO[11] GO[11]

W1WeldFltAvail

GI[11] GI[11] GI[11] GI[11] GI[11]

W1WeldFltBit1 W1WeldFltBit2 W1WeldFltBit4 W1WeldFltBit8 W1WeldFltBit16

W1Tipsdressed

11

DI 208

W1DressTipsReq

W1WldIDBit1

11

DI 209

W1RetractOut#1

W1WldIDBit2

11

DI 210

W1RetractOut#2

W1WldIDBit4

11

DI 211

W1FltMSGCode

W1WldIDBit8

11

DI 212

W1AlrtMSGCode

W1WldIDBit16

11

DI 213

Spare

W1WldIDBit32

11

DI 214

Spare

W1WldIDBit64

11

DI 215

Spare

W1WldIDBit128

11

DI 216

Spare

W1WldIDBit256

11

DI 217

Spare

W1WldIDBit512

11

DI 218

Spare

W1WldIDBit1024

11

DI 219

Spare

W1WldIDBit2048

11

DI 220

Spare

W1WldIDBit4096

11

DI 221

Spare

W1WldIDBit8192

11

DI 222

Spare

DO 223

Spare

11

DI 223

Spare

DO 224

Spare

11

DI 224

Spare

GO[12] GO[12] GO[12] GO[12] GO[12] GO[12] GO[12] GO[12] GO[12] GO[12] GO[12] GO[12] GO[12] GO[12]

ROBOT OUTPUTS

ROBOT INPUTS





12

DO 226

W2FaultRst

12

DI 226

W2NoFault

12

DO 227

W2WldFltAck

12

DI 227

W2NoAlert

12

DO 228

W2PrgBit1

12

DI 228

12

DO 229

W2PrgBit2

12

DI 229

12

DO 230

W2PrgBit4

12

DI 230

12

DO 231

W2PrgBit8

12

DI 231

12

DO 232

W2PrgBit16

12

DI 232

12

DO 233

W2PrgBit32

12

DI 233

12

DO 234

W2InitiateWld

12

DI 234

W2WeldComplete

12

DO 235

W2PressTest

12

DI 235

W2WeldInProgres

12 12

DO 236 DO 237

W2InitRet W2RstStepper

12 12

DI 236 DI 237

W2SteppersReset W2NearEndOfStep

12

DO 238

W2IsoContSvrEnb

12

DI 238

W2EndOfStepper

12

DO 239

W2ControlStop

12

DI 239

W2ReadyToWeld

12

DO 240

12

DO 241

12

DO 242

12

DO 243

12

DO 244

12

DO 245

12

DO 246

12

DO 247

12

DO 248

12

DO 249

12

DO 250

12

DO 251

12

DO 252

12

DO 253

12

DO 254

12 12

GO[13] GO[13] GO[13] GO[13] GO[13] GO[13]

W2WeldFltAvail

GI[13] GI[13] GI[13] GI[13] GI[13]


W2Tipsdressed

12

DI 240

W2DressTipsReq

W2WldIDBit1

12

DI 241

W2RetractOut#1

W2WldIDBit2

12

DI 242

W2RetractOut#2

W2WldIDBit4

12

DI 243

W2FltMSGCode

W2WldIDBit8

12

DI 244

W2AlrtMSGCode

W2WldIDBit16

12

DI 245

Spare

W2WldIDBit32

12

DI 246

Spare

W2WldIDBit64

12

DI 247

Spare

W2WldIDBit128

12

DI 248

Spare

W2WldIDBit256

12

DI 249

Spare

W2WldIDBit512

12

DI 250

Spare

W2WldIDBit1024

12

DI 251

Spare

W2WldIDBit2048

12

DI 252

Spare

W2WldIDBit4096

12

DI 253

Spare

W2WldIDBit8192

12

DI 254

Spare

DO 255

Spare

12

DI 255

Spare

DO 256

Spare

12

DI 256

Spare



25

CUSW REL1.3

ROBOT OUTPUTS

ROBOT INPUTS





13

DO 258

W3FaultRst

13

DI 258

W3NoFault

13

DO 259

W3WldFltAck

13

DI 259

W3NoAlert

13

DO 260

W3PrgBit1

13

DI 260

13

DO 261

W3PrgBit2

13

DI 261

13

DO 262

W3PrgBit4

13

DI 262

13

DO 263

W3PrgBit8

13

DI 263

13

DO 264

W3PrgBit16

13

DI 264

13

DO 265

W3PrgBit32

13

DI 265

13

DO 266

W3InitiateWld

13

DI 266

W3WeldComplete

13

DO 267

W3PressTest

13

DI 267

W3WeldInProgres

13

DO 268

W3InitRet

13

DI 268

W3SteppersReset

13

DO 269

W3RstStepper

13

DI 269

W3NearEndOfStep

13

DO 270

W3IsoContSvrEnb

13

DI 270

W3EndOfStepper

13

DO 271

W3ControlStop

13

DI 271

W3ReadyToWeld

13

DO 272

13

DO 273

13

DO 274

13

DO 275

13

DO 276

13

DO 277

13

DO 278

13

DO 279

13

DO 280

13

DO 281

13

DO 282

13

DO 283

13

DO 284

13

DO 285

13

DO 286

13 13

GO[15] GO[15] GO[15] GO[15] GO[15] GO[15]

W3WeldFltAvail

GI[15] GI[15] GI[15] GI[15] GI[15]


W3Tipsdressed

13

DI 272

W3DressTipsReq

W3WldIDBit1

13

DI 273

W3RetractOut#1

W3WldIDBit2

13

DI 274

W3RetractOut#2

W3WldIDBit4

13

DI 275

W3FltMSGCode

W3WldIDBit8

13

DI 276

W3AlrtMSGCode

W3WldIDBit16

13

DI 277

Spare

W3WldIDBit32

13

DI 278

Spare

W3WldIDBit64

13

DI 279

Spare

W3WldIDBit128

13

DI 280

Spare

W3WldIDBit256

13

DI 281

Spare

W3WldIDBit512

13

DI 282

Spare

W3WldIDBit1024

13

DI 283

Spare

W3WldIDBit2048

13

DI 284

Spare

W3WldIDBit4096

13

DI 285

Spare

W3WldIDBit8192

13

DI 286

Spare

DO 287

Spare

13

DI 287

Spare

DO 288

Spare

13

DI 288

Spare


ROBOT OUTPUTS

ROBOT INPUTS





14

DO 290

W4FaultRst

14

DI 290

W4NoFault

14

DO 291

W4WldFltAck

14

DI 291

W4NoAlert

14

DO 292

W4PrgBit1

14

DI 292

14

DO 293

W4PrgBit2

14

DI 293

14

DO 294

W4PrgBit4

14

DI 294

14

DO 295

W4PrgBit8

14

DI 295

14

DO 296

W4PrgBit16

14

DI 296

14

DO 297

W4PrgBit32

14

DI 297

14

DO 298

W4InitiateWld

14

DI 298

W4WeldComplete

14

DO 299

W4PressTest

14

DI 299

W4WeldInProgres

14

DO 300

W4InitRet

14

DI 300

W4SteppersReset

14

DO 301

W4RstStepper

14

DI 301

W4NearEndOfStep

14

DO 302

W4IsoContSvrEnb

14

DI 302

W4EndOfStepper

14

DO 303

W4ControlStop

14

DI 303

W4ReadyToWeld

14

DO 304

14

DO 305

14

DO 306

14

DO 307

14

DO 308

14

DO 309

14

DO 310

14

DO 311

14

DO 312

14

DO 313

14

DO 314

14

DO 315

14

DO 316

14

DO 317

14

DO 318

14 14

GO[17] GO[17] GO[17] GO[17] GO[17] GO[17]

W4WeldFltAvail

GI[17] GI[17] GI[17] GI[17] GI[17]


W4Tipsdressed

14

DI 304

W4DressTipsReq

W4WldIDBit1

14

DI 305

W4RetractOut#1

W4WldIDBit2

14

DI 306

W4RetractOut#2

W4WldIDBit4

14

DI 307

W4FltMSGCode

W4WldIDBit8

14

DI 308

W4AlrtMSGCode

W4WldIDBit16

14

DI 309

Spare

W4WldIDBit32

14

DI 310

Spare

W4WldIDBit64

14

DI 311

Spare

W4WldIDBit128

14

DI 312

Spare

W4WldIDBit256

14

DI 313

Spare

W4WldIDBit512

14

DI 314

Spare

W4WldIDBit1024

14

DI 315

Spare

W4WldIDBit2048

14

DI 316

Spare

W4WldIDBit4096

14

DI 317

Spare

W4WldIDBit8192

14

DI 318

Spare

DO 319

Spare

14

DI 319

Spare

DO 320

Spare

14

DI 320

Spare



26

CUSW REL1.3

ROBOT OUTPUTS

ROBOT INPUTS

NELSON STUD WELDER COMMUNICATIONS

NELSON STUD WELDER COMMUNICATIONS

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 16 DO 321 Y 0.0 StartWeld1

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 16 DI 321 X 0.0 NOError1

16

DO 322

StartWeld2

16

DI 322

WeldComp1

16

DO 323

StartWeld3

16

DI 323

WeldGunRetrctd1

16

DO 324

StartWeld4

16

DI 324

StudTouchingWrk1

16

DO 325

StartWeld5

16

DI 325

SuspectWeld1

16

DO 326

FeedStud1

16

DI 326

NOError2

16

DO 327

FeedStud2

16

DI 327

WeldComp2

16

DO 328

FeedStud3

16

DI 328

WeldGunRetrctd2

16

DO 329

FeedStud4

16

DI 329

StudTouchingWrk2

16

DO 330

FeedStud5

16

DI 330

SuspectWeld2

16

DO 331

GO[21]

SelectProgBit1

16

DI 331

NOError3

16

DO 332

GO[21]

SelectProgBit2

16

DI 332

WeldComp3

16

DO 333

GO[21]

SelectProgBit4

16

DI 333

WeldGunRetrctd3

16

DO 334

GO[21]

SelectProgBit8

16

DI 334

StudTouchingWrk3

16

DO 335

GO[21]

SelectProgBit16

16

DI 335

SuspectWeld3

16

DO 336

GO[21]

SelectProgBit32

16

DI 336

NOError4

16

DO 337

GO[21]

SelectProgBit64

16

DI 337

WeldComp4

16

DO 338

GO[21]

SelectProgBit128

16

DI 338

WeldGunRetrctd4

16

DO 339

Restart

16

DI 339

StudTouchingWrk4

16

DO 340

SetWeldComp

16

DI 340

SuspectWeld4

16

DO 341

GO[22]

SelectOperMode0

16

DI 341

NOError5

16

DO 342

GO[22]

SelectOperMode1

16

DI 342

WeldComp5

16

DO 343

ResetFault

16

DI 343

WeldGunRetrctd5

16

DO 344

Std1Output24

16

DI 344

StudTouchingWrk5

16

DO 345

Std1Output25

16

DI 345

SuspectWeld5

16

DO 346

Std1Output26

16

DI 346

MaintCountReachd

16

DO 347

Std1Output27

16

DI 347

FeederLow

16

DO 348

Std1Output28

16

DI 348

UnitOnline

16

DO 349

Std1Output29

16

DI 349

AllGunsReady

16

DO 350

Std1Output30

16

DI 350

SimModeActive

16

DO 351

Std1Output31

16

DI 351

Std1Input31

16

DO 352

Std1Output32

16

DI 352

16

DO 353

Std1Output33

16

DI 353

16

DO 354

Std1Output34

16

DI 354

16

DO 355

Std1Output35

16

DI 355

16

DO 356

Std1Output36

16

DI 356

16

DO 357

Std1Output37

16

DI 357

16

DO 358

Std1Output38

16

DI 358

16

DO 359

Std1Output39

16

DI 359

16

DO 360

Std1Output40

16

DI 360

16

DO 361

Std1Output41

16

DI 361

Std1Input41

16

DO 362

Std1Output42

16

DI 362

Std1Input42

16

DO 363

Std1Output43

16

DI 363

Std1Input43

16

DO 364

Std1Output44

16

DI 364

Std1Input44

16

DO 365

Std1Output45

16

DI 365

Std1Input45

16

DO 366

Std1Output46

16

DI 366

Std1Input46

16

DO 367

Std1Output47

16

DI 367

Std1Input47

16

DO 368

Std1Output48

16

DI 368

Std1Input48

16

DO 369

AdvWeldGun1

16

DI 369

Std1Input49

16

DO 370

AdvWeldGun2

16

DI 370

Std1Input50

16

DO 371

AdvWeldGun3

16

DI 371

Std1Input51

16

DO 372

AdvWeldGun4

16

DI 372

Std1Input52

16

DO 373

AdvWeldGun5

16

DI 373

Std1Input53

16

DO 374

Std1Output54

16

DI 374

Std1Input54

16

DO 375

Std1Output55

16

DI 375

Std1Input55

16

DO 376

Std1Output56

16

DI 376

Std1Input56

16

DO 377

Std1Output57

16

DI 377

Std1Input57

16

DO 378

Std1Output58

16

DI 378

Std1Input58

16

DO 379

Std1Output59

16

DI 379

Std1Input59

16

DO 380

Std1Output60

16

DI 380

Std1Input60

16

DO 381

Std1Output61

16

DI 381

Std1Input61

16

DO 382

Std1Output62

16

DI 382

Std1Input62

16

DO 383

Std1Output63

16

DI 383

Std1Input63

16

DO 384

Std1Output64

16

DI 384

Std1Input64


27

Std1Input32

GI[22] GI[22] GI[22] GI[22] GI[22] GI[22] GI[22] GI[22]

ErrorCodeBit1 ErrorCodeBit2 ErrorCodeBit4 ErrorCodeBit8 ErrorCodeBit16 ErrorCodeBit32 ErrorCodeBit64 ErrorCodeBit128

CUSW REL1.3

ROBOT OUTPUTS

ROBOT INPUTS

NORDSON DISPENSE (PS2) #1 COMMUNICATIONS


NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 25 DO 385 Y 0.0 Disp1StyBit1 GO[31]

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 25 DI 385 X 0.0 Dsp1DispenRdy

25

DO 386

25

DO 387

25

DO 388

25

DO 389

25

DO 390

25

DO 391

25

DO 392

25

GO[31] GO[31] GO[31] GO[31] GO[31] GO[31] GO[31]

Disp1StyBit2

25

DI 386

Dsp1DispenInPrc

Disp1StyBit3

25

DI 387

Dsp1VolumeOK

Disp1StyBit4

25

DI 388

Reserved

Disp1StyBit5

25

DI 389

Reserved

Disp1StyBit6

25

DI 390

Reserved

Disp1StyBit7

25

DI 391

Reserved

Disp1StyBit8

25

DI 392

Reserved

DO 393

Disp1RbtinPrc

25

DI 393

Dsp1LowVolFlt

25

DO 394

Disp1StyStrobe

25

DI 394

Dsp1HighVolFlt

25

DO 395

Disp1GunON

25

DI 395

Dsp1LowPressFlt

25

DO 396

Reserved

25

DI 396

Dsp1HighPressFlt

25

DO 397

Disp1ManPurgeEnbl

25

DI 397

Dsp1ColDetd

25

DO 398

Reserved

25

DI 398

Reserved

25

DO 399

Reserved

25

DI 399

Reserved

25

DO 400

Reserved

25

DI 400

Reserved

25

DO 401

Disp1Complete

25

DI 401

Reserved

25

DO 402

Reserved

25

DI 402

Reserved

25

DO 403

Reserved

25

DI 403

Reserved

25

DO 404

Reserved

25

DI 404

Reserved

25

DO 405

Reserved

25

DI 405

Reserved

25

DO 406

Reserved

25

DI 406

Reserved

25

DO 407

Reserved

25

DI 407

Reserved

25

DO 408

Reserved

25

DI 408

Reserved

25

DO 409

Reserved

25

DI 409

Reserved

25

DO 410

Reserved

25

DI 410

Reserved

25

DO 411

Reserved

25

DI 411

Reserved

25

DO 412

Reserved

25

DI 412

Reserved

25

DO 413

Reserved

25

DI 413

Reserved

25

DO 414

Reserved

25

DI 414

Reserved

25 25 25

DO 415 DO 416 DO 417

Reserved Reserved Dsp1MatFlwCmdB1

25 25 25

DI 415 DI 416 DI 417

Reserved Reserved Reserved

25

DO 418

Dsp1MatFlwCmdB2

25

DI 418

Reserved

25

DO 419

Dsp1MatFlwCmdB3

25

DI 419

Reserved

25

DO 420

Dsp1MatFlwCmdB4

25

DI 420

Reserved

25

DO 421

Dsp1MatFlwCmdB5

25

DI 421

Reserved

25

DO 422

Dsp1MatFlwCmdB6

25

DI 422

Reserved

25

DO 423

Dsp1MatFlwCmdB7

25

DI 423

Reserved

25

DO 424

Dsp1MatFlwCmdB8

25

DI 424

Reserved

25

DO 425

Dsp1MatFlwCmdB9

25

DI 425

Reserved

25

DO 426

Dsp1MatFlwCmdB10

25

DI 426

Reserved

25

DO 427

Dsp1MatFlwCmdB11

25

DI 427

Reserved

25

DO 428

Dsp1MatFlwCmdB12

25

DI 428

Reserved

25

DO 429

Reserved

25

DI 429

Reserved

25

DO 430

Reserved

25

DI 430

Reserved

25

DO 431

Reserved

25

DI 431

Reserved

25

DO 432

Reserved

25

DI 432

Reserved

25

DO 433

Reserved

25

DI 433

Reserved

25

DO 434

Reserved

25

DI 434

Reserved

25

DO 435

Reserved

25

DI 435

Reserved

25

DO 436

Reserved

25

DI 436

Reserved

25

DO 437

Reserved

25

DI 437

Reserved

25

DO 438

Reserved

25

DI 438

Reserved

25

DO 439

Reserved

25

DI 439

Reserved

25

DO 440

Reserved

25

DI 440

Reserved

25

DO 441

Reserved

25

DI 441

Reserved

25

DO 442

Reserved

25

DI 442

Reserved

25

DO 443

Reserved

25

DI 443

Reserved

25

DO 444

Reserved

25

DI 444

Reserved

25

DO 445

Reserved

25

DI 445

Reserved

25

DO 446

Reserved

25

DI 446

Reserved

25

DO 447

Reserved

25

DI 447

Reserved

25

DO 448

Disp1FaultRst

25

DI 448

Reserved

GO[32] GO[32] GO[32] GO[32] GO[32] GO[32] GO[32] GO[32] GO[32] GO[32] GO[32] GO[32]


28

CUSW REL1.3

ROBOT OUTPUTS

ROBOT INPUTS



NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 26 DO 449 Y 0.0 Disp2StyBit1 GO[36]

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 26 DI 449 X 0.0 Dsp2DispenRdy

26

DO 450

26

DO 451

26

DO 452

26

DO 453

26

DO 454

26

DO 455

26

DO 456

26

GO[36] GO[36] GO[36] GO[36] GO[36] GO[36] GO[36]

Disp2StyBit2

26

DI 450

Dsp2DispenInPrc

Disp2StyBit3

26

DI 451

Dsp2VolumeOK

Disp2StyBit4

26

DI 452

Reserved

Disp2StyBit5

26

DI 453

Reserved

Disp2StyBit6

26

DI 454

Reserved

Disp2StyBit7

26

DI 455

Reserved

Disp2StyBit8

26

DI 456

Reserved

DO 457

Disp2RbtinPrc

26

DI 457

Dsp2LowVolFlt

26

DO 458

Disp2StyStrobe

26

DI 458

Dsp2HighVolFlt

26

DO 459

Disp2GunON

26

DI 459

Dsp2LowPressFlt

26

DO 460

Reserved

26

DI 460

Dsp2HighPressFlt

26

DO 461

Disp2ManPurgeEnbl

26

DI 461

Dsp2ColDetd

26

DO 462

Reserved

26

DI 462

Reserved

26

DO 463

Reserved

26

DI 463

Reserved

26

DO 464

Reserved

26

DI 464

Reserved

26

DO 465

Disp2Complete

26

DI 465

Reserved

26

DO 466

Reserved

26

DI 466

Reserved

26

DO 467

Reserved

26

DI 467

Reserved

26

DO 468

Reserved

26

DI 468

Reserved

26

DO 469

Reserved

26

DI 469

Reserved

26

DO 470

Reserved

26

DI 470

Reserved

26

DO 471

Reserved

26

DI 471

Reserved

26

DO 472

Reserved

26

DI 472

Reserved

26

DO 473

Reserved

26

DI 473

Reserved

26

DO 474

Reserved

26

DI 474

Reserved

26

DO 475

Reserved

26

DI 475

Reserved

26

DO 476

Reserved

26

DI 476

Reserved

26

DO 477

Reserved

26

DI 477

Reserved

26

DO 478

Reserved

26

DI 478

Reserved

26 26 26

DO 479 DO 480 DO 481

Reserved Reserved Dsp2MatFlwCmdB1

26 26 26

DI 479 DI 480 DI 481

Reserved Reserved Reserved

26

DO 482

Dsp2MatFlwCmdB2

26

DI 482

Reserved

26

DO 483

Dsp2MatFlwCmdB3

26

DI 483

Reserved

26

DO 484

Dsp2MatFlwCmdB4

26

DI 484

Reserved

26

DO 485

Dsp2MatFlwCmdB5

26

DI 485

Reserved

26

DO 486

Dsp2MatFlwCmdB6

26

DI 486

Reserved

26

DO 487

Dsp2MatFlwCmdB7

26

DI 487

Reserved

26

DO 488

Dsp2MatFlwCmdB8

26

DI 488

Reserved

26

DO 489

Dsp2MatFlwCmdB9

26

DI 489

Reserved

26

DO 490

Dsp2MatFlwCmdB10

26

DI 490

Reserved

26

DO 491

Dsp2MatFlwCmdB11

26

DI 491

Reserved

26

DO 492

Dsp2MatFlwCmdB12

26

DI 492

Reserved

26

DO 493

Reserved

26

DI 493

Reserved

26

DO 494

Reserved

26

DI 494

Reserved

26

DO 495

Reserved

26

DI 495

Reserved

26

DO 496

Reserved

26

DI 496

Reserved

26

DO 497

Reserved

26

DI 497

Reserved

26

DO 498

Reserved

26

DI 498

Reserved

26

DO 499

Reserved

26

DI 499

Reserved

26

DO 500

Reserved

26

DI 500

Reserved

26

DO 501

Reserved

26

DI 501

Reserved

26

DO 502

Reserved

26

DI 502

Reserved

26

DO 503

Reserved

26

DI 503

Reserved

26

DO 504

Reserved

26

DI 504

Reserved

26

DO 505

Reserved

26

DI 505

Reserved

26

DO 506

Reserved

26

DI 506

Reserved

26

DO 507

Reserved

26

DI 507

Reserved

26

DO 508

Reserved

26

DI 508

Reserved

26

DO 509

Reserved

26

DI 509

Reserved

26

DO 510

Reserved

26

DI 510

Reserved

26

DO 511

Reserved

26

DI 511

Reserved

26

DO 512

Disp2FaultRst

26

DI 512

Reserved

GO[37] GO[37] GO[37] GO[37] GO[37] GO[37] GO[37] GO[37] GO[37] GO[37] GO[37] GO[37]


29

CUSW REL1.3

ROBOT OUTPUTS

ROBOT INPUTS

MH EOAT MODULE #1 OUTPUT COMMUNICATIONS (SMC)

MH EOAT MODULE #1 INPUT COMMUNICATIONS

ROBOT NODE ROBOT PMC INTERNAL ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 39 DO 513 K0.0 VLV1Extend DO 10001

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 31 DI 513 X 0.0 Part1Present

VLV1Retract

31

DI 514

Part2Present

VLV2Extend

31

DI 515

Part3Present

K2.0

DO 10002 DO 10003 DO 10004 DO 10005 DO 10006 DO 10007 DO 10008 DO 10009 DO 10010 DO 10011 DO 10012 DO 10013 DO 10014 DO 10015 DO 10016 DO 10017

DO 530

K2.1

DO 10018

VLV9Retract

39

DO 531

K2.2

DO 10019

VLV10Extend

MH EOAT MODU LE #2 INPUT COMMUNICATIONS

39

DO 532

K2.3

DO 10020

VLV10Retract

39

DO 533

K2.4

VLV11Extend

39

DO 534

K2.5

39

DO 535

K2.6

39

DO 536

K2.7

39

DO 537

K3.0

39

DO 538

K3.1

39

DO 539

K3.2

39

DO 540

K3.3

39

DO 541

K3.4

39

DO 542

K3.5

39

DO 543

K3.6

39

DO 544

K3.7

DO 10021 DO 10022 DO 10023 DO 10024 DO 10025 DO 10026 DO 10027 DO 10028 DO 10029 DO 10030 DO 10031 DO 10032

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 32 DI 529 X 0.0 Part5Present

39

DO 514

K0.1

39

DO 515

K0.2

39

DO 516

K0.3

39

DO 517

K0.4

39

DO 518

K0.5

39 39 39

DO 519 DO 520 DO 521

K0.6 K0.7 K1.0

39

DO 522

K1.1

39

DO 523

K1.2

39

DO 524

K1.3

39

DO 525

K1.4

39

DO 526

K1.5

39

DO 527

K1.6

39

DO 528

K1.7

39

DO 529

39

VLV2Retract

31

DI 516

Part4Present

VLV3Extend

31

DI 517

MHDev1Retracted

VLV3Retract

31

DI 518

MHDev1Extended

VLV4Extend VLV4Retract VLV5Extend

31 31 31

DI 519 DI 520 DI 521

MHDev2Retracted MHDev2Extended MHDev3Retracted

VLV5Retract

31

DI 522

MHDev3Extended

VLV6Extend

31

DI 523

MHDev4Retracted

VLV6Retract

31

DI 524

MHDev4Extended

VLV7Extend

31

DI 525

MHDev5Retracted

VLV7Retract

31

DI 526

MHDev5Extended

VLV8Extend

31

DI 527

MHDev6Retracted

VLV8Retract

31

DI 528

MHDev6Extended

VLV9Extend

ROBOT INPUTS

VLV11Retract

32

DI 530

Part6Present

VLV12Extend

32

DI 531

Part7Present

VLV12Retract

32

DI 532

Part8Present

VLV13Extend

32

DI 533

MHDev7Retracted

VLV13Retract

32

DI 534

MHDev7Extended

VLV14Extend

32

DI 535

MHDev8Retracted

VLV14Retract

32

DI 536

MHDev8Extended

VLV15Extend

32

DI 537

MHDev9Retracted

VLV15Retract

32

DI 538

MHDev9Extended

VLV16Extend

32

DI 539

MHDev10Retracted

VLV16Retract


32

DI 540

MHDev10Extended

32

DI 541

MHDev11Retracted

32

DI 542

MHDev11Extended

32

DI 543

MHDev12Retracted

32

DI 544

MHDev12Extended

30

CUSW REL1.3

ROBOT OUTPUTS ROBOT INPUTS

MH EOAT MODUL E MISC OUTPUT COMMUNICATIONS (AB) COMB O EOAT VAC/CLA MPS/MISC NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 36 DO 545 Y 0.0 User Define Output1

MH EOAT MODULE #3 INPUT COMMUNICATIONS NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 33 DI 545 X 0.0 Part9Present

