IRC5 Programming and Operation_2007

7/26/2019 IRC5 Programming and Operation_2007

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IRC5PROGRAMMING AND OPERATION

ABBLimited-Robotics


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Facilities Guide

Workshop Area

Must be accompanied by a member of ABB staff

Health & Safety / Customer confidentiality

Please ask if you would like a guided tour

Phones, Faxes and Internet access

Outgoing calls - Phones available in training rooms and reception

relay

Internet access - via terminal in main training area

Password: Trainme2day11

Contacting ABB personnel

Please ask instructor if you would like to contact or meet up withfriends or acquaintances at ABB

Smoking area

Access via main entrance


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Site Map

VisitorsParking

Fire Assembly point

Employee parking

SmokingArea


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Training Suite

Room3

PaintTrainingroomsOffice

Auriga House Ground Floor Plan

Fire Exit

Workshop gangways

MechTraining

Area

Fire Exit

Room 1

Weld Trainingrooms

Reception

Smoking shelter

Please use main entrance

TechnicalHelp desk

Robot Spare Parts

SolutionsCentre

Main Entrance

Fire Exit


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Programming&

Operation5 day

Programming &Operation for

Mig / Mag5 day

Operator

2day

IRC5 Training course scheme

RobotStudio 5Certified User

3 da

Mig MagProcess

Appreciation3 da

Electrical

4 da

MultiMoveProgramming

3 da

RotaryExternal AxisProgramming

2 day

AdvancedStage1

5 day

Advanced

Stage2

3 day

SmarTac

2 day

PickMaster

5 day

Mechanical

4 day

WebWare

2 day


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System warm start up, shut down and error recovery

Basic program operation

Basic production programming techniques

Course Objectives

Safety requirements for basic programming and operation




Create and use routines

Use input output instructions

Flexpendant communication instructions

Numerical data instructions

Saving and opening programs




Numerical data instructions

Saving and opening programs


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Potential Accident Risks

Modifying program within robot cell

Test run

Fault tracing

Repair Process hazards


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ABB Safety Solutions an Overview

Emergency stop

Operating mode

Auto

Manual < 250 mm/s

Manual 100%

Enabling device

Hold-to-run

Safeguard stop(Auto and Manual)

Limiting the workspace Lockouts and Interlocks


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Law Demands

The construction design for the robot is to comply withrequirements that are stated in ISO 10218, Jan 1992,

industrial robot safety. Robot also comply with

requirements for ANSI/RIA 15.06-1999. Definition of safety function / regulations:

Emergency stop IEC 204-1, 10.7

Enabling device ISO 11161, 3.4 Safeguard ISO 10218 (EN 775), 6.4.3

Reduced speed ISO 10218 (EN 775), 3.2.17

Interlock ISO 10218 (EN 775), 3.2.8

Hold to run ISO 10218 (EN 775), 3.2.7

ANSI: American National Standards Institute

RIA: Robotics Industries Association

ISO: International Standards Organisation

IEC: International Electrotechnical Commission

EN: European Normalisation


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Emergency Stop

Built in emergency stop

pushbuttons are found bothon the FlexPendant andController-X-module as

default.

be connected to the robotsystems safety chain.


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Operating Mode

Automatic mode

Production mode (no speed limit)

Manual mode < 250 mm/s max velocity 250 mm/s

100 % Option, robot can beogge teste w t no spee m t.


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Enabling Device (Dead Mans Grip)

The enabling device is a press switch with threepositions

The switch must be in the middle positions in order toactivate the motors

All robot movement will immediately stop if the switch is

re ease or presse o e o om

Enabling device


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Hold-to-Run (Manual 100 %)

Only found on Version 1 FlexPendants

Hold-to-run buttons removed on Version 2 FlexPendant

Option (this function can be selected in the parameters)

The enabling device and one of the hold-to-run buttonsmust be pressed simultaneously to start the motors

Enabling device

Hold-to-run buttons

(for left or right hand)


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Version 2 FlexPendant Hold-to-Run

Hold-to-Run buttons and

prompt message removed

Hold down the play key, to run the program

Hold down the FWD or BWD key to step through program

Release the pressed key to stop execution


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Safeguard Stop

The connection of safeguard stop enables inter-locking

of external safety equipment, such as: doors, photo-electric trip device, photo cells or pressure mats.

