FANUC Robot series R--J3iB CONTROLLER ARC TOOL
OPERATOR’S MANUAL
B--81464EN--3/01
Table of Contents
B--81464EN--3/01
Volume 1 1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.1
MANUAL PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
1.2
WORKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
1.3
GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
1.4
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
2. OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
2.1
ARC TOOL SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5
2.2
ROBOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 2.2.2
2.3
System setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jog feed of the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test operation (test execution) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic operation (operation execution) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Robot arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arc welding torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1
16 16 16 16 17 17
18 18 19
20
Teach pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1.1 Keys on the teach pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 23
2.3.1.2
LEDs on the teach pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
2.3.1.3
Display screen of the teach pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
2.3.1.4 Screen menu and function menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator’s panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRT/KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input/output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peripheral I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motion of the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extended axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 31 32 32 32 32 32 33 33 33
3. SETTING UP THE ARC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.3.7 2.3.8 2.3.9 2.3.10
3.1
WELDING INPUT/OUTPUT SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1 3.1.2 3.1.3 3.1.4
Welding input signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welding output signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting a reference value range and command value range for specifying an analog input/output signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting welder power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 37 38 42 44
3.2
SETTING THE ARC WELDING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
3.3
SETTING THE ARC WELDING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
3.4
SETTING ARC WELDING CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52
3.5
WELD SCHEDULE ADVISE SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54
3.5.1
Process Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
3.6
SETTING FOR WEAVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
3.7
WEAVE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64
c--1
Table of Contents
3.8
B--81464EN--3/01
INPUT/OUTPUT SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.1 3.8.2 3.8.3
Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67 73 78 81
3.9
ROBOT I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86
3.10
PERIPHERAL I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89
3.11
OPERATOR’S PANEL I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
96
I/O LINK SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99
3.12
3.12.1 3.12.2 3.12.3
3.13 3.14
99 100 101
I/O CONNECTION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
102
SETTING AUTOMATIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104
3.14.1 3.14.2
3.15
I/O Link list screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODEL B unit list screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal count setting screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Robot service request (RSR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program number selection (PNS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETTING COORDINATE SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15.1 3.15.2 3.15.3
Setting a tool coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting a user coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting a jog coordinate system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
105 108
111 113 122 131
3.16
SETTING A REFERENCE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
136
3.17
JOINT OPERATING AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
139
3.18
USER ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
141
3.19
VARIABLE AXIS AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
142
3.20
SPECIAL AREA FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
144
3.21
SYSTEM CONFIG MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
148
3.22
SETTING UP GENERAL ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
155
3.23
OTHER SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
157
4. PROGRAM STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 4.1
PROGRAM DETAIL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6
4.2 4.3
161 161 162 162 163 163 163
LINE NUMBER, PROGRAM END SYMBOL, AND ARGUMENT . . . . . . . . . . . . . . . . . . . . . . . .
166
MOTION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
168
4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6
4.4
Program name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program comment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Subtype . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group mask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Write protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interruption disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motion format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weld speed statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Positioning path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional motion instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ARC INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.1 4.4.2 4.4.3 4.4.4
Arc start instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arc end instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRACK{Sensor} instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c--2
169 171 176 178 179 180
191 191 192 194 197
B--81464EN--3/01
4.5
REGISTER INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.1 4.5.2 4.5.3
4.6
Digital I/O instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Robot I/O instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog I/O instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group I/O instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welding I/O instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRANCH INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7.1 4.7.2 4.7.3 4.7.4 4.7.5
4.8
Register instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position register instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position register axis instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5
4.7
Table of Contents
Label instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program end instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unconditional branch instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conditional branch instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arguments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WAIT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8.1 4.8.2
Time--specified wait instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conditional wait instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
198 198 200 201
203 203 204 206 207 208
209 209 209 210 210 213
220 220 220
4.9
SKIP CONDITION INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
223
4.10
OFFSET CONDITION INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
225
4.11
TOOL OFFSET CONDITION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
226
4.12
FRAME INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
227
PROGRAM CONTROL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
228
4.13
4.13.1 4.13.2
4.14
OTHER INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14.1 4.14.2 4.14.3 4.14.4 4.14.5 4.14.6 4.14.7 4.14.8
4.15
RSR instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . User alarm instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timer instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Override instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Comment instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Message instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parameter instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum speed instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MULTIAXIS CONTROL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15.1 4.15.2 4.15.3
4.16
Halt instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abort instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Semaphore instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Semaphore wait instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program execution instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION GROUP INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16.1 4.16.2
Asynchronous operation group instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Synchronous operation group instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
228 228
229 229 229 230 230 230 231 231 233
234 234 234 235
236 236 236
5. PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 5.1
TIPS ON EFFECTIVE PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1 5.1.2 5.1.3
5.2
Motion instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Predefined position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arc welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURNING ON THE POWER AND JOG FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1 5.2.2 5.2.3
Turning on the power and turning off the power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three--Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moving the robot by jog feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c--3
239 239 239 240
241 241 243 249
Table of Contents
5.3
CREATING A PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6
5.4
Registering a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing a standard motion instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Teaching a motion instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Teaching a supplementary motion instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Teaching a control instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TP start prohibition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING A PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.1 5.4.2 5.4.3 5.4.4
5.5
B--81464EN--3/01
Selecting a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing a motion instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing a control instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program edit instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROGRAM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.1
Changing program information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
258 259 263 266 268 273 280
282 282 284 292 295
310 310
5.6
BACKGROUND EDITING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
315
5.7
SINGULARITY POINT CHECK FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
324
6. EXECUTING A PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 6.1
PROGRAM HALT AND RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.1 6.1.2 6.1.3
6.2
EXECUTING A PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.1 6.2.2 6.2.3
6.3
6.6
Specifying test execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuous test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program look/monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL I/O CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.1 6.4.2 6.4.3
6.5
Starting a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Robot motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resuming a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.1 6.3.2 6.3.3 6.3.4
6.4
Halt by an emergency stop and recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Halt by a hold and recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Halt caused by an alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forced output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Simulated I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standby release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
326 327 328 329
332 332 333 335
340 340 342 345 347
348 348 349 351
MANUALLY OPERATING WELDING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
352
AUTOMATIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
353
6.6.1 6.6.2 6.6.3
Automatic operation by robot start request (RSR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic operation with program number selection (PNS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External override selection function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
354 356 358
6.7
ONLINE POSITION MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
360
6.8
WELDING TUNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
366
7. STATUS DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368 7.1
LEDS ON THE TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
369
7.2
USER SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
370
7.3
REGISTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
371
7.4
POSITION REGISTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
372
7.5
ARC WELDING STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
375
7.6
CURRENT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
376
c--4
B--81464EN--3/01
Table of Contents
7.7
SYSTEM VARIABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
378
7.8
PROGRAM TIMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
379
7.9
SYSTEM TIMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
381
7.10
EXECUTION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
382
7.11
MEMORY USE STATUS DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
384
8. FILE INPUT/OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385 8.1
FILE INPUT/OUTPUT UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1.1 8.1.2 8.1.3 8.1.4
8.2 8.3
394
FILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
398
Loading using program selection screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loading a specified program file using the file screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRINTING FILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.1 8.6.2
8.7
Saving with the program selection screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Saving all the program files using the file screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Saving with a function menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . File manipulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASCII save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOADING FILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.1 8.5.2
8.6
Program file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Default logic file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASCII file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAVING FILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.1 8.4.2 8.4.3 8.4.4 8.4.5
8.5
387 388 389 391
SETTING A COMMUNICATION PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.1 8.3.2 8.3.3 8.3.4 8.3.5
8.4
Memory card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Floppy Cassette adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handy file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
386
Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printing files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC BACKUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.1 8.7.2 8.7.3 8.7.4 8.7.5 8.7.6
Overview of Automatic Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Usable Memory Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting of Automatic Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Perform Automatic backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Version management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Restore the backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
398 398 399 399 399
400 400 402 405 407 409
412 413 414
419 419 421
424 424 424 425 426 426 427
9. UTILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428 9.1
MACRO INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.1 9.1.2
9.2
Setting macro instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Executing macro instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.1 9.2.2 9.2.3
Program shift function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mirror shift function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle--input shift function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
429 430 435
439 440 445 449
9.3
COORDINATE SYSTEM CHANGE SHIFT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
454
9.4
SOFT FLOAT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
459
9.5
CONTINUOUS ROTATION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
464
9.6
POSITION REGISTER LOOK--AHEAD EXECUTION FUNCTION . . . . . . . . . . . . . . . . . . . . . . .
468
c--5
Table of Contents
B--81464EN--3/01
9.7
OPERATION GROUP DO OUTPUT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
470
9.8
PRE--EXECUTION INSTRUCTION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
472
9.9
DISTANCE BEFORE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
477
9.9.1 9.9.2 9.9.3 9.9.4 9.9.5 9.9.6 9.9.7 9.9.8
9.10 9.11
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entering Distance Before . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caution and limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
477 477 477 477 485 487 488 490
STATE MONITORING FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
491
AUTOMATIC ERROR RECOVERY FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
498
9.11.1 9.11.2 9.11.3 9.11.4 9.11.5 9.11.6 9.11.7 9.11.8 9.11.9 9.11.10 9.11.11
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outline of the automatic error recovery function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Defining a resume program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Teaching the RETURN_PATH_DSBL instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the automatic error recovery function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flowchart for resuming a suspended program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual operation screen of the automatic error recovery function . . . . . . . . . . . . . . . . . . . . . . . . . . . . Execution of the resume program from the teach pendant and test mode . . . . . . . . . . . . . . . . . . . . . . . Changing conditions for executing the resume program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other specifications and restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
498 498 501 502 503 510 511 513 513 513 514
9.12
TORCH POSTURE CONVERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
515
9.13
TORCH POSTURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
525
TAST TRACKING FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
530
9.14
9.14.1
Tast tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14.1.1 Weave plane (XY-plane) lateral tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
531 532
9.14.2 9.14.3 9.14.4 9.14.5 9.14.6 9.14.7 9.14.8
9.14.1.2 Vertical plane (Z-plane) tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Factors that affect tast tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tast application guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tast hardware requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tast programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tast schedule setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment of gain value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14.8.1 Tracking failure conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
533 534 535 535 536 536 540 542 542
9.14.9
9.14.8.2 Fine adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tast troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14.9.1 Poor tracking performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
542 543 543
9.14.9.2 No compensation with high vertical or lateral gain setting . . . . . . . . . . . . . . . . . . . . . . . . . . . .
543
9.14.9.3 TAST schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
544
9.14.9.4 Robot wanders from path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
544
9.14.9.5 Weld path is shifted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
544
9.14.9.6 Slow response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
544
9.14.9.7 Weld path is snaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
545
9.14.9.8 Weld Path has Changed at a Specific Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
545
9.14.9.9 Significant changes in joint gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
545
9.14.9.10 Extreme changes in workpiece temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
545
c--6
B--81464EN--3/01
9.15
AUTOMATIC VOLTAGE CONTROL TRACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15.1 9.15.2 9.15.3 9.15.4 9.15.5
9.16
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INITIAL SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TUNING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GRAVITY COMPENSATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23.1 9.23.2
9.24
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Estimation Procedure (for 6--Axis Robots) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration Procedure (for 6--Axis Robots) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other Related Matters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COLLISION DETECTION FOR AUXILIARY AXIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22.1 9.22.2 9.22.3 9.22.4
9.23
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motion Performance Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOAD ESTIMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21.1 9.21.2 9.21.3 9.21.4 9.21.5
9.22
Assigning touch sensing I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting up touch sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Touch sensing programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Touch sensing hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Touch sensing mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOAD SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20.1 9.20.2 9.20.3
9.21
Data monitor setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data monitor schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOUCH SENSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19.1 9.19.2 9.19.3 9.19.4 9.19.5
9.20
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting a coordinated motion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coordinated jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coordinated motion in a program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main alarm codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DATA MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18.1 9.18.2 9.18.3
9.19
Root pass memorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coordinated motion with RPM and multipass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COORDINATED MOTION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17.1 9.17.2 9.17.3 9.17.4 9.17.5
9.18
AVC Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Factors that affect avc tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AVC hardware requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AVC schedule setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AVC programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROOT PASS MEMORIZATION AND MULTIPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16.1 9.16.2 9.16.3
9.17
Table of Contents
System Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOTION Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ARC SMART HIGH--SPEED RECOVERY FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24.1 9.24.2 9.24.3 9.24.4 9.24.5 9.24.6
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torch guard function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Related alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torch recovery function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
546 546 549 549 549 554
555 555 558 566
569 569 575 584 588 589
590 592 596 599
600 600 602 618 625 627
635 635 635 636
638 638 638 638 641 643
645 645 645 645 645
647 647 647
649 649 649 649 651 652 652
9.25
MULTI EQUIPMENT CONTROL FOR ARC WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
663
9.26
ARC START SYNCHRONIZATION FOR ARC MULTI--EQUIPMENT CONFIGUTARION . . . .
667
9.26.1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c--7
667
Table of Contents
9.26.2 9.26.3 9.26.4
9.27
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specification & Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sample Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
667 668 669
ADJUSTMENT OF ANALOG OUTPUT CONVERSATION FACTOR BY MULTIPLE POINTS
671
9.27.1 9.27.2
9.28
Function Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enabling or Disabling the Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assigning Welder Program Select Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting a Welder Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting a Welder Program in a Welding Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVO TORCH CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30.1 9.30.2 9.30.3
9.30.4
9.31
Function Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes on Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation at Recovery from Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the Welding Fine--Tune Function Concurrently . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the Arc Sensor Concurrently . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sample Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WELDER PROGRAM SELECT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29.1 9.29.2 9.29.3 9.29.4 9.29.5
9.30
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WELDING PARAMETER GRADE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28.1 9.28.2 9.28.3 9.28.4 9.28.5 9.28.6 9.28.7
9.29
B--81464EN--3/01
674 674 674 674 676 676 676 677
678 678 678 678 680 680
682
Outline of Servo Torch control function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attention and Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Detail of Servo Torch control function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30.3.1 Arc welding instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
682 682 682 682
9.30.3.2 Wire inching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
682
9.30.3.3 Air purge function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup for Servo Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30.4.1 Setup Servo Torch axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
683 683 684
9.30.4.2 Setup in Weld equipment setup screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
685
9.30.4.3 Servo Torch setup screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
686
SERVO TORCH FINE ADJUSTMENT FUNCTION OF WIRE VELOCITY COMMANDS . . . . 9.31.1 9.31.2
671 671
Six--Points Touchup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
688 688 692
Volume 2 APPENDIX A. APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 697 A.1
LIST OF MENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
698
A.2
TYPES OF SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
702
A.3
LIST OF PROGRAM INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
725
A.4
PROGRAM INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
729
A.4.1 A.4.2 A.4.3 A.4.4 A.4.5 A.4.6
Motion instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional motion instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Register and I/O instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conditional branch instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wait instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unconditional branch instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c--8
729 729 731 733 734 734
B--81464EN--3/01
A.4.7 A.4.8 A.4.9 A.4.10 A.4.11 A.4.12 A.4.13 A.4.14 A.4.15 A.4.16 A.4.17
Table of Contents
Program control instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Skip and Offset condition instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frame setup instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Macro instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multiaxis control instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position register look--ahead execution instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Soft float instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status monitoring instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motion group instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arc instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
735 735 736 737 737 737 738 738 738 738 739
B. APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 740 B.1
START MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.1 B.1.2 B.1.3 B.1.4 B.1.5
B.2
Start up Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controlled start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hot start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.1 B.2.2 B.2.3 B.2.4 B.2.5
Jig mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mastering at the zero--degree positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single axis mastering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting mastering data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
741 741 741 742 744 745
746 748 750 752 755 758
B.3
SOFTWARE VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
760
B.4
ROBOT AXIS STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
763
DIAGNOSIS SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
769
B.5
B.5.1 B.5.2 B.5.3 B.5.4
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About Reducer Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Each item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
769 769 770 771
B.6
WORLD FRAME ORIGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
774
B.7
I/O MODULE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
775
B.8
POSITIONER SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
780
B.9
EXTENDED AXIS SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
786
B.10 INDEPENDENT ADDITIONAL AXIS BOARD (NOBOT) STARTUP PROCEDURE . . . . . . . . .
791
C. FANUC I PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 795 C.1 C.2
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
796
APPEARANCE AND OPERATIONSAPPEARANCE AND OPERATIONS . . . . . . . . . . . . . . . . . .
797
C.2.1 C.2.2 C.2.3 C.2.4 C.2.5 C.2.6 C.2.7 C.2.8
Appearance and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Splitting the Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the Operation Target Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internet Browser Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen Selection Menu and Screen Menus on the Edit Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status Subwindow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.2.8.1 Current Position Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
797 798 799 800 802 803 806 807 808
C.2.8.2 Operator Panel Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
808
C.2.8.3 Safety Signal Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
809
c--9
Table of Contents
C.2.9
C.3
B--81464EN--3/01
Color Display According to the Alarm Severity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESTRICTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
810
811
D. ALARM CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 812 D.1
DESCRIPTION OF AN ALARM CODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
813
D.2
ALARM CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
820
E. SYSTEM VARIABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 941 E.1
FORMAT OF A SYSTEM VARIABLE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
942
E.2
SYSTEM VARIABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
944
c--10
1. INTRODUCTION
B--81464EN--3/01
1. INTRODUCTION This chapter explains the manual plan and the safety precautions that must be observed when working with the FANUC Robot. j Contents of this chapter 1.1 1.2 1.3 1.4
Manual Plan Workers General Safety Precautions Safety Precautions
1
1. INTRODUCTION
B--81464EN--3/01
1.1 Manual Plan FANUC Robot series (R--J3iB CONTROLLER) ARC TOOL Operator’s Manual. This manual describes how to operate the FANUC Robot, an all--purpose compact robot. It is controlled by the FANUC R--J3iB controller (Called the robot controller here in after) containing the ARC Tool software. This manual describes the following procedures for manipulating workpieces with the robot: F
Setting the system for manipulating workpieces
F
Operating the robot
F
Creating and changing a program
F
Executing a program
F
Status indications
F
Alarm codes and system variables
Using this manual Each chapter of the manual describes a single operation of the robot. The user can select and read chapters describing required operations. Chapter 1 Introduction
Describes how to use this manual and the safety precautions that must be observed in working with the robot. All users must read the safety precautions.
Chapter 2 Overview
Gives a basic knowledge of the robot. It describes the basic configuration of the robot and the system for manipulating workpieces.
Chapter 3 Setting the System for Arc Welding
Describes the procedure for setting the system for manipulating workpieces, including input/output, coordinate system, and reference position.
Chapter 4 Program Structure
Describes the program structure and the syntax of program instructions.
Chapter 5 Creating a Program
Describes how to design, create, change, delete, and copy a program. It also describes the procedures for turning the power on and moving the robot by jog feed.
Chapter 6 Executing a Program
Describes how to execute and stop a program. It also describes the test operation, automatic operation, and recovery from the alarm state.
Chapter 7 Status Indicators
Describes how to check the operating status of the robot, using the status indicator LEDs.
Chapter 8 File Input/Output
Describes how to store, read, and print a program file or system file.
Chapter 9 Utility
Describes additional utility functions and macro functions, program shift and mirror shift.
Appendix
Describes lists of the menus, screens, and program instructions.
Alarm Codes and System Variables
Lists the alarm codes and system variables.
2
1. INTRODUCTION
B--81464EN--3/01
Identification For editions and order files of software, read the following sections: Section
Item to be checked Edition of your software
B.3 Software Version
Order No. of your software
A.1 List of Menus
Specifications of products For memory statuses or software option list, see the following sections: Section
Item to be checked Memory status
7.11 Memory Use Status Display
Software option list
A.1 List of Menus
Menu displayed when an option is selected
A.1 List of Menus
Program instruction that can be used when an option is selected A.3 List of Program Instructions
Related manuals The following manuals are available: R-J3iB Controller
Mechanical unit
OPERATOR’S MANUAL ARC TOOL
Intended readers: Operators responsible for designing, introducing, operating, and adjusting the robot system at the work site. Topics: Functions, operations and the procedure for operating the robot. Programming procedure, interface, and alarm. Use: Guide to teaching, introducing, and adjusting the robot at the work site, and application designing.
MAINTENANCE MANUAL B--81465EN
Topics: Installing and activating the system, connecting the mechanical unit to the peripheral device, and maintaining the robot.
Maintenance manual
Intended readers: Maintenance person, system designer Topics: Installing and activating the robot, connecting the mechanical unit to the controller, maintaining the robot. Use: Guide to installation, activation, connection, and maintenance.
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Notation This manual contains safety precautions against injury and property damage. Those precautions are labelled “Warning” or “Caution,” according to the degree of importance. Supplementary explanation is given under “Note.” Before starting to use a robot, carefully read the “Warning,” “Caution,” and “Note.” WARNING Failure to follow the instruction given under “Warning” can cause fatal or serious injury to the user. This information is indicated in bold type in a box so that it can be easily distinguished from the main body of this manual.
CAUTION Failure to follow the instruction given under “Caution” can cause injury to the user or property damage. This information is indicated in a box so that it can be easily distinguished from the main body of this manual.
NOTE The information given under “Note” is a supplementary explanation, which is neither a warning nor a caution. Carefully read and save this manual.
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1.2 Workers A robot cannot do anything alone. The robot can operate only after it is equipped with a hand or other device and connected with peripheral equipment to form a system. Give considerations for the safety of not only the robot but also the entire system. When using the robot, provide a safety fence and other safety measures. FANUC defines the system personnel as indicated below. Check which worker should be trained in a specialist robot course. Operator The jobs of an operator are: F
Turning on and off the system
F
Starting and stopping programs
F
Recovering the system from an alarm state
The operator must not enter the area enclosed by the safety fence to do his or her work. Programmer or teaching operator The jobs of the programmer or teaching operator include the jobs of the operator and the following: F
Teaching of a robot, adjustment of the peripheral equipment, and other work that must be done in the area enclosed by the safety fence
The programmer or teaching operator should be trained in a specialist robot course. Maintenance engineer The jobs of the maintenance engineer include the jobs of the programmer and the following: F
Repair and maintenance of the robot
The maintenance engineer should be trained in a specialist robot course.
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1.3 General Safety Precautions This section lists general safety precautions. Before starting to use the robot, read the precautions. The subsequent sections of the manual indicate other precautions. Take each of the precautions. General rules WARNING When the robot is used, the following precautions should be taken. Otherwise, the robot and peripheral equipment can be adversely affected, or workers can be severely injured. -- Avoid using the robot in a flammable environment. -- Avoid using the robot in an explosive environment. -- Avoid using the robot in an environment full of radiation. -- Avoid using the robot under water or at high humidities. -- Avoid using the robot to carry a person or animal. -- Avoid using the robot as a stepladder. (Never climb up on or hang from the robot.) WARNING Robot personnel must wear the following safety articles: -- Clothing suitable for each job -- Safety shoes -- Helmet NOTE
Programmers and maintenance staff should be trained in a suitable course at FANUC. Notes on installation
WARNING The robot should be transported and installed by accurately following the procedures recommended by FANUC. Incorrect transportation or installation may cause the robot to fall, resulting in severe injury to workers. CAUTION
In the first operation of the robot after installation, the operation should be restricted to low speeds. Then, the speed should be gradually increased to check the operation of the robot. Notes on operation
WARNING Before the robot is started, it should be checked that no one is in the area of the safety fence. At the same time, a check must be made to ensure that there is no risk of hazardous situations. If detected, such a situation should be eliminated before operation. CAUTION
Operators should be ungloved while manipulating the operator’s panel or teach pendant. Operation with gloved fingers could cause an operation error.
NOTE
Programs, system variables, and other information can be saved on floppy disks (option). It is wise to save the data periodically in case the data is lost in an accident. (Refer to the operator’s manual.)
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Notes on programming WARNING Programming should be done outside the area of the safety fence as much as possible. If programming needs to be done in the area of the safety fence, the programmer should take the following precautions: -- Before entering the area of the safety fence, ensure that there is no risk of dangerous situations in the area. -- Be prepared to press the emergency stop button whenever necessary. -- Robot motions should be made at low speeds. -- Before starting programming, check the entire system status to ensure that no remote instruction to the peripheral equipment or motion would be dangerous to himself or herself. CAUTION NOTE
After programming is completed, a test execution should be given according to a specified procedure. (Refer to the operator’s manual). During the test execution, workers must stay out of the safety fence. Programmers should be trained in a suitable course at FANUC. Notes on maintenance
WARNING During maintenance, the robot and system should be in the power--off state as much as possible. If the robot or system is in the power--on state, some maintenance operations can cause a shock hazard. If necessary, a lock should be provided to prevent any other person from turning on the robot or system. If maintenance needs to be executed in the power--on state, the emergency stop button should be pressed if possible. WARNING When replacing a part, the maintenance worker should read the maintenance manual and learn the replacement procedure beforehand. If a wrong procedure is followed, an accident may occur, causing damage to the robot and injury to the worker. WARNING When entering the area enclosed by the safety fence, the maintenance worker should check the entire system to make sure that no dangerous situations are present. If the worker needs to enter the area of the fence while a dangerous situation exists, the worker should always take extreme care and check the current system status. WARNING A part should be replaced with a part recommended by FANUC. If other parts are used, malfunction or damage could occur. Especially, a fuse that is not recommended by FANUC should not be used. Such a fuse may cause a fire. WARNING When a motor or brake is removed, the robot arm should be supported with a crane or other equipment beforehand so that the arm can not fall during the removal. WARNING If robot motion is necessary during maintenance, the following precautions should be taken: -- Reserve an escape route. During the maintenance, always check the motions of the whole system so that the escape route will not be blocked by the robot or peripheral equipment. -- Always pay attention to the risk of dangerous situations and be prepared to press the emergency stop button whenever necessary. WARNING When a motor, decelerator, or other heavy load is handled, a crane or other equipment should be used to protect maintenance workers from excessive load. Otherwise, the maintenance workers can be severely injured. CAUTION
Whenever grease is spilled on the floor, it should be removed as quickly as possible to prevent dangerous falls.
CAUTION
The robot should not be stepped on or climbed on during maintenance. If it is attempted, the robot could be adversely affected. In addition, a misstep can cause injury to the worker.
CAUTION
The following parts are heated. If a maintenance worker needs to touch such a part when it is heated, the worker should wear heat--resistant gloves or use other protective tools. -- Servo motor -- Inside the control unit
CAUTION
When a part is replaced, all bolts and other related components should put back into their original places. A careful check must be given to ensure that no components are missing or left unmounted.
CAUTION
Before the maintenance of the pneumatic system is started, the supply pressure must be shut off and the pressure in the piping must be reduced to zero.
CAUTION
After a part is replaced, a test execution should be given for the robot according to a predetermined method. (Refer to the operator’s manual.) During the test execution, the maintenance staff should work outside the safety fence.
CAUTION
After maintenance is completed, spilled oil or water and metal chips should be removed from the floor around the robot and within the safety fence.
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CAUTION
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When a part is replaced, care must be taken to prevent dust from entering the robot.
NOTE
Each maintenance worker or inspection worker should be trained in a suitable course at FANUC.
NOTE
Maintenance should be done under suitable light. Care must be taken that the light does not cause any danger.
NOTE
The robot should be periodically inspected. (Refer to the maintenance manual.) Failure to do period inspection can adversely affect the performance or service life of the robot and also may cause an accident.
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1.4 Safety Precautions Safety precautions Unlike ordinary automatic machines, robots have arms and wrists which can be moved. A robot is quite flexible, but on the other hand, it is quite dangerous. The robot is usually connected with peripheral equipment to comprise an automated system. Users must take safety precautions for the entire system. The safety precautions are described below. Safety precautions related to installation and layout F
Use warning lamps and other provisions to indicate that the robot is operating.
Figure 1--1. Alarm Indications
Teaching Do not enter
F
Danger
Put a protective fence with a safety door around the system so that only the operator can enter the operating area by the door. Design the system so that it will stop when the door is opened.
NOTE Connect the *FENCE input signal to the safety door. Refer to the maintenance manual for explanations about how to connect.about how to connect. NOTE When the *SFSPD (safety speed) input signal is turned off, the control unit stops the robot immediately. F
Put a protective fence so that the motion range of the robot is completely surrounded. Install the controller outside of the protective fence.
Figure 1--2. Protective Fence Improper installation
Proper installation
F
Install an emergency stop button where it will be readily accessible to the operator.
NOTE Upon receiving an emergency stop signal, the controller immediately stops the robot.
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Figure 1--3. Safety Plug Safety plug When the safety plug is removed, the contact opens.
Control circuit to stop the robot
* SFSPD input
Safety precautions related to system design F
Install a safety joint between robot wrists. If an abnormal external force is applied to the robot, the safety joint breaks and the robot stops.
NOTE When the hand break (*HBK) input signal goes off, the controller immediately stops the robot. F
Hand breakage detection can be disabled when the *HBK input signal is off. This can be set on the system setting screen. See the system config menu section.
F
Ground all peripheral units properly.
F
When a desired operating area is smaller than the maximum operating area of the robot, the desired area can be specified by software parameters.
F
The robot receives interlock signals sent from remote equipment. Upon receiving a signal indicating the operating status of the remote equipment, the robot can stop or halt.
F
When required, install a lock so that only authorized personnel can switch the power on.
NOTE The circuit breaker on the control unit door is designed such that power--on can be disabled by setting a padlock. Figure 1--4. Locking the Circuit Breaker
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Safety precautions related to inspection and maintenance F
Before starting the inspection or maintenance, turn off the power to the controller. Lock the circuit breaker or place a guard to prevent someone else from switching the power on.
F
Before disconnecting the pneumatic system, release the supply pressure.
F
Before starting an inspection in which the electrical system of the robot does not to be operated, press the emergency stop button.
F
When carrying out an inspection in which the robot needs to be operated, carefully observe the motion of the robot. Immediately press the emergency stop button whenever required.
Figure 1--5. Emergency Stop Button
ON
EMEGENCY STOP
Emergency stop button OFF PORT
Emergency stop button
Safety precautions related to transportation F
When transporting the robot or another unit on a carrier such as a crane or fork lift, securely fasten the robot to the carrier.
F
Carefully inspect the crane, fork lift, other carrying equipment, and carrying handle on the product.
Figure 1--6. Carrying the Robot
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Safety precautions related to operation F
F
F
F
All robot system operators are requested to attend FANUC training courses to learn the safety precautions and functions of the robot. Before beginning to program the robot, make sure that there are no abnormal or dangerous conditions around the robot and peripheral equipment. Before working within the operating area of the robot, even when the robot is not running, switch the power off or press the emergency stop button. Install a guard to prevent someone else from entering the operating area of the robot or activating the robot from the operator’s panel. While programming the robot in its operating area, install a guard so that the robot can be immediately stopped in an emergency.
Figure 1--7. Danger Monitoring by Two Persons
Table 1--1.
Safety precautions item
Operator Workshop Avoid dangerous behavior. Wear Keep the workshop neat, tidy, and work clothes, safety shoes, and a clean. Install a protective fence and safety helmet. warning indications. Provide ventilation. Never bring flammable material to the workshop.
Transportation and installation Keep the transportation lane free from obstacles. When transporting the robot or another unit on a carrier such as a fork lift or crane, securely fasten it to the carrier. Keep a sufficient operating area. Make connections properly. Operation Maintenance and inspection Welding machine and torch Attend training classes. Master the Use only FANUC products for repair. Inspect and maintain the cables. operating procedures. Exclude Before starting maintenance or Check the pneumatic pressure. unauthorized personnel. inspection, turn the power off. Close Insulate the gun from the robot. the controller door. Provide a spatter protection wall. Check for leakage of the cooling water. Figure 1--8. Safety Clothes and Safety Helmet
Before approaching the robot to program it, hold the teach pendant in your hand, press the deadman switch, and set the teach pendant enable switch on. NOTE If the deadman switch is released while the teach pendant enable switch is on, the robot immediately stops. F
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Figure 1--9. Deadman switch and Teach pendant enable switch Teach pendant enable switch
Deadman switch
F
Before moving the robot by jog feed, carefully observe the operation of the jog keys and the robot.
F
Before moving the robot by jog feed, sufficiently lower the feedrate override of the robot.
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2. OVERVIEW This chapter shows the basic configuration of the FANUC Robot System and briefly describes the functions of each component. j Contents of this chapter 2.1 Arc Tool Software 2.2 Robot 2.3 Controller
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A FANUC robot for arc welding consists of the tool software for arc welding, the mechanical unit of the robot itself (FANUC Robot series), and the robot control unit. The robot system offers superior performance suited to arc welding of industrial products. ARC tool software The ARC tool software is a software package designed for welding. It is installed in the robot controller. The operator can perform welding by selecting from menus and issuing instructions using the teach pendant. The ARC tool software provides all the instructions necessary to control the robot, welding machine, remote controller, and other peripheral units. The ARC tool software can also control input and output between the robot with six basic axes or controller and the peripheral equipment. The peripheral equipment includes the cell controller, external disk drive unit, and printer. Robot The robot has a welding torch or another end effector interface for control to do work. The FANUC robot ARC Mate 100iB is ideal for arc welding. Controller The robot control unit supplies power to drive the mechanical unit. The tool software for arc welding is installed on the robot control unit to control the teach pendant, operator’s panel, and external peripheral devices. Peripheral devices, including remote control units, are required to configure a system for arc welding. F
The remote control units are used to control the robot control unit.
F
The workpiece clamp, floppy disk drive, printer, and other devices are operated using I/O and serial communication units.
Fig. 2--1 shows a typical robot system for arc welding. The system consists of a robot, the robot control unit, and peripheral devices. Figure 2--1. System
Robot Remote controller
R--J3iB robot controller
Weld Equipment
Conveyor
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2.1 Arc Tool Software The Arc tool software has been specially designed to perform arc welding operations. The Arc tool software is contained in the robot controlunit and enables the following: F
Setting up the system for arc welding applications
F
Creating a program
F
Testing the operation of a program
F
Performing automatic operations
F
Status display or monitoring
When optional functions (for connecting a printer, connecting a floppy disk drive unit, selecting an external program, etc.) are incorporated, the system can be expanded and the management functions can be enhanced.
2.1.1 System setting The Arc tool software has an interface for specifying parameters of operation of the arc welding system. (For how to set the arc welding system, see Chapter 3.) With the ARC tool software, the welding torch, welding machine, remote controller, and other external units can be controlled. Before the arc welding is started, the following must be specified: input from and output to the welding torch, welding machine and other peripheral units, the coordinate system, communication, and automatic operation.
2.1.2 Jog feed of the robot Jog feed of the robot is the operation of moving the robot as desired by manually entering commands on the teach pendant. When a motion instruction of a program is executed, the robot is moved to the target position by jog feed, then the position is recorded. (For the jog feed of the robot, see Chapter 5.)
2.1.3 Program A program contains motion instructions, input/output instructions, register instructions, and branch instructions. (For the program structure, see Chapter 4.) Each instruction is assigned a statement number. The target work is accomplished by sequentially executing the instructions. The Arc teach pendant is used to create or correct a program. (For creation of a program, see Chapter 5.) The program contains the following instructions. Figure 2--2 shows a basic program for arc welding. F
Motion instruction: Moves the tool to the target position within the operating range.
F
Additional motion instruction: Performs an additional (special) operation during a motion.
F
Arc welding instruction: Controls the welding machine and welding torch.
F
Register instruction: Places (loads) numerical data into a register.
F
Position register instruction: Places (loads) position data into a register.
F
Input/output instruction: Sends or receives a signal to or from a peripheral unit.
F
Branch instruction: Changes the flow of a program.
F
Wait instruction: Delays the execution of a program.
F
Routine call instruction: Calls and executes a subprogram.
F
Macro instruction: Calls a specified program and executes it.
F
Program end instruction: Terminates execution of a program.
F
Comment instruction: Adds a comment to a program.
F
Other instructions
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Figure 2--2. Arc welding Program Program name
SAMPLE1
Line number
1: 2: 3: : 4: 5: 6: : 7: 8:
Motion instruction Program instructions Arc welding instruction Weaving instruction
Program end symbol
JOINT 10% 1/9
J P [1] 100% FINE J P [2] 70% CNT50 L P [3] 500mm/s FINE Arc Start [1] Weave Sine [1] L P [4] 50cm/m CNT80 L P [5] 50cm/m CNT80 Arc End [55V, 75A, 0.1s] Weave End J P [1] 100% FINE
[End] POINT
ARCSTRT WELD_PT
ARCEND
TOUCHUP>
2.1.4 Test operation (test execution) After the system is set up and a program is created, perform the test operation in the test execution mode to check the program for normal operation. (For test operation, see Sections 6.2 and 6.3.) Test execution of the program is one of the most important steps in creating a good program. Before starting automatic operation, test each program.
2.1.5 Automatic operation (operation execution) Automatic operation (operation execution) is the final step in executing programs. In automatic operation, the following processing is executed: F
Specified programs are started one after another. (For automatic operation, see Sections 3.14 and 6.6.)
F
During automatic operation, position data can be corrected (online position correction Section 6.7).
F
During automatic operation, the welding schedule data can be adjusted. (For fine--tuning of welding, see Section 6.8.)
F
The processing is halted, then aborted or resumed. (For halting a program, see Section 6.1.)
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2.2 Robot A robot is a mechanical unit consisting of axes and arms driven by servo motors. The place at which an arm is connected is a joint, or an axis. J1, J2, and J3 are main axes. The basic configuration of the robot depends on whether each main axis functions as a linear axis or rotation axis. The wrist axes are used to move an end effecter (tool) mounted on the wrist flange. The wrist itself can be wagged about one wrist axis and the end effector rotated about the other wrist axis. Figure 2--3. Main axes and wrist axes
+J3 --J3 +J4 +J5 --J5
--J4
Wrist axes
+J6 --J2
--J6 +J2
--J1
+J1
Main axes
2.2.1 Robot arms FANUC offers the ARC Mate 100iB. Figure 2--4 shows the robots. The robot is a 6--axis articulated robot with three basic axes and three wrist axes. With an arc welding system, an arc welding torch is usually attached to the wrist. Figure 2--4. FANUC Robot ARC Mate 100iB
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Figure 2--5. FANUC Robot ARC Mate 120iβ
2.2.2 Arc welding torch An arc welding torch is mounted on the robot’s wrist flange. The arc tool software controls the torch as well as the welding machine, thus ensuring optimum welding. Consult a system designer and select a welding torch that is suitable for your application. Figure 2--6. Welding torch
Curved torch for MAG welding
Straight torch for TIG welding
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2.3 Controller The robot controller includes a power unit, user interface circuit, motion controlling circuit, memory circuit, and input/output circuit. The user should use a teach pendant and operator’s box to operate the control unit. The operation control circuit controls the servo amplifier which moves all the robot axes, including any additional axes, via the main CPU printed circuit board. The memory circuit can store programs and data set by the user in the S--RAM on the main CPU printed circuit board. The input/output (I/O) circuit interfaces the controller with the peripheral units by receiving and sending signals via the I/O link cable and peripheral connecting cable. The remote input/output signal is used for communication with the remote controller. Figure 2--7. Robot controller R--J3i MODEL B controller
Operator panel Three mode switch
Teach pendant
The circuitry of the controller depends on the robot and the system it controls. For details, refer to the maintenance manual.
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2.3.1 Teach pendant The teach pendant interfaces the Arc tool software with the operator. The teach pendant is connected to the PC board for controlling the robot in the controller by a cable. The following operations can be performed using the teach pendant: F
Jog feed of the robot
F
Program generation
F
Test execution
F
Actual work
F
Status check
The teach pendant includes the following: F
Liquid crystal display of 40 characters by 16 lines
F
11 LEDs including three LEDs for the ARC tool
F
61 keys including three keys for the ARC tool CAUTION
The operator of the teach pendant should use gloves that will not cause any operation error.
The following switches are also provided: Teach pendant enable switch
This switch enables or disables the teach pendant. When the teach pendant is disabled, a jog feed, program generation, or test execution cannot be carried out.
DEADMAN switch
DEADMAN SWITCH is used as an enabling device. When the teach pendant is enabled, this switch allows robot motion only while the DEADMAN switch is gripped. If you release this switch, the robot stops immediately.
Emergency stop button
When pressed, the emergency stop button immediately stops the robot.
Figure 2--8. Switches on the Teach Pendant
EMERGENCY STOP button
Teach pendant enable switch
DEADMAN switch
Figure 2--9 shows the teach pendant.
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Figure 2--9. Teach Pendant
LCD screen (16*40): Displays programs, data, diagnostic etc.
Status indicators: Indicates alarm, running, busy status, etc.
SAMPLE1
Return key: Used to move back to the previous operation.
FAUL T PAUSED STEP BUSY RUNNING
Arc LEDs: Displays arc welding status.
WELD ENBL ARC ESTAB DRY RUN JOINT
Enable/Disable switch (Teach pendant ON/OFF switch): Selects teach pendant enable/disable.
XYZ
1: 2: 3: : 4: 5: 6: : 7: 8: [End] POINT
JOINT 10% 1/9
J P [1] 100% FINE J P [2] 70% CNT50 L P [3] 500mm/s FINE Arc Start [1] Weave Sine [1] L P [4] 50cm/m CNT80 L P [5] 50cm/m CNT80 Arc End [55V, 75A, 0.1s] Weave End J P [1] 100% FINE ARCSTRT WELD_PT
ARCEND
Next page key: Displays the function key menu of the next page.
TOUCHUP>
TOOL OFF
ON
MENUS key: Use this key to display the menu screen.
Emergency Stop button: Use this button for Emergency stop
FCTN key: Use this key to display the supplementary menu.
Cursor keys: Use these keys to move the cursor. STEP key: Use this key to switch between step execution and cycle execution.
Program keys: Use these keys to select menu options. WELD ENBL
RESET key: Use this key to clear the alarm.
HOLD key: Use this key to stop the robot.
WIRE +
BACK SPACE key: Use this key to delete the character or number immediately before the cursor. ITEM key: Use this key to select an item using its number ENTER key: Use this key to enter a numeric value or to select an item from the menu.
Function key (F key): Selects a function key menu item.
FWD (forward) key: Use this key to execute the next program statement.
WIRE --
MAN FCTN
POSN
STATUS
Jog keys: Use this key to move the robot manually.
MOVE MENU
WELD ENBL Key: Alternately Enable and Disable Weld equipment.
POSN key: Use this key to display the POSITION screen.
COORD (coordinate) key: Use this key to select the jog coordinate system or select another group.
Jog Speed keys: Use these keys to adjust the speed of the robot when it moves. WIRE keys: Advance and Retract the wire manually.
STATUS key: Use this key to dispaly the STATUS screen. MOVE MENU Key: Use this key to invoke a Macro program. The Macro program can move the orobt to its HOME position.
MAN FCTN keys: Use this key to display the Manual function screen.
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2.3.1.1 Keys on the teach pendant The teach pendant has the following keys: F Keys related to menus F Keys related to jog feed F Keys related to execution F Keys related to editing F Keys related to arc welding Table 2--1.
Keys related to menus Function
Key
The function (F) key selects a function menu at the bottom of the screen.
F1
F2
F3
F4
F5 The NEXT page key displays the function menu on the next page. NEXT
SELECT
MENUS
FCTN
EDIT
DATA
MOVE MENU
The MENUS key displays the screen menu. The FCTN key displays the function menu. The SELECT key displays the program selection screen. The EDIT key displays the program edit screen. The DATA key displays the program data screen. The MOVE MENU key moves the robot to the reference position. Create a program which moves the robot to the reference position and assign this program to a macro instruction so that this can be started by this MOVE MENU key. The SET UP key displays the setup screen.
SETUP
The STATUS key displays the current position screen. STATUS
The I/O key displays the I/O screen.
I/O The POSN key displays the current position screen. POSN
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Table 2--2.
Keys related to jog feed
Key
Function SHIFT
--Z (J3)
--Y (J2)
--X (J1)
+Z (J3)
+Y (J2)
+X (J1)
--Z (J6)
--Y (J5)
--X (J4)
+Z (J6)
+Y (J5)
+X (J4) COORD
+% Table 2--3.
--%
The SHIFT key is used to execute a jog feed of the robot, teach position data, and start a program. The jog key executes a jog feed of the robot.
The manual feed coordinate system key is used to switch the manual feed coordinate system (jog type) from JOINT to JGFRM to RECT to TOOL to USER to PATH then back to JOINT. Pressing this key together with the shift key displays the jog menu for coordinate system switching. The override key adjusts the feedrate override. Each time the override key is pressed, it selects the next override in the order: VFINE, FINE, 1%, 5%, 50%, 100%.(changing amount 1% for 5% or less and changing amount 5% for 5% or more.)
Keys related to execution
Key
Function FWD
BWD
The start key (+ SHIFT key) starts a program. When the shift key is released during regeneration, the program halts. The HOLD key causes a program to halt.
HOLD
The STEP key selects step or continuous test operation. STEP
Table 2--4.
Keys related to editing
Key
Function The PREV key restores the most recent state. PREV The ENTER key enters a numeral or selects a menu. ENTER
BACK SPACE
The BACK SPACE key deletes the character or numeral immediately before the cursor. The cursor key moves the cursor. The cursor is the highlighted part which can move on the teach pendant screen. This part becomes the object of operation ( input or change of the value or contents) from the teach pendant key.
The ITEM key moves the cursor to a line whose number is specified. ITEM
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Table 2--5.
Keys related to arc welding
Key
Function The WELD ENBL key (+ SHIFT key) enables/disables welding. WELD ENBL
The WIRE+/-- key (+ SHIFT key) feeds/rewinds the wire manually. WIRE --
WIRE +
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2.3.1.2 LEDs on the teach pendant Figure 2--10. LEDs on the teach pendant FAULT HOLD STEP BUSY RUNNING WELD ENBL ARC ESTAB
DRY RUN JOINT XYZ TOOL OFF ON
Table 2--6.
LEDs on the teach pendant LED
Function
FAULT
The FAULT LED indicates that an alarm has occurred.
HOLD
The HOLD LED indicates that the HOLD button is being pressed
STEP
The STEP LED indicates that it is in step operation mode.
BUSY
The BUSY LED is lit while the robot is working. It is also lit when a program is executed or when the printer or floppy disk drive unit is operating.
RUNNING
The RUNNING LED indicates that the program is being executed.
WELD ENBL
The WELD ENBL LED, when lit, indicates that arc welding is enabled.
ARC ESTAB
The ARC ESTAB LED, when lit, indicates that arc welding is in progress.
DRY RUN
The DRY RUN LED, when lit, indicates that test operation mode, using dry run, is selected.
JOINT
The JOINT LED is lit when joint jog is selected as the manual--feed coordinate system (jog type).
XYZ
The XYZ LED is lit when Cartesian jog (JGFRM or USER) is selected as the manual--feed coordinate system (jog type).
TOOL
Indicates that the manual feed coordinate system is a tool coordinate system or path coordinate system.
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2.3.1.3 Display screen of the teach pendant The liquid crystal display screen (liquid crystal display) displays the Arc tool software screen shown in Figure 2--11. To operate the robot, select a screen corresponding to a desired function. The screen is selected by the screen menus shown in Figure 2--12. Figure 2--11. Program Edit Screen
Program which is being executed Program which is being edited
Line number Program end symbol
Manual--feed coordinate system (jog type) Indicates the current jog type. TP forward/backward disable FBD is displayed when the teach pendant is effective and is set that start from teach pendant is FBD prohibited. PAUSED
Current line number Indicates the number of the line in the program being executed.
SAMPLE1 SAMPLE1
LINE 1 PAUSED
1: J 2: J 3: L 4: L 5: J [End]
P[1] P[2] P[3] P[4] P[1]
JOINT 30% 1/6
100% FINE 70% CNT50 1000cm/min CNT30 500mm/sec FINE 100% FINE
Enter value of press ENTER [CHOICE] POSITION
Prompting message Prompts the operator to enter data. The message depends on the selected screen and the position of the cursor.
Execution status Indicates ABORTED, PAUSED, or RUNNING. Feedrate override The override key specifies the percentage of the maximum feedrate. Current line and total number of lines Indicates the number of the line in the program being executed or edited and the total number of lines in the current program.
Function key menu Indicates the function key labels. The menu depends on the selected screen and the position of the cursor. Labels including [ ] shows that the selection menu is displayed when this label is selected.
27
2. OVERVIEW
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2.3.1.4 Screen menu and function menu Menus are used to operate the teach pendant. The screen menu is selected by the MENUS key. The function menu is selected by the FCTN key. Figure 2--12, Figure 2--13, and Figure 2--14 show the screen menu, function menu, and quick menu respectively. Screen menu The screen menu is used to select a screen. The screen menu lists the following options. (For the list of menus, see Appendix A.1. For the screen type, see Appendix A.2.) To display the screen menu, press the MENUS key on the teach pendant. Figure 2--12. Screen menu
1 2 3 4 5 6 7 8 9 0
MENUS
1 2 3 4 5 6 7 8 9 0
UTILITIES TEST CYCLE MANUAL FCTNS ALARM I/O SETUP FILE USER --NEXT--
Page 1
Table 2--7.
SELECT EDIT DATA STATUS POSITION SYSTEM
--NEXT--
Page 2
Screen menu LED
Function
UTILITIES
The utility screen is used to display hints.
TEST CYCLE
The test cycle screen is used to specify the data for test operation.
MANUAL FCTNS
The manual operation screen is used to execute macro instructions.
ALARM
The alarm history screen shows the history and details of alarms.
I/O
The I/O screen is used to display and set manual output, simulated input/output, and assignment of signals.
SETUP
The setting screen is used to setup the system.
FILE
The file screen is used to read or store files.
USER
The user screen shows user messages.
SELECT
The program selection screen is used to list or create programs.
EDIT
The program edit screen is used to correct and execute a program.
DATA
The program data screen shows the values in registers, position registers, and pallet register.
STATUS
Indicates the system or arc welding state.
POSITION
The current position screen shows the current position of the robot.
SYSTEM
The system screen is used to set system variables and for mastering.
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2. OVERVIEW
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Function menu The function menu is used to execute a miscellaneous function. (For the list of menus, see Appendix A.1.) To display the function menu, press the FCTN key on the teach pendant. Figure 2--13. Function menu
1 2 3 4 5 6 7 8 9 0
FCTN
ABORT (ALL) Disable FWD/BWD CHANGE GROUP TOGGLE SUB GROUP TOGGLE WRIST JOG
1 2 3 4 5 6 7 8 9 0
RELEASE WAIT
-- NEXT --
Page 1
Table 2--8.
QUICK/FULL MENUS SAVE PRINT SCREEN PRINT
-- NEXT --
Page 2
Function menu LED
Function
ABORT (ALL)
ABORT forces a program which is being executed or temporarily halted to terminate.
Disable FWD/BWD
Disable FWD/BWD enables or disables starting a program with the teach pendant
CHANGE GROUP
Changes the operation group for jog feed. Displayed only when multiple groups are set.
TOGGLE SUB GROUP
TOGGLE SUB GROUP toggles jog feed between robot standard axes and extended axes.
TOGGLE WRIST JOG
TOGGLE WRIST JOG toggles jog between the attitude control feed and the wrist joint feed which does not maintain the wrist attitude in linear feed.
RELEASE WAIT
Skips the wait instruction currently being executed. When the wait state is released, execution of the program stops temporarily at the line immediately following the wait instruction.
QUICK/FULL MENUS
QUICK/FULL MENUS toggles the menu between a usual screen menu and a quick menu.
SAVE
SAVE saves the data related to the current screen on a floppy disk.
PRINT SCREEN
PRINT SCREEN prints the data displayed on the current screen.
PRINT
PRINT prints the data on the current screen.
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2. OVERVIEW
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Quick menu When a quick menu is selected, the screen that can be displayed by using the screen menu is limited to the following: F
ALARM / alarm history screen
F
UTILITIES / hint screen
F
Setup screen
F
DATA / register screen
F
MANUAL FUNCTIONS Screen
F
STATUS screen
F
I/O screen
F
POSITION screen
Figure 2--14. Quick menu
1 2 3 4 5 6 7 8 9 0
ALARM UTILITIES TEST CYCLE DATA MANUAL FCTNS I/O STATUS POSITION
NOTE The program selection screen can be displayed by using the SELECT key. But the function except selecting a program can not be used. NOTE The program edit screen can be displayed by using the EDIT key. But the function except changing of the position and the speed value can not be used.
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2. OVERVIEW
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2.3.2 Operator’s panel The operator’s panel/box has buttons, switches, and connectors. Fig. 2--22 shows the operator’s box on the cabinet. The buttons on the operator’s panel can be used to turn the power on and off, start a program, release the alarm state, and perform other operations. CAUTION Do not wear gloves that could cause operator errors when using the operator’s panel. The operator’s panel also has an RS--232C communication port and a memory card slot. Table 2--9 lists the switches on the operator’s panel. Table 2--10 lists the LEDs on the operator’s panel. Table 2--9.
Switches on the Operator’s Panel
Switch Function Power--on button Turns on the power to the robot control unit. Lit while the power is on. Power--off button Turns off the power to the robot control unit. Emergency stop button Press this button to stop the robot immediately. Turn the emergency stop button clockwise to release it. Remote switch Switches between remote and local operation modes. Alarm release button Releases the alarm state. Start button Starts the currently selected program. Lit while the program is being started. User #1 and #2 buttons Execute the functions defined for the user keys. Three mode switch Enables the user to select operation mode suitable to the robot operation conditions or the status of its use. Table 2--10. LED Alarm
LEDs on the Operator’s Panel Function Indicates the alarm state. Press the alarm release button to release the alarm state.
Figure 2--15. Operator’s Box Power--on button Three mode switch Start button Alarm release
31
Emergency stop button
2. OVERVIEW
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2.3.3 Remote controller Remote control units are external devices connected to the robot control unit to configure a system. These control units operate systems that are configured by the custome using peripheral devices and Robot I/O.
2.3.4 CRT/KB The CRT/KB is an optional operation unit. An external CRT/KB is connected to the control unit via an RS--232C cable. The CRT/KB can be used to execute almost all teach pendant functions excluding those related to robot operation. Functions related to robot operation can only be executed using the teach pendant.
2.3.5 Communication For communications, the following interfaces are provided (Refer to communication ports Section 8.2). F
One standard RS--232C port (external)
F
Two optional RS--232C ports (internal)
2.3.6 Input/output General--purpose and specialized input/output (I/O) signals are used to send the data of an external unit to the Arc tool software. The general--purpose signal (user--defined signal) is controlled by a program and is used to send or receive data to or from the external units or hand. The specialized signal (system--defined signal) is applied to a specific use. The input/output signals include the following: F
Welding Input/Output (See Section 3.1.)
F
Peripheral I/O (See Section 3.10.)
F
Operator’s panel I/O (See Section 3.11.)
F
Robot I/O (See Section 3.9.)
F
Digital I/O (See Subsection 3.8.1.)
F
Group I/O (See Subsection 3.8.2.)
F
Analog I/O (See Subsection 3.8.3.)
The number of the I/O signals and their types depend on the hardware of the control unit and the number of selected I/O modules and their types. I/O unit model A, I/O unit model B, and Process I/O PC board can be connected to the controller. Process I/O PC board has the maximum number of I/O signal lines which can be used. (See MAINTENANCE MANUAL)
2.3.7 Peripheral I/O Peripheral I/O is a signal specialized for sending and receiving data to or from the remote controller or peripheral equipment. As a result, the following operations can be done (See Section 3.10, “Peripheral I/O”). Peripheral I/O signals perform the following: F
Select a program
F
Start and stop a program
F
Recover the system from the alarm state
F
Others
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2. OVERVIEW
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2.3.8 Motion of the robot A single motion instruction specifies a motion of the robot, or a movement of the tool center point (TCP) from the current position to the target position. The robot controller uses a motion control system that comprehensively controls the tool path, acceleration/deceleration, positioning, feedrate, and other factors. The robot control unit can control up to 16 axes, divided into up to three operation groups (multiple motion function). The control unit can control up to nine axes for a group. The operation groups are independent of one another, but can be synchronized to operate the robot simultaneously. The robot moves according to a jog feed specified on the teach pendant or a motion instruction specified in a program. To execute a jog feed of the robot, use the corresponding key on the teach pendant. In jog feed, the motion of the robot depends on the selected manual--feed coordinate system (jog type) and feedrate override. When a motion instruction is used, the motion of the robot depends on the position data, motion format, positioning path, traveling speed, and feedrate override specified in the instruction. One of three motion formats ---- Linear, Circular, and Joint ---- can be selected to operate the robot. When Joint is selected, the tool is moved arbitrarily between two specified points. When Linear is selected, the tool is moved along a straight line between the two specified points. When Circular is selected, the tool is moved along an arc connecting three specified points. A positioning path can be selected from two options, Fine and Cnt.
2.3.9 Emergency Stop devices This robot has the following emergency stop devices. F
two emergency stop buttons ( installed on the operator’s panel and the teach pendant )
F
external emergency stop ( input signal )
When the emergency stop button is pushed, the robot stops immediately in all cases. The external emergency stop outputs or inputs the emergency stop signal for peripheral devices (e.g. safety fence, gate). The signal terminal is on the controller and operator’s box inside.
2.3.10 Extended axis A maximum of 3 axes in one group can be added to the standard axes (usually six axes) of the robot. The robot controller can control up to 16 axes (with optional servo card). The extended axis has the following two types: F
Extended axes This can be controlled regardless of the robot motion and can move only at the joint motion.
F
Integrated axes Controlled together with the robot during linear or circular robot operation. Use these axes to perform linear or circular robot operation.
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3. SETTING UP THE ARC SYSTEM
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3. SETTING UP THE ARC SYSTEM The ARC Tool application can be used after required data is specified. This chapter describes the data that can be specified. j Contents of this chapter 3.1
Welding Input/Output Signals
3.2
Setting the Arc Welding System
3.3
Setting the Arc Welding Equipment
3.4
Setting Arc Welding Conditions
3.5
Weld Schedule Advise Screen
3.6
Setting for Weaving
3.7
Weave Schedule
3.8
Input/Output Signals
3.9
Robot I/O
3.10 Peripheral I/O 3.11 Operator’s Panel I/O 3.12 I/O Link Screen 3.13 I/O Connection Function 3.14 Setting Automatic Operation 3.15 Setting coordinate systems 3.16 Setting a Reference Position 3.17 Joint Operating Area 3.18 User Alarm 3.19 Variable Axis Areas 3.20 Special Area Function 3.21 System Config Menu 3.22 Setting Up General Items 3.23 Other Settings
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3. SETTING UP THE ARC SYSTEM
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3.1 Welding Input/Output Signals Welding input/output (I/O) signals are used to control welding equipment exclusively via the process I/O printed circuit board during program execution. The signal numbers for the welding input/output signals (WDI/WDO or AI/AO) are fixed on the welding process I/O printed circuit board, as listed below. Table 3--1.
Welding input signals Welding input signals
Arc detect
Arc detection
WI [ 2 ]
Gas fault
Gas alarm
WI [ 3 ]
Wire fault
Wire alarm
WI [ 4 ]
Water fault
Cooling water alarm
WI [ 5 ]
Power fault
Power alarm
WI [ 6 ]
Voltage feed back
Feedback voltage
AI [ 1 ]
Current feed back
Feedback current
AI [ 2 ]
Arc enable
Enable welding
DI [ 0 ]
Wire stick
Wire stick detection
WS [ 1 ]
Table 3--2.
Welding output signals Welding output signals
Weld start
Arc
WO [ 1 ]
Gas start
Gas
WO [ 2 ]
Inch forward
Manual wire feed
WO [ 4 ]
Inch backward
Manual wire rewind
WO [ 5 ]
Wire stick alarm
Wire stick alarm
WO [ 6 ]
Voltage
Command voltage
AO [ 1 ]
Current
Command current
AO [ 2 ]
Wire inch
Wire inching
AO [ 2 ]
Figure 3--1. Interface for the CA Welding Process I/O Printed Circuit Board Printed circuit board for robot control
Process I/O printed circuit board CA
JD1A
CRM2A
Peripheral unit A1
JD4A CRM2B
Peripheral unit A2
JD4B
CRW1 01 02 03 04 05 06 07 08 09 10 11 12
aout 1 aout 1--C aout 2 aout 2--C WDI 1 WDI 2 WDI 3 WDI 4 WDI 5 WDI 6 WDI 7 WDI 8
13 14 15 16 17 18 19 20 21 22
ain 1 ain 1--C ain 2 ain 2--C
0V 0V 0V 0V
CRW1
Peripheral unit
CRW2
Peripheral unit CRW2
23 24 25 26 27 28 29 30 31 32 33 34
WDO 1 WDO 2 WDO 3 WDO 4 WDO 5 WDO 6 WDO 7 WDO 8 WDI + WDI -+24V +24V
35
01 02 03 04 05 06 07
08 ain 6 09 ain 6--C 10 11 12 13
14 15 16 17 18 19 20
ain 3 ain 3--C ain 4 ain 4--C ain 5 ain 5--C
ain *--C is the common signal line for ain *.
3. SETTING UP THE ARC SYSTEM
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Welding sequence Figure 3--2. Welding Sequence (Accompanied by a Motion Instruction) Operating Robot operation
At stop Arc end instruction
Arc start instruction Gas start Gas purge time
Gas preflow time
Gas postflow time
Weld start Specified voltage Postprocessing time Specified current Start--up time
Crater prevention time
Arc detection Arc detect time
Wire stick detect instruction delay
Wire stick detect instruction (WST) Wire stick detection delay Wire stick detection (WDI+) (WDI--)
Wire stick detection time
Figure 3--3. Welding Sequence (Not Accompanied by a Motion Instruction) Operating At stop
Robot operation
Arc start instruction
Arc end instruction
Gas start Gas preflow time
Gas postflow time
Weld start Specified voltage Postprocessing time Specified current Start--up time
Crater prevention time
Arc detection Arc detect time
Wire stick detect instruction delay
Wire stick detect instruction (WST) Wire stick detection delay Wire stick detection (WDI+) (WDI--) Wire stick detection time
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3. SETTING UP THE ARC SYSTEM
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3.1.1 Welding input signals Welding input signals are supplied from the welding equipment and peripheral units. These signals are specified at the [5 I/O Weld] on the welding I/O screen. Table 3--3.
Welding input signals
Input signal
Description
Arc detect WI [2]
When the arc detect signal is on, it indicates that an arc is being generated on the torch and welding is in progress. If it turns off during welding, it means that an arc loss occurred. If the arc loss detection function (welding system screen) is enabled, the robot stops immediately when an arc loss occurs, and the program is aborted.
Gas fault WI [3]
The gas fault signal is usually connected to the gas output switch. This signal is input when a gas shortage occurs. If the gas shortage detection function (welding system screen) is enabled, the gas fault signal generates a weld alarm.
Wire fault WI [4]
The wire fault signal is input if trouble such as a wire shortage occurs in the wire feed unit during welding. If the wire shortage detection function (welding system screen) is enabled, the wire fault signal generates a weld alarm.
Water fault WI [5]
The water fault signal is input if trouble occurs in the cooling unit or water circulation hose during welding. If the coolant shortage detection function (welding system screen) is enabled, the water fault signal generates a weld alarm.
Power fault WI [6]
The power fault signal is input if a failure occurs in the power supply during welding. If the power supply failure detection function (welding system screen) is enabled, the power fault signal generates a weld alarm.
Voltage feedback AI [1]
The voltage feedback signal is an analog voltage signal representing the welding voltage being currently used for welding. It is supplied to the controller. The actual voltage used depends on the specified voltage input scaling factor.
Current feedback AI [2]
The current feedback signal is an analog voltage signal representing the welding current being currently used for welding. It is supplied to the controller. The actual current used depends on the specified current input scaling factor.
Arc enable DI [0]
The arc enable signal is a peripheral unit input signal for enabling/disabling welding. It works only in the remote mode (when the remote switch on the operator’s panel is set to on). The arc enable signal is used by peripheral units to enable/disable welding. The WELD ENBL key is used with the teach pendant to enable/disable welding. If the signal number is 0, this signal is ineffective. When the arc enable signal is effective, if the *SFSPD or ENBL input signal becomes off, welding is disabled.
Wire stick WS [1]
The wire stick detection signals are fixed on the process I/O board. A wire stick can be detected by reading the voltage across the weld detection circuit (software switch in the controller) when it is operating. A wire stick is judged depending on whether the voltage reading is below a certain level.
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3. SETTING UP THE ARC SYSTEM
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3.1.2 Welding output signals Welding output signals are supplied to the welding equipment and peripheral units. These signals are defined as follows: Table 3--4.
Welding output signals
Output signal
Description
Weld start WO [1]
When the weld start signal is on, it directs the welding machine to generate arc.
Gas start WO [2]
When the gas start signal is on, it directs the welding machine to output welding gas.
Weld output WO [3]
The weld output signal is not in use at present.
Inch forward WO [4]
The inch forward signal is used on the teach pendant to direct wire feed.
Inch backward WO [5]
The inch backward signal is used on the teach pendant to direct wire rewind.
Wire stick alarm WO [6]
The wire stick alarm signal is output to the welding machine, if the wire stick detection function is enabled (welding system screen) and a wire stick is detected (when the wire stick detection signal is on). If an automatic wire stick reset is enabled (welding equipment screen), a wire stick reset is performed a specified number of times. If a wire stick is still detected, this signal is output.
Voltage AO [1]
The specified--voltage signal is an analog voltage output signal representing the welding voltage. It is sent to the welding machine. The voltage value of the analog signal depends on the voltage output scaling factor.
Current or wire feed speed AO [2]
The specified--current signal is an analog voltage output signal representing the welding current. It is sent to the welding machine. The wire feed speed signal is an analog voltage output signal representing the speed at which the welding wire is to be fed. It is sent to the welding machine. The output voltage value of the analog signal depends on the current output scaling factor. NOTE The name of this signal is automatically changed when the model of welding power supply is set.
WST
The wire stick detect instruction signal is used within the controller. This signal is used to operate the weld detection circuit relay in the controller, thereby reading the voltage difference between the wire stick detection signals (WDI+ and WDI--).
Wire inch AO [2]
The wire inch signal sets a wire feed/rewind amount when the wire feed/rewind signal is output from the control unit.
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3. SETTING UP THE ARC SYSTEM
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Procedure 3--1 Step
Setting welding I/O signals
1 Press the MENUS key. 2 Select 5 (I/O). 3 Press F1 (TYPE). 4 Select “Weld.” The welding I/O signal screen is displayed. Welding input screen
4 ALARM 5 I/O 6 SETUP
I/O Weld In
G1
10 % 1/12 TYPE # SIM STATUS ] AI[ 1] U 0.0 ] AI[ 2] U 0.0
WELD SIGNAL 1 [Voltage 2 [Current
MENUS
3 4 5 6 7 8 9 10
Weld [TYPE]
F1
[ [Arc detect [Gas fault [Wire fault [Water fault [Power fault [ [
WI[ WI[ WI[ WI[ WI[ WI[ WI[ WI[
1] 2] 3] 4] 5] 6] 7] 8]
U U U U U U U U
OFF OFF OFF OFF OFF OFF OFF OFF
11 [Wirestick
] WS[
1]
U
OFF
12 [Are enable
]
[***]
*
***
[ TYPE ]
HELP HELP
] ] ] ] ] ] ] ]
JOINT
IN/OUT SIMULATE UNSIM > CONFIG SIMULATE UNSIM >
NOTE The analog signal display area of the screen shown above increases or decreases in accordance with the number of analog input/output signals. 5 To switch between the input and output screens, press F3 (IN/OUT). Welding output screen I/O Weld Out [ TYPE ]
HELP
G1
JOINT
IN/OUT
F3
WELD SIGNAL 1 [Voltage 2 [Current 3 [Wire inch 4 5 6 7 8 9 10 11
TYPE # SIM ] AO[ 1] U ] AO[ 2] U ] AO[ 2] U
[Weld start ] [Gas start ] [ ] [Inch forward ] [Inch backward ] [Wire stick alarm] [Feed forward ] [Feed backward ]
[ TYPE ] [ TYPE ]
HELP HELP
WO[ WO[ WO[ WO[ WO[ WO[ WO[ WO[
1] 2] 3] 4] 5] 6] 7] 8]
U U U U U U U U
10 % 1/11 STATUS 0.0 0.0 0.0 OFF OFF OFF OFF OFF OFF OFF OFF
IN/OUT SIMULATE UNSIM > CONFIG SIMULATE UNSIM >
NOTE The analog signal display area of the screen shown above increases or decreases in accordance with the number of analog input/output signals. 6 To set or reset the simulation flag, place the cursor on the simulation flag and select the function key.
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3. SETTING UP THE ARC SYSTEM
I/O Weld In
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JOINT 30%
2 Arc detect:
WI[
[ TYPE ]
IN/OUT
2]
U
OFF
SIMULATE UNSIM
I/O Weld In 2 Arc detect: [ TYPE ]
JOINT 30% WI[ IN/OUT
2]
S
OFF
SIMULATE UNSIM
F4 7 For forcible output and simulated input/output, place the cursor at ON/OFF, and select the function key. I/O Weld In
JOINT 30%
2 Arc detect: [ TYPE ]
WI[ IN/OUT
2]
S
ON
OFF OFF
I/O Weld In 2 Arc detect: [ TYPE ]
JOINT 30% WI[ IN/OUT
2]
S
ON
ON OFF
F4 NOTE Forcible output or simulated input/output cannot be specified for items having no line number. WARNING The controller controls peripheral units using signals. Forcible output or simulated input/output might cause an adverse effect to the safety of the system. Do not use forcible output or simulated input/output before you understand how the signals are used in the system.
Increasing/decreasing the number of controlled analog input/output signals In the initial state, the number of analog input/output signals that can be controlled is 2 channels. When three or more controlled analog input/output signals are required, the number of analog input/output signals needs to be set. Two methods of increasing/decreasing the number of controlled analog input/output signals are available. F
A floppy disk that holds welding power supply data including the changed number of analog input/output signals is supplied. Select a welding power supply from the welding power supply selection screen held in the floppy disk data. For welding power supply data creation, inform FANUC of the following items beforehand: -- Welding power supply name -- Number of controlled analog input/output signals (AO: 1 to 6, AI: 1 to 6) -- Name and unit of each analog input/output signal -- Reference value and command value for each analog input/output signal
F
The number of controlled analog input/output signals can be increased or decreased by changing the value of a system variable according to the procedure below.
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3. SETTING UP THE ARC SYSTEM
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Procedure 3--2 Step
Increasing/decreasing the controlled analog input/output signals
1 Turn off the power, then perform a control start. Then, the screen shown below appears. ArcTool Setup
CONTROLLED START MENUS 1/3 1 F Number: F00000 Equipment: 1 2 Manufacturer: DAIDEN 3 Model: UR200/Fe0.8
Press FCTN then START (COLD) when done. [ TYPE ]
HELP
2 Press the MENUS key, then select 4 SYSTEM. 3 Change the setting of the system variable $AWECFG[1].$NUM_AO (number of analog output signals) and $NUM_AI (number of analog input signals) as required. 4 To set the attribute of each analog signal, modify the following system variables in the system variable $AWEPRR[1]: To change $NUM_AO to 3, and set a frequency (Hz) in AO[3], for example, make the following settings: a Set the value 3 in $AWEPRR[1].$CURRENT_CMD.$PORT_NUM. b Enter the word FREQUENCY in $AWEPRR[1].$CURRENT_CMD.$NAME (which allows up to 12 characters to be set). c Enter the word Hz in $AWEPRR[1].$CURRENT_CMD.$UNITS (which allows up to 6 characters to be set). 5 Press the auxiliary key, then select START (COLD). 6 After startup, set a reference value range and command value range for each analog input/output signal on the welding I/O screen. (See the welding I/O screen.) 7 When making a modification to each analog input/output signal, change the following system variables according to $AWEPRR[1].$CURRENT_CMD above: AO [1] AO [2] AO [3] AO [4] AO [5] AO [6] AI [1] AI [2] AI [3] AI [4] AI [5] AI [6]
: $ AWEPRR [1]. $ VOLTAGE_CMD : $ AWEPRR [1]. $ WFS_CMD : $ AWEPRR [1]. $ CURRENT_CMD : $ AWEPRR [1]. $ PK_CURR_CMD : $ AWEPRR [1]. $ FREQ_CMD : $ AWEPRR [1]. $ PULSE_CMD : $ AWEPRR [1]. $ VOLTAGE_FBK : $ AWEPRR [1]. $ CURRENT_FBK : $ AWEPRR [1]. $ WFS_FBK : $ AWEPRR [1]. $ FBK4 : $ AWEPRR [1]. $ FBK5 : $ AWEPRR [1]. $ FBK6
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3. SETTING UP THE ARC SYSTEM
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3.1.3 Setting a reference value range and command value range for specifying an analog input/output signal Set the correspondence between each analog input/output signal (reference value) of the control unit and an actual output value (command value) of the welding equipment. Input Reference value: Voltage of an analog input (feedback) signal sent from the welding equipment to the control unit Command value: Value actually output by the welding equipment for the reference value above Output Reference value: Voltage of an analog output signal sent from the control unit to the welding equipment Command value: Value actually output by the welding equipment for the reference value above Procedure 3--3 Step
Setting a reference value range and command value range for specifying an analog input/output signal
1 On the welding input or output signal screen, move the cursor to an analog signal to be modified. For example, move the cursor to voltage input AI[1]. 2 After pressing the F! key, press the F3 (CONFIG) key. The screen shown below appears. I/O Weld In 1
2 3
4
G1
JOINT
10 % 1/4
AI[ 1 ] ^ (Volts) | | * 10.000 + - - - - - - - - * | * | 0.000 + - - * | * | | +-----+-----------+------> 0.000 50.000 Voltage (Volts )
[ TYPE ] MONITOR VERIFY
HELP
3 Move the cursor to a reference value (on the vertical axis) or command value (on the horizontal axis) to be newly set. The modifiable items are as follows: F
Minimum reference value (lower side on the vertical axis)
F
Maximum reference value (upper side on the vertical axis)
F
Minimum command value (left side on the horizontal axis)
F
Maximum command value (right side on the horizontal axis)
4 By pressing the F3 (VERIFY) key, whether an assigned signal type and number actually exist can be checked. 5 Pressing the F2 (MONITOR) key returns the screen display to the welding I/O monitor screen.
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3. SETTING UP THE ARC SYSTEM
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Procedure 3--4 Step
Changing a welding signal type and number
1 On the welding input or output signal screen, move the cursor to a digital signal to be modified. For example, move the cursor to the Enable Weld signal on the welding input screen. 2 After pressing the F! key, press the F3 (CONFIG) key. The screen shown below appears. I/O Weld In
G1
WELD SIGNAL 1 [Arc enable
JOINT
10 % 1/1
TYPE # ] [***]
[ TYPE ] MONITOR VERIFY [CHOICE]
HELP
3 To change the signal type: F
Move the cursor to the signal type field.
F
Press the F4 (CHOICE) key.
F
Choose a desired signal type from WI, DI, and RI, then press the ENTER key.
4 To change the signal number: F
Move the cursor to the signal number field.
F
Enter a desired number.
5 By pressing the F3 (VERIFY) key, whether an assigned signal type and number actually exist can be checked. 6 Pressing the F2 (MONITOR) key returns the screen display to the welding I/O monitor screen.
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3. SETTING UP THE ARC SYSTEM
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3.1.4 Selecting welder power supply This screen enables you to load welding power supply data for a welder power supply to be used from internal memory, according to the following procedure. This procedure saves you the trouble of specifying analog instruction reference values and instruction values, which cannot conventionally be avoided. So, it becomes possible to start welding immediately when the control unit gets started. The procedure for loading welder power supply data is as follows: Procedure 3--5 Step
Selecting welder power supply
1 Switch the power off, and perform controlled start. The following screen appears.
ArcTool Setup 1 F Number: Equipment: 2 Manufacturer: 3 Model:
CONTROLLED START MENUS 1/3 F00000 1
Press FCTN then START (COLD) when done. [ TYPE ]
HELP
2 Place the cursor at [2 Manufacturer], and click F4 [CHOICE]. Select the manufacturer of the desired welder power supply.
[ CHOICE ]
F4
1 DAIDEN 2 DAIDEN 3 General Purpose 4 KEMPPI ArcTool Setup
CONTROLLED START MENUS 5 KOBELCO 6 Lincoln Electric 7 NAS 8 -- NEXT --
3 Move the cursor to 3 Model, then press F4 (CHOICE). The options displayed at this time depend on the power supply manufacturer selected in step 2. Examples of screens are provided below. When the power supply manufacturer is DAIDEN [ CHOICE ]
F4
1 UR200/Fe0.8 2 UR200/Fe1.0 3 UR200/Fe1.2 4 UR350/Fe0.9 ArcTool Setup
CONTROLLED START MENUS 5 UR350/Fe1.0 6 UR350/Fe1.2 7 UR350/Fe1.6 8 -- NEXT --
When the power supply manufacturer is General Purpose CONTROLLED START MENUS 1 MIG (Volts, WFS) 2 MIG (Volts, Amps) 3 TIG (Amps) 4 TIG (Amps, WFS) ArcTool Setup
4 After selecting a welding power supply, press the auxiliary key, then select 1 START (COLD).
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3. SETTING UP THE ARC SYSTEM
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3.2 Setting the Arc Welding System For the welding process, the items related to control of the welding machine are specified at the [6 SETUP Weld System] on the system configuration screen. Table 3--5.
Setting arc welding system
ITEMS
DESCRIPTIONS
Arc loss
Specifies whether to enable/disable the arc loss detection function. If this function is enabled, a weld alarm is issued the arc loss detection time (welding equipment screen) after the arc detection signal becomes off during welding.
Gas shortage
Specifies whether to enable/disable the gas shortage detection function. If this function is enabled, a check is made to see whether a gas fault signal is input the gas detection time (welding equipment screen) after the gas start signal becomes on. If the gas fault signal is on, a weld alarm is issued.
Wire shortage
Specifies whether to enable/disable the wire shortage detection function. If this function is enabled, a check is made to see whether a wire fault signal is input during welding. If the wire fault signal is on, a weld alarm is issued.
Wire stick
Specifies whether to enable/disable the wire stick detection function. If this function is enabled, the wire stick detect instruction signal (WST, internal signal) is turned on to check for a voltage difference between the wire stick detection signals. If there is a voltage difference, an automatic wire stick reset occurs (if enabled), or a weld alarm is issued. If the wire stick detection function is disabled, the automatic wire stick reset function (welding equipment screen) is disabled automatically.
Power supply failure
Specifies whether to enable/disable the power supply failure detection function. If this function is enabled, a check is made to see whether a power fault signal is on. If the signal is on, a weld alarm is issued.
Coolant shortage
Specifies whether to enable/disable the coolant shortage detection function. If this function is enabled, a check is made to see whether the water fault signal is input during welding. If the signal is on, a weld alarm is issued.
Return to path
Specifies whether to enable/disable the return--to--path function. If welding stops due to a hold request or alarm occurrence, the return--to--path function enables restarting welding at the point of break. When directed to restart from a stopped state, the robot moves to the point of break and restarts welding there, provided that welding has been enabled. Figure 3--4. Return--to--Path Function 2 When restarted, the robot moves back through the overlap distance from the point of break, then restarts welding.
1 Welding is stopped, and the robot is moved away.
Return--to--path speed
Welding is stopped.
Overlap distance
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3. SETTING UP THE ARC SYSTEM
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Table 3--5. (Cont’d) Setting arc welding system ITEMS
DESCRIPTIONS
Overlap distance
When directed to restart, the robot moves back from the point of break through the overlap distance, then restarts welding. This is intended to prevent the sequence of beads from being cut. If the specified overlap distance extends beyond the previous teach point, the actual overlap distance is limited to within that teach point.
Return--to--path speed
Specifies the return--to--path speed at which the robot moves to the point of break when restarted.
Scratch start
Specifies whether to enable/disable the scratch start (automatic welding error recovery) function. If this function is enabled, and arc is not generated at start of welding, the robot moves in a specified direction through a specified distance. If arc is generated during this movement, the robot moves back to the start point and runs as directed by the program. Figure 3--5. Scratch Start Function 1 The robot starts moving even if arc is not generated.
2 When arc is generated, the robot moves back for a restart. Return--to--start speed
Direction of welding
Scratch start distance Distance
Specifies the distance through which the robot runs in the scratch start mode. If arc is not generated even after this distance is exceeded, a weld alarm is issued. If the scratch start distance is specified to be 0, a weld alarm is issued without performing a scratch start.
Return--to--start speed
Specifies the speed at which the robot moves back to the welding start point if arc is generated during scratch start.
Default speed
Operation speed when a welding speed instruction is executed under the following conditions: -- In the single--step mode -- When the move statement including a welding speed instruction is executed without executing the Arc Start instruction -- When a backward movement is made
Default unit
Unit of speed used for a welding speed instruction
Weld from teach pendant
Specifies whether to enable/disable welding directed from the teach pendant. More specific, specifies whether to generate arc at program start (SHIFT + FWD) directed from the teach pendant. Welding paths are checked without using arc during test operation directed from the teach pendant. This function is used to prevent accidental generation of arc during test operation.
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3. SETTING UP THE ARC SYSTEM
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Table 3--5. (Cont’d) Setting arc welding system ITEMS
DESCRIPTIONS
Runin
Specifies whether to enable/disable the run--in function. This function specifies the start--up current and voltage slightly higher than normal so that welding can start smoothly.
Wire burnback/retract
Specifies whether to enable/disable the wire postprocessing (burnback/retract) function. This function prevents the welding wire from sticking to the work by applying voltage for proper time after wire feed is stopped. Figure 3--6. Run--In and Wire Postprocessing
Weld start Postprocessing voltage Specified voltage Start--up voltage
Crater prevention voltage
Specified current
Crater prevention current
Postprocessing time
Start--up current Arc detection
Arc detect time Start--up time
Crater prevention time
NOTE While the system variable $AWSEMGOFF.$NOFLTR_OFF is held TRUE, arc generation stops for safety if the robot continues stopping longer than the period specified by the system variable $AWSEMGOFF.$CHK_TIME during the arc generation. If this arc stop occurs during run--in, wire postprocessing, or crater prevention, set the time to have the possibility for a robot that to stop it in $AWSEMGOFF.$CHK_TIME.
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3. SETTING UP THE ARC SYSTEM
Procedure 3--6 Step
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Setting arc welding system
1 Press the MENUS key. 2 Select 6 (SETUP). 3 Press F1 (TYPE). 4 Select “Weld System.” Arc welding system screen
5 I/O 6 SETUP 7 FILE
SETUP Weld System
MENUS
Weld System [TYPE]
F1
G2
JOINT
NAME Monitoring Functions 1 Arc loss: 2 Gas shortage: 3 Wire shortage: 4 Wire stick: 5 Power supply failure: 6 Coolant shortage: Weld Restart Function 7 Return to path: 8 Overlap distance: 9 Return to path speed: Scratch Start Function 10 Scratch start: 11 Distance: 12 Return to start speed: Weld Speed Function 13 Default speed: 14 Default unit: . Other Functions 15 On-The-Fly: 16 Weld from teach pendant: 17 Runin: 18 Wire burnback/retract: [ TYPE ]
10 % 1/18
VALUE ENABLED DISABLED DISABLED ENABLED ENABLED DISABLED ENABLED 0 mm 200 mm/s ENABLED 10 mm 100 mm/s 100 cm/min ENABLED ENABLED DISABLED DISABLED
ENABLED DISABLED
5 To input values, place the cursor at the target item and enter the corresponding value. Alternatively, select the function key menu.
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3. SETTING UP THE ARC SYSTEM
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3.3 Setting the Arc Welding Equipment For the welding process, the items related to control of the welding machine are specified at [6 SETUP Weld Equip] on the welding equipment screen. The following items are set up for the welding equipment. F
Welding equipment general items
F
Run--in and wire postprocessing functions
F
Welding sequence
F
Automatic wire stick reset function
F
Analog I/O scaling factor
Table 3--6.
Setting the Arc Welding Equipment
SETTING ITEM
DESCRIPTION
Welder
This item indicates the type of the welding power supply currently set.
Process
This item indicates the type of welding to be performed: -- MIG = CO2--MAG welding -- TIG = TIG welding
Process control
This item indicates the model of welding power supply control currently set: -- VLT + WFS = [voltage, wire speed] control -- VLT + AMP = [voltage, current] control -- AMPS = [current] control -- AMP + WFS = [current, wire speed] control This item is indicated only when [power supply maker: General Purpose] is selected in the welding power supply setting.
WIRE+ WIRE-- speed
Specifies the speed for manual wire feed and rewind using the WIRE+ and WIRE-- keys on the teach pendant, respectively. The measurement unit of the specified speed can be mm/s, cm/min, or IPM (inch/min).
Wire feed speed units
Selects the measurement unit of the manual wire feed, rewind, and wire feed speeds from mm/s, cm/min, and IPM (inch/min).
Feed forward/backward
This item enables or disables the function for outputting the wire feed signal during welding.
Timing Arc start error time
Specifies the time during which a check is made to see whether an arc detection signal is input. The arc start error time is measured from the output of a weld start signal. If arc is not detected within the specified time, a weld alarm is generated, or a scratch start (if enabled) occurs. The measurement unit of the specified time is seconds.
Timing
Specifies the time after which arc can be assumed to be continuously being generated. The arc detect time is measured from the input of an arc detection signal. If the arc detection signal does not stay continuously on for more than the specified time, arc is not detected. The measurement unit of the arc detect time is seconds.
Arc detect time
Timing Arc loss error time
Specifies the time lag from when an arc detection signal becomes off during arc welding until a weld alarm is generated. A weld alarm is generated if the arc detection signal is not input again within the specified time. The measurement unit of the specified time is seconds.
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3. SETTING UP THE ARC SYSTEM
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Table 3--6. (Cont’d) Setting the Arc Welding Equipment SETTING ITEM Timing Gas detect time
DESCRIPTION Specifies the time lag from when a gas start signal is output until a gas fault signal is checked for to see whether the gas is output. If a gas fault signal is input within the specified time, a weld alarm is generated. The measurement unit of the specified time is seconds. Figure 3--7. Various Detection Times Operating Robot operation
At stop Arc start instruction
Gas start Gas detect time Weld start Arc start error time Arc detection Arc detect time Timing
Arc loss error time
Gas purge time
Specifies the gas output time from when a gas start signal is output until the weld start position is reached. The specified time is ignored in a welding sequence not accompanied by a motion instruction. The measurement unit of the specified time is seconds.
Gas preflow time
Specifies the gas output time from when a gas start signal is output until the weld start position is reached and a weld start signal is output. The measurement unit of the specified time is seconds.
Timing
Timing Gas postflow time Wire stick Reset
Specifies the gas output time from when a weld start signal becomes off until a gas start signal turns off. The measurement unit of the specified time is seconds. Specifies whether to enable/disable the automatic wire stick reset function. If a wire stick occurs at the end of welding, this function burns off the stick by applying a voltage for a fraction of a second. When the function is enabled, it is necessary to specify the necessary parameters (reset tries, voltage, and time) for the function. The wire stick detection function must also be enabled. -- ENABLED: The automatic wire stick reset function is enabled. -- DISABLED: The automatic wire stick reset function is disabled.
Wire stick Reset tries
Specifies the number of times an automatic wire stick reset is to be tried. If a wire stick is detected, a wire stick reset is performed. If a wire stick is detected again, a wire stick reset is repeated. After a wire stick reset is repeated a specified number of reset tries, if a wire stick is still detected, a weld alarm is generated.
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3. SETTING UP THE ARC SYSTEM
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Procedure 3--7 Step
Setting the arc welding equipment
1 Press the MENUS key. The screen menu is displayed. 2 Select 6 (SETUP). 3 Press F1 (TYPE). The screen change menu is displayed. 4 Select Weld Equip. Arc welding equipment screen SETUP Weld Equip Welder:
G1
JOINT
10 % 1/12 ROBOWELD CO2/MAG 350
Process: MIG Feeder: **************** 1 2 3 4 5
Wire feed speed units: WIRE+ WIRE- speed: Feed forward/backward: Wire stick reset: Wire stick reset tries:
cm/min 50 cm/min DISABLED ENABLED 3
Timing: 6 7 8 9 10 11 12
Arc Arc Arc Gas Gas Gas Gas
start error time: detect time: loss error time: detect time: purge time: preflow time: postflow time:
2.00 .06 1.00 .05 .35 .30 .30
[ TYPE ]
sec sec sec sec sec sec sec HELP
NOTE The displayed items depend on the specified welder model. The sample screen shown above is displayed when the following welder model is selected: Manufacturer: DAIDEN Model: 350UR/Fe1.2 5 To specify each item, place the cursor in the corresponding field, and: a Press F4 (CHOICE), to select the corresponding menu. b Enter the value or select the function key menu. If it is necessary to turn the power off and on again after the item is specified, a prompt will appear at the bottom of the screen.
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3. SETTING UP THE ARC SYSTEM
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3.4 Setting Arc Welding Conditions Arc welding conditions are previously defined. Arc welding instructions in a program are executed by specifying an arc welding condition number for the necessary arc welding conditions. Up to 32 arc welding conditions can be defined at [3 DATA Weld Sched] on the arc welding condition list screen. Table 3--7.
Setting Arc Welding Conditions
ITEMS
DESCRIPTIONS
Command voltage
Specifies the welding voltage. The welding voltage can range from 0.0 to 99.9 V.
Command current or command wire feed
Specifies the welding current or wire feed speed. The welding current can range from 0.0 to 500.0 A. The wire feed speed can range from 0.0 to 500.0 inch/min, cm/min, or mm/s.
Travel speed
Travel speed means welding speed. When the WELD_SPEED instruction is taught between the Arc Start instruction and Arc End instruction, the value set in this item is used as the operation speed. As the unit of speed, the unit set in Default unit on the weld system setting screen is used. For details of the WELD_SPEED instruction, see the section of the operation speed instruction.
Delay time
Specifies a crater prevention time for the arc end instruction. The crater prevention time can range from 0.00 to 0.50 seconds. This setting is invalid for the arc start instruction. See Figure 3--2.
Feedback voltage
Displays the present welding voltage (V) output from the welding machine. It is fed back to the controller.
Feedback current
Displays the present welding current (A) output from the welding machine. It is fed back to the controller.
The setting items increase or decrease, depending on the settings of the model of the welding power supply and the number of analog input/output signals.
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3. SETTING UP THE ARC SYSTEM
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Procedure 3--8 Step
Setting arc welding conditions
1 Press the MENUS key. The screen menu is displayed. 2 Select 3 (DATA). 3 Press F1 (TYPE). The screen change menu is displayed. 4 Select Weld Sched. Arc welding condition list screen
5 EDIT 6 DATA 7 STATUS
DATA Weld Sched
1 2 3 4 5 6 7 8 9
MENUS
Weld Sched [TYPE]
Volts 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
[ TYPE ]
G1
Amps cm/min 0.0 0 0.0 0 0.0 0 0.0 0 0.0 0 0.0 0 0.0 0 0.0 0 0.0 0 DETAIL
JOINT
10 % 1/32 COMMENT
ADVISE
HELP >
F1 5 Press F2 (DETAIL). Arc welding condition detail screen DATA Weld Sched [ TYPE ]
DETAIL
G1
HELP > 1 2 3 4 5
F2
Weld Schedule: 1 Command voltage Command current Travel speed Delay Time Feedback voltage Feedback current
JOINT
10 % 1/5
[WELDCNDITON ] 20.0 Volts 5.0 Amps 1 cm/min 0.00 sec 0.0 Volts 0.0 Amps
[ TYPE ]SCHEDULE ADVISE
HELP >
NOTE The item display changes, depending on the settings of the model of the welding power supply and the number of analog input/output signals. To return to the list screen, press the PREV key. 6 To add a comment: a Move the cursor to the comment line and press the ENTER key. JOINT 1
[
30 % ]
ENTER
b Select the method of naming the comment. c Press the appropriate function keys to add the comment. d When you are finished, press the ENTER key. 7 To specify an item, place the cursor in the corresponding field and enter the necessary value. 8 To switch to the detail of another welding condition, press F2 (SCHEDULE), then enter the corresponding condition number. The arc welding condition detail screen corresponding to the specified number will appear.
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3. SETTING UP THE ARC SYSTEM
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3.5 Weld Schedule Advise Screen The weld schedule advise function provides welding conditions as reference information from a joint figure, plate thickness, and wire diameter. Note that this function does not provide directly usable values but provides reference data only. So, this function does not optimize the welding conditions. Welding conditions need to be adjusted using the welding fine--adjustment function. Welding novices do not even know appropriate values for welding conditions. The purpose of this function is to offer initial welding conditions and allow best conditions to be determined with the welding fine--adjustment function. Welding novices need to reference a document describing welding conditions. This function serves for this purpose. In addition, if there are user--specific reference welding conditions (such as a database), those conditions can be set on the weld schedule advise screen instead of being directly set on the weld schedule data screen. In this case, set the system variable $AWSADVATR.$PROTECT to TRUE. This setting protects changes made by the user. If this setting is not made, changes made by the user are initialized before moving to another screen. If appropriate values cannot be determined for welding conditions, this function can provide appropriate values from joint figure, wire diameter, plate thickness, and root gap amount. However, no fine selection conditions (joint figure, wire diameter, plate thickness, and route gap amount) are available. So, make selections from similar patterns. CAUTION If incorrect welding conditions are selected, a hole might be made in the target workpiece.
WARNING This function does not provide suitable values for welding conditions but provides reference data only. So, if such reference data is directly used, spatters might be produced. In such a case, you might get burned. When performing welding, protect yourself carefully, for example, by wearing a helmet type protector.
This function can be used only when the welding system is “MIG + current control.” In other cases, the F3 (ADVISE) key on the screen below is not displayed. To set the welding system to “MIG + current control,” make settings as described in operation 3--5 on the weld equipment setting screen. Otherwise, you could injure personnel or damage equipment.
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3. SETTING UP THE ARC SYSTEM
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Procedure 3--9 Step
Welding system setting to use the weld schedule advise function
1 Press the MENUS key. 2 Select 6 SETUP. 3 Press F1 (TYPE). 4 Select Weld Equip. SETUP Weld Equip
6 STATUS
Welder: MENUS
G1
JOINT
10 % 1/12
DAIDEN 200UR/Fe0.8
Process: MIG Feeder: **************** 1 2 3 4
Weld Equip [TYPE]
Wire feed speed units: WIRE+ WIRE- speed: Feed forward/backward: Wire stick reset:
[ TYPE ]
cm/min 50 cm/min DISABLED ENABLED
[CHOICE]
HELP >
F1
Procedure 3--10 Step
Displaying the weld schedule advise screen
1 Press the MENUS key. 2 Select DATA. 3 Press F1 (TYPE). 4 Select Weld Sched. DATA Weld Sched
1
Volts 0.0
[ TYPE ]
G1
Amps cm/min 0.0 0 DETAIL
ADVISE
DATA Weld Advise
G1
JOINT
10 % 1/32 COMMENT
5 Press F3 (ADVISE).
1 2 3 4 5 6 7 8 9
Butt Butt Butt Butt Butt Lap Lap Lap Lap
[ TYPE ]
: : : : : : : : :
T= T= T= T= T= T= T= T= T=
DETAIL
0.7 1.0 1.6 2.3 3.2 0.7 1.0 1.6 2.3
W=0.9 W=1.0 W=1.0 W=1.0 W=1.2 W=0.9 W=1.0 W=1.0 W=1.0
SELECT
55
JOINT
10 % 1/20
WA=90 WA=90 WA=90 WA=90 WA=90 WP=0 WA=60 WP=0 WA=60 WP=2 WA=60 WP=2 WA=60 HELP
3. SETTING UP THE ARC SYSTEM
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6 Press F4 (DETAIL). DATA Weld Advise
1 2 3 4 5
Butt
G1
LIST
10 % 1/5
: T= 0.7 W=0.9 WA=90
Command voltage: Command current: Command wire feed: Travel speed:
[ TYPE ]
JOINT
16.5 40.0 0 55.0
Volts Amps cm/min cm/min
SELECT
HELP
7 Press F3 (SELECT). The welding conditions are reflected. Press F5 (HELP) to proceed to step 8. DATA Weld Sched
1 2 3 4 5 6 7 8 9
Volts 19.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
[ TYPE ]
10 % 1/32 Amps cm/min COMMENT 80.0 55 Weld schdule 1 0.0 0 0.0 0 0.0 0 0.0 0 0.0 0 0.0 0 0.0 0 0.0 0
DETAIL
G1
ADVISE
JOINT
HELP >
8 This help screen explains the symbols used on the advise screen. DATA Weld Advise G1 JOINT 10 % HELP Arrows to scroll, PREV to exit
[ Discription of Joint type ] Fillet : Fillet joint Bevel : Single bevel fillet joint Lap : Lap fillet joint Butt : Sequare-butt joint V-Butt : Single V-butt joint B-Butt : Single bevel butt joint X-Butt : Double V butt joint T-Joint : T-joint K-Joint : K-joint [ Discription of sign ] T : Thickness(mm) W : Wire diameter(mm) F : Fillet leg(mm) R : Root gap(mm) A : Angle(degree) C : Coating G : Gas flow WA: Work Angle(degree) TA: Travel Angle(degree) WP: Wire position(mm) D : Direction
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3. SETTING UP THE ARC SYSTEM
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Procedure 3--11 Step
Displaying the weld schedule advise screen (display from the weld schedule detail screen)
1 Press the MENUS key. 2 Select DATA. 3 Press F1 (TYPE). 4 Select Weld Sched. 5 Press F2 (DETAIL). DATA Weld Sched
1 2 3 4 5
G1
Weld Schedule: 1 Command voltage Command current Travel speed Delay Time Feedback voltage Feedback current
JOINT
10 % 1/5
[WELDCNDITON ] 20.0 Volts 5.0 Amps 1 cm/min 0.00 sec 0.0 Volts 0.0 Amps
[ TYPE ]SCHEDULE ADVISE
HELP >
6 The advise screen can also be displayed from the weld schedule detail screen. Press F4 (ADVISE). DATA Weld Advise
1 2 3 4 5 6 7 8 9
Butt Butt Butt Butt Butt Lap Lap Lap Lap
[ TYPE ]
: : : : : : : : :
T= T= T= T= T= T= T= T= T=
DETAIL
G1
0.7 1.0 1.6 2.3 3.2 0.7 1.0 1.6 2.3
W=0.9 W=1.0 W=1.0 W=1.0 W=1.2 W=0.9 W=1.0 W=1.0 W=1.0
SELECT
57
JOINT
10 % 1/20
WA=90 WA=90 WA=90 WA=90 WA=90 WP=0 WA=60 WP=0 WA=60 WP=2 WA=60 WP=2 WA=60 HELP
3. SETTING UP THE ARC SYSTEM
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3.5.1 Process Conditions As process conditions, a startup processing condition, post--processing condition, stick clearance condition, and welding fine--adjustment increment/decrement are set. The table below indicates the conditions and their respective items. Table 3--8.
Process Conditions
SETTING ITEM Startup processing
DESCRIPTION The startup processing function is used to set slightly higher command values for voltage and current in order to start up welding smoothly. Set the items below for this condition setting. Voltage:
Set a welding voltage to be used when the welding equipment is started up. The unit is volts.
Current:
Set a welding current to be used when the welding equipment is started up. The unit is amperes.
Welding speed: Set a wire feedrate to be used when the welding equipment is started up. The unit is cm/min. Processing time: Set a time required to start up the welding equipment. The unit is sec. Post--processing
The post--processing function is used to apply a voltage for an appropriate time after the end of wire feed in order to prevent the wire from sticking to the workpiece. Set the items below for this condition setting. Voltage:
Set a wire post--processing voltage for CO2 (MAG) welding. The unit is volts.
Current:
Set a wire post--processing current for TIG welding. The unit is amperes.
Welding speed: Set a speed for wire retraction at the end of arc welding. The unit is cm/min. Figure 3--8. Wire Power Control
Weld start Specified voltage Retracting
Specified current
WO[7] WO[8]
If a negative value is specified at “Wire feed” on the welding equipment screen, WO[8] is output during postprocessing (retracting), as shown above. The amount of wire to be retracted is specified as follows:
D MIG current control: A value specified at “Current” is output. D MIG wire control: The absolute value of a value specified at “Wire feed” is output.
D TIG wire control: The absolute value of a value specified at “Wire feed” is output.
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3. SETTING UP THE ARC SYSTEM
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Table 3--8. (Cont’d) Process Conditions SETTING ITEM Post--processing
DESCRIPTION Processing time: Set a time required for wire post--processing. The unit is sec. Figure 3--9. Run--In and wire Postprocessing
Weld start
Postprocessing voltage
Specified voltage
Crater prevention voltage
Start--up voltage
Postprocessing time
Specified current
Crater prevention current
Start--up current Arc detection
Arc detect time Start--up times
Stick clearance
Crater prevention time
The automatic stick clearance function is used to apply a voltage for a short period of time at the end of arc welding in order to burn off a point, if any, where the welding wire is sticking to the workpiece. Set the items below for this condition setting. NOTE When using this function, enable the welding detection function (on the welding system screen). Voltage:
Set a voltage used for automatic stick clearance. The unit is volts.
Current:
Not used
Welding speed: Not used Processing time: Set a processing time required for stick clearance. The unit is sec. Figure 3--10. Automatic Wire Stick Reset Operating At stop
Robot operation Arc end instruction Gas start
Gas postflow time Weld start Wire stick reset delay
Wire stick reset time
Specified voltage Crater prevention time Wire postprocessing time Specified current Wire stick detect instruction delay Wire stick detect instruction (WST) Wire stick detection delay Wire stick detection (WDI+) Wire stick detection (WDI--)
59
Wire stick detection time
3. SETTING UP THE ARC SYSTEM
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Table 3--8. (Cont’d) Process Conditions SETTING ITEM Welding fine--adjustment
DESCRIPTION The welding fine--adjustment function allows the welding voltage, welding current, and wire feedrate currently used for welding to be increased or decreased by function key operation on the teach pendant. Set a value incremented or decremented by one key operation as described below. Voltage:
Set a voltage incremented or decremented by one function key operation on the welding fine--adjustment screen.
Current:
Set a current incremented or decremented by one function key operation on the welding fine--adjustment screen.
Welding speed: A wire feedrate incremented or decremented by one function key operation on the welding fine--adjustment screen is displayed. This value is fixed at 1 cm/min, and an attempt to change this value has no effect. Processing time: Not used Procedure:
Procedure 3--12 Step
Displaying the process condition screen
Displaying process conditions screen
1 Press the data key. 2 Press F1 ([SCREEN]), then select Process Condition. The screen shown below appears. DATA Weld Process
1 2 3 4
Volts 2.0 0.0 20.0 .5
[ TYPE ]
G1
JOINT
10 % 1/4
Amps cm/min 210.0 0 0.0 0 0.0 0 1.0 1 DETAIL
HELP >
3 Pressing F2 (DETAIL) displays the screen shown below. DATA Weld Process Schedule: 1 1 2 3 4
G1 [ RUNIN
Command Voltage Command Current Travel speed Delay Time
[ TYPE ]
SCHEDULE
JOINT
10 % 3/4
] 2.0 210.0 0 0.00
Volts Amps cm/min sec HELP >
4 Pressing the return key returns the screen display to the list screen. NOTE The incremental or decremental welding speed for welding fine--adjustment is fixed at 1 cm/min. If an attempt is made to change this value, the actual incremental or decremental value remains unchanged.
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3. SETTING UP THE ARC SYSTEM
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3.6 Setting for Weaving Weaving means swinging the welding torch right and left periodically at a certain angle relative to the welding direction, thus increasing the width of a bead to increase the strength of welding. (For information about types of weaving, see Section 4.4.3.) A setting for weaving can be made with [6 SETUP -- Weave] on the weaving setting screen. Table 3--9.
Setting for Weaving
SETTING ITEM
DESCRIPTION
Weave Enable Group Mask
This item specifies a motion group for which weaving is enabled. Set 1 for the part corresponding to a motion group for which weaving is enabled.
Dwell delay type
This item is used to specify whether to stop the robot completely or stop sideway movements only at both end points during weaving. The dwell time during which the robot stops at end points is determined by the values set in R_DW and L_DW (weave schedule screen). -- Stop: Completely stops the robot at both weaving end points. -- Move: Stops only sideway movements at both weaving end points.
Frame type
This item is used to select a coordinate system for weaving plane determination. -- Tool & Path: Formed by the Z direction of the tool coordinate system and move direction -- Tool: Tool coordinate system Figure 3--11. Weaving Coordinate System Tool coordinate system + Z direction
Z
Pitch
a
Welding speed Frequency
Weaving plane
Y
Welding speed
Move direction Pitch
Azimuth
Amplitude
X
This item specifies the inclination of weaving swing direction on the weaving plane (in degrees). Figure 3--12. Swing Direction
Y
Swing direction (= 0 degrees)
X Y Swing direction (= 10 degrees)
X
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3. SETTING UP THE ARC SYSTEM
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Table 3--9. (Cont’d) Setting for Weaving SETTING ITEM Elevation
DESCRIPTION This item specifies the inclination of the weaving plane relative to the weaving coordinate system (in degrees). Figure 3--13. Elevation Angle
Z
Z Elevation angle (= 0 degrees)
Elevation angle (= 15 degrees)
Y
Y
X
X
Current rise
This item specifies the amount the torch is raised at the center of weaving (in mm). When multi--layer welding is performed, this item is set to clear the height of the previous bead(s). Figure 3--14. Amount Raised at the Center
Z Y
Amount raised at the center
Radius
X
This item specifies the amplitude relative to the welding direction when circular weaving or 8--shaped weaving is performed (in mm). Figure 3--15. Radius
Y
Y Amplitude
X
Radius
X
Travel speed
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3. SETTING UP THE ARC SYSTEM
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Table 3--9. (Cont’d) Setting for Weaving SETTING ITEM Blend weare end
DESCRIPTION This item specifies whether to ignore the taught points of the move instruction to continue weaving. -- YES: Does not follow taught points but links an end point of weaving with a start point of weaving. -- NO: Moves to taught points at all times. Figure 3--16. Weaving Linkage
Y
Weaving linkage disabled
X Y
Weaving linkage enabled
X Group # Peak output port DO
This item specifies the signal number of an SDO signal output at a weaving end point. When the torch reaches an end point during weaving, a specified output SDO signal is output. The sharp # represents a motion group number that can range from 1 to 5. Weaving of each motion group can be specified.
Group # Peak output pulse
This item specifies the output pulse width of the end point output SDO signal (in sec). The sharp # represents a motion group number that can range from 1 to 5. Weaving of each motion group can be specified.
Group # Peak output shift
This item specifies the time delay in output of the end point output SDO signal (in sec). The sharp # represents a motion group number that can range from 1 to 5. Weaving of each motion group can be specified.
Procedure 3--13 Step
Setting for Weaving
1 Press the MENUS key to display the screen menu. 2 Select 6 SETUP. 3 Press F1 (TYPE) to display the screen switch menu. 4 Select Weave.
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3. SETTING UP THE ARC SYSTEM
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Weaving setting screen 5 I/O 6 SETUP 7 FILE
SETUP Weave
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
MENUS
Weave [TYPE]
F1
G1
JOINT
10 % 1/10
NAME VALUE Weave Enable Group Mask [1,*,*,*,*] Dwell delay type: Move Frame type: Tool & Path Flevation: 0 deg Azimuth: 0 deg Center rise: 0.0 mm Radius: 0.0 mm Blend weave end: YES Group 1 Peak output port DO: 0 Group 1 Peak output pulse: .0.1 sec Group 1 Peak output shift: 0.0 sec Group 2 Peak output port DO: 0 Group 2 Peak output pulse: .0.1 sec Group 2 Peak output shift: 0.0 sec Group 3 Peak output port DO: 0 Group 3 Peak output pulse: .0.1 sec Group 3 Peak output shift: 0.0 sec Group 4 Peak output port DO: 0 Group 4 Peak output pulse: .0.1 sec Group 4 Peak output shift: 0.0 sec Group 5 Peak output port DO: 0 Group 5 Peak output pulse: .0.1 sec Group 5 Peak output shift: 0.0 sec
[ TYPE ]
[CHOICE]
HELP
5 When setting an item, move the cursor to the setting field, then a Press F4 (CHOICE), then select a desired menu. b Enter a desired value or select an F key menu item.
3.7 Weave Schedule A weave schedule defines a pattern of weaving performed during welding. A weaving instruction is executed by specifying a weave schedule number in the program. A weave schedule is defined with [DATA -- Weave Sched] on the weave schedule screen. Up to 16 weave schedules can be set. Table 3--10.
Weave Schedule Setting
SETTING ITEM
DESCRIPTION
Frequency
This item specifies the number of weaving cycles per second. 0.0 to 99.9 (Hz)
Frame type
This item specifies the distance from the welding line to an end point. 0.0 to 25.0 (mm) Figure 3--17. Amplitude Tool coordinate system + Z direction
Z
Pitch
a
Welding speed Frequency
Weaving plane
Y
Welding speed
Move direction Pitch
Right dwell
Amplitude
X
This item specifies a dwell time at the right end points of weaving. When Move is specified for dwell at end points, the robot moves in the welding direction. 00 to 1.00 (sec)
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Table 3--10. (Cont’d) Weave Schedule Setting SETTING ITEM
DESCRIPTION
Left dwell
This item specifies a dwell time at the left end points of weaving. When Move is specified for dwell at end points, the robot moves in the welding direction. 00 to 1.00 (sec)
L pattern angle
This item specifies the angle made by the left weaving plane and right weaving plane in L--pattern weaving. 0 to 360 (degrees) Figure 3--18. Angle of L--pattern weaving
Angle of L--pattern weaving
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3. SETTING UP THE ARC SYSTEM
Procedure 3--14 Step
B--81464EN--3/01
Weave Schedule Setting
1 Press the MENUS key to display the screen menu. 2 Select 3 DATA. 3 Press F1 (TYPE). 4 Select Weave Sched. Weave schedule list screen
5 EDIT 6 DATA 7 SETUP
DATA Weave Sched
MENUS
Weave Sched [TYPE]
10 % 1/10 FREQ(Hz) AMP(mm) R_DW(sec) L_DW(sec) 1 1.0 4.0 0.000 0.000 2 1.0 4.0 0.000 0.000 3 1.0 4.0 0.000 0.000 4 1.0 4.0 0.000 0.000 5 1.0 4.0 0.000 0.000 6 1.0 4.0 0.000 0.000 7 1.0 2.0 1.000 0.000 8 1.0 2.0 1.000 2.000 9 2.0 2.0 1.000 1.000
[ TYPE ]
G1
JOINT
DETAIL
HELP >
F1 5 When copying a set schedule, move the cursor to the schedule number to be copied, press F2 (COPY) on the next page, then enter a copy destination schedule number. 6 When deleting a set schedule, move the cursor to the schedule number to be deleted, then press F3 (delete) on the next page. 7 For detail setting, press F2 (DETAIL).
[ TYPE ]
DETAIL
DATA Weave Sched
F2
G1
JOINT
10 % 5/5
Weave Schedule: 1
1 2 3 4 5
Frequency: Amplitude: Right dwell: Left dwell: L pattern angle:
[ TYPE ]SCHEDULE
1.0 4.0 0.000 0.000 90.0
Hz mm sec sec deg
HELP >
To return to the list screen, press the return key. 8 To set an item, move the cursor to the setting field, then enter a desired value. 9 To switch to another weld schedule detail screen, press F2 (SCHEDULE), then enter the desired schedule number. The weld schedule detail screen of the specified number is displayed.
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3.8 Input/Output Signals Input/output signals (I/O) are electric signals that allow the controller to communicate with the robot, end effector, external equipment, and other peripheral equipment of the system. The signals are divided into two groups: general--purpose I/O and specialized I/O. General--purpose I/O The user can define the general--purpose I/O as required. The number of Input/Output signal lines can be expanded. The maximum number for each signal line is 512. Note that this maximum number is in terms of digital I/O signals and that one analog I/O signal, for example, uses the same amount of memory that 16 digital I/O signals do. This group includes the following signals: F
Digital I/O: SDI[i]/SDO[i]
F
Group I/O: GI[i]/GO[i]
F
Analog I/O: AI[i]/AO[i]
Specialized I/O The use of the specialized I/O has already been defined. This group includes the following signals: F
Peripheral (UOP) I/O: UI[i]/UO[i]
F
Operator’s panel (SOP) I/O: SI[i]/SO[i]
F
Robot I/O: RDI[i]/RDO[i]
F
Welding I/O: WDI[i]/WDO[i]
[i] represents the logic number of each I/O signal and group signal. F
For Digital, Group, Analog, and Peripheral I/O, the logic ports can be mapped to the physical ports. They can be redefined.
F
The physical numbers of the robot I/O are always the same as the logic numbers. They cannot be redefined.
Configuring I/O An I/O module consists of the following hardware components. For details, refer to the “Maintenance Manual” (! “R--J3iB Maintenance Manual”). Rack The rack indicates the kind of hardware which composes I/O module. -- 0 = Process I/O PC board -- 1 to 16 = I/O Unit--MODEL A / B SLOT The slot indicates numbers of I/O module parts which compose the rack. F
When the process I/O PC board is used, the first connected board is SLOT 1, the second is SLOT 2 and others are numbered sequentially in the same way.
F
When the I/O Unit--MODEL A or B is used, SLOT is the slot number of the MODEL A or MODEL B rack.
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3. SETTING UP THE ARC SYSTEM
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Process I/O PC board As for Input/Output signal lines on the process I/O PC board, when the peripheral I/O is allocated to the process I/O PC board, 18 input and 20 output signals are allocated in the peripheral I/O. (See Section 3.10 “Peripheral I/O”) I/O signal lines except the peripheral I/O are allocated in digital I/O and group I/O (See Section 3.8.1, “Digital I/O” and Section 3.8.2 “Group I/O”). To use the process I/O PC board, the controller needs to be mount type or panel--mount type and the printed circuit board for controlling the robot needs to be in master mode. NOTE The first four signal lines on the process I/O printed circuit board are fixed to 24 V common. Figure 3--19. Process I/O PC board Process I/O PCB CA CRM2B
CRW2
CRW1
CRM2A
JD4B JD4A
Figure 3--20. Process I/O PC board Configuration Printed circuit board for controlling the robot
Process I/O printed board CA / CB RACK 0 SLOT 1
JD4
CRM2A
Peripheral equipment A1
JD4A
CRM2B
Peripheral equipment A2
JD4B
CRW1 CRW2
Process I/O printed board DA
JD4A JD4B
CRM2A
Peripheral equipment A1
CRM2B
Peripheral equipment A2
CRM2C
Peripheral equipment A3
CRM2D
Peripheral equipment A4
CRM4A
Peripheral equipment B1
CRM4B
Peripheral equipment B2
For details of process I/O PC board, refer to CONNECTION MANUAL. (Refer to THE MAINTENANCE MANUAL)
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3. SETTING UP THE ARC SYSTEM
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Figure 3--21. Process I/O PC board interface Peripheral equipment A1 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
CRM2A
in 1 in 2 in 3 in 4 in 5 in 6 in 7 in 8 in 9 in 10 in 11 in 12 in 13 in 14 in 15 in 16
19 20 21 22 23 24 25 26 27 28 29 30 31 32
out 13 out 14 out 15 out 16 out 17 out 18 out 19 out 20 in 17 in 18 in 19 in 20
Peripheral equipment A2
out 1 out 2 out 3 out 4
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
out 5 out 6 out 7 out 8 out 9 out 10 out 11 out 12
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
Peripheral equipment A3 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
CRM2C
in 41 in 42 in 43 in 44 in 45 in 46 in 47 in 48 in 49 in 50 in 51 in 52 in 53 in 54 in 55 in 56
19 20 21 22 23 24 25 26 27 28 29 30 31 32
out 53 out 54 out 55 out 56 out 57 out 58 out 59 out 60 in 57 in 58 in 59 in 60
CRM2B 19 20 21 22 23 24 25 26 27 28 29 30 31 32
out 45 out 46 out 47 out 48 out 49 out 50 out 51 out 52
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
Peripheral equipment B1
in 61 in 62 in 63 in 64 in 65 in 66 in 67 in 68 in 69 in 70 in 71 in 72 in 73 in 74 in 75 in 76
in 81 in 82 in 83 in 84 in 85 in 86 in 87
08 09 10 11 12 13
out 85 out 86 out 87 out 88 in 88
13 14 15 16 17 18 19 20 21 22
ain 1 ain 1--C ain 2 ain 2--C
0V 0V 0V 0V
out 21 out 22 out 23 out 24 out 25 out 26 out 27 out 28 out 29 out 30 out 31 out 32
19 20 21 22 23 24 25 26 27 28 29 30 31 32
out 73 out 74 out 75 out 76 out 77 out 78 out 79 out 80 in 77 in 78 in 79 in 80
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
out 61 out 62 out 63 out 64 out 65 out 66 out 67 out 68 out 69 out 70 out 71 out 72
CRM4B 14 15 16 17 18 19 20
out 81 out 82 out 83 out 84
01 02 03 04 05 06 07
in 89 in 90 in 91 in 92 in 93 in 94 in 95
08 09 10 11 12 13
out 93 out 94 out 95 out 96 in 96
14 15 16 17 18 19 20
out 89 out 90 out 91 out 92
Analog input interface
CRW1 aout 1 aout 1--C aout 2 aout 2--C WDI 1 WDI 2 WDI 3 WDI 4 WDI 5 WDI 6 WDI 7 WDI 8
in 37 in 38 in 39 in 40
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
Peripheral equipment B2
Welding interface 01 02 03 04 05 06 07 08 09 10 11 12
out 37 out 38 out 39 out 40
CRM2D
CRM4A 01 02 03 04 05 06 07
out 33 out 34 out 35 out 36
Peripheral equipment A4
out 41 out 42 out 43 out 44
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
in 21 in 22 in 23 in 24 in 25 in 26 in 27 in 28 in 29 in 30 in 31 in 32 in 33 in 34 in 35 in 36
CRW2 23 24 25 26 27 28 29 30 31 32 33 34
WDO 1 WDO 2 WDO 3 WDO 4 WDO 5 WDO 6 WDO 7 WDO 8 WDI + WDI -+24V +24V
69
01 02 03 04 05 06 07
08 ain 6 09 ain 6--C 10 11 12 13
14 15 16 17 18 19 20
ain 3 ain 3--C ain 4 ain 4--C ain 5 ain 5--C
in** and out** are physical numbers. ain *--C is the common signal line for ain *.
3. SETTING UP THE ARC SYSTEM
B--81464EN--3/01
I/O Unit--MODEL A I/O Unit--MODEL A (Modular I/O) is the I/O module that includes the plural modules. Plural modules can be connected within the limits of 512 signal lines in all modules. The I/O unit--MODEL A can be used only in master mode. Before using it, contact FANUC. Figure 3--22. I/O Unit--MODEL A
I/O Unit--MODEL A JD1B
JD1A
CP32
SLOT (Connector) (Terminal)
JD2
Figure 3--23. I/O Unit--MODEL A Configuration Main CPU printed board
Operator’s box printed board 24V 0V
JRM2
JD1A
Base unit
Rack 1
Slot 1
CP32
JD1A
I/O unit model A
JD1B
JD26A
Peripheral device
Slot 2 Slot 3 Slot 4 Slot 5
When using only the I/O unit, assign 18 inputs and 20 outputs of the peripheral device I/O to appropriate signal lines (Refer to Section 3.10, “Peripheral Devices”). When the I/O unit and process I/O printed circuit board are used simultaneously, the inputs and outputs of the peripheral device I/O are automatically assigned to signal lines on the process I/O printed circuit board.
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For details of FANUC I/O Unit--MODEL A, refer to FANUC I/O Unit--MODEL A manual (B--61813EN) Figure 3--24. I/O Unit MODEL A interface
AID 32 E/F
AID 32 A/B 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
in 31 in 28 in 25 + 24V 0V in 20 in 17 + 24V 0V in 15 in 12 in 9 + 24V 0V in 4 in 1 + 24V 0V
19 20 21 22 23 24 25 26 27 28 29 30 31 32
in 29 in 26 CMC in 23 in 21 in 18
in 13 in 10 CMA in 7 in 5 in 2
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
in 32 in 30 in 27 CMC in 24 in 22 in 19 CMC CMC in 16 in 14 in 11 CMA in 8 in 6 in 3 CMA CMA
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
AOD 32 A/C/D 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
out 31 out 28 out 25 + 24V 0V out 20 out 17 + 24V 0V out 15 out 12 out 9 + 24V 0V out 4 out 1 + 24V 0V
19 20 21 22 23 24 25 26 27 28 29 30 31 32
out 29 out 26 CMD out 23 out 21 out 18
out 13 out 10 CMB out 7 out 5 out 2
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
out 1 out 3 out 5 CMA out 7 out 9 out 11 CMB
02 04 06 08 10 12 14 16 18 20
19 20 21 22 23 24 25 26 27 28 29 30 31 32
in 29 in 26 CMD in 23 in 21 in 18
in 13 in 10 CMB in 7 in 5 in 2
AID 16 C/D 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
in 32 in 30 in 27 CMD in 24 in 22 in 19 CMC CMC in 16 in 14 in 11 CMB in 8 in 6 in 3 CMA CMA
AOD 16 C/D 01 03 05 07 09 11 13 15 17 19
CMA out 2 out 4 out 6 out 8 CMB out 10 out 12 out 14 out 16
02 04 06 08 10 12 14 16 18 20
out 2 out 4 out 6
out 8 out 10 out 12
02 04 06 08 10 12 14 16 18 20
CM in 2 in 4 in 6 in 8 in 10 in 12 in 14 in 16
01 03 05 07 09 11 13 15 17 19
in 1 in 3 in 5 in 7 in 9 in 11 in 13 in 15
02 04 06 08 10 12 14 16 18 20
in 1 in 3 in 5 in 7 in 9 in 11 in 13 in 15 CM
CM
02 04 06 08 10 12 14 16 18 20
in 2 in 4 in 6 in 8 in 10 in 12 in 14 in 16
AOD 08 C/D out 1 out 3 out 5 out 7 CMA out 9 out 11 out 13 out 15 CMB
01 03 05 07 09 11 13 15 17 19
AOA 08 E 01 03 05 07 09 11 13 15 17 19
01 03 05 07 09 11 13 15 17 19
AIA 16 G
CM indicates the common signal line. out 32 out 30 out 27 CMD out 24 out 22 out 19 CMC CMC out 16 out 14 out 11 CMB out 8 out 6 out 3 CMA CMA
AOA 12 F 01 03 05 07 09 11 13 15 17 19
in 31 in 28 in 25 + 24V 0V in 20 in 17 + 24V 0V in 15 in 12 in 9 + 24V 0V in 4 in 1 + 24V 0V
02 04 06 08 10 12 14 16 18 20
in 1 in 2 in 3 in 4 in 5 in 6 in 7 in 8
AOA 05 E out 1 out 2 out 3 out 4 CMA out 5 out 6 out 7 out 8 CMB
01 03 05 07 09 11 13 15 17 19
CMA out 2 out 4 out 6 out 8 CMB out 10 out 12 out 14 out 16
02 04 06 08 10 12 14 16 18 20
out 1 out 1--C out 2 out 2--C out 3 out 3--C out 4 out 4--C out 5 out 5--C
in**, out** indicates the physical number
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3. SETTING UP THE ARC SYSTEM
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I/O unit--MODEL B The I/O unit--MODEL B consists of an interface unit and more than one DI/DO unit. The DI/DO units are used to input/output signals. The interface unit is used to assemble I/O information in the DI/DO units and transfers it to or from the robot controller. Combining an appropriate number of DI/DO units of different types makes it possible to provide a necessary number of input/output points. Twisted pair cables are used to connect the DI/DO units with the interface unit, thus allowing the DI/DO units to be installed at a distance from the interface unit. Figure 3--25. I/O Unit--MODEL B Main CPU printed board
I/O unit--MODEL B Interface unit
JD1A
CP4
JD1B
S1+ S1--
CRS7
JD1A
S2+ S2--
CRS8A
24V 0V
S3+ S3--
CRS8B
Power supply unit
Operator box printed board 24V 0V
TBOP3
I/O unit--MODEL B Basic unit
24V 0V DI/DO
S1+ S1-FG
Peripheral device 24V 0V S1+ S1-FG
DI/DO
Refer to the FANUC I/O Unit MODEL B Connection Manual (B--62163E) for details of the I/O unit--MODEL B.
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3.8.1 Digital I/O Digital I/O (SDI/SDO) is a group of general--purpose signals that send or receive the data of the peripheral equipment via the process I/O printed circuit board (or I/O unit). Moreover, this can send or receive the data of master (CNC) of I/O link. The digital signal is set on or off. Configuration of Input/Output In digital I/O, the configuration of the signal lines can be redefined. Eight signal lines band. Eight signal lines which is included in the same class are allocated at the same time. The following items are set. Refer to 3.8 for the configuration of the rack and slot. CAUTION When a process I/O printed circuit board is connected, the standard assignment is made at the factory. When no process I/O printed circuit board is connected and I/O unit model A/B is connected, all digital input/output signals are assigned to the digital I/O at the factory. No digital input/output signals are assigned to the peripheral device I/O. Divide the digital input/output signals between the digital I/O and peripheral device I/O and reassign the signals to them.
CAUTION Before the physical numbers are re--defined, the use of the signals should be carefully checked. Otherwise, injury or property damage would occur.
RACK The rack indicates the kind of hardware which composes I/O module. -- 0 = Process I/O PC board -- 1 to 16 = I/O Unit--MODEL A and MODEL B Racks 1, 2, and so on are assigned to the base units of I/O unit model A and the interface units of I/O unit model B in the order in which they are connected. SLOT The slot indicates the number of I/O module parts which composes RACK. F
When the process I/O PC board is used, the first connected board is SLOT 1, the second is SLOT 2 and others are numbered sequentially as this.
F
When the I/O unit of model A is used, the number of the backplane slot in which the module is placed is the slot value of the module.
F
When the I/O unit--MODEL B is used, the slot number of the basic unit is specified by the DIP switch in the basic unit.
START PT START PT allocates the logical number to the physical number to map the signal lines. The first physical number in the class of eight signals should be specified. NOTE A physical number specifies the pin of Input/Output lines on the I/O module. Logical number is allocated to this physical number. And eight signal lines which are represented in logical number and are included in the same class are allocated at the same time. NOTE Physical numbers starting with in 19 and out 21 can be assigned to the digital I/O because 18 input physical numbers (in 1 to 18) and 20 output physical numbers (out 1 to 20) on the process I/O printed circuit board are assigned to the peripheral device I/O. NOTE Any physical number can be specified as the start point. Not allocated signal is automatically allocated to other logical number. Polarity The polarity selects whether the current is switched on or off when the signal is set on. -- NORMAL = The current is turned on when the signal is set on. -- INVERSE = The current is turned on when the signal is set off.
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Complementary Complementary is the function to set on or off two successive digital output signals: When a signal having an odd number goes on (off), complementary sets the next signal having an even number off (on). I/O configuration can be done with I/O configuration screen and I/O detail screen. When the allocation or settings of I/O is changed, turn the power off and on to use new information. When the kind of I/O PC board are changed to the different one, I/O configuration may be done again. Output The value of a digital output signal can be specified by executing a program or performing manual operation. (See Section 4.6, “I/O Instruction,” and Section 6.4, “Manual I/O Control.”) Simulated input/output When simulated input/output is selected, a program can be tested without sending or receiving signals to or from the external equipment. (See Section 6.3.1,“Specifying test execution”) Figure 3--26. Digital I/O and Group I/O Interfaces Process I/O printed circuit board CA or CB
Main CPU printed circuit board
JD1A
CRM2A
Peripheral device A1
JD4A
CRM2B
Peripheral device A2
JD4B
CRW1 CRW2
Peripheral device A1 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
in 1 in 2 in 3 in 4 in 5 in 6 in 7 in 8 in 9 in 10 in 11 in 12 in 13 in 14 in 15 in 16
CRM2A 19 20 21 22 23 24 25 26 27 28 29 30 31 32
out 13 out 14 out 15 out 16 out 17 out 18 out 19 out 20 in 17 in 18 in 19 in 20
Peripheral device A2 Connector number
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
out 1 out 2 out 3 out 4 out 5 out 6 out 7 out 8 out 9 out 10 out 11 out 12
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
Physical number in 21 in 22 in 23 in 24 in 25 in 26 in 27 in 28 in 29 in 30 in 31 in 32 in 33 in 34 in 35 in 36
CRM2B 19 20 21 22 23 24 25 26 27 28 29 30 31 32
out 33 out 34 out 35 out 36 out 37 out 38 out 39 out 40 in 37 in 38 in 39 in 40
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
out 21 out 22 out 23 out 24 out 25 out 26 out 27 out 28 out 29 out 30 out 31 out 32
Standard digital I/O settings Physical number in 19 in 20 in 21 in 22 in 23 in 24 in 25 in 26 in 27 in 28 in 29 in 30
Digital input SDI 1 SDI 2 SDI 3 SDI 4 SDI 5 SDI 6 SDI 7 SDI 8 SDI 9 SDI 10 SDI 11 SDI 12
in 31 in 32 in 33 in 34 in 35 in 36 in 37 in 38 in 39 in 40
SDI 13 SDI 14 SDI 15 SDI 16 SDI 17 SDI 18 SDI 19 SDI 20 SDI 21 SDI 22
74
Physical number out 19 out 20 out 21 out 22 out 23 out 24 out 25 out 26 out 27 out 28 out 29 out 30
Digital output
SDO 1 SDO 2 SDO 3 SDO 4 SDO 5 SDO 6 SDO 7 SDO 8 SDO 9 SDO 10
out 31 out 32 out 33 out 34 out 35 out 36 out 37 out 38 out 39 out 40
SDO 11 SDO 12 SDO 13 SDO 14 SDO 15 SDO 16 SDO 17 SDO 18 SDO 19 SDO 20
3. SETTING UP THE ARC SYSTEM
B--81464EN--3/01
Procedure 3--15
Configuring Digital I/O
CAUTION When a process I/O printed circuit board is connected, the standard assignment is made at the factory. When no process I/O printed circuit board is connected and I/O unit model A/B is connected, all digital input/output signals are assigned to the digital I/O at the factory and no digital input/output signals are assigned to the peripheral device I/O. Divide the digital input/output signals between the digital I/O and peripheral device I/O and reassign the signals to them.
Step
1 Press the MENUS key. The screen menu is displayed. 2 Select 5 [I/O]. 3 Press F1 [TYPE]. The screen change menu is displayed. 4 Select “Digital.” Digital I/O Selection Screen
4 ALARM 5 I/O 6 SETUP
I/O Digital Out # SIM STATUS DO[1] U OFF [ DO[2] U OFF [ DO[3] U OFF [ DO[4] U OFF [ DO[5] U OFF [ DO[6] U OFF [ DO[7] U OFF [ DO[8] U OFF [ DO[9] U OFF [
MENUS
Digital
JOINT 30% ] ] ] ] ] ] ] ] ]
[TYPE] [TYPE]
CONFIG
IN/OUT
ON
OFF
F1 5 To switch the input screen to the output screen, or vice versa, press the F3 key, IN/OUT.
[ TYPE ] CONFIG
IN/OUT
F3 6 To allocate I/O, press F2,CONFIG.To return to the selection screen, press F2,MONITOR. Digital I/O Configuration Screen [ TYPE ] CONFIG
F2
IN/OUT
I/O Digital Out # RANGE 1 DO[ 1- 20] 2 DO[ 21-512]
RACK 0 0
[ TYPE ] MONITOR IN/OUT
SLOT 1 0
JOINT 10 % START STAT. 21 ACTIV 0 UNASG
DELETE
HELP
7 Manipulating the I/O assignment screen a) Place the cursor on “Range,” and specify the range of signals to be assigned. b) Line division is performed automatically according to the specified range.
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c) Enter appropriate values for “Rack,” “Slot,” and “Start point.” d) When the entered values are valid, abbreviation “PEND” is displayed in “Status.” If any entered value is invalid, abbreviation “INVAL” is displayed in “Status.” Unnecessary lines can be deleted by pressing F4 (Delete). The abbreviations that will appear in “Status” mean the following: ACTIV: This assignment is now in use. PEND: Assignment is normal. Turning the power off and on again causes the ACTIV status to be entered. INVAL: A specified value is invalid. UNASG: No assignment has been made. NOTE If process I/O printed circuit boards are connected, 18 input signals and 20 output signals on the first board are connected to the peripheral I/O by standard setting. 8 To return to the list screen, press F2,MONITOR. I/O Digital Out # SIM STATUS SDO[ 1] U OFF [DT SDO[ 2] U OFF [DT SDO[ 3] U OFF [DT SDO[ 4] U OFF [DT [ TYPE ] MONITOR IN/OUT
JOINT SIGNAL SIGNAL SIGNAL SIGNAL DETAIL
1 2 3 4
30 % ] ] ] ] HELP >
9 To set the attribute of I/O, press NEXT key and press F4, DETAIL of the next page. Digital I/O detail screen DETAIL
HELP > I/O Digital Out Port Detail
F4
JOINT
Digital Output: [
1]
1 Comment : [ 2
]
Polarity : NORMAL
3 Complementary : FALSE
[ TYPE ]
10 % 1/3
PRV-PT
[
1 -
2]
NXT-PT
To return to the selection screen, press PREV key. 10 To add a comment: a Move the cursor to the comment line and press the ENTER key. JOINT 1
[
30 % ]
ENTER
b Select the method of naming the comment. c Press the appropriate function keys to add the comment. d When you are finished, press the ENTER key. 11 To set the item, move the cursor to the setting column, and select the function key menu. 12 To set the next digital I/O group, presses F3, NEXT. [ TYPE ]
PREV
NEXT
F3
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13 When you are finished, press the PREV key to return to the selection screen. I/O Digital Out # 1 2 3 4
JOINT
RANGE RACK SDO[ 1- 8] 0 SDO[ 9- 16] 0 SDO[ 17- 24] 0 SDO[ 25- 32] 0
SLOT 1 1 1 2
[ TYPE ] MONITOR IN/OUT
30 % 3/32 START PT 21 29 37 1
DETAIL
HELP >
[ TYPE ] VERIFY
>
14 Turn off the controller. Turn on the controller so it can use the new information. WARNING Power should be turned on again to make a new setting valid. Otherwise, injury or property damage would occur. CAUTION In the first power--up after I/O re--allocation, power recovery would not be executed even if it is enabled. CAUTION After all I/O signals are set, the setting information should be saved in external storage (floppy disk, for example) in case the information needs to be re--loaded. Otherwise, the current setting information would be lost when it is changed. 15 To perform forced output or simulated input/output of a signal, place the cursor on ON or OFF and press the corresponding function key. I/O Digital In
I/O Digital In DI[1]
S
OFF
DI[1] [TYPE]
IN/OUT
ON
S CONFIG
ON
JOINT 30% [DIGITAL1 IN/OUT
ON
] OFF
OFF
F4 For the forced output and simulated input of a signal, see Chapter 6, Section 6.4. WARNING The controller uses signals to control the peripheral equipment. The forced output or simulated input/output may adversely affect the security of the system. Check the use of signals in the system before attempting the forced output or simulated input/output.
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3.8.2 Group I/O Group I/O (GI/GO) is a group of general--purpose signals that send or receive the data by using two or more signal lines as the same group. The value of the group I/O is represented in decimal or hexadecimal. When the data is sent, the value is transformed to the binary number. Assignment of I/O signal In the group I/O, the signal number can be defined to one group. Signal lines from 2 to 16 can be defined as one group. The defined group can overlap with the digital I/O. NOTE However, the defined group can not overlap with the digital output which is included in the complementary pair. RACK The rack indicates the kind of hardware which composes I/O modules. -- 0 = process I/O PC board -- 1 to 16 = I/O Unit--MODEL A / B The base unit of the I/O unit--MODEL A and the interface unit of the I/O unit--MODEL B are defined as racks 1, 2, ⋅⋅⋅ 2, according to the sequence of connection. SLOT The slot indicates the number of I/O module parts which composes the rack. F
F
F
When the process I/O PC board is used, the first connected board is SLOT 1,the second is SLOT 2 and others are numbered sequentially as this. When the I/O unit of model A is used, the number of the backplane slot in which the module is placed is the slot value of the module. When the I/O unit--MODEL B is used, the slot number of the basic unit is specified by the DIP switch in the basic unit.
START PT START PT allocates the logical number to the physical number to map the signal lines. The first physical number in the class of eight signals should be specified. The first physical number of the signal line is specified with this rack. NOTE A physical number specifies the Input/Output pin on the I/O module. Logical number is allocated to this physical number. NOTE Because the physical numbers for eighteen inputs (“in 1” to “in 18”) and twenty outputs (“out 1” to “out 20”) on the first process I/O printed circuit board on the I/O link are allocated to the peripheral I/O signals, the physical numbers for the group I/O signals are “in 19” and above and “out 21” and above. The physical number can start from any number. NOTE When two or more I/O boards are connected, the signal lines on the different boards can not be allocated to one group. NUM PTS NUM PTS specifies the number of the digital signals which is assigned to one group. NOTE The number of the signal allocated to 1 group is from 2 to 16 points. I/O configuration can be done with I/O configuration screen and I/O detail screen. When I/O configuration is changed, turn off the controller, and turn on the controller to use the new information. CAUTION At the first power--on after the I/O assignment is modified, the output signals are all off regardless of whether processing for power failures is enabled. Execution of output The value of the group output can be set by executing the program or manual I/O control.(See Section 4.6, “I/O instruction”, and Section 6.4,“Manual I/O Control”)
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Execution of simulated I/O Simulating I/O allows you to test a program that uses I/O. Simulating I/O does not actually send output signals or receive input signals.(See Section 6.3.1 “Specifying test execution”) Procedure 3--16 Step
Configuring group I/O
1 Press the MENUS key. The screen menu is displayed. 2 Select 5 [I/O]. 3 Press F1 [TYPE]. The screen change menu is displayed. 4 Select Group. Group I/O list screen is displayed. Group I/O list screen
4 ALARM 5 I/O 6 SETUP
I/O Group Out JOINT 30 % # SIM VALUE GO[ 1] * 0 [ ] GO[ 2] * 0 [ ] GO[ 3] * 0 [ ] GO[ 4] * 0 [ ] GO[ 5] * 0 [ ] GO[ 6] * 0 [ ] GO[ 7] * 0 [ ] GO[ 8] * 0 [ ] GO[ 9] * 0 [ ] GO[ 10] * 0 [ ] [ TYPE ] CONFIG IN/OUT SIMULATE UNSIM
MENUS
Group [TYPE]
F1 5 To switch the input screen to the output screen, or vice versa, press the F3 key, IN/OUT. [ TYPE ] CONFIG
IN/OUT
F3 6 To allocate I/O, press F2,CONFIG. Group I/O configuration screen [ TYPE ] CONFIG
IN/OUT
F2
I/O Group Out JOINT 30 % GO # RACK SLOT START PT NUM PTS 1 0 0 0 0 2 0 0 0 0 3 0 0 0 0 4 0 0 0 0 5 0 0 0 0 6 0 0 0 0 7 0 0 0 0 8 0 0 0 0 9 0 0 0 0 [ TYPE ] MONITOR IN/OUT DETAIL HELP >
To return to the list screen, press F2,MONITOR. [ TYPE ] MONITOR IN/OUT
F2 7 To configure the I/O,move the cursor to each item and type the value.
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NOTE The physical number to which the logical number of group I/O is assigned can be the same to which the digital I/O is assigned. 8 To set the attribute of I/O, press NEXT key of the selection screen and press F4,DETAIL of the next page. Group I/O detail screen IN/OUT
DETAIL
HELP >
I/O Group Out Port Detail
F4
JOINT
Group Output: [
10 % 1/1
1]
1 Comment : [
[ TYPE ]
PRV-PT
]
NXT-PT
To return to the selection screen, press PREV key. PREV 9 To add a comment: a Move the cursor to the comment line and press the ENTER key. JOINT 1
[
30 % ]
ENTER
b Select the method of naming the comment. c Press the appropriate function keys to add the comment. d When you are finished, press the ENTER key. 10 To set the item, move the cursor to the setting column,and select the function key menu. 11 When you are finished, press the PREV key to return to the selection screen. 12 Turn off the controller. Turn on the controller so it can use the new information. WARNING Power should be turned on again to make a new setting valid. Otherwise, injury or property damage would occur. CAUTION In the first power--up after I/O re--allocation, power recovery would not be executed even if it is enabled. CAUTION After all I/O signals are set, the setting information should be saved in external storage (floppy disk, for example) in case the information needs to be re--loaded. Otherwise, the current setting information would be lost when it is changed.
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3.8.3 Analog I/O Analog I/O (AI/AO) signals are sent to and from the arc welding machine and peripheral equipment via the input/output signal lines on the process I/O printed circuit board (or I/O unit). The analog input/output voltages are converted to digital form when they are read or written. Therefore, they do not directly correspond to the input/output voltages. Configuration of input/output The physical numbers for the analog signal lines can be redefined. NOTE The standard configuration is factory--set up. To use a different configuration from the standard setting, make a reconfiguration. CAUTION Before the physical numbers are re--defined, the use of the signals should be carefully checked. Otherwise, injury or property damage would occur. RACK Indicates the type of hardware composing the I/O modules. -- 0 = process I/O printed circuit board -- 1 to 16 = I/O unit--MODEL A / B The base unit of the I/O unit--MODEL A and the interface unit of the I/O unit--MODEL B are defined as racks 1, 2, ..., according to the sequence of connection. SLOT Indicates the number for the I/O module parts which compose RACK. The slot number for the backplane in the I/O unit--MODEL A serves as the slot number for the module. CHANNEL Allocates the physical number to the logical number for mapping the signal lines. NOTE A physical number specifies the pin of an input/output line on the I/O module. The logical number is allocated to this physical number. This allocation can be altered. I/O configuration can be done on the I/O configuration screen and I/O detail screen. When I/O configuration is changed, turn the controller off and on again to use the new information. CAUTION At the first power--on after the I/O assignment is modified, the output signals are all off regardless of whether processing for power failures is enabled. Execution of output The value of the analog output can be set by executing the program or manual I/O control (Sections 4.6 and 6.4). Execution of simulated I/O Simulating I/O allows you to test a program that uses I/O. Simulating I/O does not actually send output signals or receive input signals (Section 6.3.1).
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Figure 3--27. Analog I/O Interface Printed circuit board for robot control
CA process I/O printed circuit board
JD1A
CRM2A
Peripheral unit A1
JD4A
CRM2B
Peripheral unit A2
JD4B CRW1
CRW1
Peripheral unit
CRW2
Peripheral unit
Welding interface
Analog input interface CRW2
CRW1 01 02 03 04 05 06 07 08 09 10 11 12
aout 1 aout 1--C aout 2 aout 2--C WDI 1 WDI 2 WDI 3 WDI 4 WDI 5 WDI 6 WDI 7 WDI 8
13 14 15 16 17 18 19 20 21 22
ain 1 ain 1--C ain 2 ain 2--C
0V 0V 0V 0V
23 24 25 26 27 28 29 30 31 32 33 34
WDO 1 WDO 2 WDO 3 WDO 4 WDO 5 WDO 6 WDO 7 WDO 8 WDI + WDI -+24V +24V
82
01 02 03 04 05 06 07
08 ain 6 09 ain 6--C 10 11 12 13
14 15 16 17 18 19 20
ain 3 ain 3--C ain 4 ain 4--C ain 5 ain 5--C
ain *--C is the common signal line for ain *.
3. SETTING UP THE ARC SYSTEM
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Procedure 3--17
Setting analog I/O
NOTE The standard configuration is factory--set up. To use a different configuration from the standard setting, reconfigure the I/O. Step
1 Press the MENUS key. The screen menu is displayed. 2 Select 5, [I/O]. 3 Press F1, [TYPE]. The screen change menu is displayed. 4 Select Analog. The analog I/O list screen is displayed. Analog I/O list screen
4 ALARM 5 I/O 6 SETUP
I/O Analog In # SIM VALUE AI[ 1] U 0 [ AI[ 2] U 0 [ AI[ 3] * 0 [ AI[ 4] * 0 [ AI[ 5] * 0 [ AI[ 6] * 0 [ AI[ 7] * 0 [ AI[ 8] * 0 [ AI[ 9] * 0 [ AI[ 10] * 0 [
MENUS
Analog [TYPE]
[ TYPE ] CONFIG
JOINT
30 % 1/25 ] ] ] ] ] ] ] ] ] ]
IN/OUT SIMULATE UNSIM
F1 5 To switch the input screen to the output screen, press F3, [IN/OUT]. [ TYPE ] CONFIG
IN/OUT
F3 6 To allocate I/O, press F2, [CONFIG]. Analog I/O configuration screen [ TYPE ] CONFIG
IN/OUT
F2
I/O Analog In AI # 1 2 3 4 5 6 7 8 9
RACK 0 0 0 0 0 0 0 0 0
JOINT SLOT 1 1 0 0 0 0 0 0 0
30 % 1/25
CHANNEL 1 2 0 0 0 0 0 0 0
[ TYPE ] MONITOR IN/OUT
DETAIL
HELP >
To return to the list screen, press F2, [MONITOR]. [ TYPE ] MONITOR IN/OUT
F2 7 To configure the signals, move the cursor to each item and enter the value.
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8 To return to the list screen, press F2, [MONITOR]. I/O Analog In JOINT 30 % # SIM VALUE 1/25 AI[ 1] U 0 [analog sign1] AI[ 2] U 0 [analog sign2] AI[ 3] * 0 [ ] AI[ 4] * 0 [ ]
[ TYPE ] MONITOR IN/OUT
F2
[ TYPE ] CONFIG
IN/OUT SIMULATE UNSIM
9 Press NEXT key of the selection screen and press F4, [DETAIL] of the next page. The analog I/O detail screen is displayed. Analog I/O detail screen IN/OUT
DETAIL
HELP >
I/O Analog Out Port Detail
F4
JOINT
Analog Output: [
10 % 1/1
1]
1 Comment : [
[ TYPE ]
PRV-PT
]
NXT-PT
To return to the configuration screen, press the PREV key. PREV
10 To add a comment: a Move the cursor to the comment line and press the ENTER key. JOINT 1
[
30 % ]
ENTER
b Select the method of naming the comment. c Press the appropriate function keys to add the comment. d When you are finished, press the ENTER key. 11 To specify the signal attribute, move the cursor to the corresponding field, and select the function key. 12 When you are finished, press the PREV key to return to the selection screen. 13 Turn the controller off and on again so that it can use the new information. WARNING Power should be turned on again to make a new setting valid. Otherwise, injury or property damage would occur. CAUTION In the first power--up after I/O re--allocation, power failure recovery would not be executed even if it is enabled.
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CAUTION After all I/O signals are set, the setting information should be saved in external storage (floppy disk, for example) in case the information needs to be re--loaded. Otherwise, the current setting information would be lost when it is changed.
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3.9 Robot I/O Robot I/O are signals digital signals Robot to operate the following executions. F
Other signals are used as the end effector I/O via the robot. The end effector I/O is connected to the connector at the end of the robotic arm to enable its use.
The end effector I/O consists of eight input and eight output general--purpose signals. No signal numbers can be redefined for these signals. NOTE The number of general--purpose input/output signals of the end effector I/O depends on the model of the robot. Refer to the mechanical unit maintenance manual. Hand breakage input signal, *HBK The *HBK signal is connected to the robot hand and detects a breakage in the tool. In the normal state, the *HBK signal is set on. When the *HBK signal goes off, an alarm occurs and the robot is immediately stopped. NOTE Hand breakage detection can be disabled on the system setting screen. See the item of enabling and disabling hand breakage detection in Section 3.21, “SYSTEM CONFIG MENU.” Abnormal air pressure input signal, *PPABN input The *PPABN signal detects a drop in the air pressure. In the normal state, the *PPABN signal is set on. When a drop in air pressure occurs, the *PPABN signal goes off, an alarm is issued, and the robot is immediately stopped. *ROT input The overtravel (robot overtravel) signal indicates an overtravel along each axis of the mechanical unit of the robot. In the normal status, the *ROT signal is on. When this signal is turned off, an alarm is generated and the robot is stopped immediately. The *ROT input does not appear on the cable terminal of the end effector because it is processed within the mechanical unit of the robot. While the *HBK or *ROT signal is off, the alarm state can temporarily be released by holding down the shift key and pressing the alarm release key. While holding down the shift key, move the tool to the appropriate position by jog feed. RDI [1 to 8] INPUT RDO [1 to 8] OUTPUT The end effector signals, (RDI [1 to 8] and RDO [1 to 8], are general--purpose input and output signals.
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Procedure 3--18 Step
Setting Robot I/O
1 Press the MENUS key. The screen menu is displayed. 2 Select 5 (I/O). 3 Press the F1 key, [TYPE]. The screen change menu is displayed. 4 Select “Robot.” Robot I/O Selection Screen
4 ALARM 5 I/O 6 SETUP
I/O Robot Out # STATUS RDO[1] OFF [ RDO[2] OFF [ RDO[3] OFF [ RDO[4] ON [ RDO[5] ON [ RDO[6] OFF [ RDO[7] OFF [ RDO[8] ON [ RDO[9] ON [
MENUS
Robot [TYPE]
[TYPE]
JOINT 30% 1/24 ] ] ] ] ] ] ] ] ]
IN/OUT
ON
OFF
>
F1 5 To switch the input screen to the output screen, press the F3 key, IN/OUT. [TYPE]
IN/OUT
F3 6 To set the attribute of I/O, press NEXT key and press F4, DETAIL of the next page. Robot I/O Detail Screen [TYPE]
NUM-SRT CMT-SRT DETAIL
HELP > I/O Robot Out Port Detail
F2
JOINT
Robot Dig. Output: [
1]
1 Comment : [ 2
]
Polarity : NORMAL
3 Complementary : FALSE
[ TYPE ]
PRV-PT
NXT-PT
NOTE On the detailed robot I/O screen, Items 1: COMMENT Items 2: POLARITY Items 3: COMPLEMENTARY To return to the selection screen, press the PREV key. 7 To add a comment: a Move the cursor to the comment line and press the ENTER key. b Select the method of naming the comment. c Press the appropriate function keys to add the comment. d When you are finished, press ENTER key.
87
10 % 1/3
[
1 -
2]
3. SETTING UP THE ARC SYSTEM
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8 To set the polarity and the complementary pair, move the cursor to the setting column,and select the function key menu. 9 When you are finished,press PREV to return to the list screen.
I/O Robot Out # STATUS RO[ 1] OFF RO[ 2] OFF RO[ 3] OFF RO[ 4] ON [ TYPE ]
JOINT 30 % 1/24 ] ] ] ]
[ [ [ [ IN/OUT
ON
OFF
10 Turn off the controller. Turn on the controller so it can use the new information. WARNING Power should be turned on again to make a new setting valid. Otherwise, injury or property damage would occur.
CAUTION After all I/O signals are set, the setting information should be saved in external storage (floppy disk, for example) in case the information needs to be re--loaded. Otherwise, the current setting information would be lost when it is changed.
11 To perform forced output of a signal, place the cursor on ON or OFF and press the corresponding function key. I/O Robot Out
I/O Robot Out RO[1]
OFF
RO[1] [TYPE]
IN/OUT
ON
JOINT 30% ON
[
IN/OUT
] ON
OFF
OFF
F4 For the forced output of a signal, see Chapter 6, Section 6.4. WARNING The controller uses signals to control the peripheral equipment. The forced output may adversely affect the security of the system. Check the use of signals in the system before attempting the forced output.
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3.10 Peripheral I/O Peripheral I/O signals (UI/UO) are a group of specialized signals whose usage is decided by the system. These signals are connected with a remote controller and the peripheral devices via the following interfaces and I/O links and they are used to control the robot from the outside. Configuration of I/O The peripheral device I/O is automatically assigned to the first 18 input and 20 output I/O signal lines on the first process I/O printed circuit board. For the assignment of the peripheral device I/O, see Figure 3--28. CAUTION When a process I/O printed circuit board is connected, the standard assignment is made at the factory. When no process I/O printed circuit board is connected and I/O unit model A/B is connected, all digital input/output signals are assigned to the digital I/O at the factory. No digital input/output signals are assigned to the peripheral device I/O. Divide the digital input/output signals between the digital I/O and peripheral device I/O and reassign the signals to them. Remote condition When the robot is in the remote state,the program can be started by using the peripheral I/O. Signals(*HOLD,ENBL) which has relation to safety is always effective whether the remote condition is satisfied or not. When the following remote conditions are satisfied,the robot is in the remote state. J
The teach pendant enable switch is set off.
J
The remote signal (SI[2]) is on. (For how to turn the remote signal on and off, see the description of Remote/Local setup in Section 3.16, “SYSTEM CONFIG MENU.”)
J
The *SFSPD input of the peripheral device I/O is on.
J
The ENBL input of the peripheral device I/O is on.
J
A value of 0 (peripheral device) is set for system variable $RMT_MASTER.
NOTE $RMT_MASTER Specifies the kind of remote device. 0 : Peripheral device 1 : CRT/KB 2 : Host computer 3 : No remote device A program including a motion (group) can be started only when the remote conditions and the following operation conditions are satisfied: J
The ENBL signal of the peripheral I/O is set on.
J
The servo power is on (not in the alarm state).
The CMDENBL signal indicates whether the above conditions are satisfied. The signal is output when the following conditions are satisfied: J
The remote conditions are satisfied.
J
Not alarm status.
J
The continuous operation mode is selected (the single step mode is disabled).
NOTE Peripheral I/O signals are disabled in the initial state. To enable these signals, set TRUE at “Enable UI signals” on the system configuration screen.
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Figure 3--28. Peripheral I/O Interface Process I/O printed circuit board
Main CPU printed circuit board
JD1A
JD4A
CRM2A
Peripheral device A1
CRM2B
Peripheral device A2
JD4B
Peripheral device A1 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
Physical number in 1 in 2 in 3 in 4 in 5 in 6 in 7 in 8 in 9 in 10 in 11 in 12 in 13 in 14 in 15 in 16
CRM2A 19 20 21 22 23 24 25 26 27 28 29 30 31 32
out 13 out 14 out 15 out 16 out 17 out 18 out 19 out 20 in 17 in 18 in 19 in 20
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
out 1 out 2 out 3 out 4 out 5 out 6 out 7 out 8 out 9 out 10 out 11 out 12
Standard peripheral device I/O settings Physical number in 1 in 2 in 3 in 4 in 5 in 6 in 7 in 8 in 9 in 10 in 11 in 12 in 13 in 14 in 15 in 16 in 17 in 18 in 19 in 20
Logical number UI 1 UI 2 UI 3 UI 4 UI 5 UI 6 UI 7 UI 8 UI 9 UI 10 UI 11 UI 12 UI 13 UI 14 UI 15 UI 16 UI 17 UI 18
Peripheral device input *IMSTP *HOLD *SFSPD CSTOPI FAULT RESET START HOME ENBL RSR1/PNS1 RSR2/PNS2 RSR3/PNS3 RSR4/PNS4 RSR5/PNS5 RSR6/PNS6 RSR7/PNS7 RSR8/PNS8 PNSTROBE PROD_START
Physical number out 1 out 2 out 3 out 4 out 5 out 6 out 7 out 8 out 9 out 10 out 11 out 12 out 13 out 14 out 15 out 16 out 17 out 18 out 19 out 20
Logical number UO 1 UO 2 UO 3 UO 4 UO 5 UO 6 UO 7 UO 8 UO 9 UO 10 UO 11 UO 12 UO 13 UO 14 UO 15 UO 16 UO 17 UO 18 UO 19 UO 20
Peripheral device input CMDENBL SYSRDY PROGRUN PAUSED HELD FAULT ATPERCH TPENBL BATALM BUSY ACK1/SNO1 ACK2/SNO2 ACK3/SNO3 ACK4/SNO4 ACK5/SNO5 ACK6/SNO6 ACK7/SNO7 ACK8/SNO8 SNACK RESERVED
WARNING When connecting the peripheral equipments related to the emergency stop function (for example Protective Fence) to each signal of a robot (for example external emergency stop, fence, servo, etc.), confirm whether emergency stop can work to prevent from connecting incorrectly.
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*IMSTP input UI [1] (Always enabled.) The immediate stop signal specifies an emergency stop by the software. The *IMSTP input is on in the normal status. When this signal is turned off, the following processing is performed: F
An alarm is generated and the servo power is turned off.
F
The robot operation is stopped immediately. Execution of the program is also stopped. WARNING
The *IMSTP signal is controlled by software. The use of this signal for safety--critical processing is not recommended. To link this signal with the emergency stop, use this signal together with the EMGIN1 or EMGIN2 signal on the operator’s panel printed circuit board. For details of these signals, refer to the “Maintenance Manual.” *HOLD input UI [2] (Always enabled.) The temporary stop signal specifies a temporary stop from an external device. The *HOLD input is on in the normal status. When this signal is turned off, the following processing is performed: F
The robot is decelerated until its stops, then the program execution is halted.
F
If ENABLED is specified at “Break on hold” on the general item setting screen, the robot is stopped, an alarm is generated, and the servo power is turned off.
*SFSPD input UI [3] (Always enabled.) The safety speed signal temporarily stops the robot when the safety fence door is opened. This signal is normally connected to the safety plug of the safety fence door. The *SFSPD input is on in the normal status. When this signal is turned off, the following processing is performed: F
The operation being executed is decelerated and stopped, and execution of the program is also stopped. At this time, the feedrate override is reduced to the value specified for $SCR.$FENCEOVRD.
F
When the *SFSPD input is off and a program is started from the teach pendant, the feedrate override is reduced to the value specified for $SCR.$SFRUNOVLIM. When jog feed is executed, the feedrate override is reduced to the value specified for $SCR.$SFJOGOVLIM. When *SFSPD is off, the feedrate override cannot exceed these values. WARNING
The *SFSPD signal controls deceleration and stop by software. To stop the robot immediately for safety purposes, use this signal together with the FENCE1 or FENCE2 signal on the operator’s panel printed circuit board. For details of these signals, refer to the “Maintenance Manual.” NOTE When the *IMSTP, *HOLD, and *SFSPD signals are not used, jumper these signal lines. CSTOPI input UI [4] (Always enabled.) The cycle stop signal terminates the program currently being executed. It also releases programs from the wait state by RSR. F
When FALSE is selected for CSTOPI for ABORT on the Config system setting screen, this signal terminates the program currently being executed as soon as execution of the program completes. It also releases (Clear) programs from the wait state by RSR. (Default)
F
When TRUE is selected for CSTOPI for ABORT on the Config system setting screen, this signal immediately terminates the program currently being executed. It also releases (Clear) programs from the wait state by RSR. WARNING
When FALSE is selected for CSTOPI for ABORT on the Config system setting screen, CSTOPI does not stop the program being executed until the execution is complete. Fault reset input signal, RESET, UI [5] The RESET signal cancels an alarm. If the servo power is off, the RESET signal turns on the servo power. The alarm output is not canceled until the servo power is turned on. The alarm is canceled at the instant this signal falls in default setting.
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Enable input signal, ENBL, UI [8] The ENBL signal allows the robot to be moved and places the robot in the ready state. When the ENBL signal is off, the system inhibits a jog feed of the robot and activation of a program including a motion (group). A program which is being executed is halted when the ENBL signal is set off. NOTE When the ENBL signal is not monitored, strap the signal with the ground. RSR1 to RSR8 inputs UI [9--16] (Enabled in the remote state.) These are robot service request signals. When one of these signals is received, the RSR program corresponding to the signal is selected and started to perform automatic operation. When another program is being executed or is stopped temporarily, the selected program is added to the queue and is started once the program being executed terminates. (! Section 3.14.1, “Robot service request”) PNS1 to PNS8 UI [9--16] PNSTROBE UI [17] (Enabled in the remote state.) [Option = external program selection] These are program number select signals and a PN strobe signal. When the PNSTROBE input is received, the PNS1 to PNS8 inputs are read to select a program to be executed. When another program is being executed or temporarily stopped, these signals are ignored. (! Section 3.14.2, “Program number select”) When the remote conditions are satisfied, program selection using the teach pendant is disabled while PNSTROBE is on. PROD_START input UI [18] (Enabled in the remote state.) The automatic operation start (production start) signal starts the currently selected program from line 1. This signal functions at its falling edge when turned off after being turned on. When this signal is used together with a PNS signal, it executes the program selected by the PNS signal starting from line 1. When this signal is used together with no PNS signal, it executes the program selected using the teach pendant starting from line 1. When another program is being executed or temporarily stopped, this signal is ignored. (Program number select Section 3.14.2) START input UI [6] (Enabled in the remote state.) This is an external start signal. This signal functions at its falling edge when turned off after being turned on. When this signal is received, the following processing is performed: F
When FALSE is selected for START for CONTINUE only on the Config system setting screen, the program selected using the teach pendant is executed from the line to which the cursor is positioned. A temporarily stopped program is also continued. (Default)
F
When TRUEis selected for START for CONTINUE only on the Config system setting screen, a temporarily stopped program is continued. When the program is not temporarily stopped, it cannot be started.
NOTE To start a program from a peripheral device, the RSR or PROD_START input is used. To start a temporarily stopped program, the START input is used. CMDENBL input UO [1] The input accept enable (command enable) signal is output when the following conditions are satisfied. This signal indicates that a program including an operation (group) can be started from the remote control units. J
The remote conditions are satisfied.
J
The operation enable conditions are satisfied.
J
The mode is continuous operation (single step disable).
SYSRDY output UO [2] SYSRDY is output while the servo power is on. This signal places the robot in the operation enable state. In the operation enable state, jog feed can be executed and a program involving an operation (group) can be started. The robot enters the operation enable state when the following operation enable conditions are satisfied: J
The ENBL input of the peripheral device I/O is on.
J
The servo power is on (not in the alarm state).
PROGRUN output UO [3] PROGRUN is output while a program is being executed. It is not output while a program is temporarily stopped.
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PAUSED output UO [4] PAUSED is output when a program is temporarily stopped and waits for restart. HELD output UO [5] HELD is output when the hold button is pressed or the HOLD signal is input. It is not output when the hold button is released. FAULT output UO [6] FAULT is output when an alarm occurs in the system. The alarm state is released by the FAULT_RESET input. FAULT is not output when a warning (WARN alarm) occurs. ATPERCH output UO [7] ATPERCH is output when the robot is in a previously defined reference position. Up to three reference positions can be defined. This signal is output only when the robot is in the first reference position. For any other reference positions, general--purpose signals are assigned. TPENBL output UO [8] TPENBL is output when the enable switch of the teach pendant is set to on. BATALM output UO [9] BATALM indicates a low--voltage alarm for the backup battery of the control unit or robot pulse coder. Turn the power to the control unit on and replace the battery. BUSY output UO [10] BUSY is output while a program is being executed or while processing using the teach pendant is being performed. It is not output while a program is temporarily stopped. ACK1 to ACK8 outputs UO [11--18] When the RSR function is enabled, ACK1 to ACK4 are used together with the function. When an RSR input is accepted, a pulse of the corresponding signal is output as an acknowledgment. The pulse width can be specified. (! Section 3.14.1, “Robot service request”) SNO1 to SNO8 outputs UO [11--18] [Option = external program selection] When the PNS function is enabled, SNO1 to SNO8 are used together with the function. The currently selected program number (signal corresponding to the PNS1 to PNS8 inputs) is always output, in binary code, as confirmation. The selection of another program changes SNO1 to SNO8. (! Section 3.14.2, “Program number select”) SNACK output UO [19] [Option = external program selection] When the PNS function is enabled, SNACK is used together with the function. When the PNS inputs are accepted, a pulse of this signal is output as an acknowledgment. The pulse width can be specified. (! Section 3.14.2, “Program number selection”)
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Procedure 3--19
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Configurating Peripheral I/O 1
CAUTION When a process I/O printed circuit board is connected, the standard assignment is made at the factory. When no process I/O printed circuit board is connected and I/O unit model A/B is connected, all digital input/output signals are assigned to the digital I/O at the factory and no digital input/output signals are assigned to the peripheral device I/O. Divide the digital input/output signals between the digital I/O and peripheral device I/O and reassign the signals to them. Step
1 Press the MENUS key. The screen menu is displayed. 2 Select 5, [I/O]. 3 Press the F1 key, [TYPE]. The screen change menu is displayed. 4 Select UOP. Peripheral I/O Selection Screen
4 ALARM 5 I/O 6 SETUP
I/O UOP Out # UO[1] UO[2] UO[3] UO[4] UO[5] UO[6] UO[7] UO[8] UO[9]
MENUS
UOP [TYPE]
JOINT 30% STATUS ON [*HOLD OFF [FAULT reset OFF [Start ON [Enable OFF [PNS1 OFF [PNS2 OFF [PNS3 OFF [PNS4 * [
[ TYPE ] DETAIL
IN/OUT
ON
] ] ] ] ] ] ] ] ] OFF
F1 5 To switch the input screen to the output screen, or vice versa, press the F3 key, IN/OUT. [ TYPE ] DETAIL
IN/OUT
F3 6 To allocate I/O, press F2,CONFIG. Peripheral I/O configuration screen [ TYPE ] DETAIL
IN/OUT I/O UOP In
F2
# 1 2 3
RANGE UI[ 1- 8] UI[ 9- 16] UI[ 17- 18]
JOINT RACK 0 0 0
[ TYPE ] MONITOR IN/OUT
SLOT 1 1 1
10 % 1/3 START STAT. 1 ACTIV 9 ACTIV 17 ACTIV
DELETE
HELP
To return to the list screen, press F2,MONITOR 7 Manipulating the I/O assignment screen a) Place the cursor on “Range,” and specify the range of signals to be assigned. b) Line division is performed automatically according to the specified range. c) Enter appropriate values for “Rack,” “Slot,” and “Start point.” d) When the entered values are valid, abbreviation “PEND” is displayed in “Status.” If any entered value is invalid, abbreviation “INVAL” is displayed in “Status.”
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Unnecessary lines can be deleted by pressing F4 (Delete). The abbreviations that will appear in “Status” mean the following: ACTIV: This assignment is now in use. PEND: Assignment is normal. Turning the power off and on again causes the ACTIV status to be entered. INVAL: A specified value is invalid. UNASG: No assignment has been made. NOTE In default setting, input pins 1 to 18 and output pins 1 to 20 is assigned to the peripheral I/O. 8 To set the attribute of I/O, press NEXT key of the selection screen and press F4, DETAIL of the next page. Peripheral I/O detail screen DETAIL
HELP > I/O UOP In Port Detail
F4
JOINT
User Opr. Panel Input: [
10 % 1/1
1]
1 Comment : [*IMSTP
[ TYPE ]
PRV-PT
]
NXT-PT
To return to the configuration screen,press the PREV key. 9 To add a comment: a Move the cursor to the comment line and press the ENTER key. JOINT 1
[
30 % ]
ENTER
b Select the method of naming the comment. c Press the appropriate function keys to add the comment. d When you are finished, press the ENTER key. NOTE The comment of peripheral equipment I/O is written by the tool software and can be changed. Even if the comment is rewritten, the function is not changed. 10 To set the item, move the cursor to the setting column,and select the function key menu. 11 When you are finished, press the PREV key to return to the selection screen. 12 Turn off the controller. Turn on the controller so it can use the new information. WARNING Power should be turned on again to make a new setting valid. Otherwise, injury or property damage would occur.
CAUTION In the first power--up after I/O re--allocation, power failure recovery would not be executed even if it is enabled. CAUTION After all I/O signals are set, the setting information should be saved in external storage (floppy disk, for example) in case the information needs to be re--loaded. Otherwise, the current setting information would be lost when it is changed.
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3.11 Operator’s Panel I/O The operator’s panel I/O includes dedicated digital signals for passing data indicating the status of the buttons and LEDs on the operator’s panel/box. The status of each input signal depends on whether the corresponding button on the operator’s panel is on or off. Each output signal is used to turn the corresponding LED lamp on the operator’s panel on or off. For the operator’s panel I/O, the signal numbers cannot be mapped (redefined). Sixteen input and sixteen output signals are defined as standard. For the definition of the signals of the operator’s panel I/O, see Fig. 3--29. When the operator’s panel is enabled, the operator’s panel I/O can be used to start a program. However, any signals which have a significant effect on safety are always enabled. The operator’s panel is enabled when the following operator’s panel enable conditions are satisfied: J
The enable switch on the teach pendant is set to off.
J
The remote switch on the operator’s panel is set to the local position.
J
The *SFSPD input of the peripheral device I/O is on.
To start a program involving operation (group), the following conditions must be satisfied: J
The ENBL input of the peripheral device I/O is on.
J
The servo power is on (not in the alarm state).
For the operator’s panel on the B cabinet control unit, additional functions can be assigned to user keys (SI[4] and SI[5]) on the operator’s panel by setting macro instructions [option functions] (See Section 9.1, “Macro Instructions”). Figure 3--29. Operator’s Panel I/O Main CPU printed circuit board
Operator’s box
Logical number SI 0 SI 1 SI 2 SI 3 SI 4 SI 5 SI 6 SI 7
Table 3--11.
Operator’s panel input
Logical number SO 0 SO 1 SO 2 SO 3 SO 4 SO 5 SO 6 SO 7
FAULT_RESET REMOTE *HOLD USER#1 USER#2 START
Operator’s panel output REMOTE LED CYCLE START HOLD FAULT LED BATTERY ALARM USER#1 USER#2 TPENBL
Operator’s Panel Input Signals
Input signal
Description
*HOLD SI [3] Always enabled.
The temporary stop (hold) signal specifies temporary stop of the program. The *HOLD signal is on in the normal status. When this signal is turned off: F The robot operation being executed is decelerated, then stopped. F The program being executed is temporarily stopped.
FAULT_RESET SI [2] Always enabled.
The alarm release (fault reset) signal releases the alarm state. When the servo power is off, this signal turns on the servo power. In this case, the alarm state is not released until the servo power is turned on.
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Table 3--11. (Cont’d) Operator’s Panel Input Signals Input signal REMOTE SI [2] Always enabled.
Description The remote signal switches between system remote and local mode. In remote mode, when the remote conditions are satisfied, a program can be started using the peripheral device I/O. In local mode, when the operator’s panel enable conditions are satisfied, a program can be started from the operator’s panel.
START The start signal starts the currently selected program using the teach pendant SI [6] from the line to which the cursor is positioned or restarts a temporarily stopped Enabled in the operator’s panel enable program. This signal functions at its falling edge when turned off after being state. turned on.
Table 3--12.
Operator’s Panel Output Signals
Output signal
Description
REMOTE SO [0]
The remote signal is output when the remote conditions are satisfied (See remote conditions Section 3.3, “Peripheral Device I/O”).
BUSY SO [1] Not provided for the operator’s box.
The busy signal is output while processing such as program execution or file transfer is being performed. It is not output when a program is temporarily stopped.
HELD SO [2] Not provided for the operator’s box.
The hold signal is output when the hold button is pressed or the HOLD signal is input.
FAULT SO [3]
The alarm (fault) signal is output when an alarm occurs in the system. The alarm state is released by the FAULT_RESET input. This signal is not output when a warning (WARN alarm) occurs.
BATAL output SO [4] Not provided for the operator’s box.
The abnormal battery (battery alarm) signal indicates a low--voltage alarm for the battery in the control unit. While keeping the power to the control unit on, replace the battery.
TPENBL output SO [7] Not provided for the operator’s box.
The teach pendant enable (TP enable) signal is output when the enable switch on the teach pendant is on.
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Procedure 3--20
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Displaying the operator’s panel I/O
NOTE For the operator’s panel I/O, the signal numbers cannot be redefined. Step
1 Press MENU to display the screen menu. 2 Select “5 I/O.” 3 Press F1 (TYPE) to display the screen switching menu. 4 Select “SOP.” Operator’s panel I/O list screen
4 ALARM 5 I/O 6 SETUP
I/O Sop Out # SO[0] SO[1] SO[2] SO[3] SO[4] SO[5] SO[6] SO[7] SO[8] SO[9]
MENUS
SOP TYPE
JOINT 30% STATUS ON [Remote LED OFF [Cycle start OFF [Hold ON [Fault LED ON [Butt alarm OFF [User LED#1 OFF [User LED#2 ON [TP enabled OFF [ OFF [
] ] ] ] ] ] ] ] ] ]
F1 5 Press F3 (IN/OUT) to switch the display between the input and output screens.
[ TYPE ]
IN/OUT
NOTE The input signal status can only be checked. Values cannot be changed forcibly.
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3.12 I/O Link Screen The I/O link screen can be used to make settings related to FANUC I/O unit MODEL B and to display the configuration of the I/O link units. The I/O link screen consists of the following screens: F I/O link list screen F MODEL B unit list screen F Signal count setting screen
3.12.1 I/O Link list screen The I/O link list screen displays a list of I/O units in slave mode that are connected to the I/O link. It also displays the rack and slot numbers of each unit. For I/O unit MODEL A/B, only the interface units are displayed. In this case, a value of 0 is displayed for the rack number. The following figure is an example of the I/O link list screen when process I/O board CA, one unit of I/O unit MODEL B, and two units of I/O unit MODEL A are connected to the robot control unit. The names of the I/O units are displayed in the order in which the units are connected to the robot control unit. I/O Link Device
1 2 3 4
Device name PrcI/O CA Model B Model A Model A
[TYPE]
JOINT 100% Comment
[ [ [ [
] ] ] ]
DETAIL
Rack 0 1 2 3
Slot 1 0 0 0
CLR_ASG
To display this screen, first press MENUS to display the screen menu, then select “5 I/O.” Then, press F1 (TYPE) to display the screen switching menu, then select Link Device. The following table lists the device names displayed on the screen and the corresponding actual device names. Word on TP
Device
PrcI/O AA PrcI/O AB PrcI/O BA PrcI/O BB PrcI/O CA PrcI/O CB
Process I/O Board AA Process I/O Board AB Process I/O Board BA Process I/O Board BB Process I/O Board CA Process I/O Board CB
PrcI/O DA PrcI/O EA PrcI/O EB PrcI/O FA PrcI/O GA PrcI/O HA R--J2 Mate Weld I/F Others
Process I/O Board DA Process I/O Board EA Process I/O Board EB Process I/O Board FA Process I/O Board GA Process I/O Board HA R--J2 Mate. Slave Mode Weld Interface Board Other I/O devices except above devices
When F3 (DETAIL) is pressed, MODEL B screen or Number of Ports Setting Screen is displayed according to the type of the unit. When F3 (DETAIL) is pressed for the following units, the detail screen is displayed. When F3 (DETAIL) is pressed for other units, no screen change occurs. Each detail screen is described later. Word on TP Model B 90--30 PLC I/O adptr R--J2 Mate Unknown
Detail Screen Model B Number of Ports Number of Ports Number of Ports Number of Ports
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On this screen, a comment can be specified for each I/O unit. Move the cursor to Comment and press the enter key. The screen enters comment input mode. F5 (CLR_ASG) is described later.
3.12.2 MODEL B unit list screen The MODEL B unit list screen displays a list of units of FANUC I/O unit MODEL B. FANUC I/O unit MODEL B does not automatically recognize the connected DI/DO units. On this screen, set the types of the DI/DO units. The address set using the DIP switch of each DI/DO unit is used as the line number on this screen. One additional unit can be connected to each DI/DO unit. This screen can also be used to specify whether to connect an additional unit and the type of additional unit. When the cursor is positioned to a “MODEL B” item on the I/O link list screen, press F3 (DETAIL) to display MODEL B screen as shown below: I/O Link Device Model B Slot Base Exp. 1 ******* ******* 2 ******* ******* 3 ******* ******* : : : 30 ******* ******* [TYPE]
LIST
[ [ [ [
JOINT 100% Rack 1 1/30 Comment ] ] ] : ]
[CHOICE] CLR_ASG
At first, nothing is set, as shown above. To use MODEL B, set the types of the units on this screen. When DI/DO unit BOD16A1 is connected to the interface unit and the address is set to 1, set the unit as shown below. Position the cursor to the position shown above (Base column on line 1), then press F4 [CHOICE]. Options are displayed as shown below:
1 2 3 4
******* BID16A1 BOD16A1 BMD88A1
Slot 1 2 3 : 30
Base ******* ******* ******* : *******
[TYPE]
5 BOA12A1 6 BIA16P1 7 BMD88Q1
Exp. ******* ******* ******* : ******* LIST
Comment [ [ [
] ] ] :
[
]
[CHOICE] CLR_ASG
Select BOD16A1 on this screen. The unit is set as shown below: I/O Link Device Model B Slot Base Exp. 1 BOD16A1 ******* 2 ******* ******* 3 ******* ******* : : : 30 ******* ******* [TYPE]
LIST
[ [ [ [
JOINT 100% Rack 1 1/30 Comment ] ] ] : ]
[CHOICE] CLR_ASG
When the cursor is positioned to column Base and F4 [CHOICE] is pressed, a menu appears. This menu contains the following items. When no unit is set, “*******” is displayed. “*******” indicates that no unit is connected. F BMD88A1 F BID16A1 F BOD16A1 F BOA12A1 When the cursor is positioned to column Exp. and F4 [CHOICE] is pressed, a menu appears. This menu contains the following items. When no unit is set, “*******” is displayed. “*******” indicates that no unit is connected. F MBD88P1
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3. SETTING UP THE ARC SYSTEM
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F F F F
BID16P1 BOD16P1 BIA16A1 BMD88Q1
After a unit is set on this screen, the unit I/O can be used by turning the power off, then on again. When the setting of a unit is changed, processing for I/O power failures is not performed at the next power--on, even when processing for power failures is enabled. To enter a comment, press ENTER with the cursor positioned to the Comment column. The comment is displayed following PRIO--100 MODEL B comm fault, displayed when the DI/DO unit is disconnected from the interface unit. When SAVE is selected on this screen while the auxiliary key is held down, a file named DIOCFGSV.IO is saved. This file contains the contents set on the I/O link screen. It also contains the I/O assignment, comments, and other information. Such information can be saved in this file from other I/O and file screens in the same way as normal. F5 (CLR_ASG) is described later.
3.12.3 Signal count setting screen For I/O units such as the I/O link connection unit and 90--30PLC that cannot be used without setting the number of signals, set the number of signals on this screen. When the cursor is positioned to “90--30PLC” on the I/O link list screen, press the F3 (DETAIL) key. Then, Number of ports setting screen appears as shown below. I/O Link Device 90-30 PLC
JOINT 100% Rack 1
Slot 1
Pore name 1 Digital Input: 2 Digital Output:
[TYPE]
Points 0 0
LIST
CLR_ASG
Move the cursor to the number indicating the number of signals and enter a numeric value to set the number of signals. The target I/O unit can be used by turning the power off, then on again after the number of signals is set on this screen. When the number of signals is changed, processing for I/O power failures is not performed at the next power--on, even when processing for power failures is enabled. When SAVE is selected on this screen while the auxiliary key is held down, a file named DIOCFGSV.IO is saved. This file contains the contents set on the I/O link screen. It also contains the I/O assignment, comment, and other information. Such information can be saved in this file from other I/O and file screens in the same way as normal. Explanation of F5 (CLR_ASG) When the number of signals is set for a MODEL--B unit or I/O unit on the I/O link screen, the I/O assignment may differ from the standard assignment according to the setting procedure. The following operation can set all I/O assignment to the standard settings. When setting the number of signals for a MODEL--B unit or I/O unit for the first time, perform the following operation. * When the unit is used with non--standard settings, this operation deletes the assignment information. Press F5 (CLR_ASG). The following message appears. Clear all assignments? YES
NO
F4
F5
Press F4 (YES) to delete all assignment information. When the power to the control unit is turned off, then on again, the assignment is set to the standard settings.
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3.13 I/O Connection Function The I/O connection function enables the RDI/SDI status to be output to SDO/RDO to report the signal input status to external devices. The standard input/output ranges are shown below: F
RDI[mmm] ! SDO[nnn]. ( 1<=mmm<=8, 0<=nnn<=256 )
F
SDI[iii] ! RDO[jjj]. ( 0<=iii<=256, 1<=jjj<=8 )
F
SDI[kkk] ! SDO[lll]. ( 0<=kkk<=256, 0<=lll<=256 )
Explanation of the function/settings Assign signals and enable or disable each assignment on Interconnect. The following three types of screens are available: F
DI DO connection setting screen (RDI ! SDO)
F
DI DO connection setting screen (SDI ! RDO)
F
DI DO connection setting screen (SDI ! SDO)
DI DO connection setting screen (RDI ! SDO) DI DO connection setting screen (SDI ! RDO) Assign SDI signal numbers to RDO1 to RDO8. Whether to enable or disable each assignment can also be set. DI DO connection setting screen (SDI ! RDO) Assign SDI signal numbers to RDO1 to RDO8. Whether to enable or disable each assignment can also be set. DI DO connection setting screen (SDI ! SDO) Assign an SDO signal number to each SDI number. Whether to enable or disable each assignment can also be set. Example) When “ENABLE DI[2] ! RO[3] ! RDO[ 3]” is set, the status of SDI[2] is output to RDO[3]. NOTE When SDI[i] ! SDO[j] is set and this assignment is enabled, the status of SDI[i] is output to SDO[j] at regular intervals. Therefore, if the contents of SDO[j] are changed using the TP or a program, the change is not reflected. NOTE Whether to enable or disable each assignment can be changed only on the setting screen, described above. NOTE When different multiple input signals are assigned to the same output signal, the status of each input signal is output. For example, assume that the following settings are made: ENABLE DI[1] ! DO[1] ! SDO[ 1] ENABLE DI[2] ! DO[1] ! SDO[ 1] In this case, when the status of RDI[1] is ON and the status of RDI[2] is OFF, the SDO[1] output will be unpredictable. (SDO[1] alternately indicates ON and OFF in practice.)
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Procedure 3--21 Step
Setting the I/O connection function
1 Press MENU to display the screen menu. 2 Select “5 I/O.” 3 Press F1 (TYPE) to display the screen switching menu. 4 Select Interconnect. The DI DO connection setting screen appears. DI DO connection setting screen (RDI SDO)
4 ALARM 5 I/O 6 SETUP
INTERCONNECT No. 1 2 3 4 5 6 7 8
MENUS
Interconnect TYPE
Enb/Disabl ENABLE DISABLE DISABLE DISABLE DISABLE DISABLE DISABLE DISABLE
[TYPE]
INPUT RI [1] RI [2] RI [3] RI [4] RI [5] RI [6] RI [7] RI [8]
[SELECT]
JOINT 100% 1/8 OUTPUT ! DO [0] ! DO [0] ! DO [0] ! DO [0] ! DO [0] ! DO [0] ! DO [0] ! DO [0] ENABLE
DISABLE
F1 5 Press SELECT. 6 Position the cursor on the screen to be displayed and press the ENTER key or specify the item number of the screen to be displayed using a numeric key. DI RO connection setting screen (SDI RDO) 1 RI!DO 2 DI!RO 3 DI!DO [ TYPE ]
SELECT
INTERCONNECT No. 1 2 3 4 5 6 7 8 [TYPE]
Enb/Disabl ENABLE DISABLE DISABLE DISABLE DISABLE DISABLE DISABLE DISABLE
INPUT DI [0] DI [0] DI [0] DI [0] DI [0] DI [0] DI [0] DI [0]
[SELECT]
103
JOINT 100% 1/8 OUTPUT ! RO [1] ! RO [2] ! RO [3] ! RO [4] ! RO [5] ! RO [6] ! RO [7] ! RO [8] ENABLE
DISABLE
3. SETTING UP THE ARC SYSTEM
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3.14 Setting Automatic Operation Automatic operation is the function with which the remote controller starts a program, using the peripheral I/O. Automatic operation includes the following functions: F
The robot service request (RSR) function selects and starts a program according to the robot service request signals (RSR1 to RSR4 inputs). When another program is being executed or is temporarily stopped, the selected program enters the wait state and is started once the program currently being executed terminates.
F
The program number selection (PNS) function selects or examines a program, using the program number selection signals (PNS1 to PNS8 PNSTROBF) and the START signal. While a program is temporarily stopped or being executed, these signals are ignored.
F
The automatic operation start signal (PROD_START input) starts the currently selected program from line 1. When another program is temporarily stopped or is being executed, this signal is ignored.
F
The cycle stop signal (CSTOPI input) is used to terminate the program currently being executed. -- When FALSE is selected for CSTOPI for ABORT on the system setting menu, this signal terminates the program currently being executed once the execution is complete. It also releases programs from the wait state by RSR. (Default) -- When TRUE is selected for CSTOPI for ABORT on the system setting menu, this signal forcibly terminates the program currently being executed immediately. It also releases (Clear) programs from the wait state by RSR.
F
The external start signal (START input) is used to start a program that is temporarily stopped. -- When FALSE is selected for START for CONTINUE only on the system setting menu, this signal starts the currently selected program from the current line. This signal also starts a temporarily stopped program. (Default) -- When TRUE is selected for START for CONTINUE only on the system setting menu, this signal starts only a temporarily stopped program. When no program is temporarily stopped, this signal is ignored.
A program can be started by entering the peripheral I/O only when the robot is in the remote state. The remote state is established when the following remote conditions are satisfied: J
The teach pendant enable switch is set off.
J
The remote signal (SI[2]) is on. (For how to turn the remote signal (SI[2]) on and off, see the description of Remote/Local setup in Section 3.16, “SYSTEM CONFIG MENU.”)
J
The *SFSPD signal of the peripheral I/O is set on.
J
The ENBL signal of the peripheral I/O is set on.
J
System variable $RMT_MASTER is set to 0 (peripheral equipment).
NOTE The value of $RMT_MASTER can be set to 0 (peripheral equipment, 1 (CRT/KB), 2 (host computer), or 3 (no remote equipment). A program including a motion (group) can be started when the following ready conditions are satisfied: J
The ENBL input signal of the peripheral I/O is set on.
J
The servo power is turned on (not in the alarm state).
The CMDENBL signal indicates whether the above conditions are satisfied. The CMDENBL signal is output when the following conditions are satisfied: J
The remote conditions are satisfied.
J
The ready conditions are satisfied.
J
The continuous operation mode is selected (the single step mode is disabled).
NOTE If TRUE is specified at “START for CONTINUE only” on the system configuration screen, the START signal is effective for only a program on hold.
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3.14.1 Robot service request (RSR) The robot service request (RSR) starts a program from an external device. The four robot service request signals (RSR1 to RSR4) are used for this function. 1 The control unit uses the RSR1 to RSR4 inputs to determine whether the input RSR signal is enabled. When the signal is disabled, it is ignored. Whether to enable or disable RSR1 to RSR4 is set in system variables $RSR1 to $RSR4 and can be changed on the RSR setting screen or by using the program RSR instruction. NOTE In the initial status, the peripheral device input signal (UI) is disabled. To enable the signal, select TRUE for Enable UI signals on the system setting screen. 2 Eight RSR registration numbers can be registered for RSR. The value obtained by adding a base number to an RSR registration number is used as the program number (four digits). For example, when RSR2 is input, the following value is used as the program number: (Program number) = (RSR2 registration number) + (base number) The selected program is named as follows: RSR + (program number) NOTE Specify the name of a program for automatic operation in “RSR” + (program number) format. Enter a 4--digit number such as RSR0121m, not RSR121. If not, the robot will not operate. The base number is set in $SHELL_CFG.$JOB_BASE and can be changed using Base number on the RSR setting screen or a program parameter instruction. 3 A pulse of the RSR acknowledgment output (ACK1 to ACK4) corresponding to the RSR1 to RSR8 input is output. When the ACK1 to ACK8 signal is output, the control unit accepts another RSR input. 4 When a program is in the terminated state, the selected program is started. When another program is being executed or is temporarily stopped, the request (job) is entered into the queue and the selected program is started when the program being executed terminates. Jobs (RSR programs) are executed in the order in which they are entered into the queue. 5 Waiting programs are canceled (cleared) by the cycle stop signal (CSTOPI input) or upon forced program termination.
Figure 3--30. Robot Service Request Whether to enable or disable RSR $RSR 1 Enabled $RSR 2 Enabled
Base number
$RSR 3 Enabled $RSR 4 Enabled
$SHELL_CFG.$JOB_BASE 100
RSR registration numbers RSR 1 RSR 2
On
RSR 1
12
RSR 2
21
RSR 3
RSR 3
33
RSR 4
RSR 4
48
1 2 3
RSR program number 0121
RSR program RSR 0121
Inputs the RSR2 signal. Checks whether RSR2 is enabled or disabled. Starts the RSR program having the selected RSR program number.
Starting a program by RSR is enabled in the remote state. Starting a program involving operation (group) by RSR is enabled when the operation enable conditions as well as the remote conditions are satisfied. The CMDENBL output is provided to indicate whether the above conditions are satisfied.
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Figure 3--31. Sequence of Automatic Operation by RSR CMDENBL ( O )
(The remote conditions are satisfied.)
RSR1 ( I ) Within 32 msec ACK1 ( O ) (The pulse width is set using a parameter.) (The program is started at the rising edge.) Within 35 msec PROGRUN ( O ) (When an RSR signal is being input or an ACK signal is being output, another RSR signal can also be accepted.) RSR2 ( I ) ACK2 ( O )
Set RSR for SETUP RSR/PNS on the RSR setting screen. Table 3--13.
RSR Setting Items
Item RSR or PNS
Description Select either the RSR or PNS automatic operation function. Both functions cannot be used simultaneously. After changing this setting, to enable the change, turn the power off, then on again.
RSR1 to 4 program number Specifies whether to enable or disable RSR1 to RSR8 and the RSR registration numbers. When an RSR signal is disabled and the specified signal is input, the program is not started. Setting whether to enable or disable each RSR is stored in system variable $RSR1 to $RSR8. Base number Added to the RSR registration number to obtain the RSR program number. Acknowledge function Sets whether to output RSR acknowledgment signals (ACK1 to ACK8). Acknowledge pulse width Sets the pulse output period (unit: msec) when the output of each RSR acknowledgment signal (ACK1 to ACK8) is enabled.
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Procedure 3--22 Step
Setting RSR
1 Press MENUS to display the screen menu. 2 Select SETUP. 3 Press F1 (TYPE) to display the screen switching menu. 4 Select “RSR/PNS.” The RSR/PNS setting screen appears. 5 Position the carsor to “Program select mode”. Press F4 [CHOICE] and select RSR, then press F3 DETAIL. RSR
5 I/O 6 SETUP 7 FILE
RSR/PNS
1 2 3 4 5 6 7 8 9 10 11
MENUS
RSR/PNS TYPE
F1
JOINT 30% 1/11 RSR [ RSR] RSR1 program number [ENABLE] [ 12] RSR2 program number [ENABLE] [ 21] RSR3 program number [ENABLE] [ 33] RSR4 program number [ENABLE] [ 49] RSR5 program number [ENABLE] [ 50] RSR6 program number [ENABLE] [ 60] RSR7 program number [ENABLE] [ 70] RSR8 program number [ENABLE] [ 80] Base number [ 100] Acknowledge function [TRUE] Acknowledge pulse width (msec) [ 200]
[TYPE]
6 Position the cursor to the target item and enter a value. 7 After changing PNS to RSR, to enable the change, turn the power off, then on again. WARNING After the type of automatic operation function is changed, the power to the control unit must be turned off, then on again to enable the change. If not, the setting is not accepted.
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3.14.2 Program number selection (PNS) The remote controller uses the program number selection (PNS) function to select or collate a program. Specify a desired PNS program number with the input signals, PNS1 to PNS8. Step
1 The control unit reads the PNS1 to PNS8 input signals as a binary number by the PNSTROBE pulse input. When a program is being executed or is temporarily stopped, these signals are ignored. When the PNSTROBE pulse input is on, the selection of a program from the teach pendant is disabled. NOTE In the initial status, the peripheral device input signal (UI) is disabled. To enable the signal, select TRUE for Enable UI signals on the system setting screen. 2 The data of signals PNS1 to PNS8 is converted into a decimal PNS number. The sum of the PNS number and the reference number is a PNS program number (four digits). (Program number)=(PNS number)+(Base number) The specified PNS+(Program number) program number is named as follows. When a zero is input by the PNS1 to PNS8 inputs, the system enters the status in which no program is selected on the teach pendant. NOTE Specify the name of a program for automatic operation in “PNS” + (program number) format. Enter a 4--digit number such as PNS0138, not PNS138. If not, the robot will not operate. The base number is set in $SHELL_CFG.$JOB_BASE and can be changed using Base number on the PNS setting screen or a program parameter instruction. 3 SNO1 to SNO8 are output to indicate a PNS number as a binary code as confirmation. An SNACK pulse is output simultaneously. If the PNS number cannot be represented as an 8--bit numeric value, SNO1 to SNO8 output a zero. 4 The remote control unit checks that the SNO1 to SNO8 output value is the same as the PNS1 to PNS8 input value when SNACK is output, and sends the automatic operation start input (PROD_START). 5 The control unit receives the PROD_START input and starts the program. Starting a program by PNS is enabled in the remote state. Starting a program involving an operation (group) is enabled when the operation enable conditions as well as the remote conditions are satisfied. The CMDENBL output is provided to indicate whether the above conditions are satisfied.
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Figure 3--32. Program Number Selection PNSTROBE
BASE number $SHELL_CFG.$JOB_BASE 100
PNS1 PNS2 On PNS3 On PNS4
00100110
PNS5
PNS program number
PNS number Binary
38 Decimal
0138
PNS program PNS 0138
PNS6 On PNS7 PNS8
SNACK PROD_START
1. 2. 3. 4.
The PNSTROBE signal is input. Signals PNS1 to PNS8 are read and the value is converted into a decimal number. The PNS program having the specified PNS program number is selected. When the PROD--START signal goes low, the selected PNS program is started.
Figure 3--33. Sequence of Automatic Operation by PNS CMDENBL ( O ) (The remote conditions are satisfied.) PNS 1 to 8 ( I ) At least 0 msec PNSTROBE ( I ) About 30 msec (After detecting the rising edge of PNSTROBE, the control unit reads the PNS value two or more times at intervals of about 15 msec to confirm that the signals are stable, then selects a program.) PNS read (internal processing)
Within 130 msec
SNO 1 to 8 ( O ) SNACK ( O ) (SNACK rises at almost the same time as SNOs rise, but after the SNOs rise. The pulse width is set using a parameter.) At least 0 msec PROD_START ( I ) At least 100 msec (The program is started at the falling edge. Keep this signal on for at least 100 msec, however. This signal cannot be used when it is always on.) Within 35 msec PROGRUN ( O )
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Setting the PNS function Set the PNS function on the PNS setting screen [6 (SETUP). RSR/PNS]. Table 3--14.
Setting the PNS function
ITEMS
DESCRIPTIONS
RSR or PNS
Select either the RSR or PNS automatic operation function. These functions cannot be used simultaneously. After changing this setting, to enable the change, turn the power off, then on again.
Base number
The reference number is added to the PNS number to obtain a PNS program number.
Acknowledge pulse width (msec)
Sets the pulse output period (unit: msec) of the PNS acknowledgment signal (SNACK).
Procedure 3--23 Step
Setting the PNS function
1 Press the MENUS key. The screen menu is displayed. 2 Select “6 (SETUP).” 3 Press the F1 key, TYPE. The screen change menu is displayed. 4 Select RSR/PNS. RSR/PNS Setting screen is displayed. 5 Position the cursor to “RSR or PNS” and press F4 (PNS). The PNS setting screen appears. PNS Setting Screen
5 I/O 6 SETUP 7 FILE
RSR/PNS
JOINT 30% 1/3
PNS 1 Base number [ 100] 2 Acknowledge pulse width (msec) [ 200]
MENUS
RSR/PNS [TYPE] [TYPE]
F1 PNS
RSR
F4 6 Place the cursor on a desired field and enter a value. 7 After changing RSR to PNS, to enable the change, turn the power off, then on again. WARNING After the type of automatic operation function is changed, the power to the control unit must be turned off, then on again to enable the change. If not, the setting is not accepted.
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3.15 Setting coordinate systems A coordinate system defines the position and attitude of the robot. The system is defined for the robot or in a work space. A joint coordinate system and a Cartesian coordinate system are used. Joint coordinate system The joint coordinate system is defined for robot joints. The position and attitude of the robot are defined by angular displacements with regard to the joint coordinate system of the joint base. Figure 3--34. Joint Coordinate System The coordinate system for each axis in the figure on the right is in the status in which all axes are 0 .
Cartesian coordinate system The position and attitude of the robot in the Cartesian coordinate system are defined by coordinates x, y, and z from the origin of the space Cartesian coordinate system to the origin (tool tip point) of the tool Cartesian coordinate system and angular displacements w, p, and r of the tool Cartesian coordinate system against the X--, Y--, and Z--axis rotations of the space Cartesian coordinate system. The meaning of (w, p, r) is shown below. Figure 3--35. Meaning of (w, p, r) Zu
Zu Zt Zt
w
Zu
p
W R
Yt Xu
w
Yt Xu
Yu
P
p
Xu
r Yu
r
Yu
Xt
Xt
Zu
Zt
Yt
Xu, Yu, Zu Xt, Yt, Zt
Coordinate system defined in the work space Coordinate system defined for the tool
Xu
Yu Xt
To operate the robot in a user--specified environment, use a corresponding Cartesian coordinate system. The following five coordinate systems are available:
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Mechanical interface coordinate system ( Coordinate system fixed to the tool ) A standard Cartesian coordinate system defined for the mechanical interface of the robot (the surface of wrist flange). The coordinate system is fixed at a position determined by the robot. On the basis of the coordinate system, a tool coordinate system is specified. Tool coordinate system A coordinate system that defines the position of the tool center point (TCP) and the attitude of the tool. The tool coordinate system must be specified. If the coordinate system is not defined, the mechanical interface coordinate system substitutes for it. World coordinate system ( Coordinate system fixed in the work space ) A standard Cartesian coordinate system fixed in a work space. The coordinate system is fixed at a position determined by the robot. On the basis of the coordinate system, a user coordinate system and a jog coordinate system are specified. The world coordinate system is used for specifying position data and executing the corresponding instruction. Refer to the Appendix B.6 “World Frame Origin” for the origin of the world frame. Figure 3--36. World and Tool Coordinate Systems
Z World coordinate sysyem
Z Y X Y
Tool coordinate system
X User coordinate system A Cartesian coordinate system defined by the user in each work space. It is used to specify a position register, execute the corresponding position register instruction and position compensation instruction, etc. If the coordinate system is not defined, the world coordinate system substitutes for it. WARNING If the tool or user coordinate system is changed after program teaching, the programmed points and ranges should be reset. Otherwise, the equipment could be damaged.
Jog coordinate system A coordinate system defined by the user. The jog coordinate system is used to efficiently move the robot by jog feed. You need consider the jog frame origin, since it is used only when the jog frame is selected as the manual--feed coordinate systems. If the coordinate system is not defined, the world coordinate system substitutes for it.
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3.15.1 Setting a tool coordinate system A tool coordinate system is a Cartesian coordinate system that defines the position of the tool center point (TCP) and the attitude of the tool. On the tool coordinate system, the zero point usually represents the TCP and the Z--axis usually represents the tool axis. When the tool coordinate system is not defined, the mechanical interface coordinate system substitutes for it. Tool coordinates include (x, y, z) indicating the position of the tool center point (TCP), and (w, p, r) indicating the attitude of the tool. Coordinates x, y, and z indicate the position of TCP on the mechanical interface coordinate system. Coordinates w, p, and r indicate the attitude of the tool and the angular displacement around the X--, Y--, and Z--axes of the mechanical interface coordinate system. The tool center point is used to specify the position data. The attitude of the tool is required to perform tool attitude control. Figure 3--37. Tool Coordinate System
X Z Y Mechanical interface coordinate system
Z
Tool coordinate system
Y X Tool center point
The tool coordinate system is defined by using the frame setup screen or changing the following system variables. Ten tool coordinate systems can be defined. The desired one can be selected. F
$MNUTOOL [ 1, i ] (Frame number i = 1 to 10) is set the value.
F
$MNUTOOLNUM [ 1 ] is set the used tool frame number.
The tool frame can be set by three following methods. Three Point Method (TCP auto set) [Optional function] Use the three point method to define the tool center point(TCP).The three approach points must be taught with the tool touching a common point from three different approach directions. As a result, the location of the TCP is automatically calculated. To set the TCP accurately, the three approach directions should differ as much as possible. In the three point method, only the tool center point (x,y,z) can be set. The setting value of the tool orientation (W, P, V) is the standard value(0,0,0). The tool orientation should be defined by the six point method or the direct list method after the location is set. Figure 3--38. TCP auto set by the three point method Reference point 2
Reference point 1
Reference point 3
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Six Point Method The tool center point can be set in the same method as the three point method. Then, set the tool attitude (w, p, r). Teach the robot so that w, p, and r indicate a given point in space, a point in the positive direction of the X--axis parallel to the tool coordinate system, and a point on the XZ plane. Also, teach the robot using Cartesian or tool jog so that the tilt of the tool does not change. Figure 3--39. Six point method
Positive direction of the Z--axis
Z Origin
Y
Positive direction of the X--axis
Coodinate system which is parallel to the tool coodinate system
X Direct list method The following values can be entered directly. One is the value (x,y,z) of the TCP position. The other is the rotating angle (w,p,r), which specifies the tool frame orientation, around the x--,y--,and z--axis of the mechanical interface frame. Figure 3--40. Meaning of (w, p, r) used in direct teaching method Xm, Xt
Xt
Xm
Xm Xt
p
r
W
Ym
w
w Yt
Xm, Ym, Zm Xt, Yt, Zt
Zm
R
Zt p
Zt Ym, Yt
P
Mechanical interface coordinate system Tool coordinate system
114
Ym Zm
r Yt
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Procedure 3--24 Step
TCP auto set (Three Point Method)
1 Press the MENUS key. The screen menu is displayed. 2 Select “6 (SETUP).” 3 Press the F1 key, TYPE. The screen change menu is displayed. 4 Select Frames. 5 Press F3, OTHER and then select Tool Frame. Tool frame list screen is displayed. Tool frame list screen
5 I/O 6 SETUP 7 FILE
SETUP Frames JOINT 30 % Tool Frame Setup/ Direct Entry 1/5 X Y Z Comment 1: 0.0 0.0 0.0 ************* 2: 0.0 0.0 0.0 ************* 3: 0.0 0.0 0.0 ************* 4: 0.0 0.0 0.0 ************* 5: 0.0 0.0 0.0 ************* Active TOOL $MNUTOOLNUM[1]=1 [ TYPE ] DETAIL [OTHER ] CLEAR SETIND
MENUS
Frames [TYPE]
F1
1 Tool Frame 2 Jog Frame 3 User Frame
[ TYPE ] DETAIL
OTHER
F3 6 Move the cursor to the line of the tool frame number you want to set. 7 Press F2,DETAIL.The tool frame setup screen of the selected frame number is displayed. [ TYPE ] DETAIL [OTHER ]
F2 8 Press F2,METHOD and then select Three Point. Tool frame setup screen (Three Point Method) 1 Three Point 2 Six Point 3 Direct Entry
[ TYPE ] METHOD FRAME
F2
SETUP Frames JOINT 30 % Tool Frame Setup/ Three Point 1/4 Frame Number: 1 X: 0.0 Y: 0.0 Z: 0.0 W: 0.0 P: 0.0 R: 0.0 Comment: TOOL 1 Approach point 1: UNINIT Approach point 2: UNINIT Approach point 3: UNINIT Active TOOL $MNUTOOLNUM[1]=1 [ TYPE ][METHOD] FRAME
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9 To add a comment: a Move the cursor to the comment line and press the ENTER key. JOINT 1
[
30 % ]
ENTER
b Select the method of naming the comment. c Press the appropriate function keys to add the comment. d When you are finished, press the ENTER key. 10 Record each approach point: a Move the cursor to each approach point. b Jog the robot to the position you want to record. c Press and hold the SHIFT key and press F5,RECORD to record the data of the current position as the reference position. As for the taught reference point, RECORDED is displayed. NOTE Move the tool in three different directions to bring the tool tip to an identical point. Then, record the three reference points.
