manual robo kawasaki.pdf

Explosion-Proof Type

Operation Manual 操作説明書

Kawasaki Heavy Industries, Ltd.

Caution Read this manual carefully before you use the robot actually and keep it safe, so as to fully bring out the functions of your Kawasaki Robot for yourself.

90203－1075DEB

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

C Series Controller

For safety

FOR SAFETY This operation manual and the labels on the products are indicated with the symbols below for proper use and to avoid injuries or property damage. Read this manual and the related documents thoroughly before installation, operation, maintenance and inspection.

！

DANGER

Identifies procedures that, if not properly followed, can result in imminent injury or death.

！

WARNING

Identifies procedures that, if not properly followed, may possibly lead to injury or death.

！

CAUTION

Identifies procedures that, if not properly followed, may lead to human and/or mechanical injury.

[ NOTE ] Denotes easily-misunderstood items regarding product performance, operation, and maintenance.

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C Series Controller, Explosion-Proof Type Kawasaki Robot Operation Manual

For safety

PREFACE This manual describes operational procedures for the Kawasaki C Series Controller, Explosion-Proof Type. Please read the Safety Manual thoroughly, a separate volume, before reading this manual. Also, this manual should be read before actual operation of the robot, and be stored for safe-keeping for later reference. This manual is written on the following assumptions: The robot is installed according to the Installation and Connection Manual (for robot arm), a separate volume. The controller is installed and connected according to the Installation and Connection Manual (for robot controller), a separate volume. The peripheral equipment is connected with the controller according to the External I/O Manual, a separate volume.

This manual intends to explain the operational procedures as detailed as possible. As not all operations can be explained in one manual, only the major functions are explained. Therefore, only the operation of functions specifically described herein can be guaranteed.

Because Kawasaki constantly strives to improve the quality of its products, this manual may be changed or revised without prior notice. This manual may not, in whole or in part, be reproduced or copied without the prior written consent of Kawasaki. Though this manual was prepared to be as thorough and accurate as possible, the authors apologize should any information be found in error. The screen examples in this manual may differ depending on software version. Some functions may not be installed depending on software version. This manual concerns operating procedures. It is not a guarantee of safety, and Kawasaki is not responsible for damages by the system or any industrial property troubles related with patent, as in the event of unforeseen trouble. MS-DOS is a registered trademark of Microsoft Corporation, USA. The other company and product names are also registered. All rights reserved. Copyright @ 2001 by KAWASAKI HEAVY INDUSTRIES, LTD.

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For safety

BASIC CONFIGURATION OF THIS MANUAL

This manual describes the fundamental operational procedures for the Kawasaki C Series Controller, Explosion-Proof Type. Overview and basic operations that need to be understood first for using Kawasaki Robot Controller are explained. Operations which are common in every application and are peculiar to painting application are included and need to be read thoroughly. Many functions for making full use of the controller are also explained and should be read depending on the aim of the user. A glossary is included at the end of the manual as a reference for commonly used language and keywords regarding robots. The ) indicates a reference. For example, ) A-142 indicates that the auxiliary function 142 should be referenced.

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For safety

TEACHING METHODS The Kawasaki C Series Controller, Explosion-Proof Type can be programmed by a variety of equipment including the explosion-proof teach pendant. Select a teaching method that best suits the needs of your application and level of expertise.

Explosion-proof teach pendant: Manual operation and teaching for the robot can be conducted using the explosion-proof teach pendant. Manual operation can be conducted only by the teach pendant.

Multifunction panel:

Various data can be displayed and set using the multifunction panel. Its keyboard screen is used for programming.

PC (Option):

It is possible to create an advanced application program by entering program instructions on PC. (This is called general programming.) Robot Language (AS Language) functions can be fully used, so that programs using advanced functions, such as coating operations, communication, and vision sensing, are possible.

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For safety

SYSTEM STRUCTURE The system structure of the Kawasaki C Series Controller, Explosion-Proof Type is as follows: Kawasaki Robot

C Series Controller

Multifunction Panel Explosion-Proof Teach Pendant

Peripheral Equipment Multifunction Panel

PC

Explosion-Proof Type Controller

PC (Prepared by the user)

Explosion-Proof Teach Pendant

KOSMOS Monitoring Software [For PC] (Provided by Kawasaki; Optional)

[ NOTE ] Monitoring software for PC is run by the OS such as MS-DOS. OS needs to be prepared by the user.

Multifunction Panel

Controller

Program selection Displays programs and steps Monitoring the signals Setting the repeat conditions General teaching Explosion-Proof Teach Pendant

Regular operation

Program selection Programs and steps Display Manual operation of the robot Monitoring the signals Setting the repeat conditions Positional teaching General teaching v

PC Instruction entry of AS Language Keyboard entry of AS Language programs Loading/Saving of the programs into/from disk



Contents

CONTENTS SAFETY 1 ENSURING SAFETY.......................................................................................... 2 2 SAFETY IN GENERAL....................................................................................... 2 3 ROBOT SPEED LIMITATIONS.......................................................................... 3 4 ROBOT MOTION RANGE ................................................................................. 3 5 FIVE SAFETY RULES TO BE OBSERVED FOR KHI ROBOTS...................... 4 6 SAFETY DURING START-UP ........................................................................... 7 7 ENSURING SAFETY DURING TEACHING OPERATIONS............................. 8 8 DANGER PREVENTION DURING OPERATIONS........................................... 9 １ SWITCHES AND KEYS 1.1 SWITCHES ON THE CONTROLLER...........................................................1-2 1.2 MULTIFUNCTION PANEL ............................................................................1-4 1.2.1 SWITCHES ON THE MULTIFUNCTION PANEL ...................................1-4 1.2.2 LIQUID CRYSTAL DISPLAY ...................................................................1-5 1.2.3 KEYS ON THE LIQUID CRYSTAL DISPLAY .........................................1-6 1.2.4 KEYBOARD..............................................................................................1-7 1.3 EXPLOSION-PROOF TEACH PENDANT....................................................1-8 1.3.1 KEYS AND SWITCHES ...........................................................................1-8 1.3.2 DISPLAY DURING TEACHING.............................................................1-13 ２ PROCEDURES FOR POWER ON/OFF AND STOPPING THE ROBOT MOTION 2.1 TURNING THE POWER ON.........................................................................2-2 2.2 TURNING THE POWER OFF .......................................................................2-5 2.3 STOPPING THE ROBOT MOTION ..............................................................2-6 ３ BASIC OPERATION OF MULTIFUNCTION PANEL 3.1 SWITCHING THE SCREEN OF THE MULTIFUNCTION PANEL ...............3-2 3.1.1 BASIC SCREEN STRUCTURE ON THE MULTIFUNCTION PANEL ..............................................................................................3-4 3.1.2 STATUS SCREEN ...................................................................................3-5 3.1.3 OTHERS .............................................................................................. 3-6 3.1.4 STATUS SCREEN ...................................................................................3-8 3.1.5 SPRAY STATUS SCREEN......................................................................3-9 3.1.6 PROGRAM LIST SCREEN....................................................................3-13 3.1.7 MONITOR SCREEN ..............................................................................3-14 3.1.8 CURRENT POSITION SCREEN ...........................................................3-17 3.2 MOVING CURSORS ...................................................................................3-18 3.3 SELECTION BY ENTERING NUMERIC VALUES OR USING CURSOR OPERATION...............................................................................3-19 3.4 ENTERING CHARACTERS ........................................................................3-20 3.5 SELECTING PROGRAMS ..........................................................................3-21 3.6 SELECTING STEPS....................................................................................3-23 vi



Contents

４ MANUAL OPERATION 4.1 KEYS USED FOR MANUAL OPERATION...................................................4-2 4.2 PROCEDURES FOR MANUAL OPERATION..............................................4-3 4.2.1 TYPES OF THE MANUAL OPERATION COORDINATE SYSTEM.......4-5 4.2.2 SELECTING THE MANUAL OPERATION COORDINATE SYSTEM ..............................................................................................4-5 4.2.3 SELECTING THE MANUAL OPERATION SPEED ................................4-5 4.2.4 MANUAL OPERATION ON THE JOINT COORDINATE SYSTEM........4-6 4.2.5 MANUAL OPERATION ON THE CARTESIAN COORDINATE SYSTEM ..............................................................................................4-9 4.2.6 MANUAL OPERATION ON THE EASY COORDINATE SYSTEM ......4-11 4.2.7 GUN COORDINATE SYSTEM ..............................................................4-15 4.2.8 SELECTING THE OPERATION FOR TRAFERSE EQUIPMENT........4-17 4.2.9 MANUAL OPERATION OF THE TRAVERSE EQUIPMENT................4-17 ５ TEACHING 5.1 OPERATION FOR TEACHING .....................................................................5-2 5.1.1 DISPLAY DURING TEACHING...............................................................5-2 5.1.2 REGISTERING THE PROGRAM NUMBER ...........................................5-3 5.1.3 TEACHING PROCEDURES....................................................................5-4 5.1.4 MANUAL POSITIONING........................................................................5-18 5.1.5 TEACHING THE MOVE INSTRUCTIONS ............................................5-20 5.1.6 TEACHING THE OTHER INSTRUCTIONS (ADD)...............................5-22 5.1.7 THE PROCEDURES FOR CHECKING PROGRAMS (CHECK OPERATION) .........................................................................................5-24 5.1.8 CORRECTING INSTRUCTIONS...........................................................5-25 5.2 EXPLANATION OF INSTRUCTIONS.........................................................5-29 5.2.1 SPEED INSTRUCTION .........................................................................5-30 5.2.2 SPRAY INSTRUCTION .........................................................................5-32 5.2.3 EXTERNAL OUTPUT INSTRUCTION ..................................................5-36 5.2.4 EXTERNAL INPUT INSTRUCTION ......................................................5-40 5.2.5 SMOOTH INSTRUCTION......................................................................5-42 5.2.6 CALL DATA BANK INSTRUCTION.......................................................5-46 5.2.7 TIMER INSTRUCTION ..........................................................................5-48 5.2.8 CALL PROGRAM INSTRUCTION.........................................................5-49 5.2.9 JUMP INSTRUCTION............................................................................5-50 5.2.10 CONVEYOR INSTRUCTION ..............................................................5-59 5.2.11 GUN CONTROL INSTRUCTION........................................................5-61 5.2.12 TABLE INSTRUCTION (OPTION)......................................................5-62 5.2.13 SENSING INSTRUCTION...................................................................5-63 5.2.14 MOVE INSTRUCTION ........................................................................5-64 5.2.15 OTHER INSTRUCTIONS....................................................................5-67 5.3 REPEAT OPERATION FOR CHECKING ..................................................5-71 ６ PROGRAM EDIT WITH EXPLOSION-PROOF TEACH PENDANT 6.1 DISPLAY DURING EDITING ..........................................................................6-2 6.2 STARTING EDIT PROGRAM MODE .............................................................6-3 6.3 HOW TO EDIT INSTRUCTION.......................................................................6-5 vii



Contents

6.4 HOW TO SEARCH INSTRUCTIONS .............................................................6-7 6.5 EDITING OF MOVE INSTRUCTION ............................................................6-10 6.6 ENDING EDIT PROGRAM MODE ...............................................................6-11 7 PROGRAM EDITING WITH MULTIFUNCTION PANEL OPTION） 7.1 OVERVIEW OF PROGRAM EDITING ...........................................................7-2 7.2 PROGRAM EDITING SCREEN ......................................................................7-3 7.3 PROGRAM EDITING PROCEDURES ...........................................................7-4 7.3.1 EDIT OF AN ENTIRE STEP ....................................................................7-4 7.3.2 EDIT OF ALL DATA IN MULTIPLE STEPS ..........................................7-10 8 REPEAT OPERATION PROCEDURES 8.1 BEFORE EXECUTING REPEAT OPERATION .............................................8-2 8.2 METHOD OF REPEAT OPERATION.............................................................8-3 8.3 STOP AND RESTART REPEAT OPERATION PROCEDURES...................8-7 8.4 REPEAT CONDITION SELECTION ...............................................................8-8 8.5 WAIT OVERRIDE..........................................................................................8-10 8.6 SLOW REPEAT MODE.................................................................................8-12 9 AUXILIARY FUNCTIONS 9.1 AUXILIARY FUNCTION LIST .........................................................................9-3 A－2 LOCATION & SPEED DISPLAY.........................................................9-6 A－3 DATA TRANSFER...............................................................................9-8 A－5 KILL PROGRAM..................................................................................9-9 A－6 MIRROR CONVERSION (OPTION).................................................9-10 A－9 DATA CONVERSION (OPTION) ......................................................9-12 A－10 MEMORY→PC CARD (SAVE)...........................................................9-13 A－11 PC CARD→MEMORY (LOAD)...........................................................9-15 A－12 FILE DIRECTORY (FDIRECTORY) ...................................................9-16 A－14 PC CARD AUX. FUNCTION...............................................................9-17 A－40 AUTO TOOL SET (OPTION)..............................................................9-18 A－41 ZEROING ............................................................................................9-19 A－42 POSITION ERROR RANGE AT EMERGENCY STOP .....................9-20 A－43 ENCODER ERROR RANGE..............................................................9-21 A－44 ZEROING DATA SET DISPLAY.........................................................9-22 A－46 INSTALLATION POSTURE................................................................9-23 A－47 BASE COORDINATES .......................................................................9-24 A－48 TOOL DIMENSIONS ..........................................................................9-25 A－51 SOFTWARE LIMIT..............................................................................9-27 A－53 ACCURACY ........................................................................................9-28 A－55 SLOW REPEAT MODE ......................................................................9-33 A－56 CHECK SPEED ..................................................................................9-34 A－57 TEACH SPEED...................................................................................9-35 A－70 MEMORY AVAILABLE .......................................................................9-36 A－71 RECORD DATA/INHIBIT ....................................................................9-37 A－72 AUTOMATIC PATH GENERATION ...................................................9-38 viii



Contents

A－73 SPRAY ON/OFF .................................................................................9-47 A－75 SYSTEM SWITCH ..............................................................................9-48 A－76 HOME POSITION ...............................................................................9-51 A－77 WORK SPACE OUTPUT (OPTION) ..................................................9-52 A－78 CLEAR CHECK SUM ERROR ...........................................................9-53 A－80 XYZ SHIFT (OPTION).........................................................................9-54 A－81 JOINT SHIFT (OPTION) .....................................................................9-55 A－82 TOOL SHIFT (OPTION)......................................................................9-56 A－83 WORK SHIFT (OPTION) ....................................................................9-57 A－87 PROGRAM ARGUMENT/COMMENT (OPTION) ..............................9-58 A－90 SOFTWARE VERSION DISPLAY......................................................9-60 A－91 ENVIRONMENT DATA.......................................................................9-61 A－95 ENVIRONMENT DATA ２ ..................................................................9-62 A－96 ENVIRONMENT DATA OF PANEL....................................................9-63 A－99 CHECK SPECIFICATION...................................................................9-64 A－100 SYSTEM INITIALIZATION................................................................9-65 A－101 BATTERY ERROR CHECK..............................................................9-66 A－103 TOUCH PANEL SHORT CIRCUIT CHECK.....................................9-67 A－110 TIME ............................................................................................9-68 A－111 DEDICATED INPUT SIGNAL ...........................................................9-69 A－112 DEDICATED OUTPUT SIGNAL.......................................................9-70 A－113 DEDICATED SIGNAL DISPLAY ......................................................9-71 A－114 GUN SPECIFICATIONS ...................................................................9-73 A－114-1 GUN APPLICATION...................................................................9-74 A－114-20 HANDLING CLAMP DEFINITION ...............................................9-75 A－114-30 PAINTING/SEALING GUN DEFINITION ....................................9-76 A－114-32 GUN RELATIVE DISTANCE CHECK .........................................9-77 A－120 ERROR LOGGING ...........................................................................9-78 A－122 OPERATION LOGGING...................................................................9-79 A－124 MOTOR TORQUE INFORMATION (OPTION)................................9-80 A－124－1 WORNING LOG.............................................................................9-80 A－124－2 PEAK CURRENT...........................................................................9-80 A－127 OPERATION INFORMATION (OPTION).........................................9-81 A－130 PC PROGRAM RUN/STOP (OPTION) ............................................9-82 A－130－1 START (PCEXECUTE) ...............................................................9-83 A－130－2 ABORT (PCABORT) ...................................................................9-83 A－130－3 STOP (PCEND)...........................................................................9-84 A－130－4 CONTINUE (PCCONTINUE) ......................................................9-84 A－130－5 KILL (PCKILL)..............................................................................9-85 A－130－6 STATUS (PCSTATUS) ...............................................................9-85 A－131 INTERFACE PANEL (OPTION) .......................................................9-86 A－133 AS INSTRUCTION DEFINITION (OPTION) ....................................9-87 A－140 ENCODER ROTATION COUNTER RESET....................................9-88 A－142 PROGRAM QUEUE (OPTION) ........................................................9-89 ix



Contents

A－142-1 DISPLAY ........................................................................................9-90 A－142-2 REGIST..........................................................................................9-91 A－142-3 INSERT ..........................................................................................9-92 A－142-4 DELETE .........................................................................................9-93 A－142-5 ALL DELETE..................................................................................9-94 A－142-6 ENVIRONMENT SET ....................................................................9-95 A－143 START DELAY (OPTION) ................................................................9-97 A－143-1 COMMON DELAY DISTANCE......................................................9-98 A－143-2 INDIVIDUAL DELAY DISTANCE ..................................................9-98 A－143-2-1 INDIVIDUAL SETTING...............................................................9-99 A－143-2-2 SET SAME DIST ......................................................................9-100 A－143-3 MULTI START DELAY ................................................................9-100 A－143-3-1 DISPLAY...................................................................................9-101 A－143-3-2 CHANGE...................................................................................9-101 A－143-3-3 DELETE ....................................................................................9-102 A－143-3-4 ALL DELETE ............................................................................9-102 A－144 INTERRUPT PROGRAM................................................................9-103 A－149 TOOL REGISTRATION (OPTION).................................................9-104 A－153 PROGRAMS IN DETAIL.................................................................9-105 A－154 TOTAL REPEAT CYCLES OF PROGRAM ...................................9-106 A－154-1 DISPLAY AND MODIFY..............................................................9-107 A－154-2 ALL CLEAR..................................................................................9-107 A－155 HOME POSITION CHECK AXIS SET............................................9-108 A－158 DOUT FUNCTION ASSIGNMENT.................................................9-109 A－159 HISTORY CLEAR ...........................................................................9-110 A－166 PG PARTIAL DELETE....................................................................9-111 A－167 SINGULAR POINT ALARM RANGE SET......................................9-112 A－168 DIFF. OF WORK/AIR-CUT SPEED................................................9-113 A－169 OPERATION CONDITION SETTING ............................................9-114 A－172 SYSCOUNT DISPLAY/SETTING...................................................9-116 A－172-1 SYSCOUNT DISPLAY/SETTING................................................9-116 A－172-2 GENERAL SYSCOUNT SETTING .............................................9-117 A－172-3 PRIVATE SYSCOUNT SETTING ...............................................9-117 A－173 MOVING AREA XYZ LIMIT ............................................................9-118 A－176 DATA BANK....................................................................................9-119 A－176-1 LIST ..........................................................................................9-119 A－176-2 EDIT ..........................................................................................9-120 A－176-3 COPY ..........................................................................................9-121 A－176-4 DELETE .......................................................................................9-121 A－176-5 ENVIRONMENT SET ..................................................................9-122 A－197 PASSWORD SET (OPTION)..........................................................9-123 A－198 AUXILIARY FUNCTION SET (OPTION)........................................9-124

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Contents

10 OTHER FUNCTIONS THAN TEACHING BY EXPLOSION-PROOF TEACH PENDANT 10.1 LIST OF OTHER FUNCTIONS BY EXPLOSION-PROOF TEACH PENDANT .................................................................................................10-4 1-0 PROGRAM SETTING ............................................................................10-7 1-1 REPEAT STATUS DISPLAY .................................................................10-8 1-2 PRODUCT RATE VALUE SETTING.....................................................10-9 1-3 PRODUCT PAINT_IO RATIO..............................................................10-10 3-0-0 PRORAM LIST DISPLAY (DETAIL) ....................................................10-11 3-0-1 PROGRAM NUMBER LIST DISPLAY.................................................10-11 3-0-2 AVAILABLE MEMORY CAPACITY DISPLAY.....................................10-11 3-0-3 PROGRAM NAME REGISTRATION...................................................10-12 3-1 PROGRAM COPY ...............................................................................10-14 3-2 PTOGRAM LINK ..................................................................................10-15 3-3 PROGRAM DELETION........................................................................10-16 3-4-0 PARTIAL PROGRAM COPY ...............................................................10-17 3-4-1 PARTIAL PROGRAM DELETION .......................................................10-19 3-5-0 PARALLEL SHIFT................................................................................10-20 3-5-1 GUN-TIP DIRECTION SHIFT ..............................................................10-21 3-5-2 MIRROR IMAGE CONVERSION ........................................................10-22 3-5-3 TRAVELLER SHIFT WITH GUN TIP FIXED.......................................10-23 3-5-4 SHUTTLE RIGHT-LEFT CONVERSION (OPTION) ...........................10-23 3-5-5 CONVEYOR POSITION SHIFT (OPTION) .........................................10-24 3-6 AUTOMATIC PATH GENERATION ....................................................10-25 4-0 DATA BANK EDITING .........................................................................10-26 4-1-0 DATA BANK DETAILS DISPLAY ........................................................10-28 4-1-1 DATA BANK NUMBER DISPLAY........................................................10-28 5-0-0 GUN POSITION/ANGLE......................................................................10-29 5-0-1 JOINT VALUE DISPLAY......................................................................10-30 5-0-2 JOINT COMMAND VALUE DISPLAY .................................................10-31 5-0-3 ENCODER VALUE DISPLAY..............................................................10-31 5-0-4 POSITION DISPLAY OF TRAVERSE AXES ......................................10-32 5-0-5 TABLE POSITION DISPLAY (OPTION)..............................................10-32 5-0-6 GUN POSITION/ WRIST ANGLE DISPLAY .......................................10-32 5-1-0 EXTERNAL OUTPUT SIGNAL DISPLAY ...........................................10-33 5-1-1 EXTERNAL INPUT SIGNAL DISPLAY ...............................................10-34 5-1-2 INTERNAL SIGNAL DISPLAY.............................................................10-35 5-1-3 HOME POSITION SIGNAL DISPLAY .................................................10-36 5-2-0 GENERAL COUNTER DISPLAY.........................................................10-37 5-2-1 DEDICATED COUNTER DISPLAY.....................................................10-37 6-0-0 OPERATION CONDITION SELECTION (EXTERNAL OUTPUT)......10-38 6-0-1 OPERATION CONDITION SELECTION (INPUT WAIT) ....................10-39 6-0-2 OPERATION CONDITION SELECTION (CONVEYOR WAIT) ..........10-40 6-0-3 OPERATION CONDITION SELECTION (TIME WAIT) ......................10-41 6-0-4 OPERATION CONDITION SELECTION (CV TRACK MODE)...........10-42 6-0-5-0 OPERATION CONDITION SELECTION (SENSOR SETTING/ DOOR SENSING).............................................................................10-43 6-0-5-1 OPERATION CONDITION SELECTION (SENSOR SETTING/ CAMERA SENSING)........................................................................10-43 xi



6-1 6-2 6-3 7-0 7-1 8-0 8-1 8-2 8-3 8-4 8-5 8-6 8-7

Contents

CURRENT CONVEYOR POSITION SETTING (CURRENT CV_POS) ..........................................................................................10-44 COUNTER VALUE SETTING..............................................................10-45 LOCATION VARIABLES REGISTRATION .........................................10-46 ERROR HISTORY DISPLAY...............................................................10-47 TOTAL PLAYBACK COUNT DISPLAY ...............................................10-48 MANUAL EXTERNAL OUTPUT EXECUTION (GENERAL SIGNALS) ..........................................................................................10-49 MANUAL EXTERNAL OUTPUT EXECUTION (SPRAY SIGNALS)...10-50 MANUAL EXTERNAL OUTPUT EXECUTION (FLOW RATE)...........10-51 MANUAL EXTERNAL OUTPUT EXECUTION (SHAPING/ PATTERN AIR).....................................................................................10-52 MANUAL EXTERNAL OUTPUT EXECUTION (AIR MOTOR/ ATOMIZING AIR) .................................................................................10-53 MANUAL EXTERNAL OUTPUT EXECUTION (HIGH VOLTAGE) ....10-54 MANUAL EXTERNAL OUTPUT EXECUTION (FLUSHING) .............10-55 MANUAL EXTERNAL OUTPUT EXECUTION (PUSH THINNER) ....10-56

11 AUTOMATIC TOOL REGISTRATION (OPTIONAL) 11.1 AUTOMATIC TOOL REGISTRATION FUNCTION - OVERVIEW............11-2 11.2 REQUIRED DATA FOR AUTOMATIC TOOL REGISTRATION...............11-3 11.2.1 TEACHING TOOL DIMENSIONS FOR 4 BASE POINTS ....................11-3 11.2.2 TEACHING TOOL POSTURE FOR TOOL Z DIRECTION...................11-4 11.2.3 TACHING TOOL ORIENTATION WHEN DISPLACED IN Y DIRECTION............................................................................................11-4 11.3 MEASURING TOOL DIMENSIONS – POINTS FOR CAUTION ..............11-5 11.3.1 METHOD FOR TEACHING POINTS B, C (EXAMPLE)........................11-6 11.4 OPERATION METHOD .............................................................................11-7 11.4.1 PREPARATIONS FOR AUTOMATIC TOOL REGULATION................11-7 11.4.2 REGISTERING BASE POSTURE .........................................................11-8 11.4.3 REGISTERING MEASUREMENT VALUES .........................................11-9 12 CONVEYOR TRACKING (OPTION) 12.1 OVERVIEW OF CONVEYOR TRACKING FUNCTION............................12-2 12.2 OPERATION OF CONVEYOR TRACKING FUNCTION ..........................12-3 12.2.1 SELECTING CONVEYOR TRACING ..............................................12-3 12.2.2 CURRENT POSITION DISPLAY......................................................12-4 12.2.3 SETTING THE DATA ........................................................................12-5 12.2.4 SETTING ENVIRONMENTAL DATA................................................12-7 12.3 OPERATING THE SIMULATION FUNCTION ........................................12-10 12.3.1 SELECTING ....................................................................................12-10 12.4 TEACHING STANDARDS .......................................................................12-12 12.4.1 OVERVIEW OF TEACHING OPERATIONS BY CONVEYOR TRACKING .......................................................................................12-12 12.4.2 PREPARATORY OPERATIONS FOR TEACHING .......................12-15 12.5 TEACHING ...............................................................................................12-16 12.5.1 CAUTIONS TO BE TAKEN DURING TEACHING .........................12-16 12.5.2 EXAMPLES OF TEACHING ...........................................................12-16 12.6 REPEAT RUN AND PROGRAM CHECKING METHOD........................12-32 xii



Contents

12.6.1 OVERVIEW OF CHECKING OPERATION....................................12-32 12.6.2 FLOW OF CHECKING OPERATION AND REPEAT RUN............12-33 12.7 INTERLOCK SIGNALS ............................................................................12-37 12.8 CONVEYOR POSITION SHIFT FUNCTION...........................................12-38 13 INTERFACE PANEL SETTINGS (OPTION) 13.1 OVERVIEW OF THE INTERFACE PANEL...............................................13-2 13.2 PROCESSING SEQUENCE ON INTERFACE PANEL ............................13-3 13.3 SELECTING THE INTERFACE PANEL SCREEN ...................................13-4 13.4 METHODS FOR SETTING INTERFACE PANEL.....................................13-5 13.4.1 SWITCH SETUP ...............................................................................13-5 13.4.2 PUSH BUTTON SETUP ...................................................................13-6 13.4.3 PUSH BUTTON WITH LAMP - SWITCH SETUP ............................13-7 13.4.4 2-NOTCH SELECTOR SWITCH - SETUP .....................................13-8 13.4.5 3-NOTCH SELECTOR SWITCH - SETUP.......................................13-9 13.4.6 PILOT LAMP - SETUP....................................................................13-10 13.4.7 DIGITAL SWITCH - SETUP............................................................13-11 13.4.8 DIGITAL DISPLAY - SETUP...........................................................13-12 13.4.9 TEXT WINDOW – SETUP (OPTION).............................................13-13 13.4.10 SOFTWARE DEDICATED SIGNALS.............................................13-14 14 COUNTER MEASURES FOR ERRORS 14.1 SYSTEM INITIALIZATION .........................................................................14-2 14.1.1 CALLING UP INITIALIZATION SCREEN..............................................14-3 14.1.2 OPERATION PROCEDURES ON THE INITIALIZATION SCREEN ....14-4 14.2 NORMAL PROCEDURES WHEN ERRORS OCCUR .............................14-5 APPENDIX APPENDIX1 APPENDIX2 APPENDIX3 APPENDIX4 APPENDIX5 APPENDIX6

PROGRAM SHEET.......................................................................A-2 EXPLOSION-PROOF TEACH PENDANT MENU DIRECTORY LIST........................................................................A-5 MULTI-FUNCTION PANEL MENU DIRECTORY LIST ............ A-11 MULTI-FUNCTION PANEL AUXILIARY FUNCTION LIST....... A-12 INITIAL DATA SETTINGS ......................................................... A-16 OAT ............................................................................................ A-18

AS LANGUAGE LIST ................................................................................................ AS-1 ERROR MESSAGE TABLE.........................................................................................E-1 GLOSSARY................................................................................................................. G-1 INDEX............................................................................................................................ I-1

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Memo

This section summarizes safety precautions to be taken prior to operating your Kawasaki Robot. Also, safety measures and the speed, motion range limitations on the robot are described.

1 2 3

ENSURING SAFETY ........................................................................................................ 2 SAFETY IN GENERAL ..................................................................................................... 2 ROBOT SPEED LIMITATIONS........................................................................................ 3

4 5 6 7

ROBOT MOTION RANGE................................................................................................ 3 FIVE SAFETY RULES FOR KHI ROBOTS..................................................................... 4 SAFETY DURING START-UP ......................................................................................... 7 ENSURING SAFETY DURING TEACHING OPERATIONS.......................................... 8

8

DANGER PREVENTION DURING OPERATIONS........................................................ 9


SAFETY

Safety [ Note ]

The safety content described here applies only to operations with the robot unit and is not intended as a safety explanation for the whole system.

1 ENSURING SAFETY In order to ensure safety, all local, regional, municipal and national safety laws and regulations must be strictly observed. 1. The teaching and maintenance work on the robot must be carried out in accordance with labor safety laws and regulations. 2. The user should prepare safety regulations for working on the robot itself and observe these regulations responsibly. 3. In order to ensure safety, the following safety standards should be observed: JIS B8433, ISO10218, EN775, for robots used in production applications. 4. Safety administrators and full-time personnel should be assigned for work on the robot. In addition, a safety administrative system should be established as a means of providing thorough education regarding safety.

2 SAFETY IN GENERAL 1. The plant administrator should create safety and work regulations in consideration of structure of the line and peripheral equipment so that injuries from the robot are prevented. Moreover, appropriate steps should be taken so that safety education and work standards are created for the benefit of the workers. 2. Never use a Kawasaki Robot beyond the standard ability of the robot as set in the specifications manual. (Including specifications for payload, speed, motion range, environment, etc.) 3. Prior to starting operation, operators are expected to fully understand operation manuals and materials relating to the robot usage. And, care must be taken so that no injury occurs as a result of carelessness during operation. 4. Care must be taken so that none of the electrical components become loose or disconnected while the robot is energized. (e.g. connectors, circuit boards, etc.) 5. Also, care must be taken so that neither the explosion-proof teach pendant nor the multifunction panel are dropped or exposed to heavy impact, as they consist of a variety of precision instruments.

2


C Series Controller, Explosion-proof Type Kawasaki Robot Operation Manual

Safety

3 ROBOT SPEED LIMITATIONS The maximum speed is limited to 250mm/sec. when operating the robot in check or teach mode from the multifunction panel or the teach pendant.

4 ROBOT MOTION RANGE A maximum possible motion range has been established for every robot model, unless the robot is given special specifications at the time of purchase. However, the motion range can be restricted to support the requirements according to the needs of the application.

1.

Motion Range Limits via Software Motion range limits can also be set for the robot by software.

！WWARNING Setting only software limits on the robot’s motion range is insufficient as a countermeasure for preventing serious or fatal accidents. Mechanical stoppers as well as a safety fence must also be established. 2.

Motion Range Limits via Mechanical Stoppers When mechanical stoppers are needed refer to the separate volume “Installation and Connection manuals for the robot arm”.

3



Safety

5 FIVE SAFETY RULES FOR KHI ROBOTS

！ WARNING Before operating, the following five basic points must be given attention in order to use the robot safely. Because the content here describes only fundamental points regarding safety, thorough reading of the separate safety manual is highly recommended.

1.

Without exception, install the robot within a safety fence. Ensure that the robot is not easily approachable by people.

2.

Provide a safety plug mechanism on the door of the safety fence. The safety plug should be installed so that the door cannot be opened without removing the plug and so that motor power to the robot will be cut off if the plug is removed during operation.

4



Safety

3a. When performing work inside the safety fence, such as robot teaching or confirming that the work is complete, the worker must enter only after removing the safety plug. This will prevent the robot from being switched on to automatic run by another worker.

3b. In addition, during teaching operations an observer must be stationed in front of the controller and be ready and able to stop the robot at any time in case of an emergency. These duties can only be assigned to persons who have completed special training and are qualified to use the robot.

4. While the robot is operating automatically (running) or waiting in stand by mode, never enter the fenced area.

5



5.

Safety

Indicate the current status of the robot clearly and simply so that anyone can understand, for example with a sign showing automatic operation, teaching, emergency stop, etc.

6



Safety

6 SAFETY DURING START-UP

When starting up the robot, switch on the power to the motor and control panel. Pay special attention to the items below to ensure safety during start-up.

1.

Before switching Motor Power on, make certain that the work cell is empty and that no one is within the safety fence, also confirm that there are no obstructions in the path of the robot. When switching Motor Power on, be ready and able to press the Emergency Stop switch in the event the robot moves abnormally.

2.

Before starting operations in repeat mode, confirm that the work cell is empty and that no one is within the safety fence, also confirm that there are no obstructions in the path of the robot.

7



Safety

7 ENSURING SAFETY DURING TEACHING OPERATIONS

Confirm the contents of the teaching when creating programs or teaching point information to the robot. Pay special attention to the items below to ensure safety during teaching.

1.

When entering the safety fence area, confirm that all safety and indicator devices, as well as the functions and devices for regulating the motion range of the robot are in good working order. Moreover, the worker should hold the teach pendant and perform teaching so as to be able to stop the robot or find cover immediately in the event the robot moves abnormally.

2.

The robot must be installed in an area where the entire motion range of the robot can be overseen by an observer responsible for holding the Emergency Stop switch. When one worker (teacher) is inside the safety fence, the observer must be stationed outside and be able to press the Emergency Stop switch immediately if trouble arises. Duties including observing and working inside the safety fence are limited to those who have completed special training on robot usage.

3.

In order to run at a safe speed during teaching, operate the robot at 10% (or lower) of the repeat speed when: jogging the robot to the teaching point, and confirming the teaching by moving either in one step increments or in 1 continuous cycle of steps.

4.

During teaching, alert the attention of others so that none of the robotic instruments are handled carelessly or accidently. Instruments include: controller, multi-function panel, teach pendant, keyboard, etc.

5.

When observer and teacher work together, one person must be designated as supervisor before the teaching operation can proceed. In addition, any signals used during teaching and the step order of the teaching must be understood and confirmed in advance.

6.

While working within the area of the safety fence the observer and teacher must never take their eyes off the robot.

8



Safety

8 DANGER PREVENTION DURING OPERATIONS

Typically, the robot is running in a state of continuous motion during automatic operation. In order to prevent any accidents during automatic operation pay special attention to the items below.

1.

During automatic operation, never enter the safety fence area under any circumstances.

2.

In automatic operation, the robot may stop motion during timer mode or while waiting for input signal. Be careful at these times because the robot will restart motion as soon as the signal conditions are realized or the time count is completed.

3.

If the installation of the tool or the grasp of the work is insufficient during automatic operation, the tool may become disengaged or the work may be ejected from the robot. To prevent these kinds of accidents, take extra care in checking the conditions of the tool attachment and the grasping of the work. Moreover, for applications in which the work is manipulated with a pneumatic device (hand, end-effector), set up a fail safe structure so that the work is not thrown as a result of an accidental cut in air or power to the solenoid valve.

4.

When the robot stops due to some malfunction during automatic operation, confirm the contents of the error message shown on the display and perform an appropriate restoration of the system. Responsibility for resolving the error code numbers/messages that may arise should be assigned to teaching, operations and maintenance supervisors in advance. In addition, it is essential to clearly define the steps to be taken by each supervisor during system trouble.

9



10


Memo

SWITCHES AND KEYS This chapter describes the switches and keys for the controller, explosion-proof teach pendant, and multifunction panel.

1.1

SWITCHES ON THE CONTROLLER............................................................. 1-2

1.2 1.2.1 1.2.2 1.2.3

MULTIFUNCTION PANEL .............................................................................. 1-4 SWITCHES ON THE MULTIFUNCTION PANEL........................................... 1-4 LIQUID CRYSTAL DISPLAY........................................................................... 1-5 KEYS ON THE LIQUID CRYSTAL DISPLAY................................................. 1-6

1.2.4 1.3 1.3.1 1.3.2

KEYBOARD ..................................................................................................... 1-7 EXPLOSION-PROOF TEACH PENDANT ..................................................... 1-8 KEYS AND SWITCHES................................................................................... 1-8 DISPLAY DURING TEACHING .................................................................... 1-13

1-1


1

1.1

1. Switches and Keys

SWITCHES ON THE CONTROLLER

This unit provides information about the switches located on the C Series Controller, Explosion-Proof Type. Backside of the controller

Multifunction Panel

Multifunction panel connector

Operation panel 10

3 4 6 9 Control power switch (circuit breaker)

8 7 5 Communication port

1 2 Connector for the explosionproof teach pendant

Explosion-proof teach pendant

Control power switch (breaker): Switch to ON to turn on the control power of the controller. Switch to OFF to turn off the control power of the controller. 1-2




These switches are mainly for the regular repeat operation. No. Switch or light Function Illuminates when the control power of the controller is ON.

1 Hour meter

2

０１９９６９

Indicates the total motor power ON time.

3

Illuminates when errors occur. initialization screen appears.

4

An error is reset when pressed. The error light is turned off after the error is reset properly. (Sequential errors cannot be reset.)

5

Switches the robot condition between operable (RUN) and temporary stop (HOLD).

6

Switches modes between TEACH and REPEAT. (This needs the attached keys.)

7

Repeat operation starts when pushed. This light illuminates when repeat operation starts properly.

8

Motor power is turned on when pushed. This light illuminates when motor power is applied properly.

9

Switches the method to start repeat operation. REMOTE: From the external start signal. LOCAL: From the Cycle Start button on the controller. Emergency Stop

10

Blinks when the

The motor power is shut off and the robot stops when pushed. Motor Power light and Cycle Start light are turned off at the same time. (Control power is not shut off).

Terms Teach mode: A mode for teaching by the remote control box for teaching (called explosion-proof teach pendant). Repeat operation is not possible in this mode. Repeat mode: A mode for starting repeat operation. Repeat operation: A robot condition in which taught operations are automatically repeated.

1-3



1.2


MULTIFUNCTION PANEL

1.2.1

SWITCHES ON THE MULTIFUNCTION PANEL

Multifunction panel uses a large-sized color liquid crystal VGA display equipped with touch panel function. Keys are easily operated just by touching lightly on the liquid crystal display. These keys are for entering and editing various data.

1

4

3

2

No. 1 2 3 4

Switch or light Liquid crystal display PC card slot Contrast adjustment knob Touch panel pen

Function Provides keys for entering and editing various data on robots. Also displays status, teaching and various data. For inserting a PC card. See A –14 PC card Adjusts the shading (brightness) of the display. Used for touch panel operation.

1-4



1.2.2


LIQUID CRYSTAL DISPLAY

The liquid crystal display contains the following areas:

1

4

2

3

(The actual display may be different in some parts.) 1. System message area: Errors are indicated. 2. Title area: Displays the title of the selected status or function. 3. Auxiliary data area: Displays the present status and the teaching status of the present step. 4. Status information area: Displays status information. For example: {M-OFF {HOLD {TEACH {

1-5

{M-ON {RUN {REPEAT {

Repeat Accept

Slow repeat Inhibit



1.2.3


KEYS ON THE LIQUID CRYSTAL DISPLAY

Keys associated with programs and steps: STEP

PROGRAM

pg1

PC

1

Key

Function

PROGRAM

pg1 STEP

Displays the program name that is currently selected. The program selection screen appears when pushed.

Displays the current step number. 1 The step selection screen appears when pushed.

PC

Displays the PC program name that is currently selected.

Keys for selecting screen:

Key

Function Used for teaching programs. Screens for teaching appear when pushed: AS TEACHING (option), PROGRAM INPUT (option). Toggles screens: STATUS, PROGRAM LIST, MONITOR, and CURRENT POSITION, PAINTING STATUS. Repeat conditions can be selected in the STATUS screen. Toggles screens among status, function selection, and keyboard entry. STATUS, FUNCTION, INTERFACE PANEL SETTING (option), KEYBOARD screens are equipped with auxiliary functions with which various data can be displayed and set.

As for the multifunction panel with specification 2 (pull-down menu type), pushing STATUS and MENU keys drops menu selection keys below each key.

1-6



1.2.4


KEYBOARD

The keyboard screen can be selected when the

key on the multifunction panel is pressed. MENU

Robot language programming and operation control of the robot are possible using AS Language in this screen. NEXT MENU key CTL+L key Backspace key

SPACE key Switch ＢＳ

SHIFT key

ENTER key

Function The BACK SPACE key is used to delete the entered characters one by one.

NEXTMENU

The NEXT MENU key switches the multifunction panel display from the keyboard screen to the status screen.

ＥＮＴＥＲ

The ENTER key is used for setting the AS Language commands, executing, and entering data.

SHIFT

The SHIFT key is used to enter the special symbols indicated on the top of the character keys by pressing with the other character keys. For example, when is pressed with the shift key, the symbol ! can be entered.

NEXT PG

Goes to the next page.

ＣＴＬ＋Ｌ

SPACE key

Displays the previously entered character strings (can go back a maximum of 10 previous entries). When the SHIFT key is pressed, this key turns into CTL+N key. CTL+N key displays the next character string to the present string. Used to enter a space.

1-7




1.3 EXPLOSION-PROOF TEACH PENDANT 1.3.1 KEYS AND SWITCHES The explosion-proof teach pendant is equipped with the keys for robot manual operation, teaching programs, entering and editing various data.

Liquid crystal display

Trigger switch Emergency stop switch

Backside of the explosion-proof teach pendant

1-8




Key SPRAY

X-OUT GUN

X-IN

SMOTH

DATA

TIMER

CALL

JUMP

CONVR

SPEED

SHIFT

Function For entering the numeric value of 1. Decimal point can be entered when pressed with the shift key. For entering the numeric value of 2. Numeric value A (hexadecimal) can be entered when pressed with the shift key. For entering the numeric value of 3. Numeric value B (hexadecimal) can be entered when pressed with the shift key. For entering the numeric value of 4. Numeric value C (hexadecimal) can be entered when pressed with the shift key. For entering the numeric value of 5. For entering the numeric value of 6. The minus can be entered when pressed with the shift key. For entering the numeric value of 7. Numeric value D (hexadecimal) can be entered when pressed with the shift key. For entering the numeric value of 8. Numeric value E (hexadecimal) can be entered when pressed with the shift key. For entering the numeric value of 9. Numeric value F (hexadecimal) can be entered when pressed with the shift key. For entering the numeric value of 0. Used with the other keys. The additional values such as A – F can be entered when pressed with the other keys. Moves the cursor up the screen (to smaller numbers).

SHIFT

＋

Goes back to the previous screen. Moves the cursor down the screen (to larger numbers).

SHIFT

＋ CLR

Goes to the next screen. Cancels the numeric entry and clears all.

1-9



Key END

SHIFT

＋ END

SUSPEND


Function Returns to the main menu. Cancel the selection of program. The repeat operation ends when pushed during the repeat operation. Holds the present mode and moves to the other mode. The original mode appears when this key is pressed again. Returns to the upper screen.

SET

RT

LFT

FRNT

SHIFT

＋ FRNT BCK

Moves to the next screen when pressed for confirmation of menu selection or numeric value entry. Moves the robot in the right direction in the Cartesean coordinates or swivels the 1st axis to the right. The table axis rotates in normal (+) direction. Moves the robot in the left direction in the Cartesean coordinates or swivels the 1st axis to the left. The table axis rotates in reverse (-) direction. Moves the robot forward in the Cartesean coordinates or rotates the 2nd axis forward. Moves in the forward direction of the gun (only for the frame coordinates). Moves the robot backward in the Cartesean coordinates or rotates the 2nd axis backward.

＋ BCK

Moves in the backward direction of the gun (only for the frame coordinates).

UP

Moves the robot upward in the Cartesean coordinates or rotates the 3rd axis upward.

DWN

Moves the robot downward in the Cartesean coordinates or rotates the 3rd axis downward.

SWING RT

Turns the gun to the right in the Cartesean coordinates or rotates the 4th axis to the right.

SWING LFT

Turns the gun to the left in the Cartesean coordinates or rotates the 4th axis to the left.

BEND FRNT

Rotates the gun upward in the Cartesean coordinates or rotates the 5th axis to the right.

BEND BCK

Rotates the gun downward in the Cartesean coordinates or rotates the 5th axis to the left.

SHIFT

1-10




Key

Function

TURN UP

Rotates the gun to the right in the Cartesean coordinates or rotates the 6th axis to the right.

TURN DWN

Rotates the gun to the left in the Cartesean coordinates or rotates the 6th axis to the left.

FRAME

Toggles the coordinate system at manual operation: Easy → Gun → Joint

＋

SHIFT

FRAME

ROB

TRV

TBL

Selects the coordinate system to be switched with the coordinate selection key: Easy → XYZ1 → XYZ2 Selects an axis to be operated with the axis key: robot or other axes. LED toggles by pressing the device selection key as: Robot → Traverse → Table

EQPMT

Note: The detail of the device selection key may be different depending on the robot system structure. Toggles the manual speed of the robot and the peripheral devices among three levels: High → Medium → Low

H M L SPEED

Selects interpolation when recording positions. pressing the interpolation key as: Linear → Circular (middle → end)→ Joint

L C J

MOTION

SHIFT

＋

MOTION

STORE

In teaching and edit modes, selects a type for correcting command codes from among Prohibit/Add/Modify/Delete/ Search.

CRCT

＋

The circular LED is lit up in the middle of the circular arc and blinks at the end. During linear/circular interpolation toggles among: Retaining gun posture/wrist axis angle. Note: When retaining wrist axis angle, linear and circular interpolation LEDs are lit up and joint interpolation LED blinks. Records the present location as a teaching point.

POS

SHIFT

LED toggles by

CRCT

RESET

Changes the default correction mode to Prohibit/Add/Modify when correcting command codes on the command display screen for teaching and editing. Resets all the errors.

1-11



Key SHIFT

＋


Function RESET

Resets errors one by one when more than one errors occur at the same time.

SPRAY ON/OFF

Selects whether or not to spray paint. When spraying (ON), the LED is lit up.

SPRAY 1/2

Turns on the Spray 1 signal (outputs while key is pressed).

SHIFT

＋

SPRAY 1/2

TEACH LOCK

STEP

Turns on the Spray 2 signal (outputs while key is pressed). Switch is designed to avoid repeat operation from being conducted accidentally during teaching. This switch needs to be ON after stopping repeat operation before entering into the safety fence. Cycle start cannot be conducted while Teach Lock is ON (LED is on). Toggles the way to move through steps, backwards or forwards, when in check mode (confirming the trajectory). Every time the key is pressed, the way to move from the first move in the screen toggles as: Move Command Continuous Jump

STEP NEXT

Shifts the program forward when in check mode (confirming the trajectory).

STEP BACK

Shifts the program backward when in check mode (confirming the trajectory).

The keys below are the LED indication only: Key Function Indicates that the servo of the robot (manipulator) is ON SERVO ROB TBL when this LED is lit. Indicates that the servo of the table is ON when this LED is SERVO ROB TBL lit. Note: LED names may be different depending on the robot system structure. (The above is for standard specification.)

Switch and push-button switch on the explosion-proof teach pendant: Key Function Emergency stop Turns OFF the servo power and stops the robot. switch Trigger switch Enables/disables the robot’s motion (enabled only while pressed.) These switches can be engaged only in teach mode.

1-12



1.3.2


DISPLAY DURING TEACHING

The display during teaching appears as follows: 1

2

3

4

5

6

7 Correction mode (Prohibit/Add/Modify/Delete/Search), which is a sub-mode, is 1

displayed. Use

CRCT

key to change the mode.

Displays coordinate system (Easy (XYZ1)(XYZ2)/Gun/Joint) at manual operation. 2

Use

FRAME

key to change the system.

Displays how the program is shifted (per move/command/continuous/jump) when 3 pressing

STEP NEXT

and

STEP BACK

keys in check mode.

Use

STEP

key to change

the shifting method. 4 Displays program number that is presently taught. Displays present point number. 5 Counts MOVE commands in the program from the top and displays as a point number. 6 Displays operation guidance. Displays commands taught in each step below the 3rd line. The sequential number on the left indicates in command unit. 7 The highlighted number indicates that the the command execution is complete. The above example means that the commands up to the command unit 3, turning on the spray No.1, are executed.

1-13



1-14


Memo

This chapter describes the procedures for power on/off of the controller and for stopping the robot motion.

2.1 TURNING THE POWER ON ............................................................................................................2-2 2.2 TURNING THE POWER OFF ............................................................................................................2-5 2.3 STOPPING THE ROBOT ................................................................................................................2-6

2-1


2

PROCEDURES FOR POWER ON/OFF AND STOPPING THE ROBOT MOTION

2.1

2. Procedures for Power ON/OFF and Stopping the Robot Motion

TURNING THE POWER ON

The procedure for starting the robot operation is as follows:

！

WARNING

When turning the Control and Motor Power of the robot controller on, thorough attention should be taken to prevent personnel from entering the motion range of the robot and the peripheral equipment controlled by the robot controller. The robot may move or operate accidentally when turning on the motor power, if the robot servo system is damaged.

<1> Turn the Control Power on.

<2>

The version information is displayed on the teach pendant screen. Note: The version displayed depends on the software.

<3>

Air purging process is automatically started. Note: This process is executed in pressurized explosion-proof type of robots such as KE and KF series. Steps 3-5 are skipped in the flame-proof type of robots. After confirming that the the purge air is supplied, step 4 is automatically started.

2-2




<4>

The purging time starts to be counted down. Note: Purging time depends on the manipulator type. When purging is complete, the next screen automatically appears. <5>

After purging, the robot waits for the pressure to rise in the pressurized enclosure. When the pressure rises, the next screen automatically appears. <6>

The main menu appears.

<7> Turn the TEACH/REPEAT Switch to TEACH.

<8> Turn the MOTOR POWER on. The lamp is lit up. 2-3




In teach mode, turning the motor power ON will not bring actual motor power to the robot immediately. The motor brake holds the robot at the current posture. After the motor power is on, the motor current is activated by pressing the trigger switch located on the backside of the explosion-proof teach pendant. Then, after 0.5 second, the motor brake is released and the robot becomes servo-locked.

2-4



2.2


TURNING THE POWER OFF

The procedure for turning the power off when finishing the robot operation is as follows. In this example external signals are not used. See the External I/O Manual, a separate volume, for using external signals.

！

WARNING

When shutting off the control power (breaker) of the robot, be sure to turn off the motor power by pressing the EMERGENCY STOP Switch located on the controller before turning off the control power switch (breaker).

<1> Press the EMERGENCY STOP switch and Turn the MOTOR POWER off. (The light goes off.)

<2> Turn the CONTROL POWER switch off.

Turning off the motor and control power is complete.

2-5




2.3 STOPPING THE ROBOT MOTION The following emergency stop procedures are provided for stopping the robot motion immediately. These procedures can be executed regardless of the robot mode, repeat or teach. The robot motor power is shut off and the arm comes to a complete stop when executed.

Controller EMERGENCY 非常停止STOP

Press the EMERGENCY STOP switch located on the controller. The MOTOR POWER and CYCLE START lights on the controller turn off.

Explosion-proof teach pendant Press the EMERGENCY STOP switch located on the explosion-proof teach pendant. The MOTOR POWER and CYCLE START lights on the controller turn off.

External equipment such as interlock board Press the EMERGENCY STOP switch. The MOTOR POWER and CYCLE START lights on the controller turn off. See the External I/O Manual (Interlock Signals), a separate volume.

When stopping the robot motion using the above procedures, the ERROR light on the controller may turn on or an error message may appear on the display. For restarting the robot from the stopped condition, press the ERROR RESET switch and then the MOTOR POWER or CYCLE START switch. [ NOTE ]

The EMERGENCY STOP switch should be used only for urgency during the robot operation. An emergency stop gives a sudden brake on the motor that drives the robot arm. This means that the robot is forced to stop by excessive power, and this may give a damage to the robot components.

2-6




The following three procedures are provided for stopping the robot motion during repeat operation.

Switches used for stopping the robot motion E-STOP SWITCH on the teach pendant

E-STOP

SWITCH

RUN

HOLD

CYCLE START ON

To REPEAT

E-STOP

CYCLE START OFF

MOTOR POWER ON

E-STOP

MOTOR POWER OFF

Arm in a complete stop

Arm in hold

Arm in motion

TOGGLE SWITCH TOGGLE SWITCH

To TEACH E-STOP

Press Press

2-7



2-8


Memo

3

BASIC OPERATION OF MULTIFUNCTION PANEL This chapter describes the basic operation procedures for using the multifunction panel.

3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8

SWITCHING THE SCREEN OF THE MULTIFUNCTION PANEL..............................3-2 BASIC SCREEN STRUCTURE ON THE MULTIFUNCTION PANEL ........................3-4 STATUS SCREEN.........................................................................................................3-5 OTHERS ........................................................................................................................3-6 STATUS SCREEN.........................................................................................................3-8 SPRAY STATUS SCREEN ...........................................................................................3-9 PROGRAM LIST SCREEN ........................................................................................ 3-13 MONITOR SCREEN................................................................................................... 3-14 CURRENT POSITION SCREEN ............................................................................... 3-17

3.2 3.3

MOVING CURSORS .................................................................................................. 3-18 SELECTION BY ENTERING NUMERIC VALUES OR CURSOR OPERATION .... 3-19

3.4 3.5 3.6

ENTERING CHARACTERS....................................................................................... 3-20 SELECTING PROGRAMS ......................................................................................... 3-21 SELECTING STEPS................................................................................................... 3-23

3-1


操作説明書

3. Basic Operation of Multifunction Panel

3.1 SWITCHING THE SCREEN OF THE MULTIFUNCTION PANEL

or

Press

keys to display pull-down menu. MENU

STATUS

Select the desired key to switch screens.

