Kawasaki Programming Guide RIV0016 MIG

Rivian Robot Programming Guide – Kawasaki Implementation
Appendix AW – Arc Welding with Fronius Welder
REVISION 0 – November 8, 2019

TABLE OF CONTENT
INTRODUCTION ........................................................................................................................................ 7
1.1 PURPOSE ......................................................................................................................................................................... 7
1.1.1 Document Description ................................................................................................................................................ 7
1.1.2 Who should use the document .................................................................................................................................... 7
1.1.3 What should be learned .............................................................................................................................................. 7
1.2 SYSTEM OVERVIEW......................................................................................................................................................... 8
1.2.1 System Components ................................................................................................................................................... 8
1.2.2 Reference Documents ................................................................................................................................................ 9
ROBOT SETTINGS ................................................................................................................................... 10
2.1 AUX FUNCTION ............................................................................................................................................................. 10
2.1.1 Dedicated Input ........................................................................................................................................................ 10
2.1.2 Dedicated Output ..................................................................................................................................................... 12
2.1.3 Fronius Arc Welder (Setting 1 Communication) ...................................................................................................... 14
2.2 ARC WELDING SPECIFIC SETTINGS................................................................................................................................ 17
2.2.1 Fronius Option ......................................................................................................................................................... 17
2.2.2 Fronius Linearization Setup...................................................................................................................................... 18
2.2.3 Weld Output Signal Setting ...................................................................................................................................... 26
2.2.4 Arc Weld Setting-Others .......................................................................................................................................... 27
2.3 SOFTWARE LIMITS ........................................................................................................................................................ 31
ROBOT ARC WELDING TOOL TCP .................................................................................................... 32
3.1 ARC TOOL REQUIREMENTS FOR TCP ............................................................................................................................ 32
3.2 TEACH TCP USING THE FOUR POINT METHOD .............................................................................................................. 34
3.2.1 Setup Condition ........................................................................................................................................................ 34
3.2.2 Procedure to Teach TCP........................................................................................................................................... 34
3.3 VERIFY THE TCP POINT ................................................................................................................................................ 36
TORCH CLEAN ......................................................................................................................................... 37
WELDING PROCESS CONTROL .......................................................................................................... 41
5.1 WELD PROGRAM – PG21_WELD1 .................................................................................................................................. 41
5.2 WELD MODE – JOB........................................................................................................................................................ 43
5.3 WELD CONDITION DATA ............................................................................................................................................... 46
5.3.1 Change Weld Condition Number in Program........................................................................................................... 46
5.3.2 Change Condition Data for a Weld Condition Number ............................................................................................ 48
6.1 PG02_MIG_CUT_CLEAN ................................................................................................................................................. 51
6.2 PG20 ............................................................................................................................................................................. 54
6.3 PG20_R1T_PROC1_WELD1 ............................................................................................................................................ 55
ERROR RECOVERY ................................................................................................................................ 58
7.1 ARC FAILURE FAULT ..................................................................................................................................................... 58
7.2 GAS FLOW FAULT ......................................................................................................................................................... 59
7.3 WIRE SHORTAGE FAULT................................................................................................................................................ 60
Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

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7.4 WATER COOLING FAULT ............................................................................................................................................... 61
7.5 TORCH BREAKAWAY FAULT ......................................................................................................................................... 63
ROBOT I/O – ARC WELDING ................................................................................................................ 65
SOFTWARE INTERFACE ....................................................................................................................... 67
KLOGIC ...................................................................................................................................................... 68

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TABLE OF FIGURES
Figure 1: Arc welding robot system ........................................................................................................ 8
Figure 2: AUX 0601 - Dedicated Input Signals (2/6) ............................................................................ 10
Figure 3:AUX 0601 - Dedicated Input Signals (3/6) ............................................................................. 11
Figure 6: AUX 0602 - Dedicated Output Signals (4/12) ....................................................................... 13
Figure 7: AUX 0602 - Dedicated Output Signals (8/12) ....................................................................... 13
Figure 8: AUX 0602 - Dedicated Output Signals (9/12)Ethernet/IP Setup............................................ 14
Figure 9: Aux 0608-9-4-1 – Setting 1 (page 1/3) ................................................................................... 15
Figure 10: Aux 0608-9-4-1 – Setting 1 (page 2/3) ................................................................................. 15
Figure 11: Aux 0608-9-4-1 – Setting 1 (page 3/3) ................................................................................. 16
Figure 12: Aux 1417-1 Fronius Welder: Basic setting .......................................................................... 17
Figure 13: Aux 1417-2 Fronius Welder: Linearization, Internal Parameter .......................................... 18
Figure 14: Aux 1417-2 Fronius Welder: Linearization, Internal Parameter (page 1/4) ......................... 19
Figure 18: Aux 1417-2 Fronius Welder: Linearization, Special 2 step.................................................. 21
Figure 19: Aux 1417-2 Fronius Welder: Linearization, Special 2 step (page 1/4) ................................ 21
Figure 23: Aux 1417-2 Fronius Welder: Linearization, 2 step .............................................................. 23
Figure 24: Aux 1417-2 Fronius Welder: Linearization, 2 step (page 1/4) ............................................. 24
Figure 28: Aux 1413 Weld Output Signal Setting (page 1/3) ................................................................ 26
Figure 31: Auxiliary Function 1404 Arc Weld Setting .......................................................................... 27
Figure 32: Auxiliary Function 1404-03 Weld Start Sequence ............................................................... 28
Figure 33: Auxiliary Function 1404-03 Weld Start Sequence 1 ............................................................ 29
Figure 34: Auxiliary Function 1404-05 Weld Stuck Cancel Sequence ................................................. 29
Figure 35: Auxiliary Function 1404-09 Motion Setting for Arc Weld .................................................. 30
Figure 36: Auxiliary Function 507 Motion limits .................................................................................. 31
Figure 37: Auxiliary Function 20-04 Mechanical Motion limits ........................................................... 31
Figure 38: Arc Weld Robot Tool Coordinates ....................................................................................... 32
Figure 39: Auxiliary Function 0304 Tool Coordinates .......................................................................... 33
Figure 40: Auxiliary Function 0304 Tool Coordinates .......................................................................... 34
Figure 41: Auxiliary Function 0410 Auto Tool Coordinates Register (page 1/2) ................................. 35
Figure 42: Auxiliary Function 0410 Auto Tool Coordinates Register (page 2/2) ................................. 35
Figure 43: Torch Cleaning position ....................................................................................................... 37
Figure 44: Torch Clean Station .............................................................................................................. 38
Figure 45: PG02 structure ...................................................................................................................... 38
Figure 46: Torch Clean Subroutine ........................................................................................................ 39
Figure 47: Torch Clean Subroutine ........................................................................................................ 40