Approach point 3: SETUP Frames FRAME
MOVE_TO RECORD
F5
SHIFT
JOINT
Approach point 1: Approach point 2: Approach point 3: [ TYPE ][METHOD] FRAME
30 %
RECORDED RECORDED UNINIT MOVE_TO RECORD
d When all the reference points are taught, USED is displayed. The tool frame has been set.
SETUP Frames JOINT 30 % Tool Frame Setup/ Three Point 4/4 Frame Number: 1 X: 100.0 Y: 0.0 Z: 120.0 W: 0.0 P: 0.0 R: 0.0 Comment: TOOL 1 Approach point 1: USED Approach point 2: USED Approach point 3: USED [ TYPE ][METHOD] FRAME
MOVE_TO RECORD
11 To move the robot to a recorded position, press and hold the SHIFT key and press F4,MOVE_TO. FRAME
SHIFT
MOVE_TO RECORD
F4 12 To see the data of each recorded position, move the cursor to each reference position item and press the ENTER key. The position detail screen of each position data is displayed. To return to the previous screen, press the PREV key.
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13 To display the tool frame list screen, press the PREV key. You can see the settings(x,y,z,and comment) for all tool frames. PREV
SETUP Frames JOINT 30 % Tool Frame Setup/ Direct Entry 1/5
1: 2: 3: 4: 5:
X 100.0 0.0 0.0 0.0 0.0
Y 0.0 0.0 0.0 0.0 0.0
Z 120.0 0.0 0.0 0.0 0.0
[ TYPE ] DETAIL [OTHER ]
Comment TOOL1 ************* ************* ************* ************* CLEAR
SETIND
14 To use the set tool frame as an effective tool frame now, press F5,SETIND. FRAME
MOVE_TO RECORD
F5 CAUTION To make the set frame effective, move the cursor to the desired frame and press F5,SETIND. NOTE To select the number of a coordinate system to be used, the jog menu can also be used. See Section 5.2.2 “Moving the robot jog feed.” CAUTION After all coordinate systems are set, the setting information should be saved in external storage (floppy disk, for example) in case the information needs to be re--loaded. Otherwise, the current setting information will be lost when it is changed.
15 To delete the data of the set frame, move the cursor to the desired frame and press F4,CLEAR.
[OTHER ]
CLEAR
SETIND
F4
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3. SETTING UP THE ARC SYSTEM
Procedure 3--25 Step
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Setting Up Tool Frame Using the Six Point Method
1 Display the tool frame list screen (Refer to the three point method).
SETUP Frames JOINT 30 % Tool Frame Setup/ Direct Entry 2/5 X Y Z Comment 1: 100.0 0.0 120.0 TOOL1 2: 0.0 0.0 0.0 ************* 3: 0.0 0.0 0.0 ************* 4: 0.0 0.0 0.0 ************* 5: 0.0 0.0 0.0 ************* Active TOOL $MNUTOOLNUM[1]=1 [ TYPE ] DETAIL [OTHER ] CLEAR SETIND
2 Move the cursor to the tool frame number line you want to set. 3 Press F2,DETAIL. The tool frame setup screen of the selected frame number is displayed. 4 Press F2,METHOD. 5 Select Six Point. The tool frame setup / six point screen is displayed. Tool frame setup screen (Six Point Method) [ TYPE ] DETAIL [OTHER ]
F2 1 Three Point 2 Six Point 3 Direct Entry
[ TYPE ] METHOD FRAME
SETUP Frames JOINT 30 % Tool Frame Setup/ Six Point 1/7 Frame Number: 2 X: 0.0 Y: 0.0 Z: 0.0 W: 0.0 P: 0.0 R: 0.0 Comment:******************** Approach point 1: UNINIT Approach point 2: UNINIT Approach point 3: UNINIT Orient Origin Point: UNINIT X Direction Point: UNINIT Z Direction Point: UNINIT Active TOOL $MNUTOOLNUM[1]=1 [ TYPE ][METHOD] FRAME
F2 6 Add a comment and teach the reference point. For details, refer to TCP auto set (Three Point Method). a Press and hold the SHIFT key and press F5,RECORD to record the data of the current position as the reference position. As for the taught reference point, RECORDED is displayed.
FRAME
SHIFT
MOVE_TO RECORD
F5
SETUP Frames JOINT 30 % Approach point 1: RECORDED Approach point 2: RECORDED Approach point 3: RECORDED Orient Origin Point: RECORDED X Direction Point: UNINIT Z Direction Point: UNINIT Active TOOL $MNUTOOLNUM[1]=1 [ TYPE ][METHOD] FRAME MOVE_TO RECORD
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b When all the reference points are taught, USED is displayed. The tool frame has been set.
SETUP Frames JOINT 30 % Tool Frame Setup/ Six Point 1/7 Frame Number: 2 X: 200.0 Y: 0.0 Z: 255.5 W: -90.0 P: 0.0 R: 180.0 Comment: TOOL2 Approach point 1: USED Approach point 2: USED Approach point 3: USED Orient Origin Point: USED X Direction Point: USED Z Direction Point: USED Active TOOL $MNUTOOLNUM[1]=1 [ TYPE ][METHOD] FRAME
7 Press the PREV key. The tool frame list screen is displayed. You can see all the tool frame settings. PREV
SETUP Frames JOINT 30 % Tool Frame Setup/ Direct Entry 2/5 X Y Z Comment 1: 100.0 30.0 120.0 TOOL1 2: 200.0 0.0 255.0 TOOL2 3: 0.0 0.0 0.0 ************* 4: 0.0 0.0 0.0 ************* 5: 0.0 0.0 0.0 ************* Active TOOL $MNUTOOLNUM[1]=1 [ TYPE ] DETAIL [OTHER ] CLEAR SETIND
8 To make the set tool frame effective, press F5 (SETIND), then enter the frame number. [OTHER ]
CLEAR
SETIND
F5 CAUTION To make the set frame effective, move the cursor to the desired frame and press F5,SETIND. NOTE To select the number of a coordinate system to be used, the jog menu can also be used. See Section 5.2.2 “Moving the robot jog feed.” CAUTION After all coordinate systems are set, the setting information should be saved in external storage (floppy disk, for example) in case the information needs to be re--loaded. Otherwise, the current setting information will be lost when it is changed.
To delete the data of the set frame, move the cursor to the desired frame and press F4,CLEAR. [OTHER ]
CLEAR
SETIND
F4
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Procedure 3--26 Step
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Setting Up Tool Frame Using the Direct List Method
1 Display the tool frame list screen (Refer to the three point method).
SETUP Frames JOINT 30 % Tool Frame Setup/ Direct Entry 3/5 X Y Z Comment 1: 100.0 30.0 120.0 TOOL1 2: 200.0 0.0 255.0 TOOL2 3: 0.0 0.0 0.0 ************* 4: 0.0 0.0 0.0 ************* 5: 0.0 0.0 0.0 ************* Active TOOL $MNUTOOLNUM[1]=1 [ TYPE ] DETAIL [OTHER ] CLEAR SETIND
2 Move the cursor to the tool frame number line you want to set. 3 Press F2,DETAIL or press the ENTER key. The tool frame setup screen of the selected frame number is displayed. 4 Press F2,METHOD. 5 Select Direct Entry. Tool Frame Setup / Direct Entry screen is displayed. Tool frame setup screen (Direct List Method) [ TYPE ] DETAIL [OTHER ]
F2 1 Three Point 2 Six Point 3 Direct Entry
[ TYPE ] METHOD FRAME
SETUP Frames JOINT 30 % User Frame Setup/ Direct Entry 1/7 Frame Number: 3 1 Comment: ******************** 2 X: 0.000 3 Y: 0.000 4 Z: 0.000 5 W: 0.000 6 P: 0.000 7 R: 0.000 Configuration: N D B, , 0 Active TOOL $MNUTOOLNUM[1]=1 [ TYPE ][METHOD] FRAME
F2 6 Add a comment. Refer to TCP auto set (Three Point Method) for details. JOINT 1
[
30 % ]
ENTER
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7 Enter the coordinate values of the tool frame. a Move the cursor to each component. b Enter a new numerical value by using the numerical keys. c Press the ENTER key. A new numerical value is set.
JOINT
30 %
0.0
3
5
0
SETUP Frames JOINT 30 % User Frame Setup/ Direct Entry 4/7 Frame Number: 3 1 Comment: TOOL3 2 X: 0.000 3 Y: 0.000 4 Z: 350.000 5 W: 180.000 6 P: 0.000 7 R: 0.000 8 Configuration: N D B, , 0 Active TOOL $MNUTOOLNUM[1]=1 [ TYPE ][METHOD] FRAME
8 To display the tool frame list screen, press the PREV key. You can see the settings of all the tool frame. PREV
SETUP Frames JOINT 30 % Tool Frame Setup/ Direct Entry 3/5 X Y Z Comment 1: 100.0 30.0 120.0 TOOL1 2: 200.0 0.0 255.0 TOOL2 3: 0.0 0.0 350.0 TOOL3 4: 0.0 0.0 0.0 ************* 5: 0.0 0.0 0.0 ************* Active TOOL $MNUTOOLNUM[1]=1 [ TYPE ] DETAIL [OTHER ] CLEAR SETIND
9 To make the set tool frame effective, press F5 (SETIND), then enter the frame number. [OTHER ]
CLEAR
SETIND
F5 CAUTION To make the set frame effective, move the cursor to the desired frame and press F5,SETIND. NOTE To select the number of a coordinate system to be used, the jog menu can also be used. See Section 5.2.3 “Moving the robot jog feed.” CAUTION After all coordinate systems are set, the setting information should be saved in external storage (floppy disk, for example) in case the information needs to be re--loaded. Otherwise, the current setting information will be lost when it is changed.
To delete the data of the set frame, move the cursor to the desired frame and press F4,CLEAR. [OTHER ]
CLEAR
SETIND
F4
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3.15.2 Setting a user coordinate system A user coordinate system is a Cartesian coordinate system defined for each work space by the user. If the coordinate system is not defined, the world coordinate system substitutes for it. Define the user coordinate system by (x, y, z) indicating the position of the zero point and (w, p, r) indicating the angular displacement around the X--, Y--, and Z--axes on the world coordinate system. The user coordinate system is used to specify a position register and execute the corresponding position register instruction and position compensation instruction. For the specification of the position register, see Section 7.4, “Position Register.” For the execution of the position register instruction, see Section 4.3.2, “Position Data.” For the execution of the position compensation instruction, see Section 4.3.6, “Additional Motion Instruction.” CAUTION If teaching is made by joint coordinates, changing the user coordinate system does not affect the position variables and position registers. When the robot is taught in the Cartesian format and the user coordinate system input option is not used, the position variables are not affected by the user coordinate systems. Note that both position variables and registers are affected by the user coordinate systems in other cases.
Figure 3--41. World and User Coordinate Systems
Z --
+
World coodinate system
--
Y +
Z
-Y
+
Z
X
User coordinate system 1
Y User coordinate system 2
X
X
The following system variables are changed by defining the user frame with the frame setup screen. Nine user coordinate systems can be defined. The desired one can be selected F
$MNUFRAME [ 1, i ] (Frame number i = 1 to 9 ) is set the value.
F
$MNUFRAMENUM [ 1 ] is set the user frame number you want to use.
The user frame can be defined by the following three methods.
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Three Point Method Teach the following three points: the origin of the x--axis, the point which specifies the positive direction of the x--axis, and the point on the x--y plane. The origin of the x--axis is used as the origin of the frame. Figure 3--42. Three Point Method
Z
Origin Positive direction of the Y axis
Y X Positive direction of the X axis
Four Point Method Teach the following four points:the origin of the x--axis parallel to the frame,the point which specifies the positive direction of the x--axis, a point on the x--y plane, and the origin of the frame. Figure 3--43. Four Point Method
Z
Y Origin Origin of the X axis
X Positive direction of the Y axis Positive direction of the X axis
Direct List Method Enter the following values directly: the value (x,y,z) which specifies the origin of the user frame and is the coordinate values of the world frame and the rotating angle (w,p,r) around the x--,y--,and z--axis of the world frame. Figure 3--44. Meaning of (w,p,r) used in direct list method Zw
Zw Zu
Zu
w
Zw, Zu
p
W R
Yu w Xw, Xu
Xw Yw
p Xu
Xw, Yw, Zw World coordinate system Xu, Yu, Zu User coordinate system
123
P
Xw Yw, Yu
r Xu
r Yu Yw
3. SETTING UP THE ARC SYSTEM
Procedure 3--27 Step
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Setting Up the User Frame Using the Three Point Method
1 Press the MENUS key. The screen menu is displayed. 2 Select “6 (SETUP).” 3 Press the F1 key, TYPE. The screen change menu is displayed. 4 Select Frames. 5 Press F3, OTHER and then select User Frame. The user frame list screen is displayed. User frame list screen
5 I/O 6 SETUP 7 FILE
SETUP Frames
JOINT
User Frame Setup/ Direct Entry MENUS
30 % 1/5
X Y Z Comment 1: 0.0 0.0 0.0 ************* 2: 0.0 0.0 0.0 ************* 3: 0.0 0.0 0.0 ************* 4: 0.0 0.0 0.0 ************* 5: 0.0 0.0 0.0 ************* Active UFRAME $MNUFRAMNUM[1]=0 [ TYPE ] DETAIL [OTHER ] CLEAR SETIND
Frames [TYPE]
F1
1 Tool Frame 2 Jog Frame 3 User Frame
[ TYPE ] DETAIL
OTHER
F3 6 Move the cursor to the line of the user frame number you want to set. 7 Press F2,DETAIL. The user frame setup screen of the selected frame number is displayed. [ TYPE ] DETAIL [OTHER ]
F2 8 Press F2,METHOD and then select Three Point. User frame setup screen (Three Point Method) 1 Three Point 2 Four Point 3 Direct Entry
[ TYPE ] METHOD FRAME
F2
SETUP Frames JOINT 30 % User Frame Setup/ Three Point 1/4 Frame Number: 1 X: 0.0 Y: 0.0 Z: 0.0 W: 0.0 P: 0.0 R: 0.0 Comment:******************** Orient Origin Point: UNINIT X Direction Point: UNINIT Y Direction Point: UNINIT Active UFRAME $MNUFRAMNUM[1]=0 [ TYPE ][METHOD] FRAME
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9 To add a comment: a Move the cursor to the comment line and press the ENTER key. JOINT [
30 %
]
ENTER
b Select the method of naming the comment. c Press the appropriate function keys to add the comment. d When you are finished, press ENTER key.
SETUP Frames Comment:
JOINT
30 %
REFERENCE FRAME
[ TYPE ][METHOD] FRAME
10 Record each approach point: a Move the cursor to each approach point. b Jog the robot to the position you want to record. c Press and hold the SHIFT key and press F5, RECORD to record the current position as the approach point. As for the taught reference point, RECORDED is displayed. X Direction Point: FRAME
MOVE_TO RECORD
SETUP Frames JOINT 30 % Orient Origin Point: RECORDED X Direction Point: RECORDED Y Direction Point: UNINIT Active UFRAME $MNUFRAMNUM[1]=0 [ TYPE ][METHOD] FRAME MOVE_TO RECORD
F5
SHIFT
d When all the reference points are taught, USED is displayed. The user frame has been set.
SETUP Frames JOINT 30 % User Frame Setup/ Three Point 4/4 Frame Number: 1 X: 1243.6 Y: 0.0 Z: 10.0 W: 0.1 P: 2.3 R: 3.2 Comment: REFERENCE FRAME Orient Origin Point: USED X Direction Point: USED Y Direction Point: USED Active UFRAME $MNUFRAMNUM[1]=0 [ TYPE ][METHOD] FRAME MOVE_TO RECORD
11 To move to a recorded position, press and hold the SHIFT key and press F4,MOVE_TO. FRAME
SHIFT
MOVE_TO RECORD
F4 12 To see the data of each recorded position, move the cursor to each reference position item and press the ENTER key. The position detail screen of each position data is displayed. To return to the previous screen, press the PREV key.
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13 To display the user frame list screen, press the PREV key. You can see the settings for all user frames. PREV
SETUP Frames JOINT 30 % User Frame Setup/ Three Point 1/5 X Y Z Comment 1: 1243.6 0.0 43.8 REFERENCE FR> 2: 0.0 0.0 0.0 ************* 3: 0.0 0.0 0.0 ************* 4: 0.0 0.0 0.0 ************* 5: 0.0 0.0 0.0 ************* Active UFRAME $MNUFRAMNUM[1]=0 [ TYPE ] DETAIL [OTHER ] CLEAR SETIND
14 To make the set user frame effective, press F5 (SETIND), then enter the frame number. [OTHER ]
CLEAR
SETIND
F5 CAUTION To make the set frame effective, move the cursor to the desired frame and press F5,SETIND. NOTE To select the number of a coordinate system to be used, the jog menu can also be used. See Section 5.2.3 “Moving the robot jog feed.” CAUTION After all coordinate systems are set, the setting information should be saved in external storage (floppy disk, for example) in case the information needs to be re--loaded. Otherwise, the current setting information will be lost when it is changed.
15 To delete the data of the set frame, move the cursor to the desired frame and press F4,CLEAR. [OTHER ]
CLEAR
SETIND
F4
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Procedure 3--28 Step
Setting the User Frame Using the Four Point Method
1 Display the user frame list screen (Refer to the three point method)
SETUP Frames JOINT 30 % User Frame Setup/ Three Point 2/5 X Y Z Comment 1: 1243.6 0.0 43.8 REFERENCE FR> 2: 0.0 0.0 0.0 ************* 3: 0.0 0.0 0.0 ************* 4: 0.0 0.0 0.0 ************* 5: 0.0 0.0 0.0 ************* Active UFRAME $MNUFRAMNUM[1]=0 [ TYPE ] DETAIL [OTHER ] CLEAR SETIND
2 Move the cursor to the user frame number line you want to set. 3 Press F2,DETAIL. The user frame setup screen of the selected frame number is displayed. [ TYPE ] DETAIL [OTHER ]
F2 4 Press F2,METHOD 5 Select Four Point. The user frame setup / four point screen is displayed. User frame setup screen (Four Point Method) 1 Three Point 2 Four Point 3 Direct Entry
[ TYPE ] METHOD FRAME
F2
SETUP Frames JOINT 30% User Frame Setup/ Four Point 1/5 Frame Number: 2 X: 0.0 Y: 0.0 Z: 0.0 W: 0.0 P: 0.0 R: 0.0 Comment:******************** Orient Origin Point: UNINIT X Direction Point: UNINIT Y Direction Point: UNINIT System Origin: UNINIT Active UFRAME $MNUFRAMNUM[1]=0 [ TYPE ][METHOD] FRAME
6 Add a comment and teach the reference point. For details, refer to TCP auto set ( Three Point Method ).
SETUP Frames JOINT 30% User Frame Setup/ Four Point 5/5 Frame Number: 2 X: 1243.6 Y: 525.2 Z: 43.9 W: 0.123 P: 2.34 R: 3.2 Comment: RIGHT FRME Orient Origin Point: USED X Direction Point: USED Y Direction Point: USED System Origin: USED Active UFRAME $MNUFRAMNUM[1]=0 [ TYPE ][METHOD] FRAME MOVE_TO RECORD
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7 Press the PREV key. The user frame list screen is displayed. You can see all the user frame settings. PREV
SETUP Frames JOINT 30 % User Frame Setup/ Four Point 2/5 X Y Z Comment 1: 1243.6 0.0 43.8 REFERENCE FR> 2: 1243.6 525.2 43.8 RIGHT FRAME 3: 0.0 0.0 0.0 ************* 4: 0.0 0.0 0.0 ************* 5: 0.0 0.0 0.0 ************* Active UFRAME $MNUFRAMNUM[1]=0 [ TYPE ] DETAIL [OTHER ] CLEAR SETIND
8 To make the set user frame effective, press F5 (SETIND), then enter the frame number. [OTHER ]
CLEAR
SETIND
F5 CAUTION To make the set frame effective, move the cursor to the desired frame and press F5,SETIND. NOTE To select the number of a coordinate system to be used, the jog menu can also be used. See Section 5.2.3 “Moving the robot jog feed.” CAUTION After all coordinate systems are set, the setting information should be saved in external storage (floppy disk, for example) in case the information needs to be re--loaded. Otherwise, the current setting information will be lost when it is changed.
9 To delete the data of the set frame, move the cursor to the desired frame and press F4,CLEAR. [OTHER ]
CLEAR
SETIND
F4
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3. SETTING UP THE ARC SYSTEM
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Procedure 3--29 Step
Setting the User Frame Using the Direct Entry Method
1 Display the user frame list screen (Refer to the three point method).
SETUP Frames JOINT 30 % User Frame Setup/ Four Point 3/5 X Y Z Comment 1: 1243.6 0.0 43.8 REFERENCE FR> 2: 1243.6 525.2 43.8 RIGHT FRAME 3: 0.0 0.0 0.0 ************* 4: 0.0 0.0 0.0 ************* 5: 0.0 0.0 0.0 ************* Active UFRAME $MNUFRAMNUM[1]=0 [ TYPE ] DETAIL [OTHER ] CLEAR SETIND
2 Move the cursor to the user frame number line you want to set. 3 Press F2,DETAIL or press the ENTER key. The user frame setup screen of the selected frame number is displayed. 4 Press F2,METHOD. 5 Select Direct Entry. The user frame setup / direct list is displayed. User frame setup screen (Direct Entry Method) [ TYPE ] DETAIL [OTHER ]
F2 1 Three Point 2 Four Point 3 Direct Entry
[ TYPE ] METHOD FRAME
SETUP Frames JOINT 30 % User Frame Setup/ Direct Entry 1/7 Frame Number: 3 1 Comment: ******************** 2 X: 0.000 3 Y: 0.000 4 Z: 0.000 5 W: 0.000 6 P: 0.000 7 R: 0.000 Configuration: N D B, , 0 Active UFRAME $MNUFRAMNUM[1]=0 [ TYPE ][METHOD] FRAME MOVE_TO RECORD
F2 6 Add a comment and enter the coordinate values. For details, refer to tool frame (Direct Entry Method).
SETUP Frames JOINT 30 % User Frame Setup/ Direct Entry 4/7 Frame Number: 3 1 Comment: LEFT FRAME 2 X: 1243.6 3 Y: -525.2 4 Z: 43.9 5 W: 0.123 6 P: 2.34 7 R: 3.2 Configuration: N D B, , 0 Active UFRAME $MNUFRAMNUM[1]=0 [ TYPE ][METHOD] FRAME MOVE_TO RECORD
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3. SETTING UP THE ARC SYSTEM
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7 To display the user frame list screen, press the PREV key. You can see the settings of all the user frame. PREV
SETUP Frames JOINT 30 % User Frame Setup/ Three Point 3/5 X Y Z Comment 1: 1243.6 0.0 43.8 REFERENCE FR> 2: 1243.6 525.2 43.8 RIGHT FRAME 3: 1243.6 -525.2 43.8 LEFT FRAME 4: 0.0 0.0 0.0 ************* 5: 0.0 0.0 0.0 ************* Active UFRAME $MNUFRAMNUM[1]=0 [ TYPE ] DETAIL [OTHER ] CLEAR SETIND
8 To make the set user frame as effective, press F5,SETIND. [OTHER ]
CLEAR
SETIND
F5 CAUTION To make the set frame effective, move the cursor to the desired frame and press F5,SETIND. NOTE To select the number of a coordinate system to be used, the jog menu can also be used. See Section 5.2.3 “Moving the robot jog feed.” CAUTION After all coordinate systems are set, the setting information should be saved in external storage (floppy disk, for example) in case the information needs to be re--loaded. Otherwise, the current setting information will be lost when it is changed.
9 To delete the data of the set frame, move the cursor to the desired frame and press F4,CLEAR. [OTHER ]
CLEAR
SETIND
F4
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3.15.3 Setting a jog coordinate system A jog coordinate system is a Cartesian coordinate system defined in a work space by the user. It is used to efficiently move the robot by Cartesian jog in the work space. (See Section 5.2.3.) The jog coordinate system is defined by (x, y, z) indicating the position of the zero point, and (w, p, r) indicating the angular displacement around the X--, Y--, and Z--axes on the world coordinate system. NOTE You need not consider the jog frame origin, since it is used only when the jog frame is selected as the manual--feed coordinate systems. The zero point of the jog coordinate system has no special meaning. Select any convenient position for defining the jog coordinate system. Moreover, it is not affected by changes of the user frame or the execution of the program. Figure 3--45. Jog Coordinate System
Z Y X
The following system variables are changed by setting the jog frame with the frame setup screen. F
$JOG_GROUP [ 1 ] . $JOGFRAME is set the jog frame you want to used.
Five jog frames can be set and they can be switched according to the situation. When they are undefined, the world frame substitutes for them. Jog frame can be set by two methods. Three Point Method Three reference points need be taught. They are the start point of the x--axis,the positive direction of the x--axis,and one point on the x--y plane. The start point of the x--axis is used as the origin of the frame. Refer to Figure 3--42. Direct List Method The origin position x,y and z of the jog frame in the world frame and the rotating angle w,p, and r around the x--,y--, and z--axis of the world frame can be input directly. Refer to Figure 3--44.
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3. SETTING UP THE ARC SYSTEM
Procedure 3--30 Step
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Setting Up the Jog Frame Using the Three Point Method
1 Press the MENUS key. The screen menu is displayed. 2 Select 6 (SETUP). 3 Press the F1 key, TYPE. The screen change menu is displayed. 4 Select Frames. 5 Press F3, OTHER 6 Select Jog Frame. Jog frame entry screen is displayed. Jog frame list screen
5 I/O 6 SETUP 7 FILE
SETUP Frames JOINT 30 % Jog Frame Setup / Three Point 1/5 X Y Z Comment 1: 0.0 0.0 0.0 ************* 2: 0.0 0.0 0.0 ************* 3: 0.0 0.0 0.0 ************* 4: 0.0 0.0 0.0 ************* 5: 0.0 0.0 0.0 *************
MENUS
Frames
[ TYPE ] DETAIL [OTHER ]
CLEAR
JGFRM
TYPE 1 Tool Frame 2 Jog Frame 3 User Frame
F1 [ TYPE ] DETAIL
OTHER
F3 7 Move the cursor to the line of the jog frame number you want to set. 8 Press F2,DETAIL. The jog frame setup screen of the selected frame number is displayed. [ TYPE ] DETAIL [OTHER ]
F2 9 Press F2,METHOD. 10 Select Three Point. Jog frame setup screen ( Three Point Method) 1 Three Point 2 Direct Entry
[ TYPE ] METHOD FRAME
F2
SETUP Frames JOINT 30 % Jog Frame Setup / Three Point 1/4 Frame Number: 1 X: 0.0 Y: 0.0 Z: 0.0 W: 0.0 P: 0.0 R: 0.0 Comment:******************** Orient Origin Point: UNINIT X Direction Point: UNINIT Y Direction Point: UNINIT [ TYPE ][METHOD] FRAME
132
3. SETTING UP THE ARC SYSTEM
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11 Add a comment and teach the reference point. For details, refer to TCP auto set (Three Point Method). SETUP Frames JOINT 30 % Jog Frame Setup / Three Point 4/4 Frame Number: 1 X: 1243.6 Y: 0.0 Z: 10.0 W: 0.1 P: 2.3 R: 3.2 Comment: WORK AREA 1 Orient Origin Point: RECORDED X Direction Point: RECORDED Y Direction Point: UNINIT [ TYPE ][METHOD] FRAME
MOVE_TO RECORD
12 Press the PREV key. The jog frame list screen is displayed. You can see all the jog frame settings. 13 To display the user frame list screen, press the PREV key. You can see the settings for all user frames. PREV
SETUP Frames JOINT 30 % Jog Frame Setup / Three Point 1/5 X Y Z Comment 1: 1243.6 525.2 60.0 WORK AREA 1 2: 0.0 0.0 0.0 ************* 3: 0.0 0.0 0.0 ************* 4: 0.0 0.0 0.0 ************* 5: 0.0 0.0 0.0 ************* [ TYPE ] DETAIL [OTHER ]
CLEAR
JGFRM
14 To make the set jog frame effective, press F5 (JGFRM), then enter the frame number. [OTHER ]
CLEAR
JGFRM
F5 CAUTION To make the set frame effective, move the cursor to the desired frame and press F5,JGFRM. NOTE To select the number of a coordinate system to be used, the jog menu can also be used. See Section 5.2.3 “Moving the robot jog feed.” CAUTION After all coordinate systems are set, the setting information should be saved in external storage (floppy disk, for example) in case the information needs to be re--loaded. Otherwise, the current setting information will be lost when it is changed.
15 To delete the data of the set frame, move the cursor to the desired frame and press F4,CLEAR. [OTHER ]
CLEAR
JGFRM
F4
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3. SETTING UP THE ARC SYSTEM
Procedure 3--31 Step
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Setting Up Jog Frame Using the Direct List Method
1 Display the jog frame list screen (Refer to the three point method).
SETUP Frames JOINT 30 % Jog Frame Setup / Three Point 2/5 X Y Z Comment 1: 1243.6 525.2 60.0 WORK AREA 1 2: 0.0 0.0 0.0 ************* 3: 0.0 0.0 0.0 ************* 4: 0.0 0.0 0.0 ************* 5: 0.0 0.0 0.0 ************* [ TYPE ] DETAIL [OTHER ]
CLEAR
JGFRM
2 Move the cursor to the jog frame number line you want to set. 3 Press F2,DETAIL or press the ENTER key. The jog frame setup screen of the selected frame number is displayed. 4 Press F2,METHOD. 5 Select Direct Entry. Jog Frame Setup Screen (Direct Entry Method) [ TYPE ] DETAIL [OTHER ]
F2
1 Three Point 2 Direct Entry
[ TYPE ] METHOD FRAME
SETUP Frames JOINT 30 % Jog Frame Setup / Direct Entry 1/7 Frame Number: 2 1 Comment: ******************** 2 X: 0.000 3 Y: 0.000 4 Z: 0.000 5 W: 0.000 6 P: 0.000 7 R: 0.000 Configuration: N D B, , 0 [ TYPE ][METHOD] FRAME
MOVE_TO
RECORD
F2 6 Add a comment and teach the reference point. For details, refer to TCP auto set (Three Point Method). SETUP Frames JOINT 30 % Jog Frame Setup / Direct Entry 4/7 Frame Number: 2 1 Comment: WORK AREA 2 2 X: 1003.000 3 Y: -236.000 4 Z: 90.000 5 W: 0.000 6 P: 0.000 7 R: 0.000 Configuration: N D B, , 0 [ TYPE ][METHOD] FRAME
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MOVE_TO
RECORD
3. SETTING UP THE ARC SYSTEM
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7 Press the PREV key. The jog frame list screen is displayed. You can see all the jog frame settings. PREV
SETUP Frames JOINT 30 % Jog Frame Setup / Three Point 2/5 X Y Z Comment 1: 1243.6 525.2 60.0 WORK AREA 1 2: 1003.0-236.0 90.0 WORK AREA 2 3: 0.0 0.0 0.0 ************* 4: 0.0 0.0 0.0 ************* 5: 0.0 0.0 0.0 ************* [ TYPE ] DETAIL [OTHER ]
CLEAR
JGFRM
8 To make the set jog frame effective, press F5 (JGFRM), then enter the frame number. [OTHER ]
CLEAR
JGFRM
F5 CAUTION If you don’t press F5,JGFRM, the set frame will not be effective. NOTE To select the number of a coordinate system to be used, the jog menu can also be used. See Section 5.2.3 “Moving the robot jog feed.” CAUTION After all coordinate systems are set, the setting information should be saved in external storage (floppy disk, for example) in case the information needs to be re--loaded. Otherwise, the current setting information will be lost when it is changed.
9 To delete the data of the set frame, move the cursor to the desired frame and press F4,CLEAR. [OTHER ]
CLEAR
JGFRM
F4
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3. SETTING UP THE ARC SYSTEM
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3.16 Setting a Reference Position A reference position is a fixed (predetermined) position that is frequently used in a program or when the robot is moved by jog feed. The reference position is a safe position, which is usually distant from the operating area of the machine tool or peripheral equipment. Three reference positions can be specified. Figure 3--46. Reference Position
When the robot is at the reference position, a predetermined digital signal, SDO, is output. If the reference position is invalidated, the DO signal is not output. When the robot is at reference position 1, the reference position output signal (ATPERCH) of the peripheral device I/O is output. For this function, the reference position settings can be disabled so that the signal is not output. To make the robot move to the reference position, create a program which specifies the return path and execute this program. At this time, also specify the order in which axes return to the reference position in the program. It is convenient to set the return program as a macro instruction.(See Section 9.1, “Macro instruction”) Specify the reference position on the reference position setting screen [6 (SETUP). Ref Position].
Procedure 3--32 Step
Setting a reference position
1 Press the MENUS key. 2 Select SETUP. 3 Press the F1 key, TYPE. 4 Select “Ref Position.” The reference position selection screen is displayed. Reference Position Selection Screen
5 I/O 6 SETUP 7 FILE MENUS
REF Position
REF POSN NO 1 2 3
[TYPE]
End/Dsbl DISABLE DISABLE DISABLE
JOINT 30% 1/3 @Pos FALSE FALSE FALSE
DETAIL
TYPE
F1
136
Comment [ [ [
] ] ]
ENABLE
DISABLE
3. SETTING UP THE ARC SYSTEM
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5 Press the F3 key, DETAIL. The detailed reference position screen is displayed. Detailed Reference Position Screen DETAIL
ENABLE DISABLE
F3
REF POSN Reference Position Ref.Position Number: 1 Comment: 2 Enable/Disable: 3 Sinal definition: 4 J1 0.0 5 J2 0.0 6 J3 0.0 7 J4 0.0 8 J5 0.0 9 J6 0.0 [TYPE]
JOINT 30% 1/12 1 [**********] DISABLE DO[ 0] +/0.0 +/0.0 +/0.0 +/0.0 +/0.0 +/0.0 RECORD
6 To enter a comment, follow these steps: a Place the cursor on the comment line and press the ENTER key. b Determine whether the comment is entered by words, alphabetic characters, or katakana. c Press the corresponding function key and enter the desired comment. d After entering the comment, press the ENTER key.
JOINT 30% [
] ENTER
REF POSN Reference Position 1 Comment:
JOINT 30% 1/12 [Refpos1***]
[TYPE]
7 In the “Signal definition” line, specify the digital output signal to be output when the tool is at the reference position. JOINT 30% 3/12
REF POSN 3
DO[ 0] DO
RO
JOINT 30%
Signal definition: RO[ 0]
[TYPE]
DO
RO
F5 JOINT 30% 3/12 RO[ 0]
REF POSN 3
1
ENTER
JOINT 30%
Signal definition:
RO[ 1]
[TYPE]
RECORD
8 To teach the reference position, place the cursor on the setting fields J1 to J9. While pressing the SHIFT key, press the F5 key, RECORD. The current position is recorded as the reference position. RECORD REF POSN
SHIFT
F5
4
J1
JOINT 30% 0.0
+/-
[TYPE]
0.0 RECORD
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3. SETTING UP THE ARC SYSTEM
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9 To enter the numeric value of the reference position directly, place the cursor on the setting fields J1 to J9 and enter the coordinates of the reference position. Enter the coordinates in the left column and allowable errors in the right column. Any value entered in the setting field which specifies a nonexistent axis is ignored. * Avoid setting an allowable error to 0. Specify 0.1 or a greater value. The allowable error of an additional axis is related to gear ratio and other factors. After setting a provisional allowable error, carry out operations at various speeds (low, medium, and high). Then, specify such an allowable error that the reference position signal is always output. REF POSN Reference Position Ref.Position Number: 1 Comment: 2 Enable/Disable: 3 Sinal definition: 4 J1 129.000 5 J2 -31.560 6 J3 3.320 7 J4 179.240 8 J5 1.620 9 J6 33.000 [ TYPE ]
JOINT 30% 1/12 1 [Refpos1 ENABLE RO[ 1] +/+/+/+/+/+/-
]
2.000 2.000 2.000 2.000 2.000 2.000 RECORD
10 After the reference position is specified, press the PREV key. The reference position selection screen is displayed again. PREV
REF POSN NO 1 2 3
Enb/Dsbl DISABLE DISABLE DISABLE
[TYPE]
JOINT 30% 1/3 @Pos FALSE FALSE FALSE
DETAIL
Comment [Refpos1 [ [
ENABLE
] ] ]
DISABLE
11 To enable or disable the reference position output signal, place the cursor on the ENABLE/DISABLE field and press the corresponding function key. REF POSN NO 1
REF POSN
Enb/Dsbl DISABLE
ENABLE
@Pos FALSE
DISABLE
NO 1 [TYPE]
Enb/Dsbl ENABLE
JOINT 30% 1/3 @Pos FALSE DETAIL
F4
138
Comment [Refpos1 ENABLE
] DISABLE
3. SETTING UP THE ARC SYSTEM
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3.17 Joint Operating Area The software restricts the operating area of the robot according to a specified joint operating area. The standard operating area of the robot can be changed by specifying the joint operating area. Specify the joint operating area at [6 SYSTEM Axis Limits] on the joint operating area setting screen. WARNING The robot operating area should not be controlled only by the joint moving range function. Limit switches and mechanical stoppers should be used together with the function. Otherwise, injury or property damage could occur.
WARNING The mechanical stoppers should be adjusted to the software settings. Otherwise, injury or property damage could occur.
CAUTION Changing the joint moving range will affect the robot operating area. Before the joint moving range is changed, the expected effect of the change should be carefully studied in order to prevent possible trouble. Otherwise, the change could produce unpredictable results. For example, an alarm might occur at a position programmed earlier.
UPPER Specifies the upper limit of the joint operating area, which is the limit of the motion in the positive direction. LOWER Specifies the lower limit of the joint operating area, which is the limit of the motion in the negative direction. Enabling the new setting After a new joint operating area is specified, turn the controller off and on again to enable the new setting.
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Procedure 3--33 Step
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Setting the joint operating area
1 Press the MENUS key. The screen menu is displayed. 2 Select 6 (SYSTEM). 3 Press F1 (TYPE). The screen change menu is displayed. 4 Select Axis Limits. The joint operating area setting screen is displayed. Joint operating area setting screen
5 POSITION 6 SYSTEM 7
SYSTEM Axis Limits AXIS GROUP LOWER 1 2 3 4 5 6 7 8 9
MENUS
Axis Limits TYPE
1 1 1 1 1 0 0 0 0
-160.00 -30.00 -156.50 -120.00 -200.00 0.00 0.00 0.00 0.00
JOINT 30 % UPPER 1/16 160.00 150.00 206.10 120.00 200.00 0.00 0.00 0.00 0.00
dg dg dg dg dg mm mm mm mm
[ TYPE ]
F1
WARNING The robot operating area should not be controlled only by the joint moving range function. Limit switches and mechanical stoppers should be used together with the function. Otherwise, injury or property damage could occur.
NOTE Value 0.000 means that the robot does not have the corresponding axis. 5 Place the cursor on the target axis limits field, and enter a new value from the teach pendant. SYSTEM Axis Limits AXIS GROUP LOWER 2 1 -30.00
SYSTEM Axis Limits AXIS GROUP LOWER 2 1 -50.00
JOINT 30 % UPPER 2/16 100.00 dg
[ TYPE ]
--
5
0
ENTER
6 Repeat the above step for all the axes. 7 To make the set information effective, turn the controller off and on again in cold start mode (See Section 5.2.1). WARNING Power should be turned on again to make a new setting valid. Otherwise, injury or property damage could occur.
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3.18 User Alarm The user alarm setup screen allows you to set the message that is displayed when the user alarm is generated. The user alarm is the alarm which is generated when the user alarm instruction is executed. (See Section 4.14.2 “User alarm instruction”) Settings for user alarm are done in the user alarm setup screen [6 SETUP.User Alarm]. Procedure 3--34 Step
Setting Up the User Alarm
1 Select the MENUS key. The screen menu is displayed. 2 Select 6(SETUP). 3 Press the F1 key, TYPE. The screen change menu is displayed. 4 Select User Alarm. The user alarm setup screen is displayed. User Alarm Setup Screen
5 I/O 6 SETUP 7 FILE
Setting/User Alarm Alarm No. [1]: [2]: [3]: [4]: [5]: [6]: [7]: [8]: [9]: [ TYPE ]
MENUS
User Alarm TYPE
[ [ [ [ [ [ [ [ [
JOINT 30 % 1/200 User Message ] ] ] ] ] ] ] ] ]
F1 5 Move the cursor to the line of the user alarm number you want to set and press the ENTER KEY. Enter the message with the function keys. [2]: [3]: [4]:
[ [ [ ENTER
Setting/User Alarm JOINT 30 1 Upper Case 2 Lower Case 3 Punctuation 4 Options Setting/User Alarm Alarm No. User Message [1]: [ [2]: [ [3]: [WORK Old Value: ABCDEF GHIJKL MNOPQR STUVWX YZ_@*
%
] ] ]
6 When you are finished defining the message of the user alarm, press the ENTER key. The user alarm message has been set. Setting/User Alarm
JOINT 30 % 3/200 Alarm No. User Message [1]: [ ] [2]: [ ] [3]: [NO WORK ] [4]: [ ] [5]: [ ] [6]: [ ] [7]: [ ] [8]: [ ] [9]: [ ] [ TYPE ]
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3.19 Variable Axis Areas On the variable axis area setting screen, multiple (up to three) sets of stroke limits can be set for the J1 axis and an additional axis. The variable axis area function allows the user to switch from one set of stroke limits to another during program execution. * This function is offered by the FANUC Robot S--430i series only. Upper limit Indicates the upper limit for a joint operating area. Operating area in the plus direction. Lower limit Indicates the lower limit for a joint operating area. Operating area in the minus direction. After changing an upper or lower limit, turn off the power to the control unit and then turn it on with a cold start. With a cold start, the new upper or lower limit takes effect and the selected joint operating area is returned to the standard value ($PARAM_GROUP.$SLMT_**_NUM). CAUTION Changing a joint operating area affects the operating area of the robot. To avoid problems, it is necessary to thoroughly consider the effect of a change in the joint operating area before making the change.
Procedure 3--35 Step
Setting a variable axis area
1 Press MENUS. The screen menu appears. 2 Select SETUP. 3 Press F1 “TYPE.” The screen switching menu appears. 4 Select Stroke limit. The variable axis area setting screen appears. Variable Axis Area Setting Screen
5 I/O 6 SETUP 7 FILE
Stroke limit setup GROUP:1 No. Lower>-180.0 1: 0.0 deg 2: 0.0 deg 3: 0.0 deg Default 0: -180.0 deg
MENUS
JOINT 30% AXIS:J1 UPPER<180.0 0.0 deg 0.0 deg 0.0 deg 180.0 deg
Stroke limit Active limit: & MRR_GRP[1]. $SLMT_J1_NUM=0
TYPE
[TYPE]
GROOP#
AXIS#
F1 5 Position the cursor on the desired axis area. Enter new values using the numeric keys on the teach pendant. F
The upper and lower limits must be within the stroke limits of the system. (See Section 3.17, “Joint Operating Area”). If an attempt is made to set a value outside the limits, the upper or lower limit is fixed to the system default value.
F
To switch from one motion group to another, use the F2 key (group #).
F
To set an additional axis, press the F3 key (axis #) to switch to the additional axis setting screen.
6 To make the settings effective, turn off the power and then back on. When the power is turned on for the first time after the settings have been changed, a cold start is automatically performed.
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Procedure 3--36 Condition Step
Using a variable axis area
H A proper axis area has been set and is effective. 1 To switch to the joint operating area that has been set on the variable axis area setting screen during program execution, use the parameter instruction (See Section 4.14.7, “Parameter instruction”). For example, after the following program has been executed PRG1 1: 2:
JOINT 30% $MRR_GRP[1]. $SLMT_J1_NUM=1 $PARAM_GROUP[1]. $SLMT_J1_NUM=1
[INST]
[EDCMD]
Value No.1 is used for the joint operating area for the J1 axis. To switch to another joint operating area for the additional axis, use the following command: PRG1 3: 4:
JOINT 30% $MRR_GRP[1]. $SLMT_J1_NUM=2 $PARAM_GROUP[1]. $SLMT_J1_NUM=2
[INST]
[EDCMD]
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3.20 Special Area Function The special area function (option) is a function that automatically stops the robot when a move instruction that causes the robot to enter the preset interference area is issued. If another robot or peripheral device is located in that interference area and, after confirming that the other robot or peripheral device has moved out of the interference area, automatically releases the robot from the stopped state to restart its operation. Communication between a robot and a peripheral device is accomplished with a set of interlock signals (one signal for each of input and output). One set of interlock signals is allocated to one interference area. Up to three interference areas can be defined. The relationship between the interlock signals and the robot is as described below. Output signal The output signal is off when the tool endpoint is located inside the interference area. It is on when it is located outside the area. State Safe (tool endpoint located outside the interference area) Dangerous (tool endpoint located inside the interference area)
Output signal On Off
Input signal When the input signal is off, and the robot attempts to enter the interference area, the robot enters the hold state. When the input signal is turned on, the robot is released from the hold state, automatically restarting its operation. CAUTION The robot decelerates to stop at the point where the tool endpoint enters the interference area, so that the robot actually stops at a position inside the interference area. The faster the operating speed of the robot, the deeper the robot enters the interference area. Consider this and other factors, such as the tool size, to ensure that a sufficiently large interference area is set.
To set up the special area function, use the special area function.
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To set up the following items, use the Rectangular Space/DETAILED SCREEN screen. Table 3--15.
Items of the Special Area Function (Area Details Screen)
Item Enable/disable
Comment Output signal Input signal
Description Enables and disables this function. To change the settings of the other items, this function must be disabled for the area for which the settings of the items are to be changed. Allows the user to enter a comment of up to 10 characters. Sets up the output signal. Sets up the input signal. When two robots use this function, this item specifies which robot is to enter the interference area first if the two robots attempt to enter the interference area at the same time. The robot for which High is set enters the interference area first. When the robot completes its operation and moves out of the interference area, the robot for which Low is set enters the interference area. The setting for one robot must be different from that for the other.
Driority
NOTE If High or Low is set for both robots, and the robots attempt to enter the interference area at the same time, they both enter the stopped (deadlock) state. If this occurs, perform the recovery operation described below and check that the settings are correct. 1 Perform an emergency stop on both robots. WARNING If an emergency stop is not performed on both robots, one robot will automatically start its operation when the other moves out of the interference area. This is very dangerous. 2 Check that there are no objects or bystanders that a robot could hit. 3 Disable this function. 4 Move either robot out of the interference area, using a jog operation. inside/outside
Specifies whether the inside or outside of a rectangular is to be an interference area.
To set up the following items, use the Rectangular Space/SPACE SETUP screen. Table 3--16.
Items of the Special Area Function (Area Setting Screen)
Item BASIS VERTEX SIDE LENGTH/SECOND VERTEX
Description Position of the vertex of a rectangular that is to become the reference. If SIDE LENGTH is selected, specify the lengths of the sides of a rectangular parallelepiped from the reference vertex along the X, Y, and Z axes in the user coordinate system. (The sides of the rectangular must be parallel to the respective axes of the user coordinate system.) If SECOND VERTEX is selected, the rectangular having the reference vertex and the diagonal vertex, specified here, becomes an interference area.
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Procedure 3--37 Step
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Setting up the special area function
1 Press MENUS. The screen menu appears. 2 Select SETUP. 3 Press F1 “TYPE.” The screen switching menu appears. 4 Select Space fnct.. The area list screen appears. Area List Screen
5 I/O 6 SETUP 7 FILE
Rectangular Space LIST SCREEN No. End/Dsbl Comment 1 ENABLE [ 2 DISABLE [ 3 DISABLE [
MENUS
JOINT 30% Usage ] Common Space ] Common Space ] Common Space
Space fnct. TYPE [TYPE]
DETAIL
ENABLE
DISABLE
F1 5 The area list screen allows the user to enable and disable each interface area with the appropriate function key. To enter a comment, use the procedure below: a. Move the cursor to the desired comment line and press the Enter key. b. Specify which alphabetic or katakana characters are to be used to enter a comment. c. Press the appropriate function key to enter a comment. d. When the comment is entered, press the Enter key.
Rectangular Space LIST SCREEN No. Enb/Dsbl 1 ENABLE [ 2 DISABLE [ 3 DISABLE [ ENTER
6 To set up an item other than Enb/Dsbl or Comment, press F3 (DETAIL). The details screen appears.
DETAIL ENABLE DISABLE
Rectangular Space DETAILED SCREEN SPACE:1 GROUP:1 USAGE: Common Space 1 Enable/Disable: ENABLE 2 Comment: [**********] 3 Output Signal: DO[0] 4 Input Signal: DI[0] 5 Priority: High 6 Inside/Outside: Inside [TYPE]
SPACE
ENABLE
DISABLE
7 Position the cursor to the desired item. Change the setting of the item using the function or numeric keys.
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8 To set an area, press SPACE. The area setting screen appears.
[TYPE]
Rectangular Space SPACE SETUP SPACE:1 UFRAME:0 1:BASIS VERTEX 2:X 0.0 mm 3:Y 0.0 mm 4:Z 0.0 mm
SPACE
[TYPE]
OTHER
JOINT 30% 1/4 GROUP:1 UTOOL:1 [SIDE LENGTH] 0.0 mm 0.0 mm 0.0 mm
RE10RD
9 The reference vertex and the side lengths or diagonal vertex can be set in either of two ways: a. Position the cursor to the X, Y, and Z coordinate fields and enter the desired coordinates directly using the numeric keys. b. Move the robot to a vertex of a rectangular, then read the current position of the robot with SHIFT key +F5 RECORD. RE10RD
F5 SHIFT
NOTE If UF or UT is to be changed, perform operation b first. This operation selects the current UF or UT value. NOTE When the user coordinate system values are changed, the spatial position of the interference area does not change. When the user coordinate system values have been changed and an interference area is to be defined in the new user coordinate system, use SHIFT key +F5 RECORD to set an interference area again. 10 After setting the area, press PREV. The area details screen reappears. To return to the area list screen, press PREV again. PREV
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3.21 System Config Menu The System Config Menu includes some important components which should be set when the system is established. In the system config menu,the following items can be referred or set. F
Use HOT START (Hot Start)
F
I/O power fail recovery
F
Autoexec program for Cold start Autoexec program for Hot start
F
HOT START done signal
F
Restore selected program
F
Disable UI signals
F
START for CONTINUE only
F
CSTOPI for ABORT
F
Abort all programs by CSTOPI
F
PROD--START depend on PHSTROBE
F
Detect FAULT_RESET signal
F
Use PPABN signal
F
WAIT timeout
F
RECEIVE timeout
F
Return to top of program
F
Original program name (F1 to F5)
F
Default logical command
F
Maximum of ACC instruction
F
Minimum of ACC instruction
F
WJNT for default motion
F
Auto display of alarm menu
F
Force Message
F
Hand broken
F
Reset CHAIN FAILURE detection
F
Remote / Local setup
F
External I/O (ON : Remote)
F
Allow force I/O in AUTO mode
F
Allow chg. ovrd. in AUTO mode
F
Signal to set in AUTO mode
F
Signal to set in T1 mode
F
Signal to set in T2 mode
F
Signal to set if E--STOP
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Table 3--17.
System config menu
ITEMS
DESCRIPTIONS
Use HOT START (Hot Start)
When the hot start is set to TRUE, hot start is done at turning on the controller. (Default setting = FALSE)
I/O power fail recovery
Specifies whether or how to perform I/O power failure recovery if the hot start function is enabled and how to perform simulated recovery if the hot start function is disabled. There are four power failure recovery modes, as described below. -- NOT RECOVER I/O power failure recovery is not performed regardless of whether the hot start function is enabled. All outputs are turned off, and the simulated state is reset. -- RECOVER SIM Simulated--state recovery is performed regardless of whether the hot start function is enabled, and the simulated state is reset, but all actual outputs and simulated inputs/outputs are turned off. -- UNSIMULATE I/O power failure recovery is performed, but all the simulated states are reset. This is equivalent to NOT RECOVER if the hot start function is disabled, because the output states are not recovered. -- RECOVER ALL I/O power failure recovery is performed if the hot start function is enabled. The output and simulated states are recovered to the states that existed immediately before the power is turned off. If the hot start function is disabled, RECOVER ALL is equivalent to RECOVER SIM, because the output states are not recovered.
CAUTION Even if power failure handling is enabled, the output signal is turned off without being recovered in the following cases: F When the I/O allocation is changed before the power is turned off. F When the fuse of an I/O unit blows, or when an I/O unit is turned off. F When the I/O unit configuration is changed. Autoexec program for Cold start Autoexec program for Hot start
Specifies the name of the auto--start program for the hot start. The specified program is executed immediately after the power is turned on. If it does not end within 15 seconds, it will be aborted.
CAUTION The program automatically executed at turning on the controller is executed just before the servo power is turned on. Therefore the robot can not be moved by this program. Set the program which initializes the condition of setup and I/O of the system. You should set the name of program which sets up the system,initializes I/O...etc. Moreover,the attributes should be set as the following with the program detail screen. Group Mask: [*,*,*,*,*] Ignore pause: [ON]
HOT START done signal
Specifies the digital signal (SDO) that is to be output at the hot start. If the hot start is not performed, the digital signal is turned off. This function is disabled if 0 is specified.
Restore selected program
Specifies whether the program selected when the controller is turned off is selected after turning on the controller when the cold start is done. When this is set to TRUE,the program selected at power off is selected after the power on again. When this is set to FALSE,the program is not selected after power is turned on again. This is set to TRUE in standard setting.
Disable UI signals
Selects whether a UI signal is valid or invalid. When this is set to FALSE,the peripheral input signals (UI[1 to 8]) are disabled. See Section 3.10 “Peripheral I/O”.
START for CONTINUE only
If this item is enabled, the external start signal (START) starts only those programs that have been paused. See Section 3.3 “Peripheral I/O”.
CSTOPI for ABORT
If this item is enabled, those programs that are currently running are forcibly terminated immediately upon the input of CSTOPI. See Section 3.3 “Peripheral I/O”.
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Table 3--17. (Cont’d) System config menu ITEMS Abort all programs by CSTOPI
DESCRIPTIONS Specifies whether all programs are to be forcibly terminated with the CSTOPI signal in a multitasking environment. If this item is set to TRUE, the CSTOPI input signal functions as follows: F If RSR is selected for the RSR/PNS item, all programs are forcibly terminated. F If PNS is selected for the RSR/PNS item, the selected program is forcibly terminated. If no program is selected, however, all programs are forcibly terminated. Start no
Is Abort all programs by CSTOPI enabled?
The selected program is forcibly terminated.
yes RSR RSR / PNS ?
All programs are forcibly terminated.
PNS yes
Is program selected?
The selected program is forcibly terminated.
no Forcibly terminate all programs
End
If this item is set to FALSE, the CSTOPI input signal causes only the currently selected program to be forcibly terminated. (Default setting) PROD--START depend on PHSTROBE
If this item is enabled, the PROD_START input is enabled only when the PNSTROBE input is on. By enabling this item, it is possible to prevent a program that should not be started from being started accidentally due to noise or a sequence error when that program is displayed on the teach pendant.
Detect FAULT_RESET signal
Specifies whether the reset signal is detected the instant it rises or falls. When this setting is changed, turn the controller off and on again to use the new information. At this time the cold start is done automatically. The falling edge is detected by standard setting.
Use PPABN signal
Specifies if the pneumatic pressure alarm(*PPABN) is detected for each motion group. Move the cursor to this line and press ENTER key. The setup screen for each motion group is displayed. When *PPABN signal is not used, set this invalid. When this setting is changed, turn off the controller, and turn on the controller to use the new information. At this time the cold start is done automatically.
WAIT timeout
Specifies the period of time used in the conditional wait instruction(WAIT ..., TIMEOUT LBL[...] ). (Corresponding system variable : $WAITTMOUT) The period of time is 30 second.
RECEIVE timeout
For this item, set the limit time for register receive instruction RCV R[...] LBL[...] (can be specified only when the sensor interface option is specified).
Return to top of program
After a program has terminated, this item specifies whether the cursor is positioned at the start of the program upon termination of that program. When this item is enabled, the cursor remains positioned at the end of the program (not positioned at the start of the program) upon termination of the program.
Original program name (F1 to F5)
Specifies the words which is displayed as the soft key at registering a program. It is convenient to set the words used many times as the program name to this.
Default logical command
It is possible to enter the screen to which standard instruction function key is set by pushing the input key from the condition that there is a cursor in setting a standard instruction. -- Name Specifies the name which is displayed as the function key title.(Up to 7 characters) -- Lines Specifies the number of the logic command registered in on function key. The default logical command up to four can be registered in one function key. When the Lines is set to 0,the function of teaching the default logical command is invalid.
Maximum of ACC instruction
Specifies the maximum override value used in the acceleration override motion option(ACC ...). The default value is 150.
Minimum of ACC instruction
Specifies the minimum override value used in the acceleration override motion option(ACC ...).
WJNT for default motion
Adds the Wjnt motion option to all linear and circular default motion instructions or deletes it from them. -- Pressing the F4 (ADD) key adds the Wjnt motion option to all the linear and circular default motion instructions and changes the screen display from “DELETE” (or ******) to “ADD.” -- Pressing the F5 (DELETE) key deletes the Wjnt motion option from all the linear and circular default motion instructions and changes the screen display from “ADD” (or ******) to “DELETE.”
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Table 3--17. (Cont’d) System config menu ITEMS
DESCRIPTIONS
Auto display of alarm menu
Toggles the function for automatically displaying the alarm screen between FALSE and TRUE. The default setting is FALSE. If the setting of this item is changed, the power must be turned off and then back on. F FALSE: Does not display the alarm screen automatically. F TRUE: Displays the alarm screen automatically.
Force Message
Specifies whether the user screen is to appear automatically when a message instruction is executed in a program.
Hand broken
Enables and disables hand breakage (*HBK) detection. When multiple robots are used, hand breakage detection can be enabled and disabled for two robots. Press the Enter key with the cursor positioned on this line. Then, the screen for enabling or disabling hand breakage detection for each robot appears. On this screen, move the cursor to ENABLE or DISABLE, then press the ENABLE (F4) or DISABLE (F5) key to enable or disable hand breakage detection. When hand breakage detection is enabled, and the *HBK signal is off, alarm “--SRVO--006 Hand broken” is issued. See Appendix D--2, “RECOVERY FROM THE HAND BREAKAGE ALARM,” and release the alarm. When the *HBK signal is off, and this signal is not to be used, disable the hand breakage detection. When hand breakage detection is disabled although a hand is installed, and the *HBK signal is used, “SRVO 302 Set hand broken to ENABLE” is displayed if the *HBK signal is on. Enable hand breakage detection. If the *HBK signal is turned off when hand breakage detection is disabled, “SRVO 300 Hand broken / HBK disabled” is issued. In this case, this alarm can be released by pressing the reset key. By default, hand breakage detection is enabled.
Reset CHAIN FAILURE detection
Resets a chain abnormality alarm (servo 230 or 231) when it is issued. For details on the chain abnormality alarm and for how to make hardware checks, refer to the maintenance manual.
1) Check for any hardware problem. 2) Press the emergency stop button on the teach pendant. (Input an emergency stop signal other than the emergency stop signal currently generated.) 3) Turn the emergency stop button on the teach pendant to release the emergency stop condition. 4) Move the cursor to this line, then press the F4 (TURE) key. 5) Press the reset button on the teach pendant.
Remote / Local setup
Select the method for setting the remote signal (SI[2]) that switches between remote mode and local mode of the system. -- Remote : Keeps SI[2] on (remote mode) at all times. -- Local : Keeps SI[2] off (local mode) at all times. -- External I/O : Reflects the external signal status on SI[2]. When selecting this item, specify an external signal for External I/O (ON : Remote) on the next line. -- OP panel key: When the R--J3i MODEL B controller is used, this item cannot be selected.
External I/O (ON : Remote)
When External I/O (ON : Remote) is selected in Remote / Local setup above, specify an external signal to be used here. Choose from SDI, SDO, RDI, RDO, UI, and UO.
Allow force I/O in AUTO mode
Enables or disables signal setting from TP when AUTO mode is set. By default, setting is enabled. -- Yes: Enables signal setting. -- No: Disables signal setting.
Allow chg. ovrd. in AUTO mode
Enables or disables override change from TP when AUTO mode is set. By default, change is enabled. -- Yes: Enables override change. -- No: Disables override change.
Signal to set in AUTO mode
If the three--mode switch is set to AUTO mode, a specified SDO is turned on. When 0 (default) is set, this function is disabled. When the setting has been changed, the power must be turned off then back on.
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Table 3--17. (Cont’d) System config menu ITEMS
DESCRIPTIONS
Signal to set in T1 mode
If the three--mode switch is set to T1 mode, a specified SDO is turned on. When 0 (default) is set, this function is disabled. When the setting has been changed, the power must be turned off then back on.
Signal to set in T2 mode
When the three--mode switch is set to T2 mode, a specified SDO is turned on. When 0 (default) is set, this function is disabled. When the setting has been changed, the power must be turned off then back on.
Signal to set if E--STOP
When an emergency stop (TP external emergency stop, operator’s panel) is applied, a specified SDO is output. When 0 (default) is set, this function is disabled. When the setting has been changed, the power must be turned off then back on.
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Procedure 3--38 Step
Setting The System
1 Select the MENUS key. The screen menu is displayed. 2 Select 6(SYSTEM) in the next page. 3 Press the F1 key, [TYPE]. The screen change menu is displayed. 4 Select Config. The system configuration screen is displayed. System Configuration Screen
5 I/O 6 SETUP 7 FILE
System/Config 1 2 3
MENUS
4 Config
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
TYPE
JOINT 30% 1/37 Use HOT START: FALSE I/O power fail recovery: RECOVER ALL Autoexec program [********] for Cold start: Autoexec program [********] for Hot start: HOT START done signal: DO[0] Restore selected program: TRUE Enable UI signals : TRUE START for CONTINUE only : FALSE CSTOPI for ABORT : FALSE Abort all programs by CSTOPI : FALSE PROD_START depend on PNSTROBE :FALSE Detect FAULT_RESET signal : FALL Use PPABN signal : <*GROUPS*> WAIT timeout : 30.00 sec RECEIVE timeout : 30.000 sec Return to top of program : TRUE Original program name (F1) : [PRG ] Original program name (F2) : [MAIN ] Original program name (F3) : [SUB ] Original program name (F4) : [TEST ] Original program name (F5) : [*******] Default logical command : <*DETAIL*> Muximum of ACC instruction : 150 Minimum of ACC instruction : 0 WJNT for default motion : ****** Auto display of alarm menu : FALSE Force Message : ENABLE Reset CHAIN FAILURE detection : FALSE Allow Force I/O in AUTO mode : TRUE Allow chg. ovrd. in AUTO mode : TRUE Signal to set in AUTO mode DOUT [ 0] Signal to set in T1 mode DOUT [ 0] Signal to set in T2 mode DOUT [ 0] Signal to set if E-STOP DOUT [ 0] Hand broken : <*GROUPS*> Remote / Local setup : Remote External I/O (ON : Remote) : DI [ 0]
[TYPE]
[CHOICE]
5 Move the cursor to the field you want to set and enter the new value by using the numerical key or the function key on the teach pendant. As for the field which should be set character string, move the cursor to it and press the ENTER key. Then the character input becomes possible. NOTE To set the “Use PPABN signal:” or “Default logical command:”, move the cursor to “<*GROUPS*>” or “<*DETAIL*>” and press the ENTER key. Each setting screen will be displayed. Press the PREV key to get out of these screens. 13 Use PPABN signal: 14 WAIT timeout: 15 RECEIVE timeout:
<********> 30.00 sec 30.00 sec
ENTER
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6 When you change the setting that the cold start need to be done after the setting is changed, the message to inform it is displayed at changing it. In case of that, do the cold start.(See Section 5.2,“Turning on the Power and Jog Feed”) Please power on again [ TYPE ]
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3.22 Setting Up General Items [6 SETUP General] has the following items. F
Brake on hold
F
Current language
F
Ignore Offset command
F
Ignore Tool--offset
Table 3--18.
Setting the general items
ITEMS Break on hold
DESCRIPTIONS Specifies whether to issue an alarm and turn off the servo alarm when the HOLD key is pressed. -- If the function is DISABLED, no alarm is issued when the operation is halted by the HOLD key (standard setting). -- If the function is ENABLED, an alarm is issued and the servo power is turned off, when the operation is halted by the HOLD key. This setting is recorded in system variable $SCR.$BRKHOLD_ENB. WARNING Not all axes are equipped with a brake. The brake on hold function has no effect on an axis without a brake even if the function is enabled. Before the brake on hold function is enabled, it should be checked which axis has a brake. Otherwise, injury could occur.
Current language
The current language is set to “DEFAULT” by standard setting. Changing the current language requires special work. Usually, the standard setting should be used.
Ignore Offset command
Specifies whether to ignore the offset command (See Section 4.3.6 “Additional motion instructions”). -- If the function is DISABLED, the robot moves to the position for which the offset command has been executed (standard setting). -- If the function is ENABLED, the robot moves to the taught position (for which the offset command has not been executed). See Section 4.3.6 “Additional motion instructions” for details of the Offset command.
Ignore Tool--offset
Specifies whether to ignore the tool offset command (See Section 4.3.6 “Additional motion instructions”). -- If the function is DISABLED, the robot moves to the position for which the tool offset command has been executed (standard setting). -- If the function is ENABLED, the robot moves to the taught position (for which the tool offset command has not been executed). See Section 4.3.6 “Additional motion instructions” for details of the Tool--offset command.
155
3. SETTING UP THE ARC SYSTEM
Procedure 3--39 Step
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Setting the general items
1 Press the MENUS key. The screen menu is displayed. 2 Select 6 (SYSTEM). 3 Press F1, [TYPE]. The screen change menu is displayed. 4 Select General. General item setting screen
5 I/O 6 SETUP 7 FILE MENUS
SETUP General 1 2 3 4
JOINT
Break on hold: Current language: Ignore Offset command: Ignore Tool_offset:
[ TYPE ]
30 % 1/4
DISABLED DEFAULT DISABLED DISABLED
ENABLED DISABLED
General [TYPE]
F1 5 Place the cursor on the target field, and select the function key menu. 6 If the value for the brake on hold function is re--set, to make the new setting effective, turn the controller off and on again in cold start mode. The setting of the other functions is made effective immediately when they are re--set.
156
3. SETTING UP THE ARC SYSTEM
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3.23 Other Settings The other settings are specified at [6 SYSTEM Variables] on the system variable screen. F
Override restore function
Override restore function The override restore function is a function that decreases the speed override to a prescribed value when a safety fence is opened and the *SFSPD input is turned off, but restores the speed override immediately when the safety fence is closed. This function is effective under the following conditions: J
$SCR.$RECOV_OVRD = TRUE. (A control start is required.)
J
The system is in remote control state.
J
The speed override is not changed while the safety fence is open.
Other items are set up on the system variable screen, [6 SYSTEM Variables]. To specify system variables, see the appropriate appendix (See Appendix D, “System Variables”).
157
4. PROGRAM STRUCTURE
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4. PROGRAM STRUCTURE
This chapter describes the program structure and program instructions. j Contents of this chapter 4.1
Program Detail Information
4.2
Line Number, Program End Symbol, and Argument
4.3
Motion Instructions
4.4
Arc Instructions
4.5
Register Instructions
4.6
I/O Instructions
4.7
Branch Instructions
4.8
Wait Instructions
4.9
Skip Condition Instruction
4.10 Offset Condition Instruction 4.11 Tool Offset Condition Instructions 4.12 Frame Instructions 4.13 Program Control Instructions 4.14 Other Instructions 4.15 Multiaxis Control Instructions 4.16 Operation Group Instructions
158
4. PROGRAM STRUCTURE
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A arc welding application program consists of user--coded instructions for performing arc welding work, and other associated information. A program contains program information specifying how arc welding work is to be performed, and also contains program detail information defining program attributes. Figure 4--1. Program Information Screen
Program detail
JOINT
30 % 1/6 Creation Date: 10-MAR-1994 Modification Date: 11-MAR-1994 Copy Source: [****************] Positions: FALSE Size: 312 Byte 1 Program name: [SAMPLE3 ] 2 Sub Type: [ None] 3 Comment: [SAMPLE PROGRAM 3] 4 Group Mask: [1,*,*,*,*] 5 Write protect: [ OFF] 6 Ignore pause: [ OFF] END PREV NEXT
Program detail information consists of the following information items: F
Attribute--related information items such as a creation date, modification date, a copy source file name, presence/absence of position data, and program data size.
F
Information items related to an execution environment such as a program name, subtype, comment, group mask, write protection and interruption disable.
Figure 4--2. Program Selection Screen Memory available capacity Select
JOINT 30 % 58740 bytes free 1/7 No. Program name Comment 1 SAMPLE1 [SAMPLE PROGRAM 1] 2 SAMPLE2 [SAMPLE PROGRAM 2] 3 SAMPLE3 [SAMPLE PROGRAM 3] 4 PROG001 [PROGRAM001 ] 5 PROG002 [PROGRAM001 ] 6 CLAMP1 [CLAMP OPEN ] 7 CLAMP2 [CLAMP CLOSE ]
Attribute
Program name [ TYPE ] CREATE DELETE
MONITOR [ATTR ]>
COPY
SAVE
DETAIL
LOAD
PRINT
>
Figure 4--3. Program Edit Screen Program name
SAMPLE1
Line number
1: 2: 3: : 4: 5: 6: : 7: 8:
Motion instruction Program instructions Arc welding instruction Weaving instruction
Program end symbol
JOINT 10% 1/9
J P [1] 100% FINE J P [2] 70% CNT50 L P [3] 500mm/s FINE Arc Start [1] Weave Sine [1] L P [4] 50cm/m CNT80 L P [5] 50cm/m CNT80 Arc End [55V, 75A, 0.1s] Weave End J P [1] 100% FINE
[End] POINT
159
ARCSTRT WELD_PT
ARCEND
TOUCHUP>
4. PROGRAM STRUCTURE
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A program consists of the following information: F
Line number assigned to each program statement
F
Motion instructions specifying how and where the robot is to move
F
Program instructions including the following: -- Arc welding instruction for controlling arc welding. -- Weaving instruction for controlling weaving. -- Arc sensor instruction for controlling arc sensor. -- Instructions for storing numerical data in registers (register instructions) -- Instructions for storing robot position data in position registers (position register instructions) -- I/O instructions to output and input signals to and from peripheral devices -- Branch instructions for changing the flow of program control when a defined condition is satisfied (IF, JMP/LBL, CALL/END) -- Wait instructions for suspending program execution -- Skip condition instruction for operating the robot until a signal is received. If the signal is not received, a branch to a specified statement occurs. If the signal is received, the next statement is executed, cancelling the operation. -- Program comments -- Other instructions
F
Program end symbol indicating that the program contains no more instructions
Program detail information is set on the program information screen. (See Subsection 5.3.1 and 5.5.) A program is registered on the program registration screen (See Subsection 5.3.1.) A program is created and changed on the program edit screen. (See Sections 5.3 and 5.4.)
160
4. PROGRAM STRUCTURE
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4.1 Program Detail Information Program detail information names a program and defines the attributes of the program. Program detail information consists of the following items: F
Attribute--related information items such as a creation date, modification date, a copy source file name, presence/absence of position data, and program data size.
F
Information items related to an execution environment such as a program name, subtype, comment, group mask, write protection and interruption disable.
The program information screen is used to set program detail information. The program information screen is displayed by selecting F2 (DETAIL) on the program selection screen. (For program detail information setting, see Subsection 5.3.1 and 5.5) To enter a program comment, set write protection, a modification date, memory size of the program, or a copy source, press F5,[ATTR] to display the selection screen, and select the desired item from a pull up menu.
1 SELECT 2 EDIT
Program detail
30 % 1/6 Creation Date: 10-MAR-xxxx Modification Date: 11-MAR-xxxx Copy Source: [****************] Positions: FALSE Size: 312 Byte 1 Program name: [SAMPLE3 ] 2 Sub Type: [ None] 3 Comment: [SAMPLE PROGRAM 3] 4 Group Mask: [1,*,*,*,*]
MENUS
END
PREV
JOINT
NEXT
4.1.1 Program name Program name is used to assign a name to a program. When a new program is created, a unique program name must be assigned to the program. The program name is used to distinguish the program from the other programs stored in the memory of the controller. Length A program name must consist of one to eight characters. A unique name must be assigned to each program. Usable characters Character: Alphabetic characters, Number: 0 to 9. No program name can start with a number. Symbol: Underscore (_) only. The at mark (@) and asterisk (*) cannot be used. Informative name A program should be named so that purpose or function of the program can be known from its name. Naming the arc--welding program for workpiece No.1 WELD_1, for example, allows anyone to guess the contents of the program. NOTE Observe the following when writing a program for automatic operation using RSR or PNS. Otherwise, the program will not run. F
A program using RSR must be named RSRnnnn, where nnnn is a 4--digit number. Example: RSR0001.
F
A program using PNS must be named PNSnnnn, where nnnn is a 4--digit number. Example: PNS0001.
161
4. PROGRAM STRUCTURE
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4.1.2 Program comment When a new program is created, a program comment can be added to the program name. A program comment is used to describe additional information to be displayed on the selection screen together with the program name. Length A program comment must consist of one to sixteen characters. Usable characters Character: Alphabetic characters, Number: 0 to 9 Symbol: Underscore (_), at mark (@), and asterisk (*) Informative comment A program comment should describe the purpose or function of the program.
4.1.3 Subtype Subtype is used to set a type of program. The following subtypes are available: F
Job (JB): This represents a main program that can be started using a device such as a teach pendant. Process programs are called in a main program for execution.
F
Process (PR): This represents a subprogram that is called by a job program for execution of a particular job.
F
Macro (MR): This represents a program for executing a macro instruction. The subtype of a program registered on the macro instruction setting screen is automatically set to MR.
F
State: Specify this when creating a conditional program with the state monitoring function (option).
162
4. PROGRAM STRUCTURE
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4.1.4 Group mask A motion group sets up an operation group of a program. An operation group represents a group of different axes (motors) used for independent robots, positioning tables, and other jigs. NOTE A motion group must be set before it is used. The robot control unit can divide up to 16 axes (when a multifunction board is inserted) into up to three operation groups and control those groups simultaneously. A single group can control up to nine axes (multimotion function). If the system has only one operation group, the default motion group is group 1 (1, *, *, *, *). For a program that has no motion group (that is, a program involving no robot motion), this item is to be specified as (*, *, *, *, *). A program that has no motion group can be started even when the system is not ready for operation. The system is ready for operation when the following ready conditions are satisfied: J
The peripheral I/O, ENBL input, is on.
J
The peripheral I/O, SYSRDY output, is on (With the servo power is on).
4.1.5 Write protection Write protection specifies whether the program can be modified. F
When this item is set to ON, no data can be added to the program, and the program cannot be modified; that is, the program is write protected. When a program has been created, and its operation is confirmed, the user can set this item to ON to prevent the program from being modified by the user or someone else.
NOTE When this item is set to ON, other items in the program detail information (Program name, Comment, Sub Type, Group Mask, Ignore pause) cannot be changed. F
When this item is set to OFF, the program can be modified; that is, program instructions can be added to the program, and existing instructions can be modified. Write protection is normally set to OFF as standard.
4.1.6 Interruption disable Interruption disable (ignore pause) prevents a program being executed and not having the motion group from being interrupted by an alarm (with a severity of SERVO or lower), emergency stop, or halt. When these signals are to be ignored, set interruption disable to ON. When interruption disable is set to ON, a program being executed can only be interrupted by an abort instruction in the program or an alarm with a severity higher than SERVO. (See Subsection 4.13.2.) WARNING When interruption disable is set to ON, a program being executed cannot be interrupted by pressing the emergency stop or halt button on the teach pendant or operator’s panel.
WARNING While the interruption disable setting is enabled, programs should not execute motion instructions. If this is not observed, injury or property damage could occur.
163
4. PROGRAM STRUCTURE
Procedure 4--1 Step
B--81464EN--3/01
Program Detail Information
1 Press the MENUS key. The screen menu is displayed. 2 Select 1(SELECT). The program selection screen is displayed. The program selection screen can also be displayed by pressing the SELECT key without using steps 1 and 2 above.
1 SELECT 2 EDIT
Select
JOINT 30 % 58740 bytes free 1/7 No. Program name Comment 1 SAMPLE1 [SAMPLE PROGRAM 1] 2 SAMPLE2 [SAMPLE PROGRAM 2] 3 SAMPLE3 [SAMPLE PROGRAM 3] 4 PROG001 [PROGRAM001 ] 5 PROG002 [PROGRAM001 ] 6 CLAMP1 [CLAMP OPEN ] 7 CLAMP2 [CLAMP CLOSE ]
MENUS
[ TYPE ] CREATE DELETE
MONITOR [ATTR ]>
COPY
SAVE
DETAIL
LOAD
PRINT
>
3 Switching the screen using sub type To select the program to be displayed for the sub type, press F1,[TYPE] and select the sub type of the program you want to display as follows: -- All : All the programs are displayed. -- Job : Only job programs are displayed. -- Process : Only process programs are displayed. -- Program : All the programs except macro programs are displayed. -- Macro : Only macro programs are displayed.
1 2 3 4 5
All Jobs Processes TP Programs Macro
SAMPLE1 Select 1 2
LINE 1
ABORTED JOINT 30 % 61276 bytes free 1/4 SAMPLE1 [SAMPLE PROGRAM 1] SAMPLE2 [SAMPLE PROGRAM 2]
[ TYPE ] CREATE DELETE
MONITOR [ATTR ]>
TYPE
F1 4 Switching the display using the attribute To select the program attribute to be displayed,press F5,[ATTR] and select the attribute type of the program you want to display as follows: -- Comment : The comment is displayed. -- Protection : The setting of the write protection is displayed. -- Last Modified : The latest date of the modification is displayed. -- Size : The number of the line and the program size are displayed. -- Copy Source : The name of the copy source program is displayed. 1 2 3 4 5
Comment Protection Last Modified Size Copy Source ATTR
Select
JOINT 30 % 58740 bytes free 1/2 No. Program name Size 1 SAMPLE1 [ 32/ 839] 2 SAMPLE2 [ 12/ 1298]
[ TYPE ] CREATE DELETE
F5
164
MONITOR [ATTR ]>
4. PROGRAM STRUCTURE
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5 Program Detail Screen Press NEXT,> and press F2,DETAIL in the next page. The program detail screen is displayed. COPY
DETAIL
LOAD
F2
Program detail
JOINT
30 % 1/6 Creation Date: 10-MAR-xxxx Modification Date: 11-MAR-xxxx Copy Source: [****************] Positions: FALSE Size: 312 Byte 1 Program name: [SAMPLE3 ] 2 Sub Type: [ None] 3 Comment: [SAMPLE PROGRAM 3] 4 Group Mask: [1,*,*,*,*] 5 Write protect: [ OFF] 6 Ignore pause: [ OFF] END PREV NEXT
6 When you finish setting the program header information, press F1,END. END
PREV
NEXT
F1
165
4. PROGRAM STRUCTURE
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4.2 Line Number, Program End Symbol, and Argument Line number A line number is automatically inserted in front of an instruction when it is added to a program. When an instruction is deleted, or an instruction is moved to another location, the lines of the program are renumbered in ascending order; that is, the first line is numbered as 1, the second line is numbered as 2, and so forth. When a program is to be modified, the cursor can be used to specify a line or a range of lines for movement or deletion by line number. The user can make the cursor jump to a desired line number by specifying a line number (with the ITEM key). Program end symbol The program end symbol ([End]) is automatically displayed on the line after the last instruction of a program. Whenever a new instruction is added, the program end symbol moves downward on the screen. As a result, it is always displayed on the last line. When the execution of a program reaches the program end symbol after the last instruction in the program is executed, the program execution automatically returns to the first line of the program for termination. However, when the setting of “Return to top of program” is FALSE, the cursor stays on the last line of the program after program execution is completed. (See Section 3.21 “System Config Menu”.) A description of the program instructions required to create and change a program follows. (For how to create a program, see Section 5.3. For how to change a program, see Section 5.4.) Argument i Argument i is an index used in teaching control instructions (program instructions other than motion instruction). Some arguments are specified directly; others are specified indirectly. In direct specification, an integer from 1 to 32767 is usually specified. The range of values used depends on the type of instruction. In indirect specification, the register number of a register holding a value is specified. Figure 4--4. Format of Argument i
Argument
i Direct specification
: Number.(Example: R[i])
Indirect specification
: Uses the value of the register with register number i as the argument.(Example: R[R[i]])
Register Screen
R[i]
DATA Registers R [ 1: R [ 2:
166
JOINT 30% ] = ] =
11 0
4. PROGRAM STRUCTURE
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Procedure 4--2 Condition Step
Program Edit Screen
H The teach pendant must be enabled. 1 Display the program selection screen. 2 Move the cursor to the program you want to edit and press the ENTER key. The program edit screen is displayed.
Select
SMPLE1
61276 No. Program name 1 SAMPLE1 2 SAMPLE2 ENTER 3 SAMPLE3 4 PROG001
1:J 2:J 3:L 4:L 5:J [End] POINT
JOINT P[1] P[2] P[3] P[4] P[5]
30 % 1/6
100% FINE 70% CNT50 1000cm/min CNT30 500mm/sec FINE 100% FINE
ARCSTRT WELD_PT
ARCEND TOUCHUP>
3 Moving the cursor To move the cursor, use the arrow keys such as up, down, right, and left. To move quickly through the information, press and hold the SHIFT key and press the down or up arrow keys. 4 To select the line number, press the ITEM key and enter the line number to which you want to move the cursor. ITEM
5
ENTER
SMPLE1
JOINT
30 % 5/6
4:L P[4] 500mm/sec FINE 5:J P[5] 100% FINE [End]
5 Entering the numerical value To enter the numerical value, move the cursor to the argument and press the numerical value keys. When you are finished, press the ENTER key.
PROG2
PROG2
9:L P[5] 100% FINE 10: DO[...]=...
1
ENTER
JOINT
30 % 10/11
10: DO[ 1]=... [End] Enter value DIRECT INDIRECT[CHOICE]
6 To use indirect addressing with the register, press F3,INDIRECT.
DIRECT INDIRECT
F3
PROG2
JOINT
10: DO[R[1]]=... [End]Enter value DIRECT INDIRECT[CHOICE]
167
30 % 10/11
4. PROGRAM STRUCTURE
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4.3 Motion Instructions A motion instruction moves a robot tool to a specified point within the operating area at a specified feedrate and in a specified traveling mode. The items listed below must be specified in a motion instruction. The format of a motion instruction is shown in Figure 4--5. F
Motion format:
Specifies how to control the path of motion to a specified position.
F
Position data:
Teaches a position to which the robot is to move.
F
Feedrate:
Specifies the feedrate of the robot.
F
Positioning path:
Specifies whether to position the robot at a specified point.
F
Additional motion instruction:
Specifies the execution of an additional instruction while the robot is in motion.
Figure 4--5. Motion Instructions Position data UF:0 UT:1 X: 1500.374 W: 10.000 Y: --342.992 P: 20.000 Z: 956.895 R: 40.000 CONF: N, R, D, F, 0, 0, 0
Position data format P 1 to 1500 * PR 1 to 10
J
P[ i ]
Motion format J L C
J%
Feedrate 1 to 100% 1 to 2000mm/sec 1 to 12000cm/min 0.1 to 4724.0inch/min 1 to 240deg/sec 1 to 272deg/sec 1 to 3200deg/sec 0.1 to 200.0sec
CNTk Positioning path FINE CNT 0 to 100
* A position number can be as large as the memory capacity allows. In teaching a motion instruction, a standard motion instruction is selected using one of the keys F1, F5. (For modifying a standard motion instruction, see Subsection 5.3.2. For teaching a motion instruction, see Subsection 5.3.3. For changing a motion instruction, see Subsection 5.4.2.) POINT
ARCSTRT WELD_PT
ARCEND TOUCHUP>
-- F1 (POINT) is used to teach a motion instruction. -- F2 (ARCSTRT) is used to teach an arc motion instruction that includes an arc start instruction. -- F3 (WELD_PT) is used to teach a motion instruction that specifies linear motion to a welding passing point. -- F4 (ARCEND) is used to teach an arc motion instruction that includes an arc end instruction. -- F5 (TOUCHUP) is used to reteach taught position data.
168
4. PROGRAM STRUCTURE
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4.3.1 Motion format For the motion format, the path of motion to a specified position is specified. Three options are available: joint motion, which does not exercise path/attitude control, and linear motion and circular motion, which exercise path/attitude control. F
Joint motion (J)
F
Linear motion (including the rotation motion)(L)
F
Circular motion (C)
Joint motion J The joint motion mode is the basic mode for moving the robot to a specified position. The robot accelerates along or about all axes, moves at a specified feedrate, decelerates, and stops at the same time. The path of motion is usually non--linear. The motion format is specified to teach an end point. A percentage of a maximum feedrate is specified as the feedrate of joint motion. The attitude of a tool being moved is not controlled. Figure 4--6. Joint Motion
P2 Destinaiton position
P1 Start position
Example 1: JP [1] 100% FINE 2: JP [2] 70% FINE
Linear motion L The linear motion mode controls the path of tool center point (TCP) motion from a start point to an end point; the tool center point moves linearly. The motion format is specified to teach an end point. For linear feedrate specification, a desired option must be chosen from mm/sec, cm/min, and inch/min. The attitude of a tool being moved is controlled by distinguishing the attitude at a start point from the attitude at a target point. Figure 4--7. Linear Motion
P2 Destination position
P1 Start position
Example 1: JP [1] 100% FINE 2: LP [2] 500mm/sec FINE
Rotary operation is a method of travel in which the tool is rotated about the tool endpoint from the start position to the end position by using linear operation. The orientation of the tool during travel is controlled by dividing the orientation at the start position and that at the destination position. The feedrate is specified in deg/sec. The focus is controlled linearly (if the tool endpoint moves).
169
4. PROGRAM STRUCTURE
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Figure 4--8. Rotation Motion P2 Destination position
P1 Example 1: JP [1] 100% FINE
Start position
2: LP [2] 30deg/sec FINE
Circular motion The circular motion mode controls the path of tool center point motion from a start point to an end point through a passing point. Both a passing point and a target point are taught in one instruction. For circular feedrate specification, a desired option must be chosen from mm/sec, cm/min and inch/min. The attitude of a tool being moved is controlled by distingushing the attitude at a start point from the attitude at a target point. Figure 4--9. Circular motion
P3 Target point P2 Passing point
P1 Start point
170
Example 1: JP [1] 100% FINE 2: CP [2] 2: P [3] 500mm/sec FINE
4. PROGRAM STRUCTURE
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4.3.2 Position data Position data includes the positions and attitudes of the robot. When a motion instruction is taught, position data is written to the program at the same time. Position data is classified into two types. One type consists of joint coordinates in a joint coordinate system. The other type consists of Cartesian coordinates representing tool positions and attitudes in work space. Standard position data uses Cartesian coordinates. Cartesian coordinates Position data consisting of Cartesian coordinates is defined by four elements: the position of the tool center point (origin of the tool coordinate system) in a Cartesian coordinate system, the inclination of the axis along which the tool moves (tool coordinate system), configuration, and a Cartesian coordinate used. A Cartesian coordinate system may be a world coordinate system. How to select the coordinate systems is explained later in this subsection. Figure 4--10. Position Data (Cartesian Coordinates)
UF , UT , ( X , Y , Z , W , P , R ) , Configuration User coordinate system number
Position
Attitude
Configuration
Tool coordinate system number
Position and attitude F
The position (x,y,z) represents the three--dimensional position of the tool center point (origin of the tool coordinate system) in the Cartesian coordinate system.
F
The attitude (w,p,r) represents angular displacements about the X--axis, Y--axis, and Z--axis in the Cartesian coordinate system.
Figure 4--11. World Coordinate System/User Coordinate System and Tool Coordinate System
World coodinate system
Z
Z
Tool coodinate system
Y X
Y Z Z
User coodinate system 1
User coodinate system 2
Y
X
X
Y X
171
4. PROGRAM STRUCTURE
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Configuration A configuration represents the attitude of the robot. Several configurations are available which meet the condition of Cartesian coordinates (x,y,z,w,p,r). The turn number and joint placement of each axis must be specified. Figure 4--12. Configuration Axis specified with $SCR_GRP[group].$TURN_AXIS[3] Axis specified with $SCR_GRP[group].$TURN_AXIS[2] Axis specified with $SCR_GRP[group].$TURN_AXIS[1] ( F,
L,
U,
T,
0,
Joint placement
Left or right of the arm
Up or down of the arm
0)
Turn number
FRONT { FLIP { LEFT {UP NOFLIP RIGHT DOWN { BACK Flip or no flip of the wrist
0,
{
Front or back of the arm
1:
180_ to 539_
0: --1:
--179_ to 179_ --539_ to 180_
Joint placement Joint placement specifies the placement of the wrist and arm. This specifies which side the control point of the wrist and arm is placed on against the control plane. When a control point is placed on the control plane, the robot is said to be placed at a singularity, or to be taking a peculiar attitude. At the singularity, since the configuration can not be decided to one by the specified cartesian coordinate values, the robot can not move. F
An operation that ends at a singular point cannot be programmed. (In some cases, the most feasible configuration can be selected.) To specify such an operation, define the axial coordinate values.
F
During linear or circular motion, the tool cannot pass through a singularity point (the joint placement cannot be changed). In this case, execute a joint motion. To pass through a singularity point on the wrist axis, a wrist joint motion (Wjnt) can also be executed.
Figure 4--13. Joint Placement J5--axis joint placement
J3--axis joint placement
J1--axis joint placement
FLIP
NOFLIP
UP
DOWN
BACK
FRONT
Turn number Turn number represents the number of revolutions of the wrist axis (J4, J5, J6). Each axis returns to the original position after one revolution. This specifies how many turns have been made. Turn number is 0 when each axis is at an attitude of 0. The turn numbers can be displayed for up to three axes. The axis number to correspond to each field is specified with system variable $SCR_GRP[i].$TURN_AXIS[j] (where i is a group number), as follows: Left field
: Axis number specified with $SCR_GRP[i].$TURN_AXIS[1]
Middle field : Axis number specified with $SCR_GRP[i].$TURN_AXIS[2] Right field
: Axis number specified with $SCR_GRP[i].$TURN_AXIS[3]
172
4. PROGRAM STRUCTURE
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When programmed linear motion or circular motion is executed, the robot tool moves toward the target point while adopting an attitude very similar to that at the start point. The number of revolutions performed at the target point is selected automatically. The actual number of revolutions performed at the target point might differ from the number specified in the position data. Cartesian coordinate system reference In playback of position data consisting of Cartesian coordinates, a Cartesian coordinate system reference checks the coordinate system number of a Cartesian coordinate system to be used. If the coordinate system number (a number from 0 to 9) specified in the position data does not match the coordinate system number currently selected, the program is not executed for safety, and an alarm is issued. A coordinate system number is written into position data in position teaching. To change a coordinate system number after it has been written, use the tool replacement/coordinate replacement shift function [option]. Tool coordinate system number (UT) The tool coordinate system number specifies the coordinate system number of a mechanical interface coordinate system or tool coordinate system. Thus, the coordinate system of the tool is determined. F
0
F
1 to 9 : The tool coordinate system of a specified tool coordinate system number is used.
: The mechanical interface coordinate system is used.
F
F
: The coordinate system of the tool coordinate system number currently selected is used.
User coordinate system number (UF) The user coordinate system number specifies the coordinate system number of a world coordinate system or user coordinate system. Thus, the coordinate system of work space is determined. F 0 : The world coordinate system is used. F
1 to 9 : The tool coordinate system of a specified tool coordinate system number is used.
F
F
: The coordinate system of the tool coordinate system number currently selected is used.
Detail position data To display the detail position data, position the cursor to the position number, then press the F5 (POSITION) key. SAMPLE1 1: J 2: J
Position Detail P[2] GP:1 UF:0 X: 1500.374 mm Y: -242.992 mm Z: 956.895 mm SAMPLE1
P[1] 100% P[2] 70%
COMMENT CHOICE POSITION
UT:1 W: P: R:
JOINT 30% CONF: N T,O 40.000 deg 10.000 deg 20.000 deg
F5 Switching the coordinate system check function The coordinate system check function allows the user to perform FWD/BWD execution easily between two points with different coordinate system numbers. By changing the setting of the following system variable, this function can be switched to one of three specifications. Setting of the system variable $FRM_CHKTYP = --1 $FRM_CHKTYP = --2 $FRM_CHKTYP = 2
Description Disables FWD/BWD execution between two points having different coordinate system numbers. Enables FWD/BWD execution between two points having different numbers. Enables FWD/BWD execution between two points having different numbers, and changes the current coordinate system number ($MNUFRAME_NUM or $MNUTOOL_NUM) to the number specified in the position data in the program.
The system variable is explained, using a specific program as an example. Example
1: UTOOL_NUM = 1 2: JP [1] 100% FINE (specified with P [1] UT = 1) 3: JP [2] 100% FINE (specified with P [2] UT = 2)
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-- If $FRM_CHKTYP = --1, FWD: An alarm is generated if the coordinate system numbers differ on the third line. BWD: If the currently selected tool coordinate system number is 2, an alarm is generated when the second line is executed after BWD execution on the third line. -- If $FRM_CHKTYP = --2, FWD: An alarm is not generated on the third line. The third line is executed with a tool coordinate system number of 2. (Operation is performed at the specified position.) BWD: As with FWD, an alarm is not generated. -- If $FRM_CHKTYP = 2, An alarm is not generated in the same way as for $FRM_CHKTYP = --2. FWD: An alarm is not generated on the third line. The third line is executed with a tool coordinate system number of 2. Immediately after the start of the operation for the third line, the tool coordinate system number of the system is changed to 2. BWD: An alarm is not generated on the second line. Immediately after the start of the operation for the second line, the tool coordinate system number of the system is changed to 1. NOTE Regardless of the value of $FRM_CHKTYP, BWD operation between arcs having different coordinate system numbers result in an alarm. Joint coordinates Position data consisting of joint coordinates is defined using angular displacements with respect to the joint coordinate system on the base side of each articulation. Figure 4--14. Position Data (Joint Coordinates)
( J1 , J2 , J3 , J4 , J5 , J6 , E1 , E2 , E3 ) Main axis
Wrist axis
Additional axis
Figure 4--15. Joint Coordinate System
detail position data Detail position data is displayed by pressing F5 (POSITION). SAMPLE1 1: J 2: J
P[1] 100% P[2] 70%
CHOICE POSITION
Position Detail P[2] J1: 0.125 deg J2: 23.590 deg J3: 30.300 deg SAMPLE1
JOINT 30% J4: -95.000 J5: 0.789
F5
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Position variable and position register In a motion instruction, position data is represented by a position variable (P[i]) or position register (PR[i]). Usually, a position variable is used. Figure 4--16. Position Variable and Position Register
P[i]
PR [GPK: i ] Direct: Position register number(1 to 10)
Position number (1 to 1500)
Example
Group number (1 to 5)
1: J 2: L 3: L
Indirect: Register
P[12] 30% FINE PR[1] 300mm/s CNT50 PR[R[3]] 300mm/s CNT50
Position variable The position variable is the variable usually used to hold position data. In motion instruction teaching, position data is automatically saved. When Cartesian coordinates are taught, the following Cartesian coordinate system and coordinate system number are used: F Coordinate system of the tool coordinate system number currently selected (UT = 1 to 10) F World coordinate system (UF = 0)(When $USE_UFRAME is FALSE) In playback, the following Cartesian coordinate system and coordinate system number are used: Coordinate system of the user coordinate system number currently selected (UF = 0 to 9) (When $USE_UFRAME is TRUE) NOTE System variable $USE_UFRAME cannot be used if the user coordinate system input function option is not provided. When a position is copied, F F
F F
Coordinate system with the specified tool coordinate system number (UT = 1 to 10) Coordinate system with the specified user coordinate system number (UF = 0 to 9)
Position register The position register functions as a general--purpose register for holding position data. (For position teaching using a position register, see Section 7.4.) When Cartesian coordinates are taught, the following Cartesian coordinate system and coordinate system number are used: F Coordinate system of the tool coordinate system number currently selected (UT = F) F Coordinate system of the user coordinate system number currently selected (UF = F) In playback, the following Cartesian coordinate system and coordinate system number are used: F F
Coordinate system of the tool coordinate system number currently selected (UT = F) Coordinate system of the user coordinate system number currently selected (UF = F)
Position number The position number is used to reference a position variable. A position number is automatically assigned each time a motion instruction is taught and it is reflected in the program. For example, the first position number assigned is P[1], the second P[2], and so on. When a motion instruction is added, it is assigned the position number obtained by incrementing the position number assigned to the motion instruction added immediately before by one, regardless of where the newly added instruction is placed in the program. However, this is not the case when a position number is changed. When a position is deleted, the position numbers of other taught points remain unchanged. However, this is not the case when a position number is changed. (For changing a position number, see Section 5.4 “Changing a Program”.) A comment consisting of up to 16 characters can be described for a position number or position register number. To add a comment,press the ENTER key when the cursor is at the position number or position register number. Example 4: J 5: L
P[11: APPROACH POS ] 30% FINE PR[1: WAIT POS ] 300mm/s CNT50
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4.3.3 Feedrate The feedrate specifies the speed at which the robot moves. During program execution, the feedrate is controlled by feedrate overriding. A feedrate override value of 1% to 100% can be used. The unit used to specify a feedrate depends on the motion format taught with a motion instruction. NOTE The programmed travelling speed cannot exceed the allowable range of the robot. If a speed exceeding the range is programmed, a warning alarm would be issued. J P[1] 50% FINE When the motion type is joint, a feedrate is specified as the following: F F
F
A percentage from 1% to 100% of the maximum feedrate is to be specified. When the unit is sec,specify the value from 0.1 to 3200sec as the time took for motion. This specification is required,when the time took for motion is important. An operation cannot sometimes takes place in a specified time. When the unit is msec,specify the value from 1 to 32000msec as the time took for motion.
L P[1] 100mm/sec FINE If the specified motion format is linear motion or circular motion, specify a feedrate as follows: F F F F F
When the unit is mm/sec, specify a feedrate from 1 to 2000 mm/sec. When the unit is cm/min, specify a feedrate from 1 to 12000 cm/min. When the unit is inch/min, specify a feedrate from 0.1 to 4724.4 inch/min. When the unit is sec, specify the value from 0.1 to 3200sec as the time took for motion. When the unit is msec,specify the value from 1 to 32000msec as the time took for motion.
L P[1] 50deg/sec FINE When the mode of motion is rotation about the tool center point, specify an angular displacement as follows: F F F
When the unit is deg/sec, specify an angular displacement from 1 to 272 deg/sec. When the unit is sec, specify the value from 0.1 to 3200sec as the time took for motion. When the unit is msec,specify the value from 1 to 32000msec as the time took for motion.
Specifying the feedrate with a register The feedrate can be specified with a register. This allows the user to specify the feedrate for an operation instruction after calculating the feedrate using a register. The feedrate can also be specified externally, using group input (GI) or data transfer, for example. CAUTION This function allows the user to change the feedrate of a robot freely by setting a register. This means that the robot may operate at an unexpected speed depending on the specified register value. When using this function, specify the register value with great care during both teaching and operation. The format in which an operation instruction is displayed when the feedrate is specified with a register F F F
F
Joint Linear Arc
J P[1] R[i]% FINE L P[1] R[i]mm/sec FINE C P[1] P[2] R[i]mm/sec FINE Pallet operation instruction J PAL_1[A_1] R[i]% FINE J PAL_1[BTM] R[i]% FINE J PAL_1[R_1] R[i]% FINE
NOTE The pallet operation instruction is a software option of palletizing. F
Pallet operation instruction J PAL_1[A_1] R[i]% FINE J PAL_1[BTM] R[i]% FINE J PAL_1[R_1] R[i]% FINE
NOTE The pallet operation instruction is a software option of palletizing. Operation group instruction
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Asynchronous operation group GP1 JP[1] R[i]% FINE GP2 JP[1] R[i]% FINE NOTE The operation group instruction is a software option of multimotion. The feedrate for a standard operation instruction is also supported. Search/replace functions -- Search function The search function is not supported. Search using register items cannot be performed. -- Replace function Replacement is possible with the operation statement modification item. Replacement using register items cannot be performed. The additional axis feedrate for an operation addition instruction is not supported. In program editing, a range check is not performed on the feedrate (register value). The feedrate (register value) is not automatically converted when the feedrate unit is changed. If the feedrate specification for an operation statement is made with a register, the read--ahead of execution is stopped. (It is possible to specify whether to stop read--ahead using a system variable. This is described later.) If the value entered in the register is not within the upper and lower limits, or if the value is of a type other than those appropriate to a feedrate (integer/real), an alarm is generated during execution. Allowable range
Unit % sec msec mm/sec cm/min inch/min deg/sec
1 to 100 0.1 to 3200.0 1 to 32000 1 to 2000 1 to 12000 0.1 to 4724.2 1 to 272
Integer (*1) Real/effective up to the first decimal place. (*1) Integer (*1) Integer (*1) Integer (*2) Real/effective up to the first decimal place. (*3) Integer
The allowable range (maximum value) differs depending on the robot type. *1: System variable $MPR_GRP.$SPPEDLIM *2: System variable $MPR_GRP.$SPPEDLIM/10 *3: System variable $MPR_GRP.$ROTSPEEDLIM * 180/3.1415 Read--ahead can be enabled. If the feedrate specification for an operation statement is made with a register, the read--ahead of execution is stopped. It is possible to specify whether to stop read--ahead using the following system register. The default is FALSE (read--ahead is stopped). $RGSPD_PREXE = TRUE: Enables read--ahead. = FALSE: Disables read--ahead. NOTE If the read--ahead of the register feedrate is enabled with the above system variable, it is possible that the new value is not reflected in the operating speed, causing the robot to move with the old value, depending on the timing at which the register value is changed. If read--ahead of the register feedrate is enabled, it is necessary to take appropriate measures such as interlocking or not changing the value of the register used for the feedrate during program execution. 10: R [1] = 100 11:J P[5] R[1]% FINE 12:R[1]=10 14:J P[6] R[1]% FINE If read--ahead is enabled, 100 on line 10, not 10 on line 12, is used for the operating speed on line 14.
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4.3.4 Weld speed statement This function is used to specify a weld speed as a weld condition. The weld voltage, weld current, and weld speed can all be managed as weld conditions. The weld speed and units need not be coded in the program. If the motion speed setting in a motion instruction is changed to WELD_SPEED, the robot will operate at the weld speed specified in the ARC START schedule, executed prior to the motion instruction.
1 L P[1] 50 50
cm/min FINE
REGISTER
WELD
1 L P[1] WELD_SPEED WELD_SPEED SPEED
[CHOICE]
FINE
REGISTER
The units can be specified from the weld system setup screen. Provided the following conditions are satisfied, however, the robot will operate not at the speed specified as a weld schedule but at the standard speed specified from the weld system setup screen. F
Single step mode is selected.
F
Motion instructions including a weld speed statement are executed without execution of the ARC START statement.
F
Backward execution is performed.
Sample program 12: 13: 14: 15:
L L L L
P[10] P[11] P[12] P[13]
500 mm/sec WELD_SPEED WELD_SPEED WELD_SPEED
FINE ARCSTART[10] CNT100 CNT100 FINE ARCEND[10]
The motion speeds of the 13th, 14th, and 15th lines are the weld speed specified for ARC START schedule 10. NOTE If the speed specified in the following program is adjusted from the On--The--Fly screen while the second line is being executed, the operation coded in the third line will be executed at the original speed. 1: L P[1] 500 mm/sec FINE ARCSTART[10] 2: L P[2] WELD_SPEED CNT100 3: L P[3] WELD_SPEED CNT100 WARNING In the same way as the register speed statement, the weld speed statement is such that the speed cannot be easily checked by a program because the motion speed is set from the weld schedule screen. Failure to make this setting correctly could, therefore, cause the robot to move at an unexpected speed. Before a program is executed to start operation, the speed should be checked on the weld schedule screen.
WARNING The units in which speed is specified in the weld speed statement are specified as the WELD SPEED FUNCTION DEFAULT UNIT on the weld system setup screen. The units cannot be easily checked by the program. If motion instructions including a weld speed statement are executed without first checking the units used to specify the speed, the robot may move at an unexpected speed. Before a program is executed to start operation, the units used to specify the speed must be checked on the weld system setup screen.
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WARNING Provided the following conditions are satisfied, the execution of motion instructions including a weld speed statement causes the robot to move at the speed specified for WELD SPEED FUNCTION DEFAULT SPEED on the weld system setup screen. D Single step mode is selected. D Motion instructions including a weld speed statement are executed without execution of the ARC START statement. D Backward execution is performed. If the operator fails to apply the precautions given above, the robot may move at an unexpected speed. WARNING After the default speed or units have been modified, the power must be briefly turned off, then on again, in order for the settings to take effect. If you do not do this, the robot will move at an unexpected speed.
4.3.5 Positioning path The positioning path defines the method of ending robot operation in a motion instruction. Two positioning path modes are available: F
FINE positioning path
F
CNT positioning path
FINE positioning path J P[i] 50% FINE When the FINE positioning path is specified, the robot stops at a target point before moving to the next target point. CNT positioning path J P[i] 50% CNT50 When the CNT positioning path is specified, the robot approaches a target point but does not stop at the point and moves to the next point. How closely the robot must approach a target point can be defined by specifying a value from 0 to 100. When 0 is specified,the robot moves the nearest path to the destination position but moves to the next target point without stopping at the target point. When 100 is specified, the robot moves along the farthest path to the target point because the robot does not decelerate near the target point and it starts to move to the next target point soon. NOTE When an instruction such as a wait instruction is taught, the robot stops at the target point to execute that instruction. NOTE Several short--distance, high--speed motions that are performed continuously with CNT specified may be decelerated, even if the specified CNT value is 100.
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4. PROGRAM STRUCTURE
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Figure 4--17. Robot motion path using CNT continuous termination type
Next point P3 Target point P2
FINE CNT 0 CNT 50 CNT 100
Start point P1
4.3.6 Additional motion instructions An additional motion instruction causes the robot to perform a particular job. The following additional motion instructions are available: F
Wrist joint motion instruction (Wjnt)
F
Acceleration override instruction (ACC)
F
Skip instruction (Skip,LBL[i])
F
Offset condition instruction (Offset)
F
Direct offset condition (Offset,PR[i])
F
Tool offset instruction (Tool_Offset)
F
Direct tool offset instruction (Tool_Offset, PR[i])
F
Incremental instruction (INC)
F
Simultaneous EV instruction (EV i%)
F
Independent EV instruction (Ind.EV i%)
F
Path instruction (PTH)
F
Pre--execution instruction (pre--execution/post--execution) (!Section 9.8, “Pre--execution Instruction”)
F
Arc welding instruction
When teaching an additional motion instruction, move the cursor after the motion instruction, then press the F4 (CHOICE) to display the list of additional motion instructions. Then select a desired additional motion instruction.
JOINT 30% 4/5 500mm/sec CNT10 CHOICE
Motion Modify 1 No option 2 Wrist Joint 3 Offset 4 Offset.PR[ ] PROGRAM1
JOINT 30% 5 Incremental 6 Skip,LBL[ ] 7 8
F4
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Wrist joint motion instruction L P[i] 50% FINE Wjnt
Motion Modify 1 No option 2 Wrist Joint 3 Offset 4 Offset,PR[ ]
5 In 6 Sk 7 8
The wrist joint motion instruction specifies a path control operation that does not control the attitude of the wrist. (In the standard mode, the attitude of the wrist is controlled until the end of the motion.) The wrist joint motion instruction is used when a linear motion or circular motion is specified. When the wrist joint motion instruction is used, the attitude of the wrist changes during the motion. However, the tool center point can move along a programmed path without causing the wrist axis to invert due to a wrist axis singularity point. Acceleration override J P[1] 50% FINE ACC200 Motion modify 1 No option 2 Wrist Joint 3 ACC 4 Skip,LBL[] PROGRAM1
This instruction specifies the percentage of the acceleration/deceleration rate during motion. When the acceleration override is reduced, acceleration time will be long (Acceleration and deceleration are done slowly). To perform a potentially dangerous operation such as hot water scooping, use an ACC value of less than 100%. When acceleration override is raised, acceleration time will be short (Acceleration and decelerate are done quickly). For portions where the operation is felt to be very slow, use an ACC value greater than 100%. The time used for motion from a starting point to a destination point depends on the acceleration override. The acceleration override value ranges from 0 to 150%. Acceleration override is programmed at the destination position. Figure 4--18. Acceleration Override ACC = 100
Acceleration
Deceleration
Programmed Speed
ACC = 50
Deceleration Acceleration
CAUTION If the acceleration override value is large, awkward movement and vibration may occur. This may cause a servo alarm. If this occurs with an operation instruction to which an acceleration/deceleration override instruction is added, either reduce the acceleration/deceleration override value or delete the accelerate/deceleration override instruction.
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4. PROGRAM STRUCTURE
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Skip instruction SKIP CONDITION [I/O] = [value]
J P[1] 50 FINE Skip,LBL[3]
JOINT 30% 5 Incremental 6 Skip,LBL[ ] 7 8
A skip instruction causes a jump to a branch destination label if the skip condition is not satisfied. If the skip condition is satisfied while the robot is moving to a target point, the robot cancels the motion and program execution proceeds to the program statement on the next line. If the skip condition is not satisfied, program execution skips (jumps) to the line of the branch destination label after completion of the robot motion. The skip condition instruction specifies, in advance, a skip condition (condition for executing a skip instruction) to be used with it. Before a skip instruction can be executed, a skip condition instruction must be executed. A skip condition once specified is valid until the execution of the program is completed, or the next skip condition instruction is executed. (For the branch instructions, see Section 4.7. For the skip condition instruction, see Section 4.9.) Figure 4--19. Skip Instruction
When DI[1] is not entered P2 P4
P1 When DI[1] is entered Example
1: 2: 3: 4: 5: 6:
P3
SKIP CONDITION DI[1] = ON J P[1] 100% FINE L P[2] 1000mm/sec FINE Skip, LBL[1] L P[3] 50% FINE LBL[1] J P[4] 50% FINE
High--speed skip Function outline (1) The position of the robot when the skip conditions are met can be stored in programmed position registers. (2) Digital servo control stops the robot quickly by developing the maximum torque of the motor when the robot detects that the skip conditions are met. Use method The high--speed skip function can be used in program teaching. There is no need to set system variables. Program teaching a) Teaching skip conditions The skip conditions for the high--speed skip function are taught in the same way as the ordinary skip function. b) Teaching a high--speed skip instruction (an additional operation instruction) In the same way as the ordinary line skip instruction, select the high--speed skip instruction from the additional operation instruction menu.
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4. PROGRAM STRUCTURE
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Motion modify 1 Skip, LBL, PR 3 Skip, LBL,
JOINT 30%
High--speed skip instruction Ordinary skip instruction
c) Specify the label, position register, and position storage format. Skip, LBL[10], PR[5]=LPOS or JPOS
[Sample program] : 8: SKIP CONDITION SDI[3]=ON : 10: LP[2]500mm/sec FINE 11: LP[3]100mm/sec : SKIP, LBL[10], PR[5]=LPOS : : 30: LBL[10]
Explanation of the execution example When SDI[3] is turned on during execution of the 11th line, the current position is stored in a form of Cartesian coordinates. When SDI[3] is not turned on during execution of the 11th line, a branch to LBL[10] is made after the execution of the 11th line ends. In this case, no position data is stored in PR[5]. Limitations and notes <1> Position read error As the programmed operation speed is slower, the position read accuracy under skip conditions becomes higher. (As a guideline, an error of about 1.5 mm is generated for 100 mm/sec. The error is proportional to the speed.)
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OFFSET instruction Offset,PR[2] (UFRAME [1]) J P[1] 50% FINE Offset
5 6 7 8
JOINT 30 % Offset Offset,PR[ ] Incremental ---next page---
The OFFSET instruction alters positional information programmed at the destination position by the offset amount specified by a position register, and moves the robot to the altered position. The offset condition is specified by the OFFSET CONDITION instruction. The OFFSET CONDITION instruction specifies the offset amount used by the OFFSET instruction in advance. The OFFSET CONDITION instruction has to be specified before the OFFSET instruction is executed. The specified offset condition is available until the program is finished or the next OFFSET CONDITION instruction is executed. For an offset condition, the following elements should be specified: F F F
The position register specifies the shifting direction and the shift amount. When the positional information is expressed in the joint frame, the shift amount of each axis is applied. When the positional information is expressed in the Cartesian coordinate system, the user frame by which the offset condition is decided should be specified.(See Section 4.12, “FRAME INSTRUCTION) When it is not specified, the user frame (UF) being selected now is used.(See Section 4.10, “OFFSET CONDITION INSTRUCTION”) CAUTION
If teaching is done by joint coordinates, changing the user coordinate system does not affect the position variables and position registers. If teaching is performed in orthogonal format, and the user coordinate system input option is not used, the position variable is not influenced by the user coordinate system. In other cases, both the position variable and position register are influenced by the user coordinate system. The setting values of the tool frame number (UT) and the configuration (CONF:) are ignored. When you teach or edit the positional information of the motion instruction with the OFFSET option, you can teach the position which is subtracted the offset amount. When you teach or edit the positional information of the motion instruction with the OFFSET option, the prompt message is displayed to inquire the following element. F
Subtract offset data from current pos? -- Yes The positional information minus the offset data is taught. -- No The positional information is directly taught.
F
Enter PR index of offset data : -- Enter the number of the position register specified in the OFFSET CONDITION instruction.
F
Enter uframe no of offset data : -- Enter the number of the user frame which is used when the offset amount is subtracted.
When the positional information is manually edited with the numerical keys, you can not teach the positional information subtracted the offset amount. Even if the position teaching by which the amount of the correction is subtracted is effective, the current position will be taken in the following cases as it is. F F
The specified position register is non--initialization. “Ignore Offset command” is set to ENABLED. (See Section 3.22 “Setting the general items”)
When “Ignore Offset command” is set to ENABLED, the current position is directly taught as the positional information (The prompt message is not displayed) and the robot stops at the teaching position even if the OFFSET instruction is executed. When the offset amount is changed after the program is paused while the OFFSET instruction is on progress,this change is reflected in the motion after the program is resumed. But, when you change the number of a position register in the OFFSET CONDITION instruction, this change is not reflected to the motion. The robot moves to the offset position at the backward execution.(See Section 6.3.2,“Step test”) This is the same as the following explanation for the direct offset condition instruction.
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4. PROGRAM STRUCTURE
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Direct offset condition instruction J P[1] 50% FINE Offset,PR[2]
5 6 7 8
JOINT 30 % Offset Offset,PR[ ] Incremental ---next page---
The direct offset condition instruction alters positional information by the offset amount directly specified in the position register without using the offset condition specified in the OFFSET CONDITION instruction. The reference frame is specified by the number of the user frame currently selected. CAUTION If teaching is done by joint coordinates, changing the user coordinate system does not affect the position variables and position registers. If teaching is performed in cartesian format, and the user coordinate system input option is not used, the position variable is not influenced by the user coordinate system. In other cases, both the position variable and position register are influenced by the user coordinate system. When you change or edit the motion instruction with the direct offset condition option, you can teach the positional information by subtracting the offset amount. When you teach or edit the motion instruction with the direct offset condition option,the prompt message is displayed to inquire the following elements: F Subtract offset data from current pos? -- Yes The positional information subtracted the offset data is taught. -- No The positional information is directly taught. When the positional information is manually edited with the numerical keys, you can not teach the positional information subtracted from the offset amount. Moreover, even if the position teaching by which the offset amount is subtracted is effective, the current position will be taught as it is in the following cases: F The specified position register is non--initialized. F The position register number used by direct offset condition instruction is non--initialized. F “Ignore Offset command” is set to ENABLED.(See Section 3.22 “Setting the general items”) When the “Ignore Offset command” is set to ENABLED,the current position is directly taught as the positional information (The prompt message is not displayed) and the robot stops at the teaching point even if the offset instruction is executed. Figure 4--20. Offset Instruction Z PR [1]
Y X User frame which is being selected
P1
Offset data PR [1] UF: F 0.000 W: X: Y: 300.000 P: Z: 100.000 R:
P2 Example 1
1: OFFSET CONDITION PR[1] 2: J P[1] 100% FINE 3: L P[2] 500mm/sec FINE Offset
Example 2
1: J 2: L
P[1] 100% FINE P[2] 500mm/sec FINE Offset, PR[1]
185
UT:F 0.000 0.000 0.000
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Tool offset instruction TOOL_OFFSET_CONDITION PR[2] ( UTOOL[1] ) J P[1] 50% FINE Tool_offset
5 6 7 8
JOINT 30 % Tool_Offset Tool_Offset,PR[ Incremental ---next page---
A tool offset instruction moves the robot to the position shifted from the target position, recorded in the position data, by the offset specified in the tool offset conditions. The condition when the offset is applied is specified by a tool offset condition instruction. A tool offset condition instruction specifies the offset condition used in a tool offset instruction. Execute a tool offset condition instruction before executing the corresponding tool offset instruction. Once the tool offset condition has been specified, it remains effective until the program terminates or the next tool offset condition instruction is executed. Note the following when specifying tool offset conditions. F
The position register specifies the direction in which the target position shifts, as well as the amount of shift.
F
The tool coordinate system is used for specifying offset conditions.
F
When the number of a tool coordinate system is omitted, the currently selected tool coordinate system is used.
When a motion statement which includes a tool offset instruction is taught or a certain position is modified, the position to which the offset is not to be applied can be taught. When a motion statement which includes a tool offset instruction is taught or a certain position is modified, the system prompts the operator to respond to enter data in response to the following messages. F
Subtract tool offset data? -- Pressing the YES soft key subtracts the tool offset from the position data and the robot is taught the new position. -- Pressing the NO soft key stores the current position as the position data.
F
Enter PR index of tool offset data? -- Specify the position--register number specified by the tool offset condition instruction.
F
Enter tool no. of tool offset data? -- Specify the number of the tool coordinate system in which the offset is to be specified.
When the position data is manually modified with the numeric keys, the position is taught without subtracting the offset. Even when teaching the position from which the offset is subtracted is enabled, the current position is stored in the following cases. F
When the specified position register has not yet been initialized
F
When “Ignore Tool--offset” is set to ENABLED. (See Section 3.22 “Setting the general items”.)
When “Ignore Tool--offset” is set to ENABLED, the current position is taught as position data (no prompt messages are output) and the robot is moved to the taught position, even if a tool offset instruction is executed. When the robot is temporarily stopped during the execution of a tool offset instruction and the shift distance is modified, the modified distance is used in the resumed movement. When a position register number specified by a tool offset condition instruction is modified, the modified number is not used. In backward execution (See Section 6.3.2, “Step test”), the robot is moved to the position to which the offset has been applied. This also applies to the direct tool offset instruction, described next.
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Direct tool offset instruction J P[1] 50% FINE Tool_Offset, PR[2]
5 6 7 8
JOINT 30 % Tool_Offset Tool_Offset,PR[ Incremental ---next page---
The robot moves according to the offset stored in the specified position register, ignoring the tool offset conditions specified by the tool offset condition instruction. The currently selected tool coordinate system is used. When a motion statement which includes a direct tool offset instruction is taught or a certain position is modified, the position to which the offset is not to be applied can be taught. When a motion statement which includes a direct tool offset instruction is taught or a certain position is modified, the system prompts the operator to enter data in response to the following messages. F
Subtract tool offset data? -- Pressing the YES soft key subtracts the tool offset from the position data and the robot is taught the new position. -- Pressing the NO soft key stores the current position as position data.
When the position data is manually modified with the numeric keys, the position is taught without subtracting the offset. When teaching the position from which the offset is subtracted is enabled, the current position is stored in the following cases. F
When the specified position register has not yet been initialized
F
When the direct tool offset instruction has not specified the number of a position register
F
When “Ignore Tool--offset” is set to ENABLED. (See Section 3.22 “Setting the general items”.)
When “Ignore Tool--offset” is set to ENABLED, the current position is taught as position data (no prompt messages are output) and the robot is moved to the taught position even if a tool offset instruction is executed. Figure 4--21. Tool Offset Instruction
Z
Y
P2
X
Z P1
Y
Currently selected tool coordinate system OFFSET DATA
X X: Y: Z:
PR [1] UF: F UT: F 0.000 W: 0.000 0.000 P: 0.000 0.000 10.000 R:
Example 1
1: TOOL_OFFSET CONDITION PR[1] 2: J P[1] 100% FINE 3: L P[2] 500mm/sec FINE Tool_Offset
Example 2
1: J P[1] 100% FINE 2: L P[2] 500mm/sec FINE Tool_Offset, PR[1]
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Incremental instruction J P[1] 50% FINE INC
5 6 7 8
JOINT 30 % Offset Offset,PR[ ] Incremental ---next page---
The incremental instruction uses the positional data in the motion instruction as the incremental amount from the current position, and causes the robot to move to the destination position that the incremental amount is added to the current position. This means that the incremental motion amount from the current position is recorded in the positional data in the motion instruction. The incremental condition is specified by the following elements: F
When the positional data is joint frame value, the incremental amount of each axis is applied.
F
When the positional variable (P[]) is used as the positional data, the reference user frame is specified by the number of the user frame which is specified in the positional data. However, the frame is verified.(For the cartesian coordinate system reference, See Section 4.3.2)
F
When the position register is used as the position data, the reference frame is the user frame being selected now.
F
When the INC instruction is used with the OFFSET instruction, the type of the positional data in the motion instruction should correspond to the type of the positional register for the offset. In this case, the offset amount is used as the offset amount of the specified incremental amount.
Figure 4--22. Incremental instruction
Z User frame 2
Y P1
X
Position data P [2] UF: X: 500.000 Y: 100.000 Z: 100.000
Example
1: J 2: L
2 UT: W: P: R:
P2
1 0.000 0.000 0.000
P[1] 100% FINE P[2] 500mm/sec FINE INC
Note the following when teaching an incremental instruction (See Section 5.3.4, “Teaching a supplementary motion instruction”): F
Adding the INC option causes the positional data to be non--initialized.
F
When the motion instruction with the INC option is taught, the positional data is set to be non--teaching.
F
Editing the position in the motion instruction with the INC option removes the INC option automatically.
When the motion instruction with the INC option is paused and the position data is changed, that change is not immediately reflected. To move the robot to the changed position, resume the program from the just previous motion instruction.
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Simultaneous EV instruction J P[1] 50% FINE EV 50% Motion modify 1 Independent EV 2 Simultaneous EV 3 4 PROGRAM1
The additional axis speed instruction (synchronous) moves the robot in sync with the additional axis. When this instruction is used, the robot and additional axis operations are synchronized as follows: F
If the robot operation time is longer than the additional axis operation time, the additional axis operation is synchronized with the robot operation.
F
If the additional axis operation time is longer than the robot operation time, the robot operation is synchronized with the additional axis operation.
The extended axis speed is specified as a ratio (1% to 100%) to the maximum travel speed of the extended axis.
Independent EV instruction (Ind.EV i%) J P[1] 50% FINE Ind.EV 50% Motion modify 1 Independent EV 2 Simultaneous EV 3 4 PROGRAM1
The additional axis speed instruction (asynchronous) moves the robot asynchronously with the additional axis. When this instruction is used, the robot and the additional axis start moving at the same time, but stop at different times because they are not synchronized. The extended axis speed is specified as a ratio (1% to 100%) to the maximum travel speed of the extended axis. If a motion statement is not accompanied with either extended axis speed instruction, the extended axis moves in synchronization with the speed of the robot.
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Path instruction J P[1] 50% Cnt10 PTH Motion modify 1 Independent EV 2 Simultaneous EV 3 PTH 4 PROGRAM1
This function is designed to improve the performance of continuous motion (the termination type is Cnt1 to Cnt100) when the robot moves through a short distance. In a motion where the robot moves through a short distance, the robot speed cannot be increased to the speed specified by a motion statement. For this reason, in an operation statement for which the positioning format is “FINE,” operation planning for such an operation must be based on the “attainable speed,” the speed that the robot can actually attain, rather than the specified speed. (Motion planning entails calculating the path along which the robot will travel, before actual operation.) By using this instruction, operation planning is performed using the “attainable speed” in a CNT operation. The use of this function enables the following effects in normal operation: F
Improvement in cycle time
F
Improvement in path accuracy
This function is more effective as the movement distance is shorter and the Cnt value is smaller (the value n in Cntn is smaller). When using this function, note the following: In the following cases, use of the PTH instruction may actually incur a longer cycle time: Before using this function, therefore, confirm its effect. F
A large Cnt value is specified in a motion statement.
F
A motion statement causes the robot to move through a long distance.
F
Successive Cnt motion statements appear. CAUTION
Some motion instructions that use the PTH switch might cause jerky motion or vibration. If the motion that is attached to PTH has a vibration, delete the PTH motion option.
Arc welding instruction J P[1] 50% FINE Arc Start[i] An arc welding instruction is added, as an additional motion instruction, to a motion instruction (additional arc motion instruction). For details of the additional arc motion instructions listed below, see Chapter 4 (See Section 4.4.1). J J J J
P[1] P[1] P[1] P[1]
50% 50% 50% 50%
FINE FINE FINE FINE
Arc Arc Arc Arc
Start[1] Start[V,A] End[1] End[V, A, s]
When using an arc welding instruction as an additional motion instruction in combination with an offset instruction or tool compensation instruction, specify the arc welding instruction after the offset instruction or tool compensation instruction. f J P[1] 50cm/min FINE Offset Arc Start[1] × J P[1] 50cm/min FINE Arc Start[1] Offset
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4.4 Arc Instructions Arc instructions are used to direct when and how the robot should execute arc welding. F
Arc start instruction: Instructs the robot to start arc welding.
F
Arc end instruction: Instructs the robot to stop arc welding.
F
Weaving start instruction -- Specifies the start of weaving.
F
Weaving end instruction -- Specifies the end of weaving.
To teach an arc motion instruction, press the F2 or F4 key, then select a standard arc instruction (See Sections and 5.3.3).
To specify a single arc instruction, select F1, INST. A submenu is displayed. Then, select Arc from the submenu (see Section 5.3.5). Instruction 1 Registers 2 I/O 3 IF/SELECT 4 WAIT SAMPLE1
5 6 7 8
JOINT 30 % JMP/LBL CALL Arc ---next page---
4.4.1 Arc start instruction The arc start instruction is used to direct the robot to start arc welding. The following two types of arc start instructions are supported: F
Arc Start [i]: Specifies a welding condition number.
F
Arc Start [V, A]: Specifies the welding conditions.
Arc Start [i] The Arc Start [i] instruction starts arc welding according to predetermined welding conditions. Figure 4--23. Arc Start Instruction (Condition Number Specified)
Arc Start [ i ] Welding condition number (1 to 32) Example
1: Arc Start [32] 2: Arc Start [R[12]]
Welding condition screen
Arc Start [ 3 ] Welding condition number
DATA Weld Sched
Welding voltage
20.0Volts
Welding current
180.0Amps
1 2 3 4
(Volts) 16.0 18.0 20.0 22.0
(Amps) 140.0 160.0 180.0 200.0
JOINT
(sec) 0.00 Weld 0.00 Weld 0.00 Weld 0.15 Weld
30 % 1/32 COMMENT Schedule 1 Schedule 2 Schedule 3 Schedule 4
Example
NOTE When the arc start instruction is executed, the processing time specified as part of the welding conditions is ignored.
191
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Arc Start [V, A] The Arc Start [V, A, ...] instruction starts welding by directly specifying arc welding conditions such as a welding voltage and welding current (or wire feedrate). The types and number of conditions to be specified depend on the settings of the model of welding power supply and the number of analog input/output signals. Figure 4--24. Arc Start Instruction (Condition Values Specified)
Arc Start [ V, A ] Welding current ( 0.0 to 450.0A ) Welding voltage ( 0.0 to 50.0V )
Arc Start [ V, mm/sec ] Wire feed speed (0.0 to 500.0 mm/sec, cm/min, inch/min) Example
1: Arc Start [180V, 180.0A] 2: Arc Start [140V, 400.0cm/min]
4.4.2 Arc end instruction The arc end instruction is used to direct the robot to stop arc welding. The following two types of arc end instructions are supported: F
Arc End [i]: Specifies a welding condition number.
F
Arc End [V, A, s]: Specifies the welding conditions.
Arc End [i] The Arc End [i] instruction executes crater prevention, according to a predetermined welding condition, then stops arc welding. The crater prevention function decreases the voltage and current upon the completion of welding so that crater holes are not created by a sudden voltage drop. To suppress crater prevention, set TIME 0 as a welding condition. Figure 4--25. Arc End Instruction (Condition Number Specified)
Arc End [ i ] Welding condition number (1 to 32) Example
1: Arc End [11] 2: Arc End [R[31]]
Welding condition screen
Arc End [ 4 ] Welding condition number
DATA Weld Sched
Crater prevention voltage
20.0 Volts
Crater prevention current Crater prevention time
200.0 Amps 0.15 sec
1 2 3 4
192
(Volts) 16.0 18.0 20.0 22.0
(Amps) 140.0 160.0 180.0 200.0
JOINT
(sec) 0.00 Weld 0.00 Weld 0.00 Weld 0.15 Weld
30 % 1/32 COMMENT Schedule 1 Schedule 2 Schedule 3 Schedule 4
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Arc End [V, A, s] The Arc Start [V, A, sec] instruction performs crater processing at the end of arc welding by directly specifying the conditions of crater processing such as a crater processing voltage, crater processing current (or wire feedrate), and crater processing time. The types and number of conditions to be specified depend on the settings of the model of the welding power supply and the number of analog input/output signals. Figure 4--26. Arc End Instruction (Condition Values Specified)
Arc End [ V, A, sec ] Crater prevention time (0.0 to 9.9 sec) Crater prevention current (0.0 to 450.0 A) Crater prevention voltage (0.0 to 50.0 V)
Arc End [ V, mm/sec, sec] Wire feed speed (0.0 to 500.0 mm/sec, cm/min, inch/min)
Example
1: Arc End [54.0V, 33.0A, 0.3sec] 2: Arc End [62.0V, 5.0mm/sec, 0.1sec]
Figure 4--27. Sequence of Crater Prevention Processing Weld start
Welding voltage
Crater prevention voltage
Specified voltage Start--up voltage
Postprocessing voltage Postprocessing time
Specified current Start--up current
Welding current
Arc detection
Crater prevention current Crater prevention time
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4.4.3 Weaving The weaving instructions direct the robot to perform weaving. The term “weaving” refers to arc welding in which the welding torch cyclically sweeps right and left at a certain angle with the direction of welding. Weaving is intended to increase the width of beads, thereby intensifying the strength of welding. Once started by the weaving start instruction, weaving continues until the weaving end instruction is executed. Figure 4--28. Weaving Tool coordinate system + Z direction
Z
Pitch
a
Welding speed Frequency
Weaving plane
Y
Welding speed
Move direction Pitch
Amplitude
X
The weaving instructions include: F
Weave (pattern) [i] instruction
F
Weave (pattern) [Hz, mm, sec, sec] instruction
F
Weave End instruction
To teach the weaving instructions to the robot, click F1 [INST] to display the related submenu, then select [Weave] from the submenu (see Section 5.3.5, “Teaching of the weaving instruction”). Instruction 1 Miscellaneous 2 Weave 3 Skip 4 Payload WELD_1
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JOINT 10 % Track Offset Offset Frames program control ---next page---
The weaving instructions specify the following weaving patterns: F
Weave Sine
F
Weave Circle
F
Weave Figure 8
F
Weave L
NOTE The following restrictions are placed on Weave L. F
“Centerise” is disabled.
F
It is impossible to use TAST, AVC, RPM & MPass, MIG EYE, Soft float, Space check, and Continuous turn.
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Figure 4--29. SIN--type Weaving
Y Left end point
Y
Amplitude
X
X Travel speed
Right end point
Figure 4--30. Circular Weaving
Y
Y Amplitude
X
X Travel speed
Radius
Figure 4--31. 8--shaped Weaving
Y
Y Amplitude
X
X
Radius
Travel speed
Figure 4--32. L--pattern weaving
Z
Z Travel speed Amplitude
Y
Y X
X
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Weave (pattern) [i] The Weave (pattern) [i] instruction starts weaving according to a weaving condition and pattern specified beforehand. Figure 4--33. Weaving Start Instruction
Weave (pattern) [ i ] Weaving pattern Example
Weaving condition (1 to 16)
1: Weave Sine[1] 2: Weave Circle[2] 3: Weave Figure 8[R[31]]
Weaving condition
Weave Sine [ 4 ] Weaving condition number Frequency Amplitude Dell time at the left end Dwell time at the right end
DATA Weave Sched
10 % 1/10 FREQ(Hz) AMP(mm) R_DW(sec) L_DW(sec) 1 1.0 4.0 .100 .100 2 1.0 4.0 .100 .100 3 1.0 4.0 .100 .100 4 1.0 4.0 .100 .100 5 1.0 4.0 .100 .100 6 1.0 4.0 .100 .100 7 1.0 2.0 .100 .100 8 1.0 2.0 .100 .100 9 2.0 2.0 .100 .100
1.55 Hz 1.00 mm 0.150 sec 0.150 sec
[ TYPE ]
JOINT
DETAIL
HELP >
Weave (pattern) [Hz, mm, sec, sec] The Weave (pattern) [Hz, mm, sec, sec] instruction starts weaving by directly specifying weaving conditions such as a frequency, amplitude, dwell time at the left end, and dwell time at the right end. Figure 4--34. Weaving Start Instruction (Condition Description)
Weave (pattern) [ Hz. mm, sec, sec, deg ] Frequency (0.0 to 99.9 Hz)
Angle for L--pattern weaving (only for L-pattern weaving)
Amplitude (0.0 to 25.0 mm)
Dwell time at the right end Dwell time at the left end (0.0 to 1.0 sec)
Example
1: Weave Sine[5.0Hz, 20.0mm, 1.0s, 1.0s] 2: Weave Circle[1.0Hz, 2.0mm, 1.0s, 1.0s] 3: Weave Figure 8[1.0Hz, 2.0mm, 1.0s, 1.0s]
Weave End The Weave End instruction ends weaving in progress. Figure 4--35. Weave End Instruction
Weave End
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4.4.4 TRACK{Sensor} instruction The TRACK{Sensor} instruction specifies sensing using an arc sensor. The arc sensor function applies compensation to robot operation so that the value of current that flows between the welding wire and workpiece can be maintained at a certain level. So, this function ensures proper welding even if a workpiece is slightly displaced. The TRACK{Sensor} instruction is divided into two types: F
Track TAST[i] instruction
F
Track End instruction
To teach the TRACK{Sensor} instruction, display the submenu by pressing F1 (INST), then select T. (For teaching of the TRACK{Sensor} instruction, see Section 5.3.5.) Instruction 1 Miscellaneous 2 Weave 3 Skip 4 Track PROG
JOINT 30% 5 Offset 6 7 8 ---next page---
The Track TAST[i] instruction starts sensing using an arc sensor according to an arc sensor condition specified beforehand. Figure 4--36. Track TAST[i] Instruction
Trak TAST [ i ] Arc sensor condition number (1 to 32) Example
1: Trak TAST[R[1]] 2: Trak TAST[2] [End]
Arc sensor condition list screen
Track TAST [ 3 ] Arc sensor condition number Up/down gain Left/right gain Up/down reference voltage Up/down bias Left/right bias
DATA Weave Sched
25.5 24.0 180.0Amps 4.0% 1.0%
1 2 3 4 5 6 7 8 9
V-Gain-L V_Cur(A) 25.0 20.0 40.0 25.0 20.0 0.0 25.0 20.0 0.0 25.0 20.0 0.0 25.0 20.0 0.0 25.0 20.0 0.0 25.0 20.0 0.0 25.0 20.0 0.0 25.0 20.0 0.0
[ TYPE ]
Track End The Track End instruction ends sensing using an arc sensor. Figure 4--37. Track End Instruction
Track End Example
Trak End
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DETAIL
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10 % 1/20 V-Bias(%)-L 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 HELP >
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4.5 Register Instructions The register instructions perform arithmetic operations on registers. The following register instructions are available: Instruction 1 Registers 2 I/O 3 IF/SELECT 4 WAIT PROGRAM
5 6 7 8
JOINT 30% JMP/LBL CALL Palletizing ---next page---
Register instructions Position register instructions F Position register axis instructions In register operations, polynomial operations such as those shown below are possible: F F
Example
1: R[2]=R[3]--R[4]+R[5]--R[6] 2: R[10]=R[2]*[100/R[6] The following restrictions are imposed: F
F
Up to five operators can be written on a single line. Example 1: R[2]=R[3]+R[4]+R[5]+R[6]+R[7]+R[8] Up to five operators The “+” and “--” operators can be mixed on a single line. So can the “*” and “/” operators. “+” and “--” cannot, however, be mixed with “*” and “/”.
4.5.1 Register instructions A register instruction performs an arithmetic operation on registers. A register is a variable for holding an integer or a decimal fraction. (For registers, See Section 7.3.) Two hundreds registers are provided. R[i] = (value) The instruction, R[i] = (value), loads a value into a specified register. Figure 4--38. Instruction R[i] = (value)
R [ i ] = (value) Register number(1 to 200)
Constant Value of R[i] R[i] : PR [ i, j ] : Value of position register element [i, j] GI [ i ] : Group input signal GO [ i ] : Group output signal AI [ i ] : Analog input signal AO [ i ] : Analog output signal SDI [ i ] : System digital input signal SDO [ i ] : System digital output signal RDI [ i ] : Robot digital input signal RDO [ i ] : Robot digital output signal SI [ i ] Operation panel input signal SO [ i ] : Operation panel output signal UI [ i ] : Peripheral device input signal UO [ i ] : Peripheral device output signal Timer [ i ] : Value of program timer [i] Timer overflow [ i ] : Overflow flag of program timer [i] 0: The timer has not overflowed. 1: The timer has overflowed.
WI [ i ] : WO [ i ] :
Welding input signal Welding output signal
* The timer overflow flag is cleared with the timer [i] = reset instruction. Example
1: R[1] = RDI[3] 2: R[R[4]] = AI[R[1]]
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R[i] = (value) + (value) The instruction, R[i] = (value) + (value), loads the sum of two values into a specified register. R[i] = (value) -- (value) The instruction, R[i] = (value) -- (value), loads the difference between two values into a specified register. R[i] = (value) * (value) The instruction, R[i] = (value) * (value), loads the product of two values into a specified register. R[i] = (value) / (value) The instruction, R[i] = (value) / (value), loads the quotient of two values into a specified register. R[i] = (value) MOD (value) The instruction, R[i] = (value) MOD (value), loads the remainder (value after decimal point) of the quotient of two values into a specified register. R[i] = (value) DIV (value) The instruction, R[i] = (value) DIV (value), loads the integer of the quotient of two values into a specified register. R [ i ] = ( x -- ( x MOD y ) ) / y Figure 4--39. Arithmetic Register Instruction Register number(1 to 200)
R [ i ] = (value) (operator) (value) + -* / MOD DIV
Constant Value of R[i] R[i] : PR [ i, j ] : Value of position register element [i, j] GI [ i ] : Group input signal GO [ i ] : Group output signal AI [ i ] : Analog input signal AO [ i ] : Analog output signal SDI [ i ] : System digital input signal SDO [ i ] : System digital output signal RDI [ i ] : Robot digital input signal RDO [ i ] : Robot digital output signal SI [ i ] Operation panel input signal SO [ i ] : Operation panel output signal UI [ i ] : Peripheral device input signal UO [ i ] : Peripheral device output signal Timer [ i ] : Value of program timer [i] Timer overflow [ i ] : Overflow flag of program timer [i] 0: The timer has not overflowed. 1: The timer has overflowed.
WI [ i ] : WO [ i ] :
Welding input signal Welding output signal
* The timer overflow flag is cleared with the timer [i] = reset instruction. Example
3: R[3:flag] = SDI[4]+PR[ 1, 2 ] 4: R[ R[4] ] = R[1]+1
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4.5.2 Position register instructions A position register instruction performs an arithmetic operation on position registers. A position register instruction can load position data, the sum of two values, or the difference of two values, into a specified position register. A position register instruction uses the same format as a register instruction. A position register is a variable for holding position data (x,y,z,w,p,r). (For position registers, See Section 7.4.) One hundred position registers are provided. NOTE Before using position register instructions, lock position registers by specifying LOCK PREG. When position register instructions are used with the position registers unlocked, operation may become tight. For the LOCK PREG instruction, see Section 9.6, “POSITION REGISTER LOOK--AHEAD EXECUTION FUNCTION.” PR[i] = (value) The instruction, PR[i] = (value), loads position data into a specified position register. Figure 4--40. Instruction PR[i] = (value)
PR [ i ] = (value) Position register number (1 to 100)
Example
PR [ i ] : P[i]: Lpos : Jpos : UFRAM [ i ] : UTOOL [ i ] :
Value of position register [i] Value of position [i] specified in the program Cartesian coordinates of the current position Joint coordinates of the current position Value of user coordinate system [i] Value of tool coordinate system [i]
1: PR[1] = Lpos 2: PR[ R[4] ] = UFRAME[ R[1] ] 3: PR[9] = UTOOL[1]
PR[i] = (value) + (value) The instruction, PR[i] = (value) + (value), loads the sum of two values into a specified register. The instruction, PR[i] = (value) -- (value), loads the difference of two values into a specified register. Figure 4--41. PR[i] Arithmetic Instruction
Position register number(1 to 100)
PR [ i ] = (value) (operator) (value) (operator) (value) .... PR [ i ] :
Value of position register [i] Value of position [i] P[i]: specified in the program Cartesian coordinate Lpos : s of the current position Joint coordinates of Jpos : the current position UFRAM [ i ] : Value of user coordinate system [i] UTOOL [ i ] : Value of tool coordinate system [i]
Example
+ --
4: PR[3] = PR[3]+Lpos 5: PR[4] = PR[ R[1] ]
200
PR [ i ] : Value of position register [i] P [ i ] : Value of position [i] specified in the program Lpos : Cartesian coordinates of the current position Jpos : Joint coordinates of the current position UFRAM [ i ] : Value of user coordi-nate system [i] UTOOL [ i ] : Value of tool coordi-nate system [i]
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4.5.3 Position register axis instructions A position register axis instruction performs an arithmetic operation on position register elements. i of PR[i,j] represents a position register number, and j of PR[i,j] represents a position register element number. The position register axis instructions can load the value of one position data element, or the sum, difference, product, or quotient of two values into a specified position register element. A position register axis instruction uses the same format as a register instruction. Figure 4--42. Format of PR[i,j]
PR [ i, j ] Position register number (1 to 100)
Position register element number Cartesian coordinate system: 1=X 2=Y 3=Z 4=W 5=P 6=R
Joint coordinate system: 1 = J1 2 = J2 3 = J3 4 = J4 5 = J5 6 = J6 n = Jn
PR[i,j] = (value) The instruction, PR[i,j] = (value), loads the value of a position data element into a position register element. Figure 4--43. Instruction PR[i,j] = (value)
PR [ i, j ] = (value) Constant Register [i] R[i] : PR [ i, j ] : Position register element [i, j] GI [ i ] : Group input signal GO [ i ] : Group output signal AI [ i ] : Analog input signal AO [ i ] : Analog output signal SDI [ i ] : System digital input signal SDO [ i ] : System digital output signal RDI [ i ] : Robot digital input signal RDO [ i ] : Robot digital output signal SI [ i ] Operation panel input signal SO [ i ] : Operation panel output signal UI [ i ] : Peripheral device input signal UO [ i ] : Peripheral device output signal Timer [ i ] : Value of program timer [i] Timer overflow [ i ] :
Position register number (1 to 100)
Overflow flag of program timer [i] 0: The timer has not overflowed. 1: The timer has overflowed.
WI [ i ] : WO [ i ] :
Welding input signal Welding output signal
* The timer overflow flag is cleared with the timer [i] = reset instruction. Example
1: PR[ 1, 2 ] = R[3] 2: PR[ 4, 3 ] = 324.5
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PR[i] = (value) + (value) The instruction, PR[i,j] = (value) + (value), loads the sum of two values into a specified position register element. PR[i] = (value) -- (value) The instruction, PR[i,j] = (value) -- (value), loads the difference of two values into a specified position register element. PR[i] = (value) * (value) The instruction, PR[i,j] = (value) * (value), loads the product of two values into a specified position register element. PR[i] = (value) / (value) The instruction, PR[i,j] = (value) / (value), loads the quotient of two values into a specified position register element. R[i] = (value) MOD (value) The instruction, R[i] = (value) MOD (value), loads the remainder (value after decimal point) of the quotient of two values into a specified register. R[i] = (value) DIV (value) The instruction, R[i] = (value) DIV (value), loads the integer of the quotient of two values into a specified register. R [ i ] = ( x -- ( x MOD y ) ) / y Figure 4--44. PR[i,j] Arithmetic Instruction Position register number(1 to 100)
PR [ i ] = (value) (operator) (value) + -* / MOD DIV
Constant Register [i] R[i] : PR [ i, j ] : Position register element [i, j] GI [ i ] : Group input signal GO [ i ] : Group output signal AI [ i ] : Analog input signal AO [ i ] : Analog output signal SDI [ i ] : System digital input signal SDO [ i ] : System digital output signal RDI [ i ] : Robot digital input signal RDO [ i ] : Robot digital output signal SI [ i ] Operation panel input signal SO [ i ] : Operation panel output signal UI [ i ] : Peripheral device input signal UO [ i ] : Peripheral device output signal Timer [ i ] : Value of program timer [i] Timer overflow [ i ] : Overflow flag of program timer [i] 0: The timer has not overflowed. 1: The timer has overflowed.
WI [ i ] : WO [ i ] :
Welding input signal Welding output signal
* The timer overflow flag is cleared with the timer [i] = reset instruction. Example
1: PR[ 3, 5 ] = R[3]+DI[4] 2: PR[ 4, 3 ] = PR[ 1, 3 ]-3.528
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4.6 I/O Instructions The I/O (input/output signal) instructions are used to change the state of a signal output to peripheral devices and read the state of an input signal. Instruction 1 Registers 2 I/O 3 IF/SELECT 4 WAIT PROGRAM
F
(System) digital I/O instruction
F
Robot (digital) I/O instruction
F
Analog I/O instruction
F
Group I/O instruction
5 6 7 8
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NOTE As for the I/O signal, allocate the logical number to the physical number before using it.(For configuring I/O, See Section 3.8.)
4.6.1 Digital I/O instructions The digital input signal (DI) and digital output signal (DO) are input/output signals that can be controlled by the user. R[i] = DI[i] The instruction, R[i] = DI[i] loads the state of a digital input signal (on = 1/off = 0) into a specified register. Figure 4--45. Instruction R[i] = DI[i]
R [ i ] = DI [ i ] Register number (1 to 200) Example
Digital input signal number
1: R[1] = DI[1] 2: R[ R[3] ] = DI[ R[4] ]
SDO[i] = ON/OFF The instruction, SDO[i] = ON/OFF, turns on or off a specified digital output signal. Figure 4--46. Instruction SDO[i] = ON/OFF
DO [ i ] = (value) ON : Turns on the digital output signal. OFF: Turns off the digital output signal.
Digital output signal number
Example
3: SDO[1] = ON 4: SDO[ R[3] ] = OFF
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SDO[i] = PULSE,[TIME] The SDO[i] = PULSE, [TIME] instruction inverts the current status of a specified digital output for a specified duration. When no duration is specified, pulse output is executed for the duration specified with $DEFPULSE (0.1--second units). Figure 4--47. Instructions SDO[i] = PULSE,(WIDTH)
SDO [ i ] = PULSE, (value) Pulse width (sec) (0.1 to 25.5 sec)
Digital output signal number
Example
5: SDO[1] = PULSE 6: SDO[2] = PULSE, 0.2sec 7: SDO[ R[3] ] = PULSE, 1.2sec
SDO[i] = R[i] The instruction, SDO[i]=R[i],turns on or off a specified digital output signal according to the value of a specified register. When the value of the specified register is 0, the digital output signal is turned off. When the value of the specified register is other than 0, the digital output signal is turned on. Figure 4--48. Instruction SDO[i] = R[i]
SDO [ i ] = R [ i ] Register number (1 to 200)
Digital output signal number
Example
7: SDO[1] = R[2] 8: SDO[ R[5] ] =R [ R[1] ]
4.6.2 Robot I/O instructions The robot input signal (RDI) and robot output signal (RDO) are input/output signals that can be controlled by the user. SR[i] = RI[i] The instruction, R[i] = RI[i], loads the state of a robot input signal (on = 1/off = 0) into a specified register. Figure 4--49. Instruction R[i] = RI[i]
R [ i ] = RDI [ i ] Robot input signal number
Register number (1 to 200)
Example
1: R[1] = RDI[1] 2: R[ R[3] ] = RDI[ R[4] ]
RDO[i] = ON/OFF The instruction, ROD[i] = ON/OFF, turns on or off a specified robot digital output signal. Figure 4--50. Instruction RDO[i] = ON/OFF
RDO [ i ] = (value) ON : Turns on the robot output signal. OFF: Turns off the robot output signal.
Robot output signal number
Example
3: RDDO[1] = ON 4: RDDO[ R[3] ] = OFF
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RDO[i] = PULSE,[TIME] The RDO[i] = PULSE,[TIME] instruction inverts the current status of a specified digital output for a specified duration. When no duration is specified, pulse output is executed for the duration specified with $DEFPULSE (0.1--second units). Figure 4--51. Instruction of RDO[i] = PULSE,[WIDTH]
RDO [ i ] = PULSE, [ WIDTH ] Pulse width (sec) (0.1 to 25.5 sec)
Robot output signal number
Example
5: RDO[1] = PULSE 6: RDO[2] = PULSE, 0.2sec 7: RDO[ R[3] ] = PULSE, 1.2sec
RDO[i] = R[i] The instruction, RDO[i] = R[i], turns on or off a specified robot output signal according to the value of a specified register. When the value of the specified register is 0, the robot output signal is turned off. When the value of the specified register is other than 0, the robot output signal is turned on. Figure 4--52. Instruction RDO[i] = R[i]
RDO [ i ] = R [ i ] Register number (1 to 200)
Robot output signal number
Example
7: RDO[1] = R[2] 8: RDO[ R[5] ] = R[ R[1] ]
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4.6.3 Analog I/O instructions Analog input (AI) and analog output (AO) signals indicate levels as a value on a continuum. Thus, the magnitude of a signal represents a temperature, voltage, or other data. R[i] = AI[i] The R[i] = AI[i] instruction stores the value of an analog input signal in a register. Figure 4--53. R[i] = AI[i] Instruction
R [ i ] = AI [ i ] Analog input signal number
Register number (1 to 200)
Example
1: R[1] = AI[2] 2: R[ R[3] ] = AI[ R[4] ]
AO[i] = (value) The AO[i] = (value) instruction outputs a value as a specified analog output signal. Figure 4--54. AO[i] = (value) Instruction
AO [ i ] = (value) Value of analog output signal
Analog output signal number
Example
3: AO[1] = 0 4: AO[ R[3] ] = 3276
AO[i] = R[i] The AO[i] = R[i] instruction outputs a register value as an analog output signal. Figure 4--55. AO[i] = R[i] Instruction
AO [ i ] = R [ i ] Register number (1 to 200)
Analog output signal number
Example
5: AO[1] = R[2] 6: AO[ R[5] ] = R[ R[1] ]
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4.6.4 Group I/O instruction R [ i ] = GI [ i ] The signal of the group input(GI) and the group output(GO) is that some digital input/output signals are grouped and this group is controlled by one instruction. The instruction,R[i]=GI[i], converts the binary value of the specified group input signal to the decimal value and inputs it to the specified register. Figure 4--56. Instruction R [ i ] = GI [ i ]
R [ i ] = GI [ i ] Group input signal number
Register number ( 1 to 200 )
Example
7: R[1] = GI[1] 8: R[ R[3] ] = GI[ R[4] ]
GO [ i ] = (value) The GO[i]=(VALUE) instruction sends the binary equivalent of a value on the specified group output lines. Figure 4--57. Instruction GO [ i ] = ( value)
GO [ i ] = ( value ) Group output signal value
Group output signal number
Example
3: GO[1] = 0 4: GO[ R[3] ] = 32767
GO [ i ] = R [ i ] The GO[i]=R[i] instruction sends the binary equivalent of the contents of specified register on the specified group output lines. Figure 4--58. Instruction GO [ i ] = R [ i ]
GO [ i ] = R [ i ] Register number (1 to 200)
Group output signal number
Example
5: GO[1] = R[2] 6: GO[ R[5] ] = R[ R[1] ]
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4.6.5 Welding I/O instructions The welding input (WDI) and welding output (WO) signals are I/O signals that can be controlled by the user. R[i] = WDI[i] The R[i] = WDI[i] instruction stores the welding input status (On = 1, Off = 0) in a register. Figure 4--59. R[i] = WDI[i] Instruction
R [ i ] = WI [ i ] Welding input signal number
Register number (1 to 200)
Example
1: R[1] = WI[2] 2: R[ R[3] ] = WI[ R[4] ]
WO[i] = On/Off The WO[i] = On/Off instruction turns a specified welding output signal either on or off. Figure 4--60. WO[i] = On/Off Instruction
WO [ i ] = (value) On : Turns the output on. Off : Turns the output off.
Welding output signal number
Example
3: WO[1] = On 4: WO[ R[3] ] = Off
WO[i] = PULSE (time) The WO[i] = PULSE (time) instruction holds a specified welding output on for a specified duration. When a duration is not specified, the instruction executes pulse output for the duration specified with $DEFPULSE (0.1--second units). Figure 4--61. WO[i] = PULSE (time) Instruction
WO [ i ] = PULSE (value) Pulse output time width (0.1 to 25.5 s)
Welding output signal number
Example
5: WO[1] = PULSE 6: WO[2] = PULSE, 0.2sec 7: WO[ R[3] ] = PULSE, 1.2sec
WO[i] = R[i] The WO[i] = R[i] instruction turns a specified welding output either on or off according to the value held in a specified register. When 0 is set in the register, this instruction turns the output off. When a value other than 0 is set in the register, this instruction turns the output on. Figure 4--62. WO[i] = R[i] Instruction
WO [ i ] = R [ i ] Register number (1 to 200)
Welding output signal number
Example
7: WO[1] = R[2] 8: WO[ R[5] ] = R[ R[1] ]
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4.7 Branch Instructions A branch instruction causes a branch from one line of a program to another. Four types of branch instructions are supported. F
Label instruction
F
Program end instruction
F
Unconditional branch instruction
F
Conditional branch instruction
4.7.1 Label instruction LABEL[i] The label instruction (LBL[i]) is used to specify a program execution branch destination. A label is defined with a label definition instruction. Instruction 1 Registers 2 I/O 3 IF/SELECT 4 WAIT PROGRAM
5 6 7 8
JOINT 30% JMP/LBL CALL Palletizing ---next page---
A comment can be added to explain a label. Once a label is defined, it can be used for either an unconditional branch or conditional branch. It is not possible to specify the label number as the indirect addressing. To add a comment, move the cursor to the label number and press the ENTER key. Figure 4--63. LBL[i] Instruction
LBL [ i : Comment ] A comment can consist of up to 16 characters including alphanumeric characters, asterisks (*), underlines (_), and at marks (@).
Label (1 to 32767)
Example
1: LBL[1] 2: LBL[ R[3] ]
4.7.2 Program end instruction END The program end instruction indicates the end of a program. The execution of a program is terminated by this instruction. If a program is called from another main program, control is returned to the main program. Instruction 1 Registers 2 I/O 3 IF/SELECT 4 WAIT PROGRAM
5 6 7 8
JOINT 30% JMP/LBL CALL Palletizing ---next page---
Figure 4--64. Program End Instruction
END
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4.7.3 Unconditional branch instructions An unconditional branch instruction invariably causes a branch from one line to another in the same program . Two types of unconditional branch instructions are supported. F
Jump instruction: Causes a branch to a specified label or program.
F
Program call instruction: Causes a branch to another program.
Jump instruction JMP LBL[i] The JMP LBL[i] instruction transfers program control to a specified label. Figure 4--65. JMP LBL[i] Instruction
JMP LBL [ i ] Label (1 to 32767) Example
3: JMP LBL[2:hand open] 4: JMP LBL[ R[4] ]
Program call instruction CALL (program) The CALL (program) instruction transfers program control to another program (subprogram) in order to execute it. When program end instruction (END) in a called program is executed, control is returned to the instruction immediately after the program call instruction in the calling program (main program). To enter the calling program name, select it with the sub--menu automatically displayed or press F5,STRINGS to enter characters directly. Figure 4--66. CALL (program) Instruction
CALL ( Program ) Name of a program to be called Example
5: CALL SUB1 6: CALL PROGRAM2
*) It is possible to set an argument for the program call instruction and use its value in a subprogram. See Section 4.7.5, “Arguments” for details.
4.7.4 Conditional branch instructions A conditional branch instruction causes a branch from one location in a program to another when some condition is satisfied. Two types of conditional branch instructions are available.
Instruction 1 Registers 2 I/O 3 IF/SELECT 4 WAIT PROGRAM
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JOINT 30% JMP/LBL CALL Palletizing ---next page---
F
Conditional compare instruction: Causes a branch to a specified label or program when some condition is satisfied. The register conditional compare instruction and I/O conditional compare instruction are available.
F
Conditional select instruction: Causes a branch to a specified jump instruction or subprogram call instruction according to the value of a register.
Register conditional compare instruction IF R[i] (operator) (value) (processing) A register conditional compare instruction compares the value stored in a register with another value and, when the compare condition is satisfied, executes processing.
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Figure 4--67. Register Conditional Compare Instruction
IF (variable) (operator) (value) (Processing) R[i]
> >= = <= < <>
Constant R[i]
JMP LBL [ i ] CALL ( Program )
CAUTION When the contents of register are compared with the real value with the operator,“=”, the contents do not always correspond to the real value because of the rounding--off error of the contents. To compare with the real value, use any operator except the equal.
I/O conditional compare instruction IF (I/O) (operator) (value) (processing) The I/O conditional compare instruction compares the value of an input/output signal with another value. When the comparison condition is satisfied, specified processing is executed. Figure 4--68. I/O Conditional Compare Instruction 1
IF (variable) (operator) (value) (Processing) AO [ i ] AI [ i ] GO [ i ] GI [ i ]
Example
> >= = <= < <>
Constant R[i]
JMP LBL [ i ] CALL ( Program )
7: IF R[1] = R[2], JMP LBL[1] 8: IF AO[2] >= 3000, CALL SUBPRO1 9: IF GI[ R[2] ] = 100, CALL SUBPRO2
Figure 4--69. I/O Conditional Compare Instruction 2
IF (variable) (operator) (value) (Processing) SDO [ i ] SDI [ i ] RDO [ i ] RDI [ i ] SO [ i ] SI [ i ] UO [ i ] UI [ i ] WO [ i ] WI [ i ]
Example
= <>
ON JMP LBL [ i ] CALL ( Program ) OFF SDO [ i ] SDI [ i ] RDO [ i ] RDI [ i ] SO [ i ] SI [ i ] UO [ i ] UI [ i ] WO [ i ] WI [ i ] R [ i ] : 0 = Off, 1 = On
10: IF RO[2] <> OFF, JMP LBL[1] 11: IF DI[3] = ON, CALL SUB1
In a conditional branch instruction, multiple conditions can be specified on a single line in the condition statement, using the logical operators (“and” and “or”). This simplifies the program structure, allowing the conditions to be evaluated efficiently.
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Instruction format F Logical product (and) IF and and , JMP LBL [3] F Logical sum (or) F or , JMP LBL [3] If the “and” (logical product) and “or” (logical sum) operators are used together, the logic becomes complex, impairing the readability of the program and ease of editing. For this reason, this function prohibits the use of the logical operators “and” and “or” in combination. If multiple “and” (logical product) or “or” (logical sum) operators are specified for an instruction on a single line, and one of the operators is changed from “and” to “or” or from “or” to “and,” all other “and” or “or” operators are changed accordingly, and the following message appears: TPIF--062 AND operator was replaced to OR TPIF--063 OR operator was replaced to AND Up to five conditions can be combined with “and” or “or” operators on a single line. Example
IF and and and and , JMP LBL [3]
Conditional select instruction SELECT R[i] = (value) (processing) = (value) (processing) = (value) (processing) ELSE (processing) The conditional select instruction consists of several register compare instructions. The conditional select instruction compares the value of a register with one or more values, then selects a statement that satisfies the comparison condition. F
If the value of a specified register matches one value, the jump instruction or subprogram call instruction corresponding to the value is executed.
F
If the value of a specified register does not match any of the values, the jump instruction or subprogram call instruction corresponding to ELSE is executed.
Figure 4--70. Conditional Select Instruction
SELECT R [ i ] Register number (1 to 200)
= (value) = (value) = (value) ELSE
(Precessing) (Precessing) (Precessing)
Constant R[i]
Example
11: SELECT R[1] = 1, JMP LBL[1] 12: = 2, JMP LBL[2] 13: = 3, JMP LBL[2] 14: = 4, JMP LBL[2] 15: ELSE, CALL SUB2
212
JMP LBL [ i ] CALL ( Program )
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4.7.5 Arguments By using “arguments” and “argument registers,” it is possible to transfer data between two programs only. Example
In this example, the main program MAIN calls the subprogram PROC_1 with two arguments. PROC_1 can use the values of the arguments with the argument registers. The first argument corresponds to AR[1] while the second argument corresponds to AR[2].
MAIN
10: CALL PROC_1 (1, R[3])
PROC_1
5: IF R[1]>AR[2], JMP LBL[1] 6: R[1]=R[1]+AR[1]
Arguments can be used in macro instructions in the same way. Argument types The following arguments are supported. Table 4--1.
Argument types
Argument type
Example
Constant Character string Argument register Register
1, 3.5 ’Perch’ AR[3] R [6]
*1 Available in KAREL programs only. *2 Used as argument registers in subprograms. CALL WELD_1 (AR[1], R[1],
WELD_1 :
2)
AR[1], AR[2], AR[3]
Instructions for which arguments can be set Table 4--2.
Instructions for Which Arguments Can be Set
Instruction Program call instruction Macro instruction
Example CALL WELD (1, R[3], AR[1]) CLAMP OPEN (2.5)
NOTE A program call used for branching with an instruction such as a conditional branch instruction cannot use arguments. This problem can be solved by programming as follows: (Arguments cannot be set) (Arguments can be set) IF R[1]=3, CALL WELD_5 ! 1: IF R[5]<>2, JMP LBL[1] 2: CALL WELD_1 (1, R[1]) 3: LBL[1] [End]
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Instructions that can use argument registers Table 4--3.
Instructions That Can Use Argument Registers
Instruction Right side of an instruction and conditional expression having a register on the left side Right side of the analog output (AO[]) and group output (GO[]) instructions Right side of a conditional expression having analog input/output (AI[]/AO[]) or group input/output (GI[]/GO[]) on the left side Right side of the user coordinate system selection instruction and the tool coordinate system selection instruction Indirect index specification Argument of a program call instruction Argument of a macro instruction
Example R[1]=AR[1]+R[2]+AR[2] IF R[1]=AR[1], JMP LBL[1] AO[1]=AR[1] GO[1]=AR[2] IF AO[7]=AR[1], JMP LBL[1] WAIT GI[1]<>AR[1], TIMEOUT, LBL[1] UTOOL_NUM=AR[4]
R[AR[1]]=R[AR[2]] SDO[AR[1]]=ON CALL WELD_1 (AR[5]) CLAMP_3_OPEN (AR[1])
Restrictions on arguments The following restrictions are imposed on arguments: F
Up to 10 arguments can be set.
F
An argument of character string type can be one to sixteen characters in length. (An argument with 0 characters is regarded as being uninitialized.)
F
An indirect specification cannot be used for an already indirectly specified element of an index. f R[AR[1]] × R[R[AR[1]]]
F
The value stored in an argument register cannot be changed in a subprogram.
Specifying arguments When a program call instruction or macro instruction is specified, the cursor stops at the end of the line. If no arguments need be specified, press the ENTER key or “!” or “#” key to move the cursor to the next line. To display the argument selection submenu, press function key [CHOICE]. JOINT 10% CALL WELD_1. [CHOICE]
Parameter select 1 R[ ] 2 Constant 3 AR[ ] 4 WELD_1
G1 JOINT 5 6 7 8
10 %
F4 Specifying arguments of the constant type To specify an argument of the constant type, press function key [CHOICE] and select “1 Constant” from the submenu (see “Specifying arguments”). Parameter select 1 R[ ] 2 Constant 3 String 4 AR[]
1: CALL PROC_1 (Constant)
1: CALL PROC_1 ( 1 )
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Specifying arguments of character type To specify an argument of character type, press function key [CHOICE] and select String from the submenu (see “Specifying arguments”). The character string type selection menu appears. String select 1 PARTS 2 TOOL 3 WORK 4 POS MAIN
Parameter select 1 5 AR[ ] 2 Constant 3 String 4 R[ ]
JOINT 10% DEV ARC TORCH --- next page ---
5 6 7 8
1/2 1: CALL WELD_1 (1, [End]
)
[CHOICE]
STRING
When a character string type is selected, the character string selection menu appears. String select 1 Parts P567 2 Parts P568 3 Parts P569 4 Parts P570
5 6 7 8
JOINT 10% Parts P571 Parts P572 Parts P573 --- next page ---
Select a character string from the menu. The character string is confirmed. 1: CALL PROC_1 (‘Parts p568’) Select Parts p568 from menu To enter a character string directly, press function key STRINGS from the character type selection menu or the character string selection menu. JOINT 10% 1 Words 2 Upper Cuse 3 Lower Cuse 4 Options MAIN 1/2 1: CALL PROC_1 (’Tool12 [End]
$
[
’)
]
Press the Enter key to confirm the character string. 1: CALL PROC_1 (‘Tool 12’ )
JOINT 10% CALL PROC_1 (1, ’Parts P568’) [CHOICE]
CHANGE
F5 To change a character string, move the cursor to the character string and press function key CHANGE. The character string type selection menu appears.
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Specifying arguments of the argument register type To set an argument of the argument register type, press function key CHOICE and select AR[] from the submenu (see “Specifying arguments”). Parameter select 1 R[ ] 2 Constant 3 String 4 AR[ ]
1: CALL PROC_1 (AR[ ... ]) Enter an index. 1: CALL PROC_1 (AR[1] ) To toggle between direct and indirect index specifications, press function key INDIRECT. The display changes as follows: AR[R[...]] ! AR[AR[...]] ! AR[R[...]] ! ⋅⋅⋅ Specifying arguments of the register type To set an argument of register type, press function key CHOICE and select “4 R[]” from the submenu (see “Specifying arguments”). Parameter select 1 R[ ] 2 Constant 3 String 4 AR[ ]
1: CALL PROC_1 (R[ ... ]) Enter an index. 1: CALL PROC_1 (R[1] ) To toggle between direct and indirect index specifications, press function key INDIRECT. The display changes as follows: R[R[...]] ! R[AR[...]] ! R[R[...]] ! ⋅⋅⋅ Adding arguments Move the cursor to “)” at the end of the line. 1: CALL PROC_1 (1 ) Press function key CHOICE and select an argument type from the submenu (see “Specifying arguments”). A new argument can be added to the cursor position. 1: CALL PROC_1 (1, Constant ) Select an argument type and set a value. 1: CALL PROC_1 (1, Constant ) 1: CALL PROC_1 (1, 2 )
Select the constant type Set a value of “2”
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Inserting arguments Move the cursor to the argument for which an argument is to be inserted. JOINT 10% 5 6
1: CALL PROC_1 (1, 2 ) Press function key [CHOICE] and select from the submenu (see “Specifying arguments”). A new argument can be inserted at the cursor position. 1: CALL PROC_1 (1..., 2) Select an argument type and set a value, index, and so on. 1: CALL PROC_1 (1, R[ ... ],2) 1: CALL PROC_1 (1, R[3], 2 )
Select the constant type Set a value of “3”
NOTE An argument cannot be inserted when no argument has been set, and at “)” at the end of a line. The same submenu reappears; select the argument type. Deleting arguments Position the cursor to the argument to be deleted. JOINT 10% 5 6
1: CALL PROC_1 (1, 2 , 3) Press function key [CHOICE] and select from the submenu (see “Specifying arguments”). The argument is deleted from the cursor position. 1: CALL PROC_1 (1, 3 ) NOTE Selecting when no argument has been set, and at “)” at the end of a line, simply closes the submenu; no argument is deleted. Specifying argument registers The following explanation uses a register instruction as an example. The selections for the right side of a register instruction are as follows: JOINT 10% R[1]=...
REGISTER Statement 1 R[ ] 2 AR[ ] 3 Constant 4 AO[ ]
JOINT 10% 5 AI[] 6 GO[] 7 GI[] 8--- next page---
To use an argument with the instruction, select AR[] from the menu. 1: R[1]=AR[ ... ] Specify the index. 1: R[1]=AR[ 1 ]
DIRECT INDIRECT [CHOICE]
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If function key F3 “Indirect specification” is pressed twice at an element having an index, an argument register can be used for an indirect index specification. 1: WAIT R[R ... ]] 1: WAIT R[AR ... ]]
When F3 is pressed once When F# is pressed again
Notes on using arguments Note the following when specifying arguments: F
The contents of an argument are not checked when the argument is specified. If the type of an argument does not match the type of the corresponding one in the subprogram, an error occurs during execution. Example
In this example, although a value of AR[1] is assigned to the register in subprogram PROC_1, an argument of character string type is specified in the main program. An error occurs when line 5 of the subprogram is executed.
MAIN
10: CALL PROC_1 (’ABCD’)
PROC_1
5: R[1]=AR[1]
F
The number of arguments is not checked when arguments are specified. Even if the number of arguments is not correct, no errors occur if the arguments specified in the main program are not used in a subprogram. Example
In this example, only one argument is specified in the main program, but two arguments are used in subprogram PROC_1. An error occurs when line 6 of PROC_1 is executed.
MAIN
10: CALL PROC_1 (1, 2) 30: CALL PROC_1 (R[1]) PROC_1
5: R[1]=AR[1] 6: R[1]=R[1]+AR[2]
Notes on specifying arguments for a program call instruction F
When the program name is changed, the arguments that have been set are kept intact.
F
When the program call instruction itself is re--specified, not only the program name but all the arguments are deleted.
Notes on specifying arguments for a macro instruction F
When the macro name is changed, those arguments that have been set are kept intact.
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Notes on execution As described in “Notes on using arguments,” the contents and number of arguments to be passed between the calling program and the called program are not checked when they are specified. If an argument is set or used incorrectly, an error occurs on a line where a conflict is detected during program execution. F
Check that the number of arguments specified in the main program is equal to that of the arguments used in the subprogram.
F
If the arguments specified in the main program are not used in the subprogram, an error does not occur.
F
Check that the contents of the arguments specified in the main program match the types of instructions in the subprogram that use those arguments.
F
Check that the indexes and values of the specified arguments are set correctly. An error occurs because the value is uninitialized The index is uninitialized
1: CALL PROC_1 ( Constant ) 1: CALL PROC_1 (R[ ... ])
When lines containing these are executed, the error “INTP--201 Unspecified Statement” occurs. System variables relating to arguments The argument--attached program call/macro instruction function displays, as selections, the character strings set as system variables when an argument of the character string type is to be selected. These system variables are given below. Table 4--4.
System Variables Relating to Arguments Item
Single character string type Two--character string
Three--character string
Four word at character entry
System variable
Remarks
$STRING_PRM=TRUE/FALSE (Note) Standard value=FALSE $ARG_STRING[i].$TITLE More than 1 and up to 16 (i = 1 to 10) characters (Note) $ARG_STRING[i].$ITEMJ Up to 16 characters (i = 1 to 10, j=1 to (Note) 20) $ARG_WORD [i] Up to 7 characters (i = 1 to 5) (Note)
NOTE Arguments of character string is able to use on KAREL program only.
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4.8 Wait Instructions A wait instruction is used to stop program execution for a specified period of time or until a condition is satisfied. When a wait instruction is executed, the robot performs no processing. Two types of wait instructions are available. Instruction 1 Registers 2 I/O 3 IF/SELECT 4 WAIT PROGRAM
5 6 7 8
JOINT 30% JMP/LBL CALL Palletizing ---next page---
F
Time--specified wait instruction: Stops program execution for a specified period of time.
F
Conditional wait instruction: Stops program execution until a specified condition is satisfied or a specified period of time has elapsed.
4.8.1 Time--specified wait instruction WAIT (TIME) The time--specified wait instruction stops program execution for a specified period of time (in seconds). Figure 4--71. Time--Specified Wait Instruction
WAIT (value) Constant R[i]
Example
Wait time (0 to 327.67 sec) Wait time (sec)
1: WAIT 2: WAIT 10.5sec 3: WAIT R[1]
4.8.2 Conditional wait instructions WAIT (condition) (processing) A conditional wait instruction stops program execution until a specified condition is satisfied or a specified period of time has elapsed. Two methods of specifying time--out processing are available: F
If no processing is specified, program execution is stopped until a specified condition is satisfied.
F
Timeout, LBL[i] stops program execution for the duration specified in 14 WAIT timeout on the system configuration screen. Program control is transferred to a specified label if the specified condition is not satisfied during that wait time.
Register conditional wait instruction The register conditional wait instruction compares the value of a register with another value, and waits until the comparison condition is satisfied, Figure 4--72. Register Conditional Wait Instruction
WAIT (variable) (operator) (value) (Processing) R[i] $System Variable
Example
Constant R[i]
> >= = <= < <>
Omitted: Wait for an unlimited period of time. TIMEOUT, LBL [ i ]
3: WAIT R[2] <> 1, TIMEOUT LBL[1] 4: WAIT R[ R[1] ]> = 200
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I/O conditional wait instruction The I/O conditional wait instruction compares the value of an input/output signal with another value, and waits until the comparison condition is satisfied. Figure 4--73. I/O Conditional Wait Instruction 1
WAIT (variable) (operator) (value) (Processing) AO AI GO GI
[i] [i] [i] [i]
Constant R[i]
> >= = <= < <>
Omitted: Wait for an unlimited period of time. TIMEOUT, LBL [ i ]
Figure 4--74. I/O Conditional Wait Instruction 2
WAIT (variable) (operator) (value) (Processing) SDO SDI RDO RDI SO SI UO UI WO WI
[i] [i] [i] [i] [i] [i] [i] [i] [i] [i]
Example
ON OFF SDO [ i ] SDI [ i ] RDO [ i ] RDI [ i ] On+ (Note) Off-- (Note) SO [ i ] SI [i] UO [ i ] UI [i] WO [ i ] WI [ i ] R [ i ] : 0OFF,
= <>
Omitted: Wait for an unlimited time. TIMEOUT, LBL [ i ]
1ON
5: WAIT SDI[2] <> OFF, TIMEOUT LBL[1] 6: WAIT RDI[ R[1] ] = R[1]
NOTE Off--: The falling edge of a signal is regarded as being a detection condition. The condition is not satisfied while the signal remains off. The detection condition is satisfied when the signal changes from the on state to the off state. On+: The rising edge of a signal is regarded as being a detection condition. The condition is not satisfied while the signal remains on. The detection condition is satisfied when the signal changes from the off state to the on state. Error condition wait instruction The error condition wait instruction waits for the occurrence of an alarm having a specified error number. Figure 4--75. Error condition wait instruction
WAIT ERR_NUM=(Value) (Processing) Constant (Note)
Omitted: Wait for an unlimited period of time. TIMEOUT, LBL [ i ]
NOTE An error number is specified with an alarm ID followed by an alarm number. Error number = aabbb where aa = alarm ID bbb = alarm number For an explanation of alarm IDs and numbers, refer to the alarm code table given in the operator’s manual. Example For SRVO--006 HAND broken, the servo alarm ID is 11, and the alarm number is 006. Thus, Error number = 11006 In the condition wait instruction, multiple conditions can be specified on a single line in the condition statement, using the logical operators (“and” and “or”). This simplifies the program structure, allowing the conditions to be evaluated efficiently.
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Instruction format F
Logical product (and) WAIT and and
F
Logical sum (or) WAIT or or
If the “and” (logical product) and “or” (logical sum) operators are used in combination, the logic becomes complex, impairing the readability of the program and the ease of editing. For this reason, this function prohibits the use of the logical operators “and” and “or” in combination. If multiple “and” (logical product) or “or” (logical sum) operators are specified for an instruction on a single line, and one of the operators is changed from “and” to “or” or from “or” to “and,” all other “and” or “or” operators are changed accordingly, and the following message appears: TRIF--062 AND operator was replaced to OR TRIF--063 OR operator was replaced to AND Up to five conditions can be combined with “and” or “or” operators on a single line. Example
WAIT and and and and
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4.9 Skip Condition Instruction The skip condition instruction specifies, in advance, a skip condition (condition for executing a skip instruction) used with a skip instruction. Before a skip instruction can be executed, a skip condition instruction must be executed. A skip condition once specified is valid until the execution of the program is completed, or the next skip condition instruction is executed. (For the skip instruction, see Section 4.3.6.) Instruction 1 Miscellaneous 2 Program control 3 Skip 4 Offset/Frames
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MACRO SENSOR Multiple control ---next page---
A skip instruction causes a jump to a branch destination label if the skip condition is not satisfied. If the skip condition is satisfied, a skip instruction causes the robot to suspend the current motion toward a target point, instead executing the program instruction on the next line. If the skip condition is currently not satisfied, a skip instruction causes a jump to a destination label upon the completion of the current motion. Figure 4--76. Skip Condition Instruction (Register Condition)
SKIP CONDITION [ Variable] (operator) (value) > >= = <= < <>
R[i] $System Variable
Constant R[i]
Figure 4--77. Skip Condition Instruction (I/O condition 1)
SKIP CONDITION (Variable) (operator) (value) > >= = <= < <>
AO [ i ] AI [ i ] GO [ i ] GI [ i ] ]
Constant R [i]
Figure 4--78. Skip Condition Instruction (I/O condition 2)
SKIP CONDITION (Item) (operator) (value) SDO SDI RDO RDI SO SI UO UI WO WI
Example
= <>
[i] [i] [i] [i] [i] [i] [i] [i] [i] [i]
1: 2: 3: 4: 5: 6:
ON OFF SDO [ i ] SDI [ i ] RDO [ i ] RDI [ i ] On+ (Note) Off-- (Note) SO [ i ] SI [i] UO [ i ] UI [i] WO [ i ] WI [ i ] R [ i ] : 0OFF, 1ON
SKIP CONDITION DI[ R[1] ] <> ON J P[1] 100% FINE L P[2] 1000mm/sec FINE Skip, LBL[1] J P[3] 50% FINE LBL[1] J P[4] 50% FINE
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NOTE Off--: The falling edge of a signal is regarded as being a detection condition. The condition is not satisfied while the signal remains off. The detection condition is satisfied when the signal changes from the on state to the off state. On+: The rising edge of a signal is regarded to be a detection condition. The condition is not satisfied while the signal remains on. The detection condition is satisfied when the signal changes from the off state to the on state. Figure 4--79. Skip Condition Instruction (Error condition)
SKIP CONDITION ERR_NUM=(Value) Constant (Note)
NOTE An error number is specified with an alarm ID followed by an alarm number. Error number = aabbb where aa = alarm ID bbb = alarm number For an explanation of alarm IDs and numbers, refer to the alarm code table in the operator’s manual. Example
For SRVO--006 Hand broken, the servo alarm ID is 11, and the alarm number is 006. Thus, Error number = 11006 In the skip condition instruction, multiple conditions can be specified on a single line in the condition statement, using the logical operators (“and” and “or”). This simplifies the program structure, allowing the conditions to be evaluated efficiently. Instruction format F
Logical product (and) SKIP CONDITION and and
F
Logical sum (or) SKIP CONDITION or or
If the “and” (logical product) and “or” (logical sum) operators are used in combination, the logic becomes complex, impairing the readability of the program and case of editing. For this reason, this function prohibits the use of the logical operators “and” and “or” in combination. If multiple “and” (logical product) or “or” (logical sum) operators are specified for an instruction on a single line, and one of the operators is changed from “and” to “or” or from “or” to “and,” all other “and” or “or” operators are changed accordingly, and the following message appears: TRIF--062 AND operator was replaced to OR TRIF--063 OR operator was replaced to AND Up to five conditions can be combined with “and” or “or” operators on a single line. Example
SKIP CONDITION and and and and
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4.10 Offset Condition Instruction The OFFSET CONDITION instruction specifies the offset condition used in the OFFSET CONDITION instruction, in advance. The OFFSET CONDITION should be executed before the OFFSET instruction is executed. The specified offset condition is effective until the program execution finishes or the next OFFSET CONDITION instruction is executed.(For the offset instruction, see Section 4.3.6.) Instruction 1 Miscellaneous 2 Offset 3 MACRO 4 Program control PROGRAM
JOINT 30% 5 Skip 6 7 8 ---next page---
F
The position register specifies the shifting direction and the shift amount.
F
When the positional information is expressed in the joint frame, the shift amount of each axis is applied.
F
When the positional information is expressed in the Cartesian coordinate system, the number of the user frame by which the offset condition is decided should be specified. When it is not specified, the user frame being selected now is used. CAUTION
If teaching is done by joint coordinates, changing the user coordinate system does not affect the position variables and position registers. If teaching is performed in orthogonal format, and the user coordinate system input option is not used, the position variable is not influenced by the user coordinate system. In other cases, both the position variable and position register are influenced by the user coordinate system.
The OFFSET instruction shifts positional information programmed at the destination position by the offset amount specified by position register, and moves the robot to the shifted position. The shifting condition is specified by the OFFSET CONDITION instruction. Figure 4--80. Offset Conditional Instruction
OFFSET CONDITION PR [ i ] ( UFRAME [ j ] ) Position register number ( 1 to 100 )
Example
1: OFFSET CONDITION PR[ R[1] ] 2: J P[1] 100% FINE 3: L P[2] 500mm/sec FINE Offset
225
User frame number ( 1 to 9 )
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4.11 Tool Offset Condition Instructions A tool offset condition instruction specifies the offset condition used in a tool offset instruction. Execute a tool offset condition instruction before executing the corresponding tool offset instruction. Once the tool offset conditions have been specified, they remain effective until the program terminates or the next tool offset condition instruction is executed. (For the tool offset instruction, see Section 4.3.6 “Additional motion instructions”) Instruction 1 Miscellaneous 2 Offset 3 MACRO 4 Program control PROGRAM
JOINT 30% 5 Tool_Offset 6 7 8 ---next page---
F
The position register specifies the direction in which the target position shifts, as well as the amount of shift.
F
The tool coordinate system is used for specifying offset conditions.
F
When the number of a tool coordinate system is omitted, the currently selected tool coordinate system is used.
F
When the position data is given as coordinates, an alarm is issued and the program stops temporarily.
A tool offset instruction moves the robot to a position shifted from the target position, recorded in the position data, by the offset specified in the tool offset conditions. The condition when the offset is applied is specified by a tool offset condition instruction. Figure 4--81. Tool Offset Condition Instruction
TOOL_OFFSET CONDITION PR[ i ] ( UTOOL[ j ] ) Position register number (1 to 100) Tool frame number ( 1 to 9 ) Example
1: TOOL_OFFSET PR[1] 2: J P[1] 100% FINE 3: L P[2] 500mm/sec FINE Tool_Offset
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4.12 Frame Instructions The FRAME instruction is used to change the setting of the Cartesian coordinate system by which the robot works. There are two kinds of FRAME instruction. SYST-035 Low or No Battery Power in PSU. Instruction G1 JOINT 10 % 1 Miscellaneous 5 Track/Offset 2 Weave 6 Offset/Frames 3 Skip 7 Program control 4 Payload 8 ---next page--WELD_1 F F
Frame setup instruction -- The definition of the specified frame is changed. Frame select instruction -- The frame number being selected now is changed.
The frame setup instruction The tool frame setup instruction changes the setting of the tool frame specified by the tool frame number in this instruction. The user frame setup instruction changes the setting of the user frame specified by the user frame number in this instruction. Figure 4--82. Tool Frame Setup Instruction
UTOOL [ i ] = (value) PR [ i ]
Tool frame number ( 1 to 9 ) Figure 4--83. User Frame Setup Instruction
UFRAME [ i ] = (value) PR [ i ]
User frame number ( 1 to 9 ) Example
1: TOOL[1] = PR[1] 2: UFRAME[3] = PR[2]
Frame select instruction The tool frame select instruction changes the tool frame number being selected now. The user frame select instruction changes the user frame number being selected now. Figure 4--84. Tool Frame Select Instruction
UTOOL_NUM = (Value) R[i] Constant
Tool frame number (0 to 9)
Figure 4--85. User Frame Select Instruction
UFRAME_NUM = (Value) R[i] Constant Example
1: 2: 3: 4: 5: 6:
UFRAME_NUM = 1 J P[1] 100% FINE L P[2] 500mm/sec FINE UFRAME_NUM = 2 L P[3] 500mm/sec FINE L P[4] 500mm/sec FINE
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User frame number (0 to 9)
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4.13 Program Control Instructions The program control instructions control program execution. Instruction 1 Miscellaneous 2 Weave 3 Skip 4 Payload WELD_1 F
Halt instruction
F
Abort instruction
5 6 7 8
G1 JOINT 10 % Track/Offset Offset/Frames Program control ---next page---
4.13.1 Halt instruction PAUSE The halt instruction interrupts program execution in the following way, causing the robot in motion to decelerate and stop: F
If an operation instruction is being executed, the program stops before the operation is completed.
F
The cursor moves to the next line. When restarted, the program is executed from this line.
F
If the program timer is active, it is stopped. When the program is restarted, the program timer is activated.
F
If a pulse output instruction is being executed, the program stops after that instruction has been executed.
F
If an instruction other than a program call instruction is being executed, the program stops after that instruction has been executed. A program call instruction is executed when the program is restarted.
Figure 4--86. Halt Instruction
PAUSE 4.13.2 Abort instruction ABORT The abort instruction aborts program execution in the following way, causing the robot in motion to decelerate and stop: F
If an operation instruction is being executed, the program stops before the operation is completed.
F
The cursor stops on the current line.
F
When the abort instruction is executed, the execution of the program cannot be continued. Information held by a program call instruction about the main program is lost.
Figure 4--87. Abort Instruction
ABORT
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4.14 Other Instructions The following miscellaneous instructions are available: Instruction 1 Arc 2 Miscellaneous 3 Weave 4 Skip WELD_1 F
RSR instruction
F
User alarm instruction
F
Timer instruction
F
Override instruction
F
Comment instruction
F
Message instruction
F
Parameter instruction
F
Maximum speed instruction
5 6 7 8
JOINT 30 % Payload Track Offset/Frames ---next page---
4.14.1 RSR instruction RSR [i] = (value) The RSR instruction alternately enables and disables the RSR function having a specified RSR number. Figure 4--88. RSR instruction
RSR [ i ] (value) ENABLE: RSR function enabled DISABLE: RSR function disabled
(1 to 4)
Example
RSR[2:Workproc.2.]=ENABLE
4.14.2 User alarm instruction UALM[i] The user alarm instruction displays the alarm message corresponding to an already set user alarm number on the alarm display line. The user alarm instruction pauses the program which is in progress. A user alarm is specified on the user alarm setting screen(See Section 3.18) and this setting is registered in the system variable $UALM_MSG . The total number of user alarms can be changed at a controlled start (See Section 3.11, “Start mode”). Figure 4--89. User Alarm Instruction
UALM [ i ] Alarm number
Example
1: UALM[1]
($UALRM_MSG[1] = WORK NOT FOUND
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4.14.3 Timer instruction timer [i] = (state) The timer instruction starts/stops the program timer. The operating state of the program timer can be viewed on the program timer screen STATUS PRGTIMER (option). Figure 4--90. Timer instruction
Timer [ i ] (processing) SATRT: starts the timer STOP: stops the timer RESET: resets the timer clears timer overflow flag
Timer Number
Example
1: TIMER [1]=START TIMER [1]=STOP TIMER [1]=RESET
The value of the timer can be referenced in a program, using a register instruction. It is possible to determine whether the timer has overflowed by using a register instruction. The program timer overflows if it exceeds 2147483.647 seconds. R[1]=TIMER [1] R[2]=TIMER_OVER FLOW[1] 0: 1:
4.14.4 Override instruction OVERRIDE = (value)% The override instruction changes a feedrate override. Figure 4--91. Override Instruction
OVERRIDE = (value) % R [i] Const AR [i] (value): Feedrate override (1 to 100) Example
1: OVERRIDE = 100%
4.14.5 Comment instruction !(Remark) The comment instruction adds a comment in a program. A comment has no effect on program execution. A comment specified in a comment instruction can consist of up to 32 characters including alphanumeric characters, asterisks (*) underlines (_), and at marks (@). To add a comment, press the ENTER key. Figure 4--92. Comment Instruction
! (Remark) A comment can consist of up to 32 characters including alphanumeric characters, asterisks (*), underlines (_), and at marks (@). Example
1: !APPROACH POSITION
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4.14.6 Message instruction MESSAGE[message statement] The message instruction displays a specified message on the user screen. (For the user screen, see Section 7.2.) A message can consist of up to 24 characters including alphanumeric characters, asterisks (*), underlines (_) , and at marks (@). To add a comment, press the ENTER key. Figure 4--93. Message Instruction
Message [message statement] A message statement can consist of up to 24 characters including alphanumeric characters, asterisks (*), underlines (_), and at marks (@). Example
1: MESSAGE[ DI[1] NOT INPUT ]
4.14.7 Parameter instruction $(SYSTEM VARIABLE NAME) = (value) The parameter instruction changes the value of a system variable. This instruction can be used only for a system variable containing a numeric value (constant). You can enter the parameter name after pressing the ENTER key. It is possible to enter the parameter name up to 30 characters or less without the first character,“$”. There are two types of system variables, variable type and position type. A system variable of variable type can be assigned to a register. A system variable of position type can be assigned to a position register. System variables of position data type are divided into three data types, orthogonal type (XYZWPR type), joint type (J1--J6 type), and matrix type (AONL type). When a system variable of position data type is assigned to a position register, the data type of the position register is converted to the data type of the system variable. If a system variable of position type is assigned to a register, or if a system variable of variable type is assigned to a position register, the following alarm is generated during execution. INTP--240 Incomputible datatype Figure 4--94. Parameter Instruction (Writing)
$ ( SYSTEM VARIABLE name ) = (value) System variable value (numeric value)
System variable name
R [X] PR [X]
Example
1: $SHELL_CONFIG.$JOB_BASE = 100
Figure 4--95. Parameter Instruction (Reading)
(value) = $ ( SYSTEM VARIABLE name ) System variable name
R [X] PR [X]
Example
1: R[1] = $SHELL_CONFIG.$JOB_BASE
WARNING The operation of the robot and control unit is controlled with system variables. Only a person who knows details of the influence of changes in system variables should set system variables. If a person without detailed knowledge attempts to set the system variables, the robot and control unit could malfunction, causing injury.
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Procedure 4--3 Step
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Specifying parameter instructions
1 On the program edit screen, press function key [INST]. Select item Miscellaneous from the menu. Then, select item Parameter name from the menu. Miscellaneous stat 1 $...=... 5 2 ...=$... 6 3 7 4 8 PNS0001
JOINT 10%
1/1 [End]
Select item [CHOICE]
2 Select item 2 “... =$ ...” Miscellaneous stat 1 R[ ] 5 2 PR[ ] 6 3 7 4 8 PNS0001
JOINT 10%
1: ...=$... [End] Select item [CHOICE]
3 Select item 1 “R[ ]” and enter the desired register number. PNS0001
JOINT 10% 1/2
1: R[1]=$... [End]
Press ENTER [CHOICE]
4 To display the system variable menu, press function key CHOICE. To enter a character string, press the Enter key. When function key CHOICE is pressed Parameter menu 1 DEFPULSE 2 WAITTMOUT 3 RCVTMOUT 4 PNS0001
JOINT 10% 5 6 7 8 --- next page --1/2
1: R[1]=$... [End] Select item [CHOICE]
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5 Select item 1 “DEFPULSE.” PNS0001
JOINT 10% 1/2
1: R[1]=$DEFPULSE [End] [INST]
[EDCMD]
6 When ENTER is pressed JOINT 10% 1 Words 2 Upper Case 3 Lower Case 4 Options PNS0001
-- Insert --
1: R[1]=$... [End]
$
[
]
.
7 Enter the desired system variable name.
4.14.8 Maximum speed instructions A maximum speed instruction specifies the maximum operating speed of a program. There are two maximum speed instructions, the instruction for specifying the joint operation speed and that for specifying the path control operating speed. If a speed exceeding the speed specified with a maximum speed instruction is specified, the speed specified with the maximum speed instruction is assumed. JOINT_MAX_SPEED[i]=(value) Figure 4--96.
JOINT_MAX_SPEED [ i ] = (value) Comstant (deg/sec) R [i] (deg/sec)
LINEAR_MAX_SPEED= (value) Figure 4--97.
LINEAR_MAX_SPEED = (value) Comstant (deg/sec) R [i] (deg/sec)
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4.15 Multiaxis Control Instructions Multiaxis control instructions control the execution of a multitask program. These instructions can be specified and executed only when the multitask option is supported. Instruction 1 Miscellaneous 2 Program control 3 Skip 4 Offset/Frames
F
Semaphore instruction
F
Semaphore wait instruction
F
Program execution instruction
5 6 7 8
MACRO SENSOR Multiple control --- next page ---
4.15.1 Semaphore instruction The semaphore instruction switches a semaphore, specified with a number, between on and off. A semaphore is a kind of switch used to synchronize the execution of tasks. F
For example, if the execution of a certain step and subsequent steps of a program is to wait until a certain condition is satisfied in another program being executed simultaneously, first turn off the semaphore having the specified number and make the program wait until the semaphore is turned on, using the semaphore wait instruction (See Section 4.15.2, “Semaphore wait instruction”). When the semaphore is turned on by the other program that is being executed simultaneously, the program is released from the wait state. This allows the execution of multiple programs at prescribed timings.
F
Each semaphore remembers how many times it has been turned on. When a wait statement for waiting for a semaphore whose “on” count is other than zero is executed, its execution ends immediately and the “on” count is decremented by 1.
F
When a program uses a wait statement to wait for a semaphore whose “on” count is zero, the program enters the wait state until the semaphore is turned on by another program.
F
When a semaphore is turned off, the “on” count is cleared to zero.
F
Semaphores numbered 1 through 32 can be used.
Figure 4--98. Semaphore instruction
SEMAPHORE [ i ] = (value) Semaphore number (1 to 32)
ON OFF
4.15.2 Semaphore wait instruction The semaphore instruction causes the program to wait until a semaphore having a specified number is turned on. F
The program is placed in the wait state until the specified semaphore is turned on by another program.
F
Either unlimited waiting (waiting time not limited) or specified time waiting can be selected. The waiting time is specified for system variable $WAITTMOUT, in the same way as in normal wait statements.
Figure 4--99. Semaphore wait instruction
WAIT SEMAPHORE [ i ] = (Processing) Semaphore number (1 to 32)
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Omitted: Forever TIMEOUT, LBL [ i ]
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4.15.3 Program execution instruction During the execution of a program, the program execution instruction starts the execution of another program. F
The difference from the program call instruction is that, with the program call instruction, those lines following the call instruction are executed after the called program has been executed, whereas with the program execution instruction, the program that starts the execution of another program continues concurrently.
F
To synchronize programs that are being executed simultaneously, use the semaphore instruction and the semaphore wait instruction.
F
If an attempt is made to execute a program for which the same motion group is specified, an alarm is generated. If this occurs, specify a different motion group.
Figure 4--100. Program execution instruction
RUN (Program name) Name of the program to be executed Example
PROG1 1: SEMAPHORE[1]=OFF 2: RUN PROG1
PROG2 1: J P[3] 100% FINE 2: J P[4] 100% FINE
3: J P[1] 100% FINE
3: J P[5] 100% FINE
4: J P[2] 100% FINE
4: J P[6] 100% FINE
5: WAIT SEMAPHORE[1]
5: SEMAPHORE[1]=ON
MOTION GROUP[1,*,*,*,*]
MOTION GROUP[*,1,*,*,*]
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4.16 Operation Group Instructions The operation group instructions enable the following in single--line operation instructions in a program having multiple operation groups: F
Specification of the operation format for each operation group (excluding the arc)
F
Specification of the feedrate for each operation group
F
Specification of the positioning format for each operation group
This allows each operation group to operate asynchronously. These instructions can be specified and executed only when the multitask option is supported. Instruction 1 Miscellaneous 2 Program control 3 Skip 4 Offset/Frames
5 MACTO 6 Independent GP 7 Simultaneous GP
F
Asynchronous operation group instruction
F
Synchronous operation group instruction
With ordinary operation instructions for which these operation group instructions are not specified, all operation groups are executed with the same operation format, feedrate, and positioning format, and are synchronized with the operation add instructions. The operation group having the longest travel time is that with which the other operation groups are synchronized.
4.16.1 Asynchronous operation group instruction The asynchronous operation group instruction controls operation groups asynchronously, with the operation formats, feedrates, and positioning formats specified separately for the individual operation groups. Figure 4--101. Asynchronous operation group instruction
Independent GP GPi (Operation statement of operation group i) GPj (Operation statement of operation group j) Operation statement for the operation group
Operation group number (operation group of the program)
4.16.2 Synchronous operation group instruction The synchronous operation group instruction controls operation groups synchronously, with the operation formats specified separately for the individual operation groups. F
As with ordinary operation instructions, the operation group having the longest travel time is that with which the other operation groups are synchronized. Thus, the feedrate is not always the same as that specified in the program.
F
The positioning format for an operation group with the smallest CNT value (closest to FINE) is also applied to the other operation groups.
Figure 4--102. Synchronous operation group instruction
Simultaneous GP GPi (Operation statement of operation group i) GPj (Operation statement of operation group j) Operation statement for the operation group
Operation group number (operation group of the program)
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5. PROGRAMMING This chapter describes how to create and change a program for moving the robot. j Contents of this chapter 5.1 Tips on Effective Programming 5.2 Turning on the Power and Jog Feed 5.3 Creating a Program 5.4 Changing a Program 5.5 Program Operation 5.6 Background Editing 5.7 Singular Point Check Function
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Various program instructions are issued to the robot and peripherals to specify motions and arc welding. When these instructions are combined together, they create what is called an arc welding application program. A arc welding application program for instance, can: F
Move the robot to desired positions in the operating area along the specified path
F
Perform arc welding
F
Send output signals to the peripherals
F
Receive input signals from the peripherals
Before programming, design the outline of a program. In the design, incorporate the most effective method for the robot to do the target work. This enables efficient programming and ensures that only the instructions appropriate for the purpose are used. Instructions must be selected from menus displayed on the teach pendant during programming. To teach a target position to the robot, the robot must be moved to the target position by jog feed. After you have finished creating the program, change the program if necessary. To change, add, delete, copy, find, or replace an instruction, select the desired item from the menu displayed on the teach pendant. This chapter describes the following: F
Tips on effective programming
F
Turning on the power and jog feed
F
Creating a program
F
Changing a program
See Chapter 4 for the configuration of a program and the program instructions. Figure 5--1. Programming by Teaching
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5.1 Tips on Effective Programming This section describes tips on effective programming. The following items are explained: F Motion instructions F Fixed positions F Arc welding NOTE This section describes tips on programming, but does not describe tips on jog feed.
5.1.1 Motion instructions Refer to the following instructions when teaching motions to the robot. Arc start/end = FINE positioning Use FINE positioning for the arc start and arc end positions. The tool thus stops precisely at each welding position. If CNT positioning is used, the tool will not stop at the programmed positions. Moving around workpieces = CNT positioning Use CNT positioning for moving around workpieces. The robot continuously moves to the next target point without stopping at taught points. If the robot moves near the workpieces, adjust the path of CNT positioning. Figure 5--2. Adjusting the path of CNT Positioning
FINE CNT0 CNT50 CNT100 Fixing the attitude of the tool Cycle time is wasted when the robot motion abruptly changes the attitude of the tool. The robot moves much faster when the attitude of the tool is changed smoothly and gradually. Teach positions so that the attitude of the tool changes as gradually as possible with respect to the robot. When the attitude of the tool must be changed substantially, teach one large motion by dividing it into several small motions. To change the attitude of the hand as smoothly as possible: 1 Teach the first position of the work so that the robot has a normal attitude. 2 Move the robot to the last position of the work by jog feed. Then check that the robot has a normal attitude. 3 Teach the last position. 4 In accordance with the work, teach a position between the first and last positions. 5 Select a Cartesian coordinate system (World, user or jog coordinate system) and move the robot to the first position by jog feed. 6 Select the Cartesian coordinate system, move the robot toward the last position by jog feed, then stop the robot at the next position to be taught. 7 Correct the taught position so that the robot has a normal attitude. WARNING If the J5 axis passes singularity points (near 0 degrees) when the robot is operated by setting the move type to linear, the additional move instruction with no attitude must be used for these points, or the move type must be changed from linear to axial. 8 Repeat steps 6 and 7 for all the remaining positions to be taught between the first and last positions.
5.1.2 Predefined position The predefined position is used in the program. This is the position that is referenced many times in the program. The predefined positions that are used often are the pounce position and the home(perch) position. You should define these positions to program efficiently or delete cycle time.
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Pounce position The pounce position is the reference position of the robot for all work. This is the safe position away from the motion area of the machine tool and peripheral device. Home(perch) position The home position, or perch position, is a safety position away from the machine tool and the workpiece transfer area. The reference position digital output signal is turned on when the robot is at this position.(See Section 3.16, “Setting a Reference Position”) NOTE HOME is a peripheral device I/O input signal, and does not represent a home position. A reference position is one of the home positions, but there is no utility used to move the robot to the reference position. Other predefined position The pounce position, reference position, or any other position can be defined as a predetermined position. Specify those positions that are frequently used in a program as predetermined positions. When using the fixed position, use position registers (See Section 7.4) and macro instructions (See Section 9.1). CAUTION If the position variable and position register are taught according to axial type, they are not affected when the user coordinate system is changed. If the position variable is taught according to rectangular type, and the user coordinate system input option is not used, the position variable is not affected by the user coordinate system. In other cases, both the position variable and position register are affected when the user coordinate system is changed. NOTE To move the robot to the same spatial position when the position register is shared by two programs, the two programs must have the same tool and user coordinate system.
5.1.3 Arc welding When programming arc welding instructions, pay particular attention to the following: F
To move the tool to an arc welding start point, use joint motion and FINE positioning for the motion instruction.
F
To move the tool to an arc welding passing point, use linear motion and CNT positioning for the motion instruction.
F
Specify the correct orientation of the torch relative to the workpiece to be welded.
F
Use suitable welding conditions. For details, refer to the detailed description of arc welding.
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5.2 Turning on the Power and Jog Feed 5.2.1 Turning on the power and turning off the power Turning on the power starts up the robot system. Turning on the power normally executes internal processing called a cold start or hot start, then the system is started up. The special operation is necessary to perform processing with a control or initial start.(See Section B.1, “START MODE”) CAUTION Some systems require inspection before the robot is turned on. For the sake of safety, how to start the system should be checked before the robot is turned on.