Status Display screen

STATUS

Ø

⇒ Status screen

See 4 Status screen.

⇒

See 3.1.6 Program List screen.

Program List screen

⇒ Monitor screen

See 3.1.7 Monitor screen.

⇒ Current Position screen

See 3.1.8 Current Position screen.

⇒ Spray Status screen

See 3.1.5 Spray Status screen.

3-2


C Series Controller, Explosion-Proof Type Kawasaki Robot Operation


Menu screen

Ø

⇒ Status screen See 3.1.4 Status screen, 3.1.5 Spray Status screen, 3.1.6 Program List screen, 3.1.7 Monitor screen (Output signal), and 3.1.8 Current Position screen ⇒ Aux function screen See 9. Auxiliary Functions ⇒ Setting screen for interface panel (option) See 13. Interface Panel Setting ⇒ Keyboard screen (Option) See 1.2.4 Keyboard

3-3




3.1.1 BASIC SCREEN STRUCTURE ON THE MULTIFUNCTION PANEL (1) Keys for switching screens (A): Left menu key for teaching (B): Right menu key for status display (C): Menu key (A)

(B)

(C)

Status

Status Display

Program List

Aux. Function

Monitor

Interface Panel

Current Position

Keyboard

Spray Status

Note: The left and right menu keys can be switched by pressing the keys indicated by (A) and (B) above. The selected menu key is darkened. (D): Returns to the STATUS screen by pressing the EXIT key on the function list screen of the Aux screen. (2) Keys for program and step selection PROGRAM STEP (A): Program selection and display key (B): Step selection and display key (C): PC program display key (A) (B) (C) A small screen for step selection appears. Switches to the program selection screen. (3) Others Program List screen contains two pages which can be switched by the PRE PG and NEXT PG keys. NEXT Program List Program List PRE PG (1/2) (2/2) Monitor screen contains Input, Output, and Internal Signal screens which can be switched by each key located on the downside. Output Monitor Monitor Input (Input Signal) (Output signal) Internal Output Input

Monitor (Internal Signal) 3-4

Internal




3.1.2 STATUS SCREEN (1) Status

(2) Program List

(3) Monitor

3-5




(4) Current Position

(5) Spray status

3.1.3 OTHERS (1) Auxiliary Function

3-6




(2) Key board

(3) Program selection

(4) Step selection (When the status screen is displayed.)

3-7




3.1.4 STATUS SCREEN Shows the current status and repeat conditions.

Shows the monitor speed. Shows year, date, and time. Shows the repeat condition. Shows the current mode. The displayed color changes when turned ON and OFF. Displayed only when STEP ONCE is selected. Shows the step number and data. The second line is highlighted and shows the step in progress. Shows the location data of the step in progress.

Set Items Repeat 10% Repeat condition Display Items E-STOP Motor power Cycle start Teach/Repeat Hold/Run Error Normal Release ext. hold Record accept Step forward Repeat Cont/Once Step Cont/Once

Descriptions The repeat speed is indicated in percentage. See 8.5 Repeat Condition Selection Descriptions Turns on when the EMERGENCY STOP switch is pressed. Turns on when the MOTOR POWER switch is pressed. Turns on when the CYCLE START switch is engaged. Indicates robot mode; Teach or Repeat. Indicates the robot condition; Hold or Run Turns on when errors occur. Turns on when the robot is operating normally without any errors. Turns on when the stop release is engaged.

The color changes when teaching becomes effective. Appears when STEP ONCE is selected. Indicates the status of the repeat operation programmed, one cycle only (Repeat Once) or continuous cycle (Repeat Cont). Indicates the program execution status, step by step (Step Once) or continuously (Step Cont). Indicates that RPS (Random Program Selection) function is enabled or RPS disabled. RPS is a function for selecting programs by external input Enable/Disable signal to the robot. Dryrun Indicates that the Dryrun mode is effective (ON) or not effective (OFF). ON/OFF 3-8




3.1.5 SPRAY STATUS SCREEN

Set items Spray output All ratio set Signal output

Descriptions Switches to the Spray output screen. Switches to the All ratio set screen. Switches to the Signal output screen.

Display items Production speed ratio

Descriptions Indicates the production speed ratio data. Indicates the conveyor speed. (when the conveyor synchronization function is enabled.) Indicates the conveyor position. (when the conveyor synchronization function is enabled.) Indicates the production number. Indicates the repeat time.

Conveyor speed Conveyor position Production number Repeat time

3-9




(1) Spray output Changes the manual spray output signal. Verify that the mode is in TEACH and the Teach lock keys on the explosion-proof teach pendant is OFF before changing.

Ø

The screens for entering numeric values appear when the AIRMOTOR , HIGH VOLT keys are pressed.

Display items Spray 1 Spray 2 Flow rate Shaping air / Pattern air Air motor / Atomize air High voltage Flushing Push thinner Flow rate upper Shaping air upper / Pattern air upper Air motor upper / Atomize air upper High volt upper

FLOWRATE ,

SHAPING AIR ,

Descriptions Indicates the ON/OFF condition of the spray 1. Indicates the ON/OFF condition of the spray 2. Indicates the dedicated signal condition of the flow rate in numeric values for the corresponding signal. The numeric value screen appears for entering. Indicates the dedicated signal conditions of the shaping or pattern air in numeric values for the corresponding signal. The numeric value screen appears for entering. Indicates the dedicated signal conditions of the air motor or atomizing air in numeric values of the signal. The numeric value screen appears for entering. Indicates the dedicated signal condition of the high voltage in numeric values for the corresponding signal. The numeric value screen appears for entering. Indicates the ON/OFF condition of the dedicated signal for flushing. Indicates the ON/OFF condition of the dedicated signal for push thinner. Indicates the upper limit setting of the flow rate in numeric values for the signal. The numeric value screen appears for entering. Indicates the upper limit setting of the shaping or pattern air in numeric values for the signal. The numeric value screen appears for entering. Indicates the upper limit setting of the air motor or atomizing air in numeric values for the signal. The numeric value screen appears for entering. Indicates the upper limit setting of the high voltage in numeric values for the signal. The numeric value screen appears for entering. 3-10




(2) All ratio set Ratios for all the manual spray output signals can be set.

Ø

Display items Flow rate Shaping air / Pattern air Air motor air / Atomize air High volt

Descriptions Ratio for all the spray signals of the flow rate is indicated in percentage. The numeric entry screen appears when entering with keys. Ratios for all the spray signals of the shaping or pattern air are indicated in percentage. The numeric entry screen appears when entering with keys. Ratios for all the spray signals of the air motor or atomizing air are indicated in percentage. The numeric entry screen appears when entering with keys. Ratios for all the spray signals of the high voltage are indicated in percentage. The numeric entry screen appears when entering with keys.

(3) Signal output Sets ON/OFF for the general output signals.

Ø

The ON/OFF status of the signal is indicated by the LED on each key. Red : ON Blue: OFF Switched ON and OFF by pressing the keys. The signals assigned to the dedicated signal cannot be switched by the key. 3-11




(4) Screen for entering numeric values Numeric values can directly be entered from the Spray output and All ratio set screen.

* The above is a screen called from the All ratio set/Flowrate.

Flow rate Pattern air Atomize air High volt ※When the

Setting range for manual spray output 0 – upper limit (0 – 10000) 0 – upper limit (0 – 10000) 0 – upper limit (0 – 10000) 0 – upper limit (0 – 10000) RETURN

Setting range for All ratio set 0 – 200 0 – 200 0 – 200 0 – 200

key is pressed, the original screen appears again.

3-12




3.1.6 PROGRAM LIST SCREEN Displays the current program list.

•

Pressing the

or

key scrolls up/down the program steps by five lines based

on the step with the cursor. [ NOTE ] When inserting, deleting, and modifying the program steps by teaching/editing from the explosion-proof teach pendant, the currently displayed screen does not reflect changes instantaneously.

3-13




3.1.7 MONITOR SCREEN Indicates the status of the current input/output signals. The displayed color changes when the signal is ON.

⇑

⇓

⇑

⇓

If the Built in sequencer function option is installed, the Input signals : IN*** Output signals : OUT*** Internal signals : INT***

INTEGER DATA

The following IN/OUT signal keys appear in some versions.

3-14

key appears.



When the

IN/OUT


signal key is pressed:

Ø

3-15




The signal names displayed on the monitor screen can be set by the user. The procedure is as follows: 1. Save the auxiliary data. SAVE/A File name. Or Select AUX 10. MEMORY → PC CARD, then select 3 for Auxiliary data and save it. 2. Add the following between .AUXDATA and .END using the editor function of the PC that saved the file: For output signal, N_OX1 “signal name 1” N_OX2 “signal name 2” ： For input signal, N_WX1 “signal name 1” N_WX1 “signal name 2” ： For internal signal, N_INT1 “signal name 1” N_INT2 “signal name 2” ： Enter the desired signal name in “ ”. The name should be within 14 bytes. 1 – 64 can be set for output and input signals. 3. Load the file created by the editor. 4. When deleting the set file names, enter items without signal names between .AUXDATA and .END as shown below and load. N_OX1“ ” ： N_WX1“ ” ： N_INT1“ ” ：

When the same name is set as the dedicated signals, the name for the dedicated signal will be taken. [ NOTE ] The initial name is set when the system is initialized (SYSINIT).

3-16




3.1.8 CURRENT POSITION SCREEN Indicates the robot’s current position.

Joint angle value

Transformation value

3-17




3.2 MOVING CURSORS

keys to select items.

Move the cursor using the The moving range of the cursor depends on the screens.

PROGRAM SELECT

pg?? pg10 pg2 pg7

PROGRAM SELECT

pg1 pg5 pg8

⇒

⇒

pg?? pg10 pg2 pg7

⇓

⇑

PROGRAM SELECT

pg?? pg10 pg2 pg7

pg1 pg5 pg8

pg1 pg5 pg8

PROGRAM SELECT

⇐

⇐

3-18

pg?? pg10 pg2 pg7

pg1 pg5 pg8



3.3


SELECTION BY ENTERING NUMERIC VALUES OR CURSOR OPERATION

Item selection can be made by entering numeric values or operating cursor on the following screens of the multifunction panel. Selecting programs Selecting items for program edit Selecting auxiliary items Selecting auxiliary items is explained in this example:

Ø By entering numeric

By operating cursor

With the cursor position at 2 LOCATION & SPEED DISPLAY, enter desired numeric value.

Move the cursor to desired item. For example, move to 9 DATA CONVERSION.

１

４

12 FILE DIRECTORY (FDIRECTORY) 14 PC CARD AUX. FUNCTION 41 ZEROING FUNCTION NUMBER: 14

Ø RETURN

3-19

6 MIRROR CONVERSION 9 DATA CONVERSION 10 MEMORY→PC CARD (SAVE) 11 PC CARD→MEMORY (LOAD) 12 FILE DIRECTORY (FDIRECTORY)



3.4


ENTERING CHARACTERS

In some screens on the multifunction panel, operation can be made by entering characters. Press CHARACTER key on the screen for the character entry screen.

CHARACTER

Press the

CHARACTER

key.

Ø

Ø Ａ … Ｚ

１ … ０

Press desired keys.

Ø ＥＮＴＥＲ

Fix the entered characters using the ENTER key.

Press the NEXT MENU key to exit the character entry mode. The character entered at the tail end is deleted by pressing the BS

3-20

key.



3.5


SELECTING PROGRAMS PROGRAM

Press the

PROGRAM

Ø

Ø By entering numeric values

By operating cursor

Enter numeric values with pg?? displayed.

１

Move the cursor to desired program.

０

Ø RETURN

1. When the program name exceeds the screen, press NEXT PG key to show the rest. 2. When setting the program name like set1, enter from the keyboard screen by pressing CHARACTER key. 3. The contents of the program selected by cursor can be checked by pressing the PROGRAM LIST key.

3-21

key.




Deleting programs:

Move the cursor to the program to be deleted. For example, select pg10.

Ø Ø

Ø

Press the RETURN key to delete. Or press the EXIT key to cancel.

RETURN

Ø pg?? pg1 pg8

pg2

The program list is displayed after deletion.

pg

3-22



3.6


SELECTING STEPS STEP

Press the

STEP

key.

Ø

(Some types have a different way to switch toward the first or last step.) When FIRST STEP is indicated for the key, press it to select the first step of the program. The key display changes to LAST STEP by pressing the S key. When FIRST/LAST is indicated, press it with BACKWARD key to select the first step of the program. Press it with FORWARD key to select the last step. Pressing S key does not make any change in display. Press STEP SELECT key to directly specify the step number.

Ø

Ø

By entering numeric value

３

By operating cursor Select steps using the BACKWARD or FORWARD key. Pressing the FORWARD key shifts one step ahead. Pressing the BACKWARD key shifts one step back.

STEP

3

Step: 3 is indicated.

Ø RETURN

3-23



3-24


Memo

MANUAL OPERATION

This chapter describes the procedures for manual operation of the robot.

4.1 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.2.9

KEYS USED FOR MANUAL OPERATION .................................................................4-2 PROCEDURES FOR MANUAL OPERATION............................................................4-3 TYPES OF THE MANUAL OPERATION COORDINATE SYSTEM.........................4-5 SELECTING THE MANUAL OPERATION COORDINATE SYSTEM......................4-5 SELECTING THE MANUAL OPERATION SPEED....................................................4-5 MANUAL OPERATION ON THE JOINT COORDINATE SYSTEM..........................4-6 MANUAL OPERATION ON THE CARTESIAN COORDINATE SYSTEM...............4-9 MANUAL OPERATION ON THE EASY COORDINATE SYSTEM.........................4-11 GUN COORDINATE SYSTEM ................................................................................4-15 SELECTING THE OPERATION FOR TRAVERSE EQUIPMENT..........................4-17 MANUAL OPERATION OF THE TRAVERSE EQUIPMENT ..................................4-17

4-1


4

4.1

4. Manual Operation

KEYS USED FOR MANUAL OPERATION

The robot is manually operated when: Moving the robot to the position to teach. Moving the robot arm when an error occurs. The explosion-proof teach pendant is used for manual operation of the robot. Hold the teach pendant firmly with both hands.

Shift key Axis keys Manual speed key Coordinates selection key Equipment selection key

Teach lock key

Trigger switches Backside of the explosion-proof teach pendant The following keys are mainly used for manual operation: Coordinates selection key, Equipment selection key, Axis key, Manual speed key, Teach lock key, Trigger switches. 4-2



4.2

4. Manual Operation

PROCEDURES FOR MANUAL OPERATION

This section describes the basic procedures for manual operation of the robot. Preparation: Turn the CONTROL POWER ON. The CONTROL POWER light illuminates.

Setting switches:

Turn the TEACH/REPEAT switch to TEACH.

Turn the HOLD/RUN switch to RUN.

TEACH LOCK

Turn the TEACH LOCK key on the explosionproof teach pendant ON. (The LED on this key will illuminate. When the TEACH LOCK key is ON, CYCLE START is not engaged by turning the TEACH/REPEAT switch to REPEAT. The MOTOR POWER light turns on.

Press the MOTOR POWER switch.

！

WARNING

Enter the safety fence for manual operation of the robot after confirming that the above preparation and setting switches are complete.

4-3



4. Manual Operation

Selecting motion coordinate system and speed:

FRAME

H M L SPEED

Select the coordinate system for manual operation.

Select the robot motion speed. See 4.2.1 Types of the Manual Operation Coordinate System, 4.2.2 Selecting the Manual Operation Coordinate System and 4.2.3 Selecting the Manual Operation Speed

Release the motor brake by pressing the trigger switches on the backside of the explosion-proof Trigger switches teach pendant. Keep these switches pressed during the manual operation of the robot. Either switch, right or left, works. Backside of the explosion-proof teach pendant Select the axis and motion direction (+ or -) to be moved by the axis keys. TURN RT UP The robot moves while these keys are … pressed. TURN LFT

DWN

！ CAUTION The robot operates by pressing the axis keys with the trigger switches grasped.

Manual operation is complete.

！

WARNING

Be sure to turn the TEACH LOCK key OFF (LED goes off) after coming out of the safety fence when manual operation is complete.

4-4



4.2.1

4. Manual Operation

TYPES OF THE MANUAL OPERATION COORDINATE SYSTEM

The robot moves differently according to the coordinate system types at manual operation. The characteristics of each coordinate system should be fully understood before conducting manual operation. XYZ1 : Moves the gun parallel to the Cartesian coordinate system based on the gravity direction. The gun posture is during operation. XYZ2 : Moves the gun parallel to the Cartesian coordinate system based on the gravity direction. The wrist axis angle is kept during operation. Joint : Moves each axis independently. Gun : Moves parallel to the tool coordinate system based on the gun posture. The gun referred to is the last one that was selected by the gun selection instruction. Easy : This is the mode for orthogonal operations which are used most frequently at manual operation.

4.2.2

SELECTING THE MANUAL OPERATION COORDINATE SYSTEM

The 1st line of the coordinate system display on the explosion-proof teach pendant toggles by pressing the FRAME key. SHIFT ＋ FRAME

keys are used for switching XYZ1 and XYZ2.

The Cartesian and Work coordinate systems are switched by the condition setting mode.

EASY XYZ1 XYZ2

4.2.3

Gun

Joint

SELECTING THE MANUAL OPERATION SPEED

The LED illuminates in turn as below by pressing the SPEED key, to indicate the manual operation speed. Low High Med H M L

The initial setting: →150mm/s equiv. → 80mm/s equiv. SPEED → 10mm/s equiv. The maximum speed is approximately 150mm/sec at the gun tip. The ratio (%) to the max. speed is defined by the auxiliary data. See 9. A-57 Check Speed 4-5



4.2.4

4. Manual Operation

MANUAL OPERATION ON THE JOINT COORDINATE SYSTEM

3rd axis

Up

4th axis Swing left 5th axis Bend down

Down

Swing right

6th axis

Bend up Turn left nd

2 axis

Turn right

Back Front

Right

Left

1st axis

* The above manipulator is from the KE610 model series.

4-6



4. Manual Operation

Up 3rd axis 4th axis Down

Swing left

Swing right 2nd axis

Bend up 6th axis

5th axis Bend down

Back

Turn left Turn right

Front Right

Left 1st axis

* The above manipulator is from the KF121 model series.

4-7



4. Manual Operation

The axis keys move the robot as follows on the Joint Coordinate System. Wrist motion of standard models

Wrist motion of KF192 and KF262

Rotates 1st axis

Rotates 1st axis

Rotates 2nd axis

Rotates 2nd axis

Rotates 3rd axis

Rotates 3rd axis

Rotates 4th axis

Rotates 5th axis

Rotates 5th axis

Rotates 4th axis

Rotates 6th axis

Rotates 6th axis

RT LFT

FRNT BCK

UP DWN

SWING RT SWING LFT

BEND FRNT BEND BCK

TURN UP TURN DWN

4-8



4.2.5

4. Manual Operation

MANUAL OPERATION ON THE CARTESIAN COORDINATE SYSTEM Up

Left

Back

Front Right

Swing left

Down

Swing right Bend up Turn left

Turn right

The above figures indicate the robot motion for XYZ1. Bend down Refer to the figure for Joint coordinate system regarding the motion direction of the wrist axes (4th – 6th axes) for XYZ2. The above manipulator is from the KE610 model series. In these sample figures, the manipulator is installed on the floor. In case of installation on the wall or from the ceiling for some models, manual operation can be conducted in the same way as a floor-installed robot, by defining the antigravity direction as +Z direction. 4-9



4. Manual Operation

The Axis keys move the robot as follows on the cartesian coordinate system (XYZ1 and XYZ2): Coordinate

Motion

XYZ1 XYZ2

XYZ2 of standard models

XYZ1

XTZ2 of KF192 and KF262

RT

X axis

Moves parallel to X axis

Y axis

Moves parallel to Y axis

Z axis

Moves parallel to Z axis

LFT

FRNT BCK

UP DWN

Z axis

Rotates around Z axis (with gun tip fixed)

Rotates 4th axis Rotates 5th axis (with gun tip (with gun tip fixed) fixed)

X axis

Rotates around X axis (with gun tip fixed)


Y axis

Rotates around Y axis (with gun tip fixed)


SWING RT SWING LFT

BEND FRNT BEND BCK

TURN UP TURN DWN

4-10



4.2.6

4. Manual Operation

MANUAL OPERATION ON THE EASY COORDINATE SYSTEM Up

Back

Left

Front Right

Down

Shift+back (key)

Bend up Swing right Bend down Turn left Turn right Shift+front (key)

The above manipulator is from the KE610 model series. In these sample figures, the manipulator is installed on the floor. In case of installation on the wall or from the ceiling for some models, manual operation can be conducted in the same way as a floor-installed robot, by defining the antigravity direction as +Z direction.

4-11



4. Manual Operation

The Axis keys move the robot as follows on the easy coordinate system: Coordinate

Motion

X axis


Y axis


Z axis


With Shift key

RT LFT

FRNT BCK

UP DWN

SWING RT SWING LFT

Swings horizontally (with gun tip fixed)

BEND FRNT

Swings vertically (with gun tip fixed)

BEND BCK

TURN UP TURN DWN

Rotates around the gun (with gun tip fixed)

4-12

Moves in gun direction



4. Manual Operation

Up

Back Left

Right Front

Down

Shift+back (key) Bend up Swing right

Swing left

Bend down Turn left Turn right Shift+front (key)

* The above manipulator is from the KF121 model series. 4-13



4. Manual Operation

The Axis keys move the robot as follows on the easy coordinate system: Coordinate

Motion

X axis


Y axis


Z axis


With Shift key

RT LFT

FRNT BCK

UP DWN

SWING RT

Swings horizontally (with gun tip fixed)

SWING LFT

BEND FRNT

Swings vertically (with gun tip fixed)

BEND BCK

TURN UP

Rotates around gun (with gun tip fixed)

TURN DWN

4-14

Moves in gun direction



4.2.7

4. Manual Operation

GUN COORDINATE SYSTEM

The gun coordinate system has the Z axis in the direction where the gun is engaged (normally the direction in which the painting material is sprayed.) The gun which is subject to the Gun coordinate system is the last one that was selected by the Gun selection instruction in teach and repeat modes. (Gun 1 is selected right after the control power of the controller is turned ON.) Coordinate RT

X axis

Moves parallel to X axis of gun coordinates

Z axis

Moves parallel to Z axis of gun coordinates

Y axis

Moves parallel to Y axis of gun coordinates

Y axis

Rotates around Y axis of gun coordinates (with gun tip fixed)

X axis

Rotates around X axis of gun coordinates (with gun tip fixed)

Z axis

Rotates around Z axis of gun coordinates (with gun tip fixed)

LFT

FRNT BCK

UP DWN

SWING RT SWING LFT

BEND FRNT BEND BCK

TURN UP TURN DWN

Motion

4-15



4. Manual Operation

Shift+back (key) Bend up Swing right Bend down

Swing left

Turn right

Turn left

x (Right)

z (Front) y (Down)

Shift+front (key)

* The Gun coordinates are defined by the parameters, 9 Auxiliary, A-48 Tool Dimensions.

4-16



4.2.8

4. Manual Operation

SELECTING THE OPERATION FOR TRAVERSE EQUIPMENT

EQPMT

key is used for selecting the traverse equipment.

Select TRAVERSE for operation of the traverse equipment. The LED toggles as below when pressing the EQPMNT key. Robot

Traverse

Table

The detail of the EQPMNT key differs according to the robot system structure. (This example is for the standard specification.) When the system is equipped with a 6 axis robot, no traverse equipment can be selected. (Robot is stationary.) Except for servo package cell types, Table cannot be selected (Robot and Traverse can be selected).

4.2.9

MANUAL OPERATION OF THE TRAVERSE EQUIPMENT

RT LFT

FRNT BCK

UP

Coordinate

Motion

X axis of traverse

Moves traverse equipment in X axis direction.

Y axis of traverse

Moves traverse equipment in Y axis direction.

Z axis of traverse

Moves traverse equipment in Z axis direction.

DWN

When operaton coordinate system is set as JOINT, only the traverse equipment moves. When set as other modes, the robot arm and wrist moves together with the traverse equipment so as to keep the gun tip position (TCP).

4-17



4-18


Memo

This chapter describes the teaching procedures using the explosion-proof teach pendant.

5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 5.1.7 5.1.8

OPERATION FOR TEACHING ...................................................................................5-2 DISPLAY DURING TEACHING...................................................................................5-2 REGISTERING THE PROGRAM NUMBER..............................................................5-3 TEACHING PROCEDURES........................................................................................5-4 MANUAL POSITIONING............................................................................................5-18 TEACHING THE MOVE INSTRUCTIONS ...............................................................5-20 TEACHING THE OTHER INSTRUCTIONS (ADD) .................................................5-22 THE PROCEDURES FOR CHECKING PROGRAMS (CHECK OPERATION)...5-24 CORRECTING INSTRUCTIONS ..............................................................................5-25

5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.7 5.2.8 5.2.9 5.2.10 5.2.11 5.2.12 5.2.13 5.2.14 5.2.15

EXPLANATION OF INSTRUCTIONS .....................................................................5-29 SPEED INSTRUCTION..............................................................................................5-30 SPRAY INSTRUCTIONS...........................................................................................5-32 EXTERNAL OUTPUT INSTRUCTIONS...................................................................5-36 EXTERNAL INPUT INSTRUCTION..........................................................................5-40 SMOOTH INSTRUCTION..........................................................................................5-42 CALL DATA BANK INSTRUCTION ..........................................................................5-46 TIMER INSTRUCTION...............................................................................................5-48 CALL PROGRAM INSTRUCTION............................................................................5-49 JUMP INSTRUCTION ................................................................................................5-50 CONVEYOR INSTRUCTION (OPTION) ................................................................5-59 GUN CONTROL INSTRUCTION............................................................................5-61 TABLE INSTRUCTION (OPTION) ..........................................................................5-62 SENSING INSTRUCTION (OPTION).....................................................................5-63 MOVE.........................................................................................................................5-64 OTHER INSTRUCTIONS ........................................................................................5-67

5.3

REPEAT OPEARTION FOR CHECKING..............................................................5-71

5-1


５

TEACHING

5.1

5. Teaching

OPERATION FOR TEACHING

5.1.1

DISPLAY DURING TEACHING

The items displayed during teaching are as follows: 1

2

3

4

5

6

7 Correction mode (Prohibit/Add/Modify/Delete/Search), which is a sub-mode, is displayed. 1

Use

CRCT

key to change the mode.

Displays coordinate system (Easy (XYZ1)(XYZ2)/Gun/Joint) at manual operation. 2

Use

FRAME

key to change the system.

Displays how the program is shifted (per step/command/continuous/jump) when pressing 3

STEP NEXT

and

STEP BACK

keys in check mode. Use

STEP

key to change the shifting method.

4 Displays program number that is presently taught. 5

Displays present point number. Counts MOVE commands in the program from the top and displays as a point number.

6 Displays operation guidance. Displays commands taught in each step below the 3rd line. The sequential number on the left indicates in command unit. 7 The highlighted number indicates that the the command execution is complete. The above example means that the commands up to the command unit 3, turning on the spray No.1, are executed.

5-2



5.1.2

5. Teaching

REGISTERING THE PROGRAM NUMBER

Select teach mode and enter a program number. Selecting teach mode

Select 0. TEACH in the main menu.

Ø · Move the cursor to 0. TEACH and fix with the SET key. · Or enter the mode number using the number keys.

or SET

Ø Specifying a program number

Enter a program number using the number keys and press SET key. The default correction mode at teaching can be set at this time by selecting PRHBT, ADD, or CHG with

CRCT

key.

Ø SET

Ø Displaying the program contents

In this example, the instructions in the Program No.10 are indicated. When starting new programs, [PROGRAM END] is indicated, meaning the end of the program. 5-3



5. Teaching

5.1.3 TEACHING PROCEDURES 1. Confirming the operations to teach Determine the robot operations to teach and define the teaching points. An example for teaching the five points shown in the picture below will be explained here.

The beginning of the operation 1

4 The end of the operation

2 3

Teaching points

1 2 3 4

Teaching The beginning of the operation. The robot moves at the air-cut joint speed of 20% and spray speed of 500mm/s through the whole operation. Each joint move to the Point 1. Linear move from the Point 1 to 2. Turn the spray #1 on. Linear move from the Point 2 to 3 while spraying. Turn the spray #1 off. Linear move from the Point 3 to 4. Operation ends.

Requirements for teaching · The positional data of each point and basic instructions for moving, speed, and spray are taught. · Signals are not exchanged with the peripheral equipment. The above should be taken into account when teaching the robot.

！

CAUTION

“Tool dimensions” must be registered before program teaching can begin. These dimensions define the tip position and direction of the gun mounted on the robot. If tool dimensions are changed after program teaching, the robot will not operate as taught. To register tool dimensions, see Aux-48, Tool dimensions in chapter 9.

5-4



5. Teaching

2. Creating program sheets After defining the robot operations to teach, fill in each instruction on the program sheet. The following is an example program sheet for teaching four points. Step 1 2 3 4 5 6 7 8 9

Point (teaching point)

1 2 3 4

Instruction PROGRAM NAME = pg10 AIRCUT JSPEED 20% SPRAY SPEED 500mm/s JMOVE (JOINT) LMOVE (XYZ1) SPRAY #1, ON LMOVE (XYZ1) SPRAY #1, OFF LMOVE (XYZ1) PROGRAM END

3. Operating the switches Confirm the EMERGENCY STOP switch condition and set the other switches and keys before actual teaching. EMERGENCY STOP switch Confirm that the EMERGENCY STOP switch operates properly before entering the safety fence. · Press the EMERGENCY STOP switches on the explosion-proof teach pendant and the controller, and confirm that the motor power is shut off and that the MOTOR POWER lamp goes off. · Press the MOTOR POWER switch to turn the motor power ON. The MOTOR POWER lamp illuminates. Setting switches Turn the CONTROL POWER switch ON. The CONTROL POWER lamp illuminates. Set the TEACH/REPEAT switch to TEACH.

Press the MOTOR POWER switch. The MOTOR POWER lamp illuminates. Set the HOLD/RUN switch to RUN.

TEACH LOCK

Press the TEACH LOCK key on the explosion-proof teach pendant to turn ON (the LED illuminates).

5-5



5. Teaching

The following is a brief sequence of teaching procedures. See section, 5.1.4 Positioning, and the following sections for more detailed procedures.

！

WARNING

The operations followed hereafter are carried out inside the safety fence. Therefore two people, a teacher and a supervisor, both of whom have completed special education, are needed for operation. 4. Selecting programs Select a program (PG10, for example) on the explosion-proof teach pendant. See 5.1.2 Registering Program Number Setting to ADD mode

Ø SHIFT

＋

· Press the SHIFT and CRCT keys at the same time to set the correction mode to ADD.

CRCT

Teaching the aircut joint speed

Ø SET

· Go to the instruction selection menu by pressing SET key.

Ø

5-6



5. Teaching

Ø or

· Move the cursor to 0. SPEED. · Fix with the SET key.

SET

Ø

Ø or

· Move the cursor to 3. AIRCUT JSPEED. · Fix with the SET key.

SET

Ø

Ø SET

· Enter the aircut joint speed value. · Fix the instruction in the program with the SET key.

Ø

The aircut joint speed instruction (Step 1) is taught in the program.

5-7



5. Teaching

Teaching the Spray speed

Ø · Go directly to the selection menu for speed instruction.

Ø

Ø or

· Move the cursor to 0. SPRAY SPEED. · Fix with the SET key.

SET

Ø

Ø SET

· Enter the spray speed value. · Fix the instruction in the program with the SET key.

Ø

The spray speed instruction (Step 2) is taught in the program.

5-8



5. Teaching

Teaching the point 1 The maximum motion speed is approximately 150mm/sec at the gun tip. → 150mm/sec → 80mm/sec → 10mm/sec

H M L SPEED

· Set the speed to MED. · The display is switched by pressing the SPEED key: HIGH MED LOW

H M L SPEED

Ø

Ø

· Set the motion coordinate system to JOINT. · The display is switched by pressing the FRAME key: EASY GUN JOINT

FRAME

Ø

Ø RT

FRNT

UP

LFT

BCK

DWN

· Move the robot to the Step 3 (teaching point 1) using AXIS keys while pressing the TRIGGER switch on the backside of the explosion-proof teach pendant. The robot does not move without pressing this switch.

Ø L C J

MOTION

· Set the interpolation mode to JOINT. · The display is switched by pressing the MOTION key. (L) Linear (C) Circular (MID END) (J) Joint

Ø 5-9



5. Teaching

Ø STORE POS

· Record the Step3 with STORE POS key.

Ø The point number is added by recording the position.

Recording Step 3 is complete. Teaching the point 2 H M L SPEED

· Set the speed to MED. · The display is switched by pressing the SPEED key: HIGH MED LOW

Ø

Ø FRAME

· Set the motion coordinate system to EASY. · The display is switched by pressing the FRAME key: EASY GUN JOINT

Ø

Ø

5-10



RT

FRNT

UP

LFT

BCK

DWN

5. Teaching

· Move the robot to the Step 4 (teaching point 2) using AXIS key while pressing the TRIGGER switch on the backside of the explosion-proof teach pendant. The robot does not move without pressing this switch.

Ø · Set the interpolation mode to LINEAR. · The display is switched by pressing the MOTION key. (L) Linear (C) Circular (MID END) (J) Joint

L C J

MOTION

Ø

Ø STORE POS

· Record the step4 with

STORE POS key.

Ø

Recording Step 4 is complete. Teaching the spray-on instruction

Ø · Go to the instruction selection menu with SET key.

SET

Ø

5-11



5. Teaching

Ø or

· Move the cursor to 1. SPRAY. · Fix with the SET key.

SET

Ø

Ø or

· Move the cursor to 0. SPRAY_1. · Fix with the SET key.

SET

Ø

Ø or

· Move the cursor to 1. ON and select it. · Fix with the SET key.

SET

5-12



5. Teaching

Ø

The spray on instruction (Step5) is taught to the program. Teaching the teaching point 3

Ø

· Set the motion coordinate system to EASY. [ NOTE ]

FRAME

If easy coordinate system is already selected, this operation is not necessary. (No need to do every time.)

Ø

· The display is switched by pressing the FRAME key: EASY GUN JOINT

Ø RT

FRNT

UP

LFT

BCK

DWN

· Move the robot to Step 6 (teaching point 3) using AXIS keys while pressing the TRIGGER switch on the backside of the explosion-proof teach pendant. The robot does not move without pressing this switch.


L C J

MOTION

[ NOTE ]

Ø

If linear interpolation is already selected, this operation is not necessary. (No need to do every time.)

5-13



5. Teaching

Ø STORE POS

· Record step 6 with STORE POS key.

Ø

Recording step 6 is complete. Teaching the spray off instruction

Ø Go directly to the selection screen for spray instruction.

Ø

Ø or

· Move the cursor to 0. SPRAY_1 and select. · Fix with the SET key.

SET

Ø 5-14



5. Teaching

Ø · Move the cursor to 0. OFF and select.

or

· Fix with the SET key.

SET

Ø

The spray off instruction (step7) is taught to the program. Teaching the point 4

Ø

· Set the motion coordinate system to EASY. [ NOTE ]

FRAME

If easy coordinate system is already selected, this operation is not necessary. (No need to do every time.)

Ø

· The display is switched by pressing the FRAME key: EASY GUN JOINT

Ø RT

FRNT

UP

LFT

BCK

DWN

· Move the robot to Step 8 (teaching point 4) using AXIS keys while pressing the TRIGGER switch on the backside of the explosion-proof teach pendant. The robot does not move without pressing this switch.

5-15



5. Teaching


L C J

MOTION

[ NOTE ]

If the linear interpolation is already selected, this operation is not necessary. (No need to do every time.)

Ø

Ø STORE

· Record the step 6 with STORE POS key.

POS

Ø

Recording step 8 is complete. Terminating teach mode

Ø END

or

Go to the screen to terminate teaching.

Ø

5-16



Ø SET

5. Teaching

· Enter 1 (YES). · Fix with the SET key to go back to the screen for entering the teaching program number.

If not terminating teaching, the instruction display screen will appear by pressing keys: SET

Ø

Teaching is terminated and the program is created. [ NOTE ] When terminating teaching with EXIT key, the main menu screen appears.

5-17



5. Teaching

5.1.4 MANUAL POSITIONING

！

WARNING

When turning the servo power of the robot on, make certain that no personnel enters the motion range of the robot and the peripheral equipment controlled by the robot controller. When entering the robot motion range to manually move the robot to the teaching position, minimize the time spent in the area.

This unit describes the operation procedures for guiding the robot to the teaching position. Setting the manual operation speed H M L SPEED

The lit LED switches among: H M L This indicates the manual operation speed in three levels.

Setting the manual operation coordinate system The coordinate system displayed on the 1st line of the screen is switched by pressing the

FRAME

key.

EASY/XYZ1/XYZ2 are switched using the SHIFT + FRAME keys. EASY (XYZ1) (XYZ2)

GUN

JOINT

5-18



5. Teaching

Press the trigger switches ON

Press the trigger switches located on the backside of the explosion-proof teach pendant. When the trigger switches are pressed with the main servo power ON, the current in the robot motor is activated, the brake is released, and the robot becomes operable.

Backside of the explosion-proof teach pendant

Positioning by manual operation RT

FRNT

UP

SWING RT

BEND FRNT

TURN UP

LFT

BCK

DWN

SWING LFT

BEND BCK

TURN DWN

Positioning is executed using the axis keys of the above.

！

WARNING

Never force the trigger switches of the explosion-proof teach pendant ON, for example, by applying adhesives or taping on the switches.

5-19



5.1.5

5. Teaching

TEACHING THE MOVE INSTRUCTIONS

This section describes the procedures for teaching MOVE instructions using the current position as positional data. Fixing interpolation type The positional data is taught in the chosen interpolation type and recorded as a MOVE instruction. First, select the interpolation and point types before recording the position. The point types that can be used with MOVE instructions are as follows: Point type XYZ1 XYZ2 JOINT Interpolation Linear ○ ○ ● Mid ○ ○ ● Circular ● End ○ ○ ○: Can be used Joint ● ● ○ ●: Can not be used

L C J

MOTION

The lit LED toggles when pressing the + MOTION key. Linear Circular Joint The Circular LED blinks at circular end. LED changes as follows by pressing when the Linear/Circular LED is lit.

SHIFT

+

MOTION

keys

XYZ1 XYZ2 (Joint LED is off) (Joint LED blinks)

Type

Joint interpolation

Linear interpolation

Circular interpolation (intermediate)

Key L C J

MOTION

P1・

P1・ (Illuminates)

L C J

MOTION

・ P2

(Illuminates) When JOINT is selected at P2, each joint of the robot starts simultaneously from P1 to stop at P2. This is used when there is no need to specify the motion path or when moving joint individually.

L C J

MOTION

Detail

・ P2

When LINEAR is selected at P2, the tool tip executes a linear motion between the P1 and P2. This is used for the linear motion. The wrist posture is also interpolated. P1

・

・ P2

P3

・

(Illuminates) Is selected as intermediate point for the circular motion. When CIRCULAR (MID) is selected at P2, the path draws a circle passing through P1, P2, P3.

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Circular interpolation (end)

L C J

5. Teaching

P1 (Blinks)

MOTION

・P2 ・

P3

・

Is selected as the end point for circular motion. When CIRCULAR (END) is selected at P3, the path makes a circle which passes P1 (the 1st point) and P2 (the 2nd point).

Deciding how to correct Select beforehand the type of editing, adding MOVE instructions, replacing with the MOVE instruction of the current step, or deleting the MOVE instruction of the current step. TCH/PRHBT ↓ TCH/ADD/･････ ↓ TCH/CHG/･････ ↓ TCH/DEL/･････ ↓ TCH/SCH/･････

Pressing the

CRCT

PRHBT

key toggles the correction mode among: ADD

CHG

DEL

SCH

(After editing, the correction mode automatically returns to the default setting: (prohibit, add,orchange) .) The default correction mode can be changed by pressing the SHIFT + CRCT keys on the instruction display screen. Select ADD in this example.

Recording the position When pressing the

STORE POS

key in the ADD mode, a MOVE instruction is added

according to the interpolation data. The point number increases when added.

5-21



5. Teaching

5.1.6 TEACHING THE OTHER INSTRUCTIONS (ADD)

In addition to MOVE instructions shown thus far, this section describes procedures for teaching instructions such as speed, input and output. Selecting instruction Select from the list of the instructions available for teaching.

Ø ・ Press the SET key at the program content screen.

SET

Ø

Access items below No.6 by scrolling with the ↑ ↓ keys.

A group list of the available instructions appears.

Ø

SET

・Select the instruction to be taught.

or to

[ NOTE ]

Instruction select screen appears also by pressing the number key at the program content screen.

5-22



5. Teaching

Entering the parameters for instructions For example, select [0 SPEED/0 SPRAY SPEED] instruction.

Ø SET

・Enter the speed data.

Ø

After teaching, the program contents screen appears again.

5-23



5. Teaching

5.1.7 THE PROCEDURES FOR CHECKING PROGRAMS (CHECK OPERATION)

Types of programs checking The 4 methods for checking programs toggles by pressing the STEP key as follows: MOVE

LINE

CONT

JUMP The type is displayed. A dedicated screen appears when JUMP is selected.

Ø STEP

Ø

MOVE: The program scrolls forward by every MOVE instruction. If some instructions (besides MOVE) are recorded before the next MOVE instruction, all of them are executed. The program also scrolls backward by every MOVE instruction. If some instructions are recorded before the next MOVE instruction, only the instructions related with trajectory or motion such as SMOOTH, CALL, and TRACK are executed. LINE: The program scrolls forward line by line for every instruction. It scrolls backward by every MOVE instruction. If some instructions are recorded before the next MOVE instruction, only instructions related with trajectory or motion such as SMOOTH, CALL, and TRACK are executed. CONT: The program scrolls continuously while pressing the STEP NEXT and STEP BACK keys. The instructions (including MOVE) are executed when scrolling forward. Only the instructions related with trajectory or motion such as SMOOTH, CALL, and TRACK are executed when scrolling backward. JUMP: Enter the step number by number key and the current step number changes without using the STEP NEXT and STEP BACK keys.

5-24



5. Teaching

5.1.8 CORRECTING INSTRUCTIONS

This unit describes the procedure for correcting programs. Checking programs Move the manipulator forward or backward to the point for editing using the STEP BACK

STEP NEXT

•

keys.

Highlighting the instruction number The number on the lines 3 – 5 is highlighted when the instruction is complete. Instructions are added after the last highlighted instruction. If the checking type is set to LINE, the instructions are executed one by one and it is possible to scroll the program to the desired line for editing

Ø STEP NEXT

Ø

5-25



5. Teaching

Correcting MOVE instructions Use the

STEP NEXT

•

STEP BACK

keys to scroll to the MOVE instruction for editing and position

the robot with the axis keys if necessary. Select ADD, CHANGE, or DELETE using the Correction is fixed by pressing the

STORE POS

CRCT

key.

key.

[ NOTE ]

1. When PROHIBIT is selected as the correction mode, any attempt to record the position results in an error and teaching of MOVE instructions is not possible. Change the correction mode with the CRCT key. 2. When ADD is selected as the correction mode, new MOVE instructions are added after the instruction number (the current cursor position) or step that has currently completed execution. 3. When CHANGE or DELETE is selected as the correction mode, if the MOVE instruction is taught on the teaching point, that point will be corrected. When taught while moving forward, the next teaching point (the target point to move) is corrected. When taught while moving backward, the previous teaching point (the target point to return) will be corrected.

5-26



5. Teaching

Procedures for correcting the other instructions (1) Shift to the instruction to be edited by forwading the program in increments of instruction. (2) Select ADD with the CRCT key. (3) Teach using the same procedures as teaching the other instructions. (1) Shift to the instruction to be edited by forwading the program in increments of instruction. (2) Select CHANGE with the CRCT key. (3) The screen for parameter entry of instruction appears by pressing the SET key.

Ø SET

Ø

Hereafter, instructions can be modified using the same procedures as adding. The DELETE mode deletes the instruction at the current step but confirmation is required. (1) Shift to the instruction to be corrected by forwading the program in the increments of instruction. (2) Select DELETE with the CRCT key (3) When pressing the SET key, the instruction to be deleted is displayed and confirmation of deletion appears.

5-27



SET

5. Teaching

The instruction is deleted when 1 (YES) is entered. The point number is decreased.

Indicates the end of the program.

Displays the specified group of instructions. When SEARCH is selected, a list of instructions belonging to the same group appears.

[ NOTE ]

When attempting a change/deletion at the top of the program, an error occurs (the step at the top can not be corrected). Recording or changing the program names can be set in the program control mode. See 10. 3-0-0 Program Detail Display.

5-28



5. Teaching

5.2 EXPLANATION OF INSTRUCTIONS

！

CAUTION

If the system is not configured with “conveyor”, “table” or “sensing” items the applicable menus will not displayed on screen. Be advised that some items may not be displayed as shown in the example screen below. (For example, menu B in the figure below is blank in systems without table axis.)

Scroll items below No.6 with the keys.

5-29



5. Teaching

5.2.1 SPEED INSTRUCTION 0. SPEED

0. SPRAY SPEED Specifies the tip speed of the selected gun while SPRAY is ON. This instruction is valid for linear and circular movement.

The spray speed can be set up to 9999mm/s. However, the actual speed may be restricted because of the speed limit of each axis.

1. AIRCUT SPEED Specifies the tip speed of the selected gun while SPRAY is OFF. This instruction is valid for linear and circular movement.

The aircut speed can be set up to 9999mm/s. However, the actual speed may be restricted because of the speed limit of each axis. 2. SPRAY JSPEED Specifies the joint speed of the robot while SPRAY is ON. This instruction is valid for joint movement.

SPRAY JSPEED 100% is the max. motor rotation rate of each axis. 3. AIRCUT JSPEED Specifies the joint speed of the robot while SPRAY is OFF. This instruction is valid for joint movement.

5-30



5. Teaching

AIRCUT JSPEED 100% is the max. motor rotation rate of each axis. 4. MOVING TIME Specifies the time required for moving between two taught points. This instruction is valid only for the first MOVE instruction which appears after its execution, and does not affect the following MOVE instructions.

The moving time can be set up to 9999.9 seconds. However, the actual time may become long because of the speed limit of each joint. 5. PLAYBACK RATE Specify the ration of actual speed to set speed for the robot to playback programs.

The playback rate can be set up to 999%. However, the actual rate may be restricted because of the speed limit of each axis.

5-31



5. Teaching

5.2.2 SPRAY INSTRUCTIONS 1. SPRAY

0. SPRAY 1 Turns ON/OFF the SPRAY 1.

1. SPRAY 2 Turns ON/OFF the SPRAY 2.

2. PRE_SPRAY (Distance) Turn the spray on/off in advance at a certain distance before arriving at the taught point. Specify the spray number and the distance for ON/OFF.

3. PRE_SPRAY (Time) Turn the spray on/off in advance at a certain amount of time before arriving at the taught point. Specify the spray number and the time for spray ON/OFF.

5-32



4. DLY_SPRAY (Distance) Turn the spray on/off with overrun after arriving at the taught point. Specify the spray number and the distance for spray ON/OFF.

5. DLY_SPRAY (Time) Turn the spray on/off with delay time after arriving at the taught point. Specify the spray number and the time.

6. SPRAY 3 Turn spray 3 on/off.

7. SPRAY 4 Turn spray 4on/off.

5-33

5. Teaching



5. Teaching

Application sample of SPRAY instructions: SPRAY instruction The Spray instruction should be described following the MOVE instruction at the points specified for spray on/off. When turning spray on at th Point 1 and off at Point 2:

Taught point Spray ON point Spray OFF point 0 1 2 3 4 5

Spraying section Aircut section

PROGRAM_NAME = LMOVE (XYZ1) [P1] SPRAY #1, ON LMOVE (XYZ1) [P2] SPRAY #1, OFF LMOVE (XYZ1) [P3]

PRE_SPRAY instruction When turning the spray on 10mm before the Point 1 and off 5mm before the Point 2:



PROGRAM_NAME = PRE_SPRAY LMOVE (XYZ1) [P1] PRE_SPRAY #1, 10mm, ON LMOVE (XYZ1) [P2] PRE_SPRAY #1, 5mm, OFF LMOVE (XYZ1) [P3] [ NOTE ]

When the distance between P1 and P2 is shorter than 5mm, the spray is turned OFF right after passing P1.

5-34



5. Teaching

DLY_SPRAY instruction When turning the spray on 10mm after the Point 1 and off 5mm after the Point 2:



PROGRAM_NAME = DLY_SPRAY LMOVE (XYZ1) [P1] DLY_SPRAY #1, 10mm, ON LMOVE (XYZ1) [P2] DLY_SPRAY #1, 5mm, OFF LMOVE (XYZ1) [P3] [ NOTE ]

When the distance between P1 and P2 is shorter than 10mm, the spray is turned right after passing P1.

5-35



5.2.3

5. Teaching

EXTERNAL OUTPUT INSTRUCTIONS

2. EXTERNAL OUTPUT

This instruction outputs signals to the specified general-purpose output port. 0. GENERAL EX-OUT Outputs ON/OFF signals to the specified signal output port number. A time can be specified to delay the signal output. Without delay time:

With delay time:

5-36



5. Teaching

1．FLOW RATE 2．SHAPING/PATTERN AIR 3．AIR MOTOR/ATOMIZING AIR 4．HIGH VOLTAGE These instructions are used to adjust the coating process of the coating equipment, e.g. setting the level of flow rate, etc. The signals are output to several ports assigned to the instruction according to the set level.

AIR MOTOR SHAPING

Example: When FLOW_RATE signals are assigned at the output range from 3 to 5 the instructions sets level at 6 and the output signals are set as follows; Output port No. 5 4 3 ON ON OFF 5．FLUSHING 6．PUSH THINNER These instructions are used to turn on/off the external output signals, for example, for flushing the gun when the color needs to be changed.

[ NOTE ]

The flow rate signal can be assigned to any number on the screen via A-112 Dedicated Output Signal. See chapter 9 for more details. 5-37



5. Teaching

7. PAINT_SIGNAL RATIO These instructions are used to change the output values of FLOW_RATE, PATTERN AIR, ATOMIZING AIR, and HIGH VOLTAGE to the painting equipment at a specified ratio. When a RATIO instruction is executed, the current output value set by the output instruction for painting equipment is changed by multiplication of the set value and the specified ratio. The multiplication includes the ratio set by 4.PRDCT PNTIO RATIO function in the PLAYBACK mode. PAINT_IO RATIO includes the following 4 items: 7.0. FLOW_RATE RATIO, 7.1. PATTERN RATIO, 7.2. ATOMIZING RATIO, 7.3. H_VOLTAGE RATIO These instructions change the value of the program’s GENERAL EX-OUT instruction for painting equipment by multiplying it at specified ratio. Executing these instructions immediately changes the value.

The initial value (the ratio before the instruction is executed) is 100%. When teaching or repeating ends, the ratio will be reset to the initial value (100%).

[ NOTE ]

1. The relation between GENERAL EX-OUT instruction for painting equipment and output signals: 2. Output signals = GENERAL EX-OUT instruction PRDCT PNTIO RATIO function

PAINT_IO RATIO instruction

2y (y=number of output signals) Upper limit value of setting data * Fractions are rounded off to be integer numbers. When the value exceeds the upper limit of the set signal output, the upper limit value is taken for output. The upper limit value is defined in the auxiliary data. See 9. AUX A-176 Databank/Environment Setting. 2. ON/OFF status of SPRAY and GENERAL EX-OUT signals can be checked on the teach pendant. See 10. 5-1-0 OUTPUT SIGNALS. 5-38



！

5. Teaching

CAUTION

When the EX-OUT ON signal is set as the final step of the program, the playback operation ends immediately after arriving at the final step. In this case, there is almost no time for the signal to be ON and the signal output circuit may not operate properly. For example, when using external output signals as interlock signals to the superior controller, the controller may not recognize the signals properly. This can be avoided by adding a dummy final step, which keeps the same position as the last step. Example: Step No. 8 LMOVE P8 9 EX-OUT #8, ON [PROGRAM END]

Step No. 8 LMOVE P8 9 EX-OUT #8, ON 10 LMOVE P9 (Dummy step) [PROGRAM END]

Note: P8 and P9 are the same position.

5-39



5. Teaching

5.2.4 EXTERNAL INPUT INSTRUCTION

！

WARNING

When the servo power of the robot is on, do not enter the motion range of the robot or the peripheral equipment controlled by the robot controller. If the robot is waiting for an input signal from the peripheral equipment due to the DIN WAIT instruction, it only appears stopped during operation. However, it is ready to move upon receiving the release signal. 3. External Input External Input instruction confirms the input signals condition and functions as an interlock with other robots. 0. Data Input Wait Monitors the ON/OFF status of the designated input signal. The robot waits for the status to be as specified. Even in cases when the robot is in stand-by and no change occurs, it is possible to designate a time-out period and a time-out error. When the timeout time is not set:

When the timeout time is set:

5-40



5. Teaching

1. Mutual Wait (Option) For two robots connected by Ethernet, it is possible for one robot to wait in standby until the second robot reaches a specified point. An Ethernet connection setting is required between the two robots in order to use this command. Refer to the separate volume “Mutual Wait and Gun Relative Distance Check Function Operation Manual” for more details on setting/using this funciton.

5-41



5. Teaching

5.2.5 SMOOTH INSTRUCTION 4. SMOOTH

This should be described prior to the MOVE instruction at the area where this function is to be used. 0. Acceleration Specifies the acceleration rate at which the robot moves between the teaching points.

1. Smooth range Specifies how far the robot’s trajectory is separated from the teaching point at the corner. The larger the smooth level is, the earlier the robot heads to the next interpolation trajectory from the teaching point as shown below. A value of default 1 is set for positioning if not specified.

The taught trajectory The trajectory of smooth level 1 P2 The trajectory of smooth range 50mm When smooth range is to 50, the robot turns inward at a distance of 50mm in front of P2.

