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Arc Welding
Operation Manual
902031085DEB
D Series Controller
PREFACE
This manual describes operating instructions for arc welding specification of the Kawasaki Robot
Controller D series. This manual is supplemental for standard Operation Manual. Once the
contents of the manuals are thoroughly read and understood the robot can be used.
This manual provides as much detailed information as possible on the standard operating methods
for arc welding specification of the Kawasaki robot. However, not every possible operation,
condition or situation that should be avoided can be described in full. Therefore, should any
unexplained questions or problems arise during robot operation, please contact Kawasaki
Machine Systems. Refer to the contact information listed on the rear cover of this manual for
the nearest Kawasaki Machine Systems office.
The explanations in this manual include information on optional functions, but depending on the
specification of each unit, not every optional function detailed here may be included with the
robot. Also, note that figures given here may differ partially from actual screens.
1. This manual does not constitute a guarantee of the systems in which the robot is utilized.
Accordingly, Kawasaki is not responsible for any accidents, damages, and/or problems
relating to industrial property rights as a result of using the system.
2. It is recommended that all personnel assigned for activation of operation, teaching,
maintenance or inspection of the robot attend the necessary education/training course(s)
prepared by Kawasaki, before assuming their responsibilities.
3. Kawasaki reserves the rights to change, revise, or update this manual without prior notice.
4. This manual may not, in whole or in part, be reprinted or copied without the prior written
consent of Kawasaki.
5. Store this manual with care and keep it available for use at any time. In the event the
manual is lost or damaged severely, contact your Kawasaki agent.
6. Though this manual was prepared to be as thorough and accurate as possible, the authors
apologize should any information be found incomplete or erroneous.
All rights reserved. Copyright 2004 by Kawasaki Heavy Industries Ltd.
i
D Series Controller
SYMBOLS
The items that require special attention in this manual are designated with the following symbols.
Ensure proper and safe operation of the robot and prevent physical injury or property damage by
complying with the safety matters given in the boxes with these symbols.
DANGER
WARNING
CAUTION
[ NOTE ]
WARNING
ii
D Series Controller
INTRODUCTORY NOTES
D series controller provides hardware keys and switches on the operation panel and the teach
pendant for various kinds of operations. In this manual the names of the hardware keys and
switches are enclosed with a square as follows. The terms key or switch which should
follow the relevant names are sometimes omitted for simpler expression. When pressing two or
more keys at the same time, the keys are indicated by + as shown in the example below.
EXAMPLES
SELECT : expresses the hardware key SELECT.
A + MENU : indicates pressing and holding down A then pressing MENU.
D series controller provides software keys and switches which appear on the screen of the teach
pendant for various kinds of operations depending on specifications and situations. In this
manual, the names of software keys and switches are enclosed by < > parentheses. The terms
key or switch which should follow the relevant names are sometimes omitted for simpler
expression.
EXAMPLES
<ENTER> : expresses an ENTER key that appears on the teach pendant screen.
<NEXT PAGE> : expresses a NEXT PAGE key on the teach pendant screen.
3. SELECTION ITEMS
Quite often an item must be selected from a menu or pull-down menu on the teach pendant screen.
In this manual the names of these menu items will be enclosed [XXX] in brackets.
EXAMPLES
[BASIC SETTING] : expresses the item BASIC SETTING in a menu. To select it, press
the SELECT key after moving the cursor to the relevant item by the
arrow keys. For detailed description, this procedure should be
described every time, but select [XXX] item will be used instead for
simpler expression.
iii
D Series Controller
CONTENTS
1.0 Overview of Arc Welding Control 1-1
1.1 Configuration of Arc Welding Robot System 1-2
1.2 D Controller Specifications for Arc Welding 1-3
vi
D Series Controller 1. Overview of Arc Welding Control
The standard D series controller has been incorporated with control functions specific to arc
welding. With these functions, the robot can be programmed to work flexibly and efficiently
with weld machines to produce variety of high quality welds.
1-1
D Series Controller 1. Overview of Arc Welding Control
Arc welding robot system consists mainly of the following components. See the figure below.
This manual mainly focuses on No.2 above, regarding items relating to D Series Controller for
arc welding. For details about other materials, see the standard operation manual, specification
sheets, etc.
Wire feeder
1-2
D Series Controller 1. Overview of Arc Welding Control
Specifications for arc welding control are as follows. For details about other standard
specifications, refer to Operation Manual for D series controller.
D40 Controller
1-3
D Series Controller 1. Overview of Arc Welding Control
3. Arc welding control functions: Command of arc welding voltage/current to the weld power
supply, motor control for wire feed (including inching/retract),
gas supply ON/OFF, weld stuck detection
1-4
D Series Controller 2. Hardware Keys on Teach Pendant
This chapter describes hardware keys on teach pendant specially for arc welding specification.
For details about other standard keys, refer to Operation Manual for D series controller- 2.4
Switches on Teach Pendant and Functions of Hardware Keys.
2-1
D Series Controller 2. Hardware Keys on Teach Pendant
Figure 2.1 shows the arrangement of the hardware keys on arc welding teach pendant.
CHECK INTER
CANCEL
MENU TEACH
SPEED A
SELECT
PROG
EXT AXIS
STEP (Robot)
S
GO
JOG CONT
CHECK
S
BACK
1
X
INS DEL
2
O. WRITE
Y
AUX POS
MOD REC MOD
3
Z
GAS ON CND.CHG.
WIRE WIRE WELD
INCHING RETRACT ON/OFF
4
INSTR.
rx
SPD ACC TMR
7 D 8 E 9 F BS
5
ry
OX WX CND.NUM. WELD CND.
?
4 A 5 B 6 C CLEAR
6
ON OFF SPEC.CND. OPTION
rz
1 2 3 C
7
, - J/E
0 . I
*****-*****
Figure 2.1
2-2
D Series Controller 2. Hardware Keys on Teach Pendant
This chapter describes the function of each of the hardware keys for arc welding closed by
in Figure 2.1
Keys Function
Feeds weld wire when pressed. See 4.2 Inching Operation for Weld
GAS ON
WIRE Wire for more details. Pressing TEACH SPEED changes the speed at
INCHING
which wire is fed.
Turns ON shield gas supply when pressing A +
GAS ON/WIRE INCHING.
Retracts weld wire when pressed. See 4.2 Inching Operation for Weld
CND.CHG.
WIRE
Wire for more details. Pressing TEACH SPEED changes the speed at
RETRACT
which wire is pulled back.
Pressing A + CND.CHG./WIRE RETRACT displays Real Time
Condition Modify screen in C area.
WELD
A + WELD ON/OFF selects weld ON and OFF during repeat/check
ON/OFF operations.
WELD CND. S + WELD CND./CLEAR selects the weld conditions (Spd Amp Vlt Tmr
CLEAR Amp Vlt) set for the weld condition number on block teaching screen.
See 5.2.3 Configuration of Teach Screen for picture.
SPEC.CND. S + SPEC.CND./3 selects the special condition column on block teaching
3 screen. See 5.2.3 Configuration of Teach Screen for picture.
2-3
D Series Controller 2. Hardware Keys on Teach Pendant
MEMO
2-4
D Series Controller 3. Instructions for Operating Screen on Teach Pendant
This chapter describes the screens on the teach pendant used for operating the arc welding
functions. For details about other standard operating screens, the functions available on each
screen and their operation procedures, refer to Operation Manual for D series controller- 4.0
Instructions for Operating Screen on Teach Pendant.
3-1
D Series Controller 3. Instructions for Operating Screen on Teach Pendant
When weld is set ON by pressing A + WELD ON/OFF, the following icon is displayed in the
status (F) area as shown below.
For a description of other icons displayed in the status area, see Operation Manual for D series
controller- 4.2.5 Status Area.
C area displays various status screens for the robot. There are four kinds of screens for the arc
welding specification, each is accessed by pull-down menu.
This section describes 3. Program information screen and 4. Arc status screen. For details about
1. Joint monitor screen and 2. Signal monitor screen, refer to Operation Manual for D series
controller- 4.4.2 Joint Monitor Screen and 4.4.3 Signal Monitor Screen, respectively. To
navigate between screens, see 4.4.1 Switching Screens.
3-2
D Series Controller 3. Instructions for Operating Screen on Teach Pendant
Program Info. screen contains two kinds of screen as shown in Figure 3.1.
Figure 3.1
Selecting [Step (Aux)] in Figure 3.1 displays the screen in C area similar to Figure 3.2.
Figure 3.2
This screen displays all the auxiliary data for the selected step in the selected program. During
repeat operation, etc., when a step moves forward, the contents of the currently running step are
displayed.
Selecting [PC Program.] in Figure 3.1 displays the screen in C area similar to Figure 3.3
Figure 3.3
3-3
D Series Controller 3. Instructions for Operating Screen on Teach Pendant
Pressing SELECT with the screen shown as in Figure 3.3 displays the screen for Auxiliary
Function 0810 PC Program Run/Stop.
Selecting [Arc Status] displays current robot status, arc weld conditions, etc. as shown in Figure
3.4.
Figure 3.4
The following items are shaded in orange when the I/O signal is ON.
Input Signal: Current Detect, Pole Stuck, Torch Interfere, Wire Touch, Wire Stuck
Output Signal: Arc ON, Wire Inching*, Wire Retract*, Gas ON, Touch Sensor ON, Weld ON
NOTE* For Wire Inching or Wire Retract, only one output signal can be ON. They cannot be
ON simultaneously.
In Curr. Comm. and Volt. Comm., the current command values are displayed.
3-4
D Series Controller 4. Robot Manual Operation
When wire feeder or shield gas supplying unit are connected to D series controller, the teach
pendant can be used to manually inch/retract weld wire or turn ON/OFF gas supply in addition to
the normal robot operations by teach pendant. For details about connecting devices, see
Installation and Connection Manual for arc welding D series controller.
4-1
D Series Controller 4. Robot Manual Operation
Same as standard specification robots, the arc welding robot can be driven manually in the
desired mode: joint, base or tool. For more details, see Operation Manual for D series
controller- 5.0 Robot Manual Operation.
This section describes the align operation, a function useful for arc weld teaching. Instructions
are also given for setting the robot installation posture in Aux. Function 0505 Robot Installation
Posture. In addition, the fixing of the +Z base axis in vertical direction regardless of the posture
set in Aux. 0505 is explained in detail.
4-2
D Series Controller 4. Robot Manual Operation
Align function rotates the tool to make the tool coordinates Z axis parallel to the nearest base
coordinates axis during teaching. This is convenient for aligning the tool direction with the base
coordinates Z axis (especially when teaching downward welds) before teaching a weld line.
Base coordinates
system
2. While depressing the TRIGGER, press S + JT6 for 45 align, and S + JT7 for 90 align.
For 90 align, robot arm stops and align is complete when Z axis of the tool becomes parallel to
the base coordinates Z axis.
Z
X
45 Z
X
45 Base coordinates Base coordinates
Y system Y system
45 align 90 align
[ NOTE ]
Align operation can also be used for aligning the tool with the base
coordinates X or Y axes. Before aligning, move the tool near the desired
base coordinates axis and then execute the procedure described above.
4-3
D Series Controller 4. Robot Manual Operation
The +Z direction of the base coordinate motion can be set perpendicular upwards during teaching,
once the actual installation posture is made to match the posture set in the controller.
The direction of robots base coordinates is set as shown in the figure below. However, the
value of the base coordinates must have O, A, and T set to 0(zero) in Aux. Function 0506 Base
Coordinates.