Hot start You can select if the hot start is effective when starting up the robot system. The hot start is the function that saves the condition of the system just before power off and revives it after the next power on.(See Section 3.21, “System config menu”) F
If the hot start is set to be disable($SEMIPOWERFL=FALSE), the system starts up with the cold start. In cold start mode,the system software of the controller is initialized during starting. When you change the setting of the system such as I/O configuration, you should start up in cold start mode.
F
If the hot start is set to be effective($SEMIPOWERFL=TRUE), the system starts up in hot start mode. In hot start mode, the system software of the controller is not initialized during start up.
HOT START done signal You can set the digital output signal(DO) to be turned on when the hot start is finished. This function is set with the system configuration screen [6 SYSTEM.Config].(See Section 3.21, “System Config Menu”) Automatic start program An automatic start program can be specified. The program is automatically started when the power is turned on. If override and parameter instructions are specified in the program to be started, the system can be customized when the power is turned on. F
In Autoexec program for Cold start of the system setting menu, register a program to be automatically started when power interrupt handling is disabled. Such a program, if not defined, is not started.
The automatic start program cannot operate the robot. The automatic start program is used to set up the system or initialize the state of I/O, etc.(See Section 3.21, “System config menu”)
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Program selection after power on The condition of the program selection after power on is the following: F
When the hot start is disabled, it depends on the setting of the system variable,$DEFPROG_ENB. You can set $DEFPROG_ENG with the system config menu. -- TRUE : The program which had been selected at power off is selected. -- FALSE : No program is selected.
F
When the hot start is effective, a program which had been selected at power off is selected.
System condition The table below lists settings in different start modes. Table 5--1.
System Statuses in Different Start Modes Hot start Effective
Disable(default setting)
Contents of register
○
○
Override
○
× [10%]
Selection program
○
n (NOTE 3)
Execution line
○
× [First line]
Condition of I/O
○ (NOTE 1)
× [All off]
TP screen
n (NOTE 2)
× [Hint screen]
○ : All values that are current at power--down are saved and restored at power--up. n : Only some of the values that are current at power--down are saved. × : The values that are current at power--down are not saved. At power--up, the default values are set. NOTE 1 Generally, the status existing at power--down is restored, but digital output (SDO), being performed by a pulse instruction at power--down, is turned off. To restore the I/O status, specify the desired restoration status in [6 SYSTEM Config] (see Section 3.21). Even if power interrupt handling is enabled, none of the output signals are resumed, but all output signals are turned off in the following cases: -- The I/O allocation was changed before power--off. -- The fuse of the I/O device blew, or the power to the I/O device was turned off. -- The I/O device configuration was changed. NOTE 2 The screen type selected at power--down is restored, but the page, cursor, and other screen statuses are not restored. Instead, the screen is restored using the same page, cursor, and other screen statuses assumed immediately after a cold start. NOTE 3 The name of the main program that calls the subprogram is stored. CAUTION Before the power is turned on, system statuses in the corresponding start mode described above should be checked.
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5.2.2 Three--Mode Switch The three--mode switch is a key operation switch installed on the operator’s panel or operation box. This switch is used to select an optimum robot operation mode according to the robot operation conditions and use status. There are operation modes AUTO, T1, and T2. See Figure 5--3. Figure 5--3. Three--mode switch < 250 mm/s T1 AUTO
100% T2
When the three--mode switch is used to switch between operation modes, a message appears on the screen of the teach pendant, and the robot halts. When the key is removed from the switch, the switch setting position can be fixed. (For the CE and RIA specifications, when the switch is set to T2 mode, the key cannot be removed to fix the switch setting position.) CAUTION For the RIA specification, if switching between T1 or T2 mode and AUTO mode is made with the deadman’s switch kept holded, a system error occurs. In this case, selected mode is not set until the deadman’s switch is released. Release the deadman’s switch, then hold the deadman’s switch again.
Connection: Connect the *FENCE signal to the protective fence. Make a connection in such a way that, when the protective fence is open, the signal entered to the robot is off and, when it is closed, the signal is on. The *SFSPD signal can be used in accordance with the design of your system. The following explains the operation modes that can be selected using the three--mode switch:
T1 (<250 mm/s): Test mode 1 This mode is intended for use to teach the position of operation to the robot. It can also be used to check the robot path at low speed and the program sequence. Program execution: A program can be executed only from the teach pendant. Robot speed at jogging F
The speeds at the tool tip and flange are both limited not to exceed 250 mm/sec.
Robot speed at executing program F
The override value can be increased to up to 100%, but the speeds at the tool tip and flange surface are limited to 250 mm/sec or slower. For example, if the taught speed is 300 mm/sec, the speeds at the tool tip and flange surface are limited to 250 mm/sec. If the taught speed is 200 mm/sec, they are not limited. Even when the taught speed is 250 mm/sec or below, the speed on the flange surface may exceed 250 mm/sec in a portion (for example, a corner) where the posture of the tool changes. In this case, the actual operation speed is limited. The warning message MOTN -- 231 T1 speed limit (G:i ) appears only if the operation speed is limited and the taught speed is 250 mm/sec or below.
F
Speed limitation is performed based on the taught speed with an override value of 100%. Therefore, if the taught speed is, for example, 2000 mm/sec, the operation speed is limited to 250 mm/sec for an override value of 100%. However, the operation speed can be decreased further, for example, to 125 mm/sec by lowering the override value to 50%.
Protective fence: If you want to work with the protective fence kept open, it is necessary to set the three--mode switch to T1 or T2 before starting operating the robot.
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F
It is possible to operate the robot only when the teach pendant is enabled and the deadman switch is pressed (gripped).
F
Disabling the teach pendant puts the robot in an emergency stop alarm condition, so the robot cannot run.
F
When the teach pendant is enabled, but the deadman switch is not pressed, the robot is in an emergency stop alarm condition, so it cannot run. CAUTION
When checking the program you created, be sure to follow the safety manual.
Fixing operation mode: When the switch is set in the T1 mode position, the operation mode can be fixed to T1 mode by removing the key. Troubleshooting F
When the switch is set in the T1 mode position, turning off the teach pendant enable switch stops the robot and causes an error message to appear. To release the error, set the teach pendant enable switch to on, then press the RESET key.
T2 (100%): Test mode 2 The T2 mode is intended for use to make a final check of the program you created. In the T1 mode, it is impossible to verify the robot’s actual tool path and cycle time because the operation speed is limited. In the T2 mode, it is possible to verify them by running the robot at the production speed because there is basically no speed limitation(*). * Using a safety speed based on the *SFSPD signal can limit the operation speed of the robot even in the T2 mode by lowering the override value. (Reference) If *SFSPD is off, the override value is limited to within a value specified by $SCR.$SFRUNOVLIM (default: 30%). Program execution: A program can be executed only from the teach pendant. Robot speed at jogging F
The speeds at the tool tip and flange are both limited not to exceed 250 mm/sec.
Robot speed at executing program F
The override value can be increased to up to 100%. There is no special speed limitation.
Protective fence: If you want to work with the protective fence kept open, it is necessary to set the three--mode switch to T1 or T2 before starting operating the robot. F
It is possible to operate the robot only when the teach pendant is enabled and the deadman switch is pressed (gripped).
F
Disabling the teach pendant puts the robot in an emergency stop alarm condition, so the robot cannot run.
F
When the teach pendant is enabled, but the deadman switch is not pressed, the robot is in an emergency stop alarm condition, so it cannot run. CAUTION
When checking the program you created, be sure to follow the safety manual.
Fixing operation mode: When the switch is set in the T2 mode position, the operation mode can be fixed to T2 mode by removing the key. (For the CE and RIA specifications, however, the key cannot be removed.) Troubleshooting F
When the switch is set in the T2 mode position, turning off the teach pendant enable switch stops the robot and causes an error message to appear. To release the error, set the teach pendant enable switch to on, then press the RESET key.
AUTO: Auto mode The AUTO mode is intended for use at production. Program execution: There is no restrictions on program execution. A program can be executed from external devices, operator’s panel, and teach pendant. Only when the RIA specification is used, however, program execution from the teach pendant is impossible if the switch is set in the AUTO mode position.
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Robot speed at jogging: The robot can be operated at a maximum speed. Only for the CE and standard specifications, jogging is possible. For the RIA specification, jogging is not possible. F
The speeds at the tool tip and flange are both limited not to exceed 250 mm/sec.
Robot speed at executing program F
The robot can be operated at a maximum speed.
Safety devices: Close the protective fence. When the protective fence is opened during program execution, the robot responds as follows: F
The robot decelerates and stops. After a certain time, the robot enters the emergency stop state. If the protective fence is opened while the robot is operating at a high speed, the robot may enter the emergency stop state during deceleration. In this case, the robot stops immediately at this point.
F
The robot stops immediately in the same manner as when another emergency stop signal is applied.
Fixing operation mode: When the switch is set in the AUTO mode position, the operation mode can be fixed to AUTO mode by removing the key. Troubleshooting When the switch is set in the AUTO mode position, turning on the teach pendant enable switch stops the robot and causes an error message to appear. To release the error, set the teach pendant enable switch to off, then press the RESET key.
Three--mode switch and program operation The following table lists the relationships among the three--mode switch setting, protective fence status (*FENCE signal), teach pendant (TP) enabled/disabled, deadman switch setting, *SFSPD signal status, and program--specified robot operation speed.
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Relationships between three--mode switch settings and program operations [standard (domestic) specification] Three-mode switch
Protective fence(*1)
*SFSPD
TP enabled/ disabled
TP deadman Gripped
Enabled Released Open
ON
Closed
ON
Released
Emergency stop (fence open)
Disabled
Enabled Open
ON
Released
Closed
ON
TP only
Programmed speed
Emergency stop (deadman) Operable
External start(*2)
Programmed speed
Released
Operable
External start(*2)
Programmed speed
Gripped
Operable
TP only
T1 speed
TP only
T1 speed
TP only
Programmed speed(*3)
TP only
Programmed speed
Released
Emergency stop (deadman)
Gripped
Alarm and stop (T1/T2 and TP disabled)
Released
Emergency stop (T1/T2 and TP disabled)
Gripped Enabled
Operable
Gripped
Disabled T1
Program--specified operation speed
Emergency stop (deadman, fence open) Emergency stop (fence open)
Gripped Enabled
Units that can be started
Emergency stop (fence open)
Gripped Disabled
AUTO
Robot status
Released
Operable Emergency stop (deadman)
Gripped
Alarm and stop (T1/T2 and TP disabled)
Released
Emergency stop (T1/T2 and TP disabled)
Disabled
Gripped
Operable
Enabled Released Open
ON(*4)
Gripped
Alarm and stop (T1/T2 and TP disabled)
Released
Emergency stop (T1/T2 and TP disabled)
Disabled T2 Gripped Enabled Closed
ON
Emergency stop (deadman)
Released
Operable Emergency stop (deadman)
Gripped
Alarm and stop (T1/T2 and TP disabled)
Released
Emergency stop (T1/T2 and TP disabled)
Disabled
*1 Protective fence status Open: *FENCE is off. Closed: *FENCE is on. *2 External speed Remote mode: Program start on the line control panel Local mode: Start button on the robot operation panel *3 When the three--mode switch is in the T2 position and the fence is open, if you want to clamp a program--specified speed with the SFSPD override value, configure the system in such a way that the *SFSPD mentioned at *4 becomes off. NOTE
SFSPD override:When the program is executed with *SFSPD turned off, the override value is limited to within a value specified in $SCR.$SFRUNOVLIM (default value: 30%).
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Relationships between three--mode switch settings and program operations [CE specification] Three-mode switch
Protective fence(*1)
*SFSPD
TP enabled/ disabled
TP deadman Gripped
Enabled Released Open
ON
Closed
ON
Released
Emergency stop (fence open)
Disabled
Enabled Open
ON
Released
Closed
ON
TP only
Programmed speed
Alarm and stop (deadman) Operable
External start(*2)
Programmed speed
Released
Operable
External start(*2)
Programmed speed
Gripped
Operable
TP only
T1 speed
TP only
T1 speed
TP only
Programmed speed(*3)
TP only
Programmed speed
Released
Emergency stop (deadman)
Gripped
Emergency stop (T1/T2 and TP disabled)
Released
Emergency stop (T1/T2 and TP disabled)
Gripped Enabled
Operable
Gripped
Disabled T1
Program--specified operation speed
Emergency stop (deadman, fence open) Emergency stop (fence open)
Gripped Enabled
Units that can be started
Emergency stop (fence open)
Gripped Disabled
AUTO
Robot status
Released
Operable Emergency stop (deadman)
Gripped
Emergency stop (T1/T2 and TP disabled)
Released
Emergency stop (T1/T2 and TP disabled)
Disabled
Gripped
Operable
Enabled Released Open
ON(*4)
Gripped
Emergency stop (T1/T2 and TP disabled)
Released
Emergency stop (T1/T2 and TP disabled)
Disabled T2 Gripped Enabled Closed
ON
Emergency stop (deadman)
Released
Operable Emergency stop (deadman)
Gripped
Emergency stop (T1/T2 and TP disabled)
Released
Emergency stop (T1/T2 and TP disabled)
Disabled
*1 Protective fence status Open: *FENCE is off. Closed: *FENCE is on. *2 External speed Remote mode: Program start on the line control panel Local mode: Start button on the robot operation panel *3 When the three--mode switch is in the T2 position and the fence is open, if you want to clamp a program--specified speed with the SFSPD override value, configure the system in such a way that the *SFSPD mentioned at *4 becomes off. NOTE
SFSPD override:When the program is executed with *SFSPD turned off, the override value is limited to within a value specified in $SCR.$SFRUNOVLIM (default value: 30%).
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Relationships between three--mode switch settings and program operations [RIA specification] Three-mode switch
Protective fence(*1)
*SFSPD
TP enabled/ disabled
TP deadman Gripped
Enabled Released Open
ON
Released
Emergency stop (fence open)
Gripped Closed
Released
ON Disabled
Enabled Open
ON
Closed
ON
Alarm and stop (deadman) Operable
External start(*2)
Programmed speed
Released
Operable
External start(*2)
Programmed speed
Gripped
Operable
TP only
T1 speed
TP only
T1 speed
TP only
Programmed speed(*3)
TP only
Programmed speed
Released
Emergency stop (deadman)
Gripped
Emergency stop (T1/T2 and TP disabled)
Released
Emergency stop (T1/T2 and TP disabled)
Gripped Enabled
Alarm and stop (AUTO and TP enable)
Gripped
Disabled T1
Program--specified operation speed
Emergency stop (deadman, fence open) Emergency stop (fence open)
Enabled
Units that can be started
Emergency stop (fence open)
Gripped Disabled AUTO
Robot status
Released
Operable Emergency stop (deadman)
Gripped
Emergency stop (T1/T2 and TP disabled)
Released
Emergency stop (T1/T2 and TP disabled)
Disabled
Gripped
Operable
Enabled Released Open
ON(*4)
Gripped
Emergency stop (T1/T2 and TP disabled)
Released
Emergency stop (T1/T2 and TP disabled)
Disabled T2 Gripped Enabled Closed
ON
Emergency stop (deadman)
Released
Operable Emergency stop (deadman)
Gripped
Emergency stop (T1/T2 and TP disabled)
Released
Emergency stop (T1/T2 and TP disabled)
Disabled
*1 Protective fence status Open: *FENCE is off. Closed: *FENCE is on. *2 External speed Remote mode: Program start on the line control panel Local mode: Start button on the robot operation panel *3 When the three--mode switch is in the T2 position and the fence is open, if you want to clamp a program--specified speed with the SFSPD override value, configure the system in such a way that the *SFSPD mentioned at *4 becomes off. NOTE
SFSPD override:When the program is executed with *SFSPD turned off, the override value is limited to within a value specified in $SCR.$SFRUNOVLIM (default value: 30%).
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5.2.3 Moving the robot by jog feed The robot moves by jog feed when the jog keys on the teach pendant are pressed. The robot must be moved to a target position when motion instructions are specified in the program. Jog feed depends on the following two factors: F F
Feedrate override: Robot motion speed (jog feedrate) Manual--feed coordinate system: Coordinate system for robot motion (jog feed type)
Feedrate override A feedrate override is one of the two factors on which jog feed depends. The feedrate override is represented in percentage (%). The current feedrate override is displayed at the upper right corner of the screen of the teach pendant. Pressing the feedrate override key displays a pop up window in reverse video at the upper right of the screen to call the user’s attention. The popup window in reverse video automatically disappears after a few seconds or when another key is pressed. Figure 5--4. Screen Display for Feedrate Override Feedrate override JOINT 30% JOINT 30%
VFINE FINE
Very low speed Low speed
1% ↓ 50% ↓ 100%
Feedrate override 100% means that the robot moves at the maximum feedrate. The step feed--rate of FINE is specified by a system variable, $JOG_GROUP.$FINE_DIST in linear jog.(Standard : 0.1mm). In standard setting,each axis rotates at 0.001deg per step. The step width of VFINE is one--tenth of that of FINE. NOTE If VFINE or FINE is used as the current speed override, the robot makes a motion of a single step at a time. To resume the robot motion, release and press the jog key. Table 5--2 shows the change in feedrate override when the override key is pressed. Table 5--2.
Feedrate Override
When the override key is pressed
VFINE → FINE → 1% → 5% → 50% → 100% In 1% In 5% increments increments
When the override key is pressed while pressing the SHIFT key(*1)
VFINE → FINE → 5% → 50% → 100%
*1 Enabled only when $SHFTOV_ENB is 1
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To change the feedrate override, press the override key. Whenever the override key is pressed while the shift key is pressed, the feedrate changes sequentially in the order: FINE, VFINE, 5%, 50%, and 100%. However, the feedrate is changed in this way only when system variable $S HFTOV_ENB = 1. Figure 5--5. Override Keys
+%
+%
+% SHIFT +
--%
--%
--%
OR A feedrate override must be determined according to the condition of the machining cell, type of the robot motion, or the skill of the operator. Therefore, an inexperienced robot operator should use a low feedrate override. NOTE When the override key is pressed, a window indicating the manual feed coordinate system and speed override appears on the screen in reverse video. Pressing the override key again enables you to change the override value. If the override key is not pressed, the window closes automatically. This window is automatically closed if the override keys are not pressed for a while. When the safe speed signal (*SFSPD input) (See Section 3.10) is turned off, the speed override is reduced to the value of $SCR.$FENCEOVRD. In this state, the speed override cannot be increased beyond the upper limit specified by $SCR.$SFJOGOVLIM (See Section 3.10). A function is available which restores the speed override when the safety fence is closed (See Section 3.23). Jog feedrate A jog feedrate is a speed at which the robot moves during jog feed. The jog feedrate is obtained by the following expression: If the following value exceeds the speed limit 250 mm/sec for the T1 or T2 mode described above, the operation speed is clamped at the one described earlier. Figure 5--6. Jog Feedrate Jog feedrate (joint feed) = Maximum joint feedrate
Each axis jog override 100
Jog feedrate (linear feed) (mm/sec) = Jog override Maximum linear feedrate 100 Jog feedrate (Circular feed) (mm/sec) = Jog override Maximum circular feedrate 100 Each axis jog override Jog override Maximum joint feedrate Maximum linear feedrate Maximum circular feedrate
Feedrate override 100
Feedrate override 100
Feedrate override 100
$SCR_GRP.$JOGLIM_JNT[i] (%) $SCR.$JOGLIM (%) $PARAM_GROUP.$JNTVELLIM (deg/sec) $PARAM_GROUP.$SPEEDLIM (mm/sec) $PARAM_GROUP.$ROTSPEEDLIM (deg/sec)
Manual--feed coordinate systems (Jog type) Manual--feed coordinate systems determine how the robot moves during jog feed. The manual--feed coordinate systems are classified into three types: Joint jog (JOINT) During joint jog, the robot moves independently around each axis according to each joint coordinate system. See Section 3.15 for the joint coordinate systems.
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Figure 5--7. Joint Jog Joint coordinate systems
Cartesian jog (XYZ) During Cartesian jog, the tool center point of the robot moves along the X--, Y--, and Z--axes of the user or jog coordinate systems. You can not cause the robot to rotate the tool around x--,y--,and z--axis of the user frame or jog frame.(See Section 3.15.2, “Setting a user coordinate system”, and Section 3.15.3, “Setting a jog coordinate system”) Figure 5--8. Cartesian Jog
--
Z
Z
+ R
Y
--
+
Y
-W +
X
251
P
X
Cartesian coordinate systems (jog or user coordinate systems)
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Tool jog (TOOL) During tool jog, the tool center point (TCP) moves along the X--, Y--, and Z--axes of the tool coordinate system defined for the wrist of the robot. You can not cause the robot to rotate the tool around x--,y--,and z--axis of the tool frame.(See Section 3.15.1, “Setting a tool coordinate”) Figure 5--9. Tool Jog
Z --
R+
--
Y +
P
-+
X
Torch jog function The torch jog function defines a coordinate system called a path coordinate system with respect to a taught path, and allows the robot to be manually operated in the coordinate system. A path coordinate system is a non--Cartesian coordinate system where the X--axis is a taught path, the Z--axis is the Z--axis direction of the tool coordinate system, and the Y--axis is an axis perpendicular to these two axes. With this function, a path already taught can be easily modified. WARNING In torch jog, the robot makes movements different from ordinary jog operations because the robot moves in a dynamic path coordinate system generated from a taught path. So, when using the path jog function, take sufficient safety precautions such as decreasing the override value and checking the direction of movement beforehand.
WARNING When multiple groups or sub--groups are involved, check which group is selected.
The major features of the path jog function are listed below. F
When the torch path jog function is used, the wrist switch function and remote TCP function are disabled.
F
Path jog is determined by a taught path, so that torch jog can be used only when the program is temporarily stopped. So, if an attempt is made to perform torch jog after the program is terminated, torch jog is disable with a warning.
F
If there is not a path coordinate system for a reason such as the absence of a travel distance, torch jog is disabled with a warning.
F
If the direction of a path is parallel with the Z--axis of the tool coordinate system, torch jog is disabled with a warning.
F
If torch jog is performed after recovery from a power failure, the robot operates in the torch coordinate system present before the power failure.
F
The torch jog function can be used for a linear or circular movement path only; the function cannot be used for axial movement paths.
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Path jog along a linear path WELD_1
JOINT
10 % 3/4
1:L P[1] 50cm/min FINE 2:L P[2] 50cm/min FINE 3:L P[3] 50cm/min FINE [End]
POINT
ARCSTRT WELD_PT
ARCEND TOUCHUP>
-- If the robot temporarily stops at point A in the program above, a path coordinate system is generated as shown below.
Z Y
Path coordinate system
X X
X
P [1]
A
X P [2]
-- If the robot temporarily stops at point 2 during forward movement in the program above, a path coordinate system is generated as shown below by referencing the most recently executed operation.
Z Y
Path coordinate system
X X P [1]
X P [2]
X P [3]
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5. PROGRAMMING
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-- If the robot temporarily stops at point 2 during backward movement in the program above, a path coordinate system is generated as shown below by referencing the most recently executed operation.
Z Path coordinate system
Y X
X
P [1]
P [2]
X X P [3]
Torch jog along a circular path If torch jog is performed during movement along a circular path, the robot moves along the X direction and the Y direction as follows: X direction: Movement along the arc Y direction: Movement along the straight line that connects the center of the arc and a temporary stop point
Alarm Codes JOG--020 PAUSE Can not PATH JOG now The Z direction matches the taught path, so that a Y--axis direction calculation cannot be made. Cause: Remedy:
Accordingly, a path coordinate system cannot be generated, thus disabling torch jog. Perform another type of jog.
JOG--021 PAUSE Multi key is pressed. If two jog keys are pressed simultaneously in an attempt to perform torch jog, torch jog cannot be Cause: Remedy:
performed. When torch jog is selected, do not press two jog keys at a time.
Selecting a manual--feed coordinate system The current manual--feed coordinate system is displayed at the upper right corner of the screen of the teach pendant. Pressing the COORD key displays a popup menu in reverse video at the upper right of the screen to call the user’s attention. The popup menu in reverse video automatically disappear after a few seconds or when another key is pressed. Figure 5--10. Screen Display for Manual--Feed Coordinate Systems Manual--feed coordinate systems
JOINT
JOINT JGFRM USER TOOL PATH
XYZ TOOL OFF
COORD key
ON
COORD
254
Joint jog Cartesian jog Cartesian jog Tool jog Tool jog
JOINT 30% 1/6 JOINT 30%
5. PROGRAMMING
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Whenever the COORD key on the teach pendant is pressed, the selected manual--feed coordinate system change cyclically. When a manual--feed coordinate system changes sequentially in the order shown in Table 5.2. is selected, its corresponding LED lights. Table 5--3.
Jog type Selection Sequence →
JGFRM
→
TOOL
→
USER
→ PATH→
Screen display
JOINT
JOINT
LED state
JOINT LED on→XYZ LED on→TOOL LED on→XYZ LED on→TOOL→JOINT LED on
Enabling a wrist joint feed In wrist joint feed, the attitude of the tool is not held during linear feed (Cartesian jog feed) or circular feed (tool jog feed). F
When wrist joint feed is disabled, the attitude of the tool is held during jog feed. (Standard setting)
F
When wrist joint feed is enabled, the attitude of the tool is not held during jog feed. In this case, W is displayed on the screen. -- In linear feed (linear motion along the axes of the Cartesian coordinate system), the tool center point moves linearly while the wrist joint is fixed. -- The wrist axis is moved in axial movement while the position of the tool tip is held in rotational feed (attitude rotation about the wrist axis).
Figure 5--11. Indication that Wrist Joint Feed Is Enabled Wrist joint feed enabled
W/TOOL 30% W/TOOL 30%
NOTE When the motion instruction for linear or circular motion under path control is executed, wrist joint feed has the same function as the wrist joint motion instruction (WRIST JOINT). Switching to additional axes In addition to the standard robot axes (usually 4 to 6 axes) in one operation group, up to three additional axes can be controlled as a subgroup. NOTE The user can switch to a subgroup by using the auxiliary menu or jog menu described below. Jog menu With the jog menu function, the following data related to jog operation can be displayed or updated easily: F
Tool, jog, or user coordinate system number currently selected
F
Group number currently selected
F
Subgroup selection state (robot or additional axes)
To display the jog menu, press the manual feed coordinate system key while holding down SHIFT key. TEST UTILITIES Hints
TOOL 100% Tool 2 Jog 3 User 1 Group 2 Robot/Ext
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5. PROGRAMMING
Table 5--4.
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Operation Procedure Using the Jog Menu
Operation Opening the menu Closing the menu
Moving the cursor Changing the coordinate system number
Procedure Press the manual feed COORD key while holding down SHIFT key. F Press the manual feed COORD key while holding down SHIFT key. F Press PREV key. F Value modification using numerical key (See the descriptions of coordinate system number change and group switching.) cursor key F Tool coordinate system, jog coordinate system 1 to 5 F User coordinate system 0 to 5 Numeric key (valid for existing group numbers only)
Group switching (for a multi--group system only) Subgroup switching After moving the cursor to the line containing Robot/Ext, switch between (for a system with a subgroup) Robot and Ext by using the left/right cursor key. (The position of reverse video switches.) WARNING Operation for coordinate system number/group number switching is so simple that the operator might forget that the operator performed a switching operation. In such a case, a robot might move in an unexpected direction at jog time, or a robot of an unexpected group might move, thus leading to a fatal accident. Be sure to remember the current coordinate system number/group number. Otherwise you could injure personnel or damage equipment.
WARNING If the jog menu is left open, the operator might change the coordinate system number or group number by touching a numeric key of the teach pendant unconsciously. In such a case, a robot may move in an unexpected direction at jog time, or a robot of an unexpected group might move, thus leading to a fatal accident. After coordinate system number/group number switching, be sure to close the jog menu.
256
5. PROGRAMMING
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Procedure 5--1 Condition
Moving the robot by jog feed
H Do not enter the operating area. Do not put any obstacles within the work area. CAUTION Before jog feed of the robot is started, it should be ensured that all safety requirements for the work area are satisfied. Otherwise, injury or property damage could occur.
Step
1 Press the COORD key to display a desired manual--feed coordinate system on the teach pendant. NOTE The feedrate override is automatically set to 10%. 2 Press the override key to adjust the jog feedrate displayed on the teach pendant. 3 Hold the teach pendant and press the deadman switch on the back of the teach pendant. Continue pressing the deadman switch during jog feed. 4 Turn on the teach pendant enable switch. NOTE If the deadman switch is released when the teach pendant enable switch is on, an alarm occurs. To reset the alarm, press and hold down the deadman switch again, then press the RESET key on the teach pendant. NOTE If the operator is not accustomed to the operation of the robot or is not sure about the robot motions, low feedrate overrides should be set. CAUTION The robot starts its motion in the next step. If the jog feed of the robot needs to be stopped in an emergency in order to avoid danger, the operator should release the deadman’s switch or press the emergency stop button.
5 To move the robot by jog feed, press the jog key corresponding to the desired robot motion direction while pressing the SHIFT key. When the jog key is released, the robot stops. NOTE When the override is FINE or VFINE, press the jog key and release it every time one step. Switch to wrist joint feed 6 Press the FCTN key. The function menu is displayed. 7 Select 5,TOGGLE WRIST JOG. The mark,W, is displayed to show the wrist joint jog mode. To release this mode, select 5,TOGGLE WRIST JOG again. 3 4 TOGGLE WRIST JOG 5 SAVE
SAMPLE1
W/TOOL
30 % 1/6
FCTN
Switch to a extended axis 8 Press the FCTN key. The function menu is displayed. 9 Select 4,TOGGLE SUB GROUP. The control of jog is switched from the robot standard axes to an extended axis. The control will be returned when it is done again. 3 CHANGE GROUP 4 TOGGLE SUB GROUP 5 TOGGLE WRIST JOG
SAMPLE1
S
W/TOOL
30 % 1/6
FCTN
10 To terminate jog feed, turn off the teach pendant enable switch and release the deadman switch.
257
5. PROGRAMMING
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5.3 Creating a Program To create a program, use the following procedure: F
Register a program and specify program information
F
Modify standard instruction (standard motion instructions and standard arc instructions)
F
Teach motion instructions
F
Teach arc welding instructions and other control instructions.
Figure 5--12. Creating and Changing a Program Change an existing program.
Create a new program.
Register the program.
Select a program.
Change standard motion instructions. Teach motion instructions. Correct the instructions. End
Registering a program Create a null program with a new name. Specifying program information Specify the attributes of the program. Changing standard motion instructions Respecify the standard instructions to be used when teaching motion instructions. Teaching motion instructions Teach a arc motion instruction, a motion instruction and an supplementary motion instruction. Teaching control instructions Teach control instructions including a palletizing instruction and arc welding instructions. Use the teach pendant to create a new program and correct an existing program. To do this, the teach pendant must be enabled beforehand. To enable the teach pendant, satisfy the following condition: J
The teach pendant enable switch must be turned on.
To prevent the program from being started by mistake, prohibit starting a program with a teach pendant while teaching.(See Figure 2--12, “Function menu”)
258
5. PROGRAMMING
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5.3.1 Registering a program Enter a program name and register the program. A program name consists of up to eight alphanumeric characters including symbols to discriminate program names from one another. For the program name, see Section 4.1.1. Register a program on the program registration screen. CAUTION When a new program is made, the current program or halted program is halted.
Entering a program name There are three methods for entering a program name: F
Words: Up to five words consisting of up to seven characters can be used as program names. Enter these reserved words, such as PRG, MAIN, SUB, and TEST, in $PGINP_WORD[1 TO 5] in advance (See Sectioin 3.21, “System config menu”)
F
Uppercase or lowercase alphabetic characters: Any letter of the alphabet can be specified for a program name. The alphabetic characters combined with any numeric characters and/or any symbols are used as the characters of a program name. CAUTION
Asterisks (*) and at marks (@) should not be used in a program name.
Options During optional settings, an overwrite or insert mode can be specified for character entry, or character string deletion. F
In the overwrite mode, entered characters are written over existing characters.
F
In the insert mode, entered characters are inserted before the character pointed to by the cursor. In this case, all the characters to the right of the entered character(s) are shifted to the right. INSERT or OVRWPT is displayed on the screen.
F
All the characters in the field where the cursor is positioned are deleted.
NOTE The program name should not begin with a numeral. Setting program information Set the following program information items on the program information screen. See Section 4.1. F
Program name
F
Subtype
F
Comments: Comments can be written in a program. Up to 16 alphanumeric characters and symbols, which can be used for a program name. In some cases, comments may not be entered.
F
Group mask: Specifies a motion group to be controlled in a program. You can also set a program that has no motion group.
F
Write protection: Prevents a program from being changed.
F
Interruption disable: Causes the program having no motion not to be paused by an alarm whose severity is WARN, PAUSE, STOP, and SERVO, emergency stop, and HOLD. However, this setting is not applied to the alarm that is generated by the program.
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5. PROGRAMMING
Procedure 5--2 Condition Step
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Registering a program
H The teach pendant must be enabled. 1 Press the MENUS key to display the screen menu. 2 Select SELECT. Alternatively, the following program selection screen can also be displayed by pressing the SELECT key. SELECT 1 2 3 4
SAMPLE1 SAMPLE2 PROG001 PROG002
JOINT 30% 61276 bytes free SAMPLE PROGRAM1 SAMPLE PROGRAM2 PROGRAM001 PROGRAM002
[TYPE]
CREATE
DELETE
MONITOR
[ATTR] >
COPY
DETAIL
LOAD
SAVE
PRINT
>
3 Press the F2 (CREATE) key. The program registration screen is displayed. JOINT 30% 1 Words 2 Upper Case 3 Lower Case 4 Options SELECT
---Insert---
---Create Teach Pendant Program--Program Name [ ] Sub type [ ] ---End--Enter program name PRG MAIN SUB TEST
4 Select a method for entering a program name (words or alphabetic characters) using the cursor keys. JOINT 30% 1 Words 2 Upper Case 3 Lower Case 4 Options SELECT
---Insert---
---Create Teach Pendant Program--Program Name [ ] ---End--Enter program name abcdef ghijkl mnopqr
260
stuvwx
yz_@*.
>
5. PROGRAMMING
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5 Enter a program name by pressing the function keys corresponding to the characters in the program name. The function key menu displayed depends on the method selected in step 4. With alphabetic character entry, for instance, press the function key corresponding to a desired character repeatedly until the character is displayed in the program name field; that is, if you want to enter P, press the F4 function key four times. Press the NEXT key to move the cursor to the right one character. Repeat this procedure until the program name is completely entered. abcdef ghijkl mnopqr st
F4
Select
JOINT 30% 1/3 ---Create Teach Pendant Program--Program name: [S ]
abcdef
ghijkl
mnopqr
stuvwx
yz_@*.
>
NOTE When creating a program using RSR or PNS for automatic operation, follow the rule below. Otherwise, the program does not run. F
F
An RSR program must be written as RSRnnnn, where nnnn represents a four--digit number. An example is RSR0001. A PNS program must be written as PNSnnnn, where nnnn represents a four--digit number. An example is PNS0001.
6 After entering a program name, press the ENTER key. SELECT ---Create Teach Pendant Program Name: [SAMPLE3 ENTER
Select JOINT 30% 1 Jobs 5 2 Processes 6 3 Macro 7 4 8 Select ---Create Teach Pendant Program--Program Name: [SAMPLE3 ] Sub type [ ] ---End--Select Sub type
7 To edit the registered program, press the F3 (EDIT) key. The program edit screen for the registered program is displayed. Select function DETAIL EDIT
SAMPLE3
JOINT 30% 1/1
[End]
F3 POINT
ARCSTRT WELD_PT
ARCEND TOUCHUP>
8 To enter program information, press the F2 (DETAIL) key (or the ENTER key). The program information screen is displayed. Select function DETAIL EDIT
F2
Program detail
30 % 1/6 Creation Date: 10-MAR-1994 Modification Date: 11-MAR-1994 Copy Source: [****************] Positions: FALSE Size: 312 Byte 1 Program name: [SAMPLE3 ] 2 Sub Type: [ Process] 3 Comment: [SAMPLE PROGRAM 3] 4 Group Mask: [1,*,*,*,*] 5 Write protect: [ OFF] 6 Ignore pause: [ OFF] END
PREV
JOINT
NEXT
261
5. PROGRAMMING
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9 Specify the following program information items: F
To change a program name, move the cursor to the setting field, change the program name, then press the ENTER key.
F
To change a subtype (see Section 4.1.3), press the F4 (CHOICE) key to display a subtype menu. Then, select None, Job, Process, or Macro. JOB or PROCESS can be selected only when system variable $JOBPROC_ENB is set to 1.
F
To enter comments, move the cursor to the setting field, enter the comments, then press the ENTER key (see Subsection 4.1.2).
F
To specify a group mask, move the cursor to the setting field and select 1, *. The specified motion group is controlled (see Section 4.1.4). For safety, specify (*, *, *, *, *) for programs which do not contain any motion instruction. CAUTION
After a motion group is set and a motion instruction is specified in a program, the motion group setting of the program cannot be changed.
NOTE If the system used does not have the multi--group setting, only either of the following settings is allowed: The first group is set as 1; An asterisk (*) indicating no group is set. F
To specify write protection, move the cursor to the setting field and select ON or OFF (see Subsection 4.1.5).
F
To specify interruption disable, move the cursor to the setting field and press the function key (ON or OFF) (see Section 4.1.6). Select ON for programs not to be halted when an alarm occurs such as macro instructions or automatic start programs.
NOTE To return to the list screen, press the PREV key repeatedly until the list screen is displayed.
Program detail
30 % 1/6 Creation Date: 10-MAR-xxxx Modification Date: 11-MAR-xxxx Copy Source: [****************] Positions: FALSE Size: 312 Byte 1 Program name: [SAMPLE3 ] 2 Sub Type: [ Process] 3 Comment: [SAMPLE PROGRAM 3] 4 Group Mask: [1,*,*,*,*] 5 Write protect: [ OFF] 6 Ignore pause: [ OFF] END
PREV
JOINT
NEXT
10 After entering the program information items, press the F1 (END) key. The program edit screen for the registered program is displayed. END
PREV
NEXT
SAMPLE3
JOINT 30% 1/1
[End]
F1 POINT
ARCSTRT WELD_PT
262
ARCEND TOUCHUP>
5. PROGRAMMING
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5.3.2 Changing a standard motion instruction The standard motion instruction specifies the most frequently used motion instruction items: motion type, feedrate, positioning type, and supplementary motion instruction. Standard arc instruction The standard arc instruction is the standard setting for a motion instruction that includes an arc welding instruction as an additional motion instruction. To change a standard motion instruction, press one of the keys F1 to F4 to display the standard motion instruction menu. Then, press the same function key again to display the standard instruction edit screen. POINT
ARCEND TOUCHUP>
F
Pressing the F1 (POINT) key displays the standard motion instruction menu.
F
Pressing the F2 (ARCSTRT) key displays the menu of standard arc instructions, including the arc start instructions.
F
Pressing the F3 (WELD_PT) key displays the menu of standard motion instructions for those linear motions that are used to teach welding points.
F
Pressing the F4 (ARCEND) key displays the menu of standard arc instructions, including the arc end instructions.
Procedure 5--3 Condition
ARCSTRT WELD_PT
Changing a standard motion instruction
H The program edit screen must be selected. H The teach pendant must be enabled. SAMPLE3
JOINT 30% 1/1
[End]
POINT
Step POINT
F1
ARCSTRT WELD_PT
ARCEND TOUCHUP>
1 Press the F1 (POINT) key. The standard motion instruction menu is displayed. ARCSTRT WELD_PT
Joint default menu 1 J P[ ] 100% FINE 2 J P[ ] 100% FINE 3 L P[ ] 1000cm/min CNT50 4 L P[ ] 1000cm/min CNT50 SAMPLE3
JOINT 30%
1/1 [End] ED_DEF ARCSTRT WELD_PT
ARCEND TOUCHUP>
NOTE If the instructions listed on the submenu are necessary, they need not be changed. 2 To change a standard motion instruction, press the F1 (ED_DEF). ED_DEF
F1
Default Motion 1 2 3 4
J J L L
P[ P[ P[ P[
] ] ] ]
JOINT 30% 1/4
100% FINE 100% FINE 1000cm/min CNT50 1000cm/min CNT50
DONE >
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5. PROGRAMMING
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3 Move the cursor to the instruction item to be changed (motion type, feedrate, positioning type, or supplementary motion instruction) using the cursor keys. Default Motion 1 2 3 4
J J L L
P[ P[ P[ P[
] ] ] ]
JOINT 30% 2/4
100% FINE 100% FINE 1000cm/min CNT50 1000cm/min CNT50
Enter value [CHOICE]
DONE >
4 Select numeric keys and function keys to correct the instruction item. To change the feedrate, for instance, move the cursor to feedrate. Enter a new value with numeric keys, then press the ENTER key.
7
0
Default Motion 1 2 3 4
Old Value: 100
J J L L
P[ P[ P[ P[
] ] ] ]
JOINT 30% 2/4
100% FINE 70% FINE 1000cm/min CNT50 1000cm/min CNT50
ENTER
Enter value DONE >
5 When CHOICE is displayed in the F4 key name field, press the F4 key. Then, an option of another instruction item can be selected from the submenu. Motion Modify 1 Fine 2 Cnt 3 4 Default Motion
[CHOICE]
F4
JOINT 30% 5 6 7 8 2/4
1 2 3 4
J J L L
P[ P[ P[ P[
] ] ] ]
100% FINE 70% FINE 1000cm/min CNT50 1000cm/min CNT50
Select item [CHOICE]
Default Motion Motion Modify 1 FINE ENTER 2 CNT 3 4 Default Motion
5
0
1 2 3 4
J J L L
P[ P[ P[ P[
] ] ] ]
JOINT 30% 4/4
100% FINE 70% CNT50 1000cm/min CNT50 1000cm/min CNT50
Enter value
ENTER
[CHOICE]
6 Repeat steps 3 to 5 for each instruction to be changed. 7 After teaching is completed, press the F5 (DONE) key. DONE
DONE >
>
F5
264
DONE >
5. PROGRAMMING
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Procedure 5--4 Condition Step
POINT
Changing a standard arc instruction
H Display the program edit screen. 1 Press the F2 (ARCSTRT) key. The standard arc instruction menu is displayed. F2, F3, and F4 are used to program the arc start point, welding passing points, and arc end point, respectively.
ARCSTRT WELD_PT
F2
Arc Start def menu JOINT 30 % 1 J P[] 70% FINE Arc Start[1] 2 J P[] 70% FINE Arc Start[3] 3 L P[] 500cm/min FINE Arc Start[1] 4 L P[] 500mm/sec FINE Arc Start[3] SAMPLE1 [End] POINT
ED_DEF WELD_PT
ARCEND TOUCHUP>
2 To change a standard arc instruction, press the ED_DEF key.
POINT
ED_DEF WELD_PT
Start Default 1:J : 2:J : 3:L : 4:L :
F2
P[] Arc P[] Arc P[] Arc P[] Arc
JOINT
30 % 1/4
70% FINE Start[1] 70% CNT50 Start[3] 500mm/min CNT30 Start[1] 500mm/sec CNT30 Start[3] DONE
3 Position the cursor to an element of the instruction (motion type, travel speed, positioning type, additional motion) and change the data. 4 After changing the data, press the F5 (DONE) key. DONE
F5
265
5. PROGRAMMING
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5.3.3 Teaching a motion instruction A motion instruction moves the robot to the specified position in the work area at the specified feedrate using the specified movement method. When the motion instruction is taught, the instruction items of the motion instruction and position data are simultaneously taught. The instruction items of a motion instruction are as follows (see Section 4.3 for the motion instruction): F
Motion type:
Controls a path to the specified position. (joint, linear, circular)
F
Position variable: Stores data on positions to which the robot moves.
F
Feedrate:
Specifies the speed of the robot when it moves.
F
Positioning type:
Specifies whether positioning is performed at the specified position.
F
Supplementary motion instruction: Specifies the execution of an additional instruction while the loader robot is moving.
Teaching a motion instruction is selected after a standard motion instruction is created. In this case, the current position (position data) is stored in the position variable. F
Press the F1, F2, F3, or F4 key to list the stored standard statements. Choose a desired statement from the list, and then program that statement.
F
To program a single standard statement repeatedly, hold down the shift key and press the F1, F2, F3, or F4 key. POINT
ARCSTRT WELD_PT
ARCEND TOUCHUP>
F
Pressing the F1 (POINT) key displays the standard motion instructions menu.
F
Pressing the F2 (ARCSTRT) key displays the menu of standard arc instructions, including the arc start instructions.
F
Pressing the F3 (WELD_PT) key displays the menu of standard motion instructions for those linear motions that are used to teach welding points.
F
Pressing the F4 (ARCEND) key displays the menu of standard arc instructions, including the arc end instructions.
F
Check whether the position to be programmed is one of the robot’s singular points (for singular points, see Position data in 4.3.2). The user can program the position by using the axial method, if so desired. (see Singular point check functions in 5.7)
266
5. PROGRAMMING
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Procedure 5--5 Step
Teaching a motion instruction
1 Move the robot to the desired position in the work area by jog feed. 2 Move the cursor to END. SAMPLE1
JOINT 30% 1/1
[End]
POINT
ARCSTRT WELD_PT
ARCEND TOUCHUP>
3 Press the F1 (POINT) key to display the standard motion instruction menu. POINT
Joint default menu 1 J P[ ] 100% FINE 2 J P[ ] 100% FINE 3 L P[ ] 1000cm/min CNT50 4 L P[ ] 1000cm/min CNT50 SAMPLE3
F1
JOINT 30%
1/1 [End] ED_DEF ARCSTRT WELD_PT
ARCEND TOUCHUP>
4 Select the standard motion instruction to be taught, press the ENTER key, and specify the desired position and the motion instruction. Joint 1 J 2 J 3 L 4 L
default menu P[ ] 100% FINE P[ ] 100% FINE P[ ] 1000cm/min ENTER P[ ] 1000cm/min
SAMPLE1
JOINT 30% 2/2
1: J P[1] 100% FINE [End]
Position has been recorded to P[1]. POINT
ARCSTRT WELD_PT
ARCEND TOUCHUP>
5 Repeat steps 2 to 4 for each motion instruction to be specified in the program. 6 To specify the same standard motion instruction repeatedly, press the F1 (POINT) key while pressing the SHIFT key. This adds the previously specified motion instruction to the currently selected standard motion instruction. POINT
SHIFT
F1
SAMPLE1
JOINT 30% 3/3
1: J P[1] 100% FINE 2: J P[2] 100% FINE [End] Position has been recorded to P[2]. POINT
ARCSTRT WELD_PT
267
ARCEND TOUCHUP>
5. PROGRAMMING
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5.3.4 Teaching a supplementary motion instruction The supplementary motion instruction makes the robot do special work while it is moving according to the motion instruction. Some of the following supplementary motion instructions are provided (see Section 4.3.6 for the supplementary motion instructions): F
Wrist joint motion instruction
F
Acceleration/deceleration override instruction
F
Skip instruction
F
Position compensation instruction
F
Direct position compensation instruction
F
Tool offset instruction
F
Direct tool offset instruction
F
Incremental instruction
F
Path instruction
F
Soft float
F
Asynchronous additional speed
F
Synchronous additional speed
F
Pre--execution
F
Post--execution
F
Arc welding instruction
To teach a supplementary motion instruction, place the cursor behind the motion instruction and press the F4 (CHOICE) key to display the supplementary motion instruction menu. Select a supplementary motion instruction from the menu. (See Appendix A.3 for the program instruction menu.) JOINT 30% 4/5 500mm/sec CNT10 [CHOICE]
Motion modify 1 No option 2 Wrist Joint 3 ACC 4 Skip,LBL[] PROGRAM1
5 6 7 8
JOINT 30 % Offset Offset,PR[ ] Incremental ---next page---
F4 NOTE The supplementary motion instructions vary according to the software configuration. Purchase the software having the options necessary for your purposes.
268
5. PROGRAMMING
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Procedure 5--6 Step
Teaching the supplementary motion instruction
1 Place the cursor immediately behind the motion instruction. PROGRAM1
JOINT 30% 4/5
4: L P[3] 500mm/sec CNT10 [End]
[CHOICE]
2 Press the F4 (CHOICE) key. The supplementary motion instruction menu is displayed. JOINT 30% 4/5 500mm/sec CNT10 [CHOICE]
Motion modify 1 No option 2 Wrist Joint 3 ACC 4 Skip,LBL[] PROGRAM1
5 6 7 8
JOINT 30 % Offset Offset,PR[ ] Incremental ---next page--4/5
F4
4:J P[3] 100% FINE [End] [CHOICE]
3 Select a desired item. For example, the following screen teaches an acceleration override instruction. Motion Modify 1 No option 2 Wrist Joint 3 ACC 4 Skip,LBL[ ] PROGRAM1
PROGRAM1 5 6 7 8
JOINT 30% 4/5
4: L P[3] 500mm/sec CNT10 : ACC 150 [End]
[CHOICE]
For details of the instructions, see Chapter 4.
269
5. PROGRAMMING
Procedure 5--7 Step
B--81464EN--3/01
Teaching the incremental instruction
1 Move the cursor to the space at the end of the motion instruction. Teaching the incremental instruction is shown as follows.
SAMPLE1
JOINT
30 % 4/5
4:J P[3] 100% FINE [End] [CHOICE] JOINT 30% 4/5 500mm/sec CNT10 [CHOICE]
F4
Motion modify 1 No option 2 Wrist Joint 3 ACC 4 Skip,LBL[] PROGRAM1
5 6 7 8
JOINT 30 % Offset Offset,PR[ ] Incremental ---next page--4/5
4:J P[3] 100% FINE
SAMPLE1
JOINT
30 % 4/5
4:J P[3] 100% FINE INC [End] [CHOICE]
CAUTION Teaching the incremental instruction makes the position data have no position information. Enter the incremental amount to the position data.
2 Enter the incremental amount directly to the position data.
SAMPLE1
JOINT
30 % 4/5
4:J P[3] 100% FINE INC [End] [CHOICE] POSITION
[CHOICE] POSITION
F5
Position Detail P[3] GP:1 UF:0 UT:1 X ******* mm W Y ******* mm P Z ******* mm R SAMPLE1
CONF:N 00 ******* deg ******* deg ******* deg 4/5
4:J P[3] 100% FINE INC [End] Enter value PAGE CONFIG DONE
270
[REPRE]
5. PROGRAMMING
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3 Enter the incremental amount directly. P R
0.000 *******
0
deg deg
ENTER
Position Detail P[3] GP:1 UF:0 UT:1 X 500.000 mm W Y 100.000 mm P Z 100.000 mm R SAMPLE1
CONF:N 00 0.000 deg 0.000 deg 0.000 deg 4/5
4:J P[3] 100% FINE INC [End] PAGE CONFIG DONE
[REPRE]
4 When you are fished entering the position data, press F4,DONE. CONFIG
DONE
[REPRE]
JOINT
30 % 4/5
4:J P[3] 100% FINE INC [End] Enter value or press ENTER [CHOICE] POSITION
F4
Procedure 5--8 Step
SAMPLE1
Teaching an arc instruction (as an additional motion instruction)
1 Position the cursor to a point after the end of a motion instruction. PRG1
JOINT
30 % 4/5
4:L P[3] 500mm/sec CNT10 [End] [CHOICE]
2 Press the F4 (CHOICE) key. The additional motion instruction menu is displayed. Motion Modify 1 No option 2 Wrist Joint 3 ACC 4 Skip,LBL[] PRG1
5 6 7 8
JOINT 30 % Offset Offset,PR[ ] Incremental ---next page---
3 Select ------ next page ------ to display the arc welding instruction menu. Then, teach an arc start instruction. Motion Modify 1 Arc Start[ ] 2 Arc End[ ] 3 4 PRG1
JOINT 30 % 5 6 7 8 ---next page---
PRG1
JOINT
30 % 4/5
4:L P[3] 500mm/sec CNT10 : Arc Start[...] [End] Enter schedule number. REGISTER VALUE [CHOICE] PRG1
JOINT
4:L P[3] 500mm/sec CNT10 : Arc Start[1] [End] [CHOICE]
271
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5. PROGRAMMING
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4 To indirectly specify conditions by using a register, press the F1 (REGISTER) key. REGISTER
VALUE
PRG1
JOINT
30 % 4/5
4:L P[3] 500mm/sec CNT10 : Arc Start[R[...]] [End] Enter register number. SCHED VALUE [CHOICE]
F1
PRG1
JOINT
30 % 4/5
4:L P[3] 500mm/sec CNT10 : Arc Start[R[1]] [End] [CHOICE]
5 To directly enter values for the arc welding conditions, press the F3 (VALUE) key. REGISTER
VALUE
F3
PRG1
JOINT
30 % 4/5
4:L P[3] 500mm/sec CNT10 : Arc Start[0.0V,0.0A] [End] Enter voltage. REGISTER SCHED [CHOICE] PRG1
JOINT
4:L P[3] 500mm/sec CNT10 : Arc Start[20.0V,180.0A] [End] [CHOICE]
272
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5.3.5 Teaching a control instruction A control instruction is a program instruction for controller that is not a motion instruction. The control instructions are as follows: F
Arc welding instruction
F
Weaving instruction
F
Arc sensor instruction
F
Register instruction
F
Position register instruction
F
I/O (input/output) instruction
F
Branch instruction
F
Wait instruction
F
Macro instruction
F
Program end instruction
F
Comment instruction
F
Supplementary motion instruction
F
Other instructions
To teach a control instruction, first press the F1 (INST) key to display the submenu. Then, select a desired control instruction item from the menu (see Appendix A.3 for the menu of the program instructions).
Instruction 1 Registers 2 I/O 3 IF/SELECT 4 WAIT PROGRAM
5 6 7 8
JOINT 30% JMP/LBL CALL Arc ---next page---
Instruction 1 Miscellaneous 2 Program control 3 Skip 4 Offset PROGRAM
JOINT 30 % 5 MACRO 6 7 8 ---next page---
NOTE The program instructions vary according to software configuration. Purchase the software having the options necessary for your purposes.
Procedure 5--9 Condition
Teaching a register instruction
H The teach pendant must be enabled. H The program edit screen must be selected.
PROGRAM1 1: J [End]
JOINT 30% 2/2
P[1] 100% FINE
[INST]
Step
[EDCMD] >
1 Move the cursor to END. 2 Press the F1 (INST) key. Then, the control instruction menu is displayed.
[INST]
F1
Instruction 1 Registers 2 I/O 3 IF/SELECT 4 WAIT PROGRAM
5 6 7 8
273
JOINT 30% JMP/LBL CALL Arc ---next page---
5. PROGRAMMING
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3 To teach a register instruction, select REGISTERS. The following screens indicate that the value of register [1] is increased by one.
Instruction 1 Registers 5 2 I/O 6 3 IF/SELECT ENTER 7 4 WAIT 8 -
REGISTER statement 1 ...=... 2 ...=...+... 3 ...=...-... 4 ...=...*... PROGRAM1
JOINT 30% 5 ...=.../... 6 ...=...DIV... 7 ...=...MOV... 8
REGISTER statement 1 R[ ] 2 PL[ ] 3 PR[ ] 4 PR[i,j] PROGRAM1
JOINT 30% 5 6 7 8 2/3
2: ...=...+... [End]
REGISTER statement 1 R[ ] 2 Constant 3 DO[ ] 4 DI[ ] PRG1
5 6 7 8
JOINT 30 % RO[ ] RI[ ] GO[ ] ---next page--2/2
2: [End]
R[1]=...+...
REGISTER statement 1 R[ ] 2 Constant 3 DO[ ] 4 DI[ ] PROGRAM1
5 6 7 8
JOINT 30% RO[ ] RI[ ] GO[ ] ---next page--2/3
2: R[1]=R[1]+... [End]
PROGRAM11 1: J 2: [End]
JOINT 30% 3/3
P[1] 100% FINE R[1]=R[1]+1
[INST]
[EDCMD] >
For details of the register instruction, see Chapter 4.
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Procedure 5--10 Step
Teaching the position register instruction
1 Move the cursor to END. 2 Press the F1 (INST) key. Then, the control instruction menu is displayed. Instruction 1 Registers 2 I/O 3 IF/SELECT 4 WAIT PROGRAM1
5 6 7 8
JOINT 30% JMP/LBL CALL Arc ---next page---
3 Select REGISTERS. REGISTER statement 1 ...=... 2 ...=...+... 3 ...=...-... 4 ...=...*... PROGRAM1
JOINT 30% 5 ...=.../... 6 ...=...DIV... 7 ...=...MOV... 8
4 Select PR[ ]. Teach the instruction assigning the Cartesian coordinates of the current position to the position register on the following screens. REGISTER statement 1 R[ ] 2 PR[ ] 3 PR[i,j] 4 PRG1
5 6 7 8
REGISTER statement 1 Lpos 2 Jpos 3 P[ ] 4 UFRAME[ ] PRG1
5 UTOOL[ 6 PR[ ] 7 8
JOINT
30 %
JOINT ]
30 %
2/3 2: PR[1]=... [End] Select item [CHOICE]
PROGRAM1
JOINT 30% 3/3
2: PR[1]=LPOS [End]
[INST]
[EDCMD] >
For details of the instruction, see Chapter 4.
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5. PROGRAMMING
Procedure 5--11 Step
B--81464EN--3/01
Teaching an I/O instruction
1 Move the cursor to END. 2 Press the F1 (INST) key. Then, the control instruction menu is displayed.
[INST]
Instruction 1 Registers 2 I/O 3 IF/SELECT 4 WAIT PROGRAM
F1
JOINT 30% JMP/LBL CALL Palletizing ---next page---
5 6 7 8
3 Select I/O. Teach the instruction that turns on RO[1] on the following screens. Instruction 1 Registers 2 I/O 3 IF/SELECT 4 WAIT
5 6 7 8
I/O statement 1 DO[ ]=... 2 R[ ]=DI[ ] 3 RO[ ]=... 4 R[ ]=RI[ ] PRG1
I/O statement 1 On 2 Off 3 Pulse (,width) 4 R[ ] PROGRAM1
JOINT 30 % GO[ ]=... R[ ]=GI[ ] WO[ ]=... ---next page---
5 6 7 8
JOINT 30% 5 6 7 8 2/3
2: RO[1]=... [End]
PRG1 2: [End]
JOINT
30 % 3/3
RO[1]=ON
[ INST ]
[EDCMD]>
For details of the instruction, see Chapter 4.
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5. PROGRAMMING
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Procedure 5--12 Step
Teaching of the weaving instruction
1 Move the cursor to END. 2 Press F1 (INST). A list of control instructions is displayed. Instruction 1 Registers 2 I/O 3 IF/SELECT 4 WAIT WELD_1
JOINT 10 % JMP/LBL CALL Arc ---next page---
5 6 7 8
3 Select Weave on the next page. The weaving start instruction for controlling weaving is taught below. Instruction 1 Miscellaneous 2 Weave 3 Skip 4 Payload WELD_1
5 6 7 8
JOINT 10 % Track/Offset Offset/Frames Program control ---next page---
WELD_1
JOINT
10 % 2/4
1:L P[1] 100mm/sec FINE : Arc Start[1] 2: Weave Sine[...] [END] Enter schedule number. REGISTER VALUE
CHOICE
WELD_1
JOINT
10 % 3/3
1:L P[1] 100mm/sec FINE : Arc Start[1] 2: Weave Sine[1] [END] [ INST ]
[EDCMD]>
4 Press F1 (REGISTER) for register--based indirect specification.
277
5. PROGRAMMING
REGISTER
VALUE
B--81464EN--3/01
WELD_1
JOINT
10 % 2/3
1:L P[1] 100mm/sec FINE : Arc Start[1] 2: Weave Sine[R[...]] [END]
F1
Enter register number. SCHED VALUE
CHOICE
WELD_1
JOINT
10 % 3/3
1:L P[1] 100mm/sec FINE : Arc Start[1] 2: Weave Sine[1] [END] [ INST ]
[EDCMD]>
5 Press F3 (VALUE) to directly enter values for weaving conditions. REGISTER
VALUE
F3
WELD_1
JOINT
10 % 2/3
1:L P[1] 100mm/sec FINE : Arc Start[1] 2: Weave Sine[...,...,0.0s,0.0s] [END] Enter frequency (Hz). REGISTER SCHED
WELD_1 1:L : 2: : [END]
CHOICE
JOINT
10 % 3/3
P[1] 100mm/sec FINE Arc Start[1] Weave Sine[1.0Hz,5.0mm,0.0s, 0.0s]
[ INST ]
[EDCMD]>
The arc welding instruction and TRACK Sensor instruction can be taught similarly. For details of the instructions, see Chapter 4.
278
5. PROGRAMMING
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Procedure 5--13 Step
Teaching move group instructions
1 Move the cursor to the line number of a desired move statement (other than for circular movement). PROGRAM1
JOINT 30%
1: L P[1] 1000mm/sec CNT100 [End]
POINT
TOUCHUP>
2 Press F1 [INST]. Then, a list of control instructions is displayed. Instruction 1 Register 2 I/O 3 IF/SELECT 4 WAIT PROGRAM1
5 6 7 8
JMP/LBL Independent GP Simultaneous GP --- next page ---
3 Select Independent GP or Simultaneous GP. The contents of group 1 are moved to another group. Note that in this case, position data remains unchanged. PROGRAM1
JOINT 30%
1: Independent GP : GP1 L P[1] 1000mm/sec CNT100 : GP2 L P[1] 1000mm/sec CNT100
[INST]
[EDCMD]>
4 For a move statement within the move group instructions, edit the move type, move speed, and positioning type in the same way as for an ordinary move statement. Note that the following operations cannot be performed: F
Changing the move type to circular
F
Specification of position data type (R[], PR[])
F
Position number change
F
Teaching of additional move instructions (Deletion is allowed.)
F
Deletion/creation of move groups
F
Position modification by SHIFT + TOUCHUP
For details of instructions, see Chapter 4.
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5. PROGRAMMING
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5.3.6 TP start prohibition The robot controller can execute the program immediately while editing it. To prevent the program from being executed by mistake, you can prohibit starting the program while teaching with this function. When you select Disable FWD/BWD in the function menu, starting a program with a teach pendant is prohibited. At this time,“FBD” is reversely displayed in the upper right hand corner of the teach pendant screen to inform that TP FWD/BWD key is disabled. This “FBD”means “Forward,Backward Disabled”. To release the prohibition mode, press Disable FWD/BWD in the function menu again. At this time, the indicator of “FBD” disappears and the override is decreased to the setting value specified in the system variable, $SCR.$FWDENBLOVRD,when it is larger than the setting value.(Standard value : 10%) Though the indicator,“FBD”, displayed in upper right hand corner of the screen disappears when the teach pendant is disabled,“FBD” is displayed again when the teach pendant is enabled again. Press and hold the SHIFT key, and press FWD or BWD in prohibition mode. At this time, a warning message, “Teach pendant is disabled”, is displayed at the first line of the screen. Jog feed during TP start prohibition A system variable can be set to enable jog feed only in the TP start prohibition state. To make this setting, system variable $SCR.$TPMOTNENABL is used. To enable this function (to enable jog feed only in the TP start prohibition state), change the value of system variable $SCR.$TPMOTNENABL from 0 to 1 (or from 2 to 3) on the system variable screen. The table below indicates the relationship between the value of system variable $SCR.$TPMOTNENABL and whether TP start and jog feed are enabled. Table 5--5.
Setting for Jog feed during TP start prohibition TP start Enabled Enabled Disabled Disabled
$SCR.$TPMOTNENABL 0 1 2 3
Jog feed Enabled Disabled Enabled Disabled
With the standard setting, this function is disabled (jog feed is enabled irrespective of whether the teach pendant can start a program).
280
5. PROGRAMMING
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Procedure 5--14 Step
Prohibiting Starting with Teach Pendant
1 Press the FCTN key. The function menu is displayed. 2 Select 2 Disable FWD/BWD. “FBD” is displayed in the uppermost right hand line of the screen.
1 ABORT (ALL) 2 Disable FWD/BWD 3 CHANGE GROUP
FBD SAMPLE SAMPLE
LINE 0 JOINT
FCTN
30 % 1/1
[End]
[ INST ]
[EDCMD]>
3 To release the prohibition mode, select “2 Disable FWD/BWD” in the function menu again. “FBD” disappears and the override is reduced to a setting of $SCR.$FWDENBLOVRD. 1 ABORT (ALL) 2 Disable FWD/BWD 3 CHANGE GROUP
SAMPLE SAMPLE
LINE 0 JOINT
FCTN
30 % 1/1
[End]
[ INST ]
Procedure 5--15 Condition
[EDCMD]>
When effective/disable of teach pendant is switched
H TP is in prohibition mode. H The teach pendant is disabled.
Step
1 The following program edit screen is displayed. “FBD” is not displayed in TP prohibition state because a teach pendant is disabled.
SAMPLE SAMPLE
LINE 0 JOINT
30 % 1/1
[End]
[ INST ]
[EDCMD]>
2 Enable the teach pendant. “FBD” is displayed at uppermost right hand corner of the screen and the override is reduced to the setting of $SCR.$FWDENBLOVRD. FBD SAMPLE SAMPLE
LINE 0 JOINT
30 % 1/1
[End]
[ INST ]
[EDCMD]>
281
5. PROGRAMMING
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5.4 Changing a Program An existing program can be changed (modified) whenever it needs to be. The following subsections related to changing a program are described in this section: F
Selecting a program
F
Modifying a standard motion instruction
F
Changing a motion instruction
F
Changing an arc welding instruction or another control instruction
F
Editing a program instruction -- Inserting a blank line -- Deleting a program instruction -- Copying a program instruction -- Finding a program instruction item -- Replacing a program instruction item -- Renumbering program lines
Selecting a program Select a program from the menu of existing programs. Changing a motion instruction Change a motion instruction item. An example is position data, which is an instruction item that must be frequently changed. Changing other instructions Change other instructions.
5.4.1 Selecting a program When selecting a program, call the registered program to display the program edit screen for editing, changing and playing back a program. Once a program is selected, the program is effective until another program is selected. While another screen is displayed such as the current position screen, the currently selected program is started by the start switch. F
When the teach pendant is enabled (The current or halted program is forcibly terminated when a program is selected.)
F
When the teach pendant is disabled
Another program cannot be selected while a program is being executed or halted. Select a program on the program selection screen.
282
5. PROGRAMMING
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Procedure 5--16 Step
Selecting a program
1 Press the MENUS key. 2 Select SELECT. Alternatively, press the SELECT key to enable a program to be selected. In this case, the program selection screen is displayed. Select 1 2 3 4 5
SAMPLE1 SAMPLE2 SAMPLE3 PROG001 PROG002
[TYPE]
JOINT 30% 61092 bytes free 3/5 JB[SAMPLE PROGRAM1 ] JB[SAMPLE PROGRAM2 ] JB[SAMPLE PROGRAM3 ] PR[PROGRAM001 ] PR[PROGRAM002 ]
CREATE
DELETE
MONITOR
[ATTR] >
3 Move the cursor to the name of a program to be corrected using the cursor keys (↑ and ↓) press the ENTER key.The selected program edit screen is displayed. SAMPLE3
JOINT 30% 1/6
1 J 2 J 3 L 4 L 5 J [End]
P[1] P[2] P[3] P[4] P[1]
100% FINE 70% CNT50 1000cm/min CNT30 500mm/sec FINE 100% FINE
POINT
ARCSTRT WELD_PT
283
ARCEND TOUCHUP>
5. PROGRAMMING
B--81464EN--3/01
5.4.2 Changing a motion instruction When changing a motion instruction, change the instruction items of the motion instruction or change taught position data. For motion instructions, see Section 4.3. Changing position data To change position data, assign new position data to the position variable by pressing the F5 (TOUCHUP) key while pressing the SHIFT key. Position data information The coordinates and configuration for position data can be directly changed on the position data information screen. PAGE
CONFIG
DONE
[REPRE]
F
F2 (PAGE): Toggles between the standard axes and the extended axes
F
F3 (CONFIG): Edits the configuration value.
F
F4 (DONE): Terminates changing the position data information.
F
F5 (REPRE): Toggles between Cartesian coordinates and joint coordinates.
Changing an instruction item To change an instruction item, press the F4 (CHOICE) key to display the motion instruction item menu, then select an instruction item from the menu. F
Motion type: Controls a path to the specified position. When the motion type is changed, the feedrate unit is also automatically changed.
F
Position variable: The variable storing position data and the variable number are changed.
F
Feedrate: The speed of the robot when it moves (robot motion speed) and the feedrate unit are changed.
F
Positioning type: Positioning at the specified position is changed.
F
Supplementary motion instruction: An additional instruction to be executed when the robot is moving is changed. CAUTION
If teaching is done by joint coordinates, changing the user coordinate system does not affect the position variables and position registers. If the position variable is taught according to rectangular type, and the user coordinate system input option is not used, the position variable is not affected by the user coordinate system. In other cases, both of the position variable and position register are affected by the user coordinate system.
284
5. PROGRAMMING
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Procedure 5--17 Condition Step
Changing position data
H The program to be changed must be selected. H The teach pendant must be enabled. 1 Move the cursor to the line number at which the motion instruction to be changed is displayed. SAMPLE1
JOINT 30% 2/6
1 J 2 J 3 L 4 L 5 J [End]
P[1] P[2] P[3] P[4] P[1]
100% FINE 70% CNT50 1000cm/min CNT30 500mm/sec FINE 100% FINE
POINT
ARCSTRT WELD_PT
ARCEND TOUCHUP>
2 Move the robot to a new position and press the F5 (TOUCHUP) while pressing the SHIFT key. The new position is recorded. WELD_PT
ARCEND TOUCHUP>
F5
SHIFT
SAMPLE1
JOINT 30% 2/6
1 J P[1] 100% FINE 2 J P[2] 70% CNT50 3 L P[3] 1000cm/min CNT30 4 L P[4] 500mm/sec FINE 5 J P[1] 100% FINE [End] Position has been recorded to P[2]. POINT ARCSTRT WELD_PT ARCEND TOUCHUP>
3 When the position data is taught to the motion instruction with a incremental option again,a incremental option is removed. SAMPLE1
JOINT
30 % 4/5
4:J P[3] 100% FINE INC [End] POINT WELD_PT
ARCSTRT WELD_PT
ARCEND TOUCHUP>
ARCEND TOUCHUP> SAMPLE1
F5
SHIFT
F F
YES
JOINT
30 % 4/5
4:J P[3] 100% FINE INC [End] Delete Inc option and record position ? YES NO
YES : A incremental option is removed and position data is taught. NO : The position data is not taught. NO SAMPLE1
F4
JOINT
30 % 4/5
4:J P[3] 100% FINE [End] Position has been recorded to P[3]. POINT ARCSTRT WELD_PT ARCEND TOUCHUP>
4 When position data is taught in the position register as a position variable,the position data in a register is changed by editing. WELD_PT
ARCEND TOUCHUP> SAMPLE1
SHIFT
F5
JOINT
30 % 5/6
5:J PR[3] 100% FINE [End] Position has been recorded to PR[3]. POINT ARCSTRT WELD_PT ARCEND TOUCHUP>
285
5. PROGRAMMING
Procedure 5--18 Step
B--81464EN--3/01
Changing position data information
1 To display position data information, move the cursor to the desired position variable, then press the F5 (POSITION) key. The position data information screen is displayed.
SAMPLE 1 2 3 4
J J L L
P[1] P[2] P[3] P[4]
100% FINE 70% CNT50 1000cm/min 500mm/sec
Position Detail P[2] UF:0 UT:1 CONF:FT. X: 1500.374 mm W: 40.000 Y: -342.992 mm P: 10.000 Z: 956.895 mm R: 20.000
JOINT 30% deg deg deg 2/6
2: J
COMMENT CHOICE POSITION
P[2] 70% CNT50
Enter value PAGE
F5
CONFIG
DONE
[REPRE]
2 To change the position, move the cursor to the coordinates for each axis and enter new coordinates. Position Detail P[2] UF:0 UT:1 CONF:FT. X: 1500.374 mm W: 40.000 Y: -300.000 mm P: 10.000 Z: 956.895 mm R: 20.000
Position Detail P[2] UF:0 UT:1 X: 1500.374 mm Y: -342.992 mm Z: 956.895 mm
--
3
0
0
JOINT 30% deg deg deg
ENTER
3 To change the configuration value, press the F3 (CONFIG) key, move the cursor to the configuration field, then enter a new configuration value with the cursor keys (↑ and ↓). CONFIG
DONE
[REPRE]
F3
Position Detail P[2] UF:0 UT:1 CONF:FT. X: 1500.374 mm W: 40.000 Y: -300.000 mm P: 10.000 Z: 956.895 mm R: 20.000
JOINT 30% deg deg deg 2/6
2: J
P[2] 70% CNT50
Select Flip or Non-flip by UP/DOWN key POSITION DONE [REPRE]
4 To change a coordinate system, press the F5 (REPRE) key and select the coordinate system to be changed. 70% CNT501 Cartesian 2 Joint CONFIG
DONE
[REPRE]
Position Detail P[2] J1: 0.125 deg J2: 23.590 deg J3: 30.300 deg
JOINT 30% J4: -95.000 J5: 0.789 E1: 0.000
deg deg deg
F5 NOTE JOINT display is valid when the robot is adjusted to the zero--degree position or when non--kinematic operation such as table operation control is executed. 5 After changing position data information, press the F4 (DONE) key. CONFIG
DONE
[REPRE]
F4
286
5. PROGRAMMING
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Procedure 5--19 Step
Changing a motion instruction
1 Move the cursor to the instruction item of a motion instruction to be changed. 2 Press the F4 (CHOICE) key to display the submenu of the instruction items, then select the instruction item to be changed from the submenu. The following screens show changing the motion type from linear motion to joint motion:
SAMPLE1 5: L [End]
P[5] 500cm/min
[CHOICE]
JOINT 30%
5/6 5: L P[5] 500cm/min CNT30 [End] Select item [CHOICE]
F4
Motion Modify 1 Joint 2 Linear 3 Circular 4
Motion Modify 1 Joint 2 Linear 3 Circular 4 SAMPLE1
SAMPLE1
ENTER
JOINT 30% 5/6
5: J P[5] 100% CNT30 [End]
Enter value or press ENTER COMMENT [CHOICE]
POSITION
3 The following screens show changing from the position variable to the position register.
SAMPLE1 5: J [End]
P[5] 100% CNT3
Motion Modify 1 P[ ] 2 PR[ ] 3 4 SAMPLE1
JOINT 30%
[CHOICE]
5/6 5: J P[5] 100% CNT30 [End]
F4
Motion Modify 1 P[ ] 2 PR[ ] 3 4
SAMPLE1
JOINT 30% 5/6
5: J PR[...] 100% CNT30 [End] ENTER
Enter Value DIRECT INDIRECT [CHOICE] POSITION
4 Change the feedrate. SAMPLE1
SAMPLE1 2: J
7
P[2] 100% FINE
0
JOINT 30% 2/6
2: J P[2] 70% FINE [End]
ENTER
Enter Value [CHOICE]
287
5. PROGRAMMING
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5 Change the feedrate unit.
SAMPLE1 4: L
P[2] 500cm/mm
[CHOICE]
Motion Modify 1 mm/sec 2 cm/min 3 inch/min 4 deg/sec SAMPLE1
JOINT 30% 5 6 7 8
sec
4/6 4: L P[4] 500cm/min CNT30 [End]
F4
6 Change the positioning type. JOINT 30% 2/6 70% FINE [CHOICE]
Motion Modify 1 Fine 2 Cnt 3 4 SAMPLE1
JOINT 30%
2/6
F4
2: L
P[2] 70% FINE
Select item [CHOICE]
288
5. PROGRAMMING
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Procedure 5--20 Step
Changing a circular motion instruction
1 Place the cursor at the motion type of the circular motion instruction to be changed. The following screens show changing the circular motion instruction to the linear motion instruction. SAMPLE1
JOINT 30% 6/7
6: C P[5] : P[6] 500cm/min CNT30 [End] [CHOICE]
SAMPLE1 6: C :
P[5] P[6] 500cm/min [CHOICE]
Motion Modify 1 Joint 2 Liner 3 Circular 4 SAMPLE1
JOINT 30%
6/7 6: C :
F4
P[5] P[6] 500cm/min CNT30
SAMPLE1
Motion Modify 1 Joint 2 Linear 3 Circular 4
JOINT 30% 6/7
6: L P[6] 500cm/min CNT30 [End] ENTER
COMMENT
[CHOICE]
POSITION
NOTE When a circular motion is changed to a joint or linear motion, two motion instructions are created as a result. One instruction moves the tool to the passing point of the circular motion, while the other moves the tool to the end point. 2 The following screens show changing the linear motion instruction to the circular motion instruction. SAMPLE1 6: L [End]
P[6] 500cm/min
[CHOICE]
Motion Modify 1 Joint 2 Liner 3 Circular 4 SAMPLE1
JOINT 30%
6/7 6: L
P[6] 500cm/min CNT30
F4 SAMPLE1 Motion Modify 1 Joint 2 Linear 3 Circular 4
ENTER
JOINT 30% 6/7
6: C P[6] : P[...] 500cm/min CNT30 [End] Enter value or press ENTER [CHOICE]
NOTE When a joint or linear motion instruction is changed to a circular motion instruction, the taught data for the end point of the arc is canceled.
289
5. PROGRAMMING
Procedure 5--21 Step
B--81464EN--3/01
Adding and deleting an additional motion instruction
1 Position the cursor to an additional motion instruction. To add an offset condition instruction, for example, follow the procedure below:
SAMPLE1
JOINT 30% 7/8
7: L P[2] 300mm/sec FINE [End]
[CHOICE]
JOINT 30% 7/8 100% FINE [CHOICE]
Motion Modify 1 No Option 2 Wrist Joint 3 Offset 4 Offset,PR[ ] SAMPLE1
5 6 7 8
JOINT 30% Incremetal Skip,LBL[ ]
7/8 7: L [End]
F4
P[2] 300mm/sec FINE
SAMPLE1 Motion Modify 1 No Option 2 Wrist Joint 3 Offset 4 Offset,PR[ ]
7: L P[2] 300mm/sec FINE [End]
JOINT 30% 7/8 offset
[CHOICE] ENTER
2 To delete an offset condition instruction, for example, follow the procedure below:
SAMPLE1 7: L P[2] 300mm/sec FINE [End]
JOINT 30% 7/8 offset
[CHOICE]
JOINT 30% 7/8 300mm/sec FINE offset [CHOICE]
Motion Modify 1 No Option 2 Wrist Joint 3 Offset 4 Offset,PR[ ] SAMPLE1
5 6 7 8
JOINT 30% Incremetal Skip,LBL[ ]
7/8
F4
7: L [End]
P[2] 300mm/sec FINE
offset
SAMPLE1
Motion Modify 1 No Option 5 2 Wrist Joint 6 3 Offset 7 ENTER 4 Offset,PR[ ] 8
JOINT 30% 7/8
7: L P[2] 300mm/sec FINE [End]
[CHOICE]
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Procedure 5--22
Changing the move speed (between numeric specification and register specification)
PNS0001
JOINT 10% 1/2
1: J P[1] 100% FINE [End] Enter Value REGISTER
Step
[CHOICE]
1 Operation for switching from numeric specification to register specification for the move speed of a move instruction Move the cursor to the speed value. Then, press the function key F1 (REGISTER). PNS0001
JOINT 10% 1/2
1: J P[1] R[...]% FINE [End]
Enter Value SPEED DIRECT
INDIRECT
[CHOICE]
2 Enter a desired register number (2 for example). For indirect specification, press F3 (INDIRECT). (To return to direct specification mode, press F2 (DIRECT).) PNS0001
JOINT 10% 1/2
1: J P[1] R[2]% FINE [End]
[CHOICE]
3 Operation for switching from register specification to numeric specification for the move speed of a move instruction PNS0001
JOINT 10% 1/2
1: J P[1] R[2]% FINE [End]
Enter Value SPEED DIRECT
INDIRECT
291
[CHOICE]
5. PROGRAMMING
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4 Move the cursor to the speed value. Then, press the function key F1 (SPEED).
PNS0001
JOINT 10% 1/2
1: J P[1] ...% FINE [End]
Enter Value REGISTER
[CHOICE]
5 Enter a desired speed value (20 for example).
PNS0001
JOINT 10% 1/2
1: J P[1] 20% FINE [End]
[CHOICE]
5.4.3 Changing a control instruction You can change the syntax, item, or variable of a control instruction. Procedure 5--23 Step
Changing an arc welding instruction
1 Position the cursor to an arc welding instruction.
PRG1
JOINT
30 % 4/5
4:L P[3] 500mm/sec CNT10 : Arc Start[...] [End] Enter schedule number. REGISTER VALUE
[CHOICE]
2 To specify a welding condition number in a register, press the F1 (REGISTER) key.
REGISTER
F1
VALUE
PRG1
JOINT
30 % 4/5
4:L P[3] 500mm/sec CNT10 : Arc Start[R[...]] [End] Enter register number. SCHED VALUE
[CHOICE]
PRG1
JOINT
4:L P[3] 500mm/sec CNT10 : Arc Start[R[1]] [End]
[CHOICE]
292
30 % 4/5
5. PROGRAMMING
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3 To directly enter the values for the welding conditions, press the F3 (VALUE) key. REGISTER
VALUE
PRG1
JOINT
F3
4:L P[3] 500mm/sec CNT10 : Arc Start[0.0V,0.0A] [End] Enter voltage. REGISTER SCHED
30 % 4/5
[CHOICE]
PRG1
JOINT
4:L P[3] 500mm/sec CNT10 : Arc Start[45.0V,70.0A] [End]
[CHOICE]
For details of instructions, see Chapter 4.
293
30 % 4/5
5. PROGRAMMING
Procedure 5--24 Step
B--81464EN--3/01
Changing a control instruction
1 Move the cursor to the instruction item to be changed.
PROGRAM1
JOINT 30% 11/20
10: J P[5] 100% FINE 11: WAIT RI[1]=ON 12: RO[1]=ON
[CHOICE]
2 Press the F4 (CHOICE) key to display the instruction menu and select the instruction item to be changed. The following screens show changing the wait instruction.
Wait statements 1 R[ ] 2 Constant 3 On 4 Off PRG1
[CHOICE]
F4
5 6 7 8
JOINT 30 % DO[ ] DI[ ] RO[ ] ---next page--11/20
11: WAIT RI[1]=ON 12: RO[1]=ON Select item [CHOICE]
Wait statements 1 R[ ] 2 Constant 3 On ENTER 4 Off
2
ENTER
PRG1
JOINT 30 % 11/20
11: WAIT RI[1]=R[...] Enter value DIRECT INDIRECT[CHOICE]
PRG1
LIST
JOINT 30% 11/20
11: WAIT RI[1]=R[2] 12: RO[1]=ON DIRECT INDIRECT[CHOICE]
LIST
[CHOICE]
F4 PRG1 Wait statements 1 2 Timeout-LBL[ ] 3 ENTER 4
2
ENTER
JOINT 30 % 11/20 11: WAIT RI[1]=R[2] TIMEOUT,LBL[...] 12: RO[1]=ON Enter value DIRECT INDIRECT[CHOICE]
PRG1 11: 12:
JOINT 30 % 12/20 WAIT RI[1]=R[2] TIMEOUT,LBL[2] RO[1]=ON
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5.4.4 Program edit instructions The program edit instructions are used to edit an existing program. Press the F5 (EDCMD) key to display the program edit instruction menu and select a desired program edit instruction from the menu. 1 2 3 4 5 6 7 8
Insert Delete Copy Find Replace Renumber Comment Undo
[EDCMD]
Insert Inserts blank lines, the number of which is specified, between the existing lines of a program. When blank lines are inserted, the program lines are renumbered. Delete Deletes a series of instructions from a program. After the instructions are deleted, the program lines are renumbered. Copy Copies a series of instructions and inserts the instruction group into another location in the program. When a series of instructions is copied, the instruction group is selected and recorded in memory. Once the series of instructions is copied, it can be inserted into other locations in the program repeatedly. Find A specified element of a program instruction is found. A specified element of a long program can be found quickly. Replace Replaces an item of the specified program instruction with another item. This program is used, for example, when setup data for the program is changed. (For example, when the I/O allocation is changed, and SDO[1] is to be changed to SDO[2] in the program) Renumber Renumbers the program lines by line number in ascending order. Whenever a motion instruction is taught, the line number is increased regardless of locations in the program. When insertion and deletion are repeated, the line numbers are not sequentially arranged in a program. Renumbering arranges them sequentially in the program. The progress of renumbering is displayed as it is being performed. NOTE Do not perform power down before the progress indication reaches 100%. 3/6 (50%) [ INST ]
[EDCMD]>
Progress Total number of line numbers Number of line numbers already renumbered
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5. PROGRAMMING
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Comment On the program editing screen, the user can choose whether to display or hide a comment for the instructions listed below. Note that no comment can be edited. F
SDI instruction, SDO instruction, RDI instruction, RDO instruction, GI instruction, GO instruction, AI instruction, AO instruction, UI instruction, UO instruction, SI instruction, SO instruction
F
Register instructions
F
Position register instructions (including position registers in the position data format for move instructions)
F
Welding instructions
F
Move instruction register speed specifications
NOTE The AI and AO instructions are analog I/O soft options. The position register instructions are position register soft options. The instructions listed below are always accompanied by a comment, and do not allow display switching but allow editing. F
Move instruction position variable
F
Label instructions
F
Power control instructions
NOTE The comment display area for an instruction item that is too long to be displayed on one line of the screen might be shortened. NOTE No comment is displayed for a register indirect specification. Position register [register [1]] = ... Undo Program edit operations such as an instruction modification, line insertion, and line deletion can be cancelled to return to the state present before those edit operations are performed. If an undo operation is performed during editing of a program line, all operations performed for that line are undone. For example, if a line is inserted or deleted, the state before the insertion or deletion operation is restored. If an undo operation is immediately followed by another undo operation, the state present before the first undo operation is performed is restored. NOTE If an undo operation is performed for a line during program editing, all operations performed for that line are undone. This means that if an instruction is taught in a blank line or the last line of a program, and an undo operation is performed for that line during editing, the taught instruction is deleted.
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5. PROGRAMMING
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Procedure 5--25 Step
Inserting blank lines
1 Press the next page key (NEXT) to display EDCMD in the F5 key name field. SAMPLE1
NEXT
1: J 2: J 3: L 4: L 5: J [End]
JOINT 30% 4/6 P[1] P[2] P[3] P[4] P[1]
100% FINE 70% CNT50 1000cm/min CNT30 500mm/sec FINE 100% FINE
[INST]
[EDCMD]
2 Press the F5 (EDCMD) key. The edit instruction menu is displayed. 3 Select Insert. SAMPLE1
100% FINE 1 Insert 70% CNT50 2 Delete 1000cm/min 3CNT30 Copy 500mm/sec FINE 4 Find 100% FINE 5 Replace 6 Renumber
1: J P[1] 100% FINE 2: J P[2] 70% CNT50 3: L P[3] 1000cm/min CNT30 4: L P[4] 500mm/sec FINE 5: J P[1] 100% FINE [End] How many line to insert ?:
[EDCMD]
F5
JOINT 30% 4/6
ENTER
In the example below, two blank lines are inserted between the 3rd and 4th lines. 4 Move the cursor to the line where instructions are to be inserted. In this example, move the cursor to the 4th line. 5 Enter the number of blank lines to be inserted (two) and press the ENTER key.
2
ENTER
SAMPLE1 1: 2: 3: 4: 5: 6: 5:
JOINT 30% 4/8
J J L
P[1] 100% FINE P[2] 70% CNT50 P[3] 1000cm/min CNT30
L J
P[4] 500mm/sec FINE P[1] 100% FINE
[INST]
[EDCMD] >
The two blank lines are inserted into the program and all the lines in the program are renumbered.
297
5. PROGRAMMING
Procedure 5--26 Step
B--81464EN--3/01
Deleting instructions
1 Move the cursor to the top of the line in which the instruction to be deleted is positioned. (Specify the line to be deleted with the cursor.) 2 Press the next page key (NEXT) to display EDCMD in the F5 key name field. SAMPLE1
NEXT
1: J 2: J 3: L 4: L 5: J [End]
JOINT 30% 4/6 P[1] P[2] P[3] P[4] P[1]
100% FINE 70% CNT50 1000cm/min CNT30 500mm/sec FINE 100% FINE
[INST]
[EDCMD]
3 Press the F5 (EDCMD) key to display the editing instruction menu. 4 Select Delete SAMPLE1 100% FINE 1 Insert 70% CNT50 2 Delete 1000cm/min 3CNT30 Copy 500mm/sec FINE 4 Find 100% FINE 5 Replace 6 Renumber
1:J 2:J 3:L 4:L 5:J [End]
JOINT P[1] P[2] P[3] P[4] P[1]
30 % 4/6
100% FINE 70% CNT50 1000cm/min CNT30 500mm/sec FINE 100% FINE
[EDCMD] Delete line(s) ? YES
F5
NO
ENTER
CAUTION After an instruction is deleted, the instruction is not restored. Be sure to confirm whether an instruction to be deleted should be done before doing it, or important data could be lost. 5 Specify the range of instruction lines to be deleted with the cursor keys (↑ and ↓). 3: L 4: L 5: J [End]
P[3] 1000cm/ P[4] 500mm/s P[1] 100% FI
6 To cancel deleting the selected line, press the F5 (NO) key. To delete the selected lines, press the F4 (YES) key.
YES
F4
NO
SAMPLE1 1: J 2: J 3: L [End]
JOINT 30% 4/4 P[1] 100% FINE P[2] 70% CNT50 P[3] 1000cm/min CNT30
[INST]
[EDCMD] >
298
5. PROGRAMMING
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Procedure 5--27 Step
Copying and pasting instructions
1 Press the next page key (NEXT) until EDCMD is displayed in the F5 key name field. NEXT
SAMPLE1 1: J 2: J 3: L 4: L 5: J [End]
JOINT 30% 1/6 P[1] P[2] P[3] P[4] P[1]
100% FINE 70% CNT50 1000cm/min CNT30 500mm/sec FINE 100% FINE
[INST]
[EDCMD]
2 Press the F5 (EDCMD) key. The editing instruction menu is displayed. 3 Select 3 Copy. The following screens show copying 2nd to 4th lines to 5th to 7th lines. 1 2 3 4 5 6
Insert Delete Copy Find Replace Renumber
SAMPLE1
EDCMD
F5
ENTER
JOINT 30% 2/6
1: J P[1] 100% FINE 2: J P[2] 70% CNT50 3: L P[3] 1000cm/min CNT30 4: L P[4] 500mm/sec FINE 5: J P[1] 100% FINE [End] Select lines COPY
PASTE
4 Select the range of lines to be copied. 1: J 2: J 3: L 4: L 5: J [End]
1: J P[1] 2: J P[2] 3: L P[3] 4: L P[4] 5: J P[1] [End] Move cursor to select range COPY
P[1] P[2] P[3] P[4] P[1]
SAMPLE1 1: J P[1] 100% FINE 2: J P[2] 70% CNT50 3: L P[3] 1000cm/min CNT30 4: L P[4] 500mm/sec FINE 5: J P[1] 100% FINE [End] Select lines COPY
F2
As a result of above steps, the selected instructions (2nd to 4th lines in this example) were copied in memory. 5 Decide where you want to paste the sentences copied in the memory.
PASTE
F5
SAMPLE1 1:J 2:J 3:L 4:L 5:J [End]
JOINT P[1] P[2] P[3] P[4] P[5]
30 % 5/6
100% FINE 70% CNT50 1000cm/min CNT30 500mm/sec FINE 100% FINE INC
Paste before this line ? LOGIC POS-ID POSITION CANCEL> R-LOGIC R-POS-ID R-POSITION CANCEL>
299
5. PROGRAMMING
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6 Select the copying and pasting method (copying from the original).
POS-ID POSITION
CANCEL
SAMPLE1 1: J 2: J 3: L 4: L 5: J 6: L 7: L 8: J [End]
F3
JOINT 30% 8/9 P[1] P[2] P[3] P[4] P[2] P[3] P[4] P[1]
100% FINE 70% CNT50 1000cm/min CNT30 500mm/sec FINE 70% CNT50 1000cm/min CNT30 500mm/sec FINE 100% FINE
Select lines COPY
PASTE >
7 By repeating the above steps 5 to 6, the same instruction group can be pasted at any number of locations in the program. 8 To terminate the pasting of instructions, press the PREV key
PREV
Pasting methods The following copying and pasting methods are provided: LOGIC
POS-ID
POSITION CANCEL>
-- F2 (LOGIC)
: Copies and pastes motion instructions with no position data specified.
-- F3 (POS--ID)
: Copies and pastes motion instructions with the position numbers unchanged.
-- F4 (POSITION) : Copies and pastes motion instructions with the position numbers updated. Pressing the next page key (NEXT) displays the following function key menu:
NEXT
R-LOGIC R-POS-ID R-POSITION CANCEL>
The selected instructions are copied in reverse order. F3 and F5 have the following functions: -- F3 (RM--POS--ID) : Copies the move instructions at a copy source in reverse order without changing the position numbers of the move instructions. The move type, move speed, and so forth of each move instruction are changed so that a movement totally opposite to the movement of the copy source is made. -- F5 (RM--POS) : Copies the move instructions at a copy source in reverse order. then assigns new position numbers. The move type, move speed, and so forth of each move instruction are changed so that a movement totally opposite to the movement of the copy source is made. NOTE The copy function for a reverse movement is not supported for the additional move instructions listed below. If the move instructions at a copy source include any of the move instructions below, RM--POS--ID or RM--POS generates a warning, and only a copy operation in reverse order is performed. F
Application instruction
F
Skip and high--speed skip instructions
F
Incremental instruction
F
Continuous rotation instruction
F
Pre--execution/post--execution instruction
F
Multi--group operation
300
5. PROGRAMMING
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Example When the F4 (R--POSITION) is pressed R-LOGIC R-POS-ID R-POSITION
F4
1: J 2: J 3: L 4: L 5: J 6: L 7: L 8: J [End]
P[1] P[2] P[3] P[4] P[7] P[6] P[5] P[1]
100% FINE 70% CNT50 1000cm/min CNT30 500mm/sec FINE 500mm/sec FINE 1000cm/min CNT30 70% CNT50 100% FINE
Select lines COPY
Procedure 5--28 Step
PASTE >
Finding a program instruction item
1 Press the next page key (NEXT) until EDCMD is displayed in the F5 key name field. SAMPLE3
NEXT
1:J 2: 3: 4:L 5:L 6: 7: 8: 9: [End]
JOINT
30 % 1/10
P[1] 100% FINE R[1]=0 LBL[1] P[2] 1000cm/min CNT30 P[3] 500mm/sec FINE IF DI[1]=ON JMP LBL[2] R[1]=R[1]+1 JMP LBL[1] LBL[2]
[ INST ]
[EDCMD]>
2 Press the F5 (EDCMD) key. The editing instruction menu is displayed. 3 Select Find. 4 Select a program instruction item to be found. The following screens show how to find instruction, WAIT. Select Find menu 1 Registers 2 CALL 3 I/O 4 IF/SELECT SAMPLE3
100% FINE 1 Insert 70% CNT50 2 Delete 1000cm/min 3CNT30 Copy 500mm/sec FINE 4 Find 100% FINE 5 Replace 6 Renumber
JOINT 30 % 5 JMP/LBL 6 Miscellaneous 7 Program control 8 ---next page---
[EDCMD]
F5
ENTER
Select Find item 1 JMP LBL[ ] 2 LBL[ ] 3 4 SAMPLE3
Enter index value
301
JOINT 5 6 7 8
30 %
5. PROGRAMMING
B--81464EN--3/01
5 When the item to be found is an argument, enter the value. To find an item regardless of whether the item is an argument, press the ENTER key without entering anything.
Enter index value
ENTER
SAMPLE3 1:J 2: 3: 4:L 5:L 6: 7: 8: 9: [End]
JOINT
30 % 1/10
P[1] 100% FINE R[1]=0 LBL[1] P[2] 1000cm/min CNT30 P[3] 500mm/sec FINE IF DI[1]=ON JMP LBL[2] R[1]=R[1]+1 JMP LBL[1] LBL[2]
NEXT
EXIT
If the specified instruction is found in the program, the cursor stops at the instruction. 6 To find the same instruction again, press the F4 (NEXT) key. NEXT
EXIT SAMPLE3 1:J 2: 3: 4:L 5:L 6: 7: 8: 9: [End]
F4
JOINT
30 % 1/10
P[1] 100% FINE R[1]=0 LBL[1] P[2] 1000cm/min CNT30 P[3] 500mm/sec FINE IF DI[1]=ON JMP LBL[2] R[1]=R[1]+1 JMP LBL[1] LBL[2]
NEXT
EXIT
7 To terminate finding an instruction, press the F5 (EXIT) key. NEXT
EXIT
F5 NOTE The position of a track/offset instruction or touch sensor instruction cannot be found using the search instruction.
302
5. PROGRAMMING
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Procedure 5--29 Step
Replacing a program instruction item
1 Press the next page key (NEXT) until EDCMD is displayed in the F5 key name field.
SAMPLE3
JOINT
30 % 1/9
1:J P[1] 100% FINE 2:J P[2] 70% CNT50 3: LBL[1] 4:L P[3] 1000cm/min CNT30 5:L P[4] 500mm/sec FINE : SKIP LBL[2] 6: JMP LBL[1] 7: LBL[2] 8:J P[5] 100% FINE [End] [ INST ]
[EDCMD]>
2 Press the F5 (EDCMD) key. The changing instruction menu is displayed. 3 3. Select Replace. 4 Select a program instruction item to be replaced and press the ENTER key. In the screen below the feedrate specified in the motion instruction is changed to another value.
1 2 3 4 5 6
Select Replace menu JOINT 30 % 1 Registers 5 Motion modify 2 CALL 6 3 I/O 7 4 JMP/LBL 8 SAMPLE3
Insert Delete Copy Find Replace Renumber EDCMD
F5
ENTER
Modify motion menu 1 Replace speed 2 Replace term 3 Insert option 4 Remove option SAMPLE3
JOINT
30 %
5 6 7 8
The following replacement items are displayed: -- Replace speed:
Changes the feedrate to another value.
-- Replace term:
Changes the positioning type to another value.
-- Insert option:
Inserts a supplementary motion instruction.
-- Remove option:
Deletes a supplementary motion instruction.
5 Select Replace speed.
Modify motion menu 1 Replace speed 2 Replace term 3 Insert option 4 Remove optionENTER SAMPLE3
Select interporate 1 Unspecified type 2 J 3 L 4 C SAMPLE3
JOINT 30% 5 6 7 8 1/10
-- Unspecified type: Changes the feedrates in all motion instructions -- J: Changes the feedrates only in motion instructions for joint control. -- L: Changes the feedrates only in motion instructions for linear control. -- C: Changes the feedrates only in motion instructions for circular control.
303
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6 Specify the target type of the operation instruction.
Select interpolate 1 Unspecified type 5 2 J 6 3 L 7 4 C 8 INPUT PNS0001
Speed type menu 1 All type 2 Speed value 3 R[ ] 4 R[R[ ]] PNS0001
JOINT
10 %
5 6 7 8
F
ALL type: No speed type is specified.
F
Speed value: Operation statements that specify a speed with a numeric value are specified.
F
R[ ]: Operation statements that specify a speed with a register are specified.
F
R[R[ ]]: Operation statements that indirectly specify a speed value with registers are specified.
7 Specify a target speed format.
Speed type menu 1 All type 2 Speed value 3 R[ ] 4 R[R[ ]] PNS0001
5 6 7 8
Select motion item 1 % 2 mm/sec 3 cm/min 4 inch/min PNS0001
JOINT
10 %
JOINT
10 %
5 deg/sec 6 sec 7 8
8 Specify a target speed unit.
Select motion item 1 % 5 2 mm/sec 6 3 cm/min 7 4 inch/min 8 INPUT PNS0001
Speed type menu 1 Speed value 2 R[ ] 3 R[R[ ]] 4 PNS0001
5 6 7 8
F
Speed value: The selected statement is changed to an operation statement which specifies a speed with a numeric value.
F
R[ ]: The selected statement is changed to an operation statement which specifies a speed using a register.
F
R[R[ ]]: The selected statement is changed to an operation statement which indirectly specifies a speed by using registers.
9 Specify the motion type of the motion instruction for which the feedrate is to be changed.
Select interporate 1 Unspecified type 5 2 J 6 3 L 7 ENTER8 4 C
Select motion item 1 % 2 mm/sec 3 cm/min 4 inch/min SAMPLE3
JOINT 30% 5 deg/sec 6 sec 7 8 1/10
10 Specify the unit of the feedrate to be changed.
Select motion item 1 % 2 mm/sec 3 cm/min ENTER 4 inch/min
Enter speed value: 5 6 7 8
304
5. PROGRAMMING
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11 Enter a desired feedrate. Enter speed value:50 SAMPLE3
5
0
ENTER
JOINT
30 % 1/10
1:J P[1] 100% FINE 2:J P[2] 70% CNT50 Modify OK ? ALL
YES
NEXT
EXIT
The kinds of replacing items are displayed. -- F2 (ALL): Replaces all the items in the current line and subsequent lines. -- F3 (YES): Replaces the item at the cursor and finds the next item. -- F4 (NEXT): Finds the next item. 12 Select a replacement method. Modify OK ? ALL
YES
SAMPLE3
JOINT
30 % 1/9
1:J P[1] 50% FINE 2:J P[2] 50% CNT50 3: LBL[1] 4:L P[3] 1000cm/min CNT30 5:L P[4] 500mm/sec FINE : SKIP LBL[2] 6: JMP LBL[1] 7: LBL[2] 8:J P[5] 50% FINE [End]
F2
[ INST ]
[EDCMD]>
13 To terminate item replacement, press the F5 (EXIT) key. YES
NEXT
EXIT
F5 CAUTION The replacement instruction allows no move instruction to be replaced with the track/offset instruction or touch sensor instruction. If an attempt for such replacement is made, a memory write alarm is issued. To replace a move instruction, first delete the move instruction, then insert the touch sensor instruction or track instruction.
305
5. PROGRAMMING
Procedure 5--30 Step
B--81464EN--3/01
Renumbering the position number
1 Press the next page key (NEXT), then press the F5 (EDCMD) key. SAMPLE1 1: J 2: J 3: L 4: L 5: J 6: L 5: J [End]
JOINT 30% 1/8 P[8] P[6] P[3] P[5] P[1] P[5] P[8]
100% FINE 70% CNT50 1000cm/min CNT30 500mm/sec FINE 100% FINE 500mm/sec FINE 100% FINE
[INST]
[EDCMD]
2 Press F5, EDCMD. The changing instruction menu is displayed. 3 Select Renumber. 1 2 3 4 5 6
Insert Delete Copy Find Replace Renumber
Renumber OK? YES
NO
EDCMD
F5
ENTER
4 To renumber the program lines, press the F4 (YES) key. To cancel renumbering the program lines, press the F5 (NO) key. YES
NO SAMPLE1
F4
1: J P[1] 2: J P[2] 3: L P[3] 4: L P[4] 5: J P[5] 6: L P[4] 7: J P[1] [INST]
JOINT 30% 1/8 100% FINE 70% CNT50 1000cm/min CNT30 500mm/sec FINE 100% FINE 500mm/sec FINE 100% FINE [EDCMD]
306
5. PROGRAMMING
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Procedure 5--31 Step
Comment display switching
1 Press F! to display F5 (EDCMD). PNS0001
JOINT 10% 1/9
1: R[1]=DI[2] 2: DO[3]=ON 3: R[R[1]]=DI[R[2]] 4: PR[1]=P[3] 5: PR[1,2]=PR[R[3],R[4]] 6: PL[1]=PL[R[3]] 7: J PR[1] 100% FINE 8: J P[1] 100% FINE 9: LBL[1] [End] [INST]
[EDCMD]>
2 Press F5 (EDCMD) to display the edit instruction menu. PNS0001
JOINT 10% 1/9
1: R[1]=DI[2] 2: DO[3]=ON 1 3: R[R[1]]=DI[R[2]] 2 4: PR[1]=P[3] 3 5: PR[1,2]=PR[R[3],R[4]] 4 6: PL[1]=PL[R[3]] 5 7: J PR[1] 100% FINE 6 8: J P[1] 100% FINE 7 9: LBL[1] 8 [End] [INST]
Insert Delete Copy Find Replace Remember Comment Undo EDCMD
3 Select Item 7 Comment. PNS0001
JOINT 10% 1/9
1: R[1:Comment]=DI[2:Comment] 2: DO[3:Comment]=ON 3: R[R[1]]=DI[R[2]] 4: PR[1:Comment]=P[3:Comment] 5: PR[1,2:Comment]=PR[R[3],R[4]] 6: PL[1:Comment]=PL[R[3]] 7: J PR[1:Comment] 100% FINE 8: J P[1:Comment] 100% FINE 9: LBL[1:Comment] [End] [INST]
[EDCMD]>
4 To disable comment display, select Comment of the function key F5 (EDCMD) again.
307
5. PROGRAMMING
Procedure 5--32 Step
B--81464EN--3/01
Undoing edit operations
1 Press F! to display F5 (EDCMD). PNS0001
JOINT 10% 1/9
1: R[1]=DI[2] 2: DO[3]=ON 3: R[R[1]]=DI[R[2]] 4: PR[1]=P[3] 5: PR[1,2]=PR[R[3],R[4]] 6: PL[1]=PL[R[3]] 7: J PR[1] 100% FINE 8: J P[1] 100% FINE 9: LBL[1] [End] [INST]
[EDCMD]>
2 Press F5 (EDCMD) to display the edit instruction menu. PNS0001
JOINT 10% 1/9
1: R[1]=DI[2] 2: DO[3]=ON 1 3: R[R[1]]=DI[R[2]] 2 4: PR[1]=P[3] 3 5: PR[1,2]=PR[R[3],R[4]] 4 6: PL[1]=PL[R[3]] 5 7: J PR[1] 100% FINE 6 8: J P[1] 100% FINE 7 9: LBL[1] 8 [End] [INST]
Insert Delete Copy Find Replace Remember Comment Undo EDCMD
3 Select Item 8 Undo. PNS0001 1: 2: 3: 4: 5: 6: 7: 8: 9:
JOINT 10% 1/9
R[1]=DI[2] DO[3]=ON R[R[1]]=DI[R[2]] PR[1]=P[3] PR[1,2]=PR[R[3],R[4]] PL[1]=PL[R[3]] J PR[1] 100% FINE J P[1] 100% FINE LBL[1]
Undo? (Edit) YES
308
NO
5. PROGRAMMING
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4 To perform an undo operation, select F4 (YES). To cancel an undo operation, select F5 (NO). When F4 (YES) is selected, the edit operation is undone. PNS0001
JOINT 10% 1/9
1: R[1]=DI[2] 2: DO[3]=ON 3: R[R[1]]=DI[R[2]] 4: PR[1]=P[3] 5: PR[1,2]=PR[R[3],R[4]] 6: PL[1]=PL[R[3]] 7: J PR[1] 100% FINE 8: J P[1] 100% FINE 9: LBL[1] [End] [INST]
[EDCMD]>
5 When an additional undo operation is performed in succession, the first undo operation performed can be cancelled; this means the state present before the first undo operation is performed is restored. NOTE If an edit operation is performed after an undo operation, the undo operation cannot be cancelled. CAUTION An undo operation automatically rewrites the program, so that the results may not be those expected by the operator. Before executing a program after an undo operation, carefully check the program. F
F
F
F
F
F
F
F
This function can undo the following operations: a) Instruction modifications b) Line insertion c) Line deletion d) Copying of program statements (reading) e) Copying of program statements (insertion) f) Program instruction replacement g) Reassignment of position numbers An undo operation cancels all edit operations performed on the line where the cursor is currently placed, and restores the state present before those edit operations were performed. The undo function is disabled when any of the following operations is performed: a) Power--off b) Selection of another program Undo operation cannot be performed in any of the following states: a) The teach pendant is disabled. b) The program is write--protected. c) Program memory is insufficient. The following edit operations cannot be undone: a) Teaching and editing of palletizing instructions b) Deletion of lines including palletizing instructions c) Copying of lines including palletizing instructions (reading) d) Copying of lines including palletizing instructions (insertion) e) Replacement in a program including palletizing instructions f) Number reassignment in a program including palletizing instructions If the power is turned off while an undo operation is being performed, the undo operation is stopped. Note that in this case, the program may become unusable. If any of the following instructions is performed after an edit operation, the undo function cannot be performed: a) Laser instruction b) Palletizing instruction c) Spot welding instruction d) Line tracking instruction If any of the following functions is executed after an edit operation, the undo function cannot be performed: a) Online position modification b) Fine adjustment of welding speed
309
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5.5 Program Operation This section describes the following program operations: F
Changing program information
F
Deleting a program
F
Copying a program
F
Reading a program
F
Storing a program
F
Printing a program
F
Displaying the attribute of a program
5.5.1 Changing program information The program header information is changed with a program detail screen (see Section 4.1 ). Setting without the motion group motion group can be done. The following items can be set: F
Program name: Name of program to be changed.
F
Subtype: The subtype of a program to be changed.
F
Comments: The comments in the program to be changed.
F
Group mask: Specifies a motion group to be controlled in a program. You can also set so a program has no motion group.
F
Write protection: Prevents the modification of a program.
F
Interruption disable: Causes a program that has no motion group not to be paused by an alarm whose severity is SERVO or lower, the emergency stop, and the hold.
Display the following items on the program information screen: F
Creation Date:
F
Modification Date:
F
Name of the file to be copied
F
Positions: FALSE/TRUE
F
Memory area size of program
Deleting a program An unnecessary program can be deleted. Copying a program A program with another name with the same content can be reproduced. Display of a program attribute The following program header informations can be displayed on the program selection screen: F
Comment
-- The comment in header information is displayed.
F
Protection
-- The settings of “Write protect:” in header information is displayed
F
Last Modified -- The settings of “Modification Date:” in header information is displayed.
F
Size
F
Copy Source -- The settings of “Copy Source:” in header information is displayed.
-- The number of lines in a program and its memory size are displayed.
CAUTION All of the free memory size displayed on the directory screen might not be usable to store a program. Even if the size of free memory is not 0, for example, you will not be able to create a program.
310
5. PROGRAMMING
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Procedure 5--33 Condition Step
Changing program information
H The teach pendant must be enabled. 1 Press the MENUS key to display the screen menu. 2 Select SELECT. The program selection screen is displayed. Alternatively, press the SELECT key to display the program selection screen. Select 1 2 3 4 5
SAMPLE1 SAMPLE2 SAMPLE3 PROG001 PROG002
JOINT 30% 61092 bytes free 3/5 JB[SAMPLE PROGRAM1 ] JB[SAMPLE PROGRAM2 ] JB[SAMPLE PROGRAM3 ] PR[PROGRAM001 ] PR[PROGRAM002 ]
[TYPE]
CREATE
DELETE
COPY
DETAIL
LOAD
MONITOR
[ATTR] >
SAVE
PRINT >
3 Press the NEXT key “>” to display the next page, then press the F2 (DETAIL) key. The program information screen is displayed. COPY
DETAIL
LOAD
F2
Program detail
JOINT
30 % 1/6 Creation Date: 10-MAR-1994 Modification Date: 11-MAR-1994 Copy Source: [****************] Positions: FALSE Size: 312 Byte 1 Program name: [SAMPLE3 ] 2 Sub Type: [None ] 3 Comment: [SAMPLE PROGRAM 3] Group Mask: [1,*,*,*,*] 4 Write protect: [OFF ] 5 Ignore pause: [OFF ] END PREV NEXT
4 Specify each item (see Section 4.1). If the motion instruction is taught in the program, you can not set the 3 “Group Mask:” of this program. 5 After specifying program information, press the F1 (END) key. END
PREV
NEXT
F1
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5. PROGRAMMING
Procedure 5--34 Step
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Deleting a program
1 Press the MENUS key to display the screen menu. 2 Select SELECT. The program selection screen is displayed. The program selection screen can also be displayed by pressing the SELECT key, instead of executing steps 1 and 2 above. Select 1 2 3 4 5
SAMPLE1 SAMPLE2 SAMPLE3 PROG001 PROG002
[TYPE]
JOINT 30% 61092 bytes free 3/5 JB[SAMPLE PROGRAM1 ] JB[SAMPLE PROGRAM2 ] JB[SAMPLE PROGRAM3 ] PR[PROGRAM001 ] PR[PROGRAM002 ]
CREATE
DELETE
MONITOR
[ATTR] >
3 Move the cursor to the name of a program to be deleted, then press the F3 (DELETE) key. [TYPE]
CREATE
DELETE
Select 3 SAMPLE3
F3
JOINT 30% 61092 bytes free 5/5 JB[SAMPLE PROGRAM3 ]
Delete ? YES
NO
4 Press the F4 (YES) key. 5 The specified program is deleted. YES
NO
Select 1 2 3 4
F4
SAMPLE1 SAMPLE2 PROG001 PROG002
[TYPE]
JOINT 30% 61276 bytes free 2/4 JB[SAMPLE PROGRAM1 ] JB[SAMPLE PROGRAM2 ] PR[PROGRAM001 ] PR[PROGRAM002 ]
CREATE
DELETE
MONITOR
[ATTR] >
CAUTION After a program is deleted, the program cannot be restored. When deleting a program, be careful not to lose precious data.
312
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Procedure 5--35 Step
Copying a program
1 Press the MENUS key to display the screen menu. 2 Select SELECT. The program selection screen is displayed. 3 Press F1 (copy) on the next page and then a program copy screen is displyed. Motion Modify 1 Words 2 Upper Case 3 Lower Case 4 Options Select
---Insert---
---Copy Teach Pendant Program--From: [SAMPLE3 ] TO: [ ] Press ENTER for next item PRG MAIN SUB TEST
4 Enter the name of the program to be copied, then press the ENTER key. ---
Copy Teach Pendant Program
---
From : [SAMPLE3 ] To : [PRG1 ] -- End
--
YES
NO
Copy OK ?
5 Press the F4 (YES) key. 6 The desired program is copied to the specified program, PROGRAM1. YES
F4
NO
Select 1 2 3 4 5 6
SAMPLE1 SAMPLE2 SAMPLE3 PROG001 PROG002 PRG1
[TYPE]
JOINT 30% 48956 bytes free 6/6 JB[SAMPLE PROGRAM1 ] JB[SAMPLE PROGRAM2 ] JB[SAMPLE PROGRAM3 ] PR[PROGRAM001 ] PR[PROGRAM002 ] JB[ ]
CREATE
DELETE
313
MONITOR
[ATTR] >
5. PROGRAMMING
Procedure 5--36 Step
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Displaying the Attribute of the Program
1 Press the MENUS key. The screen menu is displayed. 2 Select “0 ---- next ----”. “1 SELECT” in the next page is displayed. You can select a program selection screen by pressing the SELECT key instead of steps 1 to 2 above. Program Selection Screen Select
JOINT 30 % 61276 bytes free 1/4 No. Program name Comment 1 SAMPLE1 [SAMPLE PROGRAM 1] 2 SAMPLE2 [SAMPLE PROGRAM 2] 3 PROG001 [PROGRAM001 ] 4 PROG002 [PROGRAM002 ]
[ TYPE ] CREATE DELETE
MONITOR [ATTR ]>
COPY
SAVE
DETAIL
LOAD
PRINT
>
3 Press F5,[ATTR]. 4 Select Size. 5 The number of lines and size of a program is displayed at the comment field. Select 1 2 3 4 5
JOINT 30 % 61276 bytes free 1/2 No. Program name Size 1 SAMPLE1 [ 10/ 1000] 2 SAMPLE2 [ 10/ 1000] 3 PROG001 [ 10/ 1000] 4 PROG002 [ 10/ 1000]
Comment Protection Last Modified Size Copy Source ATTR
[ TYPE ] CREATE DELETE
F5
MONITOR [ATTR ]>
ENTER
6 When you want to display the other item, select the desired item in the procedure 4.
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5.6 Background Editing While the robot is being operated, the background editing function allows another program to be edited in the background. With this function, another program can be modified and checked without stopping robot operation, thus increasing productivity and maintenance efficiency. This function is optional. WARNING This function allow editing when the teach pendant is disabled. However, when the teach pendant is disabled, edit operation performed by an operator near the robot is very dangerous. To ensure operator safety, be sure to perform edit operation outside the robot movement range. Outline of this function This function is outlined below. F
Background editing is started by selecting a special program name for background editing when the teach pendant is disabled. The special program name is “--BCKEDT--”.
F
During background editing, the following data is displayed on the top of the edit screen of the teach pendant: -- Program name selected in the background -- <> for indicating that background editing is in progress AAA BBB 1: 2:
RUNNING JOINT 10% <> J P[1] 100% FINE
[INST]
[EDCMD]>
a: Execution status of the program selected (status line) b: Program name selected in the background c: Indication that background editing state is set F
No modifications to a program being edited in the background are reflected in the original program until the background editing is completed.
F
To terminate background editing, press the F5 [EDCMD] key on the edit screen to display a menu, then select End_edit from the displayed menu. Here, the user can choose whether to reflect the results of background editing in the original program or discard the results of background editing.
F
Multiple programs can not be edited in the background at the same time. The background editing of a program must be terminated by End_edit operation before another program can be edited in the background.
F
If another program is selected without performing End_edit operation during background editing, the results of background editing are preserved. Background editing can be restarted by reselecting the special program name (“--BCKEDT--”) for background editing on the program directory screen.
F
When the teach pendant is disabled, and the edit screen is displayed, the user can switch between the display of the program selected in the foreground (not background) and the display of the preserved results of background editing.
F
When the teach pendant is enabled, the special program name for background editing can be selected from the program directory screen, and can be executed with the teach pendant.
F
When the teach pendant is disabled, the special program for background editing cannot be externally selected and executed.
F
When an external start signal is applied during background editing, the program selected in the foreground is started.
F
The program started during automatic operation or executed by subprogram calling is the original program selected in the background.
F
Even if a program is externally selected with the external program selection function (PNS) during background editing, the background editing can be continued without being interrupted.
315
5. PROGRAMMING
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The operation flows of the following cases are explained using figures below: F
When background editing is started with the teach pendant disabled
F
When background editing is started with the teach pendant enabled
F
When a program is externally selected during background editing
F
When a start signal is externally applied during background editing
F
When the teach pendant is enabled during background editing
F
When the teach pendant is disabled during background editing
F
When the screen is switched using the edit key on the teach pendant
F
When background editing is terminated with the teach pendant disabled
F
When background editing is terminated with the teach pendant enabled
When background editing is started with the teach pendant disabled When a program is selected in background editing, the program selected in the foreground is not modified. Even if no program is selected in the foreground, background editing is started. AAA Select 1 -BCKEDT2 AAA 3 BBB
RUNNING JOINT 10% 1/3 [ [ [
“--BCKEDT--”
] ] ] Is any program being edited in the background?
NO
AAA Select
YES
RUNNING JOINT 10% 1/2
PREV key 1 AAA 2 BBB
[ [
] ]
Select a program for the BACKGROUND EDIT
ENTER key
When you finish editing. DO NOT forget to declare End-edit in [EDCMD]
OK
ENTER key
AAA BBB <> 1:J P[1] 100% FINE 2:
316
RUNNING JOINT 10%
5. PROGRAMMING
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When background editing is started with the teach pendant enabled If the special program for background editing is selected when the teach pendant is enabled, the program is selected in the foreground, and its test execution is enabled. AAA Select
RUNNING JOINT 10% “--BCKEDT--”
1 -BCKEDT2 AAA 3 BBB
[ [ [
] ] ] Is any program being edited in the background?
NO
AAA Select
YES
PAUSED JOINT 10%
PREV key 1 AAA 2 BBB
[ [
] ]
Select a program for the BACKGROUND EDIT
ENTER key
When you finish editing DO NOT forget to declare End-edit in [EDCMD]
OK
ENTER key
-BCKEDTBBB
JOINT 10%
<> 1:J P[1] 100% FINE 2:
When a program is externally selected during background editing If a program is externally selected during background editing (with the teach pendant disabled), the status line displays the state of the selected program. The state of background editing remains unchanged. PNS0001 BBB 1: 2:
ABORTED JOINT 10%
<> J P[1] 100% FINE
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When a start signal is externally applied during background editing If a start signal is externally applied during background editing (with the teach pendant disabled), the program selected in the foreground is started, and the status line displays RUNNING. The state of background editing remains unchanged. PNS0001 BBB 1: 2:
RUNNING JOINT 10%
<> J P[1] 100% FINE
When the teach pendant is enabled during background editing If a program is selected in the foreground, background editing and the program being executed are suspended, and the program selected in the foreground is displayed on the screen. If an alarm is issued from the program being executed, for example, the point of alarm generation can be immediately located and corrected by enabling the teach pendant according to this function. To return to background editing, disable the teach pendant, then press the edit key or reselect “--BCKEDT--” from the program directory screen. Teach pendant : disable
Teach pendant : enable
PNS0001 BBB 1: 2:
RUNNING JOINT 10%
PNS0001 PNS0001
<> J P[1] 100% FINE
PAUSED JOINT 10%
1: 2:
Disable the teach pendant, then a. Press the EDIT key on the program edit screen. b. Select “--BCKEDT--” on the program directory screen.
If no program is selected in the foreground, the special program (“--BCKEDT--”) is selected to allow the program being edited in the background to be executed. The status line displays the state of “--BCKEDT--”. Teach pendant : disable
BBB
Teach pendant : enable -BCKEDTBBB
JOINT 10%
JOINT 10% <>
<> 1: 2:
1: 2:
When the teach pendant is disabled during background editing If “--BCKEDT--” is selected in the foreground, the foreground enters the program nonselection state when the teach pendant is disabled. (The status line disappears.) So, the program being edited in the background cannot be executed externally. The background editing can be continued without modification. Teach pendant : enable
BBB
Teach pendant : disable -BCKEDTBBB
JOINT 10% <>
1: 2:
1: 2:
318
<> J P[1] 100% FINE
JOINT 10%
5. PROGRAMMING
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When the screen is switched using the edit key on the teach pendant If the teach pendant is disabled, and the program edit screen is displayed, pressing the EDIT key switches screen display between the display of the program selected in the foreground and the display of suspended background editing. If there is a program in the foreground and background as well, the screen display switches between foreground display and background display each time the edit key is pressed, as shown below. Teach pendant : disable
Teach pendant : enable
PNS0001 BBB
RUNNING JOINT 10%
PNS0001 BBB
<>
EDIT key
1: 2:
RUNNING JOINT 10%
1: 2:
If no program is selected in the foreground, pressing the edit key does not switch screen display; the error Program is not selected occurs. If no program is selected for background editing, pressing the edit key does not switch screen display; the error Not editing background program occurs. This error occurs only when the background editing option is selected. When background editing is terminated with the teach pendant disabled When background editing is terminated, the program directory screen appears. At this time, the user can specify whether to reflect the results of background editing in the original program. AAA BBB 1: 2:
PAUSED JOINT 10% <> 1 Insert : 7 End-edit
Select 7 End--edit
EDCMD Do you want the modifications which have been edited in the background to be implemented? YES NO
Do you want to discard the modifications?
YES
What is the execution state of the program?
Executing/ pausing
NO
Ends the background editing, discarding the modifications. The program is not modified.
END Ends the editing with the modifications reflected in the program.
You could not implement the modifications because the program was executing or pausing
AAA Select 1 -BCKEDT2 AAA 3 BBB
OK
ENTER key
319
PAUSED JOINT 10% [ [ [
] ] ]
5. PROGRAMMING
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When background editing is terminated with the teach pendant enabled When background editing is terminated, the program directory screen appears. The program edited in the background is selected in the foreground, and the status line displays the state of the program. -BCKEDTBBB
JOINT 10% <>
1: 2:
1 Insert : 7 End-edit EDCMD Do you want the modifications which have been edited in the background to be implemented? YES NO
Do you want to discard the modifications?
YES
What is the execution state of the program?
NO
Ends the background editing, discarding the modifications. The program is not modified.
END Ends the editing with the modifications reflected in the program. You could not implement the modifications because the program was executing or pausing
BBB Select 1 -BCKEDT2 AAA 3 BBB
OK
ENTER key
Operation flow The operation flow of this function is shown on the next page.
320
ABORTED JOINT 10% [ [ [
] ] ]
5. PROGRAMMING
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AAA Select
PAUSED Select
1 -BCKEDT2 AAA 3 BBB
[ [ [
1 -BCKEDT2 AAA 3 BBB
] ] ]
[ [ [
] ] ]
Select
Not select
Select background editing. Is any program being edited in the background? Not select
Select
YES
NO AAA Select 1 AAA 2 BBB
PAUSED [ [
When you finish editing. DO NOT forget to declare End-edit in [EDCMD]
] ]
OK
Select a program for the BACKGROUND EDIT
Enable TP ?
no (disable)
yes (enable) Enable TP ?
yes (enable)
BBB <>
To enable TP
BBB <> 1: 2: 3:
1: 2: 3:
To disable TP
no (disable) AAA PAUSED BBB <> 1: 2: 3:
AAA AAA
Edit key
AAA AAA
To enable TP
PAUSED
1: 2: 3:
To disable TP
1: 2: 3:
END 1
PAUSED
END 2 END 3
End background editing.
AAA PAUSED BBB <> 1: 2: 1 Insert 2 Delete : 7 End-edit EDCMD
Select 7 End--edit
Do you want the madifications which have been edited in the background to be implemented?
YES
NO
YES
NO
What is the state of the program? Executing/ pausing
END (End--edit)
You could not implement the modifications because the program was executing or pausing
Do you want to discard the modifications?
(Discard--edit)
OK
YES
NO
NO
END 1 AAA Select 1: 2: 3:
PAUSED
END 2 BBB Select
END 3
ABORTED
a Select
1: 2: 3:
1: 2: 3:
321
YES
5. PROGRAMMING
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Notes When using this function, note the points below. F
When a program is selected for background editing, the selected program is internally copied to the special program for background editing. So, memory larger than the size of a selected program needs to be allocated beforehand.
F
When the background editing of a program is terminated, the original program is backed up, and the background program is reflected in the original program. So, memory larger than the size [(original program) + (increment produced by background editing)] needs to be allocated beforehand.
F
If background editing cannot be terminated for a cause such as insufficient memory, the following error and its cause are displayed in the alarm display lines (line 2 and 3) on the teach pendant: TPIF--054 Could not end editing MEMO--126 No more available memory
F
When the power to the robot is turned off then back on while background editing is being terminated (while the original program is being updated) To prevent the updating of the original program from being stopped halfway, restore the original program from the backup program when the power is turned on. If the results of background editing need to be reflected, check the results of background editing, then perform another editing termination operation. If an attempt to restore the original program fails, the following error is displayed: TPIF--055 Could not recover original program In this case, check the results of background editing, then perform another editing termination operation. If the power is turned off then back on when editing is terminated, check the state of the original program before starting continuous operation.
F
If the original program is executed when background editing is terminated, the robot may stop, depending on the timing of the execution. When terminating background editing, carefully check that the original program is not executed. Four cases can be considered for the timing relationship between background editing termination operation and program execution. -- Case 1:The program is being executed when background editing is terminated. In this case, the message “You could not implement the modification because the program was executing or pausing” is displayed in the central part of the teach pendant, and the results of background editing cannot be reflected. -- Case 2:The program is started exactly when the results of background editing have been reflected In this case, the program reflecting the results of background editing is executed. -- Case 3:An attempt is made to start the program while the results of background editing are being reflected One of the following errors occurs, and the robot stops: SYST--011 Failed to run task MEMO--004 Specified program is in use -- Case 4:When the original program is deleted, and a program is re--created to reflect the results of background editing, an attempt is made to start the program. One of the following errors occurs, and the robot stops: SYST--011 Failed to run task MEMO--027 Specified line does not exist
F
When the original program is write--protected (Write--protect is ON), editing cannot be terminated. In this case, one of the following errors occurs: TPIF--054 Could not end editing TPIF--008 Memory protect violation
F
Background editing can be terminated even when the special program for background editing is write--protected.
F
The status line displays the execution state of a selected program. So, if a subprogram being executed is terminated forcibly, and the main program is selected in the foreground, the status line continues to display the subprogram name. If program start operation is initiated here, the execution of the selected main program is started, and the status line displays the execution state of the main program.
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5. PROGRAMMING
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If the disabled edit key or teach pendant is enabled on the background screen in the state above, the status line does not display the subprogram but the main program selected in the foreground. F
When the teach pendant is disabled, a program can be created/deleted. However, when a program is created, the following error occurs; no selection is made in the foreground, and no direct transition to the edit screen is made: TPIF--104 Teach Pendant is disabled
F
If the teach pendant is disabled after the special program for background editing is selected and executed with the teach pendant enabled, the end state is set. If the teach pendant is disabled when a subprogram is executed from the special program, the execution is terminated, and the program directory screen appears.
F
When there is a suspended program in the background, the special program for background editing (“--BCKEDT--”) cannot be read from the floppy disk. In this case, the following message appears: This program is being edited Before reading the special program from the floppy disk, terminate background editing.
323
5. PROGRAMMING
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5.7 Singularity Point Check Function If a move statement is taught, or a position modification is made based on rectangular coordinate position data when the robot is positioned near a singularity point, the robot may move with an attitude different from the taught attitude when the move statement is executed. (See Section 4.3.2.) To prevent such trouble, the singularity point check function checks to see if a taught position is a singularity point when the position is taught. Then, the function teaches such a position according to axial type based on the user’s choice. Function To enable this function, set the system variable $MNSING_CHK to TRUE. If a move statement is taught with SHIFT + POINT key or a position modification is made with SHIFT + TOUCH UP key when the robot is at a singularity point, this function checks if the taught position is a singularity point. This check is made when the following conditions are satisfied: F
The additional instructions do no include incremental instructions, position compensation instructions, and tool compensation instructions.
F
The UF (user coordinate system number) of position data is 0.
F
The registered position type is rectangular type.
If a check finds that the taught position is a singularity point, the top two lines of the teach pendant display the following warning message: TPIF--060 Can’t record on cartesian (G:1) MOTN--023 In singularity i: Move group number at a singular point At the same time, the following prompt message is displayed at the lower part of the teach pendant: Record current position on joint At this time, the function keys YES and NO are displayed. Select one of the two keys. F
YES: Deletes position data according to axial type.
F
NO: Does not perform position teaching/modification.
The position data of a program that has multiple move groups is checked for singularity points in ascending order of group numbers. If multiple groups are at singularity points, a warning message and prompt message are displayed for each group. Notes This function is not applicable to the teaching of typical palletizing loading points and passing points.
324
6. EXECUTING A PROGRAM
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6. EXECUTING A PROGRAM This chapter describes testing a program and automatic operation. j Contents of this chapter 6.1
Program Halt and Recovery
6.2
Executing a Program
6.3
Testing
6.4
Manual I/O Control
6.5
Manually Operating Welding Equipment
6.6
Automatic Operation
6.7
Online Position Modification
6.8
Welding Tuning
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6. EXECUTING A PROGRAM
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6.1 Program Halt and Recovery Program halt refers to stopping a running program. A program halt is caused by: F
An alarm occurring accidentally while the program is running.
F
An intentional stop of a running program by the operator.
The operating robot stops in one of the following ways: F
Fast stop : The robot is quickly decelerated until it stops.
F
Slow stop : The robot is slowly decelerated until it stops.
Program halt states are classified into two types: F
Forced termination (end): The execution of a program is terminated. ABORTED is displayed on the screen of the teach pendant. If the main program is terminated while a subprogram is being executed, information on return of control to the main program is lost.
SAMPLE1 SAMPLE1 F
LINE 7
ABORTED JOINT 30%
Halt (temporary stop): The execution of a program is stopped temporarily. PAUSED is displayed on the screen of the teach pendant. The temporarily stopped program can be restarted. The subprogram called with a program call instruction returns control to the main program.
SAMPLE1 SAMPLE1
LINE 7
PAUSED JOINT 30%
To start from another line in the same program or another program, abort a program to release the paused state. There are two methods to halt a program intentionally: F
Press the emergency stop button on the teach pendant or the machine operator’s panel or release the deadman switch. Peripheral device I/O *IMSTP input
F
Press the HOLD button on the teach pendant or use the input signal *HOLD of the peripheral I/O: These inputs halt the execution of the program.
F
Select 1 ABORT(ALL) from the miscellaneous menu. Peripheral device I/O *CSTOPI input. This method aborts the program.
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6.1.1 Halt by an emergency stop and recovery To stop the robot immediately, press the emergency stop button on the machine operator’s panel/box or teach pendant. When the emergency stop button is pressed, an emergency stop alarm occurs. Pressing the emergency stop button causes the following: F
The robot stops operating immediately and the program is halted.
F
An alarm occurs and the power to the servo system is turned off.
Procedure 6--1
Emergency stop and recovery
Emergency stop procedure Step
1 Press the emergency stop button on the teach pendant or the machine operator’s panel/box. This halts the running program, and PAUSED is displayed on the teach pendant. The emergency stop button is locked to keep it pressed (on state). The emergency stop alarm message is displayed on the screen of the teach pendant. The FAULT lamp lights.
ON
EMEGENCY STOP
Emergency stop button OFF PORT
SRVO-002 Teach Pendant E-Stop SAMPLE1 LINE 2 SAMPLE1
ABORTED JOINT 30%
Recovery procedure 2 Eliminate the cause of the emergency stop. For example, correct the program. 3 Rotate the emergency stop button clockwise to unlock the button.
4 Press the RESET key on the teach pendant (or operator’s panel/box). The alarm message then disappears from the screen of the teach pendant, and the FAULT lamp goes off.
RESET
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6.1.2 Halt by a hold and recovery To decelerate the robot slowly until it stops, press the HOLD key on the teach pendant. Pressing the HOLD key causes the following: F
The robot decelerates slowly until it stops (the program is halted).
F
A setting can be made to cause an alarm to turn off the servo power. To make this setting, select SETUP General on the general item setting screen. (See Section 3.22.)
Procedure 6--2
Hold and recovery
Hold procedure Step
1 Press the HOLD key on the teach pendant. The running program is halted, and PAUSED is displayed on the teach pendant. The alarm message is only displayed when the halt alarm is enabled.
HOLD
Recovery procedure 2 To release the halt state, restart the program.
Procedure 6--3
Terminating (aborting) a program forcibly
Release paused state Step
1 To release the paused state and abort a program, press the function key to display the function menu. 2 Select ABORT(ALL). The halt state is released.
1 ABORT (ALL) 2 Disable FWD/BWD FCTN
ENTER
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6.1.3 Halt caused by an alarm An alarm is issued when a failure is detected or when the emergency stop signal or another alarm signal is input from a peripheral device while the operator teaches or plays back a program. When an alarm is generated, it is indicated on the teach pendant, and processing such as robot operation and program execution is stopped to ensure safety. Displaying an alarm The operator can check whether an alarm has occurred by watching the FAULT lamps on the teach pendant and the first line and second line on the screen of the operator’s panel. The kind of a alarm is recognized by an alarm code. The cause and corrective action of an alarm can be known by an alarm code.(See APPENDIX C.1) Figure 6--1. Display and Indication of an Alarm FAULT HOLD STEP BUSY
Alarm code INTP--224 ID No. Alarm detail code MEMO--027
INTP-224 (SAMPLE1, 7) Jump label is fail MEMO-027 Spedified line does not exist Alarm JOINT 30 % 1/7 1 INTP-224 (SAMPLE1, 7) Jump label is 2 SRVO-002 Teach pendant E-stop
Alarm history To display the alarm history, select an alarm history screen [4 ALARM].(See APPENDIX C.1, “Alarm codes”) 3 MANUAL FCTNS 4 ALARM 5 I/O MENUS
INTP-224 (SAMPLE1, 7) Jump label is fail INTP-224 (SAMPLE1, 7) Jump label is fail MEMO-027 Spedified line does not exist 30-MAY-44 07:15 STOP.L 00000110 Alarm 1/7 1 INTP-224 (SAMPLE1, 7) Jump label is 2 SRVO-002 Teach pendant E-stop 3 R E S E T 4 SRVO-027 Robot not mastered(Group:1) 5 SYST-026 System normal power up [ TYPE ]
CLEAR
HELP
NOTE The WARN alarm history is not recorded when system variable $ER_NOHIS = 1.
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Alarm detail information Alarm has the detail information. To display the alarm detail information, press F5, HELP in the alarm history screen [4 ALARM].
CLEAR
HELP INTP-224 (SAMPLE1, 7) Jump label is fail MEMO-027 Spedified line does not exist 30-MAY-44 07:15 STOP.L 00000110 Alarm
F5
1 Alarm code 2 Alarm detail code 3 Generation date 4 Alarm severity
F
Alarm code: Identifies an alarm.
F
Alarm detail code: Identifies an alarm detail.
F
Generation date: The generation date of the alarm is indicated. (It is not supported currently.)
F
Alarm severity: Indicates the severity of an alarm.
Resetting an alarm After eliminating the cause of an alarm, press the RESET key to reset the alarm. The alarm indicated in the first and second lines of the teach pendant disappears. When the servo power is turned off, it is turned on. Resetting an alarm usually enables the robot. Figure 6--2. RESET Key
RESET
FAULT
FAULT
HOLD
HOLD
STEP
STEP
Disabling the output of peripheral I/O alarm signals The output of alarm signals (FAULT output) can be disabled. F
Set $ER_NO_ALM.$NOALMENBLE to 1 (enabled).
F
Specify the number of alarms for which output is to be disabled in $ER_NO_ALM.$NOALM_NUM.
F
Specify the codes of the alarms for which output is to be disabled in $ER_NO_ALM.$ER_CODE1 to $ER_NO_ALM.$ER_CODE10. ( See Alarm code) 11 002 (Meaning: SERVO--002 alarm) Alarm ID Alarm No.
Halt alarm The halt alarm function issues an alarm and turns off the power to the servo system when the operator presses the HOLD key to halt the robot. Specify the fault alarm function in [6 SETUP General] on the general item setting screen (see Section 3.22).
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Alarm severity The alarm severity indicates the severity of an alarm and the cause of the alarm. Whether program execution and robot operation are stopped, and whether the servo power is turneds off depends on the alarm severity. Table 6--1. NONE WARN
Alarm Severity Program
Robot operation
none
none
Power to servo system
PAUSE.L STOP.L
------------------none
PAUSE.G pause p
decelerate the robot slowly y until it stops
ABORT.L
Range
Global Global
SERVO
SERVO2 SYSTEM
Local Local
STOP.G
ABORT.G
Range
abort
stop the robot immediately
off
decelerate the robot slowly until it stops
none
stop the robot immediately
off
Global Local Global Global Global
Indicates the range in which an alarm is issued when more than one program is executed (multitasking function). Local An alarm is issued only to the program that caused the alarm. Global
An alarm is issued to all programs.
NOTE Some alarms do not observe the above rules. Table 6--2. Severity WARN
PAUSE
STOP
SERVO
ABORT SYSTEM
Description of Alarm Severity Description A WARN alarm warns the operator of a comparatively minor or unimportant failure. The WARN alarm does not affect the operation of the robot. When a WARN alarm occurs, no corresponding LED on the teach pendant or the machine operator’s panel lights. To prevent a possible failure in the future, action should be taken for this alarm. When a PAUSE alarm occurs, the execution of the program is halted, and the operation of the robot is stopped. Appropriate action must be taken for the alarm before the program is restarted. When a STOP alarm occurs, the execution of the program is halted, and the robot is decelerated until it is stopped. Appropriate action must be taken for the alarm before the program is restarted. When a SERVO alarm occurs, the execution of a program is paused(or aborted) and the power to the servo system is turned off to stop the robot immediately. The most common cause of a SERVO alarm is hardware failure. When an ABORT alarm occurs, the execution of the program is forcibly terminated, and the robot is decelerated until it is stopped. A SYSTEM alarm is issued when a major system failure occurs. When a SYSTEM alarm occurs, every robot in the system is disabled. Contact the FANUC Service Division. After taking appropriate action for the alarm, turn on the power again.
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6.2 Executing a Program To execute a program is to play back a taught program. A taught program is played back just like a recorded video tape is played back.
6.2.1 Starting a program A program can be started by: F
Using the teach pendant (SHIFT key and FWD or BWD key)
F
Setting the START button on the operator’s panel/box.
F
Using the peripheral device (RSR 1 to 4 input, PROD_START input, and START input)
Figure 6--3. Starting a program Teach pendant
SHIFT FWD
BWD
For safety’s sake, a program can be started only in a device having the right to start a program. The start right can be switched by using the teach pendant enable switch and the remote switch on the operator’s panel. Figure 6--4. How to Set the Right to Start a Program
STEP key
On
On
Step operation Continuous operation
Teach pendant enable switch
Off
A program is started on the teach pendant. Cycle operation A program is started on the operator’s panel.
Off
Remote switch of operator’s panel/box
Automatic operation A program is started in a peripheral.
CAUTION When the start right is switched by using the enable switch on the teach pendant or the remote switch on the operator’s panel/box, any programs that are currently running are temporarily halted.
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6.2.2 Robot motion The robot moves just as it is instructed by the motion instructions in the program. See Section 4.3, “Motion Instructions”. The following factors determine the motion of the robot: F Feedrate override: Robot motion speed (operating speed) F Cartesian coordinate system: Work area where the robot moves Feedrate override The feedrate override determines the operating speed. The feedrate override is specified as a percentage of the feedrate specified in the program (programmed speed). The current feedrate override is displayed in the upper right corner of the screen of the teach pendant, as shown in Figure 6--5. Pressing the feedrate override key displays a popup window in reverse video in the upper right corner of the screen to call the operator’s attention. The popup window in reverse video automatically disappears a few seconds later or after another key is pressed. Figure 6--5. Screen Display for Feedrate Override Feedrate override JOINT 30% JOINT 30%
VFINE FINE
Very low speed Low speed
1% ↓ 5% ↓ 50% ↓ 100%
In 1% increments In 5% increments
A feedrate override of 100% would cause the robot to operate at the maximum speed specified in the current setting. Table 6--3 shows the change in feedrate override when the override key is pressed. Table 6--3.
Feedrate Override
When the override key is pressed
VFINE → FINE → 1% → 5% → 50% → 100% In 1% In 5% increments increments
When the override key is pressed while pressing the SHIFT key(*1)
VFINE → FINE → 5% → 50% → 100%
*1 Enabled only when $SHFTOV_ENB is 1 To change the feedrate override, press the override key. Whenever the negative override key is pressed while the SHIFT key is pressed, the feedrate is decreased in the order: VFINE, FINE, 5%, 50%,100%. However, the feedrate is changed in this way only when system variable $SHFT OV_ENB = 1. Note that FINE and VFINE are enabled only during a jog feed. When FINE or VFINE is specified, the robot moves at a feedrate override of 1%. Figure 6--6. Override Keys
+%
+%
--%
--%
+% SHIFT + OR
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A feedrate override must be determined according to the condition of the machining cell, type of robot motion, and the skill of the operator. Therefore, an inexperienced robot operator should use a low feedrate override. The feedrate override can only be increased up to the maximum value specified in $SCR.$RUNOVLIM. When the safety speed signal (*SFSPD input) (See Section 3.3) is turned off, the speed override value falls to the $SCR.$FENCEOVRD value. In this case, the speed override can be increased only up to the upper limit specified in $SCR.$SFRUNOVLIM. The system provides a function for allowing the original speed override to be restored when the safety fence is closed. (See Section 3.16.) Operating speed The operating speed is the speed at which the robot moves while the program is played back. The operating speed is obtained from the following expressions: Figure 6--7. Operating Speed Operating speed (joint control motion) (deg/sec) = Programmed feedrate 100
Coefficient of a joint feedrate Maximum joint feedrate 2000 Programmed override Feedrate override 100 100 Operating speed (motion under path control) (mm/sec) = Programmed override Feedrate override 100 100 Operating speed (motion under attitude control) (deg/sec) = Programmed override Feedrate override Programmed feedrate 100 100 Programmed feedrate
Programmed override $MCR_GRP.$PRGOVERRIDE (%) Coefficient of a joint feedrate $PARAM_GROUP.$SPEEDLIMJNT Checking a Cartesian coordinate system When position data is played back according to Cartesian coordinates, the coordinate system number of the Cartesian coordinate system to be used is checked. When one of the coordinate system numbers 0 to 9 is specified and the specified coordinate system number does not agree with the currently selected coordinate system number, the program is not executed. The coordinate system number is specified for position data when the position is taught. To change a written coordinate system number, use the tool change function/coordinate system change function [option]. Tool coordinate system number (UT) The number of a mechanical interface coordinate system or tool coordinate system is specified as a tool coordinate system number (UT). This number determines the tool coordinate system. -- 0
: The mechanical interface coordinate system is used.
-- 1 to 9 : The tool coordinate system having the specified tool coordinate system is used. -- F
: The coordinate system having the currently selected tool coordinate system number is used.
User coordinate system number (UF) The number of a world coordinate system or user coordinate system is specified as a user coordinate system number (UF). This number determines the coordinate system for the work area. -- 0
: The world coordinate system is used.
-- 1 to 9 : The user coordinate system having the specified user coordinate system is used. -- F
: The coordinate system having the currently selected user coordinate system number is used.
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Position data information Pressing the F5 (DETAIL) key displays position data information. Position Detail P[1] UF:0 UT:1 CONF:FT,0 X: 1500.374 mm W: 40.000 Y: -242.992 mm P: 10.000 Z: 956.895 mm R: 20.000 EDCMD
JOINT 30% deg deg deg
Figure 6--8. Selecting a User Coordinate System
Z World coodinate system
Z Y
Tool coodinate system
Y Z
Z X
X Y
Y X X
User coodinate system 2 User coodinate system 1
6.2.3 Resuming a program Resuming a program means to restart a halted program. Before a program is halted, the system records the program. As a result, the following is possible: F
Control can be passed to the main program called with the program call instruction.
F
The path for a circular motion can be reproduced.
Path for circular motion In circular motion, the robot moves from the current position to the target point along the path that passes through the passing point. After the robot motion is interrupted by program halt, the robot is moved by jog feed, and the program is resumed. In this case, the robot moves along a path that is similar to the one that was specified before the program was halted. (The locus of an arc is recalculated on the assumption that the pass point is the current position after jogging, and that the start point is that used before the interruption.) When a step test halted at the end of a circular motion is resumed after jog feed, the tool is returned to the end point of the circular motion, by means of a linear motion. (For a step test, see Section 6.3.2.) The motion is executed at the travel speed specified in the circular motion instruction.
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Figure 6--9. Path for a Circular Motion
Target point P[2] Current position The robot is moved by jog feed.
When the program is resumed P [1] When the terminated program is started Passing point
Position at which the robot stops when the program is halted. C Start point
P [ 1] P [ 2]
1000mm/s
FINE
Releasing the halt state The halt state of the program is released when: F
1 PROGRAM ABORT is selected from the miscellaneous menu.
F
Switching of the start right (See Section 6.2.1.)
F
Creating another program forcibly terminates the halted program when the teach pendant is enabled. For program creation, see Section 5.3.
F
Selecting another program forcibly terminates the halted program when the teach pendant is enabled. For program selection, see Section 5.4.1.
Moving the cursor in the halt state When the cursor is moved to a desired line in the halted program and the program is to be resumed, the system asks the operator whether the program is to be resumed at the line to which the cursor has been moved. When YES i s selected in response to this message, the program is halted at the line to which the cursor has been moved. When NO is selected, the cursor is returned to the line where it was located before it was moved (original line), then the program is halted at that line. For both YES and NO, when the program is resumed, program execution starts at the line to which the cursor has been moved.
Procedure 6--4
Releasing the halt state
LINE 2
Step
PAUSED JOINT 30%
1 Press the FCTN key to display the miscellaneous menu. 2 Select 1 PROGRAM ABORT. The program is terminated. (ABORTED is displayed on the screen.)
1 ABORT (ALL) 2
LINE 2
ABORTED JOINT 30%
FCTN
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Procedure 6--5 Condition
Moving the cursor in the halt state
H The program must be halted. (PAUSED is displayed on the screen.) LINE 2
Step
PAUSED JOINT 30%
1 Move the cursor to the line where the program is to be resumed. 2 Restart the program. The system asks the operator whether the program is to be resumed at the line to which the cursor has been moved.
3: L 4: L 5: J [End]
The cursor is on a different line from where the program PAUSED [2]. Are you sure you want to run from this line ? YES NO
P[3] 1( P[4] 5( P[1] 1(
3 Select YES to resume the program at the line to which the cursor has been moved. This line is then specified as the current line.
YES
NO
SAMPLE1 SAMPLE1 1: J 2: J 3: L 4: L 5: J [End]
LINE 4
P[1] P[2] P[3] P[4] P[1]
PAUSED JOINT 30% 4/6
100% FINE 70% CNT50 1000cm/min CNT30 500mm/sec FINE 100% FINE
Select NO to resume the program at the line where the cursor was located before it was moved (original line). The cursor is then returned to the original line. YES
NO
Restart position check function When a program is restarted in AUTO mode, this function compares the current robot position with the robot position present when the program was halted. If the comparison shows that the difference in position is beyond a set tolerance, the function issues a warning not to start the program. If a warning is issued, select the restart method from the choices listed below. Make a choice with the teach pendant. (1) Restart the program with no special action. (2) Change the mode and return the robot to the stop position, then restart the program. When restarting the program, on the restart position check screen of the setting menu, set the tolerable distance between the current robot position and the position at which the robot was halted.
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SETUP RESUME TOL 6/6 1 2 3 4
Group Enable Tolerance checking Distance Tolerance (mm) Orientation Tolerance (deg)
Axes Tolerance 5 Rotary Axes (deg) 6 Translational Axes (mm)
: 1 : YES [250.0] [ 20.0]
[ 20.0] [250.0]
[ TYPE ]
1. Group For each group, you can enable or disable the restart position check function and set tolerances. Set a target group number for setting. When the restart position check function is enabled for more than one group, a warning is issued if a tolerance of one group is exceeded. 2. Enabling/disabling tolerance check To enable the restart position check function, select YES. (The default setting is YES.) 3. Tolerable distance (mm) At program restart, when the difference in distance between the current robot position and the position at which the robot was halted is greater than the value set here, a warning is issued, and the program is not started. 4. Tolerable attitude (deg) At program restart, when the difference in joint angle between the current robot position and the position at which the robot was halted is greater than the value set here, a warning is issued, and the program is not started. 5. Tolerance for axes: Rotation axis (deg) When the difference in angle between the current position of a rotation axis in the robot and the position at which the robot was halted is greater than the value set here at program restart, a warning is issued, and the program is not started. 6. Tolerance for axes: Linear axis (mm) When the difference between the current position of a linear axis in the robot and the position at which the robot was halted is greater than the value set here at program restart, a warning is issued, and the program is not started. When a program is restarted, this function compares the current robot position with the position at which the robot was halted. If the comparison shows that any of the distance, attitude, and axis position data exceeds a tolerance, a warning is issued, and the program is not started. In this case, the following message appears on the teach pendant: The robot position is out of stop tolerance. Please select action. Choosing CONTINUE will require cycle start. STOP
CONTINUE
(1) When STOP is selected When “STOP” is selected, this pop--up menu is disappeared, and the program is still paused. After select “STOP”, if start signal input, the tolerance check is executed and the pop--up menu is appeared again. To resume the program, please move the robot to the position within the tolerance by jog feed, then input start signal.
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(2) When CONTINUE is selected The popup menu disappears, and the program remains halted. When the start signal is input under these circumstances, the program is started. If jog feed is performed after CONTINUE is selected, checking is made again when the program is restarted next. CAUTION This function cannot be used with the line tracking function and the constant joint path function at the same time.
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6.3 Testing Testing refers to checking the operation of the robot alone before automatically operating the robot in the site line. Testing the program is very important. It must be done to ensure the safety of the workers and the peripheral devices. The following two methods can be used for testing: F
Step test: Execute the program line by line using the teach pendant or operator’s panel.
F
Continuous test: Execute the program from the current program line to the end of the program (up to the end--of--program symbol or program end instruction) using the teach pendant or operator’s panel.
The teach pendant must be enabled before testing is performed using the teach pendant. The teach pendant is enabled when: J
The teach pendant enable switch is on.
Before test operation can be started from the operator’s panel/box, the operator’s panel must be in the enabled state. The operator’s panel can be placed in this state provided the following conditions are satisfied: J
The enable switch on the teach pendant is set to OFF.
J
The remote switch on the operator’s panel/box is set to the local position.
J
The peripheral device I/O *SFSPD input is on.
Before starting a program containing motion instructions, the following operation conditions must be satisfied: J
The input signal ENBL for the peripheral I/O must be on.
J
An alarm must not be occurring
The typical test procedure is as follows: 1 Disable welding, set the machine lock switch to ON, then execute step operation from the teach pendant. Check the program instructions and I/O. 2 Disable welding, then execute step operation from the teach pendant. Check the operation of the robot, program instructions, and I/O. 3 Disable welding, then execute low--speed continuous operation from the teach pendant. 4 Disable welding, then execute high--speed continuous operation from the teach pendant. Check the positions and operation timings of the robot. 5 Enable welding, then execute continuous operation from the teach pendant. Check the welding statuses.
6.3.1 Specifying test execution To specify test execution is to specify the requirements for test execution of a program. TEST CYCLE Setup
Table 6--4. ITEMS Robot lock
JOINT
30 % 1/7
GROUP:1 1 Robot lock: 2 Dry run: 3 Cart. dry run speed: 4 Joint dry run speed: 5 Digital/Analog I/O: 6 Step statement type: 7 Step path node:
OFF OFF 300.000 mm/s 25.000 % ENABLE STATEMENT OFF
[ TYPE ] GROUP
ON
OFF
Setting of test execution DESCRIPTIONS This function specifies whether the robot is disabled. -- ON: The robot is disabled; it ignores all motion instructions. -- OFF: The robot is enabled, it usually accepts motion instructions. When the robot lock function is ON, the power to the servo system is assumed to be on. Pressing the RESET key resets all the servo alarms.
Dry run
NOTE Even when the robot lock is ON, the robot can not be operated when the emergency stop button is pressed. When this function is enabled, the robot moves at the speed specified with “Cart. dry run speed.”
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Table 6--4. (Cont’d) Setting of test execution ITEMS Cart. dry run speed
Joint dry run speed Jog dry run speed
Digital/Analog I/O
Step statement type
Step path node
Procedure 6--6 Step
DESCRIPTIONS This parameter specifies a robot feedrate during a dry run. When the motion of the robot is under path control (linear or circular motion control), the robot constantly moves at the specified speed (unit: mm/ s). This parameter specifies a robot feedrate during a dry run. When the motion of the robot is under joint control, the robot constantly moves at the specified speed. The dry run speed (jog) indicates the robot move speed used when operation is performed with the dry run setting. When a robot motion is linear or circular, the speed indicated in this item is used from the beginning to the end of the robot motion. Digital/Analog I/O specifies whether to communicate with a peripheral device via digital I/O and group I/O signal lines or not. When this is set to disable, the robot does not send or receive the digital I/O signal with a peripheral device. Internally, all the I/O signals are given the simulated flag(S) and the simulated flag can not be released until the setting is set to enable.(See Section 6.4,“Manual I/O Control”) When you set the disable flag, the output to the peripheral device does not change. You can simulate the output without changing the state of the peripheral device. When you set the flag to enable, the output returns to the state it was in before the disable flag was set. Control of the peripheral device returns to the controller. When you set the disable flag, the input from the peripheral device to the controller is retained by the controller. When you set the flag to enable the input returns to the state it was in before the disable flag was set. Step statement type specifies how to execute a program in single step mode. -- STATEMENT : The program execution is paused at each line. -- MOTION : The program execution is paused at every motion instruction. -- ROUTINE : Almost the same as STATEMENT, however, the pause is not done in a program that is called by a CALL instruction. -- TP & MOTION : At all KAREL instruction except for motion instructions, a program does not pause. NOTE “TP & MOTION” is not used currently. When “Step path node” is set to be ON, the robot pauses at every node during execution of the KAREL instruction,“MOVE ALONG”.
Specifying test execution
1 Press the MENUS key to display the screen menu. 2 Select 2 TEST CYCLE. The test cycle screen is displayed.
1 UTILITIES 2 TEST CYCLE 3 MANUAL FCTNS MENUS
TEST CYCLE Setup
JOINT
30 % 1/7
GROUP:1 1 Robot lock: 2 Dry run: 3 Cart. dry run speed: 4 Joint dry run speed: 5 Digital/Analog I/O: 6 Step statement type: 7 Step path node:
OFF OFF 300.000 mm/s 25.000 % ENABLE STATEMENT OFF
[ TYPE ] GROUP
ON
3 Specify requirements for test execution. 4 To change the group number, press F2 GROUP.
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6.3.2 Step test To perform a step test (step operation) is to execute the program line by line. After one line of the program is executed, the program is halted. After executing a logic instruction, the next line becomes the current line and the cursor moves to the next line, but for motion instructions, the cursor stays at the line after execution is completed. Specifying the step mode (single step) To specify the step mode, press the STEP key on the teach pendant. When the step mode is specified, the STEP LED on the teach pendant is lit. The STEP LED is off when continuous operation is specified. Figure 6--10. STEP Key Teach pendant FAULT HOLD STEP STEP
BUSY
Figure 6--11. Starting Step Operation Teach pendant
SHIFT FWD BWD
Step operation can be performed in two ways: Forward execution and backward execution. Forward execution In forward execution, the program is executed in normal order. To perform forward execution of the program, press and hold down the SHIFT key, then press and release the FWD key on the teach pendant.
SHIFT
FWD
When a program is started, the program is executed for one line pointed to by the cursor, then the program is halted. When a motion instruction is executed, the cursor is held at the executed line. When a logic instruction is executed, the cursor is moved to the next line. Each time forward execution of the program is started, the next line of the program is executed. When executing the circular motion instruction in step mode, the robot pauses near the intermediate position on an arc. Moreover, if the robot is paused just before the intermediate position, the robot does not stop at the intermediate position after resuming a program.
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Backward execution In backward execution, the program is executed in reverse order. To perform backward execution of the program, press and hold down the SHIFT key, then press and release the BWD key on the teach pendant.
SHIFT
BWD
F
During backward execution, only motion instructions can be executed. However, a skip instruction, forward execution instruction, backward execution instruction, soft float instruction, and other optional move instructions are ignored while the program is executed. After one line of the program is executed, the cursor is moved to the previous line.
F
The instruction before the line where the following program instructions are taught can not be executed in backward execution. When you execute these instructions in backward execution, the cursor moves to the line following the line where these instructions are taught: -- Halt instruction (PAUSE) -- Abort instruction (ABORT) -- Program end instruction (END) -- Jump instruction (JMP LBL[ ]) -- User alarm instruction (UALM[ ]) -- Execution instruction (RUN)
F
The following program instructions cannot be executed: -- Incremental instruction (INC)
F
A blank line does not affect the execution of the program (Both Forward and Backward execution)
When the terminated program is restarted, the motion instruction in the line pointed to by the cursor is executed, then the program is halted. Each time backward execution of the program is started, the program is executed using the motion format and feedrate specified in the current line, and the position data and positioning path of the motion instruction in the previous line. F
When the motion instruction in the current line specifies a circular motion, the robot moves to the target point along the path which passes through the passing point (Start point of an arc motion in normal program execution) specified in the current line.
F
When the motion instruction in the previous line specifies a circular motion, the robot moves to the destination position specified in the previous line using the motion format and feedrate specified in the current line.
To disable backward execution of the program while the program is being executed, insert the halt instruction (PAUSE) into the desired location. After the halt instruction is executed, the cursor returns to the position where it was before the program was executed. When the halt instruction is specified in the line before the line at which the cursor points, backward execution of the program is disabled. To restart backward execution of the program, move the cursor to the line before the line having the halt instruction (two lines before the line to which the cursor points). Inter--program reverse program execution With the inter--program reverse operation function, control can be returned from a subprogram to the main program that called the subprogram by performing reverse operation (SHIFT + BWD). NOTE Even if a subprogram exists during reverse operation of a main program, the subprogram cannot be called. NOTE When program termination occurs within a subprogram, control cannot be returned to the main program. When reverse execution is performed from a subprogram to the main program, the cursor stops at the line of the instruction that calls the subprogram taught in the main program.
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Sample program Example: When reverse operation is performed starting from the fourth line of a subprogram Main_Prg 1: 2:R[1]=R[1]+1 3:J P[1] 100% FINE 4:IF R[1]=100, JMP LBL[100] 5:CALL Sub_Prog 6: . . [End] Sub_Prog 1:DO[1]=ON 2:DO[2]=ON 3:L P[2] 1000mm/sec FINE 4:L P[3] 1000mm/sec FINE [End] 1 Start reverse operation with the cursor positioned on the fourth line of the subprogram. 2 Reverse operation (SHIFT + BWS) from P[3] to P[2]. The cursor is positioned on the third line of the subprogram. 3 Reverse operation (SHIFT + BWS) to the fifth line of the main program (CALL SUBPROGRAM). The cursor is positioned on the fifth line of the main program. 4 Reverse operation (SHIFT + BWS) from P[2] to P[1]. The cursor moves from the fifth line to the third line of the main program. Program end in backward execution If the system variable $BWD_ABORT is set to TRUE, when the first line of the program is finished executing during the backward execution, this program ends.
Procedure 6--7 Condition
Step test
H The teach pendant must be enabled. H The single--step mode must be set. H The system must be in the operation enable state. H No one must be in the operating area. All obstacles must be removed from the operating area.
Step
1 Press the SELECT key. The program selection screen is displayed. 2 Select the program to be tested and press the ENTER key. The program edit screen is displayed. 3 Press the STEP key to select the step mode. The STEP LED lights. (Check that the STEP LED lights when the STEP key is pressed.) 4 Move the cursor to the program start line. 5 Press and hold down the deadman switch, then turn on the teach pendant enable switch. WARNING The execution of the program instructions starts in the next step. The execution causes the robot to make a motion, which may produce unpredictable results. The operator should check that no persons and no unnecessary equipment are in the work area and that each part of the protective fence is sound. Otherwise, injury or property damage could occur. If the program needs to be stopped before it terminates, the operator should release the SHIFT key or deadman switch or press the HOLD or emergency stop button.
6 Start the program. F
To perform forward execution of the program, press and hold down the SHIFT key, then press and release the FWD key. Do not release the SHIFT key until execution of the program is completed.
F
To perform backward execution of the program, press and hold down the SHIFT key, then press and release the BWD key. Do not release the SHIFT key until execution of the program is completed.
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7 After one line of the program is executed, the program is halted. F
When a motion instruction is executed, the cursor stops at the executed line. The next time forward execution of the program is performed, the next line of the program is executed.
F
When a control instruction is executed, the cursor moves to the next line.
8 To release the step mode, press the STEP key. 9 Turn off the teach pendant enable switch, then release the deadman switch.
6.3.3 Continuous test To perform a continuous test is to execute the program in the normal order from the current program line to the end of the program (end--of--program symbol or the program end instruction). Backward execution of the program is disabled during a continuous test. A continuous test can be started using the teach pendant or operator’s panel. To perform a continuous test using the teach pendant, press and hold the SHIFT key, then press and release the FWD key. The program is then executed from the current line. To start continuous test operation (cycle operation) from the operator’s panel/box, momentarily press the start button on the operator’s panel/box. Program execution then starts from the current line. NOTE The continuous test execution can be executed in the forward direction only.
Procedure 6--8 Condition
Continuous test (using the teach pendant)
H The teach pendant must be enabled. H The continuous mode must be set. (The STEP lamp must be off.) H The system must be in the operation enable state. H No one must be in the operating area. All obstacles must be removed from the operating area.
Step
1 Press the SELECT key. The program selection screen is displayed. 2 Select the program to be tested and press the ENTER key. The program edit screen is displayed. 3 Press the STEP key to set the continuous mode. Check that the STEP LED is off. 4 Move the cursor to the program start line. 5 Press and hold down the deadman switch, then turn on the teach pendant enable switch. WARNING The execution of the program instructions starts in the next step. The execution causes the robot to make a motion, which may produce unpredictable results. The operator should check that no persons and no unnecessary equipment are in the work area and that each part of the protective fence is sound. Otherwise, injury or property damage could occur. If the program needs to be stopped before it terminates, the operator should release the SHIFT key or deadman switch or press the HOLD or emergency stop button.
6 Press and hold down the SHIFT key, then press the FWD key. Hold down the SHIFT key until the execution of the program is completed. When the SHIFT key is released, the program is halted. The program is executed to the end, then forcibly terminated. The cursor is returned to the first line of the program.
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6. EXECUTING A PROGRAM
Procedure 6--9 Condition
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Continuous test operation (started from the operator’s panel)
H The operator’s panel must be in the enabled state. H Continuous operation mode must be set. (The step lamp must not be lit.) H The system must be ready for operation. H Nobody must be within the work area. Remove all obstacles from the work area.
Step
1 Press the select key. The program list screen is selected. 2 Select a program to be tested, and press the enter key. The program edit screen appears. 3 Set continuous operation mode. Check that the step lamp is not lit. (If the STEP lamp is on, press the STEP key to turn it off.) 4 Position the cursor to the first line. 5 Place the system in local mode. (For how to switch to local mode, see the description of Remote/Local setting in Section 3.16, “SYSTEM CONFIG MENU.” WARNING The execution of the program instructions starts in the next step. The execution causes the robot to make a motion, which may produce unpredictable results. The operator should check that no persons and no unnecessary equipment is in the work area and that each part of the protective fence is sound. Otherwise, injury or property damage would occur. If the program needs to be stopped before it terminates, the operator should release the SHIFT key or deadman switch or press the HOLD or emergency stop button.
6 Press the start button on the operator’s panel/box. Program execution is performed up to the end of the program then terminated forcibly. The cursor returns to the first line of the program.
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6.3.4 Program look/monitor When the program is executed, the screen of the teach pendant becomes a monitor screen by which the execution of the program is displayed. In the monitor screen, the cursor moves to follow the line which is executed and you can not edit a program. Program Monitor Screen PROGRAM1 PROGRAM1 1:J 2:J 3:J 4:J 5:J 6:J
LINE 1
P[1] P[2] P[3] P[4] P[5] P[6]
100% 100% 100% 100% 100% 100%
RUNNING JOINT 30 % 1/10
FINE FINE FINE FINE FINE FINE
LOOK
Press F2,LOOK, then the program monitor screen is displayed and the cursor of the program which is being executed stops (Program continues to execute). You can look at the desired part except the line which is executed with the arrow keys. Program monitor screen PROGRAM1 PROGRAM1
LINE 8
1:J P[1] 100% 2:J P[2] 100% 3:J P[3] 100% 4:J P[4] 100% 5:J P[5] 100% 6:J P[6] 100% Under the LOOK MONITOR
RUNNING JOINT 30 % 1/10
FINE FINE FINE FINE FINE FINE mode
The message “Under the LOOK mode” is highlighted at the prompt line while looking at the program. To return to the monitor screen, press F2,MONITOR. When the monitor screen is displayed, the cursor specifies the line which is executed at that time. If the execution of the program is paused or ended, the program edit screen is displayed in place of the program monitor screen. Program edit screen PROGRAM1 PROGRAM1 1:J 2:J 3:J 4:J 5:J 6:J
P[1] P[2] P[3] P[4] P[5] P[6]
LINE 6
100% 100% 100% 100% 100% 100%
ABORTED JOINT 30 % 6/10
FINE FINE FINE FINE FINE FINE
POINT
TOUCHUP>
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6.4 Manual I/O Control Under manual I/O control, signals are transmitted between the robot and peripherals before the program is executed. Manual I/O control refers to the following items: F
Forced output
F
Simulated output and simulated input
F
Wait instruction
6.4.1 Forced output Forced output is turning digital output signals on or off manually. For group output and analog output, specify the value.
Procedure 6--10
Forced output
H Assignment of the signals to be output must be completed.
Condition Step
1 Press the MENUS key to display the screen menu. 2 Select 5 I/O. The I/O screen is displayed. Manual forced digital output 3 Press the F1 (TYPE) key to display the screen change menu. 4 Select Digital. The digital output screen or digital input screen is displayed. If the input screen is displayed, press the F3 (IN/OUT) key to change the input screen to the output screen.
4 ALARM 5 I/O 6 SETUP
I/O Digital Out # SIM STATUS DO[1] U OFF [ DO[2] U OFF [ DO[3] U OFF [ DO[4] U OFF [ DO[5] U OFF [ DO[6] U OFF [ DO[7] U OFF [ DO[8] U OFF [ DO[9] U OFF [
MENUS
Digital [TYPE]
[TYPE]
CONFIG
IN/OUT
JOINT 30% ] ] ] ] ] ] ] ] ] ON
OFF
F1 WARNING Forced output activates connected equipment. Before executing the forced output, the operator should check which equipment is connected to the digital output and what operation the forced output would cause. Otherwise, injury or property damage could occur.
5 Move the cursor to the status field for the signal number to be changed, then press the F4 (ON) or F5 (OFF) key to change the signal output setting.
IN/OUT
ON
F4
OFF
I/O Digital Out DO[1] DO[2]
U U
JOINT 30%
ON OFF
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Manual forced group output 6 Press F1,TYPE. The screen change menu is displayed. 7 Select Group. The group output screen is displayed.
Group [TYPE]
F1
ENTER
I/O Group Out # SIM VALUE GO[ 1] U 1 [ GO[ 2] U 10 [ GO[ 3] U 23 [ GO[ 4] * * [ GO[ 5] * * [ GO[ 6] * * [ GO[ 7] * * [ GO[ 8] * * [ GO[ 9] * * [ [ TYPE ] CONFIG
IN/OUT
JOINT
30 % ] ] ] ] ] ] ] ] ]
FORMAT
8 Move the cursor to the setting field of the signal number you want to change, and enter the value. Pressing F4,FORMAT toggles between the decimal expression and the hexadecimal expression. I/O Group Out # SIM VALUE GO[ 1] U 3 [ GO[ 2] U 10 [
JOINT
30 % ] ]
6.4.2 Simulated I/O The Simulated I/O function changes the state of signals internally without making digital, analog or group I/O communicate with peripherals. This function is used to execute the program or to test the I/O instruction when connection of I/O with peripherals is not completed. Simulated input/output can be used for digital, analog and group I/O. To enable simulated input/output, set the simulated flag, S,. Simulated output The simulated output function internally changes the signal state using the I/O instruction of the program or manual output, but does not change the state of output to peripherals. This function holds the state of output to peripherals when the simulated flag is set. When the simulated flag is reset, the output is restored to the original state. Simulated input The simulated input function internally changes the signal state with the I/O instruction of the program or manual input. The state of input from peripherals is ignored, and the signal state is not changed internally. When the simulated flag is reset, the input enters the current state. Refer to 6.3.1,“Specifying test execution” to specify whether I/O signal is disabled in the test execution.
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6. EXECUTING A PROGRAM
Procedure 6--11
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Simulated input / output
H The input/output signal has been allocated.
Condition Step
1 Press the MENUS key. The screen menu is displayed. 2 Select I/O. I/O screen is displayed. 3 Press F1,TYPE. The screen change menu is displayed. 4 Select Digital. Digital I/O screen is displayed.
4 ALARM 5 I/O 6 SETUP
I/O Digital In # DI[1] DI[2] DI[3] DI[4] DI[5] DI[6] DI[7] DI[8] DI[9]
MENUS
Digital [TYPE]
F1
[TYPE]
SIM U U U U U U U U U
JOINT 30% 1/168
STATUS OFF [digital OFF [digital OFF [digital ON [digital ON [digital OFF [digital OFF [digital ON [digital ON [digital
CONFIG
IN/OUT
signal signal signal signal signal signal signal signal signal
ON
1 2 3 4 5 6 7 8 9
] ] ] ] ] ] ] ] ]
OFF
5 Move the cursor to the SIM field for the signal number to be changed and press the F4 (S) or F5 (U) key to change the simulated setting. I/O Digital In
I/O Digital In DI[1]
U
OFF
DI[1] [TYPE]
IN/OUT SIMULATE
S
JOINT 30%
OFF
CONFIG
[digital signal 1
IN/OUT SIMULATE
]
UNSIM
UNSIM
F4 6 Move the cursor to the status field for the number of the output signal to be simulated and press the F4 (ON) or F5 (OFF) to change the simulated output setting. I/O Digital In
I/O Digital In DI[1]
U
OFF
DI[1] [TYPE]
IN/OUT
ON
S CONFIG
ON
JOINT 30% [digital signal 1 IN/OUT
OFF
F4
350
ON
OFF
]
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6.4.3 Standby release When a standby instruction in a program waits until the I/O conditions are satisfied, the standby release function skips this instruction, and halts program execution at the next line. Standby release is enabled only when a program is being executed. Standby release is performed by choosing from the miscellaneous function menu.
Procedure 6--12 Condition
Standby release
H Program execution is currently in the I/O wait state. Sample3 10: 11: 12:
Step
JOINT 30% 11/20
J P[5] 100% FINE WAIT RI[5]=ON RO[1]=ON
1 Press the function key to display the miscellaneous function menu. 2 Select 7 RELEASE WAIT. The I/O wait is skipped, and the cursor moves to the next line. The program is then halted. When program execution is restarted, the next instruction is executed.
7 RELEASE WAIT
FCTN
INPUT
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6.5 Manually Operating Welding Equipment The manual operation of the welding equipment involves controlling arc welding using the keys on the teach pendant. Manual wire feed/rewind Wire can be fed and rewound manually, without having to execute a program. Wire is fed and rewound when the WIRE+ or WIRE-- key on the teach pendant is pressed while the SHIFT key is held down. The manual wire feed/rewind signal for welding I/O can also be used. Welding enable Arc welding can be enabled or disabled. When welding is disabled, an arc welding instruction is prevented from performing arc welding. The modes are switched by pressing the WELD ENBL key on the teach pendant while the SHIFT key is held down. The weld enable signal for welding I/O can also be used. Procedure 6--13 Condition
Manual wire feed
H The welding I/O, welding system, welding equipment, and all other welding information must be set. H The teach pendant must be enabled.
Step
1 Press and hold down the DEADMAN switch. Then, set the teach pendant enable switch to ON. 2 To feed wire manually, press the WIRE+ key while holding down the SHIFT key. Wire is fed for as long as the SHIFT key is held down.
SHIFT WIRE + WIRE --
3 To rewind wire manually, press the WIRE-- key while holding down the SHIFT key. The wire is rewound for as long as the SHIFT key is held down. 4 The wire can also be fed or rewound using the manual wire feed (WO[4]) or rewind (WO[5]) signal for welding I/O. Procedure 6--14 Condition Step
Enabling or disabling welding
H The welding I/O, welding system, welding equipment, and all other welding information must be set. 1 Press the WELD ENBL key while holding down the SHIFT key. While welding is enabled, the WELD ENBL LED is lit. Pressing the key again disables welding, such that the LED goes out. 2 Welding can be enabled or disabled using the welding enable signal (example: DI[8]) for welding I/O. (This is possible only in the remote state.)
SHIFT
WELD ENBL
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6.6 Automatic Operation Peripheral I/O input can be used to automatically start a program and operate a production line. (See Section 3.14, “Setting Automatic Operation”.) F The robot start request signals (RSR1 to RSR4 inputs) select and start a program. When a program is being executed or halted, the selected program is placed in the wait state. It is started once the currently executed program terminates. F The program number selection signals (PNS1 to PNS8 inputs and PNSTROBE input) select a program. When a program is being halted or executed, these signals are ignored. F The automatic operation start signal (PROD_START input) starts execution of the currently selected program from the first line. When a program is being halted or executed, this signal is ignored. F Cycle stop signal (CSTOPI input) forcibly stops the currently executed program. Any programs enqueued by RSR are canceled. -- If $SHELL_CFG.$USE_ABORT is false, programs enqueued by RSR are canceled. The program being executed is not affected (standard setting). -- If $SHELL_CFG.$USE_ABORT is true, any programs enqueued by RSR are canceled. The program being executed is forcibly terminated immediately. F The external start signal (START input) starts a currently halted program. -- If $SHELL_CFG.$CONT_ONLY is set to FALSE, the currently selected program is started from the current line if there is no program being halted. (Standard setting) -- If $SHELL_CFG.$CONT_ONLY is set to TRUE, this signal is ignored if no program is currently halted. To start a program by peripheral I/O input, the robot must be in the remote mode. The remote mode is set when the following remote conditions are satisfied: J The teach pendant enable switch is turned off. J The remote switch on the operator’s panel/box is set to the remote position. J Peripheral device I/O *SFSPD input is on. J ENBL input of peripheral I/O is on. J System variable $RMT_MASTER is 0 (peripherals). NOTE The value of $RMT_MASTER may be 0 (peripheral device), 1 (CRT/keyboard), 2 (host computer), or 3 (no remote device). To start a program containing motion instructions, the following ready conditions must be satisfied: J ENBL input of peripheral I/O must be on. J The servo power is turned on. (No alarm is being issued.) It is convenient to monitor the input acceptable signal (CMDENBL output) for starting a program using the peripheral I/O. The CMDENBL signal is output when the following conditions are satisfied: J Remote condition J Operation enable condition J Continuous mode (step mode is disabled) Figure 6--12. Automatic Operation of Arc Welding System
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6.6.1 Automatic operation by robot start request (RSR) The robot start request (RSR) function allows a remote device to select and start a program through the peripheral device I/O. This function uses four robot start request signals (RSR1 to RSR8). 1 When a signal from RSR1 to RSR8 is input, the control unit determines whether the input RSR signal is valid. If the signal is invalid, it is ignored. When a program is started by a non--RSR signal, such as a start signal from the teach pendant or the operator’s panel, or when a dedicated signal START is being executed or halted, an RSR signal input is ignored. Whether RSR is valid or invalid is set in system variables $RSR1 to $RSR8. These values can be changed on the RSR setting screen or by using a programmed RSR instruction. 2 Eight RSR registration numbers can be assigned to RSR. A base number is added to each RSR registration number to indicate an RSR program number (four--digit integer). For example, when the RSR2 signal is input, a program having the following name is selected: RSR + (RSR2 registration number + base number) (four digits) NOTE The name of a program to be started must be of “RSR + RSR program number” format. (Example: RSR0121) The base number is set in $SHELL_CFG.$JOB_BASE. It can be changed by using Base number on the RSR setting screen or by using a programmed parameter instruction. 3 The RSR acknowledge output signal (ACK1 to ACK8) corresponding to one of the RSR1 to RSR8 input signals is output as a pulse signal. Even when one of the ACK1 to ACK8 signals is being output, RSR input is accepted. 4 When programs are in the terminated state, a selected program is started. When another program is being executed or halted, the request (job) is placed in a queue. It is started when the program currently being executed terminates. Jobs (RSR programs) are executed in the order in which the programs were enqueued. 5 Programs in the queue are canceled (cleared) by the cycle stop signal (CSTOPI input) or forced program termination. The start of a program by RSR is enabled in the remote mode. (Normally, in remote mode, the CMDENBL input is on.) Figure 6--13. Robot Start Request RSR valid/invalid $RSR 1
Valid
$RSR 2 $RSR 3
Valid
$RSR 4
Valid
Base number
Valid
$SHELL_CFG.$JOB_BASE 100 RSR registration number
RSR 1
RSR 1
12
RSR 2 ON
RSR 2
21
RSR 3
RSR 3
33
RSR 4
48
RSR 4
RSR program number 0121
RSR program RSR 0121
1. The RSR2 signal is input. 2. A check is made to determine whether RSR2 is valid. 3. An RSR program having the selected RSR program number is started.
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Procedure 6--15 Condition
Automatic operation by robot start request (RSR)
H RSR settings are completed. (See Section 3.14.1.) H Remote mode is set. H The system is ready for operation. H Nobody must be within the work area. There must be no obstacles in the work area. WARNING Applying this procedure starts automatic operation which causes the robot to move. An unpredictable operation could occur. Check to ensure that nobody is in the work area, that there are no unnecessary objects in the work space, and that the safety fence is normal. Also, check that all the automatic operation conditions are set correctly. Otherwise, personal injury or damage to the facilities could occur.
Step
1 Set the enable switch on the teach pendant to OFF. 2 Set the remote switch on the operator’s panel/box to the remote position. 3 Send the robot start signal (RSR1 to RSR4 input) of a target RSR number to the control unit. The RSR program is placed in a queue. 4 To stop the program currently being executed, use the emergency stop button or hold button, or the immediate stop (*IMSTP input), hold (*HOLD input), or cycle stop (CSTOPI input) signal. 5 To cancel a job in the queue, use the cycle stop signal (CSTOPI input). 6 To restart a halted program, use the external start signal (START input).
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6.6.2 Automatic operation with program number selection (PNS) The program number selection (PNS) function enables selection or checking of a program, using the peripheral I/O, from the remote controller. Eight input signals, PNS1 to PNS8, specify a PNS program number. 1 When the PNSTROBE pulse signal is input, the control unit reads the PNS1 to PNS8 input signals. When a program is being executed or halted, the signals are ignored. While the PNSTROBE pulse input signal is on, no program can be selected from the teach pendant. 2 The received PNS1 to PNS8 inputs are converted into a decimal number to obtain a PNS number. A program number (four digits) can be obtained by adding a base number to the PNS number, as shown below: (Program number) = (PNS number) + (base number) The selected program has the following name: PNS + (program number) When zero is input through the PNS1 to PNS8 input signals, no program is selected on the teach pendant. NOTE The name of a started program must be of (PNS + PNS program number) format. (Example: PNS0138) The base number is set in $SHELL_CFG.$JOB_BASE. It can be changed by using Base number on the PNS setting screen or a programmed parameter instruction. Figure 6--14. Program Number Selection PNSTROBE
Base number $SHELL_CFG.$JOB_BASE
PNS1 PNS2 ON PNS3 ON PNS4
00100110 Binary
PNS5
PNS number 38 Decimal
100
PNS program number 0138
PNS program PNS 0138
PNS6 ON PNS7 PNS8 SNACK PROD_START 1. The PNSTROBE signal is input. 2. The PNS1 to PNS8 signals are read and converted into a decimal number. 3. A PNS program having the selected PNS program number is regarded as the currently selected program. 4. The PROD_START input signal starts the selected PNS program.
3 The selected program number output signals (SNO1 to SNO8) are output for PNS confirmation. The PNS acknowledge output (SNACK) signal is output as a pulse signal. This signal causes the external device to read SNO1 to SNO8 output signals. Even while the SNACK signal is being output, PNS and PROD_START input signals are accepted. 4 When confirming that the output values of SNO1 to SNO8 match the input values of PNS1 to PNS8, the remote control unit sends the automatic operation start input (PROD_START) signal. 5 The control unit receives the PROD_START input signal, then starts the program. Program start by PNS is enabled in remote mode. (Normally, in remote mode, the CMNDENBL input signal is on.)
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Procedure 6--16 Condition
Automatic operation by program number selection
H PNS setting must be completed (See Section 3.14.2). H The remote condition must be satisfied. H The operation enable condition must be satisfied. H No one must be in the operating area. All obstacles must be removed from the operating area. WARNING Start automatic operation as follows: When the robot starts operation, an unexpected situation may occur. To prevent any problem from occurring, be sure to check that no one is in the work area, that the work area is free from unnecessary equipment, that the safety barrier is in place, and that all the automatic operation conditions are correctly specified. Otherwise, the robot may injure a person or damage the equipment in the work area.
Step
1 Turn off the teach pendant enable switch. 2 Place the system in remote mode. (For how to switch to remote mode, see the description of Remote/Local setup in Section 3.16, “SYSTEM CONFIG MENU.” 3 Send the program number selection signals (PNS1 to PNS8 inputs) indicating a target PNS number and the PNS strobe signal (PNSTROBE input) to the control unit. A PNS program is then selected. The control unit outputs the selected program number signals (SNO1 to SNO8 inputs) and PNS acknowledge signal (SNACK output) for confirmation. 4 Send an external start signal (PROD_START input). The selected program is then started. 5 To stop the program currently being executed, use the emergency stop button or hold button, or the immediate stop (*IMSTP input), hold (*HOLD input), or cycle stop (CSTOPI input) signal. 6 To restart a halted program, use the external start signal (START input).
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6.6.3 External override selection function The external override selection function changes feedrate override by turning on or off digital input (DI) signals. Two DI signals are defined. These two signals can be combined in four different ways. So four types of feedrate override can be selected. OVERRIDE SELECT
JOINT 30%
1
Function Enable:
2 3
Signal1: Signal2:
4 5 6 7
Signal1 OFF OFF ON ON
ENABLE SDI[ 1][ON ] SDI[ 32][OFF]
Signal2 OFF ON OFF ON
[TYPE]
ENABLE
Override 15% 30% 65% 100% DISABLE
When the function changes the feedrate override, the feedrate override is not displayed, namely, the popup menu is not displayed at the upper right corner of the screen. To enable the external override selection function, the following requirements must be satisfied: J
The external override selection function must be enabled. (OVERRIDE SELECT on the setting screen)
J
The remote mode must be set.
When the external override selection function is enabled, the following occurs: F
The override key of the teach pendant is practically disabled. (The changed value is quickly returned to the setting value by the external override selection.)
F
The override instruction has no effect to the override value.
F
You can not change the settings of SDI signal number and Override. Before these settings can be modified, Function Enable:DISABLE must be set.
F
When this function is effective at turning off the power of the controller, the override will be assigned the value which had been set by this function when turning on it again.
F
It is possible to specify the same number as two SDI signal numbers. In this case, only the combination of ON--ON or OFF--OFF has the meaning.
Moreover, note the following: F
After this function is disabled because the remote condition is not satisfied, the override keeps the value specified by this function in effect until the value is changed by the teach pendant or override instruction.
Set this function on the external override selection setting screen (6 OVERRIDE SELECT).
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Procedure 6--17 Step
Selecting an external override
1 Press the MENUS screen to display the screen menu, then select 6 SETUP. 2 Select Ovrd Select from the screen change menu. External override selection setting screen
5 I/O 6 SETUP 8 FILE
OVERRIDE SELECT
MENUS
Ovrd Select TYPE
F1
JOINT 30%
1
Function Enable:
2 3
Signal1: Signal2:
4 5 6 7
Signal1 OFF OFF ON ON
DISABLE DI[***][***] DI[***][***]
Signal2 OFF ON OFF ON
[TYPE]
Override 10% 10% 10% 10%
ENABLE
DISABLE
3 Set items. a Enable or disable the function. b Assign SDI signals. OVERRIDE SELECT 2 3
JOINT 30%
Signal1: Signal2:
DI[ 11][ON ] DI[***][***]
[TYPE]
ENABLE
DISABLE
The states of SDI signals are indicated. When *** is displayed, the setting of the function cannot be changed. c Feedrate override can be changed by turning on or off the signals OVERRIDE SELECT
JOINT 30%
1
Function Enable:
2 3
Signal1: Signal2:
4 5 6 7
Signal1 OFF OFF ON ON
[TYPE]
ENABLE DI[ 11][ON ] DI[ 12][OFF]
Signal2 OFF ON OFF ON ENABLE
359
Override 15% 30% 65% 100% DISABLE
6. EXECUTING A PROGRAM
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6.7 Online Position Modification Online position modification [optional function] replaces all the position data and move speeds in the move instructions within a certain range in a program at one time, according to the position modification condition, during program execution. The following program information can be modified: F
Position data (position compensation)
F
Move speed
Position data is modified by adding a position compensation value. A movement speed is modified by rewriting it. Up to ten position modification conditions can be defined. Position compensation value A position compensation value is the difference between the current position and the correct position. The position data coded in the move instructions within a specified range of a program is rewritten by adding a position compensation value to the data. If the position data resulting from modification falls outside the allowable axial movement range, an alarm is generated when the program is executed. CAUTION If position compensation is performed during execution, it may take a while for the compensation to be reflected in actual operation.
The specifiable ranges (+/--) for the position compensation values are set in system variables $PRGADJ.$X_LIMIT to $R_LIMIT. The standard value is +/--26 mm for (X, Y, Z) and +/--0.5 degrees for (W, P, R). Any position compensation value falling outside these ranges cannot be set. Move speed Move speeds in the move instructions within a specified range of a program are replaced with specified speeds. The move speed for axial movement is replaced by the value specified in Joint speed, while the move speed for linear and circular movement is replaced by the value specified in Motion speed. CAUTION Once a speed has been rewritten, the original speed cannot be restored.
Position modification status The position modification statuses are classified into the following three types: -- EDIT indicates that the current position modification condition is being edited. It is not reflected in the program. This state is indicated when no position modification condition is set or when a valid position modification condition is edited. -- ENABLED indicates that the current position modification condition is reflected in the program. -- DISABLED indicates that the position modification condition reflected in the program has been canceled. The result of ENABLED is reflected immediately if the program is being executed. When the position modification condition is modified after ENABLED, changes made to the program are determined, and state EDIT is indicated. Online position modification is set by using 1 UTILITIES Prog Adjust on the utility screen. Online position modification conditions include the following information:
360
6. EXECUTING A PROGRAM
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Position modification condition list screen UTILITIES Prog Adj Program Lines 1 Sample 1 22-29 2 Sample 1 39-49 3 Sample 3 10-14 4 Sample 4 123-456 5 ******* 0-0 6 ******* 0-0 7 ******* 0-0 8 ******* 0-0 9 ******* 0-0 10 ******* 0-0 [TYPE] COPY
DETAIL CLR_ADJ
CLR_ALL
Position modification condition detail screen
JOINT 10% Status 5/10 ENABLED ENABLED DSIABLED EDIT ******* ******* ******* ******* ******* *******
UTILITIES Prog Adj
10%
>
Carrent schedule:5 status:EDIT 1 Program name: Sample 2 2 Starting line number: 1 3 Ending line number: 30 4 X adjustment: 5,000mm 5 Y adjustment: 0.000mm 6 Z adjustment: -2.500mm 7 W adjustment: 0.000deg 8 P adjustment: 0.000deg 9 R adjustment: 0.000deg 10 Motion speed: mm/s 11 Joint speed: %
>
[TYPE] COPY
Table 6--5.
JOINT
UNIT CLR_ADJ
SCHED
ENABLE
CLR_ALL
> >
Online Position Modification Settings
Item Program Range
Description Specifies the name of the target program for position modification. Specifies the range (the start and end lines) of the program lines to which position modifications are to be applied. NOTE The end line number must be greater than or equal to the start line number specified in item 2. When only one line is to be modified, the end line number must equal the start line number.
Offset relative to
Status
X to R adjustment
Motion speed Joint speed
User Modification is performed in reference to the user coordinate system. Tool Modification is performed in reference to the tool coordinate system. The position modification status indicates whether a specified position modification condition is reflected in the program. F EDIT : The position modification condition is being edited. F ENABLED : The position modification condition is reflected in the program. F DISABLED : The position modification condition is not reflected in the program. Compensation values X to R indicate the position compensation amounts. Values (X, Y, Z) are in mm or inches, while values (W, P, R) are in degrees. The values specified here are included in the position data. These speed items replace the move speeds. Motion speed replaces the linear and circular movement speed with a specified speed. Joint speed replaces the axial movement speed with a specified speed. CAUTION Once the move speed is rewritten, the original speed cannot be restored.
[TYPE] COPY
Motion group Adjust Y for
UNIT CLR_ADJ
SCHED CLR_ALL
ENABLE
> >
Select an operation group to be subjected to modification. This item is displayed only when an additional built--in traveling axis is set up as the seventh axis in group 1. The direction of the additional built--in axis is indicated in motion group. Specify the compensation target for the indicated direction. Robot: Modify only the position of the robot. Additional axis: Modify the position of the additional axis. All: Modify both the positions of the robot and the additional axis. If offset relative to is set to “Tool,” only the robot can be selected.
361
6. EXECUTING A PROGRAM
Table 6--6.
Online Position Modification Function Key Menu
Function key label UNIT SCHED ENABLE
DISABLE
COPY
CLR_ADJ
CLR_ALL
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Description The position modification unit function changes the units of the position modification values (mm or inches). The schedule function is used to input the number of the position modification condition to be edited next. ENABLED reflects the current position modification condition in a target program. The position data and move speeds are rewritten according to the position modification condition. This function key can be specified only when EDIT or DISABLED is indicated. DISABLED cancels the current position modification condition reflected in a target program. The position data used before modification is restored. This function key can be specified only when ENABLED is indicated. The original move speed cannot be restored. The position modification condition copy function copies a selected position modification condition into another condition number. After copying, EDIT is indicated as the modification status. The position modification condition erase function erases all the position modification and speed values set in a selected position modification condition. The program name and range are not erased. When erase is performed, the modified program is not restored to its original state. This function key erases a selected position modification condition entirely including the program name and range. When erase is performed, the modified program is not restored to its original state.
362
6. EXECUTING A PROGRAM
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Procedure 6--18 Condition Step
Online position modification
H There is a program to be modified. 1 Press the menus key to display the screen menu. 2 Select 1 UTILITIES. 3 Press F1, [TYPE] to display the screen selection menu. 4 Select Prog Adjust. then, the position modification condition list screen appears. Position modification condition list screen
1 UTILITIES 2 TEST CYCLE MENUS
Prog Adjust type
F1
UTILITIES Prog Adj Program Lines 1 Sample 1 22-29 2 Sample 1 39-49 3 Sample 3 10-14 4 Sample 4 123-456 5 ******* 0-0 6 ******* 0-0 7 ******* 0-0 8 ******* 0-0 9 ******* 0-0 10 ******* 0-0 [TYPE] COPY
JOINT 10% Status 5/10 ENABLED ENABLED DSIABLED EDIT ******* ******* ******* ******* ******* *******
DETAIL CLR_ADJ
> CLR_ALL
>
5 Position the cursor on the line number of a program to be modified. If the program to be modified is not indicated, select “***”. 6 Press F2 DETAIL. Then, the position modification condition detail screen appears. When “***” is selected, EDIT is indicated as the status. Position modification condition detail screen UTILITIES Prog Adj Program Lines 1 Sample 1 22-29 2 Sample 1 39-49 3 Sample 3 10-14 4 Test-pro 123-456 5 ******* 0-0
[TYPE]
DETAIL
F2
UTILITIES Prog Adj
JOINT
10%
Carrent schedule:5 status:EDIT 1 Program name: Sample 2 2 Starting line number: 0 3 Ending line number: 0 4 X adjustment: 0,000mm 5 Y adjustment: 0.000mm 6 Z adjustment: 0.000mm 7 W adjustment: 0.000deg 8 P adjustment: 0.000deg 9 R adjustment: 0.000deg 10 Motion speed: mm/s 11 Joint speed: % [TYPE] COPY
UNIT CLR_ADJ
SCHED CLR_ALL
363
ENABLE
> >
6. EXECUTING A PROGRAM
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7 Set items. NOTE When only one program line is to be modified, enter the same value for both the start and end lines.
UTILITIES Prog Adj
JOINT
10%
Carrent schedule:5 status:EDIT 1 Program name: Sample 2 2 Starting line number: 1 3 Ending line number: 30 4 X adjustment: 5,000mm 5 Y adjustment: 0.000mm 6 Z adjustment: -2.500mm 7 W adjustment: 0.000deg 8 P adjustment: 0.000deg 9 R adjustment: 0.000deg 10 Motion speed: mm/s 11 Joint speed: % [TYPE] COPY
UNIT CLR_ADJ
SCHED CLR_ALL
ENABLE
> >
8 After completing the modification condition settings, press F4 ENABLE to reflect the position modifications in the target program. The result of ENABLE is reflected immediately if the program is being executed. SCHED
ENABLE
>
F4 NOTE To modify a position modification condition after making it valid, cancel the condition once, then modify it. NOTE When move instructions include a position register or incremental instruction, modifications are not reflected. 9 To cancel a set modification condition, press F5 DISABLE. When DISABLE is used, the current position modification condition must be valid. SCHED
DISABLE >
F5 CAUTION Once a move speed has been changed, the original speed cannot be restored even by pressing DISABLE. 10 To set the position modification condition of another condition number, press F3 SCHED. SCHED
DISABLE >
F3
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6. EXECUTING A PROGRAM
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11 Press prev key to redisplay the position modification list screen.
UTILITIES Prog Adj Program Lines 1 Sample 1 22-29 2 Sample 1 39-49 3 Sample 3 10-14 4 Sample 4 123-456 5 ******* 0-0 6 ******* 0-0 7 ******* 0-0 8 ******* 0-0 9 ******* 0-0 10 ******* 0-0 [TYPE] COPY
DETAIL CLR_ADJ
JOINT 10% Status 5/10 ENABLED ENABLED DSIABLED EDIT ******* ******* ******* ******* ******* ******* >
CLR_ALL
>
12 To copy the set modification condition to another modification condition number, position the cursor on the condition number of the copy source, and press F1 COPY on the next page. Enter the condition number of the copy destination. Immediately after a copy operation, EDIT is indicated as the status. Modify the items as necessary. COPY
CLR_ADJ
CLR_ALL
F1 13 To erase the set modification condition, press F2 CLR_ADJ on the next page. COPY
CLR_ADJ
CLR_ALL
F2
365
6. EXECUTING A PROGRAM
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6.8 Welding Tuning The welding tuning function adjusts the welding condition data in real time while a program is running. This function can be used to adjust the following welding condition data: F
Welding speed (travel speed)
F
Welding voltage
F
Welding current
F
Wire feed speed
NOTE Depending on the set model of welding power supply or the welding control type setting (on the welding equipment screen), only welding current or wire feedrate is valid. The following current values are displayed: PRGM The PRGM column indicates the values for specified program instructions. The Speed value is the travel speed specified in the motion instruction. The Voltage, Current, and Wire values indicate the welding conditions specified in the arc start instruction. CMND The CMND column indicates the values to be tuned. These values can be increased and decreased by means of key input from the teach pendant. FDBK The FDBK column indicates the values set for the welding equipment (values according to which actual welding is executed) after tuning. NOT SAVING NOT SAVING means that the values specified as part of the current tuning are not saved as new values, such that the program is not affected. This setting can be changed to SAVING by pressing the F5 (SAVE) key. SAVING SAVING means that the values specified as part of the current tuning are saved as new values for the program. This setting can be changed to NOT SAVING by pressing the F5 (NO SAVE) key.
366
6. EXECUTING A PROGRAM
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Procedure 6--19 Condition
Welding tuning
H The program must be running. H Arc welding must be in progress.
Step
1 Press the MENUS key to display the screen menu. 2 Select 1, UTILITIES. 3 Press the F1, [TYPE] key to display the screen change menu. 4 Select OnTheFly. The welding tuning screen is displayed.
1 UTILITIES 2 TEST_CYCLE
UTILITIES OnTheFly
JOINT
COMMAND
10 %
FEEDBACK
200.0 Volt 19.5 Volt 210.0 Amps 200.0 Amps 0.0 cm/m 0.0 1800.0 R0B0T CM/MIN
MENUS
Group: 1
Equip: 1
NOT SAVING
OnTheFly [ TYPE ]
INCR
DECR
GROUP
[TYPE]
SAVE > HELP
F1 5 To update the program with the results of tuning, select save mode by pressing the F5 (SAVE) key. In save mode, the results of turning incorporated into the program.
INCR
DECR
SAVE >
UTILITIES OnTheFly COMMAND
F5
JOINT
10 %
FEEDBACK
200.0 Volt 19.5 Volt 210.0 Amps 200.0 Amps 0.0 cm/m 0.0 1800.0 R0B0T CM/MIN Group: 1 [ TYPE ]
Equip: 1 INCR
GROUP
NOT SAVING DECR
SAVE > HELP >
6 To change a programmed value, press the F3 (INCR) or F4 (DECR) key. Changing a programmed value causes the feedback from the welding equipment to be displayed on the screen.
367
7. STATUS DISPLAY
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7. STATUS DISPLAY The user can check various statuses of the robot with status display. Several types of screens are used for status display. j Contents of this chapter 7.1
LEDs on the Teach Pendant
7.2
User Screen
7.3
Registers
7.4
Position Registers
7.5
Arc Welding Status
7.6
Current Position
7.7
System Variables
7.8
Program Timer
7.9
System Timer
7.10 Execution History 7.11 Memory Use Status Display
368
7. STATUS DISPLAY
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7.1 LEDs on the Teach Pendant The LEDs on the teach pendant indicate the following statuses: Table 7--1.
LEDs on the Teach Pendant
LED FAULT
Description
BUSY
This LED indicates that an alarm has been issued. When the alarm is released, this LED goes off. This LED goes on while the HOLD key on the teach pendant is pressed or while the peripheral I/O signal, *HOLD, is applied. This LED goes on when the single step mode is set. This LED goes off when the continuous operation mode is set. This LED indicates that a program or other processing is being executed.
RUNNING
This LED indicates that a program is being executed.
WELD ENBL
This LED indicates that the system is ready to start arc welding.
ARC ESTAB
This LED indicates that arc welding is currently in progress.
DRY RUN
This LED lights during dry run mode.
JOINT
This LED goes on when the manual--feed coordinate system is a joint jog coordinate system. This LED goes on when the manual--feed coordinate system is a Cartesian jog coordinate system (jog coordinate system or cartesion coodinate system or user coordinate system). This LED goes on when the manual--feed coordinate system is a tool jog coordinate system.
HOLD STEP
XYZ TOOL
Figure 7--1. LEDs on the Teach Pendant FAULT HOLD STEP BUSY RUNNING WELD ENBL ARC ESTAB DRY RUN JOINT XYZ TOOL OFF ON
369
7. STATUS DISPLAY
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7.2 User Screen The user screen displays messages from a program being executed. The message instruction is used to display a program message. (For the message instruction, see Subsection 4.14.6.)
Procedure 7--1 Step
User screen display
1 Press the MENUS key. 2 Select “9 USER.” NOTE When a message instruction is not executed, nothing is displayed on this screen. NOTE Even after the program is forcibly terminated, the message remains on the screen.
370
7. STATUS DISPLAY
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7.3 Registers A register is a variable for holding an integer or fraction. Two hundred registers are provided. The register screen is used to display and set registers.
Procedure 7--2 Step
Displaying register screen
1 Press the MENUS key to display the screen menu. 2 Press “NEXT, ” then select “DATA.” Alternatively, instead of steps 1 and 2 above, the user can press the DATA key. 3 Press F1 “TYPE.” 4 Select “Registers.” The register screen appears. DATA Registers R R R R R R
[ [ [ [ [ [
JOINT 30% 1/200
1: 2: 3: 4: 5: 6:
] ] ] ] ] ]
= = = = = =
0 0 0 0 0 0
[TYPE]
WARNING Registers are used in a program. Never change the value of a register before checking how the register is used in the system. Otherwise, the program can be adversely affected. 5 To enter a comment, use the following procedure: a Move the cursor to a desired register number field, then press the ENTER key. b Select a comment input method. c Press a desired function key, then enter a comment. d Upon completion of input, press the ENTER key. 6 To change the value of a register, move the cursor to the register value field, then enter a desired value.
1
2
ENTER
DATA Registers R R R R R R
[ [ [ [ [ [
JOINT 30% 1/200
1: 2: 3: 4: 5: 6:
] ] ] ] ] ]
= 12 = 0 = 0 = 0 = 0 = 0
[TYPE]
Programming example 7 Registers are used in programs when the following are specified: -- Register instruction (See Section 4.5.1) -- Indirect specification of arguments (See Section 4.2) SAMPLE4 1: 2: 3: 4: 5: 6: 7: [End]
JOINT
30 % 1/8
R[1]=0 LBL[1] CALL PRG_A R[1]=R[1]+1 IF R[1]<=10,JMP LBL[1] CALL PRG_B ABORT
[ INST ]
[EDCMD ]>
371
Program A is repeated 11 times, program B is executed, then program execution terminates.
7. STATUS DISPLAY
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7.4 Position Registers A program register [option = position register] is a variable for holding position data. One hundred position registers are provided. The position register screen is used to display and set registers.
