Vous êtes sur la page 1sur 203
Application manual Continuous Application Platform Controller software IRC5 RobotWare 5.0

Application manual

Continuous Application Platform

Controller software IRC5 RobotWare 5.0

Application manual Continuous Application Platform Controller software IRC5 RobotWare 5.0

Application manual

3HAC 16591-1

Revision B RobotWare-Arc & Arc Sensor

RobotWare 5.0

The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no re- sponsibility for any errors that may appear in this manual.

Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific pur- pose or the like.

In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein.

This manual and parts thereof must not be reproduced or copied without ABB’s written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.

Additional copies of this manual may be obtained from ABB at its then current charge.

©Copyright 2003 ABB All rights reserved.

ABB Automation Technology Products AB Robotics SE-721 68 Västerås Sweden

Table of Contents

1 Programming

7

1.0.1

Description.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

7

1.0.2

Programming Arc Welding

 

7

1.0.3

Functions for arc welding when program execution has been stopped

13

1.0.4

Functions for arc welding during program execution

 

25

2 RobotWare-Arc sensor overview

29

2.0.1 Description.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

29

2.0.2 Adaptive process control

 

29

2.0.3 Configuration.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

30

2.0.4 Seam tracking

 

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

31

2.0.5 Sensor controlled tuning

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

33

2.0.6 Program controlled

 

33

2.0.7 Statistical process control

 

34

3 Installation and Setup

35

3.0.1 Description

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

35

3.0.2 Power Source type

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

35

3.0.3 Additional Arc Systems

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

36

3.0.4 Optical Tracking

 

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

38

3.0.5 MultiMove.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

39

4 System Parameters

41

4.0.1 Description

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

41

4.0.2 Defining arc welding systems

 

42

4.0.3 Arc System

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

43

4.0.4 Arc System Properties

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

44

Table of Contents

4.0.5 Arc Robot Properties .

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

47

4.0.6 Arc User Interface

 

50

4.0.7 Arc Equipment Class .

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

51

4.0.8 Arc Equipment Properties

 

52

4.0.9 Arc Equipment Digital Inputs

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

56

4.0.10 Arc Equipment Digital Outputs

 

60

4.0.11 Arc Equipment Analogue Outputs

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

61

4.0.12 Arc Equipment Analogue Inputs

 

62

4.0.13 Arc Equipment Group Outputs

 

62

4.0.14 Arc Sensor Class

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

62

4.0.15 Arc Sensor Properties

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

63

4.0.16 Configurable errorhandling

 

64

5 Programming Multi Move RobotWare-Arc systems

 

69

5.0.1

Description.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

69

5.0.2

Functions for arc welding when program execution has been stopped

69

5.0.3

Functions for arc welding during program execution

 

73

5.0.4

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

74

5.0.5

Limitations .

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

78

6 Weld Errors

 

79

6.1 Weld Error Recovery Overview

 

79

6.1.1

Programming the Weld Error Recovery feature

 

82

6.2 Configure weld error recovery

 

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

91

6.3 Configure the recovery menu

 

93

6.4 RecoveryMenu - Display the Recovery Menu

 

97

6.5 RecoveryPosSet - Set the recovery position

 

99

Table of Contents

6.6 RecoveryPosReset – Reset the recovery position

7 Rapid Information

103

105

7.1 Instructions

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

105

.

7.1.1 ArcLStart, ArcL1Start, ArcL2Start - Arc welding start with linear mo-

tion

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

105

7.1.2

ArcL, ArcL1, ArcL2 - Arc welding with linear motion

 

115

7.1.3

ArcLEnd, ArcL1End, ArcL2End - Arc welding end with linear motion

123

7.1.4

ArcCStart, ArcC1Start, ArcC2Start - Arc welding start with circular

motion.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

131

7.1.5 ArcC, ArcC1, ArcC2 - Arc welding with circular motion

 

141

7.1.6 ArcCEnd, ArcC1End, ArcC2End - Arc welding end with circular mo-

tion

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

149

7.1.7

ArcRefresh - Refresh arc weld

 

159

7.2 Data Types

 

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

161

7.2.1 seamdata-Seam data

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

161

7.2.2 weavedata - Weave data

 

167

7.2.3 trackdata - Seam tracking

 

177

7.2.4 welddata - Weld

data .

