Weld Tech Training

Instructor Ray Angus

Program Objective
To provide technical training and information of robotic
weld operations and provide a first response contact for
robotic or weld related issues.

Expectations for a Weld Tech

As a Weld Tech you will be the first point of contact for robot and
robotic weld cell malfunction.
As a Weld Tech you will be expected to provide robotic support for
maintenance when malfunctions require the assistance of the
maintenance staff to repair.
In addition to robotic troubleshooting as a Weld Tech you will be
required to document any issues you encountered and the time it
took you to resolve those issues.
As a Weld Tech you will report to the engineer or supervisor any and
all issues encounter during the shift and any measures or corrective
action taken to resolve those issues.
As a Weld Tech you will agree to rapidly respond to all robotic weld
cell issues minimizing downtime from those issues and helping to
ensure the dept meets its daily production schedule.

Course Content
1.
2.
3.
4.
5.
6.
7.
8.
9.

Safety
Robot anatomy
Teach pendent, Controls and Motion
Robot problems
Stud welding problems
Weld cell problems
Weld Tech specifics
Engineering problems
Preventative maintenance

Safety
Definitions
Work Envelope: The area within maximum extension of either the
robot and or the positioner, fixture, and part.
Pinch Point: Any area 2ft or less between a hard surface and the work
envelope.
TCP: The Tool Center Point is the very end of the robot tool, in the case
of a weld gun the TCP is the tip of the wire.

Maximum rotational
motion

Maximum height
This is the working
envelope of the robot
arm or its potential
range of motion.
Maximum
horizontal reach.

Indicates the
rotational
envelope of
the fixture

Indicates the
working
envelope
restricted by

Indicates
vertical
rotational
envelope of
the Positioner

Indicates the
horizontal
envelope of
the robot

Potential pinch
points are
highlighted

Electrical Hazards

Entry Detection Devices

Emergency Stops
There are 5 manually
activated emergency
stops located around
the cell, become very
familiar with them.
On the operator podium

The dead man switches on

the back of the teach
pendant

On the robot controller

On the front of the teach

pendant

The training or multiple

person dead man switch.

Robot Anatomy
Joint 6: Roll axis-rotates the tool.
Joint 5: Pitch axis-angles the tool in or
out
Joint 4: Yaw axis-angles the tool left or
right
Joint 3: Z axis-moves the tool up and
down
Joint 2: Y axis-moves the tool forward
or back
Joint 1: X axis-moves the tool left or
right
Tool: Attachment on the end of the
robot, i.e.. stud gun, weld gun.
Tool changer: mounted to the end of
joint 6
Home limit switch: indicates the robot
is in the home position and will not run
a new program in automatic unless the
switch is depressed

Controller
Hour meter: records the operating
hours of the robot.
Speed limiting switch: Allows the
operator to choose between automatic
mode, full speed teach mode, and
limited speed teach mode.
User Buttons: Allows operator to set
up specific setting for individual users.
Fault Reset: Resets current faults on
the robot after issue has been
resolved.
Cycle start: initiates cycle start in
automatic mode.
ON/OFF Button: powers up an down
the robot.
Emergency Stop: stops the robot and
activates all axis brakes.
Disconnect switch: cuts all power to
the controller.

Teach Pendant
and Controls
Emergency Stop: shuts down all power to the robot
internal and external axis, and applies the brakes to
all axis.
On/Off switch: activates teach pendent to for robot
control
Operating screen: show current running program,
speed, errors, activated signals, program name, and
motion type.
Menu Key: opens a list of menus such as utilities,
alarms, I/Os, files, status, user ,etc. Primary use of
this button for weld techs will be to view I/Os and
clear alarms, and enter passwords.
Function Key: opens supplementary menu with
options to abort current program or change group.
Cursor keys: used to scroll and navigate menus or
programs.
Shift key: must be held to allow motion in teach
modes, jog the robot, or skip multiple pages of a
menu, program or screen.
Next/Previous: moves forward or backwards through
menus or screens.
Reset: used to reset faults or clear errors.

