ArcTechDigital Pro En

ArcTechDig_P_R23 04.07.00 en

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SOFTWARE

KR C...

ArcTechDigital 2.3for power sources with program number control

Configuration

for KUKA.KR C 5.2, 5.3, 5.4, 5.5

Issued: 11 April 2006 Version: 00

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e Copyright KUKA Roboter GmbHThis documentation or excerpts therefrommay not be reproduced or disclosed to third parties without the express permission of the publishers.Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, inthe case of a replacement or service work.We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepanciescannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on aregular basis, however, and necessary corrections will be incorporated in subsequent editions.Subject to technical alterations without an effect on the function.

PD Interleaf

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Contents

1 General 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 System requirements, Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Overview of the configurable options 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Description of the ArcTechDigital commands 11. . . . . . . . . . . . . . . . . . . .

2.1 General 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.1 Keyswitch for program execution without welding 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.2 Program run mode GO 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.3 Switching on the welding process 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Start welding -- ARC ON 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2.1 Schematic sequence diagram ARC ON 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2.2 Signal diagram ARC_ON and ARC_SWI 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Welding and ending seams -- ARC OFF 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3.1 Schematic sequence diagram ARC OFF 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3.2 Signal diagram ARC_OFF 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Welding a seam in several sections -- ARC SWITCH 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.1 Schematic sequence diagram ARC SWITCH 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.2 Signal diagram ARC_SWI 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Programs of the ArcTechDigital package 19. . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Program structure 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Overview of the ArcTechDigital files 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 ArcTechDigital -- basic settings 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Activating the ARC 20 option 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Minimum configuration for power source interface 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Minimum configuration for program number control 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.1 Meaning of the variables 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Principles of the definable signal table 29. . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Overview, definition 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1.1 Index tables for configuring physical outputs and inputs 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1.2 Signal tables for digital outputs and inputs 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Digital outputs 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2.1 Index table for physical digital outputs 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2.2 Signal tables for digital outputs 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2.2.1 Definition of the signal states 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Digital inputs 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3.1 Index table for physical digital inputs 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3.2 Signal tables for digital inputs 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Assignment of the signal grouping in normal operation 35. . . . . . . . . . . .

6.1 Assignment of the outputs 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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6.1.1 Output group O_WELD_START [ ] 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1.2 Output group O_ACK_START [ ] 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1.3 Output group O_STROB_PGNO [ ] 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1.4 Output group O_SEAM_END [ ] 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1.5 Output group O_ACK_WELD_E[ ] 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Signal output groups for fault service function 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2.1 Output group O_FLT_ARC_ON [ ] 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2.2 Output group O_FLT_WELD [ ] 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2.3 Output group O_FLT_CLEAN [ ] 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2.4 Output group O_ACK_FLT [ ] 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Assignment of the inputs 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3.1 Input group I_WELD_COND [ ] 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3.2 Input group I_START_MOVE [ ] 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3.3 Input group I_WELD_END [ ] 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3.4 Input group I_WELD_FLT [ ] 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3.5 Polling of the external keyswitch (Hot/Cold) 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3.6 Time_out when polling the inputs 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Options for program number specification 47. . . . . . . . . . . . . . . . . . . . . . . . .

7.1 Signal flow of the program numbers 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 Setting -- parity bit 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 Timing diagram program number interface (a) 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Setting the restart options 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 RESTART_OPTION 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1.1 Reaction to interpreter stop (STOP key) 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Configuration in event of ignition faults 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.2.1 Ignition repetition monitoring 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3 Ignition fault message suppression option 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Enumeration of the signal groups for fault service functions 51. . . . . . . .

9.1 Types of faults and causes 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 Ignition faults 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.2.1 Signal output group O_FLT_ARC_ON[ ] 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3 Welding faults and robot faults 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.3.1 Reaction to robot faults, EMERGENCY STOP and DRIVES OFF 51. . . . . . . . . . . . . . . . . . . . .9.3.2 Signal output group O_FLT_WELD[ ] 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.3.3 Signal output group O_FLT_CLEAN[ ] 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.3.4 Signal output group O_ACK_FLT [ ] 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.3.5 Signal O_FLT_SIGNAL 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.3.6 Signal APPL_RUN 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4 Special feature IR_STOPMESS program 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.4.1 Joint activation/deactivation routines 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5 Configurable fault service functions 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.5.1 Fault service functions defined by the user 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Further options 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1 Program test in manual mode 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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10.2 Ignition fault message suppression option 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.3 Seam monitoring delay option 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 Mechanical weaving 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1 Block selection response 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2 Weave patterns 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2.1 Two--dimensional weaving 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2.2 Creating the Spiral weave pattern 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2.3 Figure--of--eight weave pattern 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2.4 Changing and creating patterns for mechanical weaving 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2.4.1 Changing existing weave patterns 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2.4.2 Creating your own weave patterns 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2.5 Notes on mechanical weaving 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 Error messages / troubleshooting 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.1 Message groups 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.2 Message time 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.3 Message number 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.4 Originator 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.5 Message text 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.6 List of error messages 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 General

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1 GeneralIn the development of a welding robot that is easy and safe to use, top priority was given tothe optimized adaptation of the operator interface and the interfacing capability to weldingequipment with program number control, as well as uncomplicated handling of theArcTechDigital technology package.

This is intended to allow the trouble--free operation, parameter and hardware configurationand programming of arc welding applications. The entire range of KRL commands areavailable to you at the expert level. Configuration requires sufficient knowledge of the KRLprogramming language.

ArcTechDigital features:

G Menu--guided creation of programs at the user level.

G Simple operation using application--specific softkeys and menus.

G Prepared programs and subroutines.

G Adaptation to the peripheral equipment and configurable options of the digital outputs.

G Simple setting of variables, entries in files and parameter lists.

G Use of the function generators for two--dimensional mechanical weaving as well as thepossibility of configuring your own weave patterns.

G Adaptation to various welding controllers with program number control and their diffe-rent coding systems.