Safeguard stop can be connected in two ways:

Always active regardless of operating modes

n y act ve w en automat c mo e s se ecte

Possibility to activate Delayed Safeguard Stop.A delayed stop gives a smooth stop. The robot stops inthe same way as at a normal program stop with no

deviation from the programmed path.


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Limiting the Workspace

To avoid the risk of getting

caught between the robot andthe outer safe equipment, e.g.a fence, the robots workspace

can be limited:

All axis can be software controlled

Axis 13 can be limited byadjustable mechanical stops andcontrolled by limit switches


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Safety Regarding Grip Device

All grip devices must be designed so the work piece will

be held on power failure and other disturbances in therobot system

Make yourself familiar with the output used to activatethe gripper

n your ngers w en manua y opera ng gr pper romFlexPendant


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Electrical Safety

Hazardous power in both the cabinet and the robot

Net power 400 VAC

Transformer 260 VAC Rectifier 260 VAC and 370 VDC

Power supply 370 VDC

Power supply to robot motors up to 370 VDC

Customer equipment


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Safety Regarding Releasing the Breaks

The breaks on the robot motors can be manually

released.

Before the breaks are released, be sure that the weightof the robot arm is supported and wont cause damage toindividual or equipment


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Operational Exercise

Execute program

Manual reduced speed

Enabling device

Manual Full speed

Enabling device and Hold-to-run

Automatic

Stepwise Operation

Fwd Bwd and limitations

E-Stop and recovery

Debug menu

Starting program from cursors position

Program Reset


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Jogging the robot


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Robot Axis

Axis 1

Axis 2

Axis 3

Axis 4


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Jogging The Robot

Motion Types

Robot

Major Axes 1,2,3

Minor Axes 4,5,6

Line r / Reorient tion

Base

World

Tool

Workobject

Can Jog the Robot in Incremental steps.


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QuickSet menu

With the QuickSet menu you can access some oftenused settings

Mechanical unit

Jogging mode

(1-3, 4-6, linear or reorient)

Increment

Running Mode

Step Mode

Override Speed


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The Jogging Window


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Exercise 1Programming movements


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ABB Main Menu

Programming with the FlexPendant


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Creating a new Program File


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Creating a new Program File


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Programming Positions


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MoveJ - moves the TCP in a way which is

easiestfor the robot and not in a straight line

Speed Data ToolData

Positional Movements Instructions

MoveJ *, v1000, z50, tool0;

Robot Position Zone Data


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Zone

Zone data describes how close to the destinationposition the axes must be before the next instruction

can be executed.

Robot path in automaticmode. Programmedposition.

MoveL p2, v100, z10, tool0;

Zone size.


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Joint & Linear Move

Joint Move

P1

near ove

P2


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MoveL - moves the TCP in a Linear direction

or straight line

Speed Data ToolData

Positional Movements Instructions

MoveL *, v1000, z50, tool0;

Robot Position Zone Data


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Modifying the position in a positioning instructions Move robot to desired position

Select the instruction or target to be changed

Press Modify position

ModPos


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Program Edit Menu

T l C P i


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Tool Centre Point

Tool MountingFlange

+X

Relative Directions X, Y & Z.

+Y

+Z

T l C t P i t


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Tool Centre Point

Position & movement of robot always related to TCP.

Defined as being somewhere at the end of the tool.

Many can be defined but only one active at any one time.

Can be programmed manually but only if accurate data.

Normally use robot to define TCP.

If tool is damaged or replaced, dont change program justredefine the tool.

