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KR C...
ArcTechDigital 2.3
for power sources with program number control
Version: 00
1 of 68
e Copyright
This documentation or excerpts therefrom may 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, in the case of a replacement or service work. We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a regular 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
1.1 1.2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System requirements, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of the configurable options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
8 9
2
2.1 2.1.1 2.1.2 2.1.3 2.2 2.2.1 2.2.2 2.3 2.3.1 2.3.2 2.4 2.4.1 2.4.2
11
11 11 11 11 11 12 13 13 14 15 15 16 17
3
3.1 3.2
19
19 20
4
4.1 4.2 4.3 4.3.1
23
23 23 25 28
5
5.1 5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.2.2.1 5.3 5.3.1 5.3.2
29
29 29 29 30 30 31 31 32 32 33
6
6.1
35
35
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ArcTechDigital 2.3 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 Output 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[ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal output groups for fault service function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output group O_FLT_ARC_ON [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output group O_FLT_WELD [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output group O_FLT_CLEAN [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output group O_ACK_FLT [ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assignment of the inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 36 37 37 38 39 39 40 41 41 42 42 43 43 44 45 45
7
7.1 7.2 7.3
47
47 47 48
8
8.1 8.1.1 8.2 8.2.1 8.3
49
49 49 50 50 50
9
9.1 9.2 9.2.1 9.3 9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6 9.4 9.4.1 9.5 9.5.1
51
51 51 51 51 51 52 52 52 52 53 53 53 54 54
10
10.1
Further options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program test in manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
55
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10.2 10.3
55 55
11
11.1 11.2 11.2.1 11.2.2 11.2.3 11.2.4 11.2.4.1 11.2.4.2 11.2.5
Mechanical weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block selection response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weave patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two--dimensional weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Creating the Spiral weave pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure--of--eight weave pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing and creating patterns for mechanical weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing existing weave patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Creating your own weave patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes on mechanical weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
56 57 59 59 61 62 62 63 64
12
12.1 12.2 12.3 12.4 12.5 12.6
65
65 65 65 66 66 66
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ArcTechDigital 2.3
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General
General
In the development of a welding robot that is easy and safe to use, top priority was given to the optimized adaptation of the operator interface and the interfacing capability to welding equipment with program number control, as well as uncomplicated handling of the ArcTechDigital technology package. This is intended to allow the trouble--free operation, parameter and hardware configuration and programming of arc welding applications. The entire range of KRL commands are available to you at the expert level. Configuration requires sufficient knowledge of the KRL programming language. ArcTechDigital features: G G G G G G G G G Menu--guided creation of programs at the user level. Simple operation using application--specific softkeys and menus. Prepared programs and subroutines. Adaptation to the peripheral equipment and configurable options of the digital outputs. Simple setting of variables, entries in files and parameter lists. Use of the function generators for two--dimensional mechanical weaving as well as the possibility of configuring your own weave patterns. Adaptation to various welding controllers with program number control and their different coding systems. Various routines used for ignition faults and monitoring of the number of ignition attempts. 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 fundamental descriptions accompanied by schematic sequence diagrams and screenshots of application tests, information on standard routines as well as specific ArcTechDigital applications have also been provided. This is intended to make parameter and hardware configuration and the programming of arc welding applications easier. In the development of a welding robot that is easy and safe to use, top priority was given to the optimized adaptation of the operator interface and the interfacing capability to welding equipment with program number control, as well as uncomplicated handling of the ArcTechDigital technology package. The entire range of KRL commands are available to you at the expert level. This requires sufficient knowledge of the KRL programming language. The ARC Tech 20 commands ARC ON, ARC OFF and ARC SWITCH are described in Chapter 2. Among other things, information is provided on variable settings, entries required in files, and parameter lists. Chapter 3 provides information on the programs and files contained in the ArcTechDigital package. Information and notes on ArcTechDigital--specific basic settings are provided in Chapter 4. Chapter 5 explains adaptation to the peripheral equipment. The configuration of the digital input and output groups is dealt with in Chapter 6. The transfer of program numbers is explained in Chapter 7. Chapter 8 contains information on the restart options. Chapter 9 finally deals with fault situations and fault service functions. Types of faults that can occur during the ignition and welding processes, their possible causes and appropriate corrective measures are described. Further ArcTechDigital settings can be found in Chapter 10.
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ArcTechDigital 2.3 The mechanical weaving option included in the ArcTechDigital technology package is described in Chapter 11. There you will find fundamental information on the mode of operation of the function generators, two--dimensional mechanical weaving, and the configuration of weave patterns. Examples are used to show you how to change existing patterns and how to create your own patterns. Chapter 12 contains a list of error messages along with their causes, effects and remedial action.