36

DO 546

User Define Output2

33

DI 546

Part10Present

36

DO 547

User Define Output3

33

DI 547

Part11Present

36

DO 548

User Define Output4

33

DI 548

Part12Present

36

DO 549

User Define Output5

33

DI 549

MHDev13Retracted

36

DO 550

User Define Output6

33

DI 550

MHDev13Extended

36

DO 551

User Define Output7

33

DI 551

MHDev14Retracted

36

DO 552

User Define Output8

33

DI 552

MHDev14Extended

36

DO 553

User Define Output9

33

DI 553

MHDev15Retracted

36

DO 554

User Define Output10

33

DI 554

MHDev15Extended

36

DO 555


33

DI 555

MHDev16Retracted

36

DO 556


33

DI 556

MHDev16Extended

36

DO 557


33

DI 557

MHDev17Retracted

36

DO 558


33

DI 558

MHDev17Extended

36

DO 559


33

DI 559

MHDev18Retracted

36

DO 560


33

DI 560

MHDev18Extended

36

DO 561


36

DO 562


36

DO 563


MH EOAT MOD ULE #4 INPUT COMMUNICATIONS

36

DO 564


36

DO 565


NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 34 DI 561 X 0.0 MHDev19Retracted

36

DO 566


34

DI 562

MHDev19Extended

36

DO 567


34

DI 563

MHDev20Retracted

36

DO 568


34

DI 564

MHDev20Extended

36

DO 569


34

DI 565

MHDev21Retracted

36

DO 570


34

DI 566

MHDev21Extended

36

DO 571


34

DI 567

MHDev22Retracted

36

DO 572


34

DI 568

MHDev22Extended

36

DO 573


34

DI 569

MHDev23Retracted

36

DO 574


34

DI 570

MHDev23Extended

36

DO 575


34

DI 571

MHDev24Retracted

36

DO 576


34

DI 572

MHDev24Extended

34

DI 573

MHDev25Retracted

34

DI 574

MHDev25Extended

OUTPUT COMMUNICATIONS

34

DI 575

MHDev26Retracted

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME DO 577 Spare

34

DI 576

MHDev26Extended

ROBOT OUTPUTS

ROBOT INPUTS

ROBOT INPUTS

DO 578

Spare

DO 579

Spare

MH EOAT MOD ULE #5 INPUT COMMUNICATIONS

DO 580

Spare

DO 581

Spare

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 35 DI 577 X 0.0 MHDev27Retracted

DO 582

Spare

35

DI 578

MHDev27Extended

DO 583

Spare

35

DI 579

MHDev28Retracted

DO 584

Spare

35

DI 580

MHDev28Extended

DO 585

Spare

35

DI 581

MHDev29Retracted

35

DI 582

MHDev29Extended

35

DI 583

MHDev30Retracted

SPOT TP LOGIC COMMUNICATIONS

35

DI 584

MHDev30Extended

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME RbtInternal DO 586 Y0073.1 W1RstWtrSvr

35

DI 585

MHDev31Retracted

35

DI 586

MHDev31Extended

RbtInternal

DO 587

Y0073.2

W1WtrOff

35

DI 587

MHDev32Retracted

RbtInternal

DO 588

Y0073.3

W2RstWtrSvr

35

DI 588

MHDev32Extended

RbtInternal

DO 589

Y0073.4

W2WtrOff

35

DI 589

MHDev33Retracted

RbtInternal

DO 590

Y0073.5

W1RstStepper

35

DI 590

MHDev33Extended

RbtInternal

DO 591

Y0073.6

W2RstStepper

35

DI 591

MHDev34Retracted

35

DI 592

MHDev34Extended

ROBOT OUTPUTS


31

CUSW REL1.3

ROBOT OUTPUTS MH EOAT COMMUNICATIONS NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME RbtInternal DO 592 MH_MAJORFLT

ROBOT OUTPUTS

ROBOT INPUTS

MH EOA T VAC MODULE #1 OUTPUT COMMUNICATIONS

MH EOA T VAC MODULE #1 INPUT COMMUNICATIONS

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 37 DO 593 Y 0.0 doVacCH1On

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 37 DI 593 X 0.0 VacuumCH1PP

37

DO 594

doBlwOffCh1On

37

DI 594

VacuumCH2PP

37

DO 595

doVacCH2On

37

DI 595

VacuumCH3PP

37

DO 596

doBlwOffCh2On

37

DI 596

VacuumCH4PP

37

DO 597

doVacCH3On

37

DI 597

37

DO 598

doBlwOffCh3On

37

DI 598

37

DO 599

doVacCH4On

37

DI 599

37

DO 600

doBlwOffCh4On

37

DI 600

ROBOT OUTPUTS

ROBOT INPUTS

MH EOA T VAC MODULE #2 OUTPUT COMMUNICATIONS

MH EOA T VAC MODULE #2 INPUT COMMUNICATIONS

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 38 DO 601 Y 0.0 doVacCH5On

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 38 DI 601 X 0.0 VacuumCH5PP

38

DO 602

doBlwOffCh5On

38

DI 602

VacuumCH6PP

38

DO 603

doVacCH6On

38

DI 603

VacuumCH7PP

38

DO 604

doBlwOffCh6On

38

DI 604

VacuumCH8PP

38

DO 605

doVacCH7On

38

DI 605

38

DO 606

doBlwOffCh7On

38

DI 606

38

DO 607

doVacCH8On

38

DI 607

38

DO 608

doBlwOffCh8On

38

DI 608

ROBOT OUTPUTS

ROBOT INPUTS

USER DEFINABL E IO #1 COMMUNICATIONS (AB)


NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 43 DO 609 Y 0.0 UserDefineddo609

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 43 DI 609 X 0.0 UserDefineddi609

43

DO 610

UserDefineddo610

43

DI 610

UserDefineddi610

43

DO 611

UserDefineddo611

43

DI 611

UserDefineddi611

43

DO 612

UserDefineddo612

43

DI 612

UserDefineddi612

43

DO 613

UserDefineddo613

43

DI 613

UserDefineddi613

43

DO 614

UserDefineddo614

43

DI 614

UserDefineddi614

43

DO 615

UserDefineddo615

43

DI 615

UserDefineddi615

43

DO 616

UserDefineddo616

43

DI 616

UserDefineddi616

ROBOT OUTPUTS

ROBOT INPUTS



NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 44 DO 617 Y 0.0 UserDefineddo617

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 44 DI 617 X 0.0 UserDefineddi617

44

DO 618

UserDefineddo618

44

DI 618

UserDefineddi618

44

DO 619

UserDefineddo619

44

DI 619

UserDefineddi619

44

DO 620

UserDefineddo620

44

DI 620

UserDefineddi620

44

DO 621

UserDefineddo621

44

DI 621

UserDefineddi621

44

DO 622

UserDefineddo622

44

DI 622

UserDefineddi622

44

DO 623

UserDefineddo623

44

DI 623

UserDefineddi623

44

DO 624

UserDefineddo624

44

DI 624

UserDefineddi624


32

CUSW REL1.3

ROBOT OUTPUTS

ROBOT INPUTS

COMMUNICATIONS NODE ADDRESS


SMC PRESURE SWITCH COMMUNICATIONS PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

SIGNAL NAME Spare

NODE ADDRESS 39

ROBOT ADDRESS DI 625

PMC ADDRESS X 0.0

GROUP ASSIGNMENT

SIGNAL NAME Air OK

DO 626

Spare

39

DI 626

Air Acceptable range

DO 627

Spare

39

DI 627

Spare

DO 628

Spare

39

DI 628

Spare

DO 629

Spare

39

DI 629

Spare

DO 630

Spare

DI 630

Spare

DO 631

Spare

DI 631

Spare

ROBOT OUTPUTS

ROBOT INPUTS

ATI TOOLCHA NGER COMMUNICATIONS PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

ATI TOOLCHA NGER COMMUNICATIONS

NODE ADDRESS 54


54

DO 633

UnlatchOrUnlock

54

DI 633

ToolUnLocked

54

DO 634

Spare

54

DI 634

DNetPowerOK

54

DO 635

ClearErrs

54

DI 635

AuxPowerOK

54

DO 636

ManualModeActd

54

DI 636

ReadyToLock1

54

DO 637

OutOfNest

54

DI 637

ReadyToLock2

54

DO 638

Spare

54

DI 638

ReadyToLockV1

54

DO 639

Spare

SIGNAL NAME LatchOrLock

NODE ADDRESS 54


PMC ADDRESS X 0.0

GROUP ASSIGNMENT

SIGNAL NAME ToolLocked

54

DI 639

ReadyToLockV2

54

DI 640

ToolStndIntlkV1

54

DI 641

ToolStndIntlkV2

ATI TOOLCHA NGER (ROBOT USER DEFINED) COMM.

54

DI 642

ToolStndRelayV1

NODE ADDRESS N/A


N/A

ROBOT OUTPUTS

54

DI 643

ToolStndRelayV2

SIGNAL NAME ToolNotPresent

54

DI 644

ToolPresent

DO 641

InvalidToolRqst

54

DI 645

ReservedTooldi13

N/A

DO 642

UnexpctdTlPrsnt

54

DI 646

ReservedTooldi14

N/A

DO 643

NestNotEmpty

54

DI 647

ReservedTooldi15

N/A

DO 644

NestIsEmpty

54

DI 648

RTLMismatch

N/A

DO 645

GeneralFaults

54

DI 649

TSIVMismatch

N/A

DO 646

Reference Position 11

UnCoupleToolPos1

54

DI 650

LatchOverLoad

N/A

DO 647


UnCoupleToolPos2

54

DI 651

UnlatchOverLoad

N/A

DO 648


UnCoupleToolPos3

54

DI 652

SpareOverload

N/A

DO 649


UnCoupleToolPos4

54

DI 653

RTLrtlvMismatch

N/A

DO 650


UnCoupleToolPos5

54

DI 654

TSIVtsrvMismatch

N/A

DO 651


UnCoupleToolPos6

54

DI 655

UnsafeUnlatch

N/A

DO 652


UnCoupleToolPos7

54

DI 656

LckUnlckSensFlt

N/A N/A

DO 653 DO 654


UnCoupleToolPos8 RbtOKtoUnCouple

54 54

DI 657 DI 658

LatchNotComplt UnlatchNotComplt

54

DI 659

TSIVFault

54

DI 660

RTLFault

54

DI 661

CommError

54

DI 662

ReservedTooldi30 ReservedTooldi31

PMC ADDRESS

GROUP ASSIGNMENT

ROBOT OUTPUTS ROBO T INTERNAL COMMUNICATIONS NODE ADDRESS

54

DI 663

SIGNAL NAME Spare

54

DI 664

DO 656

Spare

54

DI 665

DO 657

Spare

54

DI 666

DO 658

Spare

54

DI 667

DO 659

Spare

54

DI 668

DO 660

Spare

54

DI 669

DO 661

Spare

54

DI 670

DO 662

Spare

54

DI 671

DO 663

Spare

54

DI 672

DO 664

Spare

54

DI 673

DO 665

Spare

54

DI 674

DO 666

Spare

54

DI 675

DO 667

Spare

54

DI 676

DO 668

Spare

54

DI 677

DO 669

Spare

54

DI 678

DO 670

Spare

54

DI 679

DO 671

Spare

54

DI 680

DO 672

Spare

54

DI 681

DO 673

Spare

54

DI 682

DO 674

Spare

54

DI 683

DO 675

Spare

54

DI 684


PMC ADDRESS

GROUP ASSIGNMENT


33

GI[41] GI[41] GI[41] GI[41] GI[42] GI[42] GI[42] GI[42] GI[43] GI[43] GI[43] GI[43] GI[44] GI[44] GI[44] GI[44] GI[45] GI[45] GI[45] GI[45]

ToolIDswtch1bit1 ToolIDswtch1bit2 ToolIDswtch1bit4 ToolIDswtch1bit8 ToolIDswtch2bit1 ToolIDswtch2bit2 ToolIDswtch2bit4 ToolIDswtch2bit8 ToolIDswtch3bit1 ToolIDswtch3bit2 ToolIDswtch3bit4 ToolIDswtch3bit8 ToolIDSwtch4bit1 ToolIDSwtch4bit2 ToolIDSwtch4bit4 ToolIDSwtch4bit8 ToolIDSwtch5bit1 ToolIDSwtch5bit2 ToolIDSwtch5bit4 ToolIDSwtch5bit8 UnlatchEnabled

CUSW REL1.3

DO 676

Spare

54

DI 685

ReservedTooldi53

DO 677

Spare

54

DI 686

ReservedTooldi54

DO 678

Spare

54

DI 687

ReservedTooldi55

DO 679

Spare

54

DI 688

ReservedTooldi56

DO 680

Spare

54

DI 689

ReservedTooldi57

DO 681

Spare

54

DI 690

ReservedTooldi58

DO 682

Spare

54

DI 691

ReservedTooldi59

DO 683

Spare

54

DI 692

ReservedTooldi60

DO 684

Spare

54

DI 693

ReservedTooldi61

DO 685

Spare

54

DI 694

ReservedTooldi62

DO 686

Spare

54

DI 695

ReservedTooldi63

DO 687 DO 688 DO 689 DO 690 DO 691 DO 692 DO 693 DO 694 DO 695

Spare Spare Spare Spare Spare Spare Spare Spare Spare

ROBOT OUTPUTS

ROBOT INPUTS

FORM & PIERCE MOOG COMMUNICATIONS PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

FORM & PIERCE MOOG COMMUNICATIONS

NODE ADDRESS 48


NODE ADDRESS 48

48

DO 697

48

DI 697

48

DO 698

doDrvAMode1Sel

48

DI 698

48

DO 699

doDrvAMode2Sel

48

DI 699

48

DO 700

doStyleDrvALub

48

DI 700

diDrvAForce_Lub

48

DO 701

doDrvAAutomode

48

DI 701

diDrvAReturned

48

DO 702

diDrvAAtPos

48

DO 703

48

DO 704

48

SIGNAL NAME doDrvAReset


PMC ADDRESS X 0.0

GROUP ASSIGNMENT

SIGNAL NAME diDrvA_Ok diDrvA_On diDrvAHomeComp

48

DI 702

doDrvBReset

48

DI 703

48

DI 704

diDrvAMode1Ackn

DO 705

doDrvBMode1Sel

48

DI 705

diDrvAMode2Ackn

48

DO 706

doDrvBMode2Sel

48

DI 706

48

DO 707

doStyleDrvBLub

48

DI 707

diSr400On

48

DO 708

doDrvBAutomode

48

DI 708

diSrFuseOk

48

DO 709

48

DI 709

48

DO 710

48

DI 710

48

DO 711

48

DI 711

48

DO 712

48

DI 712

diDrvB_Ok

48

DO 713

48

DI 713

diDrvB_On

48

DO 714

doDrvAExtPos1

48

DI 714

48

DO 715

doDrvARetPos2

48

DI 715

diDrvBHomeComp

48

DO 716

doDrvAPosSel

48

DI 716

diDrvBForce_Lub

48

DO 717

48

DI 717

diDrvBReturned

48

DO 718

48

DI 718

diDrvBAtPos

48

DO 719

48

DI 719

48

DO 720

48

DI 720

diDrvBMode1Ackn

48

DO 721

48

DI 721

diDrvBMode2Ackn

48 48

DO 722 DO 723

doDrvBExtPos1 doDrvBRetPos2

48 48

DI 722 DI 723

48

DO 724

doDrvBPosSel

48

DI 724

48

DO 725

48

DI 725

48

DO 726

48

DI 726

48

DO 727

48

DI 727

doDrvATorqEnble

doDrvBTorqEnble

ROBOT OUTPUTS

ROBOT INPUTS

FORM & PIERCE CLINCH NUT-FEEDER COMMUNICATIONS

FORM & PIERCE CLINCH NUT-FEEDER COMMUNICATIONS

NODE ADDRESS 49


NODE ADDRESS 49

49

DO 729

doReturnPusher

49

DI 729

diPusherReturned

49

DO 730

doExtendPlunger

49

DI 730

diPlungerRetrned

49

DO 731

doReturnPlunger

49

DI 731

diPlungerExtnded

49

DO 732

49

DI 732

diClinchAirOk

49

DO 733

49

DI 733

49

DO 734

49

DI 734

49

DO 735

49

DI 735

49

DO 736

49

DI 736

49

DO 737

49

DI 737

49

DO 738

49

DI 738

49

DO 739

49

DI 739

49

DO 740

49

DI 740

49

DO 741

49

DI 741

49

DO 742

49

DI 742

49

DO 743

49

DI 743

PMC ADDRESS

GROUP ASSIGNMENT


SIGNAL NAME doExtendPusher

34


PMC ADDRESS

GROUP ASSIGNMENT

SIGNAL NAME diPusherExtended

diFdNutPresent

CUSW REL1.3

ROBOT OUTPUTS

ROBOT INPUTS

FORM & PIERCE CLINCH NUT-TOOL COMMUNICATIONS

FORM & PIERCE CLINCH NUT-TOOL COMMUNICATIONS

NODE ADDRESS 50


NODE ADDRESS 50


50

DO 745

50

DI 745

50

DO 746

50

DI 746

50

DO 747

50

DI 747

50

DO 748

50

DI 748

50

DO 749

50

DI 749

50

DO 750

50

DI 750

50

DO 751

50

DI 751

50

DO 752

50

DI 752

50

DO 753

50

DI 753

50

DO 754

50

DI 754

50

DO 755

50

DI 755

50

DO 756

50

DI 756

50

DO 757

50

DI 757

50

DO 758

50

DI 758

50

DO 759

50

DI 759

PMC ADDRESS

GROUP ASSIGNMENT

SIGNAL NAME doWkSupRetract

ROBOT OUTPUTS

GROUP ASSIGNMENT

GROUP ASSIGNMENT

SIGNAL NAME diRbtNutPresent diWorkSptRet

ROBOT INPUTS

FORM & PIERCE PUMP COMMUNICATIONS PMC ADDRESS

PMC ADDRESS

FORM & PIERCE PUMP COMMUNICATIONS

NODE ADDRESS 51


51

DO 761

51

DO 762

doExtIntensCyl

51

DI 762

51

DO 763

doRetIntensCyl

51

DI 763

51

DO 764

51

DI 764

51

DO 765

51

DI 765

51

DO 766

51

DI 766

51

DO 767

51

DI 767

SIGNAL NAME doChrgAccumultor

NODE ADDRESS 51


51

DI 761

ROBOT OUTPUTS

PMC ADDRESS

GROUP ASSIGNMENT

SIGNAL NAME diRobotAirOk diWkAtPressure diIntensCylRetd

ROBOT INPUTS

Mig weld Reamers

Mig weld Reamers

46 46

DO 768

Start

46

DI 768

Complete

DO 769

Spray

46

DI 769

Error

46

DO 770

Spare

46

DI 770

Spare

46

DO 771

Spare

46

DI 771

Spare

46

DO 772

Spare

46

DI 772

Spare

46

DO 773

Spare

46

DI 773

Spare

46

DO 774

Spare

46

DI 774

Spare

46

DO 775

Spare

46

DI 775

Spare

ROBOT INPUTS

ROBOT OUTPUTS

Laser Cut Field I/O 24

Laser Cut Field I/O

24

DO 777

Release Assist Gas Spare

24

DI 777

Collision Sens OK

24

DO 778

Spare

24

DI 778

Purge Air On

24

DO 779

Spare

24

DI 779

Purge Air Acpt Range

24

DO 780

Spare

24

DI 780

24

DO 781

Spare

24

DI 781

24

DO 782

Spare

24

DI 782

24

DO 783

Spare

24

DI 783

Pre Pounce Assist Gas Pre-Pounce Assist gas Acpt Pre-Cut Assist Gas on Pre-Cut Assist Gas Acpt

DO 784

Spare

DO 776


24

DI 776

Collision Sens OK

DI 784

35

Spare

CUSW REL1.3

NOT USED ROBOT OUTPUTS

ROBOT INPUTS

TOOLCHA NGER COVER / NEST #1 COMMUNICATIONS


NODE ADDRESS 55 55 55 55 55 55 55 55

NODE ADDRESS 55 55 55 55 55 55 55 55

ROBOT ADDRESS DO DO DO DO DO DO DO DO

PMC ADDRESS Y 0.0

GROUP ASSIGNMENT

SIGNAL NAME Close Cover #1 Open Cover #1

ROBOT ADDRESS DI DI DI DI DI DI DI DI

ROBOT OUTPUTS

PMC ADDRESS X 0.0

GROUP ASSIGNMENT

SIGNAL NAME Cover #1 Closed Cover #1 Open Tool in nest #1 switch 1 Tool in nest #1 switch 2

ROBOT INPUTS



NODE ADDRESS 56 56 56 56 56 56 56 56

NODE ADDRESS 56 56 56 56 56 56 56 56


PMC ADDRESS Y 0.0

GROUP ASSIGNMENT



ROBOT OUTPUTS

PMC ADDRESS X 0.0

GROUP ASSIGNMENT


ROBOT INPUTS



NODE ADDRESS 57 57 57 57 57 57 57 57

NODE ADDRESS 57 57 57 57 57 57 57 57


PMC ADDRESS Y 0.0

GROUP ASSIGNMENT



ROBOT OUTPUTS

PMC ADDRESS X 0.0

GROUP ASSIGNMENT


ROBOT INPUTS



NODE ADDRESS 58 58 58 58 58 58 58 58

NODE ADDRESS 58 58 58 58 58 58 58 58


PMC ADDRESS Y 0.0

GROUP ASSIGNMENT



36


PMC ADDRESS X 0.0

GROUP ASSIGNMENT


CUSW REL1.3

ROBOT OUTPUTS

ROBOT INPUTS

IPG_Laserweld_Generator

IPG_Laserweld_Generator

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 17 DO 785 doLasrRequest

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 17 DI 785 X 0.0 diLasrReady

17

DO 786

doLasrProgStart

17

DI 786

diLasrEmissionOn

17

DO 787

doLasrEnbPCCtrl

17

DI 787

diLasrIntrCtrlOn

17

DO 788

doLasrReset

17

DI 788

diLasrError

17

DO 789

doGuideLaserCtrl

17

DI 789

diGuideLaserOn

17

DO 790

doLasrAnalogCtrl

17

DI 790

diLasrAnalogCtrl

17

DO 791

doLasrProgStop

17

DI 791

diLasrAssigned

17

DO 792

doLasrProgLSB

17

DI 792

diLasrOn

17

DO 793

doLasrProg1

17

DI 793

diLasrProgActive

17

DO 794

doLasrProg2

17

DI 794

diLasrProgEnd

17

DO 795

doLasrProg3

17

DI 795

diLasrProgIntrpt

17

DO 796

doLasrProg4

17

DI 796

diLasrSyncOutput

17

DO 797

doLasrProg5

17

DI 797

diLasrWarning

17

DO 798

doLasrProgMSB

17

DI 798

diLasrChillWarn

17

DO 799

doLasrSyncInput

17

DI 799

diLasrChillError

17

DO 800

doLasrReserve

17

DI 800

diLasrChillReady

DO 801 DO 802 DO 803 DO 804 DO 805 DO 806 DO 807 DO 808 DO 809 DO 810 DO 811 DO 812 DO 813 DO 814 DO 815 DO 816

Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare

DI 801 DI 802 DI 803 DI 804 DI 805 DI 806 DI 807 DI 808 DI 809 DI 810 DI 811 DI 812 DI 813 DI 814 DI 815 DI 816

Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare

ROBOT OUTPUTS

ROBOT INPUTS

HighYag

HighYag

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 18 DO 817 doHYagTriggerA

NODE ROBOT PMC GROUP ADDRESS ADDRESS ADDRESS ASSIGNMENT SIGNAL NAME 18 DI 817 diHYagScanAvail

18

DO 818

doHYagProcError

18

DI 818

diHYagScanRdy

18

DO 819

doHYagLaserError

18

DI 819

diHYagScanMonitr

18

DO 820

doHYagRestScannr

18

DI 820

diHYagGenError

18

DO 821

doHYagPSelPart

18

DI 821

diHYagStructErr

18

DO 822

doHYagPSelRbtTrx

18

DI 822

diHYagScanAtWork

18

DO 823

doHYagPSelTrxPt

18

DI 823

diHYagSlideHoldr

18

DO 824

doHYagPSelSeam

18

DI 824

diHYagSlideWarn

18

DO 825

doHYagPSelRbtVel

18

DI 825

diHYagSlideError

18

DO 826

doHYagModeBit0

18

DI 826

diHYagPosError

18

DO 827

doHYagModeBit1

18

DI 827

diHYagTempError

18

DO 828

doHYagModeBit2

18

DI 828

diHYagC-JetError

18

DO 829

doHYagC-JetOnOff

18

DI 829

diHYagEnetActive

18

DO 830

doHYagReserve

18

DI 830

Spare

18

DO 831

doHYagNumBit0

18

DI 831

Spare

18

DO 832

doHYagNumBit1

18

DI 832

Spare

18

DO 833

doHYagNumBit2

18

DI 833

Spare

18

DO 834

doHYagNumBit3

18

DI 834

Spare

18

DO 835

doHYagNumBit4

18

DI 835

Spare

18

DO 836

doHYagNumBit5

18

DI 836

Spare

18

DO 837

doHYagNumBit6

18

DI 837

Spare

18

DO 838

doHYagNumBit7

18

DI 838

Spare

18

DO 839

Spare

18

DI 839

Spare

18

DO 840

Spare

18

DI 840

Spare

18

DO 841

Spare

18

DI 841

Spare

18

DO 842

Spare

18

DI 842

Spare

18

DO 843

Spare

18

DI 843

Spare

18

DO 844

Spare

18

DI 844

Spare

18

DO 845

Spare

18

DI 845

Spare

18

DO 846

Spare

18

DI 846

Spare

18

DO 847

Spare

18

DI 847

Spare

18

DO 848

Spare

18

DI 848

Spare


37

CUSW REL1.3

ROBOT OUTPUTS

ROBOT INPUTS

LaserCut Head

LaserCut Head

NODE ADDRESS 19


19

DO 850

19

DO 851

19

PMC ADDRESS

GROUP ASSIGNMENT GO(46]

NODE ADDRESS 19


HeightSelBit2

19

DI 850

RetdPos

HeightSelBit3

19

DI 851

TipTouch

DO 852

Tch/CtrOfTrvl

19

DI 852

19

DO 853

MotInhbt/Hold

19

DI 853

19

DO 854

TipSelBit

19

DI 854

19

DO 855

AnalogInEnbl

19

DI 855

19

DO 856

Reset

19

DI 856

GO[46] GO[46]

SIGNAL NAME HeightSelBit1

ROBOT OUTPUTS

PMC ADDRESS

GROUP ASSIGNMENT

SIGNAL NAME InPosition

Crsh/FltActive

GI[46] GI[46] GI[46] GI[46]

StatCode1 StatCode2 StatCode3 StatCode4

ROBOT INPUTS

GrinderMod1

GrinderMod1

NODE ADDRESS 20


20

DO 858

20

DO 859

20

DO 860

20

DO 861

20

DO 862

20

DO 863

20

DO 864

PMC ADDRESS

GROUP ASSIGNMENT

GO[47] GO[47] GO[47] GO[47] GO[48] GO[48] GO(48]

SIGNAL NAME ACT/RET SetActiveRetract

NODE ADDRESS 20


PMC ADDRESS

GROUP ASSIGNMENT GI[47]

GI[47] GI[47] GI[47]

