9.2 Ignition faults
9.2.1 Signal output group O_FLT_ARC_ON[ ]
If the “Arc struck” signal (I_START_MOVE[ ]) is missing after a weld start, welding is switched off and an ignition fault signal is set. The following signal table is used for this purpose:
9.3.2 Signal output group O_FLT_WELD[ ]
Welding is stopped if a seam error is detected or an interrupt function is triggered. The signal table for this reads as follows:
9.3.3 Signal output group O_FLT_CLEAN[ ]
The torch cleaning process is switched off if interrupt functions are triggered. The following signal table must be taken into account with regard to the torch cleaning device:
9.3.4 Signal output group O_ACK_FLT [ ]
These output signals are used to reset the outputs for torch cleaning.
The ignition fault output can additionally be reset here.
O_ACK_FLT[2] = {NO 13,PULS_TIME 0.0,STATE FALSE}
9.3.5 Signal O_FLT_SIGNAL
This output signal is reset when the corresponding fault has been acknowledged. This refer-ence manages general fault signals to the PLC.
9 Enumeration of the signal groups for fault service functions (continued)
9.3.6 Signal APPL_RUN
This output signal is defined and configured in the Fold AUTOEXT Globals. The signal state is managed exclusively in the IR_STROPMESS program.
Default $OUT [34]
9.4 Special feature IR_STOPMESS program
9.4.1 Joint activation/deactivation routines
All technologies are deactivated. The interrupt program is subsequently located in the Fold BASIS_STOP in the IR_STOPM.SRC file.
Once the causes have been eliminated, the technologies are switched back on again one after the other.
The user must integrate his applications into the USER blocks in order to avoid impairing other technologies.
Opened Folds:
9.5 Configurable fault service functions
9.5.1 Fault service functions defined by the user
If ignition is not successful, the welding torch is moved back by X=100 mm.
Program continuation: the torch is moved back by X=50 mm.
Torch is returned to its start position.
10 Further options
10 Further options
10.1 Program test in manual mode
For testing programs in manual mode “T1” under real welding conditions, the variable
“PROC_IN_T1” (default value = FALSE) in the block
;FOLD BAS GLOBALS
;%{E}%V2.3.0,%MKUKATPBASIS,%CGLOBALS,%VGLOBALS,%P in the file “$CONFIG.DAT” can be set to TRUE.
BOOL PROC_IN_T1=FALSE
Corresponding entry using the menu function “Monitor -- Variable -- Modify”:
Variable Type Characteristics
PROC_IN_T1 BOOL Default: FALSE
If a hot welding attempt is made with the setting FALSE, the message “Welding in operation mode T1 impossible!” appears in the message window.
10.2 Ignition fault message suppression option
Default = 0
The ignition fault messages are suppressed if the condition START_CNT< MAX_AUTO_R is met and AUTO_RETRY = 1.
If AUTO_RETRY = 0, an error message appears in the message window after every ignition fault.
10.3 Seam monitoring delay option
A_CTRL_DELAY= 800 [ms] means that the seam monitoring begins after a delay of 800 ms.
This command can be used to optimize the ignition process reliability and always force an active edge for the seam fault monitoring interrupt. Monitoring is carried out using $TIMER[1]
and $CYCFLAG[3].
This time can be increased if ignition faults occur too often following an unstable ignition
11 Mechanical weaving
Mechanical weaving is used, for example, to compensate for tolerances or to bridge gaps in a seam. The torch moves across the seam in this instance and the weave oscillation is thus superposed on the seam motion. It is also possible to rotate the torch in relation to the plane of the weld (direction of welding).
Mechanical weaving is executed in the coordinate system “TTS” (tool--based technological system). In this way, the weaving function is independent of the position of the torch in relation to the seam and of the torch angle, and irrespective of whether welding is by the
“pushing” or “dragging” technique.
11.1 Block selection response
If a block selection is made to a motion command other than ARC_SWI or ARC_OFF, mechanical weaving is switched off. In the event of a weld command, the corresponding weld data set with its weave parameters is taken into consideration. This ensures the continuous monitoring of the torch motion to the component when moving in Test mode.
11 Mechanical weaving (continued)
11.2 Weave patterns
The following weave patterns are included in the ArcTechDigital package:
No weaving
These weave patterns are defined in the file “Weav_def_d.src”.
DEF WEAV_DEF (GENERATOR :IN,FIGUR :IN ) ...
