V6.40 ServoGun Training Guide

Servo Weld Gun Control
Condensed Training Seminar

for V6.40 SpotTool+ Software with
Servo Gun Option
Designed for Project Integrators
February 8, 2006
February 8, 2006 FANUC Robotics Confidential
V6.40 Servo Weld Gun Control
Engineering Training Course Outline
• Servo gun overview • Pressure calibration
• Servo gun terminology • Pressure schedules
• Product deliverables • Backup positions
• Aux axis configuration • Manual Gun Operation
• CTRL START settings • Teaching programs
• Setup Screen References • Touching up programs
• Initial settings
• Autotuning

Servo Gun Overview
Servo weld guns are mechanically
similar to pneumatic weld guns, except
that the air cylinders have been
replaced by servo motors, encoders
and mechanical drives. Servo guns
offer more process control / flexibility.

Product Deliverables Overview
• Motor with encoder
• Servo amplifier
• Axis control card (DSP)
• Internal cabinet connections
• Cables from:
– Controller to robot
– Robot J1 to J3 - internal
– Robot J3 to Weld Gun Motor
• Servo weld gun control
software option

Servo Gun Overview
7: L[2] 750mm/sec CNT100
Automatic Pressure Process SPOT[EP=1, P=1, S=1,BU=0]
1) Record the SPOT with the
fixed tip a few mm from the
metal if the equalizer is used
(touch metal if no equalizer).
The position of the moving tip
does not matter
2) Software executes
pressure process
automatically when
the SPOT instruction Approach Pressure Pressure Pressure End Open
Start (Backup)
is executed.
Gun Jog Function

Close/Open gun
and using TP hard
keys
SHIFT
GUN
BACK
UP
Servo Gun Terminology
• Group 1 = Robot Servo System
• Group 2 = Servo Gun Servo System (NOBOT axis)
• Movable Tip, Servo Tip, Gun Tip = The tip attached to the part of the servo
weld gun that moves when group 2 is jogged
Movable Tip, Servo Tip, Gun Tip
Fixed Tip, Robot Tip
• Fixed Tip, Robot Tip = The tip attached to the part of the servo weld gun
that does not move when group 2 is jogged

• Tuning - setting servo parameters to optimize the performance of the servo
motor.
• Mastering - setting the reference zero position for the servo gun axis. This is the
position where new tips just touch.
– NOTE: do not re-master the servo gun with worn tips or shanks. Only a tip wear compensation programs can do this correctly.
• Calibration - process of establishing a relationship between a range of servo

motor torque commands and the resultant force that is created between the tips of
the servo gun
• Pushing Depth - Set in each pressure schedule. This is the maximum distance the
movable tip should move past the zero position when trying to build pressure.
This value can not exceed the stroke limit for the gun axis.
NOTE: A custo can be used to correctly set the pushing depth for the customer.
NOTE: If the servo gun actually reaches the Pushing Depth without building pressure, a “Pressure Shortage” fault
will be posted. Pushing Depth can be increased up to the Close Stroke Limit of the gun if necessary.
NOTE: If the Pushing Depth exceeds the Close Stroke Limit for the gun, an “Axis Limit” fault will be posted. If the
Close Stroke Limit is set correctly, either reduce the Pushing Depth and replace worn tips with new ones..

Servo Gun Overview
Tip Wear and Gun Sag Compensation
Moveable tip
wear Gun sag
Fixed tip
wear
Robot compensates to
reduce part bending

• Tip Wear Compensation - an adjustment to the locations of the
automatically generated positions for a spot instruction to account for the
change in the geometry of the weld caps. Measured by calling a “tipwear”
program. Adjustment is made to the fixed tip location and to the Group 2
master position (which defines the movable tip zero position)
“Movable tip” wear
“Fixed tip” wear
•Mastering should only be done with new reference tips and should only be required (1)
time at initial gun setup
•It will be required again if you get lose the battery backup (BZAL alarm) or the gun
geometry changes noticeably from a new tip holder or arm

• Gun Sag - Set in each pressure schedule. This is the distance the fixed jaw
of the weld gun deflects for the specific amount of tip force requested.
This value should be increased as tip force increases.
Gun Sag compensation value
• Gun Close Direction - Set based on the direction the movable tip should
travels when jogging Group 2.
– MINUS: gun openings will be displayed as positive values and gun closes with –X jog
key
– PLUS: gun openings are displayed as negative values and gun closes with –X jog key
NOTE: This item should be set to the same value for each gun for a given customer

