Cad-To-Path

This document contains information proprietary to its author, or one of its affiliates, and is intended solely for the use of the individual or
entity to whom addressed and shall be maintained in confidence and not disclosed to third parties without the written consent of this
documents author. Any use, dissemination, forwarding, printing, or copying of this document is strictly prohibited. September 2013
 CAD-To-Path

EOAT Properties:
The Welding Torch
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To get to the EOAT UTOOL1 Properties Window: Under Robot Controllers, open:

C: 1 – Robot Controller 1
GP: 1 – ARC Mate 120iC/10L
Tooling
Right Click UT: 1
choose Binzel 22degree neck Properties
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This Window opens. It has 10 tabs.

The General Tab contains the settings for the location and scaling of the
tool (GMAW torch). It also lets you choose whether the tool is visible or not.
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The UTOOL Tab contains the settings the Tool Center Point (TCP) of the Tool.
If the Teach Tool Triad does not appear at the tip of the wire, wire this tab to correct it.
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The Parts Tab contains a list of the workcell Parts and positional settings these Parts.
<Tooling Version="6.4"
Name="WH455D22"
Locked="-1"
MassKG="3"
ToolAxisForMoveToPartSurface="+Z"
MoveToRetryToolAxisXRangeMax="15"
MoveToRetryToolAxisXStep="3"
MoveToRetryToolAxisYRangeMax="15"
MoveToRetryToolAxisYStep="3"
MoveToRetryToolAxisZRangeMax="15"
MoveToRetryToolAxisZStep="3"
CADFileName1="%IMAGELIBRARY%\EOATs\weld_torches\Binzel\Robo_WH_455D\WH455D_22d.CSB"
LocationX="-28.2000"
LocationY="14.0000"
LocationZ="64.6000"
LocationW="180.0000"
LocationR="90.0000"
LocationTCPX="-4.1488"
LocationTCPZ="346.6485"
LocationTCPW="-180.0000"
LocationTCPP="-45.0000">

<CADToPathDefaults ApproachDistance="1.79769313486231E+308"
ApproachSpeed="100"
RetreatDistance="1.79769313486231E+308"
SpeedFirstPointOfFirstSegment="100"
SegmentSpeed="100"
SegmentSpeedUnits="1"
SpinMode="0"
TermType="100"
ApproachOffsetX="100.0000"
RetreatOffsetX="100.0000"
OffsetOrder="1"/>

</Tooling>
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The Simulation Tab contains settings for the simulated open/close of grippers
and other moving Tools.
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The Feature App/Ret Tab contains settings for Approach and Retreat points for
Cad-To-Path created TPPs.
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The Pos Offsets Tab contains settings for the Position Offsets for Cad-To-Path
created TPPs. These settings dictate the automatically generated torch angles.
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The Calibration Tab contains settings for calibration of the tool (GMAW torch) to
the workcell.
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The Features Prog Settings Tab contains the setting for various TPP items like
Motion Types, Weld Speeds, & Terminations.
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The Features Position Defaults Tab

contains the setting for tool orientations for
Cad-To-Path generated TPP moves.
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Features Properties:
The Welds
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The Feature Properties window is found by right clicking the Feature and choosing
Feature Properties.
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This Window opens. It has 7 tabs.

The General Tab contains the setting for the Cad-To-Path Feature names, TPP names,
UTool, and User Frames. It also contain the command: Generate Feature TP Program.
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The Prog Settings Tab contains the setting for various TPP items like
Motion Types, Weld Speeds, & Terminations. The Features Prog Settings
tab is identical.
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The Position Defaults Tab contains the setting for

tool orientations for Cad-To-Path generated TPP
moves. The Features Pos Defaults tab is
identical.
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The Approach/Retreat Tab contains settings for Approach and Retreat points for
Cad-To-Path created TPPs. The Features App/Ret tab is identical.
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The Pos Offsets Tab contains settings for the Position Offsets for Cad-To-Path
created TPPs. These settings dictate the automatically generated torch angles.
The Features Pos Offsets tab is identical.
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The Raw Normals are fields that define the Start/End Rotations, Translations, and Blending
of the Features and Segments.

The Raw Normals Tab contains settings for these.

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The Multi Position Offsets Tab contains the

setting for creating templates for offsets that are
used many times.
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Prepare and Organize

Actual and Virtual
Robotic Systems
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Obtain/create an accurate WeldPRO model of your robotic welding system

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Place your fixture and part onto to your robotic welding system,
where they are to be used for production
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Accurately measure the dimensional location of your part with respect to the base of the robot.
In WeldPRO, locate your virtual part in the same place as your actual part.
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Press “Menu”, “6 Setup”, “Frames”, Prev,

“F3 [OTHER]”, “3 User Frame”, “F2 Details”.