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Figure 48: Teach Pendant Display – Weld Program pg21_weld1 ......................................................... 41
Figure 49: Weld Condition example (page 1/2) ..................................................................................... 42
Figure 50: Weld Condition Example (page 2/2) .................................................................................... 42
Figure 51: Weld Mode Selection – Step 1 ............................................................................................. 43
Figure 54: Weld Mode Selection – Step 4 ............................................................................................ 45
Figure 55: Weld Condition Change – Step 1 ......................................................................................... 46
Figure 59: Auxiliary Function 1401 Arc Welding Condition ................................................................ 48
Figure 60: Auxiliary Function 1401 Arc Welding Condition -Weld Condition 1 ................................. 49
Figure 61: Auxiliary Function 1401 Arc Welding Condition -Crater condition 1................................. 49
Figure 62: Weld program structure ........................................................................................................ 50
Figure 63: E6502 Arc Failure error ........................................................................................................ 58
Figure 64: Torch Interference Error ....................................................................................................... 63
Figure 65: Software Interface Screen ..................................................................................................... 67

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Revision History
Revision Modification Date Author Description / Reason
0 2019-11-8 BC Initial Release
1 2023-08-24 SF Dedicate input and outputs, Weld program Structure, Templates

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Introduction
1.1 Purpose
1.1.1 Document Description

This document defines the basic methodology and structure for programming Kawasaki robots for
Rivian Arc Welding applications, equipped with Fronius TPSi Welder. It is designed to give the
guideline for standard programming, with expectations that integrators can customize where
required.
1.1.2 Who should use the document

This document is intended to be used by OEM and system integrator programmers and engineers,
as well as by Rivian controls and process engineers.
1.1.3 What should be learned

This document explains the general arc welding programming strategy for a Kawasaki robot. It
explains standards that are to be applied to all Arc Welding application programs. It also includes
template production programs that must be used as models for the final application programs to be
written by the integrators and end users.
This document is prepared for programming Fronius TPSi welder, and Fronius torch clean station.

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1.2 System Overview
1.2.1 System Components

The major items of Kawasaki robot system designed for Rivian arc welding application include:
• Robot (BA006L) with Fronius dressing package
• Kawasaki E01 robot controller with Fronius welding interface
• Fronius TPSi 400 welder
• Torch clean station with mechanical wire cutter
• PLC, sPLC Ethernet/IP IO interface
24V
LINE PLC ETHERNET IP DISCRETE
I/O BLOCK
SAFETY
PLC
ETHERNET IP
ETHERNET IP
SAFETY
KAWASAKI
INTERFACE
HAN 6P
CONNECTOR
ROBOT CONTROLLER
EXT ESTOP
CIRCUIT
Separate Harness
Ethernet IP
FRONIUS Dress
FRONIUS
WELDER
Figure 1: Arc welding robot system
Some items may be used in welding system to protect the welding process. The functions are
reserved in the Ethernet/IP interface between robot controller and PLC. It requires all the sensors
connect to PLC, and PLC passes the signals to robot inputs, same as the torch clean station.
• Gas flow sensor
Detects gas flows at a proper speed in welding. The system should alarm gas flow error if
the sensor value doesn’t reach the pre-defined low limit after gas on for a certain time, like
0.5s – 1s.
• Water leak sensor
Detects whether cooling water leaks.
• Wire end sensor

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Detects wire run out. If using Fronius OPT/i WF wire end option, the signal will be handled
by the interface between robot controller and the welder.
1.2.2 Reference Documents

Kawasaki Manuals:
- 90203-1036 E Series Arc Welding Operation Manual
- 90209-1023 E Series Arc Welding AS Language Reference Manual
- 90210-1277 E Series Arc Welding Option Operation Manual
- 90210-1380 Arc Welding Fronius Welder Option Operation Manual
- 90210-1184 D/E Series General Fieldbus I/O Usage Manual
- 90210-1083 E Series K-Logic / K-Ladder Operation Manual
Fronius Manuals:
- 42, 0426, 0114, EN TPS 320i/400i/500i/600i, TPS 400i LSC ADV Power Source
- 42, 0426, 0183, EN TPS/i Robotics Push Welding System Operating Instructions
- 42, 0410, 1916, EN RI FB Inside/I Ethernet/IP Robot option
- 42, 0426, 0227, EN Description of TPS/i Interface Signals
- 42, 0426, 0100, EN Robacta Reamer Brush Head for Aluminum Application

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Robot Settings
2.1 Aux Function
2.1.1 Dedicated Input

The following Figures are screenshots taken from a robot teach pendant that has been configured
as an Arc Welding application. Many of the dedicated input settings are defined common to all
applications. Therefore, only Arc Welding application specific Dedicated Inputs have been
highlighted in red to draw attention.
Dedicated Input signals are set in Auxiliary Function 0601. This is where selected input signals
are tied to functions listed in the menus shown. Be sure to reference the correct programming guide
when checking the configuration of settings.
Figure 2: AUX 0601 - Dedicated Input Signals (2/6)

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Figure 3:AUX 0601 - Dedicated Input Signals (3/6)

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2.1.2 Dedicated Output

as an Arc Welding application. Many of the Dedicated Output settings are defined common to all
applications. Therefore, only Arc Welding application specific Dedicated Outputs have been
highlighted in red to draw attention.
Dedicated Output signals are set in Auxiliary Function 0602. This is where selected output signals
are automatically turned ON due to the event listed. Be sure to reference the correct programming
guide when checking the configuration of settings.