1.1
From system software version 5.1 onwards, technology packages are offered exclusively as ad--on software modules. These are available on CD--ROM. The installation, uninstallation, reinstallation and update of technology packages are described in detail in the documentation [Installation/Uninstallation/Update of Tech Packages].
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General (continued)
1.2
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ArcTechDigital 2.3
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2
2.1
2.1.1
2.1.2
2.1.3
2.2
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ArcTechDigital 2.3
2.2.1
ARC ON
Positioning motion to ignition position
Initialization Standby test (Option polled) (Poll to see if power source ready) (Keyswitch polled) (Weld ON softkey) I_WELD_COND[ ] I_ENB_W_EXT [ ]
Prg_ON_MODE <>0
Weld start
O_WELD_START[ ]
Timeout
Current flowing
I_START_MOVE[ ] O_ACK_START[ ]
Y
Synchronization Activation of monitoring system
End ARC ON
Process continued with the next ARC OFF or ARC SWITCH command
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2.2.2
ARC_ON
PRG_SWI_MODE = 1 P0 P1 P2 I_WELD_COND [ ] I_ENB_W_EXT [ ] O_WELD_START [ ] I_START_MOVE [ ] (O_ACK_START [ ] )
if PRG_ON_MODE<> 0 Prog. no. = 1
ARC_SWI
Prog. no. = 2
Ignition time
O_STROB_PGNO PRG_SWI_MODE = 2
P0 P1 P2
Prog. no. = 1 Prog. no. = 2 Prog. no. = 3
2.3
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ArcTechDigital 2.3
2.3.1
ARC OFF
Positioning motion to the end point with weld velocity of the ARC_OFF command
O_STROB_PGNO[ ]
O_SEAM_END[ ]
Current off Y
Synchronization
I_WELD_END[ ]
O_ACK_WELD_E[ ]
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2.3.2
ARC_SWI
PRG_SWI_MODE = 1
ARC_OFF
P2
Prog. no. = 5
O_ACK_WELD_E[ ]
PRG_SWI_MODE = 2
P0 P1 P2
Prog. no. = 5
2.4
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ArcTechDigital 2.3
2.4.1
ARC SWITCH
Positioning motion to the end point with weld velocity of the ARC_SWI command
O_STROB_PGNO[ ]
Process continued with the next ARC OFF or ARC SWITCH command
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2.4.2
ARC_ON
PRG_SWI_MODE = 1 P0 P1 P2 I_WELD_COND [ ] I_ENB_W_EXT [ ] O_WELD_START [ ] I_START_MOVE [ ] (O_ACK_START [ ] )
if PRG_ON_MODE<> 0 Prog. no. = 1
ARC_SWI
Prog. no. = 2
O_STROB_PGNO PRG_SWI_MODE = 2
P0 P1 P2
Prog. no. = 1 Prog. no. = 2 Prog. no. = 3
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ArcTechDigital 2.3
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3
3.1
.dat
.dat
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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ArcTechDigital 2.3
3.2
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3 ; ;
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 Variables in the file $CONFIG.DAT is available. A20.src A20.dat Flt_serv_d.src Flt_serv_d.dat Main program for arc welding with ArcTechDigital. Local data list for the program A20.SRC. Program for fault strategies defined by the user, including ignition faults. Fault service function (additional START error). 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 indicate whether 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.
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ArcTechDigital 2.3
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4
4.1
4.2
$Config.dat
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ArcTechDigital 2.3 Digitale Eingnge Fold ArcTech Inputs in $Config.dat Digital inputs Configure physical input
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4.3
A20.dat
Info The signal declaration SIGNAL ARCD_ProgNr $OUT[from] TO $OUT[to] must correspond to the signal declaration of$Config.dat. If they do not correspond, the program number output will not function.
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4.3.1
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5.1
5.1.1
Overview, definition
Index tables for configuring physical outputs and inputs
For the purpose of configuring the physical outputs and inputs, two index tables are provided in the block FOLD A20 in the file $Config.dat. G Digital outputs (DIGITAL OUTPUTS) G Digital inputs (DIGITAL INPUTS) Digital control signals from the robot controller to the welding controller -- e.g. Weld start, Gas manual; Digital control signals from the welding controller to the robot controller -- e.g. Arc struck, Weld end.
$Config.dat
In these index tables the assignment of the physical outputs and inputs is defined and references are made to the corresponding signal tables of the controller. This has the advantage that if the terminal assignments for the periphery are changed, it is merely necessary to alter the index tables accordingly.
