M55.780805 Ravvivatori e Frese v.1.4 16 Mag.2011-En

MANUFACTURING ENGINEERING PAGE: 1/20
EDITION: 1.4
Fiat
Fiat Group Automobiles SpA BODY IN WHITE DATE: May 2011
M55.780805: Supply of tip dressers and milling cutters specification
SPECIFICATIONS
FOR THE SUPPLY OF:
TIP DRESSERS AND MILLING
CUTTERS
M55.780805
Fiat
Fiat Group Automobiles SpA
The information contained in this document is the property of FIAT GROUP S.p.A.
It is forbidden to reproduce it, including partially without the prior authorisation in writing from FIAT GROUP S.p.A.
FIAT GROUP S.p.A. reserves the right to modify, without any warning, the specifications described in this document.
It is forbidden to reproduce it, including partially, without the prior authorisation in writing from FIAT GROUP S.p.A.
EDITION: 1.4
Fiat
List of changes from previous issue:
Release Description of Variant.

Rel. 1.0 Issue
Rel. 1.1 Chapter 5 Documentation - changed indication of the languages in which the documentation must be
May 2009 drawn up.
Rel. 1.2
Page 17 - Chapter 7 "WCT requirements" added
May 2009
Rel. 1.3 Pag. 14-15-16-17 – Added chapter “Application of load cell”.
Sept. 2010 Pag. 18 – Moved chapter “Requirement in WCT vision”
Rel. 1.4
Chapter “2.6 Rotation control of milling cutter motor and milling cutter”: updated title and
May 2011 description.
16/05/2011
EDITION: 1.4
Fiat
INDEX
List of changes from previous issue: ........................................................... 2
INDEX ..................................................................................................... 3
1. PROJECT ......................................................................................... 4
1.1 DEFINITION OF THE PROJECT ................................................................ 4
2 REQUIREMENTS ............................................................................. 5
2.1 PRODUCT CHARACTERIZATION ............................................................. 5
2.2 DRIVE ....................................................................................................... 8
2.3 STANDARD DRESSER UNIT WITH ONE CUTTER HOLDER HEAD ........... 9
2.4 SPECIAL DRESSER UNIT WITH TWO CUTTER HOLDER HEADS ............ 9
2.5 SPECIAL MILLING CUTTER UNIT FOR GLUE .......................................... 9
2.6 ROTATION CONTROL OF MILLING CUTTER MOTOR AND MILLING
CUTTER ................................................................................................................ 9
2.7 SEAT FOR CUTTER HOLDER HEAD ........................................................ 10
2.8 CUTTER HOLDER HEAD ......................................................................... 10
2.9 SUPPORT ................................................................................................ 10
2.10 COMPENSATION SYSTEM .................................................................... 10
2.11 CHIPS EVACUATION SYSTEM, CHIPS COLLECTION CONTAINERS ... 10
2.12 DEVICE ON OSCILLATING DEVICE ..................................................... 11
3 COMPOSITION ............................................................................. 12
4 TECHNICAL SERVICE ................................................................... 12
5 DOCUMENTATION........................................................................ 12
6 EXAMPLES .................................................................................... 13
7 APPLICATION OF LOAD CELL ...................................................... 14
Introduction ......................................................................................... 14
Messa in funzione ................................................................................ 14
Calibration of force sensor ............................................................................................................................................ 14
Instruction for mounting and draws .................................................. 15
Mounting draw.............................................................................................................................................................. 15
Electrical connection .................................................................................................................................................... 15
Photo and draws .................................................................................. 16
8 WCT REQUIREMENTS .................................................................. 18
EDITION: 1.4
Fiat
1. PROJECT
1.1 DEFINITION OF THE PROJECT
These specifications are dedicated to defining a testing and certification method for the
following applications:
Floor-mounted dresser for gripper mounted on robot wrist.
Dresser on oscillating arm for gripper fastened to the floor.
EDITION: 1.4
Fiat
2 REQUIREMENTS
It is deemed essential to share with the supplier:
Method of certifying standard and special dressers for the robotized and manual
applications.
Manufacturer-guaranteed traceability for the following phases:
1. Design.
2. Construction.
3. Dimensional and function test.
4. Test with welding simulation.
5. Functional certification demonstrating good operation of the product and
ensuring the stability of the technological process carried out on site on the
Customer's premises.
The Manufacturer must declare:

the type of application
the dresser model
the milling cutter model
MTBF and MTTR of the dresser and milling cutter
Guaranteeing product quality and the stability of the technological process obtained, by
practice checking and defining:
Mechanical, electric and pneumatic characteristics of the dresser for the
applications: fixed and on oscillating device
Life time for the dresser and for the milling cutters.
2.1 PRODUCT CHARACTERIZATION
The characterization of the dresser + milling cutter product is executed by the

Manufacturer and must observe the following tolerances:
Electrodes coined with an HRB hardness of 90 - 95 points must be used.
The results obtained in the certification must be reconfirmed in production.
The milling cutter must guarantee the following tolerances x1, x2, x3, x4, x shared
with the Manufacturer and the Customer:
EDITION: 1.4
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The change of the

∅pa ∅pa ± X1 OK
diameter ∅pa of the active
∅Pa ∅pa > ∅Pa NOT OK
part must be equal to:
∅pa ± X1.
The axis of the active part may lose

X2 = ± 0.5 [mm]
alignment with the axis of the
electrode body by ± X2.

