KST AD Gripperspottech 23 En

KUKA.Gripper&SpotTech2.3 07.06.00 en 1 von 56

SOFTWARE

KR C...

KUKA.Gripper-- and SpotTech 2.3

for KUKA System Software (KSS) 5.x, 7.0

Issued: 10 July 2006 Version: 00

2 von 56 KUKA.Gripper&SpotTech2.3 07.06.00 en

e Copyright 2006

KUKA Roboter GmbHThis documentation or excerpts therefrommay 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, inthe case of a replacement or service work.We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepanciescannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on aregular basis, however, and necessary corrections will be incorporated in subsequent editions.Subject to technical alterations without an effect on the function.

KUKA Interleaf

3 von 56KUKA.Gripper&SpotTech2.3 07.06.00 en

Contents

1 General 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Installation / uninstallation / update 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 GripperTech 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Basic gripper functions 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.1 Type 1 2 outputs, 4 inputs, 2 switching states 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.2 Type 2 2 outputs, 2 inputs, 3 switching states 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.3 Type 3 2 outputs, 2 inputs, 3 switching states 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.4 Type 4 3 outputs, 2 inputs, 3 switching states 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.5 Type 5 2 outputs, 4 inputs, 2 switching states 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.6 Freely programmable type 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.6.1 Programming example 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.7 Initialization and configuration examples 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Manually operating a gripper 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Programming gripper functions 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.1 Gripper 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.2 Check Gripper 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 SpotTech 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Basic SpotTech user functions 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1.1 Range of commands 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1.2 The functions SPOT and RETRACT 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Programming and operation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.1 General information on programming 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.1.1 Variables in input boxes of the inline forms 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.1.2 Overview of the inline forms 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.2 Spot welding (SPOT) 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.3 Types of motion 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.3.1 Point--to--point (PTP) motion 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.3.2 Motion along a straight line (LIN) 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.3.3 Motion along a circular path (CIRC) 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.3.4 Activating/deactivating collision detection 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.4 Programming a weld spot (SPOT) 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.4.1 Menu 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.4.2 The inline form and the parameter lists for the welding command SPOT 24. . . . . . . . . . . . .4.2.4.3 Selecting the welding gun (Gun = n) 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.4.4 Retract stroke after the welding process (RETR OPN / CLO) 25. . . . . . . . . . . . . . . . . . . . . . . .4.2.4.5 Weld parameter list 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.5 Opening/closing the welding gun retract stroke (RETRACT) 26. . . . . . . . . . . . . . . . . . . . . . . . .4.2.5.1 Types of motion 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.5.2 Programming the retract stroke (RETRACT) 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.6 Motion commands 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.7 Reorientation of the welding gun 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Program example 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.1 Creating a new program 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



4.3.1.1 Welding the first spot sequence 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.1.2 Welding the second spot sequence 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.1.3 Moving from the end of the spot seam to the home position 36. . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Altering existing programs 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4.1 Altering command lines 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4.2 Deleting command lines 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4.3 Adding commands to an existing program 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4.3.1 Description of the alteration 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4.3.2 Changing the position of the welding gun (point in space P10) 39. . . . . . . . . . . . . . . . . . . . . . . .4.4.3.3 Reorientation of the welding gun -- inserting the command Motion (P11) 39. . . . . . . . . . . . . .4.4.3.4 Moving to the point in space P12 -- inserting the command Motion 40. . . . . . . . . . . . . . . . . . .4.4.3.5 Welding spot P13 -- inserting the command SPOT 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4.3.6 Moving to the weld spot P16 and welding 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4.3.7 Moving to the home position 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 SpotTech configuration 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.1 Program sequence 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.2 Retract stroke (RETRACT) and working stroke (SPOT) 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.3 Early closing of the gun (PRESPOT) 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 Components of the SpotTech package 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6.1 Program structure 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6.2 SPOT Tech--specific files 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 Adaptation to the periphery, configurable options 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.7.1 FOLD SPOT in the file $CONFIG.DAT 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.7.2 The user--specific program USERSPOT.SRC 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.7.2.1 Schematic sequence diagram for SPOT (without RETRACT) 47. . . . . . . . . . . . . . . . . . . . . . . .4.7.2.2 Schematic sequence diagram for SPOT (with RETRACT) 48. . . . . . . . . . . . . . . . . . . . . . . . . . .4.7.2.3 Robot controller -- welding controller interface 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.7.2.4 Program example for the file USERSPOT.SRC 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 Program example 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9 Manual operation of the welding gun using the status keys 53. . . . . . . . . . . . . . . . . . . . . . . . . .4.9.1 Separate control of RETRACT and SPOT 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.9.1.1 Definition of function type and assignment of physical outputs 53. . . . . . . . . . . . . . . . . . . . . . . .4.9.2 Manual control of RETRACT and SPOT in series 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



1 General

The software packagesGripperTech andSpotTech are supplied together on aSetupCDandexpand the scope of the basic KRC software.

-- The functions of the GripperTech technology package (gripper programming) enable therobot system to control and monitor tools and devices in its work environment.

-- TheSpotTech technology package is used for theconvenient programmingof spotweldingapplications.

2 Installation / uninstallation / update


2 Installation / uninstallation / update

From system software version 5.1 onwards, technology packages are offered exclusively asadd--on software modules. These are available on CD--ROM. Should you be interested inpurchasing further modules, please contact KUKA Support.

The installation procedure is the same for all technology packages and is described in aseparate documentation module.

The installation, uninstallation, reinstallation and update of technology packagesare described in detail in the documentation Installation/Uninstallation/Update ofTech Packages.



3 GripperTech

3.1 Basic gripper functions

TheGripperTech technology package includes five basic types of gripper control, withwhoselogic functions the majority of applications that occur are covered. If these basic types proveto be insufficient at any time, any additional gripper functions can be freely programmed.

Each gripper must be assigned a function type. If a gripper is to be temporarily orpermanently excluded from use, it must be assigned gripper type 0.

3.1.1 Type 1 2 outputs, 4 inputs, 2 switching states

e.g. a simple gripper with the functions OPEN and CLOSE;

State OUT1 OUT2 IN1 IN2 IN3 IN4

A TRUE FALSE TRUE FALSE TRUE FALSE

B FALSE TRUE FALSE TRUE FALSE TRUE


e.g. a slide with a center position;

State OUT1 OUT2 IN1 IN2

A TRUE FALSE TRUE FALSE

B FALSE TRUE FALSE TRUE

C FALSE FALSE FALSE FALSE


e.g. a vacuum gripper with the functions VACUUM, BLOW and OFF;

State OUT1 OUT2 IN1 IN2

A TRUE FALSE TRUE FALSE

B FALSE TRUE FALSE TRUE

C FALSE FALSE FALSE FALSE


The same as type 3 but with three control outputs (type 3 has two outputs);

State OUT1 OUT2 OUT3 IN1 IN2

A TRUE FALSE FALSE TRUE FALSE

B FALSE TRUE TRUE FALSE TRUE

C FALSE TRUE FALSE FALSE FALSE

3 GripperTech (Fortsetzung)



The same as type 1 but with a pulse signal instead of a continuous signal.

State OUT1 OUT2 IN1 IN2 IN3 IN4

A TRUE FALSE TRUE FALSE TRUE FALSE

B FALSE TRUE FALSE TRUE FALSE TRUE

In contrast to gripper type 1, a continuous signal is not applied here, but a pulse of variableduration is transmitted whenever the signal level changes. It is set by modifying the variableGRP_PULSE_TI.

During controller operation, this variable can be altered bymeans of the Modify -- Variableoptions in the Monitor menu.

Moredetailed informationon how tomodify the values of systemvariables during controlleroperation can be found in the chapter Monitor Functions, section Variables.

3.1.6 Freely programmable type

A freely programmable gripper type has been integrated in order to cover all user require-ments. Any number of completely freely definable grippers can be configured by means ofentries in the files $CONFIG.DAT, USERGRP.DAT and USER_GRP.SRC.

3.1.6.1 Programming example

Requirement

Awelding gun is to switch between the positions OPEN -- RETRACT -- WORKINGSTROKE-- RETRACT -- OPEN when the status key Manual gripper operation is pressed.

OPEN RETRACT WORKING STROKE RETRACT OPEN

Position A Position B Position C Position B Position A

This task requires the use of two double--acting pneumatic cylinders controlled via electro-magnetically operated 4/2--way valves.



Retract cylinder Working stroke cylinder

Output 1 Output 2 Output 3 Output 4

State Control

Out-put1

Out-put2

Out-put3

Out-put4

A FALSE TRUE FALSE TRUE

B TRUE FALSE FALSE TRUE

C TRUE FALSE TRUE FALSE

Programming

In order to implement the example described, make the following changes or additions to thedata shown below.

Entries in the file $CONFIG.DAT

The freely programmable gripper is defined with the identification number 100.

;==================================; Definition of grippers;==================================

DECL GRP_TYPES GRIPPER[8]

GRIPPER[1]={TYPE 100}

Entries in the file $USER_GRP.DAT:

&ACCESS RP&COMMENT USER GRIPPER packageDEFDAT USER_GRP

...

