Professional Documents
Culture Documents
KR C...
ArcTechDigital 2.3
for power sources with program number control
Configuration
for KUKA.KR C 5.2, 5.3, 5.4, 5.5
Version: 00
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e Copyright
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers.
Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in
the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a
regular basis, however, and necessary corrections will be incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.
PD Interleaf
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Contents
1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
1.2
11
2.1
2.1.1
2.1.2
2.1.3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyswitch for program execution without welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program run mode GO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switching on the welding process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
11
11
2.2
2.2.1
2.2.2
11
12
13
2.3
2.3.1
2.3.2
13
14
15
2.4
2.4.1
2.4.2
15
16
17
19
3.1
Program structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
3.2
20
23
4.1
23
4.2
23
4.3
4.3.1
25
28
29
5.1
5.1.1
5.1.2
Overview, definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index tables for configuring physical outputs and inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signal tables for digital outputs and inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
29
29
5.2
5.2.1
5.2.2
5.2.2.1
Digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index table for physical digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signal tables for digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Definition of the signal states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
30
31
31
5.3
5.3.1
5.3.2
Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index table for physical digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signal tables for digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
32
33
35
6.1
35
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6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
35
36
37
37
38
6.2
6.2.1
6.2.2
6.2.3
6.2.4
39
39
40
41
41
6.3
6.3.1
6.3.2
6.3.3
6.3.4
6.3.5
6.3.6
42
42
43
43
44
45
45
47
7.1
47
7.2
47
7.3
48
49
8.1
8.1.1
RESTART_OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reaction to interpreter stop (STOP key) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
49
8.2
8.2.1
50
50
8.3
50
51
9.1
51
9.2
9.2.1
Ignition faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signal output group O_FLT_ARC_ON[ ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
51
9.3
9.3.1
9.3.2
9.3.3
9.3.4
9.3.5
9.3.6
51
51
52
52
52
52
53
9.4
9.4.1
53
53
9.5
9.5.1
54
54
10
Further options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
10.1
55
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10.2
55
10.3
55
11
Mechanical weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
11.1
56
11.2
11.2.1
11.2.2
11.2.3
11.2.4
11.2.4.1
11.2.4.2
11.2.5
Weave patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Two--dimensional weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Creating the Spiral weave pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure--of--eight weave pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing and creating patterns for mechanical weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing existing weave patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Creating your own weave patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes on mechanical weaving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
59
59
61
62
62
63
64
12
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
66
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General
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
Adaptation to the peripheral equipment and configurable options of the digital outputs.
Use of the function generators for two--dimensional mechanical weaving as well as the
possibility of configuring your own weave patterns.
Adaptation to various welding controllers with program number control and their different coding systems.
Various routines used for ignition faults and monitoring of the number of ignition attempts.
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
required in files, and parameter lists.
Chapter 3 provides information on the programs and files contained in the ArcTechDigital
package. Information and notes on ArcTechDigital--specific basic settings are provided in
Chapter 4.
Chapter 5 explains adaptation to the peripheral equipment. The configuration of the digital
input and output groups is dealt with in Chapter 6.
The transfer of program numbers is explained in Chapter 7. Chapter 8 contains information
on the restart options.
Chapter 9 finally deals with fault situations and fault service functions. Types of faults that
can occur during the ignition and welding processes, their possible causes and appropriate
corrective measures are described.
Further ArcTechDigital settings can be found in Chapter 10.