Floor Ceiling
Z
Z
Y
Y
Wall Wall 2
Z Z
Y Y
4-4
D Series Controller 4. Robot Manual Operation
Setting procedure
Press WIRE INCHING or WIRE RETRACT to feed or withdraw weld wire. Inching operation
is possible when both weld power supply and control power are ON regardless of ON/OFF status
of TRIGGER, TEACH LOCK, HOLD/RUN, etc. However, inching operation for servo torch
spec. (Option) is possible only when TRIGGER, TEACH LOCK and MOTOR POWER are ON
and HOLD/RUN is set to RUN in teach mode.
Press A + GAS ON/WIRE INCHING to turn ON/OFF shield gas supply. Gas ON/OFF
operation is possible when both weld power supply and control power are ON regardless of
ON/OFF status of TRIGGER, TEACH LOCK HOLD/RUN, etc.
4-5
D Series Controller 4. Robot Manual Operation
MEMO
4-6
D Series Controller 5. Teaching
5.0 TEACHING
This chapter describes procedures for teaching and editing programs via the teach pendant using a
simple arc welding program as an example. For details about programming by AS language,
refer to Arc Welding AS Language Reference Manual for D series controller.
5-1
D Series Controller 5. Teaching
First enable manual operation of the robot, then start teaching by the following procedure with
teach pendant.
Air Cut (AC) Weld Start (WS) Weld Continue Weld End (WE) Arc Spot (AS)
point (P0/P3) point (P1) (WC) point point (P2) point
No Set standard
auxiliary data to the
point?
Change auxiliary data. Yes
Press RECORD
to confirm.
Yes
Final point?
No
To next point. End
5-2
D Series Controller 5. Teaching
The table below shows the types of teaching points and auxiliary data which are set/modified for
arc weld teaching. Set the teaching points with auxiliary data, instructions (Mtd).
5-3
D Series Controller 5. Teaching
By itself pose data for P0 to P3 is insufficient for operating the robot arc welding functions.
Additional data must also be taught to the robot, for example the speed for moving from P0 to P1,
how closely the torch tip comes to the taught point when arriving at P1 (accuracy), etc. This is
called auxiliary data. Furthermore, data specifying the weld quality such as weld speed, weld
current, weld voltage, etc. is also needed, which is called weld condition.
Two methods for setting the weld conditions are available during teaching.
5-4
D Series Controller 5. Teaching
The following weld conditions are available as shown in the table below.
(Unit: cm/min)
Weld current Sets weld current.
(Unit: Ampere (A))
Weld voltage Sets weld voltage.
(Unit: Volt (V))
Weaving width Sets amplitude in weaving.
(Unit: mm)
Weaving Condition
5-5
D Series Controller 5. Teaching
This section describes teaching operations specific to arc welding application. For standard
teaching methods, refer to Operation Manual for D series controller- 6.0 Teaching.
Once the teaching contents are determined, fill in the auxiliary data on program sheet.
The following sheet shows a sample program for teaching horizontal fillet welding. Teaching
operation of this program is explained in 5.2.4 Teaching Operation. A blank program sheet is
attached in Appendix 1. Program Sheet; make copies of use for when planning programs.
11 P0 AC JOINT 9 2 0
22 P1 WS LINEAR 9 - 0
3 P2 WC LINEAR - - - 0
4 P3 WE LINEAR - - - 0
5 P4 AC LINEAR 9 2 0
6 P5 AC JOINT 9 2 0
[ NOTE ]
5-6
D Series Controller 5. Teaching
To teach a program, first determine the work to be performed, then create a program sheet.
Before starting the teaching process, check the following two items.
Set the tool transformation value for the torch. When using a standard torch, refer to A-1405 in
7.0 Auxiliary Functions.
[ NOTE ]
When executing arc welding, set the wire extension length (mm) according to welding posture
and leg length. For details, refer to A-1405 in 7.0 Auxiliary Functions.
5-7
D Series Controller 5. Teaching
The configuration of the teach screen for arc welding is as shown in the figures below. To
switch between screens, press S + or . For more details about using teaching screens,
refer to Operation Manual for D series controller- 6.2 Procedure for Operating Block Teaching
Screen.
1. Displays weld condition No. (099) or D (Direct) per 2. Refer to 5.3.1 Setting
how weld conditions were set, indirect/direct. Option Switches.
* * *
5-8
D Series Controller 5. Teaching
This section describes how to teach the robot to perform horizontal fillet welding via the five
points shown in Figure 5.1 below.
P4
Escape point
(Air cut point)
P0
Work start point
P2
P5 (Weld continue
Work end point point)
P3 (Weld end point)
P1
(Weld start point)
Figure 5.1
Teaching procedure
1. First, set the program name to be edited. The teach screen in Figure 5.2 below displays the
setting of program pg10.
Figure 5.2
5-9
D Series Controller 5. Teaching
[ NOTE ]
3. Teach step1.
P0
P5
P2 P
4
P1 P3
5-10
D Series Controller 5. Teaching
(2) Set the auxiliary data, the instruction* to AC, the interpolation to joint, the speed to 9, the
accuracy to 2 and the timer to 0.**
Move cursor to Mtd (instruction) on the auxiliary data title row by pressing either S +
INSTR./BS or by or .
Pressing changes the instruction setting on the edit row as AC (Air Cut point (point not
welded)) WS (Weld Start point) WC (Weld Continue point) WE (Weld End point)
AS (Arc Spot point). Pressing changes them in the reverse order.
When the desired instruction appears (in this case, AC), then the instruction setting is complete.
NOTE** To set the interpolation, speed, accuracy and timer, refer to Operation Manual for D
series controller- 6.3 Teaching Operation. Note some interpolation modes may not be
available for an instruction as shown below.
(3) Press RECORD to teach the pose and the auxiliary data of step1 at the same time. The teach
screen will appear as shown in Figure 5.3.
Figure 5.3
5-11
D Series Controller 5. Teaching
4. Teach step2.
Switch to inching
Set torch angle (1) mode when torch
approx. 45 at P1. is set close to P1.
P1
1= approx. 45
Keep approx. 1mm
from corner.
(1) Press INTER and select base mode, then TEACH SPEED to select desired speed.
(2) Move torch tip near P1 by +/-. Then press TEACH SPEED to select the inching mode, and
move the robot at very slow speed to set the torch tip to P1 accurately.
(3) Set the auxiliary data, the instruction to WS, the interpolation to linear, the speed to 9, and the
timer to 0.
(4) Press RECORD to teach the pose and the auxiliary data of step2 at the same time. The teach
screen will appear as shown in Figure 5.4.
Figure 5.4
5. Teach step3.
P2
Approx.
P1 1=approx. 45
1mm
P2 At P2, set torch posture by
torch angle 1 and angle with
2=approx. 45 vertical plate 2 to be approx.
P1 45 respectively.
Approx.
1mm
5-12
D Series Controller 5. Teaching
(4) Move the torch tip to P2 near P2 by +/-. Then press TEACH SPEED and select the inching
mode. Move the robot at very slow speed to set the torch tip to P2 accurately.
(5) Set the auxiliary data, the instruction to WC, the interpolation to linear, and the weld condition
number* to 0. (In this example, weld condition No. 0 contains the data for welding
horizontal fillet with leg length/thickness of 5mm. For more details, refer to A-1401 (Arc
Weld Condition).)
Move cursor to Weld Condition Number on the auxiliary data title row by pressing either S +
CND.NUM./6/C or by or .
Pressing changes the weld condition No. setting on the edit row as 0 1 2 3 98
99 D (Direct). Pressing changes them in the reverse order.
When the desired weld condition No. appears (in this case, 0), then the weld condition No. setting
is complete.
For details about setting weld conditions, see 7.0 Auxiliary Functions.
(6) Press RECORD to teach the pose and the auxiliary data of step3 at the same time. The teach
screen will appear as shown in Figure 5.5.
Figure 5.5
5-13
D Series Controller 5. Teaching
6. Teach step4.
1=approx. 45 P3
Approx. 1mm
(1) Set the auxiliary data, the instruction to WE, the interpolation to linear, and the weld condition
number to 0. (In this example, weld condition No. 0 contains the data for welding horizontal
fillet with leg length/thickness of 5mm, and crater condition. For more details, refer to
A-1401 (Arc Weld Condition).)
Weld condition numbers are the same for P1P2 and P2P3, thus step4 is automatically set
with the same conditions as in step3. Take note that crater treatment condition is only
reflected in weld end step.
(2) Press RECORD to teach the pose and the auxiliary data of step4 at the same time. The teach
screen will appear as shown in Figure 5.6.
Figure 5.6
5-14
D Series Controller 5. Teaching
7. Teach step5.
P3
P4
(1) Set the auxiliary data, the instruction to AC, the interpolation to linear, the speed to 9, the
accuracy to 2 and the timer to 0.
(2) Press RECORD to teach the pose and the auxiliary data of step5 at the same time. The teach
screen will appear as shown in Figure 5.7.
Figure 5.7
8. Teach step6 by following the same procedure used in 3. above where P0 is taught. (See page
5-10 for procedure No. 3.)
5-15
D Series Controller 5. Teaching
In arc welding specification, the following auxiliary data can be set in addition to those described
above.
5-16
D Series Controller 5. Teaching
When Option functions are installed, option switches can be set in AC, WS and WE steps. For
details about the setting of these switches, refer to related option manual and 8.0 Touch Sensing
Function (Option).
1. In WC or WE steps, move cursor to Weld Conditions (Spd Amp Vlt PO* Tmr Amp Vlt PO*)
on the auxiliary data title row by pressing either S + WELD CND./CLEAR or by or ,
and press SELECT. Aux. Function 1401 Arc Weld Condition is displayed. For details
about making settings on this screen, refer to A-1401 in 7.0 Auxiliary Functions.
2. In AS (Arc Spot) steps, move cursor to Weld Conditions (Spd Amp Vlt PO* Tmr Amp Vlt
PO*) on the auxiliary data title row by pressing either S + WELD CND./CLEAR or by or
, and press SELECT. Aux. Function 1402 Arc Spot Weld Condition is displayed. For
details about making settings on this screen, refer to A-1402 in 7.0 Auxiliary Functions.
In WC or WE steps, move cursor to Special Condition on the auxiliary data title row by pressing
either S + SPEC.CND./3 or by or , and press SELECT. Aux. Function 1401 Arc Weld
Condition is displayed. For details about making settings on this screen, refer to A-1401 in 7.0
Auxiliary Functions.
5-17
D Series Controller 5. Teaching
Using the real time weld condition modification function, weld speed, current, and voltage can be
changed during check operation. Any changes made to the weld conditions can then be
overwritten onto taught data in check mode. This function is also available in repeat operation
although overwriting is not allowed.
5-18
D Series Controller 5. Teaching
[ NOTE ]
1. During weld ON, weld speed, current, and voltage can be modified. To
overwrite weld condition data with the current changes, press <Data Set>.
During weld OFF, weld conditions cannot be modified.
2. When the taught data is overwritten in this manner, the weld condition is
considered to be direct setting even though it was originally indirect setting.
3. Real time condition modification for crater treatment and arc spot welding
is not possible at WE step.
WARNING
If you watch the weld bead while using the real time weld
condition modification function, do not fail to use face shield,
and avoid looking at the arc directly.
5-19
D Series Controller 5. Teaching
MEMO
5-20
D Series Controller 6. Repeat Operation
Repeat operation plays back and executes the contents of a program that was taught to the robot.
This chapter describes the functions available for arc welding application during repeat operation.
For details about standard repeat operation procedure, refer to Operation Manual for D series
controller- 7.0 Repeat Operation.
6-1
D Series Controller 6. Repeat Operation
Using the real time weld condition modification function, weld speed, current, and voltage can be
changed during repeat operation. However, the changed weld conditions cannot be overwritten
onto taught data. Overwriting is possible in check mode. Refer to 5.4 Real Time Weld
Condition Modification Function for more details.