Procedure 7--3 Step
Position register setting
1 Press the MENUS key to display the screen menu. 2 Press “0 NEXT,” then select “3 DATA.” Alternatively, instead of steps 1 and 2 above, the user can press the DATA key. 3 Press F1 “TYPE” to display the screen change menu. 4 Select “Position Reg.” The position register screen appears. DATA Position Reg PR[ PR[ PR[ PR[ PR[ PR[
JOINT 30% 1/10
1: 2: 3: 4: 5: 6:
] ] ] ] ] ]
[ TYPE ]
= = = = = =
* * * * * *
RECORD POSITION
CLEAR
WARNING Position registers are used in a program. Never change the value of a position register before checking how the register is used in the system. Otherwise, the program can be adversely affected.
5 To enter a comment, use the following procedure: a Move the cursor to a desired position register number field, then press ENTER key. b Select a character input method. c Press a desired function key, then enter a comment. d Upon completion of input, press the ENTER key. 6 To change the value of a position register, move the cursor to the position register value field. Then, press F3 “RECORD” while holding down the SHIFT key. [ TYPE ]
RECORD DATA Position Reg
SHIFT
F3
PR[ PR[ PR[ PR[ PR[ PR[
JOINT 30% 1/10
1: 2: 3: 4: 5: 6:
[ TYPE ]
] ] ] ] ] ]
= = = = = =
R * * * * *
RECORD POSITION
CLEAR
-- “R” indicates that a position register already holds a taught value. -- An asterisk (*) indicates that it does not. NOTE In a multi--motion group system, teaching a position register records the position data for all axes regardless of the current motion group.
372
7. STATUS DISPLAY
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7 To delete position data loaded into a position register, press F5 “CLEAR” while holding down the SHIFT key. RECORD POSITION
CLEAR DATA Position Reg
F5
SHIFT
JOINT 30% 1/10
PR [ 1:REF_POSITION
] = R
PR[1] will be cleared. O.K ? YES
NO
8 Select “YES.” The position data of the desired position register is cleared. YES
NO DATA Position Reg
JOINT 30% 1/10
PR [ 1:REF POSITION
F4
] = *
PR[1] has been cleared [ TYPE ]
RECORD POSITION
CLEAR
9 To find out the current values of position data, press F4 “POSITION.” The position detail data screen appears. To change a value, move the cursor to the desired field, then enter a new value. RECORD POSITION CLEAR Position Detail JOINT 30% PR[1] GP:1 UF:F UT:F CONF: FUT O X: 1500.374 mm W: 40.000 deg Y: -342.992 mm P: 10.000 deg Z: 956.895 mm R: 20.000 deg DATA Position Reg 1/10 PR [ 1:REF POSITION ] = R
F4
CONFIG
DONE
[REPRE]
10 To change the configuration, press F3 “CONFIG.” Move the cursor to a desired field, then change joint placement data using the ↓ and ↑ keys.
CONFIG
DONE
[REPRE]
F3
Position Detail JOINT 30% PR[1] GP:1 UF:F UT:F CONF: FUT O X: 1500.374 mm W: 40.000 deg Y: -342.992 mm P: 10.000 deg Z: 956.895 mm R: 20.000 deg DATA Position Reg 1/10 PR [ 1:REF POSITION ] = R Select Flip or Non-fliip by UP/DOWN key CONFIG DONE [REPRE]
11 To change the storage form of the position data, press F5,[REPRE] and select the storage form. 1= * 1 Cartesian 2 Joint CONFIG
DONE
[REPRE]
F5
Position Detail PR[1] J1 34.304 deg J2 56.008 deg J3 -121.672 deg DATA Position Reg
JOINT J4 J5 E1
30 %
27.089 deg -10.503 deg 0.000 deg
NOTE JOINT display is valid when the robot is adjusted to the zero--degree position or when non--kinematic operation such as table operation control is executed.
373
7. STATUS DISPLAY
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12 To change the display to the additional axes (subgroup), press F2 PAGE. Position Detail PR[1] UF:F UF:F E1 0.000 mm E2 100.204 mm E3 -0.894 mm DATA Position Reg
CONF:NUT 000
1/100 PR[ 1: PR[ 2: PR[ 3: PR[ 4: PR[ 5: PR[ 6: Enter value
]=R ]=* ]=* ]=* ]=* ]=* PAGE
CONFIG
DONE
[REPRE]
13 Upon completion of setting, press F4 “DONE.” CONFIG
DONE
[REPRE] DATA Position Reg
F4
PR[ PR[ PR[ PR[ PR[ PR[
1:REF 2:REF 3:REF 4:REF 5: 6:
[ TYPE ]
POS POS POS POS
JOINT
1 2 3 4
30 % 1/10
]=R ]=R ]=R ]=R ]=* ]=* RECORD POSITION
CLEAR
14 The position register can be used in the program as the following case: -- Position data of motion instruction(See Section 4.3.2) -- Position register instruction and offset instruction,etc. (See Section 4.5 and Section 4.3.6) Programming example SAMPLE5 12: 13: 14:L 15: 16:L 17:L
JOINT
30 % 1/8
LBL[1] OFFSET CONDITION PR[1] PR[2] 1000cm/min CNT100 Offset PR[3,6]=R[10] PR[3] 1000mm/s CNT100 PR[4] 1000mm/s CNT100 Offset
[ INST ]
[EDCMD]>
374
7. STATUS DISPLAY
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7.5 Arc Welding Status The arc welding status screen displays the current arc welding status. Table 7--2.
Arc Welding Status
ITEMS
DESCRIPTIONS
COMMAND
This item indicates specified values such as a voltage and current. The meaning of each item and the number of items depend on the model of welding power supply and the number of analog input/output signals.
FEED BACK
This item indicates the current feedback value of each item.
Arc enable
Indicates whether arc welding is enabled. When not enabled, arc welding cannot be performed by issuing an arc welding instruction.
Arc detect
Indicates whether an arc is detected.
Arc on time
Indicates the total welding time. The indicated time can be reset to 0 by pressing F2 “RESET.”
Procedure 7--4 Step
Displaying the arc welding status
1 Press the MENUS key to display the screen menu. 2 Select “6 STATUS.” Alternatively, instead of performing steps 1 and 2 above, the user can simply press the STATUS key. 3 Press F1 “TYPE” to display the screen change menu. 4 Select “Weld.” The arc welding status screen appears. STATUS Weld
JOINT
COMMAND 0.0 Volts 0.0 Amps 0.0 cm/min Arc enable: Arc detect: Arc on time [ TYPE ]
10 %
FEEDBACK 0.0 Volts 0.0 Amps 0.0 cm/min
ON ON 0: 0: 0 H:M:S
RESET
HELP
375
7. STATUS DISPLAY
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7.6 Current Position The current position of the robot shows the location and the orientation of the robot in the work space. The current position can be represented in the cartesian frame and the joint frame. Joint coordinates Joint coordinates represent the current position by the angular displacement from the base side of each axis. Figure 7--2. Joint Coordinate System
Displaying joint coordinates POSITION Joint J1: J2: E1:
JOINT 30 % Tool: 1 0.000 J2: 0.000 J5: *****
[ TYPE ]
JNT
0.000 J3: 0.000
USER
WORLD
NOTE If the system has an additional axis, E1, E2 and E3 indicate the position data of the additional axis. Displaying Cartesian coordinates The current position represented in cartesian coordinates is defined by the tool frame which is defined on the wrist to specify the location and orientation of the tool ,and the cartesian frame which is fixed in the work space. Cartesian coordinates is represented by the world frame or the user frame. 4 STATUS 5 POSITION 6 SYSTEM MENUS
376
7. STATUS DISPLAY
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Figure 7--3. Cartesian coordinate system
Z
Z
Tool coodinate system
World coodinate system
Y X
Y Z Z
User coodinate system 1
Y
User coodinate system 2
X
Y
X
X
Displaying world coordinate system POSITION World Configuration: FUT O x: 1380.000 y: -380.992 w: 40.000 p: -12.676 E1: *****
[ TYPE ]
Procedure 7--5 Step
JNT
USER
Displaying user coordinate system
JOINT 30 % Tool: 1 z: r:
956.895 20.000
POSITION JOINT 30 % User Frame: 0 Tool: 1 Configuration: FUT O x: 1500.374 y: -342.992 z: 956.895 w: 40.000 p: 10.000 r: 20.000 E1: *****
[ TYPE ]
WORLD
JNT
USER
Displaying the current position screen
1 Press the MENUS key to display the screen menu. 2 Select NEXT, then select POSITION from the next menu.
MENUS
9 USER 0 -- NEXT --
4 STATUS 5 POSITION 6 SYSTEM
3 The current position screen can be also displayed by pressing the POSN key. -- To display joint coordinates, press F2 “JNT.” -- To display user coordinates, press F3 “USER.” -- To display world coordinates, press F4 “WORLD.” .PA (p.8--1)
377
WORLD
7. STATUS DISPLAY
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7.7 System Variables All the system variables can be seen with the system variable screen. Settings of the system are stored in the system variables. WARNING The operation of the robot and control unit is controlled with system variables. Only a person who knows details of the influence of changes in system variables should set system variables. If a person without detailed knowledge attempts to set the system variables, the robot and control unit would malfunction.
Procedure 7--6 Step
Displaying the system variable screen
1 Press the MENUS key. The screen select menu is displayed. 2 Select NEXT, then select SYSTEM. 3 Press F1,[TYPE]. 4 Select Variables. The system variable screen is displayed. SYSTEM Variables 1 2 3 4 5 6 7 8 9 10
$AP_MAXAX $AP_PLUGGED $AP_TOTALAX $AP_USENUM $AUTOINIT $BLT $CRT_DEFPROG $CSTOP $DEFPULSE $DEVICE
JOINT
10 % 1/98
536870912 4 16777216 [12] of Byte 2 19920216 *uninit* TRUE 4 ’P3:’
[ TYPE ]
5 To change the settings of the system variables,move the cursor to the desired field and press the ENTER key after entering the value, or select the desired item from the function labels 6 When one of the system variables has plural items which belong to this variable (hierarchical structure), move the cursor to the desired system variable and press the ENTER key. Then the list of items which belongs to this variable is displayed. WARNING Power should be turned on again to make a new setting valid. Otherwise, injury or property damage could occur.
SYSTEM Variables 47 48 49 50 ENTER
JOINT 10 % 49/98
$ORIENTTOL $OVRDSLCT $PARAM_GROUP $PASSWORD
10.000 OVRDSLCT_T MRR_GRP_T PASSWORD_T
SYSTEM Variables $PARAM_GROUP 1 $BELT_ENABLE 2 $CART_ACCEL1 3 $CART_ACCEL2 4 $CIRC_RATE 5 $CONTAXISNUM 6 $EXP_ENBL [ TYPE ]
JOINT 10 % 49/98 FALSE 192 0 1 0 TRUE
7 To return to the upper layer, press the PREV key.
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7.8 Program Timer A program timer [option = hour meter] is a timer for measuring the execution time from one line to another in a program. Ten program timers can be used as standard. A program timer can be started and stopped by using a timer instruction (see Section 4.14.3). It also stops at forced termination and upon a halt. The program timer detail screen displays the following information: F
Program name and line number for which a timer was started most recently
F
Program name and line number for which a timer was stopped most recently
Figure 7--4. Program Timer Measurement
SUB3 ⋅ ⋅ ⋅ ⋅ 12 : TIMER[1]=START ⋅ ⋅ ⋅ ⋅
Measures the time from the start of a timer until it stops. MAIN1 ⋅ ⋅ ⋅ ⋅ 34 : TIMER[1]=STOP ⋅ ⋅ ⋅ ⋅
Program timers are indicated by using 4 STATUS/Prg Timer on the program timer screen.
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7. STATUS DISPLAY
Procedure 7--7 Step
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Displaying program timers
1 Press the menus key to display the screen menu. 2 Press 0, NEXT, and select 4 STATUS. 3 Press F1, [TYPE] to display the screen selection menu. 4 Select Prg Timer. Then, the program timer screen appears. PRG TIMER LISTING
1 2 3 4 5 6 7 8 9
count comment 3.20(s)[TIMER TEST 0.00(s)[ 0.00(s)[ 0.00(s)[ 0.00(s)[ 0.00(s)[ 0.00(s)[ 0.00(s)[ 0.00(s)[
Timer[1] Timer[2] Timer[3] Timer[4] Timer[5] Timer[6] Timer[7] Timer[8] Timer[9]
[TYPE]
JOINT
10% 1/10 ] ] ] ] ] ] ] ] ]
DETAIL
5 To display detail information, press F2 DETAIL. Then, the program timer detail screen appears. PRG TIMER DETAIL
JOINT
Timer[1] Comment Count Start program line Stop program line
[TYPE]
:[ : :[ : :[ :
10% 1/1
TIMER TEST] 3.20(sec) TEST] 1 TEST] 3
LISTING
6 To enter a comment, position the cursor on the comment field, and press the enter key. Select the input method, and enter characters using function keys. 7 As the start program, a program for which the timer was started most recently is indicated. As the stop program, a program for which the timer was stopped most recently is indicated.
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7.9 System Timer A system timer [option = hour meter] is a timer for indicating the system operation time. The times for four items are indicated. Four types of timer are provided for each operation group. Table 7--3.
System Timer Display
Item
Description
Power--on time
Time during which the power to the control unit is on
Servo--on time Operation time
Time during which the system is ready for operation (servo on) after the release of an alarm. Program execution time. The halt period is not included.
Standby time
Time required to execute a standby instruction
To display the system timers, use 4 STATUS Sys Timer on the system timer screen.
Procedure 7--8 Step
Displaying the system timer screen
1 Press the menus key to display the screen menu. 2 Select 4 STATUS on the next page. 3 Press F1, [TYPE]. 4 Select Sys Timer. Then, the system timer screen appears. SYS TIMER
JOINT
GROUP:1 Timer type Total(h) On Power time: 0.2 Servo on time: 0.2 Running time: 0.0 Waiting time: 0.0
[TYPE]
GROUP#
ON/OFF
10% 1/4
Lap(m) 0.0[OFF] 0.0[OFF] 0.0[OFF] 0.0[OFF]
RESET
5 To switch between operation groups, press F2 GROUP#, and enter a group number. 6 To enable or disable lap time measurement, position the cursor to a desired item, and press F3 ON/OFF to switch the setting. 7 To reset the lap time, position the cursor to a desired item, and press F4 RESET.
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7.10 Execution History The function of the program execution history records the execution history of the most recently executed or halted program, and enables you to see the execution history after the program is finished or paused. For example, this function enables you to see the execution status of the program at power failure after the cold start is done in case that power supply was turned off for any cause while the program was executing. NOTE You can not see the execution history of the program which is been executed. The following informations can be referred with the execution history screen. F
Executed program name and line number (The status of the latest executed program is displayed at the first line.)
F
Direction of execution -- FWD: The line was executed by forward execution. -- BWD: The line was executed by backward execution.
F
Status of execution -- Not exec: The line was read but the line has not been executed. -- Paused: The program was paused while executing the line. -- Done: The execution of the line has been completed. -- Aborted: The program was terminated.
The maximum number of lines of execution history which can be recorded is 200. When the execution history exceeds the number of the lines which can be recorded, the older execution histories which exceed the limit are cleared automatically. When the maximum number of lines that can be recorded has been reached, subsequent history data recording is performed by automatically erasing the recorded data, starting from the oldest. Note the following when you use this function: F
When a macro is executed by using a method other than a program, such as manual function, user key, etc., the execution history is not recorded. If a program assigned to a macro is executed from the program edit screen, the assigned program name, not the macro name, is recorded in the execution history.
F
When a KAREL program is executed, its execution history is not recorded.
F
The execution history of a program that is automatically started at power on is not recorded.
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7. STATUS DISPLAY
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Procedure 7--9 Step
Displaying program execution history
1 Press the MENUS key. The screen select menu is displayed. 2 Select STATUS from the next page. 3 Press F1,[TYPE]. 4 Select Exec--hist. The execution history screen is displayed.
Execution history JOINT 10 % Program name Line. Dirc. Stat. PNS0001 3 FWD Done PNS0001 6 BWD Paused PNS0001 7 FWD Paused PNS0001 6 FWD Done PNS0001 5 FWD Done [ TYPE ]
CLEAR
NOTE If a single program has been executed, F2 NEXT TASK and F4 ALL CLEAR are not displayed on the execution history screen. 5 Only when the displayed status of a program is “Aborted”, the execution history can be cleared by pressing SHIFT + F5,CLEAR. 6 When multitasking is used, pressing F2 NEXT TASK displays the history of another task. 7 When multitasking is used, the execution history of all the tasks can be cleared by SHIFT+F4 ALL CLEAR provided Abort is indicated for all the tasks.
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7. STATUS DISPLAY
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7.11 Memory Use Status Display This screen displays the use status and hardware configuration of the control unit memory. The display includes the following information: Table 7--4.
Memory Use Status Display( Pools ) DESCRIPTIONS
ITEMS TPP
Displays the use of area to hold programs.
PERM
Displays the use of area to hold system variables and registers.
SYSTEM
Displays the use status for a part of the system software.
TEMP
Displays the use status of work area used by system software. Table 7--5.
Memory Use Status Display( Hardware )
ITEMS
DESCRIPTIONS
F--ROM
Storage capacity of the F--ROM module used in control unit
D--RAM
Storage capacity of the D--RAM (RAM) module used in control unit
S--RAM
Storage capacity of the S--RAM (RAM) module used in control unit
When the [STATUS memory] screen is selected, the following screen appears on the teach pendant. This screen indicates the information collected immediately before it appears. A list screen displays the use status of program area, permanent area and temporary area. Memory Status List Screen STATUS Memory
JOINT 10 % Total Available Pools ---------------------TPP CMOS 550.0 KB 540.0 KB PERM CMOS 999.8 KB 364.4 KB TEMP DRAM 1726.9 KB 1216.2 KB FR FROM 1581.5 KB 1100.5 KB Description: TPP: Used by .TP, .MR, .JB, .PR PERM: Used by .VR, RD:, Options TEMP: Used by .PC, .VR, Options
[ TYPE ] DETAIL
HELP
A detailed screen displays use status of all the areas mentioned above and displays the hardware information. Memory Status Detailed screen STATUS Memory JOINT 10 % Total Free Lrgst Free Pools ----------------------------TPP 550.0 KB 540.0 KB 540.0 KB PERM 999.8 KB 364.4 KB 364.3 KB SYSTEM 985.8 KB 9.1 KB 9.1 KB IEMP 255.9 KB 89.6 KB 89.6 KB FR 1726.9 KB 1216.2 KB 1213.2 KB Hardware ----------------------------FROM 2.0 MB DRAM 4.0 MB S-RAM 1.0 MB (C-MOS) [ TYPE ] BASIC
HELP
To move from a list screen to a detailed screen, press F2, DETAIL. To move from a detailed screen to a list screen, press F2, BASIC. Explanation of each area is displayed by pressing F5, HELP on both screens. To display the previous screen, press PREV key. NOTE This function indicates the use status of the memory. It does not change the use status.
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8. FILE INPUT/OUTPUT This chapter describes file transfer to and from a communication device. j Contents of this chapter 8.1
File Input/Output Units
8.2
Setting a Communication Port
8.3
Files
8.4
Saving Files
8.5
Loading Files
8.6
Printing Files
8.7
Automatic Backup
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8.1 File Input/Output Units With the robot control unit, the following file I/O devices can be used: F
Memory card
F
Floppy disk
The standard setting specifies the use of memory cards. When floppy disks are to be used, follow the steps shown below to change the file I/O device. The use of a memory card allows files to be saved and read quickly, which can greatly improve the work efficiency.
Procedure 8--1 Step
Changing file I/O devices
1 Press MENUS to display the screen menu. 2 Select 7 FILE. The file screen appears.
6 SETUP 7 FILE 8
FILE MC: *.* 1 * * (all 2 * KL (all 3 * CF (all 4 * TX (all 5 * LS (all 6 * DT (all 7 * PC (all 8 * TP (all 9 * MN (all 10 * VR (all Press DIR to generate [TYPE] [DIR] LOAD
MENUS
JOINT
10% 1/17
files) KAREL source) command files) text files) KAREL listings) KAREL data files) KAREL p-code) TP programs) MN programs) variable files) directory [BACKUP] [UTIL] >
3 Press F5 UTIL, and select Set Device. Then, the following screen appears:
Set Device LOAD
[BACKUP]
UTIL
F5
JOINT
10%
1 Floppy disk 2 Mem Card (MC:) 3 4 FILE 1 * * (all 2 * KL (all 3 * CF (all 4 * TX (all 5 * LS (all 6 * DT (all Press DIR to generate [TYPE] [DIR] LOAD
files) KAREL source) command files) text files) KAREL listings) KAREL data files) directory [BACKUP] [UTIL] >
4 Select a file I/O device to be used. An abbreviation for the currently selected file I/O device appears in the upper left part of the screen. FILE FLPY:
Abbreviation MC : FLPY :
File I/O device Memory card Floppy disk
FRA :
Area used for automatic backup of the F--ROM in the controller
NOTE When selecting FLPY:, set the floppy disk drive on the port setting screen beforehand. (See Section 8.2.)
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8. FILE INPUT/OUTPUT
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8.1.1 Memory card With the robot control unit, a flash ATA memory card and SRAM memory card can be used. CAUTION Flash ATA memory card 1 It is recommended that files on a flash ATA memory card be backed up to media such as floppy disks to protect the flash ATA memory card contents against accidental loss. SRAM memory card 1 The SRAM memory card requires a backup battery. When an SRAM memory card is purchased, the battery is not installed. Always install the battery in the card before attempting to use it. 2 Once the battery in the SRAM memory card reaches the end of its service life, the data on the card will be lost. Therefore, always make a backup of the card contents.
Figure 8--1. Memory Card Insertion
Memory card insertion
When a memory card is to be used, select the memory card according to the description of changing the file I/O devices (see Section 8.1).
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8. FILE INPUT/OUTPUT
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8.1.2 External memory unit Two types of floppy disk drive (FDD) are available: F
Floppy Cassette adapter (A16B--0150--B001)
F
Handy File (A16B--0159--B002)
A 3.5--inch floppy disk is used. Before a new floppy disk can be used, it must be formatted by the following method: Table 8--1.
Format Specification of Floppy Disk
Type of disk
3.5--inch, 2HD or 2DD
Floppy Cassette adapter
2HD, FANUC format, 71 files maximum
Handy File
2HD, FANUC format, 71 files maximum 2HD, MS--DOS format 2DD, MS--DOS format
The disk drive is connected via the RS--232--C port. Port 1 on the disk drive is used for connection. (For communication port setting, see Section 8.2.) Table 8--2 lists the standard disk drive settings. Table 8--2.
Standard Settings for Floppy Disk Drives Speed
Stop bit
Parity bit
Data code
Floppy Cassette adapter
9600 baud
2 bit
None
ISO
Time--out value 0 sec
Handy File
9600 baud
2 bit
None
ISO
0 sec
Handy FMS--DOS
9600 baud
1 bit
None
ISO
0 sec
Device
When a floppy disk is to be used, select the floppy disk according to the description of changing the file I/O devices (see Section 8.1). In addition, set the floppy disk drive used for communication port setting (see Section 8.2). CAUTION Do not eject the floppy disk from the external memory device accessing the floppy disk, otherwise, you could damage the contents of the floppy disk.
CAUTION If a printer, floppy disk drive, vision system, or other device is connected to the control unit, the device should be turned on after the robot is turned on. Otherwise, the device can be damaged.
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8. FILE INPUT/OUTPUT
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8.1.3 Floppy Cassette adapter The Floppy Cassette adapter is an external memory unit connected to the robot controller to save files stored in the internal memory of the controller to a floppy disk or read files from a floppy disk. For detailed information about the Floppy Cassette adapter (A16B--0150--B001), refer to the “FANUC FLOPPY CASSETTE ADAPTER Operator’s Manual” (B--66040E). Figure 8--2. Floppy Cassette Adapter Status indicator LED
ALARM OVER HEAT
CLEAN INIT RESET
ON
OFF
Power switch Alarm indicator LED
Disk insertion slot Rotary switch
Rotary switch setting For port setting on the Floppy Cassette adapter, rotary switches 1 to 4 on the side panel are used. The standard settings for connection with the robot controller are “3, 1, 0, 0” from right side. Table 8--3.
Port Setting on Floppy Cassette Adapter Speed
Standard setting
Stop bit
9600
Switch
2 bit (1)3
Parity bit None
Number of files 71
(2)1
(3)0 (4)0
Status indicator LEDs The status indicator LEDs on the Floppy Cassette adapter indicate operation statuses.
Green Yellow ALARM OVER HEAT
Red
CLEAN INIT
Button
RESET ON
OFF
Table 8--4.
Status Indicator LEDs and Switches
Green
Yellow
Status
Blinking alternately
No floppy disk is inserted, or the door is not closed.
On
On(*1)
Ready (with write protection not applied)
On
Blinking
The floppy disk is being formatted.
Blinking
On
The floppy disk is being cleaned.
On
Blinking
Data is being written.
Blinking
On(*1)
Data is being read.
Blinking simultaneously
A file is being deleted.
Button
Function
CLEAN
Used to clean the head
INIT
Used to format a floppy disk
RESET
Used to release an alarm
NOTE
*1 Turned off when the disk is write protected.
389
Data code ISO
8. FILE INPUT/OUTPUT
Procedure 8--2 Step
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Setting of the Floppy Cassette adapter
1 Connect the Floppy Cassette adapter to the controller. 2 Turn on the power to the Floppy Cassette adapter. The green LED and yellow LED blink alternately. Figure 8--3. Turning on the power to the Floppy Cassette adapter
ALARM OVER HEAT
Green Yellow
CLEAN
ALARM
INIT
Red
RESET
ON
OVER HEAT
OFF
CLEAN
Button
INIT RESET
POWER
ON
OFF
OFF
ON
3 Insert a floppy disk, then close the door. The green LED and yellow LED light to indicate that the Floppy Cassette adapter is ready for operation. If the disk is write protected, the yellow LED does not light. NOTE The Floppy Cassette adapter cannot be used if the door is not closed. Setting ports 4 To set the port, open the cover which is on the left side of the floppy cassette adapter and adjust the rotary switches. Figure 8--4. Rotary switches on the Floppy Cassette adapter RSW4 E D C B A
F 0 1
9 8 7
2 3 4 5 6
RSW3 E D C B A
F 0 1
9 8 7
2 3 4 5 6
RSW2 E D C B A
F 0 1
9 8 7
2 3 4 5 6
RSW1 E D C B A
F 0 1
9 8 7
2 3 4 5 6
Initializing the floppy disks 5 To format the floppy disks, press and release the RESET button while holding down the INIT button. Yellow LED starts blinking to inform you of the start of initialization.
CLEAN INIT RESET ON
OFF
6 If an alarm is issued, press the RESET button.
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8.1.4 Handy file The Handy File is an external memory unit connected to the robot controller to save files stored in the internal memory of the controller to a floppy disk or read files from a floppy disk. For detailed information about the Handy File (A16B--0159--B002), refer to the “FANUC Handy File Operator’s Manual” (B--61834E). Figure 8--5. Handy File Cable connector
Power switch
Display
Keyboard Disk insertion slot
The settings of the Handy file are as follows. In the way of setting, there are some differences between FANUC format and MS--DOS format. Table 8--5.
Port Setting for Handy File
Setting item
FANUC format
MS--DOS format
Protocol
Protocol B
Robot
ISO parity bit
exist
none
Speed
9600 baud
9600 baud
Stop bit
2 bits
2 bits
Parity bit
none
none
Data code
Receive
ISO / EIA
Receive
ISO / EIA
Send
ISO
Send
ISO
Channel
RS--232--C
RS--232--C
Subprogram
none
none
NOTE To initialize the floppy disk in MS--DOS format,use the protocol B. After initializing it, set the protocol to ROBOT again. After initialization, set the robot as the protocol. When the FANUC format is set, the disk can be initialized without changing the protocol. NOTE When ROBOT is set as the protocol, communication with the robot controller might be broken during operation with the Handy File, even though all the settings have been made correctly. In this case, press the following keys on the Handy File:
SHIFT
WRITE SET
END
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8. FILE INPUT/OUTPUT
Procedure 8--3 Step
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Setting a Handy File
1 Connect the Handy File to the controller.
RS--232--C interface connector 2 Turn on the power to the Handy File. 3 Insert a floppy disk, then close the door. The Handy File is now ready for operation. No file Ready
Port setting 4 The setting menu is used for port setting. Press the WRITE/SET key while holding down the SHIFT key. The setting item menu appears. WRITE SET
SHIFT
Select setting item #1 : Input/Output
In setting, switch between menu items with the ↓ and ↑ keys. To select an item, press the ENTER key. Select setting item #2 : Protocol
5 Select “#2: Protocol” to display the protocol setting menu. ENTER
Protocol : #1 : Protocol B
In setting, switch between menu items with the ↓ and ↑ keys. To select an item, press the ENTER key. 6 Select “1 Protocol B”. ENTER
NOTE Use “1 Protocol B” to use FANUC format and Use “2 Robot” to use MS--DOS format. 7 Upon completion of protocol setting, press the END key. The setting item menu is displayed. END
Select setting item #3 : Baud rate
8 Set all the setting items in the same way as the above. When all menu items have been set, press the END key. END
No file Ready
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Formatting the floppy disk 9 When the floppy disk is not formatted, a message is displayed. ! FD format error Initialize FD. >FUNC: SELECT FUNCTI.
10 The function menu is used to format the floppy disk. To display the function menu, press the READ/FUNC key while holding down the SHIFT key. READ /FUNC
SHIFT
Select function #1 : Initialize FD
11 Select “#1 : Initialize FD” to format the floppy disk. ENTER
Select format of FD #1 : 2HD, 1.02MB FANUC
12 Select a format. Set number of file > Maximum =
13 Set a maximum number of files. For this example, enter “71.” NOTE Only when the FANUC format is selected, enter the maximum number of the files.
7
1
ENTER
Set number of file > Maximum = 71
Initialize FD : Press START key
14 Press the START key to start the formatting of the floppy disk. START
Initialize FD : > Executing
Initialize FD : > Complete
15 Upon completion of floppy disk formatting, press the END key. END
Select function #1 : Initialize FD
16 To terminate the function menu, press the END key. END
No file Ready
NOTE When you initialize the floppy disk in MS--DOS format, select Protocol B as the communication protocol. After initializing it, select Robot as the communication protocol again. Cleaning the head 17 The function menu is used to clean the head. Select “#2: Cleaning” to clean the head. Select function #2 : Cleaning
18 Press the START key to start cleaning the head. Upon completion of head cleaning, press the END key.
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8.2 Setting a Communication Port The control unit performs data transfer to and from external devices through communication ports by performing serial communication via the RS--232C or RS--422 interface. The following communication ports are used. (Operator’s panel/box; see Section 2.3.2.) F
Port 1: RS--232--C On the operator’s box (standard)
F
Port 2: RS--232--C JD5B connector on the main CPU printed circuit board
F
Port 3: RS--232--C JD17 connector on the main CPU printed circuit board
F
Port 4: RS--422 JD17 connector on the main CPU printed circuit board
Figure 8--6. Communication Ports Main CPU printed circuit board JD5A
RS--232--C (port 1)
JD5B
RS--232--C (port 2)
JD17
RS--232--C/RS--422 (port 3/port 4) Operator’s panel printed circuit board
JNA10P
Teach pendant
RS--422 The use of the RS--422 interface has the following advantage: F
While the RS--232--C standard supports a cable length of only about 10 to 20 m, the RS--422 standard allows a cable to be extended to about 50 m.
F
RS--422 is less susceptible to noise than RS--232C.
Application example F
When the communication cable must be routed over a long distance, use the RS--422 interface.
NOTE The RS--422 interface uses electrical signals that are completely different from those of the RS--232--C interface. When the robot control unit and a personal computer are connected via the RS--422 interface, a commercially available RS--422--to--RS--232--C converter may be required since personal computers do not generally have an RS--422 interface. NOTE It is impossible to use port 3 (RS--232--C) and port 4 (RS--422) simultaneously. Communication ports are set by using [6 Setting; port setting] on the port setting screen. Table 8--6.
Standard Communication Devices for Communication Ports
Communication port Port 1 Port 2 Port 3
Communication device Handy File (FANUC format) Printer Not used
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Table 8--7.
Setting a Communication Port
ITEMS
DESCRIPTIONS
Device
This item specifies a communication device to communicate with the robot controller. The standard communication devices that can communicate with the robot controller are listed below: F FANUC Handy File (A13B--0159--B002) NOTE The Handy File can be set to the MS--DOS or FANUC format. F F F F F F F F F F F F F
Speed (Baud rate)
FANUC FLOPPY CASSETTE ADAPTER (A13B--0150--B001) PS--100/200 Disk FANUC PRINTER (A86L--0001--0103) Sensor Fanuc Eye V120 Host Comm Used when the robot controller is connected to the host computer to use the data transfer function. No use KCL/CRT Debug Console Factory Terminal TP Demo Device Current position Development CIM PLICITY NOTE When the communication device is changed, other settings such as a baud rate are changed to the corresponding standard values. Later on, the user can change each setting as desired.
Baud rate is the transmission rate and it is the number of codes which can be transmitted per second. Enter the transmission rate specified for the peripheral unit being used. To detect an error in data transfer, this item sets a mode of vertical parity check, which adds one extra bit to each transferred character. -- Odd : The number of 1’s in each transferred character must be an odd number. -- Even : The number of 1’s in each transferred character must be an even number. -- None : No parity check is made.
Parity bit
Enter the parity check mode specified for the peripheral unit being used. Stop bit
This item specifies the number of stop bits to be added at the end of the transferred characters, for data transfer synchronization. -- 1 bit : One stop bit is added. -- 1.5 bits : One and a half stop bits are added. -- 2 bits : Two stop bits are added. Enter the number of stop bits specified for the peripheral unit being used.
Time--out value (sec)
Table 8--8.
This item sets a maximum time during which control over transfer with a communication device must be exercised. If no data transfer occurs for a specified period of time, the communication line is disconnected. Standard Settings for Communication Devices Speed
Parity bit
Stop bit
Time--out value
Handy File
9600
None
2 bits
None
Handy FMS--DOS
9600
None
1 bit
None
FANUC Floppy
9600
None
2 bits
None
Printer
4800
None
1 bit
None
Sensor
4800
Odd parity
1 bit
None
Host Comm
4800
Odd parity
1 bit
None
Factory Terminal
9600
None
1 bit
None
KCL/CRT
9600
None
1 bit
None
TP Demo Device
9600
None
1 bit
None
Device
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8. FILE INPUT/OUTPUT
Procedure 8--4 Step
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Setting a communication port
1 Press the MENUS key to display the screen menu. 2 Select “6 SETUP.” 3 Press F1 “TYPE” to display the screen change menu, 4 Select “Port Init.” The port selection screen appears.
5 I/O 6 SETUP 7 FILE
SETUP Port Init Connector 1 RS-232-C
MENUS
[ TYPE ]
JOINT Port P3: [
30 % 1/3
Comment Handy File]
DETAIL
Port Init TYPE
F1 5 Move the cursor to a desired connecter port field, then press F3 “DETAIL.” The port setting screen appears. [TYPE]
DETAIL
F3
SETUP Port Init 1 Device [ 2 Speed(Baud rate) 3 Parity bit 4 Stop bit” 5 Time out value(sec) [ TYPE ]
LIST
JOINT 30 % Handy File] [ 9600] [ None] [ 2bits] [ 0] [CHOICE]
6 To set a communication device, move the cursor to the “Device” field, then press F4 [CHOICE]. Select a desired communication device from the menu. [CHOICE] 1 Handy File 2 FANUC Floppy 3 PS-100/200 Disk 4 Printer SETUP Port Init 1 Device
F4
5 6 7 8
JOINT 30 % Sensor Host Comm No Use ---next page--[
Handy File]
7 Select a communication device whose settings need to be changed. When the communication device is entered, the standard values are entered in the other setting fields.
1 Handy file 2 FANUC floppy 3 PS-100/200 floppy 4 Printer SETUP Port Init
SETUP Port Init JOINT 30% PORT 1 Device [FANUC floppy ] 2 Speed (Baud late) [ 9600 ] 3 Parity bit [ None ] 4 Stop bit [ 2bits ] 5 Time out value (sec) [ 0 ]
ENTER
[ TYPE ]
LIST
[CHOICE]
The other setting fields can be changed field by field. When the “Device” field is changed to another communication device, the standard values for that device are entered in the other setting fields. NOTE To indicate that a port is not used, set “No Use” in the corresponding field of communication equipment.
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8 Upon completion of setting, press F3 “LIST.” The port selection screen appears. [ TYPE ]
LIST
F3
SETUP Port Init Connector port 1 PORT
[TYPE]
JOINT 30% Comment 1/1 [FANUC floppy ]
DETAIL
NOTE When setting the communications device, the error message,“The port was not initialized.”,may be displayed and the settings of the port are returned to the previous settings. In this case, confirm the following. F
Has the communication device to be set already been set for another port? ! The same communication device cannot be set for more than one port.
F
To set ”Host Comm” to the field of device, software option, data transfer, is needed.
F
For setting a sensor, the sensor interface option is required.
F
It is impossible to use port 3 (RS--232--C) and port 4 (RS--422) simultaneously. The port selection screen displays all ports up to port 3 by default. To enable port 4 (RS--422), change the system variable $RS232_NPORT from 4 to 5 on the system variable screen, using controlled start (see Appendix B.1.3, “Controlled Start”). Port 4 is added to the port selection screen, enabling a communication unit to be set at port 4. If a communication unit is set at port 4, set port 3 to “No use,” and refrain from using it.
397
8. FILE INPUT/OUTPUT
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8.3 Files A file is a unit of data storage in the memory of the robot controller. The following types of files are typically used. F
Program file (*.TP)
F
Default Logic File (*.DF )
F
System file (*.SV)
F
I/O Config Data File (*.IO )
Used to store the settings of Input/Output configuration.
F
Date file (*.VR)
Used to store data such as register data
Used to store the settings of the system.
8.3.1 Program file A program file ( *.MN) contains a sequence of instructions for the robot. These instructions are called program instructions. Program instructions control robot operations, peripheral devices, and each application. A program file is automatically stored in the S--RAM of the controller. A directory of program files is displayed on the program selection screen (“SELECT”). NOTE The directory of program files is not displayed on the file screen. The file screen enables you to select the external memory device which includes the desired files and manipulate the files. On the program selection screen, operations such as copy, delete, and rename can be performed. (For program operations, see Section 5.5.) F
Registering a program (See Subsection 5.3.1.)
F
Deleting a program (See Section 5.5.)
F
Copying a program (See Section 5.5.)
F
Changing program detail information (including the renaming of a program) (See Section 5.5.)
A program file also includes the information items listed below. These information items can be checked on the program selection screen by pressing F5 [ATTR]. F
Comment
: The function of a program is summarized.
F
Write protection
: This prevents the program from being modified and deleted.
F
Modification Date : Indicates the latest date when the program was modified.
F
Program size
: The size of the program is indicated in bytes.
F
Copy source
: The name of the source program from which the program was copied is indicated. When the program is an original program, this information item is blank.
8.3.2 Default logic file The default logic file (*.DF) includes the settings of the default logic instruction assigned to each function key (F1 to F4 key) in the program edit screen. The default logic file is divided to the following kinds: F
DEF_MOTN0.DF Stores the settings of the default motion instructions. F1 key
The following three files store the settings of the default logic instructions assigned to each function key. F
DF_LOGI1.DF
F2 key
F
DF_LOGI2.DF
F3 key
F
DF_LOGI3.DF
F4 key
The following default logic files are prepared as standard for an application. The default logic files listed above and the default logic files listed below are switched by pressing the next page key. F
When an arc application is used, the following files are provided. -- DF_ARCST.DF
F2 key
-- DF_ARCWL.DF
F3 key
-- DF_ARCED.DF
F4 key
398
8. FILE INPUT/OUTPUT
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8.3.3 System file A system file ( *.SV ) contains a system control program for operating the application tool software, or contains data used with the system. The following types of system file are used: F
SYSVARS.SV: Used to store the settings of the system variables related to frames, reference points, joint operating area and brake control.
F
SYSSERVO.SV : Used to store servo parameter data
F
SYSMAST.SV
F
SYSMACRO.SV : Used to store the settings of the macro command.
F
FRAMEVAR.SV : Used to store the settings of the reference position which is used at setting the frame, comments, etc.
: Used to store mastering data
8.3.4 Data file Date file (*.VR,*.IO) is the file which stores the data used by the system. The following kinds are in the data file: F
Data file (*.VR) -- NUMREG.VR : Used to store the data of the register. -- POSREG.VR : Used to store the data of the position register. (Only when position register software option is used.) -- PALREG.VR
: Used to store the data of the pallet register. (only when the palletizing option is used)
F
I/O configuration data file (*.IO)
F
Robot setting data file (*.DT) This file is used to store those settings that are made on the robot setting screen. The file name varies depending on the model.
-- DIOCFGSV. IO: Used to store the settings of the I/O assignment.
8.3.5 ASCII file An ASCII file (*.LS) is in ASCII format. ASCII files cannot be read. The contents of an ASCII file can, however, be displayed or printed using a personal computer.
399
8. FILE INPUT/OUTPUT
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8.4 Saving Files The function of saving files stores the data which exists in the RAM memory in the controller to the external storage device such as a memory card or floppy disk, etc. The following screens on the teach pendant can be used to save the files. Files are saved to the default device. (See Section 8.1.) F
Program selection screen: A specified program is saved to the default device as program files.
F
File screen: The specified program file, system file, etc can be saved to the default device. The following files can be saved: When a batched save operation is executed, program files, system files, and application files can all be saved at the same time. -- Program file -- System file -- Default logic file -- Standard command file
F
“5 SAVE” in the function menu: It is possible to preserve it on the default device as a program file and a system file, etc. of the program and the data, etc. displayed on the screen. The following files can be preserved: -- Program file -- System file -- Data file -- Default logic file -- Standard command file
8.4.1 Saving with the program selection screen The program selection screen enables you to save the specified program as the program file. Procedure 8--5 Condition
Requirements for saving program files
H The file input/output device is set correctly. (See Section 8.1.) H When a program is to be saved to a floppy disk, the floppy disk drive is ready (Section 8.1), and a correct port setting is already made (Section 8.2.)
Step
1 Press the MENUS key to display the screen menu. 2 Select NEXT and then select “1 SELECT” on the next page. The program selection screen appears.
1 SELECT 2 EDIT MENUS
Select 1 2 3 4 5
PROG1 PROG2 SAMPLE1 SAMPLE2 SAMPLE3
JOINT 30% 56080 bytes free 5/5 PR [PROGRAM001 ] PR [PROGRAM002 ] JB [SAMPLE PROGRAM1 ] JB [SAMPLE PROGRAM2 ] JB [SAMPLE PROGRAM3 ]
[TYPE]
CREATE
DELETE
MONITOR
COPY
DETAIL
LOAD
SAVE
400
[ATTR] > PRINT >
8. FILE INPUT/OUTPUT
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3 Press NEXT,>, and press F4,SAVE on the next page. The program save screen appears. LOAD
SAVE
PRINT >
JOINT 30% 1 Words 2 Upper Case 3 Lower Case 4 Options Select
F4
---Insert---
---Save Teach Pendant Program--Program Name [SAMPLE3 ] Enter program name PRG MAIN SUB
TEST
4 Enter the name of a program to be saved, then press the ENTER key. The specified program is saved to the floppy disk. Select ---Save Teach Pend Program Name [SAMPLE3
ENTER
NOTE Do not include a file extension in the program name. 5 When a program having a same name as you want to save exists in the specified media, the file can not be saved. File already exists
CAUTION If the current device already has a file having the specified name, the save function cannot overwrite that file. Before a new file is saved, the current file should be deleted from the device.
6 When the media is filled, change the media and press F4,CONTINUE. No room to save file CONTINUE CANCEL
401
8. FILE INPUT/OUTPUT
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8.4.2 Saving all the program files using the file screen File screen enables you to save a program file or system file which is saved in RAM memory to a floppy disk. The following files can be saved by pressing F4, BACKUP: F
Program file (*.TP): Used to store all teach pendant program files.
F
Default logic file (*.DF): Used to store the settings of default logic instructions.
F
System file (*.SV ): Used to store the following files: -- System variable file ( SYSVARS.SV ) -- Servo parameter file ( SYSSERVO.SV ) -- Mastering data file ( SYSMAST.SV ) -- Macro data file ( SYSMACRO.SV ) -- Frame setup file (FRAMEVAR.SV)
F
I/O configuration data file (DIOCFGSV.IO)
F
Register data file (NUMREG.VR)
F
Robot setting data file (*.DT)
To interrupt the saving, press the PREV key while saving. NOTE At control start time, F4 is set to ALL SAVE instead of BACKUP. When SAVE is selected from the function menu, BACKUP is displayed for F4.
FCTN
2 SAVE
Procedure 8--6 Condition
Saving files using the file screen
H The file input/output device is set correctly. (See Section 8.1.) H When a program is to be saved to a floppy disk, the floppy disk drive is ready (Section 8.1), and a correct port setting is already made (Section 8.2.)
Step
1 Press the MENUS key to display the screen menu. 2 Select “7 FILE.” The file screen appears.
6 SETUP 7 FILE 8 MENUS
FILE P3: *.* 1 * 2 * 3 * 4 * 5 * 6 * Press DIR to
JOINT * (all KL (all CF (all TX (all LS (all DT (all generate
[ TYPE ] [ DIR ]
DELETE
COPY
files) KAREL source) command files) text files) KAREL listings) KAREL data files) directory
LOAD
DISPLAY
402
30 %
[BACKUP][UTIL ]>
>
8. FILE INPUT/OUTPUT
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Saving program files 3 Press F4 “BACKUP”, then select “TPE programs.” 1 System files 2 TPE programs 3 Application LOAD
BACKUP
FILE 7 8 9 10
[UTIL] >
F4
* * * *
PC TP MN VR
(all (all (all (all
JOINT 30% 1/13 KAREL p-code) TP programs) MN programs) variable files)
Save FLPY:\SAMPLE1.TP ? EXIT ALL
YES
NO
-- F2, EXIT Ends saving program files -- F3, ALL Saves all the program files and default logic instruction files. -- F4 YES Saves the specified file (program, default logic instruction). -- F5, NO Does not save the specified file (program, default logic instruction). After the file has been saved, the system asks whether the next program file is to be saved. 4 Select the desired function key. In this case, program file (*.MN) is saved to the default device. EXIT
ALL
Saving FLPY:\SAMPLE1.TP, please wait...
F3 5 When a file which has the same name as you specified already exists on the default device, the following message is displayed. FLPY:\SAMPLE1.TP already exists OVERWRITE SKIP
CANCEL
-- F3,OVERWRITE The specified file is overwritten and saved. -- F4,SKIP Does not save the specified file. -- F5,CANCEL Ends saving files. Saving the system file. 6 Press F4,SAVE and select System files. The following file is displayed. 1 System files 2 TPE programs 3 Application LOAD
BACKUP
[UTIL] >
F4
FILE Backup JOINT 30 % FLPY:\*.* Saving the following files to FLPY:\ DIOCFGSV.IO FRAMEVAR.SV NUMREG.VR SYSVARS.SV SYSSERVO.SV SYSMAST.SV SYSMACRO.SV Backup to disk? YES NO
7 To save all the system files, press F4,YES. System files (DIOCFGSV.IO, FRAMEVAR.SV, NUMREG.VR, SYSVARS.SV,SYSSERVO.SV,SYSMAST.SV,SYSMACRO.SV) are saved to the default device. YES
NO
Backing up to disk: FLPY:\SYSVARS.SV
F4
403
8. FILE INPUT/OUTPUT
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8 When the file having the same name as you want to save exists on the default device, the following message is displayed. FLPY:\SYSVARS.SV already exists OVERWRITE SKIP
CANCEL
-- F3,OVERWRITE The specified file is saved by overwriting. -- F4,SKIP The specified file is not saved. -- F5,CANCEL Saving files is ended. 9 When the floppy disk is filled with files, exchange the floppy disk and press R4,CONTINUE. Disk is full, change to empty disk CONTINUE CANCEL
Batched save 10 Press F4 BACKUP, then select ALL of above. FILE JOINT 10% FLPY: *.* 1/17 1 * * (all files) 2 * KL (all KAREL source) 3 * CF (all command files) 4 * TX (all text files) 5 * LS (all KAREL listings) 6 * DT (all KAREL data files) 7 * PC (all KAREL p-code) 8 * TP (all TP programs) 9 * MN (all MN programs) 10 * VR (all variable files) Del Handy File, backup all files? YES NO
NOTE Since F4 BACKUP does not appear in the control start (not control start 2), batched save operation cannot be used. 11 When F4 YES is selected, all the files in the external memory unit are erased, then all the data is saved. Processing is interrupted using the backward key. An interrupt occurs once the current file has been processed. CAUTION Before a batched save operation, all files in the external memory unit are erased. Before executing a batched save operation, check the files in the external memory unit.
YES
NO
F4
404
8. FILE INPUT/OUTPUT
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8.4.3 Saving with a function menu By selecting SAVE from a function menu, the data of a screen currently displayed can be saved to the floppy disk. The data of the following screens can be saved: F
Program edit screen Program file (*.TP)
F
System variable screen System variable file (SYSVARS.SV)
F
Positioning screen Mastering data file ( SYSMAST.SV )
F
Macro instruction setting screen Macro data file ( SYSMACRO.SV )
F
Frame setup screen Frame setup data file ( FRAMEVAR.SV )
F
Register screen Register data file ( NUMREG.VR )
F
Position register screen Position register data file ( POSREG.VR )
F
I/O screen I/O configuration data screen ( DIOCFGSV.IP)
F
Edit screen for each default logic instruction. Each default logic instruction. ( *.DF)
Procedure 8--7 Condition
Saving with a function menu
H The file input/output device is set correctly. (See Section 8.1.) H When a program is to be saved to a floppy disk, the floppy disk drive is ready (Section 8.1), and a correct port setting is already made (Section 8.2.) Saving program files.
Step
1 Display the program edit screen or the program selection screen.
Select
JOINT 30 % 49828 bytes free 1/5 No. Program name Comment 1 PROG001 PR [PROGRAM001 ] 2 PROG002 PR [PROGRAM002 ] 3 SAMPLE1 JB [SAMPLE PROGRAM 1] 4 SAMPLE2 JB [SAMPLE PROGRAM 2] 5 SAMPLE3 JB [SAMPLE PROGRAM 3]
[ TYPE ] CREATE DELETE
MONITOR [ATTR ]>
2 To display a function menu, press the FCTN key. 3 Select ”2 SAVE.” A selected program file is saved. 1 QUICK/FULL MENUS 2 SAVE 3 PRINT SCREEN FCTN
4 When a program having the same name as you want to save exists in the floppy disk, the file can not be saved. File already exists
5 When the floppy disk is filled with the files, exchange the floppy disk and press F4,CONTINUE. All the data being saved is saved into the exchanged floppy disk. Disk is full, change to empty disk. CONTINUE CANCEL
405
8. FILE INPUT/OUTPUT
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Saving other files. Step
1 Display the screen you want to save. DATA Registers R[ R[ R[ R[ R[ R[
JOINT
1:COUNTER1 2: 3: 4: 5: 6:
30 % 1/32
]=12 ]=0 ]=0 ]=0 ]=0 ]=0
[ TYPE ]
2 Display the function menu by pressing the FCTN key. 3 Select ”2 SAVE.” The contents of the screen being displayed are saved. 1 QUICK/FULL MENUS 2 SAVE 3 PRINT SCREEN FCTN
4 When a file having a same name exists on the media, the file is overwritten. 5 When the floppy disk is filled with the files, exchange the floppy disk and press F4,CONTINUE. All the data being saved is saved into the exchanged floppy disk. FLPY-005 Disk is full DATA Registers
JOINT
406
30 %
8. FILE INPUT/OUTPUT
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8.4.4 File manipulation On the file screen, files saved on a memory card or floppy disk can be listed and a file can be copied or deleted. Procedure 8--8 Condition
File manipulation
H The file input/output device is set correctly. (See Section 8.1.) H When a program is to be saved to a floppy disk, the floppy disk drive is ready (Section 8.1), and a correct port setting is already made (Section 8.2.)
Step
1 Press the MENUS key. The screen menu is displayed. 2 Select 7 FILE. The file screen is displayed.
6 SETUP 7 FILE 8
FILE JOINT 30 % FLPY: *.* 1 * * (all files) 2 * KL (all KAREL source) 3 * CF (all command files) 4 * TX (all text files) 5 * LS (all KAREL listings) 6 * DT (all KAREL data files) Press DIR to generate directory [ TYPE ] [ DIR ] LOAD [BACKUP][UTIL ]>
FCTN
DELETE
COPY
DISPLAY
>
Displaying the list of files. 3 Press F2,[DIR].
1 *.* 2 *.KL 3 *.CF 4 *.TX FILE
5 6 7 8
JOINT 30 % *.LS *.DT *.PC ---next page---
4 Select ”*.*”(all files).The list of the files being saved onto the media is displayed. FILE JOINT 30 % FLPY: *.* 1 PRG1 TP 768 2 PRG2 TP 384 3 SYSVARS SV 25600 4 SYSMACRO SV 324 5 NUMREG VR 708 6 DIOCFGSV IO 476 7 * * (all files) 8 * KL (all KAREL source) DELETE COPY DISPLAY >
WARNING Before a program set as a macro instruction is copied from a control unit onto another control unit, the macro setting screens of the two control units should be compared. It should be ensured that the lists of the two control units match. The program should be copied only when the lists match. Otherwise, an unpredictable result will be produced and you could injure personnel or damage equipment.
407
8. FILE INPUT/OUTPUT
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Deleting files 5 Select the file you want to delete and press F1,DELETE. 2 PROGRAM2 MN 3 PROGRAM3 MN 4 SYSVARS SV
DELETE
COPY
Delete FLPY:\PROGRAM3.TP?
384 768 25600
YES
NO
DISPLAY
F1 NOTE Deleting a program from memory of the control unit does not automatically delete the identical program from the default media. CAUTION The operator should check that the current device contains the file to be deleted. Otherwise, an incorrect file can be deleted.
6 Press F4,YES. The file will be deleted.
FILE JOINT 30 % FLPY:\*.* 3/19 1 PROGRAM1 TP 768 2 PROGRAM2 TP 384 3 4 SYSVARS SV 25600 5 SYSMACRO SV 324 Deleted file FLPY:\PROGRAM3.TP DELETE COPY DISPLAY >
408
8. FILE INPUT/OUTPUT
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8.4.5 ASCII save ASCII save function saves the program which is saved in the robot controller in binary (internal) format to the external memory device in ASCII format. This ASCII format is like the output of the printer. Necessary devices and software version The programs, which are saved to the floppy disk using this function, can be loaded to the personal computer and can be edited by it. Moreover, the program which is saved to the floppy disk in ASCII format can not be directly loaded into the Robot controller.(When it is converted to the internal expression by other option software on the personal computer, it can be loaded into the controller.) Preparation for ASCII save operation Before an ASCII save operation, check that no printer is connected to any port on the port setting screen. If a printer is connected to a port, set the port to No Use. (See Section 8.2.) A printer is connected to port 2 as standard. File input/output device The ASCII save function saves a file of ASCII format to a file input/output device selected according to Section 8.1. When using the Handy File, perform the operation described below. The floppy cassette adaptor cannot be used. When using other file input/output devices, proceed to Operation 8--9 for ASCII save execution. Settings of Handy File The software version of the FANUC Handy File needs to be 07G or more. Set the FANUC Handy File so the floppy disk initialized in MS--DOS format can be used.(For details,refer to FANUC Handy File OPERATOR’S MANUAL.) Table 8--9.
Example for port setting of Handy File
Setting items
MS--DOS format
Protocol
Robot
Speed
9600 baud
Stop bit
1 bit
Parity bit
None
Data code
Receive
ISO / EIA
Send
ISO
Channel
RS--232--C
Subprogram
None
Select Handy F MS--DOS as the port settings on the R--J3 controller side and set the Handy File according to the above table. CAUTION Files saved in ASCII format on a FANUC format disk cannot be read into the personal computer, and so cannot be sent back to the robot controller. Therefore, always use MS--DOS format.
Initializing floppy disks When a floppy disk which has been already initialized is prepared, there is no need to initialize. When you want to use files in the floppy disk on the personal computer side, you should use the floppy disk which has been initialized according to the format of the computer. (Refer to the FANUC Handy File operator’s manual for operation) Or, use the floppy disk with the Handy File after initializing it in MS--DOS format with the personal computer etc. Setting of robot controller Select Handy F MS--DOS as the port connected to the FANUC Handy File with the port setting screen.
409
8. FILE INPUT/OUTPUT
Procedure 8--9 Condition
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Execution of ASCII save function
H The file input/output device is set correctly. (See Section 8.1.) H When a program is to be saved to a floppy disk, the floppy disk drive is ready (Section 8.1), and a correct port setting is already made (Section 8.2.)
Step
1 If a printer is set on the port setting screen, set the port to No Use. (See Section 8.2.)
4 ALARM 5 I/O 6 SETUP
SETUP Port Init
JOINT
Connector Port Comment 1 RS-232-C P2: [Handy File 2 PORT B P3: [Printer 3 JD17 RS-232-C P4: [No Use
MENUS
[ TYPE ]
Port Init
30 % 2/3 ] ] ]
DETAIL
TYPE
F1 [ TYPE ]
DETAIL
F3 LIST
1 Handy File 2 FANUC Floppy 3 PS-100/200 Disk 4 Printer SETUP Port Init
5 6 7 8
JOINT 30 % Sensor Host Comm No Use ---next page---
[CHOICE]
F4
1 2 3 4 5
Device [Printer ] Speed(Baud rate) [4800 ] Parity bit [None ] Stop bit [2bit ] Time out value(sec) [ 0]
[ TYPE ]
LISE
[CHOICE]
2 Press the MENU key to display the screen menu. 3 Select Select on the next page. The program directory screen appears.
Select
JOINT 30 % 49828 bytes free 3/5 No. Program name Comment 1 SAMPLE1 [Sample program 1] 2 SAMPLE2 [Sample program 2] 3 SAMPLE3 [Sample program 3] 4 PROG001 [Program001 ] 5 PROG002 [Program002 ]
[ TYPE ] CREATE DELETE
410
MONITOR [ATTR ]>
8. FILE INPUT/OUTPUT
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4 Press PRINT on the next page. The program print screen appears.
LOAD
SAVE
PRINT
>
F5
Select 1 Words 2 Upper Case 3 Lower Case 4 Options Select ---
JOINT
30 %
--Insert--
Print Teach Pendant Program
---
Program Name [SAMPLE3 ] Enter program name PRG MAIN SUB
TEST
5 Enter the name of the program to be saved with the ASCII save function, then press ENTER. Select ---
Print Teach Pendant Program
--ENTER
Program Name [SAMPLE3 ]
6 The specified program is saved with the ASCII save function. A file is saved with extension LS. In the same way, print data can be output as a file of ASCII format by print operation based on the auxiliary menu (Section 8.6.2).
411
8. FILE INPUT/OUTPUT
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8.5 Loading Files Loading files is to load the files being saved to the floppy disk to the S--RAM memory in the controller. The files can be loaded with the following screens on the teach pendant: F
Program selection screen --The specified program file is loaded from the floppy disk as the program.
F
File screen --The specified program files and system files can be loaded. The following files can be loaded. -- Program file (*.MN) -- Default logic instruction (*.DF) -- System file (*.SV) -- Data file (*.VR,*.IO )
NOTE Selecting F4 RESTOR on the file screen in the control start (not control start 2) enables batched read. Files stored in an external memory unit are read in the following order: 1 Files having the same names as those saved when System files is selected 2 Files having the same names as those saved when Application is selected 3 *.TP, *.DF, and *.MN files in the external memory unit *.SV and *.VR files are automatically read by selecting YES. CAUTION If a program having the same name exists during a program read operation, the existing program is overwritten automatically.
412
8. FILE INPUT/OUTPUT
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8.5.1 Loading using program selection screen In the program selection screen, the specified program file can be loaded from the floppy disk as the program. Procedure 8--10 Condition
Loading a program file using the program selection screen
H The file input/output device is set correctly. (See Section 8.1.) H When a program is to be saved to a floppy disk, the floppy disk drive is ready (Section 8.1), and a correct port setting is already made (Section 8.2.)
Step
1 Press MENUS key to display the screen menu. 2 Select ”0 ---- NEXT ----” and select ”1 SELECT” from the next page. Program selection screen is displayed.
Select
JOINT 30 % 49828 bytes free 3/5 No. Program name Comment 1 SAMPLE1 JB [SAMPLE PROGRAM 1] 2 SAMPLE2 JB [SAMPLE PROGRAM 2] 3 SAMPLE3 JB [SAMPLE PROGRAM 3] 4 PROG001 PR [PROGRAM001 ] 5 PROG002 PR [PROGRAM002 ]
1 SELECT 2 EDIT MENUS
[ TYPE ] CREATE DELETE
MONITOR [ATTR ]>
COPY
SAVE
DETAIL
LOAD
PRINT
>
3 Press ”NEXT”,>, and press F3,LOAD, on the next page. Program load screen is displayed.
LOAD
SAVE
PRINT > 1 Words 2 Upper Case 3 Lower Case 4 Options Select
F3
---Insert---
---Load Teach Pendant Program--Program Name [ ] Enter program name PRG MAIN SUB
TEST
4 Enter the name of a program to be loaded, then press the ENTER key. Program Name PROG001 Enter program name ENTER PRG MAIN
NOTE Do not include a file extension in the program name. A specified program is loaded from the default device. 5 When the program having the same name as you want to load exists in the memory, the following message is displayed. PRG1 already exists, select function OVERWRITE
-- OVERWRITE Loads the new file and overwrites it.
413
CANCEL
8. FILE INPUT/OUTPUT
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8.5.2 Loading a specified program file using the file screen In the file screen, the specified file is loaded from the default device to the memory. The following files can be read: F
Program file (*.TP or *.MN) --Program file having contents of the program can be loaded.
F
Default logic file (*.DF) --Default logic file having the settings of the default logic instruction can be loaded. The method of loading is the same as the program file.
F
Data file (*.VR,*.IO ) --The following data file can be loaded. -- Register data file ( NUMREG.VR ) -- Position register data file ( POSREG.VR ) -- I/O config data file (DIOCFGSV.IO)
F
System file (*.SV ) --The following system files can be loaded. However, system files can be loaded only at the controlled start.(See Section B.1.3, ”Controlled start”) -- System variable file ( SYSVARS.SV ) -- Servo parameter file ( SYSSERVO.SV ) -- Mastering data file ( SYSMAST.SV ) -- Macro data file ( SYSMACRO.SV ) -- Frame setup data file( FRAMEVAR.SV )
Procedure 8--11 Condition
Loading a program file using the file screen
H The file input/output device is set correctly. (See Section 8.1.) H When a program is to be saved to a floppy disk, the floppy disk drive is ready (Section 8.1), and a correct port setting is already made (Section 8.2.) H The file is saved to a floppy disk (Section 8.2.)
Step
1 Press the MENUS key to display the screen menu. 2 Select ”7 FILE” to display the file screen.
6 SETUP 7 FILE 8 MENUS
FILE FLPY:\*.* 1 * * (all 2 * KL (all 3 * CF (all 4 * TX (all 5 * LS (all 6 * DT (all 7 * PC (all 8 * TP (all 9 * MN (all 10 * VR (all Press DIR to generate [ TYPE ] [ DIR ] LOAD DELETE
COPY
DISPLAY
414
JOINT 30% 1/13 files) KAREL source) command files) text files) KAREL listings) KAREL data files) KAREL p-code) TP programs) MN programs) variable files) directory [BACKUP][UTIL ]> >
8. FILE INPUT/OUTPUT
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Loading a program file 3 Press F2 “DIR.”
[ TYPE ] [ DIR ]
LOAD
1 *.* 2 *.KL 3 *.CF 4 *.TX FILE
F2
5 6 7 8
1 *.MN 2 *.TP 3 *.VR 4 *.SV FILE
5 6 7 8
JOINT 30 % *.LS *.DT *.PC ---next page---
JOINT 30 % *.IO *.DF *.ASCII Files ---next page---
4 Select “*.TP” (program file). The directory of program files stored on the default device is displayed.
FILE 1 2 3 4
*.MN *.TP *.VR *.SV
5 6 7 8
* * * --
JOINT
30 % 1/17
1 PROGRAM1 TP 768 2 PROGRAM2 TP 384 3 TEST1 TP 6016 4 TEST2 TP 704 5 * * (all files) 6 * KL (all KAREL source) [ TYPE ] [ DIR ] LOAD [BACKUP][UTIL ]>
5 Move the cursor to the program file you want to load and press F3,LOAD. [ TYPE ] [ DIR ]
LOAD Loading PROGRAM1.TP, Prev to exit.
F3 Selected program is loaded from the default device. Loaded PROGRAM1.TP
6 If a program with the same name already exists in the RAM, the following indication is provided: PROGRAM1.TP already exists OVERWRITE SKIP
CANCEL
-- OVERWRITE Loads the new file and overwrites it. -- SKIP Skips to the next file.
FILE 8 * 9 * 10 *
JOINT 30% 8/13 TP (all TP programs) VR (all variable files) SV (all system files)
Press DIR to generate directory [TYPE] [DIR] LOAD [BACKUP]
415
[UTIL]
8. FILE INPUT/OUTPUT
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7 If you want to load a group of program files, select ”*.TP” and press F3,LOAD. When the PREV key is pressed, the operation is canceled after the file being loaded at this time is loaded. [ TYPE ] [ DIR ]
LOAD
F3 Loading a data file 8 Press F2, DIR. Sub--menu is displayed. [TYPE]
[DIR]
LOAD
F2
Directory Subset 1 *.TP 2 *.MN 3 *.VR 4 *.SV FILE
5 6 7 8
JOINT 30% *.IO ASCII Files Loadable Files ---next page---
9 Select “*.VR” (variable data file). The directory of variable data files stored on the default device is displayed. Select a program to be loaded. The selected program is loaded from the default device. Directory Subset 1 *.TP 2 *.MN 3 *.VR ENTER 4 *.SV
FILE 1 NUMREG VR 2 POSREG VR 3 * * 4 * KL 5 * CF 6 * TX [ TYPE ] [ DIR ]
JOINT
30 % 1/15
868 1024 (all files) (all KAREL source) (all command files) (all text files) LOAD [BACKUP][UTIL ]>
10 Select a program file you want to load and press F3, LOAD. [ TYPE ] [ DIR ]
LOAD
Loading NUMREG.VR, Prev to exit.
F3 The specified program is loaded from the default device. Loaded data is set as the current data. Loaded NUMREG.VR
11 If you want to load all the files which have the same extension, Select ”*.VR”,”*.IO”,etc and press F3,LOAD. FILE
JOINT
30 % 9/13
8 * MN (all MN programs) 9 * VR (all variable files) 10 * SV (all system files) Press DIR to generate directory [ TYPE ] [ DIR ] LOAD [BACKUP][UTIL ]>
416
8. FILE INPUT/OUTPUT
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Loading system variable files Condition
H Turn on the power by controlled start (See Section B.1.3, ”Controlled start”) The following simplified system starts.
SYSTEM Variables 1 2 3 4 5 6
CNTRL START MENU 1/98 536870912 4 16777216 [12] of Byte 2 19920216
$AP_MAXAX $AP_PLUGGED $AP_TOTALAX $AP_USENUM $AUTOINIT $BLT
[ TYPE ]
12 Press the MENUS key, then select “2 File.” The file screen appears. 1 Variables 2 File 3
FILE FLPY: *.* 1 * 2 * 3 * 4 * 5 * 6 * Press DIR to
MENUS
* (all KL (all CF (all TX (all LS (all DT (all generate
[ TYPE ] [ DIR ]
LOAD
CNTRL START MENU 1/13 files) KAREL source) command files) text files) KAREL listings) KAREL data files) directory [BACKUP][UTIL ]>
13 Press F2 “DIR” to display the submenu. [TYPE]
[DIR]
LOAD
F2
Director Subset 1 *.TP 2 *.MN 3 *.VR 4 *.SV
JOINT 30% 5 6 7 8 ---next page---
14 Select “*.SV” (system variable data file). The list of the system files which are saved to the default device is displayed.
FILE FLPY: *.* 1 SYSVARS 2 SYSSERVO 3 SYSMAST 4 SYSMACRO 5 * 6 *
CNTRL START MENU 1/17 SV SV SV SV * KL
[ TYPE ] [ DIR ]
768 384 6016 704 (all files) (all KAREL source) LOAD
[BACKUP][UTIL ]>
15 Select the file you want to load and press F3,LOAD. When you press the PREV key while the system files are loaded by selecting ”*.SV”, loading continues until the file being loaded at pressing the PREV key has finished loading. [TYPE]
[DIR]
LOAD
F3
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8. FILE INPUT/OUTPUT
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16 When a system file is read, it is necessary to specify whether conversion is to be performed to maintain compatibility with the old system. Normally, select YES. Convert ? YES
NO
F4 17 Turn off the power again. Then, select “1 START (COLD)” from the function menu. The system is cold started. 1 START (COLD) 2 FCTN
Batched read Step
1 Select a file screen in the control start (not control start 2). 2 Select F4 RESTOR. 3 A message asking the user for confirmation appears on the prompt line. TEST LINE 0 FILE CONTROLLED START MENUS FLPY: *.* 2/17 1 * * (all files) 2 * KL (all KAREL source) 3 * CF (all command files) 4 * TX (all text files) 5 * LS (all KAREL listings) 6 * DT (all KAREL data files) 7 * PC (all KAREL p-code) 8 * TP (all TP programs) 9 * MN (all MN programs) 10 * VR (all variable files) Restore from Handy File(OVRWRT)? YES NO
4 Select F4 YES. Then, the read operation starts. Processing is interrupted using the backward key. An interrupt occurs once the current file has been processed.
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8. FILE INPUT/OUTPUT
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8.6 Printing Files 8.6.1 Printer The printer prints out the contents of a program, data file, system variable, and so forth. A FANUC standard printer is available for connection with the robot controller. F
FANUC Printer (A86L--0001--0103) The FANUC PRINTER is a serial, desktop dot--matrix printer which can print at high speed.
Figure 8--7. FANUC Printer
Power switch
LINE FORM FEED FEED TOP SET
SELECT
ALARM POWER
The Printer must be connected to an RS--232--C port. Normally, the printer is used by connecting it to port 2. (For communication setting, see Section 8.2.) Port 2 is located on the rear of the operator’s box. Table 8--10. Device Printer
Standard Port Setting for the Printer Speed 4800 baud
Stop bit 1 bit
Parity bit None
Figure 8--8. Connection of Communication Cable to Controller
419
Data code ISO
Time--out value 0 sec
8. FILE INPUT/OUTPUT
Table 8--11.
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Functions of LEDs and Switches
LED indication
Status
POWER (green)
Is lit when the power goes on.
ALARM (red)
Lights when a form is used up.
SELECT (green)
Is lit in the receive state (SELECT), and goes off in the local state. The SELECT switch is used to switch between the receive state and local state. Status
Switch POWER
Turns on and off the power.
SELECT
Switches between the receive state and local state.
TOP SET
Functions when the local state is set. The position of the first line is memorized. So position the form on the first line. Functions when the local state is set. This switch feeds the form to the first line of the next page. Functions when the local state is set. This switch advances the form one line.
FORM FEED LINE FEED
For detailed information about the FANUC Printer (A86L--0001--0103), refer to the “FANUC Printer Operator’s Manual.”
Procedure 8--12 Step
Operating the Printer
1 Connect the Printer to the controller.
Power connector RS--232--C interface connector
2 Turn on the power to the Printer. 3 Set an ink ribbon cartridge and form. Press the SELECT switch to set the receive state. The SELECT lamp lights. SELECT
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8. FILE INPUT/OUTPUT
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8.6.2 Printing files The contents of a file stored in the RAM can be printed out. The image being displayed on the teach pendant screen can also be printed out (print screen). Printing files can be executed by the following screens. F Program selection screen: Can print the program files. F ”4 PRINT” on the second page of the FCTN menu: Can print the contents of the following screens: -- Program edit screen: Program detail information and contents of program. -- System variable screen: System variable data NOTE If the control unit is not connected to a printer but to a PC or disk drive, printing creates a file TPSCRN.LS on the device. Procedure 8--13 Condition
Printing files using program selection screen
H Communication port setting must be completed. (See Sections 8.2 and 8.5.1.) H The Printer must be connected to the controller. CAUTION Before starting to print a file, the operator should check that the current printer is a serial printer. If not, the control unit or printer could be damaged. Printing out a program file using the program selection screen
Step
1 Press the MENUS key to display the screen menu. 2 Select “1 SELECT” on the next page. The program selection screen appears. Select 1 2 3 4 5
PROG001 PROG002 SAMPLE1 SAMPLE2 SAMPLE3
JOINT 30% 56080 bytes free 3/5 PR [PROGRAM001 ] PR [PROGRAM002 ] [SAMPLE PROGRAM1 ] [SAMPLE PROGRAM2 ] [SAMPLE PROGRAM3 ]
[TYPE]
CREATE
DELETE
MONITOR
COPY
DETAIL
LOAD
SAVE
[ATTR] > PRINT >
3 Press F5 “PRINT” on the next page. The program print screen appears. LOAD
SAVE
PRINT >
F5
JOINT 30% 1 Words 2 Upper Case 3 Lower Case 4 Options Select
---Insert---
---Print Teach Pendant Program--Program Name [SAMPLE3 ] Enter program name PRG MAIN SUB
TEST
4 Enter the name of a program file to be printed out, then press the ENTER key. Program Name SAMPLE3 Enter program name ENTER PRG MAIN SUB
5 The specified program file is printed out. To stop printing, press the PREV key.
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8. FILE INPUT/OUTPUT
Procedure 8--14
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Printing using the miscellaneous function menu
Program printing Condition
H The program edit screen is displayed. SAMPLE1 1:J 2:J 3:L 4:L 5:J [End] POINT
Step
JOINT P[1] P[2] P[3] P[4] P[5]
10% 1/6
100% FINE 70% CNT50 1000mm/sec CNT30 500mm/sec FINE 100% FINE
SINGLE
DUAL
BACKUP
TOUCHUP >
1 Press the function key to display the miscellaneous function menu. 2 Press 0 NEXT, and select 4 PRINT.
9 0 -- NEXT --
3 PRINT SCREEN 4 PRINT 5
FCTN
3 The currently displayed program is printed. To interrupt printing, press PREV key. System variable printing Condition
H The system variable screen is displayed. SYSTEM Variables 1 2 3 4 5 6
JOINT
10% 1/98 536870912 4 16777216 [12] of Byte 2 19920216
$AP_MAXAX $AP_PLUGGED $AP_TOTALAX $AP_USENUM $AUTOINIT $BLT
[TYPE]
Step
1 Press the function key to display the miscellaneous function menu. 2 Press 0 ---- NEXT ----, then select 4 PRINT.
9 0 -- NEXT --
3 PRINT SCREEN 4 PRINT 5
FCTN
3 A list of system variables is printed. NOTE It takes at least three hours to print all the system variables. To interrupt system variable printing, press the backward key.
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8. FILE INPUT/OUTPUT
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4 To print only lower level system variables, for example, to print the system variables in $PARAM_GROUP, open the screen of the target level, and perform steps 1 and 2 above. SYSTEM Variables 47 48 49 50
$ORIENTTOL $OVRDSLCT $PARAM_GROUP $PASSWORD
SYSTEM Variables $PARAM_GROUP 1 $BELT_ENABLE 2 $CART_ACCEL1 3 $CART_ACCEL2 4 $CIRC_RATE 5 $CONTAXISNUM 6 $EXP_ENBL
JOINT
10% 49/98
FALSE 192 0 1 0 TRUE
ENTER
[TYPE]
Procedure 8--15 Condition Step
Printing the displayed screen ( print screen )
H The desired screen to be printed out is displayed. 1 Press the FCTN key to display the function menu and select “3 PRINT SCREEN.”
2 3 PRINT SCREEN 4 PRINT FCTN
2 The displayed screen is printed out. ”¥” is printed as the part of the highlight display on the teach pendant. To stop printing, press the PREV key.
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8. FILE INPUT/OUTPUT
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8.7 Automatic Backup 8.7.1 Overview of Automatic Backup F
Automatic Backup function performs the transaction of “all backup” in File menu automatically at the following timing. -- The specified time (Up to 5 settings) -- The specified DI is turned on. -- Start up of the controller. (Interval can be specified.)
F
The memory card (MC:) and the automatic backup area (FRA:) of F--ROM in the control unit can be specified as a backup copy destination. The FRA: is specified by default.
F
Automatic Backup function can manage many versions of backup in one device. Even if you backup the wrong programs or settings, you can load the previous version of backup. The number of versions to keep can be set from 1 up to 99. (Default is 2.)
F
A storage device to be used for automatic backup need be previously initialized for automatic backup. Automatic backup will not be performed for any external storage device that has not been initialized for automatic backup. Therefore, if an attempt is made to cause a backup copy to be automatically created on a memory card that has not be initialized for automatic backup, its content will not be lost. The FRA: need not be initialized, since it is previously initialized.
F
If the control unit is turned off during automatic backup, or automatic backup is stopped immaturely, the latest backup copy is automatically restored into the system. No incomplete backup file is left in the storage unit, and the latest backup file can be read at any time.
NOTE This function automatically saves all files. If the storage device used for automatic backup becomes faulty, the data saved in it may not be read. In case such an unforeseen accident takes place, it is necessary to save backups to another storage device such as a memory card as well.
8.7.2 Usable Memory Cards The following table lists memory cards usable for automatic backup. Type
Recommended product
Flash ATA memory card
PCMCIA Flash ATA Card manufactured by SanDisk and sold by I--O Data Device, Inc.
Compact flash memory card + PC card adapter
CompactFlash MEMORY CARD manufactured by SanDisk CompactFlash PC CARD ADAPTER manufactured by SanDisk
SRAM memory card
Available from FANUC. A87L--0001--0150#256K (with a capacity of 256 Kbytes) A87L--0001--0150#512K (with a capacity of 512 Kbytes) A87L--0001--0150#1M (with a capacity of 1 Mbyte) A87L--0001--0150#2M (with a capacity of 2 Mbytes)
NOTE 1 The SRAM card will lose its contents when the life of its built--in battery expires. Neither the Flash ATA memory card nor the CompactFlash memory card need batteries. It is recommended to use the Flash ATA or CompactFlash memory card for this function. NOTE 2 The required storage capacity is “(program size + 200 Kbytes) ¢ (number of backup copies + 1).” If the size of a program is 500 Kbytes, 13 backup copy versions of it can be made on a 10--Mbyte memory card. NOTE 3 If a memory card other then those recommended is used, a normal operation is not guaranteed, and a bad influence may occur on the control unit.
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8. FILE INPUT/OUTPUT
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8.7.3 Setting of Automatic Backup MENU→“7 FILE”→F1([TYPE])→“Auto Backup”. The following menu is displayed.
Automatic Backup works only when it is ENABLE.
AUTO BACKUP JOINT 100% 1/ 13 1 Automatic Backup: ENABLE 2 Device: Backup (FRA:) Status: Ready for auto backup Backup Schedule------------------------3 Backup time 1: 12:00 4 Backup time 1: 23:30 5 Backup time 1: **:** 6 Backup time 1: **:** 7 Backup time 1: **:** 8 Backup at DI rising: DI[ 0] 9 Backup at Power up: DISABLE 10 Interval: 7 Day Status Output--------------------------11 Backup in progress: DO[ 0] 12 Error occurs at backup: DO[ 0] Version Management---------------------13 Maximum number of versions: 1 14 Loadable version: 01/01/30 12:00
Device to save. Default is “Backup (FRA:)”
[TY PE]INIT DEV
Settings to manage versions of backup. (→8.7.5 Version management) (→8.7.6 Restore the backup)
Current status of the device is displayed. Set the time to backup. Up to 5 settings. To clear setting, press F4 (CLEAR). When the specified DI is turned on, backup is performed. (If index is 0, it is disabled. If it is ENABLE, backup is performed at start up. The interval can be set. The specified DO is turned on when backup is performed, or when error occurs at backup. (→8.7.4 Perform Automatic backup)
CLEAR
Power--on time backup If “Backup at Power up” is enabled, a backup copy is made when the power is turned on. If the date of the latest backup copy in the storage device is within a period range (specified in “Interval”) from the current date, no backup copy is made at power--on time. The period range is 7 days by default. If the default value is left unchanged, a backup copy is made at power--on time once every 7 days provided that “Backup at Power up” is enabled. The unit of interval can be selected from “Day,” “Time,” and “Minute.” If the “Interval” is reset to 0, a back--up copy is made every time the power is turned on. Initializing of the storage device * To use Memory Card for Automatic Backup, the Memory Card must be initialized for Automatic Backup. It is to protect to write to the other Memory Card. The status of device is displayed in ”Status” line. The FRA: need not be initialized, since it is previously initialized. Ready for auto backup
Device is initialized for automatic backup
Device is not ready!
Device is not ready or device is not initialized for automatic backup
Device is initialized by the following operation. (1) If the device is not formatted, please format the device in file menu. (2) Press F2 (INIT_DEV) (3) Message “Initialize the device for auto backup?” is displayed. Press F4 (YES). (4) Message “Enter number of versions to keep:” is displayed. Please enter the number (1 to 99) of versions to keep. Pressing only the enter key sets the number of backup copy versions to 2. NOTE INIT_DEV deletes all files in the device, and create the special files and directories. NOTE INIT_DEV does not format the device. Please format the device in file menu ( F5 (UTIL)→“Format”)
425
8. FILE INPUT/OUTPUT
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8.7.4 Perform Automatic backup When the specified condition is satisfied, automatic backup is performed. AUTO BACKUP
JOINT 100 % 1/9
Automatic backup in progress Please wait Device:
FRA:
To stop backup, press [PREV] key
Saving File
Saving MC:SYSVARS. SV (3/48) F
While automatic backup is performed, the menu is displayed. When automatic backup is completed, the previous menu is displayed.
F
If you press PREV key, backup is cancelled and the previous menu is displayed. Any key except PREV is not accepted while automatic backup is performed.
F
Even if you are using Teach Pendant, when automatic backup is performed, this menu is displayed and any key except PREV is not accepted. Please wait for Automatic backup is completed.
F
If an attempt is made to perform automatic backup during program execution, it is performed while the program is running. It is also possible to start a program from the outside during backup.
F
If the backup--in--progress signal is set, the specified signal becomes on while this menu is displayed. AUTO BACKUP
JOINT 100 % 1/9
Error occurred at Automatic Backup! Check device (FRA:)
To stop backup, press [PREV] key.
Reason why backup is impossible
RETRY F
This menu appears if backup is impossible, for example, because no memory card has been inserted.
F
In this case, the robot will not enter an alarm state. If a program is already running, it continues running. Also in this case, it is possible to start a program from the outside.
F
By pressing F5(RETRY), backup is performed again.
F
Pressing the PREV key resumes the previous menu.
F
If a backup error signal is set, the specified signal becomes on while this menu is displayed.
8.7.5 Version management Automatic Backup function can keep many backups in one device. The number of versions to keep is set at initializing the device. And you can change the number of versions to keep by the item “Maximum number of versions” anytime. The number of versions exceeds the specified number, the oldest version is deleted automatically. If the device is FRA: If the size of a free storage area in F--ROM in the control unit becomes smaller than 1 Mbyte, the oldest backup version is deleted automatically. In this case, the number of back versions actually held becomes smaller than “Maximum number of versions.” If the size of a free storage area in F--ROM is too small to hold an additional backup version, an error is detected during automatic backup execution. If it is impossible to hold a specified number of backup versions on a memory card because of an insufficient storage capacity, an error is detected during automatic backup execution. Specify an appropriate number of backup versions by assuming the storage capacity required to hold one backup version is “program size + 200 Kbytes.”
426
8. FILE INPUT/OUTPUT
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If an error is detected because of an insufficient storage area during automatic backup, decrease the value specified in “Maximum number of versions.” This will causes an old backup version to be deleted, thus increasing a free area in the storage device. Once a backup version is deleted by decreasing the value specified in “Maximum number of versions,” it cannot be restored by increasing the value. Backup is stored in individual sub directories. When automatic backup is performed, backup files are saved to the root directory, then these files are copied to the appropriate directory. File menu can access the files only in root directory, so the latest version of backup can be loaded by file menu. You can also load the older versions. (→ 8.7.6 Restore the backup) When “all backup” is performed in file menu to the device that is initialized for Automatic Backup, the files are copied to the appropriate sub directory as same as automatic backup. If the control unit is turned off during backup, or backup is stopped prematurely, all backup files created during the current backup session are deleted, and the last backup version selected is restored to the root directory.
8.7.6 Restore the backup Backup files saved by Automatic Backup can be loaded by file menu. Pressing all of above on the file menu of the controlled start menu enables all files to be read simultaneously. Usually the latest version of backup is in root directory and the version can be loaded by file menu. You can load the previous version by the following operation. (1) Press F4 (CHOICE) on the “Loadable version” item. The menu that contains the backup time of all versions in the device is displayed.
1_99/06/16_12:00___ _5_99/06/14_12:00 2_99/06/15_23:30___ _6_99/06/13_23:30 3_99/06/15_12:00__ __7_99/06/13_12:00 4_99/06/14_23:30_ _ __8_--_Next Page_-AUTO BACKUP JOINT 100 % Version Management-------------------_13_Maximum number of versions:________1 _14_ Loadable version: ___99/06/16_12:00
[ TYPE ]INIT_DEV_________[CHOICE]
(2) Please select the version to load, then the item “ Loadable version ” shows the time of the selected version. At this time, the files of the selected version of backup are copied to root directory. (3) You can load the files of the selected version in file menu. When controlled start is performed, pressing all of above on the file menu of the controlled start menu enables all backup files to be read simultaneously.
427
9. UTILITIES
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9. UTILITIES
This chapter explains special functions of the R--J3 controller. j Contents of this chapter 9.1
Macro Instruction
9.2
Shift Functions
9.3
Coordinate System Change Shift Functions
9.4
Soft Float Function
9.5
Continuous Rotation Function
9.6
Position Register Look--Ahead Execution Function
9.7
Operation Group DO Output Function
9.8
Pre--Execution Instruction Function
9.9
Distance before operations
9.10 State Monitoring Function 9.11 Automatic Error Recovery Function 9.12 Torch Posture Conversion 9.13 Torch Posture Adjustment 9.14 Tast Tracking Function 9.15 Automatic Voltage Control Tracking 9.16 Root Pass Memorization and Multipass 9.17 Coordinated Motion Function 9.18 Data Monitor 9.19 Touch Sensing 9.20 Load Setting 9.21 Load Estimation 9.22 Collision Detection for Auxiliary Axis 9.23 Gravity Compensation 9.24 Arc Smart High--speed Recovery Function 9.25 Multi Equipment Control for Arc Welding 9.26 ARC START Synchronization for Arc Multi--equipment Configutarion 9.27 Adjustment of Analog Output Conversation Factor by Multiple Points 9.28 Welding Parameter Grade Function 9.29 Welder Program Select Function 9.30 Servo Torch Control Function 9.31 Servo Torch Fine Adjustment Function of Wire Velocity Commands
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9. UTILITIES
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9.1 Macro Instruction A macro instruction is a function for registering a program consisting of a sequence of instructions as one instruction, and calling such a set of instructions for execution as required. Figure 9--1. Macro Instructions Macro instruction
Macro program
Clamp open
CLOPN.TP 1: SDO [ 1 ] = ON 2: SDO [ 2 ] = OFF 3: WAIT D I
Controller
[ 1 ] = ON
To open the clamp
SDO [ 1 ] SDO [ 2 ] SD I [ 1 ] To check that the clamp is open
A macro instruction has the following capabilities: F
A macro instruction, when taught in a program, can be started as a program instruction.
F
A macro instruction can be started using the manual operation screen on the teach pendant.
F
A macro instruction can be started using a user key on the teach pendant.
F
A macro instruction can be started using the user button on the operator’s panel. (The operation box can not be used because it does not have a user key.)
F
You can start the macro command using SDI, RDI or UI.
Existing programs can be registered as macro instructions. Up to 20 macro instructions can be registered. A macro instruction can be used according to the following procedure: 1 Create a program to be executed as a macro instruction. 2 Register the created macro program as a macro instruction and determine from which device the macro instruction is to be called. 3 Execute the macro instruction. The macro instruction setting screen [6 SETUP. Macro] is used for setting a macro instruction.
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9. UTILITIES
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9.1.1 Setting macro instructions The setting of a macro instruction involves the following items: F
Macro program
F
Name of a macro instruction
F
Assignment of a device used to start the macro instruction
Macro program A macro program is a program started by a macro instruction. A macro program can be taught and played back (when played back as a program) in the same way as an ordinary program, except for the following restrictions: F
The subtype of a program, when registered as a macro program, is changed to MR (macro). When the registration of the macro program is canceled, the subtype returns to the original one. (For information about the subtypes, see Section 4.1.3.)
F
A macro program registered as a macro instruction cannot be deleted.
F
A program not including a motion (group) can be started even when the motion enabled state is not set (even when an alarm is issued). (For the group mask, see Section 4.1.4.) For group mask setting, the program information screen is used. (See Section 5.3.1.)
F
The macro command not having the motion instruction should be made as the program which does not contain the motion group.
Name of a macro instruction The name of a macro instruction is used to call the macro program in the program. A macro instruction name must consist of an alphanumeric character string not longer than 16 characters. And then the macro command can be started while the robot is moving.
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9. UTILITIES
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Assignment of a device A macro instruction must be assigned to a key, screen item, etc. so it can be called. The item to which a macro instruction is assigned is called a device. The following devices are available: F
Items on the manual operation screen on the teach pendant (MF)
F
User keys on the teach pendant (UK and SU)
F
User buttons and other buttons on the operator’s panel (not provided on the operator’s box)
F
SDI, RDI, UI
NOTE If a macro instruction is allocated to a key switch on the teach pendant, the function previously allocated to the key becomes unavailable. CAUTION The operator should check that no macro instructions are allocated to user keys of the teach pendant. If some instructions are allocated, trouble could occur during execution.
Macro instructions can be assigned to the following devices: F
MF[1] to MF[99] : Items on the manual operation screen
F
UK[1] to UK[7]
: User keys 1 to 7 on the teach pendant
F
SU[1] to SU[7]
: User keys 1 to 7 + SHIFT key on the teach pendant
F
SP[4] to SP[5]
: User button 1 to 2 on the teach pendant
F
DI[1] to DI[99]
: SDI 1 to 99
F
RI[1] to RI[24]
: RDI 1 to 24
F
UI[7] HOME signal
NOTE MF numbers from 1 to 99 can be used, but no more than 20 macro instructions can be assigned to MF items. NOTE The total number of the assign to the DI and RI is up to 5. NOTE The allocation of macros to UI signals other than the HOME signal can be enabled with system variable $MACRUOPENBL. NOTE The number which can be actually used is only logical number allocated to the input signal line. The macro instruction setting screen [6 SETUP. Macro] is used for setting a macro instruction. WARNING Before a program set as a macro instruction is copied from a control unit onto another control unit, the macro setting screens of the two control units should be compared. It should be ensured that the lists of the two control units match. The program should be copied only when the lists match. Otherwise, an unpredictable result will be produced or you could injure personnel or damage equipment.
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9. UTILITIES
Procedure 9--1 Condition
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Setting macro instructions
H A macro program is created. HOPN1
JOINT 30% 2/6
1: RDO[1]=ON 2: RDO[2]=OFF 3: WAIT RI[1]=ON [END] POINT
Condition
TOUCHUP >
H Macro program detail information is set. NOTE For greater convenience, a group mask can be set for a program not including motion instructions. NOTE If the program to be modified contains a motion instruction, the group mask cannot be set.
Program detail 1 2 3 4 5 6
END
Program name: Sub Type: Comment: Group Mask: Write protect: Ignore pause:
PREV
[ *
JOINT 30% 1/7 [HOPN1 ] [None ] [Open HAND1 ] * * * * ] [OFF ] [OFF ]
NEXT
Changing the motion group (setting a group mask) Step
1 The program information screen is used to change the group mask. 2 Press the MENUS key to display the screen menu. 3 Select “1 SELECT” on the next page. The program selection screen appears. 4 Press F2 “DETAIL” on the next page. The program information screen appears. 5 Move the cursor to group 1 of “Group Mask.” Press F5 “*” to set (*,*,*,*,*).
1
*
F5
Program detail 4
END
Group Mask:
PREV
[ *
NEXT
*
1
JOINT 30% 4/7 * * * ]
*
NOTE If a motion instruction is already taught in a program to be modified, no group mask can be set.
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Setting a macro instruction Step
1 Press the MENUS key to display the screen menu. 2 Select “6 SETUP.” 3 Press F1 “TYPE” to display the screen change menu. 4 Select “Macro.” The macro instruction setting screen appears. Macro Command Instruction name Program 1 [ ][ ] 2 [ ][ ] 3 [ ][ ] 4 [ ][ ] 5 [ ][ ] [TYPE]
JOINT 30% Assign -- [ ] -- [ ] -- [ ] -- [ ] -- [ ]
CLEAR
5 For macro instruction input, press the ENTER key to display the character string input screen, then enter characters using the function key. Macro Command Instruction name 1 [ ] [ 2 [ ] [ ENTER
Macro Command Instruction name 1 [ ] [
ABCDEF
GHIJKL
JOINT 30% 1 Words 2 Upper Case 3 Lower Case 4 Options ---Insert--Macro Command Instruction name Program Assign 1 [hand ][ ] -- [ ]
abcdef
ghijkl
mnopqr
stuvwx
yz-@*. >
MNOP
F1 Upon completion of input, press the ENTER key. Macro Command Instruction name 1 [hand1open ] [ ENTER
Macro Command Instruction name Program 1 [hand1open ][ ]
[TYPE]
CLEAR
JOINT 30% Assign -- [ ]
[CHOICE]
NOTE No duplicate macro instruction definition is allowed.
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6 For macro program input, press F4 [CHOICE] to display a directory of programs, then choose a program from the directory. When the macro program name is entered without the macro name, the program name will be used as the macro name. JOINT 30% 1 PROGRAM1 5 SAMPLE1 2 PROGRAM2 6 SAMPLE2 3 HOPN1 7 4 HCLS1 8 ---next page--Macro Command Instruction name Program Assign 1 [hand1open ][ ] -- [ ]
[CHOICE]
F4
[TYPE]
1 2 3 4
PROGRAM1 PROGRAM2 HOPN1 HCLS1
5 6 7 8 ENTER
CLEAR
Macro Command Instruction name Program 1 [hand1open ][HOPN1 ]
[TYPE]
CLEAR
JOINT 30% Assign -- [ ]
[CHOICE]
7 For device assignment, press F4 “[CHOICE]” to display a directory of programs, then choose a program from the directory.
JOINT 30% 1 -5 SP 2 UK 6 DI 3 SU 7 RI 4 MF 8 ---NEXT--Macro Command Instruction name Program Assign 1 [hand1open ][HOPN1 ] -- [ ]
[CHOICE]
F4
[TYPE]
1 2 3 4
-UK SU MF
5 6 7 ENTER 8
CLEAR
[CHOICE]
Macro Command Instruction name Program 1 [hand1open ][HOPN1 ]
[TYPE]
CLEAR
JOINT 30% Assign MF [ ]
[CHOICE]
8 Enter a desired device number.
JOINT 30% Program Assign ] [HOPN1 ] MF[ ]
1
ENTER
Macro Command Instruction name Program 1 [hand1open ][HOPN1 ]
[TYPE]
JOINT 30% Assign MF [ 1 ]
CLEAR
CAUTION After all macro instructions are set, the setting information should be saved in external storage (floppy disk, for example) in case the information needs to be re--loaded. Otherwise, the current setting information will be lost when it is changed.
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9 For macro instruction deletion, move the cursor to a desired field, then press F2“CLEAR” while holding down the SHIFT key. Macro Command Instruction name Pros 1 [hand1open ] [HOPN1 2 [hand1close ] [HCLS1 [TYPE]
CLEAR
Macro Command Instruction name Program 1 [ ][HOPN1 ] 2 [hand1close ][HCLS1 ] 3 [ ][ ] 4 [ ][ ] [TYPE]
JOINT 30% Assign MF [ 1 ] MF [ 2 ] -- [ ] -- [ ]
CLEAR
F2 10 “Clear OK?” appears. -- To delete the macro instruction, press F4 “YES.” -- To cancel deletion of the macro instruction, press F5 “NO.” Clear OK? YES
NO
YES
NO
F4
9.1.2 Executing macro instructions A macro instruction can be executed by: F Selecting an item on the manual operation screen on the teach pendant (with the SHIFT key held down) F Pressing user keys on the teach pendant (without pressing the SHIFT key) F Pressing user keys on the teach pendant (with the SHIFT key held down) F SDI, RDI, UI F Calling the macro instruction from the program When a macro instruction is started, the macro program is executed in the same way as an ordinary program is executed, except for the following restrictions: F F F
The single step mode is disabled. The continuous operation mode is always used. The macro program is always aborted without the pausing status. The macro program is always executed starting from the first line.
When a macro program includes a motion instruction (possesses a motion group), the motion enabled state must be set to execute the macro instruction. When no motion group is possessed, the motion enabled state need not be set. The motion enabled state is set when: J J
ENBL is on. SYSRDY output is on. (Servo power supply is on)
Table 9--1.
Macro Instruction Execution Conditions
MF [ 1 to 99 ] SU [ 1 to 7 ]
TP enabled
UK [ 1 to 7 ]
Without a motion group
With a motion group
Executable(*1)
Executable
Executable
--
Executable
Executable
SP [ 4 to 5 ] DI [ 1 to 99 ] RI [ 1 to 24 ]
TP disabled
UI [ 7 ] NOTE (*1) Even when the teach pendant is disabled, a macro instruction that does not possess a motion group can be executed from an MF or SU by setting system variable $MACRTPDSBEXE = TRUE. *) It is possible to supply an argument in a macro instruction call in a program and use it in a macro program. For details, see Section 4.7.5, “Arguments.”
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Procedure 9--2 Condition
Executing a macro instruction using the teach pendant (manual operation screen)
H The teach pendant is enabled. NOTE Even when the teach pendant is disabled, a macro instruction that does not possess a motion group can be executed from an MF or SU by setting system variable $MACRTPDSBEXE = TRUE. H A device from MF[1] to MF[99] is set using the macro instruction setting screen.
Macro Command Instruction name Program 1 [hand1open ][HOPN1 ] 2 [hand1close ][HCLS1 ] 3 [ ][ ] 4 [ ][ ]
JOINT 30% Assign MF [ 1 ] MF [ 2 ] -- [ ] -- [ ]
[TYPE]
Step
1 Press the MENUS key to display the screen menu. 2 Select “3 MANUAL FCTNS.” 3 Press F1 “TYPE” to display the screen change menu. 4 Select “Macros.” The manual operation screen appears.
MANUAL MACROS Instruction 1 hand1open 2 hand1close
[TYPE]
JOINT 30% 1/3
EXEC
WARNING The macro program is started in the next step, causing the robot to make a motion. Before executing the operation, the operator should check that no persons and no unnecessary equipment are in the work area. Otherwise, you could injure personnel or damage equipment.
5 To start a desired macro instruction, press F3 “EXEC” while holding down the SHIFT key. The macro program is started. [TYPE]
SHIFT
EXEC
F3 Hold down the SHIFT key until the execution of the macro program is completed. NOTE When the macro program contains a motion group, hold down the shift key until execution of the macro program terminates. If the shift key is released while the macro is being executed, the macro program is stopped. When the macro program does not contain a motion group, program execution continues even if the shift key is released. CAUTION If the SHIFT key is released during execution, the macro program is terminated forcibly. Note that when execution is interrupted and F3 “EXEC” is pressed again, the macro program is executed from the first line again.
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Procedure 9--3 Condition
Executing a macro instruction using the teach pendant (using a user key)
H The teach pendant is enabled. NOTE Even when the teach pendant is disabled, a macro instruction that does not possess a motion group can be executed from an MF or SU by setting system variable $MACRTPDSBEXE = TRUE. H A device from UK[1] to UK[7] or SU[1] TO SU[7] is set on the macro instruction setting screen. Macro Command Instruction name Program 1 [hand1open ][HOPN1 ] 2 [hand1close ][HCLS1 ] 3 [ ][ ] 4 [ ][ ]
JOINT 30% Assign SU [ 1 ] SU [ 2 ] -- [ ] -- [ ]
[ TYPE ] CLEAR
Step
1 To start a macro instruction on the teach pendant, use the assigned user key on the teach pendant. WARNING The macro program is started in the next step, causing the robot to make a motion. Before executing the operation, the operator should check that no persons and no unnecessary equipment are in the work area. Otherwise, injury or property damage could occur.
2 When a user key from UK[1] to UK[7] is assigned to a macro instruction, press the assigned user key to start the macro instruction. NOTE A macro instruction that contains a motion group cannot be executed using a device from UK[1] to UK[7]. A device from SU[1] to SU[7] must be assigned to such a macro instruction. 3 When a device from SU[1] to SU[7] is assigned to the macro instruction, press the user key while holding down the SHIFT key. NOTE When the macro program contains a motion group, hold down the shift key until execution of the macro program terminates. If the shift key is released while the macro is being executed, the macro program is stopped. When the macro program does not contain a motion group, program execution continues even if the shift key is released. CAUTION If the SHIFT key is released during execution, the macro program is terminated forcibly. Note that when execution is interrupted and F3 “EXEC” is pressed again, the macro program is executed from the first line again.
STATUS
SHIFT
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Figure 9--2. User Keys on Teach Pendant
POSN
STATUS
WELD ENBL
UK[1] or SU[1]
WIRE +
UK[2] or SU[2]
WIRE --
UK[3] or SU[3]
MAN FCTN
UK[4] or SU[4]
MOVE MENU
UK[5] or SU[5]
UK[7] UK[6] or or SU[7] SU[6]
CAUTION When a key on the teach pendant is assigned to a macro instruction, it becomes that macro instruction’s device, and the key can no longer be used for its original function.
Procedure 9--4 Condition
Execution of macro command using SDI,RDI and UI
H The teach pendant must be disabled. H DI[1 to 99], RI[1 to 24] or UI[7] is specified as the device in the macro instruction setting screen. Macro Command JOINT 30 % Instruction name Program Assign 1 [RETURN TO REFPOS][REFPOS ]UI[ 7] 2 [WORK1 CLAMP ][CLAMP1 ]DI[ 2] 3 [PROCESSING PREP ][PREP ]RI[ 3] 4 [ ][ ]--[ ] [ TYPE ] CLEAR
Step
1 To start the macro command using SDI or RDI or UI, input the digital signal from the external device or directly input these signals in the I/O screen on the teach pendant. 2 When SDI or RDI or UI which is set in the macro instruction setting screen is inputted, the macro command which is assigned to the signal will be started. NOTE $MACROUOPENBL can be changed in the system variable screen displayed at the controlled start.
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9.2 Shift Functions The shift functions shift the specified positions for the operation instructions within a certain range of a previously taught program to other locations. The shift functions perform the following: F
Shift the position data for the operation instructions within the entire range or within a certain range of an existing program.
F
Insert the shift results into a new or existing program.
F
Repeat the same shift on another program.
Figure 9--3. Shift
P1
P2 P3
P1
P4 Linear shift
P2 P3 P4 The following rules apply to converted position data: Rules governing position data: F
Position data having Cartesian coordinates is converted to Cartesian coordinates. Position data with joint coordinates is converted to joint coordinates.
F
If converted joint coordinate position data falls outside the variable axis area, it is stored as unspecified. Converted Cartesian coordinate position data is stored as is even if it falls outside the variable axis area.
F
Position data in the position registers is not converted.
F
The position data with joint coordinates for operation instructions involving incremental instructions is stored as unspecified.
Rules governing the Cartesian coordinate system number (UT, UF) in position data having Cartesian coordinates: F
The Cartesian coordinate system number is not changed due to conversion.
F
During conversion (on the shift information input screen), a user coordinate system number (UF) of 0 is used. Position data is converted to data in the Cartesian coordinate system with a UF of 0 (world coordinate system) and displayed.
Rules governing the configuration (joint placement and turn number) of position data having Cartesian coordinates: F
The configuration is not changed as a result of the conversion.
F
For the turn number, if the conversion causes rotation about the wrist axis by 180_ or greater, the turn number for the axis is optimized, and a message appears so that the user can determine whether to accept it.
The following shift functions are available: F
Program shift
: Performs a 3--dimensional linear shift or linear rotation shift.
F
Mirror shift
: Performs a 3--dimensional symmetrical shift about a specified mirror plane.
F
Angle--input shift : Performs a rotation shift about a specified rotation axis.
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9.2.1 Program shift function The program shift function performs a linear shift or linear rotation shift on the specified positions for the operation instructions within a certain range of a previously taught program. Figure 9--4. Linear Rotation Shift
P1
(Linear rotation shift) P2 P4 P6 The program shift function requires the following setup: Program name setting Program name setting specifies the name of the source program, the range of lines on which the shift is to be performed, as well as the name of the program into which the shift results are to be inserted and the line at which they are to be inserted. Shift information input Shift information input specifies the direction and amount of the program shift function. Two types of shift are supported: linear shift and linear rotation shift. The shift direction and amount can be specified in either of two ways: representative point specification and direct specification. F
In representative point specification, the user indicates (specifies) representative source and destination points to determine the shift direction and amount. For a linear shift, one source point (P1) and one destination point (Q1) must be indicated (specified).
Figure 9--5. Specifying a Linear Shift
Z Z
Q1
P1
Y Y
X
X For a linear rotation shift, three source points (P1, P2, and P3) and three destination points (Q1, Q2, and Q3) must be indicated (specified).
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Figure 9--6. Specifying a Linear Rotation Shift
Z Q1
Z
P1
Q3
P3
P2
Y Q2
Y
X
X F
In direct specification, the user directly specifies the direction and amount (X, Y, Z) of linear shift. In direct specification, linear rotation shift cannot be specified.
To execute the program shift function, use the program shift screen PROGRAM SHIFT. The figure below shows how to navigate through the program shift screen. Figure 9--7. Program Shift Screen Program name setting screen
SHIFT + ↓
SHIFT + ↑
Shift information input Representative point specification screen
F2
Direct input screen
F2 EXECUTE Execution of the program shift function The program name input screen contains the following items: Table 9--2.
Contents of the Program Name Input Screen
Item Original Program RANGE
Description Specifies the name of the source program. Specifies the type of the desired range of the source program. F WHOLE = Performs shift on the entire program. F PART = Performs shift on part of the program.
Start line
Specifies the start line of the desired range of the source program. If WHOLE is set to all, this item cannot be specified. Specifies the end line of the desired range of the source program. If WHOLE is set to all, this item cannot be specified. Specifies the program into which the shift results are to be inserted. If a new program name is specified, a new program is created with that name. If the name of an existing program is specified, the results are inserted into that program.
End line New Program
Insert line
Specifies the line at which the shift results are to be inserted, if insertion of the results are to be into an existing program is specified. If the program is a new one, this item cannot be specified.
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The representative point specification screen contains the following items: Table 9--3.
Contents of the Representative Point Specification Screen
Item Position data
Description Indicates the position of the point where the cursor is currently located. The position is always represented by coordinates in the world coordinate system. Specifies whether rotation is to be performed. Specifies the position of a representative source point.
Rotation Source position Destination position REFER
Procedure 9--5 Condition
Specifies the position of a representative destination point. F4 REFER allows the use of a position variable or position register in the source program as the position of a representative point.
Executing the program shift function
H The program on which the shift is to be performed exists. TEST2
Step
JOINT
1:J 2:J 3:L 4:L 5:J [End]
P[1] P[2] P[3] P[4] P[1]
POINT
ARCSTRT
30% 1/6
100% FINE 70% CNT50 1000cm/min CNT30 500m/sec FINE 100% FINE
WELD_PT
ARCEND
TOUCHUP >
1 Press the screen selection key. The screen menu appears. 2 Select 1, UTILITIES. 3 Press F1, [TYPE] The screen switching menu appears. 4 Select Program shift. The program name input screen appears.
1 UTILITIES 2 TEST CYCLE MENUS
Program shift TYPE
F1
PROGRAM SHIFT Program 1 Original Program: 2 Range: 3 Start line: (not used) 4 End line: (not used) 5 New Program: 6 Insert line:(not used)
JOINT
10% 1/6 [Test1 ] WHOLE *** *** [Test1 ] ***
Use shifted up, down arrows for next page [TYPE]
>
CLEAR
>
5 Specify the necessary items.
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6 After specifying the items, go to the next screen with SHIFT + ↓. The representative point specification screen appears. To return to the previous screen, use SHIFT + ↑. SHIFT
PROGRAM SHIFT Shift amount/Teach Position data P1 X ***** Y *****
JOINT
Z
1
Rotation
2
Source position
P1
3
Destination position
Q1
[TYPE]
10%
***** OFF
EXECUTE
ON
OFF
>
7 For a shift with rotation, set “Rotation” to ON. PROGRAM SHIFT Shift amout/Teach Position data X ***** Y
JOINT
*****
1
Rotation
2
Source position
3
Destination position
[TYPE]
Z
10%
***** ON
P1 P2 P3 Q1 Q2 Q3
EXECUTE
ON
OFF
>
8 Specify representative source and destination points. REFER
SHIFT
RECORD >
F5
PROGRAM SHIFT Shift amount/Teach Position data Q1 X 1234.4 Y
JOINT
100.0
1
Rotation
2
Source position
3
Destination position
[TYPE]
Z
10%
120.0 ON
EXECUTE
P1 P2 P3 Q1 Q2 Q3 REFER
Recorded Recorded Recorded Recorded
RECORD >
9 For reference point input, press F4 REFER. Select F4 P[] or F5 PR[] to enter arguments. REFER
RECORD >
F4 P[]
3
Destination position
[TYPE]
PR[]
EXECUTE
Q1 Q2 Q3 P[]
>
F4
443
Recorded P[5]
PR[]
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10 After setting shift information, press F2 EXECUTE and then F4 YES. The conversion results are written into the program. [TYPE]
EXECUTE
F2 Execute transform? YES NO
TEST2
JOINT
1:J 2:J 3:L 4:L 5:J [End] POINT
P[1] P[2] P[3] P[4] P[1]
ARCSTRT
30% 1/6
100% FINE 70% CNT50 1000cm/min CNT30 500m/sec FINE 100% FINE
WELD_PT
ARCEND
TOUCHUP >
F4 11 The direct input screen appears with F2 DIRECT on the next page. Specify the shift amount directly. PROGRAM SHIFT Shift amount/Direct entry 1 X (mm) 2 Y (mm) 3 Z (mm)
[TYPE] CLEAR
JOINT
10%
1888.92 239.87 50.52
EXECUTE
>
TEACH
>
NOTE Set the shift amount using coordinates in the world coordinate system. 12 After setting the shift amount, press F2 EXECUTE to execute the shift. 13 If the turn number is changed due to the shift, the user is notified and asked which to select. Select P[3]:J5 angle (183°) 183° -177° uninit
QUIT
>
14 F1 indicates the axial angle associated with the changed turn number. F2 indicates the axial angle associated with the original turn number. F3 uninit causes the data to become unspecified data. F5 QUIT interrupts the conversion. 15 To erase all the shift information, press F1 CLEAR on the next page. Then, the currently selected program is specified as the source program.
CLEAR
TEACH
F1
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9.2.2 Mirror shift function The mirror shift function shifts the specified positions for the operation instructions in a certain range of an already taught program symmetrically about a plane. Figure 9--8. Mirror Shift Function
Symmetrical shift of position data P[1]
P[2] P[4] P[6] Theoretically, the mirror shift function converts the attitude of the tool from right--handed coordinates to left--handed coordinates. In reality, however, the attitude is returned to the right--handed coordinate system by inverting the Y--axis because no left--handed coordinates exist. The mirror shift function, therefore, performs conversion most naturally when the plane of symmetry is parallel to the XZ plane of the tool coordinate system. Figure 9--9. Conversion from One Tool Coordinate System to Another with the Mirror Shift Function
Z Destination tool coordinate system
Z Source tool coordinate system
Y X Y
X CAUTION The tool coordinate system must be established accurately. The mirror shift function requires that the Z--axis match the tool direction. CAUTION The TCP must be set accurately to ensure correct operation with the points resulting from a symmetrical shift. Otherwise, the points resulting from the shift will contain offset values. The mirror shift function requires the following setup: Program name setting Program name setting specifies the name of the source program, the range of lines on which the shift is to be performed, as well as the name of the program into which the shift results are to be inserted and the line at which they are to be inserted.
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Shift information input Shift information input specifies the direction and amount of the mirror shift. Two types of shift are supported: symmetrical shift and symmetrical rotation shift. F
In representative point specification, the user indicates (specifies) representative source and destination points to determine the shift direction and amount. For a symmetrical shift, one source point (P1) and one destination points (Q1), two points in total, must be indicated (specified). For a symmetrical rotation shift, three source points (P1, P2, and P3) and three destination points (Q1, Q2, and Q3), six points in total, must be indicated (specified).
Figure 9--10. Specifying the Mirror Shift Function
Z
Q1
P1
Z
Q2 P2
Q3
P3
X Y
Y
X To execute the mirror shift function, use the mirror screen MIRROR IMAGE SHIFT. The explanation of the program shift screen also applies to the mirror screen.
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Procedure 9--6 Condition
Executing the mirror shift function
H The program on which the shift is to be performed exists.
TEST2
JOINT
1:J 2:J 3:L 4:L 5:J [End]
P[1] P[2] P[3] P[4] P[1]
100% FINE 70% CNT50 1000cm/min CNT30 500m/sec FINE 100% FINE
POINT
Step
30% 1/6
TOUCHUP >
1 Press the screen selection key. The screen menu appears. 2 Select 1, UTILITIES 3 Press F1, [TYPE] The screen switching menu appears. 4 Select Mirror Image. The program name input screen appears.
1 UTILITIES 2 TEST CYCLE MENUS
Mirror Image TYPE
F1
MIRROR IMAGE SHIFT Program 1 Original Program: 2 Range: 3 Start line: (not used) 4 End line: (not used) 5 New Program 6 Insert line:(not used)
JOINT
10% 1/6 [Test1 ] WHOLE *** *** [Test1 ] ***
Use shifted up, down arrows for next page [TYPE]
>
CLEAR
>
NOTE The program selected last with the list screen is automatically selected as the source program. 5 Specify the necessary items. 6 After specifying the items, go to the next screen with SHIFT + ↓. The representative point specification screen appears. To return to the previous screen, use SHIFT + ↑.
SHIFT
MIRROR IMAGE SHIFT Shift amount/Teach Position data X ***** Y *****
JOINT
Z
1
Rotation
2
Source position
P1
3
Destination position
Q1
[TYPE] CLEAR
10%
***** OFF
EXECUTE DIRECT
447
ON
OFF
> >
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7 For shift with rotation, set “Rotation” to Yes. MIRROR IMAGE SHIFT Shift amount/Teach Position data X ***** Y ***** 1
Rotation
2
Source position
3
Destination position
[TYPE]
JOINT
Z
10%
***** ON
EXECUTE
P1 P2 P3 Q1 Q2 Q3 ON
OFF
>
8 Specify representative source and destination points. For details, see the explanation of the program shift function. 9 After setting the shift amount, press F2, EXECUTE to execute the shift. [TYPE]
EXECUTE
F2 Execute transform? YES NO
F4 WARNING Avoid moving the robot to a position that is not correctly shifted. Check the shift results before moving the robot. Otherwise, serious problems can occur.
10 To erase all shift information, press F1, CLEAR on the next page.
CLEAR
TEACH
F1
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9.2.3 Angle--input shift function The angle--input shift function allows the user to perform a program shift by directly entering three or four representative points and an angular displacement. It also allows the user to perform multiple shifts at equal intervals on the same circumference at one time by specifying the iteration. If many locations on the same circumference are subject to the same machining, such as the holes on a car wheel, this function allows the user to create position data for all the locations to be machined by specifying only a single location. The angle--input shift function requires the following setup: Program name setting Program name setting specifies the name of the source program, the range of lines on which the shift is to be performed, as well as the name of the program into which the shift results are to be inserted and the line at which they are to be inserted. Shift information input Shift information input specifies the representative points for determining the rotation axis for the angle--input shift function and sets the angular displacement and shift iteration. The representative points can be specified in either of two ways: one in which the rotation axis is specified and one in which it is not specified. F If the rotation axis is not specified, three representative points (P1, P2, and P3) on the same circumference must be specified. With these three points, the rotation plane and axis are automatically calculated. The intersection of the rotation plane and axis (rotation center) is set as representative point P0. Rotation center P0, which is set automatically, can be changed directly later. From the second conversion on, the position of the rotation center can be compensated for by enabling the rotation axis. F If the rotation axis is specified, a point on the rotation axis must be specified for representative point P0 and any three points on the rotation plane must be specified for representative points P1, P2, and P3. (P1, P2, and P3 need not be on the same circumference.) The rotation plane is determined with representative points P1, P2, and P3. The axis that is vertical to the rotation plane and which passes through representative point P0 is determined as the rotation axis. In either way, the more distant the representative points P1, P2, and P3, the more precise the conversion. The direction of rotation is regarded as being positive when the rotation is from representative point P1 to P2. Figure 9--11. Specifying the Angle--Input Shift Function P0 P2 P2
Positive direction of rotation
Positive direction of rotation
P3
P1 P3 Rotation plane
P1
Rotation plane Rotation axis
Rotation axis
When the rotation axis is not specified
When the rotation axis is specified
To execute the angle--input shift function, use the angle--input shift screen ANGLE ENTRY SHIFT. The figure below shows how to navigate through the angle--input shift screen. Figure 9--12. Angle--Input Shift Screen Program name setting screen
SHIFT + ↓
SHIFT + ↑
Shift information input Shift amount setting screen
F2 EXECUTE Execution of the angle--input shift function
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The items on the program name setting screen are the same as those on corresponding screen for the program shift function. The shift amount setting screen contains the following items: Table 9--4.
Contents of the Shift Amount Setting Screen
Item Rotation plane
Rotation axis enable
Rotation axis
Angle
Repeating times
Description Specifies the positions of the representative points for determining the rotation plane. If the rotation axis is not specified, these points must be on the same circumference so that the rotation center can be calculated. If the rotation axis is specified, the representative points need not necessarily be on the same circumference. The positions must be specified with coordinates in the world coordinate system. Specifies how the rotation axis is to be determined from the representative points. The representative points must be specified differently depending on the setting made for this item. Specifies the position of representative point P0 for determining the rotation axis. This item is available only when Rotation axis enable is set to TRUE. Only representative point P0 can be specified directly with position data (numeric values) in any coordinate system. To specify P0 directly, position the cursor to this item and press the Enter key. The rotation axis direct specification screen appears. Specifies the angular displacement (in degrees) by which the shift is to be performed with the rotation axis and plane determined with the representative points. Enter an unsigned real number directly. (The plus sign need not be entered.) The direction of rotation is regarded as being positive when the rotation is from representative point P1 to P2. Specifies the conversion iteration. If the locations to be machined are arranged at equal intervals on the same circumference, specifying the iteration allows the user to machine all the locations by specifying a single location. If the iteration is 2 or greater, a comment line is automatically inserted at the beginning of the program resulting from the shift. Consider the following example: Source program: Program A 1:J P[1] 100% FINE 2:L P[2] 1500mm/sec FINE If conversion is performed with the “angular displacement” set to 20_, “iteration” set to 3, and “destination program” set to program B, program B will be as follows: Destination program: Program B 1:!Angle entry shift 1 (deg 20.00) 2:J P[1] 100% FINE 3:L P[2] 1500mm/sec FINE 4:!Angle entry shift 2 (deg 40.00) 5:J P[3] 100% FINE 6:L P[4] 1500mm/sec FINE 7:!Angle entry shift 3 (deg 60.00) 8:J P[5] 100% FINE 9:L P[6] 1500mm/sec FINE The position data in program B is as follows:
REFER
P[1]: Position resulting from rotating P[1] in program A by 20_ P[2]: Position resulting from rotating P[2] in program A by 20_ P[3]: Position resulting from rotating P[1] in program A by 40_ P[4]: Position resulting from rotating P[2] in program A by 40_ P[5]: Position resulting from rotating P[1] in program A by 60_ P[6]: Position resulting from rotating P[2] in program A by 60_ F4 REFER allows the use of a position variable or position register in the source program as the position of a representative point.
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Procedure 9--7 Condition Step
Executing the angle--input shift function
H The program on which the shift is to be performed exists. 1 Press MENUS. The screen menu appears. 2 Select 1, UTILITIES. 3 Press F1, [TYPE.] The screen switching menu appears. 4 Select Angle entry. The program name input screen appears.
1 UTILITIES 2 TEST CYCLE
ANGLE ENTRY SHIFT Program 1 Original Program: 2 Range: 3 Start line: (not used) 4 End line: (not used) 5 New Program: 6 Insert line:(not used)
MENUS
Angle entry
JOINT
10%
[
] WHOLE **** ****
[
] ****
Use shifted up, down arrows for next page
TYPE
F1
[TYPE]
>
CLEAR
>
5 Specify the necessary items. 6 After specifying the items, go to the next screen with SHIFT + ↓. The shift amount setting screen appears. To return to the previous screen, use SHIFT + ↑.
SHIFT
ANGLE ENTRY SHIFT Shift amount Position data of P1 X:*****.** Y:*****.**
1 2 3 4 5 6 7
JOINT
Z:*****.**
Rotation plane
P1: P2: P3:
Rotation axis enable: Rotation axis Angle(deg): Repeating times:
FALSE P0:Not used 0.00 1
[TYPE] CLEAR
EXECUTE
10%
REFER
RECORD >
>
7 For shift with the rotation axis specified, set “Rotation axis specification” to TRUE. If required, specify “Iteration.” 8 Specify the representative points.
REFER
SHIFT
RECORD >
1 2 3
Rotation plane
F5
451
P1:Recorded P2: P3:
9. UTILITIES
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9 For reference point input, press F4 REFER. Select F4 P[] or F5 PR[] to enter arguments.
REFER
RECORD >
1 2 3
Rotation plane
P1:Recorded P2:P[5] P3:
F4 P[]
PR[]
>
F4 10 Enter the angular displacement. 11 After setting the shift information, press F2 EXECUTE to execute the shift.
[TYPE]
EXECUTE
F2 12 If the turn number is changed due to the conversion, the user is notified and prompted to make a selection. Execute transform? YES NO
Repeat3:Select P[1]:J6 183° -177° uninit
(183°) QUIT
>
F4 13 F1 indicates the axial angle associated with the changed (optimized) turn number. F2 indicates the axial angle associated with the original turn number. F3 uninit causes the data to become unspecified data. F5 QUIT interrupts the conversion. Select one of the above keys. 14 To directly enter the position data for representative point P0, position the cursor to the P0 line and press the Enter key. The rotation axis direct specification screen appears. ANGLE ENTRY SHIFT JOINT 10% Shift amount Rotation center axis direct entry 1 Frame USER FRAME1 2 X: 0.00 3 Y: 0.00 4 Z: 0.00
[TYPE]
EXECUTE
[CHOICE]
CLEAR
> >
15 To specify the position of representative point P0 with numeric values in any coordinate system, position the cursor to line Frame and press F4 CHOICE. From the menu that appears, select the desired coordinate system.
[CHOICE]
>
F4 16 Provide the other necessary shift information has been set, press F2 EXECUTE to execute the shift.
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[TYPE]
EXECUTE
F2 Execute transform? YES NO
F4 17 To erase all the shift information, press NEXT, > then press F1, CLEAR.
CLEAR
TEACH
F1
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9.3 Coordinate System Change Shift Functions The coordinate system change shift functions changes the tool coordinate system (tool) or user coordinate system for the operation instructions within a certain range of an already taught program. It then converts the position data so that the TCP is located at the same position, considering the shift amount resulting from the change from the old to the new coordinate system. NOTE The coordinate system change shift functions allow the user to specify that the position data not be converted. Coordinate system change shift functions The coordinate system change shift functions perform the following: F
Change the tool coordinate system or user coordinate system number in the position data (Cartesian coordinates) for the operation instructions within the entire range or within a certain range of an existing program.
F
If the position data is joint coordinates, convert the coordinates considering the shift amount resulting from the tool change or user coordinate system change.
F
Insert the shift results into a new or existing program.
F
Execute the same shift on another program.
Position data conversion The following rules apply to converted position data: Rules for positions and attitudes: F
Position data with Cartesian coordinates is converted to Cartesian coordinates. Position data with joint coordinates is converted to joint coordinates.
F
If converted joint coordinate position data falls outside the variable axis area, it is stored as unspecified. Converted Cartesian coordinate position data is stored as is even if it falls outside the variable axis area.
F
Position data in the position registers is not converted.
F
Position data with joint coordinates for operation instructions involving incremental instructions is stored as unspecified.
Rules for the configuration (joint placement and turn number) of position data with Cartesian coordinates: F
The configuration is not changed due to conversion.
F
For the turn number, if the conversion causes rotation about the wrist axis by 180_ or more, the turn number for the axis is optimized, and a message appears so that the user can decide whether to accept it.
For the tool change shift functions, select the desired position data conversion method from the following: F
TCP fixed: The original position of the tool end point is preserved in the converted data. For example, TCP fixed is useful if the previously used hand was damaged and replaced by a new one. By setting the tool coordinate system number of the old hand for Old UTOOL number and the tool coordinate system number of the new hand for New UTOOL number and using a tool change shift function with TCP fixed, the TCP of the new tool is moved to the original specified point correctly.
F
Robot fixed: The original attitude of the robot (joint positions) is preserved in the converted data. For example, Robot fixed is useful if the program was taught in a tool coordinate system different from that used by the actually mounted hand and the correct tool coordinates are set later. By setting the tool number used when the program was taught for Old UTOOL number and the correct tool coordinate system number for New UTOOL number, and using a tool change shift function with Robot fixed, the program can operate in the correct tool coordinate system, with the same positions as the originals.
The coordinate change shift functions allow the user to specify whether to convert position data. F
Perform conversion: Position data is converted so that the TCP is located at the same position.
F
Do not perform conversion: Position data is not converted even if the coordinate system number is changed.
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Types of coordinate system change shift functions The following coordinate system change shift functions are supported: F
Tool change shift function: Changes the tool coordinate system number in the position data.
F
Coordinate change shift function: Changes the user coordinate system number in the position data.
To execute the coordinate system change shift functions, use the change shift screen TOOL OFFSET (UFRAME OFFSET). The figure below shows how to navigate through the change shift screen. Figure 9--13. Coordinate System Shift Screen Program name setting screen
SHIFT + ↓
SHIFT + ↑
Coordinate system number setting screen
F2 EXECUTE Execution of a change shift function
Procedure 9--8 Condition
Executing the tool change shift function
H The program on which the shift is to be performed exists.
TEST1
JOINT
1:J 2:J 3:L 4:L 5:J [End] POINT
Step
P[1] P[2] P[3] P[4] P[1]
ARCSTRT
30% 1/6
100% FINE 70% CNT50 1000cm/min CNT30 500m/sec FINE 100% FINE
WELD_PT
ARCEND
TOUCHUP >
1 Press MENUS. The screen menu appears. 2 Select 1, UTILITIES. 3 Press F1, [TYPE.] The screen switching menu appears. 4 Select Tool offset. The program name input screen appears.
1 UTILITIES 2 TEST CYCLE FCTN
Tool offset TYPE
F1
TOOL OFFSET Program 1 Original Program: 2 Range: 3 Start line: (not used) 4 End line: (not used) 5 New Program: 6 Insert line:(not used)
JOINT [Test1 WHOLE *** *** [Test2 ***
10% 1/6 ]
]
Use shifted up, down arrows for next page [TYPE] > CLEAR
>
5 Specify the necessary items.
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6 After specifying the items, go to the next screen with SHIFT + ↓. The coordinate system number setting screen appears. To return to the previous screen, use SHIFT + ↑. SHIFT
TOOL OFFSET UTOOL number 1 2 3
[TYPE]
JOINT
Old UTOOL number New UTOOL number Convert type
10% 1/6
1 2 TCP fixed
EXECUTE
>
CLEAR
>
7 Enter the current and new tool coordinate system numbers. To set F as the new tool coordinate system number, enter 15. 8 Press F2, EXECUTE to execute the shift.
[TYPE]
EXECUTE
F2 9 If the turn number is changed as a result of the conversion, the user is notified and prompted to make a selection. Select P[3]:J5 angle (183°) 183° -177° uninit
QUIT
>
10 F1 indicates the axial angle associated with the optimized turn number. F2 indicates the axial angle associated with the original turn number. F3 uninit causes the data to become unspecified data. F5 QUIT interrupts the conversion. 11 To erase all the shift information, press F-->“>” and press F1 1, CLEAR on the next page.
CLEAR
F1 CAUTION When the tool change shift function is performed, the tool coordinate system number selected by the system is changed to the new tool number.
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Procedure 9--9 Condition
Executing the coordinate change shift function
H The program on which the shift is to be performed exists. TEST1
JOINT
1:J 2:J 3:L 4:L 5:J [End] POINT
Step
P[1] P[2] P[3] P[4] P[1]
ARCSTRT
30% 1/6
100% FINE 70% CNT50 1000cm/min CNT30 500m/sec FINE 100% FINE
WELD_PT
ARCEND
TOUCHUP >
1 Press MENUS. The screen menu appears. 2 Select 1, UTILITIES. 3 Press F1, [TYPE] The screen switching menu appears. 4 Select Frame offset. The program name input screen appears.
1 UTILITIES 2 TEST CYCLE FCTN
Frame offset TYPE
UFRAME OFFSET Program 1 Original Program: 2 Range: 3 Start line: (not used) 4 Ene line: (not used) 5 New Program: 6 Insert line:(not used)
JOINT [Test1 WHOLE *** *** [Test2 ***
10% 1/6 ]
]
Use shifted up, down arrows for next page [TYPE] >
F1
CLEAR
>
5 Specify the necessary items. 6 After specifying the items, go to the next screen with SHIFT + ↓. The coordinate system number setting screen appears. To return to the previous screen, use SHIFT + ↑. SHIFT
UFRAME OFFSET UFRAME number 1 2 3
[TYPE]
JOINT
Old UFRAME number: New UFRAME number: Convert Position data (Y/N):
EXECUTE
1 2 YES
>
CLEAR
>
7 Enter the current and new user coordinate system numbers. To set F as the new user coordinate system number, enter 15. 8 Press F2, EXECUTE to execute the shift.
[TYPE]
10% 1/3
EXECUTE
F2
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9 If the turn number is changed as a result of the conversion, the user is notified and prompted to make a selection. Select P[3]:J5 angle (183°) 183° -177° uninit
QUIT
>
10 F1 indicates the axial angle associated with the optimized turn number. F2 indicates the axial angle associated with the original turn number. F3 uninit causes the data to become unspecified data. F5 QUIT interrupts the conversion. 11 To erase all the shift information, press F-->“>” and then press F1 CLEAR on the next page.
CLEAR
F1 CAUTION When the coordinate change shift function is executed, the user coordinate system number selected by the system is changed to the specified new user coordinate system number.
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9.4 Soft Float Function Usually, the robot moves accurately toward the goal specified using the teach pendant (taught point). When the robot is used to mount workpieces on a machine tool, variances in workpiece precision might result in a shift in the workpiece position relative to the tool, thus possibly causing interference between the workpiece and tool. A soft float function has been added which is effective in mounting workpieces with variances in precision onto a machine tool. The soft float function is also very effective if the synchronization speed is unstable as in the extraction of workpieces in sync with hydraulic extrusion, and if workpieces that the robot cannot grip accurately, such as rough--machined workpieces, are to be handled. Function The soft float function works as follows: F
Two types of soft float are supported: joint soft float for specifying the softness related to the direction of rotation of each arm of the robot, and Cartesian soft float for specifying the softnesses on the Cartesian axes.
F
The function is enabled/disabled using an instruction in the program. Its conditions are also specified using the instruction.
F
“Servo flexibility” can be specified for each axis. The term servo flexibility indicates how strongly the axis resists external forces. It is specified between 0% and 100%. A servo flexibility of 100% corresponds to being the most flexible. The servo flexibility is specified using a condition table that contains a set of data for one group (for nine axes).
F
If an external force above a certain level (so high as to overcome a static frictional force) is applied to a robot, the axis of the robot is pressed and moved.
F
An external force applied to a robot may prevent it from reaching the taught point. The distance between the taught point and the point the robot can reach is nearly proportional to the magnitude of the external force.
F
If static load is applied to a robot, the robot controls force to maintain its attitude even if the soft float function is enabled.
The detailed descriptions of the soft float function follow. Program instruction The following three program instructions related to the softfloat function are supported. SOFTFLOAT[n] The soft float function is enabled using condition n. * The setting of soft float condition is explained in “Condition setting menu”. SOFTFLOAT END The soft float function is disabled. FOLLOW UP When an external force is removed from a robot, it usually tries to go back to the taught point. However, this instruction causes the robot to assume that the current position is the taught point, and prevents it from going back to the taught point.
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Soft float function effective range The SOFTFLOAT[n] instruction can be used in two modes; in one mode it is used solely in a program and in the other mode it is used as an auxiliary motion instruction after a motion statement.The range in which the soft float function is effective for robot operation is determined according to the mode in which this instruction is used in. Sole instruction The soft float function is enabled after the end of the motion specified on the line preceding the solely specified SOFTFLOAT[n] instruction. In the following example, the soft float function is enabled after the motion specified on line 1 ends, and disabled by SOFTFLOAT END on line 5. 1: J P[1] 100% FINE 2: SOFTFLOAT[1] 3: L P[2] 100mm/sec FINE 4: L P[3] 100mm/sec FINE 5: SOFTFLOAT END P[1]
P[3]
P[2]
The soft float function is enabled. Auxiliary motion instruction The soft float function becomes enabled during execution of a motion statement attached with a SOFTFLOAT [n] instruction. The point at which the soft float function becomes enabled is determined by a soft float condition “Exec Start Ratio.” The exec start ratio is specified as the ratio (from 0% to 100% in 1% steps) of a distance to be traveled before the robot reaches the taught point corresponding to a motion statement attached with a SOFTFLOAT[n]. In the following example, the soft float function is effective between P[1] taught using a motion statement on line 1 and P[2] taught using a motion statement on line 2 attached with the SOFTFLOAT[n] instruction. 1: 2: 3: 4:
J P[1] 100% FINE L P[2] 100mm/sec FINE SOFTFLOAT[1] L P[3] 100mm/sec FINE SOFTFLOAT END
P[1]
P[3]
P[2]
100% 50% 0% The soft float function is enabled. NOTE The soft float start ratio is not supported by Cartesian soft float.
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Condition setting menu The soft float conditions are specified on the SETUP Softfloat menu, which consists of the following two menus. F
List menu
F
Detail menu
A function key is used to select either menu. -- Pressing the F3 (DETAIL) key on the list menu selects the detail menu. -- Pressing the F3 (LIST) key on the detail menu selects the list menu. Up to 10 conditions can usually be specified for the soft float function. List menu SETUP/SOFTFLOAT
JOINT 30%
Group 1 No
Start (%)
Comment
1
0
[
]
2
0
[
]
3
0
[
]
4
0
[
]
5
0
[
]
6
0
[
]
7
0
[
]
8
0
[
]
9
0
[
]
10
0
[
]
[ TYPE ] GROUP
DETAIL
F3, DETAIL
F3, LIST
Joint soft float details screen
Cartesian soft float screen
SOFTFLOAT (JOINT)
JOINT 30%
SOFTFLOAT (CARTES1A)
F5, CART
Group 1 1 Schedule No[
1]:[****************]
JOINT
Group 1 1 Schedule No[
1]:[
]
2 Exec Start Ratio :
0 %
3 Axis1 Soft Ratio : 4 Axis2 Soft Ratio :
0 % 0 %
DISABLE DISABLE
3 Coordinate:
5 Axis3 Soft Ratio :
0 %
DISABLE
4 X direction
[0]%
[0]%
6 Axis4 Soft Ratio :
0 %
DISABLE
5 Y direction
[0]%
[0]%
7 Axis5 Soft Ratio :
0 %
DISABLE
6 Z direction
[0]%
[0]%
8 Axis6 Soft Ratio : 9 Axis7 Soft Ratio :
0 % 0 %
DISABLE DISABLE
7 X rotation 8 Y rotation
[0]% [0]%
[0]% [0]%
10 Axis8 Soft Ratio :
0 %
DISABLE
9 Z rotation
[0]%
[0]%
11 Axis9 Soft Ratio :
0 %
DISABLE
[TYPE]
NUMBER
LIST
GROUP
LIST
JOINT
2 Enable/Disable:[DISABLE]
CART
F4, JOINT
>
[TYPE]
>
461
[WORLD] Soft Rat Soft Tol
NUMBER
LIST
GROUP
LIST
JOINT
CART
> >
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The following data can be specified on the detail menu. Table 9--5.
Setting items of Soft float detail menu
ITEMS
DESCRIPTIONS
Comment
Soft float condition number. By default, ten numbers can be set. Pressing the input key with the cursor on line 1 enables entering a comment. The comment text can be specified in the same way as on other menus.
Soft float start ratio
Line 2 specifies the point where the soft float function is enabled if the SOFTFLOAT [n] is used as an auxiliary motion instruction. See “Soft float function effective range” for the soft float start ratio.
Servo flexibility
Servo flexibility for each axis can be specified on line 3 and the subsequent lines. The servo flexibility indicates how strongly the axis resist external forces. It is specified between 0% and 100%. A flexibility of 100% corresponds to being the most flexible. Whether the soft float function is enabled/disabled can be specified for each axis on line 3 and the subsequent lines. Setting the cursor at the rightmost end (enabled/disabled setting position) of each line causes the F4 (ENABLE) and F5 (DISABLE) keys to appear. Use these keys to specify whether to enable/disable the soft float function. NOTE Pressing the F2 (NUMBER) key selects another page of the detail menu for other conditions. 10 Axis8 Soft Ratio :
0 %
DISABLE
11 Axis9 Soft Ratio :
0 %
DISABLE
[ TYPE ] NUMBER
LIST
>
10 Axis8 Soft Ratio :
0 %
DISABLE
11 Axis9 Soft Ratio :
0 %
DISABLE
[ TYPE ] NUMBER
LIST
ENABLE
DISABLE>
Enable/Disable
When this item is set to DISABLE, soft float cannot be executed.
Coordinate
Select one of WORLD, USER, and TOOL.
X direction
NOTE If the remote TP is used, USER indicates the coordinate system on the remote TCP. Set the softnesses on or around the X--, Y--, and Z--axes. If Soft Rat increases, the spring constant decreases, allowing the robot to move with less force. If Soft Tol increases, the maximum force and moment applied by the robot in that direction decreases, allowing the robot to move with less force. The difference between Soft Rat and Soft Tol is illustrated below. Force or moment Soft Tol
Soft Rat Position deviation
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Cautions/restrictions When using the soft float function, observe the following cautions/restrictions. F Restrictions imposed when the soft float function is enabled -- It is not guaranteed that the robot always follows the taught path. -- The taught route changes according to override. -- The required operation time may be prolonged compared with normal operation. F The soft float function is disabled automatically when: -- Program execution starts. -- Program execution ends. -- The program stops due to an alarm that turns off the servo. -- Jog feed is performed with the program at pause -- The program is restarted after the cursor is moved manually with the program at pause. -- Backward execution is performed. -- Power is applied F If the program is caused to pause, then restarted, the states of the soft float function (such as enabled/disabled and the soft float start ratio) are set to the conditions which exist before the program is caused to pause, except for the cases in the above operation, where the soft float function is disabled. F The soft float function cannot be enabled by any method other than the SOFTFLOAT instruction. F When the soft float function is enabled, the robot moves in the CNT 0 mode (no position check is made) even if FINE has been specified as motion statement positioning mode. F When the soft float function is enabled, if an external force causes the robot to move beyond a certain distance, the following servo alarms occur. -- If the robot is at rest : [SRVO--023 Stop error excess(G:i A:j)] -- If the robot is operating : [SRVO--024 Move error excess(G:i A:j)] F If an attempt is made to enable the soft float function with a brake applied, the brake is released automatically before the function is enabled. F When the soft float function is enabled, brake control is ineffective. F If the motion group mask in a program is [*,*,*,*,*] (there is no motion group), when the program issues instructions with the soft float function, the following alarm occurs: [INTP--216 (program name, line number) Invalid value for group number] F The range of motion with the soft float function enabled should be minimized. A weight balance may vary depending on the soft float ratio and travel distance, thus shifting the vertical axis upward or downward. The range of motion with an auxiliary motion instruction issued should also be minimized for the same reason. In addition, the speed of motion should be kept low. F When the soft float function is enabled, if follow--up processing requires more time than specified in system variable $SFLT_FUPTIM, the servo alarm or program pause alarm occurs. System variable $SFLT_ERRTP specifies which alarm to occur. $SFLT_FUPTIM Default value: 1000 (ms) This value varies from one system to another. The large value that does not cause an alarm during normal operation should be used.
F
$SFLT_ERRTYP Default value: 0 -- If 0, servo alarm “SRVO--111 Softfloat time out” occurs. -- If 1, Program pause alarm “SRVO--112 Softfloat time out” occurs. (The alarm number is different between the alarms.) The default value should be used unless turning the servo off invites any inconvenience in the system. When the soft float function is enabled, follow--up processing is normally performed for individual motion instructions. This processing is enabled or disabled according to system variable $SFLT_DISFUP.
$SFLT_DISFUP Default value: FALSE -- If FALSE, follow--up is performed at the start of each motion instruction in the program. -- If TRUE, follow--up is not performed for individual motion instructions in the program. F This function cannot be used with welding. NOTE Follow--up With the soft float function, external forces are applied to the robot so that it operates at positions slightly different from those specified. When the external force is removed after the completion of the operation, the robot usually attempts to move back to a specified point abruptly. Follow--up prevents this abrupt movement.
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9.5 Continuous Rotation Function The continuous rotation function allows continuous and limitless rotation about the final axis or an additional rotation axis of the robot in one direction. NOTE For example, the “final axis” refers to the J6 axis of a robot having six axes. For example, this function is useful for rotating those devices that require continuous rotation, such as conveyers, pumps, and grinders, about a robot axis or additional rotation axis. To specify the items for this function, such as disable/enable, use the SETUP Continuous T screen (new). The start and stop of continuous rotation are directed from a program. Before this function can be used, the setup necessary for continuous rotation must be performed. Only a single continuous rotation axis can be allocated for each operation group. The axis must satisfy the following conditions: F
Final axis of the robot
F
Final axis of the built--in additional rotation axes
F
Any of the normal additional rotation axes
F
Final axis of the independent additional axes
The continuous rotation axis must satisfy the following mechanical conditions: F
The mechanism must allow continuous operation (must be free of obstacles such as stoppers).
F
The gear reduction ratio (value of Numerator of Gear Ratio/Denominator of Gear Ratio on the setting screen, the speed of the motor required for one rotation about the axis) must be 4000 or less.
To use this function, an option (continuous rotation function) is required. Function When this function is enabled, the axis allocated as a continuous rotation axis allows limitless rotation. The angle on the axis is, therefore, represented by a relative degree within +180_, not by an absolute one. For example, the figure below shows rotation from 0_ to 200_ in the positive direction. The angle on the axis after the rotation is --160_, not 200_. Figure 9--14. Angle on the Continuous Rotation Axis 0 deg
+200 deg
--160 deg
When this function is enabled but continuous rotation is not performed (see the next page for an explanation of how to use continuous rotation), rotation is performed about the continuous rotation axis from the current angle to the target angle in whichever direction incurs the least amount of motion. (Usually, the direction of rotation about the axis is determined with the relationship between the current and target angles.) This “shorter--way operation” is effective in reducing the cycle time. Figure 9--15. Shorter--Way Operation Current angle Shorter way
Target angle
Target angle
Setup To use the function, F
Perform setup on the SETUP Continuous T screen and
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F
Specify the start/stop of continuous rotation with the operation add instruction, “continuous rotation speed instruction.”
Procedure 9--10 Step
Setting up the continuous rotation function
1 Press MENUS. The screen menu appears. 2 Select SETUP. 3 Press F1, [TYPE] The screen switching menu appears. 4 Select Cont Turn. The continuous rotation setup screen appears.
5 I/O 6 SETUP 7 FILE
SETUP Continuous T 1 2 3 4
MENUS
Cont Turn
JOINT
Group:1 Continuous Turn Axis Num Numerator of Gear Ratio Denominator of Gear Ratio
[TYPE]
: : :
10%
0 0 0
DONE
TYPE
F1 5 Specify the necessary items using the numeric and other keys. F
To disable the continuous rotation function, set “0” for Continuous Turn Axis Num.
F
The maximum value for Numerator of Gear Ratio and Denominator of Gear Ratio is 32766.
F
Set the operation group number for Group. If a different number (number of the operation group to be viewed) is entered in this field, the other settings are changed to those of the operation group.
6 After specifying the items, press F4 DONE. The following message appears.
DONE
F4 7 Turn off the power, then turn it back on with a cold start. The items on the continuous rotation setup screen are described below. Table 9--6.
Contents of the Continuous Rotation Setup Screen Item
Description
Group Continuous Turn Axis Num
Set the operation group number. Set the number of the continuous rotation axis. If “0” is set, this function is disabled for the operation group. Set the gear reduction ratio for the continuous rotation axis set for the above item. A value from 0 to 32766 can be set for each item. The items must, however, satisfy the following: Numerator of Gear Ratio÷Denominator of Gear Ratio≦4000
Numerator of Gear Ratio Denominator of Gear Ratio
Using the function After setting up the continuous rotation axis, specify the start point of continuous rotation using the operation add instruction, “continuous rotation speed instruction.” The following “continuous rotation speed instruction” is supported. The “continuous rotation speed instruction” must be specified as an operation add instruction. * The specification method is the same as that for other operation add instructions, and is therefore omitted. (See Section 5.3.4, “Specifying operation add instructions.”) F
Continuous rotation speed instruction CTV * where i = --100 to 100, which is the ratio of the rotation axis speed to the maximum axis speed (%)
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Starting continuous rotation Continuous rotation is started as soon as an operation statement with a continuous rotation speed instruction added is started. Stopping continuous rotation Continuous rotation is stopped when the first operation statement with no continuous rotation speed instruction added is started since a continuous rotation speed instruction was started. When continuous rotation is stopped, the operation on the other axes for the same operation group also terminates. The robot, therefore, decelerates even if the positioning format for the previous operation is CNT. The robot starts decelerating to stop on the continuous rotation axis after it has completely stopped on the other axes. At this time, the robot is not necessarily at the specified position on the continuous operation axis. Thus, the synchronization of the operation on the continuous rotation axis with the operation on the other axes (including those for other operation groups) is lost. If an operation statement is specified next, the robot rotates in the same direction as the previous continuous rotation direction to move to the specified position. Notes F
Continuous rotation continues even if logic instructions (instructions other than those in operation statements) are executed.
F
During program playback, the turn number for the continuous rotation axis is ignored, and is always assumed to be “0.”
F
The turn number for the continuous rotation axis at a point specified when this function is enabled is always stored as “0.”
F
If the rotation axis speed for a continuous rotation speed instruction is specified as “0,” continuous operation is not performed. If an operation statement is specified next, shorter--way operation is performed on the continuous rotation axis. This feature is useful if continuous rotation about the continuous rotation axis is to be stopped temporarily but temporary stop of the robot due to the end of the continuous rotation is to be avoided. (See the next section, “Example of use.”)
F
In single--step execution (both forward and backward), continuous rotation is not performed even if a continuous rotation speed instruction is added; shorter--way operation is performed.
F
Continuous rotation stops due to a hold. If program execution is subsequently restarted, if the target position has already been reached on axes other than the continuous rotation axis, continuous rotation is not performed. If the target position has not been reached on axes other than the continuous rotation axis, continuous rotation is restarted.
F
Continuous rotation about the continuous rotation axis is possible from jog feed.
Example of use The following shows an example of using the continuous rotation speed instruction. 1:J P[1] 100% 2:J P[2] 100% 3:J P[3] 100% 4:J P[4] 100% 5:J P[5] 100% 6:J P[6] 100% 7:J P[7] 100% 8:WAIT 100.0sec 9:J P[8] 100%
FINE CNT100 CTV100 FINE CNT100 CTV100 FINE CTV100 FINE FINE CTV100 FINE
F
Description of lines 1 to 3: During operation from P[1] to P[2], continuous operation is performed. Although the positioning format specified on line 2 is “Smooth,” the robot decelerates (stops temporarily on all axes at the start of the operation on line 3) because a continuous rotation speed instruction is not added to the next line, line 3.
F
Description of lines 4 to 5: Continuous rotation starts as soon as the execution of line 4 starts. Because the rotation axis speed specified with the continuous rotation speed instruction on line 5 is 0, continuous rotation stops temporarily at the start of the execution of line 5. Because continuous rotation continues, the positioning format CNT100 on line 4 is valid and the robot does not decelerate. When line 6 is executed, shorter--way operation is performed on the continuous rotation axis.
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F
Description of lines 7 to 9: Continuous rotation starts at the start of operation on line 7. Continuous rotation continues during the execution of the wait instruction (logic instruction) on line 8. The robot stops temporarily on all axes at the start of operation on line 9, and continuous rotation stops.
Notes/restrictions Note the following when using this function: F
When continuous rotation is to be performed on a robot axis or built--in additional axis, The X and Y components of the tool coordinate system must both be 0. (Only the Z--axis component can have a value other than 0.) If this condition is not satisfied, the path of linear or arc operation cannot be guaranteed in normal operation other than continuous rotation.
F
This function cannot be used together with the following functions: -- Asynchronous addition axis speed instruction. (The synchronous additional axis speed instruction can be used.) -- Arc sensor -- Weaving -- TCP speed estimation function (sealing flow rate control)
F
This function automatically updates the mastering data (for the continuous rotation axis only) according to the amount of rotation about the continuous rotation axis. Thus, previously recorded mastering data may not match the current mastering data. After this function is disabled, it is not necessary to perform mastering.
F
When this function is disabled, the current position on the continuous rotation axis may fall outside the stroke limits. If this occurs, move the position on continuous rotation axis within the stroke limits using jog feed or a program.
F
If, on a multigroup system, the settings on the SETUP Continuous T screen are changed and the F4 DONE key is pressed, it is necessary to set system variable $PARAM_GROUP[group].$SV_OFF_ENBL[i] (where i is an axis number) to FALSE to disable break control for all the axes for all operation groups before turning the power back on with a cold start.
F
On a multigroup system, even if there are multiple continuous rotation axes, separate continuous rotation speeds cannot be specified for them.
F
At the end of continuous rotation, one or more rotations about the continuous rotation may be performed to ensure smooth deceleration and stop. (The amount of rotation differs depending on the acceleration/deceleration constant.)
F
Even during backward execution (single--step execution), shorter--way operation is performed on the continuous rotation axis. If, therefore, forward step execution and backward execution are performed sequentially in an operation statement with the movement angle being very close to 180_, rotation may be performed about the continuous rotation axis in the same direction during the forward and backward executions.
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9.6 Position Register Look--Ahead Execution Function While the robot is executing a program, it reads the lines ahead of the line currently being executed (look--ahead execution). Conventionally, look--ahead execution was performed for motion statements having normal position data (not using position registers). Look--ahead execution could not be performed for motion statements that used position registers for their position data. Motion statements using position registers could not be read in advance because the values in the position registers could be changed by the program, data transfer function, and so forth. * If the robot reads a motion statement using a position register prior to its execution, the value of the position register may yet be changed by a program or another function (such as data transfer). Such a change is not reflected in the motion statement that has already been read by the robot. Consequently, the robot’s operation might be unpredictable. Motion statements that use position registers can be classified into two types: F
Motion statements with the target position specified by a position register
F
Motion statements with an offset instruction where an offset is given by a position register
Even when a target position or offset is calculated during program execution, and a position register holding this calculation result is used with a motion statement, look--ahead execution was not performed for the statement, for the reason explained above. The position register look--ahead execution function enables look--ahead execution for position registers. For this purpose, an instruction to lock position registers and an instruction to unlock the registers are newly provided. By means of these instructions, the user can explicitly specify a program portion. Then, for the specified program portion, even when it contains motion statements that use position registers, look--ahead execution can be performed. Function The position registers can be locked to prevent their contents from being changed after they are read. When an attempt is made to execute an instruction to change a locked position register (for example, an assign instruction for the position register, or an application instruction to set data in the position register), the following alarm message is issued: [INTP--128 Pos reg is locked] When a function (such as the data transfer function) other than the program attempts to change the value of a locked position register, the following alarm message is issued, and the attempt fails: [VARS--053 Pos reg is locked] Position registers are generally locked and unlocked with instructions taught in a program. When a program that has locked the position registers terminates, the position registers are unlocked automatically. All position registers are locked simultaneously. While the position registers are locked, access to any position register is disabled, even in a different motion group. NOTE Before using position register instructions, lock position registers. When position register instructions are used with the position registers unlocked, operation may become tight.
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Operation The following program instructions have been added: LOCK PREG Locks all position registers. This instruction prevents any change being made to any position register. UNLOCK PREG Unlocks the position registers. These are control instructions (not motion instructions). They can be taught in the same way as other control instructions (See Section 5.3.5, “Teaching a control instruction”). Example The following shows how to use the LOCK PREG and UNLOCK PREG instructions in a program: 1: J P[1] 100% FINE 2: PR[1]=PR[2] 3: PR[2]=PR[3] 4: LOCK PREG 5: L P[2] 100mm/sec Cnt100 6: L P[3] 100mm/sec Cnt100 7: L PR[1] 100mm/sec Cnt100 8: L P[4] 100mm/sec Cnt100 offset, PR[2] 9: L P[5] 100mm/sec FINE 10: UNLOCK PREG When line 4 of this sample program has been executed, the position registers are locked. They are unlocked when line 10 has been executed. Therefore, the motion statements with position registers in lines 7 and 8, which are executed with the position registers locked, are subject to look--ahead execution. If the program is terminated between lines 4 and 10, the locked position registers are unlocked automatically. If the program is paused between lines 4 and 10, the cursor is moved manually, then the program is restarted, the locked position registers are unlocked. In this case, look--ahead execution is not performed for the statements in lines 7 and 8. NOTE When back execution is performed, then normal execution is restarted, the position registers are unlocked. For example, suppose that program execution is paused during the execution of line 6, back program execution is performed up to line 5, then forward program execution is restarted. In this case, the position registers are unlocked. So, look--ahead execution is not performed for lines 7 and 8. When program execution is started from a line located after line 4, the position registers are not locked. So, look--ahead execution is not performed for lines 7 and 8. A LOCK PREG instruction can be executed even when the position registers are already locked. (Nothing occurs, however, when the LOCK PREG instruction is executed for a second time.) Similarly, the UNLOCK PREG instruction can be executed even when the position registers are not locked. (Nothing occurs, however, when the UNLOCK PREG instruction is executed for a second time.) Notes Note the following when using this function: F
The LOCK PREG and UNLOCK PREG instructions are not executed in backward program execution mode.
F
Look--ahead execution is not performed for the LOCK PREG and UNLOCK PREG instructions. This means that when one of these instructions is encountered, look--ahead execution is stopped temporarily; after the instruction is executed, look--ahead execution is again enabled.
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9.7 Operation Group DO Output Function The operation group DO function outputs information about the operation groups that are capable of jog feed, and about the operation groups of the programs being executed/temporarily stopped, to an external device with a digital output signal (SDO) or robot output signal (RDO). This allows devices other than the teach pendant to recognize the currently effective operation groups, thus improving safety. This function is effective when the multigroup option is used. Function This function allows the allocation of two DOs (jog signal and program signal) to a single operation group. For DOs, any digital output signals or robot output signals of the robot can be used. Each allocated DO signal turns on/off under the following conditions: Jog signals When the teach pendant is disabled, all signals turn off. When the teach pendant is enabled, the signal for the currently selected operation group on the teach pendant turns on, while the other signals turn off. Program signals Regardless of whether the teach pendant is enabled or disabled, the signal for the operation group of the program currently being executed/temporarily stopped turns on. (The signal does not turn on when the program is merely selected.) If other programs are being executed/temporarily stopped with the multitask option, the signals for the operation groups of these programs also turn on. Setup To set up the operation group DO output function, use the [Set up operation group DO] screen. To change the signal number for an operation group, move the cursor to the signal number and enter a new value. Motion group DO GROUP NO. PROGRAM 1 2 3
RO[1] DO[3] RO[0]
JOINT
10%
JOG RO[2] DO[3] RO[0]
[TYPE]
RO
DO
To change the type of a signal, position the cursor to the signal number and press function key F4 “RDO” or F5 “SDO.” To disable a signal, set the number of the signal to “0.” The same signal can be set for both the program and jog signals for the same operation group. In this case, the output signal is the OR of the two signals. That is, the signal turns on if either the program or jog signal turns on. (The signal turns off only if both the program and jog signals turn off.)
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Example of using this function with the multitask option This section explains the operation of this function when a subprogram call or the multitask option is used. The output program signal is the OR of the signals for all the operation groups of the program currently being executed/temporarily stopped. If a program without an operation group calls a program having an operation group by using a subprogram call, the signal for the operation group of the subprogram turns on only while the subprogram is being executed. (The signal does not turn on when the main program without an operation group is merely selected/executed.) If the execution instruction of the multitask function is to start another program that operates the robot (the main program that has the execution instruction does not have an operation group), the signal for the operation group of the program started by the execution instruction does not turn on when the main program is merely selected/executed. The program signal turns on when the program that operates the robot is actually started. Consider the following three example programs: PROGRAM MAIN : Operation group[*,*,*,*,*] 1:RUN PRG A 2:RUN PRG B : PROGRAM PRG A : Operation group[1,*,*,*,*] 1:J P[1] 100% FINE : PROGRAM PRG B : Operation group[*,1,*,*,*] 1:L P[1] 500mm/sec CNT100 : Program MAIN, which does not have an operation group, starts PRG A and PRG B having operation groups by using execution instructions. PRG A uses operation group 1 and PRG B uses operation group 2. F
The program signals for the groups do not turn on when program MAIN is merely selected.
F
When line 1 of MAIN is executed, PRG A is started and the signal for operation group 1 turns on.
F
When line 2 of MAIN is executed, PRG B is started and the signal for operation group 2 turns on.
F
When PRG A and PRG B terminates, the respective signals for operation groups 1 and 2 turn off.
Notes Note the following when using this function: F
The same signal cannot be defined for different operation groups.
F
While a program is being executed/temporarily stopped, the type (SDO or RDO) and number of the program signal cannot be changed.
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9.8 Pre--Execution Instruction Function This function calls and executes a subprogram before or after the specified time at which robot operation is to terminate. For example, if a signal output instruction is specified in a subprogram, this function allows a signal to be output during robot operation. It can also eliminate the wait time associated with the transfer of data to and from peripheral devices, thus reducing the cycle time. Function This function allows a main program to call and execute a subprogram before or after the specified operation termination time. Using an instruction in a program, specify the time at which a subprogram is to be called (in seconds). (This specified time is called the execution start time.) The time at which operation terminates is assumed to be 0 seconds, which differs depending on the positioning type FINE CNT. Using an instruction in a program, specify the name of the subprogram to be called. The pre-- (or post--) instruction is an operation add instruction. Both the subprogram name and execution start time must be specified with the operation add instruction. Instruction statement Specify the execution start time and subprogram after an operation statement. Figure 9--16. Pre--Execution Instruction (Operation Add Instruction) Operation statement
TIME BEFORE TIME AFTER TIME BEFORE TIME AFTER
Example
execution-start--time
CALL
subprogram--name
Executes the subprogram before operation termination. Executes the subprogram after operation termination.
1:J P[1] 100% FINE :TIMIE BEFORE 1.0sec CALL OPEN HAND 1:J P[1] 100% FINE :TIMIE AFTER 1.0sec CALL OPEN HAND
Description of execution start time According to the specified execution start time, the subprogram is executed at the following time: If execution start time, “n” seconds, is specified with a pre--execution instruction, the subprogram is executed n seconds before operation termination. Figure 9--17. Timing of Subprogram Execution (Pre--Execution Instruction) <---- Robot operation ---->
n <-----------------------> Start of subprogram execution
If execution start time, “n” seconds, is specified with a post--execution instruction, the subprogram is executed n seconds after operation termination.
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Figure 9--18. Timing of Subprogram Execution (Post--Execution Instruction) <---- Robot operation ---->
n --------> ----> Start of subprogram execution
If the execution start time specified with a pre--execution instruction exceeds the operation time, the subprogram is executed as soon as operation starts. Figure 9--19. Timing of Subprogram Execution (Pre--Execution Instruction) <---- Robot operation ---->
n <-------------------------------------------------> Start of subprogram execution
The execution start time that can be specified in a program is -- 0 to 30 seconds for a pre--execution instruction -- 0 to 0.5 seconds for a post--execution instruction CAUTION Even if the robot operation time is changed due to a change in the override, the time at which subprogram execution is to start depends on the execution start time. The execution start position of the subprogram is, therefore, changed due to a change in the override.
If 0 seconds is specified, the subprogram is executed at almost the same time as when the pre--execution instruction is not specified. Search/replace functions Search function By selecting a CALL program for a search item CALL, the search function searches for the call instructions of pre--execution instructions. Replace function F
By selecting a replace item TIME BEFORE/AFTER, TIME BEFORE/AFTER replacement and execution start time replacement can be performed.
F
By selecting a CALL program of replace item CALL, the subprogram names for pre--execution instructions can be replaced.
Single step When an operation statement with an execution start time adjustment instruction specified is executed in single--step mode, operation stops temporarily at the time when the subprogram is called. Subsequently, the rest of the operation is executed in sync with single--step execution of the subprogram. Power failure handling If power failure handling is enabled and the power is removed during subprogram execution, execution starts with the remaining instructions of the subprogram due to a restart after the power is turned on again. In this case, the subprogram is executed with the position the robot was located when the power was removed. Thus, the subprogram is executed with timing different from the usual timing. Great care must be taken regarding this point.
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Procedure 9--11 Step
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Specifying the pre--execution instruction
1 Position the cursor on the operation add instruction specification area (space following an operation instruction).
PNS0001 1:J [End]
JOINT P[1]
10% 1/2
100% FINE
[CHOICE]
2 Press function key F4 CHOICE. A list of operation add instructions appears.
Motion Modify 1 2 3 TIME BEFORE 4 TIME AFTER PNS0001
JOINT
10%
5 6 7 8 1/2
1:J [End]
P[1]
100% FINE
[CHOICE]
3 Select item TIME BEFORE.
PNS0001
JOINT
10% 1/2
1:J P[1] 100% FINE :TIME BEFORE sec ... [End] Enter value [CHOICE]
4 Specify the time and press the Enter key. Example: 2 seconds.
TIME statement 1 CALL program 2 3 4 PNS0001
JOINT
10%
5 6 7 8 1/2
1:J P[1] 100% FINE :TIME BEFORE 2.0sec [End] Select item [CHOICE]
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5 Select item CALL program. PROGRAM list 1 Open hand 2 Close hand 3 4 PNS0001
JOINT
10%
5 6 7 8 1/2
1:J P[1] 100% FINE :TIME BEFORE 2.0sec, CALL [End] Select item STRINGS
6 Select item Open hand. PNS0001
JOINT
10% 1/2
1:J P[1] 100% FINE :TIME BEFORE 2.0sec, CALL Open hand [End]
[CHOICE]
Program example Main program: PNS0001 1:J P[1] 100% FINE 2:J P[2] 100% CNT100 :TIME BEFORE 1.0sec CALL Open hand 3:CALL Close hand Subprogram: Hand open 1:SDO[1]=On Operation performed when the main program is executed Figure 9--20. Program Example Using a Pre--Execution Instruction Turn SDO [1] on one second before arrival at P[2]
P [1]
------>
------>
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Notes/restrictions In the subprogram specified for Call, operation statements cannot be specified. (The operation group in the subprogram must be [*, *, *, *, *].) Until the execution of the called subprogram terminates, the next instruction in the main program is not executed. No limit is imposed on the number of instructions that can be specified in a subprogram. The TIME BEFORE/AFTER add instructions can be used together with other operation add instructions (except application instructions such as spot [] and skip instructions). If the positioning specification for an operation statement is Smooth, the time of operation termination changes depending on the degree of Smooth. The time at which the subprogram is called changes accordingly. Depending on the situation, even if the execution time is set to 0 seconds with a pre--execution instruction, the subprogram may be executed too quickly. If this occurs, use a post--execution instruction. If a pre--execution instruction is specified on the last line of a main program, the execution of the main program may terminate before the subprogram is called, in which case, the subprogram is not called. Do not, therefore, specify a pre--execution instruction on the last line of a program. For direct specification of signal output, only SDO, RDO, GO and AO are supported.
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9.9 Distance before operations 9.9.1 Overview This function calls program or outputs signal when TCP is going into a region which is within specified distance from destination point. This program call and signal output is done on a parallel with main program execution. Example 1 J P[1] 100% FINE 2 L P[2] 1000mm/sec FINE DB 100mm,CALL A Figure 9.9.1 Execution timing of Distance Before
100mm P[2]
P[1]
Program A is executed on a parallel with motion to P[2].
9.9.2 Specification Item
Specification
Limitation Distance value and actual execution timing is different.
Distance value
0.0 to 999.9[mm]
Trigger condition (*1)
TCP goes into a region, which is within specified distance from destination point.
The error depends on speed of TCP.
Please refer to Chapter 4 for details. Available instructions
F F
Signal output (ex. SDO[1] = ON) CALL program
Distance value and actual execution timing is different. The error depends on speed of TCP. Program to be called cannot use motion group. Only logic instruction is available.
NOTE (*1) This is condition to precess instruction part.
9.9.3 Configuration Before using Distance Before, set following system variable. $SCR_GRP[1].$M_POS_ENB = TRUE
9.9.4 Instruction 1 Format Distance Before is taught in following format. Motion statement + DB distance value, instruction part Example L P[2] 1000mm/sec FINE DB 100mm, CALL A Instruction part (Please referr to 3.) distance value (Please refer to 2.)
CAUTION Distance Before is a motion option. You cannot use DB as a standard instruction.
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2 Distance value (i) Distance value Distance Before executes instruction part when TCP goes into a spherical region whose center is destination point. Distance value decides the radius of this sphere. Distance value is taught in millimeter. Distance value is from 0 to 999.9mm. This sphere is referred as trigger region hereafter. 1: 2:
L P[1] 2000mm/sec FINE DB 100.0mm L P[2] 2000mm/sec FINE DB 100.0mm
SDO[1] = ON SDO[1] = ON
Figure 9.9.4 (a) Cyclical checks if TCP goes into trigger region.
Robot controller recognizes TCP is in trigger region. DO[1] turns ON here.
A
100mm
P[2]
P[1]
Internal check point of current position
Internally, Robot controller calculates current position to judge if TCP is in trigger region or not. Instruction part is executed when this calculated position is in trigger region. CAUTION Execution timing of instruction part is decided by distance (in millimeter). Because judgement to trigger is done by calculating distance between current position and destination point, actual execution timing is different from distance value. (Error in case of 2000mm/sec is estimated around 16mm)
(ii) Radius of trigger region. Radius of trigger region is as follows. Radius = (distance value or $DB_MINDIST)+$DB_TOLERENCE Figure 9.9.4 (b) The size of trigger region Minimum radius: $DB_MINDIST ( default value : 5.0mm) distance value: 0 to 999.9mm
Mergin to trigger : $DB_TOLERENCE ( default 0.05mm)
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If distance value is less than $DB_MINDIST, $DB_MINDIST is used as distance value. Example
Suppose following motion statement is taught with $DB_MINDIST = 5.0 L P[1] 2000mm/secFINE DB 0.0mm DO[1]=ON
In this case, Robot controller interprets it as DB 5.0mm.Then $DB_TOLERENCE is added to decide radius of trigger region. Consequently, radius of trigger region is 5.05mm with default system variables. 3 Instruction part This part shows what is done when TCP goes into trigger region. DB can do following action. F
CALL program
F
Signal output
(i) DB Call program Specified program is executed when condition is triggered. Program to be called cannot use motion group. (Change group mask to [*,*,*,*,*] in program header information screen.) You can use arguments to call program. Example) L P[2] 1000mm/sec FINE DB 100mm, CALL A (1,2) (ii) DB signal output You can teach following signal output. You can use one signal output for one DB. ON SDO[] RDO[]
=
OFF R[] pulse
GO[] AO[]
Constant =
R[] AR[ ]
You can also output signal by calling program which use signal output instruction. But to output only one signal with one DB, this direct signal output is better. It’s easier to read and maintain. 4 Changing trigger condition Instruction part is executed when Robot controller recognizes that TCP is in trigger region. But in some cases like following “going away” and “penetrate”, robot controller doesn’t recognize that TCP is in trigger region. These cases are described in this section. Case 1 Trajectory of CNT motion doesn’t go through trigger region.(“going away”)
P[2] P[1]
P[3]
Internal check point for DB trigger condition
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Case 2 Trigger region is too small for controller to check current position in time.(“penetrate”)
P[2]
P[1]
P[3]
Internal check point for DB trigger condition
For these case, the condition for instruction part to be executed (referred as DB condition) is changed by $DB_CONDTYP. $DB_CONDTYP
DB condition
When alarm is posted.
0
TCP is in trigger region. (“region trigger”) + end of motion (*2)
“going away” +“penetrate” +end of motion
1 (default value)
“region trigger” +“going away” +“penetration” +end of motion
end of motion +(“going away”) (*1)
2
“region trigger ”+“penetration” +end of motion
“going away” end of motion
“going away” and “penetration ” is defined in (i), (ii) and (iii) respectively. Distance Before executes instruction part when DB condition is satisfied. Otherwise, posts alarm. There are two alarms for not--triggered DB. They are INTP--293 and INTP--295. $DBCONDTRIG decides which alarm is posted. Message is same but severity is different. Please refer to 5 for details. NOTE
(*1) When Distance Before is triggered by “going away” in case of $DB_CONDTYP = 1, you can post alarm in addition to execution of instruction part. Please refer to 4 (i) for details. (*2) By default configuration, if motion statement with Distance Before completes and robot stops before neither “region trigger” nor “going away” nor “penetration” trigger happens, Distance Before executes instruction part and post alarm. Please refer to 4 (iii).
(i) In case of going away. If termination type is CNT and distance value is small, TCP may not go into trigger region. Figure 9.9.4 (c) TCP doesn’t go into trigger region. Before this point, TCP was gradually approaching to destination point
L1 mm to P[2]
L2 mm to P[2]
P[2] P[1] At this point, Robot controller thinks that TCP is going away from destination point.(L1
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In case of Fig. 9.9.4 (c), TCP doesn’t go into trigger region. TCP starts to go away from destination point (P[2]). Robot controller cyclically judges if TCP is going away from destination point or not in addition to DB condition. Robot controller recognizes that TCP is going away when calculated distance between current position and destination point is greater than previous one by more than ($DB_AWAY_TRIG) millimeter. This case is referred as “going away” in this manual. F
To post alarm in addition to execution of instruction part only when the DB is triggered by “going away” trigger, set $DB_AWAY_ALM to TRUE. DB executes instruction part and post following alarm. INTP--295 (program name, line number) DB too small (away)(%dmm) This is warning.
(ii) Penetration This function cyclically checks if DB condition is triggered or not. Because of this cyclical check, CNT motion with high--speed may cause for Robot controller to omit cyclical check in small trigger region. See Fig.9.9.4 (d). Figure 9.9.4 (d) Penetration
At this point, robot controller recognizes that TCP went through trigger region.
P[1]
P[3]
P[2]
Internal check point for DB trigger condition In this case, TCP moves too fast for the robot controller to check DB condition in small trigger region. Because cyclical check is done outside of trigger region, the fact TCP is in trigger region is not recognized by the robot controller.This case is referred as “ penetration” in this manual. To handle cases like Fig. 9.9.4 (d), Distance Before checks if TCP went through trigger region or not. If trajectory of TCP penetrated trigger region (penetration), instruction part is executed by default configuration. But in this case, execution of instruction part is done after TCP passed away destination point. F
Motion with termination type FINE doesn’t cause trigger by “penetration”.
(iii) End of motion If motion statement with DB completes and robot stops before “region”,“going away” and “penetration” is satisfied, DB executes instruction part and post following alarm. INTP--297 (program name, line number) DB too small (done) (mm). This alarm is not posted by FINE motion. If you don’t want this trigger, set $DB_MOTNEND to FALSE (default value:TRUE). Distance displayed by this alarm is distance to destination. CAUTION If you stop your robot by E--stop when motion statement is about to complete, Distance Before may be trigger just after resume of the program.
CAUTION If you halt a program when motion statement with DB is near its completion, DB may not be triggered. In this case, Distance Before executes its instruction part after resume of program.
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5 Alarms for not --triggered Distance Before Distance Before posts alarm if condition is not triggered. What is posted depends on $DBCONDTRIG. Alarm to be posted
$DBCONDTRIG 0 (default value)
INTP--295 WARN (Program name, line number)DB condition was not triggered.
1
INTP--293 PAUSE.L (Program name, line number)DB condition was not triggered.
By default configuration, INTP--295 is posted. Because severity of this alarm is WARN, execution of program doesn’t stop. If you want to halt program when condition was not triggered, set $DB_CONDTRIG to 1.INTP--293 is posted when condition was not triggered. Program is halted for severity of this alarm is PAULSE.L .Robot decelerates to stop. Displayed distance is recommended value for the DB to be triggered by region trigger. 6 Step execution If Distance Before CALL program is executed by step execution, program is halted at the timing sub program is called. The rest of motion statement is done by next step execution that executes sub program step by step. Step execution of motion statement with DB signal output is just same as motion statement with out DB except signal output is done. CAUTION If distance value is small, program may be halted before completion of motion and before DB conditions are satisfied. In this case, Distance Before is not triggered by step execution of the line it is taught. The DB is triggered by execution of next line.
7 Halt and resume Halt and resume of motion statement with DB changes its radius of trigger region. After resume, radius of trigger region is changed to minimum radius ($DB_MINDIST +$DB_TORELENCE). The purpose of this process is to execute instruction part after TCP reaches to its destination point.This prevents earier trigger because of halt and resume. This means that halt and resume of program changes trigger timing of Distance Before. Not to change radius of trigger region, set $DISTBF_TTS to 0 (default value: 1). Example Default configuration Suppose following program is executed. 1: L P[1] 2000mm/sec FINE 2: L P[2] 2000mm/sec CNT100 DB 100.0mm CALL SUB 3: L P[3] 2000mm/sec CNT100
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Figure 9.9.4 (e) Trigger timing after resume of program.
If there is no halt, DB executes instruction part here. But now DB doesn’t for trigger region is now small because of change of radius.
P[1]
P[2] Halt
TCP doesn’t reach trigger re-
P[3]
Example
gion because radius of the region is changed. DB is triggered here by “going away” trigger
Resume with $DISTBF_TTS = 0
Figure 9.9.4 (f) $DISTBF_TTS = 0
Here DB is triggered as usual. P[2] P[1]
Halt
P[3]
8 Resume after JOG If you halt motion statement with DB, JOG robot and resume program, execution timing depends on TCP position at the instant of program resume. Because this procedure is accompanied by program halt, execution timing depends on $DISTBF_TTS, too. (i) Default configuration ($DISTBF_TTS = 1) After resume of program, radius of trigger region changed to minimum value ($DB_MINDIST +$DB_TOLERENCE). If TCP is in new (diminished) trigger region, DB is triggered just after resume of program. If not, DB is triggered when DB condition is satisfied. Example
Suppose following triggered yet. 1: L P[1] 2000mm/sec 2: L P[2] 2000mm/sec 3: L P[3] 2000mm/sec
program is executed and halted on line two. DB condition is not FINE CNT100 DB 100.0mm DO[1] = ON CNT100
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Figure 9.9.4 (g) Resume after JOG
DB condition is not satisfied here. At point A, SDO turns ON. After halt, move TCP by JOG
Halt P[1]
Just after program resume, DB condition is satisfied. DB is triggered.
Resume A
Resume
P[2]
P[1]
Halt P[2]
P[3] P[3]
(ii) $DISTBF_TTS = 0 Radius of trigger region is not changed. If TCP is in trigger region, DB is triggered just after resume of program. If not, DB is triggered when DB condition is satisfied. Example) Suppose following program is executed and halted on line two. DB condition was not satisfied yet. 1: L P[1] 2000mm/sec FINE 2: L P[2] 2000mm/sec CNT100 DB 100.0mm SDO[1] = ON 3: L P[3] 2000mm/sec CNT100 If TCP is distant from P[2] enough not to trigger(more than 100mm away), SDO[1] turns ON when DB condition is triggered by motion after resume, at point A in left diagram in Fig.9.9.4 (h). If TCP is in trigger region when you resume program, SDO[1] turns ON just after resume. (right diagram in Fig. 9.9.4 (h). Figure 9.9.4 (h) Resume after JOG($DISTBF_TTS = 0)
After resume, DB condition is satisfied and SDO turns ON at point A.
DB condition is satisfied. DB is triggered just after program resume. Resume
Resume
A Halt P[1]
Halt P[2]
P[1]
P[3]
P[2]
P[3]
9 Power failure recovery If power is turned down during sub program execution and power failure recovery is enabled, resume after power failure recovery executes the rest of sub program. In this case, sub program is executed where TCP was at power failure. Execution timing is different from usual one.
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9.9.5 Entering Distance Before 1 DB call program 1) Move cursor to motion option area.
PNS0001 PNS0001
LINE 1
ABORTED JOINT 10 % 1/2
1:J P[1] 100% FINE [End]
[CHOICE]
2) Press F4. The list of motion options is displayed.
Motion Modify 1 TIME BEFORE 2 TIME AFTER 3 DISTANCE BEFORE 4 PNS0001
JOINT 10 % 5 6 7 8 ---next page--1/2
1:J P[1] 100% FINE [End]
Select item [CHOICE]
3) Select DISTANCE BEFORE.DB is added to program.
4) Input distance value and press Enter. Submenu to select instruction part is displayed.
TIME statement 1 CALL program 2 CALL program( ) 3 DO[ ]= 4 RO[ ]= PNS0001
5 GO[ 6 AO[ 7 8
JOINT ]=... ]=...
10 %
1/2 1: J P[1] 100% FINE DB 100.0mm ... [End]
5) To use argument, select CALL program( ).If you don’t, select CALL program. Program list is displayed anyway.
PROGRAM list 1 HAND_OPEN 2 HAND_CLOSE 3 4 PNS0001
JOINT
10 %
5 6 7 8 1/2
1: J P[1] 100% FINE DB 100.0mm CALL ...( )
6) Select program to call.
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Parameter select 1 R[ ] 2 Constant 3 String 4 AR[ ] PNS0001
JOINT 5 6 7 8
10 %
1/2 1: J P[1] 100% FINE DB100.0mm CALL HAND_OPEN(
)
[End]
To specify argument, following procedure is needed. 7) Select argument type. Screen displayed below is example to use Constant. PNS0001 PNS0001
LINE 1
ABORTED JOINT 10 % 1/2
1:J P[1] 100% FINE DB 100.0mm CALL HAND_OPEN(Constant) [End] [CHOICE]
8) Input value of argument. F
To use more than 2 arguments, move cursor to “)” and press F4[CHOICE]. Submenu to select argument type is displayed. Teach argument by procedure 7) and 8) described above.
F
To delete argument, move cursor to argument you want to delete and press F4. Then select . To add argument to CALL without argument, following procedure is needed. 1 Move cursor to program name. 1:J P[1] 100% FINE DB 100.0mm CALL A
2 Press prev key 2 times. Following submenu is displayed. TIME statement 1 CALL program 2 CALL program( ) 3 DO[ ]= 4 RO[ ]= PNS0001
5 GO[ 6 AO[ 7 8
JOINT ]=... ]=...
10 %
JOINT
10 %
3 Select CALL program (). PROGRAM list 1 HAND_OPEN 2 HAND_CLOSE 3 4 PNS0001
5 6 7 8 1/2
1: J P[1] 100% FINE DB 100.0mm CALL ...( )
4 Select program to call and teach argument. 2 DB Signal output
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1) Do just same procedure 1)--4) for DB CALL program. Submenu to select instruction is displayed. TIME statement 1 CALL program 2 CALL program( ) 3 DO[ ]= 4 RO[ ]= PNS0001
5 GO[ 6 AO[ 7 8
JOINT ]=... ]=...
10 %
2/2 1: J P[1] 100% FINE DB 100.0mm ... [End]
2) Select signal output instruction. PNS0001 2/2 1: J P[1] 100% FINE DB 100.0mm DO[...]=... [End]
Select item [CHOICE]
3) Input index and output value just as you do for normal I/O instruction. PNS0001 PNS0001
LINE 1
ABORTED JOINT 10 % 1/2
1:J P[1] 100% FINE DB 100.0mm DO[1]= ON
3 Finding/Replacing Instructions F
Finding Instructions You can find program which is used for DB by “find” on F5 pull--up menu. By selecting “CALL” then “Call program” to find program used in DB. You can find signal output instruction by this function, too. Select item “I/O” on submenu.
F
Replacing Instructions Distance Before can be replaced to TIME BEFORE/AFTER by “replace” on F5 pull--up menu. Select “TIME BEFORE/AFTER” on replace item submenu. You can also replace CALL and signal output in instruction part just as you do when you replace usual CALL and DO etc.
9.9.6 Caution and limitations F
Distance Before cannot be used with TIME BEFORE/AFTER.
F
More than 6 motion statement with Distance Before cannot be processed at the same time.
F
Distance Before calculates the distance between current position and the destination point cyclically. Because the trigger condition is judged by this cyclical check, actual execution timing of instruction part is different from distance value. Instruction part may be executed inside of trigger region. This means the point where the instruction is executed is closer than distance value. Degree of error depends on the speed of robot. The slower TCP moves, the more accurate execution timing.
F
Distance Before is not recovered by power failure recovery if it was attached to CNT motion statement and power is down when the motion is about to complete.
F
Distance Before cannot be used with INC, skip and quick skip in a motion statement.
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F
Multi group is not supported.
F
Robots that don’t have Cartesian coordination are not supported.
F
Position data in matrix form is not supported.
F
Integrated axis is not supported.
F
FANUC Robot F--200i is not supported.
F
Line tracking is not supported.
F
If CJP or ACCUPATH is used, use this function with $DB_MOTNEND = TRUE.
F
If program ends before DB condition triggers, execution instruction is not processed even if DB condition is triggered after program execution completed.
F
During deceleration due to program halt, “going away” trigger may not work. In this case. DB is triggered after program resume.
F
After E--stop, DB doesn’t work. If TCP passes by destination point, DB is triggered after resume of program.
F
After E--stop and resume or program, DB may be triggered just after resume.
F
Single step execution of DB of small distance value may fail for program is paused before motion statement completes and DB condition satisfied. The DB is triggered by execution of next line.
F
If DB condition is satisfied after pause of program, DB is not triggered by step execution of the line. In this case, the DB is triggered by execution of next line.
9.9.7 System Variables system variable $DISTBF_VER
role This system variable set execution timing of line which is just after motion statement with DB.
default value 1
1(default) : Execution of next line doesn’t wait completion of instruction part of DB. 2:
Execution of next line waits for completion execution of instruction part. Example Suppose following program is executed. 1: L P[1] 2000mm/sec FINE 2: L P[2] 2000mm/sec CNT100 DB 1.0mm DO[1] = ON 3: L P[3] 2000mm/sec FINE With $DISTBF_VER=2, execution of line 3 doesn’t start until DO[1] is turned to ON. With $DISTBF_VER = 1, line 3 is executed just as if there were no DB. $DB_AWAYTRIG
Distance Before calculate distance between current position and destination cyclically.robot controller recognize TCP is “going away” from destination point if this calculated distance is greater previous value by $DB_AWAYTRIG millimeters. Please refer to 9.9.4, 4 (i) for details.
$DB_AWAY_ALM
This system variable decides whether INTP--295 is posted or not when FALSE DB is triggered by “going away” with $DB_CONDTYP = 1. Please refer to 9.9.4, 4 (i) for details.
$DB_TOLERENCE
The radius of trigger region is distance value +$DB_TOLERENCE. (If distance value <$DB_MINDIST, radius is $DB_MINDIST +$DB_TOLERENCE) Please refer to 9.9.4, 2 (ii) for details.
0.05(mm)
$DB_CONDTYP
This system variable defines DB trigger condition. 0:When TCP goes into a region which is within distance value (“region trigger”) 1:In addition to “region trigger”, in case of “going away” 2:In addition to “region trigger”, in case of “penetrate”. Please refer to 9.9.4, 2 and 9.9.4, 4 for details.
1
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0.08(mm)
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system variable $DBCONDTRIG
role This system variable decides alarm that is posted when DB condition was not triggered. 0:INTP--295 WARN “(program name, line number) DB condition was not triggered.” is posted. 1: INTP--293 PAUSE.L “(program name, line number) DB condition was not triggered.” is posted.
default value 0
Please refer to 9.9.4, 5 for details. $DB_MINDIST
Internal minimum value of distance value. If distance value is smaller than this value by $DB_MINDIST or more, $DB_MINDIST is used as distance value instead of distance value user taught. Please refer to 9.9.4, 2 (ii) for details.
5.0(mm)
$DB_MOTNEND
This system variable decides if motion completion trigger DB or not. Please refer to 9.9.4, 4 (iii).
TRUE
$DISTBF_TTS
This system variable decides execution timing of instruction part after motion statement with DB is halted. Please refer to 9.9.4, 7 for details.
1
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9.9.8 Error Codes The following alarms are related to Distance Before. INTP--292 PAUSE.L More than 6 motion with DB executed. [Cause]
more than 6 Distance Before were processed at the same time.
Example 1: L P[1] 2000mm/sec CNT100 DB 10mm DO[1] = ON 2: L P[2] 2000mm/sec CNT 100 DB 10mm DO[2] = ON 3: L P[3] 2000mm/sec CNT 100 DB 10mm DO[3] = ON 4: L P[4] 2000mm/sec CNT 100 DB 10mm DO[4] = ON 5: L P[5] 2000mm/sec CNT 100 DB 10mm DO[5] = ON 6: L P[6] 2000mm/sec CNT 100 7: L P[7] 2000mm/sec CNT 100 DB 10mm DO[7] = ON 8: L P[8] 2000mm/sec CNT 100 DB 10mm DO[8] = ON 9: L P[9] 2000mm/sec CNT 100 DB 10mm DO[9] = ON 10: L P[10] 2000mm/sec CNT 100 DB 10mm DO[10] = ON 11: L P[11] 2000mm/sec CNT 100 DB 10mm DO[11] = ON If CNT motion statement with DB frequently like this example, more than 6 calculation for Distance Before may be done at the same time. [Remedy] Change termination type from CNT to FINE. Otherwise, change structure of program not to execute DB frequently. INTP--293 PAUSE.L (program name, line number) DB too small (away) (distance mm) [Cause] Condition of Distance Before was not triggered. [Remedy] Change program for TCP to move into trigger region. INTP--295 WARN (program name, line number) DB too small (away)(distance mm) [Cause] Condition of Distance Before was not triggered. [Remedy] Change program for TCP to move into trigger region. INTP--296 WARN (program name, line number) $SCR_GRP[1].$M_POS_ENB is FALSE. [Cause] $SCR_GRP[1].$M_POS_ENB is FALSE. [Remedy] Change $SCR_GRP[1].$M_POS_ENB to TRUE INTP--297 WARN (program name, line number) DB too small(done) (distance mm) [Cause ] DB is triggered by completion of motion statement to which it is attached. [Remedy] Use greater distance value. This is best solution. If you do not want this trigger, set $DB_MOTNEND to FALSE.
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9.10 State Monitoring Function This function accepts, as conditions, the values of the input/output signals, alarms, and registers of the robot controller (referred to simply as the controller), and executes the specified programs if the conditions are satisfied. The controller itself monitors these conditions. This function consists of the following instructions and programs: F
Monitor start instruction Specifies the condition program to be monitored and the start of monitoring. Example: 1:MONITOR WRK FALL Condition program name
F
Monitor stop instruction Specifies the condition program to terminate. 9:MONITOR END WRK FALL Condition program name
F
Condition program Describes the condition to be monitored and specifies the program to be executed if the condition is satisfied. Program example: 1:WHEN DI[2]=Off, CALL STP RBT *1 *2 This condition program states that when RDI[2] turns off, STP RBT is to be called. *1 Describe the desired monitoring condition by following instruction WHEN. The types of monitoring condition are explained in the WHEN section. *2 Specify the program to be executed if the condition described in *1 is satisfied. The action program can be created and named in the same way as a normal program.
F
Action program Called if the condition is satisfied. The same instructions as those used in normal programs can be used. Program example: 1:DO[2]=On ! Notification to a peripheral device 2:R[8]=R[8]+1 ! Drop count 3:UALM[1] ! Alarm and robot stop $UALRM_MSG[1]=WORK HAS FALLEN
With the following program example, if the robot performing handling drops a workpiece, the user is alerted with an error message and the robot is stopped. Sample. TP (program for handling operation) 1:MONITOR WRK FALL 2:J P[1] 100% FINE : : Handling operation : : 8:J P[7] 100% FINE 9:MONITOR END WRK FALL 10:Open hand
State monitoring
Workpiece drop. condition (condition program) 1:WHEN DI[2]=Off, CALL STP RBT Robot stop. TP (action program) 1:DO[2]=On ! Notification to a peripheral device 2:R[8]=R[8]+1 ! Drop count 3:UALM[1] ! Alarm and robot stop [End]
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Monitor types There are two main types of monitors: the program monitor and system monitor. F
The program monitor starts/stops from a mnemonic program (referred to simply as a program). When the program terminates, monitoring also terminates.
F
The system monitor is started/stopped from the dedicated screen. It performs monitoring constantly regardless of the execution state of the program. (Monitoring continues even after the program terminates.)
Program monitor This type of monitor depends on the execution state of the program. It is suitable for state monitoring within a separate program. Monitoring starts with an instruction (monitor start instruction) in the program. Monitoring terminates with a monitor stop instruction or program termination. The program monitor can be switched between two settings: setting 1 in which the monitor stops when the program stops temporarily, and setting 2 in which the monitor continues monitoring. NOTE Settings 1 and 2 cannot be used at the same time. System monitor This type of monitor does not depend on the execution state of the program. It is suitable for monitoring the state of the entire system. The monitor is started and stopped from the state screen. It cannot be operated with instructions in the program. The system monitor can be switched between two settings: setting 1 in which the monitor stops after a cold start, and setting 2 in which the monitor continues monitoring. NOTE The program monitor and the system monitor can be used at the same time. The monitors can be switched between the settings using the following system variables: $TPP_MON.$LOCAL_MT = 1D Switches the program monitor to setting 1 (default). $TPP_MON.$LOCAL_MT = 2D Switches the program monitor to setting 2 (same specification as that for KAREL) $TPP_MON.$GLOBAL_MT= 0D Enables the system monitor (default). $TPP_MON.$GLOBAL_MT= 1D Switches the system monitor to setting 1. $TPP_MON.$GLOBAL_MT= 2D Switches the system monitor to setting 2. Monitor state transition The states of the monitors assumed when each operation is performed are listed in the table below: Operation
Program monitor Setting 1 Setting 2 F F f f
MONITOR instruction RESTART (state screen) START (state screen) Program Stop n -Program End/Enforced End ¢ ¢ MONITOR END ¢ ¢ PAUSE (state screen) n n END (state screen) ¢ ¢ RESUME f f Power failure handling n -Power off with monitoring state Power failure handling --Power off without monitoring state START (COLD) ¢ ¢ CONTROLLED START ¢ ¢ Other operation --Meanings of symbols F : State monitoring is started. f : State monitoring is restarted if it is stopped. n : State monitoring is stopped. ¢ : State monitoring is deleted. (Cannot be restarted) -- : The state of state monitoring does not change due to the operation.
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System monitor Setting 1 Setting 2 --F ---¢
F ---¢
---
---
--
--
¢ ¢ --
-¢ --
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Operation--by--operation description Operation MONITOR instruction
State When a monitor start instruction in the program is executed, monitoring with the specified program monitor starts. RESTART (state screen) When function key RESTART is pressed on the Program monitor screen of the state screen, monitoring with the program monitor specified with the cursor restarts. START (state screen) When function key START is pressed on the System monitor screen of the state screen, monitoring with the system monitor specified with the cursor starts. Program Stop When the temporary stop key is pressed or if the program stops temporarily due to the occurrence of an alarm, state monitoring with the program monitor previously started by the temporarily stopped program stops, if the program monitor is set to 1. Program End/Enforced End When the program terminates due to program termination, forced termination, or the occurrence of an alarm, the program monitor previously started by the terminated program is deleted. The deleted program monitor does not start unless a monitor start instruction is executed. MONITOR END When a monitor stop instruction in the program is executed, the specified program monitor is terminated. The terminated program monitor does not start unless a monitor start instruction is executed. PAUSE (state screen) When function key PAUSE is pressed on the Program monitor screen of the state screen, monitoring with the program monitor specified with the cursor stops. The stopped monitor restarts when the “Restart” key is pressed or the program restarts. When function key PAUSE is pressed on the System monitor screen of the state screen, monitoring with the system monitor specified with the cursor stops. END (state screen) When function key END is pressed on the Program monitor screen of the state screen, the program monitor specified with the cursor stops. RESUME When the temporarily stopped program restarts, the stopped program monitor restarts. Power failure handling If power failure handling is enabled and the monitor is monitoring, the following occurs when the power is turned OFF/ON. F State monitoring stops if the program monitor is set to setting 1. F State monitoring continues if the program monitor is set to setting 2. (The program stops temporarily, but state monitoring is performed.) F The system monitor continues state monitoring. If the monitor is stopped, it remains in the stopped state when the power is turned OFF/ON. Cold start
Other
If power failure handling is disabled and the power is turned OFF/ON, all monitors terminate except the system monitor of setting 2. The system monitor of setting 2 maintains the state assumed before the power was removed. For operations other than the above, the monitor state is preserved.
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Instruction statements State monitoring is performed in the section enclosed by the following instructions: F MONITOR Monitoring starts under the condition described in the condition program. F MONITOR END Monitoring performed under the condition described in the condition program stops. Condition program The monitoring condition program, which has the subtype called WHEN, can specify condition instructions only. F WHEN , CALL The following conditions can be used: Figure 9--21. Register/System Variable Condition Compare Instruction
Condition variable operator value action Register [ i ] $ System variable
>
Constant
>=
Register [ i ]
Call
= <= < <> Figure 9--22. I/O Condition Compare Instruction 1
Condition variable operator value action AO[ i ]
>
Constant
AI[ i ] GO[ i ]
>=
Register [ i ]
GI[ i ]
<=
Call
= < <>
Figure 9--23. I/O Condition Wait Instruction 2
Condition variable operator value action SDO[ i ]
=
ON
SDI[ i ]
<>
OFF
RDO[ i ]
SDO[ i ]
RDI[ i ]
SDI[ i ]
SO[ i ]
RDO[ i ]
SI[ i ]
RDI[ i ]
Call
UO[ i ]
Rising edge (Note)
UI[ i ]
Falling edge (Note)
WO[ i ]
SO[ i ]
WI[ i ]
SI[ i ] UO[ i ] UI[ i ] WO[ i ] WI[ i ] Register [ i ] : 0 OFF, 1 ON
NOTE Falling edge: The falling edge of a signal is regarded as being a detection condition. The condition is not satisfied when the signal remains off. The detection condition is satisfied when the signal changes from the on state to the off state. Rising edge: The rising edge of a signal is regarded to be a detection condition. The condition is not satisfied
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when the signal remains on. The detection condition is satisfied when the signal changes from the off to the on state. Figure 9--24. Error Condition Compare Instruction
Condition error number = Value
Processing
Constant (Note)
Call
NOTE An error number is specified with an alarm ID followed by an alarm number. Error number = aabbb where aa = alarm ID bbb = alarm number For an explanation of alarm IDs and numbers, refer to the alarm code table in the operator’s manual. (Example) For SRVO006 Hand broken, the servo alarm ID is 11, and the alarm number is 006. Thus, Error number = 11006 In the condition compare instruction, multiple conditions can be specified on a single line in the condition statement, using the logical operators (“and” and “or”). This simplifies the program structure, allowing the conditions to be evaluated efficiently. Instruction format F
Logical product (and) WHEN AND , CALL
F
Logical sum (or) WHEN OR , CALL
If the “and” (logical product) and “or” (logical sum) operators are used in combination, the logic becomes complex, impairing the readability of the program and the ease of editing. For this reason, this function prohibits the combined use of the “and” and “or” logical operators. If multiple “and” (logical product) or “or” (logical sum) operators are specified for an instruction on a single line, and one of the operators is changed from “and” to “or” or from “or” to “and,” all other “and” or “or” operators are changed accordingly, and the following message appears: TPIF-062 AND operator was replaced to OR TPIF-063 OR operator was replaced to AND Up to five conditions can be combined with “and” or “or” operators on a single line. (Example) WHEN AND AND AND AND , CALL Specification Step
1 Enter a condition program name. On the program list screen, press F2 CREATE and enter a program name. 2 Select Cond as the subtype. Press F2 DETAIL to move to the program details screen. Position the cursor to the subtype item and press F4 CHOICE. Select Cond from the subwindow. NOTE At this time, the operation group is automatically set as [*,*,*]. A condition program requires no operation group.
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State monitoring screen The state of state monitoring can be monitored using the program monitor screen and the system monitor screen. Program monitor screen For the program monitor currently being executed or stopped, the name and state (under execution, stopped) of the condition program is displayed, as well as the name of the parent program(*1) of the program that started the program monitor. NOTE If program “A” calls program “B” with a subprogram call, and program “B” executes a monitor start instruction, the name of the parent program, “A,” is displayed in the program name column. Program monitor
1 2 3
[TYPE]
Table 9--7.
JOINT
CH Prog.
Status
Program
WRK FALL WLD TIME NO WRK L
Running Paused Paused
Sample Sample Sample 2
SYSTEM
RESTART
PAUSE
10%
END
Items and Function Keys on the Program Monitor Screen Item
Description
CH Prog. Status Program F2 SYSTEM
Condition program name State of the program, either being executed or stopped Name of the parent program of the program that started the program monitor Switches the screen to the system monitor screen. If the system monitor is disabled ($TPP_MON.$GLOBAL_MT=0), this key is not effective. When pressed, this key restarts the stopped monitor. Stops the monitor. Terminates the monitor. The terminated monitor is cleared from the screen.
F3 RESTART F4 PAUSE F5 END System monitor screen
All condition programs are displayed. System monitors can be started and stopped. System monitor
1 2 3 4
[TYPE]
Table 9--8.
JOINT
CH Prog.
Status
WRK FALL WLD TIME NO WRK L VRFY HND
Running
PROGRAM
START
10%
END
Items and Function Keys on the System Monitor Screen Item
CH.Prog. Status F2 PROGRAM F3 START F5 END
Description Condition program name State of the program, either being executed or not started (blank) Switches the screen to the program monitor screen. Starts the system monitor. Stops the monitor. In the “State” column, a blank is displayed for the stopped monitor.
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Notes/restrictions If multiple condition instructions are specified in a condition program, multiple monitors are started at the same time. 1:WHEN (conditional-expression1), CALL (Program name1) 2:WHEN (conditional-expression2), CALL (Program name2) 3:WHEN (conditional-expression3), CALL (Program name3) If, before one monitor start instruction terminates, another monitor start instruction is executed, both monitors are executed at the same time. If the condition program names specified in the monitor start instructions are the same, the first condition program is overwritten by the second. The program monitor stops state monitoring under the following conditions: F
The MONITOR END instruction is executed.
F
The program terminates.
F
The program stops temporarily. (State monitoring restarts when the program restarts.)
Up to ten conditions can be monitored at the same time. Up to five “and” or “or” operators can be specified in a single monitoring condition instruction. Up to five condition (conditional--expression1) and (conditional--expression2) ......... and (conditional--expression5) condition (conditional--expressionn)or (conditional--expressionm) ......... or (conditional--expression1) : : : condition (conditional--expressiono) and (conditional--expressionp) ......... and (conditional--expressionq)
Up to ten
While the program is being executed or while it is stopped, the condition statements (condition program) cannot be edited. In the action program for a system monitor, an operation group cannot be specified. In the action program for a system monitor, the operation group must be specified as [*,*,*,*,*]. In the action program for a program monitor, an operation group can be specified. While the robot is operating, however, the robot cannot be operated with the program. While the robot is not operating, the robot can be operated with the program. If the condition is satisfied, the condition program enters the END state. If condition monitoring is to continue, specify a monitor start instruction in the program. Clear the monitoring condition beforehand. Example MON1. TP 1:WHEN R[1]=1 CALL ACT1 ACT1.TP 1:R[1]=0 <-------------------- Clear the condition. 2: 3:(Action) : 9:MONITOR MON1 <-------------------- The condition is satisfied again. If there is no line on which the condition on line 1 is dropped, the condition is immediately satisfied on the monitor start instruction on line 9, causing a MEMO--065 error. The condition program cannot be executed directly.
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9.11 Automatic Error Recovery Function 9.11.1 Overview This section consists of the following items: a) Outline of the automatic error recovery function b) Defining a resume program c) Teaching the RETURN_PATH_DSBL instruction d) Setting screen of the automatic error recovery function -- Enabling/disabling the automatic error recovery function -- Defining alarm codes to be monitored -- Defining the recovery switch SDI -- Defining the error recovery information SDO (indicating the conditions for executing the resume program) -- Enabling/disabling the alarm--time automatic start feature -- Setting the maximum number of automatic start repetitions -- Defining the automatic start count register -- Defining automatic error recovery alarm conditions e) Flowchart for resuming a suspended program f) Manual operation screen of the automatic error recovery function g) Execution of the resume program from the teach pendant and test mode h) Changing conditions for executing the resume program i) Other specifications and restrictions j) Warnings (Be sure to read this section for safety.) This function is an optional function.