T l C t P i t D fi iti M th d


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Tool Centre Point Definition Methods

Default Orientation (same direction as tool0)

TCP & Z Just Z direction defined (X stays in same plane as tool0)

TCP & Z, X both Z and X defined

From 3 to 9 approach points

TCP D f lt O i t ti


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TCP Default Orientation

No rotation about X, Y or Z

X

Y

Z

TCP & Z


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TCP & Z

Z direction defined

TCP Z & X Mag welding and Water cutting


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TCP Z & X Mag welding and Water cutting

.

Both X and Z directions defined

TCP Definition Default Orient


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TCP Definition Default Orient

1

2

3 4

1

4

23

Plan view

TCP Definition Z & X


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TCP Definition Z & X

5

Jog robot so the tools intended Z and Xdirections, visually align to the basecoordinates Z and X axis.

Z Elongator point

Tool orientations are defined by the direction the tool ispositioned away from the datum point.

136

4 Jog along Base coordinate Z Axis to definetools Z direction

Jog along Base coordinate X Axis to define

tools X direction

2

X Elongator point

Tool Centre Point Definition Method


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Tool Centre Point Definition Method

Menu

Program data

Selecttooldata

Show data

New Name tool

Initial value orOK and select tool in list andEdit Value

ass:= type n g

Press OK

For RW5.06 Press and hold on tool in list to get context menu

For RW5.07 Press Edit

Select Define

SelectMethod and number ofPoints

SelectPoint 1,jog robot to calibration position and pressModify Position

Repeat for remaining points

Press OK

You will need to activate your TCP in the jog window


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Exercise 2Create a Tool Centre Point

Logical


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Set - turns ON a Digital Output.

Set doGripper;

Logical

Reset- turns

OFFa

Digital Output.

Reset doGripper;

Logical


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SetDO - changes the value of a Digital Output.

SetDO do15, 1;

Logical

orSetDO \SDelay := 0.2, do15, 1;

SetDO \Sync do15, 1;

Routines and program flow example


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Routines and program flow example

PickPen;MoveJ ,v200,

Main

main

PickPen PutPen

,

MoveL

v100,MoveL v300,MoveL v200,MoveL v200,MoveJ ,v200,PutPen;

MoveJ ,v200,MoveL v1000Set doGripper;MoveL v200,

Main routine Sub routines

MoveJ ,v200,MoveL v1000Reset doGripper;MoveL v200,

Routines


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Repetitive instruction sequences, that occur frequently in the program,should form their own routines.

Routines separate the program into smaller more easily understoodparts, these can then be called anywhere in the program using the

ProcCall instruction.

A Max of 16 characters are allowed for naming routines, meaningfulnames such as PickBlock, CutSquare and Put_Part etc will make

the program easier to follow and operate.

Routines can be tested by moving the Program Pointer to a routine.

Routines Exercise


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Create a new routine called PickPen

Activate your TCP

Program the robot to pick up the pen using the minimum amount of instructions

Test this routine

up ca e s rou ne an e e ou pu ns ruc on o pu e pen own

Call these routines in your main routine

Test your Main Routine


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Create Routine to pick and place

Pen

Work Object Coordinate System


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p10

j y

z

(900, 60, 500)

All program positions are attached to a work object

Wobj0 is the default coordinate system

It is advisable to use custom work objects

BaseWobj0

x

(0,0,0)

Work Objects


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Custom Work ObjectX1

Work Objects contain both User and Object Frames

Userframe

Objectframe

World

Work Object Frames


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p10(200, 0, 450)

User

Object

World

(400, 0, 50)

(300, 60, 0)

Work Objects and External Axis


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Workobject disconnected from robot worldand attached to mechanical unit

Object frame may be transposed

Defining a Work Object frames


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User and Object Coordinate Systems are usually both defined

at the same position.

World

World

Work Object Definition Methods


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User and Object Coordinate Systems are usually both definedat the same position.

Jogging along axis Work Objects


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Y

X

X

Y

Work Objects Summary


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WObjData is used to describe the area that the robot welds, processes,moves within etc.

If position Data is entered manually, the values can be taken from a

drawing.

Programs can be reused quickly following changes in the robot installatione.g. a x ure s move , us re e ne user coor na e sys em.

