for power sources with program number control

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SOFTWARE

KR C...

ArcTechDigital 2.2

for power sources with program number control

Configuration

for KUKA.KR C 5.2, 5.3, 5.4

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1 General . . . . 7

1.1 System requirements, Installation . . . 8

1.2 Overview of the configurable options . . . 9

2 Description of the “ArcTechDigital” commands . . . . 11

2.1 General. . . 11

2.1.1 Keyswitch for program execution without welding. . . 11

2.1.2 Program run mode “GO” . . . 11

2.1.3 Switching on the welding process . . . 11

2.2 Start welding -- ARC ON . . . 11

2.2.1 Schematic sequence diagram ARC ON . . . 12

2.2.2 Signal diagram ARC_ON and ARC_SWI . . . 13

2.3 Welding and ending seams -- ARC OFF. . . 13

2.3.1 Schematic sequence diagram ARC OFF . . . 14

2.3.2 Signal diagram ARC_OFF . . . 15

2.4 Welding a seam in several sections -- ARC SWITCH. . . 15

2.4.1 Schematic sequence diagram ARC SWITCH . . . 16

2.4.2 Signal diagram ARC_SWI. . . 17

3 Programs of the ArcTechDigital package . . . . 19

3.1 Program structure. . . 19

3.2 Overview of the “ArcTechDigital” files . . . 20

4 ArcTechDigital -- basic settings . . . . 23

4.1 Activating the ARC 20 option . . . 23

4.2 Minimum configuration for power source interface . . . 23

4.3 Minimum configuration for program number control . . . 25

4.3.1 Meaning of the variables . . . 28

5 Principles of the definable signal table . . . . 29

5.1 Overview, definition . . . 29

5.1.1 Index tables for configuring physical outputs and inputs . . . 29

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6.1.1 Output group O_WELD_START [ ] . . . 35

6.1.2 Output group O_ACK_START [ ] . . . 36

6.1.3 Output group O_STROB_PGNO [ ]. . . 37

6.1.4 Output group O_SEAM_END [ ] . . . 37

6.1.5 Output group O_ACK_WELD_E[ ]. . . 38

6.2 Signal output groups for fault service function. . . 39

6.2.1 Output group O_FLT_ARC_ON [ ]. . . 39

6.2.2 Output group O_FLT_WELD [ ] . . . 40

6.2.3 Output group O_FLT_CLEAN [ ] . . . 41

6.2.4 Output group O_ACK_FLT [ ] . . . 41

6.3 Assignment of the inputs. . . 42

6.3.1 Input group I_WELD_COND [ ] . . . 42

6.3.2 Input group I_START_MOVE [ ]. . . 43

6.3.3 Input group I_WELD_END [ ] . . . 43

6.3.4 Input group I_WELD_FLT [ ]. . . 44

6.3.5 Polling of the external keyswitch (Hot/Cold). . . 45

6.3.6 Time_out when polling the inputs. . . 45

7 Options for program number specification . . . . 47

7.1 Signal flow of the program numbers . . . 47

7.2 Setting -- parity bit. . . 47

7.3 Timing diagram – program number interface (a) . . . 48

8 Setting the restart options . . . . 49

8.1 RESTART_OPTION. . . 49

8.1.1 Reaction to interpreter stop (STOP key). . . 49

8.2 Configuration in event of ignition faults . . . 50

8.2.1 Ignition repetition monitoring. . . 50

8.3 Ignition fault message suppression option . . . 50

9 Enumeration of the signal groups for fault service functions . . . . 51

9.1 Types of faults and causes . . . 51

9.2 Ignition faults . . . 51

9.2.1 Signal output group O_FLT_ARC_ON[ ]. . . 51

9.3 Welding faults and robot faults . . . 51

9.3.1 Reaction to robot faults, EMERGENCY STOP and DRIVES OFF. . . 51

9.3.2 Signal output group O_FLT_WELD[ ] . . . 52

9.3.3 Signal output group O_FLT_CLEAN[ ] . . . 52

9.3.4 Signal output group O_ACK_FLT [ ] . . . 52

9.3.5 Signal O_FLT_SIGNAL . . . 52

9.3.6 Signal APPL_RUN . . . 53

9.4 Special feature IR_STOPMESS program. . . 53

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10.2 Ignition fault message suppression option . . . 55

10.3 Seam monitoring delay option . . . 55

11 Mechanical weaving . . . . 56

11.1 Block selection response. . . 56

11.2 Weave patterns. . . 57

11.2.1 Two--dimensional weaving . . . 59

11.2.2 Creating the “Spiral” weave pattern. . . 59

11.2.3 “Figure--of--eight” weave pattern . . . 61

11.2.4 Changing and creating patterns for mechanical weaving. . . 62

11.2.4.1 Changing existing weave patterns . . . 62

11.2.4.2 Creating your own weave patterns . . . 63

11.2.5 Notes on mechanical weaving . . . 64

12 Error messages / troubleshooting . . . . 65

12.1 Message groups . . . 65

12.2 Message time . . . 65

12.3 Message number . . . 65

12.4 Originator . . . 66

12.5 Message text. . . 66

12.6 List of error messages . . . 66

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1 General

1 General

In the development of a welding robot that is easy and safe to use, top priority was given to the optimized adaptation of the operator interface and the interfacing capability to welding equipment with program number control, as well as uncomplicated handling of the ArcTechDigital technology package.

This is intended to allow the trouble--free operation, parameter and hardware configuration and programming of arc welding applications. The entire range of KRL commands are available to you at the expert level. Configuration requires sufficient knowledge of the KRL programming language.

ArcTechDigital features:

G Menu--guided creation of programs at the user level.

G Simple operation using application--specific softkeys and menus.

G Prepared programs and subroutines.

G Adaptation to the peripheral equipment and configurable options of the digital outputs.

G Simple setting of variables, entries in files and parameter lists.