ENUM GUN_STAT RET_OPN,RET_CLS,WRK_CLS,WRK_OPN

Data type, enumeration of gun states:



STRUC MY_GUN INT RET_OPN,RET_CLS,WRK_OPN,WRK_CLS,GUN_STATSTAT

Structure of the user--defined data type MY_GUN:

DECL MY_GUN MY_GUN1={RET_OPN 100,RET_CLS 101,WRK_OPN102,WRK_CLS 103,STAT #RET_OPN}

Assignment of outputs for the welding gun MY_GUN1 of type MY_GUN:

...

ENDDAT

Entries in the file USER_GRP.SRC

DEF GRP_MANUAL ( ) ;=================;part for manual functions;=====================================

SWITCH GRIPPER[G_NO].TYPE ;switch type of gripper

;end of example for new gripper

CASE 100

$OUT[MY_GUN1.RET_OPN]=FALSE Reset output$OUT[MY_GUN1.RET_CLS]=FALSE Reset output$OUT[MY_GUN1.WRK_OPN]=FALSE Reset output$OUT[MY_GUN1.WRK_CLS]=FALSE Reset output

SWITCH MY_GUN1.STAT Start of the control structure

CASE #RET_OPN If the state of the gunMY_GUN1.STAT has the value#RET_OPN (retract strokeopen)

PULSE($OUT[MY_GUN1.RET_CLS],TRUE,0.3) send a 0.3 secondpulse to the outputRET_CLS (retract strokecloses)

MY_GUN1.STAT=#RET_CLS set the state of the gunMY_GUN1.STAT to#RET_CLS (retractstroke closed)

CASE #RET_CLS If the state of the gunMY_GUN1.STAT has the value#RET_CLS (retract strokeclosed)

PULSE($OUT[MY_GUN1.WRK_CLS],TRUE,0.3) send a 0.3 secondpulse to the outputWRK_CLS (workingstroke closes)

MY_GUN1.STAT=#WRK_CLS set the state of the gunMY_GUN1.STATto #WRK_CLS (working



stroke closed)

CASE #WRK_CLS If the state of the gunMY_GUN1.STAT has the valueWRK_CLS (working strokeclosed)

PULSE($OUT[MY_GUN1.WRK_OPN],TRUE,0.3) send a 0.3 secondpulse to the outputWRK_OPN (workingstroke opens)

MY_GUN1.STAT=#WRK_OPN set the state of the gunMY_GUN1.STAT to#WRK_OPN (workingstroke open)

CASE #WRK_OPN If the state of the gunMY_GUN1.STAT has the value#WRK_OPN (working strokeopen)

PULSE($OUT[MY_GUN1.RET_OPN],TRUE,0.3) send a 0.3 secondpulse to the outputRET_OPN (retract strokeopens)

MY_GUN1.STAT=#RET_OPN set the state of the gunMY_GUN1.STAT to#RET_OPN (retractstroke open)

DEFAULT If none of the states listed sofar appears, execute thefollowing instructions

ENDSWITCH End of the control structure...



3.1.7 Initialization and configuration examples

On switching to state A(Open), output 17 will be setto TRUE and output 18(inverted) also to TRUE.When scanned, input 22must have the state TRUEand input 23 the stateFALSEso that the motion programcan continue.

On switching to state B(Closed), output 17 will beset to FALSE and output 18(inverted) also to FALSE.When scanned, input 22must have the state FALSEand input 23 the state TRUEso that the motion programcan continue.

Not defined

17

--18

0

0

22

23

0

0

Example_1

On switching to state A(Open), output 19 will be setto TRUE and output 21 toFALSE. When scanned,input 22 must have the stateTRUE, input 23 (inverted)the state TRUE, input 24 thestate TRUE and input 25(inverted) also the stateTRUE so that the motionprogram can continue.

On switching to state B(Closed), output 19 will beset to FALSE and output 21to TRUE. When scanned,input 22 must have the stateFALSE, input 23 (inverted)also the state FALSE, input24 the stateFALSEand input25 (inverted) also the stateFALSE so that the motionprogram can continue.

Not defined

19

21

0

0

22

--23

24

--25

Example_2



3.2 Manually operating a gripper

A configured gripper can only be operated in the modes:

G TEST1 (reduced velocity) or

G TEST2 (programmed velocity),

with an enabling switch being held down.

Use the top status key shown on the left to select from the configured grippers the one thatyou would like to operate.

You can then switch between the gripper functions using the bottom status key shown on theleft.


3.3 Programming gripper functions

Pay attention to the position of the editcursor. The next program line createdby you will be inserted as a new lineafter the cursor.

3.3.1 Gripper

Open themenu using the menu key Technology. Then select GRIPPERTech. The follow-ing submenu is displayed:

As a gripper function is to be programmed, confirm the offered selection Gripper.

An inline form for entering the parameters that are required for executing a gripper functionis opened in the programming window.

The assignment of the softkey bar changes at the same time:

It is possible to abort programming of the gripper function at any time by pressing the softkeyCmd Abort or the ESC key. The command will not be saved in this case.

If the programming window is in focus, the various input windows can be selected using the and arrow keys. The window that is currently selected is highlighted by a color back-ground.

The programming window can be activated by repeatedly pressing the Window selectionkey until the entire window is highlighted in color.

Move the cursor to the input box SET. The status key (at the bottom right of the display)changes its assignment.

You can choose between the configured grippers using this status key.

Move the cursor to the input box State. The status key (at the bottom right of the display)changes its assignment.

You can use this status key to choose between the functions that have been defined for theselected gripper.

Move the cursor to the next input box on the right. The status key (at the bottom right of thedisplay) changes its assignment.



The approximate positioning function can be switched on or off using this status key.

If you switch the approximation function off, a further input box, GDATn, appears onthe right, in this case GDAT1.

If the cursor is moved to this box with the arrow key, a status window is opened.Data that more precisely characterize the gripper function must be entered here.

Activate this status window using the Window selection key.

Decide at this point whether any sensors that may be fitted on the gripper are to beinterrogated or whether a wait time is to be used to ensure that the functions that have beenprogrammed are fully executed.

Wait Time:

If Check Gripper is switched off because, for example, it is not possible to interrogate thesensors, a wait time of up to ten seconds can be defined here.

Check Gripper:

Here you can specify whether the sensors on the gripper are to be interrogated before therobot starts moving again (it is only possible to interrogate the sensors if approximatepositioning is switched off in this block). If the sensors do not return a status message, thecontroller allows you to set the inputs so that execution of the program can continueunhindered.

Only use this simulation if you are sure that it cannot result in any unexpectedsituations!

If you switch the approximation function on, two further input boxes, at and Delay, appearon the right.

Other than in the case of the gripper function without approximation, the robot doesnot stop here after reaching the end point in order to activate the gripper.


Motion block1

End point

Execute gripperfunction

Without approximatepositioning

The gripper functionis executed alongthis line

Motion block1

Motion block2 Motion block

2

End point

End point

End point

With approximatepositioning

The parameters START, END and Delay are used to define the point at which thegripper function is executed.

START

END

Delaypositive

Delaynegative

The reference point for activation of the gripper is determined using the status key (atthe bottom, to the right of the display).

Then move the cursor to the box Delay. You can enter a value here, using thenumeric keypad, or change the default value by increments of 1 ms using the statuskey (at the bottom, to the right of the display).

Then press the softkey CmdOk. The gripper function is now fully programmed and saved.



3.3.2 Check Gripper

This command is only executed if it is located before a motion instruction.

Any sensors fitted on the gripper can be interrogated using this command. If the conditionsdefined by the function type and configuration of the gripper are not satisfied, the robot stopsmoving. It does not continue the motion program until the conditions are met.

Now open the menu by means of the menu key Technology. Then select GRIPPERTech.(The menu items contained in this menu depend on the specific software configuration.)

As a gripper sensor interrogation is to be programmed, select the option Check Gripper.The inline form for entering the parameters that are required for executing a gripper sensorinterrogation is opened in the programming window.

The assignment of the softkey bar changes at the same time:

It is possible to abort programming of the gripper sensor interrogation at any time by pressingthe softkey Cmd Abort or the ESC key. The command will not be saved in this case.

If the programming window is in focus, the various input windows can be selected using the and arrow keys. The window that is currently selected is highlighted by a color back-ground.

The programming window can be activated by repeatedly pressing the Window selectionkey until the entire window is highlighted in color.

Move the cursor to the input box CHECK. The status key (at the bottom right of the display)changes its assignment.

You can choose between the configured grippers using this status key.

Move the cursor to the input box State. The status key (at the bottom right of the display)changes its assignment.

You can use this status key to choose between the functions that have been defined for theselected gripper.

Move the cursor to the input box at. The status key (at the bottom right of the display)changes its assignment.

The reference point for the gripper interrogation is determined using this status key.


Motion block1

The gripper functionis executed alongthis line

End point

End point

Motion block2

The parameters START, END and Delay are used to define the point at which the gripperfunction is executed.