Variations in how the work object is attached can be compensated for. Forthis, however, some sort of sensor will be required to position the workobject.

Robot can be jogged along the axes of the work object.

Work Object Definition Method


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In the jogging windowactivate the TCP that you will use to define Workobject

Menu

Program data

Select wobjdata and tapShow Data

SelectNew

Name work object

Press OK

.

For RW5.07 Press Edit Select Define

Select3 points for user frame andNo Change for Object frame definition

Jog the tool to the User X1 point select and Modify Position

Repeat for User X2 and User Y1

PressOK and view the calculated result

Press OK to close

You will need to activate your workobject in the Jogging window

in order to program or jog relative to it.


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Exercise 4Create a Work Object

Positional


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MoveC - moves the TCP in a Circular

direction using the mid& endpoint of a semicircle

Speed Data ToolData

MoveC *, *, v1000, z10, tool0;

Robot Positions Zone Data

Circular Move


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p1

p2p4

Pick MoveC here

MoveL p1, v100, fine, tool0;

MoveC p2, p3, v100, z1, tool0;

MoveC p4, p1, v100, fine, tool0;

p3ModPos MoveC here

Path Following Exercise


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Start / Finish Start / Finish

Start / Finish

Direction




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Example of main routine


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Exercise 5Programming with Routines

What is a module


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%%%

VERSION:1

LANGUAGE:ENGLISH%%%

MODULE EX1

= - -

The Internal Structure of Modules

CONST robtarget p2:=[[1270.77,-93.78,386.13],[0.567071,0.054457,0.82157,0.02211],[-1,0,-

CONST robtarget p1:=[[1312.4,-132.16,381.39],[0.567077,0.054431,0.821568,0.02209],[-1,0,-

PROC main()

MoveL p1,v1000,fine,tool0;



ENDPROC

ENDMODULE

IRC5 Task Structure


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Robot Task

MainModule.mod

Program File.pgf

MainModule.mod System Modules.sys

Program Data

Routines

Program Data

MainRoutine Routines

IRC5 Task Structure


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Robot Task

ModuleA.mod

ModuleB.mod

MainModule.mod

Program File.pgf

Program Data

Routines

Program Modules.mod System Modules.sys

Program Data

Routines

Program Data

MainRoutine Routines

What are Modules

A d l i f ti d d t


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A module is a group of routines and data.

The module that contains the main routine is the MainModule

System modules are always present in memory and can be used to saveyour default data

Filename extensions are

XXXXX.mod Module

XXXXX.sys System Module

XXXXX.cfg Parameter File

XXXXX.pgf Program File

Creating a new program in IRC5


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A new program file is created (.pgf)

A MainModule with main routine is created

Saving program in IRC5


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A folder with the same name as the program is created

This folder contains the MainModule, Sub modules and theprogram file

The program file (.pgf),is an extensible mark-up language,XML, file that lists all program modules in the task

System Modules are NOT saved

Folder created with

same name

Saving Individual Modules


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Individual, Program or System modules can be saved

Select in Program Editor and Save Module As from File menu

Loading Programs


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Loading whole programs will overwrite existing programs

Each task will have its own program

Loading Modules


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Loading Program and System modules from the Program Editor

1

2

IRC5 System backup


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Backup_20050117

BACK INFO RAPID SYSPARSystem parametersSystem ID

Text information,programme.id,

HOMEMost files off

Flash disk fromActive system

System.xml

TASK 1

PROGMOD SYSMOD

TASK 1

PROGMOD SYSMOD

TASK 1

PROGMOD SYSMOD

TASK 0

PROGMOD SYSMOD

EmptyEmpty

ey. ,keystr.txt,

system.guid,template.guid

TASK 1

PROGMOD SYSMOD

System modulesProgram modulesUsed by system only!

Multitasking

Backed up regularly !!!


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Exercise 6Backup and Restore

Logical


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WaitDI - Waits until a Digital Input is set to eitherhigh or low.

WaitDI di1, 1;

Logical


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WaitUntil - Waits until 1 or several Inputs havebeen set.