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Figure 6: AUX 0602 - Dedicated Output Signals (4/12)
Figure 7: AUX 0602 - Dedicated Output Signals (8/12)

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Figure 8: AUX 0602 - Dedicated Output Signals (9/12)Ethernet/IP Setup
Please reference to the Common Programming Guide to get the full information of fieldbus
settings. For Arc Welding application, Kawasaki software Ethernet/IP is limited to support up to
3 nodes, rather than 32 nodes for common. Thus, the Ethernet/IP setup table for Arc Welding
robots is simplified as below.
Table 1: Ethernet/IP Setup
NODE Device Device Tested

Scanner PLC AB
Scanner 2 Safety PLC AB
Adapter Setting 1 Arc Welder Fronius
Adapter Setting 2 Not used
Adapter Setting 3 Not used
2.1.3 Fronius Arc Welder (Setting 1 Communication)

as an Arc Welding application.
To enable, set Instance to 16, and set the user-defined IP address of the welder. “16” is the reserved
instance number designed in the common programming guide. The remainder of the settings must
be entered as shown. The settings shown are for a Fronius TPSi 400 Welder.

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Figure 9: Aux 0608-9-4-1 – Setting 1 (page 1/3)
Enter settings exactly as shown.
Enter settings exactly as shown.

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2.2 Arc Welding Specific Settings
All the settings listed in this section have been configured in Kawasaki workshop for every
Arc Welding robot for Rivian. Users should not change these settings, unless welding process
changes required.
To work with a Fronius TPSi welder, the following robot settings must be entered exactly as
shown. If the dedicated signals highlighted in the section 2.1 do not appear, please check the
following settings, be sure all data entered exactly.
2.2.1 Fronius Option

In Auxiliary Function 1417-1, select TPS/I checkbox, and press ENTER to confirm. It will turn on
Fronius TPSi option, including Fronius related dedicated signals, signal names, and linearization
table.
Figure 12: Aux 1417-1 Fronius Welder: Basic setting

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2.2.2 Fronius Linearization Setup
In Auxiliary Function 1417-2, enter setting exactly as shown. Linearization table is used to
calibrate the command value of Weld Output Signal 1-4 set in arc weld condition, crater weld data,
arc spot weld condition with the actual value commanded to the welder.
Set all linearization data for Internal Parameter mode, Special 2-Step mode, and 2-Step mode as
the Figures shown below.
Enter Internal Parameter menu, and setup the 4 pages for WIRE FEED SPEED, ARC LENGTH
CORRECTIVE, PULSE/DYNAMIC CORRECTIVE, and WIRE RETRACT CORRECTIVE.
Figure 13: Aux 1417-2 Fronius Welder: Linearization, Internal Parameter

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Figure 14: Aux 1417-2 Fronius Welder: Linearization, Internal Parameter (page 1/4)

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Press R button to return.

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Enter Special 2-Step menu, and setup the 4 pages for WIRE FEED SPEED, ARC LENGTH
Figure 18: Aux 1417-2 Fronius Welder: Linearization, Special 2 step
Figure 19: Aux 1417-2 Fronius Welder: Linearization, Special 2 step (page 1/4)

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Enter 2-Step menu, and setup the 4 pages for WIRE FEED SPEED, ARC LENGTH
Figure 23: Aux 1417-2 Fronius Welder: Linearization, 2 step

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Figure 24: Aux 1417-2 Fronius Welder: Linearization, 2 step (page 1/4)

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2.2.3 Weld Output Signal Setting
During welding, Kawasaki robot can send up to 4 welding condition parameters to a welder. In
Auxiliary Function 1413, the Figures below shows the name conversion from Weld Output Signal
1-4 to Fronius specific signal names.
Figure 28: Aux 1413 Weld Output Signal Setting (page 1/3)

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2.2.4 Arc Weld Setting-Others

Please reference to [90203-1036] E Series Arc Welding Operation Manual, for detailed
information of Auxiliary Function 1404 Arc Weld Setting.
It introduces the arc weld options, including:
Figure 31: Auxiliary Function 1404 Arc Weld Setting

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All the settings in Auxiliary Function 1404: Arc Weld Setting, are set to the Kawasaki default.
Please reference to [90203-1036 E Series Arc Welding Operation Manual], chapter 8-5, to get
detail descriptions.
Highlighted default setting:
• The default setting prohibits weld stuck detection, and cancel sequence.
• The default setting allows welding in TEACH CHECK mode.
• Standstill start: Robot stays at weld start point until arc is generated. After arc generation,
welding continues toward to the next weld or continue to end point. Stand still time is changeable
and when arc is not generated within the set time. An error occurs.
Figure 32: Auxiliary Function 1404-03 Weld Start Sequence

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Figure 33: Auxiliary Function 1404-03 Weld Start Sequence 1
Figure 34: Auxiliary Function 1404-05 Weld Stuck Cancel Sequence

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Figure 35: Auxiliary Function 1404-09 Motion Setting for Arc Weld