[ NOTE ]
1. During weld ON, weld speed, current, and voltage can be modified.
During weld OFF, only the weld speed can be changed.
2. Real time condition modification for crater condition and arc spot
condition is not possible at WE step.
WARNING
If you watch the weld bead while using the real time weld
condition modification function, do not fail to use face shield,
and avoid looking at the arc directly.
6-2
D Series Controller 7. Auxiliary Functions
WARNING
7-1
D Series Controller 7. Auxiliary Functions
Use auxiliary functions for arc welding specification in the following cases.
Only auxiliary functions related arc welding are described here. For other auxiliary functions,
refer to Operation Manual for D series controller- 9.0 Auxiliary Functions, and for methods on
calling up the auxiliary function screen, see 9.2 How to Use Auxiliary Functions.
Select [14. Arc Weld] in the auxiliary function screen to call up the arc welding auxiliary function
list as shown below.
7-2
D Series Controller 7. Auxiliary Functions
1401 ARC WELD CONDITION Displays and sets arc weld condition data.
ARC SPOT WELD Displays and sets arc spot weld condition data.
1402
CONDITION
ARC WELD CONDITION Displays and sets arc weld condition database.
1403
DATABASE
1404 ARC WELD SETTING Displays and sets various kinds of data for arc welding.
ARC WELD TORCH Displays and sets arc weld torch dimensions.
1405
DIMENSION
ARC WELD CONDITION Changes arc weld conditions for specified steps. (direct
1406
MODIFY teaching method)
ARC SPOT WELD Changes arc spot weld conditions for specified steps.
1407
CONDITION MODIFY (direct teaching method)
7-3
D Series Controller 7. Auxiliary Functions
[ NOTE ]
1. [Pole Ratio] and [Weaving Data- Pattern] are displayed only when Option is installed.
2. Direct setting screen for arc weld conditions is not displayed. To specify or display the arc
weld condition of direct setting, see 3. below and set by A-1401 or A-1406.
3. In WC or WE steps, move cursor to weld condition No. under No. on auxiliary data title
row, select [D], and press SELECT to display the setting screen above for direct setting.
To select the weld condition No., refer to 5.2.4 Teaching Operation. (This method is also
available for indirect setting.) (Auxiliary function screen is also called up by moving
cursor to Weld Conditions (Spd Amp Vlt PO* Tmr Amp Vlt PO*) WV (Wid Freq Pat*),
and then pressing SELECT.) At this time,
(1) the screen can be called up only in teach mode with teach lock ON.
(2) arc weld condition data set by direct method cannot be seen in repeat mode.
7-4
D Series Controller 7. Auxiliary Functions
[ NOTE ]
1. [Pole Ratio] is displayed only when Option is installed.
2. Direct setting screen for arc spot weld condition is not displayed. To specify or display the
arc spot weld condition of direct setting, see 3. below and set by A-1402 or A-1407.
3. In AS (Arc Spot) steps, move cursor to weld condition No. under No. on auxiliary data
title row, select [D], and press SELECT to display the setting screen above for direct
setting. To select the weld condition No., refer to 5.2.4 Teaching Operation. (This
method is also available for indirect setting.) (Auxiliary function screen is also called up
by moving cursor to Weld Conditions (Spd Amp Vlt PO* Tmr Amp Vlt PO*), and then
pressing SELECT.) At this time,
(1) the screen can be called up only in teach mode with teach lock ON.
(2) arc spot weld condition data set by direct method cannot be seen in repeat mode.
7-5
D Series Controller 7. Auxiliary Functions
In the arc weld condition database, weld data (speed, current, voltage, polarity ratio*), crater
treatment data (time, current, voltage) and weaving data (width, frequency, pattern*) can be set
and modified for each weld joint shape and leg length/thickness. This database provides a
convenient means of calling up data when setting weld conditions by either the direct or indirect
teaching Aux. screens.
As shown in the figures below, move cursor to [Big Category] to display big category items and
to [Small Category] to display small category items which correspond to the selected big category
items. Select the desired item for each category by NUMBER (0-9).
Pressing <Display> displays the weld condition data for the selected big/small category items on
the right half of the screen. In the figures above, weld condition data is for [1. H FILLET] of
[Big Category] and [1. 3mm] of [Small Category].
7-6
D Series Controller 7. Auxiliary Functions
NOTE* [Pole Ratio] and [Weaving Data- Pattern] are displayed only when Option is installed.
CAUTION
7-7
D Series Controller 7. Auxiliary Functions
This function sets various kinds of data for arc welding operation.
Move the cursor to [1404. Arc Weld Setting] in the auxiliary function screen to display the
auxiliary function list as shown in the figure below. Some menu items are Options and may not
be shown depending on robot specification.
Overview of each function is shown in the table on next page. The subsections hereafter
describe each of these functions.
7-8
D Series Controller 7. Auxiliary Functions
Weld machine
command
Set current/voltage
Weld Start Sequence Sets various kinds of data for arc weld sequence and enables
changing of the weld sequence.
Software Slow Down Sets weld conditions for the time up until arc is generated at arc
start. Enables superior arc start settings.
Weld Stuck Cancel Sets various kinds of data to automatically release when weld
Sequence wire is stuck.
Arc Spot Sequence Sets various kinds of data for arc spot weld sequence.
Preflow/Afterflow Sets time for preflow/afterflow.
Wire Inching/Retract Sets speed for inching/retracting weld wire.
Weld ON/OFF in Check Sets weld ON/OFF at check operation.
Touch Sensing (Option) Sets various kinds of data for touch sensing function. For more
details, see also 8.0 Touch Sensing Function (Option).
Special Pattern Weaving Enables registration of special weaving patterns for reference
(Option) during program execution. For more details, see also 9.0
Special Pattern Weaving Function (Option).
Servo Torch (Option) Sets various kinds of data for servo torch function. For more
details, see also 10.0 Servo Torch Function (Option).
7-9
D Series Controller 7. Auxiliary Functions
A-1404-1 LINEARIZATION
This function calibrates the absolute values for current/voltage for each weld method, wire
diameter, wire extension length, wire type, and weld machine with the voltage that is actually
commanded to weld machine.
CAUTION
7-10
D Series Controller 7. Auxiliary Functions
Weld current
1. Move cursor to each item and
input required data by NUMBER
(0-9). If the setting is correct,
press .
Weld voltage
1. Move cursor to each item and
input required data by NUMBER
(0-9). If the setting is correct,
press .
Once setting is complete, weld current/voltage values are sorted in ascending order when the
setting screen is displayed again.
7-11
D Series Controller 7. Auxiliary Functions
When current/voltage are set for the weld condition, the voltage value to be sent to weld machine
is then determined by linearization as per the linearization data. For example, the command
value to weld machine is as follows when setting the weld current/voltage value in the figure on
the previous page (outputs 4.74V by 224A and 7.967V by 19.2V, and outputs 3.53V by 192A and
6.639V by 16V) and executing welding of 210A and 18V.
7-12
D Series Controller 7. Auxiliary Functions
A-1404-2 OFFSET/GAIN
In order to realize the specified current/voltage during actual welds, this function sets offset and
gain values for adjusting the standard linearization characteristics.
CAUTION
[ NOTE ]
7-13
D Series Controller 7. Auxiliary Functions
7-14
D Series Controller 7. Auxiliary Functions
To start welding more smoothly, the following two types of weld start sequences have been
provided.
Robot moves to the next teach point from weld start point during which time arc is generated.
This is called scratch start as it looks like the torch scratches the work, and it is used mainly for
welding a long weld line. This robot motion is further classified into two types depending on
the distance between taught weld start point and the point the arc is actually generated.
1) Distance from start point to arc generating point is less than [Keep Welding Distance (A)]
If arc is generated within (A) distance, welding continues toward the next weld continue (end)
point.
7-15
D Series Controller 7. Auxiliary Functions
2) Distance to arc generating point after passing (A) is less than [Turn Back Distance (B)]
If arc is generated within (B) distance, robot welds moving backwards to the weld start point, and
continues welding toward the next weld continue (end) point. When no arc is generated even
after passing (B) distance, error occurs.
Arc generating point
Robot stops at weld start point until arc is generated. After arc generation, welding continues
toward the next weld continue (end) point. Standstill time is variable and when arc is not
generated within the set time, an error occurs.
2. Restart sequence
This sequence is used for restarting the welding after robot stops welding for some reason.
e.g.) After arc deficiency by tip friction, etc. After holding.
Scratch start or standstill start can be executed in restart sequence. However, in order to bury the
crater caused by the weld stop, robot moves back to the point where welding stops after arc
generation and to restart welding with an overlap welding.
e.g.) After calculating remaining distance and restarting by a scratch start
Weld start point Arc generating point
Normally when No. of times for retry is not set, an error occurs if arc is not generated. However,
if set, the weld start sequence (scratch start/standstill start) will be attempted the set No. of times.
Wire can be retracted before the retry, and retract time and No. of times for retract can be set or
modified.
7-16
D Series Controller 7. Auxiliary Functions
This function changes weld conditions for the time up until arc is generated. For example, when
the base metal surface is resistant to current flow and generation of arc is difficult, weave for
increased generation until the arc is actually applied to the surface.
7-17
D Series Controller 7. Auxiliary Functions
After crater treatment or arc spot welding at weld end point, weld stuck detecting is executed
automatically. When wire is stuck, this condition is automatically released by arc generation
under the crater/arc spot conditions (Weld Stuck Cancel Sequence). When weld stuck cancel
does not succeed after attempting sequence set No. of Detecting Times, error occurs. Note
cancel sequence not possible if crater treatment was not executed.
Weld stuck? No
(Detecting)
Yes To next step
No
Error
Arc ON
7-18
D Series Controller 7. Auxiliary Functions
7-19
D Series Controller 7. Auxiliary Functions
A-1404-7 PREFLOW/AFTERFLOW
This function inches/retracts wire during air cut operation. This is executed in 0.5 sec
increments as robot moves per the air cut instruction taught this setting.
7-21
D Series Controller 7. Auxiliary Functions
7-22
D Series Controller 7. Auxiliary Functions
(1) In the setting above, distances between B and B, and B and B are both 20mm.
(2) The faster the sensing speed, the greater the weld wire bends at touch and then correcting
accuracy becomes decreased. However, wire bend varies depending on sensing direction,
wire diameter, material, etc.
(3) These parameters are provided for the work detection and work position compensation
functions. For more details, see 8.3 Work Detection Function and 8.4 Compensation
Function for Work Deviation.
7-23
D Series Controller 7. Auxiliary Functions
7-24
D Series Controller 7. Auxiliary Functions
This function sets various kinds of data for servo torch function.
Select [16. Servo torch] in [1404. Arc Weld Setting] to display the auxiliary function list shown in
the figure below.
Overview of each function is shown in the table below. The subsections hereafter describe each
of these functions.
Linearization Sets the relation between weld current command values (A) and wire
feeding speeds (rpm).
Torch data Sets the speed reduction ratio, number of bits changed per encoder
rotation and direction of motor rotation for the servo torch.
Servo adjustment Adjusts the servo parameters that control the feeding.
Inching speed Registers the wire inching/retract speed that corresponds to each
teach speed, set by pressing TEACH SPEED.
Start/End sequence Sets the parameters that control the wire feeding at weld start/end.
7-25
D Series Controller 7. Auxiliary Functions
A-1404-16-1 LINEARIZATION
This function sets the relation between weld current command values (A) and wire feeding
speeds (rpm) for each weld method, wire diameter, wire extension length, wire type, and weld
machine.