9.11.2 Outline of the automatic error recovery function Background Robots are sometimes stopped by various alarms even during production. If a robot is stopped, it is necessary to perform recovery operation then resume the program that was originally running. For example, suppose that a robot is performing arc welding. An alarm due to an arc start failure may be issued, stopping the robot. In such a case, the operator must jog the robot to a safe position to, for example, cut the end of the wire or clean the nozzle, then resume the original program. The automatic error recovery function is provided to support automatic operation of the above sequence. Figure 9--25. Example: Wire--cut. TP
10
11
Weld--l. TP 12 1 Wire cutter
3 2 5 2--3--4: Welding path
4
Position where arc start failed
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Alarm code monitoring function In the example shown above, the robot is operated by executing Weld--1.TP to perform welding along the path from 2 to 3 to 4. Assume that an arc start failure occurs at the arc start position 2. With the automatic error recovery function, another program called the resume program, which is Wire--Cut.TP in this case, can be started at the next start signal input. After this program terminates, another start signal input resumes the original program. If the resume operation function is then enabled (which is set on the welding system setting screen), the robot automatically returns to the original position where the robot was stopped, then the original program is resumed. If the return distance for resume operation is set, the robot returns from the stop position by the set distance, then the original program is resumed. If no arc is produced, a scratch start takes place. In the above example, the automatic error recovery function operates only when an arc start miss alarm is issued. The alarm to be monitored may be changed, or the number of alarms to be monitored may be increased. For example, an arc off alarm can be added as an alarm to be monitored. Then, when an arc off alarm is issued, the same operation sequence as explained above can be performed automatically. The standard maximum number of monitored alarm codes that can be defined is ten. If no alarm code is defined, the alarm code monitoring function is disabled. In this case, before the suspended original program (Weld_1.TP in the example) is resumed, the resume program is always executed. Recovery switch SDI function With the recovery switch SDI function, whether to start the resume program or not can be selected at the time of start input according to the defined SDI status. If the recovery switch SDI is off, the original program is resumed without executing the resume program. When this SDI is not defined, this function is disabled. Error recovery information SDO function With the error recovery information SDO function, whether the next start input resumes the original program or executes the resume program can be indicated. If the error recovery information SDO is on at start input, the resume program is executed. When this SDO is not defined, this function is disabled. Alarm--time automatic start feature When an alarm code is defined as explained before, and the defined alarm is issued, the program outputs an alarm signal and stops running. Input of the start signal executes the defined resume program. After the resume program terminates, another start signal input restarts the suspended original program. When the alarm--time automatic start feature is enabled, and a defined alarm is issued, the resume program is automatically executed without outputting the alarm signal and stopping the robot. When the resume program has terminated, the original program is resumed automatically. When this feature is enabled, therefore, the input of the start signal is no longer needed. Because the alarm signal is not output, other robots are not stopped when multiple robots are operating. The robot for which the alarm was issued moves by itself to the recovery station, and after recovery work, the original program is resumed. CAUTION Basically, the automatic error recovery function is designed so that it functions when the teach pendant is disabled. When the teach pendant is enabled, the automatic error recovery function does not function unless the manual test mode is set on the automatic error recovery manual operation screen. For manual testing, see “Execution of the resume program from the teach pendant and test mode.”
DI alarm function By inputting a defined digital input signal, an automatic error recovery alarm can be issued. When this alarm is defined for the alarm--time automatic start feature, the resume program can be executed automatically by inputting the digital input signal. As the message for an automatic error recovery alarm, a message defined for a user alarm can be used. The alarm severity can be set to either LOCAL or GLOBAL selectively. When LOCAL is selected, the alarm is issued only for a program that defines the resume program. The status of a digital input signal to be monitored can be set by selecting the signal type from among DI, RI, and WI, changing the signal number, and selecting the trigger status between on and off.
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Function for disabling the resume operation function after execution of the resume program In arc tool systems, the resume operation function is generally enabled. With this function enabled, return to the original stop position is always performed then arc is produced when the original program resumes after the resume program terminates. In some systems, however, return to the original stop position should not sometimes be performed. For example, when the nozzle touch state is input through DI, a resume program is used to relieve the torch slightly in the torch direction. If the resume operation function operates, return to the original stop position is performed even when relieve operation has been performed. As a result, the nozzle touch state is observed again. In such a case, the resume operation function needs to be kept enabled, but it should be disabled only after the execution of the resume program. This can be performed with the RETURN_PATH_DSBL instruction. By using this instruction within the resume program, the resume operation function can be disabled only when the original program is resumed next. This instruction is valid only when it is executed within a resume program; the instruction is invalid when executed in a program other than the resume program.
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9.11.3 Defining a resume program The automatic error recovery function executes a resume program defined in an original program, in lieu of the original program. To define a resume program, use the RESUME_PROG= instruction. To erase the defined resume program, use the CLEAR_RESUME_PROG instruction. These instructions can be displayed on the edit screen by following the procedure shown below. Program control
[INST]
In the example given in Fig--1, the following programs are used: WELD_1
JOINT
10 % 1/7
1:J P[1] 100% FINE 2: RESUME_PROG=WIRE_CUT 3:L P[2] 100mm/sec FINE : Arc Start[1] 4:L P[3] 100mm/sec CNT100 5:L P[4] 100mm/sec FINE : Arc End[2] 6: CLEAR_RESUME_PROG 7:L P[5] 100mm/sec FINE [End] POINT
ARCSTART
WELD_PT
ARCEND
WELD_CUT
JOINT
1:L 2:J 3: 4:L 5: 6:L 7:L [End]
P[10] 100mm/sec FINE P[11] 100% CNT50 WO[4]=PULSE,0.5sec P[12] 20mm/sec FINE WAIT .80(sec) P[11] 20mm/sec FINE P[10] 50% FINE
POINT
ARCSTART
WELD_PT
ARCEND
TOUCHUP >
10 % 8/8
Wire feed Wire cut
TOUCHUP >
In the above program example, the WIRE_CUT program is taught in the second line of the WELD program and is erased in the sixth line. Since the WIRE_CUT program is defined as the resume program between the third to seventh lines, it is executed as the resume program. In the seventh and subsequent lines, the resume program has been erased, so the resume program is not executed. The resume program is erased also when: F
Backward execution is performed.
F
The cursor line is changed manually.
F
The program terminates. CAUTION
When the RESUME_PROG instruction is executed within the resume program, it is defined as a resume program for the original program.
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9.11.4 Teaching the RETURN_PATH_DSBL instruction The RETURN_PATH_DSBL instruction appears in the menu containing the RESUME_PROG instruction. Program control
[INST]
The RETURN_PATH_DSBL instruction is valid only when it is taught within resume program instructions. Use this instruction as shown in the sample program given below. If the instruction is taught as shown below, the resume operation function does not operate when the original program resumes after the resume program terminates, even if the resume operation function is enabled. WELD_1
JOINT
10 % 1/7
1:J P[1] 100% FINE 2: RESUME_PROG=WIRE_CUT 3:L P[2] 100mm/sec FINE : Arc Start[1] 4:L P[3] 100mm/sec CNT100 5:L P[4] 100mm/sec FINE : Arc End[2] 6: CLEAR_RESUME_PROG 7:L P[5] 100mm/sec FINE [End] POINT
ARCSTART
WELD_PT
ARCEND
WELD_CUT
JOINT
1:L P[10] 100mm/sec FINE 2:J P[11] 100% CNT50 3: WO[4]=PULSE,0.5sec 4:L P[12] 20mm/sec FINE 5: WAIT .80(sec) 6:L P[11] 20mm/sec FINE 7:L P[10] 50% FINE 8: RETURN_PATH_DSBL [End] POINT
ARCSTART
WELD_PT
502
ARCEND
TOUCHUP >
10 % 8/8
Wire feed Wire cut
TOUCHUP >
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9.11.5 Setting the automatic error recovery function On the setting screen of the automatic error recovery function, the following settings can be made: F
Enabling/disabling the automatic error recovery function
F
Defining alarm codes to be monitored
F
Defining the recovery switch SDI
F
Defining the error recovery information SDO (indicating conditions for executing the resume program)
F
Enabling/disabling the alarm--time automatic start feature
F
Setting the maximum number of automatic start repetitions
F
Setting the automatic start count register
F
Enabling/disabling the fast exit/entry feature
F
Enabling/disabling dry run exit/entry operation
F
Defining a maintenance program
F
Defining the maintenance SDO
F
Defining automatic error recovery alarm conditions MENUS
Err recorery
6 Set up
Error Recovery Set
G1
JOINT
10 % 1/12 Error recovery function common setup 1 Error recovery function: DISABLED 2 Approval DI index No.: 0 3 Incomplete end DO index No.: 0 4 Reset DI index No.: 0 5 Automatic start feature: DISABLED RESUME PROGRAM type recovery 6 Status DO index No.: 7 Auto start Max count: 8 Auto start count R[] No.:
0 2 0
MAINTENANCE PROGRAM type recovery 9 Fast exit/entry feature: DISABLED 10 Dry run exit/entry: DISABLED 11 Maintenance program: ******** 12 MAINT DO index No.: 0 [ TYPE ]
ALARM DI_ALARM
To alarm registration screen Alarm setting screen Error Recovery Set
1 2 3 4 5 6 7 8 9
Monitored Monitored Monitored Monitored Monitored Monitored Monitored Monitored Monitored
alarm alarm alarm alarm alarm alarm alarm alarm alarm
G1
JOINT
code code code code code code code code code
[ TYPE ]
53013 53018 0 0 0 0 0 0 0 DONE
53013 indicates “ARC--013 Arc Start failed.” 53018 indicates “ARC--018 Lost arc detect.”
503
10 % 2/10
HELP
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For alarm codes, refer to the alarm code table in the operator’s manual. Enabling/disabling the automatic error recovery function This item enables or disables the automatic error recovery function. When the automatic error recovery function is enabled, and neither monitored alarm codes nor the recovery switch SDI are defined, the resume program is always executed at restart from the suspended state (except when the error recovery information SDO is off). When this item is disabled, the resume program is not executed. Defining alarm codes to be monitored To define alarm codes to be monitored, press the F2 (ALARM) key. A screen for defining alarm codes is displayed. When a defined alarm code is issued, and a program is suspended, the resume program is executed at restart. Each alarm code consists of an alarm code ID and alarm number. The alarm code ID indicates the type of alarm. For an arc start failure alarm, for example, the following alarm code is indicated:
ARC
013
--
ID (53)
Arc Start failed = 5
Number
3
ID
0
1
Number
For alarm numbers, refer to the alarm code table in the operator’s manual. Up to ten alarm codes can be defined as standard. To change the maximum number of alarm codes (up to 20 codes) that can be defined, change system variable $RSMPRG_SV.$NUM_ALARM, turn the power off then on. Pressing the F5 (HELP) key displays the following screen: Error Recovery Set G1 JOINT 10 % HELP Arrows to scroll, PREV to exit Typical alarm code IDs are specified as follows. PROG PRIO SYST SEAL SENS
: * : : :
3, 13, 24, 51, 58,
SRVO MOTN PALT ARC COMP
: : : : :
11, 15, 26, 53, 59
INTP SPOT LASR MACR
: : : :
12 23 50 57
CAUTION Do not define any warning alarm as an alarm code.
Even when a defined alarm is issued, the resume program is not executed if the recovery switch DI is off. When there is no alarm code defined, that is, when all defined values are 0, the alarm code monitoring function is disabled. The specifications of the alarm code monitoring function are listed below. Table 9--9.
Specifications of the Alarm Code Monitoring Function ALARM CODE FUNCTION STATUS
ISSUANCE OF DEFINED ALARM
EXECUTION OF RESUME PROGRAM AT RESTART
All 0s
Disabled
--------------
Executed
At least one alarm code is defined
Issued
Executed
Enabled
Not issued
Not executed
ALARM CODE DEFINITION
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Defining the recovery switch SDI To use the recovery switch SDI function, define an SDI number. After the number is defined, power must be turned off then back on. With this function, the operator can choose whether to execute the resume program or not at the time of restart from the suspended state by using a peripheral device. If this signal number is not defined, this function is disabled. The specifications of the recovery switch SDI function are listed below. Table 9--10.
Specifications of the Recovery Switch SDI Function
SDI NUMBER DEFINITION
RECOVERY SWITCH SDI FUNCTION STATUS
SDI STATUS
EXECUTION OF RESUME PROGRAM AT RESTART
0
Disabled
--------------
Executed
On
Executed
Off
Not executed
Valid number defined
Enabled
CAUTION Caution: To continue a resume program at program restart after the resume program is suspended, input the on state of the recovery switch SDI. If it is off, the original program is executed.
Defining the error recovery information SDO (conditions for executing the resume program) When the alarm code monitoring function and recovery switch SDI function are both disabled, the resume program is always executed at the time of restart after the original program is suspended. When both the functions are enabled, it is difficult to determine whether the original program or resume program is to be executed at restart. The error recovery information SDO is on only when the resume program is executed at restart. When the signal is off, the original program is executed at restart. With this function, the operator can know which program is to be executed next. If the following conditions are met, the error recovery information SDO goes on: F
The automatic error recovery function is enabled.
F
The program to be executed is not in single step mode. The single step LED on the teach pendant indicates the single step status of a program currently selected (more precisely, the program set in $TP_DEFPROG). When the resume program is suspended, the error recovery information SDO is on even if the single step LED on the teach pendant lights. This is because the resume program to be executed is not in single step mode.
F
The resume program is defined in the currently selected program (original program).
F
The currently selected program (original program) has a motion group.
F
The currently selected program (original program) is suspended, and the resume program is not yet completed.
F
There is no optional function that disables the automatic error recovery function. See “Other specifications and restrictions.”
F
The user condition parameter ($AUTORCV_ENB) is true. See “Conditions for executing the resume program.”
F
When the teach pendant is enabled: -- The operation mode (on the automatic error recovery manual operation screen) is TP_TEST.
F
When the teach pendant is disabled: -- The operation mode (on the automatic error recovery manual operation screen) is AUTO. -- The remote conditions are met when system variable $RMT_MASTER is 0. -- There is no alarm code defined. If any alarm code is defined, the alarm code is issued. -- The recovery switch SDI function is disabled. If this function is enabled, the recovery switch SDI signal is on.
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CAUTION F
The selected program means the program to be executed by inputting the start signal.
F
While the resume program is being executed, single step operation cannot be performed.
F
Even if the error recovery information SDO is on, the resume program is not executed when backward execution of the original program is performed.
F
Backward execution in the resume program is possible.
F
The update cycle period for the error recovery information SDO is 300 ms. When the conditions listed above have been changed, wait 300 ms before program execution.
The timing chart for the error recovery information SDO status and start signal is shown below. Figure 9--26. Error Recovery Information SDO Output Timing Chart
Start signal Conditions are not met Error recovery information SDO Conditions are met
Execution of resume program
Execution of original program
Defining the incomplete end SDO When an incomplete end SDO number is defined, the incomplete end SDO is output if a certain forced termination alarm is issued during execution of the resume program. The output incomplete end SDO is turned off by the next start signal input. Before inputting the start signal, the operator must check the incomplete end SDO signal status. If this signal is on, the resume program terminates in the middle, so the robot is not in a specified position. In such a case, inputting the start signal causes the robot to perform resume operation to return from the current position to the stopped position of the original program, which may interfere with obstacles such as a jig. Therefore, before inputting the start signal, check the current robot position. If an interfering object exists, jog the robot to a position near the stopped position of the original program, then input the start signal. This signal may be added to the PLC start signal acceptance conditions. If this signal is set to 0, this function is disabled. Figure 9--27. Incomplete End SDO Output Timing Chart
Start signal Resume program terminated midway Execution of resume program
Incomplete end SDO
Defining the incomplete--end reset SDI When the incomplete end SDO is included in the PLC start signal acceptance conditions, the operator requires a means to turn off the incomplete end SDO externally. Inputting the incomplete--end reset SDI signal turns off the incomplete end SDO. When the incomplete end SDO is output, the operator must first perform appropriate operation such as jogging the robot to near the stopped position of the original program, input the incomplete--end reset SDI, then input the start signal.
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When this signal is set to 0, this function is disabled. Enabling/disabling the alarm--time automatic start feature When this item is enabled, and an alarm code to be monitored is defined, this feature functions if the defined alarm is issued. If a defined alarm is issued, this feature automatically executes the resume program. In this case, the alarm signal is not output. When the execution of the resume program has terminated, the original program is resumed automatically. During then, the operator need not input the start signal. Since the alarm signal is not output, other robots operating in the same line are not stopped. CAUTION Defined alarms must have the suspension alarm attribute.
CAUTION If the error recovery information SDO is off when the resume program is executed automatically, alarm “INTP--135 Recovery DO OFF in auto start mode” is issued.
CAUTION While the resume program is being executed, the UOP PAUSED signal is output. This is because the original program is in the suspended state. This specification is the same as that for multitasking systems.
WARNING The alarm--time automatic start feature works on a program selected on the teach pendant. For example, suppose that program A having a resume program instruction has been executed from the teach pendant, then program B without a resume program instruction is selected and executed from the teach pendant. If an alarm defined in program A is then issued, the alarm signal is not output, but the resume program is not executed automatically. The reason for this is that the automatic start feature works on a selected program. In this example, program B that is currently selected does not define any resume program.
WARNING When the automatic start feature item is enabled, and no monitored alarm code is defined, inputting the start signal for executing the resume program automatically executes the resume program then resumes the original program. In other words, when the start signal is input while the original program is suspended, the resume program is executed. As the resume program has terminated, the original program is then restarted automatically.
Setting the maximum number of automatic start repetitions When a defined alarm is issued, the alarm--time automatic start feature automatically executes the resume program, then resumes the original program. If the defined alarm is issued again when the original program is resumed, the automatic start feature functions again. For example, the automatic start feature is activated by an alarm indicating an arc start failure, then the same alarm is issued again when the original program has resumed. To prevent such an endlessly repeated condition, set the maximum number of automatic start repetitions. The number of times the resume program is started repeatedly is counted internally. If the count exceeds the set value, “INTP--134 Over automatic start Max counter” is issued, and the error recovery information SDO is turned off at the same time. If this occurs, eliminate the cause of the alarm issued in the original program. Then input the start signal. CAUTION The number of repetitions counted internally is cleared when the execution of a move statement has terminated and when the CLEAR_RESUME_PROG instruction has been executed.
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Defining the automatic start count register As mentioned above, the resume program may be executed several times repeatedly by the automatic start feature. When the automatic start count register is defined, a different program can be executed as the resume program each time the resume program is executed. For example, when the resume program is executed for the first time by the automatic start feature, the register value is 1. When an alarm is issued again during execution of the original program, and the resume program is then executed again by the automatic start feature, the register value is 2. By executing a different subprogram in the resume program according to the register value, different resume program operation can be performed each time the repetition count is incremented. CAUTION When the resume program is executed by other than the automatic start feature, the register value is 0. Therefore, a resume program must be created so that the same subprogram is called when the register value is 0 and when the value is 1.
Enabling/disabling the fast exit/entry feature If an alarm is issued during operation in a complicated environment, the robot moves from the stopped position to the taught point to execute the resume program. In this case, the robot may interfere with part of a workpiece or peripheral devices. After recovery operation, similar interference may occur when an attempt is made to execute the original program. The fast exit/entry feature is provided to avoid the possibility of such interference. The feature can be enabled or disabled by setting this item. The fast exit/entry feature causes the following operation automatically: 1 From the stopped position, disable arc welding, and execute only the move statements of the original program up to the end. 2 Execute a maintenance program. 3 Disable arc welding, execute the move statements of the original program from the beginning to move the robot to the stopped position. 4 Enable arc welding, and resume the original program operation. Even when this feature is enabled, the resume program takes priority over this feature if the resume program is enabled in the original program. In other cases, the maintenance program is executed. Enabling/disabling dry run exit/entry In the fast exit/entry feature, this item specifies whether exit from the stopped position and return to the stopped position after maintenance program execution are to be performed at dry run speed. Defining a maintenance program Define the name of a maintenance program used as the standard maintenance program. The maintenance program name can also be specified using the maintenance program instruction on the edit screen. Defining the maintenance SDO Define the number of the SDO for indicating that the fast exit/entry feature is operating. Defining automatic error recovery alarm conditions Define the conditions for issuing an automatic error recovery alarm on the definition screen that is displayed by pressing F3 (DI_ALARM) on the setting screen of the automatic error recovery function. Error Recovery Set UALM 1 [ 1] 2 [ 5] 3 [ 10]
Severity LOCAL GLOBAL LOCAL
G1
JOINT
Type DI[ 1] RI[ 2] DI[ 5]
10 % 1/3 Value ON OFF ON
PLEASE POWER OFF AFTER CHANGING DI/DO [ TYPE ] DONE HELP
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On this screen, the items shown below can be set. The alarm code of the automatic error recovery alarm is 12278. F
User alarm number When the automatic error recovery alarm is issued, the user alarm message with the set number is displayed as an alarm message. When this item setting has been changed, the new setting becomes effective immediately.
F
Alarm severity This item can choose whether the automatic error recovery alarm is a local alarm or global alarm. When LOCAL is set, the automatic error recovery alarm is issued only for the program that defines a resume program. If there is no program that defines a resume program, the alarm is regarded as a global alarm. If the automatic error recovery alarm is issued when there is no program being executed, a warning is generated. When this item setting has been changed, the new setting becomes effective immediately.
F
Signal type Choose the type of the digital signal for issuing the automatic error recovery alarm from among DI, RI, and WI. When this item setting has been changed, the power must be turned off then back on for the new setting to become effective.
F
Signal number Set the number of the digital signal for issuing the automatic error recovery alarm. When this setting has been changed, the power must be turned off then back on for the new setting to become effective.
F
Detection signal status Set the status of the digital signal for issuing the automatic error recovery alarm to ON (high) or OFF (low). When this setting has been changed, the power must be turned off then back on for the new setting to become effective.
The standard number of automatic error recovery alarm conditions is three. This number can be increased to up to five by changing system variable $RSMPRG_SV.$NUM_DI_ALM. After this system variable has been changed, the power must be turned off then back on for the new setting to become effective.
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9.11.6 Flowchart for resuming a suspended program The resume program is executed according to the following flowchart: Figure 9--28. Flowchart for Executing the Resume Program (When Automatic Start is Disabled) Program suspended by hold
Program suspended by alarm
Release alarm
Input start signal
Yes
Backward execution?
Restart of resume program from stopped position?
No
No Yes No Is error recovery information SDO on? Yes Execute resume program End of resume program
Input start signal
Execute original program
CAUTION F
When forward execution is specified while the original program is suspended, the resume program is executed if the error recovery information SDO is on; if it is off, the original program resumes.
F
When forward execution is specified while the resume program is suspended, the resume program resumes if the error recovery information SDO is on; if it is off, the original program is executed.
F
When backward execution is specified while the original program is suspended, backward execution is performed for the original program without executing the resume program.
F
When backward execution is specified while the resume program is suspended, backward execution is performed for the resume program.
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9.11.7 Manual operation screen of the automatic error recovery function A manual operation screen is supported for the automatic error recovery function. This screen contains the following: F
Error recovery information SDO status
F
Name of the resume program defined in the currently selected program
F
Operation mode setting
F
Detail information about the error recovery information SDO
This screen can be selected by following the procedure shown below. MENUS
Error Recovery MNF
G1
JOINT
Error recovery DO status: Defined resume program:
10 % 1/1
OFF WIRE_CUT
1 Operation mode:
AUTO
[ TYPE ] DATAIL
[CHOICE]
Error Recovery MNF 1 2 3 4 5 6 7 8 9 10 11
Err recorery
MANUAL FCTNS
10 % 1/11 Auto error recovery enabled: No PAUSED & resume prog incomp: No Program has motion group: No Not in single step mode: No Resume program is defined: No Mode is(TP_TEST): No Approval DI is ON: None Defined alarm occurs: None Remote when $RMT_MASTER is 0: None No disabled options: No User condition param enable: Yes
[ TYPE ]
G1
JOINT
DONE
Error recovery information SDO status The error recovery information SDO status is indicated. Even when the error recovery SDO is not defined, its status can be indicated. From this information, the operator can know which program, the resume program or original program, is to be executed. Defined resume program The name of the resume program defined in the currently selected program is indicated. From this information, the operator can check whether a wrong resume program is defined or not. CAUTION If a wrong program is defined as the resume program, the robot operation is unpredictable. Therefore, check that the resume program is correct.
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Operation mode There are three operation modes. The standard setting is AUTO. When the display changes from this screen to another, AUTO is automatically set again. F
AUTO This mode should be set when the teach pendant is disabled. When this mode is selected, the resume program is executed according to the status of the alarm code monitoring function and recovery switch SDI function. If this mode is selected when the teach pendant is enabled, the resume program is not executed.
F
NO_EXEC When this mode is selected, the error recovery information SDO is always off. Therefore, in this mode, the resume program is not executed.
F
TP_TEST This mode should be set when the teach pendant is enabled. When this mode is selected, and when the teach pendant is enabled, the resume program is always executed regardless of the status of the alarm code monitoring function or error recovery switch SDI function.
Displaying detail conditions of the error recovery information SDO When F2 (DETAIL) is pressed on the manual operation screen of the automatic error recovery function, detail conditions related to the error recovery information SDO status are displayed. When all items on the detail screen are set to Yes or None, the error recovery information SDO is turned on. When the error recovery information SDO is off, and you cannot find the cause of the SDO being off, check this screen. F
Auto error recovery enabled This item indicates whether this function is enabled or disabled on the setting screen of the automatic error recovery function.
F
PAUSED & resume prog incomp This item indicates the following conditions: -- The selected program must exist. -- The selected program must be in the suspended state. -- A resume program must be defined in the selected program, and the execution of the resume program must not have been completed.
F
Program has motion group This item indicates that the selected program has a motion group.
F
Not in single step mode This item indicates that the single step mode is not set. The single step LED on the teach pendant indicates the single step status of the selected program ($TP_DEFPROG). Even when the single step key is pressed while the resume program is suspended, and the single step LED goes on, the error recovery information SDO is held on. This is because the selected program is the original program, and the LED indicates that the original program is in single step mode; the resume program is not in single step mode.
F
Resume program is defined This item indicates that a resume program is defined in the selected program.
F
Mode is (xxxx) This item indicates that the operation mode is suitable for the current status. For example, when the teach pendant is disabled, “AUTO” is indicated in the portion “xxxx.” When the teach pendant is enabled, “TP_TEST” is indicated.
F
Approval DI is ON This item indicates the recovery switch DI status. When the SDI number is not defined, or when the teach pendant is enabled, “None” is indicated.
F
Defined alarm occurs This item indicates that an alarm code is defined, and that alarm is issued. When no alarm code is defined, or when the teach pendant is enabled, “None” is indicated.
F
Remote when $RMT_MASTER is 0 This item indicates that remote conditions are met. This function is enabled only when the teach pendant is disabled, system variable $RMT_MASTER is 0, and system variable $RSMPRG_SV.$CHK_REMOTE is true.
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F
No disabled options There are options that cannot be used together with the automatic error recovery function. This item indicates whether such options are present or not.
F
User condition param enable This item indicates the status of system variable $AUTORCV_ENB for user conditions. For how to use this system variable, see “Changing conditions for executing the resume program.”
9.11.8 Execution of the resume program from the teach pendant and test mode Normally, the automatic error recovery function is used when production is started with the teach pendant disabled. When checking the resume program during teaching, set the operation mode to TP_TEST on the manual operation screen. In TP_TEST mode, the resume program can be executed regardless of the recovery switch DI status and whether a defined alarm is issued or not.
9.11.9 Changing conditions for executing the resume program To use resume program execution conditions other than alarm codes, use user condition system variable $AUTORCV_ENB and the status monitoring function. For example, to execute the resume program when R[1] is 1, create the following monitor program, and start MONIT1.CH on the system monitor screen. MONIT1.CH 1: WHEN R[1]=1,CALL DO_RESUME 2: WHEN R[1]<>1,CALL NO_RESUME
DO_RESUME. TP 1: $AUTORCV_ENB=1 2: MONITOR MONIT_3
MONITI2.CH 1: WHEN R[1]=1,CALL DO_RESUME
DO_RESUME. TP 1: $AUTORCV_ENB=0 2: MONITOR MONIT_2
MONITI3.CH 1: WHEN R[1]<>1,CALL NO_RESUME
The start conditions can be changed by modifying the monitor program. For how to use the status monitoring function, refer to the operator’s manual on the status monitoring function. In this case, the automatic start function is unavailable.
9.11.10 Other specifications and restrictions F
While the resume program is being executed, single step operation is not performed. Single step mode is valid only for the original program.
F
When the cursor line is changed and executed while the original program is suspended, the resume program is not executed.
F
While the resume program is being executed, the resume program execution status cannot be checked on the program edit screen. On the edit screen, the suspended original program is displayed.
F
When a multitasking program (a main program and subprogram) is being executed with the alarm code monitoring function disabled and the recovery switch DI undefined, pressing the hold button causes both the main program and subprogram to stop. Suppose that a resume program is defined in the subprogram, but that no resume program is defined in the main program. In this case, when the main program is selected and re--executed, the resume program for the subprogram is not executed. This is because the selected program is the main program, and the error recovery information DO is off.
In this case, when the subprogram is selected and executed, the error recovery information DO is turned on, so the resume program is executed. CAUTION When using the automatic error recovery function in multitasking systems, define a resume program only in the main program. Even when a resume program is defined in a subprogram, that resume program cannot be executed.
Definitions in the main program and subprogram are shown below.
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Main.TP
Sub.TP
1: RUN Sub 2: RESUME_PROG=WIRECUT
No resume program defined
F
While the resume program is being executed, the suspended original program is displayed on the edit screen.
F
When the cursor line in the original program is moved while the resume program is suspended, then program re--execution is performed, the resume program is resumed. After the resume program terminates, specifying program execution displays a popup menu confirming the cursor movement. When Yes is entered in response, the original program is executed starting from the new cursor line.
F
In a single task system, when the resume program is suspended, selecting a program other than the original program on the program directory screen causes the original program to terminate.
F
Never teach the arc and weaving instructions in the resume program. If an arc instruction is executed in the resume program while arc welding is being performed by the original program, alarm “ARC--034 Task does not control welding” is issued. In addition, weaving operation is not performed within the resume program.
F
The automatic error recovery function supports the power failure handling function.
F
The automatic error recovery function is disabled when one of the following options is loaded: -- Arc sensor -- AVC (TIG arc length control) -- MIG EYE option -- Root path memorization -- Line tracking -- Soft float -- Continuous turn -- Coordinated motion -- Remote TCP -- Accurate path function -- Constant joint path function (path not overridden) -- Multi robot control
9.11.11 Warnings When using the automatic error recovery function, observe the following safety precautions: F
If a wrong program or a program causing wrong operation is defined as a resume program, the robot moves in a direction the operator cannot predict. Define a correct program.
F
Before inputting the start signal and before pressing the execution key on the teach pendant, for safety, check the error recovery information DO status to confirm whether the original program or resume program is to be started.
F
If the operation mode is set to TP--TEST on the manual operation screen of the automatic error recovery function, the resume program is started even when a defined alarm is not issued or when the recovery switch DI is off.
F
When an operation mode other than AUTO is set on the manual operation screen of the automatic error recovery function, then the display is changed to another screen, the operation mode is set to AUTO again automatically. To use an operation mode other than AUTO, always keep displaying the manual operation screen of the automatic error recovery function.
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9.12 Torch Posture Conversion This function converts the torch posture on a specified reference plane according to a specified work angle and travel angle. This function has been developed to reduce the number of manhours needed for teaching. Note the following when using this function: WARNING Interference with the workpiece is not considered when calculating the torch posture. Some combinations of work angle, travel angle, and reference plane may result in the converted torch posture interfering with the workpiece. Therefore, extreme care should be applied when executing the program. For example, override should be minimized and step execution should be selected.
WARNING Conversion at a corner may suddenly change the torch posture. Therefore, exercise extreme care when executing the program to check the results of conversion. For example, override should be minimized and step execution should be selected. If the posture seems to change too suddenly, the number of additional points and the pitch of the additional points specified for the corner smoothing function should be increased.
WARNING An incorrectly specified conversion range may result in an unexpected torch posture. The user should be careful to specify the conversion range correctly. Care is necessary when executing the program to check the results of the conversion. For example, override should be minimized and step execution should be selected.
Function description The quality of arc welding depends on the torch posture. The travel angle and work angle must be specified correctly. This function changes the torch posture according to a directly specified reference plane, travel angle, and work angle. The operator can specify a position without having to consider the torch posture. Also, the number of manhours needed for teaching can be reduced. NOTE The tool frame must be set so that the Z (+) direction corresponds to the torch direction.
Torch
+Z +Y Wire
+X NOTE The TCP accuracy largely depends on the conversion accuracy of this function. All settings must be made to maximize the TCP accuracy.
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Reference plane setting The reference plane is used to calculate a work angle. The reference plane can be set using any of the following methods: F
Horizontal plane The X--Y plane of the robot world frame is set as the reference plane.
F
Three--point teaching A plane determined by three points is set as the reference plane. The three points can be specified using any of the following methods: -- Using positions specified in the program to be converted -- Using positions held in the position registers -- By recording positions
NOTE If a plane cannot be determined by the three points, such as when the three positions are on a single line, conversion cannot be successfully executed. F
Torch posture A point is stored, and a plane perpendicular to the torch at that point is set as the reference plane.
This function consists of the following two major subfunctions: F Corner smoothing function F Absolute adjustment Corner smoothing function This function adds additional points near a specified point so that the torch traverses the joints of specified paths while changing its posture smoothly. The number of additional points and the distance between those additional points (pitch) can be set as necessary. Rules governing conversion F
The motion speed at an additional point is the same as that specified in the motion instruction for the corresponding corner.
F
After conversion, CNT100 is selected as the positioning method at the corresponding corner.
F
When motion instructions include an additional statement, the statement will remain only in the corner motion instruction after conversion. Whenever possible, therefore, perform conversion before
F
For the motion instruction for an additional point, ‘‘Additional pnt’’ is displayed in the comment field of the position data. For an additional point of a circular corner, ‘‘Circle ADD_pnt’’ is displayed.
adding an additional statement.
This function cannot be used under the following conditions: F
When the conversion range contains up to two motion instructions.
F
When the conversion range contains a motion instruction that uses a position held in a position register.
F
When the conversion range contains an incremental statement.
F
When the conversion range contains a palletizing statement.
F
When the target robot is NOBOT.
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P[1]
P[2] Path 1 Path 2
1 : L P[1]...FINE 2 : L P[2]...FINE 3 : L P[3]...FINE
P[3]
Additional point : 1 pitch : 1 mm P[1]
A1
P[2]
X X
B1
P[3]
( Distance between A1 and P2 ) = ( Distance between P2 and B1) = 1 mm
1 2 3 4 5
: : : : :
L L L L L
P[1]...CNT100 P[4:Additional pnt]...CNT100 P[2]...CNT100 P[5:Additional pnt]...CNT100 P[3]...FINE
The torch posture at A1 is determined from the work angle and travel angle at P1, and half the difference between the spin angles at P2 and P1. (The spin angle is the angle of rotation around the Z--axis of the tool frame.) The torch posture at B1 is determined from the work angle and travel angle at P2 and the spin angle at P2. The torch posture at P2 is determined from half the difference between the work angles at A1 and B1, half the difference between the travel angles at A1 and B1, and the spin angle at P2. After this conversion, the torch moves along path 1, maintaining a constant work angle and travel angle. The spin angle varies, but the variation does not affect the welding. When the torch moves to welding path 2, its posture is changed quickly. NOTE The corner smoothing function is not required when a path consists of two half--circle arcs, or of straight line and an arc having tangents to match at the joint.
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If a program includes a circular motion instruction, the program is converted as shown below: from
1 : L P[1]...FINE 2 : C P[2] P[3]...FINE 3 : L P[4]...FINE to
1 : L P[1]...FINE 2 : C P[2] P[4:Circle Add_pnt]...CNT100 3 : L P[3]...CNT100 4 : L P[5:Additional pnt]...CNT100 5 : L P[4]...FINE NOTE To delete the additional point motion instructions from a program, the following must be set for the conversion: -- Corner smoothing function : TRUE -- Number of add.points : 0 -- Absolute adjustment : FALSE
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Absolute adjustment This function changes the specified position data to the specified travel angle and work angle according to the reference plane and path direction data (obtained from the teaching data for two points). (ABSOLUTE is set as Adjustment type on the setting screen.) For an explanation of setting the reference plane, see the description given above. The signs of the travel angle and work angle are defined as follows:
0 deg
Travel angle
(--)
(+)
Direction of movement 90 deg Work angle 0 deg
Direction of movement
180 deg
Apart from the directly specified travel angle and work angle, the travel angle and work angle at the beginning of the conversion range can be applied to the modification of all position data within the specified range. To do this, MATCH_1 must be specified for Adjustment type on the setting screen.
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Setting execution procedure F
Set the tool frame so that the Z (+) direction corresponds to that of the torch.
Torch
+Z +Y Wire
+X F
The TCP accuracy largely depends on the accuracy of the conversion performed by this function. All settings must be made in order to maximize TCP accuracy.
F
Specify corner points only when a weld path program is generated. The torch posture need not be considered in programming. However, care must be taken to avoid winding in the cable.
P[1]
P[2] Path 1 Path 2
P[3]
F
Specify a reference plane on the posture convert screen. If the plane has already been specified, it need not be specified again.
F
Select whether the conversion program name, conversion range, and the contents of the conversion are to be overwritten, or whether a new program is to be created.
F
To perform absolute adjustment, select TRUE for the corresponding function. Then, specify the torch posture angles (travel angle and work angle) either by directly entering the values or by reflecting the torch posture at the beginning of the conversion range.
F
To execute corner smoothing, select TRUE for the corner smoothing function. To change the number of add--points and the pitch length, enter desired values.
F
Press the F3 (EXECUTE) key, then press the F4 (YES) key. Once conversion has been completed, this message appears on the command line: ”The conversion was completed.”
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Types of settings screens and their display
POSTURE CONVERSION Program: Group :[1] 1 Original Program: [MAIN ] 2 Range: PART 3 Start line: 5 4 End line: 10 5 Create/Replace: REPLACE 6 New Program: [MAIN1 ] 7 Insert line:(Not used) ***** Corner smoothing function 8 Corner smoothing: ENABLE 9 Number of add. points: 1 10 Pitch length: 5.0mm Absolute adjustment function 11 Absolute adjustment: ENABLE 12 Adjustment type: ABSOLUTE 13 Travel angle: 10.0deg 14 Work angle: 45.0deg [ TYPE ] CLEAR
Table 9--11.
PLANE
EXECUTE
>
GROUP
>
Torch posture conversion Setup item Description DESCRIPTION
ITEM Group :[1]
Indicates the motion group to be converted. To change the indicated group, press the F7 (GROUP) key. At the prompt, enter the desired group number.
Original Program:
Enter the name of the program to be converted. If this screen is displayed when nothing is specified for this item, the current program is automatically selected.
Range:
Specify WHOLE or PART as the conversion range. When PART is selected, the start and end lines must be specified.
Start line:
Specify the start line of the conversion range.
End
Specify the end line of the conversion range.
line:
Create/Replace:
Select whether the original program is to be overwritten with the converted data (REPLACE) or whether a new program is to be created for the converted data (CREATE).
New Program:
When selecting Create for the above item, enter the name of the program to be created.
Insert line:
When inserting converted data into an existing program, specify the number of the line from which the data will be inserted.
Corner smoothing:
Enable (ENABLE) or disable (DISABLE) the corner smoothing function.
Number of add. points:
Set the number of additional points for corner smoothing. As the number increases, the wrist rotation speed at corners decreases.
Pitch length:
Set the distance between additional points for corner smoothing. As the distance increases, the wrist rotation speed at corners decreases.
Absolute adjustment:
Enable (ENABLE) or disable (DISABLE) the absolute adjustment.
Adjustment type:
Select how the torch angles (travel angle and work angle) are specified in absolute adjustment.
---
ABSOLUTE -- The travel angle and work angle are specified directly. MATCH_1 -- The travel angle and work angle of the torch at the beginning of the conversion range are used.
Travel angle:
Specify a travel angle directly. Only when Ajustment type is ABSOLUTE.
Work angle:
Specify a work angle directly. Only when Ajustment type is ABSOLUTE.
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Table 9--12.
Torch posture conversion Function keys Description
ITEM
DESCRIPTION
F3, EXECUTE
Executes the absolute adjustment and corner smoothing function.
F6, CLEAR
Initializes the Original program name, Start line, End line, New program, Insert line, motion group number, and cursor line. NOTE When the original program name is erased, the current program, if selected, is set immediately.
F7, GROUP
Specifies the motion group to be converted.
F2, PLANE
Displays the reference plane screen (See below).
POSTURE CONVERSION Reference plane Group :[1] 1 Reference Plane Teach: [ TYPE ]
Table 9--13.
HORIZON [CHOICE]
>
Reference prane screen (HORIZON case) Setup item Description DESCRIPTION
ITEM Reference Plane Teach:
Specifies a reference plane format using one of the following options: -- HORIZON -- The X--Y plane of the robot world frame is used as the reference plane. -- 3 POINTS -- A plane determined by three specified points is used as the reference plane. The points can be specified as described below: F
Positions specified in the original program are used.
F
Positions held in position registers are used.
F
New positions are stored.
NOTE If no plane is determined by the three specified points, such as when all the points fall on a single line, an alarm prompt message is output to indicate that the attempted conversion is impossible. -- ADJUST -- A single point is stored and a plane perpendicular to the torch at that point is used as the reference plane. Table 9--14.
Reference prane screen (HORIZON case) Function keys Description
ITEM F4, [CHOICE]
DESCRIPTION Selects a reference plane format from the options indicated above.
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POSTURE CONVERSION
Reference plane Group :[1] 1 Reference Plane Teach: - P1: - P2: - P3: [ TYPE ]
Table 9--15.
CLEAR
3POINTS
REFER [CHOICE] RECORD>
Reference prane screen (3POINTS case) Setup item Description DESCRIPTION
ITEM Reference Plane Teach:
See above.
P1:, P2:, P3:
Indicates whether the three points necessary to determine a reference plane have been stored. If they are not currently stored, ****** is displayed. If they have already been stored, the field appears blank.
Table 9--16.
Reference prane screen (3POINTS case) Function keys Description
ITEM
DESCRIPTION
F2, CLEAR
Erases the reference plane data.
F3, REFER
After pressing this key, select whether the position data provided by the original program, or that in the position registers, is to be used. -- F4, P [ ] -- Position data provided by original program -- F5, PR [ ] -- Then, enter the number of position data. This key is valid only for the second, third, or fourth line.
F4, CHOICE
Selects a reference plane format from the options indicated above.
F5, RECORD
This key is used to store the position data which determines a reference plane through position teaching. This key is valid only for the second, third, or fourth line.
POSTURE CONVERSION
Reference plane Group :[1] 1 Reference Plane Teach: 2 Adjust Posture: [ TYPE ]
Table 9--17.
CLEAR
ADJUST
[CHOICE] RECORD>
Reference prane screen (ADJUST case) Setup item Description DESCRIPTION
ITEM Reference Plane Teach:
See above.
Adjust Posture:
Indicates whether the torch posture for determining a reference plane has been specified. If the posture is not currently stored, ****** is displayed. If the posture has already been stored, the same field appears blank.
Table 9--18.
Reference prane screen (ADJUST case) Function keys Description
ITEM
DESCRIPTION
F2, CLEAR
Erases the reference plane data.
F4, CHOICE
Selects a reference plane format from the options given above.
F5, RECORD
This key is used to store the position data that is used to determine a reference plane by means of position teaching. This key is valid only for the second, third, or fourth line.
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Terminology WORD Travel angle
DESCRIPTION Indicates the angle between a path direction vector and a Z--vector of the tool frame. When the angle between the vectors is 90 degrees, the travel angle will be 0 degrees. The travel angle is negative when the angle between the vectors is less than 90 degrees. The travel angle is positive when the angle between the vectors is greater than 90 degrees. 0 deg
(+)
(--)
Direction of movement Work angle
Indicates the angle between the Z--vector of the tool frame and the reference plane. 90 deg 0 deg
Direction of movement
180 deg Spin angle
Indicates the angle of rotation around the Z--axis of the tool frame.
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9.13 Torch Posture Adjustment This function adjusts the torch posture by a given amount upon a function key being pressed to change the work angle, travel angle, or stick out. This function has been developed to reduce the number of manhours required for teaching. The quality of arc welding depends on the torch posture. A correct travel angle, work angle, and stick out must be specified, therefore. If the welding quality is poor, the torch posture must be adjusted by respecifying the travel angle, work angle, or stick out. This function enables fine adjustment of the torch posture over the entire welding path, resulting in fewer manhours being required for teaching. This function differs from the posture conversion function in that the reference plane need not be specified. Torch posture adjustment can thus be executed much more easily. This function adjusts the torch posture by a given amount upon a function key being pressed to change the work angle, travel angle, or stick out. When this function is used, the following must be noted: WARNING Interference with the workpiece is not considered in calculating the torch posture. There is a danger, therefore, of the torch striking the workpiece. Care should be exercised when the program is executed, therefore. For example, override should be minimized and step execution should be selected.
WARNING Adjustment at a corner may result in a sudden change in the torch posture. Care should be exercised when the program is executed to check the adjustment, therefore. For example, override should be minimized and step execution should be selected.
WARNING Specifying the adjustment range incorrectly may result in the torch assuming an unexpected posture. Care should be taken when specifying the adjustment range, therefore. Care should be taken when the program is executed to check the adjustment. For example, override should be minimized and step execution should be selected.
NOTE Torch posture adjustment is covered by the torch posture conversion function option software. Function description The quality of arc welding depends on the torch posture. A correct travel angle, work angle, and stick out must be specified, therefore. If the welding quality is poor, the torch posture must be adjusted by respecifying the travel angle, work angle, or stick out. This function enables fine adjustment of the torch posture over the entire welding path, resulting in fewer manhours being required for teaching. NOTE The tool frame must be set so that the Z (+) direction corresponds to the torch direction.
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Torch
+Z +Y Wire
+X NOTE The TCP accuracy largely depends on the accuracy of the adjustment made with this function. All settings must be made in order to maximize TCP accuracy. NOTE This function cannot be used under the following conditions: F
The conversion range does not contain two or more motion instructions.
F
The conversion range contains a motion instruction that uses a position held in a position register.
F
The conversion range contains an incremental statement.
F
The conversion range contains a palletizing statement.
F
The target robot is NOBOT.
Setting execution procedure F
Set the tool frame so that the Z (+) direction corresponds to the torch direction.
Torch
+Z +Y Wire
+X F
The TCP accuracy largely depends on the accuracy of the adjustment made with this function. All settings must be made in order to maximize TCP accuracy.
F
Specify an adjustment program name, adjustment range, and the adjustment values (stick out, travel angle, work angle) on the path adjust screen.
F
Press the F3 (EXECUTE) key. Then, press the F4 (YES) key. Once adjustment has been completed, this message appears on the command line: ”The conversion was completed.”
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F
The signs of the travel angle, work angle, and stick out are defined as shown below:
0 deg
Travel angle
(--)
(+)
Direction of movement 90 deg Work angle 0 deg
Direction of movement
180 deg
Stick out
(+)
Direction of movement (--)
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Types of settings screens and their display POSTURE CONVERSION Program: Group :[1] 1 Original Program: 2 Range: 3 Start line: 4 End line: Adjustment values 5 Stick out: 6 Travel angle: 7 Work angle: [ TYPE ] REVERSE CLEAR
Table 9--19.
[MAIN ] PART 5 10 0.0mm 0.0deg 0.0deg
EXECUTE
>
GROUP
>
Torch posture adjustment Setup item Description
ITEM
DESCRIPTION
Group :[1]
Indicates the motion group to be adjusted. To change the indicated group, press the F7 (GROUP) key. At the prompt, enter a desired group number.
Original Program:
Enter the name of the program to be adjusted. If this screen is displayed when nothing is specified for this item, the current program is selected by default.
Range:
Specify WHOLE or PART as the adjustment range. When PART is selected, the start and end lines must be specified.
Start line:
Specify the start line of the adjustment range.
End
Specify the end line of the adjustment range.
line:
Stick out:
Set the amount by which the stick out will be changed.
Travel angle:
Set the amount by which the travel angle will be changed.
Work angle:
Set the amount by which the work angle will be changed.
Table 9--20.
Torch posture adjustment Function keys Description
ITEM
DESCRIPTION
F3, EXECUTE
Executes torch posture adjustment to add the specified amount of change.
F2, REVERSE
Executes torch posture adjustment to subtract the specified amount of change.
F6, CLEAR
Initializes the Original program name, Start line, End line, motion group number, and cursor line. NOTE When the original program name is erased, the current program, if selected, is set immediately.
F7, GROUP
Specifies the motion group to be adjusted.
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Terminology WORD Travel angle
DESCRIPTION Indicates an angle between a path direction vector and a Z--vector of the tool frame. When the angle between the vectors is 90 degrees, the travel angle will be 0 degrees. The travel angle is negative when the angle between the vectors is less than 90 degrees. The travel angle is positive when the angle between the vectors is greater than 90 degrees. 0 deg
(+)
(--)
Direction of movement Work angle
Indicates the angle between the Z--vector of the tool frame and the reference plane. 90 deg 0 deg
Direction of movement
180 deg Stick out
Indicates the amount by which the wire protrudes from the contact tip.
Stick out
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9.14 Tast Tracking Function In many gas metal arc welding (MIG) applications, the weld joints are not repeatable to within one-half the weld filler material diameter. Typically, these applications cannot be satisfactorily welded by a robot without some means of adaptive control. Inconsistent forgings, stampings and castings, tolerance stack-up, distortion, and fixturing are some of the common causes of repeatability problems. Sensors adapt the path of the robot to the weld seam to ensure consistent weld quality. Through-Arc Seam Tracking (TAST) (an optional feature) is used in constant voltage gas metal arc welding (GMAW), also known as MIG, processes. In these processes, the current varies as a function of the distance between the contact tip and the weld puddle. TAST can be used with SINE type weaving that includes vertical and lateral tracking or without weaving that includes vertical tracking only. Also TAST can be used with linear or circular motion. TAST supports any ferrous metal welding where the feedback current signal is in a steady state and stable condition. TAST can be used with these kinds of processes: F
Gas metal arc welding -- Short circuit -- Globular -- Spray -- Pulse (50 to 150 Hz)
F
Shielding gases -- Ar and Ar--C02 -- C02 -- Ar and O2
NOTE TAST will not function properly if you program a weld parameter ramp during tracking. It is recommended that you program ramps only in the non-tracking portions of a weld. You can turn off tracking during the ramp and then turn it on again with a new and appropriate tracking schedule. Refer to Section 6.8 for more information on using the arc welding parameter ramping option.
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9.14.1 Tast tracking TAST allows the robot to track a weld seam both vertically, in the distance between the torch and workpiece, and laterally, across the seam by monitoring changes in the weld current. The information provided by TAST enables the system to adjust the robot path to keep the weld centered in the joint. The robot path can be adjusted for the weave plane and the vertical plane (z-direction of the tool). You can use vertical tracking with or without lateral tracking, and with or without weaving. See Figure 9--29. NOTE The six point method for setting the tool frame must be used for proper tracking. When jogging in tool, coordinate z+ should move along the nozzle of the torch and away from the work. Figure 9--29. Thru-Arc Seam Tracking Vertical tracking Lateral tracking
Torch
Stickout Resistance Metal
Groove
Arc
Weave
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9.14.1.1 Weave plane (XY-plane) lateral tracking When weaving, the current varies as the torch moves back and forth across the seam. The side walls of the seam have a higher current value than the center of the seam because of a decrease in weld wire resistance. This decrease in resistance is due to shorter wire stickout. The current feedback follows a cyclic pattern generated by changes in the wire stickout. See Figure 9--30. Figure 9--30. Current Feedback Pattern of Centered Weld
L
L
Weaving path
Vgroove ctr
R
Feedback current
Motion
(A) Lc
Rc
Lc =
Rc
If the weld becomes off-center, the pattern becomes offset and distorted. See Figure 9--31. TAST samples the current feedback and calculates the area under the curve for each side of the weld. If the area under the left side is greater than that of the right, the robot path is corrected toward the right, and vice versa. These weld path corrections occur after each weave cycle. Figure 9--31. Current Feedback Pattern of Weld Shifted to the Right
L
L Vgroove ctr
Weaving path Motion
R Feedback current
(A) Lc
Rc
Lc < Rc
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9.14.1.2 Vertical plane (Z-plane) tracking The weld can distort either downward, away from the torch or upward, toward the torch. TAST tracks the current at the center of the weld so the robot path can be offset to compensate for this distortion. See Figure 9--32. Figure 9--32. TAST Vertical Tracking Moving
Compensate upward (Z+)
Work
Current
Co C1 Co < C1
When TAST vertically tracks a weld, it compares the current at the weave center to a reference current reading. TAST samples the current after a predetermined number of weave cycles at the beginning of the weld, and uses the recorded value as the reference, or a weld current value can be entered. If the weld seam is offset downward, away from the weld torch, the current at the center of the weave decreases due to the lengthening of the wire stickout. A path offset will be issued to move the welding torch closer to the seam. If the weld seam is offset upward, toward the torch, the current increases because the wire stickout is shortened, causing less resistance. The offset then corrects the robot path by moving it farther away from the seam. The reference current can be set to a constant value when tracking vertically. Refer to the definition of V_Master Current Constant in Table 9--22.
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9.14.2 Factors that affect tast tracking TAST performance can be affected by a number of factors. For most applications, after parameters are set, in-process adjustments are not required. Factors that can affect TAST are: F
Changes in welding wire type (such as steel and stainless steel)
F
Changes in welding wire diameter
F
Extreme changes in weld size
F
Changes in the welding arc location in respect to the weld puddle
F
Gas composition
F
Transfer type or arc transfer mechanism such as spray, short circuiting, pulsed spray, or globular
F
Changes in weaving conditions (frequency, dwell time)
F
Material surface condition
F
Extreme changes in workplace temperature CAUTION
If you use the on-the-fly function to change welding conditions or welding speed during TAST execution, TAST performance will be affected.
NOTE If your system has more than two motion groups, the Adjust Delay Time should be set to 0.14 sec. This delay time is automatically set up when the software is installed. Refer to Table 9--22 for more information about Adjust Delay Time.
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9.14.3 Tast application guidelines Application guidelines include: NOTE These are guidelines only. In some cases, welds that are outside of these guidelines can be tracked successfully. F
The material thickness should be greater than 2 mm.
F
Grooves should have a consistent included angle of 90 degrees or less.
F
Fillet joints can have a maximum included angle of 90 degrees and must have at least 5 mm leg length.
F
The minimum weave width must be three times the diameter of the electrode or greater.
F
Tack weld, leg size, should be less than or equal to one-half the weld size, if possible, and concave in profile.
F
The actual weld seam should deviate less than 15 degrees rotation from the taught weld seam.
F
The torch must be positioned close to the center of the weld seam at the start of the weld; Touch Sensing might be necessary.
F
Outside corner and lap joint fillets must use a weave width of 2 mm less than the base metal thickness.
F
Fit up of the joint (gap) must be within normal (blind) welding robot tolerances. Ideally, gaps should be consistent along the weld path
F
Base metal must be ferrous or have a resistance greater than mild steel.
F
TAST uses SINE type weaving only.
Optimum TAST performance (.045, solid wire) occurs with the following weave and shielding gas combinations. Refer to Section 3.6 Setting for Weaving for more information about the Weave Setup screen. Make the following changes: F
Set amplitude to 1.5 mm or greater.
F
Set frequency to 4.0 HZ or less.
F
Set dwell time to .05 sec or greater.
F
Use Ar--O2 98/2, 95/5 or Ar--CO2 90/10
See Figure 9--33 for recommended weld joint configurations that can be used with TAST. Figure 9--33. TAST Weld Joint Configurations Fillets
Corner fillets
Lap joints
Back butt (Square grooves)
Prepared grooves
Other prepared joints
9.14.4 Tast hardware requirements The welding power source (interface) must provide 0--10 volt analog feedback signals that correspond to the weld current. Additional filtering can be required if a pulsed power supply is used and the pulse frequency approaches 15--20 times the weave frequency. Pulsing above 60 Hz will not cause problems. CS500 and CS1000 Hall Effect Current Sensors are included with the TAST software option.
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9.14.5 Tast programming See Figure 9--34 for a TAST programming example. CAUTION
Recorded positions and position registers are affected by UFRAME, and UFRAME has an effect during playback. If you change UFRAME, any recorded positions and position registers will also change. Figure 9--34. TAST Example Program
1: 2: : 3: 4: 5: : 6: 7: 8:
J P[1] 100% CNT100 J P[2] 100% FINE Arc Start [1] Weave Sine [1] Track TAST [1] L P[3] 20IPM FINE Arc End[2] Track End Weave End J P[4] 100% CNT100
9.14.6 Tast schedule setup A TAST schedule allows you to set how TAST will function. There are two screens associated with TAST: the SCHEDULE screen and the DETAIL screen. The schedule screen allows you to view limited information for all TAST schedules. The detail screen allows you to view the complete information for a single TAST schedule. Table 9--21 lists and describes each condition on the TAST SCHEDULE screen. Table 9--22 lists and describes each condition on the TAST DETAIL screen. Use Procedure 9--12 to set up TAST. Table 9--21.
TAST Setup Condition SCHEDULE Screen
CONDITION
DESCRIPTION
V--Gain--L
This item displays and allows you to change the vertical and lateral gain independently. When using both, adjust within 2%.
V_Cur(A)
This item displays and allows you to change the vertical current reference value.
V--Bias(%)--L
This item displays and allows you to change the vertical and lateral bias independently.
Table 9--22.
TAST Setup Conditions DETAIL Screen DESCRIPTION
CONDITION TAST Schedule:[n] TAST schedule: [
This item indicates the schedule whose information is currently being displayed and allows you to change to a different schedule. ]
V_compensation enable default: TRUE
This item allows you to enter a comment for this schedule. This item allows you to enable or disable TAST tracking in the vertical direction (z plane). If both L_compensation enable and V_compensation enable are disabled, TAST is non-functional. F TRUE indicates that TAST tracking in the vertical direction is enabled. F
L_compensation enable default: TRUE
FALSE indicates that TAST tracking in the vertical direction is disabled.
This item allows you to enable or disable TAST tracking in the lateral direction (xy-plane). If both L_compensation enable and V_compensation enable are disabled, TAST is non-functional. F TRUE indicates that TAST tracking in the lateral direction is enabled. F
FALSE indicates that TAST tracking in the lateral direction is disabled
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Table 9--22. (Cont’d) TAST Setup Conditions DETAIL Screen CONDITION V_master current type (feedback/constant) default: FEEDBACK
DESCRIPTION This item allows you to specify the weld current that TAST uses to compare the tracking data. F FEEDBACK indicates that the actual weld controller feedback at the center of the weave. It will be used for the reference sample. F
CONSTANT indicates that the value of the V_master current constant in the Track Schedule. It will also be used for the reference sample.
Sampling timing (no WV) default: 0.5 sec min: 0.0 sec max: 99.99 sec
This item allows you to set the length of time in seconds that the arc welding system will sample the current feedback. This is used for tracking without weaving only. If you are weaving, the arc welding system samples the current every weave cycle. This can only be used for vertical tracking without weaving.
Comp frame (no WV) default: TOOL
This item allows you to specify the frame, either Tool or User, which will be used as the reference frame when tracking vertically without weaving. This frame must be accurately defined for TAST to function correctly. Refer to Chapter 3.15 Setting coordinate systems for more information about frame setup. If you are weaving, the value of frame type on the SETUP Weave screen determines the reference frame. F TOOL indicates that the tool frame z axis will be used as the reference frame when tracking laterally without weaving. F
USER indicates that the user frame z axis will be used as the reference frame when tracking laterally without weaving.
V_compensation gain (sensitivity) default: 25.0 min: 0 max: 99.999
This item allows you to specify the conversion scale that TAST uses to convert the incoming amperage to millimeters per 10 amperes (mm/10A) and for vertical tracking. The default value is 25. If V_compensation gain enable is set to 0, vertical tracking is disabled.
V_dead band default: 0 mm min: 0 mm max: 999.9 mm
This item allows you to specify an amount of data, in millimeters, which TAST will ignore before generating an offset. If the V_dead band value is set to 0.5 mm, TAST will not generate an offset until the required offset exceeds 0.5 mm. V_dead band is used for arc welding systems that have unstable feedback conditions. See Figure Figure 9--35.
V_bias rate (up +) default: 0 min: --99.9 max: 99.9
This item allows you to set the percentage that the offset will compensate closer to or further away from the workpiece. If this value is set to a negative percentage, the offset will be towards the workpiece. If this value is set to a positive percentage, the offset will be away from the workpiece.
V_tracking limit default: 600.0 mm min: 0 mm max: 9999.9 mm
This item allows you to set the length, in millimeters, that TAST will compensate vertically. If the weld extends beyond this length, TAST will not make any vertical corrections. If this value is set to 0, vertical tracking is disabled.
V_tracking limit per cycle default: 1.0 mm min: 0 mm max: 9999.9 mm
This item allows you to specify the length, in millimeters, that TAST will compensate vertically per weave cycle.
V_compensation start count default: 5 min: 2 max: 999
This item allows you to specify the weave cycle number for TAST to start tracking the weld vertically. This allows time for the arc to stabilize prior to tracking. If the value is set to less than 4, the value is ignored and the system starts to track on the third cycle.
V_master sampling start count (feedback) default: 4 min: 2 max: 999
This item allows you to specify at which weave cycle TAST will start collecting the reference sample. This allows the arc enough time to stabilize before recording the sample data.
V_mastering sampling count (feedback)
This item allows you to specify the number of weave cycles for which the arc welding system will collect the reference weld current sample for vertical tracking.
default: 1 min: 1 max: 999
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Table 9--22. (Cont’d) TAST Setup Conditions DETAIL Screen CONDITION
DESCRIPTION
V_master current constant data (constant) default: 0 min: 0 max: 999.9
This item allows you to specify a constant weld current value which is used as the reference weld current sample instead of using feedback from the system. When V_master current type is specified as CONSTANT, then TAST will use this value.
L_compensation gain (sensitivity) default: 25.0 min: 0 max: 99.999
This item allows you to specify the conversion scale TAST uses to convert the incoming amperage to millimeters per 10 amperes (mm/10A) for lateral tracking. The default value is 25. If L_compensation gain enable is set to 0, lateral tracking is disabled.
L_dead band default: 0 min: 0 max: 999.9
This item allows you to specify an amount of data, in millimeters, which TAST will ignore before generating an offset. If the L_dead band value is set to 0.5 mm, TAST will not generate an offset until the required offset exceeds 0.5 mm. L_dead band is used for arc welding systems that have unstable feedback conditions.
L_bias rate (right +) default: 0 min: --99.9 max: 99.9
This item allows you to set the percentage that the offset will compensate towards the left or right side. If this value is set to a negative percentage, the offset will be towards the left side of the weld when looking in the direction of travel. If this value is set to a positive percentage, the offset will be towards the right side of the weld. Left and right directions are relative to robot tip travel direction.
L_tracking limit default: 600.0 mm min: 0 mm max: 9999.9 mm
This item allows you to set the length, in millimeters, that TAST will track the weld laterally. If the weld extends beyond this length, TAST will not make any lateral corrections. If this value is set to 0, lateral tracking is disabled.
L_tracking limit per cycle default: 1.0 mm min: 0 mm max: 9999.9 mm
This item allows you to specify the length, in millimeters, that TAST will compensate vertically per weave cycle.
L_compensation start count default: 5 min: 2 max: 999
This item allows you to specify the weave cycle number for TAST to start tracking the weld laterally. This allows time for the arc to stabilize prior to tracking. If the value is set to less than 3, the value is ignored and the system starts to track on the third cycle.
Motion group number default: 1 min: 1 max: 3
This item allows you to specify the motion group that is actually doing the welding. If you do not have multiple motion groups, set this to 1.
Adjust delay time default:.10 single motion group: .14sec multi motion groups: .14sec min: .01 sec max: 9.99 sec
This item is automatically set when TAST is installed. The default value for single motion and multiple motion group is set at the time of software installation.
Adaptive Gain Control
TAST checks the direction of vertical or lateral calculated compensation value (up/down or right/left) for each cycle. If the check determines the compensation value uses the same direction multiple times, then this indicates the offset is still smaller than the actual value. Adaptive gain allows you to set a value that is multiplied times the gain value. The applied offset is larger than normal and the torch can return to the weld center faster.
V_AG_correction count (0: disable) default: 0 cyc min: 0 max: 99
This item allows you to specify the weave cycle in which the adaptive gain control begins checking the vertical compensation direction. The vertical adaptive gain function is effective if the calculated compensation values tend to be biased one way, either up or down. If the V_AG correction count is set to 0, it is disabled. The vertical adaptive gain function is enabled when the V_AG correction count is set to 2 or higher.
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Table 9--22. (Cont’d) TAST Setup Conditions DETAIL Screen CONDITION L_AG_correction count (0: disable) default: 0 cyc min: 0 max: 99
DESCRIPTION This item allows you to specify the weave cycle in which the adaptive gain control begins checking the lateral compensation direction. The lateral adaptive gain function is effective if the calculated compensation values tend to be biased to one side, either left or right. If the L_AG correction count is set to 0, it is automatically disabled. The lateral adaptive gain function is enabled when the L_AG correction count is set to 2 or higher.
V_AG_correction band default: 4.0 min: 0 max: 9.9
This item allows you to specify the amount of data to which the lateral adaptive gain function compares the calculated lateral compensation. If the value is set to a small amount, the adaptive gain is disabled until the required offset exceeds the set value. A value of over 6.0 is required when using a small circular weld or when the weld is not stable.
L_AG_correction band default: 4.0 min: 0 max: 9.9
This item allows you to specify the amount of data to which the lateral adaptive gain function compares the calculated lateral compensation. If the value is set to a small amount, the adaptive gain is disabled until the required offset exceeds the set value. A value of over 6.0 is required when using a small circular weld or when the weld is not stable.
V_AG_multiplier default: 1.5 min: 1.0 max: 9.9
This item specifies the multiplier for vertical adaptive gain.
L_AG_multiplier default: 1.5 min: 1.0 max: 9.9
This item specifies the multiplier when lateral adaptive gain.
Figure 9--35. Dead Band for Vertical Tracking
Small dead band = small steps Ideal path
Offset path
Taught path Large dead band = large steps Offset path Ideal path
Taught path
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Procedure 9--12 Step
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Setting Up Thru-Arc Seam Tracking
1 Press DATA. 2 Press F1, [TYPE]. 3 Select Track Sched. You will see a screen similar to the following. DATA
TAST Sched V-Gain-L 25.0 20.0 25.0 20.0 25.0 20.0 25.0 20.0 25.0 20.0 25.0 20.0 25.0 20.0 25.0 20.0 25.0 20.0
1 2 3 4 5 6 7 8 9
[TYPE]
G1 V_Cur (A) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
JOINT
50% 1/8 V-Bias (%)-L 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
DETAIL
HELP >
4 Press F2, DETAIL. You will see a screen similar to the following. DATA
TAST Sched
G1
JOINT
50% 1/29
TAST Schedule: [1] 1 TAST Schedule: [First Pass ] 2 V_compensation enable: TRUE 3 L_compensation enable: TRUE 4 V_master current type: Feedbk (feedback/constant) 28 V_AG_multiplier 29 L_AG_multiplier [TYPE]
DETAIL
1.5 1.5 HELP>
5 Move the cursor to the TAST schedule data value that you want to change, type the new value, and press ENTER.
9.14.7 Special functions TAST has special functions that allow the robot to move to a taught position. These functions are useful to move the robot around a clamp while the last offset value is maintained. Carry On Offset The Carry On Offset function allows the robot to move to a taught position with the last TAST offset and then start to execute TAST with welding, again. These functions are useful to move the robot around a clamp while the last offset value is maintained. F
Select another TAST schedule which includes changed parameters
F
Linear motion is required on non-tracking path
See Figure 9--36 for a Carry On Offset Function Example. See Figure 9--37 for a Carry On Offset Example Program. Perform Procedure 9--13 to use the Carry On Offset function.
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Figure 9--36. Carry On Offset Function Example
X X
}
X Offset (mm)
X
p[1]
p[2]
p[3]
p[4]
X
X
X
X
Track TAST
no tracking
p[2] +offset (mm)
p[3] +offset (mm)
p[5]
X Track TAST
p[4] +offset (mm)
Figure 9--37. Carry On Offset Example Program
No Tracking Offset
{
1: : 2: 3: 4: : 5: 6: 7: 8:
9: 10: 11: 12: 13:
Procedure 9--13 Step
J P[1] 40% Fine Arc Start [1] Weave Sine [1] Track TAST [1] L P[2] 20IPM Fine Arc End[2] Weave End Change TAST schedule Track TAST [5] <--- for carry on offset L P[3] 100 mm/s Fine <--- ”L” is required L P[4] 100 mm/s Fine <--- ”L” is required Arc Start [1] Weave Sine [1] Track TAST [1] <--- Tracking resumed L P[5] 20IPM Fine Arc End [1] Weave End Track End
Carry On Offset
1 Copy the TAST Schedule to an available Track Schedule number. 2 Set V_Tracking limit per cycle: 0.0 mm. 3 Set L_Tracking limit per cycle: 0.0 mm. NOTE All other parameters = TAST [2].
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9.14.8 Adjustment of gain value Gain value adjustment might be necessary if TAST performance is poor. The TAST GAIN parameter adjusts seam tracking sensitivity. If the lateral gain is too high, the path correction for each weave cycle will be too large, causing the weld bead to ”snake” back and forth across the weld joint in a sinusoidal pattern. If the lateral gain is too low, the tracking correction to the taught path will be insufficient to match the part deviation. You should F
Write a test program to track the joint in question
F
Adjust TAST Schedule Parameters Gain Values
F
Execute TAST program with arc welding
9.14.8.1 Tracking failure conditions The following are causes for poor tracking performance or failure to track at all: F
Gain is too low -- Adjust gains using large incremental values of 20 -- 30. Re-adjust gains until snaking occurs, then decrease gains slowly until snaking no longer occurs.
F
Positions taught incorrectly -- If you do not see snaking when the gain values are 80..100, then the hardware connection, welding condition or TAST parameter settings have a problem. -- Touch up the destination position with the torch +/ -- 6 mm out of the weld joint. Execute the TAST program again and Readjust gains until snaking occurs. -- Refer to Section 9.14.9.
F
Bias is required because of torch angle and wire bending -- Bias problems can be caused by torch orientation, part orientation, or wire flip/bending. -- Change torch orientation if possible, to minimize vertical bias requirement. -- Change bias parameters and execute program again. Refer to Table 9--22, TAST Setup Conditions DETAIL Screen.
F
The welding arc is not stable -- Check the Weld Parameters and Metal Preparation. Refer to Chapter 3. SETTING UP THE ARC WELDING SYSTEM
F
Weaving amplitude is too small for a good feedback signal -- Check the Weave Parameters, and increase the weave amplitude.
F
Hardware connection has problems -- Inspect Hardware connections. See Section 9.14.4 for TAST hardware connections. -- Check the settings of the TAST parameters. For additional information refer to Section 9.14.9. -- Check feedback circuit polarity on CS Series Hall Effect Sensor.
9.14.8.2 Fine adjusting TAST performs best when the parameters for Gain and Compensation per Weave Cycle are set to just below unstable/overreaction. The adjustment is best made by causing Unstable conditions to exist, then incrementally reducing the parameters until the tracking becomes smooth. To complete Fine Adjusting of the weld parameters, follow Procedure 9--14 . Procedure 9--14 Step
Fine Adjusting
1 Execute the Weld Program Tracking. 2 Check the following: F
No snaking Vertical and Lateral gain values should be increased by the same amount. Try welding again until snaking is found.
F
Snaking The gain values should be decreased in small increments (2.0 or 3.0) until snaking stops.
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9.14.9 Tast troubleshooting This troubleshooting information is provided as an aid to solve poor robot tracking performance.
9.14.9.1 Poor tracking performance There are several reasons that might lead to poor tracking performance. They are as follows: F
No compensation with high Vertical or Lateral gain setting
F
Poor welding or workpiece conditions.
F
The robot wanders away from the path and does not return to the center
F
Weld path is shifted
F
Slow response
F
Snaking
F
Weld path has changed on specific position
F
Significant changes in joint gap
F
Extreme changes in workpiece temperature.
9.14.9.2 No compensation with high vertical or lateral gain setting If the welding path does not receive compensation with high gain values, then a gain value of 95 (V-gain) and a 90 (L-gain) should be tried. Use Procedure 9--15 to resolve no compensation. Procedure 9--15 Step
Resolve No Compensation
1 Set the value of V_master comp type to FEEDBACK on the DATA/TAST/DETAIL screen. 2 Execute TAST with arc welding and check the value of V_cur on the DATA/TAST screen. Proper value of V_cur is from 150 Amps to the maximum current capacity of the welding wire. 3 If the value is almost zero, check the hardware connection (CS-series Hall effect sensor or welding machine connection) from the welding machine to the R-J3 controller. If the value is small, check the setting of the analog input (Feedback current: port2). NOTE Be sure that scaling and hardware connections are correct for your welding equipment. 4 If the value is appropriate, check the setting data of TAST parameters compared with the value on the “TAST Parameter List.” Check the following data: F
V_track limit
F
V_tracking limit per cycle
F
L_tracking limit
F
L_tracking limit per cycle
5 If the data seems to be correct, refer to Section 9.14.9.1.
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9.14.9.3 TAST schedule If the TAST schedule data seems to be correct, use Procedure 9--16 to execute TAST. CAUTION Single step testing turns off tracking and welding. Do not use single step testing during tracking because it will cancel tracking and welding on the next motion instruction, and the desired motion will not be obtained for the next resumed motion.
Procedure 9--16 Condition
Executing TAST
H The Return to path parameter is enabled. TAST requires that this parameter be enabled. Refer to Section 3.2 Setting the Arc Welding System. H TOOL and PATH frame are set for proper weaving performance. Check the weave setup. Refer to Chapter 3. SETTING UP THE ARC WELDING SYSTEM.
Step
1 Set a large weave amplitude, such as 3.0 mm or greater. 2 Set a large weave center rise value, such as 2.0 mm center rise. 3 Test run the program. If the result is not improved, check the following items: F
Check Gas composition.
F
Adjust the weld until a good, stable arc is achieved.
F
Execute the program without arc welding and check whether the robot has any vibration during weaving. If heavy vibration is visible, slightly adjust the value of the elevation angle and the azimuth angle to decrease the vibration when weaving. Adjust in increments of 2 -- 5 degrees.
9.14.9.4 Robot wanders from path Use Procedure 9--17 to correct the path set if the robot wanders from the correct path set. Procedure 9--17 Step
Correcting the Path Set
1 Increase the V and L gain values. 2 Execute TAST again. 3 If you see snaking, then decrease the gain values in small increments until the snaking stops. Refer to Section 9.14.9.2 to solve the problem.
9.14.9.5 Weld path is shifted If the weld path shifted F
Adjust gain values properly
F
Set proper torch angle. If the torch angle is shifted, it causes weld path shifting
F
If no adjustment of torch position can be made, the bias values should be adjusted. Refer to Table 9--22.
9.14.9.6 Slow response If the robot exhibits slow response F
Review and/or adjust gain values
F
Check motion control parameters -- V_track limit -- V_tracking limit per cycle -- L_tracking limit -- L_tracking limit per cycle
Increase value of V_tracking limit per cycle and L_tracking limit per cycle, because the required compensation may be larger than those values. Also check to see whether the values of V_dead band and L_dead band are zero or small values (0.1 mm ). If too large, the tracking correction will occur only for large offsets.
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9.14.9.7 Weld path is snaking If the weld path is snaking, decrease the value of both L-gain and V-gain, in small increments until snaking stops.
9.14.9.8 Weld Path has Changed at a Specific Position If the weld path has changed at a specific position F
Check wire flip at the problem point by executing the program with weld OFF and observe the wire closely. The weld system may have weld wire delivery problems, such as torch liner or contact tip wear.
F
Check to see whether the welding schedule changes at the position.
F
Check to see whether the torch is touching the workpiece.
9.14.9.9 Significant changes in joint gap If the joint gap changes significantly, TAST performance might be affected. To avoid this problem, you should: F
Maintain a constant joint gap as much as possible.
F
Use as large a work angle as possible.
F
Apply different TAST schedules for different joint gaps.
9.14.9.10 Extreme changes in workpiece temperature If the workpiece temperature varies to an extreme degree, TAST performance may be affected. To avoid this problem, you should: F
Reduce variations in workpiece temperature whenver possible
F
Apply different TAST schedules for areas of the workpiece with extreme temperature differences.
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9.15 Automatic Voltage Control Tracking In many gas tungsten arc welding (TIG) applications, the weld joint location varies to a degree that weld quality is not acceptable. Typically, these applications cannot be welded satisfactorily by a robot without some means of adaptive control. Inconsistent forming, castings, tolerance stack-up, distortion, and fixturing are just some of the common causes of repeatability problems. Sensors adapt the path of the robot to the weld seam to ensure consistent weld quality. Automatic Voltage Control (AVC) (an optional feature) is used in constant current welding processes. In these processes, the voltage varies as a function of the distance between the electrode and the weld puddle. AVC can be used on linear or circular paths. AVC can also be used with or without weaving. However, if weaving is used, the weave type must be SINE. AVC can be used with these kinds of processes: F
Gas Tungsten arc welding -- DC electrode negative (straight) or electrode positive (reverse). -- AC -- Pulsed .1 to 10 Hz
F
Shielding gasses -- Ar -- He -- Ar/He
9.15.1 AVC Tracking AVC allows the robot to track a weld seam by monitoring changes in the weld voltage both vertically and across the seam. The information provided by AVC enables the system to adjust the robot path to keep the weld aligned with the joint. Typical applications for AVC utilize vertical tracking only to maintain the weld current along the weld path. AVC can also be used with weaving to laterally track a weld joint. See Figure 9--38. Figure 9--38. AVC Tracking Vertical tracking Lateral tracking
Torch
Stickout
Metal Groove
ARC
Weave
546
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Vertical Plane (Z-Plane) Tracking The weld can distort either downward away from the torch or upward toward the torch. AVC tracks the voltage during the weld so the robot path can be offset to compensate for distortion or inconsistent parts. See Figure 9--39. Figure 9--39. AVC Vertical Tracking
Moving
Compensate upward
Work
Voltage
Co C1 Co < C1 When AVC vertically tracks a weld, it compares the voltage to a reference voltage setting. If weaving is used, then the software can sample the voltage after a predetermined number of weave cycles and use this value as the reference voltage value. If the weld seam is offset downward away from the weld torch, the voltage of the arc increases due to resistance caused by a lengthening of the arc length. A path offset will be issued to move the welding torch closer to the seam. If the weld seam is offset upward toward the torch, the voltage decreases because the arc length is shortened, causing less resistance. The offset then corrects the robot path by moving it farther away from the seam. The reference voltage can be set to a constant value when tracking vertically. Refer to the definition of V_Master Voltage Constant in Section 9.15.4.
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Weave Plane (XY-Plane) Lateral Tracking As the torch moves back and forth across the seam, the voltage varies. The side walls of the seam produce a lower voltage value than the center of the seam because of a decrease in arc resistance. This decrease in resistance is due to a shorter electrode to work distance. The voltage feedback follows a cyclic pattern generated by changes in the electrode to work distance. See Figure 9--40. Figure 9--40. Voltage Feedback Pattern of Centered Weld
L
L Vgroove ctr
Weaving path R
Motion
Feedback voltage (V)
Lc
Rc Lc =
Rc
If the weld becomes off--center, the pattern becomes offset and distorted. See Figure 9--41. AVC samples the voltage feedback and calculates the area under the curve for each side of the weld. If the area under the left side is greater than that of the right, the robot path is corrected toward the right, and vice versa. These weld path corrections occur after each weave cycle. Figure 9--41. Voltage Feedback Pattern of Weld Shifted to the Right
L
L
Weaving path
Vgroove ctr Motion R
Feedback voltage (V) Lc
Rc
Lc > Rc
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9.15.2 Factors that affect avc tracking AVC performance can be affected by a number of factors. For most applications, however, after parameters are set, in-process adjustments are not required. Factors that can affect AVC are: F
Changes in welding electrode type or diameter
F
Extreme changes in weld size
F
Changes in the welding arc location in respect to the weld puddle
F
Gas composition
F
Changes in weaving condition (frequency, dwell time)
F
Material surface condition CAUTION
If you use the On-The-Fly function to change welding conditions or welding speed during AVC execution, AVC performance is affected. NOTE If your system has more than 2 motion groups, the Adjust Delay Time should be set to 0.14 sec. This delay time is automatically set up when the software is installed. See Table 9--24 for more information about Adjust Delay Time.
9.15.3 AVC hardware requirements The welding power source (interface) must provide 0--10 volt analog feedback signals that correspond to the voltage at the weld. Additional filtering can be required if a pulsed power supply is used. Pulsing above 60 Hz will not cause problems.
9.15.4 AVC schedule setup An AVC schedule allows you to set how AVC will function. There are two screens associated with AVC: the SCHEDULE screen and the DETAIL screen. The schedule screen allows you to view limited information for all AVC schedules. The detail screen allows you to view the complete information for a single AVC schedule. Table 9--23 lists and describes each condition on the AVC schedule screen. Table 9--24 lists and describes each condition on the AVC detail screen. Table 9--23.
AVC Setup Condition Schedule Screen
CONDITION
DESCRIPTION
V--Gain--L
This item displays and allows you to change the vertical and lateral gain.
V_Volt(V)
This item displays and allows you to change the vertical voltage.
V--Bias(%)--L
This item displays and allows you to change the vertical and lateral bias.
Table 9--24.
AVC Setup Conditions DESCRIPTION
CONDITION AVC Schedule:[n] AVC schedule:[ V_compensation enable default: TRUE
This item indicates the schedule whose information is currently being displayed and allows you to change to a different schedule. ]
This item allows you to enter a comment for this schedule. This item allows you to enable or disable AVC tracking in the vertical direction (z plane). If both L_compensation enable and V_compensation enable are disabled, AVC is non--functional. F TRUE indicates that AVC tracking in the vertical direction is enabled. F
L_compensation enable default: TRUE
FALSE indicates that AVC tracking in the vertical direction is disabled.
This item allows you to enable or disable AVC tracking in the lateral direction (xy--plane). If both L_compensation enable and V_compensation enable are disabled, AVC is non--functional. F TRUE indicates that AVC tracking in the lateral direction is enabled. F
FALSE indicates that AVC tracking in the lateral direction is disabled.
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Table 9--24. (Cont’d) AVC Setup Conditions CONDITION V_master voltage type (feedback/constant) default: FEEDBACK:
DESCRIPTION This item allows you to specify whether the arc welding system uses the actual weld controller feedback for the reference sample or uses value of V_master voltage constant as the reference sample. The reference sample is the value to which the arc welding compares the tracking data. F FEEDBACK indicates that the actual weld controller feedback will be used for the reference sample. F
CONSTANT indicates that the value of the V_master voltage constant will be used for the reference sample.
Sampling timing (no WV) default: 0.2 sec min: 0.01 sec max: 99.99 sec
This item allows you to set the length of time that the arc welding system will sample the voltage feedback. This is used for tracking without weaving only. If you are weaving, the arc welding system samples the voltage every weave cycle.
Comp frame (no WV) default: TOOL
This item allows you to specify the frame, either Tool or User, which will be used as the reference frame when tracking without weaving. This frame must be accurately defined for AVC to function correctly. Refer to Chapter 2 for more information about frame setup. If you are weaving, the value of frame type on the Setup Weave screen determines the reference frame. F TOOL indicates that the tool frame will be used as the reference frame when tracking without weaving. F
USER indicates that the user frame will be used as the reference frame when tracking without weaving.
V_compensation gain (sensitivity) default: 25.0 min: 0 max: 99.999
This item allows you to specify the conversion scale the arc welding system uses to convert the incoming voltage to millimeters per 10 volts and add to the compensation data when tracking vertically. The default value is 25. If V_compensation gain enable is set to 0, it is automatically disabled when AVC is executed.
V_dead band default: 0 mm min: 0 mm max: 999.9 mm
This item allows you to specify an amount of data, in millimeters, which the arc welding system will ignore before generating an offset. If the V_dead band value is set to 0.5mm, the software will not generate an offset until the required offset exceeds 0.5mm. V_dead band is used for arc welding systems that have unstable feedback conditions. See Figure 9--42.
V_bias rate (up+) default: 0 min: --99.9 max: 99.9
This item allows you to set the percentage that the offset will compensate towards the top or bottom of a weld. Gravity can cause the downhill side of a weld to enlarge and degrade tracking. If this value is set to a negative percentage, the bias will reduce the arc length. If this value is set to a positive percentage, the bias will increase the arc length.
V_tracking limit default: 600.0 mm min: 0 mm max: 9999.9 mm
This item sets the length, in millimeters, that arc welding system will track the weld vertically. If this value is set to 0, vertical tracking is disabled. If the weld extends beyond this length, vertical tracking is disabled.
V_tracking limit per cycle default: 1.0 mm min: 0 mm max: 9999.9 mm
This item allows you to specify the length, in millimeters, the arc welding system will track the weld per weave cycle.
V_compensation start count default: 5 min: 2 max: 999
This item allows you to specify the cycle when the arc welding system will start to track the weld vertically. This allows time for the arc to stabilize prior to tracking. If the value is set to less than 4, the value is ignored and the system starts to track on the third cycle.
V_master sampling start count (feedback) default: 4 min: 2 max: 999
This item allows you to specify at which cycle the arc welding system will start collecting the reference sample. This allows the arc enough time to stabilize before recording the sample data.
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Table 9--24. (Cont’d) AVC Setup Conditions CONDITION
DESCRIPTION
V_master sampling count (feedback) default: 1 min: 1 max: 999
This item allows you to specify the number of cycles for which the arc welding system will collect the reference sample.
V_master voltage constant data (constant) default: 0 min: 0 max: 999.9
This item allows you to specify a constant value which is used as the reference sample instead of using feedback from the system. When V_master voltage type is specified as the reference sample, the arc welding system sets the reference voltage automatically. Therefore, the reference values can be certified after AVC execution.
L_compensation gain (sensitivity) default: 25 min: 0 max: 99.999
This item allows you to specify the conversion scale the arc welding system uses to convert the incoming voltage to millimeters per 10 volts and add to the compensation data when tracking laterally. The default value is 25. If L_compensation gain enable is set to 0, it is automatically disabled when AVC is executed.
L_dead band default: 0 min: 0 max: 99.999
This item allows you to specify an amount of data, in millimeters, which the arc welding system will ignore before generating an offset. If the L_dead band value is set to 0.5mm, the software will not generate an offset until the required offset exceeds 0.5mm. L_dead band is used for arc welding systems that have unstable feedback conditions. See Figure 9--42.
L_bias rate (right+) default: 0 min: --99.9 max: 99.9
This item allows you to set the percentage that the offset will compensate towards the left or right side. This is used when welding on a slant. Gravity can cause the downhill side of a weld to enlarge and degrade tracking. If this value is set to a negative percentage, the bias will be towards the left side of the weld when looking in the direction of travel. If this value is set to a positive percentage, the bias will be towards the right side of the weld.
L_tracking limit default: 600.0 mm min: 0 mm max: 9999.9 mm
This item sets the length, in millimeters, that arc welding system will track the weld laterally. If this value is set to 0, lateral tracking is disabled. If the weld extends beyond this length, lateral tracking is disabled.
L_tracking limit per cycle default: 1.0 mm min: 0 mm max: 9999.9 mm
This item allows you to specify the length, in millimeters, the arc welding system will track the weld vertically per weave cycle.
L_compensation start count default: 5 min: 2 max: 999
This item allows you to specify the cycle when the arc welding system will start to track the weld laterally. This allows time for the arc to stabilize prior to tracking. If the value is set to less than 3, the value is ignored and the system starts to track on the third cycle.
Motion group number default: 1 min: 1 max: 3
This item allows you to specify the motion group that is actually doing the welding. If you do not have multiple motion groups, this is set to 1.
Adjust delay time default: for single motion group: .2 sec for mult motion group: .23 sec min: .01 sec max: 9.99 sec
This item sets the amount of time that elapses before tracking begins. This allows time for the arc to stabilize prior to tracking. The default value is .23 sec and is acceptable for most applications. This is used with weaving only.
Adaptive Gain Control
AVC checks the direction of vertical or lateral calculated compensation values (up/down or right/left) for each cycle. If the check determines the compensation value uses the same direction multiple times, then this indicates the offset is still smaller than the actual value. Adaptive gain allows you to set a value that is multiplied times the gain value. The applied offset is larger than normal and the torch can return to the weld center quickly. Over the weld center, the gain value is set to normal.
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Table 9--24. (Cont’d) AVC Setup Conditions CONDITION
DESCRIPTION
V_AG_correction count (0: disable) default: 0 cyc min: 0 max: 99
This item allows you to specify the cycle in which the adaptive gain control begins checking the compensation direction. The vertical adaptive gain function is effective if the calculated compensation values are found to be slanted to one side (up/down).
L_AG_correction count (0: disable) default: 0 cyc min: 0 max: 99
This item allows you to specify the cycle in which the adaptive gain control begins checking the compensation direction. The lateral adaptive gain function is effective if the calculated compensation values are found to be slanted to one side (left/right).
V_AG_correction band default: 4.0 min: 0 max: 9.9
This item allows you to specify the amount of data to which the lateral adaptive gain function compares the calculated compensation.
If the V_AG correction count is set to 0, it is automatically disabled. The vertical adaptive gain function is enabled when the V_AG correction count is set to 2.
If the L_AG correction count is set to 0, it is automatically disabled. The lateral adaptive gain function is enabled when the L_AG correction count is set to 2.
If the value is set to a small amount, the adaptive gain is disabled until the required offset exceeds the set value. A value of over 6.0 is required when using a small circular weld or when the weld is not stable.
L_AG_correction band default: 4.0 min: 0 max: 9.9
This item allows you to specify the amount of data to which the lateral adaptive gain function compares the calculated compensation. If the value is set to a small amount, the adaptive gain is disabled until the required offset exceeds the set value. A value of over 6.0 is required when using a small circular weld or when the weld is not stable.
V_AG_multiplier default: 1.5 min: 1.0 max: 9.9
This item allows you to specify the multiplier when vertical adaptive gain is enabled.
L_AG_multiplier default: 1.5 min: 1.0 max: 9.9
This item allows you to specify the multiplier when lateral adaptive gain is enabled.
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Figure 9--42. Dead Band
Small dead band = small steps Ideal path
Offset path
Taught path Large dead band = large steps Offset path Ideal path
Taught path
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Procedure 9--18 Step
Setting Up AVC Tracking
1 Press MENUS. 2 Press DATA. 3 Press F1, [TYPE.] 4 Select Track Sched. You will see a screen similar to the following. DATA AVC
Sched
JOINT
V-Gain-L 1 2 3 4 5 6 7 8
25.00 25.00 25.00 25.00 25.00 25.00 25.00 25.00
[ TYPE ]
V-Volt(V)
20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
50 % 1/8
V-Bias(%)-L 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
DETAIL
HELP
5 Press F2, DETAIL. You will see a screen similar to the following. DATA AVC
Sched
JOINT
50 % 1/29
AVC Schedule: [1] 1 2 3 4
TAST Schedule: [First Pass V_compensation enable: TRUE L_compensation enable: TRUE V_master current type: Feedbk (feedback/constant)
28 V_AG_multiplier 29 L_AG_multiplier [ TYPE ]
]
1.5 1.5 HELP
9.15.5 AVC programming See Figure 9--43 for an AVC programming example. CAUTION Recorded positions and position registers are affected by UFRAME, and UFRAME has an effect during playback. If you change UFRAME, any recorded positions and position registers will also change.
Figure 9--43. AVC Example Program
1: 2: : 3: 4: : 5: 6:
J P[1] 100% CNT100 J P[2] 100% FINE Arc Start [1] Track AVC [1] L P[3] 20IPM FINE Arc End[2] Track End J P[4] 100% CNT100
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9.16 Root Pass Memorization and Multipass Root pass memorization (RPM) (optional feature) records position offset information provided by a tracking sensor. The recorded information provides accurate weld seam information during welding. RPM is used with Multipass (MP) welding. RPM/MP is an option that is included with Thru-Arc Seam Tracking (TAST) or AVC Tracking. Multipass welding is repeatedly welding the same seam to increase the weld size. The multipass instruction offers ways to offset the different weld passes. Offsetting the weld passes allows proper fill placement for quality bead profile and weld appearance. Multipass welding can be used with or without root pass memorization.
9.16.1 Root pass memorization Root pass memorization (RPM) is the process of recording position offset information at specified intervals during the root, or first, welding pass. See Figure 9--44. Position offset information is the difference between the robot positions you recorded during programming of the weld, and the robot positions that a tracking sensor indicated were best to weld the seam. Tracking sensors include Thru-Arc Seam Tracking (TAST), Automatic Voltage Control (AVC), and others. These offsets occur because of variations in welding conditions, such as part fixturing, and welding materials that can have an effect on part fit--up. The recorded positions plus the position offsets provide the true route the robot should take when welding the seam. How RPM Functions RPM records the position offset information to a buffer data area. By default, there are ten buffers available. This means that up to 10 weld paths can be tracked and recorded. The information that RPM records is specific to the program in which RPM is used, but more than one weld path can be recorded in a single program. See Figure 9--44. The recorded position offset information is stored in controller memory. The memory area in which the information is stored is pre-assigned during software installation. 32 blocks of memory are set aside for RPM information and is used as needed. You can increase the amount of memory that is set aside for RPM if you have more memory available. Also, you can increase the number of weld paths that can be recorded. Figure 9--44. How RPM Functions PITCH
}
10 mm
}
Recorded Positions for Weld Recorded Position Offsets
Actual Weld Seam
SYSTEM R-J3 Memory Buffer 1 Buffer 2 Buffer 3
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Using RPM With Multipass RPM is used for welds that require multiple passes to complete the weld. The multipass instruction will playback, or use, the RPM position offset information to compensate robot motion while welding the seam. There are two main purposes: 1 Your program does not have to track the weld seam on every pass. Secondary passes can be performed without tracking. 2 A multipass offset can be added to the RPM offset to shift the entire weld path. For more information about the multipass function refer to Section 9.16.2. Programming RPM To program RPM you use the TRACK/OFFSET instructions. For more information about the TRACK/OFFSET instructions, refer to Chapter NO TAG. The recording of positional offset information starts simultaneously with motion and tracking. See Figure 9--45 and Figure 9--46 for programming examples. CAUTION RPM recorded position offset information is specific to the program and positions in which RPM is used. The RPM program element cannot be used in a subprogram and then called to a main program for use with multipass. The MP OFFSET program element and the TRACK {sensor} RPM program element must reside in the same program.
CAUTION Recorded positions and positions registers are affected by UFRAME, and UFRAME has an affect during playback. If you change UFRAME, any recorded positions and position registers will also change.
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Figure 9--45. RPM Program Example 1:J 2:J : 3: 4: 5:L 6:L 7:C : 8:L 9:L : 10: 11: 12:J 13: 14:L : 15: 16:L 17:L 18:C : 19:L 20:L : 21: 22:
P[9] 100% FINE P[2] 40% FINE Arc Start[1] Weave Sine[1] Track TAST[1] RPM[1] P[3] 50.0inch/min CNT100 P[4] 50.0inch/min CNT100 P[5] P[6] 50.0inch/min CNT100 P[7] 50.0inch/min CNT100 P[8] 50.0inch/min FINE Arc End[1] Weave End Track End P[9] 100% FINE MP Offset PR[32] RPM[1] P[2] 500mm/sec FINE Arc Start[1] Weave Sine[1] P[3] 50.0inch/min CNT100 P[4] 50.0inch/min CNT100 P[5] P[6] 50.0inch/min CNT100 P[7] 50.0inch/min CNT100 P[8] 50.0inch/min FINE Arc End[1] Weave End MP Offset End
-- Record RPM Offset in RPM Buffer [1] The path between P[2] and P[8] is recorded
-- Playback RPM Buffer [1] with MP Offset
Figure 9--46. Changing $PITCH and $PITCH_MODE Programming Example -- Changes $PITCH_MODE to time. 1: $RPM_PG.$PITCH_MODE=1 -- Changes $PITCH to 120 ms between recordings 2: $RPM_PG.$PITCH=120 3:J P[9] 100% FINE 4:J P[2] 40% FINE : Arc Start[1] 5: Weave Sine[1] 6: Track TAST[1] RPM[1] 7:L P[3] 50.0inch/min CNT100 8:L P[4] 50.0inch/min CNT100 9:C P[5] : P[6] 50.0inch/min CNT100 10:L P[7] 50.0inch/min CNT100 11:L P[8] 50.0inch/min FINE : Arc End[1] 12: Weave End 13: Track End 14:J P[9] 100% FINE 15: MP Offset PR[32] RPM[1] 16:L P[2] 500mm/sec FINE : Arc Start[1] 17: Weave Sine[1] 18:L P[3] 50.0inch/min CNT100 19:L P[4] 50.0inch/min CNT100 20:C P[5] : P[6] 50.0inch/min CNT100 21:L P[7] 50.0inch/min CNT100 22:L P[8] 50.0inch/min FINE : Arc End[1] 23: Weave End 24: MP Offset End
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Setting RPM System Variables Ordinarily, modifying RPM system variables is not required. However, your site and specific type of welding might require some modifications to the $RPM_PG system variable. For more information about viewing and changing system variables, refer to Section 7.7. Table 9--25 contains a description of RPM system variables that you might modify. Table 9--25.
RPM System Variables DESCRIPTION
SYSTEM VARIABLE $RPM_PG.$PITCH default : 10 mm
This item allows you to specify the distance between the recording of position offset information. In other words, $PITCH specifies how often RPM will actually record the information that the sensor is supplying. This distance can be in time, milliseconds, or in linear distance, millimeters, depending upon the setting of $PITCH_MODE. When using milliseconds, the time between recording must be greater than 100 ms or an error will occur. When pitch mode is distance, the program speed has to be adjusted so that the time between the two records is greater than 100 ms. $PITCH can be changed in your program by using the PARAMETER NAME instruction. For more information about the PARAMETER NAME instruction, refer to Chapter 4. PROGRAM STRUCTURE.
$RPM_PG.$PITCH_MODE default: 0
This item allows you to specify whether the measurement used between recorded position offset information will be based in time, milliseconds, or in linear distance, millimeters. $PITCH controls the actual length between recordings. If $PITCH_MODE is set to 0, linear distance is used. If $PITCH_MODE is set to 1, time is used. The default is 0, distance. $PITCH_MODE can be changed in your program by using the PARAMETER NAME instruction. For more information about the PARAMETER NAME instruction, refer to Chapter 4. PROGRAM STRUCTURE.
9.16.2 Multipass The multipass instruction in the ArcTool software provides an easy method of programming multipass welding. Multipass welding is repeatedly welding the same seam. Multipass welding is useful in applications where large welds are required. The large welds are created by layering and offsetting smaller welds. Figure 9--47 shows a simple multipass weld. Different weld and weave schedules can be used between passes. And multipass can be used with and without weaving. Figure 9--47. Simple Multipass Weld Overlay 1
2 3 4
1
2
3
End View
How Multipass Functions Multipass consists of two programming instructions:
MP OFFSET PR[...] RPM[...] MP OFFSET END 558
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Multipass instructions are part of the TRACK/OFFSET instructions. For more information about the TRACK/OFFSET instructions, refer to Chapter 4. PROGRAM STRUCTURE. NOTE The Arc Start instruction and the position register instruction is not supported between MP OFFSET PR and MP OFFSET END. MP OFFSET PR[...] RPM[...] The position register, PR[...], allows you to the offset the entire weld and change the tool orientation. The position register is normally set up prior to running the weld program. Also, position registers can be modified by your program to change the offset values. NOTE If the position register is set to all zeros, the weld will not be offset. However, the root pass memorization information will still be used. Refer to Section 7.4 for more information about position registers and Section 4.5.2 for more information about the position register programming instruction. Table 9--26 and Figure 9--48 explain how changes to the position register affects the weld. NOTE All offsets are relative to the tool and path. Table 9--26.
How Changes to the Position Register Affect the Weld
PR Element
Effects on the Weld
X
The position register X element elongates or shortens the weld. A positive X value adds to the weld length on both ends of the weld. A negative X value shortens both ends of the weld.
Y
The position register Y element offsets the weld laterally. When facing the end of the weld, positive Y is to the right side of the weld. The lateral movement will be perpendicular to the tool.
Z
The position register Z element elevates the weld. Movement of the torch will be perpendicular to the weld path and aligned with the tool/path plane.
W
The position register W element changes the tool orientation by rotating about X. X is the weld path. This changes the torches work angle.
P
The position register P element changes the tool orientation by rotating about Y. Y is perpendicular to the torch. This changes the torches lead/lag angle relative to the weld path.
R
The position register R element has no affect on the weld.
Figure 9--48. How Changes to the Position Register Affect the Weld
Z
X
Y
NOTE Tool frame is required especially for the WPR offset. The root pass memorization, RPM[...], allows you to specify the RPM buffer to use when performing a multipass weld. The RPM buffer contains previously recorded position offset information. RPM records position offset information on the root, or first, welding pass. A tracking sensor provides the position offset information that RPM records. Multipass uses the recorded position offset information on subsequent passes of a multipass weld. For more information about RPM, refer to Section 9.16.1.
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NOTE If you do not want to use any RPM position offset information when multipass welding, set the RPM buffer number to 99. This will allow the MP OFFSET instruction to ignore the RPM buffer number. MP OFFSET END MP OFFSET END stops the use of the MP OFFSET instruction within the program. Applications Multipass offsets change the weld path. These offsets are applied to the weld path through the use of a position register. The following multipass weld path changes are available: F
Vertical and lateral path shifts
F
Torch angle changes
F
Staggered weld stop/start (lengthen or shorten weld path)
F
Corners
Vertical and Lateral Path Shifts Path shifts permit layering individual welds to form a pattern. Each pass can be offset laterally, using the position register Y value, and vertically, using the position register Z element value. See Figure 9--49. Figure 9--49. Multipass Weld 3 Path V Groove
3
2
3
1 2 1 Top View
End View
Torch Angle Changes The lateral and vertical offsets of each pass also can be accompanied by welding torch orientation changes. The W value in the position register is used to change the torch work angle. The P value in the position register is used to change to torch travel angle. See Table 9--26 and Figure 9--50. Figure 9--50. Multipass Weld Orientation Changes
X P1
X P2
X P3
X P4
Side View
X PN
X
X
X
End View
Staggered Weld Start/Stop To offset the start/stop location of the weld, the X value in the position register is used. A positive value increases the length of the weld at the start and stop. A negative value shortens the weld at the start and stop. See Figure 9--51. The X value can be changed during welding to allow one end of the weld path to be shortened and the other end to be shortened or lengthened. This is done by adding another MP OFFSET instruction in the weld path. Only the X value in the new position register should be changed. All other values from the starting position register should be used.
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Figure 9--51. Multipass Weld with End of Pass Offsets
X P1
X P2
X P3
X P4
X
X PN
Side View
End View
Corners If any two path segments differ at all in direction, they form a corner of varying degree. The transition around the corner must be smooth to avoid loosing the arc. Record enough positions to gradually change the orientation over an appropriate distance before and after the corner. Positions that are recorded too close together and include large angle changes can produce unexpected torch motion or an error message. If this occurs, try recording the positions further apart. Figure 9--52 shows an outside corner of 90 degrees. Figure 9--52. Multipass Corners
X P1
P2
X
P3 X Multipass can offset rounded corners also. See Figure 9--53. The position register Y element controls the offset value for rounded corners. Figure 9--53. Rounded Multipass Corners
--Y
+Y Original Weld Seam
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Corners With Logic Statements If you insert logic statements, or change any values, such as position registers or frames, between robot positions, the multipass instruction stops blending, or looking ahead. This means the weld will not be following the same offset values for any positions that occur after the logic statement or change. See Figure 9--54. Figure 9--54. Multipass Corners When Logic Statements Appear Between Recorded Positions Corner Weld Program Without Blending Offset Path
P1
P1
P2
P2
4:L P[1] 50.0inch/min CNT 100 5:L P[2] 50.0inch/min CNT 100 6: If R[3] = 2 CALL weld2 7:L P[3] 50.0inch/min CNT 100
P2 Original Path P3
P3
Corner Weld Program With Blending 4:L P[1] 50.0inch/min CNT 100 5:L P[2] 50.0inch/min CNT 100 6:L P[3] 50.0inch/min CNT 100 7: If R[3] = 2 CALL weld2
Limitation Overlap distance is ignored in paths where a multipass offset is applied. Programming Examples This section contains multipass program examples. Figure 9--55 is an example of multipass without RPM. Figure 9--56 is an example of multipass with RPM. Figure 9--57 is an example of a three-pass v-groove weld with no torch angle changes. CAUTION RPM recorded position offset information is specific to the program and positions in which RPM is used. The RPM program element cannot be used in a subprogram and then called to a main program for use with multipass. The MP OFFSET program element and the TRACK {sensor} RPM program element must reside in the same program.
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Figure 9--55. Example of Multipass without RPM
1: 2:J 3:J : 4: 5:L 6:C : 7:L : 8: 9:J 10: 11:L : 12:L 13:C : 14:L : 15: 16:J 17: 18:L : 19:L 20:C : 21:L : 22: 23:J
!Multipass W_O RPM P[1:Safe Position] 100% FINE P[2] 100% FINE Arc Start[1] Weave Sine[1] P[3] 20.0inch/min CNT100 P[4] P[5] 20.0inch/min CNT100 P[6] 20.0inch/min FINE Arc End[1] Weave End P[1:Safe Position] 100% FINE MP Offset PR[1] RPM[99] P[2] 500.0inch/min FINE Arc Start[2] P[3] 20.0inch/min CNT100 P[4] P[5] 20.0inch/min CNT100 P[6] 20.0inch/min FINE Arc End[1] MP Offset End P[1:Safe Position] 100% FINE MP Offset PR[2] RPM[99] P[2] 500.0inch/min FINE Arc Start[3] P[3] 20.0inch/min CNT100 P[4] P[5] 20.0inch/min CNT100 P[6] 20.0inch/min FINE Arc End[1] MP Offset End P[1:Safe Position] 100% FINE
First pass -- no multipass offset, weld and weave
Second pass -- multipass offset, data from PR[1] RPM[99] = no RPM change weld schedule -- no weave (first move must be linear)
Third pass -- multipass offset, data from PR[2] RPM[99] = no RPM Change weld schedule -- no weave
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Figure 9--56. Example of Multipass with RPM
1:!Multipass With RPM 2:J P[1:Safe Position] 100% FINE 3:J P[2] 100% FINE : Arc Start[1] 4: Weave Sine[1] 5: Track TAST[1] RPM[1] ; 6:L P[3] 20.0inch/min CNT100 7:C P[4] : P[5] 20.0inch/min CNT100 8:L P[6] 20.0inch/min FINE : Arc End[1] 9: Weave End 10: Track End 11: R[1]=0 12:J P[1:Safe Position] 100% FINE 13: MP Offset PR[1] RPM[1] 14: JMP LBL[2] 15: LBL[1] 16: MP Offset PR[2] RPM[1] 17: LBL[2] 18:L P[2] 500.0inch/min FINE : Arc Start[2] 19: Weave Sine[2] 20:L P[3] 20.0inch/min CNT100 21:C P[4] 22: P[5] 20.0inch/min CNT100 23:L P[6] 20.0inch/min FINE : Arc End[1] 24: Weave End 25: MP Offset End 26:J P[1:Safe Position] 100% FINE 27: R[1]=R[1]+1 28: IF R[1]=1,JMP LBL[1]
First pass -- TAST with RPM using RPM buffer [1]
Multipass instructions for second and third passes
Second and third passes -- must have same position numbers as RPM pass
Logic to increment multipass sequence
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Figure 9--57. Example of Three-Pass V-Groove Weld
1: !Multipass With RPM 2:J P[1:Safe Position] 100% FINE 3:J P[2] 100% FINE : Arc Start[1] 4: Weave Sine[1] 5: Track TAST[1] RPM[1] ; 6:L P[3] 20.0inch/min CNT100 7:C P[4] : P[5] 20.0inch/min CNT100 8:L P[6] 20.0inch/min FINE : Arc End[1] 9: Weave End 10: Track End 11: R[1] = 0 12:J P[1:Safe Position] 100% FINE 13: LBL[1] 14: MP Offset PR[1] RPM[1] 15:L P[2] 500.0inch/min FINE : Arc Start[2] 16: Weave Sine[2] 17:L P[3] 20.0inch/min CNT100 18:C P[4] : P[5] 20.0inch/min CNT100 19:L P[6] 20.0inch/min FINE : Arc End[1] 20: Weave End 21: MP Offset End 22:J P[1:Safe Position] 100% FINE 23: R[1]=R[1]+1 24 PR[1,2] = -5 25: IF R[1]=1,JMP LBL[1] 26: PR[1,2] = 5
First pass -- TAST with RPM using RPM buffer [1]
Multipass instructions for second and third passes
Second and third passes -- must have same position numbers as RPM pass
Program control logic to change the position offset for second pass Program logic to change the position offset data back to the 2nd pass value
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9.16.3 Coordinated motion with RPM and multipass You can use RPM and multipass with coordinated motion, if you have the coordinated motion option. This section contains information on using coordinated motion with RPM and multipass. Refer to Section 9.16.3 for detailed information on coordinated motion. Coordinated Motion with RPM The RPM function can be used with coordinated motion. All features are the same as for non-coordinated motion. The only difference is that the RPM offset is recorded using the coordinated frame instead of the world frame. Teach Pendant Programming Restrictions RPM offset data is recorded based on either the world frame or coordinated motion frame during tracking. For example, if the tracking section of the program uses the COORD motion option, RPM offset data is recorded using the coordinated frame. When RPM offset data is used in the multipass section of a teach pendant program, the motion in this section must be the same as when the RPM offset data was recorded. Otherwise, RPM offset data will be inconsistent and invalid in the multipass section. Teach Pendant Programming Restrictions in the RPM Section All motion in the section of the program in which RPM recording (and tracking recording) is done must use the COORD motion option, if the multipass section of the program uses COORD motion. or All motion in the section of the program in which RPM recording (and tracking recording) is done must not use the COORD motion option, if the the multipass section of the program does not use COORD motion. See Figure 9--58. Figure 9--58. Example of Restrictions in the RPM Recording Section of a Teach Pendant Program
1:J : 2: 3:L 4:L : 5: : 11: 12:L : 13:L 14:L : 15:
P[1] 100% FINE Arc Start[1] Track TAST[1] RPM[1] P[2] 20.0inch/min CNT100 COORD P[3] 20.0inch/min FINE COORD Arc End[1] Track End MP Offset PR[1] RPM[1] P[1] 100% FINE COORD Arc Start[2] P[2] 20.0inch/min CNT100 COORD P[3] 20.0inch/min FINE COORD Arc End[1] MP Offset End
RPM recording section: All motion must have COORD in this section, if RPM data is used in the multipass section with coordinated motion.
Multipass section: All motion must have COORD in this section.
Coordinated Motion with Multipass The multipass function can be used with coordinated motion. All features are the same as for non-coordinated motion. The only difference is that the multipass offset is applied relative to the path on the coordinated frame instead of the world frame. Teach Pendant Programming Restrictions The multipass function forms a corner between two path segments if there is a multipass offset contained in a position register (PR[]). To form a corner, each path segment must use the same frame, world frame or the coordinated frame. This means that you cannot use any combination of COORD and non-coordinated motion in the same multipass section of a program.
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Teach Pendant Programming Restrictions in the Multipass Section All motion in the multipass section of a program must use the COORD motion option. or All motion in the multipass section of a program must not use the COORD motion option. See Figure 9--59. Figure 9--59. Example of Restrictions in the Multipass Section of a Teach Pendant Program
1: 2:L 3:L 4:L 5: : 11: 12:L 13:L 14:L 15: : 21: 22:L 23:L 24:L 25:
MP Offset PR[1] RPM[1] P[1] 20.0inch/min CNT100 COORD P[2] 20.0inch/min CNT100 COORD P[3] 20.0inch/min FINE COORD MP Offset End MP Offset PR[1] RPM[1] P[1] 20.0inch/min CNT100 P[2] 20.0inch/min CNT100 P[3] 20.0inch/min FINE MP Offset End
All COORD motion can be used in the same multipass section. or All non-COORD motion can be used in the same multipass section. but
MP Offset PR[1] RPM[1] P[1] 20.0inch/min CNT100 COORD P[2] 20.0inch/min CNT100 P[3] 20.0inch/min FINE COORD MP Offset End
Both COORD and non-COORD motion cannot be used in the same multipass section.
Program Example This section contains a program example of coordinated motion with RPM and multipass. See Figure 9--60 for a program example. Figure 9--61 and Figure 9--62 illustrate the program example. Figure 9--60. Program Example of Coordinated Motion with RPM and Multipass
1:!CD with MPS and RPM 2:J P[1:Safe Position] 100% FINE 3:J P[2] 100% FINE : Arc Start[1] 4: Weave Sine[1] 5: Track TAST[1] RPM[1] 6:L P[3] 20.0inch/min CNT100 COORD 7:C P[4] : P[5] 20.0inch/min CNT100 COORD 8:L P[6] 20.0inch/min FINE COORD : Arc End[1] 9: Weave End 10: Track End 11: 12:J P[1:Safe Position] 100% FINE 13: MP Offset PR[1] RPM[1] 14:L P[2] 100% FINE COORD : Arc Start [2] 15: Weave Sine[2] 16:L P[3] 20.0inch/min CNT100 COORD 17:C P[4] : P[5] 20.0inch/min CNT100 COORD 18:L P[6] 20.0inch/min FINE COORD : Arc End[2] 19: Weave End 20: MP Offset End 21:J P[1]:Safe Position] 100% FINE
RPM recording section: All motion must have COORD in this section, if RPM data is used in the multipass section below.
Multipass section: All motion must have COORD in this section.
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Figure 9--61. Illustration of the RPM Recording Section of Example Program
P2 P3
P4
P5
P6
RPM Recording Section Figure 9--62. Illustration of the Multipass Section of the Example Program
P2’ P3’
P4’
P5’
Multipass Section
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P6’
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9.17 Coordinated Motion Function 9.17.1 Overview What is the coordinated motion function? The coordinated motion function allows a robot to follow the movement of a positioner that is holding a workpiece. With this function, interpolation is enabled for the TOOL frame of the robot so that it can maintain a constant relationship with the TOOL frame of the positioner (see Figure 9--63). Figure 9--63. Coordinated Motion
Frame of the positioner (coordinate frame)
Constant relationship TOOL frame of the robot
Required options The following feature software and software options are required to enable coordinated motion: F
Positioner feature software
F
Coordinated motion function
F
Multi--motion function
Difference from the conventional multi--motion function With the conventional multi--motion function, the robot and positioner can be moved simultaneously, but the TOOL frame of the robot cannot be interpolated to maintain a constant relationship with the coordinate frame. The use of the coordinated motion function enables such interpolation (see Figure 9--64 and Figure 9--65).
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Figure 9--64. Conventional Multi--Motion Function Interpolation Program Position P1, Q1 Position P2, Q2
Jog
Simultaneous interpolation
Interpolation
Jog feed for one unit at a time
Figure 9--65. Coordinated Motion Function
Interpolation Program Position P1, Q1 Position P2, Q2
Jog
Interpolation with frame relationship left as is
Interpolation
Interpolation with frame relationship left as is
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Advantages of the coordinated motion function The advantages of the coordinated motion function are shown in Figure 9--66 through Figure 9--70. Figure 9--66. Significant Reduction in Number of Teaching Points Conventional operation
Many points needed to be taught according to the placement of the positioner.
Advantage of the coordinated motion function
Only a few points need to be taught, without considering the placement of the positioner.
Figure 9--67. Uniform Welding Conventional operation
Because a speed relative to the positioner speed could not be specified, welding became uneven.
Advantage of the coordinated motion function
Because the relative speed can be held constant, uniform welding is possible.
Figure 9--68. Weaving Conventional operation
Advantage of the coordinated motion function
The direction and amount of weaving can be held constant.
As the positioner position changed, the direction and amount of weaving changed.
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Figure 9--69. Improved Cycle Time Conventional operation
Advantage of the coordinated motion function
The positioner had to be positioned prior to the start of welding to ensure a good welding result. This generated an additional wait time.
Since the workpiece and robot move simultaneously, no wait time is incurred.
Figure 9--70. Reduced Teach Time
Advantage of the coordinated motion function
Conventional operation
Jog feed could not be performed for both the positioner and robot at the same time.
As jog feed is performed for the positioner, the robot also moves at the same time, maintaining its position relative to the positioner.
Principle of coordinated motion The principle of coordinated motion is as follows: 1 The positioner and robot have each their own frames (WORLD and USER frames). 2 By performing calibration for coordinated motion (for details of the actual procedure, see ”Calibration”), coordinate conversion data (the position of the positioner frame measured with respect to the robot frame) is recorded in the system (see Figure 9--71).
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Figure 9--71. Coordinate Conversion Frame of the robot
Coordinate conversion
Frame of the positioner
3 The position data of the positioner and robot are recorded as position data relative to their own frames (see Figure 9--72). 4 The robot recognizes the position data of the positioner relative to the frame of the robot itself by calculating the equation given below, and performs coordinated motion according to the positioner movement (see Figure 9--73). (Position data of the positioner relative to the frame of the robot) = (coordinate conversion data) x (position data of the positioner with respect to the frame of the positioner) Figure 9--72. Position Data Position data of the robot
Position data of the positioner
Figure 9--73. Coordinated Operation
Position data of the positioner relative to the frame of the robot
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Specifications and restrictions The specifications and restrictions of the coordinated motion function are explained below. F
A positioner with up to six axes can be used.
F
When all the axes of the positioner are at position 0, the direction of each axis must be parallel to the X--, Y--, or Z--axis of the WORLD frame of the positioner (example: Figure 9--74).
Figure 9--74. Direction of Each Axis of the Positioner
Parallel
Right hand rule
Parallel
Parallel F
The incremental instruction cannot be used.
F
Joint operation of the robot is not allowed.
F
Linear and circular wrist joint operation of the robot is not allowed.
F
This function cannot be used together with MIG EYE.
F
Allowable coordinate pairs (combinations of groups that perform coordinated operation) are shown in Figure 9--75.
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Figure 9--75. Valid Coordinate Pairs Jog
Program execution
One robot + one positioner
One robot + one positioner
The above figure shows the case in which coordinated operation is performed by one program. When alternately executing multiple programs, coordinated operation is possible in a system having two robots and one positioner.
Two robots + one positioner
9.17.2 Setting a coordinated motion system Before coordinated motion can be performed, a coordinated motion system must be set. Set up the coordinated motion system by means of the procedure below. 1 Initialize the positioner by means of a control start. 2 Set each item on the pair setting screen. 3 Perform calibration on the calibration screen. Setting a pair Call the pair setting screen (see Figure 9--76) by means of the procedure explained below. 1 Press the MENUS key. 2 Select 6, SETUP. 3 Press F1, [TYPE]. 4 Select Coord. Figure 9--76. Pair Setting Screen SETUP Coord
JOINT
Coord Pair Number : Leader Group : Follower Group : X: ********
[ 1] 1 2
Y: ********
Follower orientation Leader frame number [ TYPR ][C_TYP]
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: :
Z: ******** ATTACHED 1
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When the pair setting screen appears, enter values for each item. The meaning of each item is explained below. Coord Pair Number: The number of a coordinate pair (combination of target groups for coordinated operation) for which subsequent settings are to be made. You can set a value of either 1 or 2. Leader Group: The group number of the positioner. (This item name is assigned because the positioner leads the robot.) Follower Group: The group number of the robot. (This item name is assigned because the robot follows the positioner.) Calibration Calibration is performed to teach the coordinate conversion data (the position of the positioner frame measured relative to the frame of the robot; for details, see ”Principle of coordinated motion”). Poor calibration accuracy can result in inaccurate coordinated motion. Therefore, calibration must be performed accurately. There are three calibration types: Known 4Pt, Unknown Pt, and Known Direct. When performing calibration, select just one of these three types. An appropriate calibration type should be selected as follows (see Figure 9--78). Known 4Pt calibration: The dimensions of the positioner structure can be determined from the drawings. The offset for each axis of the positioner (see Figure 9--77) will have been set in the positioner initialization at control start. Unknown Pt calibration: The dimensions of the positioner structure are unknown. Known Direct calibration: The offset for each axis of the positioner is already set, and the relative positional relationship between the robot and positioner can be determined from the drawings. The values of coordinated conversion elements X, Y, Z, W, P, and R will have already been recognized. Call the calibration screen from the pair setting screen (see Figure 9--76) by means of the procedure explained below. 1 Press the F2 (C_TYP) key. 2 Select one of the three types (1: Known 4 Pt, 2: Unknown Pt, 3: Known Direct). Figure 9--77. Offset Value of Each Axis of the Positioner
J2 position
J3 position
J1 position
X J1 offset value 0 mm J2 offset value 0 mm J3 offset value --300 mm
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Y 0 mm --1000 mm 0 mm
Z 0 mm 250 mm 0 mm
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Figure 9--78. Selecting a Calibration Type
Select calibration type
Offset of each positioner axis already set?
Coordinate conversion elements X, Y, Z, W, P, and R already known?
Unknown Pt
Known 4Pt
Known Direct
Known 4Pt calibration Figure 9--79 shows the Known 4Pt calibration screen. Figure 9--79. Known 4Pt Calibration Screen SETUP Coord
10 % 1/4 Known type calibration Coord Pair: 1 Group Number Leader: 2 Follower: 1 X: ******** Y: ******** Z: ******** W: ******** P: ******** R: ******** Leader’s TCP Point : UNINIT Orient Origin Point : UNINIT X Direction Point : UNINIT Y Direction Point : UNINIT
[ TYPR ][C_TYP]
G2
EXEC
JOINT
MOVE_TO
RECORD
Perform Known 4Pt calibration by means of the procedure explained below (example: Figure 9--80). 1 Position the cursor to Leader’s TCP Point. 2 Jog the positioner and robot to align their tool tip points. 3 Press and hold down SHIFT and then press F5 (RECORD). (The UNINIT indication changes to RECORD.) 4 Position the cursor to Orient Origin Point. 5 Jog the robot to a position where the robot can easily be jogged in the +X and +Y directions of the WORLD frame of the positioner. 6 Press and hold down SHIFT and then press F5 (RECORD). 7 Position the cursor to X Direction Point. 8 Jog the robot in the +X direction of the WORLD frame of the positioner. 9 Press and hold down SHIFT and press F5 (RECORD). 10 Position the cursor to Y Direction Point. 11 Jog the robot in parallel with the X--Y plane of the WORLD frame of the positioner and in the +Y direction. 12 Press and hold down SHIFT and then press F5 (RECORD). 13 Check that RECORDED appears against all four items (Leader’s TPC Point through Y Direction Point). 14 Press and hold down SHIFT and then press F3 (EXEC). (The RECORDED indication changes to USED. Coordinate conversion data is calculated, and the results are displayed on the screen.) 15 Perform a cold start.
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Figure 9--80. Known 4Pt Calibration
Leader’s TCP position Along X--axis
Parallel Match TCPs of positioner and robot. WORLD frame of positioner
Reference point of direction
Move robot TCP to position where TCP can be moved easily.
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Along Y--axis
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Unknown Pt calibration Figure 9--81 shows the Unknown Pt calibration screen. Perform Unknown Pt calibration by means of the procedure explained below (example with a three--axis positioner: Figure 9--82). Figure 9--81. Unknown Pt Calibration Screen Calibration screen for a linear axis SETUP Coord
10 % 1/5 Unknown type calibration Coord Pair: 1 Group Number Leader: 2 Follower: 1 X: ******** Y: ******** Z: ******** W: ******** P: ******** R: ******** Axis Number: 1 (Total: 1) Axis Type: LINEAR Axis Direction: +Y Point 1: UNINIT Point 2: UNINIT
[ TYPR ][C_TYP]
G2
EXEC
JOINT
MOVE_TO
RECORD
Calibration screen for a rotary axis SETUP Coord
10 % 2/6 Unknown type calibration Coord Pair: 1 Group Number Leader: 2 Follower: 1 X: ******** Y: ******** Z: ******** W: ******** P: ******** R: ******** Axis Number: 1 (Total: 2) Axis Direction: -Z Point 1: UNINIT Point 2: UNINIT Point 3: UNINIT
[ TYPR ][C_TYP]
G2
EXEC
JOINT
MOVE_TO
RECORD
1 Set all the axes of the positioner to position 0. 2 Position the cursor to Axis Number, and then enter the number of the positioner axis to be taught. 3 Position the cursor to Axis Direction, then press the ENTER key. (Then, the Axis Direction menu appears.) 4 Select the axis direction (--Z, --Y, --X, +X, +Y, or +Z) to be taught. 5 For a linear axis: a. Position the cursor to Point 1. b. Determine a reference point on the positioner mechanical unit. (This point must move linearly when you jog the linear axis in the positive direction. The tool tip of the robot must also be able to touch the point.) c. Jog the tool tip point of the robot to the reference point. d. Press and hold down SHIFT and then press F5 (RECORD). (The UNINIT indication changes to RECORDED.) e. Position the cursor to Point 2. f. Jog the positioner axis to be taught as far as possible in the positive direction. g. Jog the tool tip point of the robot to the reference point. h. Press and hold down SHIFT and then press F5 (RECORD). 6 For a rotary axis: a. Position the cursor to Point 1. b. Determine a reference point on the positioner mechanical unit. (This point must be rotated by jogging the rotary axis in the positive direction. Also, the tool tip of the robot must be able to touch the point.) c. Jog the tool tip point of the robot to the reference point. d. Press and hold down SHIFT and then press F5 (RECORD). (The UNINIT indication changes to RECORDED.)
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e. Position the cursor to Point 2. f. Jog the positioner axis to be taught in the positive direction, moving it through an angle of 30o to 90o, if possible. g. Jog the tool tip point of the robot to the reference point. h. Press and hold down SHIFT and then press F5 (RECORD). i. Position the cursor to Point 3. j. Further rotate the axis to be taught, again moving it through 30o to 90o if possible. k. Jog the tool tip point of the robot to the reference point. l. Press and hold down SHIFT and then press F5 (RECORD). 7 Repeat the above procedure for all axes of the positioner. 8 Check that RECORDED appears against all the Point items for all the positioner axes. 9 Press and hold down SHIFT and then press F3 (EXEC). (Then, the RECORDED indication changes to USED. The coordinate conversion data is calculated, and the results appear on the screen.) 10 Perform a cold start. Figure 9--82. Unknown Pt Calibration
All axes at position 0
All axes at position 0
+J1 jog
All axes at position 0
+J2 jog
+J3 jog
+J2 jog
+J3 jog
Performing the above calibration operation also calculates the offset for each axis of the positioner. These offsets, however, are not displayed. This completes the calibration.
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Known Direct calibration Figure 9--83 shows the Known Direct calibration screen. Figure 9--83. Known Direct Calibration Screen SETUP Coord
10 % 1/6 Known type calibration Coord Pair: 1 Group Number Leader: 2 Follower: 1 X: ******** Y: ******** Z: ******** W: ******** P: ******** R: ******** X: 0.000 Y: 0.000 Z: 0.000 W: 0.000 P: 0.000 R: 0.000
[ TYPR ][C_TYP]
G2
JOINT
EXEC
Perform Known Direct calibration by means of the procedure explained below. 1 In the lower part of the screen, enter values for X, Y, Z, W, P, and R. 2 Check that the values entered for X, Y, Z, W, P, and R are correct. 3 Press and hold down SHIFT and press F3 (EXEC). (The entered X, Y, Z, W, P, and R values appear on the screen.) 4 Perform a cold start. Leader frame setup Leader frames function as TOOL frames of leader groups. You can use this frame to define the orientation of a workpiece mounted on the faceplate of the leader group. In the same way as a USER frame, a leader frame is also useful in teaching. With leader frame jogging, when the leader group (table) is rotated, the follower group (robot) TCP is also rotated to maintain its relationship with the leader group along the current jog path. See Figure 9--84. Figure 9--84. Leader Frame Jogging
Procedure 9--19
Leader Frame Setup
NOTE
Condition
In a table coordination application, the leader group is the table. It is thus difficult to define the leader frame by moving the leader group; therefore, use the follower group to perform leader frame teaching. H The coordinate pair must have been calibrated. H A workpiece must be mounted on the faceplate of the leader group.
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1 Press the MENUS key. 2 Select SETUP. 3 Press F1, [TYPE]. 4 Select Coord. Then, the following screen appears: SETUP Coord
JOINT
Coord Pair Number : Leader Group : Follower Group : X: ******** W: ********
10 % 3/5
[ 1] 1 2
Y: ******** P: ********
Follower orientation Leader frame number
: :
Z: ******** R: ******** ATTACHED 1
[ TYPR ][C_TYP]
5 Press F2, [C_TYP]. 1 2 3 4
Known 4 Pt Unknown Pt Known Direct Leader Frame
6 Select Leader Frame. Then, the following screen appears: SETUP Coord
G2
JOINT
10 % 1/6 Leader Frame Setup Coord Pair: 1 Group Number Leader: 2 Follower: 1 Leader Frame X: 0.000 Y: 0.000 Z: 0.000 W: 0.000 P: 0.000 R: 0.000 Leader Frame number : 1 Orient Origin Point : UNINIT X Direction Point : UNINIT Y Direction Point : UNINIT
[ TYPR ][C_TYP]
EXEC
MOVE_TO
RECORD
NOTE If the Leader Frame option is not displayed, the coordinate pair must be calibrated. NOTE The initial values of x, y, z, w, p, and r of the leader frame are 0. 7 Set the leader frame number. Follow the procedure described below. a Position the cursor to Leader Frame number. b Enter a leader frame number, and then press the ENTER key. 8 Record the origin. Follow the procedure described below. a Position the cursor to Orient Origin Point. b Jog the follower group (robot) to position its tip to the reference point on the leader group. See Figure 9--85. c Press and hold down the SHIFT key and then press F5, RECORD.
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Figure 9--85. Setting the Origin
9 Record the X direction. Follow the procedure described below. a Position the cursor to X Direction Point. b Jog the follower group (robot) to position its tip to a point on the +X axis. See Figure 9--86. NOTE
If the follower group (robot) TCP cannot be moved to a point on the +X axis, jog the leader group so that the TCP can touch this point.
Figure 9--86. Setting the X Direction
c Press and hold the SHIFT key and then press F5, RECORD. 10 Record the Y direction. Follow the procedure described below. a Position the cursor to Y Direction Point. b Jog the follower group (robot) to position its tip to a point on the +Y axis. See Figure 9--87. NOTE
If the follower group (robot) TCP cannot be moved to a point on the +Y axis, jog the leader group so that the TCP can touch this point.
Figure 9--87. Setting the Y Direction
c Press and hold down the SHIFT key and then press F5, RECORD.
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11 Press and hold down the SHIFT key and then press F3, EXEC. Then, the element values of the new leader frame are displayed.
9.17.3 Coordinated jogging In coordinated jogging, the leader group and follower group of a coordinate pair perform jogging with their motion coordinated. The jog feedrate of the coordinate pair depends on the speed of the leader group. During coordinated jogging, the relationship between the frame of the leader group and the follower group TCP is maintained. Coordinated jogging varies according to the group in the coordinate pair that is to be operated. F
In coordinated jogging, the leader group and follower group operate together. The follower group maintains its position and orientation relative to the frame of the leader group.
F
Subgroup coordinated jogging is used when an integrated extended axis of the leader group is moved. This jog type is effective only when the leader group has integrated extended axes.
F
Leader frame jogging is used when the follower group is jogged relative to the leader frame. WARNING
In each type of coordinated jogging, if the follower group TCP is located far from the rotary axis of the leader group, jogging that axis causes the follower group to move at high speed even if the same override value is set. When performing jogging, therefore, note this point. The high--speed movement presents a danger of damage or injury.
Jog mode display The method used to perform coordinated jogging is selected from the FCTN menu. When the jog key is pressed, the method being used appears in the upper part of the screen. This is indicated in C#* format, where # is the group number of the leader group, and * is the group number of the follower group. The display shown in Figure 9--88 indicates that the leader group is 2 and the follower group is 1. For subgroup coordinated jogging, S appears instead of C. In this case, an extended axis is jogged. Figure 9--88. Coordinated Jogging Display Program
C21
JOINT
50 %
The display shown in Figure 9--89 indicates that the leader group is 2 and the follower group is 1. Subgroup coordinated jogging is used, so S appears instead of C. Figure 9--89. Subgroup Coordinated Jogging Display Program
S21
JOINT
50 %
Table 9--27 lists the displayed jog modes where the leader group is assumed to be 2 and the follower groups are assumed to be 1 and 3. Table 9--27.
Coordinated Jog Mode Display MEANING
DISPLAY C21
Performs coordinated jogging for leader group (2) and follower group (1).
G1
Jogs follower group (1) only. No coordinated motion.
G2
Jogs leader group (2) only. No coordinated motion.
S23
Performs subgroup coordinated jogging for leader group (2) and follower group (3).
G2/S
Jogs subgroup of leader group (2). No coordinated motion.
LDR2
Jogs follower group relative to leader frame.
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Leader group jogging (coordinated jogging) In applications performing coordinated motion, a workpiece is mounted on the leader group and the follower group (robot) works on the workpiece. When you teach a program under these circumstances, you would normally jog the leader group to the point where the workpiece is located, jog the follower group to the next position on the workpiece, then teach the position. Jogging the leader group in coordinated jog mode enables, for example, an axis direction of the JOG frame of the follower group to be matched with the direction of movement to the next teach point on the workpiece, which allows you to jog the follower group easily. In coordinated jogging, the follower group TCP maintains its position and orientation relative to the leader group. See Figure 9--90 and Figure 9--91. CAUTION Before leader group coordinated jogging can be performed, you must set a leader frame. For an explanation of how to set the leader frame, see ”Leader frame setup.”
Figure 9--90. Coordinated Jogging -- Tilt
Side view
Figure 9--91. Coordinated Jogging -- Table Rotation
Leader frame jog mode In addition to the existing jog modes, JOINT (JOINT frame), JOG (JOG frame), USER (USER frame), TOOL (TOOL frame), and TOACH (PATH frame), a new jog mode called LDR (leader frame) is supported. With leader frame jogging, when the leader group (table) is rotated, the follower group (robot) TCP is rotated accordingly, maintaining its relationship with the leader group along the current jog path. See Figure 9--92.
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Figure 9--92. Leader Frame Jogging
When the leader group is jogged, leader frame jogging is disabled so that you can not use LDR mode. When the follower group is jogged in leader frame jog mode, LDR2 appears in the upper right part of the screen, where 2 indicates the group number of the leader group. See Figure 9--93. Figure 9--93. Leader Frame Jog Mode Display Program
G1
LDR2
50 %
CAUTION When the leader group (robot) is selected, and the jog mode is indicated as LDR2, the TCP operates relative to the WORLD frame of the leader group. See Figure 9--93.
G1 on the screen indicates that the current target for jogging is group 1. If there is more than one leader group for a follower group, you can switch between the leader groups using TOGGLE LDR GROUP on the FCTN menu. Jogging examples Table 9--28 lists the type of coordinated jogging that are supported. Table 9--28.
Types of Coordinated Jogging (Group 1: Follower Group, Group 2: Leader Group)
DISPLAY
DESCRIPTION
C21
Coordinate pair jog
The frame of the leader group moves in No effect. JOINT. The follower group moves according to coordinate conversion data, maintaining the relationship with the leader group.
S21
Subgroup (integrated extended axis) coordinated jog
The frame of the leader group moves in JOINT. The follower group moves according to coordinate conversion data, maintaining the relationship with the leader group.
The frame of the leader group moves in the X, Y, or Z direction (dependent on frame axis assignment, effective for integrated extended axes that move linearly). The follower group moves according to coordinate conversion data.
G1
Follower group (robot) jog
No coordinated motion. Only the follower group moves in JOINT.
No coordinated motion. Only the follower group moves rectangularly.
G2
Leader group (positioner) jog
No coordinated motion. Only the leader group moves in JOINT.
No effec
LDR2 (G1)
Follower group (robot) jog
The follower group moves with respect to Jogging is performed as with the JOG the leader frame. frame or USER frame, but this frame moves as the leader group moves.
EFFECT OF JOINT JOG
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Figure 9--94 through Figure 9--96 show examples of coordinated jogging. Figure 9--94. Linear Coordinated Jogging
Figure 9--95. Coordinated Jogging -- Tilt
Figure 9--96. Coordinated Jogging -- Table rotation
CAUTION The tool orientation maintains a constant positional relationship with the table during jogging. You can have coordinated motion on more than one axis being jogged at the same time.
WARNING In each type of coordinated jogging, if the follower group TCP is located far from the rotary axis of the leader group, jogging that axis causes the follower group to move at high speed even if the same override value is set. When performing jogging, therefore, note this point. The high--speed movement presents a danger of damage or injury.
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Procedure 9--20 Step
Switching to coordinated jogging
1 Press the auxiliary key. 2 Position the cursor to CHANGE GROUP, and then press the ENTER key. 3 Enter the group number of the leader group. 4 Press the auxiliary key. 5 Position the cursor to TOGGLE COORD JOG, and then press the ENTER key. In the upper part of the screen, C#* appears, where # is the group number of the leader group, and * is the group number of the follower group. The following shows the upper part of the screen: Program
C21
JOINT
10 %
6 To change the follower group, press the auxiliary key repeatedly until a desired coordinate pair is displayed, then select TOGGLE COORD JOG. 7 To terminate coordinated jogging, press the auxiliary key, and select TOGGLE COORD JOG.
9.17.4 Coordinated motion in a program To program coordinated motion, use COORD that is one of the optional move instructions (such as Wjnt and INC) (example: Figure 9--97). Figure 9--97. Example of Coordinated Motion L P[1] 100mm/sec FINE COURD
The follower group (robot) moves linearly at a speed of 100 mm/s relative to the leader group (positioner). The leader group performs joint operation at the maximum speed for which the relative speed can be maintained.
C P[1] 300mm/sec CNT100 COURD
The follower group performs circular movement at a speed of 300 mm/s relative to the leader group. The leader group performs joint operation at the maximum speed for which the relative speed can be maintained. The follower group (robot) operates as specified by the operation formats (L, C) while the leader group (positioner) always performs joint operation. Notes on programming When specifying coordinated motion in a program, note the following: F
The INC instruction cannot be used in a move statement when that statement contains a COORD instruction.
F
Wrist joint feed cannot be performed.
F
The wrist joint (Wjnt) instruction cannot be used in a move statement when that statement contains a COORD instruction.
F
Weaving is possible only in the follower group.
F
Neither the program shift nor mirror image function is supported.
F
The USER frame and TOOL frame of the leader group are not supported.
F
Even when only the robot is being operated (the positioner does not move), the COORD instruction can be added. In such a case, the operation is performed in the same way as when no coordinated motion is performed.
F
Linear and Circular move instructions with CNT 1 to 100 cannot be used immediately before a move statement that performs coordinated motion. JOINT operation or CNT 0 can be specified immediately before the move statement. See Figure 9--98.
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F
When coordinated motion is performed with the root path memorization function, the Linear instruction with the COORD instruction added must be specified at the start point of the coordinated motion.
Figure 9--98. Example Coordinated Motion Instructions Correct: 1: L P[1] 2: L P[2] 1: J P[1] 2: L P[2]
250mm/sec CNT0 20mm/sec FINE COURD 100% CNT100 20mm/sec FINE COURD
Wrong: 1: L P[1] 250mm/sec CNT0 2: L P[2] 20mm/sec FINE COURD
9.17.5 Main alarm codes The following lists the main alarms specific to the coordinated motion function:
CD--009 PAUSE.G More than one leader More than one leader group has been set up. Cause: Remedy: Check the motion command. Make correction on the leader groups, and perform cold start.
CD--016 PAUSE.G INC motion is not supported Incremental motion is not supported as coordinated motion. Cause: Remedy: Delete incremental commands. CD--018 PAUSE.G No calibration for CD Coordination control calibration has not been completed. Cause: Remedy: Perform coordination control calibration. CD--019 PAUSE.G Illegal follower setting In this motion, the number of follower groups is 0, two, or greater. Cause: Remedy: Set the number of follower group to 1. CD--020 WARN Not reach relative speed The follower group has not attained the specified speed. Cause: Remedy: Re--teach the positions of the leader and follower groups so that the specified speed can be attained. CD--021 PAUSE.G No kinematics in CD group Coordinated motion is impossible for this robot, because it has no kinematics. Cause: Remedy: Alter the robot. CD--023 PAUSE.G Illegal CD setting The specified coordination control setting is illegal. Cause: Remedy: Check the setting.
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9.18 Data Monitor Data Monitor is a tool for improving process quality. You can use it to monitor and record important process parameters. It can alert you to a parameter going out of limit and it can record data for use in a quality record. Data Monitor operates much like a strip chart recorder or a data acquisition system. To use the Data Monitor feature you make selections in two teach pendant screens and add two teach pendant program instructions. Specifically, F
Enable or disable any specific features in the Data Monitor Utility screen
F
Select items to monitor (such as arc current feedback) with one of the Data Monitor schedules
F
Add Sample Start[schedule number] and Sample End instructions to your TP program to control when monitoring occurs
You can monitor up to five items at once with a Data Monitor schedule. The maximum sampling frequency is 250 Hz. You can specify separate frequencies for limit checking and for recording. As the items specified in the schedule are recorded, the following data is also collected: time, date, distance, program name and line number. You can choose the items you want to monitor from the Data Monitor Schedule screen. As data is recorded, it can be formatted as a report and sent to a file. A short example report is shown in Figure 9--99. The data is tab delimited for importing into a spreadsheet application. Figure 9--99. Report Example DATA MONITOR REPORT Number 1 2 3 4 5 6 7
Tick Time Program Line Voltage [Volts] Wire feed[IPM] 48 .192 TEST 2 0.000 0.000 98 .392 TEST 3 20.000 200.000 148 .592 TEST 3 20.000 200.000 198 .792 TEST 3 20.000 200.000 248 .992 TEST 3 20.000 200.000 298 1.192 TEST 3 20.000 200.000 348 1.392 TEST 4 0.000 0.000
Definitions This section contains definitions of terms you should know to use Data Monitor. Item -- A specific data element to be monitored. For example, an I/O signal, like WO[2] or AI[2]. Data Monitor can monitor the following kinds of items: F
System variables (Real or Integer only)
F
KAREL program variables (Real or Integer only)
F
I/O ports (digital and analog)
F
Registers (numeric only)
Schedule --A set of parameters that define how to monitor specific items and where to save recorded data. Trigger -- A condition that must be met to begin or end monitoring. Limit -- A defined high or low value for a monitored item.
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Monitoring Limits Data monitoring can check each sampled item against upper and lower limits. If the average of the item samples is out of limits for a specified time period (Tmin in Figure 9--100) a warning or a pause alarm will occur, if enabled. You must specify a nominal value, a warning limit, a pause limit, and a time duration for each monitored data item. Figure 9--100. Process Limits
If a warning limit is crossed for the specified time, a WARN severity error is posted and the limit digital output is turned ON. If the average of the item samples returns to within the WARN limit for the specified time the digital output is turned OFF. If a pause limit is crossed for the specified time a PAUSE severity error is posted, the limit digital output is set to ON, and the program is paused. When the program ends, if a WARN or PAUSE limit error occurred during execution, the limit digital output is turned ON. It is turned OFF by a system RESET.
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9.18.1 Data monitor setup You must set up Data Monitor before you can use it. Table 9--29 lists and describes the items found on the Data Monitor Setup screen. Table 9--29.
Data Monitor Setup Screen Menu Items ITEM
DESCRIPTION
Data Monitor Operation Default: Enabled
This item enables and disables operation of the Data Monitor function.
Recording Default: Enabled
This item turns data recording ON and OFF.
Filing Default: Enabled
This item turns report filing ON and OFF.
Warning Limits Default:Disabled
This item turns Warning Limits ON and OFF.
Pause Limits Default: Disabled
This item turns Pause Limits ON and OFF.
Limit Error Output Default: DO[0]
This item defines the port type and port number for the limit output. This digital output is turned ON when a limit error is detected.
Sample Buffer Size Default:10 Min:1 Max:99
This item specifies the size of the sample buffer.
Record Buffer Size Default:10 Min:1 Max:99
This item specifies the size of the record buffer.
Setup Default: Disabled
This item enables or disables printing of data monitor setup information in the report header. See Figure 9--101.
Items Default: Disabled
This item enables or disables printing of information in the report header about each of the items you want to monitor.
Schedule Default: Disabled
This item enables or disables printing of Schedule information in the report header.
Triggers Default: Disabled
This item enables or disables printing of Trigger information in the report header.
Program Name Default: Enabled
This item enables or disables printing the program name column in the Data Monitor report. See Figure 9--101.
Line Number Default: Enabled
This item enables or disables printing the line number column in the Data Monitor report. See Figure 9--101.
Date Default: Disabled
This item enables or disables printing the date and time of day column in the Data Monitor report. See Figure 9--101.
Tick + time Default: Disabled
This item enables or disables printing the Tick and Time column in the Data Monitor report. See Figure 9--101.
NOTE Data monitoring is also disabled during step mode.
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Table 9--29. (Cont’d) Data Monitor Setup Screen Menu Items ITEM
DESCRIPTION
Event Default: Disabled
This item enables or disables printing the event column in the Data Monitor report. See Figure 9--101. NOTE At this time, there is only one event defined. An event value of 1 indicates the data was recorded as a result of the recording frequency.
Distance Default: Enabled
This item enables or disables printing the distance column in the Data Monitor report. See Figure 9--101.
Use Procedure 9--21 to set up Data Monitor Figure 9--101. Sample Report
XX XX XX XX XX XX XX XX XX XX XX
Date
Tick +Time
Distance
Event
Line Number Program Name
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Procedure 9--21 Condition Step
Setting Up Data Monitor
H Data Monitor is installed on your controller. 1 Press MENUS 2 Select UTILITIES. 3 Press F1, [TYPE]. 4 Select Data Monitor. You will see a screen similar to the following. UTILITIES DMON SET 1 2 3 4 5 6 7 8
JOINT
Data Monitor Operation: Recording: Filing: Warning limits: Pause limits: Limit error output: Sample buffer size: Record buffer size:
ENABLED ENABLED ENABLED DISABLE DISABLED RO[ 1] 10 samples 10 samples
ITEM DESCRIPTION 9 Voltage (Command)
ITEM NUM 1
REPORT TABLE CONTENTS 10 Setup: 11 Items: 12 Schedule: 13 Triggers: REPORT TABLE CONTENTS 14 Pause limits: 15 Line number: 16 Date: 17 Tick + time: 18 Event: 19 Distance [ TYPE ]
DETAIL
10 % 9/19
ENABLED ENABLED ENABLED ENABLED ENABLED ENABLED DISABLED ENABLED DISABLED ENABLED ENABLED
DISABLED
5 Select each item on the menu and set it as desired.
Edit Data Monitor Items 6 Data Monitor allows you to define 20 items to monitor. These items are initialized for you, but you can edit them to suit your needs. If you want to edit Data Monitor items, move the cursor to item 9. When the cursor is on item 9, the DETAIL, [CHOICE], and HELP function keys will be available. [CHOICE] allows you to choose an item from a list. DETAIL allows you to edit that item. Item 9 has two columns. The right column contains an item number from 1 to 20. The left column contains the corresponding item description. ITEM DESCRIPTION 9 Voltage (Command) [ TYPE ]
DETAIL [CHOICE]
ITEM NUM 1 HELP
7 Press F4, [CHOICE]. You will see a screen similar to the following
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1 Voltage (Command) 2 Wire feed (Command) 3 Voltage (Feedback) 4 Current (Feedback) UTILITIES DMON SET 5 Pause limits: 6 Limit error output: 7 Sample buffer size: 8 Record buffer size: 9 Wire feed (Command) [ TYPE ]
DETAIL
5 6 7 8
JOINT Item 5 Item 6 Item 7 -- NEXT --
10 %
ENABLED RO[ 0] 10 samples 10 samples 2 [CHOICE]
HELP
8 Select an item from the list by number or by moving the cursor and pressing ENTER. 9 Press the F3, DETAIL function key to edit the selected item. In this example, 2 Wire feed has been selected. You will see a screen similar to the following. UTILITIES DMON ITM
E1
JOINT
10 %
Item number: 2/20 1 Item type: REAL Item sub type: ** Port or register number:** 2 Program name: [ *SYSTEM*] 3 Var: [ $awepor[1].$wfs_cmd] 4 Des: [ Wire feed (Command)] 5 Units [ IPM] 6 Slope: 0.00 7 Intercept 0.00 [ TYPE ]
ITEM
EXIT
[CHOICE]
HELP
10 This is the screen you use to edit an item. Press F2, ITEM, to select a different item by number. Not all of the menu items are available for all item types. If they are not available the item is not numbered, you cannot move the cursor to it, and it displays as ***. To set the Item type, move the cursor to line 1 and press [CHOICE]. You will see a screen similar to the following. E1
JOINT
10 %
1 Integer 2 Real 3 I/O 4 Register UTILITIES DMON ITM 1 2 3
Item type: REAL Item sub type: 0 Program name: [ *SYSTEM*] Var: [ $awepor[1].$wfs_cmd]
[ TYPE ]
ITEM
EXIT
[CHOICE]
HELP
11 To change the Item type, move the cursor to Item type, and press ENTER. 12 When you are done editing this item you can press F2, ITEM to select a different item by number, or press F3, EXIT to return to the setup screen.
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9.18.2 Data monitor schedule You choose the items you want to monitor in a Data Monitor schedule. You can also specify: F
Report file naming details
F
Sampling frequencies.
F
WARN and STOP limits
F
Start and Stop triggers.
Reports Reports are created automatically when you set the Reporting item on the Data Monitor schedule screen to ENABLED. You can specify a file name and a file device on the Data Monitor Schedule screen for the Data Monitor report. Use Procedure 9--22 to set up and edit a Data Monitor schedule Table 9--30.
Data Monitor Schedule Menu Items DESCRIPTION
ITEM Schedule Comment
You can add a comment to each Data Monitor schedule.
File device
This item allows you to specify the name of the device to be used when writing a report. You can choose from FLPY:, PRN:, FR:, MC:, CONS:, or RD:.
File name Default: Blank
This item allows you to specify the name of the file to be used for a report. A .DT file extension is always used. If you leave this item blank, and Reporting is enabled, the saved data file will be named “SAMPL”.
File name index Default: 0 Min: 0 Max: 999
This item allows you to specify an index number to be appended to the file name when a report is generated. If this item is non zero, each time a report is generated this index will be incremented. For example if the file name is SAMPL then successive reports will be named SAMPL001.DT, SAMPL002.DT, and so forth.
File size Default: 0 Min:0 Max:99999
This item specifies the amount of memory in KB you expect to use on the file device. During execution of Sample Start[n], the device is checked for this amount of free memory. If it is not available, an error is posted. If you specify 0 as the file size, the system only checks that there is at least one available block on the media.
Sampling
This item specifies the sampling frequency. F Request - This is the sampling frequency you specify. F
Monitoring
This item specifies the monitoring frequency. F Request - This is the monitoring frequency you specify F
Recording
Actual - This is the actual monitoring frequency that Data Monitor will use. Since there are only certain frequencies available, it may be greater than or less than the monitoring frequency you specify.
This item specifies the recording mode. F ONE BUFFER - Data will be recorded until the record data buffer is full F
Number of items Default: 5 Min: 1 Max: 5
Actual - This is the actual monitoring frequency that Data Monitor will use. Since there are only certain frequencies available, it may be greater than or less than the monitoring frequency you specify.
This item specifies the recording frequency. F Request - This is the monitoring frequency you specify. F
Record mode Default: CONTINUOUS
Actual - This is the actual sampling frequency that Data Monitor will use. Since there are only certain frequencies available, it may be greater than or less than the sampling frequency you specify.
CONTINUOUS - The record buffer is re-used when full.
This item specifies how many items are monitored by this particular schedule.
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Procedure 9--22 Condition Step
Setting Up and Editing a Data Monitor Schedule
H You have installed the Data Monitor schedule on your controller. 1 Press MENUS. 2 Select UTILITIES. 3 Press F1, [TYPE]. 4 Select Data Monitor Schedules. You will see a screen similar to the following. UTILITIES DMON SCH JOINT 10 % Sched: 1/5 [Weld cmd + fbk ] 12/17 1 2 3 4 5
6 7 8 9 10 11 12 13 14 15
Schedule: 1 File device: File name: File name index: File size:
[Weld cmd + fbk ] [MC:] [ ] 1 0 KB
FREQUENCY REQUEST ACTUAL Sampling: 250.00 250.00 Hz Monitoring: 125.00 125.00 Hz Recording: 10.00 10.00 Hz Record mode: CONTINUOUS Number of items to monitor: 5 ITEM DESCRIPTION ITEM NUM Voltage (Command) 1 Wire Feed (Command) 2 Current (Feedback) 3 Voltage (Feedback) 4 Fast Clock 5
16 Start item: 17 Stop item:
2 > 22.5 3 < 200.0
ENABLED ENABLED
[ TYPE ] SCHEDULE LIMITS [CHOICE]
HELP
5 There are 5 Data Monitor schedules. The top line of the Schedule screen displays the current schedule number and its comment. To select a different schedule, press F2, SCHEDULE, and enter the number of the schedule you want to modify after the prompt. 6 To enter or modify the schedule comment, move the cursor to menu item 1 and press ENTER. 7 To specify the File device, move the cursor to line 2 and press F4, [CHOICE]. 8 To specify the data monitor report file name, move the cursor to menu item 3 and press ENTER. 9 If you want to generate multiple report files with an index number in the file name, specify the starting index number on line 4. If you don’t want to create a new indexed file each time this schedule is used, enter 0 on line 4. 10 Move the cursor to line 5, and specify the maximum report size, if desired, or leave it set to 0. 11 You specify the Sampling, Monitoring, and Recording frequencies on lines 6, 7 and 8 of the Data Monitor Schedule screen. There are two values shown for these three items, the Requested Frequency that you specify, and the Actual Frequency that will be used as the Sampling, Monitoring, or Recording Frequency. When you enter the desired frequency in the Requested column, the Actual column will update with the closest available frequency. NOTE
The Monitoring and Recording Frequencies must be fractions of the Actual Sampling frequency. If you have an actual sampling frequency of 125 Hz, the maximum Monitoring and Recording frequency can only be 125 Hz. If you modify the Sampling frequency, the Actual frequency may change for all three frequencies.
12 To modify the Record mode, move the cursor to line 9 on the Data Monitor Schedule screen and press F4, [CHOICE]. 13 Each Data Monitor schedule can monitor up to 5 items simultaneously. You can specify the number of items to monitor on line 10 of the Data Monitor Schedule screen.
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14 Specify the items you want to monitor on lines 11 through 15 of the Data Monitor Schedule screen. Press F4, [CHOICE], and select the item you want from the list of items displayed. You can also specify an item by number in the Item Num column. Specify WARN and STOP Limits for Process Signals 15 To specify WARN and STOP limits, move the cursor to each item you have specified on lines 11 to 15 and press the LIMITS function key. 16 Move the cursor to one of monitored items. 17 Press F3, LIMITS. You will see a that contains details on how specifically to monitor the item you selected. DATA Monitor TEST
JOINT
10 %
LINE 0 1/4
Schedule: 1
[Sample example
]
Item: 2 Des:[Wire feed (Command) ] Var:[$awepor[1].$wfs.cmd ] 1 2 3 4
Nominal value: Warning limit: Pause limit: Time before error:
[ TYPE ]
EXIT
0.00 Volts 0.00 Volts 0.00 Volts 0 seconds HELP
18 Select each item and set it as desired. 19 When you finished setting items, press F3, EXIT, to display the previous screen. Start and Stop Trigger Items 20 You can specify the Start and Stop trigger items and conditions using the fields in menu items 16 and 17 on the Data Monitor Schedule screen.
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9.18.3 Programming You can use the following teach pendant instructions to start and end data monitoring: F
Sample Start[]
F
Sample End
Sample Start[] Sample End The Start instruction has a schedule number as an input parameter. NOTE
You cannot start multiple data monitoring sessions at one time. You must end a monitoring session with a Sample End before executing another Sample Start.
Sample Start[1]Example F
To start data monitoring, include the Sample Start[] instruction in a teach pendant program.
F
Example To stop data monitoring, include the Sample End instruction in a teach pendant program.
Sample End
See Figure 9--102 for an example of how to use these instructions in a teach pendant program. Figure 9--102. Example of Using Sample Start[] and Sample End in a Teach Pendant Program
1: 2:J : 3:L : 4:
Sample Start[1] P[1] 40% FINE Arc Start[1] P[2] 20.0inch/min FINE Arc End[1] Sample End
[End] The Sample Start and Sample End instructions are located in the Data Monitor category of the Teach Pendant Editor INST menu.
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9.19 Touch Sensing Touch sensing (optional feature) allows the robot to change a path automatically to compensate for object displacement. Touch sensing consists of: F
Moving the robot tool center point (TCP) toward the object using pre-defined robot motion, speed, and direction.
F
Using an input signal to indicate that the robot has come into contact with the object.
F
Storing the found location of the object, or position offset information, in position registers.
F
Using the stored position to move the robot to the stored position, or using the stored position offset information to shift one or more positions in your welding program.
F
Support for coordinated motion.
To use touch sensing you must: F
Set up the robot Tool Center Point (TCP) properly. Refer to Section A.4.10 to set up the tool frame.
F
Set up touch sensing hardware. The hardware monitors an input signal to determine when the robot comes into contact with the object.
F
Assign I/O to enable and use the electrical interface circuit.
F
Set up how the robot moves to the object and the type of position offset information that is stored.
F
Set up a coordinated motion pair for coordinated motion touch sensing
F
Create a touch sensing program.
See Figure 9--103 for an example of a program that includes touch sensing. Figure 9--103. Example Program Including Touch Sensing Routine
INSTRUCTION
DESCRIPTION
-----------------------------------------------------------------------------------------------------------------------------------1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14:
J P[1] 100% Fine Search Start[3] PR[3] J P[2] 100% Fine J P[3] 100% Fine Search [Y] J P[4] 100% Fine J P[5] 100% Fine Search [X] Search End J P[6] 100% Fine Touch Offset PR[3] J P[7] 100% Fine Arc Start [1] L P[8] 30IPM Fine Arc End [1] Touch Offset End
Teach a point in space Use touch schedule 3. Store offset in pos. reg. 3 Teach a search starting position Do a search motion in Y direction Teach a search start position Do a search motion in X direction End of the search Teach an intermediate point (optional) The following points will be offset by PR[3] P[7] is offset by PR[3] Begin welding P[8] is offset by PR[3] End welding End of offsetting positions
9.19.1 Assigning touch sensing I/O To use touch sensing you must assign the F
Input signal that the touch sensing circuit monitors to indicate when the robot has reached the object.
F
Output signal that enables and disables the touch sensing circuit.
NOTE You must wire the necessary connections for the input and output signals to be used for touch sensing. The wire stick detection circuit on the process I/O board also can be used for touch sensing. The R-J3 controller supports numerous I/O options. If you decide to use an I/O point other than the standard, (such as a modular I/O), then the controller must be wired and configured correctly. NOTE Some welding power supplies, such as the Lincoln Electric PowerWave 450 provide internal touch sensing circuitry. These power supplies can be automatically set up for the appropriate inputs and outputs when software configuration is performed.
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Touch Sensing Input Signal The touch sensing input signal indicating contact with a part is monitored by the touch sensing circuit. When the input is received, the current robot position is stored in a position register. Refer to Section 9.19.4 for more information about the touch sensing circuit. Any of the following can be used as the touch sensing input signal: NOTE Robot inputs(RI) 1--4 or 8 are typically used because they are wired directly to the EE Connector on the robot. Refer to the Connections section of the R-J3iB Maintenance and Connection Manual for connector location, pin configuration, and I/O signal specifications. F
Welding Digital Inputs (WI) 1--8, found on the CRW1 Connector of the process I/O board.
F
Digital Inputs (DI) 1--22, found on the CRM2A and CRM2B connectors of the process I/O board.
F
Wire stick detection circuit input WSI (WDI+, WDI--), found on the CRWI connector of the process I/O board.
F
Robot Digital Inputs (RI) 1--16, found on the Axis Control PCB. CAUTION
If a WI is assigned as the touch sensing input signal, the dedicated function it performs must be disabled. Refer to Section 3.1 Welding Input/Output Signals.
F
Optional Digital I/O, (such as a Modular I/O).
You can also set up touch sensing to monitor the condition of any RO or DO signal as an input signal. When the selected output turns on during a touch sensing routine, the controller reads this as a received input signal. Touch Sensing Enable/Disable Output Signal Any of the following can be used to enable the touch sensing circuit: F
Robot Digital Outputs (RO) 1--20 found on the digital output (DO) 1--16, found on the Axis Control PCB.
F
Digital Outputs (DO) 1--20 as an option for additional digital outputs.
F
Welding Digital Outputs (WO) 1--8 found on the CRW1 Connector of the Process I/O Board.
F
Wire stick detection circuit enable WSE is an internal output on the process I/O board that enables the detection circuit and allows it to be used for touch sensing. CAUTION
If a WO is assigned as the touch sensing input signal, the dedicated function it performs must be disabled. Refer to Section 3.1 Welding Input/Output Signals.
NOTE To use touch sensing, the weld interface cable must be installed. If you are using the Lincoln PowerWave 450 weld power supply, the power source must be turned on for touch sensing to work. Refer to the Connections section of the R-J3iB Maintenance and Connection Manual for connector location, pin configurations, and I/O signal specifications. Assigning the Touch Sensing Inputs and Outputs You must assign touch sensing inputs and outputs to match the hardware interface at your site. This involves assigning both input and output type and port number. Touch sensing inputs are shown as sensor ports in the ArcTool software. Touch sensing outputs are shown as circuit ports in the ArcTool software. NOTE After you have decided what I/O to use for touch sensing, you should add a comment to the selected I/O indicating that the I/O has been assigned to touch sensing. This is done using the SETUP menu. Refer to Chapter 3. SETTING UP THE ARC WELDING SYSTEM.
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Procedure 9--23 Step
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Assigning Touch-Sensing Inputs and Outputs
1 Press MENUS. 2 Select SETUP. 3 Press F1, [TYPE] 4 Select Touch I/O. You will see a screen similar to the following. Touch I/O Setup
G1
JOINT
NAME Sensor port type Sensor port number Circuit port type Circuit port number [TYPE]
50% 1/4
VALUE RDI 1 RDO 1 [CHOICE]
NOTE This screen shows the settings of the currently selected motion group. To view the settings of another motion group, change the motion group by selecting an auxiliary menu item CHANGE GROUP. 5 Assign Sensor (input) and Circuit (output) types as follows: a Move the cursor to the line you want to assign. b Press CHOICE, [F4]. c Move the cursor to the desired input/output type. d Press ENTER. NOTE The allowable input range for the sensor and circuit ports is from 1 to 256. The ArcTool software checks the validity of the port type and port number when running your program that includes touch sensing. If the port type or number is invalid, the system displays an I/O invalid error message. 6 Assign Sensor and Circuit number: a Move the cursor to the line you want to assign. b Type the value and press ENTER. NOTE After the input signal has been wired and assigned, perform a test to verify that it is connected properly. The input signal condition can be monitored from the I/O Menu.
9.19.2 Setting up touch sensing Search motions locate an object and store the found location, or position offset information, of the object in a position register. Search motions use F
Touch frames
F
Touch patterns
F
Touch schedules
A touch frame determines the direction of the search motion. The search motion is actually a programmed move along the x, y or z axis of a selected touch frame. For touch sensing with coordinated motion, you can select the touch frame relative to the UFRAME of the robot (follower) or the coordinated frame of the reference group (leader). If the reference group is set for the leader group, the search direction will be relative to that group. Typically, only one search motion is used for each search direction. Some search patterns require two search motions in each of two search directions for the ArcTool software to calculate an angular offset. Search patterns determine the type of information stored in the position register. The stored information is either the found position or position offset information depending on the search pattern used. Up to five search motions in one search direction can be done to improve the accuracy of locating an object. When more than one search motion in a direction is used, the ArcTool software calculates an average value of the searches and uses the average for the offset calculation except when using the search pattern 1D+Rotate, 2D +Rotate, or 3D+Rotate.
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Also, you can include a maximum of 15 searches between the program instructions SEARCH START and SEARCH END. Refer to Section 9.19.2. Touch schedules allow you to set up the conditions that define the search motions. These conditions include the position register, touch frame and search pattern to use; the robot speed and motion type; and other conditions. Figure 9--104, Figure 9--105, and Figure 9--106 represent how search motions are used in a program. Touch Sense installation is a “semi-automatic” function. Touch Sense defaults to using the position register 32. Typically, systems have only 10 position registers available. A Second Controlled Start is required after you install Touch Sense before the system will “automatically” increase the number of position registers to 32. Figure 9--104. Search Using Searches in One Direction Original position
Y
X
Original position
X
SIDE VIEW
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Figure 9--105. Search Using Offsets in Two Dimensions
Original position
Z X Start Start point
X Original position
SIDE VIEW
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Figure 9--106. Search Using 2 Search Motions in 2 Different Directions to Obtain X and Y Offset and Rotation about Z
Original position
Z Y
X
Original position
Rotate About Z
SEARCH Y 1
SEARCH Y 2 SEARCH X 1 SEARCH X 2
TOP VIEW The characteristics of a search motion are controlled by variables set in touch schedules. The x, y, or z movements in a search motion are aligned with an object by using one of the touch frames. Touch Frames A touch frame determines the motion direction of the robot TCP. A touch frame is defined by three points. The first point defines the origin, or starting point. The second point defines the positive x direction of the touch frame. The third point defines the positive x-y plane. Figure 9--107 shows a touch frame and how it is used in a touch sensing program. The orientation of the touch frame to the object is arbitrary in Figure 9--107. The positive x axis could be aligned with the current z direction. This would re-define positive z to be in the opposite direction of the current positive x direction.
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Figure 9--107. Touch Frame Used in a Program FRONT VIEW
SIDE VIEW
Z Z Y
X
Y
X
NOTE You can set up a maximum of 32 touch frames. Touch frames are set up using the touch frame screen in the Setup menu. NOTE You must define a touch frame before you perform a search motion in a program. There are two ways to define touch frames: The teaching method and the direct entry method. The teaching method defines the touch frame by recording three points. The direct entry method defines the touch frame by the rotation angle value you enter in the touch sense setup screen. Table 9--31 lists and describes the items you must set to define the touch frame. Table 9--31.
Touch Frame Setup Items ITEM
DESCRIPTION
Frame Number
This item specifies the number of the touch frame you want to define.
Reference Group
This item specifies the reference group to which the touch frame is relative: F 1: Touch frame is relative to the UFRAME of the robot (follower)
Robot Group
F
2: Touch frame is relative to the coordinated frame of robot group 2 (leader)
F
3: Touch frame is relative to the coordinated frame of robot group 3 (leader)
F
4: Touch frame is relative to the coordinated frame of robot group 4 (leader)
F
5: Touch frame is relative to the coordinated frame of robot group 5 (leader)
This item specifies a motion group for which the touch frame is set.
Direct Entry -- Procedure 9--25 Rotate about X
This item specifies the rotation about X for the touch frame.
Rotate about Y
This item specifies the rotation about Y for touch frame.
Rotate about Z
This item specifies the rotation about Z for touch frame.
Teach Method -- Procedure 9--24 Origin
This item allows you to record the origin of the touch frame.
+X direction
This item allows you to define the +X direction of the touch frame.
+Y direction
This item allows you to define the +Y direction of the touch frame.
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NOTE When Reference Group is not equal to 1, the touch frame changes with the coordinate frame, but the display of the Rotate about X, Y, and Z items remains unchanged. Use Procedure 9--24 to define your touch frame by using the teaching method. Use Procedure 9--25 to define your touch frame by using the direct entry method Procedure 9--24 Step
Setting Up a Touch Frame Using the Teaching Method
1 Press MENUS. 2 Select Setup. 3 Press F1, [TYPE]. 4 Select Touch Frame. You will see a screen similar to the following. Touch Frame Setup
Joint 10% 1/7 Frame Number:10 Reference Grp:1 Robot Grp:1 Direct Entry: Rotate about X: 0.000 Rotate about Y: 0.000 Rotate about Z: 0.000 Teach Method: Origin +X +Y [TYPE]
G1
: : :
UNINIT UNINIT UNINIT
RECORD
DONE
5 Move the cursor to Frame Number. Type the number of the frame to define and press ENTER. 6 Move the cursor to Reference Grp. Type the number of the reference group and press ENTER. Move the cursor to Robot Grp. Type the robot group number and press ENTER. 7 Define the origin point of the Touch Frame a Move the cursor to Origin. b Jog the Robot TCP to the desired starting point (origin). c Press F2, RECORD. 8 Define the +X direction a Move the cursor to X. b Jog the robot TCP to a point along the +X axis of the touch frame. c Press F2, Record. 9 Define the +Y direction a Move the cursor to Y. b Jog the robot in the +Y direction of the touch frame, to a point on the X-Y plane. c Press F2, RECORD. 10 Press F5, DONE to complete the definition of the frame.
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Procedure 9--25 Step
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Setting Up a Touch Frame Using the Direct Entry Method
1 Press MENUS. 2 Select SETUP. 3 Press F1, [TYPE]. 4 Select Touch Frame. You will see a screen similar to the following. Touch Frame Setup
Joint 10% 1/7 Frame Number:10 Reference Grp:1 Robot Grp:1 Direct Entry: Rotate about X: 0.000 Rotate about Y: 0.000 Rotate about Z: 0.000 Teach Method: Origin +X +Y [TYPE]
G1
: : :
UNINIT UNINIT UNINIT
RECORD
DONE
5 Move the cursor to Frame Number. Type the number of the frame to define and press ENTER. 6 Move the cursor to Reference Grp. Type the number of the reference group and press ENTER. NOTE If you change the value of Reference Grp for an initialized frame, the following warning message will be displayed:
Frame data will be cleared! Yes No
If you press F3, Yes, the frame data will be reinitialized. If you set Reference Grp > 1, but no leader group matches the selected reference group, or it has not been calibrated for coordinated motion, the value of Reference Grp will not change and the following warning message will be displayed:
Referenced group does not exist
Move the cursor to Robot Grp. Type the robot group number and press ENTER. 7 Define the rotation angle about X. a Move the cursor to Rotate about X. b Enter the value (in degrees). 8 Define the rotation angle about Y. a Move the cursor to Rotate about Y. b Enter the value (in degrees). 9 Define the rotation angle about Z. a Move the cursor to Rotate about Z. b Enter the value (in degrees). 10 Press F5, DONE to complete the definition of the frame.
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Search Pattern Search patterns determine the kind of information stored in the position register. The stored information is either the found position, or the position offset information depending on the search pattern used and the reference group specified in the touch schedule. Four types of search patterns are available: F
Simple search
F
Fillet/lap search
F
V-Groove search
F
Outside/inside diameter search
NOTE You select the type of search pattern that is used when you set up the touch sensing schedule. See Section 9.19.2. Simple Search For a simple search, a two--dimensional search is executed to find the actual location of one position on an object. A simple search stores the found position (x, y, z, w, p, r) into a position register PR[ ]. Once completed, the robot is programmed to move to the position stored in that position register. CAUTION Do not use simple search when you use the multipass option with touch sensing because both simple search and multipass use position registers. Simple search stores the computed position in a position register. Multipass cannot use position registers to plan paths. Use the 2D fillet search pattern when using multipass with touch sensing. Simple search requires: F
That the surfaces being searched are perpendicular to each other.
F
Searches to be done in two different directions.
F
The second search motion to be performed with the desired torch angle.
The first search defines the positional information for that search direction only (x, for example). The second search defines the other direction positional information (z, for example). The starting position of the second search defines the remaining positional information, (y, w, p, r, for example) that determines the torch angle for welding and, in this case, the y value. Simple search is typically used to find the starting point of a weld path that uses the Thru-Arc Seam Tracking(TAST) option. A two-dimensional search is programmed in the software as the only valid search pattern type when a simple search is used. Changing the search pattern type has no effect. The two-dimensional search that Simple Search does is called a pattern type. The two-dimensional search is the only valid pattern type for a simple search. Refer to Table 9--32 for information on search patterns and valid pattern types for each search pattern. Refer to Section 9.19.2 for example programs using simple search. See Figure 9--108 for an illustration of a simple search routine. Figure 9--108. Simple Search Routine Using Searches in Two Directions Original Search Start
Original position
Y
X
X Original position
SIDE VIEW 609
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Fillet/Lap Search For a Fillet/Lap Search a one, two, or three dimensional search is executed to obtain positional offset information. A Fillet/Lap Search stores positional offset information in a positional register PR[ ]. This offset can be applied to one or more positions in a programmed path. The offset can be in one, two or three directions. The offset can also be in two directions plus rotation about the axis of which no searching is performed. For example, if the object is being searched for offset in both x and y directions, a fillet search can offset for a rotation about the z axis. Another type of offset can be in one direction plus rotation about an axis of which no searching is performed. For example, if the object is being searched for offset in x, a fillet search can offset for a rotation about z. Note that is this type of search, the first touch point is used as the arc start point. See Figure 9--109.
Figure 9--109. Fillet Search in One Direction (x) with Rotation about z
Z X
Y
SEARCH X 1
Rotate About Z
SEARCH X 2
TOP VIEW
Another type of offset can be in three directions plus rotation about the axis of which no searching is performed. For example, if the object is being searched for offset in x, y, and z directions, a fillet search can offset for a rotation about the z axis. A fillet search stores an offset into a position register [PR]. commands to begin and end the offset.
The robot program then uses the touch offset
The type of searches that a Fillet/Lap Search does is called a pattern type. See Figure 9--110 for information on search patterns and valid pattern types for each search pattern. Refer to Section 9.19.2 for example programs using Fillet/Lap Search. See Figure 9--110 and Figure 9--111 for illustrations of Fillet/Lap Searches.
Figure 9--110. Fillet Search in Two Directions (x and y) with Rotation about z
SEARCH Y 1
Z Y
X
SEARCH Y 2 SEARCH X 1
Rotate About Z
610
SEARCH X 2
TOP VIEW
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Figure 9--111. Fillet Search in Three Directions (x, y, z) with Rotation about z SEARCH Z 1 SEARCH Z 3 SEARCH Z 2
SEARCH Y 1
Z X
Y
Rotate About Z SEARCH X 1
SEARCH Y 2 SEARCH X 2
TOP VIEW V-Groove Search For V-Groove Search a one-dimensional search is executed to obtain positional offset information. A V-Groove Search stores positional offset information in a positional register [PR]. This offset can be applied to one or more positions in a programmed path. The types of searches that a V-Groove Search does is called a pattern type. Refer to Figure 9--112 for information on search patterns and valid pattern types for each search pattern. Refer to Section 9.19.2 for example programs using V-Groove Search. See Figure 9--112 for an illustration of a V-Groove Search. Figure 9--112. V-Groove Search Original position
X Y
X SIDE VIEW
Outside/Inside Diameter Search (OD/ID) For Outside/Inside Diameter Search (OD/ID Search) a two dimensional search is executed to obtain the positional offset information of the center point of a circular path relative to the original (master) location. An Outside/Inside Diameter Search stores positional offset information in a positional register [PR]. This offset can be applied to one or more positions in a programmed path. The types of searches that an Outside/Inside Search does is called a pattern type. Refer to Figure 9--113 for information on search patterns and valid pattern types for each search pattern. Refer to Section 9.19.2 for example programs using OD/ID Search. See Figure 9--113 for an illustration of a OD/ID Search.
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Figure 9--113. OD/ID Search in Two Directions (x and y)
+X +Y
Y
--X
X TOP VIEW
Table 9--32 shows a matrix of possible search pattern and valid pattern types. Select a combination that you would like to use on your application and verify that it will provide the proper results. Table 9--32. Search Patterns
Pattern Type 1_D
Search Pattern and Valid Pattern Type Pattern Type 2_D
Pattern Type 3_D
Pattern Type 1_D and Rotation
Pattern Type 2_D and Rotation
Pattern Type 3_D and Rotation
Simple Search
Not Valid
Requires 2 different search directions. Minimum 1 search per direction.
Not Valid
Not Valid
Not Valid
Not Valid
Fillet/Lap
Requires 1 search direction. Minimum 1 search per direction.
Requires 2 different search directions, x and y, x and z, y and z. Minimum 1 search per direction.
Requires 3 different search directions, x,y, and z. Minimum 1 search per direction.
Requires 1 search direction. Minimum 2 searches per direction.
Requires 2 different search directions. Minimum 2 searches per direction.
Requires 3 different search directions. 3 searches in one direction (usually --z) 2 searches in each of the remaining directions.
V-Groove
Requires 1 search direction. Minimum 1 search per direction.
Not Valid
Not Valid
Not Valid
Not Valid
Not Valid
OD/ID
Not Valid
Requires 3 different searches in 2 different directions. For example, +x,--x,+y, NOT x,y,z. Minimum 1 search per direction.
Not Valid
Not Valid
Not Valid
Not Valid
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Touch Schedule A touch schedule is a series of conditions that control how the search motion is completed. Thirty-two touch schedules are available. You access touch schedules from the DATA menu. There are two screens associated with touch schedules: the SCHEDULE screen and the DETAIL screen. The SCHEDULE screen allows you to view and set limited information for nine schedules at once. DETAIL allows you to view and set the complete information for a single schedule. You display the schedule screen by pressing the PREV MENU key. You display the detail screen by pressing the function key F2, DETAIL. Table 9--33 lists and describes each SCHEDULE screen condition. Table 9--34 lists and describes each DETAIL screen condition. Use Procedure 9--26 to define touch schedules. Table 9--33.
Touch Sensing SCHEDULE Screen Conditions
ITEM (mm/sec)
DESCRIPTION This item specifies how fast the robot will move when performing a Search Motion.
Default = 50.0 mm/sec
CAUTION A search motion is programmed as a motion option at the end of a position instruction. The speed at which the robot will move is determined by the search speed, not by what is indicated in the position instruction. During testing, when dry run is in effect, this search speed is also used. The dry run speed has no effect on search motion. (mm) Default = 100 mm FRAME Default = 1 Master Flag Default = OFF
This item defines how far the robot can move when it is performing a search. Error code THSR-017 (Pause) No contact with part. is displayed when this distance is reached without making contact with the object. This item defines the touch frame to be used in the touch schedule. This determines the x, y, and z directions for the search motion. The same touch frame can be used in more than one touch schedule. This item enables the search routine to be used as a mastering routine for those touch sensing programs that generate position offset information. If set to ON, when the search routine is executed, the touched positions are recorded as the reference positions to be used by future searches. This flag must be set to OFF after the master search is completed in order to generate position offset information on the objects to be searched. Also, when the search is performed, the position offset information in the position register is set to all zero values. This means the when touch sensing finds the object in its master position, no offset is to be applied to the weld path. NOTE The Master Flag condition has no effect on simple searches.
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Table 9--34.
Touch Sensing SCHEDULE Screen Conditions
ITEM
DESCRIPTION
Touch Schedule
This item indicates the number of the displayed schedule. A comment can be entered.
Search Speed
This item specifies how fast the robot will move when performing a Search Motion.
Default = 50.0 mm/sec
CAUTION A search motion is programmed as a motion option at the end of a position instruction. The speed at which the robot will move is determined by the search speed, not by what is indicated in the position instruction. During testing, when dry run is in effect, this search speed is also used. The dry run speed has no effect.
Search Distance
This item defines how far the robot can move when it is performing a search. Error code THSR-017 Pause No contact with part. is displayed when this distance is reached without making contact with the object.
Default = 100 mm Touch Frame
This item defines the touch frame to be used in the touch schedule. This determines the x, y, and z directions for the search motion. The same touch frame can be used in more than one touch schedule.
Default = 1 Search Patterns
This item defines the type of object to be searched and causes the Arctool software to compute the found position or positional offset information dependent on the search pattern selected. The computed data is stored in a position register.
Default = SIMPLE
There are four available search patterns: F Simple Search F
Fillet Search
F
V-Groove Search
F
OD/I D Search
Refer to Section 9.19.2 for a description of search patterns. Pattern Type Default = 1_D Shift 1_D Shift
This item selects the type of offset to be stored in the position register. Six pattern types are available: Stores a one dimensional offset. Offsets can be in the x, y, or z direction.
2_D Shift
Stores a two dimensional offset. Offsets can be in two of the x, y, or z direction.
3_D Shift
Stores a three dimensional offset to a program. Offsets are in the x, y, or z direction.
1_D Offset
Stores a one dimensional offset with rotation about the axis of which the search is not performed.
2_D Offset
Stores a two dimensional offset with rotation about the axis of which no searches are performed. For example, if the object is being searched for an offset in both the x and y directions, a 2_D Shift & Rotate search can offset for a rotation about the z axis.
3_D Offset
Stores a three dimensional offset with rotation about the axis of which no searches are performed. For example, if the object is being searched for an offset in both the x and y directions, a 3_D Shift & Rotate search can offset for a rotation about the z axis. NOTE Simple, OD/ID, and V-Groove search patterns are pre-defined. Changing the pattern type for these searches has no effect. See 9.19.2 for valid pattern types for selected search patterns.
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Table 9--34. (Cont’d) Touch Sensing SCHEDULE Screen Conditions ITEM Incremental Search Default = ON NOTE: Simple search does not support incremental search
DESCRIPTION Offsets the starting position of the second etc. search in a search routine by the amount of offset found by the first search motion. If set to OFF, the robot returns to the original starting position. The following illustration shows how the incremental search affects the search routine. Incremental search requires a separate SEARCH START point for each search. Program Example: J P[4] 100% FINE J P[5] 100% FINE SEARCH [-X] J P[6] 100% FINE J P[7] 100% FINE SEARCH [-Z] Search Start for z--offset based on X offset dimension X--OFFSET
X--OFFSET
Original Search Start
Original Search Start
Original Search Start
X
X
Original position
Original position
X Original position
Without incremental search, the robot found the x-offset but cannot find the z--offset. Auto Return Default = ON Return Speed Default = 100 mm/sec Return Term Type Default = Fine
Return Distance Default = 2000 mm Minimum = 0 mm Maximum = 2000 mm Reference Group
This item moves the robot back to the search start position when contact is made with the object. If set to OFF, the robot stops at the contact point and moves straight to the next position. This item specifies the speed at which the robot will return to the search start position upon making contact with the part. This item specifies the termination type the robot will use to return to the search start position. Five Return Term Types are available: F FINE F
CNT20
F
CNT40
F
CNT100
When Auto Return is set to ON, Return Distance specifies the distance the robot will return automatically. If the return distance passes the initial search start position, the robot will return to the initial start position. This item specifies how the offset is recorded: If the specified number is the same as the number specified in the robot group item, which will be described later, OFFSET is recorded with respect to the user coordinate system of the robot group of the number. (no coordination) If the specified number is different from the number specified in the robot group item, OFFSET is recorded with respect to the coordinated frame of the robot group specified in the robot group item and the robot group (leader) specified in this item. NOTE For searches other than simple search, Reference Group must equal the frame Reference Group. Otherwise, an error message, “Reference grp mismatch,” will be displayed. For simple search, Reference Group must be same as the specified number of Robot Grp. Otherwise an error message, “Illegal motion ref. grp,” will be displayed.
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Table 9--34. (Cont’d) Touch Sensing SCHEDULE Screen Conditions ITEM
DESCRIPTION
Contact Record PR Default = 32
The search output position register is used as a temporary buffer to hold the last search contact position. The purpose for this temporary position register buffer is to provide the ability to look at the positional data of an individual search, or to extract data from the buffer in a program. By default, this register is position register 32. Search output position register should be assigned to the last position register number in your system. CAUTION The data in the position register is overwritten at each search motion so the same position register should not be used to store the final positional data from the search motion. Also, the contents of this temporary buffer is a real position, not an offset. Do not program motion instructions to use this position register data as an offset.
Error on Failure
This item posts error code THSR -- 017( PAUSE) No contact with part, if the search move exceeds the distance set in Search Distance. When OFF, the program execution continues with the next instruction if the Search Distance is exceeded;
Default = ON
Programming Hint: If this is set to OFF, the next instruction in the program looks at the contents of the Error Register and branch accordingly. Error Register Number Default = 32
When Error On Failure is set to OFF, this register is set to 1 when the search distance is exceeded. A successful search sets this register to 0.
Robot Group
This item specifies the robot group which uses the touch sensing schedule.
Default = 1 Procedure 9--26 Step
Defining Touch Schedules
1 Press DATA. 2 Press F1, [TYPE]. 3 Select Touch Sched. You will see a screen similar to the following. DATA
1 2 3 4 5 6 7 8 9 [TYPE]
Touch Sched (mm/sec) 50.0 50.0 50.0 50.0 50.0 50.0 50.0 50.0 50.0
(mm) 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0
WORLD 4 % 1/32 FRAME MASTER Group 1 OFF 1 1 OFF 2 1 OFF 1 1 OFF 1 1 OFF 1 1 OFF 1 1 OFF 1 1 OFF 1 1 OFF 1
DETAIL
HELP>
4 To copy schedule information from one schedule to another: a Press NEXT, >. b Move the cursor to the schedule you want to copy. c Press F2, COPY. d Enter the schedule number to which you want to copy the data. Enter schedule number to copy to:
e Press ENTER. The data will be copied, but the comment will not be copied. 5 To clear the information you have entered for a schedule: Clear this schedule? [NO] YES NO a Move the cursor to the schedule.
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b Press NEXT, >. c Press F2, CLEAR. The data will be cleared, but the comment will remain. 6 Move the cursor to the desired schedule number. 7 To display more information about the schedule, press F2, DETAIL. See the following screen for an example. DATA
Touch Sched
Touch Schedule:8 [ 2 Master flag: 3 Search speed 4 Search distance 5 Touch frame 6 Search pattern 7 Pattern Type 8 Incremental search: 9 Auto return: 10 Return speed
11 12 13 14 15 16 17 18
WORLD 10% 1/17 1 ]
Touch OFF 50.0 mm/sec 100.0 mm 2 Simple 2_D Shift ON ON 100.0 mm/sec
Return distance: Reference Group: Return term type: Contact record PR:
50 mm 1 Fine 32
Error on failure: Error register num: Robot & group:
ON 32 1
[ TYPE]
HELP >
8 Set each schedule item as desired. 9 To add a comment: a Move the cursor to the to the comment line and press ENTER. b Select a method of naming the comment. c Press the appropriate function keys to add the comment. d When you are finished, press ENTER. 10 To copy schedule information from one schedule to another: a Press NEXT, >. b Move the cursor to the schedule you want to copy. c Press F2, COPY. d Enter the schedule number to which you want to copy the data. Enter schedule number to copy to:
e Press ENTER. The data will be copied, but the comment will not be copied. 11 To clear the information you have entered for a schedule: Clear this schedule? [NO] YES NO a Move the cursor to the schedule. b Press NEXT, >. c Press F2, CLEAR. The data will be cleared, but the comment will remain.
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9.19.3 Touch sensing programming A touch sensing routine consists of search instructions to locate an object, and offset instructions to displace programmed positions. NOTE Any changes to the tool frame affects the touch start position. CAUTION Recorded positions and position registers are affected by UFRAME, and UFRAME has an affect during playback. If you change UFRAME, any recorded positions and position registers will also change.
Touch Sensing Instructions Touch sensing instructions are used to implement touch sensing programming. Four touch sensing instructions are provided: F
Search Start
F
Search End
F
Touch Offset
F
Touch Offset End
Touch Sensing Motion Option There is one Touch Sensing motion option: Search [ ]..The Search [ ] motion option directs the motion of the robot (in a positive or negative x,y or z direction) to search for the object. The x, y and z vectors are defined by the touch frame assigned in the touch schedule. When contact is made
Search [ ] Motion Option J P[1] 50% Fine Search [ ] with the object, the robot’s current TCP position is stored and robot motion is stopped. The Search [ ] motion option is entered at the end of a motion instruction. NOTE Search and Search Start must use FINE termination type. The recorded position that has the search motion option is not executed, so motion to the search start position must be recorded in a separate motion instruction. See Figure 9--114. Figure 9--114. Touch Sensing Motion Option Example
INSTRUCTION
DESCRIPTION
-------------------------------------------------------------------------------------------------------------------------------------------------------J P[3] 100% FINE J P[3] 20% FINE SEARCH [-X]
Move to search start position Search motion
WARNING Motion speed and direction are controlled by values set in the touch schedule assigned by the Search Start instruction, not by the motion instruction associated with that line of the program. The motion and speed could be different than what is displayed on the motion instruction.
Use Procedure 9--27 to enter the Search[ ] instruction.
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Procedure 9--27
Entering a Search [ ] Instruction into a Program
NOTE Refer to Chapter 5. PROGRAMMING for details on creating and modifying a program. Step
1 Jog the robot to the search start position and record the position. 2 Record another position at the same location. This second motion instruction will be controlled by the touch sensing software during the search. 3 Move the cursor to the end of the motion instruction line of the selected position. 4 Press F4, [CHOICE] to view the motion option choices. 5 Select 8, Next Page 6 Select Search and press ENTER. 7 Select the direction of the search to be performed and press ENTER. Motion Instructions Used with Touch Sensing Touch sensing routines, using a simple search, apply the positional data by using a motion instruction. A simple search stores an actual position in the specified position register. After a “simple” search routine, the touch sense software will calculate a real position (x,y,z,w,p,r) and put the data in the position register defined by the SEARCH START[1] PR[x] instruction. Since this is a real position, the robot will be commanded to move to the position in the position register instead of to a recorded position.
Example:
J
PR [4]
100% FINE
ARC START [1]
J PR[4] 100% FINE ARC START[1] shows where position register 4 is the position register specified in the simple search routine. Executing a Touch Sensing Program When executing a touch sensing program, all testing and cautions must be followed. Refer to Chapter 6. EXECUTING A PROGRAM for more information about testing programs and running production. For Fillet/Lap, V-Groove, OD/ID search pattern programs you must establish master positions for all search motion by: 1 Setting the master flag in the touch schedule that is specified in the SEARCH START command used to ON. 2 Running the program to establish master positions for all search motions. 3 Setting the master flag in the touch schedule that is specified in the SEARCH START command to OFF. Refer to Chapter 5. PROGRAMMING for details on creating and modifying a program. Touch Sensing Robot Position Touchup You can use the function key F5, TOUCHUP when editing your program to modify the recorded robot position. When you use the TOUCHUP function with touch sensing, the new position information is added to the offset information to determine the weld path. Use Procedure 9--28 to touchup robot positions in a touch sensing program. Figure 9--115 shows an example of points that require touching up. Refer also to Sections 9.19.5. Figure 9--115. Points that Require Touching Up Touch Offset PR[3] J P[7] 100% Fine Arc Start [1] L P[8] 30IPM Fine
These points require Procedure 9--28 to touch them up.
Arc End [1] Touch Offset End
In order to correctly touch up Touch Offset positions, follow Procedure 9--28 .
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Procedure 9--28 Step
Touching Up Robot Positions in a Touch Sensing Program
1 Execute the program so that the search data is complete and the position register contains the offset information. 2 Execute the line of your program that contains the Touch Offset instruction. CAUTION Do not execute a Touch Offset End instruction and then use backward execution to move to the program line that contains the robot position you want to touchup. Otherwise, the offset data will be incorrect.
3 Single step to a line in the program that contains the first robot position that you want to touchup. 4 Jog the robot to the new position, press and hold in the SHIFT key and press F5, TOUCHUP. 5 Touch up all necessary robot positions between the Touch Offset Start and Offset End positions. Programming Examples Example programs contained in this section include: F
Simple search -- Figure 9--116
F
One-dimensional search (Fillet/Lap, V-Groove) -- Figure 9--117
F
Two-dimensional with rotation -- Figure 9--118
F
Two-dimensional with coordinated motion -- Figure 9--119, Figure 9--120, and Figure 9--121
F
Simple search with coordinated motion -- Figure 9--122
NOTE Do not use a continuous term type (CNT) for motion that is right before a Search. Instead, use the FINE term type. See line 3 in the Simple Search Example Program. If you use continuous, the search cannot compute a valid offset. Figure 9--116. Simple Search Example Program
INSTRUCTION
DESCRIPTION
-------------------------------------------------------------------------------------------------------------------------------------------------------1: 2: 3: 4: 5: 6: 7: 8:
J P[1] 100% Fine Search Start [4] PR[4] J P[2] 100% Fine J P[3] 100% Fine Search [Y] J P[4] 100% Fine Search [-Z] Search End J PR[4] 100% Fine ARC START[1]
Teach a point in space. Search uses schedule 4, position register 4, to store position Teach a search starting position. Do a search motion in the Y direction. Do a search in the --Z direction. End of the search. Move the robot to to the computed position PR[4].
NOTE Simple search is different from all other searches in two aspects: First, the master flag in the schedule is always set to off. Second, the position register contains an absolute position instead of an offset.
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Figure 9--117. One-Dimensional Search Ex. Prog. (Fillet/Lap, V-Groove)
INSTRUCTION
DESCRIPTION
-------------------------------------------------------------------------------------------------------------------------------------------------------1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12:
J P[1] 100% Fine Search Start [1] PR[1] J P[2] 100% Fine J P[3] 100% Fine Search [Y] Search End J P[4] 100% Fine Touch Offset PR[1] J P[5] 100% Fine ARC START[1] L P[6] 30IPM Fine ARC END[1] Touch Offset End
Teach a point in space Search uses schedule 1, register 1 stores Offset Teach a search starting position. Do a search motion in the Y direction. End of the search Teach an intermediate point (optional) The following positions will be offset by PR [1]. P[5] is offset by PR[1]. P[6] is offset by PR[1]. End of offsetting position.
Figure 9--118. Two Dimensional Search Example Program
INSTRUCTION
DESCRIPTION
-------------------------------------------------------------------------------------------------------------------------------------------------------1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14:
J P[1] 100% Fine Search Start [2] PR[2] J P[2] 100% Fine J P[3] 100% Fine Search [Y] J P[4] 100% Fine J P[5] 100% Fine Search [X] Search End J P[6] 100% Fine Touch Offset PR[2] J P[7] 100 Fine ARC START[1] L P[8] 30IPM Fine ARC END[1] Touch Offset End
Teach a point in space (optional). Search uses schedule 2 position, register 2 stores Offset Teach a search starting position. Do a search motion in the Y direction. Go to another search start position Do a search in the X direction End of the search. Teach an intermediate point (optional) The following positions will be offset by PR[2] P[7] is offset by PR[2]. P[8] is offset by PR[2]. End of offsetting position.
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Figure 9--119. Two Dimensional Search with Coordinated Motion Example Program (See Figure 9--120 and Figure 9--121 for illustrations)
INSTRUCTION
DESCRIPTION
-----------------------------------------------------------------------------------------------------------------------------------1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21:
J P[1] 20% FINE Search Start[2] PR[2] J P[2] 100% FINE J P[3] 100% Search[X] J P[4] 100% FINE J P[5] 100% FINE Search[X] J P[6] 100% CNT100 J P[7] 100% FINE J P[8] 100% FINE Search[Y] J P[9] 100% FINE J P[10] 100% FINE Search[Y] Search End J P[1] 100% FINE Touch Offset PR[2] J P[11] 100% FINE ARC START[1] L P[12] 30mm/sec FINE COORD L P[13] 30mm/sec FINE COORD ARC END[1] Touch Offset End J P[1] 100% FINE
Teach a home position (follower/leader) Search uses schedule 2, register 2 to store offset Teach a search start position (follower/leader) Do a search in X-direction relative to part Go to another search start position Do a search in the X-direction relative to part Teach an intermediate point Go to another search start position Do a search in Y-direction relative to part Go to another search start position Do a search in Y-direction relative to part End of search Go to home position The following positions will be offset by PR[2] Go to starting position P[12] is offset by PR[2] P[13] is offset by PR[2] End of offsetting position Go to home position
NOTE: D The search direction is part relative as shown in Figure 9--120. When the part moves, the search direction does not change. D Offset PR[2] is part relative as shown in Figure 9--121. D Motions between searches are allowed. Figure 9--120. First Illustration of Two Dimensional Search with Coordinated Motion Program Example (Figure 9--119) 1 (X) 2 (X)
4 (Y) 3 (Y)
1 2
4 3
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Figure 9--121. Second Illustration of Two Dimensional Search with Coordinated Motion Program Example (Figure 9--119)
1 2 4
3
1
4
2 3 Figure 9--122. Simple Search with Coordinated Motion Example Program
INSTRUCTION
DESCRIPTION
-----------------------------------------------------------------------------------------------------------------------------------1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12:
J P[1] 100% FINE Search Start[2] PR[2] J P[2] 100% FINE J P[3] 100% Search[X] J P[4] 100% FINE J P[5] 100% FINE Search[Y] Search End J P[6] 100% FINE J PR[2] 100% FINE ARC START[1] L P[4] 30IPM FINE COORD ARC END[1]
Teach a home position (follower/leader) Search uses shcedule 2, register 2 to store position Teach a search start position (follower/leader) Do a search in X-direction Go to another search start position, leader can’t move Do a search in Y-direction End of search Intermediate position Move the robot to PR[2] Begin welding Coordinated motion
NOTE: D The simple search frame can be relative to the follower or to the leader group. D The stored position is relative to the follower. D The leader is not allowed to move between the searches.
Three Dimensional Search Example Program The 3D search is very similar to the 2D search. To do a 3D search, add searches in the Z-direction.
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Figure 9--123. Three Dimensional Search with Rotation Example Program (See Figure 9--124 for an illustration)
INSTRUCTION
DESCRIPTION
--------------------------------------------------------------------------------------------------------------------------------------------------------
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:
J P[1] 100% Fine Search Start [3] PR[3] J P[2] 100% Fine J P[3] 100% FINE Search[X] J P[4] 100% FINE J P[5] 100% FINE Search[X] J P[6] 100% CNT100 J P[7] 100% FINE J P[8] 100% FINE Search[Y] J P[9] 100% FINE J P[10] 100% FINE Search[Y] J P[11] 100% CNT100 J P[12] 100% FINE J P[13] 100% FINE Search[Z] J P[14] 100% FINE J [15] 100% FINE Search[Z] J P[16] 100% FINE J P[17] 100% FINE Search[Z] Search End J P[1] 100% FINE Touch Offset PR[3] J P[18] 100% FINE ARC START[1] L P[19] 30IPM FINE L P[20] 30IPM FINE ARC END[1] Touch Offset End
Teach a home position Search uses schedule 3, register 3 to store offset Teach a search start position Do a search in X-direction Go to another search start position Do a search in the X-direction Teach an intermediate point Go to another search start position Do a search in Y-direction Go to another search start position Do a search in Y-direction Teach an intermediate point Go to another search start position Do a search in Z-direction Go to another search start position Do a search in Z-direction Go to another search start position Do a search in Z-direction End of search Go to home position The following positions will be offset by PR[3] Go to starting position P[19] is offset by PR[3] P[20] is offset by PR[3] End of offsetting position
Figure 9--124. Illustration of Three Dimensional Search with Rotation Program Example (Figure 9--123)
Z Z
Z P[18]
P[20] X
P[19] Y
X
Y
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9.19.4 Touch sensing hardware Typically for GMAW (Gas Metal Arc Welding), a low voltage signal is applied to the welding wire. When contact is made with the object, the circuit is completed and the required input signal is sent to the robot. When the input is received, the current robot tool center point (TCP) position is stored and robot search motion is stopped. The touch sensing circuit is enabled in a program by the SEARCH START instruction that turns on an output that has been assigned for touch sensing. Touch Sensing Input Signal The touch-sensing input signal being monitored during the touch sensing routine can be any one of the following: F
Robot Digital Inputs (RI) 1--16
F
Digital Inputs (DI) 1--22
F
Welding Digital Inputs (WI) 1--8
F
Wire stick detection circuit input WSI, an internal input through the process I/O WDI+, WDI--
You can also set up touch sensing to monitor the condition of any RDO or DO signal as an input signal. When the selected output turns on during a touch sensing routine, the controller reads this as a received input signal. Refer to Section 9.19.1 for more information. Touch Sensing Enable/Disable Output Signal Any one of the following outputs can be selected as the output to enable/disable the touch sensing circuitry: F
Robot digital output (RO) 1 -- 16.
F
Digital Outputs (DO) 1 -- 20.
F
Welding Digital Outputs (WO) 1 -- 8.
F
Wire stick detection circuit enable WSE, an internal output on the process I/O board that enables the wire stick detection circuit for touch sensing
Refer to Section 9.19.1 for more information on how to assign this output.
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Simple Low Voltage Touch Sense Detection Circuit Figure 9--125 shows the schematic for a simple low voltage circuit. Any other circuit that will provide the required input can be used. Figure 9--125. Simple Low Voltage Touch Sense Detection Circuit
LOW VOLTAGE TOUCH SENSE DETECTION CIRCUIT
WELD POWER SUPPLY
ROBOT I/O
--
PROCESS CONTROL BOARD
WELD TORCH
+ BLOCKING DIODE MILLER #O42--102 (450A) #042--104 (600 A) LINCOLN #K--826 (400A)
CRM2A(49,50) + 24VE
WORK
RV
3.3K
DI--1
CRM2A (31)
+
-L
RELAY A
ONI
DV
WIRE SHORTED
L
CRM2B
(33)
DO--1
BASIC OPERATION Enable the circuit by turning on the robot DO[1] output. Monitor DI,1 for input. The input will turn on when the weld wire touches the workpiece.
RELAY B
CIRCUIT ENABLED
+ WIRE STICK DETECTION CIRCUIT ASSY NOTE: Any I/O can be used.
626
-24 VDC POWER SUPPLY
CAUTION: DO NOT ENABLE CIRCUIT DURING WELDING
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9.19.5 Touch sensing mastering Touch sensing provides a method for determining part location and automatic adjustment of the robot path, to compensate for part displacement. This section contains the details of mastering a part for touch sensing with the following items F
Mastering
F
Remastering
F
Offsets
F
Patterns
F
Master Flag
F
Touching up Path Positions and Incorrect Touch Up
F
Adding New Positions
F
Multiple Searches
F
Touching Up Search Start Positions
Mastering Mastering refers to defining taught positions in a program as the expected locations of positions. When the robot follows the taught positions of the master path, then the offset is zero. An example is shown in Figure 9--126. Figure 9--126. Part in Mastered position and Offset Applied Illustration
Mastered Part (Expected Position)
Offset Part
Remastering The touch up procedure described in Section 9.19.5 should work for most instances where the search start positions do not need to be moved or if the parts do not change drastically. Remastering is required if the search start positions must be retaught. Also, if the path must be altered significantly, it is recommended to remaster to ensure a correct path. Remastering is accomplished by turning the Master Flag ON and running through the program. The path followed will be the master path with no offset applied. Points not in the correct location must be touched up. After executing the program, the Master Flag is turned OFF. For Touching up path positions refer to Section 9.19.5. In addition, if the specific schedule reference group is not equal to 1 (follower), all of the mastering information is stored with respect to the reference group. If you change the reference group in a schedule, you will have to remaster. NOTE Complex parts with multiple searches might only require remastering of specific portions of the path.
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Offsets Offsets generated by touch sensing are relative to the position found while mastering. An offset is computed by comparing the location of the part with the stored location. Figure 9--127 illustrates the offset value. F
The search performed during mastering establishes the expected location (which is indicated by the small straight line).
F
This location is stored when mastering the part.
F
An offset is computed by comparing the location of the part with this stored location.
F
The offset is part relative when the schedule reference group is not equal to 1.
Figure 9--127. Offset Value Illustration
Part
Mastering Position
Offset
Part
Mastering Position
Patterns Mastering is needed for search patterns that generate offset data. The search patterns that require mastering are as follows: F
Fillet/Lap
F
V-Groove
F
Outside and Inside diameter searches
NOTE A simple search does not require mastering since it produces an actual location stored in a position register. Program Example The following program example describes a part with a search start location and three points along a straight path. Refer to Figure 9--128 and the program example screen shown below. F
The points are numbered according to the program example.
F
The search is a two dimensional search, one in the X direction and the second in the --Z direction.
F
A 2_D Fillet/Lap search was performed.
F
The type of search and other details are defined in Touch Sense Schedule 3.
F
Both searches were started at point 2 and the offset information is stored in position register 1.
F
Points 5, 6, and 7 are offset according to the results of the search.
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PROG_01 JOINT 10% 1: J P[1] 100% FINE 2: Search Start[3] PR[1] 3: J P[2] 100% FINE 4: J P[3] 100% FINE Search[X] 5: J P[2] 100% FINE 6: J P[4] 100% FINE Search[-Z] 7: Search End 8: 9: Touch Offset PR[1] 10: J P[5] 100% FINE 11: L P[6] 20IPM CNT100 12: L P[7] 20IPM CNT100 13: Touch Offset End POINT
ARCSTART
WELD_PT
ARCEND
TOUCHUP >
To perform Incremental searches, each search must have its own start point. In the example program, line 5 was included so the Incremental search feature could be used for the second search. If Incremental is turned off, line 5 could be removed and both searches would start at the taught location of position 2. Master Flag The first time the program is executed the part must be mastered. F
Mastering is done by turning on the Master Flag in the Touch Sense Schedule 3.