G Various routines used for ignition faults and monitoring of the number of ignition at-tempts.

G Restart options in case of faults.

This documentation has been created as a supplement to the documentation [Arc Welding,ArcTechDigital -- Operation] for the user group Expert. In addition to fundamentaldescriptions accompanied by schematic sequence diagrams and screenshots of applicationtests, information on standard routines as well as specific ArcTechDigital applications havealso been provided. This is intended tomake parameter and hardware configuration and theprogramming of arc welding applications easier.

In the development of a welding robot that is easy and safe to use, top priority was given tothe optimized adaptation of the operator interface and the interfacing capability to weldingequipment with program number control, as well as uncomplicated handling of theArcTechDigital technology package.

The entire range of KRL commands are available to you at the expert level. This requiressufficient knowledge of the KRL programming language.

The ARC Tech 20 commands ARC ON, ARC OFF and ARC SWITCH are describedin Chapter 2. Among other things, information is provided on variable settings, entriesrequired in files, and parameter lists.

Chapter 3 provides information on the programs and files contained in the ArcTechDigitalpackage. Information and notes on ArcTechDigital--specific basic settings are provided inChapter 4.

Chapter 5 explains adaptation to the peripheral equipment. The configuration of the digitalinput and output groups is dealt with in Chapter 6.

The transfer of program numbers is explained inChapter 7. Chapter 8 contains informationon the restart options.

Chapter 9 finally deals with fault situations and fault service functions. Types of faults thatcan occur during the ignition and welding processes, their possible causes and appropriatecorrective measures are described.

Further ArcTechDigital settings can be found in Chapter 10.

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The mechanical weaving option included in the ArcTechDigital technology package isdescribed in Chapter 11. There you will find fundamental information on the mode ofoperation of the function generators, two--dimensional mechanical weaving, and theconfiguration of weave patterns. Examples are used to show you how to change existingpatterns and how to create your own patterns.

Chapter 12 contains a list of error messages along with their causes, effects and remedialaction.

1.1 System requirements, Installation

The Software ArcTechDigital can be used with the following KRC--Software:

-- KR C2, KR C2ed05-- Software Rel. 5.2, 5.3, 5.4, 5.5

From system software version 5.1 onwards, technology packages are offeredexclusively as ad--on software modules. These are available on CD--ROM.

The installation, uninstallation, reinstallation and update of technology packagesare described in detail in the documentation[Installation/Uninstallation/Update of Tech Packages].

1 General (continued)

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1.2 Overview of the configurable options

The ArcTechDigital technology package also provides a range of options in addition to thebasic configuration:

G Adaptation to various welding controllers with program number control and their differentcoding systems.

G Various routines used for ignition faults andmonitoring of the number of ignition attempts.

G Re--ignition after faults.

G Restart options in case of faults in the seam.

G Configurable user--specific strategies and routines in case of faults.

G Selection of several defined patterns for mechanical weaving as well as the possibility ofprogramming your own weave patterns.

Most options are stored in variables that are defined in the files $CONFIG.DAT andA20.DAT.

Fundamental information on operator control as well as the menu--guided creation ofprograms at user level is provided in the documentation [Arc Welding, ArcTechDigital --Operation].

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2 Description of the ArcTechDigital commands

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2 Description of the ArcTechDigital commands

2.1 General

The general ArcTechDigital commands are described in this chapter. Softkey assignmentsand their meaning. Explanations of the main terms ARC ON, ARC SWI and ARC OFF withsequence diagrams and signal diagrams.

2.1.1 Keyswitch for program execution without welding

If the keyswitch function has been configured, the appropriate status must be active(I_ENB_W_EXT.STATE TRUE or FALSE according to the configuration). Otherwiseweld-ing is not possible.

2.1.2 Program run mode GO

Welding is only possible in the program run mode GO. MSTEP and ISTEP do not allowthe program to run properly. More detailed information on selecting program run modes canbe found in the chapter [Executing and stopping programs].

2.1.3 Switching on the welding process

After the computer runs up, (hot) welding is always deactivated, as is indicatedby theweldingtorch being struck through on the left--hand status key bar. In order to be able to weld, thisstatus key must be switched to the HOT position corresponding to the symbol shown onthe left.

2.2 Start welding -- ARC ON

The command ARC ON contains the parameters for moving the welding torch (type ofmotion, velocity, etc.) from the home position to the start point of the seam, the startparameters (start delay) and the program number.

While the ARC ON program phase is being executed, the system scans the peripheralsignal I_WELD_COND to check whether the welding controller is ready.When theweldingtorch reaches the ignition position, arc ignition is enabled by means of the signalO_WELD_START[ ].

When the arc has been struck, the welding power source supplies the signalI_START_MOVE[ ], as a result of which the robot starts to move in accordance with theprogrammed path and velocity. The signal O_ACK_START[ ] informs thewelding controllerthat the robot is moving.

The movement from the home position to the start point of the seam can be executed as aPTP, LIN or CIRC motion.

Approximation is not possible for ARC ON; the torch is stopped exactly at the start ofthe seam.

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2.2.1 Schematic sequence diagram ARC ON

For the purposes of simplicity, not all options are illustrated.