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ArcTechDigital 2.3
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
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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1.2
General (continued)
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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
2.1.2
2.1.3
2.2
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2.2.1
ARC ON
Positioning motion
to ignition position
Initialization
(Option polled)
(Poll to see if power source ready)
(Keyswitch polled)
(Weld ON softkey)
Standby
test
I_WELD_COND[ ]
I_ENB_W_EXT [ ]
Prg_ON_MODE
<>0
Ignition program
number output
Weld start
O_WELD_START[ ]
Current
flowing
I_START_MOVE[ ]
N
Y
Timeout
Y
Synchronization
O_ACK_START[ ]
Activation of
monitoring
system
End
ARC ON
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2.2.2
ARC_SWI
PRG_SWI_MODE = 1
ARC_ON
P0
P1
P2
I_WELD_COND [ ]
Prog. no. = 2
Prog. no. = 1
I_ENB_W_EXT [ ]
Ignition
time
O_WELD_START [ ]
I_START_MOVE [ ]
(O_ACK_START [ ] )
if PRG_ON_MODE<> 0
PRG_SWI_MODE = 2
O_STROB_PGNO
2.3
P0
P1
P2
Prog. no. = 1
Prog. no. = 2
Prog. no. = 3
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2.3.1
ARC OFF
Positioning motion to
the end point with
weld velocity of the
ARC_OFF command
Program number
transfer
O_STROB_PGNO[ ]
O_SEAM_END[ ]
Current off
I_WELD_END[ ]
Y
Synchronization
O_ACK_WELD_E[ ]
End
ARC OFF
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2.3.2
PRG_SWI_MODE = 1
ARC_SWI
ARC_OFF
P0
P1
P2
Prog. no. = 6
Prog. no. = 5
PRG_SWI_MODE = 1
O_STROB_PGN0 [ ]
Crater time
+
Burnback time
+
Gas postflow time
O_SEAM_END [ ]
I_WELD_END [ ]
PRG_SWI_MODE = 2
O_ACK_WELD_E[ ]
2.4
P0
P1
Prog. no. = 5
P2
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ArcTechDigital 2.3
2.4.1
ARC SWITCH
Positioning motion to
the end point with
weld velocity of the
ARC_SWI command
Program number
transfer
End
ARC SWITCH
O_STROB_PGNO[ ]
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2.4.2
ARC_SWI
PRG_SWI_MODE = 1
ARC_ON
P0
P1
P2
I_WELD_COND [ ]
Prog. no. = 2
Prog. no. = 1
PRG_SWI_MODE = 1
I_ENB_W_EXT [ ]
Ignition
time
O_WELD_START [ ]
I_START_MOVE [ ]
(O_ACK_START [ ] )
if PRG_ON_MODE<> 0
PRG_SWI_MODE = 2
O_STROB_PGNO
P0
P1
P2
Prog. no. = 1
Prog. no. = 2
Prog. no. = 3
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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.
$Config.dat.
Cell.src
IR_Stopm.src
A20
GLOBALS
Global and
application
data
Autom./Ext.
organization
program
General
handling
of robot faults
Bas.src
Functions
for
robot
motion
Flt_serv_d.src
P00.src
User-definable
fault
service
functions
Functions for
Autom./Ext.
Handshake
Check Home
Weav_def_d.src
A20.src
Definition and
parameters
for
mechanical
weaving
Functions
for
arc
welding
.dat
.dat
Sps.sub
Switch--off
routine
after an
interpreter stop
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
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;
;
A20.dat
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
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4.1
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
ARC20
4.2
TRUE
FALSE
Characteristics
ArcTechDigital applications
Normal, except ArcTechDigital
$Config.dat
Signals for basic signal traffic are located in the configuration file.
Digital outputs
Fold ArcTech Outputs in $Config.dat
Digital outputs
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ArcTechDigital 2.3
Digitale Eingnge
Fold ArcTech Inputs in $Config.dat
Digital inputs
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4.3
A20.dat
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.
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Fold Internal States in A20.dat
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Fold ARC Messages in A20.dat
4.3.1
Type
Characteristics
PRG_NO.FIRST_BIT
INT
PRG_NO.LENGTH
INT
PRG_NO.PARITY
INT
PRG_NO.CODING
INT
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5.1
Overview, definition
5.1.1
$Config.dat
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 OUTPUTS)
G Digital inputs
(DIGITAL INPUTS)
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
$Config.dat
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.