SIGNAL NAME ForceFedbackBit0

ComdFourceLevBit0

20

DI 858

ComdFourceLevBit1

20

DI 859

ComdFourceLevBit2

20

DI 860

ComdFourceLevBit3

20

DI 861

PlusLimit

ToolNumBit0

20

DI 862

MinusLimit

ToolNumBit1

20

DI 863

Spare

ToolNumBit2

20

DI 864

Spare

ROBOT OUTPUTS

ForceFedbackBit1 ForceFedbackBit2 ForceFedbackBit3

ROBOT INPUTS

GrinderMod2

GrinderMod2

NODE ADDRESS 21


21

DO 866

21

DO 867

21

DO 868

21

DO 869

21

PMC ADDRESS

GROUP ASSIGNMENT

SIGNAL NAME Spare

NODE ADDRESS 21


PMC ADDRESS

GROUP ASSIGNMENT

SIGNAL NAME

UserInputBit0 UserInputBit1

21

DI 866

Spare Spare

21

DI 867

Spare

UserInputBit2

21

DI 868

Spare

UserInputBit3

21

DI 869

Spare

DO 870

Spare

21

DI 870

Spare

21

DO 871

SpindleEnable

21

DI 871

CRF Fault

21

DO 872

Spare

21

DI 872

Spare

GO[49] GO[49] GO[49] GO[49]

ROBOT OUTPUTS

ROBOT INPUTS

GRINDING ANALOG MODULE #1 NODE ADDRESS 22

ROBOT ADDRESS AO 1, 1-16

22

AO 2, 1-16

22

AO 3, 1-16

22

AO 4, 1-16

PMC ADDRESS

GRINDING ANAL OG MODULE #1 GROUP ASSIGNMENT

NODE ADDRESS 22

ROBOT ADDRESS AI 1, 1-16

Spare

22

AI 2, 1-16

CarriagePos

Spare

22

AI 3, 1-16

Spare

AMPThermister

22

AI 4, 1-16

SIGNAL NAME CommandForce

23

AO 6, 1-16

23

AO 7, 1-16

23

AO 8, 1-16

PMC ADDRESS

SIGNAL NAME ActualForce

Spare Spare

Spare

Spare

Spare

Spare

Spare

Spare

ROBOT INPUTS

GRINDING ANALOG MODULE #2 ROBOT ADDRESS AO 5, 1-16

GROUP ASSIGNMENT

Spare

ROBOT OUTPUTS

NODE ADDRESS 23

PMC ADDRESS

GRINDING ANAL OG MODULE #2 GROUP ASSIGNMENT

DO 889 DO 890 DO 891 DO 892 DO 893 DO 894 DO 895 DO 896 DO 897


NODE ADDRESS 23

ROBOT ADDRESS AI 5, 1-16

Spare

23

AI 6, 1-16

CurrentRef

Spare

23

AI 7, 1-16

Spare

Spare

23

AI 8, 1-16

SIGNAL NAME VelCommand

PMC ADDRESS

GROUP ASSIGNMENT

SIGNAL NAME VelMon

CurrentMon

Spare

Spare

Spare

Spare

Spare

Spare

Spare

Spare


DI 889 DI 890 DI 891 DI 892 DI 893 DI 894 DI 895 DI 896 DI 897

38


CUSW REL1.3

DO 898 DO 899 DO 900 DO 901 DO 902 DO 903

Spare Spare Spare Spare Spare Spare

DI 898 DI 899 DI 900 DI 901 DI 902 DI 903

Spare Spare Spare Spare Spare Spare

DO 904

Spare

DI 904

Spare

DO 905 DO 906 DO 907 DO 908 DO 909 DO 910 DO 911 DO 912

Spare Spare Spare Spare Spare Spare Spare Spare

DI 905 DI 906 DI 907 DI 908 DI 909 DI 910 DI 911 DI 912

Spare Spare Spare Spare Spare Spare Spare Spare

ROBOT OUTPUTS

ROBOT INPUTS

ISRA VISION COMMUNICATIONS NODE ADDRESS 60


60

DO 914

60

DO 915

60

DO 916

60

PMC ADDRESS Y 0.0

ISRA VISION COMMUNICATIONS GROUP ASSIGNMENT GO[38]

NODE ADDRESS 60


doISRA_CmdB2

60

DI 914

doISRA_CmdB4

60

DI 915

doISRA_CmdB8

60

DI 916

DO 917

doISRA_Strt_M

60

DI 917

diISRA_Ready

60

DO 918

doISRA_reservd

60

DI 918

diISRA_Snap_ip

60

DO 919

60

DO 920

60

DO 921

60

DO 922

60

DO 923

60

DO 924

60

DO 925

60

DO 926

60

DO 927

60

DO 928

60

DO 929

60

DO 930

60

DO 931

60

DO 932

60

DO 933

60

DO 934

60

DO 935

60

DO 936

60

DO 937

60

DO 938

60

DO 939

60

DO 940

60

DO 941

60

DO 942

60

DO 943

60

DO 944

GO[38] GO[38] GO[38]

GO[40] GO[39] GO[39] GO[39] GO[39] GO[39] GO[39] GO[39] GO[39] GO[41] GO[41] GO[41] GO[41] GO[41] GO[41] GO[41] GO[41] GO[42] GO[42] GO[42] GO[42] GO[42] GO[42] GO[42] GO[42]

SIGNAL NAME doISRA_CmdB1

PMC ADDRESS X 0.0

GROUP ASSIGNMENT GI[31]

GI[31] GI[31] GI[31]

SIGNAL NAME diISRA_StatBit1 diISRA_StatBit2 diISRA_StatBit4 diISRA_StatBit8

doISRA_Rst_E

60

DI 919

diISRA_Data_ip

doISRA_ID_Valid

60

DI 920

diISRA_ID_OK

doISRA_TpIDB1

60

DI 921

doISRA_TpIDB2

60

DI 922

doISRA_TpIDB4

60

DI 923

doISRA_TpIDB8

60

DI 924

doISRA_TpIDB16

60

DI 925

doISRA_TpIDB32

60

DI 926

doISRA_TpIDB64

60

DI 927

doISRA_TpIDB128

60

DI 928

doISRA_SubStyle

60

DI 929

doISRA_SubStyle

60

DI 930

doISRA_SubStyle

60

DI 931

doISRA_SubStyle

60

DI 932

doISRA_SubStyle

60

DI 933

doISRA_SubStyle

60

DI 934

doISRA_SubStyle

60

DI 935

doISRA_SubStyle

60

DI 936

doISRA_Color

60

DI 937

doISRA_Color

60

DI 938

doISRA_Color

60

DI 939

doISRA_Color

60

DI 940

doISRA_Color

60

DI 941

doISRA_Color

60

DI 942

doISRA_Color

60

DI 943

doISRA_Color

60

DI 944

60

ROBOT OUTPUTS APP. ERROR CODE (ROB OT USER DEFINED) COMM.

diISRA_reservd

DI 945

GI[38] GI[38] GI[38] GI[38] GI[38] GI[38] GI[38] GI[38] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[32] GI[33]

60

DI 946

GI[33]

diISRA_YB2

60

DI 947

GI[33]

diISRA_YB4

diISRA_ErrPLC diISRA_ErrRbt diISRA_OutTol diISRA_Disabl diISRA_ErrImage diISRA_reservd1 diISRA_ErrDet diISRA_XB1 diISRA_XB2 diISRA_XB4 diISRA_XB8 diISRA_XB16 diISRA_XB32 diISRA_XB64 diISRA_XB128 diISRA_XB256 diISRA_XB512 diISRA_XB1024 diISRA_XB2048 diISRA_XB4096 diISRA_XB8192 diISRA_XB16384 diISRA_XB32768 diISRA_YB1

60

DI 948

GI[33]

diISRA_YB8

SIGNAL NAME AppErrSpare01

60

DI 949

AppErrSpare02

60

DI 950

DO 947

N/A

AppErrSpare03

60

DI 951

N/A

DO 948

N/A

AppErrSpare04

60

DI 952

N/A

DO 949

N/A

AppErrSpare05

60

DI 953

N/A

DO 950

N/A

AppErrSpare06

60

DI 954

N/A

DO 951

N/A

AppErrSpare07

60

DI 955

N/A

DO 952

N/A

AppErrSpare08

60

DI 956

N/A

DO 953

N/A

AppErrSpare09

60

DI 957

N/A

DO 954

N/A

AppErrSpare10

60

DI 958

N/A

DO 955

N/A

AppErrSpare11

60

DI 959

N/A

DO 956

N/A

AppErrSpare12

60

DI 960

N/A

DO 957

N/A

AppErrSpare13

60

DI 961

N/A

DO 958

N/A

AppErrSpare14

60

DI 962

N/A

DO 959

N/A

AppErrSpare15

60

DI 963

N/A

DO 960

N/A

AppErrSpare16

60

DI 964

N/A

DO 961

N/A

AppErrSpare17

60

DI 965

N/A

DO 962

N/A

AppErrSpare18

60

DI 966

N/A

DO 963

N/A

AppErrSpare19

60

DI 967

GI[33] GI[33] GI[33] GI[33] GI[33] GI[33] GI[33] GI[33] GI[33] GI[33] GI[33] GI[33] GI[34] GI[34] GI[34] GI[34] GI[34] GI[34] GI[34]

diISRA_YB16

N/A

NODE ADDRESS N/A


N/A

DO 946

N/A

PMC ADDRESS

GROUP ASSIGNMENT N/A


39

diISRA_YB32 diISRA_YB64 diISRA_YB128 diISRA_YB256 diISRA_YB512 diISRA_YB1024 diISRA_YB2048 diISRA_YB4096 diISRA_YB8192 diISRA_YB16384 diISRA_YB32768 diISRA_ZB1 diISRA_ZB2 diISRA_ZB4 diISRA_ZB8 diISRA_ZB16 diISRA_ZB32 diISRA_ZB64

CUSW REL1.3

N/A

DO 964

N/A

AppErrSpare20

60

DI 968

N/A

DO 965

N/A

AppErrSpare21

60

DI 969

N/A

DO 966

N/A

AppErrSpare22

60

DI 970

N/A

DO 967

N/A

AppErrSpare23

60

DI 971

N/A

DO 968

N/A

AppErrSpare24

60

DI 972

N/A

DO 969

N/A

AppErrSpare25

60

DI 973

N/A

DO 970

N/A

AppErrSpare26

60

DI 974

N/A

DO 971

N/A

AppErrSpare27

60

DI 975

N/A

DO 972

N/A

AppErrSpare28

60

DI 976

N/A

DO 973

N/A

AppErrSpare29

60

DI 977

N/A

DO 974

N/A

AppErrSpare30

60

DI 978

N/A

DO 975

N/A

AppErrSpare31

60

DI 979

N/A

DO 976

N/A

AppErrSpare32

60

DI 980

N/A

DO 977

N/A

AppErrSpare33

60

DI 981

N/A

DO 978

N/A

AppErrSpare34

60

DI 982

N/A

DO 979

N/A

AppErrSpare35

60

DI 983

N/A

DO 980

N/A

AppErrSpare36

60

DI 984

N/A

DO 981

N/A

AppErrSpare37

60

DI 985

N/A

DO 982

N/A

AppErrSpare38

60

DI 986

N/A

DO 983

N/A

AppErrSpare39

60

DI 987

N/A

DO 984

N/A

AppErrSpare40

60

DI 988

N/A

DO 985

N/A

AppErrSpare41

60

DI 989

N/A

DO 986

N/A

AppErrSpare42

60

DI 990

N/A

DO 987

N/A

AppErrSpare43

60

DI 991

N/A

DO 988

N/A

AppErrSpare44

60

DI 992

N/A

DO 989

N/A

AppErrSpare45

60

DI 993

N/A

DO 990

N/A

AppErrSpare46

60

DI 994

N/A

DO 991

N/A

AppErrSpare47

60

DI 995

N/A

DO 992

N/A

AppErrSpare48

60

DI 996

N/A

DO 993

N/A

AppErrSpare49

60

DI 997

N/A

DO 994

N/A

AppErrSpare50

60

DI 998

N/A

DO 995

N/A

AppErrSpare51

60

DI 999

N/A

DO 996

N/A

AppErrSpare52

60

DI 1000

N/A

DO 997

N/A

AppErrSpare53

60

DI 1001

N/A

DO 998

N/A

AppErrSpare54

60

DI 1002

N/A

DO 999

N/A

AppErrSpare55

60

DI 1003

N/A

DO 1000

N/A

AppErrSpare56

60

DI 1004

N/A

DO 1001

N/A

AppErrSpare57

60

DI 1005

N/A

DO 1002

N/A

AppErrSpare58

60

DI 1006

N/A

DO 1003

N/A

AppErrSpare59

60

DI 1007

N/A

DO 1004

N/A

AppErrSpare60

60

DI 1008

N/A

DO 1005

N/A

AppErrSpare61

60

DI 1009

N/A

DO 1006

N/A

AppErrSpare62

60

DI 1010

N/A

DO 1007

N/A

AppErrSpare63

60

DI 1011

N/A

DO 1008

N/A

AppErrSpare64

60

DI 1012

N/A

DO 1009

N/A

AppErrSpare65

60

DI 1013

N/A

DO 1010

N/A

AppErrSpare66

60

DI 1014

N/A

DO 1011

N/A

AppErrSpare67

60

DI 1015

N/A

DO 1012

N/A

AppErrSpare68

60

DI 1016

N/A

DO 1013

N/A

AppErrSpare69

60

DI 1017

N/A

DO 1014

N/A

AppErrSpare70

60

DI 1018

N/A

DO 1015

N/A

AppErrSpare71

60

DI 1019

N/A

DO 1016

N/A

AppErrSpare72

60

DI 1020

N/A

DO 1017

N/A

AppErrSpare73

60

DI 1021

N/A

DO 1018

N/A

AppErrSpare74

60

DI 1022

N/A

DO 1019

N/A

AppErrSpare75

60

DI 1023

N/A

DO 1020

N/A

AppErrSpare76

60

DI 1024

N/A

DO 1021

N/A

AppErrSpare77

N/A

DO 1022

N/A

AppErrSpare78

N/A

DO 1023

N/A

AppErrSpare79

N/A

DO 1024

N/A

AppErrSpare80

ROBOT OUTPUTS

diISRA_ZB128 diISRA_ZB256 diISRA_ZB512 diISRA_ZB1024 diISRA_ZB2048 diISRA_ZB4096 diISRA_ZB8192 diISRA_ZB16384 diISRA_ZB32768 diISRA_RXB1 diISRA_RXB2 diISRA_RXB4 diISRA_RXB8 diISRA_RXB16 diISRA_RXB32 diISRA_RXB64 diISRA_RXB128 diISRA_RXB256 diISRA_RXB512 diISRA_RXB1024 diISRA_RXB2048 diISRA_RXB4096 diISRA_RXB8192 diISRA_RXB16384 diISRA_RXB32768 diISRA_RYB1 diISRA_RYB2 diISRA_RYB4 diISRA_RYB8 diISRA_RYB16 diISRA_RYB32 diISRA_RYB64 diISRA_RYB128 diISRA_RYB256 diISRA_RYB512 diISRA_RYB1024 diISRA_RYB2048 diISRA_RYB4096 diISRA_RYB8192 diISRA_RYB16384 diISRA_RYB32768 diISRA_RZB1 diISRA_RZB2 diISRA_RZB4 diISRA_RZB8 diISRA_RZB16 diISRA_RZB32 diISRA_RZB64 diISRA_RZB128 diISRA_RZB256 diISRA_RZB512 diISRA_RZB1024 diISRA_RZB2048 diISRA_RZB4096 diISRA_RZB8192 diISRA_RZB16384 diISRA_RZB32768

ROBOT INPUTS

ROBO T INTERNAL COMMUNICATIONS PMC ADDRESS

GI[34] GI[34] GI[34] GI[34] GI[34] GI[34] GI[34] GI[34] GI[34] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[35] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[36] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37] GI[37]

ROBO T INTERNAL COMMUNICATIONS

NODE ADDRESS RbtInternal


GROUP ASSIGNMENT

RbtInternal

DO 902

RbtInternal

DO 903

RbtInternal

DO 904

WaterValve2ON

RbtInternal

DO 905

WaterValve2OFF

RbtInternal

DO 906

RbtInternal

DO 907

VacuumCH_ON

RbtInternal

DI 907

RbtInternal

DO 908

PulseBatteryLow

RbtInternal

DI 908

RbtInternal

DO 909

XFORMTEMPOk1

RbtInternal

DI 909

XFORMTEMPOk1

RbtInternal

DO 910

XFORMTEMPOk2

RbtInternal

DI 910

XFORMTEMPOk2

RbtInternal

DO 911

XFORMTEMPOk3

RbtInternal

DI 911

XFORMTEMPOk3

RbtInternal

DO 912

XFORMTEMPOk4

RbtInternal

DI 912

XFORMTEMPOk4


SIGNAL NAME WaterValve1ON WaterValve1OFF

40

NODE ADDRESS RbtInternal


RbtInternal

DI 902

RbtInternal

DI 903

RbtInternal

DI 904

RbtInternal

DI 905

RbtInternal

DI 906

PMC ADDRESS

GROUP ASSIGNMENT

SIGNAL NAME WaterFlowOK1 WaterFlowOK2

VacuumCH_ON

CUSW REL1.3

ROBOT APPLICATION ERROR TIMING

SYNCHRONIZE PLC / IDENTIFY TOP OF PMC LOGIC Application Error Bits (Group Output)

GO[4] = FIS ID DO[121 – 128]

LOW State Error Active goes LOW when Error Ack goes HIGH

Application Error Active

DO[120]

Application Error Acknowledge (PLC Signal) d e r o t i n o m s i ) e l b a c i l p p a f i ( s r o r r E n o i t a c i l p p A L L A l i t n U P O O L d e r o t i n o m s i ) e l b a c i l p p a f i ( s r o r r E n o i t a c i l p p A L L A l i t n U P O O L

Error Ack goes LOW when Error Active goes LOW

DI[8]

ADDING APPLICATION ERROR BITS TO PLC Application Error Bits (Group Output)

GO[4] = FIS ID DO[121 – 128]

a


Error Active goes LOW when Error Ack goes HIGH

Application Error Acknowledge (PLC Signal)


DO[120]

DI[8]

REMOVING APPLICATION ERROR BITS FROM PLC Application Error Bits (Group Output)

GO[4] = FIS ID DO[121 – 128]

Application Error Remove

Error Active goes LOW when Error Ack goes HIGH DO[76] a


Error Active goes LOW when Error Ack goes H IGH b

b

Application Error Acknowledge (PLC Signal)


DO[120]

DI[8]

a = 500 msec

ROBOT INPUTS FROM PLC


ROBOT OUTPUTS TO PLC

41

Not Robot I/O

CUSW REL1.3

ROBOT APPLICATION ERRORS INPUT/S

GROUP INPUT

DESCRIPTION

ERROR PL C SEVERITY CODE

IO STATE

INTERNAL ROB OT HANDSHAKE TO PLC N/A

N/A

Clear all faults command ID

N/A

0

N/A

SPARE General Communication DeviceNet Master

Major

Low Battery Indicator

Minor

1 2 3 4

CLINCH NUT No Nut In Anvil Feeder Air Not On

5 6

Clinch Nut Still in Anvil Clinch Nut Not Present at Feeder Nut Feeder Plunger Not In Position Clinch Nut Part Present Fault Nut Feeder Pusher Not In Position

7 8 9 10 11

NET-FORM-PIERCE Work Support Pressure Fault Moog Mode Fault Moog Drive A OK Fault Moog Drive B OK Fault Moog Drive A ON Fault

12 13 14 15 16

Moog Drive B ON Fault Moog Drive A Position Fault Moog Drive B Position Fault Moog Drive A Force Fault Moog Drive B Force Fault

17 18 19 20 21

QMC/FMS AAC Error AAC Required ATC Error ATC Required ATC Expired Vision Comm Heartbeat Lost Vision System App Fault


42

Major Major Major Major Major

22 23 24 25 26

Major Major

27 28 29 30 31 32

CUSW REL1.3

INPUT/S

GROUP INPUT

DESCRIPTION


IO STATE

SPOTWELDING DI 197 -201 DI 229 -233

GI[11] I/O Error GI[13]

Major/Minor

33

N/A

DI 197 -201 DI 229 -233

GI[11] I/O Alarm GI[13]

Major/Minor

34

N/A

DI 197 -201 DI 229 -233

GI[11] Incomplete Weld GI[13]

Major/Minor

35

N/A

DI 197 -201 DI 229 -233

GI[11] Stepper Approaching Max GI[13]

Major/Minor

36

N/A

DI 197 -201 DI 229 -233

GI[11] End Of Stepper GI[13]

Major/Minor

37

N/A

DI 197 -201 DI 229 -233

GI[11] Sure Weld Trend Limit GI[13]

Major/Minor

38

N/A

DI 197 -201 DI 229 -233

GI[11] High/Low Current Limit GI[13]

Major/Minor

39

N/A

DI 197 -201 DI 229 -233

GI[11] Firing Error GI[13]

Major/Minor

40

N/A

DI 197 -201 DI 229 -233

GI[11] Cylinder Fault GI[13]

Major/Minor

41

N/A

DI 197 -201 DI 229 -233

GI[11] Cylinder Alarm GI[13]

Major/Minor

42

N/A

DI 197 -201 DI 229 -233

GI[11] Power Factor Error GI[13]

Major/Minor

43

N/A

DI 197 -201 DI 229 -233

GI[11] Compensation Error GI[13]

Major/Minor

44

N/A

DI 197 -201 DI 229 -233

GI[11] Insufficient Line Voltage GI[13]

Major/Minor

45

N/A

DI 197 -201 DI 229 -233

GI[11] Extend Weld GI[13]

Major/Minor

46

N/A

DI 197 -201 DI 229 -233

GI[11] Isolation Contactor Error GI[13]

Major/Minor

47

N/A

DI 197 -201 DI 229 -233

GI[11] Welding Buss Voltage GI[13]

Major/Minor

48

N/A

DI 197 -201 DI 229 -233

GI[11] Weld Data Not Programmed GI[13]

Major/Minor

49

N/A

DI 197 -201 DI 229 -233

GI[11] Analog Pressure Error GI[13]

Major/Minor

50

N/A

DI 197 -201 DI 229 -233

GI[11] C-Factor Limit GI[13]

Major/Minor

51

N/A

DI 197 -201 DI 229 -233

GI[11] Secondary Current GI[13]

Major/Minor

52

N/A

DI 197 -201 DI 229 -233

GI[11] Welding Transformer GI[13]

Major/Minor

53

N/A

DI 197 -201 DI 229 -233

GI[11] Over Temperature GI[13]

Major/Minor

54

N/A

DI 197 -201 DI 229 -233

GI[11] Shorted SCR GI[13]

Major/Minor

55

N/A

DI 197 -201 DI 229 -233

GI[11] Internal Timer Error GI[13]

Major/Minor

56

N/A

DI 197 -201 DI 229 -233

GI[11] Inverter Fault GI[13]

Major/Minor

57

N/A

DI 197 -201 DI 229 -233

GI[11] Timer Not Ready GI[13]

Major/Minor

58

N/A

DI 197 -201 DI 229 -233

GI[11] Reserved GI[13]

Major/Minor

59

N/A

DI 197 -201 DI 229 -233


Major/Minor

60

N/A

DI 197 -201 DI 229 -233


Major/Minor

61

N/A


43

CUSW REL1.3

INPUT/S

GROUP INPUT

DESCRIPTION


IO STATE

DI 197 -201 DI 229 -233


Major/Minor

62

N/A

DI 197 -201 DI 229 -233


Major/Minor

63

N/A

Major

64 65

N/C N/O

WATER SAVER W1OKtoWeld

DI 785 DI 787

N/A N/A

DI 817

N/A

66

N/C

DI 819

N/A

67

N/O

WELD SERVOGUN / ARC SPOT-068 ARC-006 ARC-008 ARC-010 ARC-013 ARC-017 ARC-018 ARC-030 ARC-033

N/A N/A N/A N/A N/A N/A N/A N/A N/A

ServoGun Faulted

68 69 70 71 72 73

Wire Fault Power Supply Fault Wire stick detected Arc Start failed Arc Start was Disabled Lost arc detect Wire stick is still detected Override must be 100% to weld

74 75 76

INTERNAL ROB OT N/A

Transformer over temperature

Major

77

TOOL CHANGER DO 640 DO 641 DI 648 DI 649 DI 650

N/A N/A N/A N/A N/A

DI 651 DI 652 DI 653 DI 654 DI 655 DI 656 DI 657 DI 658 DI 659 DI 660 DI 661 DI 684

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

DI 634 DI 635 DO 642 DO 643 DO 644

N/A N/A N/A N/A N/A

AuxPowerNotPresent Unexpected Tool Present Nest not empty Nest is empty

DI 321

N/A

NOError1

DI 326 DI 331 DI 336 DI 341 DI 347 DI 348 DI 349

N/A N/A N/A N/A N/A N/A N/A

NOError2 NOError3 NOError4 NOError5 Std1StudsLow Std1ReadyForAuto Std1ReadyToWeld

78 79

ToolNotPresent Invalid Tool Requested RTLMismatch TSIVMismatch LatchOverLoad UnlatchOverLoad SpareOverload RTLrtlvMismatch TSIVtsrvMismatch UnsafeUnlatch LckUnlckSensFlt

80 81 82

N/O N/O N/O N/O N/O

83 84 85 86 87 88 89 90 91 92 93 94

N/O N/O N/O N/O N/O N/O N/O N/O N/O N/O N/O N/C

95 96 97 98 99

N/O N/O N/O N/O N/O

Major

100

N/C

Major Major Major Major Minor Major Major

101 102 103 104 105 106 107

N/C N/C N/C N/C N/O N/O N/C

LatchNotComplt UnlatchNotComplt TSIVFault RTLFault Comm Error Unlatch Enabled DNetPowerNotPresent

STUD WELDING


44

CUSW REL1.3

SPARE 108 109 110 111 112 113 114 115 116 117 118 119

NORDSON DISPENSING #1 120 DI 393 DI 394 DI397 Di395 DI396

N/A N/A N/A N/A

Nozzle 1 Low Volume Fault

N/A

Nozzle 1 Collision Detected

Major Major Major

Dispense 1 Low Pressure Fault

Major

Dispense 1 High Pressure Fault

Major

Nozzle 1 High Volume Fault

121 122 123 124 125 126 127 128 129

N/O N/O N/O N/O N/O

NORDSON DISPENSING #2 130 DI 457 DI 458 DI461 DI459 DI460

N/A N/A N/A N/A N/A

Nozzle 2 Low Volume Fault

Major Major Major

Nozzle 2 High Volume Fault Nozzle 2 Collision Detected Dispense 2 Low Pressure Fault

Major Major

Dispense 2 High Pressure Fault

131 132 133 134 135 136

N/O N/O N/O N/O N/O

137 138 139 140

PERCEPTRON VISION Perceptron Communication Fault Perceptron Status Fault Perceptron Bad Measurement General Search Error

Major Major Major Major

141 142 143 144 145

N/O N/O N/O N/O

Major Major

146 147

N/O N/O

DYNALOG MEASUREMENT Dynalog Major Fault Dynalog Minor Fault

SPARE 148 149 150


45

CUSW REL1.3

ISRA VISION DI 917 DI 918 DI 919 DI 920 DI 922 DI 923 DI 924 DI 925 DI 926


DI 928

N/A

diISRA_Ready diISRA_Meas_ip diISRA_Data_ip diISRA_ID_OK diISRA_ErrPLC diISRA_ErrRbt diISRA_OutTol diISRA_Disabl diISRA_ErrImage diISRA_ErrDet