X2
The axis of the active part of the
upper electrode may lose alignment
with the axis of the active part of the X3 = ± 0.1 [mm]

X3
lower electrode by ± X3.
EDITION: 1.4
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The shape of the active part may
abandon the circular shape to take X4 = ± 0.3 [mm]
the elliptical shape with a

X4
maximum tolerance on the star of
the diameters of ± X4
The surface of the active part may
abandon the flat shape to take on the
convex shape with a maximum
tolerance of ± X5. The surfaces must X5 = ± 0.1 [mm] X5

be smooth and without roughness;
chips and witness marks must in no
case whatsoever be left in the centre
of the electrode after dressing.
EDITION: 1.4
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2.2 DRIVE
1. Three-phase motor, nominal voltage 380V - 400V - 500V (based on the power
supply voltage of the factory where it is installed) - frequency 50Hz, min. nominal
power 0.75 kW.
2. The electrical supply of the dresser unit, including the motor of the oscillating
device, if any, must be supplied by the robot control.
From the side of the dresser unit, the power cord must be
connected with a cable provided with flying connector.
The dresser unit box must be equipped with the corresponding fixed connector.
The motors of the dresser and of the oscillating device, if any, must be equipped
with their own fixed connector.
The connectors must be included in the supply volume.
3. The dresser unit and its power cord must be protected with a suitable circuit
breaker protection device contained inside the robot control.
4. The part regarding the safety of the dresser and of the oscillating device, if any,
must be managed by the robot control that by way of a special relay has to prevent
movement of the dresser motor (and of the oscillating device motor in case
dressers mounted on motorized oscillating devices are used) if the line sector is not
reset (emergency or sector accesses not closed).
5. The electrical signals from and to the dresser unit, including the oscillating arm, if
any, must be managed by the robot control.
From the side of the dresser unit, the cable must be connected with a cable
provided with flying connector.
The dresser unit box must be equipped with the corresponding fixed connector.
The connectors must be included in the supply volume.
6. The air supply for the chips suction must be shunted from the fluid panel of the
robot. The control solenoid valve is put on the dresser.
7. Rpm on the cutter holder head: >250 - 400 [rpm] travelling unladen, with load
about 230 - 300 [rpm].
8. Minimum torque on the cutter holder head 25 [Nm].
9. Protection rating IP56
10. Maximum contact temperature 40°[C] on the box.
11. The connectors connecting the sensors and the actuators must be M12.
EDITION: 1.4
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2.3 STANDARD DRESSER UNIT WITH ONE CUTTER HOLDER HEAD
The standard dresser unit must be used on robots on which there are one or more
welding guns with electrodes having the same geometry.
2.4 SPECIAL DRESSER UNIT WITH TWO CUTTER HOLDER HEADS
The special dresser unit (Twin) can be used on robots on which at least two welding guns
with electrodes having different geometries are used.
2.5 SPECIAL MILLING CUTTER UNIT FOR GLUE
If the welding electrodes come into contact with glue, the cutter holder head may get
dirty. In this case this dresser unit can be used bearing in mind the cycle time. The
electrode can be pre-cleaned with an appropriate cleaning head and dressed with the
cutter holder head. This system prevents the cutter holder head from becoming dirty
quickly. The system supplier must make this option available when required.
2.6 ROTATION CONTROL OF MILLING CUTTER MOTOR AND MILLING CUTTER
The dresser electrodes unit electrically operated must be provided with the control of the
rotation effective and of the direction of rotation of the milling cutter motor and of the
milling cutter itself.
This is to avoid the risk of elements with spot welding of reduced quality due to non
dressing of the electrodes.
The control will have to manage each of the cutter holder heads presents on the unit of
dressing electrodes.
The management of the control must be performed by the robot.
The possible anomaly of direction of rotation of the milling cutter, which must stop the
process of dressing the electrodes, must be diagnosed on the robot TP and on the HMI
line.
EDITION: 1.4
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2.7 SEAT FOR CUTTER HOLDER HEAD
The seat of the cutter holder head and the cutter holder head must be equipped with a
bayonet quick locking system so that changing the cutter holder head is fast.
2.8 CUTTER HOLDER HEAD
The milling blades with which the electrodes are machined are in the cutter holder head
The cutter holder heads must be made so that the knives are locked and not screwed on.
The geometries of the electrodes on the single welding guns may vary. This is why there
are different versions of cutter holder heads. It must be supplied with special openings for
unloading chips so as to prevent blockage. For every combination of electrodes, the
cutter holder head envisaged for it must be used.
2.9 SUPPORT
The milling unit must be secured to a support that ensures its stability. This support must
be made so that the dressing unit can be mounted horizontally or vertically, as needed, to
guarantee accessibility of the welding gun.
Support modification (lengthening the support pipe) is not allowed.
2.10 COMPENSATION SYSTEM
In order for the dressing unit to adjust itself when the welding gun closes, the milling unit
must be equipped with a vertical compensation system. The elastic travel should be at
least +/- 15 mm.
2.11 CHIPS EVACUATION SYSTEM, CHIPS COLLECTION CONTAINERS
To keep the welding systems clean and to allow the copper to be recovered, it is necessary to
provide chips collection containers with air blow or integrated suction devices next to the dressing
devices.
The volume of the collection container must be at least 2 litres and the collection container
must be easy to empty and non-inflammable
Suction of the milled material must be greater than 80%.
EDITION: 1.4
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It is essential that all dressing stations use suction cowls in order for the suction to operate well.
They can be brush or in another material (PVC) to allow the cutter head to be disassembled easily
and functionally.
For solutions with special milling cutters where the standard cowl cannot be put in, it is
essential that the feasibility study be implemented and to submit it to the Customer for approval.
Any fittings for the pneumatic system must have quick connectors.
2.12 DEVICE ON OSCILLATING DEVICE
To dress floor-mounted welding guns, it is necessary to use dressing units mounted on