CASE 1 ;triangle Triangular weaving (SGL_TRI)
CASE 2 ;double triangle Triangular weaving,
double frequency (DBL_TRI)
CASE 3 ;trapezoid Trapezoidal weaving (SGL_TRP)
CASE 4 ;double trapezoid Trapezoidal weaving,
double frequency (DBL_TRP) CASE 5 ;unsymmetrical trapezoid Trapezoidal weaving, unsymmetrical
(UNSYM_TRP)
CASE 6 ;spiral Spiral weaving (SPIRAL)
CASE 7 ;eight Figure--of--eight weaving (DBL_8)
The “Triangle” weave pattern (SGL_TRI) is described in the following example; on the left is the entry taken from the file “Weav_def_d.src”, and on the right is the assignment to the individual control points (1 ... 4) with the corresponding X and Y values.
1
The value for X can be between 0.0 and 1.0. Xn=1.0 corresponds to the weave length entered in the W--parameter list 2 (Mechanical Weaving), i.e. the length over which a pattern is executed.
The value for Y can be between --1.0 and 1.0. Yn=1.0 corresponds to the lateral deflection (weave amplitude -- zero to peak) entered in the W--parameter list 2 (Mechanical Weaving).
The weave length X, the lateral deflection Y and the angle of the torch in relation to the welding plane (weave angle) can be programmed for each weave pattern in the
11 Mechanical weaving (continued)
11.2.1 Two--dimensional weaving
Weave patterns such as triangular and trapezoidal patterns result from the lateral deflection of the torch during motion along the seam. Complex patterns are possible by means of a second function generator that causes the torch to weave in the welding direction (X--axis).
Two practical functions (for thin sheet welding, for example), namely spiral weaving and figure--of--eight weaving, are already included in the technology package. You can also develop your own patterns. The following diagram illustrates the mode of operation of the function generator using the example of spiral weaving.
(--Y’) (Y’)
(--Y) (Y)
Lateral deflection (amplitude) 1)
Deflection in direction of path 2)
Lateral deflection (amplitude) 1)
Weave width
Torch
1) Lateral deflection (amplitude) = half weave width 2) Deflection in direction of path= ¦ weave length
$TECH[FG_NR1].FCT.CPS1.Xn=x (0.0 ... 1.0)
$TECH[FG_NR1].FCT.CPS1.Yn=x (0.0 ... 1.0) Weav_def_d.src
$TECH[FG_NR2].FCT.CPS1.Xn=x (0.0 ... 1.0)
$TECH[FG_NR2].FCT.CPS1.Yn=x (0.0 ... 1.0)
The ratio of the deflection in the welding direction (...FCTCTRL.SCALE_IN) to the weave length (A.WEAVLEN_MECH) is 1:1. The lateral deflection (...FCTRL.SCALE_OUT) corresponds to the value set for half the weave width (A.WEAVAMP_MECH).
$TECH[N].FCTCTRL.SCALE_IN=1
$TECH[N].FCTCTRL.SCALE_OUT=1
The “Weave amplitude” value is defined as “zero to peak”, i.e. it corresponds to half the weave width (peak to peak).
The magnitude of the deflection in the welding direction (...FCTCTRL.SCALE_IN) in relation to the weave length (W.WEAVLEN_MECH) is set in the file “A20.SRC” at a ratio of 1:1. The lateral deflection (...FCTRL.SCALE_OUT) corresponds to the value set for the half weave width (W.WEAVAMP_MECH).
11.2.2 Creating the “Spiral” weave pattern A20.src
sin(x) cos(x)
0 1
0 1
Superposition of cosine on sine With path motion Without path
motion
Welding direction
The following diagram shows the curve shapes of the function generators derived from the sine function. This is approximately a sine for the lateral deflection (”$TECH[FG_NR1]...”) and a cosine for the deflection in the direction of the path (”$TECH[FG_NR2]...”). The corre-sponding control point parameters are stored under “CASE 6 ;spiral” in the file
“Weav_def_d.src”. The figure of a spiral results from the superpositioning of these two mo-tions.
The control points for the “Spiral” weave pattern are defined in the file “Weav_def_d.src”.
11 Mechanical weaving (continued)
The second block (A_FG_MECH2...) contains the parameters for the deflection in the direc-tion of the path.
An additional weave pattern, an asymmetrical “figure--of--eight”, is defined in the file
“Weav_def_d.src” under the designation “CASE 7 ;eight”. This pattern results from the superposition of a lateral weave motion with an orthogonally--acting weave motion in the direction of welding with double frequency.
Weav_def_d.src
11.2.4 Changing and creating patterns for mechanical weaving
The weave patterns defined by the manufacturer can be changed by the user, and new patterns can be created.
11.2.4.1 Changing existing weave patterns
You can adapt the weave patterns defined in the file “Weav_def_d.src” to your own require-ments by changing the number of control points and their parameters.
You want to shift the “Triangle” pattern -- contained in the file “Weav_def_d.src” -- by 180˚
in the phase angle.
The settings for the “Triangle” weave pattern are contained in the file “Weav_def_d.src”.