CAUTION
7-26
D Series Controller 7. Auxiliary Functions
When current/voltage are set for the weld condition, the rotation speed to be sent to servo torch
motor is then determined by linearization as per the linearization data. For example, the
command rotation speed to servo torch is as follows when setting the weld current value in the
figure on the previous page (outputs 102rpm by 250A and 81rpm by 200A) and executing
welding of 210A and 18V.
Note that max. command rotation speed cannot exceed the max. value set in this linearization
table.
7-27
D Series Controller 7. Auxiliary Functions
This function sets the speed reduction ratio, number of bits changed per encoder rotation and
direction of motor rotation for servo torch.
7-28
D Series Controller 7. Auxiliary Functions
This function adjusts the servo parameters that control the wire feeding. The following three
setting items can also be set in A-2007-2 External Axis Servo Parameter- Full Spec Tuning. In
that auxiliary function screen, Servo gain is KVP, Torque limit (plus direction) is IQCLP, and
Torque limit (minus direction) is IQCLM.
7-29
D Series Controller 7. Auxiliary Functions
This function registers the wire inching/retract speed that corresponds to each teach speed, set by
pressing TEACH SPEED.
7-30
D Series Controller 7. Auxiliary Functions
This function sets the parameters that control the wire feeding at weld start/end.
7-31
D Series Controller 7. Auxiliary Functions
Weld in progress
Time (t)
Wire feeder Waiting WCR Hot start 1 Hot start 2
on delay detection
WCR
Arc ON signal
At start of welding
7-32
D Series Controller 7. Auxiliary Functions
Arc ON signal
Time t
Wire feeder off delay Flare up time
Speed
Time t
Time1 Time2 Time3 Time4
7-33
D Series Controller 7. Auxiliary Functions
When using a standard arc weld torch as shown below, tool transformation values can be set by
registering length of the weld torch, torch installation angle and wire extension length.
CAUTION
7-34
D Series Controller 7. Auxiliary Functions
This function changes the weld conditions for a block of weld continue or weld end points that
were taught by direct teaching method. To change the weld conditions for a range of points
taught by indirect method, use A-1401.
[ NOTE ]
7-35
D Series Controller 7. Auxiliary Functions
NOTE* From the range of selected steps, the data of the step first taught by direct teaching
method is displayed in this screen.
Press <Auto Set> to refer to the arc weld condition database screen. For details about
this screen, refer to A-1403.
[Pole Ratio] and [Weaving Data- Pattern] are displayed only when Option is installed.
[ NOTE ]
1. Changes apply only to the weld continue or weld end points in the specified
range that were taught by direct teaching method. Data of other steps in
the range are not effected.
2. To change weld conditions in weld continue or end points taught by indirect
method, see A-1401 Arc Weld Condition.
7-36
D Series Controller 7. Auxiliary Functions
This function changes the weld conditions for a block of arc spot weld points that were taught by
direct teaching method. To change the arc spot weld conditions for a range of points taught by
indirect method, use A-1402.
[ NOTE ]
7-37
D Series Controller 7. Auxiliary Functions
NOTE* From the range of selected steps, the data of the arc spot step first taught by direct
teaching method is displayed in this screen.
[ NOTE ]
1. Changes apply only to the arc spot points in the specified range that were
taught by direct teaching method. Data of other arc spot steps in the range
are not effected.
2. To change AS (Arc Spot) weld conditions in arc spot points taught by
indirect method, see A-1402 Arc Spot Weld Condition.
7-38
D Series Controller 8. Touch Sensing Function (Option)
This chapter describes touch sensing function by optional specification and the teaching
operation.
8-1
D Series Controller 8. Touch Sensing Function (Option)
When using the robot to weld, good positioning accuracy is required for both work and for arc
torch relative to the work. However, at the weld production site, perfect accuracy cannot always
be guaranteed. Thus, to achieve better, more consistent accuracy, use the touch sensing function
in the following situations.
8-2
D Series Controller 8. Touch Sensing Function (Option)
When planning the weld operation, determine beforehand the direction in which the work may
deviate. In addition, the following must be considered: kind of work to be welded, type of work
to which the work is welded, and work deviation amount.
This section describes seven kinds of sensing patterns by which work deviation compensation are
made. Sensing patterns can be used singularly or in combination (max. of three patterns).
Pattern
Pattern 1 Pattern 2 Pattern 3 Pattern 4 Pattern 5 Pattern 6 Pattern 7
Item
Types of sensing
No. of sensing
points 1 2 3 3 4 3 3
(teaching points)
Relation between
work deviation No need to No need to No need to No need to be No need to
Vertical Vertical
direction and be vertical be vertical be vertical vertical be vertical
surface sensed
Relation between 1st surface: 1st surface: 1st surface: 1st surface: 1st surface: Outer or inner 1st surface:
surface sensed and 1 point 1 point 1 point 2 points 2 points surfaces of 2 points
sensing point 2nd surface: 2nd surface: 2nd surface: 2nd surface: cylinder whose 2nd surface:
(teaching point) 1 point 1 point 1 point 2 points section becomes 1 point
rd
3 surface: perfect circle:
1 point 3 points
Order of teaching
Specified Specified Specified Specified
points
8-3
D Series Controller 8. Touch Sensing Function (Option)
8-4
D Series Controller 8. Touch Sensing Function (Option)
Direction of
work deviation (1) Condition of work
Surface
sensed 2 1) Work moves parallel in space (in three
directions).
A2 2) Surfaces sensed (1, 2 and 3) are flat and
Surface
sensed 3 orthogonal to each other.
B
B22 3) Directions in which work deviates are
Work
A3 B3 vertical to each surface sensed.
Direction of
work deviation
B
B11
(2) Sensing point
Execute sensing of three points which the
A1 work moves toward, B1, B2 and B3 in left
Surface
sensed 1 figure.
Direction of Deviation
work deviation B1 A1 direction
Surface (3) Teaching point
sensed
Teach A1, B1, A2, B2, A3, and B3 as lines
A1B1, A2B2 and A3B3 parallel to the
directions in which work deviates.
8-5
D Series Controller 8. Touch Sensing Function (Option)
8-6
D Series Controller 8. Touch Sensing Function (Option)
A1
A3 (2) Sensing point
Surface
sensed 2
1) Execute sensing of four points (two
A2 Surface
sensed 1 points on each surface), B1, B2, B3, and
B4 in left figure.
2) B1 and B2 are on surface sensed 1 and
Surface
sensed Deviation
direction
B3 and B4, on surface sensed 2, as in
B1
left figure.
Set surface
8-7
D Series Controller 8. Touch Sensing Function (Option)
8-8
D Series Controller 8. Touch Sensing Function (Option)
A2
B2 (2) Sensing point
B3 1) Execute sensing of two points on one
Surface sensing surface and one point on the
sensed 1
other surface, B1, B2, and B3 in left
A3 Surface Deviation
figure.
sensed direction
Surface B1 2) B1 and B2 are on the same surface.
sensed 2
Set surface
(3) Teaching point
Teach the points in order of A1, B1 A2,
B2 A3, B3 with the following
conditions.
1) Lines A1B1, A2B2, and A3B3 are
parallel to the work setting surface.
2) Angle between lines A1B1 and A3B3 is
30 150 (90 is desirable).
3) Distance between B1 and B2 is 10mm or
more.
[ NOTE ]
8-9
D Series Controller 8. Touch Sensing Function (Option)
WARNING
1. To keep a constant wire extension length without using wire cutter devices, etc.
2. At pre welding points, set the wire to the desired length in 1. above.
The following subsection describes the teaching operations. For standard teaching methods,
refer to 5.0 Teaching and Operation Manual for D series controller- 6.0 Teaching.
Point A
8-10
D Series Controller 8. Touch Sensing Function (Option)
[ NOTE ]
1. Only air cut points can be taught the wire check function.
2. Teach the wire check to the point where the wire is inched to the desired
length (Point B in figure on previous page).
Work
Nozzle
Tip
Wire
Extension
length
To set the desired wire
Work extension length, use a scale
as shown here.
8-11
D Series Controller 8. Touch Sensing Function (Option)
The setting screen appears as in Figure 8.1. Select [3. Wire Check] to [Touch Sensing] and
press .
Figure 8.1
Press RECORD to teach the wire check in the Option Switch field. The teach screen appears as
in Figure 8.2.
Figure 8.2
Work
8-12
D Series Controller 8. Touch Sensing Function (Option)
CAUTION
Wire check function is possible only when repeat mode and continuous step
are selected. Wire check function does not operate under any other
conditions. (Doing so only plays back taught contents.)
Robot moves as shown below when the program taught in 8.2.1 Teaching for Wire Check
Function is executed in repeat mode.
Point A Point C
Point B
1. When [Wire Check] is taught at point B, wire is retracted for 0.5 sec when robot starts moving
from point A to point B.
2. When arriving at point B, robot stops and inches the wire for 5 sec at a constant speed.
3. When wire tip touches the work during wire inching, robot stops inching the wire and starts
moving to point C.
4. If wire tip does not touch the work within 5 sec, robot outputs error- E6516 Wire check
failure.- and stops.
5. The speed for inching/retracting wire can be changed. (The time cannot be changed.) For
more details, refer to A-1404-8 in 7.0 Auxiliary Functions.
8-13
D Series Controller 8. Touch Sensing Function (Option)
WARNING
Work detection function can check for presence of a work on the set table thus eliminating the
need for sensors, switches, etc.
The following subsection describes the teaching operations. For standard teaching methods,
refer to 5.0 Teaching and Operation Manual for D series controller- 6.0 Teaching.
Point
Point
Point B
Work
Point B
Touch the work
here.
8-14
D Series Controller 8. Touch Sensing Function (Option)
[ NOTE ]
1. Only air cut points can be taught the work detection function.
2. Teach the work detection to the point where the wire touches the work (Point
B in figure on previous page).
8-15
D Series Controller 8. Touch Sensing Function (Option)
Figure 8.3
Work
8-16
D Series Controller 8. Touch Sensing Function (Option)
CAUTION
Work detection function is possible only when repeat mode and continuous
step are selected. Work detection function does not operate under any
other conditions. (Doing so only plays back taught contents.)
Robot moves as shown below when the program taught in 8.3.1 Teaching for Work Detection
Function is executed in repeat mode.
Work
Point A Point B
B B
Sensing start point Sensing end point
Detection range
1. Register beforehand the distances between points B and B and points B and B by A-1404-10
in 7.0 Auxiliary Functions.
2. When [Work Detect] is taught at point B, robot moves from point A to point B at the air cut
speed.
3. The wire tip moves detecting the work at a constant speed from the point B to the point B.
Set this speed by A-1404-10 in 7.0 Auxiliary Functions.
4. When wire tip touches the work (that is, work detection) at point B during motion from B to
B, the robot moves to point C at the air cut speed.
5. When work detection did not succeed even after arriving at point B, robot outputs error-
E6509 No work detected.- and stops.
8-17
D Series Controller 8. Touch Sensing Function (Option)
When compensating for deviations in work position, the deviation amount must be acquired
correctly. In arc weld specification robot, compensation patterns are classified into seven types
as in the table below depending on shape of work, deviate direction, etc. For details on each
pattern, see 8.1.2 Sensing Patterns for Compensation of Work Deviation.
It may be necessary to use a combination of two or three of the patterns above in order to
correctly acquire the deviation amounts. Apply any combination (max. of three patterns) as
needed to accommodate work shape/size.
1. Case 1
When the condition of the work is as follows, combine pattern 1 (compensation in direction)
and pattern 6 (compensation for cylinder). Then, compensate the deviation by the following
procedure and execute welding.
(2)
Executes circumferential fillet weld of the cylinder pipe to the Cylinder pipe (1)
Compensating procedure
Working table
(1) Compensate the deviation (height of square pipe) by pattern 1.