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

185

7.2.5 arcdata

-

Arc

data.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

193

RobotWare-Arc & Arc Sensor

1 Programming

1.0.1 Description

Programming

Before an arc welding program is created, the arc welding system or systems (see Defining arc welding systems on page 42) and external axes, if any, must be configured. This is described in System parameters on page 31, of this manual.

1.0.2 Programming Arc Welding

Program structure When there are several seams to be welded on an object, the welding sequence may be of critical importance for the quality of the object. The risk of deformation due to thermal stress can be reduced by choosing a suitable seam welding sequence. It is often best to make a specific routine, object routine, for this with all the seams specified in the correct order. When the object is placed in a positioner, its orientation can also be specified in the object routine.

The object routine can call a welding routine for each seam to be welded.

Arc welding instructions An arc welding instruction contains the same information as a positioning instruction (e.g. MoveL), plus all information about the welding process, which is given through the argu- ments seamdata, welddata and weavedata.

Data for the start and end sequences of the weld

Data for the ongoing weld Data for weaving
Data for the ongoing weld
Data for weaving

L

C

ArcL p1,v100,sm1,wd1\Weave:=wv1,fine,torch; Arguments as in = Linear the MoveL instruction = Circular
ArcL p1,v100,sm1,wd1\Weave:=wv1,fine,torch;
Arguments as in
= Linear
the MoveL instruction
= Circular

Figure 1

The speed argument, v100, in the instruction is only valid during step-wise execution (for- ward or backward) and the welding process will in this case automatically be inhibited. Dur- ing normal execution, the process speed in different phases of the process is included as

RobotWare-Arc & Arc Sensor

Programming Arc Welding

components of seam and weld data. For more information on programming arc welding instructions, see Programming arc weld- ing instructions (page 9).

Defining arc welding data Before starting to program arc welding instructions, arc welding data must be defined. This data is divided into three types:

seamdata:

describes how the seam is to be started and ended,

welddata:

describes the actual welding phase,

weavedata:

describes how any weaving is to be carried out.

Number and type of the datacomponents depend on the configuration of the robot. Normally, data is stored as a part of the program. However, when data is to remain in memory regardless of which program is loaded, it is stored in a system module.

• Open the Program Data window by choosing ABB Menu -> Program Data.

• Select the type seamdata, welddata or weavedata.

• Press the function key New.

A window appears, displaying the data properties.

key New. A window appears, displaying the data properties. Figure 2 Creating welddata. • A name

Figure 2 Creating welddata.

• A name of the data is suggested. If the name needs to be changed, tap the name button and specify a new name.

RobotWare-Arc & Arc Sensor

Programming Arc Welding

• If the data needs to be saved in another module, tap the Module drop-down menu and select the desired module.

• Choose OK to close the window.

• The data will appear in the list with welddata variables. To change the declaration, tap the data. A window will appear containing the declaration of the data, Changing the declaration of the data. on page 9

Note!

Some of the components of welddata depend on the configuration of the robot. If a given feature is omitted, the corresponding component is not present in the welddata. The condi- tions feature is omitted, the corresponding component is not present in the welddata. The condi- tions that must be met for components to exist aredescribed in the System Parameters on page 41

.

exist aredescribed in the System Parameters on page 41 . Figure 3 Changing the declaration of

Figure 3 Changing the declaration of the data.

• Select the appropriate component in the data and specify the desired value. More information on the individual components can be found in seamdata - Seam data on page 125, welddata - Weld data on page 151 and weavedata - Weave data on page

135.

Tip! data on page 151 and weavedata - Weave data on page 135 . It is sometimes

It is sometimes easier to create new data by copying and modifying existing data.