5-42



5. Teaching

Application sample of SMOOTH instructions: When connecting the two linear interpolation trajectories, from P1 to P2 and from P2 to P3, with smooth range 50, and then connecting the P3 and P4 with smooth range 1 (simple acceleration/deceleration):

0 1 2 3 4 5 6

PROGRAM_NAME = SMOOTH LMOVE (XYZ1) [P1] SMOOTH_RANGE 50 LMOVE (XYZ1) [P2] LMOVE (XYZ1) [P3] SMOOTH_RANGE 1 LMOVE (XYZ1) [P4]

5-43



5. Teaching

Precautions for using the SMOOTH instructions: (1) When a program including the SMOOTH_RANGE instruction is executed as below, the external output signals (except for the SPRAY signal) are turned ON at the beginning of the curve prior to the P2 and OFF at the beginning of the curve prior to the P3. 0 1 2 3 4 5 6 7

PROGRAM_NAME ＝ LMOVE(XYZ1) SMOOTH_RANGE LMOVE(XYZ1) DOUT #5 , ON LMOVE(XYZ1) DOUT #5 , OFF LMOVE(XYZ1)

OUTPUT [P1] 50 [P2]

Output ON Output OFF

[P3] [P4]

(2) When a program including the SPRAY instruction is created within the smooth motion area as below, the spray signal is turned ON/OFF in the middle of the smooth motion area. As for the PRE_SPRAY and DLY_SPRAY instructions, the SPRAY signal turns ON/OFF according to the culculation result of distance and time for pre/delayed spraying, using the point in the middle of the smooth motion area as reference position. 0 1 2 3 4 5

PROGRAM_NAME ＝ SPRAY LMOVE (XYZ1) [P1] SMOOTH_RANGE 50 LMOVE (XYZ1) [P2] SPRAY #1, ON LMOVE (XYZ1) [P3]

Spray signal ON Spray on area

5-44



The reference position for pre/delayed spraying is shown as below: Pre and delayed spraying position is calculated based on the reference position.

Pre-spraying Delayed spraying The reference position for pre/delayed spraying

5-45

5. Teaching



5.2.6

5. Teaching

CALL DATA BANK INSTRUCTION

5. DATABANK

Calls up the databank with the specified number. The conditions set in the databank called up become effective immediately. This instruction should be set at the step where the conditions need to be changed.

Sample for setting CALL DATA BANK instruction: Databank1 enabled

Taught point (Pn) Spray ON point Spray OFF point

Databank2 enabled

Spraying (Spray ON) section Aircut section

The following is an example of changing conditions at the starting and intermediate spraying points using Databank instructions: 0 PROGRAM_NAME ＝DATABANK 1 LMOVE (XYZ1) [P1] 2 LMOVE (XYZ1) [P2] ･･･ Databank 1 is set. 3 CALL_DBK 1 4 SPRAY #1, ON 5 LMOVE (XYZ1) [P3] 6 CALL_DBK 2 ･･･ Databank 2 is set. 7 LMOVE (XYZ1) [P4] 8 SPRAY #1, OFF 9 LMOVE (XYZ1) [P5]

5-46



！

5. Teaching

CAUTION

The data bank to be called needs to be prepared beforehand. Attempting to call a data bank that does not exist in the memory results in an error: –2106 Specified PAINTING DATA BANK is undefined. To prepare a data bank, see Chapter 10, 4-0 Data Bank Editing.

5-47



5.2.7

5. Teaching

TIMER INSTRUCTION

6. TIMER Holds the robot motion during the specified waiting time. This instruction is valid only for the specified period and does not have any effect on the instructions that follow.

The waiting time can be set up to 99999msec.

！

WARNING

When the servo power of the robot is on, do not enter the motion range of the robot and the peripheral equipment controlled by the robot controller. If the robot is waiting for the specified period by the TIMER instruction, operation only appears stopped. However, the robot is ready to move after the specified period elapses.

5-48



5. Teaching

5.2.8 CALL PROGRAM INSTRUCTION

7. CALL_PGM Calls up the specified program. When execution of the called program has been completed, program returns to the original program and continues from the next instruction after CALL_PGM.

！

CAUTION

· The program which is called must be created beforehand. Attempting to call a program that does not exist in memory results in an error: –800 Program does not exist. · The nesting for calling one program from the other in series are up to 20 levels at the deepest. An error will occur when calling more than 20 levels on teaching or repeating. The program needs to be corrected in edit mode in that case.

5-49



5.2.9

5. Teaching

JUMP INSTRUCTION

8. JUMP Jumps to the specified step. JUMP instruction has COUNTER and COMPARE functions.

！

CAUTION

· The general counter value is reset whenever starting teaching or repeating, but the dedicated counter value is not reset. · Label name can be set up to eight digits (0 – 99999999). · If more than two of the same label names exist, the robot jumps to the previous instruction that is valid.

The jump function includes the following 4 items:

5-50



5. Teaching

0. 1. UC_JUMP (LABEL) Jumps straight to the specified label, (unconditionally, UC).

Sample application of UNCONDITIONAL JUMP (LABEL) instruction To execute the program by skipping the paths P3 – P4, P4 – P5, and P5 – P6 as below, insert the UC_JUMP instruction at step 3 so that the robot carries out a linear movement from P3 to P6.

Work

Step Instruciton 1 JMOVE (JOINT) 2 LMOVE (XYZ1) 3 LMOVE (XYZ1) 4 UC_JUMP LABEL 5 LMOVE (XYZ1) 6 LMOVE (XYZ1) 7 LMOVE (XYZ1) 8 LABEL 9 LMOVE (XYZ1) 10 LMOVE (XYZ1)

5-51

[P1] [P2] [P3] 1111 [P4] [P5] [P6] 1111 [P7] [P8]



5. Teaching

0. 2. TRUE_JUMP 0. 3. FALSE JUMP Jumps to the step specified by LABEL instruction in teaching program. Jumps only when the requirements for jumping (true or false) are found out to be satisfied by executing the COMPARE or COUNTER functions. When these requirements are not satisfied, the program is executed from the next instruction of the LABEL JUMP instruction.

Application sample of the TRUE_JUMP instruction: In this sample program, spraying (from the step P2 to P5) is repeated while the COMPARE requirements are satisfied. Repeated 5 times in this case. The dedicated counters are used for teaching in this sample, but the general counters can also be used.

Work

Step Instruction 1 LOAD SPE_CNT1 , 0 2 JMOVE (JOINT) [P1] 3 LMOVE (XYZ1) [P2] 4 LABEL 12345678 5 ADD SPE_CNT1 , 10 6 SPRAY #1, ON 7 LMOVE (XYZ1) [P3] 8 LMOVE (XYZ1) [P4] 9 LMOVE (XYZ1) [P5] 10 SPRAY #1, OFF 11 LESS SPE_CNT1 , 50 12 TRUE_JUMP LABEL 12345678 13 LMOVE (XYZ1) [P6]

5-52



5. Teaching

0. 4. LABEL Sets destination of the JUMP instruction specified in the teaching program.

Application sample of the LABEL instructions: To execute the program by skipping the paths P3 – P4, P4 – P5, and P5 – P6, insert the UC_JUMP instruction at step 4 so that the robot carries out a linear movement from P3 to P6 shown as a full line below.

Work

Step Instruciton 1 JMOVE (JOINT) 2 LMOVE (XYZ1) 3 LMOVE (XYZ1) 4 UC_JUMP LABEL 5 LMOVE (XYZ1) 6 LMOVE (XYZ1) 7 LMOVE (XYZ1) 8 LABEL 9 LMOVE (XYZ1) 10 LMOVE (XYZ1)

5-53

[P1] [P2] [P3] 1111 [P4] [P5] [P6] 1111 [P7] [P8]



5. Teaching

1. COMPARE The COMPARE function includes the following 7 items:

1.0. EQU COMPARE 1.1. NOT_EQU COMPARE 1.2. GREATER COMPARE 1.3. LESS COMPARE 1.4. GREATER/EQU COMPARE 1.5. LESS/EQU COMPARE Compare the values of general or dedicated counters. Jumping to the specified step according to the compared result is possible by using with the LABEL JUMP instruction.

5-54



5. Teaching

Application sample of the EQU instruction: In this sample program, movement among the teaching points (from the step P1 to P6) is repeated until the COMPARE requirements are satisfied. Repeated 10 times in this case. The dedicated counters are used in this sample, but the general counters can also be used.

Work

Step Instruction 1 LOAD GEN_CNT12, 2 LABEL 3 JMOVE (JOINT) 4 LMOVE (XYZ1) 5 SPRAY #1, ON 6 LMOVE (XYZ1) 7 SPRAY #1, OFF 8 LMOVE (XYZ1) 9 SPRAY #1, ON 10 LMOVE (XYZ1) 11 SPRAY #1, OFF 12 LMOVE (XYZ1) 13 ADD GEN_CNT12, 14 EQU GEN_CNT12, 15 TRUE_JUMP LABEL 16 UC_JUMP LABEL 17 LABEL 18 LMOVE (XYZ1)

5-55

0 111 [P1] [P2] [P3] [P4] [P5] [P6] 1 10 999 111 999 [P7]



5. Teaching

1.6. INPUT_SIGNAL COMPARE Compares the status value of the specified input signals. The input signal of the specified bits from the specified starting logic port is read as binary numbers (OFF=0, ON=1), starting logic port, and is converted to a decimal number value as shown in the example below. Jumping to the specified step based on the compared result is possible by using the LABEL JUMP instruction.

Application sample of the INPUT_SIGNAL COMPARE instructions: To execute the program by skipping paths P3 – P4, P4 – P5, and P5 – P6, insert the DIN_JUMP instruction at step 4 so that the robot carries out a linear movement from P3 to P6 shown as below, only when the input status to the robot controller from the host controller satisfies the set conditions. In this example, the robot jumps to P6 only when the combination of the ON/OF status of the two consecutive ports beginning from input signal 1, that is port 1 and 2, becomes 3. Input port No. 1 2 Compared value (port status) [ON] [ON] = 3 20 x 1 + 21 x 1 (1 + 2)

Work

Step Instruction 1 JMOVE (JOINT) 2 LMOVE (XYZ1) 3 LMOVE (XYZ1) 4 DIN_JUMP #1, 2PORT 5 TRUE_JUMP LABEL 6 LMOVE (XYZ1) 7 LMOVE (XYZ1) 8 LABEL 9 LMOVE (XYZ1) 10 LMOVE (XYZ1) 11 LMOVE (XYZ1) 5-56

[P1] [P2] [P3] 3 666 [P4] [P5] 666 [P6] [P7] [P8]



5. Teaching

2. COUNTER The COUNTER function includes the following 3 items:

2.0. LOAD 2.1. ADD 2.2. SUBTRACT Set the general or dedicated counter values. Jumping to the specified step according to the compared result is possible by using with the LABEL JUMP instruction. When executing this instruction, the current counter value can be checked by referring to the status mode. See chapter 10, 5-2-0 General Counter and 5-2-1 Dedicated Counter.

5-57



5. Teaching

3. PROGRAM SELECT

Program numbers can be switched by conducting this instruction in the system using RPS function for selecting programs. This instruction is generally entered at the final step of a program.

5-58



5.2.10

5. Teaching

CONVEYOR INSTRUCTION (OPTION)

9. CONVEYOR

0. TRACK ON The robot operates by synchronizing with the moving conveyor after this instruction is executed.

1. TRACK OFF The robot stops synchronization with the conveyor after this instruction is executed.

[ NOTE ]

In repeating programs, the robot automatically operates at simple acceleration/ deceleration (equivalent to the smooth range of 1mm) when passing the connecting section between TRACK ON and TRACK OFF, even if the smooth range is set larger.

2. CONVEYOR WAIT The robot waits for the works to be delivered to the specified conveyor position, and then upon delivery, the next instructions are executed. The conveyor position can be set with this instruction.

The upper limit of the conveyor position can be set up to 65000mm.

5-59



！

5. Teaching

WARNING

When the servo power of the robot is on, do not enter the motion range of the robot or the peripheral equipment controlled by the robot controller. If the robot is waiting for arrival of the work specified by the CONVEYOR WAIT instruction, it only appears to have stopped operation. However, it is ready to move after the conveyor reaches the upper limit position.

* See the section 12. Conveyor Synchronization (Options) for the teaching procedures of the conveyor synchronization program.

5-60



5.2.11

5. Teaching

GUN CONTROL INSTRUCTION

A. GUN CONTROL

0. GUN Selection Specifies the gun number from 1 to 9 as defined by the tool dimension. The robot moves so as to control the trajectory and speed of the specified gun tip (TCP). If not set at programming, the gun is automatically set to No. 1.

[ NOTE ]

In repeating programs, the robot automatically operates at simple acceleration/ deceleration (equivalent to the smooth level of 1mm) when passing the section where the controlled gun (TCP) is switched by this GUN CONTROL instruction, even if the smooth level is set larger.

！

WARNING

The tip position of the gun specified by the GUN CONTROL instruction is recorded by STORE POS key when teaching programs. When a gun is mounted on the robot, gun 1 is automatically selected without specifying by GUN CONTROL instruction. When more than two are mounted, the gun number should be specified by the Gun Control instruction beforehand, when creating a program which contains switching of controlled guns. The robot does not operate in playback as taught if specifying a different gun with the GUN CONTROL instruction in the edit mode after making a program by pressing the STORE POS key without specifying the controlled gun.

5-61



5.2.12

5. Teaching

TABLE INSTRUCTION (OPTION)

B. TABLE

[ NOTE ]

This function is for system equipped with an external axis such as a servo turntable. This should be used only for specific system.

5-62



5.2.13

5. Teaching

SENSING INSTRUCTION (OPTION)

C. SENSING

This instruction can be used in system where the robots open/close doors with sensing function, or compensate for work deviation by using cameras.

！

CAUTION

This instruction should not be used except in the system described above.

5-63



5.2.14

5. Teaching

MOVE

E. MOVE

Teaches positions by entry in numeric values instead of using the STORE POS key. 0. LINEAR Moves the selected gun tip to the recorded teaching point with linear interpolation. 1. JOINT Moves the selected gun tip to the recorded teaching point with joint interpolation. 2. CIRCULAR (MID) 3. CIRCULAR (END) Moves the selected gun tip to the recorded teaching point with circular interpolation. The movement trajectory is decided using three points.

* This screen appears when the conveyor axis is installed.

5-64



5. Teaching

The MOVE instruction display On the multifunction panel, MOVE instructions display: step No., interpolation type, point type, configuration data, positional data for 1st – 6th axes and X, Y, Z coordinate values for the traverse axis.

MOVE instructions

[ Example ] 9 LINE XYZ1 0004 –873.417 –485.7 40.4 88.96 –86.88 4719 0 0 0 Configuration data Point type (See next page.) Interpolation (See next page.) Step No.

Positional data of 1st – 6th axes

X, Y, Z coordinates of traverse axis (when using traverse axis)

The configuration data defines the robot’s posture in operation. Configuration Configuration instructions to define the data robot posture 0000 RIGHTY, ABOVE, DWRIST 0001 LEFTY, ABOVE, DWRIST 0002 RIGHTY, BELOW, DWRIST 0003 LEFTY, BELOW, DWRIST 0004 RIGHTY, ABOVE, UWRIST 0005 LEFTY, ABOVE, UWRIST 0006 RIGHTY, BELOW, UWRIST 0007 LEFTY, BELOW, UWRIST LEFTY, RIGHTY Specify the postures of the robot’s three basic axes (JT1, JT2, and JT3). LEFTY specifies the robot configuration to operate like a human left arm, and RIGHTY a right arm. ABOVE, BELOW ABOVE specifies the robot configuration to make the robot arm (JT3) turn up, and BELOW turn down. UWRIST, DWRIST UWRIST specifies to make the JT5 angle positive and DWRIST negative with the same posture of the flange surface. 5-65

JT5 positive (facing the flange)

JT5 negative (facing the flange)



5. Teaching

Precautions: (1) The below table shows the compatibility between interpolation and point types. Point type XYZ1 XYZ2 Joint Interpolation Linear : Can be used Circular : Can not be used Joint (2) If the combination of interpolation and point type is not correct, the screen of explosion-proof teach pendant does not go to the entry screen for positional data. (3) The difference in the robot motion between XYZ1 and XYZ2 at linear and circular interpolation is as follows: XYZ1: This type interpolates to shift the gun posture at a fixed rate from the starting point to the target. The motion of each joint does not necessarily shift at a fixed rate. XYZ2: This type interpolates to shift the wrist axis angle (4th – 6th axes) at a certain rate from the starting point to the target. The gun posture does not necessarily shift at a fixed rate. The gun tip position (X/Y/Z) shifts in the same way regardless of selecting XYZ1 or XYZ2. (4) In teach mode, the above-mentioned MOVE instructions and point types are fixed depending on the interpolation and point type that are selected when recording positions. (See 5.1.5 TEACHING THE MOVE INSTRUCTIONS.) In program edit mode, the interpolation and point type for the MOVE instruction should be selected in the screen shown on the previous page. (5) An error occurs if teaching positions for nonexistent axes. Reset the data to reflect the correct system structure in order to record the positional data. (6) The data format for MOVE instructions are different for 6 axes and 6 axes + traverse axes system structures. System structure The robot only The robot + traverse equipment

Data format 6 axes 6 axes + traverse axes

！

CAUTION

When the MOVE instructions are modified in program edit mode, confirm the robot motion trajectory in teach mode before playback. The positional data entered in edit mode is not checked as being within the robot motion range. Care should be taken to prevent the robot from operating in unexpected directions.

5-66



5.2.15

5. Teaching

OTHER INSTRUCTIONS

F. OTHER INSTRUCTIONS Teach with AS Language by entering characters and numbers using cursor keys. An exapmle for entering LMOVE P1 is explained here.

Ø Move the cursor to L. Fix with the SET key.

SET

Ø

The letter L is entered.

Ø Move the cursor to the desired letter and fix with the SET key.

SET

and

Ø

Characters spelling LMOVE P1 are entered.

Ø

Move the cursor to END.

Ø

5-67



5. Teaching

Ø Press the SET key.

SET

Ø

Screen for entry appears.

Ø SET

Enter 1 (YES). Press the SET key to register the instruction into program.

Ø

Registering current position as location variable: When AS Language is entered as [MOVE instruction location variable] as shown in the example below, pressing the STORE POS key instead of the SET key not only records the current position of the robot as the location variable but also registers the instruction.

Confirmation screen appears.

Ø STORE POS

Enter 1 (YES). Press the STORE POS key to register the current position of the robot, P1, and to register the instruction into the program. 5-68



5. Teaching

Ø

Other keys that can be used at the Instruction entry screen: In the previous pages, instructions are entered by selecting characters shown in the 3rd and 4th lines on the screen, using up and down arrow and SET keys. The following keys can also be used for entering characters: Move the cursor to ← in the character selection area and press the SET key. Move the cursor to → in the character selection area and press the SET key. Move the cursor to BS in the character selection area and press the SET key. Move the cursor to END in the character selection area and press the SET key.

Cursor position moves to the left in the character string entry field. Cursor position moves to the right in the character string entry field. The character just before the cursor position in the character string entry field is deleted. Exit the character string entry and moves to the confirmation screen.

SHIFT

+

SHIFT

+

Cursor position moves left in the character entry field. When it comes to the left end, it shifts to the last position of the next line. The cursor position moves 8 characters to the left in the character entry field. Cursor position moves to the right in the character entry column. When it comes to the right end, it shifts to the first position of the next line. The cursor position moves 8 characters to the right in the character entry field.

+

The number is inserted to the cursor position.

-

A space is inserted to the cursor position.

SHIFT

+

SHIFT

+

1

A decimal point is inserted to the cursor position.

SHIFT

+

5

A comma is inserted to the cursor position.

SHIFT

+

6

A minus is inserted to the cursor position.

5-69



SHIFT

+

2

3 ,

7

4 ,

8 ,

,

5. Teaching

A string, defined as 1 – 6 in the Aux 133 AS Teaching Character String Definition on the multifunction panel, is inserted to the cursor position.

,

Deletes the whole character string.

CLR

SHIFT

+

CLR

The character just before the cursor position is deleted in the character string entry field.

SHIFT

+

SUSPND

The cursor position shifts by one character to the left in the character string entry field.

SHIFT

+

SHIFT

+

The cursor position shifts by one character to the right in the character string entry field. SET

Exits character enrty screen and moves to the confirmation screen.

5-70



5.3

5. Teaching

REPEAT OPEARTION FOR CHECKING

！

WARNING

When turning the TEACH/REPEAT switch from TEACH to REPEAT with the servo power ON, the motor current is engaged, the brake is released, and the robot will be in servo lock condition. Therefore, confirm with absolute certainty that no one remains within the robot motion range before switching to REPEAT. The procedures for the repeat operation for checking programs taught in 5.1.3 TEACHING PROCEDURES is as follows: Setting switches · Turn the control power ON. The control power light illuminates. · Turn the TEACH/REPEAT switch to REPEAT.

· Turn the HOLD/RUN switch to HOLD.

TEACH LOCK

· Turn the TEACH LOCK key on the explosionproof teach pendant OFF (LED goes off). · Turn the motor power ON. The motor power light illuminates.

5-71



5. Teaching

Setting conditions for repeat operation for checking Confirm that the programs (pg10, for example), steps (step:1), or repeat conditions are set as below. Conduct a repeat operation for checking with repeat once and speed set at 10% for safety. See 8.4 Repeat Condition Selection · Press the STATUS key to go to the status screen. · Press the REPEAT CONDITION key and enter the setting. · Set as: Repeat speed 10%, Repeat once, Step continuous, and RPS disabled.

Starting repeat operation · Press CYCLE START switch to start the repeat operation for checking. The switch illuminates. · Turn the HOLD/RUN switch to RUN. This makes the robot start the repeat operation.

[ NOTE ]

When the motor power does not turn ON, the possible causes are: · The Emergency stop switch on the controller or explosion-proof teach pendant is pressed. Release the lock in this case. · An external operation signal (External emergency stop) is input. (The emergency stop is enabled with open condition).

5-72



！

5. Teaching

CAUTION

1. When pressing the CYCLE START switch while the program is midway through a step during check operation, the robot starts repeat operation from that step. Move the cursor to the 1st point of the program in teach mode using the STEP NEXT key in advance in order to repeat from the beginning of the program. P1 (Joint movement)

2. If the 1st step is taught as linear movement, the robot wrist axis moves to the taught posture by rotating in the closer direction within 180°. Its rotation angle may become 360° different from the wrist rotation angle that was taught, which may result in twisting of the painting hoses. Therefore, for the wrist axis, not only set the rotation angle within 180° but also set the gun tip position close to the 1st step. If the 1st step is taught as joint movement, there are no limitations regarding the wrist axis. Teaching the 1st step of the program as joint movement is recommended.

5-73



5-74


Memo

PROGRAM EDIT WITH EXPLOSION-PROOF TEACH PENDANT This chapter provides information on program edit mode with the explosion-proof.

WARNING Program edit is one kind of teaching. It is limited only to those who have completed the special education.

6.1 DISPLAY DURING EDITING ...................................................................................6-2 6.2 STARTING PROGRAM EDIT MODE .....................................................................6-3 6.3 6.4 6.5 6.6

HOW TO EDIT INSTRUCTIONS.............................................................................6-5 HOW TO SEARCH INSTRUCTIONS .....................................................................6-7 EDITING OF MOVE INSTRUCTION ....................................................................6-10 ENDING EDIT PROGRAM MODE........................................................................6-11

6-1


6

6. Program Edit with Explosion-Proof Teach Pendant

EDIT mode is used to modify(INSERT, CHANGE or DELETE) teaching programs without moving the robot. However, setting correction mode to PROHIBIT disables the modification of teaching programs, and functions only for listing program contents. * This chapter covers the editing of teaching programs using the explosion-protection teach pendant. For further explanations of each instruction, refer to 5.2 EXPLANATION OF INSTRUCTIONS.

6.1

DISPLAY DURING EDITING

The screen displayed during editing is detailed below: 1

2

3

4

5

6

Displays the correction mode (PRHBT･INS･CHG･DEL･SCH) as a sub-mode. 1 Can be changed with

CRCT

key.

Displayd the coordinate system for manual operation (EASY · (XYZ1) · (XYZ2) · GUN･JNT). 2 Can be changed with FRAME key. 3 Displays the program number which is currently being edited. 4 Displays the current step number(point number). 5 Operation guidance is displayed. The instructions taught at each step (point) are displayed on the 6 3rd and following lines. Consecutive numbers on the left indicate each instruction.

6-2



6.2


STARTING PROGRAM EDIT MODE

First select EDIT PROGRAM mode and then input a program number. Select EDIT PROGRAM mode

Select the item 2 EDIT PROGRAM from main menu.

Ø

1. Move the cursor to item 2 EDIT PROGRAM, and press the SET key. 2. Or input 2 by number.

or SET

Ø Designate a program number

Input a numerical value for program number and step number and press the SET key. (The initial value for STEP No. is "0"(zero).) CRCT

When the key is preset to select PROHIBIT, ADD or CHANGE before setting of numbers, the selected one becomes the default correction mode for editing programs. When creating a new program, even if a value is assigned to STEP No., it takes no effect, and the step No. always starts from 0. For existing programs, when a number greater than the last step is specified, the last step is displayed and then editing is started.

Ø SET

to

6-3




Ø Display the program contents

In this example, the instruction at step 0 of Program 10 is displayed. For creating new programs, the last step of program, PROGRAM END, is displayed.

6-4



6.3


HOW TO EDIT INSTRUCTIONS

Editing operation in program edit mode is described in this unit. Selection of correction mode Select correction mode in advance to choose the type of editing: inserting an instruction, or deleting the currently selected instruction. Edit/Prohibit

Ø Edit/Addition/ · · ·

Correction mode toggles among the choices below each time the

CRCT

key is pressed.

Ø Edit/Change/ · · ·

Ø

PRHBT

Edit/Search/ · · ·

CHG

DEL SCH

Edit Deletion/ · · ·

Ø

ADD

(After editing, correction mode reverts to default setting: Prohibit, Add, or Change.) The default correction mode can be changed by pressing the SHIFT ＋CRCT keys from the instruction data display screen. (See screen on page 6-4) [ NOTE ]

1.When PRHBT is selected as correction mode, any attempt to edit an instruction results in error, and no instruction can be edited. To edit instructions, change correction mode with the CRCT key. 2.When ADD is selected as correction mode, instructions are inserted following the selected instruction (on which the cursor is positioned). 3. When correction mode is set as CHG or DEL, instruction to be changed or deleted is selected by cursor position.

6-5




Editing of instructions In EDIT PROGRAM mode, select the instruction to insert, change or delete by moving the cursor with keys and pressing the SET key. In DEL mode, the highlighted instruction is displayed on the screen, And an inquiry appears for confirmation. Inputting 1 (YES) from this screen deletes the instruction.

In this example, when ADD is selected, instruction is added following line 2 AIRCUT-JSPEED, when CHG is selected, line 2 AIRCUT-JSPEED is changed, when DEL is selected, line 2 AIRCUT-JSPEED is deleted. [ NOTE ] In EDIT PROGRAM mode, STEP NEXT and STEP BACK keys are disabled. (Robot does not move.)

6-6



6.4


HOW TO SEARCH INSTRUCTIONS

Search operation in program edit mode is described in this unit. Selection of search mode

Press CRCT key to select SEARCH mode.

Ø CRCT

Ø Selection of instruction to search

Instructions following 6 can be displayed by scrolling the screen with keys.

In this example, 4 SMOOTH is selected.

Ø or

1. Move the cursor to item 4. SMOOTH, and press the SET key. 2. Or, input 4 for the item No. in the menu by number keys.

SET

6-7




Display the result of search

Display the step No. for the instruction at which the cursor is currently positioned.

The result of searching SMOOTH instruction is displayed. The cursor can be moved with keys. Pressing the SET key where, it is possible to change the set value or jump to the instruction on which the cursor is positioned.

Ø SET

Ø Edit/Jump of to the result of search

In this example, 0 CHANGE is selected.

Ø 1. Move the cursor to item 0 CHANGE, and press the SET key. 2. Or, input 0 for the item No. in the menu by number keys.

or SET

6-8




Change the result of search

Change SMOOTH_RANGE to 80.

Ø SET

Display of search result

The instruction highlighted by the cursor changed from SMOOTH_RANGE 50 to 80. [ NOTE ] To exit from search mode, press CRCT or

6-9

key.




6.5 EDITING OF MOVE INSTRUCTION In EDIT PROGRAM mode, robot's current positional stage cannot be saved as positional data. Therefore, in this mode, numeric value must be input to insert or change a step(MOVE instruction). This unit describes the editing of MOVE instructions.

Set the step to modify In EDIT PROGRAM mode, the MOVE instruction to be inserted, changed or deleted is selected by moving the cursor with keys and pressing the SET key. (New insertations are inserted after the instruction that is currently highlighted.)

Edit the program Iafter choosing the instruction for modification in CHG mode, XYZOAT or JOINT ANGLE values are displayed according to the interpolation/point type of the step. Modify the values and press the SET key, and the position data will be changed. In ADD mode, a MOVE instruction to the point indicated by the numeric value entered is inserted. In DEL mode, the MOVE instruction at the selected step is displayed with an inquiry asking for confirmation. Inputting 1(YES) on the screen deletes the MOVE instruction. Move cursor with keys and enter a numeric value.

Refer to, 5.2.14 Move Instruction, for more details regarding editing methods and precautions when using this function.

！

CAUTION

When MOVE instruction is corrected in EDIT PROGRAM mode, be sure to check the path of robot motion in TEACH mode before playing back. The positional data input in EDIT mode is not checked in terms of robot motion range or other aspects, at the time of data input. 6-10



6.6


ENDING EDIT PROGRAM MODE

Endint EDIT PROGRAM mode is described below: Selection of exit mode

Press

END

or

keys to shift to END screen.

Ø END

or

Ø EDIT PROGRAM mode END screen

Selecting 1 (YES), ends EDIT PROGRAM mode. After exiting EDIT PROGRAM mode with the

END

key,

screen shifts to the main menu screen. When exiting with

key, screen shifts to the program No.

input screen.

6-11



6-12


Memo

PROGRAM EDITING WITH MULTIFUNCTION PANEL (OPTION) This chapter provides information on program edit mode with the multifunction panel.

WARNING Program edit is one kind of teaching. It is limited only to those who have completed special education.

7.1 ................................................... OVERVIEW OF PROGRAM EDITING 7-2 7.2 ............................................................. PROGRAM EDITING SCREEN 7-3 7.3 ................................................... PROGRAM EDITING PROCEDURES 7-4 7.3.1 ................................................................EDIT OF AN ENTIRE STEP 7-4 7.3.2 .........................................EDIT OF ALL DATA IN MULTIPLE STEPS 7-10

7-1


7

7. Program Editing with Multifunction Panel (Option)

7.1 OVERVIEW OF PROGRAM EDITING Programs created by using teach pendant can be edited with multifunction panel. Program editing functions include the following: 1. Copy and paste functions of an entire step. 2. Copy and paste functions of multiple steps. Note that auxiliary data cannot be edited. Program edit mode: Copy: Program steps are copied. Cut: Program steps are cut. Delete: Auxiliary and location data taught at steps are deleted from memory. When editing program, data such as Cut, Copy or Step are stored in the paste buffer once. And the data is transferred from the paste buffer to the selected step using the paste function. Up to 10 steps of data can be stored in the paste buffer. The paste buffer is initialized when the following commands are executed. 1. SYSINT Command 2. Control power supply OFF to ON. Therefore, the data by Cut and Copied can be pasted to other program steps. The following conditions are required to perform program editing. 1. Teach mode. 2. TEACH LOCK switch ON 3. PROGRAM EDIT ON in the Aux. 96 PANEL ENVIRONMENT DATA is selected. 4. Robot program is selected. When the program editing mode is selected, the following operations cannot be done. 1. Change in auxiliary data 2. Manual clamp and manual output 3. Call of Auxiliary function. 4. Program selection. 5. Screen switching by STATUS key or NEXT MENU key.

7-2




7.2 PROGRAM EDITING SCREEN When the

key on Multi-Function Panel is pressed, the program editing screen is

displayed. Ö

Teaching (Block step) Screen

Ö Ø

Edit mode key

7-3



7.3


PROGRAM EDITING PROCEDURES

7.3.1 EDIT OF AN ENTIRE STEP 1) Overwrite Program step which contains the auxiliary and location data is edited in overwrite. Select the source step.

Press the CUT key. Or, press the COPY key.

When the STEP key is pressed, entire step’s area changes color. ［ NOTE ］ When the CUT mode is selected, the data of the source step is cut. When the RETURN key is pressed, all data for the step is stored in the paste buffer. At this time, all keys for the step return to their original color. When the CANCEL key is pressed (without pressing the ENTER key as previously described) the selected data is canceled and the Cut or Copy operation is terminated. Select the destination step.

MODE OVERWRITE

Press the MODE key, and select the OVERWRITE mode.

When the PASTE key is pressed, the data stored in the paste buffer is displayed. When the RETURN key is pressed, the entire displayed step is replaced with the data stored in the paste buffer. When CANCEL key is pressed (without pressing the RETURN key as previously described) the paste function is terminated. 7-4




(Example 1) The data of step 3 is cutout and overwrites in step 5. Before editing 1

SPLAY JSPEED 15%

2 3 4 5 :

SMOOTH RANGE 1mm JOINT JOINT 0000 115.21 –2.85 –6 3.27 36 6 .3 84 … SPLAY_2 ON FLOW_RATE 1

Ø After editing 1 SPLAY JSPEED 15% 2 SMOOTH RANGE 1mm 3 SPLAY_2 ON 4 JOINT JOINT 0000 115.21 –2.85 –6 3.27 36 6 .3 84 … : (Example 2) The data of step 3 is copied and overwrites in step 5. Before editing 1 SPLAY JSPEED 15% 2 SMOOTH RANGE 1mm 3 JOINT JOINT 0000 115.21 –2.85 –6 3.27 36 6 .3 84 … 4 SPRAY_2 ON 5 FLOW_RATE 1 :

Ø After editing 1 SPLAY JSPEED 15% 2 SMOOTH RANGE 1mm 3 JOINT JOINT 0000 115.21 –2.85 –6 3.27 36 6 .3 84 … 4 SPRAY_2 ON 5 JOINT JOINT 0000 115.21 –2.85 –6 3.27 36 6 .3 84 … : [ NOTE ] 1. When the step after Cut is a new step, the message for new step is displayed. 2. Cut and Copy data is stored, therefore, the Paste function can be performed repeatedly.

7-5




2) Insertion The program step which contains the auxiliary and location data is inserted as a new step. Select the source step.

Press the CUT key.

Or, press the COPY key.

When the STEP key is pressed, entire step’s area changes color. ［ NOTE ］ When the CUT mode is selected, the data of the source step is cut. When the RETURN key is pressed, all data for the step is stored in the paste buffer. At this time, all keys for the step return to their original color. When the CANCEL key is pressed (without pressing the RETURN key as previously described) the selected data is canceled and the Cut or Copy operation is terminated. Select the destination step.

Press the MODE key, and select the INSERT mode.

When the PASTE key is pressed, the data stored in the paste buffer is displayed. When the RETURN key is pressed, the paste function is completed. When CANCEL key is pressed (without pressing the RETURN key as previously described) the paste function is terminated.

7-6




(Example 1) Step 5 data is cutout and inserted between step 2 and 3. Before editing 1 SPLAY JSPEED 15% 2 SMOOTH RANGE 1mm 3 JOINT JOINT 0000 115.21 –2.85 –6 3.27 36 6 .3 84 … 4 SPRAY_2 ON 5 FLOW_RATE 1 :

Ø After editing 1 SPLAY JSPEED 15% 2 SMOOTH RANGE 1mm 3 FLOW_RATE 1 4 JOINT JOINT 0000 115.21 –2.85 –6 3.27 36 6 .3 84 … 5 SPRAY_2 ON :

(Example 2) Step 5 data is copied and inserted between step 2 and 3. Before editing 1 SPLAY JSPEED 15% 2 SMOOTH RANGE 1mm 3 JOINT JOINT 0000 115.21 –2.85 –6 3.27 36 6 .3 84 … 4 SPRAY_2 ON 5 FLOW RATE 1 :

Ø After editing 1 SPLAY JSPEED 15% 2 SMOOTH RANGE 1mm 3 FLOW RATE 1 4 JOINT JOINT 0000 115.21 –2.85 –6 3.27 36 6 .3 84 … 5 SPRAY_2 ON 6 FLOW RATE 1 : [ NOTE ] 1. When the step after Cut is a new step, the message for new step is displayed. 2. Cut and Copy data is stored, therefore, the Paste function can be performed repeatedly.

7-7




3) Deletion Unnecessary program step, including all auxiliary and location data, is deleted.

Select the step to delete.

When the DELETE key is pressed, the entire step is deleted.

When the STEP key is pressed, entire step’s area changes color. When the RETURN key is pressed, the entire step is deleted. The color of each key returns to its original color. When the CANCEL key is pressed (without pressing the RETURN key as previously described) the delete function is terminated.

7-8




(Example) The data of step 3 is deleted. Before editing 1

SPRAY JSPEED 15%

2 3 4 5 :

SMOOTH RANGE 1mm JOINT JOINT 0000 115.21 –2.85 –6 3.27 36 6 .3 84 … SPRAY_2 ON FLOW_RATE 1

Ø After editing 1 SPRAY JSPEED 15% 2 SMOOTH RANGE 1mm 3 4 :

SPRAY_2 ON FLOW_RATE 1

[ NOTE ] 1. When the step after Delete is a new step, the message for new step is displayed. 2. To delete multiple steps, select the step one by one and press the DELETE key for each step.

7-9




7.3.2 EDIT OF ALL DATA IN MULTIPLE STEPS 1) Overwrite Multiple steps including auxiliary and location data are edited in overwrite. Select the source step.

Press the CUT key.

Or, press the COPY key.

When the STEP key is pressed, the entire step is change color. This operation specifies the first step of the range to cut or copy multiple steps. ［ NOTE ］ When the Cut mode is selected, the data of the source step is cut. Press the BACKWARD or FORWARD key and change step. When the STEP key is pressed, the entire step’s keys change color. This operation specifies the last step of the range to cut or copy multiple steps. When the RETURN key is pressed, all data of multiple steps is stored in the paste buffer. At this time, entire step’s keys return to their original color. The selected data is canceled when the CANCEL key is pressed without pressing the RETURN key, Cut or Copy operation is released. Select the destination step.

MODE OVERWRITE

Press the MODE key, and select the Overwrite mode. When the PASTE key is pressed, the data stored in the paste buffer is displayed. When the RETURN key is pressed, the entire displayed step is replaced with the data stored in the paste buffer. When CANCEL key is pressed (without pressing the RETURN key as previously described) the paste function is terminated. 7-10




(Example 1) The data for steps 4-6 is cut and overwrites steps 11-13. Before editing : 3 JOINT JOINT 0000 115.21 –2.85 –6 3.27 36 6 .3 84 … 4 SPRAY_2 ON 5 FLOW_RATE 1 6 SHAPING/PATTERN AIR 4 7 AIR MOTOR/ATOMIZING AIR 1 :

Ø After editing : 3 JOINT JOINT 0000 115.21 –2.85 –6 3.27 36 6 .3 84 … 4 AIR MOTOR/ATOMIZING AIR 1 : 11 SPRAY_2 ON 12 FLOW_RATE 1 13 SHAPING/PATTERN AIR 4 : (Example 2) The data for steps 4-6 is copied and overwrites steps 11-13. Before editing : 3 JOINT JOINT 0000 115.21 –2.85 –6 3.27 36 6 .3 84 … 4 SPRAY_2 ON 5 FLOW_RATE 1 6 SHAPING/PATTERN AIR 4 7 AIR MOTOR/ATOMIZING AIR 1 :

Ø After editing : 3 JOINT JOINT 0000 115.21 –2.85 –6 3.27 36 6 .3 84 … 4 SPRAY_2 ON 5 FLOW_RATE 1 6 SHAPING/PATTERN AIR 4 7 AIR MOTOR/ATOMIZING AIR 1 : 11 SPRAY_2 ON 12 FLOW_RATE 1 13 SHAPING/PATTERN AIR 4 :

7-11




[ NOTE ] 1. When the step after a Cut is a new step, the message for new step is displayed. 2. When multiple steps are specified, a reverse order cannot be specified. First step =< End step 3. When the first step of the edit destination is a new step, there occurs an error. 4. Cut and Copy data is stored in the paste buffers; therefore, the Paste function can be performed repeatedly.

7-12




2) Insertion Multiple steps including all auxiliary and location data are inserted between selected steps. Select the source step.

Press the CUT key. Or, press the COPY key.

When the STEP key is pressed, the entire step’s keys change color. This operation specifies the last step of the range to cut or copy multiple steps. ［ NOTE ］ When the Cut mode is selected, the data of the source step is cut. Press the BACKWARD or FORWARD key and change step. Press the STEP key. This operation specifies the last step of the range to cut or copy multiple steps. When the RETURN key is pressed, all data of multiple steps is stored in the paste buffer. At this time, entire step’s keys return to their original color. The selected data is canceled when the CANCEL key is pressed without pressing the RETURN key and Cut or Copy operation is released. Select the destination step to insert the selected Steps. For example, when you insert between steps 3 and step 4, select step 4. Press the MODE key, and select INASERT mode. When the PASTE key is pressed, the data stored in the paste buffer is displayed. When the RETURN key is pressed, the entire displayed step is replaced with the data stored in the paste buffer. When CANCEL key is pressed (without pressing the ENTER key as previously described) the paste function is terminated. 7-13




(Example 1) The data for steps 12-13 is cutout and insert between 3-4. Before editing : 3 JOINT JOINT 0000 115.21 –2.85 –6 3.27 36 6 .3 84 … 4 SPRAY_2 ON : 12 SMOOTH RANGE 100mm 13 LINEAR XYZ1 1 0000 –874.3 –1006 .7 –1195.4 3.54 … :

Ø After editing : 3 JOINT JOINT 0000 115.21 –2.85 –6 3.27 36 6 .3 84 … 4 SMOOTH RANGE 100mm 5 LINEAR XYZ1 1 0000 –874.3 –1006 .7 –1195.4 3.54 … 6 SPRAY_2 ON : (Example 2) The data for step 3-4 is copied and overwrites in step 12-13. Before editing : 3 JOINT JOINT 0000 115.21 –2.85 –6 3.27 36 6 .3 84 … 4 SPRAY_2 ON : 12 SMOOTH RANGE 100mm 13 LINEAR XYZ1 1 0000 –874.3 –1006 .7 –1195.4 3.54 … :

Ø After editing : 3 JOINT JOINT 0000 115.21 –2.85 –6 3.27 36 6 .3 84 … 4 SMOOTH RANGE 100mm 5 LINEAR XYZ1 1 0000 –874.3 –1006 .7 –1195.4 3.54 … 6 SPRAY_2 ON : 14 SMOOTH RANGE 100mm 15 LINEAR XYZ1 1 0000 –874.3 –1006 .7 –1195.4 3.54 … :

7-14




[ NOTE ] 1. When the step after a Cut is a new step, the message for new step is displayed. 2. When multiple steps are specified, a reverse order cannot be specified. First step =< End step 3. Cut and Copy data is stored in the paste buffers; therefore, the Paste function can be performed repeatedly.

7-15




3) Deletion Multiple program steps, including auxiliary and location data is deleted. Select the step to delete.

When the DELETE key is pressed, the entire step is deleted. The data is not stored in the paste buffer.

When the STEP key is pressed, the entire step’s area changes color. This operation specifies the first step of the range to delete multiple steps. ［ NOTE ］ All data including auxiliary and location that are not displayed is selected. Press the BACKWARD or FORWARD key and change step.

Press the STEP key. This operation specifies the last step of the range to delete multiple steps. When the RETURN key is pressed, the data for the specified steps is deleted. At this time, all key for selected steps return to their original color. The Delete operation is canceled when the CANCEL key is pressed without pressing the ENTER key.

7-16




(Example) The data for step 12-13 is deleted. Before editing : 11 SPRAY SPEED 1100mm/s 12 SMOOTH RANGE 100mm 13 LINEAR LINEAR 1 0000 –874.3 –1006 .7 –1195.4 3.54 … 14 CONVEYOR TRACK ON :

Ø After editing : 11 SPRAY SPEED 1100mm/s 12 CONVEYOR TRACK ON : [ NOTE ] 1. When the step after a Delete is a new step, the message for new step is displayed. 2. When multiple steps are specified, a reverse order cannot be specified. First step =< End step 3. When deleting multiple steps in many groups, specify the range of steps each time and press the DELETE key.

7-17



7-18


Memo

8

REPEAT OPERATION PROCEDURES This chapter provides information on operation procedures of repeat motion for daily running or confirming after teaching or editing.

8.1 BEFORE EXECUTING REPEAT OPERATION ................................................8-2 8.2 8.3 8.4 8.5

METHOD OF REPEAT OPERATION.................................................................8-3 STOP AND RESTART REPEAT OPERATION PROCEDURES.....................8-7 REPEAT CONDITION SELECTION ...................................................................8-8 WAIT OVERRIDE................................................................................................8-10

8.6 SLOW REPEAT MODE......................................................................................8-12

8-1


操作説明書

8.1

8. Repeat Operation Procedures

BEFORE EXECUTING REPEAT OPERATION

Repeat operation is that the robot playbacks taught operation program. When executing repeat operation, take notice of followings:

！

WARNING

1. Ensure that no one is within safety fence. 2. Inspect tools mounted on the robot and peripherals for defect. 3. Confirm that robot does not interfere with peripherals and is on original position.

Daily repeat operation Execute operation program for daily work. Mainly it can be executed by operation panel of controller or external operation panel (Interlock board). Repeat operation for confirmation after teaching or program editing Execute confirmation after teaching to robot or editing programs.

8-2




8.2 METHOD OF REPEAT OPERATION This unit provides information how to execute programs for daily work. A procedure on operation panel of controller is described in this unit. For starting up from external, see the separate volume “External I/O for Explosion-Proof Type Controller Manual”. Basic operation procedures of repeat operation are follows:

(1) Setting of power switch

Ø (2) Mode and Program selection

Ø (3) Selection of repeat condition

Ø (4) Starting repeat operation

Ø (5) Exiting repeat operation Detailed operation procedures are described in the next pages.

！

WARNING

When turn the Teach/Repeat switch from Teach to Repeat with motor power ON, motor current is turned ON, brake is released after 0.5 seconds and the robot is servo locked. Therefore, when turning to repeat, ensure that no one is within robot motion range.

8-3




Switch setting Turn Control Power switch ON. Control Power lump lights. TEACH LOCK

Turn off the teach lock of explosion-proof teach pendant by pressing the TEACH LOCK key. (LED turns off.) When program is not play backed by external signals, turn the Remote/Local switch to Local side. Turn the Teach/Repeat switch to Repeat side.

Turn the Hold/Run switch to Hold side.

Turn the Teach/Repeat switch to Repeat side.

Program confirmation Confirm that the program and step to be executed is desired one on liquid crystal display of multifunction panel. When the program is not desired one, select by the following method.

8-4




Program selection Operate as follows on the multifunction panel. PROGRAM

pg1

Press the PROGRAM key.

Program list is displayed.

Move cursor on the desired program. For example, select the pg1.

RETURN 録

Press the RETURN key after selecting program.

Selection of repeat condition Confirm whether or not repeat condition is desired condition on the multifunction panel. For example, Repeat speed : 10%, Repeat continuous, Step continuous, RPS OFF are selected, the screen of Repeat condition on the multifunction panel is displayed as follows:

8-5



！


WARNING

Before starting repeat operation, take procedures to safety, for example, no one is within the safety fence etc.

Starting repeat operation Turn the Hold/Run switch to Run.

Press the Cycle Start switch. Cycle Start lump illuminates.

Repeat pg1 according to these operations.

！

WARNING

When robot motion is not intended one due to setting error of each items or some troubles, turn the Hold/Run switch to Hold side or press the Emergency Stop switch immediately for urgency. [ NOTE ] Repeat Speed, Repeat Cont/Once, Step Cont/Once can be selected during repeat operation. However, program and step cannot be selected during repeat operation. Select program and step with the Cycle Start lump OFF.

8-6




8.3 STOP AND RESTART REPEAT OPERATION PROCEDURES To stop robot during repeat operation, follow the next procedures: 1. Turn the Hold/Run switch to Hold side. 2. Press the Emergency Stop switch on controller or explosion-proof teach pendant. This unit provides information on how to stop and restart repeat operation after suspending. 〔During repeat operation〕

Terminating method

Method for Suspend Ö Restart

Turn the Hold/Run switch to Hold side. Though robot stops, Cycle Start lamp keep lighting.

Ø To abort cycle Operation, turn the Teach/Repeat switch to Teach side. The Cycle Start lamp lights off. The Motor Power lamp lights off.

Ø Press the Emergency Stop switch.

Ø Turn the Control Power OFF and shut off power.

8-7

Turn the Hold/Run switch to Hold side. Though robot stops, Cycle Start lamp keep lighting.

〔Robot Stop〕

Ø To restart repeat operation, turn the Hold/Run switch to run side.

Ø 〔Repeat operation restart〕




8.4 REPEAT CONDITION SELECTION Operate as follows on multifunction panel: Display Status screen by pressing the MENU key.

MENU

Ø Display Status screen by pressing the STATUS key.

STATUS

Ø Multifunction panel is displayed as shown in the figure below.

Ø

Select desired repeat condition.

Function of each key.

·····

10%

Repeat speed increases 10% with each press. (Max. 100％)

10%

Repeat speed decreases 10% with each press. (Minimum 10%)

···

10% 10%

90%

20% 10%

90%

···

90%

8-8

100 %




This key is used to select whether the program runs one cycle (Repeat Once) · · · or continuously (Repeat Cont). When REPEAT ONCE is selected, the robot stops after executing the program only one cycle.

Repeat Once

Repeat Continuously

· · · This key is used to select whether the program runs one step by one step (Step Once) or continuously (Step Cont). When Step Once is selected, robot stops at each teaching point. Press the

key to forward the step.

Step Once

Step Continuously

· · · This key is used to select whether the RPS (Remote Program Selection) is to be valid or invalid. However, when RPS and Jump signals are not defined with user defined dedicated signals, this key is not displayed. RPS ON

RPS OFF ABLE

···

Dry Run allows the user to execute programs without any robot motion. For example, when cannot operate robot, this function is used to confirm the program executing condition or the condition of input signal without any robot motion. When ON key is pressed, dry run function becomes effective. When OFF key is pressed, dry run function becomes ineffective.

！

WARNING

When DRY RUN mode is ON, robot runs repeat motion without any robot motion.

8-9




8.5 WAIT OVERRIDE The wait override function is for forwarding to the next step forcibly by passing the step in the condition of waiting input signal at repeat operation or at check operation (WX signal for block step or WAIT, SWAIT, EXTCALL command etc. of AS language.)

！

WARNING

Wait Override is a function for forwarding to the next step forcibly without waiting for external signals. Be sure to confirm the condition around the robot before overriding.

When the step of the program is on the input signal waiting condition, WAIT is displayed on status display area of multifunction panel as shown in figure below.

For Status screen, Program Contents Display screen, Monitor screen, Current Position Display screen and Painting Status screen, screen is displayed as shown in left figure. WAIT is displayed. When Waiting is displayed on screen as above, Waiting screen is displayed by pressing this key. When this key is pressed again, the screen returns to the previous display screen from Wait screen.

Ø Step No. and contents in waiting condition are displayed.

8-10




Ø

Override separately

Override at once

Override specific signal only from displayed signals. To override only WX1 and WX4:

Override all displayed signals at Once. To override all displayed WX1, WX2, WX3, and WX4:

Waiting condition is overridden, and executes the next step.

[ NOTE ] 1. When the key indicates waiting is pressed, display color change from yellow to orange. When WAIT OVERRIDE key is pressed, the signal to be overridden change color from orange to light blue. 2. When the step becomes waiting condition by WAIT, SWAIT command and so on during check operation, step can be forwarded by setting the next step and you can continue check operation.

8-11




8.6 SLOW REPEAT MODE Slow repeat mode is function for operating robot at slow speed by external input signal. This function is used when required to reduce robot operation speed and confirm, at beginning of run or after error recovery.

While the input signal for slow repeat mode is OFF Maximum repeat speed of robot is controlled with the speed set as slow repeat mode speed. (It is valid in repeat mode.) Robot operates at slow repeat mode speed at the point where robot repeat operation speed (speed set by program and monitor speed) is faster than slow repeat mode speed, and at the point where robot repeat operation speed is slower than slow repeat mode speed, robot operates at repeat operation speed. While the input signal for slow repeat mode is ON Robot operates at regular repeat operation speed (speed set by program and monitor speed). Speed

Regular repeat operation speed.

100% 75%

Slow repeat mode speed. （Slow repeat speed: 25%）

50% 25%

Time When the input signal for slow repeat mode is changed from ON to OFF or from OFF to ON during repeat operation, robot momentarily stops at the position. After that, robot restarts operation at the speed depending on the signal at the time. Regular repeat operation

Regular repeat operation Slow repeat operation

Time Slow repeat input signal ON→OFF

8-12

Slow repeat input signal OFF→ON




Setting of dedicated input signal for slow repeat mode External input signal for slow repeat mode is set as dedicated input signal. Multifunction panel operation Select A-111. Dedicated Input D Signal with auxiliary function.

Keyboard operation E

F

S

I

G

I

N

P

U

T

↓ 111.Dedicated Input Signal

See A-111.

When dedicated input signal is not set, robot executes regular repeat operation as it doesn’t become slow repeat mode.

Setting of speed for slow repeat mode The speed of slow repeat mode against maximum repeat speed of robot can be set in percentage. Select A-55. Slow Repeat Mode with auxiliary function.

↓ 55. Slow Repeat Mode

See A-55.

8-13



8-14


Memo

AUXILIARY FUNCTIONS This chapter explains methods for displaying information about robot operation and for setting required data, using the multifunction panel.

9.1 AUXILIARY FUNCTION LIST ......................................................................................9-3

9-1


9

！

9. Auxiliary Functions

WARNING

Program edit is one kind of teaching. It’s use is limited only to those who complete special education for operating . Auxiliary function is used in the following conditions: 1. When operating robot or editing program, displays mainly used data: Location Speed Display, Memory Available, Dedicated Input/Output Sign and so on. 2. Sets data regarding robot movement and operations that robot executes. Base Coordinates, Tool dimensions, Software Limit. 3. Performs maintenance for adjusting robot or when error occurs. Zeroing, Zeroing Data Set Display.

MENU

Display AUX screen by pressing the MENU key.

Ø

* Press EXIT key to return to the status screen which was displayed previous to the AUX screen, (Status, Program contents, Monitor, Present Position Display, Spray status etc). When Aux. 75 SYSTEM SWITCH, ALERE key displayed as DISCRIPTION.

9-2



9.1 AUXILIARY FUNCTION LIST Function Name LOCATION & SPEED A2 DISPLAY A3

DATA TRANSFER

A5

KILL PROGRAM

A6

MIRROR CONVERSION (Option)

A9 A 10 A 11 A 12

DATA CONVERSION (Option) MEMORY PC CARD (SAVE) PC CARD MEMORY (LOAD) FILE DIRECTORY (FDIRECTROY)


Function Description Displays present position information in real time. Used for copying all or part of one program to another program. Removes the selected program from the stack, does not delete program. Converts programmed locations into locations with mirror symmetry with the Y and Z planes of the base coordinate system. Converts off-line data into data for use in an on-line machine. Saves data from the system memory to a SRAM PC card. Loads file information from a SRAM PC card to system memory. Displays a list of files currently on the PC card.