G Use of the function generators for two--dimensional mechanical weaving as well as the possibility of configuring your own weave patterns.

G Adaptation to various welding controllers with program number control and their different coding systems.

G Various routines used for ignition faults and monitoring of the number of ignition attempts.

G Restart options in case of faults.

This documentation has been created as a supplement to the documentation [Arc Welding, ArcTechDigital -- Operation] for the user group Expert. In addition to fundamental descriptions accompanied by schematic sequence diagrams and screenshots of application tests, information on standard routines as well as specific “ArcTechDigital” applications have also been provided. This is intended to make parameter and hardware configuration and the programming of arc welding applications easier.

In the development of a welding robot that is easy and safe to use, top priority was given to the optimized adaptation of the operator interface and the interfacing capability to welding equipment with program number control, as well as uncomplicated handling of the

“ArcTechDigital” technology package.

The entire range of KRL commands are available to you at the expert level. This requires sufficient knowledge of the KRL programming language.

The “ARC Tech 20” commands “ARC ON”, “ARC OFF” and “ARC SWITCH” are described in Chapter 2. Among other things, information is provided on variable settings, entries

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The mechanical weaving option included in the “ArcTechDigital” technology package is described in Chapter 11. There you will find fundamental information on the mode of operation of the function generators, two--dimensional mechanical weaving, and the configuration of weave patterns. Examples are used to show you how to change existing patterns and how to create your own patterns.

Chapter 12 contains a list of error messages along with their causes, effects and remedial action.

1.1 System requirements, Installation

The Software ArcTechDigital can be used with the following KRC--Software:

-- KR C2

-- Software Rel. 5.2, 5.3, 5.4, 5.5

From system software version 5.1 onwards, technology packages are offered exclusively as ad--on software modules. These are available on CD--ROM.

The installation, uninstallation, reinstallation and update of technology packages are described in detail in the documentation

[Installation/Uninstallation/Update of Tech Packages].

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1 General (continued)

1.2 Overview of the configurable options

The ArcTechDigital technology package also provides a range of options in addition to the basic configuration:

G Adaptation to various welding controllers with program number control and their different coding systems.

G Various routines used for ignition faults and monitoring of the number of ignition attempts.

G Re--ignition after faults.

G Restart options in case of faults in the seam.

G Configurable user--specific strategies and routines in case of faults.

G Selection of several defined patterns for mechanical weaving as well as the possibility of programming your own weave patterns.

Most options are stored in variables that are defined in the files “$CONFIG.DAT” and

“A20.DAT”.

Fundamental information on operator control as well as the menu--guided creation of programs at user level is provided in the documentation [Arc Welding, ArcTechDigital -- Operation].

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2 Description of the “ArcTechDigital” commands

2 Description of the “ArcTechDigital” commands

2.1 General

The general ArcTechDigital commands are described in this chapter. Softkey assignments and their meaning. Explanations of the main terms ARC ON, ARC SWI and ARC OFF with sequence diagrams and signal diagrams.

2.1.1 Keyswitch for program execution without welding

If the keyswitch function has been configured, the appropriate status must be active (“I_ENB_W_EXT.STATE” TRUE or FALSE according to the configuration). Otherwise welding is not possible.

2.1.2 Program run mode “GO”

Welding is only possible in the program run mode “GO”. “MSTEP” and “ISTEP” do not allow the program to run properly. More detailed information on selecting program run modes can be found in the chapter [Executing and stopping programs].

2.1.3 Switching on the welding process

After the computer runs up, (hot) welding is always deactivated, as is indicated by the welding torch being struck through on the left--hand status key bar. In order to be able to weld, this status key must be switched to the “HOT” position corresponding to the symbol shown on the left.

2.2 Start welding -- ARC ON

The command “ARC ON” contains the parameters for moving the welding torch (type of motion, velocity, etc.) from the home position to the start point of the seam, the start parameters (start delay) and the program number.

While the “ARC ON” program phase is being executed, the system scans the peripheral signal “I_WELD_COND” to check whether the welding controller is ready. When the welding torch reaches the ignition position, arc ignition is enabled by means of the signal

“O_WELD_START[ ]”.

When the arc has been struck, the welding power source supplies the signal

“I_START_MOVE[ ]”, as a result of which the robot starts to move in accordance with the programmed path and velocity. The signal “O_ACK_START[ ]” informs the welding controller

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2.2.1 Schematic sequence diagram ARC ON

For the purposes of simplicity, not all options are illustrated.

Initialization

Weld start

Current flowing

Ignition fault message

Activation of monitoring system

End ARC ON

ARC ON

N

Y

Process continued with the next ARC OFF or ARC SWITCH command

Prg_ON_MODE

< > 0

I_WELD_COND[ ]

O_WELD_START[ ]

I_START_MOVE[ ]

O_ACK_START[ ] Standby

test

(Option polled)

I_ENB_W_EXT [ ]

Positioning motion to ignition position

Synchronization Timeout

Y

(Poll to see if power source ready) (Keyswitch polled)

(Weld ON softkey)

Ignition program number output

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2 Description of the “ArcTechDigital” commands (continued) 2.2.2 Signal diagram ARC_ON and ARC_SWI

ARC_ON ARC_SWI

P0 P1 P2

I_WELD_COND [ ] I_ENB_W_EXT [ ] O_WELD_START [ ]

I_START_MOVE [ ] (O_ACK_START [ ] )

O_STROB_PGNO

Ignition time

if PRG_ON_MODE<> 0

Prog. no. = 1 Prog. no. = 2

P0’

P1’

P2’

PRG_SWI_MODE=2

Prog. no. = 1 Prog. no. = 2 Prog. no. = 3

PRG_SWI_MODE=1

2.3 Welding and ending seams -- ARC OFF

The welding command “ARC OFF” contains the program number for the power source, the

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2.3.1 Schematic sequence diagram ARC OFF

End ARC OFF ARC OFF

Current off I_WELD_END[ ]