Hold: Used to temporarily stop the program without

applying the brakes as an E stop would.
F Keys: toggles the corresponding menus locating on
the screen.
Program Keys: used to bring up the menus to select
programs, edit current programs, or edit program data.
Step Key: Activate the step function of the robot, which
allows you to step through the motion of the program
one line at a time.
Backspace: delete lettering or numbering.
Item Key: Allows you to enter in a line number and
jump to that line without scrolling through the program.
Enter Key: used to select options, programs or menus.
Numeric Key pad: used to enter values where
prompted.
Weld Enable: used to activate welding capabilities of
the robot.
Wire Feed Keys: used to feed wire in and out of the
weld gun.
Manual Function key: allows for execution of macro
programs.
Diagnosis key: when shift is held and this button is
pressed this brings up the error code of the robot and
provide information on potential causes and remedys.
Position Key: shows the current position of the robot in
in reference to the Cartesian coordinate plane.
Status Key: show the current status of timers, weld
data, positional data, etc.
One the Fly key: allows you to adjust the weld settings
while the robot is in active.

Motion Keys: while holding shift this allows you to jog the
robot through a program. Shift key must be held through
entire motion.
Coordinate Key: changes the motion type of the robot,
between world, joint, tool, user, jog frame, and path.
Speed Keys: Changes the speed off the robot by
percentage of the programmed motion speed.
Jog Keys: Allows you to jog the robot in the direction
specified or the joint type specified by the key. This
movement is determined by the Coordinate motion that is
selected.
Dead Man Switch: This is a safety device used to E stop
the robot while in a teach mode. If too little pressure is
applied the robot will e stop if too much pressure is
applied the robot will e stop. Only one needs to be
depressed.

Stud Welder Pendant

Output buttons these buttons are used to
select which output is being controlled
(output 1 is small stud gun. Output 2 is
large stud gun)
Pendant mode Key this key activates the
different modes of the pendant
On/Off Key turns the pendant on or off
Numeric key pad allows the user to enter
values or letters when prompted
Menu button brings up the different menus
within the pendant including programs,
analysis, errors etc.
Arrow buttons allows you to scroll or navigate menus
Soft buttons these correspond to the function or command
displayed above each button. These commands will
change depending on the screen you are in
Protective gas button turns any shielding gas, used for
welding studs, on or off
Loading pin button extends and retract the inner plunger
or loading pin
Force weld button forces a stud to weld when in contact
with the base material

Process control button provide analytical

data and graphical representation of the
welds
Parameter Button provide the details of the
parameters for each weld program
Function button returns you to the main
function screen which is currently displayed
Delete button allows you to delete value that
were incorrectly entered
Esc button allow you to exit to the previous
menu or out of a selected function

Stud Welder Pendant

Head advance button this button extends
and retracts the servo head
Reference Button This button is used to
reference the location of the stud in
relationship to the part
Clamp button releases the clamp on the
servo head which allows it to be free
moving
Stud Feed button manually feeds a stud
Force complete button this button sends a
finished contact to the robot interface.
Cycle start runs a complete weld cycle
including servo head advance, weld,
retract, and feed.
Enter button used to acknowledge an
inputted value or fire a selected function
Power supply on/off This is the main
disconnect for the stud welder power
source
Feeder reset this will reset the circuit board
in the feeder unit which also interprets
output signals from the stud gun

Motion Types

Motion types for the robot can be changed by using the COORD key on the
teach pendent. Below are the most common motion types and a description
of there movements.

Joint: this mode allows you to control each joint independently. For every axis on the robot
there are corresponding jog keys to move in the positive or negative directions. A
demonstration will be provided.

World: this mode allows you to move the three lower axis, or major axis, according to the
Cartesian coordinate system (X,Y,Z) while the three upper axis, or minor axis (x,y,z), are
used to control the orientation of the TCP. Note, that by moving in either of the three
direction (X,Y,Z) the robot will move all axis needed to perform that motion. A demonstration
will be provided.

Tool: this mode allows you to move the robot about its TCP. Like the world mode the three
minor axis control the orientation of the TCP and the major axis still move relative to the
Cartesian coordinate system, however the difference is that the Cartesian coordinate
system changes to match the orientation of the TCP. A demonstration will be provided.

External Axis
External Axis: Any axis not used
in conjunction with the robot, but is
not a part of the robots original
design. i.e. positioners
To control an external axis press
the function key on the teach
pendant, and select change group
from the menu. The robot is
defaulted to group one and any
positioners are setup to be
additional groups. By changing the
group you will no longer have
control of the robot, but instead the
positioner. The top jog keys will
control the major axis of the
second group and additional axis
will be controlled by additional jog
keys.