WaitUntil di1=1;

WaitUntil di1=1 AND di2=1;

AND, OR

Logical


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WaitTime - Waits a set amount of time.

WaitTime 0.5;

(Waits 0.5 seconds)

WaitTime \ InPos, 0.5 ;(Optional Argument wait in position)

Logical


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Stop - is used to stop program execution.

Move J pTCPcheck, v100,fine,tGun;

Stop;


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Exercise 7Waiting for Inputs and Time

TPWrite


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TPWrite - writes Text/Data to FlexPendant.

TPWrite Execution Started;

TPWrite Num of produced parts= \Num:=reg1;

TPWrite String [\Num] | [\Bool] | [\Pos] | [\Orient]

TPErase


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TPErase - is used to clearthe display of the FlexPendant.

TPErase;

TPWrite Execution Started;

TPShow

TPSh i d i h h i d h Fl P d


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TPShow - is used to switch the window on the FlexPendant.

TPShow TP_PROGRAM;The Production Window will be active if the system is in AUTO mode.

Or

The Program Editor will be active if the system is in MAN mode.

TPShow TP_LATEST;

Show the previous FlexPendant Window before the current one.


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Exercise 8Operators Log Messages

C t I t li f t t t k it i t d t d

Comment


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Comment - Inserts a line of text so as to make it easier to understandthe program.

Comment / Uncomment Row

Comment Row Disabling Instructions sometimes better than delete!


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Comment Row Disabling Instructions, sometimes better than delete!

Compact IF where a single instruction is executed

CompactIF


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Compact IF - where a single instruction is executeddepending on whether a condition is met or not.

IF di1 = HIGH WaitTime 0.5;

or

IF di1 = HIGH PickPart;

The instruction may be a ProcCall which calls a

routine

IF where different instructions are executed

IF


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IF - where different instructions are executeddepending on whether a condition is met or not.

IF di1 = HIGH THEN

Circle;

IF di1 = HIGH THENCircle;

ELSEIF di2 = HIGH THEN

Outside;

ELSE

Oval;ENDIF

va ;

ENDIF


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Exercise 9Decision making with IF

TPReadNum - writes Text on FlexPendant and records

TPReadNum


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TPReadNum - writesText on FlexPendant and recordswhich Numbersare pressed.

TPReadNum reg1, How many Outsides should be produced?;

While - is used when a number of instructions are to be

While


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While - is used when a number of instructions are to berepeated as long as a given condition is met.

WHILE reg1> 0 DOOutside;

Decr reg1;

ENDWHILE

Repeats the instructions in the WHILE loop as long as

reg1 > 0

WHILE Condition DO... ENDWHILE


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Exercise 10Loops

ClkReset - is used to reset a clock that functions as a stop

Cycle Timing Instructions


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ClkReset is used to reseta clock that functions as a stopwatch, it sets it to 0.

ClkReset clock1;

ClkStart - is used to start a clock that functions as a stop.

ClkStart clock1;

ClkStop - is used to stopa clock that functions as a stop

watch.ClkStop clock1;

ClkRead() - is a function that reads a timing clock and

ClkRead()


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ClkRead() is a function that reads a timing clock andreturns its value.

ClkReset clock1;ClkStart clock1;

MoveJ *, v1000, fine, tool0;

ClkStop clock1;

TPWrite Cycle Time=\Num:=ClkRead(clock1);

TPReadFK - writestext on the FlexPendant and recordsa number.

TPReadFK


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TPReadFK nPress, Choose?, Outside, Circle, Oval ,,;

TEST - where different instructions are executed

TEST


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TEST where different instructions are executeddepending on the value of an expression or data.

TEST nPress

CASE 1:Outside;

Circle;

CASE 3:

Oval;

DEFAULT:

TPWrite Illegal choice;

Stop;

ENDTEST


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ProgrammingPractice

Course Objectives



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Numerical data instructionsSaving and opening programs




Numerical data instructionsSaving and opening programs

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IRC5 Programming and Operation_2007

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