(2) Compensate the deviation (height of cylinder pipe) by pattern 6.
(3) Execute welding.
8-18
D Series Controller 8. Touch Sensing Function (Option)
2. Case 2
When the condition of the work is as follows, combine pattern 1 (compensation in direction)
and pattern 4 (compensation on flat surface) to ensure accurate compensation for each work.
and B. Work B
Using multiple patterns to compensate for work deviation as above is called compensation by
pattern combination. The relation between patterns is explained below.
As shown in figure above, the work to be welded can be compensated only after the deviation of
mother work, daughter work and baby work are compensated in this order.
8-19
D Series Controller 8. Touch Sensing Function (Option)
[ NOTE ]
Pattern combination
Z
Pattern combination can be mathematically
explained as follows. To compensate the
deviation of coordinates systems, assume
mother work coordinates system (XM, YM,
ZM) relative to the robot base coordinates
system (X, Y, Z), daughter work coordinates
Y system (XD, YD, ZD) relative to the mother
ZM
Mother work coordinates work coordinates system (XM, YM, ZM), and
Base coordinates YM baby work coordinates system (XB, YB, ZB)
X ZD
Daughter work coordinates relative to the daughter work coordinates
XM YD
system (XD, YD, ZD) shown on left. Then
XD ZB
Baby work coordinates
obtain the deviation of the coordinates
XB
YB systems and compensate the deviation.
8-20
D Series Controller 8. Touch Sensing Function (Option)
WARNING
This section describes the teaching operations. For standard teaching methods, refer to 5.0
Teaching and Operation Manual for D series controller- 6.0 Teaching.
(6)
(2) (4)
(1) (3)
Cylinder work
(Mother work)
Part to be welded
8-21
D Series Controller 8. Touch Sensing Function (Option)
[ NOTE ]
1. Only air cut points can be taught the deviation compensation function.
2. Teach points in order of (1)(2)(6)(7). Execute the sensing to the
mother work (cylinder work) by pattern 6.
3. Teach angle made by lines (1)(2) and (3)(4) to be 30 150 (90 is desirable).
[ NOTE ]
When torch direction is parallel to the sensed surface, wire extension length need not be
accurate. However, when it is oblique or vertical, wire length must correctly match the
set length.
Teach the following data. (Weld conditions, OX, WX, etc. are omitted.)
8-22
D Series Controller 8. Touch Sensing Function (Option)
Note that point (1) defines the sensing direction to the sensing point (2) where compensation
deviation is taught (that is, robot moves (1) to (2) when sensing). Recommended distance
between (1) and (2) is 100mm or more.
Then move cursor under Option Switch on the auxiliary data title row by pressing S +
OPTION/C or by or , and press SELECT. The setting screen appears as in Figure 8.1.
Select [6. Work Reset] to [Touch Sensing]. Then move cursor to [Work] by to display the
setting screen as in Figure 8.4. Select [1. Mother] and press . Press RECORD to teach the
work reset (Mother) in the Option Switch field. The teach screen appears as in Figure 8.5.
Figure 8.4
Figure 8.5
8-23
D Series Controller 8. Touch Sensing Function (Option)
CAUTION
When teaching a program using pattern combinations for the work deviation
compensation function, be sure to set work reset mother in the first step for
safety. (This clears all work coordinates systems and resets to base
coordinates system.) This prevents robot from moving per the last set work
coordinates. Attempting to execute the program from the beginning step after
robot stops without work reset at the first step causes an error.
(2)
Cylinder work
(1) Direction
to touch
the work is
(1)(2)
Teach air cut (AC) for instruction, linear for interpolation, 9 for speed. As exact positioning is
required to point (2), set the accuracy to 1. Then move cursor under Option Switch on the
auxiliary data title row by pressing S + OPTION/C or by or , and press SELECT. The
setting screen appears as in Figure 8.1. Select [5. Work Modify] to [Touch Sensing]. Then
move cursor to [Work] by to display the setting screen as in Figure 8.6. Select [1. Mother].
Move cursor to [Pattern] by to display the setting screen as in Figure 8.7. Select reset pattern
[6] and press . Press RECORD to teach the work modify (Mother, 6) in the Option Switch
field. The teach screen appears as in Figure 8.8.
Figure 8.6
8-24
D Series Controller 8. Touch Sensing Function (Option)
Figure 8.7
Figure 8.8
3. Continue teaching points (3) to (7) following the same procedure described above. Note that
points (3) and (5) define the sensing direction to the sensing points (4) and (6) respectively
where deviation compensation is taught (that is, robot moves (3) to (4) and (5) to (6) when
sensing). Be sure to teach work mother, pattern 6 to points (2), (4), (6).
8-25
D Series Controller 8. Touch Sensing Function (Option)
WARNING
This section describes the teaching operations. For standard teaching methods, refer to 5.0
Teaching and Operation Manual for D series controller- 6.0 Teaching.
(9)
Deviation direction of cylinder work (7)
(8)
(6)
(4)
(3) (5)
(1)
Cylinder work
(Daughter work) Deviation direction of square pipe
Square work
(Mother work)
Working table
8-26
D Series Controller 8. Touch Sensing Function (Option)
[ NOTE ]
1. Only air cut points can be taught the deviation compensation function.
2. Teach points in order of (1)(2)(8)(9).
3. Execute the sensing to the mother work (square work) by pattern 1.
4. Execute the sensing to the daughter work (cylinder work) by pattern 6.
5. Teach angle made by lines (3)(4) and (5)(6) to be 30 150 (90 is desirable).
[ NOTE ]
Square pipe
Up down deviation occurs in the square Horizontal deviation occurs in the cylinder
pipe. Compensate the height by pipe. Compensate the deviation by pattern 6.
pattern 1. Height compensation of a The square pipe on which cylinder pipe is
square pipe should be executed first, placed is compensated as mother work, thus
thus select [Mother work]. the cylinder pipe becomes the second
compensation, then select [Daughter work].
8-27
D Series Controller 8. Touch Sensing Function (Option)
Teach the following data. (Weld conditions, OX, WX, etc. are omitted.)
8-28
D Series Controller 8. Touch Sensing Function (Option)
Then move cursor under Option Switch on the auxiliary data title row by pressing S +
OPTION/C or by or , and press SELECT. The setting screen appears as in Figure 8.1.
Select [6. Work Reset] to [Touch Sensing]. Then move cursor to [Work] by to display the
setting screen as in Figure 8.4. Select [1. Mother] and press . Press RECORD to teach the
work reset (Mother) in the Option Switch field. The teach screen appears as in Figure 8.5.
CAUTION
When teaching a program using pattern combinations for the work deviation
compensation function, be sure to set work reset mother in the first step for
safety. (This clears all work coordinates systems and resets to base
coordinates system.) This prevents robot from moving per the last set work
coordinates. Attempting to execute the program from the beginning step after
robot stops without work reset at the first step causes an error.
Direction to
2. First create mother work coordinates by
touch the
work (square
sensing pattern 1.
pipe) is
(1)(2).
Teach point (2). Move the torch tip to the
point (2) and then teach [Work Modify].
(1) Cylinder pipe
Then move cursor under Option Switch on the auxiliary data title row by pressing S +
OPTION/C or by or , and press SELECT. The setting screen appears as in Figure 8.1.
Select [5. Work Modify] to [Touch Sensing]. Then move cursor to [Work] by to display the
setting screen as in Figure 8.6. Select [1. Mother]. Move cursor to [Pattern] by to display
the setting screen as in Figure 8.7. Select reset pattern [1] and press . Press RECORD to
teach the work modify (Mother, 1) in the Option Switch field. The teach screen appears as in
Figure 8.9.
8-29
D Series Controller 8. Touch Sensing Function (Option)
Figure 8.9
8-30
D Series Controller 8. Touch Sensing Function (Option)
Then move cursor under Option Switch on the auxiliary data title row by pressing S +
OPTION/C or by or , and press SELECT. The setting screen appears as in Figure 8.1.
Select [5. Work Modify] to [Touch Sensing]. Then move cursor to [Work] by to display the
setting screen as in Figure 8.6. Select [2. Daughter]. Move cursor to [Pattern] by to display
the setting screen as in Figure 8.10. Select reset pattern [6] and press . Press RECORD to
teach the work modify (Daughter, 6) in the Option Switch field. The teach screen appears as in
Figure 8.11.
Figure 8.10
Figure 8.11
5. Continue teaching points (5) to (9) following the same procedure described above. Note that
points (5) and (7) define the sensing direction to the sensing points (6) and (8) respectively
where deviation compensation is taught (that is, robot moves (5) to (6) and (7) to (8) when
sensing). Be sure to teach work daughter, pattern 6 to points (4), (6), (8).
The procedure is now complete. The pattern combination taught here creates the mother work
coordinates by sensing pattern 1 and the daughter work coordinates by sensing pattern 6.
8-31
D Series Controller 8. Touch Sensing Function (Option)
CAUTION
Robot moves as shown below when the program taught in 8.4.2 Teaching- Compensation
Function for Work Deviation- 1 (Teaching of Each Pattern) is executed in repeat mode.
Point (3)
Point (1)
Sensing the
work.
Cylinder work
Point (2)
1. Register beforehand the touch sensing distance by A-1404-10 in 7.0 Auxiliary Functions.
2. The wire tip moves detecting the work at a constant speed within the touch sensing distance
(sensing range). Set this speed by A-1404-10 in 7.0 Auxiliary Functions.
3. When wire tip touches the work (that is, sensing) within the touch sensing distance (sensing
range), the robot moves to the next teaching point (point (3) in the figure above).
8-32
D Series Controller 8. Touch Sensing Function (Option)
The difference between continuation and reset of compensation are described in this section by
Figures 8.12 and 8.13 which demonstrates the welding a pipe on an iron plate. In Figure 8.12,
pipes are placed on the same iron plate and are considered to deviate in one direction on the plate.
In Figure 8.13, each pipe is on a separate iron plate but deviates in the same direction.
In the case of Figure 8.12, execute one direction compensation by pattern 1 before welding pipe
No.1, then weld No.1 No.2 No.3 in that compensated state. In the case of Figure 8.13, on
the other hand, weld pipe No.1 by executing one direction compensation by pattern 1, and reset
the compensation (that is, reset compensation when robot moves to next teaching point.).
Execute compensation by pattern 1 again before welding pipe No.2, and then execute the same
procedure to pipe No. 3.
Based on these examples, the compensation function can be performed once, compensating the
same deviation distance on multiple works Continuous Compensated state, or compensation
can be performed independently for each work Reset Compensation state. (See program
examples on next page.)
8-33
D Series Controller 8. Touch Sensing Function (Option)
Guide
Work reset mother Sets initialization Work reset mother Sets initialization
(Same state at (Same state at
teaching) teaching)
Work mother pattern 1 Work mother pattern 1
Compensated state
Weld pipe No.1. Weld pipe No.1.
8-34
D Series Controller 8. Touch Sensing Function (Option)
Cases for using continuous or reset compensation are classified in the table below.
8-35
D Series Controller 8. Touch Sensing Function (Option)
This section describes precautions when teaching a program that uses the touch sensing functions,
wire check, work detection, and compensation for work deviation. Note that incorrect operation
causes sensing error or defect.
WARNING
1. If tool dimensions are registered incorrectly, error results from the work coordinates acquired
by sensing, even if work is set correctly with no deviation. For more details, see A-1405 in
7.0 Auxiliary Functions.
8-36
D Series Controller 8. Touch Sensing Function (Option)
2. During work detection/compensation, if wire extension length is incorrect, error results from
the work coordinates acquired by sensing regardless of the work deviation. However, if torch
is parallel to the surface sensed when touching, error does not occur. Therefore, ensure the
same extension length in teaching and repeat operations using wire check function, wire cutter,
etc.