START

END

Delaypositive

Delaynegative

Then move the cursor to the box Delay. You can enter a value here, using the numerickeypad, or change the default value by increments of 1 ms using the status key (at thebottom, to the right of the display).

Thenpress the softkey CmdOk. Thegripper interrogation function is now fully programmedand saved.



4 SpotTech

4.1 Basic SpotTech user functions

Once the technology package has been correctly installed, additional commands areavailable in the SpotTech package for spot welding applications.

4.1.1 Range of commands

An initialization command and two program commands, which are used to control thewelding equipment, are basically available for spot welding. These are:

G INIThis initialization command is automatically entered at the beginning of each newprogram that is to be created (skeleton program). This sets the basic parameters for therobot and the application program and initializes the welding andmotion commands andapproximate positioning.

G SPOTThe command SPOT controls the robot motion to aweld spot, and the welding process.The opening and closing of the welding gun retract stroke after the welding process canalso be programmed by means of this command.Collision detection can also deactivated here.

G RETRACTThe command RETRACT controls the robot motion to any point, and the opening andclosing of the welding gun retract stroke after reaching the end point. This function isrequired, for example, if access to weld spots or auxiliary points with the retract strokeof the welding gun fully open or closed is impeded by obstructing contours.Collision detection can also deactivated here.

Motions that do not include a welding operation and do not change the state of the weldinggun retract stroke or which are used for reorientating the welding gun are programmed bymeans of a command belonging to the group Motion.

4.1.2 The functions SPOT and RETRACT

The SpotTech basic functions SPOT and RETRACT are shown in the following sketch.

Welding gun

Component

Retractstroke

Working

stroke

Retract stroke openRETR OPN

Retract stroke closedRETR CLO

Welding processSPOT


4.2 Programming and operation

This section describes how to create spot welding programs and how to program weldingand motion commands. It also contains information on everything that has to be taken intoaccount when setting individual parameters.

SpotTech has a universal basic structure and each of the programming possibilities givenhere is dependent on the welding equipment and user--specific subprograms that are used.

4.2.1 General information on programming

4.2.1.1 Variables in input boxes of the inline forms

The inline forms contain a series of input boxes, whose designations are freely selectable.This applies to the boxes

P1 ... Designation of the end point

PDAT1 ..., CPDAT1 ... Designation of the Movement parameters data set

SDAT1 ... Designation of the Weld parameters data set

The following must always be observed:

-- The designation can consist of letters and numbers. Special characters apart from theunderscore _ cannot be used.

-- The first character of a designation must always be a letter.

-- The designation is entered unchanged as a pure character string into all of thesubsequent program lines.

-- If the last character is a number, the value of this number is automatically incremented(n+1), e.g. SDAT1, SDAT2 ... SDATn or SEAM_FRONT1, SEAM_FRONT2... SEAM_FRONT99, in the subsequent commands.

If a number is entered at the end of the designation -- this number being incremented (n+1)in each subsequent command -- please remember that the number of characters increasesby 1 when going from 9 to 10.

4.2.1.2 Overview of the inline forms

The following sections contain screenshots of the inline forms assigned to each of theSpotTech commands, showing both the input boxes and the parameter lists that can beopened in the status window if the cursor is moved to the appropriate box in the inline form.

The operator control elements and symbols that are used here are explained below:

If the inline form is active, the desired input box can be selected bymeans of the arrow keys.The selected box is displayed in white lettering on a blue background.

The operator control elements shown below the inline form are intended to be an additionalaid to familiarize you with the possibilities of making entries in inline forms and parameterlists. These have the meanings described below:



If the cursor is positioned in the appropriate box of the inline form, the bottom right status keycan be used to alter the parameters or to select data sets that have already been defined.

It is possible to both enter and alter commands and parameters by means of the keypad (bypressing the initial letter of the command/parameter).

This symbol indicates that a parameter list (movement or weld parameters) is assigned tothe input box in the inline form. The status window together with the appropriate parameterlist is activated when the Window selection key on the graphical user interface is pressed.

This softkey (which is only available when a parameter list is active in the status window) isused to exit the status window and activate the corresponding input box in the inline form.

4.2.2 Spot welding (SPOT)

The command SPOT controls the robot motion to a weld spot, and the welding process.It can also be used to control the opening and closing of the welding gun retract stroke(RETRACT) after the welding process.

This command primarily contains the type of motion (PTP, LIN, CIRC), the designation of theweld spot (Pn), the movement parameters (PDATn or CDATn), the weld parameters(SDATn) and the designation of the welding gun (Gun= n) and the activation of collisiondetection.

4.2.3 Types of motion

Three types of motion can be selected for the command SPOT: PTP, LIN and CIRC.Since the robot must be exactly positioned to each weld spot, the approximate positioningfunction is not included.

4.2.3.1 Point--to--point (PTP) motion

PTP (point--to--point) motion allows the robot to be moved to the end position at the highestpossible velocity. This motion is the most efficient. For spot welding seams, most robotmotions between the individual weld spots are generally executed as PTP motions.However, it must be remembered that:

The path cannot be predicted exactly for PTP motions! The motion characteristicsof the robot with greater distances between points and near obstacles shouldtherefore be checked in a test run.

4.2.3.2 Motion along a straight line (LIN)

LIN (linear) motions are usedwhenever the robot has to followan exact path to the endpoint.

4.2.3.3 Motion along a circular path (CIRC)

In the case of CIRC motions, the welding gun is moved along a circular path. This type ofmotion is selected whenever the gun cannot be positioned to the end point using a linearmotion.

4.2.3.4 Activating/deactivating collision detection

Irrespective of the type of motion, collision detection can be activated or deactivated for theweld gun. If detection is activated, the necessary KRL program lines are integrated into thefold block.


4.2.4 Programming a weld spot (SPOT)

4.2.4.1 Menu

After selecting the relevant option (SPOT Tech -- SPOT -- PTP in this example) by meansof the menu key Technology, the inline form described in the next section is opened.



4.2.4.2 The inline form and the parameter lists for the welding command SPOT

Frames

Ext. TCPTrue or False

LIN/CIRC PTP

Softkey bar when the inline form is active

Softkey bar when a parameter list is active

Tool coordinatesystem

Base coordinatesystem

Example of aweld parameter list

Early closing ofthe welding gun

Timer program forthe 1st gun pair

Pressure forthe 1st gun pair

LIN/CIRCmotion

PTP motion

Velocity(0.001 to 2 m/s)

Acceleration(1 to 100 %)

Velocity(1 to 100 %)


Collision detectionTrue or False

You can switch to the commands RETRACT or Motion and change the motion type(PTP, LINorCIRC) at any timeduringprogramming, until this is concludedusing CmdOk.

Brief description of the input boxes of the inline form (from left to right), their functions andtheir range of values where applicable:

Box Function Range of values, Comments

PTP Type of motionPTP, LIN, CIRC

Change using bottom right statuskey, softkey or keypad.


P2

Designation of the end point;with CIRC motions, a furtherinput box is available for theauxiliary point.

Freely selectable

Change the designation Pn byusing the keypad or the bottomright status key.

PDAT2 Designation of the movementparametersFreely selectable (see Section4.2.1.1).

SPOT Gun= 1 Designation of the welding gun Select from up to 5 guns.

RETR OPN Retract stroke after the weldingprocess (RETRACT)CLO = retract stroke closedOPN = retract stroke open

SDAT1 Designation of the weld parame-tersFreely selectable (see Section4.2.1.1).

4.2.4.3 Selecting the welding gun (Gun = n)

It is possible to select from up to 5welding guns. This is dependent on theweldingequipmentthat is used.

4.2.4.4 Retract stroke after the welding process (RETR OPN / CLO)

In this input box, you define whether the welding gun retract stroke is to be open or closedafter the welding process.

Welding gun

Component

Retractstroke

Working

stroke

Retractstroke openRETR OPN


You can switch between Retract stroke open (RETR OPN) and Retract stroke closed(RETR CLO) by pressing the bottom right status key. This status key has a toggle functionin this instance. The pulldown menu will be opened and closed automatically after a shorttime. Alternatively, the respective initial letter (O = OPN = open; C = CLO = closed) canbe entered by means of the keypad. The cursor must be positioned in the input box next toRETR in this case.

4.2.4.5 Weld parameter list

Due to the universal basic structure of the spot welding technology, the parameters for theweldingdata canbeadapted individually to the requirements of both the user and theweldingequipment that is used.

The option of closing the welding gun early is described below on the basis of a spot weldingapplication.



Early closing of the welding gun(early closing time)

-- 1000 to 0 milliseconds

Pn

Start of earlyclosing of gun

Weld spotposition Pnreached

Gun closed

Earlyclosingtim

eWorking stroke

Early closingdistance

The point of closing the gun early (early closing time) is to optimize the time taken to executethe spot welding process. Whilst the welding gun is still moving to the weld spot, the closingoperation is already starting. In this instance, it must be ensured that the gun is not closedcompletely until just after the end position Pn is reached.