O_SEAM_END[ ] Positioning motion to

the end point with weld velocity of the ARC_OFF command

O_STROB_PGNO[ ] Program number output

Program number transfer

Cancel weld start signal at end position

Y N

O_ACK_WELD_E[ ] Synchronization

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2 Description of the “ArcTechDigital” commands (continued) 2.3.2 Signal diagram ARC_OFF

ARC_SWI ARC_OFF

P0 P1

P2 Prog. no. = 6

PRG_SWI_MODE = 1

Prog. no. = 5

O_STROB_PGN0 [ ] O_SEAM_END [ ] I_WELD_END [ ]

Crater time +Burnback time +Gas postflow time

P0’

P1’

P2’

Prog. no. = 5

O_ACK_WELD_E[ ]

PRG_SWI_MODE=2PRG_SWI_MODE=1

2.4 Welding a seam in several sections -- ARC SWITCH

The command “ARC” (shown as “ARC SWITCH” in the menu) is used between the commands “ARC ON” and “ARC OFF” when the seam is divided into several sections with different motion and/or weld parameters.

ARC SWITCH contains the program number, the motion parameters for the current section of the seam, and also the parameters for the weld velocity and the mechanical weaving for the current section of the seam.

In the interest of efficient operations, approximate positioning should be used for motions in “ARC SWITCH” commands if exact positioning between individual seam sections is not absolutely essential.

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2.4.1 Schematic sequence diagram ARC SWITCH

Positioning motion to the end point with weld velocity of the ARC_SWI command

End ARC SWITCH ARC SWITCH

O_STROB_PGNO[ ] Program number output

Program number transfer

Process continued with the next ARC OFF or ARC SWITCH command

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2 Description of the “ArcTechDigital” commands (continued)

2.4.2 Signal diagram ARC_SWI

ARC_ON ARC_SWI

P0 P1 P2

I_WELD_COND [ ] I_ENB_W_EXT [ ] O_WELD_START [ ]

I_START_MOVE [ ] (O_ACK_START [ ] )

O_STROB_PGNO

Ignition time

if PRG_ON_MODE<> 0

Prog. no. = 1 Prog. no. = 2

PRG_SWI_MODE = 1

P0’

P1’

P2’

PRG_SWI_MODE=2

Prog. no. = 1 Prog. no. = 2 Prog. no. = 3

PRG_SWI_MODE=1

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3 Programs of the ArcTechDigital package

3 Programs of the ArcTechDigital package

3.1 Program structure

In the following block diagram the program structure of the KR C1 robot controller is shown in the “Welding robot” configuration.

The interface to the welding controller is implemented in the form of a configurable “handshake”. Settings for analog outputs as well as digital outputs and inputs are defined in the file “$Config.dat”.

.dat

.dat Cell.src

$Config.dat.

A20.src

IR_Stopm.src

Flt_serv_d.src P00.src

Weav_def_d.src Bas.src

Sps.sub Switch--off

routine after an interpreter stop GLOBALSA20

Global and application

data

Autom./Ext.

organization program

General handling of robot faults

Functions robotfor motion

Functions for Autom./Ext.

Handshake Check Home

User-- definable

fault service functions

Definition and parameters mechanicalfor weaving

Functions arcfor welding

Information about the hardware periphery of the robot controller can be found in the [Operating Handbook], chapter “Connector panel / Peripheral interfaces” and in the [Periphery] handbook.

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3.2 Overview of the “ArcTechDigital” files

The files listed below are included in the “ArcTechDigital” package. To assist you in finding relevant information, you will always see the symbols shown on the left with their file names throughout this documentation wherever the corresponding file or parts of it are described.

$Config.dat

Contains data specific to ArcTechDigital within the section

;FOLD ARCTECHDIGITAL GLOBALS

; FOLD Structures and Definitions ...

; ENDFOLD (Structures and Definitions)

; FOLD Main Options ...

; ENDFOLD (Main Options)

; FOLD ArcTech Outputs ...

; ENDFOLD (ArcTech Outputs)

; FOLD ArcTech Inputs ...

; ENDFOLD (ArcTech Inputs)

; FOLD Default Datasets ...

; ENDFOLD (Default Datasets)

; FOLD Statuskey Variables ...

; ENDFOLD (Statuskey Variables)

; FOLD Peripheral Output groups

; outputs weld start

...

; outputs acknowledge start move

...

; strobe program number

...

; outputs weld end

...

; outputs acknowledge weld_end

...

; outputs fault while arc on

...

; outputs stop weld after interrupt on seam

...

; outputs stop cleaner after interrupt

...

; outputs acknowledge fault

...

; output for fault message

...

; Wirefeed control

...

; ENDFOLD (Peripheral Output groups)

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3 Programs of the ArcTechDigital package (continued)

; FOLD Peripheral Input groups

; inputs as condition befor weld can start

...

; inputs start moving

...

; inputs weld is ended

...

; Counter for Interrupt definition

...

; inputs telling faults while welding

...

; input for external enable weld

...

; ENDFOLD (Peripheral Input groups)

; FOLD Internal System States ...

; ENDFOLD (Internal System States)

;ENDFOLD (ARCTECHDIGITAL GLOBALS)

For additional entries, the section User--defined Variables in the file “$CONFIG.DAT” is available.

A20.src Main program for arc welding with “ArcTechDigital”.

A20.dat Local data list for the program “A20.SRC”.

Flt_serv_d.src Program for fault strategies defined by the user, including ignition faults.

Fault service function (additional START error).

Flt_serv_d.dat Contains local data list for the program “FLT_SERV.SRC”.

Weav_def_d.src Definition of the patterns for mechanical weaving.

You will see the following symbols at various points in this documentation; they indicate whether manual changes are permitted in the section of a file being described.

Within the section / block shown, the changes or entries described must be made.

Within the section / block shown, no changes or entries may be made.