Programming arc welding instructions

• Jog the robot to the desired destination position.

RobotWare-Arc & Arc Sensor

Programming Arc Welding

• Call up the instruction pick list by choosing IPL1: Motion & Process.

• Select the instruction ArcL or ArcC.

The instruction will be added directly to the program, as illustrated in the figure below. The arguments are set in relation to the last arc welding instruction that was programmed.

to the last arc welding instruction that was programmed. Figure 4 An arc welding instruction is

Figure 4

An arc welding instruction is added directly to the program.

The instruction is now ready for use. If an argument needs to be changed, the data can be replaced by another. The following exam- ple will illustrate this:

• Select the argument you wish to change (sm1 in this example).

• When the argument is selected, tap it again to open up the Change instruction dialog.

The window used to change instruction arguments appears. The selected argument is high- lighted see figure below. The lower part of the window displays all available seam data that can be selected.

RobotWare-Arc & Arc Sensor

Programming Arc Welding

RobotWare-Arc & Arc Sensor Programming Arc Welding Figure 5 The dialog box used to change seamdata.

Figure 5 The dialog box used to change seamdata.

Step

Action

1.

Select the desired seam data.

2.

Change another argument by tapping on the argument in the intruction.

3.

Repeat this for all arguments you want to change.

4.

Choose OK to confirm the change.

Example of an arc welding instruction The seam illustrated in Figure 6 is to be welded. The seam line is represented by the thick line in the figure. The xxxxx characters between points p10 and p20 mark a flying start. I.e. preparations for welding (e.g. gas preflowing) are carried out on the way to the starting-point, p20. The weld is terminated at point p80. The weld data, wd1, applies until position p50 is reached, where a transition to wd2 takes place.

RobotWare-Arc & Arc Sensor

Programming Arc Welding

MoveJ

XXXXX ArcLStart p20 p10 p30 p40 ArcL ArcC wd1 p50 wd2 p60 delay distance
XXXXX
ArcLStart
p20
p10
p30
p40
ArcL
ArcC
wd1
p50
wd2
p60
delay
distance

p70

Select welddata MoveJ
Select
welddata
MoveJ
p50 wd2 p60 delay distance p70 Select welddata MoveJ p80 p90 ArcLEnd xxxxxx P1 Movement with

p80

wd2 p60 delay distance p70 Select welddata MoveJ p80 p90 ArcLEnd xxxxxx P1 Movement with no

p90

p60 delay distance p70 Select welddata MoveJ p80 p90 ArcLEnd xxxxxx P1 Movement with no welding

ArcLEnd

xxxxxx

P1

Movement with no welding Flying start Welding

Figure 6 An example of an arc welding instruction.

The programming sequence for this seam could be written as follows:

MoveJ p10,v100,z10,torch; ArcLStart p20,v100,sm1,wd1,wv1,fine,torch; ArcC p30, p40, v100, sm1, wd1, wv1, z10, torch; ArcL p50,v100,sm1,wd1,wv1,z10,torch; ArcC p60,p70,v100,sm1,wd2,wv1,z10,torch; ArcLEnd p80,v100,sm1,wd2,wv1,fine,torch; MoveJ p90,v100,z10,torch;

If the seam is to be coordinated with an external axis, an argument of the type workobject has to be included in all arc welding instructions except for the start instruction. For more infor- mation, see ArcL, ArcL1, ArcL2 - Arc welding with linear motion on page 115 and ArcC, ArcC1, ArcC2 - Arc welding with circular motion on page 141.

RobotWare-Arc & Arc Sensor

Functions for arc welding when program execution has been stopped

1.0.3 Functions for arc welding when program execution has been stopped

Arcwelding functions (program execution has been stopped) in Manual mode:

Weld data tuning

Weave data tuning

Communicate with seamtracker sensor

Process blocking

Manual wirefeed

Manual gas on/off

Select arc welding system

Changing tuning increments

Arcwelding functions (program execution has been stopped) in Auto mode:

Manual wirefeed

Manual gas on/off

Select arc welding system

Changing tuning increments

Select arc welding system Changing tuning increments Note! If a window is open in Manual mode

Note!