Servo Gun Setup Overview
The tasks for setting up a FANUC servogun are as follows:
INITIAL SETUP
Done at Controlled 1) Add nobot axis
Start. A custo can be
2) Configure nobot axis
made to handle these
functions.
3) Define tool as servogun
4) Define tool frame and payload
5) Set gun close direction
6) Define robot close direction
7) Set max gun pressure (max tip force)
8) Reset the BZAL and run MPDT from the Gun Master screen
9) Run autotuning utility
record gun close direction
master servogun & set stroke limits
autotune servo parameters
10) Calibrate tip force
PROGRAMMING SETUP
10) Setup pressure schedules
11) Setup backup schedules
12) Setup tip wear compensation (if used)
13) Teach programs

Servo Gun Setup Overview
INITIAL SETUP
Task Description
1)Add nobot axis
2)Configure nobot axis Default settings can be applied to the servo gun axis by a custo. The
3)Define tool as servogun user will not have to perform these tasks in the vast majority of cases.
Payload and TCP information should be provided on gun drawing and
4)Define tool frame & payload should be entered to robot before teaching.
Setting shoud be agreed to at start of project. Use Autotune Utility to
5)Set gun close direction set the sysvars so the gun closes with the proper jog key.
Tool Frame +Z for carried guns, User Frame -Z for ped guns (confirm
6)Define robot close direction proper setting before teaching)
Should be included on the gun drawing and entered by user before
7)Set max gun pressure (max tip force) autotuning.
Done from Gun Master screen, 1-time at initial gun setup. Must be re-
8)Reset BZAL and Execute MPDT done if the pulsecoder cable is disconnected.
A menu driven task, done before going any further. Gun can be re-
9)Run autotuning utility tuned from this ulility as needed.
FRA can do a 1-time calibration with an ISO certified force gage. The
calibration table will then be populated for future re-calibrations by the
10)Calibrate tip force user, as needed.
PROGRAMMING SETUP
Task De scription
A custo can be used to preset as much of the Pressure schedule
detail as possible to a standard that should be agreed to at the start of
the project. Those settings shoulf allow user to start teaching SPOT's
but Part Thickness, W eld Pressure and gun tip openings may need to
11)Setup pressure schedules be adjusted to meet application requirements.
A custo can pre-populated these values. For ease in programming,
FRA recommends settings the backup schedules with multiples of
12)Setup backup schedules 10mm (#1=10mm, #2=20mm, etc.)
13)Setup Manual Operations Define settings for manual operations, Shift+GUN and Shift+BU
Run the tip wear setup program needed, based on the tip wear method
14)Initialize tip wear compensation being used. Also, define items in the Tip W ear Detecion screen.
FRA has programming and spot teaching guidelines that can be
followed to simplify this step for the programmer. Tip wear update
15)Teach programs instructions are needed too, if tip wear compensation is used.
Steps 1-3) Aux Axis Configuration
• Once the software is loaded,
proceed to CTRL Start and select AT7_MAIN LINE 0
ROBOT MAINTENANCE CONTROLLED START MENUS
the Maintenance menu. Setup Robot System Variables
1/6
• Aux Axis Config is also covered Group

1
Robot Library/Option
R-2000iA/210F
Ext Axes
0
in the Servo Gun Function Setup 2 Basic NOBOT 0
Manual (Appendix A)
[ TYPE ]ORD NO AUTO MANUAL
• The Gun Axis is identified as a
“NOBOT” in North American “Maintenance”
Found on CTRL START menus
software

• The following settings should be used when setting up an
ARO 6-pole servo motor for the servo gun axis:
1 Motor Size 160. Aro 6-pole 11 Acc/Dec Time 384ms****
2 Motor Type 2. 3000 12 Acc Time 2 192ms****
3 Current Limit for Amp 7. 80A 13 Min Accel Time 256ms****
4 Gear Ratio Gun specific* 14 Load Ratio 0****
5 Axis Type 1. Linear 15 Amplifier Number 2
6 Max Joint Speed 2. No change** 16 Amplifier Type 2
7 Motion Sign 2. False 17 Brake Setting 0 (no brake)
8 Upper Limit max gun 18 Servo Off Disabled
close***
9 Lower Limit -max gun
opening***
10 Master Position 0
* = Value will be provided on inspection sheet by gun manufacturer. Do not guess! This is the tip
displacement per motor revolution.
** = With the correct Gear Ratio entered, this value will be automatically calculated. Select #2- No change.
*** = Value will be provided on inspection sheet by gun manufacturer.
**** = Accept default value. Autotuning will calculate appropriate value for gun later.