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ArcTechDigital 2.3
5.2
Digital outputs
5.2.1
Physical outputs
State at initialization
Example of corresponding entries using the menu function Monitor -- Variable -- Single:
Variable
O_WELD_CTRL[1].OUT_NR
O_WELD_CTRL[1].INI
O_WELD_CTRL[1].NAME_NAT[ ]
Type
INT
BOOL
STRING
Characteristics
Assignment of the physical output,
e.g. 10 (default: 0)
State at initialization
(default: FALSE)
FALSE = LOW
TRUE = HIGH
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.
All O_WELD_CTRL[1].OUT_NR array elements are set to 0 at the factory, meaning they
are inactive. The element INI defines the state to which the respective physical output
OUT_NR is to be set on initialization. The value FALSE sets the output to LOW, the
value TRUE to HIGH.
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!).
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If you make any changes to the comments (signal name) NAME_NAT directly in the
file $CONFIG.DAT please ensure that the length of the string between the quotation
marks ( ) is exactly 20 characters long; use blanks if required.
If you use the menu function Monitor -- Variable -- Single to make changes, an error
message is displayed if the string exceeds 20 characters.
The following example shows the assignment of the physical outputs and the signal states
after initialization.
Index table
DIGITAL OUTPUTS
O_WELD_CTRL[1]={OUT_NR 10,INI FALSE,NAME_NAT[] ...}
Output 10
WELD START
INI
HIGH
LOW
Array O_WELD_CTRL[n] INI contains the initial value when the INIT routine is running
before reaching the block coincidence movement.
5.2.2
5.2.2.1
Characteristics
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ArcTechDigital 2.3
5.3
Digital inputs
5.3.1
Physical inputs
Example of corresponding entries using the menu function Monitor -- Variable -- Single:
Variable
I_WELD_CTRL[1].IN_NR
I_WELD_CTRL[1].NAME_NAT[ ]
Type
INT
STRING
Characteristics
Assignment of the physical input,
e.g. 2 (default: 0)
20 characters between ; any characters not overwritten will be retained.
All IN_NR array elements are set to 0 at the factory, meaning they are inactive. The
NAME_NAT[ ] entries (signal name) are comments with a string length of 20 characters
between the quotation marks (...) whose content may be altered while retaining the
string length. Also see the note in Section 5.2.1.
The following example illustrates the assignment of the physical inputs. I_WELD_CTRL[1]
is assigned to physical input no. 2.
Index table DIGITAL INPUTS ($CONFIG.DAT, FOLD A20 GLOBALS)
DIGITAL INPUTS
I_WELD_CTRL[1]={IN_NR 2,NAME_NAT[] WELD SOURCE READY}
Signals to:
Input 2
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5.3.2
Characteristics
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}
Status (TRUE = HIGH)
Signal name
Signals to:
Input 2
Example of corresponding entries using the menu function Monitor -- Variable -- Single:
Variable
I_WELD_COND[1].NO
I_WELD_COND[1].STATE
Type
INT
BOOL
Characteristics
Assignment of the physical input,
e.g. 2 (default: 0)
Awaited state
Default: FALSE
Two other input signals are defined in this example as the second and third conditions that
have to be met before welding can be started.
Information on the definition of the terms index table and signal table can be found in
Section 6.1.
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6.1
6.1.1
Index table
DIGITAL OUTPUTS
O_WELD_CTRL[1]={OUT_NR 10,INI FALSE,NAME_NAT[] ...}
Output 10
INI
LOW
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.
The element PULSE_TIME allows the programming of pulse times, if they are not overwritten by the current programming by means of inline forms or parameter lists. An output can
be static (PULSE_TIME 0.0) or be output in the form of a pulse, in which case the pulse duration is programmed in seconds. For example, PULSE_TIME 0.3 corresponds to a pulse
duration of 0.3 seconds.
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Entries made using the menu function Monitor -- Variable -- Single:
Variable
O_WELD_START[1].NO
6.1.2
Type
INT
Characteristics
Assignment to element in index table,
e.g. 1 (default: 0)
O_WELD_START[1].PULS_TIME
REAL
O_WELD_START[1].STATE
BOOL
Active state
Default: FALSE
Output 11
INI
ACK START
HIGH
LOW
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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6.1.3
Output 12
STROB_PGNO
HIGH
LOW
INI
Please note that PULS_TIME and STATE must be configured accordingly because
the signal is not otherwise reset.