A 14

PC CARD AUX.FUNCTION

Used to format SRAM PC card and delete files stored on SRAM PC cards.

A 40

AUTO TOOL SET (Option)

Used to register tool dimensions automatically.

A 41

ZEROING

Executes zeroing.

A 42

POSITION ERROR RANGE AT EMERGENCY STOP

A 43 A 44

Sets the deviation range for checking for errors at emergency stops. Sets a deviation range for checking for errors when the ENCODER ERROR RANGE controller power is applied. ZEROING DATA SET Allows the user to set zeroing data from the numeric DISPLAY key pad.

A 46

INSTALLATION POSTURE

Sets up the installation posture of the robot.

A 47

BASE COORDINATES

Allows the user to set the base coordinate system at a position other than zero (in parallel or rotation movement).

A 48

TOOL DIMENSIONS

Used to set tool dimensions.

A 51

SOFTWARE LIMIT

Sets the upper and lower ranges for robot motion. (Joint Axes)

A 53

ACCURACY

Sets the accuracy level (1-4) for Aux. Data.

A 55

SLOW REPEATMODE

Sets the speed at repeat operation.

A 56

CHECK SPEED

Sets the robot speeds when performing the check step function.

A 57

TEACH SPEED

Sets the speed in teach mode

A 70

MEMORY AVAILABLE

Displays the system memory status.

9-3




A 71

RECORD DATA/INHIBIT

Prevents the recording of data if set to inhibit.

A 72

AUTOMATIC PATH GENERATION

Sets parameter to generate a path automatically.

A 73

SPRAY ON/OFF

Sets Spray as OK/Prohibit.

A 75

SYSTEM SWITCH

Sets various system software switches.

A 76

HOME POSITION

Used to set and view robot home positions.

A 77

WORK SPACE OUTPUT (Option)

Sets the top and the bottom position of the workspace.

A 78

CLEAR CHECK SUM ERROR

Provides a method to clear check sum errors.

A 80

XYZ SHIFT (Option)

A 81

JOINT SHIFT (Option)

A 82

TOOL SHIFT (Option)

A 83

WORK SHIFT (Option)

A 87 A 90

PROGRAM ARGUMENT/ COMMENT (Option) SOFTWARE VERSION DISPLAY

Used to shift programmed locations in the base coordinate system. Used to change the joint values for selected programmed points. Used to shift programmed locations in the tool coordinate system. Used to shift programmed locations in the work coordinate system. Adds a comment to the program. Displays the version numbers of the installed system software (AS, Servo, etc.).

A 91

ENVIRONMENT DATA

Sets a timer to turn off servo motors automatically.

A 95

ENVIRONMENT DATA 2

Sets the hardware configuration.

A 96

ENVIRONMENT DATA OF PANEL

Used to set the type of user interface on the multi-function panel.

A 99

CHECK SPECIFICATION

Sets the specifications to be used during check mode.

A 100 SYSTEM INITIALIZATION A 101 BATTERY ERROR CHECK A 103

TOUCH PANEL SHORT CIRCUIT CHECK

A 110 TIME DEDICATED INPUT SIGNAL DEDICATED OUTPUT A 112 SIGNAL DEDICATED SIGNAL A 113 DISPLAY A 111

Program and position information is deleted; system is reset to default settings. Enables or disables the check for RAM low battery errors at power up. Displays an error message when the touch panel is pressed. Sets the data and time for the controller processor. Used for setting dedicated input signals. Used for setting dedicated output signals. Displays dedicated input and output signals.

A 114 GUN SPECIFICATION

Used for setting clamp information and specifications.

A 120 ERROR LOGGING

Displays a history of error messages. 9-4



A 122 OPERATION LOGGING A 124 A 127 A 130 A 131 A 133 A 140 A 142

MOTOR TORQUE INFORMATION (Option) OPERATION INFORMATION (Option) PC PROGRAM RUN/STOP (Option) INTERFACE PANEL (Option) AS INSTRUCTION C.S. DEFINITION (Option) ENCODER ROTATION COUNTER RESET PROGRAM QUEUE (Option)


Displays a history of operation activity. Displays the motor torque information (peak current, etc.). Displays operation information: time, etc. Used to set PC program RUN/STOP Used to set the switch and the lamp for the interface panel. Used to define character strings. Used to reset the encoder values as part of the zeroing process. Used to set program No. to be repeated.

A 143 START DELAY (Option)

Used to delay timing of robot motion start.

A 144 INTERRUPT PROGRAM

Used to register interrupt program.

A 149

TOOL INERTIA REGISTRATION (Option)

A 153 PROGRAM LIST A 154 PROGRAM CYCLES A 155 HOME POSITION MASK A 158

GENERAL OUTPUT FUNCTION ASSIGNMENT

A 159 HISTORY CLEAR A 166 PG PARTIAL DELETE A 167 A 168 A 169 A 172 A 173

SINGULAR POINT ALARM RANGE SET DIFF. OF WORK/AIR-CUT SPEED OPERATION CONDITION SETTING SYSCOUNT DISPLAY/SETTING MOVING AREA XYZ LIMIT

A 176 DATA BANK A 197 PASSWORD SET (Option) A 198

AUXILIARY FUNCTION SET (Option)

Registers the mass, the location of the center of gravity, and the inertia moment of the tool. Used to display program list. Used to display, modify and delete blocks for all repeat cycles of a program. Used to set a check of the registered home position data of each joint axis. Sets the general output function signal as effective or ineffective Used to clear the history for all stored operations and errors. Used to delete a program partially. Used to display and set the singular point alarm range function. Used to set program execution with differentiating work and air-cut speeds. Used to set operating conditions as effective/ ineffective. Used to display/set general and dedicated counter values. Used to set upper and lower limit of robot movement within XYZ area of world coordinates. Used for editing and managing of coating databank (list, copy, delete and environment settings). Used to set a password. Used to set the level for displaying level an auxiliary function. 9-5




A-2 LOCATION & SPEED DISPLAY The location & speed display provides a method to view positional information regarding the movement and location of the robot in the work envelope. The location & speed display function provides six different methods to view positional information. When the location and speed display is selected, function keys F1 to F6 are used to select the type of positional information to be displayed. Figure 9-2 shows the initial joint angle display when auxiliary function F2 is selected.

Figure 9-2 Location and Speed Display The information displayed in the location & speed display screens is continuously being updated and scrolls from the bottom of the screen. When the enter key is pressed the screen will stop scrolling. When the MENU SELECT key is pressed again the screen will resume scrolling. Pressing the exit key will change the display from the location & speed display back to the AUX function screen.

9-6




Table 9-2 provides information about the six different screens that are accessed from the location and speed display. Table 9-2 Location and Speed Display Function Key F1 JOINT ANGLE

Degrees

The tool tip speed The TCP position in the base coordinate system The current position of contained external axis The current position in base coordinate system The present commanded position for each joint The current position in the fixed work point The current position in the tool coordinate system The deviation between the commanded position The current commanded position in the orthogonalization coordinate system The current commanded position for motor

Degrees/Second

Degrees

The encoder count for each joint

Bits

MOTOR CUR.

The current position for motor

Degrees

ENCODER ORG.DATA

The original data of the encode

MOTOR SPD TCP XYZOAT YZOAT EXT.AXIS YZOAT BASE RELA. F3

JOINT COMMAND YZOAT FIXEDWORK YZOAT TOOL RELA.

F4

Unit

The present angle of each joint The speed of each joint in degrees per second The speed of the motor

JOINT

F2

Description

JOINT OFFSET XYZOAT COMMAND MOTOR CUR. COMMAND

F5 ENCODER

9-7

Degree/Second Second

mm/Degrees mm/Degrees mm/Degrees Degrees mm/Degrees mm/Degrees Degrees and the actual position mm/Degrees




A-3 DATA TRANSFER The DATA TRANSFER function allows the user to transfer program information from one program to a different program or a different location within the same program. Figure 9-3 shows the data transfer screen.

Figure 9-3 Data Transfer The use of the data transfer function is outlined in the following steps: 1. Press the F1 program input key to select a source program for information to be transferred from. A screen showing a list of available programs in the system memory will be displayed. Use the cursor keys to select the program containing the information to be transferred and press the enter key. 2. Use the numeric key pad to enter the first step to be transferred. 3. Use the numeric key pad to enter the number of steps to be transferred. 4. Press the F1 program input key to select the program for the selected steps to be transferred to. A screen showing a list of available programs in the system memory will be displayed. Use the cursor keys to select the program for the data to be transferred to and press the enter key. 5. Use the numeric key pad to enter the first step of the destination program for the transferred data to be inserted. If 0 is entered the data will be inserted after the last step of the destination program. If data is inserted into a program the existing steps will be renumbered.

9-8



A-5


KILL PROGRAM

The kill program function is used to remove the selected program from active status. The KILL PROGRAM function does not delete the program from system memory. Figure 9-4 shows the kill program screen.

Figure 9-4 Kill Program The F1 key is used to respond yes to the prompt, confirming that the program is to be killed. If the kill program selection was made in error, pressing the F2 key will return the display to the AUX function screen.

9-9




A-6 MIRROR CONVERSION (OPTION) The MIRROR CONVERSION function converts taught data into a mirror symmetry data against the robot’s YZ plane. Therefore it is possible to make symmetric data without actual operation of a robot, if the shape of the work is mirror- symmetric against the YZ plane.

YZ plane

← Displayed only for 7 axes robot.

Item

Description

PROGRAM NAME

Designate the program name (No.) for mirror conversion.

START STEP END STEP

Designate the first step for mirror conversion. Designate the last step for mirror conversion.

JT7 CONVERSION

Designate if sign of external axis (7th axis) is to be inverted.

CONVERSION METHOD FOR TRANS. JOINT

Designate the mirror conversion method for the point stored in transformation value. Joint: converts each joint once. Mirror symmetry viewing from the front face of robot regardless of base coordinate setting. Transformation: process as transformation values. Mirror symmetry based on coordinate setting.

9-10

Function Key

Numeric key Numeric key



YMMETRIC AXIS FOR TRANS


When transformation value is designated in CONVERSIONMETHOD FOR TRANS.JOINT, designates the base axis for mirror conversion. X axis: based on ＸＺ plain Ｙ axis: based on ＹＺ plain

[ NOTE ] Designation of step No. · When the end step is 0, only start step is processed. · When 0 is designated for start step, input error is returned. · When end step No. is larger than the last step of designated program, execute until the last step. [ Example of input ] Start step No. 0 0 1 3 End step No. 0 5 0 1 ↓ ↓ ↓ ↓ Input error Input error Step1 Execute only step 3

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A-9 DATA CONVERSION（Option） The DATA CONVERSION function converts data that was taught by off-line machine or CAD (ROSET) so that it can be used by on-line machines. In this function, base point data is required for fixing physical relationship between work and robot.

Item START TRANSFORMING REGISTER TOOL DIMENSIONS MEASURE TOOL AUTOMATICALLY GRAVITY COMPENSATION

Description 1. Displays the dimensions of off-line and on-line tools. 2. Sets 4 base points and tool No. 3. Displays distance and error among 4 base points. 4. Executes data conversion Registers tool dimensions for off-line machine. Measures tool dimensions automatically. 1. Compensates for gravity in the tool dimension measurement data imported from off-line machines. 2. Compensates for gravity in the 4 base points on the on-line machine. 3. Compensates for gravity in off-line data created by Cad (ROSET).

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A-10 MEMORY


PC CARD (SAVE)

This function is used to save information in the controller’s memory onto a PC card. The PC card must be inserted into the slot on the back of the multi function panel. Figure 9-5 shows the screen for selecting SAVE function.

Figure 9-5 Memory

PC Card (Save)

The memory → PC CARD (save) screen has six selections for storing different types of data. Use the numeric keypad to select the desired option, and press ENTER. Data (See table 9-3 for the different options for saving information on PC cards) is saved on the PC card is numbered files. Table 9-3 Memory to PC Save Option ALL DATA

Extension .AS

Includes all robot, system, auxiliary, program, variable, and program data.

PROGRAM

.PG

Saves program data only. System data and variables are not saved. If the saved program calls other programs (subroutines), the called program will also be saved.

AUXILIARY DATA

.AU

Includes auxiliary information such as accuracy, timer HOME positions and teach speed settings.

ALL DATA (SELECTED PROGRAM ONLY) ROBOT DATA

.AS

Saves all information including selected programs. This option saves variables, system data and auxiliary information. If subroutines are called they will not be saved unless individually identified.

.RB

Includes robot type, number of axes, and specific software settings.

ERROR

.EL

Saves up to the LOGGING last 1,000 entries from the error log, including the date and time of the entry.

Item

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A file number must be specified when storing data onto a PC card. The user will be prompted to enter a number for file identification, and the file extension is automatically added to the file name according to the file type selected. Attempting to save data using pre-existing file number will result in a backup file being automatically created, demoted by the file extension "b". Saving additional files of the same name will overwrite the backup file. Note that the settings to read data from the PC card to the PC itself vary depending upon the PC. Be sure to set the appropriate SRAM card-compatible driver according to the users manual attached with the PC. The SRAM cards listed below have confirmed compatibility with KHI specifications: 1 HITACHI MAXELL ML-1M-TB4N (1MB) ML-2M-TB4N (2MB) ML-4M-TB4N (4MB) 2 MITSUBISHI Electric MF31M1-J1DATXX (1MB) MF32M1-L6DATXX (2MB) 3 Logitech LPM-S2M (2MB) Card, which can use flash ATA specifications up to 32MB are also available.

9-14



A-11 PC CARD


MEMORY (LOAD)

This function is used to load information into the controller’s memory from a PC card. The PC card must be inserted into the drive slot in the back of the multi function panel. Figure 9-6 shows the screen when the load function is selected.

Figure 9-6 PC Card

Memory (Load)

The numeric keypad is used to select the option number for the type of information to be loaded from the PC card file into the controller memory. If option one is selected the display will prompt the user weather or not to include the robot data. After the response to loading robot data is entered the remainder of the data contained in the selected file will be loaded. If option two is selected, the user will be prompted whether or not each category of information in the PC card file should be loaded. If a program being loaded from the PC card has the same program name as a program in controller memory, the program in controller memory will be overwritten.

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A-12 FILE DIRECTORY This function allows the user to view the file names of all of the files contained on the PC card. The file extensions identify the type of file, see table 9-3 for an explanation of file extensions. Figure 9-7 shows an example of the file directory function.

Figure 9-7 File Directory

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A-14 PC CARD AUX. FUNCTION This function allows the user to delete files or format a PC card. Formatting the PC card will erase all data. When the option to format the PC card is selected the user will be prompted to confirm. Selecting the delete option will prompt the user to select the file(s) to be deleted. Once deleted, a file cannot be recovered. Figure 9-8 shows the PC card aux. Function. Note that flash ATA cards are usually pre-initialized, and cannot be initialized by the user.

Figure 9-8 PC Card Aux. Function

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A-40


AUTO TOOL SET（Option）

This function registers tool dimensions by automatic measurement of the tool in use by the robot without any user input, applies to a variety of tools: guns, hands, etc. See Chapter 11 “AUTO TOOL SET”.

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A-41 ZEROING Auxiliary function 41, zeroing, is used to set the value of the encoder count to a zero degree reference position. From this screen the user can select a single joint to be zeroed or select all joints to be zeroed. The zeroing information set from function 41 is entered in conjunction with information recorded in auxiliary function 140 to accomplish the zeroing of the mechanical unit. Figure 9-10 shows the display screen when function 41 is selected.

！

CAUTION

Users must be cognizant of the effect changes made in this function will have on the position of programmed locations. Changing this data without following the complete zeroing process may move programmed locations to positions that will cause damage to the robot, fixtures or work.

The process for simple zeroing is as follows: 1. Jog all axes to be zeroed so that the zeroing scribe marks are aligned. 2. Select auxiliary function 140, encoder count reset, and enter the joint number to be zeroed. If all joints are to be zeroed, 0 is entered for the joint number 3. Set the zero position value from the auxiliary function 41, zeroing screen, by entering the joint number to be zeroed. If all joints are to be zeroed, 0 is entered for the joint number. 4. Confirm the new zero position by operating the robot in the check mode on a previously taught program to verify playback accuracy of locations. For further information about the zeroing process, reference Kawasaki Robotics Inc. Electrical Maintenance and Troubleshooting Manual, unit 9, Zeroing.

Figure 9-10 Zeroing

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A-42 POS. ERROR RANGE AT E-STOP The pos. error range at e-stop function is used to set a comparison range to check the robots commanded position when an emergency stop was applied with the position when motor power is reapplied. If the difference between the robot’s position when motor power is reapplied and when the emergency stop was pressed is greater then the set value, a position offset error will be displayed. The position offsets error generated from this function cannot be reset and motor power can not be applied. The error range must be reset to a value that will not cause an error. The purpose of this function is to prevent interference with fixtures, jigs, or work pieces when the robot is restarted after an emergency stop condition. The acceptable range of data for the position error range at emergency stop is from 0.1 degree to 10.0 degrees for axes one to six and from 0.1mm to 100mm for a seventh axis. If 0 is entered the error check is not performed. The default setting for this function is 0. The pos. error range at e-stop function screen is shown in figure 9-11.

Figure 9-10 Zeroing

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A-43 ENCODER ERROR RANGE This function sets the range of encoder deviation that is allowed before an error is displayed upon applying power to the controller. The encoder value when control power is turned off is compared to the encoder value when control power is turned on. If the difference is larger than the range set, a JT encoder abnormality error is displayed. The range of acceptable data for this function is from 0.1 degree to 10.0 degrees for axes one to six and from 0.1mm to 100mm for a seventh axis. The default setting for the encoder error range function is 2.0 degrees. Operators should be aware that if this range is set too low, error messages may be displayed when the system is performing within design performance specifications. The display screen to set the values for the encoder error range function is shown in figure 9-12. The F1, PREV.DATA, key can be used to restore the settings if the enter key has not been pressed yet.

Figure 9-12 Encoder Error Range

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A-44 ZEROING DATA SET/DISPLAY The ZEROING DATA SET/DISPLAY function allows the user to set encoder counts and encoder offsets. Figure 9-13 shows the ZEROING DATA SET/DISPLAY. The first screen shows the current encoder reading and setting. Setting allows the user to specify a desired encoder count. The second screen shows the offset of the encoders.

！

CAUTION


Figure 9-13 Zeroing Data Set/Display

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A-46



The robot can at any time during teaching, be set perpendicular upwards in the direction of BASE +Z once the actual installation posture is made to match the posture set by the controller.

When setting installation posture, the direction of the robot base coordinates is shown below. The value for the base coordinates must have O, A, and T set to 0 (zero). To install a robot on an incline, select 4 as installation posture and enter the incline angle. Floor

Ceiling

Wall

Wall 2

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A-47 BASE COORDINATE This function allows the user to redefine the base reference frame by effectively shifting the base transformation values XYZ and OAT. When the machine is first initialized the transformation values of the base coordinate system are all set to a null or zero position. A null base has the transformation values 0,0,0,0,0,0. The BASE COORDINATE function can be used to change the base reference location. Programmers must be aware of the impact shifting the base coordinate origin will have on program playback. Shifting the base coordinate origin will result in the equivalent shift occurring for all transformation locations stored in the controller memory. However, locations recorded as precision points are played back based on the joint angles of the robot’s six axes and will not be affected by a base coordinate shift. The acceptable range for the base coordinate shift function is from -9999.9mm to 1000mm in the XYZ directions and from -180- to 180- for angles OAT. The BASE COORDINATE function screen is shown in figure 9-15.

Figure 9-15 Base Coordinate

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A-48 TOOL DIMENSIONS This function allows the user to record the unique tool orientations and dimensions. Up to nine separate tools can be defined via this function, the dimensions of each tool associated with the more tools unidentified in block step programs. Dimensions for XYZ tool coordinates are expressed in increments of 0.1mm, and in increments of 0.1 degrees for the OAT rotation axes. Nine separate screens are available for this function. The F2 and F3 keys are used to display the previous and next screens, respectively. The weight of the tool and the load it will be carrying can also be entered from the tool dimensions screens. The F1 key can be used to restore previous tool dimensions and weight information, provided the enter key has not yet been pressed to record the new data. Figure 9-16 shows the TOOL DIMENSIONS display screen for TOOL 1. [ NOTE ] 1. Setting for tools 1-9 extend for consecutive pages. Collecting the full nine pages worth will result in the data being grouped together into one lump sum. 2. Changing tool registration automatically, changes the value of AUX 149 TOOL REGISTRATION (Optional).

Figure 9-16 Tool Dimensions

！

CAUTION

For Motion type 2 (standard on Z series, optional for others) , be sure to register the correct mass and center of gravity. Registering the wrong value may decrease the life of, or cause overlord/deviation of component parts.

9-25




Example for setting tool dimensions If tool dimensions X, Y, Z, O, A and T are set to 0 (null tool), the tool coordinates are on the wrist flange surface as shown in figure below left. When installing the hand as shown in figure below right, tool dimensions are as followings; X Y Z O A T

= 0 mm = 100 mm = 200 mm = 0° = 0° = 0°

(X-axis direction is vertical to this plane.) Null tool

！

After setting tool dimension

CAUTION

For Motion type 2 (Option), be sure to register the correct mass and center of gravity. Registering the wrong value may decrease the life of, or cause overlord/deviation of component parts.

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A-51 SOFTWARE LIMIT This function allows the user to set the upper and lower limits of robot travel as expressed in degrees of axes rotation. The robot will not travel to locations that are outside of these limits. When operating the robot, an audio beep is transmitted to identify the approach of a software limit. The frequency of the audio beep will increase the closer the manipulator gets to the limit. When the limit is reached the robot will stop moving in that direction and the audio transmitted will be constant, no error message will be generated. The robot can be jogged away from software limits by simply changing its direction. If the robot is moved with the brake release to a location beyond the software limits or the software limits have changed, placing the robot outside the software limits, you can jog back into the software limits envelope. The SOFTWARE LIMIT display is shown in figure 9-17. The allowable maximum and minimum settings are displayed along with the current settings. Use the cursor keys and numeric keypad to change the settings. If data is entered that is beyond the allowable settings the display will not accept the change and identify that the data entered was out of range. The first screen displayed shows the upper limits, the lower limits are displayed by pressing the F3 key. The user must be aware that the minus sign for the lower limit settings is not assumed and, if desired, must be included when data for the lower limits is set.

Ö

Ö

Figure 9-17 Software Limit

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A-53 ACCURACY When converting “smooth level” instruction of former controller to “smooth range” instruction, use to convert “level (from 1 to 4)” to “accuracy range (mm)”.

(Set range: 0.0 to 5000.0) Figure 9-18 Accuracy In case that the waiting condition (timer, WS and so on) is taught and the waiting cancel condition is unsatisfied at the point B, it moves to the point B even if accuracy range may be set wider (for example setting 500mm) [ NOTE ] When accuracy range is set narrower, robot sometimes stops due to axis mismatch error. Be sure not setting accuracy range less than repeat accuracy. It sometimes indicates axis mismatch error depending on the robot or load condition, even if the repeat accuracy may be above the standard value, because this accuracy means error at Teach and Repeat.

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Set accuracy and trajectory 1. Case of motion type 1 For example, we think about the combination of the linear motion of A to B and B to C by CP ON. At the moment which entered within the range specified with ACCURACY (Reach D point), the current value overlaps the motion command value of the current path and the robot motion command value of the next path as shown in right figure. And, the robot moves continuously to the motion of the next path along this command value. (lower right figure)

B Command value

Accuracy

Actual trajectory (Trajectory shifts a little because of the delay time.

D

C

A

Movement of Command value

Velocity(v)

When the specification of ACCURACY is large, the robot starts overlapping the acceleration of the next path from early that much timing. (figure below)

Time (t) When the current value reaches D (B)

A

However, since the robot overlaps the acceleration of the next path at the time of when it begins to decelerate the current path, ACCURACY is saturated in a certain place. (v)

A

(B)

C

(t)

At this point, even if the current value comes within the range of ACCURACY, even only the same to deceleration beginning timing is early and robot can accelerate the next path.

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C




In the figure below, if the deceleration and the acceleration in the overlap of the path are smaller values, time which begins decelerating becomes early, and it becomes a circular arc trajectory of a larger radius. However, the attainment time from A to C almost becomes the same at the case on the previous page. v

A

(B)

C

t

Accuracy In the figure below, Even if only the deceleration of the current path is smaller, and the acceleration of the next path is larger, the compound speed in the overlapping part does not exceed each speed. (End time of deceleration is corresponding to end time of acceleration) v

A

(B)

C

t

2. Case of motion type 2 (option) In Motion type 2 (option), we have changed the concept of Accuracy and Speed in a linear motion and a circular motion in Motion type 1. You can use the program in the grammar without modifying a conventional program. However, be careful about the change of an actual motion trajectory and motion speed. We explain the changing point of Motion type 2 as follows. 1. Accuracy setting a) Accuracy in joint interpolation motion It shows the motion trajectory of the robot corresponding to the set accuracy in figure below. It is similar to Motion type 1. In figure below, the accuracy setting with B point is an example for 1mm, 100mm, and 200mm. It is not because of being the standard the motion trajectory in this case, and beginning just curve in the point which comes in the circle of the specified accuracy. By making the accuracy larger in Motion type 2; robot can go inside the distance of the remainder of the current path and the distance of the next path even half smaller. The cycle time does not change even if robot does the accuracy more than a certain value (distance which exceeds usual deceleration section and acceleration section) larger. The trajectory only changes 2. 9-30




Joint Interpolation

Maximum can be set the half of the next path. b) Accuracy in linear interpolation, circular interpolation motion It shows the motion trajectory of the robot corresponding to the set accuracy in figure below. In figure below, the accuracy setting with B point is an example for 1mm, 100mm, and 200mm. It begins to be curve in the point which enters in the circle of the specified accuracy. The trajectory in the circle of the accuracy becomes a circular trajectory. Robot can go inside the distance of the remainder of the current path and the distance of the next path even half smaller by making the accuracy larger. In this case, since the motion distance shortens by going inside, it can improve the cycle time. However, when the robot satisfies the following conditions, it becomes processing same as the accuracy in the joint interpolation motion. When the waiting condition (timer and WX, etc.) is taught to B point When the waiting instruction (TWAIT and SWAIT, etc.) is executed in B point When the work/tool is changed in B point For the connect with the joint interpolation When motion mode (usual motion and fixed work point motion) changes in the taught point b.

Linear Interpolation

Circular arc

Maximum can be set the half of the next path. CAUTION In figure below, robot moves like the solid line if you sets the accuracy very larger when A, B, C, and D is taught. However, shock might be generated in point E. In this case, you should be change setting the accuracy so that the circular arc should not collide with the circular arc. A B E C 9-31

D




2. Speed setting a) Accuracy in joint interpolation motion It is similar to Motion type 1. b) Accuracy in linear interpolation, circular interpolation motion In Motion type 2, to reach a specified speed by setting the accuracy larger, it plans the motion.

Specified speed

Motion type 2 Motion type 1 However, it becomes in the following cases as well as Motion type 1. When the waiting condition is taught in the taught point When the waiting instruction is executed in the taught point When the work/tool is changed in the taught point When motion mode (usual motion and fixed work point motion) changes in the taught point For the connect with the joint interpolation. CAUTION When a short pitch and posture change larger, the joint moving time is larger than the linear moving time. In this case, robot does not reach a specified speed to match at the joint moving time. Speed in circular interpolation In Motion type 1, there is no limitation at moving speed in the circular interpolation motion. In Motion type 2, robot has automatically decided the motion max. speed in the circular interpolation motion responding to the ability of the robot. For Motion type 2, the trajectory in the circle of the accuracy becomes a circular arc trajectory. This circular arc trajectory motion max. speed is decided as well as the speed in the above-mentioned circular interpolation.

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A-55 SLOW REPEAT MODE When function 55, slow repeat mode, is selected from the auxiliary function menu, the screen shown in figure 9-20 will be displayed. This function allows the user to set the slow repeat mode speed of the robot from 1 to 25% of maximum speed. A dedicated input signal must be assigned for the slow repeat mode function. When this signal is on, the SLOW REPEAT MODE of operation will be activated

Figure 9-20 Slow Repeat Mode

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A-56 CHECK SPEED Sets the speeds to be used in check mode. Pressing the speed key on the explosion proof teach pendant toggles through the three speed settings: Low, Medium and High (

H M L

,

H M L

and

Figure 9-21 Check Speed SPEED 1 corresponds to Low Speed SPEED 2 corresponds to Medium Speed SPEED 3 corresponds to High Speed

9-34

H M L

indicators).




A-57 TEACH SPEED Set the manual speeds and inching speeds to be used in teach mode. Pressing the speed key on the explosion proof teach pendant toggles through the three speed settings: Low, Medium and High (

H M L

,

H M L

and

H M L

indicators).

Figure 9-22 Teach Speed Setting range is: Manual speed

H M L

Low

H M L

H M L

Medium High (max. 250mm/s)

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To 1 decimal place (xxx.x)




A-70 MEMORY AVAILABLE This function is used to display the amount of memory available for programming. The available memory is displayed in both bytes and percentage of usable memory. Figure 9-24 shows the MEMORY AVAILABLE display.

Figure 9-24 Memory Available

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A-71 RECORD DATA (PRG CHG) INHIBIT The RECORD DATA (PRG CHG) INHIBIT function allows the user to prevent the recording of block step information by selecting inhibit for record. AS language programs cannot be edited if the RECORD DATA (PRG CHG) INHIBIT is set to INHIBIT. If an attempt to change data is made, an error message will be displayed. The error message instructs the programmer to set the respective switch to the ACCEPT status. The RECORD DATA (PRG CHG) INHIBIT display screen is shown in figure 9-25.

Figure 9-25 Record Data Inhibit

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Ａ-72 AUTOMATIC PATH GENERATION FUNCTION Using a source program, the “Automatic Path Generation” function duplicates a path at a given distance (path pitch) from a taught path and sets that path to be repeated the specified number of times (number of paths). The source program (“reference program”) is taught a minimum of three base points (1st endpoint, 2nd endpoint, and reference point).

* · 1st endpoint is the starting point for repeating the path. · 2nd endpoint is the end point for repeating the path. · Reference point is the point to determine in which direction to repeat the path between 1st and 2nd endpoint. · Reference program is the source program for automatic path generation including above-mentioned base points (endpoints and reference point). [Precautions before using automatic path generation function] (1) The automatic path generation function directly rewrites the position data of the program specified by “Program No.”. Therefore, a copy should be made of the reference program under a different program No. via “3. MANAGE PROGRAM /1. COPY”, before using the automatic path generation function. (2) “MOVE”, “SPEED”, “SPRAY” and “GUN SELECT” instructions are available for automatic path generation. (3) Although “MOVE / CIRCULAR” instructions may be used in the reference program for automatic path generation, in programming, this instruction must not be used at 1st or 2nd endpoints. If either instruction is used at the endpoints, error 2150 “MOVE / CIRCULAR cannot be used at an endpoint of painted block” will occur, disabling automatic path generation. (4) In reference program, maximum 15 base points can be taught. If more than 15 points are taught, error 2151 “Too many teaching points in painted block” will occur, disabling automatic path generation. (5) In reference program, maximum 8 instructions per base point can be taught. If more than 8 instructions are taught, error 2152 “Too many instructions per step in painted block” will occur, disabling automatic path generation. (6) In reference program, 3 or more base points must be taught. If only 1 or 2 base points are taught, error 2153 “Short in teaching points in painted block” will occur, disabling automatic path generation. 9-38




(7) If error 2101 “Shifted location of STEP n is out of range” occurs during conversion, the position data for path generation is at singularity. Therefore, the defective point (Step n) and its following points are not converted. To correct this error, re-execute operation after changing the base points, or modifying the point data automatically generated. (8) The generated path may not be expected if Joint or XYZ2 (angle of wrist axes maintained) mode is used in automatic path generation. In this case, use XYZ1 mode (gun posture maintained) to teach points in the reference program, before executing path generation. [ NOTE ] · When a program is composed using automatic path generation, the motion trajectory should be checked in TEACH mode before playing back. · When generating position data by this function, robot working range is not checked. · Even if the position data is expected to be within robot working range, be sure to check for interferences with work, etc. in TEACH mode before playing back.

This function can be also applied to the internal painting of box-shaped works or circular arc-shaped works as shown in the figure below. Use the automatic path generation function, referring to the following description and precautions.

ｚ

Work

Work

P9 P2

P8

P3

P11 Reference point P7 P4

2nd path (clockwise) 1st path (counterclockwise) P10 2nd endpoint P6 1st endpoint P1 P1 P5 1st endpoint

P2 P4

Reference point

P3 2nd endpoint

: Gun direction Internal painting of box-shaped work

Circular arc-shaped work

· Description of automatic path generation With the automatic path generation function, the following 4 path patterns can be generated; One way / Turn, One way / Repeat, Both ways / Turn, Both ways / Repeat

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1. One way / Turn To generate the sample path as shown below with “One way / Turn” function, reference program and generation conditions need to be set as follows; [Reference path before processing] 2nd endpoint P2 P1 1 endpoint st

P3 Reference point Spray ON period Air cut period Direction of gun

[Automatic path generation (Reference program No.1)] 1 Linear move (XYZ 1) P1 2 Spray_1 ON 3 Linear move (XYZ 1) P2 4 Spray_1 OFF 5 Linear move (XYZ 1) P3 [Conditions to be set for automatic path generation] Program No. 1 Path pitch 100mm Number of paths 5 Step No. (from) 1 Step No. (to) 5 Executing the “One way / Turn” function after setting these items automatically generates the path as shown in “Sample path to be taught” below.

As shown in this example, a program can be generated easily with the automatic path function using the 3 base points taught above. The final point (P3) specifies in which direction to repeat the path (in the direction of P2 → P3). When the automatic path generation function is used … [Sample path to be taught] P2 P1

100 P3 P6

P4 P5

P7

P8 P9

P10 Spray ON period Air cut period Direction of gun

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[Sample program for automatic path generation] 1 Linear move (XYZ 1) P1 2 Spray_1 ON 3 Linear move (XYZ 1) P2 4 Spray_1 OFF 5 Linear move (XYZ 1) P3 6 Spray_1 ON 7 Linear move (XYZ 1) P4 8 Spray_1 OFF 9 Linear move (XYZ 1) P5 10 Spray_1 ON 11 Linear move (XYZ 1) P6 12 Spray_1 OFF 13 Linear move (XYZ 1) P7 14 Spray_1 ON 15 Linear move (XYZ 1) P8 16 Spray_1 OFF 17 Linear move (XYZ 1) P9 18 Spray_1 ON 19 Linear move (XYZ 1) P10 20 Spray_1 OFF




Because the direction to repeat the path is determined by P2 and P3, P3 should be as far from P2 as possible to minimize error in the direction to reference point. 2. One way / Repeat To generate the sample path as shown below with “One way / Repeat” function, reference program and generation conditions need to be set as follows; [Reference path before processing] P2

P1 1st endpoint P4 2nd endpoint

P3

P5 Reference point

[Automatic path generation (Reference program No.2)] 1 Linear move (XYZ 1) P1 2 Spray_1 ON 3 Linear move (XYZ 1) P2 4 Spray_1 OFF 5 Linear move (XYZ 1) P3 6 Spray_1 ON 7 Linear move (XYZ 1) P4 8 Spray_1 OFF 9 Linear move (XYZ 1) P5 [Conditions to be set for automatic path generation] Program No. 2 Path pitch 160mm Number of paths 2 Step No. (from) 1 Step No. (to) 9

Spray ON period Air cut period Direction of gun

Executing the “One way / Repeat” function after setting these items automatically generates the path as shown in “Sample path to be taught” below. As shown in this example, a program can be generated easily with the automatic path function using the 5 base points taught above. The final point (P5) specifies in which direction to repeat the path (in the direction of P4 → P5).

When the automatic path generation function is used …

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[Sample path to be taught] P2 P1 160

P4

P3

P5

P6

P8

P7 Spray ON period Air cut period Direction of gun


[Sample program for automatic path generation] 1 Linear move (XYZ 1) P1 2 Spray_1 ON 3 Linear move (XYZ 1) P2 4 Spray_1 OFF 5 Linear move (XYZ 1) P3 6 Spray_1 ON 7 Linear move (XYZ 1) P4 8 Spray_1 OFF 9 Linear move (XYZ 1) P5 10 Spray_1 ON 11 Linear move (XYZ 1) P6 12 Spray_1 OFF 13 Linear move (XYZ 1) P7 14 Spray_1 ON 15 Linear move (XYZ 1) P8 16 Spray_1 OFF

The direction of gun at P1 and at the reference point taught as “P5” must be the same. Because the direction to repeat the path is determined by P4 and P5, P5 should be as far from P4 as possible to minimize error in the direction toward the base point.

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3. Both ways / Turn To generate the sample path as shown below with “Both ways / Turn” function, reference program and generation conditions need to be set as follows; [Reference path before processing]

P1 1 endpoint

2nd endpoint P2

st

[Automatic path generation (Reference program No.3)] 1 Linear move (XYZ 1) 2 Spray_1 ON 3 Linear move (XYZ 1) 4 Spray_1 OFF 5 Linear move (XYZ 1) 6 Linear move (XYZ 1)

P1 P2 P3 P4

[Conditions to be set for automatic path generation] P4 Starting point of returning path

P3 Reference point Spray ON period Air cut period Direction of gun

Program No. Path pitch Number of paths Step No. (from) Step No. (to)

3 100mm 4 1 6

Executing the “Both ways / Turn” function after setting these items automatically generates the path as shown in “Sample path to be taught” below.

As shown in this example, a program can be generated easily with the automatic path function using 4 base points taught above (3 points and the starting point of return path). The second to last point (P3) specifies in which direction to repeat the path (P2 → P3 for advance path, P3 → P2 for return path). The final point (P4) is the starting point of the return path. It is taught to be the same point as P9 in the diagram on the next page. A return path is created from the advance path by shifting the advance path the distance “L”, defined as the difference between P9 (return path start point) and P8 created by the automatic path generation function.


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[Sample path to be taught]

P1 P16 P4 P13 P5

Ｌ

P12 P8 P9 Spray ON period Air cut period Direction of gun Advance path Return path Advancing steps Returning steps


[Sample program for automatic path generation] 1 Linear move (XYZ 1) P1 2 Spray_1 ON P2 3 Linear move (XYZ 1) P2 4 Spray_1 OFF 100mm 5 Linear move (XYZ 1) P3 6 Spray_1 ON P3 7 Linear move (XYZ 1) P4 P14 8 Spray_1 OFF P6 9 Linear move (XYZ 1) P5 P11 10 Spray_1 ON P6 P 100mm 11 Linear move (XYZ 1) 12 Spray_1 OFF P10 13 Linear move (XYZ 1) P7 14 Spray_1 ON 15 Linear move (XYZ 1) P8 16 Spray_1 OFF 17 Linear move (XYZ 1) P9 18 Spray_1 ON 19 Linear move (XYZ 1) P10 20 Spray_1 OFF 21 Linear move (XYZ 1) P11 22 Spray_1 ON 23 Linear move (XYZ 1) P12 24 Spray_1 OFF 25 Linear move (XYZ 1) P13 26 Spray_1 ON 27 Linear move (XYZ 1) P14 28 Spray_1 OFF 29 Linear move (XYZ 1) P15 30 Spray_1 ON 31 Linear move (XYZ 1) P16 32 Spray_1 OFF

The direction of gun at P1 and at the reference point taught as “P3” must be the same. Because the direction to repeat the path is determined by P2 and P3, P3 should be as far from P2 as possible to minimize error in the direction toward the reference point.

9-44




4. Both ways / Repeat To generate the sample path as shown below with “Both ways / Repeat” function, reference program and generation conditions need to be set as follows; [Automatic path generation (Reference program No.4)]

[Reference path before processing] P2

P1 1st endpoint nd

2 endpoint P4

P3

P5 Reference point P6 Starting point of returning path

1 Linear move (XYZ 1) 2 Spray_1 ON 3 Linear move (XYZ 1) 4 Spray_1 OFF 5 Linear move (XYZ 1) 6 Spray_1 ON 7 Linear move (XYZ 1) 8 Spray_1 OFF 9 Linear move (XYZ 1) 10 Linear move (XYZ 1)

P1 P2 P3 P4 P5 P6

[Conditions to be set for automatic path generation] Program No. Path pitch Number of paths Step No. (from) Step No. (to)

Spray ON period Air cut period Direction of gun

4 160mm 2 1 10

Executing the “Both ways / Repeat” function after setting these items automatically generates the path as shown in “Sample path to be taught” below. As shown in this example, a program can be generated easily with the automatic path function using the 6 base points taught above (5 points and the starting point of return path). The second end point (P4) to last point (P5) specifies in which direction to repeat the path (P4 → P5 for advance path, P5 → P4 for return path). The final point (P6) is the starting point of the return path. It is taught to be the same point as P9 in the diagram on the next page. A return path is created from the advance path by shifting the advance path the distance “L”, defined as the difference between P9 (return path start point) and P8 created by the automatic path generation function.


9-45



[Sample path to be taught]

160 mm

Ｌ

P1

P2

P16 P4

P15 P3

P13 P5

P14 P6

P12 P8

P11 P7

P9

P10 Spray ON period Air cut period Direction of gun Advance path Return path Advancing steps Returning steps


[Sample program for automatic path generation] 1 Linear move (XYZ 1) P1 2 Spray_1 ON 3 Linear move (XYZ 1) P2 4 Spray_1 OFF 5 Linear move (XYZ 1) P3 6 Spray_1 ON 7 Linear move (XYZ 1) P4 8 Spray_1 OFF 9 Linear move (XYZ 1) P5 10 Spray_1 ON 11 Linear move (XYZ 1) P6 12 Spray_1 OFF 13 Linear move (XYZ 1) P7 14 Spray_1 ON 15 Linear move (XYZ 1) P8 16 Spray_1 OFF 17 Linear move (XYZ 1) P9 18 Spray_1 ON 19 Linear move (XYZ 1) P10 20 Spray_1 OFF 21 Linear move (XYZ 1) P11 22 Spray_1 ON 23 Linear move (XYZ 1) P12 24 Spray_1 OFF 25 Linear move (XYZ 1) P13 26 Spray_1 ON 27 Linear move (XYZ 1) P14 28 Spray_1 OFF 29 Linear move (XYZ 1) P15 30 Spray_1 ON 31 Linear move (XYZ 1) P16 32 Spray_1 OFF

The direction of gun at P1 and at the reference point taught as “P5” must be the same. Because the direction to repeat the path is determined by P4 and P5, P5 should be as far from P4 as possible to minimize error in the direction toward the reference point. In this example, the direction of gun at the starting point of the return path (P6) must be the same as that at 2nd endpoint (P4).

9-46




A-73 SPRAY ON/OFF This function sets the controller mode to a painting or sealing operation. The user has the option to select either on or off for this function depending on the type of application the robot is being used for. Figure 9-26 shows the display for function 73 SPRAY ON/OFF.

Figure 9-26 Spray On/Off

9-47



A-75


SYSTEM SWITCH

(This function corresponds to SWITCH instruction in AS language.) The SYSTEM SWITCH function allows system switches to be set On/Off thereby enabling changes in the basic specification of a system. This function differs depending on application or software version.

Ö

Ö…

Õ

Õ

Figure 9-27 System Switches To turn ON or OFF, select applicable system switch with cursor and set ON or OFF with F4 ON/OFF . Pressing “Explain” key on the screen, displays a description about the system switch currently selected (option). ON CHECK. HOLD OFF CP

ON OFF ON

CYCLE. STOP OFF ON OX. PREOUT OFF PREFETCH. SIGINS

ON OFF

QTOOL

ON

REP_ONCE

ON OFF

Enables command input with keyboard only in HOLD position. Enables command input with keyboard in RUN position. Enables continuous path (CP) motion control. Disables continuous path (CP) motion control. Enables cycle stop when inputting External HOLD signal. (Cycle start light will turn OFF) Disables cycle stop when inputting External HOLD signal. (Only HOLD) The timing to output OX signal taught in block step program will be after changing memory. The timing to output OX signal taught in block step program will be after conforming axes. Enables early processing of I/O signal in AS language. Disables early processing of I/O signal in AS language. Transforms a tool basing on a tool data registered automatically in advance, depending on tool number in auxiliary data of block step program. Sets the repeat cycle once. Sets the repeat cycle continuous. 9-48



RPS STP_ONCE

ON OFF ON OFF ON

AFTER.WAIT. TIMER OFF FLEXCOMP XDELTA

ON OFF ON OFF ON

MESSAGES

OFF OFF ON

SCREEN OFF ON AUTOSTART.PC OFF AUTOSTART2. PC AUTOSTART3. PC

ON OFF ON

ERRSTAR. PC OFF ON DISPIO_01 OFF HOLD. STEP (OPTION)

ON OFF


When executing JUMP/END or EXTCALL instructions in block step program, selects external program automatically and changes it to applicable program. Disables an external program selection. Steps once every step. Steps continuously. Timers in block teaching begin counting after axes coincide and all wait conditions such as WX, WAIT and RPS_ON are satisfied. Timers in block teaching begin counting after axes coincide. Enables real-time deflection correction. Disables real-time deflection correction. Enables teach point correction using the amount of correction detected by a sensor for door open/close. Disables teach point correction. Enables screen display by using PRINT and TYPE instructions. Disables screen display by using PRINT and TYPE instructions. Transforms a tool only when executing tool command and tool instruction in AS language or a block step program instruction. Stops a LIST command display at one of the screen display. Displays a LIST command screen continuously without stopping. Enables automatic PC program operation when control power is turned ON. Disables automatic PC program operation when control power is turned ON. Enables automatic PC2 (3) operation when control power is turned ON. Disables automatic PC2 (3) operation when control power is turned ON. Enables automatic program operation when an error is occurred. Disables automatic program operation when an error is occurred. For I/O status display commands, uses “1” / “0” to indicate ON / OFF respectively. For I/O status display commands, uses “x”/“o” to indicate ON / OFF. Upper/lower case letter indicates general purpose and dedicated signals, respectively. Displays a step under operation. Displays a step under operation.

9-49




ON Moves to 1st teach point at low speed. OFF Moves to 1st teach point at teach speed. Teach speed is not affected by monitor speed as long as ON not exceeding a speed that is multiplied maximum speed ABS. SPEED by monitor speed. Moves at a speed that is multiplied teach speed by OFF monitor speed. Enables operation monitoring of an integrated sequencer ON PLC. CHECK board. (OPTION) Disables operation monitoring of an integrated OFF sequencer board. FLOWRATE ON Sets flow rate control mode. (OPTION) OFF Sets speed output mode. Uses in case that a paint circulating circuit is installed at EBMATCIRC ON pump 1 (2) when controlling flow rate. EB2MATCIRC Uses in case that a paint circulating circuit is not (OPTION) OFF installed. Stops motion when mismatching a shaped flag during ON linear or circular motion. SPR_CONFIG Moves in a shape of just former motion without OFF stopping, when mismatching a shaped flag during linear or circular motion. Enables an external output, a painting equipment output ON and a spray instruction. INS_SIGOUT Disables an external output, a painting equipment output OFF and a spray instruction. ON Enables input wait and mutual wait instructions. INS_SIGWAIT OFF Disables input wait and mutual wait instructions. ON Enables conveyor wait instructions. INS_CVWAIT OFF Disables conveyor wait instructions. Enable wait instructions. ON Enables ON / OFF of spray instruction in batches. INS_DELAY Disable wait instructions. OFF Disables ON / OFF of spray instruction in batches. DOOR_SENSE ON Enables a door detect motion instruction. (OPTION) OFF Disables a door detect motion instruction. Uses the name of “pattern air” for a spray-related output ON signal. SIGNAME_PTN Uses the name of “shaping air” for a spray-related OFF output signal. Uses the name of “atomize air” for a spray-related ON output signal. SIGNAME_ATOM Uses the name of “air motor” for a spray-related output OFF signal. * Whether there is a name of system switch or not and an initial data setting value depend on specifications. See Appendix-5 Initial data settings. SLOW_START

9-50




A-76 HOME POSITION The HOME POSITION function allows the user to set two home positions for the robot. These home positions can be set to any locations within the work envelope. Home locations have two unique characteristics from other locations. A dedicated output signal can be assigned to each of the home positions so that whenever the robot is in that position the signal will be generated. Home positions are also recognized in AS language commands in a unique way, the only code needed to send the robot to the home position is the statement HOME. When this instruction is encountered the robot will perform a joint move to the home position. A second home position is identified by the designation HOME2 and is set from the second screen of function 76. Figure 9-30 shows the screen to set home position 1. From this screen the user can choose to enter the desired home position as expressed in joint angles or the current position of the robot. To enter a HOME position other than the current position, use the cursor keys to highlight KEY-IN and move to the desired joint number. Enter the desired number of degrees for each joint and press ENTER when completed. The range for the home position is also set from this screen. When the robot reaches a point within the specified range, the output signal is generated. It is recommended that the range for the home position be set to between 5mm and 10mm to ensure the home position output is generated.

Figure 9-30 Home Position

9-51




A-77 WORK SPACE OUTPUT（OPTION） When the TCP is within the space defined by the WORKSPACE OUTPUT function, the assigned signal will be on. Figure A-10 shows the display to set the UPPER and LOWER X, Y, and Z dimensions. Figure A-11 shows an example of how the dimensions are determined. Jog the robot to the Upper and LOWER locations and record the X, Y, and Z positional information for input into AUX 77. Whenever the TCP is within the three-dimensional space defined by the WORK SPACE OUTPUT function an output signal will be on.

Figure A-10 Work Space Output

Figure A-11 Work Space Output Dimensions [ NOTE ] 1. The workspace output area setting covers from 1 to 9 pages, see screen above, WORK SPACE 1. The data settings on each page are recorded in blocks. 2. The Output Signal number is an indicator only and cannot be set at this screen. For settings, refer to Aux 111-Dedicated Input/Output Signals. If an output signal is not assigned, NOT USED will be indicated on the screen. 3. Though there are multiple external axes, workspace output settings can only be made for the robot’s 6th axis tool point. 9-52




A-78 CLEAR CHECK SUM ERROR The CLEAR CHECK SUM ERROR function allows the user to clear error 1019, abnormal check sum. An abnormal check sum error is generated when the processor calculates a difference between data when the controller is powered up compared to an expected value. When this error occurs the programmer can select function 78, the first screen shown in figure 9-31 will be displayed, and change the setting to EFFECT. When control power is cycled, the error may be cleared and the setting returned to INEFFECT. If the clear check sum error does not clear with the cycling of control power, the second screen shown in figure 9-30 will be displayed identifying additional troubleshooting paths.

When EFFECT is selected, error (-1019) can be reset.

Figure 9-31 Clear Check Sum Error

When executing this function, error cannot be cleared if there is a data that sum check error remains. In such case, instruction to reset data that include sum check error is displayed.

CANNOT CLEAR SUM CHECK ERROR. CHECK THE FOLLOWING COMMAND OR AUXILIARY DATA. ZZERO DEFSIG : :

[ NOTE ] Setting of EFFECT/INEFFECT of clear error changes to EFFECT by turning the control power from OFF to ON.

9-53




A-80 XYZ SHIFT(OPTION) The XYZ SHIFT function is used in conjunction with block step programs and shifts programmed locations in the base coordinate system. The display screen used to set the shift information is shown in figure A-12.

Figure A-12

XYZ Shift

Enter the name of the program that contains the points that are to be shifted by pressing the F1 PROGRAM INPUT key. The screen that is displayed next is the program select screen; select the program name that contains the locations to be shifted. The start step is the first step to be shifted in the program. If a 0 is entered for the start step information, the first step to be shifted will be step 1. The end step is the last step to be shifted in the program. If a 0 is entered for the end step information, only the start step will be shifted. The distance and direction of shifting in the base coordinate system is entered in the X, Y, Z section of the screen. The value of the shift in each coordinate direction is entered in mm. In the teach mode of operation the shift value can be as much as ±500mm, in the repeat mode of operation the maximum shift is ±10mm.

9-54




A-81 JOINT SHIFT（OPTION） The JOINT shift function is used in conjunction with block step programs and shifts programmed locations based on joint angle information. The display screen used to set the information is shown in figure A-13.

Figure A-13 Joint Shift Enter the program name that contains the points that are to be shifted by pressing the F1 PROGRAM INPUT key. The screen that is displayed next is the program select screen. Select the program name that contains the locations to be shifted. The start step is the first step to be shifted in the program. The end step is the last step to be shifted in the program. If a 0 is entered for the end step information, only the start step will be shifted. The angular distance and joint to be shifted is entered in the JT1 to JT6 section of the screen. The value of the shift in each joint is entered in degrees. In the teach mode of operation the shift value can be as much as ±10°, in the repeat mode of operation the maximum shift is ±1°.

9-55



A-82


TOOL SHIFT（OPTION）

The tool shift function is used in conjunction with block step programs and shifts programmed locations in the tool coordinate system. The display screen used to set the tool shift information is shown in figure A-14.

Figure A-14 Tool Shift Enter the program name that contains the points that are to be shifted by pressing the F1 PROGRAM INPUT key. The screen that is displayed next is the program select screen. Select the program name that contains the locations to be shifted. The start step is the first step to be shifted in the program. If a 0 is entered for the start step information, the first step to be shifted will be step 1. The end step is the last step to be shifted in the program. If a 0 is entered for the end step information, only the start step will be shifted. The distance and direction of shifting in the tool coordinate system is entered in the X, Y and Z section of the screen. The value of the shift in each tool coordinate direction is entered in mm. In the teach mode of operation the shift value can be as much as ±500mm, in the repeat mode of operation the maximum shift is ±10mm.

9-56



A-83


WORK SHIFT（OPTION）

The work shift function is used in conjunction with block step programs and shifts programmed locations in the coordinate system defined as work. The display screen used to set the information is shown in figure A-15

Figure A-15 Work Shift Enter the name of the program that contains the points that are to be shifted by pressing the F1 PROGRAM INPUT key. The screen that is displayed next is the program select screen. Select the program name that contains the locations to be shifted. The START STOP is the first step to be shifted in the program. If a 0 is entered for the start step information, the first step to be shifted will be step 1. The END STOP is the last step to be shifted in the program. If a 0 is entered for the end step information, only the start step will be shifted. The distance and direction of shifting in the work coordinate system is entered in the X, Y and Z section of the screen. The value of the shift in each work coordinate direction is entered in mm. In the teach mode of operation the shift value can be as much as ±500mm, in the REPEAT mode of operation the maximum shift is ±10mm.

9-57



A-87


PROGRAM ARGUMENT/COMMENT

You can put the comment on the taught program. Make setting PROGRAM COMMENT of Aux 96 ENVIRONMENT DATA OF PANEL ON when you use this function.

Ø Select the program on which you input the comment with the RETURN key.

key, and press

Ø

(For example, when you select pg3.)

As shown in the above figure, Program name ( ) is displayed, and input the comment following the character of ";" For example, it is input as "work no 3".