Initialization

Weld start

Currentflowing

Ignition fault message

Activation ofmonitoringsystem

EndARC ON

ARC ON

N

Y

Process continued with the next ARC OFFor ARC SWITCH command

Prg_ON_MODE< > 0

I_WELD_COND[ ]

O_WELD_START[ ]

I_START_MOVE[ ]

O_ACK_START[ ]

Standbytest

(Option polled)I_ENB_W_EXT [ ]

Positioning motionto ignition position

Synchronization

TimeoutY

(Poll to see if power source ready)(Keyswitch polled)(Weld ON softkey)

Ignition programnumber output

2 Description of the ArcTechDigital commands (continued)

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2.2.2 Signal diagram ARC_ON and ARC_SWI

ARC_ON ARC_SWI

P0

P1

P2

I_WELD_COND [ ]

I_ENB_W_EXT [ ]

O_WELD_START [ ]

I_START_MOVE [ ]

(O_ACK_START [ ] )

O_STROB_PGNO

Ignitiontime

if PRG_ON_MODE 0

Prog. no. = 1 Prog. no. = 2

P0

P1

P2

PRG_S

WI_MODE=2

Prog. no. = 1 Prog. no. = 2 Prog. no. = 3

PRG_S

WI_MODE=1

2.3 Welding and ending seams -- ARC OFF

The welding command ARC OFF contains the program number for the power source, themotion parameters and, if relevant, the mechanical weaving parameters used for a singleseam from a weld start (ARC ON) to the end of the seam, and also parameters for craterfilling. A single seam therefore requires at least two commands, namely ARCON and ARCSWITCH.

If a seam consists of several seam sections with different motion and/or weld parameters,the command ARC OFF is used for the last seam section.

Motions from the ignition point (ARCON), or in caseof several seam sections from the targetpoint of the last section of an ARC SWITCH command to the end point of the seam, canbe LIN or CIRC motions.

Approximate positioning to the next motion block is not possible with ARC OFF; themotion concludes with the exact positioning at the target point (end of the seam).

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2.3.1 Schematic sequence diagram ARC OFF

EndARC OFF

ARC OFF

Current off I_WELD_END[ ]

O_SEAM_END[ ]

Positioning motion tothe end point withweld velocity of theARC_OFF command

O_STROB_PGNO[ ]

Program number output

Program numbertransfer

Cancel weld startsignal at endposition

Y

N

O_ACK_WELD_E[ ]Synchronization


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2.3.2 Signal diagram ARC_OFF

ARC_SWI ARC_OFF

P0

P1

P2 Prog. no. = 6PRG_SWI_MODE = 1

Prog. no. = 5

O_STROB_PGN0 [ ]

O_SEAM_END [ ]

I_WELD_END [ ]

Crater time+Burnback time+Gas postflow time

P0

P1

P2

Prog. no. = 5

O_ACK_WELD_E[ ]

PRG_S

WI_MODE=2

PRG_S

WI_MODE=1

2.4 Welding a seam in several sections -- ARC SWITCH

The command ARC (shown as ARC SWITCH in the menu) is used between thecommands ARC ON and ARC OFF when the seam is divided into several sections withdifferent motion and/or weld parameters.

ARC SWITCH contains the program number, the motion parameters for the current sectionof the seam, and also the parameters for the weld velocity and the mechanical weaving forthe current section of the seam.

In the interest of efficient operations, approximate positioning should be used for motionsin ARC SWITCH commands if exact positioning between individual seam sections is notabsolutely essential.

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2.4.1 Schematic sequence diagram ARC SWITCH

Positioning motion tothe end point withweld velocity of theARC_SWI command

EndARC SWITCH

ARC SWITCH

O_STROB_PGNO[ ]

Program number output

Program numbertransfer

Process continued with the next ARC OFFor ARC SWITCH command


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2.4.2 Signal diagram ARC_SWI

ARC_ON ARC_SWI

P0

P1

P2

I_WELD_COND [ ]

I_ENB_W_EXT [ ]

O_WELD_START [ ]

I_START_MOVE [ ]

(O_ACK_START [ ] )

O_STROB_PGNO

Ignitiontime

if PRG_ON_MODE 0

Prog. no. = 1 Prog. no. = 2

PRG_SWI_MODE = 1

P0

P1

P2

PRG_S

WI_MODE=2

Prog. no. = 1 Prog. no. = 2 Prog. no. = 3

PRG_S

WI_MODE=1

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3 Programs of the ArcTechDigital package

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3 Programs of the ArcTechDigital package

3.1 Program structure

In the following block diagram the program structure of the KR C1 robot controller is shownin the Welding robot configuration.

The interface to the welding controller is implemented in the form of a configurable hand-shake. Settings for analog outputs as well as digital outputs and inputs are defined in thefile $Config.dat.

.dat

.dat

Cell.src$Config.dat.

A20.src

IR_Stopm.src

Flt_serv_d.srcP00.src

Weav_def_d.src

Bas.src

Sps.sub

Switch--offroutineafter an

interpreter stop

A20GLOBALSGlobal andapplication

data

Autom./Ext.

organizationprogram

Generalhandling

of robot faults

Functionsforrobotmotion

Functions forAutom./Ext.HandshakeCheck Home

User--definablefault

servicefunctions

Definition andparameters

formechanicalweaving

Functionsforarc

welding

Information about the hardware periphery of the robot controller can be found in the[Operating Handbook], chapter Connector panel / Peripheral interfaces and in the[Periphery] handbook.

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3.2 Overview of the ArcTechDigital files

The files listed below are included in the ArcTechDigital package. To assist you in findingrelevant information, you will always see the symbols shown on the left with their file namesthroughout this documentation wherever the corresponding file or parts of it are described.

$Config.datContains data specific to ArcTechDigital within the section

;FOLD ARCTECHDIGITAL GLOBALS; FOLD Structures and Definitions

...; ENDFOLD (Structures and Definitions); FOLD Main Options

...; ENDFOLD (Main Options); FOLD ArcTech Outputs

...; ENDFOLD (ArcTech Outputs); FOLD ArcTech Inputs

...; ENDFOLD (ArcTech Inputs); FOLD Default Datasets

...; ENDFOLD (Default Datasets); FOLD Statuskey Variables

...; ENDFOLD (Statuskey Variables); FOLD Peripheral Output groups; outputs weld start

...; outputs acknowledge start move

...; strobe program number

...; outputs weld end

...; outputs acknowledge weld_end

...; outputs fault while arc on

...; outputs stop weld after interrupt on seam

...; outputs stop cleaner after interrupt

...; outputs acknowledge fault

...; output for fault message

...; Wirefeed control

...; ENDFOLD (Peripheral Output groups)

3 Programs of the ArcTechDigital package (continued)

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; FOLD Peripheral Input groups; inputs as condition befor weld can start

...; inputs start moving

...; inputs weld is ended

...; Counter for Interrupt definition

...; inputs telling faults while welding

...; input for external enable weld

...; ENDFOLD (Peripheral Input groups); FOLD Internal System States

...; ENDFOLD (Internal System States);ENDFOLD (ARCTECHDIGITAL GLOBALS)

For additional entries, the section User--defined Variablesin the file $CONFIG.DAT is available.