Example:
O_STROB_PGNO[1]={NO 3, PULS_TIME 0.3,STATE TRUE}
6.1.4
Output 10
HIGH
LOW
INI
ARC_ON
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6.1.5
Output 14
INI
ACK_WELD_E
HIGH
LOW
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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6.2
6.2.1
Output 10
INI
HIGH
LOW
Output 15
INI
FLT_ARC_ON
HIGH
LOW
ARC_ON
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6.2.2
Output 10
HIGH
LOW
INI
Output 13
INI
FLT_WELD
HIGH
LOW
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6.2.3
Output 9
FLT_CLEAN
INI
6.2.4
HIGH
LOW
Output 8
INI
ACK_FLT
HIGH
LOW
Please note that PULS_TIME and STATE must be configured accordingly because
the signal is not otherwise reset.
Example:
O_ACK_FLT[1]={NO 4,PULS_TIME 1.0,STATE TRUE}
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6.3
6.3.1
Signals awaited
at:
Input 1
HIGH signal
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6.3.2
Signals awaited
at:
Input 3
HIGH signal
6.3.3
Signals awaited
at:
Input 2
LOW signal
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6.3.4
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
Type
INT
BOOL
6.3.6
Characteristics
Reference to the physical input in the index
table DIGITAL INPUTS I_WELD_CTRL[ ].
Default: 6
Default: TRUE
This entry must be made
A20.DAT
Type
Characteristics
TIME_OUT1
REAL
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).
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7.1
Type Characteristics
INT
PRG_SWI_MODE
INT
PRGNO_MIN
INT
PRGNO_MAX
INT
PRGNO
INT
PRG_ON_MODE
7.2
Parity 0 = default
n = output number
positive even
negative odd
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P2
Prog. no. = 2
P1
P0
O_STROB _PGNO [ ]
P2
P1
P0
O_ACK_START [ ]
Prog. no. = 3
Prog. = 2
ARC_SWI
Prog. no. = 4
Prog. = 3
ARC_SWI
Prog. = 4
ARC_SWI
PRG_SWI_MODE= 2
PRG_SWI_MODE=1
Default
ARC_OFF
7.3
O_ACK_WELD._E [ ]
ARC_ON
ArcTechDigital 2.3
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RESTART_OPTION
Possible reactions to welding faults on the seam are defined by means of the variable
RESTART_OPT.
A20.DAT
; Variables:
INT RESTART_OPT=1
Default: 1 (range 0 -- 3)
Corresponding entries using the menu function Monitor -- Variable -- Single and characteristics:
Variable
Value
0
RESTART_OPT
8.1.1
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8.2
8.2.1
A20.DAT
; Variables:
INT MAX_AUTO_R=3
8.3
Variable
Value
MAX_AUTO_R
3 (default)
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9.1
9.2
Ignition faults
9.2.1
9.3
9.3.1
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9.3.2
9.3.3
9.3.4
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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9.3.6
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.
9.4
9.4.1
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Once the causes have been eliminated, the technologies are switched back on again one
after the other.
Opened Folds:
9.5
9.5.1
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10
10
Further options
10.1
Further options
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
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
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
process.
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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
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11
11.2
Weave patterns
The following weave patterns are included in the ArcTechDigital package:
s
Lateral deflection
(amplitude)
Weave length
Direction of welding
s
No weaving
(No Weave)
Triangular
weaving
(Triangle)
Triangular
weaving
double frequency
(Dbl Triangle)
Trapezoidal
weaving
(Sgl Trapec)
Trapezoidal
weaving
double frequency
(Dbl Trapec)
Trapezoidal
weaving
unsymmetrical
(Uns Trapec)
Spiral weaving
(Spiral)
Figure--of--eight
weaving
(Double 8)
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These weave patterns are defined in the file Weav_def_d.src.
DEF
...