Major Major Major Major Major Major Major Major Major

150 151 152 153 154 155 156 157 158

Major

159

MATERIA L HANDL ING/VISION Rack not open fault Part search fault

Major Major

160 161

N/O N/O

TRACK LUBE Track Bearing Lube Fault Track Pinion Lube Fault

Minor Minor

162 163

MATERIAL HANDLING N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A


VacuumCH1PP Fault VacuumCH2PP Fault VacuumCH3PP Fault VacuumCH4PP Fault VacuumCH5PP Fault VacuumCH6PP Fault VacuumCH7PP Fault VacuumCH8PP Fault VacuumCH9PP Fault VacuumCH10PP Fault VacuumCH11PP Fault VacuumCH12PP Fault

Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor

164 165 166 167 168 169 170 171 172 173 174 175

EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Part Present 1 Fault Part Present 2 Fault Part Present 3 Fault Part Present 4 Fault Part Present 5 Fault Part Present 6 Fault Part Present 7 Fault Part Present 8 Fault Part Present 9 Fault Part Present 10 Fault Part Present 11 Fault Part Present 12 Fault MH Device 1 Retract Fault

Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor

176 177 178 179 180 181 182 183 184 185 186 187 188

EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN

N/A N/A N/A N/A N/A

N/A N/A N/A N/A N/A

MH Device 2 Retract Fault MH Device 3 Retract Fault MH Device 4 Retract Fault MH Device 5 Retract Fault MH Device 6 Retract Fault

Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor

189 190 191 192 193

EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN



MH Device 7 Retract Fault MH Device 8 Retract Fault MH Device 9 Retract Fault MH Device 10 Retract Fault MH Device 11 Retract Fault MH Device 12 Retract Fault MH Device 13 Retract Fault

Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor

194 195 196 197 198 199 200

EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN

N/A N/A

N/A MH Device 14 Retract Fault N/A MH Device 15 Retract Fault

Major/Minor Major/Minor

201 202

EVENT DRIVEN EVENT DRIVEN


46

CUSW REL1.3

N/A N/A

N/A MH Device 16 Retract Fault N/A MH Device 17 Retract Fault

Major/Minor Major/Minor

203 204

EVENT DRIVEN EVENT DRIVEN



MH Device 18 Retract Fault MH Device 19 Retract Fault MH Device 20 Retract Fault MH Device 21 Retract Fault MH Device 22 Retract Fault MH Device 23 Retract Fault MH Device 24 Retract Fault MH Device 25 Retract Fault MH Device 26 Retract Fault MH Device 27 Retract Fault MH Device 28 Retract Fault MH Device 29 Retract Fault

Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor

205 206 207 208 209 210 211 212 213 214 215 216

EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN

N/A N/A N/A N/A N/A N/A

N/A N/A N/A N/A N/A N/A

MH Device 30 Retract Fault MH Device 31 Retract Fault MH Device 32 Retract Fault MH Device 33 Retract Fault MH Device 34 Retract Fault MH Device 1 Extend Fault

Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor

217 218 219 220 221 222

EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN

N/A N/A N/A N/A N/A

N/A N/A N/A N/A N/A

MH Device 2 Extend Fault MH Device 3 Extend Fault MH Device 4 Extend Fault MH Device 5 Extend Fault MH Device 6 Extend Fault


223 224 225 226 227




MH Device 7 Extend Fault MH Device 8 Extend Fault MH Device 9 Extend Fault MH Device 10 Extend Fault MH Device 11 Extend Fault MH Device 12 Extend Fault MH Device 13 Extend Fault


228 229 230 231 232 233 234


N/A N/A N/A N/A N/A

N/A N/A N/A N/A N/A

MH Device 14 Extend Fault MH Device 15 Extend Fault MH Device 16 Extend Fault MH Device 17 Extend Fault MH Device 18 Extend Fault


235 236 237 238 239




MH Device 19 Extend Fault MH Device 20 Extend Fault MH Device 21 Extend Fault MH Device 22 Extend Fault MH Device 23 Extend Fault MH Device 24 Extend Fault MH Device 25 Extend Fault


240 241 242 243 244 245 246




MH Device 26 Extend Fault MH Device 27 Extend Fault MH Device 28 Extend Fault MH Device 29 Extend Fault MH Device 30 Extend Fault MH Device 31 Extend Fault MH Device 32 Extend Fault MH Device 33 Extend Fault MH Device 34 Extend Fault

Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor Major/Minor

247 248 249 250 251 252 253 254 255

EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN EVENT DRIVEN

Note: If a Material Handling Fault is disabled using the DF&C function, the appropriate application error bit will be posted as a MINOR fault indicating that the MAJOR fault is disabled. The Process Fault bit will remain low.


47

CUSW REL1.3

PLC LOGIC REFERENCE The 12PF program will utilize Allen-Bradley GuardLogix Processors with DeviceNet for PLC to Robot and Robot to PLC communications. Please reference the latest 12PF Library, distributed by DCX Controls Coordinators, for the robot related m odules.


48

CUSW REL1.3

ROBOT PROGRAM NAMING Robot program names shall follow the convention described by the table below:

Table 1. Program Names Program Name (8 char. max)

Style #

Comment (16 char. max)

Program Description

Programs

1

STYLE001

Maint Style 1

(Maintenance Program) - User Specified

2

STYLE002

WeldGunForceChck

User Specified - Weld Gun Force Check

3

STYLE003

Tip Change

(Maintenance Program) - Executes motion and/or macro calls required to change the tips on the weld gun

4

STYLE004

Purge

(Maintenance Program) - Executes motion and/or macro calls required to purge the dispense gun

5

STYLE005

Tip Burn In

(Maintenance Program) - Executes motion and/or macro calls required to burn in the tips on the weld gun

6

STYLE006

Service Program

(Maintenance Program) - Executes motion and/or macro calls required to move the robot to the service position

7

STYLE007

TipDress 1st Gun / Tip1BurnIN

(Maintenance Program) - Executes motion and/or macro calls required to dress the tips on the 1st gun

8

STYLE008

TipDress 2nd Gun / Tip2BurnIN

(Maintenance Program) - Executes motion and/or macro calls required to dress the tips on the 2nd gun

9

STYLE009

Tool Change

(Maintenance Program) - Executes motion and/or macro calls required to change the tool on t he robot

10 - 19

STYLE010 STYLE019

User Specified

User Specified

20 - 29

STYLE020 STYLE029

User Specified

User Specified

30 - 39

STYLE030 STYLE039

User Specified

User Specified

40 - 49

STYLE040 STYLE049

User Specified

User Specified

50 - 63

STYLE050 STYLE063

User Specified

User Specified - Future expansion


49

CUSW REL1.3

ROBOT INTERFERENCE ZONES Zone Identification Summary/Definitions: Station / Work Area based zones. Zones 1, 2& 3: Station Zones are defined as the area where two or more robots are executing work on or exchanging (transferring) a work piece at a physical station. Examples of stations are turntables, work fixtures, holding bucks and transfers or shuttles. Work Area Zones are defined as the area where two or m ore robots are executing work on or exchanging (transferring) a work piece without the use of a physical station. Examples of this would be robot to robot hand off by the use of Geo-fector EOAT (End Of Arm Tooling). Station and Work Area Zones are applied using an non-alternating pattern. For example a robot would pick-up a part in Zone 1 then transfer it to Zone 2. The next robot would pick-up the part from Zone 1 then transfers it to Zone 2. This non-alternating pattern would continue with Zone 3 only being required for a robot that needs three Station or Work Area zones.

Transition Zones/Hand-off zones Zones 4 & 5: Transition Zones are when two or more robots, working side by side, are needed to move (transition) from one process area to another process area when a physical interference between the robots is present during the transition. For example welding robots moving from a geo weld position to a re-spot weld position would require some Transition zone protection. Hand-off Zones are used for robot to robot hand-off. Hand-off is when one robot loads the work piece from it EOAT directly onto the other robot‟s EOAT without the use of a station. Hand-off Zones are applied using an non-alternating pattern. For example a robot would pick-up a part in Zone 4 then transfers it to Zone 5. The next robot would pick-up the part f rom Zone 4 then transfers it t o Zone 5 etc.

Process Interference Zones / Duty Zones Zones 6 thru 8: Process Interference Zones are defined as the zones around the work piece that the robots application is working around. For example two or more robots might need to cross each others path in order to complete its process on the work piece. In this case these Process Zones would be used to all ow the robots to safely “chase” each other around the work piece.

Duty Zones are defined as other Duties that the process or application requires but are in excess of the previous zone definitions. For example, gantry robots having a part transfer at a higher elevation then Zones 1-3 could use these zones like a Work Area Zone. Examples:

Interference Zone Example 1: This example shows Zone 1 and 2 as Station Zones. Zones 4 & 5 are Transition Zones and Zones 6 – 8 as Process Interference Zones. Interference Zone Example 2: This example shows Zone 1 and 2 as Work Area Zones. Zone 4 is a hand-off Zone and Zones 6 & 7 are Process Interference Zones


50

CUSW REL1.3

Interference Zone Example 1


51

CUSW REL1.3



52

CUSW REL1.3


The definitions described and show above, are to be followed as described and are not subject to interpretation. If the above definitions can not be applied to a specific application then approval from a Chrysler Robotics Engineer or Launch Technician will be required to redefine how Interference Zones are to be used. Reference Pictures Only See Standard Robot Logic Reference for Details.


53

CUSW REL1.3

PLC / ROBOT TIMING DIAGRAMS New Cycle Start Robot Inputs

*Hold Resume

Production Cycle (2)

Fault Reset Style1-Style64 Option1-Option4

(3)

Prod Start

(3)

Robot Outputs

RobotInAuto RobotFaulted-ProcessFault Robot Ready Production Cycle

ActiveStyle1-ActiveStyle64 Prg Paused Prg Running In Cycle Option1Active-Option4Active RobotAtHome

1) Robot is in a starting mode of faulted i nbetween cycle 2) Fault Reset can be dropped after seeing Robot Ready go high 3) Style and option bits need to be set before Prod Start is set, Prod Start can be dropped when Prg Running goes high


54

CUSW REL1.3

Stop and Resume from Fault Robot Inputs *Hold P

P

(5)

Resume ro

d

ro

d u

u c

c

Fault Reset ti

ti o

o n

n C

Style1-Style64

C y

y c

c le

Option1-Option4

le

Prod Start

Robot Outputs RobotInAuto RobotFaulted-ProcessFault (4) Robot Ready P

P d

d

ro

ActiveStyle1-ActiveStyle64

ro u

u c

Prg Paused

c n

o

ti n

o

ti

Stop and Resume from Fault Robot Inputs *Hold P

P

(5)

Resume ro

ro

d

d u

u c

c

Fault Reset ti

ti o

o n

n C

C

Style1-Style64 y

y c

c le

le

Option1-Option4 Prod Start

Robot Outputs RobotInAuto RobotFaulted-ProcessFault (4) Robot Ready P

P d

d

ro

ro

ActiveStyle1-ActiveStyle64 u

u c

c ti

ti o

o

Prg Paused n

n C

Prg Running

C y

y c

c le

le

In Cycle Option1Active-Option4Active RobotAtHome

4) Fault occurs and robot sets RobotFaulted and/or Process Fault 5) Resume signal does not require Style Number or Option Bits


55

CUSW REL1.3

Stop and Resume from Hold Robot Inputs (6)

*Hold P

P d

d

Resume ro

ro u

u c

c

Fault Reset ti

ti o

o n

n C

Style1-Style64

C y

y c

c le

Option1-Option4

le

Prod Start

Robot Outputs RobotInAuto RobotFaulted-ProcessFault Robot Ready P

P d

d

ro

ro


u c

Prg Paused

c n

o

ti n

o

ti

Stop and Resume from Hold Robot Inputs (6)

*Hold P

P d

d

Resume ro

ro u

u c

c

Fault Reset ti

ti o

o n

n C

C

Style1-Style64 y

y c

c le

le

Option1-Option4 Prod Start

Robot Outputs RobotInAuto RobotFaulted-ProcessFault Robot Ready P

P d

d

ro

ro


u c

c ti

ti o

o

Prg Paused n

n C

C y

y c

Prg Running

c le

le

In Cycle Option1Active-Option4Active RobotAtHome

6) When *Hold signal is lost, robot pauses program without faults


56

CUSW REL1.3

REGISTER USAGE Register names shall be a maximum of 16 characters in length and the name shall reflect t he purpose of the register or counter.

NUMERICAL REGISTER USAGE Numerical Registers are used for storage of Real or Integer values. The table below shows the registers that are reserved.

Table 2. Numerical Registers

Register Number 1

Register Comment Current Tool ID

Current Tool ID

2

Desired Tool ID

Desired Tool ID

3

Devnet Status

DeviceNet Device Status Check Result

4

DevnetConnRetry

DeviceNet Connection Retries

5

Current Home Pos

Home Position to Return to During Service Macro

6

CurrentFixtureID

Current Fixture ID

7

DesiredFixtureID

Desired Fixture ID

8

Line Number

Line Number

9 10

Register Description

Spare SrvGunReserved

Preset Value

3

REGISTER USAGE Register names shall be a maximum of 16 characters in length and the name shall reflect t he purpose of the register or counter.

NUMERICAL REGISTER USAGE Numerical Registers are used for storage of Real or Integer values. The table below shows the registers that are reserved.

Table 2. Numerical Registers

Register Number 1

Register Comment Current Tool ID

Current Tool ID

2

Desired Tool ID

Desired Tool ID

3

Devnet Status

DeviceNet Device Status Check Result

4

DevnetConnRetry

DeviceNet Connection Retries

5

Current Home Pos

Home Position to Return to During Service Macro

6

CurrentFixtureID

Current Fixture ID

7

DesiredFixtureID

Desired Fixture ID

8

Line Number

Line Number

9


Preset Value

3

Spare

10

SrvGunReserved

11

SrvGunReserved

12

SrvGunReserved

13

SrvGunReserved

14

CompletedBurnIns

Completed Number Burn Ins

15

RequiredBurnIns

Required Number Burn Ins - set by user

16

ATISequenceStep

Current Step of ATI Sequence

17

ATIRecovery

ATI Recovery Method

18

Reserved for ServoGun Tip Wear and Autotuning

3

Spare

19

Gun1BurnInSched

Gun 1 Weld Schedule for Burn In

20

Gun2BurnInSched

Gun 2 Weld Schedule for Burn In

21

Gun1 Spot Count

Gun 1 Spot Weld Count

22

Gun1 Tip Dress

Gun 1 Tip Dress

23

Gun2 Spot Count

Gun 2 Spot Weld Count

24

Gun2 Tip Dress

Gun 2 Tip Dress

25

TipWR Cycle CNT

Tip Wear Cycle Count

26

TipWR Cycle MAX

27-39

Tip Wear Max Cycles Spare

40

NumWeldRetries

Number of Weld Retries

41

ColGuardDefault

Sensitivity Default Register for Collision Guard

100

42

ColGuardSensitiv

Increased Sensitivity Register for Collision Guard

150

43-100

1

Spare

101

ToolModelNum

102

1sRobot/StatNum

103

10sRobot/StatNum

104-129

Temporary Storage of Tool Model Number Temporary Storage of 1's Digit of Robot/Station Number Temporary Storage of 10's Digit of Robot/Station Number Spare

130

ISRA Mode

Vision Mode

131

ISRA Type

Vision Vehicle Type

132

ISRA Subtype

Vision Vehicle Sub

133

ISRA Color

Vision Vehicle Color

134

ISRA PR

Vision Ofset Index

135

ISRA Error

Vision Error

136

ISRA Temp

Vision Temp


57

CUSW REL1.3

Register Number 137

Register Comment


ISRA Set Nominal

ISRA Set Nominal

138

ISRA Vis Pos X

ISRA Vis Pos X

139

ISRA Vis Pos Ext

ISRA Vis Pos Ext

140

Rack Position

Rack Position

ISRA Menu ANS

ISRA Menu ANS

145

Scratch1

Scratch1

146

Scratch2

Scratch2

147

Scratch3

Scratch3

149

Part Rapid X

Part Rapid X

150

Part Delta X(mm)

Part Delta X(mm)

151

0th Part X

0th Part X

152

Calc'd Part X

Calc'd Part X

153

Calc'd Part No

Calc'd Part No

154

Search 1 Part X POS

Search 1 Part X POS

155

Search 2 Part X POS

Search 2 Part X POS

156

Search X POS DIF

Search X POS DIF

157

Found Part X

Found Part X

158

Found Part No

Found Part No

159

Part No DIF

160

Part No DIF ForcChkBadMeas

161

ForcChkFailed

162

ForcChk1ShakFail

163

ForcChk2ShakFail

Preset Value

141 142 143 144

148

164

ForcChkFShakFail

165

ForcChkPartsRack

There are a total of 200 numerical registers. The user is free to use any other numerical register. The following is an example of using a numerical register in a teach pendant program. 10: R[1] = 34 ; 11: GO[3] = R[1] ; => Meaning Robot Group Output GO[3] = 34 value


58

CUSW REL1.3

POSITION REGISTER USAGE The table below shows the position register list to be used on the WD project. Moving to these positions is handled using the appropriate macro listed in the macro section of this document.

Table 3. Position Registers Position Register Number Position Register Comment 1 Home1

Position Register Description Home1

2

Home2

Home2

3

PouncePosition

Pounce Position

4

M/HWaitPosition

M/H Wait for Dropoff Position

5

ServicePosition

Service Position

6

PurgePositionG1

Purge PositionG1

7

PurgePositionG2

Purge PositionG2

8

Spare

9

Spare

10

Spare

11

Spare

12

Spare

13

Spare

14

Spare

15

Spare

16

Spare

17

Spare

18

Spare

19

Spare

20 21 22 23

ReservedServoGun

Reserved for Servo Gun Autotuning and Tip Wear Operations

ReservedSpotTeach

28

Reserved for Servo Gun Spare

29

Spare

30

Spare

24 25 26 27

31

Pick 1 Position

PickUp Position #1

32

Drop 1 Position

DropOff Position #1

33

Pick 2 Position

PickUp Position #2

34

Drop 2 Position

DropOff Position #2

35

Pick 3 Position

PickUp Position #3

36

Drop 3 Position

DropOff Position #3

37

Pick 4 Position

PickUp Position #4

38

Drop 4 Position

DropOff Position #4

39

Spare

40

Base Frame

Base Frame

41

PF Low Lt Frame

PF Low Lt Frame

42

PF Low Rt Frame

PF Low Rt Frame

43

PF Up Lt Frame

PF Up Lt Frame

44

PF Up Rt Frame

PF Up Rt Frame

45

?? Low Lt Frame

?? Low Lt Frame

46

?? Low Rt Frame

?? Low Rt Frame

47

?? Up Lt Frame

?? Up Lt Frame

48

?? Up Rt Frame

?? Up Rt Frame


59

CUSW REL1.3

Position Register Number Position Register Comment 49 Current Position 50 Offs Base Frame 51

Above Pick

Position Register Description Current Position Offs Base Frame Above Pick

52

Spare

53

Spare

54

ISRA Vis Pos

ISRA Vis Pos

55

PF Nom Vis Pos

PF Nom Vis Pos

56

?? Nom Vis Pos

?? Nom Vis Pos

57

Rack Nom Vis Pos

Rack Nom Vis Pos

58

ISRA CAM1 CALPOS

ISRA CAM1 CALPOS

59

ISRA CAM2 CALPOS

ISRA CAM2 CALPOS

60 - 89

Spares

90

TCP Target Position

98

Payload ID Position

Starting Position to Start Payload ID

99

ZERO Position

Robot Zero Mastering Position

101

Nest 1 Drop

Spare Position where the tool changer decouples tool 1.

102

Nest 2 Drop

Position where the tool changer decouples tool 2.

103

Nest 3 Drop


104

Nest 4 Drop


100

105

Spare

106

Nest 1 Pick

Position where the tool changer couples tool 1.

107

Nest 2 Pick


108

Nest 3 Pick


109

Nest 4 Pick


110

Spare

111

Tool Offset 1

Offset used for approach and retreat positions of the robot during the drop sequence.

112

Tool Offset 2


113

Tool Offset 3


114

Tool Offset 4


115

Tool Offset 5


116

Tool Offset 6


117

Tool Offset 7


118

Tool Offset 8


119-200

Spares

Note 1: The robot must be able to move between the different Home positions in a single move without causing damage to the robot, dressout, or tooling. Note 2: Only use multiple home positions when performing a Change-out robot program (tool changer application). If no tool change application, the preferred method is only one home position, unless if a cycle time issue comes up.


60

CUSW REL1.3

USER ALARMS User Alarms are used to post an alarm and fault the robot from within a t each pendant program or macro. The table below shows the user alarms that are used f or the PF project.

Table 4. User Alarms User Alarm Number 1

User Alarm Comment ToolNotPresent

No tool present

2

Invalid Tool Requested

Invalid tool requested for pick

3

Unexpected Tool Present

Unexpected tool present for drop

4

Tool Nest not Empty

Tool nest is not empty, can not drop tool

5

Tool Nest is Empty

No tool in nest, can not pick tool

6

DNetPower Not On

Apply DNet power

7

Aux Power Not On

Apply aux power

8

ReadyToLock1 Not On

Tool not positioned properly

9

ReadyToLock2 Not On

Tool not positioned properly

10

ToolStndIntlk1 Not On

TSI limit switch fault

11

ToolStndIntlk2 Not On

TSI limit switch fault

12

RTL Sensor State Mismatch

RTL sensor states don't match

13

TSIV Sensor State Mismatch

TSIV sensor states don't match

14

Latch Overload/Short Circuit

Short circuit or overload on latch solenoid output

15

Unlatch Overload/ShortCircuit

Short circuit or overload on unlatch solenoid output

16

Spare Overload/Short Circuit

Short circuit or overload on spare solenoid output

17

RTLV / RTL Mismatch

Mismatch condition between RTLV and RTL inputs

18

TSRV / TSIV Mismatch

Mismatch condition between TSIV and TSRV inputs

19

UnsafeUnlatch

Unlatch command received resulting in an unsafe tool release and therefore was not processed.

20

LckUnlckSensFlt-Both High

Locked and Unlock inputs high at same time

21

LatchNotComplt-Latch Timeout

Timeout on locked input after latch command

22

UnltchNtComplt-UnlatchTimeout

Timeout on unlocked input after unlatch command

23

TSIVFault-Switch Failed High

Failure of TSIV limit switch(es) in high position

24

RTLFault-Switch Failed High

Failure of RTL sensor(s) in high position

25

CommError-Master to Tool

Communication error between master and tool modules

26

LckOrUnlckSensIncorrectState

Lock or Unlock Sensor in Incorrect State - Possible Failed Sensor

27 - 79

User Alarm Description

Spare

80

ISRA: Reset Errors Timeout

ISRA: Reset Errors Timeout

81

ISRA: Change Auto/Ready Prep

ISRA: Change Auto/Ready Prep

82

ISRA: Change Auto Handshake

ISRA: Change Auto Handshake

83

ISRA: Ready Prep Timeout

ISRA: Ready Prep Timeout

84

ISRA: Meas Data OK Timeout

ISRA: Meas Data OK Timeout

85

ISRA: Result Transfer ON

ISRA: Result Transfer ON

86

ISRA: Result Transfer OFF

ISRA: Result Transfer OFF

87

ISRA: Meas Still Running

ISRA: Meas Still Running

88

ISRA: Wrong Op Mode Entered

ISRA: Wrong Op Mode Entered

90

ISRA: Err Setting Meas Data

ISRA: Err Setting Meas Data

91

ISRA: Err Starting Meas

ISRA: Err Starting Meas

92

ISRA: Features/Tol Error

ISRA: Features/Tol Error

93

ISRA: Measurement Error

ISRA: Measurement Error

89

94 95 ISRA: Rack NOT OK ISRA: Rack NOT OK There are a total of 50 user alarms. The user is free to use any other user alarm. The following is an example of using a user alarm in a teach pendant program. 10: UALM[1] ; 11: UALM[4] ;


61

CUSW REL1.3

REFERENCE POSITION USAGE Reference Positions are global positions that can set an output automatically when the robot encoder values indicate that the robot is at the position. This automatic checking is done where the robot is jogged t o a position or moved via a macro or program. The table below shows the reference positions to be used on the PF project.

Table 5. Reference Positions Reference Position Number 1

Position Name Home1

At Position Digital Output 27

2

Home2

User Specified

3 - 10

Spare

User Specified

11

RobotAtUserPos1

66

12

RobotAtUserPos2

67

13

RobotAtUserPos3

68

14

RobotAtUserPos4

69

15

RobotAtUserPos5

70

23

UnCouple Tool Position 1

646

24


647

25


648

26


649

27


650

28


651

29


652

30


653

Note 1: The robot must be able to move between the different Home positions in a single move without causing damage to the robot, dressout, or tooling. Note 2: Only use multiple home positions when performing a Change-out robot program (tool changer application). If no tool change application, the preferred method is only one home position, unless if a cycle time issue comes up. Note 3: Housekeeping macros (HOME_IO) are run when the robot is in range of a reference position set as a valid home position. Reference Position #1 must be set as a valid home position to execute HOME_IO after normal program execution. HOME_IO execution follows normal program execution when a robot is moved from a non home position to a valid home position.


62

CUSW REL1.3

INTERCONNECTS The I/O Interconnect feature allows the robot to output the states of digital inputs to notify external devices of the state of those inputs. The interconnect tables displays the inputs that are mapped to outputs. For example, per the configuration in the table below if DI[95] was to turn on, the robot would then turn on DO[416]. If DI[95] then turns off, DO[416] also turns off. I/O is interconnected based on the configuration of the robot. For example, a material handling robot would have Input 513 interconnected to Output 77. It would not have Input 204 interconnected to Output 102 because these I/O points are used for spot welding robots. The table below shows the interconnects that are used for the PF project.

Table 6. Interconnects

INTERCONNECTS Table # Application Type Input 3 7 39 40 41 42 43 44 45 46 47 48 49 50 55 56 57

Reserved Reserved MH MH MH MH MH MH MH MH MH MH MH MH Tool Changing Tool Changing Tool Changing

DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO DI-DO

DI DI DI625 DI626 DI513 DI514 DI515 DI516 DI529 DI530 DI531 DI532 DI545 DI546 DI664 DI665 DI666

Description

Output

Description

Air OK Air Aceptable Range Part1Present Part2Present Part3Present Part4Present Part5Present Part6Present Part7Present Part8Present Part9Present Part10Present ToolIDSwtch1Bit1 ToolIDSwtch1Bit2 ToolIDSwtch1Bit4

DO DO DO91 DO92 DO77 DO78 DO79 DO80 DO81 DO82 DO83 DO84 DO85 DO86 DO116 DO117 DO118

AirOK AirPressAcptRng RobotPartPres1 RobotPartPres2 RobotPartPres3 RobotPartPres4 RobotPartPres5 RobotPartPres6 RobotPartPres7 RobotPartPres8 RobotPartPres9 RobotPartPres10 ToolIDOnWrist1 ToolIDOnWrist2 ToolIDOnWrist4

Description

Output

Description

OVERTEMP_SWG1 OVERTEMP_SWG2

DO909 DO910

XFORMTEMPOk1 XFORMTEMPOk2

INTERCONNECTS Table # 13 14

Type Input Spot Welding Spot Welding

SI-DO SI-DO


SI12 SI13

63

CUSW REL1.3

MACROS Macro programs can be run standalone, but are intended to be used as subroutines which are called from the main style program. Defining a program as a macro program is done by setting the program type to “Macro” in the program header.