Locating and Selecting Jobs and Programs

Jobs: Jobs are the high level files consisting of the
programs used to produce the part. For example the RSR
file is a job.
Programs: Programs are the logic or code use to produce
the motion of the robot or produce the weld. 5KROPZ is a
program
Macros: macros are smaller sub programs that are made to
do common tasks. HOME_G1 is a macro.
Selecting a program: to select a program from the main
screen or any screen, press the SELECT key and a list of
programs, jobs, and macros will come up. Use the cursor
keys to scroll up and down and highlight the program you
want.
To See the details of the program, its creation date, last
modification date, name, comments, etc, use the F key that
corresponds with details button show on the screen, if it is
not showing hit the next key to cycle through the next set of
F key functions.
Press the previous key to get back to the program select
screen. To select the program highlight it and hit the enter
key.

I/O Menus
I/O menu: The I/O menu can be found by
pressing the menu button on the teach pendent
scroll using the arrow keys to the I/O menu and
then scrolling over to the digital menu. This will
bring up all digital inputs and outputs triggered
with in the program logic of the RSR. As a weld
tech your only need to be in this menu is to
trigger an one of the I/Os manually. For
example if the weld cell has completed welding
the cab and does not unclamp and the door
does not open, you may need to manually
trigger the signal for cycle complete. To trigger
the I/O you will need to enter the password first
under the setup menu and then go to the I/O
menu to trigger the input. Do this by
highlighting the status next to the input, and
press the F key that corresponds with the green
on button, then immediately turn it off again, by
pressing the F key corresponding to the red off
button. Most I/O have separate macro
programs that can be ran to trigger them with
out having to go to this menu and without
requiring a pass word. A demonstration will be
provided.

Proper Shutdown and Start up

1)

In most situations there is no need to shut down the robot cells unless
maintenance needs to be performed, thereby maintenance will
perform the shutdown, or the weld tech is instructed by the Engineer
or Supervisor to shutdown for special purposes (ex. power outages,
and power surges). To shut down the cell: 1) turn the teach pendent
off via the switch, if it is not already off. 2) Turn the controller off, by
pressing the on/off button. 3) Turn the main breaker off on the
controller. 4) and lastly turn the main buss breaker off on the back of
the weld cell. Use proper lock out procedures of process when
performing. To power up the cell repeat the steps in reverse order.
When at all possible ensure the robot and positioners or in there
home position before shutting down the robot or weld cell.
4)

2)

3)

Errors and Recovery

Robot Errors

Stud Welder Errors

Chain Abnormal Error

No Contact

Arc Start Failure

Feeder low

Collision Detect

NIO (Not in Order)

Control Stop

Wrong stud

T1 or T2 selected

Error not cleared

Teach Pendant disabled

Run failure: block by other task

NTED (non teach enabling device)

External E-Stop

Teach Pendant E-Stop

No Arc start Detected

Hand Broken

Chain Abnormal error

Cause:

This error occurs when one of the robot motors cause the drive chain to slip. This is usually
random and rarely occurs

Remedy:

Turn the teach pendant to on

Press the menu button to locate the setup menu
Locate passwords under the setup menu
Enter press the login button twice to enter the password
Once the password is entered press the menu button to locate the Alarm menu
Under the alarm menu go to active alarms
This screen will show you the active alarms one should be the Chain abnormal error
Locate the F key that corresponds with the chain reset button and reset the chain, hit Yes to
reset
Hit the reset button on the teach pendent
This may take several attempts, if so release the dead man switch and repeat the two
previous steps
Once the error is cleared logout and turn the pendant off and restart the cycle.

Arc Start Failure

Cause:

This error is caused when the robot goes to initiate the arc and burns back the wire or the
wire sticks to the work piece.

Remedy:

Verify if it is a wire stick or burn back. If it is a wire stick trim the wire if possible and restart
the cycle. If it is a burn back proceed with the following steps
Turn the controller to T1 mode and turn on the teach pendant
Press the Coordinate button to change the motion type to TOOL
Press and hold shift while pressing the J3+ key to move the robot away from the part far
enough to change the tip if needed
Remove the gas nozzle and clean or replace the contact tip and diffuser if needed.
Once the tip is cleaned or changed, scroll up in the program using the arrow keys to the arc
start line of the weld that was about to be made.
Turn the pendant off, and the controller to auto mode and restart the cycle. The robot may
not go, if this is the case, look at the pendant. A yellow box will appear asking if you would
like to move to this line in the program. Highlight yes and hit enter.
Hit the cycle start button on the operator podium again to start the cycle

Collision Detect

Cause:

This error is caused because the robot has collided with an object in its motion path. This is
usually a piece of tooling that never closed, or a foreign object that was left In the cell, or a
part that was not located properly

Remedy:

Put the controller into T1 mode and turn the teach pendent on.
Clear the error by hitting the reset Button on the control pendent
Move the robot so that it clears the obstruction
Remove the obstruction or fix the problem what ever it is
Press the step key to activate the single step function
Jog the robot to the point it was heading to before the collision
Turn the step function off
Turn the teach pendant off and the controller to auto and restart the cycle

Control Stop/Door open

Cause:

This error is caused when one of the external entry device is active, such as the garage door
is open, or access door is open or the hold button on the pendant was pressed. This will
cause the robot motion to come to a controlled stop, but not activate the axis brakes

Remedy:

Check all doors and entry devices and verify that they have been close and there are no
obstructions
Press the reset button on the teach pendant and restart the cycle

T1 or T2 selected

Cause:

This is caused when the robot controller is still in T1 or T2 speed control while the teach
pendant is turned off

Remedy: depending on the situation

If trying to put the robot into a teach mode turn the teach pendent on, reset the error and
resume.
If trying to turn the robot into auto mode, turn the controller key to auto and reset the error

Teach pendant disabled

Cause:

This error is caused when trying to perform a function or move the robot while the teach
pendant is off

Remedy:

Turn the teach pendant key to on.

Run Failure: Blocked by Other Task

Cause:

This error occurs when you are trying to run two programs at the same time. When
attempting to reset a program and return all groups to their home position, this error may
occur if the original program is not aborted

Remedy:

If the robot is not already in teach mode, turn the controller to T1 and turn the teach pendant
on.
Press the FTCN button on the teach pendent to bring up a menu
Select the abort all function and press enter to abort the current program

By doing this you can not return to that place in the original program unless the line of the program is
noted before aborting. Re-running the aborted program will cause it to run from the start of the
program

Once the existing program is aborted, new programs can be selected from the select menu
by highlighting and pressing enter
Once the program is selected press and hold shift and then press the FWD button to run the
program. Continue to hold shift while program is running.

NTED (Non Teach Enabling Device)

Cause:

This error is caused when there is an error in the Device net System of the PLC. This error
usually requires an electrician or Electrical Engineer to repair the error.

Remedy:

To clear this error once the repair is made, hit the reset button on the teach pendant.

Some suggested things to have the electrician check to speed up the repair include

24 volt fuse located in the rear relay box on the back of the cell
Power supply in the robot controller
Sick relays in the relay panel

If this error persists, notify the Supervisor and ME

External/Teach Pendant E-Stop

Cause:

This error occurs when external emergency stop is activated. There are three external e
stops not including dead man switches which produce a different error. One is located on
the operator podium, a second on the teach pendant, and a third on the robot controller.

Remedy:

Check the three E-Stops and reset them as necessary. To reset some require a simple pull
of the button while others require you to twist the button.

No Contact (stud welder)

Cause:

This is the most common error on the stud welder and occurs when the stud welder does not sense the
contact between the stud and the work piece. There are several reason for this such as miss fed stud, no
ground, oil on the base metal, broken cables on the grounding side, or broken cable on the stud gun side,
and finally circuit board needs to be reset.

Remedy:

Grab the pendant for the stud welder and perform the following
Reset any errors by pressing the menu button on the pendant, highlight actual errors and hit enter. From
this screen press the reset button several times until the error is cleared. Press the function button to return
to the main screen.
Check and make sure there is a stud fed through the collet
If there is not a stud press the feed stud button on the pendent to feed another stud

If it does not feed the stud

Remove the isolation tube that hold the outer collet on and remove any studs jammed in the outer collet( this may require you
to move the robot to accomplish)
Press the feed stud button again to clear any other studs In the head.
Attach the outer collet and the isolation tube to the head and press the feed stud button again to feed another stud
If needed, jog the robot back to the stud location and press the cycle start button on the stud pendent and hit enter to fire the
stud.

If it does feed a stud press the cycle start button on the stud pendent and press enter to fire the stud

If there is a stud present in the collet, check and make sure the ground cables are attached and have good
contact

If the error still occurs

If not, attach the ground cables

Press the yellow reset button on the feeder unit to reset the circuit board and try and run a cycle start again
Manually fire the stud by

Lower the head by pressing the head advance button on the pendant and hitting enter
Press the start weld button on the pendent and then hit enter
Press the head retract button and hit enter, than do it a second time.
Finally press the stud feed button and press enter

Call maintenance to have them check the large black cable packs running from the stud gun to the feeder unit.