Press “F2 [METHOD]” & “1 Three Point”.

Jog the robot to each of the three points

and press “Shift” and “F5 RECORD”
simultaneously.

Create a User Frame on the part in a “base” position for both actual and virtual robots.
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Identify all the welds on your part: number them and list with weld types and sizes.
 SEQUENCE
CAD-To-Path
Aux Axis Poition 1 - Zero Degrees Aux Axis Poition 2 - +90 Degrees
1. F851F2 1/4" Fillet Weld 1. F851F13 1/4" Fillet Weld
2. F851F4 1/4" Fillet Weld 2. F851F7 1/4" Fillet Weld
3. F851FC 1/4" Fillet Weld 3. F851F5 1/4" Fillet Weld
4. F851FB 1/4" Fillet Weld
5. F851F1 1/4" Fillet Weld Aux Axis Poition 3 - 90 Degrees
6. F851F3 1/4" Fillet Weld 1. F851FA 1/4" Fillet Weld
7. F851FD 1/4" Fillet Weld 2. F851F14 1/4" Fillet Weld
8. F851FE 1/4" Fillet Weld 3. F851F8 1/4" Fillet Weld
9. F851F6 1/4" Fillet Weld
10. F851F19 1/4" Fillet Weld
11. F851F9 1/4" Fillet Weld
12. F851F1A 1/4" Fillet Weld
13. F851F16 1/4" Fillet Weld
14. F851F17 1/4" Fillet Weld
15. F851F18 1/4" Fillet Weld
16. F851FZ 1/4" Fillet Weld
17. F851F1B 1/4" Fillet Weld
18. F851F11 1/4" Fillet Weld
19. F851F10 1/4" Fillet Weld
20. F851FG 1/4" Fillet Weld
21. KLSIDE 5/16" Fillet Weld
22. KRSIDE 5/16" Fillet Weld
23. F851FL 1/4" Fillet Weld
24. F851FQ 1/4" Fillet Weld
25. F851FT 1/4" Fillet Weld
26. F851FO 1/4" Fillet Weld
27. F851FK 1/4" Fillet Weld
28. F851FP 1/4" Fillet Weld
29. F851FS 1/4" Fillet Weld
30. F851FN 1/4" Fillet Weld
31. F851FR 1/4" Fillet Weld
32. F851FF 1/4" Fillet Weld
33. F851FJ 1/4" Fillet Weld
34. F851FM 1/4" Fillet Weld

Determine the sequence in which you want to make these welds.

Group the welds by aux axis positions.
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Determine the number of aux axis positions needed to effectively weld you part.
Teach these positions in single line Teach Pendant Programs on both your actual &virtual robots.
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Teach these positions in single line Teach Pendant Programs on both your actual &virtual robots.
Use Group Mask of only one Motion Group for each of these Aux Axis Positioning programs.
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Getting the Virtual

Positioner in the
Desired Position
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In order to speed up the teach pendant program creation, it is easy to create small
teach pendant programs that move the virtual positioner to a desired location.
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Now create several small teach pendant programs that contain a point that places
the virtual positioner in the desired position.

G2_ZERO.TP G2_180.TP

G2_90.TP G2_M90.TP

G2_45.TP G2_M45.TP
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These will show up in the Cell Browser. To move the virtual positioner to a
desired location, simply clip on the teach pendant program name in the Cell
Browser, and click the RUN icon.

1
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Now use this technique to speed up the creation of teach pendant programs.

WP_011
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Cad-To-Path
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Click on the virtual part then click on the Draw Features On Part Key:
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Click on the "Surface Fit Line" Button.

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"hair" is horizontal
correct

"hair" is horizontal
incorrect

Click on the weld start so that the "hair" is horizontal, not vertical.
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Double click on weld end. Make sure the "hair" is horizontal.