If a window is open in Manual mode and corresponding functionality is inhibited in Auto mode, switching from Manual to Auto mode will close the window.

RobotWare-Arc & Arc Sensor

Functions for arc welding when program execution has been stopped

RobotWare Arc on FlexPendant To access the different functions in the Robotware Arc start by choosing ABB Menu -> Robotware Arc. After finished loading the RobotWare Arc desktop will be visible, from here all arc welding functions can be accessed.

from here all arc welding functions can be accessed. Figure 7 RobotWare Arc desktop Weld data

Figure 7 RobotWare Arc desktop

Weld data tuning The weld data components weld_speed, weld_wirefeed and weld_voltage can be tuned using the weld data tuning function. There are two stored values for the tunable data, namely, the

• “present value” (weld_speed, weld_wirefeed and weld_voltage)

• “original value” (org_weld_speed, org_weld_wirefeed and org_weld_voltage).

This allows you to see how much the “original value” was changed and to revert to the ”orig- inal value”. During tuning, it is always the “present value” that is changed. The “original value” can also be changed by setting it to the same value as the “present value”.

The same changes can be made from the Program Data window as well.

• Tap the Tuning icon

RobotWare-Arc & Arc Sensor

Functions for arc welding when program execution has been stopped

A window will appear containing functionality for tuning variables of type welddata (see Figure 8).

Select weavedata
Select
weavedata

Figure 8 Window for weld data tuning (present value).

Select welding data to be tuned

• Select welddata to be tuned by tapping the drop-down menu and selecting the desired welding data.

Tuning present values

• Select the appropriate component in the welddata to be tuned by tapping on it.

• Press “-” or “+” to decrease or increase the value. Each time these buttons are

pressed, the value will decrease/increase in increments. The tuning increment is pre- set. For adjustment of the increment see Data tuning (page 25).

Resetting the present tuning value

• Press Revert to reset the tuning value.

The “present value” will be reset to the “original value”.

Updating the original value to the present value

• Press Update Origin

The original value will be reset to the present value.

RobotWare-Arc & Arc Sensor

Functions for arc welding when program execution has been stopped

• Press OK to close the window.

Weave data tuning

• Tap the Tuning icon

• Select the Weave tuning tab to access weaving data.

icon • Select the Weave tuning tab to access weaving data. Figure 9 Selecting Weave tuning

Figure 9 Selecting Weave tuning tab

The weave data tuning dialogs have exactly the same functions as the weld data tuning dia- logs. The tunable components are: weave_width, weave_height and weave_bias.

RobotWare-Arc & Arc Sensor

Functions for arc welding when program execution has been stopped

Weaving width

Figure 10 Weaving width (W).

Y w X w W
Y w
X w
W

Weave_heigh

Figure 11 Weaving height (H).

Z w Y w
Z
w
Y
w

H

Weave_bias

Figure 12 Weaving bias (B).

Y w X w
Y
w
X w

B

RobotWare-Arc & Arc Sensor

Functions for arc welding when program execution has been stopped

Process blocking Using this display, the operator has the possibility to block Welding, Weaving, Tracking and/ or All. This may be useful during programming or testing phase.

• Tap the Blocking icon.

The following dialog box is displayed (see Figure 13):

The following dialog box is displayed (see Figure 13 ): Figure 13 Dialog box for process

Figure 13 Dialog box for process blocking.

• Tap the desired process icon to switch between active and blocked state.

• Block All blocks welding, weaving and tracking and forces the robot to use pro- grammed speed (i.e speed argument).

• Choose OK to confirm or Cancel to discard changes.

Blocking can also be activated by setting the digital process blocking inputs. The parts of the process that have been blocked will be shown on the top border in all Robot- Ware Arc windows. The blocking status indication is valid in both Manual and Auto mode.