A20.src Main program for arc welding with ArcTechDigital.

A20.dat Local data list for the program A20.SRC.

Flt_serv_d.src Program for fault strategies defined by the user, including ignition faults.Fault service function (additional START error).

Flt_serv_d.dat Contains local data list for the program FLT_SERV.SRC.

Weav_def_d.src Definition of the patterns for mechanical weaving.

You will see the following symbols at various points in this documentation; they indicatewhether manual changes are permitted in the section of a file being described.

Within the section / block shown, the changes or entries described must be made.

Within the section / block shown, no changes or entries may be made.

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4 ArcTechDigital -- basic settings

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4 ArcTechDigital -- basic settings

4.1 Activating the ARC 20 option

You must make, or check, the basic settings described below for operation withARC Tech 20.

The ARC20 option must always be activated (TRUE) when executing ArcTechDigitalapplications. At the same time itmust beensured that the variable A10_OPTION is inactive(DISABLED).

Corresponding entries using the menu function Monitor -- Variable -- Single

Variable Value for ArcTechDigital Characteristics

ARC20TRUE (default) ArcTechDigital applications

ARC20FALSE Normal, except ArcTechDigital

4.2 Minimum configuration for power source interface

Signals for basic signal traffic are located in the configuration file.

Digital outputs

Fold ArcTech Outputs in $Config.dat

Digital outputs Configure physical output

$Config.dat

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Digitale Eingnge

Fold ArcTech Inputs in $Config.dat

Digital inputs Configure physical input

4 ArcTechDigital -- basic settings (continued)

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4.3 Minimum configuration for program number control

ArcTechDigital permits a variety of coding systems for program numbers for the purpose ofensuring compatibility with the various welding controllers that are used.

Some Folds from the file A20.dat (in the directory ...\R1\TP\ArcTechDigital):

Fold Main Options in A20.dat

InfoThe signal declaration SIGNAL ARCD_ProgNr $OUT[from] TO $OUT[to] must corres-pond to the signal declaration of$Config.dat. If they do not correspond, the programnumber output will not function.

A20.dat

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Fold Internal States in A20.dat

4 ArcTechDigital -- basic settings (continued)

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Fold Internal States in A20.dat (Fortsetzung)

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Fold ARC Messages in A20.dat

4.3.1 Meaning of the variables

Corresponding entry using the menu function Monitor Variable Single:

Variable Type Characteristics

PRG_NO.FIRST_BIT INT Represents the physical output number of thefirst bit. Default = 0

PRG_NO.LENGTH INT Specification of the number of bits. Default = 4

PRG_NO.PARITY INT Output number for the parity bit.

PRG_NO.CODING INT Coding of the program numbers.-- Coding 1 = dual-- Coding 2 = 1 of n-- Coding 3 = 1 of (n--1)0 THEN$TECH[FG_NR1].FCT.ORDER=1$TECH[FG_NR1].FCT.CPNUM=4$TECH[FG_NR1].FCT.CPS1.X1=0.0$TECH[FG_NR1].FCT.CPS1.Y1=0.0$TECH[FG_NR1].FCT.CPS1.X2=0.25$TECH[FG_NR1].FCT.CPS1.Y2=1.0$TECH[FG_NR1].FCT.CPS1.X3=0.75$TECH[FG_NR1].FCT.CPS1.Y3=-1.0$TECH[FG_NR1].FCT.CPS1.X4=1.0$TECH[FG_NR1].FCT.CPS1.Y4=0.0

ENDIF

control points (CPNUM)

Thevalue for X canbebetween0.0 and1.0. Xn=1.0 corresponds to theweave lengthenteredin the W--parameter list 2 (Mechanical Weaving), i.e. the length over which a pattern isexecuted.

The value for Y can be between --1.0 and 1.0. Yn=1.0 corresponds to the lateral deflection(weave amplitude -- zero to peak) entered in the W--parameter list 2 (Mechanical Weaving).

The weave length X, the lateral deflection Y and the angle of the torch in relation to thewelding plane (weave angle) can be programmed for each weave pattern in theW--parameter list 2 Mechanical Weaving with menu prompting.

Additional information on menu--guided programming can be found in the documentation[Arc Welding, ArcTechDigital -- Operation].

11 Mechanical weaving (continued)

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11.2.1 Two--dimensional weaving

Weave patterns such as triangular and trapezoidal patterns result from the lateral deflectionof the torch during motion along the seam. Complex patterns are possible by means of asecond function generator that causes the torch to weave in the welding direction (X--axis).

Two practical functions (for thin sheet welding, for example), namely spiral weaving andfigure--of--eight weaving, are already included in the technology package. You can alsodevelop your own patterns. The following diagram illustrates the mode of operation of thefunction generator using the example of spiral weaving.

(--Y) (Y)

(--Y)

(Y)

Lateral deflection (amplitude) 1)

Deflection in direction of path 2)

Lateraldeflection(amplitude) 1)

Weave width

Torch

1) Lateral deflection (amplitude) = half weave width2) Deflection in direction of path= weave length

$TECH[FG_NR1].FCT.CPS1.Xn=x (0.0 ... 1.0)$TECH[FG_NR1].FCT.CPS1.Yn=x (0.0 ... 1.0)

Weav_def_d.src

$TECH[FG_NR2].FCT.CPS1.Xn=x (0.0 ... 1.0)$TECH[FG_NR2].FCT.CPS1.Yn=x (0.0 ... 1.0)

The ratio of the deflection in the welding direction (...FCTCTRL.SCALE_IN) to the weavelength (A.WEAVLEN_MECH) is 1:1. The lateral deflection (...FCTRL.SCALE_OUT)corresponds to the value set for half the weave width (A.WEAVAMP_MECH).