5.1.2
$Config.dat
These options are stored in variables that are defined in the file $CONFIG.DAT, FOLD A20 GLOBALS. Settings are stored in this file. You can use the edit function to set or change the values of the variables in $CONFIG.DAT. In addition, menu--prompted viewing and alteration of the variable values is also possible.. For this purpose, a list can be opened in the status window by means of the menu Monitor -- Variable -- Single.. The current value is shown when the variable name is entered. You change this value by entering a new value in the field New value. A syntax check is not performed (for example, MIN and MAX values) when entries are made with the menu function Monitor -- Variable -- Single or when the file is edited. Further information on the ARC 20 signal tables contained in $CONFIG.DAT is provided in the descriptions of the various welding commands (ARC ON, ARC OFF, ARC SWITCH) in Section 3.
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ArcTechDigital 2.3
5.2
5.2.1
Digital outputs
Index table for physical digital outputs
Altogether 15 digital outputs (O_WELD_CTRL[1] ... [O_WELD_CTRL[15]) are available; their physical assignment (OUT_NR n) is freely definable. Fold ArcTech Outputs in $Config.dat
Example of corresponding entries using the menu function Monitor -- Variable -- Single: Variable O_WELD_CTRL[1].OUT_NR Type INT Characteristics Assignment of the physical output, e.g. 10 (default: 0) State at initialization (default: FALSE) FALSE = LOW TRUE = HIGH 20 characters between ; please note that if the string is changed, any characters not overwritten (possibly because they are not visible in the window) will be retained.
O_WELD_CTRL[1].INI
BOOL
O_WELD_CTRL[1].NAME_NAT[ ]
STRING
All O_WELD_CTRL[1].OUT_NR array elements are set to 0 at the factory, meaning they are inactive. The element INI defines the state to which the respective physical output OUT_NR is to be set on initialization. The value FALSE sets the output to LOW, the value TRUE to HIGH. The NAME_NAT[ ] entries (signal name) are comments with a string length of 20 characters between the quotation marks (...) whose content may be altered (while retaining the string length!).
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If you make any changes to the comments (signal name) NAME_NAT directly in the file $CONFIG.DAT please ensure that the length of the string between the quotation marks ( ) is exactly 20 characters long; use blanks if required. If you use the menu function Monitor -- Variable -- Single to make changes, an error message is displayed if the string exceeds 20 characters. The following example shows the assignment of the physical outputs and the signal states after initialization.
Index table
Output 10 INI
WELD START
HIGH LOW
Array O_WELD_CTRL[n] INI contains the initial value when the INIT routine is running before reaching the block coincidence movement.
5.2.2
5.2.2.1
If NO is set to 0 (zero), the index is deactivated and is ignored during execution of the program.
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ArcTechDigital 2.3
5.3
5.3.1
Digital inputs
Index table for physical digital inputs
Altogether 15 digital inputs (I_WELD_CTRL[1] ... I_WELD_CTRL[15]) are available; their physical assignment (IN_NRn) is freely definable. All IN_NR array elements are set to 0 at the factory, meaning they are inactive. For the purpose of assigning the physical inputs, you can enter their corresponding numbers in the index table DIGITAL INPUTS of the file $CONFIG.DAT: Fold ArcTech Inputs in $Config.dat
Physical inputs
Example of corresponding entries using the menu function Monitor -- Variable -- Single: Variable I_WELD_CTRL[1].IN_NR I_WELD_CTRL[1].NAME_NAT[ ] Type INT STRING Characteristics Assignment of the physical input, e.g. 2 (default: 0) 20 characters between ; any characters not overwritten will be retained.