RobotWare-Arc & Arc Sensor

Functions for arc welding when program execution has been stopped

for arc welding when program execution has been stopped Blocking that is activated in the above

Blocking that is activated in the above dialog, is active only in the Manual operating mode. It is, however, possible to allow blocking in Auto mode if the arcwelding system parameter auto inhib is On.

mode if the arcwelding system parameter auto inhib is On. Note! If more than one system

Note!

If more than one system is configured in the robot, blocking from the dialog will affect all systems.The digital process blocking inputs will only affect the corresponding system.

RobotWare-Arc & Arc Sensor

Functions for arc welding when program execution has been stopped

Communicate with seamtracker sensor This display shows the corrections to the seampath, generated by the sensor.

the corrections to the seampath, generated by the sensor. Note! The seamtracker sensor communication functions can

Note!

The seamtracker sensor communication functions can only be used if the robot is configured for use of a seamtracker sensor

• Tap the Manual functions icon.

The following dialog box is displayed (see Figure 14):

Sensor icon
Sensor icon

Figure 14 Window for communication with seamtracker sensor.

This dialog has two functions:

• Switch the sensor on/off by tapping the sensor icon.

• Get the current sensor data by selecting a joint number in the combo box.

Gap

Seam tracker sensor Joint position Z-axis Z value * Y-axis Y value Sensor coordinate system
Seam tracker sensor
Joint position
Z-axis
Z value
*
Y-axis
Y value
Sensor coordinate system

Figure 15 Sensor data for a selected joint number.

• Tap Close to close the window

RobotWare-Arc & Arc Sensor

Functions for arc welding when program execution has been stopped

Manual wirefeed

• Tap the Manual Functions icon.

The following dialog box will be displayed (see Figure 16):

Wirefeed icons
Wirefeed
icons

Figure 16 Window for manual wirefeed.

Step

Action

1.

Tap Forward or Backward icon to feed wire. The wire will be fed forward or back- ward at 50 mm/s, as long as the icon is pressed.

2.

Tapping the Stickout icon feeds 15 mm wire for each tap.

3.

Tap Close to close the window.

for each tap. 3. Tap Close to close the window. Note! If more than one system

Note!

If more than one system is configured in the robot, the dialog for selection of AW systems can be used to select the corresponding wirefeed equipment.

RobotWare-Arc & Arc Sensor

Functions for arc welding when program execution has been stopped

Manual gas purge

• Tap the Manual Functions icon.

The following dialog box will be displayed (see Figure 17):

Gas icon
Gas icon

Figure 17 Window for gas on/off.

Step

Acton

Information

1.

Tap the Gas icon to purge gas.

The gas valve will be open as long as the func- tion button is pressed.

2.

Tap Close to close the window

 
pressed. 2. Tap Close to close the window   Note! If more than one system is

Note!

If more than one system is configured in the robot, the dialog for selection of AW systems can be used to select the corresponding gas valve.

RobotWare-Arc & Arc Sensor

Functions for arc welding when program execution has been stopped

Select arc welding system Up to 3 arc welding systems can exist at the same time in the robot.

• Tap the Settings icon.

The following dialog box will be displayed (see Figure 18):

Select system
Select
system

Figure 18 Window for selecting arcwelding system.

Step

Action

Information

1.

Select the desired system by checking the corresponding radio button.

 

2.

Choose OK to confirm.

If ‘Cancel’ is chosen, the original AW system is retained as the current system.

3.

 

When a system has been selected as the cur- rent system, all other manual function will operate on this system.

The selection of the AW system determines which equipment is active when manual opera- tions - i.e. ’Gas On’, ’Manual Wirefeed’ - are executed.

RobotWare-Arc & Arc Sensor

Functions for arc welding when program execution has been stopped

Changing tuning increments

• Tap the Settings icon.

The following dialog box will be displayed (see Figure 19).

following dialog box will be displayed (see Figure 19 ). Figure 19 Window for selecting tuning

Figure 19 Window for selecting tuning increments.