• At Control Start, go to the Servo
Gun Setup menu to set the
Equipment Type to Servo Gun for
SETUP SERVO GUN CONTROLLED START MENUS
the desired equipment number 1/6
1 Equip number: 1
• Motion Group assignments need 2 Equip Type: [SERVO GUN]
3 Motion Group(Gun): 2
not be changed in most typical 4 Motion Group(Robot): 1
5 Axis data: <*DETAIL*>
cases 6 Gun Data(files): <*DETAIL*>
[ TYPE ] EQUIP GUN_CFG

“Setup Servo Gun”
Found on CTRL START menus
• Now, COLD START the Robot

Step4) TCP and Payload Definition
• Define TCP and Payload
Press F6 - IDENT for

Auto Payload ID

Servo Gun Setup Screens
“Servo Gun Setup”

Found on SETUP menu

Steps 5-7) Close Direction and Max Pressure
• Close Direction (Gun)
– MINUS: gun openings will be displayed as
positive values and gun closes with –X jog key
– PLUS: gun openings are displayed as negative
values and gun closes with –X jog key
• Close Direction (Robot)
– This is the direction the robot must travel to
bring the fixed tip closer to the metal surface
• UT: 1 [+Z] for single carried guns
• UF: n [-Z] for ped guns
•With carried gun, robot will move in the Tool Frame +Z

direction to bring fixed tip up to metal
Z
Y
•If gun is on pedestal, robot will have to carry metal, down
X
in the -Z direction of the User Frame to bring the metal to
the fixed tip
• Max Pressure
• It is important to set the max pressure within the capability of the weld gun as specified by the
gun manufacturer. Units are specifed by $sgsyscfg.$prs_units. 0=kgf, 1=lbf, 2=N. The Max
Gun Torque (%) is an informative display only item.
Step 8) Reset BZAL and Execute MPDT
The Gun Master Screen is used for these tasks
Press MENU-SYSTEM-Gun Master
•BZAL is the “Battery Zero Alarm”
•This indicates that Battery Power was
disconnected. Reset this fault, then
cycle power
•Press the BZAL button to reset
•MPDT is Magnet Phase Detection

•If the motor is non-FANUC and has fewer
than 8 poles, this must be done once to
establish the relationship between the motor
phasing and the pulsecoder position
•The gun will move a very small amount
during this operation
•be sure the tips are slightly open before
executing the routine
•Press MPDT button, followed by YES
when you are ready.
•The MPDT button will not appear if the
operation is already complete.

Step 9) Auto-Tuning Utility
• Servo Gun Tuning is the process of measuring the response of
the servo system under various commands and using the
responses to optimize the performance of the servo gun.
• Servo gun tuning is necessary to determine the mechanical

characteristics of the weld gun and to identify the motor’s
torque output
• Some of the mechanical characteristics determined by tuning

include: Spring constant, static friction, motor inertia, etc.

Step 9) Auto-Tuning Utility
1) Go to the Servo Gun setup screen

– enter the maximum pressure for this gun
2) Go to the menu autotuning utility and follow the instructions
on the screen
3) The screen will force you to perform each step in the correct
order
– a scale that measures (mm) will be needed to measure the gun opening
for step 2, if you do not know the gun’s tip displacement ratio
– re-power after step 2 is completed

Step 9) Auto-Tuning/Gun Setup Utility
“Auto Tuning Utility”
Once Steps 1 & 2 are complete, Found on UTILITIES screen
Press Shift + F3 [EXEC] to Start the Autotuning Exercises Autotune
MENU-Utilitites-SG
(Robot
Calibrate Gunmust be inisAUTO)
Deflection only required if Part Thickness Checking will be used.
This cannot be done until after Pressure Calibration (step 10) is complete
• Notes
– if an item is incomplete, press enter to display the submenu ( step )
– most operations on the submenu require you to press complete when done
– if you wish to redo servogun setup including tuning, press restart
– you may have to extend the stroke limit settings in order to reach the guns true stroke
limit
– if you wish to re-tune only (not reset stroke limits), press exec
– turn controller power on and off if directed to
Step 10) Pressure Calibration
• Once the servo gun axis is properly tuned, and the initial settings are completed, the
gun will need to be calibrated so the pressure (tip force) can be commanded in units
of force.
• Pressure Calibration is the process of establishing the relationship between a range
of servo motor torque commands and the tip force that results
• FANUC software supports 3 methods for establishing this relationship.
– FRA recommends the Piecewise Linear Method, supported on V6.40-1, MU-L +
– This curve-fit will “connect the dots” with a short line between each calibration point and generally
produces the best calibration results
Servo Gun Calibration Curve
– The options for curve-fits are:
700
• LINEAR – set $sgsyscfg.$num_frc_prms=2
• QUADRATIC – set $sgsyscfg.$num_frc_prms=3 600
• PIECEWISE LINEAR – set $sgsyscfg.$cal_method =3