$TECH[N].FCTCTRL.SCALE_IN=1$TECH[N].FCTCTRL.SCALE_OUT=1

The Weave amplitude value is defined as zero to peak, i.e. it corresponds to half theweave width (peak to peak).

Themagnitude of the deflection in thewelding direction (...FCTCTRL.SCALE_IN) in relationto the weave length (W.WEAVLEN_MECH) is set in the file A20.SRC at a ratio of 1:1. Thelateral deflection (...FCTRL.SCALE_OUT) corresponds to the value set for the half weavewidth (W.WEAVAMP_MECH).

11.2.2 Creating the Spiral weave pattern

The following illustration depicts the development of the Spiral weave pattern. As a resultof the superposition of a lateral weave motion sin(x) with an orthogonally--acting weavemotion of the same frequency in the welding direction cos(x), the torch describes a motionin the form of a circle (with the same amplitude) or of an ellipse (with different amplitudes).

The spiral form results because the torch is moved by the amount of the weave length (fromX=0 to X=1) during one period (360) in the direction of welding.

A20.src

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sin(x) cos(x)

0 101

Superposition of cosine on sine With pathmotion

Without pathmotion

Welding direction

The following diagram shows the curve shapes of the function generators derived from thesine function. This is approximately a sine for the lateral deflection ($TECH[FG_NR1]...)and a cosine for the deflection in the direction of the path ($TECH[FG_NR2]...). The corre-sponding control point parameters are stored under CASE 6 ;spiral in the fileWeav_def_d.src. The figure of a spiral results from the superpositioning of these two mo-tions.

1 2

3 4

5 6--1

1Y

0X1,0

Y

01

2 3

4 5

6

--1

1

X1,0

1

1

232

6, 6

3

4

5

5

4--1

1

Y

0X

(--Y) (Y)

Deflection indirection of path

Lateral deflection (amplitude)

Resultant: spiral

Weave length

$TECH[FG_NR1]...(X 1 ... 6; Y 1 ... 6)

$TECH[FG_NR2]...(X 1 ... 6; Y 1 ... 6)

The control points for the Spiral weave pattern are defined in the file Weav_def_d.src.The parameters for the lateral deflection are stored in the first block (...NR1...).


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CASE 6 ;spiral

IF FG_NR1>0 THEN$TECH[FG_NR1].FCT.ORDER=1$TECH[FG_NR1].FCT.CPNUM=6$TECH[FG_NR1].FCT.CPS1.X1=0.0$TECH[FG_NR1].FCT.CPS1.Y1=0.0$TECH[FG_NR1].FCT.CPS1.X2=0.166666$TECH[FG_NR1].FCT.CPS1.Y2=1.0$TECH[FG_NR1].FCT.CPS1.X3=0.333333$TECH[FG_NR1].FCT.CPS1.Y3=1.0$TECH[FG_NR1].FCT.CPS1.X4=0.666666$TECH[FG_NR1].FCT.CPS1.Y4=-1.0$TECH[FG_NR1].FCT.CPS1.X5=0.833333$TECH[FG_NR1].FCT.CPS1.Y5=-1.0$TECH[FG_NR1].FCT.CPS1.X6=1.0$TECH[FG_NR1].FCT.CPS1.Y6=0.0

ENDIF

The second block (A_FG_MECH2...) contains the parameters for the deflection in the direc-tion of the path.

IF FG_NR2>0 THEN$TECH[FG_NR2].FCT.ORDER=1$TECH[FG_NR2].FCT.CPNUM=6$TECH[FG_NR2].FCT.CPS1.X1=0.0$TECH[FG_NR2].FCT.CPS1.Y1=-1.0$TECH[FG_NR2].FCT.CPS1.X2=0.083333$TECH[FG_NR2].FCT.CPS1.Y2=-1.0$TECH[FG_NR2].FCT.CPS1.X3=0.416666$TECH[FG_NR2].FCT.CPS1.Y3=1.0$TECH[FG_NR2].FCT.CPS1.X4=0.58$TECH[FG_NR2].FCT.CPS1.Y4=1.0$TECH[FG_NR2].FCT.CPS1.X5=0.916666$TECH[FG_NR2].FCT.CPS1.Y5=-1.0$TECH[FG_NR2].FCT.CPS1.X6=1.0$TECH[FG_NR2].FCT.CPS1.Y6=-1.0

ENDIF

11.2.3 Figure--of--eight weave pattern

An additional weave pattern, an asymmetrical figure--of--eight, is defined in the fileWeav_def_d.src under the designation CASE 7 ;eight. This pattern results from thesuperposition of a lateral weave motion with an orthogonally--acting weave motion in thedirection of welding with double frequency.

01

--0,5

0,5

Y Y

0 X

--1

1

X

--1

1

Y

0 X

2

3

4

5

6

7

8

91

2

3

4

5

6

7

8

91

23

4

5

6

7

8

9

$TECH[FG_NR1]...(X 1 ... 6; Y 1 ... 6)

$TECH[FG_NR2]...(X 1 ... 6; Y 1 ... 6)

Lateral deflection(amplitude)

Deflection indirection of path

Resultant: eight

Weave length

Weav_def_d.src

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11.2.4 Changing and creating patterns for mechanical weaving

The weave patterns defined by the manufacturer can be changed by the user, and newpatterns can be created.

11.2.4.1 Changing existing weave patterns

You can adapt the weave patterns defined in the file Weav_def_d.src to your own require-ments by changing the number of control points and their parameters.

You want to shift the Triangle pattern -- contained in the file Weav_def_d.src -- by 180in the phase angle.