Step

Action

1.

Tap the numpad buttons to change the increment values.

2.

Change the value using the numerical keys.

3.

Choose OK to close the window and activate the chosen values.

4.

Cancel discards the changes and closes the window.

RobotWare-Arc & Arc Sensor

Functions for arc welding during program execution

1.0.4 Functions for arc welding during program execution

General

Arc welding functions during program execution):

• Weld data tuning

• Weave data tuning

• Measured value display

Data tuning During program execution only the “present values” can be tuned. The “original values” can only be tuned when the program is stopped.

• Start the program (press Start).

The tuning window will automatically be displayed with tuning data loaded if an arcwelding instruction is executing. If no arc welding instruction is exxecuting the tuning window will be blocked and a yellow label displayed (see Figure 20, Tuning window when no arc instruction is exectuing.).

20, Tuning window when no arc instruction is exectuing. ). Figure 20 Tuning window when no

Figure 20 Tuning window when no arc instruction is exectuing.

When an arc welding instruction is executing a list of tunable data will be displayed (see Figure 21, Window for weld data tuning during program execution.).

RobotWare-Arc & Arc Sensor

Functions for arc welding during program execution

Sensor Functions for arc welding during program execution Figure 21 Window for weld data tuning during

Figure 21 Window for weld data tuning during program execution.

Selecting data type to be tuned

• Select desired type - Weld Tuning or Weave Tuning - by using the tabs in the tuning window.

or Weave Tuning - by using the tabs in the tuning window. Note! This chapter refers

Note!

This chapter refers only to Weld Tuning. The functionality is, however, exactly the same for Weave Tuning.

Tuning the data

• Select the appropriate component in the welddata to be tuned by tapping on it.

• Press “-” or “+” to decrease or increase the value. Each time these buttons are

pressed, the value will decrease/increase in increments. The tuning increment is pre- set. For adjustment of the increment see Changing tuning increments (page 24).

RobotWare-Arc & Arc Sensor

Functions for arc welding during program execution

Resetting the current tuning value

• Press Revert to reset the tuning value.

The “present value” is reset to the “original value”.

Measurement values

• Tap Meas. values on command bar.

Measurement values • Tap Meas . values on command bar. Figure 22 Window for measurement values.

Figure 22 Window for measurement values.

The measurement values are displayed only if:

• The system is configured to use the analog inputs for voltage and current - the

arcwelding system parameters voltage meas and current meas -, i.e. external mea-

surement equipment must be used.

• The system is an ARCITEC system.

RobotWare-Arc & Arc Sensor

Functions for arc welding during program execution

RobotWare-Arc & Arc Sensor

RobotWare-Arc sensor overview

2 RobotWare-Arc sensor overview

2.0.1 Description

The option RobotWare-Arc sensor is intended for more demanding arcwelding applications, where welding data or path must be dynamically changed during the welding to adapt to changes in geometry or material. The option includes, in addition to the basic RobotWare-Arc package, functions for Adaptive Process Control and Statistical Process Control. These functions are described in more detail below.

2.0.2 Adaptive process control

Adaptive process controll can be divided into three groups:

Step

Action

Note/illustration

1.

Seam Tracking, i.e. when sensorsig- nals are used, while welding a seam, to correct the path of the robot, thus track- ing the real seam.

This is useful e.g. if parts are not placed in exactly the same position each time or if the seam geometry can vary.

2.

Sensor controlled tuning. This is when sensorsignals are used to update the process data used while welding.

This is useful, e.g. if the seam features vary while the robot is welding.

3.

Program controlled tuning.

This is good when welding data is changed automatically and related to the path or position.