500
Tip Force (lbf)

400 Measured Tip
Motor Torque Force (lbf)
300 5% 120
10% 210
200 15% 270
20% 355
100 25% 430
50% 650
0
0% 10% 20% 30% 40% 50% 60%
M otor Torque (%)

• Tools Required
• Tuned Servo Gun with Initial Settings established
• Force gage (Load cell) to read force in correct units
• Data required
• Pressuring Time = set to an amount of time that gives you enough
time to read the force gage before the gun is opened
• Thickness of force gage (or load cell) in millimeters
• Pushing depth = Set to ~10 mm
• Torque % = Set 2 to 10 values that produce pressures across the
desired range of weld pressures (may require some experimenting)
– start low
• Time for average user to complete = 15 minutes

•Pressure Calibration is done
by selecting the Pressure Cal
item on the Servo Gun
General Setup Screen
• Press Enter to make way
to the calibration table
• A few prompts will
appear on the way in that
give info about how to
properly perform the
calibration
•Set-up top 5 items, then
execute measurements
• Enter a Torque % (Start low!)
and Press Shift+F3 to execute
the pressing
•Record the pressure from the
gage in the right column
•Set the recommended contact
speed in the middle column
•When done with all measurements, set status to COMP and follow prompts out to final display

Step 11) Pressure Schedule Setup
• Pressure Schedules are similar to Weld Schedules, but they
define settings for the servo system to use when doing a spot
weld
• Information included in the Pressure Schedule is:
– Motion settings required to close the gun for the spot
– Expected Part Thickness of the metal
– Weld Pressure (force)
– Motion settings required to open the gun after the spot
• All the Pressure Schedules are stored in a data table.
• The user specifies the Pressure Schedule # to use for a weld
spot and all the data associated with it, is applied to the present
weld spot.
7: L[2] 750mm/sec CNT100
SPOT[EP=1, P=1, S=1,BU=0]
•Pressure Schedule table is accessed
via the DATA key
• Press [TYPE] and select <Pressure>
to see the main table
•There are 99 pressure schedules
available
•81-89 are typically used for
Shift+GUN pressure checks
•91+ are typically reserved for special
operations (98-99 are reserved for
internal operations)
•Pressing the Detail key once takes you

into the main view of the selected
pressure Schedule.
• Most users will not have to go past
here!
•Selecting the Weld Stroke <DETAIL> item shows the motion settings for this schedule.
• Adjust motion settings (such as tip openings) here only when needed.
• Typically only the Approach Position openings require adjustment by the user
Weld Stroke Terminology

Tolerance Gun = desired distance between moving tip and metal
Approach Pressure Pressure Pressure End Open

Position Start Position Position Position
Position
Tolerance Robot= desired distance between fixed tip and metal

• Pressure schedules are used to setup
the parameters for the weld pressures SERVO GUN DATA G1 JOINT 10 %
that the servo gun will need to PRESSURE / EQ:1 Gun:1
No. Press(lbf) Manual
1/99
Comment
command 1
2
220.5
440.9
TRUE
TRUE
[
[
]
]
3 0.0 FALSE [ ]
• DETAIL for each schedule 4
5
0.0
0.0
FALSE
FALSE
[
[
]
]
determines 6
7
220.5
440.9
FALSE
FALSE
[
[
]
]
8 0.0 FALSE [ ]
– The amount of pressure the tips will 9 0.0 FALSE [ ]
apply before welding [ TYPE ] EQUIP GUN DETAIL COPY >

“Pressure Schedules”
– The expected metal thickness Found on DATA menu
– The max depth to which the gun will

push to build pressure
Tip: Work on getting DETAIL for
one schedule set-up and working
– The amount of gun sag expected properly, then press F5 to copy it to
– The route the servo gun / robot takes other pressure schedules and modify
to move to a weld position the necessary parameters. This saves
a lot of time and eliminates mistakes.
Step 12) Backup Schedule Setup
• The Backup table is also accessed
via the DATA key
• Backup positions provide a group
of pre-set distances to which the
servo gun can open for manual
operations, and after a SPOT
• Distances are entered in mm
• Pressing the “Shift + BACKUP”
hardkeys together will cause the
weld gun to move to the currently
selected Backup position
• Pressing the BACKUP hardkey Setting Manual=True will cause the
specified gun open distance to appear in
(non-shifted) will select the next
the select list when the user presses the
Backup position in the list BACKUP key

Step 13) Manual Gun Operations
• Manual settings
– These settings control the response
of the servo gun when manually
closing the gun (i.e. - pressing
“Shift+GUN”
– Settings include:
• Pressuring Time
– Duration for the gun to be closed
• Gun Open “Manual Operation Setup”
Accessed from SERVOGUN SETUP screen
– Whether the gun should open
automatically to the last selected
Backup (TRUE) or just stop at the
Pressure End Position (FALSE)
• Backup Speed
– Speed at which to move to backup
position when the gun opens
(Always leave at 100%)
• Backup Stroke
– A Shortcut to Backup data screen

OFF TO THE SPOT LAB
TO SET-UP A GUN
(Steps 9-13)
Take handout with you please.