Different!
E.g.
15mm 10mm
3. Confirm wire touches the surface sensed correctly and that there is a conduction.
4. When condition of wire tip is not good, wire check, work detection, compensation for work
deviation may not be performed correctly.
The tip is cut by wire cutter, Wire tip has a lump, or spatter,
etc. and there is a good etc. adheres to the wire.
electrical contact.
8-37
D Series Controller 8. Touch Sensing Function (Option)
5. In order to compensate correctly, execute touch sensing to the surface which deviates the same
as the weld line.
6. When sensing pattern and sensing order are not matched, an error occurs.
1 2 1 2
[ NOTE ]
8-38
D Series Controller 8. Touch Sensing Function (Option)
This section describes errors occurring during touch sensing operation and the error handling.
Error code
Error message Main cause
New Old
E6509 -910 No work detected. When sensing for work detection or compensation,
wire did not touch the work after moving the touch
sensing distance.
E6510 -911 Undefined sensing When sensing for work detection or compensation,
direction. no point was taught prior to the sensing point, or Air
Cut (defining the sensing direction) was not taught in
the prior point/step.
E6511 -912 Insufficient sensing Weld was started before acquiring the No. of sensing
points. points specified by the pattern.
E6512 -913 Undefined mother or Attempted to execute daughter or baby work before
daughter work. mother work was specified. Or, attempted to
execute baby work before daughter work was
specified.
E6513 -914 Too many sensing Without reset, executed the same sensing to work for
points. which sensing was already complete. Or, executed
sensing at more points than the No. of sensing points
specified by the pattern.
E6514 -915 Work specification Before completing sensing of all the sensing points
incorrect. of the specified pattern, a different sensing pattern
was processed.
E6515 -916 Incorrect sensing point During deviation compensation, sensing order or
specified. sensing locations were incorrect.
E6516 -917 Wire check failure. During wire check, wire did not touch the work after
inching the wire for 5 sec.
8-39
D Series Controller 8. Touch Sensing Function (Option)
If the program taught with the touch sensing function suffers an error while it is running, execute
the recovery procedures detailed here and on the following pages.
When an error occurs, robot holds detection of the work and stops at the place the error occurred.
Main cause:
1. Work deviated more than touch sensing distance registered in Aux. Function 1404-10.
2. Work is not set.
Countermeasure:
Touch sensing distance may be short, set again with a longer touch sensing distance in Aux.
Function 1404-10. (Beware that setting a longer distance lengthens the touch sensing time.)
Or, when work deviates too much, reset it to its set place.
Trajectory of robot torch tip from time of error occurrence to error handling
8-40
D Series Controller 8. Touch Sensing Function (Option)
Remarks: If robot is stopped by turning HOLD/RUN to HOLD during sensing, the trajectory of
the robot torch tip is as shown below when restarting.
Pausing A
Cycle start
A A
z z z
Pausing zB zB zB
(Sensing
location
B start point)
z B
z Pausing B
z
location
CAUTION
When an error occurs, robot holds detection of the work and stops in that step.
Main cause:
For example, when the error occurred in step4 of the program below, the following are
considered probable causes.
1. The previous step (step3) is not an air cut point, which is necessary for using the work
detection function in step4.
2. When selecting a particular step as the start step wherein the sensing function is specified, for
example, if only step4 in the above program is selected for execution.
8-41
D Series Controller 8. Touch Sensing Function (Option)
Countermeasure:
1. In the case of the program above, inset a new step containing an Air Cut point before step4
(which includes work detection). (Sensing direction is determined by the point taught sensing
function and the air cut point.)
2. When selecting a particular step for execution, specify the step that precedes the step taught
work detection function as a start step. For programs that frequently use touch sensing
functions, be sure to execute the program from the first step.
When an error occurs, robot holds creation of the work coordinates and stops in that step.
Main cause:
For example, when the error occurred in step2 of the program below, the following are
considered probable causes.
1. Although pattern 2 (with 2 sensing points) was set in step2 above, sensing was executed for
only one of the two sensing points, also a non-Air Cut instruction was specified in the next step
(step3).
Countermeasure:
1. In the case of the program above, insert new steps (steps 3, 4) for sensing the second of the two
sensing points as below. Ensure the number of steps used to execute work deviation
compensation corresponds with the number of sensing points. (As in program example each
sensing point is taught by two steps, the first being an Air Cut step and the second being
MOTHER_WORK#, DAUGHTER_WORK#, etc.)
8-42
D Series Controller 8. Touch Sensing Function (Option)
When an error occurs, robot holds creation of the work coordinates and stops in that step.
Main cause:
For example, when the error occurred in step2 of the program below, the following are
considered probable causes.
1. Attempted creation of daughter work coordinates in step2 without first making the mother
work coordinates. Or, although mother work is taught in the previous step, attempted to start
execution in repeat mode from the step containing daughter work.
Countermeasure:
1. In the case of the program above, edit the step so as to ensure mother work coordinates are
created first. Or, insert a new step creating mother work coordinates.
When selecting a step from which to begin in repeat mode, avoid starting from step with
daughter work or baby work.
8-43
D Series Controller 8. Touch Sensing Function (Option)
When an error occurs, robot stops in the place the error occurred.
Main cause:
For example, when the error occurred in step7 of the program below, the following are
considered probable causes.
1. Although work coordinates have already been created (step2), the work coordinates were to be
created again (step7). Or, the sensing was to be executed at a higher No. of sensing points
than specified in sensing pattern.
Countermeasure:
1. In the case of the program above, reset the work coordinates (step6), and edit the step so as to
create the work coordinates again. See below.
Main cause:
For example, when the error occurred in step4 of the program below, the following are
considered probable causes.
1. After specifying the first point of two point sensing pattern in step3, different sensing pattern
was specified in step4.
Countermeasure:
1. In the case of the program above, specify the same sensing pattern to complete the work
coordinates as below.
Main cause:
1. Teaching order was incorrect, for example did not follow A1B1A2B2A3B3.
2. The distance between two points taught on the same surface sensed was less than 10mm. Or,
angle made from the sensing directions for two different surfaces sensed was not within
30150.
Countermeasure:
1. Clear the error cause and teach again correctly.
Main cause:
1. The work was too far from the teaching point.
2. Wire feeder did not inch weld wire due to cut OFF of power supply in weld machine, etc.
Countermeasure:
1. When teaching point and the work are located far apart, teach again with the position closer to
the work.
2. When weld wire was not inched, adjust and check the devices and press CYCLE START
button. Then, confirm wire is inched for the full 5 sec.
8-45
D Series Controller 8. Touch Sensing Function (Option)
MEMO
8-46
D Series Controller 9. Special Pattern Weaving Function (Option)
9-1
D Series Controller 9. Special Pattern Weaving Function (Option)
By using this special pattern weaving function, weaving shapes which are normally simple
harmonic can be created or changed freely.
Simple harmonic
1
both ends stop
2 Triangular
Reciprocating
3
triangular
Circular
4
(Clockwise)
Circular
5
(Counterclockwise)
610 Unregistered
9-2
D Series Controller 9. Special Pattern Weaving Function (Option)
For weaving in a narrow groove, the torch posture often needs to be changed during weaving
operation. With the special pattern weaving function, torch posture can be changed a max. of
10. This is called pendulum weaving.
+10 -10
+50% -50%
CAUTION
Note that pendulum weaving sometimes induces large motions in the robot
even though the motion of the torch tip is small. Or, speed abnormality
may occur. In these cases, set pendulum angle smaller, or modify teaching
contents to make the motion of each robot axis smaller.
For weaving in a narrow groove, etc., weld current or weld voltage often need to be changed to
enable high quality penetrating at both ends of the weave. Via the special pattern weaving
function, weld current or weld voltage can be changed a max. of 100%. This is called weld
current/weld voltage boosts.
(%)
200
+100%
100 Weld condition set value
-100%
0
9-3
D Series Controller 9. Special Pattern Weaving Function (Option)
To use special pattern weaving function, follow the flow chart described below.
Use a standard pattern. Use a pattern example listed in Make and use a new
(See 9.2 Standard this manual. (See A-1404-11 pattern. (See 9.4.2
Weaving Patterns Special Pattern Weaving (Option) Creating Weaving
Registered for Robot.) in 7.0 Auxiliary Functions). Patterns.)
movement in created
(Pattern example can be modified.)
pattern.
Determine weaving
pattern No. and register
required data.
9-4
D Series Controller 9. Special Pattern Weaving Function (Option)
The standard weaving patterns registered in this function include: simple harmonic both ends stop
weaving, triangular weaving, reciprocating triangular weaving, circular weaving, etc.
This section describes the motion using solid figures and the expansion patterns for the weaving
patterns in back/forth, lateral, and vertical directions.
Vertical direction
Vertical direction:
Lateral direction Torch direction
Motion direction (+ moves upwards.)
Vertical plate
Lateral direction:
Direction vertical to torch
Back/forth direction
and traveling direction
Amplitude (+ moves towards vertical
(WV)
1 cycle (sec) plate (left))
Back/forth direction:
Horizontal plate
Motion direction of weld
Motion of torch tip (+ moves forward)
1 sec
Frequency
f=0.5Hz 2 sec
1 cycle
1 sec
f=1Hz 2 sec
1 cycle
1 sec
f=2Hz 2 sec
9-5
D Series Controller 9. Special Pattern Weaving Function (Option)
1. Pattern No. 1 (PN=1): Simple harmonic both ends stop weaving pattern
Amplitude
(WV)
Motion direction
Forth
Lateral
9-6
D Series Controller 9. Special Pattern Weaving Function (Option)
Amplitude
(WV)
Motion direction
Forth
Back
Lateral
9-7
D Series Controller 9. Special Pattern Weaving Function (Option)
3. Pattern No. 3 (PN=3): Reciprocating triangular weaving pattern- both ends stop, center stop
Motion direction
Amplitude
(WV)
Forth
Lateral
9-8
D Series Controller 9. Special Pattern Weaving Function (Option)
4. Pattern No. 4 (PN=4): Circular weaving pattern (1)- from vertical plate direction
Amplitude
(WV)
Motion direction
Forth
9-9
D Series Controller 9. Special Pattern Weaving Function (Option)
5. Pattern No. 5 (PN=5): Circular weaving pattern (2)- from horizontal plate direction
Amplitude
(WV)
Motion direction
Forth
9-10
D Series Controller 9. Special Pattern Weaving Function (Option)
Weld line
Weld start point
When using registered weaving patterns, there is no additional teaching procedure to use special
weaving function. Simply set the desired weaving pattern No. in the weld conditions.
For example, to use weaving pattern 4 in the arc spot weld condition of direct setting, set the
pattern No. as in Figure 9.1. ([Pole Ratio] shown only when Option is installed.)
Figure 9.1
Weaving patterns can be also set in the weld condition by the following auxiliary functions. For
details about the setting procedures of each function, see 7.0 Auxiliary Functions.
9-11
D Series Controller 9. Special Pattern Weaving Function (Option)
When creating a new weaving pattern, keep in mind the torch movements defined in the figure
below, and be careful when specifying the plus (+) and minus (-) directions on this coordinates
system. To register created weaving patterns, see A-1404-11 in 7.0 Auxiliary Functions.
Torch
Up+
Amplitude(WV)=100%
When defining an amplitude and setting the (0) point for
50% 50%
teaching origin as shown on left, motion amounts of points (1)
and (2) are as follows.