When these programs are called from a main style program, the program pointer jumps to the subroutine. Similarly, when the subroutine is complete, the program pointer jumps back to the next line in the main style program. Macro programs can be set to either prohibit or allow robot motion statements. When motion statements are prohibited, the macro program can be manually executed while a robot fault is active. Therefore, it is recommended that macro programs that only execute I/O signals be set to prohibit motion statements (i.e. open/close gripper macro programs). Prohibiting motion statements in a macro program is done by setting all available motion groups to “*” in the program header. Allowing motion statements in a macro program is done by setting the appropriate motion groups to “1”.

The user is free to place additional m acros into the macro table provided they do not t ake up a position reserved by the macro table listed below. FANUC Spottool+ standard macros such as tip wear compensation are not called out in the macro table. These macros are automatically loaded on the robot at time of software load.

Table 7. Macros Macro Table Position

Macro Name (8 Char. Max)

Macro Comment (16 Char. Max)

Macro Description

Macros

1

HOME_IO

Setup Outputs

Handles I/O for start of next cycle (housekeeping)

APP_IO

SetApplicationIO

Setup all application specific inputs and outputs

ATI_CHCK

Check ATI Errors

Handles ATI errors experienced during the tool pick and tool drop processes

CHK_TOOL

Check Tool

Checks for the correct tool on the wrist

ENTRZON1

Enter Zone 1

Handles IO for zone entering

ENTRZON2

Enter Zone 2


ENTRZON3

Enter Zone 3


ENTRZON4

Enter Zone 4


ENTRZON5

Enter Zone 5


ENTRZON6

Enter Zone 6


ENTRZON7

Enter Zone 7


ENTRZON8

Enter Zone 8


ENTRZON9

Enter Zone 9


MOV_HOME

Move to Home

Executes motion to move the robot home from the current position

MVHMPNCE

MoveHomeFromPnce

Executes motion to move the robot home from the pounce position

NST1DROP

Drop Tool Nest 1

Executes motion and/or macro calls required to drop tool 1 in nest 1

NST2DROP

Drop Tool Nest 2


NST3DROP

Drop Tool Nest 3


NST4DROP

Drop Tool Nest 4


MF 1


64

CUSW REL1.3

Macro Table Position

Macro Name (8 Char. Max) NST1PICK

Macro Comment (16 Char. Max) Pick Tool Nest 1

NST2PICK

Pick Tool Nest 2

Executes motion and/or macro calls required to pick tool 2 from nest 2

NST3PICK

Pick Tool Nest 3


NST4PICK

Pick Tool Nest 4


PED_DISP

Ped Dispense

Executes motion and/or macro calls required to perform dispensing with a pedestal mounted gun

PED_SPOT

Ped Spot Weld

Executes motion and/or macro calls required to perform spot welding with a pedestal mounted weld gun

PED_STUD

Ped Stud Weld

Executes motion and/or macro calls required to perform stud welding with a pedestal mounted gun

PREPDROP

Tool Drop Prep

Executes motion and/or macro calls required to prepare to drop the tool on the wrist in its nest

PREPPICK

Tool Pick Prep

Executes motion and/or macro calls required to prepare to pick a tool from its nest

PRGPDGN1

Purge Ped Gun 1

Executes motion and/or macro calls required to perform a purge on pedestal mounted dispense gun 1

RST_STPR

Reset Stepper

Handles IO for resetting the spot weld stepper motor

TPBURNIN

Tip Burn In

Executes motion and/or macro calls required to perform a tip burn in on a servo weld gun

TPCHNGPD

TipChangePedGun

Executes motion and/or macro calls required to perform a tip change on a pedestal mounted weld gun

TPDRSPD

TipDressPedGun

Executes motion and/or macro calls required to perform a tip dress with a pedestal mount weld gun

TPDRSGN1

DressCarriedGun1

Executes motion and/or macro calls required to perform a tip dress on carried weld gun 1

TPDRSGN2

DressCarriedGun2

Executes motion and/or macro calls required to perform a tip dress on carried weld gun 2

Macro Description Executes motion and/or macro calls required to pick tool 1 from nest 1

10 - 11

Reserved for SpotTool+

18


109 - 120


130 - 140



65

CUSW REL1.3

FLOW CHART EXAMPLES Contained in the following pages are flow charts of the processes required for the PF program. The information contained in each section is for . REFERENCE ONLY

Flow Chart Legend Process: Logic statement

Data: Data/Input from an external device is required to process this step ‟s logic

Decision: Logic decision

Move: Servo movement called in logic

Connector: Off Page

Connector: On Page


66

CUSW REL1.3

Material Handling Start

Set Robot Payload, Tool Frame, and User Frame Setup Application Specific I/O (Macro) Acknowledge Style GO[1] Reset Collision Guard Sensitivity to Default R[41]

Tool Changer Applications Only

No Tool Changer

Set Desired Tool ID R[2] Check Tool (Macro)

Set MH Gripper (if necessary) (Macro)

Set additional gripper states (if necessary) (Macro)

A

Move to Pounce

Wait for go to Pickup 1 DI[49]

Set at Pounce DO[25] Reset Clear of Pickup 1 DO[49] Reset DO[89] Reset DO[94]

Reset Clear to Transfer DO[31]

Verify Part not Present (Macro)

Zone Check (if necessary) (Macro)

Open the Gripper and Verify Open (Macro)

Go to Work or Return Home From Pounce?

Move Over Pickup 1

Return Home DI[25]

Move Home from Pounce (call Macro)

Verify Tool is Correct (Macro)

Verify Part not Present (Macro)

Go To Work DI[31] End Set Robot at Work DO[18] Reset Robot at Pounce DO[25]

B

A


67

CUSW REL1.3

Material Handling (cont’d) B

Open the Gripper and Verify Open (Macro)

Set Collision Guard Sensitivity R[42]

Move to Pickup 1

Check for Part Present (Macro)

Note: Material Handling functions may require process recovery. Refer to the MH process recovery section.

Set Reposition Tooling GO[2]

Wait for Tooling Repositioned GI[5]

Close the gripper and verify closed (Macro)

Note: Collision Guard sensitivity increased prior to moving into tooling to help prevent damage if a collision occurs

Note: Set reposition tooling handshake may be required either before or after gripper is closed

Note: Receiving robot or fixture will always set the Reposition Tooling bit to the delivering robot or fixture

Note: Reposition Tooling bits only required when Robot to Robot/Fixture handshaking is needed

Set At Pickup 1 DO[50] Select Robot Payload with Part

Note: Validate open before moving

Wait for Tooling Repositioned GI[5]

Reset Reposition Tooling GO[2]

Move Clear of Fixture Part Presence

Wait for Exit Pickup 1 DI[50]

Reset Collision Guard Sensitivity to Default R[41]

Note: This robot movement must be of “FINE” type

Note: Lessons learned, PLC is looking for a part in the robot gripper and has not been dropped

Check for Part Present (if necessary) (Macro)

C


68

CUSW REL1.3

Material Handling (cont’d)

C

Reset at Pickup 1 DO[50]

Move Clear of Pickup 1

Set Clear of Pickup 1 DO[49] Set Clear to Transfer DO[31] Set Clear of Interference Zone (if necessary) DO[33]

Move

Process Applications (as required) Dispense Inspection Spot Weld Stud Weld Wait for go to Dropoff 1 DI[51]


Reset Clear of Dropoff 1 DO[51] Reset Clear to Transfer DO[31]

Move Over Dropoff 1

Verify Tool is Correct (Macro)


Move to Dropoff 1

Set at Dropoff 1 DO[52]

D


69

CUSW REL1.3

Material Handling (cont’d)

D

Note: Receiving robot or fixture will always set the Reposition Tooling bit to the delivering robot or fixture

Wait for Reposition Tooling GI[5]

Open the Gripper (Macro) Select Payload without Part(s), Tool Frame and Us er Frame

Note: Reposition Tooling bits only required when Robot to Robot/Fixture handshaking is needed

Set Tooling Repositioned GO[2]

Note: Material Handling functions may require process recovery. Refer to the MH process recovery section.

Note: Assumes robot drops part to fixture

Move Clear of Robot Part Present

Note: This robot movement must be of “FINE” type.

Verify Parts Not Present (Macro)

Wait for Exit Dropoff 1 DI[52] (if necessary)

Reset Collision Guard Sensitivity to Default R[41] Reset at Dropoff 1 DO[52] Reset Tooling Repositioned GO[2]

Move Clear of Dropoff 1

Set Clear of Dropoff 1 DO[51] Set Clear of Interference Zone (if necessary) DO[33]

E

Move Clear of Transfer Set Work Complete DO[19] Set Clear to Transfer DO[31] Reset Robot at Work DO[18]

Wait for Work Complete Ack. DI[32]

Move Home (Macro)

Reset Work Complete DO[19]

E

End


70

CUSW REL1.3

Material Handling (cont’d) Abort Pick/Abort Override Example (if required) From Standard Material Handling Process

Note: Abort outputs are automatically set when the user selects a designated recovery option during standard material handling fault recovery (DO[89,94]). The user must manually reset these outputs when the recovery process is complete.

MH Function Macro (Ex: Check Part Present)

Abort Pick or Abort Over Ride Requested? DO[89,94]

No Continue Standard Material Handling Process


71

Yes

User Specified Macro (Ex: Abort Pick) Jump to Program Label (Ex: End Program)

CUSW REL1.3

Dispense Start

A

Set Robot Payload, Tool Frame, and User Frame

Reset Dispense Style GO[31]

Setup Application Specific I/O (Macro) Note: Collision Guard sensitivity increased prior to moving into tooling to help prevent damage if a collision occurs

Acknowledge Style GO[1] Reset Collision Guard Sensitivity to Default R[41] Reset Clear to Transfer DO[31]


Move To Seal Start and Turn on Gun

Move to Pounce

Note: The Nordson controller requires approx 500ms between the final gun off command and setting dispense complete. Therefore a move clear of part is performed between these commands to allow this time to elapse.

Set at Pounce DO[25]


Reset Dispense Style Strobe DO[394]

Return Home DI[25]

Move To Seal End and Turn off Gun

Move Clear of Part

Move Home from Pounce (Macro)

Go To Work DI[31]

Reset Collision Guard Sensitivity R[41]

Set Robot at Work DO[18] Reset Robot at Pounce DO[25]

Move Along Path

Set Dispense Complete DO[401]

End


Wait for Dispense Vol. OK

Pre-processing for Dispense Equipment

Reset Dispense Complete DO[401] Reset Dispense Robot in Process DO[393]

Wait for Dispenser Ready DI[385]

Set Dispense Robot in Process DO[393] Wait 100ms Set Dispense Style GO[31] Wait 100ms Set Dispense Style Strobe DO[394]

Post-processing for Dispense Equipment

Move Home (Macro)

Note: The Nordson controller requires 100ms delay time between setting robot in process, dispense style, and dispense style strobe. Wait statements are used here to allow the Nordson to see the delay.

Set Work Complete DO[19] Set Clear to Transfer DO[31] Set Clear of Zone DO[33]

Wait for Dispense In Process DI[386]

Wait for Work Complete Ack. DI[32]

A


End

72


CUSW REL1.3

Spot Welding Start

Set Robot Payload, Tool Frame, and User Frame Setup Application Specific I/O (Macro) Acknowledge Style GO[1] Reset Clear to Transfer DO[31]

Move to Pounce



Return Home DI[25]

Move Home from Pounce (Macro)

Go To Work DI[31] End Set Robot at Work DO[18] Reset Robot at Pounce DO[25]


Move To Weld 1

Select Schedule, Weld 1

Move To Weld 2


Move Clear of Clamps

A


73

CUSW REL1.3

Spot Welding (cont’d)


74

CUSW REL1.3

Stud Welding Start

A

Set Robot Payload, Tool Frame, and User Frame

Set Clear to Unclamp Early DO[65]

Setup Application Specific I/O (Macro) Acknowledge Style GO[1]

Move Home (Macro)

Reset Clear to Transfer DO[31]

Set Work Complete DO[19] Move to Pounce

Set Clear to Transfer DO[31] Set Clear of Zone DO[33]



Return Home DI[25]

Wait for Work Complete Ack. DI[32] Move Home from Pounce (Macro)


Go To Work DI[31] End

End

Set Robot at Work DO[18] Reset Robot at Pounce DO[25]


Move To Weld 1


Move To Weld 2


Move Clear of Clamps

A


75

CUSW REL1.3

Tip Change (Style #3) Start

Set Robot Payload, Tool Frame, and User Frame Setup Application Specific I/O (Macro) Acknowledge St yle GO[1]

Move Dress Approach (if necessary)

Note: A tip dress is performed prior to cap change to allow operator to verify tip dresser is properly dressing caps.

Do Tip Dress Gun 1 – Schedule 0 (Macro) DELAY for TipDress Complete (wait 1.0 sec)

Note: Tip Dress Macros use an argument call for the burn in schedule. Schedule 0 skips the burn in.

Reset Tip Dress Complete DO[29] Move to Tip Change Position

Pulse W1 W ater Off DO[587]

Note: 4.0 sec puls required to allow the watersaver to turn OFF and Blead down.

Wait W1OKToWeld DI[785]=OFF AND W1ValveClosed DI[ 786]=ON

Set Robot at Service DO[26]

Reset Robot at Service DO[26]

Set Ready for Tip Change DO[30]

Reset Ready for Tip Change DO[30] Reset Stepper (Macro)

Wait for Service Complete DI[26]

Seat Caps Gun 1 (Macro) Do Tip W ear Compensation Gun 1 (Macro)

Note: Tip wear compensation to be performed without measurement error checking.

Move Dress Approach (if necessary)

Pulse W1 Reset Water Saver DO[586]

Wait W 1OKtoWeld DI[785]=ON

Note: Tip dress macros perform burn in and wear compensation after dress. Refer to macros for details.

Do Tip Dress Gun 1 – (Macro)

Move Home (Macro)


76

End

CUSW REL1.3

Purge (Style #4) Start

Setup Application Specific I/O (Macro) Acknowledge Style GO[1] Set Ext Purge 1 in Progress DO[97] Pre-processing for Dispense Equipment Set Dispense 1 Purge DO[416] Wait X Seconds „

‟

Reset Dispense 1 Purge DO[416] Post-processing for Dispense Equipment

Note: Home IO may need to be manually initiated if the style program does not have any robot motion.

Reset Ext Purge 1 in Progress DO[97] Home IO (if necessary) (Macro)

End


77

CUSW REL1.3

Tip Burn In (Style #5) Start

Set Robot Payload, Tool Frame, and User Frame Setup Application Specific I/O (Macro) Acknowledge Style GO[1]

Move to Service Position (if necessary)

Tip Burn In (Macro)

Move Home (Macro) (if necessary)

Home IO (Macro) (if necessary)

End


78

CUSW REL1.3

Service (Style #6) Start


Move to Service Position

Set Robot at Service DO[26]

Wait for Service Complete Req. DI[26]

Reset Robot at Service DO[26]

Move Home (Macro)

End


79

CUSW REL1.3

Tip Dress Gun 1 (Style #7) Start


Approach Move (if necessary) Note: Tip Dress Macros use an argument call for the burn in schedule. Schedule 0 skips the burn in.

Tip Dress Gun 1 – (Macro)


Move Home (Macro)

End


80

CUSW REL1.3

Tip Dress Gun 2 (Style #8) Start


Approach Move (if necessary) Note: Tip Dress Macros use an argument call for the burn in schedule. Schedule 0 skips the burn in.

Tip Dress Gun 2 – (Macro)


Move Home (Macro)

End


81

CUSW REL1.3

Tool Change (Style #9) Start


Set Desired Tool ID GI[41]

Check Tool (Macro)

Move Home (Macro)

End


82

CUSW REL1.3

Set Application IO (Macro) Start

Set Application Specific IO

End


83

CUSW REL1.3

Check ATI Errors (Macro) Start A

Select Current Sequence AR[1]

Sequence List AR[1]: A. Ready to Pick/Latch/Unlatch B. Ready to Latch C. Exit Pick/Ready to Drop/Exit Drop D. Ready to Unlatch

Set ATI Recovery Method R[17]

No

ATI Error Present?

Yes End Post User Alarm for ATI Error and Pause Program

R[17]=1

Select Recovery Method R[17]

R[17]=0

Reset Latch Tool DO[632]

Set Clear Errors DO[635]

Reset Unlatch Tool DO[633]

Wait x seconds for ATI to reset „

Set Clear Errors DO[635]

‟

Reset Clear Errors DO[635]

Wait x seconds for ATI to reset „

‟

Reset Clear Errors DO[635] A

End

Note: This recovery method will retry the latch or unlatch operation in the pick or drop macro upon exiting.


84

CUSW REL1.3

Check Tool (Macro) Start

Set Tool ID R[1], Line Number R[8], and Tool ID for PLC GO[3]

Yes

Does Current Tool ID Match Desired Tool ID?

No

End

Is Tool on Wrist? DI[644] R[1]

Yes

No

Pick Preparation and Pick Tool (Macro)

Drop Preparation and Drop Tool (Macro)


85

CUSW REL1.3

Drop Tool Nest 1 (Macro) Start

Set Robot UTOOL and UFRAME

Set Request to Enter Tool Nest DO[71]

Wait for Clear to Enter Tool Nest DI[81]

Clear ATI Errors DO[635] Reset Clear of Tool Nest DO[72] Reset Request to Enter Tool Nest DO[71]

Set Tool Device Offline (Macro) Note: (if applicable) Tool nest 1 approach and retreat positions are to use the same position as the couple position, PR[6]. This position is then offset by a distance using a tool offset via position register, PR[14].

Move to Tool Nest Perch

ATI General Error DO[645] High?

No

Yes

ATI State Check – Sequence 5 (Macro)

Note: Turn Out of Nest off before TSIV switches are made. When the Out of Nest Output is set high, the tool changer globally disables the unlatch command. This output must be turned off to unlatch the tool changer.

Reset Out of Nest DO[637]

Move to Tool Nest

Wait for Tool in Nest 1 DI[73]


A


86

CUSW REL1.3

Drop Tool Nest 1 (cont’d) Note: In the robot ladder logic, PMC the following logic is added: (Even if you ONLY have one tool, you must define a Reference Position (below) in order to UnCouple a tool.) IF DO[646:UnCoupleToolPos1]=ON ReferncePos[11] or DO[647:UnCoupleToolPos2]=ON ReferncePos[12] or DO[648:UnCoupleToolPos3]=ON ReferncePos[13] or DO[649:UnCoupleToolPos4]=ON ReferncePos[14] or DO[650:UnCoupleToolPos5]=ON ReferncePos[15] or DO[651:UnCoupleToolPos6]=ON ReferncePos[16] or DO[652:UnCoupleToolPos7]=ON ReferncePos[17] or DO[653:UnCoupleToolPos8]=ON ReferncePos[18] THEN turn DO[RbtOKtoUnCouple]=ON

A

Note: You do NOT need to set this DO[654] output in robot TP, this will be handled in robot code. It is FYI for you.

Reset Latch Tool DO[632] Set Unlatch Tool DO[633]

RbtOKtoUnCouple DO[654]

Unlatch DI[633] High?

Code in KAREL to Unlock: IF (DO[637] = OFF) AND (DO[633]+) AND (DO[654]=ON) THEN DO[633]=ON

Yes ATI Unlatched or General Error?

General Error DO[645]


Tool Unlocked DI[633] Not Tool Locked DI[632] Note: (if applicable) Tool nest 1 approach and retreat positions are to use the same position as the couple position, PR[6]. This position is then offset by a distance using a tool offset via position register, PR[14]. This move must be 1 inch further than complete separation of the tool and be of “FINE” type

No - Timeout

Set Robot Payload without Tool Set Robot UTOOL and UFRAME

Move Clear of Tool in Nest Inputs Note: Check for disengagement of tool changer

Wait for Tool in Nest 1 DI[73]


Yes


No Wait for Tool in Nest 1 DI[73] Move 4 Inches Above Clear of Tool in Nest

Reset Unlatch Tool DO[633] Set Out of Nest DO[637] Clear ATI Errors DO[635] Set Robot UTOOL and UFRAME

Move Clear of Tool Nest


87

End

CUSW REL1.3

Enter Zone 1 (Macro) Start

Reset Clear of Zone 1 DO[33]

Wait for OK to Enter Zone 1 DI[33]

End

Home IO (Macro) Start

Set Housekeeping Outputs

End

Move Home (Macro) Start

Call Get_HOME (Karel Program)

Move Home

NOTE: Get_Home Karel program will copy the position taught in Reference position to PR[Home]

NOTE: Fine Move Required

End

Move Home From Pounce (Macro) Start

Move Home From Pounce

End


88

CUSW REL1.3

Pick Tool Nest 1 (Macro) Start

Clear ATI Errors DO[635]


Set Request to Enter Tool Nest DO[71]

Move to Tool Nest Perch

Wait for Clear to Enter Tool Nest DI[81]

Reset Clear of Tool Nest DO[72] Reset Request to Enter Tool Nest DO[71]

Note: (if applicable) Tool nest 1 approach and retreat positions are to use the same position as the couple position, PR[6]. This position is then offset by a distance using a tool offset via position register, PR[10].

Move to Tool Nest Approach

Reset Out of Nest DO[637]

No

User Alarm – Lock or Unlock Sensor Incorrect State

Note: Turn Out of Nest off before TSI switches are made. When the Out of Nest Output is set high, the tool changer globally disables the unlatch command. This output must be turned off to unlatch the tool changer.

Tool Locked and Tool Unlocked Low?

Yes Reset Latch Tool DO[632] Set Unlatch Tool DO[633]

Unlatch DI[633] High?

Yes

No - Timeout

ATI Unlatched or Error Posted?



Tool Unlocked DI[633] Move to Tool Nest


A


89

CUSW REL1.3

Pick Tool Nest 1 (cont’d)

A

Reset Unlatch Tool DO[633] Set Latch Tool DO[632]

Set Tool Device Online (Macro)

Latch DI[632] High?

Yes

No - Timeout ATI Latched or Error Posted?


Tool Locked DI[632] Not Tool Unlocked DI[633]


Set Robot Payload with Tool Set Robot UTOOL and UFRAME

Is Tool ID correct? Note: (if applicable) Tool nest 1 approach and retreat positions are to use the same position as the couple position, PR[6]. This position is then offset by a distance using a tool offset via position register, PR[10].

No User Alarm – Unexpected Tool Present

Yes Move Clear of Tool in Nest Inputs


End

Yes ATI State Check – Sequence 4 (Macro)

No

Move Clear of Tool Nest

Set Out Of Nest DO[637]


Set Tool Device Online (Macro)

No Move Clear of Tool Nest


Check Device Online

90

End

Yes

CUSW REL1.3

Process Application Macros (Spot, Dispense, Stud) MH Ped Spot Weld Start

Move To Weld 1


Move To Weld 2


Move Clear of Ped Welder

Tip Dress, Tip Change, Burn In, Service or Go To Dropoff?

Tip Change DI[105]

Dropoff 1 DI[51]

Tip Dress Ped Gun – Schedule 0 (Macro) Reset Tip Dress Complete DO[29]

Tip Burn In (Macro)

Tip Dress DI[28]

Tip Change Ped Gun (Macro) End

Tip Dress Ped Gun – Schedule 58 (Macro)

Note: Refer to flow charts for tip change and tip dress macro details

Tip Burn In DI[104]

Note: A tip dress is performed prior to tip change to allow operator to verify tip dresser is properly dressing caps.

Tip Dress Ped Gun – Schedule 62 (Macro)

Service Request DI[27] MH Service with Part – (Macro)

Note: Tip Dress Macros use an argument call for the burn in schedule. Schedule 0 skips the burn in.


91

CUSW REL1.3

Process Application Macros (cont’d) MH Ped Dispense Start

A

Pre-processing for Dispense Equipment

Wait for Dispense Vol. OK

Wait for Dispenser Ready DI[385]

Set Dispense Robot in Process DO[393] Wait 100ms Set Dispense Style GO[31] Wait 100ms Set Dispense Style Strobe DO[394]

Reset Dispense Complete DO[401] Reset Dispense Robot in Process DO[393]

Note: The Nordson controller requires 100ms delay time between setting robot in process, dispense style, and dispense style strobe. Wait statements are used here to allow the Nordson to see the delay.

Wait for Dispense In Process DI[386]

Post-processing for Dispense Equipment

Purge Gun 1 DI[95]

Reset Dispense Style GO[31]

Purge or Go To Dropoff?

Dropoff 1 DI[51]

Purge Ped Gun 1 (Macro)

Reset Dispense Style Strobe DO[394] End


Move To Seal Start and Turn on Gun

Move Along Path

Move To Seal End and Turn off Gun

Move Clear of Nozzle

Reset Collision Guard Sensitivity R[41]

Note: The Nordson controller requires approx 500ms between the final gun off command and setting dispense complete. Therefore a move clear of part is performed between these commands to allow this time to elapse.

Set Dispense Complete DO[401]

A


92

CUSW REL1.3

Process Application Macros (cont’d)

MH Ped Stud Weld Start

Move To Weld 1


Move To Weld 2


Move Clear of Ped Welder

End


93

CUSW REL1.3

Purge Ped Gun (Macro) Start

Set Ext Purge 1 in Progress DO[97] Pre-processing for Dispense Equipment Set Dispense 1 Purge DO[416] Wait X Seconds „

‟

Reset Dispense 1 Purge DO[416] Post-processing for Dispense Equipment Reset Ext Purge 1 in Progress DO[97]

End

Reset Stepper (Macro) Start

Set W1 Reset Stepper DO[590]

Wait for Stepper Reset DI[204]

Reset W1 Reset Stepper DO[590]

End


94

CUSW REL1.3

Tip Burn In (Macro) Start

Reset Register for Burn Ins Complete R[14]

Do Tip Burn In Weld Schedule 62

Completed # of Burn In‟s Required?

No

Note: Number of required burn in‟s to be set by user via register value 15.

Yes Do Tip Wear Compensation Gun 1 (Macro) Set Tip Burn In Complete DO[104]

Note: Tip wear compensation to be performed without measurement error checking.

End


95

CUSW REL1.3

Tip Change Ped Gun (Macro) Start

Pulse W1 Water Off DO[587] Set Robot at Service DO[26] Set Ready for Tip Change DO[30]

Wait for Service Complete DI[26]

Reset Robot at Service DO[26] Reset Ready for Tip Change DO[30] Reset Stepper (Macro) Seat Caps Gun 1 (Macro) Do Tip Wear Compensation Gun 1 (Macro) Pulse W1 Reset Water Saver DO[586]

End


96

CUSW REL1.3

Tip Dress Gun 1 (Macro) Start

Setup Gun 1 Burn in Schedule R[19]

No

Tip dress Bypassed R[127]

Yes Set Robot in Tip Dress DO[28]

Move Common Dress Approach Approach Set Turn on Tip Dresser DO[101] Wait for Tip Dress Motor On DI[101]

No

Tip Burn In Required R[19]

Yes

Move To Dresser

Do Tip Burn In Weld Schedule R[19]

Do Tip Dress Weld Schedule 60

Do Tip W ear Compensation Compensation Gun 1 (Macro)

Move Away from Dress

Note: Tip burn in and wear compensation can be skipped. This is to be used only prior to tip change when burn in and wear compensation is not required after a tip dress. Note: Tip wear compensation to be performed without measurement error checking.