F
Execute the program.
F
The search is performed and the path is followed according to the taught positions.
F
Once the program is completed, the Master Flag is turned OFF.
NOTE Incremental search is disabled while the Master Flag is turned ON. Program Example If Incremental search does not appear to be operating as expected, check the Master Flag. The Master Flag might have been inadvertently left on. Figure 9--128. Part with One Touch Sense Start Position, 2, and Three Points along a Path, 5, 6, 7
2
5
6
7
PROG_01 JOINT 10% 1: J P[1] 100% FINE 2: Search Start[3] PR[1] 3: J P[2] 100% FINE 4: J P[3] 100% FINE Search[X] 5: J P[2] 100% FINE 6: J P[4] 100% FINE Search[-Z] 7: Search End 8: 9: Touch Offset PR[1] 10: J P[5] 100% FINE 11: L P[6] 20IPM CNT100 12: L P[7] 20IPM CNT100 13: Touch Offset End POINT ARCSTART WELD_PT ARCEND TOUCHUP >
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F
The path represented by points 5, 6, and 7 will be offset by the amount stored in position register 1.
F
Figure 9--129 shows the position of the master path.
F
The search is performed and the offset from the master location is computed and stored in position register 1.
F
The offset is then applied to the master path to produce the new, offset path.
Figure 9--129. Illustration of the Path when an Offset is Applied 5
7
6
Master Path Touch Offset Amount Offset Path
Touching Up Path Positions Occasionally the part or its placement on a fixture will change requiring adjustment of the path. The entire process of remastering is not need to accommodate these changes. Refer to Figure 9--130 for an illustration of offset path touchup to adjust the location of points. NOTE Touch up must be performed after a successful touch sense and at the same time the offset is being applied. Figure 9--131 illustrates the result of the touch up process. Figure 9--130. Offset Path Touch Up to Adjust location of points 6 and 7 Master Path Offset Original Offset Path 5 7 Touched Up Path
6 Touch Up
Figure 9--131. New Master Touch Up Illustration 5
7 Master Path
6
New Master Touch Up
Incorrect Touch Up A common error is to alter the path without the correct offset being applied. Touching up must be done after executing the search and while the Touch Offset is applied. Example An example of a incorrect touch up is as follows: F You can move through the program without executing the touch sense. F
You can touch up point 6 to place it on the part. Refer to Figure 9--132.
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F
The master path has been altered as shown by the new master path. It was originally intended for the path to be straight and follow the part.
Figure 9--132. Incorrect Touch Up of a Path 5
7 Master Path
6
Part Touch Up New Master Path (Incorrect) 5
7
6
F
The part will not be followed correctly when the program is run. Refer to Figure 9--133.
F
The offset shifts points 5 and 7 to the correct location along the part. Point 6 will not be along the part since the master path was incorrectly touched up.
F
Figure 9--133 exhibits the path that was followed after altering one point. It shows that the part is not followed correctly.
Figure 9--133. Path Followed After Altering 1 Point Master Path
Offset
Part
Executed Path
Adding New Positions Additional points can be added in the same manner as touching up. F
The search must be completed.
F
An accurate offset must be generated.
F
Points can then be added to the offset path.
F
The program is executed by first performing the search and then generating a valid offset.
Figure 9--134 illustrates adding a point to a path. The offset must be actively applied for the master path to be correctly updated. NOTE If the program is ABORTED while adding new positions, the offset is cancelled. New positions will be taught as actual locations rather than positions with an offset applied. The results would be similar to what is shown in Figure 9--133.
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Figure 9--134. New Point Taught while Executing the Offset Path. Master Path Offset Offset Path 5
8 New Point
6
7 New Master Path
5
8
6
7
Multiple Searches Complex programs can have multiple searches generating several offsets as shown in Figure 9--135. Program Example The following program example shown in Figure 9--135 exhibits two searches that can be performed for complex shapes. F
The first search stores the offset data in position register 1 with positions 10, 11, and 12 using the offset.
F
The second search stores offset data in position register 2 with positions 13, 14, and 15 using the offset.
If a position of the taught path is to be touched up, the corresponding search must be performed. Figure 9--136 shows the complex part with a section moved and the path represented by positions, 10, 11, and 12 which must be touched up. F
The first search must be executed to obtain an accurate offset.
F
The offset is applied and the positions, 10, 11, and 12 can be touched up as normal.
F
The master will be correctly updated.
If the path using positions 13, 14, and 15 must be touched up, the second search must be executed. F
The second search stores offset data in position register 2 with positions 13, 14, and 15 using the offset.
NOTE Using this method can reduce the amount of time required to adjust a small section of the program. See the following screen for an example. PROG_01 JOINT 10% 1: J P[1] 100% FINE 2: SEARCH START[3] PR[1] 3: J P[2] 100% FINE 4: J P[3] 100% FINE SEARCH [X] 5: J P[4] 100% FINE SEARCH [-Z] 6: SEARCH END 7: J P[5] 100% FINE 8: SEARCH START[4] PR[2] 9: J P[6] 100% FINE 10: J P[7] 100% FINE SEARCH [-X] 11: J P[8] 100% FINE 12: J P[9] 100% FINE SEARCH [-Z] 13: SEARCH END 14: 15: TOUCH OFFSET PR[1] 16: J P[10] 100% FINE 17: L P[11] 20IPM CNT100 18: L P[12] 20IPM CNT100 19: TOUCH OFFSET END 20: 21: TOUCH OFFSET PR[2] 22: J P[13] 100% FINE 23: L P[14] 32IPM CNT100 24: L P[15] 32IPM CNT100 25: TOUCH OFFSET END [TYPE] CREATE DELETE [CHOICE] HELP >
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Figure 9--135. Multiple Searches can be Performed for Complex Shapes Second Search P[13] First Search
P[14]
P[15]
P[10]
P[11]
P[12]
Figure 9--136. Illustration of Part Shape Change and the Effect on Multiple Searches Performed Second Search P[13]
First Search
P[14]
P[15] Original Part Location P[10]
P[11]
P[12]
Touch Up This Section
Touching Up Search Start Positions Touching up a search start position is different from touching up the path position. If the search start position is moved, then the search and affected path positions must be remastered. There is one exception: F
Moving the search start position along the axis of the search.
Program Example The following program example shown in Figure 9--137 exhibits a part and search start position. If the search start position is too close to the part due to poor programming, changes in the part, or a change in the part location, then F
The search start position needs only to be moved back along the search direction.
F
This can be accomplished with no effect on the path positions and remastering will not be required.
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Program Example The program example shown in Figure 9--138 shows the search start position moved to a new location off the axis of the search direction. If the search position is moved off the axis of the search direction, then: F
Remastering is required. To remaster refer to Section 9.19.5.
Figure 9--137. Moving a Search Start Position along the Search Direction Part
Original Search Start Position
New Search Start Position
Figure 9--138. Search Start Position moved to a New Location Off the Axis of the Search Direction Part
Original Search Start Position New Search Start Position
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9.20 Load Setting 9.20.1 Overview Setting the information about the load on the robot appropriately can cause the following effects: F
Increase in motion performance (such as lower vibration and shorter cycle time)
F
More effective reaction of functions related to dynamics (such as increase in performance related to collision detection and gravity compensation)
For effective use of the robot, it is recommended to appropriately set information about loads such as the hand, workpiece, and devices mounted on the robot. A load estimation function is optionally available. This function enables the robot to calculate load information automatically.
9.20.2 Motion Performance Screens There are three motion performance screen types: List screen, load setting screen, and device setting screen. They are used to specify load information and the information about devices on the robot. These screens let you easily specify the information that has conventionally been set in system variables ($PAYLOAD, $PAYLOAD_X, $PAYLOAD_Y, $PAYLOAD_Z, $PAYLOAD_IX, $PAYLOAD_IY, and $PAYLOAD_IZ in the $PARAM_GROUP). They also let you switch the load setting among two or more loads. 1 Press MENUS to display the screen menu. 2 Select “6 SETUP” described on the next page. 3 Press F1 (TYPE) to display the screen switch menu. 4 Select Motion. The list screen appears. (If any other screen appears, press [PREV] several times until the list screen appears.) For a multigroup system, the list screen of another group can be reached by pressing F2 (GROUP). MOTION PERFORMANCE Group1 No. PAYLOAD[kg] 1 0.00 2 0.00 3 0.00 4 0.00 5 0.00 6 0.00 7 0.00 8 0.00 9 0.00 10 0.00
JOINT
10 %
Comment [ [ [ [ [ [ [ [ [ [
] ] ] ] ] ] ] ] ] ]
Active PAYLOAD number = 0 [ TYPE ] GROUP DETAIL ARMLOAD SETIND >
5 Load information can be specified for condition No. 1 to No. 10. As stated later, an appropriate condition number can be selected as the load is changed by a hand change. Move the cursor to the desired No., and press F3 (DETAIL) to display the related load setting screen. MOTION/PAYLOAD SET
1 2 3 4 5 6 7 8
JOINT
10 %
Group 1 Schedule No [ 1]:[****************] PAYLOAD [kg] 0.00 PAYLOAD CENTER X [cm] 0.00 PAYLOAD CENTER Y [cm] 0.00 PAYLOAD CENTER Z [cm] 0.00 PAYLOAD INERTIA X [kgfcms^2] 0.00 PAYLOAD INERTIA Y [kgfcms^2] 0.00 PAYLOAD INERTIA Z [kgfcms^2] 0.00
[ TYPE ]
GROUP
NUMBER
635
DEFAULT
HELP
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6 Specify the mass and gravity center of the load, and inertia around its gravity center. The X, Y, and Z directions displayed on the load setting screen are in reference to the default tool coordinate system (which is valid when no other tool coordinate system is set up). NOTE 1 [kgf cm s2] = 980 [kg cm2] When a value is entered, the confirmation message Path and Cycletime will change. Set it? appears. Press F4 (YES) or F5 (NO) whichever is necessary. 7 Pressing F3 “NUMBER” lets you go to the load setting screen for another condition No. For a multigroup system, pressing F2 “GROUP” lets you move to the setting screen of another group. 8 Press PREV to go back to the list screen. Press F5 “SETIND”, and enter a desired load setting condition No. The last condition No. selected is used during program execution and jog operation. (The initial condition No. is 0. Using the condition without changing from the initial setting causes the initial system variable setting to be used. Using the setting on the load setting screen requires enabling that setting.) 9 Pressing F4 “ARMLOAD” on the list screen lets you move to the device setting screen. MOTION/ARMLOAD SET
JOINT
Group 1 1 ARM LOAD AXIS #1 2 ARM LOAD AXIS #3 [ TYPE ]
[kg] [kg]
GROUP
10 %
0.00 0.00
DEFAULT
HELP
10 Specify the mass of the devices on the J1 and J3 arms. Entering values displays the message Path and Cycletime will change. Set it?. Press F4 (YES) or F5 (NO) whichever is necessary. After setting the mass of a device, turn the power off and on again.
9.20.3 Program Instructions Pressing F5 “SETIND” on the list screen lets you switch the screen, using program instructions rather than selecting a desired load setting condition No. (Even after program execution is finished, the last condition No. selected is used during later program execution and jog operation.) Instruction 1 Miscellaneous 2 Skip 3 Payload 4 Offset/Frames PRG
5 6 7 8
JOINT 10 % Multiple control SENSOR Program control ---next page---
(1) Additional setting [i] This instruction changes the load setting condition No. to be used to i. PAYLOADstatement 1 PAYLOAD[...] 2 3 4 PRG
JOINT 5 6 7 8
Example 1: Additional setting [i] This program selects load setting condition 1.
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Multi--operation group environment The PAYLOAD[i] instruction usually selects a load setting condition No. for all operation groups enabled for the program. For a multigroup system, however, it is possible for this instruction to specify what group to be subjected to load setting condition No. switching. PRG
1: [End]
JOINT
10 % 1/2
PAYLOAD[...]
Enter value GROUP DIRECT INDIRECT
Pressing F1 (GROUP) displays a menu that contains choices for specifying a group. You can select a group from the menu. Example PAYLOAD[i] This program selects load setting condition No. 1 for groups 2 and 3.
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9.21 Load Estimation 9.21.1 Overview Load estimation is a function for estimating the weight of the load, such as tool and workpiece, mounted on the hand of the robot. The function enables the information stated above to be estimated automatically by running the robot. Using the load estimation function requires the load estimation option (A05B--****--J669)(*). Using the function also requires that your model support the load estimation function. If your model does not support the function, you cannot use it.
9.21.2 Operating Procedure Load is estimated in the following flow: 1 Set the range of motion to be subjected to load estimation 2 Execute load estimation. Once a mechanical part such as a motor is replaced, it becomes necessary to make calibration. If no calibration is made after mechanical part replacement, the precision of load estimation becomes lower.
9.21.3 Load Estimation Procedure (for 6--Axis Robots) This procedure is performed on the load estimation screen. This screen is entered from the motion performance screen. 1 Press MENUS to display the screen menu. 2 Select “6 SETUP” described on the next page. 3 Press [F1] (TYPE) to display the screen switching menu. 4 Select Motion. The list screen appears. (If any other screen appears, press [PREV] several times until the list screen appears.) For a multigroup system, the list screen of another group can be reached by pressing F2 (GROUP). MOTION PERFORMANCE Group1 No. PAYLOAD[kg] 1 0.00 2 0.00 3 0.00 4 0.00 5 0.00 6 0.00 7 0.00 8 0.00 9 0.00 10 0.00
JOINT
10 %
Comment [ [ [ [ [ [ [ [ [ [
] ] ] ] ] ] ] ] ] ]
Active PAYLOAD number = 0 [ TYPE ] GROUP DETAIL ARMLOAD SETIND >
5 Press [F!], then [F2] F2 “IDENT”. The load estimation screen appears.
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MOTION/PAYLOAD JOINT 10 % Group1 Schedule No [ ]:[ ] 1 PAYLOAD ESTIMATION ***** Previous Estimated value (Maximum) Payload [Kg ]: 0.00(165.00) Axis Moment [ Nm] J4: 0.00E+00 (9.02E+02) J5: 0.00E+00 (9.02E+02) J6: 0.00E+00 (4.41E+02) Axis Inertia [Kg cm^2] J4: 0.00E+00 (8.82E+05) J5: 0.00E+00 (8.82E+05) J6: 0.00E+00 (4.41E+05) 2 MASS IS KNOWN
[ NO]
165.000[Kg]
3 CALIBRATION MODE 4 CALIBRATION STATUS [ TYPE ]
GROUP
[OFF] *****
NUMBER
EXEC
APPLY
>
6 Place the robot in the position where load estimation is to be performed. NOTE
Only the J5 and J6 axes move during load estimation. The other axes stay in the position where they are when load estimation begins. The range of motion is defined as an interval between two points specified on estimation position 1 and 2 screens. (See steps 10 and 12.) NOTE Put the J5 rotation axis in a horizontal position. The more vertical posture the J5 rotation axis takes, the lower the precision of estimation becomes. 7 Press F3 “NUMBER”, and select the load setting condition No. for which a load estimate is to be set up. 8 If the mass of the load for which load estimation is to be performed is known, move the cursor to line 2, select “YES”, and specify (enter) the mass. NOTE
F
The estimation precision becomes higher when a mass is specified. Specify the mass as much as possible. Even if no mass is specified, estimation is possible provided that the following condition is satisfied. However the precision becomes lower. The moment around the J5 and J6 axes must be sufficiently high. J5 rotation axis
B
J6 rotation axis
A
Load gravity center
F
The mass must be sufficiently great, and the distance between points A and B must be sufficiently large.
F
The load gravity center must be sufficiently far from the J5 and J6 rotation axes.
F
As for positions set up on estimation position 1 and 2 screens, the gravity center of the load must be in or near the plane that contains the J5 and J6 rotation axes.
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J5 rotation axis
Load gravity center
J6 rotation axis F
As for the J6 axis, the interval between points specified on the estimation position 1 and 2 screens must be 180° in terms of angle.
9 Press [F!], then [F4] (DETAIL). The estimation position 1 screen appears. MOTION/ID POS1 Group1 1 POSITION for ESTIMATION J1 J2 J3 J4 2 J5 3 J6 J7 J8 J9 4 SPEED 5 ACCEL [ TYPE ]
Low< 1%> Low<100%> POS.2
DEFAULT
JOINT
10 %
POSITION1 <**********> <**********> <**********> <**********> < -90.000> < -90.000> <**********> <**********> <**********> High<100%> High<100%>
MOVE_TO
RECORD
10 Specify estimation position 1. (Alternatively, the initial value can be used.) Specify the positions of the J5 and J6 axes by entering their values directly. Alternatively, move the robot to the desired position by jogging, then press [Shift] + F5 “RECORD” to record the position. Now pressing [Shift] + F4 “MOVE_TO” moves the robot to estimation position 1. Use this procedure to identify the set position. 11 Pressing [F2] POS.2 displays the estimation position 2 screen. MOTION/ID POS2 Group1 1 POSITION for ESTIMATION J1 J2 J3 J4 2 J5 3 J6 J7 J8 J9 4 SPEED 5 ACCEL [ TYPE ]
Low< 1%> Low<100%> POS.1
DEFAULT
640
JOINT
10 %
POSITION2 <**********> <**********> <**********> <**********> < 90.000> < 90.000> <**********> <**********> <**********> High<100%> High<100%>
MOVE_TO
RECORD
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12 Specify estimation position 2. (Alternatively, the initial value can be used.) Specify the positions of the J5 and J6 axes by entering their values directly. Alternatively, move the robot to the desired position by jogging, then press [Shift] + F5 “RECORD” to record the position. Now pressing [Shift] + F4 “MOVE_TO” moves the robot to estimation position 2. Use this procedure to identify the set position. 13 Press [PREV] to return to the estimation screen. 14 Set the teach pendant enable switch to OFF, and press F4 “EXEC”. The message Robot moves and estimates. Ready? appears. 15 Specify whether to execute load estimation. (Selecting “YES” causes the robot to move. Pay sufficient care to avoid danger.) F
To perform load estimation by running the robot, press [F4] (YES).
F
To quit execution, press [F5] (NO).
16 After low--speed and high--speed operations are finished, load information is estimated. (Operation switches automatically from low speed to high speed. Even when the robot is running at low speed, do not get close to it, because otherwise you may get in a dangerous situation when the robot suddenly starts running at high speed.) 17 Press F5 “APPLY” to set the estimate at a load setting condition No. The message Path and Cycletime will change. Set it? appears. 18 Specify whether to set the estimate. F
To set the estimate, press [F4] (YES).
F
Not to set the estimate, press [F5] (NO).
19 If the value to be set is greater than the maximum allowable load (indicated in parentheses), the message Load is OVER spec ! Accept? appears. Specify whether to set this value, just as in the above step.
9.21.4 Calibration Procedure (for 6--Axis Robots) Once a mechanical part such as a motor is replaced, it becomes necessary to make calibration. If no calibration is made after mechanical part replacement, the precision of load estimation becomes lower. Calibration is controlled, using the load estimation screen. Calibration is started by setting the calibration switch to ON and executing load estimation. 1 Make sure that there is nothing on the hand of the robot. Calibration must be made without attaching anything to the hand of the robot. NOTE
If calibration is performed with anything attached to the robot hand, incorrect calibration data is set up, thus hampering a normal estimation. In this case, make calibration again, properly this time. 2 Press MENUS to display the screen menu. 3 Select “6 SETUP” described on the next page. 4 Press [F1] (TYPE) to display the screen switching menu. 5 Select Motion. The list screen appears. (If any other screen appears, press [PREV] several times until the list screen appears.) For a multigroup system, the list screen of another group can be reached by pressing F2 “GROUP”. MOTION PERFORMANCE Group1 No. PAYLOAD[kg] 1 0.00 2 0.00 3 0.00 4 0.00 5 0.00 6 0.00 7 0.00 8 0.00 9 0.00 10 0.00
JOINT
10 %
Comment [ [ [ [ [ [ [ [ [ [
] ] ] ] ] ] ] ] ] ]
Active PAYLOAD number = 0 [ TYPE ] GROUP DETAIL ARMLOAD SETIND >
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6 Press [F!], then F2 “IDENT”. The load estimation screen appears. MOTION/PAYLOAD JOINT 10 % Group1 Schedule No [ ]:[ ] 1 PAYLOAD ESTIMATION ***** Previous Estimated value (Maximum) Payload [Kg ]: 0.00(165.00) Axis Moment [ Nm] J4: 0.00E+00 (9.02E+02) J5: 0.00E+00 (9.02E+02) J6: 0.00E+00 (4.41E+02) Axis Inertia [Kg cm^2] J4: 0.00E+00 (8.82E+05) J5: 0.00E+00 (8.82E+05) J6: 0.00E+00 (4.41E+05) 2 MASS IS KNOWN
[ NO]
165.000[Kg]
3 CALIBRATION MODE 4 CALIBRATION STATUS [ TYPE ]
GROUP
NUMBER
[OFF] ***** EXEC
APPLY
>
7 Place the robot in the position where load estimation is to be performed. NOTE 1 Only the J5 and J6 axes move during load estimation. The other axes stay in the position where they are when load estimation begins. The range of motion is defined as an interval between two points specified on estimation position 1 and 2 screens. (See steps 9, 10, and 12.) NOTE 2 Put the J5 rotation axis in a horizontal position. The more vertical posture the J5 rotation axis takes, the lower the precision of estimation becomes. 8 Press [F!], then F4 (DETAIL). The estimation position 1 screen appears. MOTION/ID POS1 Group1 1 POSITION for ESTIMATION J1 J2 J3 J4 2 J5 3 J6 J7 J8 J9 4 SPEED 5 ACCEL [ TYPE ]
Low< 1%> Low<100%> POS.2
DEFAULT
JOINT
10 %
POSITION1 <**********> <**********> <**********> <**********> < -90.000> < -90.000> <**********> <**********> <**********> High<100%> High<100%>
MOVE_TO
RECORD
9 Specify estimation positions 1 and 2. Try to use default values as much as possible. Press F3 “DEFAULT”, and specify default values for estimation positions 1 and 2, speed, and acceleration. 10 Pressing [Shift] + F4 “MOVE_TO” moves the robot to estimation position 1. Make sure that it is safe to move the robot to estimation position 1. If it is dangerous to move the robot to estimation position 1, manipulate the J1 to J4 axes by jogging to move the robot to a position where the robot can move safely. 11 Pressing F2 “POS.2” displays the estimation position 2 screen.
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MOTION/ID POS2 Group1 1 POSITION for ESTIMATION J1 J2 J3 J4 2 J5 3 J6 J7 J8 J9 4 SPEED 5 ACCEL [ TYPE ]
Low< 1%> Low<100%> POS.1
DEFAULT
JOINT
10 %
POSITION2 <**********> <**********> <**********> <**********> < 90.000> < 90.000> <**********> <**********> <**********> High<100%> High<100%>
MOVE_TO
RECORD
12 Pressing [Shift] + F4 “MOVE_TO” moves the robot to estimation position 2. Make sure that it is safe to move the robot to estimation position 2. If it is dangerous to move the robot to estimation position 2, manipulate the J1 to J4 axes by jogging to move the robot to a position where the robot can move safely. If you moved any of the J1 o J4 axes, press F2 “POS.2” to go back to the estimation position 1 screen, and follow this procedure again from step 10. 13 Press [PREV] to return to the load estimation screen. 14 Move the cursor to CALIBRATION MODE on line 3 to turn it “on.” NOTE
Once calibration is completed, CALIBRATION MODE becomes “off” automatically. Do not change CALIBRATION MODE during calibration or load estimation. Otherwise, calibration may be made incorrectly or may not be made at all. 15 Move the cursor to line 4 (so that “EXEC” appears at [F4]), and set the teach pendant enable switch to OFF, then press “EXEC”. The message Robot moves and estimates. Ready? appears. 16 Specify whether to perform load estimation. (Selecting “YES” causes the robot to move. Pay sufficient care to avoid danger.) F
To perform load estimation by running the robot, press [F4] (YES).
F
To quit execution, press [F5] (NO).
17 After low--speed and high--speed operations are finished, calibration is completed. (Operation switches automatically from low speed to high speed. Even when the robot is running at low speed, do not get close to it, because otherwise you may get in a dangerous situation when the robot suddenly starts running at high speed.)
9.21.5 Other Related Matters (1) Motion range If the motion range between estimation positions 1 and 2 becomes narrower, the estimation precision may get lower. The actual motion range should preferably be as wide as the default motion range. (2) Acceleration for motion used in load estimation The estimation precision is low for the load whose moment inertia is relatively low compared with the maximum allowable load of the robot. This is because the influence by the moment inertia to the torque of the robot motor is weak. The estimation precision for this light load may be able to be increased by increasing the acceleration used during operation for load estimation. Try to increase the acceleration by specifying a larger value in “ACCEL -- High” on the estimation position 1 and 2 screens; however, do not specify so large a value that vibration becomes serious during operation.
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(3) Calibration data The following system variable hold calibration data. SPLCL_GRP[group].$TRQ_MGN[axis] group : Group number axis : Axis number If improper calibration data is set up, for example, by making calibration with a load mounted by mistake, reassigning the previous data to the system variable can restore the previous calibration data. It is recommended to keep note of the previous calibration data so as to enable restoration.
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9.22 Collision Detection for Auxiliary Axis 9.22.1 General The Collision Detection Function is the feature that stops the robot immediately and reduces the damage to the robot, when the robot collides with other objects. Generally, this feature has been applied for the robot axes. But, this feature has not been applied for the auxiliary axis. Because of the auxiliary axis is design by customer, then the parameters for this feature can not be set beforehand. To apply this feature to the auxiliary axis, the parameter tuning is required with tuning procedure on this manual. NOTE To tune the collision detection parameters for auxiliary axis, Collision Detection for Auxiliary Axis Option (A05B--2400--J645) or High Sensitive Collision Detection Package Option (A05B--2400--J684) that includes above is required.
9.22.2 CAUTION The load ratio of auxiliary axis should be less than 5. Load ratio = (Load Inertia + Motor Inertia) / Motor Inertia When the auxiliary axis is designed, you must consider above. If the load ratio of auxiliary axis is more than 5 times, the motion performance and sensitivity for collision detection may deteriorate.
9.22.3 INITIAL SETTING 1 Setup auxiliary axis (Gear ratio, acceleration time, and etc.) normally 2 Turn power on 3 Set the following system variables $SBR[n].$PARAM[112] = 2097152 / ($SBR[n].$PARAM[47]) $SBR[n].$PARAM[119] = 7282 $SBR[n].$PARAM[120] = --7282 n : Hardware axis number of auxiliary axis n=7~ for aux. Axis / n=1~6 for robot axes 4 Cycle power
9.22.4 TUNING PROCEDURE The sensitivity of collision detection will be tuned by below procedure. It should be tuned without mis--detection. 1 Create the program that includes heavy motion like an inverse motion with CNT100 beforehand. If the program for production is already exist, It can be used to tune. In this case, the sensitivity can be optimized for production with this program. (However, if other program was run, the mis--detection might occur. Also, if this program was modified, the re--tuning might be required.) 2 Run the above program. Also this program must not be paused. Because of the disturbance torque, see below, will be cleared at just re--start the program 3 Measure the max. / min. disturbance torque on STATUS/AXIS/DISTURB screen after running the program.
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PNS001 STATUS Axis
J1 J2 J3 J4 J5 J6 J7
Line 1 G1
ABORT FINE 100%
Disturbance Torque (A) Curr./ Max.(Allowed)/Min.(Allowed) : 0.0 20.0( 40.0) -19.0( -40.0) : 0.0 19.0( 40.0) -20.0( -40.0) : 0.0 22.0( 40.0) -10.0( -40.0) : 0.0 12.0( 20.0) -5.0( -20.0) : 0.0 10.0( 20.0) -11.0( -20.0) : 0.0 8.0( 20.0) -4.0( -20.0) : 0.0 24.0( 56.0) -30.0( -56.0)
[TYPE]
MONITOR
TRACKING
DISTURB [UTIL] >
As said above, the disturbance torque will be reset at the start of each program. If there are some programs, F
make new program that call all program for tuning and run this main program.
F
record the max. / min. disturbance torque for each programs and find max. / min. value in these recorded value.
4 Move the cursor to allowed value in parentheses for the axis. Change the allowed value to same as measured max. or min. value.
PNS001 STATUS Axis
J1 J2 J3 J4 J5 J6 J7
Line 1 G1
ABORT FINE 100%
Disturbance Torque (A) Curr./ Max.(Allowed)/Min.(Allowed) : 0.0 20.0( 40.0) -19.0( -40.0) : 0.0 19.0( 40.0) -20.0( -40.0) : 0.0 22.0( 40.0) -10.0( -40.0) : 0.0 12.0( 20.0) -5.0( -20.0) : 0.0 10.0( 20.0) -11.0( -20.0) : 0.0 8.0( 20.0) -4.0( -20.0) : 0.0 24.0( 24.0) -30.0( -30.0)
[TYPE]
MONITOR
TRACKING
DISTURB [UTIL] >
CAUTION When the disturbance torque exceeds above allowed value, the following WARNING occurs SRVO--053 Disturbance excess (G:x,A:x) Following servo alarm (servo power off) occurs when the disturbance torque exceeds below ALARM LEVELs. Upper Limit = Max. allowed value + 0.3 × Max. current of amp. Lower Limit = Min. allowed value -- 0.3 × Max. current of amp. SRVO--050 Collision Detect alarm (G:x,A:x) Part of 0.3×Max. current of amp. is the margin to prevent the mis--detection. For example in above screen with 40A amplifier, Upper Limit = 24.0 + 0.3 × 40 = 36 A Lower Limit = --30.0 -- 0.3 × 40 = --42 A
5 Run the programs again with above disturbance allowed setting, and confirm that there is no mis--detection. 6 Finished
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9.23 Gravity Compensation Gravity compensation calculates the bending of the robot arm caused by the tool/work on the flange, the equipment on the arm, and the self weight of the arm. Then it compensates the motor position depending on the calculation of the bending, and it improves the absolute position accuracy. Gravity Compensation option (A05B--****--J649) is necessary to use this function. This function can not be used with Softfloat (A05B--****--J612) or Small Circle (not supported).
9.23.1 System Variables Gravity Compensation $PARAM_GROUP[group].$SV_DMY_LNK[8] BOOLEAN [Name]
RW
PU
FALSE TRUE/FALSE
Gravity Compensation Enable/Disable
[Meaning] TRUE Gravity Compensation Enable FALSE Gravity Compensation Disable Gravity compensation is disabled when the robot is shipped. Please set this variable to TRUE and cycle power before use. To set back to be disabled, set this variable to FALSE, do controlled start, and execute robot setup again. (By doing that, the motion parameters are set back to the default values. If the motion parameters have been modified, they need to be modified again.) $PARAM_GROUP[group].$MOUNT_ANGLE REAL [Name]
RW
0
PU
--100000 ~ 100000 (deg)
Mount Angle of Robot
[Meaning] Set 0deg for floor mount type, 180deg for upside down type, or the mount angle for wall mount or angle mount type. Cycle power after setting.
9.23.2 MOTION Screen 1 Payload and armload (equipment on the arm) parameters are set in this screen. 2 This setting screen has three sub--screens. (MOTION screen / PAYLOAD SET screen / ARMLOAD SET screen) 3 This screen is sub--screen in SYSTEM. MOTION Screen (Default screen) MOTION Group 1 No. 1 2 . . 10
JOINT PAYLOAD[kg] 100.00 120.00 . . 120.00
100%
Comment [ [
] ] . .
[
Active PAYLOAD number = 1 [ TYPE ] GROUP DETAIL ARMLOAD
]
SETIND >
4 Payload information (Schedule No.1 to 10) can be setup. Move cursor to the line of one of the schedule numbers, and press F3(DETAIL) to enter the payload set screen. PAYLOAD SET Screen
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MOTION/PAYLOAD/SET JOINT 100% Group 1 1. Schedule No [ 1] : [Comment ] 2. PAYLOAD [kg] 100.00 3. PAYLOAD CENTER X [cm] 10.00 4. PAYLOAD CENTER Y [cm] 0.00 5. PAYLOAD CENTER Z [cm] 10.00 6. PAYLOAD INERTIA X [kgfcms^2] 0.00 7. PAYLOAD INERTIA Y [kgfcms^2] 0.00 8. PAYLOAD INERTIA Z [kgfcms^2] 0.00 [ TYPE ]
GROUP
NUMBER
DEFAULT
HELP
5 Setup the payload, payload center, and payload inertia. X, Y, and Z directions in this screen mean X, Y, and Z axes of the default (the settings are all 0) tool frame. After the value is input, the message “Path and Cycletime will change. Set it ?” is displayed. Please input F4(YES) or F5(NO). 6 To enter the payload set screen of the other schedule number, press F3(NUMBER). To enter the screen for other group, press F2(GROUP). (Only in the multi--group system) 7 Press PREV key to go back to the motion screen (default screen). Press F5(SETIND) and input the schedule number to use. 8 Press F4(ARMLOAD) in the motion screen (default screen) to enter the armload set screen. ARMLOAD SET Screen MOTION/ARMLOAD/SET Group 1 1. ARM LOAD AXIS #1 2. ARM LOAD AXIS #3 [ TYPE ]
GROUP
JOINT [kg] [kg] DEFAULT
100% 20.00 10.00 HELP
9 Setup the armload on axis #1 and axis #3. After the value is input, the message “Path and Cycletime will change. Set it ?” is displayed. Please input F4(YES) or F5(NO). After setting up the armload, cycle power.
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9.24 Arc Smart High--speed Recovery Function 9.24.1 Overview The arc smart high--speed recovery function consists of a torch guard function and torch recovery function. The torch guard function swiftly detects a collision by the torch or robot with a workpiece, then stops the robot immediately. The torch guard function has a greater detection sensitivity than the ordinary basic collision detection function. So, the torch guard function detects a collision more quickly to reduce damage to the torch and robot remarkably. This function eliminates the need for a shock sensor that has been traditionally used for torch collision detection. The torch recovery function can automatically correct a TCP shift in a short time.
9.24.2 Specification The arc smart high--speed recovery function consists of the functions described below. F
Torch guard function -- The torch guard function immediately stops the robot with an alarm when a collision is detected. At this time, the function decelerates the robot to reduce damage to the robot. -- The user need not make a detection sensitivity adjustment. The detection sensitivity is adjusted on each robot beforehand. -- The torch guard function can be enabled or disabled by a programmed instruction. -- During teaching, the detection sensitivity automatically increases to protect against damage especially due to a robot collision that tends to occur by mishandling in teaching.
F
Torch recovery function -- The torch recovery function can automatically correct a TCP shift in a short time. SUPPLEMENT This function is an optional function. The specification of this function is A05B--****--J681. Use this specification when ordering.
9.24.3 Torch guard function
Overview 1 This function is enabled when the power is turned on. 2 Set load information and robot equipment information. (See Fig. 3.2.) This function uses load information and equipment information to detect a collision, so load information and robot equipment information need to be set. Set the weight of a load, gravity center of a load, and equipment weight on the robot correctly. If the inertia (figure) of a load is large, inertia setting around the gravity center may be additionally required. (If the figure of a torch, for example, is large, and the setting of the weight of a load and the gravity center position of a load alone causes a detection error, make an inertia setting.) Before operating this function, select a set load setting condition number. (See Fig. 3.2.) 3 If the application of a large force during execution is anticipated beforehand, disable detection at that portion with programmed instructions. (See Fig. 3.3.) 4 During teaching, the detection sensitivity automatically increases.
Operation performance screen 1 The operation performance screen is used to set load information and robot equipment information. 2 The operation performance screen consists of a list screen, load setting screen, and equipment setting screen. 3 Select the subscreen Motion from SYSTEM to display the list screen.
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List screen
MOTION PERFORMANCE G1 JOINT 10 % Group1 1/10 No. PAYLOAD[kg] Comment 1 16.00 [ ] 2 16.00 [ ] 3 16.00 [ ] 4 16.00 [ ] 5 16.00 [ ] 6 16.00 [ ] 7 16.00 [ ] 8 16.00 [ ] 9 16.00 [ ] Active PAYLOAD number = 0 [ TYPE ] GROUP DETAIL ARMLOAD SETIND >
IDENT
>
4 Up to 10 load information items (condition setting No. 1 through No. 10) can be set. Move the cursor to the line of a desired number, then press F3 (DETAIL) to display the load setting screen. Load setting screen MOTION PAYLOAD SET
1 2 3 4 5 6 7 8
G1
JOINT
10 % 1/8
Group1 Schedule No[ 1]:[****************] PAYLOAD [kg] 16.00 PAYLOAD CENTER X [cm] 0.00 PAYLOAD CENTER Y [cm] 0.00 PAYLOAD CENTER Z [cm] 0.00 PAYLOAD INERTIA X [kgfcms^2] 0.00 PAYLOAD INERTIA Y [kgfcms^2] 0.00 PAYLOAD INERTIA Z [kgfcms^2] 0.00
[ TYPE ]
GROUP
NUMBER
DEFAULT
HELP
5 Set the weight of a load, gravity center position, and inertia. The X, Y, and Z directions indicated on the load setting screen correspond to the directions of the standard tool coordinate system (when no special tool coordinate system is set). When desired values are entered, the confirmation message “Path and Cycle time will change. Set it?” appears. Press F4 (YES) or F5 (NO). 6 By pressing F3 (NUMBER), the user can switch to the load setting screen for another condition number. By pressing F2 (GROUP), the user can switch to the setting screen for another group (in the case of a multi--group system). 7 Press the PREV key to return to the list screen. Press F5 (SETIND), then enter a desired load setting condition number. 8 Pressing F4 (ARMLOAD) on the list screen displays the equipment setting screen. Equipment setting screen MOTION ARMLOAD SET Group1 1 ARM LOAD AXIS #1 2 ARM LOAD AXIS #3
[ TYPE ]
GROUP
G1
JOINT
[kg] [kg]
DEFAULT
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9 Set the weight of the equipment on the J1 axis and the weight of the equipment on the J3 axis. When the values are entered, the confirmation message “Path and Cycle time will change. Set it?” appears. Press F4 (YES) or F5 (NO). After setting the weight of equipment, turn the power off then back on for the setting to become effective. Program instruction 1 COL DETECT ON/OFF These instructions can disable and enable collision detection during program execution. Example 1:J 2: 3:L 4:L 5:L 6: 7:J
P[1] 100% FINE COL DETECT OFF P[2] 100mm/sec CNT100 P[3] 100mm/sec CNT100 P[4] 100mm/sec CNT100 COL DETECT ON P[5] 100% FINE
In this program, collision detection is disabled on lines 3 to 5. NOTE
Collision detection is usually enabled. When a program is terminated or temporarily stopped, collision detection is automatically enabled.
Performance An experiment using this function was conducted where torch tip shifts caused by hitting the torch with the ARC Mate 100i were measured using a dial gauge. The results are indicated below(*). Shift 0.00mm 29 times 0.01mm 3 times 0.02mm 4 times -------------------------------------------Total: Measurements as many as 36 times were conducted using many different speeds and directions. Torch tip precision required for arc welding is 0.40 mm. The force applied to the torch tip is about 10 kgf in low-- speed operation (about 100 mm/sec) or about 15 to 30 kgf in medium-- to high--speed operations (about 500 to 2,000 mm/sec). NOTE
A large torch shift can result, depending on the attitude assumed when a collision is made. When bolts are loose, a large torch shift can also result.
9.24.4 Notes 1 A collision detection error can occur in the cases listed below. -- When set load information or equipment information is incorrect -- Rough operation using ACC Override -- Rough operation such as turnaround using Cnt -- Operation such as Linear operation near a singular point where an axis turns at high speed -- When the supply voltage is too low -- When the weight of a load or inertia exceeds the upper limit of the robot Action
If a collision is detected by mistake for a cause above, first try to correct the cause. In an unavoidable case, the termination of robot operation with an alarm may be prevented by enclosing only a part of incorrect collision detection with a pair of COL DETECT OFF/ON instructions. 2 In the cases below, collision detection is disabled: -- When Soft Float is enabled -- When brake control is exercised (at brake lock time) 3 Axis dropping after detection -- To reduce excess force to the robot due to collision, the collision detection function disables position control for 200 ms after collision. For this reason, the axis may drop slightly after collision detection.
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9.24.5 Related alarms 1 SRVO--050 SERVO Collision Detection alarm (G:iA:j) This alarm is issued when a collision is detected. The robot stops with an alarm. If there is a cause described in Section 9.18.4 above, a nonexistent collision might be detected by mistake. In such a case, take the action described in Section 9.24.4. 2 SRVO--053 WARN Disturbance excess (G:iA:j) This alarm warns the operator that an estimated disturbance value is close to the level for issuing the Collision Detect alarm due to collision detection. The robot does not stop. If there is no problem, this message might be ignored. If there is a cause described in Section 9.18.4, the output of this alarm is suppressed by taking the described action.
9.24.6 Torch recovery function A welding robot system is taught so that the wire tip travels along a welding line. If welding is performed for a long time, however, the wire tip position (referred to as the tool center point) might be shifted due to the wearing of the contact chip. The tool center point might also be shifted due to interference with the torch jig caused by contact chip or torch replacement or an operation error. If the tool center point is shifted, precise welding becomes impossible. In this case, the tool center point needs to be set again, or reteaching is required in a worst case, thus stopping production for a long time. The torch recovery function can correct a shift of the tool center point of the welding torch automatically in a short time. With this function, production stop time can be reduced, and stable welding quality can be achieved. Two robots in a two--unit control system can use this function simultaneously. The two robots which use this function must be set in motion groups 1 to 3. To use the torch recovery function, follow the setup procedure given below. Carry out this setup for each robot that uses the torch recovery function. 1 Set a torch recovery jig. 2 Set the wire tip position as TCP. 3 Set the data of the torch recovery function for the specified TCP (if necessary). 4 Calibrate the torch recovery function for the specified TCP. Upon completion of the above procedure, the tool center point can be corrected with the torch recovery function at any time. The torch recovery function can be used just by executing the program prepared for correction. The program can be called from a production program (automatic correction), or can be selected and executed by the user (manual correction). The torch recovery function corrects a shift of the tool center point by touching the wire to the torch recovery jig. This means that the torch recovery function cannot correct a shift of the attitude of the torch. When a shift of the torch attitude is very small, welding is little affected. When a shift of the torch attitude is large, however, the quality of welding is much affected, and the robot and torch can interfere with the jig even if a shift of the tool center point is corrected. When a shift of the torch attitude is large, return the welding torch manually to near the place where the torch was first installed. Then, correct the tool center point precisely with the torch recovery function. CAUTION Torch recovery function adjusts the top of the wire by changing tool. Center point (TCP) data. Therefour when the teaching path is near the boundory of motion possible range, if the compensated program is executed, the alarm of ”Not reachoble” and ”Singularity point” may occur. In this case, touchup the teaching point.
Before this function can be used, the arc smart recovery function option (A05B--****--J681) must be specified. Before use Before using the torch recovery function, check the following items: F
The torch recovery function corrects a shift of the tool center point by using a stick detection circuit. So, if a stick detection circuit is not provided, set a mechanism such as a touch sensor (mechanism that applies a voltage between two points, and enters a signal for detecting a short circuit between the two points)
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between the wire and torch recovery jig. The stick detection circuit uses a low voltage. So, if a sufficient voltage is not applied, provide a similar mechanism. F
The torch recovery function cannot correct a shift of the attitude of the torch itself. When a shift of the torch attitude is very small, welding is little affected. When a shift of the torch attitude is large, however, return the welding torch manually to near the place where the torch was first installed. Then, correct the tool center point precisely with the torch recovery function.
F
A system equipped with the torch recovery function has a torch recovery macro. The position registers set on the torch recovery setup screen, which will be described later, are used for the torch recovery function.
F
On the clock screen, check that the date and time are set correctly with the clock function. Time data is used on the correction data history screen for displaying the history of correction. The clock screen can be displayed using the procedure below: MENUS ! 0 NEXT ! 6 SYSTEM ! F1(TYPE) ! CLOCK
F
When attaching a torch to the robot flange, do not perform the work desultorily, but set some reference so that when the torch is replaced, the tool center point can come at approximately the previous position. If the tool center point is shifted from the previous position after torch replacement, or the attitude of a new torch is much shifted from the previous attitude, automatic correction using the torch recovery function is impossible. CAUTION
Before creating a program, perform the torch recovery settings described below (jig installation, TCP setting, and calibration). Otherwise, the program needs to be retaught in a worst case. If TCP is not set precisely with a system that has the function added later, the program needs to be retaught.
Torch recovery jig installation Install a jig for the torch recovery function according to the procedure below. Z
Reference position Plate
Z X
X
TCP setting pin World coordinate system of the robot Y
Y Base plate
1 Install the torch recovery jig at the position that allows the robot to operate freely, then secure it firmly. 2 Connect the torch recovery jig (base block) to the base metal electrode (electrode (usually minus electrode) with the polarity opposite to the wire electrode) of the welding power supply via a wire. 3 Loosen the screws on the jig, make an adjustment so that the sides of the square plate are aligned with the world coordinate system of the robot as shown below, then tighten the screws. Adjust the plate position so that the wire travels along the side of the plate by Y--direction jogging (in the Y direction of the world coordinate system) in the jog coordinate system as shown below. Torch
Plate Y--direction jogging in the jog coordinate system
4 After tightening the screws, check the plate installation precision by performing jogging again.
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5 Bring the wire into contact with the plate by jogging. Using a continuity tester in this state, check that the wire and plate are electrically continuous.
TCP setting Set the tool center point as TCP. For details of TCP setting, see the description of tool coordinate system setting. Here, an example of TCP setting using the automatic TCP setting function (option) and a torch recovery jig is described. When teaching the origin of a coordinate system with the six --point setting method, use the following attitude by using the coordinate system origin of the torch recovery jig.
Z Tool coordinate system
Y Robot side
X
Tip
With the six--point setting method, three reference points are taught by changing the attitude. At this time, use the procedure below. Teach the first point with the attitude above. When teaching the second point, move the sixth axis by an angle from 90 degrees to less than 360 degrees by axial jogging from the first point, then match the tool center point with the tip of the jig. When teaching the third point, move the fourth axis and fifth axis by an angle less than 90 degrees from the second point by axial jogging, then match the tool center point with the tip of the jig. Ensure that the three points are directed roughly as shown below.
Torch recovery function data setting and calibration After TCP setting, the torch recovery function needs to be calibrated. The first tool center point is stored by this calibration. After this calibration is performed, no additional calibration is required. When the torch is replaced, re--calibration is not required if the tool center point and torch attitude before replacement are about the same as those after replacement. If the tool center point and torch attitude after replacement much differ from those before replacement, however, perform re--calibration or reinstall the torch manually to minimize the shift. Perform calibration according to the procedure below. 1 Press the MENUS key, then select 6 SETUP. 2 Press F1, [TYPE], then select Torch Recov. The screen shown below appears. The values in the screen are the standard settings.
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SETUP TorchRecover 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
G1
JOINT
Tool number: Input signal: Output signal: X Y offset limit: Z compensation: Z offset limit: Search speed: Search start: Search start Z: Wire advance time: Wire retract time: Wire speed: Starting PR[] number: Reference position: Error recovery method: Error output signal:
[ TYPE ] MASTER MOVE_TO
10 % 1/14
1 WSI[1 ] WSO[1 ] 20 mm DISABLED 5 mm 5 mm/sec 55 mm 41 mm .010 sec .010 sec 0 IPM 1 UNINIT PROMPT DO[0]
RECORD
HELP
CAUTION Be sure to display this setting screen at least once. By displaying this screen, the standard value is set for each data item.
3 At this stage, the screen shows the settings of the tool coordinate system (TCP) having the number displayed in item 1 Tool number on the screen, of the motion group currently subjected to jog feed. The sample screen shown above displays the settings of tool coordinate system 1 of motion group 1. Change the motion group (if the system controls two units) and tool coordinate system number as desired. The changing methods are as described below. F
Motion group: Press the auxiliary key, select 3 #615--1--1, then select a desired motion group.
F
Tool coordinate system: Type a desired tool coordinate system number in item 1 Tool number.
CAUTION Changing the motion group changes the motion group subjected to job feed. When performing jog feed after this operation, check the selected motion group in advance.
4 The meaning of each data item is explained below. Tool number: Indicates the number of the tool coordinate system for which the currently displayed settings are made. To display the settings of another tool coordinate system, type the number of the desired tool coordinate system in this field. Input signal: Specify the signal type and number of a digital signal (contact confirmation signal) that is turned on when the wire contacts the torch recovery jig plate. The user can choose from the following options: F
WSI: Stick detection circuit input signal
F
RDI: Robot digital input signal
F
WDI: Welding digital input signal
F
SDI: General--purpose digital input signal
Output signal: A voltage is applied to recognize that the wire has contacted the torch recovery plate jig. Specify the signal type and number of a signal output for this purpose. The user can choose from the following options: F
WSO: Stick detection circuit output signal
F
RDO: Robot digital output signal
F
WDO: Welding digital output signal
F
SDO: General--purpose digital output signal
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* If two welders are used with a two--unit control system and if WSI/WSO is selected, set WSI[1]/WSO[1] for the first unit and WSI[9]/WSO[9] for the second unit. X Y offset limit/Z offset limit: Set a maximum offset value that allows correction by the torch recovery function. If an offset value greater than a set maximum value is measured, torch recovery operation is stopped, and the RECOVERY screen appears to enable the user to select a recovery method. For details, see the description of Recovery from alarms. CAUTION For these data items, set a value as small as possible. A greater offset value means a greater torch bend or shift. If a correction is made in such a case, the robot or torch may interfere with the jig in the program. Set minimum offset values. If an alarm is issued to report that an offset limit is exceeded, correct the torch manually to satisfy the offset limit. Then, perform torch recovery operation according to the procedure for recovery from alarms. For the X and Y directions, set about 15 mm when using a straight torch, or set about 10 mm when using a curved torch. For the Z direction, set about 5 mm.
Z compensation: Set whether to perform tool center point compensation in the Z direction. By default, tool center point compensation is disabled. Search speed: When the tool center point is corrected, search operation is performed in the X and Y directions (or in three directions when Z compensation is enabled). Specify an approach speed used for such search operation. When a lower search speed is set, a higher precision in correction results. 3
Search return distance
1 Search lowering distance
Z
2 X
World coordinate Y Search operation (After arrow 1 operation, arrow 2 operation is performed. Then, if Z compensation is enabled, arrow 3 operation is performed.)
Search start: Specify a return distance used for tool center point correction. Search start Z: Specify a lowering distance used for tool center point correction. Wire advance time: Before the start of search operation, the wire can be fed for a short time to allow the wire to contact the plate easily. Specify such a feed time. Wire retract time: After the end of search operation, the wire can be rewound for a short time. Specify such a rewind time. This item is used if the wire has been fed as described above. Wire speed: Specify a wire speed used for wire feed and rewind operations above. The unit selected in the item of wire feed speed units on the welding equipment setting screen is used.
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Starting PR[] number: With the torch recovery function, two position registers are used to indicate the original TCP (TCP at torch recovery calibration time) and TCP after correction. Specify the numbers of such position registers. For example, [1] is set, the original TCP is set in position register 1, and the TCP after correction is set in position register 2. If a position register number already in use is set, change the value as required. Note that these data items are indicated only, and changing the value of this item has no effect on torch recovery operation. Reference position: This item is used to record a reference position for calibration. Whether a reference position is recorded is indicated. Error recovery method: During torch recovery motion, if the following situation occurs, chose the method of recovery. -- When the wire doesnt connect with the torch recovery plate -- When the wire connects with the torch recovery plate before torch recovery motion -- When the detected compensation value is over the allowable maximum value The following selections are provided. F
PROMPT Display the WARNING alarm according each alarm reason and the following confirmation screen on the teach pendant and the robot controller waits for the input by the operation. RECOVERY
G1
TOOL
50 %
Error Recovery Menu G:1 1 Redo Torch Recovery Adjustment 2 Skip Torch Recovery Adjustment 3 Abort Program
ADVWIRE
RETWIRE
HELP
Put the cursor on any line then press Enter key. When “Redo” is selected, the torch recovery motion is executed again. When “Skip” is selected, the torch recovery motion is just skipped. When “Abort” is selected, the program is aborted. Abut the detail please refer to “Recovery from Alarm”. F
REDO Display the WARNING alarm according each alarm reason and the fault signal is also turned on. Then the program is paused. After the reset of the alarm, when the program is restarted, the torch recovery motion is performed without the display of the confirmation screen.
F
SKIP Display the WARNING alarm according each alarm reason and the fault signal is also turned on. Then the program is paused. After the reset of the alarm, when the program is restarted, the torch recovery motion is skipped without the display of the confirmation screen.
F
ABORT Display the WARNING alarm according each alarm reason and the fault signal is also turned on. Then the program is paused. After the reset of the alarm, when the program is restarted, the program is aborted without the display of the confirmation screen.
Error output signal: During torch recovery motion, when the following situation occurs, the specified digital output signal is turned on. -- When the wire doesnt connect with the torch recovery plate -- When the wire connects with the torch recovery plate before torch recovery motion -- When the detected compensation value is over the allowable maximum value And this signal is turned off at the following timing Case of “PROMPT”: When the confirmation screen is disappeared.
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Case of “REDO”, “SKIP” and “ABORT”: When the program is restarted or aborted. F3 (ADVWIRE): Pressing the ADVWIRE key feeds the wire for a set wire advance time at a set wire speed. F4 (RETWIRE): Pressing the RETWIRE key rewinds the wire for a set wire retract time at a set wire speed. 5 By jogging the robot, move the tool center point (TCP) to the reference position (central pin tip) of the torch recovery jig. At this time, ensure that the torch assumes the attitude shown below with respect to the reference position of the torch recovery jig.
Z Tool coordinate system
Y Robot side
X
6 Move the cursor to the Reference position item. Then, press the F4 (RECORD) key together with the shift key to record the reference position. The indication to the right of the Reference position item changes from UNINIT to RECORDED. 7 Before proceeding to the next operation, check again that the tool center point of the robot remains at the reference position recorded in step 5 above. 8 Set an override of 100%. WARNING The next step starts robot operation to perform torch recovery calibration. Use care.
WARNING Pressing the forced termination key in the auxiliary menu during torch recovery operation (calibration operation, correction operation) stops the robot. However, the signal (WSO1) output to apply a voltage for search continues to be output. So, do not touch the wire and electrode. (This output is stopped when robot operation is temporarily stopped.) If the robot is temporarily stopped or forcibly terminated while the wire is being fed, the wire continues to be fed. If the robot is temporarily stopped or forcibly terminated while the wire is being rewound, the wire continues to be rewound. Never temporarily stop and forcibly terminate the robot during torch recovery operation.
9 Press the F2 (MASTER) key together with the shift key. The robot starts calibration operation. Search operation is first performed in the X direction of the world coordinate system, then in the Y direction. When Z compensation is enabled, search operation in the Z direction is then performed. Upon completion of calibration, set the original TCP in a position register, and store the calibration information internally. This calibration information is used for TCP correction operation. If an alarm is issued during calibration operation, see the description of Recovery from alarms. CAUTION If an attempt to do any of the following is made on this setup screen while a TP program is running or being halted, an alarm of CUST--014 Abort program using G:# (# is a group number) is issued: teaching a reference position, movement to a reference position, or calibration in a motion group which is the same as the motion group used for the TP program. The processing is not performed. If this alarm occurs, end the TP program, then carry out the operation again.
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Execution of correction with the torch recovery function After completion of torch recovery jig installation, TCP setting, and torch recovery function data setting and calibration, a tool center point shift can be corrected manually or automatically (by calling the program from a user program) at any time with the torch recovery function. To execute the torch recovery function, a torch recovery program or torch recovery macro is used. These programs and macros are provided for use with each motion group. When the function is executed, the program or macro corresponding to the motion group is used. The table below lists the programs and macros provided for the motion groups. Motion group
Program
Macro
Group 1
TM_ADJST
TorchRecv Adjust or TorchMate Adjust
Group 2
TM_ADJ2
TRecv Adjust GP2 or TMate Adjust GP2
Group 3
TM_ADJ3
TRecv Adjust GP3 or TMate Adjust GP3
To perform correction manually, use the procedure below. 1 On the program directory screen, select the torch recovery program corresponding to the motion group for which a correction is made. 2 Set the tool coordinate system of the motion group for which a correction is made as the tool coordinate system for which a correction is made. 3 When the torch recovery program is executed, the motion to the torch recovery jig starts, then the correction operation starts. If there is an obstacle between the current robot position and the torch recovery jig, the robot interferes with the obstacle. Before executing the torch recovery program, jog the robot to such a position that there will be no obstacle between the robot and the torch recovery jig. 4 Disable the teach pendant, then press the start button on the operator’s panel or enter the external start signal. The correction operation is executed on the basis of the setting of the currently selected tool coordinate system. 5 If an alarm is issued during correction, the RECOVERY screen is displayed (when the use of user alarms is disabled). For the procedure for recovery from an alarm, see the description of Recovery from alarms. When the use of user alarms is enabled, a user alarm is issued. In the case of reexecution after cancellation of a user alarm, the RECOVERY screen appears. CAUTION If an alarm is issued during correction operation, and the RECOVERY screen is displayed, do not terminate the program forcibly from the auxiliary menu. Be sure to perform the operation according to the procedure for recovery from alarms (described later).
To perform correction automatically (by calling the program from a user program), use the procedure below. 1 Teach a program, using the tool coordinate system with which calibration is performed. Alternatively, check that the program that has already been taught is based on the tool coordinate system. Modify the program so as to call the torch recovery program or macro for the motion group to which correction operation is carried out. For instance, to carry out the correction operation by the torch recovery function for motion group 1 once in every ten times of production program execution, add lines to the production program, as shown below. 20: J P[10:HOME] 100% FINE 21: R[1] = R[1] + 1 22: IF R[1] = 10 JMP LBL1 23: JMP LBL2 24: LBL1 25: TorchMate Adjust 26: R[1] = 0 27: LBL2 [END]
Original program Added instructions
2 If an alarm is issued during correction, the RECOVERY screen is displayed (when the use of user alarms is disabled). For the procedure for recovery from an alarm, see the description of Recovery from alarms. When the use of user alarms is enabled, a user alarm is issued and the program is temporarily stopped. In the case of reexecution after cancellation of a user alarm, the RECOVERY screen appears.
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CAUTION If an alarm is issued during correction operation, and the RECOVERY screen is displayed, do not terminate the program forcibly from the auxiliary menu. Be sure to perform operation according to the procedure for recovery from alarms (described below).
Recovery from alarms If an alarm is issued during torch recovery correction when the error recovery method is “PROMPT”, the RECOVERY screen described below appears. The sample screen shown below appears when an alarm is issued during the correction operation of motion group 1. RECOVERY Menu1
JOINT
10 % 1/3
Error Recovery Menu G:1 1 2 3
Redo TorchRecovery Adjustment Skip TorchRecovery Adjustment Abort Program ADVWIRE
RETWIRE
HELP
On this recovery screen, select torch recovery reexecution, skip, or program termination. To reexecute torch recovery operation, use the procedure below. 1 When this recovery screen is displayed, an alarm has been issued during torch recovery operation. From an alarm message, determine the alarm issued. For details of the alarms, see the description of TorchRecovery Alarm. 2 Referencing the description of TorchRecovery Alarm, correct the cause of the alarm. Perform recovery, for example, by repairing the voltage detection circuit (stick detection circuit, usually) used at wire contact time, and manually correcting the torch bent too much. To correct the cause of the alarm, the robot can be moved slightly away from the torch recovery jig by jogging. In this case, however, move the robot to a place that prevents the robot from interfering with the jig and so forth when performing the torch recovery operation again. 3 Cut the wire to an appropriate length. 4 Press the start button on the operator’s panel or enter the external start signal to reexecute the program. 5 Move the cursor to 1 Redo TorchRecovery Adjustment, then press the ENTER key. The robot starts search operation. To skip torch recovery operation, move the cursor to 2 Skip TorchRecovery Adjustment, then press the ENTER key. The program that is calling the program for torch recovery operation is not terminated, but the preceding torch recovery correction operation only is canceled. At this time, TCP is not updated. To terminate the program, move the cursor to 3 Abort Program, then press the ENTER key. The program that is calling the program for torch recovery operation is terminated. In a two--unit control system, the correction operations of the two robots can be simultaneously executed by the multi--task function or some other function. If an alarm is issued during the torch recovery of one robot while the RECOVERY screen is being displayed for the other robot, the RECOVERY screen for the alarm appears after the processing on the screen displayed earlier is completed. Torch recovery alarms During torch recovery operation, the alarms below may be issued. F
Standard search alarms The standard search alarms include the alarms described below.
Offset is out of range (The upper offset limit was exceeded.) The upper offset limit was exceeded as the results of tool center point correction based on torch Cause: Remedy:
recovery operation. Manually correct the torch so that the tool center point shift is within the maximum offset limit. Then, perform torch recovery operation again on the RECOVERY screen.
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Sensor is ON before search (Before search operation, the search signal is ON.) Before search operation is started, the contact confirmation signal (search signal) to be applied when Cause: Remedy:
the plate is contacted is already ON. Check the contact confirmation signal and its connection path. When the signal is made normal, perform torch recovery operation again on the RECOVERY screen.
Sensor failed during search (The recovery fixture was not contacted.) Search operation was performed, but the wire did not contact the plate. Cause: Remedy: 1 Make the wire long when it is short. 2 If the torch bends too much, correct the torch manually so that the wire can contact the plate in correction operation. 3 Check that the contact confirmation signal is entered when the wire contacts the plate. Displaying and saving correction history data Each time the torch recovery program or macro is executed to carry out a torch recovery correction operation, an offset value is reflected in TCP. The offset value is calculated on the basis of the TCP internally saved in the torch recovery calibration. Up to 100 offset values, each obtained in each correction operation, are internally recorded as correction history data together with dates. This history can be viewed, and can be saved in ASCII format to the default device. This correction history can be used to manage a tool center point shift. Correction history data can be displayed on the teach pendant according to the procedure below. 1 Press the MENUS key, then select 3 DATA. 2 Press the F1 (TYPE) key, then select Torch Recov from the menu. The screen shown below appears. In the screen shown below, motion group numbers are displayed in the G column, and tool coordinate system numbers are displayed in the T column. DATA TorchRecovery
1 2 3 4 98 99 100
Time 04:37 04:36 04:30 04:14
X Y 3.10 .60 -1.10 -.09 -.10 -.20 Mastered
10 % 1/100 Z 0.00 0.00 0.00 X Y Z
01-JAN-9x 04:10 No data No data
-.10 -.09
-1.10
Date 01-JAN-9x 01-JAN-9x 01-JAN-9x 01-JAN-9x
[ TYPE ]
JOINT
SAVE
HELP
* “Mastered X Y” means that the calibration has been performed in the XY direction. * “Mastered X Y Z” means that the calibration has been performed in the XYZ direction. 3 Check that the currently selected storage medium is connected. The currently selected storage medium can be checked by pressing the MENUS key and then selecting 7 FILE. To save the data on a floppy disk, connect the Handy File (protocol robot) to a port. Then, set the port to Handy F MS--DOS on the port setup screen. To save the data on a Memory Card, insert the card into the PCMCIA slot in the front operation panel. 4 Format the corresponding storage medium if necessary, then press F3 (SAVE). 5 The message “Copying data file to floppy disk” is displayed to indicate that the data is being saved. 6 Upon completion of saving of the data, the message “Data file copied successfully” is displayed. 7 An ASCII format file named TMDATA.DT is created on the floppy disk. If a file with the same name already exists on the floppy disk, the file is overwritten.
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Torch recovery unit The figure of a typical torch recovery unit is shown below. When this figure is used, the standard settings can be used without modification. A voltage a little higher than 10 volts is used for the stick detection circuit. So, use a material that is sufficiently conductive. If a unit can satisfy the specifications below, the unit need not have the same figure.
TCP setting pin (used to set TCP) Perspective view
Exploded view Z Oval hole (The plate setting angle can be adjusted.)
X
Y Set the torch recovery unit in a position as illustrated above, with respect to the world coordinate system.
World coordinate system Plate (The wire comes into contact with this plate. Each side of the plate must match each axis of the world coordinate system.)
Top view Base block (Connect the base block with the base metal electrode via a wire.)
Side view 54.9mm
38.1mm
41.4mm
1 to 2 mm
41.4mm 54.9mm
Backup data When the data is backed up on the file screen, the data of the torch recovery function is saved in the storage medium under the following file names. These files are saved in the storage medium when the total backup or backup of an application file is performed. F
Setting data: main_tcp.vr
F
Correction history data: offsetdt.vr
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9.25 Multi Equipment Control for Arc Welding It is necessary to go through the following procedure in the case one robot controler uses two arc welding equipments. Procedure to set up multi equipment 1 Complete the procedure in order to funtion the first welding equipmemt according to the Arc tool manual. After this step, do cold start to work the first arc welding equipment. 2 Perform a controlled set up the second weld equipment. The method of the controll start is written in the Arc tool manual. 3 Modify the following variable in order to work the second welding equipment. $AWSCFG.$TOT_ARC_EQ = 2 4 Define the following variable. This variable determines whether the controller halts the program which uses one welding equipment in the case the alarm occurrs on the other welding equipment. $AWSCFG.$GLOBAL_ER = FALSE : Not to halt the program = TRUE : To halt the program. 5 After defining the $AWSCFG, turn off and on the controler. Automatilcaly, the control start is done again. 6 After the expression about arc welding application is displayed, complete the procedure in order to funtion the second welding equipment referring to the operation manual and do cold start. How to use multi equipments In the case that the multi equipments are available, the expression “E i ” ( i is the order number of the equipment) is displayed on top of the screen.
E1
JOINT 100%
This expression means that the equipment number which can be currently controled by the teach pendant. For example, when “E1” is displayed on the screen, the first weld equipment can be controled. The following factors for the each equipment of its own are displayed. F
Data concerning about the welding The following data concerning welding are displayed depending on the currently selected equipment number. -- ArcTool Application Setup screen -- Weld Schedule Data screen -- Weld process screen -- Weld I/O screen -- Wels status screen -- OnTheFly screen
F
Manully controlling the wire feed ( + , -- ) If the wire feed key is pressed , the currently specified equipment wire is advanced.
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To change the welding equipment, press the FCTN key and select “CHANGE EQUIP”.
1 2 3 4 5 6 7 8 9 0
FCTN
FUNCTIONS ABORT (ALL) Disable FWD/BWD CHANGE GROUP
CHANGE EQUIP RELEASE WAIT
-- NEXT --
WELD ENABLE / DISALBE In the case of multi equipments, it is practical to make arc welding enable or disable by pushing the “SHIFT” key and “User key 1 ” at the same time. However, note that the above method force the both weld equiments status to change simultaneously. To change each weld equipment status, press “User key 1” to display the following “TEST CYCLE Arc screen” and set up it.
TEST CYCLE Arc
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1 Equipment 1 ARC enable: 2 Equipment 2 ARC enable:
[ TYPE ]
FALSE FALSE
TOGGLE
The status of the weld equipment on which the cursor positions can be changed by pressing the F5 key “TOGGLE”. The status of each weld equipment is confrimed not only on the above screen, but also at the “WELD ENBL” LED.
WELD ENBL ARC ESTAB
Note that this LED lights up when even one of the two equipmnets is enalbed. Refer the following table. Equipment 1
Disable
Enable
Disable
Enable
Equipment 2
Disable
Disable
Enable
Enable
LED light
OFF
ON
ON
ON
“ARC ESATB” LED also lights up when one of the two equipments is under welding. Planning and creating the program In the case of multi equipments, it is necessary to specify the equipment number on every program. The procedure of the specification is as follows: 1 Display the program detailed screen. 2 Press F3 key “NEXT” at the program detailed screen. 3 The following “Appl process ” screen is displayed. Leave this item “TRUE” and press the F3 key “NEXT”.
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Appl process
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1 ARC Weld END
PREV
TRUE NEXT
TRUE
FALSE
4 The following “ARC Welding Application DATA” is displayed. At this screen, specify the equipment number which is used on this program. In the case to specify the first equipment : [ 1, * , * , * , * ] In the case to specify the second equipment : [ *, 1 , * , * , * ] Appl process
JOINT 100% 1/1
ARC Welding Application DATA 1 Equipment Number END
PREV
NEXT
[1,*,*,*,*] 1
*
When the program which defines the equipment number is 2 is executed, all arc welding instructions are done to the second weld equipment. Note that it is impossible for one program to call another program which has the different weld equipment number. That is, one task cannot run different equipment at the same time.
Practical case PNS0001
PNS0002
Equipment 1
Equipment 2
Impractical case PNS0001
SUB1
Equipment 1 CALL SUB1
Equipment 2
Motion group and multi equipments Using multi robot control, it is practical that one controller manages two robots using two weld euipment. It is noraml case in this situation that the first group robot uses the first weld equipment, and that the second group robot uses the second weld equipment.Therefore it is sometimes desired that when the group is changed , the current equipment number is changed automatically. The following procedure enabls to assign the weld equipment automatically accoding to the current selected group. SYSTEM Coupling ARC Welding Group/Equipment Coupling: 1 Group1 2 Group2
JOINT 100% 1/4 FALSE
Equipment[1,*,*,*,*] Equipment[*,1,*,*,*] TRUE
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1 Set the “Group / Equipment Coupling” TRUE to assign the specified equipment to each group. For example, the above table means that first group is assigned to Group1 and that second group is assigned Group2. Group1 (ROBOT 1) ---- Weld equipment 1 Group2 (ROBOT 2) ---- Weld equipment 2 That is, when changing the group by the FCTN menu or jog menu, the selected equipment number is automatically changed according to the selected motion group. 2 When the “Group / Equipment Coupling ” is FALSE, this coupling is released. 3 To modify the combination of the motion group and the weld equipment number, positon the cursor to [1] or [*] and press the function key F4 for [1] or F5 for [*]. How to chgane the motion group To change the current motion group, press the “CHANGE GROUP” at the FCTN menu or specify the group number at the jog menu. FCTN menu Press “FCTN” key to display supplementary menu. The selected motion group number is increased by every pressing this “CHANG GROUP” key.
1 2 3 4 5 6 7 8 9 0
FCTN
FUNCTIONS ABORT (ALL) Disable FWD/BWD CHANGE GROUP
CHANGE EQUIP RELEASE WAIT
-- NEXT --
JOG MENU Press the “SHIFT” key and “COORD” key at the same time to display the jog menu. Position the cursor on the Group and input the number of the objective group. Appl process Tool Jog User Group
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9.26 ARC START Synchronization for Arc Multi--equipment Configutarion 9.26.1 Overview For the use of mutiple weld equipments on a robot controller, the synchronization of ARC START between these weld equipments is sometimes required. For example, when it is the use of the double torch for the purpose of thick plate or high speed welding, each torch is connected to a weld equipment. At ARC START timing both weld equipment need to generate the arc at the same time. For other example, when two robots weld a work located on a rotated positioner, after the both robot generate the arc the positioner must start to rotate. If the positioner starts to rotate when one robot generate to weld, another robot cannot weld so well. Because the relative angle between the torch and work changes or the absolute torch posture changes, the weld quailty is reduced. This functionality provides the synchronization of ARC START timing between multiple weld equipments automatically only if the synchronization data is set by the user. This functionality is available only when multi--equipment function(A05B--2400--J617) is ordered.
9.26.2 Setup This fuction works under the following conditon. -- You must set the data for synchronization between multiple weld equipment. This data can be set from the arc welding schedule data screen. Weld schedule data screen 1 Select Weld schedule data screen. The equipment number for this screen is displayed as “E1” or “E2” on the reversed line
DATA Weld shced
1 2 3
Volts 0.0 0.0 0.0
9
0.0
Amps 0.0 0.0 0.0
E1 cm/min 0 0 0
JOINT 100% 1/32 Comment
:
[TYPE]
0.0
DETAIL
0
ADVISE
SYNCDT
HELP>
2 Press F4 SYNCDT then the screen similar to the following is displayed.
DATA Arc sync E1 Synchronization data 1 EQ for sync
JOINT 100% 1/1 [*,*,*,*,*]
[TYPE]
1
*
NOTE Currently twe weld equipments are only supported. 3 Set “1” to the location of equipment to be synchronized. For example, the displayed schedule data is for equipment 1. If you want to synchronize the equipment 1 with the equipment 2, you must set “1” to the second column by pressing F4 key.
DATA Arc sync E1 Synchronization data 1 EQ for sync
JOINT 100% 1/1 [*,1,*,*,*]
[TYPE]
1
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*
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4 Change the equipment number. In the above example, the synchronization data of equipment 1 for the equipment 2 is set. You must set the synchronization data of equipment 2 for the equipment 1. To do that, at first change the euipment number by pressing CHANGE EQUIPMENT in FCTN menu. The screen similar to the following is displayed.
DATA Arc sync E2 Synchronization data 1 EQ for sync
JOINT 100% 1/1 [*,*,*,*,*]
[TYPE]
1
*
5 Set “1” to the location of equipment to be synchronized. For example, the displayed schedule data is for equipment 2. If you want to synchronize the equipment 2 with the equipment 1, you must set “1” to the first column by pressing F4 key.
DATA Arc sync E2 Synchronization data 1 EQ for sync
JOINT 100% 1/1 [1,*,*,*,*]
[TYPE]
1
*
By the above setting, ARC START for equiment 1 is synchronized with ARC START for equiment 2. And ARC START for equiment 2 is synchronized with ARC START for equiment 1. 6 Set $AWSCFG.$GLOBAL_ER to TRUE at the system variable screen in controlled start level. By this setting, when the alarm related to arc welding for the equipment 1 occurs, the arc weld control for equipment 2 is also paused. The opposite is same.
9.26.3 Specification & Limitation Specification & limitation F
For example, if ARC START of Equipment 1 should be synchronized with ARC START of Equipment 2 and ARC START of Equipment 2 should be synchronized with ARC START of Equipment 1, you should set the synchronization data as follows. EQ1 EQ2 ( object equipment ) Synchronization data for EQ1: [ *, 1, *, *, Synchronization data for EQ2: [ 1, *, *, *,
F
*] *]
The synchronization for the first ARC START is only available. That means, the synchronization for the ARC START to change the weld schedule is not available. 1 L P[1] 500mm/sec FINE ARC START[1]
Do synchronize
2 L P[2] 100cm/min CNT100 ARC START[2] Do not synchronize 3 L P[3] 100cm/min FINE ARC END[32] The ARC START[1] on the first line is the first ARC START and the ARC START[2] on the second line is for the change of weld schedule. F
For the synchronization sequence, if the arc detection input signal of the object weld equipment is not turned on, that is the non arc generation, the alarm “Arc start failed” occurs for both weld equipment control. For example, ARC START for equipment 1 is success and the arc generates. But the ARC START for equipment 2 is not success and the arc doesn’t generate. At that time, the alarm “Arc Start failed” occurs for both weld equipent control.
F
The RUNIN schedule data is used as the weld schedule until the detection of arc generation. So we recommend to set the lower weld condition to RUNIN schedule data. This functionality can prevent that the bead size at ARC START point becomes to be big.
F
The arc detection time in weld equipment setup screen should be same for both weld equipment.
F
The scratch start is automatically disabled.
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F
For the resume of arc welding sequence after pausing the program during the welding, if the object equipment resumes the arc welding, the synchronization is performed. For example, both arc welding of equipment 1 and 2 starts at the same time and the arc welding of equipment 2 finished earlier than the arc welding of equipment 1.
A
B
AS
AE
EQ1 AS
AE
EQ2
The program is paused at the timing A then when the program is restarted, the synchronization between ARC START for EQ1 and EQ2 is perfomed. The program is paused at the timing B then when the program is restarted, the synchronization is not performed because the arc welding of EQ2 has already done. F
When the robot current position is far away from the position when the program is paused, after the robot is returned to the paused position the program should be restarted. For example, when the robot current position is far away from the position when the program is paused, the original path resume motion works at the program restart. If the distance between the current position and the paused position differ between robot1 and robot2, the time to return to the paused position also differs. In this case, because the arc welding for the shorter distance generates eariler than that for the longer distance, the bead size at ARC START point becomes to be larger than usual.
F
When $AWCKMSPRG is TURE, the synchronization is perfomed only in Master/Slave program for Robot link function. If the program is Normal program, the synchronization is not performed even when the synchronization data of ARC START is defined. This system variables is TRUE only when Dual robot arc functionality is ordered.
9.26.4 Sample Application Sample application
Torch
To carry out synchronized welding by two torches of a single robot, as illustrated above, create a program as described below. In this example, this function starts synchronized welding. To end the welding at the same time, a value is set in registers.
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WELD1.TP (Equipment1)
WELD2.TP (Equipment2)
Motion group mask [1,*,*,*,*]
Motion group mask [*,*,*,*,*]
:
1: ARC START[1]
:
2: WAIT R[1]=1
7: R[1]=0
3: ARC END[2]
8: RUN WELD2 9: ARC START[1] 10: L P[4] 50cm/min CONT 100 : 13: L P[7] 50cm/min FINE
Synchronized by the synchronization function
14: R[1]=1 15: ARC END[2] :
Welding ended at the same time by setting a value in the registers
:
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9.27 Adjustment of Analog Output Conversation Factor by Multiple Points 9.27.1 Summary When voltage condition and current condition are commanded with analog output signals from Robot controller to weld supply, to match the interface for the weld supply, the calculation for the conversion is performed. Concretely the interface of a weld supply is from 0V to 14V, for example, when the current condition is 200A, the 200A must be converted to the actual voltage range( 0..14V ). At this calculation the analog output conversion factor we called is used. This factor should be changed for kind of weld supply, individual difference of weld supply, wire diameter, material Concretely a weld supply has the interface from 0V to 14V. For example, when the current condition is defined to 200A, it should be converted with the range from 0V to 14V. The “Analog output conversion factor” is used for the conversion. This analog output conversion factor is changed by kind of weld supply, difference of individual, wire diameter, material, length of weld power cable and so on. Robot controller has the weld supply file for popular weld supply and the analog output conversion factor under the range to use common weld condition is defined to the weld supply file. This analog output conversion factor is composed of linear approximation by two points. The functionalities this document describes are as follows. The purpose of them is “More accurate” and “More flexibility”. A) Touch--up functionality of analog output conversion factor by up--to 6points The difference of the analog output conversion factor described above can be modified by input the result of test welding( from 2 points up--to 6points ). The test welding must be performed with the adequate interval of weld condition then the actual volage command( 0..14V in the above example ) and the measured value on the front of weld supply are entered to the specific screen for this function. B) Definition of multiple table for analog output conversion factor Recently the weld supply has the multiple characteristic and they can be changed. By changing the characteristic the analog output conversion factor must be changed for it. In such a weld supply, multiple analog output factor conversion data is required for one weld supply. This functionality provides the multiple data table of analog output factor conversion described in the above item A then it is possible to change the data table number to use.
9.27.2 Operation procedure 1 Perform a controlled start. Select the weld power supply to use in the application setup screen then do cold start. By this choice, the analog output conversion factor by 2 points is defined. By this factor it is possible to weld basically. 2 Do the test weld. When there is many difference between the commanded weld condition and the measured value from the meter on the front of weld power supply, display the “Weld AO factor screen” by the following procedure. In this screen, it is possible to modify the analog output conversion factor data.
MENU → 5 I/O → “WeldAOFactor”
The screen similar to the following is displayed. 1234567890123456789012345678901234567890 Weld AO Factor
JOINT 100% 1/ 5 Selected weldAO factor No.: 1 Comment 1 2 3 4 5
[ [ [ [ [
] ] ] ] ]
[ TYPE ] DETAIL
CHANGE
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Done
Setup Done Done NotYet NotYet NotYet NotYet
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The specification of this screen is as follows. F
This screen is the list level screen to display/modify the analog output conversion factor data.
F
Five analog output conversion factor data table can be defined.
F
Go to the detail screen to modify the data by pressing F2 key.
F
After the setup of the analog output conversion factor data is completed, then press F4 “Done”. This means the completion of the setup. If the data is changed, the status of setup is from “Done” to “NotYet”. Please re--change the status of setup to “Done” after the changing.
F
When the welding is performed with the status of “NotYet”, the alarm occurs and the welding is impossible.
F
It is possible to enter the comment for the analog output conversion factor data. Put the cursor on the column of comment then press the enter key to edit the comment.
F
The current selected data table number is displayed on the upward of the teachpendant screen. When it is zero, the analog output conversion factor data by two points( defalut ) is used.
F
It is possible to change the analog output conversion factor data table by pressing F3 CHANGE key then enter the number. It is impossible to change it to the data table with “NotYet” then the selected number is returned to the previous data.
F
Only when $AWAOFACTENB is TRUE, this screen is displayed.
3 Press F2 DETAIL key then the screen similar to the following screen is displayed. In this screen, select the analog output signal item to be modified. 1234567890123456789012345678901234567890 Weld AO Factor Analog 1 AO[ 2 AO[ 3 AO[
JOINT 100% 1/ 3
output 1] [Voltage 2] [Current 2] [Wire inch
[ TYPE ]
] ] ]
DETAIL
The specification of this screen is as follows. F
In this screen, the list of analog output item that can be changed is displayed.
F
The analog output conversion factor can be only changed. It is impossible to change the analog input conversion factor. This is the linear approximation by two points.
4 Move the cursor to the item to be changed then press F2 DETAIL. The following screen is displayed. In this screen, by entering the data of “Actual voltage” and “Measured data” up--to 6points, the analog conversion factor data can be modified and defined. 1234567890123456789012345678901234567890 Weld AO Factor
JOINT 100% 1/ 6
AO factor table[ 1] AO[ 1][Voltage
1 2 3 4 5 6
]
VoltageCMD:V [ 0.00] [ 0.00] [ 0.00] [ 0.00] [ 0.00] [ 0.00]
[ TYPE ]
INIT
Measured:V [ 0.0] [ 0.0] [ 0.0] [ 0.0] [ 0.0] [ 0.0] DEFAULT
The specification of this screen is as follows. F
When F3 DEFAULT is pressed with SHIFT key, the data by two points( default ) is defined. When the SHIFT key is not pressed together, the message of “Press SHIFT key together” is displayed.
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F
When F2 INIT is pressed with SHIFT key, all of data is initialized to zero value. When the SHIFT key is not pressed together, the message of “Press SHIFT key together” is displayed.
F
Enter value so that the value is increased. When the value is decreased, the available data is terminated. The data before this data is used as the conversion factor data.
F
When all of data is not used, for example it is only four data, the fifth data should be zero. The data before zero value is used as the conversion factor data.
F
When the data is changed, the status of setup is returned to “NotYet”. Please changed it to “Done”.
F
During welding, it is impossible to change the data. When it is changed, the message of “Can’t change it during welding” is displayed.
5 The value of left column “VoltageCMD” in the above screen is same with the value displayed in ( **** ) on the weld status screen. Display the weld status screen then perform the test weld for the required trial number. Record the data for the test welding then enter them to the above screen. As the update cycle of the screen maybe long, please do the test welding for more than 2 second. The values in (****) are displayed only when $AWAOFACTENB is TRUE. When it is FALSE, they are not displayed.
1234567890123456789012345678901234567890 STATUS Weld
JOINT 100%
COMMAND FEEDBACK 0.0( 0.00)Volts 0.0( 0.00)Volts 0.0( 0.00)Amps 0.0( 0.00)Amps 0.0( 0.00)cm/min *****(*****)
Arc enable : Arc detect : Arc on time : [ TYPE ]
OFF OFF 0:
RESET
673
0:
0 H:M:S HELP
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9.28 Welding Parameter Grade Function 9.28.1 Function Overview The welding parameter grade function gradually increases or decreases welding schedule parameters (voltage, current, etc.) at a specified rate when the welding schedule is switched. More specifically, the function gradually increases or decreases the analog voltage output value which the arc tool software outputs to the welder, over a specified period of time. With this function, a welding schedule parameter can be smoothly changed. The welding parameter grade function can be applied to each analog output parameter of the welding schedule. The function can be applied to multiple parameters. For instance, the function can gradually increase a parameter while gradually decreasing another parameter. The welding parameter grade function can be enabled or disabled by the system variable $AWERAMP.$RAMP_ENABLE (the default value is FALSE (disabled)). When this system variable setting is changed, turn off and on the power to the robot control unit. NOTE This function does not work while the gas purge operation, run--in, crater prevention, post--processing, or weld release operation is in progress.
9.28.2 Setup The welding parameter grade function can be set up by specifying a grading time in a welding schedule in the #9.21.2--1 instruction. The following setup methods are available. F
Setting up in a welding schedule (specifying the processing time)
F
Setting up in the #9.21.2--1 instruction (in the #9.21.2--1 [..., ..., 1.0sec] format)
The grade function can be specified with the first #9.21.2--1 instruction specified at the beginning of welding as well as with the #9.21.2--1 instruction specified when changing the welding schedule. The function cannot be specified with the #9.21.2--2 instruction. The time specified in the #9.21.2--2 instruction is used as the crater prevention time.
9.28.3 Notes on Use This section gives instructions for using the welding parameter grade function, for reference purposes. F
Setting up grading at the beginning of welding If run--in is enabled, welding starts in accordance with the welding schedule specified as a run--in schedule (on the process schedule screen). Then, the welding schedule changes accordingly. If run--in is disabled, welding starts in accordance with the specified welding schedule. Grading is not performed at the beginning of welding. See Fig. 9.21.3(a).
Specified value
If run--in is disabled Welding starts in accordance with welding schedule 1.
Value specified in welding schedule 1 If run--in is enabled The value of run--in schedule changes to the value of welding schedule 1.
Value specified in run--in schedule
Time
Fig. 9.28.3(a) Specifying grading at the beginning of welding F
Robot operation at the beginning of welding The system variable $AWERAMP.$RAMP_HOLD specifies whether the program or robot operation stops while grading is being executed by the #9.21.2--1 instruction at the beginning of welding. See Fig. 9.21.3(b).
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Robot operation
Specified value
Purge
$RAMP_HOLD :FALSE (default)
$RAMP_HOLD :TRUE
The robot starts operating after run--in is completed.
The robot starts operating after the parameter reaches the value specified in the welding schedule.
Run--in
Time
Fig. 9.28.3(b) Robot operation at the beginning of welding F
Setting up grading at the end of welding To gradually decrease the value of a welding schedule parameter at the end of welding, specify the #9.21.2--1 instruction with the welding schedule in which a smaller value is specified, at the end of welding. If the #9.21.2--2 instruction is specified, the welding ends with the normal processing. The time specified in the #9.21.2--2 instruction is used as the crater prevention time, and no grading is performed. See Figs. 9.21.3(c) and 9.21.3(d).
Welding schedule 3 4
Feed speed (IPM)
Crater prevention
Voltage (Volts) 21.0 21.0
Feed speed Processing time (IPM) (sec) 250 150
Postprocessing
250 150
Time(sec)
Fig. 9.28.3(c) Normal operation at the end of welding
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Feed speed (IPM)
Voltage (Volts)
Feed speed Processing time (IPM) (sec)
21.0 21.0 21.0
250 150 150
3.00 3.00 3.00
Crater prevention Postprocessing A teach point and welding schedule are added to gradually change the parameter to the specified value at the end of welding.
250 150
0
1
2
3
Time(sec)
Fig. 9.28.3(d) Grading at the end of welding F
Robot/program operation during grading The program or robot operation continues while the grading of a welding parameter is in progress as specified by this function (except for the operation at the beginning of welding while $RAMP_HOLD is held TRUE). To stop the operation during grading, use the #9.21.3--1 instruction.
F
When another #9.21.2--1 instruction is executed before grading by this function ends Because the program or robot operation does not stop during grading by this function, another #9.21.2--1 instruction may be executed while a welding parameter is grading. If this occurs, the grading stops. This stop presents no problem and can be used in programming. To avoid this stop of grading, allow sufficient time before the next motion instruction. Alternatively, use the #9.21.3--1 instruction.
9.28.4 Operation at Recovery from Alarm At recovery from an alarm issued during welding, welding is resumed in accordance with the run--in schedule if run--in is enabled. After the run--in is completed, welding is carried out in accordance with the welding schedule which was used until the alarm was issued. If the grading time is specified in the welding schedule, grading from the run--in schedule to the specified welding schedule is performed. Meanwhile, the program or robot operation is carried out in the same way as when welding starts.
9.28.5 Using the Welding Fine--Tune Function Concurrently While the grading of a welding parameter is being performed as specified by this function, the welding fine--tune function is temporarily disabled. Changes in the welding parameter brought about by the function can be viewed on the welding fine--tune screen, but the welding parameter cannot be increased or decreased by pressing a function key. If this operation is attempted, a warning message appears.
9.28.6 Using the Arc Sensor Concurrently If the grading of a welding parameter by this function is attempted during arc sensor tracking, the arc sensor does not function correctly. Grading should not be executed while the arc sensor tracking is in progress.
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9.28.7 Sample Application In the example shown in Fig. 9.21.7, the following operation is performed: 1 After run--in, the wire feed speed starts increasing from #9.21.7--1 [2], in accordance with #9.21.2--1 [2] in the second line. The wire feed speed linearly increases from 200 IPM, which is specified in the run--in schedule, to 300 IPM, which is specified in welding schedule 2. 2 The wire feed speed continues to increase for three seconds during the motion from #9.21.7--1 [2] to #9.21.7--1 [3]. The target wire feed speed, voltage, and grading period are specified in welding schedule 2. 3 In this example, the motion to #9.21.7--1 [3] is performed over a period of five seconds. In the fourth line, the welding schedule changes (#9.21.2--1 [3]), where the wire feed speed starts decreasing. 4 The value of the wire feed speed decreases over a period of three seconds during the motion to #9.21.7--1 [5]. 5 The grading of 4. above is completed two seconds before #9.21.7--1 [5] is reached.
Welding schedule
Voltage (Volts) 21.0 21.0 21.0 21.0
Run--in 2 3 4
Feed speed Processing time (IPM) (sec) 200 2.00 300 3.00 250 3.00 100 3.00
Crater Postpro- Welding prevention cessing detected
Feed speed Gas purge Run--in 300
200
100
0 0
1
2
3
4
5
0
1
2
Fig. 9.28.7 Sample application
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9.29 Welder Program Select Function 9.29.1 Function Overview Some welders contain programs (mode setting, sequence setting, database, etc.), which can be switched by a digital signal input. Some units allow the program to be switched during welding. (The function of the welder program depends on the welder.) The welder program select function is used to switch an internal program of the welder from the robot control unit. This function has the following features. F
The welder program select function is enabled or disabled by setting the corresponding system variable.
F
Three digital output signals are assigned as program select output signals. These three digital output signals give the welder a direction specifying the welder program to be selected.
F
With the program select output signals, eight different welder programs can be selected. On the #9.22.1--1 screen, a welder program name can be specified. The welder program can also be switched on the screen. When a welder program is selected on the screen, the program select output signals are set accordingly.
F
When specifying a welding schedule, the welder program used for the welding schedule can be specified. When welding is performed in accordance with the welding schedule, the program select output signals are set in accordance with the selected welder program.
F
On the #9.22.1--2 screen, the currently selected welder program can be checked.
9.29.2 Enabling or Disabling the Function The welder program select function is enabled or disabled by setting the system variable $AWEPCR.$PRG_SEL_ENA. $AWEPCR.$PRG_SEL_ENA
= TRUE: =FALSE:
Enabled Disabled (default)
9.29.3 Assigning Welder Program Select Output Signals To use the welder program select function, three digital output signals must be assigned as program select output signals. A welder program is selected in accordance with the combination of the on/off statuses of the three digital output signals. On the #9.22.1--1 screen, eight different welder programs are displayed. Table 9.22.3 shows the relationship between the eight welder programs and combinations of the on/off statuses of the digital output signals. Table 9.29.3 Welder program numbers Welder program number
Combination of program select output signals Signal 1
Signal 2
Signal 3
OFF
OFF
OFF
2
ON
OFF
OFF
3
OFF
ON
OFF
4
ON
ON
OFF
5
OFF
OFF
ON
6
ON
OFF
ON
7
OFF
ON
ON
8
ON
ON
ON
1
Fig. 9.22.3 shows an example of selecting a welder program by the program select output signals.
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Robot control unit
Welder
Process I/O board Signal 1 Program Signal 2 select output Signal 3
Program select input
Timing chart Program 1
Program 2
Program select output signal 1 Program select output signal 2 Program select output signal 3
Fig. 9.29.3 Example of selecting a welder program Any types of digital output signals available can be assigned as program select output signals. Procedure for assigning welder program select output signals 1 Press the MENUS key. 2 Select the I/O screen. 3 Press F1 #9.22.3--1, then select #9.22.3--2. 4 Press F3 IN/OUT to switch the screen to the welding output signal screen. 5 The screen appears, as shown below. Place the cursor on the line of the program select output signal to be assigned.
6 Press the F--> key, then press F3 #9.22.3--3. The screen appears, as shown below.
7 Place the cursor on the signal type field, then select a signal type. 8 Place the cursor on the signal number field, then select a signal number.
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9 Press the #9.22.3--4 key or F2 #9.22.3--5. The digital output signal is assigned. When the digital output signal is assigned, the screen appears, as shown below.
10 Repeat steps 5 to 9 to assign the remaining two program select output signals.
9.29.4 Selecting a Welder Program On the #9.22.1--1 screen, eight welder programs are displayed. On this screen, the following operations can be performed. F
Selecting a welder program (The program select output signals are set in accordance with the selected welder program.)
F
Editing a welder program name
Procedure for selecting a welder program Condition J
The three program select output signals have already been assigned.
Procedure 1 Press the MENUS key, then select the setup screen. 2 Press F1 #9.22.4--1, then select #9.22.4--2. The screen appears, as shown below.
3 Place the cursor on the line of a desired program, then press F3 #9.22.4--3. The program is selected. When the program is selected, the program select output signals are set accordingly. 4 When editing a program name, place the cursor on the line of a desired program, then press ENTER.
9.29.5 Setting a Welder Program in a Welding Schedule With the welder program select function, the welder program to be used can be specified for each welding schedule. The welder program to be used can be specified on the #9.22.5--1 screen. See Fig. 9.22.5.
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Fig. 9.29.5 Welding schedule screen On the welding schedule screen, place the cursor on the welder program number field, then enter a desired welder program number. If the welder program number changes, the program name selected on the #9.22.1--1 screen appears. The welder program name cannot be edited on this screen. In actual welding, the welder program specified in the welding schedule is selected.
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9.30 Servo Torch Control Function 9.30.1 Outline of Servo Torch control function The Servo Torch is a mechanism which feeds welding wire by a servo motor. Servo Torch control function is a function which controls the Servo Torch. Wire feeding by a servo motor always you to stabilize actual wire feed speed during welding and to avoid influence of disturbance such as a bend of conduit tube by robot motion. This also enables high speed wire feeding.
9.30.2 Attention and Limitation F
Configuration of axes Servo Torch axes must be installed after regular axes (robot axes, extended axes, line tracking axes). And, the index of hardware start axis must be an odd number. Example 1) 6 axes robot + Servo Torch * 1 Hardware axes
Axis type
1~6
Robot axes
7
Servo Torch axis
Example 2) 6 axes robot + Extended axis(or NOBOT or Positioner) * 1 + Servo Torch * 1
F
Hardware axes
Axis type
1~6
Robot axes
7
Extended axis
8
Servo Torch axis
Weld process This function supports MIG weld process and the process control method of ’Volts, Amps’.
F
Wire type This function supports following types of welding wire Wire diameter: 0.6mm,0.8mm,0.9mm,1.0mm,1.2mm,1.4mm,1.6mm Wire material: Steel, Steel(flux cored), Aluminum
F
Recovery from alarms of ’Pulse mismatch’, ’BZAL’ and ’RCAL’ ( SRVO--038,062 and 063). For Servo Torch axes(Group:0), set sysvars of $IS_MCR.$SPC_RESET to TRUE and cycle power.
9.30.3 Detail of Servo Torch control function 9.30.3.1 Arc welding instruction Ordinary arc welding instruction is used with ordinary usage for arc welding.
9.30.3.2 Wire inching Two wire inching modes are available for Servo Torch. These modes are selected in Servo Torch setup screen. F
Normal inching ’WIRE+’ / ’WIRE--’ keys on a teach pendant are used for advancing/retracting wire as well as an ordinary wire feeder.
F
Constant inching ’WIRE+’ / ’WIRE--’ keys on a teach pendant are used for advancing/retracting wire as well as an ordinary wire feeder. When wire inching is continued and wire is inched by specified length, wire inching is stopped automatically. The length to stop inching is specified in Servo Torch setup screen. If the keys are released before wire is inched by specified length, wire inching is stopped immediately.
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9.30.3.3 Air purge function If the air purge option is attached to Servo Torch, Air purge function is available. Air purge function removes dust in wire feed mechanism of Servo Torch by blowing high--pressured air. Air purge function behaves as following. F
Starts air purge at the start of Servo Torch operation.
F
When Servo Torch is stopped and specified time (post flow time. default:0.5sec.) has been passed, air purge is stopped.
Air purge is executed not only at welding but also at inching. If E--stop is performed during air purge, post flow is not executed and air purge is stopped immediately. Air purge can be executed manually in I/O screen by switching the status of the signal which is assigned as the air purge control signal. When a RO or a DO is assigned as the air purge signal, a comment of ’SVTorch air purge’ is added for the signal in I/O screen. Procedure
Manual execution of air purge
Condition F
The air purge option is attached to Servo Torch.
F
Servo Torch control function is enabled.
F
Air purge function is enabled.
Procedure 1 Press MENU key and selelct ’5. I/O’. 2 Press F1,TYPE and select corresponding screen to the type of the air purge control signal. For example, if the signal is assigned to RO[2], select ’Robot’. 3 If the displayed screen is an input signal screen, press F3,’IN/OUT’ to switch the screen into an output signal screen. 4 Move the cursor to the air purge control signal and press F4,’ON’ or F5,’OFF’ to switch the status of the signal. If the status of the signal is ’ON’, air purge is executed. If the status of the signal is ’OFF’, air purge is stopped. Following example is the case that RO[2] is assigned as the air purge control signal.
I/O Robot Out
RO[ RO[ RO[ RO[ RO[ RO[ RO[ RO[
# 1] 2] 3] 4] 5] 6] 7] 8]
[TYPE]
JOINT 10% 2/8 STATUS OFF OFF OFF OFF OFF OFF OFF OFF
DETAIL
[ ] [SVTorch air purge ] [ ] [ ] [ ] [ ] [ ] [ ]
IN/OUT
9.30.4 Setup for Servo Torch Following procedures are required in order to use Servo Torch. F
Setup Servo Torch axes
F
Setup in weld equipment setup screen
F
Setup in Servo Torch setup screen
This section describes the details of these procedures.
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9.30.4.1 Setup Servo Torch axes You can setup Servo Torch axes in MAINTENANCE screen at controlled start status. The descriptions of the item to set are as following. Table 9.30.4.1 The description of the item for Servo Torch axes setup Item
Description
Number of axes Hardware start axis
Amp number
Procedure
Enter number of Servo Torch axes. Enter hardware axis index of the 1st Servo Torch axis. Please refer attention in Chapter 2 for setup. Ex. 1)
6 axes robot + Servo Torch * 1 : set 7
Ex. 2)
6 axes robot + Ext Axs * 1 + Servo Torch * 1 : set 8
Enter amp number for each Servo Torch axis. Ex. 1)
6 axes robot + Servo Torch * 1 : set 2
Ex. 2)
6 axes robot + Ext Axs * 1 + Servo Torch * 1 : set 3
Setup Servo Torch axes
Procedure 1 Perform a controlled start. 2 Press the MENUS key and select ’9. MAINTENANCE’. Similar screen as following is displayed.
Setup
Robot Group 1 0 [Type]
System Variables Robot S-430iF ServoTorch ORD_NO
Library /Option Floor Mnt
AUTO
Ext Axs 0 0 MANUAL
3 Press F4,’MANUAL’. Similar screen as following is displayed. Select ’1. Normal setup’.
------- Setup Servo Torch axis ------Select Setup type 0: Exit 1: Normal setup 2: Direct ISDT setup Setup type?
4 Enter number of Servo Torch axes.
Enter number of axes (1 - 2)?
5 Enter the index of hardware start axis of Servo Torch axes.
Enter hardware start axis (this must be an odd number)?:
6 Enter amp number for each Servo Torch axis.
Enter amp number (axis: 1)?:
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7 After a few moments, the main screen of MAINTENANCE screen is displayed. Confirm that the value of ’Ext Axs’ in the line of ’ServoTorch’ is equal to the number of Servo Torch axes you set. The following example is the case that 1 Servo Torch axis is set.
Setup
Robot Group 1 0
System Variables Robot S-430iF ServoTorch
[Type]
ORD_NO
Library /Option Floor Mnt
AUTO
Ext Axs 0 1
MANUAL
* If you want to delete Servo Torch axes, select ’2. Direct ISDT setup’ in procedure 3. Then select ’3. Delete proc axis’.
9.30.4.2 Setup in Weld equipment setup screen Wire type can be set in Weld equipment setup screen. Servo Torch setup screen is entered from this screen. Descriptions of the items related with Servo Torch are as following. Table 9.30.4.2 Description of the items related with Servo Torch in Weld equipment setup screen Description
Item Wire size
Specifies diameter of welding wire. Cycling power is required to enable change.
Wire material
Specifies material of welding wire. Cycling power is required to enable change.
Servo Torch
Servo Torch setup screen is entered by pressing ENTER key with the cursor located at ’DETAIL’ of this item.
NOTE Please set correct wire type. Otherwise correct wire feed speed is not issued at welding and welding is not performed correctly.
Procedure
Setup in Weld equipment setup screen
Procedure 1 Press MENU key and select ’6. SETUP’. 2 Press F1,TYPE and select ’Weld Equip’. Similar screen as following is displayed.
SETUP weld Equip
JOINT 10% 8/13 DAIDEN 350UR/Fe1.2
Welder: Process: MIG Feeder: ****************
1 Wire size: 1.2 mm 2 Wire material: Steel 3 Wire feed speed units: cm/min 4 WIRE+ WIRE- speed: 50 cm/min 5 Feed forward/backward: DISABLED 6 Wire stick reset: ENABLED 7 Wire stick reset tries: 3 8 Servo Torch( ENABLED ): <*DETAIL*> Timing: 9 Arc start error time: 2.00 sec
[ TYPE ]
3 Move the cursor to the item of ’Wire size’ or ’Wire material’. Press F4,’CHOICE’ and select items from displayed choices.
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4 If move the cursor to ’DETAIL’ of the line of ’Servo Torch’ and press ENTER key, Servo Torch setup screen is displayed. Press PREV key to return to weld equipment setup screen. 5 The status ’ENABLED’ or ’DISABLED’ of Servo Torch control function is displayed. If the status is changed in Servo Torch setup screen, this status become effective after cycling power.
9.30.4.3 Servo Torch setup screen This screen is entered from Weld equipment setup screen. Descriptions of the items in this screen are as following. Table 9.30.4.3 Description of items in Servo Torch setup screen Description
Item ServoTorch function
Enable/Disable Servo Torch control function. Cycling power is required to enable changes.
ServoTorch axis index
Specifies axis index of process axis for Servo Torch axis for current equipment. Servo Torch axes are set as the axes of Group 0. The axis index to be specified is the index number of the axis in Group 0. If the index is set to 0, Servo Torch control function is disabled.
Wire inching mode
Specifies wire inching mode.
Inch length
Specifies length to inch for constant inching mode. Unit: mm
Gas start signal
Specifies configuration of gas start signal for Servo Torch. When Servo Torch control function is enabled, this signal is used for gas start signal. Cycling power is required to enable changes. There is no need to change this configuration for usual case. Please change this configuration only when the wiring of the signal which controls the solenoidal valve for welding gas is different from standard specification. Default: Weld Eq.1~RO[1], Weld Eq.2~RO[9]
Air purge function
Enable/Disable air purge function
Air purge signal
Specifies configuration of air purge signal. There is no need to change this configuration for usual case. Please change this configuration only when the wiring of the signal which controls the solenoidal valve for air purge is different from standard specification. Default: Weld Eq.1~RO[2], Weld Eq.2~RO[10]
Post flow time
Specifies time between stopping Servo Torch and stopping air purge. Unit: sec
NOTE When Servo Torch control function is disabled, gas start signal is always set to WO[2] for weld equipment 1. For weld equipment 2, gas start signal is set to WO[10] at that case.
Procedure
Setup in Servo Torch setup screen 1 Press the MENUS key and select ’6. SETUP’. 2 Press F1,TYPE and select ’Weld Equip’ from the menu. 3 Move the cursor to ’DETAIL’ in the line of ’Servo Torch’ and press ENTER key. Similar screen as following is displayed.
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SETUP Weld Equip
JOINT 10% 1/8
Servo Torch setup 1 ServoTorch function: 2 ServoTorch axis index: 3 Wire inching mode: 4 Inch length:
DISABLE 0 NORMAL 15.0 mm
Welding gas 5 Gas start signal:
RO[
Air 6 7 8
DISABLE RO[ 2] 0.50sec
purge setup Air purge function: Air purge signal: Post flow time:
[TYPE]
ENABLE
4 Setup each items. 5 Press PREV key to return to Weld equipment setup screen.
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9.31 Servo Torch Fine Adjustment Function of Wire Velocity Commands The servo torch control function calculates the required feed speed using given welding condition values and sends a velocity command to the servo torch. If an actual welding condition value greatly differs from the specified welding condition value during actual welding work, you can adjust the conversion factors for calculating the feed speed to make the correspondence between the welding conditions and wire feed speeds more precise. The following two adjustment methods are available: -- Six--points touchup Perform welding and enter the actual welding currents flowing during welding and wire feed speed data to set the optimum conversion factors using these measured values. -- Direct setting Directly enter a conversion factor manually.
9.31.1 Six--Points Touchup Enter the welding currents flowing during welding and corresponding wire feed speed data to set the optimum conversion factors using these measured values. In ordinary cases, execute a welding program according to several types of welding conditions and enter the wire feed speed and welding current value during welding according to each welding condition. After several combinations of a welding current value and corresponding wire feed speed data are entered, this function calculates the optimum speed conversion factors using these measured values. Up to six combinations of a welding current and corresponding wire feed speed can be entered. To adjust the speed conversion factors using the 6--points touchup method, use the Wire feed speed conversion/six points touchup screen. The following describes the items and function keys on the Wire feed speed conversion/six points touchup screen.
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Table 9.31.1 (a) Items on the wire feed speed conversion/six points touchup screen Description
Item Wire size
Speed conversion factors are prepared for each type of wire. First specify the type of wire for which the speed conversion factors are to be adjusted. This item selects the size of the wire.
Wire material
Selects the material of the wire for which the speed conversion factors are to be adjusted.
Current wire feed speed (WFS) conversion factor
Indicates the current speed conversion factors for the selected type of wire. This item is only displayed and cannot directly be changed.
Touchup data [ i ] ( i:1..4)
Indicates the number of the currently selected data table. You can enter a desired number to change the displayed data table. You can also enter a comment for each data table. During adjustment of the speed conversion factors, the specified type of wire and entered measured values are stored in this selected data table. After adjusting the speed conversion factors for a type of wire, to adjust the factors for another type of wire, change the data table. If the speed conversion factors are adjusted without changing the data table, the previously entered measured values and type of wire are overwritten with new measured values and type of wire. You can use four data tables (1 to 4).
Unused
This is the leftmost item on a line for entering measured value data. When measured value data is updated, an “*” is displayed in this item on the corresponding measured value data line. After the speed conversion factors are calculated using the measure value data, the “*” goes off and this item becomes blank. That is, this item indicates that measured value data with an “*” is not reflected in calculation of the current speed conversion factors.
WFS (Wire Feed Speed)
You can enter a wire feed speed. You can also press F5 “CAPTURE” to fetch the wire feed speed at that time (described later).
Feedback current
You can enter a welding current. Read the value of the ammeter on the front panel of the welding power supply and enter the value in this field. For the ROBOWELD system, pressing F5, “CAPTURE” fetches the welding current value.
Monitor
Indicates the current wire feed speed. For the ROBOWELD system, the welding current value is also indicated. For an ordinary welding power supply, a value of 0 is always indicated as the welding current value.
Table 9.31.1 (b) Function keys on the Wire feed speed conversion/six points touchup screen Description
Item F2, [METHOD]
Changes the screen for adjusting the speed conversion factors. You can select the 6--point touchup or direct setting screen.
F3, CALC
Calculates the speed conversion factors using the currently entered measured values. This function key is unavailable during welding.
F5, CAPTURE
Fetches the current wire feed speed into the measured value input line at the cursor. For the ROBOWELD system, the welding current value is also fetched simultaneously.
F7, DEFAULT
Resets the speed conversion factors to their defaults. The defaults mean factory--settings. This function key is unavailable during welding.
F10, CLEAR
Resets all currently entered measured values to 0. At this time, an “*” is displayed for all items.
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Operation 31--1
Adjusting the speed conversion factors using the 6--point touchup method
Condition F
A welding program is ready to use.
F
The servo torch control function is enabled.
Procedure 1 Select a welding program for measuring actual values. 2 Press the MENU” key and select “6. Setup”. 3 Press the F1, [TYPE] key and select “Weld Equip” from the displayed menu. 4 Position the cursor on “<*DETAIL*>” on the “Servo Torch” line and press the ENTER key. The servo torch setting screen appears. (See Section 4--3). 5 Press the F3, “WFSCONV” key. The following screen appears:
Setup Weld Equip WFS conv factor Wire type Wire size: Wire material:
JOINT
1.2mm Steel(Flux cored)
Current WFS conv factor 1: 0.0000 2: 2.2445 Touch up Unusd [*] [ [*] [ [ ] [ [ ] [ [ ] [ [ ] [
data [1] [ WFS 302.11]cm/m 512.03]cm/m 637.56]cm/m 749.88]cm/m 0.00]cm/m 0.00]cm/m
Monitor WireFeedSpeed 0.0 cm/min
10 % 1/9
3:
0.0099
] Feedback Current [ 98.2]Amps [ 136.5]Amps [ 155.1]Amps [ 178.3]Amps [ 0.0]Amps [ 0.0]Amps
Feedback Current 0.0 Amps
[ TYPE ] [METHOD]
CALC
[CHOICE] CAPTURE>
DEFAULT
CALC
[CHOICE] CAPTURE>
6 Enter a desired number for 7 Select a type of wire. Position the cursor on “Wire size” or Wire material” and press the F4, “CHOICE” key. Options are displayed. Select a type of wire for which you want to adjust the speed conversion factors from the options. 8 Execute the welding program.
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9 During welding according to each welding condition, enter the measured wire feed speed and welding current value in each measured value input line. Operation for an ordinary welding power supply differs from that for the ROBOWELD. (For an ordinary welding power supply) Read the welding current value indicated on the welding ammeter on the front panel of the welding power supply and enter the value in the “Feedback Current field on a measured value input line. Then, press F5, “CAPTURE” before the welding condition changes. The wire feed speed at that time is automatically input in the “Wire Feed Speed” field on the same line. The cursor automatically moves to the next line. After that, enter the measured values for each welding condition in the same way. (For the ROBOWELD) Press F5, CAPTURE. The current wire feed speed and welding current value are automatically input in the measured value input line at the cursor (when the cursor is not positioned on any measured value input line, the values are input in the top measured value input line). The cursor automatically moves to the next line. After that, enter the measured values for each welding condition in the same way. NOTE Enter at least three combinations of measured values. 10 After entering measured values, terminate the welding program. Then, press F3, “CALC”. The “*” displayed for the Unusd” item on each measured value input line goes off and new wire speed conversion factors are set.
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9.31.2 Direct Setting Directly enter a speed conversion factor. Use this method when you know the speed conversion factors to be set. To make this setting, use the Wire feed speed conversion/Direct setting screen. The following describes the items and function keys on the wire feed speed conversion/direct setting screen. Table 9.31.2 (a) Items on the wire feed speed conversion/direct setting screen Item
Description
Wire size
Speed conversion factors are prepared for each type of wire. First specify the type of wire for which the speed conversion factors are to be adjusted. This item selects the size of the wire.
Wire material
Selects the material of the wire for which the speed conversion factors are to be adjusted.
Conversion factor 1..3
Indicates the current speed conversion factors for the selected type of wire. You can position the cursor on one of these items and enter a value. You cannot enter any value during welding.
Table 9.31.2 (a) Items on the wire feed speed conversion/direct setting screen Description
Item F2, [METHOD]
Changes the screen for adjusting the speed conversion factors. You can select the 6--point touchup or direct setting screen.
F7, DEFAULT
Resets the speed conversion factors to their defaults. The defaults mean factory--settings. This function key is unavailable during welding.
Wire size
Speed conversion factors are prepared for each type of wire. First specify the type of wire for which the speed conversion factors are to be adjusted. This item selects the size of the wire.
692
9. UTILITIES
B--81464EN--3/01
Operation 31--2
Adjusting the speed conversion factors using the direct setting method
Procedure 1 Press the “MENU” key and select “6. Setup”. 2 Press the F1, “[TYPE]” key and select “Weld Equip” from the displayed menu. 3 Position the cursor on <*DETAIL*>” in the “Servo Torch” line. The servo torch setting screen appears. (See Section 4--3.) 4 Press the F3, WFSCONV” key. When the 6--point touchup screen is displayed, press F2, “[METHOD]” and select “Direct entry from the displayed menu. 5 The following screen appears:
Setup Weld Equip JOINT 10 % WFS Conv Factor 1/5 Wire type 1 Wire size: 1.2mm 2 Wire material: Steel(Flux cored) WFS Conversion factor 3 Conversion factor 1: -130.8700 4 Conversion factor 2: 2.9598 5 Conversion factor 3: 0.0021 [TYPE]
[METHOD]
[CHOICE]
>
DEFAULT
[CHOICE]
>
6 Select a type of wire. Position the cursor on “Wire size” or Wire material” and press the F4, “[CHOICE]” key. Options are displayed. Select a type of wire for which you want to adjust the speed conversion factors from the options. 7 Position the cursor on conversion factor 1 to 3 and enter a conversion factor.
693
APPENDIX
APPENDIX
B--81464EN--3/01
A. APPENDIX This appendix summarizes the items necessary for using this model. It may also be used as an index. j Contents of this appendix A.1 List of Menus A.2 Types of Screens A.3 List of Program Instructions A.4 Program Instructions
697
APPENDIX
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A.1 List of Menus Figure A--1. Function menu (Page 1) Miscellaneous menu
Miscellaneous function
1 ABORT (ALL)
Program abort
2 Disable FWD/BWD
Disabling FWD/BWD from teach pendant
3 CHANGE GROUP
Change Motion Group*14
4 TOGGLE SUB GROUP
Sub group toggle*21
5 TOGGLE WRIST JOG
Wrist jog toggle
6 7 RELEASE WAIT
Release Wait
8 9 0 ---- NEXT ----
Figure A--2. Function menu (Page 2) Miscellaneous menu
Miscellaneous function
1 QUICK/FULL MENUS
Quick/full menu switch
2 SAVE
Save
3 PRINT SCREEN
Screen print
4 PRINT
Print
5 6 UNSIM ALL I/O
Unsimulates all I/O
7 8 9 0 ---- NEXT ----
698
APPENDIX
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Figure A--3. Screen Menu (Page 1) Screen menu 1 UTILITIES
Screen change menu
Screen
Hints
Hint F5! Help
Prog Adjust*2
Program Adjunst Schedule List F2→ Program Adjust
Program shif*3
Program Shift
Mirror Image*4
Mirror Image Shift
Tool offset*5
Tool Offset
Frame offset*6
UFrame Offset
Angle entry*7
Angle Entry Shift
OnTheFly*1
OnTheFly
Posture conv*22
Posture conv F2→ Datum Plane Setup
Path adjust*22
Path adjust
2 TEST CYCLE
Test Cycle
Test cycle
3 MANUAL FCNTS
Macros*8
Manual operation
4 ALARM
Alarm Log
Alarm Occurrence$ Alarm history F5! Alarm detail
5I/O
Digital
Digital I/O F2! Digital configuration F4! Digital detail
Group
Group I/O F2! Group Configuration F4! Group detail
Analog*9
Analog I/O F2! Analog configuration F4! Analog detail
Robot
Robot I/O F2! Robot I/O detail
UOP
Peripheral device I/O
Schedule Detail
SOP
System Operator Panel I/O
Inter Conect
DI--to--DO connection setting
Link Device
I/O Link Device List F3! I/O Unit Model B List F3! I/O Points Setup
Weld*1
Weld I/O F3! Analog Input/Output Range Setup screen F3! Digital Signal Type Setup screen
6 SETUP
0 ---- NEXT ----
General
General item setting
Frames
Frame entry F2! Frame detail
Macro*8
Macro entry
Ref Position*8
Reference position selection F3! Reference position setting
RSR/PNS
RSR setting ↔ PNS setting *10
Soft float*12
Soft float condition list F3! Soft float condition detail
Port Init
Port selection F3! Port setting
Ovrd Select
External override setting
User Alarm
User alarm setting screen
Torq Limit*24
Torque Limit Setup
Coord*25
Coordinate Motion Setup
Stroke limit*d
Stroke Limit Setup
Space fnct.*11
Rectangular Space Check Setup
Motion DO*14
Motion Group DO Setup
Cont Turn*13
Continuous Turn Setup
Weld System*1
Weld System
Weld Equip*1
Weld Equip
Weave*18
Weave
699
APPENDIX
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Figure A--4. Screen Menu (Page 2)
Screen menu 7 FILE*15
Screen change menu
Screen
File
File
File Memory
File Memory
8 9 USER
User
0 ---- NEXT ---1 SELECT
Program selection
2 EDIT
Program edit
3 DATA
Registers
Register
Position Reg*16
Position register F4! Position data information
Weld Sched*1
Weld Sched F2! Weld Sched Detail
Weave Sched*18
Weave Sched F2! Weave Sched Detail
F3! Weld Sched Advice
4 STATUS
Track Sched*19
Track Sched
AVC Sched*20
AVC Sched
Process Sched
Process Sched F2! Process Sched Detail
Axis
Robot axis status
Version ID
Software version
Prg Timer*17
Program Timer Status List F2! Program Timer Detail
Sys Timer*17
System Timer Status
Safety Signl
Safety Signal Status
Order File*a
Order file
Exec--hist
Execution history
Memory
Memory status list F2! Memory status detail
Condition*23
Condition Monitor
Weld*1
Weld
5 POSITION 6 SYSTEM
7 8 9
Current position Clock
Calendar
Variables
System variable
Servo Param*c
Servo parameter
Master/Cal*b
Positioning
OT Release
Over Travel Release
Axis Limits
Joint operating area setting
Config
System configuration
Motion
Motion Performance
0 ---- NEXT ----
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APPENDIX
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Setting The menu items indicated by * (alphabetical character) in Figure A--3 and Figure A--4 are displayed when the corresponding setting is made, as indicated below: Table A--1.
Option list
*
Setting
a
Can be displayed by setting $ODRDSP_ENB to 1.
b
Can be displayed by setting $MASTER_ENBL to 1.
c
Can be displayed by setting $SVPRM_ENB to 1.
d
Basic option only for Robot S--430i series
Options The menu items indicated by * (numeral) in Figure A--1 to Figure A--4 are displayed when the corresponding option is added, as indicated below: Table A--2.
Option list
*
Option
Specification
1
ARC tool
A05B--****--H541
2
Online position correction
A05B--****--J517
3
Program shift
A05B--****--J505
4
Mirror image
A05B--****--J506
5
Tool offset
A05B--****--J509
6
User coordinate system input
A05B--****--J604
7
Angle input shift
A05B--****--J614
8
Option instruction
A05B--****--J503
9
Analog I/O
A05B--****--H550
10
External program selection
A05B--****--J515
11
Area check
A05B--****--J609
12
Soft float function
A05B--****--J612
13
Continuous rotation function
A05B--****--J613
14
Multi--motion
A05B--****--J601
15
Floppy disk drive connection
A05B--****--J516
16
Position register
A05B--****--J514
17
Hour meter
A05B--****--J513
18
Weaving
A05B--****--J504
19
Arc sensor
A05B--****--J511
20
TIG arc length control
A05B--****--J526
21
Additional--axis control
A05B--****--J518
22
Torch posture conversion
A05B--****--J623
23
Schedule monitoring function
A05B--****--J628
24
Torque limit function
A05B--****--J611
25
Cooperative control
A05B--****--J619
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APPENDIX
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A.2 Types of Screens Figure A--5. [ 1 UTILITIES ]
Hint screen UTILITIES Hints
G2
JOINT
10 %
FANUC ARC Tool 7D80/10 Copyright FANUC LTD FANUC Robotics North America, Inc. All Rights Reserved
[ TYPE ]
HELP
Hints
Program Adjust Schedule List Screen SAMPL1 LINE 0 UTILITIES Prog Adj G1 Program Lines 1 SAMPL1 22-29 2 SAMPL1 39-49 3 SAMPL3 10-14 4 TESTPRG 123-456 5 ******** 0- 0 6 ******** 0- 0 7 ******** 0- 0 8 ******** 0- 0 9 ******** 0- 0 10 ******** 0- 0
Program Adjust Schedule Detail Screen
JOINT 10 % Status 3/10 ENABLED ENABLED DISABLED EDIT ******** ******** ******** ******** ******** ********
[ TYPE ] DETAIL
>
Prog Adjust COPY
SAMPL1 LINE 0 UTILITIES Prog Adj G1
Current schedule: 5 Status: EDIT 1 Program name: SAMPL2 2 Starting line number: 0 3 Ending line number: 0 4 X adjustment: 0.000 5 Y adjustment: 0.000 6 Z adjustment: 0.000 7 W adjustment: 0.000 8 P adjustment: 0.000 9 R adjustment: 0.000 10 Motion speed: 0 11 Joint speed: 0 [ TYPE ]
CLR_ADJ CLR_ALL
>
Program Shift (Program name) Screen
JOINT
COPY
UNITS CLR_ADJ
SCHED
10 % 1/11
mm mm mm dg dg dg mm/s %
[CHOICE]
>
CLR_ALL[CHOICE]
>
Program Shift (Position) Screen FLPY-009 Communications error TM_ADJST LINE 1 ABORTED PROGRAM SHIFT G1 JOINT 10 % Shift amount/Teach 1/3 Position data X :******** Y :******** Z :********
PROGRAM SHIFT G1 JOINT 10 % Program 6/6 1 Original Program : [TM_ADJST] 2 Range: PART 3 Start line: 1 4 End line: 1 5 New Program : [test1 ] 6 Insert line: (not used) *****
1 Rotation:
OFF
2 Source position
P1:
3 Destination position
Q1:
CLEAR
ON
Use shifted up,down arrows for next page
[ TYPE ]
>
Program shif CLEAR
>
702
DIRECT
OFF
>
APPENDIX
B--81464EN--3/01
Figure A--6. [ 1 UTILITIES ] Program Shift (Direct entry) Screen PROGRAM SHIFT G1 Shift amount/Direct entry 1 X (mm): 2 Y (mm): 3 Z (mm):
[TYPE] CLEAR
JOINT
10% 1/3
100.00 0.00 0.00
EXECUTE
>
TEACH
>
Mirror Image Shift (Program name) Screen MIRROR IMAGE SHIFT Program 1 Original Program : 2 Range: 3 Start line:(not 4 End line:(not 5 New Program : 6 Insert line:(not
G1
used) used) used)
Mirror Image Shift (Position) Screen
JOINT [TEST1 WHOLE ***** ***** [TEST3 *****
10% 1/6 ]
>
Mirror Image
10% 1/3
Z :********
1
Rotation:
OFF
2
Source position
P1:
3
Destination position
Q1:
[TYPE]
EXECUTE
ON
OFF
>
CLEAR
CLEAR
>
>
Tool Offset (Program name) Screen TOOL OFFSET Program 1 Original Program : 2 Range: 3 Start line:(not 4 End line:(not 5 New Program : 6 Insert line:(not
JOINT
]
Use shifted up,down arrows for next page
TYPE
MIRROR IMAGE SHIFT G1 Shift amount/Teach Position data X :******** Y :********
G1
used) used) used)
Tool Offset (Utool number) Screen JOINT [TEST1 WHOLE ***** ***** [TEST4 *****
10% 5/6 ]
TOOL OFFSET UTOOL number 1 2 3
G1
Old UTOOL number: New UTOOL number: Convert type:
JOINT
10% 1/3
0 0 TCP fixed
]
Use shifted up,down arrows for next page
TYPE
>
[TYPE]
Tool offset CLEAR
CLEAR >
703
EXECUTE
> [CHOICE]
>
APPENDIX
B--81464EN--3/01
Figure A--7. [ UTILITIES ] Uframe Offset (Uframe number) Screen
Uframe Offset (Program name) Screen UFRAME OFFSET Program 1 Original Program : 2 Range: 3 Start line:(not 4 End line:(not 5 New Program : 6 Insert line:(not
G1
used) used) used)
JOINT [TEST1 WHOLE ***** ***** [TEST4 *****
10% 5/6 ]
UFRAME OFFSET UFRAME number 1 2 3
G1
JOINT
Old UFRAME number: New UFRAME number: Convert Position data (Y/N):
10% 1/3 0 0 NO
]
Use shifted up,down arrows for next page
TYPE
>
Frame offset
> [CHOICE]
>
>
Angle Entry Shift (Program name) Screen ANGLE ENTRY SHIFT Program 1 Original Program : 2 Range: 3 Start line:(not 4 End line:(not 5 New Program : 6 Insert line:(not
G1
used) used) used)
JOINT [TEST1 WHOLE ***** ***** [TEST6 *****
Angle Entry Shift (Shift amount) Screen 10% 5/6 ]
]
Use shifted up,down arrows for next page
TYPE
>
Angle entry
ANGLE ENTRY SHIFT G1 Shift amount Position data of P1 X :******** Y :******** 1 2 3 4 5 6 7
>
Angle Entry Shift (Rotation axis direct entry) Screen ANGLE ENTRY SHIFT G1 JOINT 10% Shift amount 1/4 Rotation center axis direct entry 1 Frame: WORLD\FRAME\ 2 X (mm): 100.00 3 Y (mm): 0.00 4 Z (mm): 0.00
EXECUTE
[CHOICE]
>
[CHOICE]
>
704
JOINT
10% 1/7
Z :********
Rotation plane
P1: P2: P3:
Rotation axis enable: Rotation axis Angle(deg): Repeating times:
FALSE P0: Not used 0.00 1
[TYPE] CLEAR
CLEAR
CLEAR
EXECUTE
CLEAR
CLEAR
[TYPE]
[TYPE]
EXECUTE
REFER
RECORD > >
APPENDIX
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Figure A--8. [ 1 UTILITIES ] OnTheFly screen
Posture conv screen
UTZLITIES On The Fly Command
G1
JOINT
30 %
FEED BACK
0.0 Volt 0.0 Volt 0.0 Amps 0.0 Amps 0.0 cm/m 0.0 1800.0 ROBOT CM/MIN Group:1 [ TYPE ]
Equip:1
WEAV
INCR
NOT SAVING DECR
SAVE
POSTURE CONVERSION G1 JOINT 30 % Program: 1/14 Group :[1] 1 Original Program: [MAIN ] 2 Range: PART 3 Start line: 5 4 End line: 10 5 Create/Replace: CREATE 6 New Program: [MAIN1 ] 7 Insert line: (not used) ***** Corner smoothing function 8 Corner smoothing: ENABLE 9 Number of add. points: 1
> [ TYPE ] PLANE
EXECUTE
Posture Conv
Datum Plane Setup screen (horizontal plane) POSTURE CONVERSION G1 Reference plane Group :[1] 1 Reference Plane Teach:
[ type ]
Datum Plane Setup screen (teaching plane) POSTURE CONVERSION G1 Reference plane Group :[1] 1 Reference Plane Teach: 2 P1: 3 P2: 4 P3:
JGFRM VFINE 1/1 HORIZON
[ TYPE ] CLEAR
[CHOICE]
Datum Plane Setup screen (torch posture) POSTURE CONVERSION G1 Reference plane Group :[1] 1 Reference Plane Teach: 2 Adjust posture :
[ TYPE ] CLEAR
REFER
JGFRM VFINE 1/4 3POINTS
[CHOICE] RECORD
Path adjust screen POSTURE PATH ADJUS G2 Program: Group : [1] 1 Original Program: 2 Range: 3 Start line: 4 End line: Adjustment Values 5 Stick out: 6 Travel angle: 7 Work angle:
JGFRM VFINE 1/2 AJUSTE\
[ TYPE ] REVERSE EXECUTE
[CHOICE] RECORD
Path adjust
705
GROUP
JOINT
10 % 1/7
[MAIN PART 5 10
]
0.00mm 0.00deg 0.00deg
APPENDIX
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Figure A--9. [ 2 TEST CYCLE ] Test cycle screen TEST CYCLE
JOINT 30% 2/7
GROUP:1 1 Robot lock: 2 Dry run: 3 Cart. dry run speed: 4 Joint dry run speed: 5 Digital/Analog I/O: 6 Step statement type: 7 Step path node:
TYPE
OFF OFF 300.000mm/s 25.000% ENABLE STATEMENT OFF
ON
OFF
Test cycle
Figure A--10. [ 4 ALARM ] Alarm Screen
Alarm history screen
INTP-224 (SAMPLE1, 6) Jnmp label is fail Alarm : Active
30% 1/1 MEMO-027 Specified line does not exist
TYPE
JOINT
INTP-224 (SAMPLE1, 7) Jump label is fail MEMO-027 Spedified line does not exist Alarm JOINT 30 % 1/7 1 INTP-224 (SAMPLE1, 7) Jump label is 2 SRVO-002 Teach pendant E-stop 3 R E S E T 4 SRVO-027 Robot not mastered(Group:1) 5 SYST-026 System normal power up
[TYPE]
HIST
CLEAR
HELP
Alarm Log
Alarm detail screen INTP-224 (SAMPLE1, 7) Jump label is fail INTP-224 (SAMPLE1, 7) Jump label is fail MEMO-027 Specified line does not exist 30-MAY-44 07:15 STOP.L 00000110 Alarm 1/7 1 INTP-224 (SAMPLE1, 7) Jump label is 2 SRVO-002 Teach pendant E-stop 3 R E S E T 4 SRVO-027 Robot not mastered(Group:1) 5 SYST-026 System normal power up [TYPE] CLEAR HELP
706
APPENDIX
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Figure A--11. [ 5 I / O ] Digital input screen
Digital output configuration screen
I/O Digital In
SDI[ SDI[ SDI[ SDI[ SDI[ SDI[ SDI[ SDI[ SDI[ TYPE
JOINT 30%
# SIM STATUS 1] U ON [ 2] U OFF [ 3] U OFF [ 4] U ON [ 5] U ON [ 6] U OFF [ 7] U OFF [ 8] U ON [ 9] U ON [ CONFIG
] ] ] ] ] ] ] ] ] IN/OUT
ON
I/O Digital In # RANGE RACK 1 SDO[ 1- 20] 0 2 SDO[ 21-512] 0
[TYPE]
OFF
MONITOR
IN/OUT
JOINT 10% START PT 21 ACTIV 0 UNASG
SLOT 1 0
DETAIL
HELP >
Digital
Group output screen
Group output configuration screen
I/O Group Out # SIM VALUE GO[ 1] S 1 [ GO[ 2] U 10 [ GO[ 3] U 23 [ GO[ 4] * * [ GO[ 5] * * [ GO[ 6] * * [ GO[ 7] * * [ GO[ 8] * * [ GO[ 9] * * [ GO[ 10] * * [
JOINT
30%
] ] ] ] ] ] ] ] ] ]
I/O Group Out GO # RACK SLOT 1 0 2 2 0 2 3 0 2 4 * * 5 * * 6 * * 7 * * 8 * * 9 * *
[TYPE] TYPE Group
CONFIG
DETAIL
HELP >
Analog input configuration screen
I/O Analog In # SIM VALUE AI[ 1] S 85 [ AI[ 2] U 0 [ AI[ 3] * * [ AI[ 4] * * [ AI[ 5] * * [ AI[ 6] * * [ AI[ 7] * * [ AI[ 8] * * [ AI[ 9] * * [ AI[ 10] * * [ CONFIG
IN/OUT
JOINT 30% NUM PTS 4 4 8 * * * * * *
IN/OUT SIMULATE UNSIM
Analog input screen
TYPE
MONITOR
START PT 17 21 25 * * * * * *
JOINT 30% 1/25 ] ] ] ] ] ] ] ] ] ]
I/O Analog In AI # 1 2 3 4 5 6 7 8 9 [TYPE]
IN/OUT SIMULATE UNSIM
Analog
707
RACK 0 0 * * * * * * *
JOINT 30% 1/25 SLOT 1 1 * * * * * * *
MONITOR
CHANNEL 1 2 * * * * * * * IN/OUT
DETAIL
HELP >
APPENDIX
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Figure A--12. [ 5 I / O ] Robot data output screen
Robot output detail screen
I/O Robot Out # RDO[ RDO[ RDO[ RDO[ RDO[ RDO[ RDO[ RDO[ RDO[
1] 2] 3] 4] 5] 6] 7] 8] 9]
TYPE
JOINT 30% STATUS OFF [ OFF [ OFF [ ON [ ON [ OFF [ OFF [ ON [ OFF [
DETAIL
SAMPLE I/O Robot Out Port Detail
] ] ] ] ] ] ] ] ]
IN/OUT
ON
LINE 0 JOINT
Robot Dig. Output
[
10 % 1/3
1]
1 Comment: [ 2
]
Polarity: NORMAL
3 Complementary: FALSE[
OFF
[ TYPE ] PRV-PT
1 -
2]
NXT-PT
Robot
Peripheral device data input screen I/O UOP In # STATUS UI[ 1] ON UI[ 2] OFF UI[ 3] OFF UI[ 4] ON UI[ 5] ON UI[ 6] OFF UI[ 7] OFF UI[ 8] ON UI[ 9] * UI[ 10] * TYPE
CONFIG
System Operation Panel Output Screen JOINT
[ [ [ [ [ [ [ [ [ [
30%
I/O SOP # SO[ SO[ SO[ SO[ SO[ SO[ SO[ SO[ SO[ SO[
] ] ] ] ] ] ] ] ] ]
IN/OUT
ON
OFF
TYPE
Out STATUS 0] OFF 1] OFF 2] OFF 3] OFF 4] OFF 5] OFF 6] OFF 7] ON 8] OFF 9] OFF
G1
JOINT
[Remote LED [Cycle start [Hold [Fault LED [Batt alarm [User LED#1 [User LED#2 [TP enabled [ [ IN/OUT
ON
10% 1/15
] ] ] ] ] ] ] ] ] ] OFF
UOP
SOP
DI--to--DO connection setting screen (RDI-->SDO)
DI--to--DO connection setting screen (SDI-->RDO)
I/O INTER CONNECT NO. 1 2 3 4 5 6 7 8 9
Enb/Disabl INPUT DISABLE RI[ 1] DISABLE RI[ 2] DISABLE RI[ 3] DISABLE RI[ 4] DISABLE RI[ 5] DISABLE RI[ 6] DISABLE 1 RDI->SDO RI[ 7] DISABLE 2 SDI->RDO RI[ 8] DISABLE 3 SDI->SDO RI[ 9]
TYPE DI->DO Conect
IN/OUT
I/O INTER CONNECT
JOINT 30%
-> -> -> -> -> -> -> -> ->
ENABLE
NO. 1 2 3 4 5 6 7 8 9
OUTPUT SDO[ 0] SDO[ 0] SDO[ 0] SDO[ 0] SDO[ 0] SDO[ 0] SDO[ 0] SDO[ 0] SDO[ 0]
Enb/Disabl INPUT DISABLE SDI[ 0] DISABLE SDI[ 0] DISABLE SDI[ 0] DISABLE SDI[ 0] DISABLE SDI[ 0] DISABLE SDI[ 0] DISABLE 1 RDI->SDO SDI[ 0] DISABLE 2 SDI->RDO SDI[ 0] DISABLE 3 SDI->SDO SDI[ 0]
TYPE
DISABLE
DI->DO Conect
708
JOINT 30%
IN/OUT
-> -> -> -> -> -> -> -> ->
ENABLE
OUTPUT RDO[ 1] RDO[ 2] RDO[ 3] RDO[ 4] RDO[ 5] RDO[ 6] RDO[ 7] RDO[ 8] RDO[ 9] DISABLE
APPENDIX
B--81464EN--3/01
Figure A--13. [ 5 I / O ] DI--to--DO connection setting screen (DI-->DO)
I/O Link Device List Screen
INTER CONNECT
I/O Link Device
No. 1 2 3 4 5 6 7 8 9
JOINT
10% 1/24 OUTPUT DO [ 1] DO [ 0] DO [ 0] DO [ 0] DO [ 0] DO [ 0] DO [ 0] DO [ 0] DO [ 0]
Enb/Disabl INPUT DISABLE DI [ 0] -> DISABLE DI [ 0] -> DISABLE DI [ 0] -> DISABLE DI [ 0] -> DISABLE DI [ 0] -> DISABLE DI [ 0] -> DISABLE [ 0] -> 1DI RDI->SDO DISABLE [ 0] -> 2DI SDI->RDO DISABLE [ 0] -> 3DI SDI->SDO
TYPE
[SELECT]
ENABLE
Device Name 1 PrcI/O CA 2 Model A 3 Model B 4 Model C
DISABLE
G1
JOINT
10% 1/4 RackSlot ] 0 1 ] 1 0 ] 2 0 ] 3 0
Comment [ [ [ [
TYPE
DETAIL
CLR_ASG
Link Device
DI->DO Conect
I/O Link Device (Model B) List Screen I/O Link Device G1 Model B Slot Base Exp. 1 ******* ******* [ 2 ******* ******* [ 3 ******* ******* [ 4 ******* ******* [
[TYPE]
I/O Link Device (I/O Points Setup) Screen
JOINT
10% 1/30
I/O Link Device
Comment
JOINT
90-30 PLC Port Name Digital Input: Digital Output:
] ] ] ]
LIST
G1
CLR_ASG
[TYPE]
10% 1/2
Points 0 0
LIST
CLR_ASG
Figure A--14. [ 5 I / O ] Weld IN screen
Weld OUT screen
I/O Weld In
1 2 3 4 5 6 7 8
WELD SIGNAL [Voltage [Current
10 % 1/12 TYPE # SIM STATUS ] AI[ 1] U 0.0 ] AI[ 2] U 0.0
[ [Arc detect [Gas fault [Wire fault [Water fault [Power fault [ [
] ] ] ] ] ] ] ]
[ TUPE ]
Inter Conect
HELP
G1
WI[ WI[ WI[ WI[ WI[ WI[ WI[ WI[
I/O Weld Out
JOINT
1] 2] 3] 4] 5] 6] 7] 8]
U U U U U U U U
G1
WELD SIGNAL [Voltage [Current [Wire inch
OFF OFF OFF OFF OFF OFF OFF OFF
1 2 3 4 5 6 7
Link Device
709
TYPE # SIM ] AO[ 1] U ] AO[ 2] U ] AO[ 2] U
[Arc ] [Gas fault ] [ ] [Inch forward ] [Inch backward ] [Wire stick alarm] [Feed forward ] [Feed backward ]
[ TUPE ]
IN/OUT SIMULATE UNSIM >
HELP
JOINT
WO[ WO[ WO[ WO[ WO[ WO[ WO[ WO[
1] 2] 3] 4] 5] 6] 7] 8]
U U U U U U U U
10 % 1/11 STATUS 0.0 0.0 0.0 OFF OFF OFF OFF OFF OFF OFF OFF
IN/OUT SIMULATE UNSIM >
APPENDIX
B--81464EN--3/01
Figure A--15. [ 6 SETUP ] General item setting screen
Tool frame entry screen
SETUP General 1 2 3 4
JOINT
Break on hold: Current language: Ignore Offset command: Ignore Tool_offset:
10% 1/4
DISABLED DEFAULT DISABLED DISABLED
SETUP Frames JOINT 30% Tool Frame Setup/ Direct Entry 1/5 X 1: 2: 3: 4: 5:
0.0 0.0 0.0 0.0 0.0
Y 0.0 0.0 0.0 0.0 0.0
Z 140.5 200.0 0.0 0.0 0.0
Comment ************* ************* ************* ************* *************
1 Tool Frame 2 Jog Frame 3 User Frame TYPE
ENABLED DISABLED
TYPE
General
CLEAR
SETIND
Tool frame setup screen (Six Point Method)
SETUP Frames JOINT 30% Tool Frame Setup/ Three Point 3/4 Frame Number: 3 X: 0.0 Y: 0.0 Z: 0.0 W: 0.0 P: 0.0 R: 0.0 Comment: REF FRM Approach point 1: RECORDED Approach point 2: UNINIT Approach point 3: UNINIT 1 Three Point 2 Six Point 3 Direct Entry METHOD
FRAME
MOVE_TO
RECORD
Tool frame setup screen (Direct Entry Method)
METHOD
SETUP Frames JOINT 30% Tool Frame Setup/ Six Point 4/7 Frame Numer: 3 X: 100.0 Y: 0.0 Z: 300.0 W: 0.0 P: 0.0 R: 0.0 Comment:******************** Approach point 1: RECORDED Approach point 2: RECORDED Approach point 3: RECORDED Orient1 Origin Point: UNINIT Three Point X Direction Point: UNINIT 2 Six Point Z Direction Point: 3 Direct Entry UNINIT [TYPE]
METHOD
FRAME
MOVE_TO
RECORD
User frame entry screen
SETUP Frames JOINT 30 % Tool Frame Setup/ Direct Entry 3/7 Frame Number: 3 1 Comment:******************** 2 X: 0.000 3 Y: 0.000 4 Z: 200.000 5 W: 0.000 6 P: 0.000 7 R: 0.000 1 Three Point Configur N D B, 0, , 0 2 Six Point 3 Direct Entry [TYPE]
OTHER
Frames
Tool frame setup screen (Three Point Method)
[TYPE]
DETAIL
SETUP Frames JOINT 30 % User Frame Setup/ Three Point 1/5 X Y 1: 1243.6 0.0 2: 1243.6 525.2 3: 1243.6-525.2 4: 0.0 0.0 5: 0.0 0.0
Frames
710
Comment REF FRM ************* ************* ************* *************
1 Tool Frame 2 Jog Frame 3 User Frame TYPE
FRAME
Z 43.8 43.8 43.8 0.0 0.0
DETAIL
OTHER
CLEAR
SETIND
APPENDIX
B--81464EN--3/01
Figure A--16. [ 6 SETUP ] User frame setup screen (Three Point Method)
User frame setup screen (Four Point Method)
SETUP Frames JOINT 30% User Frame Setup/ Three Point 3/4 Frame Number: 1 X: 1243.6 Y: 0.0 Z: 43.8 W: 0.1 P: 2.3 R: 3.2 Comment:******************** Orient Origin Point: RECORDED X Direction Point: RECORDED Y Direction Point: UNINIT 1 Three Point 2 Four Point 3 Direct Entry
SETUP Frames JOINT 30% User Frame Setup/ Four Point 5/5 Frame Number: 1 X: 1243.6 Y: 0.0 Z: 10.0 W: 0.1 P: 2.3 R: 3.2 Comment: REF FRM Orient Origin Point: USED X Direction Point: USED Y Direction Point: USED System Origin: USED 1 Three Point 2 Four Point 3 Direct Entry
[TYPE]
[TYPE]
METHOD
FRAME
MOVE_TO
RECORD
Jog frame entry screen
1 Tool Frame 2 Jog Frame 3 User Frame DETAIL
OTHER
CLEAR
REF POSN Enb/Dsbl ENABLE DISABLE DISABLE
TYPE
MOVE_TO
RECORD
[TYPE]
SETIND
DETAIL
Comment [ REFPOS1 [ REFPOS2 [ REFPOS3
ENABLE
METHOD
FRAME
MOVE_TO
RECORD
Reference position setting screen JOINT 30%
@Pos TRUE FALSE FALSE
SETUP Frames JOINT 30% Jog Frame Setup / Direct Entry 2/7 Frame Number: 1 1 Comment: WORK AREA 1 2 X: 1243.600 3 Y: 0.000 4 Z: 10.000 5 W: 0.123 6 P: 2.340 7 R: 3.200 8 1Configuration: Three Point 2 Direct Entry
Reference position selection screen
No. 1 2 3
FRAME
Jog frame setup screen (Direct Entry Method)
SETUP Frames JOINT 30% Jog Frame Setup / Three Point 2/5 X Y Z Comment 1: 1243.6 0.0 0.0 WORK AREA 1 2: 1003.0 525.2 60.0 WORK AREA 2 3: 1003.0 236.0 90.0 WORK AREA 3 4: 0.0 0.0 0.0 ************* 5: 0.0 0.0 0.0 *************
[TYPE]
METHOD
] ] ]
DISABLE
Ref Position
711
REF POSN JOINT 30% Reference Position 1/12 Ref.Position Number 1 Comment [ REFPOS1 ] 2 Enable/Disable ENABLE 3 Signal definition: DO[ 0] 4 J1 129.000 +/2.000 5 J2 -31.560 +/2.000 6 J3 3.320 +/2.000 7 J4 179.240 +/2.000 8 J5 1.620 +/2.000 9 J6 33.000 +/2.000 [TYPE]
RECORD
APPENDIX
B--81464EN--3/01
Figure A--17. [ 6 SETUP ] RSR Setup Screen
PNS setting screen
RSR/PNS 1 2 3 4 5 6 7 8
G1
10% 7/8 RSR or PNS [RSR] RSR1 program number [ENABLE ] [ 12] RSR2 program number [ENABLE ] [ 21] RSR3 program number [ENABLE ] [ 33] RSR4 program number [ENABLE ] [ 49] Base number [ 100] Acknowledge function [TRUE ] Acknowledge pulse width(msec) [ 400]
TYPE
JOINT
TRUE
FALSE
RSR/PNS 1 2 3
JOINT 30% 1/3 RSR or PNS [ PNS] Base number [ 100] Acknowledge pulse width(msec) [ 200]
TYPE
RSR/PNS
PNS
RSR
RSR/PNS
Port selection screen SETUP Port Init Connector port 1 PORT
TYPE
Port setting screen
Comment [ Handy file
JOINT 30% 1/3 ]
SETUP Port Init JOINT 30% PORT 1/3 1 Device [ Handy file ] 2 Speed (Baud rate) [ 9600 ] 3 Parity bit [ None ] 4 Stop bit [ 2bits] 5 Time out value (sec) [ 0 ]
[TYPE]
DETAIL
LIST
[CHOICE]
Port Init
External override setting screen
Macro instruction setting screen
OVERRIDE SELECT
JOINT 30%
1
Function Enable:ENABLE
2 3
Signal1: Signal2:
4 5 6 7
Signal1 OFF OFF ON ON
TYPE
DI[ 1][ ON] DI[ 32][OFF] Signal2 OFF ON OFF ON
Override 15% 30% 65% 100% ENABLE
DISABLE
Macro Command Instruction name 1 [ Open hand1 2 [ Close hand1 3 [ Relax hand1 4 [ Open hand2 5 [ Close hand2 6 [ Relax hand2 7 [ 8 [ 9 [
TYPE Macro
Ovrd Select
712
CLEAR
] ] ] ] ] ] ] ] ]
Program [HOPN1 [HCLS1 [HRLX1 [ [ [ [ [ [
] ] ] ] ] ] ] ] ]
JOINT 30% Assign1/20 MF [ 1] MF [ 2] MF [ 3] MF [11] MF [12] MF [13] [ ] [ ] [ ]
APPENDIX
B--81464EN--3/01
Figure A--18. [ 6 SETUP ] User alarm setting screen Setting/User Alarm Alarm No. [1]: [2]: [3]: [4]: [5]: [6]: [7]: [8]: [9]:
JOINT
30% 1/10
User Message [ [ [ [ [ [ [ [ [
] ] ] ] ] ] ] ] ]
TYPE User Alarm
Stroke Limit Setup Screen
Rectangular Space Check Schedule List Screen
Stroke limit setup GROUP :1 No. LOWER >-180.0 1: 0.0 deg 2: 0.0 deg 3: 0.0 deg Default 0: -180.0 deg
G1
JOINT
10% 1/4
Rectangular Space G1 JOINT 10% LIST SCREEN 1/3 No.Enb/Dsbl Comment Usage 1 ENABLE [ ]Common Space 2 DISABLE[ ]Common Space 3 DISABLE[ ]Common Space
AXIS :J1 UPPER < 180.0 0.0 deg 0.0 deg 0.0 deg 180.0
deg
Active limit: $MRR_GRP[1].$SLMT_J1_NUM = 0 TYPE
GROUP#
AXIS#
TYPE
Stroke limit
Rectangular Space DETAILED SCREEN
DISABLE
G1
JOINT
10% 1/6
Rectangular Space Check Space Definition Screen Rec SPACE SETUP
SPACE :1 GROUP :1 USAGE : Common Space
SPACE :1
Enable/Disable: ENABLE Comment: [**********] Output Signal: DO [ 0] Input Signal: DI [ 0] Priority: High inside/outside: Inside
[TYPE]
ENABLE
Space fnct.
Rectangular Space Check Schedule Detail Screen
1 2 3 4 5 6
DETAIL
SPACE
ENABLE
1 2 3 4
DISABLE
713
UFRAME :0 : BASIS VERTEX :X 0.0 mm :Y 0.0 mm :Z 0.0 mm
[TYPE]
OTHER
G1
JOINT
10% 1/4
GROUP :1 UTOOL :1 [SIDE LENGTH 0.0 mm 0.0 mm 0.0 mm
]
RECORD
APPENDIX
B--81464EN--3/01
Figure A--19. [ 6 SETUP ] Program Monitoring screen Program monitor
1 2
TYPE
CH Prog. WORKDROP HANDCHCK
SYSTEM
System Monitoring screen G1
Status Running Paused
RESTART
JOINT
10% 1/2
Program SAMPLE1 SAMPLE2
PAUSE
System
1 2
END
CH Prog. WORKDROP HANDCHCK
[TYPE]
Condition
714
monitor
PROGRAM
G1
JOINT
10% 1/2
Status Running
START
END
APPENDIX
B--81464EN--3/01
Figure A--20. [ 6 SETUP ] Weld Equip screen SETUP Weld Equip Welder:
Weld System screen G2
JOINT
10 % 1/12
DAIDEN 200UR Fe0.8
Process: MIG Feeder: *************** 1 2 3 4 5
Wire feed speed units: WIRE+ WIRE- speed: Feed forward/backward: Wire stick reset: Wire stick reset tries:
cm/min 50 cm/min DISABLED ENABLED 3
Timing: 6 7 8 9 10 11 12
Arc Arc Arc Gas Gas Gas Gas
[ TYPE ]
start error time: detect time: loss error time: detect time: purge time: preflow time: postflow time:
2.00 .06 1.00 .05 .35 .30 .30
sec sec sec sec sec sec sec HELP
SETUP Weld System
G2
JOINT
NAME Monitoring Functions 1 Arc loss: 2 Gas shortage: 3 Wire shortage: 4 Wire stick: 5 Power supply failure: 6 Coolant shortage: Weld Restart Function 7 Return to path: 8 Overlap distance: 9 Return to path speed: Scratch Start Function 10 Scratch start: 11 Distance: 12 Return to start speed: Weld Speed Function 13 Default speed: 14 Default unit: Other Functions 15 On-The-Fly: 16 Weld from teach pendant: 17 Runin: 18 Wire burnback retract:
10 % 1/18
WALUE ENABLED DISABLED DISABLED ENABLED ENABLED DISABLED ENABLED 0 mm 200 mm/s ENABLED 10 mm 100 mm/s 100 cm/min ENABLED ENABLED DISABLED DISABLED
RSR/PNS [ TYPE ]
ENABLED DISABLED
RSR/PNS
Weave screen SETUP Weave 1 2 3 4 5 6 7 8 9 10
Dwell delay type: Frame type: Elevation: Azimuth: Center rise: Radius: Blend weave end: Peak output port DO: Peak output pulse: Peak output shift:
[ TYPE ] Macro
715
G2
JOINT
10 % 10/10
Move Tool&Path 0 deg 0 deg 0.0 mm 0.0 mm YES 0 .10 sec 0.00 sec HELP
APPENDIX
B--81464EN--3/01
Figure A--21. [ 7 FILE ]
File screen FILE
JOINT 30% 1/14
1 * * (all 2 * KL (all 3 * CF (all 4 * TX (all 5 * LS (all 6 * DT (all 7 * PC (all 8 * MN (all 9 * TP (all 10 * VR (all Press DIR to generate [TYPE] [ DIR ] LOAD
DELETE
COPY
files) KAREL source) command files) text files) KAREL listings) KAREL data files) KAREL p-code) MN programs) TP programs) variable files) directory [BACKUP] [UTIL ]>
DISPLAY
>
Figure A--22. [ 1 SELECT ]
Program selection screen
Program registration screen
JOINT 30% 58740bytes free 3/5 No. Program name Comment 1 SAMPLE1 [SAMPLEPROGRAM1 ] 2 SAMPLE2 [SAMPLEPROGRAM2 ] 3 SAMPLE3 [SAMPLEPROGRAM3 ] 4 PROG001 [PROGRAM001 ] 5 PROG002 [PROGRAM002 ] 1 comment 2 Protection 3 Last modifie 4 Size 5 Copy Sourse
JOINT 30%
Select
[TYPE]
CREATE
DELETE
COPY
DETAIL
LOAD
MONITOR SAVE
ATTR > PRINT>
Program information screen Program detail
30% 1/6 Creation Date: 10-MAR-1994 Modification Date: 11-MAR-1994 Copy Source: [****************] Positions: FALSE Size: 312 Byte 1 Program name: [SAMPLE3 ] 2 Sub Type: [ None] 3 Comment: [SAMPLE PROGRAM 3] 4 Group Mask: [1,*,*,*,*] 5 Write protect: [ OFF] 6 Ignore pause: [ OFF] END
PREV
JOINT
NEXT
716
1 Words 2 Upper Case 3 Lower Case 4 Options Select
---Insert---
---Create Teach Pendant Program--Program Name [SAMPLE3 ] Sub type [Jobs ] ---End--Select function DETAIL EDIT
APPENDIX
B--81464EN--3/01
Figure A--23. [ 2 EDIT ] Program edit screen
Program edit screen/control instruction selection screen
SAMPLE1 1: J 2: J 3: L 4: L 5: J [End]
Instruction 1 Registers 2 I/O 3 IF/SELECT 4 WAIT PROGRAM1
JOINT 30% 1/6 P[1] P[2] P[3] P[4] P[1]
100% FINE 70% CNT50 1000cm/min CNT301 Insert 500mm/sec FINE 2 Delete 100% FINE 3 Copy 4 Find 5 Replace 6 Renumber
[INST]
5 6 7 8
JOINT 30% JMP/LBL CALL Palletizing --next page-3/4
3: L P[3] 500mm/sec CNT10 [End]
EDCMD
POINT
[INST]
TOUCHUP
[EDCMD]
Figure A--24. [ 3 DATA ]
Register screen DATA Registers R[ R[ R[ R[ R[ R[ R[ R[ R[
JOINT 30% 1/32
1: 2: 3: 4: 5: 6: 7: 8: 9:
]=0 ]=5 ]=12 ]=50000 ]=0 ]=0 ]=0 ]=0 ]=0
TYPE Registers
Position register screen
Position register screen/position data information screen
DATA Position Reg PR[ 1:REF PR[ 2:REF PR[ 3:REF PR[ 4:REF PR[ 5: PR[ 6: PR[ 7: PR[ 8: PR[ 9: PR[ 10: TYPE
POS POS POS POS
1 2 3 4
JOINT 30% 1/10 ]=* ]=* ]=* ]=* ]=* ]=* ]=* ]=* ]=* ]=* RECORD POSITION
Position Detail PR[1] UF:F UT:1 X: 1500.374 mm W: Y: -342.992 mm P: Z: 956.895 mm R: DATA Position Reg
JOINT 30% CONF:N 00 40.000 deg 10.000 deg 20.000 deg 1/10
PR [ 1:ZERO POS PR [ 2: PR [ 3: PR [ 4: PR [ 5: Enter value
] ] ] ] ] CONFIG
CLEAR
Position Reg
717
= = = = =
R R R R R
DONE
[REPRE]
APPENDIX
B--81464EN--3/01
Figure A--25. [ 3 DATA ] Weld Sched screen
Weld Sched Detail screen
DATA Weld Sched
1 2 3 4 5 6 7 8 9
Volts 20.0 20.0 20.0 20.0 20.0 20.0 20.0 20.0 20.0
[ TYPE ] [ TYPE Weld Sched]
G2
10 1/32 cm/min COMMENT 50 Weld Schedule 50 Weld Schedule 50 Weld Schedule 50 Weld Schedule 50 Weld Schedule 50 Weld Schedule 50 Weld Schedule 50 Weld Schedule 50 Weld Schedule
Amps 210.0 210.0 210.0 210.0 210.0 210.0 210.0 210.0 210.0 DETAIL COPY
JOINT
ADVISE
%
DATA Weld Sched
1 2 3 4 5 6 7 8 9
1 2 3 4 5
HELP >
CLEAR
>
Weld Sched Advice screen DATA Weld Advise
1 2 3 4 5
Butt Butt Butt Butt Butt
[ TYPE ]
: : : : :
T= T= T= T= T=
DETAIL
Weld Schedule: 1 Command Voltage Command Current Travel speed Delay Time Feedback Voltage Feedback Current
COPY
10 % 1/5
[WELD schedulel ] 20.0 Volts 210.0 Amps 50 cm/min 0.00 sec 19.5 Volts 20.0 Amps
[ TYPE ]SCHEDULE ADVISE [ TYPE ]
JOINT
HELP >
CLEAR
>
Weave Sched screen G2
1.2 2.0 3.2 0.5 6.0
G2
R=0.9 R=0.5 R=1.0 R=1.2 R=1.0
JOINT
10 % 1/20
W=0.9 W=1.0 W=1.2 W=1.2 W=1.6
SELECT
HELP
DATA Weave Sched
10 % 4/10 FREQ(Hz) AMP(mm) R_DW(sec) L_DW(sec) 1 1.0 4.0 .100 .100 2 1.0 4.0 .100 .100 3 1.0 4.0 .100 .100 4 1.0 4.0 .100 .100 5 1.0 4.0 .100 .100 6 1.0 4.0 .100 .100 7 1.0 4.0 .100 .100 8 1.0 4.0 .100 .100 9 1.0 4.0 .100 .100
[ TYPE ]
G2
DETAIL
JOINT
HELP >
Weld Sched
Weave Sched Detail screen DATA TAST Sched
Track Sched screen G2
JOINT
10 % 4/5
1 2 3 4 5 6 7 8 9
Weave Schedule: 4 1 2 3 4 5
Frequency: Amplitude: Right dwell: Left dwell: L pattern angle:
[ TYPE ]SCHEDULE
1.5 1.0 .150 .150 90.0
DATA TAST Sched
Hz mm sec sec deg
HELP >
V-Gain-L V_Cur(A) 30.0 20.0 0.0 30.0 20.0 0.0 30.0 20.0 0.0 30.0 20.0 0.0 30.0 20.0 0.0 30.0 20.0 0.0 30.0 20.0 0.0 30.0 20.0 0.0 30.0 20.0 0.0
[ TYPE ] [ TYPE Track Sched]
718
G2
DETAIL COPY
JOINT
10 % 1/20 V-Bias(%)-L 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 HELP >
CLEAR
>
APPENDIX
B--81464EN--3/01
Figure A--26. [ 3 DATA ] Process Sched screen
Track Sched Detail screen DATA TAST Sched
G2
JOINT
10 % 1/29
DATA Weld Process
TAST Schedule: [ 1] 1 2 3 4
1 2 3 4
TAST Schedule: [ Schedule 1 ] V_compensation enable: TRUE L_compensation enable: TRUE V_master current type: FEEDBK (feedback constant) 5 Sampling timing (no WV): .50 sec 6 Comp frame (no WV): TOOL 7 V_compensation gain: 25.0 (sensitivity) 8 V_dead band: 0.0 mm 9 V_bias rate (up+): 0.0 % 10 V_tracking limit: 600.0 mm 11 V_tracking limit per cycle:1.0 mm 12 V_compensation start count:5 cyc 13 V_master sampling start: 4 cyc count (feedback) 14 V_master sampling count: 1 cyc (feedback) 15 V_master current constant: 0.0 A data (constant) 16 L_compensation gain: 20.0 (sensitivity) 17 L_dead band: 0.0 mm 18 L_bias rate (right+): 0.0 % 19 L_tracking limit: 600.0 mm 20 L_tracking limit per cycle:1.0 mm 21 L_compensation start count:5 cyc 22 Motion group number: 1 23 Adjust delay time: .136 sec -- Adaptive gain control -24 V_AG_correction count: 0 cyc (0:disable) 25 L_AG_correction count: 0 cyc (0:disable) 26 V_AG_correction band: 4.0 27 L_AG_correction band: 4.0 28 V_AG_multiplier: 1.5 29 L_AG_multiplier: 1.5 [ TYPE ] [ TYPE Weld Sched]
SCHEDULE COPY
[ TYPE ]
JOINT
10 % 1/4
Amps cm/min 210.0 0 0.0 0 0.0 0 1.0 1
DETAIL
HELP >
Process Sched Detail screen DATA Weld Process
Schedule: 1 [ 1 2 3 4
Command Voltage Command Current Travel speed Delay Time
[ TYPE ]SCHEDULE
HELP > CLEAR
Volts 2.0 0.0 20.0 .5
G1
>
719
G1
JOINT
10 % 3/4
] 2.0 210.0 0 0.00
Volts Amps cm/min sec
HELP >
APPENDIX
B--81464EN--3/01
Figure A--27. [ 4 STATUS ] Robot axis status screen (Status 1 screen) STATUS Axis
J1: J2: J3: J4:
JOINT 30%
Flag Bits1/2 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000
TYPE
Robot axis status screen (Torque monitor screen)
STATUS1
GRP[1] History (0000000000000000) (0000000000000000) (0000000000000000) (0000000000000000) (0000000000000000) (0000000000000000) (0000000000000000) (0000000000000000)
STATUS2
PULSE
[ UTIL ]
STATUS Axis
J1: J2: J3: J4: J5:
JOINT 30%
GRP[1] Torque Monitor Ave. / Max. Inpos OT VRDY 0.000/ 0.000 1 0 OFF 0.000/ 0.000 1 0 OFF 0.000/ 0.000 1 0 OFF 0.000/ 0.000 1 0 OFF 0.000/ 0.000 1 0 OFF
[TYPE]
MONITOR
TRACKING DISTURB [ UTIL ]
Axis
Software version screen (Software version screen) STATUS Version ID 1 2 3 4 5 6 7 8 9 10
JOINT
10%
FANUC ARC TOOL 7D80/01 S/W serial No. 9024000 Controller ID F00000 Default personality (from FD) M6iB-NORM-ZBK 7D80/81 Servo Code V11.005 Cart. MOT. Parameter V3.00 Joint. Mot. Parameter V3.00 Software Edition No. V610P/01 Boot Monitor V6.10/01 TYPE
SOFTWARE
CONFIG
MOTOR
SERVO
Software version screen (Motor ID screen) STATUS Version ID JOINT 30% GR: AX: MOTOR ID & INFO: 1/16 1 1 1 ACA22/2000 80A H1 DSP1-L 2 1 2 ACAM30/3000HV 80A H2 DSP1-M 3 1 3 ACA22/2000 80A H3 DSP2-L 4 1 4 ACAM9/3000 40A H4 DSP2-M 5 1 5 ACAM6/3000 40A H5 DSP3-L 6 1 6 ACAM6/3000 40A H6 DSP3-M 7 2 1 ACA6/3000 80A H DSP 8 ** ** *************************** 9 ** ** *************************** 10 ** ** *************************** [TYPE] SOFTWARE
CONFIG
MOTOR
SERVO
Version ID
Program Timer Detail Screen
Program Timer List Screen PRG TIMER LISTING
1 2 3 4 5 6 7 8 9
Timer[ Timer[ Timer[ Timer[ Timer[ Timer[ Timer[ Timer[ Timer[
TYPE
1] 2] 3] 4] 5] 6] 7] 8] 9]
G1 count 0.00(s)[ 0.00(s)[ 0.00(s)[ 0.00(s)[ 0.00(s)[ 0.00(s)[ 0.00(s)[ 0.00(s)[ 0.00(s)[
JOINT 10% 1/10 comment ] ] ] ] ] ] ] ] ]
PRG TIMER DETAIL
Timer[ 1] Comment Count Start program Line Stop program Line
[TYPE]
DETAIL
Prg Timer
720
LISTING
G1
JOINT
:[*************] : 4.01(sec) :[ : :[ :
TEST2] 12 TEST2] 34
10% 1/1
APPENDIX
B--81464EN--3/01
Figure A--28. [ 4 STATUS ] Safety Signal Status Screen
System Timer Screen SYS TIMER
G1
JOINT
GROUP : 1 Timer type Total(h) On Power time: 12.3 Servo on time: 4.5 Running time: 2.3 Waiting time: 1.2
TYPE
GROUP#
ON/OFF
10% 1/4
STATUS Safety SIGNAL NAME 1 2 3 4 5 6 7 8 9
Lap(m) 0.0[OFF] 0.0[OFF] 0.0[OFF] 0.0[OFF]
RESET
SOP E-Stop: TP E-Stop: Ext E-Stop: Fence Open: TP Deadman: TP Enable: Hand Broken: Overtravel: Low Air Alarm:
JOINT 10% STATUS 1/11 FALSE FALSE FALSE FALSE FALSE TRUE FALSE FALSE FALSE
TYPE
Sys Timer
Safety Signl
Memory status list screen
Execution history screen Execution history
1 2 3 4 5
G1
Program name PNS0001 PNS0001 PNS0001 PNS0001 PNS0001
JOINT VFINE 1/6 Line. Dirc. Stat. 3 FWD Done 6 BWD Paused 7 FWD Paused 6 FWD Done 5 FWD Done
TYPE
STATUS Memory Pools TPP CMOS PERM CMOS TEMP DRAM
JOINT 10 % Total Available ---------------------550.0 KB 540.8 KB 999.8 KB 363.5 KB 1726.9 KB 1207.7 KB
Description: TPP: Used by .MN, .MR, .JB, .PR PERM: Used by .VR, RD:, Options TEMP: Used by .PC, .VR, Options
CLEAR
Exec-hist TYPE Memory
Memory status detail screen STATUS Memory JOINT 10 % Total Free Lrgst Free Pools ----------------------------TPP 550.0 KB 529.2 KB 529.2 KB PERM 999.8 KB 367.1 KB 367.1 KB SYSTEM 1010.4 KB 59.2 KB 59.2 KB IMAGE 255.9 KB 76.9 KB 76.5 KB TEMP 1726.9 KB 1175.4 KB 1172.6 KB Hardware ----------------------------FROM 16.0 MB DRAM 16.0 MB CMOS 1.0 MB [TYPE]
BASIC
HELP
721
DETAIL
HELP
APPENDIX
B--81464EN--3/01
Figure A--29. [ 4 STATUS ] Weld screen STATUS Weld
G2
COMMAND 20.0 Volts 210.0 Amps 0.0 cm/min
Arc enable: Arc detect: Arc on time [ TYPE ]
JOINT
10 %
FEEDBACK 19.5 Volts 200.0 Amps ******
OFF OFF 0: 0: 0 H:M:S
RESET
HELP
Weld
Figure A--30. [ 5 POSITION ] Current position screen (Joint coordinates) POSITION Joint
J1: J4:
[ TYPE ]
G1
0.000 J2: 0.000 J5:
JNT
JOINT 10 % TOOL: 1
0.000 J3: 0.000 J6:
USER
Current position screen (User coordinates) POSITION Joint
J1: J4:
0.000 0.000
[ TYPE ]
WORLD
Position
722
G1
0.000 J2: 0.000 J5:
JNT
JOINT 10 % TOOL: 1
0.000 J3: 0.000 J6:
USER
WORLD
0.000 0.000
APPENDIX
B--81464EN--3/01
Figure A--31. [ 6 SYSTEM ] System clock screen
System variable screen
SYSTEM Clock Clock Display
G1
JOINT
DATE
99/06/15
TIME
10:50:44
Please select function [ TYPE ]
10 %
1 2 3 4 5 6 7 8 9 10
JOINT
10 % 1/357
150 0 [5] of STRING[21] [5] of INTEGER [9] of REAL [5] of STRING[21] 2 TRUE [5] of APCOUPLED_T [32] of APCUREQ_T
Variables
Overtravel Release screen
Positioning screen SYSTEM Master/Cal
G1
JOINT 10 % TORQUE = [ON ]
FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE Press ’ENTER’ or number key to select.
[ TYPE ]
$ACC_MAXLMT $ACC_MINLMT $AC_CRC_ID $AC_CRC_SET $ANGTOL $APPLICATION $AP_ACTIVE $AP_CHGAPONL $AP_COUPLED $AP_CUREQ
G1
[ TYPE ]
ADJUST
Clock
1 2 3 4 5 6
SYSTEM Variables
LOAD
RES_PCA
MANUAL OT RELEASE AXIS 1 2 3 4 5 6 7 8 9
OT MINUS FALSE FALSE FALSE FALSE FALSE FALSE FALSE FALSE FALSE
[ TYPE ] RELEASE
DONE
OT Release
Master/Cal
723
G1
JOINT 10 % 1/9 OT PLUS FALSE FALSE FALSE FALSE FALSE FALSE FALSE FALSE FALSE
APPENDIX
B--81464EN--3/01
System configuration screen
Joint operating area setting screen SYSTEM Axis Limits G1 AXIS GROUP LOWER 1 2 3 4 5 6 7 8 9
1 1 1 1 1 1 2 2 0
-165.00 -78.00 -170.00 -200.00 -140.00 -450.00 -190.00 -270.00 0.00
System Config
JOINT 10 % UPPER 1/16 165.00 162.00 285.00 200.00 140.00 450.00 190.00 270.00 0.00
1 2 3
dg dg dg dg dg dg dg dg mm
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
[ TYPE ] Axis Limits
10 % 1/38 Use HOT START: FALSE I/O power fail recovery:RECOVER ALL Autoexec program [********] for Cold start: Autoexec program [********] for Hot start: HOT START done signal: DO[ 0] Restore selected program: TRUE Enable UI signals: TRUE START for CONTINUE only: FALSE CSTOPI for ABORT: FALSE Abort all programs by CSTOPI: FALSE PROD_START depend on PNSTROBE:FALSE Detect FAULT_RESET signal: FALL Use PPABN signal: <*GROUPS*> WAIT timeout: 30.00 sec RECEIVE timeout: 30.00 sec Retun to top of program: TRUE Original program name(F1): [program] Original program name(F2): [main ] Original program name(F3): [sub ] Original program name(F4): [test ] Original program name(F5): [*******] Default logical command: <*DETAIL*> Maximum of ACC instruction: 150 Minimum of ACC instruction: 0 WINT for default motion: ***** Auto display of alarm menu: FALSE Force Message: ENABLE Reset CHAIN FAZLURE detection: FALSE Allow Force I/O in AUTO mode: TRUE Allow chg. oyrd. in AUTO mode: TRUE Signal to set in AUTO mode Dout [0] Signal to set in T1 mode Dout [0] Signal to set in T2 mode Dout [0] Signal to set if E-STOP Dout [0] Hand broken: <*GROUPS*> Remote/Local setup: Remote External I/O (ON:Remote): DI[0] VOP auto assignment: Foll
[ TYPE ]
724
G1
JOINT
TRUE
FALSE
APPENDIX
B--81464EN--3/01
A.3 List of Program Instructions Figure A--32. Motion (option) instruction Motion instructions J
P[]
L
PR [ ]*2
( feedrate )
FINE CNT ( value )
C Additional motion instruction Wjnt
Wrist joint motion instruction
ACC (value)
Acceleration/deceleration override instruction
Skip, LBL[ ]*3
Skip instruction
Offset*3
Offset instruction
Offset, PR[ ]*2*3
Direct offset condition instruction
Tool_offset*3
Tool offset instruction
Tool_offset, PR[ ]*2*3
Direct tool offset instruction
INC*4
Incremental instruction
SOFT FLOAT[ ]*5
Soft float instruction
Ind. EV (value) %*6
Independent EV instruction
EV (value) %*6
Simultaneous EV instruction
PTH
Path instruction
CTV (VALUE)*7
Continuous turn statement
TIME BEFORE (VALUE) CALL (SUB PRG)*8
Time before statement
Arc Start [ ] *1
Arc start instraction
Arc End [ ] *1
Arc end instraction
725
APPENDIX
B--81464EN--3/01
Figure A--33. Program instruction menu Program instruction menu 1 Register
Program instruction format R[]=
R [ ] ....
Program instruction Register instruction
Const PR [i,j]*2
DI / O [ ] RI / O [ ] GI / O [ ] AI / O [ ]*9 WI/O [ ]*1
2I/O
PR [ ]*2 = ....
Position register instruction
DO [ ] = ....
I/O instruction
RO [ ] = .... GO [ ] = ... AO [ ]*9= .... WO [ ]*1= ...
3 IF / SELECT
IF
R [ ] = ....
Comparison
I / O [ ] = .... $Parameter = SELECT R [ ] = ....
4 WAIT
Selection condition instruction
WAIT (time) WAIT
Time wait instruction R [ ] = ....
Conditional wait instruction
I / O [ ] = .... $ 5 JMP / LBL
6 CALL / END
LBL [ ]
Label instruction
JMP LBL [ ]
Jump instruction
CALL ( Program )
Program call instruction
END
Program end instruction
726
APPENDIX
B--81464EN--3/01
Figure A--34. Program instruction menu Program instruction menu 7 Arc*1
8 Program Control
9 Miscellaneous
Program instruction format
Program instruction
Arc Start [ ]
Arc start instruction
Arc End [ ]
Arc ebd instruction
PAUSE
Halt instruction
ABORT
Abort instruction
RSR [ ] = ...
RSR statement
UALM [ ]
User alarm instruction
TIMER [ ]
Timer instruction
OVERRIDE
Override instruction
Remark
Comment instruction
Message [ ]
Message instruction
$ (Parameter) =
Parameter instruction
10 Skip*3
SKIP CONDITION
11 Offset*1
OFFSET CONDITION PR [ ] *2= ....
12 Tool_Offset*3
I/O [ ] = ....
15 SENSOR
16 LOCK PREG*2 17 SOFTFLOAT*5
18 MONITOR /MON.END
Offset condition instruction
UFRAME [ ] = ....
User frame setup instruction
UFRAME_NUM = ....
User frame selection instruction
UTOOL [ ] = ....
Tool frame setup instruction
UTOOL_NUM = ....
Tool frame selection instruction
TOOL_OFFSET CONDITION PR [ ] *2= ....
Tool offset condition instruction
13 MACRO*3 14 Multiple control
Skip condition instruction
Macro instruction RUN (PRG)
Run program statement
SEMAPHORE [ ]=....
Semaphore statement
WAIT SEMAPHORE [ ]=....
Wait semaphore statement
SEND R[]
Send register statement
RCV R[], LBL[]
Receive register statement
LOCK PREG
Position register lock instruction
UNLOCK PREG
Position register unlock instruction
SOFTFLOAT [ ]
Soft float start instruction
SOFT FLOAT END
Soft float end instruction
FOLLOW UP MONITOR
Follow--up instruction Monitor start statement
MONITOR END
Monitor end statement
727
APPENDIX
B--81464EN--3/01
Program instruction menu
Program instruction format
Program instruction
19 Independent GP*12
Independent GP
Independent motion group statement
20 Simultaneous GP*12
Simultaneous GP
Simultaneous motion group statement
21 Weave*13
Weave (Pattern) [ ]
Weaving start command
Weaving End
Weaving end command
Track
21 Track*14*15
TAST [ ]*14
Arc sensor command
AVC [ ]*15
AVC command
End*14*15
Tracking end command
Option The items indicated by * (numeral) in Figure A--32 to A--35 are displayed when the corresponding option is added, as indicated below: Table A--3.
Option list
*
Option
Specification
1
Arc tool
A05B--****--J500
2
Position register
A05B--****--J514
3
Option command
A05B--****--J503
4
Incremental input
A05B--****--J510
5
Softfloat
A05B--****--J612
6
Extended axis control
A05B--****--J518
7
Continuous turn
A05B--****--J613
8
Condition monitor function
A05B--****--J628
9
Analog I/O
A05B--****--H550
10
Multi task
A05B--****--J600
11
Sensor interface
A05B--****--J502
12
Multi motion group
A05B--****--J601
13
Weaving
A05B--****--J504
14
Arc sensor
A05B--****--J511
15
AUC
A05B--****--J526
16
Torque limit function
A05B--****--J611
17
Coordinated control
A05B--****--J619
728
APPENDIX
B--81464EN--3/01
A.4 Program Instructions A.4.1 Motion instructions Table A--4. Motion format
Position variable
Feedrate unit
Motion instructions J
Enables robot operation for each joint with interpolation.
L
Moves the robot tool linearly.
C
Enables the tool tip of the robot to make a circular motion.
P[ i : Comment ]
Standard variable for storing position data.
PR[ i : Comment ]
Register for storing position data. i: 1 -- 10
%
Specify the rate of a feedrate to the highest feedrate of the robot.
mm/sec, cm/min, inch/min, Specifies the speed with which the tool tip makes a linear or deg/sec circular motion. Positioning path
sec
Specify the time required during a motion.
FINE
The robot stops at the specified position and starts the next motion.
CNTn n (0 -- 100):
The robot moves gradually from the specified position to the position at!which the next motion starts.!Degree of gradual motion. The higher the specified number, the more gradual the robot moves.
A.4.2 Additional motion instructions Table A--5.
Additional motion instructions
Wrist joint motion
Wjnt
On a linear or arc motion, the wrist axis moves with a joint motion, and the joint coordinates vary.
Acceleration/deceleration override
ACC a
Sets the rate of acceleration/deceleration when moving.
Skip
Skip, LBL[ ]
Causes a branch to the specified label when the condition specified in a skip condition instruction is not satisfied. When the condition is satisfied, cancels the motion and executes the next line.
Positional offset
Offset
Makes the robot move to the position where the value specified by the offset condition instruction is added to the positional variable.
Offset,PR[i:comment]
Makes the robot move to the position where the value specified by the offset condition instruction and the value of position register are added to the positional variable.
Tool_offset
Moves the robot to the position corresponding to the value specified by the tool offset instruction, added to the position variable.
Tool_offset,PR[(GPk:)i]
Moves the robot to the position corresponding to the position register value, added to the position variable.
Incremental
INC
Makes the robot move to the position where the value of the position variable is added to the current position.
Soft float
SOFT FLOAT[i]
Enables the soft float function.
Independent EV
Ind.EV(i)% i = 1 to 100 (%)
Moves the extended axis, independently of the robot motion.
Simultaneous EV
EV(value)% i = 1 to 100 (%)
Moves the extended axis, synchronized with the robot.
Path
PTH
Creates a motion plan, using the rate attainable in continuous operation.
Tool offset
a=0 to 500(%)
729
APPENDIX
B--81464EN--3/01
Table A--5. (Cont’d) Additional motion instructions Continuous turn
CTV i i = --100 to 100(%)
Start the execution of continuous turn.
Before execution
TIME BEFORE t CALL TIME AFTER t CALL
Before or after the specified end time, call a sub program and execute one. t=Excecution start time. =Name of sub program.
J
P[ ]
m
PR[ ]
%
FINE
ACC n
sec
CNTn
Skip, LBL [ ] Offset (,PR[ ] ) TOOL_offset (,PR[ ] ) INC SOFT FLOAT [ ] Ind.EV i % EV i % PTH CTV i TIME BEFORE t sec, CALL SUB PRG NAME TIME AFTER t sec, CALL SUB PRG NAME
L
P[ ]
m
PR[ ]
mm/sec
FINE
Wjnt
cm/min
CNTn
ACC n
inch/min
Skip, LBL [ ]
deg/sec
Offset (,PR[ ] )
sec
TOOL_offset (,PR[ ] ) INC SOFT FLOAT [ ] Ind.EV i % EV i % PTH CTV i TIME BEFORE t sec, CALL SUB PRG NAME TIME AFTER t sec, CALL SUB PRG NAME
C
P[ ]
P[ ]
PR[ ]
PR[ ]
......
Example
730
1: 2: : 3: 4: : 5:
J P[1] 100% FINE L P[2:LINE] 500mm/sec CNT100 Wjnt Offset, PR[1] L P[3] 3.5sec CNT100 INC L P[4] 100cm/min FINE Wjnt Skip,LBL[100] C P[5] P[6] 300mm/sec CNT50
APPENDIX
B--81464EN--3/01
A.4.3 Register and I/O instructions Table A--6.
Register and I/O instructions
Register
R[ i ] i: 1 to 32
i: Register number.
Position register
PR[(GPk:) i ]
Fetches a position data element. k: GPR group number. k: 1 to 3
PR[(GPk:) i , j ]
i: Position register number. i: 1 to 10 j: Number of an element in a position register. j: 1 to 9 .
P[ i :comment ]
i: Position number. i: 1 to memory limit
Lpos
Cartesian coordinates of the current position
Jpos
Joint coordinates of the current position
UFRAME [ i ]
User coordinate system
UTOOL [ i ]
Tool coordinate system
SDI[ i ], SDO[ i ]
System digital signals
RDI[ i ], RDO[ i ]
Robot digital signals
GI[ i ], GO[ i ]
Gourp signals
AI[ i ], AO[ i ]
Analog signals
Position data
Input/output signal
R[ ]
=
Constant
+
Constant
+
R[ ]
--
R[ ]
--
PR [ i, j ]
*
PR [ i, j ]
*
SDI / O [ ]
/
SDI / O [ ]
/
RDI / O [ ]
DIV
RDI / O [ ]
DIV
GI / O [ ]
MOD
AI / O [ ]
SI/O [ ]
SI/O [ ]
UI/O [ ]
UI/O [ ]
TIMER [ ]
TIMER [ ]
TIMER_
TIMER_
OVERFLOW [ ]
OVERFLOW [ ]
Example
PR [ ]
=
MOD
GI / O [ ]
AI / O [ ]
...
1: R[1] = RI[3] 2: R[3] = DI[4]*PR[1,2] 3: R[4] = AI[1]
PR [ ]
+
PR [ ]
+
PR [ ]
Lpos
--
P[]
--
P[]
Jpos
Lpos
Lpos
UFRAME [ ]
Jpos
Jpos
UTOOL [ ]
Example
731
1: 2: 3: 4:
PR[1] PR[3] PR[8] PR[9]
= = = =
PR[6] PR[4]+Lpos UFRAME[1] UTOOL[2]
...
APPENDIX
B--81464EN--3/01
PR [ i, j ]
=
Constant
+
Constant
+
R[ ]
--
R[ ]
--
PR [ i, j ]
*
PR [ i, j ]
*
SDI / O [ ]
/
SDI / O [ ]
/
RDI / O [ ]
MOD
RDI / O [ ]
MOD
GI / O [ ]
DIV
AI / O [ ]
SI/O [ ]
SI/O [ ]
UI/O [ ]
UI/O [ ]
WI/O [ ]
WI/O [ ]
TIMER [ ]
TIMER [ ]
TIMER_
TIMER_
OVERFLOW [ ] SDO [ ] SRO [ ]
=
DIV
GI / O [ ]
AI / O [ ]
OVERFLOW [ ]
ON
GO [ ]
OFF
AO [ ]
=
R[ ]
R[ ] Pulse ( , width ) Example
732
1: 2: 3: 4: 5:
SDO[1] RDO[3:] RDO[4] GO[9] AO[10]
= = = = =
Constant
ON PULSE,1.0sec R[1] R[2:control] 12.5
...
APPENDIX
B--81464EN--3/01
A.4.4 Conditional branch instructions Table A--7.
Conditional branch instructions
Comparison condition
IF ( condition ) ( branch )
Specifies a comparison condition and an instruction or program to which the program branches to. You can link (Conditions) by using operators.
Selection condition
SELECT R[ i ] = ( value ) ( branch )
Specifies a selection condition and an instruction or program to which the program branches to.
IF
R[ ]
>
Constant
$Parameter
>=
R[]
GO [ ]
=
AO [ ]
<=
GI [ ]
<
AI [ ]
<>
SDO [ ]
=
ON
RDO [ ]
<>
OFF
SDI [ ]
R[ ]
RDI [ ]
SDO [ ]
SO [ ]
RDO [ ]
UO [ ]
SDI [ ]
SI [ ]
RDI [ ]
UI [ ]
SO [ ]
WI [ ]
UO [ ]
WO [ ]
SI [ ]
,
JMP LBL [ ] CALL ( Program name )
UI [ ] WI [ ] WO [ ] PR [ ]
SELECT R [ ]
=
PR [ ]
<>
[ i, j, k ]
= ( condition )
,
JMP CALL
Others Example
1: IF R[2] >= R[3],LBL[1:HANDOPEN] 2: IF DI[2] = ON,CALL SUBPROGRAM
Example
3: SELECT R[2] = 1,JMP LBL[1] 4: = 2,JMP LBL[2] 5: = 3,JMP LBL[3] 6: ELSE,CALL MAINPROG
733
APPENDIX
B--81464EN--3/01
A.4.5 Wait instruction Table A--8.
Wait instruction WAIT < condition > WAIT < time >
Wait
WAIT
Waits until the specified condition is satisfied or until the specified time has elapsed. You can link (Conditions) by using operators.
R[ ]
>
Constant
$Parameter
>=
R[]
GO [ ]
=
AO [ ]
<=
GI [ ]
<
AI [ ]
<>
SDO [ ]
=
On
RDO [ ]
<>
Off
SDI [ ]
R[ ]
RDI [ ]
On+
SO [ ]
Off--
UO [ ]
SDO [ ]
SI [ ]
RDO [ ]
UI [ ]
SDI [ ]
WI [ ]
RDI [ ]
WO [ ]
SO [ ]
(,TIMEOUT LBL [ ])
UO [ ] SI [ ] UI [ ] WI [ ] WO [ ] ERR_NUM
=
Constant
Constant sec Example
1: WAIT RDI[1] = ON 2: WAIT 10.5sec 3: WAIT R[2],TIMEOUT,LBL[1]
A.4.6 Unconditional branch instructions Table A--9. Label
Unconditional branch instructions LBL [i : COMMENT]
Specifies the instruction which the program branches to.
JMP LBL[ i ]
Causes a branch to the specified label.
Program call
CALL (program--name)
Causes a branch to the specified program.
Program end
END
Ends the program and returns control to the calling program.
JMP LBL[ ] CALL (Program name) LBL[ ] Example
734
1: 2: 3: 4:
LBL[1: HANDCLOSE] JMP LBL[2] CALL SAMPLE1 CALL PRG2: LBL[1]
APPENDIX
B--81464EN--3/01
A.4.7 Program control instructions Table A--10.
Program control instructions
Halt
PAUSE
Halts a program.
Abort
ABORT
Aborts a program.
Example
1: PAUSE 2: ABORT
A.4.8 Other instructions Table A--11.
Other instructions
RSR
RSR[ i ]
Enables or disables RSR signals (i = 1 to 4).
User alarm
UALM[ i ]
Displays a user alarm on the alarm line.
Timer
TIMER[ i ]
Sets the timer.
Override
OVERRIDE
Sets override.
Comment
!(comment)
Inserts a comment in a program.
Message
MESSAGE [message--text] Displays a user message on a user screen.
Parameter
$(system variable name)
Changes the value of a system variable.
Maximum speed
JOINT_MAX_SPEED [ ] LINEAR_MAX_SPEED
Sets the maximum speed for operation statements in the program.
RSR [ ]
=
ENABLE DISABLE
TIMER [ ]
=
START STOP RESET
OVERRIDE = m% $(system variable name)
=
Constant R[ ] PR [ ]
R[ ]
=
$ (Parameter)
PR [ ] JOINT_MAX_SPEED [ ]
=
Constant R[ ]
LINEAR_MAX_SPEED [ ] =
Constant R[ ] Example
735
3: 4: 5: 6: 7: 8: 9: 10: 11:
OVERRIDE = 50% $NRM_TURN = 1 $NRM_TURN = 1 RSR[2] = ENABLE UALM [3:no work] ! STEP 2 START TIMER[1] = START MESSAGE [STEP1 EXECUTION] $NRM_TURN = 1
APPENDIX
B--81464EN--3/01
A.4.9 Skip and Offset condition instruction Table A--12.
Skip and Offset condition instruction
Skip condition
SKIP CONDITION (condition)
Specifies the skip execution condition for an additional motion instruction. You can link (Conditions) by using operators.
Offset condition
OFFSET CONDITION (offset amount)
Specifies the amount of offset used by the motion instruction.
Tool offset condition
TOOL_OFFSET CONDITION (offset amount)
Specifies the amount of tool offset used by the motion instruction.
SKIP CONDITION
R[ ]
>
Constant
$Parameter
>=
R[]
GO [ ]
=
AO [ ]
<=
GI [ ]
<
AI [ ]
<>
SDO [ ]
=
On
RDO [ ]
<>
Off
SDI [ ]
R[ ]
RDI [ ]
On+
SO [ ]
Off--
UO [ ]
SDO [ ]
SI [ ]
RDO [ ]
UI [ ]
SDI [ ]
WI [ ]
RDI [ ]
WO [ ]
SO [ ] UO [ ] SI [ ] UI [ ] WI [ ] WO [ ]
ERR_NUM
=
Constant
OFFSET CONDITION PR[ ] (, UFRAME[ ] ) TOOL OFFSET CONDITION PR[ ] (, UTOOL[ ]) Example
736
1: 2: 3: 4:
SKIP CONDITION SDI[1] = ON SKIP CONDITION RDI[2] <> DI[3] OFFSET CONDITION PR[1],UFRAME[1] TOOL OFFSET CONDITION PR[2],UTOOL[1]
APPENDIX
B--81464EN--3/01
A.4.10 Frame setup instruction Table A--13.
Frame setup instruction
User frame
UFRAME[i]
User frame i=1 to 9
User frame selection
UFRAME_NUM
The number of current user frame.
Tool frame
UTOOL[ ]
Tool frame. i=1 to 9
Tool frame selection
UTOOL_NUM
The number of current tool frame
=
UFRAME[ ] UTOOL[ ]
P[ ] PR[ ]
=
UFRAME_NUM UTOOL_NUM
Constant R[ ] Example
1: UFRAME[1] = P[12] 2: UTOOL[3]=PR[1] 3: UFRAME_NUM=3
A.4.11 Macro instruction Table A--14. Macro
Macro instruction (macro--instruction)
Executes a program defined on the macro instruction setting screen.
Example
1: HAND1 OPEN 2: HAND2 CLOSE
A.4.12 Multiaxis control instructions Table A--15.
Multiaxis Control Instructions
Program execution
RUN
Starts execution of a specified program in another motion group.
Semaphore variable
SEMAPHORE[i]
Defines a semaphore variable (i = 1 to 32). If the semaphore is off, other tasks cannot be executed.
SEMAPHORE [ ] =
On Off
WAIT SEMAPHORE [ ]
(,TIMEOUT LBL [ ])
RUN (Program Name) Example
737
PROGRAM 1 1: SEMAPHORE[1] = OFF 2: RUN PRG2 3: J P[1] 100% FINE 4: J P[2] 100% FINE 5: WAIT SEMAPHORE[1]
PROGRAM 2 1: J P[3] 100% FINE 2: J P[4] 100% FINE 3: J P[5] 100% FINE 4: J P[6] 100% FINE 5: SEMAPHORE[1] = ON
Group Mask[1,*,*,*,*]
Group Mask[*,1,*,*,*]
APPENDIX
B--81464EN--3/01
A.4.13 Position register look--ahead execution instruction Table A--16.
Position register look--ahead execution instruction
Position register lock
LOCK PREG
Locks a position register to prevent the register contents from being changed.
Position register unlock
UNLOCK PREG
Unlocks a position register. Example
1: 2: 3: 4: 5: 6: 7: 8: 9: 10:
J P[1] 100% FINE PR[1] = PR[2] PR[2] = PR[3] LOCK PREG L P[2] 100mm/sec CNT100 L P[3] 100mm/sec CNT100 L PR[1] 100mm/sec CNT100 L P[4] 100mm/sec CNT100 OFFSET PR[2] L P[5] 100mm/sec FINE UNLOCK PREG
A.4.14 Soft float instruction Table A--17.
Soft float instruction
Soft float start
SOFTFLOAT[ i ]
Enables the soft float function.
Soft float end
SOFTFLOAT END
Disables the soft float function.
Follow--up
FOLLOW UP
Assumes the current robot position to be the taught position (follow--up) when the soft float function is used. Example
1: 2: 3: 4: 5: 6:
J P[1] 100% FINE SOFTFLOAT[1] L P[2] 100mm/sec FINE FOLLOWUP L P[3] 100mm/sec FINE SOFTFLOAT END
A.4.15 Status monitoring instructions Table A--18.
Status Monitoring Instructions
Status monitoring start instruction
MONITOR
Starts monitoring under the conditions specified in the condition program.
Status monitoring end instruction
MONITOR END
Ends monitoring under the conditions specified in the condition program.
Example
1: MONITOR WRKFALL 2: J P[1] 100% FINE . . . 8: J P[7] 100% FINE 9: MONITOR END WRKFALL 10: OPEN HAND
A.4.16 Motion group instructions Table A--19.
Motion Group Instructions
Independent motion group Independent GP
Enables motion groups to operate independently of each other.
Simultaneous motion group
Enables motion groups to operate simultaneously with the motion group that requires the longest travel time.
Simultaneous GP
Example
738
1: : : 2: : :
Independent GP GP1 L P[1] 100% GP2 J P[1] 100% Simultaneous GP GP1 L P[2] 100% CP2 J P[2] 100%
FINE FINE FINE FINE
APPENDIX
B--81464EN--3/01
A.4.17 Arc instruction Table A--20. Arc start instruction
Arc end instruction
Arc instruction Arc Start [ i ]
Starts arc welding. i: Welding condition number 1 to 10
Arc Start [ V, A ]
V: Welding voltage A: Welding current
Arc End [ i ]
Ends arc welding. i: Crater prevention condition number 1 to 10
Arc End [ V, A, s ]
V: Welding voltage A: Welding current s: Processing time Example
Table A--21. Weaving start command
Weaving end
Tracking command
Arc Arc Arc Arc
Start[1] Start[10.0Volts,140Amps] End[R[1]] End[10.0Volts,70.0Amps,0.5s]
Weaving Commands Weave (Pattern) [ i ]
Starts weaving Pattern=Sine, Circle, Figure8 i: weave schedule number i=1 to 10
Weave (Pattern) [ Hz, mm, s1, s2 ]
Hz: Frequency mm: Amplitude s1: Right--end dwell time s2: Left--end dwell time msec
Weave End
Ends weaving. Example
Table A--22.
1: 2: 3: 4:
1: Weave Sine[8] 2: Weave Sine[3.0Hz,2.5mm,1.0ms,1.0ms] 3: Weave End
Tracking Commands Track TAST [ i ]
Starts the arc sensor. i: arc sensor schedule i=1 to 20
Track AVC [ i ]
Starts the AVC. i: AVC schedule i=1 to 20
Track End
Ends tracking.y Example
1: TRACK TAST[1] 2: TRACK AVC[1]
Example
1: : 2: 3: 4: 5: : 6:
739
J P[1] 100% FINE ARC START[1] WEAV SIN[1] TRACK TAST[2] L P[2] 50cm/min CONT.10 L P[3] 50cm/min FINE ARC END[2] WEAV END
APPENDIX
B--81464EN--3/01
B. APPENDIX This appendix summarizes items necessary for using this model. It may also be used as an index. j Contents of this appendix B.1
Start Mode
B.2
Mastering
B.3
Software Version
B.4
Robot Axis States
B.5
Diagnosis Screen
B.6
World Frame Origin
B.7
I/O Module Setting
B.8
Positioner Setup
B.9
Extended Axis Setup
B.10 Independent Additional Axis Board (Nobot) Startup Procedure
740
APPENDIX
B--81464EN--3/01
B.1 Start Mode B.1.1 Start up Methods Robot controller has the following four start up methods(start mode): Initial start When the unit is started in the initial start mode, all programs are deleted, and all settings are reset to their standard values. Upon the completion of the initial start, a controlled start is performed automatically. Controlled start When the unit is started in the controlled start mode, a controlled start menu, which is a simple system, starts up. The controlled start menu cannot be used to operate the robot. The controlled start menu can, however, be used to change a system variable which normally cannot be changed, to read a system file, and to setup the robot. From the menu displayed by pressing the Fctn key on the controlled start menu, a cold start can be made. Cold start The cold start mode is used to perform normal power--up while power restoration is disabled. The program is aborted, and all output signals are turned off. Once the cold start has been completed, the robot can be operated. A cold start can be performed while power restoration is enabled, provided the necessary setting is made at power--up. Hot start The hot start mode is used to perform normal power--up while power restoration is enabled. When the unit starts, the program runs and output signals are restored to the state existing prior to the last power--down. Once the hot start has been completed, the robot can be operated. The cold start or the hot start is started in normal operation. Which mode is used depends on whether the hot start is enabled or disabled. The initial start and the controlled start will be used during maintenance. These modes will not be used in normal operation. Figure B--1. Start mode
Start mode selection
Usual turning on Cold start
Initial start Controlled start
Hot start
System starts
Cold start System starts
B.1.2 Initial start When the unit is started in the initial start mode, all programs are deleted, and all the settings are reset to their standard values. Once the initial start has been completed, a controlled start is performed automatically.
NOTE At an initial start, programs and all data including settings will be lost. The factory--set mastering data is also erased. An initial start should be made only when the main printed circuit board or software is replaced. Before performing an initial start, therefore, make a backup copy of the necessary programs and system files.
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Procedure B--1 Step
F1
Initial start
1 Press and hold the F1 key and F5 key and then turn on the power supply switch on the operator panel. The boot monitor screen is displayed. F5
ON
ON
*** eBOOT MONITOR for R-J3iB CONTROLLER *** Base system version V5.10P/01(FRL) Initializing file device ...done ******* BMON MENU ******* 1. Configuration menu 2. All software installation 3. Init start 4. Controller backup/restore 5. Hardware diagnosis
OFF Selece :
2 Select 3. Init start.
3
INPUT
3 Enter 1 (YES) to the confirmation message of initial start. CAUTION: INIT start is selected Are you SURE? [Y=1 / N=else]
An initial start is performed. Upon the completion of the initial start, a controlled start is performed automatically, and the controlled start menu appears.
B.1.3 Controlled start When the unit is started in the controlled start mode, a controlled start menu, which is a simple system, starts up. The controlled start menu cannot be used to operate the robot. The controlled start menu can, however, be used to change a system variable which normally cannot be changed, to read a system file, and to setup the robot. Press the Fctn key on the controlled start menu. A menu appears. From that menu, select 1 START (COLD). A cold start is performed. The following screens can be displayed from the menu displayed by pressing the MENU key on the controlled start menu: Setting screens Settings can be made. Software install screen Optional software can be added or deleted. System variables screen System variables can be set. Even a system variable which cannot normally be changed (R0) can be changed. On the file screen of the controlled start menu, F4 is displayed as [RESTORE]. When the F4 key is pressed, all files are read automatically. To switch F4 to [BACKUP] as on other file screens, press the Fctn key. A menu appears. From that menu, select RESTORE/BACKUP. File screen A program or system file can be saved and read. The system file can be read only from the controlled start menu. Version ID Screen The software edition is displayed. Alarm history screen The alarm history is displayed.
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Port in:t screen A serial port is set. This screen is used to read a file from a Handy File or the like upon a controlled start. Memory screen The memory status is displayed. MAINTENANCE A robot setting can be changed. An additional axis can be set. A motion group can be added or deleted. Procedure B--2 Step
PREV
Controlled start
1 Press and hold the PREV key and F→ key and then turn on the circuit protector switch on the operator panel . The configuration manu is displayed. F!
System version:V5.1001
08/28/**
----------CONFIGURATION MANU---------ON
1. 2. 3. 4.
Hot start Cold start Controlled start Maintenance
ON
OFF Select>
2 Select 3 CONTROLLED START. The setting screen for the controlled start menu appears.
3
ENTER
Tool Setup
CONTROLLED START MENUS 1/1
FANUC Arc Tool
1 F Number [TYPE]
F00000
3 To operate the robot, a cold start must be performed. To do this, press the Fctn key. A menu appears. From that menu, select 1 START (COLD). A cold start is performed.
Fctn
1 START (COLD)
ENTER
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B.1.4 Cold start The cold start mode is used when normal power--up is performed while power restoration is disabled. Upon a cold start, the following is performed: -- Each output signal of digital I/O, analog I/O, robot I/O, and group I/O is turned off or set to 0. -- The program is aborted, and the beginning of the program becomes the current line. -- The feedrate override is reset to the initial value. -- The manual feed coordinate system enters the JOINT state. -- The machine lock is released. The cold start procedure depends on the power restoration setting. Procedure B--3 Condition Step
Cold start
H Hot start must be set to invalid. 1 Turn on the power to the controller. The following screen is displayed after the system starts by cold start. ON UTILITIES Hints
JOINT
30 %
FUNUC Arc Tool V5,10P01 Copyright 1998 FANUC LTD FANUC Robotics North America,Inc All right Reserved [ TYPE ]
Procedure B--4 Condition Step
HELP
Cold start
H Hot start is set to enable 1 Press and hold the PREV key and F→ key and then turn on the circuit protector switch on the operator panel. The configuration menu is displayed.
PREV
F!
System version:VS.1001
08/28/**
----------CONFIGURATION MANU---------ON
1. 2. 3. 4.
Hot start Cold start Controlled start Maintenance
Select>
UTILITIES Hints
2
ENTER
ON
JOINT
30 %
FUNUC Arc Tool V5,10P01 Copyright **** FANUC LTD FANUC Robotics North America, Inc All right Reserved [ TYPE ]
HELP
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B.1.5 Hot start The hot start mode is used when normal power--up is performed while power restoration is enabled. Upon a hot start, the following is performed: -- Each output signal of digital I/O, analog I/O, robot I/O, and group I/O is set in the same manner as it was prior to the last power--down. -- The program runs in the same way as it did prior to the last power--down. If the program was running up until the last power--down, the program enters the pause state. -- The feedrate override, manual feed coordinate system, and machine lock are set in the same manner as they were prior to the last power--down.
NOTE When a hot start is performed in the following state, each output signal of the digital I/O, analog I/O, robot I/O, and group I/O is turned off or set to 0: -- When the I/O allocation is changed -- When an I/O unit is mounted or removed -- When the number of signals is changed on the I/O Link screen
Procedure B--5 Condition Step
Hot start
H Hot start must be set to enable. 1 Turn on the power to the controller. The screen which was being displayed at power off will be displayed on the screen of the teach pendant after a few seconds.
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B.2 Mastering Mastering associates the angle of each axis of the robot with the pulse count of the absolute pulse coder (APC) connected to the motor of each axis. More specifically, mastering is performed by obtaining the pulse count read at the zero--degree position. The current position of the robot is determined by the pulse counts of the absolute pulse coders (APCs) for the axes. Since mastering data is factory--set, mastering is unnecessary in normal operation. If one of the following events occurs, however, mastering must be performed: F
Mastering data is lost for some reason such as a drop in the voltage of the backup battery for S--RAM in the controller or memory erasing with an initial start.