Seam tracking RobotWare-Arc sensor is prepared to be used in combination with two specific seam tracking sensor systems, which are:

• Through-the-Arc Tracker systems

• Laser Tracker systems

RobotWare-Arc & Arc Sensor

Configuration

Through-the-Arc Tracker systems These systems are based on measuring the current and voltage of the arc, while performing weaving around the expected path. Variations in current and voltage are measured and used to calculate current offset from the wanted path. Then path correction values are sent from the sensor system to the robot controller, where the corrections will be added to the ordered posi- tion values. Through-the-Arc Tracker systems can be connected to the controller via digital I/O or via a serial link. The latter is the most common e.g. in the AWC (Advanced Weld Controller) deliv- ered from ABB.

Laser Tracker systems These systems are based on using a separate sensor device mounted on the robot arm. The sensor is based on a laser emitter sending a light ray on the part. The reflected ray is received by a photo sesitive array and by triangulation the distance from the sensor to the reflecting surface can be calculated. An example of a Laser Tracker system is the M-Spot 90 system delivered from ABB/Servo Robot.

2.0.3 Configuration

Configuration of ArcWare systems for seam tracking In the system parameters of RobotWare Arc sensor, it is possible to configure the system for the use of different sensors (see the chapter 3 System Parameters).

• If track_type is set to 1, then the system will be configured for use with Through-the- Arc Tracker system (connected via I/O).

• If track_type is set to 2, then the system will be configured for use with serial Through- the-Arc Tracker (connected via a serial link).

• If track_type is set to 3, then the system will be configured for use with Laser Tracker.

Based on this, the data type trackdata will have some different components used to define the sensor functionality, see the description of trackdata.

RobotWare-Arc & Arc Sensor

2.0.4 Seam tracking

Seam tracking

Seam tracking in arc welding instructions The ArcL and ArcC instructions can be used for seam tracking in the following ways:

• If the system is configured for the use of a Through-the-Arc Tracker or Laser Tracker,

then the optional argument \Track shall be used to control the tracking function. With this argument it is possible to specify the trackdata to be used for the specific path segment. If the \Track argument is not included, no seam tracking will be active. The communication between the Through-the-Arc Tracker system and the robot con- troller can be via digital I/O both for control signals and correction values. In this case no other option is necessary in addition to RobotWare-Arc to run seamtracking.

• However, normally the communication between Through-the-Arc Tracker system or

Laser Tracker system and the controller is via a serial link using a specific link protocol (RTP1) and a specific application protocol (LTAPP). In this case the option Sensor Interface is needed, or RobotWare-Arc Sensor, which includes Sensor Interface, see description below.

• If the system is not configured for Through-the-Arc Tracker or Laser Tracker seam

tracking, i.e. none of these parameters are set, then the ArcL and ArcC instructions will

work for path corrections using CorrXXX instructions. Then the optional argument \Corr must then be used in these instructions, and no specific \Track argument is needed.

Seam tracking in other movement instructions For ordinary movement instructions like MoveL or MoveC also path corrections can be done. Then the optional argument \Corr must be used in these movement instructions. The path corrections will then be programmed using CorrXXX instructions, see below. These instruc- tions are only available if the option Path Offset or the option RobotWare-Arc sensor are installed.

If the correction values are fetched from an external sensor, then the communication between sensor and robot controller can be via a serial link. Also in this case Sensor Interface or RobotWare-Arc sensor options should be used, which will include instructions for the serial communication using a specific link protocol (RTP1) and a specific application protocol (LTAPP) (see short description below and Sensor Interface User’s Guide)

RobotWare-Arc & Arc Sensor

Seam tracking

Path correction instructions These instructions, included in the option Path offset, describe the path correction. The fol- lowing instructions and data types are available:

• CorrClear

• CorrCon

• CorrDiscon

• CorrRead

• CorrWrite

• Datatype: corrdescr

These instructions and the data type will make it possible to add certain offsets to a pro- grammed path, while the robot is moving. The offsets to add can be values given from a sensor connected to the system via e.g. serial link or via analog input.

