Robotic Arc Welding Interfacing

Josh Williamson

Fronius USA LLC

6797 Fronius Drive

Portage, IN 46368

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Presentation Topics

/ What is a Robotic Interface???

/ Interface History

/ Communication Protocols

/ Smart Interfaces

/ Overview of a robotic shipbuilding project.

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The connection and interaction between the robot, the welding hardware, and the user.

What is a Robotic Interface???

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The connection and interaction between the robot, the welding hardware, and the user. Robot

Controller and Teach Pendant

Robot Technician

Welding Power

Source & Interface

Robot and Positioning Equipment

What is a Robotic Interface

Interface Basic Signals

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Presentation Topics

/ What is a robotic interface???

/ Interface History

/ Communication Protocols

/ Smart Interfaces

/ Overview of a robotic shipbuilding project.

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Interface History

1982 Motoman System

General Interface trends

Interfaces progression over the last 25 years:

• Relays and discrete i/o

• Discrete i/o with 2 or 3 analog channels

• Increased functionality and process control

• Improved user interfaces (4 digits Windows type indefinite)

• Increased communication interfaces

(16 in/out 1024 signals, field buses, Ethernet)

• Increased computational power (8 kb 13 Mb)

• Easier to setup and diagnose

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Interface History

Early 80’s Motoman RX Controller Current Motoman DX Controller

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Interface History

ABB S1 Controller 1974-1982 ABB IRC5 Controller

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Presentation Topics

/ What is a robotic interface???

/ Interface History

/ Communication Protocols

/ Smart Interfaces

/ Overview of a robotic shipbuilding project.

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Interface Communication Protocols

EtherNet IP

IP Industrial Protocol

Developed by Rockwell 1990

Based on Common Industrial Protocol (CIP)

Ethernet (Modbus) UDP

Uses ethernet cables

Developed in 1979

No Royalty-Fee

Discrete I/O

Troubleshooting physical signals

Time consuming setup

Additional i/o boards sometimes needed

Profi-Bus

Developed 1989 in Germany

Software necessary to create network

GSD file (general station description)

DeviceNet

Developed by Rockwell

Based on CIP

Noise Sensitive

EDS file (electronic data sheet)

Profi-Net

Maintained by a community (PI)

Energy savings

GSD file (general station description)

Wireless

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Simple Interface

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Ethernet Interface BitMap

Troubleshooting (error codes)

EFD xxx Error with the wire feed system, refer to wire feeder error codes for more details Err 049, 051, and 052 Error detected in mains power input (phase missing or voltage too low/high). Check mains. Err PE Voltage detected on earth ground. Check for isolation between welding ground points and earth ground points. No H2O Error with the coolant system, check cooler for operation and system for good flow. STOP Communication or E-Stop condition with robot. Check for Robot Ready and Error Reset signals from robot.

Weld Process • The flow rate of the shielding gas is a critical aspect of

the welding process. Too high OR too low will have a

serious impact on weld results.

• Rule of thumb for the flow rate: 10 – 12 times the

diameter in l/min of flow

- 1.2mm x 10 = 12 l/min

- 1 l/min = 2.1 CFH

- 12 l/min x 2.1 = 25 CFH

• Helium and Hydrogen require about 50% more flow

than other gases due to their lighter weights.

Correct flow rate Excessive flow rate

Gas Pressure Sensor

Manually set gas valve that reports a gas error to the weld

system when flow is too low. Only errors out for low flow

and doesn’t report specific flow information.

Digital Gas Sensor

The specific gas flow is set, regulated, and monitored

using this device. Not only is a low or high flow rate

detected, but the system also reports back specific gas

flow data.

Fronius Options

Typically, the weld system opens and closes the gas

valve. If flow monitoring is desired within the system, the

following options are available.

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Presentation Topics

/ What is a robotic interface???

/ Interface History

/ Communication Protocols

/ Smart Interfaces

/ Overview of a robotic shipbuilding project.

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Smart Interfaces

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Smart Interfaces

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Smart Interfaces

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Smart Interfaces

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Smart Interfaces

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Smart Interfaces

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Smart Interfaces

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Smart Interfaces

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Smart Interfaces

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Smart Interfaces

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Smart Interfaces

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Smart Interfaces

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Smart Interfaces

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Presentation Topics

/ What is a robotic interface???

/ Interface History

/ Communication Protocols

/ Smart Interfaces

/ Overview of a robotic shipbuilding project.

32 Fronius USA /Product Overview / 6/11/2013

Tech Support USA

Service & Application Support

Weld Testing & Development

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