Menu based Auto-Tuning procedure
• Notes
– if an item is incomplete, press enter to display the submenu ( step )
– most operations on the submenu require you to press complete when done
– if you wish to redo servogun setup including tuning, press restart
– you may have to extend the stroke limit settings in order to reach the guns true stroke
limit
– if you wish to re-tune only (not reset stroke limits), press exec
– turn controller power on and off if directed to

Pressure Calibration
• Refer to Pressure Calibration in the Servo Gun
Setup Manual
SETUP Spot Weld G2 JOINT 10 %
PRESSURE CALIB / EQ:1 Gun:1 1/10
• Make sure to select the units on the pressure 1 Calibration Status: INCOMP
gage that match the units on the robot (kgf, lbf, 2 Pressuring Time(sec):
3 Thickness of Gauge(mm):
5.0
10.0
N) 4 Pushing Depth(mm): 20.0
5 Gun Open Value(mm): 75.0
Torque(%) Speed(%) Pressure(lbf)
• The Gun Open Value should be close to the 6 5.0 % 100 % 220.5 lbf
7 10.0 % 100 % 440.9 lbf
surface of the pressure gage for best results 9 0.0 % 100 % 0.0 lbf
[ TYPE ] CANCEL PRESSURE COMP INCOMP
• Complete two to ten readings to calibrate. “Pressure Calibration Setup”
Start at the lowest required force (usually tip Accessed from General Setup screen
(Accessed from SERVOGUN SETUP screen
dress) and go up to the maximum gun force
– Do not change Speed from 100%
SETUP Spot Weld G1 JOINT 10 %
• When done set the Calibration Status to COMP Pressure Calibration / 1/1
Equip number:1 Gun:1
and press YES for the following prompts.
1 Calibration Status: COMP
• To re-calibrate a servo gun, press INCOMP on Pressure(lbf) = Scale * A + B
A: 44.0925 B: 0.0000
Calibration screen. This resets all calibration Speed(mm/sec) = Pressure * C + D
C: 0.0000 D: 100.0000
data and restarts the calibration procedure.
[ TYPE ] END COMP INCOMP
“Pressure Calibration”
Accessed from General Setup screen
February 8, 2006 Accessed from SERVOGUN SETUP screen
FANUC Robotics Confidential
Pressure Schedule DETAIL
• Set Part Thickness to match • Weld Stroke DETAIL
the total thickness of the allows users to adjust the
expected part stack up path the gun takes to weld
• Pushing depth and Gun Sag – Default parameters are usually
can be set automatically for acceptable. Change for
special cases.
the requested pressure.
– User can override if desired. SERVO GUN DATA G1 JOINT 10 %
WELD STROKE / EQ:1 Gun:1 No:1 1/8
(Approach Position)
1 Tolerance Gun(mm): 25.0
2 Tolerance Robot(mm): 25.0
(Pressure Start Position)
3 Tolerance Gun(mm): 24.0
SERVO GUN DATA G1 JOINT 10 % 4 Tolerance Robot(mm): 24.0
PRESSURE / EQ:1 Gun:1 No:1 1/6 (Pressure Position)
1 Comment: [ ] 5 Decelerate Rate(%): 100.0
2 Weld Pressure(lbf): 220.5 (Release Position Setup)
3 Part Thickness(mm): 0.0 6 Tolerance Gun(mm): 24.0
4 Pushing Depth(mm): 5.0 7 Tolerance Robot(mm): 24.0
5 Gun Sag Comp Value(mm): 0.0 (Open Position)
6 Weld Stroke: <*DETAIL*> 8 Gun Open: ENABLE
[ TYPE ] EQUIP GUN LIST SETSAG [ TYPE ] EQUIP GUN END