Variations in air pressure, the position of the gun and other factors may produce differentopening and closing times for the gun. The closing time of the welding gun must thereforebe checked in a test run. Closing the gun too early while the robot is still moving results inthe weld spot being incorrectly positioned and may cause the component and the tool tobe damaged!

4.2.5 Opening/closing the welding gun retract stroke (RETRACT)

The command RETRACT controls the robot motion to any point, and the opening andclosing of the welding gun retract stroke. This function is required, for example, if access toweld spots or auxiliary points with the gun fully open or closed as far as the working stroke,is impeded by obstructing contours.


In addition to the type of motion (PTP, LIN, CIRC), the name of the end point (Pn), themovement parameters (PDATn or CDATn) and the designation of thewelding gun (Gun= n),this command also contains an instruction specifying whether the gun retract stroke is to beopen (OPN) or closed (CLO) after the end point has been reached.

Irrespective of the type of motion, collision detection can be activated or deactivated.

4.2.5.1 Types of motion

Three types of motion can be selected for the command RETRACT: PTP, LIN andCIRC. Approximate positioning is not possible; the robot is exactly positioned to eachpoint.Further details on this are given in Section 4.2.3.

4.2.5.2 Programming the retract stroke (RETRACT)

Menu (The menu items contained depend on the specific software configuration.)

After selecting the relevant option by means of the menu key Technology (SPOT Tech --RETRACT -- PTP in this example), the inline form described in the next section is opened.



The inline form and the parameter lists for the command RETRACT

Frames

LIN/CIRCPTP

Tool coordinatesystem

Base coordinatesystem

LIN/CIRCmotion

Velocity(0.001 to 2 m/s)


PTP motion

Velocity(1 to 100 %)


Softkey bar when the inline form is active

Softkey bar when a parameter list is active

Ext. TCPTrue or False

Collision detectionTrue or False

You can switch to the commands SPOT or Motion and change the motion type (PTP,LIN or CIRC) at any time during programming, until this is concluded using Cmd Ok.

Brief description of the input boxes of the inline form (from left to right), their functions andtheir range of values where applicable:


Box Function Range of values, Comments

PTP Type of motionPTP, LIN, CIRC

Change using bottom right statuskey, softkey or keypad

P1

Designation of the end point;with CIRC motions, a furtherinput box is included for theauxiliary point.

Freely selectable

Change the designation Pn byusing the keypad or the bottomright status key.

PDAT1 Designation of the movementparameters. Freely selectable

RETR OPN Retract stroke after reaching theend point.OPN = retract stroke open

CLO = retract stroke closed

SPOT Gun= 1 Designation of the welding gun Select from up to 5 guns.

Retract stroke after reaching the end point (RETR OPN / CLO)

In this box, you define whether the welding gun retract stroke is to be open or closed afterthe end point has been reached.

Welding gun

Component

Retractstroke

Working

stroke

Retractstroke openRETR OPN


You can switch between Retract stroke open (RETR OPN) and Retract stroke closed(RETR CLO) by pressing the bottom right status key. This status key has a toggle functionin this instance. The pulldown menu will be opened and closed automatically after a shorttime. Alternatively, the respective initial letter (O = OPN = open; C = CLO = closed) canbe entered by means of the keypad. The cursor must be positioned in the input box next toRETR in this case.

4.2.6 Motion commands

Motions of the tool which do not feature a welding operation and which do not change thewelding gun retract stroke can be programmed by means of the command Motion from theCommands menu.

A corresponding inline form is opened bymeans of the softkey Motion, with themotion type(PTP, LIN or CIRC) that was predefined with the last command being displayed; this mustbe changed, if necessary.



4.2.7 Reorientation of the welding gun

Pn(P2) Pn

(P3)

P4

P1 P3

P2

Reorientation of thewelding gun by 90

If the spot welding plane changes -- as shown in the sketch above -- the welding gun mustbe reorientated. To do so, the gun must first be moved into a position (P2) where there is norisk of it colliding with the component or with other obstructing contours during reorientation.

The reorientation (point in space P2 to P3) is carried out using the command Motion -- LINor -- if the gun retract stroke (RETRACT) is to be changedduring the sameoperation -- SPOTTech -- RETRACT -- LIN (see Section 4.2.5). The gun can subsequently be positionedto the next weld spot (P4).

Dependingon theposition of the robot axes, it may alsobe possible to select a PTPmotion.As PTP motions cannot be predicted exactly, a test run should be carried out.


4.3 Program example

In this section, the use of the basic commands of the spot welding technology will bedescribed step by step on the basis of a simple program example. The assembly shownbelow, consisting of three individual parts, is to be fabricated by means of spot welding.

Homeposition

4.3.1 Creating a new program

To create a new program, press the softkey New and enter a program name (e.g. Test)in the input box.

Now press the softkey Select. The following skeleton program is displayed in the program-ming window:

Pay attention to the position of the edit cursor. The following program line created by youwillbe inserted as a new line after the cursor.

Alternatively, you can program in edit mode by means of the softkey Edit. The syntax willnot be checked, however.



The first weld spot

Homeposition

When moving the welding gun from the home position to the first weld spot, it must beensured that no obstructing contours (e.g. those of the component) can cause a collision.For example, the path of the PTP motion cannot be exactly predicted! The motioncharacteristics of the robot near obstacles should therefore always be checked in a testrun.

The diagram given below shows a collision situation on the left. As can be seen in thesituation on the right, you can ensure that thewelding gun is positioned safely to the first weldspot (P2) by inserting an additional point in space (P1).

Homeposition

Homeposition

PTPmotion

Risk of a colli-sion with thecomponent!

Endposition

Positioning the welding gundirectly to the end point

Component Component

Point in space P11st weldspot P2

Inserting an additional pointin space

If the motion between the point in space P1 and the first weld spot (P2) is executed as aPTPmotion, the distance between these two points should not be too great. The robot canuse approximate positioning for moving from the homeposition toP2 viaP1 becauseexactpositioning is not required until the welding gun moves to the position of the weld spot.

Moving from the home position to the point in space P1 -- RETRACT

The welding gun is moved from the home position to the point in space P1 by means of aPTP motion. During the same operation, you ensure that the retract stroke is open after thepoint has been reached.

Press the menu key Technology and select the options shown below (menu items in whitelettering on a blue background):


After selecting the command SPOT Tech -- RETRACT -- PTP, the following inline form isopened on the screen:

If the programming window is active, the input boxes can be selected by means of the arrowkeys. The selected box appears in white lettering on a blue background.

At the same time that the inline form given above is opened, the assignment of the softkeybar changes to that shown below:

You can also correct your original selection (SPOT, Motion and type of motion) bymeansof this softkey. The inline formchanges accordinglywhen aselection ismade. The commandcan be aborted bymeans of the softkey CmdAbort or the ESC key. This will close the inlineform.

The welding gun retract stroke must be open after the point in space P1 has been reached.This is set in the input box RETR. In the example given above, OPN (open) is alreadyentered; otherwise, CLO (closed) appears here.

To change the setting, move the cursor to the input box RETR. You canswitch between RETR CLO and RETR OPN by means of the bottom rightstatus key. This status key has a toggle function. Alternatively, the letter C(=closed) or O (=open) can be enteredbymeans of the keypad. In this case,enter O.

For the purpose of positioning the welding gun, move it to the position P1 by means of theSpaceMouseor the traversing keys. Informationon controllingmotions of the robotmanuallycan be found in the chapter [Manual traversing of the robot].

You can now press the softkey Touch Up. In this case, press the softkey Yes to confirmthe query Touchup (Y/N)? that is displayed in themessage window. Alternatively, press thesoftkey Cmd Ok or the Enter key. The current robot coordinates are automatically saved.

The command is ended by pressing the softkey Cmd Ok or the Enter key. If the point P1has not yet been touched up, the current robot coordinates are nowautomatically saved. Theinformation message Point P1 created automatically is displayed in the message window.

The inline form is closed and the generated program line is inserted into the program formafterwards. The numbers of the following program lines are automatically updated.



Setting the first weld spot (SPOT)

A PTP motion is used to move the welding gun from the point in space P1 to the weld spotP2. The gun is exactly positioned to point P2 where the welding process will then beexecuted. Since a sequence of further spot welds follows P2, the retract stroke can remainclosed.

Press the menu key Technology and select the options shown below (menu items in whitelettering on a blue background):

After selecting the command SPOT Tech -- SPOT -- PTP, the following inline formappears on the display.

Alternatively, you can also press the softkey Last Cmd. If you had last entered aRETRACT command, an inline form for the command RETRACT is displayed. SPOTcan then be called by means of the softkey SPOT. The same inline form is thus available.

As can be seen, the names for the end point (P2) and the data set (PDAT2) have beenadapted. A further box is also displayed: the designation of the weld parameter set (SDAT1).

The welding gun retract stroke can be left closed (RETR CLO) in this program example.If the first command to beenteredwas RETROPN (retract strokeopen), this has beenusedas a default setting in the input box of the new inline form.