CASE 1 ;triangle
In order to achieve a phase shift of 180˚, it is merely necessary to change the parameters for control points Y2 and Y3. The required changes have been made in the following list and are underlined for ready identification.
Weav_def_d.src
11 Mechanical weaving (continued)
CASE 1 ;triangle (phi = 180 degrees) IF FG_NR1>0 THEN
11.2.4.2 Creating your own weave patterns
The following example shows the practical approach for creating your own weave patterns.
A weave pattern is to be created as a combination of a trapezoid and a triangle.
It is recommendable to start by drawing the desired pattern. A range from 0.0 to 1.0 for the path “X” covered within a period and 1 for the lateral deflection “Y” are predefined.
1
CASE 8 ;Trapez - Dreieck
$TECH[A_FG_MECH1].FCT.ORDER=1
$TECH[FG_NR1].FCT.CPNUM=6 Number of control points
$TECH[FG_NR1].FCT.CPS1.X1=.0 Value X for control point 1
$TECH[FG_NR1].FCT.CPS1.Y1=.0 Value X for control point 1
$TECH[FG_NR1].FCT.CPS1.X2=.2 Value X for control point 2
$TECH[FG_NR1].FCT.CPS1.Y2=1.0 Value Y for control point 2
$TECH[FG_NR1].FCT.CPS1.X3=.4 ...
11.2.5 Notes on mechanical weaving
The quality of a seam welded with mechanical weaving is influenced by a variety of physical and mechanical factors, such as the mechanical play in the gears, axis torsion, robot position, path tangent, etc. In addition, interdependencies with the interpolation cycle as well as the set robot--specific $Filter value also exist.
The weave motion is superposed on the path motion. In case of weave patterns such as
“Trapezoid” or “Spiral”, this leads to an irregular welding speed during a period. This can vary between the set path velocity and a multiple of it, depending on the relation of the weave length (frequency) to the lateral deflection (amplitude).
The maximum weave frequency for mechanical weaving is – depending on the robot type concerned – influenced by several factors, for example by the resonant frequency of the
“robot/tool” mechanical unit. Weave frequencies of up to 3 Hz (corresponding, for example, to a weave length of 3.33 mm at a travel speed of 0.6 m/min) are possible without causing problems according to previous experience.
With higher weave frequencies, undesirable effects are liable to result in certain conditions (depending on the tool design and/or tool orientation). With weave frequencies > 3 Hz, the motion characteristics of the robot should therefore be individually tested in each case.
Weav_def_d.src
12 Error messages / troubleshooting
12 Error messages / troubleshooting
Messages of all categories are displayed in the message window. These can be either informative messages that do not need to be acknowledged or messages that have to be acknowledged.
A message consists of the following items of information, for example:
Message group Message time
Message number Originator
Message text
ACTIVE COMMANDS INHIBITED
COMMAND ACCELERATION EXCEEDED A2
12.1 Message groups
Hint messages
provide the operator with explanatory information, for example, if an illegal key has been pressed.
Operational messages
signal the status of the system that has led to a control reaction, e.g. Emergency Stop. The message is cleared once its cause has been eliminated. In some cases, a secondary signal that has to be acknowledged is set for reasons of safety.
Acknowledgement messages
indicate a situation that must in all instances be recognized and acknowledged with the acknowledge key. They are often a consequence of a status (operational) message. An acknowledgement message stops a movement or prevents further operation.
Dialog messages
require confirmation by the operator (“Yes” or “No” softkeys). The message is cleared after
12.4 Originator
The origin of the error is indicated in this field. In the case of ArcTechDigital, the entry is TPA20.
12.5 Message text
The text of the error message is shown here.
12.6 List of error messages
To make it easier to find error messages in the following list, the message number is shown first, unlike on the display. By referring to this message number, it is possible to obtain further information on an error and the appropriate remedial action. This information is subdivided into:
Message text
is the actual text of the error message as displayed.
Cause
gives a detailed description of the cause of the error.
Monitor
indicates when the conditions for generation of the message are checked.
Effect
describes how the controller reacts to the error.
Remedy
describes what action the user can take to eliminate the error.
12 Error messages / troubleshooting (continued)
1 Message text Option bit ARC20 not set Cause -- ARC20 = FALSE Monitor -- In ARC ON command
Effect -- Endless loop always with this message
Remedy -- Set ARC20 to TRUE, stop and restart Submit interpreter, data backup 2 Message text Submit is not running
Cause -- Submit interpreter has been stopped, etc.