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4 ArcTechDigital -- basic settings

4 ArcTechDigital -- basic settings

4.1 Activating the ARC 20 option

You must make, or check, the basic settings described below for operation with

“ARC Tech 20”.

The “ARC20” option must always be activated (TRUE) when executing ArcTechDigital applications. At the same time it must be ensured that the variable “A10_OPTION” is inactive (DISABLED).

Corresponding entries using the menu function “Monitor -- Variable -- Single”

Variable Value for ArcTechDigital Characteristics

ARC20 TRUE (default) ArcTechDigital applications ARC20

FALSE Normal, except ArcTechDigital

4.2 Minimum configuration for power source interface

Signals for basic signal traffic are located in the configuration file.

Digital outputs

Fold ArcTech Outputs in “$Config.dat”

Digital outputs Configure physical output

$Config.dat

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Digitale Eingänge

Fold ArcTech Inputs in “$Config.dat”

Digital inputs Configure physical input

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4 ArcTechDigital -- basic settings (continued)

4.3 Minimum configuration for program number control

ArcTechDigital permits a variety of coding systems for program numbers for the purpose of ensuring compatibility with the various welding controllers that are used.

Some Folds from the file ”A20.dat” (in the directory “...\R1\TP\ArcTechDigital”):

Fold Main Options in “A20.dat”

Info

The signal declaration “SIGNAL ARCD_ProgNr $OUT[from] TO $OUT[to]” must correspond to the signal declaration of$Config.dat. If they do not correspond, the program number output will not function.

A20.dat

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Fold Internal States in “A20.dat”

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4 ArcTechDigital -- basic settings (continued) Fold Internal States in “A20.dat” (Fortsetzung)

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Fold ARC Messages in “A20.dat”

4.3.1 Meaning of the variables

Corresponding entry using the menu function “Monitor” → “Variable” → “Single”:

Variable Type Characteristics

PRG_NO.FIRST_BIT INT Represents the physical output number of the first bit. Default = 0

PRG_NO.LENGTH INT Specification of the number of bits. Default = 4 PRG_NO.PARITY INT Output number for the parity bit.

PRG_NO.CODING INT Coding of the program numbers.

-- Coding 1 = dual -- Coding 2 = 1 of n -- Coding 3 = 1 of (n--1)<

-- Coding 4 = BCD code Default = 1

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5 Principles of the definable signal table

5 Principles of the definable signal table

This section describes the definition of the “ArcTechDigital” peripheral interfaces, their specific adaptation as well as configurable options:

5.1 Overview, definition

5.1.1 Index tables for configuring physical outputs and inputs

For the purpose of configuring the physical outputs and inputs, two index tables are provided in the block “FOLD A20” in the file “$Config.dat”.

G Digital outputs Digital control signals from the robot controller to the (DIGITAL OUTPUTS) welding controller -- e.g. “Weld start”, “Gas manual”;

G Digital inputs Digital control signals from the welding controller to the (DIGITAL INPUTS) robot controller -- e.g. “Arc struck”, “Weld end”.

In these index tables the assignment of the physical outputs and inputs is defined and references are made to the corresponding signal tables of the controller. This has the advantage that if the terminal assignments for the periphery are changed, it is merely necessary to alter the index tables accordingly.

5.1.2 Signal tables for digital outputs and inputs

The interface concepts are variable. Configuring peripheral outputs and inputs by means of signal tables (so--called “triple groups”) allows processes to run synchronously. The capability of setting or scanning several signals makes it possible for various welding controllers to be adapted and the timing to be optimized.

Signal names of a group beginning with “O_...” designate digital outputs, and those with “I_...”

designate digital inputs.

These options are stored in variables that are defined in the file $CONFIG.DAT, FOLD A20 GLOBALS. Settings are stored in this file. You can use the edit function to set or change the values of the variables in “$CONFIG.DAT”.

In addition, menu--prompted viewing and alteration of the variable values is also possible..

For this purpose, a list can be opened in the status window by means of the menu “Monitor -- Variable -- Single”..The current value is shown when the variable name is entered. You change this value by entering a new value in the field “New value”.

A syntax check is not performed (for example, MIN and MAX values) when entries are made with the menu function “Monitor -- Variable -- Single” or when the file is edited.

Further information on the ARC 20 signal tables contained in “$CONFIG.DAT” is provided in the descriptions of the various welding commands (ARC ON, ARC OFF, ARC SWITCH) in Section 3.

$Config.dat

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5.2 Digital outputs

5.2.1 Index table for physical digital outputs

Altogether 15 digital outputs (O_WELD_CTRL[1] ... [O_WELD_CTRL[15]) are available;

their physical assignment (OUT_NR n) is freely definable.

Fold ArcTech Outputs in “$Config.dat”

Comment (signal name) Physical outputs

State at initialization

Example of corresponding entries using the menu function “Monitor -- Variable -- Single”:

O_WELD_CTRL[1].OUT_NR INT Assignment of the physical output, e.g. “10” (default: 0)

O_WELD_CTRL[1].INI BOOL

State at initialization (default: FALSE) FALSE = LOW TRUE = HIGH

O_WELD_CTRL[1].NAME_NAT[ ] STRING

20 characters between “ ”; please note that if the string is changed, any characters not overwritten (possibly because they are not visible in the window) will be retained.

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5 Principles of the definable signal table (continued) If you make any changes to the comments (signal name) “NAME_NAT” directly in the file “$CONFIG.DAT” please ensure that the length of the string between the quotation marks (“ ”) is exactly 20 characters long; use blanks if required.

If you use the menu function “Monitor -- Variable -- Single” to make changes, an error message is displayed if the string exceeds 20 characters.

The following example shows the assignment of the physical outputs and the signal states after initialization.

O_WELD_CTRL[1]={OUT_NR 10,INI FALSE,NAME_NAT[] “...”}

Output 10 DIGITAL OUTPUTS

Index table

INI _LOW^HIGH

WELD START

Array “O_WELD_CTRL[n] INI” contains the initial value when the INIT routine is running before reaching the block coincidence movement.