Once a stud has been fired leave the cell, close all doors and reset any errors on the robot
Arrow down one line in the robot program and hit the cycle start button on the operator podium. Return to
the pendant and answer yes to the yellow box asking you to start from this new location in the program.
Return to the podium and press the cycle start again. The robot should resume.
If maintenance is called, notify the supervisor. If maintenance can not fix the issue Contact the ME.

Feeder low

Cause:

This error occurs when the feeder is running low on studs. This error does not usually stop
the robot until a miss feed.

Remedy:

Verify that there is an adequate amount of stud in the feeder

Remove or clear any obstruction that may be causing studs not to slide down the rail

NIO (Not In Order)

Cause:

This error is cause when the a weld is made outside the parameter set within the program

Remedy:

Press the soft key that corresponds with the FK button in the lower right hand corner of the
screen. The robot should continue running.
If this does not work, open the door and close it, arrow down to the next line od the robot
program and restart the cycle. You will get a a yellow box asking if this is okay, say yes, and
hit the cycle start again

Wrong Stud

Cause:

This error is cause when the gun conducts a push in to identify the stud or the ensure the
part is in the proper location.

Remedy:

Check the teach pendant and make sure the proper output is selected
Check to make sure the stud is in contact with the part and the part is not out of position
Reference the stud by pressing the reference button on the pendant and hit enter
Press the Cycle start button on the pendant and hit enter to fire the stud
Arrow down to the next line in the robot program and restart the robot.

Weld Cell Errors

The following are errors of the weld cell indicated by either the stack
lights, operator podium, or by lack of motion from the robot.
1.

If a clamp pressure not reach error shows on the operator podium perform the
following:
1.
2.
3.

2.

Unclamp the part, unload, and reload the part and attempt to clamp it again
If the first does not work call maintenance and notify the supervisor
If the maintenance can not resolve the issue notify the ME

If the Sick lights or light curtain are tripped while the cell is running
1.
2.

3.

Put the robot into T2 teach mode and run the remainder of the program in teach mode
When complete reset all errors and verify the next cycle start up

If all signals indicate green and no errors are shown, but the robot will not start
perform the following checks:
1.

Verify the sick lights indicate weld cell clear by displaying a yellow and green light
1.

2.

Verify all light curtains are aligned with reflectors indicated by a red and green light
1.

3.

If not, adjust the transmitter until the red and green lights are indicated

Verify robot is in the home position

1.

4.

If not, check for obstruction if any, or wipe the lens of the sick light with a clean dry cloth.

If not, turn the controller to teach mode and run the Home program (program name usually contain
the word home in it and is followed by and MR on the program select menu)

Check to see if the anti repeat is active by removing and replacing the cab (ensure the
cab has moved far enough such that the proximity switch is turned off)

Weld Cell Errors Cont.

4.

If the operator is attempting to change over tooling and the positioner will not
rotate check the following
1.

Verify all clamp pressure has been reached for both sides
1.

2.

Ensure the robot is in the home position and the positioner is in the home position and
attempt to re-clamp
1.

3.

5.

If the clamp pressure has not been reached you will need to rotate the fixture manually and ensure
both side are clamped. If problem persists contact maintenance.

If the positioner is not home, use the teach pendant to rotate the positioner until the prox. switches
are lit.

Rotate the fixture manually using the teach pendant and then try to reset any errors

Cab not identified in the fixture

1.

Remove the cab and check the prox. Switch for damage
1.
2.

If damaged, contact maintenance to change out prox.

If problem persists contact Supervisor and ME.

Documentation
As a Weld tech you will have additional responsibilities above that of clearing robot faults
and errors. One of which includes assisting the Engineer in documenting and
resolving downtime issues. As a weld tech you will be responsible for recording any
and all issues that occurred though your shift, including robot error recoveries, tooling
repairs, program changes, maintenance issues, weld issues etc. At each robot
station there is a binder with record sheets. These sheets will need to be filled out for
each issue.
Sample Sheet: Downtime Tracking Sheet
At the end of the week they will be collected by the Engineer and tracked, generating a
pareto chart of the issues seen and rank by highest occurrence. From this chart the
engineer will consult with the weld techs possible solutions for these issues and CI
projects will be developed based on the findings.

Weld Touch Up Policy

As a Weld Tech part of your job may be to touch up welds that are consistently out of
position. The Following is Engineerings policy and procedure supported by
Supervision and Management, for touching up a weld.