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2.3 Software limits
To be able to protect the dress package of robot during its motion, there are some software limits
that it must follow and set on the next screen. In Auxiliary Function 507, refer to the provided
image to set upper and lower limits for JT3, JT4, JT5 and JT6 values, then press ENTER to
confirm. Please in Auxiliary Function 020-04, Set same values as Auxiliary Function 507 and
confirm.
Figure 36: Auxiliary Function 507 Motion limits
Figure 37: Auxiliary Function 20-04 Mechanical Motion limits

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Robot Arc Welding Tool TCP
3.1 Arc Tool Requirements for TCP
A proper tool center point (TCP) needs to be taught before developing welding programs. Weld
options such as weave welding and start point sensing require robot motions under tool coordinates.
Only the four-point method or Direct Entry using vendor supplied data should be used to set the
tool coordinates.
Arc Weld robot tool center point is at the wire end with correct weld wire stickout length.
Typically, this is 17mm.
If the TCP is set to all zeros, the zero tool TCP is located at the center of the faceplate of robot
joint 6.
+X
Tool Coordinate
+Y
+Z
+Z
Base Coordinate
+Y
+X
Figure 38: Arc Weld Robot Tool Coordinates
The robot tool TCP data is set by the Auxiliary Function 0304 [Aux Data Setting: Tool
Coordinates]. Users can directly enter the TCP data supplied by the vendor. The XYZOAT is
relative to the NULL tool that is at the center of the robot faceplate of joint 6.
Then press ENTER on Teach Pendant to save the data. The screen shown below is an example.

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Figure 39: Auxiliary Function 0304 Tool Coordinates
The next section introduces how to teach the TCP using the four-point method.

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3.2 Teach TCP using the Four Point Method
3.2.1 Setup Condition
• Make sure that the weld wire stickout length is correct for welding. Typically, this is 1/2"
– 3/4”.
• The robot is positioned such as the TCP (wire tip) can touch the fixed pointer.
3.2.2 Procedure to Teach TCP

1. Initialize the current tool XYZOAT to all zeros in Aux Function 0304.
Figure 40: Auxiliary Function 0304 Tool Coordinates
2. Select the Auxiliary Function 0410 [Auto Arc Tool Coordinate Register]. Set a Tool Name,
and press ENTER.

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Figure 41: Auxiliary Function 0410 Auto Tool Coordinates Register (page 1/2)
Figure 42: Auxiliary Function 0410 Auto Tool Coordinates Register (page 2/2)
3. Teach 5 positions as shown in the screen, and press RECORD button on teach pendant.
The question mark means the position is NOT RECORDED.
4. After all positions are recorded, press ENTER to calculate the TCP value.
Please reference to [90203-1036 E Series Arc Welding Operation Manual] for detail descriptions.

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3.3 Verify the TCP Point
To check that the TCP has been defined properly, move the robot wire tip to a fixed pointer. Select
TOOL coordinate in Teach mode, and jog about the +rx, +ry, +rz hard keys. Determine whether
the TCP remains close to the pointer tip while jogging.
If the TCP does not remain close to the pointer tip, repeat Chapter 3.2 to redefine the tool center
point.

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Torch Clean
The MIG welding process can cause a buildup of weld spatter to accumulate in the nozzle of the
torch. This can cause a flow restriction to the shielding gas used for the MIG welding process.
Insufficient gas flow can cause weld defects.
Figure 43: Torch Cleaning position
Fronius torch clean station is installed in each welding robot unit. It also has a mechanical wire cut
unit attached to trim the wire to a specified stickout length.
By 10/22/2019, the torch clean station is assumed to use a Harting Han6P connecting to I/O module
of PLC. Its control signals are reserved in the I/O map. If the torch clean station is changed to
connect to Robot controller, the control signals will be different from the sample program PG10.

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Figure 44: Torch Clean Station
Program PG02 is used to run the cycle for wire cut and torch cleaning, with control signals from
PLC.
Figure 45: PG02 structure

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The subroutine mig_cut_clean is called inside the PG02.
Figure 46: Torch Clean Subroutine

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Figure 47: Torch Clean Subroutine

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Welding Process Control
5.1 Weld Program – pg21_weld1
For Rivian Arc welding application, Kawasaki uses Block Step for robot programming, and uses
weld condition number to indirectly control the welding process. For each weld condition, we
only set the robot travel speed during welding, and the JOB number for welding process control
under Fronius JOB mode.
A weld program sample is shown as below.
Set to Job Mode
Set welding condition 1 for welding

Set crater condition 1 for crater fill
Figure 48: Teach Pendant Display – Weld Program pg21_weld1
Key steps in the sample program:

1. Step 8
Before welding start point (WS instructor), we set the welder in JOB mode.
2. Step 10
During welding, we set the weld condition number to 1.
Weld condition 1 data is shown in Figure 46.
3. Step 11
For crate fill, we set the crater condition number to 1.
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Crater condition 1 data is shown in Figure 47.
Set to robot travel speed for welding
Set to call Fronius JOB number 1

To control welding parameters
Figure 49: Weld Condition example (page 1/2)
Set to zero, and use the Fronius Job #1

to control crater fill.
Figure 50: Weld Condition Example (page 2/2)

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5.2 Weld Mode – Job
In Fronius Job mode, the robot controls robot travel speed during welding, and sends the JOB
number to the welder before welding. All welding parameters are saved in the JOB memory in the
welder. The weld mode must be selected before welding. And once the weld mode is selected, it
will remain the selected weld mode. Thus, users only need to add this command one time at the
very beginning of each weld program.
To select Fronius Job mode,

1. Switch Robot to Teach mode, select the first Air Cut point (AC instructor) in weld program.
Note, only Air Cut point can select Fronius Job mode.
Figure 51: Weld Mode Selection – Step 1
2. Move the cursor to Option Switch (Instruction) on the auxiliary data title row by pressing
 / ➔, then press ENTER. (See Figures in next page)
Enter “3” in the working mode input box.
Then press ENTER to return.