5.2.2 Signal tables for digital outputs 5.2.2.1 Definition of the signal states

Up to three outputs can be controlled and for each of these outputs the following parameters can be defined.

Output parameters Characteristics

{NO 0,PULS_TIME 0.0,STATE TRUE} Index disabled (ignored)

{NO 1,PULS_TIME 0.0,STATE TRUE} Index NO 1 (refers to field 1 of the index table “O_WELD_CTRL[1]”) with static HIGH signal

{NO 2,PULS_TIME 0.0,STATE FALSE} Index NO 2 (refers to field 2 of the index table “O_WELD_CTRL[2]”) with static LOW signal

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5.3 Digital inputs

5.3.1 Index table for physical digital inputs

Altogether 15 digital inputs (I_WELD_CTRL[1] ... I_WELD_CTRL[15]) are available; their physical assignment (IN_NRn) is freely definable. All “IN_NR” array elements are set to “0”

at the factory, meaning they are inactive. For the purpose of assigning the physical inputs, you can enter their corresponding numbers in the index table “DIGITAL INPUTS” of the file

“$CONFIG.DAT”:

Fold ArcTech Inputs in “$Config.dat”

Comment (signal name) Physical inputs

I_WELD_CTRL[1].IN_NR INT Assignment of the physical input, e.g. “2” (default: 0)

I_WELD_CTRL[1].NAME_NAT[ ] STRING 20 characters between “ ”; any characters not overwritten will be retained.

All “IN_NR” array elements are set to “0” at the factory, meaning they are inactive. The

“NAME_NAT[ ]” entries (signal name) are comments with a string length of 20 characters between the quotation marks (”...”) whose content may be altered while retaining the string length. Also see the note in Section 5.2.1.

The following example illustrates the assignment of the physical inputs. “I_WELD_CTRL[1]”

is assigned to physical input no. 2.

I_WELD_CTRL[1]={IN_NR 2,NAME_NAT[] “WELD SOURCE READY”}

DIGITAL INPUTS

Index table “DIGITAL INPUTS” ($CONFIG.DAT, FOLD A20 GLOBALS)

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5 Principles of the definable signal table (continued)

5.3.2 Signal tables for digital inputs

Up to three inputs can be scanned. The following states can be checked for each of these inputs:

Input parameter Characteristics

{NO 0,STATE TRUE} NO 0: input disabled (ignored)

{NO 1,STATE TRUE} A HIGH signal is awaited at the physical input referring to field 1 of the index table

“I_WELD_CTRL[ ]”.

{NO 2,STATE FALSE} A LOW signal is awaited at the physical input referring to field 2 of the index table

“I_WELD_CTRL[ ]”.

The following example shows a signal table from the file “$CONFIG.DAT” for a digital input.

The element “I_WELD_COND[1].NO” with the value “2” refers to array 2 of the index table

“DIGITAL INPUTS” (I_WELD_CTRL[15]) and thus to the physical input configured in it (see Section 5.3).

The element “STATE” specifies the awaited state, in this case “TRUE”.

; inputs as condition before weld can start DECL FCT_IN_T I_WELD_COND[3]

I_WELD_COND[1]={NO 1,STATE TRUE}

I_WELD_COND[2]={NO 0,STATE FALSE}

I_WELD_COND[3]={NO 0,STATE FALSE}

Signal name Status (TRUE = HIGH)

Index for addressing

in index table “I_WELD_CTRL[1 ]”

I_WELD_CTRL[1]={IN_NR 2,NAME_NAT[] “WELD SOURCE READY”}

DIGITAL INPUTS

Input 2 Signals to:

IN_NR 0 = Input disabled

Index table “DIGITAL INPUTS” ($CONFIG.DAT, FOLD A20 GLOBALS)

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6 Assignment of the signal grouping in normal operation

6 Assignment of the signal grouping in normal operation

The signal tables provide the capability of defining up to three signals, i.e. of activating up to three different physical outputs with different signal levels by means of one event.

There is of course no practical application for this setting; this example is merely intended to illustrate that the reason for missing or incorrect peripheral signals can be an incorrect value assignment. In such cases, it is therefore advisable to check the setting of the variables before looking for faults in the hardware.

6.1 Assignment of the outputs

The blocks with a gray background show the pre--configuration and do not normally need to be changed.

See also Section 4.2 Minimum configuration for power source interface.

6.1.1 Output group O_WELD_START [ ]

The “Weld Start” signal should be assigned to physical output 10. The signal level should be LOW at initialization and statically HIGH at the start of welding.

In the index table “Digital Outputs”, the designation (NAME_NAT) “Weld Start” and “INI” = FALSE are already entered in the first line “O_WELD_CONTROL[1]”. Assign the value “10”

to the variable “OUT_NR”.

Index table

INI ^LOW

WELD START HIGH

In the signal table “outputs weld start”, assign the value “1” to the variable “NO” in the first line “O_WELD_START[1]”. The signal level should be static, so enter the value “0.0” for

“PULS_TIME”.

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Entries made using the menu function “Monitor -- Variable -- Single”:

O_WELD_START[1].NO INT Assignment to element in index table, e.g. “1” (default: 0)

O_WELD_START[1].PULS_TIME REAL Pulse duration in secondsDefault: 0.0 (static) O_WELD_START[1].STATE BOOL Active stateDefault: FALSE

6.1.2 Output group O_ACK_START [ ]

The “O_ACK_START[ ]” signal informs the welding controller that the robot has started to move. Assign the value “11” to the variable “OUT_NR” and set “INI” = TRUE.

Index table

INI _LOW^HIGH

ACK START

Please note that “PULS_TIME” and “STATE” must be configured accordingly because the signal is not otherwise reset.