Policy: To touch up a weld requires the deliberate manipulation of the weld

program to improve the quality or correct a problem caused by, but not limited to,
serious crash of the robot arm, unwarranted change in the program, severe
damage to robot tooling, or the loss of robotic or fixture positioning.
It will be left to the Weld Tech to determine if the situations requires a weld to be
touched up after considering all potential causes and reasons why a particular
weld is out of position as described in the procedures listed below. The Weld Tech
must understand that if the decision is made to touch up a weld, only after the
proper procedures have been followed and all considerations have been made,
that the shift in which the change was made will still be expected to meet the Daily
Production Requirements. It is also required, as specified in the expectations of
the weld tech, that any changes is thoroughly documented in the downtime
tracking sheets, specifying the weld location and joining parts as well as the line
location within the program and program name. It is a part of the departments pay
plan to reclaim poor robotic welds. Therefore, the alternative and preferred
response, to touching up a weld, is to inform Engineering and Supervision of the
issue resulting in a thorough investigation prior to any changes. The line may then
continue to operate under current conditions by repairing the welds as needed to
meet their daily production schedule.

Weld Touch Up Procedure

If it appears that a weld is out of position or requires touch up in the weld program,
investigate the following prior to making any changes to the program.
1.

Verify that this a consistent or continuing weld issue

1.
2.
3.

2.

Run the Torch mate program and check for any changes
1.
2.
3.
4.
5.

3.

Try a part from another batch or contico, does it still have the weld issue?

If the weld connects a part to an assembly, or an assembly to an assembly, verify

that the assemblies and the stations they are welded in are correct.
1.

6.

Watch him load a few cabs, does it still have the same weld issue?
Watch another certified operator load the cab, does it still have the issue?

Verify that the parts are consistent

1.

5.

Turn the controller to TI and turn the teach pendant on

From the teach pendant under the select menu, highlight the torchmate program and press enter.
Jog the robot through the program then press the data button.
Under type, select torchmate. This will bring up a list of coordinates in XYZ, verify that the top
coordinates are close to the ones below them.
Reset the cell.

Verify that the operator is loading it the same way

1.
2.

4.

Check the next 3 cabs that come out of the weld cell, do they also have the same weld issue?
Check the previous 3 cabs, do they have the same weld issue?
If possible check the previous shifts cabs, do they have the same weld issue?

Follow these same procedures for the assembled part.

Verify the tooling has not changed or been modified

1.
2.

Check the downtime log to see if a change was made by another shift (also good to verify if other
shifts had the same problem and what measures were take to correct them).
Call a tool maker and together examine the tooling for changes, modifications, damage or just
loose locators and clamps.

Weld Touch Up Procedure

7.

If the weld issue still persists, document the problem and your findings from
following the procedure
1.

8.

Record the necessary information in the downtime tracking sheet and email or leave a note with
the engineer, a more detail record of your findings from the procedure

Touch up the weld

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

Turn the controller to T2 and the teach pendant on

Run the program in teach mode through to the weld that needs touched up. (let it weld all weld
prior to the bad weld
Under the menu screen select setup and then passwords and login
Press the edit button to return to the program screen
Turn the controller to T1 and the speed down to 10% or less, turn the weld enable off, and turn
step function on.
Jog the robot to the arc start point. The program line will contain arc start in it and the and @
symbol when the robot is at that point
Move the robot using the jog buttons to the new starting point of the weld.
Press and hold shift and press the F button corresponding to the touch up button on the screen to
touch up the arc start point
Jog the robot to the arc end point The program line will contain arc end in it and the and @ symbol
when the robot is at that point.
Move the robot to its new arc end point or end of the weld.
Press and hold shift and press the F button corresponding to the touch up button on the screen to
touch up the arc end point
Jog the robot backwards and enure it traces the weld joint
Return to the arc start point and turn the step function off and the weld enable on.
Run the program and produce the weld and verify the changes.
If changes are correct, turn the controller to T2 and finish welding the cab complete in Teach mode.
Reset the cell for automatic operation

Weld Touch Up Procedure

9.

Document the changes in the downtime tracking sheet and the notes to the
engineer.
1.

Include detail such as program name, weld location and parts welded, and the line of the program
that was changed.

Again I must emphasize that policy dictates that if the decision is made to touch up a
weld, the shift in which the change was made will be expected to meet the daily
production schedule, and the weld tech must document all changes and findings
from following the procedures. If you do not feel that there is adequate time to
follow the procedure and make the change, than I would encourage you do the
alternative by documenting the issue and inform the Engineer or Supervisor who
will investigate the issue thoroughly.