Reset Turn On Tip Dresser DO[101]

Reset Tip Dress Request 1 DO[100] [PR Home

–

Fine Move]

Set Tip Dress Complete Complete DO[29]

Reset Robot in Tip Dress DO[28]

End


97

CUSW REL1.3

Tip Dress Gun 2 (Macro) Start

Setup Gun 2 Burn in Schedule R[20]

No

Tip dress Bypassed R[127]

Yes Set Robot in Tip Dress DO[28]

Move Common Dress Approach Approach Set Turn on Tip Dresser DO[101] Wait for Tip Dress Motor On DI[101]

No


Yes

Move To Dresser

Do Tip Burn In Weld Schedule R[20]


Do Tip Wear Compensation Gun 2 (Macro)

Move Away from Dress

Note: Tip burn in and wear compensation can be skipped. This is to be used only prior to tip change when burn in and wear compensation is not required after a tip dress. Note: Tip wear compensation to be performed without measurement error checking.

Reset Turn On Tip Dresser DO[101]

Reset Tip Dress Request 1 DO[100] [PR Home

–

Fine Move]

Set Tip Dress Complete Complete DO[29]


End


98

CUSW REL1.3

Tip Dress Ped Gun (Macro) Start

Setup Gun 1 Burn in Schedule R[19] Set Robot in Tip Dress DO[28]

Wait for Tip Dress Dump Ext DI[99]

Turn on Tip Dresser DO[101]

Wait for Tip Dress Motor On DI[101]


Reset Turn on Tip Dresser DO[101] Reset Tip Dress Request 1 DO[100] Set Tip Dress Complete DO[29]

Wait for Tip Dress Dump Retracted DI[100]

No


Yes Do Tip Burn In Weld Schedule R[19]

Do Tip Wear Compensation Gun 1 (Macro)


End


99

CUSW REL1.3

Tool Drop Preparation (Macro) Start

Select Tool from Tool Number R[16]

Unknown Tool

Tool 1

A

Set Application Error Output


User Alarm – Unexpected Tool Present

User Alarm – Tool Nest Not Empty

Reset App Error Output


Verify Part Not Present (Macro) Set Active MH Tool and Gripper State for Drop (Macro)

Tool Nest 1 Empty?

Yes

Drop Tool Nest 1 (Macro)

No A

Tool 2


Tool Nest 2 Empty?

Yes

Drop Tool Nest 2 (Macro)

No A

Tool 3


Tool Nest 3 Empty?

Yes Drop Tool Nest 3 (Macro)

No A

Tool 4


Tool Nest 4 Empty?

Yes Drop Tool Nest 4 (Macro)

No A


100

End

CUSW REL1.3

Tool Pick Preparation (Macro) Start

Select Tool Nest from Pick Tool GI[4] or Style Program

Unknown Tool

Tool 1

A

Set Applic ation Error Output


User Alarm – Invalid Tool Requested

User Alarm – Tool Nest Empty



No

Tool Nest 1 Empty?

Pick Tool Nest 1 (Macro)

Yes A

Tool 2

No

Tool Nest 2 Empty?


Yes

A

Tool 3

No

Tool Nest 3 Empty?


Yes

A

Tool 4

No

Tool Nest 4 Empty?


Yes

A End


101

CUSW REL1.3

TEACH PENDANT LOGIC EXAMPLES Contained in the following pages are examples of TP logic of the processes required for the PF program. The information contained in each section is for REFERENCE ONLY .


102

CUSW REL1.3

Material Handling 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23: 24: 25: 26: 27: 28: 29: 30: 31: 32: 33: 34: 35: 36: 37: 38: 39: 40: 41: 42: 43: 44: 45: 46: 47: 48: 49: 50: 51: 52: 53:J 54: 55: 56: 57: 58: 59: 60: 61: 62: 63: 64: 65: 66: 67: 68: 69: 70: 71: 72: 73: 74: 75:

!Material Handling Template ; !****************************** ; !Remove these comments ; !Before Build!!! ; !Rename Program as Necessary ; !Edit Program to Match Part Type ; ; !Modify Zone Numbers and ; !Locations as Required ; ; !Uncomment the MACROs before ; ! finalizing the OLPs ; ; !EXAMPLE PROGRAM ONLY ; !****************************** ; ; !Set Robot Payload ; PAYLOAD[2] ; ; !Set Robot UTOOL Number ; UTOOL_NUM=1 ; ; !Set Robot UFRAME Number ; UFRAME_NUM=1 ; ; !MACRO-Setup App Specific IO ; CALL APP_IO ; ; !Set Acknowledge Style ; GO[1:ActiveStyleBits]=10 ; ; !Reset Coll Guard Sensitivity ; COL GUARD ADJUST ; ; !****************************** ; !TOOL CHANGE APPLICATION ONLY ; ; !Set Desired Tool ID Register ; R[2:Desired Tool ID]=2 ; ; !MACRO-Check Tool ; CALL CHK_TOOL ; ; !MACRO-Set MH Tool ; Set MH Tool(1) ; !****************************** ; ; !MACRO-Set Additional Gripper ; !States (if necessary) ; !Grip Part(2) ; ; !Move to Pounce ; P[1] 100% CNT100 ; ; !Set At Pounce Position Bit ; DO[25:RbtAtPounce]=ON ; ; !MACRO-Verify Part Not Present ; Check No Part(1) ; ; !MACRO-Open the Gripper ; Release Part(1) ; ; DO[89:PickOverride]=OFF ; DO[94:AbortPickReq]=OFF ; ; !Wait For Go To Work ; !or Return Home From Pounce ; WAIT DI[31:GoToWork]=ON OR DI[25:RetFromPounce]=ON ; ; !Check For Go To Work ; IF DI[31:GoToWork]=ON,JMP LBL[20] ; ; !Return Home From Pounce ; CALL MVHMPNCE ;


76: 77: 78: 79: 80: 81: 82: 83: 84: 85: 86: 87: 88: 89: 90: 91: 92: 93: 94: 95: 96: 97: 98: 99: 100: 101: 102:L 103: 104: 105: 106: 107: 108: 109: 110: 111: 112: 113: 114: 115: 116: 117:L 118: 119: 120: 121: 122: 123: 124: 125: 126: 127: 128: 129: 130: 131: 132: 133: 134: 135: 136: 137: 138: 139: 140: 141: 142: 143: 144:L 145: 146: 147: 148: 149: 150: 151:

103

; !Jump To Program End ; JMP LBL[1000] ; ; LBL[20:Go To Work] ; ; !Set Robot At Work ; DO[18:RbtAtWork]=ON ; ; !Reset Robot At Pounce ; DO[25:RbtAtPounce]=OFF ; ; !Wait For Go To Pickup 1 ; WAIT DI[49:GoToPickup1]=ON ; ; !Reset Clear Of Pickup 1 ; DO[49:ClrOfPickup1]=OFF ; ; !Reset Clear To Transfer ; DO[31:CleartoTransfer]=OFF ; ; !MACRO-Zone Check ; !(if necessary) ; CALL ENTRZON1 ; ; !Move Over Pickup 1 ; P[2] 1000mm/sec CNT100 ; ; !MACRO-Verify Correct Tool ; !Call TOOL_VER ; ; !MACRO-Verify Part Not Present ; Check No Part(1) ; ; !MACRO-Open the Gripper ; Release Part(1) ; ; !Set Coll Guard Sensitivity ; COL GUARD ADJUST R[42]; ; !Move To Pickup 1 ; P[3] 500mm/sec FINE ; ; !MACRO-Check For Part Present ; Part Present(1) ; ; !Set Reposition Tooling ; !GO[2:ReposTooling]=1 ; ; !Wait for Tooling Repositioned ; !WAIT GI[5:ToolingRepod1]=1 ; ; !MACRO-Close The Gripper ; Grip Part(1) ; ; !Set At Pickup 1 ; DO[50:AtPickup1]=ON ; ; !Select Payload With Parts ; PAYLOAD[3] ; ; !Wait for Tooling Repositioned ; !WAIT GI[5:ToolingRepod1]=1 ; ; !Reset Reposition Tooling ; !GO[2:ReposTooling]=0 ; ; !Move Clear Fixt Part Presence ; P[4] 1000mm/sec FINE ; ; !Wait For Exit Pickup 1 ; WAIT DI[50:ExitPickup1]=ON ; ; !Reset Coll Guard Sensitivity ; COL GUARD ADJUST ; ;

CUSW REL1.3

152: 153: 154: 155: 156: 157: 158: 159:L 160: 161: 162: 163: 164: 165: 166: 167: 168: 169: 170: 171: 172:L 173: 174: 175: 176: 177: 178: 179: 180: 181: 182: 183: 184: 185: 186: 187: 188: 189: 190: 191: 192:L 193: 194: 195: 196: 197: 198: 199: 200: 201:L 202: 203: 204: 205: 206: 207: 208: 209: 210: 211: 212: 213:

!MACRO-Check For Part Present ; Part Present(1) ; ; !Reset At Pickup 1 ; DO[50:AtPickup1]=OFF ; ; !Move Clear Of Pickup 1 ; P[5] 1000mm/sec FINE ; ; !Set Clear Of Pickup 1 ; DO[49:ClrOfPickup1]=ON ; ; !Set Clear To Transfer ; DO[31:CleartoTransfer]=ON ; ; !Set Clear Of Interference ; !Zone (If Necessary) ; DO[33:RbtClrZone1]=ON ; ; !Move ; P[6] 1000mm/sec FINE ; ; !Insert Process Application ; !as Required ; !CALL (MACRO) ; ; !Wait For Go To Dropoff 1 ; WAIT DI[51:GoToDropoff1]=ON ; ; !MACRO-Zone Check ; !(If Necessary) ; CALL ENTRZON1 ; ; !Reset Clear Of Dropoff 1 ; DO[51:ClrOfDropoff1]=OFF ; ; !Reset Clear To Transfer ; DO[31:CleartoTransfer]=OFF ; ; !Move Over Dropoff 1 ; P[7] 1000mm/sec CNT100 ; ; !MACRO-Verify Correct Tool ; !Call CHK_TOOL ; ; !Set Coll Guard Sensitivity ; COL GUARD ADJUST R[42] ; ; !Move To Dropoff 1 ; P[8] 1000mm/sec FINE ; ; !Set At Dropoff 1 ; DO[52:AtDropoff1]=ON ; ; !Wait for Reposition Tooling ; !WAIT GI[5:ToolingRepod1]=2 ; ; !MACRO-Open the Gripper ; Release Part(1) ; ; !Select Payload Without Parts ; PAYLOAD[2] ;


214: 215: 216: 217: 218: 219: 220: 221: 222: 223: 224: 225: 226:L 227: 228: 229: 230: 231: 232: 233: 234: 235: 236: 237: 238: 239: 240: 241: 242: 243: 244: 245:J 246: 247: 248: 249: 250: 251: 252: 253: 254:J 255: 256: 257: 258: 259: 260: 261: 262: 263: 264: 265: 266: 267: 268: 269: 270: 271: 272: 273: 274: 275:

104

; !Set Robot UTOOL Number ; UTOOL_NUM=1 ; ; !Set Robot UFRAME Number ; !If Necessary ; UFRAME_NUM=1 ; ; !Set Tooling Repositioned ; !GO[2:ReposTooling]=2 ; ; !Move Clr Robot Part Present ; P[9] 1000mm/sec FINE ; ; !MACRO-Verify No Part Present ; Check No Part(1) ; ; !Wait For Exit Dropoff 1 ; !(if necessary) ; WAIT DI[52:ExitDropoff1]=ON ; ; !Reset Coll Guard Sensitivity ; COL GUARD ADJUST ; ; !Reset At Dropoff 1 ; DO[52:AtDropoff1]=OFF ; ; !Reset Tooling Repositioned ; !GO[2:ReposTooling]=0 ; ; !Move Clear Of Dropoff 1 ; P[10] 100% CNT100 ; ; !Set Clear Of Dropoff 1 ; DO[51:ClrOfDropoff1]=ON ; ; !Set Clear Of Interference Zone ; DO[33:RbtClrZone1]=ON ; ; !Move Clear of Transfer ; P[11] 100% FINE ; ; !Set Clear To Transfer ; DO[31:CleartoTransfer]=ON ; ; !Reset Robot At Work ; DO[18:RbtAtWork]=OFF ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ; !Set Work Complete ; DO[19:WorkComplete]=ON ; ; !Wait For Work Complete Ack ; WAIT DI[32:WorkCompleteAck]=ON ; ; !Reset Work complete ; DO[19:WorkComplete]=OFF ; ; LBL[1000:End] ; ;

CUSW REL1.3

Dispense 1: !Carried Dispense Template ; 2: !******************************** ; 3: !Remove these comments ; 4: !Before Build!!! ; 5: !Rename Program as Necessary ; 6: !Edit Program to Match Part Type ; 7: ; 8: !Modify Zone Numbers and ; 9: !Locations as Required ; 10: ; 11: !Uncomment the MACROs before ; 12: ! finalizing the OLPs ; 13: ; 14: !EXAMPLE PROGRAM ONLY ; 15: !******************************** ; 16: ; 17: !Set Robot Payload ; 18: PAYLOAD[2] ; 19: ; 20: !Set Robot UTOOL Number ; 21: UTOOL_NUM=1 ; 22: ; 23: !Set Robot UFRAME Number ; 24: UFRAME_NUM=1 ; 25: ; 26: !MACRO-Setup App Specific IO ; 27: CALL APP_IO ; 28: ; 29: !Set Acknowledge Style ; 30: GO[1:ActiveStyleBits]=10 ; 31: ; 32: !Reset Coll Guard Sensitivity ; 33: COL GUARD ADJUST ; 34: ; 35: !Reset Clear To Transfer ; 36: DO[31:CleartoTransfer]=OFF ; 37: ; 38: !Move to Pounce ; 39:J P[1] 100% FINE ; 40: ; 41: !Set At Pounce Position Bit ; 42: DO[25:RbtAtPounce]=ON ; 43: ; 44: !Wait For Go To Work ; 45: !or Return Home From Pounce ; 46: WAIT DI[31:GoToWork]=ON OR DI[25:RetFromPounce]=ON ; 47: ; 48: !Check For Go To Work ; 49: IF DI[31:GoToWork]=ON,JMP LBL[20] ; 50: ; 51: !Return Home From Pounce ; 52: CALL MVHMPNCE ; 53: ; 54: !Jump To Program End ; 55: JMP LBL[1000] ; 56: ; 57: LBL[20:Go To Work] ; 58: ; 59: !Set Robot At Work ; 60: DO[18:RbtAtWork]=ON ; 61: ; 62: !Reset Robot At Pounce ; 63: DO[25:RbtAtPounce]=OFF ; 64: ; 65: !MACRO-Zone Check ; 66: !(if necessary) ; 67: !CALL ENTRZON1 ; 68: ; 69: !Pre-process Dispense Equipment ; 70: !(insert statements) ; 71: ; 72: !Wait for Dispenser Ready ; 73: WAIT (DI[385:Dsp1DispenRdy]=ON) ; 74: ;


75: 76: 77: 78: 79: 80: 81: 82: 83: 84: 85: 86: 87: 88: 89: 90: 91: 92: 93: 94: 95: 96: 97: 98: 99: 100: 101:L 102: 103: 104:L 105: 106: 107:L 108: 109: 110:L 111: 112: 113: 114: 115: 116: 117: 118: 119: 120: 121: 122: 123: 124: 125: 126: 127: 128: 129: 130: 131: 132: 133: 134: 135: 136: 137: 138: 139: 140: 141: 142: 143: 144: 145: 146: 147: 148: 149:

105

!Set Disp Robot in Process ; DO[393:Disp1RbtinPrc]=ON ; ; WAIT .10(sec) ; ; !Set Dispense Style ; GO[31:Disp1StyBits]=1 ; ; WAIT .10(sec) ; ; !Set Disp Style Strobe ; DO[394:Disp1StyStrobe]=ON ; ; !Wait for Disp in Process ; WAIT DI[386:Dsp1DispenInPrc]=ON ; !Reset Dispense Style ; GO[31:Disp1StyBits]=0 ; ; !Reset Disp Style Strobe ; DO[394:Disp1StyStrobe]=OFF ; ; !Set Coll Guard Sensitivity ; COL GUARD ADJUST R[42] ; ; !Move Seal Start, Turn On Gun ; P[2] 1000mm/sec CNT100 SS[1] ; !Move along Path ; P[3] 1000mm/sec CNT100 ; ; !Move To Seal End, Turn Off Gun P[4] 1000mm/sec CNT100 SE ; ; !Move Clear of Part ; P[5] 1000mm/sec FINE ; ; !Reset Coll Guard Sensitivity ; COL GUARD ADJUST ; ; !Set Dispense Complete ; DO[401:Disp1Complete]=ON ; ; !Wait for Dispense Vol. OK ; WAIT DI[387:Dsp1VolumeOK]=ON ; !Reset Dispense Complete ; DO[401:Disp1Complete]=OFF ; ; !Reset Disp Robot in Process ; DO[393:Disp1RbtinPrc]=OFF ; ; !Post-process Dispense Equip ; !(insert statements) ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ; !Set Work Complete ; DO[19:WorkComplete]=ON ; ; !Set Clear To Transfer ; DO[31:CleartoTransfer]=ON ; ; !Set Clear Of Interference Zone DO[33:RbtClrZone1]=ON ; ; !Wait For Work Complete Ack ; WAIT DI[32:WorkCompleteAck]=ON ; !Reset Work complete ; DO[19:WorkComplete]=OFF ; ; LBL[1000:End] ; ;

;

;

;

;

;

;

CUSW REL1.3

Spot Welding 1: !Carried Spot Welding Template ; 2: !******************************** ; 3: !Remove these comments ; 4: !Before Build!!! ; 5: !Rename Program as Necessary ; 6: !Edit Program to Match Part Type ; 7: ; 8: !Modify Zone Numbers and ; 9: !Locations as Required ; 10: ; 11: !Uncomment the MACROs before ; 12: ! finalizing the OLPs ; 13: ; 14: !EXAMPLE PROGRAM ONLY ; 15: !******************************** ; 16: ; 17: !Set Robot Payload ; 18: PAYLOAD[2] ; 19: ; 20: !Set Robot UTOOL Number ; 21: UTOOL_NUM=1 ; 22: ; 23: !Set Robot UFRAME Number ; 24: UFRAME_NUM=1 ; 25: ; 26: !MACRO-Setup App Specific IO ; 27: CALL APP_IO ; 28: ; 29: !Set Acknowledge Style ; 30: GO[1:ActiveStyleBits]=1 ; 31: ; 32: !Reset Clear To Transfer ; 33: DO[31:CleartoTransfer]=OFF ; 34: ; 35: !Move to Pounce ; 36:J P[1] 100% FINE ; 37: ; 38: !Set At Pounce Position Bit ; 39: DO[25:RbtAtPounce]=ON ; 40: ; 41: !Wait For Go To Work ; 42: !or Return Home From Pounce ; 43: WAIT DI[31:GoToWork]=ON OR DI[25:RetFromPounce]=ON ; 44: ; 45: !Check For Go To Work ; 46: IF DI[31:GoToWork]=ON,JMP LBL[20] ; 47: ; 48: !Return Home From Pounce ; 49: CALL MVHMPNCE ; 50: ; 51: !Jump To Program End ; 52: JMP LBL[1000] ; 53: ; 54: LBL[20:Go To Work] ; 55: ; 56: !Set Robot At Work ; 57: DO[18:RbtAtWork]=ON ; 58: ; 59: !Reset Robot At Pounce ; 60: DO[25:RbtAtPounce]=OFF ; 61: ; 62: !MACRO-Zone Check ; 63: !(if necessary) ; 64: CALL ENTRZON1 ; 65: ; 66: !Move to Weld 1 ; 67: !insert motion if necessary ; 68:L P[2] 1000mm/sec FINE ; 69: ; 70: !Select Schedule Weld 1 ;


71:L : 72: 73: 74: 75:L 76: 77: 78:L : 79: 80: 81:L 82: 83: 84: 85: 86: 87: 88: 89: 90: 91: 92: 93: 94: 95: 96: 97: 98: 99: 100: 101: 102: 103: 104: 105: 106: 107: 108: 109: 110: 111: 112: 113:J 114: 115: 116: 117: 118: 119: 120: 121: 122: 123: 124: 125: 126: 127: 128: 129: 130: 131: 132: 133: 134: 135: 136: 139: 140: ;

106

P[3] 100mm/sec FINE SPOT[SD=1,P=1,S=1,ED=1] ; ; !Move to Weld 2 ; !insert motion if necessary ; P[4] 1000mm/sec FINE ; ; !Select Schedule Weld 2 ; P[5] 100mm/sec FINE SPOT[SD=1,P=1,S=1,ED=1] ; ; !Move Clear of Clamps ; P[6] 1000mm/sec FINE ; ; !Set Clear to Unclamp Early ; DO[65:Clr2UnclampEarly]=ON ; ; !Check for Tip Dress Req ; IF DI[28:TipDressGunReq]=ON,JMP LBL[30] ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ; !Set Work Complete ; DO[19:WorkComplete]=ON ; ; !Set Clear To Transfer ; DO[31:CleartoTransfer]=ON ; ; !Set Clear Of Interference Zone ; DO[33:RbtClrZone1]=ON ; ; !Wait For Work Complete Ack ; WAIT DI[32:WorkCompleteAck]=ON ; ; !Reset Work complete ; DO[19:WorkComplete]=OFF ; ; JMP LBL[1000] ; ; LBL[30] ; ; !Move Clear of Transfer ; !To Tip Dress ; P[7] 50% FINE ; ; !Set Work Complete ; DO[19:WorkComplete]=ON ; ; !Set Clear To Transfer ; DO[31:CleartoTransfer]=ON ; ; !Set Clear Of Interference Zone ; DO[33:RbtClrZone1]=ON ; ; !Wait For Work Complete Ack ; WAIT DI[32:WorkCompleteAck]=ON ; ; !Reset Work complete ; DO[19:WorkComplete]=OFF ; ; !MACRO-Tip Dress Gun 1 ; CALL TPDRSGN1(62) ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ; CALL WR_UPDAT(1,0) ; ; LBL[1000:End] ;

CUSW REL1.3

Stud Welding 1: !Carried Stud Welding Template ; 2: !******************************** ; 3: !Remove these comments ; 4: !Before Build!!! ; 5: !Rename Program as Necessary ; 6: !Edit Program to Match Part Type ; 7: ; 8: !Modify Zone Numbers and ; 9: !Locations as Required ; 10: ; 11: !Uncomment the MACROs before ; 12: ! finalizing the OLPs ; 13: ; 14: !EXAMPLE PROGRAM ONLY ; 15: !******************************** ; 16: ; 17: !Set Robot Payload ; 18: PAYLOAD[2] ; 19: ; 20: !Set Robot UTOOL Number ; 21: UTOOL_NUM=1 ; 22: ; 23: !Set Robot UFRAME Number ; 24: UFRAME_NUM=1 ; 25: ; 26: !MACRO-Setup App Specific IO ; 27: CALL APP_IO ; 28: ; 29: !Set Acknowledge Style ; 30: GO[1:ActiveStyleBits]=1 ; 31: ; 32: !Reset Clear To Transfer ; 33: DO[31:CleartoTransfer]=OFF ; 34: ; 35: !Move to Pounce ; 36:J P[1] 100% FINE ; 37: ; 38: !Set At Pounce Position Bit ; 39: DO[25:RbtAtPounce]=ON ; 40: ; 41: !Wait For Go To Work ; 42: !or Return Home From Pounce ; 43: WAIT DI[31:GoToWork]=ON OR DI[25:RetFromPounce]=ON ; 44: ; 45: !Check For Go To Work ; 46: IF DI[31:GoToWork]=ON,JMP LBL[20] ; 47: ; 48: !Return Home From Pounce ; 49: CALL MVHMPNCE ; 50: ; 51: !Jump To Program End ; 52: JMP LBL[1000] ;


53: 54: 55: 56: 57: 58: 59: 60: 61: 62: 63: 64: 65: 66: 67: 68:L 69: 70: 71:L : 72: 73: 74: 75:L 76: 77: 78:L : 79: 80: 81:L 82: 83: 84: 85: 86: 87: 88: 89: 90: 91: 92: 93: 94: 95: 96: 97: 98: 99: 100: 101: 102: 103:

107

; LBL[20:Go To Work] ; ; !Set Robot At Work ; DO[18:RbtAtWork]=ON ; ; !Reset Robot At Pounce ; DO[25:RbtAtPounce]=OFF ; ; !MACRO-Zone Check ; !(if necessary) ; CALL ENTRZON1 ; ; !Move to Weld 1 ; !insert motion if necessary ; P[2] 1000mm/sec FINE ; ; !Select Schedule Weld 1 ; P[3] 100mm/sec FINE SPOT[S=1] ; ; !Move to Weld 2 ; !insert motion if necessary ; P[4] 1000mm/sec FINE ; ; !Select Schedule Weld 2 ; P[5] 100mm/sec FINE SPOT[S=1] ; ; !Move Clear of Clamps ; P[6] 1000mm/sec FINE ; ; !Set Clear to Unclamp Early ; DO[65:Clr2UnclampEarly]=ON ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ; !Set Work Complete ; DO[19:WorkComplete]=ON ; ; !Set Clear To Transfer ; DO[31:CleartoTransfer]=ON ; ; !Set Clear Of Interference Zone ; DO[33:RbtClrZone1]=ON ; ; !Wait For Work Complete Ack ; WAIT DI[32:WorkCompleteAck]=ON ; ; !Reset Work complete ; DO[19:WorkComplete]=OFF ; ;

CUSW REL1.3

Tip Change (Style #3) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23: 24: 25: 26: 27: 28: 29: 30: 31: 32: 33: 34: 35: 36: 37: 37: 37: 37: 38: 39: 40:

!Tip Change Template ; !****************************** ; !Remove these comments ; !Before Build!!! ; !Rename Program as Necessary ; !Edit Program to Match Part Type ; ; !Modify Zone Numbers and ; !Locations as Required ; ; !Uncomment the MACROs before ; ! finalizing the OLPs ; ; !EXAMPLE PROGRAM ONLY ; !****************************** ; ; !Set Robot Payload ; PAYLOAD[2] ; ; !Set Robot UTOOL Number ; UTOOL_NUM=1 ; ; !Set Robot UFRAME Number ; UFRAME_NUM=1 ; ; !MACRO-Setup App Specific IO ; CALL APP_IO ; ; !Set Acknowledge Style ; GO[1:ActiveStyleBits]=3 ; ; !Insert Dress Approach Movement ; !(if necessary) ; ; !MACRO-Tip Dress Gun 1 ; CALL TPDRSGN1(0) ; ; !Wait for TipDressComplete ; WAIT (1) sec. ; ; !Reset Tip Dress Complete ; DO[29:TipDressComplt]=OFF ; ;

41: 42:J 43: 44: 45: 46: 47: 48: 49: 50: 51: 52: 53: 54: 55: 56: 57: 58: 59: 60: 61: 62: 63: 64: 65: 66: 67: 68: 69: 70: 71: 72: 73: 74: 75: 76: 77: 78: 79: 80: 81: 82:

!Move to Tip Change Position ; P[1] 100% FINE ; ; !Set Robot at Service ; DO[26:RbtAtService]=ON ; ; !Set Ready for Tip Change ; DO[30:RdyForTipChg]=ON ; ; !Wait for Service Complete ; WAIT (DI[26:ServiceCompltReq]=ON) ; ; !Reset Robot at Service ; DO[26:RbtAtService]=OFF ; ; !Reset Ready for Tip Change ; DO[30:RdyForTipChg]=OFF ; ; !MACRO-Reset Stepper ; CALL RST_STPR ; ; !MACRO-Seat Caps Gun 1 ; CALL TW_PRSRT(1,500,2,4,1,10,5,15) ; ; !Tip Wear Compensation Gun 1 ; CALL WR_UPDAT(1,0) ; ; !Insert Dress Approach Movement ; !(if necessary) ; ; !Pulse W1 Reset Water Saver ; DO[586:W1RstWtrSvr]=PULSE,1.0sec ; ; !Wait for WaterOK ; WAIT (DI[785:W1OKtoWeld]=ON) ; ; !MACRO-Tip Dress Gun 1 ; CALL TPDRSGN1(62) ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ;