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3. Press A+AUX MOD button to overwrite the auxiliary data to the AC step.
It should display W.Mode 3 in the option switch column.

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5.3 Weld Condition Data
Kawaski robot can save 0-99 weld conditions. We can save different weld travel speed, and
different job number, then they can be called in weld programs. Non-configured weld condition
cannot be called in program before entering a proper weld speed, and a valid job number.
In weld programs, all the welding points (WC instructor and WE instructor) must be assigned with
a valid weld condition number.
5.3.1 Change Weld Condition Number in Program

1. Switch the robot to Teach mode, select the weld point (WC, WE instruction).
Figure 55: Weld Condition Change – Step 1
2. Move cursor to select No. (Instruction) on the auxiliary data title row by pressing  / ➔,
then press ENTER. (See Figures in next page)
Enter the right condition number (0-99) in the box.
Then press ENTER to return.

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3. Press A+AUX MOD button to overwrite the auxiliary data to the weld step.

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5.3.2 Change Condition Data for a Weld Condition Number

Weld condition data can be changed in Auxiliary Function 1401-Arc Weld Condition.
1. Enter the condition number you want to change. Press ENTER.
2.
Figure 59: Auxiliary Function 1401 Arc Welding Condition
3. Change the weld speed data and the job number. The following four parameters are not
used in Fronius Job mode. Users can change the weaving data and frequency if weaving
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motion is required for this weld condition.
Figure 60: Auxiliary Function 1401 Arc Welding Condition -Weld Condition 1
4. Press NextItem button to set the crater condition for crater time. This crater time should set to 0
in Fronius Job mode.
Figure 61: Auxiliary Function 1401 Arc Welding Condition -Crater condition 1

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Weld Program Structure Sample
Figure 62: Weld program structure

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6.1 Pg02_mig_cut_clean
Pg02 is the torch cleaning program. Robot runs wire cut and torch clean subroutines. The wire cut
can be disabled from PLC by turning off the robot input signal 1787.
.PROGRAM pg02();CUT CLEAN SPRAY

;************************************************
; COMPANY : RIVIAN MOTOR COMPANY
; PROGRAM : pg02, WIRE CUT TORCH CLEAN ANTI SPATTER
; REVISED LAST: 06/22/2021 MIG REV 1.0
; Produced by KAWASAKI ROBOTICS (USA) Inc.
;************************************************
;
CALL pgverify(2); VERIFY PROGRAM IS BEING CALLED BY PLC
;
CALL mov_home; MOVE TO HOME
;
;************************************************
; CALL WIRE CUT, TORCH CLEAN AND ANTI SPATTER
CALL mig_cut_clean
;************************************************
;
;
.END
.PROGRAM mig_cut_clean();TOURCH CLEAN

;************************************************
; COMPANY : RIVIAN
; PROGRAM : mig_cut_clean(),WIRE CUT AND TORCH CLEAN
; REVISED LAST: 12/28/2022
; Produced by Rivian Automotive, LLC
;************************************************
;
;SUB PROCESS FOR WIRE CUT, TORCH CLEAN AND
;ANTI-SPATTER SPRAY. THIS CAN BE CALLED FROM
;PG02 OR RFR_PROC
;************************************************
;
CALL entzone(12); REQUEST TO ENTER ZONE 12 W/ Z11 220L05
;
AC JOINT SPEED2 ACCU2 TIMER0 OX= WX= #[-80.992,-46.244,-160.31,2.5017,-57.874,-0.29271]
;COMMON
AC JOINT SPEED2 ACCU4 TIMER0 OX= WX= #[-75.678,-4.6887,-166.33,9.711,19.632,-4.9524] ;
;
;************************************************
;START OF WIRE CUT PROCESS
IF SIG(-1787) THEN ;IF WIRECUT BYPASS OFF
;
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AC LINEAR SPEED2 ACCU1 TIMER0 OX= WX= #[-89.094,25.988,-152.37,17.76,36.305,1.176] ;BEFORE
WIRE CUT
;
W.INCHING 50,1
TWAIT 1; WAIT FOR INCHING WIRE TO FINISH
;
;AT WIRE CUT POSITION/ WIRE CUT TRIGGER
AC LINEAR SPEED6 ACCU1 TIMER0 OX= WX= #[-89.124,26.656,-150.71,18.216,35.362,0.65139] ;AT
WIRE CUT
;
TWAIT 1; FOR WIRE CUT COMPLETE
;
;DEPART WIRE CUT
AC LINEAR SPEED2 ACCU1 TIMER0 OX= WX= #[-89.094,25.988,-152.37,17.76,36.305,1.176] ;DEPART
WIRE CUT
AC LINEAR SPEED2 ACCU3 TIMER0 OX= WX= #[-89.42,12.468,-156.34,23.582,27.37,-5.2698] ;
;
END
;
;************************************************
10;START OF REAMER AND TIP SPRAY PROCESS
;
UTIMER @reamerfault = 0; RESET REAMER FAULT TIMER
WAIT SIG(1788) OR UTIMER(@reamerfault)>2; REAMER MOTOR LOW
IF UTIMER(@reamerfault)>2 THEN
SIGNAL (882);REAMER UNIT FAULTED
WAIT SIG(1788); REAMER MOTOR LOWER/HOLD CLAMP OPEN
SIGNAL (-882);REAMER UNIT FAULTED OFF
END; IF REAMER FAULTED
IF SIG(-1788) GOTO 10; ANTI WAIT OVERRIDE
;
AC LINEAR SPEED2 ACCU1 TIMER0 OX= WX= #[-90.798,9.3921,-161.54,24.042,27.656,-4.1876] ;BEFORE
REAMER
;
;AT REAMER POSITION
AC LINEAR SPEED2 ACCU1 TIMER0 OX= WX= #[-90.799,24.47,-158.08,17.653,38.504,3.3703] ;AT
REAMER
;
SIGNAL (800);AT REAMER POSITION
;WAIT CLEAN COMP AND REAMER LOWERED/HOLD CLAMP OPEN
PULSE 886,4.5;GAS ON
WAIT SIG(1797) AND SIG(1788);
SIGNAL (-800);AT REAMER POSITION OFF
;
TWAIT 1; WAIT IS FOR SPRAY
;
;
;DEPART REAMER MOVE TOWARDS SPRAYER
AC LINEAR SPEED2 ACCU1 TIMER0 OX= WX= #[-90.798,8.1961,-161.75,24.836,26.757,-5.0812] ;DEPART
REAMER
;
WAIT SIG(-886);GAS OFF
Page 52 of 78
;
AC JOINT SPEED2 ACCU4 TIMER0 OX= WX= #[-85.087,-4.6887,-166.33,9.7105,19.632,-4.9524] ;
AC JOINT SPEED2 ACCU2 TIMER0 OX= WX= #[-80.992,-46.244,-160.31,2.5017,-57.874,-0.29271]
;COMMON
;
PULSE 799,1; CUT CLEAN SPRAY PROC COMPLETE
;
;
CALL extzone(12);EXIT Z12 W/ Z11 220L05
;
.END