Example:

O_ACK_WELD_E[1]={NO 12, PULS_TIME 0.5,STATE TRUE}

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6 Assignment of the signal grouping in normal operation (continued)

6.1.3 Output group O_STROB_PGNO [ ]

The “TRIGGER PROGRAM NO.” signal to the welding controller defines the validity of the program number. Assign the value “12” to the variable “OUT_NR”.

STROB_PGNO Output 12

DIGITAL OUTPUTS Index table

INI _LOW^HIGH

Example:

O_STROB_PGNO[1]={NO 3, PULS_TIME 0.3,STATE TRUE}

6.1.4 Output group O_SEAM_END [ ]

End of seam reached, crater filling can begin -- O_SEAM_END[ ]. Assign the value “10” to the variable “OUT_NR”.

The configured signal cancels the WELD_START signal following the ARC_OFF command.

DIGITAL OUTPUTS Index table

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6.1.5 Output group O_ACK_WELD_E[ ]

Activated when the weld is finished and the crater has been filled, this output signal enables the program to be continued. Assign the value “14” to the variable “OUT_NR”.

Index table

INI _LOW^HIGH

ACK_WELD_E

Example:

O_ACK_WELD_E[1]={NO 12,PULS_TIME 0.5,STATE TRUE}

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6.2 Signal output groups for fault service function

6.2.1 Output group O_FLT_ARC_ON [ ]

This output signal group means that a fault occurred during the ARC_ON command. An ignition fault output is set and, at the same time, the “WELD_START” signal is cancelled. Assign the value “15” or “10” to the variable “OUT_NR”.

Output 10 Index table

INI

LOW HIGH O_WELD_CTRL[1]={OUT_NR 10,INI FALSE,NAME_NAT[] “...”}

FLT_ARC_ON Output 15

DIGITAL OUTPUTS

INI ^LOW

HIGH

ARC_ON

DIGITAL OUTPUTS

Index table

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6.2.2 Output group O_FLT_WELD [ ]

This output signal switches the welding off and sets an error message for the PLC. Assign the value “10” or “13” to the variable “OUT_NR”.

Index table

INI LOW

HIGH

FLT_WELD Output 13

Index table

INI

DIGITAL OUTPUTS

HIGH LOW

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6.2.3 Output group O_FLT_CLEAN [ ]

These output signals are used to reset the outputs for torch cleaning. Assign the value “9”

to the variable “OUT_NR”.

Index table

INI LOW

HIGH O_WELD_CTRL[6]={OUT_NR 9,INI FALSE,NAME_NAT[] “...”}

FLT_CLEAN

6.2.4 Output group O_ACK_FLT [ ]

These output signals are used to acknowledge error states. Assign the value “8” to the variable “OUT_NR”.

Index table

INI LOWHIGH

ACK_FLT

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6.3 Assignment of the inputs

The signal tables provide the capability of assigning up to three input signals to a condition.

References to the index table “Digital Inputs” can of course also be made from other signal tables. If several conditions must be met, accordingly more signals must be configured. The inputs are polled using logical ANDing.

The signal input groups with a gray background represent the pre--configuration from V2.3 onwards and do not normally need to be adapted.

See also Section 4.2 Minimum configuration for power source interface.

6.3.1 Input group I_WELD_COND [ ]

A precondition for welding is a successful check that the peripheral interface signal “WELD- ING SOURCE READY” is set. The signal table for “I_WELD_COND[ ]” reads as follows:

Signals awaited at:

Input 1 HIGH signal DIGITAL INPUTS

Index table

I_WELD_CTRL[1]={IN_NR 1,NAME_NAT[] “...”}

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6.3.2 Input group I_START_MOVE [ ]

After successful ignition the welding source supplies the “ARC STRUCK” signal. This signal is a precondition for the robot to start moving along the path, i.e. for continuation of the process. The corresponding signal table for “I_START_MOVE[ ]” is as follows:

DIGITAL INPUTS Index table

Signals awaited at:

Input 3 HIGH signal 6.3.3 Input group I_WELD_END [ ]

The “WELD END” signal is issued on completion of welding and end crater filling. The corresponding signal table for “I_WELD_END[ ]” is as follows:

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6.3.4 Input group I_WELD_FLT [ ]

The current welding process (ARC OFF, ARC SWITCH) is monitored, the welding controller supplying a signal in the event of a welding fault or malfunction occurring. The corresponding signal table for “I_WELD_FLT[ ]” is as follows:

I_WELD_FLT[2] and [3] generally monitor the following: shielding gas, cooling or wire feed.

I_WELD_FLT[1] generally monitors the current flow.

Signals awaited at:

Input 3 HIGH signal

Signals awaited at:

Input 4 HIGH signal

Signals awaited at:

Input 5 HIGH signal

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6.3.5 Polling of the external keyswitch (Hot/Cold)

This keyswitch is used for executing programs without “hot” welding and can only be configured if the welding system is equipped accordingly.

For this purpose, configuration of the physical input in the index table “DIGITAL INPUTS”

(see Section 5.3) is required, as too is the reference to this input in the section “input for external enable weld” of the $CONFIG.DAT file.

; input for external enable weld

DECL FCT_IN_T I_ENB_W_EXT={NO 6,STATE TRUE}

Corresponding entry using the menu function “Monitor -- Variable -- Single”:

I_ENB_W_EXT.NO INT Reference to the physical input in the index table “DIGITAL INPUTS” I_WELD_CTRL[ ].

Default: “6”

I_ENB_W_EXT.STATE BOOL Default: TRUE

I_WELD_CTRL[6] = {IN_NR 7...} This entry must be made

6.3.6 Time_out when polling the inputs

The wait time for digital input signals is limited by the variable

; time out while waiting (until fault message) REAL TIME_OUT1=3.0 ; [s]

After this configurable wait time, the program is stopped and a corresponding error message is displayed in the message window.