Ø 9-58




Ø ;

w

o

r

k

space

n

o

space

3

Ø pg3;work no 3

Ø Ø

Figure A-16 Program Argument/Comment It is displayed as shown in the figure above, and it completes the input of the comment. The input comment is displayed with program name in PROGRAM SELECT screen. Moreover, if you input the variable name to ( ), you can input the argument used by the subroutine call with the argument of the AS language.

9-59




A-90 SOFTWARE VERSION DISPLAY This function allows the user to view the software version operating in the controller and multi function panel. The screen that is displayed when function 90 is selected is shown in figure 9-32.

Figure 9-32 Software Version Display

[ NOTE ] 1. Displays the robot arm controlled by AS software. In the event the indicated arm does not coincide with the actual arm, do not operate while the motor power is ON, and contact Kawasaki immediately. 2. Display built-in system data.

9-60




A-91 ENVIRONMENT DATA The ENVIRONMENT DATA function is used to set an auto servo timer and identify if the controller is operating with a teach pendant or multi function panel installed. The AUTO SERVO OFF TIMER sets a time period that motor power will remain ON if no movement of the robot has occurred. The auto servo timer function is designed to save energy by allowing the brakes to maintain robot position as opposed to using electrical power and servo motors. When the robot has not moved and the auto servo timer has reached its set value, the brakes will be applied and power will be removed from the servo motors. The motor power light will remain ON and the robot will begin motion under the same conditions it would have if the auto servo timer had not removed power from the motors. The ENVIRONMENT DATA function also allows the user to identify weather or not a teach pendant is installed. The dead man buttons and the emergency stop button are hard-wired and a jumper (or a different user interface) must be installed if the teach pendant is removed. Figure 9-33 shows the screen that is displayed when auxiliary function 91 is selected.

Figure 9-33 Environment Data Procedure by which sets TEACH PENDANT in DISCONN. (1) Place TEACH/REPEAT switch of the operation panel in the REPEAT position. (2) Set TEACH PENDANT in DISCONN. (3) Turn OFF the CONTROL POWER. (4) Pull out the connector of Multi Function Panel or Small Teach Pendant. (5) Insert the short-circuit plug. (6) Turn ON the CONTROL POWER. [ NOTE ] Place TEACH/REPEAT switch in the REPEAT position without fail before you sets it in Disconnect. It automatically returns to setting CONNECT in Teach mode when Multi Function Panel or Small Teach Pendant is connected.

9-61




A-95 ENVIRONMENT DATA 2 The ENVIRONMENT DATA2 function allows the user to identify if a multi function panel or terminal is installed. The deadman buttons and the emergency stop buttons of the multi function panel are hard-wired and a jumper (or a different user interface) must be installed if the multi function panel is removed. Figure 9-34 shows the ENVIRONMENT DATA 2 screen.

Figure 9-34 Environment Data 2

9-62




A-96 ENVIRONMENT DATA OF PANEL The AS INSTR.POS. TEACHING, AS INSTRUCTION TEACHING, KEYBOARD, and PROGRAM EDIT menu items from this function affect the menus available from the teaching screens of the multi function panel. If ON is selected for these items, they will be available when the teaching key is pressed. If OFF is selected, pressing the teaching key will not display the associated function and screen. Figure 9-35 shows the ENVIRONMENT DATA OF PANEL screen.

(OPTION) (OPTION)

(OPTION)

Figure 9-35 Environment Data of Panel

9-63




A-99 CHECK SPEC. (CHECK SPECIFICATION) The CHECK SPEC. function is used to select whether certain AS language instructions are performed when programs are run in the check step mode. The following commands can be set as effect (on) or INEFFECT (off) during the check step process: CALL, TIMER, JUMP/END, OX, WX, and CLAMP. If ineffective is selected for any of these commands, when a program is executed using the check mode process the command will not be processed as a program instruction and will be bypassed. When the check step process is conducted in reverse program order, only the CLAMP and OX instructions are dependent on the settings of auxiliary function 91. The AS language instructions CALL, TIMER, JUMP/END, and WX will not be processed when reverse order check stepping. Figure 9-36 shows the auxiliary function 99, check spec. screen.

Figure 9-36 Check Spec. Screen

9-64



A-100


SYSTEM INIT. (SYSTEM INITIALIZATION)

The SYSTEM INIT. function is used to clear everything from the system memory and reset all default settings. When the system is initialized all programs, variable data, system switches, and system settings are deleted or returned to default settings. The only information not affected by the initialization process is the error and operations logs.

！

CAUTION

Initializing the system will erase all program and variable data and reset system data to default settings. If a PC is connected to the controller and the initialization function is selected, care must be taken not to initialize the hard drive of the PC.

Figure 9-37 shows the screen that appears when function 100, system INIT. is selected. ENTER is selected to activate initialization of the system from this screen. If the system is not to be initialized, exit is selected returning the screen to the first auxiliary function screen.

Figure 9-37 System Initialization

9-65



A-101


BATTERY ERROR CHECK

If EFFECT is selected from this function, when control power is applied, the batteries that maintain RAM memory are checked for low voltage. If a low voltage is detected an error message is displayed. If INEFFECT is selected from this function the batteries will not be checked when control power is applied. Figure 9-38 shows the screen for the battery error check.

Figure 9-38 Battery Error Check

9-66



A-103



If the touch panel is pressed when the CONTROL POWER is ON or changes the TEACH/ REPEAT, the error is displayed. The error is displayed in case of Error (-1029) Touch Panel is Short-Circuited. When Aux. 103 TOUCH PANEL SHORT CIRCUIT CHECK is only EFFECT, it checks this function.

Figure 9-39 Touch Panel Short Circuit Check

9-67



A-110


TIME

The TIME function is used to set the current year, month, day and time. The controller will automatically display the day of the week based on the date information. The cursor keys are used to select the data field to be modified. Error and operations logs are date and time stamped based on the information from this function. Figure 9-40 shows the TIME function screen.

Figure 9-40 Time

9-68



A-111


DEDICATED INPUT SIGNAL

(This function corresponds to DEFSIG INPUT command in AS language.) Sets input signals from among the definable dedicated signals. For information on the functions of each dedicated signal, see separate volume, External I/O Manual.

Ö

Ö

Õ

Õ

Figure 9-41 Dedicated Input Signal Move cursor to a definable dedicated signal and select “SET” or “RESET” to set an input signal function. When selecting “SET”, assign a signal number (channel number) to the dedicated signal using numeric key. Dedicated Input Signals External motor ON External phototube signal External error reset Conveyor position set External cycle start I/F panel page 1 select External program reset I/F panel page 2 select External program select (JUMP) Door detect signal JUMP_ON Suspend playback JUMP_OFF Interrupt start from 1 to 3 JUMP_ST External start enable External program select (RPS) Operation condition valid RPS_ON External RPS enabled RPS_ST External repeat mode Number of RPS code signals External PC program start First signal No. of RPS code External PC program abort Code (0:Binary, 1:BCD) External motor OFF EXIT_IT Multi start delay reset External slow repeat mode External spray OFF [ NOTE ] The definable dedicated signals differ depending on application or software version.

9-69




A-112 DEDICATED OUTPUT SIGNAL (This function corresponds to DEFSIG OUTPUT command in AS language) Sets output signal from among the definable dedicated signals. For information on the function of each dedicated signal, see separate volume, External I/O of Explosion-proof Type Controller Manual.

Ö

Ö

Ö

Õ

Õ

Õ

Figure 9-42 Dedicated Output Signal Move cursor to a definable dedicated signal and select “SET” or “RESET” to set an input signal function. When selecting “SET”, assign a signal number (channel number) to the dedicated signal using numeric key. Dedicated Output Signals Motor ON RPS_OK Error Program No. Automatic Delayed limit switch signal Panel switch in RUN Delayed phototube switch signal EXT_IT not set to hold Mechanical warning Panel switch in repeat In conveyor simulation mode Repeat continuous Flow rate Step continuous Shaping / pattern air Teach lock OFF Air motor / atomizing air Cycle start ON High voltage RGSO ON Flushing Dry run mode OFF Push thinner Cycle start Under waiting Teach mode External start enable mode Home1 Conveyor normal Home2 External PC program executing Power ON In emergency stop RGSO In dry run mode External program select (RPS) enabled Program auto-selected Work space from 1 to 9 Entry of delay-queue Out_spray_OK Hold mode * Items from “Work space 1 to 9” are displayed only when the Option is enabled. [ NOTE ] The definable dedicated signals differ depending on application or software version. 9-70




A-113 DEDICATED SIGNAL DISPLAY Displays currently set user- defined dedicated signal (both of dedicated input and output signals). For each setting, see A-111 and A-112.

×

Ø

×

Ø

Figure 9-43 Dedicated Signal Display

9-71



Dedicated input signals External motor ON External error reset External cycle start External program reset External program select (JUMP) JUMP_ON JUMP_OFF JUMP_ST External program select (RPS) RPS_ON RPS_ST Number of RPS code signals First signal No. of RPS code EXIT_IT EXIT_WAIT External phototube signal External spray OFF Door detect signal Suspend playback Interrupt start from 1 to 3 External start enable Operation condition valid External RPS enabled External repeat mode External PC program start External PC program abort External motor OFF Multi start delay reset


Dedicated output signals Motor ON Error Automatic Panel switch in RUN EXT_IT not set to hold Panel switch in repeat Repeat continuous Step continuous Teach lock OFF Cycle start ON RGSO ON Dry run mode OFF Cycle start Teach mode Home1 Home2 Power ON RGSO External program select (RPS) enabled Work space from 1 to 9 Out_spray_OK RPS_OK Program No. Delayed limit switch signal Delayed phototube switch signal Mechanical warning In conveyor simulation mode Flow rate Shaping / pattern air Air motor / atomizing air High voltage Flushing Push thinner Under waiting External start enable mode Conveyor normal External PC program executing In emergency stop In dry run mode Program auto-selected Entry of delay-queue Hold mode

[ NOTE ] The definable dedicated signals differ depending on application or software version.

9-72




A-114 GUN SPECIFICATIONS Sets the specifications of the gun signals used for handling, sealing and painting operations.

Using cursor or entering the function number with number keys can select each setting screen. 1 Gun application 2 Gun condition

Sets the application type for the gun signal. Sets the data corresponding to the CC No. of teaching data. 20 Handling clamp definition Sets data relating to the clamp (open/close hands) signal in handling applications. 30 Painting/sealing gun Sets data relating to the gun signal in painting/sealing definition applications. 32 Gun relative distance check Sets approach distance limit and relative position of the function partner robot for gun distance check.

9-73




A-114-1 GUN APPLICATION Sets an application type for each of the gun signals from gun 1 to gun 4.

Select a gun with

and

keys, set 0, 2 or 3 for each gun, and press Return key. [ Note ]

1. For gun numbers set to 3: Sealing, the data specified in 114-2 Gun condition and 114-30 Painting/Sealing gun data will become effective. 2. For gun numbers set to 2: Handling, the data specified in 114-20 Handling clamp data will become effective.

0: Not used 2: Handling 3: Sealing

The gun signal is not used. The gun signal is used as a clamp signal for handling. The gun signal is used as a gun signal for painting/sealing.

9-74




A-114-20 HANDLING CLAMP DEFINITION Sets the output signal number of gun numbers which is identified as handling clamp from gun 1 to gun 4 in “114-1 Gun application”

[ Note ]

· For gun signal output in TEACH and CHECK mode, use SPRAY 1/2 key. · GS (Gun spray timing control) function is enabled.

9-75




A-114-30 PAINTING/SEALING GUN DEFINITION Sets the output signal number for the guns (gun 1 – 4) set to 3: painting/sealing in 114-1 Gun application.

[ Note ]

· The gun signals are output in teach and check (motion) mode using Spray 1/2 key. · GS (Gun ON/OFF timing control) function is effective.

9-76




A-114-32 GUN RELATIVE DISTANCE CHECK FUNCTION (OPTION) Sets approach distance limit and relative position of the partner robot for gun distance check.

Relative position of the partner robot

Item Gun distance check Lower limit distance

Description Sets effective or ineffective. Initially set to ineffective. Sets approach distance limit. Initially set to 450.0mm. Sets shifting distance in X-axis direction of the X direction partner robot’s coordinates based on its own coordinates. Sets shifting distance in Y-axis direction of the Y direction partner robot’s coordinates based on its own coordinates. Sets shifting distance in Z-axis direction of the partner Z direction robot’s coordinates based on its own coordinates. Sets rotation angle around the Z-axis of the partner O Rotation robot’s coordinates based on its own coordinates. Sets rotation angle around the Y-axis after the above A Rotation rotation of the partner robot’s coordinates based on its own coordinates. Sets rotation angle around the Z-axis after the above T Rotation rotation of the partner robot’s coordinates based on its own coordinates.

Setting

0 to 9999.9mm -9999.9 to 10000.0mm -9999.9 to 10000.0mm -9999.9 to 10000.0mm -180.0 to 180.0° -90.0 to 90.0° -180.0 to 180.0°

When the robots get too close during teaching, an alarm sound will be made in three levels according to the distance. The alarm sounds in the same way as when checking the joint motion range. When the robots get too close during repeat and check, an error appears; -2128 Relative distances between guns is too near. In this case, move the robots by manual operation to make the distance larger. 9-77




A-120 ERROR LOGGING The ERROR LOGGING function allows the user to view a history of the errors that have occurred on an individual controller. Up to 1,000 errors will be recorded by this function. The errors are listed in chronological order with the most recent entry first. The date, time, error number, and a description of the error are all listed. Error messages cannot be deleted or edited and remain in memory even after the controller has been initialized. Figure 9-54 shows an example of the error logging function screen. Pressing the F3 key moves the display to the next group of errors in the log.

Figure 9-54 Error Logging

9-78




A-122 OPERATION LOGGING The OPERATION LOGGING function allows the user to view a history of the operations that have occurred on an individual controller. Up to 40 previously performed operations will be recorded by this function. The operations are listed in chronological order with the most recent entry first. The operation logging function also displays the user interface the operation was performed on, date, time, and a description of the operation performed. Operation log entries cannot be deleted or edited and remain in memory even after the controller has been initialized. Figure 9-55 shows an example of the operations logging function screen. Pressing the F3 key moves the display to the next group of operations in the log.

Figure 9-55 Operation Logging

9-79




A-124 MOTOR TORQUE INFORMATION (OPTION) This screen can provide information on the motors of all axes (JT1-JT6) such as warning logs and peak current values.

Figure A-19 Motor Torque Information A-124-1 WARNING LOG A display of all past warnings.

Figure A-20 Warning Log A-124-2 PEAK CURRENT Display the program name, step number, current value and percentage to mechanical current limit or motor current limit.

9-80




A-127 OPERATING INFORMATION (OPTION) The following operational data can be accessed: Total hours, controller power ON Total hours, servo ON Number of times for MC operation Number of times for servo ON Number of Emergency-stops during robot operation Total hours of robot operation Total displacement traveled by the robot

×

Ø

×

Ø

9-81




A-130 PC PROGRAM RUN / STOP（OPTION） While executing the robot motion program, a program which does not contain robot motion instructions (PC program) can be executed in parallel. Auxiliary function 130 allows control of this program.

Figure A-23 PC Program RUN/STOP Item START (PCEXECUTE) ABORT (PCABORT) STOP (PCEND) CONTINUE (PCCONTINUE) KILL (PCKILL)

Explanation AS language Execute the designated PC program. The program PCEXECUTE number and starting step can be selected. command PCABORT Interrupts the currently executing PC program. command Stops the execution of the currently executing PC PCEND program following a STOP instruction, or when the command final step of the program has been executed. Continue running the PC program that is currently PCCONTINUE interrupted by PCABORT or PCEND. command PCKILL Cancels the currently selected PC program. command

9-82




A-130-1 START (PCEXECUTE) Execute the designated PC program. The program number and starting step can be selected.

Figure A-24 START(PCEXECUTE)

A-130-2 ABORT (PCABOR) Interrupts the currently executing PC program.

Figure A-25 ABORT (PCABORT)

9-83




A-130-3 STOP (PCEND) Stops the execution of the currently executing PC program following a STOP instruction, or when the final step of the program has been executed.

Figure A-26 STOP (PCEND)

A-130-4 CONTINUE (PCCONTINUE) Continue running the PC program that is currently interrupted by PCABORT or PCEND.

Figure A-27 CONTINUE (PCCONTINUE)

9-84



A-130-5


KILL (PCKILL)

Cancels the currently selected PC program.

Figure A-28 KILL (PCKILL)

A-130-6 STATUS (PCSTATUS) Displays status information for the executing PC program.

Figure A-29 STATUS (PCSTATUS)

9-85




A-131 INTERFACE PANEL (OPTION) The switch and lamp for the interface panel can be set on the display of Multi-Function Panel. You can arrange the type of the switch and lamp and displaying position freely within the range which can be set.

Figure A-30 Interface Panel Specification of switch and lamp 1 Push-button switch 2 Push-button switch with lamp 3 2-notch switch 4 3-notch switch 5 Lump 6 Digital Switch 7 Digital display device 8 Text window. Select the item with a Cursor key and spec. code is input. And then, details such as 7 kinds of switch and lamps can be set by pressing the key.

9-86




A-133 AS INSTRUCTION DEFINITION (OPTION) AS INSTRUCTION TEACHING can define the program instruction, the variable name, and the comment, etc. used with Screen up to 32 kinds or less.

Figure A-31 AS Instruction Definition After pressing NEXT.PAGE (F3) key, the character string can define character string 17-32 (maximum). Only the defined character string is displayed in the key displaying part of AS INSTRUCTION TEACHING screen. After you presses CHARACTER (F4) key, you can input the character string with Keyboard screen. [ NOTE ] 1. You can define the character string up to eight digits or less. 2. You can define the character string only at the time set in RECORD ACCEPT by Auxiliary 71 RECORD(PRG CHG)INHIBIT.

9-87




A-140 ENCODER ROT. COUNTER RESET The ENCODER ROT. (rotation) COUNTER RESET function is used in conjunction with auxiliary function 41 ZEROING and auxiliary function 44 ZEROING DATA SET DISPLAY, as part of the zeroing process. When maintenance has been performed that moves the robot from the position that the encoders identify or a servo motor has been changed, zeroing is required.

！

CAUTION


Auxiliary function 140 provides the user with the option of selecting a single joint or all joints to reset encoder rotation count. If a single joint is selected, a set degree angle for that axis may also be entered. When the data for this function has been entered, the encoder rotation count(s) are calibrated by the 1GA board to provide accurate robot motion. Figure 9-56 shows the ENCODER ROT. COUNTER RESET screen.

Figure 9-56 Encoder Rot. Counter Reset

9-88




A-142 PROGRAM QUEUE（OPTION） The PROGRAM QUEUE is a memory function that stores program numbers for playback in a specified order. This is useful when there are several kinds of works during the process of program number entries and robot operations. By storing the robot’s repeat patterns in PROGRAM QUEUE, this function saves the user the trouble of inputting program numbers each time before playback when the works (and the patterns of works carried in by conveyor) are known in advance.

Display each setting screen by using cursor or by selecting function No.. [ NOTE ] 1. 100 programs can be registered in PROGRAM QUEUE. 2. Unfinished programs can be registered with numbers in PROGRAM QUEUE. 3. The same program No. can be registered a number of times. 4. The program queue address numbers are played back in numerical order.

1 DISPLAY 2 REGIST 3 INSERT 4 DELETE 4 ALL DELETE 6 ENVIRONMENT SET

Displays PROGRAM QUEUE. Programs cannot be registered. Registers program in PROGRAM QUEUE. Inserts program into PROGRAM QUEUE. Deletes designated program from PROGRAM QUEUE. Deletes all the programs stored in PROGRAM QUEUE. Sets up the environment of PROGRAM QUEUE.

9-89




A-142-1 DISPLAY This function allows the user to view the contents that are registered in PROGRAM QUEUE. Registration to PROGRAM QUEUE is not possible.

×

Ø

×

Ø

Latest data is displayed by pressing the RENEW (F4) key.

9-90




A-142-2 REGISTER This function is used to register program No. to PROGRAM QUEUE.

×

Ø

×

Ø

When number is input on previously registered data, the data is overwritten.

9-91




A-142-3 INSERT This function is used to insert programs into PROGRAM QUEUE.

×

Ø

×

Ø

1. When pressing the F4 key on the cursor’s current position, data following the cursor is shifted by one position. The position with the cursor becomes blank and data can be inserted. 2. When the INSERT (F4) key is pressed again without registering data, insert mode is released. （Screen displays previously set values.） 3. Insert mode must be on in order to register the data.

9-92




A-142-4 DELETE This function is used to delete the designated program from PROGRAM QUEUE.

×

Ø

×

Ø

When the DELETE (F4) key is pressed at the current cursor position, the following enquiry screen is displayed.

YES (F1): Delete data at the current position with cursor. NO (F4): Cancel Delete operation.

9-93




A-142-5 ALL DELETE This function is used to delete all the data stored in PROGRAM QUEUE.

YES (F1): Delete all the data from PROGRAM QUEUE. NO (F4): Cancel All Delete operations.

9-94




A-142-6 ENVIRONMENT SET This function is used to set shift type and shift mode of PROGRAM QUEUE.

PROGRAM QUEUE SHIFT TYPE Select shift type of the queue table when PROGRAM QUEUE is updated. When program is updated, programs are moved forward sequentially. When the last program of the queue is executed, all the data is deleted. FIFO type

Example: Address 1 2 3 Program 10 11 3

4 5 6 5 6 0 ↓ update Address 1 2 3 4 5 6 Program 11 3 5 6 0 0 When program is updated, the executed program is registered again at the last position of the queue and looped.

LOOP type

Example: Address 1 2 3 Program 10 11 3

6 0

Address 1 2 Program 11 3

6 0

4 5 5 6 ↓ update 3 4 5 5 6 10

PROGRAM QUEUE SHIFT MODE This sets the queue shift to be executed automatically or by external signals when program is updated. INTERNAL shift EXTERNAL shift

Queues are shifted automatically when the program is updated. Queues are shifted by external signals.

9-95




Program Queue Registration Sequence Registration to PROGRAM QUEUE can be done by using dedicated input signals. Program No.

(input) RPS_ON

(input) Queue writing

· After a program No. is entered, a queue input signal is input (see above-Queue writing) and the program is registered to the queue table. · This operation is optional. · When the PROGRAM QUEUE OPTION is ON, program change cannot be executed by RPS_ON. Program Execution Sequence RPS_ST (output) Queue start (input) Program No. (output) RPS_OK (output) Robot operation Queue shift (input)

In case of INTERNAL shift

Queue update

In case of EXTERNAL shift t · When the program waits for RPSEND, RPS_ST is output. If QUE START is input in this condition, the program switches to the first program of the queue table. · When RPS_ST is not output (RPS_ST waiting), Queue Start Input cannot be executed. · When SHIFT SYSTEM is set EXTERNAL, inputting the queue shift optional. · When PROGRAM QUEUE OPTION is OFF, programs are switched by RPS_ON, not by Queue Start. · When START DELAY option is ON, programs are registered to DELAY QUEUE by the Queue writing signal (see sequence, top of page). At this time, programs can be registered to DELAY QUEUE regardless of the RPSEND waiting condition. 9-96




A-143 START DELAY (OPTION) This function is used to delay the timing of the robots actual motion start after start signal is input depending on the conveyor moving distance. The DELAY DISTANCE is set by COMMON DELAY DISTANCE, a feature is common in all programs, or, by INDIVIDUAL DELAY DISTANCE, a setting for particular programs. When both of them are set, the values of both distances are added for determining the delay distance.

COMMON DELAY DISTANCE INDIVISUAL DELAY DISTANCE MULTI START DELAY

Sets a delay distances that is common to all the programs. Sets a delay distances for each program. Displays, changes and deletes the program No. and delay distance of Start Delay Queue (queue).

[ NOTE ] 1. When the conveyor remaining distance is 0, programs cannot be changed if the current program in operation is in RPSEND waiting. 2. When attempting to change a program during run, there is an error, and robot stops. 3. Programs that are left unchanged remains at queue. （Delete any unnecessary programs on menu screen.）

9-97




A-143-1 COMMON DELAY DISTANCE This function is used to set a delay distance that is common to all the programs.

Input range Default value

: 0mm to 99999 mm : 0 mm

A-143-2 INDIVIDUAL DELAY DISTANCE This function is used to set a delay distance for each program.

9-98




A-143-2-1 INDIVIDUAL SETTING This function is used to set delay distance in each program.

Ø to RETURN

Ø Ø For long queues, 4 programs prior to and following the input program (total 9) are displayed.

Ø Ø

1. Page can be changed by pressing the NEXT PG and PRE PG keys. (However, when changing programs, registration is necessary to change pages.) 2. Press the PROGRAM SELECT (F4) key to jump between programs. 3. Input range: from 0mm to 99999mm 4. Default value: 0mm 5. Program No. : from 1 to 999 6. Unregistered programs can be stored.

9-99




A-143-2-2 SET SAME DISTANCE This function is used to set DELAY DISTANCE in each program to the same value all at once.

Ø to RETURN

Ø

Input range: from 0 to 99999 mm Default val : 0

A-143-3 MULTI START DELAY This function is used to display, change and delete PROGRAM No. and DELAY DIST of START DELAY QUEUE (queue). 20 programs can be registered in queue.

9-100




A-143-3-1 DISPLAY This function allows the user to view the present state of START DELAY QUEUE.

1. Displays the remaining distance to the sum of COMMON DELAY DISTANCE + INDIVIDUAL DELAY DISTANCE. 2. Updated data is displayed by pressing RENEW (F4) key.

A-143-3-2 CHANGE This function is used to change PROGRAM No. and DELAY DISTANCE of present QUEUE.

1. After changing by using numeric key, press MODIFY (F4) key to change the data of PROGRAM No. or DELAY DIST highlighted by the cursor. 2. Unregistered address is not valid.

9-101




A-143-3-3 DELETE This function is used to delete registered queue.

Ø Ø

1. The PROGRAM No. and DELAY DISTANCE highlighted by cursor is deleted by pressing the DELETE (F4) key. 2. Unregistered address is not effected.

A-143-3-4 ALL DELETE This function is used to delete all the registered queues in block.

YES (F1): Delete all the queues. No (F4): Cancel. 9-102




A-144 INTERRUPT PROGRAM INTERRUPT PROGRAM is a function changing to the program set in advance and executing it, when RPS is in a waiting state at the program end and an interrupt start signal is input.

When following dedicated input signal is set, program changes to a designated interrupt program. 1. INTERRUPT PROGRAM 1: changes to the interrupt program 1 set in AUX. 144. 2. INTERRUPT PROGRAM 2: changes to the interrupt program 2 set in AUX. 144. 3. INTERRUPT PROGRAM 3: changes to the interrupt program 3 set in AUX. 144.

！

CAUTION

When start signal of interrupt program is input externally during repeat operation, the interrupt program is played back after the current program has been completed. See the External I/O Manual for interrupt start signals.

9-103




A-149 TOOL REGISTRATION(OPTION) Records tool mass, center of gravity, and inertia moment of data. Total of nine tools may be recorded and monitored. Note: This function is valid only when the Collision Detection Function is enabled. [ NOTE ] 1. Information on each tool is recorded on an individual page, for a total of nine pages. Utilizing the entire nine pages worth will result in tool information being grouped together in to one lump sum. 2. The value of AUX 48 TOOL DIMENSIONS changes automatically when tool registration is altered.

Press the NEXT (F3) key is to set tools the 2-9. * Holding down the NEXT PG (F3) key changes the pages to advance and stop finally on the 9th and 1st page. Holding down the PRE PG (F2) key cause the pages to reverse and stop finally on the 1st initial page. Item

0 to Payload

X POSITION OF LOAD

Description Load mass to be installed on the robot (Handling spec; includes the held work-piece) Load value, center of gravity on X axis

Y POSITION OF LOAD

Load value, center of gravity on X axis Y axis

-9999.9 to 10000.0mm

Z POSITION OF LOAD

Load value, center of gravity on X axis Z axis

-9999.9 to 10000.0mm

INATIA AROUND X AXIS

The value of inertia moment around X axis

0 to 999.99

INATIA AROUND Y AXIS

The value of inertia moment around Y axis

0 to 999.99

INATIA AROUND Z AXIS

The value of inertia moment around Z axis

0 to 999.99

WEIGHT OF LOAD

！

Setting

-9999.9 to 10000.0mm

CAUTION

Be sure to register the correct mass and center of gravity for Motion type 2 (standard on Z series optional for others). Entering wrong value may decrease the life of, or cause overload/deviation of component parts.

9-104




A-153 PROGRAMS IN DETAIL This function allows the user to view a listing of the program information: COMMENT, TOTAL STEP NUMBERS, DATE EDITED.

9-105




A-154 TOTAL REPEAT CYCLES OF PROGRAM This function allows the user to view the total repeat cycles of program, or to clear the repeat cycles.

1. 2. 3. 4. 5.

[ NOTE ] When repeating a dry run (playing back without stopping robot’s motion with turning servo power OFF), the number of repeat cycle is not counted. When repeating (operating continuously) program that has branch command (JUMP) at the end of program, the number of repeat cycle is not counted. When terminating forcedly during repeating, the number of repeat cycle is not counted. When terminating at the repeat cycle display screen, the repeat cycle is not updated. However, the internal counter counts the repeat cycle and the correct cycle number is displayed when starting up the screen again. The repeat cycle is counted up to 65535 and it does not change if exceeding the number.

9-106



A-154-1 DISPLAY AND MODIFY

A-154-2 ALL CLEAR

9-107





A-155 HOME POSITION CHECK AXIS SET This function is used for setting a check of the data registered for the home position of each joint.

×

Ø

×

Ø

EFFECT: Home position of specified axis is checked. INEFFEECT: Home position of specified axis is not checked. [ NOTE ] Screen changes as follows by page change. HOME POSITION 1 JT1 – JT6 (JT7)

Ø （HOME POSITION 1 JT8 – JT12

Ø HOME POSITION 2 JT1 – JT6 (JT7)

Ø （HOME POSITION 2 JT8 – JT12 Screen contents change depending on the number of axes.

9-108




A-158 DOUT FUNCTION ASSIGNMENT This function is used to set the following functions to the general output signals (No.1 – No.32) as effective/ineffective. · Selection of Output Signal function as either work or not work for operation conditions. · Selection of signal output condition at hold. · Selection of signal output condition when program repeat is completed. · Selection of signal output condition when program repeat is started.

×

Ø

×

Ø

This screen is displayed as follows depending on cursor position. TYPE 1: Selection for Output Signal Function Effective/Ineffective （0: work 1: not work） TYPE 2: Output at program hold （0: OFF 1: ON 2: HOLD） TYPE 3: Output at program end （0: OFF 1: ON 2: HOLD） TYPE 4: Output at program starting （0: OFF 1: ON 2: HOLD） Default settings are 0.

TYPE 1 Selection for Output Signal Function Effective/Ineffective Select the validity for Output Signal function Effective/Ineffective. When the Output Signal is effective, signal is output, and when 0: work the output signal is ineffective, signal is not output. 1: not work Signal is output regardless of Output Signal setting Effective/Ineffective. TYPE 2 Output at Program Hold Select signal output condition at hold. 0: OFF At program hold, signal is turned OFF forcibly. 1: ON At program hold, signal is turned ON forcibly. 2: HOLD Signal condition before holding is kept. TYPE 3 Output at Program End Select signal output condition at program repeat ending. 0: OFF At program end, signal is turned OFF forcibly. 1: ON At program end, signal is turned ON forcibly. 2: HOLD Signal condition at program end is kept. TYPE 4 Output at Program Start Select signal output condition at program repeat starting. 0: OFF At program start, signal is turned OFF forcibly. 1: ON At program end, signal is turnd ON forcibly. 2: HOLD Signal condition at program end is kept.

9-109




A-159 HISTORY CLEAR This function is used to clear the logs for all stored operations and errors.

YES (F1): All operation and error logs are cleared. No (F4): Cancel.

9-110




A-166 PG PARTIAL DELETE This function is used to delete every step by step for a prepared program in memory.

[ NOTE ] When designating a step that does not exist (for example, in case of a 15step program, the step from 15 to 20 are deleted), the contents of program do not change and a completion message is displayed normally.

9-111




A-167 SINGULAR POINT ALARM RANGE SET This function is used to display and set the singular point alarm function. For robot controller, when calculating to convert the position and posture at tool tip (XYZOAT) into the angle of each joint, the robot posture unable to calculate due to following situations is called singular point. (1) Combination of each joint angle that satisfies the position and posture of required tool tip are multiple and each joint angle cannot be determined. (2) Required position and posture at tool tip cannot be realized due to structural constraint. (For example, designated point is out of operating range and the arm does not reach.) Above-mentioned conversion calculation can be done when designated point is out of singular point range even if it is close to singular point. However, robot operation gets rapid around singular point and the robot controller sets singular point range including the vicinity of singular point. When robot enters within singular point range, an error message is displayed and the robot is suspended. This function allows robot to be stopped before moving abruptly.

The alarm range can be changed by selecting singular point with up and down keys. Input range : 0-30 Default value : 5.0 deg Displayed error codes are as follows: When the Singular Point 1 occurs: -2103 Wrist can’t be straightened any more (Singular Point 1) When the Singular Point 2 occurs: -2104 Wrist can’t be bent any more (Singular Point 2) Or, error may occur from extending beyond operation range or going over speed limit.

9-112




A-168 DIFFERENCE BETWEEN WORK SPPED AND AIR-CUT SPEED This function is used to select Yes or No considering the difference between work speed and air-cut speed.

Operation speed when setting YES · Robot operates at application speed or air-cut speed according to the difference between application step and air-cut step. Operation speed when setting NO · Robot operates at the speed executed by the last APPLICATION SPEED command, AIR-CUT command or SPEED command of ALWAYS until the next SPEED command is executed regardless of difference between application step and air-cut step. However, each joint operation occurs only when SPR_JSPEED and SPR_AC_JSPEED commands are effective, and linear operation occurs only when SPR_SPEED and SPR_AC_SPEED commands are effective. · When SPEED command is not executed, robot operates at default value (Joint: 10%, Linear: 100mm/s). · When SPEED is executed without designating ALWAYS command, only the next step is operated at the specified speed.

9-113




A-169 OPERATION CONDITION SETTING 1. Set EFFECTIVE/INEFFECTIVE of operation conditions. SIGNAL OUTPUT SIGNAL WAIT CONVEYOR WAIT DELAY TIME DOOR SENSE CAMERA SENSE 2. Each of the operation conditions is a system switch and can be changed to EFFECTIVE/INEFFECTIVE by inputting following commands; SIGNAL OUTPUT “INS_SIGOUT ON/OFF” SIGNAL WAIT “INS_SIGWAIT ON/OFF” CONVEYOR WAIT “INS_CVWAIT ON/OFF” DELAY TIME “INS_DELAY ON/OFF” DOOR SENSE “DOOR_SENSE ON/OFF” CAMERA SENSE “CAMERA_SENSE ON/OFF” 3. When a condition dedicated signal is set as effective, change the operation condition to default value by inputting signals. See the External I/O Manual for details.

SIGNAL OUTPUT

Ineffective

The following commands relating to signal output, spray device output and spray are not executed when teaching/repeating, and signal output is not executed even by using manual signal output.

Signal Output command

SIGNAL

Spray device output command

SPR_FRATE, SPR_FRATE_R, SPR_FRATE_A, SPR_FRATE_U, SPR_PATTERN, SPR_PATTERN_R, SPR_PATTERN_A, SPR_PATTERN_U, SPR_ATOMIZE, SPR_ATOMIZE_R, SPR_ATOMIZE_A, SPR_ATOMIZE_U, SPR_HVOLT, SPR_HVOLT_R, SPR_HVOLT_A, SPR_HVOLT_U, SPR_FLUSH, SPR_PTHINNER

Spray command

GUNON, GUNOFF

9-114



SIGNAL WAIT

Ineffective

The following DIN_WAIT command is not executed when teaching/repeating.

Signal wait command

DIN_WAIT

Ineffective CONVEYOR WAIT Conveyor wait command DELAY TIME

DOOR SENSE CAMERA SENSE


The following CVWAIT command is not executed when teaching/repeating. CVWAIT

Ineffective

The following DELAY command is not executed when teaching/repeating.

Delay time command

DELAY

Ineffective

The following XDELTA and XDSTART command are not executed when teaching/repeating.

Door sense command

XDELTA,

Ineffective

Not supported at present.

9-115

XDSTART




A-172 SYSCOUNT DISPLAY/SETTING This function is used to display the condition of system counter and to set general/private system counter values.

[ NOTE ] 1. All of the general/private counter value is cleared to 0 immediately after turning the main power of control panel ON. 2. General counter value is cleared to 0 when starting a teaching/repeating. 3. The counter No. of general and private system can be set up to 32.

A-172-1 SYSCOUNT DISPLAY/SETTING This function is used to display state of the general/private counter values.

9-116



A-172-2 GENERAL SYSCOUNT SETTING This function is used to set the general system counter values.

A-172-3 PRIVATE SYSCOUNT SETTING This function is used to set the private system counter value.

9-117




A-173


MOVING AREA XYZ LIMIT

For the robot’s edge, this function is used to set upper and lower limit of robot motion within the XYZ area of world coordinate including traverse axis. The upper and lower limits of moving range of XYZ area are checked only during repeat or check mode and teaching operation. (The range is not checked when changing or registering location data.) Moving from out of range to within the range is allowed.

Input range: -99999.9 to 99999.9 [ NOTE ] 1. When upper and lower limit is same value, check is not executed. 2. The area of XYZ including traverse axis is checked. （Only for a robot with traverse axis for conv. synch .） 3. When the values, for the upper and lower limit are inverted and input, error is returned.

9-118




A-176 DATA BANK DATA BANK is a data base function to register the user-specified spray conditions. If the spray condition is set in advance, DATA BANK can be read and used by the program. Edit and management (LIST, COPY, DELETE and ENVIRONMENT SET) are executed.

A-176-1 LIST List (Num. COMMENT, FLOW RATE, SHAPING AIR (PATTERN AIR), AIRMOTOR (ATOMIZING AIR), HIGH VOLTAGE, SPRAY SPEED and SPRAY JOINT SPEED) is displayed.

9-119




A-176-2 EDIT This is used to create new data banks or edit a previous data banks.

Ø to

SET

Ø

Specify the data bank No. (1 – 500) to be created or edited.

This is used to edit the contents of a specific data bank.

* Data Bank No. cannot be inputted using numeric key. （The number is for display only） Item FLOW RATE SHAPING AIR or PATTERN AIR AIRMOTOR or ATOMIZINGAIR HIGH VOLTAGE SPRAY SPEED SPRAY JOIINT SPEED

Setting range Upper limit set within 0 – the value set in A176-5. Upper limit set within 0 – the value set in A176-5. Upper limit set within 0 – the value set in A176-5. Upper limit set within 0 – the value set in A176-5. 1 - （Set Spray Speed/Linear Interpolation Max. Speed）100 or less 0 -100 9-120




A-176-3 COPY This is used to copy the contents of a specified data bank (1 - 500).

Ø to

ENTER

Ø

A-176-4 DELETE This is used to delete the contents of a specified data bank (1 - 500).

Ø to

ENTER

Ø

9-121




A-176-5 ENVIRONMENT SET This is used to set the upper limit of the spray device.

Item FLOW RATE UPPER VALUE SHAPING AIR UPPER VALUE or PATTERN AIR UPPER VALUE AIRMOTOR UPPER VALUE or ATOMIZING AIR UPPER VALUE HIGH VOLTAGE UPPER VALUE

Setting range

Correspond command

0- 10000

SPR_FRATE_U

0- 10000

SPR_PATTERN_U

0- 10000

SPR_ATOMIZE_U

0- 10000

SPR_HVOLT_U

9-122



A-197


PASSWORD SET（OPTION）

Figure A-36 Password Set The password relates to the Aux198 AUXILIARY FUNCTION SELECT function. The password can be set to 1-3. The password number is compared with the number set by AUX.198 AUXILIARY FUNCTION SELECT. The auxiliary function of the number set by the password is displayed. For example, when the password is set to 2, the displayed as level of the AUX.198 AUXILIARY FUNCTION SELECT is displayed 1 or 2, the displayed level does not indicate 3.

9-123




A-198 AUXILIARY FUNCTION SELECT（OPTION） You can set the displayed level of each Auxiliary function on the Auxiliary function screen.

Figure A-37 Auxiliary Function Select The set data shows the displaying level. This displayed level relates to the AUX.197 PASSWORD SET function. The displayed level can be set to 1-3. The state of the Auxiliary number set by AUX.197 PASSWORD SET is displayed. For example, the password is set to 1, the auxiliary function does not display level 2 or 3. Level 0 indicates that the Auxiliary function does not exist.

9-124



Thischapter explains the methods for displaying robot operating information and for setting necessary data by using the explosion-proof teach pendant.

10.1

List Of Other Functions by Explosion-Proof Teach Pendant .................. 10-4

10-1


10

OTHER FUNCTIONS THAN TEACHING BY EXPLOSION-PROOF TEACH PENDANT

10. Other Functions than Teaching by Explosion-Proof Teach Pendant

Explosion-Protection Teach Pendant has the following functions apart from Teaching/Editing. 1. Indicates data mainly used when operating the robot and editing the program: current position of robot, available user memory, Input/Output signals, etc. 2. Maintains the program: copying, panel shifting and deleting ports of the user program. 3. Sets robot operation conditions during Teaching/Repeating: ENABLE/DISABLE of output signals, current conveyor position display/setting, etc. The desired function screen is called out by selecting the corresponding number from the menu screen. Example: 5-0-1 Joint Angle

Ø Ø

Ø Ø

10-2




Ø Ø

To move to the upper screen, press When End is pressed, the default screen returns to view.

10-3



10.1


List Of Other Functions by Explosion-Proof Teach Pendant

Index

Function Names

1-0

Program Setting

1-1

Repeat Status Display

1-2

Product Rate Value Setting

1-3

Product Paint_IO Ratio

3-0-0

Program List Display (Detail)

3-0-1

3-0-3

Program Number List Display Available Memory Capacity Display Program Name Registration

3-1

Program Copy

Copies program contents to other programs

3-2

Program Link

Add program contents after another program.

3-3

Program Deletion

Delete programs.

3-4-0

Partial Program Copy

Inserts a part of program into another program.

3-4-1

Partial Program Deletion

Delete a part of program contents.

3-5-0

Parallel Shift

Shifts taught postion data parallel to the base coordinate.

3-5-1

Gun-tip Direction Shift

Shifts taught position data toward gun tip direction.

3-5-2

Mirror Image Conversion Traveler Shift With Gun Tip Fixed Shuttle Right-Left Conversion (Option)

Converts taught position data using Mirror Image. Transfers traverse axis while keeping the guntip position. For Servo shuttle system, converts position data from left to right and vice versa. Shifts the conveyor positions in taught data uniformly. Shifts one taught path by equal intervals and generates a path to be repeated automatically. Displays or edits data bank contents Displays a listing of stored data bank numbers, names, partial contents information. Displays list of stored data bank numbers. Displays current gun position and direction in real time. Displays each axis angle in real time. Displays current command values for each joint angle. Indicates current encoder value.

3-0-2

3-5-3 3-5-4 3-5-5

Conveyor Position Shift (Option)

3-6

Automatic Path Generation

4-0

Data Bank Editing

4-1-0

Data Bank Details Display

4-1-1

Data Bank Number Display

5-0-0

Gun Position/Angle

5-0-1

Joint Value Display

5-0-2

Joint Command Value Display

5-0-3

Encoder Value Display

Descriptions Sets the program numbers for repeat operation. Displays the status of the repeat operation on the screen. Determines the overall repeat operation speed. Changes the output ratio for the overall painting program. Displays program names, step numbers, and production date and time. Shows the list of all avalilable program numbers. Indicates available memory of teach program. Give names or comments to programs

10-4



Index 5-0-4 5-0-5

Function Names Position Display Of Traverse Axes Table Position Display (option)


Descriptions Displays current position of traverse axes. Indicates current table axis angle.

5-1-0

Gun Position/ Wrist Angle Display External Output Signal Display

5-1-1

External Input Singal Display

Displays current status of input signals.

5-1-2

Internal Signal Display

5-1-3

Home Position Signal Display

5-2-0

General Counter Display

Displays current status of internal signals. Displays current status of home signals and work space output signals (option). Displays current status of General counter values.

5-2-1

Dedicated Counter Display Operation Condition Selection (External Output) Operation Condition Selection (Input Wait) Operation Condition Selection (Conveyor wait) Operation Condition Selection (Time wait)

5-0-6

6-0-0 6-0-1 6-0-2 6-0-3 6-0-4

Operation Condition Selection (CV Track Mode)

Operation Condition Selection (Sensor Setting/Door Sensing) Operation Condition Selection 6-0-5-1 (Sensor Setting/ Camera Sensing) Current Conveyor Position Setting 6-1 (option) 6-2 Counter Value Setting 6-0-5-0

6-3

Location Variables Registration

7-0

Error History Display

7-1

Total Playback Count Display

8-0 8-1 8-2 8-3

Manual External Output Execution (General Signal) Manual External Output Execution (Spray signals) Manual External Output Execution (Flow Rate) Manual External Output Execution (Shaping/Pattern Air)

Displays current gun positions and wrist angles. Displays current status of output signals.

Displays current status of Dedicated counter values. Sets ENABLE/DISABLE for External Output Sets ENABLE/DISABLE for Input Waiting Sets ENABLE/DISABLE for Conveyor waiting Sets ENABLE/DISABLE for Time Waiting. Sets the method, False pulse (Simulation mode) or Real pulse for synchronizing the robot with conveyor. Sets ENABLE/DISABLE for Door Sensor. Sets ENABLE/DISABLE for Camera Compensation. Sets current conveyor position Sets General/Special Counter value Registers location variable using AS HERE monitor command or POINT instruction Displays error history Displays and sets the number of tiem a program is repeated Manual On/Off for external signals Manual On/Off for spray signals Sets the flow rate manually. Sets the level of Shaping/Pattern Air manually 10-5



Index 8-4 8-5 8-6 8-7

Function Names Manual External Output Execution (Air Motor/Atomizing Air) Manual External Output Execution (High Voltage) Manual External Output Execution (Flushing) Manual External Output Execution (Push Thinner)

10. Other Functions than Teaching by Explosion-Proof Teach Pendant Descriptions Sets Air motor/Atomizing air manually Sets High Voltage level manually ManualOn/Off for the Flushing start signal Manual On/Off for the thinner spray signal

10-6



1-0


PROGRAM SETTING

Sets program number to be play backed when conducting a repeat operation after program teaching or making a change to the program.

Input the program number and the starting step number to be play backed.

Ø SET

Ø

Ø Check the numbers, and press

SET

Ø

Moves to the status display screen. [NOTE] Replay can be started from a desired step by inputting the step number.

10-7



1-1


REPEAT STATUS DISPLAY

Status of repeat operation is displayed on the monitor screen.

Displays repeat operation status. (In above example, Program No. 1 is being repeated.) Every time the operation status changes, the display in the right side on the second row changes accordingly (In above example, “REPEAT mode” changes.). Use keys to scroll the screen. [NOTE] · On the right half of the first row, the program number and the point number in action are displayed. REPEAT COMPLETED is displayed at the end of the playback. · The ( ) on the right half of the 2nd row indicates one of the following conditions. However, if the instruction requires a short operation/waiting time (completes just in a moment), condition may not be indicated. Error Occurrence, Motor Power Off, Teach Mode, Repeat Mode, Cycle Start On, Program WAIT · The 3rd and lower rows periodically indicate by which current values for the following five items. 1. Production Rate: Ratio determined by the overall repeating speed of all programs is adjusted. 2. Conveyor Speed: Moving speed of the conveyor. (m/min.) 3. Conveyor Position: Current position of conveyor (amount of displacement after resetting) (mm). 4. Product Count: Indicates the number of repetitions for the program being repeated. 5. Playback Time: During a repetition, it displays the time elapsed from the program start. At the end of the playback, it indicates the required repeat operation time. (Cycle time) However, it does not count beyond 99999 seconds. (Nos. 2, 3 are displayed only when conveyor synchronization mode is enabled.) · On the back screen, program instruction being repeated is displayed. When playback is not being performed, indication of no instruction is displayed. However, if the instruction only requires a short time or waiting time (completes in a moment of time), it may not be displayed.

10-8



1-2


PRODUCTION RATE VALUE SETTING

Equally changes the repeat operation speed for all programs stored in the robot control system memory.

Enter the desired value at PRODUCT RATE value. At the beginning, the current value is displayed.

Ø Enter the value, and press

SET

[NOTE] · When PRODUCT RATE value is entered, gun speed at repeat operation is determined by the following. (Actual Gun Speed = Gun Speed × REPEAT RATE value × PRODUCT RATE value) Assigned in the program · If REPEAT RATE value is set during a program playback, the set value becomes valid from the next repeated program. However, note that values shown on the playback status display screen changes immediately after setting. · PRODUCT RATE value can be set up to 999%, but speed limitations on each axis may restrict actual speed. · When PRODUCT RATE value is changed, it reflects in the check speed of forwarding/backing during teach mode as well. (It does not affect manual operation).

10-9



1-3


PRODUCT PAINT_IO RATIO SETTING

When the robot is in operation, changes the output ratio in repeat operation equally for all the programs stored in the robot controller memory and for all the painting equipment output instructions (FLOW RATIO, SHAPING/PATTEN AIR, AIR MOTOR/ATOMIZING AIR, HIGH VOLTAGE) in manual signal output mode.

Enter each value for PRODUCT PAINT_IO ratio. The monitor displays the current settings at the beginning. Set the ratio for only those items which need to be changed.

[NOTE] · When setting PRODUCT PAINT_IO ratio during a program playback, it will immediately become valid and be reflected on the current output rate. · PRODUCT PAINT_IO ratio can be set up to 200%; however, if ratio is beyond the limit for the output signal of each painting equipment, the set limit takes precedence. · Refer to 5.2.3, External Input Instructions for the relationship between PRODUCT PAINT_IO ratio and the painting equipment output instruction.

10-10



3-0-0


PROGRAM LIST DISPLAY (DETAIL)

The Explosion-Proof Teach Pendant displays information about the program that is stored in memory. Information includes: program number, name, step number, number of instruction, and creation date, and each row displays for a different program.（scroll with keys）

Use keys to scroll the information Programs created with non-numerical names are indicated as “***”.

3-0-1

PROGRAM NUMBER LIST DISPLAY

The numbers of the programs that are stored in memory are displayed on screen. Each row shows up to eight numbers. (Use keys to scroll.)

Programs stored with non-numerical names are indicated as ***

3-0-2

AVAILABLE MEMORY CAPACITY DISPLAY

Indicates the residual memory of the teach program.

Available Memory/Total memory capacity is shown in K byte form, and its ratio is indicated in %. Storable Memory indicates remaining memory capacity for numbers of teach points. [NOTE] · Total memory capacity varies depending on system specifications (equipped RAM capacity). · Storable memory points vary with system configuration. · The programming method also creates some differences in memory capacity. 10-11



3-0-3


PROGRAM NAME REGISTRATION

Registers new name or changes existing one for the programs stored in memory. Up to eight (8) letters can be used.

Ø Enter a program number and press

SET

Ø

Use keys to select letters to enter, and press Set key. With Shift key + key or ( ), the cursor moves by 16 letters at a time. For example, when the cursor is at the G on the above screen, by pressing the Shift key + it moves to the W.

Ø Set the cursor at the desired letter, and press

SET

Ø

Ø Set the cursol at End , and press

SET

Ø

10-12

key,




Check the name and confirm the registration. [NOTE] Delete tab shown in the previous page is available for clearing the last letter entered. Select this tab for incorrect entries.

10-13



3-1


PROGRAM COPY

This section describes methods for copying programs (one program at a time) stored in memory.

Enter the source and destination program number and set YES/NO for overwrite. (Original programs which will be overwritten unconditionally.) When YES is selected in the final row (OVERWRITE) the value will be fixed automatically, and the screen changes without pressing the SET key. (If NO is selected, processing stops and an error arises.)

Ø Enter program number and press

SET

Ø

Confirm the numbers and enter YES or NO.

10-14



3-2


PROGRAM LINK

This section describes linking of programs stored in the memory. connect one program to another.

Linking, here, means to

Enter destination program number and source program number.

Ø Check numbers, and press

SET

Ø

After confirming the numbers, enter YES or NO to execute instruction. (If destination does not exist, processing is the same as copy.) · Using the above explanation as an example, following describes the program connection in schematic drawing form. Program 11 Program 11 Program 2 Link Program 2

· The following figure describes the case when the same number is set for the source program and the destination program. Program 11 Program 11 Link Program 11

10-15



3-3


PROGRAM DELETION

This section describes deletion of programs (a program as a unit) stored in memory.

Enter the number of the program to be deleted.

Ø After checking the number, press

SET

Ø

Confirm the number and enter YES or NO for execution.

10-16



3-4-0


PARTIAL PROGRAM COPY

This function makes copies of specific steps from one program and inserts them into another program.

Enter the number of the source program and Start/Finish step number.

Ø After checking the numbers, press

SET

Ø

Enter the program number for the copy destination and the insert step number.


SET

Ø

Enter YES or NO to execute. Using the above explanation as an example, the following describes a Partial Program Copy in schematic drawing form. Program 4 3 5 Program 13 2 3

Program 13 Program 4 3 2 Partial 3 5 Copy 5 6

10-17



10. Other Functions than Teaching by Explosion-Proof Teach Pendant [NOTE]

When designating a non-existing step number in the destination program (For example, attempting to insert into step 999 when the program only has 15 steps), the source program will be inserted after the final step (step 16 in this case), ignoring all the non-existing steps.

10-18



3-4-1


PARTIAL PROGRAM DELETION

With this function, it is possible to delete specific steps from a partial deletion (by step) of programs stored in memory.

Enter the program number and Start/End step numbers to be deleted.


SET

Ø

Enter YES or NO for program execution. The following schematic drawing describes the Program Partial Deletion from the above example. Program No.5 Program No.5 2 4

Partial Delete

[NOTE] When non-existing step numbers are designated, (For example, steps 15-20 are selected for deletion when only 15 steps are available) no change will be made in the contents of the program though the completion message will be shown at the end.

10-19



3-5-0


PARALLEL SHIFT

This section explains parallel shifting of taught positions in forward/backward, left/right or upward/downward directions. This function is suitable for simple parallel shifting such as shifting data taught in the program by 30mm in forward direction.

Enter the program number to convert and the start/end step numbers, (FROM) and (TO).


SET

Ø

Input numeric values for parallel shifting in each direction.

10-20



3-5-1


GUN-TIP DIRECTION SHIFT

This section explains the shift in gun tip direction (spraying direction) for each step. This function is suitable for shifting the teach data in the spraying direction.

Enter the program number and start/end step numbers, (FROM) and (TO).


SET

Ø

Ø Enter the desired shift value, and press

SET

When approaching a work to be sprayed, enter (+) distance (positive number), and if departing from it, enter (–) distance (negative number).