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6.2 Pg20
.PROGRAM pg20(); R1T_RSR_230L_01_WELD

;************************************************
; COMPANY : RIVIAN
; PROGRAM : pg20, MIG WELD PROGRAM
; Produced by KAWASAKI ROBOTICS (USA) Inc.
;************************************************
;
TIMER (1) = 0
;
CALL pgverify(20); VERIFY PROGRAM IS BEING CALLED BY PLC
;
;
CALL mov_pnce; MOVE TO POUNCE
;
; ******** POUNCE LOOP ********
10; POUNCE LOOP LABEL
;
SIGNAL 8; ROBOT AT POUNCE
SIGNAL 11; ROBOT IN PROGRAM LOOP
;
WAIT SIG(1002) OR SIG(1014); CYCLE START OR RETURN TO HOME
IF SIG(1014) THEN; RETURN TO HOME
GOTO 15; RETURN TO HOME LABEL
END; IF SIG(1014) THEN; RETURN TO HOME
IF SIG(1002) GOTO 11; START CYCLE LABEL
GOTO 10; ANTI WAIT OVERRIDE
;
; ******** POUNCE LOOP END ********
;
11; START CYCLE EXIT POUNCE LOOP
;
SIGNAL -8; ROBOT AT POUNCE OFF
SIGNAL -11; ROBOT IN PROGRAM LOOP OFF
;
CALL r1t_proc1_weld1; Weld SEQUENCE OF PROGRAM pg20
;
15; RETURN HOME LABEL
;
;
PRINT "Elapsed time=",TIMER(1),"seconds"
;
.END