Step 14) Tip Wear Compensation
• Tip Wear Compensation is used to compensate for the change in the position of
the servo gun’s weld electrode tips due to wear from welding, dressing, etc. Tip
Wear Compensation adjusts the final position of both weld tips when executing
the SPOT or Press_Motion instructions.
• The tip wear compensation function is provided through a set of Teach Pendant
programs that are included with the Servo Gun software option.
• Two standard methods of tip wear measurement are available that do not
require external sensors:
– TWO-STEP (i.e. fixture-based, fixture-touch) First, the gun is closed and re-mastering is
done. Second, the gun is brought to a rigid plate/fixture in the cell and the moving tip closes to
the fixture. The unique wear amount on each tip is determined accurately using this method.
– ONE-STEP (i.e. fixture-less, tip-to-tip) The gun is closed and only the combined wear of
both tips is determined. There is no robot motion.
• The basic tip wear compensation function is broken into two main tasks that are
executed with TP programs:
– SETUP (initialization) – run once, to initialize tip wear reference data*
– UPDATE/MEASUREMENT – run after setup, every time an updated tip wear measurement
is desired

Tip Wear Measurement
(2) measurement techniques supported
Method 1 - One Step Method 2 – Two Step
• Tips brought together to

measure total tip wear
• User decides on wear
ratio between tips (50/50
or other) • Robot brings moving tip
• No robot motion to fixture after doing
• Usually sufficient when Step 1
metal complies to a • Tip wear calculated for
small positioning error each tip
OR if a counterbalance • Provides the most
device is used with the accurate measurement
gun but includes robot
motion and takes longer
(1) Step Measurement
• Tip Wear data is initialized by running the program
WR_SETUP, one time with new tips on the gun
• Tip Wear is measured after that, by running the program
WR_UPDAT whenever a new wear measurement is needed
• The user can specify a wear ratio when needed. If the tip
wear on the fixed tip is more or less than 50% of the total
wear, the ratio can be specified in the program WR_UPDAT,
here
(2) Step Measurement

• Tip Wear data is initialized by running the program TW_SETUP, one
time with new tips on the gun
• Tip Wear is measured after that, by running the program TW_UPDAT
whenever a new wear measurement is needed
• For the (2) step measurement, robot positions must be taught as well.
These positions are recorded in the program TW_MV2PT.

Setup Overview
• Reference data must be established for servogun
– Program wr_setup(ar[1]) does this for One-Step Method
• ar[1] = gun number, usually 1
– Program tw_setup(ar[1]) does this for Two-Step Method
• ar[1] = gun number, usually 1
NOTE: a rigid fixture to touch with the moving tip is required with the Two-Step method
NOTE: The Two-Step method includes robot motion and teaching of points

Update/Measurement Overview
• Wear software checks for
– overall excessive wear
– excessive change in wear amount from last measurement
• Program wr_updat(ar[1],ar[2]) does this for the One-Step Method
• Program tw_updat(ar[1],ar[2]) does this for the Two-Step Method
– ar[1] = gun number, usually 1
– ar[2] = new caps indicator
0 = used caps
1 = new caps
• Other programs are provided for convenience to recover from special

failures such as:
– loss of cap during part
– seating of new cap
– etc.

Setup Procedure
1) make sure that gun is fully setup and has been tuned and calibrated
2) install new, production weld tips and properly seat them
3) accurately re-master gun if tips do not meet at exactly 0.0mm (+/- 0.1mm)
4) set strokelimits to their proper values (if they’re not already)
5) select the program wr_setup or tw_setup and specify the gun number
7) execute the program wr_setup or tw_setup in T2-100% override, or local
auto if available
• (1) time prior to teaching production paths
• after loss of mastering for gun or robot
– new image installed
– servo gun encoder cable disconnected
– battery connection lost during power off
– etc.
• if there is a major geometry change in the gun
– new shanks or arms
– new gun
– gun jaws bend
– etc.

Update/Measurement Procedure
1) make sure that gun is fully setup and has been tuned
2) make sure that setup has run previously for this gun
3) select the program wr_updat or tw_updat
4) specify the gun number and new caps indicator (if new caps)
5) execute the program wr_updat or tw_updat
• after tip dress
• after tip change
• as desired between parts
Please refer to the Servo Gun Setup and

Operations Manual for more detail about
tip wear compensation programs and setup!