10-21



3-5-2


MIRROR IMAGE CONVERSION

This section explains Mirror Image Conversion of position data of programs of stored in memory by converting to a position that is symmetric with respect to the planes formed by the front/back and up/down directions of the robot.



SET

Procedures for converting external axes and transformation values comply with the conditions set in Auxiliary Function 6: Mirror Conversion. See A-6 Mirror Conversion

10-22



3-5-3


TRAVELER SHIFT WITH GUN TIP FIXED

For systems equipped with manipulator and traverse equipment, this function enables movement on the traverse axes while keeping the gun tip fixed against ground.



SET

Ø

Ø Enter shift values for each traverse axis, and press

3-5-4

SET

SHUTTLE RIGHT-LEFT CONVERSION (OPTION)

This function automatically converts programs which were taught with use of the right shuttle so that it makes it usable for the left shuttle. Also, conversion is possible in the reverse condition (left to right). [NOTE] This function is dedicated for use with the servo shuttle system, and cannot be used for other systems. Right-left conversion of the shuttle programs can be performed only when the robot configuration has the servo shuttle system. For description of this function, please refer to Operation Manual for Servo Shuttle Exclusive Functions.

10-23



3-5-5


CONVEYOR POSIOTION SHIFT (OPTION)

With this function, the conveyor position in program can be shifted for a designated distance. This function can be used when conveyor origin (a position where the work cuts Start LS and phototube) is changed after completing a teaching.

Enter the converting program number and start/end (FROM/TO) step numbers.

Ø SET

Ø

Ø Enter conveyor shift amount, and press

SET

10-24



3-6



“Automatic path generation” is the function to easily teach a path which is to be repeated. What the operator has to do is only specify how far to shift the taught path (path pitch) and how many times to repeat the path (the number of paths) for the reference program to which minimum 3 points (1st endpoint, 2nd endpoint and reference point) are taught. For more details, see “A-72 Automatic path generation” in chapter 9.

Select path generation method from 1 to 4.

Ø After entering numbers, press

SET

Ø

Enter reference program No., path pitch, number to be repeated, and start/end (FROM/TO) step numbers.

Ø After entering numbers, press

SET

10-25



4-01


DATA BANK EDITING

This mode is used to edit the user data banks. Use this mode to enter or change instruction values for conditional items in the data banks.

！WARNING g (1) Call_DBK instruction can be set multiple times in a single step. If the same condition item is set multiple times in such cases, the last setting becomes applicable (enabled). (2) A Call_DBK instruction is executed even if it is set in the aircut (spray off) section. However, the conditional items which are effective within the spraying section do not function in the air cut section. (3) Only an existing data bank should be referenced by the Call_DBK instruction in TEACH mode. If the data bank does not exist, an alarm is output. (4) In EDIT mode, the availability of the specified data bank is not checked. If unavailable, there is an error message at execution in TEACH or REPEAT mode. (5) Because many conditional items can be set in a data bank, its setting varies depending on usages.

Enter data bank number


SET

Ø

Input desired instruction for each conditional item.

Ø After checking the contents, press

SET

10-26




Ø

Enter YES or NO for execution. The date bank contains conditional items that can be set according to the needs of the user. The following conditional items are available for setting. No Condition setting items 1 FLOW_RATE 2

SHAPING AIR

3

AIR MOTOR

4

HIGH VOLTAE

5

APPLYING SPEED

Conditon items FLOW_RATE SHAPING/ PATTEN AIR AIR MOTOR/ ATOMIZING AIR HIGH VOLTAGE SPRAY SPEED (mm/s) SPRAY JSPEED (%)

Content FLOW_RATE RANGE PATTEN AIR RANGE ATOMIZING AIR RANGE HIGH PRESSURE Gun tip speed with spray ON Joint speed with spray ON

[NOTE] Existing data bank displays the set values, and it is possible to change them to new values. Items set as "–1" do not change the current settings when executing if CALL_DBK. In the next example, output levels for Shaping Air and High-Voltage do not change.

10-27



4-1-0


DATA BANK DETAILS DISPLAY

The No., name and created date of the data banks registered in memory are displayed on Teach pendant (one row for each data bank). (The screen can be scrolled with ↓ ↑ keys.) Pressing SET key shifts to the editing screen.

Displays a name and a portion of the set contents. Names can be set by “Auxiliary 176 data bank” of Multi-function panel. ↓ ↑ keys scroll the screen.

Ø After checking the contents, press

SET

Ø

Shifts to data bank editing screen.

4-1-1

DATA BANK NUMBER DISPLAY

Displays only the numbers of data banks stored in memory. Each row displays up to eight (8) numbers. (Use keys to scroll the screen)

Displays data bank numbers.

10-28



5-0-0


GUN POSTION/ ANGLE DISPLAY

Displays current values of gun tip position and angle in the form of a transformation value.

Gun position and direction are displayed. [NOTE] · Gun tip positions is displayed on the upper row (4th row) as X, Y, Z values on the robot coordinate system. · Gun tip direction is displayed on the bottom row (5th row) as OAT rotation angles of the robot coordinate system. · The units used are "mm" for position and "deg" for direction.

· The following figure shows the definition of robot coordinate system and (+) direction.

* For OAT values, see transformation value in “Appendix-6 OAT”. 10-29



5-0-1


JOINT VALUE DISPLAY

This function displays the value of each joint angle.

[NOTE] The unit for angle is "deg". (+/-) direction of each joint is shown in the below figure.

3S wrist The manipulator shown above is from the KE610 series.

10-30



5-0-2


JOINT COMMAND VALUE DISPLAY

This function displays command value for each joint.

The displayed values may differ from the current values of 5-0-1 Joint Value.

5-0-3

ENCODER VALUE DISPLAY

This function displays current robot encoder values for each axis.

Above display is from a robot system configuration with 6 axes (Single robot).

Above display is from a robot system configuration with 7 axes (single robot + traverse axis). [NOTE] Arrangement of encoder values on display may differ depending on the system configurations. · Six joints are located at the set position; joints1 to 3 are displayed left to right on the 3rd row, and joints 4 to 6 are shown on the 4th row. · When any of X, Y and Z traverse axes are included in the system configuration, their values are displayed on the 5th row in the above-mentioned order.

10-31



5-0-4


POSTION DISPLAY OF TRAVERSE AXES

This function displays current positions of X, Y, and Z traverse axes.

Displayed are current positions of traverse axes. [NOTE] The position data is displayed in (mm) units.

5-0-5

TABLE POSITION DISPLAY (OPTION)

This function displays current angles of the table system. [NOTE] · Table angles are displayed on the screen in fixed fields. Values for axes 10 (SYSTEM_1/TABLE_1) and 11 (SYSTEM_1/TABLE_2) are displayed on the 3rd row, and those for axes 12 (SYSTEM_2/TABLE_1) and 13 (SYSTEM_2/TABLE_2) are on the 4th row in order from left to right. For those not assigned axes, indications do not change ("0.00" is fixed). · The unit displayed is "deg". · For information on the table system display function of Servo shuttle systems, refer to Operation Manual of Servo Shuttle Exclusive Functions.

5-0-6

GUN POSITION/ WRIST ANGLE DISPLAY

This function displays current gun tip position and wrist angle.

[NOTE] · Gun position is displayed on the upper row (4th line) as X, Y, Z values on the robot coordinate system. · Robot wrist angles are displayed on the lower row (5th line) as joint values on the robot wrist axes. · The units are "mm" for position and "deg" for wrist angles. 10-32



5-1-0


EXTERNAL OUTPUT SIGNAL DISPLAY

This function displays the status of output signal ports.

Enter a desired output port number.


SET

Ø

The status of each output port is displayed. In the above example, the status of six consecutive output ports, starting from a selected port, is displayed. The example above indicates the following. Port 27: OFF Port 28: ON Port 29: OFF Port 30: OFF Port 31: OFF Port 32: ON [NOTE] · Output status is shown using " ", " " and "-". " " indicates OFF (Low) status for the output port. " " indicates ON (High) status for the output port. · For the port assignment and meaning of each output signal, refer to the Manual, External I/ O Signal.

10-33



5-1-1


EXTERNAL INPUT SIGNAL DISPLAY

This function displays the status of input signal ports.

Enter a desired input port number.


SET

Ø

Statuses of six consecutive input ports, starting from a selected port, are displayed. The above figure example indicates the following. Port 01: ON Port 02: ON Port 03: OFF Port 04: ON Port 05: OFF Port 06: ON [NOTE] · Output condition is shown using " ", " " and "-". " " indicates OFF (Low) status for the input port. " " indicates ON (High) status for the input port. · For the port assignment and meaning of each assigned signal, please refer to External I/ O Manual.

10-34



5-1-2


INTERNAL SIGNALS DISPLAY

This function displays status of internal signals.

Enter a desired internal signal port number.


SET

Ø

The status for internal signal ports is displayed. The status of six ports, starting from the selected port, is displayed. The example shown above indicates the following. Port 01: ON Port 02: OFF Port 03: OFF Port 04: ON Port 05: OFF Port 06: ON [NOTE] · Internal signal status is shown using " ", " " and "-". " " indicates OFF (Low) status for the internal port. " " indicates ON (High) status for the internal port. · For the port assignment and the meaning of each internal signal, refer to External I/ O manual.

10-35



5-1-3


HOME SIGNALS

This function displays status of home signals.

Output status of home position signals is displayed together with the status of workspace output signals. Output status signals indicate each axial posture and workspace output signals indicate gun tip position. The above example indicates the following; Home position1: OFF Home position2: ON Work space output 1: ON Work space output 2: OFF Work space output 3: Unassigned Work space output 4: Unassigned Work space output 5: Unassigned Work space output 6: Unassigned Work space output 7: Unassigned Work space output 8: Unassigned Work space output 9: Unassigned [NOTE] · Status of output signals are indicated using " ", " " and "-". " " indicates that the robot posture or gun tip position is located outside the home position range. " " indicates that it is located within the range. When the output port is not assigned, "−" is displayed. · For the meanings of assigned output signals, refer to External I/O manual. · For setting function related to the home position and work space, refer to A-76 Home Position and A-77 Work Space Output.

10-36



5-2-0


GENERAL COUNTER DISPLAY

This function displays the status of general counter values. four counters.

Use

Each row shows the values for

to scroll the screen.

5-2-1

DEDICATED COUNTER DISPLAY

This function displays status of dedicated counters. Each row shows the values for four counters.

Use

to scroll the screen. [NOTE] · All the General/ Dedicated counter values will be initialized (cleared to 0) immediately after the control power of the controller is turned ON. · General counter values are also initialized (cleared to 0) at teaching/ repeat start. 10-37



6-0


OPERATION CONDITION SELECTION [NOTE]

· Prior to operation, switch each set condition from DISABLE to ENABLE. · When robot controller main power is ON or the mode is switched between Teach and Repeat on the operation panel, each condition automatically switches to ENABLE.

6.0.0

OPERATION REQUIREMENT: EXTERNAL OUTPUT

This function sets the external output instruction to ENABLE/DISABLE. When DISABLE is selected, each of the instructions: External output, Painting equipment output, Output delay and Spray will not be executed in Teach/Repeat. Also, manual signal output is disabled. Therefore, this function makes it possible to conduct a repeat operation to check the robot movement without outputting the control signals for turning ON/OFF the peripheral external devices.

Select ENABLE or DISABLE for the execution of external output. The menu number highlighted by the cursor and the menu number with (SELECT) are not necessarily consistent.

Ø After checking the content, press

SET

！ CAUTION When the operating conditions are switched from DISABLE to ENABLE, such as during a program playback, signals that were masked may output at that moment. Therefore, take care when changing the conditions during a program playback.

10-38



6-0-1


OPERATION CONDITION SELECTION : INPUT WAIT

Sets ENABLE /DISABLE for DIN WAIT (digital input wait) instructions. When DISABLE is selected, DIN WAIT instructions are not executed during teach/repeat. When DIN WAIT is specified in a program, the robot waits in the middle of a step until conditions are established. However, if the peripheral external devices are not ready during teaching or a test run, the input wait release signal may not be entered to the robot. In this case, the robot can be operated by forcefully terminating (disabling) the external input waiting. At startup of the controller, the initial condition is set as ENABLE.

Select ENABLE or DISABLE for the execution of the input waiting. The menu number highlighted by the cursor and the menu number with (SELECT) are not necessarily consistent.


SET

！ CAUTION If the condition is switched to DISABLE during program playback, the robot held in standby by the DIN WAIT instruction may suddenly restart operation. Therefore, extreme care should be exercised when changing the condition during program playback.

10-39



6-0-2


OPERATION CONDITION SELECTION: CONVEYOR WAIT (OPTION)

This function sets ENABLE or DISABLE to CV WAIT instructions. When DISABLE is selected, CV WAIT instructions are not executed during teaching/repeating. ENABLE is set as initial status of the function immediately after turning on the controller.

Enter whether or not to enable execution of CV_WAIT. SELECT indicates the current status of the robot. The menu number highlighted by the cursor and the menu number with (SELECT) are not necessarily consistent.


SET

！ CAUTION If the condition is switched to DISABLE during program playback, the robot operation held in standby by the CV_WAIT instruction may suddenly re-start. Therefore, extreme care should be exercised when changing the condition during program playback.

10-40



6-0-3


OPERATION CONDITION SELECTION: TIMER WAIT

This function sets ENABLE or DISABLE to the TIMER WAIT instruction. When DISABLE is selected, TIMER WAIT instructions are not executed during repeat operation. ENABLE is set initially immediately after turning on the controller.

Enter whether or not to enable execution of TIMER_WAIT. SELECT indicates the current status of the robot. The menu number highlighted by the cursor and the menu number with (SELECT) are not necessarily consistent.


SET

！

CAUTION

If the condition is switched to DISABLE during a repeat operation, the robot under the TIMER WAIT instructions may suddenly re-start the action. Therefore, extreme care should be exercised when changing the condition during repeat operation.

10-41



6-0-4


OPEARATION CONDITION SELECTION: CONVEYOR TRACK (CV) MODE (OPTION)

This function sets the method for synchronizing the robot with the conveyor. CV_TRACK MODE function provides 2 modes: REAL PULSE TRACK and FALSE PULSE TRACK (Simulation Mode). REAL PULSE TRACK synchronizes the robot with the conveyor in an actual run. FALSE PULSE TRACK (Simulation Mode) checks the robot motion with non-moving conveyor. With the later function, a dummy pulse is generated in the robot controller to synchronize the robot with the conveyor at the pulse rate. Also, it is possible for the robot to start synchronizing at any point by setting an optional start position for CV_TRACK. REAL PULSE TRACK is set as initial status of the function immediately after turning on the controller.

Enter the desired method for CV TRACK MODE. The menu number highlighted by the cursor and the menu number with (SELECT) are not necessarily consistent.


SET

！

CAUTION

Be sure to confirm which CV_TRACK MODE is selected before starting a playback of the conveyor-tracking program. If a program is played back while the conveyor is actually running and FALSE PULSE TRACK is mistakenly selected, the robot will move per the false pulse and may collide with works, peripheral equipment, etc.

10-42



6-0-5-0


OPEARATION CONDITION SELECTION: SENSOR SETTING (DOOR DETECTING) (OPTION)

This screen sets ENABLE or DISABLE to the DOOR SENSING function for the door opening/closing robot.

Select ENABLE or DISABLE for execution of DOOR SENSING. The menu number highlighted by the cursor and the menu number with (SELECT) are not necessarily consistent.


SET

[NOTE] This function should not be used if the system is not equipped with the above-mentioned function.

6-0-5-1 OPERATION CONDITION SELECTION: SENSOR SETTING (CAMERA SENCING) (OPTION) This screen sets the work location compensation function as ENABLE or DISABLE. Compensation is performed using a camera sensor.

Select ENABLE or DISABLE for execution of CAMERA SENCING. SELECT indicates the current status of the robot. The menu number highlighted by the cursor and the menu number with (SELECT) are not necessarily consistent.


SET

[NOTE] This function should not be used if the system is not equipped with the above-mentioned function. 10-43




6-1 CURRENT CONVEYOR POSITION SETTING (CURRENT CV_POS) (OPTION) This function sets the current position of the conveyor.

Enter current conveyor position. Maximum of 65000 mm can be set for the CURRENT CV_POS value. The presently set conveyor position is displayed as the initial value.


SET

[NOTE] Teaching methods for conveyor synchronization programs are outlined in detail in Ch. 12, Conveyor Synchronization. (Option)

10-44




6-2 COUNTER VALUE SETTING This function sets the values for GENERAL/ SPECIAL counters. The counter value can be set regardless of current operation mode (during teaching or repeating). All the counter values, GEN/SPE, are cleared (to zero) when the controller main power is turned ON. Only GEN counter values are cleared (to zero) when starting teach/repeat.

Sets desired counter condition. For example, set 500 to GENERAL counter No. 1.


SET

[NOTE] · Up to 32 different counters can be set for each type, GENERAL/SPECIAL. · The set counter values can be checked at the counter status in Status Display Mode.

10-45




6-3 LOCATION VARIABLES REGISTRATION Location Variables are registered by inputting HERE or POINT command from AS monitor instruction. Refer to AS Language Instruction Manual for each information on command. The example below uses the POINT command.

Ø Select 2 POINT and press

SET

Ø

Ø

↑

↓

SET

and Enter name of variable after POINT and values in [ ] using "," between each value entered

Ø

Ø

Ø Finally, move the cursor to END and press SET to transmit the POINT command and register location variables. Refer to 5.2.15, Other Instructions for inputting character strings.

10-46



7-0


ERROR HISTORY DISPLAY

This function displayes the last 100 errors which have occurred. Errors are stored in order of occurrence with small numbers being more recent.

The error number and the first few words of each error message are displayed on the error history screen. Three (3) errors are shown on screen. Use keys to scroll to different errors.

Ø SET

Ø

Detail information is displayed by pressing Set key. Error No. , date and time of occurrence and an error message are shown. Each screen shows the information for one error. Use key to scroll different errors.

10-47



7-1


TOTAL PLAYBACK COUNT DISPLAY

This function displays the repeat counts for a specified program. Also, the repeat count value can be rewritten.

Input the number of a desired program to display.


SET

Ø

Input a desired repeat count value. The repeat count value can go up to 65535 times, and this value stays fixed if repeated beyond this number. Zero (0) may also be entered.


SET

[NOTE] · For dry-run-repeat (executing a repeat program without operating the robot with the servo power OFF), the repeat count value will not be incremented. · When continuously repeating a program that has a JUMP instruction (JUMP_STEP, etc.) at the end, the repeat count value will not be incremented. · If a program was forced to terminate during repeat, the repeat count value will not be incremented. · When a repeat-run ends while the repeat count value indicator screen is displayed, the count value does not change. However, the internal counter continues counting, and the updated count value will be reflected on screen the next time it is displayed. · The repeat count value is incremented to 65535, and is fixed to this value even if repeated more times.

10-48



8-0


MANUAL EXTERNAL OUTPUT EXECUTION: GENERAL SIGNAL

This function executes External Output instructions regardless of the robot status.

Enter a desired output signal number and the signal (ON/OFF) on the screen.


SET

10-49



8-1


MANUAL EXTERNAL OUTPUT EXECUTION: SPRAY SIGNALS

This function executes SPRAY instruction regardless of the robot status.

Enter the spray signal number and signal (ON/OFF) on the screen.


SET

10-50



8-2


MANUAL EXTERNAL OUTPUT EXECUTION: FLOW RATE

This function executes FLOW RATE instruction regardless of the robot status.

At the condition-setting screen for flow rate, enter the desired condition (level).


SET

10-51



8-3


MANUAL EXTERNAL OUTPUT EXECUTION: SHAPING/PATTERN AIR

This function executes the SHAPING/PATTEN AIR instruction regardless of the robot status.

At the condition-setting screen for SHAPING/PATTERN AIR, input the desired condition (level).


SET

10-52



8-4


MANUAL EXTERNAL OUTPUT EXECUTION: AIR MOTOR/ATOMIZING AIR

This function executes AIR MOTOR/ ATOMIZING AIR instruction regardless of the robot status.

At the condition-setting screen for AIR MOTOR/ATOMIZING AIR, enter the desired condition (level).


SET

10-53



8-5


MANUAL EXTERNAL OUTPUT EXECUTION: HIGH VOLTAGE

This function executes HIGH VOLTAGE instruction regardless of the robot status.

At the condition-setting screen for High Voltage, enter a desired level.


SET

10-54



8-6


MANUAL EXTERNAL OUTPUT EXECUTION: FLUSHING

This function executes Flushing instruction regardless of the robot status.

At the condition-setting screen for Flushing, enter a desired condition (OFF/ON).


SET

10-55



8-7


MANUAL EXTERNAL OUTPUT EXECUTION: PUSH THINNER

This function executes PUSH THINNER instruction regardless of the robot status.

At the condition-setting screen for PUSH THINNER, enter a desired condition (OFF/ON).


SET

10-56



This chapter explains operation procedures for automatic registration of tool transformation value using the multifunction panel.

WARNING Because automatic tool registration is one type of teaching, operating this function is limited only to those who have completed special training.

11.1

AUTOMATIC TOOL REGISTRATION FUNCTION - OVERVIEW.......................11-2

11.2

REQUIRED DATA FOR AUTOMATIC TOOL REGISTRATION .........................11-3

11.3

TEACHING FOR 4 BASIC POINTS....................................................................11-3

11.3.1 TEACHING TOOL POSTURE FOR TOOL Z DIRECTION .................................11-4 11.3.2 TEACHING TOOL POSTURE FOR TOOL Y DIRECTION. ................................11-4 11.4

CAUTIONS FOR TEACHING BASIC POINTS ...................................................11-5

11.4.1 METHOD FOR TEACHING POINTS B, C (EXAMPLE) ......................................11-6 11.5

OPERATION METHOD .....................................................................................11-7

11.5.1 PREPARATIONS FOR AUTOMATIC TOOL REGISTRATION...........................11-7 11.5.2 REGISTERING BASIC POINT DATA.................................................................11-8 11.5.3 REGISTERING MEASUREMENT VALUES .......................................................11-9

11-1


11

AUTOMATIC TOOL REGISTRATION (OPTION)

11.1

11. Automatic Tool Registration (Option)

AUTOMATIC TOOL REGISTRATION FUNCTION - OVERVIEW

A variety of tools of different shapes (gun, hand, etc.) can be mounted on the wrist flange when operating the robot. If the tool transformation value is not set correctly at this time, the robot motion path may be affected and there is a possibility of any errors or malfunctions will become larger through off-line transformation. In other words, the tool transformation value is essential for operating the robot correctly. In general, the data values are input by keyboard and registered, but accurate setting of the tool length and posture may require the long time. This function makes it possible to automatically register the values by measuring the tool currently in use by the robot without entering the values by key. In this way, the time taken for accurate measurement of the tool becomes unnecessary.

11-2



11.2


REQUIRED DATA FOR AUTOMATIC TOOL REGISTRATION

When using the auto tool registration function, the following set of measurement data is required depending on the shape of the tool and mounting condition.

Tool length based on tool x, y, z directions only Teaching point consists of four points, A1, A2, A3, A4.

Tool Transformation value

Tool length + tool posture (angle degrees for O, A, T). Teaching point consists of six points, A1, A2, A3, A4; B and C.

11.3

TEACHING FOR 4 BASIC POINTS

As shown below, take the posture for the four basic points (A1, A2, A3, A4) so that the angles between each point are within the range of 45° to 90°. When teaching 4 basic points, each wrist flange face should not have an identical plane. Teach while the tool tip point and the measuring jig origin point are in contact with each other.

Teach point A1

Teach point A2

Teach point A3

Teach point A4 origin Measuring Jig

11-3




11.3.1 TEACHING TOOL POSTURE FOR TOOL Z DIRECTION When creating the teach data for point B, execute teaching as if there is contact made between the measuring jig origin point and a position 100mm or more away from the tool tip in the tool’s z direction through the tool tip.

Teach point B

100mm or more

Origin Tool Z direction Measuring Jig

11.3.2 TEACHING TOOL POSTURE FOR TOOL Y DIRECTION. When creating the teach data for point C, execute teaching as if there is contact made between the measuring jig origin point and a position 100mm or more away from the tool tip in the tool’s y direction through the tool tip. Teach point C 100mm or more Origin

Tool Y direction

Measuring Jig

11-4



11.4


CAUTIONS FOR TEACHING BASIC POINTS

The purpose of the tool automatic registration function is to automate to register the tool transformation value. When teaching, pay attention to the followings below. If not, errors in the tool transformation values may increase. 1.

The angles between tools at each point A1, A2, A3, A4 must be within the range of 45° to 90° as shown in the below figure. Teach point A2

Teach point A3

Teach point A1

Teach point A4 Origin Measuring Jig

2.

Between the origin point and tool tip point at teach point B, C the distance must be 100mm or more. Moreover, teach points B, C must not be set at the same position. (Results in error.)

Teach point C

Teach point B

100mm or more 100mm or more

Origin origin

Tool Z direction Measuring Jig

Measuring Jig

Tool Y direction

When teaching points A1, A2, A3, A4, B, C, take note that if the data for 2 or more points is the same, an error may occur.

11-5




11.4.1 METHOD FOR TEACHING POINTS B, C (EXAMPLE)

Y

A2

A3

Point C

A4 X

A1

Point B

Z

· Teach point A3 to run parallel with the base Y-axis coordinates. · Teach point A4 to run parallel with the base X-axis coordinates

Ø

Ø

Teaching Point B · Teach Point B by moving 100mm or more from A4 position to base coordinates +X direction (tool –z direction).

11-6

Teaching Point C · Teach Point C by moving 100mm or more from A3 position to base coordinates +Y direction (tool –y direction).



11.5


OPERATION METHOD

11.5.1 PREPARATIONS FOR AUTOMATIC TOOL REGISTRATION

MENU

· Press Menu, Function keys to display Aux. screen.

Ø FUNCTION

Ø 40 AUTO TOOL SET

Ø · Select Aux 40.

Ø · Enter tool name and type. Numbers from 1 to 9 can be assigned for tool names via Aux 48, Tool Dimensions. Also, optional names may be entered by pressing VAR NAME INPUT (F1) key to register as Aux data system data. Select type by pressing: · 0, tool dimensions only, X, Y, Z. · 1, tool dimensions, posture, X, Y, Z, O, A, T.

Ø

RETURN

11-7




11.5.2 REGISTERING BASIC POINT DATA

Display the screen for registering the basic points for each tool.

To register the basic point data, push: · 0, for tool dimensions only, A1 to A4. · 1, for tool dimensions and posture, with the addition of B and C.

Move the cursor to A1 – A4, (B, C).

Ø RT

TURN UP

LFT

TURN DWN

RECORD

Ø

d

After registration of item number X disappears.

In teaching the 4 points (A1 - A4), set each value for d within the range of 45° to 90°.

d

d

Ø F2 PRE PG

· If the basic point data is registered correctly, push F2.

Ø RETURN

11-8

· Push Record key to register all the basic point data.




11.5.3 REGISTERING MEASUREMENT VALUES Indicate the measured values and register.

Ø Confirm measured values on screen: For dimensions only, X, Y, Z. For dimensions and posture, X, Y, Z, O, A, T.

Press YES (F1) key to register the data indicated into memory. · For tool names of 1 to 9, the data are registered in 1 to 9 of Aux 48. · For tool names of other characters (abc, 1c2, etc.), the data are registered as transformation values to its variable name.

11-9



11-10


Memo

This chapter explains teaching methods and program checking methods for the conveyor synchronization function.

12.1 12.2 12.2.1 12.2.2 12.2.3 12.2.4 12.3 12.3.1

VERVIEW OF CONVEYOR SYNCHRONIZATION FUNCTION ............................... 2 PERATION OF CONVEYOR SYNCHRONIZATION FUNCTION ............................. 3 SELECTING THE CONVEYOR SYNCHRONIZATION.............................................. 3 CURRENT POSITION DISPLAY................................................................................ 4 SETTING THE DATA ..................................................................................................... 5 SETTING ENVIRONMENTAL DATA............................................................................ 7 PERATING THE SIMULATION FUNCTION .............................................................. 10 SELECTING THE SIMULATION FUNCTION............................................................ 10

12.4 TEACHING METHOD FOR CONVEYOR SYNCHRONIZATION ........................... 12 12.4.1 OVERVIEW OF TEACHING OPERATIONS THROUGH CONVEYOR SYNCHRONIZATION................................................................................................... 12 12.4.2 PREPARATOR OPERATIONS FOR TEACHING..................................................... 15 12.5 12.5.1 12.5.2 12.6 12.6.1 12.6.2 12.7

TEACHING .................................................................................................................... 16 CAUTIONS TO BE TAKEN DURING TEACHING .................................................... 16 EXAMPLES OF TEACHING........................................................................................ 16 REPEAT RUN AND PROGRAM CHECKING METHOD.......................................... 32 OVERVIEW OF CHECKING OPERATION................................................................32 FLOW OF CHECKING OPERATION AND REPEAT RUN ...................................... 33 INTERLOCK SIGNALS ................................................................................................ 37

12.8

CONVEYOR POSITION SHIFT FUNCTION ............................................................. 38 12-1


12

CONVEYOR SYNCHRONIZATION (OPTION)

12.1

12. Conveyor Synchronization (Option)

OVERVIEW OF CONVEYOR SYNCHRONIZATION FUNCTION

Normally, the robot performs operations on stationary work, but this function makes it possible for the robot to operate synchronously with the work on a moving conveyor. For this, the system services and tracks/ follows the work using all 6 axes of the robot or a traverse axis. But, since the operation range of the robot is limited, the robot may not be able to perform all operations in some situations. In these cases, the works are divided into several blocks to fit the operating range of the robot. By utilizing this method, the robot motion can be synchronized with conveyor speed in the application such as painting. The conveyor synchronization function is enabled for setting and displaying of each data after AUX. 68 CONVEYOR SYNCHRO screen is selected. The Conveyor Synchronization functions are explained below. Function No.

Function

1

Current Location Indicator

2

Data Settings

3

Setting Data

Environmental

4

Simulation

5

Conveyor Position Shift

Explanation of Function Displays the following data: current joint angle and XYZ including conveyor data, encoder value and joint angle speed. Sets the current values of the conveyor data as well as CVF_LS2 and CVF_PH2. Miscellaneous data for each conveyor type are also set. Turns On/Off conveyor simulation mode. When the simulation mode is On, the following is possible: Run/Hold of conveyor, setting/resetting of present conveyor data, setting of conveyor speed, displaying present joint angle data, as well as setting the conveyor’s maximum value. Shifts all the conveyor positions recorded in the program’s move instructions by the distance specified.

12-2



12.2


OPERATION OF CONVEYOR SYNCHRONIZATION FUNCTION

This section explains how to set each of the functions necessary for running a robot which uses the Conveyor Synchronization function.

12.2.1 SELECTING THE CONVEYOR SYNCHRONIZATION Press the Function key. FUNCTION

Ø

Auxiliary Function Menu is displayed on the screen as shown above.

Ø

6

8 RETURN

Ø

Select 68 CONVEYOR SYNCHRO.

Referring to the above figure, if the panel display shows the CONVEYOR SYNCHRO screen, it is possible to set and display various data for the conveyor synchronization function. 12-3




12.2.2 CURRENT POSITION DISPLAY While the robot system is running, or in hold, the location information for the tool tip, as well as the displacement value of each axis can be displayed on the screen. 1 Return

Select 1 Current Position from the menu.

Ø

F1

Displays present values for each joint axis. (Present joint data [deg, mm] including data for conveyor synchronization are displayed.)

F2

Displays present XYZ OAT data. (Present XYZOAT [mm, deg, mm] including data for conveyor synchronization are displayed.)

F3

Displays present joint command data. (Excludes data for conveyor synchronization.)

F4

Displays the present joint axis deviation data. (Present joint deviation data [bit] excluding conveyor data is displayed.)

F5

Displays the present encoder data. (Present encoder data for each axis [bit] including data for conveyor synchronization are displayed.)

F6

Displays present speed for each joint axis. (Present joint data [deg/sec, mm/sec] including data for conveyor synchronization are displayed.)

EXIT

The display returns to the conveyor synchronization menu.

12-4




12.2.3 SETTING THE DATA The following describes how to set the current conveyor data and the data for CVF_LS2, CVF_PH2. Select 2 DATA SET from the menu.

2 Return

Ø 0

to

9 Return

Ø

Enter numeric value in response to inquiry. For example, for inputting 10mm, press 1 0 .

Press Exit key to return to the conveyor synchronization menu. [ NOTE ] · When resetting the conveyor values, press the 0 key at the current conveyor position. · When interlock signals of CVF_LS2，CVF_PH2 are not used, setting is not required. · When CVF_LS2,CVF_PH2 are used. CVF_LS2, CVF_PH2 and PH_PULSE should be set as dedicated signals. This setting is made at the Aux. 111 and 112 screens.

12-5




How to use PH_PULSE, CVF_LS2, CVF_PH2. Referring to the figure below, when two robots are installed opposite each other on the same line, one set of phototube and LS (Limit Switch) enable both the robots to set-up work reference positions with respect to each robot. Ref. Pos. relating to No. 1 Robot No. 1 Robot Line Work

No. 2 Robot LS PH

Ref. Pos. relating to No. 2 Robot Work Reference Position

Actual phototube and LS signals (for RPS-ON) are input to the interlock panel for the No. 1 Robot. But, for the interlock panel of No. 2 Robot, after actual phototube signal (PH-Pulse) has been input, virtual phototube signal (CVF-PH2) and LS signal (CVF-LS2) can be output from the No. 1 Robot based on the distance between both the reference positions. The signal time chart is shown below.

PH_PULSE (Input)

X CVF_LS2 (Output)

Y

CVF_PH2(Output）

[ NOTE ] Referring to the above figure, X and Y represent the distance from the actual phototube. Unit (mm)

12-6




12.2.4 SETTING ENVIRONMENTAL DATA Set up miscellaneous environmental data for the conveyor. Select 3 SET ENVIRONMENT DATA SET from the menu.

3 RETURN

Ø

Press Exit key to return to the CONVEYOR SYNCHRO menu.

12-7




1.

Work pitch. Set up a distance from the front edge of a work conveyed on the conveyor line to the front edge of the next work. This is for preventing the phototube from issuing an erroneous signal (a reset signal for the conveyor position) by checking the distance between works. At the input of the phototube signal, if the conveyor present value is smaller than the set distance, a message, Work pitch abnormal, is displayed. Only input from the phototube is valid.

2.

Gain For Conveyor Speed Bias. Normally, the robot is so designed to move with a delay in relation to the work moving on the conveyor. Therefore, it is necessary to set up the gain so as to compensate for the delay time of the robot with respect to the conveyor. The standard value is set to 50%, and as a rule, no change is required.

Gain Value Delaying Amount

Range of Gain Value Change Small (0) (50%) Large (100%) (*) Large

Small

(*) Up to 200 may be entered, depending on software versions.

！

CAUTION

When increasing the gain value, be careful that if the conveyor speed fluctuations are excessively large, the robot motion will lack stability and become shaky.

3.

Conveyor scale. Set the conveyor moving distance at 1-bit of conveyor encoder count, in mm/bit units.

4.

Conveyor Maximum Speed. When the conveyor pulsation is vigorous, and the speed variation becomes large, the robot motion is affected and there may be shaking. In these instances, the sudden speed fluctuations can be suppressed by setting a maximum speed for the conveyor. This function is effective in correcting the conveyor speed. But, it does not influence the present value of conveyor encoder. The max. conveyor speed should be set at approx. twice the average conveyor speed, using 200mm/sec. is set as the standard speed.

5.

Conveyor Maximum Position. This function enables an error message to be displayed on screen and cut off the motor power if the conveyor value at steps in which conveyor synchronization has been taught. 12-8




[ NOTE ] · When the conveyor max. value is set to zero (0) mm, this function is inoperable. The initial value setting is (0). · Even if the system has been initialized, the conveyer maximum value will not change. · If the value for the conveyor exceeds the set maximum value during operation, then the following error message is displayed, Error (-1700) Conveyor passed the limit.

6.

Ineffective pitch. After the conveyor present value has been reset by RPS-ON input, the next RPS-ON input will be invalid until the conveyor moves by designated distance of invalid pitch. When repeating operations for a work on twin hanger conveyor executing a single program, RPS-ON may be input twice per a work. This function can be used to avoid false reset of the conveyor position value. If the RPS input is required to be valid at all times, set zero (0) as the value.

7.

Line increase direction. The positive direction of robot X/Y axis can be set to either conveyor advancing direction or the reverse direction.

8.

Conveyor Increase Direction. The direction in which the conveyor encoder value increases can be set to either the conveyor advance direction or reversing direction.

！

CAUTION

In addition to the above environmental data settings, be sure to set the actual conveyor speed via AS language monitor command, CVSPEED.

12-9



12.3


OPERATING THE SIMULATION FUNCTION

The simulation function can confirm operation of Conveyor Synchronization through operation of the robot without actually running the conveyer. In other words, simulation makes it possible to examine robot operations in relation to the moving conveyor even if a conveyor is not moving. The robot is not equipped with a conveyor encoder or the conveyor is not moving without any work. (Dummy conveyor moves in the controller.). For example, the simulator can check whether or not any sudden change occurs in the taught wrist posture during operation. In addition, this function can be used for the purpose of checking whether or not a particular operation can be executed within the robot motion range.

12.3.1 SELECTING THE SIMULATION FUNCTION Select 4 Simulation from the menu.

4 RECORD

Ø

As shown in the figure above, the simulation menu is shown on screen.

12-10



1.


Conveyor Simulator Effect/Ineffect. Set to a state where the robot Conveyor Synchronization function can be confirmed in the off-line condition. In other words, switch the conveyor encoder data to either effective or ineffective without energizing the conveyor.

！

CAUTION

If the simulation mode has been changed over from SIMULATION OFF (INEFFECT) to SIMULATION ON (EFFECT), the present data of the conveyor encoder is set to zero (0).

2.

Conveyor Run/Hold. When you set the simulation mode to Effect, the dummy conveyor is activated and the conveyor data increases. This function makes it possible to increase or hold the conveyor data at the same value.

3.

Conveyor Speed. It is also possible to set the conveyor speed in simulation mode.

4.

Conveyor Maximum Position While the dummy conveyor is running in the simulation mode, conveyor data might be increased abnormally, resulting in an error of out of range. In order to prevent this error, you can set up the conveyor maximum position. If the conveyor data has exceeded the set maximum value, the robot will stop immediately.

12-11



12.4


TEACHING METHOD FOR CONVEYOR SYNCHRONIZATION

12.4.1 OVERVIEW OF TEACHING OPERATIONS THROUGH CONVEYOR SYNCHRONIZATION In order to run a robot to track the moving conveyor, the system configuration below is necessary.

Controller Section Robot Body

Interlock Box

Phototube Limit Switch

Conveyor

12-12

Conveyor Encoder




The example below demonstrates the operation procedures in teaching for a painting process application, using the Conveyor Synchronization function.

Direction of increase for X axis conveyor encoder.

Y axis

Conveyor Advancing Block 2

Block 1 Direction Work

Work

Painted portion of work Block 2

Block

Taught Point 1

Block 1

2

Block 2

3 4 5 5 6 7 8 9

Block 1

Detail of Teaching Move gun just above coating start point on block 1 (stand-by home position). Set the start of the Conveyor Synchronization for block 1. Set Spray No. 1 ON, move gun tip to block 1 coating start point. Set Spray No. 1 OFF and conveyor synchronization is complete. Move gun tip 1 to the clearance position of block one. Again, move the gun tip to the stand-by home position. Set the start of the Conveyor Synchronization for block 2. Set Spray No. 1 ON, move gun tip to block 2 coating start point. Set Spray No. 1 OFF and conveyor synchronization is complete. Move gun tip 2 to the clearance position of block 2. Again, move the gun tip to the stand-by home position.

12-13




Conditions for Teaching The work is detected using a limit switch and phototube installed at the conveyor start point. After the limit switch and phototube signals are processed in the interlock panel, then enter the signals to the robot as RPS ON signals. Composing the Program Sheet

Block

Step Number 1 2

Teaching Point (No.)

1

3

Block 1

4 5 6 7 8 9 10

2

3

11 12 13

4 5

14

Block 2

15 16 17 18

6 7

19 20 21 22

8 9

12-14

Instruction PROGRAM NAME＝pg10 AIRCUT JSPEED 50% JMOVE (JOINT) CONVEYOR SYNCHRONIZATION ON AIRCUT SPEED 1500mm/sec LMOVE (XYZ1) FLOW_RATE 1 SPRAY1ON SPRAY SPEED 800mm/sec LMOVE (XYZ1) SPRAY1 OFF CONVEYOR SYNCHRONIZATION OFF LMOVE (XYZ1) JMOVE (JOINT) CONVEYOR SYNCHRONIZATION ON LMOVE (XYZ1) SPRAY1 ON LMOVE (XYZ1) SPRAY1 OFF CONVEYOR SYNCHRONIZATION OFF LMOVE (XYZ1) JMOVE (JOINT) PROGRAM END




12.4.2 PREPARATORY OPERATIONS FOR TEACHING When using the conveyor synchronization function, it is necessary for the robot to complete the specified operation of each block following along with the moving conveyor. In other words, by entering the synchronization zone for the respective blocks, set up the allowable range of work positions within which the robot can complete specified operations.

CAUTION When setting synchronization zone, ensure the following conditions. 1. Even if the conveyor moves at maximum speed without any pause in process, the task should be completed. 2. Even if the work stops at any place in the specified synchronization zone, the same block operations should be completed.

Setting the Conveyor Synchronization Function According to this teaching example, set the conveyor synchronization function as follows: 1.

Setting of Work pitch: (Example) Set the Work pitch to 1,000mm.

2.

Setting of conveyor encoder resolution scale: (Example) Set the resolution to be 0.5mm/bit. (Standard)

3.

Setting of conveyor encoder increase direction: (Example) Set the same direction.

4.

Setting of robot’s X-axis direction: (Example) Set the same direction.

5.

Setting of Gain for conveyor speed bias: (Example) Set at 50%. (Standard)

12-15



12.5


TEACHING

12.5.1 CAUTIONS TO BE TAKEN DURING TEACHING It is essential to take note of the motion range of the robot when teaching steps using the Conveyor Synchronization function. 1.

For the Conveyor Synchronization function, take note as there may occur an error out of range during the repeat run because the work positional relationship between the work and the robot is different in teaching and repeating.

2.

For determining the robot motion range, first, confirm the movement of the traverse axis. Next, examine the setting for the synchronization zone and the conveyor speed, etc.

12.5.2 EXAMPLES OF TEACHING The following demonstrates program teaching for setting up a coating process on works divided into two blocks, incorporating the conveyor synchronization function. In preparation of the teaching work, a new coating program PG10 and tool transformation value in compliance with the gun shape are registered. In addition, it is assumed that the teach mode has been selected. On the following pages the teaching steps of actual coating applications are given and explained in examples.

12-16




Teaching for point 1

Phototube

Limit Switch

Block 2

Block 1

Work

Execute teaching so that point 1 does not interfere with other work. Switch ON the phototube signals at the front edge of Block 1, then reset the conveyor encoder value. Verify that the value of the conveyor encoder is reset. SPEND

Ø １

6

Ø

Ø Confirm that the current conveyor position is zero.

Ø SPEND

After confirmation, press SUSPEND key

Ø Press,

Shift

and

CRCT

keys on the teach pendant at the same time to toggle the correction mode to ADD (insert).

Ø Then press

Set

to move to the Step Menu

12-17




Ø

Press

Move the cursor to 0 Speed.

or

Press the Set key.

Set

Ø

Ø Move the cursor to, 3 Aircut Jspeed. or Press the Set key.

Set

Ø

Ø Set

Ø

Ø

12-18

Enter the Aircut speed value. Press the Set key to enter the instruction into the program.




RT

FRNT

UP

LFT

BCK

DWN

Move the robot to step 2 by the Axis keys while pressing the Trigger switch on the backside of the Teach Pendant. The robot will not move without holding the trigger switch.

Ø L C J

Set Interpolation mode to Joint (J).

MOTION

Ø

Ø STORE

Record Step 2 by pressing STORE POS.

POS

Ø

Ø Go to the instruction selection menu by pressing the SET key.

Set

Ø

Ø or

Move the cursor to, 9 Conveyor. Press the Set key.

Set

Ø

12-19




Ø or

Move the cursor to, 0 Track On, press the Set key.

Set

Ø

Ø Go to the command selection menu by pressing the Set key.

Set

Ø

Ø Set

or

Move the cursor to, 0 Speed. Press the Set key to.

Ø

Ø Move the cursor to, 1 Aircut Speed.

or

Ø

Ø Set

12-20

Enter Aircut Speed value. Press Set key.




Teaching for point 2 Ph ot otu b e

Li mit

Block 2

Block 1

Wo rk

Activate the conveyor to move the work into position where the coating of Block 1 begins. Coating is done from the taught point for Block 1, to the work on the conveyor by means of the conveyor synchronization function. H M L

Set the RMT SPEED to high (H).

RMT SPEED

Ø

Ø FRAME

Set the coordinates for manual operation to EASY

Ø

Ø RT

FRNT

UP

LFT

BCK

DWN

Ø

12-21

Move the robot to step 4 by the axis keys while holding down the trigger switch on the back side of the teach pendant. The robot will not move without pressing the trigger.



12. Conveyor Synchronization (Option) L C J

Set the Interpolation Mode to Linear (L).

MOTION

Ø

Ø STORE

Record Step 5 by pressing the STORE POS.

POS

Ø

Ø Go to the instruction selection menu by pressing the Set key.

Set

Ø

Ø or Set

Move the cursor to, 2 External Output. Press the Set key to store.

Ø

Ø or

12-22

Move the cursor to, 1 Spray.



12. Conveyor Synchronization (Option) Set

Press the Set key to store.

Ø

Ø to

Enter the level of flow rate. Press the Set key to store.

Set

Ø

Ø Move to Instruction selection menue by pressing the Set key.

Set

Ø

Ø or

Move the cursor to, 1 Spray.

Press the Set key to store.

Set

Ø

Ø or

12-23

Move the cursor to, 0 Spray 1.



12. Conveyor Synchronization (Option) Press the Set key to store.

Set

Ø

Ø or

Move the cursor to, #1, ON. Select SPRAY ON. Press the Set key.

Set

Ø

Ø Go to the instrution selection menu by pressing the Set key.

Set

Ø

Ø or Set

Move the cursor to, 0 Speed.

Press the Set key.

Ø

Ø or

Ø 12-24

Move the cursor to, 0 Spray Speed.




Ø

Enter the spray speed value. Set

Press Set key to store.

12-25





Block 1

Block 2 Work

Activate the conveyor. Move the work to the point where the coating is complete for Block 1. This teaching point is the coating completion point.

！

CAUTION

In conveyor synchronization, when the robot tracks the moving work, teaching should be made so that compensation motion can be made for maintaining a constant wrist posture. Without being able to make compensation motion, there may be sudden changes in wrist axis posture during repeat mode, resulting in an interruption of the robot motion per code, Command position of jt x has suddenly changed. Therefore, examine the way in which the gun is installed so that coating can be performed without the trouble. In case a particular posture is required for the application, move the wrist axis step be step slowly and teach the posture so that any sudden changes are prevented. H M L

Set the speed level to medium (M).

RMT SPEED

Ø

Ø FRAME

Ø

12-26

Set the coordinates system to Easy.




Ø RT

FRNT

UP

LFT

BCK

DWN

Move the robot to Step 8 by the axis keys while pressing down the trigger switch on the back of the teach pendant. The robot will not move without holding the trigger switch.

Ø L C J

Set the Interpolation Mode to Linear, (L).

MOTION

Ø

Ø STORE

Press the Store Pos key to record Step 9.

POS

Ø

Ø Press 1 to move to the spray instruction selection screen.

Ø

Ø or Set

Move the cursor and select, 0 Spray 1. Press the Set key.

Ø

12-27




Ø or

Move the cursor to, 0 OFF. Press the Set key.

Set

Ø

Ø Press the Set key to move to the Instruction Selection Menu.

Set

Ø

Ø or


Set

Ø

Ø or

Move the cursor to, 1 Track Off. Press the Set key.

Set

Ø

12-28



Teaching for point


4

Block 2 Block 1 Work

Do not activate the conveyor at this teaching point. At this teaching point, the arm is moved once to the withdrawal position while synchronizing with the conveyor. RT

FRNT

UP

LFT

BCK

DWN

Ø L C J


Set Interpolation Mode to Linear (L).

MOTION

Ø STORE POS

Ø

12-29

Press the Store Pos key to record step 12.





Block 2 Block 1

Work

As shown above, move the gun tip to the stand-by position for Block 2 with the axis keys. At this teaching step, set the path of the robot, and there is no need for accurate positioning. RT

FRNT

UP

LFT

BCK

DWN

Ø L C J


Set the Interpolation Mode to Joint (J).

MOTION

Ø STORE

Press the Store Pos key to record Step 13

POS

Ø

Ø Press the Set key to move to the instruction selection menu.

Set

Ø

12-30




Ø or Set


Ø or

Move the cursor to, 0 Track On. Press the Set key.

Set

Perform Teaching for points 6, 7, 8 and 9 via the same operations up to this point.

12-31



12.6


REPEAT RUN AND PROGRAM CHECKING METHOD

12.6.1 OVERVIEW OF CHECKING OPERATION In order to check the operation and the contents of a program, the Check Mode is provided. The programs taught in the prior section, 12.5 Teaching, are checked so as to verify that the programs are running correctly. Flows of checking a taught program

Program check on Block 1 (Spray disabled)

Program check on Block 2 (Spray disabled)

Confirmation of Block 1 by Repeat Run (Spray disabled)

Confirmation of Block 2 by Repeat Run (Spray disabled)

Confirmation of connection between blocks

Confirmation of entire program by Repeat run (Spray disabled)

12-32




12.6.2 FLOW OF CHECKING OPERATION AND REPEAT RUN Checking of program End of teaching operation

Ø Conveyor is being held and not moving. In Check Mode, spray automatically disabled.

Ø The first step of each block is displayed. STEP

FIRST STEP

Ø While holding down the trigger switch on the teach pendant, press the STEP NEXT key. Robot arm moves to next step and stops. STEP NEXT

Ø Is the taught point OK? No

Ø Yes

No Press the Exit key to exit from Check Mode. Modify the program.

Ö

Is this the last step in the block?

Ø Yes Check Complete

Check the robot operations for each block in the order outlined above.

12-33




Confirmation in Repeat Run Verify that the following items are set up. 1. 2. 3. 4. 5. 6.

Encoder increase direction Line increase direction Conveyor maximum speed Conveyor scale Setting of work pitch Setting of present conveyor data

Confirm that conveyor is on hold and stopped. Switch to repeat mode. Set the repeat speed to low.

Ø Repeat run start

Ø Is the speed set by the program?

No

ØYes Is robot operating as per taught step?

No

ØYes Move conveyor without the work.

Ø Redo the repeat run at the speed specified in the program.

Ø Is robot operating as per taught step?

No

ØYes Repeat run by actually conveying the work.

Ø

No

Is robot operating as per taught step?

ØYes Terminate the per block repeat run.

12-34

Ö

Modify the taught program.




Confirmation of connection between blocks Confirm that the conveyor is on hold and stopped

Ø Move the work until it exceeds the value set as the lower limit (100 mm or more) for coating Block 1.

Ø Display the first step of Block 1 (Step:1).

Ø Enter into Check Mode.

Ø Move the work to the final step of Block 1.

Ø While pressing down the trigger switch on the Teach Pendant, activate the conveyor.

Ø Move the work until it exceeds the value set as the lower limit (500 mm or more) for coating Block 2.

Ø Is the robot set in a synchronization No Repeat the test, and make Ö any program modifications. standby condition?

ØYes Terminate the confirmation of connection between blocks.

12-35




Confirmation by repeat run on overall program

First, actovate the conveyor. Switch to repeat mode. Put the work on the conveyor.

Ø Execute actual spraying and confirm the No Modify the taught program. coating conditions as passing quality standards. Ö

ØYes Terminate the checking of all programs.

12-36



12.7


INTERLOCK SIGNALS

For the conveyor synchronization functions programs can be selected by RPS-ON signals to the robot. Simultaneously, the required conveyor data is reset. A connection example is shown below. (No phototube is used.)

RPS-ON

SL signal

Limit Switch

Interlock Panel

！

Robot Controller

CAUTION

Program selection is effective only when the RPS-ST signal is being output. (Refer to: External I/O Signal Manual.) But, resetting conveyor data is effective at all times.

12-37



12.8


CONVEYOR POSITION SHIFT FUNCTION

When teaching programs with conveyor synchronization, current conveyor positions at time of teaching are recorded with the move instructions. If the conveyor origin is changed after the teaching, the conveyor positions recorded in the move instructions of the program require changing. In this case, the “Conveyor Position Shift” function enables conveyor positions uniform changing of the program by the distance specified. Example) After teaching current conveyor position to be 1000mm, the conveyor origin shifts 1000mm downstream. By shifting the conveyor position 1000mm with the conveyor position shift function, the conveyor positions recorded in the program’s move instruction are rewritten to 2000mm.

Set

Selects 2 DATA SET from menu.

Ø

Items

Descriptions

Program Name

Designate the program name (No.) for conveyor position shift.

Key

Start Step End Step

Set first step No. to be applied with shift amount. Numeric key Set last step No. to be applied with shift amount. Numeric key Shift amount for conveyor axis shift Numeric key C/V Shift Value Unit: mm * For designations of “Start Step No.” and “End Step No.”, see notes in “A-6 Mirror conversion” Pressing EXIT key on the screen, returns the screen to “conveyor synchronization” menu, Aux. 68.

12-38



This chapter explains the method for setting the switches and lamps used as the interface panel.

WARNING Because setting the interface panel is one type of teaching, operation of this function is limited only to those who have completed special training in its use.