F
The APC pulse counts are lost for some reason such as a drop in the voltage of the backup battery for APC pulse counts backup in the mechanical unit or exchange of pulse coder.
F
The pulse counts do not indicate the angles of the axes because the mechanical unit was hit, bumped, etc. CAUTION
The robot data including mastering data and the pulse coder data are maintained independently by backup batteries. If the batteries go empty, data is lost. To prevent this, replace both batteries periodically. When the battery voltage drops, an alarm ‘BLAL’ notifies the user.
There are five types of mastering as listed below. Table B--1.
Mastering types
Type of mastering
Explanation
Jig mastering
Mastering is performed using a special jig. Jig mastering is performed at the factory.
Mastering at the zero--degree positions
Mastering is performed with each axis of the robot aligned with the zero--degree position. The zero--degree position mark attached to each axis of the robot is referenced.
Quick mastering
The mastering position can be set at any position. To do this, reference points must be set in advance.
Single axis mastering
Single axis mastering is that the mastering is performed every one axis.
Setting mastering data
Mastering data is set in mastering counters directly.
CAUTION After the robot is installed, the quick mastering reference points must be stored in case the factory--adjusted settings are needed in mastering in the future.
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After mastering, be sure to perform positioning (calibration). Positioning means that the controller reads the current pulse counts and recognizes the current position. Figure B--2. Mastering Mastering table 1 Angle of axis 1 deg
pulse count 144,000 $PARAM_GROUP . $ENCSCALE
Mastering table 2 Angle of axis
pulse count
90 deg
28,600,000
9 deg
16,900,000
Quick mastering
0 deg
15,600,000
Mastering at the zero--degree positions
$DMR_GRP . $MASTER_COUN --90 deg
2,600,000
Jig mastering
The current position of the robot is determined by the following data: F
Pulse count per degree (See mastering table 1.) This value is defined in system variable $PARAM_GROUP.$ENCSCALE.
F
Pulse count at the zero--degree position (See mastering table 2.) This data is stored in $DMR_GRP.$MASTER_COUN by mastering. -- In jig mastering, the pulse count at the jig position is received and converted to mastering data. -- In quick mastering, the pulse count at the quick mastering reference position defined by the user is received and converted to mastering data.
F
Current pulse count. The current pulse count is received from the calibration.
Mastering and calibration are performed on the Master/Cal screen [6 SYSTEM, Master/Cal]. NOTE Mastering by accident may cause the robot to move unexpectedly and it is very dangerous. Therefore, the Master/Cal screen will be displayed only when the system variable, $MASTER_ENB, is set to 1 or 2. Press F5,DONE,which is displayed in the Master/Cal screen after mastering. $MASTER_ENG is automatically set to 0 and then the Master/Cal screen can not be displayed. If you want to display the Master/Cal screen again, set $MASTER_ENB to 1 in the system variable screen again.
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B.2.1 Jig mastering Jig mastering is performed at the factory using a special jig. This mastering is performed at the mastering position set beforehand. With this mastering, accurate mastering can be performed by using the special jig. This mastering is usually unnecessary to perform in normal operation because this is used at shipment. For details of jig mastering, refer to the maintenance manual. Procedure B--6 Condition
Jig mastering
H System variable $MASTER_ENB must be set to 1 or 2. SYSTEM Variables
JOINT 10% 57/136 1
57 $MASTER_ENB
Step
1 Press the MENUS key. The screen menu is displayed. 2 Select “0 ---- NEXT ----” and then select “6 SYSTEM”. 3 Press F1 “TYPE.” The screen change menu is displayed. 4 Select “Master/Cal” on the screen change menu. The positioning screen appears.
9 USER 0 -- NEXT --
SYSTEM Master/Cal 1 2 3 4 5 6
MENUS
5 POSITION 6 SYSTEM 7
JOINT 30%
FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE
Press ’ENTER’ or number key to select. Master/Cal [TYPE]
LOAD RES_PCA
DONE
TYPE
F1 5 Move the robot by jog feed to the mastering position. Release the brake on the manual brake control screen if necessary.
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6 Select “1 FIXTURE POSITION MASTER” and press the F4 key (yes). Mastering data is set. SYSTEM Master/Cal
SYSTEM Master/Cal ENTER
1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER Master at master position? [NO] Master at master position? [NO] [ TYPE ] YES
NO
F4
JOINT
30 %
1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Mastered! Mastering Data: <0> <11808249> <38767856> <9873638> <122000309> <2000319> [ TYPE ] LOAD RES_PCA DONE
7 Select “6 CALIBRATE” and press the F4 key (yes). Calibration is performed. 5 SET QUICK MASTER REF 6 CALIBRATE ENTER Calibrate? [NO] Calibrate? [NO] [ TYPE ]
SYSTEM Master/Cal
YES
NO
F4
JOINT
30 %
1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Calibrated! Cur Jnt Ang(deg): <10.000> <-25.000> <40.000> <5.000> <-15.000> <0.000> [ TYPE ] LOAD RES_PCA DONE
8 Press F5 “DONE”, after mastering. DONE
F5 9 Alternatively, to perform positioning, turn the power off, then turn it on again. Calibration is performed whenever the power is turned on.
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B.2.2 Mastering at the zero--degree positions Mastering at the zero--degree positions is performed for the robot with all its axes at the zero--degree positions. On each axis of the robot, a zero--degree position mark is attached. Using these marks as a reference, move the robot by jog feed to the zero--degree positions for all axes. Mastering at the zero--degree positions cannot be performed as accurately as other types of mastering because it relies on visual alignment. Perform mastering at the zero--degree positions only as an emergency measure. For details of mastering at the zero--degree positions, refer to the maintenance manual. Procedure B--7 Condition Step
Mastering at the zero--degree positions
H System variable $MASTER_ENB must be set to 1 or 2. 1 Press the MENUS key. The screen menu is displayed. 2 Select “0 ---- NEXT ----” and then select “6 SYSTEM”. 3 Press F1,TYPE. The screen change menu is displayed. 4 Select “Master/Cal” on the screen change menu. The Master/Cal screen appears.
9 USER 0 -- NEXT --
SYSTEM Master/Cal 1 2 3 4 5 6
MENUS
5 POSITION 6 SYSTEM 7
JOINT 30%
FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE
Press ’ENTER’ or number key to select. Master/Cal
[TYPE]
LOAD RES_PCA
DONE
TYPE
F1 5 Move the robot by jog feed to the zero--degree positions for all axes. Set brake control to off, if necessary.
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6 Select “2 ZERO POSITION MASTER” and press the F4 key (yes). Mastering data is set. 1 FIXTURE POSITION MASTER ENTER 2 ZERO POSITION MASTER 3 QUICK MASTER Master at zero position? [NO] YES
NO
F4
SYSTEM Master/Cal
JOINT
30 %
1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Mastered! Mastering Data: <0> <11808249> <38767856> <9873638> <122000309> <2000319> [ TYPE ]
LOAD
RES_PCA
DONE
7 Select “6 CALIBRATE” and press the F4 key (yes). Calibration is performed. 5 SET QUICK MASTER REF 6 CALIBRATE ENTER Calibrate? [NO]
YES
SYSTEM Master/Cal
JOINT
30 %
1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Robot Calibrated! Cur Jnt Ang(deg): <0.000> <0.000> <0.000> <0.000> <0.000> <0.000>
NO
F4
[ TYPE ]
LOAD
RES_PCA
DONE
8 Press F5 “DONE”, after mastering. DONE
F5 9 Alternatively, to perform calibration, turn the power off, then turn it on again. Calibration is performed whenever the power is turned on.
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B.2.3 Quick mastering Quick mastering allows mastering at any user--defined position. The pulse counts are calculated from the speed and angular displacement within one rotation of the APCs connected to the motors. Quick mastering uses the fact that the absolute angular displacement within one rotation is not lost. F
If mastering data is lost due to the failure of the backup battery for the pulse coder, quick mastering can be used.
F
When the pulse coder is replaced or when mastering data in the robot controller is lost, quick mastering cannot be used.
To perform simple mastering, a reference point set after mastering is necessary (reference point setting). The reference point is factory--set to the zero position. Figure B--3. Quick Mastering Angle of axis Absolute pulse coder value
9 deg
10 deg
260,000
304,000
1 deg = 144,000
1 rotation = 520,000 16,900,000
Pulse count
Quick mastering uses the fact that the deviation of the angle of the axis from the reference point can accurately be compensated when it is within one rotation of the APC. For details of quick mastering, refer to the maintenance manual. CAUTION If the robot is installed in such a way that the robot cannot be set to the 0° position, which is the reference point of initial simple mastering, the reference point of simple mastering should be stored after the installation. This must be done to store the factory--set mastering setting, providing for future mastering.
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Procedure B--8 Condition
Quick mastering
H System variable $MASTER_ENB must be set to 1 or 2. H Quick mastering reference position (reference position) must be set.
Step
1 Display the Master/Cal screen. SYSTEM Master/Cal 1 2 3 4 5 6
JOINT 30%
FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE
Press ’ENTER’ or number key to select. [TYPE]
LOAD RES_PCA
DONE
2 Jog the robot to the quick mastering position(reference position). If necessary, turn off the brake control. 3 Select “3 QUICK MASTER” and press the F4 key (yes). Mastering data is set. 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER
YES
ENTER
NO
F4 4 Select “6 CALIBRATE” and press the F4 key (yes). Calibration is performed. 5 Press F5 “DONE” after mastering. DONE
F5
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Procedure B--9
Setting reference points for quick mastering (If the robot is installed in such a way that the robot cannot be set to the 0° position)
CAUTION This operation cannot be executed if the mastering data is lost because of mechanical disassembly or maintenance. If that is the case, jig mastering or zero--degree positions mastering should be executed to restore the mastering data.
Condition Step
H System variable $MASTER_ENB must be set to 1 or 2. 1 Select “6 SYSTEM” on the screen menu. 2 Select “Master/Cal” on the screen change menu. The Master/Cal screen appears.
5 POSITION 6 SYSTEM 7
SYSTEM Master/Cal 1 2 3 4 5 6
MENUS
Master/Cal
JOINT 30%
FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE
Press ’ENTER’ or number key to select.
TYPE
[TYPE]
LOAD RES_PCA
DONE
F1 3 Move the robot by jog feed to the quick mastering reference position. Set brake control to off, if necessary. 4 Select “5 SET QUICK MASTER REF” and press the F4 key (yes). The reference points for quick mastering are stored in memory. 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE
YES
ENTER
NO
F4
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B.2.4 Single axis mastering User can select the arbitrary position for the mastering of each axis. Single axis mastering should be used when the mastering data of some axes is lost for some reason such as the drops of the voltage of the backup battery for pulse coder or exchanging of the pulse coder. SINGLE AXIS MASTER
J1 J2 J3 J4 J5 J6 E1 E2 E3
ACTUAL POS 25.255 25.550 -50.000 12.500 31.250 0.000 0.000 0.000 0.000
JOINT
(MSTR POS ) ( 0.000) ( 0.000) ( 0.000) ( 0.000) ( 0.000) ( 0.000) ( 0.000) ( 0.000) ( 0.000)
30 % 1/9 (SEL)[ST] (0) [2] (0) [2] (0) [2] (0) [2] (0) [2] (0) [2] (0) [2] (0) [2] (0) [2]
GROUP
Table B--2
EXEC
Settings for single axis mastering
ITEMS
DESCRIPTIONS
ACTUAL POS
The current position expressed by joint (degree) of the robot is displayed.
MSTR POS
Specifies the mastering position to the axis to be performed the single axis mastering. It is usually specified 0 degree.
SEL
For the axis to be performed mastering,set this item to 1. It is usually 0.
ST
Display the state of completion of the single axis mastering. The value displayed at this item can not be directly changed. The values of $EACHMST_DON[1 to 9] are displayed at this column. -- 0 Specifies that the mastering data has been lost. Single axis mastering needs to be performed. -- 1 The mastering data has been lost.(Only other interactive axes is performed mastering.) This axis need to be mastered. -- 2 The mastering has been completed. Refer to the maintenance manual for an accurate method of single axis mastering.
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Procedure B--10 Single axis mastering Condition Step
H System variable $MASTER_ENBL must be set to 1. 1 Select “6 SYSTEM” on the screen menu. 2 Select “Master/Cal” on the screen change menu. The Master/Cal screen appears.
5 POSITION 6 SYSTEM 7
SYSTEM Master/Cal 1 2 3 4 5 6
MENUS
JOINT 30%
FIXTURE POSITION MASTER ZERO POSITION MASTER QUICK MASTER SINGLE AXIS MASTER SET QUICK MASTER REF CALIBRATE
Master/Cal Press ’ENTER’ or number key to select. TYPE [TYPE]
LOAD RES_PCA
DONE
F1 3 Select “4 SINGLE AXIS MASTER”. The single axis mastering screen is displayed. In a right example, mastering of the J5 and the J6 axis needs to be executed.
SINGLE AXIS MASTER
J1 J2 J3 J4 J5 J6 E1 E2 E3
ACTUAL POS 25.255 25.550 -50.000 12.500 31.250 43.382 0.000 0.000 0.000
JOINT
30 % 1/9 (MSTR POS ) (SEL)[ST] ( 0.000) (0) [2] ( 0.000) (0) [0] ( 0.000) (0) [0] ( 0.000) (0) [2] ( 0.000) (0) [2] ( 0.000) (0) [2] ( 0.000) (0) [2] ( 0.000) (0) [2] ( 0.000) (0) [2] GROUP EXEC
4 Enter 1 to SEL setting field of the axis that you want to master. SEL can be specified for one axis or plural axes simultaneously. R ( (
JOINT 0.000) 0.000)
(0) (0)
30 % 2/9 [0] [0]
SINGLE AXIS MASTER J2 J3
25.550 -50.000
( (
JOINT 0.000) 0.000)
(1) (1)
GROUP
30 % 3/9 [0] [0] EXEC
5 Jog the robot to the mastering position. Turn off the brake control if necessary. 6 Enter the axis data of the mastering position. R ( (
JOINT 0.000) 0.000)
(1) (1)
30 % 2/9 [0] [0]
SINGLE AXIS MASTER J2 J3
25.550 -50.000
( (
JOINT 0.000) 90.000)
(1) (1)
GROUP
756
30 % 3/9 [0] [0] EXEC
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7 Press F5 “EXEC.” The mastering is performed. This operation causes SEL to be set to 0 and ST to be set to 2 or 1. GROUP
EXEC
F5
SINGLE AXIS MASTER
J1 J2 J3 J4 J5 J6 E1 E2 E3
ACTUAL POS 25.255 25.550 -50.000 12.500 0.000 90.000 0.000 0.000 0.000
JOINT
30 % 1/9 (MSTR POS ) (SEL)[ST] ( 0.000) (0) [2] ( 0.000) (0) [2] ( 0.000) (0) [2] ( 0.000) (0) [2] ( 0.000) (0) [2] ( 90.000) (0) [2] ( 0.000) (0) [2] ( 0.000) (0) [2] ( 0.000) (0) [2] GROUP EXEC
8 When the single axis mastering is completed, press the PREV key to display the Master/Cal screen. PREV
SYSTEM Master/Cal
JOINT 30%
1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Press ’ENTER’ or number key to select. [TYPE] LOAD RES_PCA DONE
9 Select “6 CALIBRATE” and press F4 “YES.” The calibration is performed. 10 Press F5 “DONE”, after calibration. DONE
F5
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B.2.5 Setting mastering data Mastering data can be set directly in the system variable. Setting mastering data can be performed when the pulse counts are not changed. F
If C--MOS mastering data is lost for some reason such as an initial start, set the recorded mastering data.
F
Setting mastering data cannot be performed when pulse count data is lost.
Procedure B--11 Directly setting mastering data Step
1 Select “6 SYSTEM” on the screen menu. 2 Select “Variables” on the screen change menu. The system variable screen appears.
5 POSITION 6 SYSTEM 7 MENUS
Variables
SYSTEM Variables 1 2 3 4 5 6
JOINT 10% 1/98
$AP_MAXAX $AP_PLUGGED $AP_TOTALAX $AP_USENUM $AUTOINIT $BLT
536870912 4 16777216 [12] 0f Byte 2 19920216
[TYPE]
TYPE
F1 3 Change mastering data. Mastering data is stored in system variable $DMR_GRP.$MASTER_COUN. 13 $DMR_GRP 14 $ENC_STAT
DMR_GRP_T [2]of ENC_STAT_T
[TYPE]
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4 Select “$DMR_GRP.” DMR_GRP_T [2] of ENC_STAT_T
SYSTEM Variables $DMR_GRP 1 [1]
JOINT 10% 1/1 DMR_GRP_T
ENTER
SYSTEM Variables $DMR_GRP 1 $MASTER_DONE 2 $OT_MINUS 3 $OT_PLUS 4 $MASTER_COUN 5 $REF_DONE 6 $REF_POS 7 $REF_COUNT 8 $BCKLSH_SIGN [ TYPE ]
JOINT
30 % 1/8
FALSE [9]of Boolean [9]of Boolean [9]of Integer FALSE [9]of Real [9]of Integer [9]of Boolean TRUE FALSE
5 Select “$MASTER_COUN” and enter mastering data. [9] of Boolean [9] of integer FALSE
SYSTEM Variables $DMR_GRP[1].$MASTER_COUN 1 [1] 2 [2] 3 [3] 4 [4] 5 [5] 6 [6]
ENTER
JOINT 10% 1/9 95678329 10223045 3020442 304055030 20497709 2039490
[TYPE]
6 Press the PREV key. 7 Set “$MASTER_DONE” to “TRUE.” TRUE
FALSE
F4
SYSTEM Valiables $DMR_GRP[1] 1 $MASTER_DONE 2 $OT_MINUS
JOINT 10% 1/8 TRUE [9]of Boolean
8 Display the Master/Cal screen and select “6 CALIBRATE.” 9 Press F5 “DONE”, after calibration. DONE
F5
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B.3 Software Version Screens related to the software version display identification information of the controller. This information is to be reported to FANUC if a failure occurs in the controller. The following are the screens related to the software version: [TYPE] SOFTWARE
MOT_ID
MOT_INF
SER_PAR
-- F2 “SOFTWARE” : Displays the software version screen. -- F3 “MOT_ID”: Displays the motor ID screen. -- F4 “MOT_INF”: Displays the motor information screen. -- F5 “SER_PAR”: Displays the servo parameter information screen. Software version screen The software version screen displays the following information: STATUS Version ID
1 2 3 4 5 6 7 8 9 10
ITEM: SOFTWARE: FANUC Arc Tool S/W Serial No. Controller ID. M6-1NLN-NORM-BRK[N] Servo Code. Cart. Mot. Parameter Joint Mot. Parameter Boot MONITOR Teach Pendant Software. Edition No.
JOINT
30 % 1/21
V5.1001 9024000 F00000 N/A V01.02 ******* ******* V5.1001 7D01/09I V5.1001
[ TYPE ]SOFTWARE MOT_ID MOT_INF SER_PAR
Software configuration The software configuration screen displays the software installed. STATUS Version ID JOINT 30 % FEATURE: ORD NO: 1/128 1 English Dictionary H521 2 Multi Language (KANA) H530 3 FANUC Arc Tool H541 4 Kernel Software CORE 5 Basic Software H510 6 KAREL Run-Time Env J539 7 Robot Servo Code H930 8 R-200i/165F H740 9 NOBOT H895 10 Analog I/O H550 [ TYPE ]SOFTWARE MOT_ID MOT_INF SER_PAR
760
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Motor ID screen The motor ID screen displays the ID of each axis. STATUS Version ID
1: 2: 3: 4: 5: 6: 7: 8: 9:
GRP: 1 1 1 1 1 1 * * *
JOINT
AXIS: 1 2 3 4 5 6 * * *
30 % 1/16
MOTOR ID: ACA22/2000 80A ACA22/2000 80A ACA22/2000 80A ACA22/1500 40A ACA12/2000 80A ACM6/3000 40A Uninitialized Uninitialized Uninitialized
[ TYPE ]SOFTWARE MOT_ID MOT_INF SER_PAR
Servo parameter information screen The servo parameter information screen displays the ID of the servo parameter for each axis.
STATUS Version ID GRP: AXIS: 1: 1 1 2: 1 2 3: 1 3 4: 1 4 5: 1 5 6: 1 6 7: 2 1 8: * * 9: * *
JOINT SERVO PARAM ID: P01.01 P01.01 P01.01 P01.01 P01.01 P01.01 P00.11 Uninitialized Uninitialized
30 %
[ TYPE ]SOFTWARE MOT_ID MOT_INF SER_PAR
761
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B--81464EN--3/01
Procedure B--12 Software version screen Step
1 Press the MENUS key to display the screen menu. 2 Select “0 ---- NEXT ----” and then select “4 STATUS” on the next page. 3 Press F1 “TYPE” to display the screen change menu. 4 Select “Version ID” . The software version screen is displayed.
9 USER 0 -- NEXT --
STATUS Version ID
1 2 3 4 5 6 7 8 9 10
MENUS
3 DATA 4 STATUS 5 POSITION
JOINT
ITEM: SOFTWARE: FANUC Arc Tool S/W Serial No. Controller ID. M6-1NLN-NORM-BRK[N] Servo Code. Cart. Mot. Parameter Joint Mot. Parameter Boot MONITOR Teach Pendant Software. Edition No.
30 % 1/21
V5.1001 9024000 F00000 N/A V01.02 ******* ******* V5.1001 7D01/091 V5.1001
Version ID [ TYPE ]SOFTWARE
CONFIG
MOTOR
SERVO
TYPE
F1 -- F2 “SOFTWARE” : Displays the software version screen. -- F3 “MOT_ID”: Displays the motor ID screen. -- F4 “MOT_INF”: Displays the motor information screen. -- F5 “SER_PAR”: Displays the servo parameter information screen.
762
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B.4 Robot Axis Status The robot axis status screens displays the status of each axis motor of the robot. The status of each axis is updated in real time. This status information is used during maintenance. Status 1 screen The status 1 screen displays the alarm status of the servo system. The status information consists of servo alarm status 1 (16 bits) and servo alarm status 2 (16 bits). STATUS Axis
JOINT
Flag Bits 1/2 J1: 0000000000000000 0000000000000000 J2: 0000000000000000 0000000000000000 J3: 0000000000000000 0000000000000000
GRP[ 1 ] History (0000000000000000) (0000000000000000) (0000000000000000) (0000000000000000) (0000000000000000) (0000000000000000)
[ TYPE ]STATUS1 STATUS2
Flag 1
Servo alarm status 1
Flag 2
Servo alarm status 2
Table B--3.
30 %
PULSE
[UTIL ]>
Servo Alarm Status 1
Address: FC80h (L--axis), FCC0h (M--axis)
MSB
B14
B13
B12
B11
B10
B9
B8
OHAL
LVAL
OVC
HCAL
HVAL
DCAL
FBAL
ALDF
B7
B6
B5
B4
B3
B2
B1
LSB
MCAL
MOFAL
EROFL
CUER
SSTB
PAWT
SRDY
SCRDY
OHAL
Amplifier overheat alarm
LVAL
It indicates a low voltage alarm.
OVC
It indicates an overcurrent (OVC) alarm.
HCAL
It indicates a high current alarm.
HVAL
It indicates a high voltage alarm.
DCAL
It indicates a regenerative discharge alarm.
FBAL
Disconnection alarm (ALDF indicates whether the disconnection is associated with the hardware or software.)
ALDF
Alarm distinction bit If an amplifier alarm (OHAL, LVAL, HCAL, FSAL, IPMAL, or DCLVAL) is raised while ALSF is set to 1, the alarm is detected by PSM. When both FBAL and ALDF are set to 1, the disconnection alarm is detected by the hardware.
MCAL
Amplifier MCC adhesion alarm
MOFAL
Move command overflow alarm When this bit is set to 1, it indicates that an overflow occurred when the move command was distributed.
EROFL
Error counter overflow alarm for line tracking When this bit is set to 1, it indicates that the error counter has overflowed.
CUER
Current offset error This bit is set to 1 when the current offset value of the A/D converter is higher than permitted.
SSTB
Servo standby signal After POWON, this signal is set to 1, and the system waits for ITP. When SSTB is set to 1, the host outputs ITPCON and generates ITP.
PAWT
Parameter change completion signal When the servo CPU finishes rewriting parameters, only 1ITP is set to 1.
763
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B--81464EN--3/01
SRDY
Servo ready signal While this flag is held to 1, a move command is accepted.
SCRDY
Servo communication flag The servo CPU sets this flag to 1 once data writing to the shared RAM is completed. After reading the data, the host CPU resets the flag to 0.
OVL
FBAL
ALDF
1
0
1
Motor overload alarm (not used for a serial pulse coder)
1
0
0
Amplifier overload alarm
0
1
1
Pulse coder disconnection alarm (not used for a serial pulse coder)
Table B--4.
Alarm
Servo Alarm Status 2
Address: FC81h (L--axis), FCC1h (M--axis)
MSB
B14
B13
B12
B11
B10
B9
B8
SRCMF
CLALM
FSAL
DCLVAL
BRAKE
IPMAL
SFVEL
GUNSET
B2
B1
LSB
B7
B6
B5
B4
B3
FSSBDC
SCUCAL
AMUCAL
CHGAL
NOAMP
SRCMF
Compensation warning flag When part of the position data is missing because of noise or some other reason, data compensation is performed. This data, however, should not be used for mastering or other purposes. To inform the host of this state, the flag is set to 1.
CLALM
It indicates a collision detection alarm. When the servo CPU detects a collision, the flag is set to 1. The host CPU starts alarm handling after a lapse of a predetermined period from when the flag is set to 1.
FSAL
Fan stop alarm
DCLVAL
Low DC Link voltage alarm
BRAKE
Brake alarm of 6--axis amplifier
IPMAL
IPM alarm IPM is an abbreviation for intelligent power module, which is a power component to replace IGBT. The IPM detects overheating and HC by itself.
SFVEL
Soft float start permission signal When the velocity feedback falls below the velocity specified in a parameter, this flag is set to 1 to allow soft float to be started.
GUNSET
Servo gun switch completion signal Once the resetting (initialization) of the pulse coder has been completed after the servo gun is switched, the signal is set to 1 only for 1ITP.
FSSBDC
FSSB disconnection alarm When a disconnection of FSSB is detected, this bit is set to 1. (Hardware detection by FSSBC)
SVUCAL
FSSB communication alarm When two consecutive alarms are detected in data communication between the slave and a servo module, this bit is set to 1. (Detected by the servo software)
AMUCAL
FSSB communication alarm When two consecutive alarms are detected in data communication between the servo module and a slave, this bit is set to 1. (Detected by the slave)
CHGAL
Amplifier charge alarm
NOAMP
No amplifier connection alarm This bit is set to 1 when an amplifier is not connected while the presence of the corresponding axis is specified (B3 of AXIS register set to 0).
764
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B--81464EN--3/01
Status 2 screen The status 2 screen indicates the pulse coder alarm status (12 bits). STATUS Axis
J1: J2 J3: J4 J5: J6:
JOINT
Alarm Status 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000 0000000000000000
GRP[ 1 ] History (0000000000000000) (0000000000000000) (0000000000000000) (0000000000000000) (0000000000000000) (0000000000000000)
[ TYPE ]STATUS1 STATUS2
Alarm Status Table B--5.
30 %
PULSE
[UTIL ]>
Pulse coder alarm status Pulse Coder Alarm Status MSB
B10
B9
B8
SPHAL
STBERR
CRCERR
DTERR LSB
B7
B6
B5
B4
B3
B2
B1
OHAL
CSAL
BLAL
PHAL
RCAL
BZAL
CKAL
SPHAL
When this bit is 1, it indicates a soft phase alarm (abnormal acceleration).
STBERR
When this bit is 1, it indicates a start/stop bit alarm.
CRCERR
When this bit is 1, it indicates a CRC alarm.
DTERR
When this bit is 1, it indicates a data alarm.
OHAL
When this bit is 1, it indicates a over heat alarm.
CSAL
When this bit is 1, it incicates a check sum alarm.
BLAL
When this bit is 1, it indicates the low voltage alarm of the battery.
PHAL
When this bit is 1, it indicates a phase alarm.
RCAL
When this bit is 1, it indicates a rotating speed counter abnormal alarm
BZAL
When this bit is 1, it indicates an exhausted battery alarm.
CKAL
When this bit is 1, it indicates a clock alarm.
765
APPENDIX
B--81464EN--3/01
Pulse screen The pulse screen displays the servo delay, machine position, and status of the motion command. STATUS Axis Position Error J1: J2: J3: J4: J5:
[TYPE] STATUS1
JOINT 30% GRP[1] Motion Command 0 0 0 0 0
Machine Pulse 0 0 0 0 0
0 0 0 0 0
STATUS2
PULSE [ UTIL ]
Position Error
Servo delay (pulses). Delay of the actual pulse to the command pulse
Machine Pulse
Machine position (pulses). Actual absolute pulses
Motion Command
Relative command pulses from the host (pulses)
Monitor screen The monitor screen displays the current values, and the status of the position, overtravel, and servo amplifier. Load to the motor and thermal loss can be estimated using the root--mean--square current values.
STATUS Axis
JOINT 30 % GRP[ 1 ]
Torque Monitor Ave. / Max. Inpos OT VRDY J1: 0.000/ 0.000 1 0 OFF J2: 0.000/ 0.000 1 0 OFF J3: 0.000/ 0.000 1 0 OFF J4: 0.000/ 0.000 1 0 OFF J5: 0.000/ 0.000 1 0 OFF J6: 0.OOO/ 0.000 1 0 OFF
[ TYPE ]MONITOR TRACKING DISTURB[UTIL ]>
Ave.
Average of the root--mean--square current values (A)
Max.
Maximum of the root--mean--square current values (A)
Inpos
Position status (0 or 1)
OT
Overtravel status (0 or 1)
VRDY
Servo amplifier ready status (on or off)
766
APPENDIX
B--81464EN--3/01
Tracking screen The tracking screen displays the status of the tracking servo system. STATUS Axis
P1: P2: P1: P2:
JOINT 30% GRP[1]
Tracking Status Flag Bits1 Flag Bits2 0000000000000000 0000000000000000 0000000000000000 0000000000000000 Alarm status Counter Value 000000000000 0 000000000000 0
[TYPE] MONITOR
TRACKING
Flag Bits 1
Servo alarm status 1
Flag Bits 2
Servo alarm status 2
Alarm Status
Pulse coder alarm status
Counter Value
Line tracking counter
DISTURB
For the servo and pulse coder alarm statuses, see Table B--3, Table B--4, and Table B--5 Disturbance torque screen The disturbance torque screen displays the disturbance torque to each motor (current torque and maximum and minimum torque for each ITP). The disturbance torque is indicated with the current values estimated from the difference between the scheduled and actual values of the pulse coder. If the maximum or minimum value set for the disturbance torque is exceeded, the collision detection function of the servo system regards a collision as occurring and turns the servo power off. STATUS Axis
JOINT 30% GRP[1]
Disturbance Torque Current Max. J1: 0.000 / 0.0 (90.9) J2: 0.000 / 0.0 (84.3) J3: 0.000 / 0.0 (97.4) J4: 0.000 / 0.0 (30.2) J5: 0.000 / 0.0 (34.3) J6: 0.000 / 0.0 (21.7) [TYPE]
MONITOR TRACKING
/ / / / / /
Min. 0.0 (-90.9) 0.0 (-84.3) 0.0 (-97.4) 0.0 (-30.2) 0.0 (-34.3) 0.0 (-21.7)
DISTURB [UTIL ]>
Current
Estimated disturbance torque to the servo motor (A)
Max.
Maximum value of the above estimated disturbance torque (A)
Min.
Minimum value of the above estimated disturbance torque (A)
767
APPENDIX
B--81464EN--3/01
Procedure B--13 Robot axis status screens Step
1 Press the MENUS key to display the screen menu. 2 Select “0 ----NEXT----” to display the next page, then select “4 STATUS.” 3 Press the F1 key “[TYPE]” to display the screen change menu. 4 Select “Axis.” The robot axis status screens can be displayed.
9 USER 0 --NEXT--
MENUS
3 DATA 4 STATUS 5 POSITION
STATUS Axis
JOINT
Flag Bits 1/2 J1: 0000000000000000 0000000000000000 J2: 0000000000000000 0000000000000000 J3: 0000000000000000 0000000000000000
GRP[ 1 ] History (0000000000000000) (0000000000000000) (0000000000000000) (0000000000000000) (0000000000000000) (0000000000000000)
[ TYPE ]STATUS1 STATUS2 Axis
30 %
PULSE
[UTIL ]>
[ TYPE ]MONITOR TRACKING DISTURB[UTIL ]>
TYPE
F1 -- F2 “STATUS 1”: Displays the status 1 screen. -- F3 “STATUS 2”: Displays the status 2 screen. -- F4 “PULSE”: Displays the pulse screen. -- F2 “MONITOR” on the next page: Displays the monitor screen. -- F3 “TRACKING” on the next page: Displays the tracking screen. -- F4 “DISTURB” on the next page: Displays the disturbance torque screen. -- When F2 REG.DIS is selected on the next page, the regenerative discharge screen appears. 5 To change the group number, press F5 [UTIL]. A menu appears. On that menu, select 1 GROUP, then enter a desired group number.
768
APPENDIX
B--81464EN--3/01
B.5 Diagnosis Screen B.5.1 Outline This function is a function to show users very useful information at maintenance of the robot. Each information has help that shows the description and the recommended action. You can use the robot long time without trouble. The following items are shown. F
Main (List)
F
Reducer diagnosis
F
Overheat diagnosis
F
Torque diagnosis
F
Disturbance diagnosis
F
OVC diagnosis
F
collision diagnosis
F
Help
This function is supported in V6.11P/11 or later. (This function is shipped from April 2001) You can use this function in supported type of robots only. (In supported type, bit 0 of initial $scr.$diag_func is 1)
B.5.2 About Reducer Diagnosis Servo diagnosis function includes reducer’s recommended overhaul time diagnosis. The overhaul time depends on the future motion of reducer. This function indicates the overhaul time in the motion of recent 50 hours. When the exchange or overhaul of the reducer is done, you have to reset parameters. Pleasae refer maintainance manual.
769
APPENDIX
B--81464EN--3/01
B.5.3 Procedure Procedure B--14 Diagnosis screen Step
1 Press the MENUS key to bring up the screen menu. 2 Select “4 STATUS” on the next page. 3 Press F1“[TYPE]” to display the pull--up menu. 4 Select “Axis”. 5 Press [next] key until “diag” is shown above function key. 6 Press F4“diag”. Diagnosis main screen is shown first. Diagnosis
JOINT
group[ 1] reducer overheat(motor) overheat(trans) current disturbance OVC collision detection discharge
[ TYPE ]
main reducer
10 % 1/9
55542.2 hours 11.31 % 12.12 % 76.39 % 21.75 % 9.824 % 19 times 13 4 W
ov.heat help
>
Procedure B--15 Change diagnosis screen Step
1 Each item is allocated to the function key. Press function key to show the item. For example, by pressing F3 key reducer diagnosis screen is shown. Diagnosis
JOINT
reducer group[ 1] J1 J2 J3 J4 J5 J6
[ TYPE ]
76863.3 57686.3 85768.6 93217.6 76876.8 65337.8
main reducer
10 % 2/2
hours hours hours hours hours hours
ov.heat help
>
2 You can change the allocation of function keys by pressing the [next] key.
770
APPENDIX
B--81464EN--3/01
Diagnosis
JOINT
reducer group[ 1] J1 J2 J3 J4 J5 J6
torque
76863.3 57686.3 85768.6 93217.6 76876.8 65337.8
disturb
OVC
10 % 2/2
hours hours hours hours hours hours
cl.det.
3 To show the Axis screen again, press [prev] key.
B.5.4 Each item Main: Each item shows the value of the worst axis. Diagnosis
JOINT
group[ 1] reducer overheat(motor) overheat(trans) current disturbance OVC collision detection discharge
[ TYPE ]
main reducer
10 % 1/9
55542.2 hours 11.31 % 12.12 % 76.39 % 21.75 % 9.824 % 19 times 13 4 W
ov.heat help
>
Reducer: The time until the recomended overhaul of reducers Diagnosis
JOINT
reducer group[ 1] J1 J2 J3 J4 J5 J6
[ TYPE ]
76863.3 57686.3 85768.6 93217.6 76876.8 65337.8
main reducer
771
10 % 2/2
hours hours hours hours hours hours
ov.heat help
>
APPENDIX
B--81464EN--3/01
Over heat: The ratio of root mean square current to the rated current Diagnosis
JOINT
over heat trans motor group[ 1] J1 J2 J3 J4 J5 J6
[ TYPE ]
10 % 3/3
13.7 % 17.33 23.63 14.74 21.65 14.55 15.32
main reducer
% % % % % %
ov.heat help
>
Torque: The ratio of the current torque to the maximum. Diagnosis
JOINT
torque group[ 1] J1 J2 J3 J4 J5 J6
[ TYPE ]
17.33 23.63 14.74 21.65 14.55 15.32
main reducer
10 % 2/2
% % % % % %
ov.heat help
>
Disturbance: The ratio of the force observed by the servo software to the alarm threshold. Diagnosis
JOINT
disturbance group[ 1] current max(%) min(%) J1 23.63 % 32.33 / -23.52 J2 26.37 % 45.21 / -23.43 J3 -17.74 % 21.56 / -35.21 J4 12.65 % 15.41 / -23.65 J5 -16.55 % 19.37 / -16.55 J6 19.32 % 21.65 / -10.54
[ TYPE ]
main reducer
772
ov.heat help
10 % 2/2
>
APPENDIX
B--81464EN--3/01
OVC: The ratio of the temperature simulated by the software to the alarm threshold. Diagnosis
JOINT
OVC group[ 1] J1 J2 J3 J4 J5 J6
[ TYPE ]
17.33 23.63 14.74 21.65 14.55 15.32
main reducer
10 % 2/2
% % % % % %
ov.heat help
>
Collision detection: The count of the collision and the data of the last collision detection. Diagnosis
JOINT
last detection 2001 / 4/ 6, 16: 55: 26 group[ 1] count / position J1 ***** times -17.33 J2 ***** times 23.63 J3 ***** times -14.74 J4 ***** times 121.65 J5 14 times 114.55 J6 ***** times 115.32
[ TYPE ]
main reducer
10 % 3/3
deg deg deg deg deg deg
ov.heat help
>
Help: Information of the last shown item
Diagnosis
JOINT
10 %
INFORMATION: The count of the collision and the data of the last collision detection. REMEDY: If many collision detection occur, execute the overhaul more frquently. DETAIL: You can watch the count of the collision detection ever occured.You can also watch the information of the last detection(time, position).
[ TYPE ]
main reducer
773
ov.heat help
>
APPENDIX
B--81464EN--3/01
B.6 World Frame Origin This section describes the world frame origin of the each robot model (See Section 3.15,“Setting Coordinate Systems” for the world frame). When the user frame or tool frame is set, refer to this. S series/LR Mate (Other than S--450) A crossing point between J1 axis and level plane which includes the J2 axis. (S--450U/L) Intersection of rotation axes U and γ when the robot is set to the zero positions on all linear axes (S--450S) Position at which rotation axis U, moved parallel to itself in the horizontal direction, intersects with rotation axis θ when the robot is set to the zero positions on all linear axes M series (M--410i/M--500) Intersection of the J2--axis, moved parallel to itself, and the J1--axis
774
APPENDIX
B--81464EN--3/01
B.7 I/O Module Setting FANUC I/O Link The FANUC I/O Link is a serial interface used for high--speed I/O signal (bit data) transmission between the robot controller and I/O modules, such as the process I/O printed circuit board and I/O Unit--MODEL A. Using the FANUC I/O Link, one master and multiple slaves can be connected. Generally, the robot controller is used as the master, with the I/O modules connected to the controller being used as slaves. Up to 16 slave groups can be connected to one I/O Link. Figure B--4. FANUC I/O Link configuration
Master
Slave
Main CPU printed circuit board
Process I/O printed circuit board Peripheral unit JD4A
JD1A
JD4B
I/O unit model B interface unit I/O Link JD1B
DI/DO unit
Power supply unit JD1A 24V 0V
CP4
DI/DO unit :
:
I/O signals The following I/Os are used for signal transmission between the robot controller and system peripheral units, via the I/O modules connected to the FANUC I/O Link: F
Digital I/O SDI[i]/SDO[i]
F
Group I/O GI[i]/GO[i]
F
Analog I/O AI[i]/AO[i]
F
Peripheral unit I/O UI[i]/UO[i]
i = logical number
I/O modules The following I/O modules can be connected to the robot controller via the I/O Link: Table B--6.
I/O modules Abbreviation
Process I/O printed circuit board (CA, CB, DA, EA, EB, FA, GA, -HA) FANUC I/O Unit--MODEL A
I/O Unit -- A
FANUC I/O Unit--MODEL B
I/O Unit -- B
FANUC I/O Link connection unit
--
Programmable Controller SERIES 90--30A
--
775
APPENDIX
B--81464EN--3/01
Assignment I/O logical number i is assigned to a physical number of I/O modules. I/O logical numbers can be redefined. Logical number I/O index used to reference an I/O in the robot controller Physical number Number assigned to each signal pin of an I/O module. A specific signal pin of a particular I/O module can be specified with the rack, slot, and physical number. Figure B--5. Logical number and physical number assignment
Digital I/O configuration screen I/O Digital Out
Logical number
# 1 2 3 4 5 6 7 8 9
DO[ DO[ DO[ DO[ DO[ DO[ DO[ DO[ DO[
RANGE 1- 8] 9- 16] 17- 24] 25- 32] 33- 40] 41- 48] 49- 56] 57- 64] 65- 72]
JOINT RACK 0 0 0 0 0 0 0 0 0
SLOT 1 1 1 2 2 2 2 2 0
[ TYPE ] MONITOR IN/OUT
10 % 1/32 START PT 21 29 37 1 9 17 25 33 0
DETAIL
Physical number
HELP >
Assignment
Process I/O printed circuit board
I/O Digital Out # SIM STATUS DO[ 1] U OFF DO[ 2] U OFF DO[ 3] U OFF DO[ 4] U OFF DO[ 5] U OFF DO[ 6] U OFF DO[ 7] U OFF DO[ 8] U OFF DO[ 9] U OFF DO[ 10] U OFF [ TYPE ] CONFIG
Process I/O printed circuit board Rack 0, slot 1 JOINT
[ [ [ [ [ [ [ [ [ [
IN/OUT
ON
CRM2B Pin No. Physical No.
10 % 1/256 ] ] ] ] ] ] ] ] ] ]
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
OFF
On the configuration screen, SDO[1] to SDO[8] are assigned to out21 to out28 of connector CRM2B on the process I/O printed circuit board. When SDO[1] is set to ON, a signal is output on pin 33.
776
in in in in in in in in in in in in in in in in
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
19 20 21 22 23 24 25 26 27 28 29 30 31 32
33 out 21 34 out 22 33 34 35 out 23 35 36 out 24 36 37 38 out 25 39 out 26 out 37 out 38 40 out 27 out 39 41 out 28 42 out 40 43 out 29 44 out 30 in 37 in 38 45 out 31 in 39 46 out 32 47 in 40 48 49 50 out out out out
CRM2B CRM2A
APPENDIX
B--81464EN--3/01
Rack number Rack numbers indicate the hardware types and connection orders of I/O modules. I/O modules are classified into two major types: those having rack number 0, and those to which rack numbers are assigned in the order in which they are connected. Slot number I/O modules whose rack numbers are 0 are assigned slot numbers in the order in which they are connected. When the rack number of an I/O module is a non--zero value, indicating the order in which it is connected, a slot number is used to indicate the I/O module part of that I/O module. I/O module parts include, for example, modules of I/O Unit--A and DI/DO units of I/O Unit--B. START PT (channel number) Digital I/Os and peripheral I/Os are assigned in groups of eight signals. Specify the first physical number for eight sequential signals. For group I/Os, specify the first physical number for the sequential signals specified in NUM PTS. For an analog I/O, specify a channel number. Table B--7.
Specifying rack and slot numbers for each I/O module Rack
I/O module
Slot
Process I/O printed circuit board
Always 0
(*2)
FANUC I/O Unit--MODEL A
(*1)
Number indicated on the base unit
FANUC I/O Unit--MODEL B
(*1)
Unit number (set with DIP switches)
FANUC I/O Link connection unit
Always 0
(*2)
Programmable Controller SERIES 90--30A
(*1)
1 (fixed)
NOTE *1 Numbers beginning with 1 are to be assigned to I/O modules, except those I/O modules having rack number 0, in the order in which they are connected. NOTE *2 To those I/O modules having rack number 0, numbers beginning with 1 are to be assigned in the order in which they are connected. Figure B--6. Example of rack and slot specification
R--J3iB controller
R--J3iB controller
Process I/O printed circuit board
Rack 0, slot 1
I/O Unit--B
Rack 1, slot 1
Connection unit
Rack 0, slot 2
90--30 A
Rack 2, slot 1
Rack 1, slot 1
Connection unit
90--30 A
777
Rack 0, slot 1
APPENDIX
B--81464EN--3/01
I/O Link setting When connected to the controller, some I/O modules require that the user make several additional specifications. Other I/O modules, however, do not require such specification. When additional specification is not necessary After connecting an I/O module to the robot controller, via a cable, turn on the power. Data assignment is performed automatically. When additional specification is necessary Specify the system variables from the robot controller. Specification Process I/O printed circuit board (CA, CB, DA, EA, EB, FA, GA, HA)
Unnecessary
FANUC I/O Unit--MODEL A
Unnecessary
FANUC I/O Unit--MODEL B
Necessary
FANUC I/O Link connection unit
Necessary
Programmable Controller SERIES 90--30A
Necessary
Number of available I/Os Up to 16 slave groups can be connected to each I/O Link. Therefore, up to 16 I/O modules can be connected to the robot controller. The FANUC I/O Link supports 1024 inputs and 1024 outputs for a master. These I/Os are assigned to the slaves to enable the periodic transmission of I/O data between the master and slaves. The total number of I/Os used by the slaves connected to the FANUC I/O Link must satisfy the following: Number of inputs per I/O Link =< 1024 Number of outputs per I/O Link =< 1024 Therefore, I/Os can be expanded within the above range. For details of the number of I/Os used for each I/O module that becomes a slave, refer to the relevant I/O module manual. The process I/O printed circuit board, however, always uses 128 inputs and 128 outputs, regardless of its type. Figure B--7. Relation between master and slave in I/O signal points Master
Slave #0 Out Input
1024 outputs Slave #1 Out Input :
1024 inputs
Teach pendant display On both the digital input and output screens, displayed on the teach pendant of the robot controller, up to 256 signals can be displayed. Using these screens, a user can specify and change the assignment of up to 256 signals, in groups of eight signals. On both the analog input and output screens, up to 25 channels can be displayed. Using these screens, a user can specify and change the assignment of up to 25 channels, on a channel--by--channel basis.
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I/O module manuals For details of each I/O module, refer to the following manuals: Manual name
I/O module name
Drawing number
Process I/O printed circuit board (CA, CB, DA, EA, EB, FA, GA, HA)
FANUC Robot series R--J3iB Controller Maintenance Manual
B--81465JA
FANUC I/O Unit--MODEL A
FANUC I/O Unit--MODEL A Connection and Maintenance Manual
B--61813
FANUC I/O Unit--MODEL B
FANUC I/O Unit--MODEL B Connection Manual
B--62163
FANUC I/O Link connection unit
FANUC I/O Link Connection Unit Specifications
A--68806
Programmable Controller SERIES 90--30A
Programmable Controller SERIES 90--30A User’s Manual
B--76014
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B.8 Positioner Setup Step
1 Turn ON the controller with “ PREV” key and F! key pressed. Then select “3. Controlled start”. 2 Press MENUS key and select “9. MAINTENANCE”. 3 You will see similar screen to the following one. Setup Robot System Variables Group
Robot
Library /Option
1
R--2000i/165F
2
POSITIONER
[Type]
ORD_NO
Ext Axs
*
AUTO
MANUAL
Press arrow(↑,↓) keys and move the cursor to “POSITIONER”. Then press F4,“MANUAL”. 4 You will see similar screen to the following ---- Hardware start axis setting ---enter Hardware start axis (1..16)? Default value = 1
Enter axis number and press ENTER key. * Which axis in the system is assigned to 1st axis of POSITIONER is set in this screen. For example, if the system has R--2000i and POSITIONER, start axis number of POSOTIONER is 7 because R--2000i has 6 axes. 5 You will see similar screen to the following ---- Kinematics Type Setting ---1:Known Kinematics 2:Unknown Kinematics Select Kinematics Type? default value = 1
If the measurements of offset values between POSITONER axes are accurately known, item 1 should be selected. Otherwize item 2 should be selected. 6 You will see similar screen to following one. Group number is displayed instead of “?” in following screen. Total number of axes is displayed instead of “#” in following screen. Initial value of number of axes is 0. ****Group ? Total POSITIONER Axis=# 1.Display/Modify POSITIONER axis 2.Add POSITIONER axis 3.Delete POSITIONER axis 4.Exit Select item?
If you want to add POSITIONER axis, select “2. Add POSITIONER axes”. Then setup procedure starts. If you want to delete POSITIONER axis, select “3. Delete POSITIONER axes”. Then following screen is displayed. POSITIONER Axis ? Was Deleted Press ENTER to Continue.
(* The deleted axis number is displayed instead of “?” in above screen.) After this setup, please set values according to the specification of the mechanism.
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7 Select the Motor size ****POSITIONER Axis 1 Initialization**** 33.ACb0.5
38.ACa12
43.ACa100
34.ACal
39.ACa22
44.ACa150
:
:
:
:
:
:
0. Next page. Select Motor size?
8 Select the motor type. MOTOR TYPE 1./2000
6.F/3000
2./3000
7.F/2500
3.S/2000
8.L/3000
:
:
Select Moter Type?
9 Select Amplifier Current Limit. CURRENT LIMIT FOR AMPLIFIER
1. 2A
6. 60A
2. 4A
7. 80A
3. 12A
8. 100A
:
:
Select Amplifier Current Limit?
10 Set amplifier number. ---- Amplifier number Setting -Enter Amplifier Number (1→16)?
11 Set amplifier type. ---- Amplifier Type Setting -Amplifier ? Type = # Enter (1:Change, 2:No Change)?
* Amplifier number which is set in previous procedure is displayed instead of “?”. * If 0 is displayed instead of “#”, this indicates that amp type is not set yet. If you select “1: Change” in above screen, you will see following screen. Select the amplifier type. SELECT AMP TYPE 1. A06B--6100 series 6 axes amplifier 2. A06B--6093 Beta series (FSSB)
12 Select the axis type. Axis Type Setting -1: Linear Axis 2: Rotary Axis Select Axis Type?
If the axis does linear motion, select item 1. If the axis does rotary motion, select item 2.
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13 Select the direction of the axis. ---- Direction Setting -1: +X
3: +Y
5: +Z
2: --X
4: --Y
6: --Z
Select Direction?
Directions in above screen indicate the directions of axes of the world coordinate system. The +/-- direction must be considered in this setting. Example) World coordinate frame
Z
X · Linear axis + Direction of joint jog.
In this case, the direction should be set to “+Z”. · Rotary axis + Direction of joint jog.
In this case, the direction should be set to “+X”. 14 If you set the Kinematics Type to “Known Kinematics” in procedure 4., you will see the following screens. If the Kinematics is “Unknown Kinematics”, this procedure is skipped. Enter the Offset value in X direction. ---- Offset Setting -Enter Offset X (mm)?
Enter the Offset value in Y direction. Enter Offset Y (mm)?
Enter the Offset value in Z direction. Enter Offset Z (mm)?
For 1st axis, offset values between the origin of the world coordinate and that of the axis must be set. For the 2nd or later axes, offset values between the origin of the axis and that of the previous axis must be set.
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Example)
The origin of (N--1) th axis.
Z Y
250mm
300mm
World coordinate frame
The origin of (N) th axis.
X In this case, offset values for (N)th axis must be set as follows. Offset X: 300mm Offset Y:
0mm
Offset Z: -- 250mm 15 Set Gear Ratio. For a linear axis, enter the distance of the motion which corresponds to one revolution of the the axis of the motor.(UNIT: mm/rev) Following screen is displayed for linear axes. ---- Gear Ratio Setting ---Enter Gear Ratio (mm/rev)?
For a rotary axis, enter the number of revolution of the motor which corresponds to one revolution of the axis. (UNIT: motor_rev / axis--rev) Following screen is displayed for rotary axes. ---- Gear Ratio Setting ---Enter Gear Ratio (mot--rev/axs--rev)?
16 Set the maximum speed for the axis. You will see the similar screen to following one. ---- Maximum Speed Setting ---Suggested Speed = 150.000 (mm/sec) (Calculated with Max Motor Speed) Enter (1: Change, 2: No Change)?
If you want to change suggested value, select “1: Change”. Then following screen will be displayed. Enter Max Speed (mm/sec)?
Enter Max speed. 17 Set motion sign. MOTOR DIRERCTION Ext_axs 1 Motion Sign = TRUE Enter ( 1: TRUE, 2: FALSE)?
18 Set the upper limit of the POSITIONER axis (UPPER LIMITS). Input unit of it by the “mm” in case of linear axis and by “degree” in case of rotary axis. UPPER LIMITS Enter Upper Limit ( deg ) ?
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warning) Determine upper limit of POSITIONER axis by user. So, the following condition must be consisted: -- = length of POSITIONER axis For example, if the length of POSITIONER axis is 100 mm, you may set the upper limit. = 50mm = --50mm 19 Set the lower limit of the POSITIONER axis (LOWER LIMITS). Input unit of it by the “mm” in case of linear axis and by “degree” in case of rotary axis. LOWER LIMITS Enter Lower Limit ( deg ) ?
20 Set the mastering position data (MASTER POSITION). MASTER POSITION Enter Master Position ( deg ) ?
21 Set the constant of acceleration/deceleration time (ACC/ DEC TIME) . Set the value when you change the constant of acceleration/deceleration time of the first joint. In case of changing it, input “1”, or in case of using the recommending value, input “2”. ACC/DEC TIME Default acc_time1=256(ms) Enter ( 1: Change, 2: No Change ) ?
22 Set the value when you change the constant of acceleration/deceleration time of the second joint. In case of changing it, input “1”. In case of using the recommending value, input “2”. Default acc_time2=128(ms) Enter ( 1: Change, 2: No Change ) ?
23 Set the value when you change the constant of exponential acceleration/deceleration time of first joint. In case of changing it, input “1”. In case of using the recommending value, input “2”. EXP_ACCEL TIME Default exp_accel time =0(ms) Enter (1: Change, 2: No Change)?
24 Set the “Minumum Access Time”. This value is used when the real acceleration/deceleration time is smaller than specified time. In case of changing it, input “1”. In case of not changing, input “2”. MIN_ACCEL TIME Default min_accel time =384(ms) Enter ( 1: Change, 2: No Change ) ?
25 Set the inertia ratio of all load inertia caluculated in moter axis to inertia (to rotary inertia). On setting inertia ratio, its value must be 1< the value<5. On not setting it, input “0”. Load Ratio is Load Inertia ( Kg*cm*s*2) Motor Inertia (Kg*cm*s*2) Enter Load ratio ? ( 0:None 1→5: Valid)
26 Set the brake number (0--4) using the POSITIONER axis. BRAKE SETTING Enter Brake Number (0→4)?
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27 Select the type of brake control. On valid of brack contrl, choose “1:Enable” and input the delay time of brake control. On invalid of it, choose “2:Disable”. SERVO TIMEOUT Servo Off is Enable Enter (1: Enable 2: Disable)? Select?
(On choosing “1:Enable” ) Enter Servo Off Time ? (0.0→30.0 Sec)
28 Come back screen of step 6. **** Group ? Total POSITIONER Axis = # **** 1.Display/Modify POSITIONER Axis = # 2.Add POSITIONER axis 3.Delete POSITIONER axis 4.Exit Select item ? F
In case of displaying/modifying the POSITIONER axis setting, select “1.Display/Modify Ext axis”.
F
When you set the POSITIONER axis successively, select the item “2” and text and continues after the step 7 in this text.
F
In case of deleting the POSITIONER axis, select “3.Delete Ext axis”.
F
In case of finishing the setting, select “4.EXIT→0.EXIT”.
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B.9 Extended Axis Setup Step
1 Turn ON the controller with “ PREV” key and “F→” key pressed. Then select “3. Controlled start”. 2 Press the MENUS key and select “9. MAINTENANCE”. 3 You will see similar screen to the following one.
Setup Robot System Variables Group 1
Robot
R--2000i/165F Extended
[Type]
Library /Option
Ext Axs
*
Axis Control
ORD_NO
AUTO
MANUAL
Press arrow(↑,↓) keys and move the cursor to “Extended Axis Control”. Then press F4,“MANUAL”. 4 You will see similar screen to the following. Select the group of the extended axis and input its number. **** EXTENDED AXIS SETTING PROGRMA **** SELECT GROUP 0.
EXIT
1.
Group1
Display the information about extended axis of the selected group E1 E2 E3 Group 1 Total Ext Axis = * * * 1.Display/Modify Ext axis 2.Add Ext axes 3.Delete Ext axes 4.Exit Select?
Select “2. Add Ext axes” in case of setting new extended axis. 5 Set the number of extended axis. For the first extended axis of the group, input “1”, for the second extended axis of the group, input “2”, for the third axis of the group, input “3”. You should set the number from “1” in turn. Enter axis to add (1→3) ?
6 You will see the initial setup screen of extended axis. Select the kind of motor used extended axis. **** Ext Axis 1 Initialization **** 33.ACb0.5 34.ACa1
38.ACa12 39.ACa22
43.ACa100 44.ACa150
:
:
:
:
:
:
0.
Next page.
Select ?
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7 Select the type of motor on screen. MOTOR TYPE 1. /2000
6.F/3000
2. /3000
7.F/2500
3. S/2000 :
8.L/3000 :
Select ?
8 Select the max current value of motor on screen. CURRENT LIMIT FOR AMPLIFIER
1. 2A
6. 60A
2. 4A
7. 80A
3. 12A
8. 100A
:
:
Select ?
9 Select the type of extended axis through the four types to the following. EXTENDED AXIS TYPE 1. Integrated Rail (Linear axis) 2. Integrated Arm (Rotary axis) 3. Auxiliary Linear Axis 4. Auxiliary Rotary Axis Select ?
Warning 1) Integrated: Robot coordinate is added to the distance of extended axis. The world coordinates are unchanged by the changed extended axis. So the current position changes only the distance transfered by the extended axis. Auxiliary: Robot coordinate is NOT added to the distance of extended axis. World coordinate is transferred with changed extended axis, and remains the fixed robot coordinate. Warning 2) Integrated Rail (Linear axis): Set the direction of attaced extended axis to the direction (X,Y,Z) of world coordinate Direction 1:X 2:Y 3:Z Enter Direction (1→3) ?
Integrated Arml (Rotary axis): Set the offset length to Z direction between the origin of rotary center of extended axis and the origin of robot coordinate Enter Off Set Length (mm) ?
Next, set the arm length of extended axis. Correspondence of the X--axis of robot coordinate and the rotary axis of extended axis: Set the offset length to the Y direction between the origin of rotary center of extended axis and the origin of robot coordinate. Correspondence of the Y--axis of robot coordinate and the rotary axis of extended axis: Set the offset length to the X direction between the origin of rotary center of extended axis and the origin of robot coordinate. Correspondence of the Z--axis of robot coordinate and the rotary axis of extended axis:
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Set the offset length to the X direction between the origin of rotary center of extended axis and the origin of robot coordinate. Enter Arm Length (mm) ?
Finally, set the direction of attacehed extended axis. Input the direction of the rotary axis to the axis (X,Y,Z) of world coordinate 10 Set the gear ratio (GEAR RATIO). For linear axis, the gear ratio is in “mm” of travel per revolution of motor. For rotary axis, the gear ratio is in motor turns per single rotations of the rotary axis. For linear axis: GEAR RATIO
For a linear axis it is the number of Mm’s traveled for one rotation of the Motor Enter Gear Ratio ? (mm)
For rotary axis: GEAR RATIO Enter Gear Ratio ?
11 Set the max joint speed. You will see the max rotary numbers and gear ratio on screen. With Changing, input “1”and the value. With using the recommending value, input “2”. MAX JOINT SPEED SETTING Suggested Speed = 150.000 ( deg / s ) ( Calculated with Max motor speed) Enter ( 1: Change, 2: No Change ) ?
In case of changing the max speed Enter Max Speed (mm/sec) ?
12 Set the direction of extended axis to the motor axis. If the motion direction is positive to the positive rotation of motor, input “1”. If the motion direction is negative to the negative rotation of motor, input “2”. MOTOR DIRERCTION Ext_axs 1 Motion Sign = TRUE Enter ( 1: TRUE, 2: FALSE) ?
13 Set the upper limit of the extended axis (UPPER LIMITS). Input unit of it by the “mm” degree in case of linear axis and by “degree” in case of rotary axis. UPPER LIMITS Enter Upper Limit ( deg ) ?
warning) Determine upper limit of extended axis by user. So, the following condition must be consisted: -- = length of extended axis For example, if the length of extended axis is 100 mm, you may set the upper limit. = 50mm = --50mm 14 Set the lower joint orient area of the extended axis (LOWER LIMITS). Input unit of it by the “mm” degree in case of linear axis and by “degree” in case of rotary axis. LOWER LIMITS Enter Lower Limit ( deg ) ?
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15 Set the mastering position data (MASTER POSITION). MASTER POSITION Enter Master Position ( deg ) ?
16 Set the constant of acceleration/deceleration time (ACC/ DEC TIME) . Set the value when you change the constant of acceleration/deceleration time of the first joint. In case of changing it, input “1”, or in case of using the recommending value, input “2”. ACC/DEC TIME Default acc_time1=256(ms) Enter ( 1: Change, 2: No Change ) ?
Set the value when you change the constant of acceleration/deceleration time of the second joint. In case of changing it, input “1”, or in case of using the recommending value, input “2”. Default acc_time2=128(ms) Enter ( 1: Change, 2: No Change ) ?
17 Set the value when you change the constant of exponential acceleration/deceleration time of first joint. In case of changing it, input “1”, or in case of using the recommending value, input “2”. EXP_ACCEL TIME Default exp_accel time =0(ms) Enter ( 1: Change, 2: No Change ) ?
18 Set the “Minumum Access Time”. This value is used when the real acceleration/deceleration time is smaller than specified time. In case of changing it, input “1”, or in case of not changing, input “2”. MIN_ACCEL TIME Default min_accel time =384(ms) Enter ( 1: Change, 2: No Change ) ?
19 Set the inertia ratio of all load inertia calculated in motor axis to inertia (to rotary inertia). On setting inertia ratio, its value must be 1< the value<5. On not setting it, input “0”. Load Ratio is Load Inertia ( Kg*cm*s*2) Motor Inertia (Kg*cm*s*2) Enter Load ratio ? ( 0:None 1→5: Valid)
20 Set the amplifier number (AMP NUMBER). SELECT AMP NUMBER Enter amplifier number (1→16) ?
21 Set the type of amplifier (AMP TYPE). SELECT AMP TYPE 1. A06B--6100 series 6 axes amplifier 2. A06B--6093 Beta series (FSSB)
22 Set the brake number (0--4) using the POSITIONER axis. BRAKE SETTING Enter Brake Number (0→4)?
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23 Select the type of brake control. For brake control, choose “1:Enable” and input the delay time of brake control. To disable brake control, choose “2:Disable”. SERVO TIMEOUT Servo Off is Enable Enter (1: Enable 2: Disable) ? Select?
(On choosing “1:Enable” ) Enter Servo Off Time ? (0.0→30.0 Sec)
24 You will see a screen similar to the following. **** Group 1 Total Ext Axis = **** 1.Display/Modify Ext axis 2.Add Ext axes 3.Delete Ext axes 4.EXIT Select? F
In case of displaying/modifying the extended axis setting, select “1.Display/Modify Ext axis”.
F
When you set the extended axis successively, select the item “2” and text and contines after the step 5 in this text.
F
In case of deleting the extended axis, select “3.Delete Ext axis”.
F
In case of finishing the setting, select “EXIT→4.EXIT”.
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B.10 Independent Additional Axis Board (Nobot) Startup Procedure Step
1 Execute control start: Press and hold down the “PREV” and “F→” keys and turn the power switch ON. Then, select 3. Control start. 2 On the teach pendant, select Screen selection, then 9. Robot setting. 3 The following screen appears: Setup Robot System Variables Group
Robot
Library /Option
Ext Axs
1
R--2000iA/165F
0
2
NOBOT
0
[Type]
ORD_NO
AUTO
MANUAL
Position the cursor on 1NOBOT and press the F4 key, MANUAL. 4 The following screen appears. For this setting item, specify that the first axis of the independent additional axis board (NOBOT) should be the n--th axis in the entire system. For the R--2000iA plus NOBOT, for example, because the R--2000iA as the first group is a 6--axis robot, the first axis of the independent additional axis board (NOBOT) as the second group will be the seventh. ---- Hardware start axis setting ---enter Hardware start axis (1..16)? Default value = 1
5 The following screen appears. The “?” on the screen will be replaced by a group number. The “#” on the screen will be replaced by the number of axes of the NOBOT currently set. **** Group ? Total Nobot Axis = # 1.Display/Modify Nobot axis 1→6 2.Add Nobot axis 3.Delete Nobot axis 4.Exit Select item?
To add an axis of the independent additional axis board (NOBOT), select “2: Add Nobot axis.” To delete an axis, select “3: Delete Nobot axis.” If 3 is selected, the following screen appears. To return to the above screen, press the Enter key. Nobot Axis? Was Deleted Press ENTER to Continue.
(The “?” on the screen will be replaced by the number of the axis just deleted.) For the subsequent settings, use the values mentioned in the specifications of the mechanical unit of the robot. 6 From the screen, select the size of the motor used for an axis of the independent additional axis board (NOBOT). **** Nobot Axis 1 Initialization **** 33.ACb0.5 38.ACa12 43.ACa100 34.ACa1 39.ACa22 44.ACa150 : : : : : : 0. Next page. Select Motor size?
7 Select a motor type from the screen.
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MOTOR TYPE 1. /2000 2. /3000 3. S/2000 : Select Motor Type?
6.F/3000 7.F/2500 8.L/3000 :
8 From the screen, select the maximum current control value of the motor (maximum permissible current value of the amplifier). CURRENT LIMIT FOR AMPLIFIER 1. 2A 6. 60A 2. 4A 7. 80A 3. 12A 8. 100A : : Select Amplifier Current Limit?
9 Set the amplifier number. ---- Amplifier number Setting -Enter Amplifier Number (1→16)?
10 Set the amplifier type. ---- Amplifier Type Setting -Amplifier ? Type = # Enter (1: Change, 2: No Change)?
* The “?” on the screen will be replaced by the amplifier number set previously. * If 0 is displayed in place of “#,” this indicates that no amplifier has been set. To change the amplifier type, select “1: Change.” The following screen appears: SELECT AMP TYPE 1. A06B--6100 series 6 axes amplifier 2. A06B--6093 Beta series (FSSB)
Select an amplifier type. 11 Select the axis type of the independent additional axis board (NOBOT). Axis Type Setting -1: Linear Axis 2: Rotary Axis Select Axis Type?
Linear Axis: Linear axis Rotary Axis: Rotary axis 12 Enter the gear reduction ratio. For a linear axis, enter the distance of travel along the axis due to one rotation of the motor (in mm). For a rotary axis, enter the number of revolutions of the motor required for one rotation about the output axis. ---- Gear Ratio Setting ---Enter Gear Ratio ?
13 Set the maximum axis speed. A suggested value is calculated with the maximum motor speed and the gear ratio and displayed on the screen. To change the value, enter 1 and enter a new value. To use the suggested value, enter 2. ---- Maximum Speed Setting ---Suggested Speed = 150.000 ( mm / sec ) ( Calculated with Max Motor Speed) Enter ( 1: Change, 2: No Change ) ?
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To change the maximum speed, use the following screen: Enter Max Speed (mm/sec) ?
Enter the maximum speed. 14 Set the axis direction in relation to the motor. If the direction of rotation about the axis due to the forward rotation of the motor is plus, enter 1 for TRUE; if minus, enter 2 for FALSE. MOTOR DIRERCTION Motion Sign = TRUE Enter ( 1: TRUE, 2: FALSE) ?
15 Enter the upper limit (UPPER LIMITS) of the axis operation range in mm for a linear axis and in deg. for a rotary axis. UPPER LIMITS Enter Upper Limit ( deg ) ?
Note) The user must decide on the upper limit. The upper limit and the lower limit, to be entered next, must satisfy the following condition: -- = Axis length For example, if the axis length is 100 mm, the following limits may be entered: = 50 mm = --50 mm 16 Enter the lower limit (LOWER LIMITS) of the axis operation range in mm for a linear axis and in deg. for a rotary axis. LOWER LIMITS Enter Lower Limit ( deg ) ?
17 Enter the mastering position. MASTER POSITION Enter Master Position ( deg ) ?
18 Set the acceleration/deceleration time constant. To change the first acceleration/deceleration time constant for each axis, enter 1 and then a new value. To use the suggested value, enter 2. ACC/DEC TIME Default Value of acc_time1=256(ms) Enter ( 1: Change, 2: No Change ) ?
To change the second acceleration/deceleration time constant for each axis, enter 1 and then a new value. To use the suggested value, enter 2. Default Value of acc_time2=128(ms) Enter ( 1: Change, 2: No Change ) ?
19 Set the minimum acceleration/deceleration time. The acceleration and other instructions will use this value if the actual acceleration/deceleration time is below the time specified here. To change the time, enter 1 and then a new value. To use the suggested value, enter 2. MIN_ACCEL TIME Default Value of min_accel time =384(ms) Enter ( 1: Change, 2: No Change ) ?
20 Set the ratio of the motor phase conversion total load inertia to the inertia (rotor inertia ratio). The inertia ratio must be larger than 1 and less than 5. To set no ratio, enter 0. Load Ratio is Load Inertia ( Kg*cm*s*2*) Motor Inertia (Kg*cm*s*2*) Enter Load ratio ? ( 0:None 1→5: Valid)
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21 Set the brake number: Enter the number of the brake used for the axis, in the range of 0 to 4. BRAKE SETTING Enter Brake Number (0→4)
22 Specify whether to enable or disable brake control. To enable it, select “1: Enable” and then the brake control delay time. To disable it, select “2: Disable.” SERVO TIMEOUT Servo Off is Enable Enter (1: Enable 2: Disable) ? Select?
(If 1: Enable is selected) Enter Servo Off Time ? (0.0→30.0 Sec)
23 The system returns to the screen in step 6. **** Group ? Total Nobot Axis = # 1.Display/Modify Nobot axis 1→6 2.Add Nobot axis 3.Delete Nobot axis 4.Exit Select item? F
To display/change the settings of the independent additional axis board (NOBOT), select 1. Display/Modify Nobot axis.
F
To set up another axis of the independent additional axis board (NOBOT), select 2. and repeat the procedure starting at step 7.
F
To delete an axis of the independent additional axis board (NOBOT), select 3. Delete Nobot axis.
F
To exit from the screen, select 4. Exit, then 0. EXIT.
This is the end of the procedure.
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C. FANUC i Pendant Note) This function is available with edition A0 or later of series 7D80. Note) This function is optional. j Contents of this appendix C.1
Overview
C.2
Appearance and Operations
C.3
Restrictions
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C.1 Overview The iPendant is an Internet--type robot teach pendant having a large color liquid--crystal display panel. This teach pendant allows you to reference multiple data items simultaneously and its visibility has been remarkably increased. The current user interface is also available with this teach pendant, so those who are familiar with operations of conventional teach pendants can use this teach pendant easily. This manual mainly describes differences between the conventional teach pendant and iPendant. Operations which are not described in this manual are common to the conventional teach pendant and iPendant. For the common operations, refer to “FANUC Robot R--J3i B Operator’s Manual.” The following items are different from those of the conventional teach pendant: F
Software LED display While the conventional teach pendant uses 11 LEDs to display the status, the iPendant displays the status with icons in the status window on the screen.
F
Screen split function The iPendant can display two or three split screens as well as one screen to enable multiple data items to be checked at a time.
F
How to change the operation target screen when multiple screens are displayed When multiple screens are displayed simultaneously, the operation target screen can be changed in turn.
F
Function of displaying one screen and status subwindow This function displays information such as the current position and safety signals with icons in the status subwindow (left screen).
F
Screen menus displayed by pressing the MENU key and those displayed on the edit screen The screen menus which are all displayed at a time allow you to quickly move to a desired screen and quickly insert a required command.
F
Internet browser screen You can enter a URL to access data on the network.
F
Color display according to the alarm severity Each message on the alarm list screen is displayed in the color specified according to its severity.
The iPendant is an optional function.
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C.2 Appearance and Operationsappearance and Operations This chapter describes the appearance of the iPendant and operations specific to the iPendant.
C.2.1 Appearance and Switches Fig. C--1 shows the locations of the emergency stop button, teach pendant enable switch, and deadman switches. Figure C--1. Teach pendant switches
Emergency stop button Deadman switches (*1)
Teach pendant enable switch
NOTE *1 Three--position switch
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C.2.2 Key Switches Fig. 2 shows the iPendant key switch layout. This section describes the screen focus change/screen split key and Diagnose/Help key specific to the iPendant. Figure C--2. Teach pendant key switches
Screen focus change/ Screen split key
Diagnose/ Help key
Key
Function Pressing this key singly changes the operation target screen. Pressing this key together with SHIFT key splits the screen (single Screen, double screens, triple screens, or status/single screen). Pressing this key singly moves to the hint screen. Pressing this key together with the SHIFT key moves to the alarm screen.
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C.2.3 Status Window The window at the top of the iPendant screen is called the status window. In this window, eight software LEDs, alarm indication, and override value are displayed. Each software LED is “on” when displayed together with an icon or “off” when displayed with no icon.
Table C--1 LEDs (Upper : On, Lower : Off)
Menu--related key switches DESCRIPTIONS
Busy
Indicates that the robot is working. This LED is on during execution of a program. It is also on when the printer or floppy disk drive is busy.
Step
Indicates that the robot is in the step operation mode.
Hold
Indicates that the HOLD button is being held or the HOLD signal is input.
Fault
Indicates that an alarm occurs.
Run
Indicates that a program is being executed.
I/O
Application--specific LED. This is a sample LED for a handling tool.
Prod
Application--specific LED. This is a sample LED for a handling tool.
TCyc
Application--specific LED. This is a sample LED for a handling tool.
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C.2.4 Splitting the Screen Pressing
key together with the SHIFT key displays the following screen menu:
Figure C--3. Screen split menu (one screen display)
Table C--2
Description of the screen split menu
ITEMS
DESCRIPTIONS
Single
Displays only one data item on the screen. The screen is not split.
Double
Splits the screen into right and left screens.
Triple
Splits the right screen into top and down screens and displays a total of three screens.
Status/Single
Splits the screen into right and left screens. The right screen is slightly larger than the left screen and the status subwindow with icons is displayed on the left screen.
Change focus
Changes focus of the operation target screen when multiple screens are displayed.
Figure C--4. Example of displaying double screens
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Figure C--5. Example of displaying triple screens
Figure C--6. Example of displaying the status/single screen
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C.2.5 Changing the Operation Target Screen Pressing the
key changes the operation target screen in turn. The title line of the screen which can be
operated is displayed in blue and the frame of the screen is displayed in red. Press the above key together with the SHIFT key. The following screen menu appears. By selecting “5. Change focus from this menu, you can also change the operation target screen. Figure C--7. Screen switch menu
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C.2.6 Internet Browser Screen To display the internet browser screen, press the MENU key. The following screen menu appears: Figure C--8. Screen menu
Select “BROWSER” from the screen menu. The following screen appears: Figure C--9. Internet browser screen
Select “Add a Link” and press the ENTER key. The following URL input screen appears:
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Figure C--10. URL input screen
Position the cursor on “Enter a Name” or “Enter an Address” in the above screen and press the ENTER key. The following software keyboard appears. Enter alphabetic and other characters. After confirming your entry, press the exit key at the lower right to exit the software keyboard.
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In the following sample screen, the name and address have been entered. After you have entered the name and address, position the cursor on the continue button and press the ENTER key.
After the continue button is pressed, the registered link information is displayed as follows: Figure C--11. Link screen
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C.2.7 Screen Selection Menu and Screen Menus on the Edit Screen Pressing the MENU key displays the following screen menu. Positioning the cursor on a menu item with " displays its submenus at a time. Use the right arrow key to select the item corresponding to a screen to be displayed. Figure C--12. Screen selection menu
Pressing F1 “INST” on the edit screen displays the following screen menus. You can reference all commands at a time. Position the cursor on a desired command to insert it. Figure C--13. Screen menus on the edit screen
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C.2.8 Status Subwindow The status subwindow displays various types of statuses graphically. To display the status subwindow, select “4 Status/Single” from the following screen menu
The left screen of the following two screens is the status subwindow. Position the cursor on Position Display, Operator Panel or Safety Signals and press the ENTER key. The corresponding status screen appears. Figure C--14. Status subwindow
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C.2.8.1 Current Position Display When “Position Display” is selected, the following screen appears:
C.2.8.2 Operator Panel Status Display When “Operator Panel” is selected, the following screen appears. Each graphic indicator is on or off according to the status of the remote device.
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C.2.8.3 Safety Signal Status Display When “Safety Panel” is selected, the following screen appears. Each graphic indicator is on or off according to the status of the corresponding safety signal.
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C.2.9 Color Display According to the Alarm Severity On the following alarm history screen, each message is displayed in the color specified according to its alarm severity.
The color assigned to each alarm severity is listed below:
Alarm severity
Color
Description
NONE WARN
White
The program being executed is not affected.
PAUSE.L PAUSE.G
Yellow
The program being executed stops, but can be restarted after the cause of the alarm is removed.
STOP.L STOP.G
Yellow
SERVO SERVO2
Red
ABORT.L ABORT.G
Red
SYSTEM
Red
RESET(*)
Blue
SYST--026 System normal power up(*2)
Blue
The program being executed stops and cannot be restarted.
NOTE *2 Messages “RESET” and “SYST--026 System normal power up” are displayed in blue.
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C.3 Restrictions F
Two program edit screens cannot be opened simultaneously. The edit screen is always displayed in the left window.
F
When two or more screens are displayed at a time, the same menu screen may not be displayed on the screens. Example: Online position modification screen
F
The iPendant is available only with edition A0 or later of series 7D80 of the R--J3iB.
*
NetFront by ACCESS Co. Ltd. is adopted for the Internet function of this product.
*
NetFront is registered trademark of Access Co. Ltd. in Japan.
*
Part of the software of this product includes modules developed by Independent JPEG Group.
*
This product use a technology included in LZW patent of Unisys Co. Ltd. Please keep following restrictions. (1) Do not modify or copy the software of this product. Do not sale or provide the software extracted from this product. (2) Do not use the software of this product for different purpose from browser. (3) Do not use a technology included in LZW patent of Unisys Co. Ltd. without this product.
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D. ALARM CODES This part of this manual describes alarm codes, alarm severity, causes, and actions. j Contents of this appendix D.1 Description of an Alarm Code Table D.2 Alarm Codes
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D.1 Description of an Alarm Code Table
Message
Alarm code
SRVO--001 SERVO OPERATING
PANEL E--stop
Alarm severity
Alarm code
Alarm ID: Alarm type Alarm number
Alarm message: Description of the alarm Alarm severity
Program
Robot
Power to the servo system
NONE Does not stop stop.
WARN
------------
Does not stop stop.
------------
PAUSE.L Not turned off
PAUSE.G STOP.L
Decelerates and stops.
Halts.
Local Global Local
STOP.G
Global
SERVO
Stops immediately.
Turned off
ABORT.L
Decelerates and stops.
Not turned off
Stops immediately. immediately
Turned off
ABORT.G
Terminates forcibly. forcibly
SERVO SYSTEM Range
Range
Global Local Global Global Global
Range in which the alarm is applied when multiple programs run simultaneously (multitask function) Local
The alarm is applied only to a program which has caused the alarm.
Global
The alarm is applied to all programs.
Alarm An alarm is issued when a failure occurs while the program is taught or played back or when the emergency stop signal or another alarm signal is input from a peripheral unit. The alarm is issued to notify the operator of the failure so the operator can halt processing for safety’s sake. NOTE If an alarm whose number is not described herein occurs, contact our service center serving your locality.
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Alarm codes display or indication When an alarm is issued, the alarm LED lights on the teach pendant and the alarm message is displayed in the first and second line of the screen. The operator can find out which alarm has been issued by looking at the LED and message. Figure D--1. Alarm Display
Alarm code Detail code (ID--number)
INTP-224 (SAMPLE1, 6) Jump label is fail MEMO-027 Specified line does not exist SAMPLE1 JOINT 30 % 6/7
Alarm severity How to operate the program or the robot until the program or the robot stops depends on the seriousness of the cause of the alarm. This “seriousness” is called alarm severity. The degree of alarm severity is indicated as follows: Table D--1.
Alarm severity
Alarm severity
Description
WARN alarm
A WARN alarm warns the operator of a comparatively minor or unimportant failure. The WARN alarm does not affect the operation of the robot. When the WARN alarm occurs, no corresponding LED on the teach pendant or the machine operator’s panel lights. To prevent a possible failure, appropriate action should be taken.
PAUSE alarm
When a PAUSE alarm occurs, the execution of the program is halted, and the operation of the robot is stopped after the operation in progress is completed. Appropriate action must be taken for the alarm before the program is restarted.
STOP alarm
When a STOP alarm occurs, the execution of the program is halted, and the robot is decelerated until it is stopped. Appropriate action must be taken for the alarm before the program is restarted.
SERVO alarm
When a SERVO alarm occurs, the power to the servo system is turned off to halt the execution of the program and to stop the robot immediately. A SERVO alarm is issued for safety’s sake or when a failure occurs during robot operation.
ABORT alarm
When an ABORT alarm occurs, the execution of the program is forcibly terminated, and the robot is decelerated until it is stopped.
SERVO 2 alarm
When a SERVO 2 alarm occurs, the power to the servo system is turned off to forcibly terminate the program and to stop the robot immediately. A SERVO alarm is issued for safety’s sake or when a failure occurs during robot operation.
SYSTEM alarm
A SYSTEM alarm is issued when a major system failure occurs. When the SYSTEM alarm is issued, every robot in the system is disabled. After taking appropriate action for the alarm, turn the power off, the turn it on again.
Active alarm screen The active alarm screen displays only active alarm(s). Once the alarms have been eliminated by alarm clear signal input, the active alarm screen reads “THERE ARE NO ACTIVE ALARMS.” The screen displays the alarm(s) output after the last alarm clear signal input. When the delete key (+ shift) is pressed on the alarm history screen, the corresponding alarm is cleared from the active alarm screen. The screen shows alarms having a severity level of PAUSE or higher. WARN or NONE alarms or resets are not displayed. Some PAUSE alarms or more severe alarms might not be displayed if system variables such as $ER_NOHIS are set accordingly. If multiple alarms are detected, the screen displays the alarms in the opposite order to that in which they were detected. Up to 100 lines can be displayed. If an alarm has a cause code, the cause code is displayed below the alarm display line.
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Figure D--2. Procedure for Displaying the Active Alarm Screen and Alarm History Screen MENU key pressed, then 4 ALARM selected
Alarm key pressed
Automatically displayed when an alarm is output
Active alarm screen displayed F3 [ACTIVE] pressed
F3 [HIST] pressed
Alarm history screen displayed
Automatic alarm display function When an alarm which will cause the system to stop (PAUSE or severer alarm) is detected, the automatic alarm screen display function automatically displays the alarm screen. This function frees the operator of having to display the alarm screen and enables the direct cause of the system failure to be found quickly. NOTE Once the display requirements are satisfied, the alarm screen is automatically displayed even if an alarm is detected at start--up. The automatic alarm display is performed irrespective of the start mode. NOTE If an alarm is detected when a CRT is connected, the alarm screen is displayed on both the teach pendant and the CRT. The requirements for automatic alarm screen display are as described below: F
When the flag of the automatic alarm screen display function is set On the system setting screen, select AUTO.DISPLAY OF ALARM MENU to enable or disable the automatic display function. The function is disabled by default. For this change to take effect, the power must be turned off and then on again. --> See Section 3.14.
F
When the Auto. display of alarm menu flag for an alarm severity level is set $ER_SEV_NOAUTO[] sets whether automatic alarm screen display is enabled or disabled for each alarm severity level. There are seven levels of alarm severity. NONE and WARN alarms will not affect program execution or robot operation and will not instigate the automatic display. Automatic display is enabled for PAUSE and severer alarms by default. The setting can be changed on the system variable screen.
System variable
Corresponding alarm severity level
Standard setting
$ER_SEV_NOAUTO [1]
PAUSE
TRUE
$ER_SEV_NOAUTO [2]
STOP
TRUE
$ER_SEV_NOAUTO [3]
SERVO
TRUE
$ER_SEV_NOAUTO [4]
ABORT
TRUE
$ER_SEV_NOAUTO [5]
SYSTEM
TRUE
FALSE: Automatic alarm screen display is disabled. TRUE: Automatic alarm screen display is enabled. NOTE If a PAUSE alarm is detected, followed by an ABORT alarm, when the automatic display of a PAUSE alarm is disabled, automatic display is not performed during fault output. F
Automatic display of a particular alarm can be disabled.
The automatic alarm screen display function can be disabled for a particular alarm. Up to ten such alarms can be set on the system variable screen. If a specified alarm is detected while automatic alarm screen display is enabled, the alarm screen will not be automatically displayed.
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This setting is made with the following system variables: Description
System variable $ER_NOAUTO. $NOAUTO_ENB
Enables or disables the function to suppress automatic alarm screen display for an alarm specified in $ER_NOAUTO.NOAUTO_CODE[] while the automatic alarm screen display is enabled. D FALSE: The function to suppress automatic alarm screen display is disabled. D TRUE: The function to suppress automatic alarm screen display is enabled.
$ER_NOAUTO. $NOAUTO_NUM
Sets the number of alarms set in $ER_NOAUTO.NOAUTO_CODE[].
$ER_NAOUTO. $NOAUTO_CODE [1 to 10]
Error number consisting of alarm ID and alarm number Example 11 002 (Servo 002 alarm) Alarm ID Alarm number Alarm ID → See Section C.2.
For the alarms listed below, which are caused by a user operation and which cause the system to stop, $ER_NOAUTO.$NOAUTO_ENB is set to TRUE by default. When the setting is changed to FALSE, the corresponding alarm screen is automatically displayed. Servo 001
Operator’s panel emergency stop
Servo 002
Teach pendant emergency stop
Servo 003
Deadman’s switch
Servo 004
Fence open
Servo 005
Teach pendant released (mount/unmount button of the teach pendant pressed)
Servo 012
Power restoration
When an alarm set in $ER_NOAUTO.$NOAUTO_CODE[] and another alarm are detected in that order while $ER_NOAUTO.$NOAUTO_ENB is set to TRUE, automatic display is not performed. F
When fault output is in progress If the alarm screen is automatically displayed each time a PAUSE or severer alarm is detected, the alarm screen may be displayed while alarm recovery or setting check is being performed on another screen. The screens will be frequently switched, which can interfere with recovery and other operations. To prevent this from occurring, automatic display is not performed while an alarm is active. Whether there is an active alarm can be checked by the fault signal output. While the fault signal is output irrespective of the servo start--up, automatic display is not performed even if an alarm is detected.
NOTE When a PAUSE, STOP, or ABORT alarm is detected, the fault signal is output with the servo system started. Each time an alarm clear signal is input, the fault signal is reset. If continuous monitoring is performed to raise an alarm (NO ARC PROCESS I/O BOARD, for instance), automatic alarm display might be performed at each reset input. NOTE When a SERVO or SYSTEM alarm is detected, the fault signal is reset after the servo system starts. Automatic return function The automatic return function displays the screen which was displayed until automatic screen display when an alarm clear signal is input. This function is used together with the automatic display function. The automatic return function operates as described below: F
When the automatic alarm screen display function is enabled, the alarm screen is automatically displayed if an alarm is raised. When the alarm is eliminated by the input of an alarm clear signal, the previous screen is automatically displayed.
F
If the alarm screen is not displayed automatically because of an alarm but displayed by means of menu selection, the previous screen is not displayed even if an alarm clear signal is input.
F
If another screen is displayed before an alarm clear signal is input, the automatic return function does not operate.
F
The automatic return function operates when the fault signal output is turned off.
F
If the power is turned off or on after the alarm screen is displayed by the automatic display function, the automatic return function does not work after the start--up. This is not affected by the start mode (cold start, hot start, etc.).
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Procedure D--1 Step
Displaying the alarm occurrence/alarm history/alarm detail information
1 Press the MENUS key to display the screen menu. 2 Select “4 ALARM”. The alarm occurrence screen is displayed. If an alarm is detected, the active alarm screen is automatically displayed.
3 MANUAL FCTNS 4 ALARM 5 I/O
INTP-224 (SAMPLE1, 6) Jump label failed Alarm:ACTIVE
JOINT
30 % 1/1
MENUS
MEMO-027 Specified line. does not exist
[ TYPE ]
Alarm cause code
HIST
3 To display the alarm history screen, press F3 [HIST]. When F3 [ACTIVE] is pressed, the active alarm screen appears again. 3 4 ALARM 5 I/O
INTP-224 (SAMPLE1, 7) Jump label is fail MEMO-027 Specified line does not exist Alarm JOINT 30 % 1/25 1 INTP-224 (SAMPLE1, 7) Jump label is 2 SRVO-002 Teach pendant E-stop 3 R E S E T 4 SRVO-027 Robot not mastered(Group:1) 5 SYST-026 System normal power up
MENUS
[ TYPE ]
CLEAR
HELP
NOTE The latest alarm is assigned number 1. To view messages that are currently not on the screen, press the F5, HELP, then press the right arrow key. 4 To display the alarm detail screen, press the F5 “HELP” key. CLEAR
HELP
F5
INTP-224 (SAMPLE1, 7) Jump label is fail INTP-224 (SAMPLE1, 7) Jump label is fail MEMO-027 Specified line does not exist 30-MAY-44 07:15 STOP.L 00000110 Alarm 1/25 1 INTP-224 (SAMPLE1, 7) Jump label is 2 SRVO-002 Teach pendant E-stop
[ TYPE ]
CLEAR
5 To return to the alarm history screen, press the PREV key. PREV
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6 To delete all the alarm histories, press and hold down the SHIFT key, then press the F4 “CLEAR” key. CLEAR
HELP
F4
SHIFT
NOTE When system variable $ER_NOHIS = 1, NONE alarms or WARN alarms are not recorded. When $ER_NOHIS=2, resets are not recorded in the alarm history. When $ER_NOHIS=3, resets, WARN alarms, and NONE alarms are not recorded. Procedure D--2
Halt caused by a major alarms and recoveries
Halt caused by a major alarm Step
1 When an alarm is issued, the running program is halted, and PAUSED or END is displayed on the screen of the teach pendant. An alarm message is also displayed on the screen of the teach pendant and the ALARM lamp lights. FAULT HOLD STEP BUSY
Recovery from a deadman switch alarm (SERVO--003) Step
1 Press and hold down the deadman switch, then press the RESET key. SRVO-003 Deadman switch released SAMPLE1 LINE 2 SAMPLE1 JOINT 30%
Eliminating an overtravel alarm (servo 005) Step
1 Press the MENUS key to display the screen menu. SRVO-005 Robot Overtrabel SAMPLE1 LINE 2 SAMPLE1
PAUSE JOINT 30%
2 Press 0 NEXT PAGE, then select 6 SYSTEM on the next page. Press F1 [TYPE], then select OT RELEASE. The OT Release screen appears. 5 POSITION 6 SYSTEM 7 System OT Release MENU
AXIS 1 2
OTMINUS ---
[ TYPE ]
RELEASE
OT REREASE TYPE
F1
818
OTPLUS OT --
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3 Press F2 [RELEASE] to release the overtravel axis. 4 While holding down the shift key, press the alarm clear button. 5 While holding down the shift key, press the jog key to move the tool along the overtravel axis into the movable range. Recovery from a broken wrist alarm (SERVO--006) Step
1 Press and hold down the SHIFT key, then press the RESET key. SRVO-006 Hand broken SAMPLE1 LINE 2 SAMPLE1
JOINT 30%
2 While pressing the SHIFT key, press the appropriate jog key to move the robot to a position where it can be repaired. NOTE The mastering data may be correct even if a pulse count mismatch alarm is detected. If the mastering data is correct, mastering need not be performed. Merely set $DMR_GRP.$MASTER_DONE to true, then select 6 MASTER/CAL on the positioning screen. Recovery from a pulse mismatch alarm, a BZAL alarm and a RCAL alarm (SRVO--038, 062, 063) Step
1 Press the MENUS key to display the screen menu. SRVO-038 Pulse mismatch SAMPLE1 LINE 2 SAMPLE1
JOINT
PAUSED 30 %
2 Press “0 ---- NEXT ----” and then select “6 SYSTEM” on the next page. Press F1 “[TYPE]” and then select “Variables”. A system variable screen is displayed. 5 POSITION 6 SYSTEM 7 MENUS
Variables TYPE
F1 3 Set TRUE to $MCR.$SPC_RESET. ( This system variable is automatically set to FALSE soon again.) 4 Press RESET key to release a alarm. Recovery from other alarms Step
1 Remove the cause of an alarm. For example, correct the program. 2 Press the RESET key to reset the alarm. Then, the alarm message disappears on the screen of the teach pendant. The ALARM LED goes off.
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D.2 Alarm Codes
ARC Alarm
( ID = 53 )
ARC--001 WARN Illegal arc equipment config An attempt was made to use or add more than a usable number of pieces of welding equipment. Cause: ARC--002 PAUSE.L Illegal arc schedule number The specified weld schedule number is illegal. Cause: Remedy: Check the specified weld schedule number. ARC--003 PAUSE.L No gas flow No shielding gas was supplied when arc was generated. Cause: Remedy: Check the gas supply unit. ARC--004 WARN Gas flow after weld The gas output signal was turned off, but the gas input signal was not turned on. Cause: Remedy: Check the gas valve and gas supply unit. ARC--005 PAUSE.L Gas fault The gas fault signal was detected when welding was under way. Cause: Remedy: Check the gas supply unit. ARC--006 PAUSE.L Wire fault The wire fault signal was detected when welding was under way. Cause: Remedy: Check the gas supply unit. ARC--007 PAUSE.L Water fault The cooling water fault signal was detected when welding was under way. Cause: Remedy: Check the cooling water supply unit. ARC--008 PAUSE.L Power supply fault The power supply fault signal was detected when welding was under way. Cause: Remedy: Check the power supply unit. ARC--010 PAUSE.L Wire stick detected A wire stick condition occurred. Cause: Remedy: Ensure the robot and welding equipment safety, then cut the weld wire. ARC--011 PAUSE.L Wire stick, not reset A wire stick condition was detected, but not reset. Cause:
Remedy:
It is likely that a wire stick reset has been disabled. Note that if TIG welding was under way or welding was not under way, a wire stick reset will not be performed. Ensure the robot and welding equipment safety, then cut the weld wire.
ARC--012 PAUSE.L Wire stick reset (s) failed A wire stick condition was detected, but an automatic wire stick reset failed. Cause: Remedy: Ensure the robot and welding equipment safety, then cut the weld wire. ARC--013 PAUSE.L Arc start failed No arc occurrence was detected within the arc detection time after a command to start arc was issued. Cause: Remedy: 1 Check the weld wire and welding equipment. 2 Adjust the arc detection time, using the Weld System screen. 3 Alter the arc schedule.
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ARC--014 WARN Teach pendant is disabled When the teach pendant had been disabled, the weld possible or manual wire feed key of the teach Cause: Remedy:
pendant was pressed. Enable the teach pendant.
ARC--015 WARN Press shift with this key The weld possible or manual wire feed key was pressed without pressing the shift key. Cause: Remedy: Perform this operation while holding down the shift key. ARC--016 PAUSE.L Weld by shift FWD is disabled An attempt was made to execute arc welding from the teach pendant, when the teach pendant had been Cause: Remedy:
disabled for welding. 1 Execute arc welding from the operator’s panel or remote control unit. 2 Enable welding from TP on the Weld System screen.
ARC--017 WARN Arc start was disabled An attempt was made to execute an arc start command when welding had been disabled. Cause: Remedy: 1 If the teach pendant is enabled, press the enable welding key on the teach pendant to enable welding. 2 If the remote switch is set to the remote position, turn on the weld I/O weld enable signal. 3 Check the Test Execution screen to see whether the machine lock or dry run is enabled.
ARC--018 PAUSE.L Lost arc detect It became impossible to detect the arc detection signal when welding was under way. Cause: Remedy: 1 Check the wire supply unit. 2 Check the speed and arc--off time specified as weld schedules.
ARC--019 PAUSE.L Can’t read arc detect input The arc detection signal cannot be detected. Cause: Remedy: Check that the process I/O printed--circuit board is connected. ARC--020 PAUSE.L No plan data area available There is no sufficient memory for executing arc commands. Cause: Remedy: Reduce the number of programs. ARC--021 ABORT.L Program aborted while welding The program was aborted when welding was under way. Cause: Remedy: Check that the arc end command has been taught. ARC--022 WARN Cause: Remedy:
The analog output has exceeded the permissible range of the unit because an argument specified in the welding schedule is beyond the permissible range. Set the weld schedule argument to within the permissible range.
ARC--023 PAUSE.L Illegal arc schedule type The value in the register specified in the arc command is not an integer. Cause: Remedy: Use a register that holds an integer. ARC--024 WARN Invalid equipment range The difference between the maximum and minimum analog setting values for the welding equipment Cause: Remedy:
is too small. Increase the difference between the maximum and minimum analog setting values for the welding equipment, using the Weld Equip screen.
ARC--025 WARN Invalid A/D or D/A range The value of the $AWEPRR system variable was changed illegally. Cause: Remedy: Change the correct field of the $AWEPRR system variable to a valid value. 821
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ARC--026 WARN Cannot scale AIO while welding An attempt was made to modify the analog conversion value when welding was under way, but the Cause: Remedy:
conversion value has not been altered. Switch the power off and on again.
ARC--027 STOP.G The analog conversion value of welding voltage is incorrect. Cause: Remedy: Adjust the conversion value of voltage output on the welder setup screen. ARC--028 STOP.G The analog conversion value of welding current is incorrect. Cause: Remedy: Adjust the conversion value of current output on the welder setup screen. ARC--029 STOP.G The analog conversion value of wire feed speed is incorrect. Cause: Remedy: Adjust the conversion value of wire feed speed output on the welder setup screen. ARC--030 WARN Wire stick is still detected A wire stick condition was detected even after a reset. Cause: Remedy: Ensure the robot and welding equipment safety, then cut the weld wire. ARC--031 PAUSE.L No motion while welding The robot was suspended for a period longer than specified in $ARC_LOS_TIM when welding was Cause: Remedy:
under way. If you need not keep the robot operating, increase the arc--off detection time, using the Weld Equip screen, or disable arc--off detection, using the Weld System screen.
ARC--032 PAUSE.L Weld stopped by single step A single step mode was entered when welding was under way, leading to interruption of the welding. Cause: Remedy: To continue welding, exit the single step mode. ARC--033 PAUSE.L Override must be 100% to weld An attempt was made to perform welding, using an override of below 100%. Cause: Remedy: Perform welding, using an override of 100%. ARC--034 PAUSE.L Task does not control welding When a task was performing welding, another task attempted to perform welding. Cause: Remedy: Terminate the task that is currently performing welding, or abort it, then execute the other task. ARC--035 PAUSE.L Equipment number isn’t set The arc command does not contain an equipment number. Cause: Remedy: Specify the desired equipment number in the detail data of the program or the arc command. ARC--036 PAUSE.L Such equipment mask isn’t supported ARC--037 WARN Another equipment is inching now Another piece of welding equipment is inching now. Cause: Remedy: Release the shift key or user key to cause that welding equipment to stop inching. ARC--038 PAUSE.L Already held another equipment This program (task) is already, using another piece of welding equipment. Cause: Remedy:
One task can use only one piece of welding equipment. Use another task to control the welding equipment of interest.
ARC--039 PAUSE.L %s^1 AO[%d^2] is not scaled The conversion value for the AO signal is incorrect. Cause: Remedy: Re--set the conversion value, using the Weld IO screen. 822
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ARC--040 PAUSE.L Missing I/O: %s^1 The weld I/O signal cannot be detected normally. Cause: Remedy: Check that the I/O hardware has been connected. Also check that the corresponding port number has been set correctly on the Weld I/O screen.
ARC--072 PAUSE.L Illegal AMR packet This is a system internal error. Cause: Remedy: If this error occurs, it might be necessary to switch the power off and on again. ARC--084 ABORT.L Application process is changed during welding The application process was altered when welding was under way. Cause: Remedy: Correct the program.
CD Alarm
( ID = 82 )
CD--001 WARN No global variables There is no system variable for coordination control. Cause: Remedy: Perform controlled start or initial start. CD--002 WARN Unable to allocate memory It is impossible to newly allocate memory. Cause: Remedy: Check the amount of unused memory. CD--003 PAUSE.G Follower recv invalid segment Remedy: Call the FANUC Service Center. CD--004 PAUSE.G Illegal leader INTR point data Remedy: Call the FANUC Service Center. CD--005 PAUSE.G Non--coordinated group detected A coordination command was used for a group which had not been set up for coordination. Cause: Remedy: Check the motion command. Set the group as coordination group, then perform cold start.
CD--006 PAUSE.G Illegal follower joint motion Individual--axis motion was used by a follower group during coordinated motion. Cause: Remedy: Use linear or circular motion. CD--007 PAUSE.G Circular motype not supported No circular motion is supported for a leader group. Cause: Remedy: Use linear motion. CD--008 PAUSE.G No leader No leader group has been set up. Cause: Remedy: Check the motion command. Set up a leader group, and perform cold start.
CD--009 PAUSE.G More than one leader More than one leader group has been set up. Cause: Remedy: Check the motion command. Make correction on the leader groups, and perform cold start.
CD--010 PAUSE.G Invalid angle in point data The position data is invalid. Cause: Remedy: Call the FANUC Service Center. 823
ALARM CODES
B--81464EN--3/01
CD--011 PAUSE.G Error in flushing CD mailbox An error has occurred in the mailbox. Cause: Remedy: Perform cold start. CD--012 PAUSE.G Illegal leader motion Issue a motion command for both leader and follower groups as motion after the coordinated motion. Cause: Remedy: Specify the motion of the follower group also. CD--013 WARN Jog group is not leader Coordinated jog cannot be performed for a non--leader group. Cause: Remedy: Select a leader group. CD--014 WARN Jog group has multi follower Coordinated jog cannot be performed for a leader group that has more than one follower group. Cause: Remedy: Perform coordinated jog for a leader group that has only one follower group. CD--015 PAUSE.G Wrist joint is not supported Motion with no wrist posture is not supported as a coordinated motion. Cause: Remedy: Delete commands with no wrist posture. CD--016 PAUSE.G INC motion is not supported Incremental motion is not supported as coordinated motion. Cause: Remedy: Delete incremental commands. CD--017 PAUSE.G INDEP moth is not supported Independent motion is not supported as coordinated motion. Cause: Remedy: Change independent motion to dependent motion. CD--018 PAUSE.G No calibration for CD Coordination control calibration has not been completed. Cause: Remedy: Perform coordination control calibration. CD--019 PAUSE.G Illegal follower setting In this motion, the number of follower groups is 0, two, or greater. Cause: Remedy: Set the number of follower group to 1. CD--020 WARN Not reach relative speed The follower group has not attained the specified speed. Cause: Remedy: Re--teach the positions of the leader and follower groups so that the specified speed can be attained. CD--021 PAUSE.G No kinematics in CD group Coordinated motion is impossible for this robot, because it has no kinematics. Cause: Remedy: Alter the robot. CD--022 PAUSE.G Prev term type is not FINE The motion that precedes coordinated motion has not been set to calibration or CNT0. Cause: Remedy: Set the motion that precedes coordinated motion to calibration, CNT0, or individual--axis motion. CD--023 PAUSE.G Illegal CD setting The specified coordination control setting is illegal. Cause: Remedy: Check the setting. CD--024 WARN Calibration was inaccurate The taught position is not correct, or the start group is not mechanically exact. Cause: Remedy: Check the leader group, and re--teach its position. 824
ALARM CODES
B--81464EN--3/01
CD--025 PAUSE.G Can’t convert position It is impossible to convert the position. Cause: Remedy: Call the FANUC Service Center. CD--026 PAUSE.G Illegal transition:nonCD<-->CD A request to switch from coordinated motion to non--coordinated motion or vice versa has occurred. Cause: Remedy: Add or delete an additional--coordination command. CD--027 PAUSE.G Illegal follower transition An attempt was made to use a follower group in more than one pair. Cause: Remedy: Insert non--coordinated motion for a pair with a different follower group.
MUPS Alarm
( ID = 48 )
MUPS--001 WARN use of M--PASS SP’s bef. init The variables have not be initialized because of M--PASS SP’s. Cause: Remedy: Perform controlled start. MUPS--002 PAUSE.G Isolated offset destination The compensation amount for the offset destination is divided. Cause: Remedy: At least two points are necessary. MUPS--003 PAUSE.G Invalid motype with offset A motion type for the compensation path is invalid. Cause: MUPS--004 PAUSE.G Segment too short using OFFSET The motion segment is shorter than the compensation amount. Cause: Remedy: Make the motion segment longer. MUPS--005 PAUSE.G Invalid OFFSET_MODE value The specified OFFSET_MODE value is invalid. Cause: MUPS--006 PAUSE.G BWD not allowed in M--PASS Backward motion is impossible in the M--PASS function. Cause: MUPS--007 PAUSE.G Illegal transition:nonCD<-->CD A request to switch from coordinated motion to non-- coordinated motion or vice versa has occurred. Cause: Remedy: Add or delete an additional--coordination command.
RPM Alarm
( ID = 43 )
RPM--001 WARN N_buffers invalid The specified $RPM_CFG.$N_BUFFERS value is invalid Cause: Remedy: Set $RPM_CFG.$N_BUFFERS to a value between 1 and 100. RPM--002 WARN Record size invalid The specified $RPM_CFG.$DATA_SIDE Cause: Remedy: Set $RPM_CFG.$DATA_SIZE to a value between 4 and 32.
825
ALARM CODES
B--81464EN--3/01
RPM--003 WARN N_segments invalid RPM--004 WARN N_record invalid RPM--005 SYSTEM Memory allocation failed RPM--006 PAUSE.G Invalid record no. RPM--007 PAUSE.G No data block left RPM--008 PAUSE.G Program id is different RPM--009 PAUSE.G Segment not in buffer There is no path data. Cause: Remedy:
Specify a path data number. Check the RPM command for recording this segment. Set the correct path data number.
RPM--010 PAUSE.G Invalid record_offset RPM--011 PAUSE.G All segments used RPM--012 PAUSE.G Segment already in buffer RPM--013 PAUSE.G Invalid buffer no The specified path data number is invalid. Cause: Remedy: Specify a path data number, using a value in a range set up in $RPM_CONFIG.$N_BUFFERS. RPM--014 PAUSE.G Record not stored RPM--015 WARN Use of RPM SP’s bef. init RPM--016 WARN Change in pitch mode RPM--017 WARN Change in distance RPM--018 WARN Not in playback mode RPM--019 WARN All data records used RPM--020 WARN Read record not stored There is no path data. Cause: Remedy: Confirm the position number, or fetch the data. RPM--021 WARN Not in record mode RPM--022 WARN Store in same record RPM--023 WARN No TIR for motion RPM--024 PAUSE.G No data in specified buffer RPM--025 PAUSE.G Unexpected restart dest RPM--026 PAUSE.G Pitch value too small The fetch interval is too small. Cause: Remedy: When $RPM_PG.$PITCH_MODE is 1, set $RPM_PG.$PITCH to 100 or greater. 826
ALARM CODES
B--81464EN--3/01
RPM--027 PAUSE.G Illegal arc instruction Independent arc start is in use. Cause: Remedy: Specify additional--command arc start. RPM--028 PAUSE.G Segment too short The motion segment is 0 or too short. Cause: Remedy: The motion segment that is 0 is not supported. Make it longer.
TAST Alarm
( ID = 47 )
TAST--000 WARN Unknown error (TAST00) This is a software internal error. Cause: Remedy: Switch the power off and on again. TAST--001 WARN TAST global vars failure No system variable has been loaded for the arc sensor. Cause: Remedy: Switch on the power, using controlled start, and initialize “Motion Software Parts.” TAST--002 PAUSE.G TAST error IO allocation An attempt to allocate I/O memory failed. Cause: Remedy: Switch the power off and on again. TAST--003 PAUSE.G TAST IO initialization failed An attempt to allocate an analog signal failed. Cause: Remedy: An attempt to initialize the process I/O printed--circuit board failed. TAST--004 PAUSE.G TAST IO failed This is a software internal error. Cause: Remedy: Switch the power off and on again. TAST--005 WARN TAST time tick missing This is a software internal error. Cause: Remedy: Increase the frequency or sampling period. TAST--006 PAUSE.G TAST memory dispose failure This is a software internal error. Cause: Remedy: Switch the power off and on again. TAST--007 PAUSE.G TAST PRM saving failure This is a software internal error. Cause: Remedy: Switch the power off and on again. TAST--008 PAUSE.G TAST incorrect schedule num The specified arc sensor schedule number is incorrect. Cause: Remedy: Correct the schedule number. TAST--009 PAUSE.G TAST weave freq is too low The weaving frequency is too low. Cause: Remedy: Increase the frequency. TAST--010 PAUSE.G TAST software error (SRIF) This is a software internal error. Cause: Remedy: Switch the power off and on again. TAST--011 PAUSE.G TAST software error (PMPT) This is a software internal error. Cause: Remedy: Switch the power off and on again. 827
ALARM CODES
B--81464EN--3/01
TAST--012 PAUSE.G TAST software error (INTP) This is a software internal error. Cause: Remedy: Switch the power off and on again. TAST--013 PAUSE.G TAST software error This is a software internal error. Cause: Remedy: Switch the power off and on again. TAST--014 PAUSE.G TAST weave freq is too high The weaving frequency is too high. Cause: Remedy: Decrease the frequency.
THSR Alarm
( ID = 60 )
THSR--001 PAUSE.G Illegal instruction sequence An attempt was made to execute touch sensor commands in the wrong sequence. Cause: Remedy:
For example, once an offset start command was executed, a search start command was executed before an offset end command. Ensure that the touch sensor commands are executed in the correct sequence. Stop the current program, and restart it.
THSR--002 PAUSE.G Illegal schedule number The entered schedule number is out of the valid range. Cause: Remedy: Set the number to a value between 1 and 32. THSR--003 PAUSE.G Illegal work frame number The entered workpiece coordinate system number is out of the valid range. Cause: Remedy: Set the number to a value between 1 and 32. THSR--004 PAUSE.G Illegal output PR number The entered position register number is out of the valid range. Cause: Remedy: Specify a valid position register number. THSR--005 PAUSE.G Illegal search PR number The specified search result position register number is out of the valid range. Cause: Remedy: Specify a valid position register number. THSR--006 PAUSE.G Search without search start A search command was executed before a search start command. Cause: Remedy: Add a search start command. THSR--007 PAUSE.G Invalid touch I/O assignment I/O assignment for the touch sensor is incorrect. Cause: Remedy: Check the assignment with Touch I/O Setup screen. THSR--008 PAUSE.G Arc enable detected The arc welding circuit has been enabled. Cause: Remedy: Disable the arc welding circuit before enabling touch sensing. THSR--009 WARN Teach pendant not enabled The teach pendant has been disabled. Cause: Remedy: Enable the teach pendant. THSR--010 PAUSE.G Illegal motion state The system is in an error condition. Cause: Remedy: Press the reset button to reset the system. 828
ALARM CODES
B--81464EN--3/01
THSR--011 PAUSE.G Illegal sensor port number The specified search port is out of the valid range. Cause: Remedy: Re--specify the port type and number, using the Touch I/O Setup screen. THSR--012 PAUSE.G Illegal search pattern The specified search pattern is not found. Cause: Remedy: Alter the search pattern, using the Touch Sched screen. THSR--013 PAUSE.G Illegal number of search The number of search commands does not match the specified search pattern. Cause: Remedy: Change the search pattern or the number of search commands. THSR--014 WARN Illegal search distance This is a warning message. Cause: Remedy:
The specified search distance is out of the valid range. A standard speed will be used. Correct the search speed, using the Touch Sensor Sched screen.
THSR--015 WARN Illegal search speed The specified search speed is out of the valid range. Cause: Remedy: Correct the search speed, using the Touch Sensor Sched screen. THSR--016 WARN Illegal return speed The specified return speed is out of the valid range. Cause: Remedy:
A standard speed will be used. Correct the return speed, using the Touch Sensor Sched screen.
THSR--017 PAUSE.G No contact with part No contact was made to the part when a search was under way. Cause: Remedy: Teach a new start point, using touch--up. THSR--018 PAUSE.G Too many searches There are too many searches for the specified pattern. Cause: Remedy: Delete unnecessary search commands. THSR--019 PAUSE.G Mixing search types Two or more one--dimensional searches can be done in one NONE--search type search. Cause: Remedy: Select another search type, or delete two or more search directions. THSR--020 PAUSE.G Geometic computing error No normal offset can be computed in this search. Cause: Remedy: Check the search pattern and search command. THSR--021 PAUSE.G Points are too close The touched points are too close to each other. Cause: Remedy: Teach a new search start point. THSR--022 PAUSE.G Part is not mastered The search command does not have mastering data. Cause: Remedy: First perform mastering for the part. THSR--023 WARN No search start There in no search start command among search commands. Cause: Remedy: Add a search command before the search. THSR--024 WARN No offset start There is no touch offset start command that corresponds the touch offset end command. Cause: Remedy: Add a touch offset start command. 829
ALARM CODES
B--81464EN--3/01
THSR--025 PAUSE.G Nested search start Once a search start command was executed, another search start command was executed before a Cause: Remedy:
search end command. Add a search end command at an appropriate position, or delete the latter search start command.
THSR--026 PAUSE.G Nested offset start Once a search start command was executed, another touch offset start command was executed before Cause: Remedy:
a touch offset end command. Add a touch offset end command at an appropriate position, or delete the latter touch offset start command.
THSR--027 PAUSE.G Preplan is not allowed No preplan can be executed during the execution of a search start command. Cause: Remedy: It is normal that an error occurs if a preplan is specified in a search start command. THSR--028 PAUSE.G Group number mismatch A search motion must be in group 1. Cause: Remedy: Use group 1 to memorize the search motion. THSR--029 WARN No contact warning No contact was made to the part when a search was under way. Cause: Remedy: Teach a new search start point, using touch--up. THSR--030 PAUSE.G Contact before search The wire contacted the part before a search is started. Cause: Remedy: Check the part and wire, or teach a new search start point. THSR--031 WARN Illegal register number The entered register number is invalid. Cause: Remedy:
The software will reset the entered register number and set the maximum valid number. Check the number.
THSR--032 PAUSE.G Position type mismatch The position register must be of XYZWPR type. Cause: Remedy:
No individual--axis representation can be used. Set the position type to XYZWPR.
THSR--033 PAUSE.G Not enough points Calculation was impossible because of an insufficient number of interpolation points. Cause: Remedy: Increase the number of interpolation points. THSR--034 PAUSE.G No bwd on search motion No backward search motion can be made when a search is under way. Cause: Remedy: Do not press the shift + backward keys when a search is under way. THSR--035 PAUSE.G Error Allocating data There is no sufficient memory. Cause: Remedy: Delete unnecessary variables and programs. THSR--036 PAUSE.G Coord pair is not available No coordination function has been installed, or calibration has not be completed. Cause: Remedy: Install a coordination function, or perform calibration. THSR--037 PAUSE.G Illegal motion ref. grp. The reference group does not match the leader group. Cause: Remedy:
schd_ref_grp = 1 must be specified for a simple search. Change the reference group.
830
ALARM CODES
B--81464EN--3/01
THSR--038 PAUSE.G Not matches to leader grp. The touch coordinate system reference group does not match the leader group. Cause: Remedy: Change the coordinate system reference group. THSR--039 PAUSE.G Reference grp mismatch A value other than 1 cannot be specified for the reference group in a simple search. Cause: Remedy: Change the reference group.
TRAK Alarm
( ID = 54 )
TRAK--000 WARN Unknown error (TO00) This is a system internal error. Cause: Remedy: Switch the power off and on again. TRAK--001 PAUSE.G Track jnt move not allowed Individual--axis motion cannot be performed. Cause: Remedy: Change to linear motion. TRAK--002 PAUSE.G Track error allocating data This is a system internal error. Cause: Remedy: Increase the size of RAM. TRAK--003 PAUSE.G Track global variable failure This is a system internal error. Cause: Remedy: Increase the size of RAM. TRAK--004 PAUSE.G Track illegal schedule number The entered tracking schedule number is out of the valid range. Cause: Remedy: Enter a value that falls in the valid range. TRAK--005 PAUSE.G Track destination gone error The tracking destination is outside the window. Cause: Remedy: Move the conveyer backward. TRAK--006 WARN Track destination gone warning The tracking destination is outside the window. Cause: Remedy: Re--teach the tracking destination again. TRAK--007 WARN Unsupported function code This is a system internal error. Cause: Remedy: No measures need be taken. TRAK--008 WARN Not support semi hot start No power interruption recovery is supported for the tracking function. Cause: TRAK--009 PAUSE.G Track cart move not allowed Orthogonal filter--based motion cannot be made in tracking. Cause: Remedy: Change to individual--axis filter motion. TRAK--010 PAUSE.G Track no line track functn ptr No tracking function (FP pointer) is found. Cause: Remedy: Load the tracking function. TRAK--011 PAUSE.G Track no CIRC wrist joint Circular motion with no wrist posture used can be performed when line tracking is under way. Cause: Remedy: Change to motion with wrist posture used. 831
ALARM CODES
B--81464EN--3/01
( ID = 45 )
WEAV Alarm
WEAV--000 WARN Unknown error (WV00) This is software internal error. Cause: Remedy: Switch the power off and on again. WEAV--001 WARN Weave global variable failure This is software internal error. Cause: Remedy: After controlled start is finished, initialize the motion software part. WEAV--002 PAUSE.G Weave motion data missing This is software internal error. Cause: Remedy: Switch the power off and on again. WEAV--003 PAUSE.G Weave error allocating data There is no sufficient memory. Cause: Remedy: Delete unnecessary files. WEAV--004 PAUSE.G Weave system variable failure The weaving system variables have not be loaded or initialized. Cause: Remedy: After controlled start is finished, initialize the system variables. WEAV--005 PAUSE.G Weave pattern does not exist This is a software internal error. Cause: Remedy: Delete the incorrect error. WEAV--006 PAUSE.G Weave illegal schedule number The weaving schedule number is invalid. Cause: Remedy: Change the schedule number to a number within the valid range. WEAV--007 PAUSE.G Weave illegal frequency value The weaving frequency is invalid Cause: Remedy: Change the frequency to a value within the valid range. WEAV--008 PAUSE.G Weave illegal amplitude value The amplitude is invalid. Cause: Remedy: Change the amplitude value to a value within the valid range. WEAV--009 PAUSE.G Weave illegal dwell value The dwell timer value is invalid. Cause: Remedy: Change the dwell timer value to a value within the valid range. WEAV--010 WARN Weave too many pre--exec WS More than one weaving command was pre--executed. Cause: Remedy: No measures need be taken. WEAV--011 WARN Unsupported function code This is a software internal error. Cause: Remedy: Switch the power off and on again. WEAV--012 WARN Multi--group stop dwell invalid No dwell stop can be used in a program with multiple groups specified. Cause: Remedy: Set dwell stop to “move” on the Weave Setup screen. WEAV--013 PAUSE.G Incorrect weaving vectors The weaving vector is incorrect. It is impossible to calculate the weaving vector. Cause: Remedy: To calculate the correct weaving vector, set up a user coordinate system, or change the vector of the welding path.
832
ALARM CODES
B--81464EN--3/01
WEAV--014 PAUSE.G Wrist joint limit Wrist motion was not caught by a range limit. Cause: Remedy: Change the wrist posture so that the wrist will not be caught by a motion range limit. WEAV--015 PAUSE.G Wrist axes 5 closes to zero The angle of the fifth--axis is too small. Cause: Remedy: Change the posture of the wrist so that a singularity can be avoided. WEAV--016 PAUSE.G Unknown wrist configuration error An unknown wrist configuration was detected. Cause: Remedy: Change the posture of the wrist. WEAV--017 PAUSE.G Run_ang exceeds tol_ang tol_ang is too small. Cause: Remedy: Change the posture of the torch, or increase tol_ang. WEAV--018 PAUSE.G Invalid utool The current tool coordinate data is invalid. Cause: Remedy: Correct it.
SRVO Error Codes
( ID = 11 )
SRVO--001 SERVO Operator panel E--stop The operator panel emergency stop push button is pressed. Cause: Remedy: Twist the operator panel emergency stop push button clockwise to release. Press RESET. SRVO--002 SERVO Teach pendant E--stop The emergency stop button on the teach pendant was pressed. Cause: Remedy: Release the emergency stop button on the teach pendant. SRVO--003 SERVO Deadman switch released The deadman’s switch was not pressed when the teach pendant was enabled. Cause: Remedy: Press the deadman’s switch to enable operation of the robot. SRVO--004 SERVO Fence open On the terminal block on the printed circuit board of the operator’s panel, no connection is established Cause: Remedy:
between the FENCE1 and FENCE2 signals. When a safety door is connected, it is open. Establish a connection between FENCE1 and FENCE2, then press the reset key. When a safety door is connected, close the door before starting work.
SRVO--005 SERVO Robot overtravel A hardware limit switch on an axis was tripped. Usually, the movement of the robot is prevented from Cause: exceeding a limit beyond the maximum range of movement (software limits) for each axis. However, when the robot is shipped, the overtravel state is set for transit.
Remedy: Step
1 Check the fuse (F4) in the power supply unit. Replace the fuse if it has blown. 2 Release the overtravel axis by using the overtravel release screen [SYSTEM OT RELEASE]. 3 While holding down the shift key, press the alarm release button to release the alarm. 4 Move the overtravel axis to within the movable range by holding down the shift key and performing jog feed. 5 For the model using the B cabinet, check the fuse (F2) on the printed circuit board for emergency stop control. Replace the fuse if it has blown. 6 Replace the printed circuit board for emergency stop control.
833
ALARM CODES
B--81464EN--3/01
SRVO--006 SERVO Hand broken A safety hand has broken. If no broken hand can be found, however, the most likely cause is the HBK Cause: signal of a robot connection cable being at the 0 V level.
Remedy: Step
1 Check the fuse (F4) in the power supply unit. Replace the fuse if it has blown. 2 While holding down the shift key, press the alarm release button to clear the alarm. 3 While holding down the shift key, position the tool to the workplace by performing jog feed. a Replace the safety hand. b Check the cable.
SRVO--007 SERVO External emergency stops Cause: The external emergency stop push button is pressed. Remedy:
On the terminal block of the printed circuit board for emergency stop control, no connection is established between EMGIN1 and EMGIN2. If using external emergency stop, clear source of fault and press RESET. If not using external emergency stop, check wiring at EMGIN1, EMGIN2.
SRVO--008 SERVO Brake fuse blown The brake fuse is blown on the EMG Control pcb. Cause: Remedy: Replace the fuse. Check the LED (FALM) on the printed circuit board for emergency stop control to determine whether the fuse has blown.
SRVO--009 SERVO Pneumatic pressure alarm The pneumatic pressure alarm indicates the presence of a defect. If the pneumatic pressure alarm is Cause: Remedy:
not detected, however, the most likely cause is the PPABN signal of a robot connection cable being at the 0 V level. If the pneumatic pressure alarm is not detected, check the cable.
SRVO--010 SERVO Belt broken The belt broken robot digital input (RDI7) is asserted. Cause: Remedy: 1 If the belt is found to be defective in any way, repair it and then press the reset key. 2 When the belt is found to be normal, signal RDI [7] in the robot connection cable may be abnormal. Check the cable. 3 Check system variable $PARAM_GROUP.$BELT_ENABLE.
SRVO--011 SERVO TP released while enabled The teach pendant attachment switch on the operator’s panel was operated while the teach pendant Cause: Remedy:
was enabled. Reconnect the teach pendant cable to continue operation.
SRVO--012 SERVO Power failure recovery Normal power on (hot start). Cause: Remedy: This is just a notification. You do not have to do anything for this warning message. SRVO--013 SYSTEM Srvo module config changed Upon power--up with power restoration enabled (hot start), the configuration of the DSP modules on the Cause: Remedy:
axis control printed circuit board and the multi--function printed circuit board has been changed. Turn on the power in cold start mode.
SRVO--014 WARN Fan motor abnormal A fan motor in the control unit is abnormal. Cause: Remedy: Check the fan motors and fan motor connection cables. Replace any faulty fan motor(s) and/or cable(s).
834
ALARM CODES
B--81464EN--3/01
SRVO--015 SERVO System over heat The temperature of the control unit is higher than the specified value. Cause: Remedy: 1 If the ambient temperature is higher than the specified temperature (45øC), provide ventilation to reduce the ambient temperature to the specified value. 2 Check that the fans are operating normally. If not, check the fan motors and fan motor connection cables. Replace any faulty fan motor(s) and/or cable(s). 3 If the thermostat on the backplane printed circuit board is faulty, replace the backplane unit.
SRVO--016 SERVO Cooling water volume drop Cooling water volume dropped. Cause: Remedy: Consult our service representative. SRVO--017 SERVO No robot internal mirror No robot internal mirror. Cause: Remedy: Consult our service representative. SRVO--018 SERVO Brake abnormal The current for brake exceeded the specification. Cause: Remedy: 1 For the S--800 or S--900 robot, check the fuse (F1) on the printed circuit board for emergency stop control. 2 Check the brake cable. 3 Replace the amplifier. 4 Check the 100--VAC input voltage. If a voltage of 90 VAC or less is detected, check the input power supply voltage.
SRVO--019 SERVO SVON input On the terminal block on the printed circuit board of the operator’s panel, no connection is established Cause: Remedy:
between signals *SVON1 and *SVON2. When an external switch is connected, it should be checked. Establish a connection between *SVON1 and *SVON2.
SRVO--020 SERVO SRDY off (TP) The teach pendant cable is disconnected or a momentary break occurred in any one of the TP Cause: Remedy:
emergency stop circuits; TP emergency stop, DEADMAN, or fence. Check the teach pendant cable and connections.
SRVO--021 SERVO SRDY off (Group:%d Axis:%d) When HRDY is on, SRDY is off even though no other alarm cause is present. (HRDY is the signal sent Cause:
Remedy:
from the host to the servo system to specify whether to turn the servo amplifier’s MCC on or off. SRDY is the signal sent from the servo system to the host to indicate whether the servo amplifier’s MCC is on or off. Generally, if a servo amplifier’s MCC is not turned on despite the signal for turning the MCC on having been issued, an alarm is issued for the servo amplifier. The host does not issue this alarm (SRDY off) if an alarm for the servo amplifier is detected. So, this alarm indicates that the MCC is not turned on when no error can be found.) 1 Check whether the door is open. Also check the door switch. 2 Check the 200 VAC voltage applied to the servo amplifier. If the voltage is found to be 170 VAC or lower, check the input power supply voltage. 3 Replace the emergency stop control printed board. 4 Replace the main CPU printed circuit board. 5 Check the following cables. Replace them if necessary. 6 Replace the servo amplifier.
835
ALARM CODES
B--81464EN--3/01
SRVO--022 SERVO SRDY on (Group:%d Axis:%d) SRDY was already on when an attempt was made to turn on the MCC with HRDY. (HRDY is the signal Cause:
Remedy:
sent from the host to the servo system to specify whether to turn the servo amplifier’s MCC on or off. SRDY is the signal sent from the servo system to the host to indicate whether a servo amplifier’s MCC is on or off.) 1 Replace the emergency stop control printed board. 2 Replace the main CPU printed circuit board. 3 Check the cable linking the servo amplifier and main CPU printed circuit board. If any abnormality is found, replace the cable. 4 Replace the servo amplifier.
SRVO--023 SERVO Stop error excess(Group:%d Axis:%d) An excessive servo positional error occurred when the motor stopped. Cause: Remedy: 1 Check whether the applied load exceeds the rating. If so, reduce the applied load. (If an excessive load is applied, the torque required for acceleration, deceleration, and so forth exceeds the maximum available torque of the motor. Therefore it may prove impossible to correctly respond to an issued command, resulting in the output of this alarm.) 2 Check each interphase voltage of the three--phase voltage (200 VAC) applied to the servo amplifier. If the voltage is found to be 170 VAC or below, check the input power supply voltage. (A sub--standard voltage, applied to a servo amplifier results in a lower--than--normal torque. Therefore, it may prove impossible to correctly respoud to an issued command, thus resulting in the output of this alarm.) 3 If the input power supply voltage is found to be 170 VAC or higher, replace the servo amplifier. 4 Replace the motor.
SRVO--024 SERVO Move error excess(Group:%d Axis:%d) When the robot moved, the servo positional error exceeded a previously specified value Cause: Remedy:
($PARAM_GROU.$MOVER_OFFST or $PARAM_GROUP.$TRKERRLIM). For example, this error will occur if the feedrate of the robot differs from that specified. Perform the same action as that described for the previous item.
SRVO--025 SERVO Motn dt overflow (Group:%d Axis:%d) The value entered with a command is too large. Cause: Remedy: Perform a cold start : 1 Turn off the robot. 2 On the teach pendant, press and hold the SHIFT and RESET keys. 3 While still pressing the SHIFT and RESET keys, turn on the robot. If the error is not cleared, document the events that led to the error.
SRVO--026 WARN Motor speed limit(Group:%d Axis:%d) An attempt was made to exceed the maximum rated motor speed ($PARAM_GROUP.$MOT_SPD_LIM). Cause: Remedy:
The motor speed is clamped to its maximum rated value. This is just a notification. However, you should attempt to eliminate this error and not repeat the circumstances that led up to it.
SRVO--027 WARN Robot not mastered(Group:%d) An attempt was made to perform calibration, but mastering has not yet been completed. Cause: Remedy: Perform mastering from the calibration screen [6 SYSTEM CALIBRATION]. SRVO--030 SERVO Brake on hold (Group:%d) When the temporary stop alarm function ($SCR.$BRKHOLD_ENB=1) is enabled, this alarm is issued Cause: Remedy:
whenever a temporary stop is made. When this function is not to be used, disable the function. Disable [TEMPORARY STOP/SERVO OFF] on the general item setting screen [6 GENERAL SETTING ITEMS].
SRVO--031 SERVO User servo alarm (Group:%d) A user servo alarm was issued.This alarm is raised when system variable $MCR_GRP[i]. Cause: Remedy:
$SOFT_ALARM is set to TRUE. Only KAREL users can use this variable, however. This is just a notification. You do not have to do anything for this warning message.
836
ALARM CODES
B--81464EN--3/01
SRVO--033 WARN Robot not calibrated(Group:%d) An attempt was made to set a reference point for simple mastering, but calibration has not yet been Cause: completed. Perform calibration by following the procedure below. 1 Turn on the power.
Remedy: Step
2 Execute [CALIBRATION] from the calibration screen [6 SYSTEM CALIBRATION].
SRVO--034 WARN Ref pos not set (Group:%d) An attempt was made to perform simple mastering, but a required reference point has not yet been set. Cause: Remedy: Set a reference point for simple mastering from the calibration screen. SRVO--035 WARN Joint speed limit(Group:%d Axis:%d) An attempt was made to exceed the maximum joint speed ($PARAM_GROUP.$JNTVELLIM). The joint Cause: speed is clamped to its maximum rated value.
SRVO--036 SERVO Inpos time over (Group:%d Axis:%d) The in--position monitor time ($PARAM_GROUP.$INPOS_TIME) has elapsed, but the in--position state Cause: Remedy:
($PARAM_GROUP.$STOPTOL) has not yet been set. Perform the same action as that specified for Servo -- 023 (stop error excess).
SRVO--037 SERVO IMSTP input (Group:%d) The *IMSTP signal, which is a peripheral device I/O signal, is applied. Cause: Remedy: Turn on the *IMSTP signal. SRVO--038 SERVO2 Pulse mismatch (Group:%d Axis:%d) A pulse count detected at power--off differs from that detected at power--on. Cause: Remedy: Contact our service center serving your locality. SRVO--039 SERVO Motor speed excess(Group:%d Axis:%d) The maximum speed that can be used with vector acceleration/deceleration control was exceeded. Cause: Remedy: Reduce the teaching speed. SRVO--040 WARN Mastered at mark pos(Group:%d) Zero position master is done with mark position (not with zero position). Cause: Remedy: This is not an alarm. SRVO--041 SERVO2 MOFAL alarm (Group:%d Axis:%d) A value specified with a command is too large. Cause: Remedy: Document the events that led to the error and contact our service center serving your locality. SRVO--042 SERVO MCAL alarm(Group:%d Axis:%d) The servo amplifier magnetic contactor (MCC) is welded closed. This is an S--900--specific alarm. Cause: Remedy: 1 If this alarm occurs with a SRVO--049 OHAL1, turn the power off for fifteen seconds. Then turn the power back on. 2 Check the cable between the servo amplifier and the axis control printed circuit board. 3 Replace the servo amplifier. 4 Replace the axis control printed circuit board.
837
ALARM CODES
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SRVO--043 SERVO DCAL alarm(Group:%d Axis:%d) The energy produced by regenerative discharge is excessive. As a result, all the generated energy Cause:
Remedy:
cannot be dissipated as heat. (When a robot is to be operated, a servo amplifier feeds energy to the robot. Along its vertical axis, however, the robot moves downword using potential energy. If the decrease in the potential energy exceeds the acceleration energy, the servo amplifier receives energy from the motor. This also occurs during deceleration even if the force of gravity has no effect. This energy is called regenerative energy. Normally, the servo amplifier dissipates this regenerative energy by converting it to heat. When the amount of regenerative energy exceeds the amount of energy that can be dissipated as heat, excess energy accumulates in the servo amplifier, thus triggering this alarm.) 1 When the LED indicator of the servo amplifier PSM displays “8” (DCOH alarm) (The DCOH alarm is issued when the thermostat detects overheating of the regenerative resistor.): 2 This alarm may be raised when acceleration/deceleration is frequently performed or when a large amount of regenerative energy is generated in the vertical axis. In such cases, the robot should be used under less demanding conditions. 3 Replace the regenerative resistor. 4 Check the cable between the servo amplifier (CN8A) and the regenerative resistor. Replace it if necessary. 5 Replace the servo amplifier.
SRVO--044 SERVO HVAL alarm(Group:%d Axis:%d) The DC voltage (DC link voltage) of the main circuit power supply is abnormally high. The LED indicator Cause: Remedy:
of the servo amplifier PSM displays “7.” 1 Check the three--phase input voltage applied to the servo amplifier. When the voltage is 253 VAC or higher, check the input power supply voltage. (If the motor is abruptly accelerated or decelerated while the three--phase input voltage exceeds 253 VAC, this alarm may be issued.) 2 Check whether the applied load is within the rated value. If the rated load is exceeded, reduce the applied load. (If a load exceeds the rated value, built--up regenerative energy may cause this alarm to be issued even when the three--phase input voltage satisfies the specifications.) 3 Check the cables (CN3 and CN4) in the amplifier. Replace them if necessary. 4 Check the cable between the main CPU printed circuit board (JRV1) and the printed circuit board for emergency stop control (JRV1). 5 Replace the servo amplifier.
SRVO--045 SERVO HCAL alarm(Group:%d Axis:%d) An excessively high current flowed through the main circuit of a servo amplifier. The LED indicator on Cause: Remedy:
the servo amplifier PSM displays “--.” One of the red LEDs (HC1 to HC6) above the 7--segment LED is lit, indicating the axis for which the HCAL alarm is detected. 1 Disconnect the motor power line from the terminal block of the servo amplifier, then turn on the power. If this alarm is still issued, replace the servo amplifier. 2 Remove the motor power line from the terminal block of the servo amplifier, then check the insulation between U, V, and W of the motor power line and GND. If a short circuit is found, check the motor, robot connection cable, or robot internal cable. If any abnormality is found, replace the faulty hardware. 3 Remove the motor power line from the terminal block of the servo amplifier, then check the resistance between U and V, V and W, and W and U of the motor power line using a measuring instrument capable of detecting very low resistances. If the measured resistances differ from each other, check the motor, robot connection cable, or robot internal cable. If any abnormality is found, replace the faulty hardware. 4 Replace the main CPU printed circuit board.
SRVO--046 SERVO2 OVC alarm (Group:%d Axis:%d) This alarm is issued to protect the motor when there is a danger of thermal destruction when the Cause: Remedy:
root--mean--square current value, calculated internally by the servo system, exceeds the maximum permissible value. 1 Check the operating conditions of the robot. If the robot’s ratings, such as the rated duty cycle and load, are exceeded, modify the use of the robot such that the rated values are not exceeded. 2 Check each interphase voltage of the three--phase voltage (200 VAC) applied to the servo amplifier. If the applied voltage is found to be 170 VAC or less, check the input power supply voltage. 3 Replace the main CPU printed circuit board. 4 Replace the servo amplifier. 5 Replace the motor.
838
ALARM CODES
B--81464EN--3/01
SRVO--047 SERVO LVAL alarm(Group:%d Axis:%d) Despite the external magnetic contactor for a servo amplifier being on, the DC voltage (DC link voltage) Cause: Remedy:
of the main circuit power supply or the control power supply voltage (+5 V) is excessively low. 1 When the LED indicator on servo amplifier displays “6” (This alarm is issued when the control power supply voltage (+5 V) is excessively low.): a Check each interphase voltage of the three--phase voltage (200 VAC) applied to the servo amplifier. If the applied voltage is found to be 170 VAC or less, check the input power supply voltage. b Replace the servo amplifier. 2 When the LED indicator on the servo amplifier displays “4” (This alarm is issued when the DC voltage (DC link voltage) of the main circuit power supply is excessively low.): a Check each interphase voltage of the three--phase voltage (200 VAC) applied to the servo amplifier. If the applied voltage is found to be 170 VAC or less, check the input power supply voltage. Check the servo amplifier’s circuit breaker. Close the circuit breaker if it is found to be off. b Replace the servo amplifier.
SRVO--049 SERVO OHAL1 alarm (Group:%d Axis:%d) 1 A servo amplifier’s built--in thermostat was actuated. The LED indicator on the servo amplifier PSM Cause: Remedy:
displays“3.” 1 Check the operating conditions of the robot. If any of the ratings specified for the robot, such as its rated duty cycle or load, are exceeded, modify the use of the robot such that the ratings are not exceeded. 2 Check whether the fuse (F1) in the servo amplifier has blown. 3 Check the cable between the servo amplifier (CN8B) and the transformer. Replace it if necessary. 4 Check the cable (CN4) in the servo amplifier. Replace it if necessary. 5 Replace the servo amplifier.
SRVO--050 SERVO CLALM alarm (Group:%d Axis:%d) An excessively large disturbance torque is estimated by the servo software. (A collision was detected.) Cause: Remedy: 1 Check whether the robot has collided with an object. If so, reset the system, then move the robot away from the location of the collision by using jog feed. 2 Check that the applied load does not exceed the maximum rating. If the rated load is exceeded, reduce the applied load. (If the robot is used with an excessive load applied, the estimated disturbance may become excessively large, resulting in this alarm being output.) 3 Check each interphase voltage of the three--phase voltage (200 VAC) applied to the servo amplifier. If the applied voltage is found to be 170 VAC or less, check the input power supply voltage. 4 Replace the servo amplifier.
SRVO--051 SERVO2 CUER alarm(Group:%d Axis:%d) The offset of a current feedback value is excessively large. Cause: Remedy: 1 Replace the main CPU printed circuit board. 2 Replace the servo amplifier.
SRVO--053 WARN Disturbance excess(Group:%d Axis:%d) Disturbance estimated in the software exceed the threshold value. There is a possibility that the load Cause: Remedy:
held in the wrist exceed the robot specification. If operation is allowed to continue, a detection error may result. On the status screen containing the disturbance value, specify a new value for the acceptable disturbance limit.
SRVO--054 DSM memory error (DSM:%d) The DSP module program memory is defective. Cause: Remedy: Replace the DSP module. SRVO--055 FSSB com error 1 (Group:%d Axis:%d) FSSB communication error from SRVO to SLAVE occured Cause: Remedy: Check FSSB hardware connection. SRVO--056 FSSB com error 2 (Group:%d Axis:%d) FSSB communication error from SLAVE to SRVO occured Cause: Remedy: Check FSSB hardware connection. 839
ALARM CODES
B--81464EN--3/01
SRVO--057 FSSB disconnect (Group:%d Axis:%d) FSS’B for communication from SLAVE to SRVO is disconnected. Cause: Remedy: Check FSSB hardware connection. SRVO--058 FSSB init error (N:%d) FSSB communication error occured during initialization Cause: Remedy: Check FSSB hardware connection. SRVO--059 SYSTEM Servo amp init error Servo amplifier initializing is failed. Cause: Remedy: Check the servo amplifier and its wiring. Refer to the maintenance manual.
SRVO--061 SERVO2 CKAL alarm(Group:%d Axis:%d) The clock for the rotation counter in the pulse coder is abnormal. Cause: Remedy: If this alarm occurs along with a SRVO--068 DTERR, SRVO--069 CRCERR, or SRVO--070 STBERR, disregard this alarm and refer to the other three alarm remedies. Replace the pulse coder or motor and master the robot.
SRVO--062 SERVO2 BZAL alarm(Group:%d Axis:%d) This alarm is issued when the battery for backing up the absolute position data of the pulse coder is not Cause: Remedy:
connected. The battery cable inside the robot may have become disconnected. Correct the cause of the alarm, then turn on the power again after setting the system variable ($MCR.$SPC_RESET) to true. Mastering is required.
SRVO--063 SERVO2 RCAL alarm(Group:%d Axis:%d) The built-in rotation counter on the pulse coder is abnormal. Cause: Remedy: 1 Eliminate the cause of the alarm. Set system variable $MCR.$SPC_RESET to TRUE, and turn the power off and then on again. Mastering must be performed. 2 Replace the pulse coder. Mastering must be performed. NOTE The RCAL alarm may be displayed when any of the “SERVO--068 DTERR,” “SERVO--069 CRCERR,” or “SERVO--070 STBERR” alarms is raised. In this case, however, the RCAL alarm is not actually raised.
SRVO--064 SERVO2 PHAL alarm(Group:%d Axis:%d) This alarm is issued when the phase of a pulse signal generated by the pulse coder is abnormal. Cause: Remedy: Replace the pulse coder. After replacing, perform mastering. NOTE If the DTERR, CRCERR, or STBERR alarm is issued, this alarm may also be output at the same time. Should this occur, however, this alarm can be safely ignored. SRVO--065 WARN BLAL alarm(Group:%d Axis:%d) The battery voltage for the pulse coder has dropped below the allowable minimum. Cause: Remedy: Replace the battery. (When this alarm is issued, immediately replace the battery while the system power is turned on. If the BZAL alarm is issued because the battery is not replaced in time, position data will be lost, thus necessitating robot mastering.)
SRVO--066 SERVO2 CSAL alarm(Group:%d Axis:%d) The pulse coder ROM checksum data are abnormal. Cause: Remedy: If this alarm occurs along with a SRVO--068 DTERR, SRVO--069 CRCERR, or SRVO--070 STBERR, disregard this alarm and refer to the other three alarm remedies. Replace the pulse coder or motor and master the robot.
840
ALARM CODES
B--81464EN--3/01
SRVO--067 SERVO2 OHAL2 alarm (Group:%d Axis:%d) The temperature inside the pulse coder has become too high, causing the built--in thermostat to actuate. Cause: Remedy: 1 Check the operating conditions of the robot. If any of the rating specified for the robot, such as its rated duty cycle or load, are exceeded, modify the use of the robot such that the ratings are not exceeded. 2 If this alarm is issued, even when the power is turned on and the motor has not overheated, replace the motor.
SRVO--068 SERVO2 DTERR alarm (Group:%d Axis:%d) A request signal was sent to the serial pulse coder, but no serial data was returned. Cause: Remedy: 1 Check the cable between the main CPU printed circuit board (JRF2) and the printed circuit board for emergency stop control (JRF2). Replace it if necessary. 2 For a model with the robot connection cable, check the cable and replace it if necessary. Then, check connector P1 on the connector panel of the mechanical unit. 3 Replace the serial pulse coder.
SRVO--069 SERVO2 CRCERR alarm (Group:%d Axis:%d) Cause: Serial data changed during transfer. SRVO--070 SERVO2 STBERR alarm (Group:%d Axis:%d) A serial data start bit or stop bit error occurred. Cause: Remedy: 1 Check that the shields of the robot connection cable (for the pulse coder signal) and peripheral device 2 3 4 5 6 7
cables are securely connected to a ground plate. Check that each unit is securely grounded. Replace the printed circuit board for emergency stop control. Replace the cable between the printed circuit board for emergency stop control and the main CPU. Replace the main CPU printed circuit board. Replace the pulse coder, after which mastering must be performed. Replace the robot connection cable (for the pulse coder signal).
SRVO--071 SERVO2 SPHAL alarm (Group:%d Axis:%d) The feedback speed is abnormally high (3750 rpm or greater). Cause: Remedy: 1 This alarm does not indicate the main cause of the problem if issued together with the PHAL alarm (alarm No. 064). 2 Check whether the load applied to the robot exceeds the maximum rating. If the rated load is exceeded, reduce the applied load. After replacing perform mastering. 3 Replace the pulse coder of the motor.
SRVO--072 SERVO2 PMAL alarm(Group:%d Axis:%d) Cause: The pulse coder may be faulty. Remedy: Replace the pulse coder, then perform mastering. SRVO--073 SERVO2 CMAL alarm(Group:%d Axis:%d) Cause: The pulse coder may be faulty, or noise may be causing the pulse coder to malfunction. Remedy: Perform simple mastering and improve the shielding. SRVO--074 SERVO2 LDAL alarm(Group:%d Axis:%d) Cause: The LED on the pulse coder has become disconnected. Remedy: Replace the pulse coder, then perform mastering. SRVO--075 WARN Pulse not established(Group:%d Axis:%d) Cause: The absolute position of the pulse coder has not yet been established. Remedy: Using job feed, move the robot along each axis for which this alarm is issued, until the alarm is not re--issued after being cleared.
841
ALARM CODES
B--81464EN--3/01
SRVO--076 Tip Stick Detection (Group:%d Axis:%d) The servo software has detected an excessive disturbance torque at the beginning of operation. Cause: Remedy: Press the reset key on the teach pendant to cause a reset, and separate the robot from all obstacles by jogging. If neither a deposition nor a collision has occurred, it is likely that the load on the robot is heavier than the rating. Check the input voltage of the servo amplifier. Each phase--to--phase voltage must be higher than 170 VAC. Check the U--V, V--W, and U--W voltages. They must be the same voltage (210 VAC or below). Refer to the maintenance manual.
SRVO--081 WARN EROFL alarm (Track enc:%d) The line tracking pulse count overflowed. Cause: Remedy: Contact our service center serving your locality. SRVO--082 WARN DAL alarm(Track enc:%d) Line tracking pulse coder disconnected. Cause: Remedy: 1 Check the corresponding line tracking connection to the axis control printed circuit board. 2 Check the pulse coder cable. 3 Replace the SIF and DSM modules on the axis control printed circuit board. 4 Replace the pulse coder.
SRVO--083 WARN CKAL alarm (Track enc:%d) The clock for the rotation counter in the line tracking pulse coder is abnormal. Cause: Remedy: Refer to SRVO--061. SRVO--084 WARN BZAL alarm (Track enc:%d) This alarm is issued when the battery for backing up the absolute position data for the pulse coder is Cause: Remedy:
not connected. See the description for Servo -- 062 BZAL alarm.
SRVO--085 WARN RCAL alarm (Track enc:%d) The built-in rotation counter on the line tracking pulse coder is abnormal. Cause: Remedy: Refer to SRVO--063. SRVO--086 WARN PHAL alarm (Track enc:%d) This alarm is issued when the phase of a pulse signal generated by the pulse coder is abnormal. Cause: Remedy: See the description for Servo -- 064 PHAL alarm. SRVO--087 WARN BLAL alarm (Track enc:%d) This alarm is issued when the battery voltage for backing up the absolute position data of the pulse Cause: Remedy:
coder has dropped. See the description for Servo -- 065 BLAL alarm.
SRVO--088 WARN CSAL alarm (Track enc:%d) The line tracking pulse coder ROM checksum data are abnormal. Cause: Remedy: Refer to SRVO--066. SRVO--089 WARN OHAL2 alarm (Track enc:%d) The motor has overheated. Cause: Remedy: See the description for Servo -- 067 OHAL2 alarm. SRVO--090 WARN DTERR alarm (Track enc:%d) An error occurred during communication between the pulse coder and main CPU printed circuit board. Cause: Remedy: See the description for Servo -- 068 DTERR alarm. SRVO--091 WARN CRCERR alarm (Track enc:%d) An error occurred during communication between the pulse coder and main CPU printed circuit board. Cause: Remedy: See the description for Servo -- 069 CRCERR alarm. 842
ALARM CODES
B--81464EN--3/01
SRVO--092 WARN STBERR alarm (Track enc:%d) An error occurred during communication between the pulse coder and main CPU printed circuit board. Cause: Remedy: See the description for Servo -- 070 STBERR alarm. SRVO--093 WARN SPHAL alarm (Track enc:%d) This alarm is issued when the position data sent from the pulse coder is considerably greater than the Cause: Remedy:
previous data. See the description for Servo -- 071 SPHAL alarm.
SRVO--094 WARN PMAL alarm (Track enc:%d) The pulse coder may be faulty. Cause: Remedy: See the description for Servo-- 072 PMAL alarm. SRVO--095 WARN CMAL alarm (Track enc:%d) The pulse coder may be faulty. Or, noise may have caused the pulse coder to malfunction. Cause: Remedy: See the description for Servo-- 073 CMAL alarm. SRVO--096 WARN LDAL alarm (Track enc:%d) The LED on the pulse coder has become disconnected. Cause: Remedy: See the description for Servo -- 074 LDAL alarm. SRVO--097 WARN Pulse not established(Enc:%d) The absolute position of the pulse coder has not yet been established. Cause: Remedy: See the description for Servo -- 075 Pulse not established. SRVO--101 SERVO Robot overtravel(Robot:%d) A Robot overtravel limit switch is pressed. Cause: Remedy: Refer to SRVO--005 . SRVO--102 SERVO Hand broken (Robot:%d) The hand broken (*HBK) robot input is asserted. Cause: Remedy: Refer to SRVO--006. SRVO--103 SERVO Air pressure alarm(Rbt:%d) The pneumatic pressure (PPABN) robot input is asserted. Cause: Remedy: Refer to SRVO--009. SRVO--105 Door open or E.Stop Controller door is opened Cause: Remedy:
Or E.stop signals are detected for a quite short time Or mis--wiring of hardware connection Close controller door And press RESET If reset is not effective, correct hardware connection
SRVO--106 SERVO Door open/E.Stop (Robot:%d) The controller door was opened. Cause: Remedy:
An emergency stop signal was detected temporarily. A hardware disconnection occurred. Close the controller door, and press the reset key. If no reset occurs, repair the hardware wiring. Refer to the maintenance manual.
SRVO--108 Press RESET to enable robot When the enable/disable switch is set to “Enable,” it is necessary to cause a reset. Cause: Remedy: To enable the robot, press the reset key. 843
ALARM CODES
B--81464EN--3/01
SRVO--111 SERVO Softfloat time out(Group:%d) Follow-up time is over when softfloat is OFF. Cause: Remedy: Make $SFLT_FUPTIM larger. SRVO--112 PAUSE.G Softfloat time out(Group:%d) Follow-up time is over when softfloat is OFF. Cause: Remedy: Make $SFLT_FUPTIM larger. SRVO--121 SERVO Excessive acc/dec time(Group:%d) Acceleration time is much longer. Cause: Remedy: Contact our service center serving your locality. SRVO--122 SERVO Bad last ang(internal)(Group:%d) Last angle update request does not match current angle. Cause: Remedy: Contact our service center serving your locality. SRVO--126 Quick stop error (Group:%d) Program was over in process of quick stop. Cause: Remedy: Press reset SRVO--130 OHAL1(PSM) alarm (Group:%d Axis:%d) The servo amplifier(PMS) overheated. Cause: Remedy: Refer to the maintenance manual. SRVO--131 LVAL(PSM) alarm(Group:%d Axis:%d) The DC voltage on the main power circuit of the servo amplifier is lower than the specification even Cause: Remedy:
though MCC is on. Refer to the maintenance manual.
SRVO--132 HCAL(PSM) alarm(Group:%d Axis:%d) The current in the main power circuit of the servo amplifier exceeded specification. Cause: Remedy: Refer to the maintenance manual. SRVO--133 FSAL(PSM) alarm (Group:%d Axis:%d) Cooling fan for Control circuit stops. Cause: Remedy: Refer to the maintenance manual. SRVO--134 DCLVAL(PSM) alarm (Group:%d Axis:%d) Back--up charge circuit for amplifier have trouble. Cause: Remedy: Check the cables and connections between amplifier(CN1) and MCC. Check the fuse(F1,F3) in transformer. If using B--cabinet Replace the EMG Control printed circuit board. Replace the amplifier.
SRVO--135 FSAL alarm (Group:%d Axis:%d) Cooling fan for Control circuit stops. Cause: Remedy: Check or Replace the fan. SRVO--136 DCLVAL alarm (Group:%d Axis:%d) Back--up charge circuit for amplifier have trouble. Cause: Remedy: Check the cables and connections between amplifier(CN1) and MCC. Check the fuse(F1,F3) in transformer. If using B--cabinet Replace the EMG Control printed circuit board. Replace the amplifier.
844
ALARM CODES
B--81464EN--3/01
SRVO--138 SDAL alarm (Group:%d Axis:%d) SDAL alarm of an amplifier. Cause: Remedy: Refer to the maintenance manual. SRVO--148 HCAL(CNV) alarm (Group:%d Axis:%d) The current of the main power supply circuit of the servo amplifier has exceeded the rating. Cause: Remedy: Remove the motor power lines from the servo amplifier, and then turn the power on. If HCAL still occurs, replace the servo amplifier and transistor module. Measure the resistance between the grounding wire and each of the U, V, and W lines at the cable terminals. If there is a short--circuit, check whether the cable or motor is defective. Check the U--V, V--W, and U--W resistances with a measuring instrument that can detect a low resistance at the end of a cable. If the same resistance is observed, replace the servo amplifier. If a different resistance is observed, check whether the cable or motor is defective. If the problem is not yet solved, replace the axis control SIF module for the axis of interest. Refer to the maintenance manual.
SRVO--151 FSAL(INV) alarm (Group:%d Axis:%d) The cooling fan for the control circuit has stopped. Cause: Remedy: Check the fan, or remove it. Refer to the maintenance manual.
SRVO--156 IPMAL alarm (Group:%d Axis:%d) IPM module has trouble. Cause: Remedy: Replace the IPM mudule. Refer to the maintenance manual for detail. SRVO--157 CHGAL alarm (Group:%d Axis:%d) Charge of the main circuit could not finish within specified time. Cause: Remedy: DC link may short--circuit. Check the connections. Electric resistance to restrict charge current may be defective. Replace the wiring board. Refer to the maintenance manual for deteil.
SRVO--160 SERVO Panel/External E--stop The emergency stop button on the operator’s panel was pressed, or the external emergency stop Cause: Remedy:
function was activated. (EMGIN1 and EMGINC are not strapped to each other. Or, EMGIN2 and EMGINC are not strapped to each other.) Release the emergency stop button. If the external emergency stop function has been activated, remove the cause. If no cause can be found, and no jumper is installed between EMGIN1 and EMGINC or between EMGIN2 and EMGINC on the terminal block of the emergency stop control printed circuit board, but cables are connected to the terminals, check the cables.
SRVO--171 MotorSpd lim/DVC(Group:%d Axis:%d) Motor can not rotate as fast as the calculated speed required for the current motion. Cause: Remedy: This is just a notification. You do not have to do anything for this warning message. SRVO--172 MotorSpd lim/DVC0(Group:%d Axis:%d) Motor can not rotate as fast as the calculated speed required for the current motion. Cause: Remedy: This is just a notification. You do not have to do anything for this warning message. SRVO--173 MotorSpd lim/DVC1(Group:%d Axis:%d) Motor can not rotate as fast as the calculated speed required for the current motion. Cause: Remedy: This is just a notification. You do not have to do anything for this warning message. SRVO--174 MotorAcc lim/DVC(Group:%d Axis:%d) Motor can not accelerate as much as the calculated acceleration required to for the current motion Cause: Remedy: This is just a notification. You do not have to do anything for this warning message. 845
ALARM CODES
B--81464EN--3/01
SRVO--176 CJ/Illegal Mode %d,%d Wrong CJ mode was used. Cause: Remedy: Internal motion error. Contact service immideately.
SRVO--177 CJ error %d,%d,%d,%d Wrong CJ mode was used. Cause: Remedy: Contact service representative. SRVO--178 CJ error %d,%d,%d,%d Wrong CJ mode was used. Cause: Remedy: Contact service representative. SRVO--179 Motor torque limit (Group:%d Axis:%d) The torque of the axis has exceeded the limit. Cause: Remedy: This is a warning message. No action is needed for this warning message.
SRVO--181 Mcmd input while estimating(Group:%d) Cause: Robot was going to move while identifying the payload.. Remedy: Press RESET. Be careful not to move robot while identifying the payload. SRVO--182 Needed init. has not been done This is an error internal to the system. Cause: Remedy:
A system variable or internal work memory has not been initialized normally. Turn the power off and on again. 1 Turn the power off. 2 Turn the power on. If the alarm is still issued, take a note of what caused this alarm, and then contact the service personnel.
SRVO--183 ROBOT isn’t ready Servo activation is off. Cause: Remedy: Remove the factor that turned servo activation off, and press the reset button. SRVO--184 Other task is processing The data area that this instruction tried to use had been locked by another task. Cause: Remedy: Execute the instruction after the task that uses the data area ends. SRVO--185 Data is for other group The data the instruction tries to use belongs to another group. Cause: Remedy: Collect the data of the desired group before executing the instruction. SRVO--186 Needed Data has not been got No data has been collected, or any collected data does not belong to the desired mode. Cause: Remedy: Collect the necessary data before executing the instruction. SRVO--187 Need specfing Mass Estimating the load information of this type requires specifying the mass of the load. Cause: Remedy: Specify the mass of the load before estimating load information. SRVO--191 Illegal Joint Speed (Group:%d Axis:%d) The motion command exceeded specification. Cause: Remedy: Internal motion error. Contact service immideately.
SRVO--193 SVON input SVON input circuit is open. Cause: Remedy: Close SVON input circuit, and then press reset. Refer to the maintenance manual for detail.
846
ALARM CODES
B--81464EN--3/01
SRVO--194 Servo disconnect Servo is disconnected. Cause: Remedy: Connect servo, and then press reset. Refer to the maintenance manual for detail.
SRVO--195 NTED/Servo disconnect Non Teacher Enabling Device is released or servo is disconnected. Cause: Remedy: Press Non Teacher Enabling Device or connect servo, and then press reset. Refer to the maintenance manual.
SRVO--199 Control Stop Control Stop is detected. Cause: Remedy: After this alarm, Fence open or SVON input alarm is detected. See the remedy of the next alarm.
SRVO--200 Control box fan abnormal Cause: Control box fan motor is failure Remedy: Check and/or replace the fan. Refer to the maintenance manual.
SRVO--201 Panel E--stop or SVEMG abnormal The operator panel emergency stop push button is pressed and miswiring on SVEMG is detected. Cause: Remedy:
Or the operator panel emergency stop push button is pressed slowly so that SVEMG signal is delayed Check the wiring of SVEMG. If the wiring of SVEMG is not connceted, correct wiring of SVEMG. If the wiring has no problem, twist the operator panel emergency stop push button clockwise to release. Press reset. Refer to the maintenance manual for detail.
SRVO--202 TP E--stop or SVEMG abnormal The teach pendant emergency stop push button is pressed and miswiring on SVEMG is detected. Cause: Remedy: Check the wiring of SVEMG. If the wiring of SVEMG is not connceted, correct wiring of SVEMG. If the wiring has no problem, twist the teach pendant emergency stop push button clockwise to release. Press reset. Refer to the maintenance manual for detaile.
SRVO--203 SVON input(SVEMG abnormal) The SVON signal line is opened while the SVEMG wiring is incorrect. Cause: Remedy: Correct any SVEMG wiring errors. Input an SVON signal, and turn the power off and then on again. Refer to the maintenance manual for details.
SRVO--204 External(SVEMG abnormal) E--stop The external emergency stop push button is pressed and mis--wiring on SVEMG is detected. Cause: Remedy: Turn power off. Correct the wiring on SVEMG. If using external emergency stop, clear source of fault, and press reset. Refer to the maintenance manual for details.
SRVO--205 Fence open(SVEMG abnormal) Fence circuit is open and mis--wiring on SVEMG is detected. Cause: Remedy: Turn power off. Correct the wiring on SVEMG. Close fence circuit and then press reset. Refer to the maintenance manual for details.
847
ALARM CODES
B--81464EN--3/01
SRVO--206 Deadman switch (SVEMG abnormal) The teach pendant deadman switch is released while the teach pendant is enabled. And miswiring on Cause: Remedy:
SVEMG is detected. Turn power off. Correct the wiring on SVEMG Power on. Press teach pendant deadman switch. Press reset. Refer to the maintenance manual for details.
SRVO--207 TP switch abnormal or Door open SVEMG signal is detected while fence is opened and TP is enabled and Deadman switch is not released Cause: Remedy:
Or controller door is opened while fence is opened and TP is enabled and Deadman switch is not released Close controller door. If door is not opened, correct the wiring on SVEMG. Or correct enable switch and deadman switch of teach pendant. And press RESET Refer to the maintenance manual for details.
SRVO--208 Extended axis brake abnormal The FET current for brake of extended axis (brake number 2 or greater) exceeded the specification. Cause: Remedy: Check brake for zero or abnormally low impedence. Then check the brake cable. Then check 200VAC. Then check servo amplifier or emergency stop control PCB if brake ports are used. Refer to the maintenance manual for detail.
SRVO--209 SERVO Robot--2 SVEMG abnormal A disconnection of the SVEMG signal for robot 2 was detected. Cause: Remedy: Turn the power off. Rewire the SVEMG of the controller for robot 2. Close the fence circuit, and press the reset button. Refer to the maintenance manual.
SRVO--210 SERVO EX_robot SVEMG abnormal A disconnection of the SVEMG signal for an additional robot (a third robot, such as a positioner or Cause: Remedy:
additional axis) was detected. Turn the power off. Rewire the SVEMG of the controller for the additional robot. Close the fence circuit, and press the reset button. Refer to the maintenance manual.
SRVO--211 SERVO TP OFF in T1, T2 The teach pendant was disabled while the mode switch was set in the T1 or T2 position and robot 1 and Cause: Remedy:
2 were disconnected. Alternatively, there is a broken wire in the hardware. Set the teach pendant enable/disable switch to on, and press the reset key. If a reset does not take effect, repair the hardware wiring. Refer to the maintenance manual.
SRVO--213 SERVO Fuse blown (PanelPCB) The fuse on the panel PBC board has blown. Cause: Remedy: Replace the fuse on the panel PBC. Refer to the maintenance manual.
SRVO--214 SERVO Fuse blown (Amp) The fuse in the six--axis amplifier has blown. Cause: Remedy: Replace the fuse in the six--axis amplifier. Refer to the maintenance manual.
848
ALARM CODES
B--81464EN--3/01
SRVO--215 SERVO Fuse blown (Aux axis) The fuse for additional axis control in the six--axis amplifier has blown. Cause: Remedy: Replace the fuse for additional axis control in the six--axis amplifier. Refer to the maintenance manual.
SRVO--216 SERVO OVC (total) (%d) The current flowing through the robot cable has exceeded its limit. Cause: Remedy: Modify the program in such a way that the operating condition can be relaxed. SRVO--221 SERVO Lack of DSP (Group:%d Axis:%d) The DSP (servo control CPU) for this axis was not found, though it was specified in the system variable Cause: Remedy:
$AXISORDER. Check that the number of DSPs on the DSP board is sufficient for the quantity specified in $SCR_GRP[].$AXISORDER[]. Replace the DSP board with one having sufficient DSPs if necessary. Alternatively, change the setting of $AXISORDER.
SRVO--222 SERVO Lack of Amp (Amp:%d) FSSB indicates that there is no amplifier module. Cause: Remedy: Check that the fiber cable is connected to the amplifier correctly. Replace the fiber cable leading to the amplifier. Check that the amplifier power is normal. Check that $AXISORDER and $AMP_NUM are specified correctly. Refer to the maintenance manual.
SRVO--230 SERVO Chain 1 (+24v) abnormal A failure occurred in chain 1 (+24 V). Cause: Remedy: If the failure occurred because of the deadman switch being released, grip it again. Repair the chain 1 (+24 V) circuit in the hardware. On the system setting screen, set whether to reset the chain failure to “Yes.” Press the reset key on the teach pendant. Refer to the maintenance manual.
SRVO--231 SERVO Chain 2 (0v) abnormal A failure occurred in chain 2 (0 V). Cause: Remedy: If the failure occurred because of the deadman switch being released, grip it again. Repair the chain 2 (0 V) circuit in the hardware. On the system setting screen, set whether to reset the chain failure to “Yes.” Press the reset key on the teach pendant. Refer to the maintenance manual.
SRVO--232 SERVO NTED input The NTED (non--teacher enabling device) was released. Cause: Remedy: Press the NTED (non--teacher enabling device), and then press the reset key. SRVO--233 SERVO TP OFF in T1, T2/Door open The mode switch is set in the T1 or T2 position, and the teach pendant is disabled. Cause: Remedy:
Alternatively, the controller door is open. Still alternatively, there is a disconnection in the hardware. After setting the teach pendant enable/disable switch to on, close the controller door, and press the reset key. If a reset does not take effect, repair the hardware wiring. Refer to the maintenance manual.
SRVO--234 WARN Deadman switch released The deadman switch on the teach pendant was released. Cause: Remedy: This is a warning message. 849
ALARM CODES
B--81464EN--3/01
SRVO--235 SERVO Short term Chain abnormal A temporary chain failure was detected. Cause: Remedy: If this failure occurred simultaneously with the “deadman switch released” alarm, release the deadman switch, and press it again. If this failure occurs simultaneously with any other safety--related error, cause the same error to occur again, and press the reset key.
SRVO--236 WARN Chain failure is repaired A chain failure was removed. Cause: Remedy: When the system checked for the chain failure again, the chain failure had been removed. Press the reset key.
SRVO--237 WARN Cannot reset chain failure An attempt to reset the chain failure failed. Cause: Remedy: Repair the chain 1 (+24 V) circuit in the hardware. Press the emergency stop button on the teach pendant, and rotate it clockwise to release. Then, press the reset key. Refer to the maintenance manual.
SRVO--240 SERVO Chain 1 (FENCE) abnormal When the fence circuit was opened, a chain 1 (+24 V) failure occurred. Cause: Remedy: Repair the chain 1 (+24 V) circuit in the fence hardware. On the system setting screen, set whether to reset the chain failure to “Yes.” Press the reset key on the teach pendant. Refer to the maintenance manual.
SRVO--241 SERVO Chain 2 (FENCE) abnormal When the fence circuit was opened, a chain 2 (0 V) failure occurred. Cause: Remedy: Repair the chain 2 (0 V) circuit in the fence hardware. On the system setting screen, set whether to reset the chain failure to “Yes.” Press the reset key on the teach pendant. Refer to the maintenance manual.
SRVO--242 SERVO Chain 1 (EXEMG) abnormal When an external emergency stop signal was input, a chain 1 (+24 V) failure occurred. Cause: Remedy: Repair the chain 1 (+24 V) circuit in the external emergency stop hardware. On the system setting screen, set whether to reset the chain failure to “Yes.” Press the reset key on the teach pendant. Refer to the maintenance manual.
SRVO--243 SERVO Chain 2 (EXEMG) abnormal When an external emergency stop signal was input, a chain 2 (0 V) failure occurred. Cause: Remedy: Repair the chain 2 (0 V) circuit in the fence hardware. On the system setting screen, set whether to reset the chain failure to “Yes.” Press the reset key on the teach pendant. Refer to the maintenance manual.
SRVO--244 SERVO Chain 1 abnormal (Rbt:%d) A chain 1 (+24 V) failure occurred. Cause: Remedy: Repair the chain 1 (+24 V) circuit in the hardware. On the system setting screen, set whether to reset the chain failure to “Yes.” Press the reset key on the teach pendant. Refer to the maintenance manual.
SRVO--245 SERVO Chain 2 abnormal (Rbt:%d) A chain 2 (0 V) failure occurred. Cause: Remedy: Repair the chain 2 (0 V) circuit in the hardware. On the system setting screen, set whether to reset the chain failure to “Yes.” Press the reset key on the teach pendant. Refer to the maintenance manual.
850
ALARM CODES
B--81464EN--3/01
SRVO--246 SERVO Chain 1 abnormal (EX_robot) A chain 1 (+24 V) failure occurred in an additional robot (a third robot, such as a positioner or additional Cause: Remedy:
axis). Repair the chain 1 (+24 V) circuit in the hardware. On the system setting screen, set whether to reset the chain failure to “Yes.” Press the reset key on the teach pendant. Refer to the maintenance manual.
SRVO--247 SERVO Chain 2 abnormal (EX_robot) A chain 2 (0 V) failure occurred in an additional robot (a third robot, such as a positioner or additional Cause: Remedy:
axis). Repair the chain 2 (0 V) circuit in the hardware. On the system setting screen, set whether to reset the chain failure to “Yes.” Press the reset key on the teach pendant. Refer to the maintenance manual.
SRVO--250 SERVO SVEMG/MAINON1 abnormal When the SVEMG became on, the MAINON1 signal remained off. Cause: Remedy:
This is an emergency stop circuit failure. Repair the emergency stop circuit hardware. Turn the power off and on again.
SRVO--260 SERVO Chain 1 (NTED) abnormal A chain 1 (+24 V) failure occurred when the NTED (non--teacher enabling device) was released. Cause: Remedy: Repair the chain 1 (+24 V) circuit in the NTED (non--teacher enabling device) hardware. On the system setting screen, set whether to reset the chain failure to “Yes.” Press the reset key on the teach pendant. Refer to the maintenance manual.
SRVO--261 SERVO Chain 2 (NTED) abnormal A chain 2 (0 V) failure occurred when the NTED (non--teacher enabling device) was released. Cause: Remedy: Repair the chain 2 (0 V) circuit in the NTED (non--teacher enabling device) hardware. On the system setting screen, set whether to reset the chain failure to “Yes.” Press the reset key on the teach pendant. Refer to the maintenance manual.
SRVO--262 SERVO Chain 1 (SVDISC) abnormal When the servo power supply off signal was input, a chain 1 (+24 V) failure occurred. Cause: Remedy: Repair the chain 1 (+24 V) circuit for the servo power supply off signal circuit. On the system setting screen, set whether to reset the chain failure to “Yes.” Press the reset key on the teach pendant. Refer to the maintenance manual.
SRVO--263 SERVO Chain 2 (SVDISC) abnormal When the servo disconnect signal was input, a chain 2 (0 V) failure occurred. Cause: Remedy: On the system setting screen, set whether to reset the chain failure to “Yes.” Press the reset key on the teach pendant. Refer to the maintenance manual.
SRVO--264 SYSTEM E.STOP circuit abnormal 1 A deposition occurred in the emergency stop unit. Cause: Remedy: Repair the MON3 circuit in the emergency stop unit. Refer to the maintenance manual.
SRVO--265 SERVO E.STOP circuit abnormal 2 When the servo was activated, the MON3 was already on. Cause: Remedy:
The MON3 is abnormal. Repair the MON3 circuit in the emergency stop unit. Refer to the maintenance manual.
851
ALARM CODES
B--81464EN--3/01
SRVO--266 SERVO FENCE1 status abnormal When the fence signal was input, the FENCE1 remained on. Cause: Remedy: Repair the FENCE1 circuit. Refer to the maintenance manual.
SRVO--267 SERVO FENCE2 status abnormal When the fence signal was input, the FENCE2 remained on. Cause: Remedy: Repair the FENCE2 circuit. Refer to the maintenance manual.
SRVO--268 SERVO SVOFF1 status abnormal When the SVOFF signal was input, the SVOFF1 remained on. Cause: Remedy: Repair the SVOFF1 circuit. Refer to the maintenance manual.
SRVO--269 SERVO SVOFF2 status abnormal When the SVOFF signal was input, the SVOFF2 remained on. Cause: Remedy: Repair the SVOFF2 circuit. Refer to the maintenance manual.
SRVO--270 SERVO EXEMG1 status abnormal When an external emergency stop signal was input, the EXEMG1 remained on. Cause: Remedy: Repair the EXEMG1 circuit. Refer to the maintenance manual.
SRVO--271 SERVO EXEMG2 status abnormal When an external emergency stop signal was input, the EXEMG2 remained on. Cause: Remedy: Repair the EXEMG2 circuit. Refer to the maintenance manual.
SRVO--272 SERVO SVDISC1 status abnormal When the servo power off signal was input, the SVDISC1 remained on. Cause: Remedy: Repair the SVDISC1 circuit. Refer to the maintenance manual.
SRVO--273 SERVO SVDISC2 status abnormal When the servo power off signal was input, the SVDISC2 remained on. Cause: Remedy: Repair the SVDISC2 circuit. Refer to the maintenance manual.
SRVO--274 SERVO NTED1 status abnormal When the NTED signal was input, the NTED1 remained on. Cause: Remedy: Repair the NTED1 circuit. Refer to the maintenance manual.
SRVO--275 SERVO NTED2 status abnormal When the NTED signal was input, the NTED2 remained on. Cause: Remedy: Repair the NTED2 circuit. Refer to the maintenance manual.
SRVO--276 SERVO Disable on T2 mode The robot cannot operate in the T2 mode. Cause: Remedy: Set the mode switch to the T1 or auto position. SRVO--277 SYSTEM Panel E--stop (SVEMG abnormal) When the emergency stop button on the operator’s panel was pressed, the SVEMG signal was not Cause: Remedy:
input. The wiring of the SVEMG is incorrect. Correct it, and turn the power on again.
852
ALARM CODES
B--81464EN--3/01
SRVO--278 SYSTEM TP E--stop (SVEMG abnormal) When the emergency stop button on the teach pendant was pressed, the SVEMG signal was not input. Cause: Remedy: The wiring of the SVEMG is incorrect. Correct it, and turn the power on again. SRVO--280 SERVO SVOFF input The SVOFF (servo off signal) was input. Cause: Remedy: Find out what caused the SVOFF to be input, and remove the cause. SRVO--281 SYSTEM SVOFF input (SVEMG abnormal) The SVOFF input circuit was detected, and a disconnection of the SVEMG was detected. Cause: Remedy: Turn the power off. Repair the wiring of the SVEMG. Close the SVOFF input circuit, and press the reset key. Refer to the maintenance manual.
SRVO--282 SERVO Chain 1 (SVOFF) abnormal When the SVOFF (servo off signal) was input, a chain 1 (+24 V) failure occurred. Cause: Remedy: Repair the chain 1 (+24 V) circuit in the SVOFF hardware. On the system setting screen, set whether to reset the chain failure to “Yes.” Press the reset key on the teach pendant. Refer to the maintenance manual.
SRVO--283 SERVO Chain 2 (SVOFF) abnormal When the SVOFF (servo off signal) was input, a chain 2 (0 V) failure occurred. Cause: Remedy: Repair the chain 2 (0 V) circuit in the SVOFF hardware. On the system setting screen, set whether to reset the chain failure to “Yes.” Press the reset key on the teach pendant. Refer to the maintenance manual.
SRVO--290 SERVO DClink HC alarm (Group:%d Axis:%d) An abnormal current flowed through the amplifier DC link circuit. Cause: Remedy: It is likely that there is a short--circuit in a motor power line or the motor coil. Refer to the maintenance manual.
SRVO--291 SERVO IPM over heat (Group:%d Axis:%d) It was detected that the IPM element in the amplifier had overheated. Cause: Remedy: Decrease the duty cycle of operation. If this symptom occurs frequently, replace the amplifier.
SRVO--292 SERVO EXT.FAN alarm (Group:%d Axis:%d) A fan for cooling the amplifier heat--release fins is defective. Cause: Remedy: Replace the cooling fan. Refer to the maintenance manual.
SRVO--293 SERVO DClink (PSM) HCAL (Group:%d Axis:%d) An abnormal current flowed through the DC link circuit of the PSM amplifier. Cause: Remedy: It is likely that there is a short--circuit in a motor power line or the motor coil. Refer to the maintenance manual.
SRVO--294 SERVO EXT.FAN (PSM) alarm (Group:%d Axis:%d) A fan for cooling the PSM amplifier heat--release fins is defective. Cause: Remedy: Replace the cooling fan. Refer to the maintenance manual.
SRVO--295 SERVO A communication error occurred between the PSM and SVM. Cause: Remedy: Replace the cable between the PSM and SVM. Alternatively, replace the SVM or PSM. Refer to the maintenance manual for details.
853
ALARM CODES
B--81464EN--3/01
SRVO--296 SERVO The power regenerated in the PSM is too much. Cause: Remedy: Check whether a fan cooling the regenerative resistor for the PSMR is running. If the fan is running, it is likely that the operating condition is severe. Lower the teaching speed set in the program. Refer to the maintenance manual for details.
SRVO--297 SERVO The voltage of the PSM control power supply has dropped. Cause: Remedy: Check that the three--phase input voltage is low. Replace the PSM or the PSMR if necessary. Refer to the maintenance manual for details.
SRVO--298 SERVO The speed calculated in the servo circuit is abnormal. Cause: Remedy: Contact the service personnel. To reset the alarm condition requires turning the power off and on again. SRVO--300 SERVO Hand broken/HBK disabled When the HBK setting is disabled, a hand--broken signal was detected. Cause: Remedy: To remove the alarm condition, press the reset button. Check whether the hand--broken signal circuit is connected to the robot. If the circuit is connected to the robot, enable the hand--broken setting. Refer to the maintenance manual.
SRVO--301 SERVO Hand broken/HBK dsbl (Rbt:%d) When the HBK setting is disabled, a hand--broken signal was detected. Cause: Remedy: To remove the alarm condition, press the reset button. Check whether the hand--broken signal circuit is connected to the robot. If the circuit is connected to the robot, enable the hand--broken setting. Refer to the maintenance manual.
SRVO--302 SERVO Set Hand broken to ENABLE When the HBK setting was disabled, a hand--broken signal was input. Cause: Remedy:
The hand--broken setting is incorrect. Enable a hand broken. To remove the alarm condition, press the reset button. Refer to the maintenance manual.
SRVO--303 SERVO Set HBK to ENABLE (Rbt:%d) When the HBK setting was disabled, a hand--broken signal was input. Cause: Remedy:
The hand--broken setting is incorrect. Enable a hand broken. To remove the alarm condition, press the reset button. Refer to the maintenance manual.
SRVO--310 SERVO Internal alarm Cause: Remedy: Contact the service personnel.
SYST Error Codes
( ID = 24 )
SYST--001 PAUSE.G HOLD button is being pressed You attempted an operation while the hold button (input) is pressed. Cause: Remedy: Clear the hold button (input), and try the same operation. SYST--002 PAUSE.G HOLD is locked by program The condition that the robot is being held in is locked by the program and cannot be cleared. If a HOLD Cause:
Remedy:
statement is executed in a KAREL program, the held condition can only be cleared by the same program using the UNHOLD statement/action, or by aborting the program. If you attempt a motion in such a condition, this error message is displayed. Wait until the UNHOLD statement is executed by the KAREL program, or abort the KAREL program.
854
ALARM CODES
B--81464EN--3/01
SYST--003 WARN TP is enabled The attempted operation could not be done because the teach pendant is enabled. Cause: Remedy: Disable the teach pendant, and try the same operation again. SYST--004 WARN SOP is enabled The attempted operation could not be done because the System Operator Panel is enabled. Cause: Remedy: Turn the REMOTE switch on the SOP to REMOTE side, and try the same operation again. SYST--005 WARN UOP is the master device The attempted operation could not be done because the User Operator Panel is enabled. Cause: Remedy: Turn the REMOTE switch to local (if the operation is attempted from the SOP), or set the $RMT_MASTER system variable correctly.
SYST--006 WARN CRT is the master device The attempted operation could not be done because CRT is the master device. Cause: Remedy: 1 To perform the operation from the operator’s panel, set the remote switch to the local position. 2 To perform the operation from the remote unit, set an appropriate value for $RMT_MASTER.
SYST--007 WARN NETWORK is the master device The attempted operation could not be done because the NETWORK command processor is the master Cause: Remedy:
device. 1 To perform the operation from the operator’s panel, set the remote switch to the local position. 2 To perform the operation from the remote unit, set an appropriate value for $RMT_MASTER.
SYST--008 WARN Nothing is the master device The system variable $RMT_MASTER is set to disable all devices. Therefore, no remote device can Cause: Remedy:
issue motion. 1 To perform the operation from the operator’s panel, set the remote switch to the local position. 2 To perform the operation from the remote unit, set an appropriate value for $RMT_MASTER.
SYST--009 WARN Safety Fence open The attempted operation could not be done because the safety fence is open. Cause: Remedy: Close the safety fence and try the same operation again. SYST--010 WARN Max num task reached The number of tasks has reached the maximum allowed. Cause: Remedy: Abort one of the running task. SYST--011 WARN Failed to run task The system has failed to run the program. Cause: Remedy: Determine the cause of the alarm on the alarm cause screen. Then, eliminate the cause. SYST--012 WARN Not in remote Remote condition is not satisfied. Cause: Remedy: Turn the remote switch on. SYST--013 WARN Invalid program number The specified PNS number is not within its valid range. Cause: Remedy: Specify a program number that is within the valid range of 1 to 9999. SYST--014 WARN Program select failed PNS operation has failed. Cause: Remedy: Determine the cause of the alarm on the alarm cause screen. Then, eliminate the cause. SYST--015 WARN Robot Service Request failed RSR operation has failed. Cause: Remedy: Determine the cause of the alarm on the alarm cause screen. Then, eliminate the cause. 855
ALARM CODES
B--81464EN--3/01
SYST--016 WARN ENBL signal is off ENBL signal on the User Operator Panel is off. Cause: Remedy: Set ENBL signal ON. SYST--017 WARN Single step operation effective Single step operation is effective. Cause: Remedy: Disable single step switch. SYST--018 WARN Continuing from different line You attempted to continue program execution from a line different that the paused line. Cause: Remedy: Respond YES or NO in the prompt box on at the teach pendant. SYST--019 WARN Program not selected Program has not been selected. Cause: Remedy: Select a program from the program select menu on the teach pendant, or by using PNS. SYST--020 WARN Program not verified by PNS The program specified by PNS is different then the program currently selected. Cause: Remedy: Select a correct program from the program select menu on the teach pendant. SYST--021 WARN System not ready, press RESET Because program verification failed, program start--up is disabled. Cause: Remedy: Press RESET to clear the error condition. SYST--022 WARN PNS not zero, cannot continue A paused program cannot continue if PNS input ports are not zero. Cause: Remedy: Input an error clear signal to set all PNS inputs to 0, then input a start signal. SYST--023 SYSTEM Teach Pendant communication error A communication cable is broken. Cause: Remedy: Check the communication cable. Replace the cable if necessary. SYST--024 WARN PNSTROBE is OFF. Cannot start exec Prod_start could not be processed because PNSTROBE is off. Cause: Remedy: Set PNSTROBE input to ON. SYST--025 WARN Teach Pendant is different type The type of teach pendant being connected, is different from the one that was disconnected. Cause: Remedy: Connect the same type of teach pendant, as that which was disconnected. SYST--026 System normal power up System has executed normal power startup. Cause: Remedy: This is just a notification. You do not have to do anything for this warning message. SYST--027 PAUSE.G HOT start failed (Error:%d) HOT start has failed for one of the following reasons: Cause:
Remedy:
1. Power failed during system start up. 2. Flash ROM module was changed. 3. A run-time error occurred. 4. System internal error 1. 5. System internal error 2. COLD start is selected automatically.
SYST--028 WARN (%s) Program timed out $PWR_HOT, $PWR_SEMI program has been aborted by the system due to time out (40sec). Cause: Remedy: Decrease program size so that it can be executed within the time out limit. 856
ALARM CODES
B--81464EN--3/01
SYST--029 PAUSE.G Robot was connected (Group:%d) The connect/isolate key was turn to the connect side. Cause: Remedy: This is just a notification. You do not have to do anything for this warning message. SYST--030 PAUSE.G Robot was isolated (Group:%d) The connect/isolate key was turned to the isolate side Cause: Remedy: This is just a notification. You do not have to do anything for this warning message. SYST--031 SYSTEM F--ROM parity A parity error has been detected in the system FROM memory. Cause: Remedy: Reload system software. SYST--032 WARN ENBL signal from UOP is lost ENBL input signal from the User Operator Panel is lost. Cause: Remedy: Restore input signal. SYST--033 WARN SFSPD signal from UOP is lost SFSPD input signal from User Operator Panel is lost. Cause: Remedy: Restore input signal. SYST--034 WARN HOLD signal from SOP/UOP is lost HOLD input signal from System Operator Panel/User Operator Panel is lost. Cause: Remedy: Restore input signal. SYST--035 WARN Low or No Battery Power in PSU. Battery power in the PSU board is low. Cause: Remedy: Replace the old battery with a new battery of the same kind. SYST--036 WARN Semi power failure recovery System did a semi-hot start. Cause: Remedy: This is just a notification. You do not have to do anything for this warning message. SYST--037 ABORT.G CE Sign key switch broken Improper input from CE Sign key switch. Cause: Remedy: Fix the CE Sign key switch. SYST--038 PAUSE.G Operation mode T1 Selected Operation mode T1 Selected Cause: SYST--039 PAUSE.G Operation mode T2 Selected Operation mode T2 Selected Cause: SYST--040 PAUSE.G Operation mode AUTO Selected Operation mode AUTO Selected Cause: SYST--041 Ovrd Select could not ENABLED DI index is invalid Cause: Remedy: Please set valid DI index SYST--042 DEADMAN defeated The mode switch was changed from T1 or T2 mode to AUTO mode and the DEADMAN was already Cause: Remedy:
pressed. The DEADMAN must be released when switching to AUTO mode Release the DEADMAN and press RESET.
SYST--043 TP disabled in T1/T2 mode The mode selector is in T1 or T2 and the TP ON/OFF switch is in the OFF position Cause: Remedy: Turn the TP ON/OFF switch to ON.Press RESET. 857
ALARM CODES
B--81464EN--3/01
SYST--044 (Abnormal) TP disabled in T1/T2 mode The mode selector is in T1 or T2 and the TP ON/OFF switch is in the OFF position and SVON is ON. Cause: Remedy:
This is an abnormal condition. Call your FANUC technical representative.
SYST--045 TP enabled in AUTO mode The mode selector is in AUTO and the TP ON/OFF switch is in the ON position Cause: Remedy: Turn the TP ON/OFF switch to OFF. Press RESET.
SYST--046 Control Reliable config mismatch Either 1. Control Reliable hardware exists but the option has not been loaded, or 2. The Control Reliable Cause: Remedy:
option has been loaded but the hardware is not available. Consult our service representative.
SYST--047 Continuing from distant position Attempt to continue program from distant position from stopped position. Cause: Remedy: Respond ABORT or CONTINUE in the prompt box on at the teach pendant SYST--048 NECALC couldn’t get work memory The OS could not allocate work memory to the NUCALC software part. Cause: Remedy:
The memory may be insufficient. Increase the controller memory.
SYST--049 SFCALC couldn’t get work memory The OS could not allocate work memory to the SFCALC software part. Cause: Remedy:
The memory may be insufficient. Increase the controller memory.
SYST--067 Panel HSSB disconnect Communication with the panel board is disabled. Cause: Remedy: Check the cable of the panel HSSB. SYST--095 Remote diagnose internal error An internal error occurred with the remote diagnosis function. Cause: Remedy: Internal error SYST--096 Designated task is not valid A task specified by the PC in remote diagnosis is invalid. Cause: Remedy: Check the remote diagnosis software of the PC. SYST--097 Fail to initialize Modem Modem initialization failed. Cause: Remedy: Check if a modem is installed. Check the modem type setting.
SYST--098 Card Modem is removed The modem card was removed during communication. Cause: Remedy: Reinsert the modem card, then restart the remote diagnosis function. Check if the modem card is inserted into the PCMIA slot correctly.
SYST--099 Card Modem is not responded There is no response from the modem card. Cause: Remedy: Check if a modem card is inserted correctly. Check the modem card.
SYST--100 DSR in Modem OFF DSR was turned off during communication. Cause: Remedy: Check the connection between R--J3 and the modem. If a modem card is used, check if the modem card is not destroyed and if the modem card is inserted correctly.
858
ALARM CODES
B--81464EN--3/01
SYST--101 Connection is stopped The line was disconnected. Cause: Remedy: Check the telephone line. SYST--144 Bad DO specfied by %s An invalid or unassigned SDO was allocated by a system variable. Cause: Remedy: Change the value of the system variable to 0 (for no use) or a valid number. Check that a specified SDO is allocated.
SYST--148 Dynamic Brake is Disabled The dynamic brake release request signal SDI[$DYN_BRK.$DI_IDX] was turned on, so that the Cause: Remedy:
dynamic brake was released. IMSTP is generated while the dynamic brake release request signal is on.
SYST--149 Dynamic Brake is Enabled The dynamic brake release request signal was turned off, so that the dynamic brake was actuated. Cause: Remedy: This is not an alarm. SYST--150 Cursor is not on line 1 The program was started on a line other than the first line. Cause: Remedy: Reply Yes/No in response to the inquiry displayed on the screen. Then, restart the program.
SYST--151 Start again (%s, %d) After the program was started on a line other than the first line, Yes was replied to the inquiry displayed Cause: Remedy:
on the screen. Restart the program.
SYST--152 Cannot force DO’s in AUTO mode An attempt was made to output a signal in the AUTO mode. Cause: Remedy: Before performing this operation, exit from the AUTO mode. SYST--153 Cannot SIM/UNSIM DO’s in AUTO mode An attempt was made to simulate signal output in the AUTO mode. Cause: Remedy: Before performing this operation, exit from the AUTO mode. SYST--156 Unknown hard ware The PCB does not match the control unit. Cause: Remedy: Replace the PCB with a correct PCB. SYST--157 CE/RIA software does not exist The CE/RIA option is not installed. Cause: Remedy: Install the CE/RIA option. SYST--158 Robot cannot move in T2 mode The tri--mode switch is set to the T2 mode. Cause: Remedy:
In the T2 mode, the robot cannot be moved. Set the switch to the T1 or AUTO mode.
INTP Error Codes
( ID = 12 )
INTP--000 ABORT.G.G Req has not been processed yet Internal system error. Cause: Remedy: Contact our service center serving your locality. INTP--001 PAUSE.G Cannot lock the motion grp Internal system error. Cause: Remedy: Contact our service center serving your locality. 859
ALARM CODES
B--81464EN--3/01
INTP--002 ABORT.G Program manager internal error Internal system error. Cause: Remedy: Contact our service center serving your locality. INTP--003 ABORT.G Invalid request Internal system error. Cause: Remedy: Contact our service center serving your locality. INTP--004 PAUSE.G Cannot ATTACH with TP enabled The ATTACH statement requires the teach pendant to be disabled. Cause: Remedy: Disable the teach pendant. INTP--005 PAUSE.G Cannot release motion control Motion control cannot be released. Cause: Remedy: Abort the running or paused program. INTP--100 to 102 ABORT.L (%s^4, %d^5) Internal error (PXnn) Internal system error. Cause: Remedy: Contact our service center serving your locality. INTP--103 ABORT.L (%s^4, %d^5) Program error An error occurred while the program was running. Cause: Remedy: Refer to the error cause code. INTP--104 ABORT.L (%s^4, %d^5) Single step failed Single step cannot be executed Cause: Remedy: Refer to the error cause code. INTP--105 ABORT.L (%s^4, %d^5) Run request failed The program cannot be started. Cause: Remedy: Refer to the error cause code. INTP--106 PAUSE.L (%s^4, %d^5) Continue request failed Program cannot be resumed. Cause: Remedy: Refer to the error cause code. INTP--107 ABORT.L (%s^4, %d^5) Pause request failed An error occurred when program execution was held. Cause: Remedy: Refer to the error cause code. INTP--108 ABORT.L (%s^4, %d^5) Abort request failed An error occurred when program execution was aborted. Cause: Remedy: Refer to the error cause code. INTP--109 WARN (%s^4, %d^5) BWD motion request failed Backward motion cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--110 (%s^4, %d^5) Get task status request failed The specified task attribute is not found or is not read accessible. Cause: Remedy: Check the attribute. INTP--111 WARN (%s^4, %d^5) Skip statement request failed The currently executing line cannot be changed. Cause: Remedy: Refer to the error cause code. 860
ALARM CODES
B--81464EN--3/01
INTP--112 PAUSE.L Cannot call interrupt routine The interrupt routine cannot be executed. Cause: Remedy: Refer to the error cause code. Cause: If this alarm is raised together with the “MEMO--004 WARN SPECIFIED PROGRAM IS IN USE” alarm, Remedy: Cause: Remedy:
the conditions in the condition program are satisfied, and the desired action program is currently being edited, executed, or suspended. Select another program from the program list. Terminate the current action program. If this alarm is raised together with the “PROG--020 TASK IS ALREADY ABORTED” alarm, it is possible that the program that executed the monitoring start instruction has already been terminated when the conditions in the condition program are satisfied. When program monitoring is enabled, an action program can run only if the program that executed the monitoring start instruction is running.
INTP--113 PAUSE.L (%s^4, %d^5) Stop motion request failed An error occurred when motion was stopped. Cause: Remedy: Refer to the error cause code. INTP--114 PAUSE.L (%s^4, %d^5) Cancel motion request failed An error occurred when motion was canceled. Cause: Remedy: Refer to the error cause code. INTP--115 PAUSE.L (%s^4, %d^5) Resume motion request failed An error occurred when motion was resumed. Cause: Remedy: Refer to the error cause code. INTP--116 PAUSE.L (%s^4, %d^5) Hold motion request failed An error occurred when motion was held. Cause: Remedy: Refer to the error cause code. INTP--117 PAUSE.L (%s^4, %d^5) Unhold motion request failed An error occurred when motion was unheld. Cause: Remedy: Refer to the error cause code. INTP--118 to 123 PAUSE.L (%s^4, %d^5) System error Internal error of software. Cause: Remedy: Refer to the error cause code. INTP--124 ABORT.L (%s^4, %d^5) Invalid ITR routine Internal error of software Cause: Remedy: Refer to the error cause code. INTP--125 ABORT.L Failed to convert position The conversion of one position type to another failed. Cause: Remedy: Refer to the error cause code. INTP--126 ABORT.L Vision built--in return failed The vision built-in failed to return. Cause: Remedy: Refer to the error cause code. INTP--127 WARN Power fail detected Power failure was detected. Cause: Remedy: Resume the program after hot start is complete. INTP--128 PAUSE.L Pos reg is locked Pos register is locked. Cause: Remedy: Wait a moment. The error should resolve itself. 861
ALARM CODES
B--81464EN--3/01
INTP--129 ABORT.L Cannot use motion group You tried to lock the motion group even though this program cannot use motion groups. Cause: Remedy: Clear the motion group mask in the program detail screen. INTP--130 ABORT.L (%s^4, %d^5) Exec status recovery failed Failed to recover execution status. Cause: Remedy: Refer to the error cause code. INTP--131 ABORT.L Number of stop exceeds limit Too many stop data is created at one time. Cause: Remedy: Decrease the number of stop data. INTP--132 Unlocked groups specified The specified motion groups are already unlocked. Cause: Remedy: Change the specify of motion group. INTP--133 Motion is already released Some specified motion groups are already unlocked. Cause: Remedy: Change the specify of motion group. Lock the motion group.
INTP--134 Over automatic start Max counter The automatic start was done the defined times but the alarm was not fixed. Cause: Remedy: Please fix the alarm by manual. INTP--135 Recovery DO OFF in auto start mode The error recovery DO status is OFF in the automatic start feature Cause: Remedy:
So the resume program cannot be exeucted automatically. Please check the condition of error recovery DO status
INTP--136 Can not use motion group for dry run function In $PAUSE_PROG and $RESUME_PROG, a program using a motion group is specified. Cause: Remedy: Specify a program not specifying a motion group. INTP--137 Program specified by $PAUSE_PROG doesn’t exist. $PAUSE_PROG does not include a specified program. Cause: Remedy: Check $PAUSE_PROG. INTP--138 Program specified by $RESM_DRYPROG doesn’t exist. $RESUME_PROG does not include a specified program. Cause: Remedy: Check $RESUME_PROG. INTP--139 (%s^4, %d^5) Local variable request failed Execution failed. Cause: Remedy: Check the alarm history screen to see if another alarm is output. INTP--200 PAUSE.L (%s^4, %d^5) Unimplemented TP instruction This instruction cannot be used. Cause: Remedy: Make sure that the appropriate option is loaded. INTP--201 PAUSE.L (%s^4, %d^5) Untaught element encountered The program contains a portion without teaching data. Cause: Remedy:
The specified condition program contains an error (statement without teaching data). Teach the instruction.
INTP--202 PAUSE.L (%s^4, %d^5) Syntax error Instruction syntax error. Cause: Remedy: Reteach the instruction. 862
ALARM CODES
B--81464EN--3/01
INTP--203 PAUSE.L (%s^4, %d^5) Variable type mismatch The variable type is not correct. Cause: Remedy: Check the variable type. INTP--204 PAUSE.L (%s^4, %d^5) Invalid value for index The index value is invalid. Cause: Remedy: Check the index value. INTP--205 PAUSE.L (%s^4, %d^5) Analog port access error Analog I/O is not functioning properly. Cause: Remedy: Refer to the error cause code. INTP--206 PAUSE.L (%s^4, %d^5) Digital port access error Digital I/O is not functioning properly. Cause: Remedy: Refer to the error cause code. INTP--207 PAUSE.L (%s^4, %d^5) Group I/O port access error Group I/O is not functioning properly. Cause: Remedy: Refer to the error cause code. INTP--208 PAUSE.L (%s^4, %d^5) Divide by 0 Division by 0 was executed. Cause: Remedy: Check the value. INTP--209 PAUSE.L (%s^4, %d^5) SELECT is needed A CASE instruction was executed before a SELECT instruction. Cause: Remedy: Add a SELECT instruction before the CASE instruction. INTP--212 PAUSE.L (%s^4, %d^5) Invalid value for OVERRIDE The indicated value cannot be used for the OVERRIDE instruction. Cause: Remedy: Check the value. INTP--213 PAUSE.L %s^7 (%s^4, %d^5) UALM[%d^9] A user alarm occurred. Cause: Remedy: Refer to the user alarm code. INTP--214 PAUSE.L (%s^4, %d^5) Specified group not locked The position register or frame setup instructions were executed in a program without a motion group. Cause: Remedy: Set up the motion group in the program DETAIL screen. Refer to the user alarm code. INTP--215 PAUSE.L (%s^4, %d^5) Group mismatch The position data is invalid. Cause: Remedy: Check the position data. INTP--216 PAUSE.L (%s^4, %d^5) Invalid value for group number The indicated value is invalid for the motion group number. Cause: Remedy: Check the value. INTP--217 PAUSE.L (%s^4, %d^5) SKIP CONDITION needed The SKIP instruction was executed before a SKIP CONDITION instruction. Cause: Remedy: Add a SKIP CONDITION instruction. INTP--218 PAUSE.L (%s^4, %d^5) Skip failed The SKIP instruction or SKIP CONDITION instruction cannot be executed. Cause: Remedy: Refer to the error cause code. 863
ALARM CODES
B--81464EN--3/01
INTP--219 ABORT.L (%s^4, %d^5) Pause task failed The pause instruction cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--220 ABORT.L (%s^4, %d^5) Abort task failed The ABORT instruction cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--221 PAUSE.L (%s^4, %d^5) Application failed The application instruction cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--222 PAUSE.L (%s^4, %d^5) Call program failed The program CALL instruction cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--223 PAUSE.L (%s^4, %d^5) Delay time failed The WAIT instruction cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--224 PAUSE.L (%s^4, %d^5) Jump label failed The BRANCH instruction cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--225 PAUSE.L (%s^4, %d^5) Motion statement failed The MOTION instruction cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--226 PAUSE.L (%s^4, %d^5) Read position register failed The position register cannot be read. Cause: Remedy: Refer to the error cause code. INTP--227 PAUSE.L (%s^4, %d^5) Write position register failed The position register cannot be written. Cause: Remedy: Refer to the error cause code. INTP--228 PAUSE.L (%s^4, %d^5) Read register failed The register cannot be read. Cause: Remedy: Refer to the error cause code. INTP--229 PAUSE.L (%s^4, %d^5) Write register failed The register cannot be written. Cause: Remedy: Refer to the error cause code. INTP--230 PAUSE.L (%s^4, %d^5) Wait condition failed A condition WAIT instruction cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--231 PAUSE.L (%s^4, %d^5) Read next line failed The next line cannot be read. Cause: Remedy: Refer to the error cause code. INTP--232 PAUSE.L (%s^4, %d^5) Invalid frame number The frame number is invalid. Cause: Remedy: Check the frame number. 864
ALARM CODES
B--81464EN--3/01
INTP--233 PAUSE.L (%s^4, %d^5) Read frame value failed The specified frame cannot be read. Cause: Remedy: Refer to the error cause code. INTP--234 PAUSE.L (%s^4, %d^5) Write frame value failed The specified frame cannot be written. Cause: Remedy: Refer to the error cause code. INTP--235 PAUSE.L (%s^4, %d^5) Read pos item failed The position variable cannot be read. Cause: Remedy: Refer to the error cause code. INTP--236 PAUSE.L (%s^4, %d^5) Write pos item failed The position variable cannot be written. Cause: Remedy: Refer to the error cause code. INTP--237 WARN (%s^4, %d^5) No more motion for BWD Backward execution cannot be executed any further because the current program line is at the top. Cause: Remedy: Stop using backward execution at this point. INTP--238 WARN (%s^4, %d^5) BWD execution completed Backward execution was completed. Cause: Remedy: Do not use backward execution from this point. INTP--239 WARN (%s^4, %d^5) Cannot execute backwards This instruction cannot be executed backwards. Cause: Remedy: Set the cursor to execute at the next line. INTP--240 PAUSE.L (%s^4, %d^5) Incompatible data type The specified data type in the PARAMETER instruction is invalid for the parameter type. Cause: Remedy: Check the data type. INTP--241 PAUSE.L (%s^4, %d^5) Unsupported parameter This type of parameter cannot be used. Cause: Remedy: Check the parameter type. INTP--242 PAUSE.L (%s^4, %d^5) Offset value is needed An OFFSET instruction was executed before an OFFSET CONDITION instruction. A position register Cause: Remedy:
was not taught in the OFFSET PR[] instruction. Add an OFFSET CONDITION instruction before the OFFSET instruction. Teach the position register.