Purge (Style #4) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23:

!Purge Template ; !****************************** ; !Remove these comments ; !Before Build!!! ; !Rename Program as Necessary ; !Edit Program to Match Part Type ; ; !Modify Zone Numbers and ; !Locations as Required ; ; !Uncomment the MACROs before ; ! finalizing the OLPs ; ; !EXAMPLE PROGRAM ONLY ; !****************************** ; ; !MACRO-Setup App Specific IO ; CALL APP_IO ; ; !Set Acknowledge Style ; GO[1:ActiveStyleBits]=3 ; ; !Set Ext Purge 1 in Progress ;


24: 25: 26: 27: 28: 29: 30: 31: 32: 33: 34: 35: 36: 37: 38: 39: 40: 41: 42: 43: 44: 45: 46:

108

DO[97:ExtPurg1InProgrs]=ON ; ; !Pre-process Dispense Equipment ; !(insert statements) ; ; !Turn On Gun-Purge Schedule ; DO[416:Disp1Purge]=ON ; ; !Wait 'X' Seconds ; WAIT 7.00(sec) ; ; !Turn Off Gun ; DO[416:Disp1Purge]=OFF ; ; !Post-process Disp Equipment ; !(insert statements) ; ; !Reset Ext Purge 1 in Progress ; DO[97:ExtPurg1InProgrs]=OFF ; ; !MACRO-Home IO (if necessary) ; CALL HOME_IO ; ;

CUSW REL1.3

Tip Burn In (Style #5) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20:

!Tip Burn In Template ; !****************************** ; !Remove these comments ; !Before Build!!! ; !Rename Program as Necessary ; !Edit Program to Match Part Type ; ; !Modify Zone Numbers and ; !Locations as Required ; ; !Uncomment the MACROs before ; ! finalizing the OLPs ; ; !EXAMPLE PROGRAM ONLY ; !****************************** ; ; !Set Robot Payload ; PAYLOAD[2] ; ; !Set Robot UTOOL Number ;

21: 22: 23: 24: 25: 29: 30: 31: 32: 33: 34:J 35: 36: 37: 38: 39: 40: 41: 42: 43:

UTOOL_NUM=1 ; ; !Set Robot UFRAME Number ; UFRAME_NUM=1 ; ; !Set Acknowledge Style ; GO[1:ActiveStyleBits]=5 ; ; !Move to Service Position ; !if necessary ; PR[5] 100% FINE ; ; !MACRO-Tip Burn In ; CALL TPBURNIN ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ; !MACRO-Home IO ; CALL MOVE_IO ;

Service Program (Style #6) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23:

!Service Program Template ; !****************************** ; !Remove these comments ; !Before Build!!! ; !Rename Program as Necessary ; !Edit Program to Match Part Type ; ; !Modify Zone Numbers and ; !Locations as Required ; ; !Uncomment the MACROs before ; ! finalizing the OLPs ; ; !EXAMPLE PROGRAM ONLY ; !****************************** ; ; !Set Robot Payload ; PAYLOAD[2] ; ; !Set Robot UTOOL Number ; UTOOL_NUM=1 ; ; !Set Robot UFRAME Number ;

24: 25: 26: 27: 28: 29: 30: 31: 32: 33:J 34: 35: 36: 37: 38: 39: 40: 41: 42: 43: 44: 45: 46:

UFRAME_NUM=1 ; ; !MACRO-Setup App Specific IO ; CALL APP_IO ; ; !Set Acknowledge Style ; GO[1:ActiveStyleBits]=6 ; ; !Move to Service Position ; PR[5] 100% FINE ; ; !Set Robot at Service ; DO[26:RbtAtService]=ON ; ; !Wait for Service Complt Req ; WAIT (DI[26:ServiceCompltReq]=ON) ; !Reset Robot at Service ; DO[26:RbtAtService]=OFF ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ;

;

Tip Dress Gun 1 (Style #7) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20:

!Tip Dress 1st Gun Template ; !****************************** ; !Remove these comments ; !Before Build!!! ; !Rename Program as Necessary ; !Edit Program to Match Part Type ; ; !Modify Zone Numbers and ; !Locations as Required ; ; !Uncomment the MACROs before ; ! finalizing the OLPs ; ; !EXAMPLE PROGRAM ONLY ; !****************************** ; ; !Set Robot Payload ; PAYLOAD[2] ; ; !Set Robot UTOOL Number ;


21: 22: 23: 24: 25: 26: 27: 28: 29: 30: 31: 32: 33: 34: 35: 36: 37: 38: 39: 40:

109

UTOOL_NUM=1 ; ; !Set Robot UFRAME Number ; UFRAME_NUM=1 ; ; !MACRO-Setup App Specific IO ; CALL APP_IO ; ; !Set Acknowledge Style ; GO[1:ActiveStyleBits]=7 ; ; !Insert Approach Movement ; !(if necessary) ; ; !MACRO-Tip Dress Gun 1 ; CALL TPDRSGN1(60) ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ;

CUSW REL1.3

Tip Dress Gun 2 (Style #8) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20:

!Tip Dress 2nd Gun Template ; !****************************** ; !Remove these comments ; !Before Build!!! ; !Rename Program as Necessary ; !Edit Program to Match Part Type ; ; !Modify Zone Numbers and ; !Locations as Required ; ; !Uncomment the MACROs before ; ! finalizing the OLPs ; ; !EXAMPLE PROGRAM ONLY ; !****************************** ; ; !Set Robot Payload ; PAYLOAD[2] ; ; !Set Robot UTOOL Number ;

21: 22: 23: 24: 25: 26: 27: 28: 29: 30: 31: 32: 33: 34: 35: 36: 37: 38: 39: 40:

UTOOL_NUM=1 ; ; !Set Robot UFRAME Number ; UFRAME_NUM=1 ; ; !MACRO-Setup App Specific IO ; CALL APP_IO ; ; !Set Acknowledge Style ; GO[1:ActiveStyleBits]=8 ; ; !Insert Approach Movement ; !(if necessary) ; ; !MACRO-Tip Dress Gun 2 ; CALL TPDRSGN2(61) ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ;

Tool Change (Style #9) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20:

!Tool Change Template ; !****************************** ; !Remove these comments ; !Before Build!!! ; !Rename Program as Necessary ; !Edit Program to Match Part Type ; ; !Modify Zone Numbers and ; !Locations as Required ; ; !Uncomment the MACROs before ; ! finalizing the OLPs ; ; !EXAMPLE PROGRAM ONLY ; !****************************** ; ; !Set Robot Payload ; PAYLOAD[2] ; ; !Set Robot UTOOL Number ;


21: 22: 23: 24: 25: 26: 27: 28: 29: 30: 31: 32: 33: 34: 35: 36: 37: 38: 39: 40:

110

UTOOL_NUM=1 ; ; !Set Robot UFRAME Number ; UFRAME_NUM=1 ; ; !MACRO-Setup App Specific IO ; CALL APP_IO ; ; !Set Acknowledge Style ; GO[1:ActiveStyleBits]=9 ; ; !Set Desired Tool ID ; R[2]=GI[4:PickToolBits] ; ; !MACRO-Check Tool on Wrist ; CALL CHK_TOOL ; ; !MACRO-Return To Home ; CALL MOV_HOME ; ;

CUSW REL1.3

Check ATI Errors (Macro) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23: 24: 25: 26: 27: 28: 29: 30: 31: 32: 33: 34: 35: 36: 37: 38: 39: 40: 41: 42: 43: 44: 45: 46: 47: 48: 49: 50: 51: 52: 53: 54: 55: 56: 57: 58: 59: 60: 61: 62: 63: 64: 65: 66: 67: 68: 69: 70: 71: 72: 73: 74: 75:

!****************************** ; !MACRO CHECK ATI ERRORS ; !****************************** ; !Parameters: AR[] ; !1: Current Sequence ; !****************************** ; ; !Jump to Current Sequence ; R[16]=AR[1] ; JMP LBL[R[16]] ; ; !****************************** ; !READY TO PICK/LATCH/UNLATCH ; !****************************** ; LBL[1:ReadyToPick] ; LBL[3:Latch] ; LBL[7:Unlatch] ; ; !Set ATI Recovery Method ; R[17]=1 ; ; IF (DI[648:RTLMismatch]),JMP LBL[648] ; IF (DI[649:TSIVMismatch]),JMP LBL[649] ; IF (DI[650:LatchOverLoad]),JMP LBL[650] ; IF (DI[651:UnlatchOverLoad]),JMP LBL[651] ; IF (DI[652:SpareOverload]),JMP LBL[652] ; IF (DI[659:TSIVFault]),JMP LBL[659] ; IF (DI[660:RTLFault]),JMP LBL[660] ; IF (DI[653:RTLrtlvMismatch]),JMP LBL[653] ; IF (DI[654:TSIVtsrvMismatch]),JMP LBL[654] ; IF (DI[655:UnsafeUnlatch]),JMP LBL[655] ; IF (DI[656:LckUnlckSensFlt]),JMP LBL[656] ; IF (DI[657:LatchNotComplt]),JMP LBL[657] ; IF (DI[658:UnlatchNotComplt]),JMP LBL[658] ; ; !OK - Exit ; JMP LBL[999] ; ; !****************************** ; !READY TO LATCH ; !****************************** ; LBL[2:ReadyToLatch] ; ; !Set ATI Recovery Method ; R[17]=0 ; ; IF (!DI[636:ReadyToLock1]),JMP LBL[636] ; IF (!DI[637:ReadyToLock2]),JMP LBL[637] ; ; !OK - Exit ; JMP LBL[999] ; ; !****************************** ; !EXIT PICK/RDY TO DROP/EXT DROP ; !****************************** ; LBL[4:ExitPick] ; LBL[5:ReadyToDrop] ; LBL[8:ExitDrop] ; ; !Set ATI Recovery Method ; R[17]=0 ; ; IF (DI[648:RTLMismatch]),JMP LBL[648] ; IF (DI[649:TSIVMismatch]),JMP LBL[649] ; IF (DI[650:LatchOverLoad]),JMP LBL[650] ; IF (DI[651:UnlatchOverLoad]),JMP LBL[651] ; IF (DI[652:SpareOverload]),JMP LBL[652] ; IF (DI[659:TSIVFault]),JMP LBL[659] ; IF (DI[660:RTLFault]),JMP LBL[660] ; IF (DI[653:RTLrtlvMismatch]),JMP LBL[653] ; IF (DI[654:TSIVtsrvMismatch]),JMP LBL[654] ; IF (DI[655:UnsafeUnlatch]),JMP LBL[655] ; IF (DI[656:LckUnlckSensFlt]),JMP LBL[656] ; IF (DI[657:LatchNotComplt]),JMP LBL[657] ; IF (DI[658:UnlatchNotComplt]),JMP LBL[658] ;


76: 77: 78: 79: 80: 81: 82: 83: 84: 85: 86: 87: 88: 89: 90: 91: 92: 93: 94: 95: 96: 97: 98: 99: 100: 101: 102: 103: 104: 105: 106: 107: 108: 109: 110: 111: 112: 113: 114: 115: 116: 117: 118: 119: 120: 121: 122: 123: 124: 125: 126: 127: 128: 129: 130: 131: 132: 133: 134: 135: 136: 137: 138: 139: 140: 141: 142: 143: 144: 145: 146: 147: 148: 149: 150:

111

; !OK - Exit ; JMP LBL[999] ; ; !****************************** ; !READY TO UNLATCH ; !****************************** ; LBL[6:ReadyToUnlatch] ; ; !Set ATI Recovery Method ; R[17]=0 ; ; IF (!DI[640:ToolStndIntlkV1]),JMP LBL[640] ; IF (!DI[641:ToolStndIntlkV2]),JMP LBL[641] ; ; !OK - Exit ; JMP LBL[999] ; ; !****************************** ; !ERROR HANDLING ; !****************************** ; ; !AUX POWER ; LBL[635] ; UALM[7] ; JMP LBL[900] ; ; !READY TO LOCK1 ; LBL[636] ; UALM[8] ; JMP LBL[900] ; ; !READY TO LOCK2 ; LBL[637] ; UALM[9] ; JMP LBL[900] ; ; !TOOL STAND INTERLOCK1 ; LBL[640] ; UALM[10] ; JMP LBL[900] ; ; !TOOL STAND INTERLOCK2 ; LBL[641] ; UALM[11] ; JMP LBL[900] ; ; !RTL MISMATCH ; LBL[648] ; UALM[12] ; JMP LBL[900] ; ; !TSIV MISMATCH ; LBL[649] ; UALM[13] ; JMP LBL[900] ; ; !LATCH OVERLOAD ; LBL[650] ; UALM[14] ; JMP LBL[900] ; ; !UNLATCH OVERLOAD ; LBL[651] ; UALM[15] ; JMP LBL[900] ; ; !SPARE OVERLOAD ; LBL[652] ; UALM[16] ; JMP LBL[900] ; ; !RTLRTLV MISMATCH ; LBL[653] ; UALM[17] ;

CUSW REL1.3

151: 152: 153: 154: 155: 156: 157: 158: 159: 160: 161: 162: 163: 164: 165: 166: 167: 168: 169: 170: 171: 172: 173: 174: 175: 176: 177: 178: 179: 180: 181: 182: 183: 184: 185: 186: 187: 188:

JMP LBL[900] ; ; !TSIVTSRV MISMATCH ; LBL[654] ; UALM[18] ; JMP LBL[900] ; ; !UNSAFE UNLATCH ; LBL[655] ; UALM[19] ; JMP LBL[900] ; ; !LOCK UNLOCK SENSOR FAULT ; LBL[656] ; UALM[20] ; JMP LBL[900] ; ; !LATCH NOT COMPLETE ; LBL[657] ; UALM[21] ; JMP LBL[900] ; ; !UNLATCH NOT COMPLETE ; LBL[658] ; UALM[22] ; JMP LBL[900] ; ; !TSIV FAULT ; LBL[659] ; UALM[23] ; JMP LBL[900] ; ; !RTL FAULT ; LBL[660] ; UALM[24] ; JMP LBL[900] ; ; !****************************** ;

189: 190: 191: 192: 193: 194: 195: 196: 197: 198: 199: 200: 201: 202: 203: 204: 205: 206: 207: 208: 209: 210: 211: 212: 213: 214: 215: 216: 217: 218: 219: 220: 221: 222: 223: 224: 225:

!RECOVERY ; !****************************** ; ; LBL[900:Recovery] ; ; !Check Recovery Type ; IF R[17]=1,JMP LBL[910] ; ; !Set Clear Errors ; DO[635:ClearErrs]=ON ; ; !Wait 2 Seconds ; WAIT 2.00(sec) ; ; !Reset Clear Errors ; DO[635:ClearErrs]=OFF ; ; !Retry ; JMP LBL[R[16]] ; ; LBL[910] ; ; !Reset Latch and Unlatch Tool ; DO[632:LatchOrLock]=OFF ; DO[633:UnlatchOrUnlock]=OFF ; ; !Set Clear Errors ; DO[635:ClearErrs]=ON ; ; !Wait 2 Seconds ; WAIT 2.00(sec) ; ; !Reset Clear Errors ; DO[635:ClearErrs]=OFF ; ; LBL[999:End] ; ;

Check Tool (Macro) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16:

!****************************** ; !MACRO CHECK TOOL ON WRIST ; !****************************** ; ; LBL[1:Verify Tool] ; ; !Set Current Tool ID and ; !Line Number ; R[1]=(GI[41:ToolIDswtch1Bits]) ; R[8]=(GI[45:ToolIDSwtch5Bits]) ; GO[3:ToolIDOnWrstBits]=R[1] ; ; !Is Tool ID Correct? ; IF R[1]=R[2],JMP LBL[999] ; ; !Is Tool on Wrist? ;


17: LBL[2] 18: 19: 21: 22: 23: 24: 25: 26: 27: 28: 29: 30: 31: 32: 33:

112

IF (!DI[644:ToolPresent] AND R[1]=15),JMP ; ; !Drop Prep and Drop Tool ; CALL PREPDROP ; ; JMP LBL[1] ; ; LBL[2:Pick Tool] ; ; !Select Pick Fixture & Pick ; CALL PREPPICK ; ; JMP LBL[1] ; ; LBL[999:End] ; ;

CUSW REL1.3

Drop Tool Nest 1 (Macro) 1: !************* **************** ***************** * ; 2: !MACRO DROP TOOL IN NEST 1 ; 3: !************* **************** ***************** * ; 4: ; 5: UTOOL_NUM=5 ; 6: UFRAME_NUM=0 ; 7: ; 8: DO[635:ClearErrs DO[635:ClearErrs]=PULSE,1.0sec ]=PULSE,1.0sec ; 9: ; 10: !Set Request to Enter Tool Nest ; 11: DO[71:Req2Entr ToolNest]=ON ; 12: ; 13: !Wait Clear to Enter Tool Nest ; 14: WAIT DI[81:Clr2EntTo olNest]=ON ; 15: ; 16: !Reset Clear of Tool Nest ; 17: DO[72:ClearOfT oolNest]=OFF ; 18: ; 19: !Reset Request to Enter Nest ; 20: DO[71:Req2Entr ToolNest]=OFF ; 21: ; 22: !MACRO-Set Tool Device Offline ; 23: CALL DV_OFFLN(2,31,1 0) ; 23: CALL DV_OFFLN(2,39,1 0) ; 24: ; 25: !Move to Tool Nest Perch/Approach ; 26:J P[3:Perch In] 100% FINE ; 27: ; 28: !PR[111:ToolOf fset1] ; 29: !X=-150 Y=0 Z=65 Rx=0 Ry=0 Rz=0 ; 30:L PR[101:ToolNest1Drop] 1200mm/sec FINE Tool_Offset,PR[111:ToolOffset1] : ; 31: ; 32: !PR[112:ToolOffs !PR[112:ToolOffset2] et2] ; 33: !X=-5 Y=0 Z=65 Rx=0 Ry=0 Rz=0 ; 34:L PR[101:ToolNest1Drop] 200mm/sec FINE Tool_Offset,PR[112:ToolOffset2] : ; 35: ; 36: !PR[113:ToolOf fset3] ; 37: !X=0 Y=0 Z=25 Rx=0 Ry=0 Rz=0 ; 38:L PR[101:ToolNest1Drop] 50mm/sec FINE Tool_Offset,PR[113:ToolOffset3] : ; 39: ; 40: !MACRO-ATI State Check - Seq5 ; 41: IF DO[645:General Faults]=ON,CALL ATI_CHCK(5) ; 42: ; 43: !Reset Out of Nest ; 44: DO[637:OutOfNe st]=OFF ; 45: ; 46: !Move to Tool Nest ; 47: UTOOL_NUM=5 ; 48:L PR[101:ToolNes t1Drop] 50mm/sec FINE ; 49: ; 50: !Wait for Tool in Nest 1 ; 51: WAIT DI[73:ToolInNes t1]=ON ; 52: ; 53: !MACRO-ATI State Check - Seq6 ; 54: CALL ATI_CHCK(6) ; 55: ; 56: LBL[7:RetryATI Seq7] ; 57: ; 58: !Reset Latch Tool ; 59: DO[632:LatchOr Lock]=OFF ; 60: ; 61: !Set Unlatch Tool ; 62: DO[633:Unlatch OrUnlock]=ON ; 63: ; 64: !Wait for ATI switches to settle in ; 64: WAIT DI[633:ToolUnLo cked]=ON TIMEOUT,LBL[63 3] ; 65: LBL[633] ; 66: ;


113

67: !Wait for ATI ; 68: WAIT ((DI[633:ToolUn Locked] AND !DI[632:ToolLocked]) OR : DO[645:GeneralF aults]) ; 69: ; 70: !Check for Errors ; 71: IF DO[645:General Faults]=OFF,JMP LBL[17] ; 72: ; 73: !MACRO-ATI State Check - Seq7 ; 74: CALL ATI_CHCK(7) ; 75: ; 76: JMP LBL[7] ; 77: ; 78: LBL[17:ATIUnloc ked] ; 79: ; 80: !Set Payload Without Tool ; 81: PAYLOAD[2] ; 82: ; 83: UTOOL_NUM=9 ; 84: UFRAME_NUM=0 ; 85: ; 86:L PR[106:ToolNest 1Pick] 150mm/sec FINE ; 87: ; 87: !Move Clear of Tool in Nest IO ; 88: !PR[114:ToolOff set4] ; 89: !X=0 Y=0 Z=-15 Rx=0 Ry=0 Rz=0 ; 90:L PR[106:ToolNest1Pick] 150mm/sec FINE Tool_Offset,PR[114:ToolOffset4] : ; 91: ; 92: !Wait for Tool in Nest 1 ; 93: !Check for Disengagement ; 94: !of Tool Changer ; 95: WAIT DI[73:ToolInNes t1]=ON ; 96: ; 97: !MACRO-ATI State Check - Seq8 ; 98: IF DO[645:General Faults]=OFF,JMP LBL[8] ; 99: ; 100: !MACRO-ATI State Check ; 101: CALL ATI_CHCK(8) ; 102: ; 103: !Wait for Tool in Nest 1 ; 104: !Check for Disengagement ; 105: !of Tool Changer ; 106: WAIT DI[73:ToolInNes t1]=ON ; 107: ; 108: LBL[8] ; 109: !Clear of Tool in Nest ; 110: ; 111: !PR[115:ToolOff set5] ; 112: !X=0 Y=0 Z=-155 Rx=0 Ry=0 Rz=0 ; 113:L PR[106:ToolNest1Pick] 150mm/sec FINE Tool_Offset,PR[115:ToolOffset5] : ; 114: ; 115: !Reset Unlatch Tool ; 116: DO[633:UnlatchO rUnlock]=OFF ; 117: ; 118: !Set Out of Nest ; 119: DO[637:OutOfNes t]=ON ; 120: ; 121: !Clear Ati Errors ; 122: DO[635:ClearErr s]=PULSE,1.0sec ; 123: ; 124: UTOOL_NUM=9 ; 125: UFRAME_NUM=0 ; 126: ; 127: !Move Clear of Tool Nest ; 128:J P[2:Perch Out] 50% FINE ;

CUSW REL1.3

Pick Tool Nest 1 (Macro) 1: !************* **************** ***************** * ; 2: !MACRO PICK TOOL FROM NEST 1 ; 3: !************* **************** ***************** * ; 4: ; 5: UTOOL_NUM=9 ; 6: UFRAME_NUM=0 ; 7: ; 8: !Move to Tool Nest Perch ; 9:J P[1:Perch In] 100% FINE ; 10: ; 11: !Clear Ati Errors ; 12: DO[635:ClearEr rs]=PULSE,1.0sec ; 13: ; 14: !Set Request to Enter Tool Nest ; 15: DO[71:Req2Entr ToolNest]=ON ; 16: ; 17: !Wait Clear to Enter Tool Nest ; 18: WAIT DI[81:Clr2EntTo olNest]=ON ; 19: ; 20: !Reset Clear of Tool Nest ; 21: DO[72:ClearOfT oolNest]=OFF ; 22: ; 23: !Reset Request to Enter Nest ; 24: DO[71:Req2Entr ToolNest]=OFF ; 25: ; 26: ! 27: ; 28: !Move Clear of Tool in Nest IO ; 29: !PR[115:ToolOf fset5] ; 30: !X=0 Y=0 Z=-155 Rx=0 Ry=0 Rz=0 ; 31:L PR[106:ToolNest1Pick] 150mm/sec FINE Tool_Offset,PR[115:ToolOffset5] : ; 32: ; 33: !PR[116:ToolOf fset6] ; 34: !X=0 Y=0 Z=-50 Rx=0 Ry=0 Rz=0 ; 35:L PR[106:ToolNest1Pick] 150mm/sec FINE Tool_Offset,PR[116:ToolOffset6] : ; 36: !Reset Out of Nest ; 37: DO[637:OutOfNe st]=OFF ; 38: ; 39: LBL[10] ; 40: ; 41: !Check ATI Sensor States ; 42: WAIT (!DI[632:ToolL ocked] AND !DI[633:ToolUnLocked]) TIMEOUT,LBL[90] ; 43: ; 44: LBL[1:RetryATI Seq1] ; 45: ; 46: !Reset Latch Tool ; 47: DO[632:LatchOr Lock]=OFF ; 48: ; 49: !Set Unlatch Tool ; 50: DO[633:Unlatch OrUnlock]=ON ; 51: ; 52: WAIT DI[633:ToolUnLo cked]=ON TIMEOUT,LBL[633 ] ; 53: LBL[633] ; 54: ; 55: !Wait for ATI Feedback ; 56: WAIT (DI[633:ToolUnL ocked] OR DO[645:GeneralFaults]) ; 57: ; 58: !Check for General Errors ; 59: IF DO[645:General Faults]=OFF,JMP LBL[11] ; 60: ; 61: !ATI State Check - Seq1 ; 62: CALL ATI_CHCK(1) ; 63: ; 64: JMP LBL[1] ; 65: ; 66: LBL[11:ToolUnl ocked] ; 67: ; 68: !Move to Tool Nest ; 69: ; 70: !PR[117:ToolOf fset7] ;


114

71: !X=0 Y=0 Z=-25 Rx=0 Ry=0 Rz=0 ; 72:L PR[106:ToolNest1Pick] 150mm/sec FINE Tool_Offset,PR[117:ToolOffset7] : ; 73:L PR[106:ToolNest 1Pick] 50mm/sec FINE ; 74: ; 75: !ATI State Check - Seq2 ; 76: CALL ATI_CHCK(2) ; 77: ; 78: LBL[3:RetryATIS eq3] ; 79: ; 80: !Reset Unlatch Tool ; 81: DO[633:UnlatchO rUnlock]=OFF ; 82: ; 83: !Set Latch Tool ; 84: DO[632:LatchOrL ock]=ON ; 85: ; 86: !MACRO-Set Tool Devices Online ; 87: CALL DV_ONLN(2,31,0) ; 87: CALL DV_ONLN(2,39,0) ; 88: ; 89: WAIT DI[632:ToolLock ed]=ON TIMEOUT,LBL[63 2] ; 90: LBL[632] ; 91: ; 92: !Wait for ATI ; 93: WAIT ((DI[632:ToolLo cked] AND !DI[633:ToolUnLocked]) OR : DO[645:GeneralF aults]) ; 94: ; 95: !Check for Errors ; 96: IF DO[645:General Faults]=OFF,JMP LBL[13] ; 97: ; 98: !ATI State Check - Seq3 ; 99: CALL ATI_CHCK(3) ; 100: ; 101: JMP LBL[3] ; 102: ; 103: LBL[13:ToolLock ed] ; 104: ; 105: !Set Payload With Tool ; 106: PAYLOAD[1] ; 107: ; 108: !Verify Tool ID ; 109: IF GI[41:ToolIDswt ch1Bits]<>R[2:De ch1Bits]<>R[2:Desired sired Tool ID],JMP LBL[6] ; 110: ; 111: !Set Frames with new Tool ; 111: UTOOL_NUM=5 ; 112: UFRAME_NUM=0 ; 113: ; 114: !Move Clear of Tool in Nest IO ; 115:L PR[6:ToolNest1] 50mm/sec FINE ; 116: ; 117: !PR[113:ToolOff set3] ; 118: !X=0 Y=0 Z=25 Rx=0 Ry=0 Rz=0 ; 119:L PR[101:ToolNest1Drop] 50mm/sec FINE Tool_Offset,PR[113:ToolOffset3] : ; 120: !ATI State Check - Seq4 ; 121: IF DO[645:GeneralF aults]=ON,CALL ATI_CHCK(4) ; 122: ; 123: !Set Out of Nest ; 124: DO[637:OutOfNes t]=ON ; 125: ; 126: !PR[112:ToolOff set2] ; 127: !X=-5 Y=0 Z=65 Rx=0 Ry=0 Rz=0 ; 128:L PR[101:ToolNest1Drop] 200mm/sec FINE Tool_Offset,PR[112:ToolOffset2] : ; 129: !Move Clear Tool Nest ; 130: ; 131: !PR[111:ToolOff set1] ; 132: !X=-150 Y=0 Z=65 Rx=0 Ry=0 Rz=0 ; 133:L PR[101:ToolNest1Drop] 1200mm/sec FINE Tool_Offset,PR[111:ToolOffset1] : ;