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6.3 Pg20_r1t_proc1_weld1
.PROGRAM r1t_proc1_weld1();R1T_RSR_230L_01
;************************************************
; COMPANY : RIVIAN
; PROGRAM : r1t_proc1_weld1(), 230L01 R1T WELD PROC
; Produced by Rivian Automotive, LLC
;************************************************
;
AC JOINT SPEED7 ACCU4 TIMER0 OX= WX= #[-25.836,-44.914,-113.6,28.261,-90.084,-9.423] ;POUNCE
;
CALL enttool(1); REQUEST TO ENTER TOOL 1 - RSR_230L_01
;
CALL entzone(8); REQUEST TO ENTER ZONE 8 W/ Z8 205-01
;
; REPO1 SQUEEZERS AT WORK
SIGNAL 57; REPO REQUEST ON
;
AC JOINT SPEED7 ACCU4 TIMER0 OX= WX= #[2.397,35.966,-66.193,7.451,-101.98,10.929] ;P40
AC JOINT SPEED7 ACCU4 TIMER0 OX= WX= #[15.971,55.866,-60.582,1.724,-105.88,17.974] ;via122
;
; REPO1 SQUEEZERS AT WORK
CALL reporeq(1); REPO REQUEST ON
;
;
;************************************************
;****** WELD CONDITION 9 ******
;M-PT00030568-H-400
;
CALL arctime_start(9)
;
WS LINEAR SPEED4 TIMER0 OX= WX= #[16.345,57.265,-62.609,4.6717,-111.98,18.499] ;P42
WC LINEAR WELD_COND9 OX= WX= #[16.345,58.152,-62.845,4.6359,-110.86,18.401] ;P43
WE LINEAR WELD_COND9 OX= WX= #[16.345,58.865,-62.973,4.6106,-110.02,18.329] ;P44
;
CALL arctime_end;
;************************************************
;
AC JOINT SPEED7 ACCU4 TIMER0 OX= WX= #[14.384,44.226,-63.14,-2.299,-93.505,11.425] ;P46
AC JOINT SPEED7 ACCU4 TIMER0 OX= WX= #[22.376,-23.162,-136.09,3.697,-51.737,146.04] ;P47
AC LINEAR SPEED7 ACCU2 TIMER0 OX= WX= #[16.532,-3.536,-132.31,1.901,-33.12,157.09] ;P48
;
;************************************************
;M-PT00030568-H-156
;
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;
WS LINEAR SPEED5 TIMER0 OX= WX= #[16.433,-3.1569,-131.85,1.8406,-33.197,157.23] ;weld_ws_45mm
WC LINEAR WELD_COND10 OX= WX= #[15.218,-3.6064,-132.29,1.1554,-33.187,158.96] ;we_5mm_overlap
WC LINEAR WELD_COND10 OX= WX= #[12.917,-4.3569,-133.01,-0.1435,-33.201,162.24] ;we_5mm_overlap
WE LINEAR WELD_COND10 OX= WX= #[11.849,-4.6614,-133.31,-0.74529,-33.221,163.75]
;we_5mm_overlap
;
CALL arctime_end;
;************************************************
;
AC LINEAR SPEED7 ACCU2 TIMER0 OX= WX= #[11.012,-8.842,-135.65,-1.157,-35.071,164.88] ;P53
AC JOINT SPEED7 ACCU4 TIMER0 OX= WX= #[17.079,-14.675,-120.71,12.04,-65.467,131.98] ;P54
AC JOINT SPEED7 ACCU4 TIMER0 OX= WX= #[-15.933,-21.119,-127.34,-10.357,-61.329,-145.76] ;P55
;
;************************************************
;M-PT00030568-H-157
;
;
WS LINEAR SPEED5 TIMER0 OX= WX= #[-16.124,-9.8855,-137.5,-5.2746,-37.433,-156.95]
;ws_5mm_overlap_104mm
WC LINEAR WELD_COND11 OX= WX= #[-13.856,-8.4443,-135.4,-2.174,-41.751,-161.57]
;ws_5mm_overlap_104mm
WC LINEAR WELD_COND11 OX= WX= #[-12.665,-9.3051,-136.35,1.2191,-40.252,-160.51] ;P59
WC LINEAR WELD_COND11 OX= WX= #[-7.0901,-11.578,-141.41,5.4806,-31.153,-171.43] ;weld_we
WE LINEAR WELD_COND11 OX= WX= #[-5.0311,-11.494,-141.69,11.833,-30.856,-180.72] ;weld_we
;
CALL arctime_end;
;************************************************
;
AC LINEAR SPEED7 ACCU2 TIMER0 OX= WX= #[-9.4653,-16.058,-142.97,-2.6647,-34.984,-159.6] ;P70
AC LINEAR SPEED7 ACCU2 TIMER0 OX= WX= #[-30.154,-5.7245,-129.53,4.9723,-37.996,-137.25] ;P73
;
;************************************************
;M-PT00030568-H-158
;
;
WS LINEAR SPEED5 TIMER0 OX= WX= #[-31.489,-0.93475,-125.56,-5.4807,-42.862,-139.79]
;ws_5mm_olap_162mm
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WC LINEAR WELD_COND12 OX= WX= #[-31.939,-1.2681,-126.21,-7.7129,-42.046,-136.61] ;P76
WE LINEAR WELD_COND12 OX= WX= #[-26.474,-3.7286,-131.77,-10.374,-39.779,-135.85] ;P86
;
CALL arctime_end;
;************************************************
;
AC JOINT SPEED7 ACCU4 TIMER0 OX= WX= #[-22.445,-16.593,-119.81,6.334,-59.186,-143.95] ;P88
AC JOINT SPEED7 ACCU1 TIMER0 OX= WX= #[-38.543,-55.742,-130.54,34.821,-103.65,-84.871] ;P89
;
CALL extzone(8); EXIT ZONE 8 W/ Z8 205-01
;
CALL proccomp(1); PROCESS 1 COMPLETE
;
SIGNAL 85; CLEAR OF TOOL 1 - RSR_230L_01
;
.END

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Error Recovery
7.1 Arc Failure Fault
Arc failure error is a robot detect error during welding that weld current is not detected within the
specified time (1sec by default) after robot attempted to weld, or after attempting retry at weld start
point.
The robot performs error stop, with error E6502 Arc failure.
Figure 63: E6502 Arc Failure error
To recover from this fault,

• Switch the robot to Teach mode. Manually jog the robot away from the workpiece for
inches.
• Other welder detect faults can also cause this error occurs. When the error occurs, check
the robot software interface screen, check if the welder is not ready, and the error code
received. Solve the welder detect fault first.
• Some insulating object may interrupt arc generation. Check for and remove any foreign
object, insulating item, etc. If this error occurred during welding, check if wire feed has run
out or tip is stuck.
• Manually jog the robot back close to where the weld is interrupted.
• Switch to Repeat mode, and cycle start the program. The robot will slowly move back to
the arc stop point, then continue the welding.

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7.2 Gas Flow Fault
To detect a gas flow fault, the Fronius gas flow sensor is required. Please contact Fronius to check
if this option exists in your arc welding system. If it does not exist, no gas flow fault can be detected.
The welder will stop weld current, and output gas flow fault.
The robot will stop welding once the arc failure is detected. And the robot will receive a weld error
code on teach pendant interface screen.
Table 2: Fronius gas flow error
Error Solution
16832 Set value of gas flow not reached Check gas supply, check if supply pressure is
good, check gas nozzle for gas blockage, kinks
in gas line.
16839 Lower gas flow limit exceeded Check gas supply, check gas flow limit

• Switch the robot to Teach mode. Manually jog the robot away from the workpiece for
inches.
• Check the gas supply pressure. If it is low, install a new gas supply.
• Press GAS PURGE button on Teach pendant, check the gas flow reading.
• Check for any gas line blockage, kinks, leaks.
• Manually jog the robot back close to where the weld is interrupted.

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7.3 Wire Shortage Fault
To detect a wire shortage, such as empty drum and wire spool, the Fronius wire end sensor option
is required. Please contact Fronius to check if this option exists in your arc welding system. If it
does not exist, no wire shortage fault can be detected.
Available Fronius sensor options:
• Wire end option 4,100,869,CK
Contact Fronius for details.
The welder will stop weld current, and output wire shortage fault.
Table 3: Fronius wire shortage error
Error Solution
16828 Wire end. Wire drum or spool empty Install new wire drum or spool.
16837 Wire end detected on ring sensor Install new wire drum or spool.
16838 Wire end detected on drum sensor Install new wire drum or spool.