All IN_NR array elements are set to 0 at the factory, meaning they are inactive. The NAME_NAT[ ] entries (signal name) are comments with a string length of 20 characters between the quotation marks (...) whose content may be altered while retaining the string length. Also see the note in Section 5.2.1. The following example illustrates the assignment of the physical inputs. I_WELD_CTRL[1] is assigned to physical input no. 2. Index table DIGITAL INPUTS ($CONFIG.DAT, FOLD A20 GLOBALS) DIGITAL INPUTS I_WELD_CTRL[1]={IN_NR 2,NAME_NAT[] WELD SOURCE READY}
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5.3.2
The following example shows a signal table from the file $CONFIG.DAT for a digital input. The element I_WELD_COND[1].NO with the value 2 refers to array 2 of the index table DIGITAL INPUTS (I_WELD_CTRL[15]) and thus to the physical input configured in it (see Section 5.3). The element STATE specifies the awaited state, in this case TRUE. ; inputs as condition before weld can start DECL FCT_IN_T I_WELD_COND[3] I_WELD_COND[1]={NO 1,STATE TRUE} I_WELD_COND[2]={NO 0,STATE FALSE} I_WELD_COND[3]={NO 0,STATE FALSE} Signal name Status (TRUE = HIGH) Index for addressing in index table I_WELD_CTRL[1 ] Index table DIGITAL INPUTS ($CONFIG.DAT, FOLD A20 GLOBALS) DIGITAL INPUTS I_WELD_CTRL[1]={IN_NR 2,NAME_NAT[] WELD SOURCE READY}
Example of corresponding entries using the menu function Monitor -- Variable -- Single: Variable I_WELD_COND[1].NO I_WELD_COND[1].STATE Type INT BOOL Characteristics Assignment of the physical input, e.g. 2 (default: 0) Awaited state Default: FALSE
Two other input signals are defined in this example as the second and third conditions that have to be met before welding can be started.
Information on the definition of the terms index table and signal table can be found in Section 6.1.
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ArcTechDigital 2.3
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6.1
6.1.1
Index table
Output 10 INI
In the signal table outputs weld start, assign the value 1 to the variable NO in the first line O_WELD_START[1]. The signal level should be static, so enter the value 0.0 for PULS_TIME. The element PULSE_TIME allows the programming of pulse times, if they are not overwritten by the current programming by means of inline forms or parameter lists. An output can be static (PULSE_TIME 0.0) or be output in the form of a pulse, in which case the pulse duration is programmed in seconds. For example, PULSE_TIME 0.3 corresponds to a pulse duration of 0.3 seconds.
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ArcTechDigital 2.3 Entries made using the menu function Monitor -- Variable -- Single: Variable O_WELD_START[1].NO O_WELD_START[1].PULS_TIME O_WELD_START[1].STATE Type INT REAL BOOL Characteristics Assignment to element in index table, e.g. 1 (default: 0) Pulse duration in seconds Default: 0.0 (static) Active state Default: FALSE
6.1.2
Output 11 INI
ACK START
HIGH LOW
Please note that PULS_TIME and STATE must be configured accordingly because the signal is not otherwise reset. Example: O_ACK_WELD_E[1]={NO 12, PULS_TIME 0.5,STATE TRUE}
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6.1.3
Output 12 INI
STROB_PGNO
HIGH LOW
Please note that PULS_TIME and STATE must be configured accordingly because the signal is not otherwise reset. Example: O_STROB_PGNO[1]={NO 3, PULS_TIME 0.3,STATE TRUE}
6.1.4
Output 10 INI
ARC_ON
HIGH LOW
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ArcTechDigital 2.3
6.1.5
Output 14 INI
ACK_WELD_E
HIGH LOW
Please note that PULS_TIME and STATE must be configured accordingly because the signal is not otherwise reset. Example: O_ACK_WELD_E[1]={NO 12,PULS_TIME 0.5,STATE TRUE}
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6.2
6.2.1
Output 15 INI
FLT_ARC_ON
ARC_ON
HIGH LOW
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ArcTechDigital 2.3
6.2.2
Output 10 INI
HIGH LOW
Output 13 INI
FLT_WELD
HIGH LOW
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6.2.3
Output 9 INI
FLT_CLEAN
HIGH LOW
6.2.4
Output 8 INI
ACK_FLT
HIGH LOW
Please note that PULS_TIME and STATE must be configured accordingly because the signal is not otherwise reset. Example: O_ACK_FLT[1]={NO 4,PULS_TIME 1.0,STATE TRUE}
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ArcTechDigital 2.3
6.3
6.3.1
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6.3.2
6.3.3
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ArcTechDigital 2.3
6.3.4
Index table DIGITAL INPUTS I_WELD_CTRL[2]={IN_NR 3,NAME_NAT[] ...} I_WELD_FLT[1] generally monitors the current flow. I_WELD_FLT[2] and [3] generally monitor the following: shielding gas, cooling or wire feed.
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6.3.5
6.3.6
A20.DAT
If you receive the message Object not found (no. 2047) while viewing or modifying variables in the file A20.DAT, you must set the value of the variable $DATAPATH[] to /R1/A20 (the characters are part of the string).
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ArcTechDigital 2.3
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7
7.1
PRG_ON_MODE
INT
PRG_SWI_MODE
INT
PRG_ON_MODE and PRG_SWI_MODE are normally identical. If PRG_ON_MODE=0, no O_ACK_START[ ] group is set.