To change the setting,move the cursor to the input box RETR. Press thebottom right statuskey or enter the letter C by means of the keypad. CLO (=closed) subsequently appearsin the input box of the inline form.

Enter the movement and weld parameters into both the inline form and the parameter listsand move the welding gun to the desired position P2.

If your welding system has been configured appropriately, the functioning of the gun can bechecked at this point by means of the gun status keys. For information on this, see Section4.9 and the chapter [SPOT Tech -- Expert Programming].

After entering all of the parameters, press the softkey Cmd Ok. The current robotcoordinates are saved and the program form is updated accordingly.


4.3.1.1 Welding the first spot sequence

P2P3P4P5

RETR CLORETR OPN

The further points (P3 to P5) can be programmed using the procedure described in the lastsection. In this case, leave thewelding gun retract stroke closed (RETRCLO) for P3 andP4.

As the welding gun is to be positioned to the first weld spot (P6) of the second weldingsequence (see the sketch at the beginning of Section 4) after P5, the retract stroke must beopened at P5. To do so, select the option RETR OPN when programming P5.

After all of the entries for the first spot sequence have beenmade, the program formappearsas follows:

As can be seen, the numeric values for the designation of the movement parameters(PDATn) have each been increased by 1 in command lines 4 to 7. The numeric values forthedesignation of theweld parameters (SDATn) have likewise been increased. Theparame-ters entered in SDAT1 have automatically been entered in SDAT2 .... SDAT4.

For spot sequences that are to be welded with the same welding tool and the same weldparameters, programming can be simplified if each weld spot is not programmedindividually but by using the procedure described below:

G Program the first weld spot of the sequence.

G Determine the number of spots that are to be welded after the first spot.

G Press the softkey Last Cmd and then the softkey Cmd Ok.Repeat this according to the number of weld spots.

G To save the robot coordinates, subsequently move the edit cursor (vertical line) to theappropriate line of the program form in sequence. Position the robot manually to therespective point, press the softkey Touch Up and confirm the request for confirmationto save the coordinates. The current robot coordinates are saved for the point that iscurrently selected.

With the motion type CIRC, the coordinates for the required auxiliary point must alwaysbe touched up manually.



4.3.1.2 Welding the second spot sequence

The second spot sequence begins at P6. A PTPmotion can be used between the weld spotsP5 and P6 as the distance between them is small and the welding gun retract stroke is open.

The weld spot P6 can be programmed in the program example given above.

Now program theweld spots P7 to P9 following the description given in the previous section.Select the option RETR OPN again for the last weld spot (P9) to open the welding gunretract stroke after P9 has been welded.

4.3.1.3 Moving from the end of the spot seam to the home position

To move the welding gun back to the home position, a further point in space outside thecomponent is required so that a collision is safely avoided. This is P10 in this programexample, where it is assumed that there are no obstacles between P10 and the homeposition.

Thepath between theweld spot P9and thepoint in spaceP10 is executedasa PTPmotion.

Press the softkey Motion. An inline form is opened:

After entering the parameters, press the key Cmd Ok.

Alternatively, this motion can also be programmed by means of the command SPOT Tech-- RETRACT -- PTP.

The motion from P10 to the home position (PTP -- HOME) is already included in theskeleton program. Programming of this program example is thus completed.


4.4 Altering existing programs

It is possible to alter commands and/or parameters and to delete command lines in anexisting program at any time. Two examples are given below.

4.4.1 Altering command lines

The procedure for altering command lines is demonstrated below by using a different typeof motion for the command SPOT -- RETRACT to the point in space P1 to that used in theabove program example. The parameter PTP for P1 is to be changed to LIN.

Move the edit cursor to line 3 by means of the arrow keys.

Press the softkey Change. The inline form for this command line is opened.Move thecursorto the first input box on the left.

Press the bottom right status key until LIN appears in the input box.

Then press the softkey CmdOk. The inline form is closed and the program form is updatedaccordingly.

4.4.2 Deleting command lines

The motion command that appears in line 13 of the program form given below (P11) is to bedeleted. To do so, move the edit cursor to line 13.

Press the menu key Program

and select Delete by means of the arrow key. Then press the Enter key. The key 1 in thenumeric keypad can also be pressed (do not press Enter).



Line 13 has been deleted and the original line 14 is now line 13.

4.4.3 Adding commands to an existing program

The procedure for adding commands to an existing program is given below. A further partis added to the welded assembly described in Section 4.3:

Homeposition

Reorientation ofthe welding gunby 90

The new part is welded to the two brackets by means of two spots (P13 and P16 in thediagram). As thewelding gun has to be reorientatedby 90 to weld these twospots in relationto welding the spot sequences P2 to P5 and P6 to P9, it is advisable to weld them beforewelding spot sequences P2 to P9.

In this example, these twospots are to bewelded afterweld spot P9. This requires the follow-ing changes to be made to the program:

-- Alter the command Motion (P10)

-- Insert the command Motion (P11) to reorientate the welding gun

-- Insert the command Motion (P12)

-- Insert the command SPOT -- SPOT (P13)



-- Insert the command SPOT -- SPOT (P16)

-- Insert the command RETRACT (P17)



4.4.3.1 Description of the alteration

Open the program form from the previous section.

4.4.3.2 Changing the position of the welding gun (point in space P10)

Move the edit cursor to line 12. Position the welding gun to the point in space P10. Whendoing so, ensure that it cannot collide with the component or with other obstructing contoursduring the following reorientation to P11. Press the softkey Touch Up to save the new robotcoordinates.

4.4.3.3 Reorientation of the welding gun -- inserting the command Motion (P11)

P10P11

Ensure that the edit cursor is positioned in line 12 (P10). An inline form is opened by pressingthe softkey Motion.

Select themotion type LIN. Use the traversing keys or theSpaceMouse to align theweldinggun accordingly (rotate by 90). Save the current robot coordinates (Touch Up) and pressthe softkey Cmd Ok after entering all the parameters.


4.4.3.4 Moving to the point in space P12 -- inserting the command Motion

Now insert the command Motion -- PTP to move the welding gun to the point in space P12,which is located above the weld spot P13.

4.4.3.5 Welding spot P13 -- inserting the command SPOT

Select SPOT Tech -- SPOT -- PTP. Select the option RETR OPN in the inline form,enter the required parameters and close the inline form with Cmd Ok.

4.4.3.6 Moving to the weld spot P16 and welding

The welding gun is moved to the weld spot P16 via the points in space P14 and P15. TwoPTPmotions are programmed from P13 to P14 and from P14 to P15. The appropriate inlineforms are shown below:

This is followed by the welding command SPOT Tech -- SPOT -- PTP:

4.4.3.7 Moving to the home position

The welding gun is moved to the home position via the points in space P17 and P18. Themotions from P16 to P17 and from P17 to P18 are to be programmed. The motion to PTP-- HOME is already included in the skeleton program.

Alteration of the program is now completed.

The altered line 12 (P10) and the new lines 13 to 20 (P11 to P18) are indicated by the whiteline on the left in the diagram.



4.5 SpotTech configuration

Configuration of the SpotTech software package is only possible in expert mode.

4.5.1 Program sequence

The following diagram shows the basic sequence of a spot welding program between twoweld spots.

P(n--1)

Pn

t

t

t

t

Weld spot

TriggerPRESPOT

TriggerSPOT

Weld spotor starting point

Robotmotion

ADVSPOT

PRESPOT

SPOT

Weldduration

(weld start --weld complete)

Gun closing time

Weld completeWLD_CMP

Communication with thewelding controller (e.g.setting program parameters)

Weld start

WLD_STRT

ADVSPOT

Time t

Workingstroke open

Retract open(if programmed)

RETRACT

The usable functions depend on the type of welding gun used as well as its controller. Theindividual functions:

Name Description

Retract strokeRETRACT

Retract stroke of the welding gun. Completely opens the gun, forexample, to approach weld spots over component edges.

Working stroke Working stroke of the welding gun. The working stroke is generallysufficient for spot sequences along even surfaces.

ADVSPOTAdvance communication with the welding controller (during gunmovement) so that all required weld data are available when the endpoint is reached.


PRESPOTEarly closing of the gun; programmable in the parameter list Selec-tion. The closing operation already starts while the welding gun isstill moving to the weld spot.

SPOTThe actual welding process, initiated with the Weld start command(WLD_STRT) to the welding periphery until the arrival of the Weldcomplete signal (WLD_CMP).

4.5.2 Retract stroke (RETRACT) and working stroke (SPOT)

The basic SpotTech functions SPOT and RETRACT are shown schematically in thefollowing sketch.

Retractstroke

Welding gun

Component

Working

stroke

Retract stroke openRETR OPN


Working stroke closedSPOT

4.5.3 Early closing of the gun (PRESPOT)

The PRESPOT function allows the gun to close while the welding gun is moving to the endpoint.