The settings for the Triangle weave pattern are contained in the file Weav_def_d.src.

CASE 1 ;triangle

IF FG_NR1>0 THEN$TECH[FG_NR1].FCT.ORDER=1$TECH[FG_NR1].FCT.CPNUM=4$TECH[FG_NR1].FCT.CPS1.X1=0.0$TECH[FG_NR1].FCT.CPS1.Y1=0.0$TECH[FG_NR1].FCT.CPS1.X2=0.25$TECH[FG_NR1].FCT.CPS1.Y2=1.0$TECH[FG_NR1].FCT.CPS1.X3=0.75$TECH[FG_NR1].FCT.CPS1.Y3=-1.0$TECH[FG_NR1].FCT.CPS1.X4=1.0$TECH[FG_NR1].FCT.CPS1.Y4=0.0ENDIF

Represented graphically:

1

--1

0.00.25 0.5 0.75 1.0

X

Y2

1

=n

3

4


In order to achieve a phase shift of 180, it is merely necessary to change the parametersfor control points Y2 and Y3. The required changes have been made in the following list andare underlined for ready identification.

Weav_def_d.src


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CASE 1 ;triangle (phi = 180 degrees)

IF FG_NR1>0 THEN$TECH[FG_NR1].FCT.ORDER=1$TECH[FG_NR1].FCT.CPNUM=4$TECH[FG_NR1].FCT.CPS1.X1=0.0$TECH[FG_NR1].FCT.CPS1.Y1=0.0$TECH[FG_NR1].FCT.CPS1.X2=0.25$TECH[FG_NR1].FCT.CPS1.Y2=-1.0$TECH[FG_NR1].FCT.CPS1.X3=0.75$TECH[FG_NR1].FCT.CPS1.Y3=1.0$TECH[FG_NR1].FCT.CPS1.X4=1.0$TECH[FG_NR1].FCT.CPS1.Y4=0.0ENDIF

1

--1

0.00.25 0.5 0.75 1.0

X

Y

1

=n

3

4

2


11.2.4.2 Creating your own weave patterns

The following example shows the practical approach for creating your own weave patterns.A weave pattern is to be created as a combination of a trapezoid and a triangle.

It is recommendable to start by drawing the desired pattern. A range from 0.0 to 1.0 for thepath X covered within a period and 1 for the lateral deflection Y are predefined.

1

--1

0.0 0.4X

Y 32

=n

41

5

6

0.60.2 0.8 1.0


The first value for X must be 0 (zero) and the last value must be 1. Multiple X values thatare identical cannot be used.

The number of control points determined (CPNUM) as well as the X and Y values can beentered, for example, in the block CASE 8 ;default as minimums and flag for beginning ofthe file Weav_def_d.src, as shown in the following.

Weav_def_d.src

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CASE 8 ;Trapez - Dreieck

$TECH[A_FG_MECH1].FCT.ORDER=1

$TECH[FG_NR1].FCT.CPNUM=6 Number of control points$TECH[FG_NR1].FCT.CPS1.X1=.0 Value X for control point 1$TECH[FG_NR1].FCT.CPS1.Y1=.0 Value X for control point 1$TECH[FG_NR1].FCT.CPS1.X2=.2 Value X for control point 2$TECH[FG_NR1].FCT.CPS1.Y2=1.0 Value Y for control point 2$TECH[FG_NR1].FCT.CPS1.X3=.4 ...$TECH[FG_NR1].FCT.CPS1.Y3=1.0 ...$TECH[FG_NR1].FCT.CPS1.X4=.6$TECH[FG_NR1].FCT.CPS1.Y4=.0$TECH[FG_NR1].FCT.CPS1.X5=.8$TECH[FG_NR1].FCT.CPS1.Y5=-1.0$TECH[FG_NR1].FCT.CPS1.X6=1.0$TECH[FG_NR1].FCT.CPS1.Y6=.0

ENDIF

11.2.5 Notes on mechanical weaving

The quality of a seam welded with mechanical weaving is influenced by a variety of physicaland mechanical factors, such as the mechanical play in the gears, axis torsion, robotposition, path tangent, etc. In addition, interdependencies with the interpolation cycle as wellas the set robot--specific $Filter value also exist.

The weave motion is superposed on the path motion. In case of weave patterns such asTrapezoid or Spiral, this leads to an irregular welding speed during a period. This can varybetween the set path velocity and a multiple of it, depending on the relation of the weavelength (frequency) to the lateral deflection (amplitude).

The maximum weave frequency for mechanical weaving is depending on the robot typeconcerned influenced by several factors, for example by the resonant frequency of therobot/tool mechanical unit. Weave frequencies of up to 3 Hz (corresponding, for example,to a weave length of 3.33 mm at a travel speed of 0.6 m/min) are possible without causingproblems according to previous experience.

With higher weave frequencies, undesirable effects are liable to result in certain conditions(depending on the tool design and/or tool orientation). With weave frequencies > 3 Hz, themotion characteristics of the robot should therefore be individually tested in each case.

Weav_def_d.src

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12 Error messages / troubleshootingMessages of all categories are displayed in the message window. These can be eitherinformative messages that do not need to be acknowledged or messages that have to beacknowledged.

A message consists of the following items of information, for example:

Message group

Message timeMessage number

OriginatorMessage text

ACTIVE COMMANDS INHIBITED

COMMAND ACCELERATION EXCEEDED A2

12.1 Message groups

Hint messages

provide the operator with explanatory information, for example, if an illegal key has beenpressed.

Operational messages

signal the status of the system that has led to a control reaction, e.g. Emergency Stop. Themessage is cleared once its cause has been eliminated. In some cases, a secondary signalthat has to be acknowledged is set for reasons of safety.

Acknowledgement messages

indicate a situation that must in all instances be recognized and acknowledged with theacknowledge key. They are often a consequence of a status (operational) message. Anacknowledgement message stops a movement or prevents further operation.

Dialog messages

require confirmation by the operator (Yes or No softkeys). The message is cleared afterit has been confirmed.