7.2
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7.3
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ARC_ON
ARC_SWI ARC_SWI
ARC_SWI ARC_OFF
O_ACK_WELD._E [ ]
O_ACK_START [ ]
P0
P1
O_STROB _PGNO [ ]
P0 Prog. no. = 3
Prog. no. = 4
P1
PRG_SWI_MODE= 2
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8
8.1
Corresponding entries using the menu function Monitor -- Variable -- Single and characteristics: Variable Value 0 Characteristics -- Remedial action In the event of control or welding faults, the seam is completed without welding after a restart. After welding has been interrupted, the robot repositions the torch to the point of interruption. Welding is subsequently restarted. If welding is interrupted by pressing the STOP key (interpreter stop), the program cannot be restarted. Remedy: release the Start key after releasing the enabling switch. The same function as with RESTART_OPT=1, with the restriction that the number of permissible welding interruptions is limited to a maximum value. This maximum value is defined in the variable MAX_REA20. If this value is exceeded, the seam is completed without welding and a corresponding message is generated. The value specified in MAX_REA20 (default = 3) is valid for the entire seam between the commands ARC ON and ARC OFF. One or more user--defined fault service functions can be specified. Occurrence of a fault triggers a branch to the program FLT_SERV.SRC. Users can define their own fault service functions in this program.
RESTART_OPT 2
8.1.1
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8.2
8.2.1
Corresponding entries using the menu function Monitor -- Variable -- Single: Variable MAX_AUTO_R Value 3 (default) Meaning for repeat ignition attempts Maximum number of restart attempts
8.3
The entry A_FLT_SV_FCT=0 corresponds to the subroutine CASE 0 in the file FLT_SERV.SRC. This procedure is suitable, for instance, for cutting through insulating oxide layers (for example during aluminum welding) when the wire contacts the workpiece in order to allow a fault--free ignition process in a restart.
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9.1
9.2
9.2.1
Ignition faults
Signal output group O_FLT_ARC_ON[ ]
If the Arc struck signal (I_START_MOVE[ ]) is missing after a weld start, welding is switched off and an ignition fault signal is set. The following signal table is used for this purpose:
9.3
9.3.1
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9.3.2
9.3.3
9.3.4
The ignition fault output can additionally be reset here. O_ACK_FLT[2] = {NO 13,PULS_TIME 0.0,STATE FALSE}
9.3.5
Signal O_FLT_SIGNAL
This output signal is reset when the corresponding fault has been acknowledged. This reference manages general fault signals to the PLC.
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9.3.6
Signal APPL_RUN
This output signal is defined and configured in the Fold AUTOEXT Globals. The signal state is managed exclusively in the IR_STROPMESS program.
9.4
9.4.1
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ArcTechDigital 2.3 Once the causes have been eliminated, the technologies are switched back on again one after the other. Opened Folds:
The user must integrate his applications into the USER blocks in order to avoid impairing other technologies.
9.5
9.5.1
If ignition is not successful, the welding torch is moved back by X=100 mm. Program continuation: the torch is moved back by X=50 mm. Torch is returned to its start position.
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10
Further options
10
10.1
Further options
Program test in manual mode
For testing programs in manual mode T1 under real welding conditions, the variable PROC_IN_T1 (default value = FALSE) in the block ;FOLD BAS GLOBALS ;%{E}%V2.3.0,%MKUKATPBASIS,%CGLOBALS,%VGLOBALS,%P in the file $CONFIG.DAT can be set to TRUE. BOOL PROC_IN_T1=FALSE Corresponding entry using the menu function Monitor -- Variable -- Modify: Variable PROC_IN_T1 Type BOOL Characteristics Default: FALSE
If a hot welding attempt is made with the setting FALSE, the message Welding in operation mode T1 impossible! appears in the message window.
10.2
The ignition fault messages are suppressed if the condition START_CNT< MAX_AUTO_R is met and AUTO_RETRY = 1. If AUTO_RETRY = 0, an error message appears in the message window after every ignition fault.
10.3
A_CTRL_DELAY= 800 [ms] means that the seam monitoring begins after a delay of 800 ms. This command can be used to optimize the ignition process reliability and always force an active edge for the seam fault monitoring interrupt. Monitoring is carried out using $TIMER[1] and $CYCFLAG[3]. This time can be increased if ignition faults occur too often following an unstable ignition process.