Weld spotposition Pnreached

Welding gunclosed

Early closingdistance

Working stroke

Pn

Earlyclosingtim

e

Trigger for early gunclosing (PRESPOT)

TRIGGER WHEN DISTANCE=1DELAY=SSDAT1.CLO_TM DOUSERSPOT(#PRESPOT,S_ACT)PRIO= -1

Trigger for weld startTRIGGER WHEN DISTANCE=1DELAY=0.0 DO USERSPOT(#SPOT,S_ACT) PRIO= -1

The point of closing the gun early (PRESPOT) is to optimize the time taken to execute thespot welding process. The closing operation already starts while the welding gun is stillmoving towards the weld spot. In this instance, it must be ensured that the gun is not closedcompletely until just after the end position Pn is reached.

Variations in air pressure, the orientation of thegun andother factorsmay producedifferentgun opening and closing times. The closing time of the welding gun must therefore bechecked in a test run. Closing the gun too early while the robot is still moving results in theweld spot being incorrectly positioned and may cause the component and the tool to bedamaged!


4.6 Components of the SpotTech package

4.6.1 Program structure

The interface to the welding controller is implemented in the form of a configurablehandshake. The settings and assignments of the physical inputs and outputs are definedin the file $CONFIG.DAT.

In the following block diagram the program structure of the KR C1 robot controller is shownin the Spot welding robot configuration.

BAS(...)H50(...)USERSPOT

*.SRC

*.DAT

H50.SRC BAS.SRC P00.SRC

CELL.SRC SPS.SUB

BAS(...)H50(...)USERSPOT

*.SRC

*.DATBAS(...)H50(...)USERSPOT

*.SRC

*.DAT

. . .

DEF SPS()CWRITE (...RUN/R1/CELL())

LOOP...ENDLOOP

USERSPOT.SRC IR_STOPM.SRC

$CONFIG.DAT

USERSPOT

PACKAGE

Technology--specific

organizationprogram

Part 1 Part 2 Part n

Functionsfor grippercontrol

Functionsfor robotmotion

Functionsfor spotwelding

Functionsfor

AutomaticExternal

Routines forhandlingfaults

KR C1 program structure

4.6.2 SPOT Tech--specific files

The following files, which are included in the SPOT Tech package, are required forexecuting spot welding applications. You will always see the symbols shown on the left withthe file names throughout this document whenever the corresponding file or parts of it aredescribed.

$CONFIG.DAT Contains data specific to SPOT Tech within the FoldUSERSPOT.

USERSPOT.SRC This file is supplied as a skeleton program. This iswhere youenterdata for your own spot welding programs, e.g. for initializing, forRETRACT, ADVSPOT, SPOT, etc.


4.7 Adaptation to the periphery, configurable optionsThis section describes the SpotTech peripheral interfaces with an example illustrating theassignment of the digital outputs and inputs. The Fold USERSPOT contained in the file$CONFIG.DAT as well as the file USERSPOT.SRC are described.

4.7.1 FOLD SPOT in the file $CONFIG.DAT

The Fold SPOT from the file $CONFIG.DAT is shown below.

;FOLD SPOT GLOBALS;;==================================; Structures:;==================================ENUM S_COMMAND SPOT,RETR,PRESPOT,INIT,ADVSPOT Branch

SWITCH CMDin fileUSERSPOT.SRCC

ENUM S_PAIR_SLCT FIRST,SECOND,BOTH Gun--specificparameters

STRUC SPOT_SUGG_T CHAR GUN[24],RETR_CMD[24],CHOISE[24],CLO_TM[24],PGNO1[24],PRESS1[24],PGNO2[24],PRESS2[24],SPOT_PARAMS[24]

STRUC SPOT_TYPE INT GUN,S_PAIR_SLCT PAIR,COMMAND RETR,INT CLO_TM,INT PGNO1,REAL PRESS1,INT PGNO2,REAL PRESS2

;==============================; External declarations:;==============================EXT USERSPOT (S_COMMAND :IN,SPOT_TYPE :IN )

;==============================; Variables:;==============================DECL SPOT_TYPE SDEFAULT={GUN 1,PAIR Default data set#FIRST,RETR #OPN,CLO_TM 0,PGNO1 1, for SPOTPRESS1 0.0,PGNO2 0,PRESS2 0.0}

DECL SPOT_TYPE S_ACT Global variablesDECL INT S_ACT_DELAY that are used inDECL BOOL S_READY the robot program.

INT BOSCHCMD_OK=534INT BOSCHSTAT_OK=528

;==============================; all for Bosch-Serial-Interface;==============================EXT BOSCH (INT :IN,INT :IN,INT :OUT ); BOSCH-OUTWORD 1 (513-528) paramSIGNAL BOSCHPAR $OUT[513] TO $OUT[528]; BOSCH-OUTWORD 2 (529-544) commandSIGNAL BOSCHCMD $OUT[529] TO $OUT[533]; BOSCH-INWORD 1 (513-528) status+validbitSIGNAL BOSCHSTAT $IN[513] TO $IN[527];ENDFOLD

If adaptation to the peripheral hardware used is required, please consult the correspondingdocumentation.



4.7.2 The user--specific program USERSPOT.SRC

The skeleton program USERSPOT.SRC provided in the SpotTech technology packageserves as the framework for applications individually tailored to thewelding equipment beingused. In the following sections, you will find examples of the configuration options available.

&COMMENT USERSPOT packageDEF USERSPOT (CMD :IN,S :IN );********************************; USERSPOT - Package KR C1; R2.2.x; Date: 23.03.98;;********************************DECL S_COMMAND CMDDECL SPOT_TYPE S

SWITCH CMD

CASE #INIT Initialization (contained in INI FOLD)INIT ( )

CASE #ADVSPOT Call during advance runADVSPOT (CMD,S )

CASE #PRESPOT Triggering of early closing ofPRESPOT (CMD,S ) the welding gunCASE #SPOT Triggering Weld start atSPOT (CMD,S ) weld spot position

S_READY=TRUE Enable for further program execution

CASE #RETR Gun retract stroke (RETRACT)

RETRACT (CMD,S )S_READY=TRUE

ENDSWITCH

END ; END OF MAIN;*****************************

DEF ADVSPOT (CMD :IN,S :IN ) User data for ADVSPOTDECL S_COMMAND CMDDECL SPOT_TYPE SEND ;(ADVSPOT);*****************************

DEF PRESPOT (CMD :IN,S :IN ) User data for PRESPOTDECL S_COMMAND CMDDECL SPOT_TYPE SEND ;(PRESPOT);*****************************

DEF SPOT (CMD :IN,S :IN ) User data for SPOTDECL S_COMMAND CMDDECL SPOT_TYPE SEND ;(SPOT);*****************************

DEF RETRACT (CMD :IN,S :IN ) User data for RETRACTDECL S_COMMAND CMDDECL SPOT_TYPE SEND ;(RETR);*****************************DEF INIT ( ) User data for INITEND ;(INIT)


4.7.2.1 Schematic sequence diagram for SPOT (without RETRACT)

The following diagram shows the basic program sequence of the command SPOT. Theoptions PRESPOT (early closing of the gun) and RETRACT (open/close retract strokeof the gun) are not shown.

Weld parameterdesignation

0

t

t

t

t

t

t

Robotmotion

GUN_WRKWorking strokeactivation(output)

WRK_STATWorking strokestatus(input)

WLD_STRTWeld start(output)

WLD_CMPWeldcomplete(input)

PNUMProgramnumber(output)

OPEN

CLOSE

OPEN

CLOSE

TRUE

FALSE

TRUE

FALSE

S01 S02(Auxiliary point)

ADVSPOTS.PGN01

After welding the spot S01 the weld complete signal (WLD_CMP=TRUE) triggers, with itsfalling edge (WLD_CMP=FALSE), the instruction for opening the working stroke of thewelding gun (GUN_WRK=G_OPN). At the same time the weld start signalWLD_STRT=FALSE as well as the program number PNUM=0 are set.

The robot controller now waits for the status message WRK_STAT==G_OPN indicatingthat the working stroke of the gun is open. This signal enables robot movement to the nextweld spot.

To ensure that all the data required for welding are available at the end point (in this examplepoint S02), theweldingprogramnumber, for example PNUM=S.PGN01, is already outputduring the actual movement, provided this has been configured in the section ADVSPOTof the file USERSPOT.SRC.

At the end point (in this example point S02), the control instruction is given to close theworking stroke (GUN_WRK=W_CLO). The status message from the welding controller thatthe working stroke is closed (WRK_STAT=W_CLO) triggers the weld start(WLD_STRT=TRUE).

At the conclusion of the welding process, the instruction is given once again, by means ofthe falling edgeof theweld complete signal (WLD_CMP=FALSE), to open theworking stroke



of the gun (GUN_WRK=G_OPN) as well as to set the weld start signal WLD_STRT toFALSE and the program number PNUM to ZERO.