CASE 1 ;triangle
Triangular weaving,
double frequency (DBL_TRI)
CASE 3 ;trapezoid
Trapezoidal weaving,
double frequency (DBL_TRP)
CASE 6 ;spiral
CASE 7 ;eight
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.
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.X2=0.25
$TECH[FG_NR1].FCT.CPS1.Y2=1.0
$TECH[FG_NR1].FCT.CPS1.X3=0.75
$TECH[FG_NR1].FCT.CPS1.Y3=-1.0
$TECH[FG_NR1].FCT.CPS1.X4=1.0
$TECH[FG_NR1].FCT.CPS1.Y4=0.0
ENDIF
0.5
0.0
--1
0.75
0.25
1.0 X
4
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
W--parameter list 2 Mechanical Weaving with menu prompting.
Additional information on menu--guided programming can be found in the documentation
[Arc Welding, ArcTechDigital -- Operation].
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11
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.
Weav_def_d.src
(Y)
(--Y)
(Y)
(--Y)
Torch
Weave width
A20.src
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
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Superposition of cosine on sine
Without path
motion
0
1
sin(x)
With path
motion
Welding direction
1
cos(x)
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.
Lateral deflection (amplitude)
Y
1
$TECH[FG_NR1]...
(X 1 ... 6; Y 1 ... 6)
6 X
1,0
--1
4
Y
Deflection in
direction of path
3
$TECH[FG_NR2]...
(X 1 ... 6; Y 1 ... 6)
X
1,0
Resultant: spiral
1
2
0
Y
1
2
(--Y)
(Y)
Weave length
1 2
5 6
5
--1
--1
6, 6
The control points for the Spiral weave pattern are defined in the file Weav_def_d.src.
The parameters for the lateral deflection are stored in the first block (...NR1...).
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11
11.2.3
1
2
0
0,5
Resultant: eight
Y
3
9
5
1
6
--1
Deflection in
Y direction of path
$TECH[FG_NR1]...
(X 1 ... 6; Y 1 ... 6)
8
7
5
1
--0,5
$TECH[FG_NR2]...
(X 1 ... 6; Y 1 ... 6)
--1
X
6
Weave length
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11.2.4
0.0
0.25
0.5
0.75
1.0
4
--1
n = control points (CPNUM)
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.
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11
1
0.25
0.0
0.5
0.75
1.0
4
--1
--1
0.2
0.4
0.6
0.8
1.0
6
5
n = control points (CPNUM)
The first value for X must be 0 (zero) and the last value must be 1. Multiple X values that
are identical cannot be used.
The number of control points determined (CPNUM) as well as the X and Y values can be
entered, for example, in the block CASE 8 ;default as minimums and flag for beginning of
the file Weav_def_d.src, as shown in the following.
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Weav_def_d.src CASE 8 ;Trapez - Dreieck
$TECH[A_FG_MECH1].FCT.ORDER=1
$TECH[FG_NR1].FCT.CPNUM=6
$TECH[FG_NR1].FCT.CPS1.X1=.0
$TECH[FG_NR1].FCT.CPS1.Y1=.0
$TECH[FG_NR1].FCT.CPS1.X2=.2
$TECH[FG_NR1].FCT.CPS1.Y2=1.0
$TECH[FG_NR1].FCT.CPS1.X3=.4
$TECH[FG_NR1].FCT.CPS1.Y3=1.0
$TECH[FG_NR1].FCT.CPS1.X4=.6
$TECH[FG_NR1].FCT.CPS1.Y4=.0
$TECH[FG_NR1].FCT.CPS1.X5=.8
$TECH[FG_NR1].FCT.CPS1.Y5=-1.0
$TECH[FG_NR1].FCT.CPS1.X6=1.0
$TECH[FG_NR1].FCT.CPS1.Y6=.0
ENDIF
11.2.5
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12
12
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
it has been confirmed.
12.2
Message time
The message time indicates the time at which the message was generated.
12.3
Message number
With the aid of the message number, the corresponding cause, effect and remedy can quickly
be located in the list of error messages.