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11
Mechanical weaving
Mechanical weaving is used, for example, to compensate for tolerances or to bridge gaps in a seam. The torch moves across the seam in this instance and the weave oscillation is thus superposed on the seam motion. It is also possible to rotate the torch in relation to the plane of the weld (direction of welding). Mechanical weaving is executed in the coordinate system TTS (tool--based technological system). In this way, the weaving function is independent of the position of the torch in relation to the seam and of the torch angle, and irrespective of whether welding is by the pushing or dragging technique.
11.1
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11
11.2
Weave patterns
The following weave patterns are included in the ArcTechDigital package:
s Lateral deflection (amplitude) Direction of welding s Weave length
Triangular weaving (Triangle) Triangular weaving double frequency (Dbl Triangle) Trapezoidal weaving (Sgl Trapec) Trapezoidal weaving double frequency (Dbl Trapec) Trapezoidal weaving unsymmetrical (Uns Trapec) Spiral weaving (Spiral)
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ArcTechDigital 2.3 These weave patterns are defined in the file Weav_def_d.src. DEF WEAV_DEF (GENERATOR :IN,FIGUR :IN ) Triangular weaving (SGL_TRI) Triangular weaving, double frequency (DBL_TRI) Trapezoidal weaving (SGL_TRP) Trapezoidal weaving, double frequency (DBL_TRP) Trapezoidal weaving, unsymmetrical (UNSYM_TRP) Spiral weaving (SPIRAL) Figure-of-eight weaving (DBL_8) ... CASE 1 ;triangle CASE 2 ;double triangle CASE 3 ;trapezoid CASE 4 ;double trapezoid CASE 5 ;unsymmetrical trapezoid CASE 6 ;spiral CASE 7 ;eight
The Triangle weave pattern (SGL_TRI) is described in the following example; on the left is the entry taken from the file Weav_def_d.src, and on the right is the assignment to the individual control points (1 ... 4) with the corresponding X and Y values. Weav_def_d.src SWITCH
FIGUR
n = control points (CPNUM) Y 1 2
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=0.0 ENDIF
0.75
1.0 X 4
--1
The value for X can be between 0.0 and 1.0. Xn=1.0 corresponds to the weave length entered in the W--parameter list 2 (Mechanical Weaving), i.e. the length over which a pattern is executed. 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 the welding plane (weave angle) can be programmed for each weave pattern in the W--parameter list 2 Mechanical Weaving with menu prompting. Additional information on menu--guided programming can be found in the documentation [Arc Welding, ArcTechDigital -- Operation].
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11
11.2.1
Two-dimensional weaving
Weave patterns such as triangular and trapezoidal patterns result from the lateral deflection of the torch during motion along the seam. Complex patterns are possible by means of a second 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 and figure--of--eight weaving, are already included in the technology package. You can also develop your own patterns. The following diagram illustrates the mode of operation of the function generator using the example of spiral weaving.
Weav_def_d.src
Lateral deflection (amplitude) 1) $TECH[FG_NR1].FCT.CPS1.Xn=x (0.0 ... 1.0) $TECH[FG_NR1].FCT.CPS1.Yn=x (0.0 ... 1.0) Deflection in direction of path 2) $TECH[FG_NR2].FCT.CPS1.Xn=x (0.0 ... 1.0) $TECH[FG_NR2].FCT.CPS1.Yn=x (0.0 ... 1.0)
Lateral deflection (amplitude) 1) (-Y)
Weave width
1) Lateral deflection (amplitude) = half weave width 2) Deflection in direction of path= weave length The ratio of the deflection in the welding direction (...FCTCTRL.SCALE_IN) to the weave length (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). A20.src $TECH[N].FCTCTRL.SCALE_IN=1 $TECH[N].FCTCTRL.SCALE_OUT=1 The Weave amplitude value is defined as zero to peak, i.e. it corresponds to half the weave width (peak to peak). The magnitude of the deflection in the welding direction (...FCTCTRL.SCALE_IN) in relation to the weave length (W.WEAVLEN_MECH) is set in the file A20.SRC at a ratio of 1:1. The lateral deflection (...FCTRL.SCALE_OUT) corresponds to the value set for the half weave width (W.WEAVAMP_MECH).
11.2.2
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The following diagram shows the curve shapes of the function generators derived from the sine function. This is approximately a sine for the lateral deflection ($TECH[FG_NR1]...) and a cosine for the deflection in the direction of the path ($TECH[FG_NR2]...). The corresponding control point parameters are stored under CASE 6 ;spiral in the file Weav_def_d.src. The figure of a spiral results from the superpositioning of these two motions.