4.7.2.2 Schematic sequence diagram for SPOT (with RETRACT)

0

t

t

t

t

t

t

t

t

t

t

t

With PRESPOTGUN_RETRetract strokeactivation(output)

RET_STATRetract strokestatus(input)

GUN_WRKWorking strokeactivation(output)

WRK_STATWorking strokestatus(input)

WLD_STRTWeld start(output)

WLD_CMPWeldcomplete(input)

PNUMProgramnumber(output)

Robotmotion

S01 S02(Auxiliary point)

OPEN

CLOSE

OPEN

CLOSE

OPEN

CLOSE

OPEN

CLOSE

TRUE

FALSE

TRUE

FALSE

TRUE

FALSE

ADVSPOTS.PGN01

If RETR OPNselected

If RETR CLOselected

After welding the spot S01 the weld complete signal (WLD_CMP=TRUE) triggers, with itsfalling edge (WLD_CMP=FALSE), the instruction for opening the working stroke of thewelding gun (GUN_WRK=G_OPN). At the same time the weld start signalWLD_STRT=FALSE as well as the program number PNUM=0 are set.

When the status message WRK_STAT==G_OPN is given, indicating that the workingstroke of the gun is open, movement is initiated to the next weld spot, provided the optionRETR CLO (gun retract stroke remains closed) has been programmed with the SPOTcommand.

If the option RETR OPN has been programmed (the gun retract stroke is opened after thespot has been welded), the command GUN_RET=G_OPN is executed. In this case,


movement to the next weld spot is not enabled until the status signal RET_STAT=OPENis set. During this movement, the welding program number (PNUM) is output if this has beenconfigured in the section ADVSPOT of the file USERSPOT.SRC.

At the end point (in this example point S02), the control instruction is given to close theworking stroke (GUN_WRK=CLOSE). Theweldingprogramnumber (PNUM) is output at thesame time. If the retract stroke at point S02 is open (RET_STAT=OPEN), thecorresponding close instruction (GUN_RET=CLOSE) is given first of course.

The status message from the welding controller that the working stroke is closed(WRK_STAT=W_CLO) triggers theweld start (WLD_STRT=TRUE). At the conclusion of thewelding process, an instruction is given once again by means of the weld complete signal(WLD_CMP) to open the working stroke of the gun (GUN_WRK=G_OPN).

4.7.2.3 Robot controller -- welding controller interface

The following table provides anoverviewof the configurable physical inputs and outputs. Theaddresses refer to the extension of the file USERSPOT.SRC shown in Section 4.7.2.4.

Name Description, signal states Output / Input(example)

PNUM Welding program no. (max. 255 characters) Output 1 ... 8

WLD_STRT Weld start Output 15

WLD_CMP Weld complete signal (from welding controller) Input 15

Working stroke control (SPOT)

GUN WRKClose stroke Open stroke

GUN_WRKTRUE FALSE Output 10

FALSE TRUE Output 11

Working stroke status message (SPOT)

WRK STATStroke closed Stroke open

WRK_STATTRUE FALSE Input 10

FALSE TRUE Input 11

Retract stroke control (RETRACT)

GUN RETClose stroke Open stroke

GUN_RETTRUE FALSE Output 12

FALSE TRUE Output 13

Retract stroke status message (RETRACT)

RET STATStroke closed Stroke open

RET_STATTRUE FALSE Input 12

FALSE TRUE Input 13

4.7.2.4 Program example for the file USERSPOT.SRC

&COMMENT USERSPOT packageDEF USERSPOT (CMD :IN,S :IN );********************************; USERSPOT - Package KR C1; R2.2.x



; Date: 23.03.98; Example No 1; SPOT / RETRACT;********************************DECL S_COMMAND CMDDECL SPOT_TYPE S

Assignment of inputs/outputs;Program No.SIGNAL PNUM $OUT[1] TO $OUT[8] Program number, outputs 1...8;GUN-RETRACTSIGNAL GUN_RET $OUT[10] TO $OUT[11] Retract stroke (RETRACT),

outputs 10, 11;State RETRACTSIGNAL RET_STAT $IN[10] TO $IN[11] Retract stroke status, inputs 10, 11;GUN work (SPOT)SIGNAL GUN_WRK $OUT[12] TO $OUT[13] Working stroke (SPOT),

outputs 12, 13;State SPOTSIGNAL WRK_STAT $IN[12] TO $IN[13] Working stroke status, inputs 12, 13;Weld StartSIGNAL WLD_STRT $OUT[15] Weld start, output 15;Weld doneSIGNAL WLD_CMP $IN[15] Weld complete signal, input 15;=================================;GROUP DefinitionsINT R_CLO,R_OPN,W_CLO,W_OPN Retract stroke / working stroke statesR_CLO=B0001R_OPN=B0010W_CLO=B0001W_OPN=B0010;=================================SWITCH CMD

CASE #INITINIT ( )

CASE #ADVSPOT

ADVSPOT (CMD,S )CASE #PRESPOTPRESPOT (CMD,S )

CASE #SPOTSPOT (CMD,S )S_READY=TRUE

CASE #RETRRETRACT (CMD,S )S_READY=TRUEENDSWITCHEND ; END OF MAIN

;*********************************

DEF ADVSPOT (CMD :IN,S :IN )WLD_STRT=FALSE Reset weld startPNUM=S.PGNO1 Issue program number

END ;(ADVSPOT)

;*****************************


DEF PRESPOT (CMD :IN,S :IN )GUN_RET=R_CLO Close retract stroke (RETRACT)WAIT FOR RET_STAT==R_CLO Waiting for Retract closedGUN_WRK=W_CLO Close working stroke

END ;(PRESPOT)

;*****************************

DEF SPOT ( )WAIT FOR WRK_STAT==W_CLO Waiting for Working stroke closedWLD_STRT=TRUE Set weld startWAIT FOR WLD_CMP Waiting for weld complete

signal (TRUE)PNUM=0 Set program number to ZEROWAIT FOR NOT (WLD_CMP) Waiting for weld complete

signal (FALSE)WLD_STRT=FALSE Reset weld start (FALSE)GUN_WRK=W_OPN Open working strokeWAIT FOR WRK_STAT==W_OPN Waiting for Working stroke open

SWITCH S.RETR If RETR OPN programmedCASE #OPN after weld spot:GUN_RET=R_OPN open retract stroke (RETRACT)WAIT FOR RET_STAT==R_OPN Waiting for Retract stroke open

ENDSWITCH

END ;(SPOT)

;*****************************

DEF RETRACT ( )SWITCH S.RETR Retract stroke (RETRACT)CASE #OPN If RETR OPN programmed:GUN_RET=R_OPN open retract stroke (RETRACT)WAIT FOR RET_STAT==R_OPN Waiting for Retract stroke openCASE #CLO If RETR CLO programmed:GUN_RET=R_CLO close retract strokeWAIT FOR RET_STAT==R_CLO Waiting for Retract stroke closed

ENDSWITCHEND ;(RETR)

;*****************************

DEF INIT ( )PNUM=0 Set program number to ZEROWLD_STRT=FALSE Reset weld startGUN_WRK=W_OPN Open working stroke (SPOT)WAIT FOR WRK_STAT==W_OPN Waiting for Working stroke openGUN_RET=R_OPN Open retract stroke (RETRACT)WAIT FOR RET_STAT==R_OPN Waiting for Retract stroke openS_READY=TRUE Enable for further program execution

END ;(INIT)



4.8 Program example

A simple demonstration program (for example, DEMO01.SRC) for welding a single spot isdescribed in the following. Add the command SPOT Tech--SPOT--PTP to a skeletonprogram as shown in program line 4 below.

Now move the edit cursor to line 4 and select FOLD -- Act FOLD op/cl with the menufunction Program (to do so you must be within the user group Expert). You will now seethe complete program listing for the entered command.

File DEMO01.SRC

PTP P1 PDAT1 SPOT Gun= 1 RETR OPN SDAT

PDAT_ACT=PPDAT1 BAS (#PTP_DAT ) FDAT_ACT=FP1 Motion parametersBAS (#FRAMES ) BAS (#VEL_PTP,PPDAT1.VEL ) Ref. to data set (for

precalculation)

S_ACT.GUN=1 Selection of welding gun (1...5)S_ACT.PAIR=SDEFAULT.PAIR Selection of gun pairS_ACT.RETR=#OPN Retract stroke openS_ACT.CLO_TM=SSDAT1.CLO_TMS_ACT.PGNO1=SSDAT1.PGNO1 Welding program numberS_ACT.PGNO2=SDEFAULT.PGNO2S_ACT.PRESS1=SSDAT1.PRESS1S_ACT.PRESS2=SDEFAULT.PRESS2S_READY=FALSEUSERSPOT (#ADVSPOT,S_ACT )TRIGGER WHEN DISTANCE=1 Trigger for gun closingDELAY=SSDAT1.CLO_TM DO USERSPOT (working stroke)(#PRESPOT,S_ACT ) PRIO= -1 Trigger for early gun closing

(PRESPOT)

TRIGGER WHEN DISTANCE=1 Trigger for weld start (SS)DELAY=0.0 DO USERSPOT(#SPOT,S_ACT) PRIO= -1PTP XP1WAIT FOR S_READY


4.9 Manual operation of the welding gun using the status keys

When carrying out tests, it is useful to be able to test the retract stroke (RETRACT) andworking stroke (SPOT) functions of thegun in addition to the gunmovement, without actuallywelding.