• Switch the robot to Teach mode, manually jog the robot to a maintenance position, but DO
NOT break the program sequence
• Install new wire drum or spool, feed wire to the torch.
• Reset the weld error
• Manually jog the robot back close to where the weld was interrupted.

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7.4 Water Cooling Fault
To detect the cooler unit (CU) fault, the Fronius OPT/I CU flow temperature sensor is required.
Please contact Fronius to check if this option exists in your arc welding system. If it does not exist,
no cooler fault can be detected.
With this Fronius option, the welder will output CU fault to stop the welding current, shut off the
cooler unit.
Table 4: Fronius coolant unit error
Error Solution
913 Coolant flow rate less than 0.7 l/min Check water connections and pipes for debris,
kinks, damage or too long torch hose pack
914 Coolant flow rate less than 0.4 l/min Check water connections and pipes for debris,
kinks, damage or too long torch hose pack
942 Coolant temperature too high Let the cooling unit cool down. Check
duticycle

• Switch Robot to Teach mode, manually jog the robot to a proper maintenance position, but
DO NOT break the program sequence.
• Fix the mechanical problem
• Reset the welder fault
• Switch on the cooler unit from the welder front panel.
• Manually jog the robot back close to where the weld was interrupted.

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Page 62 of 78
7.5 Torch Breakaway Fault
When the weld torch collides with a workpiece, fixture, and other objects, it will activate the torch
collision box, to protect the robot arms from collision.
The welder will stop weld current, and output the torch breakaway fault.
The robot will receive E6506 Torch Interference, and switch off the motor power.
Figure 64: Torch Interference Error
The robot error can be reset in Teach mode, to allow the robot, move away from the collision area.
In Repeat mode, the error only can be reset after the torch back to its original state.
Even with the torch collision box, the torch is still possible to get bent. In this case, the robot
cannot continue to weld before operating a TCP check.
To recover from this fault:

• Switch the robot to Teach mode, clear the robot error. Manually jog the robot move away
from the collision area
• Put the torch back to its original state
• Check the workpiece, and the robot program if they are damaged, analyze the cause of the
collision.
• Move the robot to a taught reference point, check whether the robot TCP aligns to the
pointer tip. This reference point is usually taught close to the torch clean station.
o The wire tip does not align to the pointer tip
The torch gets bended. Users need to fix the torch, or re-calibrate TCP and re-teach
all weld positions.
o The wire tip aligns to the pointer tip

Page 63 of 78
The torch is not bended.
Users can kick out the junk part, load a new part, and re-start the program pg0.

Page 64 of 78
Robot I/O – Arc Welding

Page 65 of 78
Page 66 of 78
Software Interface
Figure 65: Software Interface Screen
• MIG WELD COMM OK

o Solid Green -Communication with Fronius welder is OK.
o Red -Communication with Fronius welder is not OK.
• MIG WELD READY INDICATOR
o Solid Green -Fronius welder is ready.
o Red -Fronius welder is not ready, error may occur.
• GAS ON INDICATOR
o Solid Green -Gas is on.
o Red -Gas is off.
• ARC ON/OFF SWITCH
o Solid Green -Arc ON.
o Red -Arc OFF.
• GAS ON/OFF SWITCH

o Solid Green - Gas is on.
o Red - Gas is off.
• MIG ERROR RESET BUTTON

o Solid Green -Fronius welder with no error.
o Red -Fronius welder with error.

Page 67 of 78
KLOGIC
The remainder of this document lists the Kawasaki KLogic that has been configured for the Arc
Welding application. In addition, the Common KLogic should be loaded.

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Kawasaki Programming Guide RIV0016 MIG

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Rivian Robot Programming Guide – Kawasaki Implementation

Appendix AW – Arc Welding with Fronius Welder

REVISION 0 – November 8, 2019

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

1.1.1 Document Description

1.1.2 Who should use the document

1.1.3 What should be learned

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

1.2.1 System Components

Figure 1: Arc welding robot system

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

1.2.2 Reference Documents

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

2.1.1 Dedicated Input

Figure 2: AUX 0601 - Dedicated Input Signals (2/6)

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Figure 4: AUX 0601 - Dedicated Input Signals (4/6)

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

2.1.2 Dedicated Output

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Figure 7: AUX 0602 - Dedicated Output Signals (8/12)

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Table 1: Ethernet/IP Setup

NODE Device Device Tested

2.1.3 Fronius Arc Welder (Setting 1 Communication)

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Enter settings exactly as shown.

Figure 10: Aux 0608-9-4-1 – Setting 1 (page 2/3)

Enter settings exactly as shown.

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

2.2.1 Fronius Option

Figure 12: Aux 1417-1 Fronius Welder: Basic setting

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Figure 13: Aux 1417-2 Fronius Welder: Linearization, Internal Parameter

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Press R button to return.

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Figure 18: Aux 1417-2 Fronius Welder: Linearization, Special 2 step

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Press R button to return.

Figure 23: Aux 1417-2 Fronius Welder: Linearization, 2 step

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Press R button to return.

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

2.2.4 Arc Weld Setting-Others

Figure 31: Auxiliary Function 1404 Arc Weld Setting

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Highlighted default setting:

Figure 32: Auxiliary Function 1404-03 Weld Start Sequence

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Figure 34: Auxiliary Function 1404-05 Weld Stuck Cancel Sequence

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Rivian-Kawasaki ArcWelding_Appendix -2019_10_23

Figure 36: Auxiliary Function 507 Motion limits