Step 15) Teaching programs
• When teaching a servo gun, always teach the fixed tip to touch the surface of
the metal, or a few mm off it with an equalizer
• The underlying application software determines the appropriate approach,
weld and open positions according to the “Weld Stroke” settings in the
specified pressure schedule
• The SPOT instruction looks very similar to the syntax used for air guns.
7: L[2] 750mm/sec CNT100
The fields for servo gun are:

EP#: Controls whether equalizer is used (1=YES, 0=NO)
P# : Controls gun close. Selects pressure schedule from table (affects tip force and
motion for close stroke)
S# : Controls welding. Selects weld schedule to send to the weld controller
BU# : Controls gun open. Selects gun open distance from table

• Linear motion type is recommended for all SPOT’s
– The approach direction will not be normal to the metal surface if Joint motion type
is used
– Linear motion type is faster for SPOT instruction
• Speed (mm/sec) selection
– Use 500-1000mm/sec for the 1st spot in a series
• lower velocities typically go faster on short motions
– Use 2000mm/sec for all spots after the 1st one in a series
• when there are no via points between spots.
• this is a special exception to the short motion rule, for servo gun SPOT’s only
• Termination Type of SPOT should be CNT
– The termination value of the SPOT is only applied to the Approach position
• the programmed spot location will always be reached, regardless of term type
– If obstructions (clamps, etc.) are cleared by using via points in the TP program,
CNT100 can often be used for SPOT
• CNT100 will always be fastest. The approach position will be noticeably rounded off, but the tips
will not close before reaching the spot.
• Typically, CNT50 is good for the 1st spot in a series, and higher CNT’s (50-100) can be used for
successive spots in a series
• If tips drag or tug metal when closing to
the SPOT
– Reduce CNT of the Approach Position
• this appears in the SPOT instruction
7: L[2] 750mm/sec CNT50
• If tips drag or tug metal when opening

from the SPOT
– Reduce CNT of the Open Position
• must go the WELD STROKE of the selected
Pressure Schedule to find this item
7: L[3] 2000mm/sec CNT100
25

• If the tips are open more than necessary
on the approach to the spot, reduce the
tolerance’s of the Approach position
– Must go the WELD STROKE of the
7.5
selected Pressure Schedule to find this item 2.5
• keep the Gun tolerance at least 5mm higher

than the Robot tolerance when using a gun
with an equalizer !!!

• If the tips are open more than necessary when opening after the
weld, reduce the Open distance by selecting a different BU #
• The fastest way to open the gun to a large distance after a weld
is to the select a BU with a large opening (rather than teaching
an extra point)
7: L[2] 750mm/sec CNT100 90mm total gun opening
SPOT[EP=1, P=1, S=1,BU=9] (if the backup table is
pre-populated by FRA)
• To have the Open position be the same as the Approach

Position use, BU=0
• With BU=0, the gun will not use a Backup from the Backup table, it will create a
temporary Backup that matches the Approach position used on this SPOT
• this is actually the preferred method for most spot’s
7: L[2] 750mm/sec CNT100
Step 15) Touching up programs
• When touching up a weld point with a servo gun, move to the
weld position, then jog the robot so the fixed tip touches the
surface of the metal (just a few mm away if equalizer used) at
the new location, then press shift-touchup.
– Stepping to a weld point with Shift-FWD moves the gun to the taught
position (fixed tip should be few mm from metal surface)
– A second Shift-FWD executes the closing and opening stroke,
including firing the equalizer

Advanced Servo Gun Features
Pressing Shift + RESET will temporarily
disable the Servo Gun OverTorque Protection
and the Robot Collision Guard !!
OverTorque Protection Only use the Shift+RESET sequence to jog out of a

collision condition, otherwise you can endanger
equipment and personnel
• Designed to protect servo guns from

damage caused by exceeding
maximum specified tip force
250
• Protection is enabled during teaching
and automatic cycles
• Includes capability to notify PLC if
feature is enabled and/or excessive
torque condition is detected
• Prompts user when servo gun settings • Software Automatically selects settings most appropriate
are changed that will effect for the gun based on motor type selected and tuning
parameters set during servo gun setup
protection settings • Sensitivity adjustment allows for increasing or
decreasing the detection parameters

Part Thickness Check

• Measures the part thickness when the
gun closes and compares it to the part
thickness specified in the Pressure
Schedule
• Out-of-Tolerance values can be used
to generate a message or fault
• Several different modes of operation
available
• Gun Deflection Calibration must be
done first, from the Autotune Utility

Gun Change
• Software used to support hand
change of servo gun
• Setup page to specify the
DETACH and ATTACH
operation
• Supports up to 6 guns per robot
• Supports guns with or without
Battery backup of pulsecoder
data

Pneumatic Equalization
Setup
• A few sysvars must be set first, to enable the
pneumatic equalizer function for a servo gun.
• $spoteqsetup[#].$equal_press = TRUE
• $spoteqsetup[#}.$num_eqp=31 or higher
• Cycle power for these changes to take effect
• Settings are defined on the Spot Equipment
Setup screen
• Before and After weld:
• specify the position to fire valve
• specify whether item should appear in the
spot instruction or be set to a constant for all
spots
• The equalizer is controlled via a Group Output
• select the group output to map to the
equalizer on the Spot Equip I/O screen

Other Servo Gun Functions
Disabling the Servo Gun Axis
• The servo gun can be disabled by turning off Motion Group 2,
temporarily
• This will allow the user to operate the robot while the servo gun is faulted or
damaged. Any faults it has, will be ignored and servo power is shut off.
• This can be done if the gun or its cables are damaged and the robot still needs to
be moved.