Sensor interface. This is the same as the separate option Sensor Interface. The option, included in RobotWare- Arc sensor, will make serial communication possible with an external sensor or other unit. The communication will use the link protocol RTP1. With this function it is possible to read data from or write data to the sensor using the instructions listed below. Thus it will be pos- sible to use sensor data for path corrections or for process tuning. The following instructions will be included for the data communication:

instructions will be included for the data communication: • IVarValue • ReadBlock • ReadVar • WriteBlock

• IVarValue

• ReadBlock

• ReadVar

• WriteBlock

• WriteVar

Note!

Path corrections for ArcL/ArcC instructions can be done in two ways as indicated above.

• In system which are not configured for Through-the-Arc Tracker or Laser Tracker, the

instructions Corrxxx (see above) must be used to write the correction values to a cor- rection generator

• In system configured for serial Through-the-Arc Tracker or Laser Tracker, path cor-

rections will be automatically active if the \Track argument is used, where the trackdata

RobotWare-Arc & Arc Sensor

Sensor controlled tuning

to be used is included. This requires that the application protocol LTAPP is used for the communication with the sensor.

2.0.5 Sensor controlled tuning

Sensor controlled tuning provides a powerful tool for changing/tuning a process during the execution of a weld due to the input signals from a sensor.

Example of application are:

• Change processdata like voltage, wirefeed, speed based on current sensor values for seam volume or gap detected by a sensor.

The function is generally used in connection with trap routines and interrupts where the instruction ArcRefresh can be used to update the weld data

The communication with the external sensor, which provides the feedback data, can for instance be done using the option Sensor Interface, which is included in RobotWare-Arc sen- sor.

2.0.6 Program controlled tuning

Program controlled tuning means that the weld data can be changed during welding related to specific positions on the path or other known geometry changes.

Example of application are:

• Change processdata with reference to a time or distance before or after a defined position

• Change the wire-feed speed with reference to the volume of the seam

• Set up a heat pulse variation along a seam

• Set up high penetration on one side of a seam and low penetration on the other side

• Initiate a ramp-down towards the end of a weld

The function is generally used in connection with trap routines and interrupts where the instruction ArcRefresh can be used to update the weld data.

RobotWare-Arc & Arc Sensor

Statistical process control

2.0.7 Statistical process control

General

The option RobotWare-Statistical Process Control, includes a set of software tools which can be used to supervise the welding process and to take certain measures if some data values are drifting outside the permitted limits.

Tools

The tools includes the following functions:

• Definition of the welding process data to be monitored

• Read and write data

• Transfer data to a file or to a serial channel

Examples

Examples of application are for instance:

• A normal gauss-curve with a "permitted limit" of +-1.5 or +-3 standard deviation can be used to identify diverging data.

• Information about average data-values, maximum and minimum values can be iden- tified and reported.

The instructions included are the following:

• SpcCon

• SpcDiscon

• SpcDump

• SpcRead

• SpcWrite

Instructions

The datatypes included are:

• spcdata

• spcdescr

• spcstat

RobotWare-Arc & Arc Sensor

3 Installation and Setup

3.0.1 Description

Installation and Setup

The installation of RobotWare Arc can be customized to fit various application demands, such as a different Power Source types and MultiMove support.

Major Areas The following major areas can be selected as options in RobotStudioOnline - SystemBuilder and customized according to application demands.

•Power Source Type

•Additional Arc Systems

•Optical Tracking

•MultiMove

3.0.2 Power Source type

The Power Source type option includes support for different Power Sources.

type The Power Source type option includes support for different Power Sources. Figure 23 3HAC 16591-1

Figure 23

RobotWare-Arc & Arc Sensor

Additional Arc Systems

Options

The following Power Sources are selectable from RobotStudio Online - SystemBuilder.

Option

Description

650-1 Arcitec IRC5

Arcitec Welder

650-2 MigRob 500

MigRob500 Welder

650-3 Fronius

Fronius Welder

650-4 Miller AutoAxcess

Miller Auto Axcess Welder

650-5 Miller DeltaWeld

Miller Delta Welder

650-6 RPB

RPB Welder

650-7 Standard I/O Welder

Standard I/O Welder

650-8 Simulated Welder