Left Up Right Amount of oscillation for point (1):
(1) (2)
upward direction 50%, left direction 50%
50%
Amount of oscillation for point (2):
upward direction 50%, right direction -50%
Down (0)
When registering weaving patterns, specify the motion amount in each oscillation direction by
percentage (%) to the amplitude.
9-12
D Series Controller 9. Special Pattern Weaving Function (Option)
As robot travels along weld direction, this weaving rotates the torch vertical to surface of weld
with torch tip set as center of rotation. For angle, minus () direction is toward the vertical plate.
+
Vertical
plate
Current and voltage values set in weld condition can be changed within a max. of 100%.
(%)
200
+100%
100 Weld condition set value
-100%
0
9-13
D Series Controller 9. Special Pattern Weaving Function (Option)
When creating a weaving pattern, follow the procedure described in the flow chart below. A
blank program sheet is attached in Appendix 3. Pattern Example of Special Pattern Weaving
(List); make copies and use when creating weaving patterns.
(2) Determine a position for defining teaching origin and weaving width.
(3) Create expansion pattern diagrams for back/forth, lateral, vertical dir.
(4) Fill in sheet with the data from expansion pattern diagram in (3).
(5)
(1)
(2)
(4)
(3)
9-14
D Series Controller 9. Special Pattern Weaving Function (Option)
(2) Determine a position for defining the teaching origin and weaving width.
1) Teaching origin: Be sure to match the teaching point and the teaching origin.
Case 1
Up
B C
A During weaving
Lateral+ Lateral-
operation, torch tip
Teaching origin
moves as
Down
ABCA.
9-15
D Series Controller 9. Special Pattern Weaving Function (Option)
Case 2
Up
B C
Lateral+
During weaving
A D
operation, torch tip
moves as
Down Lateral- ABCDA.
Teaching origin
Case 3
Up
C D
During weaving
Lateral+ operation, torch tip
B A E moves as
ABCDEA.
Lateral-
Down Teaching origin
2) Defining position for weaving width: Normally, weaving width (lateral direction) is set at 90
to the torch axis. However, a root gap (or groove
dimension) can be used as basis for setting the weaving
width, as shown below right. Be careful as the
dimensions and directions set for the weaving width will
affect the weaving pattern that can be created.
Weaving width
(Groove dimension)
Left Right
Left
Right
9-16
D Series Controller 9. Special Pattern Weaving Function (Option)
(3) Create expansion pattern diagrams for the back/forth, lateral, and vertical directions. See
diagrams at bottom.
Case 1
Up
Stop time on vertical plate=26%
2
Weaving width=6mm (0)
1 (1)
(1) 3
(2) (2)
(1) 3mm (0) (2) 5
4 Stop time on horizontal
(0) plate=26%
Lateral+ Lateral-
(0)
In the groove in the figure above, set weaving In the weaving pattern in the figure above, set time
width 6mm (100%) between (1) and (2). (0) is ratio between paths in the case where stop time on
teaching origin. Note if weaving motion vertical plate=26% and stop time on horizontal
component in any one (+/-) direction exceeds plate=26%. Weaving speed in each path is
200%, an error occurs. considered to be the same.
0mm to vertical dir. .......................... 0% 100% - ( 26% + 26%)
(0) = 12%
0mm to lateral dir. ............................ 0% 4
Then, time ratio in each point is as follows.
3mm(3mm/6mm) upward.............. 50%
(1) Time ratio at point 1: .................................. 12%
3mm(3mm/6mm) to left................. 50%
Time ratio at point 2: 12%+26% ................ 38%
3mm(3mm/6mm) upward.............. 50%
(2) Time ratio at point 3: 38%+12% ................ 50%
-3mm(-3mm/6mm) to right...........-50%
Time ratio at point 4: 50%+12% ................ 62%
Time ratio at point 5: 62%+26% .................88%
Forth+
1 2 3 4 5
0 Time ratio
12 38 50 62 88 100%
Back-
50 50
Lateral+
0 0% Time ratio
0
Lateral-
-50 -50
50 50 50 50
Up+
0 Time ratio
0 0%
Down-
9-17
D Series Controller 9. Special Pattern Weaving Function (Option)
Case 2
This example shows weaving with torch inclined 22.5 toward the groove: 45 horizontal and
bevel shape with 4mm root gap. Calculate the time, motion amount in vertical, lateral directions,
etc. in consideration of the 22.5 angle. When calculation seems too complicated, draw the
groove diagram in x10 scale, then use the expanded groove diagram to get the vertical, lateral
motion amounts.
When reading by scale
Approx. 6.9mm
(1) Up 2
(0)
22.5 Weaving width (2) (1)
=10mm 4 (3)
6 mm (3) 5
1 3
45
Lateral+ (0) (3) (2)
(0)
Stop time=10%
4 mm Stop time=10%
Lateral-
Down
In the groove in the figure above, set weaving In weaving pattern above, set time ratio for each path
width 10mm (100%) among (0) to (3). (0) is assuming a 10% stop time at bottom of each wall.
teaching origin. Note if weaving motion Weaving speed in each path is considered to be the
component in any one (+/-) direction exceeds same. Weaving motion is executed in 80% of
200%, an error occurs. weaving cycle.
0mm to vertical dir............................... 0 Time ratio at point 1:..............................................10%
(0) 6mm
0mm to lateral dir................................. 0 Time ratio at point 2: 1080 28.5m ......26.8
6cos22.5mm upward ........................ 55 10mm
(1) Time ratio at point 3: 26.880 28.5m ...54.9
6sin22.5mm to left............................ 23
6cos22.5+10sin22.5mm upward..... 94 8.5mm
(2) Time ratio at point 4: 54.980 28.5m ...78.8
6sin22.5-10cos22.5mm to right ...... 69
4sin22.5mm upward......................... 15 Time ratio at point 5: 7810.....................88.8
(3)
-4cos22.5mm to right ......................-37
Forth+
1 2 3 4 5
0 Time ratio
10 26.8 54.9 78.8 88.8 100
Back-
Lateral+
0 0%
23 Time ratio
0
-37 -37
Lateral- -69
Up+
94
55 15 15
0 0%
0 Time ratio
Down-
9-18
D Series Controller 9. Special Pattern Weaving Function (Option)
(4) Fill in sheet with the data from the expansion pattern diagram created in (3).
Using the expansion weaving pattern diagram created in Case 1 in (3) above, the data will be as
follows. When filling in data for each point, do not fill in the last point or specify all 0%.
Back-
50 50
Lateral+
0 0%
0 Time ratio
Lateral-
-50 -50
50 50 50 50
Up+
0 Time ratio
0 0%
Down-
Time B&F [X] Lateral [Y] Vertical [Z] Angle Current Voltage
Point
(%) (%) (%) (%) () (%) (%)
Do not fill in the
1 12 0 50 50 0 0 0
first point (prior
2 38 0 50 50 0 0 0
to point 1).
3 50 0 0 0 0 0 0
4 62 0 -50 50 0 0 0
5 88 0 -50 50 0 0 0
6 (0) (0) (0) (0) (0) (0) (0) Do not fill in
the last point, or
specify all 0%.
9-19
D Series Controller 9. Special Pattern Weaving Function (Option)
For weaving patterns with stops at both ends or a center stop, do not fail to fill in the ratio of
stopping time.
(1) When specifying a big weaving width in a short time during weaving operation, an error
occurs. In this case, the torch tip speed became 100mm/s or more, and error message
(E1123) Speed error jtXX. is displayed. (For some specific robots, this error may occur at
speeds less than100mm/s.)
(2) In sequential steps, when time ratios of back/forth direction are the same, or when time ratio to
the next point is smaller than the time ratio to the last point, the last point becomes the final
point. (Point 3 is the final point in the following three examples.)
(3) When weaving motion component in back/forth, lateral, or vertical directions is 400% (200%
in either plus (+) or minus (-) direction) or more, an error occurs.
9-20
D Series Controller 10. Servo Torch Function (Option)
This chapter describes servo torch function by optional specification and the teaching operation.
10-1
D Series Controller 10. Servo Torch Function (Option)
Typically when a robot and weld machine are used together to perform arc welding, the weld
machine controls the wire feeding. However, this system may not be effective for welding all
types of works. This is especially true if the weld machine lacks the sensitivity for feeding the
wire on to delicate works such as thin aluminum plates which can damage easily. Using
this servo torch function makes the following possible:
1. By controlling the wire feeding servo motor as robot-controller controlled external axis,
detailed weld conditions can be set and the welding of thin works/plates becomes possible with
much greater accuracy.
2. Features of servo adjusted by feedback gain of wire feeding servo motor, etc. and sequence at
weld start/end can be changed depending on its application condition.
10-2
D Series Controller 10. Servo Torch Function (Option)
This section describes the procedure for registering a servo torch as an external axis. For more
details on the procedure for setting external axes, refer to External Axis Servo Parameter Setting
of D Series Controller, a separate volume.
As described in the External Axis Servo Parameter Setting manual, select A-2002 External Axis
to display the screen below.
CAUTION
Be sure to set the servo torch with the highest axis number
in the system. Failure to do so may cause malfunction.
For settings made after pressing <Next Page>, see the External Axis Servo Parameter Setting
manual. Note that the number of setting items for [Servo torch] is smaller than those required
for [Linear Axis] or [Rotary Axis].
10-3
D Series Controller 10. Servo Torch Function (Option)
For details on auxiliary functions specific to the servo torch, see A1404-16 in 7.0 Auxiliary
Functions.
The differences between the servo torch specification and standard arc specification are explained
below. Take these characteristics into account when planning you system and the work required
for your application.
10-4
D Series Controller 10. Servo Torch Function (Option)
This section describes errors occurring during servo torch operation and the error handling.
Error code
Error message Main cause
New Old
E6559 -947 Wire feeding speed Difference between command speed and actual wire
deviation error. feeding speed exceeds allowable range.
If the program taught with the servo torch function suffers error E6559 while it is running,
execute the recovery procedures below.
Main cause:
1. Difference between the command speed and actual wire feeding speed exceeds the allowable
range.
Countermeasure:
1. Check if the power cable to the servo torch motor is disconnected. If disconnected, speed
command will still be output even though robot does not actually work and thus result in error.
2. Determine why the actual wire feeding speed has decreased. Check the system for possible
causes: the wire is being supplied correctly, etc.
10-5
D Series Controller 10. Servo Torch Function (Option)
MEMO
10-6
D Series Controller 11. Error Message for Arc Weld Specification
This chapter describes errors occurring in arc weld specification robot. Some errors only occur
if optional functions for arc weld application are installed.