Disabling the Servo Gun Axis
•To disable the servo gun, proceed to
the Test Cycle Screen and activate
Motion Group 2
•You will see this screen, and can set

the motion item to DISABLE

Mastering/Zeroing
If the tips are new and

the position display is
not near 0.0 when they
touch, the gun can be
manually mastered by
the user
•Manually mastering the Servo Gun needs to be done only with new tips. It should be
done:
• (1) time when the gun is initially being setup
• Again, if the mastering data is lost because the battery backup was lost.
•A properly mastered gun will have a position of 0.0mm (+/- 1mm) when the gun is
closed with new tips
•If the tips do not meet at or near 0.0mm with new tips, the user can re-master the gun.
•NOTE: If tip wear compensation is used, the tip wear compensation program will automatically re-
master the gun, so the user does not need to.
Mastering/Zeroing
•The Servo Gun can be mastered by
proceeding to the Gun Master Screen
•Once here, jog the new tips until they touch

and press the F4 key, labeled EXEC to
master the gun

Status screen
• Feedback on
– Last pressure schedule
– tip wear amounts
– gun position
– thickness check ( if used )
– etc.

V6.40 ServoGun Training Guide

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Servo Weld Gun Control

Condensed Training Seminar

Designed for Project Integrators

February 8, 2006 FANUC Robotics Confidential

February 8, 2006 FANUC Robotics Confidential

February 8, 2006 FANUC Robotics Confidential

Gun Jog Function

Movable Tip, Servo Tip, Gun Tip

Fixed Tip, Robot Tip

February 8, 2006 FANUC Robotics Confidential

• Calibration - process of establishing a relationship between a range of servo

February 8, 2006 FANUC Robotics Confidential

February 8, 2006 FANUC Robotics Confidential

“Movable tip” wear

“Fixed tip” wear

February 8, 2006 FANUC Robotics Confidential

Gun Sag compensation value

February 8, 2006 FANUC Robotics Confidential

February 8, 2006 FANUC Robotics Confidential

• Aux Axis Config is also covered Group

February 8, 2006 FANUC Robotics Confidential

February 8, 2006 FANUC Robotics Confidential

[ TYPE ] EQUIP GUN_CFG

• Now, COLD START the Robot

February 8, 2006 FANUC Robotics Confidential

Press F6 - IDENT for

February 8, 2006 FANUC Robotics Confidential

“Servo Gun Setup”

February 8, 2006 FANUC Robotics Confidential

•With carried gun, robot will move in the Tool Frame +Z

•MPDT is Magnet Phase Detection

February 8, 2006 FANUC Robotics Confidential

• Servo gun tuning is necessary to determine the mechanical

• Some of the mechanical characteristics determined by tuning

February 8, 2006 FANUC Robotics Confidential

1) Go to the Servo Gun setup screen

February 8, 2006 FANUC Robotics Confidential

• PIECEWISE LINEAR – set $sgsyscfg.$cal_method =3

Tip Force (lbf)

February 8, 2006 FANUC Robotics Confidential

February 8, 2006 FANUC Robotics Confidential

February 8, 2006 FANUC Robotics Confidential

•Pressing the Detail key once takes you

Weld Stroke Terminology

Approach Pressure Pressure Pressure End Open

Tolerance Robot= desired distance between fixed tip and metal

February 8, 2006 FANUC Robotics Confidential

apply before welding [ TYPE ] EQUIP GUN DETAIL COPY >

– The max depth to which the gun will

February 8, 2006 FANUC Robotics Confidential

February 8, 2006 FANUC Robotics Confidential

Take handout with you please.

February 8, 2006 FANUC Robotics Confidential

February 8, 2006 FANUC Robotics Confidential

[ TYPE ] EQUIP GUN LIST SETSAG [ TYPE ] EQUIP GUN END

February 8, 2006 FANUC Robotics Confidential

February 8, 2006 FANUC Robotics Confidential

Method 1 - One Step Method 2 – Two Step

• Tips brought together to

(2) Step Measurement

February 8, 2006 FANUC Robotics Confidential

February 8, 2006 FANUC Robotics Confidential