13.1

OVERVIEW OF THE INTERFACE PANEL .......................................................13-2

13.2 13.3 13.4 13.4.1 13.4.2 13.4.3 13.4.4 13.4.5 13.4.6 13.4.7 13.4.8 13.4.9 13.4.10

PROCESSING SEQUENCE ON INTERFACE PANEL .....................................13-3 SELECTING THE INTERFACE PANEL SCREEN ............................................13-4 METHODS FOR SETTING INTERFACE PANEL..............................................13-5 SWITCH SETUP ................................................................................................13-5 PUSH BUTTON SETUP.....................................................................................13-6 PUSH BUTTON WITH LAMP - SWITCH SETUP ..............................................13-7 2-NOTCH SELECTOR SWITCH SETUP...........................................................13-8 3-NOTCH SELECTOR – SWITCH SETUP........................................................13-9 PILOT LAMP – SETUP ....................................................................................13-10 DIGITAL SWITCH - SETUP .............................................................................13-11 DIGITAL DISPLAY – SETUP ...........................................................................13-12 TEXT WINDOW – SETUP (OPTION) ..............................................................13-13 SOFTWARE DEDICATED SIGNALS ..............................................................13-14

13-1


13

INTERFACE PANEL SETTING (OPTION)

13.1

13. Interface Panel Settings (Option)

OVERVIEW OF THE INTERFACE PANEL

Typically, an operation panel (interlock panel) equipped with a variety of switches and lamps is used for interfacing the robot with the peripheral equipment. For the C Series Controller, it is possible to setup an interface panel to correspond to the interlock panel in the multi-function panel display. The interface panel elements can be arranged in a variety of ways. The types of elements include: switches, lamps, digital displays and settings. 1. Setup Using Auxiliary Function The interface panel can be setup using Auxiliary function 131. 2. The interface panel can also be setup, using a personal computer, by downloading the interface panel configuration file to the personal computer, editing this file, and then uploading this file to the controller. To select the file to be loaded or saved, perform the following: (xxxxxx is the file name) LOAD xxxxxx.if, when loading the file with the data into memory. SAVE/if xxxxxx, when saving to the disk file. The following is an example of an interface panel program, also refer to screen shown in 13.3, Selecting the Interface Panel Screen

Specify the data in the following order. The display position parameter (1-64), type code (0-7), data details (in the same order as the screen setting), and the selection item shows that the following is selected. 0 : right side -1 : left side 13-2



13.2


PROCESSING SEQUENCE ON INTERFACE PANEL

Create the sequence logic for the interface panel using AS language, and execute it with the PC program. Type Signal An internal signal (2001-2256 or 2512) or the output Switch signal (one-number of I/O) is turned on and off. Refer to internal signals (2001-2256 or 2512), the output signal (one-number of I/O), and the input signal Lamp Display (1001-number of I/O). Limitation, I/O signals exceeding 192 cannot be assigned. Dedicated Signal This can also be assigned to an internal signal (2001-2256 (cycle start, etc.) or 2512). Use the signal numbers above when setting up the interface panel. (Moreover, use the mounted signals.) Ensure that duplicate signal numbers are not used when setting up switches for the interface panel. If duplicate signal numbers are used, an error will occur.

Interface Panel

Output Signal (1-Number of I/O)

Peripheral

Input Signal (1001-Number of I/O)

PC program

Internal Signal (2001-2256/2512)

Processing Dedicated Signals [ Note ] Because the PC program is processed only at available times in the robot’s operations, there is a limit on the speed at which signals can be executed.

13-3



13.3 Press


SELECTING THE INTERFACE PANEL SCREEN key on the Multi-Function panel to display the INTERFACE PANEL screen.

Status Screen

Ö

Ö MENU

Ø When this is set to INH, the operation becomes inhibited. It is not possible to operate a switch where OPERATION INHIBIT is set to YES.

Screen example, INTERFACE PANEL

Operation Inhibit is automatically set to YES when: 1) switching screens, 2) there is no operation for 5 minutes. 33-64

Ö Ｉ／Ｆ Ö arrangement Õ Ｉ／Ｆ Õ screens

(1-32 arrangement screens)

Ø WORK MODE

Ø

By pressing the WORK MODE or PROGRAM NO. keys the number representing the particular work type and the program number can be set.

Ø Õ MENU

KEYBOAR D Screen 13-4

Õ MENU



13.4


METHODS FOR SETTING INTERFACE PANEL

13.4.1 SWITCH SETUP This section describes the procedure for setting up various switches and lamps, for display on the multi-function panel screen, using auxiliary function 131. Switch, lamp or display

Press the NEXTPG (F3) key to switch to the setting screen for 33-64. Number [2] classification: indicates push button with lamp. When placing the cursor in the lower brackets, the switch and lamp types appear. Arrangement plan when indicating particular switches.

1

2

3

4

5

6

7

8

9

10 11 12 13 14 15 16

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 The switch appears at the location. As long as numbers 1-32 (64) do not overlap then the switch appearance locations can be changed. Select an item by the cursor key (right side of screen), and set the type (switch, lamp, display) and placement of the indicator by the number keys (left side of screen).

Ø PARAMETER SET

Ø Press the PARAMETER SET key to display the screen for setting up the detail information for the indicator, including: labeling, color, signal number assignment. 13-5




13.4.2 PUSH BUTTON SETUP The label name, ON/OFF indicating colors and corresponding signal numbers for the push button are set by the below steps. For example, set the

HOME

switch.

Cursor movement area

Label 1 2 Set the name for the push button. 3 Up to 10 characters per line. 4 A total of 4 lines can be indicated. Set the ON/OFF indicating colors for the switch by number. Color (See note below.) Set the signal number to be designated for the push button Signal Number switch. Set an internal signal number or an output signal number. Operation becomes possible only at the time of Operation Operate Inhibit Accept if YES is specified. If the CHARACTER (F4) key is pressed when the cursor is at the LABEL position, the KEYBOARD screen is displayed and the label name can be typed. When the cursor is at the COLOR position, the color can be assigned by pressing the number key for the desired color. When the ENTER key is pressed after the data is set, the message, Normally complete, is displayed. Pressing the EXIT key returns the display to the initial auxiliary function 131 screen. (Note) Indicating colors: a total 16 colors are available for assignment. Indicating color code 0 Ash 10 Black 1 Blue 11 Cyan The color These may not be 2 Red 12 Navy Blue sample is available depending 3 Orange 13 Red brown displayed in on the software 4 Green 14 Dark-green the numeric version. 5 Light blue 15 Light-purple key. 6 Yellow 7 White 8 Pink 9 Light-brown 13-6




13.4.3 PUSH BUTTON WITH LAMP - SWITCH SETUP The label name, ON/OFF indicating colors and corresponding signal numbers for push buttons equipped with lamps are set by the below steps. For example, set the

PALETTE EJECT

switch.


Label 1 2 Set the name for the push button. 3 Up to 10 characters per line. 4 A total of 4 lines can be indicated. Set the ON/OFF indicating colors for the switch by number. Color (See note below.) Signal Number Set the signal number to be designated for the push button (Switch) switch. Set an internal signal number or an output signal number. Operation becomes possible only at the time of Operation Operate Inhibit Accept if YES is specified. If the CHARACTER (F4) key is pressed when the cursor is at the LABEL position, the KEYBOARD screen is displayed and the label name can be typed. When the cursor is at the COLOR position, the color can be assigned by pressing the number key for the desired color. When the ENTER key is pressed after the data is set, the message, Normally complete, is displayed. Pressing the EXIT key returns the display to the initial auxiliary function 131 screen. (Note) Indicating colors: a total 16 colors are available for assignment. Indicating color code 0 Ash 10 Black 1 Blue 11 Cyan 2 Red 12 Navy Blue 3 Orange 13 Red brown The color sample is 4 Green 14 Dark-green displayed in the 5 Light blue 15 Light-purple numeric key. 6 Yellow 7 White 8 Pink 9 Light-brown 13-7

These may not be available depending on the software version.




13.4.4 2-NOTCH SELECTOR SWITCH SETUP The label name, indicating colors, corresponding signal numbers and indicating style for 2-Notch Selector Switches are set by the below steps. MODE

MAN AUTO

For example, set the switch in a Rotary style

or in an Up-Down Menu style.

MANUAL AUTOMATIC


Label 1 2 Set the name for the notch switch. 3 Up to 10 characters per line. 4 A total of 4 lines can be indicated. Color Set the indicating color for each notch of the switch by number. Signal Number Set a signal number to be designated for each switch position. (Switch) Set an internal signal number or an output signal number. Up-Down: example, the mode switches between automatic ↔ manual. Display Type Rotary: example, the mode switches MAN/MANUAL by rotation Operation becomes possible only at the time of Operation Operate Inhibit Accept if YES is specified. If the CHARACTER (F4) key is pressed when the cursor is at the LABEL position, the KEYBOARD screen is displayed and the label name can be typed. When the cursor is at the COLOR position, the color can be assigned by pressing the number key for the desired color. When the ENTER key is pressed after the data is set, the message, Normally complete, is displayed. Pressing the EXIT key returns the display to the initial auxiliary function 131 screen.

13-8




13.4.5 3-NOTCH SELECTOR – SWITCH SETUP The label name, indicating colors, corresponding signal numbers and indicating style for 3-Notch Selector Switches are set by the below steps. OFF

MODE

OFF-LINE AUTO

or in an Up-Down Menu style

For example, set the switch in a Rotary style,

OFF OFF-LINE AUTO

.

Ｆ３

Ö

NEXT PG

Ö

Cursor Selections

F2

Õ

PRE PG

Õ

Label 1 2 Set the name for the 3-notch switch. 3 Up to 10 characters per line. 4 A total of 4 lines can be indicated. Set the indicating color for each notch of the switch by Color number. Signal Number Set a signal number to be designated for each switch position. (Switch) Set an internal signal number or an output signal number. Rotary or Up-Down types for switching among: Display Type Off - Offline - Auto Operation becomes possible only at the time of Operation Operate Inhibit Accept if YES is specified. If the CHARACTER (F4) key is pressed when the cursor is at the LABEL position, the KEYBOARD screen is displayed and the label name can be typed. When the cursor is at the COLOR position, the color can be assigned by pressing the number key for the desired color. When the ENTER key is pressed after the data is set, the message, Normally complete, is displayed. Pressing the EXIT key returns the display to the initial auxiliary function 131 screen.

13-9




13.4.6 PILOT LAMP - SETUP The round lamp label name, ON/OFF indicating colors, and corresponding signal numbers are set by the below steps. ENABLE

For example, set the enable switch.

Cursor Movement Area

Label 1 2 Set the name for the 3-notch switch. 3 Up to 10 characters per line. 4 A total of 4 lines can be indicated. Color Set the color for indicating ON/OFF by number. Set a signal number to be designated for when the lamp is ON. Number (Lamp) Set an internal signal number or an output signal number. If the CHARACTER (F4) key is pressed when the cursor is at the LABEL position, the KEYBOARD screen is displayed and the label name can be typed. When the cursor is at the COLOR position, the color can be assigned by pressing the number key for the desired color. When the ENTER key is pressed after the data is set, the message, Normally complete, is displayed. Pressing the EXIT key returns the display to the initial auxiliary function 131 screen.

13-10




13.4.7 DIGITAL SWITCH - SETUP The digital switch label name, the number of signals and the signal numbers corresponding to the start point (TOP SIGNAL) are set by the below steps. For example, set the work type switch.

WORK TYPE


Set the name for the switch. Label 1 Up to 10 characters per line. 2 A total of 2 lines can be indicated. Figures Set the number of digits to be displayed (1 to 4) Ten Key: Input directly with number keys Push switch: Increases incrementally when pressed, returns to Input Data a minimum value when the maximum value is reached. Yes: The range of input data is limited. Limit Data No: The range of input data is unlimited. Set the first signal number Top Signal No. (Use either internal signal number or output signal number.) Number Of Set the number of consecutive signals, including the top Signals To Use signal number for use on the digital switch. BCD: Binary Coded Decimal Signal Type Binary: Binary Upper Limit/ Specify the maximum/minimum value which can be set. Lower Limit Operation becomes possible only at the time of Operation Operate Inhibit Accept if YES is specified. If the CHARACTER (F4) key is pressed when the cursor is at the LABEL position, the KEYBOARD screen is displayed and the label name can be typed. When the ENTER key is pressed after the data is set, the message, Normally complete, is displayed. Pressing the EXIT key returns the initial display to the auxiliary function 131 screen. 13-11




13.4.8 DIGITAL DISPLAY - SETUP The digital display label name, the digits, the number of signals and the signal numbers corresponding to the start point (TOP SIGNAL) are set by the below steps. For example, set the Program No. switch.

PROGRAM NO.


Set the name for the digital display switch. Label 1 Up to 10 characters per line. 2 A total of 2 lines can be indicated. Figures Specify the number of digits to be displayed Set the first signal number Top Signal No. (Use either internal signal number or output signal number.) Number of Set the number of consecutive signals, including the top signal Signals to Use number for use on the digital switch. BCD: Binary Coded Decimal Signal Type Binary: Binary If the CHARACTER (F4) key is pressed when the cursor is at the LABEL position, the KEYBOARD screen is displayed and the label name can be typed. When the ENTER key is pressed after the data is set, the message, Normally complete, is displayed. Pressing the EXIT key returns the display to the initial auxiliary function 131 screen.

13-12




13.4.9 TEXT WINDOW - SETUP (OPTION) The character can be displayed in a specified window of the Aux. 131 Interface Panel screen.

Window Number Window Size

Assign a display window number (1-4) using the AS language command/instruction IFPWPRINT. See, AS Language Manual, for more details. Specify the size occupied with right horizontal direction by each standard size of the switch, (1-4). There is an input error when there is no size for the input size. (The character protrudes./ The character has already been set by another.)

Default Back When not selected by AS language, the color defaults to white. Ground Color Some items may not be available depending on the software version. In the arrangement setup screen (see 13.4.1, Switch Setup.), display the desired character (e.g. “-“), in the type column of the area occupied by TEXT WINDOW, so that other types cannot be set. When the ENTER key is pressed after the data is set, the message, Normally complete, is displayed. Pressing the EXIT key returns the display to the initial auxiliary function 131 screen. [Reference] IFPWPRINT Window No., Display line, Display figures, Character color, Back Ground Color = “Character”, “Character”, “Character”, “Character” Explanation Window No. Display line. Display figures Character color. Back Ground color. “Character”

Designates the window number specified in Aux. 131. for display. Displays the character in the specified window. Displays the digits in the specified window. Designates the color of the character for display. Specifies background color. Specifies the character to be shown. Characters from the second item onward appear from a specified place on the next line. 13-13




13.4.10 SOFTWARE DEDICATED SIGNALS It is possible to display the Interface Panel screen automatically by using an External Input Signal. The External Input Signal can be set by the DEFSIG INPUT command or through the Aux. 111 screen. - Selecting page one of I/F panel. - Selecting page two of I/F panel. There are two Software Dedicated Signals. By dedicating each signal, the interface page will switch whenever the signal changes between OFF and ON.

13-14



In this chapter, we explain the basic procedures for treating errors in the system. Please refer to Trouble Shooting Manual for details.

14.1 14.1.1 14.1.2

SYSTEM INITIALIZATION ................................................................................................................. 2 CALLING UP INITIALIZATION SCREEN ......................................................................................... 3 OPERATION PROCEDURE ON THE INITIALIZATION SCREEN................................................ 4

14.2

NORMAL PROCEDURE WHEN ERRORS OCCUR...................................................................... 5

14-1


14

COUNTERMEASURES FOR SYSTEM ERRORS

14.1

14. Counter Measures for System Errors

SYSTEM INITIALIZATION

！

CAUTION

System initialization should only be executed when a major error occurs or when updating system software. Initialization erases all information settings in the system.

The following screens are called Initialization Screen. Using Multifunction Panel: Displayed when the control power switch is turned on.

Choice of language may be inquired. Using Personal Computer (PC): Displayed when AS monitor software is running.

Choice of language may be inquired These screens appear only when 14.1.1 CALLING UP INITIALIZATION SCREEN process is executed. 14-2



14.1.1


CALLING UP INITIALIZATION SCREEN

！

CAUTION

Make sure to turn off the control power before switching DIP switch.

The following describes the procedures for calling up the initialization screen. Turn OFF the control power.

Connect PC, and turn the power ON.

Connect Multifunction panel.

Activate the AS monitor software in PC.

Dip switch

Turn on Dip switch No. 8 on 1HA board.

ON side

OFF side

NO.8 System Initialization switch

Turn ON the control switch.

[NOTE] Make sure to leave Dip switch No. 8 on the 1HA board OFF when the initialization screen is not needed to be called out.

14-3



14.1.2


OPERATION PROCEDURES ON THE INITIALIZATION SCREEN.

When replacing system software, there may be an inquiry of language choice. Press 0 or 1 and ENTER key according to your choice of language. · When not initializing >Initialize (YES:1, NO: 0 )?

Ø The system will start up and run without initializing when 0 and ENTER are pressed.

· When initializing > Initialize? (YES: 1, NO: 0) ?

Ø Press 1 and ENTER keys on PC. > Initialize? (YES: 1, NO:0) ? >Confirmation!> Execute (YES:1, NO:0)?

Ø

* When initializing after replacing a system software, enter 9894 for the confirmation.

When 1 and ENTER keys are pressed on PC, the system will start up and run after initialization.

Ø

Initializing Set the memory capacity. (0: 1M bit, 1:4M bit)

Ø

Normally, 0 is entered.

Ø No. = 1 Robot Name: KE610_A001 6-axes Machine No. XXXX

！

CAUTION

When initialization is executed, · All the programs are erased. · System switches are set to their initial default values. · The recorded values in auxiliary data are set to their initial default values.

14-4



14.2


NORMAL PROCEDURE WHEN ERRORS OCCUR

Error occurs

Check the error message, and remove/ fix the cause. Press Error Reset switch.

Error lamp off ?

OFF

Still ON

Check the robot and condition of the peripheral equipment, and resume operation. Cannot resume

End

Operation resumed

Press the emergency stop switch to turn off the motor power. Turn OFF the control power switch. Check the robot and the peripheral equipment, and resume operation.

Turn ON the control power switch.

Cannot resume Press the emergency stop switch to turn OFF the motor power.

Turn OFF the control power switch.

14-5

End

Operation resumed



Call up the initialization screen and run the system without initializing. Refer to 14.1.1 Calling Up Initialization Screen.


Check the robot and peripheral condition, and resume operation

End

Operation resumed

Cannot resume operation Press the emergency stop switch to turn off the motor power.

Store all the data in PC card or floppy disk.

Turn OFF the control power switch.

Call up the initialization screen and run the system without initializing,. Refer to 14.1.1 Calling up Initialization Screen.

Load all the data saved in PC card or floppy disk into the system.

Check the robot and peripheral condition and resume the operation

End

Operation resumed

Cannot resume Please consult with the Maintenance person or Kawasaki service assistance. [NOTE] Make note of all the system conditions at the time of error when consulting the Maintenance or Kawasaki service engineer. In case of a bus error, take a note of displayed data. 14-6



This section supplements useful information when using the robot.

APPENDIX 1 APPENDIX 2 APPENDIX 3 APPENDIX 4

PROGRAM SHEET ....................................................................................A-2 EXPLOSION-PROOF TEACH PENDANT MENU DIRECTORY LIST ....A-5 MULTI-FUNCTION PANEL MENU DIRECTORY LIST ..........................A-11 MULTI-FUNCTION PANEL AUXILIARY FUNCTION LIST ....................A-12

APPENDIX 5 INITIAL DATA SETTINGS........................................................................A-16 APPENDIX 6 OAT ...........................................................................................................A-18

A-1


APPENDIX

APPENDIX

APPENDIX 1

Appendix

PROGRAM SHEET

Once the contents of the robot operations have been decided, fill in the program sheet with the teaching contents and the program information.

1 SPRAY SPEED 15% 2 SMOOTH LEVEL 1mm 3 JOINT JOINT 0000 115.21 -2.85 -63.27 4 SPRAY_2 ON 5 FLOW_RATE 1 6 SHAPING/PATTERN AIR 4 7 AIR MOTOR/ATOMIZING AIR 8 SPRAY JSPEED 800mm/s 9 LINEAR XYZ1 0004 -873.4 17 -485.7 40.4

A-2



A-3

Speed Accuracy

Work

Gun 1

Gun 2

Gun 3

Gun 4

Creator

Object work Timer Tool

Creation Date

Serial No.

OX

WX

Revision

J/E Comment

Appendix


Step No. Point No. Interpo-l Point (Teach ation type point)

PROGRAM NAME

PROGRAM SHEET FOR SPRAY


A-4

Point (Teach point)

Creator

Object work Instruction

Creation Date

Serial No.

Comment

Revision

Appendix


Step

PROGRAM SHEET FOR AS TEACHING PROGRAM NAME


APPENDIX 2 0 TEACH

Appendix

EXPLOSION-PROOF TEACH PENDANT MENU DIRECTORY LIST

PROGRAM No.

DISPLAY INSTRUCTION

0 SPEED

0 SPRAY SPEED

SPEED

1 AIRCUT SPEED PRHBT

PRHBT

2 SPRAY JSPEED

INS

INS

3 AIRCUT JSPEED

CHG

CHG

4 MOVING TIME

MOVING TIME

5 PLAYBACK RATE

PLYBK RATE

0 SPRAY_1

OFF/ON

*(CRCT) DEL *(The default mode for SCH modifying program.)

1 SPRAY

(CRCT)

1 SPRAY_2 2 PRE_SPRAY(D) 3 PRE_SPRAY(T) 4 DLY_SPRAY(D) 5 DLY_SPRAY(T) 2 EXTERNAL OUTPUT

0 GENERAL EX-OUT

1 FLOW_RATE

SPRAY No./DISTANCE/SIGNAL (OFF/ON) SPRAY No. /TIME/SIGNAL(OFF/ON) SPRAY No./ DISTANCE/SIGNAL(OFF/ON) SPRAY No./ TIME/SIGNAL(OFF/ON) OUTPUTSIGNAL/ SIGNAL(OFF/ON)/ DELAY TIME LEVEL

2 SHAP/PAT AIR 3 A MOT/ATOM AIR 4 HIGH VOLTAGE 5 FLUSHING

OFF/ON

6 PUSH THINNER 7 PAINT_IO RATIO

0 FLOW_RATE RATIO

RATIO

1 PATTERN RATIO 2 ATOMIZING RATIO 3 EXTERNAL INPUT

0 INPUT WAIT

3 H_VOLTAGE RATIO INPUT SIGNAL/ 0 NONOFF/ON/ ERROR TIMEOUT 1 ERROR

1 MUTUAL WAIT 4 SMOOTH

0 ACCELERATION

ACCELATION

1 SMOOTH (LEVEL)

LEVEL

5 DATA BANK

DATA BANK No.

6 TIMER

WAIT TIME

7 CALL

PROGRAM No.

8 JUMP

0 JUMP

0 UC_JUMP

LABEL NAME

1TRUE_JUMP 2 FALSE_JUMP 3 SET LABEL 1 COMPARE

0 EQU(=) 1 NOT EQU 2 GREATER(>) 3 LESS(<) 4GREATER/EQU 5 LESS/EQU

A-5

CNT_TYP (GEN/DED) /CNT No./ COMP VALUE



0 TEACH

PROGRAM No.

DISPLAY INSTRUCTION

PRHBT

PRHBT

INS

INS

CHG

CHG

Appendix

8 JUMP

1 COMPARE

6 INPUT_SIGNAL

2 COUNTER

0 LOAD

1 ADD

* (CRCT) DEL * (The default mode for SCH modifying program.)

2 SUBTRACT

* (CRCT)

9 CONVEYOR

PORT No. / No. OF BITS / VALUE CNT_TYP (GEN/SPE) / CNT No./ VALUE CNT_TYP (GEN/SPE) / CNT No./ VALUE CNT_TYP (GEN/SPE) / CNT No./ VALUE

0 TRACK ON 1 TRACK OFF 2 CONVEYOR WAIT

A GUN CONTROL

GUN No.

B TABLE

0 TRACK ON

CONVEYOR – UPPER LIMIT CV_POS

1 TRACK OFF 2 SELF TURN 3 SELF TURN OFF 4 TABLE WAIT 5 DIRECTION 6 START_ENA C SENSING

0 DOOR SENS

0 START_DR_SENSE

LIMIT (+) / LIMIT (-)

1 DOOR COMPENSATION

0 OFF 1 ON

1 CAMERA SENS

0 CAMERA_COMPEN

0 LINEAR

0 XYZ1 (OAT)

1 START E MOVE

XYZ COORD or joint angle

1 XYZ2 (JT456) 1 JOINT 2 CIRCULAR (MID)

1 JOINT 0 XYZ1 (OAT) 1 XYZ2 (JT456)

3 CIRCULAR (END)

0 XYZ1 (OAT)

1 XYZ2 (JT456) * Depending of system configuration, traverse joint position/device (1/2)/ table (1/2) position * 10 to 13 joint names vary by system configuration

A-6



1 PLAYBACK

0 SET PLAYBACK NO. 1 DISP PLAYBK STATUS

Appendix

PROGRAM NO. /SET NO. (FROM)/(TO) PRDCT RAT/CV_SPEED/PRDCT CNT/ CV_POS/PLYBKTIME/ Disp PLYBK INSTRUCTION

2 SET PRODUCT RATE PRODUCT RATE 3 PRDCT PNTIO RATIO PRDCT FLOW RATIO/ PRDCT PTRN RATIO/ PRDCT ATOM RATIO/ PRODCT HV RATIO 2 EDIT PROGRAM

PROGRAM NO./

DISPLAY INSTRUCTION

0 SPEED

STEP NO.

0 SPRAY SPEED

SPEED

1 AIRCUT SPEED

PRHBT

PRHBT

2 SPRAY JSPEED

INS

INS

3 AIRCUT JSPEED

CHG

CHG

4 MOVING TIME

TIME

5 PLAYBACK RATE

PLYBK RATE

0 SPRAY_1

OFF/ON

(*CRCT) * The default mode of modifying program.

DEL SCH

1 SPRAY

(CRCT)

1 SPRAY_2 SPRAY NO./ DISTANC/ SIGNAL (OFF/ON) SPRAYNO./TIME/SIGNAL 3 PRE_SPRAY(T) (OFF/ON) SPRAY NO./DISTANCE/ 4 DLY_SPRAY(D) SIGNAL (OFF/ON) SPRAY NO./TIME/SIGNAL 5 DLY_SPRAY(T) (OF/ON) OUTPUT SIGNAL/ 2 EXTERNAL OUTPUT 0 GENERAL EX-OUT SIGNAL (OFF/ON)/DELAY TIME 2 PRE_SPRAY(D)

1 FLOW_RATE 2 SHAPING/ PATTERN AIR 3 AIR MOTOR/ ATOMIZING AIR

LEVEL

4 HIGH VOLTAGE 5 FLUSHING

OFF/ON

6 PUSH THINNER 7 PAINT_IO RATIO

3 EXTERNAL INPUT

0 INPUT WAIT

0 FLOW_RATE RATIO 1 PATTERN RATIO 2 ATOMIZING RATIO 3 H_VOLTAGE RATIO INPUTSIGNAL/ SIGNAL (OF/ON)/ TIMEOUT

RATIO

0 NONERROR 1 ERROR

1 INTERROCK 4SMOOTH

0 ACCEOLERATION

ACCELERATION

1 SMOOTH (LEVEL)

LEVEL

5 DATA BANK

DATA BANK NO.

6 TIMER

WAIT TIME

7 CALL

PROGRMA NO.

8 JUMP

0 JUMP

0 UC_JUMP

LABEL

1 TRUE_JUMP

NAME

2 FALSE_JUMP 3 LAVEL

A-7



2 EDIT PROGRAM

PROGRAM NO./

DISPLAY INSTRUCTION

Appendix

8 JUMP

1COMPARE

STEP NO.

0 EQU (=) 1 NOT EQU (=)

PRHBT

2 GREATER (>)

PRHBT

INS

3 LESS (<)

INS

CHG

4 GREATER/EQU (≥)

CHG

DEL

GEN/DED/ CNT NO./ VALUE

5 LESS/EQU (≤)

(*CRCT) SCH * The default mode of modifying instruction (CRCT) codes.

6INPUT_SIGNAL

2 COUNTER

0 LOAD

1 ADD

2 SUBTRACT

9 CONVEYOR

PORT NO./ NO. OF BITS/ VALUE GEN/DED/ CNT NO./ VALUE GEN/DED/ CNT NO./ VALUE GEN/DED/ CNT NO./ VALUE

0 TRACK ON 1 TRACK OFF 2 CONVEYOR WAIT

A GUN CONTROL

GUN NO.

B TABLE

0 TRACK ON

UPPER LIMIT CV_POS

1 TRACK OFF 2 SELF TURN 3 SELF TURN OFF 4 TURN WAIT 5 DIRECTION 6 START_ENA C SENSING

0 DOOR SENS

LIMIT (+)/ 0 START_DR_SENSE LIMIT (-) 1 LIMIT OF 0 OFF COMPENSATION 1 ON

1 CAMERA SENS

0 OFF 1 ON

E MOVE

0 LINEAR

0 XYZ1 (OAT) 1 XYZ 2 (JT456)

1 JOINT

1 JOINT

2 CIRCULAR (MID)

0 XYZ 1 (OAT)

XYZ COOR OR JOINT ANGLE

1 XYZ 2 (JT456) 3 CIRCULAR (END)

0 XYZ 1 (OAT)

1 XYZ 2 (JT456) * Some system configurations require to select TRAVELLER/TABLE POSITION. * The name of axes 10 to 13 changes with system configuration.

A-8



3 MANAGE PROGRAM

0 LIST

0 DETAILS

Disp PROGRAM LIST

1 PROGRAM NO.

Disp PROGRAM LIST

2 MEMORY CAPACITY

Disp MEMORY CAPACITY

2 LINK

3 NAMING SOURCE/ DESTINATION PGM NO./ OVERWRITE (NO/YES) DESTINATION/ SOURCE PGM NO.

3 DELETE

PROGRAM NO.

4 PARTIAL EDIT

0 PARTIAL COPY

1 COPY

1 PARTIAL DELETE 5 CONVERT/SHIFT

Appendix

0 PARALLEL SHIFT

PROGRAM NO.

PROGRAM NAME

(NO/YES)

DESTINATION PGM NO./ STEP NO. (INTO)

COPY (NO/YES)

COPY(NO/YES)

SOURCE PGM NO./ STEP NO.(FROM)/(TO) PROGRAM NO./ STEP NO. (FROM)/(TO) PROGRAM NO./ STEP NO. (FROM)/(TO)

1 GUN SHIFT 2 MIRROR IMAGE 3 PARALLEL & ROTATION

DELETE (NO/YES) FRONT/BACK/ LEFT/RIGH/ UP/DOWN (RBT) FRONT/BACK/,L/R UP/DOWN (TRAV) GUN SHIFT LENGTH

SEARCHING CONVERT INSTRUCTION (NO/YES)

FRONT/BACK/ LEFT/RIGHT/ UP/DOWN (RBT)

4 SHUTTLE R/L 6 AUTO PATH GEN

0 ONE WAY/TURN 1 ONE WAY/REPEAT

PROGRAM NO./ PASS PITCH/ NO. OF PASS/ STEP NO.

PATH GEN (NO/YES)

2 BOTH WAYS/TURN 3 BOTH WAYS/REPEAT 4 DATA BANK

5 DISPLAY

0 EDIT DATA BANK DATA BANK NO.

INPUT INSTRUCTION

1 LIST (DATA BANK) 0 DETAILS

DISPLAY DATA BANK LIST

0 ROBOT POSITION

STATUS

REGISTER (NO/YES)

1 DATA BANK NO.

DISPLAY DATA BANK LIST

2 DATA BANK NAMING

DATA BANK NO.

0 GUN_POS/GUN_ANGLE

DISPLAY XYZ 1 DATA (XYZOAT)

1 JOINT ANGLE 2 JOINT ANGLE INSTRUCTION VALUE

DISPLAY JOINT ANGLE (JT1-JT6)

3 ENCODER VALUE

DISPLAY ENCODER

DATA BANK NAME

NO/YES

DISPLAY JOINT ANGLE INSTRUCTION VALUE

4 TRAV POSITION

DISPLAY TRAV POSITION (XYZ)

5 TABLE POSITION

DISPLAY TABLE POSITION (SYSTEM_1/2, TABLE_1/2)

6 GUN_POS/WRST_ANGLE DISPLAY XYZ2 DATA (XYZJT456) 1 SIGNAL

2 CNT_VALUE

0 OUTPUT SIGNAL

PORT NO.

DISPLAY OUTPUT STATUS (for 6 ports)

1 INPUT SIGNAL

PORT NO.

DISPLAY INPUT STATUS (for 6 ports)

2 INTERNAL SIGNAL

INTERNAL PORT NO.

DISP INTERNAL SIGNAL STATUS (for 6 ports)

3 HOME SIGNAL

DISPLAY HOME STATUS

0 GENERAL CNT

DISPLAY COUNTER VALUE (NO. 1- 32)

1 SPECIAL CNT

DISPLAY OUNTER VALUE (NO. 1- 32)

3 SHUTTLE STATUS

A-9



6 SET CONDITION

0 PLYBK CONDITION

0 DOUT

Appendix

0 DISABLE 1 ENABLE

1 DIN WAIT

0 DISABLE

2 CV_WAIT

0 DISABLE

3 TIME WAIT

0 DISABLE

4 CV_TRACK MODEﾞ

0 REAL PULSE TRACK 1 FALSE PULSE CV_TRACK_POS TRACK

5 SENSOR

0 DOOR SENSING

1 ENABLE

1 ENABLE

1 ENABLE

0 DISABLE 1 ENABLE

1 CAMERA SEVSING

0 DISABLE 1 ENABLE

7 PRODUCT/ HISTORY 8 MANUAL EX-OUT

1 CURRENT CV_POS

CURRENT CV_POS

2 SET COUNTER

GEN/SPE/CNT NO./VALUE

0 ERROR HISTORY 1 TOTAL PLYBK COUNT

DISPLAY PGM NO.

0 GENERAL EX-OUT

OUTPUT SIGNAL/SIGNAL (OFF/ON)

1 SPRAY SIGNAL

GUN SIGNAL/SIGNAL (OFF/ON)

2 FLOW_RATE 3 SHAPING/ PATTERN AIR 4 AIR MOTOR/ ATOMIZING AIR

LEVEL

5 HIGH VOLTAGE

LEVEL

DISPLAY ERROR HISTORY DISPLAY ETAIL ERROR HISTORY DISPLAY /REWRITTEN DAILY PLYBK COUNT

LEVEL LEVEL

6 FLUSHING

OFF/ON

7 PUSH THINNER

OFF/ON

A-10



APPENDIX 3

MULTI-FUNCTION PANEL MENU DIRECTORY LIST

STATUS

STATUS

Status screen

PROGRAM LIST

Program List

MONITOR

Monitor

CURRENT POSITION

SPRAY STATUS

Current Position

Spray Status

Repeat Speed (%) Repeat Cont/Once Step Cont/Once RPS enable/disable Dry Run On/Off Wait E-STOP Motor Power Cycle Start Teach/Repeat Hold/Run Error Normal Release ext. hold Record Accept/Inhibit Step Forward Output signal Input signal Internal signal Joint Angle Value Base Coordinate Value Product Rate Conveyor Speed Conveyor Pos Production N Repeat Time

MENU

Status screen STATUS

Aux. screen FUNCTION

Setting screen for Interface Panel

Spray 1 Spray 2 Flow Rate Pattern Air Atomize Air High Voltage Flushing Push Thinner Upper Limit of Flow Rate Upper Limit of Pattern Air Upper Limit of Atomizing Air Upper Limit of High Voltage

Keyboard screen KEYBOARD

A-11

Appendix



APPENDIX 4

Appendix

MULTI-FUNCTION PANEL AUXILIARY FUNCTION LIST Function Name

A2

LOCATION & SPEED DISPLAY

A3

DATA TRANSFER

A5

KILL PROGRAM

A6

MIRROR CONVERSION (Option)

A9

DATA CONVERSION (Option)

A 10

MEMORY

PC CARD (SAVE)

A 11

PC CARD

MEMORY (LOAD)

Function Description Displays present position information in real time. Used for copying all or part of one program to another program. Removes the selected program from the stack, does not delete program. Converts programmed locations into locations with mirror symmetry with the Y and Z planes of the base coordinate system. Converts off-line data into data for use in an on-line machine. Saves data from the system memory to a SRAM PC card. Loads file information from a SRAM PC card to system memory. Displays a list of files currently on the PC card. Used to format SRAM PC card and delete files stored on SRAM PC cards. Used to register tool dimensions automatically.

A 12

FILE DIRECTORY (FDIRECTROY)

A 14

PC CARD AUX.FUNCTION

A 40

AUTO TOOL SET (Option)

A 41

ZEROING

Executes zeroing.

A 42

POSITION ERROR RANGE AT EMERGENCY STOP

A 43

ENCODER ERROR RANGE

A 44

ZEROING DATA SET DISPLAY

Sets a deviation range for error message display at emergency stop. Sets a deviation range for error message display when the controller power is applied. Allows the user to set zeroing data from the numeric key pad.

A 46


Sets up the installation posture of the robot.

A 47

BASE COORDINATES

Allows the user to set the base coordinate system at a position other than zero (in parallel or rotation movement).

A 48

TOOL DIMENSIONS

Used to set tool dimensions.

A 51

SOFTWARE LIMIT

Sets the upper and lower ranges for robot motion. (Joint Axes)

A 53

ACCURACY

Sets the accuracies for Aux. Data 1 – 4.

A 55

SLOW REPEATMODE

Sets the speed at repeat operation.

A 56

CHECK SPEED

Sets the robot speeds used when performing the check step function.

A-12



Function Name

Appendix

Function Description

A 57

TEACH SPEED

Sets the speed in teach mode

A 70

MEMORY AVAILABLE

Displays the system memory status.

A 71

RECORD DATA/INHIBIT

A 72


Prevents the recording of data if set to inhibit. Sets parameter to generate a path automatically.

A 73

SPRAY ON/OFF

Sets Spray as OK/Prohibit.

A 75

SYSTEM SWITCH

Sets various system software switches.

A 76

HOME POSITION

Set and view robot home positions.

A 77

WORK SPACE OUTPUT (Option)

A 78

CLEAR CHECK SUM ERROR

A 80

XYZ SHIFT (Option)

A 81

JOINT SHIFT (Option)

A 82

TOOL SHIFT (Option)

A 83

WORK SHIFT (Option)

A 87

PROGRAM ARGUMENT / COMMENT (Option)

A 90

SOFTWARE VERSION DISPLAY

A 91

ENVIRONMENT DATA

A 95

ENVIRONMENT DATA 2

Sets the hardware configuration.

A 96

ENVIRONMENT DATA OF PANEL

A 99

CHECK SPECIFICATION

A 100

SYSTEM INITIALIZATION

A 101

BATTERY ERROR CHECK

A 103


A 110

TIME

Used to set the type of user interface on the multi-function panel. Sets the specifications to be used during Check Mode. Program and position information is deleted; system is reset to default settings. Enables or disables the check for RAM low battery errors at power up. Displays an error message when the touch panel is pressed. Sets the date and time for the controller processor.

A 111

DEDICATED INPUT SIGNAL

Sets the top and the bottom position of the workspace. Provides a method to clear check sum errors. Used to shift programmed locations in the base coordinate system. Used to change the joint values for selected programmed points. Used to shift programmed locations in the tool coordinate system. Used to shift programmed locations in the work coordinate system. Adds a comment to the program.

A-13

Displays the version numbers of the installed system software (AS, Servo, etc.). Sets a timer to turn off servo motors automatically.

Used for setting dedicated input signals.



Function Name

Appendix

Function Description

A 112

DEDICATED OUTPUT SIGNAL

A 113

DEDICATED SIGNAL DISPLAY

A 114

CLAMP SPECIFICATION

A 120

ERROR LOGGING

Displays a history of error messages.

A 122

OPERATION LOGGING

Displays the history of operation activity.

MOTOR TORQUE INFORMATION (Option) OPERATION INFORMATION (Option) PC PROGRAM RUN/STOP (Option)

Displays the motor torque information (peak current, etc.).

A 124 A 127 A 130 A 131 A 133 A 140

INTERFACE PANEL (Option) AS INSTRUCTION C.S. DEFINITION (Option) ENCODER ROTATION COUNTER RESET

Used for setting dedicated output signals. Displays dedicated input and output signals. Used for setting clamp information and specifications.

Displays operation information: time, etc. Used to set PC program RUN/STOP Used to set the switch and the lamp for the interface panel. Used to define character strings. Used to reset the encoder values as part of the zeroing process.

A 142

PROGRAM QUEUE (OPTION)

Used to set program No. to be repeated.

A 143

START DELAY (OPTION)

Used to delay timing of robot motion start.

A 144

INTERRUPT PROGRAM

Used to register interrupt program.

A 149

Registers the mass, the location of the TOOL INERTIA REGISTRATION center of gravity, and the inertia moment of (Option) the tool.

A 153

PROGRAM LIST

A 154

PROGRAM CYCLES

A 155

HOME POSITION MASK

A 158

GENERAL OUTPUT FUNCTION ASSIGNMENT

A 159

HISTORY CLEAR

A 166

PG PARTIAL DELETE

Used to delete a program partially.

SINGULAR POINT ALARM RANGE SET DIFF. OF WORK/AIR-CUT SPEED OPERATION CONDITION SETTING

Used to display and set the singular point alarm range function. Used to set program execution with differentiating work and air-cut speed. Used to set operating conditions as effective/ ineffective.

A 167 A 168 A 169

Used to display program list.

A-14

Used to display, modify and delete blocks for all repeat cycles of a program. Used to set a check of the registered home position data of each joint axis. Sets the general output function signal as effective or ineffective Used to clear the history for all stored operations and errors.



Function Name

Appendix

Function Description Used to display/set general and dedicated counter values. Used to set upper and lower limit of robot movement within XYZ area of world coordinates. Used for editing and managing of coating databank (list, copy, delete and environment settings).

A 172

SYSCOUNT DISPLAY/SETTING

A 173

MOVING AREA XYZ LIMIT

A 176

DATA BANK

A 197

PASSWORD SET (Option)

Used to set a password.

A 198

AUXILIARY FUNCTION SET (Option)

Used to set the level for displaying an auxiliary function.

A-15



APPENDIX 5

Appendix

INITIAL DATA SETTINGS

♦ SYSTEM SWITCHES CHECK. HOLD CP CYCLE. STOP OX. PREOUT PREFETCH. SIGINS QTOOL REP_ONCE RPS STP_ONCE MESSAGE SCREEN AUTOSTART. PC AUTOSTART2. PC AUTOSTART3. PC ERRSTAR. PC DISPIO_01 HOLD. STEP AFTER.WAIT.TMR WS_COMPOFF FLOWRATE STOP_OP WS. ZERO INS_SIGOUT INS_SIGWAIT INS_CVWAIT INS_DELAY DOOR_SENSE SPR_CONFIG

OFF ON OFF ON OFF ON OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF

A-16



Appendix

♦ Command

SPEED

SMOOTH TIMER

SPRAY SPEED AIRCUT SPEED SPRAY JSPEED AIRCUT JSPEED MOVING TIME PLAYBACK RATE Acceleration Smooth level Timer

♦ Check Specification Setting CALL TIMER JUMP/END OX WX CLAMP VELOCITY PRIORITY VELOCITY PRIORITY 2

100mm/s 100mm/s 20％ 20％ 0.1sec 100％ 100％ 5mm 1000msec

YES YES YES YES YES YES YES YES

A-17



APPENDIX 6

Appendix

OAT

■Transformation value Transformation value (X, Y, Z, O, A, T) is composed of parallel displacement components (X, Y, Z) and rotation components (O, A, T) which indicate the necessary movement of the base coordinate system to fit with target coordinate system. Z Z

Move

Target

X Y

Basis (Base coordinate)

Y

X

The transformation values applied in HERE command, JMOVE command as robot location information indicate the tool coordinate system of the wrist tip, using the robot base coordinate system as basis. Therefore, in this case, XYZ components of the transformation values indicate the tool coordinate position seen from the base coordinate. Also, OAT components indicate the tool coordinate direction (inclination) towards the base coordinate system. Z

ZT OAT angles are set as the following.

YA A

T Y

Ｏ X XO

A-18

O: Rotation around Z-axis on Base coordinate system A: Rotation around Y-axis after O’s rotation T: Rotation around Z-axis after A’s rotation



AS Language List

AS Language List (Alphabetical order) * The languages included vary depending on the version of software. M (Monitor Command) E (Editor Command) P (Program Instruction) S (Switch) F (Function) O (Operator) K (Other keywords) NAME

FUNCTION

TYPE

FORMAT (ARGUMENT)

ABORT

Stops program execution

M

ABORT

ABOVE

Positions elbow higher above

P

ABOVE

ABS

Absolute value

F

ABS (Real value expression)

ABS.SPEED

Absolute speed motion

S

...ABS.SPEED...

ACCEL

Changes acceleration factor

P

ACCEL acceleration ALWAYS

ACCURACY

Changes accuracy

P

ACCURACY range ALWAYS

AFTER.WAIT.T MR

Controls when timer

S

...AFTER.WAIT.TMR...

ALIGN

Aligns tool Z axis

P

ALIGN

AND

Logical AND

O

.... AND.....

ASC

Gets ASCII value

F

ASC (string, index))

ATAN2

Arctangent

F

ATAN2 (real-value, real-value)

AVE TRANS

Returns the average for two

F

AVETRANS (transformation value, transformation value2

AUTOSTART.PC

Starts PC program execution

S

...AUTOSTART.PC...


S

...AUTOSTART2.PC...


S

...AUTOSTART3.PC...

BAND

Binary logical AND

O

...BAND...

BASE

Base transformation

M/P

BASE

Returns the base transformation value

F

BASE

BATCHK

Battery error check on power up

M

BATCHK

BELOW

Changes configuration

P

BELOW

BITS

Sets output signals

BITS

Gets signal states

F

BOR

Binary logical OR

O

...BOR.....

BRAKE

Brakes robot motion

P

BRAKE

BREAK

Causes break in CP motion

P

BREAK

BSHIFT

Shifts to base direction

AUTOSTART2. PC AUTOSTART3. PC

M/P

M/P

AS-1

BASE transformation value

BITS first signal, number of signals=value BITS (first signal, number of signals)

BSHIFT transformation value, X, Y, Z, O, A, T



NAME

AS Language List

FUNCTION

TYPE

BSPEED

Sets speed of block programs

P

BSPEED speed

BXOR

Binary exclusive logical OR

O

...BXOR...

K

SHIFT (Transformation value BY X, Y, Z shift) C program name, step number

BY C

Changes program

E

C1MOVE

Circular interpolation move

P

C2MOVE

Circular interpolation move

P

CALL

Call subroutine

P

CALLAUX

Displays auxiliary function screen

M

CASE

CASE structure

P

CCENTER

Transformation value

F

CHECK.HOLD $CHR CHSUM

Changes usages of some motion commands Returns value of ASCII character string Resets check sum error on power up

FORMAT (ARGUMENT)

C1MOVE location name, clamp number C2MOVE location name, clamp number CALL program name CALLAUX auxiliary function number CASE number OF.... VALUE.... END CCENTER (transformation value1, 2, 3)

S

.... CHECK.HOLD....

F

$CHR (real value)

M

CHSUM

CLAMP

Open/close control

P

CLAMP clamp1, clamp2, clamp3

CLOSE

Hand close Hand close Hand close One’s complement Resumes execution Copies an existing program(s) to a new program name Cosine CP (continuous path) Sets cycle start activation mode

P

CLOSE clamp number

P

CLOSEI clamp number

P

CLOSES clamp number

O

.... COM....

M

CONTINUE (NEXT)

M

COPY (new name=old name(s) + old name(s)+…)

F

COS (real value expression)

S

...CP.....

S

Switch (CS)

F

CSHIFT (transformation value 1, 2, 3 objective transformation value BY shift amount)

S

.... CYCLE.STOP....

E

D number of steps

CLOSEI CLOSES COM CONTINUE COPY COS CP CS

CSHIFT

CYCLE.STOP D

Transformation value Sets program restart point after external hold reset Delete program steps

AS-2



NAME $DATE DECEL

$DECODE

AS Language List

FUNCTION

TYPE

Returns date Changes deceleration factor Changes characters partially

F P

F

FORMAT (ARGUMENT) $DATE (date setting) DECEL (deceleration) (ALWAYS) $DECODE (character string variable, separating character, mode) DECOMPOSE array name 〔index〕=location

Extracts location components Defines special signals Stops the robot for a given time

M

DEFSIG OUTPUT/INPUT

P

DELAY time (seconds)

DELETE

Deletes data in memory

M/P

DEST

Destination location Destination location Returns an element of a location name

F

DEST

F

#DEST

F

DEXT (location name, index)

DIRECTORY

Lists data in memory

M

DIRECTORY (/P)(/L)(/R)(/S) (program name, location name, variable…)

DISPIO 01

Changes I/O display from x/o to 1/0

S

.... DISPIO 01....

DISTANCE

Distance

F

DISTANCE (location, location)

DLYSIG

Outputs delay signal Executes a program instruction Do structure Moves the robot by given amount (mm) Moves a single joint (degrees) Configuration with negative JT5 X component Y component Z component Exits editor mode Enters editor mode IF structure Sets the range of emergency situation

M/P

DLYSIG (signal, time)

DECOMPOSE DEFSIG DELAY

#DEST DEXT

DO DO DRAW DRIVE DWRIST DX DY DZ E EDIT ELSE ENCCHK EMG

AS-3

P

DELETE (/P)(/L)(/R)(/S) (Program name, location name, variable)

M

DO (instruction)

P

DO.... UNTIL....

P

DRAW (x, y, z, rx, ry, rz, speed)

P

DRIVE (joint, degree, speed)

P

DWRIST

F

DX (location)

F

DY (location)

F

DZ (location)

E

E

M

EDIT (program name, step)

P

IF...ELSE...END

M

ENCCHK EMG



NAME

AS Language List

FUNCTION

TYPE

FORMAT (ARGUMENT)

ENCCHK PON

Sets the range of emergency situation

M

$ENCODE

Changes characters

F

END

End control Sets MFP environment data Sets MFP environment2 data Displays history of errors Resets error condition Error occurrence Returns error number Changes characters Starts PC program at occurrence of specified error

P

$ENCODE (output data, output data…) FOR…END， CASE…END

M

ENV DATA

M

ENV2 DATA

M

ERRLOG

M

ERESET

S

Switch (ERROR)

F

ERROR

F

$ERROR (error number)

S

...ERRSTART.PC...

M

EXECUTE (program name, cycles, step number)

P

EXTCALL

E

F character string

F

...FALSE...

M

FDELETE file name

M

FDIRECTORY

S

...FLOWRATE...

M

FORMAT

ENV DATA ENV2 DATA ERRLOG ERESET ERROR ERROR $ERROR ERRSTART.PC EXECUTE

Executes program

GOTO

Calls program selected by signals Search characters False value Deletes PC card or disk files Lists PC card or disk files Controls flow rate and chooses speed output Formats PC card or floppy disk Part of FOR/TO control flow structure Transformation of relative coordinate system Shows free memory amount Branch execution

GUNOFF

Gun spray timing

P

GUNOFFTIMER

Gun spray timing

P

GUNON

Gun spray timing

P

EXTCALL F FALSE FDELETE FDIRECTORY FLOWRATE FORMAT FOR FRAME FREE

AS-4

P F

ENCCHK PON

FOR (loop variable=start value) To (end value)…END FRAME (location 1, location 2, location 3, location 4)

M

FREE

P

GOTO label IF condition GUNOFF (gun number, distance) GUNOFFTIMER (gun number, time) GUNON (gun number, distance)



NAME

AS Language List

FUNCTION

TYPE

FORMAT (ARGUMENT)

GUNONTIMER

Gun spray timing

P

GUNONTIMER (gun number, time)

HALT

Stops execution Displays list of AS commands Displays list of AS DO command arguments Displays list of AS function commands Displays list of AS monitor commands Displays list of AS program control monitor commands Displays list of AS program commands Displays list of AS process control program command Displays list of system switches Record current location Returns current transformation location Returns current precision location Linear move used to prevent stimulatory errors Stop execution Displays step at hold Moves the robot to home Joint transformation values at home Sets clamp specification Starts line insert Displays software version IF structure Cause conditional branch

P

HALT

M

HELP

M

HELP/DO

M

HELP/F

M

HELP/M

M

HELP/MC

M

HELP/P

M

HELP/PPC

M

HELP/SW

HELP HELP/DO HELP/F HELP/M

HELP/MC

HELP/P

HELP/PPC

HELP/SW HERE HERE #HERE HMOVE HOLD HOLD.STEP HOME #HOME HSETCLAMP I ID IF IF

IFPWPRINT

Displays characters on the character displaying window

AS-5

M/P

HERE (location name)

F

HERE

F

#HERE

P

HMOVE (location name)， clamp number

M

HOLD

S

.... HOLD.STEP....

P

HOME (home number)

F

#HOME (home number)

M

HSETCLAMP

E

I

M

ID

P

IF.... THEN...ELSE.... END

P

IF logic (equation) GOTO label

M/P

IFPWPRINT (window number, displayed line, displayed digits, color of background, color of letters = displayed character string, displayed character string



NAME

AS Language List

FUNCTION

TYPE

FORMAT (ARGUMENT)

P

IGNORE signal number

INPUT

Cancels interruption Specifies input

K

DEFSIG INPUT

INRANGE

Judges motion range

F

IGNORE

INRANGE (location name, joint transformation value) INSTR (search start position, character string fomula1, 2)

LEN

Changes characters partially Integer function Displays I/O signal status Clears peak current value Displays peak current value Approaching displacement Departing displacement Joint interpolating movement Initializes program stack Chooses predecessor step Approaching displacement Departing displacement Changes configuration Changes specified characters Number of characters

LIST

Displays data in list

LLIMIT

Sets lower software limit

M/P

LMOVE

Starts linear interpolation motion

P

LOAD

Loads data from PC card or disk file

M

LOCK

Used to change the priority of a robot program

P

LOCK (priority number)

LSTRACE

Displays logging data

M

LSTRACE step number: logging number

M

Replaces characters Compares values Executes monitor commands

E

M/old string/new string

F

MAXVAL (Real value 1, 2…)

P

MC (monitor command)

INSTR INT IO IPEAKCLR IPEAKLOG JAPPRO JDEPART JMOVE KILL L LAPPRO LDEPART LEFTY $LEFT

MAXVAL MC

F F

INT (numerical expression)

M

IO /E number

M

IPEAKCLR

M

IPEAKLOG

P

JAPPRO location name, distance

P

JDEPART distance

P

JMOVE location name, clamp number

M

KILL

E

L

P

LAPPRO location name, distance

P

LDEPART distance

P

LEFTY

F

$LEFT (character string, selected character number)

F

LEN (string)

M

AS-6

LIST (/P) (/L) (/R) (/S) (program name, location name, variable…) LLIMIT (joint displacement value) LMOVE (location name) clamp number LOAD (file name) LOAD/Q (file name) for selected data load



NAME

AS Language List

FUNCTION

TYPE

FORMAT (ARGUMENT)

MESSAGES

Message switch

$MID

Changes specified characters

F

MINVAL

Compares values

F

MM／S

K K

…MM／MIN

O

...MOD...

F

MSPEED

F

MSPEED2

M

MSTEP (program, count, step number)

P

MVWAIT (numeric value)

M

MWCLR

M

MWLOG

K

CONTINUE NEXT

P

NCHOFF

NCHON

Millimeter per second Millimeter per minute Remainder Returns monitor speed Returns monitor speed Executes one motion instruction Signal timing and program processing, in time or distance Clears mechanical warning history Displays mechanical warning history Skips to the next step Turns the notch filter OFF Turns notch filter ON

$MID (character string formula, number of selected characters) MINVAL (numerical value 1, real value 2…) …MM／S

P

NCHON

NLOAD

Loads data

P

NLOAD (/IF)(/ARC) device number= file name+ file name+…

NOT

Negation Null transformation value Places cursor on current step Switches OFF False value Switches ON True value Sets interruption condition Sets interruption condition Calls program at errors Sets interruption condition

O

...NOT...