appropriate pneumatically or electrically powered oscillating devices (FGA will determine
the type of drive). This drive must have a sufficiently broad field of oscillation (at least 0-
135 degrees); the field of oscillation should possibly be freely adjustable. The assembly
elements (arms) must be made in board materials; the necessary connection elements
such as angle bars and sleeves must be in stable execution. The length of the levering
arm should not be greater than the 1200 mm of the arms; if necessary, no greater than
600 mm including the dressing unit. Prevent additional oscillation of the dressing unit in
the dressing position.
The movement of the oscillating device can be both horizontal and vertical.
The oscillating device and the position of the dressing unit must be equipped so that the
chips collection container can be assembled in a functional manner, without causing
encumbrances. The adjustable dressing units must also be equipped with a compensation
system
The electrofluid management of the electrode dressing unit on oscillating device, whether
with pneumatic or electric drive, must be totally part of the robot control (see details
indicated in paragraph 2.2 Drive).
EDITION: 1.4
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3 COMPOSITION
The oscillating electrode dressing unit basically consists of:

Tip dresser and milling cutter
Cylinder holder base and 4 floor mounting attachments
Oscillating arm
Suction system with chips collection tank
Electric box on dresser
If the oscillating device has pneumatic drive, solenoid valves for pneumatic
cylinder control. As for the stem locking valve, the control wiring is
connected on the 2 pins of the safety module inside the robot control.
Kit of power cables and signals for dresser connection.
4 TECHNICAL SERVICE
Technical service
The Manufacturer of the equipment must describe the technical services provided at the
place of use and attach them to the offer.
5 DOCUMENTATION
The documentation of the dresser unit must include all the certifications of compliance
with current legislation for the place in which it will be installed, the mechanical drawings,
the electrical wiring diagrams, the fluid diagrams, the plate data, the electrofluid energy
consumption, the list of parts with their prices and the operation & maintenance manual,
and the documentation must be supplied both in electronic format and in hardcopy format
in the languages specified in the general supply specifications FGA M55.780013 and/or
other relevant documentation.
EDITION: 1.4
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6 EXAMPLES
Fig. 1
Fig. 2
Two construction examples of oscillating devices offered by various manufacturers.
Fig. 3
A classic application with horizontal oscillating device.
EDITION: 1.4
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7 APPLICATION OF LOAD CELL
Introduction
The load cell is used for monitor during the time the strength that the weld gun can really to
impress based on force requirements, or the current request.
The management of the load cell is provided by Robot constructor through application and installed
into Robot cabinet.
The load cell returns to a given analog application, using the instructions exported from a library
technology, and manages changes to user information.
The load cell restituisce an analog data that the application, by technologic instructions exported
from a library, manage and transform in information for user.
The load cell is composed by a support to mount on tip dresser, a force sensor and a 5 pin
moulded cable that transmit signals from/to Robot cabinet.
Messa in funzione
Calibration of force sensor

The sensor calibration consists of find the value of the conversion factor from N / bit to be included
into initialization routine force_meas_init.
1- Warm the weld gun with the routine warm_up.