CUSW REL1.3

134: 134: 135: 136: 137: 138:L 139: 140: 141: 142: 143: 144: 145: 146: 147:

!Set Frames with new Tool again ; UTOOL_NUM=5 ; UFRAME_NUM=0 ; ; !Move to Tool Nest Perch ; P[2:Perch Out] 2000mm/sec FINE ; ; !Check If Device Is Online ; CALL DV_STCHK(2,31,3 ) ; IF R[3:Devnet Status]=2,JMP LBL[99] ; ; !Set Device Online ; CALL DV_ONLN(2,31,30 ) ; JMP LBL[99] ; ;


148: 149: 150: 151: 152: 153: 154: 155: 156: 157: 158: 159: 160: 161: 162:

115

LBL[6:ToolIDMis match] ; ; !User Alarm - Unrecognized ; !Tool on End-effector ; UALM[1] ; ABORT ; ; LBL[90:ATILockU nlockSns] ; ; !User Alarm - Lock or Unlock ; !Sensor Incorrect State ; UALM[26] ; JMP LBL[10] ; ; LBL[99:End] ;

CUSW REL1.3

Enter Zone 1 (Macro) 1: 2: 3: 4: 5:

!****************************** ; !Enter Zone 1 Macro ; !****************************** ; ; !Reset Clear of Zone 1 ;

1: 2: 3: 4: 5: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23: 24: 25: 26: 27: 28: 29: 30: 31: 32: 33: 34: 35:

!****************************** ; !MACRO Setup Outputs ; !****************************** ; ; GO[1:ActiveStyle]=0 ; ; DO[18:RbtAtWork]=OFF ; DO[19:WorkComplete]=OFF ; DO[25:RbtAtPounce]=OFF ; DO[26:RbtAtService]=OFF ; DO[28RbtInTipDress]=OFF ; DO[29:TipDressComplt]=OFF ; DO[31:ClearToTransfer]=ON ; ; !Zones ; DO[33:RbtClrZone1]=ON ; DO[34:RbtClrZone2]=ON ; DO[35:RbtClrZone3]=ON ; DO[36:RbtClrZone4]=ON ; DO[37:RbtClrZone5]=ON ; DO[38:RbtClrZone6]=ON ; DO[39:RbtClrZone7]=ON ; DO[40:RbtClrZone8]=ON ; ; !Pickup/Dropoff ; DO[49:ClrOfPickup1]=ON ; DO[50:AtPickup1]=OFF ; DO[51:ClrOfDropoff1]=ON ; DO[52:AtDropoff1]=OFF ; DO[53:ClrOfPickup2]=ON ; DO[54:AtPickup2]=OFF ; DO[55:ClrOfDropoff2]=ON ; DO[56:AtDropoff2]=OFF ; DO[57:ClrOfPickup3]=ON ;

6: 7: 8: 9: 10:

DO[33:RobotClrZone1]=OFF ; ; !Wait for OK To Enter Zone 1 ; WAIT DI[33:Zone1ClrToEnter]=ON ; ;

Home IO (Macro)


36: 37: 38: 39: 40: 41: 42: 43: 44: 45: 46: 47: 48: 49: 50: 51: 52: 53: 54: 55: 56: 57: 58: 59: 60: 61: 62: 63: 64: 65: 66: 67: 68:

116

DO[58:AtPickup3]=OFF ; DO[59:ClrOfDropoff3]=ON ; DO[60:AtDropoff3]=OFF ; DO[61:ClrOfPickup4]=ON ; DO[62:AtPickup4]=OFF ; DO[63:ClrOfDropoff4]=ON ; DO[64:AtDropoff4]=OFF ; ; DO[65:Clr2UnclampEarly]=OFF; DO[71:Req2ToEnterTN]=OFF ; DO[72:ClrOfToolNest]=ON ; DO[89:PickOverride]=OFF ; DO[94:AbortPickReq]=OFF ; DO[102:StepperRst1Ack]=OFF ; DO[103:StepperRst2Ack]=OFF ; DO[104:TipBurnInComplt]=OFF ; DO[105:RbtClrFixt1]=ON ; DO[106:RbtClrFixt2]=ON ; DO[107:RbtClrFixt3]=ON ; GO[2:ReposTooling]=0 ; ; GO[31:Disp1StyleBits]=0 ; DO[393:Disp1RbtinPrc]=OFF ; DO[394:Disp1StyStrobe]=OFF ; DO[401:Disp1Complete]=OFF ; ; DO[637:OutOfNest]=ON ; DO[640:ToolNotPresent]=OFF ; DO[641:InvalidToolReqd]=OFF ; DO[642:UnxpctdToolPrsnt]=OFF ; DO[643:Nest not Empty]=OFF ; DO[644:Nest is Empty]=OFF ; ;

CUSW REL1.3

Process Application – Ped Spot (Macro) 1: 2: 3: 4: 5: 6: 7:L 8: 9: 10:L : 11: 12: 13: 14:L 15: 16: 17:L : 18: 19: 20:L 21: 22: 23: 24: 25:

26: 27: 28: 29: 30: 31: 32: 33: 34: 35: 36: 37: 38: 39: 40:

!****************************** ; !MACRO PED SPOT WELD; !****************************** ; ; !Move to Weld 1 ; !insert motion if necessary ; P[1] 1000mm/sec FINE ; ; !Select Schedule Weld 1 ; P[2] 100mm/sec FINE SPOT[SD=1,P=1,S=1,ED=1] ; ; !Move to Weld 2 ; !insert motion if necessary ; P[3] 1000mm/sec FINE ; ; !Select Schedule Weld 2 ; P[4] 100mm/sec FINE SPOT[SD=1,P=1,S=1,ED=1] ; ; !Move Clear of Ped Welder ; P[5] 1000mm/sec FINE ; ; LBL[20] ; ; !Dropoff/Tip Change/Tip Dress ; WAIT (DI[51:GoToDropoff1]=ON OR DI[28:TipDressGunReq]=ON OR DI[105:TipChangeReq]=ON OR DI[104: TipBurnInReq]=ON OR DI[27: ServiceRequest]=ON); ; !Check for Tip Change ; IF DI[105:TipChangeReq]=ON,JMP LBL[30] ; ; !Check for Tip Dress ; IF DI[28:TipDressGunReq]=ON,JMP LBL[40] ; ; !Check for Tip Burn In ; IF DI[104:TipBurnInReq]=ON,JMP LBL[50] ; ; !Check for Service Request ; IF DI[27:ServiceRequest]=ON,JMP LBL[60] ; !Check for go to Dropoff ; IF DI[51:GoToDropoff1]=ON,JMP LBL[70] ;


41: 42: 43: 44: 45: 46: 47: 48: 49: 50: 51: 52: 53: 54: 55: 56: 57: 58: 59: 60: 61: 62: 63: 64: 65: 66: 67: 68: 69: 70: 71: 72: 73: 74: 75: 76: 77: 78: 79: 80: 81: 82: 83: 84: 85:

117

; !****************************** LBL[30:TipChange] ; ; !MACRO-Tip Dress Ped ; CALL TPDRSPD(0) ; ; !Reset Tip Dress Complete ; DO[29:TipDressComplt]=OFF ; ; !MACRO-Tip Change Ped ; CALL TPCHGPD ; ; !MACRO-Tip Dress Ped ; CALL TPDRSPD(58) ; ; JMP LBL[20] ; ; !****************************** LBL[40:TipDress] ; ; !MACRO-Tip Dress Ped ; CALL TPDRSPD(62) ; ; JMP LBL[20] ; ; !****************************** LBL[50:TipBurnIn] ; ; !MACRO-Tip Burn In ; CALL TPBURNIN ; ; JMP LBL[20] ; ; !****************************** LBL[60:Service_W_Part] ; ; !MACRO-Srv_With_Prt ; CALL Srv_With_Prt ; ; JMP LBL[20] ; ; !****************************** LBL[70:Dropoff] ; ;

;

;

;

;

;

CUSW REL1.3

Process Application – Ped Dispense (Macro) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23: 24: 25: 26: 27: 28: 29: 30: 31: 32: 33: 34: 35: 36: 37:L 38: 39: 40:L 41:

!****************************** ; !MACRO PED DISPENSE ; !****************************** ; ; !Pre-processing for Disp Equip ; !Insert Statements ; ; !Wait for Dispenser Ready ; WAIT (DI[385:Dsp1DispenRdy]=ON) ; !Set Disp Robot in Process ; DO[393:Disp1RbtinPrc]=ON ; ; WAIT .10(sec) ; ; !Set Dispense Style ; GO[31:Disp1StyBits]=1 ; ; WAIT .10(sec) ; ; !Set Disp Style Strobe ; DO[394:Disp1StyStrobe]=ON ; ; !Wait for Disp in Process ; WAIT DI[386:Dsp1DispenInPrc]=ON ; !Reset Dispense Style ; GO[31:Disp1StyBits]=0 ; ; !Reset Disp Style Strobe ; DO[394:Disp1StyStrobe]=OFF ; ; !Set Coll Guard Sensitivity ; COL GUARD ADJUST R[42] ; ; !Move Seal Start, Turn On Gun ; P[1] 1000mm/sec CNT100 SS[1] ; ; !Move along Path ; P[2] 100mm/sec CNT100 ; ;


;

Example: SS[1] – seal schedule is using BW TCPP (robot tool center point position) changes digital ; IO per robot speed. In the SS command use the following per robot speed 500mm/sec: 200mm=10volt 100mm=5volts OR Change SS[1] flow rate to be direct voltage

118

Need Fine term type or more robot positions (delay time). Because the SE instruction is to close to the DO[401:dispe nsecomplete]. The Nordson may see both signals turn ON at the same time due to their scan rate.

42: !Move To Seal End, Turn Off Gun ; 43:L P[3] 1000mm/sec CNT100 SE ; 44: ; 45: !Move Clear of Nozzle ; 46:L P[4] 1000mm/sec FINE ; 47: ; 48: !Reset Coll Guard Sensitivity ; 49: COL GUARD ADJUST ; 50: ; 51: !Set Dispense Complete ; 52: DO[401:Disp1Complete]=ON ; 53: ; 54: !Wait for Dispense Vol. OK ; 55: WAIT DI[387:Dsp1VolumeOK]=ON ; 56: ; 57: !Reset Dispense Complete ; 58: DO[401:Disp1Complete]=OFF ; 59: ; 60: !Reset Disp Robot in Process ; 61: DO[393:Disp1RbtinPrc]=OFF ; 62: ; 63: !Post-processing for Disp Equip ; 64: !Insert Statements ; 65: ; 66: LBL[20] ; 67: ; 68: !Purge or Go To Dropoff ; 69: WAIT (DI[51:GoToDropoff1]=ON OR DI[95:PurgeGun1Req]=ON) ; 70: ; 71: !Check for Dropoff ; 72: IF DI[51:GoToDropoff1]=ON,JMP LBL[30] ; 73: ; 74: !MACRO - Purge Ped Gun 1 ; 75: CALL PRGPDGN1 ; 76: ; 77: JMP LBL[20] ; 78: ; 79: LBL[30:Dropoff] ; 80: ;

CUSW REL1.3

Process Application – Ped Stud (Macro) 1: 2: 3: 4: 5: 6: 7:L 8: 9: 10:L : 11:

!****************************** ; !MACRO PED STUD WELD; !****************************** ; ; !Move to Weld 1 ; !insert motion if necessary ; P[1] 1000mm/sec FINE ; ; !Select Schedule Weld 1 ; P[2] 100mm/sec FINE SPOT[S=1] ; ;

12: 13: 14:L 15: 16: 17:L : 18: 19: 20:L 21:

!Move to Weld 2 ; !insert motion if necessary ; P[3] 1000mm/sec FINE ; ; !Select Schedule Weld 2 ; P[4] 100mm/sec FINE SPOT[S=1] ; ; !Move Clear of Ped Welder ; P[5] 1000mm/sec FINE ; ;

Purge Ped Gun (Macro) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13:

!****************************** ; !MACRO PURGE PED GUN 1 ; !****************************** ; ; !Set Ext Purge 1 in Progress ; DO[97:ExtPurg1InProgrs]=ON ; ; !Pre-process Dispense Equipment ; !(insert statements) ; ; !Turn On Gun-Purge Schedule ; DO[416:Disp1Purge]=ON ; ;

14: 15: 16: 17: 18: 19: 20: 21: 22: 23: 24: 25:

!Wait 'X' Seconds ; WAIT 7.00(sec) ; ; !Turn Off Gun ; DO[416:Disp1Purge]=OFF ; ; !Post-process Disp Equipment ; !(insert statements) ; ; !Reset Ext Purge 1 in Progress ; DO[97:ExtPurg1InProgrs]=OFF ; ;

Reset Stepper (Macro) 1: 2: 3: 4: 5: 6: 7:

!****************************** ; !MACRO RESET STEPPER ; !****************************** ; ; !Set Weld 1 Reset Stepper ; DO[590:W1ResetStepper]=ON ; ;

8: 9: 10: 11: 12: 13:

!Wait for Stepper Reset ; WAIT DI[204:W1 SteppersReset]=ON ; ; !Reset Weld 1 Reset Stepper ; DO[590:W1ResetStepper]=OFF ; ;

Tip Burn In (Macro) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11:L : 12:

!****************************** ; !MACRO TIP BURN IN ; !****************************** ; ; !Reset Registers for Burn In ; R[14]=0 ; ; LBL[1] ; ; !Burn In ; P[1] 100mm/sec FINE SPOT[SD=1,P=1,S=62,ED=1] ; ;

13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23: 24:

!Total Number of Burn Ins ; R[14]=R[14]+1 ; ; !Check Number of Burn-ins ; IF R[14]
Tip Change Ped Gun (Macro) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17:

!****************************** ; !MACRO TIP CHANGE PED GUN ; !****************************** ; ; !Pulse W1 Water Off ; DO[587:W1WtrOff]=PULSE,1.0sec ; ; !Set Robot at Service ; DO[26:RbtAtService]=ON ; ; !Set Ready for Tip Change ; DO[30:RdyForTipChg]=ON ; ; !Wait for Service Complete ; WAIT (DI[26:ServiceCompltReq]=ON) ; !Reset Robot at Service ;


18: 19: 20: 21: 22: 23: 24: 25: 26: 27: 28: 29: 30: 31: 32: 33: 34:

;

119

DO[26:RbtAtService]=OFF ; ; !Reset Ready for Tip Change ; DO[30:RdyForTipChg]=OFF ; ; !MACRO-Reset Stepper ; CALL RST_STPR ; ; !MACRO-Seat Caps Gun 1 ; CALL TW_PRSRT(1,500,2,4,1,10,5,15) ; ; !Tip Wear Compensation Gun 1 ; CALL WR_UPDAT(1,0) ; ; !Pulse W1 Reset Water Saver ; DO[586:W1RstWtrSvr]=PULSE,1.0sec ; ;

CUSW REL1.3

Tip Dress Gun 1 (Macro) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14:J 15:J 16:J 17:J 18:J 19: 20: 21: 22: 23: 24: 25: 26: 27:L 28: 29: 30:L : 31: 32: 33:L 34: 35: 36:

!******************************** ; !MACRO Tip Dress Carried gun 1 ** ; !******************************** ; ; !Setup Weld Register ; R[19:Gun1BurnInSched]=AR[1] ; ; IF DI[127:TipdressBypassed]=ON,JMP LBL[20] ; ; !Set Robot In Tip Dress ; DO[28:RobotInTipDress]=ON ; ; !T/Dress Approach (Common Pos.) ; PR[4:MHWait/TDCom Pos] 50% FINE ; P[1] 80% CNT25 ; P[2] 80% CNT25 ; P[3] 80% CNT25 ; P[4] 80% CNT10 ; ; !Turn On Tip Dress Motor ; DO[101:TurnOnTipDresser]=ON ; ; !Wait Tip Dress Motor On ; WAIT DI[101:TipDrsMotorOn]=ON ; ; !Before/After Tip Dress ; P[5] 800mm/sec FINE ; ; !At Tip Dress ; P[6] 500mm/sec FINE SPOT[SD=2,P=60,S=60,ED=2] ; ; !Before/After Tip Dress ; P[5] 800mm/sec CNT10 ; ; !Turn Off Tip Dress Motor ; DO[101:TurnOnTipDresser]=OFF ;

37: 38:L 39:J 40:J 41:J 42: 43: 44:J 45: 46: 47: 48: 49: 50: 51: 52: 53: 54: 55: 56: 57: 58: 59: 60: 61: 62: 63: 64: 65: 66: 67:J 68: 69: 70: 71:

; P[4] 1600mm/sec CNT50 ; P[3] 80% CNT25 ; P[2] 80% CNT25 ; P[1] 80% CNT25 ; ; !T/Dress Approach (Common Pos.) ; PR[4:MHWait/TDCom Pos] 80% CNT50 ; ; !STYLE003 Wear Update & ; !Burn In Skip ; IF R[19:Gun1BurnInSched]=0,JMP LBL[10] ; ; !MACRO-Tip Wear Compensation ; CALL WR_UPDAT(1,0) ; ; !Set Tip Dress Complete ; DO[29:TipDressComplt]=ON ; ; LBL[20:TIPDRESS BYPASS] ; ; IF R[19:Gun1BurnInSched]=0,JMP LBL[10] ; ; !Do Tip Burn In Weld Schedule ; SPOT[SD=4,P=62,S=R[19],ED=4] ; ; LBL[10:SKIP TIPBURN] ; ; !******************************** ; !CNT CAN NOT CHANGE MUST BE FINE ; PR[1:Home 1] 80% FINE ; !******************************** ; ; !Reset Robot In Tip Dress ; DO[28:RobotInTipDress]=OFF ;

Tip Dress Gun 2 (Macro) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14:J 15:J 16:J 17:J 18:J 19: 20: 21: 22: 23: 24: 25: 26: 27:L 28: 29: 30:L : 31: 32: 33:L 34: 35:

!******************************** ; !MACRO Tip Dress Carried gun 2 ** ; !******************************** ; ; !Setup Weld Register ; R[20:Gun2BurnInSched]=AR[1] ; ; IF DI[127:TipdressBypassed]=ON,JMP LBL[20] ; ; !Set Robot In Tip Dress ; DO[28:RobotInTipDress]=ON ; ; !T/Dress Approach (Common Pos.) ; PR[4:MHWait/TDCom Pos] 50% FINE ; P[1] 80% CNT25 ; P[2] 80% CNT25 ; P[3] 80% CNT25 ; P[4] 80% CNT10 ; ; !Turn On Tip Dress Motor ; DO[101:TurnOnTipDresser]=ON ; ; !Wait Tip Dress Motor On ; WAIT DI[101:TipDrsMotorOn]=ON ; ; !Before/After Tip Dress ; P[5] 800mm/sec FINE ; ; !At Tip Dress ; P[6] 500mm/sec FINE SPOT[SD=2,P=60,S=61,ED=2] ; ; !Before/After Tip Dress ; P[5] 800mm/sec CNT10 ; ; !Turn Off Tip Dress Motor ;


36: 37: 38:L 39:J 40:J 41:J 42: 43: 44:J 45: 46: 47: 48: 49: 50: 51: 52: 53: 54: 55: 56: 57: 58: 59: 60: 61: 62: 63: 64: 65: 66: 67:J 68: 69: 70: 71:

120

DO[101:TurnOnTipDresser]=OFF ; ; P[4] 1600mm/sec CNT50 ; P[3] 80% CNT25 ; P[2] 80% CNT25 ; P[1] 80% CNT25 ; ; !T/Dress Approach (Common Pos.) ; PR[4:MHWait/TDCom Pos] 80% CNT50 ; ; !STYLE003 Wear Update & ; !Burn In Skip ; IF R[20:Gun2BurnInSched]=0,JMP LBL[10] ; ; !MACRO-Tip Wear Compensation ; CALL WR_UPDAT(1,0) ; ; !Set Tip Dress Complete ; DO[29:TipDressComplt]=ON ; ; LBL[20:TIPDRESS BYPASS] ; ; IF R[20:Gun2BurnInSched]=0,JMP LBL[10] ; ; !Do Tip Burn In Weld Schedule ; SPOT[SD=4,P=62,S=R[19],ED=4] ; ; LBL[10:SKIP TIPBURN] ; ; !******************************** ; !CNT CAN NOT CHANGE MUST BE FINE ; PR[1:Home 1] 80% FINE ; !******************************** ; ; !Reset Robot In Tip Dress ; DO[28:RobotInTipDress]=OFF ;

CUSW REL1.3

Tip Dress Ped Gun (Macro) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23: 24:L : 25: 26:

!****************************** ; !MACRO TIP DRESS PED GUN ; !****************************** ; !Parameters: AR[] ; !1: Burn In Schedule Gun 1 ; !****************************** ; ; !Setup Weld Register ; R[19:Gun1BurnInSched]=AR[1] ; ; !Set Robot in Tip Dress ; DO[28:RbtInTipDress]=ON ; ; !Wait for Tip Dress Dump Ext ; WAIT DI[99:TipDressDumpExtd]=ON ; ; !Turn On Tip Dresser ; DO[101:TurnOnTipDresser]=ON ; ; !Wait Tip Dress Motor On ; WAIT DI[101:TipDrsMotorOn]=ON ; ; !Do Tip Dress Weld Schedule ; P[1] 100mm/sec FINE SPOT[SD=1,P=1,S=60,ED=1] ; ; !Reset Turn On Tip Dresser ;


27: 28: 29: 30: 31: 32: 33: 34: 35: 36: 37: 38: 39: 40: 41: 42:L : 43: 44: 45: 46: 47: 48: 49: 50: 51:

121

DO[101:TurnOnTipDresser]=OFF ; ; !Reset Tip Dress Request ; DO[100:TipDressReq1]=OFF ; ; !Set Tip Dress Complete ; DO[29:TipDressComplt]=ON ; ; !Wait for Tip Dress Dump Ret ; WAIT DI[100:TipDrsDumpRtrct]=ON ; ; !Check If Burn In Required ; IF R[19:Gun1BurnInSched]=0,JMP LBL[10] ; ; !Do Tip Burn In Weld Schedule ; P[2] 100mm/sec FINE SPOT[SD=1,P=1,S=R[19],ED=1] ; ; !MACRO-Tip Wear Compensation ; CALL WR_UPDAT(1,0) ; ; LBL[10:SkipBurnIn] ; ; !Reset Robot in Tip Dress ; DO[28:RbtInTipDress]=OFF ; ;

CUSW REL1.3

Tool Drop Preperation (Macro) 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23: 24: 25: 26: 27: 28: 29: 30: 31: 32: 33: 34: 35: 36: 37: 38: 39: 40: 41: 42: 43: 44: 45: 46: 47: 48: 49: 50: 51: 52: 53: 54: 55: 56: 57: 58: 59: 60: 61: 62: 63:

!****************************** ; !MACRO TOOL DROP PREPARATION ; !****************************** ; ; LBL[1:Retry] ; ; !Select Tool ; SELECT R[1]=1,JMP LBL[10] ; =2,JMP LBL[20] ; =3,JMP LBL[30] ; =4,JMP LBL[40] ; ELSE,JMP LBL[90] ; ; LBL[10:Tool1] ; ; !Verify Part Not Present ; Check No Part(1,2,3,4) ; ; !MACRO-Set Active MH Tool ; Set MH Tool(1) ; ; !Set Tool 1 Drop State ; Release Part(1) ; ; !Verify Nest Empty Before Drop ; IF DI[73:ToolInNest1]=ON,JMP LBL[95] ; ; !MACRO-Drop Tool in Nest 1 ; CALL NST1DROP ; ; JMP LBL[99] ; ; ; LBL[20:Tool2] ; ; !Verify Part Not Present ; Check No Part(1,2,3,4) ; ; !MACRO-Set Active MH Tool ; Set MH Tool(2) ; ; !Set Tool 2 Drop State ; Release Part(1) ; ; !Verify Nest Empty Before Drop ; IF DI[74:ToolInNest2]=ON,JMP LBL[95] ; ; !MACRO-Drop Tool in Nest 2 ; CALL NST2DROP ; ; JMP LBL[99] ; ; ; LBL[30:Tool3] ; ; !Verify Part Not Present ; Check No Part(1,2,3,4) ; ; !MACRO-Set Active MH Tool ; Set MH Tool(3) ; ; !Set Tool 3 Drop State ; Release Part(1) ;


64: 65: 66: 67: 68: 69: 70: 71: 72: 73: 74: 75: 76: 77: 78: 79: 80: 81: 82: 83: 84: 85: 86: 87: 88: 89: 90: 91: 92: 93: 94: 95: 96: 97: 98: 99: 100: 101: 102: 103: 104: 105: 106: 107: 108: 109: 110: 111: 112: 113: 114: 115: 116: 117: 118: 119: 120: 121: 122: 123: 124: 125: 126:

122

; !Verify Nest Empty Before Drop ; IF DI[75:ToolInNest3]=ON,JMP LBL[95] ; ; !MACRO-Drop Tool in Nest 3 ; CALL NST3DROP ; ; JMP LBL[99] ; ; ; LBL[40:Tool4] ; ; !Verify Part Not Present ; Check No Part(1,2,3,4) ; ; !MACRO-Set Active MH Tool ; Set MH Tool(4) ; ; !Set Tool 4 Drop State ; Release Part(1) ; ; !Verify Nest Empty Before Drop ; IF DI[76:ToolInNest4]=ON,JMP LBL[95] ; ; !MACRO-Drop Tool in Nest 4 ; CALL NST4DROP ; ; JMP LBL[99] ; ; !****************************** ; !ALARMS ; !****************************** ; ; !Unexpected Tool Present ; LBL[90:WrongTool] ; ; !Set Application Error Output ; DO[642:UnxpctdToolPrsnt]=ON ; ; !Post User Alarm ; UALM[3] ; ; !Reset Appliction Error Output ; DO[642:UnxpctdToolPrsnt]=OFF ; ; JMP LBL[1] ; ; !Nest not Empty; LBL[95:Nest not Empty] ; ; !Set Application Error Output ; DO[643:Nest not Empty]=ON ; ; !Post User Alarm ; UALM[4] ; ; !Reset Not not Empty ; DO[643:Nest not Empty]=OFF ; ; JMP LBL[1] ; ; LBL[99:End] ; ;

CUSW REL1.3

Chrysler Cusw Fanuc Robot Standard Rel 1.3

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