Y 1
Y 1
--1 Y 1 2 0 1 1
Resultant: spiral
2 (--Y) 6, 6 5 3 (Y) 3 X 4 5 4 --1 1 2 5 6
--1
Weave length
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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11 Weav_def_d.src 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 direction 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
Resultant: eight
Y 4 2 5 1 8 7 9 X 6
Weave length
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11.2.4
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 requirements 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 180 in the phase angle. The settings for the Triangle weave pattern are contained in the file Weav_def_d.src.
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=0.0 ENDIF Represented graphically: Y 1 2
0.0
0.25 1
0.5
0.75
1.0 4
--1
n = control points (CPNUM) In order to achieve a phase shift of 180, it is merely necessary to change the parameters for control points Y2 and Y3. The required changes have been made in the following list and are underlined for ready identification.
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11 Weav_def_d.src 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=0.0 ENDIF Y 1 1 0.25 0.5 3
0.0
0.75
1.0 4
--1
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 the path X covered within a period and 1 for the lateral deflection Y are predefined. Y 1 0.0 1 2 3
0.2
0.4
0.6 4
0.8
1.0 6
--1
The first value for X must be 0 (zero) and the last value must be 1. Multiple X values that are identical cannot be used. The number of control points determined (CPNUM) as well as the X and Y values can be entered, for example, in the block CASE 8 ;default as minimums and flag for beginning of the file Weav_def_d.src, as shown in the following.
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ArcTechDigital 2.3 Weav_def_d.src CASE 8 ;Trapez - Dreieck $TECH[A_FG_MECH1].FCT.ORDER=1 $TECH[FG_NR1].FCT.CPNUM=6 $TECH[FG_NR1].FCT.CPS1.X1=.0 $TECH[FG_NR1].FCT.CPS1.Y1=.0 $TECH[FG_NR1].FCT.CPS1.X2=.2 $TECH[FG_NR1].FCT.CPS1.Y2=1.0 $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 Number of control points Value X for control point 1 Value X for control point 1 Value X for control point 2 Value Y for control point 2 ... ...
11.2.5
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12
12
12.1
Message groups
Hint messages provide the operator with explanatory information, for example, if an illegal key has been pressed. Operational messages signal the status of the system that has led to a control reaction, e.g. Emergency Stop. The message is cleared once its cause has been eliminated. In some cases, a secondary signal that 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 the acknowledge key. They are often a consequence of a status (operational) message. An acknowledgement message stops a movement or prevents further operation. Dialog messages require confirmation by the operator (Yes or No softkeys). The message is cleared after it has been confirmed.
12.2
Message time
The message time indicates the time at which the message was generated.
12.3
Message number
With the aid of the message number, the corresponding cause, effect and remedy can quickly be 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 is TPA20.
12.5
Message text
The text of the error message is shown here.
12.6
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12 1 Message text Cause Monitor Effect Remedy 2 Message text Cause Monitor Effect Remedy 3 Message text Cause Monitor Effect Remedy 4 Message text Cause
Option bit ARC20 not set -- ARC20 = FALSE -- In ARC ON command -- Endless loop always with this message -- Set ARC20 to TRUE, stop and restart Submit interpreter, data backup Submit is not running -- Submit interpreter has been stopped, etc. -- In ARC ON command -- Endless loop always with this message -- Restart Submit interpreter Wrong submit routine selected -- No SPS.SUB submit program running while ARC20=TRUE -- During initialization of A20_INIT commands -- Endless loop with this message, as deactivation not otherwise possible in event of interpreter stop -- $PRO_I_O[ ] = R1/SPS ( ) Weld controller not ready -- 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) -- In ARC ON command -- Endless loop with this message -- Move the keyswitch to the correct position -- Switch on power source (I_WELD_COND [ ]) Ignition failure, no arc -- 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 -- ARC_ON command -- Ignition process is cancelled and restarted, once message acknowledged, in accordance with configured option and number of ignition attempts set -- For test purposes or start--up, the I_START_MOVE [ ] condition may be deactivated