Entries made using the menu function “Monitor -- Variable -- Single”:

TIME_OUT1 REAL Wait time in seconds, default = 3s

If you receive the message “Object not found” (no. 2047) while viewing or modifying variables in the file “A20.DAT”, you must set the value of the variable $DATAPATH[] to

“/R1/A20” (the “ ” characters are part of the string).

A20.DAT

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7 Options for program number specification

7 Options for program number specification

7.1 Signal flow of the program numbers

Variable Type Characteristics

PRG_ON_MODE INT

Function for ARC ON.

-- PRG_ON_MODE=1: The program number is set when the point is reached.

-- PRG_ON_MODE=2: The program number is set before the point is reached, during the advance run.

Default: 1

PRG_SWI_MODE INT

Function for ARC SWITCH.

-- PRG_SWI_MODE=1: The program number is set when the point is reached.

-- PRG_SWI_MODE=2: The program number is set before the point is reached, during the advance run.

Default: 1

PRGNO_MIN INT Defines the smallest program number.

Default: 0

PRGNO_MAX INT

Defines the largest program number. *) Default: 15 corresponding to

PRG_NO.LENGTH = 4

PRGNO INT Current program number

PRG_ON_MODE and PRG_SWI_MODE are normally identical.

If PRG_ON_MODE=0, no O_ACK_START[ ] group is set.

7.2 Setting -- parity bit

A20.DAT

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7.3 Timing diagram – program number interface (a)

ARC_ONARC_SWIARC_SWIARC_OFF O_ACK_WELD._E[] O_ACK_START[] O_STROB_PGNO[] Prog.no.=4 Prog.no.=3P0 P1 P2

P0 P1 P2 PRG_SWI_MODE=1 Default

Prog.=2Prog.=3Prog.=4 Prog.=2forSGL

PRG_SWI_MODE=2

ARC_SWI Prog.=3forSGL butprog.no.3isalreadyset!butprog.no.4isalreadyset!

P rogr am num be r h ands ha ke

Prog.no.=2

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8 Setting the restart options

8 Setting the restart options

8.1 RESTART_OPTION

Possible reactions to welding faults on the seam are defined by means of the variable

“RESTART_OPT”.

; Variables:

INT RESTART_OPT=1 Default: 1 (range 0 -- 3)

Corresponding entries using the menu function “Monitor -- Variable -- Single” and characteristics:

Variable Value Characteristics -- Remedial action

0 In the event of control or welding faults, the seam is completed without welding after a restart.

1

After welding has been interrupted, the robot repositions the torch to the point of interruption. Welding is subsequently restarted.

If welding is interrupted by pressing the STOP key (interpreter stop), the program cannot be restarted.

Remedy: release the Start key after releasing the enab- ling switch.

RESTART_OPT

2

The same function as with “RESTART_OPT=1”, with the restriction that the number of permissible welding inter- ruptions is limited to a maximum value.

This maximum value is defined in the variable

“MAX_REA20”. If this value is exceeded, the seam is completed without welding and a corresponding message is generated.

The value specified in “MAX_REA20” (default = 3) is valid for the entire seam between the commands ARC ON and ARC OFF.

3 One or more user--defined fault service functions can be specified. Occurrence of a fault triggers a branch to the program “FLT_SERV.SRC”. Users can define their own fault service functions in this program.

8.1.1 Reaction to interpreter stop (STOP key)

Pressing the STOP key triggers an interpreter stop. The welding process and torch cleaning station are switched off by the constantly--running parallel program “SPS.SUB”. Welding is A20.DAT

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8.2 Configuration in event of ignition faults

8.2.1 Ignition repetition monitoring

The following variables are available for repeat ignition attempts on a seam:

The number of permissible restart attempts is programmed with the variable

“MAX_AUTO_R”, and the maximum number of welding faults per seam before an error message is generated is programmed with “MAX_REA20”.

; Variables:

INT MAX_AUTO_R=3 Maximum number of ignition attempts

Corresponding entries using the menu function “Monitor -- Variable -- Single”:

Variable Value Meaning for repeat ignition attempts MAX_AUTO_R 3 (default) Maximum number of restart attempts

8.3 Ignition fault message suppression option

The file “FLT_SERV.SRC” contains a fault service function with the designation “CASE 0”

as well as five other examples (CASE 1 ... 5) that can be freely configured.

The selection of the fault service subroutine to be used is made in the file “$CONFIG.DAT”

by means of the variable “A_FLT_SV_FCT” (default setting: 0):

INT A_FLT_SV_FCT=0 ; Number of user defined FLT_SERV-Subroutine

The entry “A_FLT_SV_FCT=0” corresponds to the subroutine “CASE 0” in the file

“FLT_SERV.SRC”. This procedure is suitable, for instance, for cutting through insulating oxide layers (for example during aluminum welding) when the wire contacts the workpiece in order to allow a fault--free ignition process in a restart.

A20.DAT

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9 Enumeration of the signal groups for fault service functions

9 Enumeration of the signal groups for fault service functions

If a welding or robot fault occurs during ignition or welding, the process is interrupted. Due to the variety of causes and types of faults, different fault service subroutines are required.

In addition to the standard measures included in the technology package, the user can configure his own fault service subroutines tailored to specific requirements.

The descriptions and information in this chapter require the error--free installation, commis- sioning and configuration of the robot and the hardware and software of the robot controller, the proper functioning of all peripheral equipment (welding controller, bus systems, etc.) according to their specifications, and correct programming and parameter settings.

9.1 Types of faults and causes

A distinction is made between application--specific seam faults caused by peripheral equipment (ignition faults, path faults), and faults attributable to the robot controller (e.g. IR_STOPMESS faults).

The possible causes of faults may be, for example:

G Ignition and seam faults resulting from unreliable operating states of the torch and/or welding equipment;

G Ignition and seam faults resulting from workpiece characteristics (e.g. oxidation);

G Media faults (e.g. shielding gas, welding wire, cooling);

G Controller faults (e.g. IR_STOPMESS faults, EMERGENCY STOP actuation);

G Operator control function “Interpreter STOP”.