Note: the measures of force execute with weld gun cold could lead to inconsistent results.
A major reason the calibration must be performed with the weld gun in optimal conditions
2- Execute a dressing of electrodes.
3- Put the weld gun in measuring position with fixed electrode almost at contact with surface
sensor.
4- Execute a measure of thickness sensor.
5- Fill in the fields of force_meas_init entering a high tolerance, 1 as a conversion factor,
and run it. With 1, a control returns a value in bits.
6- Run a measure of force with instruction force_measure setting a mean force to be applied
(eg. 200 daN) and the thickness measured by the previous measure. Despite the high
tolerance being the result in bits, the control will generate an error. The measurement result
can be read into space reserved for messages on the TP or TP-INT.
7- Repeat step 4 a few times and then averaging the results obtained from the measurement
8- Dividing the force applied to the average score in bits is obtained by the conversion factor
to be included into force_meas_init.
Example
- force applied: 200 daN
- medium result: 2850 bit
- convertion factor = 200/2850 → 0.07
9- To improve the accuracy of calibration can repeat steps 6, 7 and 8 using different forces.
The conversion factor obtained should be, approaching, the same.
EDITION: 1.4
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Instruction for mounting and draws

For mounting force sensor, consult mounting draw, provided by Robotics with application and force
sensor Kit.
Mounting draw
Electrical connection
For electrical interface of sensor, consult manuals and/or Constructor of Robot cabinet.
EDITION: 1.4
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Photo and draws
Force sensor
Support stirrup
EDITION: 1.4
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Example for installation
EDITION: 1.4
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8 WCT REQUIREMENTS
Provide for the electrode dressers:
on the chips collection container, indication of the level above which it must be emptied:
EDITION: 1.4
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insertion of dressing chips and welding dust collection container:
moving dresser arm lubrication from manual to automatic:
EDITION: 1.4
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possibility to inspect the milling cutter without disassembling the protective device:
POLYCARBONATE
PROTECTIVE
DEVICE
Insertion of milling cutters with interchangeable cutting tools.

M55.780805 Ravvivatori e Frese v.1.4 16 Mag.2011-En

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MANUFACTURING ENGINEERING PAGE: 1/20

List of changes from previous issue:

Release Description of Variant.

1.1 DEFINITION OF THE PROJECT

Floor-mounted dresser for gripper mounted on robot wrist.

Dresser on oscillating arm for gripper fastened to the floor.

It is deemed essential to share with the supplier:

Manufacturer-guaranteed traceability for the following phases:

The Manufacturer must declare:

2.1 PRODUCT CHARACTERIZATION

The characterization of the dresser + milling cutter product is executed by the

The change of the

The axis of the active part may lose

electrode body by ± X2.

The axis of the active part of the

upper electrode may lose alignment

with the axis of the active part of the X3 = ± 0.1 [mm]

The shape of the active part may

abandon the circular shape to take X4 = ± 0.3 [mm]

the elliptical shape with a

The surface of the active part may

abandon the flat shape to take on the

convex shape with a maximum

tolerance of ± X5. The surfaces must X5 = ± 0.1 [mm] X5

chips and witness marks must in no

case whatsoever be left in the centre

of the electrode after dressing.

2.3 STANDARD DRESSER UNIT WITH ONE CUTTER HOLDER HEAD

2.4 SPECIAL DRESSER UNIT WITH TWO CUTTER HOLDER HEADS

2.5 SPECIAL MILLING CUTTER UNIT FOR GLUE

2.6 ROTATION CONTROL OF MILLING CUTTER MOTOR AND MILLING CUTTER

2.7 SEAT FOR CUTTER HOLDER HEAD

2.8 CUTTER HOLDER HEAD

2.10 COMPENSATION SYSTEM

2.11 CHIPS EVACUATION SYSTEM, CHIPS COLLECTION CONTAINERS

2.12 DEVICE ON OSCILLATING DEVICE

To dress floor-mounted welding guns, it is necessary to use dressing units mounted on

The oscillating electrode dressing unit basically consists of:

Two construction examples of oscillating devices offered by various manufacturers.

A classic application with horizontal oscillating device.

7 APPLICATION OF LOAD CELL

Calibration of force sensor

1- Warm the weld gun with the routine warm_up.

Instruction for mounting and draws

Photo and draws

Example for installation

Provide for the electrode dressers:

insertion of dressing chips and welding dust collection container:

moving dresser arm lubrication from manual to automatic:

Insertion of milling cutters with interchangeable cutting tools.

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