Monitor Effect
Remedy
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ArcTechDigital 2.3 6 Message text Cause Monitor Effect Remedy 7 Message text Cause Continue without welding -- Too many ignition attempts; too many seam faults or interruption with RESTART_OPT = 0 (continue Cold) -- In ARC ON command -- Seam not welded -- Clean ignition position and make new block selection to ARC_ON position Switch off welding -- Power source does not switch welding off or does so too late -- Incorrect configuration -- Incorrect burnback parameters -- In ARC OFF command -- Single message for user -- Optimization of the burnback parameters Weld controller fault -- Periphery error: robot waiting for the inputs expected in I_WELD_FLT [ ]. Normally configured as current flow Gas present, coolant monitoring -- Configuration error (OK state configured) -- Continuous between ignition process and ARC_OFF command if welding -- Welding is switched off; weld process is restarted, once message acknowledged, depending on RESTART_OPTION -- Complete the configuration Reconnect gas, water, etc. or check respective sensor Welding in operation mode T1 impossible! -- T1 mode and PROC_IN_T1 = FALSE -- In advance run section of ARC ON command -- Program remains in this loop after message acknowledged -- Set the above variable to TRUE ($config.dat)
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Index
Zeichen
$CONFIG.DAT, 29 $Config.dat, 19, 20 $STOPMESS, 51
A
A.WEAVAMP_MECH, 59 A.WEAVLEN_MECH, 59 A_FLT_SV_FCT, 50 A10.SRC, 59 A20.dat, 21 A20.src, 21 Activating, 23 Adaptation to the periphery, 29 ARC OFF, 13, 14 ARC ON, 11, 12 ARC SWITCH, 15, 16 ARC20, 23
Fault service functions, 54 Fault situations and fault service functions, 51 Figure--of--eight weave pattern, 61 Figure--of--eight weaving, 57 Files for ARC Tech 20, 20 Flt_serv_d.dat, 21 Flt_serv_d.src, 21 Fold ARC Messages in A20.dat, 28 Fold ArcTech Inputs in $Config.dat, 24, 32 Fold ArcTech Outputs in $Config.dat, 23, 30 Fold Internal States in A20.dat, 26, 27 Fold Main Options in A20.dat, 25
I
I_ENB_W_EXT.NO, 45 I_ENB_W_EXT.STATE, 45 I_WELD_CTRL[ ], 32 Ignition faults, 51 Ignition repetition, 50 IN_NR, 32 Index table for physical digital inputs, 32 Index table for physical digital outputs, 30 Index tables, 29 Input group I_START_MOVE [ ], 43 Input group I_WELD_COND [ ], 42 Input group I_WELD_END [ ], 43 Input group I_WELD_FLT [ ], 44 Installation, 8 Interpreter stop (STOP key), 49 IR_STOPMESS program, 53
B
Basic settings, 23 Block selection response, 56
C
Changing existing weave patterns, 62 Control points (CPNUM), 58 Coordinate system TTS, 56 Crater filling, 37 Creating your own weave patterns, 63
D
DIGITAL INPUTS, 32 Digital inputs, 29 Digital inputs (physical), 32 Digital outputs, 23, 29 Digital outputs (physical), 30 Digitale Eingnge, 24 DRIVES OFF, 51
L
Lateral deflection (weave amplitude), 58
M
MAX_AUTO_R, 50 Maximum weave frequency, 64 Mechanical weaving, 56 Minimum configuration, 23, 25 Motion characteristics of the robot, 64
E
EMERGENCY STOP, 51 External keyswitch, 45
N
NAME_NAT[ ], 30, 32 Notes on mechanical weaving, 64
F
FAULT SERVICE FUNCTION, 50
O
Index -- i
Index O_SEAM_END[ ], 37 O_WELD_CTRL[ ], 30 OUT_NR, 30 Output group O_ACK_FLT [ ], 41 Output group O_ACK_START [ ], 36 Output group O_ACK_WELD_E[ ], 38 Output group O_FLT_ARC_ON [ ], 39 Output group O_FLT_CLEAN [ ], 41 Output group O_FLT_WELD [ ], 40 Output group O_SEAM_END [ ], 37 Output group O_STROB_PGNO [ ], 37 Output group O_WELD_START [ ], 35 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 Power source interface, 23 PRG_NO.CODING, 28 PRG_NO.FIRST_BIT, 28 PRG_NO.LENGTH, 28 PRG_NO.PARITY, 28 PRG_ON_MODE, 47 PRG_SWI_MODE, 47 PRGNO_MAX, 47 PRGNO_MIN, 47 PROC_IN_T1, 55 Program number control, 25 Program number specification, 47 Program run mode GO, 11 Program structure, 19 Program test, 55 PULS_TIME, 31 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
R
Resonant frequency, 64 RESTART_OPT, 49 RESTART_OPTION, 49
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 -- ARC SWITCH, 15 Welding and ending seams -- ARC OFF, 13 Index -- ii
S
Schematic sequence diagram ARC OFF, 14 Schematic sequence diagram ARC ON, 12 Schematic sequence diagram ARC SWITCH, 16 Seam error, 52 Signal APPL_RUN, 53 Signal diagram ARC_OFF, 15 Signal diagram ARC_ON, 13 Signal diagram ARC_SWI, 17 Signal flow of the program numbers, 47