"Features" box opens automatically.
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Change the names of the Feature and the Teach Pendant Program to match the weld number.
Enter the User Frame or UFrame Number that you setup earlier.
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Click on the Pos Offsets tab, and set Work Angle and Push Angle as shown.
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Click on the Pos Defaults tab, and set the Tool Frame Axis values as shown.
If you weld paths are generally straight lines, select a low "Circular Move Detection".
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Weld_001

WELD_001

Apply

Click on the General Tab, click "Apply" button, and

click on the "Generate Feature TP Program" button.
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The following window will appear and a Teach Pendant Program has been generated.
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Cad-To-Path_Exp

Press the "Cycle Start" button and the Generated Teach Pendant Program will run.
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The automatically Generated Teach Pendant Program will look like this.
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Continue this process for all welds that you want to generate using Cad-to-Path.
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To combine these individual teach pendant programs, create a Job:

in the Cell Browser, right click on "Jobs" and choose "Add Job".
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A "Job" dialog box will appear. Rename the Job and the
TP Program to match the name of the weldment.
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Click on the "Processes" tab. Add each Feature TPP to the Items in Job column.
Arrange these Feature TPP's in the sequence order that is desired.
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Apply

Click on the General tab, click on Insert all process TP lines button,
click on "Apply". Then click on "Generate".
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Press the "Cycle Start" button to run the newly generated TPP
containing the Cad-to-Path generated Feature TPPs.
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Example:

WPJ_009
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Alternative Method

Cad-To-Path
Using Current
Robot’s Orientation
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Sometimes it is easier to utilize Cad-To-Path using an alternative method:
Use the robot’s current orientation. To set this up as a default, from the Cell
Browser, double click on the UTool to open its properties, click on the Feature
Pos Offset tab, and choose: Use the robot’s current orientation.

1
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To use this when creating a feature, click on the Pos Offsets tab, and choose
Use the robot’s current orientation in the Orientation Offsets.

2
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Now create several small teach pendant programs that contain a point that places
the torch at various usable orientations.

A_TORCH_POS_DOWN.TP A_TORCH_POS_OUT.TP A_TORCH_POS_IN.TP

A_TORCH_POS_RIGHT.TP A_TORCH_POS_LEFT.TP
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These will show up in the Cell Browser. To move the robot so that the torch is in
one of these orientations, simply clip on the teach pendant program name in the
Cell Browser, and click the RUN icon.

1
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WP_010
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Now use this alternative method of using the robot’s current orientation, to create
teach pendant programs using Cad-To-Path:

WP_012
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Transferring
Virtual TPP's to
Actual Robots
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After you have run and reviewed this TPP (Teach Pendant Program), transfer it to your actual robot.
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From the Cell Browser, right click on the Teach Pendant Program name and click on "Export".
Choose Export To Loadset.
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The "Export to loadset" dialog box will appear.

Click on the folder icon to choose which file to receive it.
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Click on the browser and choose the Teach Pendant Program's destination file.
Press the OK button.
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The "Export to loadset" dialog box will re-appear.

Click on Export to send the Teach Pendant Program.
 Weld PRO
Insert a the USB memory stick that contains the TPP that you exported
from WeldPROin into USB Port UT1 on the i-Pendent
 Weld PRO

To load the TPP from the USB memory stick to your Controller:
press MENU, select File, and select File.
 Weld PRO

This screen appears

 Weld PRO

To choose memory storage device, press F5-UTIL, and select 1 Set Device
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Choose the device: UT1:

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This screen will appear. Press F2-DIR. The directory for UT1 will be show.
Weld PRO

Press F3-Load.
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You will be prompted to “Load UT1:\the TPP? Press F4-YES.

 Weld PRO

You have now loaded the TPP file from WeldPRO to your Actual Workcell
 Cad-To-Path
END

This document contains information proprietary to its author, or one of its affiliates, and is intended solely for the use of the individual or
entity to whom addressed and shall be maintained in confidence and not disclosed to third parties without the written consent of this
documents author. Any use, dissemination, forwarding, printing, or copying of this document is strictly prohibited.
 Lab 6
Cad-To-Path
This document contains information proprietary to its author, or one of its affiliates, and is intended solely for the use of the individual or
entity to whom addressed and shall be maintained in confidence and not disclosed to third parties without the written consent of this
documents author. Any use, dissemination, forwarding, printing, or copying of this document is strictly prohibited. September 2013
 CAD-To-Path

1. Using workcell call Lab 3, create three fillets welds on the

part call Box_Section_Weldment.igs.

a. the Feature names and TPP names should be WELD1,

WELD2, and WELD3.

b. make sure you setup your Position Offsets & Pos Defaults
correctly.

2. Combine WELD1, WELD2, & WELD3 into a Job called

JOB111. This new TPP should also be called JOB111.

3. Save your work.

 Lab 6
Cad-To-Path
END

This document contains information proprietary to its author, or one of its affiliates, and is intended solely for the use of the individual or
entity to whom addressed and shall be maintained in confidence and not disclosed to third parties without the written consent of this
documents author. Any use, dissemination, forwarding, printing, or copying of this document is strictly prohibited. September 2013