F

NULL

E

O

MM／MIN MOD MSPEED MSPEED2 MSTEP

MVWAIT

MWCLR MWLOG NEXT NCHOFF

NULL O OFF OFF ON ON ON ON ONE ONI

S

AS-7

M/P F M/P F P P

...MESSAGES...

(Switch name), OFF ...OFF.... (Switch name), ON ...ON... ON mode, signal name CALL program name, priority ON mode, signal name GOTO label, priority

P

ONE program name

P

ONI mode, signal name CALL program name, priority



NAME ONI OPEN OPENI OPENS OPEINFO OPEINFOCLR OPLOG OR OX.PREOUT OUTPUT P PAUSE PCABORT PCCONTINUE

PCEND PCEXECUTE

AS Language List

FUNCTION

Sets interruption condition Hand open Hand open Hand open Displays operating time Clears operating time Displays history of operations Logical OR Sets OX signal timing Specifies output Displays program steps Suspends execution Stops PC program execution Resumes PC program execution Terminates PC program execution at the next STOP EXECUTE PC program

TYPE

FORMAT (ARGUMENT)

P

ONI mode, signal name GOTO label, priority

P

OPEN clamp number

P

OPENI clamp number

P

OPENS clamp number

M

OPEINFO

M

OPEINFOCLR

M

OPLOG

O

...OR...

S

.... OX.PREOUT....

K

DEFSIG OUTOUT

E

P (number of steps)

P

PAUSE

M/P M

PCEND (program, cycles, step number)

M/P

PCEXECUTE (program, cycles, step number)

PI PLCAIN

Returns input data values

F

PLCAOUT

Sets output data value

M

PLCAOUT

Sets output data value

F

POINT

Defines location variable Sets value to A component

PCSCAN PCSTATUS PCSTEP

POINT/A

AS-8

PCCONTINUE NEXT

M/P

Initializes PC program stack Sets PC program scan time Displays PC program status Executes one step of a PC program π (3.14)

PCKILL

PCABORT

M

PCKILL

P

PCSCAN (time)

M

PCSTATUS (program number)

M

PCSTEP (program, cycles, step number)

F

PI PLCAIN (integer input data number) PLCAOUT integer output data= real value PLCAOUT integer output data = real value

M/P

POINT (location 1 = location 2)

M/P

POINT/A (location 1 = location 2)



NAME POINT/O POINT/OAT POINT/T POINT/X POINT/Y POINT/Z

AS Language List

FUNCTION

Sets value to component Sets value to components Sets value to component Sets value to component Sets value to component Sets value to component

TYPE

O

M/P

O, A, T

M/P

T

M/P

X

M/P

Y

M/P

Z

M/P

FORMAT (ARGUMENT) POINT/O (location 1= location2) POINT/OAT (location 1= location2) POINT/T (location 1= location2) POINT/X (location 1= location2) POINT/Y (location 1= location2) POINT/Z (location 1= location2) POINT/7 (location 1= location2)

POINT/7

Sets value to seventh axis

POWER

Displays status of motor power

S

SWITCH POWER (ON/OFF)

#PPOINT

Joint displacement value

F

#PPOINT (jt1, jt2, jt3, jt4, jt5, jt6)

PREFETCH.SIGI NS

S

.... PREFETCH.SIGINS....

M

PRIME (program, cycle, step)

M/P

PRINT (device: output data…)

RELAXS

Sets AS language signal timing Sets up program for execution Displays specified number of program steps Sets program run status priority Prompts operator to enter data Pulse output signal Pulse output signal Sets type of tool used, ON block step, OFF AS Language Replaces characters Random Value Inhibits or enable recording of data Hand relax Hand relax Hand relax

RENAME

Changes program name

PRIME PRINT PRIORITY PROMPT PULSE PULSE QTOOL R RANDOM REC ACCEPT RELAX RELAXI

AS-9

M/P

F

PRIORITY

P

PROMPT (device, output character string, variable)

M

PULSE (signal number, time)

P

PULSE (signal number, time)

S

.... QTOOL....

E

R (characters)

F

RANDOM

M

REC ACCEPT

P

RELAX clamp number

P

RELAXI clamp number

P

RELAXS clamp number

M

RENAME (new name= old name)



NAME REP CYC

REP ONCE REPCYCLE

AS Language List

FUNCTION

TYPE

Specifies repeat number and presence or absence of this function Repeat once/ continuous setting Specifies repeat number

RIGHTY

Shows status of TEACH/REPEAT switch Turns off all output signals Opens logging memory range Returns execution to caller program Returns to the next step at errors Servo command ON/OFF Changes configuration

$RIGHT

Changes characters

REPEAT RESET RESTRACE RETURN RETURNE RGSO

FORMAT (ARGUMENT)

S

...REP CYC...

S

...REP ONCE...

M

REPCYCLE repeat cycle number

S

SWITCH REPEAT

M/P

RESET

M

RESTRACE

P

RETURN

P

RETURNE

S

Switch (RGSO)

P

RIGHTY

F

$RIGHT (character string, selected letter number)

S

.... RPS....

S

Switch (RUN)

RUN

Selects program externally Hold/ Run switch

RUNMASK

Masks signals

P

RUNMASK (first signal, number of signals)

RX

Rotation about X axis Rotation about Y axis Rotation about Z axis Selects program step Saves data in a PC card or disk file

F

RX (angle)

F

RY (angle)

F

RZ (angle)

E

S (step number)

RPS

RY RZ S SAVE

SAVE/P，L， R， Saves program/ variable S，A save

SAVE/SYS

Saves error log information Saves mechanical warning history Saves robot data Saves system data

SCALL

Calls sub-routine

SAVE/ELOG SAVE/MWLOG SAVE/ROB

AS-10

M

M

SAVE (file name= program name) SAVE (/P)(/L)(/R)(/S)(/A) /SEL file name= program name…

M

SAVE/ELOG (file name)

M

SAVE/MWLOG (file name)

M

SAVE/ROB file name

M

SAVE/SYS (file name)

P

SCALL character string, state variable



NAME SCNT

AS Language List

FUNCTION

TYPE

Sets an output associated with a counter value

SIN

Resets a counter Screen auto-stop Sets home position Sets home position 2 Start time Start time Keeps logging memory Sets the ON/OFF time of flicker signals Sets an output signal based on status of a set signal and a reset signal Transformation shifted from original location by given amount Logical AND of signal status Turns output signals ON or OFF Sine

SLOAD

Loads data

SCNTRESET SCREEN SETHOME SET2HOME SETPICK SETPLACE SETTRACE SFLK

SFLP

SHIFT

SIG SIGNAL

SLOW REPEAT SLOW START SQRT STABLE STATUS STEP

STIM

SOUT $SPACE

Used to reduce robot speed Sets speed of low speed repeat mode Square root Stops the robot for the given time Displays system status Executes a single program step Sets 1FS board timer output when specified time is elapsed Sets 1FS board output based on conditional statement Changes character string AS-11

FORMAT (ARGUMENT)

M/P

SCNT (count up signal, count down signal, reset signal, count)

M/P

SCNTRESET (reset signal)

S

.... SCREEN....

M

SETHOME (accuracy), HERE

M

SET2HOME (accuracy), HERE

M/P

SETPICK time1, …time 8

M/P

SETPLACE time 1…time 8

M

SETTRACE step number

M/P

SFLK (flicker signal = time)

M/P

SFLP (output signal= set signal, reset signal)

F

SHIFT (transformation value BY dx, dy, dz)

F

SIG (signal number)

M/P

SIGNAL (signal number)

F

SIN (real value expression)…

P

SLOAD (/IF)(/ARC) device number= character string, state variable

M

SLOW REPEAT

S

...SLOW_START...

F

SQRT (real value expression)

P

STABLE (time)

M

STATUS

M

STEP (program name, count, step number)

M/P

STIM (timer number= input signal, time)

M/P

SOUT (signal number= signal condition)

F

$SPACE (number of space)



NAME SPEED SPEED SPOT_OP STOP STPNEXT

STP_ONCE

SWAIT SWITCH SWITCH SYSDATA SYSINIT T TASK TDRAW TEACH TEACH LOCK THEN

AS Language List

FUNCTION

TYPE

Sets monitor speed Sets program speed Switches Spot welding learning Terminates execution cycle Used to execute the next step in a program with STP ONCE switch ON With STP ONCE ON, a program executes one step at a time Waits for desired signal states

M

SPEED (speed)

P

SPEED (speed) ALWAYS

S

...SPOT_OP....

P

STOP

M

STPNEXT

S

...STP_ONCE...

P

SWAIT (signal number)

Sets system switches

M

SWITCH (switch name) = ON/ OFF

F

SWITCH (switch name)

F

SYSDATA (keywords, opt1, opt2)

M

SYSINIT

M

T

F

TASK (task number)

P

TDRW speed)

M

TEACH (location name)

S

SWITCH TEACH LOCK

K

IF (logical) THEN…ELSE…END

F

$TIME

M

TIME yy: mm: dd hh: mm: ss

P

TIMER (timer number)= (time)

F

TIMER (timer number)

K

FOR.... TO.... END

Returns system switch condition Returns AS internal parameter Initializes system Teaches motion command State of program execution Moves robot by given amount in tool coordinates Teaches locations with pendant Displays status of TEACH LOCK switch (ON? OFF) IF structure

TPLIGHT

Returns system time character string Sets date and time Sets timer Timer value FOR structure Specifies tool transformation Tool transformation value Turns rear light ON.

TRACE

Traces ON/OFF

$TIME TIME TIMER TIMER TO TOOL TOOL

AS-12

M/P F

FORMAT (ARGUMENT)

(dx, dy, dz, rx, ry, rz,

TOOL (transformation value) TOOL

M/P

TPLIGHT

M/P

TRACE stepper number: ON/OFF



NAME TRADD TRANS TRHERE TRIGGER TRPOINT TRSUB TRUE

AS Language List

FUNCTION

Adds component of a traverse axis to a transformation location Transformation value Records transformation location including the traverse axis component Trigger switch ON/OFF Compound transformation value Subtracts traverse axes component Logical TURE

TYPE

FORMAT (ARGUMENT)

F

TRADD (transformation value)

F

TRANS (X, Y, Z, O, A, T)

M/P

TRHERE (location name)

S

Switch (TRIGGER)

F

TRPOINT (transformation value 1, 2)

F

TRSUB (transformation value)

F

...TRUE...

TSHIFT

Shifts to tool direction

M/P

TWAIT

Waits for the specified time

P

TYPE

Displays data

M/P

ULIMIT

Sets upper software limit

M/P

UNTIL

DO structure

P

UTIMER

Sets user timer value

P

UTIMER

Current timer value

F

UVC1MOVE UVC2MOVE UVLAPPRO UVLDEPART UVLMOVE UWRIST VAL WAIT

WEIGHT

WHERE

Constant speed circular interpolation move Constant speed circular interpolation move Constant speed approaching Constant speed departing Constant speed linear interpolation move Changes wrist configuration Changes real value Waits until condition is satisfied Changes servo feedback calculations to compensate for carrying load Displays current robot location status AS-13

P P P

TSHIFT transformation value, X, Y, Z, O, A, T TWAIT (time) TYPE output data, device number: print data ULIMIT joint displacement value DO…UNTIL logical UTIMER @ timer variable= timer value UTIMER (@ timer variable name) UVC1MOVE location name, clamp number UVC2MOVE location name, clamp number UVLAPPRO location name, distance

P

UVLDEPART distance

P

UVLMOVE location name, clamp number

P

UWRIST

F

VAL (character string, code)

P

WAIT (condition)

M/P

M

WEIGHT (load mass), load position x, y, z WHERE (mode) (1-6)



NAME WHILE WS_COMPOFF WS.ZERO XD XFER

XMOVE

XOR XP XQ XS XY ZSIGSPEC ZZERO + + * / ^ < <= == <> >= > =< =>

AS Language List

FUNCTION

TYPE

DO structure Selects welding condition output timing Switches welding process Stores in paste buffer Transfers data within a program or to another program Robot moves to the taught location until the specified signal is received, then moves to the following location Exclusive logical OR Inserts content of paste buffer Inserts content of paste buffer Displays content of paste buffer Stores in paste buffer Sets signal numbers Sets/displays zeroing data Link Addition Subtraction Multiplication Division Power Less than Less than or equal to Mathematically equal to Not equal to Greater than or equal to Greater than Less than or equal to Greater than or equal to

P

WHILE.... DO.... END

S

...WS_COMPOFF...

S

...WS.ZERO...

E

XD line number

M

XFER (destination program, start step = source program, first step, number of steps)

P

XMOVE (location) TILL (signal number)

O

...XOR...

E

XP

E

XQ

E

XS

E

XY line number

M

ZSIGSPEC

M

ZZERO joint number

O

...+...

O

...+...

O

...-...

O

...*...

O

... /...

O

...＾...

O

...<...

O

...<=...

O

...==...

O

...<>...

O

...>=...

O

...>...

O

...=<...

O

... =>...

AS-14

FORMAT (ARGUMENT)



Error Message Table

ERROR MESSAGE TABLE ERROR CODE -50 -57 -58

ERROR MESSAGE Warning! Cannot move along straight line JT in this configuration. Set low speed, exceeds joint max. speed in CHECK. Operation information ware cleared.

-100 -101 -102 -105

Matrix calculation error Turn motor power off. Application is changed. Turn control power OFF & ON. Cannot change data, user data exists.

-200 -201 -202 -207 -208 -211

Cannot execute program, motor power is OFF. Cannot execute a program in TEACH mode. Cannot execute program, TEACH LOCK is ON. Turn to HOLD at HOLD/RUN sw. Teach pendant is not connected. Cannot edit program, TEACH LOCK is ON.

-300 -301 -302 -303 -304 -306 -308 -314 -316 -317 -318 -319 -320 -324 -325 -326 -327 -328 -329 -350 -351 -353 -360 -361 -365 -367 -368

Program is already running. Robot control program is already running. Can't continue. Use EXEC. Robot is moving now. Error, Cannot execute. Reset error. Cannot execute with DO command. PC program is running. Cannot execute, program is already used. Waiting for weld completion. Position offset error at last E-stop JT xxx. Waiting retract or extend pos. input signal. Spot sequence is running. Cannot operate, teach pendant set to TEACH. Cannot execute with MC instruction. Cannot execute the instruction in robot program. Cannot delete, in use by another command. Used in programs. Used in editor. KILL or PCKILL to delete program. Illegal input data. Too many arguments. Input value is too large. Illegal WHERE parameter. Illegal PC number. Illegal robot number. Illegal priority. Invalid coordinate value. E-1



ERROR CODE -400 -401 -402 -403 -404 -405 -406 -407 -408 -410 -411 -412 -413 -414 -415 -416 -417 -418 -419 -420 -421 -422 -423 -424 -425 -426 -430 -431 -432 -433 -434 -435 -440 -441 -442 -443 -450 -451 -452 -453 -454 -455 -456 -457

Error Message Table

ERROR MESSAGE Syntax error Invalid statement. Ambiguous statement. Cannot use this command or instruction here. Cannot execute with DO command. Statement cannot be executed. Not a program instruction. Too many arguments. Missing argument. Illegal expression. Illegal function. Illegal argument of function. Invalid variable (or program) name. Illegal variable type. Illegal array suffix. Missing parenthesis. Expect binary operator. Illegal constant. Illegal qualifier. Invalid label. Invalid name. Missing expected character. Illegal switch name. Ambiguous switch name. Illegal format specifies. Duplicate statement label. Cannot define as array. Dimension exceeds 3. Different dimensional array exists. Array variable exists. No array variable exists. Array variable expected. Local variable expected. Unexpected suffix. Mismatch of arguments at subroutine call. Mismatch of argument type at subroutine call. Control structure error Step:xxx Wrong END statement. Step:xxx Extra END statement. Step:xxx Cannot terminate DO with END. Step:xxx No VALUE statement after CASE. Step:xxx Preceding IF missing. Step:xxx Preceding CASE missing. Step:xxx Preceding DO missing. E-2



ERROR CODE

Error Message Table

ERROR MESSAGE

-458 -459 -460 -461 -465 -466 -470 -471 -472 -473 -474 -475 -476 -490 -494 -499

Step:xxx Can't find END of ···. Step:xxx Too many control structures. Variable (or program) already exists. Variable of different type already exists. Undefined Variable (or program). Illegal clock value. Expect ′ = ′. Expect ′) ′. Expect ′] ′. Expect "TO "!. Expect "BY "!. Expect ′ : ′!. Expect "ON/OFF "!. Program name not specified. Program is interlocked by another procedure. Invalid statement.

-507 -514 -523 -543 -544 -545 -551 -580 -581 -583 -584 -585 -586 -591 -596 -597 -598 -599

Communication error Device is not ready. Illegal file name. Data read error Floppy disk data transfer error Record inhibited. Set ""record accept"" and operate again. Cannot open the file. Retry error Process stop. Data not received. Received data too long. Abnormal data (EOT) received in communicating. Time out. Illegal device number. Cannot attach terminal. Cannot attach communication port. Cannot execute on this terminal. Waiting for input data PROMPT. Connect input device.

-600 -610 -611 -612 -613 -614 -615 -616

Motor power OFF. Weld completion time over. Illegal extend (retract) output signal. Weld fault input. Retract pos. monitor error. Extend pos. monitor error. Weld completion signal is already inputted. Gun retract position mismatch. E-3



ERROR CODE -653 -654 -662 -671 -672 -673 -674 -675 -676 -700 -800 -801 -802 -803 -804 -805 -807 -808 -809 -810 -811 -812 -813 -814 -815 -816 -817 -820 -821 -822 -823 -824 -825 -826 -827 -828 -829 -832 -834 -835 -837 -838 -839 -840 -842

Error Message Table

ERROR MESSAGE Illegal DOUBLE OX output. Cannot use DOUBLE OX. Start point position error for circle. Cannot execute in check back mode. Cannot execute in ONE program. Angle between JT2 and JT3 is out of range at start location. Angle between JT2 and JT3 is out of range at end location. Terminal is not connected. Cannot input/output to multi function panel. No free memory. Program does not exist. No program step. Invalid label. Undefined variable. Undefined location data. Undefined string variable. Undefined program or label. Illegal value. Undefined array suffix. Divide by zero error. Floating point overflow. String too long. Illegal exponential operation. Expression too complicated. No expressions to evaluate. Unexpected error while evaluating expression. SQRT parameter is negative. Illegal array suffix. Illegal argument value. Illegal joint number. Illegal signal number. Illegal timer number. Illegal signal number. Illegal clamp number. Illegal time value. No value set. Illegal signal number. Illegal time input data. Program name already exists. Cannot KILL, program is running. Cannot use dedicated signal. Not RPS mode. Cannot use negative number. Too many subroutines. Invalid subroutine. E-4



ERROR CODE -846 -850 -851 -852 -853 -855 -856 -857 -858 -871 -872 -873 -874 -875 -876 -877 -879 -896

Error Message Table

ERROR MESSAGE No programs exist. Out of absolute lower limit. Out of absolute upper limit. Out of user lower limit. Out of user upper limit. Motion start location of xxx is out of range. Motion end location of xxx is out of range. Destination is out of range. Illegal configuration for linear motion. Illegal joint number. Cannot execute motion instruction in PC program. Illegal auxiliary data number. No circular location. No C1MOVE (or CIRC1) instruction. Cannot create circle. Cannot execute, sealing type. Cannot execute, not sealing type. Option not set up.

-1003 -1012 -1014 -1017 -1019 -1022 -1025 -1026 -1029 -1051 -1100 -1101 -1102

Data base error. Command position of xxx suddenly changed. Commanded position of xxx is out of range. Angle between JT2 and JT3 is out of range. Check sum error of system data. RAM battery low voltage. AS flash memory check sum error Servo flash memory check sum error Touch panel switch is short circuited. Cannot execute in this robot arm. CPU error Main CPU BUS error VME BUS error

-1200 -1201 -1202 -1203 -1204 -1205 -1206 -1247 -1248 -1249 -1250 -1251

Encoder board not installed. Power sequence board not installed. No.2 power sequence board not installed. No I/O board not installed. Option SIO port not installed. Power sequence board error Built-in sequence board not installed. Axis setting data incorrect. Number of axes changed! SYSINI Servo parameter changed! Turn control power OFF & ON. Servo board ( ) Initialize error Servo board ( ) communication error E-5



ERROR CODE

Error Message Table

ERROR MESSAGE

-1252 -1253 -1254 -1255 -1256 -1257 -1258 -1259 -1260 -1261

Servo board (A) hardware error. Servo board (B) hardware error. Servo board (C) hardware error. Servo board (D) hardware error. Servo board (A) software error. Servo board (B) software error. Servo board (C) software error. Servo board (D) software error. Option changed! SYSINI. Servo board ( ) parameter setting error.

-1300 -1306 -1308 -1333 -1334

Servo CPU-( ) watch-dog error Servo board command error Motor power off. Monitor ID of servo board mismatch! Servo control line error.

-1401 -1407 -1413 -1420

Amp over current xxx. Servo unit error Regenerative resistor overheat or disconnect. Current detector type (X) mismatch!

-1500 -1501 -1503 -1504 -1505 -1506 -1507 -1510 -1511 -1513 -1516 -1517 -1518 -1521 -1524 -1550 -1553 -1554 -1555 -1556 -1557 -1558 -1559

Xxx of motor overload. Overheat or motor harness disconnected. Speed error xxx Position envelope error xxx Velocity envelope error xxx Commanded speed error xxx Commanded acceleration error xxx Encoder harness disconnected xxx Encoder battery voltage low Encoder rotation data abnormal xxx Encoder data abnormal xxx Cannot read encoder value xxx Miscount of encoder data xxx Mismatch ABS and INC encoder of xxx Encoder line error for xxx Encoder initialize error xxx Encoder response error xxx Encoder communication error xxx Encoder data conversion error xxx Encoder ABS-track error xxx Encoder INC-pulse error xxx Encoder MR-sensor error xxx Power module error xxx E-6



ERROR CODE

Error Message Table

ERROR MESSAGE

-1561 -1563 -1567 -1568 -1569 -1570

Current sensor disconnect. [Servo( )] Servo unit 12VDC error [Servo( )] Regenerative resistor error [Servo( )] Servo unit P-N low voltage. [Servo( )] Servo unit P-N high voltage. [Servo( )] Regenerative resistor over-heat. [Servo( )] or controller hot

-1600 -1601 -1602

Uncoincidence error xxx Limit switch of xxx is ON. Limit switch signal line disconnected.

-1700

(Conveyer passed the limit)

-1800 -1801 -1802 -1803 -1804 -1805

AC primary power OFF. 24VDC power source low. Primary power source high. Primary power source low. +12VDC or -12VDC is abnormal. Memory locked, AC_FAIL.

-2100 -2101 -2102 -2103 -2104 -2105 -2106 -2107 -2108 -2128 -2140 -2141 -2142 -2143 -2144 -2145 -2146 -2147 -2148 -2170 -2171 -2172 -2173 -2174

Explosion proof TP is not connected. Shifted location of STEP n is out of range. STEP n in source program is out of motion range. Wrist can't be straightened any more (Singular Point 1). Wrist can't be bent any more (Singular Point 2). Out of MOVING AREA XYZ LIMIT. Specified PAINTING DATA BANK is undefined. Set TEACH mode and TEACH LOCK to ON. Turn motor power and trigger ON. The next step of XD (2)START must be LMOVE or HMOVE. Signal condition is already inputted. Signal not detected. Door Detect Signal Error. Cannot execute program because of suspend playback. Location data has not detected. Relative distance between guns is too near. Cannot set program no. in program queue Cannot set program no. in delay queue Internal pressure sensor error. Lacks of air flux. Internal pressure low. Illegal barrier unit setting. Communication board to TP watch-dog error. E-7



E-8


Memo

Glossary

GLOSSARY [This

g l o s s a r y c o n t a i n s d e f i n i t i o n s t h a t i s n o t u s e d i n t h i s ma n u a l ]

A A/D TRANSFORMATION

Transforming analog signal to digital signal. (A/D is short for Analog to Digital.)

ABNORMAL STOP (IS)

A stop that caused by system (including robot) error.

ABSOLUTE COORDINATE (IS)

A coordinate that is set independently with robot. Design basis plane is based on.

ABSOLUTE ENCODER

A position sensor that can be recognized current position without calibrating origin after applying control power.

AIR CUT (IS)

Moving a weld gun into position but without generating an arc.

ALIGNMENT

Sequence of elements in more than one dimension.

AMPLIFIER

A device that amplify electrical signal to drive motor.

APPRICATION PROGRAM

A program that actually process work like AS language program. There are two types of programs: the program that is created by user and the program that is created by maker and supplied as pay service.

ARC SENSOR (IS)

A sensor that detects weld lines utilizing arc characteristics.

ARC SPOT WELD (IS)

An ark welds method that heat from one side of board and fusion bond in spot.

ARC WEDL (IS)

A weld to unite (metallic parts) by heating.

ARGUMENT

A value applied to a procedure; data used by a function or other command. For instance, in the AS command JMOVE flange, 2. The variable, flange, and the clamp number 2 are the arguments of the function JMOVE.

ARM

A part of robot that equip function similar to human arm.

AS LANGUAGE

A robot language equipped with Kawasaki Robot Controller A/AD series. (AS is short for Advanced Superior)

ASCII

Refer to the item of AXCII.

ASCII

Character code expressed in 8 bit. (ASCII is short for American Standard Code for Information Interchange)

G-1


C Series Controller, Explosion-Proof-Type Kawasaki Robot Operation Manual

Glossary

AUTOMATIC SETTING OFWELD CONDITION (IS)

A function that set weld condition automatically only by teaching joint geometry, type of bevel, board thickness, leg etc.

AUXILIARY DATA

Information about a point, other than the positional data, such as speed, accuracy, weld schedule and clamp condition.

AXIS COINCIDENCE

Current angle of robot’s joint is within the range specified against teaching point.

AXIS DISSIDENCE

Current angle of robot’s joint is not within the range specified against teaching point.

B BCD CODE

Code expresses the value from 0 to 9 by 4 bits. Called binary coded decimal. (BCD is short for Binary Coded Decimal)

BEAD

A weld metal that is made by one path.

BINARY CODE

A system in which characters are represented by a group of binary digits, that has the value of either 0 or 1, true or false, on or off.

BIT

Acronym for binary digit, having one of two values: 0 or 1.

BITE

Unit of data expressed in 8 bits.

BLOCK COMMAND

A command with auxiliary data such as target position data and interpolation at moving, stop accuracy and so on.

BUS

The primary communication path in the controller along which internal signals are sent among processors and memories.

C CARD RACK

A box within controller that various boards (print board) are put up.

CHECK OPERATION (IS)

A execution of whole or a part of appropriate work to check robot operation after teaching.

CHECKSUM

A method by which the contents of data or a transmission are verified to be accurate. This method "sums" all the characters and translates them into a number which is appended to the data.

CIRCULAR INTERPOLATION

A path taken by the robot that connects at least three points with an arching motion. The CPU will calculate a path that places the taught points on a section of a circle.

CLAMP

Clapping hold of work and so on.

G-2



COMPOUND TRANSFORMATION VALUE

Glossary

Transformation value that is used to express location with relative index. It is described as follows: Compound transformation value = Transformation value 1＋ Transformation value 2

CONFIGURATION

An index that express posture of robot arm. Right hand configuration, left hand configuration.

CONNECTOR

A part of junction that is used when connecting each devices with cable.

CONTINUOUS PATH CONTROL

Refer to the item of CP CONTROL.

CONTROLLER

A control device that control robot.

CONVEYER FOLLOW

Used to make the robot follow a work on a moving conveyor, with the use of a traverse axis.

CONVEYER TRACKING

Used to make the robot track a work on a moving conveyor, without the use of a traverse axis.

COORDINATE TRANSFORMATION

Convert a location or vector on a coordinate to on other coordinate.

COPY

Writing data on other place as leaving original data on the place.

CP CONTROL (IS)

Control that all start or all path is designated. (CP is short for Continuous Path)

CPU

Acronym for central processing unit. A collection of hardware in a computer which performs all calculations, handles I/O, and executes programmed tasks.

CRATER CONDITION

A weld condition to improve craters in ark weld.

CRATER (IS)

A crater that appear out at the end of bead.

CURSOR

A pointer or indicator on a computer screen that identifies the current position on the screen.

CYCLE TIME

A time takes for one operation.

D D/A TRANSFORMATION

Transforming digital signal to analog signal. (D/A is short for Digital to Analog)

DATA BASE

A large collection of data organized especially for rapid search and retrieval (as by a computer)

G-3



Glossary

DATA CONVERSION

Convert data to other from for some purposes. Convert offline teach data to data for actual robot and so on.

DEADMAN FUNCTION (IS)

Robot operation stops automatically when letting down.

DEDICATED SIGNAL

A term used to describe a signal which is used for only one purpose, or assigned a single function. Both inputs and outputs can be dedicated.

DEFAULT VALUE

A value that is automatically entered by the system, if the operator does not specify one.

DEVIATION

A gap between the position instruction value output by controller and current position detected by position transducer.

DIGITAL SERVO SYSTEM

Servo system that input signal and main part of data processing are digital quantity.

DISKETTE

Refer to the item of FLOPPY DISK.

DRY CONTACT

A contact open-ended in direction of current flow. Contact of relay with contact and so on.

DRY RUN

Execute program without moving robot actually.

DSP

A processing digital operation at a high speed. (DSP is short for Digital Signal Processor)

E EDIT

Modifying, adding, and deleting existing data.

EDITOR

An aid for entering information into the computer system and modifying existing text.

ELECTRO MAGNETIC VALVE

A valve that open and close by electromagnet.

EMERGENCY STOP (IS)

An immediate stop of robot motion, selected by the operator with a switch.

ENCODER

An electromechanical device that is connected to a shaft to produce a series of pulses that indicate the position of the shaft.

ERROR LOG

A report which contains a sequential list of system error messages.

EULER ANGLES

A angle that expresses posture against XYZ coordinate of vector.

EXPLOSION-PROOF STRUCTURE (IS)

A structure that measured not to be ignition source by occurring of spark or ark.

EXTENSION LENGTH (IS)

A length of weld wire that exert from the edge of contact tip.

G-4



Glossary

EXTERNAL AXIS

Axes other than robot axes. (traverse or positional axes.)

EXTERNAL MEMORY

A memory device that is exists externally to maintain a large quantity of data and programs.

F FA (IS)

Integrating element making up producing function of factory and act of generation, and automate totally. (FA is short for Factory Automation)

FDD

Drive saving and playing data to floppy disk. (FDD is short for Floppy Disk Drive)

FILE

A set of related records or data elements, which are stored using one name and are arranged in a structure that can be used by a program.

FLOPPY DISK

An electromagnetic mass storage device which can be removed and exchanged.

FORMAT

Initialization of floppy disk.

H HALT (IS)

A state that device are not operating.

HAND

A tool used for handling.

HANDLING

A operation that robot grabs work and transfer to other place.

HARD COPY

Screen image is printed out to printer as it is.

HEXADECIMAL

A expression of number based on 16. 10,11,12,13,14,15 are expressed with one letter of A, B, C, D, E, F.

HOLD (IS)

When an external or an internal input is available for a hold condition, the robot will stop its motion and servo drive power will be removed from the robot.

HOLD(IS)

When an external or an internal input is available for a hold condition, the robot will stop its motion and servo drive power will be removed from the robot. When an external hold reset is performed, the servo drive power will be energized.

HOME RETURN (IS)

Return to the position that becomes base of robot.

I I/O

Acronym for Input/Output.

INCHING (IS)

A value that is used during the jogging process that allows the user to position the robot in small minute increments.

G-5



INTERLOCK (IS)

Glossary

An arrangement whereby the operation of one part or mechanism automatically brings about or prevents the operation of another.

INTERPORATION (IS)

The mathematical process that the CPU utilizes to plot a path for the robot to travel from one position to another. A mathematical process that evaluates a number of dependent and independent variables for the purpose of comparison and prediction.

INTERRUPTION

While a program is run, interrupt the program and execute another program.

J JOINT INTERPOLATION

A method of interpolation that operate with allotting an equal share of the joint shift amount between teaching points.

JOINT QUANTILE

A location information of AS language that is expressed in degree of robot’s each axis.

L LAN (IS)

An acronym for local area network. A group of computer terminals interconnected by cables, allowing communication of information via the network.

LCD

Refer to item of the LIQUID CRYSTAL DISPLAY. (LCD is short for Liquid Crystal Display)

LEARNING CONTROL (IS)

A control to operate proper work reflecting work experiences.

LED

A Indicator lamp using light emitting diode. (LED is short for Light Emitting Diode)

LINEAR INTERPOLATION

Interpolation that operate the path between teaching point becomes a line.

LIQUID CRYSTAL DISPLAY

A constantly operating display that consists of segments of a liquid crystal whose reflectivity varies according to the voltage applied to them.

M MAN MACHINE INTERFACE

Measures that make the information transfer between human and machine in two way street possible.

MANIPULATOR (IS)

Another term for the mechanical portion of the robot system.

MANUAL OPERATION

Operation to move robot manually.

MEAN TIME BETWEEN FAILURE

Refer to item of the MTBF

G-6



Glossary

MECHANICAL ORIGIN (IS)

A specific reference point on each operation’s degrees of freedom.

MEMORY

An area of the computer, which stores data, either permanently or temporarily. When a program is requested, it is first loaded into memory so it can be accessed quickly by the processor.

MEMORY CAPACITY

All capacity of memory. Usually expressed in bite unit.

MENU SCREEN

A screen that displays method and contents of operations.

MOMENT OF INERTIA

Used to calculate end of arm tooling and handling weights. The sum of the products formed by multiplying the mass of the load by the square of the distance from the tool mounting flange.

MOTION COORDINATE SYSTEM MODE

A coordinate system mode that is selected when operating robot manually.

MOTION SPACE (IS)

A space that all robot’s movable parts occupies.

MOTOR POWER

A motor power used to move robot axis.

MS-DOS

A operating system developed by Microsoft. (MS-Dos is registered trademark of Microsoft.)

MTBF (IS)

Mean time between failures.

N NOISE

Any unwanted disturbance within a dynamic, mechanical, or electrical system.

O OAT

Expressing vector.

posture

against

XYZ

coordinate

of

(OAT is short for Orientation, Azimuth, Tool) OPERATION LOGGING FUNCTION

Function that stores procedures operated in the past.

OPERATION PANEL

A panel that switches are allocated to control robot operation (start, stop, teaching etc.) by manually.

OPERATOR

Any mathematical action or function. and so on.)

OVER RUN (IS)

Running part runs or goes beyond or past set position due to error of robot controller.

OX

Information transferred from the robot controller through output modules to control output devices.

G-7

(+, -, *,



Glossary

P PAL

Trademark that MMI company (present AMD company) applied to PLD. (PAL is short for Programmable Array Logic)

PATH (IS)

A spatial path that are drawn by shifting designated point related robot structure.

PC PROGRAM

A program that is processed independently of robot operation. (PC is short for Process Control)

PDU

Refer to item of the PRAZMA DISPLAY (PDU is short for Plasma Display Unit)

PHOTOCOUPLER

An element that is combined optically between the light emitting diode that input signal operates and the photo detector. They are combined optically, so that signal is insulated electrically.

PLASMA DISPLAY

A luminescent type display device that light came of gas discharge is applied.

PLAYBACK

Refer to item of the REPEAT OPERATION.

PLC

Acronym for programmable logic controller. Usually referred to as the cell or system controller.

PLD

A Logic IC that logical function can be written. (PLD is short for Programmable Logic Device)

POSITION VARIABLE

A variable that expresses position used in AS language.

POSITIONING ACCURACY (IS)

Conformity in actual position and instructed position.

POSITIONING REPEATABILITY (IS)

Extent of coincidence in positions that are positioned on a same condition and a same method.

PROGRAMABLE CONTROLLER (IS)

A kind of sequence controller. A stored program system controller that control contents in software is changeable.

PROGRAM (IS)

A predefined, step-by-step set of instructions that are entered into a computer so a specific process can be performed repeatedly without re-entering all the steps. Robot paths are stored and run as part of programs.

PROM

A ROM that memory can be written with PROM writer. (PROM is short for Programmable Read Only Memory)

PROMPT

A display that informs command input is ready to accept.

PROTOCOL

A agreement of data format and transmission order etc. on data transmission.

G-8

of



PTP CONTROLL (IS)

Glossary

Controls that pass points on path are specified at intervals. (PTP is short for Point To Point)

R RAM

Acronym for random access memory. An area used by the CPU for processing and temporarily loading programs so they can be accessed quickly. The contents of RAM are lost when the computer is powered down, unless battery backup is provided.

RATED LOAD

A range that insure specified performance. The weight that can be careered by robot. (including the weight of hand etc.)

RATED WRIST LOAD

A maximum acceptable load torque within the range that robot wrist part is guaranteed specified performance.

REAL TIME

Refer to the section of REAL TIME.

REAL VARIABLE

A variable language.

REAL-TIME

The actual time during which the computer analyzes and processes data: information is usually processed as it is received.

RECTANGULAR COORDINATE

Refer to the item of XYZ COORDINATE.

REGULAR STOP (IS)

Stop arises from regular program during normal operation.

REPEAT OPERATION

Operation that executes the operation by reading stored information. Also called PLAY BACK.

RESERVED WORD

A spelling that user cannot be used for user-specific variable name because meaning and usage are defined previously.

RESTART (IS)

Start the robot again that stop by error stop or emergency stop.

REWRITE

Modifying data by overwriting.

RGSO

Signal that instruct amplifier to drive motor.

that

expresses

real

number

in

AS

(RGSO is short for Remote Gate Servo On) ROBOT LANGUAGE (IS)

A language used to describe or change information between human and robot.

ROM

A memory device which is programmed at the factory and whose contents thereafter cannot be altered.

G-9



Glossary

RPS FUNCTION

Function to select program to be repeat operation by exchanging signals of robot controller with peripherals. (RPS is short for Random Program Selection)

RTPM

Modifying robot path in real time by external signal. (RTPM is short for Real Time Path Modification)

RUN (IS)

A state that device is executing designated action.

S SAFETY FENCE (IS)

A fence that is placed to prevent human from going into robot movable area.

SAFETY PLUG (IS)

A device used with safety fencing to interlock the opening of the fence with the removal of power to the robot.

SCROLL

When more information exists than can be displayed on one screen, the operator can move up and down through the data to view it. When data is scrolled to the screen, the information previously viewed moves up off the screen, and new information enters the screen from the bottom.

SEAM TRACKING (IS)

Seaming weld line automatically.

SENSOR (IS)

A device used to detect various conditions: proximity, heat, pressure, etc. An electrical signal from the sensor can be used to communicate information to a robot program.

SEQUENCE CONTROL

Control that each step is determined sequentially according to the information set previously.

SERVO AMPLIFIER

Refer to the section of AMPLIFIER.

SERVO SYSTEM (IS)

Control system that is set up as follows given change of targeted value. The location, direction, posture and so on of object are as controlled variable.

SHIFT FUNCTION

Function that shift teaching point to some direction by given value.

SINGULAR ATTITUDE

A posture that some axis move rapidly when operating linear interpolation or circular interpolation.

SOFTWARE LIMITS

Programmed values that are included in a program at the point before a mechanical device hits an over travel limit switch or a hard limit.

SOFTWARE SERVO SYSTEM (IS)

Servo system that execute signal processing with software.

SOLENOID VALVE

Refer to the item of ELECTRO MAGNETIC VALVE.

G-10



Glossary

SOLID STATE RELAY

Relay of structure that is no contact. (Semi-conductor relay.)

SPOT WELD (IS)

Resistance welding that pinch the superimposed matrix with tip of electrode that tip is molded properly, heat partially and pressurize with electrode simultaneously.

SSR

Refer to item of the SOLID STATE RELAY. (SSR is short for Solid State Relay)

STEP

Each stage of program. What to be done at the stage is described. (A bunch of steps becomes program.)

STEP NO. (IS)

Numbers assigned in each step.

STICKING

A state that ark welds wire and work, or gun tip for spot weld and work are stick on.

STUD WELD (IS)

A weld that generate ark between edge of bolt or round bar and matrix, and press to molten pool.

SUBROUTINE

A set of instructions that is run by another routine.

SUM CHECK

Checking whether there is an error in data using the check sum.

SURGE KILLER

An element or device to remove surge.

SYSTEM DATA

Data that is specific to a individual robot. Zeroing data, upper and lower software limits, and software switch settings are all examples of system data.

SYSTEM SWITCH

Software switches that are set to determine various configurations and characteristics of the robot system performance.

T T/P

Refer to item of the TEACH PENDANT. (T/P is short for Teach Pendant)

TACT TIME (IS)

A maximum time that takes for each process of operation. (Processing time).

TEACH LOCK

A switch equipped teach pendant to protect teaching operator, not to executed repeat operation during teaching.

TEACH MODE

A mode selected on the operator panel, during which robot arm axes positions can be taught by the operator and are recorded by the robot.

TEACH PENDANT

A hand-held, portable device used by the operator during teach and jogging operations.

TEACHING

A teaching operation using teach pendant.

TEACHING (IS)

A operation to store information required for desired work to robot.

G-11



Glossary

TIMER CONTACTOR

A device to control turning on and off electricity by setting time applying current in spot weld.

TOOL

A tool installed in robot wrist and operates.

TOOL COORDINATES

The orientation of the tool can be expressed in terms of a 3-dimensional space representation of X, Y, and Z projections.

TOOL DIMENSION

Tool transformation value. Register in controller with X, Y, Z, O, A, T.

TRAJECTORY (IS)

A temporal and spatial trajectory that are drawn by shifting of designated point related robot structure.

TRANSFORMATION VALUE

Location information of AS language that is expressed with XYZ coordinate and OAT.

TRANSMISSION PROTOCOL

Refer to the item of PROTOCOL.

U USER

People who use robot for producing.

USER DEFINED DEDICATED SIGNAL

Dedicated signal that have specific function that can be defined by user freely.

V VARIABLE

The name of a memory location or stored value. variable can refer to a scalar or an array.

VECTOR

Direction and size are expressed.

VME BUS

A kind of bus specification. (VME is short for Versa Module Europe)

A

W WAIT (IS)

A state that can be run immediately.

WATCH DOG TIMER

A timer to monitor the software operation.

WEAVING

An execution method that weld as shaking torch edge in ark weld.

WELD (IS)

Operation that integrate more than two members by heat continuity between members to be weld, pressure or both of them.

WIRE TOUCH SENSOR (IS)

A sensor that detects the position by contacting weld wire to non-weldment.

WORK COORDINATE

A coordinate defined against work.

WORK ORIGIN (IS)

A reference point on robot operation.

G-12



Glossary

WORK SPACE (IS)

A space that robot can be operated.

WORK (IS)

Physical object that is handled by robot.

WX

The wait external signal is one of many inputs that are processed by the robot controller. When the robot encounters a wait external condition, the robot will cease motion and the servo power will be removed.

X XYZ COORDINATE

A coordinzate formed by orthogonal three axes (X, Y and Z axes)

Z ZEROING

This procedure provides the robot controller with encoder data that is referenced from a known mechanical position and then establishes an encoder value for this known position.

ZEROING DATA

A data of mechanical origin of robot joint.

Reference specification: JIS B0134 Industrial Robot Language JIS Z3001 Weld Term (Indicated with IS mark in this glossary.)

G-13



G-14


MEMO

Index

INDEX conveyor synchronization.................... 12-2 conveyor wait ...................................... 5-59 copy ................................................... 9-121 counter ................................................. 5-57 counter value setting.......................... 10-45 current conveyor position setting ...... 10-44 cycle stop switch.................................. 9-48

A abort..................................................... 9-83 acceleration.......................................... 5-42 accuracy............................................... 9-28 add ....................................................... 5-57 after. wait timer switch........................ 9-49 air motor/atomizing air........................ 5-37 air purging process ................................ 2-2 aircut jspeed......................................... 5-30 aircut speed.......................................... 5-30 all clear .............................................. 9-107 all delete ...................................9-94, 9-102 as instruction definition....................... 9-87 atomizing ratio..................................... 5-38 auto tool set ......................................... 9-18 automatic path generation ................... 9-38 autostart.pc switch............................... 9-49 aux function screen................................ 3-3 auxiliary data area ................................. 1-5 auxiliary function select .................... 9-123 available memory capacity display ... 10-11

D data bank...................................5-46, 9-119 data bank editing................................ 10-26 data conversion .................................... 9-12 data input wait ..................................... 5-40 data transfer ........................................... 9-8 dedicated counter display .................. 10-37 dedicated input signal .......................... 9-69 dedicated output signal ........................ 9-70 dedicated signal display....................... 9-71 delete............................. 9-93, 9-102, 9-121 deletion .........................................7-8, 7-16 diff. of work/air-cut speed ................. 9-113 dispio_01 switch .................................. 9-49 display.................................................. 9-90 display and modify ............................ 9-107 dly spray (distance).............................. 5-33 dly spray (time).................................... 5-33 dly spray instruction ............................ 5-35 dout function assignment................... 9-109

B base coordinate.................................... 9-24 battery error check............................... 9-66 C call program......................................... 5-49 change................................................ 9-101 check specification .............................. 9-64 check speed ......................................... 9-34 check.hold switch ................................ 9-48 circular (end) ....................................... 5-64 circular (mid)....................................... 5-64 clear check sum error .......................... 9-53 common delay distance ....................... 9-97 compare ............................................... 5-50 continue ............................................... 9-82 continuous path switch ........................ 9-48 contrast adjustment knob....................... 1-4 conveyor .............................................. 5-59 conveyor increase direction................. 12-9 conveyor maximum position............... 12-8 conveyor maximum speed................... 12-8 conveyor scale ..................................... 12-8

E edit ..................................................... 9-120 emergency stop ...................................... 2-5 encoder error range.............................. 9-21 encoder rot. counter reset .................... 9-88 encoder value display ........................ 10-31 environment data ................................. 9-61 environment data of panel ................... 9-63 environment set ........................9-95, 9-122 equ compare......................................... 5-54 error history display........................... 10-47 error logging ........................................ 9-78 errstart.pc switch.................................. 9-49 external input signal display .............. 10-34 external output signal display ............ 10-33

1



Index

J

F

joint...................................................... 5-64 joint command value display............. 10-31 joint shift.............................................. 9-55 joint value display.............................. 10-30 jump ..................................................... 5-50

false jump ............................................ 5-52 file directory ........................................ 9-16 flow rate............................................... 5-37 flow rate ratio ...................................... 5-38 flowrate................................................ 9-50 flushing................................................ 5-37

K

G

keyboard screen ..................................... 3-3 kill........................................................ 9-85 kill program ........................................... 9-9

gain for conveyor speed bias............... 12-8 general counter display...................... 10-37 general ex-out...................................... 5-36 general syscount setting .................... 9-117 greater compare ................................... 5-54 greater/equ compare ............................ 5-54 gun application .................................... 9-74 gun control........................................... 5-61 gun postion/ angle display................. 10-29 gun position/ wrist angle display....... 10-32 gun relative distance check function ... 9-77 gun selection........................................ 5-61 gun specifications................................ 9-73 gun-tip direction shift ........................ 10-21

L label ..................................................... 5-53 less compare ........................................ 5-54 less/equ compare ................................. 5-54 line increase direction.......................... 12-9 linear .................................................... 5-64 liquid crystal display.......................1-4, 1-5 list ...................................................... 9-119 load ...................................................... 5-57 location variables registration............ 10-46 M

H

manual external output execution...... 10-49 memory available ................................ 9-36 messages switch................................... 9-49 mirror conversion ................................ 9-10 mirror image conversion.................... 10-22 motor torque information .................... 9-80 move .................................................... 5-64 move instructions................................. 5-20 moving area xyz limit ........................ 9-118 moving time......................................... 5-31 multi start delay ................................. 9-100 mutual wait .......................................... 5-41

high voltage ......................................... 5-37 high voltage ratio................................. 5-38 history clear ....................................... 9-110 hold step .............................................. 9-49 home position ...................................... 9-51 home position check axis set............. 9-108 home signals...................................... 10-36 I individual delay distance..................... 9-98 individual setting ................................. 9-99 ineffective pitch................................... 12-9 initialization screen ............................. 14-2 initializing............................................ 14-4 input signal compare ........................... 5-56 insert .................................................... 9-92 insertion........................................7-7, 7-13 installation posture .............................. 9-23 interface panel ...................9-86, 13-2, 13-4 internal signals display ...................... 10-35 interrupt program............................... 9-103

N not equ compare .................................. 5-54 O operating information .......................... 9-81 operation condition selection............. 10-38 operation condition setting ................ 9-114 operation logging................................. 9-79 overwrite.......................................7-4, 7-10 ox.preout switch .................................. 9-48

2



Index

S

P painting/sealing gun definition............ 9-76 parallel shift....................................... 10-20 partial program copy ......................... 10-17 partial program deletion .................... 10-19 password set ...................................... 9-123 pattern ratio ......................................... 5-38 PC card aux function ........................... 9-17 PC card load ........................................ 9-15 PC card save ........................................ 9-13 PC card slot ........................................... 1-4 PC program run/stop ........................... 9-82 peak current ......................................... 9-80 pg partial delete ................................. 9-111 playback rate ....................................... 5-31 pos. error range at e-stop ..................... 9-20 position display of traverse axes ....... 10-32 pre spray (distance) ............................. 5-32 pre spray (time) ................................... 5-32 prefetch sigins switch .......................... 9-48 private syscount setting ..................... 9-117 product paint IO ratio setting ............ 10-10 production rate value setting ............... 10-9 program argument/comment ............... 9-58 program copy..................................... 10-14 program deletion ............................... 10-16 program edit mode ................................ 6-3 program link ...................................... 10-15 program list display........................... 10-11 program name registration ................ 10-12 program number list display.............. 10-11 program queue..................................... 9-89 program setting.................................... 10-7 purging time .......................................... 2-3 push thinner ......................................... 5-37

screen switch ....................................... 9-49 set same distance ............................... 9-100 setting screen ......................................... 3-3 shaping/pattern air ............................... 5-37 shuttle right-left conversion............... 10-23 simulation function ............................ 12-10 singular point alarm range set............ 9-112 slow repeat mode ........................8-13, 9-33 smooth range ....................................... 5-42 software limit....................................... 9-27 software version display ...................... 9-60 spray 1 ................................................. 5-32 spray 2 ................................................. 5-32 spray 3 ................................................. 5-33 spray 4 ................................................. 5-33 spray instruction .................................. 5-34 spray jspeed ......................................... 5-30 spray on/off.......................................... 9-47 spray speed .......................................... 5-30 start ...................................................... 9-83 start delay............................................. 9-97 status .................................................... 9-85 status information area .......................... 1-5 status screen........................................... 3-3 step once switch................................... 9-49 stop ...................................................... 9-84 stop and restart repeat operation............ 8-7 subtract ................................................ 5-57 syscount display/setting..................... 9-116 system initialization............................. 9-65 system message area.............................. 1-5 system switch....................................... 9-48 T table position display ......................... 10-32 teach mode............................................. 1-3 teach speed........................................... 9-35 time ...................................................... 9-68 timer..................................................... 5-48 title area ................................................. 1-5 tool dimensions.................................... 9-25 tool registration.................................. 9-104 tool shift............................................... 9-56 total playback count display .............. 10-48 total repeat cycles of program ........... 9-106 touch panel pen...................................... 1-4 touch panel short circuit check ............ 9-67

Q qtool switch ......................................... 9-48 R record data inhibit................................ 9-37 register................................................. 9-91 registering the program number ............ 5-3 repeat mode ........................................... 1-3 repeat once switch ............................... 9-48 repeat operation ..................................... 8-2 repeat status display ............................ 10-8 rps switch............................................. 9-49 3



Index

track off ............................................... 5-59 track on................................................ 5-59 traveler shift with gun tip fixed ......... 10-23 true jump ............................................. 5-52

W wait override ........................................ 8-10 warning log .......................................... 9-80 work pitch ............................................ 12-8 work shift............................................. 9-57 work space output................................ 9-52

U uc jump ................................................ 5-51

X

V

xyz shift ............................................... 9-54

version information ............................... 2-2

Z zeroing ................................................. 9-19 zeroing data set/display ....................... 9-22

4



October 2001: 1st Edition November 2002: 2nd Edition Publication : KAWASAKI HEAVY INDUSTRIES, LTD. ROBOT DIVISION 90203-1075DEB All rights reserved. Copyright © 2001 KAWASAKI HEAVY INDUSTRIES, LTD.


KAWASAKI ROBOT C Series Controller, Explosion-proof Type OPERATION MANUAL

Kawasaki Robotics (USA), Inc.

Kawasaki Robotics GmbH Kawasaki Machine Systems Korea

Kawasaki Robotics San Jose Office

Taiwan Kawasaki Robot Center

Kawasaki Heavy Industries, LTD. Tokyo Head Office

KAWASAKI HEAVY INDUSTRIES, LTD. ROBOT DIVISION

Kawasaki Heavy Industries, Ltd.

41, 2-Chome Hamamatsu-cho Minato-ku Tokyo, 105-6116 JAPAN(World Trade Center building)

TEL 81-(0)3-3435-2501 FAX 81-(0)3-3437-9880

Kawasaki Robotics (USA), Inc.

28059 Center Oaks Court Wixom, Michigan, 48393 U.S.A

TEL 1-248-305-7610 FAX 1-248-305-7618

Kawasaki Robotics San Jose Office.

1020 Commercial Street, Suites 104-106 San Jose, CA95112 U.S.A

TEL 1-408-392-0290 FAX 1-408-392-0294

Kawasaki Robotics GmbH

29 Sperberweg, 41468 Neuss, GERMANY

TEL 49-(0)2131-3426-0 FAX 49-(0)2131-3426-22

Kawasaki Robotics (UK) Limited

Units 6&7, Easter Court, Europa Boulevard Westbrook, Warrington, WA5 5ZB, England

TEL 44 -1925-71-3000 FAX 44 -1925-71-3001

Kawasaki Machine Systems Korea, Ltd

3Fl(307), Industrial Complex Support Bldg., 637 Kojan-Don, Namdong-Gu, Inchon, 405-310 Korea

TEL 82-32-821-6941/5 FAX 82-32-821-6947

Taiwan Kawasaki Robot Center

1F 122 Ching Hsan 7 Street, Hsinchu, Taiwan R.O.C.

TEL 886-3-666-1558 FAX 886-3-666-1559

Kawasaki Heavy Industries, Akashi

1-1, Kawasaki-cho Akashi, 673-8666 JAPAN

TEL 81-(0)78-921-1560 FAX 81-(0)78-923-6548

* All descriptions in this booklet are subject to change for improvement without prior notice.


Kawasaki Robotics (UK) Limited

manual robo kawasaki.pdf

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