11-1
D Series Controller 11. Error Message for Arc Weld Specification
Error
Old code Error message Option
code
P6502 -934 No weld database. Standard
P6503 -935 Cannot change weld condition. Standard
E6500 -999 No welding Interface board. Standard
E6502 -900 Arc failure. Standard
E6503 -901 Wire stuck. Standard
E6505 -948 Arc weld insulation defect. Standard
E6506 -1610 Torch interference. Standard
E6509 -910 No work detected. Touch sensing
E6510 -911 Undefined sensing direction. Touch sensing
E6511 -912 Insufficient sensing points. Touch sensing
E6512 -913 Undefined mother or daughter work. Touch sensing
E6513 -914 Too many sensing points. Touch sensing
E6514 -915 Work specification incorrect. Touch sensing
E6515 -916 Incorrect sensing point specified. Touch sensing
E6516 -917 Wire check failure. Touch sensing
E6517 -920 Incorrect weld condition number. Standard
E6518 -921 No weld data set. Standard
E6519 -922 Weld data is out of range. Standard
E6533 -951 No RTPM board. RTPM
E6534 -960 Too many taught points for RTPM. RTPM
E6535 -961 RTPM arc sensor error. RTPM
E6536 -964 RTPM current deviation error. RTPM
E6537 -962 RTPM tracking value is out of range. RTPM
E6538 -963 Out of RTPM tracking capacity. RTPM
E6539 -969 Out of AVC tracking value. AVC
E6540 -971 Out of AVC tracking capacity. AVC
E6541 -967 No AVC board. AVC
E6542 -972 AVC voltage deviation error. AVC
E6543 -968 Too many taught points for AVC. AVC
E6544 -990 Hyper Arc tracking value is out of range. Hyper arc
E6545 -991 Out of Hyper Arc tracking capacity. Hyper arc
E6546 -993 Bead end is not found. Hyper arc
E6547 -994 Finish end is not found. Hyper arc
11-2
D Series Controller 11. Error Message for Arc Weld Specification
Error
Old code Error message Option
code
E6548 -995 Hyper Arc revolution beyond normal deviation. Hyper arc
E6549 -996 Hyper Arc torch calibration error. Hyper arc
E6550 -997 Hyper Arc Z phase index error. Hyper arc
E6551 -985 No Hyper Arc board. Hyper arc
E6552 -986 Hyper Arc board error. code is XXXX. Hyper arc
E6553 -987 Hyper Arc current sensor error. Hyper arc
E6554 -988 Hyper Arc voltage sensor error. Hyper arc
E6555 -989 Hyper Arc current deviation error. Hyper arc
E6556 -992 Hyper Arc amplifier error. code is XXXX. Hyper arc
E6559 -947 Wire feeding speed deviation error. Servo torch
E6560 -965 Cannot calibrate again while welding. Hyper arc
E6561 -966 Cannot weld during re-calibration. Hyper arc
E6562 -902 Electric pole stuck. TIG welding
This section describes troubleshooting for standard errors occurring in arc specification. For
errors which occur in optional functions for arc welding, refer to the related Option Manuals.
Main cause:
Signal showing welding in process (current detection: WCR) was not returned from weld
machine 1 sec (or more) after robot attempted to weld.
Countermeasure:
Some insulating object may interrupt arc generation at arc start point. 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.
11-3
D Series Controller 11. Error Message for Arc Weld Specification
Main cause:
Wire is stuck to the base material when welding has completed.
Countermeasure:
If wire is stuck to the base material, cut the wire. When wire is often stuck at the same point,
reexamine the weld conditions.
Main cause:
When control power was turned ON, interface board for arc welding was not detected.
Countermeasure:
Turn OFF the CONTROL POWER, and check whether weld interface board is mounted in the
card rack of the controller. When mounted, insert it correctly and firmly as the interface board
may be loose.
After error reset, robot can be moved in teach mode. In repeat mode, operation is only possible
after setting the torch back to its original state.
Main cause:
Torch interfered with something, and limit switch in the torch bracket came off.
Countermeasure:
Reset the error, and move robot in teach mode to set the torch back to its original state. (Set the
limit switch back to the original state.)
11-4
D Series Controller 11. Error Message for Arc Weld Specification
Main cause:
Torch short-circuited to the work when INSUL_CHK instruction was executed.
Countermeasure:
Check and make the insulation as needed.
11-5
D Series Controller 11. Error Message for Arc Weld Specification
MEMO
11-6
D Series Controller Appendix 1. Program Sheet
Once the robot work is determined, fill in the teaching contents on the program sheet.
Instruction Interpolation Speed Accuracy Timer Weld condition Arc Spot condition
1 Air cut Joint 9 4 0
2 Weld start Joint 9 0
3 Weld continue Linear Direct
4 Weld end Linear Direct
5 Air cut Linear 9 4 0
6 Arc spot Joint 9 1 0 Direct
A-1
SHEET OF
Welding
Weld Condition Arc Spot Condition Option
Condition
D Series Controller
Typeofof Inter-
Step Teachcing Type Air
Speed Accu- Timer Jump
Point teaching
Teach polation Cut racy Direct Direct
/End In- In-
point
Point Speed direct
direct
SP A V WV f PN Ct CA CV A V
Kawasaki Robot Arc Welding Operation Manual
A-2
Appendix 1. Program Sheet
[ NOTE ]
Database provided at time of factory shipment contains weld conditions whose
contents were tested and confirmed by Kawasaki. Be advised these
conditions may not be best for the planned work. Kawasaki cannot guarantee
that this database will provide the best possible welding operation and quality
for every work.
Preconditions for using this database with the standard arc specification:
Weld gas ........................CO2
Wire diameter ................1.2
Wire extension length ....15mm
Wire type .......................Solid wire JIS YGW12 (equivalent to KC-50T KAWASAKI
STEEL)
Weld machine ................DAIHEN CPVB350, CPVP350, etc.
(For other weld machines, please contact Kawasaki.)
If conditions differ from those described above, no data is stored in weld database at time of
factory shipment.
A-3
D Series Controller Appendix 2. Weld Database
1. Horizontal fillet
2. Flat fillet
A-4
D Series Controller Appendix 2. Weld Database
3. Lap fillet
4. Corner fillet
A-5
D Series Controller Appendix 2. Weld Database
5. Butt I fillet
6. Downhill fillet
A-6
D Series Controller Appendix 3. Pattern Example of Special Pattern Weaving
Weaving pattern for 1 cycle Weld gas: CO2, MAG Center stop time: 0%
Amplitude
Teaching origin
Back/forth direction:
Points for weaving pattern
100%
B&F Lat. Vert.
F + Point
Time
X Y Z
Ang. Cur. Vol.
(%) () (%) (%)
50 (%) (%) (%)
0 Time ratio 1 12 0 50 50 0 0 0
12 38 62 88 100%
-50 2 38 0 50 50 0 0 0
B - -100 3 62 0 -50 50 0 0 0
4 88 0 -50 50 0 0 0
Lateral direction: 5
100% 6
Lat. + 50 50
50 7
0 Time ratio 8
0%
-50 9
-50 -50
Lat. - 10
-100
11
Vertical direction: 12
100% 13
Up + 50 50 50 50 14
50
15
0 Time ratio
0%
-50
Down - -100
A-7
D Series Controller Appendix 3. Pattern Example of Special Pattern Weaving
Weaving pattern for 1 cycle Weld gas: CO2, MAG Center stop time: 0%
Teaching origin
Back/forth direction:
Points for weaving pattern
100% B&F Lat. Vert.
Time Ang. Cur. Vol.
F + Point
(%)
X Y Z
() (%) (%)
50 (%) (%) (%)
0 Time ratio 1 25 0 50 50 0 0 0
25 50 75 100%
-50 2 50 0 0 0 0 0 0
B - -100
3 75 0 -50 50 0 0 0
4
Lateral direction: 5
100% 6
Lat. + 50
50
7
0
0 Time ratio 8
0%
9
-50
-50
10
Lat. - -100
11
12
Vertical direction:
13
100%
Up + 50 50 14
50
0 15
0 Time ratio
0%
-50
Down - -100
A-8
D Series Controller Appendix 3. Pattern Example of Special Pattern Weaving
Weaving pattern for 1 cycle Weld gas: CO2, MAG Center stop time: 0%
Teaching origin
Amplitude
Back/forth direction:
Points for weaving pattern
100% B&F Lat. Vert.
Time Ang. Cur. Vol.
F + Point
(%)
X Y Z
() (%) (%)
50 (%) (%) (%)
B - -100
3 75 0 -46 19 0 0 0
4
Lateral direction: 5
100% 6
Lat. + 46
50
7
0
0 Time ratio
8
0%
9
-50
-46
10
Lat. - -100
11
12
Vertical direction:
13
50%
Up + 19 14
25
0 15
0 Time ratio
0%
-25
-19
Down - -50
A-9
D Series Controller Appendix 3. Pattern Example of Special Pattern Weaving
Weaving pattern for 1 cycle Weld gas: CO2, MAG Center stop time: 0%
Teaching origin
Amplitude
Back/forth direction:
Points for weaving pattern
100% B&F Lat. Vert.
Time Ang. Cur. Vol.
F + 50 Point
(%)
X Y Z
() (%) (%)
50 (%) (%) (%)
0 0%
0 Time ratio 1 25 50 0 0 0 0 0
25 50 75 100%
-50 2 50 0 0 0 0 0 0
-50
B - -100
3 75 -50 0 0 0 0 0
4
Lateral direction: 5
100% 6
Lat. +
50
7
0 Time ratio 8
0 0 0 0%
9
-50
10
Lat. - -100
11
12
Vertical direction:
13
100%
Up + 14
50
15
0 Time ratio
0 0 0 0%
-50
Down - -100
A-10
D Series Controller Appendix 3. Pattern Example of Special Pattern Weaving
Weaving pattern for 1 cycle Weld gas: CO2, MAG Center stop time: 0%
Torch angle
Weld posture: Horizontal Hor. plate stop time: 0%
Incline torch 7.5.
No. of points: 4 Remarks:
15
30
Teaching origin and amplitude:
45
4mm
Teaching point
0 Time ratio
7 28 63 93 100%
1 7 0 18 -8 2.5 0 0
2 28 0 41 47 7.5 0 0
Back -
3 63 0 -50 86 -7.5 0 0
4 93 0 -18 8 -2.5 0 0
Lat. +
5
41
18
0 6
Time ratio 7
Lat. - -18
-50 8
9
Up + 47
86 10
8
11
0 Time ratio
-8 12
Down - 13
Angle + 14
7.5
2.5
15
0 Time ratio
-7.5 -2.5
Angle -
A-11
D Series Controller Appendix 3. Pattern Example of Special Pattern Weaving
Weaving pattern for 1 cycle Weld gas: CO2, MAG Center stop time: 0%
Amplitude
Teaching origin
Lat. + 50 50
1 15 0 38 0 0.0 0 0
65 70 80 85 100% 2 20 0 50 0 0.0 20 0
0 Time ratio
15 20 30 35 50
3 30 0 50 0 0.0 20 0
-50 -50
Lat. - 4 35 0 38 0 0.0 0 0
5 50 0 0 0 0.0 0 0
Current + 20 30 20 20
6 65 0 -38 0 0.0 0 0
Time ratio 7 70 0 -50 0 0.0 20 0
0
8 80 0 -50 0 0.0 20 0
Voltage - 9 85 0 -38 0 0.0 0 0
10
11
12
13
14
15
A-12
D Series Controller Appendix 3. Pattern Example of Special Pattern Weaving
Back/forth direction:
Points for weaving pattern
100%
B&F Lat. Vert.
F + Point
Time
X Y Z
Ang. Cur. Vol.
(%) () (%) (%)
50 (%) (%) (%)
0 Time ratio 1
50 100%
-50 2
B - -100 3
4
Lateral direction: 5
100%
6
Lat. +
50 7
0 Time ratio 8
50 100%
-50 9
Lat. - 10
-100
11
Vertical direction: 12
100% 13
Up + 14
50
15
0 Time ratio
50 100%
-50
Down - -100
A-13
D Series Controller Appendix 3. Pattern Example of Special Pattern Weaving
Back/forth direction:
Points for weaving pattern
100%
B&F Lat. Vert.
F + Point
Time
X Y Z
Ang. Cur. Vol.
(%) () (%) (%)
50 (%) (%) (%)
0 Time ratio 1
50 100%
-50 2
B - -100 3
4
Lateral direction: 5
100%
6
Lat. +
50 7
0 Time ratio 8
50 100%
-50 9
Lat. - 10
-100
11
Vertical direction: 12
100% 13
Up + 14
50
15
0 Time ratio
50 100%
-50
Down - -100
A-14
COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY
Kawasaki Robot Controller D Series
ARC WELDING OPERATION MANUAL
90203-1085DEB