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:

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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 reference manages general fault signals to the PLC.

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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.

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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.

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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”:

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

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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.

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11 Mechanical weaving (continued)

11.2 Weave patterns

The following weave patterns are included in the ArcTechDigital package:

No weaving (No Weave)

(Triangle)

Triangular double frequency (Dbl Triangle)

(Sgl Trapec)

double frequency (Dbl Trapec)

unsymmetrical (Uns Trapec)

(Spiral)

(Double 8)

Weave length Lateral deflection

(amplitude) Direction of welding s

s

Trapezoidal weaving

Trapezoidal weaving weaving Triangular weaving

Trapezoidal weaving

Spiral weaving

Figure--of--eight weaving

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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

--1

0.0 0.25

0.5 0.75 1.0 X

Y 2

1 n =

3

4 Weav_def_d.src

SWITCH FIGUR CASE 1 ;triangle

IF FG_NR1>0 THEN

$TECH[FG_NR1].FCT.ORDER=1

$TECH[FG_NR1].FCT.CPNUM=4

$TECH[FG_NR1].FCT.CPS1.X1=0.0

$TECH[FG_NR1].FCT.CPS1.Y1=0.0

$TECH[FG_NR1].FCT.CPS1.Y3=-1.0

$TECH[FG_NR1].FCT.CPS1.Y4=0.0 ENDIF

control points (CPNUM)

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

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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

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sin(x) cos(x)

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 corresponding 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 motions.

1’ 2’

3’ 4’

5’ 6’

--1 Y1

0 X

1,0 Y

0 1 2 3

4 5 6

--1 1

X 1,0

1 1’

2’ 2 3

6, 6’

3’

4’

5 5’

--1 4 1 Y

0 X

(--Y’) (Y’)

Deflection in direction of path Lateral deflection (amplitude)

Resultant: spiral

Weave length

$TECH[FG_NR1]...

(X 1 ... 6; Y 1 ... 6)

$TECH[FG_NR2]...

(X 1 ... 6; Y 1 ... 6)

The control points for the “Spiral” weave pattern are defined in the file “Weav_def_d.src”.

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CASE 6 ;spiral IF FG_NR1>0 THEN

$TECH[FG_NR1].FCT.CPNUM=6

$TECH[FG_NR1].FCT.CPS1.X1=0.0

$TECH[FG_NR1].FCT.CPS1.Y1=0.0

$TECH[FG_NR1].FCT.CPS1.Y4=-1.0

$TECH[FG_NR1].FCT.CPS1.Y6=0.0 ENDIF

The second block (A_FG_MECH2...) contains the parameters for the deflection in the direction of the path.

IF FG_NR2>0 THEN

$TECH[FG_NR2].FCT.CPS1.Y6=-1.0 ENDIF

11.2.3 “Figure--of--eight” weave pattern

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

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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 requirements 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 IF FG_NR1>0 THEN

Represented graphically:

1

--1

0.0 0.25 0.5 0.75 1.0

X

Y 2

1

= n

3

4

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

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CASE 1 ;triangle (phi = 180 degrees) IF FG_NR1>0 THEN

$TECH[FG_NR1].FCT.CPS1.Y2=-1.0

1

--1

0.0 0.25 0.5 0.75 1.0

X Y

1

n =

3

4 2

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

--1

0.0 0.4

X

Y 2 3

n = 1 4

5

6 0.6

0.2 0.8 1.0

control points (CPNUM) Weav_def_d.src

for power sources with program number control

SOFTWARE

KR C...

ArcTechDigital 2.2

for power sources with program number control

Configuration

for KUKA.KR C 5.2, 5.3, 5.4

Contents

1 General . . . . 7

2 Description of the “ArcTechDigital” commands . . . . 11

3 Programs of the ArcTechDigital package . . . . 19

4 ArcTechDigital -- basic settings . . . . 23

5 Principles of the definable signal table . . . . 29

7 Options for program number specification . . . . 47

8 Setting the restart options . . . . 49

9 Enumeration of the signal groups for fault service functions . . . . 51

11 Mechanical weaving . . . . 56

12 Error messages / troubleshooting . . . . 65

1 General

1.1 System requirements, Installation

1.2 Overview of the configurable options

2 Description of the “ArcTechDigital” commands

2.1 General

2.2 Start welding -- ARC ON

ARC_ON ARC_SWI

2.3 Welding and ending seams -- ARC OFF

ARC_SWI ARC_OFF

2.4 Welding a seam in several sections -- ARC SWITCH

ARC_ON ARC_SWI

3 Programs of the ArcTechDigital package

3.1 Program structure

3.2 Overview of the “ArcTechDigital” files

4 ArcTechDigital -- basic settings

4.1 Activating the ARC 20 option

4.2 Minimum configuration for power source interface

4.3 Minimum configuration for program number control

5 Principles of the definable signal table

5.1 Overview, definition

5.2 Digital outputs

5.3 Digital inputs

6 Assignment of the signal grouping in normal operation

6.1 Assignment of the outputs

6.2 Signal output groups for fault service function

6.3 Assignment of the inputs

7 Options for program number specification

7.1 Signal flow of the program numbers

7.2 Setting -- parity bit

7.3 Timing diagram – program number interface (a)

P rogr am num be r h ands ha ke

8 Setting the restart options

8.1 RESTART_OPTION

8.2 Configuration in event of ignition faults

8.3 Ignition fault message suppression option

9 Enumeration of the signal groups for fault service functions

9.1 Types of faults and causes

9.2 Ignition faults

9.4 Special feature IR_STOPMESS program

9.5 Configurable fault service functions

10 Further options

10.1 Program test in manual mode

10.2 Ignition fault message suppression option

10.3 Seam monitoring delay option

11 Mechanical weaving

11.1 Block selection response

11.2 Weave patterns

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--1

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