12.2 Message time

The message time indicates the time at which the message was generated.

12.3 Message number

With theaid of themessagenumber, the corresponding cause, effect and remedy canquicklybe located in the list of error messages.

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12.4 Originator

The origin of the error is indicated in this field. In the case of ArcTechDigital, the entry isTPA20.

12.5 Message text

The text of the error message is shown here.

12.6 List of error messages

To make it easier to find error messages in the following list, the message number is shownfirst, unlike on the display. By referring to this message number, it is possible to obtain furtherinformation on an error and the appropriate remedial action. This information is subdividedinto:

Message text

is the actual text of the error message as displayed.

Cause

gives a detailed description of the cause of the error.

Monitor

indicates when the conditions for generation of the message are checked.

Effect

describes how the controller reacts to the error.

Remedy

describes what action the user can take to eliminate the error.

12 Error messages / troubleshooting (continued)

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1 Message text Option bit ARC20 not set

Cause -- ARC20 = FALSE

Monitor -- In ARC ON command

Effect -- Endless loop always with this message

Remedy -- Set ARC20 to TRUE, stop and restart Submit interpreter, data backup

2 Message text Submit is not running

Cause -- Submit interpreter has been stopped, etc.


Effect -- Endless loop always with this message

Remedy -- Restart Submit interpreter

3 Message text Wrong submit routine selected

Cause -- No SPS.SUB submit program running while ARC20=TRUE

Monitor -- During initialization of A20_INIT commands

Effect -- Endless loop with this message, as deactivation not otherwisepossible in event of interpreter stop

Remedy -- $PRO_I_O[ ] = R1/SPS ( )

4 Message text Weld controller not ready

Cause -- The inputs configured in the signal input group I_WELD_COND [ ]are missing when welding is activated

-- Position of the keyswitch (incorrect status for welding)


Effect -- Endless loop with this message

Remedy -- Move the keyswitch to the correct position-- Switch on power source (I_WELD_COND [ ])

5 Message text Ignition failure, no arc

Cause -- Configured signals not returned to input group I_START_MOVE [ ]Current flow not established

Power source sends this output too late or not at all

Weld current connections broken

Monitor -- ARC_ON command

Effect -- Ignition process is cancelled and restarted, once messageacknowledged, in accordance with configured option and number ofignition attempts set

Remedy -- For test purposes or start--up, the I_START_MOVE [ ] condition maybe deactivated

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6 Message text Continue without welding

Cause -- Too many ignition attempts; too many seam faults or interruptionwith RESTART_OPT = 0 (continue Cold)


Effect -- Seam not welded

Remedy -- Clean ignition position and make new block selection to ARC_ONposition

7 Message text Switch off welding

Cause -- Power source does not switch welding off or does so too late-- Incorrect configuration

-- Incorrect burnback parameters

Monitor -- In ARC OFF command

Effect -- Single message for user

Remedy -- Optimization of the burnback parameters

8 Message text Weld controller fault

Cause -- Periphery error: robot waiting for the inputs expected inI_WELD_FLT [ ]. Normally configured as current flow Gas present,coolant monitoring

-- Configuration error (OK state configured)

Monitor -- Continuous between ignition process and ARC_OFF command ifwelding

Effect -- Welding is switched off; weld process is restarted, once messageacknowledged, depending on RESTART_OPTION

Remedy -- Complete the configurationReconnect gas, water, etc. or check respective sensor

9 Message text Welding in operation mode T1 impossible!

Cause -- T1 mode and PROC_IN_T1 = FALSE

Monitor -- In advance run section of ARC ON command

Effect -- Program remains in this loop after message acknowledged

Remedy -- Set the above variable to TRUE ($config.dat)

1

Index

Index -- i

Zeichen$CONFIG.DAT, 29

$Config.dat, 19, 20

$STOPMESS, 51

AA.WEAVAMP_MECH, 59

A.WEAVLEN_MECH, 59A_FLT_SV_FCT, 50

A10.SRC, 59A20.dat, 21

A20.src, 21

Activating, 23Adaptation to the periphery, 29

ARC OFF, 13, 14

ARC ON, 11, 12ARC SWITCH, 15, 16

ARC20, 23

BBasic settings, 23

Block selection response, 56

CChanging existing weave patterns, 62

Control points (CPNUM), 58

Coordinate system TTS, 56Crater filling, 37

Creating your own weave patterns, 63

DDIGITAL INPUTS, 32

Digital inputs, 29Digital inputs (physical), 32

Digital outputs, 23, 29

Digital outputs (physical), 30Digitale Eingnge, 24

DRIVES OFF, 51

EEMERGENCY STOP, 51

External keyswitch, 45

FFAULT SERVICE FUNCTION, 50

Fault service functions, 54Fault situations and fault service functions, 51

Figure--of--eight weave pattern, 61

Figure--of--eight weaving, 57Files for ARC Tech 20, 20

Flt_serv_d.dat, 21Flt_serv_d.src, 21

Fold ARC Messages in A20.dat, 28

Fold ArcTech Inputs in $Config.dat, 24, 32Fold ArcTech Outputs in $Config.dat, 23, 30

Fold Internal States in A20.dat, 26, 27

Fold Main Options in A20.dat, 25

II_ENB_W_EXT.NO, 45

I_ENB_W_EXT.STATE, 45I_WELD_CTRL[ ], 32

Ignition faults, 51

Ignition repetition, 50IN_NR, 32

Index table for physical digital inputs, 32Index table for physical digital outputs, 30