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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
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12
1
Message text
Cause
-- ARC20 = FALSE
Monitor
-- In ARC ON command
Effect
Remedy
-- Set ARC20 to TRUE, stop and restart Submit interpreter, data backup
Message text
Cause
Monitor
-- In ARC ON command
Effect
Remedy
Message text
Cause
Monitor
Effect
Remedy
-- $PRO_I_O[ ] = R1/SPS ( )
Message text
Cause
Monitor
-- In ARC ON command
Effect
Remedy
Message text
Cause
Monitor
-- ARC_ON command
Effect
Remedy
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6
Message text
Cause
Monitor
-- In ARC ON command
Effect
Remedy
Message text
Cause
-- Power source does not switch welding off or does so too late
-- Incorrect configuration
-- Incorrect burnback parameters
Monitor
Effect
Remedy
Message text
Cause
Monitor
Effect
Remedy
Message text
Cause
Monitor
Effect
Remedy
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Index
Zeichen
$CONFIG.DAT, 29
$Config.dat, 19, 20
$STOPMESS, 51
A
A.WEAVAMP_MECH, 59
A.WEAVLEN_MECH, 59
A_FLT_SV_FCT, 50
A10.SRC, 59
A20.dat, 21
A20.src, 21
Activating, 23
Adaptation to the periphery, 29
ARC OFF, 13, 14
ARC ON, 11, 12
ARC SWITCH, 15, 16
ARC20, 23
I
I_ENB_W_EXT.NO, 45
I_ENB_W_EXT.STATE, 45
I_WELD_CTRL[ ], 32
Ignition faults, 51
Ignition repetition, 50
IN_NR, 32
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
B
Basic settings, 23
Block selection response, 56
C
Changing existing weave patterns, 62
Control points (CPNUM), 58
Coordinate system TTS, 56
Crater filling, 37
Creating your own weave patterns, 63
D
DIGITAL INPUTS, 32
Digital inputs, 29
Digital inputs (physical), 32
Digital outputs, 23, 29
Digital outputs (physical), 30
Digitale Eingnge, 24
DRIVES OFF, 51
M
MAX_AUTO_R, 50
Maximum weave frequency, 64
Mechanical weaving, 56
Minimum configuration, 23, 25
Motion characteristics of the robot, 64
E
EMERGENCY STOP, 51
External keyswitch, 45
NAME_NAT[ ], 30, 32
Notes on mechanical weaving, 64
Index -- i
Index
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
Power source interface, 23
PRG_NO.CODING, 28
PRG_NO.FIRST_BIT, 28
PRG_NO.LENGTH, 28
PRG_NO.PARITY, 28
PRG_ON_MODE, 47
PRG_SWI_MODE, 47
PRGNO_MAX, 47
PRGNO_MIN, 47
PROC_IN_T1, 55
Program number control, 25
Program number specification, 47
Program run mode GO, 11
Program structure, 19
Program test, 55
PULS_TIME, 31
STATE, 31
STOP key, 49
Switching on the welding process, 11
System requirements, 8
T
Time_out, 45
Timing diagram, 48
Trapezoidal weaving, 57
Triangular weaving, 57
Triple groups, 29
Two--dimensional weaving, 59
Types of faults, 51
R
Resonant frequency, 64
RESTART_OPT, 49
RESTART_OPTION, 49
W
WEAV_DEF.SRC, 58, 62
Weav_def_d.src, 21
S
Schematic sequence diagram ARC OFF, 14
Schematic sequence diagram ARC ON, 12
Schematic sequence diagram ARC SWITCH,
16
Seam error, 52
Signal APPL_RUN, 53
Signal diagram ARC_OFF, 15
Signal diagram ARC_ON, 13
Signal diagram ARC_SWI, 17
Signal flow of the program numbers, 47
Weave length, 58
Weave patterns, 57
Weave patterns, changing of, 62
Weave patterns, creating of, 63
Weaving, 56
Weaving, two--dimensional, 59
Welding a seam in several sections -- ARC
SWITCH, 15
Welding and ending seams -- ARC OFF, 13
Index -- ii