4.9.1 Separate control of RETRACT and SPOT

The configuration described below allows separate manual control of the gun retract stroke(RETRACT) and working stroke (SPOT).

Using the Gripper selection status key, you can choose from the following:

-- Retract stroke (RETRACT) -- (Gripper) no. 1 and

-- Working stroke (SPOT) -- (Gripper) no. 2

The retract stroke (1) or the working stroke (2) can be controlled corresponding to theselection you make with the status key for manual gripper operation.

Working stroke (SPOT)Retract stroke (RETRACT)

GUN_WRKOPEN CLOSE OPEN

GUN_RETOPEN CLOSE OPEN

Operation of retract stroke Operation of working stroke

Retract/working stroke selection

4.9.1.1 Definition of function type and assignment of physical outputs

The GRIPPER Tech package provides a number of gripper function types. Two functiontypes are available for implementing the above configuration:

Function type 1 static outputs (for static valves)

Function type 5 pulse outputs (for pulse valves)

Logic table for function types 1 and 5:

State OUT1 OUT2

A TRUE FALSE

B FALSE TRUE

The changes required in the file $CONFIG.DAT for manual gun operation are describedbelow.

Static outputs

Entries in the file $CONFIG.DAT when using gripper function type 1:

; Definition of grippers;==================================INT MAXGRIPPER=8




GRIPPER[1]={TYPE 1,OUT1 10,OUT2 11, Retract stroke (RETRACT)OUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0, Definition of function type (1) andIN4 0,GRP_OLD 1} assignment of the physical outputs

(in this example 10 and 11)

GRIPPER[2]={TYPE 1,OUT1 12,OUT2 13, Working stroke (SPOT)OUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0, Definition of function type (1) andIN4 0,GRP_OLD 1} assignment of the physical outputs


Pulse outputs

Entries in the file $CONFIG.DAT when using gripper function type 5:



GRIPPER[1]={TYPE 5,OUT1 10,OUT2 11, Retract stroke (RETRACT)OUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0, Definition of function type (5) andIN4 0,GRP_OLD 1} assignment of the physical outputs


GRIPPER[2]={TYPE 5,OUT1 12,OUT2 13, Working stroke (SPOT)OUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0, Definition of function type (5) andIN4 0,GRP_OLD 1} assignment of the physical outputs


Thepulseduration for function type5 is preset to 0.5 seconds. It is possible tomake achangeat the end of the block Definition of grippers in the file $CONFIG.DAT.

REAL GRP_PULSE_TI=0.5 ; pulse time for gripper type 5

Corresponding entry using the menu function Monitor -- Variable -- Modify:

Variable Default (sec.)

GRP_PULSE_TI 0.500

The inputs (IN1 ... IN4) are not polled in these examples because the mechanical gunfunction can be checked visually. For this reason the configuration and addressing of thephysical inputs are irrelevant for the manual gun control function.

In the examples above, the retract stroke control for gripper no. 1 and working strokecontrol for gripper no. 2 were assigned. You can also assign other numbers if thesenumbers are reserved for other applications, for example.


The assignment of gripper no. 8, for example, requires the following entry in the file$CONFIG.DAT:

GRIPPER[8]={TYPE 1,OUT1 10,OUT2 11, ...

Note that the value of the variable MAXGRIPPER must be at least as high as theconfigured gripper number. MAXGRIPPER=8 is the default setting.

4.9.2 Manual control of RETRACT and SPOT in series

The following example describes how the retract stroke and working stroke of guns with4--way valves can bemanually controlled. Switching between the following states should bepossible using the status key for manual gripper control:

-- Retract stroke (RETRACT) open, working stroke (SPOT) open

-- Retract stroke closed, working stroke closed

-- Retract stroke closed, working stroke open

GUN_RET

GUN_WRK

OPEN

OPEN

CLOSE

CLOSE

CLOSE

OPEN

Operation

Selection of welding gun 1 / 2

OPEN

OPEN

Definition of function type and assignment of physical outputs

For implementation of the above configuration, the GRIPPER Tech H50 package providesfunction type 4, with only the outputs 2 and 3 being used.

Logic table of function type 4, outputs 2 and 3:

State OUT2 OUT3

A FALSE FALSE

B TRUE TRUE

C TRUE FALSE

The changes required in the file $CONFIG.DAT for manual gun operation are describedbelow.





GRIPPER[1]={TYPE 4,OUT1 10,OUT2 12, Retract (OUT 10) and working strokeOUT3 0,OUT4 0,IN1 0,IN2 0,IN3 0, (OUT 12), definition of the functionIN4 0,GRP_OLD 1} type (4) and assignment of the

physical outputs (e.g. 10 and 11)

1

Index

Index -- i

Zeichen$CONFIG.DAT, 9, 10, 44, 45, 53

Zahlen4/2--way valves, 9

AAdding commands, 38

ADVSPOT, 41, 47, 48Altering existing programs, 37

Approximation function, 16

Arrow keys, 15Assignment of inputs/outputs, 50

at, 16, 18

BBasic functions, 42BLOW, 8

CCall during advance run, 46

CASE #ADVSPOT, 46

CASE #INIT, 46CASE #PRESPOT, 46

CASE #SPOT, 46

CHECK, 18Check Gripper, 16, 18

CIRC, 22Cmd Ok, 17

Continuous signal, 9

Creating a new program, 31

DDefault data set, 45Delay, 16, 17, 19

Deleting command lines, 37

Designation of the welding gun, 22

EEarly closing of the welding gun, 26

Early closing time, 26

Early gun closing, 42Enabling switch, 14

END, 17, 19Exclusion from use, 8

FFOLD, 52Function type, 8

GGDAT, 16Gripper sensor interrogation, 18GRIPPERTech, 15, 18GRP_PULSE_TI, 9Gun, 22Gun opening and closing times, 43

IIdentification number, 10INI, 20Initialization command, 20Initialization and configuration examples, 13Inline form, 15, 18, 21, 23Inline form RETRACT, 28Inline form SPOT, 24Inputs, 45Issue program number, 50

LLIN, 22

MManual control of RETRACT and SPOT in se-ries, 55Manual gripper operation, 9Manual operation of the welding gun, 53Manually operating a gripper, 14Monitor, 9

OOFF, 8Outputs, 45

PP1, 21Parameter lists RETRACT, 28

Index

Index -- ii

Parameter lists SPOT, 24PDAT, 21, 25

Peripheral interfaces, 45

Pneumatic cylinders, 9PRESPOT, 42

Program example, 31, 49, 52

Program number output, 50Program sequence, 41

Program structure, 44

Programmed velocity, 14Programming a weld spot, 23

Programming gripper functions, 15

Programming the retract stroke, 27PTP, 22

Pulse, 9

Pulse outputs, 54

RReduced velocity, 14Reorientation of the welding gun, 20, 30, 38,39

Reset weld start, 50RETR CLO, 20, 25, 29, 48

RETR OPN, 20, 25, 29, 48

RETRACT, 9, 20, 26, 41Retract stroke, 20, 41, 42, 50

Retract stroke after the welding process, 25

Robot motion to a weld spot, 22

SS_READY, 46, 52SDAT, 21, 25

Selecting the welding gun, 25

Sensor interrogation, 16Sensors, 16

Sequence diagram for SPOT (with RETRACT),48

Sequence diagram for SPOT (without RE-TRACT), 47SET, 15

Set program number to ZERO, 51

Simulation, 16Softkey bar, 15

SPOT, 20, 22, 23, 42, 47

SPOT Gun=, 25Spot welding, 22

START, 17, 19

State, 15, 18

Static outputs, 53

Status key, 14

System variables, 9

T

TEST1, 14

TEST2, 14

Time optimization, 43

Trigger for early gun closing, 43, 52

Trigger for weld start, 43, 52

Types of motion, 22, 27

U

USER_GRP.DAT, 10

USER_GRP.SRC, 9, 11

USERGRP.DAT, 9

USERSPOT, 45

USERSPOT.SRC, 44, 45, 46, 47, 49

V

VACUUM, 8

Vacuum gripper, 8

Variables, 9, 45

W

Wait Time, 16

Weld complete signal, 47, 48, 49, 50

Weld parameters, 22, 25

Weld start, 49, 50

Welding gun, 9

Welding gun retract stroke, 22

Welding process, 20

Welding program number, 47, 49

WORKING STROKE, 9

Working stroke, 26, 41, 42, 50

Working stroke status, 50

1 General2 Installation / uninstallation / update3 GripperTech3.1 Basic gripper functions3.1.1 Type 1 2 outputs, 4 inputs, 2 switching states3.1.2 Type 2 2 outputs, 2 inputs, 3 switching states3.1.3 Type 3 2 outputs, 2 inputs, 3 switching states3.1.4 Type 4 3 outputs, 2 inputs, 3 switching states3.1.5 Type 5 2 outputs, 4 inputs, 2 switching states3.1.6 Freely programmable type3.1.6.1 Prog

KST AD Gripperspottech 23 En

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