Index tables, 29

Input group I_START_MOVE [ ], 43Input group I_WELD_COND [ ], 42

Input group I_WELD_END [ ], 43

Input group I_WELD_FLT [ ], 44Installation, 8

Interpreter stop (STOP key), 49

IR_STOPMESS program, 53

LLateral deflection (weave amplitude), 58

MMAX_AUTO_R, 50Maximum weave frequency, 64

Mechanical weaving, 56

Minimum configuration, 23, 25Motion characteristics of the robot, 64

NNAME_NAT[ ], 30, 32Notes on mechanical weaving, 64

O

Index

Index -- ii

O_SEAM_END[ ], 37O_WELD_CTRL[ ], 30

OUT_NR, 30

Output group O_ACK_FLT [ ], 41Output group O_ACK_START [ ], 36

Output group O_ACK_WELD_E[ ], 38

Output group O_FLT_ARC_ON [ ], 39Output group O_FLT_CLEAN [ ], 41

Output group O_FLT_WELD [ ], 40

Output group O_SEAM_END [ ], 37

Output group O_STROB_PGNO [ ], 37Output group O_WELD_START [ ], 35

PPower source interface, 23

PRG_NO.CODING, 28

PRG_NO.FIRST_BIT, 28PRG_NO.LENGTH, 28

PRG_NO.PARITY, 28

PRG_ON_MODE, 47

PRG_SWI_MODE, 47PRGNO_MAX, 47

PRGNO_MIN, 47

PROC_IN_T1, 55Program number control, 25

Program number specification, 47

Program run mode GO, 11Program structure, 19

Program test, 55

PULS_TIME, 31

RResonant frequency, 64

RESTART_OPT, 49RESTART_OPTION, 49

SSchematic sequence diagram ARC OFF, 14

Schematic sequence diagram ARC ON, 12

Schematic sequence diagram ARC SWITCH,16

Seam error, 52

Signal APPL_RUN, 53Signal diagram ARC_OFF, 15

Signal diagram ARC_ON, 13

Signal diagram ARC_SWI, 17Signal flow of the program numbers, 47

Signal grouping in normal operation, 35

Signal O_FLT_SIGNAL, 52

Signal output group O_ACK_FLT [ ], 52

Signal output group O_FLT_CLEAN[ ], 52

Signal output groups for fault service function,39

Signal tables for digital inputs, 33

Signal tables for digital outputs, 31

Signal tables for digital outputs and inputs, 29

Spiral weave pattern, 59

Spiral weaving, 57

Start welding -- ARC ON, 11

STATE, 31

STOP key, 49

Switching on the welding process, 11

System requirements, 8

T

Time_out, 45

Timing diagram, 48

Trapezoidal weaving, 57

Triangular weaving, 57

Triple groups, 29

Two--dimensional weaving, 59

Types of faults, 51

W

WEAV_DEF.SRC, 58, 62

Weav_def_d.src, 21

Weave length, 58

Weave patterns, 57

Weave patterns, changing of, 62

Weave patterns, creating of, 63

Weaving, 56

Weaving, two--dimensional, 59

Welding a seam in several sections -- ARCSWITCH, 15

Welding and ending seams -- ARC OFF, 13

GeneralSystem requirements, InstallationOverview of the configurable options

Description of the ArcTechDigital commandsGeneralKeyswitch for program execution without weldingProgram run mode GOSwitching on the welding process

Start welding -- ARC ONSchematic sequence diagram ARC ONSignal diagram ARC_ON and ARC_SWI

Welding and ending seams -- ARC OFFSchematic sequence diagram ARC OFFSignal diagram ARC_OFF

Welding a seam in several sections -- ARC SWITCHSchematic sequence diagram ARC SWITCHSignal diagram ARC_SWI

Programs of the ArcTechDigital packageProgram structureOverview of the ArcTechDigital files

ArcTechDigital -- basic settingsActivating the ARC 20 optionMinimum configuration for power source interfaceMinimum configuration for program number controlMeaning of the variables

Principles of the definable signal tableOverview, definitionIndex tables for configuring physical outputs and inputsSignal tables for digital outputs and inputs

Digital outputsIndex table for physical digital outputsSignal tables for digital outputsDefinition of the signal states

Digital inputsIndex table for physical digital inputsSignal tables for digital inputs

Assignment of the signal grouping in normal operationAssignment of the outputsOutput group O_WELD_START [ ]Output group O_ACK_START [ ]Output group O_STROB_PGNO [ ]Output group O_SEAM_END [ ]Output group O_ACK_WELD_E[ ]

Output group O_FLT_ARC_ON [ ]Signal output groups for fault service functionOutput group O_FLT_WELD [ ]Output group O_FLT_CLEAN [ ]Output group O_ACK_FLT [ ]

Assignment of the inputsInput group I_WELD_COND [ ]Input group I_START_MOVE [ ]Input group I_WELD_END [ ]Input group I_WELD_FLT [ ]Polling of the external keyswitch (Hot/Cold)Time_out when polling the inputs

Options for program number specificationSignal flow of the program numbersSetting -- parity bitTiming diagram program number interface (a)

Setting the restart optionsRESTART_OPTIONReaction to interpreter stop (STOP key)

Configuration in event of ignition faultsIgnition repetition monitoring

Ignition fault message suppression option

Enumeration of the signal groups for fault service functionsTypes of faults and causesIgnition faultsSignal output group O_FLT_ARC_ON[ ]

Welding faults and robot faultsReaction to robot faults, EMERGENCY STOP and DRIVES OFFSignal output group O_FLT_WELD[ ]Signal output group O_FLT_CLEAN[ ]Signal output group O_ACK_FLT [ ]Signal O_FLT_SIGNALSignal APPL_RUN

Special feature IR_STOPMESS programJoint activation/deactivation routines

Configurable fault service functionsFault service functions defined by the user

Further optionsProgram test in manual modeSeam monitoring delay optionIgnition fault message suppression option

Mechanical weavingBlock selection responseWeave patternsTwo--dimensional weavingCreating the Spiral weave patternFigure--of--eight weave patternChanging and creating patterns for mechanical weavingChanging existing weave patternsCreating your own weave patterns

Notes on mechanical weaving

Error messages / troubleshootingMessage groupsMessage timeMessage numberOriginatorMessage textList of error messages

Date post:	25-Nov-2015
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