INTP--243 ABORT.G (%s^4, %d^5) Def grp is not specified This program has no motion group defined. The MOTION instruction cannot be executed. Cause: Remedy: Remove the MOTION instruction or set up the motion group in the program DETAIL screen. INTP--244 PAUSE.L (%s^4, %d^5) Invalid line number The input line number is incorrect. Cause: Remedy: Check the line number. INTP--245 PAUSE.L (%s^4, %d^5) RCV stmt failed The RECEIVE R[] instruction cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--246 PAUSE.L (%s^4, %d^5) SEMAPHORE stmt failed The SEMAPHORE instruction cannot be executed. Cause: Remedy: Refer to the error cause code. 865
ALARM CODES
B--81464EN--3/01
INTP--247 PAUSE.L (%s^4, %d^5) Pre exec failed Internal error of software. Cause: Remedy: Contact our service center serving your locality. INTP--248 PAUSE.L (%s^4, %d^5) MACRO failed The MACRO instruction cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--249 PAUSE.L Macro is not set correctly The MACRO setup was invalid. Cause: Remedy: Check the MACRO setup. INTP--250 PAUSE.L (%s^4, %d^5) Invalid uframe number The user frame number is invalid. Cause: Remedy: Refer to the error cause code. INTP--251 PAUSE.L (%s^4, %d^5) Invalid utool number The tool frame number is invalid. Cause: Remedy: Refer to the error cause code. INTP--252 PAUSE.L User frame number mismatch The user frame number in the positional data is not the same as the currently selected user frame Cause: Remedy:
number. Check the user frame number.
INTP--253 PAUSE.L Tool frame number mismatch The tool frame number in the positional data is not the same as the currently selected tool frame number. Cause: Remedy: Check the tool frame number. INTP--254 PAUSE.L (%s^4, %d^5) Parameter not found The specified parameter name cannot be found. Cause: Remedy: Check the parameter name. INTP--255 PAUSE.L (%s^4, %d^5) CAL_MATRIX failed The CAL_MATRIX instruction cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--256 PAUSE.L (%s^4, %d^5) No data for CAL_MATRIX The origin 3 points or destination 3 points are not taught. Cause: Remedy: Teach the origin 3 points or destination 3 points. INTP--257 PAUSE.L (%s^4, %d^5) Invalid delay time The wait time value is negative or exceeds the maximum value of 2147483.647 sec. Cause: Remedy: Input a correct value. INTP--258 PAUSE.L (%s^4, %d^5) Weld port access error The weld is not functioning properly. Cause: Remedy: Refer to the error cause code. INTP--259 PAUSE.L (%s^4, %d^5) Invalid position type The data type of the position register was taught using joint type. Cause: Remedy: Change position register data to Cartesian. INTP--260 PAUSE.L (%s^4, %d^5) Invalid torque limit value The specified torque limit is not in the range of 0.0 to 100.0. Cause: Remedy: Specify a torque limit in the range of 0.0 to 100.0. 866
ALARM CODES
B--81464EN--3/01
INTP--261 PAUSE.L (%s^4, %d^5) Array subscript missing No array element number is specified. Cause: Remedy: Specify an array element number. INTP--262 PAUSE.L (%s^4, %d^5) Field name missing No element name is specified. Cause: Remedy: Specify an element name. INTP--263 PAUSE.L (%s^4, %d^5) Invalid register type The register type is not valid. Cause: Remedy: Check the register type. INTP--265 PAUSE.L (%s^4, %d^5) Invalid value for speed value The indicated value cannot be used for the AF instruction. Cause: Remedy: Specify a value in the range of 0 to 100. INTP--266 ABORT.L (%s^4, %d^5) Mnemonic in interrupt is failed The execution of mnemonic instructions in the KAREL interrupt program failed. Cause: Remedy: insert a CANCEL or STOP instruction before calling an interrupt routine. INTP--267 PAUSE.L (%s^4, %d^5) RUN stmt failed Specified program is already running. Cause: Remedy: Abort the specified program. INTP--268 PAUSE.L (%s^4, %d^5) This statement only one in each line A single line contains more than one application instruction. Only one of these statements can exist per Cause: Remedy:
line. Delete the extra statement.
INTP--269 PAUSE.L (%s^4, %d^5) Skip statement only one in each line A single line contains more than one skip instruction. Only one Skip statement can exist per line. Cause: Remedy: Delete the extra Skip statement. INTP--270 PAUSE.L (%s^4, %d^5) different group cannot BWD During backward execution, a move is encountered that has a different group number from the previous Cause: Remedy:
motion statement. Use FWD execution carefully.
INTP--271 WARN (%s^4, %d^5) Excessive torque limit value Cause: The torque limit value was modified to exceed it’s maximum value. The torque limit value was clamped Remedy:
at the upper torque limit. Set torque limit value less than or equal to the maximum value.
INTP--272 PAUSE.L (%s^4, %d^5) Unsupported operator This operator is not supported. Cause: Remedy: Check the operator. INTP--274 (%s^4, %d^5) CH program error This monitor statement cannot be executed. Cause: Remedy: Refer to the error cause code. Cause: Remedy: Cause:
Use MENU to display the Alarm Log screen. If this alarm is raised together with the “MEMO--004 WARN SPECIFIED PROGRAM IN USE” alarm, the specified condition program is currently being edited. Select another program from the program list. If this alarm is raised together with the “INTP--275 PAUSE.L INVALID SUB TYPE OF CH PROGRAM” alarm, the sub type of the specified condition program may not be CH, or that program may not exist.
INTP--275 Invalid sub type of CH program The sub type of specified ch program cannot be used. Cause: Remedy: Check the sub type of this CH program. 867
ALARM CODES
B--81464EN--3/01
INTP--276 (%s^4, %d^5) Invalid combination of motion option The motion option instructions (SKIP, TIME BEFORE/AFTER, and application instruction) cannot be Cause: Remedy:
taught together Delete the motion option instruction
INTP--277 (%s^4, %d^5) Internal MACRO EPT data mismatch The EPT index in macro table doesn’t point the program name defined in macro table. Cause: Remedy:
That is, the EPT index in macro table is incorrect. Please set the correct EPT index for the program name defined in macro table.
INTP--278 (%s^7) PAUSE.L %s^7 The DI monitor alarm for auto error recovery function occurs. Cause: Remedy: This alarm is defined by the customer. Therefore the customer knows the remedy for this alarm. INTP--279 (%s^4, %d^5) Application instruction mismatch The application instruction was executed. But this application instruction doesn’t match to the Cause: Remedy:
application process data of this program. Please change the application process data of this program to the adequate application for this application instruction.
INTP--280 (%s^4, %d^5) Application data mismatch The application data of called program is different from that of the original program. Cause: Remedy: Please change the structure of program INTP0281 No application data This program doesn’t have the application data Cause: Remedy: Please define the application data in the program detail screen INTP--282 (%s^4, %d^5) Fast fault status mismatch There is no Cause. Cause: Remedy: There is no Remedy. INTP--283 (%s^4, %d^5) Stack over flow for fast fault recovery Stack over flow to record the fast fault recovery nesting data Cause: Remedy: Reduce the nesting of the program INTP--284 No detection of fast fault recovery The point for the fast fault recover cannot detected Cause: INTP--285 Karel program cannot entry in fast fautl recovery The fast entry cannot be performed in the karel program. Cause: Remedy: Use TP program. INTP--286 MAINT program isn’t defined in fast fautl recovery MAINT program is not defined in fast fault recovery. Cause: INTP--287 Fail to execute MAINT program It failed to execute MAINT program Cause: Remedy: Confirm the MAINT program name is correct or MAINT program exist in acutual. INTP--288 (%s^4, %d^5) Parameter does not exist The parameter designated by AR register does not exist. Cause: Remedy: Please confirm the index of AR register and the parameter in CALL/MACRO command in main program. INTP--289 Can’t save ffast point at program change When fast fault is enabled, the program was paused at the part of program change Cause: Remedy: Check whether the CONT terminaton exists at end of sub--program. If exist, please change it to FINE. This is the limitation of the fast fault recovery function.
868
ALARM CODES
B--81464EN--3/01
INTP--290 Fast fault recovery position is not saved During fast fault recovery sequence, any alarm occurs. So the fast fault recovery position is not saved. Cause: INTP--291 (%s^4, %d^5) Index for AR is not correct The AR register number is incorrect. At present, this alarm is not issued. Cause: Remedy: Check the index of the AR register and the argument specified in the call/macro instruction of the main program.
INTP--292 more than 6 motion with DB executed Six or more advanced execution (distance) motions overlapped each other. Cause: Remedy: Modify the teaching so that six or more advanced execution (distance) motions do not overlap each other.
INTP--293 (%s,%d)DB too small(away)(%dmm) The condition for advanced execution (distance) is not satisfied. Cause: Remedy: Increase the specified distance value. INTP--294 TPE parameter error An incorrect argument is specified for call/macro instruction execution. Cause: Remedy: Contact your FANUC customer service representative, and inform the representative of an alarm message displayed.
INTP--295 (%s,%d)DB too small(away)(%dmm) The condition for advanced execution (distance) is not satisfied. Cause: Remedy: Increase the specified distance value. INTP--296 (%s,%d) $SCR_GRP[%d].$M_POS_ENB is FALSE Advanced execution (distance) does not function when $SCR_GRP[].$M_POS_ENB is FALSE. Cause: Remedy: Change $SCR_GRP[].$M_POS_ENB to TRUE. INTP--297 (%s,%d)DB too small(done)(%dmm) A motion statement ended before the condition for advanced execution (distance) is satisfied. Cause: Remedy: Increase the specified distance value. INTP--300 ABORT.L (%s^4, %d^5) Unimplemented P--code KAREL program error. This KAREL statement cannot be executed. Cause: Remedy: Check the KAREL translator software version. INTP--301 ABORT.L (%s^4, %d^5) Stack underflow KAREL program error. Execution entered into a FOR loop by the GOTO statement. Cause: Remedy: A GOTO statement cannot be used to enter or exit a FOR loop. Check the label of the GOTO statement. INTP--302 ABORT.L (%s^4, %d^5) Stack overflow 1 A recursive program instruction was executed repeatedly without limit. Cause: Remedy:
2 Too many programs are called at one time. 1 Before executing a recursive instruction, perform programming so that a call to the instruction can be cleared at any point of execution. 2 Reduce the number of programs to be called at any one time. For KAREL programs, the stack size can be increased.
INTP--303 ABORT.L (%s^4, %d^5) Specified value exceeds limit KAREL program error. The specified value exceeds the maximum limit. Cause: Remedy: Check the value. INTP--304 ABORT.L (%s^4, %d^5) Array length mismatch KAREL program error. The dimensions of the arrays are not the same. Cause: Remedy: Check the dimensions of the arrays. 869
ALARM CODES
B--81464EN--3/01
INTP--305 ABORT.L (%s^4, %d^5) Error related condition handler KAREL program error. A condition handler error occurred. Cause: Remedy: Refer to the error cause code. INTP--306 ABORT.L (%s^4, %d^5) Attach request failed KAREL program error. The ATTACH statement failed. Cause: Remedy: Refer to the error cause code. INTP--307 ABORT.L (%s^4, %d^5) Detach request failed KAREL program error. The DETACH statement failed. Cause: Remedy: Refer to the error cause code. INTP--308 ABORT.L (%s^4, %d^5) No case match is encountered KAREL program error. The CASE statement does not match any branches. Cause: Remedy: Check the CASE value and branches. INTP--309 ABORT.L (%s^4, %d^5) Undefined WITHCH parameter KAREL program error. The specified parameter cannot be used in the with clause of the condition Cause: Remedy:
handler. Check the parameter.
INTP--310 ABORT.L (%s^4, %d^5) Invalid subscript for array KAREL program error. The index of the array is invalid. Cause: Remedy: Check the length of the array and index value. INTP--311 PAUSE.L (%s^4, %d^5) Uninitialized data is used KAREL program error. Untaught or uninitialized data was used. Cause: Remedy: Teach or initialize the data before using it. INTP--312 ABORT.L (%s^4, %d^5) Invalid joint number KAREL program error. The wrong axis number was used. Cause: Remedy: Check the axis number and the data value. INTP--313 ABORT.L (%s^4, %d^5) Motion statement failed KAREL program error. The MOTION statement cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--314 ABORT.L (%s^4, %d^5) Return program failed KAREL program error. Execution cannot be returned from the routine. Cause: Remedy: Refer to the error cause code. INTP--315 ABORT.L (%s^4, %d^5) Built--in execution failed KAREL program error. A built-in routine error occurred. Cause: Remedy: Refer to the error cause code. INTP--316 ABORT.L (%s^4, %d^5) Call program failed KAREL program error. The routine cannot be called. Cause: Remedy: Verify the routine is loaded by referring to the error cause code. INTP--317 ABORT.L (%s^4, %d^5) Invalid condition specified KAREL program error. The specified condition was invalid. Cause: Remedy: Check the condition. INTP--318 ABORT.L (%s^4, %d^5) Invalid action specified KAREL program error. The specified action was invalid. Cause: Remedy: Check the action. 870
ALARM CODES
B--81464EN--3/01
INTP--319 ABORT.L (%s^4, %d^5) Invalid type code KAREL program error. The data type was invalid. Cause: Remedy: Check the data type. INTP--320 ABORT.L (%s^4, %d^5) Undefined built--in KAREL program error. The built-in routine is not defined. Cause: Remedy: Check the appropriate option is loaded. INTP--321 ABORT.L (%s^4, %d^5) END stmt of a func rtn KAREL program error. The END statement was executed in a function routine instead of a RETURN Cause: Remedy:
statement. Add a RETURN statement to the function routine.
INTP--322 ABORT.L (%s^4, %d^5) Invalid arg val for builtin KAREL program error. The argument value of a built-in routine was wrong. Cause: Remedy: Check the argument value. INTP--323 ABORT.L (%s^4, %d^5) Value overflow KAREL program error. The data value for the variable was too large. Cause: Remedy: Check the variable’s type and data value. INTP--324 ABORT.L (%s^4, %d^5) Invalid open mode string KAREL program error. The usage string in the OPEN FILE statement was invalid. Cause: Remedy: Check the usage string in the OPEN FILE statement. INTP--325 ABORT.L (%s^4, %d^5) Invalid file string KAREL program error. The file string in the OPEN FILE statement was invalid. Cause: Remedy: Check the file string. INTP--326 ABORT.L (%s^4, %d^5) File var is already used KAREL program error. The FILE variable is already being used. Cause: Remedy: Close the file before reusing the FILE variable or add a new FILE variable. INTP--327 ABORT.L (%s^4, %d^5) Open file failed KAREL program error. The file could not be opened. Cause: Remedy: Refer to the error cause code. INTP--328 ABORT.L (%s^4, %d^5) File is not opened KAREL program error. The specified file was not opened before operation. Cause: Remedy: Open the file before operation. INTP--329 ABORT.L (%s^4, %d^5) Write variable failed KAREL program error. Cause: Remedy: Refer to the error cause code. INTP--330 ABORT.L (%s^4, %d^5) Write file failed KAREL program error. Writing to the file failed. Cause: Remedy: Refer to the error cause code. INTP--331 ABORT.L (%s^4, %d^5) Read variable failed KAREL program error. Reading the variable failed. Cause: Remedy: Refer to the error cause code. INTP--332 ABORT.L (%s^4, %d^5) Read data is too short KAREL program error. Data read from the file is too short. Cause: Remedy: Make sure the data in the file is valid. 871
ALARM CODES
B--81464EN--3/01
INTP--333 ABORT.L (%s^4, %d^5) Invalid ASCII string for read KAREL program error. The string read from the file is wrong. Cause: Remedy: Check the data of the file. INTP--334 ABORT.L (%s^4, %d^5) Read file failed KAREL program error. Reading from the file failed. Cause: Remedy: Refer to the error cause code. INTP--335 ABORT.L (%s^4, %d^5) Cannot open pre--defined file KAREL program error. A file pre-defined by the system cannot be opened. Cause: Remedy: Use the file defined by the system without opening it. INTP--336 ABORT.L (%s^4, %d^5) Cannot close pre--defined file KAREL program error. A file pre-defined by the system cannot be closed. Cause: Remedy: Do not try to close it. INTP--337 ABORT.L (%s^4, %d^5) Invalid routine type KAREL program error. This routine cannot be used. Cause: Remedy: Make sure you have the correct routine type and name. INTP--338 ABORT.L (%s^4, %d^5) Close file failed KAREL program error. Closing the file failed. Cause: Remedy: Refer to the error cause code. INTP--339 ABORT.L (%s^4, %d^5) Invalid program name KAREL program error. The program name is invalid. Cause: Remedy: Make sure you have the correct program name. INTP--340 ABORT.L (%s^4, %d^5) Invalid variable name KAREL program error. The variable name is invalid. Cause: Remedy: Make sure you have the correct variable name. INTP--341 ABORT.L (%s^4, %d^5) Variable not found KAREL program error. The variable cannot be found. Cause: Remedy: Verify the program name and variable name. INTP--342 ABORT.L (%s^4, %d^5) Incompatible variable KAREL program error. The data type defined by the BYNAME function and the variable type are Cause: Remedy:
mismatched. Make sure you have the correct data type and variable type.
INTP--343 ABORT.L (%s^4, %d^5) Reference stack overflow KAREL program error. Too many variables are passed using the BYNAME function. Cause: Remedy: Decrease the number of BYNAME functions. INTP--344 ABORT.L (%s^4, %d^5) Readahead buffer overflow KAREL program error. The buffer to read ahead from the device overflowed. Cause: Remedy: Increase the buffer size. INTP--345 ABORT.L (%s^4, %d^5) Pause task failed KAREL program error. The PAUSE statement cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--346 ABORT.L (%s^4, %d^5) Abort task failed KAREL program error. The ABORT statement cannot be executed. Cause: Remedy: Refer to the error cause code. 872
ALARM CODES
B--81464EN--3/01
INTP--347 ABORT.L (%s^4, %d^5) Read I/O value failed KAREL program error. The digital input signal cannot be input. Cause: Remedy: Refer to the error cause code. INTP--348 ABORT.L (%s^4, %d^5) Write I/O value failed KAREL program error. The digital output signal cannot be output. Cause: Remedy: Refer to the error cause code. INTP--349 ABORT.L (%s^4, %d^5) Hold motion failed KAREL program error. The HOLD statement cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--350 ABORT.L (%s^4, %d^5) Unhold motion failed KAREL program error. The UNHOLD statement cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--351 ABORT.L (%s^4, %d^5) Stop motion failed KAREL program error. The STOP statement cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--352 ABORT.L (%s^4, %d^5) Cancel motion failed KAREL program error. The CANCEL statement cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--353 ABORT.L (%s^4, %d^5) Resume motion failed KAREL program error. The RESUME statement cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--354 ABORT.L (%s^4, %d^5) Break point failed KAREL program error. The break point function cannot be executed. Cause: Remedy: Refer to the error cause code. INTP--355 ABORT.L (%s^4, %d^5) AMR is not found KAREL program error. The AMR operated by the RETURN_AMR built-in routine was not found. Cause: Remedy: Check program operation. INTP--356 ABORT.L (%s^4, %d^5) AMR is not processed yet KAREL program error. The RETURN_AMR built-in routine cannot be used for an unoperated AMR. Cause: Remedy: Operate the AMR using the WAIT_AMR built-in routine. INTP--357 ABORT.L (%s^4, %d^5) WAIT_AMR is cancelled KAREL program error. The execution of the WAIT_AMR built--in routine was cancelled. Cause: Remedy: The program executing the WAIT_AMR must be restarted. INTP--358 ABORT.L (%s^4, %d^5) Timeout at read request KAREL program error. The READ statement timed out. Cause: Remedy: Check the device being read. INTP--359 ABORT.L (%s^4, %d^5) Read request is nested KAREL program error. Another READ statement was executed while a READ statement was waiting Cause: Remedy:
for input. Remove nested reads.
INTP--360 ABORT.L (%s^4, %d^5) Vector is 0 KAREL program error. The vector value was invalid. Cause: Remedy: Check the vector value. 873
ALARM CODES
B--81464EN--3/01
INTP--361 PAUSE.L (%s^4, %d^5) FRAME:P2 is same as P1 KAREL program error. The X--axis direction cannot be calculated in the FRAME built-in routine because Cause: Remedy:
P1 and P2 are the same point. Teach P1 and P2 as different points.
INTP--362 PAUSE.L (%s^4, %d^5) FRAME:P3 is same as P1 KAREL program error. The X--Y plane cannot be calculated in the FRAME built-in routine because P1 Cause: Remedy:
and P3 are the same point. Teach P1 and P3 as different points.
INTP--363 PAUSE.L (%s^4, %d^5) FRAME:P3 exists on line P2--P1 KAREL program error. The X--Y plane cannot be calculated in the FRAME built-in routine because P3 Cause: Remedy:
is located in the X--axis direction. Teach P3 out of the X--axis direction.
INTP--364 ABORT.L (%s^4, %d^5) String too short for data KAREL program error. The target string is too short. Cause: Remedy: Increase the target string size. INTP--365 ABORT.L (%s^4, %d^5) Predefined window not opened KAREL program error. A FILE pre-defined by the system is not opened. Cause: Remedy: Check the use of this file. INTP--366 ABORT.L (%s^4, %d^5) I/O status is not cleared KAREL program error. The last file operation failed. Cause: Remedy: Reset the error using the CLR_IO_STAT built-in routine. INTP--367 ABORT.L (%s^4, %d^5) Bad base in format KAREL program error. I/O mode operates only from binary to hexdecimal. Cause: Remedy: Check the specified mode. INTP--368 PAUSE.L (%s^4, %d^5) Cannot use specified program KAREL program error. The specified program cannot be used. Cause: Remedy: Refer to the error cause code. INTP--369 ABORT.L (%s^4, %d^5) Timeout at WAIT_AMR KAREL program error. The WAIT_AMR built-in routine timed out. Cause: Remedy: If an AMR was expected within the time--out value check logic in the task that should have posted the AMR
INTP--370 ABORT.L (%s^4, %d^5) Vision CPU not plugged in KAREL program error. The vision CPU board is not plugged in. Cause: Remedy: Plug in the vision CPU board. INTP--371 ABORT.L (%s^4, %d^5) Vision built--in overflow KAREL program error. The operation overflowed in the vision built-in routine. Cause: Remedy: Modify your program so that fewer vision built-ins are executing at the same time. INTP--372 ABORT.L (%s^4, %d^5) Undefined vision built--in KAREL program error. The vision built-in routine is not defined. Cause: Remedy: Check the appropriate option is loaded. INTP--373 ABORT.L (%s^4, %d^5) Undefined vision parameter type KAREL program error. The parameter to the vision built-in routine is invalid. Cause: Remedy: Check the parameter of the vision built-in routine. 874
ALARM CODES
B--81464EN--3/01
INTP--374 ABORT.L (%s^4, %d^5) Undefined vision return type KAREL program error. The return value from the vision built-in routine is invalid. Cause: Remedy: Check the return value from the vision built-in routine. INTP--375 (%s^4, %d^5) System var passed using BYNAME This alarm is related to the KAREL program. With the BYNAME function, no system variable can be used. Cause: Use Pass without BYNAME, GET_VAR, or SET_VAR.
INTP--376 ABORT.L (%s^4, %d^5) Motion in interrupt is failed There is no CANCEL or STOP instruction. Cause: Remedy: insert a CANCEL or STOP instruction before call a interrupt routine. INTP--377 WARN (%s^4, %d^5) Local COND recovery failed This local condition cannot be recovered. Cause: Remedy: Refer to the error cause code. INTP--378 WARN (%s^4, %d^5) Local variable is used Local variable or parameter is used for the condition. Cause: Remedy: Use global variable to recover local condition. INTP--379 ABORT.L Bad condition handler number An invalid condition handler number was used in either a condition handler definition, or with an Cause: Remedy:
ENABLE, DISABLE, or PURGE statement or action. Correct the condition handler number. Condition handler numbers must be in the range of 1--1000.
INTP--380 ABORT.L Bad program number An invalid program number has been specified. Cause: Remedy: Use a valid program number. Program numbers must be in the range of 1 -- $SCR,$MAXNUMTASK + 2.
INTP--381 (%s^4, %d^5) Invalid Delay Time An invalid delay time has been specified in DELAY statement. Cause: Remedy: Use a valid delay time. Delay time must be in the range 0..86400000 . INTP--382 (%s^4, %d^5) Invalid bit field value An invalid value has been specified in bit field Cause: Remedy: Use a valid value for the bit field. INTP--383 (%s^4, %d^5) Path node out of range The specified path node is out of range. Cause: Remedy: Check the path node. INTP--400 ABORT.L (%s^4, %d^5) Number of motions exceeded Too many motions are executed at the same time. Cause: Remedy: Decrease the number of motions executed at the same time. Execute the next motion after the completion of the last motion.
INTP--401 ABORT.L (%s^4, %d^5) Not On Top Of Stack Paused motion exists after the motion was resumed. Cause: Remedy: Resume the motion that was previously paused. INTP--420 (%s^4, %d^5) OFIX is not available The attitude fix instruction cannot be used. Cause: Remedy: Check the motion format and the motion addition instruction. INTP--421 (%s^4, %d^5) Stitch disable(S/S) The single step mode is set. Cause: Remedy: Cancel the single step mode. 875
ALARM CODES
B--81464EN--3/01
INTP--422 (%s^4, %d^5) Stitch enable signal off The stitch enable signal is set to OFF. Cause: Remedy: Set the stitch enable signal to ON. INTP--423 (%s^4, %d^5) Eq.condition signal error The equipment condition signal is incorrect. Cause: Remedy: Check the equipment condition signal. INTP--424 (%s^4, %d^5) Stitch speed error The stitch speed value is incorrect. Cause: Remedy: Check the stitch speed value. INTP--425 (%s^4, %d^5) Illegal motion type(J) The stitch function cannot be used with joint motion. Cause: Remedy: Make a change to linear motion. INTP--426 (%s^4, %d^5) Another prog is in stitching Another program is using the stitch function. Cause: Remedy: Terminate the program that is using the stitch function. INTP--450 (%s^4, %d^5) Cannot call KAREL program From the master/slave/single slave program of the robot link, the KAREL program was called. Cause: Remedy: Do not call the KAREL program from the master/slave/single slave program. INTP--451 (%s^4, %d^5) Cannot call Motion program From the master/slave/single slave program of the robot link, a normal program with a motion group was Cause: Remedy:
called. Do not call a normal program with a motion group from the master/slave/single slave program.
INTP--452 (%s^4, %d^5) Robot link type mismatch From the master/slave/single slave program of the robot link, a program of a different type was called. Cause: Remedy: Do not call a program of a different type from the master/slave/single slave program. INTP--453 (%s^4, %d^5) Not in remote The slave program of the robot link can be executed only in the remote mode. Cause: Remedy: Ensure that the remote condition is satisfied. INTP--454 (%s^4, %d^5) Illegal return occurred In the robot link, the type of a calling program differs from the type of a called program. Cause: Remedy: Match the type of a calling program with the type of a called program. INTP--455 (%s^4, %d^5) Group mismatch(Link pattern) The master program motion group of the robot link does not match the master robot motion group Cause: Remedy:
specified with the link pattern. Match the master program motion group with the master robot motion group specified with the link pattern.
INTP--456 (%s^4, %d^5) Group mismatch(Slave group) The slave program motion group of the robot link does not match the slave robot motion group specified Cause: Remedy:
with the slave group. Match the slave program motion group with the slave robot motion group specified with the slave group.
INTP--457 (%s^4, %d^5) Master tool number mismatch The tool coordinate system number currently selected by the master robot does not match the robot link Cause: Remedy:
data master tool coordinate system number of the slave program. Match the tool coordinate system number currently selected by the master robot with the robot link data master tool coordinate system number of the slave program.
876
ALARM CODES
B--81464EN--3/01
INTP--458 (%s^4, %d^5) Robot is still moving The robots are moving with the robot link, so that the master/slave/single slave cannot establish Cause: Remedy:
synchronization. After the robot stops, restart the program.
INTP--459 (%s^4, %d^5) Slave cannot JOINT motion The motion statement in the slave program of the robot link specifies a joint motion. Cause: Remedy: Change the motion statement of the slave program to orthogonal motion. INTP--460 (%s^4, %d^5) Cannot use JOINT pos for Slave The position data format of the slave program of the robot link is the joint format. Cause: Remedy: Change the position data format of the slave program to the orthogonal format. INTP--461 (%s^4, %d^5) Master TP is enabled The master program of the robot link was activated from the teach pendant. The slave program stops Cause: Remedy:
temporarily. The master program was activated from the teach pendant, so that the slave program stops temporarily.
INTP--462 (%s^4, %d^5) Cannot start Robot Link The setting of the robot link may be incorrect. Cause: Remedy: Check the setting. INTP--463 (%s^4, %d^5) Motion group is Master The motion group of a program whose execution was attempted with the robot link is master. Cause: Remedy: Cancel the setting of master, then restart the program. INTP--465 (%s^4, %d^5) Tracking error The robot link could not perform synchronous motion. Cause: Remedy: Check the setting of the robot link. INTP--466 (%s^4, %d^5) Robot link not calibrated The robot link is not calibrated. Cause: Remedy: Calibrate the robot link. INTP--467 (%s^4, %d^5) Cannot use INC for Slave In a motion statement of the slave program of the robot link, an incremental instruction is taught. Cause: Remedy: The incremental instruction cannot be used in a motion statement of the slave program. INTP--468 (%s^4, %d^5) Cannot use OFFSET for Slave In a motion statement of the slave program of the robot link, a compensation instruction is taught. Cause: Remedy: The compensation instruction cannot be used in a motion statement of the slave program. INTP--469 (%s^4, %d^5) BWD is failed for Master An attempt for BWD synchronization of the mater of the robot link failed. Cause: Remedy: Place the slave in the synchronization wait state. INTP--470 (%s^4, %d^5) Not support BWD for Slav BWD synchronization is not supported for the slave program of the robot link. Cause: Remedy: BWD synchronization is supported for the slave program. INTP--471 (%s^4, %d^5) Robot is Master(Manual) In the robot link, the robot is placed in the master (manual) state. Cause: Remedy: In the master (manual) state, external activation is disabled. For external activation, set the master (single) state on the manual operation screen.
INTP--472 (%s^4, %d^5) Robot is Slave(Manual) In the robot link, the robot is placed in the slave (manual) state. Cause: Remedy: In the slave (manual) state, other slaves cannot be executed. Hold the program, and cancel the slave (manual) state.
877
ALARM CODES
B--81464EN--3/01
INTP--474 (%s^4, %d^5) Synchro ID mismatch In the robot link, a program with a synchronous motion ID different from the synchronous motion ID of Cause: Remedy:
the currently executed program was executed. Programs with different synchronous motion IDs cannot be executed at the same time.
INTP--475 (%s^4, %d^5) Cannot single step The slave program of the robot link cannot be executed in the single step mode. Cause: Remedy: Cancel the single step mode. INTP--476 (%s^4, %d^5) BWD is failed In the robot link, BWD failed. Cause: Remedy: BWD failed. INTP--477 (%s^4, %d^5) Cannot run Slave directly The slave program of the robot link cannot be activated directly. Cause: Remedy: Execute the slave by calling from the normal program. INTP--478 This group can not be MASTER This alarm is issued when an attempt is made to specify as a mater a robot not set as a master in the Cause: Remedy:
robot link or when an attempt is made to specify as a master a group not set as a master on the manual operation screen. Specify another group as a master, or modify the setting.
INTP--479 Bad Hostname or Address(MASTER An attempt was made to execute the robot link when a host name not registered is specified or the Cause: Remedy:
setting of an IP address is incorrect on the host communication screen or the master setting screen. Check the master in the robot link setting and host communication setting.
INTP--480 Bad Hostname or Address(SLAVE) An attempt was made to execute the robot link when a host name not registered is specified or the Cause: Remedy:
setting of an IP address is incorrect in the host communication setting or link pattern setting. Check the slave in the robot link setting and host communication setting.
INTP--481 Bad Synchronization ID In the robot link, a program--specified synchronous motion ID is incorrect. Cause: Remedy: Correct the synchronous motion ID on the list screen. INTP--482 Bad Link Pattern Number In the robot link, a program--specified link pattern number is incorrect. Cause: Remedy: Correct the link pattern number on the list screen. INTP--483 Bad Master Number In the robot link, a program--specified master number is incorrect. Cause: Remedy: Correct the master number on the list screen. INTP--484 Bad Group number (MASTER) The group number of the master of the robot link is incorrect. Cause: Remedy: Check the group number of the master. INTP--485 Bad Group number (SLAVE) The group number of the slave of the robot link is incorrect. Cause: Remedy: Check the group number of the slave. INTP--486 SLAVE is not calibrated In the robot link, there is a slave not calibrated. Cause: Remedy: Calibrate the slave robot. 878
ALARM CODES
B--81464EN--3/01
INTP--488 RLINK communication timeout In the robot link, communication initialization timed out. Cause: Remedy: Increase the value of $RK_SYSCFG.$RMGR_PHTOUT by 100. INTP--489 Bad Hostname or Address, Group An attempt was made to execute the robot link when the setting of a host name, IP address, or motion Cause: Remedy:
group is incorrect in the host communication setting or robot link setting. Check the robot link setting and host communication setting.
INTP--490 Timeout for link start An attempt was made to execute the robot link when the setting of a host name, IP address, or motion Cause: Remedy:
group is incorrect in the host communication setting or robot link setting or when the robot link program is not executed at the communication destination. So, a synchronization start timeout occurred. Check the robot link setting and host communication setting, and also check the state of the robot at the communication destination.
INTP--491 Linked robot or comm stopped During robot link execution, the robot at the communication destination stopped program execution, or Cause: Remedy:
stopped communication for a cause such as a power failure. Check the state of the robot at the communication destination.
INTP--493 Slave program stopped During slave program execution, the master program at the communication destination stopped. Cause: Remedy: Check the state of the robot at the communication destination. INTP--493 Slave program stopped During robot link execution as the master, the slave program at the communication destination stopped. Cause: Remedy: Check the state of the robot at the communication destination.
JOG Error Codes
( ID = 19 )
JOG--001 WARN Overtravel Violation A robot overtravel has occurred. Cause: Remedy: While holding down the shift key, press the alarm clear button to clear the alarm. Then, while holding down the shift key, perform jog feed to move the overtravel axis into the movable range.
JOG--002 WARN Robot not Calibrated Robot has not been calibrated. Cause: Remedy: Apply one the following methods for positioning: 1 Make positioning settings on the positioning screen. 2 Turn the power off and then on again.
JOG--003 WARN No Motion Control Other program has motion control Cause: Remedy: Abort the program that has motion control by pressing FCTN key then selecting ABORT. JOG--004 WARN Illegal linear jogging You cannot do more than one rotational jog at a time. Cause: Remedy: Only press one rotational jog key at a time. JOG--005 WARN Can not clear hold flag The hold key or hold button is held down. Or, *HOLD input is off. Cause: Remedy: Release the hold key or hold button. Or, turn on *HOLD input. JOG--006 WARN Subgroup does not exist No extended axis exist in this group with which to jog. Cause: Remedy: No action is required. 879
ALARM CODES
B--81464EN--3/01
JOG--007 WARN Press SHIFT key to jog The SHIFT key is not pressed. Cause: Remedy: You must press the SHIFT key when jogging the robot. Release the JOG key then hold the SHIFT key and press the JOG key to jog.
JOG--008 WARN Turn on TP to jog Teach pendant is not enabled. Cause: Remedy: Hold the DEADMAN and turn on the teach pendant before jogging the robot. JOG--009 WARN Hold deadman to jog The DEADMAN switch is not pressed. Cause: Remedy: Press the DEADMAN switch, then press RESET key to clear the error. JOG--010 WARN Jog pressed before SHIFT The JOG key was pressed before the SHIFT key was pressed. Cause: Remedy: Release the JOG key. Then hold down the SHIFT key and press the JOG key. JOG--011 WARN Utool changed while jogging The selected tool frame changed while jogging. Cause: Remedy: Release the SHIFT key and the JOG key. The new TOOL frame will take effect automatically. JOG--012 WARN manual brake enabled The manual brake enabled. Cause: Remedy: Engage all the brakes by pressing EMERGENCY STOP button, then press the RESET key. JOG--013 WARN Stroke limit (Group:%d Axis:%x Hex) Robot axis reaches its specified stroke limit. Cause: Remedy: The robot already reach the stroke limit and cannot jog in the current direction any more. Extend the axis limit if it does not exceed the robot and software specifications.
JOG--014 WARN Vertical fixture position Robot reaches its vertical fixture position on the LR-MATE system. Cause: Remedy: To continue jogging, release the JOG key then press it again. JOG--015 WARN Horizontal fixture position Robot reaches its horizontal fixture position on the LR-MATE system. Cause: Remedy: To continue jogging, release the JOG key then press it again. JOG--016 SERVO Softfloat time out(Group:%d) Follow-up time is over when softfloat is ON. Cause: Remedy: Make the system variable $SFLT_FUPTIM larger. JOG--017 At R--Theta robot posture In remote TCP jogging, the robot assumed the R--Theta attitude. Cause: Remedy: To continue jogging, release the jog key, then press the jog key again. JOG--020 Can not PATH JOG now PATH JOG has selected, but robot is not currently on a taught path, or tool Z direction is same teaching Cause: Remedy:
path, so Y direction can not be determined. Can not PATH JOG Use shift--FWD to execute program path, or specify another jog frame.
JOG--021 Multi key is pressed Use of multiple jog keys is not supported in PATH JOG Cause: Remedy: Use only one jog key at a time. 880
ALARM CODES
B--81464EN--3/01
JOG--022 Disabled in JOINT path PATH jog is disabled in JOINT path Cause: Remedy: PATH jog is available in LINEAR and CERCULAR path JOG--023 Available only in PAUSE PATH jog is available only in PAUSE status Cause: Remedy: PATH jog is available only in PAUSE status JOG--024 Currently this key is invalid This key is currently disabled. Cause: Remedy: Change the jog coordinate system. JOG--025 J4 is not zero J4 is not at the 0_ position. Cause: Remedy: To use attitude--fixed jogging, J4 needs to be at the 0_ position. JOG--026 J4 is zero J4 is now at the 0_ position. Cause: Remedy: Attitude--fixed jogging is enabled. JOG--027 Reverse direction from J4=0 The direction of jogging is opposite to the 0_ direction of J4. Cause: Remedy: Press the jog key for the opposite direction. JOG--028 Attitude fix mode limit (TCP) A linear motion range limit was reached. Cause: Remedy: Change the target position, or switch to joint motion. A stroke limit in the TCP mode was reached. JOG--029 OFIX jog error Internal error Cause: Remedy: Contact your FANUC customer service representative, and inform the representative of an alarm message displayed.
JOG--030 Can’t jog as OFIX Attitude--fixed jogging is disabled. An additional alarm is issued. Cause: Remedy: Check the additional alarm on the alarm history screen.
TPIF Error Codes
( ID = 9 )
TPIF--001 to 003 WARN Mnemonic editor error (%s^1) Illegal case occurred on software. Cause: Remedy: Contact our service center serving your locality. TPIF--004 WARN Memory write error The instruction cannot be used because the corresponding software option is not provided. Cause: Remedy: Install the software option. TPIF--005 WARN Program is not selected The program was not selected when the program was displayed at the edit screen. Cause: Remedy: Select a program in the SELECT screen. TPIF--006 WARN SELECT is not taught This taught statement needed the SELECT statement before the current line. Cause: Remedy: Teach the SELECT statement before the current line. 881
ALARM CODES
B--81464EN--3/01
TPIF--007 WARN Robot is not calibrated The calibration was not finished yet Cause: Remedy: Finish the calibration. TPIF--008 WARN Memory protect violation Program’s write protection is set on. Cause: Remedy: Release protection on select screen. TPIF--009 WARN Cancel delete by application The program cannot be deleted because program deletion is disabled by the application tool software. Cause: Remedy: Enable program deletion on the application setting screen. TPIF--010 WARN Cancel enter by application The program cannot be edited because program editing is disabled by the application tool software. Cause: Remedy: Enable program editing on the application setting screen. TPIF--011 WARN Item is not found Item is not found below this line Cause: Remedy: Try another item or close search function TPIF--012 WARN Kinematics solution is invalid Can not translate position data Cause: Remedy: Check the configuration of robot and $MNUTOOL/$MNUFRAM of system variables TPIF--013 WARN Other program is running Can not select the program when other is running or pausing. Cause: Remedy: Select program after aborting the program which is running or pausing. TPIF--014 WARN Teach pendant is disabled Can not be edit a program when the Teach pendant is disabled. Cause: Remedy: Edit program after Teach pendant is enabled. TPIF--015 WARN Bad position register index The specified position register index is invalid. Cause: Remedy: Check the index of the position register. TPIF--016 to 017 WARN Memory access failed (%s^1) Illegal case occurred on software. Cause: Remedy: 1 Select a program again. 2 Contact your FANUC Service Center.
TPIF--018 WARN Unspecified index value Specified index value is invalid. Cause: Remedy: Check specified index value. TPIF--019 WARN This item cannot be replaced This item can not be replaced. Cause: Remedy: Try another item or close replace function. TPIF--020 NONE Mnaction search error Illegal case occurred on software. Cause: Remedy: Contact our service center serving your locality. TPIF--023 WARN WJNT and RTCP are not compatible Wjnt and RTCP are not compatible Cause: Remedy: Remove Wjnt or RTCP before add the other 882
ALARM CODES
B--81464EN--3/01
TPIF--030 WARN Program name is NULL Program name was not entered. Cause: Remedy: Enter program name. TPIF--031 WARN Remove num from top of Program name Top of program name is number. Cause: Remedy: Remove number from top of program name. TPIF--032 WARN Remove space from Program name A space is included in the program name. Cause: Remedy: Remove space from program name. TPIF--033 WARN Remove comma from Program name A comma is included in the program name. Cause: Remedy: Remove comma from program name. TPIF--034 WARN Remove dot from Program name A dot is included in the program name. Cause: Remedy: Remove dot from program name. TPIF--035 WARN Remove minus from Program name A minus is included in the program name. Cause: Remedy: Remove minus from program name. TPIF--036 WARN Memory is not enough Not enough memory available. Cause: Remedy: Delete unused programs. TPIF--037 WARN Program must be selected by TP Only the Teach Pendant default program can be edited on the CRT Cause: Remedy: Please select the program on the Teach Pendant before editing on the CRT TPIF--038 WARN Invalid char in program name Invalid character in program name Cause: Remedy: Please remove invalid character from program name TPIF--040 WARN Label is already exist Same label No. already exists. Cause: Remedy: Change to different label No. TPIF--041 WARN MNUTOOLNUM number is invalid Specified MNUTOOLNUM number is invalid. Cause: Remedy: Check MNUTOOLNUM number in SYSTEM variables. TPIF--042 WARN MNUFRAMENUM number is invalid Specified MNUFRAMNUM number is invalid. Cause: Remedy: Check MNUFRAMNUM number in SYSTEM variables. TPIF--043 WARN External change is valid Can not change robot (group), because the function that select robot by external DI is valid. Cause: Remedy: Set $MULTI_ROBO.CHANGE_SDI in SYSTEM variables to ZERO. TPIF--044 WARN Program is unsuitable for robot The group mask of program differs from selected robot (group). Cause: Remedy: Check to select robot (group) or check group mask of program attribute. 883
ALARM CODES
B--81464EN--3/01
TPIF--045 WARN Pallet number is over max Palletizing instruction can not teach more than 16 in one program. Cause: Remedy: Teach another program. TPIF--046 WARN Motion option is over max Too many motion options for default motion Cause: Remedy: Please decrease motion options for default motion TPIF--047 WARN Invalid program is selected Program type is wrong. Cause: Remedy: Select TPE program. TPIF--048 WARN Running program is not found Running program does not exist. Cause: TPIF--049 WARN Port number is invalid Port is not set for outside device. Cause: Remedy: Set port for outside device. TPIF--050 WARN Macro does not exist A program is not assigned to this macro command. Cause: Remedy: Assign a program to this macro command. TPIF--051 WARN Program has been selected by PNS When a program has been selected by PNS, you can not select program at SELECT screen. Cause: Remedy: Turn off the signal of PNSTROBE. TPIF--052 WARN FWD/BWD is disabled When the Disabled FWD function has been selected, you can not execute the program by TP Cause: Remedy: Please select the Disabled FWD in the function menu, then you can release from the Disable FWD TPIF--053 WARN Not editing background program The program has not been selected by the BACKGROUND editing Cause: Remedy: Please select the BACKGROUND program in the SELECT screen TPIF--054 WARN Could not end editing Memory is not enough or background program is invalid Cause: Remedy: Please delete useless program or confirm the background program TPIF--055 WARN Could not recovery original program Failed recovering original program which has been selected by the BACKGROUND Cause: Remedy: Please end editing by the END_EDIT of [EDCMD] again before executing the origianl program which has been selected by the BACKGROUND
TPIF--056 WARN This program is used by the CRT The program of BACKGROUND can not be selected by the CRT and TP at the same time Cause: Remedy: Please end editing by the END_EDIT of [EDCMD] at the CRT TPIF--057 WARN This program is used by the TP The program of BACKGROUND can not be selected by the CRT and TP at the same time Cause: Remedy: Please end editing by the END_EDIT of [EDCMD] at the TP TPIF--060 WARN Can’t record on cartesian (Group:%d) This current position is in singularity Cause: Remedy: You can record this position on joint type only. Please select the function key 884
ALARM CODES
B--81464EN--3/01
TPIF--061 WARN Group[%s] has not recorded This position data has not been changed to displayed groups because you selected the function key Cause: Remedy:
which did not record the position, when checking in singularity Please check this recorded position again before excution
TPIF--062 AND operator was replaced to OR All AND operators on this line were replaced with OR operators. Cause: Remedy: You cannot mix AND and OR operator on a the same line. Verify that all logical operators on this line are the same before execution.
TPIF--063 OR operator was replaced to AND All OR operator on this line were replaced by AND operators. Cause: Remedy:
You cannot mix AND OR operaotr on a the same line Verify all logical operators on this line before execution
TPIF--064 Too many AND/OR operator(Max.4) Too many AND/OR operators (Max.4 on a single line) Cause: Remedy: Teach the logical operation on another line TPIF--065 Arithmetic operator was unified to +-- or */ Arithmetic operator on this line was changed to +-- or */. Cause: Remedy:
Cannot mix arithmatic + and -- operators with * and /operators on the same line. Verify all arithmetic operators on this line before execution
TPIF--066 Too many arithmetic operator(Max.5) Too many arithmetic operators (Max.5 on a single line) Cause: Remedy: Teach the arithmetic operation on another line TPIF--067 Too many arguments (Max.10) Too many arguments (Max.10 for a program or a macro) Cause: Remedy: Check arguments of the program/macro TPIF--070 Cannot teach the instruction Cannot teach the instruction. Cause: Remedy: Check the sub type of the program. TPIF--071 Cannot change sub type Cannot change sub type Cause: Remedy: Check sub type of the program TPIF--072 Cannot change motion group Cannot change motion group Cause: Remedy: Check sub type of the program TPIF--090 WARN This program has motion group The program specified in $PWR_HOT, $PWR_SEMI and $PWR_NORMAL must not have motion Cause: Remedy:
group. Set * to all motion group in program detail screen on TP.
TPIF--091 WARN PREG access error An error occurred when accessing a position register. Cause: Remedy: Refer to the error cause code. TPIF--092 Value %d expected %s The value_array that was passed to a KAREL built--in was incorrectly specified. Cause: Remedy: Make sure the value_array specifies the correct names for the variables and that the types expected are correct.
885
ALARM CODES
B--81464EN--3/01
TPIF--093 USER menu must be selected Software internal error. Cause: Remedy: Consult our service representative. TPIF--094 USER2 menu must be selected Software internal error. Cause: Remedy: Consult our service representative. TPIF--095 WARN Execution history table error Software internal error Cause: Remedy: Please do controlled start( it isn’t necessary to re--set the new item) TPIF--097 WARN Running task’s history can’t display The execution history of the executing program can not be displayed Cause: Remedy: Please refer this screen when the program is paused or aborted TPIF--098 WARN %s was not run The program of $PWR_HOT, $PWR_SEMI or $PWR_NORMAL is not executed Cause: Remedy: Read the cause code TPIF--099 WARN This program is edited The program specified in $PWR_HOT, $PWR_SEMI and $PWR_NORMAL is not executed, when the Cause: Remedy:
program is in editing. Select the other program
TPIF--100 WARN No vacant table space Illegal case occured on software. Cause: Remedy: Contact our service center serving your locality. TPIF--101 WARN No such menu Illegal case occured on software. Cause: Remedy: Contact our service center serving your locality. TPIF--102 WARN E.STOP is asserted FWD execution is selected while, E.STOP is asserted. Cause: Remedy: Turn the E.STOP off. Then select FWD execution TPIF--103 WARN Dead man is released When starting the program with the teach pendant, the deadman switch was released. Cause: Remedy: Press and hold the deadman switch and start a program. TPIF--104 WARN Teach Pendant is disabled A program was not started because the teach pendant was disabled. Cause: Remedy: After turning on the enable switch of the teach pendant, start a program. TPIF--105 WARN Program is not selected A program was started without selecting a program. Cause: Remedy: After selecting a program, start the program. TPIF--106 WARN Program is already running While a program was running, starting from teach pendant was performed. Cause: Remedy: Start a program after waiting for program’s ending or aborting it. TPIF--107 WARN FWD/BWD is disabled 1 Starting a program was performed when the starting was prohibited such as entering the value into Cause: Remedy:
the message line. 2 A program was not selected. 1 After finishing the procedure of entering the value, start a program. 2 Select a program and then start a program.
886
ALARM CODES
B--81464EN--3/01
TPIF--108 WARN Form error, line %d, item %d The Form Manager detected an error on the specified line with the specified item. Cause: Remedy: Refer to the cause code for the actual error. TPIF--109 WARN %v not specified correctly An internal software error occurred. Cause: Remedy: Contact your FANUC Service Center. TPIF--110 WARN Screen used by other device An internal software error occurred. Cause: Remedy: Contact your FANUC Service Center. TPIF--111 op_global does not exist Internal system error. Cause: Remedy: Consult our service representative. TPIF--112 op_sel does not exist Internal system error. Cause: Remedy: Consult our service representative. TPIF--113 Illegal param in op menu Internal system error. Cause: Remedy: Consult our service representative. TPIF--114 Illegal data in op menu Internal system error. Cause: Remedy: Consult our service representative. TPIF--115 Data is full Internal system error. Cause: Remedy: Consult our service representative. TPIF--116 System variable error: %s System variable name is invalid Cause: Remedy: Check the spelling and format of the name. TPIF--117 Cannot backup to device: %s The default device is not valid for backup Cause: Remedy: Select a valid device and try again TPIF--118 File error for %s File error Cause: Remedy: Perform a cold start: 1 Turn off the robot. 2 On the teach pendant, press and hold the SHIFT and RESET keys. 3 While still pressing the SHIFT and RESET keys, turn on the robot. If the error is not cleared, document the events that
TPIF--119 File compression failed Failed creating compressed file Cause: Remedy: Check backup device TPIF--120 Device failure Device failure Cause: Remedy: Check device and try again 887
ALARM CODES
B--81464EN--3/01
TPIF--121 Invalid copy. Use MOVE key. Cannot COPY a file on a Memory device to the same Memory device. Cause: Remedy: Use the MOVE key and try again TPIF--122 Specified softpart ID is illegal Internal system error. Cause: Remedy: Consult our service representative. TPIF--123 No active applications Internal system error. Cause: Remedy: Consult our service representative. TPIF--124 Current application is nothing Internal system error. Cause: Remedy: Consult our service representative. TPIF--125 Specified softpart ID is nothing Internal system error. Cause: Remedy: Consult our service representative. TPIF--126 THKY ASLOAD is failed Internal system error. Cause: Remedy: Consult our service representative. TPIF--127 TOPK ASLOAD is failed Internal system error. Cause: Remedy: Consult our service representative. TPIF--128 Verify logic of pasted line(s) The reverse motion copy function does not support the following motion option instruction. Cause:
Remedy:
1 Application command 2 Skip, Quick Skip 3 Incremental 4 Continuous turn 5 Ahead execution command Check the above motion option instruction. And modify the copied statement correctly.
TPIF--129 Group motion inst. is pasted The group motion instruction is copied. The reverse motion copy function does not supported group Cause: Remedy:
motion instruction. Check the group motion instruction. And modify the copied statement correctly.
TPIF--130 Specified application has no EQ Internal system error. Cause: Remedy: Consult our service representative. TPIF--131 Please set application mask data This program has no application mask Cause: Remedy: Please set the application mask in the program detail screen TPIF--132 Can’t recover this operation Because the data for UNDO can not be saved, this operation can not recover by UNDO function Cause: Remedy: Check the cause code. If the memory is full, please delete program or disable UNDO function. TPIF--133 Can’t recover this command Palletizing command and Compliance control command can not be recovered by UNDO function Cause: 888
ALARM CODES
B--81464EN--3/01
MOTN Error Codes
( ID = 15)
MOTN--001 to 008 STOP.G Internal error in osmkpkt Internal system error. Cause: Remedy: Cycle start controller MOTN--009 STOP.G Internal error for single step The tool stopped at the midpoint of an arc in single step mode. Cause: Remedy: Ignore this alarm. MOTN--010 to 011 STOP.G Internal error in osathpkt Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--012 STOP.G Invalid softpart MIR Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--013 STOP.G Invalid softpart SEG Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--017 STOP.G Limit error (Group:%d^2, Axis:%x^3 Hex) The specified position falls outside the joint movable range ($PARAM_GROUP.$LOWERLIMS, Cause:
Remedy:
$PARAM_GROUP.$UPPERLIMS). Axis j is defined in hexadecimal, as shown below. Axis 1: 1, Axis 2: 2, Axis 3: 4, Axis 4: 8, Axis 5: 10, Axis 6: 20, Axis 7: 40, Axis 8: 80, Axis 9: 100 If two or more axes have caused this alarm, the total of their values, shown above, is indicated in hexadecimal. Example Axis 1 + Axis 3 + Axis 4 + Axis 6 + Axis 9 = 12D 1 4 8 20 100 1 Correct the position so that it falls within the movable range. 2 Change the movable range settings on the joint movable range screen, which is displayed by selecting 6 SYSTEM AXIS LIMITS.
MOTN--018 STOP.G Position not reachable The position is not reachable or is near a singularity point. Cause: Remedy: Reteach the position that is not reachable. MOTN--019 WARN In singularity The position is near a singularity point. Cause: Remedy: Reteach the position that is near a singularity point. MOTN--020 WARN Wristjoint warning Wrist joint warning Cause: Cause: Wrist joint warning MOTN--021 STOP.G No kinematics error No kinematics. Cause: Remedy: Use joint motion. MOTN--022 STOP.G Invalid limit number Invalid limit number. Cause: Remedy: Set limit number correctly. MOTN--023 STOP.G In singularity The position is near a singularity point. Cause: Remedy: Reteach the position that is near a singularity point. 889
ALARM CODES
B--81464EN--3/01
MOTN--024 STOP.G Kinematics not defined Kinematics is not defined. Cause: Remedy: Define Kinematics. MOTN--030 to 046 STOP.G Internal error in MMGR:PEND Internal system error. Cause: Remedy: Contact our service center serving your lacality. MOTN--047 Internal error in MMGR:PRST Internal error Cause: Remedy: Contact your FANUC customer service representative, and inform the representative of an alarm message displayed.
MOTN--049 STOP.G Attempt to move w/o calibrated Robot not calibrated. Cause: Remedy: Calibrate the robot. MOTN--050 STOP.G Invalid spdlim (Group:%d^2 Axis:%x^3 H) An internal software error occurred. The joint speed factor ($PARAM_GROUP.$SPEEDLIMJNT) is Cause:
Remedy:
invalid. Axis j is defined in hexadecimal, as shown below. Axis 1: 1, Axis 2: 2, Axis 3: 4, Axis 4: 8, Axis 5: 10, Axis 6: 20, Axis 7: 40, Axis 8: 80, Axis 9: 100 If two or more axes have caused this alarm, the total of their values, shown above, is indicated in hexadecimal. Example Axis 1 + Axis 3 + Axis 4 + Axis 6 + Axis 9 = 12D 1 4 8 20 100 Correct the joint speed factor.
MOTN--051 to 53 STOP.G Speed out of range (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--054 STOP.G Uninitialized dest pos (Group:%d^2) Uninitialized destination position. Cause: Remedy: Teach destination position. MOTN--055 STOP.G Uninitialized via pos (Group:%d^2) Uninitialized via position. Cause: Remedy: Teach via position. MOTN--056 WARN Speed limits used (Group:%d^2) Speed limits used. Cause: Remedy: This is just a notification. You do not have to do anything for this warning message. MOTN--057 to 062 STOP.G Invalid mir (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--063 STOP.G Position config change (Group:%d^2) For path--controlled operation (linear or circular operation), different position data formats are set for the Cause: Remedy:
start point and end point. 1 Set the same position data format for the start point and end point. 2 Specify joint operation mode. 3 Specify a wrist joint operation instruction (operation addition instruction).
MOTN--064 and 065 STOP.G Rs orientation error (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. 890
ALARM CODES
B--81464EN--3/01
MOTN--066 STOP.G Degenerate circle (Group:%d^2) For circular operation, the position data for the start point, passing point, and end point is invalid. Cause: Remedy:
a. Two of the start, passing, and end points overlap one another. b. All of the start, passing, and end points are arranged in a straight line. Specify appropriate start, passing, and end points for circular operation.
MOTN--067 to 072 STOP.G Ata2 error in circle (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--073 STOP.G Error in orientype (Group:%d^2) Internal error: planner received invalid orientype. Cause: Remedy: Contact our service center serving your locality. MOTN--074 to 079 STOP.G Error in speed (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--080 STOP.G Via position required (Group:%d^2) Missing via position for circular motion. Cause: Remedy: Teach via position. MOTN--081 STOP.G Extended position error (Group:%d^2) No value is set for the additional axis. Cause: Remedy: Set a value for the additional axis. MOTN--082 to 087 STOP.G (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--088 STOP.G Not cartesian move (Group:%d^2) Motype is not cartesian. Cause: Remedy: Must set motype to cartesian. MOTN--089 to 091 STOP.G (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--092 STOP.G Extended not supported (Group:%d^2) Extended axes not supported Cause: Remedy: Do not use extended axes. MOTN--093 and 094 STOP.G Internal (Group:%d^2) Internal plan error Cause: Remedy: Contact our service center serving your locality. MOTN--095 WARN Can’t blend corner line:%d^5 Under acceleration vector control, the specified operation instruction results in an inconstant robot path. Cause: Remedy: 1 Turn off acceleration vector control. 2 Correct the operation instruction so that it can be executed normally.
MOTN--096 STOP.G Cart rate not equal(Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--097 WARN INTR overrun %d^3 (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. 891
ALARM CODES
B--81464EN--3/01
MOTN--098 to 109 STOP.G INTR (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--110 STOP.G Use FINE in last L (Group:%d^2) During the execution of the specified operation instruction, joint operation could not be performed. Cause: Remedy: Correct the operation instruction, according to the desired path--controlled operation. MOTN--111 WARN Can’t switch filter(Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--112 Increment move turn Mismatch Incremental motion causes turn number mismatch Cause: Remedy: Change position to absolute position MOTN--113 WARN Robot not calibrated Robot not calibrated. Cause: Remedy: Calibrate the robot. MOTN--114 WARN Servo is on (Group:%d^2) Servo in still on. Cause: Remedy: Turn off servo. MOTN--115 WARN Invalid brake mask (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--116 WARN Invalid solution (Group:%d^2) Invalid kinematics solution. Cause: Remedy: Reteach position. MOTN--117 WARN Robot not mastered (Group:%d^2) Robot not mastered. Cause: Remedy: Master the robot. MOTN--118 WARN Robot in over travel (Group:%d^2) Robot in overtravel. Cause: Remedy: Reset over travel jog the robot outside of the overtravel position. MOTN--119 WARN Servo is off (Group:%d^2) Robot servo is on. Cause: Remedy: Turn off servo. MOTN--120 to 121 WARN Invalid reference position (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--122 STOP.G Dfilter not empty (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--123 WARN Not enough node (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. 892
ALARM CODES
B--81464EN--3/01
MOTN--124 to 127 STOP.G INTR:Bad Mirpkt req_code(Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--128 STOP.G Group mtn not supported(Group:%d^2) Group motion not supported. Cause: Remedy: Document the events that led to the error and contact our service center serving your locality. MOTN--129 and 130 STOP.G Local cond ptr conflict(Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--131 STOP.G In singularity Position near by a singularity point. Cause: Remedy: a. Move the target point well away from the singular point. b. Use joint coordinates to specify the target point in joint operation mode.
MOTN--132 STOP.G Group circ not supported(Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--133 WARN Time after limit used(Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--134 STOP.G Can not move path backward (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--135 STOP.G Last motype can’t be circular (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--136 STOP.G Illegal filter switch line:%d^5 Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--137 STOP.G No circular softpart (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--138 STOP.G No joint short motion SP (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--139 STOP.G No cart short motion SP (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--140 STOP.G No KAREL motion softpart (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--141 STOP.G No KAREL motion func. ptr (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. 893
ALARM CODES
B--81464EN--3/01
MOTN--142 STOP.G No Group Motion SP (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--143 STOP.G No Motion Resume SP (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--144 STOP.G No joint Turbo Move SP (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--145 STOP.G No cart Turbo Move SP (Group:%d^2) Internal system error. Cause: Remedy: Contact our service center serving your locality. MOTN--146 STOP.G INTR can’t replan major axis(Group:%d^2) Mismatch in major axis turn number. Cause: Remedy: Reteach position. MOTN--147 WARN L-->J replan joint slowdown (Group:%d^2) Linear motions ignore turn numbers. Therefore, when a joint motion follows several linear motions, the Cause: Remedy:
turn number might be mismatched, causing the robot to slow down Change the current motion’s motype to linear or change the previous motion’s motype to joint. If the problem persists, re-teach the path.
MOTN--148 SWARN Can’t move concurrently (Group:%d^2) Two motion groups cannot synchronize with each other due to replanning of one group. This will cause Cause: Remedy:
slow down on both groups. If slow down is not acceptable, re-teach the path.
MOTN--149 STOP.G CF:rotspeedlim exceeded line:%d^5 CF:rotspeedlim exceeded. Cause: Remedy: 1 Set system variable $cf_paramgp[].$cf_framenum to 1 or 2. Turn the power off and then on again. 2 Reduce the speed. 3 Specify positioning as the previous operation.
MOTN--161 (%s^4 L:%d^5) Can’t look ahead With the shortest time control function, program lines cannot be read in advance. Cause: The following situations can be considered: -- The position register is used without locking. -- The if/selection instruction is used. -- Another program is called.
Remedy: -- Use the lock position register instruction. -- Remove the if/selection instruction. -- Integrate the programs into one.
MOTN--171 Overload An overload is imposed. Cause: Remedy: Reduce the load. MOTN--172 Another robot is re--linked The robot at a link destination was relinked, so that operation stopped. Cause: Remedy: Stop all linked robots once, then restart the robots. 894
ALARM CODES
B--81464EN--3/01
MOTN--173 Robot link configuration error The robot link setting is incorrect. Cause: Remedy: Check the host name and IP address in the host communication setting, and also check the robot link setting.
MOTN--174 No motion control This alarm is issued, for example, when an operation for master or slave setting such as manual Cause: Remedy:
operation screen manipulation or program execution is performed while the robot is moving according to a program or jog operation. Perform an operation after the robot stops.
MOTN--175 Failed to be MASTER At the time of switching to the master state by program execution or manual operation, robot motion is Cause: Remedy:
not completed, or the setting is incorrect. Modify the program, or check the robot link setting.
MOTN--176 Failed to be SLAVE At the time of switching to the master state by program execution or manual operation, robot motion is Cause: Remedy:
not completed, or the setting is incorrect. Modify the program, or check the robot link setting.
MOTN--177 Failed to end sync motion If the master and slave have not stopped or the setting is incorrect, synchronous motion cannot be Cause: Remedy:
completed. Check the motion instruction of the program, and the robot link setting.
MOTN--178 Link robot is HELD After start of synchronous motion, it was detected that the robot at the communication destination lost Cause: Remedy:
synchronism for a cause such as program termination. The programs temporarily stop. Restart the programs of the master and slave.
MOTN--179 Robot link internal error Internal error Cause: Remedy: Contact your FANUC customer service representative, and inform the representative of an alarm message displayed.
MOTN--180 Robot link Calib--data not found Calibration data cannot be found. Cause: Remedy: Calibrate the robot link. MOTN--181 Robot link Version mismatch The robot link software differs between the master robot and slave robot. Cause: Remedy: Match the software version of the master robot with that of the slave robot. MOTN--182 Failed to get data from master Communication data is not sent from the master robot. Cause: Remedy: Check the Ethernet cable, cable connection, hub, main board, and robot link setting. MOTN--184 Invalid MNUTOOL data array The value of the system variable $MNUTOOL is invalid. Cause: Remedy: Check the value of the system variable $MNUTOOL. MOTN--185 Protect of ACK BF to be sent The memory in the slave robot for communication from the slave robot to the master robot is protected. Cause: Remedy: No particular action is required. MOTN--186 Protect of BCST BF to be sent The memory in the master robot for communication from the master robot to the slave robot is protected. Cause: Remedy: No particular action is required. 895
ALARM CODES
B--81464EN--3/01
MOTN--187 Protect of ACK BF to be read The memory in the master robot for communication from the slave robot to the master robot is protected. Cause: Remedy: No particular action is required. MOTN--188 Protect of BCST BF to be read The memory in the slave robot for communication from the master robot to the slave robot is protected. Cause: Remedy: No particular action is required. MOTN--189 Slave motion remained In the slave robot, the amount of travel of the previous motion remains before the slave program is Cause: Remedy:
started. Restart after the previous motion is completed.
MOTN--190 Slave cannot use JOINT pos The motion instruction data of the slave robot is in the joint format. Cause: Remedy: Change the data to the orthogonal format. MOTN--191 Slave cannot JOINT motion The slave program cannot make a joint motion. Cause: Remedy: Change the instruction to an orthogonal motion instruction. MOTN--192 UT of MASTER was changed In the master state, the tool coordinate system of the master robot was changed. Cause: Remedy: Do not change the tool coordinate system in the master state. MOTN--193 UT of SLAVE was changed In the slave state, the tool coordinate system of the slave robot was changed. Cause: Remedy: Do no change the tool coordinate system in the slave state. MOTN--194 Machine Lock is ENABLED In the master lock state, synchronous motion is disabled. Cause: Remedy: Cancel the machine lock state. MOTN--195 RLINK internal error %d^5 Internal error Cause: Remedy: Contact your FANUC customer service representative, and inform the representative of an alarm message displayed.
MOTN--198 CRC Start--Via too close(L:%d^5) The start point and center point of an arc are too close to each other. Cause: Remedy: Reteach the robot. The taught points of an arc must be on the same plane. Otherwise, a minor modification to the teaching can cause a major change in motion.
MOTN--199 CRC Via--Dest too close(L:%d^5) The intermediate point and end point of an arc are too close to each other. Cause: Remedy: Reteach the robot. The taught points of an arc must be on the same plane. Otherwise, a minor modification to the teaching can cause a major change in motion.
MOTN--200 (%s^4, %d^5) Too long anticipate time The value of advanced processing time (Timebefore) is too large. Cause: Remedy: -- Reteach the previous taught point to increase the distance of motion. -- Decrease the advanced processing time.
MOTN--230 T1 rotspeed limit (G:%d^2) The attitude change speed in the T1 mode was clamped. Cause: Remedy: Decrease the speed of teaching. Alternatively, use a motion instruction in deg/sec or sec. 896
ALARM CODES
B--81464EN--3/01
MOTN--231 T1 Speed restriction (G:%d^2) When the taught speed is 250 mm/sec or less in the T1 mode, speed restriction processing was Cause: Remedy:
performed. The speed of the flange section exceeded 250 mm/sec because of a change in the tool attitude. This alarm is a warning, and does not represent a failure. However, the actual motion of this portion needs to be checked in the T2 mode.
MOTN--240 J4 is not zero The J4--axis is not at the 0_ position. Cause: Remedy: Make a motion so that the J4--axis is at the 0_ position. MOTN--241 OFIX stroke limit In attitude--fixed motion, a stroke limit was detected. Cause: Remedy: Check the motion range, and reteach the robot so that the motion does not exceed the range. MOTN--242 OFIX is disabled The attitude--fixed motion instruction is disabled. Cause: Remedy: Check if the robot supports attitude--fixed motion. MOTN--243 OFIX error The attitude--fixed motion instruction cannot be executed for another cause. Cause: Remedy: Check the alarm history to see if other alarms are issued. MOTN--244 OFIX Detect J4 is not 0 J4 at the motion start position or target position is not at the 0_ position. Cause: Remedy: Check the value of J4 at each position, and make modifications. MOTN--245 OFIX Wrist config mismatch The configuration differs between the motion start position and target position. Cause: Remedy: Check the attitude and make modifications. If motion is still unsuccessful, use joint motion. MOTN--246 OFIX Invalid rail vector The attitude--fixed motion instruction is disabled. Cause: Remedy: Check if the robot supports attitude--fixed motion. MOTN--247 E--Effector is not vertical to rail The flange surface is not parallel with the J1--axis. Cause: Remedy: Cause the robot to assume such an attitude that the flange surface is parallel with the J1--axis. MOTN--248 OFIX Too large tool rotation In attitude--fixed motion, the rotation angle of the flange between the start point and end point exceeded Cause: Remedy:
the range allowable in one motion. Split the motion, and teach each split part of the motion.
MOTN--249 OFIX Too large tool spin In attitude--fixed motion, the rotation angle of J6 between the start point and end point exceeded the Cause: Remedy:
range allowable in one motion. Split the motion, and teach each split part of the motion.
MOTN--250 Use CNT0/FINE for L/C before OFIX A circular motion or a linear motion other than attitude--fixed motion continues to an attitude--fixed Cause: Remedy:
motion through a smooth motion. Change the positioning mode of the circular motion or linear motion to smooth 0 or positioning.
MOTN--251 Can’t use OFIX with this motion A motion statement, such as an incremental motion instruction or remote TCP, which cannot be used Cause: Remedy:
at the same time with the attitude fix instruction, is specified. Modify the instruction.
897
ALARM CODES
B--81464EN--3/01
MOTN--252 OFIX: No plan data Internal error Cause: Remedy: Contact your FANUC customer service representative, and inform the representative of an alarm message displayed.
MOTN--253 OFIX: Motion type mismatch Internal error Cause: Remedy: Contact your FANUC customer service representative, and inform the representative of an alarm message displayed.
MOTN--254 OFIX: Detect large spin The tool attitude change per motion is too large. Cause: Remedy: Split the motion, and teach each split part of the motion. MOTN--255 OFIX: Detect J4 is not 0 During motion, it was detected that J4 is not at the 0_ position. Cause: Remedy:
This alarm is issued because J4 is slightly shifted from the 0_ position at the start point or end point of motion, or the angular change of the flange per motion is too large. Check the values of the start point and end point of J4. If this alarm is issued even when J4 is taught to assume exactly the 0_ position at both points, split the motion statement.
MOTN--256 OFIX: TCP config limit A linear motion range limit was reached. Cause: Remedy: Change the target position, or switch to joint motion. MOTN--257 Wrist start angle mismatch The motion start angle of the wrist axis does not match the internal calculation for attitude--fixed motion. Cause: Remedy: Modify the teaching only so that the J4--axis moves completely with 0 degree. Moreover, check if an application such as for tracking that compensates for a motion is used and check also if a motion addition instruction such as for compensating for a track is used.
MOTN--258 Not reached to dest rotation At the end of attitude--fixed motion, the tool arrival attitude does not match the internal calculation for Cause: Remedy:
attitude--fixed motion. Modify the teaching only so that the J4--axis moves completely with 0 degree. Moreover, check if an application such as for tracking that compensates for a motion is used and check also if a motion addition instruction such as for compensating for a track is used.
MOTN--259 Not reached to dest spin At the end of attitude--fixed motion, the tool arrival attitude does not match the internal calculation for Cause: Remedy:
attitude--fixed motion. Modify the teaching only so that the J4--axis moves completely with 0 degree. Moreover, check if an application such as for tracking that compensates for a motion is used and check also if a motion addition instruction such as for compensating for a track is used.
MOTN--300 CD not support:Use CNT L:%d^5 Term type CD is not supported. Cause: Remedy: Change termtype FINE or CNT. MOTN--301 Path to resume is changed(G:%d^2) Can’t resume motion. Cause: Remedy: Abort and run program. MOTN--302 Corner speed slowdown L:%d^5 Corner speed slows down automatically because of robot constraint. Cause: Remedy: If slow down is not acceptable, re--teach the path. 898
ALARM CODES
B--81464EN--3/01
MOTN--303 Can’t maintain CDist L:%d^5 Can’t maintain corner distance because path is short or speed is high. Cause: Remedy: Lengthen path or reduce speed. MOTN--304 CS:Prog speed achieved L:%d^5 SPD value does not affect corner speed anymore. Cause: Remedy: This is just a notification. You do not have to do anything for this warning messsage. MOTN--305 Can’t maintain speed L:%d^5 Can’t maintain program speed on the path because of robot constraint. Cause: Remedy: This is just a notification. You do not have to do anything for this warning messsage. MOTN--306 Can’t replan (G:%d^2, A:%x^3 Hex) Resume motion cannot reach stop position Cause: Remedy:
Can’t resume orginal path. Abort program and rerun
MOTN--307 Mismatch MMR (G:%d^2) Internal error Cause: Remedy: Contact your FANUC customer service representative, and inform the representative of an alarm message displayed.
MOTN--308 FINE termtype used L:%d^5 Can’t generate corner between two motion because of motion instruction. Cause: Remedy:
And CNT or CD is ignored. Use LOCK PREG instructiion when PR[] is used for positiion or OFFSET instruction is used.
MOTN--309 Circular speed reduced L:%d^5 Circular speed is reduced because of robot contraint Cause: Remedy: Reduce program speed not to display. MOTN--310 Pos. Cfg. change 2 (G:%d^2) Configuration mismatch Cause: Remedy: string matches the start position’s configuration string. MOTN--311 Path to resume is changed(G:%d^2) Can’t resume motion on the original path. Cause: Remedy: Abort and run program. Then, the resumed motion may not be on the original path.
MOTN--312 Can’t resume in single step CJ Can’t resume motion in single step mode. Cause: Remedy: Abort program and rerun. MOTN--313 Can’t resume motion CJ(2) Can’t resume motion on the original path. Cause: Remedy: Abort and run program. Then, the resumed motion may not be on the original path.
MOTN--314 Can’t resume motion CJ(3) Can’t resume motion on the original path due to motion condition. Cause: Remedy: Abort and run program. Then, the resumed motion may not be on the original path.
MOTN--315 Command speed is changed CJ Can’t resume motion on the original path due to command speed change. Cause: Remedy: Modify back the command speed, or abort program 899
ALARM CODES
B--81464EN--3/01
MOTN--316 Override change not allowed An override change was made when CJP was disabled and the program was being restarted. Cause: Remedy: Make an override change before restarting the program. Do not make an override change immediately after the program is restarted.
MOTN--319 CRC large orient change (G:%d^2) The small circle causes a large attitude change. Cause: Remedy: Reteach the robot. MOTN--320 Adj out of limit at line %s During a fine adjustment check, a position that cannot be reached was detected. Cause: Remedy: From the alarm message, identify the line that generated the alarm. Use CLR_Adj to clear the adjustment value.
MOTN--321 Posn unreachable at line %s During a fine adjustment check, a position that cannot be reached was detected. Cause: Remedy: From the alarm message, identify the line that generated the alarm. Use CLR_Adj to clear the adjustment value.
MOTN--340 Fast fault recovery This is notification for application process enabled in the fast fault recovery when the alarm position is Cause: Remedy:
found. N/A
MOTN--341 NO Z offset for INC motion A Z offset value cannot be applied to an incremental motion. Cause: Remedy: Do not use an incremental motion. MOTN--342 Override change not allowed Change in teach pendant override setting while the program is running. Cause: Remedy: Set Teach Pendant’s override to the desired value and resume the program
PROG Error Codes PROG--001 to 004 ABORT.L Invalid pointer is specified System internal error. Cause: Remedy: Contact our service center serving your locality. PROG--005 WARN Program is not found The specified program cannot be found. Cause: Remedy: Check the program name. PROG--006 WARN Line is not found The specified line number cannot be found. Cause: Remedy: Check the line number. PROG--007 WARN Program is already running The specified program is already being executed. Cause: Remedy: Check the program name. PROG--008 WARN In a rtn when creating a task Execution cannot be started in sub-routine program. Cause: Remedy: Check the line number. PROG--009 WARN Line not same rtn as paused at The program attempted to resume at a line different from the paused line. Cause: Remedy: Check the line number. 900
ALARM CODES
B--81464EN--3/01
PROG--010 WARN Not same prg as paused A program, different from the paused program, attempted to resume. Cause: Remedy: Check the program name. PROG--011 PAUSE.L Cannot get the motion control Motion control cannot be obtained. Cause: Remedy: Check the teach pendant enable switch and other running programs to determine who has motion control.
PROG--012 WARN All groups not on the top The program attempted to resume at a motion different from the paused motion. Cause: Remedy: Resume the motion paused the last time. PROG--013 WARN Motion is stopped by program This motion was paused by the MOTION PAUSE instruction. Only the RESUME MOTION program Cause: Remedy:
instruction can resume the motion. Use the RESUME MOTION instruction in the program.
PROG--014 WARN Max task number exceed The number of programs you attempted to start exceeded the maximum number allowed. Cause: Remedy: Abort any unnecessary programs. PROG--015 WARN Cannot execute backwards Backward execution cannot be used. Cause: Remedy: Do not use backward execution at this point. PROG--016 WARN Task is not found The specified task is not running or paused. Cause: Remedy: Check the task name. PROG--017 WARN Task is not running The specified task is not running. Cause: Remedy: Check the task name. PROG--018 ABORTG Motion stack overflowed Too many programs are paused. Cause: Remedy: Resume or abort some programs. PROG--019 WARN Ignore pause request The request to pause the program was ignored. Cause: PROG--020 WARN Task is already aborted The specified program was already aborted. Cause: Remedy: Check the program name. PROG--021 WARN Ignore abort request The request to abort the program was ignored. Cause: PROG--022 WARN Invalid request type Internal error Cause: Remedy: Contact our service center serving your locality. PROG--023 WARN Task is not paused The specified program is not paused. Cause: Remedy: Pause the program. 901
ALARM CODES
B--81464EN--3/01
PROG--024 WARN Not have motion history The motion path record is lost. Cause: Remedy: Do not attempt backwards execution at this time. PROG--025 WARN Cannot execute backwards Backward execution cannot be used. Cause: Remedy: Do not use backwards execution here. PROG--026 WARN No more motion history Backward execution cannot be used any more. The current line is on top of the memorized path. Cause: PROG--027 to 033 WARN Invalid task number Internal system error. Cause: Remedy: Contact our service center serving your locality. PROG--034 WARN Routine not found The specified routine cannot be found. Cause: Remedy: Check the routine name and verify it is loaded. PROG--035 WARN Not locked the specified group Motion control for the specified group cannot be locked. Cause: Remedy: Check the teach pendant enable switch and other running programs to determine who has motion control.
PROG--036 WARN The length of trace array is 0 Either there is not enough memory available, or the task attribute is set incorrectly. Cause: PROG--037 WARN No data in the trace array There is no execution record in memory. Cause: Remedy: Turn on tracing using the KCL SET TRACE ON command. PROG--038 Inconsistency in task status Internal system error. Cause: Remedy: Consult our service representative. PROG--039 WARN locked, but not get mctl Motion control for the specified group was reserved, but it cannot be obtained. Cause: PROG--040 PAUSE.L Already locked by other task Motion control for the specified group was already reserved by another program. Cause: Remedy: Check the other running programs to determine who has motion control. PROG--041 WARN mctl denied because released Motion control is released. The teach pendant currently has motion control. The robot cannot be started Cause: Remedy:
until motion control is obtained. Disable the teach pendant.
PROG--042 WARN Already released Motion control was already released. Cause: PROG--043 WARN Already released by you Motion control was already released by request of this program. Cause: PROG--044 WARN Arm has not been released yet Motion control was not released yet. Cause: 902
ALARM CODES
B--81464EN--3/01
PROG--045 WARN Other than requestor released Motion control was already released by the request of another program. Cause: PROG--046 PAUSE.L TP is enabled while running (%s^7) The teach pendant was enabled while the program was executing. Cause: PROG--047 PAUSE.L TP is disabled while running (%s^7) The teach pendant was disabled while the program was executing. Cause: PROG--048 PAUSE.L Shift released while running (%s^7) The shift key was released while the program was executing. Cause: PROG--049 WARN Cannot release, robot moving Motion control cannot be released because the robot is moving. Cause: Remedy: Check the status of robot motion. PROG--050 WARN Abort still in progress The program is in the process of being aborted. Cause: Remedy: Wait a few seconds. PROG--051 WARN Cannot skip the return stmt The specified lines to which a move was attempted exceed the number of lines in the program. Cause: Remedy: Check the line number. PROG--052 ABORT.L Process is aborted while executing The user application task was forced to abort while the application was executing. Cause: PROG--053 ABORT.L User AX is not running The user application task was not executed. Cause: Remedy: Start the user application task before executing the application. PROG--054 FWD released while running (%s^7) FWD key was released while the program is executing. Cause: Remedy: Hold the FWD key with shift key to resume execution. PROG--055 BWD released while running (%s^7) BWD key was released while the program is executing. Cause: Remedy: Hold the BWD key with shift key to resume execution. PROG--056 Motion data out is enable The machine lock function is disabled, and the motion data output function is enabled. Cause: Remedy: On the test execution screen, disable the motion data output function.
MACR Error Codes
( ID = 57 )
MACR--001 WARN Can’t assign to MACRO command The conditions for assigning macros are not correct. Cause: Remedy:
1 The allocation definition is duplicated. 2 The index is beyond the set range. Modify the device allocation.
MACR--003 WARN Can’t assign motn_prog to UK It is not possible to assign a program with MOTION lock group to the User Key(UK) button. Cause: Remedy: Remove the motion lock group from the program. MACR--004 WARN Can’t execute motn_prog by UK It is not possible to execute a program with MOTION lock group with the User Key(UK) button. Cause: Remedy: 1 Remove all the motion groups from the group mask for detailed program information. 2 Allocate the program to other devices (SU, SP, and MF).
903
ALARM CODES
B--81464EN--3/01
MACR--005 WARN Please enable teach pendant It is not possible to execute a program when the teach pendant is disabled. Cause: Remedy: Enable the teach pendant. MACR--006 WARN Please disable teach pendant It is not possible to execute a program when the teach pendant is enabled. Cause: Remedy: Disable the teach pendant. MACR--007 WARN The same macro type exists The macro assign type already exists. Cause: Remedy: Change the assign type. MACR--008 WARN Remote--cond isn’t satisfied This assign type is only enabled at a REMOTE condition. Cause: Remedy: Create a REMOTE condition. MACR--009 WARN The index is out of range This assign index is out of range. Cause: Remedy: Change the assign index so that it is within the valid range. MACR--010 WARN This SOP button is disabled This SOP button is disable for macro execution. Cause: Remedy: Change the value of the $MACRSOPENBL system variable. MACR--011 WARN This UOP button is disabled This UOP signal is disabled for macro execution. Cause: Remedy: Change the value of the $MACRUOPENBL system variable. MACR--012 WARN Number of DI+RI is over The number of RI+DI is over the maximum number. Cause: Remedy: First deassign the other RI or DI assignments. Then assign the new macro as RI or DI. MACR--013 WARN MACRO execution failed Cannot execute this MACRO. Cause: Remedy: Refer to the error cause code. MACR--016 WARN The macro is not completed The macro aborted while executing. Cause: Remedy: The macro will begin executing from the first line at the next execution.
MEMO Error Codes
( ID = 7 )
MEMO--001 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--002 WARN Specified program is in use The specified program is editing or executing. Cause: Remedy: Either abort the specified program or select it once more after selecting another program. MEMO--003 WARN Specified program is in use The specified program is editing or executing. Cause: Remedy: Either abort the specified program or select it once more after selecting another program. MEMO--004 WARN Specified program is in use The specified program is editing or executing. Cause: Remedy: Either abort the specified program or select it once more after selecting another program. 904
ALARM CODES
B--81464EN--3/01
MEMO--006 WARN Protection error occurred The specified program is protected by a user. Cause: Remedy: Cancel the protection of the specified program. MEMO--007 WARN Invalid break number Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--008 WARN Specified line no. not exist Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--009 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--010 WARN Program name error The specified program name is different from the one in the P-code file. Cause: Remedy: Specify the same program name. MEMO--011 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--012 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--013 WARN Program type is different The specified program type is different from that of the object being processed. Cause: Remedy: Specify the same program type. MEMO--014 WARN Specified label already exists The specified label id already exists in the program. Cause: Remedy: Specify another label number. MEMO--015 WARN Program already exists The specified program already exists in the system. Cause: Remedy: Either specify another program name or delete the registered program. MEMO--016 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--017 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--018 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--019 WARN Too many programs The number of the programs and routines exceeded the maximum allowed (3200). Cause: Remedy: Delete unnecessary programs and routines. 905
ALARM CODES
B--81464EN--3/01
MEMO--020 to 024 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--025 WARN Label does not exist Specified label does not exist. Cause: Remedy: Set the index to an existing label. MEMO--026 WARN Line data is full The number of line data exceeded the maximum possible line number (65535). Cause: Remedy: Delete unnecessary line data. MEMO--027 WARN Specified line does not exist The specified line data does not exist. Cause: Remedy: Specify another line number. MEMO--028 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--029 WARN The line data can’t be changed The specified line data cannot be changed. The size of modified data is different from that of original Cause: Remedy:
data when replacing it. Specify another line number or data of the same size.
MEMO--030 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--031 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--032 WARN Specified program is in use The specified program is editing or executing. Cause: Remedy: Either abort the specified program or select it once more after selecting another program. MEMO--034 WARN The item can’t be changed The specified item is locked to change by system. Cause: Remedy: Specify another item. MEMO--035 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--036 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--037 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--038 WARN Too many programs The number of programs exceeded the maximum allowed. Cause: Remedy: Delete unnecessary programs. 906
ALARM CODES
B--81464EN--3/01
MEMO--039 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--040 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--041 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--042 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--043 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--044 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--045 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--046 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--047 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--048 WARN Break point data doesn’t exist The specified break point data does not exist. Cause: Remedy: Specify another break point. MEMO--049 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--050 WARN Program does not exist The specified program does not exist in the system. Cause: Remedy: Specify another program or create the new program first. MEMO--051 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--052 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. 907
ALARM CODES
B--81464EN--3/01
MEMO--053 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--054 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--055 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--056 WARN Program does not exist The specified program does not exist in the system. Cause: Remedy: Specify another program or create the new program first. MEMO--057 to 064 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--065 WARN Too many opened programs Too many CALL instructions being used. The number of opened programs exceeded the maximum Cause: Remedy:
allowed ( 100 ). Abort any unnecessary programs or remove unnecessary CALL instructions.
MEMO--066 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--067 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--068 WARN Specified program is in use 1. The specified program is editing or executing. Cause: Remedy:
2. The specified program is tied to a MACRO. 1. Either abort the specified program or select it once more after selecting another program. 2. Remove the program from the MACRO entry.
MEMO--069 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--070 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--071 WARN Position does not exist The specified position data does not exist. Cause: Remedy: Specify another position. MEMO--072 WARN Position data already exists Position data already exists in the position you specified to move. Cause: Remedy: Specify another position or delete the data in the specified position. MEMO--073 WARN Program does not exist The specified program does not exist in the system. Cause: Remedy: Specify another program or create the new program first. 908
ALARM CODES
B--81464EN--3/01
MEMO--074 WARN Program type is not TPE The operation can be applied only to teach pendant programs. Cause: Remedy: Select a teach pendant program. MEMO--075 WARN Program can’t be used The program must be opened before attempting read or write operations. Cause: Remedy: Open the program before reading or writing. MEMO--076 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--077 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--078 WARN Program can’t be used The specified operation is not supported for program type. Cause: Remedy: Specify a program whose program type matches the operation. MEMO--079 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--080 WARN Protection error occurred The specified program is protected by a user. Cause: Remedy: Cancel the protection of the specified program. MEMO--081 WARN Specified program is in use The specified program is editing or executing. Cause: Remedy: Abort the specified program or select it once more after selecting another program. MEMO--082 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--083 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--084 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--085 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--086 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--087 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. 909
ALARM CODES
B--81464EN--3/01
MEMO--088 WARN Program does not exist The specified position data does not exist. Cause: Remedy: Specify another position. MEMO--089 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--090 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--091 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--092 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--093 WARN Specified program is in use The specified program is editing or executing. Cause: Remedy: Abort the specified program or select it once more after selecting another program. MEMO--094 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--095 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--096 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--097 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--098 WARN EOF occurs in file access EOF occurs in file access. When the P-code file was scanned, EOF occurs. Cause: Remedy: The P-code data may be broken. Translate the specified KAREL program again. Then reload the P-code.
MEMO--099 WARN Program name is wrong The length of the program name is different from that of the P-code data. Cause: Remedy: Check the name of the specified program. MEMO--100 to 102 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--103 WARN Check sum error occurred The specified data was broken. This is the internal error. Cause: Remedy: Contact our service center serving your locality. 910
ALARM CODES
B--81464EN--3/01
MEMO--104 WARN Program already exists The specified program already exists in the system. Cause: Remedy: Specify another program name or delete the registered program. MEMO--105 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--106 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--107 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--108 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--109 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--110 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--111 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--112 WARN Break data already exists The specified break point data already exists in the program. Cause: Remedy: Specify another break point. MEMO--113 WARN File access error The port that has the program you want to load is not connected. Cause: Remedy: Check the port setting and the connected device. MEMO--114 WARN Break point can’t be removed The break point data can not be overwritten because the program is protected by a user or is executing. Cause: Remedy: Cancel the protection of the program or abort the program. MEMO--115 WARN Break point can’t be removed The break point data can not be removed because the program is protected by a user or is executing. Cause: Remedy: Cancel the protection of the program or abort the program. MEMO--116 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--117 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. 911
ALARM CODES
B--81464EN--3/01
MEMO--118 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--119 WARN Application data doesn’t exist The specified application data does not exist because the program does not correspond to the specified Cause: Remedy:
application. Specify another application data. Then create the program in the current system.
MEMO--120 WARN Application data doesn’t exist The specified application data does not exist because the program does not correspond to the specified Cause: Remedy:
application. Specify another application data. Create the program in the current system.
MEMO--121 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--122 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--123 WARN Application data doesn’t exist The specified application data does not exist because the program does not correspond to the specified Cause: Remedy:
application. Specify another application data. Then create the program in the current system.
MEMO--124 WARN Program version is too new KAREL program version number is newer than that of the system. Cause: Remedy: Translate the program with an older version of the Translator. MEMO--125 WARN Program version is too old KAREL program version number is older than that of the system. Cause: Remedy: Translate the program with a newer version of the Translator. MEMO--126 WARN No more available memory Lack of the memory which can be used. Cause: Remedy: Delete unnecessary programs. MEMO--127 WARN Pos reference over 255 times Reference of the same position exceeded the maximum count (256). Cause: Remedy: Set new position ID for the referenced position. MEMO--128 WARN %s parameters are different A routine exists in memory with a different parameter definition than the routine in the PC file being Cause: Remedy:
loaded. Update the calling convention in the KAREL program being loaded or delete the obsolete routine from system memory.
MEMO--129 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--130 SYSTEM Please power up again System data in CMOS has been broken. Cause: Remedy: Turn power off and then back on. 912
ALARM CODES
B--81464EN--3/01
MEMO--131 SYSTEM Please power up again System data in CMOS has been broken. Cause: Remedy: Turn power off and then back on. MEMO--132 WARN %s has been broken Program data has been broken at the power fail recover. Cause: Remedy: Delete the program and create it again. Contact our service center serving your locality. MEMO--133 SYSTEM Please power up again System data in CMOS has been broken. Cause: Remedy: Turn power off and then back on. MEMO--134 WARN TPE program %s already exists A teach pendant (TP) program with the same name already exists. Cause: Remedy: Delete the teach pendant (TP) program. Then load the specified KAREL program again. MEMO--135 WARN Cannot create TPE program here The teach pendant (TP) program cannot be created in this start mode. Cause: Remedy: On the auxiliary menu, switch the start mode to cold start or control start 2. MEMO--136 WARN Cannot load P--code here The KAREL program cannot be loaded in this start mode. Cause: Remedy: Select the function menu to change the start mode, or power on again. MEMO--137 WARN Load at Control Start Only Specified KAREL program cannot be loaded in this mode. Because the same name program has Cause: Remedy:
already been loaded at controlled start. Load the program at controlled start.
MEMO--138 WARN Delete at Control Start Only Specified program has already been loaded at controlled start. Because of this, you can only delete Cause: Remedy:
the program at controlled start. Delete the program at controlled start.
MEMO--139 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--140 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--141 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--142 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--143 WARN System error Internal system error. Cause: Remedy: Contact our service center serving your locality. MEMO--144 WARN Header size too big The teach pendant (TP) header size specified is too big. Must be less than 256. Cause: Remedy: Change size to range of 1--256. If necessary, use multiple header records. 913
ALARM CODES
B--81464EN--3/01
MEMO--145 TPE cannot have KAREL routine A KAREL program with the same name already exists, so that a program with the specified name cannot Cause: Remedy:
be created. Change the name to a different one.
MEMO--146 Invalid variable is used A KAREL program includes an invalid variable. Cause: Remedy: Check the variable of the KAREL program. MEMO--147 Flash File access error(write) An attempt to write to the F--ROM failed. Cause: Remedy:
Program data may be destroyed. The F--ROM may be faulty.
MEMO--148 Flash File access error(read) An attempt to read from the F--ROM failed. Cause: Remedy:
Program data may be destroyed. The F--ROM may be faulty.
MEMO--149 Specified program is broken Program data is destroyed. Cause: Remedy: Check the contents of the program. MEMO--151 No more available memory(TEMP) Temporary memory is insufficient. Cause: Remedy: Delete unnecessary programs.
CMND Error Codes CMND--001 WARN Directory not found The specified directory can not be found. Cause: Remedy: Check the device and path that you entered. CMND--002 WARN File not found The specified file could not be found. Cause: Remedy: Check to make sure the file has been spelled correctly and that it exists. Also verify the device and path name are correct.
CMND--003 WARN File already exists The file already exists and could not be overwritten. Cause: Remedy: Make sure the overwrite option has been specified. CMND--006 WARN Self copy not allowed A file cannot be copied to itself. Cause: Remedy: Change the name of the destination file so it is different from the source file. CMND--009 WARN Position types are the same Internal error. Cause: CMND--010 WARN Source type code is invalid Internal error. Cause: CMND--011 WARN Destination type code is invalid Internal error. Cause: CMND--012 WARN Type codes do not match Internal error. Cause: 914
ALARM CODES
B--81464EN--3/01
CMND--013 WARN Representation mismatch Internal error. Cause: CMND--014 WARN Positions are not the same Internal error. Cause: CMND--015 WARN Both arguments are zero Internal error. Cause: CMND--016 WARN Division by zero Internal error. Cause: CMND--017 WARN Angle is out of range Internal error. Cause: CMND--018 WARN Invalid device or path You have specified an invalid device or path. Cause: Remedy: Check the device and path that you entered. CMND--019 WARN Operation cancelled The operation was cancelled because CTRL--C or CTRL--Y was pressed. Cause: CMND--020 WARN End of directory The directory listing is finished. Cause: CMND--021 WARN Cannot rename file The destination file name contained both alphanumeric characters and the global Cause: Remedy:
character ’*’. Use only alphanumeric characters or a single global character when renaming a file.
CMND--022 STOP.G Time motion with dist before Unknown Cause: Remedy: Unknown
COND Error Codes COND--001 WARN Condition does not exist The number of a monitor to be enabled, disabled, or deleted is specified, but it is not found. Cause: Remedy: Check the existing monitor numbers and specify one of them. COND--002 WARN Condition handler superseded The specified condition number already exists in the system, and has been superseded by the new Cause: Remedy:
condition. This is a notification. You do not have to do anything for this warning message.
COND--003 WARN Already enabled, no change The specified condition is already enabled. No change has been made. Cause: Remedy: This is a notification. You do not have to do anything for this warning message. COND--004 WARN Already disabled, no change The specified condition is already disabled. No change has been made. Cause: Remedy: This is a notification. You do not have to do anything for this warning message. COND--009 WARN Break point encountered Break point has been encountered. Cause: Remedy: No action is required 915
ALARM CODES
B--81464EN--3/01
COND--010 WARN Cond exists, not superseded The specified condition already exists. Condition was not superseded. Cause: COND--011 ABORT.G Scan time took too long There are too many conditions defined. It took too long to scan them all. Cause: Remedy: Reduce the number of conditions defined.
DICT Error Codes DICT--001 WARN Dictionary already loaded A dictionary cannot be reloaded if it was loaded into FROM. Cause: Remedy: Load into a different language and use KCL SET LANG to set the language. DICT--002 WARN Not enough memory to load dict There is no more permanent memory available in the system to load another dictionary. Cause: Remedy: Clear all unnecessary programs, dictionaries, or variables. DICT--003 WARN No dict found for language There are no dictionaries loaded for the specified language. Cause: Remedy: Use the DEFAULT language or a language in which a dictionary has been loaded. DICT--004 WARN Dictionary not found The specified dictionary was not found. Cause: Remedy: Use KCL LOAD DICT to load the dictionary into the DEFAULT language or the current language. DICT--005 WARN Dictionary element not found The dictionary element was not found. Cause: Remedy: Check the dictionary or element number to be sure it is specified correctly. DICT--006 WARN Nested level too deep Only five levels of dictionary elements can be nested. Cause: Remedy: Fix the dictionary text file to include fewer nested levels. DICT--007 WARN Dictionary not opened by task The dictionary was never opened. Cause: Remedy: Remove the close operation. DICT--008 WARN Dictionary element truncated The dictionary element was truncated because the KAREL string array is not large enough to hold all Cause: Remedy:
the data. Increase either the size of the string or the number of strings in the array.
DICT--009 WARN End of language list The language list has completed. Cause: DICT--010 WARN End of dictionary list The dictionary list has completed. Cause: DICT--011 WARN Dict opened by too many tasks Only five dictionaries can be open by one task at one time. Cause: Remedy: Load the dictionary files into F--ROM or C--MOS memory, where file open processing is not required. Close any unused dictionary files.
DICT--012 WARN Low on FROM, loaded to memory Not enough memory exists in FROM so the dictionary was loaded to CMOS. Cause: Remedy: Store the dictionaries into C--MOS memory. 916
ALARM CODES
B--81464EN--3/01
DICT--013 WARN Cannot open dictionary file The dictionary file does not exist on the specified device or in the specified directory. Cause: Remedy: Select the proper device/directory and try again. DICT--014 WARN Expecting $ in dictionary file The dictionary text incorrectly specifies an element without a $. Cause: Remedy: Make sure all dictionary elements begin with a $. DICT--015 WARN Reserved word not recognized A reserved word was not recognized in the dictionary text. Cause: Remedy: Check for misspellings or look up the correct word in the KAREL Reference Manual. DICT--016 WARN Ending quote expected The dictionary text incorrectly specifies an element without using quotes. Cause: Remedy: Make sure all dictionary text is surrounded by double quotes. Use a backslash if you want an actual quote to appear in the text. For example, \”This is an example\” will produce ”This is an example”
DICT--017 WARN Expecting element name or num A reference to another element is expected. Cause: Remedy: Use the element number to reference the element. DICT--018 WARN Invalid cursor position The cursor position is specified incorrectly or the values are outside the limits. Cause: Remedy: Make sure the cursor position is valid. For example, use @1,1 for the first row and col respectively. DICT--019 WARN ASCII character code expected A series of digits are expected after the # to specify an ASCII character code. Cause: Remedy: Remove the # or look up the ASCII character code in the KAREL Reference Manual. DICT--020 WARN Reserved word expected An identifier is expected after the & to specify a reserved word. Cause: Remedy: Remove the & or look up the reserved word in the KAREL Reference Manual. DICT--021 WARN Invalid character An unexpected character was found in the dictionary text file. Cause: Remedy: Make sure all dictionary text is correct. DICT--022 WARN Dict already opened by task The dictionary is already open by the task. Cause: Remedy: This is a notification. You do not have to do anything for this warning message. DICT--023 WARN Dict does not need to be opened Dictionaries loaded to memory do not need to be opened. Cause: Remedy: Do not try to open the dictionary file. DICT--024 WARN Cannot remove dictionary file Dictionaries loaded to FROM cannot be removed or a dictionary cannot be removed if another task has Cause: Remedy:
it opened. Do not try to remove a dictionary loaded to FROM. Remove the dictionary from the same task which loaded it.
DICT--025 Invalid state -- internal error Incorrect scanning. Cause: Remedy: Correct the text of the dictionary. DICT--028 WARN No FROM write, loaded to memory Not enough memory exists in FROM so the dictionary was loaded to CMOS for R-J. Cause: Remedy: This is a notification. You do not have to do anything for this warning message. 917
ALARM CODES
B--81464EN--3/01
DICT--029 WARN Help element not found The help dictionary element was not found. Cause: Remedy: Check the dictionary to be sure the help dictionary element was specified correctly. The help dictionary element must be specified with a question mark (?) followed by the element number.
DICT--030 WARN Function key element not found The function key dictionary element was not found. Cause: Remedy: Check the dictionary to be sure the function key element was specified correctly. The function key element must be specified with a caret (^) followed by the element number.
LANG Error Codes LANG--004 WARN File is not open 1 A file having the same name already exists. Cause:
Remedy:
2 3 4 1 2 3 4
The specified file has already been opened. The file is write--protected. When a floppy disk is used, it has no free space. Delete any unnecessary files, or rename the file. Close the file. Cancel write protection. Use a new floppy disk. Or, delete any unnecessary files from the existing floppy disk to create sufficient free space to save the file.
LANG--005 WARN Program type is different Only able to process teach pendant programs. Cause: Remedy: Please select a teach pendant program. LANG--006 Invalid or corrupted TP file The data of a program file cannot be read correctly. Cause: Remedy: Check the port setting. Check the Handy File setting. Check the floppy or memory card connection. If the checks above cannot correct the error, the data of the file may be destroyed.
LANG--007 System Error The data of a program file cannot be read correctly. Cause: Remedy: Check the port setting. Check the Handy File setting. Check the floppy or memory card connection. If the checks above cannot correct the error, the data of the file may be destroyed.
LANG--014 WARN Program already exists The program that is about to load, already exists in the system. Cause: Remedy: Before you load it, delete the program already in the system. LANG--015 WARN Can not write file 1 The file is write--protected. Cause: Remedy:
2 Data of the specified size could not be written. 1 Cancel write protection. 2 The disk may be faulty. Replace the disk.
LANG--016 WARN Can not read file Data of the specified size could not be read. Data communication failed. Cause: Remedy: Check the connection of the device. LANG--017 WARN File format is incorrect The data you are trying to save to a file is either abnormal or broken, therefore the file cannot be loaded. Cause: Remedy: The file cannot be loaded with the data as it is. The data must be normal to load the file. 918
ALARM CODES
B--81464EN--3/01
LANG--018 WARN Group mask value is incorrect When printing the program, there was an illegal position that did not match the group mask of the Cause: Remedy:
program. Reteach the position data so that the group number matches the group mask of the program.
LANG--050 WARN %s contains %s, program/file names must match The file name and the program name are not same. Their names must match. Cause: Remedy: Rename the file name to be same as the program name. LANG--094 WARN File already exists The specified file already exists on the floppy. Cause: Remedy: Before you write the new file to the floppy, delete the file that already exists on the floppy. LANG--095 WARN File does not exist The specified file does not exist on the floppy. Cause: Remedy: Check the file name or content of the floppy. LANG--096 WARN Disk is full The floppy disk has reached its limit and is full. Cause: Remedy: Either use a new floppy disk or delete an necessary file in order to make room for saving to the floppy. LANG--098 WARN Disk timeout Could not access the disk. Cause: Remedy: Check if the correct device is set to port and if it turns on. LANG--099 WARN Write protection violation The disk has write protection. Cause: Remedy: Cancel the write protection. LANG--100 WARN Device error Could not access the device. Cause: Remedy: Connect the correct device to the correct port.
MCTL Error Codes MCTL--001 NONE TP is enabled The teach pendant is enabled, and the motion control was not granted. Cause: Remedy: Disable the teach pendant and try the operation again. MCTL--002 NONE TP is disabled The teach pendant is disabled, and the motion control was not granted. Cause: Remedy: Enable the teach pendant and try the operation again. MCTL--003 NONE system is in error status The motion control was not granted because the system is in error status. Cause: Remedy: Clear the error, and try the operation again. MCTL--004 NONE motion is in progress The motion is still in progress, and the motion control was not granted. Cause: Remedy: Wait until the robot comes to a complete stop. MCTL--005 NONE not in control of motion The motion control was not granted because of some unknown reason. Cause: Remedy: Clear the reason, and try the operation again. 919
ALARM CODES
B--81464EN--3/01
MCTL--006 NONE TP has motion control The motion control was not granted because the teach pendant currently has motion control. Cause: Remedy: Disable the teach pendant, and try the same operation again. MCTL--007 NONE PROG has motion control The motion control was not granted because the program has motion control Cause: Remedy: Pause or abort the program, and try the operation again. MCTL--008 NONE Operator panel has motion control The motion control was not granted because the operator panel has the motion control. Cause: Remedy: Set the $RMT_MASTER system variable correctly, and try the operation again. MCTL--009 NONE Other has motion control Another device has motion control, and the motion control was not granted. Cause: Remedy: Set the $RMT_MASTER system variable correctly, and try the operation again. MCTL--010 Other than msrc is rel’ing Internal error Cause: Remedy: Contact your FANUC customer service representative, and inform the representative of an alarm message displayed.
MCTL--011 Due to error processing Internal error Cause: Remedy: Contact your FANUC customer service representative, and inform the representative of an alarm message displayed.
MCTL--012 subsystem code unknown Internal error Cause: Remedy: Contact your FANUC customer service representative, and inform the representative of an alarm message displayed.
MCTL--013 NONE ENBL input is off ENBL input on the UOP is off. Cause: Remedy: Set ENBL input ON. MCTL--014 NONE Waiting for Servo ready The motion control was not granted because servo was not up. Cause: Remedy: Wait for a few seconds until servo is up and ready. MCTL--015 NONE Manual brake enabled The motion control was not granted because manual brake control is enabled. Cause: Remedy: Disable the manual brake control.
PRIO Error Codes PRIO--001 WARN Illegal iotype Port type specified is invalid. Cause: Remedy: Use one of the port types defined in IOSETUP.KL. PRIO--002 WARN Illegal index Port number is invalid or not presently assigned. Cause: Remedy: Correct the port number. PRIO--003 SYST No memory available The memory required for this operation is not available. Cause: Remedy: Delete KAREL programs and/or variables to free memory. 920
ALARM CODES
B--81464EN--3/01
PRIO--004 WARN Too few ports on mod too few ports on mod There are not enough ports on the specified board or module to make the specified assignments Cause: Remedy: Correct either the first port number or the number of ports. PRIO--005 WARN bad logical port no The specified port number in an assignment is invalid. It must be in the range of 1 -- 32767. Cause: Remedy: Correct the logical port number, so that it is within the valid range. PRIO--006 WARN bad log port number in asgt The specified port number in an assignment is invalid. It must be in the range of 1 -- 32767. Cause: Remedy: Correct the logical port number, so that it is within the valid range. PRIO--007 WARN no match in deassign call Port being deassigned is not presently assigned. Cause: Remedy: Correct the port number. PRIO--008 WARN phys ports not found Physical port being assigned to, does not exist. Cause: Remedy: Correct the rack number, slot number, or port number. PRIO--009 WARN n_ports invalid The number of ports in an assignment is invalid. It must be in the range of 1 -- 128. Cause: Remedy: Correct the number of ports, so that it is within the valid range. PRIO--010 WARN bad phys port number is asgt Invalid physical port number in assignment request. It must be greater than 1. Cause: Remedy: Correct the physical port number, so that it is greater than 1. PRIO--011 WARN asgt overlaps existing asgt The logical port numbers being assigned overlap existing assignments. Cause: Remedy: Correct the first port number or number of ports. PRIO--012 WARN bad board num The specified rack and/or slot number is invalid or refers to an unused rack/slot number. Cause: Remedy: Correct the rack and/or slot number. PRIO--013 WARN no aiseq for bd An attempt was made to delete an analog input sequence which has not been defined. Cause: Remedy: Check the rack and/or slot number. PRIO--014 WARN ai seq too long The specified analog input sequence is too long. The sequence has from 1 to 15 port numbers. Cause: Remedy: Supply a sequence of an appropriate length. PRIO--016 WARN log port already asgnd The specified logic number is already in use. Cause: Remedy: Use another logic number. PRIO--017 WARN I/O point not sim I/O point not sim You attempted to set an input port that was not simulated. Cause: Remedy: Use the I/O menu to set the port simulated or avoid setting the port. PRIO--020 SYST SLC communications error %d %d %d %d An unrecoverable error is detected in communication with a process I/O board. Cause: Remedy: Check the cable between the main CPU board and the I/O unit. Check the SLC2 mounted on the main CPU board or I/O unit.
921
ALARM CODES
B--81464EN--3/01
PRIO--021 Unknown I/O hardware An unknown device is connected to the I/O Link connector. Cause: Remedy: Replace the device with a device that is compatible with the current software or install a version of software that recognizes the device.
PRIO--022 Too much I/O data on I/O link The devices connected to the I/O Link exceed the I/O link capacity. Cause: Remedy: Disconnect some devices. PRIO--023 WARN no ports of this type There are no ports of the specified type. Cause: Remedy: Change the port type, or define ports (e.g., GIN or GOUT) of the specified type. PRIO--032 WARN too many DIO modules More than 31 I/O units are connected through an I/O link. Cause: Remedy: Disconnect some of the I/O units so that no more than 31 are connected. PRIO--063 WARN Bad IO asg: rack% d^1 slot %d^2 The I/O unit to which a signal is allocated is not found. There is no I/O unit corresponding to the rack Cause:
Remedy:
and slot numbers subsequent to the alarm message. Possible causes are as follows: (1) The I/O unit has been replaced with another type of I/O unit. (2) The I/O unit fuse has blown. (3) Power is not supplied to the I/O unit. (4) The I/O link cable is either disconnected or not securely connected. (5) The I/O link cable is broken. (6) The I/O unit is faulty. (1) If the I/O unit has been replaced, apply the following procedure to clear the I/O allocation. 1 Press MENU and select I/O. Then, press F1 (TYPE) and select I/O LINK to display the I/O link screen. 2 Press F5 (INTER CONNECT). 3 In response to the prompt “RECOVER ALL,” press F4 (YES). 4 Turn the power off and then back on. In this case, even when power restoration is enabled, all output signals are turned off. (2) Replace the I/O unit fuse. (3) Check the power supply to the I/O unit. (4) Ensure that the I/O link cable is connected securely. (5) Replace the I/O link cable. (6) Replace the I/O unit.
PRIO--072 WARN Pulse output is full Max of pulse output is 255 at the same time. Cause: Remedy: Check the count of pulse output. PRIO--081 I/O is not initialized This indicates that an severe error has occured during I/O initialization at controller power--up. Cause: Remedy: Check other error messages displayed on the TP alarm screen. PRIO--083 Digital I/O is not recovered Digital output port states are not recovered when semi--hot start is enabled because I/O device Cause: Remedy:
configuration or assignments have changed. Initialize I/O.
PRIO--085 BUSY in SLC2 does not turn off BUSY bit in SLC2 does not turn off. Cause: Remedy: Check SLC2 on Main CPU board or I/O device and I/O link cable. PRIO--100 Model B comm fault %srack:%d slot:%d Communication between the MODEL B interface unit and DI/DO units, or between DI/DO units, is lost. Cause: Remedy: Check the power and cabling from MODEL B interface unit and DI/DO unit, or between DI/DO units. 922
ALARM CODES
B--81464EN--3/01
PRIO--119 Too many DIGITAL I/O ports There are too many DIGITAL I/O ports. Cause: Remedy: Disconnect some DIGITAL I/O devices. PRIO--125 SLC2 initialization error The SLC2 is in an error state at the end of initialization. Cause: Remedy: Check SYSFAIL of the other PCB. Also check the main PCB.
ROUT Error Codes ROUT--022 PAUSE.G Bad index in ORD Internal error of software. Cause: ROUT--023 PAUSE.G Bad index in SUBSTR Internal error of software. Cause: ROUT--024 PAUSE.G SUBSTR length less than 0 Internal error of software. Cause: ROUT--025 ABORT.G Illegal semaphore number Incorrect number is specified for semaphore id. Cause: Remedy: Specify a number between 1 to 255. ROUT--026 WARN Illegal group number Invalid group number is specified. Cause: Remedy: Specify existing group number. ROUT--027 WARN String size not big enough Specified string variable does not have enough room to hold the return data. Cause: Remedy: Specify a larger size string variable. ROUT--028 ABORT.G Illegal file attribute number Incorrect file attribute id was specified. Cause: Remedy: Specify a correct file attribute id. ROUT--029 ABORT.G Illegal file attribute value Incorrect file attribute value was specified. Cause: Remedy: Specify a correct attribute value. ROUT--030 WARN Non existent register number A register number, that does not exist, is specified. Cause: Remedy: Specify a correct register number. ROUT--031 WARN Illegal register type Incorrect register type is specified. Cause: Remedy: Specify the correct register type for the attempted operation. ROUT--032 ABORT.G Position type mismach Position type is not correct for the operation. Cause: Remedy: Specify correct position type. ROUT--033 ABORT.G Illegal attribute type Illegal attribute id was specified. Cause: Remedy: Specify correct attribute id. 923
ALARM CODES
B--81464EN--3/01
ROUT--034 WARN Not a TPE program A non-teach pendant program is specified. Cause: Remedy: Specify a program name other than a KAREL program. ROUT--035 WARN Value is out of range Internal error of software. Cause: ROUT--037 ABORT.G Bad TPE header size Value used in SET_HEAD_TPE for bfr_size is invalid. Cause: Remedy: Use buffer size in the range 1--255. ROUT--038 PAUSE.G Uninitialized TPE position It indicates that the position data in the specified line of the specified TP program has not been recorded. Cause: Remedy: Confirm the contents of position data. ROUT--039 WARN Executing motion exists Cannot unlock group while motion is executing. Cause: Remedy: Wait until executing motion has completed. ROUT--040 WARN Stopped motion exists Cannot unlock group while stopped motion exists. Cause: Remedy: Resume stopped motion and wait until motion has completed or cancel stopped motion. ROUT--041 Dym. disp. var. not static Internal system error. Cause: Remedy: Consult our service representative. ROUT--042 TPE parameters do not exist The parameter designated by param_no does not exist. Cause: Remedy: Confirm the param_no and the parameter in CALL/MACRO command in main TPE program.
SCIO Error Codes SCIO--001 constants type is illegal Internal system error. Cause: SCIO--002 data size is illegal Internal system error. Cause: SCIO--004 write flag is illegal. Internal system error. Cause: SCIO--005 top of string is not $ in scwrtpar Internal system error. Cause: SCIO--006 read line is illegal when call mmreadln Internal system error. Cause: SCIO--007 opw_sw is illegal in xxmov routine Internal system error. Cause: SCIO--008 interp. type is illegal Internal system error. Cause: SCIO--009 string size is illegal in xxstr routine Internal system error. Cause: 924
ALARM CODES
B--81464EN--3/01
SCIO--010 string size is illegal in xxlbl routine Internal system error. Cause: SCIO--011 string size is illegal in xxcal routine Internal system error. Cause: SCIO--012 string size is illegal in xxpar routine Internal system error. Cause: SCIO--013 string size is illegal in xxpro routine Internal system error. Cause: SCIO--014 opt_sw is illegal Internal system error. Cause: SCIO--015 pos type is illegal in xxmov routine Internal system error. Cause: SCIO--016 WARN This option does not exist This option does not exist Cause: Remedy: Confirm the bought option. SCIO--017 checksum did not match Internal system error. Cause: SCIO--018 option switch is illegal Internal system error. Cause: SCIO--019 chechk sum error pos_id =%d Internal system error. Cause: SCIO--020 WARN LBL[%d] exists in line %d: This label number exists in another line. Cause: Remedy: Select another label number. SCIO--022 EPT_idx is different from before power down Internal system error. Cause: SCIO--023 Line number is 0, when screcov is called Internal system error. Cause: SCIO--024 recov_sw is illegal Internal system error. Cause: SCIO--030 JOINT motion in slave program The single slave execution program and slave program of the robot link cannot use a joint motion Cause: Remedy:
instruction. For teaching, use a linear or circular motion instruction.
SCIO--031 JOINT position in slave program The single slave execution program and slave program of the robot link cannot use the joint position Cause: Remedy:
format for motion instruction position data. Use the orthogonal position format.
SCIO--032 Master UT mismatch The current tool coordinate system number of the master robot does not match the tool coordinate Cause: Remedy:
system number specified on the program detail screen. Modify the tool coordinate system number of the master robot. Alternatively, modify the tool coordinate system number of the master robot on the program detail screen.
925
ALARM CODES
B--81464EN--3/01
SCIO--033 Slave can have ony one motion line The robot link slave program allows only one line of motion instructions to be taught. Cause: Remedy: Ensure that the slave program contains only one line of motion instructions.
SRIO Error Codes SRIO--002 SERIAL PORT NOT OPEN Serial port is not opened. Cause: Remedy: Open serial port before using it. SRIO--003 SERIAL PORT ALREADY OPEN Serial port has already been opened, and it was tried to be opened again. Cause: Remedy: Do not try to open the serial port which has already be opened. SRIO--004 SERIAL PORT NOT INITIALIZE Serial port is not initialized. Cause: Remedy: Initialize the serial port before using it. SRIO--005 SERIAL PORT DSR OFF Serial port DSR is off. Cause: Remedy: Check if serial port setup is correct. Check if cable is broken. Check if there exists a noise source near controller. Check target device status.
SRIO--006 SERIAL PORT PARITY ERROR Serial port parity error occured. Cause: Remedy: Check if serial port setup is correct. Check if cable is broken. Check if there exists a noise source near controller.
SRIO--007 SERIAL PORT OVERRUN ERROR Serial port overrun error occured. Cause: Remedy: Check if serial port setup is correct. Check if cable is broken. Check if there exists a noise source near controller.
SRIO--008 SERIAL PORT FRAME ERROR Serial port frame error occured. Cause: Remedy: Check if serial port setup is correct. Check if cable is broken. Check if there exists a noise source near controller.
SRIO--009 S. PORT PARITY & OVERRUN Serial port parity error and overrun error occured. Cause: Remedy: Check if serial port setup is correct. Check if cable is broken. Check if there exists a noise source near controller.
SRIO--010 S. PORT PARITY & FRAME Serial port parity error and frame error occured Cause: Remedy: Check if serial port setup is correct. Check if cable is broken. Check if there exists a noise source near controller.
SRIO--011 S. PORT OVERRUN & FRAME Serial port overrun error and frame error occured. Cause: Remedy: Check if serial port setup is correct. Check if cable is broken. Check if there exists a noise source near controller.
SRIO--012 S. PORT PRTY & OVRRN & FRM Serial port parity error, overrun error, and frame error occured. Cause: Remedy: Check if serial port setup is correct. Check if cable is broken. Check if there exists a noise source near controller.
926
ALARM CODES
B--81464EN--3/01
SRIO--013 S. PORT DSR OFF & HARDWARE ERR Serial port DSR is off and harware error occured. Cause: Remedy: Check if serial port setup is correct. Check if cable is broken. Check if there exists a noise source near controller. Check target device status. Check the hardware.
FLPY Error Codes FLPY--001 End of directory reached Your listing has reached the end of the directory. Cause: Remedy: This is a notification. You do not have to do anything for this warning message. FLPY--002 File already exists The file name you are trying to create already exists on this device. Cause: Remedy: Delete the file of this name or choose a different file name. FLPY--003 File does not exist The file you are trying to open does not exist on this device. Cause: Remedy: Open a file that does exist on the device. FLPY--004 Unsupported command Operation is not supported on floppy disk. Cause: Remedy: Use only operations supported on floppy disk. FLPY--005 Disk is full The disk file capacity has been reached. Cause: Remedy: Delete some unneeded files or use a disk with sufficient free space. FLPY--006 End of file reached The end of the file was reached while reading. Cause: Remedy: Do not attempt to read beyond the end of a file. FLPY--008 Only one file may be opened An attempt was made to open more than one file. Cause: Remedy: Do not attempt to open more than one file at a time. FLPY--009 Communications error The protocol format was invalid. Cause: Remedy: Retry the operation. FLPY--015 Write protection violation The disk has write protection enabled. Cause: Remedy: Remove write protection from the disk or use a disk that is not write protected. FLPY--100 Directory read error The directory information is corrupted and unreadable. Cause: Remedy: Try another disk or reformat the disk. FLPY--101 Block check error The checksum data is bad. Cause: Remedy:
Data is corrupted on disk and can not be read. Try another disk, or reformat the disk
FLPY--103 Seek error There is a bad sector or track on the disk. Cause: Remedy: Clean the disk drive, try another disk, or reformat the disk. 927
ALARM CODES
B--81464EN--3/01
FLPY--104 Disk timeout The drive did not respond to a command. Cause: Remedy: Check the cable to the drive and make sure drive power is on. FLP--105 Write protection violation The disk has write protection enabled. Cause: Remedy: Remove write protection from the disk or use a disk that is not write protected. FLPY--106 Memory Card hardware error Memory Card hardware error is detected. Cause: Remedy: Check Memory Card I/F unit connection or battery of the card. FLPY--107 Not formatted card The Memory Card is not formatted. Cause: Remedy: Format the card with UTILITY menu on FILE screen.
FILE Error Codes FILE--001 Device not ready Specified file device is not ready. Cause: Remedy: Check if the device is mounted and ready to use. FILE--002 Device is Full Device is full. There is no more space to store data on the device. Cause: Remedy: Delete any unnecessary files or change to a new device. FILE--003 Device is protected Device is protected. So, you cannot write to the device. Cause: Remedy: Release the device protection. FILE--005 Device not mounted Device is not mounted. You should mount the device before using it. Cause: Remedy: Mount the correct file device. FILE--006 Device is already mounted You tried to mount the device which had been already mounted. Cause: Remedy: Mount device only once. FILE--008 Illegal device name Device name contains an illegal character. Cause: Remedy: Check spelling and validity of device name. FILE--009 Illegal logical unit number Illegal LUN is used. Cause: Remedy: This is an internal error. Check the validity of the logical unit number. FILE--010 Directory not found Specified directory does not exist Cause: Remedy: Check validity of directory name. FILE--011 Directory full Directory is full. Cause: Remedy:
You tried to create a file in the root directory which execeeded the maximum number of files allowed on the device. Delete unnecessary files in the root directory.
928
ALARM CODES
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FILE--012 Directory is protected You tried to write to a write protected directory. Cause: Remedy: Release the protection to the directory. FILE--013 Illegal directory name Directory name contains an illegal character. Cause: Remedy: Check spelling of directory name. FILE--014 File not found The specified file was not found. Cause: Remedy: Check that the file exists and that the file name was spelled correctly. FILE--015 File is protected You tried to access a protected file. Cause: Remedy: Release the protection from file. FILE--017 File not open You tried to access a file which is not open. Cause: Remedy: Open the file before accessing. FILE--018 File is already opened You tried to create/delete/rename a file which is already opened. Cause: Remedy: Close file before such operations. FILE--019 File is locked You tried to access a file which is locked. Cause: Remedy: Release the lock. FILE--020 Illegal file size File size is invalid. Cause: Remedy: Change file size to be correct. FILE--021 End of file End of file was detected. Cause: FILE--022 Illegal file name File name contains an illegal character. Cause: Remedy: Check spelling of file name. FILE--023 Illegal file number File number is illegal. Cause: Remedy: Use a valid file number which is the ID returned from an open request. FILE--024 Illegal file type File type contains an illegal character. Cause: Remedy: Check the spelling and validity of the file type. FILE--025 Illegal protection code File protection code is illegal. Cause: Remedy: Check if the protection code is correct. FILE--026 Illegal access mode File access mode is illegal. Cause: Remedy: Check if the access mode is correct. 929
ALARM CODES
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FILE--027 Illegal attribute File attribute in the SET_ATTRIBUTE request is illegal. Cause: Remedy: Check that attribute specified is valid. FILE--028 Illegal data block Data block is broken which is used in FIND_NEXT request. Cause: Remedy: You should keep the data block which is returned from the previous FIND_FIRST or FIND_NEXT request.
FILE--029 Command is not supported Illegal request command is specified. Cause: Remedy: Check if the request code is corect. FILE--030 Device lun table is full Device management table is full. Cause: Remedy: Dismount any unnecessary devices. FILE--031 Illegal path name Path name contains an illegal character. Cause: Remedy: Check if the path name is correct. FILE--032 Illegal parameter Illegal parameter is detected. Cause: Remedy: Check that all parameters for the request are valid. FILE--033 System file buffer full File management buffer is full. Cause: Remedy: Close unnecessary files. FILE--034 Illegal file position Illegal file position is specified. Cause: Remedy: Check that the file position parameter from SEEK request is positive and not beyond the end of file. FILE--035 Device not formatted You tried to access a unformatted device. Cause: Remedy: Format the device before using it. FILE--036 File already exist You tried to rename a file to an already existing file name. Cause: Remedy: Change the new file name to be unique or delete the existing file. FILE--037 Directory not empty You tried to remove a subdirectory which contains some files or directories. Cause: Remedy: Remove all files and directories in the subdirectory before removing subdirectory. FILE--038 File locked by too many tasks There are too many lock requests to same file. Cause: Remedy: Unlock any unnecessary file lock requests. FILE--039 Directory already exists You tried to create a sub--directory that already exists. Cause: Remedy: Use a unique name for new sub--directory FILE--040 Illegal file access mode You tried to read from a write only opened file or tried to write to a read only opened file. Cause: Remedy: Open a file with correct access mode. 930
ALARM CODES
B--81464EN--3/01
FILE--041 File not locked You tried to unlock file which you had not locked. Cause: Remedy: Don’t unlock a file that is not locked. You can only unlock files which YOU have locked.
SSPC Error Codes SSPC--001 Waiting until space gets clear Special checking space is not clear. Cause: SSPC--002 Occer dead lock condition The priority of space is invalid Cause: Remedy: Set the priority valid SSPC--003 AccuPath not allowed Space Check function is not compatible with AccuPath. Cause: Remedy:
AccuPath is not allowed. Not use AccuPath or disable space check function
SSPC--004 CTV option not allowed Space Check function is not compatible with Continuous Turn CTV option. The CTV motion option is Cause: Remedy:
not allowed. Remove CTV option or disable space check function
SSPC--011 APDT error (i) Internal error Cause: Remedy: Contact your FANUC customer service representative, and inform the representative of the character string indicated in (i) of the message.
SSPC--012 Invalid element (s:i j) The setting of model elements is incorrect. Cause: Remedy:
Example of display: “Invalid element (G:1 6)” The sixth model element of group1 is set incorrectly. “Invalid element (H:2 1)”The first model element of hand 2 is set incorrectly. Check the setting of model elements. Check that the setting of a link number and link type is correct.
SSPC--013 Invalid hand num (G:i UT:j) The hand number assigned to tool coordinate system number (UT:j) of group (G:i) is invalid. Cause: Remedy: On the model setting screen, check the hand number assignment. SSPC--014 Common frame setting (G:i) The inter--robot calibration of group (G:i) is not completed. Cause: Remedy: Perform inter--robot calibration. SSPC--015 Not calibrated (G:i) The calibration of group (G:i) is not completed. Cause: Remedy: Perform calibration. SSPC--016 Invalid comb type (C:i s) The model type on the (s) side (L [left], R[right]) of combination setting (C:i) is invalid. Cause: Remedy: On the model combination setting screen, check the model type. SSPC--017 Invalid comb index (C:i s) The model number on the (s) side (L[left], R[right]) of combination setting (C:i) is invalid. Cause: Remedy: On the model combination setting screen, check the model number. SSPC--018 APDT is not supported (G:i) The robot of group (G:i) does not support the proximity stop function. Cause: Remedy: On the model combination setting screen, check the model type and model number. 931
ALARM CODES
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SSPC--019 (G:i) is close to target An interference was detected. Cause: Remedy: The alarm can be released by an ordinary reset operation. SSPC--020 Invalid fixture obj (F:i) The teach group number of jig model (F:i) is invalid. Cause: Remedy: On the jig model setting screen, check the teach group number. SSPC--021 Too many settings There are an excessive number of model settings or combination settings. Cause: Remedy: Reduce the number of settings. SSPC--101 (G:i) is close to target Proximity was detected. ( i: Group number) Cause: Remedy: The alarm can be released by an ordinary reset operation. SSPC--101 SSPC--102 (G:i) is close to target(qstop) Proximity was detected. ( i: Group number) Cause: Remedy: The alarm can be released by an ordinary reset operation. SSPC--103 (G:i) is near to target A gradual stop occurred. ( i: Group number) Cause: Remedy: The alarm can be released by an ordinary reset operation. SSPC--104 APDT error (i) Internal error ( i: Error number) Cause: Remedy: This alarm is not issued usually. Inform your FANUC customer service representative of the numeric value indicated in (i) of the message.
SSPC--105 Too many settings There are an excessive number of model settings or combination settings. Cause: Remedy: Reduce the number of settings. SSPC--106 Failed to get dist (j,C:i) The distance between model elements could not be calculated. Cause: Remedy: SSPC--111. This alarm is not issued usually. Inform your FANUC customer service representative of the numeric value indicated in (j,C:i) of the message.
SSPC--111 Invalid comb type (ST,C:i,s) The model type on the (s) side (L[left], R[right]) of combination number (C:i) in the proximity stop Cause: Remedy:
combination setting is invalid. On the proximity stop combination setting screen, check the model type.
SSPC--112 Invalid comb index(ST,C:i,s) The model number on the (s) side (L[left], R[right]) of combination number (C:i) in the proximity stop Cause: Remedy:
combination setting is invalid. On the proximity stop model combination setting screen, check the model number.
SSPC--113 APDT isn’t supported (ST,G:i) The robot of group (G:i) does not support the proximity stop function. Cause: Remedy: On the proximity stop combination setting screen, check the model type and model number. SSPC--114 Not calibrated (ST,G:i) The calibration of group (G:i) is not completed. Cause: Remedy: Perform calibration. 932
ALARM CODES
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SSPC--115 Invalid utool number (ST,G:i) The tool coordinate system number of group (G:i) is invalid. Cause: Remedy: Check the tool coordinate system number. SSPC--116 Invalid hand num(ST,G:i,UT:j) The hand number assigned to tool coordinate system number (UT:j) of group (G:i) is invalid. Cause: Remedy: On the model setting screen, check the hand number assignment. SSPC--117 Common frame setting (ST,G:i) The inter--robot calibration of group (G:i) is not completed. Cause: Remedy: SSPC--111. Perform inter--robot calibration. SSPC--118 Invalid element (ST,s:i,j) The setting of model elements is incorrect. Cause: Remedy:
Example of display: “Invalid element (ST,G:1 6) ”The sixth model element of group1 is set incorrectly. “Invalid element (ST ,H:2 1)”The first model element of hand 2 is set incorrectly. Check the setting of model elements. Check that the setting of a link number and link type is correct.
SSPC--119 Can’t get elem pos(ST,G:i,j) The current position of a model element could not be calculated. Cause: Remedy: This alarm is not issued usually. Inform your FANUC customer service representative of the numeric value indicated in (ST,G:i, j) of the message.
SSPC--120 Invalid fixture obj (ST,F:i) The teach group number of jig model (F:i) is invalid. Cause: Remedy: On the jig model setting screen, check the teach group number. SSPC--131 Invalid comb type (WT,C:i,s) The model type on the (s) side (L[left], R[right]) of combination number (C:i) in the proximity wait Cause: Remedy:
combination setting is invalid. On the proximity wait combination setting screen, check the model type.
SSPC--132 Invalid comb index(WT,C: i,s) The model number on the (s) side (L[left], R[right]) of combination number (C:i) in the proximity wait Cause: Remedy:
combination setting is invalid. On the proximity wait combination setting screen, check the model number.
SSPC--133 APDT isn’t supported (WT,G:i) The robot of group (G:i) does not support the proximity wait function. Cause: Remedy: On the proximity wait combination setting screen, check the model type and number. SSPC--134 Not calibrated (WT,G:i) The calibration of group (G:i) is not completed. Cause: Remedy: Perform calibration. SSPC--135 Invalid utool number (WT,G:i) The tool coordinate system number of group (G:i) is invalid. Cause: Remedy: Check the tool coordinate system number. SSPC--136 Invalid hand num(WT,G:i,UT:j) The hand number assigned to tool coordinate system number (UT:j) of group (G:i) is invalid. Cause: Remedy: On the model setting screen, check the hand number assignment. SSPC--137 Common frame setting (WT,G:i) The inter--robot calibration of group (G:i) is not completed. Cause: Remedy: Perform inter--robot calibration. 933
ALARM CODES
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SSPC--138 Invalid element (WT,s:i,j) The setting of model elements is incorrect. Cause:
Remedy:
Example of display: “Invalid element (WT,G:1 6)”The sixth model element of group1 is set incorrectly. “Invalid element (WT,H:2 1)”The first model element of hand 2 is set incorrectly. Check the setting of model elements. Check that the setting of a link number and link type is correct.
SSPC--139 Can’t get elem pos(WT,G:i,j) The current position of a model element could not be calculated. Cause: Remedy: This alarm is not issued usually. Contact your FANUC customer service representative of the numeric value indicated in (WT,G:i, j) of the message.
SSPC--140 Invalid fixture obj (WT,F:i) The teach group number of jig model (F:i) is invalid. Cause: Remedy: On the jig model setting screen, check the teach group number. SSPC--151 App_STOP (ST,C:i) is disabled An attempt was made to temporarily disable invalid proximity stop combination (C:i) on the setting Cause: Remedy:
screen with a program instruction. Enable the proximity stop combination on the setting screen before using it.
SSPC--152 App_STOP (ST,C:i) is disabled An attempt was made to temporarily disable invalid proximity stop combination (C:i) on the setting Cause: Remedy:
screen with a program instruction. Enable the proximity stop combination on the setting screen before using it.
SSPC--153 (WT,C:i) is enabled by other An attempt was made to enable/disable proximity wait condition number (C:i) already enabled by Cause: Remedy:
another task. The proximity wait condition number is currently used by another program. Use it after it is freed.
SSPC--154 (ST,C:i) is disabled by other The proximity stop instruction was used for proximity stop condition number (C:i) being used by another Cause: Remedy:
task. The proximity stop condition number is currently used by another program. Use it after it is freed.
SSPC--155 Invalid host name (ST,C:i) In a specified proximity stop combination, an invalid host name is set. Cause: Remedy: On the host communication screen of the setting screen, check the host name. Set a correct host name.
SSPC--156 Invalid host name (WT,C:i) In a specified proximity wait combination (C:i), an invalid host name is set. Cause: Remedy: On the host communication screen of the setting screen, check the host name. Set a correct host name.
SSPC--157 Intrupt signal (WT,C:i) In the proximity wait state, the proximity wait halt signal was input. Cause: Remedy: If the halt is unexpected, check the setting of the proximity wait halt signal. Moreover, check if the same signal is used for another purpose.
SSPC--158 App_WAIT timeout (WT,C:i) In the proximity wait state, the time set in time--out has elapsed. Cause: Remedy: Adjust the wait time. To wait infinitely, set 0 in “time--out” on the proximity wait combination setting screen.
934
ALARM CODES
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SSPC--159 App_WAIT can’t be used(WT,G:i) In the following operations, automatic stop/restart based on the proximity wait function cannot be Cause: performed: F When slave robot follow--up operation is being performed based on robot link synchronization F When the continuous rotation function is being used
Remedy:
Do not use any of the two functions above at the time of automatic stop/restart operation.
SSPC--160 App_STOP is TMP_DISed(ST,C:i) This message is output for confirmation when combination (C:i) is temporarily disabled by the proximity Cause: stop instruction.
Remedy: SSPC--161 App_STOP is enabled (ST,C:i) This alarm is issued in the following cases: Cause: Case where the program is temporarily stopped with combination (C:i) temporarily disabled by the proximity stop instruction, then is restarted by changing the line
F
Case where the program is temporarily stopped with combination (C:i) temporarily disabled by the proximity stop instruction, then is executed after retraction
F
After this alarm is issued, the combination is not temporarily disabled even if the program is restarted.
Remedy:
When the program is restarted by changing the line, reply NO in response to the confirmation message to prevent execution from being disabled.
SSPC--162 App_WAIT is enabled (WT,C:i) This message is issued for confirmation when combination (C:i) is enabled by the proximity wait Cause: instruction.
Remedy: SSPC--163 App_WAIT is disabled (WT,C:i) This alarm is issued in the following cases: Cause: Case where the program is temporarily stopped with combination (C:i) enabled by the proximity wait instruction, then is restarted by changing the line
F
Case where the program is temporarily stopped with combination (C:i) enabled by the proximity wait instruction, then is executed after retraction
F
After this alarm is issued, the proximity wait function is disabled even if the program is restarted.
Remedy:
When the program is restarted by changing the line, reply NO in response to the confirmation message to prevent execution from being disabled.
SSPC--168 (s,i) invalid group number An invalid group number is specified with the proximity stop sensitivity instruction. Cause: Remedy: Specify a correct group number. (s: Program name, i: Line number) SSPC--169 PAUSE.G (s, i) invalid rate value An invalid sensitivity is specified with the proximity stop sensitivity instruction. (s: Program name, i: Line Cause: Remedy:
number) Enter a correct value (0 to 100).
SSPC--181 Comm init error i s An error occurred at communication initialization time. (i: Error cause number, s: Control unit name) Cause: Remedy: For the control unit name indicated by the error message, check the address setting, host name, and communication line state.
SSPC--182 Invalid hostname (s) After the setting of a new control unit name with a proximity stop or proximity wait combination, an Cause: Remedy:
attempt was made to enable the setting before the power is turned off then back on. Alternatively, an invalid control unit name is specified. (s: Control unit name) When a new control unit name is specified, the power must be turned off then back on for the setting to become effective. Moreover, check the control unit name on the host communication setting screen.
935
ALARM CODES
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SSPC--183 Invalid address (s) For the control unit name for which this alarm is issued, the communication address setting is incorrect. Cause: Remedy:
(s: Control unit name) The control unit name and its address must be checked and modified as required. Next, the power must be turned off then back on for the setting to become effective.
SSPC--184 Number of host exceed limit The number of control units specifiable for proximity stop setting and proximity wait setting on one Cause: Remedy:
control unit exceeded the limit. Delete unused control units, if any, from the proximity stop setting screen and the proximity wait setting screen. Alternatively, reduce the number of control units specified.
SSPC--185 Number of element exceed limit The number of elements whose settings can be enabled on one control unit exceeded the limit. Cause: Remedy: Check the settings of elements, and disable the settings of those elements that may not be used. Alternatively, reduce the number of elements whose settings are enabled.
SSPC--186 Invalid element (s,i,j) The setting of an element of the control unit indicated by the control unit name in this alarm message Cause:
Remedy:
is invalid. (s: Control unit name, i: Element type, j: Element number) Element type 1 represents the robot, element type 2 represents the hand, and element type 3 represents the jig. Check and modify the setting of the element.
SSPC--187 Receive invalid data i s Data received from another control unit contains an error. Cause: Remedy: Check if an error has occurred on the source control unit or hub. SSPC--188 Invalid data for send i Data to be sent to another control unit contains an error. Cause: Remedy: SSPC--111. Open the element setting screen, then check if the settings are correct and also check if all data is displayed correctly. If this alarm is issued even when all elements are set correctly, contact your FANUC customer service representative.
SSPC--189 Timeout element (s,i,j) The position data of a remote element received from another control unit is obsolete. Cause: Remedy:
Communication with the control unit may have been disconnected. (s: Control unit name, i: Element type, j: Element number) If communication is disconnected, the no--response alarm is usually issued. Turn off the power, then turn on the power.
SSPC--190 No communication (s) This alarm is issued when no response is received from another control unit. (s: Control unit name) Cause:
Remedy:
This function does not communicate with a control unit not specified as a proximity stop or proximity wait target. So, this alarm is issued also when the control unit indicated in the alarm does not have a proximity stop or proximity wait setting made for the target control unit. Check the communication line cabling, and the address, host name, and hub settings. Moreover, on the remote control unit as well, make a proximity stop or proximity wait setting for the target control unit.
936
ALARM CODES
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SSPC--191 Target elem not exist(ST,C:i,s) The element on the (s) side (L[left], AR[right]) of proximity stop combination (C:i) contains an error. Cause: There may be one of the following errors: F A nonexistent element type or number is specified. F
A nonexistent group is specified.
F
All elements of the target $IA_GRP.$ROBOT, $IA_HAND, or $IA_FOBJ are disabled.
The communication destination control unit does not have a target set correctly for a cause indicated above or because of nonexecution of calibration.
F
Remedy:
Check the items listed above.
SSPC--192 Target elem not exist(PA,C:i,s) The element on the (s) side (L[left], AR[right]) of proximity wait combination (C:i) contains an error. Cause: There may be one of the following errors: F A nonexistent element type or number is specified. F
A nonexistent group is specified.
F
All elements of the target $IA_GRP.$ROBOT, $IA_HAND, or $IA_FOBJ are disabled.
The communication destination control unit does not have a target set correctly for a cause indicated above or because of nonexecution of calibration.
F
Remedy:
Check the items listed above.
SSPC--193 IAL detect overload (i) The operation, communication processing, proximity stop processing, and proximity wait processing Cause: Remedy:
in the control unit are causing an overload. For the current robot setting, the interpolation period may be is too short. This alarm is not issued usually. Contact your FANUC customer service representative.
CNTR Error Codes CNTR--004 WARN No cnir pointer Internal software error. Cause: Remedy: Contact your FANUC service center. CNTR--005 WARN Wrong CN Axis/N1 or N2 (G:i) The number of the continuous rotation axis is invalid. Cause: Remedy: Set a valid axis number. CNTR--006 WARN Unable to Allocate Memory Internal software error. Cause: Remedy: Contact your FANUC service center. CNTR--007 STOP.G Serious Internal error (G:i) Internal software error. Cause: Remedy: Contact your FANUC service center. CNTR--008 STOP.G Invalid dest.angle (G:i) An operation option that cannot be used with the continuous rotation function is specified. Cause: Remedy: Check the operation option. CNTR--009 WARN Warn--Cont Vel too high (G:i) The continuous rotation speed is relatively high. Cause: Remedy: This does not present any problem. Ignore this message. CNTR--010 STOP.G Ind.EV option not allowed Both an additional axis speed instruction and continuous rotation instruction are used. Cause: Remedy: Delete either instruction. 937
ALARM CODES
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CNTR--011 STOP.G Axis speed exceeds lim (G:i) The continuous rotation speed exceeds the upper limit. Cause: Remedy: Decrease the continuous rotation speed. CNTR--012 STOP.G Ending Cont Rot on Rel Motion The continuous rotation speed instruction ended with a relative operation. Cause: Remedy: Check the operation add instruction used together with the continuous rotation instruction.
RTCP Error Codes RTCP--001 Wrist Joint is not allow Wrist Joint is used on the resume motion. Cause: Remedy: RTCP does not coexist with Wrist Joint. Normally, Wrist Joint is used with the resume motion, so this error always occurs. Change the setting about the resume motion and do not use wrist joint.
TAST Error Codes TAST--000 WARN An internal software error has occurred. Cause: Remedy: Turn the power off and on. TAST--001 WARN The arc sensor system variable is not loaded. Cause: Remedy: Turn the power on in the control start mode, then initialize motion software parts. TAST--002 STOP.G The I/O memory could not be allocated. Cause: Remedy: Turn the power off and on. TAST--003 STOP.G The analog signals could not be allocated. Cause: Remedy: The process I/O printed circuit board could not be initialized. TAST--004 STOP.G An internal software error has occurred. Cause: Remedy: Turn the power off and on. TAST--005 WARN An internal software error has occurred. Cause: Remedy: Decrease the frequency. Alternatively, increase the sampling period. TAST--006 STOP.G An internal software error has occurred. Cause: Remedy: Turn the power off and on. TAST--007 WARN An internal software error has occurred. Cause: Remedy: Turn the power off and on. TAST--008 STOP.G The arc sensor schedule number is incorrect. Cause: Remedy: Change the schedule number. TAST--009 STOP.G The weaving frequency is too low. Cause: Remedy: Increase the frequency. 938
ALARM CODES
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TAST--010 STOP.G An internal software error has occurred. Cause: Remedy: Turn the power off and on. TAST--011 STOP.G An internal software error has occurred. Cause: Remedy: Turn the power off and on. TAST--012 STOP.G An internal software error has occurred. Cause: Remedy: Turn the power off and on. TAST--013 STOP.G An internal software error has occurred. Cause: Remedy: Turn the power off and on. TAST--014 STOP.G The weaving frequency is too high. Cause: Remedy: Lower the weaving frequency.
WEAV Error Codes
( ID = 45 )
WEAV--000 WARN An internal software error has occurred. Cause: Remedy: Turn the power off and on. WEAV--001 WARN An internal software error has occurred. Cause: Remedy: Start up in the control start mode, then initialize the motion software parts. WEAV--002 STOP.G An internal software error has occurred. Cause: Remedy: Turn the power off and on. WEAV--003 STOP.G The memory space is insufficient. Cause: Remedy: Erase an unnecessary file. WEAV--004 STOP.G The weaving system variable is not loaded or is not initialized. Cause: Remedy: Start up in the control start mode, then initialize the system variable. WEAV--005 STOP.G An internal software error has occurred. Cause: Remedy: Delete the line. WEAV--006 STOP.G The weaving schedule number is incorrect. Cause: Remedy: Change the schedule number to a value within the correct range. WEAV--007 STOP.G The weaving frequency is incorrect. Cause: Remedy: Change the frequency to a value within the correct range. WEAV--008 STOP.G The amplitude is incorrect. Cause: Remedy: Specify a value within the correct range. 939
ALARM CODES
B--81464EN--3/01
WEAV--009 STOP.G The value of the end point timer is incorrect. Cause: Remedy: Specify a value within the correct range. WEAV--010 WARN Multiple weaving instructions were executed in advance. Cause: Remedy: No remedy is required. WEAV--011 WARN An internal software error has occurred. Cause: Remedy: Turn the power off and on. WEAV--012 WARN A multi--group program cannot use the end--point stop function. Cause: Remedy: Set #812--12--1 in the end--point stop field on the weave setup screen. WEAV--013 WARN The weaving direction is incorrect. The weaving direction cannot be calculated. Cause: Remedy: To calculate a correct weaving direction, change the user coordinate system setting or the direction of the welding path.
940
SYSTEM VARIABLES
B--81464EN--3/01
E. SYSTEM VARIABLES This part of this manual describes the names, functions, standard settings, and valid ranges of system variables. j Contents of this appendix E.1 Format of a System Variable Table E.2 System Variables
941
SYSTEM VARIABLES
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E.1 Format of a System Variable Table Whether the power must be turned off then on again
System variable name
$PARAM_GROUP [ group ] . $PPABN_ENBL BOOLEAN Variable type
Table E--1.
RW
PU
Standard value
TRUE TRUE / FALSE
Changeable/unchangeable
Valid range
Format of a system variable table
System variable name Standard value
* Intrinsic value for each model
Variable type
BOOLEAN
True/false type (TRUE/FALSE)
BYTE
Integer (0 to 255)
SHORT
Integer (--32768 to 32767)
INTEGER
Integer (--1000000 to 1000000)
REAL
Real number (--10000000000 to 1000000000)
CHAR
Character string (“abcdefg”)
XYZWPR
Cartesian coordinates
RW
Changeable
RO
Unchangeable
PU
Indicates that the power must be turned on again.
Changeable/unchangeable
Whether the power must be turned off then on again Valid range (unit)
942
SYSTEM VARIABLES
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Procedure E--1 Step
Setting a system variable
1 Press the MENUS key. 2 Select 0 (NEXT), then select 6 (SYSTEM). 3 Press the F1 (TYPE) key. 4 Select Variables. Then, the system variable screen is displayed.
9 USER 0 -- NEXT --
SYSTEM Variables 1 2 3 4 5 6 7 8 9 10
MENUS
5 POSITION 6 SYSTEM 7
JOINT 10% 1/98
$AP_MAXAX $AP_PLUGGED $AP_TOTALAX $AP_USENUM $AUTOINIT $BLT $CRT_DEFPROG $CSTOP $DEFPULSE $DEVICE
536870912 4 16777216 [12] of Byte 2 19920216 *uninit* TRUE 4 ’P3:’
[TYPE]
Variables TYPE
F1 5 To change the value of a system variable, move the cursor to a desired item, enter a new value, then press the ENTER key or select a desired item by pressing the corresponding function key. 6 When a system variable contains multiple system variables, move the cursor to a desired item and press the ENTER key. Then, the low--order system variables are displayed. SYSTEM Variables
ENTER
47 48 49 50
JOINT 10% 49/98
$ORIENTTOL $OVRDSLCT $PARAM_GROUP $PASSWORD
10.000 OVRDSLCT_T MRR_GRP_T PASSWORD_T
SYSTEM Variables $PARAM_GROUP 1 $BELT_ENABLE 2 $CART_ACCEL1 3 $CART_ACCEL2 4 $CIRC_RATE 5 $CONTAXISNUM 6 $EXP_ENBL
JOINT 10% 49/98 FALSE 192 0 1 0 TRUE
[TYPE]
7 After changing the setting of the system variable for which PU is specified, turn off the power, then turn it on again. (PU is specified for all $PARAM_GROUP system variables.) NOTE The setting of a system variable for which RO (unchangeable) is specified cannot be changed.
943
SYSTEM VARIABLES
B--81464EN--3/01
E.2 System Variables Power failure recovery $PARAM_GROUP[ group ] . $SV_OFF_ALL BOOLEAN RW PU TRUE / FALSE [Function]
TRUE
Enables or disables the brake control function
[Description] Specifies how the brakes are applied. TRUE: It sets on/off brakes for all axes at the same time, i.e. it does not put on all brakes until all axes finish moving and it shuts off all brakes when one axis starts to move. FALSE: It allows the brakes to engage after the conditions specified in $SV_OFF_ENB and $SV_OFF_TIME are satisfied. Mastering $MASTER_ENB
0
ULONG [Function]
RW
1/0
Displays positioning screen
[Description] When this variable is enabled, the positioning screen [6 (SYSTEM).Master/Cal] is displayed on the teach pendant. 0: Positioning screen not displayed. 1: Positioning screen displayed. $DMR_GRP[ group ]. $MASTER_DONE BOOLEAN [Function]
RW
TRUE
TRUE / FALSE
Indicates if mastering is completed.
[Description] Indicates if mastering has been completed. [Setting]
On the positioning screen [6 (SYSTEM).Master/Cal]
$DMR_GRP[ group ]. $MASTER_COUN[ 1 ]
*
$DMR_GRP[ group ]. $MASTER_COUN[ 2 ]
*
$DMR_GRP[ group ]. $MASTER_COUN[ 3 ]
*
$DMR_GRP[ group ]. $MASTER_COUN[ 4 ]
*
$DMR_GRP[ group ]. $MASTER_COUN[ 5 ]
*
$DMR_GRP[ group ]. $MASTER_COUN[ 6 ]
*
$DMR_GRP[ group ]. $MASTER_COUN[ 7 ]
*
$DMR_GRP[ group ]. $MASTER_COUN[ 8 ]
*
$DMR_GRP[ group ]. $MASTER_COUN[ 9 ]
*
INTEGER [Function]
RW
0 to 100000000 ( pulse )
Store mastering pulse counts
[Description] Pulse coder count at zero degree position is stored. This value is calculated from current count at mastering and current position. $PARAM_GROUP[ group ]. $MASTER_POS[ 1 ]
*
$PARAM_GROUP[ group ]. $MASTER_POS[ 2 ]
*
$PARAM_GROUP[ group ]. $MASTER_POS[ 3 ]
*
$PARAM_GROUP[ group ]. $MASTER_POS[ 4 ]
*
$PARAM_GROUP[ group ]. $MASTER_POS[ 5 ]
*
$PARAM_GROUP[ group ]. $MASTER_POS[ 6 ]
*
$PARAM_GROUP[ group ]. $MASTER_POS[ 7 ]
*
$PARAM_GROUP[ group ]. $MASTER_POS[ 8 ]
*
$PARAM_GROUP[ group ]. $MASTER_POS[ 9 ]
*
REAL [Function]
RW
PU
--100000 to 100000 ( deg )
Store jig position for jig mastering
[Description] Jig position for jig mastering is stored. Mastering pulse count is calculated from this data.
944
SYSTEM VARIABLES
B--81464EN--3/01
Quick mastering $DMR_GRP[ group ]. $REF_DONE BOOLEAN [Function]
RW
FALSE
TRUE / FALSE
Indicates if setting of the reference point for quick mastering is completed.
[Description] When the reference point of simple mastering is set, the pulse coder count and coordinate values of the reference position are stored. [Setting]
On the positioning screen [6 (SYSTEM).Master/Cal]
$DMR_GRP[ group ]. $REF_COUNT[ 1 ]
0
$DMR_GRP[ group ]. $REF_COUNT[ 2 ]
0
$DMR_GRP[ group ]. $REF_COUNT[ 3 ]
0
$DMR_GRP[ group ]. $REF_COUNT[ 4 ]
0
$DMR_GRP[ group ]. $REF_COUNT[ 5 ]
0
$DMR_GRP[ group ]. $REF_COUNT[ 6 ]
0
$DMR_GRP[ group ]. $REF_COUNT[ 7 ]
0
$DMR_GRP[ group ]. $REF_COUNT[ 8 ]
0
$DMR_GRP[ group ]. $REF_COUNT[ 9 ]
0
INTEGER [Function]
RW
0 to 100000000 ( pulse )
Store reference point mastering count
[Description] Store the count of the pulse coder when the robot is positioned at the reference point. $DMR_GRP[ group ]. $REF_POS[ 1 ]
0
$DMR_GRP[ group ]. $REF_POS[ 2 ]
0
$DMR_GRP[ group ]. $REF_POS[ 3 ]
0
$DMR_GRP[ group ]. $REF_POS[ 4 ]
0
$DMR_GRP[ group ]. $REF_POS[ 5 ]
0
$DMR_GRP[ group ]. $REF_POS[ 6 ]
0
$DMR_GRP[ group ]. $REF_POS[ 7 ]
0
$DMR_GRP[ group ]. $REF_POS[ 8 ]
0
$DMR_GRP[ group ]. $REF_POS[ 9 ]
0
REAL [Function]
RW
--100000 to 100000 ( deg )
Store reference point to be set during quick mastering
[Description] Store the reference point to be set during quick mastering. Positioning $MOR_GRP[ group ]. $CAL_DONE BOOLEAN [Function]
RW
TRUE
TRUE / FALSE
Indicates if calibration is completed.
[Description] To check the current position of the robot, the count of the pulse coder issued and the current position is calculated using mastering count. This check is usually performed when the power is turned on. [Setting]
On the positioning screen [6 (SYSTEM).Master/Cal]
945
SYSTEM VARIABLES
B--81464EN--3/01
Specifying coordinate systems $MNUFRAMENUM[ group ] BYTE [Function]
RW
0
0 to 9
Specifies user coordinate system number
[Description] Specifies the number of the user coordinate system currently used. 0: 1 to 9: [Setting]
World coordinate system User coordinate system
On the tool coordinate system setting & screen [6 SYSTEM, Coordinate, User]
$MNUFRAME[ group, 1 ]
XYZWPR
$MNUFRAME[ group, 2 ]
XYZWPR
$MNUFRAME[ group, 3 ]
XYZWPR
$MNUFRAME[ group, 4 ]
XYZWPR
$MNUFRAME[ gropu, 5 ]
XYZWPR
$MNUFRAME[ group, 6 ]
XYZWPR
$MNUFRAME[ group, 7 ]
XYZWPR
$MNUFRAME[ group, 8 ]
XYZWPR
$MNUFRAME[ group, 9 ]
XYZWPR
POSITION [Function]
RW
XYZWPR
Specifies user coordinates system number
[Description] Specifies the Cartesian coordinates in the user coordinate system. Up to nine user coordinate systems can be registered. $MNUTOOLNUM[ group ] BYTE [Function]
RW
0 0 to 9
Specifies tool coordinate system number
[Description] Specifies the number of the tool coordinate system currently used. 0: 1 to 9: [Setting]
Mechanical interface coordinate system Tool coordinate system
On the tool coordinate system setting screen [6 SYSTEM.Coordinate.Tool]
$MNUTOOL[ group, 1 ]
XYZWPR
$MNUTOOL[ group, 2 ]
XYZWPR
$MNUTOOL[ group, 3 ]
XYZWPR
$MNUTOOL[ group, 4 ]
XYZWPR
$MNUTOOL[ group, 5 ]
XYZWPR
$MNUTOOL[ group, 6 ]
XYZWPR
$MNUTOOL[ group, 7 ]
XYZWPR
$MNUTOOL[ group, 8 ]
XYZWPR
$MNUTOOL[ group, 9 ] POSITION [Function]
XYZWPR RW
XYZWPR
Specifies the tool coordinate system
[Description] Specify the Cartesian coordinates in the tool coordinate system. Nine tool coordinate systems can be registered. $JOG_GROUP[ group ]. $JOG_FRAME POSITION [Function]
RW
XYZWPR
XYZWPR
Specifies the jog coordinate system
[Description] Specifies the Cartesian coordinates in the jog coordinate system. [Setting]
On the jog coordinate system setting screen [6 SYSTEM, Coordinate, jog]
946
SYSTEM VARIABLES
B--81464EN--3/01
Setting motors $SCR_GRP[ group ]. $AXISORDER[ 1 ]
1
$SCR_GRP[ group ]. $AXISORDER[ 2 ]
2
$SCR_GRP[ group ]. $AXISORDER[ 3 ]
3
$SCR_GRP[ group ]. $AXISORDER[ 4 ]
4
$SCR_GRP[ group ]. $AXISORDER[ 5 ]
5
$SCR_GRP[ group ]. $AXISORDER[ 6 ]
6
$SCR_GRP[ group ]. $AXISORDER[ 7 ]
0
$SCR_GRP[ group ]. $AXISORDER[ 8 ]
0
$SCR_GRP[ group ]. $AXISORDER[ 9 ]
0
BYTE [Function]
RW
0 to 16
Specify axis order
[Description] Specifies the order of axes by assigning the physical number of a servo motor controlled by the servo amplifier (servo register) to the logical number of a robot joint axis specified in software (Jx--axis). For instance, when $AXISORDER[1] = 2, servo motor 2 is assigned to the J1--axis. When $AXISORDER[1] = 0, no servo motor is assigned as the J1--axis. $SCR_GRP[ group ]. $ROTARY_AXS[ 1 ]
*
$SCR_GRP[ group ]. $ROTARY_AXS[ 2 ]
*
$SCR_GRP[ group ]. $ROTARY_AXS[ 3 ]
*
$SCR_GRP[ group ]. $ROTARY_AXS[ 4 ]
*
$SCR_GRP[ group ]. $ROTARY_AXS[ 5 ]
*
$SCR_GRP[ group ]. $ROTARY_AXS[ 6 ]
*
$SCR_GRP[ group ]. $ROTARY_AXS[ 7 ]
*
$SCR_GRP[ group ]. $ROTARY_AXS[ 8 ]
*
$SCR_GRP[ group ]. $ROTARY_AXS[ 9 ]
*
BOOLEAN [Function]
RO
TRUE / FALSE
Specify axis type
[Description] Specifies whether joint axes of the robot are rotational or linear. TRUE: Rotational FALSE: Linear $PARAM_GROUP[ group ]. $MOSIGN[ 1 ]
*
$PARAM_GROUP[ group ]. $MOSIGN[ 2 ]
*
$PARAM_GROUP[ group ]. $MOSIGN[ 3 ]
*
$PARAM_GROUP[ group ]. $MOSIGN[ 4 ]
*
$PARAM_GROUP[ group ]. $MOSIGN[ 5 ]
*
$PARAM_GROUP[ group ]. $MOSIGN[ 6 ]
*
$PARAM_GROUP[ group ]. $MOSIGN[ 7 ]
*
$PARAM_GROUP[ group ]. $MOSIGN[ 8 ]
*
$PARAM_GROUP[ group ]. $MOSIGN[ 9 ]
*
BOOLEAN [Function]
RW
PU
TRUE / FALSE
Specify direction of rotation around axes
[Description] Specify whether the robot moves in the positive or negative direction when the motor rotates positively for each axis. TRUE: The robot moves in a positive direction when the motor rotates positively. FALSE: The robot moves in a negative direction when the motor rotates positively.
947
SYSTEM VARIABLES
B--81464EN--3/01
$PARAM_GROUP[ group ]. $ENCSCALES[ 1 ]
*
$PARAM_GROUP[ group ]. $ENCSCALES[ 2 ]
*
$PARAM_GROUP[ group ]. $ENCSCALES[ 3 ]
*
$PARAM_GROUP[ group ]. $ENCSCALES[ 4 ]
*
$PARAM_GROUP[ group ]. $ENCSCALES[ 5 ]
*
$PARAM_GROUP[ group ]. $ENCSCALES[ 6 ]
*
$PARAM_GROUP[ group ]. $ENCSCALES[ 7 ]
*
$PARAM_GROUP[ group ]. $ENCSCALES[ 8 ]
*
$PARAM_GROUP[ group ]. $ENCSCALES[ 9 ]
*
REAL [Function]
RW
PU
--10000000000 to 10000000000 ( pulse/deg, pulse/mm )
Specify unit of pulse coder count
[Description] Specify how many pulses are required for the pulse coder when the robot moves around a joint axis one degree or the robot moves along a joint axis 1 mm. Rotation axis: $ENCSCALES = 2E19 x deceleration ratio/360 $PARAM_GROUP[ group ]. $MOT_SPD_LIM[ 1 ]
*
$PARAM_GROUP[ group ]. $MOT_SPD_LIM[ 2 ]
*
$PARAM_GROUP[ group ]. $MOT_SPD_LIM[ 3 ]
*
$PARAM_GROUP[ group ]. $MOT_SPD_LIM[ 4 ]
*
$PARAM_GROUP[ group ]. $MOT_SPD_LIM[ 5 ]
*
$PARAM_GROUP[ group ]. $MOT_SPD_LIM[ 6 ]
*
$PARAM_GROUP[ group ]. $MOT_SPD_LIM[ 7 ]
*
$PARAM_GROUP[ group ]. $MOT_SPD_LIM[ 8 ]
*
$PARAM_GROUP[ group ]. $MOT_SPD_LIM[ 9 ]
*
INTEGER [Function]
RW
PU
0 to 100000 ( rpm )
Specify maximum motor speed
[Description] Specifies the maximum speed of each servo motor for the robot for each axis. When the robot moves around or along a certain axis at a speed exceeding the maximum speed, a warning is issued. Then, the robot decelerates and moves at a speed not exceeding the maximum speed. In this case, the robot may not trace the specified path. Override $SHIFTOV_ENB
0
ULONG [Function]
RW
0/1
Enables or disables shift override
[Description] The shift override function changes the feedrate override in five steps. To change the feedrate override, press and hold down the SHIFT key, then press the override key as many times as necessary to select the desired override. 1: Enables shift override. 0: Disables shift override. Press and hold down the SHIFT key, then press the override key: The feedrate override changes in the order: VFINE → FINE → 5% → 50% → 100%. $MCR. $GENOVERRIDE INTEGER [Function]
10 RW
0 to 100 ( % )
Specifies the rate of change in feedrate override
[Description] Specifies the rate of changes in the robot feedrate in percentage. The feedrate changes in this order: FINE → VFINE → 0% → 50% → 100%. From 0% to 100% it changes in 5% increments. [Setting]
Use the override keys on the teach pendant.
948
SYSTEM VARIABLES
B--81464EN--3/01
$MCR. $PROGOVERRIDE INTEGER [Function]
100 RW
0 to 100 ( % )
Specifies program override
[Description] Specifies the percentage of the robot feedrate while the program is being played back. $SCR_GRP . $JOGLIM INTEGER [Function]
12 RO
0 to 100%
Maximum speed scale for coordinate jogging
[Description] Percentage of the maximum speed when jogging the robot in the x, y, or z directions using XYZ or TOOL frame. The maximum speed at linear motion is specified in $PARAM_GROUP[group].$SPEEDLIM. $SCR . $JOGLIMROT INTEGER [Function]
12 RO
0 to 100%
Maximum speed scale for orientation jogging
[Description] Percentage of the maximum speed when jogging the robot about the x, y, or z axes using XYZ or TOOL frame. The maximum speed at orientation motion is specified in $PARAM_GROUP[group].$ROTSPEEDLIM. $SCR_GRP[ group ]. $JOGLIM_JNT[ 1 ]
*
$SCR_GRP[ group ]. $JOGLIM_JNT[ 2 ]
*
$SCR_GRP[ group ]. $JOGLIM_JNT[ 3 ]
*
$SCR_GRP[ group ]. $JOGLIM_JNT[ 4 ]
*
$SCR_GRP[ group ]. $JOGLIM_JNT[ 5 ]
*
$SCR_GRP[ group ]. $JOGLIM_JNT[ 6 ]
*
$SCR_GRP[ group ]. $JOGLIM_JNT[ 7 ]
*
$SCR_GRP[ group ]. $JOGLIM_JNT[ 8 ]
*
$SCR_GRP[ group ]. $JOGLIM_JNT[ 9 ]
*
INTEGER [Function]
RO
0 to 100 ( % )
Specify joint jog override
[Description] The joint jog override function specifies the percentage of the robot feedrate for each axis during jog feed. Specify a low jog override because it is generally unnecessary to move the robot at high speed, and because it is always prudent to avoid danger. $SCR. $COLDOVRD INTEGER [Function]
10 RO
0 to 100 ( % )
Specifies maximum feedrate override after a cold start
[Description] The feedrate override is set to this value after a cold start. $SCR. $COORDOVRD INTEGER [Function]
10 RO
0 to 100 ( % )
Specifies maximum feedrate override when the manual--feed coordinate system is changed
[Description] The feedrate override is set to this value or less when the manual--feed coordinate system is changed. $SCR. $TPENBLEOVRD INTEGER [Function]
10 RO
0 to 100 ( % )
Specifies the maximum feedrate override when the teach pendant is enabled
[Description] The feedrate override is set to this value when the teach pendant is enabled. $SCR. $JOGOVLIM INTEGER [Function]
100 RO
0 to 100 ( % )
Specifies the maximum feedrate override during jog feed
[Description] The feedrate override is set to this value or less during jog feed.
949
SYSTEM VARIABLES
B--81464EN--3/01
$SCR. $RUNOVLIM INTEGER [Function]
50 RO
0 to 100 ( % )
Specifies the maximum feedrate override when the program is executed
[Description] The feedrate override is set to this value or less when the program is executed. $SCR. $FENCEOVRD INTEGER [Function]
RO
0 to 100(%)
Maximum feedrate override when the safety fence is open
[Description] When the safety fence is opened (*SFSPD input is turned off), the feedrate override is set to this value or below. $SCR. $SFJOGOVLIM INTEGER [Function]
50 RO
0 to 100(%)
Maximum feedrate override of jog feed when the safety fence is open
[Description] If jog feed is performed while the safety fence is open, the feedrate override is set to this value or below. $SCR. $SFRUNOVLIM INTEGER [Function]
30 RO
0 to 100(%)
Maximum feedrate override of program execution while the safety fence is open
[Description] When a program is executed with the safety fence open (*SFSPD input set off), the feedrate override is set to this value or below. $SCR. $RECOV_OVRD BOOLEAN [Function]
FALSE RW
TRUE/FALSE
Function to restore feedrate override when the safety fence is closed
[Description] When the safety fence is closed (*SFSPD input set on), the previous feedrate override is restored. Then, automatic operation can be started immediately. This function is enabled when the following conditions are satisfied: 1 $SCR.$RECOV_OVRD is set to TRUE. 2 The system is in the remote state. 3 The feedrate override is not changed while the safety fence is open. If the safety fence is closed while the above conditions are not satisfied, the previous override cannot be restored. [Setting]
General item setting screen [6 SETTING, GENERAL]
Feedrate $PARAM_GROUP[ group ]. $JNTVELLIM[ 1 ]
*
$PARAM_GROUP[ group ]. $JNTVELLIM[ 2 ]
*
$PARAM_GROUP[ group ]. $JNTVELLIM[ 3 ]
*
$PARAM_GROUP[ group ]. $JNTVELLIM[ 4 ]
*
$PARAM_GROUP[ group ]. $JNTVELLIM[ 5 ]
*
$PARAM_GROUP[ group ]. $JNTVELLIM[ 6 ]
*
$PARAM_GROUP[ group ]. $JNTVELLIM[ 7 ]
*
$PARAM_GROUP[ group ]. $JNTVELLIM[ 8 ]
*
$PARAM_GROUP[ group ]. $JNTVELLIM[ 9 ]
*
REAL [Function]
RW
PU
0 to 100000 ( deg/sec, mm/sec )
Specify the maximum joint speed
[Description] Specify the maximum joint speed for each axis. When the robot moves around or along a certain axis at a speed exceeding the maximum joint speed, a warning is issued. Then, the robot decelerates and moves at a speed not exceeding the maximum joint speed.
950
SYSTEM VARIABLES
B--81464EN--3/01
$PARAM_GROUP[ group ]. $SPEEDLIM REAL [Function]
RW
PU
2000
0 to 3000 ( mm/sec )
Specifies the maximum linear feedrate
[Description] Specifies the maximum feedrate during linear or circular motion under path control. $PARAM_GROUP[ group ]. $ROTSPEEDLIM REAL [Function]
RW
PU
90
0 to 1440 ( deg/sec )
Specifies the maximum circular feedrate
[Description] Specifies the maximum feedrate during circular motion under attitude control. Jog feedrate (joint feed) = Joint jog override
×
Maximum joint speed
Feedrate override
×
100
100
Jog feedrate (linear feed) ( mm/sec ) = Jog override
×
Maximum linear feedrate
Feedrate override
×
100
100
Jog feedrate (circular feed) ( mm/sec ) = ×
Maximum circular feedrate
Jog override
×
Feedrate override
100
100
Joint jog override
$SCR_GRP . $JOGLIM_JNT [ i ] ( % )
Jog override
$SCR . $JOGLIM ( % )
Maximum joint speed
$PARAM_GROUP . $JNTVELLIM
Maximum linear feedrate
$PARAM_GROUP . $SPEEDLIM ( mm/sec )
Maximum circular feedrate
$PARAM_GROUP . $ROTSPEEDLIM ( deg/sec )
Operation speed (joint motion) = Maximum joint speed
×
Coefficient of joint speed
×
2000 ×
Programmed override
Programmed speed 100
×
100
Feedrate override 100
Operation speed ( linear motion ) ( mm/sec ) = Programmed override Programmed speed × × 100
Feedrate override
Operation speed ( circular motion ) ( deg/sec ) = Programmed override Programmed speed × × 100
Feedrate override
Programmed override
$MCR_GRP . $PROGOVERRIDE ( % )
Coefficient of joint speed
$PARAM_GROUP . $SPEEDLIMJNT
951
100
100
SYSTEM VARIABLES
B--81464EN--3/01
$PARAM_GROUP[ group ]. $LOWERLIMS[ 1 ]
*
$PARAM_GROUP[ group ]. $LOWERLIMS[ 2 ]
*
$PARAM_GROUP[ group ]. $LOWERLIMS[ 3 ]
*
$PARAM_GROUP[ group ]. $LOWERLIMS[ 4 ]
*
$PARAM_GROUP[ group ]. $LOWERLIMS[ 5 ]
*
$PARAM_GROUP[ group ]. $LOWERLIMS[ 6 ]
*
$PARAM_GROUP[ group ]. $LOWERLIMS[ 7 ]
*
$PARAM_GROUP[ group ]. $LOWERLIMS[ 8 ]
*
$PARAM_GROUP[ group ]. $LOWERLIMS[ 9 ]
*
REAL [Function]
RW
PU
--100000 to 100000 ( deg, mm )
Specify the lower limit of the joint operating area
[Description] Specify the lower limit of the joint operating area which is the limit of the motion in the negative direction. [Setting]
Joint operating area screen [6 (SETTING).Joint Area]
$PARAM_GROUP[ group ]. $UPPERLIMS[ 1 ]
*
$PARAM_GROUP[ group ]. $UPPERLIMS[ 2 ]
*
$PARAM_GROUP[ group ]. $UPPERLIMS[ 3 ]
*
$PARAM_GROUP[ group ]. $UPPERLIMS[ 4 ]
*
$PARAM_GROUP[ group ]. $UPPERLIMS[ 5 ]
*
$PARAM_GROUP[ group ]. $UPPERLIMS[ 6 ]
*
$PARAM_GROUP[ group ]. $UPPERLIMS[ 7 ]
*
$PARAM_GROUP[ group ]. $UPPERLIMS[ 8 ]
*
$PARAM_GROUP[ group ]. $UPPERLIMS[ 9 ]
*
REAL [Function]
RW
PU
--100000 to 100000 ( deg, mm )
Specify the upper limit of the joint operating area
[Description] Specify the upper limit of the joint operating area, which is the limit of the motion in the positive direction. [Setting]
Joint operating area screen [6 (SETTING).Joint Area]
Payload specification The following payload--related information must be entered. These values are used whenever the robot operates. Therefore, be particularly careful when setting these values. F
$GROUP[group].$PAYLOAD
F
$PARAM_GROUP[group].$PAYLOAD
F
$PARAM_GROUP[group].$PAYLOAD_X
F
$PARAM_GROUP[group].$PAYLOAD_Y
F
$PARAM_GROUP[group].$PAYLOAD_Z
F
$PARAM_GROUP[group].$PAYLOAD_IX
F
$PARAM_GROUP[group].$PAYLOAD_IY
F
$PARAM_GROUP[group].$PAYLOAD_IZ
F
$PARAM_GROUP[group].$AXISINTERTIA[1 to 9]
F
$PARAM_GROUP[group].$AXISMOMENT[1 to 9]
F
$PARAM_GROUP[group].$AXIS_IM_SCL
F
$PARAM_GROUP[group].$ARMLOAD[1 to 3]
$GROUP [ group ] . $PAYLOAD REAL [Function]
RW
*
0 to 10000(kgf)
Payload
[Description] Specify a payload. If the load varies during an operation, specify the maximum value.
952
SYSTEM VARIABLES
B--81464EN--3/01
$PARAM_GROUP [ group ] . $PAYLOAD REAL [Function]
RW
PU
*
0 to 10000(kgf)
Payload
[Description] Specify a payload. If the load varies during an operation, specify the maximum value. $PARAM_GROUP[ group ]. $PAYLOAD_X
*
$PARAM_GROUP[ group ]. $PAYLOAD_Y
*
$PARAM_GROUP[ group ]. $PAYLOAD_Z
*
REAL [Function]
RW
PU
--100000 to 10000(cm)
Load gravity center distance
[Description] Center of gravity of load viewed on the mechanical interface coordinate system (default tool coordinate system). The center of gravity of a load is measured along the X--axis, Y--axis, and Z--axis of the mechanical interface coordinate system. NOTE
This variable is valid for software of edition V4.10P/01 or above. Avoid setting this variable for software of an earlier edition. $PARAM_GROUP[ group ]. $PAYLOAD_IX * $PARAM_GROUP[ group ]. $PAYLOAD_IY
*
$PARAM_GROUP[ group ]. $PAYLOAD_IZ
*
REAL [Function]
RW
0 to 10000(kg ¯ cm2)
PU
Load gravity center inertia
[Description] Inertia around the center of gravity of load. The inertia of a heavy load is calculated around the X--axis, Y--axis, and Z--axis of the mechanical interface coordinate system. The meaning of $PARAM_GROUP[group].$PAYLOAD_* is as illustrated below: x
x Center of robot flange y
z Mass m (kg) xg (cm)
Iy (kg¯cm2 )
Center of gravity
Center of gravity
2
Iz (kg¯cm ) Ix (kg¯cm2 )
zg (cm) xg (cm) yg (cm) zg (cm) Ix (kg¯cm2) Iy (kg¯cm2) Iz (kg¯cm2) NOTE
yg (cm)
: PARAM_GROUP[group].$PAYLOAD_X : PARAM_GROUP[group].$PAYLOAD_Y : PARAM_GROUP[group].$PAYLOAD_Z : PARAM_GROUP[group].$PAYLOAD_IX : PARAM_GROUP[group].$PAYLOAD_IY : PARAM_GROUP[group].$PAYLOAD_IZ
This variable is valid for software of edition V4.10P/01 or above. Avoid setting this variable for software of an earlier edition.
953
SYSTEM VARIABLES
B--81464EN--3/01
$PARAM_GROUP [ group ]. $AXISINERTIA[ 1 ]
*
$PARAM_GROUP [ group ]. $AXISINERTIA[ 2 ]
*
$PARAM_GROUP [ group ]. $AXISINERTIA[ 3 ]
*
$PARAM_GROUP [ group ]. $AXISINERTIA[ 4 ]
*
$PARAM_GROUP [ group ]. $AXISINERTIA[ 5 ]
*
$PARAM_GROUP [ group ]. $AXISINERTIA[ 6 ]
*
$PARAM_GROUP [ group ]. $AXISINERTIA[ 7 ]
*
$PARAM_GROUP [ group ]. $AXISINERTIA[ 8 ]
*
$PARAM_GROUP [ group ]. $AXISINERTIA[ 9 ]
*
SHORT [Function]
RW
PU
0 to 32767 ( kgf ⋅ cm ⋅ sec2 )
Payload inertia
[Description] For each axis, specify an integer as the value of the inertia resulting from the applied payload. The values for the 1st to 3rd axes are calculated automatically; therefore, they need not be specified. (Set a value for each of the 4th, 5th, and 6th axes.) The inertia for each axis is calculated using the following expression:
$AXISINERTIA [ i ] =
payload ¢ ( I_max [ i ] )2
(kgf ⋅ cm ⋅ sec2)
g payload :
Payload [kgf]
l_max[i]: Maximum distance from the rotation center of the axis (axis i) to the mass center of the load on the robot [cm] For the 4th and 5th axes, the distance may vary depending on the angle of the other axes. In such a case, set the maximum distance than can be achieved. g: Gravity acceleration (= 980 [cm/sec2]) NOTE When specifying or changing this variable, refer to the explanation of $PARAM_GROUP[].$AXIS_IM_SCL, below. $PARAM_GROUP [ group ]. $AXISMOMENT[ 1 ]
*
$PARAM_GROUP [ group ]. $AXISMOMENT[ 2 ]
*
$PARAM_GROUP [ group ]. $AXISMOMENT[ 3 ]
*
$PARAM_GROUP [ group ]. $AXISMOMENT[ 4 ]
*
$PARAM_GROUP [ group ]. $AXISMOMENT[ 5 ]
*
$PARAM_GROUP [ group ]. $AXISMOMENT[ 6 ]
*
$PARAM_GROUP [ group ]. $AXISMOMENT[ 7 ]
*
$PARAM_GROUP [ group ]. $AXISMOMENT[ 8 ]
*
$PARAM_GROUP [ group ]. $AXISMOMENT[ 9 ]
*
SHORT [Function]
RW
PU
0 to 32767 ( kgf ⋅ cm )
Axis moment
[Description] For each axis, specify an integer as the moment value resulting from the applied payload. The values for the 1st to 3rd axes are calculated automatically; therefore, they need not be specified. (Set a value for each of the each of 4th, 5th, and 6th axes.) The moment value for each axis is calculated using the following expression:
954
SYSTEM VARIABLES
B--81464EN--3/01
(kgf ⋅ cm)
$AXISMOMENT [ i ] = payload ¢ I_max [ i ]
payload :
Payload [kgf]
l_max[i]: Maximum distance from the rotation center of the axis (axis i) to the mass center of the load on the robot [cm] For the 4th and 5th axes, the distance may vary depending on the angle of the other axes. In such a case, set the maximum distance than can be achieved.
NOTE When specifying or changing this variable, refer to the explanation of $PARAM_GROUP[].$AXIS_IM_SCL, below. $PARAM_GROUP [ group ]. $AXIS_IM_SCL SHORT [Function]
RW
PU
0 to 32767
Inertia/moment value adjustment scale
[Description] This variable is used to set the fractional value of an axis inertia or moment described above. NOTE
Normally, this variable setting need not be changed. Actually, the following values are used as the inertia and moment. (Inertia) =
(Moment ) =
$PARAM_GROUP[group].$AXISINERTIA[i] $PARAM_GROUP[group].$AXIS_IM_SCL
$PARAM_GROUP[group].$AXISMOMENT[i] $PARAM_GROUP[group].$AXIS_IM_SCL
Accordingly, $AXISINERTIA[i] and $AXISMOMENT[i] must be correctly specified in accordance with this variable setting. For instance, to set the inertia of the fourth axis of a robot to 1.23, F
Set $PARAM_GROUP[group].$AXIS_IM_SCL to 100.
F
Set $PARAM_GROUP[group].$AXISINERTIA[4] to 123.
F
Change the inertia and moment values of the other axes in accordance with the value of $AXIS_IM_SCL.
$PARAM_GROUP [ group ]. $ARMLOAD[ 1 ]
*
$PARAM_GROUP [ group ]. $ARMLOAD[ 2 ]
*
$PARAM_GROUP [ group ]. $ARMLOAD[ 3 ]
*
REAL [Function]
RW
PU
0 to 10000 ( kgf )
Equipment weight
[Description] When equipment such as welding equipment is installed on a robot axis, specify the payload incurred by that equipment. $ARMLOAD[1]: Specify the weight of the equipment installed on the 3rd--axis arm. $ARMLOAD[2]: Specify the weight of the equipment installed on the 2nd--axis base. $ARMLOAD[3]: Not used. Executing a program $DEFPULSE
4
SHORT [Function]
RW
0 to 10000 ( 100 msec )
Specifies the standard DO output pulse width
[Description] This value is used when the pulse width is not specified for the output of a DO signal pulse.
955
SYSTEM VARIABLES
B--81464EN--3/01
Automatic operation $RMT_MASTER
0
INTEGER [Function]
RW
0 to 3
Specifies which remote unit is used
[Description] Specifies which remote unit is used. The specified remote unit has the right to start the robot. 0: 1: 2: 3:
Peripheral unit (remote controller) CRT/keyboard Host computer No remote unit
Deleting the warning history $ER_NOHIS
0 BYTE
[Function]
RW
0/3
Warning history delete function
[Description] WARN alarms, NONE alarms and resets can be deleted from the alarm history. 0: Disables the function. (All alarms and resets are recorded in the history.) 1: Does not record WARN and NONE alarms in the history. 2: Does not record resets. 3: Does not record resets, WARN alarms, and NONE alarms. Disabling alarm output $ER_NO_ALM. $NOALMENBL BYTE [Function]
RW
0 0/1
Enables the no--alarm output function
[Description] When this function is enabled, the LEDs on the teach pendant and the machine operator’s panel corresponding to the alarms specified with system variable $NOALM_NUM do not light. In addition, the peripheral I/ O alarm signal (FAULT) is not output. $ER_NO_ALM. $NOALM_NUM BYTE [Function]
RW
5 0 to 10
Specifies the number of alarms not output
[Description] Specifies the number of alarms that are not output. $ER_NO_ALM. $ER_CODE1
11001
$ER_NO_ALM. $ER_CODE2
11002
$ER_NO_ALM. $ER_CODE3
11003
$ER_NO_ALM. $ER_CODE4
11007
$ER_NO_ALM. $ER_CODE5
11037
$ER_NO_ALM. $ER_CODE6
0
$ER_NO_ALM. $ER_CODE7
0
$ER_NO_ALM. $ER_CODE8
0
$ER_NO_ALM. $ER_CODE9
0
$ER_NO_ALM. $ER_CODE10
0
INTEGER [Function]
RW
0 to 100000
Specify the alarms not output
[Description] Specify the alarms that are not output. Setting : 11 002 ( Meaning: SERVO--002 alarm ) Alarm ID Alarm number
956
SYSTEM VARIABLES
B--81464EN--3/01
Error code output $ER_OUT_PUT. $OUT_NUM LONG [Function]
0 RW
0 to 512
SDO start number for error code output
[Description] Specify the start number for the SDOs used for error code output. An error code is output, in binary format, using 33 SDOs starting from that having the specified number. If 0 is specified, no error code is output. $ER_OUT_PUT. $IN_NUM
0
LONG [Function]
RW
0 to 512
SDI number for error code output request
[Description] Every time the SDI specified in this variable is set to ON, an error code is output to the SDOs specified in $ER_OUTPUT.$OUT_NUM, explained above. User alarm $UALRM_SEV[ ]
6
BYTE [Function]
RW
0 to 255
User alarm severity
[Description] Sets the user alarm severity. $UALRM_SEV[i] corresponds to the severity of user alarm [i]. 0 WARN 6 STOP.L 38 STOP.G 11 ABORT.L 43 ABORT.G The initial severity for each user alarm is 6 (STOP.L). Jogging $JOG_GROUP . $FINE_DIST REAL [Function]
RW
0.5
0.0 to 1.0 ( mm )
Move distance for linear step jogging
[Description] Specify an amount of travel in low--speed linear step feed by Cartesian/tool manual feed. The amount of travel in very low speed step feed is one tenth of the value specified here. $SCR . $FINE_PCNT INTEGER [Function]
10 RO
1 to 100 %
Move distance for joint or orientation step jogging
[Description] Specify an amount of travel for step feed in attitude rotation by axial manual feed or Cartesian/tool manual feed. Specify manual feed with a precentage and an override of 1%. I/O setting $IOLNK[ 16 ] . $RACK INTEGER [Function]
* RW
Unknown I/O device setting
[Description] If you use non the I/O device of process I/O PC board or process I/O unit modelA (ex. 90--30 PLC, I/O link adapter, JEMA PC), you must set this variable for the device as follows. You can use 16 unknown device. Set this variable with the following $IOLNK[i].$SLOT, IOLNK[i].$INPUT_N and IOLNK[i].$OUTPUT_N. Max. sixteen devices can be installed. $IOLNK[ 16 ] . $SLOT INTEGER [Function]
* RW
Unknown I/O device slot number
$IOLNK[ 16 ] . $INPUT_N INTEGER [Function]
*
RW
Unknown I/O device input signal number
957
SYSTEM VARIABLES
B--81464EN--3/01
$IOLNK[ 16 ] . $OUTPUT_N INTEGER [Function]
*
RW
Unknown I/O device output signal number
$OPWORK . $UOP_DISABLE BYTE [Function]
RW
*
0/1
Enable/disable UOP I/O
[Description] Specify whether the peripheral equipment input signal is enabled or disabled. If the peripheral equipment input signal is enabled when the robot is operated without any peripheral equipment connected, an alarm cannot be cleared. By disabling the signal with this setting, the alarm can be cleared. When any peripheral equipment is connected, set this variable to 0 before using that equipment. $SCR . $RESETINVERT
FALSE
BOOLEAN [Function]
RW
TRUE / FALSE
FAULT_RESET input signal detection.
[Description] When you set this value to “TRUE”, an error is reset by rising edge of FAULT_RESET input signal. If “FALSE” is set, an error is reset by falling edge is detected. TRUE: Check rising edge of reset input signal. FALSE: Check falling edge of reset input signal. $PARAM_GROUP . $PPABN_ENBL BOOLEAN [Function]
RW
FALSE
TRUE / FALSE
Enable/disable pressure abnormal *PPABN input
[Description] Specifies if pressure abnormal signal is detected or not. If you want to use *PPABN input, you should set this variable to TRUE. TRUE: Enable FALSE: Disable $PARAM_GROUP. $BELT_ENBLE BOOLEAN [Function]
RW
FALSE
TRUE / FALSE
Belt rupture signal enabled/disabled
[Description] Specify whether the belt rupture signal (RDI[7]) is detected. For a robot utilizing the belt rupture signal (A--510, L--1000), this value is automatically set to TRUE. TRUE: Belt rupture signal enabled FALSE: Belt rupture signal disabled Software version $ODRDSP_ENB
0
ULONG [Function]
RW
1/0
Display of an order file
[Description] An order listing, showing the configuration of the software components installed in the controller can be displayed on the display (order file screen) of the teach pendant. Soft float function $SFLT_ERRTYP INTEGER [Function]
0 RW
1 to 10
Flag for specifying the alarm to be generated when time--out occurs during follow--up processing of the soft float function
[Description] This variable specifies the alarm (a servo alarm or program pause alarm) to be generated if a time--out occurs during follow--up processing of the soft float function. 0: Generates servo alarm “SRVO--111 Softfloat time out.” 1: Generates program pause alarm “SRVO--112 Softfloat time out.”
958
SYSTEM VARIABLES
B--81464EN--3/01
$SFLT_DISFUP
FALSE
BOOLEAN [Function]
RW
TRUE / FALSE
Specifies whether to perform follow--up processing at the start of each motion instruction.
[Description] Specify whether to perform follow--up processing of the soft float function at the start of each program motion instruction. TRUE: Does not perform follow--up processing at the start of each program motion instruction. FALSE: Performs follow--up processing at the start of each program motion instruction. Register speed specification function $RGSPD_PREXE BOOLEAN [Function]
FALSE RO
TRUE/FALSE
Advanced register speed read enabled or disabled
[Description] Specify whether an advanced read of operation statement is performed (enabled) or not (disabled) when the movement speed specified by an operation statement is held in a register. TRUE: Advanced read enabled FALSE: Advanced read disabled
NOTE When an advanced register speed read is enabled with the setting indicated above, the timing at which the register value is changed is important. With some timings, a change in the register value may not be reflected in the operation speed, and the register value existing before the change may be applied to the movement. To enable advanced register speed read, some consideration is needed: The value of a register used for the movement speed during program execution should not be changed; An interlock should be provided; for instance.
959
Index
B--81464EN--3/01
Note Volume 1 : Up to Page 693 / Volume 2 : Page 695 and later
[A]
AVC hardware requirements, 549 AVC programming, 554
Abort instruction, 228
AVC schedule setup, 549
About Reducer Diagnosis, 769
AVC Tracking, 546
Additional motion instructions, 180, 729 Adjustment of Analog Output Conversation Factor by Multiple Points, 671
[B]
Adjustment of gain value, 542 Air purge function, 683
Background Editing, 315
Alarm Codes, 812, 820
Branch Instructions, 209
Analog I/O, 81 Analog I/O instructions, 206
[C]
Angle--input shift function, 449
Calibration Procedure (for 6--Axis Robots), 641
Appearance and Operationsappearance and Operations, 797
Caution and limitations, 487
Appearance and Switches, 797
Changing a control instruction, 292
Arc end instruction, 192
Changing a motion instruction, 284
Arc instruction, 739
Changing a Program, 282
Arc Instructions, 191
Changing a standard motion instruction, 263
Arc Smart High--speed Recovery Function, 649
Changing conditions for executing the resume program, 513
Arc start instruction, 191
Changing program information, 310
ARC START Synchronization for Arc Multi--equipment Configutarion, 667
Changing the Operation Target Screen, 802
Arc Tool Software, 16
Cold start , 744
Arc welding, 240
Collision Detection for Auxiliary Axis, 645
Arc welding instruction, 682
Color Display According to the Alarm Severity, 810
Arc Welding Status, 375
Comment instruction, 230
Arc welding torch, 19
Communication, 32
Arguments, 213
Conditional branch instructions, 210, 733
ASCII file, 399
Conditional wait instructions, 220
ASCII save, 409
Configuration, 477
Assigning touch sensing I/O, 600
Continuous Rotation Function, 464
Assigning Welder Program Select Output Signals, 678
Continuous test, 345
Asynchronous operation group instruction, 236
Controlled start, 742
Attention and Limitation, 682
Controller, 20
Automatic Backup, 424
Coordinate System Change Shift Functions, 454
Automatic Error Recovery Function, 498
Coordinated jogging, 584
Automatic Operation, 353
Coordinated Motion Function, 569
Automatic operation (operation execution), 17
Coordinated motion in a program, 588
Automatic operation by robot start request (RSR), 354
Coordinated motion with RPM and multipass, 566 Creating a Program, 258
Automatic operation with program number selection (PNS), 356
CRT/KB, 32
Automatic voltage control tracking, 546
Current Position, 376 i--1
Index
B--81464EN--3/01
Note Volume 1 : Up to Page 693 / Volume 2 : Page 695 and later Fanuc i Pendant, 795
Current Position Display, 808
Feedrate, 176 File Input/Output, 385
[D]
File Input/Output Units, 386
Data file, 399
File manipulation, 407
Data Monitor, 590
Files, 398
Data monitor schedule, 596
Fine adjusting, 542
Data monitor setup, 592
Floppy Cassette adapter, 389
Default logic file, 398
Flowchart for resuming a suspended program, 510
Defining a resume program, 501
Forced output, 348
Description of an Alarm Code Table, 813
Format of a System Variable Table, 942
Detail of Servo Torch control function, 682
Frame Instructions, 227
Diagnosis Screen, 769
Frame setup instruction, 737
Digital I/O, 73
Function Overview, 674, 678
Digital I/O instructions, 203 Direct Setting, 692
[G]
Display screen of the teach pendant, 27
General Safety Precautions, 6
Distance before operations, 477
Gravity Compensation, 647 Group I/O, 78 Group I/O instruction, 207
[E]
Group mask, 163
Each item, 771 Emergency Stop devices, 33 Enabling or Disabling the Function, 678
[H]
Entering Distance Before, 485
Halt by a hold and recovery, 328
Error Codes, 490
Halt by an emergency stop and recovery, 327
Executing a Program, 325, 332
Halt caused by an alarm, 329
Executing macro instructions, 435
Halt instruction, 228
Execution History, 382
Handy file, 391
Execution of the resume program from the teach pendant and test mode, 513
Hot start, 745
Extended axis, 33 Extended Axis Setup, 786
[I]
External memory unit, 388
I/O Connection Function, 102
External override selection function, 358
I/O Instructions, 203
Extreme changes in workpiece temperature, 545
I/O Link list screen, 99 I/O Link Screen, 99 I/O Module Setting, 775
[F] Factors that affect avc tracking, 549
Independent Additional Axis Board (Nobot) Startup Procedure, 791
Factors that affect tast tracking, 534
INITIAL SETTING, 645 i--2
Index
B--81464EN--3/01
Note Volume 1 : Up to Page 693 / Volume 2 : Page 695 and later Manual operation screen of the automatic error recovery function, 511
Initial start, 741 Input/output, 32
Manual Plan, 2
Input/Output Signals, 67
Manually Operating Welding Equipment, 352
Instruction, 477
Mastering, 746
Internet Browser Screen, 803
Mastering at the zero--degree positions, 750
Interruption disable, 163
Maximum speed instructions, 233
Introduction, 1
Memory card, 387 Memory Use Status Display, 384
[J]
Message instruction, 231 Mirror shift function, 445
Jig mastering, 748
MODEL B unit list screen, 100
Jog feed of the robot, 16
Motion format, 169
Joint Operating Area, 139
Motion group instructions, 738 Motion Instructions, 168
[K]
Motion instructions, 239, 729
Key Switches, 798
Motion of the robot, 33
Keys on the teach pendant, 23
Motion Performance Screens, 635 MOTION Screen, 647 Moving the robot by jog feed, 249
[L]
Multi Equipment Control for Arc Welding, 663
Label instruction, 209
Multiaxis Control Instructions, 234
LEDs on the Teach Pendant, 369
Multiaxis control instructions, 737
LEDs on the teach pendant, 26
Multipass, 558
Line Number, Program End Symbol, and Argument, 166
[N]
List of Menus, 698 List of Program Instructions, 725 Load Estimation, 638
No compensation with high vertical or lateral gain setting, 543
Load Estimation Procedure (for 6--Axis Robots), 638
Notes on Use, 674
Load Setting, 635 Loading a specified program file using the file screen, 414
[O]
Loading Files, 412
Offset Condition Instruction, 225
Loading using program selection screen, 413
Online Position Modification, 360 Operating Procedure, 638 Operation at Recovery from Alarm, 676
[M]
Operation Group DO Output Function, 470
Macro Instruction, 429
Operation Group Instructions, 236
Macro instruction, 737
Operation procedure, 671
Main alarm codes, 589
Operator Panel Status Display, 808
Manual I/O Control, 348
Operator’s panel, 31 i--3
Index
B--81464EN--3/01
Note Volume 1 : Up to Page 693 / Volume 2 : Page 695 and later Program execution instruction, 235 Program file, 398 Program Halt and Recovery, 326 Program Instructions, 636, 729 Program look/monitor, 347 Program name, 161 Program number selection (PNS), 108 Program Operation, 310 Program shift function, 440 Program Structure, 158 Program Timer, 379 Programming, 237, 599
Operator’s Panel I/O, 96 Other Instructions, 229 Other instructions, 735 Other Related Matters, 643 Other Settings, 157 Other specifications and restrictions, 513 Outline of Servo Torch control function, 682 Outline of the automatic error recovery function, 498 Override instruction, 230 Overview of Automatic Backup, 424
[P]
[Q]
Parameter instruction, 231 Quick mastering, 752
Perform Automatic backup, 426 Peripheral I/O, 32, 89 Poor tracking performance, 543
[R]
Position data, 171
Register and I/O instructions, 731 Register Instructions, 198 Register instructions, 198 Registering a program, 259 Registers, 371 Related alarms, 652 Remote controller, 32 Restore the backup, 427 Restrictions, 811 Resuming a program, 335 Robot, 18 Robot arms, 18 Robot Axis Status, 763 Robot I/O, 86 Robot I/O instructions, 204 Robot motion, 333 Robot service request (RSR), 105 Robot wanders from path, 544 Root pass memorization, 555 Root Pass Memorization and Multipass, 555 RSR instruction, 229
Position register axis instructions, 201 Position register instructions, 200 Position Register Look--Ahead Execution Function, 468 Position register look--ahead execution instruction, 738 Position Registers, 372 Positioner Setup, 780 Positioning path, 179 Pre--Execution Instruction Function, 472 Predefined position, 239 Printer, 419 Printing Files, 419 Printing files, 421 Procedure, 770 Process Conditions, 58 Program, 16 Program comment, 162 Program Control Instructions, 228 Program control instructions, 735 Program Detail Information, 161
[S]
Program edit instructions, 295 Program end instruction, 209
Safety Precautions, 9 i--4
B--81464EN--3/01
Index
Note Volume 1 : Up to Page 693 / Volume 2 : Page 695 and later Safety Signal Status Display, 809
Setup in Weld equipment setup screen, 685
Sample Application, 669, 677
Setup Servo Torch axes, 684
Saving all the program files using the file screen, 402
Shift Functions, 439
Saving Files, 400
Signal count setting screen, 101
Saving with a function menu, 405
Significant changes in joint gap, 545
Saving with the program selection screen, 400
Simulated I/O, 349
Screen menu and function menu, 28
Single axis mastering, 755
Screen Selection Menu and Screen Menus on the Edit Screen, 806
Singularity Point Check Function, 324
Selecting a program, 282
Skip and Offset condition instruction, 736
Selecting welder power supply, 44
Skip Condition Instruction, 223
Semaphore instruction, 234
Slow response, 544
Semaphore wait instruction, 234
Soft Float Function, 459
Servo Torch Control Function, 682
Soft float instruction, 738
Servo Torch Fine Adjustment Function of Wire Velocity Commands, 688
Software Version, 760
Servo Torch setup screen, 686
Special functions, 540
Setting a Communication Port, 394
Specification, 649
Setting a coordinated motion system, 575
Specification , 477
Setting a jog coordinate system, 131
Specification & Limitation, 668
Setting a Reference Position, 136
Specifying test execution, 340
Setting a reference value range and command value range for specifying an analog input/output signal, 42
Splitting the Screen, 800
Setting a tool coordinate system, 113
Start Mode, 741
Setting a user coordinate system, 122
Start Up Methods, 741
Setting Arc Welding Conditions, 52
Starting a program, 332
Setting Automatic Operation, 104
State Monitoring Function, 491
Setting coordinate systems, 111
Status Display, 368
Setting for Weaving, 61
Status monitoring instructions, 738
Six--Points Touchup, 688
Special Area Function, 144
Standby release, 351
Status Subwindow, 807
Setting macro instructions, 430
Status Window, 799
Setting mastering data, 758
Step test, 342
Setting of Automatic Backup, 425
Subtype, 162
Setting the Arc Welding Equipment, 49
Summary, 671
Setting the Arc Welding System, 45
Synchronous operation group instruction, 236
Setting the automatic error recovery function, 503
System Config Menu, 148
Setting Up General Items, 155
System file, 399
Setting Up the ARC System, 34
System setting, 16
Setting up touch sensing, 602
System Timer, 381
Setup, 667, 674
System Variables, 378, 488, 647, 941, 944
Setup for Servo Torch, 683 i--5
Index
B--81464EN--3/01
Note Volume 1 : Up to Page 693 / Volume 2 : Page 695 and later
[T]
[U]
Tast application guidelines, 535
Unconditional branch instructions, 210, 734
Tast hardware requirements, 535
Usable Memory Cards, 424
Tast programming, 536
User Alarm, 141
TAST schedule, 544
User alarm instruction, 229
Tast schedule setup, 536
User Screen, 370
Tast tracking, 531
Using the Arc Sensor Concurrently, 676
Tast Tracking Function, 530
Using the Welding Fine--Tune Function Concurrently, 676
Tast troubleshooting, 543
Utility, 428
Teach pendant, 21 Teaching a control instruction, 273
[V]
Teaching a motion instruction, 266 Teaching a supplementary motion instruction, 268
Variable Axis Areas, 142
Teaching the RETURN_PATH_DSBL instruction, 502
Version management, 426
Test operation (test execution), 17
Vertical plane (Z--plane) tracking, 533
Testing, 340 Three--Mode Switch, 243
[W]
Time--specified wait instruction, 220 Timer instruction, 230
Wait instruction, 734
Tips on Effective Programming, 239
Wait Instructions, 220 Weave plane (XY--plane) lateral tracking, 532
Tool Offset Condition Instructions, 226
Weave Schedule, 64
Torch guard function, 649
Weld Path has Changed at a Specific Position, 545
Torch Posture Adjustment, 525
Weld path is snaking, 545
Torch Posture Conversion, 515
Weld Schedule Advise Screen, 54
Torch recovery function, 652
Weld speed statement, 178
Touch Sensing, 600
Welder Program Select Function, 678
Touch sensing hardware, 625
Welding I/O instructions, 208
Touch sensing mastering, 627
Welding input signals, 37
Touch sensing programming, 618
Welding Input/Output Signals, 35
TP start prohibition, 280
Welding output signals, 38
TRACK{Sensor} instruction, 197
Welding Parameter Grade Function, 674
Tracking failure conditions, 542
Welding Tuning, 366
TUNING PROCEDURE, 645
Wire inching, 682
Turning on the Power and Jog Feed, 241
Workers, 5
Turning on the power and turning off the power, 241
World Frame Origin, 774
Types of Screens, 702
Write protection, 163
i--6
Revision Record FANUC Robot series ARC TOOL (With R--J3iB CONTROLLER) OPERATOR’S MANUAL (B--81464EN--3)
01
Feb., 2002
Edition
Date
Contents
Edition
Date
Contents