Monitor -- In ARC ON command
Effect -- Endless loop always with this message Remedy -- Restart Submit interpreter
3 Message text Wrong submit routine selected
Cause -- No SPS.SUB submit program running while ARC20=TRUE Monitor -- During initialization of A20_INIT commands
Effect -- Endless loop with this message, as deactivation not otherwise possible in event of interpreter stop
Remedy -- $PRO_I_O[ ] = “R1/SPS ( )”
4 Message text Weld controller not ready
Cause -- The inputs configured in the signal input group I_WELD_COND [ ] are missing when welding is activated
-- Position of the keyswitch (incorrect status for welding) Monitor -- In ARC ON command
Effect -- Endless loop with this message
Remedy -- Move the keyswitch to the correct position -- Switch on power source (I_WELD_COND [ ]) 5 Message text Ignition failure, no arc
Cause -- Configured signals not returned to input group I_START_MOVE [ ] Current flow not established
Power source sends this output too late or not at all Weld current connections broken
Monitor -- ARC_ON command
Effect -- Ignition process is cancelled and restarted, once message
6 Message text Continue without welding
Cause -- Too many ignition attempts; too many seam faults or interruption with RESTART_OPT = 0 (continue “Cold”)
Monitor -- In ARC ON command Effect -- Seam not welded
Remedy -- Clean ignition position and make new block selection to ARC_ON position
7 Message text Switch off welding
Cause -- Power source does not switch welding off or does so too late -- Incorrect configuration
-- Incorrect burnback parameters Monitor -- In ARC OFF command
Effect -- Single message for user
Remedy -- Optimization of the burnback parameters 8 Message text Weld controller fault
Cause -- Periphery error: robot waiting for the inputs expected in
I_WELD_FLT [ ]. Normally configured as current flow “Gas present”, coolant monitoring
-- Configuration error (OK state configured)
Monitor -- Continuous between ignition process and ARC_OFF command if welding
Effect -- Welding is switched off; weld process is restarted, once message acknowledged, depending on RESTART_OPTION
Remedy -- Complete the configuration
Reconnect gas, water, etc. or check respective sensor 9 Message text Welding in operation mode T1 impossible!
Cause -- T1 mode and PROC_IN_T1 = FALSE
Monitor -- In advance run section of ARC ON command
Effect -- Program remains in this loop after message acknowledged Remedy -- Set the above variable to TRUE ($config.dat)
1
Index
Adaptation to the periphery, 29 ARC OFF, 13, 14
Changing existing weave patterns, 62 Control points (CPNUM), 58
Coordinate system ”TTS”, 56 Crater filling, 37
Creating your own weave patterns, 63
D
Fault situations and fault service functions, 51 Figure--of--eight weave pattern, 61
Figure--of--eight weaving, 57 Files for ”ARC Tech 20”, 20 Flt_serv_d.dat, 21
Flt_serv_d.src, 21
Fold ARC Messages in A20.dat, 28 Fold ArcTech Inputs in $Config.dat, 24, 32 Fold ArcTech Outputs in $Config.dat, 23, 30 Fold Internal States in A20.dat, 26, 27 Fold Main Options in A20.dat, 25
I
Index table for physical digital inputs, 32 Index table for physical digital outputs, 30 Index tables, 29
Input group I_START_MOVE [ ], 43 Input group I_WELD_COND [ ], 42 Input group I_WELD_END [ ], 43 Input group I_WELD_FLT [ ], 44 Installation, 8
Interpreter stop (STOP key), 49 IR_STOPMESS program, 53
L
Lateral deflection (weave amplitude), 58
M
MAX_AUTO_R, 50
O_SEAM_END[ ], 37 O_WELD_CTRL[ ], 30 OUT_NR, 30
Output group O_ACK_FLT [ ], 41 Output group O_ACK_START [ ], 36 Output group O_ACK_WELD_E[ ], 38 Output group O_FLT_ARC_ON [ ], 39 Output group O_FLT_CLEAN [ ], 41 Output group O_FLT_WELD [ ], 40 Output group O_SEAM_END [ ], 37 Output group O_STROB_PGNO [ ], 37 Output group O_WELD_START [ ], 35
P
Program run mode ”GO”, 11 Program structure, 19Schematic sequence diagram ARC OFF, 14 Schematic sequence diagram ARC ON, 12 Schematic sequence diagram ARC SWITCH, 16
Signal grouping in normal operation, 35 Signal O_FLT_SIGNAL, 52
Signal output group O_ACK_FLT [ ], 52 Signal output group O_FLT_CLEAN[ ], 52 Signal output groups for fault service function, 39
Signal tables for digital inputs, 33 Signal tables for digital outputs, 31
Signal tables for digital outputs and inputs, 29 Spiral weave pattern, 59
Spiral weaving, 57
Start welding -- ARC ON, 11 STATE, 31
STOP key, 49
Switching on the welding process, 11 System requirements, 8
Weave patterns, changing of, 62